DHIM C/S

ZF Transmission 4WG190/210
Mega V Construction equipment B/G Product Support Team

Lay Out (1) 4WG-190/210

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

Lay Out Front view (2) 4WG-190/210

1. Lifting plug 2. Drive flange 3. Transmission suspension 4. Attachment for

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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

Lay Out Side view (3) 4WG-190/ 210

1. Driving Flange 2. Cover 3. Converter Bell Housing 4. Breather 5. Transmission Case Cover

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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

Lay Out Rear view (4) 4WG-190/210

1. Lifting Lugs 2. Power Take Off

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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)

Measuring Point (1) 4WG-190/210

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21. Inductive transmitter : Turbine 34. Speed Sensor : Output and Speedmeter 47.Inductive transmitter : Central Gear Train 48. Inductive transmitter : Engine

Measuring Point (2)4WG-190 /210

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Driving Direction Forward

Speed 1st 2nd 3rd 4th 1st 2nd 3rd

Y1

Y2

Y3

Y4

Y5

Y6

Engaged Clutch K1,KV KV,K2 K3,KV K4,K3 KR,K1 KR,K2 KR,K3

K4 F 60 162 KR E 55 162

Reverse

K1 D 56 162 K3 C 58 162 KV B 53 162 K2 A 57 162

Neutral Related Clutch Location Measuring Point System Pressure (bar)

Oil Circulation (System Pressure)

3~5 bar

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WGV : Converter Back Pressure Valve 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)

Working of Proportional Valve

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Oil Circulation - Neutral Position (System Pressure) DHIM C/S

16bar @ Port No 65

Oil Circulation - Neutral Position (Pilot Pressure)

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9 bar

Oil Circulation - Neutral Position (T/Q Converter)

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11 bar @ Port No 51

3~5 bar @ Port No 52/63

Oil Circulation - Forward 1st

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Oil Circulation - Reverse 1st

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Engaged EPPR Valve Summary

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Driving Direction Forward

Speed 1st 2nd 3rd 4th 1st 2nd 3rd

Y1

Y2

Y3

Y4

Y5

Y6

Engaged Clutch K1,KV KV,K2 K3,KV K4,K3 KR,K1 KR,K2 KR,K3

K4 KR

Reverse

K1 K3 KV K2

Neutral Relatived Clutch

Oil Circulation - Hydraulic Control (1)

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Oil Circulation - Hydraulic Control (2)

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Gear Schema - 4WG190/210

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KV :Clutch Forward K1: Clutch 1st Speed K3: Clutch 3rd Speed IN : Input

KR: Clutch Reverse K2: Clutch 2nd Speed K4: Clutch 4th Speed Out : Out Put

Power Flow - Forward 4WG 190/210

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Power flow - Reverse 4WG190/210

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MEGA-V T/M Electric Control System

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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

Electric system

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Description of Components
Sensors Sensor Engine & Turbine Speed Specification Volt(V) 0.45~7.0 Frequency 30Hz~50kHz Resistance() 1050 10% Gap(mm) 0.5~0.8 Remark

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-Output torque Control signal -Shifting quality (max 1.6sec) -Keep the original gap -Output Propellar shaft speed -Travel Speed display signal -LIS system (over 8 km)

1.0~12.5

2~5

1.0~1.5

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

Condition of Pressure Regulator Operation 1) Parking brake released 2) Transmission Oil Temperature : over 10 degree C

Description of Components
Transmission Oil Temperature Sensor (built in TCV) Condition Open or Short Circuit -30 degree C (T/M oil) -30 ~ -10 degree C (T/M oil) -10 degree C (T/M oil) Function -Error Code Display only -Travels Normally - Parking Brake Engaged - 1st, 2nd Speed mode only - Travels Normally Remark

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

Others 1. 2. TCU (Transmission Control Unit) Working Voltage : 18 ~ 32 VDC Kick Down 1) 2) Manual Mode : 2nd -> 1st Speed Change Only Auto Mode : Every Travel Speed, 1 stage shift down @ after 200 ~ 300 engine speed drop (except 4th -> 3rd) 3. Transmission Cut Off : Available @ 1st & 2nd Speed mode only

Electric system (Neutral)

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X X X X X X

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

Electric system (Forward 1st)

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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

Electric system (Down Shift 2nd -> 1st - Manual mode)

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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.

Electric system (Down Shift - Auto mode)

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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.

Electric system (Transmission Cut Off )

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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 ).

Electric system (AEB )

No 1 2 3 Order Warm up transmission about 10 to 20 minutes Turn off ignition key Plug in AEB starter to AEB connector located at the seat base closest to the cab door Put T/M gear selector Lever to Neutral position Engage park brake Start Engine Display message

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Remark

4 5 6

PL

The AEB has the task to compensate 7 tolerances 8 (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
9

TCU must recognize PL for at least 2sec before you press AEB starter button The button must not be released before TCU has started the AEB or quit with an error code (see Error code list) TCU has started the AEB, and goes on adjusting K1, K2,, KR. (Button may be released from starting)

On idling RPM Press button of the AEB Starter

PL ST

Hold button until AEB has been started

K1 (Information about the AEB state)

10

Wait until AEB has been finished Turn off ignition and unplug AEB Starter

OK (AEB has been successful)

11

Electric system (AEB DISPLAY )

Symbol PL ST K1..K4,KV,KR _ and Kx and Kx OK STOP STOP and Kx Spanner and Kx E E T T FT FB Meaning Remarks

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FO FN FP STOP

AEB - Starter is plugged at the diagnostic plug AEB Starter button is pressed Calibrating each clutch K1..K4,KV,KR Wait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R fast fill time determination of clutch Kx compensating pressure determination of clutch Kx calibration for all clutches finished Transmissions stays in neutral, have to restart the TCU (ignition off/on) after removing AEB-Starter AEB canceled (activation Transmissions stays in neutral, have to restart the stopped) TCU (ignition off/on) AEB stopped, clutch Kx Transmissions stays in neutral, have to restart the can't be calibrated TCU (ignition off/on) Kx couldn't be calibrated, Transmissions stays in neutral, have to restart the AEB finished TCU (ignition off/on) Engine speed too low, E/G RPM should be raised Engine speed too high E/G RPM should be down Transmission oil Warm up Transmission temperature too low Transmission oil Cool down Transmission temperature too high T/M temp not in defined T/M stays in neutral, have to range during calibration restart the TCU (key off/on) 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 Output speed not zero Transmissions stays in neutral, have to restart the TCU (ignition off/on) Shift lever not in Neutral Transmissions stays in neutral, have to restart the position TCU (ignition off/on) Parking brake not applied Transmissions stays in neutral, have to restart the TCU (ignition off/on) AEB - Starter was used Transmissions stays in neutral, have to restart the incorrect or is defective TCU (ignition off/on)

Frequency of Speed sensor

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Hz

Shaft

Shaft rpm = (Hz/Z) X 60

You can measure the frequency with an electric multi meter.

Machine Speed Machine Speed (km/hr) =

-

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Hz Z

1 r
total

x 2R x

3600 (sec/hr) 1000 (m/km)

Hz Z r total R

Frequency from Speed Sensor Number of Ring gear Teeth Total Reduction Ratio of Axle (r diff X r hub) Tire Radius in meter

M160-V M200-V M250-V M300-V M400-V M500-V Z 53 53 44 44 66 66