DHIM C/S

ZF Transmission 4WG190/210

Mega V

Construction equipment B/G

Product Support Team

DHIM C/S

1. Clutch Shaft “ KR”2. Power Take Off Coaxial3. Clutch Shaft “KV”4. Clutch Shaft “K2”5. Clutch Shaft “K3”6. Output flange Rear7. Output flange Converter8. Output shaft9. Transmission Pump10. Input Flange11. Converter12. Transmitter for Engine speed13. Clutch Shaft “K4”14. Converter Relief V/V15. Clutch Shaft “K1”

Lay Out (1) 4WG-190/210

DHIM C/S

1. Lifting plug

2. Drive flange

3. Transmission suspension

4. Attachment for

Emergency Steering Pump

5. Model I/D

6. Output Flange Converter Side

7. Oil Drain Plug

8. Attachment for oil filter pipe

9. Oil Dipstick

Lay Out Front view (2) 4WG-190/210

DHIM C/S

1. Driving Flange

2. Cover

3. Converter Bell Housing

4. Breather

5. Transmission Case Cover

6. Filter head & Alarm Switch

7. Fine Filter

8. Oil Dipstick

9. Output Flange-Rear

10. Oil Drain Plug

11. Out Flange - Front

12.Transmission Case

Lay Out Side view (3) 4WG-190/ 210

DHIM C/S

1. Lifting Lugs

2. Power Take Off

3. Electro- Hydraulic Control

4. Return port

(Option-Parking brake)

5. Oil Dipstick

6. Transmission Suspension

7. Output Flange

8. Fine Filter

9. Filter Head & Alarm Switch

10. System Pressure Port

(Option- Parking Brake)

Lay Out Rear view (4) 4WG-190/210

DHIM C/S

21. Inductive transmitter :

Turbine

34. Speed Sensor : Output and Speedmeter

47.Inductive transmitter : Central Gear Train

48. Inductive transmitter : Engine

Measuring Point (1) 4WG-190/210

DHIM C/S

Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 EngagedClutch

Forward 1st ◆ ◆ K1,KV2nd ◆ ◆ KV,K23rd ◆ ◆ K3,KV4th ◆ ◆ K4,K3

Reverse 1st ◆ ◆ KR,K12nd ◆ ◆ KR,K23rd ◆ ◆ KR,K3

NeutralRelated Clutch K4 KR K1 K3 KV K2Location F E D C B AMeasuring Point 60 55 56 58 53 57System Pressure (bar) 16±2 16±2 16±2 16±2 16±2 16±2

Measuring Point (2)4WG-190 /210

DHIM C/S

WGV : Converter Back Pressure Valve

3~5 bar

WSV : Converter Relief Valve 11 bar

HDV : System pressure 16 bar

RV-9 : Pressure Reducing Valve 9 bar

NFS : Follow-on Slide

D : Oscillation Damper

P : Proportional Valve Clutch

Y : Pressure Regulator

B : Orifice

Temp : Temperature Sensor

( RV-9 Pressure measuring

after being detached)

Oil Circulation (System Pressure)

DHIM C/SWorking of Proportional Valve

DHIM C/S

16bar @ Port No 65

Oil Circulation - Neutral Position (System Pressure)

DHIM C/S

9 bar

Oil Circulation - Neutral Position (Pilot Pressure)

DHIM C/S

11 bar @ Port No 51

3~5 bar @ Port No 52/63

Oil Circulation - Neutral Position (T/Q Converter)

DHIM C/SOil Circulation - Forward 1st

DHIM C/SOil Circulation - Reverse 1st

DHIM C/S

Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 EngagedClutch

Forward 1st ◆ ◆ K1,KV2nd ◆ ◆ KV,K23rd ◆ ◆ K3,KV4th ◆ ◆ K4,K3

Reverse 1st ◆ ◆ KR,K12nd ◆ ◆ KR,K23rd ◆ ◆ KR,K3

NeutralRelatived Clutch K4 KR K1 K3 KV K2

Engaged EPPR Valve Summary

DHIM C/SOil Circulation - Hydraulic Control (1)

DHIM C/SOil Circulation - Hydraulic Control (2)

DHIM C/S

KV :Clutch Forward KR: Clutch Reverse K1: Clutch 1st Speed K2: Clutch 2nd SpeedK3: Clutch 3rd Speed K4: Clutch 4th SpeedIN : Input Out : Out Put

Gear Schema - 4WG190/210

DHIM C/SPower Flow - Forward 4WG 190/210

DHIM C/SPower flow - Reverse 4WG190/210

DHIM C/S

1. EST 37 CONTROL UNIT

2. KICKDOWN SWITCH

3. T/M CUT OFF SWITCH

4. AUTO SELECT SWITCH

5. DISPLAY

6. DW-3 CONTROLLER INCLUDING

KICK DOWN SWITCH

7. SUPPLY SYSTEM CONNECTION

8. TRANSMISSION

9. CENTRAL GEAR TRAIN SPEED SENSOR

10. TURBINE SPEED SENSOR

11. ENGINE SPEED SENSOR

12. OUTPUT SPEED SENSOR

13. CABLE

( TO ELECTRO HYDRAULIC

CONTROL UNIT)

14.DIAGNOSIS LAPTOP (OPTION)

15. BRAKE PRESSURE SENSOR

MEGA-V T/M Electric Control System

DHIM C/SElectric system

DHIM C/S

-Output Propellar shaft speed-Travel Speed display signal-LIS system (over 8 km)

1.0~1.52~51.0~12.5Speed

-Output torque Control signal-Shifting quality (max 1.6sec)-Keep the original gap

0.5~0.81050 ±

10%30Hz~50kHz0.45~7.0Engine

& Turbine

Gap(mm)Resistance(Ω)FrequencyVolt(V)Remark

SpecificationSensor

♣

Sensors

♣Pressure Regulator in Transmission Control Block

0.8 ~ 9.0

Output Press(bar)

Within 1.69.51.919500100Y1~Y6

EngagedNeutralEngagedNeutral

Shifting(sec)

Voltage(VDC)Resistance(Ω)

Input Current(mA)Regulator

♣Condition of Pressure Regulator Operation1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C

Description of Components

DHIM C/S

♣

Transmission Oil Temperature Sensor (built in TCV)

- 1st, 2nd Speed mode only-30 ~ -10 degree C (T/M oil)

- Travels Normally↑

-10 degree C (T/M oil)

- Parking Brake Engaged↓

-30 degree C (T/M oil)-Output Voltage :5.2 ~ 24V-Resistance : 1000 ~ 1500 Ω-No Buzzer

-Error Code Display only-Travels Normally

Open or Short Circuit

RemarkFunctionCondition

♣

Others

1. TCU (Transmission Control Unit) Working Voltage : 18 ~ 32 VDC

2. Kick Down

1) Manual Mode : 2nd -> 1st Speed Change Only

2) Auto Mode : Every Travel Speed, 1 stage shift down

@ after 200 ~ 300 engine speed drop (except 4th -> 3rd)

3. Transmission Cut Off : Available @ 1st & 2nd Speed mode only

Description of Components

DHIM C/S

XXXXXX

A voltage between each terminal ( # 58,10,32,55,9,51) and ground : 1.9 V

Electric system (Neutral)

DHIM C/S

XXXX

A voltage between each terminal # 32, 9 and ground : 9.5 VThe voltage between each terminal #58,10,55,51 and ground : 1.9 V

Electric system (Forward 1st)

DHIM C/S

If the downshift switch is pressed, the gear shift changes to 1st gear and when the downshift switch is pressed once again, downshifting is released and returns to 2nd gear automatically.

Electric system (Down Shift 2nd -> 1st - Manual mode)

DHIM C/S

When the auto selector switch is “on” position and the downshift switch pressed,the transmission changes automatically to the next lower gear.Note: The third to the second gear and the second to the first gear change

occur when the engine speed is reduced 200 - 300 rpm from current speed.

Electric system (Down Shift - Auto mode)

DHIM C/S

When the T/M cut off switch(1) is “on” position and the T/M cut off switch(2) has been connected by foot braking (25bar) in the cabin,the transmission will be in neutral position automatically (This function works on 1st, 2nd gear only ).

Electric system (Transmission Cut Off )

DHIM C/S

The AEB has the task to compensate tolerances (plate clearance and pressure level) which are influencing the fiIling procedure of the clutches.

For each clutch, the correct filling parameters are determined in one test cycle for period of the quick-fllling timelevel of the filling compensating pressure

No Order Displaymessage

Remark

1 Warm up transmissionabout 10 to 20 minutes

2 Turn off ignition key3 Plug in AEB starter to

AEB connector locatedat the seat base closestto the cab door

4 Put T/M gear selectorLever to Neutral position

5 Engage park brake6 Start Engine “PL“ TCU must recognize

“PL” for at least 2secbefore you pressAEB starter button

7 On idling RPM “PL”8 Press button of the AEB

Starter“ST” The button must not

be released beforeTCU has started theAEB or quit withan error code(see Error code list)

9 Hold button until AEB hasbeen started

“K1”(Information about the AEB state)

TCU has started theAEB, and goes onadjusting K1, K2,…,KR. (Button may bereleased fromstarting)

10 Wait until AEB hasbeen finished

“OK”(AEB has been successful)

11 Turn off ignition andunplug AEB Starter

Electric system (AEB )

DHIM C/S

Symbol Meaning RemarksPLSTK1..K4,KV,KR_ and Kx≡ and Kx

OK calibration for all clutches finished Transmissions stays in neutral, have to restart theTCU (ignition off/on) after removing AEB-Starter

STOP AEB canceled (activation Transmissions stays in neutral, have to restart thestopped) TCU (ignition off/on)

STOP and Kx AEB stopped, clutch Kx Transmissions stays in neutral, have to restart thecan't be calibrated TCU (ignition off/on)

Spanner and Kx Kx couldn't be calibrated, Transmissions stays in neutral, have to restart theAEB finished TCU (ignition off/on)

↑ E Engine speed too low, E/G RPM should be raised↓ E Engine speed too high E/G RPM should be down↑ T Transmission oil Warm up Transmission

temperature too low↓ T Transmission oil Cool down Transmission

temperature too highFT T/M temp not in defined T/M stays in neutral, have to

range during calibration restart the TCU (key off/on)FB Operating mode not T/M stays in neutral, have to

NORMAL or T/M temp restart the TCU (key off/on)sensor defective or storingof Calibrated values toEEPROM-has failed

FO Output speed not zero Transmissions stays in neutral, have to restart theTCU (ignition off/on)

FN Shift lever not in Neutral Transmissions stays in neutral, have to restart theposition TCU (ignition off/on)

FP Parking brake not applied Transmissions stays in neutral, have to restart theTCU (ignition off/on)

STOP AEB - Starter was used Transmissions stays in neutral, have to restart theincorrect or is defective TCU (ignition off/on)

fast fill time determination of clutch Kxcompensating pressure determination of clutch Kx

AEB - Starter is plugged at the diagnostic plugAEB Starter button is pressedCalibrating each clutch K1..K4,KV,KRWait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R

Electric system (AEB DISPLAY )

DHIM C/S

Shaft rpm = (Hz/Z) X 60You can measure the frequency with an electric multi meter.

Z

Hz

Shaft

Frequency of Speed sensor

DHIM C/S

- Hz Frequency from Speed Sensor - Z Number of Ring gear Teeth- r total Total Reduction Ratio of Axle (r diff X r hub)- R Tire Radius in meter

Machine Speed (km/hr)

Hz 1 3600 (sec/hr)= x x 2πR x

Z r total 1000 (m/km)

M160-V M200-V M250-V M300-V M400-V M500-V

Z 53 53 44 44 66 66

Machine Speed