LG958L Training material

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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Section I Structure and Principle of Torque Converter

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Figure 4-1 Diagram of Transmission System for LG958L Loader

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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Figure 4-2 Internal Structure Diagram of ZF Torque Converter

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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Section II Structure and Principle of Transmission

1. Characteristics of ZF transmission:
4 forward gears and 3 reverse gears
High working efficiency
Low repair rate
Ultra-long service life
Low fuel consumption
Low noise

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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Rear view of transmission

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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Press once KD button

Use of KD button function of ZF transmission in actual applications

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Electric control box of ZF

transmission

Gearshift valve of ZF transmission

(including pressure measuring point)

M4 Oil pipe to twostage pressure pilot

control valve
1Mpa
reducing valve
Clutch K3
Two-stage
pressure control
valve
System
pressure
Clutch K1

During electric welding of

main unit for repair, unplug
the connector of electric
control box
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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

Clutch KV and K1 of ZF transmission

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Schematic diagram of clutch

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Clutch KV and K1 of ZF transmission

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Clutch KR and K2 of ZF transmission

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Clutch K3 and K4 of ZF transmission

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The travel for pistons of various clutches is 1.8~2.4mm.

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The axial clearance is 0.1~0.3mm after assembly of various shafts.

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3. Route diagram for various gears of ZF transmission

Internal structural diagram of ZF transmission

Route diagram for various gears of ZF transmission

(4 forward gears and 3 reverse gears)
1st forward
Output

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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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Section III Oil Supply and Lubrication System of ZF Transmission

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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Section IV Electric Control System of ZF Transmission

1. ZF built-in electric system

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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2. ZF built-in harnesses and connectors

Gearshift operating

Yellow

lever connector

Blue

Cable electric control

Purple

box connector
Sensor 2

(I)

Red

Green

Grey

Lever 5
Black
Pink
Solenoid valve connector

Sensor 1

Complete machine wire connector

Lever 8

Lever 7
Lever 9
Lever 10
Lever 4

Lever 6

Starter interlocker 584

Lever 2

Pressure switch 600

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3. ZF peripheral electric system

To electric control box

Intermediate relay
(power cutoff)

Intermediate relay
(starter interlocker)

Intermediate
relay
(reversing)

Parking brake indicator switch

To starter relay To brake

signal terminal lamp
To starter relay terminal G2
To instrument panel electric control
box working indicator

Brake switch (left)

To brake lamp
Brake switch (right)

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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

Neutral gear locking switch

Neutral start interlocking

function
Neutral locking function.
Rotate the red neutral
gear locking switch.
Lock direction
Power cutoff function
during braking at 1st gear
or 2nd gear.
Kick-down function (KD
button)

Gearshift operating lever of ZF transmission

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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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5. Electric control box

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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.

1) Sequence of solenoid valve: 4, 3, 5, 2, and 1 from top to bottom.

2) If the O-ring is not properly seated, it will easily cause oil leakage at
side cap.
3) The resistance of solenoid valve is 9010.
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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

Transmission speed sensor

Resistance of speed sensor:

1020100

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Section V Operation and Maintenance of ZF Transmission

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

Cold 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

(1) Preparations and maintenance before driving

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Before the operation of the transmission, make sure to add an

appropriate amount of lubricating oil as per the specified specification
of lubricating oil. While adding oil to the transmission for the first
time, make sure to take into consideration that the oil radiator, filter,
and connecting pipeline must be fully filled with oil. Therefore, the
lubricating oil amount to be added for the first time will be much
more than the lubricating oil amount to be added during normal
maintenances.

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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(2) Driving and gearshift

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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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(3) Driving and gearshift

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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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(2) Replace the oil.

Make sure to replace the oil for the first time after the machine is working
for the first 100 hours. Afterwards, replace the oil once every 1,000 working
hours or once a year. At the replacement of oil, park the vehicle at a level
place. Under the working temperature of the transmission, take out the oil
drainage plug and seal ring and fully drain the used oil.
- Start the engine and idle run the engine.
- Shift the transmission operating lever to neutral gear N.
- Add oil to the upper mark of the oil range Cold.
- Set the parking brake at safe place.
- Shift to every gear for once.
- Check the oil level and when necessary add the oil.
Part Name
Transmission
(4WG200)

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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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(3) Replace oil filter.

Make sure to replace ZF fine filter at the replacement of oil

each time. Replace as per the following requirements:

- Apply a thin film of oil onto the seal ring.

- 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.

- Start the engine.

- Idle run the engine (at approximate 1,000r/min). When the

transmission oil temperature reaches working temperature,
check the transmission oil level.
- Check whether the filter is tightened. If necessary, tighten again
with hand.

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(4) Assembly precautions for ZF transmission:

I. Fitting and connection between ZF transmission and engine
1. Wipe clean the anti-rusting oil from the engine flywheel and the inside of
flywheel housing to be fitted.
2. Place the transmission at the fitting station and disassemble the fixing wood
plate from the torque converter middle flange on the transmission (It's
absolutely prohibited to slide outward the torque converter and its middle
flange).
3. While fitting and connecting the transmission with engine, without moving the
transmission, fit the flywheel housing of engine with the torque converter
connecting housing on the transmission and ensure that the middle flange of
torque converter enters into the junction surface of the engine flywheel.

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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III. Installation of torque converter temperature sensor

1.

While installing the temperature sensor at the oil temperature measuring

point of the torque converter, upon detection that the top of the sensor is
pushed against the core of backpressure valve, do not forcibly screw in the
sensor. Please timely notify the technician to solve the malfunction, in order
to prevent the damage of sensor and valve core due to interference.

IV.

Fluid within side cap of gearshift operating valve

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.

Do not open the side cap of gearshift operating valve at will.

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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.

VII. Electric control box

1.
2.

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At the time of electric welding, unplug the connector of electric

control box to disconnect the electric control box from circuits and
prevent the burnout of electric control box.
Guard the electric control box against moisture and rainfall.

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Section VI Cause Judgment and Troubleshooting

for Common Malfunctions of ZF Transmission
1. No gear, though the complete machine can be started.

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Check oil level

Check the cable for presence of worn damage.

Check the connectors and fuses

Check whether the power voltage is at a stable normal value.

Check the parking brake for normal functioning.

Check for normal power connection between engine and torque

converter.
Check for normal gearshift oil pressure.

Check for normal functioning of gearshift operating lever.

Check for normal functioning of solenoid valve.

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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

Check cable connectors for normal connections.

Check cables for worn damage.

Check speed sensor for normal functioning.

Check lever for normal functioning.

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.

Check pressure sensor for normal functioning.

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4. Noise of transmission
Check oil level

Check the connecting bolts between transmission and frame

and engine for presence of looseness.
Check the drive shaft and its support for normal functioning.
Check the hydraulic pump for abnormality.

Check the articulations for normal functioning.

5. Weak complete machine
Check oil level

Check whether the gearshift pressure is at 1.6~1.8MPa.

Check for normal power of engine.

Check the oil for improper trademark, deterioration, and

presence of air bubble.

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THE END

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