Professional Documents
Culture Documents
Walter Rehberger
MAVG 73
ZF Friedrichshafen AG
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
High efficiency
On-board electronic
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
Hydrostatic Unit
Transmission-oil
line
Output shaft
TCU + Control
Unit
12 MAVG 73, cPower © ZF Friedrichshafen AG, 2016
Physical design
Drive
direction
clutches
Planetary
gear
Hydrostatic
unit
Driving
range
clutches
PTO2
KR
PTO1
z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
vibration absorber) z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
Reverse unit KR
PTO1
z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
input speed) An
KV
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
synchronous rangeshift z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
Hydromodul with KR
PTO1
double yoke z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
Range clutches KR
PTO1
z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
PTO2
Output KR
PTO1
z3 z4
KV
An
z1 z2
z6
z5
zP1
zP2
z7
zS2
zS1
P1-M2
zH
z9
z8
M1-P2
z10
z11
K1
z12
K2
z13
z14
Ab Ab
nHydropumpe nHydropumpe
iHydro very high iHydro very low
nHydromotor nHydromotor
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HE
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
HP 180
Position
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HE
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
HP 180
Position
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HE
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
HP 180
Position
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HE
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
Synchronus rangeshift
Position
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
180 500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
60
Dp2 150
40
100
Pump and 20 50
Engine 0 0
0 5 10 15 20 25 30 35 40 45
changes v [km/h]
HE 180
Position
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HP
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
HE 180
Position
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HP
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
HE 180
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
Position
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HP
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
HE 180
neu: CVT 210 (160ccm) CNH PL18 V8-V11C 44°
Fördervolumen, Druck
displacement - pressure
Position
500
160 450
400
140
350
120
VgP1
300
V g [c m 3 ]
VgM2
D p [b a r ]
100
VgM1 250
80 VgP2
200
Dp1
HP
60
Dp2 150
40
100
20 50
0 0
0 5 10 15 20 25 30 35 40 45
v [km/h]
Pump starts in 0°
Motor starts in 44°
combined movement until
pump is in 44° and motor in 0°
Combination of two kits in one
double yoke
Hydrostat KitP
Lubrication Adjustment cylinder
1,5 bar
feeler
Lubrication
5 bar PRV
HP-Channel B adjustment Hydrostat
Leakage Shuttle valve HP-channel „AB“
(routes HP )
2 high pressure sensor
• 1 sensor always at HP-Channel
• 1 sensor always at A-Channel
Hydraulic plan
PRV-Magnet
p_HP_Sensor_A p_HP_Sensor_AB
Feed-Spring
feeler
spring
PRV-Cartridge
Adjusting arm
adjust cylinder
Double
yoke
F Magnet F spring
AB channel
Kit P -> 0°
Kit P -> 44°
Oil sump
Pressure reduce
Lubrication valve 9bar
pressure valve
4,5 bar
44 MAVG 73, cPower © ZF Friedrichshafen AG, 2016
Filterbypass
valve
Sump temp.
sensor
K2
KV
KR
Circut diagram
Breather
KR
Sun 2
Out
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
PTO2
z15
PTO2
z15 z15
Forwards Reverse
KR KR
PTO2
PTO1 PTO2
PTO1
z3 z4 z3 z4
KR
KV KR
KV
An PTO1 An PTO1
z1
z3 z4
z2 z1
z3 z4
z2
z6 z6
z5 z5
zP1
zP1
zP2
zP2
z7 z7
KV KV
zS2
zS2
An An
P1-M2
zS1
zS1
P1-M2
z1 z2 z1 z2
z6 z6
z5 zH z5 zH
zP1
zP1
zP2
zP2
z7 z7
z9 z9
Planetary
z8
/ Kit C shaft Planetary
z8
/ Kit C shaft
zS2
zS2
P1-M2 P1-M2
zS1
zS1
M1-P2 M1-P2
z10 zH z10 zH
z11 z11
1. Range z8
K1
z9
2. Range z8
K1
z9
M1-P2 M1-P2
z10 z10
z12 z11 z12 z11
K1 K2 K1 K2
z13 z13
z12 z12
K2 z14 K2 z14
Ab Ab Ab Ab
z13 z13
z14 z14
FB1 FB1
load coast
Pump Motor
Motor Pump
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
The oil level can be checked with an oil sight glass which is located on the PTO
side. The oil level must be within the cold/hot marks.
The Transmission has a filter bypass valve. With the „SPN523305 FMI0“(oil filter
contaminated) error code the transmission shows the operator a contaminated
filter. After this message at the display the filter needs to be replaced.
Filter
59 MAVG 73, cPower © ZF Friedrichshafen AG, 2016
cPower Training – Course of action
1. Introduction
2. Why cPower?
3. What is cPower?
4. Advantages / Challenge
5. Physical Design
6. Theory of operation
7. Maintainance
8. Software Functions
Some Software Functions are able to limit the functionality of the transmission!
Especially „ZF Test Service“ employees should keep this in mind for customer claims!
furthermore these functions are designed to protect the transmission in certain cases:
- Cold Start Function:
- Clutch Calibration:
- Hydrostat Calibration:
- Limp Home
Engine running
Vehicle standstill
Neutral request
TCU
Clutch calibration must be performed at the end of the customer production line
Until clutch calibration was carried out by the customer for the first time the failure code 360.9
„Calibration data lost“ will be sent on CAN
Successful end of clutch calibration at the end of the customer production line will be indicated by the
status information on CAN: 0x01 „clutch cal. successful“
If the clutch calibration must be aborted, the reason will be broadcasted on CAN in message ZFCC
(Byte 2: Break condition)
When commanding „clutch calibration“, the start conditions have to be fulfilled. Otherwise, after a
timeout period, the transmission will go to TCU shutdown and broadcast the failure „Operation Mode
command invalid“
During clutch calibration the TCU must be able to control the engine by means of TSC1
Hydrostat calibration must be performed at the end of the customer production line
Until hydrostat calibration was carried out by the customer for the first time the failure code 360.9
„Calibration data lost“ will be sent on CAN
Successful end of hydrostat calibration at the end of the customer production line will be indicated by
the status information on CAN: 0x01 „hydrostat cal. successful“
If the Clutch calibration must be aborted, the reason will be broadcasted on CAN in message ZFHC
(Byte 2: Break condition)
When commanding „hydrostat calibration“, the start conditions have to be fulfilled. Otherwise, after a
timeout period, the transmission will go to TCU shutdown and broadcast the failure „Operation Mode
command invalid“
During hydrostat calibration the TCU must be able to control the engine by means of TSC1
Signals values for hydrostat calibration start condition: Signals values for hydrostat calibration break condition:
• Signals values for hydrostat calibration start condition: • 0x00 "All conditions fulfilled"
• 0x01 "aborted by user"
• 0x00 "All conditions fulfilled"
• 0x02 "eng. speed too high"
• 0x01 "false command for hydrocalibration" • 0x03 "eng. speed too low"
• 0x04 "trm oil sump temp. too high"
• 0x02 "eng. speed too high" (>2000rpm) • 0x05 "trm oil sump temp. too low"
• 0x06 "no neutral request"
• 0x03 "eng. speed too low“(<700rpm) • 0x07 "trm output speed not zero"
• 0x08 “driver presence condition not fulfilled"
• 0x04 "trm oil sump temp. too high“ (>80°C) • 0x09 "park brake not applied"
• 0x05 "trm oil sump temp. too low" (<50°C) • 0x0A "aborted by internal failure (see DTC)”
• 0x0B “max value for hydrostat angle could not be reached”
• 0x06 "no neutral request" • 0x0C “HYK timeout – max. calibration time exceeded“
• 0x0D „current value when hydrostat pump starts turning is too high“
• 0x07 "trm output speed not zero" • 0x0E „current value when hydrostat pump starts turning is too low“
• 0x0F „negative hydostat angles could not be reached“
• 0x08 “driver presence condition not fulfilled“ • 0x10 „current too high for max value of hydrostat angle"
• 0x09 "park brake not applied" • 0x11 „Direction clutch could not be closed“
90
Range1 Range2
t_active
85
83
100
Lim_Reset_Thd
t Trm Output
Speed: n_out
t0 t1= t2 t3 t4 t5= High pressure
tReset reduction corresponding
tSet to a 25kW power loss
Activation: Deactivation:
If the transmission sump oil temperature The transmission sump oil temperature C_Sump
C_Sump exceeds the 85° threshold while the falls below a value of 83 °C
machine is running in range 1, the limitation to the Accelerator Pedal Position signal received
range 1 becomes active immediately and the rim from the CAN bus falls below threshold
pull limitation as described above becomes Lim_Reset_Thd (e.g. 5%).
68 active MAVG 73, cPower © ZF Friedrichshafen AG, 2016
Limp Home
Intention:
• limited operation of the transmission
• Intended to allow operator to leave area of work or
area of danger
• Not intended to further continuing productive work
Functionality
• Limited to first range, Limited to forward/reverse in Normal Limp
case of a problem with the clutches Home
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70 MAVG 73, cPower © ZF Friedrichshafen AG, 2016
ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.