ZF 4 WG 90 - 94 POWERSHIFT TRANSMISSION

Order no.
: 5872 137 002
ZF – POWERSHIFT TRANSMISSION
4 WG-90/94
DESCRIPTION
INSTALLATION INSTRUCTIONS
OPERATION
MAINTENANCE
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Subject to technical modifications!
POWERSHIFT Corporate Division
Off-Road Driveline Technology
TRANSMISSION and Axle Systems
1st Edition: 2006/12
2
Preface
This documentation has been developed for specialized staff trained by ZF Passau for repair
and maintenance work to be made on ZF units.
Due to the continuous technical upgrading of the product, however, the repair and
maintenance of the unit at your disposal may require both deviating work steps and differing
setting and testing data.
This manual is based on the state-of-the-art at the time of printing.

It was prepared with utmost care in order to avoid errors.
However, we shall not be liable for any possible errors in figures or descriptions.
We reserve the right to make modifications without prior notice.
The owner and the user shall be responsible for complying with the safety instructions and for
implementing the maintenance work according to the specified guidelines.
ZF shall not be liable for any incorrect installation, improper handling, insufficient
maintenance, improperly or incompetently performed work and any consequential damage
resulting thereof.
It is imperative to observe the relevant instructions and manuals of the vehicle manufacturer.
Important information regarding technical reliability and operational safety are highlighted by
the following symbols:
This is applicable for instructions to be observed for maintenance, operation

or handling of the vehicle!
Refers to working and operating processes which must be strictly observed to

avoid any damage to or destruction of the unit or to exclude any endangerment
to persons!
3
TABLE OF CONTENTS
Page
Summary of TECHNICAL DATA 6–7
Identification plate 8
IMPORTANT INSTRUCTIONS 9
I. Description 11
1.1 Operating mode of the converter
1.2 Powershift transmission
1.2.1 4 WG-90
1.2.2 4 WG-94
1.3 Transmission control
1.4 Output
1.5 Gear selector LS
II. INSTALLATION INSTRUCTIONS 15
III. OPERATION 17
3.1 Driving preparation and maintenance
3.2 Start the engine
3.3 Starting-off and driving
3.4 Stopping
3.5 Shifting differential lock (rear axle)
3.6 Stopping and parking
3.7 Towing
3.8 Oil temperature
IV. MAINTENANCE 21
4.1 Oil grade
4.2 Oil level check
4.3 Oil change and oil fill quantity
4.4 Filter change
4
ANNEX consisting of:
Illustrated tables:
1 Configuration 4 WG-90/94 without front wheel drive
2 Configuration 4 WG-90/94 with front wheel drive
3 Installation sheet 4 WG-90/94 without front wheel drive – front view
4 Installation sheet 4 WG-90/94 with front wheel drive- front view
5 Installation sheet 4 WG-90/94 – rear view
6 Measuring points and connections 4 WG-90
7 Oil circuit diagram 4 WG-90 - 1st gear forward
8 Measuring points and connections 4 WG-94
9 Oil circuit diagram 4 WG-94 - 1st gear forward
10 Power flow 4 WG-90 - forward / reverse gears
11 Power flow 4 WG-94 – forward / reverse gears
12 Gear selector LS
13 Wiring diagram - 6029 717 143
5
Technical data:
Details Unit 4 WG-90 4 WG-94

Engine power: max. KW* 65 75
Turbine torque: max. Nm* 630 730
Engine speed: max. min-1* 2600 2600
Stall torque ratio:
Engine dependent PTOs:

Torque: Nm 400 400
Speed: n 1x n engine 1x n engine
Maximum vehicle weight t* 7500 9000
Weight (without oil), with front axle approx. 215 230

disconnection kg**
* = depending on vehicle type and application

** = depending on transmission version
Description:
The ZF-transmissions 4 WG-90/94 are composed of a hydrodynamic torque converter and a
rear-mounted multi-speed powershift transmission with integrated transfer box (see table 1and
2).
The torque converter is a wear-free start up device which, due to its continuously variable
design, adapts itself to the required situations.
Input by direct mount via flexplate to the engine or remote mount (input via U-joint shaft)
with Spicer input flange.
Torque converter:
Size W-280 with torque multiplication.
Powershift transmission:
Type Driving direction

Gears
Forward Reverse
4 WG-90 4 2
4 WG-94 4 3
6
Output:
The powershift transmission has the following axle distances between input and output shaft:
Rear axle: 181 mm center distance with shifting output flange.

Front axle: 316 mm with powershiftable front axle drive.
PTO:
For driving an external oil pressure pump, the system incorporates an engine-dependent PTO
which can optionally be supplied in disconnectible version.
4 WG-90: SAE B or SAE C

4 WG-94: SAE C
Transmission Ratio (mechanical)
Gear Driving direction Ratio

4 WG-90 4 WG-94
1 Forward 4.932 4.932
2 Forward 2.681 2.681
3 Forward 1.295 1.295
4 Forward 0.704 0.704
1 Reverse 3.900 3.900
2 Reverse 2.120 2.120
3 Reverse 1.314
* = Other ratios are possible, depending on the transmission version.
7
LABELING OF IDENTIFICATION PLATE FOR

ZF-POWERSHIFT TRANSMISSIONS
1 = Transmission type
2 = Transmission number
3 = ZF parts list no.
4 = Overall transmission ratio
5 = Oil filling (oil specification)
6 = ZF-List of Lubricants
7 = Oil fill quantity
8 = Customer number
1 2
3 4
5 6
7
8
INFORMATION ON SPARE PARTS ORDERING:
Please indicate the following information when ordering genuine ZF spare parts:
1. = Transmission type
2. = Unit number You will find this information on the identification plate!
3. = ZF parts list number
4. = Make and type of spare part
5. = Denomination of spare part
6. = Spare part number
7. = Shipping mode
Please indicate all a.m. details to avoid any mistakes in the delivery of the ordered spare
parts!
8
IMPORTANT INSTRUCTIONS
Oil level check (see 4.2):

In the cold-start phase, the engine must be running at idling speed for about
2 – 3 min. and the marking of the oil dipstick must then be above the cold-start
level. The oil level check in the transmission must be carried out at engine
idling speed and operating temperature of the transmission ( 80° to 90° C ).
At shut-off engine, the oil level in the transmission is rising essentially,

depending on the installation conditions!
Observe intervals for oil changes!
The ZF filter must be replaced at every oil change.
When starting the engine, always place the gear selector into neutral position.
At running engine and transmission in neutral, make sure that the parking
brake has been engaged or the service brake has been actuated, in order to
prevent the vehicle from rolling away.
Loosen the parking brake prior to every start-off.
Gear selector in neutral position is not allowed at increased vehicle speeds

(above walking speed). Promptly engage a suitable gear, or slow down the
vehicle immediately.
When the engine is shut off, there is no power flow between transmission and
engine in spite of a preselected speed on the gear selector, that means the
transmission is in idling position.
Therefore, the parking brake must be fully actuated!
When leaving the vehicle, secure it additionally by wheel chocks!
Do not skip gears when shifting up and down.
Reduce the engine speed when reversing and keep the driving speed low while
reversing.
Operating temperature after the converter 65° min. and 100° C in continuous
operation; short-term increase up to max. 120° C is permitted.
9
In any case, the towing speed must not exceed 10 km/h and the towing distance
must not be longer than 10 km.
It is imperative to observe this instruction, since otherwise the transmission
will be damaged due to insufficient oil supply!
For longer-distance transport of the defective vehicle we recommend to use a
flatbed truck.
In case of irregularities on the transmission put the vehicle out of service and
ask for specialists.
10
I. DESCRIPTION
1.1 Operating mode of the converter:
The torque converter is composed of three main parts:
• Pump wheel
• Turbine wheel
• Stator (reaction member)
Operating mode of a hydrodynamic torque converter

(schematic view)
pump wheel
turbine wheel
TP = torque of pump
wheel
TT = torque of
TT turbine wheel
from the TR= torque of
engine reaction member
(stator)
TP
towards the
transmission
NT = 0
starting condition
1 1,5
TR 2,5 vehicle at standstill
reaction member
(stator) nT = <n engine
intermediate condition 1 <1,5 <2,5
nT = ≈ 0,8 n engine
condition in the lock-up
point 1 0 1
Fig. no. 1.1
These three impellers allow the transmission oil to flow through as operating fluid.
Therefore the converter is integrated into the transmission oil circuit, i.e. it is provided with
oil by the transmission pump. The arrangement of a converter safety valve before the
converter makes sure that the permitted internal converter pressure is not exceeded.
The direction of flow of the oil streaming out of the pump wheel is reversed in the turbine
wheel. Depending on the rate of reversal, a different input torque is applied to the turbine
wheel and thus to the transmission input shaft. In the following stator the oil streaming is once
again reversed to the pump wheel. Thereby the occurring reaction torque must be stationarily
supported by the stator.
11
The relation turbine torque/pump torque is called torque multiplication. Torque multiplication
increases with increasing differential speed between pump and turbine wheel, i.e. the
maximum torque multiplication is generated at turbine speed 0, i.e. when the output is
stationary.
This point is called stall point.

Depending on the tractive resistance, i.e. on the necessary output torque the optimum
operating condition is set on the converter (turbine speed > torque multiplication > input
torque)!
The hydrodynamic converter operates according to the Trilok system. This means that in case
of small difference speeds between pump and turbine, i.e. in the area of the smaller torque
multiplication the converter is operating similar to a hydrodynamic fluid clutch. This
materializes by backing up the stator in one direction over a freewheel.
After the lock-up point torques are no more backed-up by the stator and the converter is
working as fluid clutch.
1.2 Powershift transmission
1.2.1 4 WG-90
The multi-speed reversing transmission in countershaft design is powershiftable by

hydraulically actuated multi-disk clutches.
All gears are in constant mesh and carried on antifriction bearings.
The gears, bearings and clutches are cooled and lubricated with oil.
The 4-speed reversing transmission is equipped with 5 multi-disk clutches.
In shifting operation, the respective disk package is compressed by a piston which is movable
in axial direction and pressurized by pressure oil.
A compression spring pushes the piston of clutches KV, KR, K1, and K4 back and thus
releases the disk package.
A cup spring package pushes the piston of clutch K2 back.
For the transmission configuration and information on the closed clutches in the different
gears please refer to Table-1, 2, 6 and 7.
1.2.2 4 WG-94
The multi-speed reversing transmission in countershaft design is powershiftable by

hydraulically actuated multi-disk clutches.
All gears are in constant mesh and carried on antifriction bearings.
The gears, bearings and clutches are cooled and lubricated with oil.
The 4-speed reversing transmission is equipped with 6 multi-disk clutches.
In shifting operation, the respective disk package is compressed by a piston which is movable
in axial direction and pressurized by pressure oil.
A compression spring pushes the piston of clutches KV, KR, K1, K3 and K4 back and thus
releases the disk package.
A cup spring package pushes the piston of clutch K2 back.
12
For the transmission configuration and information on the closed clutches in the different
gears please refer to Table 1, 2, 8 and 9.
1.3 Transmission control
Transmission control see measuring points (Table-6 and 8) and oil circuit diagram
(Table-7 and 9).
The transmission pump which is necessary for the oil supply of the converter and for the
transmission control is located within the transmission on the engine-dependent input shaft.
The pump feed rate is Q = 45 l /min, at nengine = 1 500 min -1.
This pump is sucking the oil out of the oil sump via the coarse filter and delivers it to the main
pressure valve via the ZF filter (control pressure valve).
ZF-Filter:
Filtration ratio acc. to ISO 4572: ß30 ≥ 20 ß10 ≥ 1.5
min. filter surface: 2780 cm2
min. dust capacity acc. to ISO 4572 19 g
ZF coarse filter (screen):

Mesh size: 0.800 mm
The 5 clutches of the transmission 4 WG-90 are controlled via the proportional valves Y1,
Y2, Y3, Y4 and Y5.
The 6 clutches of transmission 4 WG-94 are controlled via the 6 proportional valves Y1, Y2,
Y3, Y4, Y5 and Y6.
The pressure modulation to the respective clutch is controlled by cup springs in the clutch
package.
In addition to this the pressure modulation for each gear clutch K1, K2 and K3 (only with 4
WG-94) is controlled over a separate orifice and to the direction clutches KV, KR and K4 by
an orifice.
For the control the system pressure between 18 and 21 bar is directed to the following
components through solenoid valves:
• Y MFWD front axle drive (all-wheel)

• Y PB parking brake (rear axle)
• Y DL differential lock (rear axle)
The main pressure valve (shift pressure valve) limits the max. control pressure to 18 until 21
bar and releases the main stream towards the converter and lubrication circuit.
The converter inlet incorporates a converter safety valve which protects the converter from
high internal pressures (opening pressure 11+2 bar).
Within the converter, the oil serves for transmitting the power according to the well-known
hydrodynamic principle (see Chapter torque converter 1.1).
13
To avoid cavitation, the converter must always be completely filled with oil.
The oil coming out of the converter is directed to a heat exchanger.

The selection and determination of the heat exchanger must be carried out by the customer on
his own responsibility, according to our Installation Guidelines for Hydrodynamic Powershift
Transmissions.
The heat exchanger is not included in the delivery scope of ZF Passau GmbH.
From the heat exchanger, the oil is directed to the transmission and the lubricating oil circuit,
so that all lubricating points are supplied with cooled oil.
1.4 Output:
See table-2.
The powershift transmission has the following center distances between input and output
shafts:
Rear axle:
Center distance of 181 mm - can be equipped with shifting output flange for various U-joint
shafts.
Front axle:
316 mm with powershiftable front axle drive.
The front axle drive (all-wheel) is powershiftable by a hydraulic multi-disk clutch.
A cup spring package pushes the piston back and thus releases the disk package.
1.5 Gear selector LS

See table-12.
The switch has been designed for assembly on the steering column left. By a rotary motion the
positions (gears) 1 to 4 are selected, by pivoting the lever the driving direction (Forward (F) -
Neutral (N) - Reverse (R) is selected.
Gear selector LS
Fig. no. 1.5
14
II. INSTALLATION INSTRUCTIONS
This Guideline for the installation of hydrodynamic powershift transmissions of the

Ergopower range is the basis for the technically correct installation of these transmissions into
the vehicle. The Guideline is part of the transmission documentation and must be strictly
observed.
A faulty installation of the transmission into the vehicle can
* affect the operating quality

* cause malfunctions of the transmission
* lead to transmission damage or failures.
The vehicle manufacturer shall be responsible for the correct installation of the
transmission.
ZF shall not accept any warranty claims for any damage due to incorrect installation.
In order to support the customer in case of new or initial applications, ZF carries out a
transmission installation study by authorized personnel. On that occasion, ZF examines all
transmission-specific installation features and informs the vehicle or equipment manufacturer
of the defects found.
In case of improper installation ZF reserves the right to refuse any warranty coverage for the
installed ZF products.
Any damage caused by defects which are the vehicle manufacturer’s responsibility and which
could not be revealed during the installation study by ZF personnel, shall be the exclusive
liability of the vehicle manufacturer.
These installation instructions

0000 702 270 GERMAN
0000 702 271 ENGLISH
can be requested at the following address:
ZF Passau GmbH
Abt. ACETS
e-mail: stefan.altmann@zf.com
Donaustr. 25 – 71
94034 Passau
15
III. OPERATION
3.1 Driving preparation and maintenance
Prior to putting the transmission into operation, take care that the correct quantity of the
specified oil grade is filled in. At the initial filling of the transmission special care is to be
taken that the oil cooler, the pressure filter and the pipes are getting filled with oil.
Due to these hollow spaces, the quantity of the oil to be filled in is lager than during later oil
fillings in the course of the usual maintenance service.
Since the converter and the oil cooler which is installed into the vehicle, as well as
the pipes can empty into the transmission at standstill,
the oil level check must be carried out at engine idling and transmission at
operating temperature (see Chapter Oil level check 4.2).
For the oil level check, strict observance of the mandatory safety regulations
according to § 6 of the Regulations for the Prevention of Accidents for
Transmissions in Germany and the respective national regulations in all other
countries is imperative.
The vehicle is to be secured against rolling away by means of wheel chocks;
articulated vehicles are to be secured additionally against unintentional
turning-in.
3.2 Start the engine:
The telltale lamps lighting up on the INFOCENTER (dashboard) for functional

control may differ from one vehicle manufacturer to the other.
Operating elements and displays may be provided by ZF, but also could be
customer-specific products. For detailed information please refer to the operating
instructions of the respective vehicle manufacturer.
When starting the engine, the gear selector must always be in NEUTRAL POSITION. For
safety reasons, we recommend to always securely brake the vehicle with the parking brake
prior to starting the engine.
After engine start-off and preselection of driving direction and gear, the vehicle can be moved
by accelerating.
At the start-off, the converter takes over the function of a main clutch. On flat terrain, start-off
in higher gears is also possible.
However, in this case acceleration will be lowered.
17
3.3 Starting and driving:
Release the parking brake when starting. Our experience with converter transmissions showed
that the omission of this quite normal operating step might not be immediately noted since,
due to its high ratio, a converter can easily overcome the brake torque of the parking brake.
Temperature increases in the converter oil and overheated brakes will be the consequences
which can be detected at a later date only.
We wish to point out that when shifting down gears the engine speed - also in case of a
converter transmission - is increased and the reached speed levels can jeopardize the engine,
in particular when skipping a gear.
Do not shift until the maximum speed of the lower gear is reached.
If necessary, brake the vehicle down with the foot brake until this speed is reached.
During driving operation the vehicle may not be shifted to Neutral.

When reversing, reduce the engine speed and keep the driving speed low while reversing.
3.4 Stopping
When the vehicle is stopped and is standing with running engine with engaged gear and
driving direction clutch, the engine cannot be stalled. On level roadway or slight downhill
gradients the vehicle may start to crawl, since the engine generates a low drag torque via the
converter in idle position. We recommend to securely brake the vehicle with the parking brake
at each stoppage. In case of longer stops, shift the gear selector to NEUTRAL POSITION and
securely brake with the parking brake.
3.5 Shifting differential lock (rear axle)
Connection is only possible, if the vehicle is at standstill and the gear selector is in
neutral position.
3.6 Stopping and parking
Due to the converter, there is no rigid connection from the engine to the axle. When the driver
wants to leave the vehicle, we therefore recommend to secure the vehicle against unintentional
rolling away on uphill and downhill gradients not only by pulling the parking brake but
additionally by means of a wheel chock.
3.7 Towing
See IMPORTANT INSTRUCTIONS on page 9
18
3.8 Oil temperature
When the system is trouble-free and the vehicle is operated properly, there will be no
increased temperatures. If the temperature rises above 120° C, stop the vehicle, check for
external oil loss and run the engine at a speed of 1200 – 1500 min-1 in transmission
NEUTRAL POSITION.
During this process, the temperature must quickly (within approx. 2 – 3 minutes) drop to
normal values.
If this is not the case, there is a trouble which must be eliminated prior to continue working.
In addition, the oil temperature after the converter is monitored by an indicator on the ZF-
display or analogously in the INFOCENTER.
Operating temperature after the converter 65° min. and 100° C in continuous operation, short-
term increase up to 120° C max. is permissible.
The temperature is measured at the measuring point „63“

(see measuring points Table 6 and 8)!
19
IV. MAINTENANCE
4.1. Oil grade:
Approved oils for powershift transmissions 4 WG-90/94 see ZF List of Lubricants

TE-ML 03.
The list of lubricants is being continuously updated and can be obtained or viewed as
follows:
- At all ZF plants
- At all ZF service centers
- Internet http://www.zf.com Service/Technische Informationen/
4.2 Oil level check
For the oil level check, strict observance of the mandatory safety regulations
according to § 6 of the Regulations for the Prevention of Accidents for
Transmissions in Germany and
the respective national regulations in all other countries is imperative.
For example: the vehicle is to be secured against rolling away by means of
wheel chocks, articulated vehicles are to be secured additionally against
unintentional turning-in.
The oil level check must be carried out as follows:

- Oil level check (weekly)
- Vehicle in horizontal position
- Transmission in neutral position „N“
- In the cold-start phase, the engine must be running at idling speed for about 2-3 min. and
the marking on the oil dipstick must then be above the cold-start level „COLD“ (see Figure
no.: 4.2 B2).
- At operating temperature of the transmission (approx. 80° - 90° C)
at engine idling
all measurements are to be done at low engine idling speed.
- Oil dipstick „A“ (not included in ZF’s delivery scope)

• Loosen the screws and remove the oil dipstick for cleaning.
Oil dipstick „B“ (Option)
• Loosen oil dipstick by counterclockwise rotation, remove and clean it.
- Insert oil dipstick slowly into the oil level tube until contact is obtained and pull it out
again.
- On the oil dipstick, the oil level must be within the „HOT“ range (see Figure no.: 4.2 B2)
- Oil dipstick „A“
• Insert the oil dipstick once again and tighten the screws.
Oil dipstick „B“
• Insert the oil dipstick once again and tighten it by clockwise rotation.
21
If, in operating temperature condition, the oil level has dropped below the „HOT“
range, it is imperative to refill oil according to ZF List of Lubricants TE-ML 03.
An oil level above the „HOT“ marking leads to an excessive oil temperature.
Figure no. 4.2 B1
Legend:
Thread Tightening torque

1 = Installation oil dipstick „A“ with breather
(not included in ZF’s delivery scope)
2 = Mounting provision for ZF oil filler tube
with oil dipstick „B“ (Option)
3 = Oil drain plug 7/8" - 14 UNF 30 Nm
4 = ZF-Filter
Oil dipstick „A“
ENGINE OFF MEASURET AT LOW HOT COLD

IDLING-NEUTRAL
Range
”HOT”
Fig. No. 4.2 B2
22
Oil dipstick „B“ (Option)
ENGINE OFF MEASURET AT LOW HOT COLD

IDLING-NEUTRAL
Range
”HOT”
Fig. No. 4.2 B3
4.3 Oil change and oil fill quantity:
In this connection refer to specification in the ZF List of Lubricants TE-ML 03.

The oil change must be carried out as follows:

- With the transmission at operating temperature and the vehicle in horizontal position, open
the oil drain plug (see Fig. no.: 4.2 B1 and 4.2 B3) and drain the used oil.
It is only possible to drain the quantity of oil which is in the transmission and
in the upper part of the converter.
- Clean the oil drain plug and the sealing surface on the housing and reinstall it.
- Fill in oil (approx. 12 - 13 liters) according to ZF List of Lubricants TE-ML 03.
(Sump volume, external oil volumes, e.g. in the heat exchanger and in the lines etc. are
depending on the vehicle).
Absolute cleanliness of oil and filter is imperative!

In any case, the marking on the oil dipstick is binding!
- Start the engine, idling speed.

- Transmission in neutral position ”N”.
- Refill oil up to ”COLD-MIN”marking.
- Securely brake the vehicle and heat up the transmission.
- Shift through all gear selector positions.
- Check the oil level once again and refill oil if required.
- The oil level on the dipstick must be within the ”HOT” range (see Figure no.: 4.2 B2).
- Insert the dipstick once again and tighten it by clockwise rotation.
If, in operating temperature condition, the oil level has dropped below the ”HOT”
range, it is imperative to refill oil according to ZF List of Lubricants TE-ML 03.
An oil level above the ”HOT” marking leads to an excessive oil temperature.
23
At the initial filling of the transmission special care is to be taken that the heat
exchanger, the pressure filter and the pipes are getting filled with oil.
Due to these hollow spaces, the quantity of oil to be filled in is larger than during
later oil fillings in the course of the usual maintenance service.
4.4 Filter change:

When changing the ZF filter in the main oil stream, pay attention that no dirt or oil sludge
enters the circuit.
Avoid any application of force when installing the filter.
Carefully treat the filter during installation, transport and storage!!

Damaged filters must not be reinstalled!
The filter has to be installed as follows:

- Slightly oil the seal.
- Turn in the filter until contact with the sealing surface is obtained, and then tighten it by
hand with approx. 1/3 to 1/2 rotation.
24
CONFIGURATION 4 WG-90/94
15
WITHOUT FRONT WHEEL DRIVE
1 14
TABLE-1
2
13
1 = Converter
2 = Flexplate for direct mount
3 = Transmission pump
4 = Converter bellhousing 12
5 = Clutch shaft „K2“ 3
6 = Mounting provision for front wheel drive
7 = Transmission housing – front part
8 = Transmission housing – rear part 4 11
9 = Clutch shaft „K3“
(Only with version 4 WG-94)
10 = Output flange 5
13 = Input shaft PTO „PTO“
engine-dependent (central shaft)
14 = Input shaft /clutch shaft „KR“
15 = Clutch shaft „KV“
16 = Converter safety valve
9
6
8
7
Table-1 / Page 1 of 3
Installation position of clutches 4 WG-90 Transmission schematics 4 WG-90
16 1 3
15
13
15
14
14
12
13
5 11
12
5 10
11
7 8 Table-1 / Page 2 of 3
16 1 3
15
13
15
14
14
12
13
5 11
12
5 9 10
9
11
7 8 Table-1 / Page 3 of 3
CONFIGURATION 4 WG-90/94 17
WITH FRONT WHEEL DRIVE
1 16
TABLE-2
2
1 = Converter 15
2 = Flexplate for direct mount
3 = Transmission pump
6 = Front wheel drive „VA“
7 = Output for front axle
8 = Transmission housing – front part 4 13
9 = Transmission housing – rear part
10 = Screen sheet
(Only with version 4 WG-94)
15 = Input shaft PTO „PTO“
engine-dependent (central shaft)
11
16 = Input shaft /clutch shaft „KR“
17 = Clutch shaft „KV“ 6
18 = Converter safety valve
10
7
9
8
Table-2/ Page 1 of 3
18 1 3
17
15
17
16
16
14
15
5 13
14
5 12
7 6
13
7 6 10 8 9 Table-2 / Page 2 of 3
18 1 3
17
15
17
16
16
14
15
5 13
14
5 11 12
11
7 6
13
7 6 10 8 9 Table-2 / Page 3 of 3
INSTALLATION SHEET 4 WG-90/94 - DIRECT MOUNT
FRONT VIEW 1 2 3 4 5 6
WITHOUT FRONT WHEEL DRIVE

TABLE-3
1 = Direct mount via flexplate

2 = Converter
3 = Converter bellhousing
5 = Transport bracket
7 = Transmission mounting holes M16
8 = Closing cover for version without
front wheel drive
8
FRONT VIEW 1 2 3 4 5 6

TABLE-4
2 = Converter
3 = Converter bellhousing
8 = Input shaft front wheel drive
8
REAR VIEW 1 2 3 4 5 6
TABLE-5
4 = Oil filler and oil dipstick
(Oil dipstick delivery scope of the customer)
7 = Filter head 14
8 = ZF filter
10 = Oil drain plug 7/8“ 14 UNF
11 = Mounting provision for oil filler tube with oil dipstick (option) 8
12 = Identification plate
14 = PTO; engine-dependent
9
12
11
10
MEASURING POINTS, VALVES AND CONNECTIONS 4 WG-90
TABLE-6
The marked items (e.g. 53) correspond with the items on Table-7!
Take measurements when the transmission has reached operating temperature (approx. 80° - 90° C)! Transmission schematics
No. Denomination of item Connection

KV
Measuring points for pressure oil and temperature:
51 = Before the converter – opening pressure 11+2 bar M10x1
53 = Forward clutch KV 18+3 bar M10x1
55 = Reverse clutch KR 18+3 bar M10x1 AN/KR PTO
56 = Clutch K1 18+3 bar M10x1
60 = Clutch K4 18+3 bar M10x1 K4
63 = Temperature after the converter 100° C; short-term 120° C M14x1.5
67 = System pressure 18+3 bar M10x1
68 = Parking brake PB 18+3 bar 9/16“ - 18 UNF
69 = Differential lock DL 18+3 bar 3/4“ - 18 UNF K1
70 = Front wheel drives WD 18+3 bar M10x1
Connections:
13 = Connection to parking brake (rear axle) 9/16“ - 18 UNF
14 = Connection return flow into the transmission sump 9/16“ - 18 UNF K2/AB
15 = Connection to heat exchanger 7/8“ 14 UNF
16 = Connection from heat exchanger 7/8“ 14 UNF
Inductive sensor:
35 = Inductive sensor n speedometer (option) M18x1.5 VA
Valves:
Y1 … Y5 = Control valves
YWD = Front wheel drive
YDL = Differential lock (rear axle)
YPB = Parking brake (rear axle)
Table-6 / Page 1of 3

YDL YPB 67 Y3 55 Y2 YPB YDL
Y3
Y2 68 Y1
Y1
53 13
13
51 60
14
56 Y5
57
57
Y4
YWD 69
YWD
70 70
Encoding
Solenoid under current
Forward Reverse Neutral
Gear 1 2 3 4 1 2 N
Y1
Y2
Y5
Y4
Y3
Engaged clutches KV KV K4 K4 KR KR
K1 K2 K1 K2 K1 K2
15 35
63
16
OIL CIRCUIT DIAGRAM 4 WG-90 - WITH FRONT WHEEL DRIVE
– 1st GEAR FORWARD -
TABLE-7
GF = Coarse filter mesh size 800 mm

GP = Transmission pump
Q = 45 l/min, at n engine = 1500 min-1 18+3 bar Encoding
FT Filter
Filtration ratio acc. to ISO 4572: ß30 ³ 20 ß10 ³ 1.5
Min. filter surface: 2780 cm2 Solenoid under current
Min. dust capacity acc. to ISO 4572: 19 g Forward Reverse Neutral
HVD = Main pressure valve (control pressure valve) 18+3 bar Gear 1 2 3 4 1 2 N
WSV = Converter safety valve 11+2 bar Y1
Y2
SKR = Lubrication of KR clutch Y5
WT = Heat exchanger (not included in ZF’s delivery scope) Y4
Y3
Y1 …Y5 = Solenoid valves to the control valves Engaged clutches KV KV K4 K4 KR KR
BL-1 / BL-2 = Orifice to the gear clutches K1 K2 K1 K2 K1 K2
BLTP = Orifice to the directional clutches
DL = Differential lock rear axle
VA = Front axle drive (option)
PB = Parking brake rear axle
YDL = Solenoid valve differential lock rear axle
YWD = Solenoid valve front axle drive (option)
YPB = Solenoid valve parking brake rear axle
KV 53
Alarm
Relay 60
57
BL-2
K2 K4
56 Y3
K3
Relay K1
BL-1 KR
Gear selector LS D1 55
(see table -12) D2
K4
Relay K2
Relay Y5
Neutral/Start
Y2
Relay
To the starter Y4
1
engine
Parking brake P
Battery
Y1
Parking brake 18 (+) BLTP
Pressure switch
Parking brake valve YDL

DL Converter 51 65
50 HDV
Parking brake
Relay
VA WSV FT
Vehicle YWD 63
17
1 R M Hydraulic pump
Battery(+) WT 15 SKR
Starter GP
Engine PB
Not included in
Zf’s delivery scope GF Oil sump
YPB
14 Main oil circuit 16 Lubrication
MEASURING POINTS, VALVES AND CONNECTIONS 4 WG-94
TABLE-8
Take measurements when the transmission has reached operating temperature (approx. 80° - 90° C)! Transmission schematics
No. Denomination of item Connection

KV
Measuring points for pressure oil and temperature:
51 = Before the converter – opening pressure 11+2 bar M10x1
53 = Forward clutch KV 18+3 bar M10x1
55 = Reverse clutch KR 18+3 bar M10x1 AN/KR PTO
58 = Clutch K3 18+3 bar M10x1 K4
63 = Temperature after the converter 100° C; short-term 120° C M14x1.5
67 = System pressure 18+3 bar M10x1
68 = Parking brake PB 18+3 bar 9/16“ - 18 UNF K1
69 = Differential lock DL 18+3 bar 3/4“ - 18 UNF
70 = Front wheel drives WD 18+3 bar M10x1
Connections:
13 = Connection to parking brake (rear axle) 9/16“ - 18 UNF K2/AB
14 = Connection return flow into the transmission sump 9/16“ - 18 UNF
15 = Connection to heat exchanger 7/8“ 14 UNF
16 = Connection from heat exchanger 7/8“ 14 UNF
Inductive sensor: K3
35 = Inductive sensor n speedometer (option) M18x1.5
Valves:
Y1 … Y6 = Control valves
YWD = Front wheel drive
YDL = Differential lock (rear axle)
VA
YPB = Parking brake (rear axle)
YDL YPB 67 Y3 55 Y2 YPB YDL
Y3
Y2 68 Y1
Y1
53 13
13
51 60
14
56
Y5
57 Y4
Y6
Y6
YWD 69
YWD
70 58 70 58
Encoding
Gear 1 2 3 4 1 2 3 N
Y1
Y2
Y5
Y4
Y6
Y3
Engaged clutches KV KV K4 K4 KR KR KR
K1 K2 K1 K2 K1 K2 K3
15 35
63
16
OIL CIRCUIT DIAGRAM 4 WG-94 - WITH FRONT WHEEL DRIVE
- 1st GEAR FORWARD-
TABLE-9
GF = Coarse filter mesh size 800 mm

GP = Transmission pump Encoding
Q = 45 l/min, at n engine = 1500 min-1 18+3 bar
FT Filter Forward Reverse Neutral
Filtration ratio acc. to ISO 4572: ß30 ³ 20 ß10 ³ 1.5 Gear 1 2 3 4 1 2 3 N
Min. filter surface: 2780 cm2 Y1
Y2
Min. dust capacity acc. to ISO 4572: 19 g Y5
HVD = Main pressure valve (control pressure valve) 18+3 bar Y4
WSV = Converter safety valve 11+2 bar Y6
Y3
SKR = Lubrication of KR clutch Engaged KV KV K4 K4 KR KR KR
WT = Heat exchanger (not included in ZF’s delivery scope) clutches K1 K2 K1 K2 K1 K2 K3
Y1 …Y6 = Solenoid valves to the control valves
BL-1.. BL-3 = Orifice to the gear clutches
BLTP = Orifice to the directional clutches
DL = Differential lock rear axle
VA = Front axle drive (option)
PB = Parking brake rear axle
YDL = Solenoid valve differential lock rear axle
YWD = Solenoid valve front axle drive (option)
YPB = Solenoid valve parking brake rear axle
Legend:
BL-3
= Main pressure K3 58 KV 53
Alarm
= Main pressure modulated Relay 60
57
= Converter input pressure BL-2
= Lubrication K2 K4
= Return flow into the oil sump
= Current
Y6
56 Y3
K3
Relay K1
BL-1 KR
Gear selector LS D1 55
(see Table-12) D2
K4
Relay K2
Relais Y5
Neutral/Start
Y2
Relay
To the starter Y4
1
engine
Parking brake P
Battery
Y1
Parking brake 18 (+) BLTP
Pressure switch
Parking brake valve YDL

DL Converter 51 65
50 HDV
Parking brake
Relais
VA WSV FT
Vehicle YWD 63
17
1 R M Hydraulic pump
Battery WT 15 SKR
Starter GP
(+) Engine
(Not included in Zf’s PB
delivery scope GF Oil sump
YPB
14 Main oil circuit 16 Lubrication
POWER FLOW 4 WG-90 - FORWARD / REVERSE GEARS
WITH FRONT WHEEL DRIVE TABLE -10
Transmission schematics Gear schematics 1st gear reverse 2nd gear reverse
View / sense of rotation
KV
KV KV KV
AN/KR PTO
K4 K4 K4
AN/KR AN/KR AN/KR
K4
K1 K1 K1
K1 K2/AB K2/AB
K2/AB
K2/AB
VA VA VA
VA
Table-10 / Page1 of 2
1st gear forward 2nd gear forward 3rd gear forward 4th gear forward
KV KV KV KV
K4 K4 K4 K4
AN/KR AN/KR AN/KR AN/KR
K1 K1 K1 K1
K2/AB K2/AB K2/AB K2/AB
VA VA VA VA
Legend:
Driving Gear Engaged
KV = Forward clutch direction clutches
KR = Reverse clutch Forward 1 KV/K1
K1 = 1st gear clutch 2 KV/K2
K2 = 2nd gear clutch 3 K4/K1
K4 = 4th gear clutch 4 K4/K2
VA = Front wheel drive
Reverse 1 KR/K1
AN = Input
AB = Output 2 KR/K2 Table-10 / Page 2 of 2
POWER FLOW 4 WG-94 - FORWARD/REVERSE GEARS
TABLE-11
Transmission schematics Gear schematics
KV
View / sense of rotation
AN/KR PTO KV
K4 K4
AN/KR
K1
K1
K2/AB
K2/AB
K3
VA
K3
VA
1st gear forward 2nd gear forward 3rd gear forward 4th gear forward
KV KV KV KV
K4 K4 K4 K4
AN/KR AN/KR AN/KR AN/KR
K1 K1 K1 K1
K2/AB K2/AB K2/AB K2/AB
K3 K3 K3 K3
VA VA VA VA
GEAR SELECTOR LS Encoding transmission
TABLE-12 LE
Before horizontal activation from position N P Gear

Y1 (AD4)
1 2 3 4 1 2 3 N
the shift lever must be lifted.
A M Y2 (AD5)
Y5 (AD3)
3
S Y4 (AD2)
Y6 (AD7)
4 Y3 (AD1)
Engaged KV KV K4 K4 KR KR KR
clutches K1 K2 K1 K2 K1 K2 K3
Encoding gear selector

Output
View “X” Identification plate Digital
Inputs
Digital
Outputs
Selection of
Direction
Speed range
Gear
RDH 12 poles PIN PIN F N R 1 2 3 4
ED1 (VP) 1 AD4 F 5
6 7 X AD5
AD6
R
N
6
4
5 8
ED2 (VP) 9 AD1 B3 7
4 9
3 10 AD2 B2 3
2 11 AD3 B1 2
1 12 AD7 B4 8
The following notes are printed:
Place F-N-R lever in-N-and set Park Brake Legend:
before leaving seat or using backhoe
(Fahrhebel F-N-R in Neutral stellen, und VP = Supply voltage

F vor Verlassen oder Starten des Fahrzeugs
die Parkbremse betätigen.) F = Forward
N = Neutral
N 1 R = Reverse
2 B = Gear range signal
Y = Solenoid valves Y1 … Y6
R
Identification plate Note:
STEUERUNG 203.902/AT314144 Customer parts number
Week of production V 30/05 NR. XXXX Consecutive serial number Y6 = Not available for version 4 WG-90
ZF GETR. MADE IN HUNGARY Country of manufacture (4 forward / 2 reverse gears)
Table-12 /Page 1 of 2 STÜCKL. 0501 214 269 ZF parts number
Wiring diagram gear selector
S7
BL 7
2 1
AD 1 AD 1
S5
2 1 GN 3
AD 2 AD 2
Legend:
87 87a K1 = Starter interlock relay

86
S4 S2 K2 = Cut off relay
2 1 SW 2
30 K3 = 3rd gear reverse relay
AD 3 85 AD 3
K4 = F/R time relay (t = 1 sec.)
S6 V1
87
1 8
30
AD 7 AD 7
WS 9 1 87a
3 86
4
S2 S2
1 7 85
RT 6
ED 1 ED 1 (+ / VP)
1
3 2
S1 GR
4 87a
AD 6 AD 6 (N) 87
86
1 K1
85
S2 3 2 GE 5
AD 4 AD 4
30
(Vorwärts)
D1
1 Pin connection
X1
S3 3 2
D2
RS
6 Contact
AD 5 AD 5
(Rückwärts)
12 11 10 9 8 7
X1 1 2 3 4 5 6
12-poles
Plug view Socket contact
WIRING DIAGRAM (6029 717 143)
TABLE-13
POS LEGEND
F1 Fuse 7.5 A
S1 Switch front wheel drive

S2 Switch differential lock rear axle
S3 Switch parking brake
K1 Starting interlock – Relay Note:

K2 Y5 Cut-off relay
K3 3rd gear reverse relays Transmission temperature sensor not included in ZF’s delivery scope!
K4 Time relay (Normally open contact) t = 1 Provision and cable routing by the customer!
sec.)
Y1 Forward (V)
Y2 Reverse (R)
Y3 B3
Y4 B2
Y5 B1
Y6 B4
Y-DL Differential lock rear axle
Y-PB Parking brake
MFWD Front wheel drive
1817 17 18
1615 15 16
1413 13 14 2pol. Delphi-Metripack Socket
AMPJPT 1211 11 12 AMPJPT Y2, Y5: Delphi-Partno. 12162197 X6:3/1.5 1
12 1 18-pin
10 9 9 10
18-pin WG:GND1/1.5 2 X11 Y3
Series DT 11 2 8 7 7 8
10 3 6 5 5 6
12-pin 4 3 Y1, Y3, Y4, Y6, MFWD, Y-Dl, Y-Pb:
9 4 3 4 X6:6/1.5 1
8
7
5
6
2 1 1 2 Delphi-Partno. 12162193 WG:GND1/1.5 2 X10 Y2
Y5:1/1.2 1 1 X13:1/1.8 X6:5/1.5 1

Y4:1/1.2 2 2 X14:1/1.8 WG:GND1/1.5 2 X9 Y1
X1:7/1.2 3 3 X11:1/1.8
1 X4:1/1.4 Y6:1/1.2 4 4 X15:1/1.8
2 X4:5/1.4 Y1:1/1.2 5 5 X9:1/1.8 X6:9/1.5 1
3 X4:4/1.4 Y2:1/1.2 6 6 X10:1/1.8 WG:GND1/1.5 2 X8 Y-DL
4 X4:13/1.4 GND:1/1.2 7 7 WG:GND2/1.6
Gear selector 5 X4:12/1.4 MFWD:1/1.2 8 8 X16:1/1.9
6 X4:10/1.4 Y_DL:1/1.2 9 9 X8:1/1.8 X6:10/1.5 1
7 X3:3/1.4 Y_PB:1/1.2 10 10 X7:1/1.7 WG:GND1/1.5 2 X7 Y-Pb
8 X4:8/1.4 11 11
9 X4:2/1.4 12 12
10 13 13
11 14 14
12 15 15
16 16
X1 17 17
18 18
X6:1/1.5 1
X3:2/1.4 Y4 X3 X6 WG:GND2/1.6 2 X13 Y5
X4:3/1.4 1
X11:2/1.8
X10:2/1.8
WG
X3:1/1.4 Y5 GND1
1 X9:2/1.8 X6:2/1.5 1
X4:6/1.4 X8:2/1.8 WG:GND2/1.6 2 X14 Y4
Y2
X7:2/1.7
X13:2/1.8 WG
X3:6/1.4 WG:GND2/1.6
X14:2/1.8 GND2
X4:9/1.4 1 2122 22 21 X15:2/1.8
19 20 20 19
18 17 X16:2/1.9
1718 X6:4/1.5 1
X3:5/1.4 Y1 15 16 16 15 WG:GND1/1.5
WG:GND2/1.6 2 X15 Y6
X4:11/1.4 1 AMPJPT 1314 14 13 AMPJPT X6:7/1.5
11 12 12 11
X3:4/1.4 Y6 22-pin 9 10 10 9 22-pin
7 8 8 7
X4:7/1.4 1 5 6 6 5 7,5A X6:8/1.5 1
3 4
1 2
4 3
2 1 KL.15 WG:GND2/1.6 2 X16 MFWD
X3:7/1.4 GND
X4:18/1.4 1 F1
X3:8/1.4 MFWD
X4:14/1.4 1
X1:1/1.2 1 1
X3:9/1.4 Y_DL X1:9/1.2 2 2
X4:15/1.4 1 Y4:1/1.2 3 3
87a 86
X1:3/1.2 4 4
X3:10/1.4 Y_PB X1:2/1.2 5 5
85
X4:16/1.4 1 Y5:1/1.2 6 6 30
K2
S1 S2 S3
Y6:1/1.2 7 7
X1:8/1.2 8 8
Y2:1/1.2 9 9 86 30
X1:6/1.2 10 10 3
Y1:1/1.2 11 11 87
X1:5/1.2 12 12 K4 7 K3
X1:4/1.2 13 13 V1 V2 6
MFWD:1/1.2 14 14
Y_DL:1/1.2 15 15
Y_PB:1/1.2 16 16
17 17
GND:1/1.2 18 18
19 19
86
20 20
21 21
22 22
K1 85
X4 X5

ZF 4 WG 90 - 94 POWERSHIFT TRANSMISSION

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ZF 4 WG 90 - 94 POWERSHIFT TRANSMISSION

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Order no.

: 5872 137 002

1st Edition: 2006/12

This manual is based on the state-of-the-art at the time of printing.

We reserve the right to make modifications without prior notice.

This is applicable for instructions to be observed for maintenance, operation

Refers to working and operating processes which must be strictly observed to

Summary of TECHNICAL DATA 6–7

II. INSTALLATION INSTRUCTIONS 15

ANNEX consisting of:

1 Configuration 4 WG-90/94 without front wheel drive

2 Configuration 4 WG-90/94 with front wheel drive

3 Installation sheet 4 WG-90/94 without front wheel drive – front view

4 Installation sheet 4 WG-90/94 with front wheel drive- front view

5 Installation sheet 4 WG-90/94 – rear view

6 Measuring points and connections 4 WG-90

7 Oil circuit diagram 4 WG-90 - 1st gear forward

8 Measuring points and connections 4 WG-94

9 Oil circuit diagram 4 WG-94 - 1st gear forward

10 Power flow 4 WG-90 - forward / reverse gears

11 Power flow 4 WG-94 – forward / reverse gears

13 Wiring diagram - 6029 717 143

Details Unit 4 WG-90 4 WG-94

Turbine torque: max. Nm* 630 730

Engine speed: max. min-1* 2600 2600

Stall torque ratio:

Engine dependent PTOs:

Maximum vehicle weight t* 7500 9000

Weight (without oil), with front axle approx. 215 230

* = depending on vehicle type and application

Type Driving direction

Rear axle: 181 mm center distance with shifting output flange.

4 WG-90: SAE B or SAE C

Transmission Ratio (mechanical)

Gear Driving direction Ratio

* = Other ratios are possible, depending on the transmission version.

LABELING OF IDENTIFICATION PLATE FOR

INFORMATION ON SPARE PARTS ORDERING:

Oil level check (see 4.2):

At shut-off engine, the oil level in the transmission is rising essentially,

Observe intervals for oil changes!

The ZF filter must be replaced at every oil change.

Loosen the parking brake prior to every start-off.

Gear selector in neutral position is not allowed at increased vehicle speeds

Do not skip gears when shifting up and down.

1.1 Operating mode of the converter:

The torque converter is composed of three main parts:

Operating mode of a hydrodynamic torque converter

Fig. no. 1.1

This point is called stall point.

1.2 Powershift transmission

The multi-speed reversing transmission in countershaft design is powershiftable by

The multi-speed reversing transmission in countershaft design is powershiftable by

1.3 Transmission control

The pump feed rate is Q = 45 l /min, at nengine = 1 500 min -1.

ZF coarse filter (screen):

• Y MFWD front axle drive (all-wheel)

The oil coming out of the converter is directed to a heat exchanger.

1.5 Gear selector LS

Fig. no. 1.5

II. INSTALLATION INSTRUCTIONS

This Guideline for the installation of hydrodynamic powershift transmissions of the

A faulty installation of the transmission into the vehicle can