02 Transmission System LG958L PDF

LG958L Training material
Chapter IV ZF Transmission
Tuesday, May 19, 2015
1 RELIABILITY IN ACTION
CONTENTS
Structure and Principle of Torque Converter
Structure and Principle of Transmission
Oil Supply and Lubrication System of ZF Transmission
Electric Control System of ZF Transmission
Operation and Maintenance of ZF Transmission
Common Malfunctions and Troubleshooting of ZF

Transmission
Section I Structure and Principle of Torque Converter
2 3 4 5
Figure 4-1 Diagram of Transmission System for LG958L Loader

1. Torque converter 2. Rear drive axle 3. Transmission 4. Drive shaft 5. Front drive axle
The hydraulic torque converter is installed between the engine and transmission
and is mainly function to change the torque outputted by the engine so that the
torque output of the turbine will probably exceed the input torque of engine via
pump impellor so as to improve the power performance of loader and ensure the
stable transmission.
Figure 4-2 Internal Structure Diagram of ZF Torque Converter
Torque converter: It’s mainly composed of pump impellor, turbine, idler pulley
(commonly referred to as three-element part.), and housing and it’s capable of
automatically regulating the torque output and speed output of the engine.
Pump impellor Turbine
Guide pulley
Working principle of torque converter: Some blades are uniformly arranged within each working
impellor of the torque converter. These blades work together with each other to form an
enclosed annular space, in which the fluid can recirculate. When the engine flywheel drives the
rotation of pump impellor, the blades of the pump impellor drives the rotation of fluid. Under the
action of the centrifugal force, the fluid flows from the inner edges of blades to the outer edges
to impact the turbine blades and drive the rotation of turbine for torque output. The flowing fluid
flows from the outer edges of blades to the inner edges of blades within the turbine to impact
the blades of guide pulley and then returns to the pump impellor along the blades of guide
pulley for next cycle. The torque conversion of the hydraulic torque converter is attributed to the
presence of guide pulley. The guide pulley is connected with the torque converter housing via
fixed guide pulley seat and the torque converter is connected with engine flywheel via elastic
plate.
Section II Structure and Principle of Transmission
1. Characteristics of ZF transmission:
● 4 forward gears and 3 reverse gears
● High working efficiency
● Low repair rate
● Ultra-long service life
● Low fuel consumption
● Low noise
Structural diagram of ZF
transmission
Connecting
flange with
2. Structure of ZF
torque converter
and engine
transmission
The ZF transmission is
ZF mainly composed of
electronic control units
transmission
Torque
(gearshift operating
converter
lever, electric control

ZF box, and gearshift
transmission valve) and mechanical
gearshift transmission
Transmission
(6 clutches and drive

gears and output
ZF transmission
Gearshift shaft).
operating lever
ZF transmission
Rear view of transmission
1 power
st
1 power
st 2 power
nd
takeoff port takeoff port takeoff
Oil filter port
Clutch K1
Clutch KV
Optional
emergency
Clutch KR pump port
Output speed
sensor
Clutch K2 Clutch KV
Transmissio
n filler port
Clutch K3
Removed part
Output on right side of
Clutch K4 flange, fitted transmission
with parking
brake
Press once KD button
Use of KD button function of ZF transmission in actual applications
M4 Oil pipe to two-
Electric control box of ZF Gearshift valve of ZF transmission stage pressure pilot
control valve
transmission (including pressure measuring point)
1Mpa
reducing valve
Clutch K3
Two-stage
pressure control
valve
System
pressure
Clutch K1
During electric welding of Solenoid valve Clutch K2 Reverse K4 clutch Forward

main unit for repair, unplug (resistance: 90±10Ohm) clutch KR clutch KV
the connector of electric
control box
Clutch
KV
Clutch
K1
Power
drive
gear
Clutch KV and K1 of ZF transmission Schematic diagram of clutch
Clutch KV and K1 of ZF transmission
Clutch KR and K2 of ZF transmission
Clutch K3 and K4 of ZF transmission
The travel for pistons of various clutches is 1.8~2.4mm.
The axial clearance is 0.1~0.3mm after assembly of various shafts.
3. Route diagram for various gears of ZF transmission
Internal structural diagram of ZF transmission Route diagram for various gears of ZF transmission
(4 forward gears and 3 reverse gears)
1st forward
Output gear
Route diagram for various gears of ZF transmission (4 forward gears and 3 reverse gears)
3rd forward
2nd forward
Output gear
Output gear
4th forward 1st

Output reverse
Countershaft
Output gear
gear
2nd reverse 3rd reverse

Output gear Output gear
Section III Oil Supply and Lubrication System of ZF Transmission
Oil recirculation schematic diagram of transmission with two-stage pressure control valve
Cast aluminum gearshift control valve with 5 solenoid valves and two-stage pressure control valve
Section IV Electric Control System of ZF Transmission
1. ZF built-in electric system
1. Electric control
box EST-17T
2. Transmission
3. Gearshift
operating lever
DW-2
4. Connecting port to
circuits of
complete machine
5. To transmission
solenoid valve
6. To output speed
sensor
2. ZF built-in harnesses and connectors
Gearshift operating Yellow Cable electric control

Blue
lever connector Purple box connector
Sensor 2 (I)
Red
Grey Green
Lever 5
Black
Pink
Sensor 1
Complete machine wire connector
Solenoid valve connector
Lever 7
Lever 8
Lever 9
Lever 10
Lever 4
Lever 6
Lever 2
Starter interlocker 584
Pressure switch 600
3. ZF peripheral electric system
To electric control box
Intermediate
Intermediate relay relay
Intermediate relay (starter interlocker) (reversing)
(power cutoff)
Parking brake indicator switch
To starter relay To brake

signal terminal lamp
To starter relay terminal G2
Brake switch (left) To instrument panel electric control
box working indicator
To brake lamp
Brake switch (right)
4. Gear selector
The gear selector is the gear signal input device of the ECU. Its normal
functioning directly influences the normal functioning of the system. Use
the multimeter for measurement and judgment.
KD button ● Neutral start interlocking

function
● Neutral locking function.
Rotate the red neutral
Lock direction gear locking switch.
● Power cutoff function
during braking at 1st gear
or 2nd gear.
● Kick-down function (KD
button)
Neutral gear locking switch
Gearshift operating lever of ZF transmission
• The continuity and logic relationships between the red wire in the harness
of gear selector and other wires and various gears are as below:
With red FI F2 F3 F4 R1 R2 R3
Blue √ × × √ √ × ×
Green × × √ √ × × √
Black √ √ √ √ √ √ √
Yellow √ √ √ √ × × ×
Grey × × × × × × ×
Pink × × × × √ √ √
Purple × × × × × × ×
If the grey wire is under continuity state, the complete machine can’t be started. The purple
is the KD function, the pink is the control of reverse gear, and the yellow is the forward gear.
5. Electric control box
• As the main control part for judgment of gear, the electric control box analyzes the
signal of selector and issues command to the solenoid valve.
6. Gearshift valve
The gearshift valve is the actuator unit that engages and disengages the
control gear of the solenoid valve as per the command of ECU.
1) Sequence of solenoid valve: 4, 3, 5, 2, and 1 from top to bottom.

2) If the O-ring is not properly seated, it will easily cause oil leakage at
side cap.
3) The resistance of solenoid valve is 90±10Ω.
Clutch for
KV K1 K2 K3 K4 KR
various gears
Control M2 and
M3 M4 \ M5 M1
solenoid valve M4
7. Speed sensor
Transmission speed sensor
• Resistance of speed sensor:

1020±100Ω
Section V Operation and Maintenance of ZF Transmission
1. Operation Precautions
(1) To check the transmission oil level, the engine shall idle run (at approximate
1,000r/min) and the oil temperature shall be at normal working temperature.
(2) When the oil temperature is at 40ºC, the oil level shall be between the middle
mark and lower mark of the oil dipstick.
When the oil temperature is at 80ºC, the oil level shall be between the middle
mark and upper mark of the oil dipstick.
Hot oil level zone
Cold oil level zone

(3) Periodically replace the transmission oil and replace the filter strictly as per the
maintenance schedule.
(4) Before starting the engine, ensure that the operating lever is at neutral gear.
(5) Before starting up the machine each time, release the parking brake.
(6) When it's necessary to hoist the transmission to fit the engine with transmission or
separate the engine from the transmission, avoid the fall-off of the torque converter.
(7) While parking the machine, the gearshift operating lever shall be at neutral gear.
(8) The normal working oil temperature shall be within 80~110ºC. Under heavy load, the oil
temperature is allowed to rise to 120ºC for a short time. Pay special attention to the
controlling oil pressure of the transmission. Upon detection of any abnormality in the
transmission during operation, immediately stop the machine for checking.
(9) When the electric welding is required for repair in event of the machine malfunction, make
sure to disconnect the cable connector from the EST – electronic control unit (to cut off
the current to the electronic control unit), or the impact current during the electric
welding will probably burn out the electronic control unit.
2. Operations
(1) Preparations and maintenance before driving
• Before the operation of the transmission, make sure to add an
appropriate amount of lubricating oil as per the specified specification
of lubricating oil. While adding oil to the transmission for the first
time, make sure to take into consideration that the oil radiator, filter,
and connecting pipeline must be fully filled with oil. Therefore, the
lubricating oil amount to be added for the first time will be much
more than the lubricating oil amount to be added during normal
maintenances.
• The oil level can be checked only when the operating level is at
neutral gear. While checking the oil level, insert the oil dipstick to the
dead end of the dipstick tube. While cleaning the filter of main oil line,
pay attention to prevent the ingress of dirt and sediments into the oil
circuit. Therefore, place a cover plate to guard the parking brake
against being dipped by the oil.
• While installing the filter, pay attention not to tighten excessively.
(2) Driving and gearshift
• To start the engine, make sure that the gearshift operating lever is at neutral gear.
For the purpose of safety, before starting the engine, the parking brake shall be
under braked state to prevent the startup of machine due to the start of engine. After
the engine is started, release the parking brake, select the driving direction and gear,
and depress the throttle slowly to start up the machine. During the traveling of the
machine, the torque converter substitutes the function of main clutch. When the road
condition is good, it‘s possible to travel at higher gear.
• If the machine stops traveling, but the engine is still running and the transmission is
shifted to a gear other than neutral gear, the engine will not stop at that time. On a
straight road, the machine will probably crawl, as the idling of engine will generate a
certain traction force via the torque converter. The appropriate method is to place
the parking brake at braked state whenever the machine is parked.
• To park the machine for a long period, make sure to shift the operating lever to
neutral gear. During the traveling of the machine, make sure to release the parking
brake. Due to the influence of the torque converter, while shifting from a high speed
gear to a low speed gear, the engine speed will increase, especially at the time of
gear jump. Therefore, whenever the condition permits, while shifting from a high
speed gear to a low speed gear, depress the foot brake for slow deceleration before
the gearshift. When the machine is traveling at high speed or changing driving
direction, lower the engine speed.
(3) Driving and gearshift
• The maximum oil temperature at outlet of torque converter shall not exceed 120ºC.
For non-malfunctioned control subassembly and transmission with sufficient
traveling mileage, the temperature shall not be too high. If the oil temperature
exceeds 120ºC, make sure to stop the machine and check for presence of external
oil leakage. At the same time, shift the transmission to neutral gear and run the
engine at 1,200~1,500rpm. In such case, the oil temperature will lower rapidly to
the normal value (approximate within 2~3min). If the oil temperature fails to drop,
certain portion within the system is malfunctioned. Make sure to resolve the
malfunction before proceeding the operations.
• Normal range for gearshift oil pressure: 1.6~1.8MPa (16~18bar). To monitor the
control pressure, make sure to install a pressure gauge or pressure monitoring
unit. If the pressure drops to below the specified minimum pressure after a certain
gear is engaged and the clutch is depressed (though the pressure at moment of
gearshift will drop automatically temporarily), make sure to resolve the cause of
pressure drop. The under-low control pressure will lead to damage of clutch, as the
clutch is short of sufficient contact pressure and the continual skid of friction plate
leads to over-heating.
3. Maintenance
(1) Check the oil level.
- Park the machine on a level place.
- Shift the gearshift operating lever of the transmission to neutral gear “N” and
set the parking brake at braked position.
- Idle run the engine at approximate 1,000r/min.
- Counterclockwise the oil dipstick and take out and wipe clean the oil dipstick.
- Insert the oil dipstick into the oil dipstick tube and tighten to place. Wait for 3s
and take it out (measure for at least two times).
- When the oil temperature is at 40ºC, the oil level shall be between the middle
mark and lower mark "Cold” of the oil dipstick.
- When the oil temperature is at 80ºC, the oil level shall be between the middle
mark and upper mark "Hot” of the oil dipstick.
Caution: Checking the oil level under cold state is to ensure sufficient
recirculation flow for transmission and torque converter and the decisive criterion
for oil level is to meet the oil level requirement under hot state.
•
(2) Replace the oil.
Make sure to replace the oil for the first time after the machine is working
for the first 100 hours. Afterwards, replace the oil once every 1,000 working
hours or once a year. At the replacement of oil, park the vehicle at a level
place. Under the working temperature of the transmission, take out the oil
drainage plug and seal ring and fully drain the used oil.
- Start the engine and idle run the engine.
- Shift the transmission operating lever to neutral gear “N”.
- Add oil to the upper mark of the oil range “Cold”.
- Set the parking brake at safe place.
- Shift to every gear for once.
- Check the oil level and when necessary add the oil.
Initial oil Normal oil Checking of oil

Part Name Oil specification
replacement replacement level
At interval of Mobil Delvac 1300
After 100 1,000 working SAEl5W40 or Titan Before
Transmission working hours. hours, but no universal oil HD15W-40 operation each
(4WG200) Replace filter more than 1 year. (manufactured by day
as well. Replace filter as Shanghai Desi Oils Co.,
well. Ltd.)
(3) Replace oil filter.
Make sure to replace ZF fine filter at the replacement of oil
each time. Replace as per the following requirements:
- Apply a thin film of oil onto the seal ring.
- Push in the filter, till it comes into contact with the sealing
surface on the transmission, and then tighten for approximate
1/3~1/2 turn with hand.
- Add oil.
- Start the engine.
- Idle run the engine (at approximate 1,000r/min). When the
transmission oil temperature reaches working temperature,
check the transmission oil level.
- Check whether the filter is tightened. If necessary, tighten again
with hand.
(4) Assembly precautions for ZF transmission:
I. Fitting and connection between ZF transmission and engine
1. Wipe clean the anti-rusting oil from the engine flywheel and the inside of
flywheel housing to be fitted.
2. Place the transmission at the fitting station and disassemble the fixing wood
plate from the torque converter middle flange on the transmission (It's
absolutely prohibited to slide outward the torque converter and its middle
flange).
3. While fitting and connecting the transmission with engine, without moving the
transmission, fit the flywheel housing of engine with the torque converter
connecting housing on the transmission and ensure that the middle flange of
torque converter enters into the junction surface of the engine flywheel.
Fall-off of torque
converter
4. Completely fit and fix the connecting housing of torque converter and
flywheel housing of engine with three bolts and then tighten the connecting
bolts of torque converter middle flange and engine flywheel in turn.
5. Finally tighten all connecting bolts of torque converter connecting flange and
engine flywheel housing.
6. Through the square observation port on the connecting housing of the
torque converter, check the connecting elastic plate between torque
converter and its middle flange for presence of squeezed deformation
(Under normal status, the plane of elastic plate shall be perpendicular to the
axis of middle flange).
7. Control size for connecting the connecting housing of transmission with
engine flywheel housing: 39.6±0.5.
II. Precautions for installation from transmission and radiator oil pipe
The tightening depth for the connection between pipe connector and
transmission shall not come into contact with the core of the backpressure valve.
If the insertion depth exceeds 21mm, it will cause working failure of the
backpressure valve due to blockage of core and obstruct the recirculation oil line
between transmission torque converter and radiator so that the working oil of the
torque converter can’t be sufficiently recirculated for heat radiation to cause
over-high oil temperature of the torque converter.
III. Installation of torque converter temperature sensor
1. While installing the temperature sensor at the oil temperature measuring
point of the torque converter, upon detection that the top of the sensor is
pushed against the core of backpressure valve, do not forcibly screw in the
sensor. Please timely notify the technician to solve the malfunction, in order
to prevent the damage of sensor and valve core due to interference.
IV. Fluid within side cap of gearshift operating valve

1. After the engine is started, a part of oil in the gearshift operating oil system
will overflow and return to the tank via the oil line within the side cap of the
gearshift operating valve. Therefore, when the side cap is opened during the
running of the engine, the oil will spray from the valve body. Therefore, while
installing the side cap, make sure properly seat the O-ring of side cap and
clamp the hoop to the required place, in order to prevent the so-called valve
leakage symptom.
2. Do not open the side cap of gearshift operating valve at will.
V. Speed sensor
1. The gap between the end of speed sensor and the tooth top of gear is
0.5~0.8mm. The disassembly of sensor without prior consent and the
incorrect installation will lead to damage of the sensor.
Do not disassemble the speed sensor without prior consent.
2. The service personnel is disallowed to add or remove the adjustment
washer at the time of assembly.
Speed
sensor
VI. ZF cables
1. While arranging the cables, ensure that the cables at all positions
are free of friction with any other part.
2. The cables at all positions shall be correctly fixed.
VII. Electric control box

1. At the time of electric welding, unplug the connector of electric
control box to disconnect the electric control box from circuits and
prevent the burnout of electric control box.
2. Guard the electric control box against moisture and rainfall.
Section VI Cause Judgment and Troubleshooting
for Common Malfunctions of ZF Transmission
1. No gear, though the complete machine can be started.

Check oil level
Check the cable for presence of worn damage.
Check the connectors and fuses
Check whether the power voltage is at a stable normal value.
Check the parking brake for normal functioning.
Check for normal power connection between engine and torque
converter.
Check for normal gearshift oil pressure.
Check for normal functioning of gearshift operating lever.
Check for normal functioning of solenoid valve.
2. No 3rd gear or 4th gear is available, though the 1st gear and
2nd gears are available in complete machine.
» Check oil level
» Check cable connectors for normal connections.
» Check cables for worn damage.
» Check speed sensor for normal functioning.
» Check lever for normal functioning.
3. No 1st gear or 2nd gear is available, though the 3rd gear and
4th gears are available in complete machine.
» Check the cables for normal connection.
» Check pressure sensor for normal functioning.
4. Noise of transmission
» Check oil level
» Check the connecting bolts between transmission and frame
and engine for presence of looseness.
» Check the drive shaft and its support for normal functioning.
» Check the hydraulic pump for abnormality.
» Check the articulations for normal functioning.
5. Weak complete machine
» Check oil level
» Check whether the gearshift pressure is at 1.6~1.8MPa.
» Check for normal power of engine.
» Check the oil for improper trademark, deterioration, and
presence of air bubble.
THE END

02 Transmission System LG958L PDF

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LG958L Training material

Tuesday, May 19, 2015

Structure and Principle of Torque Converter

Structure and Principle of Transmission

Oil Supply and Lubrication System of ZF Transmission

Electric Control System of ZF Transmission

Operation and Maintenance of ZF Transmission

Common Malfunctions and Troubleshooting of ZF

Figure 4-1 Diagram of Transmission System for LG958L Loader

lever, electric control

(6 clutches and drive

Use of KD button function of ZF transmission in actual applications

During electric welding of Solenoid valve Clutch K2 Reverse K4 clutch Forward

Clutch KV and K1 of ZF transmission Schematic diagram of clutch

4th forward 1st

2nd reverse 3rd reverse

Gearshift operating Yellow Cable electric control

To electric control box

Parking brake indicator switch

To starter relay To brake

KD button ● Neutral start interlocking

Gearshift operating lever of ZF transmission

1) Sequence of solenoid valve: 4, 3, 5, 2, and 1 from top to bottom.

Transmission speed sensor

• Resistance of speed sensor:

Hot oil level zone

Cold oil level zone

Initial oil Normal oil Checking of oil

IV. Fluid within side cap of gearshift operating valve

VII. Electric control box

1. No gear, though the complete machine can be started.

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