Zf5-Wg-261-311.Pdf

OPERATING INSTRUCTIONS ZF – ERGOPOWER TRANSMISSION WG-261/311 5872.368.002 en ERGOPOWER Off-Road Transmissions and Axle Systems Division Subject to technical modifications Copyright by ZF This documentation is protected by copyright Any reproduction and dissemination in whatever form which does not fully comply with the intended purpose of this documentation is prohibited without the approval of ZF Friedrichshafen AG Printed in Germany ZF Friedrichshafen AG ZF Services Donaustr 71 D - 94034 Passau Section: MAIP21 Design Level Edition 2005/06 2011/03 Copyright © ZF Friedrichshafen AG This document is protected by copyright Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG Infringements lead to civil and criminal prosecution Printed in Germany ERGOPOWER Off-Road Transmissions and Axle Systems Division 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 ! ERGOPOWER Off-Road Transmissions and Axle Systems Division TABLE OF CONTENTS Summary of the TECHNICAL DATA Page: 6–7 Type plate IMPORTANT INSTRUCTIONS - 10 I DESCRIPTION 11 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.5 1.5.1 1.5.2 1.5.3 1.6 1.7 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.7.6 1.7.7 Function of the Converter Powershift transmission Transmission control Controllers General Controller DW-3 Controller ERGO II Display General Possible Indications on the Display Error code definition Electronic control unit TCU Electronic control for the ZF-Powershift transmission General Description of the Basic functions AEB Downshifting functions (Down-Shift Button) Pressure cut-off Inching device Special functions II INSTALLATION SPECIFICATION 25 III OPERATION 26 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Driving preparation and Maintenance Driving and Shifting Cold start Transmission control in the Driving range Automatic Stopping and Parking Towing Oil temperature IV MAINTENANCE 4.1 4.2 4.3 4.3.1 4.3.2 Oil grade Oil level check Oil change and Filter replacement intervals Oil change and Oil filling capacity Filter replacement V ZF-DIAGNOSIS SYSTEMS 5.1 5.2 Laptop-Version ZF-Testman ZF-Multi-System 5060 29 32 ERGOPOWER Off-Road Transmissions and Axle Systems Division APPENDIX, composed of: Tables: Layout WG-261/311 Installation view - Front view Installation view - Side view Installation view - Rear view Schedule of measuring points and Connections Oil circuit diagram (Forward 1st speed) Electrohydraulic shift control with Proportional valves Inductive transmitter and Speed sensor (setting values) Fully-automatic control EST-37 A - Standard Circuit diagram - 6029 717 040 – 10 Controller DW-3 11 Controller ERGO II Abbreviations in the Text: Code EST-37 AEB ISK TCU Description Ergocontrol Automated determination of the filling parameters Inch sensor calibriation Electronic control unit Off-Road Transmissions and Axle Systems Division ERGOPOWER TECHNICAL DATA WG-261 WG-311 Engine power: max KW 280* 320* Turbine torque : max Nm 500* 750* Engine speed: max min-1 500* 500* 2,0 to 3,0 1,50 to 2,5 500 x nEngine 500 x nEngine 780** 740** Starting torque multiplication: Engine-dependent Power take-offs: Torque: Speed: Nm n Mass (without oil): kg about * = dependent on Vehicle type and application ** = dependent on the Transmission version Description: The ZF-Transmissions WG-261/5 WG-311 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 A Torque converter: Unit size W 370 and 400 with torque multiplication Powershift transmission: Forward speeds and Reverse speeds Output: The powershift transmission has between input and output shaft a center distance of 380 mm, and can be equipped with the following components: - Output flange (rear-side) different universal shafts - Output (rear-side) with a disk brake as parking brake ERGOPOWER Off-Road Transmissions and Axle Systems Division Power take-off: For the drive of external hydraulic pressure pumps, up to four power take-offs are provided as follows: 1st engine-dependent power take-off which are arranged on the output side, and one sidemounted engine-dependent power take-off with the connection for the 3rd and 4th power takeoff on the front and the rear 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 A offers a speedometer signal - Inching speed valve (Inching valve) Transmission ratio (mechanical)* SPEED * DRIVING DIRECTION Forward Forward Forward Forward Forward Reverse Reverse Reverse Ratio 5,350 3,446 2,207 1,421 0,970 5,350 2,207 0,970 = According to the Transmission version, other ratios are also possible ERGOPOWER Off-Road Transmissions and Axle Systems Division INSCRIPTIONS ON A ZF-MODEL INDENTIFICATION PLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION = = = = = = = Gearbox type Gearbox-No ZF-Parts List-No Total ratio of the Gearbox Value for the control pressure ZF-Parts List-No of the Torque Converter Type of the ZF-Torque Converter NOTES REGARDING THE SPARE PARTS ORDERS: When ordering genuine ZF-Spare Parts, please indicate: = = = = = = = Gearbox type Serial-No ZF-Parts List-No Mark and type of vehicle Denomination of the spare part Spare parts-No Way of transport See Model identification Plate! When all of the above required indications are considered, errors in the delivery of spare parts Orders can be avoided! ERGOPOWER Off-Road Transmissions and Axle Systems Division IMPORTANT INSTRUCTIONS Oil level check (see 4.2): In the cold start phase, the engine must be running about – 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 independent 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 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! ERGOPOWER Off-Road Transmissions and Axle Systems Division 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 damaged due to insufficient oil supply! At a longer distance, the best solution would be to transport the defective 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 By overstepping results by 105 ° C notice "WS" on the display 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 10 LAYOUT WG-261/311 TABLE-1 = = = = = = = = = 10 = 11 = Converter with Diaphragm – Direct mounting Breather Electrohydraulic control unit Transmission pump 1st Power take-off Clutch axle „KV/K1“ Clutch axle „KR/K2“ Clutch axle „K4/K3“ Output flange (rear-side) Output shaft Countershaft 11 10 INSTALLATION VIEW WG-261/311 - DIRECT MOUNTING FRONT VIEW TABLE-2 = = = = = = = Electrohydraulic shift control Lifting lugs Breather 4th Power take-off Diaphragms – Direct mounting with Converter Coarse filter Attachment possibility for Oil filler tube with Oil dipstick (converter-side) INSTALLATION VIEW WG-261/311 SEPARATE INSTALLATION SIDE VIEW TABLE-3 = = = = = = = = = 10 = 11 = 12 = 13 = Diaphragms for Direct mounting Cover Converter bell Lifting lug Electrohydraulic shift control Mounting face 3rd Power take-off Lubricating oil line 3rd and 4th Power take-off Oil filler tube with Oil dipstick (rear-side) Output flange Cover Gearbox housing Transmission suspension M20 Mounting face 4th Power take-off 13 12 11 10 INSTALLATION VIEW WG-261/311 REAR VIEW TABLE-4 18 = = = = = = = = = 10 = 11 = 12 = 13 = 14 = 15 = 16 = 17 = 18 = Lifting lug Pressure oil line Clutch KR Lubricating oil line „S1“ Clutch KR/K2 Electrohydraulic shift control Pressure oil line Clutch K1 Pressure oil line Clutch KV Pressure oil line Clutch K3 Pressure oil line Clutch K4 Oil filler tube with Oil dipstick Model Identification Plate Oil drain plug M22x1,5 Output flange Attachment possibility for Emergency steering pump Lubricating oil line „S2“ Clutch K4/K3 1st Power take-off Lubricating oil line 3rd and 4th Power take-off 3rd Power take-off Pressure oil line Clutch K2 17 16 15 14 13 12 11 10 SCHEDULE OF MEASURING POINTS AND CONNECTIONS WG-261/311 TABLE-5 The marked positions (e.g 53) correspond with the positions on the table-6! The measurements have to be carried out at hot transmission (about 80° - 95° C) ! No Denomination of the position 51 52 53 55 56 57 58 60 63 = = = = = = = = = 65 = 10 15 16 28 29 30 = = = = = = 49 = 13 14 = = = = Measuring points for hydraulic oil and temperature: In front of the converter – opening pressure 9+2 bar Behind the converter – opening pressure 5,0 bar Clutch Forward KV 16+2 bar Clutch Reverse KR 16+2 bar Clutch K1 16+2 bar Clutch K2 16+2 bar Clutch K3 16+2 bar Clutch K4 16+2 bar Behind the converter Temperature 100° C; short-time 120° C System pressure 16+2,5 bar Connections Breather Connection to the heat exchanger Connection from the heat exchanger To filer From filter From filter pressure differential valve Plug connection on the electro-hydraulic control unit Inductive transmitters and speed sensor Inductive transmitter n Central gear train Inductive transmitter n Engine Spee sensor n Output Inductive transmitter n Turbine Connection X Marking on the valve block M10x1 M10x1 M10x1 M10x1 M10x1 M10x1 M10x1 M10x1 M14x1,5 H M10x1 K 14 16 B F D A C E M10x1 M42x2 M42x2 M30x1,5 15 M18x1,5 M18x1,5 M18x1,5 63 52 Y Page from VIEW X 56 29 28 58 60 10 W 53 13 57 30 65 51 49 VIEW Y 63 VIEW W 15 DRIVING DIRECTION FORWARD REVERSE 52 55 CODING SPEED NEUTRAL ENGAGED CLUTCH POSITIONS ON THE VALVE BLOCK CURRENT NO OF THE MEASURING POINTS · PRESSURE REGULATOR UNDER VOLTAGE Y1 Y2 Y3 Y4 Y5 Y6 · · · · · · · · · · · · · · · · KR F 55 K4 E 60 K1 D 56 K3 C 58 KV B 53 ENGAGED CLUTCHES K1 KV K4 K1 KV K2 K4 K2 K3 KV KR K1 KR K2 KR K3 K2 A 57 Page from OIL CIRCUIT DIAGRAM WG-261/311 FORWARD 1st SPEED TABLE-6 The marked positons (e.g 53) correspond with the positions on the table-5! GEARBOX DIAGRAM Legend: 4th power take-off WT WGV WSV HDV RV-9 NFS D B P1 P2 P3 P4 P5 P6 Y1 Y6 TEMP FDV = = = = = = = = = = = = = = = = = Heat exchanger Converter back pressure valve 5,0 bar Converter safety valve 9+2 bar Main pressure valve 16+2,5 bar Pressure reducing valve bar Follow-on slide Vibration damper Orifice Proportional valve K4 Proportional valve KR Proportional valve K1 Proportional valve K3 Proportional valve KV Proportional valve K2 Pressure regulators Temperature sensor Filter pressure differential valve (Bypass-valve) Dp=5,7 +1,5 - 0,5 bar 3rd power take-off 14 Converter KV K1 Pump Input 1st power take-off KR K2 13 Emergency steering pump K4 K3 Output Output Page / KR F P1 B 55 D Y1 K4 E P2 B NFS Y2 60 K1 D P3 D B NFS 56 K3 D Y3 58 C P4 A B Y5 NFS K2 P6 D B Y4 53 B P5 D B NFS KV NFS 57 D Y6 NFS RV-9 TEMP K HDV 65 Valve block control circuit Converter Legend: 30 H = Main pressure = Regulated main pressure = Pilot pressure = Converter input pressure = Converter output pressure = Lubrication = Return into the sump Page / 29 51 63 52 FDV WSV 28 WGV WT (Scope of supply customber) Bypassvalve D p=2+ bar Main oil circuit ZF fine filter: Filter grade according ISO 4572: ß30 ³75 ß15 =25 ß 10 =5.0 5.0 Dust capacity according ISO 4572: 17g Filter screen surface cm : x 6700 = 13 400 WS Transmission pump: p = 16+2 bar Qp = 115 l/min bei -1 n = Engine 000 15 16 Lubrication Oil sump Coarse filter: Mesh width mm: 450 Screen surface cm : 000 ELECTRO-HYDRAULIC CONTROL WITH PROPORTIONAL VALVES TABLE-7 Pressure reducing valve bar Main pressure valve 16+2 bar Housing Plug (Cable harness) A Y6 Y1 Y5 Y2 B B Y4 Cover Housing A Y3 Cover Valve block Page / SECTION A - A Main pressure valve 16+2 bar Valve block Pressure reducing valve bar Plug (Cable harness) Ductplate Intermediate plate SECTION B - B Proportional valve P5 Y5 Vibration damper Pressure regulator Follow-on slide Page / INDUCTIVE TRANSMITTER AND SPEED SENSOR (HALL SENSOR) TABLE-8 INDUCTIVE TRANSMITTER Housing The speeds required for the Electronic control EST-37 will be picked-up by the following sensors: 13 14 = = = = Inductive transmitter Inductive transmitter Speed sensor Inductive transmitter n Central gear train n Engine n Output and Speedometer n Turbine Inductive transmitter S nTURBINE Gear wheel On the Schedule of measuring points, Table-5, the installation positions of the sensors are illustrated Attention: For the inductive transmitters, the following different setting dimensions between contact face inductive transmitter and tooth tip must be respected: n Central gear train (5) n Engine (9) n Turbine (14) S = 0,3 ± 0,1 mm S = 0,5 +0,3 mm S = 0,5 +0,3 mm SPEED SENSOR (HALL SENSOR) S = 1.0 - 1,5 mm Speed sensor (Hall sensor) SPUR GEAR K3 Housing Clutch axle K4/K3 WG-261/311 FULLY-AUTOMATIC CONTROL EST-37 A CIRCUIT DIAGRAM STANDARD (6029 717 040) TABLE-9 ITEM LEGEND ITEM A1 A2 A3 S2 S3 S9 LEGEND SWITCH PRESSURE CUT-OFF SWITCH DRIVING PROGRAM AUTOMATIC/MANUAL SWITCH PARKING BRAKE RELEASE (OPTION) S10 S31 S34 SWITCH FILTER CONTAMINATION SWITCH ACHNOWLEDGMENT PARKING BRAKE SWITCH DISPLAY ILLUMINATION * K1 K2 RELAIY STARTER INTERLOCK * RELAIY REVERSE DRIVE * A5 A6 A7 ELECTRONIC CONTROL UNIT TCU CONTROLLER DW-3 ELECTRO HYDRAULIC CONTROL UNIT WG-261/5 WG-311 DIAGNOSIS – INTERFACE (PLUG) DISPLAY CAN-INTERFACE (PLUG) B1 B2 B3 B4 B15 SPEED SENSOR n ENGINE SPEED SENSOR n TURBINE SPEED SENSOR n CENTRAL GEAR TRAIN SPEED SENSOR n OUTPUT SENSOR TEMPERATURE BEHIND CONVERTER F1 F2 FUSE 7,5 A* FUSE 7,5 A* H3 ACOUSTIC - / OPTICAL WARNING * NOTE: * = SCOPE OF SUPPLY CUSTOMER F1 Kl.30/1.12 Kl.30/1.1 Kl.15/1.12 Kl.15/1.1 F2 S E L P AM P S2 B4 62 04 1 2 86 P S3 S9 S31 H3 K2 45 23 68 44 66 29 21 30 31 52 VPI VPE1 VPE2 ED8 ED9 ED11 ED10 ED12 ED13 ADM1 EF4 46 A2 86 D1 B1 K1 22 43 64 64 63 65 20 ED7 ED4 ED6 ED5 ED1 ED2 ED3 19 03 EF1 VMG1 B2 41 AIP1 AIP2 AIP3 AIP4 AIP5 AIP6 VPS1 VPS1 ER1 VMGA2 A1 EF2 68 45 22 23 ER2 B3 42 68-pin 6029 199 063 EF3 CAN_H CAN_LCAN_T VGS Mini Timer 2-pin 6029 199 011 25 1 2 AMP JPT 8-pin 6029 199 108 A5 06 05 33 A6 14 85 MNL 6-pin 6029 199 074 ADM2 SDDK 15 18 EUPR ADM3 ADM4 ADM8 SD1 24 KD F N R B1 B2 B3 VMG2 Superseal 3-pin 6029 199 071 VP D2 85 26 27 28 ER3 VM1 VM2 VPS2 VPS2 ADM5 ADM6 ADM7 53 57 11 34 01 02 03 04 05 06 07 56 10 32 55 09 51 12 13 39 46 08 09 49 B15 S34 Y1 = KR Y2 = K4 Y3 = K1 Y4 = K3 Y5 = KV Y6 = K2 VPS1(+) A3 TEMP TEMP 2 17 Mini Timer 2-pin 6029 199 011 S10 Superseal 2-pin 6029 199 045 10 11 12 13 14 15 16 Kostal 16-pin 6029 199 072 A7 JPT 4-pin 6029 199 076 Kl.31/1.6 Kl.31 VERDRILLTE LEITUNGEN (30 SCHLÄGE/M) AB L > 2M Polbilder entsprechen den Steckern an der Verkabelung! ALLE RELAIS MIT SCHUTZDIODEN 1A/400V BUSABSCHLUSS WENN PIN 26 UND 27 VERBUNDEN CONTROLLER DW-3 TABLE-10 LEVER FOR MECHANICAL NEUTRAL INTERLOCK CONNECTION DIAGRAM CONTROLLER CODING CONTROLLER OUTPUT SPEED N D KD FORWARD REVERSE 1 (+) NEUTRAL X2 : A (+) AD1 B1 AD2 B2 A2 AD3 B3 IN POSITION (NEUTRAL), F-R NOT SWITCHABLE AD4 V AD5 R X1 :C X1 : B X1 : A X1 : B X1 : C X1 : D B1 B2 B3 V R AS A1 AD6 AS AD7 F GEAR POSITIONS X1 TYPENSCHILD S F N N N P A B C D A B C D X2 A L M K1 E (-) K1 = RELAY STARTER INTERLOCK K2 = RELAY REVERSING LIGHTS CIRCUIT DIAGRAM CONTROLLER D S6 R S4 2 1S5 SW A GN B BL C VI D R F N R D = = = = = = = = AD3 (B3) AD2 (B2) AD1 (B1) AD7 (KD) X1 FORWARD NEUTRAL REVERSE MECHANICAL NEUTRAL INTERLOCK 1st SPEED 2nd SPEED 3rd SPEED 4th SPEED S1 TYPE PLATE CONTROL STUECKL S2 DW-3 V 12/24 NR K2 S3 RT A GR D GE B RS C ED1 (+/VP) 2 0501 210 148 X2 AD6 (N) AD4 (FORWARD) AD5 (REVERSE) A1 = ELECTRONIC UNIT EST-37 A2 = CONTROLLER CONTROLLER ERGO II TABLE-11 CONNECTION DIAGRAM CONTROLLER CODING CONTROLER OUTPUT + N V - R KD/ SN E N T+ T- AD1 B1 AD3 B3 KD AD5 V AD6 R AD7 N VP (+) (+) AD2 B2 A2 AD8 KD AD9 SN KD/E (AD8) T+ (AD1) T(AD2) C (AD3) (AD5) (AD6) N (AD7) SN (AD9) ED7 ED1 ED2 ED3 ED4 ED5 ED6 K3 (-) K1 A1 AD7 AD9 VM(-) : = U OUTPUT = OV (ACTIVE LOW) : = U SERVICE - 0,3 V K1 K2 K3 A1 A2 = = = = = RELAY STARTER INTERLOCK RELAY REVERSING LIGHTS RELAY SHOVEL NEUTRAL (CUSTOMIZED) ELECTRONIC UNIT EST-17T/EST-25 CONTROLLER ERGO II CIRCUIT DIAGRAM CONTROLLER RT MEANING OF PUSHBUTTONS S1 S2 N + - (SN) KD/E = = = = = = DRIVING DIRECTION FORWARD DRIVING DIRECTION REVERSE NEUTRAL UPSHIFTING DOWNSHIFTING SHOVEL-NEUTRAL (SHOVEL HORIZONTAL) = KICKDOWN CONTROL AND SAFETY RELEASE GE WS RS AD3 AD6 S1' V (FORWARD) POS LEGEND B3/C (CONTROL-SIGNAL) R (REVERSE) S1 PUSHBUTTON DRIVING DIRECTION FORWARD AND C-SIGNAL FORWARD PUSHBUTTON DRIVING DIRECTION REVERSE AND C-SIGNAL REVERSE PUSHBUTTON NEUTRAL PUSHBUTTON UPSHIFTING PUSHBUTTON DOWNSHIFTING PUSHBUTTON KICKDOWN/RELEASE PUSHBUTTON SHOVELNEUTRAL ( ) V' S2' ( ) R' S3 BR S4 BL S5 OG S6 VI AD7 AS/N AD1 B1/T+ AD2 B2/T- S2 S3 S4 S5 S6 S7 : 10 S7 +/VP AD5 SW 11 (1) X1 AD8 KD/E AD9 SN VM(-) K2