Innovationsof Great Value.

Driveline Technology for Heavy Material Handling Vehicles

Driveline Technology for Heavy Material Handling

Material handling vehicles with internal combus-tion engines are real “all-rounders”. In outdoorapplications, for example, they must not only beable to quickly transport extremely heavy loadsover long distances, but they must also be able toprecisely maneuver their load and set it down inthe tightest of spaces.

ZF transmissions meet all demands

The widely varying functions make the highestdemands on the driveline, in particular on thetransmission: It must be designed for strongengines with a high input torque and smoothgear shifts that take place under full load, with-out interruption to the tractive effort.

Important for the manufacturer and the end user

The transmissions must however not take upmuch space. Manufacturers who want to keeptheir products small and maneuvrable arerestricted with installation space.

Specially designed range of transmissions

With Ergopower ZF is offering a complete rangeof transmissions which fea ture this variety offunctions: Apart from high flexibility and com-pact design, the transmis sions from this range,which were specially conceived for material han-dling vehicles with combustion engines, alsohave a highly deve loped electro-hydraulic control.

Conclusion

Consequently, the transmissions are easy to oper -ate and have finely graded gears. Manu facturersand users also appreciate the low operating costsand the customer-orientated service friendlinessof the lift-truck, RoRo-tractor, straddle carrier orreachstacker transmissions “Made in Passau,Germany”.

High precision with heavyloads and fully automaticgear shift

ZF offers a wide range of fullyautomatic transmissions in theERGOPOWER® series to pro-vide driveline systems techno -logy for combustion drivenmaterial handling machinery.This applies to lift-trucks,reachstackers, yard-tractorsand RoRo-/terminal-trucks inthe full range from 6 to 60 tonslifting capacity. ZF systemstechnology, tailored to users,represents excellent quality and reliability.

ZF is a partner to manufacturers of material handling vehicles throughout the world.� � � Autopogrutschik (UA) � CMHA (ROK) � CVS (I) �

Doosan (ROK) � Douglas (GB) � Fantuzzi (I) � FMC (USA) � Fresia (I) � Godrej (IND) � Hangzhou (CN) � Heli (CN) �

Hyundai (ROK) � Indital (IND) � Kalmar (S) � Kamag (D) �

Mafi (D) � Meclift (FIN) � Milan (BR) � MOL (B) � Noell (D) � Pimespo (I) � Sahand (IR) � Schopf (D) � Svetruck (S) �

Taylor (USA) � Terberg (NL) � TIL (IND) � TLD (F) � � �

Power packs for material handling

The products of the ZF-ERGOPOWERseries extend over a wide range ofinput torques: from 800 Nm for theWG 115 to 2,750 Nm for the WG 311,respectively 750 Nm for the fully auto-matic transmission WG 94, and thusmatch many different vehicles. Theshifting can be fully automatic andwithout interrupting the tractive forceor with powershift.

Special design for material handling vehicles

The ZF-ERGOPOWER transmissions WG 115 up to WG 311 as well as thefully automatic transmission WG 94have been specially designed for themost versatile applications in materialhandling with combustion engines. Byoptimum matching of transmissionhardware and electronic control, theZF-ERGOPOWER units assure soft

shift transitions in operation – a deci-sive criteria in practical applications.

User-friendly with electronic assistance

A new, particularly user-friendly fea-ture of the latest, compact ZF trans-missions is the electronic inching. Thisoffers a “creep func tion” which makesit easier to position loads with highestlevels of accuracy.

WG 211

WG 94

WG 311

WG 161

ZF-ERGOPOWER fully automatic Transmissions

Precise positioning with electronic inching

Also available in the ZF-ERGOPOWERseries: Electronic inching. By actuating a pedal the driver can re ducethe speed during operation to maneuver ina “creeper mode” without himself having todeclutch or shift gear. This enables loads to be positioned sensitively and accuratelyto the milli meter.

The system

The expansion of functions to include elec-tronic inching has become possible by theelectro-hydraulic ZF-ERGO CONTROL whichis also supplied by ZF and which ideallymatches the functions of engine, converterand transmis sion. ZF-Ergocontrol works without mechanicallinkage, but by a load sensor and the con-trol unit. The CANbus-compatible transmis-sion control unit has a diagnostic interfacewhich simplifies service and maintenance.The controller software can be programmednot only specifically to the vehicle, but alsoaccording to the application, which makesthe overall transmission package even moreuser-friendly.

The inching pressure depends on the inch pedal position in the range between min. andmax. inching pressure. When leaving the inching mode the closing pressure gradient isdependent on the engine speed.

Easy handling, short cycling time,exact positioning of the materialare just some requirements formodern material handling vehicles.

With ZF driveline technology formaterial handling, moving heavyloads could not be easier.

Pres

sure

TimeInching on Slipping Inching off

Inching pressure =f(inch pedal position)

Gradient =f(engine speed)

Direction clutch

Max. clutch pressure

Inching

Main product advantages� Electronical inching possibility available

(no mechanical linkages)� No tractive effort interruption by using

proportional valves� Logistic advantages, less different parts� High sophisticated shift quality (soft and smooth

shifting), developed with the know-how from ZF passenger car automatic

� Low noise level (high contact helical gears)� Various torque converters for different engines

available� Stiff and short rotating shafts – less deflexion� Special design for material handling application

(ratios, center drop, installation dimensions)� Durable clutch packs with increased oil flow

(optimized cooling)� For WG 261 - WG 311 up to three PTO possible� For WG 94 - WG 211 one PTO is standard� Electronic system with self diagnostic� Easy maintenance and repair

(set right bearings, no shiming)� Short and long drop gear boxes available

For various requirements and numerousclasses of material handling equipment,ZF offers a finely graded range of trans-missions.

2 WG 94 / 3 WG 94

ApplicationsLift-trucks

Product features� 2 WG 94� 2 forward and 2 reverse gears� Engine dependent PTO � Electronics package including

inching only in combinationwith CAN and rotation anglesensor

� 3 WG 94 � 3 forward and 3 reverse gears� Engine dependent in-line PTO� Electronics package including

inching only in combinationwith CAN and rotation anglesensor or with engine speedsensor (integrated in thetransmission) and rotationangle sensor

� Electronic control = 24 V� Free-wheel torque converter

ERGOPOWERWG 115/130/131/160/161/171

ApplicationsLift-trucks, terminal- and yard- tractors

Product features� For vehicles up to approx. 72 t

GVW (32 tons lifting capacity)� 3 forward and 3 reverse gears� Hydrodynamic converter

(without free-wheel)� 6 shafts and 5 clutches� Powershiftable with

proportional control� Inching electronically controlled

by EST-37 A, 24 V� Drop input / output

300 mm (short drop)500 mm (long drop)

� 1 PTO, co-axial, non-disconnectable

ERGOPOWERWG 190/191/210/211

ApplicationsRoRo-, terminal- and yard-tractors,lift-trucks, straddle carriers

Product features� For vehicles up to approx. 98 t

GVW (42 tons lifting capacity)� 3-6 forward and 3 reverse gears� Full / semi-automatic gear

shift control� Various hydrodynamic torque

converters, lock-up clutch available

� Drop input / output 190 mm (short drop)540 mm (long drop)

� 1 PTO, co-axial� Proportional controlled

powershift� Electronic inching� Integrated oil lines

ERGOPOWERWG 260/261/310/311

ApplicationsLift-trucks, reachstackers, RoRo-tractors, straddle carriers

Product features� For vehicles up to approx. 140 t

GVW (60 tons lifting capacity)� 3-5 forward and 3 reverse gears� Up to 2,750 Nm transmission

turbine torque� Fully automatic gear shift

control� Various hydrodynamic torque

converters, lock-up clutch available

� Drop input / output 380 mm (short drop)575 mm (long drop)

� Max. 3 PTO possible:1 co-axial PTO, 2 side PTO

Engi

ne p

ower

(kW

)

Turb

ine

torq

ue (

Nm

)

Lift

ing

capa

city

(to

ns)

Gro

ss v

ehic

le w

eigh

t (t

ons)

140

120

98

80

72

44

36

23

60

50

42

37

32

22

16

12

330

280

240

200

180

160

130

90

2750

2500

1700

1500

1300

1100

950

800

WG 94 WG 115 WG 131 WG 161 WG 171 WG 191 WG 211 WG 261 WG 311

Technichal data ZF-ERGOPOWER

Engine power (kW)

Engine speed (rpm)

T/M input torque (Nm)

PTO torque (Nm)

GVW (to)

Lifting capacity (to)

Center distance (mm)short-droplong-drop

90

2,600

750

400

23

10

155306

WG 94WG 94

Transmission short-droplong-drop

130

2,600

950

800

36

16

300500

WG 131WG 130

90

2,600

800

800

23

12

–500

–WG 115

160

2,600

1,100

800

44

22

300500

WG 161WG 160

180

2,600

1,300

800

72

32

300–

WG 171–

200

2,600

1,500

800

80

37

190540

WG 191WG 190

240

2,600

1,700

800

98

42

190540

WG 211WG 210

280

2,500

2,500

1,500

120

50

380575

WG 261WG 260

330

2,500

2,750

1,500

140

60

380575

WG 311WG 310

Engine Power Control via CAN possible (individual application process)

Driveline and Chassis Technology

ZF Passau GmbHDriveline Technologyfor Material Handling VehiclesD-94030 PassauGermanyPhone +49 851 494-2732Fax +49 851 494-2191sales.ac@zf.com

www.zf.com

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