ZF 4WG210

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ZF Transmission

4WG190/210

Mega V

Construction equipment B/G

Product Support Team

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DHIM C/S

1. Clutch Shaft “ KR”

2. Power Take Off Coaxial

3. Clutch Shaft “KV”

4. Clutch Shaft “K2”

5. Clutch Shaft “K3”

6. Output flange Rear

7. Output flange Converter

8. Output shaft

9. Transmission Pump

10. Input Flange

11. Converter

12. Transmitter for Engine

speed

13. Clutch Shaft “K4”

14. Converter Relief V/V

15. Clutch Shaft “K1”

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DHIM C/S

1. Lifting plug

2. Drive flange

3. Transmission suspension

4. Attachment for

Emergency Steering Pump

5. Model I/D

6. Output Flange Converter Side

7. Oil Drain Plug

8. Attachment for oil filter pipe

9. Oil Dipstick

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DHIM C/S

1. Driving Flange

2. Cover

3. Converter Bell Housing

4. Breather

5. Transmission Case Cover

6. Filter head & Alarm Switch

7. Fine Filter

8. Oil Dipstick

9. Output Flange-Rear

10. Oil Drain Plug

11. Out Flange - Front

12.Transmission Case

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DHIM C/S

1. Lifting Lugs

2. Power Take Off

3. Electro- Hydraulic Control

4. Return port

(Option-Parking brake)

5. Oil Dipstick

6. Transmission Suspension

7. Output Flange

8. Fine Filter

9. Filter Head & Alarm Switch

10. System Pressure Port

(Option- Parking Brake)

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DHIM C/S

21. Inductive transmitter :

Turbine

34. Speed Sensor :

Output and Speedmeter

47.Inductive transmitter :

Central Gear Train

48. Inductive transmitter :

Engine

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DHIM C/S

Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 Engaged Clutch Forward 1st ◆ ◆ K1,KV 2nd ◆ ◆ KV,K2 3rd ◆ ◆ K3,KV 4th ◆ ◆ K4,K3 Reverse 1st ◆ ◆ KR,K1 2nd ◆ ◆ KR,K2 3rd ◆ ◆ KR,K3 Neutral Related Clutch K4 KR K1 K3 KV K2 Location F E D C B A Measuring Point 60 55 56 58 53 57 System Pressure (bar) 16±2 16±2 16±2 16±2 16±2 16±2

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DHIM C/S

WGV : Converter Back Pressure Valve 3~5 bar

WSV : Converter Relief Valve 11 bar HDV : System pressure 16 bar

RV-9 : Pressure Reducing Valve 9 bar NFS : Follow-on Slide

D : Oscillation Damper

P : Proportional Valve Clutch Y : Pressure Regulator

B : Orifice

Temp : Temperature Sensor ( RV-9 Pressure measuring

after being detached)

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DHIM C/S

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DHIM C/S

16bar @ Port No 65

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DHIM C/S

9 bar

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11 bar @ Port No 51

3~5 bar @ Port No 52/63

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DHIM C/S

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DHIM C/S

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DHIM C/S

Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 Engaged

Clutch Forward 1st ◆ ◆ K1,KV 2nd ◆ ◆ KV,K2 3rd ◆ ◆ K3,KV 4th ◆ ◆ K4,K3 Reverse 1st ◆ ◆ KR,K1 2nd ◆ ◆ KR,K2 3rd ◆ ◆ KR,K3 Neutral Relatived Clutch K4 KR K1 K3 KV K2

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DHIM C/S

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DHIM C/S

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DHIM C/S

KV :Clutch Forward KR: Clutch Reverse K1: Clutch 1st Speed K2: Clutch 2nd Speed K3: Clutch 3rd Speed K4: Clutch 4th Speed

IN : Input Out : Out Put

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DHIM C/S

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DHIM C/S

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DHIM C/S

1. EST 37 CONTROL UNIT 2. KICKDOWN SWITCH 3. T/M CUT OFF SWITCH 4. AUTO SELECT SWITCH 5. DISPLAY

6. DW-3 CONTROLLER INCLUDING KICK DOWN SWITCH

7. SUPPLY SYSTEM CONNECTION 8. TRANSMISSION

9. CENTRAL GEAR TRAIN SPEED SENSOR

10. TURBINE SPEED SENSOR 11. ENGINE SPEED SENSOR 12. OUTPUT SPEED SENSOR 13. CABLE

( TO ELECTRO HYDRAULIC CONTROL UNIT)

14.DIAGNOSIS LAPTOP (OPTION) 15. BRAKE PRESSURE SENSOR

MEGA-V T/M Electric Control System

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DHIM C/S

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DHIM C/S

-Output Propellar shaft speed -Travel Speed display signal -LIS system (over 8 km) 1.0~1.5

2~5 1.0~12.5

Speed

-Output torque Control signal -Shifting quality (max 1.6sec) -Keep the original gap

0.5~0.8 1050 ±10% 30Hz~50kHz 0.45~7.0 Engine & Turbine Gap(mm) Resistance(Ω) Frequency Volt(V) Remark Specification Sensor ♣ Sensors

♣Pressure Regulator in Transmission Control Block

0.8 ~ 9.0 Output Press (bar) Within 1.6 9.5 1.9 19 500 100 Y1~Y6 Engaged Neutral Engaged Neutral Shifting (sec) Voltage(VDC) Resistance (Ω) Input Current(mA) Regulator

♣Condition of Pressure Regulator Operation

1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C

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DHIM C/S

♣ Transmission Oil Temperature Sensor (built in TCV)

- 1st, 2nd Speed mode only -30 ~ -10 degree C (T/M oil)

- Travels Normally

↑-10 degree C (T/M oil)

- Parking Brake Engaged

↓-30 degree C (T/M oil)

-Output Voltage :5.2 ~ 24V -Resistance : 1000 ~ 1500 Ω -No Buzzer

-Error Code Display only -Travels Normally

Open or Short Circuit

Remark Function

Condition

♣ Others

1. TCU (Transmission Control Unit) Working Voltage : 18 ~ 32 VDC

2. Kick Down

1) Manual Mode : 2nd _{-> 1}st _{Speed Change Only}

2) Auto Mode : Every Travel Speed, 1 stage shift down

@ after 200 ~ 300 engine speed drop (except 4th _{-> 3}rd₎

3. Transmission Cut Off : Available @ 1st _{& 2}nd _{Speed mode only}

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DHIM C/S

X X X X X X

A voltage between each terminal ( # 58,10,32,55,9,51) and ground : 1.9 V

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DHIM C/S

X X X X

A voltage between each terminal # 32, 9 and ground : 9.5 V

The voltage between each terminal #58,10,55,51 and ground : 1.9 V

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DHIM C/S

If the downshift switch is pressed, the gear shift changes to 1st gear

and when the downshift switch is pressed once again, downshifting is

released and returns to 2nd gear automatically.

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DHIM C/S

When the auto selector switch is “on” position and the downshift switch pressed,the transmission changes automatically to the next lower gear.

Note: The third to the second gear and the second to the first gear change occur when the engine speed is reduced 200 - 300 rpm from current speed.

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DHIM C/S

When the T/M cut off switch(1) is “on” position and the T/M cut off switch(2) has been connected by foot braking (25bar) in the cabin,the transmission will be in neutral position automatically (This function works on 1st, 2nd gear only ).

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DHIM C/S

The AEB has the task to compensate tolerances

(plate clearance and pressure level) which are influencing the fiIling

procedure of the clutches. For each clutch,

the correct filling parameters are determined in one test cycle for

period of the quick-fllling time

level of the filling compensating pressure No Order Display message Remark 1 Warm up transmission about 10 to 20 minutes 2 Turn off ignition key 3 Plug in AEB starter to

AEB connector located at the seat base closest to the cab door

4 Put T/M gear selector Lever to Neutral position 5 Engage park brake

6 Start Engine “PL“ TCU must recognize “PL” for at least 2sec before you press AEB starter button 7 On idling RPM “PL”

8 Press button of the AEB Starter

“ST” The button must not be released before TCU has started the AEB or quit with an error code (see Error code list) 9 Hold button until AEB has

been started

“K1”

(Information about the AEB state)

TCU has started the AEB, and goes on adjusting K1, K2,…, KR. (Button may be released from starting) 10 Wait until AEB has

been finished

“OK”

(AEB has been successful) 11 Turn off ignition and

unplug AEB Starter

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DHIM C/S

Symbol Meaning Remarks

PL ST

K1..K4,KV,KR _ and Kx ≡ and Kx

OK calibration for all clutches finished Transmissions stays in neutral, have to restart the TCU (ignition off/on) after removing AEB-Starter STOP AEB canceled (activation Transmissions stays in neutral, have to restart the

stopped) TCU (ignition off/on)

STOP and Kx AEB stopped, clutch Kx Transmissions stays in neutral, have to restart the can't be calibrated TCU (ignition off/on)

Spanner and Kx Kx couldn't be calibrated, Transmissions stays in neutral, have to restart the AEB finished TCU (ignition off/on)

↑ E Engine speed too low, E/G RPM should be raised

↓ E Engine speed too high E/G RPM should be down

↑ T Transmission oil Warm up Transmission

temperature too low

↓ T Transmission oil Cool down Transmission

temperature too high

FT T/M temp not in defined T/M stays in neutral, have to range during calibration restart the TCU (key off/on) FB Operating mode not T/M stays in neutral, have to

NORMAL or T/M temp restart the TCU (key off/on) sensor defective or storing

of Calibrated values to EEPROM-has failed

FO Output speed not zero Transmissions stays in neutral, have to restart the TCU (ignition off/on)

FN Shift lever not in Neutral Transmissions stays in neutral, have to restart the

position TCU (ignition off/on)

FP Parking brake not applied Transmissions stays in neutral, have to restart the TCU (ignition off/on)

STOP AEB - Starter was used Transmissions stays in neutral, have to restart the incorrect or is defective TCU (ignition off/on)

fast fill time determination of clutch Kx

compensating pressure determination of clutch Kx AEB - Starter is plugged at the diagnostic plug AEB Starter button is pressed