Off-Road Transmissions

Repair Instruction and Axle Systems

Division

REPAIR INSTRUCTIONS 1-2

____________________________________________________________________________________________________________________________-

ZF – ERGOPOWER
4/6 WG-110

REFERENCE
For information concerning description, installation instructions, operation and maintenance, see
respective Operating Instructions, ZF-Ordering-No. 5872 196 002.
_____________________________________________
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau

Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous réserve de modifications techniques!
1.Auflage / 1.Edition
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

PREFACE

This documentation has been developed for skilled staff trained by the ZF Passau for the repair and
maintenance works on ZF-units.

Documented is a ZF-serial product representing the design state at the time of the edition.

However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.

Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.

The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

Here, all operations are carried out for you with utmost care and reliability.

Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of
the applicable contractual conditions.

Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.

ZF Passau GmbH

Off-Road Transmissions
and Axle Systems
Division
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

GENERAL

The Service Manual covers all works required for dismantling and the pertaining installation.

When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.

Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:

REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!

CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
By no means, Molykote is permitted to be used.
Lined plates must not be washed. They must be cleaned with a leather cloth.

DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

Structure of the Repair Manual

The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.

Important information on industrial safety

Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.

The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.

The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.

The following safety references are used in the present Repair Manual:

) Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc..

CAUTION Is used, if a deviating and improper working procedure can

damage the product.

Is used, if lacking care can lead to personal injury or danger to

DANGER life.

___________________________________________________

REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE

CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description..

REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again. .
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Densité lineaire en kg/m; Densité superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Unité Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Masse
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION

25,40 mm = 1 in ( inch)

1 kg ( Kilogramm ) = 2,205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5,560 lb / in ( pound per inch )

1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per square inch lbf/in2 )

=
0,070 bar ( 0,071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4,456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )

3,785 Liter = 1 Gallon ( US )

=
1609,344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273,15 Kelvin
 Off-Road Transmissions
Repair Instruction and Axle Systems
Division

TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148

Friction value: µ total= 0,12 for screws and nuts without after-treatment as well as phosphatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following List:

Metric ISO-Standard thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine thread DIN 13, page 13
Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12 x 1,5 83 120 145
M 14 x 1,5 135 200 235
M 16 x 1,5 205 300 360
M 18 x 1,5 310 440 520
M 18 x 2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1,5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1,5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1,5 3450 4900 5700
M 39 x 3 3200 4600 5300
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Preface

The present Documentation has been developped for skilled personnel which has been trained
by the ZF for the Maintenance and Repair operations on ZF-units.
However, because of technical development of the product, the Maintenance and Repair of
the unit in your hands may require differing steps as well as also different setting and test
data.

This Manual is based on the technical state at the printing.

At the preparation, every possible care has been taken to avoid errors.
However, we are not liable for possible mistakes concerning the representation and the des-
cription.

We are reserving ourselves the right of modifications without previous information.

The responsibility lies with the owner and the user, to pay attention to the safety indications,
and to carry out the Maintenance operations according to the prescribed Specifications.

The ZF is not liable for faulty installation, incorrect treatment, insufficient Maintenance, im-
pro-perly and unskilled performed works, and for the subsequential damages resulting from it.

It is imperative to pay attention to the corresponding Specifications and Manuals of the Vehi-
cle Manufacturer.

Important Informations concerning the technical reliability and reliability in service are ac-
cen-tuated by the following Symbols:

) Valid for Instructions which must be observed at the Maintenance, the Perfor-
mance or the Operation of the vehicle !

Is inserted at working and operating procedures which have to be exactly res-

pected to avoid a damage or destruction of the unit or to exclude a danger to
persons !

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TABLE OF CONTENTS
Indentification Plate
IMPORTANT INSTRUCTIONS

I. DESCRIPTION
1.1 Function of the Converter
1.2 WK
1.3 Powershift transmission
1.4 Transmission control
1.5 Controllers
1.5.1 General
1.5.2 Controller VTS-3
1.5.3 Controller D7
1.5.4 DW 3
1.5.5 Ergo II
1.6 Display
1.6.1 General
1.6.2 Possible Indications on the Display
1.6.3 Error code definition
1.7 Electronic control unit TCU
1.8 Electronic control for the ZF-Powershift transmission
1.8.1 General
1.8.2 Description of the Basic functions
1.8.3 AEB (Automatic determination of the filling parameters)
1.8.4 1.8.9 Various function
1.9 Interaxle differential
1.9.1 Description
1.9.2 Function
1.10 Front axle disconnect
1.11 Retarder
1.11.1 General
1.11.2 Layout and Functions of the Retarder

II. INSTALLATION SPECIFICATION

III. OPERATION
3.1 Driving preparation and Maintenance
3.2 Driving and Shifting
3.3 Cold start
3.4 Transmission control in the Driving range Automatic
3.5 Stopping and Parking
3.6 Towing
3.7 Oil temperature
3.8 Shifting of the various outputs

IV. MAINTENANCE
4.1 Oil grade
4.2 Oil level check
4.3 Oil change and Filter replacement intervals
4.3.1 Oil change and Oil filling capacity
4.3.2 Filter replacement

V. DIAGNOSTIC SYSTEMS
5.1 General
5.2 MOBIDIG 2001
5.3 Laptop Version
5.4 Multi-System 5000

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ANNEX, comprising:

Tables: 4 WG 190/210

1 Layout 4 WG-190/210

Installation view 4 WG-190/120

1 Front view - Direct installation
2 Front view - Separate mounting
4 Rear view - Standard version
5 Rear view - With disc brake
6 Rear view - With 1. and 2. power take-off

7 Schedule of measuring points and connections 4 WG-190/210

8 Oil circuit diagram 4 WG-190/210 (Forward 1st speed)

9 Electro- hydraulic control with proportional valves

10 Power flow 4 WG-190/210 Forward/Reverse Speed

11 4 WG-190/210 Fully automatic control EST-37

Circuit diagram - 6029 717 040 –

12 Controller DW-3

13 Controller ERGO II

14 Type plate

Abbreviations used in the text:

Abbreviation Description
EST-37 Ergocontrol
AEB Automated determination of the filling parameters
TCU Electronic control unit

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APPENDIX, composed of:

Tables: 6 WG 190/210
1 Layout 6 WG-210

2 Layout 6 WG-210 with retarder

Installation view 6 WG-210 – Separate installation with WK and Retarder
3A Front view
3B Side view
3C Rear view

Installation view 6 WG-210 – Separate installation with disk brake

and without WK
4A Front view
4B Side view
4C Rear view

Installation view 6 WG-210 – Separate installation with axle disconnection

and WK
5A Front view
5B Side view
5C Rear view

Installation view 6 WG-210 – Separate installation with interaxle differential

and WK
6A Front view
6B Side view
6C Rear view

Installation view 6 WG-210 – Separate installation with axle disconnection and

WK-Valve – Side-mounting
7A Front view
7B Side view
7C Rear view

Installation view 6 WG-210 – Direct mounting with axle disconnection

8A Front view
8B Side view
8C Rear view

9 Schedule of measuring points and Connections 6 WG-210 without WK

10 Oil circuit diagram 6 WG-210 without WK – Forward 1st Speed -

11 Schedule of measuring points and Connections 6 WG-210 with WK

12 Oil circuit diagram 6 WG-210 with WK – Forward 1st Speed -

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13 Schedule of measuring points and Connections 6 WG-210 with WK and retarder

14 Oil circuit diagram 6 WG-210 with WK and retarder – Forward 1st Speed -

15 Gearbox diagram 6 WG-210

16 Power flow 6 WG-210 – Forward speeds -

17 Power flow 6 WG-210 - Reverse speeds -

18 Electrohydraulic shift control with Proportional valves

19 6 WG-210 fully-automatic Control unit EST-37 – Standard

Circuit diagram – 6029 717 039 –

20 6 WG-210 fully-automatic Control unit EST-37 – Crane vehicle

Circuit diagram – 6029 701 057 –

21 Controller VTS-3

22 Controller D7

Abbreviations in the Text:

Code Description
WK Converter lock-up clutch
EST-37 Ergocontrol
AEB Automatic determination of the filling parameters
TCU Electronic control unit

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TECHNICAL DATA 4 WG 190/210

WG-190 WG-210

Engine power: max. KW* ........... 190 210

Turbine moment: max. Nm* ........... 1 500 1 650

Engine speed: max. min-1* ........... 2 600

Starting torque multiplication: ............ 2,0 bis 3,0

Engine-dependent Power take-offs:

Torque: Nm ........... 800
Speed: n ........... 1 x nEngine

Mass (without oil): kg about** ........... 470

* = dependent on Vehicle type and application

** = dependent on the Transmission version

Description:
The ZF-Transmissions 4 WG-190/210 are composed of a hydrodynamic torque converter
and a rear-mounted multi-speed powershift transmission with integrated transfer case (see

Table- 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself
to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via uni-
versal shaft) with DIN-, Mechanic- or Spicer-input flange.
The transmission can be shifted manually or fully-automatically by means of the Electronic
unit EST-37.

Torque converter:
Unit size W 300 and 340 with torque multiplication.

Powershift transmission:
4 Forward speeds and 3 Reverse speeds.

Output:
The powershift transmission has between input and output shaft a center distance of 540 mm,
and can be equipped with the following components:
- with output flanges to the front and rear axle for different universal shafts
- on the rear output (rear-side) with a disk brake as parking brake
- on the converter side with axle disconnection.
Power take-off:
For the drive of an external oil pressure pump, an engine-dependent, coaxial power take-off is
planned.
It allows the attachment of pumps with „SAE-B and C“ Connection.
If desired engine dependent power take- off are available also up to 2.
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Transmission accessories:
Upon request, the transmissions can be additionally equipped with the following components:
- Emergency steering pump with a feed rate of 16 cm 3/rev. or 32 cm 3/rev.
- Electronic speedometer signal, here the Electronic unit EST-37 offers a speedometer sig-
nal.

Transmission ratio (mechanical)*

SPEED DRIVING Ratio 4 WG-190/210

DIRECTION
1 Forward 3,632
2 Forward 2,089
3 Forward 1,072
4 Forward 0,636
1 Reverse 3,444
2 Reverse 1,981
3 Reverse 1,017

* = According to the Transmission version, other ratios are also possible.

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TECHNICAL DATA 6 WG 210

Engine power: max. KW ------------------------------ 210*

Turbine moment: max. Nm ------------------------------ 1 650*

Engine speed: max. min-1 ------------------------------ 2 600*

Starting torque multiplication: ------------------------------ 1,55 to 3,0

Engine-dependent Power take-offs:

Torque: Nm ------------------------------ 800
Speed: n ------------------------------ 1 x nEngine

Mass (without oil): kg about ------------------------------ 540**

* = dependent on Vehicle type and application

** = dependent on the Transmission version

Description:
The ZF-Transmissions 6 WG-210 are composed of a hydrodynamic torque converter and a
rear-mounted multi-speed powershift transmission with integrated transfer case (see Table 1).

The torque converter is a wear-free starting device which is infinitely variable adapting itself
to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via uni-
versal shaft) with DIN-, Mechanic- or Spicer-input flange.
Between engine and torque converter, a Retarder can be arranged (fluid brake) whereby a
good braking effect will be achieved in all speeds.
The transmission can be shifted manually or fully-automatically by means of the Electronic
unit EST-37.

Torque converter:
Unit size W 300 and 340 with torque multiplication according to the version and a WK.

Powershift transmission:
6 Forward speeds and 3 Reverse speeds.

Output:
The powershift transmission has between input and output shaft a center distance of 540 mm,
and can be equipped with the following components:
- with output flanges to the front and rear axle for different universal shafts
- on the rear output (rear-side) with a disk brake as parking brake
- on the converter side with axle disconnection
- with an integrated, lockable interaxle differential

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Power take-off:
For the drive of an external hydraulic pressure pump,an engine-dependent, coaxial power
take-off is existing, upon request also disconnectable.
It allows the mounting of pumps with SAE-C connection.

Transmission accessories:
Upon request, the transmissions can be additionally equipped with the following components:
- Emergency steering pump with a feed rate off 16 cm3/rev. or 32 cm3/rev.
- Electronic speedometer signal for:
- Construction site vehicles here, the Electronic unit EST-37 offers a speedometer signal.
- Road vehicles, the signal required for the speedometer interpretation will be picked-up on
the output side by a pulse generator (e.g. is needed for trip recorders).
For this, a frequency divider from the Customer side is necessary.
- Separate mounting of the ZF-Fine filter.

Transmission ratio (mechanical)*

SPEED DRIVING DIRECTION Ratio

1 Forward 5,562
2 Forward 3,615
3 Forward 2,255
4 Forward 1,466
5 Forward 0,842
6 Forward 0,613
1 Reverse 5,274
2 Reverse 2,138
3 Reverse 0,894

* = According to the Transmission version, other ratios are also possible.

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INSCRIPTIONS ON A ZF-MODEL INDENTIFICATION

PLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION

1 = Gearbox type
2 = Gearbox Serial-No.
3 = ZF-Parts List-No.
4 = Total ratio of the Gearbox
5 = Oil (Oil specification)
6 = List of lubricants
7 = Oil capacity
8 = Customer no.

1 2
3 4
5 6
7
8

NOTES REGARDING THE SPARE PARTS ORDERS:

When ordering genuine ZF-Spare Parts, please indicate:

1. = Gearbox type
2. = Serial-No. See Model identification Plate!
3. = ZF-Parts List-No.
4. = Mark and type of vehicle
5. = Denomination of the spare part
6. = Spare parts-No.
7. = Way of transport

When all of the above required indications are considered, errors in the delivery of
spare parts Orders can be avoided!

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IMPORTANT INSTRUCTIONS

Oil level check (see 4.2):

In the cold start phase, the engine must be running about 2 – 3 minutes at idling
speed and the marking on the oil dipstick must then be lying above the cold start
mark.
The oil level check in the transmission must be carried out at engine idling speed
and operating temperature of the transmission (80° to 90° C).

At stationary engine, the oil level in the transmission is rising essentially, accord-
ing to the installation conditions !

At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF rec-
ommends to start the autonomous calibration of the shifting elements (AEB).

The autonomous calibration of the shifting elements (AEB) must be started after
the initial installation of the transmission and the Electronics in the vehicle at the
Vehicle Manufacturer and after every replacement of the transmission, the elec-
trohydraulic control or the TCU in case of a failure.

Put the Controller at the starting of the engine always to the Neutral position.
At running engine and transmission in Neutral, the parking brake must be en-
gaged or the service brake be actuated, to prevent the vehicle from rolling.

Prior to every start off, loosen the parking brake.

The engagement of the speed out of Neutral is only possible under the pro-
grammed transmission input speed (turbine speed).

Neutral position of the selector switch at higher vehicle speeds (above stepping
speed) is not admissible.
Either a suitable gear is to be shifted immediately, or the vehicle must be
stopped at once.

Reversing (Standard):
The reversing must be performed at standstill, resp. at very low driving speed.
Above the programmed reversing limit, the vehicle will be shifted to Neutral by
the Electronic unit EST-37, and the vehicle continues rolling in the old driving
direction.
The gear of the new driving direction will be only engaged when the pro-
grammed reversing speed and the transmission input speed (turbine speed) has
fallen below.
The programming is customized and can therefore be different from standard.
Therefore, the exact procedure must be taken from the Operating Instructions
of the respective Vehicle Manufacturer !

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At stopped engine, there is on the Controller, despite a preselected gear, no

power flow between transmission and engine, i.e. the transmission is in the idling
position.
The parking brake must therefore be completely actuated !
When leaving the vehicle, secure it additionally by brake blocks !

The towing speed must in no case be higher than 10 km/h, the towing distance
not longer than 10 km.
It is imperative to observe this Specification because otherwise the transmission
will be damages due to insufficient oil supply !
At a longer distance, the best solution would be to transport the vehicle with a
Low loader.

Operating temperature behind the converter at least 65° and 100° C in continu-
ous operation, a short-time increase up to max. 120° C is permitted.
Temperature in the sump 60° - 90° C.

In case of irregularities on the transmission, put the vehicle out of service and
ask for Specialists.

Protective measures for the ZF-Electronics at electrical operations on the

vehicle:

At the following operations, the ignition must be switched off and the control
unit plug must be pulled off from the ZF-Electronics:

∗ At any kind of electrical operations on the vehicle.

∗ At welding operations on the vehicle.
∗ At insulation tests on the electric system.

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L A Y O U T 4 W G -1 1 0
T A B L E -1 1 2 3 4 5

1 = E n g in e c o n n e c tio n
A = S e p a ra te m o u n tin g – d riv e n v ia u n iv e rs a l s h a ft
B = D ire c t m o u n tin g – d riv e n v ia fle x p la te 6
2 = C o n v e rte r
3 = T ra n s m is s io n p u m p
4 = O il in ta k e fla n g e A
5 = In p u t " IN " 7
6 = A tta c h m e n t p o s s ib ility P o w e r ta k e -o ff; c o a x ia l e n g in e -d e p e n d e n t
B
7 = C lu tc h s h a ft " K V /K 1 "
8 = C lu tc h s h a ft " K R /K 2 " p

9 = E m e rg e n c y s te e rin g p u m p
K V

A = w ith e m e rg e n c y s te e rin g p u m p 8
B = w ith o u t e m e rg e n c y s te e rin g p u m p
1 0 = D ru m b ra k e
1 1 = O u tp u t (re a r) " O U "
1 2 = O il s u m p G e a rb o x d ia g ra m
1 3 = G e a rs h ift s h a ft fo r a x le d is c o n n e c tio n
1 4 = O u tp u t (c o n v e rte r s id e ) " O U " 1 6 5 3 .3 8 0 K 3

- 7 ,5
A 9
B
°

A = w ith o u t a x le d is c o n n e c tio n A N K 4

B = w ith a x le d is c o n n e c tio n 1 0
K V /K 1
1 5 = L a y sh a ft " L S "
1 6 = C lu tc h s h a ft " K 4 /K 3 " K R /K 2
1 5 1 1
A 7 ,5
°

K 4 /K 3
V W B

A B

1 4 1 3 1 2
IN S T A L L A T IO N V IE W 4 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
F R O N T V IE W 1
T A B L E -2 A
1  = D ire c t m o u n tin g v ia d ia p h ra g m
2  = E le c tro -h y d ra u lic c o n tro l
3  = T ra n s m is s io n s u s p e n s io n h o le s M 2 0 2
4  = P re s s u re -o il p ip e K 3
5  = P re s s u re -o il p ip e K 4
6  = O il s u c tio n p ip e
7  = C o a rs e filte r
8  = O il d ra in p lu g M 3 3 x 2 1 3
9  = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k
1 0 = In p u t fla n g e – F ro n t a x le (c o n v e rte r-s id e )
1 1 = M o d e l id e n tific a tio n p la te
1 2 = P re s s u re -o il p ip e K V
1 2
1 3 = P re s s u re -o il p ip e K 1 3
3

4
Z F

5
1 1 3
6
1 0

9 8 7
IN S T A L L A T IO N V IE W 4 W G -1 1 0 – D IR E C T M O U N T IN G
S ID E V IE W 1 2 3 4
T A B L E -2 B

1 = D ire c t m o u n tin g v ia fle x p la te

2 = C o n v e rte r
3 = C o n v e rte r b e ll h o u s in g 5
4 = O il in ta k e p ip e
5 = E le c tro -h y d ra u lic c o n tro l A F

6 = Z F fin e filte r B E

7 = O u tp u t (re a r) C D
8 = O u tp u t (c o n v e rte r s id e )
9 = P re s s u re o il p ip e " K 4 "
1 0 = P re s s u re o il p ip e " K 3 " 6
1 1 = P re s s u re o il p ip e " K 1 "
1 2 = P re s s u re o il p ip e " K V " 1 2
1 1
1 0
7
9
8
IN S T A L L A T IO N V IE W 4 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
R E A R V IE W - S T A N D A R D V E R S IO N 1 2
T A B L E -2 C
1 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
2 = liftin g lu g s
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = A tta c h m e n t p o s s ib ility fo r e m e rg e n c y s te e rin g p u m p 8
5 = O u tp u t fla n g e – re a r - s id e
6 = O il d ra in p lu g M 3 3 x 2
7 = Z F fin e p re s s u re filte r
8 = E le c tro -h y d ra u lic c o n tro l
7 3

3 4
3

5
3

6 3
IN S T A L L A T IO N V IE W 4 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
R E A R V IE W - W IT H D R U M B R A K E 1 2
T A B L E -2 D
1 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
2 = L iftin g lu g s
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = A tta c h m e n t p o s s ib ility fo r e m e rg e n c y s te e rin g p u m p 9
5 = C o n tro l le v e r – D ru m b ra k e
6 = O il d ra in p lu g M 3 3 x 2
7 = O u tp u t fla n g e w ith d ru m b ra k e – re a r s id e
8 = Z F fin e p re s s u re filte r
9 = E le c tro -h y d ra u lic c o n tro l 8 3

3 4
3
7
5
3

6 3
IN S T A L L A T IO N V IE W 4 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
R E A R V IE W - W IT H D IS C B R A K E 1 2
T A B L E -2 E

1 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
2 = L iftin g lu g s
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0 8
4 = A tta c h m e n t p o s s ib ility fo r e m e rg e n c y s te e rin g p u m p
5 = O li d ra in p lu g M 3 3 x 2
6 = O u tp u t fla n g e w ith d ru m b ra k e – re a r s id e
7 = Z F fin e p re s s u re filte r
8 = E le c tro -h y d ra u lic c o n tro l 7 3

3 4
3

5
3

6 3
IN S T A L L A T IO N V IE W 4 W G -1 1 0 – S E P A R A T E M O U N T IN G
F R O N T V IE W 1
T A B L E -3 A

1 = In p u t fla n g e – d riv e n v ia u n iv e rs a l s h a ft 2
2 = E le c tro -h y d ra u lic c o n tro l
3 = T ra n s m is s io n su sp e n s io n M 2 0
4 = P re s s u re o il p ip e " K 3 "
5 = P re s s u re o il p ip e " K 4 "
6 = O il in ta k e p ip e
7 = C o a rs e filte r
8 = O il d ra in p lu g M 3 3 x 2 1 3
9 = In p u t fla n g e ( c o n v e rte r s id e )
1 0 = M o d e l id e n tif ic a tio n p la te 1 2
1 1 = O il le v e l tu b e w ith o il d ip s tic k 3
1 2 = P re s s u re o il p ip e " K V "
1 3 = P re s s u re o il p ip e " K 1 " 3

4
1 1
5
1 0 3
6

8 7
 IN S T A L L A T IO N V IE W 4 W G -1 1 0 – S E P A R A T E M O U N T IN G
S ID E V IE W 1 2 3 4
T A B L E -3 B

1 = In p u t fla n g e – d riv e n v ia u n iv e rs a l s h a ft
2 = C o n v e rte r c o n n e c tin g h o u s in g
3 = C o n v e rte r b e ll h o u s in g 5
4 = O il in ta k e p ip e
5 = E le c tro -h y d ra u lic c o n tro l A F
6 = O u tp u t (re a r) B E
7 = O il le v e l tu b e w ith o il d ip s tic k
8 = O u tp u t (c o n v e rte r s id e ) C D

9 = P re s s u re o il p ip e " K 4 "
1 0 = P re s s u re o il p ip e " K 3 "
1 1 = P re s s u re o il p ip e " K 1 "
1 2 = P re s s u re o il p ip e " K V " 1 2
1 1
1 0
6
9
8
7
IN S T A L L A T IO N V IE W 4 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
R E A R V IE W - S T A N D A R D V E R S IO N 1 2
T A B L E -3 C

1 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
2 = L iftin g lu g s
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = A tta c h m e n t p o s s ib ility fo r e m e rg e n c y s te e rin g p u m p 8
5 = O u tp u t fla n g e – re a r-s id e
6 = O il d ra in p lu g M 3 3 x 2
7 = O il s u c tio n p ip e
8 = E le c tro -h y d ra u lic c o n tro l
7 3

3 4
3

5
3

6 3
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 4 W G -1 1 0
W IT H Z F F IN E F IL T E R D IR E C T IN S T A L L E D A T T H E T R A N S M IS S IO N
T A B L E -4
T h e m a r k e d p o s itio n s ( e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e T a b le - 5 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s s io n (a b o u t 8 0 ° - 9 5 ° C )!
X
N O . D E N O M IN A T IO N O F T H E P O S IT IO N C O N N E C T IO N M A R K IN G O N T H E
V A L V E B L O C K
M E A S U R IN G P O IN T S F O R H Y D R A U L IC O IL A N D T E M P E R A T U R E :
5 1 = In fro n t o f th e c o n v e rte r – o p e n in g p re s s u re 1 1 b a r M 1 0 x 1 H
5 2 = B e h in d th e c o n v e rte r – o p e n in g p re s s u re 1 ,5 b a r M 1 4 x 1 ,5
5 3 = C lu tc h F o rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h R e v e rs e 1 6 + 2 b a r K R M 1 0 x 1 E
5 6 = C lu tc h 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C lu tc h 1 6 + 2 b a r K 2 M 1 0 x 1 A A F
5 8 = C lu tc h 1 6 + 2 b a r K 3 M 1 0 x 1 C
B E
6 0 = C lu tc h 1 6 + 2 b a r K 4 M 1 0 x 1 F
6 3 = B e h in d th e c o n v e rte r M 1 4 x 1 ,5 C D
T e m p e ra tu re 1 0 0 ° C ; s h o rt-tim e 1 2 0 ° C
6 5 = S y s te m p re s s u re 1 6 + 2 b a r M 1 0 x 1 K
M E A S U R IN G P O IN T S F O R D E L IV E R Y R A T E S :
1 5
1 6
=
=
C o n n e c tio n to th e h e a t e x c h a n g e r
C o n n e c tio n fro m th e h e a t e x c h a n g e r
M 2 6 x 1 ,5
M 2 6 x 1 ,5
3 4
IN D U C T IV E T R A N S M IT T E R S , S P E E D S E N S O R A N D S W IT C H E S :
6 = In d u c tiv e tra n s m itte r n S p e e d o m e te r (O p tio n ) M 1 8 x 1 ,5
2 1 = In d u c tiv e tra n s m itte r n T u rb in e M 1 8 x 1 ,5
3 4 = S p e e d se n so r n O u p u t a n d S p e e d o m e te r -----------
4 7 = In d u c tiv e tra n s m itte r n C e n tra l g e a r tra in M 1 8 x 1 ,5
4 8 = In d u c tiv e tra n s m itte r n E n g in e M 1 8 x 1 ,5
5 4 = F IL T E R C O N T A M IN A T IO N S W IT C H M 1 4 x 1 ,5
C O N N E C T IO N S :
4 9 = P lu g c o n n e c tio n o n th e e le c tro -h y d ra u lic c o n tro l u n it
6 8 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 G
6 9 = C o n tro l (O p tio n ) M 1 6 x 1 ,5 J
P a g e 1 / 2
 VIEW X 63/52
65 51 68
49 48

69 H J 49
K
G 54 47
57 A F

B E
60
53 55
C D
34 6

58 56

CODING 15
16
• PRESSURE REGULATOR ACTIVE ENGAGED CLUTCHES

DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6 X 21

FORWARD 1 • • K1 KV
2 • • KV K2 47
3 • • K3 KV
4 • • K4 K3
REVERSE 1 • • KR K1
10
2 • • KR K2
3 • • KR K3 48
NEUTRAL
ENGAGED CLUTCH K4 KR K1 K3 KV K2
POSITION ON THE VALVE BLOCK F E D C B A
CONSECUT. No. of Measuring points 60 55 56 58 53 57 Page 2 / 2
OIL CIRCUIT DIAGRAM 4 WG-110
WITH ZF FINE FILTER DIRECT INSTALLED AT THE TRANSMISSION
- FORWARD 1st SPEED -
TABLE-5
The marked positons (e.g. 53) correspond with the positions on the table-4!
Gearbox diagram
Converter
Legend:

WT = Heat exchanger
WGV = Converter back pressure valve 1,5 bar KV K1
WSV = Converter safety valve 11 bar
HDV = Main pressure valve 16+2 bar
RV-9 = Pressure reducing valve 9 bar KV K1 Power take-off
Input
NFS = Follow-on slide KR K2 Engine-dependent
D = Vibration damper
B = Orifice
P1 = Proportional valve K4 KR K2
P2 = Proportional valve KR K4 K3
P3 = Proportional valve K1
P4 = Proportional valve K3 Transmission pump
P5 = Proportional valve KV K4 K3
P6 = Proportional valve K2 Countershaft
Y1...Y6 = Pressure regulators
TEMP = Temperature sensor
FDV = Filter pressure differential valve (Bypass-valve) ∆p=5,5 bar Output Output
Converter side Rear-side

Page 1 / 2
 K 4 K R K 1 K 3 K V K 2

F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D

Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S

R V -9
T E M P

H D V
K 6 5
V A L V E B L O C K
C O N T R O L C IR C U IT

C O N V E R T E R
5 1

F IN E F IL T E R
F D V
H W S V F IL T E R G R A D E A C C O R D IN G IS O 4 5 7 2 :
ß 30 ³ 7 5 ß 1 5 = 2 5 ß 1 0 = 5 .0
L E G E N D : 6 3 5 2 D U S T C A P A C IT Y A C C O R D IN G IS O 4 5 7 2 :
m in . 1 7 g
= M A I N P R E S S U R E F IL T E R S U R F A C E :
= R E G U L A T E D M A IN P R E S S U R E W G V m in . 6 7 0 0 c m
2

= P IL O T P R E S S U R E
= C O N V E R T E R IN P U T P R E S S U R E B Y P A S S - 1 5 T R A N S M IS S IO N P U M P
= C O N V E R T E R O U T P U T P R E S S U R E V A L V E p = 1 6 + 2 b a r
D p = 1 ,5 b a r Q p = 5 0 l/m in a t
= L U B R IC A T IO N n = E N G IN E 2 0 0 0 m in -1
1 6
= R E T U R N IN T O T H E S U M P
W T
(S O U P E O F S U P P L Y
C U S T O M E R ) O IL S U M P
M A IN O IL C IR C U IT
P a g e 2 / 2 L U B R IC A T IO N
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 4 W G -1 1 0
W IT H E X T E R N A L L Y IN S T A L L E D Z F - F IN E F IL T E R
T A B L E -6
T h e m a r k e d p o s itio n s ( e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e T a b le - 7 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n ( a b o u t 8 0 ° - 9 5 ° C )!

N O . D E N O M IN A T IO N O F T H E P O S IT IO N C O N N E C T IO N M A R K IN G O N T H E

X
V A L V E B L O C K
M E A S U R IN G P O IN T S F O R H Y D R A U L IC O IL A N D T E M P E R A T U R E :
5 1 = In fro n t o f th e c o n v e rte r – o p e n in g p re s s u re 1 1 b a r M 1 0 x 1 H
5 2 = B e h in d th e c o n v e rte r – o p e n in g p re s s u re 1 ,5 b a r M 1 4 x 1 ,5
5 3 = C lu tc h F o rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h R e v e rs e 1 6 + 2 b a r K R M 1 0 x 1 E
5 6 = C lu tc h 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C lu tc h 1 6 + 2 b a r K 2 M 1 0 x 1 A
5 8 = C lu tc h 1 6 + 2 b a r K 3 M 1 0 x 1 C
6 0 = C lu tc h 1 6 + 2 b a r K 4 M 1 0 x 1 F
6 3 = B e h in d th e c o n v e rte r T e m p e ra tu re 1 0 0 ° C ; S h o rt tim e 1 2 0 ° C M 1 4 x 1 ,5
6 5 = S y s te m p re s s u re
M E A S U R IN G P O IN T S F O R D E L IV E R Y R A T E S
1 6 + 2 b a r
:
M 1 0 x 1 K A F
1 4
B E
1 3 = C o n n e c tio n to th e Z F -fin e filte r M 2 6 x 1 ,5
1 4 = C o n n e c tio n fro m Z F -fin e filte r M 2 6 x 1 ,5 C D 1 3
1 5 = C o n n e c tio n to th e h e a t e x c h a n g e r M 2 6 x 1 ,5
1 6 = C o n n e c tio n fro m th e h e a t e x c h a n g e r M 2 6 x 1 ,5
IN D U C T IV E T R A N S M IT T E R S ; S P E E D S E N S O R A N D S W IT C H E S :
6 = In d u c tiv e tra n s m itte r n S p e e d o m e te r (O p tio n ) M 1 8 x 1 ,5
2 1 = In d u c tiv e tra n s m itte r n T u rb in e M 1 8 x 1 ,5
3 4
3 4 = S p e e d se n so r n O u tp u t a n d S p e e d o m e te r -----------
4 7 = In d u c tiv e tra n s m itte r n C e n tra l g e a r T ra in M 1 8 x 1 ,5
4 8 = In d u c tiv e tra n s m itte r n E n g in e M 1 8 x 1 ,5
5 4 = F IL T E R C O N T A M IN A T IO N S W IC H M 1 4 x 1 ,5
C O N N E C T IO N S :
4 9 = P lu g c o n n e c tio n o n th e e le c tro -h y d ra u lic c o n tro l u n it
6 8 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 G
6 9 = C o n tro l (O p tio n ) M 1 6 x 1 ,5 J P a g e 1 / 2
 VIEW X 63/52
65 51 68
49 48

69 H J 49
K
G 54 47
57 A F

B E
60
53 55
C D
34 6

58 56

CODING 15
16
• PRESSURE REGULATOR ACTIVE ENGAGED CLUTCHES
DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6
FORWARD 1
2
• •
• •
K1
KV
KV
K2
X 21
3 • • K3 KV
4 • • K4 K3 47
REVERSE 1 • • KR K1
2 • • KR K2
3 • • KR K3 10
NEUTRAL
ENGAGED CLUTCH K4 KR K1 K3 KV K2
48
POSITION ON THE VALVE BLOCK F E D C B A
CONSECUT. No. of Measuring points 60 55 56 58 53 57

Page 2 / 2
O IL C IR C U IT D IA G R A M 4 W G -1 1 0
W IT H E X T E R N A L L Y IN S T A L L E D Z F - F IN E F IL T E R
- F O R W A R D 1 st S P E E D -
T A B L E -7
T h e m a r k e d p o s itio n s ( e .g .5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e T a b le - 6 !

G e a rb o x d ia g ra m
C o n v e rte r
L e g e n d :

W T = H e a t e x c h a n g e r
K V K 1
W G V = C o n v e rte r b a c k p re s s u re v a lv e 1 ,5 b a r
W S V = C o n v e rte r s a fe ty v a lv e 1 1 b a r
H D V = M a in p re s s u re v a lv e 1 6 + 2 b a r K V K 1 P o w e r ta k e -o ff
R V -9 = P re s s u re re d u c in g 9 b a r In p u t
E n g in e -d e p e n d e n t
K R K K2 2
N F S = F o llo w -o n s lid e
D = V ib ra tio n d a m p e r
B = O rific e K R K K2 2
P 1 = P ro p o rtio n a l v a lv e C lu tc h K 4
K 4 K K3 2
P 2 = P ro p o rtio n a l v a lv e C lu tc h K R
P 3 = P ro p o rtio n a l v a lv e C lu tc h K 1 T ra n s m is s io n p u m p
P 4 = P ro p o rtio n a l v a lv e C lu tc h K 3 K 4 K K3 2
P 5 = P ro p o rtio n a l v a lv e C lu tc h K V
C o u n te rs h a ft
P 6 = P ro p o rtio n a l v a lv e C lu tc h K 2
Y 1 ...Y 6 = P re s s u re re g u la to rs
T E M P = T e m p e ra tu re s e n s o r O u tp u t O u tp u t
F D V = F ilte r p re s s u re d iffe re n tia l (B y p a s s - v a lv e ) , p = 5 ,5 b a r C o n v e rte r s id e R e a r-s id e

P a g e 1 / 2
 K 4 K R K 1 K 3 K V K 2

F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D

Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S

R V -9
T E M P

H D V
K 6 5
V A L V E B L O C K
C O N T R O L C IR C U IT

C O N V E R T E R
5 1 1 4

F IN E F IL T E R
F D V
H W S V F IL T E R G R A D E A C C O R D IN G IS O 4 5 7 2 :
ß 30 ³ 7 5 ß 1 5 = 2 5 ß 1 0 = 5 .0
L E G E N D : 6 3 5 2 D U S T C A P A C IT Y A C C O R D IN G IS O 4 5 7 2 :
m in . 1 7 g
= M A I N P R E S S U R E F IL T E R F L Ä C H E :
= R E G U L A T E D M A IN P R E S S U R E W G V 1 3 m in . 6 7 0 0 c m
2

= P IL O T P R E S S U R E
= C O N V E R T E R IN P U T P R E S S U R E B Y P A S S - 1 5 T R A N S M IS S IO N P U M P
= C O N V E R T E R O U T P U T P R E S S U R E V A L V E p = 1 6 + 2 b a r
D p = 1 ,5 b a r Q p = 5 0 l/m in a t
= L U B R IC A T IO N n = E N G IN E 2 0 0 0 m in -1
1 6
= R E T U R N IN T O T H E S U M P
W T
(S O U P E O F S U P P L Y
C U S T O M E R ) O IL S U M P
M A IN O IL C IR C U IT
P a g e 2 / 2 L U B R IC A T IO N
E L E C T R O -H Y D R A U L IC C O N T R O L W IT H P R O P O R T IO N A L V A L V E S
T A B L E - 8

M A IN P R E S S U R E V A L V E 1 6 + 2 b a r P R E S U R E R E D U C IN G V A L V E 9 b a r

H O U S IN G

P L U G (C A B L E H A R N E S S )

A Y 6 Y 1 A

Y 5 Y 2

B B
Y 4 Y 3

C O V E R C O V E R

H O U S IN G V A L V E B L O C K
 S E C T IO N A - A
M A IN P R E S S U R E V A L V E P R E S S U R E R E D U C IN G V A L V E
1 6 + 2 b a r V A V L E B L O C K 9 b a r

P L U G (C A B L E H A R N E S S )

D U C T P L A T E IN T E R M E D IA T E P L A T E

S E C T IO N B - B
P R O P O R T IO N A L V A L V E P 5

Y 5
V IB R A T IO N D A M P E R

P R E S S U R E
R E G U L A T O R
F O L L O W -O N S L ID E
 P O W E R F L O W 4 W G -1 1 0
T A B L E - 9 F o rw a rd
1 st S p e e d
F o rw a rd
2 n d S p e e d
F o rw a rd
3 n d S p e e d
F o rw a rd
4 th S p e e d

A N A N A N A N
T ra n s m is s io n d ia g ra m
K V /K 1 K V /K 1 K V /K 1 K V /K 1
K V K 1
K R /K 2 K R /K 2 K R /K 2 K R /K 2
O p in io n d ire c tio n o f ro ta tio n
K V K 1
A N
K R K K2 2 V W V W V W V W
K 4 /K 3 K 4 /K 3 K 4 /K 3 K 4 /K 3

K R K K2 2
K 4 K K3 2

A B A B A B A B
K 4 K K3 2

A B
R e v e rse R e v e rse R e v e rse
A B
1 st S p e e d 2 . G a n g 3 n d S p e e d

L e g e n d :
= P o w e r flo w g e a r tra in A N A N A N
= G e a rs a re n o t m e s h in g
K V /K 1 K V /K 1 K V /K 1
D ia g r a m - C lu tc h e s
K R /K 2 K R /K 2 K R /K 2
K V = C lu tc h F o rw a rd
D r iv e d ir e c tio n S p e e d C lu tc h K R = C lu tc h R e v e rse
F o rw a rd 1 K V /K 1 V W V W V W K 1 = C lu tc h 1 st S p e e d
K 4 /K 3 K 4 /K 3 K 4 /K 3 K 2 = C lu tc h 2 n d S p e e d
2 K V /K 2
3 K V /K 3 K 3 = C lu tc h 3 rd S p e e d
4 K 4 /K 3 K 4 = C lu tc h 4 th S p e e d
A N = In p u t
R e v e rse 1 K R /K 1 A B A B A B A B = O u tp u t
2 K R /K 2
V W = C o u n te rsh a ft
3 K R /K 3
4 W G -1 1 0 F U L L Y -A U T O M A T IC C O N T R O L E S T -3 7
C IR C U IT D IA G R A M S T A N D A R D (6 0 2 9 7 1 7 0 4 0 )
T A B L E -1 0

IT E M L E G E N D IT E M L E G E N D
A 1 E L E C T R O N IC C O N T R O L U N IT T C U S 2 S W IT C H P R E S S U R E C U T -O F F
A 2 C O N T R O L L E R D W -3 S 3 S W IT C H D R IV IN G P R O G R A M A U T O M A T IC /M A N U A L
A 3 E L E C T R O H Y D R A U L IC C O N T R O L U N IT 4 W G -3 1 0 S 9 S W IT C H P A R K IN G B R A K E R E L E A S E (O P T IO N )
A 5 D IA G N O S IS – IN T E R F A C E (P L U G ) S 1 0 S W IT C H F IL T E R C O N T A M IN A T IO N
A 6 D IS P L A Y S 3 1 S W IT C H A C H N O W L E D G M E N T P A R K IN G B R A K E
A 7 C A N -IN T E R F A C E (P L U G ) S 3 4 S W IT C H D IS P L A Y IL L U M IN A T IO N *

K 1 R E L A IY S T A R T E R IN T E R L O C K *
B 1 S P E E D S E N S O R n E N G IN E K 2 R E L A IY R E V E R S E D R IV E *
B 2 S P E E D S E N S O R n T U R B I N E
B 3 S P E E D S E N S O R n C E N T R A L G E A R T R A IN
B 4 S P E E D S E N S O R n O U T P U T
B 1 5 S E N S O R T E M P E R A T U R E B E H I N D C O N V E R T E R

F 1 F U S E 7 ,5 A *
F 2 F U S E 7 ,5 A *

H 3 A C O U S T IC - / O P T IC A L W A R N IN G *
 F 1

E
K l.3 0 /1 .1 2 K l.3 0 /1 .1
K l.1 5 /1 .1 2 K l.1 5 /1 .1
F 2
L
P
M
1 1 8 6
P
2 2
P 1 D 2

A
2 6 3

S 2 S 3 S 9 S 3 1 H 3 K 2 8 5 5
4
2
1

S 3
2 6 2
4 5
V P I V P E 1 V P E 2
2 3 6 8
E D 8 E D 9
4 4 6 6 2 9
E D 1 1 E D 1 0
2 1 3 0 3 1
E D 1 2 E D 1 3 A D M 1
5 2
A D M 2
7

1 5
M N L 6 -p in
6 0 2 9 1 9 9 0 7 4

2
1 8
6
4
2
7
5
3
1

B 4 E F 4 S D D K
A 5 A M P J P T 8 -p in
1 8 4 6 0 2 9 1 9 9 1 0 8
0 4 E U P R
1 2 3 1
V M G 2 4 6
1
0 6
S u p e rs e a l 3 -p in
2 4
2 A D M 3
A D M 4 0 5 3 8 A 6
6 0 2 9 1 9 9 0 7 1 A D M 8 3 3
4 1
V P S D 1
1 4
K D 2 2
4 3 E D 7 6
F
N 6 4 E D 4
E D 6
S 3 4
A 2 B 1
R 6 4
6 3 E D 5
6 5 E D 1 5 6 0 1
B 2 E D 2 A IP 1 0 2 Y 1 = K 4
2 0 1 0
B 3 E D 3 A 1 A IP
A IP
3
2
3 2 0 3 Y 2 =
Y 3 =
K R
K 1
8 6 5 5 0 4
1 1 9 A IP 4 0 9 0 5 Y 4 = K 3
A IP 5
D 1 B 1 2 0 3 E F 1
V M G 1 A IP 6 5 1 0 6
0 7
Y 5 =
Y 6 =
K V
K 2 A 3
V P S 1 1 2
K 1 8 5
1 4 1 V P S 1
3 9
1 3
0 8
V P S 1 (+ )
E F 2 E R 1 T E M P
B 2 2
6 8
4 5
2 3
2 2
V M G A 2 4 6 0 9
T E M P
4 9 1 2
1 E R 2 B 1 5
B 3 2 4 2
E F 3
6 8 -p in
6 0 2 9 1 9 9 0 6 3
1 7 1 2 3
1 2
5
E R 3 4
C A N _ H C A N _ L C A N _ T V G S 6 7 8 9
V M 1 V M 2 V P S 2 V P S 2 A D M 5 A D M 6 A D M 7 M in i T im e r 2 -p in
M in i T im e r
2 -p in 2 5 2 6 2 7 2 8 1 2 8 5 3 5 7 1 1 3 4
S 1 0 6 0 2 9 1 9 9 0 1 1 1 0 1 1 1 2 1 3
1 2 1 4 1 5 1 6
6 0 2 9 1 9 9 0 1 1 S u p e rse a l
2 -p in 1 2
6 0 2 9 1 9 9 0 4 5 K o s ta l 1 6 -p in
6 0 2 9 1 9 9 0 7 2
1 2 4

4
2
3
1 A 7
J P T 4 -p in
6 0 2 9 1 9 9 0 7 6

K l.3 1 K l.3 1 /1 .6
P o le p a tte rn s a re c o rre s p o n d in g w ith th e p lu g s o n th e w irin g !
T W IS T E D L IN E S (3 0 W IN D IN G S /M E T E R ) F R O M A L E N G T H O F > 2 M E T E R S O N
A L L R E L A Y S W IT H P R O T E C T IV E D IO D E S 1 A /4 0 0 V

B U S T E R M IN A T IO N IF P IN 2 6 A N D 2 7 A R E C O N N E C T E D
 C O N T R O L L E R D W -3
T A B L E -1 1
L E V E R F O R M E C H A N IC A L C O N N E C T IO N D IA G R A M C O N T R O L L E R
N E U T R A L IN T E R L O C K C O D IN G C O N T R O L L E R
(+ )
O U T P U T K D

S P E E D F O R W A R D R E V E R S E N E U T R A L
X 2 : A
1 2 3 4 1 2 3 4 1 2 3 4
N D (+ )
A D 1 B 1
B 1 X 1 :C
A D 2 B 2
A 2 B 2
B 3
X 1
X 1
: B
: A A 1
A D 3 B 3 X 1 : B
IN P O S IT IO N (N E U T R A L ), V
A D 4 X 1 : C
F -R N O T S W IT C H A B L E V R
X 1 : D
A S
A D 5 R
A D 6 A S
A D 7
E
L K 1 K 2

P
M
(-)

A
A B C D
A B C D
X 2 X 1 K 1 = R E L A Y S T A R T E R IN T E R L O C K

F G E A R P O S IT IO N S T Y P E N S C H IL D S C IR C U IT D IA G R A M C O N T R O L L E R
K 2
A 1
=
=
R E L A Y R E V E R S IN G L IG H T S

E L E C T R O N IC U N IT E S T -3 7
A 2 = C O N T R O L L E R
F
S W A
A D 3 (B 3 )
N N N D
S 6 1 S 4 1 1 S 5
R 2 2 2 G N B
A D 2 (B 2 )
B L C
A D 1 (B 1 )
V I D
A D 7 (K D )
R X 1
R T A
E D 1 (+ /V P )
F = F O R W A R D S 1 1
N = N E U T R A L 3 2 G R D
A D 6 (N )
R = R E V E R S E T Y P E P L A T E S 2 1
D = M E C H A N IC A L N E U T R A L IN T E R L O C K C O N T R O L D W - 3
3 2 G E B
A D 4 (F O R W A R D )
1 = 1 st S P E E D N R .
S 3 1
V 1 2 / 2 4

2 = 2 n d S P E E D
3 2 R S C
3 = 3 rd S P E E D S T U E C K L . 0 5 0 1 2 1 0 1 4 8 A D 5 (R E V E R S E )
4 = 4 th S P E E D X 2
 C O N T R O L L E R E R G O II
T A B L E -1 2 C O D IN G C O N T R O L E R C O N N E C T IO N D IA G R A M C O N T R O L L E R
O U T P U T

V R N T + T - K D / S N
+ E
-
N A D 1 B 1 (+ ) V P (+ )

A D 2 B 2 K D /E (A D 8 ) E D 7
A D 3 B 3 T + (A D 1 ) E D 1 A 1
T - (A D 2 ) E D 2
A D 5 V
A 2 C (A
(A
D 3 )
D 5 )
E D 3
E D 4
A D 6 R A D 7
K D (A D 6 ) E D 5
A D 7 N N (A D 7 ) E D 6 A D 9
S N (A D 9 )
A D 8 K D
V M (-)
A D 9 S N (-)
K 3 K 1 K 2
: = U O U T P U T = O V (A C T IV E L O W )
: = U S E R V IC E - 0 ,3 V

K 1 = R E L A Y S T A R T E R IN T E R L O C K
K 2 = R E L A Y R E V E R S IN G L IG H T S
K 3 = R E L A Y S H O V E L N E U T R A L (C U S T O M IZ E D )
A 1 = E L E C T R O N IC U N IT E S T -1 7 T /E S T -2 5
A 2 = C O N T R O L L E R E R G O II

C IR C U IT D IA G R A M C O N T R O L L E R

R T + /V P
2

M E A N IN G O F P U S H B U T T O N S
S 1 G E
4
A D 5 V (F O R W A R D ) P O S L E G E N D
W S
S 2 A D 3 B 3 /C (C O N T R O L -S IG N A L )
R S 9
A D 6 R (R E V E R S E ) S 1 P U S H B U T T O N D R IV IN G D I R E C T I O N
6
= D R IV IN G D IR E C T IO N F O R W A R D S 1 '
( ) V ' S 2
F O R
P U S
W A R D
H B U T T O N
A N D C -S IG N
D R IV IN G
A L
D I
F O
R E
R W
C T I
A R D
O N
= D R IV IN G D IR E C T IO N R E V E R S E S 2 '
( ) R '
S 3
R E V
P U S
E R S E A
H B U T T O N
N D C -S IG N A
N E U T R A L
L R E V E R S E

N = N E U T R A L S 3

S 4
B R
5
A D 7 A S /N S 4 P U S H B U T T O N U P S H IF T IN G
B L S 5 P U S H B U T T O N D O W N S H IF T IN G
+ = U P S H IF T IN G S 5 O G
7
A D 1 B 1 /T +
S 6 P U S H B U T T O N K IC K D O W N /R E L E A S E
A D 2 B 2 /T - P U S H B U T T O N S H O V E L N E U T R A L
- = D O W N S H IF T IN G 8 S 7
:
S 6
(S N ) = S H O V E L -N E U T R A L V I
1 0
A D 8 K D /E

(S H O V E L H O R IZ O N T A L ) S 7 S W
1 1
A D 9 S N

K D /E = K IC K D O W N C O N T R O L A N D (1 )
V M (-)

S A F E T Y R E L E A S E X 1
 TABLE-13

INSCRIPTIONS ON A ZF-MODEL INDENTIFICATION

PLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION

1 = Gearbox type
2 = Gearbox-No.
3 = ZF-Parts List-No.
4 = Total ratio of the Gearbox
5 = Value for the control pressure
6 = ZF-Parts List-No. of the Torque Converter
7 = Type of the ZF-Torque Converter

1 2

3 4

6 7

NOTES REGARDING THE SPARE PARTS ORDERS:

When ordering genuine ZF-Spare Parts, please indicate:

1. = Gearbox type
2. = Serial-No.
See Model identification Plate!
3. = ZF-Parts List-No.
4. = Mark and type of vehicle
5. = Denomination of the spare part
6. = Spare parts-No.
7. = Way of transport

When all of the above required indications are considered, errors in the delivery of spare parts
Orders can be avoided!
L A Y O U T 6 W G -1 1 0
T A B L E -1 1 2 3 4 5

1 = E n g in e c o n n e c tio n
A = S e p a ra te m o u n tin g – d riv e n v ia u n iv e rs a l s h a ft
B = D ire c t m o u n tin g – d riv e n v ia fle x p la te 6
2 = C o n v e rte r
3 = T ra n s m is s io n p u m p
4 = O il in ta k e fla n g e A
5 = In p u t " IN " 7
6 = A tta c h m e n t p o s s ib ility P o w e r ta k e -o ff; c o a x ia l e n g in e -d e p e n d e n t
B
7 = C lu tc h s h a ft " K V /K 1 "
8 = C lu tc h s h a ft " K R /K 2 " p

9 = E m e rg e n c y s te e rin g p u m p
K V

A = w ith e m e rg e n c y s te e rin g p u m p 8
B = w ith o u t e m e rg e n c y s te e rin g p u m p
1 0 = D ru m b ra k e
1 1 = O u tp u t (re a r) " O U "
1 2 = O il s u m p G e a rb o x d ia g ra m
1 3 = G e a rs h ift s h a ft fo r a x le d is c o n n e c tio n
1 4 = O u tp u t (c o n v e rte r s id e ) " O U " 1 6 5 3 .3 8 0 K 3

- 7 ,5
A 9
B
°

A = w ith o u t a x le d is c o n n e c tio n A N K 4

B = w ith a x le d is c o n n e c tio n 1 0
K V /K 1
1 5 = L a y sh a ft " L S "
1 6 = C lu tc h s h a ft " K 4 /K 3 " K R /K 2
1 5 1 1
A 7 ,5
°

K 4 /K 3
V W B

A B

1 4 1 3 1 2
IN S T A L L A T IO N V IE W 6 W G -1 1 0 – S E P A R A T E M O U N T IN G
F R O N T V IE W 1
T A B L E -2

1 = In p u t fla n g e – d riv e n v ia u n iv e rs a l s h a ft 2
2 = E le c tro -h y d ra u lic c o n tro l
3 = T ra n s m is s io n su sp e n s io n M 2 0
4 = P re s s u re o il p ip e " K 3 "
5 = P re s s u re o il p ip e " K 4 "
6 = O il in ta k e p ip e
7 = C o a rs e filte r
8 = O il d ra in p lu g M 3 3 x 2 1 3
9 = In p u t fla n g e ( c o n v e rte r s id e )
1 0 = M o d e l id e n tif ic a tio n p la te 1 2
1 1 = O il le v e l tu b e w ith o il d ip s tic k 3
1 2 = P re s s u re o il p ip e " K V "
1 3 = P re s s u re o il p ip e " K 1 " 3

4
1 1
5
1 0 3
6

8 7
IN S T A L L A T IO N V IE W 6 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
F R O N T V IE W 1
T A B L E -3
1  = D ire c t m o u n tin g v ia d ia p h ra g m
2  = E le c tro -h y d ra u lic c o n tro l
3  = T ra n s m is s io n s u s p e n s io n h o le s M 2 0 2
4  = P re s s u re -o il p ip e K 3
5  = P re s s u re -o il p ip e K 4
6  = O il s u c tio n p ip e
7  = C o a rs e filte r
8  = O il d ra in p lu g M 3 3 x 2 1 3
9  = O il fille r tu b e w ith o il d ip s tic k
1 0 = In p u t fla n g e – F ro n t a x le (c o n v e rte r-s id e )
1 1 = M o d e l id e n tific a tio n p la te
1 2 = P re s s u re -o il p ip e K V
1 2
1 3 = P re s s u re -o il p ip e K 1 3
3

4
Z F

5
1 1 3
6
1 0

9 8 7
IN S T A L L A T IO N V IE W 6 W G -1 1 0 – D IR E C T M O U N T IN G
S ID E V IE W 1 2 3 4
T A B L E -4

1 = D ire c t m o u n tin g v ia fle x p la te

2 = C o n v e rte r
3 = C o n v e rte r b e ll h o u s in g 5
4 = O il in ta k e p ip e
5 = E le c tro -h y d ra u lic c o n tro l A F

6 = Z F fin e filte r B E

7 = O u tp u t (re a r) C D
8 = O u tp u t (c o n v e rte r s id e )
9 = P re s s u re o il p ip e " K 4 "
1 0 = P re s s u re o il p ip e " K 3 " 6
1 1 = P re s s u re o il p ip e " K 1 "
1 2 = P re s s u re o il p ip e " K V " 1 2
1 1
1 0
7
9
8
 IN S T A L L A T IO N V IE W 6 W G -1 1 0 – S E P A R A T E M O U N T IN G
S ID E V IE W 1 2 3 4
T A B L E -5

1 = In p u t fla n g e – d riv e n v ia u n iv e rs a l s h a ft
2 = C o n v e rte r c o n n e c tin g h o u s in g
3 = C o n v e rte r b e ll h o u s in g 5
4 = O il in ta k e p ip e
5 = E le c tro -h y d ra u lic c o n tro l A F
6 = O u tp u t (re a r) B E
7 = O il le v e l tu b e w ith o il d ip s tic k
8 = O u tp u t (c o n v e rte r s id e ) C D

9 = P re s s u re o il p ip e " K 4 "
1 0 = P re s s u re o il p ip e " K 3 "
1 1 = P re s s u re o il p ip e " K 1 "
1 2 = P re s s u re o il p ip e " K V " 1 2
1 1
1 0
6
9
8
7
IN S T A L L A T IO N V IE W 6 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
R E A R V IE W - S T A N D A R D V E R S IO N 1 2
T A B L E -6

1 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
2 = L iftin g lu g s
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = A tta c h m e n t p o s s ib ility fo r e m e rg e n c y s te e rin g p u m p 8
5 = O u tp u t fla n g e – re a r-s id e
6 = O il d ra in p lu g M 3 3 x 2
7 = O il s u c tio n p ip e
8 = E le c tro -h y d ra u lic c o n tro l
7 3

3 4
3

5
3

6 3
IN S T A L L A T IO N V IE W 6 W G -1 1 0 - D IR E C T IN S T A L L A T IO N
R E A R V IE W - W IT H D R U M B R A K E 1 2
T A B L E -7
1 = P o w e r ta k e -o ff, c o a x ia l, e n g in e -d e p e n d e n t
2 = L iftin g lu g s
3 = T ra n s m is s io n s u s p e n s io n h o le s M 2 0
4 = A tta c h m e n t p o s s ib ility fo r e m e rg e n c y s te e rin g p u m p 9
5 = C o n tro l le v e r – D ru m b ra k e
6 = O il d ra in p lu g M 3 3 x 2
7 = O u tp u t fla n g e w ith d ru m b ra k e – re a r s id e
8 = Z F fin e p re s s u re filte r
9 = E le c tro -h y d ra u lic c o n tro l 8 3

3 4
3
7
5
3

6 3
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 6 W G -1 1 0
W IT H Z F F IN E F IL T E R D IR E C T IN S T A L L E D A T T H E T R A N S M IS S IO N
T A B L E -8
T h e m a r k e d p o s itio n s (e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e T a b le - 9 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s s io n (a b o u t 8 0 ° - 9 5 ° C )!
X
N O . D E N O M IN A T IO N O F T H E P O S IT IO N C O N N E C T IO N M A R K IN G O N T H E
V A L V E B L O C K
M E A S U R IN G P O IN T S F O R H Y D R A U L IC O IL A N D T E M P E R A T U R E :
5 1 = In fro n t o f th e c o n v e rte r – o p e n in g p re s s u re 1 1 b a r M 1 0 x 1 H
5 2 = B e h in d th e c o n v e rte r – o p e n in g p re s s u re 1 ,5 b a r M 1 4 x 1 ,5
5 3 = C lu tc h F o rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h R e v e rs e 1 6 + 2 b a r K R M 1 0 x 1 E
5 6 = C lu tc h 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C lu tc h 1 6 + 2 b a r K 2 M 1 0 x 1 A A F
5 8 = C lu tc h 1 6 + 2 b a r K 3 M 1 0 x 1 C
B E
6 0 = C lu tc h 1 6 + 2 b a r K 4 M 1 0 x 1 F
6 3 = B e h in d th e c o n v e rte r M 1 4 x 1 ,5 C D
T e m p e ra tu re 1 0 0 ° C ; s h o rt-tim e 1 2 0 ° C
6 5 = S y s te m p re s s u re 1 6 + 2 b a r M 1 0 x 1 K
M E A S U R IN G P O IN T S F O R D E L IV E R Y R A T E S :
1 5
1 6
=
=
C o n n e c tio n to th e h e a t e x c h a n g e r
C o n n e c tio n fro m th e h e a t e x c h a n g e r
M 2 6 x 1 ,5
M 2 6 x 1 ,5
3 4
IN D U C T IV E T R A N S M IT T E R S , S P E E D S E N S O R A N D S W IT C H E S :
6 = In d u c tiv e tra n s m itte r n S p e e d o m e te r (O p tio n ) M 1 8 x 1 ,5
2 1 = In d u c tiv e tra n s m itte r n T u rb in e M 1 8 x 1 ,5
3 4 = S p e e d se n so r n O u p u t a n d S p e e d o m e te r -----------
4 7 = In d u c tiv e tra n s m itte r n C e n tra l g e a r tra in M 1 8 x 1 ,5
4 8 = In d u c tiv e tra n s m itte r n E n g in e M 1 8 x 1 ,5
5 4 = F IL T E R C O N T A M IN A T IO N S W IT C H M 1 4 x 1 ,5
C O N N E C T IO N S :
4 9 = P lu g c o n n e c tio n o n th e e le c tro -h y d ra u lic c o n tro l u n it
6 8 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 G
6 9 = C o n tro l (O p tio n ) M 1 6 x 1 ,5 J
P a g e 1 / 2
 VIEW X 63/52
65 51 68
49 48

69 H J 49
K
G 54 47
57 A F

B E
60
53 55
C D
34 6

58 56
CODING

• PRESSURE REGULATOR UNDER ENGAGED CLUTCHES

VOLTAGE 15
DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6 16
FORWARD 1 • • K1 KV
2 • • K4 K1
3
4 •
• •
•
KV
K4
K2
K2
X 21
5 • • K3 KV
6 • • K4 K3 47
REVERSE 1 • • KR K1
2 • • KR K2
3 • • KR K3 10
NEUTRAL 48
ENGAGED CLUTCH K4 KR K1 K3 KV K2
POSITIONENS ON VALVE BLOCK F E D C B A
CONSEC. No. OF MEAS. POINTS 60 55 56 58 53 57
Page 2 / 2
O IL C IR C U IT D IA G R A M 6 W G -1 1 0
W IT H Z F F IN E F IL T E R D IR E C T IN S T A L L E D A T T H E T R A N S M IS S IO N
- F O R W A R D 1 st S P E E D -
T A B L E -9
T h e m a r k e d p o s ito n s ( e .g . 5 3 ) c o r re s p o n d w ith th e p o s itio n s o n th e ta b le - 8 !
G e a rb o x d ia g ra m
C o n v e rte r
L e g e n d :

W T = H e a te x c h a n g e r
W G V = C o n v e r t e r b a c kp r e s s u r e v a l v e 1 ,5 b a r K V K 1
W S V = C o n v e r t e rs a f e t y v a l v e 1 1 b a r
H D V = M a in p re s s u re v a lv e 1 6 + 2 b a r
R V -9 = P re s s u rere d u c in g v a lv e 9 b a r K V K 1 P o w e r ta k e -o ff
N F S = F o llo w -o ns lid e K R K K2 2 E n g in e -d e p e n d e n t
D = V ib ra tio n d a m p e r
B = O rific e
P 1 = P r o p o r t i o n a lv a l v e K 4 K R K K2 2
P 2 = P r o p o r t i o n a lv a l v e K R K 4 K K3 2
P 3 = P r o p o r t i o n a lv a l v e K 1
P 4 = P r o p o r t i o n a lv a l v e K 3 T ra n s m is s io n p u m p
P 5 = P r o p o r t i o n a lv a l v e K V K 4 K K3 2
P 6 = P r o p o r t i o n a lv a l v e K 2 C o u n te rs h a ft
Y 1 ...Y 6 = P re s s u re re g u la to rs
T E M P = T e m p e r a t u r es e n s o r
F D V = F i l t e r p r e s s u r e d i f f e r e n t i a v l a l v e (B y p a s s - v a l v e ), p = 5 , 5 b a r O u tp u t O u tp u t
C o n v e rte r s id e R e a r-s id e

P a g e 1 / 2
 K 4 K R K 1 K 3 K V K 2

F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D

Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S

R V -9
T E M P

H D V
K 6 5
V A L V E B L O C K
C O N T R O L C IR C U IT

C O N V E R T E R
5 1

F IN E F IL T E R
F D V
H W S V F IL T E R G R A D E A C C O R D IN G IS O 4 5 7 2 :
ß 30 ³ 7 5 ß 1 5 = 2 5 ß 1 0 = 5 .0
L E G E N D : 6 3 5 2 D U S T C A P A C IT Y A C C O R D IN G IS O 4 5 7 2 :
m in . 1 7 g
= M A I N P R E S S U R E F IL T E R S U R F A C E :
= R E G U L A T E D M A IN P R E S S U R E W G V m in . 6 7 0 0 c m
2

= P IL O T P R E S S U R E
= C O N V E R T E R IN P U T P R E S S U R E B Y P A S S - 1 5 T R A N S M IS S IO N P U M P
= C O N V E R T E R O U T P U T P R E S S U R E V A L V E p = 1 6 + 2 b a r
D p = 1 ,5 b a r Q p = 5 0 l/m in a t
= L U B R IC A T IO N n = E N G IN E 2 0 0 0 m in -1
1 6
= R E T U R N IN T O T H E S U M P
W T
(S O U P E O F S U P P L Y
C U S T O M E R ) O IL S U M P
M A IN O IL C IR C U IT
P a g e 2 / 2 L U B R IC A T IO N
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 6 W G -1 1 0
W IT H E X T E R N A L L Y IN S T A L L E D Z F - F IN E F IL T E R
T A B L E -1 0
T h e m a r k e d p o s itio n s (e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e T a b le - 1 1 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n (a b o u t 8 0 ° - 9 5 ° C )!

N O . D E N O M IN A T IO N O F T H E P O S IT IO N C O N N E C T IO N M A R K IN G O N T H E

X
V A L V E B L O C K
M E A S U R IN G P O IN T S F O R H Y D R A U L IC O IL A N D T E M P E R A T U R E :
5 1 = In fro n t o f th e c o n v e rte r – o p e n in g p re s s u re 1 1 b a r M 1 0 x 1 H
5 2 = B e h in d th e c o n v e rte r – o p e n in g p re s s u re 1 ,5 b a r M 1 4 x 1 ,5
5 3 = C lu tc h F o rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h R e v e rs e 1 6 + 2 b a r K R M 1 0 x 1 E
5 6 = C lu tc h 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C lu tc h 1 6 + 2 b a r K 2 M 1 0 x 1 A
5 8 = C lu tc h 1 6 + 2 b a r K 3 M 1 0 x 1 C
6 0 = C lu tc h 1 6 + 2 b a r K 4 M 1 0 x 1 F
6 3 = B e h in d th e c o n v e rte r T e m p e ra tu re 1 0 0 ° C ; S h o rt tim e 1 2 0 ° C M 1 4 x 1 ,5
6 5 = S y s te m p re s s u re
M E A S U R IN G P O IN T S F O R D E L IV E R Y R A T E S
1 6 + 2 b a r
:
M 1 0 x 1 K A F
1 4
B E
1 3 = C o n n e c tio n to th e Z F -fin e filte r M 2 6 x 1 ,5
1 4 = C o n n e c tio n fro m Z F -fin e filte r M 2 6 x 1 ,5 C D 1 3
1 5 = C o n n e c tio n to th e h e a t e x c h a n g e r M 2 6 x 1 ,5
1 6 = C o n n e c tio n fro m th e h e a t e x c h a n g e r M 2 6 x 1 ,5
IN D U C T IV E T R A N S M IT T E R S ; S P E E D S E N S O R A N D S W IT C H E S :
6 = In d u c tiv e tra n s m itte r n S p e e d o m e te r (O p tio n ) M 1 8 x 1 ,5
2 1 = In d u c tiv e tra n s m itte r n T u rb in e M 1 8 x 1 ,5
3 4
3 4 = S p e e d se n so r n O u tp u t a n d S p e e d o m e te r -----------
4 7 = In d u c tiv e tra n s m itte r n C e n tra l g e a r T ra in M 1 8 x 1 ,5
4 8 = In d u c tiv e tra n s m itte r n E n g in e M 1 8 x 1 ,5
5 4 = F IL T E R C O N T A M IN A T IO N S W IC H M 1 4 x 1 ,5
C O N N E C T IO N S :
4 9 = P lu g c o n n e c tio n o n th e e le c tro -h y d ra u lic c o n tro l u n it
6 8 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 G
6 9 = C o n tro l (O p tio n ) M 1 6 x 1 ,5 J P a g e 1 / 2
 VIEW X 63/52
65 51 68
49 48

69 H J 49
K
G 54 47
57 A F

B E
60
53 55
C D
34 6

58 56

CODING
• PRESSURE REGULATOR UNDER ENGAGED CLUTCHES
VOLTAGE 15
DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6 16
FORWARD 1 • • K1 KV
2 • • K4 K1
3
4 •
• •
•
KV
K4
K2
K2
X 21
5 • • K3 KV
6 • • K4 K3 47
REVERSE 1 • • KR K1
2 • • KR K2
3 • • KR K3 10
NEUTRAL 48
ENGAGED CLUTCH K4 KR K1 K3 KV K2
POSITIONENS ON VALVE BLOCK F E D C B A
CONSEC. No. OF MEAS. POINTS 60 55 56 58 53 57
Page 2 / 2
O IL C IR C U IT D IA G R A M 6 W G -1 1 0
W IT H E X T E R N A L L Y IN S T A L L E D Z F - F IN E F IL T E R
- F O R W A R D 1 st S P E E D -
T A B L E -1 1
T h e m a r k e d p o s itio n s ( e .g .5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e T a b le - 1 0 !

G e a rb o x d ia g ra m
C o n v e rte r
L e g e n d :

W T = H e a t e x c h a n g e r
K V K 1
W G V = C o n v e rte r b a c k p re s s u re v a lv e 1 ,5 b a r
W S V = C o n v e rte r s a fe ty v a lv e 1 1 b a r
H D V = M a in p re s s u re v a lv e 1 6 + 2 b a r K V K 1 P o w e r ta k e -o ff
R V -9 = P re s s u re re d u c in g 9 b a r In p u t
E n g in e -d e p e n d e n t
K R K K2 2
N F S = F o llo w -o n s lid e
D = V ib ra tio n d a m p e r
B = O rific e K R K K2 2
P 1 = P ro p o rtio n a l v a lv e C lu tc h K 4
K 4 K K3 2
P 2 = P ro p o rtio n a l v a lv e C lu tc h K R
P 3 = P ro p o rtio n a l v a lv e C lu tc h K 1 T ra n s m is s io n p u m p
P 4 = P ro p o rtio n a l v a lv e C lu tc h K 3 K 4 K K3 2
P 5 = P ro p o rtio n a l v a lv e C lu tc h K V
C o u n te rs h a ft
P 6 = P ro p o rtio n a l v a lv e C lu tc h K 2
Y 1 ...Y 6 = P re s s u re re g u la to rs
T E M P = T e m p e ra tu re s e n s o r O u tp u t O u tp u t
F D V = F ilte r p re s s u re d iffe re n tia l (B y p a s s - v a lv e ) , p = 5 ,5 b a r C o n v e rte r s id e R e a r-s id e

P a g e 1 / 2
 K 4 K R K 1 K 3 K V K 2

F 6 0 E 5 5 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
B D B D B D B D B D B D

Y 1 N F S Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6 N F S
N F S N F S

R V -9
T E M P

H D V
K 6 5
V A L V E B L O C K
C O N T R O L C IR C U IT

C O N V E R T E R
5 1 1 4

F IN E F IL T E R
F D V
H W S V F IL T E R G R A D E A C C O R D IN G IS O 4 5 7 2 :
ß 30 ³ 7 5 ß 1 5 = 2 5 ß 1 0 = 5 .0
L E G E N D : 6 3 5 2 D U S T C A P A C IT Y A C C O R D IN G IS O 4 5 7 2 :
m in . 1 7 g
= M A I N P R E S S U R E F IL T E R F L Ä C H E :
= R E G U L A T E D M A IN P R E S S U R E W G V 1 3 m in . 6 7 0 0 c m
2

= P IL O T P R E S S U R E
= C O N V E R T E R IN P U T P R E S S U R E B Y P A S S - 1 5 T R A N S M IS S IO N P U M P
= C O N V E R T E R O U T P U T P R E S S U R E V A L V E p = 1 6 + 2 b a r
D p = 1 ,5 b a r Q p = 5 0 l/m in a t
= L U B R IC A T IO N n = E N G IN E 2 0 0 0 m in -1
1 6
= R E T U R N IN T O T H E S U M P
W T
(S O U P E O F S U P P L Y
C U S T O M E R ) O IL S U M P
M A IN O IL C IR C U IT
P a g e 2 / 2 L U B R IC A T IO N
E L E C T R O -H Y D R A U L IC C O N T R O L W IT H P R O P O R T IO N A L V A L V E S
T A B L E -1 2

M A IN P R E S S U R E V A L V E 1 6 + 2 b a r P R E S S U R E R E D U C IN G V A L V E 9 b a r

H O U S IN G

P L U G (C A B L E H A R N E S S )

A Y 6 Y 1 A

Y 5 Y 2

B B
Y 4 Y 3

C O V E R C O V E R

H O U S IN G V A L V E B L O C K
 S E C T IO N A - A
M A IN P R E S S U R E V A L V E P R E S S U R E R E D U C IN G V A L V E
1 6 + 2 b a r V A V L E B L O C K 9 b a r

P L U G (C A B L E H A R N E S S )

D U C T P L A T E IN T E R M E D IA T E P L A T E

S E C T IO N B - B
P R O P O R T IO N A L V A L V E P 5

Y 5
V IB R A T IO N D A M P E R

P R E S S U R E
R E G U L A T O R
F O L L O W -O N S L ID E
P O W E R F L O W 6 W G -1 1 0
F O R W A R D S P E E D S
T A B L E -1 3 F o rw a rd F o rw a rd F o rw a rd
1 st S p e e d 2 n d S p e e d 3 n d S p e e d

A N A N A N

K V /K 1 K V /K 1 K V /K 1

T ra n s m is s io n d ia g ra m K R /K 2 K R /K 2 K R /K 2

V W V W V W
K V K 1 K 4 /K 3 K 4 /K 3 K 4 /K 3

K V K 1
A N O p in io n d ire c tio n o f ro ta tio n
K R K K2 2
A B A B A B

K R K K2 2
K 4 K K3 2

F o rw a rd F o rw a rd F o rw a rd
K 4 K K3 2 4 th S p e e d 5 th S p e e d 5 th S p e e d

A B A B A N A N A N

K V /K 1 K V /K 1 K V /K 1

K R /K 2 K R /K 2 K R /K 2

V W V W V W
K 4 /K 3 K 4 /K 3 K 4 /K 3

A B A B A B
6 W G -1 1 0 F U L L Y -A U T O M A T IC C O N T R O L U N IT E S T -3 7
C IR C U IT D IA G R A M - S T A N D A R D (6 0 2 9 7 1 7 0 3 9 )
T A B L E -1 4
IT E M L E G E N D IT E M L E G E N D
A 1 E L E C T R O N IC C O N T R O L U N IT T C U S 1 S W IT C H R E T A R D E R
A 2 C O N T R O L L E R S 4 S W IT C H K IC K D O W N (O P T IO N )
A 3 E L E C T R O H Y D R A U L IC O N T R O L U N IT 6 W G -1 1 0 S 5 S W IT C H R E Q U E S T E N G IN E B R A K E
A 5 D I A G N O S T IC IN T E R F A C E (P L U G ) S 1 0 S W IT C H F IL T E R C O N T A M IN A T IO N
A 6 D I S P L A Y S 2 8 S W IT C H P R E S E L E C T IO N D IF F E R E N T IA L L O C K
A 7 C A N -IN T E R F A C E (P L U G ) S 3 2 S W IT C H T R O U G H O N T O P *
A 9 S P E E D O M E T E R W IT H F R E Q U E N C Y D IV ID E R * S 3 4 S W IT C H D IS P L A Y IL L U M IN A T IO N *

B 1 S P E E D S E N S O R n E N G IN E Y 7 S O L E N O ID V A L V E W K
B 2 S P E E D S E N S O R n T U R B I N E Y 8 S O L E N O ID V A L V E R E T A R D E R
B 3 S P E E D S E N S O R n C E N T R A L G E A R T R A IN Y 9 S O L E N O ID V A L V E D IF F E R E N T IA L L O C K
B 4 S P E E D S E N S O R n O U T P U T
B 6 L O A D S E N S O R K 1 R E L A Y S T A R T E R IN T E R L O C K *
B 9 S E N S O R – T E M P E R A T U R E - R E T A R D E R K 2 R E L A Y R E V E R S E D R IV E *

F 1 F U S E 7 ,5 A *
F 2 F U S E 7 ,5 A *

H 3 A C O U S T IC / O P T IO N A L W A R N IN G *
H 7 P IL O T L A M P R E S T R IC T E D G E A R R A N G E *

N O T E : * = S C O P E O F S U P P L Y C U S T O M E R
 F 1

E
K l.3 0 K l.3 0
K l.1 5 K l.1 5
F 2
L
P
M
1 1 1 8 6
2 2 2
1 D 2

A
2 6 3

S 1 S 4 S 5 S 2 8 S 3 2 H 3 K 2 8 5 5
4
2
1

S 3
2 6 2 V P I
4 5 2 3 6 8
V P E 1 V P E 2 E D 1 0
2 1
E D 7
? ? 4 4
E D 8 E D 1 2
3 0
H 7
E D 9
6 6 5 2
A D M 1 E D 1 3 A D M 2
3 1 0 7

1 5
M N L 6 -p in
6 0 2 9 1 9 9 0 7 4

2
1 8
6
4
2
7
5
3
1

B 4 E F 4 S D D K
A 5 A M P J P T 8 -p in
1 8 4 6 0 2 9 1 9 9 1 0 8
0 4 E U P R
1 2 3 1
V M G 2 4 6
1

1
S u p e rs e a l 3 -p in
1 3 7
A U 1
2 4
2
S D 4 3 6
A 9 3 8 A 6
2 3 8
V P
6 0 2 9 1 9 9 0 7 1 B 6 3 2 4 E U 1
S D 1
1 4 4 1
V M G A 1
A D M 3 0 6
* K D 2 2 E D 7 A D M 4 5 7
6
F
N
4 3 E D 4
E D 6
A D M 8 3 3 S 3 4
6 4
A 2 T +
R 6 4 E D 5
E D 1
6 3 5 6 0 1
T - 6 5 E D 2 A IP 1 1 0 0 2 Y 1 K 4
* N -R e le a s e In te rlo c k
C h a n g e A u to m a tic
2 0 E D 1 1
E D 3
A 1 A IP
A IP
3
2 3 2
5 5
0 3 Y 2 K
Y 3 K
R
1
0 4
8 6 1 1 9 A IP 4 0 9 0 5 Y 4 K 3
E F 1 A IP 5 Y 5 K V
K 1 8 5
B 1 2 0 3
V M G 1 A IP 6
5 1
1 2
0 6
0 7 Y 6 K 2 A 3
* = O P T IO N A L V P S 1 1 3 V P S 1 (+ )
1 4 1 V P S 1 3 9 0 8
E F 2 E R 1 T E M P
B 2 2
6 8
4 5
2 3
2 2
V M G A 2 4 6 0 9
T E M P
4 9 1 2
1 E R 2 B 9
B 3 2 4 2
E F 3
6 8 -p in
6 0 2 9 1 9 9 0 6 3
1 7 3
1 2
5
E R 3 4
C A N _ H C A N _ L C A N _ T V G S 6 7 8 9
V M 1 V M 2 V P S 2 V P S 2 A D M 7 A D M 5 A D M 6
M in i T im e r
2 -p in 2 5 2 6 2 7 2 8 1 2 8 5 3 3 4 5 7 1 1
S 1 0 1 0 1 1 1 2 1 3
1 2 1 4 1 5 1 6
6 0 2 9 1 9 9 0 1 1 S u p e rse a l
1 1 2 -p in 1 2
6 0 2 9 1 9 9 0 4 5 K o s ta l 1 6 -p in
2 2 6 0 2 9 1 9 9 0 7 2
1 2 4 Y 7 Y 9
1
1 2
4
2
3
1 A 7 Y 8 2 K o s ta l M 2 7
2 -p in
J P T 4 -p in 6 0 2 9 1 9 9 0 0 3
6 0 2 9 1 9 9 0 7 6

K l.3 1 K l.3 1
P o le p a tte rn s a re c o rre s p o n d in g w ith th e p lu g s o n th e w irin g !
T W IS T E D L IN E S (3 0 W IN D IN G S /M E T E R ) F R O M A L E N G T H O F > 2 M E T E R S O N A L L R E L A Y S W IT H P R O T E C T IV E D IO D E S 1 A /4 0 0 V

B U S T E R M IN A T IO N IF P IN 2 6 A N D 2 7 A R E C O N N E C T E D
 C O N T R O L L E R D W -3
T A B L E -1 5
L E V E R F O R M E C H A N IC A L C O N N E C T IO N D IA G R A M C O N T R O L L E R
N E U T R A L IN T E R L O C K C O D IN G C O N T R O L L E R
(+ )
O U T P U T K D

S P E E D F O R W A R D R E V E R S E N E U T R A L
X 2 : A
1 2 3 4 1 2 3 4 1 2 3 4
N D (+ )
A D 1 B 1
B 1 X 1 :C
A D 2 B 2
A 2 B 2
B 3
X 1
X 1
: B
: A A 1
A D 3 B 3 X 1 : B
IN P O S IT IO N (N E U T R A L ), V
A D 4 X 1 : C
F -R N O T S W IT C H A B L E V R
X 1 : D
A S
A D 5 R
A D 6 A S
A D 7
E
L K 1 K 2

P
M
(-)

A
A B C D
A B C D
X 2 X 1 K 1 = R E L A Y S T A R T E R IN T E R L O C K

F G E A R P O S IT IO N S T Y P E N S C H IL D S C IR C U IT D IA G R A M C O N T R O L L E R
K 2
A 1
=
=
R E L A Y R E V E R S IN G L IG H T S

E L E C T R O N IC U N IT E S T -3 7
A 2 = C O N T R O L L E R
F
S W A
A D 3 (B 3 )
N N N D
S 6 1 S 4 1 1 S 5
R 2 2 2 G N B
A D 2 (B 2 )
B L C
A D 1 (B 1 )
V I D
A D 7 (K D )
R X 1
R T A
E D 1 (+ /V P )
F = F O R W A R D S 1 1
N = N E U T R A L 3 2 G R D
A D 6 (N )
R = R E V E R S E T Y P E P L A T E S 2 1
D = M E C H A N IC A L N E U T R A L IN T E R L O C K C O N T R O L D W - 3
3 2 G E B
A D 4 (F O R W A R D )
1 = 1 st S P E E D N R .
S 3 1
V 1 2 / 2 4

2 = 2 n d S P E E D
3 2 R S C
3 = 3 rd S P E E D S T U E C K L . 0 5 0 1 2 1 0 1 4 8 A D 5 (R E V E R S E )
4 = 4 th S P E E D X 2
CONTROLLER VTS-3
TABLE - 16
FUNCTIONAL KNOB

V N R
CIRCUIT DIAGRAM CONTROLLER CODING CONTROLLER

RT/5 POSITION
ED1
2 +/VP V R N T+ T- KD/E
AD1 T+ •
S1 AD2 T- •

FUNKTION
WS/10

SWITCH
AD6
5 AS/N AD4 V •
AD5 R •
S2 AD6 AS/N •
SW/6 AD8 KD/E •
AD4
S3 4 V, F

VI/4
AD5
6 R
S6
GR/3
AD8
10 KD/E

GEAR SHIFTING GATE

S4
GN/1
AD1
7 T+

S5
+
+
+
R
V
N

GE/2
AD2
-
-
-

8 T-

X1
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Off-Road Transmissions
Filter and Axle Systems
Division

1. Coarse filter

Loosen the hexagon screws. Take off the cover and remove
the filter insert.

Figure 1

Place the filter insert into the locating.

) Observe installation position, see figure!

Figure 2

Assemble the O-ring (arrow).

Assemble the cover and fasten it by means of hexagon screws.

Tightening torque (M8/8.8) .................... MA = 23 Nm

) Observe the radial position, see figure!

Figure 1

1/1
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Off-Road Transmissions
Inductive Sensor and Axle Systems
Division

2. Inductive and speed transmitters

48 21
Figures 333 and 334 show the installation positions, also see the
exploded views in the corresponding spare parts list.

34 = Speed transmitter n-Output and speedo

21 = Inductive transmitter n-Turbine
47 = Inductive transmitter n-Internal speed input
6 48 = Inductive transmitter n-Engine
6 = Inductive transmitter n-Speedo or sealing plug
47
(depending on version)

Figure 1 Grease the O-rings and install the speed and inductive transmit-
ter acc. to the Figures 333 and 334.

Tightening torque (Cap screw–speed transmitt.) MA = 23 Nm

Tightening torque (Inductive transmitter) .......... MA = 30 Nm

34

Figure 2

2/1
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Off-Road Transmissions
Bypass- Relief- and Axle Systems
andConverter Pressure Division
Valve

3. ELECTRO-HYDRAULIC CONTROL
WITH PROPORTIONALVALVES

3.1 DISASSEMBLY

Loosen the cap screws and separate the gear shift housing from
the duct plate.

(S) Socket spanner TX-27 5873 042 002

Figure 1

Remove both gaskets as well as the intermediate sheet.

(S) Adjusting screw (M6) 5870 204 063

Figure 2

Remove the oil pipes.

Figure 3

Loosen the cap screws and remove the duct plate.

(S) Socket spanner TX-40 5873 042 004

Figure 4

3/1
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Off-Road Transmissions
Bypass- Relief- and Axle Systems
andConverter Pressure Division
Valve

Remove the gaskets.

(S) Adjusting screw (M8) 5870 204 011

Figure 5

Pull out the converter safety valve from the housing bore.

(S) Internal extractor 5870 300 004

(S) Counter support 5870 300 003

Figure 6

Loosen the cap screws and remove the released intermediate

sheet as well as the gasket.

Figure 7

Remove the single parts.

1 = Temperature sensor
2 = Converter pressure back-up valve
3 = Differential pressure switch/bypass valve

3
2
1

Figure 8

3/2
 Off-Road Transmissions
Bypass- Relief- and Axle Systems
andConverter Pressure Division
Valve

3.2 ASSEMBLY
3.2.1Duct plate
9 1 2 3
4 Install single parts.
5
Bypass valve pressure filter
1 = Compr.spring
2 = Piston
6 7
3 = Diff.pressure switch (Warning switch-fouling)
8
4 = Compr.spring Converter press.
5 = Shims s = 1.5 mm (2 pcs.) back-up valve
Figure 9 6 = Piston
7 = Screw plug

8 = Temperature sensor
9 = Screw plug
) Grease the O-rings (arrows)!
Tightening torque (Pos. 3) .......... MA = 30 Nm
Tightening torque (Pos. 7) .......... MA = 23 Nm
Tightening torque (Pos. 8) .......... MA = 30 Nm
Tightening torque (Pos. 9) .......... MA = 40 Nm

Provide the screw-in sleeve (arrow) with new O-rings and

install it.

Tightening torque ........................ MA = 80 Nm

Figure 10

Install the converter safety valve (cpl.) into the housing

bore until contact.

Figure 11

3/3
 Off-Road Transmissions
Bypass- Relief- and Axle Systems
andConverter Pressure Division
Valve

3.2.1 Mounting of duct plate and gear shift housing

Install two adjusting screws and assemble the gasket.

(S) Adjusting screw (M8) 5870 204 011

Figure 12

Assemble the intermediate sheet.

Figure 13

Assemble the gasket.

Figure 14

Assemble the duct plate and fasten it with cap screws.

) Pay attention to different lengths of the screws

(27 pcs. M8x40 mm, and 9 pcs, M8x35)!

Tightening torque ........................ MA = 23 Nm

(S) Socket spanner TX-27 5873 042 002

Figure 15

3/4
 Off-Road Transmissions
Bypass- Relief- and Axle Systems
andConverter Pressure Division
Valve

Install two adjusting screws and assemble the gasket.

) Pay attention to different gaskets, see Figure 47 or

Figure 49 !

(S) Adjusting screw (M6) 5870 204 063

Figure 16

Assemble the intermediate sheet.

Figure 17

Install the gasket.

Figure 18

Fasten the gear shift housing equally by means of cap screws.

Tightening torque ........................ MA = 12 Nm

(S) Socket spanner TX-27 5873 042 002

Figure 19

3/5
 Off-Road Transmissions
Bypass- Relief- and Axle Systems
andConverter Pressure Division
Valve

1 Install the screw-in sleeve (install new O-rings) and oil pipes.

1 = Clutch – K1
3 3 = Clutch – K3
4 = Clutch – K4
V V = Clutch – KV

Tightening torque (Screw-in sleeve) ... MA = 80 Nm

4 Tightening torque (Oil pipes)................ MA = 50 Nm

Figure 20

3/6
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Off-Road Transmissions
HSG 94 and Axle Systems
Division

4. ELECTRO-HYDRAULIC CONTROL
WITH PROPORTIONALVALVES

4.1 DISASSEMBLY

Loosen the cap screws and separate the gear shift housing from
the duct plate.

(S) Socket spanner TX-27 5873 042 002

Figure 1

Loosen the cap screws.

Separate the duct plate, gaskets and the intermediate sheet

from the valve block.

(S) Socket spanner TX-27 5873 042 002

Clean screens

Figure 2

4.2 Assembly

) Install two adjusting screws and put on the gasket (arrow).

Pay attention to different gaskets, see Figure 34
and 37!

(S) Adjusting screw (M6) 5870 204 063

Figure 3

Intermediate sheet – Version with screens:

Screens (6x) are to be flush mounted into the bores of the

intermediate sheet, see arrows !

) Observe the installation position – the screen are showing

upwards (to the duct plate)!

Figure 4

4/1
 Off-Road Transmissions
HSG 94 and Axle Systems
Division

Place the intermediate sheet (arrow) with the screens showing

upwards.

Figure 5

Put on the gasket (arrow).

Figure 62

Put on the duct plate (arrow) and fasten it equally by means of

cap screws.

Tightening torque .......................... MA = 11 Nm

(S) Socket spanner TX-27 5873 042 002

Figure 7

Install two adjusting screws and assemble the gasket.

) Pay attention to different gaskets, see Figure 47 or

Figure 49 !

(S) Adjusting screw (M6) 5870 204 063

Figure 8

4/2
 Off-Road Transmissions
HSG 94 and Axle Systems
Division

Assemble the intermediate sheet.

Figure 9

Install the gasket.

Figure 10

Fasten the gear shift housing equally by means of cap screws.

Tightening torque ........................ MA = 12 Nm

(S) Socket spanner TX-27 5873 042 002

Figure 11

4/3
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
 Off-Road Transmissions
Output and Axle Systems
Division

5.1 DISASSEMBLY Output:

Version with drum brake

Loosen the hexagon screws and by means of forcing screws the

brake drum is to be separated from the output flange.

(S) Forcing screw 5870 204 005

Figure 1

Remove the lock plate. Loosen the hexagon screws and

take off the washer.

(S) Fixture 5870 240 025

Figure 1

Press the output flange from the shaft.

(S) Pry bar set 5870 345 036

Figure 3

Remove the brake shoes.

Figure 2

5/1
 Off-Road Transmissions
Output and Axle Systems
Division

Loosen the cap screw and take off the cover plate.

Figure 5

Press out the shaft seal from the housing bore.

Figure 3

Rotate the housing by 180°.

Remove the lock plate and loosen the hexagon screws.

Take off the output flange.

Figure 4

Remove the sealing caps (3x, see arrows) and loosen the
cap screws (oil baffle fixing).

Figure 8

5/2
 Off-Road Transmissions
Output and Axle Systems
Division

Press out the shaft seal from the housing bore.

Figure 5

5.2 ASSEMBLY

Install the shaft seal with the sealing lip showing to the
) oil sump.

Exact installation position is obtained by use of the

specified driver (S)!
Depending on the version different shaft seals can be used:
Outer diameter rubber-coated – wet with spirit!
Outer diameter metallic – wet with sealing compound
(Loctite, Type No. 574)!

Figure 10

Assemble the output flange. Insert the O-ring into the gap
of output flange and shaft.

Figure 11

Put on the washer and fasten the output flange by means of

hexagon screws.

Tightening torque (M8/10.9) .............. MA = 34 Nm

(S) Fixture 5870 240 025

Figure 12

5/3
 Off-Road Transmissions
Output and Axle Systems
Division

Fasten the lock plate by means of hexagon screws.

(S) Driver 5870 057 011

(S) Handle 5870 260 002

Figure 13

Rotate the transmission housing by 180°.

Install the shaft seal with the sealing lip showing to the
oil sump.

) specified
Exact installation position is obtained by use of the
driver (S)!
Depending on the version different shaft seals can be used:
Outer diameter rubber-coated – wet with spirit!
Outer diameter metallic – wet with sealing compound
(Loctite, Type No. 574)!

Figure 14 (S) Driver 5870 048 135

Put on the cover plate and fasten it with cap screws.

Tightening torque (M6/8.8) ............... MA = 9.5 Nm

Figure 15

Install the brake shoes.

For maintenance and repair work on the brake, the

instructions and specifications of the brake manufacturer
have to be observed!

Figure 16

5/4
 Off-Road Transmissions
Output and Axle Systems
Division

Heat the inner diameter of the output flange. Assemble

the output flange until contact.

Insert the O-ring into the gap of output flange and shaft.

Inner diameter is heated – Danger of burns !

Figure 17

Put on the washer and fasten the output flange by means

of hexagon screws.

Tightening torque (M8/10.9) .............. MA = 34 Nm

(S) Fixture 5870 240 025

Figure 18

Fasten the lock plate by means of hexagon screws.

(S) Driver 5870 057 011

(S) Handle 5870 260 002

Figure 19

Install two adjusting screws.

Assemble the brake drum and fasten it with hexagon screws
(install washers).

Tightening torque (M10/8.8) ................... MA = 46 Nm

(S) Adjusting screw 5870 204 007

Figure 20

5/5