Plano Electrico 856h

ORDER-NO: 5872 174 002
订单号：5872 174 002
ZF - REVERSING TRANSMISSION
4 WG-200
DESCRIPTION INSTALLATION INSTRUCTIONS OPERATION
MAINTENANCE
ZF——换档变速箱
4 WG-200
安装、操作、维护说明书
Zahnradfabrik Passau Gmbh 采埃浮公司
Donaustr. 25 - 71
D - 94034 Passau
D - 94034 Passau Edition: 1996/09 With the reserve of
modifications!
版本：1996 年 09 月
修改版本保留版本
TECHNICAL DATA
技术参数
Engine power: Max. KW ................. 200*
Turbine moment: Max. Nm ................ 1500*
Engine speed: Max min-' .............. 2500*
Mass (without oil): kg .................. about 430 ** * = dependent on vehicle type
and use** = dependent on the Transmission Version
发动机功率：最大 KW................. 200*
涡轮力矩：最大 Nm................ 1500*
发动机：最大 min-' .............. 2500*
质量（不带油）：千克..................大约 430 **
* =由车辆类型和用途决定
** =由变速箱类型决定
简介：
Description
The ZF-Hydromedia Transmission 4 WG-200 is composed of a hydrodynamic torque

converter and a rear-mounted multi-speed Powershift reversing transmission with
integrated transfer case - see Table 1.
ZF—Hydromedia 变速箱 4WG-200 包括一个液力变矩器和一个后置多级速度动力换
档变速箱，配有整体转换箱，详见表一。
The torque converter is a wear-free start-up device, which is adapting it self infinitely
variable to the required situations (required driving torque).
变矩器是一个耐磨启动装置，可使无级变速适用于所需要的条件（所需要驱动力矩）。
Drive by direct mounting on the engine, through membrane for engine connection
SAE 2 and 3 or separate installation (drive through universal shaft) with DIN-,
Mechanic- or Spicer drive flange.
由直接安装在发动机上进行驱动，通过 SAE 2 和 3 发动机连接薄膜或单独安装（通过

万向轴驱动），DIN 机械或 Spicer 驱动法兰。
The signals for the gear changes are issued according to the Version of the vehicle by
the following ZF-Control units:
齿轮转换符号根据如下 ZF 控制装置的车辆类型来确定：
- Semi-Automatic EST-17 T (24V) EST-19 T (12V)
- Fully-Automatic EST-25 (24V) EST-26 (12V)
- 半自动 EST-17 T (24V) EST-19 T (12V)

- 全自动 EST-25 (24V) EST-26 (12V)
Torque converter:
变矩器：
Different Versions:
不同类型：
Unit Size W 280 to W 340 with torque increase according to the Version.
力矩增加按照类型来定，单位规格 W280~W340。
Starting conversion 1,9 to 3,1.
开始转换 1,9 to 3,1。
Upon request, all Converter Versions can be additionally equipped with stator
freewheel or, resp. and sprag pack.
根据要求，所有的变矩器类型可以另外配定子飞轮或档圈垫。
Powershift - Reversin transmissions:

动力换档变速箱：
4 Forward speeds and 3 Reverse speeds.
四个前进档和三个后退档。
Shift control:
换档控制：
Electro-hydraulic.
电液式。
起飞功率：
Power take-off:
有两种发动机起飞功率：液压马达 i = 1,0，同时可以分解任选。
Up to 2 engine-dependent power take-offs i = 1,0 for hydraulic pumps,
optionally also available with disengagement.
油泵连接 SAE A，B 和 C。
Pump connections SAE A, B and C.
输出：
Output:
Through integrated transfer case with the following center distances of 400,
500 and 555 mm. - See Table 4, 5, 6, 7, 8, 9, 10, 11, 12A/B/C
通过整体转换箱进行，配有如下的中心距 400、500 和 555 mm。
见表 4、5、6、7、8、9、10、11、12A/B/C。
变速箱附件：
transmissions accessories:
电气或机械速度仪传感器、轴分开离合器、紧急转身油泵、轴间差速器（长
度补偿差速器）、根据要求，可以提供鼓式或盘式制动器作为停车制动器。
Electric or mechanical Speedometer sensor, Axle declutch, Emergency
steering pump, Interaxle differential (Length-compensating differential), Drum
or Disk brake as Parking brake are possible upon request.
传动比（机械）*
transmissions ratio (mechanical)*
4-Spe
1st-Speed Forward 4,576
2nd-Speed Forward 2,533
3rd-Speed Forward 1,238
4th-Speed Forward 0,713
1st-Speed Reverse 4,576

2nd-Speed Reverse 2,53
3rd-Speed Reverse 1,23
* = According to the transmissions Version, other ratios are also possible.
四档速度
前进一档 4，576
前进二档 2，533
前进三档 1，238
前进四档 0，713
后退一档 4，576
后退二档 2，53
后退三档 1，23
 = 根据变速箱类型，其它比率也可以提供。
IMPORTANT INFORMATIONS
重要说明
Carry out transmissions oil-level check at engine idling (about 1000 min') and
operating temperature of the transmissions.
在发动机怠速（大约 1000 min-1）时，检查变速箱油位和变速箱工作温度。
For temperatures of about 40 ℃ , the lower mark on the oil dipstick is valid. For
temperatures of about 80℃, the upper mark on the oil dipstick is valid.
当油温为 40℃时，油位应在油尺中间刻度线和下刻度线之间。
当油温为 80℃时，油位应在油尺中间刻度线和上刻度线之间。
ATTENTION: At stopped engine, the oil level in the transmissions can rise
essentially, according to the installation conditions!
注意：发动机停止转动时，变速箱油位基本上都会升高，升高多少与变速箱的安装条件有关！
Observe the oil change intervals with simultaneous filter cleaning resp. filter
replacement.
严格参照维护要求，定时更换变速箱油，定时更换过滤器。
At the start of the engine, bring the Controller always to the Neutral position.
在起动发动机时，始终将控制器置于空档位置。
Release the parking brake every time before driving off.
每次行车前，松开停车制动器（解除刹车）。
At reverse driving, reduce the engine speed, reverse in the 1st Speed only.
在后退时，降低发动机速度，只宜放在后退一档上。
Avoid to skip speeds during the drive.
在行驶期间避免跳档。
The engaged speed has no effect at stopped engine.

在发动机停止时无论选择任何速度均不起作用。
Before leaving the vehicle, secure it additionally by brake blocks.

驾驶员离开车辆前，使用阻动块以确保安全。
The towing speed must under no condition be higher than 10 km/h, the towing
distance not longer than 10 km (without secondary pump).
拖车时，车速严禁超过 10 Km/h，拖车距离严禁超过 10 Km（无辅助泵）。
Operating temperature 80℃-110℃，a short-time increase up to max. 120℃ is permitted.

正常工作油温在 80-110℃内，在承受重负载时，允许短时间上升到 120℃。
Pay attention to the control pressure.

要特别注意变速箱的控制油压。
In case of irregularities on the transmission, immobilize the vehicle, ask for trained
personnel.
使用中，发现变速箱有异常现象时，应立即停车检查，并与当地维修服务中心联
系。
-7-
I. DESCRIPTION
I. 简历
1.1 Function of the converter:
1.1 变矩器功能：
The converter works according to the Trilok-System, ie. it assumes at a high
turbine speed the characteristics, and with it the favourable efficiency of a fluid
clutch.
变矩器根据 Trilok 系统进行工作，即，如果涡轮速度特性越高，液力离合器
的效果越显示
The converter is designed according to the engine power so that the most
favourable operating conditions for every installation purpose are existing.
变矩器根据发动机功率设计，所以每次安装的目的在于获得最好的工作条
件。
The torque converter is composed of 3 main components:
液力变矩器包括三个主要元件：
Pump wheel - Turbine wheel - Stator (Reaction member)
泵轮——涡轮——定子(导轮)
These 3 impeller wheels are arranged in such a ring-shape system that the
fluid is flowing through the circuit components in the indicated order.
这三个叶轮位于这样一个环形系统中：液体按所示顺序流经回路元件。
The ZF-Converter charge and control pressure pump is constantly pumping
pressure oil through the converter.
ZF——变矩器的充压和控制压力泵不断地通过变矩器输送压力油。
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 eliminated by the
escaping oil.
因此，变矩器可以完成其扩大发动机扭矩的任务，同时，变矩器产生的热
量可以通过排除的油来消除。
The oil escaping out of the pump wheel, enters the turbine wheel and is there
inverted in the direction of flow.
从油泵轮中排除的油进入涡轮并且朝流动的方向转移。
According to the rate of inversion, the turbine wheel and with it also the output
shaft receives a more or less high reaction moment. The stator (reaction
member), following the turbine, has the task to invert the oil, which is
streaming out of the turbine again and to deliver it under the suitable
discharge direction to the pump wheel.
根据转换率，涡轮以及输出轴可以接收一个或多或少的高反应转矩。从动
涡轮的定子（反应构件）的任务是转换从涡轮中出来的油，并朝合适的流出方
向送到油泵轮上。
Due to the inversion, the stator receives a reaction moment.
由于转换的作用，定子接收一个反应转矩。
The relation turbine moment/pump moment is called torque conversion. This
is the higher, the greater the speed difference of pump wheel and turbine
wheel will be.
涡轮/油泵转矩关系称为矩力转换。矩力转换越多，油泵轮和涡轮的速度差
距越大。
Therefore, the maximum conversion is created at standing turbine wheel.
因此，在立式涡轮上产生最大的转换。
With increasing output speed, the torque conversion is decreasing. The
adaptation of the output speed to a certain required output moment is infinitely
variable and automatically achieved by the torque converter.
随着输出速度的增加，扭距转换减少了。输出速度不断适应一定要求的输
出力矩并且由变矩器自动获得。
If the turbine speed is reaching about 80% of the pump speed, the conversion
becomes 1,0, i.e. the turbine moment becomes equal to that of the pump
moment.
如果涡轮速度达到泵的速度的 80%，转换变成了 1，0，即涡轮转矩与油泵
的转矩相等。
From this point on, the converter is working similar to a fluid clutch.
因此，变矩器类似于液力离合器工作。
A stator free wheel serves to improve the efficiency in the upper driving range,
in the conversion range, it backs up the moment upon the housing and is
released in the coupling range. In this way, the stator can rotate freely.An
installed sprag pack has the purpose to connect at overrunning vehicle the drive
shaft and turbine shaft (converter output) frictionally with each other.
定子飞轮用于提高上驱动范围的效率，在此转换范围中，它支持壳体上的力
矩，并在连接范围内释放，因此，定子可以自由旋转。安装档圈垫目的在于车辆
超速运行时，传动轴和涡轮轴（变矩器输出）互相摩擦连接。
This condition appears for example at downhill driving. In this case, the
braking effect of the engine can be utilized.
例如，在下坡行驶时，此条件的出现。在此情况下，可以采用发动机的制
动效果。
from the engine 自发动机
Pump wheel 泵轮 Turbine wheel 涡轮
Tp = Torque of the pump wheel 泵轮扭矩
Tt = Torque of the turbine wheel 涡轮扭矩
Tr = Torque of the reaction member (stator) 导轮（定子）扭矩
Starting condition 起动条件 Intermediate condition 中间条件
condition shortly before the converter clutch is closed 在变矩器的离合器关闭
前的条件
to the gearbox 至齿轮箱 nT 0 vehicle speed 车辆速度
nT < n engine 发动机 nT 0，8 n engine 发动机
turbine wheel is running with about the same speed as pump wheel 涡轮与泵
轮以同样的速度运行。
1.2
Powershifttransmissions:
1．2 动力换档变速箱：
The multi-speed reversing transmissions in layshaft design is engageable
under load by hydraulically controlled multi-disk clutches.
多级速度换档变速箱的机轴设计在液压控制多片离合器负载下是啮合式的。
All gear wheels are constantly meshed and running in antifriction bearings.
所有的齿轮不断啮合，在抗摩擦轴承中运转。
The gear wheels, bearings and clutches are lubricated with cooled oil.
齿轮、轴承和离合器采用冷却油润滑。
The 4-Speed Reversing transmissions is equipped with 6 multi-disk clutches.
四种速度换档变速箱配有六个多片离合器。
At the shifting, the corresponding plate pack'is compressed by a piston,
movable in axial direction,which is pressurized with pressure oil.
在换档时，相应的板垫由一个活塞压缩，在轴向方向移动，采用压力油加
压。
A compression spring is pushing back the piston, thus releasing the plate pack.
As to the Layout of the transmissions as well as the indication of the closed
clutches in the single speeds, see Table 1, 13, 14, 15, 16, 17, 18, 19, 20, 21,
and 22.
压缩弹簧向后推动活塞，因此，可以释放板垫。关于变速箱的布置图以及
每个速度的关闭离合器说明，见表 1，13，14，15，16，17，18，19，20，21
和 22。
1.3 transmissions controls:

1．3 变速箱控制:
1.3.1 STANDARD
1．3．1 标准类型
VERSION
transmissions control see Oil circulation diagram, Schedule of measuring
points, and Aluminum Die-casting shift control, Table 13, 18 and 23.
有关变速箱控制，见油回路图、测量点的确定、铝铸模换档控制、表 13、
18 和 23。
The converter charge and control pressure pump, necessary for the oil supply
of the converter and the transmissions control, is fitted in the transmissions on
the engine-dependent drive shaft. The feed rate of the pump is Q = 801/min, at
nenoe = 2000 min -1.
用于变矩器油输送和变速箱控制的变矩器的充压和控制压力泵安装在发动
机传动轴的变速箱上。
油泵的输送速度在 n 发动机= 2000 min –1 时，是 q = 80 升/分。
This pump is sucking the oil through the coarse filter out of the oil sump and
delivers it through the ZF-Fine filter - the filter can be fitted also externally from
the transmissions - to the control pressure valve.
此油泵通过油底壳上的粗过滤器吸油，并通过 ZF 精过滤器输送，精过滤器
也可以安装在变速箱的外面到控制压力阀上。
Grade of filtration: '30 > 20 131o >1,5

Filter area: 3500 cmz
过滤等级：ß30 ≥20 ß 10≥1，5
过滤范围：3500 cm2
The oil which is pressurized by the control pressure valve is directed through
the pressure control valve by the shift valves 1, 2, 3, 4 and 5 to the multi-disk
clutches.
由控制压力阀压缩的油通过压力控制阀由换档阀 1、2、3、4、5 输送到多
片离合器中。
The pressure control valve regulates during the shifting procedure the
pressure build-up in the clutches. At the change over, the pressure is
short-time dropping and is increasing after the completed shifting procedure
again to 16 +2 bar.
压力控制阀调节换档顺序时离合器中的加压。在转换结束时，压力短时间下
降，在完成换档步骤后，又增加到 16 +2 bar。
The signals for the gear changes are issued according to the Version of the
vehicle by the following ZF-Control units:
齿轮变换信号根据车辆的类型来定，由如下 ZF 控制装置来发出：
- Semi-Automatic EST-17T (24V) EST-19T (12V) - see Table - 28, 29, 30,
31 - Fully Automatic EST-25 (24V) EST-26 (12V)
——半自动 EST-17T (24V) EST-19T (12V) ——见表 28，29，30，

31
——全自动 EST-25 (24V) EST-26 (12V)
The reset valve resets the pressure control valve to its starting position as
soon as the speed has been shifted, so that the piston is ready for the next
gear change.
当转换速度时，复位阀将压力控制阀复位到其开始位置，使活塞准备下一
次齿轮转换。
These shifting procedures are exactly adapted to the different models and
types of vehicle.
这些换档步骤可以精确地用于不同型号和不同类型的车辆。
The pilot pressure for the control of the shift valves is reduced by the
reducing valve to 10 bar and directed to them through the solenoid valves M1,
M2. M3, M4 and M5.
用于控制换档阀的先导压力由减压阀降低到 10bar，并且通过电磁阀 M1、
M2、M3、M4 和 M5 进行。
The control pressure valve is limiting the maximum control pressure and
releases the main flow to the converter and lubricating circuit.
控制压力阀限制最大控制压力和释放主流量给变矩器和润滑回路。
A safety valve is installed in the converter inlet which protects the converter
against high internal pressures (opening pressure 8,5 bar).
安全阀安装在变矩器入口处，保护变矩器防止产生过高内部压力(开启压
力 8，5 bar)。
Within the converter, the oil serves as transfer of the power according to the
well-known hydrodynamic principle (see Chapter Torque converter).
在变矩器中，根据熟悉的液压动力原理，油用于动力的转换（见变矩器一
章）。
To avoid cavitation, the converter must be always completely filled with oil.
为了避免气穴现象，变矩器必须一直完全充满油。
This is achieved by a converter pressure holding valve, following the
converter, with an opening pressure of about 5 bar.
这由变矩器的压力保持阀获得，变矩器的开启压力大约为 5bar。
The oil which is escaping from the converter, is directed to a heat exchanger
(oil-water, resp. oil-air).
从变矩器释放出来的油进入一个热交换器（油——水，油——空气）。
At water-cooled engines, the heat exchanger has to be arranged in the
cooling-water flow which is directed to the engine.
在水冷式发动机中，热交换器必须位于进入发动机的冷却水流中。
An oil-air cooler can be also used. At air-cooled engines, the heat exchanger
must be arranged in the cold-air flow of the cooling fan.
同时也可以使用油——空气冷却器。在气冷发动机中，热交换器必须位于
冷却风扇的冷气流中。
The heat exchanger has to be connected according to the counterflow principle.
These units are not supplied by the Zahnradfabrik Passau GmbH.
热交换器必须根据逆流原理连接。这些装置不是由 Zahnradfabrik Passau
Gmbh 公司提供的。
从油冷却器中，油进入变速箱中并且润滑油回路中，以使所有的润滑点都配有
冷却润滑油。
For the safety of the oil cooler, a bypass valve has to be planned which is
reacting at cold oil or clogged oil cooler.
为了油冷却器的安全，要备有一个旁通阀，在冷却油或油堵塞冷却器时起
作用。
From the oil cooler, the oil is directed to the transmissions and there to the
lubricating-oil circuit so that all lubricating points are supplied with cooled
lubricating oil.
Five solenoid valves are installed in the d The allocation of the solenoid valves
from the Tables 13 and 18.
安装五个电磁阀在控制装置中——见表 23。电磁阀的位置——移动位置—
—到每个速度可以从表 13 和 18 中找到。
The selection of the solenoids will be
根据速度的不同组合来选择电磁阀。
These combinations are called coding.
这些组合称为编码。
The electric shift control offers the adva~
电气移动控制具有操作简单、精确的优点。
It is an essential advantage that due to are created.
一个基本的优点就是：由于是电缆连接，不会产生安装的问题。
1.3.2 VERSION WITH 2-STAGE P SSURE CONTROL VALVE - VARIANT I

1．3．2 二级压力控制阀的类型——变量 I
transmissions control see Oil circulation 'agram, Schedule of measuring

points and Aluminum Die-casting shift control Table 14, 19 an 24.
有关变速箱的控制，见油回路图、测量点的确定、铝铸模换档控制、表 14、
19 和 24。
The converter charge and control pressure pump which is necessary for the
oil supply of the converter and the transmissions control, is fitted in the
transmissions on the engine-dependent drive shaft.
变矩器的充压和控制压力泵用于变矩器油的供应和变速箱控制，安装在发动机
驱动轴的变速箱上。
The delivery rate of the pump is Q = 801/min, at n,„ginr = 2000 min "'.
在 n 发动机= 2000 min-1 时，油泵的排量为 Q = 80 升/分。
delivers the oil through the ZF-Fine filter - the filter can be fitted also externally
from the transmissions - to the control pressure valve.
此油泵通过油底壳中的粗过滤器吸油并且通过 ZF 精过滤器油输送油，此过
滤器可以从变速箱的外面安装到控制压力阀上。
Grade of filtration: B30 - 20 1310 2 1,5
Filter area: 3500 cm2
过滤等级：ß30 ≥20 ß 10≥1，5
the 2-stage pressure control valve with bleeder valve by the shift valves 1, 2, 3,
4 and 5 to the multi-disk clutches.
由控制压力阀压缩的油通过配有排放阀的二级压力控制阀，由换档阀 1、2、
3、4、5 输送到多片离合器中。
again to 16 +2 bar.
压力控制阀调节换档顺序时离合器中的加压。在转换结束时，压力短时间
下降，在完成换档步骤后，又增加到 16 +2 bar。
The signals for the gear changes are issued according to the design of the
- Semi-Automatic EST-17T (24V) EST-19T (12V) - see Table 28, 29, 30, 31 -
Fully-Automatic EST-25 (24V) EST-26 (12V)
31
——全自动 EST-25 (24V) EST-26 (12V)
The pressure control can be „soft or fast", to be more precise as follows:

压力控制可以是“慢或快”的，如下是更精确的控制：
,,Soft shifting"
“慢速换档”
At shiflings from V1 (Forward 1st Speed) q RI (Reverse 1st Speed), resp. vice
versa, the control pressure to the 2-stage pressure control valve is interrupted
by the reversing valve, which is selected by the Clutch Kl. In this way, the
pressure build-up is realized without the 2stage pressure control valve.
从 V1 （前进一档）→R1（后退一档），反之亦然，通过换档阀（由离合器
Kl 来选择），可以中断控制压力到二级压力控制阀。这样，不采用二级压力控
制阀，就可实现压力的增加。
This is resulting in a „soft shifting".
这就可以产生“慢速换档”。
In this position, the gear change is realized at low control pressure.
在此位置上，低控制压力可以实现换档。
JEast
“快速换档”
At all other gear changes, the reversing valve is reset by the elastic force. In
this way, the system pressure becomes quickly effective behind the 2-stage
pressure control valve, and the gear change is realized at higher pressure
level.
在所有其它的齿轮转换中，换档阀通过弹力复位。这样，系统压力在二级压
力控制阀中很快有效，并且可以在高压力值时可以实现换档。
This is resulting in a fast shifting.
这就可以产生“快速换档”。
The bleeder valve has the task to ventilate the pressure chamber behind the
pressure control valve for a longer time.
排放阀的任务是排出长时间压力控制阀后的压力室中的压力。
The reset valve resets the pressure control valve into its starting position as
soon as the speed has been shifted so that the piston is ready for the next
gear change.
当转换速度时，复位阀将压力控制阀复位到其开始位置，使活塞准备下一次
齿轮转换。
These shifting procedures will be exactly adapted to the different models and
types of vehicle.
The pilot pressure for the control of the shift valves is reduced by the reducing
valve to 10 bar and directed to them through the solenoid valves M1, M2, M3,
M4 and M5.
A relief valve is installed in the inlet to the converter which is protecting the
converter against high internal pressures (opening pressure 8,5 bar).
安全阀安装在变矩器入口处，保护变矩器防止产生过高内部压力(开启压力
8，5 bar)。
章）。
To avoid cavitation, the converter must be always be completely filled with oil.
This is achieved by a converter pressure holding valve, following the converter,
with an opening pressure of about 5 bar.
The oil which escaping from the converter is directed to a heat exchanger
(oil-water, resp. oilair).
cooling-water stream wich is directed to the engine.
must be arranged in the cold-air stream of the cooling fan.
The heat exchanger has to be connected according to the counterflow
principle. These units are not supplied by the Zahnradfabrik Passau GmbH.
作用。
From the oil cooler, the oil is delivered to the transmissions and there to the
lubricating oil.
从油冷却器中，油进入变速箱中并且润滑油回路中，以使所有的润滑点都
配有冷却润滑油。
Five solenoid valves are intalled in the control unit - see Table 24.
安装五个电磁阀在控制装置中——见表 24。
The alloction of the solenoid valves - shifting positions - to the single speeds
can be taken from the Tables 14 and 19.
电磁阀的位置——移动位置——到每个速度可以从表 14 和 19 中找到。
The selection of the solenoids will be differently combined according to
the speed.
The electric shift control offers the advantage of an easy and exact operation.
It is an essential advantage that due to the electric cable connection, no
installation problems are created.
1.3.3 VERSION WITH 2-STAGE PRESSURE CONTROL VALVE - VARIANT II
1．3．3 二级压力控制阀的类型——变量Ⅱ
points and Aluminum Die-casting shift control, Table 15, 20 and 25.
20 和 25。
oil supply of the converter and the transmissions control is fitted in the
变矩器的充压和控制压力泵用于变矩器油的供应和变速箱控制，安装在发
动机驱动轴的变速箱上。
The feed rate of the pump is Q = 80 h/min, at n,,g117E = 2000 min "1.
This pump is sucking the oil through the coarse filter out of the sump and
Grade of filtration: 1330 - 20 10 > 1,5
过滤等级：ß30 ≥20 ß 10≥1，5
4 and 5 to the multi disk clutches.
short-time dropping and is increasing after the completed shifting procedure to
16 +2 bar again.
The signals for the gear changes are issued according to the design of the
vechicle by the following ZF-Control units:
Semi-Automatic EST-17T (24V) EST-19T (12V) - see Table 28, 29, 30, 31
Fully-Automatic EST-25 (24V) EST-26 (12V)
31
——全自动 EST-25 (24V) EST-26 (12V)
„Soft shifting"
“慢速换档”
At the shifting in the 1st and 2nd Speed Forward and Reverse, the reduced
system pressure (10 bar) is fed forward by the solenoid valve M4 to the shift
valve and to the reversing valve.
在前进和后退一、二档中，由电磁阀 M4 输送降低的系统压力（10bar）到
换档阀和换向阀中。
In this way, the control pressure to the 2-stage pressure control valve is
interrupted, and the pressure build-up is realized without the 2-stage pressure
control valve.
这样，可以中断到二级压力控制阀压力控制，不采用二级压力控制阀，就
可实现压力的增加。
In this position, the gear change is realized at low control pressure.
„Fast
“快速换档”
At all other gear changes, the reversing valve will be reset by the elastic force.
In this way, the system pressure becomes quickly effective behind the 2-stage
pressure control valve, and the gear change is realized at a higher pressure
level.
This is resulting in a „fast shifting".
The bleeder valve has the task to ventilate the pressure chamber behind the
The reset valve resets the pressure control valve into its starting position as
soon as the speed has been changed so that the piston is ready for the next
gear change.
当转换速度时，复位阀将压力控制阀复位到其开始位置，使活塞准备下一
次齿轮转换。
These shifting operations will be exactly adapted to the different models and
types of vehicle.
valve to 10 bar, and is directed to them through the solenoid valves M1, M2,
M3, M4 and 5.
A safety valve is installed in the inlet to the converter which protects the
8，5 bar)。
章）。
This is achieved by a converter pressure holding valve, following the converter,
with an opening pressure of about 5 bar.
The oil which is escaping from the converter is directed to a heat exchanger
(oil-water resp. oil-air).
cooling-water stream which is delivered to the engine.
The heat exchanger has to be connected according to the counterdow
为了油冷却器的安全，要备有一个旁通阀，在冷却油或油堵塞冷却器时起作
用。
lubricating oil.
Five solenoid valves are installed in the control unit - see Table 25.
The allocation of the solenoid valves - shifting positions - to the single speeds
the speed.
1.3.4 VERSION WITH EXPANSION VALVE

1．3．4 膨胀阀的类型
21 和 26。
oil supply of the converter and the transmissions control is fitted in the
动机驱动轴的变速箱上。
The delivery rate of the pump is Q = 80 Umin, at
nrng111C = 2000 min 1.
Grade of filtration: 1)30 > 20
过滤等级：ß30 ≥20 ß 10≥1，5

the pressure control valve with bleeder valve by the shift valves 1, 2, 3, 4 and 5
to the multi-disk clutches. The pressure control valve regulates during the
shifting procedure the pressure build-up in the clutches. At the change over,
the pressure is short-time dropping and is increasing after the completed
shifting procedure again to 16 12 bar.
由控制压力阀压缩的油通过配压力控制阀调节换档顺序时离合器中的加
压。在转换结束时，压力短时间下降，在完成换档步骤后，又增加到 16 +2 bar。
有排放阀的二级压力控制阀，由换档阀 1、2、3、4、5 输送到多片离合器
中。
Semi-Automatic EST-17T (24V) EST-19T (12V) - see Table 28, 29, 30,
31 Fully-Automatic EST-25 (24V) EST-26 (12V)
31
——全自动 EST-25 (24V) EST-26 (12V)
The expansion valve (M6) is normally always cut in and is cut off at shiftings
for a programmed period.
一般在编程期间换档时，可以开启和切断膨胀阀（M6）。
At the start of a shifting, the expansion valve is still hold cut in for a short
programmed period. During this period, the clutch filling can be realized at
high pressure level.
在换档开始时，膨胀阀仍然在短的编程期间保持切断。在此期间，在高压
时，可以实现离合器的加油。
After the clutches are filled, the expansion valve is cut ofl; and the hydraulic
engagement of clutches will be completed with the modulated control
pressure.
在离合器的加油后，膨胀阀切断，采用中等控制压力可以完成离合器的液
压啮合。
After completion of the hydraulic engagement, the expansion valve is cut in
again.
在完成液压啮合后，膨胀阀又可以开启了。
In this way, the pressure control valve is reset into its starting position and is
ready for the next gear change.
这样，复位阀将压力控制阀复位到其开始位置，使活塞准备下一次齿轮转
换。
The bleeder valve has the task, to ventilate the pressure chamber behind the
valve to 10 bar, and directed to them through the solenoid valves Ml, M2, M3,
M4 and M5.
8，5 bar)。
章）。
To avoid cavitation, the converter must be always completely
filled with oil.
converter with an opening pressure of about 5 bar.
The oil, escaping from the converter, is directed to a heat exchanger (oil-water
resp. oil-air).
cooling-water stream which is directed to the engine.
The heat exchanger has to be connected according to the counterflow
作用。
From the oil cooler, the oil is directed to the transmissions and there to the
lubricating oil.
从油冷却器中，油进入变速箱中并且润滑油回路中，以使所有的润滑点都配有
冷却润滑油。
Five solenoid valves are installed in the control unit.- see Table 26.
the speed.
It is an essential advantage that due the electric cable connection, no
1.3.5 VERSION WITH 2-STAGE PRESSURE CONTROL VALVE AND

EXPANSION VALVE
1．3．5 二级压力控制阀和膨胀阀的类型
有关变速箱的控制，见油回路图、测量点的确定、铝铸模换档控制、表 17、22
和 27。
The converter charge and control pressure pump necessary for the oil supply
of the converter and the transmissions control, is fitted in the transmissions on
the engine-dependent drive shaft. The delivery rate of the pump is Q = 80
Umin, at n,„ gi„c = 2000 min "1.
动机驱动轴的变速箱上。在 n 发动机= 2000 min-1 时，油泵的排量为 Q = 80 升/
分。
Grade of filtration: JJ30 > 20 1310 > 1,5
过滤等级：ß30 ≥20 ß 10≥1，5
4 and 5 to the multi-disk clutches.
again to 16 +2 bar.
31
——全自动 EST-25 (24V) EST-26 (12V)
- Semi-Automatic EST-17T (24V) EST-19T (12V) - see Table 28, 29, 30,
- Fully-Automatic EST-25 (24V) EST-26
31 (12V)

„Soft shifting"
“慢速换档”
At the shifting in the 1st and 2nd Speed Forward and Reverse, the reduced
system pressure (10 bar) will be fed forward by the solenoid valve M4 to the
shift valve and to the reversing valve. In this way, the control pressure to the
2-stage pressure control valve is interrupted, and the pressure build-up is
realized without the 2-stage pressure control valve.
在前进和后退一、二档中，由电磁阀 M4 输送降低的系统压力（10bar）到
换档阀和换向阀中。这样，可以中断到二级压力控制阀压力控制，不采用二级压
力控制阀，就可实现压力的增加。
In this position, the gear change will be realized at low control pressure.
,.Fast shifting"
“快速换档”
At all other gear changes, the reversing valve is reset by the elastic force. In
this way, the system pressure becomes quickly effective behind the 2-stage
pressure control valve, and the gear change will be realized at higher pressure
level.
This is resulting in a „fast shifting".
The expansion valve (M6) is normally always cut in and is cut off at shiftings
for a programmed period.
一般在编程期间换档时，可以开启和切断膨胀阀（M6）。
At the start of a shifting, the expansion valve is still hold cut in for a short
programmed period.
在换档开始时，膨胀阀仍然在短的编程期间保持切断。
In this period, the clutch filling can be realized at high pressure level.
在此期间，在高压时，可以实现离合器的加油。
After the clutches are filled, the expansion valve is cut off and the hydraulic
engagement of the clutches will be completed with the modulated control
pressure.
在离合器的加油后，膨胀阀切断，采用中等控制压力可以完成离合器的液压啮
合。
After completion of the hydraulic engagement, the expansion valve is cut in
again.
在完成液压啮合后，膨胀阀又可以开启了。
In this way, the pressure control valve will be reset into its starting position and
is ready for the next gear change.
这样，复位阀将压力控制阀复位到其开始位置，使活塞准备下一次齿轮转
换。
The bleeder valve has the task, to ventilated the pressure chamber behind the
valve to 10 bar and directed to them through the solenoid valves M1, M2, M3,
M4 and M5.
8，5 bar)。
在变矩器中，根据熟悉的液压动力原理，油用于动力的转换（见变矩器一章）。
converter, with an opening pressure of about 5 bar.
The oil which is escaping from the converter is directed to a heat exchanger
(oil-water resp. oil-air).
cooling-water stream which is directed to the engine.
An oil-air cooler can be also used.
也可以采用油——空气冷却器。
At air-cooled engines, the heat exchanger must be arranged in the cold-air
stream of the cooling fan. The heat exchanger has to be connected according
to the counterflow principle.
同时也可以使用油——空气冷却器。在气冷发动机中，热交换器必须位于冷
却风扇的冷气流中。热交换器必须根据逆流原理连接。
These units are not supplied by the Zahnradfabrik Passau GmbH.
这些装置不是由 Zahnradfabrik Passau Gmbh 公司提供的。
作用。
lubricating oil.
Five solenoid valves are installed in the control unit - see Table 27.
can be taken from the Table 17 and 22.
the speed.
1.4 Controller
1.4.1 Controller DW-2
1．4 控制器
1．4．1 控制器 DW-2
- see Table - 32
——见表 32。
The Controller is designed for the LH-mounting on the steering column.
控制器用于转向柱的 LH 安装。
The Positions (Speeds) 1 to 4 are selected by the rotary motion; the driving
direction (Forward (V) - Neutral (N) - Reverse (R), by tiling the lever.
位置（速度）1 至 4 档由旋转运动来选择；驱动方向（前进（V）——空档
（N）——后退（R）通过倾斜操作杆获得。
A Neutral lock is installed as protection against unwanted drive off.
中档锁定用于不必要的驱动保护。
,,D": Driving; Position,,N" : Controller lever blocked in position.
“D”：驱动；位置，“N”：控制器操作杆锁住定位。
DW-2 CONTROLLER
DW-2 控制器
1．4．2 控制器 ERGO II

——见表 33。
1.4.2 Controller ERGO II - see Table - 33.
将安装此控制器，不采用轮式装载机的工作液压系统的控制杆。
This Controller will be installed instead of the control lever for the working
hydraulics in the Wheel loader.
驱动方向通过按下箭头按键， “前进”和“后退” 来选择，采用“+”和“-”
可以在驱动范围作预选择。
The driving direction is selected by pressing the Arrow keys „Forward"
and ,Reverse"; the Keys „+" and „" are preselecting the driving range.
在显示器上有说明（见 1．5）。
The indication appears on the Display (see 1.5).
借助于“N”键，可将变速箱置于空档。
By means of the , N"- Key, the transmissions is shifting to Neutral.
控制面板的另一个按键可以连接电气铲装——水平调节（铲装——空档）。
Another key from the control panel allows the connection of an electric
shovel-horizontal adjustment (Shovel-Neutral).
另一个控制按钮安装在后面。它根据驱动情况用作一个降档按钮，作为速
度下降按钮或作为驱动停止的释放按钮。
Another control button is installed on the back. It serves, according to the
driving situation as kickdown knob, as speed-downshift knob or as release
knob for the drive off
CONTROLLER ERGO II
控制器 ERGO—II
1.5 Display
- General
1 .5 显示器
——简介——l
显示器可以用于所有控制器类型，例如 DW—2 或 ERGO—II。它指示齿轮
和驱动方向以及所驱动的降档（在配有变矩器锁定离合器（WK）的车辆中，任
选“状态，“WK 关闭” ）。
The display can be used with all Controller types, e.g. with the DW-2 or
ERGO-IL It indicates the gear and the driving direction as well as the activated
Kickdown (at vehicles with converter lockup clutch (WK) optionally the
Status ,,WK closed").
Errors, which appear sporadically can be also displayed.
如果采用自动控制 EST 25，一个 bar 指示器另外同时指示关于所选择驱动

范围信息；自动范围采用上面和下面的 bar 指示箭头标注。在系统出现错误时，
在显示器上会出现一个扳手，并指示错误信息。
偶然出现的错误也可以显示。
If the Automtic control EST 25 is used, a bar indicator gives additionally also
informations about the selected driving range; the automatic range is
symbolized by Arrows above and below the bar indication. In case of possible
errors in the system, a wrench appears on the display, combined with the
indication of the error number.
符号说明:
1 = 选择的速度
2 = 驱动方向前进
三档 = 显示错误号码
4 = 系统错误的符号
5 = 驱动方向后退
LEGEND:
1 = Selected speed
2 = Driving direction Forward
3 = Display error number
4 = Symbol for error in the system
5 = Driving direction Reverse
1.5.1 错误图表：
1.5.1 Error Chart:
In case of unrecoverable errors, the System shuts down completely (RESET;
New start only through Ignition OFF/ON).
如果遇到不可恢复的错误，系统必须完全切断(复位; 只通过点火开关的开/
关重新起动)。
特别是输出线路中断和速度电磁阀的线路是外面供应时。
To it belong especially Output line interruption and Outside supply at lines to
the speed solenoid valves.
这些错误不会显示。
These errors CANNOT be displayed.
Another error category is leading to an immediate RESET, whereas however,
the electronics is still indicating the errors as error numbers as long as a)
these are still present and/or b) the Controller is not yet in position Neutral"
(Status „Waiting for Neutral").
另一个错误类型会导致立即复位，然而，电子系统仍然指示错误是一个错
误号码：只要 a)这些错误仍然会出现和/或 b)控制器还没有位于“空档位置” （状
态，等待“空档”）。
After the error is cancelled, and in position „Neutral", the electronics is starting
the transmissions-control program and clears the error display.
在取消错误后，和定位在“空档”时，电子系统开始起动传送控制程序并
且消除错误显示。
To this belong the following Error classes/Error numbers:
错误级别/错误代码如下：
• Invalid Controller input-line combination: 22

• Short circuit of an output against ground: 23
• Defective voltage supply: 24
• Error in the data field: 31
• Error in the program operation: 32
• Error in the processor-RAM: 33
• 无效控制器输入线路组合： 22
• 对地输出短路： 23
• 电压故障： 24
• 数据段错误： 31
• 翻译操作错误： 32
• 处理器 RAM 错误： 33
Finally, there are still errors, which are not directly critical In this case, no
RESET will be initiated, i. e. the transmissions-control program is running on
with limitations; the errors will be only displayed after the shifting to
Controller-Neutral, and are only cancelled again with the shifting from Neutral:
最后，如果仍然有错误，在此情况下，不是直接的关键错误。在此情况下，
不要重新恢复，例如变速箱控制程序有限制地运行；在转换到控制器空档时，只
有从空档转换再次消除错误：
• Failure of the turbine speed sensor: 02(42*)
• Failure of the output speed sensor: 10(50*)
• Interruption/Foreign power supply 21(61*)
of only less critical outputs:
•涡轮机速度传感器故障： 02(42*)
•输出速度传感器故障： 10(50*)
•关键输出少的中断/外部电源: 21(61*)
一般地，错误通过降压电阻器的指示灯发出，降压电阻器必须与诊断连接
器连接（闪光信号长：十进制值，短：单位值，例如相当于错误代码 22 的长/
长/短/短）。
As a standard, errors are issued through a LED with dropping resistor which
must be connected on the diagnostic connector (Flashing signal long: Decimal
value, short: Units value, e.g. corresponding to „long/long/short/short" of the
error number „22").
指示灯在点火接通后（灯检测）立刻闪烁。
The LED is flashing shortly after the ignition is switched on (lamp test).
In the Status „Waiting for Controller-Neutral", it is lighting permanently
(possibly with flashing-code output), at trouble-free driving, it is completely off
在“等待控制器——空档”状态下，就一直亮着（带有闪光代码输出），在
无故障驾驶时，它完全熄灭。
(*): If the optional display is used, the errors can be issued on this one as error
number. In this case, these error numbers 02, 10 and 21 are also displayed if
they had occurred only temporarily and disappeared again in the mean time.
(*)：如果采用任选显示，可以发出错误作为错误代码。在此情况下，这些错误
代码 02、10 和 21 同时显示，如果它们仅临时出现，同时又消失。
然后这种零星错误代码值增加+ 40，因此到 42、50 和 61。

The value of the error number for such sporadic errors is then increased for +
40, therefore to 42, 50 resp. 61.
Still another NOTE concerning the Display:

有关显示的另一个注意事项：
At a very short-time OFF/ON switching of the power supply (ignition), wrong
error messages can be issued on the display, because after the switching off of
the ignition, the microprocessor is still „hunting"
在切断电源（点火）开/关时，在显示屏上可以发出错误信息，因为在切断
点火之后，微机仍然在“监控”。
If requested, the error indication on the display can therefore be completely
suppressed.
如果需要，显示器上的错误显示可以完全禁止。
-21-
1.6 Electronic control units for ZF-Powershift transmissionss:
General:
1.6 ZF 动力换档变速箱的电子控制装置：
概述：
Because of the different designs of the electronic transmissions controls at the
different vehicles, the corresponding details must be taken from the Operating
Instructions of the Vehicle Manufacturer or from the Technical fly leafs of the
corresponding Parts-List Versions.
因为在不同的车辆电子变速箱控制的设计不同，有关的详细内容，可从车
辆制造商的操作说明书或有关零件表等的技术资料中了解。
In these are also indicated the relative wiring and connection diagrams, see
Sample - Tables 28, 29, 30 and 31.
这些资料中同时介绍有关的接线和连接图，详见样表 28、29、30 和 31。
These Informations can be also requested from the ZF-PASSAU. Furthermore,
a separate description of these Control units is existing.
这些资料同时也可以从 ZF-PASSAU 获得。此外，这些控制装置另有介绍。
According to the type of vehicle, the wiring will be realized according to the
wiring diagrams. Variations as double-control platform operation (e.g.
RT-Crane Vehicles) are available.
根据车辆的类型，接线可以参看线路图。可以提供双控制车架操作说明（如
RT 起重机）。
The corresponding switching diagrams are available upon request.
根据需要可以提供有关的连接图
Upon request, the wiring can be also supplied by the ZF.
根据需要，ZF 同时可提供接线。
If the wiring is realized by the Vehicle Manufacturer, it should correspond to
our conditions.
如果接线由车辆制造商完成，应当符合我们的条件。
1.6.1 Description of the Basic function:

1.6.1 基本功能的介绍：
The Powershift-Reversing transmissionss of the WG-Series are mostly
equipped with the Electro-hydraulic transmissions control developped for
them.
大多数 WG 系列动力换档变速箱配有专门开发的电液变速箱控制。
With this Control unit it is possible to automate the transmissions control in a
simple manner from the Semi Automatic EST- 17T up to the Fully-Automatic
EST-25.
采用此控制装置，可以以简单方式从半自动 EST-17T 到全自动 EST-25 使
传送控制自动化。
For Wheel loaders, ZF has developped a special Controller concept by means
of the Controllers DW-2 and ERGO II with integrated kickdown knob.
轮式装载机，ZF 已经通过控制器 DW-2 和 ERGO II（配整体降档按钮）。
The System is processing the request of the driver concerning driving direction
and speed as well as the actual vehicle speed, and offers essential
advantages:
系统处理驾驶员有关驾驶方向、速度以及实际车辆速度的请求，具有的基
本优点如下：
• Optimal adaptation to engine, vehicle and application criteria by specific
programming
• Adaption of the shifting points in relation to the load level of the engine •
Optimal reversing behavior
• Comfortable kickdown function
• Wide range of Controllers (for each case of application, the optimal Controller
type is available)
• Electric system resistant to short circuit and overvoltage
• Far-reaching protection against operating errors (Software) Semi- and
Fully-Automatic units available.
• 通过特定程序使发动机、车辆和使用标准达到最佳适应
• 使换档点位适合于发动机的负载值
• 最佳动力换档
• 舒适的换档功能
• 控制器范围广（每种情况运用，获得最佳控制类型）
• 电气系统能防止短路和过压
• 防止操作错误（软件）的远程保护
半自动和全自动装置。
EST-25 - Family pack
(Example transmissions WG-200. Maximum System *)
EST-25——家庭型
(WG-200 变速箱图例，最大系统*)
LEGEND:
Supply sytem connection Display
EST-25 transmissions control Cable to the speed valves
Cable to the WK (Converter lockup clutch) transmissions of the WG-Series
Cable to the Inductive transmitter Output Cable to the Inductive transmitter
Turbine Idle rotary switch
Load cell Kickdown Switch Controller DW-2
图形符号：
1=供应系统连接
2=显示器
3=EST-25 变速箱控制
4=与速度阀连接的电费
5=与 WK（变矩器锁止离合器）
6=WG 系列变速箱
7=与感应发送器输出连接的电缆
8=与感应发送器涡轮连接的电缆
9=怠速旋转开关
10=负载传感器
11=降档开关
12=控制器 DW-2
1.6.2 Description of the Microprocessor Control unit EST-..

1.6.2.1 General:
1.6.2 微机控制装置 EST 介绍
1.6.2.1 简介：
The Microprocessor Control units are distinguished between:
- Semi-Automatic EST-17T (24V Supply system voltage), resp. EST-19T (12V)
and
- Fully-Automatic EST-25 (24V) resp. EST-26 (12V)
微机控制装置的区别：
——半自动 EST-17T （24V 供应系统电压），
EST-19T (12V)和
——全自动 EST-25 (24V)T
EST-26 (12V)
The difference between Semi- and Fully-Automatic is essentially consisting in

the load and speed-dependent automatic gear changes at the Fully-Automatic
unit (see 1.6.2.5).
半自动和全自动之间的区别基本上在负载上，速度型自动齿轮在全自动控
制装置时改变（见 1.6.2.5）。
The installation of the Electronic system, resistant to short circuit and
overvoltage, must be realized on a protected point in the driver's cabin, and by
means of the enclosed rubber buffers.
防止短路和过压的电子系统必须安装在驾驶室的保护点上，并且要安装封
闭的橡胶缓冲垫。
The housing must be connected with the chassis-ground. Besides, the Limit
values and Specifications, indicated on the Installation drawing resp. in the
Technical Costumer documentation have to be observed.
机罩必须与底盘连接。此外，限制值和规格在安装图上介绍，必须遵守技
术用户说明书。
With slipped on plug, the box is splash-proof
变速箱配有防飞溅滑动塞。
Pay attention to the correct installation of the supply line according to the
ZF-Instructions.
注意根据 ZF 说明书进行正确的供电线路的安装。
1.6.2.2 Direct selection of the solenoid valves:

1.6.2.2 电磁阀的直接选择：
electronic unit without interconnection of relays. This means that under normal
conditions, only the outputs for starter interlock and back-up lamps have still to
be connected through relays (see in this connection the corresponding circuit
diagram) Sample - Table 28 and 30.
电液控制阀座的电磁阀直接采用电子装置选择，不需要内部连接继电器。
意味着在正常的情况下，只有起动器联锁和倒车灯输出仍然通过继电器连接（有
关此连接，见有关的电路图）式样——表 28 和 30。
1.6.2.3 Sneed engagement:

1.6.2.3 速度啮合：
After the switching on of the ignition, the electronic unit is remaining in the
Waiting State; by the position NEUTRAL of the Controller, resp. by pressing on
the Key NEUTRAL, it becomes ready for operation.
在开启点火开关后，电子装置仍然处于等待状态；按下空档键，将控制器处
于空档位置，以等待操作。
Now, a speed can be engaged. For the speed engagement from NEUTRAL,
the following is generally applicable:
If the driving speed is too high in relation to the preselected speed (danger of
overspeeds), the lowest still permitted speed will be engaged and is then
downshifted, possibly in dependence on the driving speed.
现在，可以啮合速度。从空档进行速度啮合，一般地，可以适合如下情况：
如果驾驶速度太高，与预选速度有关（超速危险），仍然允许啮合最低速度，
然后降档，根据驾驶速度来确定。
1.6.2.4 Passive reversin lock:

1.6.2.4 被动换档联锁：
The Controllers DW-2 and ERGO II are not equipped with an active
reversing lock.
控制器 DW2 和 ERGO II 没有配备主动换档联锁。
On the contrary, the driver can start reverse shiftings at any time.
然而，驾驶员可以随时起动动力换档。
Example,, Wheel loader":
例如：“轮式装载机”：
Dependent on the actual driving speed, the following is resulting:
根据实际的驾驶速度，产生如下情况：
• In the speeds 1 and 2, direct reversing is realized at any time (1F <* lR and
2F < 2R).
• Reverse shiftings in the speeds 3 and 4, are carried out in dependence on
the driving speed according to the following Algorithm:
• • Semi Automatic EST-17T (EST-19T): - Above a programmable speed
limit (as a rule, the maximum speed of the 2nd Speed)
After a short hold time, the 2nd Speed will be upshifted. If the limit speed
falls below, during this operation, this procedure will be interrupted and the
reversing in the target speed is immediately realized.
- Below this speed, reversing is realized immediately. • • Fully Automatic
EST-25 (EST-26):
• 在速度一和二档时，随时可以实现直接换档（1F←lR 和 2F←2R）。
• 根据如下运算法则的驾驶速度进行速度 3 和 4 进行换档：
• •半自动 EST-17T (EST—19T)：
——高于可编程速度限制（一般地，最大速度为二档速度）
在短暂保持时间后，二档速度将升档。
如果限制速度在此期间下降，此程序将被中断，立即实现目标速度。
——低于此速度时，立即实现换档。
• • 全自动 EST-25（EST-26）：
At driving speeds below the reversing limit, the Automatic control is
generally downshifting at first for one speed, and is then reversing in this
speed.
在驾驶速度低于换档限制时，一般自动控制降到一档，然后在此速度进
行换档。
Apart from that remains valid what has been mentioned before under
„Semi-Automatic".
除此之外，在上述半自动下的操作仍然有效。
At vehicles as Dumpers, Cranes and Rail vehicles, reversing can be permitted

in all speeds, however it is limited to very low driving speeds.
如铲斗车、起重机和轨道车等车辆，可以允许所有速度档，然而，限制于非
常低的驾驶速度。
At a too high driving speed, the electronic unit is shifting the transmissions to
Neutral and is finally carrying out the reversing only at relatively low output
speeds.
如果驾驶速度太快，电子装置将变速箱换成空档，最后只在相对低的速度
下进行换档。
1.6.2.5 Gear shiftings:

General:
1.6.2.5 齿轮换档：
简介：
In relation to the gear shiftings, maximally four load conditions, Partial load
(TL), Full load (VL), Kickdown (KD and Retarder/engine brake (RET) can be
distinguished.
齿轮换档最大四个负载可以区别：部分换档（TL）、全负载（VL）、降档（KD
和缓冲器/发动机（RET）。
For each of these load ranges, separate values for Upshiftings, Downshiftings
and WK-Shiftings as well as different speed allocations (available speeds) are
programmable.
这些负载范围每个速度：升档、降档和 WK 换档以及不同的速度分配（获
得的速度）可以编程。
In the driving program, a difference is made in dependence on the charge
lever position (injection pump) between the Load ranges TL and VL. As far as
a kickdown switch is planned, an additional Load range KD can be
distinguished.
在驾驶程序中，根据负载范围 TL 和 VL 之间的加油杆位置（注射泵）进行
区别。至于配有一个降档开关，可以区别另外一个负载范围 KD。
A load-dependent adaptation of the shifting points is therefore ensured.
因此，可以确保适应换档点的负载控制。
TL: Since the full engine power is not required, speed-upshiftings can be
carried out relatively early i.e. at low driving speeds, and downshiftings
correspondingly late.
The engine is run in a range of low fuel consumption and at a low
noise level.
TL：因为不需要完全发动机功率，可以相当早地进行速度升档，如低驾驭速度，
稍后进行有关的降档。
发动机在低油耗和低噪音下运行。
VL: In this load range, the shifting points of the speeds are tuned in such a
way that the zone of the optimal engine torque will be fully utilized.
engine and transmissions are collaborating ideally.
VL：在此负载范围下，速度的换档点以完全采用最佳发动机扭矩区域进行调
节。
发动机和变速箱可以很完美地结合。
KD: The engine power is now fully utilized in order to achieve an optimal
acceleration. At the same time, it is possible by actuation of the
kickdown switch, to achieve an optimal deceleration of the vehicle by
earliest possible downshiftings.
Then overspeeds of the engine are excluded.
KD：现在可完全利用发动机功率，以获得最佳加速度。同时，可以驱动降档
开关，以通过最早的降档获得车辆的最佳减速度。
然后，不包括发动机的超速。
RET: For vehicles with engine brake and/or Retarder, this shifting-point field
allows an optimal vehicle-specific adaptation.
RET：对于配有发动机制动器和/或缓速器，此换档点范围可以获得特定车辆的
最佳适应。
Retarder/engine-brake operation is practically only permitted in the overrun
实际上，只允许在超速行驶，即部分负载操作时进行缓速器/发动机制动操
作，并且因此需要信号（状态）“TL”。
升档：
Uushiftinas•
Semi-Automatic EST-17T (EST-197):
半自动 EST-17T (EST-197)：
If the preselected target speed is at least 2 gear steps higher than the speed
just engaged, upshiftings are realized in a cycle of 2,0 seconds (typical value
for Wheel loaders).
如果预选目标速度至少高于啮合速度的两个变速齿轮级数，在 2，0 秒周期
上实现升档（轮式装载机的典型值）。
Fully Automatic EST-25 (EST-26):
全自动 EST-25 (EST-26)：
In the Automatic driving range, upshiftings at normal driving are realized in
dependence on driving speed and load. If a so-called LL-switch (switch for the
acknowledgment „accelerator pedal in idle position", i.e.in the range 0 up to
about 20%) is used, the Automatic control is suppressing any upshiftings in the
overrun condition, so holding the actual speed.
在自动行驶速度内，根据驾驶速度和负载可以实现普通驾驶的升档。如果
采用了所谓的 LL 开关（用于确认开关，在“怠速位置上的加速度踏板”，如在 0
到大约 20%），自动控制在超速运行下可以抑制任何升档，以保持实际速度。
Downshiftings•
降档：
EST-17T (EST-19T):
EST-17T (EST-19T)：
Downshiftings are only released if after the downshifting, the turbine speed
does not exceed 1,0 ... 2,0 times (according to the vehicle type; Wheel loaders:
2,0) the permitted maximum engine speed, and the just engaged speed has
been shifted longer than the so-called minimum dwell time (t)pical value: 2,0
seconds).
只有在降档之后才能释放降档，涡轮机速度不能超过 1、0…2，0 次（根据
车辆类型；轮式装载机：2，0），最大允许发动机速度，并且已经啮合速度切换
比所谓的最小停机时间（典型值：2，0 秒）。
Upon request of the customer, also other speed sequences e.g. 4 = 2 = 1
can be
programmed.
根据客户要求，也可以对其它速度次序如 4 = 2 = 1 进行编程。
Fully Automatic EST-25 (EST-26):

全自动 EST-25 (EST-26)：
Here, downshiftings are principally carried out in dependence of driving speed
and load.
这里，主要根据驾驶速度和负载进行降档。
In addition, a downshifting for one gear step can be forced by pressing a knob
(kickdown knob in double function or separate knob). According to the request,
this function can be at disposal or generally or only in idle operation (LL-switch,
see above).
另外，可以按下按钮（双作用的降档按钮或独立按钮）对一级齿轮进行降档。
根据需要，此功能可以处理，或一般地或只在怠速操作时（LL 开关，见上
面）。
1.6.2.6 轮式装载机的特别降档功能：
1.6.2.6 Special kickdown function for Wheel loaders:
Through the kickdown knob, integrated in the Controller lever, the 1st Speed
can be selected at any time in the Speeds 2F and 2R (i.e. Pos. 2 of the
Controller, at Automatic control also in the 2nd Speed of the Automatic range)
by a short touch..
通过组装在控制杆的降档按钮，在速度 2F 和 2R 时，通过点动可以随时选
择第一速度（如控制器的第二位置，在自动控制同时在自动范围的第二速度时）。
This kickdown condition can be cut off- according to the programming - by:
此降档条件可以根据编程进行切断：
1. Another pressing of the kickdown knob
2. Carrying out of a reverse operation
3. Change of the Controller lever position by changing (rotating) of the driving
position 1 ... 4, resp. by pressing the Keys „+" or „ -cc.
4. Exceeding of a rotational speed limit
The kickdown will be always completed after shifting to Neutral.
1．再次按下降档按钮
2．进行换档操作
3．按下按键“+”或“—”，改变（转动）驾驶位置改变控制杆的位置 1~4。
4．超过旋转速度限制。
降档总是在切换至空档后才能完成。
1.6.2.7 Pressure cutoff:

1．6．2．7 切断压力：
Especially at Wheel loaders and Lift trucks, the pressure cutoff can be
activated in the speeds 1 and 2 Forward and Reverse through an external plus
signal.
特别是轮式装载机和叉车，可以通过外部信号在前进和后退速度一和二切
断压力。
It is interrupting the power flow in the transmissions as long as this signal is
present.
只要这个信号存在，就会中断变速箱的动力流。
At other vehicles, this function can be used for the Neutral shifting of the
transmissions at applied hand brake or as „Emergency Stop" (in this case,
another drive off is only possible through the Controller-Neutral position).
在其它车辆上，此功能可用于施加手制动或“紧急停止”下变速箱的空档转
换（在此情况下，只能通过控制器——空档位置再次进行取消高速档）。
1.6.2.8 Special function:

1．6．2．8 特别功能：
There are different special functions possible, as for example:
有不同的特殊功能，例如：
• Control of Converter clutch, Retarder/engine brake, Antigas, engine power
• Starter interlock from Neutral at too high engine speed during speed
engagement from Neutral
• Limitation of the available speeds in dependence on Control platform (I or II),
All-wheel steering, Front-axle engagement (Crane vehicles)
• Control/Limitation of the available speeds at inching operation (Lift truck)
• 控制变矩器离合器、缓速器/发动机制动器、Antigas、发动机功率
• 在太高的发动机速度下、在从空档速度啮合期间，从空档进行起动器联锁
• 限制控制台站的（I 或 II），所有车辆转向，前桥啮合（起重车辆）
• 点动操作下控制/限制速度（叉车）
1.6.2.9 Customized control outputs:

1.6.2.9 定制的控制输出：
The Electronic unit disposes of a total of 8 line outputs (+24 V resp. +12 V, max.
0,5 A each). According to the type of the transmissions and the vehicle,
possibly not all of them will be needed, and can then be used for customized
purposes.
电子装置处理总共八个线路输出（+24V、+12V，最大分别是 0，5）。根据
变速箱和车辆的类型，并不是所有的都需要，然后可以达到定制之目的。
Typical parameters are:
典型参数为：
• Vehicle speed
• Controller lever position / Speed range
• Engaged speed
• Preselected driving direction
• Reversing condition
• 车辆速度
• 控制杆位置/速度范围
• 啮合速度
• 预选驾驶方向
• 换档情况
At the same time, logical operations can be also created.
同时，也可以创造逻辑操作。
1.6.2.10 Solenoid valve selection in Position Neutral:

1．6．2．10 在空档位置上选择电磁阀：
Especially at Wheel loaders and Lift trucks, determined, transmissions-specific
solenoid valve combinations are issued in the Positions 1 and 2 in the Neutral
position of the Controller lever for the pre-filling of the speed clutches. These
will be cancelled if the vehicle is exceeding a determined maximum speed
(Wheel loaders: the maximum speed of the 2nd Speed). (See Table 13, 14, 15,
16, 17, 18, 19, 20, 21, and 22).
特别是轮式装载机和叉车，在控制操作杆的空档位置的位置一和二上发出变
速箱特定电磁阀组合对速度离合器进行预载。如果车辆超过预定最大速度时，这
些可以取消（轮式装载机：最大速度为第二档速度）。（见表 13、14、15、16、
17、18、19、20、21 和 22）。
1.6.2.11 Inductive transmitter - Failure reco nition: Example .. Wheel loader "
1．6．2．11 感应式传感器——故障确认：
例如：“轮式装载机”
The driving speed is acquired through an output-side inductive transmitter.
驾驶速度通过输出端感应式传感器获得。
Its failure during the drive will be acquired and recognized by the Electronic
unit. The maximally permitted speed is then the highest speed, in which a
direct reversing, independently from the driving speed is permitted, i.e. the
2nd Speed.
在驾驶期间的故障将通过电子装置获得和确认。然后，允许的最大速度是
最高速度，可进行直接换档，与允许的驾驶速度如第二档无关。
A failure will be also supposed if the vehicle has already at least one time
reversed, and is standing in a speed higher than the 2nd for more than 10
seconds.
如果车辆已经至少是换过档，故障同时也会产生，在高于第二档速度 10
秒后的速度停止。
If the Electronic unit has recognized a sensor failure, upshiftings beyond the
limit ,,2nd Speed" can no more be realized, and from the speeds 3 and 4 only
reverse shillings are still possible. Besides, reverse shiftings from the speeds
3 and 4 are only still possible into the 2nd Speed of the other driving direction.
如果电子装置已经确认传感器有故障，可以不再实现第二档速度外的升档，
从速度三和四的换档仍然有可能。此外，从速度三和四档的换档只能进入到其
它驾驶方向的第二速度。
At the speed engagement from Neutral, the highest disposable speed will be
generally engaged and then downgraded in the preselected (lower) speed.
在从空档中进行速度啮合时，一般可以啮合最高使用速度，然后在预选（较
低）速度降档。。
At vehicles equipped with WK, and generally at all Automatic vehicles, a
sensor for the acquisition of the turbine speed is additonally planned. Its
signals are constantly checked for plausibility with those of the output sensor.
在配有 WK 的车辆中，一般在所有自动车辆中，另外安排涡轮速度的传感
器。不断地似真性检查输出传感器的此信号。
The maximally disposable speed at output sensor failure on vehicles
equipped with WK, is normally the 1st Speed. The above-mentioned is
applicable accordingly.
在配有 WK 车辆的输出传感器出故障时，最大可处理速度一般是第一档速
度。上述内容相应地可以适用。
The Status „Sensor failure" will be cancelled, as soon as the inductive
transmitter signal is recognized again. Then however, follows an automatic
upshifting in a possibly preselected speed (see also 1.6).
状态“传感器故障”将被取消，一旦感觉传送器信号再次确认时。然后，然
而，按照预选速度的自动升档说明去做（也可以参见 1.6）。
1.6.2.12 System behavior at faults:
1.6.2.12 故障下的系统动作
The Control unit is constantly monitoring all inputs from the Controller and outputs to
the solenoid valves as well as the speed sensors. In case of illegal combinations (e.g.
by a cable break, external supply), the Electronic unit is going immediately in the
Neutral condition and switches off all outputs. The same happens if the voltage supply
is exceeding determined limit values or a short circuit is existing. The cutoff can be
cancelled again by shifting the Controller lever beyond the position „NEUTRAL". The
cancelation of the upshifling lock after (terminated) sensor failure, is realized by
shifting to Neutral or automatically as soon as preselected and the actual speed are
coinciding.
控制单元不间断地监控来自控制器，电磁阀输出和速度传感器的的输入信号。万一联
结出错（例如，通过电缆切断外部供应），电子单元将马上切换到中位，切断所有输出。
如果电源电压超过确定值或发生短路，则也会有相同的情况发生。通过把控制器杆拨出
中位来实现再次取消切断功能。在传感器出错后，通过把档位锁拨到中位或预先选定的
速度来取消档位锁止功能。
It will be distinguished between unrecoverable failures (emergency properties plus

display, see Appendix A). At a repeated fault, it is absolutely necessary to check the
supply system electrics; defective components must be immediately replaced.
1.6.3
Diagnosis-System:
辨别可重获故障间的差距（备用工具+显示，见附录 A）。如果重复出现故障，一定要检
查电源系统，必须马上替换有缺陷的部件。
An error readout is possible by connection of a diplay unit on the diagnostic connector.

This unit can be a LED with dropping resistor (flash code) or the ZF-Display (Wrench
symbol plus errror number).
读取错误可能是由于诊断连接器上的显示单元接线造成的。该单元可以是带散布电阻器
（闪烁代码）的 LED 或 ZF 显示器（矢量符号+错误代码）。
IMPORTANT: According to the programming, only the LED or the Display can be
used, i.e. the type of the display unit must be already determined prior to the
programming of the EST. Statically and sporadically occurring faults will be acquired
and displayed.
重点：根据程序设计，只能使用 LED 或显示器，例如，显示单元的类型必须优
先于 EST 程序设计而确定。
1.6.4 Wiring:
1.6.4 配线
In the so-called compact wirings, we have combined the cable connection to Solenoid
valves, Inductive transmitter, Controller, Electronic unit, Diagnosis, Supply system
etc.
在结构紧凑的配线线路中，我们已经把电缆线路与电磁阀，感应传感器，控制器，电子
元件，电源系统等连接在一起了。
Thereby, the laying and connecting of single cables is eliminated. This compact
wiring is regularly available in different lengths.
因此，已经排除了单线缆的连接方式和排布。该种配线被有规则地用在不同长度中。
For the perfect function of the system, the use of a ZF-Wiring is recommended.
基于系统完美功能的考虑，推荐使用 ZF 配线。
1.6.5 Test of the Electronic transmission control:

1.6.5 电子变速箱控制测试:
The different ZF-Control units can be tested with the Testers PR-68 and PR-78 A + B
(see Table 34, 35 and 36) combined with the special equipments of the actually
installed Automatic shift control.
ZF 控制单元的差异通过带 PR68 检测器和装配有换档控制特殊装配 PR78A+B(见表

34,35 和 36)来检测.
The relative Operating Instructions are delivered together with the corresponding
Tester. These Test Instructions can be requested from the ZF-Passau Service
Department against a fee of DM 15.--.
相关操作说明和所用的相应检测器一起共同提供. 这些测试说明来自于反对免费维修
DM15 的 ZF 维修部门
1.7 Interaxle differential (Length -compensating differential):
1.7 内轮差速器(长度—补偿差速器)
- see Table 2
见表 2
1.7.1 Description:
1.7.1 描述
The differential, installed in the final drive, has the task to deliver different torques to
the vehicle axles and to act as intermediate balance in driving direction (longitudinal
direction of the vehicle).
安装在终传动上的差速器具有传递不同扭矩给车桥和在驱动方向保持平衡的功能。
By the installed differential lock, both functions can be put out of function, and a rigid
connection between the axles can be created.
通过安装的差速器锁,可以让上述的两个功能失效,并且可以在桥轴间建立刚性连接。
1.7.2 Function:
1.7.2 功能
The planetary gear train (differential) is designed in such a way that the outboard
internal gear is driven. The drive is realized through the planetary carrier (long lever
arm) and through the inboard sun gear (short lever arm).
以外侧内齿轮驱动方式设计行星轮系(差速器)。通过行星轮架(长杆臂)和内侧太阳轮(短
杆臂)来实现.
Since different diameters (lever arm) of planetary carrier (r 1) and sun gear (r 2)
become effective, a torque distribution 2 : 1 is realized.
行星轮壳(r1)和太阳轮(r2)的不同尺寸生效，则扭矩比例为 2:1.
Due to the special arrangement of the planetary carriers (Ravignaux-System), the
required inversion takes place within the planetary gear train so that both outputs
(planetary carrier and sun gear) are running in the same sense of rotation.
由于行星轮壳的特殊排布,在行星轮系中发生倒置致使所有的输出(行星轮壳和太阳轮)
都在相同的旋转方向上进行。
If an axle of the vehicle is slipping, a rigid connection between the vehicle axles can
be created by the differential lock.
如果机器上的桥松动，则通过差速器锁创建机器桥间的刚性连接。
In this connection, a torque output 1 : 1 is realized.
在该连接中，扭矩输出为 1‖1.
DRIVE ENGAGEMENT AND DISENGAGEMENT DIFFERENITAL. LOCK
传动拆装差速器锁.
1.8 Power take-offs:

1.8 取力器
For the drive of outboard oil pressure pumps, up to 2 engine-dependent power
take-offs, upon request with mechanical or pneumatic disengagement, can be
planned.
因为外侧油压泵的驱动，根据机械式或气动式拆卸需求，可以设计 2 个依靠发动机式
取力器。
The fitting of the pumps with SAE-A, B and C connections, is realized on the output
side of the transmission.
带 SAE-A,B,C 接头的泵装配通过变速箱侧输出实现。
1.9 Final drive:
1.9 轮边减速
The final drive is realized through an integrated transfer case. According to the
application, one axle can be disengaged. The control can be mechanical or
pneumatic.
通过一个综合传感器实现轮边减速.根据要求，桥可被拆卸.控制装置为机械式或气动式。
1.10 Emergency steering pump:
1.10 应急转向泵
The attachment of an emergency steering pump is possible (16 cm 3/rev. or 32
cm 3/rev.). Instead of an emergency steering pump, a secondary pump can be
also mounted.
应急转向泵附件可以为 16 cm 3/rev. or 32 cm 3/rev。作为替换，可以安装分泵。
The secondary pump will be output-side driven, and has therefore always a constant
delivery direction. At the towing of the vehicle, it supplies the transmission
automatically with the necessary quantity of lubricating oil
分泵为输出端驱动，因此传输方向为恒定不变的。在机器的牵引架上，提供了带符合质
量要求润滑油的变速箱。
1.11 Speedometer drive:
1.11 转速表驱动
Electric Version
电子版
The signal necessary for the speedometer evaluation, is inductively picked-up on the output
side.
为了评估转速表，要在输出端采集所需信号。
Mechanical Version
机械版
The connection of the speedometer terminal is fitted on the output gear. The sense of
rotation is reversing at the change of the driving direction.
转速表接线端与输出齿轮相连。其旋转方向跟随驱动方向的改变而换向。
II. INSTALLATION INSTRUCTIONS
II. 安装说明
1. Preferred is an elastic 3-(4)-point transmissions
support.
Tensions in the vehicle frame should not be transmitted upon the
transmissions case.
1．首先安装弹性 3-(4)-点变速箱支撑。
车辆机架的张力不会通过变速箱传递。
2. At direct mounting on the engine, the end play between converter pin and
engine crank shaft, prescribed in the installation drawing, has to be met.
We want to point out that the converter is supporting itself axially upon the
crankshaft with 2850 N, at a cold start for a short time up to 5100 N.
2．在发动机直接安装中，变矩器销和发动机曲轴之间的轴向间隙必须满足安装
图纸中的要求。
我们想要指出的是当曲轴为 2850N 和短时达到 5100N 的冷起动时时，变矩
器本身可轴向支撑。
3. A torsional vibration damper is necessary if the transmissions is separately
installed from the engine.
3．如果变速箱与发动机单独安装，必须提供一个扭力振动阻尼器。
4. Max. three-dimensional working angle of the drive-universal shaft 70
Max. three-dimensional working angle of the output-universal shaft 10°
Shift angles are not permitted!
4．驱动万向轴的最大三维工作角度为 7°。
输出万向轴的最大三维工作角度为 10°。
不允许出现位差角。
5. The universal shafts have to be equipped with length compensation,
lubrication and shield tube. At movable axles and on the buckling joint, the
universal shafts must be equipped in addition with a profile coating and
ventilation.
5．万向轴必须配有长度补偿、润滑和套管。另外，在移动轴和套管接头上，万
向轴必须配有外观喷涂和通气。
6. The installation position of the joint yokes must be conform with the
Catalogue of the Vehicle Manufacturer.
6．万向节轭的安装位置必须符合车辆制造商的说明书。
7. Connect the starter interlock.
7．连接起动器联锁。
8. The pressure cutoff of the transmissions must become effective only at 30%
of the maximum brake pressure (air or oil).
8．在最大制动压力（空气或油）的 30%时，切断变速箱压力才能有效。
9. Cable harness installation with sufficient bending radii and abrasion-proof.
The plug-and-socket connections should be moisture-proof
9．电缆束的安装必须具有有效的转弯半径和防磨损。
10. Controllable power take-off
The Gearshift lever must not be under preload in engaged and
disengaged condition, the stop must be in the operating mechanism
or in the cylinder.
10．可控制的取力器
换档操作杆不一定在啮合和无啮合的预负载条件下，必须停止在工作机
构或油缸工作时。
11. At separate filter installation, the ZF-Filter head has to be used.
As to the filter area or the grade of filtration, the ZF-Recommendation
has to be observed. The nominal filter flow rate should be about 150
dm3.
The line guidance to the external filter must be on the same level or lower than
the line connection on the transmissions case.
11．在分开过滤器安装时，必须使用 ZF 过滤器护罩。
至于过滤器大小或过滤等级，必须遵守 ZF 推荐。标准的过滤器流速应当
大约为 150 dm3。
与外部过滤器的线路导向必须在一个水平面上或低于变速箱的线路连接。
12. If during the use of the vehicle inclined positions greater than 30°in the
longitudinal axis and 15° in the transverse axis are required, please ask for
information.
12．如果需要使用大于纵向轴 30°和横向轴的 15°的车辆倾斜位置时，请进行咨
询。
13. The required cooling capacity is based on a normal outside temperature of

max. 300 C. The relation of the cooling capacity to the maximum converter
power (mostly about 80 100% of the nominal engine power) should be at the
minimum:
Caterpillars, Dozers, Wheel loaders, Scrapers
Graders, RT-Cranes, Dumpers = 35 - 40%
Lift trucks, Road
vehicles, Trucks
Vehicles with WK in all speeds = 30 - 35%
13．所需要的冷却量根据普通外面温度最大 30℃确定。冷却量与最大变矩器功
率的关系(大多数大约是标称发动机功率的大约 80~100%)应当为最小：
卡特彼勒，推土机、轮式装载机、铲土机、平地机、RT 起重机、翻斗车= 35
~40%叉车、道路车辆、卡车、带 WK 的，所有速度= 30~ 35%
14. At the cooler calculation, corresponding supplementary air-temperature
values must serve as basis for the operation in hot countries.
14．在计算冷却器时，补充的对应气温值必须根据气候热的国家来定。
15. The transmissions cooler should be situated on the cold-water side of the
cooling circuit. If a retarder is used, the total cooling-water quantity must flow
through the transmissions cooler also at closed thermostatic valve.
15．变速箱冷却器应当位于冷却回路的冷水侧。如果采用液力缓速器，在封闭
的恒温阀中，总的冷却水量必须流经变速箱冷却器。
16. Special attention mut be payed to utmost cleanliness of the Lines, the
Filters and the Cooling system prior to the initial installation (also at
transmissions replacement).
16．在初次安装以前（同时在更换变速箱时，特别要注意必须最大程度的保持
回路、过滤器和冷却系统的清洁。
17. Internal width of the cooler resp.the filter lines and screw connections is at
the minimum 32 mm. For line lengths > 1 in, the nominal width must be
+ 20%.
17．冷却器的内部宽度即过滤器回路中，螺纹连接最小为 32mm。回路长度大
于 1 米，标称宽度必须为+20%。
18. Easy accessibility to the oil filter, oil dipstick and oil filler neck.
18．容易接近油过滤器、油标尺和油过滤口颈。
19. Monitoring of the control pressure (Measuring point 65) and of the oil
temperature (Measuring point 63) in the driver's cab.
19．在驾驶室中可以监视控制压力（测量点 65）和油温（测量点 63）。
20. Use oils according to the ZF-List of lubricants (Oil-level check, see
Operating instructions).
20．根据 ZF 滑润油表使用油（油位检查，见操作说明书）。
21. It must be possible, to remove the transmissions control unit without
removal of the transmissions.
21．必须尽可能拆除变速箱的控制装置，而不拆除变速箱。
22. At welding operations on the vehicle, separate electric or electronic
components from the supply system.
22．在车辆焊接操作时，将电气或电子元件从供应系统中分离。
23. Separate ground connections for transmissions, control unit and battery
must be planned.
23．分离变速箱的接地连接，控制装置和电池必须配备。
24. Pay attention to the specific ZF-Plug assignment, because only then, the
use of ZF-Testers will be possible.
24．注意 ZF 插头的特定说明，因为只有到那时，可能使用 ZF 的检测器。
25. Connect back-up lamps, resp.alarm only through relay.
25．连接备用灯，仅通过继电器报警用。
NOTE:
The correct installation is the Vehicle Manufacturer's duty!
注意：
正确的安装是车辆制造商的责任！
III．操作
3．1 行驶前的准备与维护：
3.1 Driving preparation and Maintenance:
Before the transmissions is put into service, take care that the correct quantity
of the prescribed oil type is filled in. At the initial filling of the transmissions has
to be considered that the oil cooler, the pressure filter as well as the tubings
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 program.
Since the converter and also the oil cooler installed in the vehicle as well as
the tubings can discharge themselves at standstill into the transmissions, the
Oil-level check must be carried out at engine idling and operating temperature
of the transmissions.
变速箱运行前，务必按照规定的润滑油规格加入适量的润滑油。变速箱初次加油
时，必须考虑到油散热器、过滤器及连接管路须注满油。
为此，首次加注的润滑油量要比以后正常的维护保养的润滑油量要多。
由于装在车辆上的变矩器油经油散热器、油管在静止状态时回流至变速箱，
所以应在停车挂空档、发动机怠速、变速箱处于正常工作的热平衡温度时来控
制正确油位。
Permitted transmissions oils, see ZF-List of lubricants TE-ML 03!

许可的变速箱油：请参照 ZF-润滑油 TE-ML 03 表格执行！
At the oil-level check, the prescribed Safety Regulations according to § 6 of

the Rules for Accident prevention for power plants in Germany and the
corresponding National Regulations in all other Countries must be absolutely
respected.
For example, the vehicle must be secured against rolling away with blocks,
articulated vehicles must be additionally secured against inadvertent
turning-in.
检查油位时，必须绝对按照规定的安全规程操作，该规程是根据德国动力设备事
故防范条例第 §6 条制定的，同时在其他国家内要遵守其相应国家的安全规章
制度。例如，必须保证用档块来防止车辆溜动，另外还须防止铰接式车辆的转动。
The test has to be carried out at NEUTRAL POSITION of the Controller.

控制手柄须处于空档位置时方可进行油位检测。
The oil level must be at 80℃ on the upper mark, up to 40℃ on the lower mark
of the oil dipstick. At the oil-level check, the oil dipstick has to be inserted into
the oil-level pipe until contact is obtained.
油温为 80℃时，油位必须在油尺上刻度线；到油温为 40℃时，油位必须在油尺

下刻度线。检查油位时应将油尺插入油管尽头。
At the oil drain must be considered that only the quantities of oil within the
transmissions and in the upper part of the converter can be drained on the oil
drain plug.
在排油时，必须考虑只有在变速箱内和变矩器的上端，在放油塞上释放油。
At the cleaning of the pressure filter in the main oil stream, pay attention that
no dirt or oil sludge can enter into the circuit. Besides, a cover plate has to be
planned to protect the output shaft against oil wetting.
清理主油路的过滤器时，注意应防止杂物及沉淀物进入油回路。此外，须放置一
块盖板以防止停车制动器受油浸湿。
At the insertion of the filter, any kind of force has to be avoided.

安装过滤器时注意不要拧得太紧。
3.2 Driving and Shifting:

3．2 行驶和换档：
The starting of the engine has to be always carried out in the NEUTRAL
POSITION of the Controller.
启动发动机前，必须确认换档手柄是在空档位置。
For safety reasons, it is recommended to brake the vehicle always securely in

position with the parking brake prior to start the engine.
为安全起见，启动发动机前，停车制动器应处于制动状态，使车辆不能因发动机
启动而起步。
After the starting of the engine and the preselection of the driving direction
and the speed, the vehicle can be put into motion by acceleration.
At the drive off, the converter takes over the function of a main clutch.
发动机启动后，解除停车制动，选择好行驶方向和档位，通过缓慢加油门，车辆
起步。
On a level road, it is possible to drive off also in higher gears.

路况很好时也可以高档位行驶。
The acceleration will be only lower.

加速只有降档时才用。
If the vehicle has been stopped and is standing with running engine and
engaged transmissions, the engine cannot be stalled. On a level and
horizontal roadway it is possible that the vehicle begins to creep, because the
idling engine is creating through the converter a slight drag torque.
如果车辆已停止行驶，发动机还在运转、变速箱挂档，这时发动机不会熄火，在
一条平直路面上，车辆可能会爬行，因为发动机的怠速会通过变矩器产生一定的
牵引力。
It is advisable to brake the vehicle at every stop securely in position with the
parking brake. At longer standstills, the Controller must be shifted to the
NEUTRAL POSITION:
合理的作法是，每次停车时将停车制动器置于制动状态。如果较长时间停车，控制手柄必须
换到空档位置：
At the drive off, the parking brake must be released. We know from experience
that you do not immediately note, at a converter transmissions, to have
forgotten this quite normal operation, because a converter, due to its high ratio,
can easily overcome the braking torque of the parking brake.
车辆行驶时，务必要松开停车制动器。
我们从经验中得出，操作者难以立即发现的是，当变矩器工作时，由于变矩器大的输出
扭矩比，即使在正常的操作情况下车辆也能够克服刹车扭矩而强行行驶。
Temperature increases in the converter oil as well as overheated brakes are

the consequences to be found out later.
随后其结果是变矩器的油温升高，制动器过热。
We want to point out that at the downshifting of speeds, especially at the

skipping of one speed, the engine speed can be increased, due to the braking
effect of the converter, thus reaching rotational speeds which could be
dangerous to the engine.
应该指出：由于变矩器的影响，由高速档位转换低速档位时，特别是在跳级换档时，发
动机转速会加快，因此达到的转速可能对发动机产生危险。
Shifting should be carried out only then if the top speed of the lower gear
is reached.
只有机器在低档位时达到最高速度时，才可以进行换档。
If necessary, the vehicle must be braked down to this speed with the foot
brake.
必要时，可使用脚制动器把机器的行驶速度降下来。
This must be also considered at NEUTRAL POSITION of the Controller, to
avoid a dangerous speed of the manual transmissions.
同时，控制手柄必须处于空档位置，以避免人工变速产生的危险速度。
Reverse shiftings should be carried out only up to a speed of 10 km/h.
只有在 10 公里/小时速度时才能进行换倒档。
3.3 transmissions control with Electronic automatic unit:

3．3 采用电子自动装置的变速箱控制：
Precise Informations about the design of the Controllers as well as the speeds
shifted in the single driving ranges, can be taken from the Operating
Instructions belonging to the vehicle.
关于控制器设计的具体信息以及单一行驶速度换档速度的详细资料，可以
从配给车辆的操作说明书上获得。
A manual intervention into the automatic shifting procedure (shifting through of
the driving ranges) is little practical
手动干预自动换档步骤（通过行驶速度的换档）是不实际的。
In extreme driving situtions, e.g. drive off on upgrades, a lower driving range
can be preselected and at standstill or after the rolling away of the vehicle
immediately shifted in higher driving ranges. This causes the utilization of the
lower starting speed without blocking afterward the upshifting in higher
speeds.
在恶劣的驾驶条件下，例如，上坡时，可以按预先选择的低速度行驶，当
机器中途停住或向下滑时可以立即换到高档行使。这样机器在高速行驶换档后
低档起动速度不会被锁死。
If necessary, all speeds of the transmissions can be automatically shifted
through by means of this measure (Details, see Operating Instructions of the
vehicle).
如果需要，变速箱的所有速度可以自动地通过此方法来换档（有关详情，
详见车辆的操作说明）。
On certain upgrades, up- and downshiftings may occur in short intervals,
namely then if the traction force in the fast speed is too low, however in the
slow speed too high for the upgrade.
在上坡时，在短时间内会产生升档和降档，行驶速度快时牵引力小，行驶
速度慢时牵引力大。
This shift swinging can be prevented by accelerator throttling or by selection of
a lower driving range.
通过加速器油门或通过低行驶速度的选择来防止换档引起的摆动。
At downhill driving, an unwanted upshifting will be prevented by selection of a
lower driving range.
在下坡驾驶时，通过选择低的行驶速度防止不必要的升档。
If for the reason of acceleration or at uphill driving the next lower speed shall
be engaged, this is possible by the kickdown position of the accelerator pedal.
如果因为速度过快或者上坡行驶中要换成低档时，可以通过控制油门踏板的
位置实现。
This pedal position is causing the earliest possible downshifting in the lower
speed.
油门踏板位置在低速时会引起最早的降档。
3.4 Engagement and Disengagement of Differential lock and Front

axle drive:
Interaxle differential:
3．4 差速器锁和前桥的啮合和断开：
桥间差速器：
The engagement and disengagement of the differential lock must be carried

out only at standing vehicle.
只有在车辆停止不动时才能进行差速器锁定的啮合和断开。
Axle declutch:
桥分开离合器：
The engagement and disengagement of the front-axle drive must be carried
out only at standing vehicle.
只有在车辆停止不动时，才能进行前桥驱动的啮合和断开。
3.5 Stopping and Parking:

3．5 暂停与停车：
Since due to the converter there is no rigid connection existing from engine to
axle, we recommend to secure the vehicle on upgrades, resp. downgrades
against inadvertent rolling away not only by application of the parking brake
but additionally by a brake block on the wheel, if the driver has the intention to
leave thevehicle.
由于发动机、桥与变速箱之间没有刚性连接，所以当车辆停在坡上（上坡或下坡）
而司机打算离开时，为防止车辆产生滑坡现象，我们建议不但要使用停车制动器
而且要在车轮下放置阻动块。
3.6 Towing:
3．6 拖动：
The towing speed at transmissions Versions without secondary pump must be
maximally 10 km/h, and the towing distance not longer than 10 km.
对于未装有辅助泵的变速箱，拖行最高速度 10 km/h，最大拖行距离为 10 km。
At transmissions Versions with secondary pump, a towing at max. 30 km/h up

to a distance of 50 km is possible.
对于装有辅助泵的变速箱，拖行最高速度 30 km/h，最大拖行距离为 50 km。
These Instructions must be absolutely respected because otherwise the

transmissions becomes defective because of insufficient oil supply
In case of a longer distance, the defective vehicle must be transported.
必须严格遵守这些规则，否则，变速箱会因为供油不足而遭受破坏。
当距离较远时，发生故障的车辆须放置在其它车辆上运输。
3.7 Oil temperature:

3．7 油温：
The oil temperature of the transmissions must be monitored by a
temperature sensor. A max. temperature of 120° C on the
converter exit must not be exceeded.
At a trouble-free unit and an adequate driving style, a higher temperature will
not appear. If the temperature is increasing above 120°C, the vehicle has to
be stopped and must be controlled for external oil loss, whilst the engine
should be running with a speed of 1200 - 1500 min -1 at the NEUTRAL
POSITION of the transmissions.
Now, the temperature must drop quickly (in about 2 - 3 minutes) to normal
values.
If this is not the case, a trouble is existing which must be eliminated prior to
continue working.
变速箱油温必须使用温度传感器来进行监控。
变矩器出口最高油温不得超过 120℃
对无故障的控制组件和有充足行驶里程的变速箱，不会出现较高的温度。如果油
温超过 1200C，车辆必须停下来，检查是否有油外漏，同时变速箱挂空档、发动
机应以 1200—1500rpm 转动，在这种情况下油温会迅速降低到正常值（大约在
2-3 分中内）。
如果油温不降低，则系统内可能存在故障，必须排除故障后方可作业。
Control pressure:
控制压力：
For the monitoring of the control pressure, a manometer or a pressure monitor
has to be installed. If this pressure is dropping at engaged clutch below the
prescribed minimum pressure (at the shifting itself the pressure will drop for a
short time), the reason for the pressure drop must be eliminated. The
consequences of a too low control pressure are damages of the clutches
which are constantly slipping because of a too low contact force, and are
therefore damaged by overheating. On the Schedule of measuring points and
the oil circulation diagrams, the measuring points of the single speeds, the
converter pressures and the lubricating pressure can be seen (see Table 16,
17,18, 19, 20, 21, 22, 23).
为了监视控制压力，必须安装一个压力表或压力监控仪。如果挂上某档位，用上离合器
后压力下降到低于规定的最低压力（换档瞬间压力会暂时自行下降），必须清除压力降
的原因。太低的控制压力会导致离合器的损坏，因为离合器缺乏足够的接触压力，摩擦
片持续不断的打滑会导致过热（详见表 16，17，18，19，20，21，22，23）。
-35-
IV. MAINTENANCE
IV．维护
4.1. Oil quality
4．1．油品
Permitted for the Powershift transmissionss 4 WG-200 are oils according to
the ZF-List of lubricants TE-ML 03.
This List of lubricants can be requested from all ZF-Service
WG 动力换档变速箱必须严格按照 ZF TE-ML 03 润滑油表推荐用油。欲索取
TE-ML 03 油表可与 ZF 维修中心联系。
4.2 Oil-level check:

4．2 油位的检查：
Oil-level check (weekly)
- At horizontally standing
vehicle
- transmissions in Neutral position ,,N"
- Operating temperature of the transmissions - At engine idling, about 1000
min-'
- Loosen oil dipstick by anticlockwise rotation, remove and clean it
- Insert oil dipstick into the oil level pipe until contact is obtained and take it out
(at least 2x)
- Oil level at 80 C on the upper mark .
-HOT" Oil level at 40 C on the lower mark „COLD"
检查油位（每周一次）
- 将车辆停在平坦的地方
- 变速箱换档手柄在空挡位置“N”
- 变速箱在工作温度范围内，发动机怠速，约 1000 转/分
- 逆时针方向拧松油尺，取出并擦干净
- 油尺插入油位管内并旋紧，到位后再取出（至少 2 次）
- 40℃时，油位应在下刻度“冷”和中间刻度之间
- 80℃时，油位应在上刻度“热”和中间刻度之间
ATTENTION: If the oil level has dropped, in relation to its condition, below the
Min-Zone, it is abolutely necessary to top up oil according to the ZF-List of
lubricants, until the oil level is lying between the corresponding temperature
marking - see Draft .
注意：与其它条件有关，如果油位低于最低刻度时，必须按照 ZF TE-ML 03 油
表所推荐的润滑油加油，直到油位升到相应温度的正确刻度范围为止—（见图）。
NOTE: According to the transmissions Version, the oil dipstick and the oil filler
pipe can have different lengths and shapes. Besides, the fitting on the
transmissions can be optionally realized on the converter side or on the output
side.
注：
根据不同类型的变速箱，油尺和加油管的长度及形状不同。另外，加油管和变速
箱的连接有两种方式，一种是加油管在变矩器侧或在输出端上。
The Ilustration shows the fitting of the oil dipstick as follows:

Center distance 400 mm - converter side
Center distance 500 mm - output side
Center distance 555 mm - converter side
- Insert the oil dipstick again and tighten it by clockwise rotation.
下图为加油管（与油尺）和变速箱连接的情况：
中心距 400 mm——在变矩器侧
中心距 500 mm——输出端
中心距 555 mm —— 变矩器侧
再插入油尺并顺时针方向旋紧。
Center distance 400 mm Center distance 500 mm Center distance 555 mm

中心距 400 mm 中心距 500 中心距 555 mm
OIL DIPSTICK 油标尺 HOT 热 COLD 冷 ZONE HOT 热区 ZONE COLD 冷区
Legend
1 = Oil filler pipe with oil dipstick
2 = -Oil drain plug M22x1,5
3 = Oil drain plug M38xl,5
图表符号
1 = 带油标尺的加油口
2 = 放油塞 M22x1，5
3 = 放油塞 M38xl，5
-36-
4．3 换油及加油量：
4.3 Oil change and oil filling capacity:
First oil change after 100 operating hours on duty.

Every further oil change after 1000 operating hours on duty, however at least
once a year!
车辆首次达到 100 工作小时后，必须进行第一次换油。此后，在每 1000 工作小

时更换一次油,每年至少更换一次油！
The oil change must be carried out as follows:

必须按照下述要求进行换油：
- At operating temperature of the transmission, horizontally standing vehicle,

open the oil drain plug along with sealing ring and drain the used oil.
- 将车辆停在平坦的地方，变速箱在工作温度内，拆下放油塞及密封圈，排干旧
油。
NOTE:
注意：
Only the quantities of oil in the transmissions and in the upper part of the
converter can be drained.
只能排出变速箱的油量和变矩器上端的油。
Clean the oil drain plug and the sealing surface on the housing, and install it
again along with new O-Ring.
- 擦干净放油塞及壳体密封面，连同密封圈一起安装好。
Fill in oil according to the ZF-List of lubricants,

( about 28 liters, sump capacity, external oil quantities, e.g. in the cooler, in the
lines etc. are dependent on the vehicle).
The indicated value is a guide value.
- 按照 ZF 推荐的润滑油表加油。
（约 28 升油，此数值为油池容量；外部油量，如散热器及管路内的油量根
据车辆类型不同而有差异）。
- 给定的值为指导值。
It is absolutely necessary to pay attention to a perfect cleanliness of oil and

filter ! Binding is at any rate the marking on the oil dipstick!
非常有必要使用干净的变速箱油及过滤器！
在任何情况下都须符合油尺上的标记！
Start the engine, idle speed
transmissions in Neutral position ,,N"
Top up oil up to the upper marking of the Zone „COLD"
Brake the vehicle securely in position
Shift all selector switch positions through
Check oil level again, and top up oil again if necessary
Oil level at 80°C on the upper marking H~ OT"
Oil level at 40°C on the lower marking „COLD", on the oil dipstick
- 启动发动机并怠速运转
- 变速箱控制手柄在空档位置“N”
- 加油至“冷”油区域的上刻度
- 停车制动在安全位置上
- 依次转动所有的档位一次
- 再检查一次油位，需要时重新加油
- 80℃时，油位应在上刻度“热”和中间刻度之间
- 40℃时，油位应在下刻度“冷”和中间刻度之间
4.4 Filter replacement:

4.4 更换滤油器
The ZF-Fine filter (pressure filter) has to be replaced at every oil change.
Handle the filter with care at the installation, the transport and the storage!
每次换油必须同时更换 ZF 过滤器。小心安装、运输、储存过滤器！
Damaged filters must no more be installed!

不允许使用损坏的滤油器！
The installation of the filter must be carried out as follows:

必须按以下要求安装过滤器：
- Cover the gasket with a small amount of oil

- Screw the filter in until contact with the sealing surface is obtained and
tighten it subsequently by hand about 1/3 to 1/2 turn
- Fill in oil
- Start the engine
- Carry out the transmission oil-level check at engine idling (about 1000 min-1)
and at operating temperature of the transmission:
Oil level at 40℃ on the lower marking ―COLD‖.
Oil level at 80℃ on the upper marking ―HOT‖, on the oil dipstick.
- Check tightness, if necessary tighten by hand again.
- 在密封圈上涂一层薄油。
- 将过滤器按进直到与箱上的密封面相接触，然后用手拧紧约 1/3 至 1/2 圈。
- 加油
- 启动发动机。
- 发动机怠速运转（约 1000 转/分）、变速箱油温为正常工作温度时,检查变速
箱油位。
油温为 400C 时应在“冷”车油位范围。
油温为 800C 时应在“热”车油位范围。
- 检查是否拧紧。必要的话，用手再次拧紧。
-37-
4 WG-200 平面图
表-1
1 = ENGINE CONNECTION 发动机连接

A = DRIVE THROUGH UNIVERSAL SHAFT 通过万向节轴
B = DIRECT MOUNTING 直接安装
2 = CONVERTER 变矩器
3 = CLUTCH KV 离合器 KV
4 = CLUTCH K1 离合器 K1
5 = 2nd POWER TAKE-OFF 第二取力器
6 = CONVERTER CHARGE AND CONTROL PRESSURE PUMP 变矩器
充压和控制压力油泵
7 = 1st POWER TAKE-OFF 第一取力器
10= OUTPUT - FRONT AXLE 前桥输出
11= OIL SUMP 油底壳
12 = OIL DRAIN PLUG 放油塞
13 = OUTPUT - REAR AXLE 后桥输出
14= LAYSHAFT 副轴
16 = CLUTCH KR 离合器 KR
P38
4WG-200 轴间差速器
表-2
1 = OUTPUT - FRONT AXLE 前桥输

出
2 = ENGAGEMENT AND DISENGAGEMENT
DIFFERENTIAL LOCK FRONT AXLE 啮合和断开锁定前
桥
3 = HOLLOW SHAFT 空心轴
4 = PLANETARY CARRIER 行星架
5 = PLANETARY PIN/PLANETARY GEAR (RAVIGNAUX-SYSTEM
OUTER HOLE CIRCLE)行星齿轮销/行星齿轮（Ravignaux 系
统外孔圈）
6 = SUN GEAR 太阳齿轮
8 = ATTACHMENT POSSIBILITY SPEEDOMETER 附件速度计
9 = BACK-UP WASHER/DRIVE GEAR/ SUPPORTING TUBE 支
撑垫圈/驱动齿轮/支撑管
10= PLANETARY PIN/PLANETARY GEAR (RAVIGNAUX-SYSTEM
INNER HOLE CIRCLE)行星齿轮销/行星齿轮（Ravignaux 系统内
孔圈）
11= MECHANICAL ENGAGEMENT AND DISENGAGE MENT OF
THE DIFFERENTIAL LOCK 差速器锁定的机械啮合和切断
P39
4WG-200 轴分离合器
表-3
1 = 前桥输出
2= 啮合和断开前桥
3= 输出齿轮
4= 机械速度计
5= 输出轴
6= 后桥输出
7= 变速箱悬挂点承 M20
8= 放油塞 M22x1，5
9= 差速器机械啮合和切断
P40
4 WG-200 安装图
独立安装，配轴分离离合器，中心距 400 mm，前视图，表-4A
1 = CONNECTION FROM HEAT EXCHANGER 从热交换器连接
2 = LIFTING LUGS 起升接线片
3 = DRIVE FLANGE - DRIVE THROUGH UNIVERSAL SHAFT 驱
动法兰——通过万向轴驱动
4 = ELECTRO-HYDRAULIC SHIFT CONTROL 电液换档控制
5 = TRANSMISSION SUSPENSION POINTS M20 变速箱悬挂点 M20
6 = OIL SUCTION PIPE 吸油管
7 = AXLE DECLUTCH - FRONT AXLE 前桥轴分离离合器
8 = OIL DRAIN PLUG M22x1,5 放油塞 M22x1，5
9 = MARKING OIL LEVEL 油位
11= INDUCTIVE TRANSMITTER FOR TURBINE SPEED 感应式传感器
涡轮机速度
P41
4 WG-200 安装图
独立安装，配轴分离离合器，中心距离 400 mm，侧视图，表-4B
1 = DRIVE FLANGE - DRIVE THROUGH UNIVERSAL SHAFT 驱
动法兰——通过万向轴驱动
2 = BREATHER 透气盖
3 = PLUG CONNECTION - CANNON 插头连接 — —
Cannon
4 = BOX FILTER 盒式过滤器
6 = SPEEDOMETER - MECHANICAL 机械式转速表
8 = ATTACHMENT POSSIBILITY FOR ELECTRIC
SPEEDOMETER 电子转速表附件
10= MODEL IDENTIFICATION PLATE 铭牌
11= AXLE DECLUTCH - FRONT AXLE 前桥离合器
12 = OUTPUT - FRONT AXLE 前桥输出
13 = CONNECTION TO HEAT EXCHANGER 连接至热交换器
14 = TEMPERATURE SWITCH MEASURING POINT 温度开关测量点
P42
4 WG-200 安装图
独立安装，配轴分离离合器，中心距离 400 mm，后视图，表-4C
1 = 盒式过滤器
2 = 第一取力器
4 = 感应式传感器涡轮机速度
8 = 配油位标尺油位管的可能性附件
9 = 后桥输出
10= 感应式传感器输出速度
从多通道板到离合器的软管管道
3 = KV
5 = K1
6 = K2
7 = KR
11= K3
12 = K4
P43
4 WG-200 安装图
直接安装，配轴间差速器，中心距离 400 mm，前视图，表-5A
1 = 热交换器连接
2 = 起升接线片
3 = 发动机连接——直接安装
4 = 电液换档控制
5 = 变速箱悬挂点 M20
6 = 吸油管
7 = 啮合和断开轴间差速器
8 = 前桥输出
9 = 标注油位
10= 油标尺加油管
11= 感应式传感器涡轮机速度
P44
4 WG-200 安装图
直接安装，配轴差速器，中心距离 400 mm，侧视图，表-5B
1= 发动机连接——直接安装
2= 透气盖
3= 插头连接——Cannon
4= 盒式过滤器
5= 电液换档控制
6 = 速度计——电子
7 = 后桥输出
8 = 吸油管
9 = 铭牌
10= 啮合和断开轴间差速器
11= 前桥输出
12 = 连接至热交换器
13 = 在变矩器后面的温度开关测量点
P45
4 WG-200 安装图
直接安装，配轴差速器，中心距离 400 mm，后视图，表-5C
1 = 盒式过滤器
2 = 第一取力器
8 =配油位标尺油位管的可能性附件
9 = 后桥输出
3 = KV
5 = K1
6 = K2
8 = KR
12= K3
13 = K4
P46
4 WG-200 安装图
直接安装，中心距离 500 mm，前视图，表-6A
1 = 透气盖
2 = 起升接线片
3 = 发动机连接——直接安装
7 = 吸油管
8 = 后桥输出
9 = 放油塞 m22x1，5
10= 标注油位
12 = 从热交换器连接
P47
4 WG-200 安装图
直接安装，中心距离 500 mm，侧视图，表-6B
1= 发动机连接——直接安装
2= 变矩器壳盖
3= 透气盖
4= 起升接线片
5 = 插头连接——Cannon
6 = 盒式过滤器
8 = 吸油管
9 = 机械速度计的可能性附件
10= 前桥输出
11= 铭牌
12 = 后桥输出
13 = 电子转速表附件
14 = 从热交换器连接
P48
4 WG-200 安装图
直接安装，中心距离 500 mm，后视图，表-6C
1= 盒式过滤器
2= 起升接线片
3= 第一取力器
9 = 输出前桥
10= 吸油管
4 = KV
5 = K1
6 = K4
8 = K3
11= K2
12= KR
P49
4 WG-200 安装图
独立安装，中心距离 500 mm，前视图，表-7A
1 = 透气盖
2 = 起升接线片
3 = 驱动法兰——通过万向轴驱动
5 = 变速箱悬挂点 m20
6 = 吸油管
7 = 后桥输出
8 = 配油标尺的加油管
9 = 感应式传感器输出速度
10= 从热交换器连接
P50
4 WG-200 安装图
独立安装，中心距离 500 mm，侧视图，表-7B
1= 驱动法兰——通过万向轴驱动
2= 透气盖
3= 插头连接——Cannon
4= 盒式过滤器
6 = 吸油管
7 = 机械速度计
8 = 前桥输出，配停车制动（鼓式制动）
9 = 标注油位
10= 放油塞 m22x1，5
11= 铭牌
12 = 后桥输出
16 = 安装孔
P51
4 WG-200 安装图
独立安装，中心距离 500 mm，侧视图，表-7C
1 = 盒式过滤器
2 = 起升接线片
3 = 第二取力器的可能性附件
4 = 第一取力器
8 = 感应式传感器输出速度
10= 配油标尺的加油管
11= 前桥输出，配停车制动（鼓式制动）
12 = 放油塞 M22x1，5
13 = 机械速度计
5 = KV
6 = K1
7 = K4
9 = K3
14=K2
15=KR
P52
4 WG-200 安装图
直接安装，中心距离 555 mm，前视图，表-8A
2 = ENGINE CONNECTION - DIRECT MOUNTING 发动机连接——直接安
装
4 = MEASURING POINT FOR TEMPERATURE BEHIND THE
CONVERTER 在变矩器后面的温度开关测量点
9 = MARKING OIL LEVEL 标注油位
10= OIL FILLER PIPE WITH OIL DIPSTICK 配油标尺的加油管
11= CONNECTION FROM HEAT EXCHANGER 从热交换器连接
12 = INDUCTIVE TRANSMITTER FOR TURBINE SPEED 感应式传感器
涡轮机速度
P53
4 WG-200 安装图
直接安装，中心距离 555 mm，侧视图，表-8B
1 = ENGINE CONNECTION - DIRECT MOUNTING 发动机连接——直
接安装
2 = CONVERTER HOUSING COVER 变矩器壳盖
5 = PLUG CONNECTION -CANNON 插头连接——
Cannon
8 = EMERGENCY STEERING PUMP 紧急转向油泵
12 = ATTACHMENT POSSIBILITY FOR ELECTRIC SPEEDOMETER 速
度计的可能性附件
14 = ATTACHMENT POSSIBILITY FOR MECHANICAL SPEEDOMETER 机
械速度计的可能性附件
15 = CONNECTION TO HEAT EXCHANGER 连接至热交换器
16 = TEMPERATURE SWITCH MEASURING POINT BEHIND THE
P54
4 WG-200 安装图
直接安装，中心距离 555 mm，侧视图，表-8C
6 = INDUCTIVE TRANSMITTER FOR TURBINE SPEED 感应式传感器涡轮
机速度
8 = EMERGENCY STEERING PUMP 紧急转向油泵
5 = KV
7 = K1
9 = K3
10= K4
12= K2
13= KR
INSTALLATION VIEW 4WG-200 DIRECT MOUNTING WITH DRUM BRAKE CENTER DISTANCE 555 MM FRONT VIEW
TABLE-9A
4 WG-200 安装图直接安装，配鼓式制动器，中心距离 555 mm，侧视图，表-9A
2 = ENGINE CONNECTION - DIRECT MOUNTING 发动机连接——直接安
装
4 = MEASURING POINT FOR TEMPERATURE BEHIND THE
5 = TRANSMISSION SUSPENSION POINTS M20 变速箱悬挂点 m20
10= OIL FILLER PIPE WITH OIL DIPSTICK 配油标尺的加油管
11= CONNECTION FROM HEAT EXCHANGER 从热交换器连接
12 = INDUCTIVE TRANSMITTER FOR TURBINE SPEED 感应式传感器
涡轮机速度
INSTALLATION VIEW 4WG-200 DIRECT MOUNTING WITH DRUM BRAKE CENTER DISTANCE 555 MM SIDE VIEW TABLE-9B
4 WG-200 安装图直接安装，配鼓式制动器，中心距离 555 mm，侧视图，表-9B
接安装
2 = CONVERTER HOUSING COVER 变矩器壳盖
5 = PLUG CONNECTION - CANNON 插头连接——Cannon
9 = OUTPUT - FRONT AXLE WITH PARKING BRAKE (DRUM BRAKE) 前
桥输出，配停车制动（鼓式制动）
11= ATTACHMENT POSSIBILITY FOR ELECTRIC SPEEDOMETER 电
子转速表附件
13 = ATTACHMENT POSSIBILITY FOR MECHANICAL SPEEDOMETER 机
械速度计的可能性附件
14 = CONNECTION TO HEAT EXCHANGER 热交换器与连接
15 = TEMPERATURE SWITCH MEASURING POINT BEHIND THE
INSTALLATION VIEW 4WG-200 DIRECT MOUNTING WITH DRUM BRAKE CENTER DISTANCE 555 MM 12 REAR VIEW
TABLE-9C
4 WG-200 安装图直接安装，配鼓式制动器，中心距离 555 mm，后视图，表-9C
6 = INDUCTIVE TRANSMITTER FOR TURBINE SPEED 感应式传感器涡
轮机速度
8 = ATTACHMENT POSSIBILITY FOR EMERGENCY STEERING PUMP 紧
急转向油泵的可能性附件
11= OUTPUT - FRONT AXLE WITH PARKING BRAKE (DRUM BRAKE)
前桥输出，配停车制动（鼓式制动）
5 = KV
7 = K1
9 = K3
10= K4
12 = K2
13 = KR
P58
WITH DISK BRAKE CENTER DISTANCE 555 MM FRONT VIEW TABLE-10A
4 WG-200 安装图直接安装，配盘式制动器，中心距离 555 mm，前视图，表-10A
接安装
7 = INDUCTIVE TRANSMITTER FOR ELECTRIC SPEEDOMETER 电
速度计的感应式传感器
10= OUTPUT - REAR AXLE 后桥输出
11 = CONTROL LEVER FOR DISK BRAKE 盘式制动器控
制杆
12 = CONNECTION FROM HEAT EXCHANGER 从热交换器连接
P59
4 WG-200 安装图
直接安装，配盘式制动器，中心距离 555 mm，侧视图，表-10B
1 = 发动机连接——直接安装，配中间环
2 = 变矩器壳盖
3 = 起升接线片
6 = 吸油管
7 = 盘式制动——停车制动
8 = 前桥输出配制动盘
9 = 铭牌
10= 后桥输出
11= 电速度计感应式传感器
12 = 连接到热交换器
14 = 安装孔
P60
4 WG-200 安装图
直接安装，配盘式制动器，中心距离 555 mm，后视图，表-10C
1 = 透气盖
2 = 连接至盒式过滤器：——独立安装
3 = 从盒式过滤器连接——独立安装
4 = 第一取力器
5 = 第二取力器
8 = 紧急转向油泵的可能性附件
12 = 盘式制动——停车制动
13 = 前桥输出，配制动盘
14 = 电速度计感应式传感器
6 = KV
7 = K1
9 = K3
11= K4
15 = K2
16= KR
P61
4 WG-200 安装图
独立安装，中心距离 555 mm，前视图，表-11A
1 = 起升接线片
5 = 吸油管
6 = 输出后轴
7 = 放油塞 M38x1，5
8 = 标注油位
11= 涡轮机速度的感应式传感器
P62
4 WG-200 安装图
独立安装，中心距离 555 mm，侧视图，表-11B
2 = 变矩器壳盖
3 = 起升接线片
4 = 透气盖
6 = 盒式过滤器
8 = 紧急转向油泵
9 = 吸油管
10= 前桥输出
11= 铭牌
13 = 后桥输出
P663
4 WG-200 安装图
独立安装，中心距离 555 mm，后视图，表-11C
1= 透气盖
2= 盒式过滤器
3= 第一取力器
4= 第二取力器
8 = 紧急转向油泵
11= 前桥输出
5 = KV
7 = K1
9 = K3
10= K4
12= K2
13= KR
P64
4 WG-200 安装图
独立安装，配鼓式制动器，中心距离 555 mm，前视图，表-12A
1 = 起升接线片
6 = 吸油管
6 = 后桥输出
7 = 放油塞 M38x1，5
8 = 标注油位
11= 感应式传感器涡轮机速度
P65
4 WG-200 安装图
独立安装，鼓式制动器，中心距离 555 mm，侧视图，表-12B
2 = 变矩器壳盖
3 = 起升接线片
4 = 透气盖
7 = 吸油管
9 = 铭牌
10= 电子转速表附件
11= 后桥输出
P66
4 WG-200 安装图
独立安装，鼓式制动器，中心距离 555 mm，后视图，表-12C
1 = 透气盖
2 = 连接至盒式过滤器——独立安装
3 = 从盒式过滤器连接——独立安装
4 = 第一取力器
5 = 第二取力器
9 = 紧急转向油泵可能性附件
6 = KV
8 = K1
10= K3
11= K4
13=K2
14=KR
P67
4 WG-200 测量点布局，配铝铸模，换档控制，标准版，表-13
标注位置（如 53）相当于表 18 的位置！！
在变速箱油温大约 80°C ~ 95°C 时进行测量！
压力油和温度测量点
IN FRONT OF THE CONVERTER OPENING
51 = PRESSURE 8,5 bar M10X1
变矩器前端开启压力 8，5 bar
53= CLUTCH FORWARD 离合器前进 KV M10X1
55= CLUTCH REVERSE 离合器后退 KR M10X1

56= CLUTCH 离合器 K1 M10X1
60 = CLUTCH 离合器 K4 M10X1
BEHIND THE CONVERTER 在变矩器后面
63 = M14X1，5
温度 100°C (短时 120°C) 和开启压力 5bar
65 = 系统压力 16+2 bar M10X1
66 减压阀 10bar M10X1
排量的测量点
15 = CONNECTION TO HEAT EXCHANGER 连接至热交换器 M26X1，5
16= CONNECTION FROM HEAT EXCHANGER 从热交换器连接 M26X1，5
TRANSMITTER 感应式传感器
21 = INDUCTIVE TRANSMITTER TURBINE SPEED 感应式传感器涡轮机速度 M18X1，5
34= INDUCTIVE TRANSMITTER OUTPUT SPEED 感应式传感器输出速度 M18X1，5
P68
TRANSMISSION DIAGRAM 变速箱图
Converter 离合器 Drive 驱动 Output 输出 Speedometer 速度计

Interaxle differential 轴间差速器
图代码“G”4——速度型
Magnet under Voltage 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
离合器 KV KV KV K4 KR KR KR K3
4 WG-200 测量点布局，配铝铸模，换档控制和二级压力控制阀——变量 I，表-14
变矩器前端
51 = M10X1
开启压力 8，5bar
53= 离合器前进 KV M10X1
55= 离合器后退 KR M10X1
56= 离合器 K1 M10X1
57= 离合器 K2 M10X1
58= 离合器 K3 M10X1
60 = 离合器 K4 M10X1
在变矩器后面
63 = 温度 100°C (短时 120°C) 和开 M14X1，5
启压力 5bar
65 = 系统压力 16+2 bar M10X1
排量的测量点
15 = 连接至热交换器 M26X1，5
16= 从热交换器连接 M26X1，5
感应式传感器
6 = 电速度计感应式传感器 M18X1，5
21 = 感应式传感器涡轮机速度 M18X1，5
34= 感应式传感器输出速度 M18X1，5
P70
变速箱图
Converter 离合器
Drive 驱动
Output 输出
Emergency steering pump 紧急转向泵
Speedometer-mechanical 机械速度计
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
L
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
离合器 K1 K2 K3 K3 K1 K2 K3
detail it “x " “X”明细图

2-stagepresure control valve 二级压力控制阀
P71
4 WG-200 测量点布局，配铝铸模，换档控制和二级压力控制阀——变量 II，表-15

变矩器前端
51 = M10X1
56= 离合器 K1 M10X1
57= 离合器 K2 M10X1
58= 离合器 K3 M10X1
60 = 离合器 K4 M10X1
在变矩器后面
63 = M14X1，5
温度 100°C (短时 120°C) 和开启压力 5bar
65 = 系统压力 16+2 bar M10X1
排量的测量点
感应式传感器
变速箱图
Converter 离合器
Drive 驱动
Output 输出
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •

Hose line from M4 to reversing valve 从 M4 至换档阀的软管
P73
4 WG-200 测量点布局，配铝铸模，换档控制和膨胀阀，表-16
变矩器前端
51 = M10X1
56= 离合器 K1 M10X1
57= 离合器 K2 M10X1
58= 离合器 K3 M10X1
60 = 离合器 K4 M10X1
在变矩器后面
63 = M14X1，5
温度 100°C (短时 120°C) 和工作压力 5bar
65 = 系统压力 16+2 bar M10X1
排量的测量点
感应式传感器
P74
变速箱图
Converter 离合器
Drive 驱动
Output 输出
图纸代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •

Expansion valve 膨胀阀
4 WG-200 测量点布局，配铝铸模，换档控制，膨胀阀和二级压力控制阀，表-17
在变速箱发热时（大约 80°~ 95°），应当进行测量！
变矩器前端
51 = M10X1
56= 离合器 K1 M10X1
57= 离合器 K2 M10X1
58= 离合器 K3 M10X1
60 = 离合器 K4 M10X1
在变矩器后面
63 = M14X1，5
温度 100°C (短时 120°C) 和工作压力 5bar
65 = 系统压力 16+2 bar M10X1
排量的测量点
感应式传感器
P76
变速箱图
Converter 离合器
Drive 驱动
Output 输出
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •

Hose line from M4 to reversing valve 从 M4 至换档阀的软管
P77
4 WG-200 油循环图——标准版
表-18
标注位置（如 53）相当于表-13 的位置。
Reducing valve 减压阀 10 bar

On the operator's platform：在操作员平台上
Converter exit temperature 变矩器出口温度
Reset valve 复位阀
Pressure control valve 压力控制阀
Converter 变矩器
Converter relief valve 变矩器溢流阀
Opening pressure 开启压力 8，5 bar
Converter pressure holding vavle 变矩器压力控制阀
Opening pressure 5 bar (converter FICHTEL & SACHS) 开启压力 5bar（变矩器 FICHTEL & SACHS）
Heat exchange pressure drop≤1 bar 热交换器压力降≤1 bar
Control pressure vavle 压力控制阀 16+2bar
Lubrication 润滑
Oil sump 油底壳
ZF fine filter ZF 精过滤器
Grade of filtration m: 过滤等级 m:
ß30 20 ß10 15
Filter area cm2 过滤面积 cm2
3500
Oil pressure pump 油压泵

P=16+2bar
Qp=80l/min-1 at 2000 min-1 在 2000 min-1 下时为 Qp=80l/min-1
Check valve 0.15bar 单向阀 0.15bar
Neutral 空档
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
LEGEND:
= Control pressure
= Control pressure reduced
= Control pressure modulated
= Converter inlet pressure
= Converter exit pressure
=Lubrication
=Return flow into the sump
图形符号：
= 控制压力
= 控制压力下降
= 控制压力适中
= 变矩器入口压力
= 变矩器出口压力
= 润滑
= 回流入油底壳
P78
4 WG-200 油循环图，配二级压力控制阀——变量 I
表-19

Bleeder valve 旁路阀
Reversing valve 换档阀
2-stage vavle 二级压力阀
Control pressure valve 16+2 bar 压力控制阀 16+2bar
Converter 变矩器
Lubrication 润滑
Oil sump 油底壳
20 15
ß30 ß10
3500

P=16+2 bar
Neutral 空档
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
LEGEND:
= Control pressure
=Lubrication
图形符号：
= 控制压力
= 润滑
P79
4 WG-200 油循环图，配二级压力控制阀——变量 II 表-20


Control pressure valve 16+2 bar 控制压力阀 16+2bar
Converter 变矩器
Lubrication 润滑
Oil sump 油底壳
ß30 20 ß10 15
3500

P=16+2 bar
Reset valve 0.15bar 复位阀 0.15bar
Neutral 空档
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
LEGEND:
= Control pressure
=Lubrication
图形符号：
= 控制压力
= 润滑
P80
4 WG-200 油循环图，配膨胀阀表-21


Converter 变矩器
Lubrication 润滑
Oil sump 油底壳
ß30 20 ß10 15
3500

P=16+2 bar
Neutral 空档
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
LEGEND:
= Control pressure
=Lubrication
图形符号：
= 控制压力
= 润滑
4 WG-200 油循环图，配膨胀阀和二级压力控制阀表-22

Converter 变矩器
Lubrication 润滑
Oil sump 油底壳
ß30 20 ß10 15
3500

P=16+2 bar
Neutral 空档
图代码“G”
4——速度型
• 欠压磁铁
前进后退空档
速度 1 2 3 4 1 2 3 1 2 3 4
M1 • • •
M2 • • •
M3 • • •
M4 • • • • • •
M5 •
LEGEND:
= Control pressure
=Lubrication
图形符号：
= 控制压力
= 润滑
P82
铝铸模，换档控制，配五个电磁阀，标准型，表-23
cable harness 电缆束

shift valve 4 换档阀 4
reducing valve 减压阀
control pressue valve 控制压力阀
pressure control valve 压力控制阀
reset valve 复位阀
shift vavle 3 换档阀 3
P83
铝铸模，换档控制，配五个电磁阀和二级压力控制阀——变量 I，表-24

reversing valve 换向阀
2-stage pressure control valve 二级压力控制阀
bleeder vavle 旁路阀
P84
铝铸模，换档控制，配五个电磁阀和二级压力控制阀——变量 II，表-25

Hose line from M4 to reversing valve 从 M4 到换向阀的软管管路
Detail ―X‖ 明细图“X”

P85
铝铸模，换档控制，配五个电磁阀和膨胀阀，表-26

solenoid valve 电磁阀
expansion valve 膨胀阀
P86
铝铸模，换档控制，配五个电磁阀、膨胀阀和二级压力控制阀，表-27

solenoid valve 电磁阀
Detail ―X‖ 明细图“X”

P87
4WG-200 半自动和全自动换档控制线路图-6029 700 875-DW-2 “代码 G” 表-28
Operational status (only for ZF diagnosis) 工作状态（仅对 ZF 诊断）

Speepometer signal 速度计信号
位置图型符号位置图型符号位置图型符号
A1 电控制 EST-17 TE，EST-25E P1 保险丝 8A S2 开关压力切断

A2 控制器 DW-2 S4 开关强制降档
A3 电液换档控制 H1 灯降档和传感器故障 SS 开关怠速
A5 诊断 S6 开关温度（60℃关闭)
A6 速度计 Kl 继电器起动联锁 S7 开关驾驶程序 A/M
K2 继电器备用灯
B1 速度传感器输出
B2 速度传感器涡轮机 Y6 膨胀阀
Y7 任选
Note: binding is the corresponding parts-list version connection circuit - 6029 700 876 -see table 29!
注意：仅限于相应的零件表版本，接线图——6029 700 876——见表 29！
P88
4WG-200 半自动和全自动换档控制线路图-6029 700 876-DW-2 “代码 G” 表-29

illustrated pole patterns: 所示孔的类型
view on plug-in side of the instruments 仪表插入端图
pole pattern X9 孔的类型 X9
pole pattern X10；X11 孔的类型 X10；X11
cannon 6-pole screw socket X5 佳能 6-孔螺纹插座 X5
circular plug 2-pole M24 圆形插头 2-孔 M24
circular plug 2-pole M27 圆形插头 2-孔 M27
location housing amp mate-N-lok 15-pole pin 位置外壳啮合锁定 15-孔销
plug 3-pole socket 插头 3-孔插座
socket box 2-pole AMP 插座盒 2 孔
AMP35-pole socket 35 孔插座
View on plug: 插头图
Dignosis 诊断
P89
4WG-200 半自动和全自动换档控制线路图-6029 700 781-ERGO II“代码 G” 表-30
service lamp (error display on tester) 工作灯（测试仪的错误显示）

Speepometer signal 速度计信号
位置图型符号位置图型符号位置图型符号
A1 电控制 EST-17 TE，EST-25E F1 保险丝 8A S2 开关压力切断

A2 控制器 ERGO II S4 开关强制降档
A3 电液换档装置 Kl 继电器起动联锁 SS 开关怠速
A5 诊断 K2 继电器备用灯 S6 开关温度（60℃关闭）
A6 速度计
Y6 膨胀阀
B1 速度传感器输出
B2 速度传感器涡轮机
P90

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Plano Electrico 856h

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ORDER-NO: 5872 174 002

订单号：5872 174 002

Zahnradfabrik Passau Gmbh 采埃浮公司

D - 94034 Passau Edition: 1996/09 With the reserve of

The ZF-Hydromedia Transmission 4 WG-200 is composed of a hydrodynamic torque

由直接安装在发动机上进行驱动，通过 SAE 2 和 3 发动机连接薄膜或单独安装（通过

- Semi-Automatic EST-17 T (24V) EST-19 T (12V)

- Fully-Automatic EST-25 (24V) EST-26 (12V)

- 半自动 EST-17 T (24V) EST-19 T (12V)

Powershift - Reversin transmissions:

1st-Speed Reverse 4,576

* = According to the transmissions Version, other ratios are also possible.

The engaged speed has no effect at stopped engine.

Before leaving the vehicle, secure it additionally by brake blocks.

Operating temperature 80℃-110℃，a short-time increase up to max. 120℃ is permitted.

Pay attention to the control pressure.

1.3 transmissions controls:

Grade of filtration: '30 > 20 131o >1,5

——半自动 EST-17T (24V) EST-19T (12V) ——见表 28，29，30，

1.3.2 VERSION WITH 2-STAGE P SSURE CONTROL VALVE - VARIANT I

transmissions control see Oil circulation 'agram, Schedule of measuring

The pressure control can be „soft or fast", to be more precise as follows:

1.3.4 VERSION WITH EXPANSION VALVE

过滤等级：ß30 ≥20 ß 10≥1，5

1.3.5 VERSION WITH 2-STAGE PRESSURE CONTROL VALVE AND

The pressure control can be „soft or fast", to be more precise as follows:

1．4．2 控制器 ERGO II

如果采用自动控制 EST 25，一个 bar 指示器另外同时指示关于所选择驱动

• Invalid Controller input-line combination: 22

然后这种零星错误代码值增加+ 40，因此到 42、50 和 61。

Still another NOTE concerning the Display:

1.6.1 Description of the Basic function:

1.6.2 Description of the Microprocessor Control unit EST-..

The difference between Semi- and Fully-Automatic is essentially consisting in

1.6.2.2 Direct selection of the solenoid valves:

1.6.2.3 Sneed engagement:

1.6.2.4 Passive reversin lock:

At vehicles as Dumpers, Cranes and Rail vehicles, reversing can be permitted

1.6.2.5 Gear shiftings:

Fully Automatic EST-25 (EST-26):

1.6.2.7 Pressure cutoff:

1.6.2.8 Special function:

1.6.2.9 Customized control outputs:

1.6.2.10 Solenoid valve selection in Position Neutral:

It will be distinguished between unrecoverable failures (emergency properties plus

An error readout is possible by connection of a diplay unit on the diagnostic connector.

1.6.5 Test of the Electronic transmission control:

ZF 控制单元的差异通过带 PR68 检测器和装配有换档控制特殊装配 PR78A+B(见表

Department against a fee of DM 15.--.

1.8 Power take-offs:

The attachment of an emergency steering pump is possible (16 cm 3/rev. or 32

cm 3/rev.). Instead of an emergency steering pump, a secondary pump can be

应急转向泵附件可以为 16 cm 3/rev. or 32 cm 3/rev。 作为替换，可以安装分泵。

13. The required cooling capacity is based on a normal outside temperature of

Permitted transmissions oils, see ZF-List of lubricants TE-ML 03!

At the oil-level check, the prescribed Safety Regulations according to § 6 of

The test has to be carried out at NEUTRAL POSITION of the Controller.

油温为 80℃时，油位必须在油尺上刻度线；到油温为 40℃时，油位必须在油尺

At the insertion of the filter, any kind of force has to be avoided.

3.2 Driving and Shifting:

For safety reasons, it is recommended to brake the vehicle always securely in

On a level road, it is possible to drive off also in higher gears.

The acceleration will be only lower.

Temperature increases in the converter oil as well as overheated brakes are

应急转向泵附件可以为 16 cm 3/rev. or 32 cm 3/rev。作为替换，可以安装分泵。

4 WG-200 油循环图，配膨胀阀表-21

位置图型符号位置图型符号位置图型符号

位置图型符号位置图型符号位置图型符号