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DHIM C/S
ZF Transmission 4WG190/210
Mega V
Construction equipment B/G
Product Support Team
DHIM C/S
1. Clutch Shaft “ KR”2. Power Take Off Coaxial3. Clutch Shaft “KV”4. Clutch Shaft “K2”5. Clutch Shaft “K3”6. Output flange Rear7. Output flange Converter8. Output shaft9. Transmission Pump10. Input Flange11. Converter12. Transmitter for Engine speed13. Clutch Shaft “K4”14. Converter Relief V/V15. Clutch Shaft “K1”
Lay Out (1) 4WG-190/210
DHIM C/S
1. Lifting plug
2. Drive flange
3. Transmission suspension
4. Attachment for
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 Front view (2) 4WG-190/210
DHIM C/S
1. Driving Flange
2. Cover
3. Converter Bell Housing
4. Breather
5. Transmission Case Cover
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 Side view (3) 4WG-190/ 210
DHIM C/S
1. Lifting Lugs
2. Power Take Off
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)
Lay Out Rear view (4) 4WG-190/210
DHIM C/S
21. Inductive transmitter :
Turbine
34. Speed Sensor : Output and Speedmeter
47.Inductive transmitter : Central Gear Train
48. Inductive transmitter : Engine
Measuring Point (1) 4WG-190/210
DHIM C/S
Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 EngagedClutch
Forward 1st ◆ ◆ K1,KV2nd ◆ ◆ KV,K23rd ◆ ◆ K3,KV4th ◆ ◆ K4,K3
Reverse 1st ◆ ◆ KR,K12nd ◆ ◆ KR,K23rd ◆ ◆ KR,K3
NeutralRelated Clutch K4 KR K1 K3 KV K2Location F E D C B AMeasuring Point 60 55 56 58 53 57System Pressure (bar) 16±2 16±2 16±2 16±2 16±2 16±2
Measuring Point (2)4WG-190 /210
DHIM C/S
WGV : Converter Back Pressure Valve
3~5 bar
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)
Oil Circulation (System Pressure)
DHIM C/SWorking of Proportional Valve
DHIM C/S
16bar @ Port No 65
Oil Circulation - Neutral Position (System Pressure)
DHIM C/S
9 bar
Oil Circulation - Neutral Position (Pilot Pressure)
DHIM C/S
11 bar @ Port No 51
3~5 bar @ Port No 52/63
Oil Circulation - Neutral Position (T/Q Converter)
DHIM C/SOil Circulation - Forward 1st
DHIM C/SOil Circulation - Reverse 1st
DHIM C/S
Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 EngagedClutch
Forward 1st ◆ ◆ K1,KV2nd ◆ ◆ KV,K23rd ◆ ◆ K3,KV4th ◆ ◆ K4,K3
Reverse 1st ◆ ◆ KR,K12nd ◆ ◆ KR,K23rd ◆ ◆ KR,K3
NeutralRelatived Clutch K4 KR K1 K3 KV K2
Engaged EPPR Valve Summary
DHIM C/SOil Circulation - Hydraulic Control (1)
DHIM C/SOil Circulation - Hydraulic Control (2)
DHIM C/S
KV :Clutch Forward KR: Clutch Reverse K1: Clutch 1st Speed K2: Clutch 2nd SpeedK3: Clutch 3rd Speed K4: Clutch 4th SpeedIN : Input Out : Out Put
Gear Schema - 4WG190/210
DHIM C/SPower Flow - Forward 4WG 190/210
DHIM C/SPower flow - Reverse 4WG190/210
DHIM C/S
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
MEGA-V T/M Electric Control System
DHIM C/SElectric system
DHIM C/S
-Output Propellar shaft speed-Travel Speed display signal-LIS system (over 8 km)
1.0~1.52~51.0~12.5Speed
-Output torque Control signal-Shifting quality (max 1.6sec)-Keep the original gap
0.5~0.81050 ±
10%30Hz~50kHz0.45~7.0Engine
& Turbine
Gap(mm)Resistance(Ω)FrequencyVolt(V)Remark
SpecificationSensor
♣
Sensors
♣Pressure Regulator in Transmission Control Block
0.8 ~ 9.0
Output Press(bar)
Within 1.69.51.919500100Y1~Y6
EngagedNeutralEngagedNeutral
Shifting(sec)
Voltage(VDC)Resistance(Ω)
Input Current(mA)Regulator
♣Condition of Pressure Regulator Operation1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C
Description of Components
DHIM C/S
♣
Transmission Oil Temperature Sensor (built in TCV)
- 1st, 2nd Speed mode only-30 ~ -10 degree C (T/M oil)
- Travels Normally↑
-10 degree C (T/M oil)
- Parking Brake Engaged↓
-30 degree C (T/M oil)-Output Voltage :5.2 ~ 24V-Resistance : 1000 ~ 1500 Ω-No Buzzer
-Error Code Display only-Travels Normally
Open or Short Circuit
RemarkFunctionCondition
♣
Others
1. TCU (Transmission Control Unit) Working Voltage : 18 ~ 32 VDC
2. Kick Down
1) Manual Mode : 2nd -> 1st Speed Change Only
2) 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
Description of Components
DHIM C/S
XXXXXX
A voltage between each terminal ( # 58,10,32,55,9,51) and ground : 1.9 V
Electric system (Neutral)
DHIM C/S
XXXX
A voltage between each terminal # 32, 9 and ground : 9.5 VThe voltage between each terminal #58,10,55,51 and ground : 1.9 V
Electric system (Forward 1st)
DHIM C/S
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 2nd -> 1st - Manual mode)
DHIM C/S
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 (Down Shift - Auto mode)
DHIM C/S
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 (Transmission Cut Off )
DHIM C/S
The AEB has the task to compensate tolerances (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 timelevel of the filling compensating pressure
No Order Displaymessage
Remark
1 Warm up transmissionabout 10 to 20 minutes
2 Turn off ignition key3 Plug in AEB starter to
AEB connector locatedat the seat base closestto the cab door
4 Put T/M gear selectorLever to Neutral position
5 Engage park brake6 Start Engine “PL“ TCU must recognize
“PL” for at least 2secbefore you pressAEB starter button
7 On idling RPM “PL”8 Press button of the AEB
Starter“ST” The button must not
be released beforeTCU has started theAEB or quit withan error code(see Error code list)
9 Hold button until AEB hasbeen started
“K1”(Information about the AEB state)
TCU has started theAEB, and goes onadjusting K1, K2,…,KR. (Button may bereleased fromstarting)
10 Wait until AEB hasbeen finished
“OK”(AEB has been successful)
11 Turn off ignition andunplug AEB Starter
Electric system (AEB )
DHIM C/S
Symbol Meaning RemarksPLSTK1..K4,KV,KR_ and Kx≡ and Kx
OK calibration for all clutches finished Transmissions stays in neutral, have to restart theTCU (ignition off/on) after removing AEB-Starter
STOP AEB canceled (activation Transmissions stays in neutral, have to restart thestopped) TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx Transmissions stays in neutral, have to restart thecan't be calibrated TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, Transmissions stays in neutral, have to restart theAEB finished TCU (ignition off/on)
↑ E Engine speed too low, E/G RPM should be raised↓ E Engine speed too high E/G RPM should be down↑ T Transmission oil Warm up Transmission
temperature too low↓ T Transmission oil Cool down Transmission
temperature too highFT T/M temp not in defined T/M stays in neutral, have to
range during calibration restart the TCU (key off/on)FB Operating mode not T/M stays in neutral, have to
NORMAL or T/M temp restart the TCU (key off/on)sensor defective or storingof Calibrated values toEEPROM-has failed
FO Output speed not zero Transmissions stays in neutral, have to restart theTCU (ignition off/on)
FN Shift lever not in Neutral Transmissions stays in neutral, have to restart theposition TCU (ignition off/on)
FP Parking brake not applied Transmissions stays in neutral, have to restart theTCU (ignition off/on)
STOP AEB - Starter was used Transmissions stays in neutral, have to restart theincorrect or is defective TCU (ignition off/on)
fast fill time determination of clutch Kxcompensating pressure determination of clutch Kx
AEB - Starter is plugged at the diagnostic plugAEB Starter button is pressedCalibrating each clutch K1..K4,KV,KRWait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R
Electric system (AEB DISPLAY )
DHIM C/S
Shaft rpm = (Hz/Z) X 60You can measure the frequency with an electric multi meter.
Z
Hz
Shaft
Frequency of Speed sensor
DHIM C/S
- Hz Frequency from Speed Sensor - Z Number of Ring gear Teeth- r total Total Reduction Ratio of Axle (r diff X r hub)- R Tire Radius in meter
Machine Speed (km/hr)
Hz 1 3600 (sec/hr)= x x 2πR x
Z r total 1000 (m/km)
M160-V M200-V M250-V M300-V M400-V M500-V
Z 53 53 44 44 66 66
Machine Speed