DHIM C/S

ZF Transmission
4WG190/210

Mega V

Construction equipment B/G

Product Support Team
Lay Out (1) 4WG-190/210 DHIM C/S

1. Clutch Shaft “ KR”

2. Power Take Off Coaxial
3. Clutch Shaft “KV”
4. Clutch Shaft “K2”
5. Clutch Shaft “K3”
6. Output flange Rear
7. Output flange Converter
8. Output shaft
9. Transmission Pump
10. Input Flange
11. Converter
12. Transmitter for Engine
speed
13. Clutch Shaft “K4”
14. Converter Relief V/V
15. Clutch Shaft “K1”
Lay Out Front view (2) 4WG-190/210 DHIM C/S

1. Lifting plug
2. Drive flange
3. Transmission suspension
4. Attachment for
Emergency Steering Pump
5. Model I/D
6. Output Flange Converter Side
7. Oil Drain Plug
8. Attachment for oil filter pipe
9. Oil Dipstick
Lay Out Side view (3) 4WG-190/ 210 DHIM C/S

1. Driving Flange
2. Cover
3. Converter Bell Housing
4. Breather
5. Transmission Case Cover
6. Filter head & Alarm Switch
7. Fine Filter
8. Oil Dipstick
9. Output Flange-Rear
10. Oil Drain Plug
11. Out Flange - Front
12.Transmission Case
Lay Out Rear view (4) 4WG-190/210 DHIM C/S

1. Lifting Lugs
2. Power Take Off
3. Electro- Hydraulic Control
4. Return port
(Option-Parking brake)
5. Oil Dipstick
6. Transmission Suspension
7. Output Flange
8. Fine Filter
9. Filter Head & Alarm Switch
10. System Pressure Port
(Option- Parking Brake)
Measuring Point (1) 4WG-190/210 DHIM C/S

21. Inductive transmitter :

Turbine

34. Speed Sensor :

Output and Speedmeter

47.Inductive transmitter :
Central Gear Train

48. Inductive transmitter :

Engine
Measuring Point (2)4WG-190 /210 DHIM C/S

Engaged
Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6
Clutch
Forward 1st ◆ ◆ K1,KV
2nd ◆ ◆ KV,K2
3rd ◆ ◆ K3,KV
4th ◆ ◆ K4,K3
Reverse 1st ◆ ◆ KR,K1
2nd ◆ ◆ KR,K2
3rd ◆ ◆ KR,K3
Neutral
Related Clutch K4 KR K1 K3 KV K2
Location F E D C B A
Measuring Point 60 55 56 58 53 57
System Pressure (bar) 16±2 16±2 16±2 16±2 16±2 16±2
Oil Circulation (System Pressure) DHIM C/S

WGV : Converter Back Pressure Valve

3~5 bar
WSV : Converter Relief Valve 11 bar
HDV : System pressure 16 bar
RV-9 : Pressure Reducing Valve 9 bar
NFS : Follow-on Slide
D : Oscillation Damper
P : Proportional Valve Clutch
Y : Pressure Regulator
B : Orifice
Temp : Temperature Sensor
( RV-9 Pressure measuring

after being detached)

Working of Proportional Valve DHIM C/S
Oil Circulation - Neutral Position (System Pressure) DHIM C/S

16bar @ Port No 65
Oil Circulation - Neutral Position (Pilot Pressure) DHIM C/S

9 bar
Oil Circulation - Neutral Position (T/Q Converter) DHIM C/S

11 bar @ Port No 51

3~5 bar @ Port No 52/63

Oil Circulation - Forward 1st DHIM C/S
Oil Circulation - Reverse 1st DHIM C/S
Engaged EPPR Valve Summary DHIM C/S

Engaged
Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6
Clutch
Forward 1st ◆ ◆ K1,KV
2nd ◆ ◆ KV,K2
3rd ◆ ◆ K3,KV
4th ◆ ◆ K4,K3
Reverse 1st ◆ ◆ KR,K1
2nd ◆ ◆ KR,K2
3rd ◆ ◆ KR,K3
Neutral
Relatived Clutch K4 KR K1 K3 KV K2
Oil Circulation - Hydraulic Control (1) DHIM C/S
Oil Circulation - Hydraulic Control (2) DHIM C/S
Gear Schema - 4WG190/210 DHIM C/S

KV :Clutch Forward KR: Clutch Reverse

K1: Clutch 1st Speed K2: Clutch 2nd Speed
K3: Clutch 3rd Speed K4: Clutch 4th Speed
IN : Input Out : Out Put
Power Flow - Forward 4WG 190/210 DHIM C/S
Power flow - Reverse 4WG190/210 DHIM C/S
MEGA-V T/M Electric Control System DHIM C/S

1. EST 37 CONTROL UNIT

2. KICKDOWN SWITCH
3. T/M CUT OFF SWITCH
4. AUTO SELECT SWITCH
5. DISPLAY
6. DW-3 CONTROLLER INCLUDING
KICK DOWN SWITCH
7. SUPPLY SYSTEM CONNECTION
8. TRANSMISSION
9. CENTRAL GEAR TRAIN SPEED
SENSOR
10. TURBINE SPEED SENSOR
11. ENGINE SPEED SENSOR
12. OUTPUT SPEED SENSOR
13. CABLE
( TO ELECTRO HYDRAULIC
CONTROL UNIT)
14.DIAGNOSIS LAPTOP (OPTION)
15. BRAKE PRESSURE SENSOR
Electric system DHIM C/S
Description of Components DHIM C/S

♣ Sensors
Specification
Sensor Remark
Volt(V) Frequency Resistance(Ω) Gap(mm)
Engine -Output torque Control signal
& 0.45~7.0 30Hz~50kHz 1050 ± 10% 0.5~0.8 -Shifting quality (max 1.6sec)
Turbine -Keep the original gap
-Output Propellar shaft speed
Speed 1.0~12.5 2~5 1.0~1.5 -Travel Speed display signal
-LIS system (over 8 km)

♣Pressure Regulator in Transmission Control Block

Input Current(mA) Resistance Voltage(VDC) Output Press Shifting

Regulator
(Ω) (bar) (sec)
Neutral Engaged Neutral Engaged
Y1~Y6 100 500 19 1.9 9.5 0.8 ~ 9.0 Within 1.6

♣Condition of Pressure Regulator Operation

1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C
Description of Components DHIM C/S

♣ Transmission Oil Temperature Sensor (built in TCV)

Condition
Open or Short Circuit
↓ -30 degree C (T/M oil)
-30 ~ -10 degree C (T/M oil)
↑ -10 degree C (T/M oil)
Function Remark
-Error Code Display only
-Travels Normally
-Output Voltage :5.2 ~ 24V
- Parking Brake Engaged -Resistance : 1000 ~ 1500 Ω
- 1st, 2nd Speed mode only -No Buzzer
- Travels Normally

♣ Others
1. TCU (Transmission Control Unit) Working Voltage : 18 ~ 32 VDC
2. Kick Down
1) Manual Mode : 2nd -> 1st Speed Change Only
2) Auto Mode : Every Travel Speed, 1 stage shift down
@ after 200 ~ 300 engine speed drop (except 4th -> 3rd)
3. Transmission Cut Off : Available @ 1st & 2nd Speed mode only
Electric system (Neutral) DHIM C/S

X
X
X
X
X
X

A voltage between each terminal ( # 58,10,32,55,9,51) and ground : 1.9 V

Electric system (Forward 1st) DHIM C/S

X
X
X
X

A voltage between each terminal # 32, 9 and ground : 9.5 V

The voltage between each terminal #58,10,55,51 and ground : 1.9 V
Electric system (Down Shift 2nd -> 1st - Manual mode) DHIM C/S

If the downshift switch is pressed, the gear shift changes to 1st gear
and when the downshift switch is pressed once again, downshifting is
released and returns to 2nd gear automatically.
Electric system (Down Shift - Auto mode) DHIM C/S

When the auto selector switch is “on” position and the downshift switch
pressed,the transmission changes automatically to the next lower gear.
Note: The third to the second gear and the second to the first gear change
occur when the engine speed is reduced 200 - 300 rpm from current speed.
Electric system (Transmission Cut Off ) DHIM C/S

When the T/M cut off switch(1) is “on” position and the T/M cut off switch(2) has
been connected by foot braking (25bar) in the cabin,the transmission will be in
neutral position automatically (This function works on 1st, 2nd gear only ).
Electric system (AEB ) DHIM C/S
No Order Display Remark
message
1 Warm up transmission
about 10 to 20 minutes
2 Turn off ignition key
3 Plug in AEB starter to
AEB connector located
at the seat base closest
to the cab door
4 Put T/M gear selector
Lever to Neutral position
5 Engage park brake
6 Start Engine “PL“ TCU must recognize
“PL” for at least 2sec
before you press
The AEB has the task to compensate AEB starter button
tolerances 7 On idling RPM “PL”
8 Press button of the AEB “ST” The button must not
(plate clearance and pressure level) Starter be released before
which are influencing the fiIling TCU has started the
procedure of the clutches. AEB or quit with
an error code
(see Error code list)
For each clutch, 9 Hold button until AEB has “K1” TCU has started the
the correct filling parameters are been started (Information AEB, and goes on
determined in one test cycle for about the AEB adjusting K1, K2,…,
period of the quick-fllling time state) KR. (Button may be
released from
level of the filling compensating starting)
pressure 10 Wait until AEB has “OK”
been finished (AEB has been
successful)
11 Turn off ignition and
unplug AEB Starter
Electric system (AEB DISPLAY ) DHIM C/S

Symbol Meaning Remarks

PL AEB - Starter is plugged at the diagnostic plug
ST AEB Starter button is pressed
K1..K4,KV,KR Calibrating each clutch K1..K4,KV,KR
_ and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R
≡ and Kx fast fill time determination of clutch Kx
compensating pressure determination of clutch Kx
OK calibration for all clutches finished Transmissions stays in neutral, have to restart the
TCU (ignition off/on) after removing AEB-Starter
STOP AEB canceled (activation Transmissions stays in neutral, have to restart the
stopped) TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx Transmissions stays in neutral, have to restart the
can't be calibrated TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, Transmissions stays in neutral, have to restart the
AEB finished TCU (ignition off/on)
↑E Engine speed too low, E/G RPM should be raised
↓E Engine speed too high E/G RPM should be down
↑T Transmission oil Warm up Transmission
temperature too low
↓T Transmission oil Cool down Transmission
temperature too high
FT T/M temp not in defined T/M stays in neutral, have to
range during calibration restart the TCU (key off/on)
FB Operating mode not T/M stays in neutral, have to
NORMAL or T/M temp restart the TCU (key off/on)
sensor defective or storing
of Calibrated values to
EEPROM-has failed
FO Output speed not zero Transmissions stays in neutral, have to restart the
TCU (ignition off/on)
FN Shift lever not in Neutral Transmissions stays in neutral, have to restart the
position TCU (ignition off/on)
FP Parking brake not applied Transmissions stays in neutral, have to restart the
TCU (ignition off/on)
STOP AEB - Starter was used Transmissions stays in neutral, have to restart the
incorrect or is defective TCU (ignition off/on)
Frequency of Speed sensor DHIM C/S

Hz

Z
Shaft

Shaft rpm = (Hz/Z) X 60

You can measure the frequency with an electric multi meter.
Machine Speed DHIM C/S

Machine Speed (km/hr)

Hz 1 3600 (sec/hr)
= x x 2πR x
Z r total 1000 (m/km)
- Hz Frequency from Speed Sensor
- Z Number of Ring gear Teeth
- r total Total Reduction Ratio of Axle (r diff X r hub)
- R Tire Radius in meter

M160-V M200-V M250-V M300-V M400-V M500-V

Z 53 53 44 44 66 66