LZ-ZF T/M (4WG208)

Introduction

2013. 01. 15
DISD W/L R&D Center
A. Name_part(1)

The name of TM’s main part

A. Name_part(2)

The name of TM’s main part

• breather

Torque • Control
convertor valve

Joint • sensor
flange

Charging
Pump
• Suction
(inside)
tube

Sensor
• Behind
flange
TM
housing

Oil filling • Bleeding

tube plug
B. Function_oil hole(1)

The founction of TM’s oil hole

MEASURING POINT FOR MEASURING POINT FOR

PRESSURE OIL RESSURE OIL BEFORE C
2.SPEED (M10x1) ONVERTER

MEASURING POINT FOR MEASURING POINT FOR

PRESSURE OIL PRESSURE OIL
1.SPEED (M10x1) 3.SPEED (M10x1)

MEASURING POINT FOR MEASURING POINT FOR

PRESSURE OIL PRESSURE OIL
REVERSE SPEED (M10x1) FORWARD SPEED (M10x1
)
MEASURING POINT OF
TEMPERATUR BEHIND
CONVERTER
(100°C;FOR A SHORT
TIME 120°C
MEASURING POINT OF
SYSTEM PRESSURE
MEASURING POINT FOR
(15+2 bar)
PRESSURE OIL
M10x1/15 DEEP
4.SPEED (M10x1)
B. Function_oil hole(2)

The function of TM’s oil hole

MEASURING POINT FOR

PRESSURE OIL BEFORE INDUCTIVE SENSOR
CONVERTER TO MEASURE
THE OUTPUT SPEED
(M24×1.5)
 B. Function_oil hole(3)

The founction of TM’s oil hole

Oil inlet to
filter

Oil outlet to
filter
Oil outlet of
pump

Oil inlet to T/C Oil return

Oil inlet to T/C
port
and retaining
valve
Oil inlet of oil
Oil inlet of suction pipe
pump

Oil outlet from

T/C Oil outlet to
(Connect with Cooler
retaining valve
of T/C outlet)

Oil Temp Test T/M Inlet port

Port
B. Function_oil hole(4)

The founction of TM’s oil hole

Oil outlet of Oil inlet of Charging

Charging pump pump
B. Function_oil hole(5)

The founction of TM’s oil hole

Fine filter Inlet of fine filter

Outlet of fine
filter
C. Driven principle(1)
The diagram of driven principle
C. Driven principle(2)
The way of driven
C. Driven principle(3)
The way of driven
C. Driven principle(4)
The way of driven
C. Driven principle(5)
The way of driven
C. Driven principle(6)
The way of driven
C. Driven principle(7)
The way of driven
C. Driven principle(8)
The way of driven
 D. Controller information (1)

Controller information
Function
 This transmission is based on components having excellent worldwide reputations.
 It is equipped with a modulation system allowing soft gear shifting and inversion of travel direction.
 Safety devices also protect the transmission of bad operations.
 The gear and direction shifting is operated by a single lever to the left of the steering wheel. .
 A travel direction control is also mounted on the hydraulic joystick.
 With a special electronic device, the transmission can be tested and adjusted easily for optimum
performance and efficiently.
 The transmission can be de-clutched by the operation of brake pedal to increase the power
available to the hydraulic pumps.
 A safety device prevents the starting of the engine when not in neutral.
D. Controller information (2)

Controller diagram
Shift handle diagram

Cable Shifting F R N KD
joint handle
1 2 3 4 1 2 3 4 1 2 3 4
7 AD1 B1 ● ● ● ● ● ●
8 AD2 B2 ● ● ● ● ● ●

9 AD3 B3 ● ● ● ● ● ● ● ● ● ● ● ●

4 AD4 V ● ● ● ●

6 AD5 R ● ● ● ●
5 AD6 AS ● ● ● ●
10 AD7 ●
2 (+)
D. Controller information (3)

Controller diagram
Solenoid diagram

Cable F R N KD
Valve
joint 1 2 3 4 1 2 3 4 1 2 3 4
B M1 ● ● ●
C M2 ● ● ●
D M3 ● ● ●
E M4 ● ● ● ● ● ●
A M5 ●
F (-)
KV KV KV K4 KR KR KR K1 K2 K3
Clutch
K1 K2 K3 K3 K1 K2 K3
E. Control valve(1)
Control valve of ZF208B information
E. Control valve(1)
Control valve of ZF208 information
E. Control valve(2)

Control valve information M1,M2,M3,M4,M5

no_ZF208B
Valve diagram Yes_ZF208 Solenoid valve

Reducing valve
1.0MPa Valve7,valve8,valve9,v
alve10,valve11
Shift gear valve

Control pressurev
Check valve
alve
0.015MPa
1.6+0.2MPa

K1,K2,K3,K4,KV,KR
Pressure control v
clutch
alve
 E. Control valve(3)

Control valve information

Valve function
1.Supply oil to TC and hydraulic operation system, and adjust pressure and flow rate
2.Gear shift ,to make sure clutch work regularly
3.Control shifting quality, control oil pressure dynamic features to obtain smooth gears shift
4.Oil supply to T/C and cooling and lubricating system
 valve 1: control pressure valve
Function: keep pressure of hydraulic system, and send overflow oil to TC and lubrication system at highest pressure
 valve 2 and valve 3 : pressure control valve and reset valve
Main part of regulating circuit. Its function is to adjust instant pressure rise feature of clutch cylinder when shifting
gears, to improve reliability and stability.
 valve 6 :reducing valve
Function: lower system pressure as pilot circuit of gear shift valve
 M1,M2, M3, M4, M5, & valve7,valve 8,valve9,valve 10,valve 11
Solenoid valve ,pilot valve , is to control gear shift valve to realize clutch motion.
Solenoid valve ,always two-position three way valve.
Gear shift valve ,always two-position valve, and one end is forced by a spring and the other by pilot solenoid valve
pressure .Gear shift valve shaft is forced by spring in one position if no pressure in pilot circuit ,and in the other
position if there is pressure in pilot circuit.
E. Control valve(4)

Control valve information no_ZF208B

Valve structure Yes_ZF208
E. Control valve(5)

Control valve information

Valve structure
 E. Control valve(6)

Control valve information

Valve structure analysis
Hydraulic system mainly include two parts : shifting circuit and
pressure adjust circuit
Shifting circuit : shifting circuit include group A and group B .
Group A : 3 pilot Solenoid valves (M5,M3,M1) control 3 gear shift
valves to realize motion of clutch K4,KV,KR respectively and there
3 oil circuit are independent .
Group B : 2 pilot Solenoid valves (M2,M4) control 2 gear shift
valves to realize motion of clutch K1,K2,K3.
This circuit can avoid two clutch working at the same time.
Pressure of Pilot circuit is reduced by reducing valve. Oil pass
through pressure control valve and reset valve branches into group
A and group B. Group B also have oil source from pump. So clutch
of group B can bond together more quickly.
E. Control valve(7)

Control valve information

Valve structure analysis
Adjust circuit
ZF208B adjust circuit and hydraulic symbol are as picture (a) and (b).
Adjust circuit include control pressure valve1,accumulator 2 and reset valve3.
One end of accumulator 2 spring seat braced by shaft of control pressure valve 1 ,and the other end by

1.Control pressure valve

2.Accumulator
3.Reset valve

(a) (b)
 A. Oil level and oil type

Oil level information

Oil level check

When checking the oil level，the TM should be in idle state （1000rpm)，
The level should be between the middle scale mark and the low scale mark
When the temp of oil is 40℃；
The level should be between the middle scale mark and the high scale mark
When the temp of oil is 80℃
Oil type
API CD/CD/CF/SF/SG SAE15W-40

ZONE_HOT

HOT_80
HOT_40

ZONE_COLD
END OF DOCUMENT

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