新zf实用版 2011.7 ZF Transmission system..pdf

Transmission system

1. ZF SEMI AUTOMATIC SYSTEM
ALL MATERIAL CONSIDERED TRADE SECRETS, PROPRIETARY AND CONFIDENTIAL FOR
AUTHORIZED USE BY LIUGONG EMPLOYEE’S INTERNALY ONLY.

2. Specialfunctionoftransmission &axle Special
function
of

transmission

&
axle

3. The 4WG-200 transmission

4. 1.
Transmission
control unit EST-17
2.
Transmission WG range
3.
Speed selector switch DW-2
4.
Connection to vehicle circuit
5.
T
ransmission
wiring
Sl id l
6.
S
o
l
eno
id
va
l
ue
Thetransmissioncontrolsystem The
transmission
control
system

5. The transmission rear face

6. The transmission right side face

7. The transmission right side face

8. the transmission control valve

11. The transmission connect wire NO

12. The transmission function
1. High adaptability to engine, vehicle and operating
condition thanks to specific programming.
2.Automatic date processing of the shift point according to
ild
eng
i
ne
l
oa
d
.
3.Optimumreversingbehavior. 3.Optimum
reversing
behavior.
4.Confortable kick-down function.

13. The transmission function
5.short-circuit-proof and overvoltage-protected electrical
system.
6.Many safety features to protect against operating errors(software) errors
.
(software)
.
7.customer-s
p
ecific control out
p
uts available.
pp
8.semi-and fully automatic controls available.

14. The transmission specification
1. On the go speed and direction change. 2. Hydraulic modulation assures smooth cushioned
hifi
s
hif
t
i
ng.
3Cl hl d i l il
ldf
3
.
Cl
utc
h
p
l
ate an
d
gears cont
i
nuous
l
y o
il
-coo
l
e
d
f
or
dependable performance long life.

15. Up-shifts Ifthepre
selectedgearisatleast2gearstepshigherthanthe
If

the
pre
-
selected
gear
is

at
least
2

gear
steps
higher
than
the

currently engaged gear up-shifts are made at 2.0 second intervals.
Down-shifts down-shifts are onl
y
released if. After the sown-shift
,
the turbine
y
,
speed does not exceed 2 times the max. perm. Engine speed and
currently engaged speed has been engaged longer than the
ii hldi i ( l )
m
i
n
i
mum
h
o
ldi
ng t
i
me
(
typ. Va
l
ue:2.0 sec.
)

16. Correct operation of workin
g

18. The converter has following advantages: 1.it can automatically change the output torque and speed of the transmissiontomeettherequirementofthevehicleatvariousroad transmission
to
meet
the
requirement
of

the
vehicle
at
various
road

conditions and operating modes.
2.it has high efficiency and wide range, so the engine can be operated more effectively and this results in good economy. 3.since power is transmitted by hydraulic oil, reducing shock to the vehicleanditismorecomfortableforoperation vehicle
and
it
is

more
comfortable
for

operation

19. The torque convertor is composed of 3 main parts:
1. impeller wheel. 2 turbinewheel 2
.
turbine
wheel
.
3. stator.

20. There three impeller are arranged in such a ring-shaped system
that the fluid passes through them in the above-indicated
sequence. Thecon ertorp mpisconstantl pressingpress reoilthro gh The
con
v
ertor
p
u
mp

is
constantl
y
pressing
press
u
re

oil
thro
u
gh

the converter.
This way, the converter is able to accomplish its task, i.e. to multiply the torque of the engine. In the same time, the heat created in the converter will be absorbedbytheescapingoil absorbed
by

the
escaping
oil
.

21. The oil escaping from the impeller wheel enters into the turbine
wheel, where the direction of the fluid is revered. According to
the reversing moment, the turbine wheel, and with it also the output shaft, will receive a more or less high reaction moment . Th t t ( ti b ) f ll i th t bi h l h Th
e s
t
a
t
or
(
reac
ti
on mem
b
er
)
,
f
o
ll
ow
i
ng
th
e
t
ur
bi
ne w
h
ee
l
,
h
as
the task to redirect again the oil, which is streaming out of the
turbine,andtodirectitinthecorrectdirectionintothepump turbine,
and
to

direct
it
in
the
correct
direction
into
the
pump

wheel, the stator receives a reaction moment due to this
reversing motion

22. The relation between the turbine moment/pump moment is calledtorqueconversion Theconversionisincreasingin called
torque
conversion
.
The
conversion
is

increasing
in

correspondence with the speed difference with the speed
difference between pump wheel and turbine wheel. therefore,
the maximal conversion takes pl ace when the turbine wheel is
stop, with increasing output speed the torque conversion is
did
ecreas
i
ng.

23. A h bi d f b 80% f h d h A
t t
h
e tur
bi
ne spee
d
o
f
a
b
out
80%
o
f
t
h
e pump spee
d
, t
h
e
conversion becomes 1.0,i.e. the turbine moment is equal to
thatofthepumpmoment Thetorqueconverteristhatacting that
of

the
pump
moment
.
The
torque
converter
is

that
acting

similar to a fluid clutch.

24. Introduction of s
y
stem main functions
y
•Neutral/start interlock protection function
Machine can only be started when it’s on neutral
Pfffi(bkdlhifi)
•
P
ower cut o
ff

f
unct
i
on
(b
ra
k
e
d
ec
l
utc
hi
ng
f
unct
i
on
)
This function applies to the I, II gear only
•
Directreversingfunction
•
Direct
reversing
function
when machine is on forward I or II gear, it can be reversed to
I or II corres
p
ondin
g
l
y
pgy
when machine is on top gear, it will reduce the gear to II,
and then reverse to desired gear

25. •Take-off speed limit function ( 14km/h)
Machine can only takes off from I or II gear ignoring
the position of the selecting handle

26. •KD function
increase efficiency
To cancel this function: push the KD button again changethedirection change
the
direction
change gear overthespeedlimit over
the
speed
limit
•Self-protection function
any abnormal signal from
selector, speed sensor, solenoid
valve detected by control
unit machinewillbeshiftedto unit
,
machine
will
be
shifted
to
neutral and output cut off
ZFSEMI
AUTOTRANSMISSIONCONTROLSYSTEM
ZF

SEMI
-
AUTO
TRANSMISSION

CONTROL

SYSTEM

27. The 27 step check

28. MAJOR COMPONENTS OF ZF SYSTEM
RANGER SELECTOR CONTROLUNIT(EST) CONTROL

UNIT

(EST)
SOLENOIDS SOLENOIDS SPEED SENSOR

29. X10
X5
X1
X2
X9
X2
Positions of ZF connectors

30. •Transmission system voltage and earth
Core 18 and 35 are earthed
O h i ii 24V h ldb d d O
n t
h
e
i
gn
i
t
i
on,
24V
s
h
ou
ld

b
e
d
etecte
d

between core 1 & 2, otherwise
checkifthe75Atransmissioncontrol check
if

the
7
.
5A

transmission
control

fuse melts
•S
p
eed sensor
p
The resistance between core 17 & 27
should be 920-1120 Ohm
hihk
ot
h
erw
i
se, c
h
ec
k
:
if connector X10 is secured properly
observethepinsonspeedsensorifthey observe
the
pins

on

speed
sensor

if

they

are rusted or dirty
Ch ki fZF Ch
ec
ki
n
g
o
f
ZF
s
y
stem parts

31. selector testing table
gear wire connected core solenoid valve on/off clutch on/off
red
:
power,
black
:
earth
19
-
25
red
:
power,
black
:
earth
19
25
neutral 1 grey,black and blue 29-25-26
neutral 2 grey and black 29-25
neutral
3
grey black
and
green
29
25
8
neutral
3
grey
,
black
and
green
29
-
25
-
8
neutral 4 grey, black,green and blue 29-25-8-26 forward 1 yellow,black and blue 23-25-26 M2、M3、M4
KV+K1
forward 2
y
ellow and blac
k
23-25 M3、M4
KV+K2
forward 3 yellow black and green 23-25-8 M3
KV+K3
forward 4 yellow,black,green and blue 23-25-8-26 M5
K4+K3
reverse 1 pink,black and blue 5-25-26 M1、M2、M4
KR+K1
reverse 2 pink and black 5-25- M1、M4
KR+K2
reverse 3 pink, black and green 5-25-08 M1
KR
+
K3
KR K3
reverse 4 pink, black, green and blue 5-25-8-26 none

32. •
Five solenoid valves on transmission
ll
contro
l
va
l
ve
Check solenoid valves from X1.
35-14
35-15
From 85 ohm to 100 ohm. 35-31
35-32
35
33
35
-
33
35-14: Y4, 35-15: Y2, 35-31: Y5, 35-32: Y3, 35- 33 Y1 33
:
Y1

33. QSB
e
Familiarization
Introduction 1. Instructor
2. QSB
e
Engine.
3. This program has been produced for training
purposes only, and is an uncontrolled document.

34. Aim
To provide the participant with a level of instruction on
the
QSB
e
Enginewhichwillgiveanunderstandingofsome
the

QSB
Engine

which

will

give

an

understanding

of

some

existing and future product functionality and complexity.