Repair Instruction
REPAIR INSTRUCTIONS 1-2
REFERENCE
For information concerning description, installation instructions, operation and maintenance, see respective Operating Instructions, ZF-Ordering-No. 5872 196 002.
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt.: ASTDM / Section : ASTDM
Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous réserve de modifications techniques!
1.Auflage / 1.Edition
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Repair Instruction
PREFACE
Off-Road Transmissions and Axle Systems Division
This documentation has been developed for skilled staff trained by the ZF Passau for the repair and maintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:
1. Continuously trained staff
2. Prescribed facilities, e.g. special tools
3. Genuine ZF-spare parts meeting the latest state of development
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting consequential costs, if any, are excluded from this contractual liability. This also applies, if the use of genuine ZF-spare parts is renounced.
ZF Passau GmbH
Off-Road Transmissions and Axle Systems Division
Repair Instruction
GENERAL
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expertlike manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again. Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage. All bearings must be treated with operating oil prior to installing them:
REFERENCE:
CAUTION
For heating up parts such as bearings, housings etc., only a heating furnace or an electric drier is permitted to be used!
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data. Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified. In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted. By no means, Molykote is permitted to be used. Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding handling of the respective detergent.
Repair Instruction
Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Important information on industrial safety
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works. Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff. The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods, information, the use of auxiliaries etc..
CAUTION
DANGER
REFERENCE
Is used, if a deviating and improper working procedure can damage the product
Is used, if lacking care can lead to personal injury or danger to life
Prior to starting the checks and repair works, thoroughly study the present instructions.
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and weight must not be drawn (not even within one representation). The works must be performed according to the description..
REFERENCE:
After the repair works and the checks, the expert staff must convince itself that the product is properly functioning again. .
Repair Instruction
Off-Road Transmissions and Axle Systems Division
BEZEICHNUNG DER GESETZLICHEN EINHEITEN
DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m;areal density in t/m2
Nota : Densité lineaire en kg/m;Densité superficielle en t/m2
BegriffFormelzeichenneualtUmrechnung Bemerkungen UnitNewoldConversionNote UnitéNouveauVieuConversionNota
Masse m kg (Kilogramm)kg
Mass
Masse
KraftFN (Newton)kp1 kp = 9,81 N
Force
Force
ArbeitAJ (Joule)kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
LeistungPKW (Kilowatt)PS (DIN)1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
DrehmomentTNm kpm 1 kpm = 9,81 Nm T (Nm) = Torque(Newtonmeter)F (N) . r (m)
Couple
KraftmomentMNm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force)(Newtonmeter)F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü1,02 atü = 1,02 kp/cm2
Pressure (Overpress)= 1 bar = 750 torr
Pression (Sur-)
Drehzahlnmin -1
Speed
Nombre de Tours
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25,40 mm
1 kg ( Kilogramm )
9,81 Nm ( 1 kpm )
1,356 Nm ( 0,138 kpm )
1 kg / cm
1 bar ( 1,02 kp/cm2 )
0,070 bar ( 0,071 kp/cm2 )
1 Liter
4,456 Liter
1 Liter
3,785 Liter
1609,344 m
0° C ( Celsius )
0 ° C ( Celsius )
Repair Instruction
Off-Road Transmissions and Axle Systems Division
VERGLEICHSTABELLE FÜR MASSEINHEITEN
CONVERSION TABLE TABLEAU DE CONVERSION
1 in ( inch)
2,205 lb ( pounds )
7,233 lbf x ft ( pound force foot) 1 lbf x ft ( pound force foot )
5,560 lb / in ( pound per inch )
14,233 psi (pound force per square inch lbf/in2 ) 1 psi ( lbf/in2 )
0,264 Gallon ( Imp. ) 1 Gallon ( Imp. )
0,220 Gallon ( US ) 1 Gallon ( US )
1 Mile ( Landmeile ) + 32° F ( Fahrenheit )
273,15 Kelvin
Repair Instruction
TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148
Friction value: µ total= 0,12 for screws and nuts without after-treatment as well as phosphatized nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following List:
M
Preface
The present Documentation has been developped for skilled personnel which has been trained by the ZF for the Maintenance and Repair operations on ZF-units. However, because of technical development of the product, the Maintenance and Repair of the unit in your hands may require differing steps as well as also different setting and test data.
This Manual is based on the technical state at the printing. At the preparation, every possible care has been taken to avoid errors. However, we are not liable for possible mistakes concerning the representation and the description.
We are reserving ourselves the right of modifications without previous information.
The responsibility lies with the owner and the user, to pay attention to the safety indications, and to carry out the Maintenance operations according to the prescribed Specifications.
The ZF is not liable for faulty installation, incorrect treatment, insufficient Maintenance, impro-perly and unskilled performed works, and for the subsequential damages resulting from it.
It is imperative to pay attention to the corresponding Specifications and Manuals of the Vehicle Manufacturer.
Important Informations concerning the technical reliability and reliability in service are accen-tuated by the following Symbols:
Valid for Instructions which must be observed at the Maintenance, the Performance or the Operation of the vehicle !
Is inserted at working and operating procedures which have to be exactly respected to avoid a damage or destruction of the unit or to exclude a danger to persons !
TABLE OF CONTENTS
Indentification Plate
IMPORTANT INSTRUCTIONS
I. DESCRIPTION
1.1Function of the Converter
1.2WK
1.3 Powershift transmission
1.4Transmission control
1.5Controllers
1.5.1General
1.5.2Controller VTS-3
1.5.3 Controller D7
1.5.4 DW 3
1.5.5 Ergo II
1.6 Display
1.6.1General
1.6.2Possible Indications on the Display
1.6.3Error code definition
1.7Electronic control unit TCU
1.8Electronic control for the ZF-Powershift transmission
1.8.1General
1.8.2Description of the Basic functions
1.8.3AEB (Automatic determination of the filling parameters)
1.8.41.8.9Various function
1.9Interaxle differential
1.9.1 Description
1.9.2 Function
1.10Front axle disconnect
1.11Retarder
1.11.1General
1.11.2Layout and Functions of the Retarder
II. INSTALLATION SPECIFICATION
III. OPERATION
3.1Driving preparation and Maintenance
3.2 Driving and Shifting
3.3 Cold start
3.4 Transmission control in the Driving range Automatic
3.5 Stopping and Parking
3.6 Towing
3.7 Oil temperature
3.8 Shifting of the various outputs
IV. MAINTENANCE
4.1Oil grade
4.2Oil level check
4.3Oil change and Filter replacement intervals
4.3.1 Oil change and Oil filling capacity
4.3.2 Filter replacement
V. DIAGNOSTIC SYSTEMS
5.1 General
5.2MOBIDIG 2001
5.3 Laptop Version
5.4 Multi-System 5000
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ANNEX, comprising:
Tables: 4 WG 190/210
1Layout 4 WG-190/210
Installation view 4 WG-190/120
1 Front view - Direct installation
2 Front view - Separate mounting
4Rear view - Standard version
5Rear view - With disc brake
6Rear view - With 1. and 2. power take-off
7Schedule of measuring points and connections 4 WG-190/210
8Oil circuit diagram 4 WG-190/210 (Forward 1st speed)
9Electro- hydraulic control with proportional valves
10Power flow 4 WG-190/210 Forward/Reverse Speed
114 WG-190/210 Fully automatic control EST-37 Circuit diagram - 6029 717 040 –
12Controller DW-3
13 Controller ERGO II
14 Type plate
Abbreviations used in the text:
Abbreviation Description
EST-37 Ergocontrol
AEB Automated determination of the filling parameters
TCU Electronic control unit
und Achssysteme
APPENDIX, composed of:
Tables: 6 WG 190/210
1Layout 6 WG-210
2Layout 6 WG-210 with retarder
Installation view 6 WG-210 – Separate installation with WK and Retarder
3AFront view
3BSide view
3CRear view
Installation view 6 WG-210 – Separate installation with disk brake and without WK
4AFront view
4BSide view
4CRear view
Installation view 6 WG-210 – Separate installation with axle disconnection and WK
5AFront view
5BSide view
5CRear view
Installation view 6 WG-210 – Separate installation with interaxle differential and WK
6AFront view
6BSide view
6CRear view
Installation view 6 WG-210 – Separate installation with axle disconnection and WK-Valve – Side-mounting
7AFront view
7BSide view
7CRear view
Installation view 6 WG-210 – Direct mounting with axle disconnection
8AFront view
8BSide view
8CRear view
9Schedule of measuring points and Connections 6 WG-210 without WK
10Oil circuit diagram 6 WG-210 without WK – Forward 1st Speed -
11Schedule of measuring points and Connections 6 WG-210 with WK
12Oil circuit diagram 6 WG-210 with WK – Forward 1st Speed -
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13Schedule of measuring points and Connections 6 WG-210 with WK and retarder
14Oil circuit diagram 6 WG-210 with WK and retarder – Forward 1st Speed -
15Gearbox diagram 6 WG-210
16 Power flow 6 WG-210 – Forward speeds -
17Power flow 6 WG-210 - Reverse speeds -
18 Electrohydraulic shift control with Proportional valves
196 WG-210 fully-automatic Control unit EST-37 – Standard Circuit diagram – 6029 717 039 –
206 WG-210 fully-automatic Control unit EST-37 – Crane vehicle Circuit diagram – 6029 701 057 –
21Controller VTS-3
22Controller D7
Abbreviations in the Text:
Code Description
WK Converter lock-up clutch
EST-37 Ergocontrol
AEB Automatic determination of the filling parameters
TCU Electronic control unit
TECHNICAL DATA 4 WG 190/210
Engine power:
Turbine moment:
Engine speed:
Starting torque multiplication:
Engine-dependent Power take-offs: Torque: Speed:
Mass (without oil):
KW*
Nm*
*= dependent on Vehicle type and application ** = dependent on the Transmission version
Description:
The ZF-Transmissions 4 WG-190/210 are composed of a hydrodynamic torque converter and a rear-mounted multi-speed powershift transmission with integrated transfer case (see Table- 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via universal shaft) with DIN-, Mechanic- or Spicer-input flange.
The transmission can be shifted manually or fully-automatically by means of the Electronic unit EST-37.
Torque converter: Unit size W 300 and 340 with torque multiplication.
Powershift transmission: 4 Forward speeds and 3 Reverse speeds.
Output:
The powershift transmission has between input and output shaft a center distance of 540 mm, and can be equipped with the following components: -with output flanges to the front and rear axle for different universal shafts -on the rear output (rear-side) with a disk brake as parking brake - on the converter side with axle disconnection.
Power take-off:
For the drive of an external oil pressure pump, an engine-dependent, coaxial power take-off is planned.
It allows the attachment of pumps with „SAE-B and C“ Connection. If desired engine dependent power take-off are available also up to 2.
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Transmission accessories:
Upon request, the transmissions can be additionally equipped with the following components:
-Emergency steering pump with a feed rate of 16 cm 3/rev. or 32 cm 3/rev.
-Electronic speedometer signal, here the Electronic unit EST-37 offers a speedometer signal.
Transmission ratio (mechanical)*
*= According to the Transmission version, other ratios are also possible.
und Achssysteme
TECHNICAL DATA 6 WG 210
Engine power:
Turbine moment:
Engine speed:
Starting torque multiplication:
Engine-dependent Power take-offs: Torque: Speed: Mass (without oil):
*= dependent on Vehicle type and application
**= dependent on the Transmission version
Description:
The ZF-Transmissions 6 WG-210 are composed of a hydrodynamic torque converter and a rear-mounted multi-speed powershift transmission with integrated transfer case (see Table 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via universal shaft) with DIN-, Mechanic- or Spicer-input flange.
Between engine and torque converter, a Retarder can be arranged (fluid brake) whereby a good braking effect will be achieved in all speeds.
The transmission can be shifted manually or fully-automatically by means of the Electronic unit EST-37.
Torque converter: Unit size W 300 and 340 with torque multiplication according to the version and a WK.
Powershift transmission: 6 Forward speeds and 3 Reverse speeds.
Output:
The powershift transmission has between input and output shaft a center distance of 540 mm, and can be equipped with the following components: -with output flanges to the front and rear axle for different universal shafts -on the rear output (rear-side) with a disk brake as parking brake - on the converter side with axle disconnection - with an integrated, lockable interaxle differential
Arbeitsmaschinen-Antriebe und Achssysteme
Power take-off:
For the drive of an external hydraulic pressure pump,an engine-dependent, coaxial power take-off is existing, upon request also disconnectable. It allows the mounting of pumps with SAE-C connection.
Transmission accessories:
Upon request, the transmissions can be additionally equipped with the following components:
- Emergency steering pump with a feed rate off 16 cm3/rev. or 32 cm3/rev.
-Electronic speedometer signal for:
-Construction site vehicles here, the Electronic unit EST-37 offers a speedometer signal.
- Road vehicles, the signal required for the speedometer interpretation will be picked-up on the output side by a pulse generator (e.g. is needed for trip recorders). For this, a frequency divider from the Customer side is necessary.
-Separate mounting of the ZF-Fine filter.
Transmission ratio (mechanical)*
* = According to the Transmission version, other ratios are also possible.
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INSCRIPTIONS ON A ZF-MODEL INDENTIFICATION
PLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION
1 = Gearbox type
2 = Gearbox Serial-No.
3 = ZF-Parts List-No.
4 = Total ratio of the Gearbox
5 = Oil (Oil specification)
6 = List of lubricants
7 = Oil capacity
8=Customer no.
NOTES REGARDING THE SPARE PARTS ORDERS:
When ordering genuine ZF-Spare Parts, please indicate:
1. = Gearbox type
2. = Serial-No.
3. = ZF-Parts List-No.
4. = Mark and type of vehicle
5. = Denomination of the spare part
6. = Spare parts-No.
7. = Way of transport
When all of the above required indications are considered, errors in the delivery of spare parts Orders can be avoided!
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und Achssysteme
IMPORTANT INSTRUCTIONS
Oil level check (see 4.2):
In the cold start phase, the engine must be running about 2 – 3 minutes at idling speed and the marking on the oil dipstick must then be lying above the cold start mark.
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 stationary engine, the oil level in the transmission is rising essentially, according to the installation conditions !
At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF recommends to start the autonomous calibration of the shifting elements (AEB).
The autonomous calibration of the shifting elements (AEB) must be started after the initial installation of the transmission and the Electronics in the vehicle at the Vehicle Manufacturer and after every replacement of the transmission, the electrohydraulic control or the TCU in case of a failure.
Put the Controller at the starting of the engine always to the Neutral position. At running engine and transmission in Neutral, the parking brake must be engaged or the service brake be actuated, to prevent the vehicle from rolling.
Prior to every start off, loosen the parking brake.
The engagement of the speed out of Neutral is only possible under the programmed transmission input speed (turbine speed).
Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible. Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.
Reversing (Standard):
The reversing must be performed at standstill, resp. at very low driving speed. Above the programmed reversing limit, the vehicle will be shifted to Neutral by the Electronic unit EST-37, and the vehicle continues rolling in the old driving direction.
The gear of the new driving direction will be only engaged when the programmed reversing speed and the transmission input speed (turbine speed) has fallen below.
The programming is customized and can therefore be different from standard. Therefore, the exact procedure must be taken from the Operating Instructions of the respective Vehicle Manufacturer !
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At stopped engine, there is on the Controller, despite a preselected gear, no power flow between transmission and engine, i.e. the transmission is in the idling position.
The parking brake must therefore be completely actuated ! When leaving the vehicle, secure it additionally by brake blocks !
The towing speed must in no case be higher than 10 km/h, the towing distance not longer than 10 km.
It is imperative to observe this Specification because otherwise the transmission will be damages due to insufficient oil supply !
At a longer distance, the best solution would be to transport the vehicle with a Low loader.
Operating temperature behind the converter at least 65° and 100° C in continuous operation, a short-time increase up to max. 120° C is permitted.
Temperature in the sump 60° - 90° C.
In case of irregularities on the transmission, put the vehicle out of service and ask for Specialists.
Protective measures for the ZF-Electronics at electrical operations on the vehicle:
At the following operations, the ignition must be switched off and the control unit plug must be pulled off from the ZF-Electronics:
∗ At any kind of electrical operations on the vehicle.
∗ At welding operations on the vehicle.
∗ At insulation tests on the electric system.
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OIL CIRCUIT DIAGRAM 4 WG-110 WITH ZF FINE FILTER DIRECT INSTALLED AT
THE TRANSMISSION
- FORWARD 1st SPEED -
TABLE-5
The marked positons (e.g. 53) correspond with the positions on the table-4!
Legend:
WT = Heat exchanger
WGV = Converterbackpressurevalve 1,5bar
WSV = Convertersafety valve 11bar
HDV = Mainpressurevalve 16+2bar
RV-9 = Pressurereducingvalve 9bar
NFS = Follow-onslide
D = Vibrationdamper
B = Orifice
P1 = Proportional valve K4
P2 = Proportional valve KR
P3 = Proportional valve K1
P4 = Proportional valve K3
P5 = Proportional valve KV
P6 = Proportional valve K2
Y1...Y6 = Pressureregulators
TEMP = Temperaturesensor
FDV = Filterpressuredifferential valve(Bypass-valve) p=5,5bar
Gearbox diagram
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INSCRIPTIONS ON A ZF-MODEL INDENTIFICATION
PLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION
1 = Gearbox type
2 = Gearbox-No.
3 = ZF-Parts List-No.
4 = Total ratio of the Gearbox
5 = Value for the control pressure
6 = ZF-Parts List-No. of the Torque Converter
7 = Type of the ZF-Torque Converter
NOTES REGARDING THE SPARE PARTS ORDERS:
When ordering genuine ZF-Spare Parts, please indicate:
1. = Gearbox type
2. = Serial-No.
3. = ZF-Parts List-No.
4. = Mark and type of vehicle
5. = Denomination of the spare part
6. = Spare parts-No.
7. = Way of transport
When all of the above required indications are considered, errors in the delivery of spare parts Orders can be avoided! See Model identification Plate!
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