ZF Reversing Transmission 4WG-200 Operation & Maintenance Manual – PDF DOWNLOAD
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ZF Reversing Transmission 4WG-200 Operation & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 93
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
ZF Reversing Transmission 4WG-200 Operation & Maintenance Manual – PDF DOWNLOAD
I.DESCRIPTION:
1.1 Function of the converter:
The converter works according to the Trilok-System, i.e. it assumes at a high turbine speed the
characteristics, and with it the favourable efficiency of a fluid clutch.
The converter is designed according to the engine power so that the most favourable operating
conditions for every installation purpose are existing.
The torque converter is composed of 3 main components:
Pump wheel – Turbine wheel – Stator (Reaction member)
- These 3 impeller wheels are arranged in such a ring-shape system that the fluid is
flowing through the circuit components in the indicated order. - The ZF-Converter charge and control pressure pump is constantly pumping pressure oil
through the converter. - In this way, the converter can ful:fill its task to multiply the torque of the engine, and at the
same time, the heat created in the converter is eliminated by the escaping oil. - The oil escaping out of the pump wheel, enters the turbine wheel and is there inverted in the di
rection of flow. - According to the rate of inversion, the turbine wheel and with it also the output shaft receives a
more or less high reaction moment. The stator (reaction member), following the turbine,
has the task to invert the oil, which is streaming out of the turbine again and to deliver it
under the suitable discharge direction to the pump wheel. - Due to the inversion, the stator receives a reaction moment.
- The relation turbine moment/pump moment is called torque conversion. This is the higher, the
greater the speed difference of pump wheel and turbine wheel will be. - Therefore, the maximum conversion is created at standing turbine wheel.
With increasing output speed, the torque conversion is decreasing. The adaptation of the
out put speed to a certain required output moment is infinitely variable and automatically
achieved by the torque converter. - If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1,0, i.e.
the turbine moment becomes equal to that of the pump moment.
From this point on, the converter is working similar to a fluid clutch.
TABLE OF CONTENTS:
ZF Reversing Transmission 4WG-200 Operation & Maintenance Manual – PDF DOWNLOAD
ZF - REVERSING TRANSMISSION 4 WG-200............................................................................................... 1 Text............................................................................................................................ 1 Summary of the Technical Data............................................................................................... 2 Important Instructions...................................................................................................... 4 I. DESCRIPTION.............................................................................................................. 5 1.1 Function of the converter........................................................................................... 5 1.2 Powershift transmission............................................................................................. 6 1.3 Transmission controls............................................................................................... 6 1.3.1 Standard Version.............................................................................................. 6 1.3.2 Version with 2-stage pressure control valve - Variant I -.................................................... 8 1.3.3 Version with 2-stage pressure control valve - Variant II - ...................................................10 1.3 4 Version with expansion valve..................................................................................11 1.3.5 Version with 2-stage pressure control valve and expansion valve...............................................13 1.4 Controller..........................................................................................................15 1.4.1 Controller DW-2...............................................................................................15 1.4.2 Controller ERGO II............................................................................................15 1.5 Display.............................................................................................................16 1.5.1 Error Chart...................................................................................................17 1.6 Electronic Control units for ZF-Powershift transmission.............................................................18 1.6.1 Description of the Basic function.............................................................................18 1.6.2 Description of the Microprocessor Control unit EST............................................................19 1.6.2.1 General.................................................................................................19 1.6.2.2 Direct selection of the solenoid valves.................................................................20 1.6.2.3 Speed engagement........................................................................................20 1.6.2.4 Passive reversing lock..................................................................................20 1.6.2.5 Gear shiftings..........................................................................................21 1.6.2.6 Special kickdown function for Wheel loaders.............................................................22 1.6.2.7 Pressure cutoff.........................................................................................22 1.6.2.8 Special function........................................................................................22 1.6.2.9 Customized control outputs..............................................................................23 1.6.2.10 Solenoid valve selection in Position Neutral...........................................................23 1.6.2.11 Inductive transmitter - Failure recognition............................................................23 1.6.2.12 System behavior at faults..............................................................................24 1.6.3 Diagnosis-System..............................................................................................24 1.6.4 Wiring........................................................................................................24 1.6.5 Test of the Electronic transmission control...................................................................24 1.7 Interaxle differential (Length- compensating differential)..........................................................24 1.7.1 Description...................................................................................................25 1.7.2 Function......................................................................................................25 1.8 Power take-offs.....................................................................................................25 1.9 Final drive.........................................................................................................25 1.10 Emergency steering pump............................................................................................26 1.11 Speedometer drive..................................................................................................26 II. INSTALLATION INSTRUCTIONS...............................................................................................27 III. OPERATION..............................................................................................................29 3.1 Driving preparation and Maintenance.................................................................................29 3.2 Driving and Shifting................................................................................................29 3.3 Transmission control with Electronic automatic unit.................................................................30 3.4 Engagement and Disengagement Differential lick and Front-axle drive.................................................30 3.5 Stopping and Parking................................................................................................31 3.6 Towing..............................................................................................................31 3.7 Oil temperature.....................................................................................................31 IV. MAINTENANCE.............................................................................................................32 4.1 Oil type............................................................................................................32 4.2 Oil-level check.....................................................................................................32 4.3 Oil change and Oil filling capacity.................................................................................33 4.4 Filter replacement..................................................................................................33 Tables..........................................................................................................................34 Layout 4 WG-200 (Wheel loader Version)......................................................................................34 Interaxle differential......................................................................................................35 Axle declutch...............................................................................................................36 Installation view Center distance 400 mm - separate installation front view.................................................37 Installation view Center distance 400 mm - separate installation side view..................................................38 Installation view Center distance 400 mm - separate installation rear view..................................................39 Installation view Center distance 400 mm direct mounting front view.........................................................40 Installation view Center distance 400 mm - direct mounting side view........................................................41 Installation view Center distance 400 mm - direct mounting rear view........................................................42 Installation view Center distance 500 mm - direct mounting front view.......................................................43 Installation view Center distance 500 mm - direct mounting side view........................................................44 Installation view Center distance 500 mm - direct mounting rear view........................................................45 Installation view Center distance 500 mm - separate installation front view.................................................46 Installation view Center distance 500 mm - separate installation side view..................................................47 Installation view Center distance 500 mm - separate installation rear view..................................................48 Installation view Center distance 555 mm - direct mounting front view.......................................................49 Installation view Center distance 555 mm - direct mounting side view........................................................50 Installation view Center distance 555 mm - direct mounting rear view........................................................51 Installation view Center distance 555 mm - direct mounting front view.......................................................52 Installation view Center distance 555 mm - direct mounting side view........................................................53 Installation view Center distance 555 mm - direct mounting rear view........................................................54 Installation view Center distance 555 mm - direct view front side...........................................................55 Installation view Center distance 555 mm - direct mounting side view........................................................56 Installation view Center distance 555 mm - direct mounting side view........................................................57 Installation view Center distance 555 mm - separate installation front view.................................................58 Installation view Center distance 555 mm - separate installation side view..................................................59 Installation view Center distance 555 mm - separate installation rear view..................................................60 Installation view Center distance 555 mm - separte installation front view..................................................61 Installation view Center distance 555 mm - separte installation side view...................................................62 Installation view Center distance 555 mm - separte installation rear view...................................................63 Schedule of measuring points with Aluminum die-casting shift control standard version.......................................64 Schedule of measuring points with Aluminum die-casting shift control and 2-stage pressure control valve - variant I.........66 Schedule of measuring points with Aluminum die-casting shift control and 2-stage pressure control valve - Variant II........68 Schedule of measuring points with Aluminum die-casting shift control and expansion valve....................................70 Schedule of measuring points with Alumium die-casting shift control, expansion valve and 2-stage pressure control valve....72 Oil circulation diagram - standard version..................................................................................74 Oil circulation diagram with 2-stage pressure control valve - Variant I.....................................................75 Oil circulation diagram with 2-stage pressure control valve - Variant II....................................................76 Oil circulation diagram with expansion valve................................................................................77 Oil circulation diagram with expansion valve and 2-stage pressure control valve.............................................78 Aluminum die-casting shift control with 5 solenoid valves standard version..................................................79 Aluminum die-casting shift control with 5 solenoid valves and 2-stage pressure control valve - Variant I ...................80 Aluminum die-casting shift control with 5 solenoid valves and 2-stage pressure control valve - Variant II...................81 Aluminum die-casting shfit control with 5 solenoid valves and expansion valve...............................................82 Aluminum die-casting shift control with 5 solenoid valves and expansion valve...............................................83 Shift control circuit diagram - 6029 700 875 - with DW-2 "Code G"...........................................................84 Automatic shift control circuit diagram - 6029 700 876 - with DW-2 "Code G".................................................85 Automatic shift control circuit diagram - 6020 700 781 - with ERGO II "Code G"..............................................86 Automatic shift control circuit diagram - 6029 700 876 - ERGO II "Code G"...................................................87 Controller DW-2.............................................................................................................88 Controller ERGO II..........................................................................................................89 Inductive transmitter and electronic module.................................................................................90 Tester PR-78 A + B..........................................................................................................91 Tester PR-68................................................................................................................92 Multi-System 5000...........................................................................................................93
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