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ZF ASTRONIC

16 AS 2602 IT
Automated power shift gear UWT-06
UWT-06

2.6 ZF ASTRONIC 16 AS 2602 IT with intarder:

Function:
Conversion of the engine torque and speed corresponding to the tractive power required by the carrier.
Automatic starting and selection of the speeds. Automatic speed control and clutch actuation.

Design:
connector carrier

gear actuator
heat exchanger
oil filling plug
reservoir
filling valve

compressed-air
connection

oil check
plug

speed sensor oil reservoir


output shaft intarder

clutch actuator intarder solenoid valve


intarder

· Automated power shift gear


gear,, without clutch pedal
. Automatic mode or manual speed selection possible
. Electro-pneumatic controlled clutch and speed control
. Synchronization of the speeds by engine and gear brake
. 16 forward and 2 reverse speeds
. Intarder (abrasionproof sustained action brake integrated into the gear)
. Joint oil management for gear and intarder
. Electric control unit
. Control software with error stack

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Kundendienst-Schulung
ZF ASTRONIC Automated power shift gear
16 AS 2602 IT UWT-06
UWT-06

Set-up of gear:

Power division into constant K1 and K2


on both countershafts 4-speed gear

gear brake
secondary range group
split group 4-speed gear
Fig. 06-01

The ZF-ASTRONlC gear consists of a four-speed section for the l6-


speed version or a three-speed section for the 12- and 1O-speed version
as well as of a split-type group (GV) and a secondary range group (GP) of
the planetary type.

The gear is designed as a 2 countershaft version. This compact and


weight-reduced execution ensures an advantageous torque distribution,
for a reduced load exposure of the toothings and consequently for a high
efficiency.
clutch control module with
integrated electronics
The 4(3)-speed gear section is
realized with a claw-type control.
The synchronization is performed
by the EDC and the gear brake.
The primary and range groups
are synchronized.
ZF INTARDER
clutch actuator
with heat exchanger

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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT Automated power shift gear UWT-06
UWT-06

Outline of components - gear control:


gear electronics
connector
carrier
electrics
-X44

clutch actuator
ECU / -A1
-X44 -X45
Sensors
• path sensorics
• temperature sensor
• air-pressure sensor
• speed sensor
compressed CAN
-X45
air connection connector
carrier gear
electrics ABV
SCI
ECU

Location: Centre console (driver's cab)


engine
ECU

E/A module
1 - addr
addr.. 2
clutch

-X47
actuator with
-X21

4 solenoid
control valves diagnostic
+ path connector
sensorics
-X104 E/A
modules
2/5
-X75

speed
-A4 sensor
(output) -A7

compr.
air
approx.
8 bar)
Liebherr-Werk Ehingen GmbH -3-
Kundendienst-Schulung
ZF ASTRONIC Automated power shift gear
16 AS 2602 IT UWT-06
UWT-06

Outline of components - intarder control:

engine
ECU

E/A module

Location: Centre console (driver's cab)


1 - addr.2

E/A module
2 - addr.3

CAN

switch

OFF
ON
E/A module
5 - addr
addr.. 6
-X46

-X48
diagnostic
connector -A2 / ECU - EST 42

-X46
(intarder)
prop. solenoid valve
(intarder activation) heat exchanger
-X46

-X22

-Y37 solenoid valve


(open rservoir
filling valve)

air-pressure
(approx. 8
bar)

-Y38
oil
reservoir

intarder

-B15 coolant
temper.
sensor
(heat
exchanger
output)
-X287

SCI

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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT
Automated power shift gear UWT-06
UWT-06

Set-up - control:

The control cylinders are integrated into


the gear actuator (control module) and
are operated pneumatically.

Power division by
K1 and K2 to both
countershafts. Feed
back within the 4-
speed section to
the main shaft in the
respective speed.

control module
control cylinder for
secondary range group selection cylinder for
main gear section

control cylinder for


main gear section

control cylinder for


split-type group
Output by the
secondary range
group. Speeds 1-
8 with transmis-
sion of the
group, speeds 9- Splitgruppe
split-type group

16 directly to the K1 Rückwärtsgang-


reverse speed
reversing wheel
cardan K2 Umkehrrad
shaft..

Getriebe-
gear brake
bremse

output
Viergangteil mit
four-speed section with
Abtriebs-
flange
Rückwärtsgang
reverse speed flansch

secondary range group


Bereichsgruppe
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ZF ASTRONIC Automated power shift gear
16 AS 2602 IT UWT-06
UWT-06

Technical data - direct speed:


direct

Engine torque:

Drive speed:
Number of forward speeds:
Length:
Number of reverse speeds:
Speed jump: Oil volume:
Weight:
Transmission range: Forward
Reverse

* Without peripherie, oil filling, secondary drives, intarder, clutch, clutch fork, shaft, bearing, pressure rod and clutch actuator.
Weight: Clutch fork, shaft, bearing, pressure rod and clutch actuator approx. 10 kg.

Direct speed Force flow diagram

Speed Transmission Speed step Inertia moment

1° Speed

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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT Automated power shift gear UWT-06
UWT-06

Technical data - overdrive:

Engine torque:
Drive speed:

Number of forward speeds:


Length:
Number of reverse speeds:
Oil volume:
Speed jump:
Transmission range: Forward Weight:
Reverse

*Without peripherie, oil filling, secondary drives, intarder, clutch, clutch fork, shaft, bearing, pressure rod and clutch actuator.
Weight: Clutch fork, shaft, bearing, pressure rod and clutch actuator approx. 10 kg.

Overdrive Force flow diagram

Speed Transmission Speed step Inertia moment


1° Speed

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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT
Automated power shift gear UWT-06
UWT-06

Set-up - gear actuator:

All functions required for the control/regulation of the gear are comprised in the gear
actuator. It is provided with a mechanical, electrical and pneumatical interface and is
integrated into the gear housing in a space-saving manner.

- The gear electronic system comprises all functions required for the control/regulation of
the gear and the clutch.
- The electro-pneumatic valves control the control valves and the gear brake.
- The pneumatic control cylinders operate the mechanical control elements in the gear.
- The sensors measure:
-the actual position of all control cylinders Sensors:
-the gear input speed - temperature
- speed
-the gear temperature compressed-air
-the amount of the air-pressure integrated connection and
pressure relief
available gear electronics
valve

- The carrier-side connector is the


electric interface to the carrier
CAN system interconnection, the interface
to the display, to the speed selector, to
the voltage supply, to diagnostic devices,
etc. gear-side
connector
- The gear electronic system is integrated
into the housing cover. Fig. (010834) carrier-side
demonstrates the gear actuator with connector Sensors:
- path
open housing cover.
- Electric and pneumatic connections are incorporated into the gear
actuator by short connecting circuits.

Sensors:
- pressure Valves: control module with
- control integrated control
- selection electronics
- gear

Control cylinders:
- GV
- GP
- main gear (control, selection)

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ZF ASTRONIC
16 AS 2602 IT Automated power shift gear UWT-06
UWT-06

Set-up - clutch:

2-disk dry clutch:


clutch disk 1
clutch disk 2

load ring with hook-on


device
release bearing

release
fork

Fig. 06-01

cover service opening clutch actuator


clutch gear electronics path
sensor

valves
clutch released

valves
clutch engaged

operating piston
control
electronics

clutch air
actuator supply

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ZF ASTRONIC Automated power shift gear
16 AS 2602 IT UWT-06
UWT-06

Set-up - clutch actuator:


The clutch actuator is flanged to the integrated clutch cone of the gear. The clutch is
operated by the clutch actuator which in turn is controlled by the electronics of the clutch
actuator.
The electric connection to the gear electronic system is realized by a robust cable
connection between the connector of the clutch actuator and the gear-side connector of the
gear actuator.
Besides the pneumatic operating pistons for the clutch release, the following components
are integrated into the clutch actuator:
Two redundant, clocked valves each are employed to release and engage the clutch, both
valves are equipped with restrictors of different diameters downstream.
The position of the pneumatic piston is measured by a path sensor. An electronic module,
located directly on the sensor, transmits the sensor signal for the gear control.

A precisely dosed engagement of the clutch is practicable for sensitive starting and
manoeuvring . For a very quick clutch actuation, situation-conformant adjustment speeds
can be realized by variation of the release and engagement times or the clock
frequencies.
The clutch actuator calibrates the actual clutch contact point at each starting process and
transmits this information to the gear electronic system. Consequently, the electronic
system avails of the actaul abrasion state of the friction lining .
The operator is warned against the entire abrasion of the clutch on time.

Electro-pneumatic clutch control:


Starting:
Clutch path

engaged

released

time

1. Partial engagement of clutch until vehicle starts moving


2. Controlled adaptation of speeds between engine and gear
3. Complete engagement of clutch

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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT
Automated power shift gear UWT-06
UWT-06

Electro-pneumatic clutch control:

Upshift:

engaged
Clutch path

released

time

1 Controlled, slight release of the 4 Qick prepositioning of the clutch


clutch during the reduction of the fue 5 Controlled engagement of the clutch until the
volume to the engine speeds of the engine and gear are matching
2 Quick release of the clutch 6 Complete engagement of clutch
3 Controlled retaining the clutch released
(shifting the gear)
Backshift:

engaged
clutch path

released

time

1 Controlled, slight release of the clutch 6 Quick prepositioning of the clutch after
during reduction of the oil volume to the engine speed has been shifted
2 Quick release of the clutch 7 Controlled engagement of the clutch
3 Controlled retaining the clutch released until the speeds of the engine and gear are
4 Controlled adaptation to the synchronizing point matching
5 Release of clutch, start of shifting the speed 8 Complete engagement of clutch

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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT
Automated power shift gear UWT-06
UWT-06

Drive control:

Upshift:

engine

engine speed
gear speed

clutch path clutch engaged

clutch released
speed shifted
gear
gear neutral
shaft-mounted brak OFF
time
speed adaptation shaft-mounted brake ON

1 Start of shifting: 2a •speed shifted off •clutch engages


•clutch slightly released 3 •gear shifted to neutral •engine injection volume increased
•injection volume reduced 4 •shaft-mounted brake active until max. operating value has
2 •quick release of clutch 5 •speed shifted been attained at 7
•injection volume attains lowest 6 •new speed shifted 8 •clutch engages
value •shifting terminated

Backshift:

engine speed
engine

gear speed

synchronizing clutch engaged

clutch path
clutch released

gear speed shifted

neutral

1 Start of shifting: 3•speed shifted off 5•clutch releases, speed shifted


•clutch releases slightly 4•gear shifted to neutral 6•new speed shifted
•engine injection volume reduced •engine speed increases •clutch engages
2 •quick release of clutch •clutch "synchronized" •injection volume re-increases
•injection volume attains lowest value until operating value is attained (7)
7•clutch engaged
shifting terminated
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Kundendienst-Schulung
ZF ASTRONIC
16 AS 2602 IT Automated power shift gear UWT-06
UWT-06

Function intarder:

The intarder is an abrasion-proof sustained-action brake with 5 braking


steps, integrated into the gear which relieves the service brakes.

Set-up of intarder:

oil reservoir
intarder
solenoid valve
intarder reservoir filling valve

heat exchanger

coolant
temperature sensor

intarder

Fig. 06-01

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Kundendienst-Schulung
ZF ASTRONIC Automated power shift gear
16 AS 2602 IT UWT-06

Function of intarder:

Schematic diagram:
high-driver
1 rotor / stator

hydraulic control

heat exchanger

reservoir

pump

5
2

3
4
Fig. 06-01

The intarder is coupled to the gear output shaft by a high-driver step (1)
with the transmission 1:2. The heat exchanger (4) is flanged directly to the
intarder. Short response times are obtained due to the additional oil
reservoir (5).

Intarder and gear are provided with a joined oil management. During the
braking process, the oil is running separately from the gear between
intarder and heat exchanger and will be re-transferred to the joined circuit
only after it has been cooled down. When the intarder is switched-off, the
gear oil is conducted from the pump (6) through the heat exchanger and
consequently, the gear is cooled continuously..

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System picture ASTRONIC:
Kundendienst-Schulung
Liebherr-Werk Ehingen GmbH

ZF ASTRONIC
16 AS 2602 IT
electric
clutch actuator
pneumatic operating and
check display elements
valve
Fig. 06-01

Automated power shift gear


- 15 -

gear actuator
sec. range group

pressure pressure
relief sensor
valve

gear
electronics
engine
electronics
control valves

main cut-off valve

UWT-06
vehicle CAN
ZF ASTRONIC
16 AS 2602 IT Automated power shift gear UWT-06
UWT-06

Pneumatic system:

Required air pressure: 7-12 bar


Required compressed-air volume: 5 l/min (at 8-10 bar)

Outline diagram solenoid valves:


SO
O LENOID

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Kundendienst-Schulung

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