TRANSMISSION on

-7(A) WHEEL LOADERS

- HHIE - - Instructor: P. Everaerts - A/S Dept. - - JANUARY 2009 -

 CONTENT

PAGE

1 OVERVIEW 2
2 ELECTRONIC CONTROL SYSTEM 5
3 OPERATING MODES OF EST37 8
4 SECTIONAL VIEW 9
5 INSTALLATION VIEW 10
6 HYDRAULIC CIRCUITS 11
7 TRANSMISSION MEASURING POINTS 13
8 ELEC.HYDR. CONTROL BLOCK + FILTER PR. REMARK 75
9 AEB PROCEDURE 21
10 DATA TRANSMITTERS & PROPORTIONAL VALVES 24
11 “Zf” electric functioning 27
12 PARKING / DECLUTCHING / RIDE CONTROL SIG. 32
13 ZF ERROR CODES LIST 35

Arranged by Pieter Everaerts Tel 0032 (0)14 56 22 44

Instructor HHIE Fax 0032 (0)14 56 22 65
page 1
1. OVERVIEW
Zf full automatic ERGOPOWER transmissions

HL730-3 HL740-3 HL757-7(A)

(#848~)
HL730-7(A)
HL740-7(A)

HL760-3 HL770-3 HL780-3

(#1302~) (#1171~) (#141~)

HL760-7(A) HL770-7(A) HL780-7A

C page 2
ZF SYMBOLS (DISPLAY):

C page 3
ZF SYMBOLS TRANSMISSION WARNING

((LH)) There is a failure in the transmission system,

y
causing limitations for TCU: see p.8 for more
information

* * Transmission temp
temp. is lower then -12
12 °C
C

Transmission temp. (control valve) is too high

WS (corresponding transm. error code: B7)

Transmission temp. (convertor exit) is too high

WT T > 105 °C
(corresponding transm. error code: C3)

Transmission
temp sender 49120 Ohm ± 4.0% (at 25degree)
at convertor 6120 Ohm ± 2.0% (at 80degree)
exit 3300 Ohm ± 1.5% (at 100degree)
1886 Ohm ± 2.0% (at 120degree)
(CD-15 Æ
Part
a t nr (Measuring Condition : current ≤ 1 mA)
HL730-7 0501-317-655
~HL770-7) (HL730-7~HL770-7)

Grad C Ohm Grad C Ohm

Transmission
temp sender -46.0 537.5 77.3 1433.3
in control -9.2 755.4 89.7 1556.9
valve box 15 4
15.4 921 4
921.4 103 8
103.8 1689 3
1689.3
27.7 1011.8 118.0 1831.5
(see pict. on Part nr 40.1 1107.6 132.1 1984.6
page 18) ZGAQ-00633
52.5 1209.4 146.3 2150.0
64.9 1317.7

C page 4
2. ELECTRONIC CONTROL SYSTEM

EST37
Zf CONTROL UNIT

TURBINE SPEED
HL757-7, HL760-7 HL770-7 (≈HL780-7A)
(≈HL730-7, HL740-7)

C page 5
 (1)

(2)

OPERATION

In automatic mode are 2 settings possible (mode 1 or

mode 2) . Refer to cluster-menu for activating the
prefered setting)

AUTOMATIC SHIFT: CHOOSE BETWEEN MODE 1 & 2:

MODE 1 AUTOMATIC SHIFT RANGE = [1 <--> 4 GEAR]

MODE 2 AUTOMATIC SHIFT RANGE = [2 <--> 4 GEAR]

page 6
 (or quick shift) KICK DOWN SWITCH (OR QUICK SHIFT)

The kick down switch can be programmed in 2 ways (mode 1 or mode 2) . QUICK SHIFT FUNCTION : CHOOSE BETWEEN MODE 1 & 2:
Refer to page 6 for activating the prefered setting)
MODE 1 PUSHING QUICK SHIFT BUTTON RESULTS

Pushing the switch results in linking PIN ED7 of the transmission controller to ALWAYS IN SHIFTING DOWN: 2 --> 1
the ground.
MODE 2 PUSHING QUICK SHIFT BUTTON RESULTS

IN SHIFTING DOWN & UP: 2 --> 1 --> 2 --> 1

GEAR SELECTOR CONNECTORS (CN121, CN122)

ARE SITUATED BEHIND FRONT WIPER PANEL:

Declucth electric mechanism: see page 33

page 7
3. OPERATING MODES OF EST37

error codes table in service manual)

AEB Procedure see page 21

“ “

In this case "LH

LH or LF or LR
LR" will appear on the display

page 8
4. SECTIONAL VIEW
4WG-210(HL760-7) (≈4WG190Æ HL757-7) 4WG-260/310 (HL770-7/HL780-7A)

CONTROL VALVE
BLOCK

CONTROL VALVE
BLOCK

CONVERTOR RELIEF VALVE

page 9
5 .INSTALLATION VIEW

HL730 HL757/760 (≈730/740) HL770-7

HL740-7

(PTO, main
(PTO, main pump conn.)
pump conn.)

Coarse filter

page 10
6. HYDRAULIC CIRCUITS
A. HL730~760-7(A)

Pressure
(INSIDE BLOCK) reducing valve
9 bar
System pressure
valve 16 + 2 bar

Relief
Back valve 9 bar
pressure
valve 3.5
bar
Filter

Press sw
5.5 bar
Oil cooler
²

Coarse filter

page 11
B. HL770-7(A), HL780-7A

Pressure
(INSIDE BLOCK) reducing valve
9 bar

System pressure
valve 16 + 2 bar

Back pressure Filter

valve
5 bar
Relief valve
8.5 bar
(11barÆ780)
Press sw
5.5 bar
Oil cooler
3 bar
(1.5barÆ 780)

KR
K4

page 12
7. TRANSMISSION MEASURING POINTS
A. HL730~760-7(A) RIGHT SIDE VIEW
PICTURE AT PAGE 19

SYSTEM PILOT
BACK SIDE VIEW PRESSURE 9 b
PRESS 16b

ENG K2
(SOL Y6)
(SOL Y1)
K4

KV KR
(T-transm CD-15) (SOL Y2)
(SOL Y5)

Transm. K3 (SOL Y3) K1

LEFT SIDE VIEW (SOL Y4)
filter

Emergency Filter contamination

SW (CD52) (Output speed)
Steering pump

Not Conn. CD-27

N tC
Not Conn. CD 51
CD-51
CD-50
E CD-17

47 VENT
21
TRANSMISSION CONVERTOR
48
F
CD-15

page 13
B. HL770-7(A) FRONT SIDE VIEW

PICTURE AT PAGE 19
RIGHT SIDE VIEW

K3
K1
(T-transm CD-15) (SOL Y4)
(SOL Y3)

K4 KV
(SOL Y2) (SOL Y5)

KR K2
(SOL Y1) (SOL Y6)

(Output speed)

PILOT SYSTEM
Emergency PRESSURE 9 b PRESS 16b
Steering pump

Not Conn.
Not Conn.

CD-15

CD-50
PS
Transm. filter Filter contamination CD 17
CD-17
SW (CD52)
CD-51
CD-27

page 14
C. HL780-7A Transm. filter
PS

(Output speed) Filter contamination

RIGHT SIDE VIEW SW (CD48)
FRONT SIDE VIEW

Not Conn.
Not Conn.

E
(T-transm CD-49)
CD-49

PICTURE AT PAGE 19
VIEW B

K3
K1
(SOL Y4)
(SOL Y3)

K4 KV
(SOL Y2) (SOL Y5)

KR K2
(SOL Y1) (SOL Y6)

PILOT SYSTEM
PRESSURE 9 b PRESS 16b
30
CD-27
CD-47

VIEW A CD-46
36 29

page 15
8. ELECTRO HYDRAULIC CONTROL BLOCK
A. SECTIONAL VIEW

CABLE
HARNESS

-1- -2-

-3- -4- -1- -2-

-3- -4-
SOLENOID

COVER
COVER

HOUSING

VALVE BLOCK
RIGHT SIDE

COVER

page 16
B. PROPORTIONAL VALVE (SOLENOID)
Pressure regulator part
SECTION B - B

Current Connection -4- -3-

Clutch Neutral : at 100 mA
Clutch Active: at 500 mA
-2- -1-

(NFS BOOSTER Valve)

(NFS,

ScreenFilter

(to Tank)

EXAMPLE OF FILL PRESSURE AND CURRENT AS FUNCTION OF TIME

ScreenFilter

(TO NFS)

(9 bar)
K2 (press) K1 (press)

9 bar
Amp2 Amp1
Operating pressure
(TO NFS)

page 17
C. PICTURE VIEW OF CONTROL BLOCK

SOLENOIDS CONNECTORS MAIN PLUG OF Zf – CONTROL

Resistance 19Ω (±10%) @ 20°C TO SOLENOIDS BLOCK HARNESS
Current 100 500mA
100-500mA
Pressure Range 0.8 bar - 8.3 bar

SUMP TEMP SENSOR

SCREEN FILTERS
DATA
INSIDE PLATE
RESISTANCE
1000 Ω - 1500Ω

CHECK
TCU HARNESS PINS 46 & 39

TIP OF TEMPERATURE SENSOR MUST NEVER

CONTACT VALVE HOUSING (POSSIBLE S.C.)

page 18
 CONTROL BLOCK PRESSURE CHECK PORTS OVERVIEW

SYSTEM PRESSURE

H
CABLE
J HARNESS
K

G
K4 (730<>760)
K2
F KR (770,780)
SOL Y6
A SOL Y1

SOL Y5 SOL Y2 KR (730<>760)

KV
B K4 (770,780)
E

K3 K1
SOL Y4 C SOL Y3
D

page 19
REMARK “CLOGGED FILTER” WARNING SIGNAL

HL730~760-7(A) HL770-7(A), HL780-7A

P-IN P-OUT
SPOOL
SPOOL

ATTACH ATTACH
TRANSMISSION TRANSMISSION
FILTER FILTERS

PRESSURE SWITCH (PN. ZGAQ-00697)

Æ “ NORMAL OPEN” SO,, INFINITE RESISTANCE WHEN UNSCREWED FROM HOUSING
Æ ± 510 Ohm IN MOUNTED CONDITION UNDER SPRING FORCE
Æ OPEN (INFINITE RESISTANCE) IN MOUNTED CONDITION WITH CLOGGED FILTER ( diff. press > 5.5 bar)
REMARK
AN ALARM WILL APPEAR ON THE CLUSTER, TOGETHER WITH TRANSM. ERROR CODE “BA” WHEN
PRESSURE SWITCH (and/or CABLE) IS OUT OF RESISTANCE RANGE
Æ CHECK TRANSMISSION FILTER(S) / CHECK PRESSURE SWITCH & WIRING / CHECK SPOOL
P. S. THE ALARM ONLY APPEARS AT RPM < 2000 & TRANSM TEMP > 50 °C !!!!!!

page 20
9. AEB (AUTOMATIC FILLING PARAMETER DETERMINATION)
A. DESCRIPTION

Before starting the AEB cycle :

1) warm up the transmission (T transm > 80°C)
2) move shift lever to Neutral position
3) engage parking brake
4) make sure that RPM is between 900 - 1000
How to operate AEB procedure
On the display: - select Menu / Adjustment
- push “AEB” during 2 seconds

Now, “K1, K2, K3, K4, KV, KR” and finally “OK” should be displayed on the screen successively
If not so, refer to the AEB table on next page and make sure that all parameters are OK . Then, try again

page 21
B DISPLAY DURING AEB MODE (1/2)

page 22
B DISPLAY DURING AEB MODE (2/2)

( f other error codes appear during the AEB mode, please consult page 35 Æ Zff error codes list))
(If

page 23
10. DATA TRANSMITTERS & PROPORTIONAL VALVES

HL760-7 HL770-7

HL757-7,760-7,770-7
, ,

page 24
LOCATION SPEED SENSORS ON HL730-7 <-> HL760-7
4WG130/160/190/210
SENSORS

44

43
41

42

page 25
LOCATION SPEED SENSORS ON HL770-7, HL780-7A 4WG260/310 SENSORS

8 - Turbine Speed Sensor

7 - Central Gear Train Sensor
5 - Engine Speed Sensor
6
6 - Output Speed Sensor (Hall)

page 26
 ALL MODELS -7A

11. ZF ELECTRIC FUNCTIONING

page 27
“Zf” ELECTRIC FUNCTIONING (1/4)
Zf ELECTRICAL CIRCUIT
(FOR EXACT MACHINE DIAGRAMÆ REFER
TO THE FULL ELECTIC DIAGRAM OF THE
CONCERNED MACHINE) !!!!

SPEED

PEED
INT-SPEED

ENG SP
TURB S
ET03

13B
ET02

13A
13C
DIAGNOSTIC
PLUG

T22
ET01

CAN F_H
CAN F_L

CAN F_T
G73

T12
3

VGS

T13
T23

T11

T10
T32

VER)
Temp Sens Conv. 2
T09B T45 T24

KICK DOWN (LEV

49 25 26 27 28 02 01 57 08 03 42 41 19 14 15 18 4 1
Temp Sens T27B
T09A T09 DW-3
Sump TEMP 9 46 T27 T27C
22 KD
TEMP 8 T08 39
20 T25 B3
T07B DESCRIPTION OF CODES
13 T35
VP Feed “+” Voltage 65 B2
BLOCK
VALVE

VSP1 7 T07A 12 VPE Feed “+” Voltage at Input T33

TOR
63 B1
Y6 6 T06 VM Feed “-” Voltage

LEVER DW-3
3
51
SOLENOID B

T34
CONTROL V

GEAR SLECET
E... Input 64 R
Y5 5 T05 09 A... Output T37
67 N
T04 ED Input, digital
Y4 4
Y3 3 T21
55
32
AD
EF
Output, digital
Input frequence
TCU 43 T31 F
VP
T20

T27A
Y2 2 10

TRAL
Y1 1 T19
56 T16

8C
04 1

K)
T18

K DOWN (JOYSTCIK
24V IN NEUT
17 52 36 21 29 66 45 68 23 62 T17 2 3

OUTPUT
SPEED
T26
T40

Speed T36

T18B
T38

T29
Press SW T36

T18A

T28B

T28A

T18
T/M Filter

PS Clutch
T09C
Met sig

R10D
cut off

24V (IG.)

KICK
2
MCU
T37B
CLUSTER
P ark Autom. Clutch
BAT+

Park SW SW cut off

SW

F23
F17
F25
F8

BATTERY RELAY
BATTERY

page 28
“Zf” ELECTRIC FUNCTIONING (2/4)) -7 MODEL -7A MODEL

TRANSMISSION CONTROLLER CONNECTOR

NUMBERING

1
23

45

24
68
46

ADDED SIGNALS ON THE “-7A”

MODELS

page 29
“Zf” ELECTRIC FUNCTIONING (3/4) ALL MODELS
DW3 GEAR SELECTOR DIAGRAM

(Configuration for all -7(&A) models)

GEAR SLECETOR

Zf CNTROLLER
LEVER DW-3
In case of F,R,N selection on
joystick (-7A) Æ See p. 8

page 30
“Zf” ELECTRIC FUNCTIONING (4/4)
Example diagram Æ ALL MODELS
Example “1e GEAR FORWARD”

Black A
AD3 (B3)
1 1 1
S6 S4 S5
2 2 2
Green B

KICK DOWN
AD2 (B2)
Blue C
AD1 (B1)

Violet D
AD7 (KD)

CONNECTOR X1

Red A
ED1 (+/VP)
1
S1

3 2 D
Grey
AD6 (N)
S2 1

3 2 Yellow B
AD4 (FORWARD)

S3 1

3 2
Pink C
AD5 (REVERSE)

CONNECTOR X2

page 31
12.1 ELECTRIC PARKING SYSTEM ALL MODELS

- MACHINE NOT OPERATED NO VOLTAGE PARKING BRAKE ALWAYS ENGAGED

PARKING BRAKE RELEASED

- MACHINE (IGNITION) ON
24V PARKING SOLENOID

PARKING SWITCH OFF

24V

HL757~770-7

CONTROLLER
OFF (MACHINE
PARK PS CONTROL UNIT)
,( )
NC,(CD-26)

24V 0V HL730/740-7
PARKING SIG
PIN 2

24V EST 37
(TRANSMISSION
CONTROL UNIT)

24V TRANSMISSION OPERATIVE

ED 10
PIN 21
PARKING SWITCH ON

24V

0V
0V
PARKING BRAKE ENGAGED & TRANSMISSION IN NEUTRAL
ON
0V

page 32
12.2 ELECTRIC DECLUTCH SYSTEM ALL MODELS
CONTROLLER
(MACHINE
CONTROL UNIT)

24V
CLUTCH CUT OFF SW
PIN 10
24V

CLUTCH CUT OFF PS

PIN 29
OFF

ON

CLUTCH CUT-OFF SWITCH EST 37

(TRANSMISSION
CONTROL UNIT)
CLUTCH CUT-OFF PS
NO (CD-5)

24V ED 9
PIN 66

Closed , when pushing on the

brake pedal

TRANSMISSION IN NEUTRAL

page 33
12.3 ELECTRIC RIDE CONTROL SYSTEM ALL MODELS
Second solenoid for old type of
ride control system
Fuse 24V

1 AUTO = SPEED DEPENDING

2 OFF
3 ON, CONTINUOUSLY
RIDE CONTROL
SWITCH

1 EST37
TRANSMISSION
CONTROL UNIT

2
8 (VPS2)

RIDE
CONTROL RY
3

57 (ADM5)

signal from speed sensor

page 34
13. ZF ERROR CODES LIST ALL MODELS

(see also next

page
p g 4))
(sender in control valve) C3 hex overtemp convertor output
27 hex s.c to bat volt or o.c at temp sens input
28 hex s.c to ground at temp sens input (sender at convertor exit) (in control valve)

3D hex turbine speed zero doesn’t fit to other speed signals

3E hex output speed zero doesn’t fit to other speed signals

F4 hex limphome_request
F5 hex Clutch failureÆ affective clutch appears on display
F6 hex Clutch adjustment data lost Æ execute AEB

FIND FULL EXPLANATION OF TRANSMISSION ERROR CODES IN THE

7D hex s.c. ground at engine derating device WHEEL LOADER SERVICE MANUALS:
7E hex s.c. battery voltage at engine derating device
7F hex o.c. at engine derating device Æ CHAPTER 3 POWER TRAIN SYSTEM
Æ GROUP 1 STRUCTURE & FUNCTION

page 35