ZF 3 WG-94 EC Technical Data Manual
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ZF 3 WG-94 EC Technical Data Manual

ZF 3 WG-94 EC Technical Data Manual

Ergopower transmission
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ZF – ERGOPOWER
TRANSMISSION
3 WG-94 EC
TECHNICAL DATA
DESCRIPTION
OPERATION
MAINTENANCE
DIAGNOSTIC SYSTEMS
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Order No.: 5872 138 002
Subject to technical modifications!

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  • Page 1 Order No.: 5872 138 002 ZF – ERGOPOWER TRANSMISSION 3 WG-94 EC TECHNICAL DATA DESCRIPTION OPERATION MAINTENANCE DIAGNOSTIC SYSTEMS ZF Passau GmbH Donaustr. 25 - 71 D - 94034 Passau Subject to technical modifications!
  • Page 2 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems 1st Edition: 11/2007...
  • Page 3 Axle Systems Preface This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be made on ZF units. Due to the continuous technical upgrading of the product, however, the repair and maintenance of the unit at your disposal may require both deviating work steps and differing setting and testing data.

  • Page 4: Table Of Contents

    Operating mode of the converter Powershift transmission Transmission control Controller DW-3 Electronic control unit TCU Electronic controls for ZF powershift transmissions 1.6.1 General 1.6.2 Description of basic functions 1.6.3 AEB (=Automatic Determination of Filling Parameters=ADFP) 1.6.4 Electrical inching Description of the fault codes for ERGO-Control EST-65 1.7.1 Abbreviations...
  • Page 5 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems ANNEX consisting of: Tables 3 WG-94 : Configuration Installation sheet of direct mount - front view Installation sheet of direct mount – rear view Measuring points, valves and connections Oil circuit diagram (1st speed forward) Power flow of forward and reverse gears Controller DW-3 Fully-automatic control EST-65 (Standard)

  • Page 6: Technical Data

    ** = depending on transmission version Description: The ZF transmissions 3 WG-94 EC are composed of a hydrodynamic torque converter and a rear-mounted multi-speed powershift transmission with integrated transfer box (see table 1). The torque converter is a wear-free start-up device which, due to its continuously variable design, adapts itself to the required situations (necessary input torque).
  • Page 7 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems Transmission ratio (mechanical)* Gear DRIVING Ratio DIRECTION forward 4,446 forward 2,341 forward 0,974 reverse 4,443 reverse 2,340 reverse 0,973 * = Other ratios are possible, depending on the transmission version.

  • Page 8: Identification Plate

    ZF List of Lubricants Oil fill quantity Customer number INFORMATION ON SPARE PARTS ORDERING: Please indicate the following information when ordering genuine ZF spare parts: 1. = Transmission type 2. = Unit number You will find this information on the identification plate! 3.

  • Page 9: Important Instructions

    At shut-off engine, the oil level in the transmission is rising essentially, depending on the installation conditions ! The ZF filter must be replaced at every oil change. In addition, ZF recommends to start the automatic calibration of the shifting elements (AEB).
  • Page 10 In case of irregularities on the transmission put the vehicle out of service and ask for specialists. Protective measures for the ZF electronic system during electrical work on the vehicle: At the following operations, the ignition must be shut off and the control unit plug must be pulled off the ZF electronic system: ∗...

  • Page 11: Description

    Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems DESCRIPTION Operating mode of the converter: Operating mode of a hydrodynamic torque converter (schematic view) = torque of pump pump wheel turbine wheel wheel = torque of turbine wheel = torque of reaction member (stator) from the...

  • Page 12: Powershift Transmission

    The pump feed rate is Q = 45 l /min, at n = 1 500 min engine This pump is sucking the oil out of the oil sump via the coarse filter, and delivers it to the main pressure valve via the ZF filter.
  • Page 13 Installation Guidelines for Hydrodynamic Powershift Transmissions. The heat exchanger is not included in the delivery scope of ZF Passau GmbH. From the heat exchanger, the oil is directed to the transmission and the lubricating oil circuit,...

  • Page 14: Controller

    Due to the great number of available TCUs, the exact technical data are to be taken from the respective installation drawing. The installation of the TCU is optional. Preferably, ZF recommends the version shown in Figure No. 1.5 B1. The TCU is to be installed in a protected place in the driver's cab.
  • Page 15 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems TCU installation position 90° 90° 90° 90° Fig. No.: 1.5 B1 TCU installation dimensions ZF identif. plate Minimum distance to release the plug Fig. No.: 1.5 B2...

  • Page 16: Electronic Controls For Zf Powershift Transmissions

    ZF requirements (see Installation Guidelines). 1.6.2 Description of basic functions The powershift transmission 3 WG-94 EC of series WG-90 is equipped with the electronic transmission control EST-65 specially developed for this purpose. The system processes the driver command according to the following criteria: •...
  • Page 17 17 = Proportional valve Y1 - KV clutch 18 = Proportional valve Y5 - KE clutch 19 = Proportional valve Y4 - KD clutch 17 = Ergopower transmission 3 WG-94 EC Overall system of EST-65 Figure No.: 1.6.2 The EST-65 system reactions in case of error described in Table-9 are for information only.
  • Page 18 There are two basic possibilities for starting the AEB cycle: 1. AEB start by separate tools which are connected to the diagnostic port of the wiring. The ZF Service Department offers the following tools for AEB start: Testman/Pro (see item 5.3 - diagnostic systems) AEB starter Order No.: 0501 211 778...

  • Page 19: Electrical Inching

    Since these setting phenomena may affect the shifting quality, ZF recommends to repeat the AEB cycle at the maintenance intervals (see 4.3.1). If the shifting quality deteriorates, ZF also recommends to repeat the AEB cycle as a first measure. IPK (Inch Pedal Calibration - Inch Sensor Calibration) shall also be carried out after each AEB start (see 1.7.5).

  • Page 20: Display

    ERGOPOWER Off-Road Driveline Technology and Axle Systems 1.7.2 ZF - Display: If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the gear selector is on neutral position.
  • Page 21 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems Symbol meaning remarks 2 bars manual mode 2 gear 3 bars manual mode 3 gear 4 bars manual mode 4 gear and also 5 gear in 6WG 4 bars and 2 automatic mode arrows Bars flashing...
  • Page 22 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems Symbol meaning remarks KA…..KE Calibrating clutch KA..KE, KV or KR KA, KB for 2 gear transmission KV,KR resp. KC, KD, KE for 3 gear transmission _ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R fast fill time determination of clutch Kx ≡...

  • Page 23: Definition Of Operating Modes

    Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems Symbol meaning remarks FN and Stop Shift lever not in Neutral position Calibration is aborted FS and Stop sensor supply voltage AU1 is out of the Calibration is aborted specified range FO and Stop Outputspeed is not zero Calibration is aborted...
  • Page 24 Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems TRANSMISSION-SHUTDOWN: TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8.

  • Page 25: Installation Instructions

    ZF shall not accept any warranty claims for any damage due to incorrect installation. In order to support the customer in case of new or initial applications, ZF carries out a transmission installation study by authorized personnel. On that occasion, ZF examines all transmission-specific installation features and informs the vehicle or equipment manufacturer of the defects found.

  • Page 26: Operation

    The telltale lamps lighting up on the INFOCENTER (dashboard) for functional control may differ from one vehicle manufacturer to the other. Operating elements and displays can be from ZF, but may also be customer-specific products. For detailed information please refer to the operating instructions of the respective vehicle manufacturer.

  • Page 27: Cold Start

    The electronics remain in NEUTRAL until this oil temperature has been reached. The ZF display shows the symbol of the cold start phase. Displayed symbol : After the symbol on the ZF display has extinguished, the full driving program can be utilized out of "NEUTRAL":...

  • Page 28: Transmission Control In "Automatic" Driving Range

    If this is not the case, there is a trouble which must be eliminated prior to continue working. In addition, the oil temperature after the converter is monitored by an indicator on the ZF- display or analogously in the INFOCENTER.

  • Page 29: Maintenance

    If, in operating temperature condition, the oil level has dropped below the "HOT“ range, it is imperative to refill oil according to ZF List of Lubricants TE-ML 03. An oil level above the "HOT" marking leads to an excessive oil temperature.

  • Page 30: Oil And Filter Change Intervals

    Figure No.: 4.2 B2 Oil and filter change intervals: In this connection refer to specification in the ZF List of Lubricants TE-ML 03. The ZF filter must be replaced at every oil change. 4.3.1 Oil change and oil fill quantity:...

  • Page 31: Filter Change

    Off-Road Driveline Technology and Axle Systems - Fill in oil (approx. 24 liters ) according to ZF List of Lubricants TE-ML 03 (sump volume, external oil volumes, e.g. in the heat exchanger, in the lines etc. are depending on the vehicle).
  • Page 32 Off-Road Driveline Technology and Axle Systems - Fill in oil (approx. 17 liters ) according to ZF List of Lubricants TE-ML 03 (sump volume, external oil volumes, e.g. in the heat exchanger, in the lines etc. are depending on the vehicle).

  • Page 33: Diagnostic Systems

    (EEPROM) and transmits the fault code to the vehicle controller of the vehicle manufacturer. The ZF diagnostic LAPTOP version (see 5.2) is required for the following applications: Diagnosis...

  • Page 34: Laptop Version

    Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems Laptop version: Pentium Laptop 900 MHz min. Windows 95/98 or Windows NT Windows 2000 /Windows XP Basic software Testman/Pro on CD German/English Adapter cable RS 232 Diagnostic set in progress WIN 95-98-98.2 WIN 2000 NT-XP Programming adapter DPA-05 is just sold as a set, together...

  • Page 35: Multi-System 5060

    Corporate Division ERGOPOWER Off-Road Driveline Technology and Axle Systems ZF Multi-System 5060: Multi-System 5060 Measuring equipment case with corresponding sensors for pressure, temperature and speed. 5870 221 300 Multi -System 5060 Portable measuring unit without accessories. 5870 221 318 Accessories: Sensors for flow, current transformer etc.
  • Page 36 CONFIGURATION 3 WG-94 EC TABLE - 1 1 = Flex plate for direct mount 2 = Converter 3 = Converter bell housing 4 = Transmission pump 5 = Clutch shaft „KV“ 6 = Input shaft / clutch shaft „KR“ 7 = Central shaft / input shaft PTO 8 = Connection, PTO;...
  • Page 37 Installation position of clutches Transmission schematics Inductive sensor n central gear chain Inductive sensor n turbine Inductive sensor n engine Speed sensor n output Table-1 / Page 2 of 2...
  • Page 38 INSTALLATION SHEET 3 WG-94 EC - DIRECT MOUNT FRONT VIEW TABLE-2 1 = Converter 2 = Direct mount via flex plate 3 = Converter bell housing 4 = Transmission housing - front part 5 = Transport bracket 6 = Transmission housing - rear part...
  • Page 39 INSTALLATION SHEET 3 WG-94 EC - DIRECT MOUNT REAR VIEW TABLE-3 1 = Filter head 2 = Transport bracket 3 = Oil filler tube with oil dipstick 4 = Converter bell housing 5 = Direct mount via flex plate 6 = Transmission mounting holes M16x1.5 7 = Oil drain plug 7/8“...
  • Page 40 MEASURING POINTS, VALVES AND CONNECTIONS 3 WG-94 EC TABLE-4 The marked items (e.g. 53) correspond with the items on Table-5! Take measurements when the transmission has reached operating temperature (approx. 80° - 90° C)! Transmission schematics Inductive sensor Inductive sensor...
  • Page 41 21 64 11 21 57 67 Table-4 / Page 2 of 3...
  • Page 42 AN/KR The following markings are cast in raised characters on the rear side of the transmission housing: Denomination Proportional valve Y1 Proportional valve Y2 Proportional valve Y3 Proportional valve Y4 Proportional valve Y5 AN / KR Input / Clutch reverse Clutch forward Clutch KC Clutch KD...
  • Page 43 = Main pressure valve (control pressure valve) 16 Encoding = Converter safety valve = Lubrication of KR clutch Druckregler unter Spannung Geschaltete Kupplungen = Heat exchanger (not included in ZF's delivery scope) Fahrtrichtung Gang = Proportional valve Y1 clutch KV Vorwärts = Proportional valve Y2 clutch KR = Proportional valve Y2 clutch KC Rückwärts...
  • Page 44 Gear-shift signal Turbine speed Output speed Engine speed Speed central gear chain Inch enable signal Inch pedal signal 1 Oil sump temperature (option) Inch pedal signal 2 Oil temperature after the converter Converter Display Park brake feedback signal Lubrication Legend: Main pressure Controlled main pressure Converter input pressure...
  • Page 45 POWER FLOW 3 WG-94 EC - FORWARD/REVERSE GEARS TABLE-6 View sense of rotation 1st gear forward 2nd gear forward 3rd gear forward KR/PTO AN/KR AN/KR AN/KR Table-6 / Page 1 of 2...
  • Page 46 1st gear reverse 2nd gear reverse 3rd gear reverse AN/KR AN/KR AN/KR Legend: Driving direction Gear Clutch KV = Forward clutch Forward KV/KC KR = Reverse clutch KV/KD KC = 1st gear clutch KV/KE KD = 2nd gear clutch Reverse KR/KC KE = 2rd gear clutch KR/KD...
  • Page 47 CONTROLLER DW-3 TABLE-7 Lever for mechanical CONNECTION DIAGRAM CONTROLLER CODING CONTROLLER Neutralinterlock AUSGABE GANG VORWAERTS RUECKW NEUTRAL X2 : A X1 : C X1 : B X1 : A X1 : B In position (Neutral), X1 : C F-R not switchable X1 : D A B C D K1 = RELAY STARTER INTERLOCK...
  • Page 48 3 WG-94 EC FULLY AUTOMATIC CONTROL EST-65 WIRING DIAGRAM- STANDARD (6029 701 xxx) TABLE-8 ITEM LEGEND Electric control unit EST-65 Shift lever DW-3 Diagnostics (interface) Display (optional) CAN interface (connector) Speed sensor - engine Speed sensor - turbine Speed sensor - central gear chain...
  • Page 49 Kl.30/1.12 Kl.30/1.1 Kl.15/1.12 Kl.15/1.1 S3 S31S32 Mini 6-pin Superseal 3-pin 6029 199 074 6029 199 071 VPEI VPE2 ED11 Ed10 ED12 SDDK OPTIONAL EUPR VMG2 CANAPE H X2 / A CANAPE L X2 / B X2 / D X2 / C X1 / A AIP1 X1 / B...
  • Page 50 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) TCU shifts transmission to failure cannot be detected in systems • check the cables from TCU to shift lever LOGICAL ERROR AT GEAR RANGE SIGNAL TCU detected a wrong signal combination neutral...
  • Page 51 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) • connector pin is contacted to vehicle ground no reaction, • check the cable from TCU to the sensor TO BATTERY VOLTAGE OR O TCU uses default temperature •...
  • Page 52 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) • speed sensor has an internal defect • connector pin is contacted to battery voltage or has no contact OP-Mode: substitute clutch •...
  • Page 53 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) OP-Mode: substitute clutch This fault is reset after power up of TCU • check the cable from TCU to the sensor LOGICAL ERROR AT TURBINE SPEED INPUT TCU measures a turbine speed over a control...
  • Page 54 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) special mode for gear selection • check the cable from TCU to the sensor TO BATTERY VOLTAGE OR O OP-Mode: substitute clutch OUTPUT SPEED INPUT...
  • Page 55 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) TCU shifts to neutral • check vehicle controller EHICLE TIMEOUT Timeout of CAN-message Vehicle1 from NN (because of shifting lever) •...
  • Page 56 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) TCU shifts to neutral see chapter Error! Reference source • check the cable from TCU to the AT CLUTCH the measured resistance value of the valve OP-Mode: limp home...
  • Page 57 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) TCU shifts to neutral see chapter Error! Reference source • check the cable from TCU to the TO BATTERY VOLTAGE AT CLUTCH KE/KB OP-Mode: limp home...
  • Page 58 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) TCU shifts to neutral see chapter Error! Reference source • check the cable from TCU to the TO GROUND AT CLUTCH the measured resistance value of the valve OP-Mode: limp home...
  • Page 59 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) TCU shifts to neutral see chapter Error! Reference source • check the cable from TCU to the AT CLUTCH the measured resistance value of the valve OP-Mode: limp home...
  • Page 60 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) OP-Mode: TCU shutdown • low pressure at clutch KE/KB • check sensor gap at output speed sensor •...
  • Page 61 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) CONVERTER no reaction • cool down machine OVERTEMP TCU measured a temperature in the OP-Mode: normal •...
  • Page 62 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) shift to neutral • check power supply battery LOW VOLTAGE AT BATTERY measured voltage at power supply is lower OP-Mode: TCU shutdown •...
  • Page 63 Table-9 „Fault code tables“ Fault reaction of the TCU possible steps to repair remarks MEANING OF THE FAULT CODE Code possible reason for fault detection (hex) • cable or connectors are defective and are contacted to battery voltage • display has an internal defect no reaction •...

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