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Chapter IV ZF Transmission
Tuesday, May 19, 2015
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CONTENTS
Structure and Principle of Torque Converter
Structure and Principle of Transmission
Oil Supply and Lubrication System of ZF Transmission
Electric Control System of ZF Transmission
Operation and Maintenance of ZF Transmission
Common Malfunctions and Troubleshooting of ZF
Transmission
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1. Torque converter 2. Rear drive axle 3. Transmission 4. Drive shaft 5. Front drive axle
The hydraulic torque converter is installed between the engine and transmission
and is mainly function to change the torque outputted by the engine so that the
torque output of the turbine will probably exceed the input torque of engine via
pump impellor so as to improve the power performance of loader and ensure the
stable transmission.
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Torque converter: Its mainly composed of pump impellor, turbine, idler pulley
(commonly referred to as three-element part.), and housing and its capable of
automatically regulating the torque output and speed output of the engine.
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Pump impellor
Guide pulley
Turbine
Working principle of torque converter: Some blades are uniformly arranged within each working
impellor of the torque converter. These blades work together with each other to form an
enclosed annular space, in which the fluid can recirculate. When the engine flywheel drives the
rotation of pump impellor, the blades of the pump impellor drives the rotation of fluid. Under the
action of the centrifugal force, the fluid flows from the inner edges of blades to the outer edges
to impact the turbine blades and drive the rotation of turbine for torque output. The flowing fluid
flows from the outer edges of blades to the inner edges of blades within the turbine to impact
the blades of guide pulley and then returns to the pump impellor along the blades of guide
pulley for next cycle. The torque conversion of the hydraulic torque converter is attributed to the
presence of guide pulley. The guide pulley is connected with the torque converter housing via
fixed guide pulley seat and the torque converter is connected with engine flywheel via elastic
plate.
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Structural diagram of ZF
transmission
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Connecting
flange with
torque converter
and engine
ZF
transmission
Torque
converter
ZF
transmission
Transmission
ZF transmission
Gearshift
operating lever
2. Structure of
transmission
The ZF transmission is
mainly composed of
electronic control units
(gearshift
operating
lever, electric control
box,
and
gearshift
valve) and mechanical
gearshift transmission
(6 clutches and drive
gears
and
output
shaft).
ZF transmission
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ZF
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1 power
takeoff port
st
Oil filter
1 power
2 power
takeoff port takeoff
port
st
nd
Clutch K1
Clutch KV
Clutch KR
Optional
emergency
pump port
Output speed
sensor
Clutch K2
Clutch K3
Clutch K4
Clutch KV
Transmissio
n filler port
Output
flange, fitted
with parking
brake
Removed part
on right side of
transmission
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Solenoid valve
(resistance: 9010Ohm)
Clutch K2
Reverse
clutch KR
K4 clutch
Forward
clutch KV
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Clutch
KV
Clutch
K1
Power
drive
gear
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gear
Route diagram for various gears of ZF transmission (4 forward gears and 3 reverse gears)
2nd forward
gear
Output
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3rd forward
gear
Output
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Route diagram for various gears of ZF transmission (4 forward gears and 3 reverse gears)
Countershaft
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4th forward
Output gear
1st
Output reverse
gear
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Route diagram for various gears of ZF transmission (4 forward gears and 3 reverse gears)
2nd reverse
gear
Output
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3rd reverse
Output gear
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Oil recirculation schematic diagram of transmission with two-stage pressure control valve
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Cast aluminum gearshift control valve with 5 solenoid valves and two-stage pressure control valve
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1. Electric control
box EST-17T
2. Transmission
3. Gearshift
operating lever
DW-2
4. Connecting port to
circuits of
complete machine
5. To transmission
solenoid valve
6. To output speed
sensor
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Yellow
lever connector
Blue
box connector
Sensor 2
(I)
Red
Green
Grey
Lever 5
Black
Pink
Solenoid valve connector
Sensor 1
Lever 7
Lever 9
Lever 10
Lever 4
Lever 6
Lever 2
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Intermediate relay
(power cutoff)
Intermediate relay
(starter interlocker)
Intermediate
relay
(reversing)
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4. Gear selector
The gear selector is the gear signal input device of the ECU. Its normal
functioning directly influences the normal functioning of the system. Use
the multimeter for measurement and judgment.
KD button
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The continuity and logic relationships between the red wire in the harness
of gear selector and other wires and various gears are as below:
With red
FI
F2
F3
F4
R1
R2
R3
Blue
Green
Black
Yellow
Grey
Pink
Purple
If the grey wire is under continuity state, the complete machine cant be started. The purple
is the KD function, the pink is the control of reverse gear, and the yellow is the forward gear.
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As the main control part for judgment of gear, the electric control box analyzes the
signal of selector and issues command to the solenoid valve.
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6. Gearshift valve
The gearshift valve is the actuator unit that engages and disengages the
control gear of the solenoid valve as per the command of ECU.
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Clutch for
various gears
Control
solenoid valve
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KV
K1
K2
K3
K4
KR
M3
M2 and
M4
M4
M5
M1
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7. Speed sensor
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1. Operation Precautions
(1) To check the transmission oil level, the engine shall idle run (at approximate
1,000r/min) and the oil temperature shall be at normal working temperature.
(2) When the oil temperature is at 40C, the oil level shall be between the middle
mark and lower mark of the oil dipstick.
When the oil temperature is at 80C, the oil level shall be between the middle
mark and upper mark of the oil dipstick.
Hot oil level zone
(3) Periodically replace the transmission oil and replace the filter strictly as per the
maintenance schedule.
(4) Before starting the engine, ensure that the operating lever is at neutral gear.
(5) Before starting up the machine each time, release the parking brake.
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(6) When it's necessary to hoist the transmission to fit the engine with transmission or
separate the engine from the transmission, avoid the fall-off of the torque converter.
(7) While parking the machine, the gearshift operating lever shall be at neutral gear.
(8) The normal working oil temperature shall be within 80~110C. Under heavy load, the oil
temperature is allowed to rise to 120C for a short time. Pay special attention to the
controlling oil pressure of the transmission. Upon detection of any abnormality in the
transmission during operation, immediately stop the machine for checking.
(9) When the electric welding is required for repair in event of the machine malfunction, make
sure to disconnect the cable connector from the EST electronic control unit (to cut off
the current to the electronic control unit), or the impact current during the electric
welding will probably burn out the electronic control unit.
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2. Operations
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The oil level can be checked only when the operating level is at
neutral gear. While checking the oil level, insert the oil dipstick to the
dead end of the dipstick tube. While cleaning the filter of main oil line,
pay attention to prevent the ingress of dirt and sediments into the oil
circuit. Therefore, place a cover plate to guard the parking brake
against being dipped by the oil.
While installing the filter, pay attention not to tighten excessively.
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To start the engine, make sure that the gearshift operating lever is at neutral gear.
For the purpose of safety, before starting the engine, the parking brake shall be
under braked state to prevent the startup of machine due to the start of engine. After
the engine is started, release the parking brake, select the driving direction and gear,
and depress the throttle slowly to start up the machine. During the traveling of the
machine, the torque converter substitutes the function of main clutch. When the road
condition is good, its possible to travel at higher gear.
If the machine stops traveling, but the engine is still running and the transmission is
shifted to a gear other than neutral gear, the engine will not stop at that time. On a
straight road, the machine will probably crawl, as the idling of engine will generate a
certain traction force via the torque converter. The appropriate method is to place
the parking brake at braked state whenever the machine is parked.
To park the machine for a long period, make sure to shift the operating lever to
neutral gear. During the traveling of the machine, make sure to release the parking
brake. Due to the influence of the torque converter, while shifting from a high speed
gear to a low speed gear, the engine speed will increase, especially at the time of
gear jump. Therefore, whenever the condition permits, while shifting from a high
speed gear to a low speed gear, depress the foot brake for slow deceleration before
the gearshift. When the machine is traveling at high speed or changing driving
direction, lower the engine speed.
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The maximum oil temperature at outlet of torque converter shall not exceed 120C.
For non-malfunctioned control subassembly and transmission with sufficient
traveling mileage, the temperature shall not be too high. If the oil temperature
exceeds 120C, make sure to stop the machine and check for presence of external
oil leakage. At the same time, shift the transmission to neutral gear and run the
engine at 1,200~1,500rpm. In such case, the oil temperature will lower rapidly to
the normal value (approximate within 2~3min). If the oil temperature fails to drop,
certain portion within the system is malfunctioned. Make sure to resolve the
malfunction before proceeding the operations.
Normal range for gearshift oil pressure: 1.6~1.8MPa (16~18bar). To monitor the
control pressure, make sure to install a pressure gauge or pressure monitoring
unit. If the pressure drops to below the specified minimum pressure after a certain
gear is engaged and the clutch is depressed (though the pressure at moment of
gearshift will drop automatically temporarily), make sure to resolve the cause of
pressure drop. The under-low control pressure will lead to damage of clutch, as the
clutch is short of sufficient contact pressure and the continual skid of friction plate
leads to over-heating.
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3. Maintenance
(1) Check the oil level.
- Park the machine on a level place.
- Shift the gearshift operating lever of the transmission to neutral gear N and
set the parking brake at braked position.
- Idle run the engine at approximate 1,000r/min.
- Counterclockwise the oil dipstick and take out and wipe clean the oil dipstick.
- Insert the oil dipstick into the oil dipstick tube and tighten to place. Wait for 3s
and take it out (measure for at least two times).
- When the oil temperature is at 40C, the oil level shall be between the middle
mark and lower mark "Cold of the oil dipstick.
- When the oil temperature is at 80C, the oil level shall be between the middle
mark and upper mark "Hot of the oil dipstick.
Caution: Checking the oil level under cold state is to ensure sufficient
recirculation flow for transmission and torque converter and the decisive criterion
for oil level is to meet the oil level requirement under hot state.
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Initial oil
replacement
After 100
working hours.
Replace filter
as well.
Normal oil
replacement
At interval of
1,000 working
hours, but no
more than 1 year.
Replace filter as
well.
Oil specification
Mobil Delvac 1300
SAEl5W40 or Titan
universal oil HD15W-40
(manufactured by
Shanghai Desi Oils Co.,
Ltd.)
Checking of oil
level
Before
operation each
day
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- Push in the filter, till it comes into contact with the sealing
surface on the transmission, and then tighten for approximate
1/3~1/2 turn with hand.
- Add oil.
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Fall-off of torque
converter
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4.
Completely fit and fix the connecting housing of torque converter and
flywheel housing of engine with three bolts and then tighten the connecting
bolts of torque converter middle flange and engine flywheel in turn.
5. Finally tighten all connecting bolts of torque converter connecting flange and
engine flywheel housing.
6. Through the square observation port on the connecting housing of the
torque converter, check the connecting elastic plate between torque
converter and its middle flange for presence of squeezed deformation
(Under normal status, the plane of elastic plate shall be perpendicular to the
axis of middle flange).
7. Control size for connecting the connecting housing of transmission with
engine flywheel housing: 39.60.5.
II. Precautions for installation from transmission and radiator oil pipe
The tightening depth for the connection between pipe connector and
transmission shall not come into contact with the core of the backpressure valve.
If the insertion depth exceeds 21mm, it will cause working failure of the
backpressure valve due to blockage of core and obstruct the recirculation oil line
between transmission torque converter and radiator so that the working oil of the
torque converter cant be sufficiently recirculated for heat radiation to cause
over-high oil temperature of the torque converter.
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IV.
1.
After the engine is started, a part of oil in the gearshift operating oil system
will overflow and return to the tank via the oil line within the side cap of the
gearshift operating valve. Therefore, when the side cap is opened during the
running of the engine, the oil will spray from the valve body. Therefore, while
installing the side cap, make sure properly seat the O-ring of side cap and
clamp the hoop to the required place, in order to prevent the so-called valve
leakage symptom.
2.
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V.
1.
2.
Speed sensor
The gap between the end of speed sensor and the tooth top of gear is
0.5~0.8mm. The disassembly of sensor without prior consent and the
incorrect installation will lead to damage of the sensor.
Do not disassemble the speed sensor without prior consent.
The service personnel is disallowed to add or remove the adjustment
washer at the time of assembly.
Speed
sensor
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VI. ZF cables
1.
2.
While arranging the cables, ensure that the cables at all positions
are free of friction with any other part.
The cables at all positions shall be correctly fixed.
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2. No 3rd gear or 4th gear is available, though the 1st gear and
2nd gears are available in complete machine.
Check oil level
3. No 1st gear or 2nd gear is available, though the 3rd gear and
4th gears are available in complete machine.
Check the cables for normal connection.
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4. Noise of transmission
Check oil level
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THE END
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