Professional Documents
Culture Documents
ZF – ERGOPOWER TRANSMISSION
6 WG-210
TECHNICAL DATA
DESCRIPTION
OPERATION
MAINTENANCE
DIAGNOSTIC SYSTEMS
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau Edition: 2002/07
Subject to changes w/o notice
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
3. Edition
2
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Preface
The present Documentation has been developped for skilled personnel which has been trained
by the ZF for the Maintenance and Repair operations on ZF-units.
However, because of technical development of the product, the Maintenance and Repair of the
unit in your hands may require differing steps as well as also different setting and test data.
The responsibility lies with the owner and the user, to pay attention to the safety indications,
and to carry out the Maintenance operations according to the prescribed Specifications.
The ZF is not liable for faulty installation, incorrect treatment, insufficient Maintenance, im-
pro-perly and unskilled performed works, and for the subsequential damages resulting from it.
It is imperative to pay attention to the corresponding Specifications and Manuals of the Vehi-
cle Manufacturer.
Important Informations concerning the technical reliability and reliability in service are accen-
tuated by the following Symbols:
Valid for Instructions which must be observed at the Maintenance, the Perfor-
mance or the Operation of the vehicle !
3
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
TECHNICAL DATA
Engine power: max. KW ------------------------------ 210*
Description:
The ZF-Transmissions 6 WG-210 are composed of a hydrodynamic torque converter and a
rear-mounted multi-speed powershift transmission with integrated transfer case (see Table 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself
to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via uni-
versal shaft) with DIN-, Mechanic- or Spicer-input flange.
Between engine and torque converter, a Retarder can be arranged (fluid brake) whereby a
good braking effect will be achieved in all speeds.
The transmission can be shifted manually or fully-automatically by means of the Electronic
unit EST-37.
Torque converter:
Unit size W 300 and 340 with torque multiplication according to the version and a WK.
Powershift transmission:
6 Forward speeds and 3 Reverse speeds.
Output:
The powershift transmission has between input and output shaft a center distance of 540 mm,
and can be equipped with the following components:
- with output flanges to the front and rear axle for different universal shafts
- on the rear output (rear-side) with a disk brake as parking brake
- on the converter side with axle disconnection
- with an integrated, lockable interaxle differential
7
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Power take-off:
For the drive of an external hydraulic pressure pump,an engine-dependent, coaxial power
take-off is existing, upon request also disconnectable.
It allows the mounting of pumps with SAE-C connection.
Transmission accessories:
Upon request, the transmissions can be additionally equipped with the following components:
- Emergency steering pump with a feed rate off 16 cm3/rev. or 32 cm3/rev.
- Electronic speedometer signal for:
- Construction site vehicles here, the Electronic unit EST-37 offers a speedometer signal.
- Road vehicles, the signal required for the speedometer interpretation will be picked-up on
the output side by a pulse generator (e.g. is needed for trip recorders).
For this, a frequency divider from the Customer side is necessary.
- Separate mounting of the ZF-Fine filter.
8
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
1 = Gearbox type
2 = Gearbox Serial-No.
3 = ZF-Parts List-No.
4 = Total ratio of the Gearbox
5 = Oil (Oil specification)
6 = List of lubricants
7 = Oil capacity
8 = Customer no.
1 2
3 4
5 6
7
8
1. = Gearbox type
2. = Serial-No. See Model identification Plate!
3. = ZF-Parts List-No.
4. = Mark and type of vehicle
5. = Denomination of the spare part
6. = Spare parts-No.
7. = Way of transport
When all of the above required indications are considered, errors in the delivery of
spare parts Orders can be avoided!
9
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
IMPORTANT INSTRUCTIONS
At stationary engine, the oil level in the transmission is rising essentially, accord-
ing to the installation conditions !
At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF rec-
ommends to start the autonomous calibration of the shifting elements (AEB).
The autonomous calibration of the shifting elements (AEB) must be started after
the initial installation of the transmission and the Electronics in the vehicle at the
Vehicle Manufacturer and after every replacement of the transmission, the elec-
trohydraulic control or the TCU in case of a failure.
Put the Controller at the starting of the engine always to the Neutral position.
At running engine and transmission in Neutral, the parking brake must be en-
gaged or the service brake be actuated, to prevent the vehicle from rolling.
The engagement of the speed out of Neutral is only possible under the pro-
grammed transmission input speed (turbine speed).
Neutral position of the selector switch at higher vehicle speeds (above stepping
speed) is not admissible.
Either a suitable gear is to be shifted immediately, or the vehicle must be stopped
at once.
Reversing (Standard):
The reversing must be performed at standstill, resp. at very low driving speed.
Above the programmed reversing limit, the vehicle will be shifted to Neutral by
the Electronic unit EST-37, and the vehicle continues rolling in the old driving
direction.
The gear of the new driving direction will be only engaged when the pro-
grammed reversing speed and the transmission input speed (turbine speed) has
fallen below.
The programming is customized and can therefore be different from standard.
Therefore, the exact procedure must be taken from the Operating Instructions of
the respective Vehicle Manufacturer !
11
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
The towing speed must in no case be higher than 10 km/h, the towing distance
not longer than 10 km.
It is imperative to observe this Specification because otherwise the transmission
will be damages due to insufficient oil supply !
At a longer distance, the best solution would be to transport the vehicle with a
Low loader.
Operating temperature behind the converter at least 65° and 100° C in continu-
ous operation, a short-time increase up to max. 120° C is permitted.
Temperature in the sump 60° - 90° C.
In case of irregularities on the transmission, put the vehicle out of service and
ask for Specialists.
At the following operations, the ignition must be switched off and the control
unit plug must be pulled off from the ZF-Electronics:
12
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
I. DESCRIPTION
TP = Torque of the
Impeller Turbine wheel
Impeller
TT = Torque of the
Turbine wheel
TR= Torque of the
TT Reaction member
(Stator)
from the
Engine
TP
to the
Transmission
NT = 0
Condition in the Vehicle is stationary
1 1,5 2,5
mo-ment of the start TR
off Reaction member
nT = <n Engine
(Stator)
Intermediate condi- 1 <1,5 <2,5
tion
nT = ≈ 0,8 n Engine
Condition in the
lock-up point 1 0 1
Figure-No.: 1.1
The converter is working according to the Trilok-System, i.e. it assumes at 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 are obtained for each installation case.
These 3 impellers are arranged in such a ring-shaped system that the fluid is streaming
through the circuit components in the indicated order.
Pressure oil from the transmission pump is constantly streaming through the converter. In this
way, the converter can fulfill its task to multiply the torque of the engine and at the same time,
the heat created in the converter is dissipated via the escaping oil.
The oil which is streaming out of the impeller, enters the turbine wheel and is there reversed
in the direction of flow.
According to the rate of reversion, the turbine wheel and with it also the output shaft is receiv-
ing a more or less high reaction torque.
13
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
The stator (reaction member) following the turbine, has the task to reverse the oil, which is
streaming out of the turbine once more and to deliver it under the suitable discharge direction
to the impeller.
Due to the reversion, the stator is receiving a reaction torque.
The relation turbine torque/pump torque is called torque multiplication. This is the higher, the
greater the speed difference of impeller and turbine wheel will be.
When the turbine speed is reaching about 80% of the pump speed, the torque multiplication
becomes 1,0 i.e. the turbine torque becomes equal to that of the pump torque.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, in the torque
multiplication range it is backing-up the torque upon the housing, and is released in the clutch
range.
In this way, the stator can rotate freely.
1.2 WK
WK - open WK – closed
1 2 1 2
6 6
Pressure oil
from the
WK-Valve
5 5
4 3 4 3
Figure-No. 1.2 B1:
14
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
At closed WK, the slip between impeller and turbine wheel, and with it the hydraulic loss in
the converter is equal to „Zero“ (see Figure-No. 1.2 B1).
The WK will be automatically shifted dependent on the turbine speed.
The pressure oil (15 + 1 bar) for the closing of the WK, is directed via a solenoid shift valve
(see Figure-No. 1.1 B2) to the piston (6), which is compressing the plate pack.
Duct plate
Figure-No.: 1.2 B2
1.3 Powershift transmission
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 6-speed reversing transmission is equipped with 6 multi-disk clutches.
At the shifting, the actual plate pack is compressed by a piston, movable in axial direction,
which is pressurized by pressure oil.
A compression spring takes over the pushing back of the piston, thus the release of the plate
pack. As to the layout of the transmission as well as the specifications of the closed clutches
in the single speeds, see Table 1, 9, 10, 11,12, 13 and 14.
Transmission control, see Schedule of measuring points, Oil circuit diagram and Electro-
hydraulic control unit Table-9, 10, 11, 12,13, 14 and 18.
The transmission pump, necessary for the oil supply of the converter, and for the transmission
control, is located in the transmission on the engine-dependent input shaft.
The feed rate of the pump is Q = 105 l /min, at nEngine = 2000 min -1.
This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF-
Fine filter – the filter can be fitted also externally from the transmission – to the main pressure
valve.
If because of contamination, resp. damage, the through-flow through the ZF-Fine filter is not
ensured, the oil will be directly conducted via a filter differential pressure valve (bypass valve
∆p=5,5+3 bar) to the lubrication.
In this case, an error indication is shown on the ZF-Display.
15
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
ZF-Fine filter:
Filtration ratio according to ISO 4572: ß30 > 75 ß15 = 25 ß10 = 5.0
Filter surface at least: 6700 cm2
Dust capacity according to ISO 4572 at least: 17 g
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6.
The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6),
follow-on slide and vibration damper.
The control pressure of 9 bar for the actuation of the follow-on slides is created by the pres-
sure reducing valve. The hydraulic oil (16+2 bar) is directed via the follow-on slide to the
respective clutch.
Due to the direct proportional selection with separate pressure modulation for each clutch, the
pressures to the clutches, which are engaged in the gear change, will be controlled. In this
way, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible.
This is creating spontaneous shiftings without traction force interruption.
The main pressure valve is limiting the max. control pressure to 16+2 bar and releases the
main flow to the converter and lubricating circuit.
In the inlet to the converter, a converter safety valve is installed which protects the converter
from high internal pressures (opening pressure 11+2 bar).
Within the converter, the oil serves to transmit the power according to the well-known hydro-
dynamic principle (see Chapter Torque converter 1.1).
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter pressure back-up valve, rear-mounted to the converter, with an
opening pressure of about 4,3+3 bar.
The oil, escaping out of the converter, is directed to a heat exchanger.
The selection and definition of the heat exchanger must be carried out according to our Instal-
lation Specification for hydrodynamic powershift transmissions by the Customer on his own
responsibility.
The heat exchanger is not within the scope of supply of the ZF Passau GmbH.
From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil
circuit so that all lubricating points are supplied with cooled oil.
In the Electrohydraulic control unit, are 6 pressure regulators installed – see Table-18.
The allocation of the pressure regulators to the single gears can be seen on the Tables 9, 10,
11,12, 13 and 14.
16
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
1.5 Controllers
1.5.1 General:
Due to the great number of the available Controllers, the precise Technical Data
must be taken from the respective installation drawing.
At the Console selector VTS-3 (preselection pushbutton switch), the driving direction will be
preselected by horizontal tilting of the Controller lever.
By pressing the Controller lever to the right (+) or to the left (-), the speeds can be preselected.
The Controller is equipped with a function knob, it serves according to the driving mode as
kickdown knob or release knob for the start off and for the automatic and manual driving
mode.
CONTROLLER VTS-3
Function knob
V N
R
Gearsh. gate
+ + +
N
R
V
Figure-No. 1.5.2
General:
For the selection to the manual mode, there are two possibilities:
- Pressing of the function knob (remaining in the running gear).
17
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
- Selection of a lower or higher gear by pressing the Controller lever to the left (-) or to the
right (+).
Speed engagement out of Neutral is only then possible when the turbine speed is lying below
1200 min –1 .
The EST-37 offers the possibility of max. two gear limitations. This can be different from
vehicle to vehicle.
In the following, two possibilities are described how gear limitations can be defined:
- Dumper:
Trough in top position, vehicle can be driven only in the 1st and 2nd speed Forward and
only in the 1st speed Reverse.
- Crane:
- All-wheel engaged, vehicle can be driven only in the 1st and 2nd speed.
- Operation changed over to the upper chassis, driving only possible in the 1st speed.
Pushbutton switch D7
1 2 3 D N R
Figure-No.: 1.5.3
The single keys are marked as follows:
1.6 Display
1.6.1 General:
Because the Display can be used with all Controller types, as e.g. with the DW-3 or ERGO II
for Wheel loaders Lift trucks, RoRo trucks as well as with the VTS-3 or D7 for Cranes, Dum-
pers, Graders and Rail vehicles.
18
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
DISPLAY
a b c g
Figure-No.: 1.6.2
Spec. charact. Display (see Figure-No.: 1.6.2)
a, f Automatic range (up- and downshifting)
b, c, d, e Preselected gear
g EST-37 has recognized an error, is flashing
h This special character is not used for the moment at the EST-37
Left Side For the moment without function
Central and On the two alphanumeric 16-segment displays, the EST-37 issues the ac-
right Side tual state of gear and driving direction. Besides, a two-digit error code will
be indicated for these two segments.
Waiting for Controller-Neutral: Indication on the Display: NN (central and right Side).
In this condition, Neutral is pending on transmission.
To engage a gear, at first Neutral must be shifted on
the Controller before the electronics allows to engage a
gear again.
Preselected Driving range: The number of the lines indicates the driving range,
(Special characters b, c, d, e) resp. the gear preselected:
1 Bar: Driving range 1
2 Bars: Driving range 2
3 Bars: Driving range 3
4 Bars: Driving range 4, 5 or 6
19
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Display Manual/ Automatic: If the two Symbols a , f (Arrows) and the bars b, c, d, e
(Special characters a, f) are indicated, the system is in the Automatic mode
(automatic up- and downshiftings).
20
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Main reasons:
Since there are different Software versions for the Customers, the listing of the error
codes must be taken from the Documentation of the Vehicle Manufacturer.
For the EST-37, a general Diagnostic and Trouble shooting Specification is available,
for which the following Order-No. has been defined:
21
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
This Diagnostic and Trouble shooting Specification can be requested under the fol-
lowing address:
ZF Passau GmbH
Abt. ASPL
Donaustr. 25 – 71
94034 Passau
The basic functions of the automatic system are the automatic shifting of speeds, adaption of
the optimum shifting points, the comfortable kickdown function as well as comprehensive
safety functions in relation to operating errors and overloading of the power-transmitting
components with a comprehensive fault storage.
The control units can be programmed – customer- and vehicle-specific – in a wide spectrum,
control parameters can be logically linked, and also special functions such as gear limitation,
converter or retarder functions can be integrated.
Due to the great number of the available TCU, the exact Technical Data must be
taken from the respective installation drawing.
Figure-No.: 1.7 B1
The installation position of the TCU can be at random. As an advantage, the ZF rec-
ommends the Version illustrated in the Figure-No. 1.7 B1.
The installation of the TCU must be realized on a protected point in the cabin.
An overfloating with water must be excluded. Besides, the penetration of water via
the plug connection must be prevented by corresponding measures on the cable har-
ness.
22
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
100
ZF-Typ plate
50
209
100
Minimum Distance to disengage the plug
Figure-No.: 1.7 B2
1.8.1 General:
23
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
The Powershift transmission of the Ergopower-Series 6 WG-210 is equipped with the Elec-
tronic control EST-37, developped for it.
For Dumpers, Graders and Crane vehicles, the ZF has developped with the Controllers VST-3,
SG-6 and D7 a special Controller configuration.
The system is processing the desire of the driver according to the following criteria:
• Gear determination dependent on controller position driving speed and load condition.
• Protection from operating error as far as necessary, is possible via electronic protection
(programming).
• Protection from over-speeds (on the base of engine and turbine speed).
• Automatic reversing (driving speed-dependent, depending on vehicle type).
• Pressure cut-off possible (vehicle-specific, only after contact with ZF).
• Change-over possibility for Auto- / Manual mode.
• Gear holding function possible (kickdown).
8 = CAN-Connection
9 = Diagnosis Mobidig 2001 is only for ZF-Service stations
10 = Diagnosis Laptop with ZF-Diagnostic system Testmann
11 = Cable to plug connection on the electrohydraulic control unit
12 = Cable to WK-Valve
13 = Cable to temperature measuring point behind the converter „No. 63“
14 = Cable to inductive transmitter – speed turbine
15 = Cable to inductive transmitter – speed central gear train
16 = Cable to inductive transmitter – speed engine
17 = Cable to filter contamination switch
18 = Cable to speed sensor output and speedometer
19 = Ergopower transmission 6 WG-210
24
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Afer a replacement of the transmission, the electrohydraulic control or the TCU in the
vehicle, the Aeb-Cycle must be as well carried out again.
The AEB-Cycle continues for about 3 to 4 minutes. The determined filling parameters are
stored in the EEProm of the Electronics. In this way, the error message F6 shown on the Dis-
play will be cancelled also at non-performed AEB.
For the start of the AEB-Cycle, there are principally two possibilities:
1. Start of the AEB by separate Tools which are connected on the diagnostic port
of the wiring.
Following Tools for the AEB start will be offered by the ZF Service.:
- Mobidig 2001 (see Point 5.2 – Diagnostic systems)
- Testmann (see Point 5.3 – Diagnostic systems)
- AEB Starter
Order-No.: 0501 211 778
Figure-No.: 1.8.3 B1
Due to the operation of the transmission, the paper friction linings, installed in the Er-
gopower transmissions are settling, i.e. the plate clearance becomes greater.
Because these settling appearances can interfere the shifting quality, ZF recommends to
repeat the AEB-Cycle at the Maintenance intervals (see 4.3.1)
The ZF recommends likewise at a reduced shifting quality as first measure to repeat the
AEB-Cycle.
Figure-No.: 1.8.3 B2
26
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Figure-No..: 1.8.3 B3
At the actuation of the KD-switch, up- and downshiftings take place at higher speeds.
Upon request, upshiftings can be completely suppressed (e.g. driving and upgrades with a
Dumper).
Further available Special functions upon request after contact with the ZF.
1.9.1 Description:
The differential, installed in the output, has the task to transmit different torques on the vehi-
cle axles and to function as intermediate compensation in the driving direction (longitudinal
direction of the vehicle).
Due to the installed differential lock, both functions can be put out of service, and a rigid con-
nection between the axle can be created.
The engagement and disconnection can be realized:
- mechanics
- hydraulically or pneumatically
- powershift.
1.9.2 Function:
The planetary drive (differential) is designed in such a way that the external internal gear will
be driven.
The output is realized via the planet carrier (4) – great lever arm – and via the internal sun
gear (6) – small lever arm.
Due to these different lever arms (diameter), a torque splitting of 1 : 2 is given in the actual
case as follows:
27
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
If an axle of the vehicle is showing slip, a rigid connection between the vehicle axles can be
created by the differential lock.
In this condition, a torque output of 1 : 1 is realized.
1 8
HA
5
2
3 4
Figure-No.1.9.2 B1
Gearbox diagram
1:2
VA HA VA HA
1:1
1:1
Figure-No.1.9.2 B2
28
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
4 4 4 4 4 4 4 4
i=1:2
VA HA
i=1:1
14 13 12 5 3 6
Figure-No.1.9.2 B3
15 1 2 3 4 11
i=1:2
VA HA
i=1:1
7 16 5 3 6
Figure-No.1.9.2 B4
29
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
1 2 3 4 engagement
disconnection
76
6 5
Figure-No.1.10
30
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
1.11 Retarder:
1.11.1 General:
The hydrodynamic Retarder (fluid brake), installed upon request, is arranged between engine
and torque converter thus achieving a good braking effect in all gears.
The Retarder is a wear-free, gear-depending acting hydrodynamic-brake.
The application of the Retarder is therefore especially to recommend at longer downgrade
drives or to brake down out of high driving speeds, because in this way, the service brake will
be saved and in an emergency case, the full braking effect (no fading) of the service brake will
be disponible.
This is the case of a so-called primary retarder, i.e. it is positively engaged with the engine.
Therefore, in the lower gear, higher braking moments can be achieved then in the correspon-
ding higher gears.
Because of this fact, it is necessary that by a control device, supplied by ZF, the installed WK
must be closed, so that the full retarder moment can become effective.
The Retarder in its functional components (see Draft) is composed of the Rotor, the Stator and
the Control device. The Rotor (the rotating part of the retarder) is driven from the overrunning
vehicle via axle, universal shaft, transmission and shift clutch.
The two-piece stator is composed of the stator itself, which is rigidly connected with the gear-
box housing and the stator ring. This stator ring is a vane ring which is arranged between rotor
and stationary stator, and serves to reduce the idling losses.
The control device is a valve block which is controlled by means of compressed air.
In shut off condition, i.e. without oil filling, the stator ring will be hold in a position by spring
force by which bypass ducts between rotor and stator impellers will be created.
In the retarder mode, i.e. with oil filling, the stator ring will be displaced by the circulating oil
by exceeding the spring forces up to a stop.
In this position, it is creating together with the stationary part of the stator a closed impeller
ring „counter-rotating“, to the rotor.
The braking procedure itself will be started via a hand- or foot-actuated control valve.
31
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
With this valve it is possible to adjust a certain air pressure and with it the desired brake per-
formance infinitely variable. The possible air pressure value is in this situation between 3,5
and 8 bar, because only from about 3 bar on, the existing preload of the cooling circuit is o-
vercome.
The retarder control valve, pressurized with this compressed air, released by it the correspon-
ding oil stream into the retarder circuit.
Function of a Retarder
(Schematic view)
Retarder valve
Discharge spiral
Stator Rotor
Control-air
connection Rotor
Connectin from
the heat
exchanger
Connectin to
the heat
exchanger
Stator
Cooling
water
Heat exchanger
Figure-No.1.11B1
Due to the rotation and the impeller configuration of the rotor, the oil will be directed into the
stator and comes from there back again to the rotor, in order to start the circuit anew (see
Draft).
Due to the actual reversion of the oil, the rotary motion of the rotor and with it the speed of
the vehicle will be retarded.
This energy, converted in this way from speed into pressure, will be finally transfered by fluid
friction into thermal energy and then delivered via a heat exchanger to the cooling water.
If during the retarder operation the shift clutch will be actuated, a 3/2-way valve is blocking
the compressed air supply to the control valve, in this way, the retarder will be cut-off, thus
saving the shift clutch.
32
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Connection
Intermediate for air
plate pressure
Intermediate D kl ft
plate
Stator
after Converter
from Retarder
to Lubrication
to lubrication
to Retarder
Breather
Figure-No.1.11B2
33
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
This Specification for the installation of hydrodynamic Powershift transmissions of the Ergo-
power-Series is the basis for the technically faultless installation of these transmissions in the
vehicle. The Installation Specification is part of the Transmission Documentation and must be
absolutely respected.
Responsible for the correct installation of the transmission is the Vehicle Manufacturer.
ZF does not admit any guarantee or warranty claims for damages
which has been caused by a faulty installation.
In order to assist the Customer in case of new, resp. initial applications, the ZF carries out by
authorized personnel transmission checks. On this occasion, all transmission-specific instal-
lation features are examined and the Vehicle Manufacturer, resp. the Equipment Manufacturer
will be informed about the encountered defects.
At improperly installation, ZF reserves itself the right to acknowledge no guarantee for the
installed ZF-Products.
For damages, caused by defects for which the Vehicle Manufacturer is responsible, and could
not be discovered at the installation examination by ZF-Personnel, the Vehicle Manufacturer
alone is liable.
ZF Passau GmbH
Abt. ASPL
Donaustr. 25 – 71
94034 Passau
35
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
III. OPERATION
Prior to the commissioning of the transmission, take care that the prescribed oil grade will be
filled in with the correct quantity. At the initial filling of the transmission has to be considered
that the oil cooler, the pressure filter as well as the pipes must get filled with oil.
According to these cavities, the quantity of oil to be filled in, is greater than at the later oil fil-
lings in the course of the usual Maintenance service.
Because the converter and also the oil cooler, installed in the vehicle, as well as the
pipes can empty at standstill into the transmission, the
Oil level check must be carried out at engine idling speed and operating
Temperature of the transmission (see Chapter Oil level check 4.2).
At the oil level check, the prescribed safety directions according to § 6 of the
regulations for the prevention of accidents for power plants in Germany, and in
all other countries, the respective national regulations have to be absolutely
observed.
For example, the vehicle has to be secured against rolling by blocks, articulated
vehicles additionally against unintended turning-in.
Which control lamps in the INFOCENTER (dashboard) are illuminated for the
functional check, can be different from Vehicle Manufacturer to Vehicle Manufac-
turer.
Control elements and displays can be from the ZF, however can be also customizer-
specific products; the precise specifications must therefore be taken from the Oper-
ating Instructions of the respective Vehicle Manufacturer.
- Neutral position:
Neutral position will be selected via the Controller.
After the ignition is switched on, the electronics remains in the waiting state.
By the position.
NEUTRAL of the Controller, resp. by pressing the pushbutton NEUTRAL, the EST-37
becomes ready for operation.
Now, a gear can be engaged.
- Starting:
The starting of the engine has to be always carried out in the NEUTRAL POSITION of the
Controller.
For safety reasons, it is to recommend to brake the vehicle securely in position with the par-
king brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
vehicle can be set in motion by acceleration.
37
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load.
Upshifting under load will be then realized if the vehicle can continue to accelerate by it.
- Downshifting under load.
Downshifting under load will be then realized if more traction force is needed.
- Upshifting in coasting condition.
In the coasting mode, the upshifting will be suppressed by accelerator pedal idling position
, if the speed of the vehicle on a downgrade should not be further increased.
- Downshifting in coasting condition.
Downshifting in the coasting mode will be then carried out if the vehicle should be retar
ded.
- Reversing
See important Note-Page 9.
If the vehicle will be stopped and is standing with running engine and engaged transmission,
the engine cannot be stalled. On a level and horizontal roadway it is possible that the vehicle
begins to crawl, because the engine is creating at idling speed a slight drag torque via the con-
verter.
It is convenient to brake the vehicle at every stop securely in position with the parking brake.
At longer stops, the Controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a con-
verter transmission it might not immediately be noted to have forgotten this quite normal op-
erating step because a converter, due to its high ratio, can easily overcome the braking torque
of the parking brake.
Temperature increases in the converter oil as well as overheated brakes will be the conse-
quences to be find out later.
Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not
admissible.
Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.
After the indication on the ZF-Display is extinguished, the full driving programm can be util-
ized out of „NEUTRAL“.
Precise informations about the design of the Controllers as well as the speeds shifted
in the single driving ranges, must be taken from the Operating Instructions belong-
ing to the vehicle.
38
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
A manual intervention into the automatic shifting sequence is only then practical if the road
condition or the form of the terrain is suitable.
Since due to the converter there is no rigid connection existing from the engine to the axle, it
is recommended to secure the vehicle on upgrades, resp. downgrades against unintended roll-
ing not only by applying the parking brake but additionally by a block on the wheel, if the
driver has the intention to leave the vehicle.
3.6 Towing:
At Versions with Retarder, the monitoring of the oil temperature is additionally realized be-
hind the Retarder with an indication on the ZF-Display or analog in the INFOCENTER.
39
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
40
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
IV. MAINTENANCE
4.1. Oil grade:
Permitted for the Powershift transmissions 6 WG-210 are oils according to ZF-List
of lubricants TE-ML 03.
This List of lubricants will be updated every two years and can be requested, resp.
inspected as follows:
- At all ZF-Plants
- At all ZF-Service Stations
- Internet http://www.zf.com Informationen/Tech. Informationen
At the oil level check, the prescribed safety directions according to § 6 of the
rules for accident prevention for power plants in Germany, and in all other
countries the respective national regulations have to be absolutely respected.
For example, the vehicle has to be secured against rolling with blocks, articu-
lated vehicles additionally against unintended turning-in.
If the oil level has dropped in operating temperature condition below the „HOT“
Zone, it is absolutely necessary to replenish oil according to the ZF-List of lubricants
TE-ML-03.
An oil level above the „HOT“ marking, is leading to a too high oil temperature.
The oil dipstick and the oil filler tube can have different lengths and shapes, ac-
cording to the Transmission version. Besides, the mounting on the transmission can
be optionally realized on the converter side or on the output side.(In this Illustration,
the mounting of the oil dipstick is illustrated on the output side).
41
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
1
3
Figure-No.: 4.2 B1
Legend:
Oil dipstick
Zone
„HOT“
Figure-No.: 4.2 B2
42
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
At the initial filling of the transmission has to be considered that the oil cooler, the
pressure filter as well as the pipes must get filled with oil.
According to these cavities, the oil capacity to be filled in is greater than at the later
oil fillings in the course of the usual Maintenance service.
At the replacement of the ZF-Filter in the main oil stream, pay attention that no dirt or oil
sludge can penetrate into the circuit. Besides, the parking brake has to be covered, resp. pro-
tected from oil wetting.
At the mounting of the filter, any exertion of force has to be avoided.
Treat the filter carefully at the installation, the transport and the storage !
Damaged filters must no more be installed !
The filter differential pressure valve (bypass valve) is equipped with a filter contami-
nation switch which is informing the driver about the contamination of the ZF-Fine
filter.
At the lighting up of the symbol, the ZF-Fine filter must be replaced.
43
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
5. ZF-DIAGNOSTIC SYSTEMS
5.1 General:
The Control electronics EST-37 for the Transmission Series Ergopower is equipped with a
diagnostic package, which makes the Trouble shouting and the Repair of damages easier for
the Service.
The Electronics is able to monitor the states of certain inputs and outputs.
If the Electronics recognizes at it an error, it stores an error code in the fault storage
(EEPROM) and is transmitting the error code also to the vehicle controller of the Vehicle
Manufacturer.
The ZF-Diagnostic and Programming systems MOBIDIG-2001 (see 5.2) and LAPTOP-
Version (see 5.3) are needed for the following applications:
Diagnosis -
-
Actual errors
Reat fault storage
- Cancel fault storage
AEB - Automatic calibration of the shifting elements
Testing Inputs and Outputs - Outputs (select components)
- Check inputs
- Check systems downtime
- System test drive
Additionally for the Diagnosis can be used the Multi-System 5000 (see 5.4) with correspond-
ing sensor system for pressure, temperature, speed, through-flow, current transformer etc.
Figure-No.: 5.2
45
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Windows 95/98 or NT
Basic-Software
Testman WIN 95/98 or NT
Adapter cable
DPA-04I ⇔ EST-37
6029 017 005
Figure-No.:5.3
46
Geschäftsbereich
ERGOPOWER Arbeitsmaschinen-Antriebe
und Achssysteme
Accessories:
Sensor system for through-flow, current transformer etc.
Figure-No.: 5.4
47
L A Y O U T 6 W G -2 1 0 1 3
1
T A B L E -1 1 2
1 = C lu tc h s h a ft K R
2 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
3 = C lu tc h s h a ft K V 1 1
4 = C lu tc h s h a ft K 2 2
5 = C lu tc h s h a ft K 3
6 = O u tp u t fla n g e - re a r s id e
7 = O u tp u t fla n g e - c o n v e rte r s id e 1 0
8 = O u tp u t s h a ft " A B "
9 = T ra n s m is s io n p u m p 3
1 0 = In p u t fla n g e - in p u t th ro u g h u n iv e rs a l s h a ft " A N "
1 1 = C o n v e rte r
1 2 = W K (c o n v e rte r c lu tc h ) 9
1 3 = In d u c tiv e tra n s m itte r fo r e n g in e s p e e d 4
1 4 = C lu tc h s h a ft K 4
1 5 = C o n v e rte r s a fe ty v a lv e
1 6 = C lu tc h s h a ft K 1
G E A R B O X D IA G R A M 46 230 803
5
K R
K V A N 1 6 8
K 2 K 4 1 5
E .I . 1 31 3 3 0 4 0 4 3
0 73 0 74 9 1 8 4 (O Z )
6
A B
1 4 z = 5 6
A EH NL . 46 4 2 30 1 14 8
7
L A Y O U T 6 W G -2 1 0 W IT H R E T A R D E R
1
T A B L E -2 1 3
1 = C lu tc h s h a ft K R
2 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t 1 2
3 = C lu tc h s h a ft K V
4 = C lu tc h s h a ft K 2
1 1 2
5 = C lu tc h s h a ft K 3
6 = O u tp u t fla n g e - re a r s id e
7 = O u tp u t fla n g e - c o n v e rte r s id e 1 0
8
9
=
=
O u tp u t s h a ft " A B "
T ra n s m is s io n p u m p
3
1 0 = In p u t fla n g e - in p u t th ro u g h u n iv e rs a l s h a ft " A N "
1 1 = C o n v e rte r
1 2 = W K (c o n v e rte r c lu tc h ) 9
1 3 = R e ta rd e r 4
1 4 = C lu tc h s h a ft K 4
1 5 = C o n v e rte r s a fe ty v a lv e
1 6 = C lu tc h s h a ft K 1
G E A R B O X D IA G R A M 46 230 803
5
K R
K V A N 1 6 8
K 2 K 4 1 5
E .I . 1 31 3 3 0 4 0 4 3
0 73 0 74 9 1 8 4 (O Z )
A B
A EH NL . 46 4 2 30 1 14 8
7
IN S T A L L A T IO N V IE W 6 W G -2 1 0 W IT H R E T A R D E R
F R O N T V IE W 1
T A B L E -3 A
1 = B re a th e r
2 = In p u t fla n g e D riv e v ia u n iv e rs a l s h a ft 2
3 = E m e rg e n c y s te e rin g p u m p 1 1
S = S u c tio n p o r t M 2 6 x 1 ,5
D = P r e s s u r e p o r t M 2 2 x 1 ,5
4 = O u tp u t fla n g e (c o n v e rte r-s id e ) 1 0
5 = M o d e l id e n tific a tio n p la te
6 = O il d r a in p lu g M 3 8 x 1 ,5
7 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k 9
(c o n v e rte r-s id e )
8 = B re a th e r lin e
9 = P re s s u re o il lin e fro m b e h in d th e c o n v e rte r to th e re ta rd e r v a lv e
( C o n n e c tio n s e e ta b le 3 B F ig .- N o .: 1 2 ) D
7 Z F
6 5
IN S T A L L A T IO N V IE W 6 W G -2 1 0 W IT H R E T A R D E R
S ID E V IE W 1 2 3 4 5
T A B L E -3 B
1 = In p u t fla n g e - d riv e v ia u n iv e rs a l s h a ft
6
2 = R e ta rd e r
3 = C o n v e rte r b e ll
4 = b re a th e r
5 = W K -V a lv e
6 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t
7 = E le c tro -h y d ra u lic c o n tro l
8 = O u tp u t fla n g e - re a r a x le (re a r-s id e )
7
9 = O il d r a in p lu g M 3 8 x 1 ,5
1 3
1 0 = O u tp u t fla n g e - fro n t a x le ( c o n v e rte r-s id e )
1 1 = E m e rg e n c y s te e rin g p u m p 1 2
1 2 = C o n n e c tio n P re s s u re o il lin e fro m b e h in d th e c o n v e rte r
= to th e re ta rd e r v a lv e
1 3 = C o n n e c tio n L u b ric a tin g o il lin e fro m th e h e a t e x c h a n g e r
v ia re ta rd e r v a lv e to th e tra n s m is s io n 8
1 1 1 0 9
IN S T A L L A T IO N V IE W 6 W G -2 1 0 W IT H R E T A R D E R
R E A R V IE W 1 2
T A B L E -3 C
1 1
3
1 = W K -V a lv e
2 = O il p re s s u re lin e fro m W K -V a lv e to th e W K
3 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t 1 0 4
4 = B re a th e r lin e W K
5 = P re s s u re o il lin e fro m in fro n t o f th e c o n v e rte r to th e re ta rd e r v a lv e
6 = E le c tro -h y d ra u lic c o n tro l
7 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0 5
8 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k
(re a r-s id e )
9 = O u tp u t fla n g e - re a r a x le (re a r s id e )
)
*
.
-
6
1 0 = O il p re s s u re lin e fro m c o n tro l u n it to W K -v a lv e + ,
1 1 = L iftin g lu g s
7 7
8
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H D IS K B R A K E A N D W IT H O U T W K 1
F R O N T V IE W
T A B L E -4 A
1 = L iftin g lu g s
2 = In p u t fla n g e D riv e v ia u n iv e r sa l sh a ft
2
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = E m e rg e n c y s te e rin g p u m p
S = S u c tio n p o r t M 2 6 x 1 ,5 8
D = P r e s s u r e p o r t M 2 2 x 1 ,5
5 = M o d e l id e n tific a tio n p la te
6 = O il d r a in p lu g M 3 8 x 1 ,5
7 = O u tp u t fla n g e (c o n v e rte r-s id e ) 3
7 = A tta c h m e n t p o s s ib ility fo r o il f ille r tu b e w ith o il d ip s tic k 3
(c o n v e rte r-s id e ) D
3 3
7
Z F
6 5
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H D IS K B R A K E A N D W IT H O U T W K
S ID E V I E W 1 2 3 4 5
T A B L E - 4 B
1 = In p u t fla n g e - d riv e v ia u n iv e rs a l s h a ft
2 = C o v e r
3 = C o n v e rte r b e ll
4 = b re a th e r
5 = O il fille r tu b e w ith o il d ip s tic k
6 = F ilte r h e a d
7 = E x c h a n g e f ilte r (Z F -fin e filte r)
8 = O u tp u t fla n g e w ith b ra k e d is k - re a r a x le (re a r-s id e )
6
9 = O u tp u t fla n g e - fro n t a x le ( c o n v e rte r-s id e )
1 0 = E m e rg e n c y s te e rin g p u m p
8
1 0
9
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H D IS K B R A K E A N D W IT H O U T W K
R E A R V IE W
T A B L E -4 C 8
1 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t 1
2 = O il fille r tu b e w ith o il d ip s tic k
3 = E le c tro -h y d ra u lic c o n tro l
4 = T ra n sm is s io n s u s p e n s io n h o le s M 2 0
5 = O u tp u t fla n g e w ith b ra k e d is k - re a r a x le (re a r-s id e )
6 = E x c h a n g e filte r (Z F - fin e filte r) 2
7 = F ilte r h e a d
8 = L iftin g lu g s 7
3
6
4 4
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N A N D W K 2 1
1
F R O N T V IE W
T A B L E -5 A
1 = L iftin g lu g s
2 = W K -V a lv e 3
3 = In p u t fla n g e D riv e v ia u n iv e rs a l s h a ft
4 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
5 = E m e rg e n c y s te e rin g p u m p
S = S u c tio n p o r t M 2 6 x 1 ,5
D = P r e s s u r e p o r t M 2 2 x 1 ,5
6 = M o d e l id e n tific a tio n p la te
7 = P n e u m a tic o r h y d ra u lic e n g a g e m e n t a n d d is c o n n e c tio n
4
8 = O il d r a in p lu g M 3 8 x 1 ,5 4
9 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k
(c o n v e rte r-s id e ) D
4 4
1 0
Z F
9 8 7 6
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N W IT H W K
S ID E V I E W 1 2 3 4 5
T A B L E - 5 B
1 = In p u t fla n g e - d riv e v ia u n iv e rs a l s h a ft
2 = C o v e r 6
3 = C o n v e rte r b e ll
4 = b re a th e r
5 = W K -V a lv e 7
6 = O il fille r tu b e w ith o il d ip s tic k
7 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t
8 = D is c o n n e c tio n P o w e r ta k e -o ff
8
9 = F ilte r h e a d
1 0 = E x c h a n g e filte r (Z F -fin e filte r)
9
1 1 = O u tp u t fla n g e - re a r a x le (re a r-s id e )
1 2 = O il d r a in p lu g M 3 8 x 1 ,5
1 3 = P n e u m a tic o r h y d ra u lic e n g a g e m e n t a n d d is c o n n e c tio n
1 4 = O u tp u t fla n g e - fro n t a x le ( c o n v e rte r-s id e ) 1 0
1 5 = E m e rg e n c y s te e rin g p u m p
1 5 1 1
1 4 1 3 1 2
IN S T A L L A T IO N V IE W 6 W G -2 1 0
W IT H IN T E R A X L E D IF F E R E N T IA L A N D W K
R E A R V IE W 1
T A B L E -5 C 2
1 = W K -V a lv e 1 4
2 = O il p re s s u re lin e fro m W K -V a lv e to th e W K 3
3 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t
4 = O il fille r tu b e w ith o il d ip s tic k 1 3
5 = L u b ric a tio n lin e P o w e r ta k e -o ff
6 = B re a th e r lin e W K 4
7 = E le c tro -h y d ra u lic c o n tro l
8 = O u tp u t fla n g e - re a r a x le (re a r s id e ) 1 2
9 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0 5
1 0 = E x c h a n g e filte r (Z F -fin e filte r)
1 1 = F ilte r h e a d
1 2 = D is e n g a g e m e n t P o w e r ta k e -o ff
1 1 A F 6
1 3 = P re s s u re o il lin e fro m in fro n t o f th e c o n v e rte r to th e re ta rd e r v a lv e B E
1 4 = L iftin g lu g s
1 0
C D
9 9
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H IN T E R A X L E D IF F E R E N T IA L A N D W K 2 1
F R O N T V IE W
1
T A B L E -6 A
1 = L iftin g lu g s
3
2 = W K -V a lv e
3 = In p u t fla n g e D riv e v ia u n iv e rs a l s h a f t
4 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
5 = A tta c h m e n t p o s s ib ility fo r E m e rg e n c y s te e rin g p u m p
6 = M o d e l id e n tific a tio n p la te
7 = E n g a g e m e n t a n d d is c o n n e c tio n in te ra x le d iffe re n tia l
P n e u m a tic o r h y d ra u lic 4 4
8 = O il d r a in p lu g M 3 8 x 1 ,5
9 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k
(c o n v e rte r-s id e )
1 0 = O u tp u t fla n g e (c o n v e rte r-s id e ) 5
4 4
1 0 Z F
9 8 7 6
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H IN T E R A X L E D IF F E R E N T IA L A N D W K
S ID E V I E W 1 2 3 4 5
T A B L E - 6 B
1 = In p u t fla n g e - d riv e v ia u n iv e rs a l sh a ft
2 = C o v e r
3 = C o n v e rte r b e ll
4 = b re a th e r
5 = W K -V a lv e
6 = F ilte r h e a d
7 = E x c h a n g e filte r (Z F -fin e filte r)
8 = O il fille r tu b e w ith o il d ip s tic k 6
9 = O u tp u t fla n g e - re a r a x le (re a r-s id e )
1 0 = O il d r a in p lu g M 3 8 x 1 ,5
1 1 = E n g a g e m e n t a n d d is c o n n e c tio n in te ra x le d iffe rtia l 7
p n e u m a tic o r h y d ra u lic
1 2 = O u tp u t fla n g e - fro n t a x le ( c o n v e rte r-s id e )
8
1 2 1 1 1 0
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H IN T E R A X L E D IF F E R E N T IA L A N D W K
R E A R V IE W 1 2
T A B L E -6 C
1 = W K -V a lv e 1 2
2 = O il p re s s u re lin e fro m W K -V a lv e to th e W K
3 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t 3
4 = E le c tro -h y d ra u lic c o n tro l
5 = B re a th e r lin e W K 1 1
6 = O il fille r tu b e w ith o il d ip s tic k
7 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
8 = O u tp u t fla n g e - re a r a x le (re a r s id e )
9 = E x c h a n g e filte r (Z F -fin e filte r) 4
1 0 = F ilte r h e a d
1 1 = P re s s u re o il lin e fro m in fro n t o f th e c o n v e rte r to th e re ta rd e r v a lv e
1 2 = L iftin g lu g s 1 0
5
A F
B E
C D
6
8
7 7
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N A N D W K -V A L V E
S ID E - M O U N T IN G 1
F R O N T V IE W
T A B L E -7 A 2
1 = L iftin g lu g s
2 = In p u t fla n g e D riv e v ia u n iv e rs a l s h a ft 1 0
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = E m e rg e n c y s te e rin g p u m p
S = S u c tio n p o r t M 2 6 x 1 ,5
D = P r e s s u r e p o r t M 2 2 x 1 ,5
5 = M o d e l id e n tific a tio n p la te
3 3
6 = P n e u m a tic o r h y d ra u lic e n g a g e m e n t a n d d is c o n n e c tio n
7 = O il d r a in p lu g M 3 8 x 1 ,5
8 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k 4
(c o n v e rte r-s id e )
9 = O u tp u t fla n g e (c o n v e rte r-s id e )
1 0 = W K -V a lv e
3 3
9
Z F
8 7 6 5
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N A N D W K -V A L V E
S ID E -M O U N T IN G 1 2 3 4
S ID E V IE W
T A B L E -7 B
5
1 = In p u t fla n g e - d riv e v ia u n iv e rs a l s h a ft
2 = C o v e r
3 = C o n v e rte r b e ll
4 = b re a th e r 6
5 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t
6 = D is c o n n e c tio n P o w e r ta k e -o ff
7 = F ilte r h e a d
8 = E x c h a n g e filte r (Z F -fin e filte r)
7
9 = O u tp u t fla n g e - re a r a x le (re a r-s id e )
1 0 = O il d r a in p lu g M 3 8 x 1 ,5
1 1 = E n g a g e m e n t a n d d is c o n n e c tio n in te ra x le d iffe re n tia l
P n e u m a tic o r h y d ra u lic 8
1 2 = O u tp u t fla n g e - fro n t a x le ( c o n v e rte r-s id e )
1 3 = E m e rg e n c y s te e rin g p u m p
1 3 9
1 2 1 1 1 0
IN S T A L L A T IO N V IE W 6 W G -2 1 0 S E P A R A T E IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N A N D W K -V A L V E
S ID E - M O U N T IN G 1
R E A R V IE W 1 4
2
T A B L E -7 C
1 = W K -V a lv e 1 3
2 = O il p re s s u re lin e fro m W K -V a lv e to th e W K
3 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t 3
4 = E le c tro -h y d ra u lic c o n tro l
5 = B re a th e r lin e W K
1 2
6 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
7 = A tta c h m e n t p o s s ib ility o il fille r tu b e w ith o il d ip s tic k 4
8 = O u tp u t fla n g e - re a r a x le (re a r s id e ) 1 1 A F
9 = E x c h a n g e filte r (Z F -fin e filte r)
1 0 = F ilte r h e a d
B E
5
1 1 = P re s s u re o il lin e fro m in fro n t o f th e c o n v e rte r to th e re ta rd e r v a lv e 1 0
C D
1 2 = L iftin g lu g s 6
8 8
9
IN S T A L L A T IO N V IE W 6 W G -2 1 0 D IR E C T IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N 2 1
F R O N T V IE W
T A B L E -8 A 1
1 = L iftin g lu g s
2 = W K -V a lv e 3
3 = D ia p h ra g m - d ire c t m o u n tin g
4 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
5 = E m e rg e n c y s te e rin g p u m p
S = S u c tio n p o r t M 2 6 x 1 ,5
D = P r e s s u r e p o r t M 2 2 x 1 ,5
6 = M o d e l id e n tific a tio n p la te
7 = P n e u m a tic o r h y d ra u lic e n g a g e m e n t a n d d is c o n n e c tio n
8 = O il d r a in p lu g M 3 8 x 1 ,5 4 4
9 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k
(c o n v e rte r-s id e ) D
1 0 = O u tp u t fla n g e (c o n v e rte r-s id e ) S
5
4 4
1 0 Z F
9 8 7 6
IN S T A L L A T IO N V IE W 6 W G -2 1 0 D IR E C T IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N
1 2 3 4
S ID E V I E W
T A B L E - 8 B
1 = D ia p h ra g m fo r d ire c t m o u n tin g
2 = C o v e r
3 = b re a th e r
4 = W K -V a lv e
5 = F ilte r h e a d
6 = E x c h a n g e filte r (Z F -fin e filte r)
7 O u tp u t fla n g e - re a r a x le (re a r-s id e )
8 = O il d r a in p lu g M 3 8 x 1 ,5 5
9 = P n e u m a tic o r h y d ra u lic e n g a g e m e n t a n d d is c o n n e c tio n
1 0 O u tp u t fla n g e - fro n t a x le ( c o n v e rte r-s id e )
1 1 = E m e rg e n c y s te e rin g p u m p
1 1 7
1 0 9 8
IN S T A L L A T IO N V IE W 6 W G -2 1 0 D IR E C T IN S T A L L A T IO N
W IT H A X L E D IS C O N N E C T IO N 1 2
R E A R V IE W
T A B L E -8 C 1 2
3
1 = W K -V a lv e
2 = O il p re s s u re lin e fro m W K -V a lv e to th e W K 1 1
3 = P o w e r ta k e -o ff; c o a x ia l; e n g in e -d e p e n d e n t
4 = E le c tro -h y d ra u lic c o n tro l
5 = B re a th e r lin e W K
6 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0 4
7 = A tta c h m e n t p o s s ib ility o il fille r tu b e w ith o il d ip s tic k
8 = O u tp u t fla n g e - re a r a x le (re a r s id e )
9 = E x c h a n g e filte r (Z F -fin e filte r) 1 0 A F
1 0 = F ilte r h e a d B E
5
8
6 6
7
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 6 W G -2 1 0 W IT H O U T W K
T A B L E -9
T h e m a r k e d p o s itio n ( e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n o n th e ta b le - 1 0 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n (a b o u t 8 0 ° - 9 5 ° C ) !
69 K
H J 49
G
57 A F 16 X
60
B E
15 34
53 55
C D 52/63
6
58 56
CODING
Legend:
WT = Heat exchanger
WGV = Converter back pressure valve 4,3+3 bar
WSV = Converter safety valve 11+2 bar CODING
HDV = Main pressure valve 16+2,5 bar
• Pressure regulator under voltage Engaged clutch
RV-9 = Pressure reducing valve 9±0,5 bar
Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
NFS = Follow-on slide Forward 1 • • K1 KV
D = Vibration damper 2 • • K4 K1
B = Orifice 3 • • KV K2
4 • • K4 K2
P1 = Proportional Valve – clutch KR 5 • • K3 KV
P2 = Proportional Valve – clutch K4 6 • • K4 K3
P3 = Proportional Valve – clutch K1 Reverse 1 • • KR K1
P4 = Proportional Valve – clutch K3 2 • • KR K2
3 • • KR K3
P5 = Proportional Valve – clutch KV Neutral
P6 = Proportional Valve – clutch K2 Engaged clutch K4 KR K1 K3 KV K2
Y1 – Y6 = Pressure regulator Position on valve block F E D C B A
Consec. No. Of measuring points 60 55 56 58 53 57
TEMP = Temperature sensor
UEDV = Pressure relief valve 40±5 bar
FDV = Filter pressure differential valve ∆p=5,5+3 bar
Page 1 from 2
K 4 K R K 1 K 3 K V K 2
F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D
Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S
R V -9
T E M P
H D V
K 6 5
V a lv e b lo c k
c o n tro l c irc u it
C o n v e rte r 1 9
5 1
F in e filte r
F ilte r g ra d e a c c o rd in g IS O 4 5 7 2 :
H W S V F D V ß 30 ³ 7 5 ß 15 = 2 5 ß 1 0 = 5 .0
6 3 5 2 S D u st c a p a c ity a c c o rd in g IS O 4 5 7 2 : m in . 1 7 g
L e g e n d : F ilte r a re a : m in . 6 7 0 0 c m 2
= M a in p rs s u re W G V 3 5
= C o n tro lle d m a in p re ss u re
= P ilo t p rs s u re 1 5
B y p a s s -v a lv e T ra n s m is s io n p u m p p = 1 6 + 2 b a r
= C o n v e rte r in p u t p re ss u re p = D 1 ,5 b a r m a x U E D V
Q p = 1 0 5 l/m in a t n = e n g in e 2 0 0 0 m in -1
= C o n v e rte r o u tp u t p re ssu re
1 6
= L u b ric a tio n C o a r s e f ilte r m e s h w id th : 0 ,8 0 0 m m
= R e tu rn flo w in to s u m p W T
(S c o p e o f s u p p ly c u s to m e r) o il s u m p
S c h m ie ru n g M a in o il c irc u it
P a g e 2 fro m 2
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 6 W G -2 1 0 W IT H W K
T A B L E -1 1
T h e m a r k e d p o s itio n ( e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n o n th e ta b le - 1 2 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n (a b o u t 8 0 ° - 9 5 ° C ) !
N o . D e n o m in a tio n o f th e p o s itio n C o n n e c tio n M a r k in g o n th e
v a lv e b lo c k 4 8 4 7 2 1
M e a s u r in g p o in ts fo r h y d r a u lic o il a n d t e m p e r a tu r e :
5 1 = I n fro n t o f th e c o n v e rte r - o p e n in g p re s s u re 1 1 + 2 b a r M 1 0 x 1 H
5 2 = B e h in d th e c o n v e rte r - o p e n in g p re s s u re 4 ,3 + 3 b a r M 1 4 x 1 ,5
5 3 = C lu tc h fo rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h re v e rs e 1 6 + 2 b a r K R M 1 0 x 1 E
5 6 = C lu tc h 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C lu tc h 1 6 + 2 b a r K 2 M 1 0 x 1 A
5 8 = C lu tc h 1 6 + 2 b a r K 3 M 1 0 x 1 C
6 0 = C lu tc h 1 6 + 2 b a r K 4 M 1 0 x 1 F
6 3 = B e h in d th e c o n v e rte r M 1 4 x 1 ,5
T e m p e ra tu re 1 0 0 ° C s h o rt-tim e 1 2 0 ° C
6 5 = S y s te m p re s s u re 1 6 + 2 ,5 b a r M 1 0 x 1 K
6 7 = W K -s h ift p re s s u re 1 5 + 1 b a r M 1 0 x 1
M e a s u r in g p o in ts fo r d e liv e r y r a te s :
1 5 = C o n n e c tio n to th e h e a t e x c h a n g e r 1 5
/16 1 2 U N -2 B 5 4
5
1 6 = C o n n e c tio n fro m th e h e a t e x c h a n g e r 1 /16 1 2 U N -2 B
I n d u c tiv e tr a n s m itte r -im p u ls e -s p e e d s e n s o r a n d s w itc h
6 = I n d u c tiv e tra n s m itte r n S p e e d o m e te r M 1 8 x 1 ,5
2 1 = I n d u c tiv e tra n s m itte r n T u rb in e M 1 8 x 1 ,5 3 4
3 4 = S p e e d se n so r n o u tp u t a n s p e e d o m e te r ---------
4 7
3 6
=
=
I
A x le d is c o n n e c tio n -in d ic a to r
n d u c tiv e tra n s m itte r n C e n tra l g e a r tr a in
M 2 7
M 1 8
x 1
x 1 ,5
6
4 8 = I n d u c tiv e tra n s m itte r n E n g in e M 1 8 x 1 ,5
5 4 = F ilte r c o n ta m in a tio n s w itc h M 1 4 x 1 ,5
C o n n e c tio n s :
5 = C o m p re s s e d a ir lin e fo r a x le d is c o n n e c tio n M 1 2 x 1 ,5
4 9 = P lu g c o n n e c tio n o n th e e le c to r-h y d ra u lic c o n tro l u n it
6 8 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 G
6 9 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 J
7 0 = E m e rg e n c y s te e rin g p u m p -p re s s u re lin e M 1 6 x 1 ,5
7 1 = E m e rg e n c y s te e rin g p u m p -s u c tio n lin e M 2 8 x 1 ,5 5 3 6 P a g e 1 fro m 2
VIEW X VIEW Y
65 51 68
69 K
H J 49
G
57 A F
16 X A F
60 B E
B E 15
34 C D
53 55 52/63
C D
6
58 56
CODING 67
• Pressure regulator under voltage Engaged clutch
Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
16
• •
Forward 1
2 • •
K1
K4
KV
K1 Y 15
3 • • KV K2
4 • • K4 K2 52/63
5 • • K3 KV
6 • • K4 K3
Reverse 1 • • KR K1 70
2 • • KR K2
3 • • KR K3
Neutral
Engaged clutch K4 KR K1 K3 KV K2
Position on valve block F E D C B A 71
Consec. No. Of measuring points 60 55 56 58 53 57
Page 2 from 2
OIL CIRCUIT DIAGRAM 6 WG-210 WITH WK
- FORWARD 1st SPEED –
TABLE-12
The marked positions (e.g. 53) correspond with the positions on the table-11 !
Legend:
WT = Heat exchanger
WK-V = WK-shift valve 15+1 bar CODING
WK-M = WK-solenoid valve
WGV = Converter back pressure valve 4,3+3 bar • Pressure regulator under voltage Engaged clutch
WSV = Converter safety valve 11+2 bar Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
Forward 1 • • K1 KV
HDV = Main pressure valve 16+2 bar 2 • • K4 K1
RV-9 = Pressure reducing valve 9±0,5 bar 3 • • KV K2
NFS = Follow-on slide 4 • • K4 K2
5 • • K3 KV
D = Vibration damper 6 • • K4 K3
B = Orifice Reverse 1 • • KR K1
P1 = Proportional Valve – clutch KR 2 • • KR K2
P2 = Proportional Valve – clutch K4 3 • • KR K3
Neutral
P3 = Proportional Valve – clutch K1 Engaged clutch K4 KR K1 K3 KV K2
P4 = Proportional Valve – clutch K3 Position on valve block F E D C B A
P5 = Proportional Valve – clutch KV Consec. No. Of measuring points 60 55 56 58 53 57
Page 1 from 2
K 4 K R K 1 K 3 K V K 2
F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D
Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S
R V -9
T E M P
H D V
K 6 5
V a lv e b lo c k
c o n tro l c irc u it
W K -M
W a n d le r W K
W K -V 5 1 1 9
F in e filte r
F ilte r g ra d e a c c o rd in g IS O 4 5 7 2 :
H W S V F D V ß 30 ³ 7 5 ß 15 = 2 5 ß 1 0 = 5 .0
6 3 5 2 S D u st c a p a c ity a c c o rd in g IS O 4 5 7 2 : m in . 1 7 g
6 7 F ilte r a re a : m in . 6 7 0 0 c m 2
L e g e n d :
= M a in p rs s u re W G V 3 5
= C o n tro lle d m a in p re ss u re
= P ilo t p rs s u re 1 5
B y p a s s -v a lv e T ra n s m is s io n p u m p p = 1 6 + 2 b a r
= C o n v e rte r in p u t p re ss u re p = D 1 ,5 b a r m a x U E D V
Q p = 1 0 5 l/m in a t n = e n g in e 2 0 0 0 m in -1
= C o n v e rte r o u tp u t p re s su re
1 6
= L u b ric a tio n C o a r s e f ilte r m e s h w id th : 0 ,8 0 0 m m
= R e tu rn flo w in to su m p W T
(S c o p e o f s u p p ly c u s to m e r) o il s u m p
S c h m ie ru n g M a in o il c irc u it
P a g e 2 fro m 2
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 6 W G -2 1 0 W IT H W K A N D
R E T A R D E R
T A B L E -1 3
T h e m a r k e d p o s itio n ( e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n o n th e ta b le - 1 4 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n (a b o u t 8 0 ° - 9 5 ° C ) !
Y 6 7 5 8 5 6
6 6
5 2 7 0
D
S
1 9
3 5 ) .
* -
5 4 + ,
X
7 1 3 4
Z F
P a g e 2 fro m 2
OIL CIRCUIT DIAGRAM 6 WG-210 WITH WK AND RETARDER
- FORWARD 1st SPEED -
TABLE-14
The marked positions (e.g. 53) correspond with the positions on the table-13 !
Legend:
WT = Heat exchanger
WK-V = WK-shift valve 15+1 bar CODING
WK-M = WK-solenoid valve • Pressure regulator under voltage Engaged clutch
WGV = Converter back pressure valve 4,3+3 bar Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
WSV = Converter safety valve 11+2 bar Forward 1 • • K1 KV
HDV = Main pressure valve 16+2 bar 2 • • K4 K1
3 • • KV K2
RV-9 = Pressure reducing valve 9±0,5 bar 4 • • K4 K2
RT = Retarder 5 • • K3 KV
RTV = Retarder valve 6 • • K4 K3
Reverse 1 • • KR K1
NFS = Follow-on slide 2 • • KR K2
LZD = Powershift interaxle differential 3 • • KR K3
LZDM = Powershift interaxle differential valve Neutral
D = Vibration damper Engaged clutch K4 KR K1 K3 KV K2
Position on valve block F E D C B A
B = Orifice Consec. No. Of measuring points 60 55 56 58 53 57
P1 = Proportional Valve – clutch KR
P2 = Proportional Valve – clutch K4
P3 = Proportional Valve – clutch K1
P4 = Proportional Valve – clutch K3
P5 = Proportional Valve – clutch KV
P6 = Proportional Valve – clutch K2
Y1 – Y6 = Pressure regulator
TEMP = Temperature sensor
UEDV = Pressure relief valve 40±40 bar
FDV = Filter pressure differential valve ∆p=5,5+3 bar
Page 1 from 3
K 4 K R K 1 K 3 K V K 2
F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D
Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S
R V -9
T E M P
H D V
K 6 5
V a lv e b lo c k
c o n tro l c irc u it
L Z D M
L e g e n d :
L Z D
= M a in p rs s u re
= C o n tro lle d m a in p re ss u re
= P ilo t p rs s u re
= C o n v e rte r in p u t p re ss u re
= C o n v e rte r o u tp u t p re ssu re
= L u b ric a tio n
= R e tu rn flo w in to s u m p P a g e 2 fro m 3
N o t s c o p e o f s u p p ly -Z F
p re s s u re a ire
W K -M
W K -V C o n v e rte r W K
5 1 1 9
F in e filte r
P re s s u re re d u c in g v a lv e l
W S V F D V F ilte r g ra d e a c c o rd in g IS O 4 5 7 2 :
4 b a r
H ß 30 ³ 7 5 ß 15 = 2 5 ß 1 0 = 5 .0
6 7 S D u st c a p a c ity a c c o rd in g IS O 4 5 7 2 : m in . 1 7 g
S o le n o id v a lv e 6 3 5 2 F ilte r a re a : m in . 6 7 0 0 c m 2
3 5
W G V
W T
B y p a s s -v a lv e l
(S c o b e o f s u p p ly c u s to m e r)
p =D 3 + 1 b a r
3 9
1 6 1 5
3 8
F illu n g P o s itio n
U E D V T ra n s m is s io n p u m p p = 1 6 + 2 b a r
Q p = 1 0 5 l/m in a t n = e n g in e 2 0 0 0 m in -1
R T V W ith R e ta rd e r
6 6
C o a r s e f ilte r m e s h w id th : 0 ,8 0 0 m m
W ith o u t R e ta rd e r
L u b ric a tio n
o il s u m p
3 7 3 6
R T
M a in o il c irc u it
P a g e 3 fro m 3
G E A R B O X D IA G R A M 6 W G -2 1 0
T A B L E -1 5
K 1 K R
K V A N
O p in io n d ire c tio n o f ro ta tio n
K 4
P u m p K 4
K 2
W K
K R
K 3 K 1
In p u t P o w e r ta k e -o ff
e n g in e -d e p e n d e n t
K V A B
C o n v e rte r
D ia g r a m C lu tc h e s
K 2 D r iv in g d ir e c tio n S p e e d C lu tc h
L e g e n d : F o rw a rd 1 K V /K 1
2 K 4 /K 1
M o u n tin g p o s s ib ib ility K V = C lu tc h fo rw a rd 3 K V /K 2
e m e rg e n c y s te e rin g p u m p
K 3 K R = C lu tc h re v e rse 4 K 4 /K 2
K 1 = C lu tc h 1 st sp e e d 5 K V /K 3
K 2 = C lu tc h 2 n d sp e e d 6 K 4 /K 3
K 3 = C lu tc h 3 rd sp e e d R e v e rse 1 K R /K 1
K 4 = C lu tc h 4 th s p e e d 2 K R /K 2
O u tp u t O u tp u t
A N = In p u t 3 K R /K 3
A x le d is c o n n e c tio n A B = O u tp u t
P O W E R F L O W 6 W G -2 1 0 -F O R W A R D S P E E D S -
T A B L E -1 6 1 st S P E E D 2 n d S P E E D 3 rd S P E E D 4 th S P E E D
K R K R K R K R
K V A N K V A N K V A N K V A N
G e a rb o x d ia g ra m
K 4 K 4 K 4 K 4
K 2 K 2 K 2 K 2
K 1
K 3 K 1 K 3 K 1 K 3 K 1 K 3 K 1
K 4
A B A B A B A B
K R
6 th S P E E D 5 th S P E E D
A N O p in io n d ire c tio n o f ro ta tio n
L e g e n d : K R K R
K V K V A N K V A N
= P o w e r flo w g e a r tra in
= G e a rs n o t m e s h in g
K 4 K 4
K 2 L e g e n d : D ia g r a m C lu tc h e s K 2 K 2
K V = C lu tc h fo rw a rd D r iv in g d ir e c tio n S p e e d C lu tc h
K R = C lu tc h re v e rse K 3 K 1 K 3 K 1
K 3 F o rw a rd 1 K V /K 1
K 1 = C lu tc h 1 st sp e e d
K 2 = C lu tc h 2 n d sp e e d 2 K 4 /K 1
K 3 = C lu tc h 3 rd sp e e d 3 K V /K 2
K 4 = C lu tc h 4 th s p e e d 4 K 4 /K 2
A B A B
A B A B
A N = In p u t 5 K V /K 3
A B = O u tp u t 6 K 4 /K 3
P O W E R F L O W 6 W G -2 1 0 - R E V E R S E S P E E D S -
T A B L E -1 7
1 st S P E E D 2 n d S P E E D 3 rd S P E E D
K R K R K R
G e a rb o x d ia g ra m K V A N K V A N K V A N
K 4 K 4 K 4
K 2 K 2 K 2
K 1
K 3 K 1 K 3 K 1 K 3 K 1
K 4
A B A B A B
K R
K V
K 2 L e g e n d : D ia g r a m C lu tc h e s
K V = C lu tc h fo rw a rd D r iv in g d ir e c tio n S p e e d C lu tc h
K 3 K R = C lu tc h re v e rse R e v e rse 1 K R /K 1
K 1 = C lu tc h 1 st sp e e d
2 K R /K 2
K 2 = C lu tc h 2 n d sp e e d L e g e n d :
3 K R /K 3
K 3 = C lu tc h 3 rd sp e e d = P o w e r flo w g e a r tra in
K 4 = C lu tc h 4 th s p e e d = G e a rs n o t m e s h in g
A B A B
A N = In p u t
A B = O u tp u t
E L E C T R O -H Y D R A U L IC S H IF T C O N T R O L W IT H P R O P O R T IO N A L V A L V E S
T A B L E -1 8
M a in p re s s u re v a lv e 1 6 + 2 b a r P re s s u re re d u c in g v a lv e 9 b a r
H o u s in g
P lu g (C a b le h a rn e s s )
A Y 6 Y 1 A
Y 5 Y 2
B B
Y 4 Y 3
C o v e r C o v e r
H o u s in g V a lv e b lo c k
S E C T IO N A - A
M a in p re s s u re v a lv e 1 6 + 2 b a r V a lv e b lo c k P re s s u re re d u c in g v a lv e 9 b a r
P lu g (C a b le h a rn e s s )
D u c t p la te In te rm e d ia te p la te
S E C T IO N B - B
P R O P O R T IO N A L V A L V E P 5
Y 5
V ib ra tio n d a m p e r
P re s s u re re g u la to r
F o llo w -o n s id e
6 W G -2 1 0 F U L L Y -A U T O M A T IC C O N T R O L U N IT E S T -3 7
C IR C U IT D IA G R A M - S T A N D A R D (6 0 2 9 7 1 7 0 3 9 )
T A B L E -1 9
IT E M L E G E N D IT E M L E G E N D
A 1 E L E C T R O N IC C O N T R O L U N IT T C U S 1 S W IT C H R E T A R D E R
A 2 C O N T R O L L E R S 4 S W IT C H K IC K D O W N (O P T IO N )
A 3 E L E C T R O H Y D R A U L IC O N T R O L U N IT 6 W G -2 1 0 S 5 S W IT C H R E Q U E S T E N G IN E B R A K E
A 5 D I A G N O S T IC IN T E R F A C E (P L U G ) S 1 0 S W IT C H F IL T E R C O N T A M IN A T IO N
A 6 D I S P L A Y S 2 8 S W IT C H P R E S E L E C T IO N D IF F E R E N T IA L L O C K
A 7 C A N -IN T E R F A C E (P L U G ) S 3 2 S W IT C H T R O U G H O N T O P *
A 9 S P E E D O M E T E R W IT H F R E Q U E N C Y D IV ID E R * S 3 4 S W IT C H D IS P L A Y IL L U M IN A T IO N *
B 1 S P E E D S E N S O R n E N G IN E Y 7 S O L E N O ID V A L V E W K
B 2 S P E E D S E N S O R n T U R B I N E Y 8 S O L E N O ID V A L V E R E T A R D E R
B 3 S P E E D S E N S O R n C E N T R A L G E A R T R A IN Y 9 S O L E N O ID V A L V E D IF F E R E N T IA L L O C K
B 4 S P E E D S E N S O R n O U T P U T
B 6 L O A D S E N S O R K 1 R E L A Y S T A R T E R IN T E R L O C K *
B 9 S E N S O R T E M P E R A T U R E - R E T A R D E R K 2 R E L A Y R E V E R S E D R IV E *
F 1 F U S E 7 ,5 A *
F 2 F U S E 7 ,5 A *
H 3 A C O U S T IC / O P T IO N A L W A R N IN G *
H 7 P IL O T L A M P R E S T R IC T E D G E A R R A N G E *
N O T E : * = S C O P E O F S U P P L Y C U S T O M E R
F 1
E
K l.3 0 K l.3 0
K l.1 5 K l.1 5
F 2
L
P
M
1 1 1 8 6
2 2 2
1 D 2
A
2 6 3
S 1 S 4 S 5 S 2 8 S 3 2 H 3 K 2 8 5 5
4
2
1
S 3
2 6 2 V P I
4 5 2 3 6 8
V P E 1 V P E 2 E D 1 0
2 1
E D 7
? ? 4 4
E D 8 E D 1 2
3 0
H 7
E D 9
6 6 5 2
A D M 1 E D 1 3 A D M 2
3 1 0 7
1 5
M N L 6 -p in
6 0 2 9 1 9 9 0 7 4
2
1 8
6
4
2
7
5
3
1
B 4 E F 4 S D D K
A 5 A M P J P T 8 -p in
1 8 4 6 0 2 9 1 9 9 1 0 8
0 4 E U P R
1 2 3 1
V M G 2 4 6
1
1
S u p e rs e a l 3 -p in
1 3 7
A U 1
2 4
2
S D 4 3 6
A 9 3 8 A 6
2 3 8
V P
6 0 2 9 1 9 9 0 7 1 B 6 3 2 4 E U 1
S D 1
1 4 4 1
V M G A 1
A D M 3 0 6
* K D 2 2 E D 7 A D M 4 5 7
6
F
N
4 3 E D 4
E D 6
A D M 8 3 3 S 3 4
6 4
A 2 T +
R 6 4 E D 5
E D 1
6 3 5 6 0 1
T - 6 5 E D 2 A IP 1 1 0 0 2 Y 1 K 4
* N -R e le a s e In te rlo c k
C h a n g e A u to m a tic
2 0 E D 1 1
E D 3
A 1 A IP
A IP
3
2 3 2
5 5
0 3 Y 2 K
Y 3 K
R
1
0 4
8 6 1 1 9 A IP 4 0 9 0 5 Y 4 K 3
E F 1 A IP 5 Y 5 K V
K 1 8 5
B 1 2 0 3
V M G 1 A IP 6
5 1
1 2
0 6
0 7 Y 6 K 2 A 3
* = O P T IO N A L V P S 1 1 3 V P S 1 (+ )
1 4 1 V P S 1 3 9 0 8
E F 2 E R 1 T E M P
B 2 2
6 8
4 5
2 3
2 2
V M G A 2 4 6 0 9
T E M P
4 9 1 2
1 E R 2 B 9
B 3 2 4 2
E F 3
6 8 -p in
6 0 2 9 1 9 9 0 6 3
1 7 3
1 2
5
E R 3 4
C A N _ H C A N _ L C A N _ T V G S 6 7 8 9
V M 1 V M 2 V P S 2 V P S 2 A D M 7 A D M 5 A D M 6
M in i T im e r
2 -p in 2 5 2 6 2 7 2 8 1 2 8 5 3 3 4 5 7 1 1
S 1 0 1 0 1 1 1 2 1 3
1 2 1 4 1 5 1 6
6 0 2 9 1 9 9 0 1 1 S u p e rse a l
1 1 2 -p in 1 2
6 0 2 9 1 9 9 0 4 5 K o s ta l 1 6 -p in
2 2 6 0 2 9 1 9 9 0 7 2
1 2 4 Y 7 Y 9
1
1 2
4
2
3
1 A 7 Y 8 2 K o s ta l M 2 7
2 -p in
J P T 4 -p in 6 0 2 9 1 9 9 0 0 3
6 0 2 9 1 9 9 0 7 6
K l.3 1 K l.3 1
P o le p a tte rn s a re c o rre s p o n d in g w ith th e p lu g s o n th e w irin g !
T W IS T E D L IN E S (3 0 W IN D IN G S /M E T E R ) F R O M A L E N G T H O F > 2 M E T E R S O N A L L R E L A Y S W IT H P R O T E C T IV E D IO D E S 1 A /4 0 0 V
B U S T E R M IN A T IO N IF P IN 2 6 A N D 2 7 A R E C O N N E C T E D
6 W G -2 1 0 F U L L Y -A U T O M A T IC C O N T R O L E S T -3 7
C IR C U IT D IA G R A M - C R A N E V E H IC L E (6 0 2 9 7 0 1 0 5 7 )
T A B L E -2 0
IT E M L E G E N D IT E H M L E G E N D
A 1 E L E C T R O N IC C O N T R O L U N I T E S T -3 7 K 1 R E L A Y S T A R T E R IN T E R L O C K A 2 .1 *
A 2 .1 C O N T R O L L E R D 7 (U N D E R C A R R IA G E U W ) K 1 .1 R E L A Y S T A R T E R IN T E R L O C K A 2 .2 *
A 2 .2 C O N T R O L L E R D 9 (U N D E R C A R R IA G E O W ) K 2 R E L A Y S T A R T E R R E V E R S E D R IV E *
A 3 E L E C T R O H Y D R A U L IC C O N T R O L U N IT 6 W G -2 1 0 K 7 R E L A Y R E L E A S E A L L -W H E E L S T E E R IN G (C R A W L E R )*
A 5 D IA G N O S IS
A 6 D IS P L A Y S 4 S W IT C H A L L -W H E E L S T E E R IN G (C R A W L E R ) *
A 7 C A N -IN T E R F A C E (P L U G ) S 1 1 S W IT C H C H A S S IS L O W E R IN G *
S 3 3 S W IT C H C H A N G E -O V E R O W /U W *
B 1 S P E E D S E N S O R n E N G IN E
B 2 S P E E D S E N S O R n T U R B IN E Y 7 S O L E N O ID V A L V E W K
B 3 S P E E D S E N S O R C E N T R A L G E A R T R A IN Y 9 S O L E N O ID V A L V E F R O N T A X L E *
B 4 S P E E D S E N S O R n O U T P U T
H 3 W A R N IN G B U Z Z E R T R A N S M IS S IO N *
F 1 F U S E 7 ,5 A *
F 2 F U S E 7 ,5 A *
N O T E : * = S C O P E O F S U P P L Y C U S T O M E R
F 1
(+ )
E
L
K L .3 0
(+ )
P
K L .1 5
F 2 S 1 1 1
1 1 1 8 6
2
S 3 3 H 3 K 2 K 7
M S 4
6 3
2 2 2 5 2
8 5 4 1
A
4 5 2 3 8 8 2 2 3 1 5 2 0 7
3
V P 1 V P E 1 V P E 2 E D 7 E D 1 3 A D M 1 A D M 2 M N L 6 -p in
B 4
S
1 2 3 2 6 2 E F 4 6 0 2 9 1 9 9 0 7 4
0 6
A D M 3 1 8 7
6 5
S u p e rs e a l 3 -p in 1
6 0 2 9 1 9 9 0 7 1 0 4 1 5 2 4 3
S D D K
2 V M G 2
1 1 8 4
A 5 A M P J P T 8 -p in
2 1
4 6
4 2 9 E D 1 1
2 4
6 0 2 9 1 9 9 1 0 8
V 2
3
A 2 .2 N
5
6
4 4
6 6
E D 8
E D 9
R 4
1 8 6 S D 1
1 4 11
A 6
1 2 2
E D 2 V P K 1 .1
8 5 A 1 A IP 1
5 6 1 Y 1 = K 4
3
1 0 2 Y 2 = K R
4 A IP 2 3 2 3 Y 3 = K 1
A D 4 V 4 3 E D 4
1 0 A IP 3 5 5 4 Y 4 = K 3
A D 7 N 6 7 E D 6
6 A IP 4 9 5 Y 5 = K V
A 2 .1 A D 5 R
7
6 4
6 3
E D 5 A IP 5 5 1 6 Y 6 = K 2
A D 1
A D 2
B 1
B 2
8 6 5
E D 1
E D 2
A IP
V P S
6
1
1 2
1 3
7 V P S 1 )+ ) A 3
9 2 0
A D 3 B 3 E D 3 V P S 1
1 9 3 9 8 T E M P
V M E F 1 E R 1 4 6 9 V M G A 2
1 8 6
B 1 2 2
V M G A 2
3
1
4
2
5
4 1 E F 2 6 8
4 5
6 7 8 9
B 2
2 3
1 0 1 1 1 2 1 3
8 5
K 1 4 2 E F 3
6 8 -p in 1 4 1 5 1 6
B 3 0 3 V M G 1
6 0 2 9 1 9 9 0 6 3
K o s ta l 1 6 -p in
6 0 2 9 1 9 9 0 7 2
V G S C A N F _ H C A N F _ L V M 1 V M 2 A D M 6 V P S 2 A D M 7
M in i T im e r 2 8 2 5 2 6 0 1 0 2 5 3 3 4
2 -p in
6 0 2 9 1 9 9 0 1 1 1 2
1 1
1 2
4 1 2
Y 9 Y 7 K o s ta l M 2 7
2 -p in
2 2
4 3 6 0 2 9 1 9 9 0 0 3
2 1
J P T 4 -p in A 7
6 0 2 9 1 9 9 0 7 6
(-)
T W IS T E D L IN E S (3 0 W IN D IN G S /M E T E R ) F R O M A L E N G T H O F > 2 M E T E R S O N
P o le p a tte rn s a re c o rre s p o n d in g w ith th e p lu g o n th e w irin g !
A L L R E L A Y S W IT H P R O T E C T IV E D IO D E S 1 A /4 0 0 V
B U S T E R M IN A T IO N IF P IN 2 6 A N D 2 7 A R E C O N N E C T E D
CONTROLLER VTS-3
TABLE-21
FUNCTIONAL KNOB
V N R
CIRCUIT DIAGRAM CONTROLLER CODING CONTROLLER
RT/5 POSITION
ED1
2 +/VP V R N T+ T- KD/E
AD1 T+ •
S1 AD2 T- •
FUNKTION
WS/10
SWITCH
AD6
5 AS/N AD4 V •
AD5 R •
S2 AD6 AS/N •
SW/6 AD8 KD/E •
AD4
S3 4 V, F
VI/4
AD5
6 R
S6
GR/3
AD8
10 KD/E
S5
+
+
+
R
V
N
GE/2
AD2
-
-
-
8 T-
X1
PUSHBUTTON SWITCH D7 CONNECTION DIAGRAM CONTROLLER
TABLE-22 CODING
E (+)
PL
POSITION
(+)
R N D 3 2 1
3 2 AD1 B1 • • •
ED1 VP
• • •
M D7
AD1
AD2
7
8
9
AD2
AD3
B2
B3 •
S A N
1 2 3 D N R
H1
AD3
AD4
AD5
ED2
4
6
12
A1 AD4
AD5
AD6
V
R
AS
•
•
• • • •
K6 K8
(-)
D7 = PUSHBUTTON SWITCH D7
A1 = ELECTRONIC CONTROLLER UNIT TCU
K6 = STARTER INTERLOCK
1 = 1st SPEED FORWARD
2 = 2nd SPEED FORWARD K7 = NEUTRAL CIRCUIT DIAGRAM CONTROLLER
3 = 3rd SPEED FORWARD K8 = REVERSING LIGHT
D = AUTOMATIC H1 = LIGHTING 12 12 12
ED2
N = NEUTRAL R5 2 2 2
VP
R = REVERSE A
1 5
R 2 4 6 8 11 11 11
6 6 6
AD8
H1
3 3 3
AD5
1 5
ED1
N 2 4 6 8 5 5 5
10 10 10
AD6
H2 AD7
R1
1 5
D 2 4 6 8
V1
4 4 4
7 7 7
AD4
H3 AD1
1 5 R2
3 2 4 6 8
V2
H4
5 1 R3
2 6 8 2 4 V3
8 8 8
H5 AD2
1 R4
5
1 2
4 6 8 V4
9 9 9
H6 AD3
Z 1 1 1
VM