Off-Road Transmissions

Repair Instruction and Axle Systems

Division

REPAIR INSTRUCTIONS 1-2

____________________________________________________________________________________________________________________________-

ZF – ERGOPOWER
3 WG 116-171

REFERENCE
For information concerning description, installation instructions, operation and maintenance, see
respective Operating Instructions.
_____________________________________________
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau

Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous réserve de modifications techniques!
1.Auflage / 1.Edition
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

PREFACE

This documentation has been developed for skilled staff trained by the ZF Passau for the repair and
maintenance works on ZF-units.

Documented is a ZF-serial product representing the design state at the time of the edition.

However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.

Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.

The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

Here, all operations are carried out for you with utmost care and reliability.

Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of
the applicable contractual conditions.

Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.

ZF Passau GmbH

Off-Road Transmissions
and Axle Systems
Division
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

GENERAL

The Service Manual covers all works required for dismantling and the pertaining installation.

When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.

Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:

REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!

CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
By no means, Molykote is permitted to be used.
Lined plates must not be washed. They must be cleaned with a leather cloth.

DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

Structure of the Repair Manual

The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.

Important information on industrial safety

Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.

The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.

The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.

The following safety references are used in the present Repair Manual:

) Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc..

CAUTION Is used, if a deviating and improper working procedure can

damage the product.

Is used, if lacking care can lead to personal injury or danger to

DANGER life.

___________________________________________________

REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE

CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description..

REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again. .
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Densité lineaire en kg/m; Densité superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Unité Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Masse
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION

25,40 mm = 1 in ( inch)

1 kg ( Kilogramm ) = 2,205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5,560 lb / in ( pound per inch )

1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per square inch lbf/in2 )

=
0,070 bar ( 0,071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4,456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )

3,785 Liter = 1 Gallon ( US )

=
1609,344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273,15 Kelvin
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148

Friction value: µ total= 0,12 for screws and nuts without after-treatment as well as phosphatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following List:

Metric ISO-Standard thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine thread DIN 13, page 13
Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12 x 1,5 83 120 145
M 14 x 1,5 135 200 235
M 16 x 1,5 205 300 360
M 18 x 1,5 310 440 520
M 18 x 2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1,5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1,5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1,5 3450 4900 5700
M 39 x 3 3200 4600 5300
 L A Y O U T 3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
T A B L E -1
G e a rb o x d ia g ra m
1 = E n g in e c o n n e c tio n 2 4 3 5 7
A = S e p a ra te m o u n tin g – d riv e n v ia u n iv e rs a l s h a ft
B = D ire c t m o u n tin g – d riv e n v ia fle x p la te
2 = C o n v e rte r
3 = In p u t sh a ft
4 = T ra n s m is s io n p u m p
5 = In p u t g e a r 8
6 = C lu tc h s h a ft " K 2 "
7 = A tta c h m e n t p o s s ib ility 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 = C lu tc h s h a ft " K V "
9 = C lu tc h s h a ft " K R " 9
1 0 = C lu tc h s h a ft " K 1
1 1 = O u tp u t fla n g e
1 2 = C lu tc h s h a ft " K 3 " /O u tp u t 1 0

1 2
1 1

6
 1 2 3 4 5 6

8
7
3
A
B 8
6
9
9
1 0
1 2
1 1
1 0
1 2
IN S T A L L A T IO N V IE W 3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
F R O N T V IE W
T A B L E -2 1 2 3 4

5
1  = C o n v e rte r
2  = C o n v e rte r b e ll
3  = L iftin g lu g s
4 = In d u c tiv e tra n s m itte r n C e n tra l g e a r tra in
5 = In d u c tiv e tra n s m itte r n T u rb in e 6
6 = G e a rb o x h o u s in g - fro n t s e c tio n
7 = O il le v e l tu b e w ith o il d ip s tic k (re a r s id e )
8 = G e a rb o x h o u s in g - re a r s e c tio n
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
1 0 = A tta c h m e n t p o s s ib ility o il le v e l tu b e w ith o il d ip s tic k (re a r s id e )
1 1 = O il d r a in p lu g M 3 8 x 1 ,5

9
8

1 1 1 0 9
 IN S T A L L A T IO N V IE W 3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
R E A R V IE W - S T A N D A R D V E R S IO N
T A B L E -3 1 2 3

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
2 = L iftin g lu g s 1 4
3 = B re a th e r
4 = E le c tro -h y d ra u lic c o n tro l
5 = M e a s u r in g p o in t f o r te m p e r a tu r e b e h in d th e c o n v e rte r 4
6 = C o n n e c tio n to th e h e a t e x c h a n g e r
7 = F ilte r h e a d
8 = 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
9 = E x c h a n g e filte r (Z F -fin e filte r)
1 0 = 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 1 = S p e e d s e n s o r n O u tp u t
1 2 = O u tp u t fla n g e 1 3
1 3 = O il fille r tu b e w ith o il d ip s tic k
6
1 4 = T y p e p la te 7
8

1 2 1 1 1 0
 IN S T A L L A T IO N V IE W 3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
R E A R V IE W - W IT H D IS K B R A K E
T A B L E -4 1 2 3

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
2 = L iftin g lu g s
3 = B re a th e r
4 = E le c tro -h y d ra u lic c o n tro l 1 3
5 = M e a s u rin g p o in t fo r te m p e ra tu re b e h in d th e c o n v e rte r
6 = C o n n e c tio n to th e h e a t e x c h a n g e r
7 = F ilte r h e a d
8 = 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
9 = E x c h a n g e filte r (Z F -fin e filte r)
1 0 = O il fille r tu b e w ith o il d ip s tic k
1 1 = B ra k e d is c w ith O u tp u t fla n g e
4
1 2 = P a rk in g b ra k e o p e ra te d h y d ra u lic a lly
1 3 = T y p e p la te 1 2 5
6
7
8

1 1 1 0
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
3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
T A B L E -5
T h e m a r k e d p o s itio n s (e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e ta b le - 6 !
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 ) !
1 0

N O . D E N O M IN A T IO N O F T H E P O S IT IO N C O N N E C T IO N M A R K IN G O N T H E
V A L V E B L O C K
M E A S U R IN G P O IN T S F O R H Y D R A U L IC O IL A N D T E M P E R A T U R E :
5 1 = In 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 0 x 1
5 3 = C lu tc h F o rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h R e 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 = N o t a p p lic a b le 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
M E A S U R IN G P O IN T S F O R D E L IV E R Y R A T E 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 /1 6 ” – 1 2 U N -2 B
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 5 /1 6 ” – 1 2 U N -2 B
IN D U C T IV E T R A N S M IT T E R S , S P E E D S E N S O R A N D S W IT C H E S :
2 1 = In 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 = S p e e d se n so r n O u tp u t -----------
4 7 = In d u c tiv e tra n s m itte r n C e n tra l g e a r tra in M 1 8 x 1 ,5
4 8 = In 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 3 4
C O N N E C T IO N S :
1 0 = B re a th e r
4 9 = P lu g c o n n e c tio n o n th e e le c tro -h y d ra u lic c o n tro l u n it
P a g e 1 fro m 2
 65 51 54 10

21
49
60
57
48
52
53 55 47
58
56
55
63

Coding

• Pressure regulator active Engaged clutches

Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
15 16 Forward 1 N • • K1 KV
2 o • • KV K2
3 t • • K3 KV
Reverse 1 • • KR K1
u
2 • • KR K2
s
3 e • • KR K3
Neutral d
Engaged clutches K4 KR K1 K3 KV K2
Position on the valve block F E D C B A
Consecutively No. of the measurement points 60 55 56 58 53 57 Page 2 from 2
OIL CIRCUIT DIAGRAM 3 WG-116/131/161/171
FORWARD 1st SPEED
TABLE-6
The marked positons (e.g. 53) correspond with the positions on the table-5!

Legend:

WT = Heat exchanger
WGV = Converter back pressure valve 4,3+3 bar
WSV = Converter safety valve 11+2 bar CODIERUNG
HDV = Main pressure valve 16+2,5 bar
RV-9 = Pressure reducing valve 9 bar
• Pressure regulator active Engaged clutches
NFS = Follow-on slide Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
D = Vibration damper Forward 1 N • • K1 KV
B = Orifice 2 o • • KV K2
3 t • • K3 KV
P1 = Not used
Reverse 1 • • KR K1
P2 = Proportional valve KR 2
u
• • KR K2
s
P3 = Proportional valve K1 3 e • • KR K3
P4 = Proportional valve K3 Neutral d
P5 = Proportional valve KV Engaged clutches K4 KR K1 K3 KV K2
Position on the valve block F E D C B A
P6 = Proportional valve K2 Consecutively No. of the measurement points 60 55 56 58 53 57
Y1...Y6 = Pressure regulators
TEMP = Temperature sensor
UEDV = Pressure relief valve 40±5 bar
WS = Maintenance switch
FDV = Filter pressure differential valve (Bypass-valve) ∆p=5,5 bar

Page 1 from 2
 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
5 1

Z F fin e filte r
H F ilte r g ra d e a c c o rd in g IS O 4 5 7 2 :
W S V
ß 30 ³ 7 5 ß 15 = 2 5 ß 1 0 = 5 .0
6 3 5 2 D u s t c a p a c ity a c c o rd in g IS O 4 5 7 2 :
L e g e n d : W T m in . 1 7 g
(S c o p e o f s u p p ly c u s to m b e r) F D V F ilte r s u rfa c e :
= M a in p re s s u re W G V
m in . 6 7 0 0 c m
2

= R e g u la te d m a in p re s s u re
= P ilo t p re s s u re B y p a ss- W S T ra n sm is s io n p u m p
1 5
P = 1 6 + 2 b a r
= C o n v e rte r in p u t p re s s u re B y p a s s v a lv e -1
D p = 1 ,5 b a r Q P = 8 5 l/m in Þ 3 W G -1 1 6 /1 3 1
= C o n v e rte r o u tp u t p re s s u re U E D V Q P = 1 0 5 l/m in -1
Þ 3 W G -1 6 1 /1 7 1
= L u b ric a tio n 1 6 -1
n E n g in e = 2 0 0 0 m in
= R e tu rn in to th e s u m p
C o a r s e f ilte r m e s h w id th 0 ,8 0 0 m m

O il s u m p M a in o il c irc u it
P a g e 2 fro m 2 L u b ric a tio n
GEARBOX DIAGRAM 3 WG-116/131/161/171
TABLE-7

KV

AN

AN PTO
KR
K2
KV

K1
KR K3/AB

K1

Legend: Diagram Clutches

K3/AB
AN = Input Driving direction Speed Clutch
KV = Clutch forward Forward 1 KV/K1
KR = Clutch reverse 2 KV/K2
K2 K1 = Clutch 1st speed 3 KV/K3
K2 = Clutch 2nd speed Reverse 1 KR/K1
K3 = Clutch 3rd speed / Output 2 KR/K2
PTO = Power take-off 3 KR/K3
 P O W E R F L O W 3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
F O R W A R D S P E E D S 1 st sp e e d -fo rw a rd 2 n d sp e e d -fo rw a rd 3 rd sp e e d -fo rw a rd

T A B L E -8
T ra n s m is s io n d ia g ra m K V K V K V

A N A N A N

K R K R K R
K 2 K 2 K 2
A N P T O

K 1 K 1 K 1
K V
K 3 /A B K 3 /A B K 3 /A B

K R

O p in io n d ire c tio n o f ro ta tio n

K 1 L e g e n d : D ia g ra m C lu tc h e s

A N = In p u t D r iv in g d ir e c tio n S p e e d C lu tc h
K V = C lu tc h fo rw a rd F o rw a rd 1 K V /K 1
K 3 /A B
K R = C lu tc h re v e rse 2 K V /K 2
K 1 = C lu tc h 1 st sp e e d 3 K V /K 3
K 2 = C lu tc h 2 n d sp e e d R e v e rse 1 K R /K 1
K 2
K 3 = C lu tc h 3 rd s p e e d / O u tp u t 2 K R /K 2
P T O = P o w e r ta k e -o ff 3 K R /K 3
 P O W E R F L O W 3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1
R E V E R S E S P E E D S 1 st sp e e d -re v e rse 2 n d sp e e d -re v e rse 3 rd sp e e d -re v e rse

T A B L E -9
K V K V K V
T ra n s m is s io n d ia g ra m
A N A N A N

K R K R K R
K 2 K 2 K 2
A N P T O

K 1 K 1 K 1
K V
K 3 /A B K 3 /A B K 3 /A B

K R

O p in io n d ire c tio n o f ro ta tio n

K 1
L e g e n d : D ia g ra m C lu tc h e s

A N = In p u t D r iv in g d ir e c tio n S p e e d C lu tc h
K 3 /A B K V = C lu tc h fo rw a rd F o rw a rd 1 K V /K 1
K R = C lu tc h re v e rse 2 K V /K 2
K 1 = C lu tc h 1 st sp e e d 3 K V /K 3
K 2 = C lu tc h 2 n d sp e e d R e v e rse 1 K R /K 1
K 2 K 3 = C lu tc h 3 rd s p e e d / O u tp u t 2 K R /K 2
P T O = P o w e r ta k e -o ff 3 K R /K 3
E L E C T R O -H Y D R A U L IC 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 0

M a in p r e s s u r e v a lv e 1 6 + 2 ,5 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
P a g e 1 fro m 2
 S E C T IO N A - A
M a in p r e s s u r e v a lv e 1 6 + 2 ,5 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 ro p o rtio n a l v a lv e P 5

Y 5
V ib a 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 lid e
P a g e 2 fro m 2
3 W G -1 1 6 /1 3 1 /1 6 1 /1 7 1 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 A
C IR C U IT D IA G R A M S T A N D A R D (6 0 2 9 7 0 1 6 1 2 )
T A B L E -1 1

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 3 S W IT C H D R IV IN G P R O G R A M A U T O M A T IC /M A N U A L
A 2 C O N T R O L L E R D W -3 S 8 S W IT C H S E L C T IO N S T A R T IN G G E A R (O P T IO N )
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 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 5 D I A G N O S IS – IN T E R F A C E (P L U G ) S 1 5 S W IT C H E N A B L E IN C H E N
A 6 D I S P L A Y S 2 5 S W IT C H L IM P H O M E M O N IT O R IN G O N /O F F (O P T IO N )
A 7 C A N -IN T E R F A C E (P L U G ) S 3 1 S W IT C H A C H N O W L E D G M E N T P A R K IN G B R A K E
A 9 S P E E D O M E T E R W IT H F R E Q U E M C Y D IV ID E R *
K 1 R E L A IY S T A R T E R IN T E R L O C K *
B 1 S P E E D S E N S O R n E N G IN E K 2 R E L A IY R E V E R S E D R IV E *
B 2 S P E E D S E N S O R n T U R B I N E
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
B 4 S P E E D S E N S O R n O U T P U T
B 6 IN C H IN G P O T E N T IO M E T E R
B 1 5 S E N S O R T E M P E R A T U R E B E H IN D C O N V E R T E R

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 IC A L W A R N IN G *

P a g e 1 fro m 2
 F 1
K l.3 0
K l.1 5
F 2
K 2
S 8 S 1 5 S 3 1 S 3 S 2 5
B 4 3
1 1 P 1 1 1 8 6
1
2 2 2 2 2 A 9
S u p e rS e a l 1 8 5
2
3 -p in 2
6 0 2 9 1 9 9 0 7 1 3
4 5 2 3 6 8 6 6 6 6 2 1 2 9 3 1 7 A M P M -N -L
1

6 2
V P E 1 V P E 1 V P E 2 E D 8 E D 9 E D 1 0 E D 1 1 E D 1 3 A D M 2 S D 4 3 6 A 5 6 -p in
6 0 2 9 1 9 9 0 7 4
4 1
1 5 2 6 3
1 S D D K
4 6 5 2
2 4 4
6
3 6 1
E U 2
2 E U P R 1 8 4 1 A 6
5 4
3 4
B 6 1 3 7 A U 1 S D 1 1 4
1 3
4 3 8 2
E U 1 1
2 2 4 V M G A 1
V P 5 6 1 3 A M P M N L
F
4
5
4 3
6 7
E D 4 A 1 A IP
A IP
1
2 1 0
3 2
2
3
Y 2 4 -p in
N E D 6 A IP 3 Y 3 6 0 2 9 1 9 9 x x x
6 6 4 5 5 4 Y 4
R E D 5 A IP 4
A 2 B 1
B 2
7
8
6 3
6 5
E D 1
E D 2
A M P T im e r
6 8 -p in
A IP
A IP
5
6 5 1
9 5
6
Y 5
Y 6
9 6 0 2 9 1 9 9 0 6 3 V P S 1 1 2 7 V P S 1 (+ )
B 3
1 0 1 3
fu n c tio n b u tto n V P S 1
E R 1 3 9 8 T E M P
4 6 9 T E M P
1 1 9 V M G A 2
E F 1
8 6 B 1 2 3
V M G 1
A 3
3 6 9 1 2 2
E R 2 4 9 1
2 5 8 1 1 8 5 1 4 1 2 2
E F 2
1 4 7 1 0 B 2 2 6 8 4 5
2 3 1 2

K 1 4 2 1 7
B 1 5 6
3
7
4
8
5
9 K o s ta l
1 V G S C A N F _ H C A N F _ L C A N F _ T V M 1 V M 2 V P S 2 V P S 2 A D M 5 E R 3
E F 3
A M P M -N -L B 3 2
2 8 2 5 2 6 2 7 2 5 3 8 5 7
1 2
1 0 1 1 1 2 1 3 1 6 -p in
6 0 2 9 1 9 9 0 7 2
1 2 -p in 1 4 1 5 1 6
6 0 2 9 1 9 9 x x
A M P M in itim e r
4 2 -p in
8 5
1 2 6 0 2 9 1 9 9 0 1 1
K 9
A M P M in itim e r 8 6

E
2 -p in 1 2
6 0 2 9 1 9 9 0 1 1
4 3

L
2 1
2 1 A 7

P A M P JP T
S 1 0
4 -p in

M
6 0 2 9 1 9 9 0 7 6 K l.3 1
1
2

A A M P S u p e rse a l

S
2 -p in
6 0 2 9 1 9 9 0 4 5
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 s o n th e w irin g !

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 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 P a g e 2 fro m 2
 C O N T R O L L E R D W -3
T A B L E -1 2
L E V E R F O R M E C H A N IC A L C O N N E C T IO N D IA G R A M C O N T R O L L E R
N E U T R A L IN T E R L O C K C O D IN G C O N T R O L L E R
(+ )
O U T P U T K D

S P E E D F O R W A R D R E V E R S E N E U T R A L
X 2 : A
1 2 3 4 1 2 3 4 1 2 3 4
N D (+ )
A D 1 B 1
B 1 X 1 :C
A D 2 B 2
A 2 B 2
B 3
X 1
X 1
: B
: A A 1
A D 3 B 3 X 1 : B
IN P O S IT IO N (N E U T R A L ), V
A D 4 X 1 : C
F -R N O T S W IT C H A B L E V R
X 1 : D
A S
A D 5 R
A D 6 A S
A D 7
E
L K 1 K 2

P
M
(-)

A
A B C D
A B C D
X 2 X 1 K 1 = R E L A Y S T A R T E R IN T E R L O C K

F G E A R P O S IT IO N S T Y P E N S C H IL D S C IR C U IT D IA G R A M C O N T R O L L E R
K 2
A 1
=
=
R E L A Y R E V E R S IN G L IG H T S

E L E C T R O N IC U N IT E S T -3 7
A 2 = C O N T R O L L E R
F
S W A
A D 3 (B 3 )
N N N D
S 6 1 S 4 1 1 S 5
R 2 2 2 G N B
A D 2 (B 2 )
B L C
A D 1 (B 1 )
V I D
A D 7 (K D )
R X 1
R T A
E D 1 (+ /V P )
F = F O R W A R D S 1 1
N = N E U T R A L 3 2 G R D
A D 6 (N )
R = R E V E R S E T Y P E P L A T E S 2 1
D = M E C H A N IC A L N E U T R A L IN T E R L O C K C O N T R O L D W - 3
3 2 G E B
A D 4 (F O R W A R D )
1 = 1 st S P E E D N R .
S 3 1
V 1 2 / 2 4

2 = 2 n d S P E E D
3 2 R S C
3 = 3 rd S P E E D S T U E C K L . 0 5 0 1 2 1 0 1 4 8 A D 5 (R E V E R S E )
4 = 4 th S P E E D X 2
 C O N T R O L L E R E R G O II
T A B L E -1 3 C O D IN G C O N T R O L E R C O N N E C T IO N D IA G R A M C O N T R O L L E R
O U T P U T

V R N T + T - K D / S N
+ E
-
N A D 1 B 1 (+ ) V P (+ )

A D 2 B 2 K D /E (A D 8 ) E D 7
A D 3 B 3 T + (A D 1 ) E D 1 A 1
T - (A D 2 ) E D 2
A D 5 V
A 2 C (A
(A
D 3 )
D 5 )
E D 3
E D 4
A D 6 R A D 7
K D (A D 6 ) E D 5
A D 7 N N (A D 7 ) E D 6 A D 9
S N (A D 9 )
A D 8 K D
V M (-)
A D 9 S N (-)
K 3 K 1 K 2
: = U O U T P U T = O V (A C T IV E L O W )
: = U S E R V IC E - 0 ,3 V

K 1 = R E L A Y S T A R T E R IN T E R L O C K
K 2 = R E L A Y R E V E R S IN G L IG H T S
K 3 = R E L A Y S H O V E L N E U T R A L (C U S T O M IZ E D )
A 1 = E L E C T R O N IC U N IT E S T -1 7 T /E S T -2 5
A 2 = C O N T R O L L E R E R G O II

C IR C U IT D IA G R A M C O N T R O L L E R

R T + /V P
2

M E A N IN G O F P U S H B U T T O N S
S 1 G E
4
A D 5 V (F O R W A R D ) P O S L E G E N D
W S
S 2 A D 3 B 3 /C (C O N T R O L -S IG N A L )
R S 9
A D 6 R (R E V E R S E ) S 1 P U S H B U T T O N D R IV IN G D I R E C T I O N
6
= D R IV IN G D IR E C T IO N F O R W A R D S 1 '
( ) V ' S 2
F O R
P U S
W A R D
H B U T T O N
A N D C -S IG N
D R IV IN G
A L
D I
F O
R E
R W
C T I
A R D
O N
= D R IV IN G D IR E C T IO N R E V E R S E S 2 '
( ) R '
S 3
R E V
P U S
E R S E A
H B U T T O N
N D C -S IG N A
N E U T R A L
L R E V E R S E

N = N E U T R A L S 3

S 4
B R
5
A D 7 A S /N S 4 P U S H B U T T O N U P S H IF T IN G
B L S 5 P U S H B U T T O N D O W N S H IF T IN G
+ = U P S H IF T IN G S 5 O G
7
A D 1 B 1 /T +
S 6 P U S H B U T T O N K IC K D O W N /R E L E A S E
A D 2 B 2 /T - P U S H B U T T O N S H O V E L N E U T R A L
- = D O W N S H IF T IN G 8 S 7
:
S 6
(S N ) = S H O V E L -N E U T R A L V I
1 0
A D 8 K D /E

(S H O V E L H O R IZ O N T A L ) S 7 S W
1 1
A D 9 S N

K D /E = K IC K D O W N C O N T R O L A N D (1 )
V M (-)

S A F E T Y R E L E A S E X 1