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1 Order-No.: ZF ERGOPOWER TRANSMISSION 4 WG-190/210 TECHNICAL DATA DESCRIPTION OPERATION MAINTENANCE DIAGNOSTIC SYSTEMS ZF Passau GmbH Donaustr Edition: 2001/08 D Passau Subject to changes w/o notice!

2 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 2. Edition 2

3 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 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 description. 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, impro-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 Vehicle Manufacturer. Important Informations concerning the technical reliability and reliability in service are accentuated by the following Symbols: Valid for Instructions which must be observed at the Maintenance, the Performance or the Operation of the vehicle! Is inserted at working and operating procedures which have to be exactly respected to avoid a damage or destruction of the unit or to exclude a danger to persons! 3

4 ERGOPOWER Off-Road Transmissions and Axle Systems Division TABLE OF CONTENTS Page: Summary of the TECHNICAL DATA 6-7 IMPORTANT INSTRUCTIONS 9-10 I. DESCRIPTION Function of the Converter 1.2 Powershift transmission 1.3 Transmission control 1.4 Controllers General Controller DW Controller ERGO II 1.5 Display General Possible Indications on the Display Error code definition 1.6 Electronic control unit TCU 1.7 Electronic control for the ZF-Powershift transmission General Description of the Basic functions AEB Downshifting functions (Down-Shift Button) Pressure cut-off Inching device Special functions II. INSTALLATION SPECIFICATION 25 III. OPERATION 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 IV. MAINTENANCE Oil grade 4.2 Oil level check replacement intervals 4.3 Oil change and Filter replacement intervals Oil change and Oil filling capacity Filter replacement V. DIAGNOSTIC SYSTEMS General 5.2 MOBIDIG Laptop Version 5.4 Multi-System

5 ERGOPOWER Off-Road Transmissions and Axle Systems Division ANNEX, comprising: Tables: 1 Layout 4 WG-190/210 Installation view 4 WG-190/120 2 Front view - Direct installation 3 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 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 5

6 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme TECHNICAL DATA WG-190 WG-210 Engine power: max. KW* Turbine moment: max. Nm* Engine speed: max. min -1 * Starting torque multiplication: Engine-dependent Power take-offs: Torque: Speed: Mass (without oil): Nm n kg about** * = dependent on Vehicle type and application ** = dependent on the Transmission version ,0 bis 3, x n Engine 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 universal 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

7 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 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 signal. 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. 7

8 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 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, according to the installation conditions! At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF recommends to start the autonomous calibration of the shifting elements (AEB). The independent 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 electrohydraulic 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 engaged 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 programmed transmission input speed (turbine speed). Neutral position of the selector switch at higher vehicle speeds (above stepping speed) s not admissible. Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once. Reversing (Standard): In the speeds, released for the direct reversing, as a rule in the speeds 1 F 1 R and 2 F 2 R, it is possible to reverse directly at any time. Reversings in the speeds 3 and 4 are realized dependent on the driving speed, the permitted reversing speed is then normally the maximum speed of the 2 nd speed. - Beyond the programmed reversing limit, the vehicle will be braked down by the Electronic unit EST-37 by downshiftings, and only then the reversing is carried out into the correspondingly preselected gear. - Below the permitted speed, the reversing will be carried out. The programming is customized and can therefore be different from the standard. Therefore, the exact procedure must be taken from the Operating Instructions of the respective Vehicle Manufacturer! 9

9 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 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 damaged due to insufficient oil supply! At a longer distance, the best solution would be to transport the defective vehicle with a Low loader. Operating temperature behind the converter at least 65 and 100 C in continuous operation, a short-time increase up to max. 120 C is permitted. Temperature in the sump 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. 10

10 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme I. DESCRIPTION 1.1 Function of the Converter: From engine Condition at the time of starting Intermediate condition Condition in the coupling point T P Function of a hydrodynamic Torque converter (Schematic view) Pump wheel 1,5 <1, T R Turbine wheel Reaction element (Reaction wheel) T P = Torque pump wheel T T = Torque turbine wheel T R = Torque reaction member (Reaction wheel) To gearbox N T = 0 Vehicle standing still n T = <n Mot n T = 0,8 n Mot Figure-No. 1.1 The converter is working according to the Trilok-System, i.e. it assumes at high turbine speed the characteristics, and with it the favourable efficiency of a fluid clutch. The converter is designed according to the engine power so that the most favourable operating conditions are obtained for each installation case. The Torque converter is composed of 3 main components: Impeller Turbine wheel Stator (Reaction member) These 3 impellers are arranged in such a ring-shaped system that the fluid is streaming through the circuit components in the indicated order. Pressure oil from the transmission pump is constantly streaming through the converter. In this way, the converter can fulfill its task to multiply the torque of the engine and at the same time, the heat created in the converter is dissipated via the escaping oil. The oil which is streaming out of the impeller, enters the turbine wheel and is there reversed in the direction of flow. According to the rate of reversion, the turbine wheel and with it also the output shaft is receiving a more or less high reaction torque. The stator (reaction member), following the turbine, has the task to reverse the oil streaming out of the turbine once more and to deliver it under the suitable discharge direction to the impeller. 2,5 <2,5 1 T T

11 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme Due to the reversion, the stator is receiving a reaction torque. The relation turbine torque/pump torque is called torque multiplication. This is the higher, the greater the speed difference of impeller and turbine wheel will be. Therefore, the maximum torque multiplication is created at stationary turbine wheel. With increasing output speed, the torque multiplication is decreasing. The adaption of the output speed to a certain required output torque will be infinitely variable and automatically achieved by the torque converter. When the turbine speed is reaching about 80% of the pump speed, the torque multiplication becomes 1,0 i.e. the turbine torque becomes equal to that of the pump torque. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, in the torque multiplication range it is backing-up the torque upon the housing, and is released in the clutch range. In this way, the stator can rotate freely. 1.2 Powershift transmission: The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 4-speed reversing transmission is equipped with 6 multi-disk clutches. At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is pressurized by pressure oil. A compression spring takes over the pushing back of the piston, thus the release of the plate pack. As to the layout of the transmission as well as the specifications of the closed clutches in the single speeds, see Table-1, 7 and Transmission control: Transmission control, see Schedule of measuring points, Oil circuit diagram ans Electro- hydraulic control unit see Table-7, 8 and 9. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 105 l/min, at n Engine = 2000 min -1. This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF- Fine filter the filter can also be fitted externally from the transmission to the main pressure valve. If because of contamination, resp. damage, the through-flow through the ZF-Fine filter is not ensured, the oil will be directly conducted via a filter differential pressure valve (bypass valve p= 5,5 bar to the lubrication. In this case, an error indication is shown on the ZF-Display. 12

12 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme ZF-Fine filter: Filtration ratio according to ISO 4572: ß 30 > 75 ß 15 = 25 ß 10 = 5.0 Filter surface at least: 6700 cm 2 Dust capacity according to ISO 4572 at least: 17 g The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6), follow-on slide and vibration damper. The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressure reducing valve. The pressure oil (16+2 bar) is directed via the follow-on slide to the respective clutch. Due to the direct proportional selection with separated pressure modulation for each clutch, the pressures to the clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible. This is creating spontaneous shiftings without traction force interruption. At the shifting, the following criteria will be considered: - Speed of engine, turbine, central gear train and output. - Transmission temperature. - Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral). - Load condition (full and part load, traction, overrun inclusive consideration of load cycles during the shifting). The main pressure valve is limiting the max. control pressure to 16+2 bar and releases the main stream to the converter and lubricating circuit. In the inlet to the converter, a converter safety valve is installed which protects the converter from high internal pressures (opening pressure 11,0 bar). Within the converter, the oil serves to transmit the power according to the well-known hydrodynamic principle (see Chapter Torque converter 1.1). To avoid cavitation, the converter must be always completely filled with oil. This is achieved by a converter pressure back-up valve, rear-mounted to the converter, with an opening pressure of at least 4,3 bar. The oil, escaping out of the converter, is directed to a heat exchanger. The selection and definition of the heat exchanger must be carried out according to our Installation specification for hydrodynamic powershift transmissions by the Customer on his own responsibility. The heat exchanger is not within the scope of supply of the ZF Passau GmbH. From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil circuit, so that all lubricating points are supplied with cooled oil. In the Electrohydraulic control unit are 6 pressure regulators installed see Table-9. The allocation of the pressure regulators to the single speeds can be seen on the Tables 7 and 8. 13

13 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 1.4 Controller General: Due to the great number of the available Controllers, the precise Technical Data must be taken from the respective installation drawing Controller DW-3 - see Table-12 The Controller is designed for the mounting on the steering column left side. By a rotative motion, the positions (speeds) 1 to 4 are selected by tilting the lever, the driving direction (Forward (F) Neutral (N ) Reverse (R). The DW-3 Controller is also available with integrated Kickdown pushbutton. For the protection from unintended start off, a Neutral interlock is installed: Position N Controller lever blocked in this position Position D Driving N Controller ERGO II - see Table-13 F R Controller DW-3 Gear positions 14 F N R N D Type plate Figure-No.: This lever will be installed in the Wheel loader instead of the operating lever for the hydraulic system for implement operation. By pushing the arrow button Forward and Reverse, the driving direction will be selected, the Buttons + and - are preselecting the driving range. The indication for gear and driving direction is shown on the Display (see 1.5). By means of the N -Button, the transmission is shifting to Neutral. Gear limitation, if second cabin is activated an the all-wheel drive is engaged. Another Button on the operating field allows the connection of an electric shovel-horizontal Regulation (Shovel-Neutral). Another function button is installed on the back. It serves, according to the programming, as Kickdown button, Down-shift button or Release button for the start off.

14 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme Controller ERGO II N Display General: Figure-No.:1.4.3 The Display can be used with all Controller types, e.g. with the DW-3 or ERGO II for Wheel loaders, Lift trucks, RoRo trucks as well as with the VTS-3, SG-6 or D7 for Cranes, Dumpers, Graders and Rail vehicles Possible Indications on the Display Display left central right h f e d Side Side Side a b c g Figure-No.:

15 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme Spec. charact. Display (see Figure-No.: 1.5.2) a, f Automatic range (up- and downshifting) b, c, d, e Preselected gear g EST-37 has recognized an error, is flashing h This special character is not used for the moment at the EST-37 Left Side Central and Right Side Display of the Driving direction: (right Side) Display of the engaged gear: (central Side) Waiting for Controller-Neutral: Preselected Driving range: (Special characters b, c, d, e) Display Manual/ Automatic: (Special characters a, f) For the moment still without function On the two alphanumeric 16-segment displays, the EST-37 issues the actual state of gear and driving direction. Besides, a two-digit error code will be indicated via these two segments. V : Forward N: Neutral R: Reverse Display 1, 2, 3, 4 Indication on the Display: NN (central and right Side). In this condition, Neutral is pending on transmission. To engage a gear, at first Neutral must be shifted on the Controller before the electronics allows to engage a gear again. The number of the lines indicates the driving range, resp. the gear preselection: 1 Bar: Manual Mode 1 speed 2 Bars: Manual Mode 2 speed 3 Bars: Manual Mode 3 speed 4 Bars: Manual Mode 4 speed If the two Symbols a, f (Arrows) and the bars b, c, d, e are indicated, the system is in the Automatic mode (automatic up- and downshiftings). If the Arrows (a, f) are flashing, the KD (Kick- Down) Mode is activated. Display of the Cold-start phase: Transmission remains in Neutral Bars are flashing: Error display: Downshifting mode active If the system is recognizing an error, the spanner (Special symbol g ) is flashing. If Neutral is preselected on the Controller, a two-digit error number appears on the two alphanumeric indicating positions (central and right Side). 16

16 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme If more than one error is pending, the different error numbers will be indicated one after the other on the Display in cycles (about 1 second). The error code will be only then indicated if the Controller is in Neutral! Warning display: At exceeding the warning threshold Temperature Sump / behind the Converter and the warning threshold Speed Engine, changes the indication on the Display to the actual gear and the corresponding warning indicator. Display PN F or R flashing Display EE If several warnings are simultaneously active, only the warning with the highest priority will be indicated. Warning Warning Priority code WT Temperature behind Converter 1 WS Temperature in the Sump 2 WE Engine speed 3 Driving direction F or R selected whilst the parking brake is actuated. Transmission in Neutral until parking brake will be released. After the release of the parking brake, the vehicle begins to roll. Driving direction F or R selected, whilst the turbine speed is too high. Speed will be engaged when the turbine speed is decreasing. Indication on Display: EE (central and right side). In this state, the Display has a timeout, i. e. it is receiving no Data from the EST-37. Main reasons: - EST-37 is in TOTAL RESETTING MODE (e.g. because of output train disconnection or external power supply at the lines to the gear-solenoid valves). - EST-37 without supply Data line not correctly connected, etc. 17

17 ERGOPOWER Off-Road Transmissions and Axle Systems Division Error code definition: The error codes are composed of two hexadecimal numbers: The first number indicates the kind of signal, the second number the signal and the kind of error. Since there are different Software versions for the Customers, the listing of the error codes must be taken from the Documentation of the Vehicle Manufacturer. First Number Meaning of the Number 1 hex Digital input signal 2 hex Analog input signal 3 hex Speed signal 4 hex CAN signal error 5 hex CAN signal error 6 hex CAN signal error 7 hex Analog current output signal 8 hex Analog current output signal 9 hex Digital output signal A hex Digital output signal B hex Transmission error, Clutch error C hex Logical error D hex Power supply E hex Highspeed signal F hex General error For the EST-37, a general Diagnostic and Trouble shooting Specification is available, for which the following Order-No. has been defined: GERMAN ENGLISH This Diagnostic and Trouble shooting Specification can be requested under the following address: ZF Passau GmbH Abt. ASI Donaustr Passau 1.6 Elektronic Control unit TCU The electrohydraulic transmission control can be automated by connection on the electronic TCU. The basic functions of the automatic system are the automatic shifting of speeds, adaption of the optimum shifting points, the comfortable kickdown function as well as comprehensive safety functions in relation to operating errors and overloadings of the power-transmitting components with a comprehensive fault storage. 18

18 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme The Control units can be programmed customized and vehicle-specific in a large spectrum, Control parameter can be logically chained, and also Special functions such as gear limitation, Converter or Retarder functions can be integrated. Because of the great number of available TCU, the precise Technical Data must be taken from the corresponding Installation drawing. Installation position of the TCU Installation position of the TCU 209 Figure-No..: 1.6 B1 ZF-Type plate 100 Minimum Distance to disengage the plug 100 Figure-No.: 1.6 B2 19

19 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme The installation position of the TCU can be at random. As an advantage, the ZF recommends the Version illustrated in the Figure-No.: 1.6 B1. The installation of the TCU must be realized on a protected point in the cabin. An overfloating with water must be excluded. Besides, the penetration of water via the plug connection must be prevented by corresponding measures on the cable harness. 1.7 Electronic Controls for ZF-Powershift transmissions: General: Because of the different configurations of the electronic transmission controls at the various vehicles, the corresponding documentation must be taken from the operating Instructions of the Vehicle Manufacturer or from the Technical Data sheet of the concerned Parts List Versions. In these are also indicated the respective circuit diagram (see Sample Table-11) - and the connection diagram (upon request, these Informations can be asked for at the ZF Passau). According to the type of vehicle, the wiring will be performed according to the wiring diagrams. The corresponding electric circuit diagrams (proposals) will be realized by ZF. Upon request, the wiring can be also supplied by ZF. If the wiring will be realized by the Vehicle Manufacturer, it must be in accordance with the ZF-Requirements (see Installation Specification) Description of the Basic functions: The Powershift transmission of the Ergopower-Series 4 WG-190/210 is equipped with the Electronic control unit EST-37, developped for it. For Wheel loaders, Lift trucks and RoRo Trucks, the ZF has developped with the Controllers DW-3 and ERGO II a special Controller configuration. The system is processing the desire of the driver according to the following criteria: Gear determination depending on controller position, driving speed and load condition. Protection from operating error as far as necessary, is possible via electronic protection (programming). Protection from over-speeds (on the base of engine and turbine speed). Automatic reversing (driving speed-dependent, depending on vehicle type). Pressure cut-off possible (vehicle-specific, only after contact with ZF). Change-over possibility for Auto- / Manual mode. Downshifting functions possible. 20

20 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme Legend ref. Figure-No.: = Acoustic / optical warning (Option) 2 = Display 3 = Controller DW-3 (optionally also with Controller e. g. ERGO II possible) 4 = Power supply connection 5 = Switch for pressure cut-off (Option) 6 = Switch for driving program Manual/Automatic (Option) 7 = Downshifting functions (Option) 8 = TCU 9 = CAN-Connection 10 = Wiring 11 = Diagnosis Mobidig 2001 only for ZF-Service Stations 12 = Diagnosis Laptop with ZF-Diagnostic system Testmann 13 = Cable to Inductive transmitter Speed Central gear train 14 = Cable to Inductive Speed Engine 15 = Cable to Inductive transmitter Speed Turbine 16 = Cable to Temperature measuring point behind the Converter No = Cable to Plug connection on the electrohydraulic Control unit 18 = Cable to filter contamination switch 19 = Cable to Speed sensor Output and Speedometer 20 = Ergopower Transmission 4 WG-190/ Family package of the EST Figure-No.:

21 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme Independent calibration of the Shifting elements (AEB) The AEB has the task to compensate tolerances (plate clearance and pressure level) which are influencing the filling procedure of the clutches. For each clutch, the correct filling parameters are determined in one test cycle for: Period of the quick-filling time Level of the filling compensating pressure The filling parameters are stored, together with the AEB-Program and the driving program in the transmission electronics. Because the Electronics will be separately supplied, the AEB- Cycle must be started only after the installation of both components in the vehicle, thus ensuring the correct mating (Transmission and Electronics). At any rate, the AEB-Cycle must be carried out at the Vehicle Manufacturer prior to the commissioning of the vehicles. It is imperative, to respect the following Test conditions: - Shifting position Neutral - Engine in idling speed - Parking brake actuated - Transmission in operating temperature After a replacement of the transmission, the electrohydraulic control or the TCU in the vehicle, the AEB-Cycle must be as well carried out again. The AEB-Cycle continues for about 3 to 4 minutes. The determined filling parameters are stored in the EEProm of the Electronics. In this way, the error message F6 shown on the Display will be cancelled also at non-performed AEB. For the start of the AEB-Cycle, there are principally two possibilities: 1. Start of the AEB by separate Tools which are connected on the diagnostic port of the wiring. Following Tools for the AEB start will be offered by the ZF Service.: - Mobidig 2001 (see Point 5.2 Diagnostic systems) - Testmann (see Point 5.3 Diagnostic systems) - AEB Starter Order-No.: The Special Tool, developped by the ZF for it can be used only for the starting of the AEB! (see Figure-No.: 1.7.3) 22 Figure-No.: B1 2. Start of the AEB by operating elements on the vehicle. For it, a CAN-Communication between transmission and vehicle electronics is necessary.

22 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme At the operating of the transmission, the paper friction linings, installed in the Ergopower transmissions are settling, i.e. the plate clearance becomes creater. Because these settling appearances can affect the shifting quality, ZF recommends to repeat the AEB-Cycle at the Maintenance intervals (see 4.3.1). At a deterioration of the shifting quality, the ZF recommends likewise as first measure to repeat the AEB-Cycle. The AEB can be started from the following Software-No. on: From the Version 7** on, the AEB can be started with the Tools Laptop and MOBIDIG (See Type plate Figure-No B2) From the Version 812 on, the AEB can be started with the Tools Laptop, MOBIDIG 2001 and the AEB-Starter. (See Type plate Figure-No B3) Down-Shift functions (Down-Shift Button) If necessary, it is possible to select from 3 different possibilities: Down-Shift Button - 1 Function: Figure-No.: B2 Figure-No.: B3 The downshifting from the second speed (mode manual) into the first speed is performed at the first actuation. At a second actuation, the upshifting from the first speed into the second speed follows again. Down-Shift Button - 2 (Ouick-Shift Button) Function: The range limitation on the actual speed will be performed at the first actuation, after a second actuation, the full range is existing again. 23

23 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme Down-Shift Button - 3: Function: Every actuation is leading to a downshifting for one speed. The Down-Shift Button (pushbutton) must be in all 3 possibilities provided by the Customer-side, if as Controller the DW-3 or ERGO II with integrated Down-Shift Button will not be used Pressure cut-off In order to provide, e.g. at Shovel loaders, the full engine power for the hydraulic system, the control can be enlarged for the function of a pressure cut-off in the 1 st and 2 nd speed. In this way, the pressure in the powershift clutches will be cut-off, and the torque transmission in the drive train will be eliminated by it. This function will be released at the actuation of a switch, arranged on the brake pedal. For a soft restart, the pressure will be build-up via a freely programmable characteristic line Inching device This function is especially suitable for Lift trucks. It allows to reduce the driving speed infinitely variable without modification of the engine speed in such a way that driving with a very low speed will be possible. In this way, the driver can move the vehicle very exactly to a determined position. At the same time, an important part of the engine power for the output of the hydraulic system is at disposal by the high engine speed. The operation is realized via a separate inching pedal. With increasing pedal travel, the driver can reduce the driving speed. The special Software is regulating the pressure in the driving direction clutch in such a way that the driving speed will be adjusted on the inching pedal according to the setting. A clutch overload will be prevented by an integrated protection Special functions According to the desires of the Vehicle Manufacturer, further additional functions can be programmed. Functions such as can be realized: * Selection of a Parking brake * Automatic Neutral shifting at vehicle standstill * Gear range limitation depending on determined Input signals * Blocking of the speed engagement beyond a determined Engine speed * Upshifting prevention in the overrunning range Further available Special function upon request after contact with the ZF. 24

24 ERGOPOWER Off-Road Transmissions and Axle Systems Division II. INSTALLATION SPECIFICATION This Specification for the installation of hydrodynamic Powershift transmissions of the Ergopower-Series is the basis for the technically faultless installation of these transmissions in the vehicle. The Installation Specification is part of the Transmission Documentation and must be absolutely respected. A faulty installation of the transmission into the vehicle, can * affect the operating quality, * cause malfunctions of the transmission, * lead to transmission damages, resp. transmission failures. Responsible for the correct installation of the transmission is the Vehicle Manufacturer. ZF does not admit any guarantee or warranty claims for damages which has been caused by a faulty installation. In order to assist the Customer in case of new, resp. initial applications, the ZF carries out by authorized personnel a transmission installation check. On this occasion, all transmissionspecific installation features are examined and the Vehicle Manufacturer, resp. the Equipment Manufacturer will be informed about the encountered defects. At improperly installation, ZF reserves itself the right to acknowledge no guarantee for the installed ZF-Products. For damages, caused by defects for which the Vehicle Manufacturer is responsible, and could not be discovered at the installation examination by ZF-Personnel, the Vehicle Manufacturer alone is liable. This Installation Specification DEUTSCH ENGLISCH can be requested under the following address: ZF Passau GmbH Dep. ACETS stefan.altmann@zf.com Donaustr Passau 25

25 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme III. OPERATION 3.1 Driving preparation and Maintenance: Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter as well as the pipes must get filled with oil. According to these cavities, the quantity of oil to be filled in, is greater than at the later oil fillings in the course of the usual Maintenance service. Because the converter and also the heat exchanger, installed in the vehicle, as well as the pipes can empty at standstill into the transmission, the Oil level check must be carried out at engine idling speed and operating Temperature of the transmission (see Chapter Oil level check 4.2). At the oil level check, the prescribed safety directions according to 6 of the regulations for the prevention of accidents for power plants in Germany, and in all other countries, the respective national regulations have to be absolutely observed. For example, the vehicle has to be secured against rolling by blocks, articulated vehicles additionally against unintended turning-in. 3.2 Driving and Shifting: Which control lamps in the INFOCENTER (dashboard) are illuminated for the functional control, can be different from Vehicle Manufacturer to Vehicle Manufacturer. Control elements and displays can be from the ZF, however can be also customerspecific products; the precise specifications must therefore be taken from the Operating Instructions of the respective Vehicle Manufacturer. - Neutral position: Neutral position will be selected via the Controller. After the ignition is switched on, the electronics remains in the waiting state. By the position NEUTRAL of the Controller, resp. by pressing the pushbutton NEUTRAL, the EST-37 becomes ready for operation. Now, a gear can be engaged. - Starting: The starting of the engine has always to be carried out in the NEUTRAL POSITION of the Controller. For safety reasons it is to recommend to brake the vehicle securely in position with the parking brake prior to start the engine. After the starting of the engine and the preselection of the driving direction and the gear, the vehicle can be set in motion by acceleration. 27

26 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme At the start off, the converter takes over the function of a master clutch. On a level road it is possible to start off also in higher gears. - Upshifting under load. Upshifting under load will be then realized if the vehicle can continue to accelerate by it. - Downshifting under load. Downshifting under load will be then realized if more traction force is needed. - Upshifting in overrunning condition. In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the vehicle on a downgrade should not be further increased. - Downshifting in overrunning condition. Downshifting in overrunning mode will be then carried out if the vehicle should be retaded. - Reversing See important Note Page 9. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled. On a level and horizontal roadway it is possible that the vehicle begins to crawl, because the engine is creating at idling speed a slight drag torque via the converter. It is convenient to brake the vehicle at every stop securely in position with the parking brake. At longer stops, the Controller has to be shifted to the NEUTRAL POSITION. At the start off, the parking brake has to be released. We know from experience that at a converter transmission it might not immediately be noted to have forgotten this quite normal operating step because a converter, due to its high ratio, can easily overcome the braking torque of the parking brake. Temperature increases in the converter oil as well as overheated brakes will be the consequences to be find out later. 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. 3.3 Cold start: At an oil temperature in the shifting circuit < -12 C, the transmission must be warmed-up for some minutes. This must be carried out in Neutral with an increased engine speed (about 1500 min -1 ). Until this oil temperature is reached, the Electronics remains in Neutral, and the symbol of the cold start phase will be indicated on the ZF-Display. Indication on the Display : After the indication on the ZF-Display is extinguished, the full driving programm can be utilized out of NEUTRAL. 28

27 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 3.4 Transmission control in the Driving mode Automatic: Precise Informations about the design of the Controllers as well as the speeds shifted in the single driving ranges, must be taken from the Operating Instructions belonging to the vehicle. A manual intervention into the automatic shift sequence is only then practical if the roadway condition or the configuration of the ground is suitable. 3.5 Stopping and Parking: Since due to the converter there is no rigid connection existing from the engine to the axle, it is recommended to secure the vehicle on upgrades, resp. downgrades against unintended rolling not only by applying the parking brake but additionally by a block on the wheel, if the driver has the intention to leave the vehicle. 3.6 Towing: See Important Instructions Page Oil temperature: The oil temperature in the transmission sump is monitored by a temperature sensor in the electrohydraulic control unit. The service temperature in the sump of C must not be exceeded (indication appears on the Display in the cabine)! At a trouble-free unit and an adequate driving mode, a higher temperature will not occour. If the temperature is rising above 90 C, the vehicle has to be stopped and controlled for external oil loss and the engine must run with a speed of min -1 at NEUTRAL POSITION of the transmission. Now, the temperature must drop quickly (in about 2 3 minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working. The monitoring of the oil temperature is additionally realized behind the converter with an indication on the ZF-Display or analog in the INFOCENTER. Operating temperature behind the converter at least 65 C and 100 C in continuous operation, a short-time increase up to max. 120 C is permitted. The temperature is measured on the measuring point 63 (see Schedule of measuring points Table-8!) 29

28 ERGOPOWER Off-Road Transmissions and Axle Systems Division IV. MAINTENANCE 4.1. Oil grade: Permitted for the Powershift transmissions 4 WG-190/210 are oils according to ZF- List of lubricants TE-ML 03. The list of lubricants is being continuously updated and can be obtained or viewed as follows: - At all ZF-Plants - At all ZF-Service Stations - Internet Informationen/Tech. Informationen 4.2 Oil level check (measurements only with running engine): At the oil level check, the prescribed safety directions according to 6 of the rules for accident prevention for power plants in Germany, and in all other countries the respective national regulations have to be absolutely respected. For example, the vehicle has to be secured against rolling with blocks, articulated vehicles additionally against unintended turning-in. The oil level check must be carried out as follows: - Oil level check (weekly) - At horizontally standing vehicle - Transmission in Neutral position N - 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 COLD (see Figure-No. 4.2 B2) - At operating temperature of the transmission (about C) With engine idling speed all measurements must be carried out with low engine idling speed. - Loosen oil dipstick by counterclock rotation, remove and clean it - Insert oil dipstick slowly into the oil level tube until contact is obtained, and pull it out again. - On the oil dipstick, the oil level must be lying in the zone HOT (see Figure-No.: 4.2 B2) - Insert the oil dipstick again, and tighten it by clockwise rotation If the oil level has dropped in operating temperature condition below the HOT Zone, it is absolutely necessary to replenish oil according to the ZF-List of lubricants TE-ML-03. An oil level above the HOT marking, is leading to a too high oil temperature. The oil dipstick and the oil filler tube can have different lengths and shapes, according to the Transmission version. Besides, the mounting on the transmission can be optionally realized on the converter side or on the rear side.(in this Illustration, the mounting of the oil dipstick is illustrated on the rear side). 31

29 ERGOPOWER Off-Road Transmissions and Axle Systems Division 1 Legend: 1 = Oil filler tube with oil dipstick 2 = Oil drain plug M32x2 3 = ZF-Fine filter (Pressure filter) Oil dipstick 4.3 Oil change and Filter replacement intervals: 2 3 MIEASURED AT LOW IDLING-NEUTRAL Bereich HOT HOT Figure-No.: 4.2 B1 COLD Figure-No.: 4.2 B2 In this connection refer to specification in the ZF List of Lubricants TE-ML 03. The ZF filter must be replaced at every oil change Oil change and Oil filling capacity: The oil change has to be carried out as follows: - At operating temperature of the transmission, horizontally standing vehicle open the oil drain plug and drain the used oil. - Clean oil drain plug with magnetic insert and surface on the housing and install again along with O-ring. 32

30 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme - Fill in oil (about 21 liters) according to ZF-List of lubricants TE-ML 03. (Sump capacity, external oil capacities e.g. in the heat exchanger, in the lines etc. are dependent on the vehicle). The indicated value is a guide value. It is imperative to pay attention to absolute cleanliness of oil and filter! Binding is in any case the marking on the oil dipstick! - Start the engine idling speed - Transmission in Neutral position N - Top up oil up to the marking COLD - Brake the vehicle securely in position and warm up the transmission - Shift all Controller positions through - Check the oil level once more and top up oil once more if necessary - On the oil dipstick, the oil level must be lying in the Zone HOT (see Figure-No.: 4.2 B2) - Insert the oil dipstick again and tighten it by clockwise rotation. At the initial filling of the transmission has to be considered that the heat exchanger, the pressure filter as well as the pipes must get filled with oil. According to these cavities, the oil capacity to be filled in is greater than at the later oil fillings in the course of the usual Maintenance service. ZF recommends, to start the AEB at every oil change (see 1.7.3) Filter replacement: At the replacement of the ZF-Filter in the main oil stream, pay attention that no dirt or oil sludge can penetrate into the circuit. Besides, the parking brake has to be covered, resp. protected from oil wetting. At the mounting of the filter, any exertion of force has to be avoided. The filters are installed separately from the transmission in the vehicle! Treat the filter carefully at the installation, the transport and the storage! Damaged filters must no more be installed! The filter differential pressure valve (bypass valve) is equipped with a maintenanceswitch (opening switch) which is informing the driver about the contamination of the ZF-Fine filter. At the lighting up of the symbol, the ZF-Fine filter must be replaced. The mounting of the filter must be carried out as follows: - Cover the gasket with a small amount of oil. - Screw the filter in until contact with the sealing surface is obtained and tighten it now by hand about 1/3 to 1/2 turn. 33

31 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme V. ZF-DIAGNOSTIC SYSTEMS 5.1 General: The Control electronics EST-37 for the Transmission Series Ergopower is equipped with a diagnostic package, which makes the Trouble shouting and the Repair of damages easier for the Service. The Electronics is able to monitor the states of certain inputs and outputs. If the Electronics recognizes at it an error, it stores an error code in the fault storage (EEPROM) and is transmitting the error code also to the vehicle controller of the Vehicle Manufacturer. The ZF-Diagnostic and Programming systems MOBIDIG-2001 (see 5.2) and LAPTOP- Version (see 5.3) are needed for the following applications: Diagnosis - Read actual errors - Read fault storage - Cancel fault storage AEB - Independent calibration of the shifting elements Testing Inputs and Outputs - Check Outputs - Check Inputs - Check systems downtime - System test drive Additionally for the Diagnosis can be used the Multi-System 5000 (see 5.4) with corresponding sensor system for pressure, temperature, speed, through-flow, current transformer etc. 5.2 ZF - MOBIDIG 2001 The ZF-Diagnostic system MOBIDIG 2001 is only reserved to ZF-Service Stations. All necessary, transmission-specific Data for a quick and comprehensive Diagnosis can be retrieved with this Diagnostic system. The Data are stored on CD-Rom and will be updated 2 3 times a year. It is universally to be used for all diagnosis-capable ZF-Vehicle systems. MOBIDIG 2001 with ZF-Diagnostic Software Diagnostic Software with Operator guidance Terminal tester 68-pin For the test of single control signals, line connections etc Figure-No.:

32 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 5.3 Laptop Version: Specialized Dealers Pentium Laptop min. 90 MHz Windows 95/98 or NT Basic-Software Testman WIN 95/98 or NT RS-232 Connecting cable Laptop DPA-04I Programming adapter DPA-04I Adapter cable DPA-04I EST Diagnostic Software WG-190/210 Diagnostic set WIN 95/98 or NT GERMAN ENGLISH FRENCH Terminal Tester 68-pin For the test of single control signals, line interruptions etc Figure-No.:5.3 36

33 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 5.4 ZF-Multi-System 5000: Multi- System 5000 Measuring box with corresponding sensor system for pressure, temperature and speed without printer Multi- System 5000 Measuring box with corresponding sensor system for pressure, temperature and speed with printer Multi - System 5000 Portable measuring instrument without accessories Accessories: Sensor system for through-flow, current transformer etc. Current transformer: Turbine Metering tubes: l/min = l/min = Figure-No.:

34 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme 38

35 ERGOPOWER Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme APPENDIX TABLE 1 TO 14 39

36 ) ; 7 6"9 6 ) * - 8! ) ) * " 4 # / ' + K J? D I D = BJ 4 2 M AHJ= A BB? =NE= A CE J! + K J? D I D = BJ 8 " + K J? D I D = BJ 8 # + K J? D I D = BJ! $ KJFKJB = CA HA=H % KJFKJB = CA? LAHJAHIE@A & KJFKJID=BJ ' 6H= I EIIE FK F 1 FKJB = CA E FKJJDH KCDK ELAHI= ID=BJ + LAHJAH I EJJAHB HA CE AIFAA@! + KJ?DID=BJ " " + LAHJAHHA EABL= LA # + KJ?DID=BJ / - ) 4 2 ) 6 6-4! " ' & %! " # $

37 1 56) ) "9 / ', ) * - EBJE C KCI, E=FDH=C `@EHA?J K JE C! 6 H= I EIIE IKIFA IE D AI " ) JJ=?D A JF IIE>E EJOB HA AHCA?OIJAAHE CFK F E@A JEBE?=JE F =JA $ KJFKJB = CA? LAHJAHIE@A % H= E F K C M EJD = C A J! & N # & ) JJ=?D A JF IIE>E EJOB H E BE AHJK>AM EJD ' E BE A HJK > A M EJD EF I JE? HA = HI E@ A! + LAHJAH '! & % $. #! "!

38 1 5 6 ) ) " 9 / ', ) * -! EBJE C K C I 1 FKJB = CA`@HELALE=K ELAHI= ID=BJ! 6H= I EIIE IKIFA IE D AI " - AHCA?OIJAAHE CFK F 5!! N, N # E@A JEBE?=JE F =JA! $ KJFKJB = CA? LAHJAHIE@A % F KCM EJD =C AJ!&N # & ) JJ=?D A JF IIE>E EJOB H E BE AHJK>AM EJD LAHJAHIE@A! & % $, 5. #! "!

39 1 5 6 ) ) " 9 / ' 5 6 ), ) 4, ) ) * - " EBJE C K C I 2 M AHJ= A BB? =NE= A J! - A?JH DO@H=K E?? JH " + A?JE HAJKH E ABH F=H E C>H= A $N # # E BE A HJK > A M EJD EF IJE? $ 6H= I EIIE IKIFA IE D AI % KJFKJB = CAHA=HIE@A ' & -N?D= CABE JAHBE ABE JAH '. E JA HD A M EJD + A?JE IOIJA FHAIIKHA $N # & % $! " # $

40 1 5 6 ) ) " 9 / ' , * 4 - ) ) * - # EBJE C KCI 2 M AHJ= A BB? =NE= A J! - A?JH DO@H=K E?? JH " + A?JE HAJKH E ABH F=H E C>H= A $N # # 2=H E C>H= A FAH=JA@DO@H=K E?= O $ 6H= I EIIE IKIFA IE D AI % ) JJ=? D A JF IIE> E EJO B H E BE A HJK > A M EJD EF IJE? HA = HIE@ A & * H= A@EI? ' KJFKJB = CAHA=HIE@A -N?D= CABE JAHBE ABE JAH. E JA HD A M EJD + A?JE IOIJA FHAIIKHA $N # ' $ & %! " # $

41 1 5 6 ) ) " 9 / ' ), 4 - ) ) * - $ EBJE C KCI 2 M AHJ= A BB? =NE= A J!! - A?JH DO@H=K E?? JH " + A?JE HAJKH E ABH F=H E C>H= A $N # # 2=H E C>H= A FAH=JA@DO@H=K E?= O $ 6H= I EIIE IKIFA IE D AI % ) JJ=? D A JF IIE> E EJO B H E BE A HJK > A M EJD EF IJE? HA = HIE@ A * & H = E I? ' KJFKJB = CAHA=HIE@A -N?D= CABE JAHBE ABE JAH. E JA HD A M EJD + A?JE IOIJA FHAIIKHA $N #! 2 M AHJ= A BB? =N=E A J ' $ & %! " # $

42 , ) / ), ) * - % 6 D A =H F IEJE C #!? EJDJDAF I HHA EJE I I JD A J=> A & 6DA A=IKHA A JID=LAJ >A?=HHEA@ KJ=JD JJH= I EIIE => KJ& '# +, - 1 ) ) 4 1 / ) 8 - * + - ) / ;, 4 ) ), ) # 1 BH J BJD A? L A HJA H` F A E C F HA I I K HA N > =H 0 # * A D JD A? L A HJA H` F A E C F HA I I K HA " " N #! > =H #! + K J? D. HM =H@ $ > =H 8 N * # # + K J? D 4 A L A HI A $ > =H 4 N - # $ + K J? D $ > =H N, # % + K J? D $ > =H N ) # & + K J? D $ > =H! N + $ + K J? D $ > =H " N. $! * LAHJAH " N # 6 A F A H = J K H A + I D H J J E A + $ # 5 O I JA F HA I I K HA $ > =H N A = IK H E C F E JIB A EL A H O H = JA I # + A?JE J JDADA=JAN?D= CAH # $ ] 7 * $ + A? J E B H J D A D A = J A N? D = C A H # $ ] 7 * 1, ) , ), K? JEL A JH= I EJJA H 6 K H> E A & N #! " 5 F A I A I H K J F K J 5 F A A J A H " % K? JEL A JH= I EJJA H + A JH= C A =HJH=E & N # " & K? JEL A JH= I EJJA H - C E A & N # # " ) 1 ) " N # " ' 2 K C? A? JE I JD A A A? JH D H=K E?? JH K EJ $& 5OIJA FHAIIKHA FJE $N # / $' + JH FJE $N # % - AHCA?OIJAHHE CFK F 2HAIIKHA E A N # % - AHCA?OIJAAHE CFK F 5K?JE E A!!N "& "% #"!" 2 =C A BH

43 K VIEW X VIEW Y A B C H G 68 F E D J CODING Pressure regulator active Engaged clutches Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6 FORWARD 1 K1 KV 2 KV K2 3 K3 KV 4 K4 K3 REVERSE 1 KR K1 2 KR K2 3 KR K3 NEUTRAL Engaged clutches K4 KR K1 K3 KV K2 Position on the valve block F E D C B A Consecutively No. of the measurement points /63 Y X /63 D S Page 2 from

44 OIL CIRCUIT DIAGRAM 4 WG-190/210 FORWARD 1st SPEED TABLE-8 The marked positons (e.g. 53) correspond with the positions on the table-7! Legend: WT = Heat exchanger WGV = Converter back pressure valve 4,3+3 bar WSV = Converter safety valve 11+2 bar HDV = Main pressure valve 16+2,5 bar RV-9 = Pressure reducing valve 9±0,5 bar NFS = Follow-on slide D = Vibration damper B = Orifice P1 = Proportional valve K4 P2 = Proportional valve KR P3 = Proportional valve K1 P4 = Proportional valve K3 P5 = Proportional valve KV P6 = Proportional valve K2 Y1...Y6 = Pressure regulators TEMP = Temperature sensor UEDV = Pressure relief valve 40±5 bar FDV = Filter pressure differential valve (Bypass-valve) p=5,5 bar WS = Maintenance switch CODING Pressure regulator active Engaged clutches Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6 Forward 1 K1 KV 2 KV K2 3 K3 KV 4 K4 K3 Reverse 1 KR K1 2 KR K2 3 KR K3 Neutral Engaged clutches K4 KR K1 K3 KV K2 Position on the valve block F E D C B A Consecutively No. of the measurement points Page 1 from 2

45 K4 KR K1 K3 KV K2 P1 B Y1 Valve block control circuit Legend: Page 2 from 2 F 60 E 55 D 56 C 58 B 53 A 57 P2 P3 P4 P5 P6 D B D B D B D B D B D NFS Y2 NFS = Main pressure = Regulated main pressure = Pilot pressure = Pilot pressure = Converter input pressure = Converter output pressure = Lubrication moduladted = Return into the sump Y3 NFS Converter WT (Scope of supply customber) Bypassvalvel p=1,5 bar max. Y4 TEMP H WSV WGV NFS Y5 HDV FDV Lubrication WS UEDV NFS Y6 ZF-fine filter Filtration ratio according ISO 4572: ß30 75 ß15 25 ß10 5 Dust capacity according ISO 4572: min. 17g Filter surface:: min cm 2 Transmission pump p = 16+2,5 bar Q p= 105 l/min bei n = Engine 2000 min Coarse filter mesh width mm Oil sump RV-9 NFS -1 Main oil circuit

46 ;, 4 ) ) 6 ) * - ' ) ) 8 - $ > = H , / 8 ) 8 - ' > = H / ) ) * / ; $ ; # 8 ) 8 - * + * ; " ;! ; ; + ) * - 0 ) 4-5 5

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48 "9 / '. 4 9 ) 4, IJIFAA@ B HM =H@ 6 ) * B HM =H@!H@IFAA@ B HM =H@" JD IF AA@ B HM =H@ FE BH J=JE ) 8 ) 8 ) ) * ) * A C " 4 8! 2 M AHB M C A=HJH=E / A=HI J AIDE C " " "!, E=CH= + KJ?DAI ) * A C 8 + K J? D B HM = H@ 4 + K J? D HAL AHIA + K J? D IJIF AA@ + + K J? D! I F A " + K J? D " JD IF AA@ ) 1 FKJ ) * K J F K J A A A, HELE C@EHA?JE 5 F A + K J? D. H M = 8 8! 8! " "! 4 L H I 4 4! 4!! ) *! ) ) * )! ) * " IJIFAA@ HALAHIA!H@IFAA@ HALAHIA ) 8 ) 8 ) " " "!!! ) * ) * ) *

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53 TABLE-14 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 NOTES REGARDING THE SPARE PARTS ORDERS: When ordering genuine ZF-Spare Parts, please indicate: 1. = Gearbox type 2. = Serial-No. 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 See Model identification Plate! When all of the above required indications are considered, errors in the delivery of spare parts Orders can be avoided! 2 4 7

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67 ZF FRIEDRICHSHAFEN Aktiengesellschaft Description: Add. Description: AEB-Starter Operating instructions No.: DIN A4 Page 1 of 4 Operating Instructions AEB Starter

68 ZF FRIEDRICHSHAFEN Aktiengesellschaft Description: Add. Description: AEB-Starter Operating instructions No.: DIN A4 Page 2 of 4 List of Modifications ZF-Number Index Chapter Change Date first edition remark 7, step to do add display description

69 ZF FRIEDRICHSHAFEN Aktiengesellschaft Description: Add. Description: AEB-Starter Operating instructions No.: DIN A4 Page 3 of 4 1 Introduction The AEB - Starter is a tool to start the AEB of ergopower transmissions by an easy way. It s useful to work with the ZF - Display, because you get all messages about the AEB state via the ZF - Display. The AEB-Starter itself doesn t show any information. The AEB-Starter works with the diagnostic plug. 2 list of abbreviations AEB: TCU: automatic filling parameter adjustment transmission control unit 3 Procedure to start AEB Note: AEB will not start with any fault codes on display except fault F6 step to do Display message remark 1 warm up transmission normal operating messages 2 turn off ignition nothing 3 plug in AEB - starter 4 move shift lever to N position engage parkbrake 5 start engine PL TCU must recognize PL for at least 2s before you can press the button 6 set engine speed to 800 rpm PL if start conditions are ok 7 press button of the AEB-Starter ST if start conditions are ok The button must not be released before TCU has started the AEB or quit with an error code (see chapter 4) 8 hold button until AEB has started K1... (Information about the AEB state) 9 wait until AEB has finished OK 10 turn off ingnition and unplug AEB - Starter (AEB has been sucessful) nothing TCU has started the AEB, and goes on adjusting K1, K2,..., KR. (Button may be released)

70 ZF FRIEDRICHSHAFEN Aktiengesellschaft Description: Add. Description: AEB-Starter Operating instructions No.: DIN A4 Page 4 of 4 4 Display symbol meaning remarks PL AEB - Starter is plugged at the ST diagnostic plug AEB-Starter-button is pressed K1..K4,KV,KR calibrating clutch K1..K4,KV,KR wait for start, initialization of clutch Kx _ and Kx and Kx fast fill time determination of clutch Kx = and Kx compensating pressure determination of clutch Kx OK calibration for all clutches finished Transmissions stays in neutral, you have to restart the TCU (ignition off/on) after removing AEB-Starter STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart the STOP and Kx AEB stopped, clutch Kx can't be calibrated TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Spanner and Kx Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart the E engine speed too low, -> raise engine speed engine speed too high, -> lower engine E speed T transmission oil temperature too low, -> heat up transmission T transmission oil temperature too high -> FT FB cool down transmission transmission temperature not in defined range during calibration operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed. TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the STOP AEB - Starter was used incorrect or is defective TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

71 ZF FRIEDRICHSHAFEN Aktiengesellschaft Benennung: Zusatzbenennung: fault codes description of fault codes for Ergo control Nr.: DIN A4 Seite 1 von 38 Diese technische Unterlage darf weder kopiert Schwarz noch dritten Personen ohne unsere Erlaubnis 24 mitgeteilt werden. Index Nr. Datum Name Film K3 ZFN 904 Ä N D E R U N G E N Erstellt: Geprüft: Freigegeben : Name: Neudorfer Rainer Sieger Abteilung: ACETS TE-AB Datum: document created for customer "TUG" Description of the fault codes for ERGO-Control EST37

72 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A Index of changes: date index comment software version Seite 2 von 38

73 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 1 Introduction 1.1 Abbreviations o.c. s.c. OP-Mode TCU EEC PTO open circuit short circuit operating mode transmission control unit electronic engine controller power take off 1.2 ZF - Display: If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the gear selector is on neutral position. If more than one fault is detected, each fault code is shown for about 1 second. 1.3 Display during operation h f e d S T O P (special symbols a-h) left character right character a b c g Symbol meaning remarks 1F, 1R 2F, 2R 3F, 3R 4F 5F 6F LF, LR F or R, no gear F or R flashing actual gear and direction left digit shows actual gear right digit shows actual direction limp home gear Clutch Cutoff direction F or R selected while turbine speed is too high NN not neutral, waiting for neutral after power up or a severe fault ** oil temperature too low, no gear available *N oil temperature low, only one gear available 1 bar (special manual mode 1 st gear CAUTION gear will engage if turbine speed drops to engage a gear, first move shift selector to neutral position and again to F or R position warm up engine / transmission warm up engine / transmission Seite 3 von 38

74 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A symbol) 2 bars manual mode 2 nd gear 3 bars manual mode 3 rd gear 4 bars manual mode 4 th gear and also 5 th and 6 th gear in 6WG 4 bars and 2 automatic mode arrows Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a certain limit and lockup clutch not activated 4 WG: Downshift mode activ Spanner at least one fault activ select neutral to get fault code displayed Fault code see faultcode list WS warning sump temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WR warning retarder temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WT warning torque converter temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WE warning high engine speed changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WV warning high output speed (velocity) changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WL WO PN warning high transmission input torque (load) warning high transmission output torque (load) direction F or R selected while parking brake engaged changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) transmission in neutral until parking brake is released CAUTION: vehicle starts to move after release of parking brake EE flashing no communication with display checked wiring from TCU to display Seite 4 von 38

75 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 1.4 Display during AEB-Mode symbol meaning remarks PL AEB - Starter is plugged at the ST diagnostic plug AEB-Starter-button is pressed K1..K4,KV,KR calibrating clutch K1..K4, KV or KR resp. _ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R fast fill time determination of clutch Kx and Kx = and Kx compensating pressure determination of clutch Kx OK calibration for all clutches finished Transmissions stays in neutral, you have to restart the TCU (ignition off/on) after removing AEB-Starter STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart the STOP and Kx AEB stopped, clutch Kx can't be calibrated Spanner and Kx Kx couldn't be calibrated, AEB finished E E T T FT FB engine speed too low, raise engine speed engine speed too high, lower engine speed transmission oil temperature too low, heat up transmission transmission oil temperature too high cool down transmission transmission temperature not in defined range during calibration operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed. TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the STOP AEB - Starter was used incorrect or is defective. Wrong device or wrong cable used TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Seite 5 von 38

76 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 1.5 Display during Inchpedal Calibration symbol meaning remarks IP IP IP flashing OK push down the pedal slowly until endposition is reached and hold this position Release the pedal slowly until endposition is reached A problem occurred, release the pedal slowly until endposition is reached Finished inchpedal calibration successful If the expected enposition could not be reached, release the pedal and try again FN and Stop Shift lever not in Neutral position Calibration is aborted FS and Stop sensor supply voltage AU1 is out of Calibration is aborted the specified range FO and Stop Outputspeed is not zero Calibration is aborted SL and Stop sensor voltage below specified Calibration is aborted SU and Stop IL and Stop IU and Stop TO and Stop DL and Stop DU and Stop FI and Stop rangel sensor voltage above specified rangel sensor position for released pedal out of specified range sensor position for pressed pedal out of specified range time-out calibration, pedal not moved after calibration start angle between pedalpositions released and pressed to small angle between pedalpositions released and pressed to big sensor signal 1 and 2 don't match together Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Seite 6 von 38

77 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 2 definition of operating modes NORMAL: There's no failure detected in the transmission-system or the failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (see following table) SUBSTITUTE CLUTCH CONTROL: TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the substitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25) LIMP-HOME: The detected failure in the system has strong limitations to transmission control. TCU can engage only one gear in each direction. In some cases only one direction will be possible. TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or reverse, the TCU will select the limp-home gear. If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direction. If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position. TRANSMISSION-SHUTDOWN: TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8. The operator has to slow down the vehicle. The transmission will stay in neutral. TCU-SHUTDOWN: TCU has detected a severe failure that disables control of system. TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are disabled which use ADM 1 to ADM 8. The transmission will stay in neutral. Seite 7 von 38

78 ZF Friedrichshafen AG description of fault codes for ERGO-Control table of fault codes Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection LOGICAL ERROR AT GEAR RANGE SIGNAL TCU detected a wrong signal combination for the gear range cable from shift lever to TCU is broken cable is defective and is contacted to battery voltage or vehicle ground shift lever is defective LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU detected a wrong signal combination for the direction cable from shift lever to TCU is broken cable is defective and is contacted to battery voltage or vehicle ground shift lever is defective LOGICAL ERROR AT ENGINE DERATING DEVICE TCU detected no reaction of engine while derating device activ LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT LEVER TCU detected a wrong signal combination for the direction cable from shift lever 2 to TCU is broken cable is defective and is contacted to battery voltage or vehicle ground reaction of the TCU possible steps to repair remarks TCU shifts transmission to neutral OP-Mode: transmission shutdown TCU shifts transmission to neutral OP-Mode: transmission shutdown after selecting neutral, TCU changes to OP-Mode limp home TCU shifts transmission to neutral if selector activ OP-Mode: transmission shutdown if selector activ check the cables from TCU to shift lever check signal combinations of shift lever positions for gear range check the cables from TCU to shift lever check signal combinations of shift lever positions F-N-R failure cannot be detected in systems with DW2/DW3 shift lever fault is taken back if TCU detects a valid signal for the position fault is taken back if TCU detects a valid signal for the direction at the shift lever check engine derating device This fault is reset after power up of TCU check the cables from TCU to shift lever 2 check signal combinations of shift lever positions F-N-R fault is taken back if TCU detects a valid neutral signal for the direction at the shift lever Seite 8 von 38

79 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection shift lever is defective LOGICAL ERROR AT AXLE CONNECTION feedback axle connection measured by TCU and output signal axle connection don't fit axle can t be connected or disconnected due to mechanical problem one of the cables from feedback axle connection -switch to TCU is broken S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION SUMP TEMPERATURE SENSOR INPUT the measured voltage is too high: cable is defective and is contacted to battery voltage cable has no connection to TCU temperature sensor has an internal defect connector pin is contacted to battery voltage or is broken S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE SENSOR INPUT the measured voltage is too low: cable is defective and is contacted to vehicle ground temperature sensor has an internal defect connector pin is contacted to vehicle ground reaction of the TCU possible steps to repair remarks OP-Mode: normal no reaction, TCU uses default temperature OP-Mode: normal no reaction, TCU uses default temperature OP-Mode: normal check the cables from TCU to feedback axle connection switch check signals of the feedback axle connection switch check the cable from TCU to the sensor check the connectors check the temperature sensor check the cable from TCU to the sensor check the connectors check the temperature sensor S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, check the cable from TCU to the sensor Seite 9 von 38

80 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection RETARDER / TORQUECONVERTER TEMPERATURE SENSOR INPUT the measured voltage is too high: cable is defective and is contacted to battery voltage cable has no connection to TCU temperature sensor has an internal defect connector pin is contacted to battery voltage or is broken S.C. TO GROUND AT RETARDER / TORQUECONVERTER TEMPERATURE SENSOR INPUT the measured voltage is too low: cable is defective and is contacted to vehicle ground temperature sensor has an internal defect connector pin is contacted to vehicle ground S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE SENSOR INPUT the measured voltage is too high: cable is defective and is contacted to battery voltage cable has no connection to TCU sensor has an internal defect connector pin is contacted to battery voltage or is broken 2A S.C. TO GROUND PARKING BRAKE SENSOR INPUT the measured voltage is too low: reaction of the TCU possible steps to repair remarks TCU uses default temperature OP-Mode: normal no reaction, TCU uses default temperature OP-Mode: normal TCU uses default value OP-Mode: normal check the connectors check the temperature sensor check the cable from TCU to the sensor check the connectors check the temperature sensor check the cable from TCU to the sensor check the connectors check the parking brake sensor TCU uses default value OP-Mode: normal check the cable from TCU to the sensor check the connectors check the parking brake sensor Seite 10 von 38

81 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection cable is defective and is contacted to vehicle ground sensor has an internal defect connector pin is contacted to vehicle ground 2B INCHSENSOR-SIGNAL MISMATCH the measured voltage from CCO and CCO2 signal don t match: cable is defective sensor has an internal defect 2C S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TRACTION ADJUST DASHBOARD DEVICE INPUT the measured voltage is too high: cable is defective and is contacted to battery voltage cable has no connection to TCU sensor has an internal defect connector pin is contacted to battery voltage or is broken 2D S.C. TO GROUND DLM TRACTION ADJUST DASHBOARD DEVICE INPUT the measured voltage is too low: cable is defective and is contacted to vehicle ground sensor has an internal defect connector pin is contacted to vehicle ground 2E S.C. TO BATTERY VOLTAGE OR O.C. AT DLM STEERING ANGLE SENSOR INPUT reaction of the TCU possible steps to repair remarks During inching mode: TCU shifts to neutral While not inching: no change OP-Mode: normal TCU uses default value OP-Mode: normal TCU uses default value OP-Mode: normal check the cable from TCU to the sensor check the connectors check sensor check the cable from TCU to the sensor check the connectors check the DLM Traction Adjust dashboard device check the cable from TCU to the sensor check the connectors check the DLM Traction Adjust dashboard device TCU uses default value OP-Mode: normal check the cable from TCU to the sensor check the connectors Seite 11 von 38

82 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection the measured voltage is too high: cable is defective and is contacted to battery voltage cable has no connection to TCU sensor has an internal defect connector pin is contacted to battery voltage or is broken 2F S.C. TO GROUND DLM STEERING ANGLE SENSOR INPUT the measured voltage is too low: cable is defective and is contacted to vehicle ground sensor has an internal defect connector pin is contacted to vehicle ground S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE SPEED INPUT TCU measures a voltage higher than 7.00 V at speed input pin cable is defective and is contacted to battery voltage cable has no connection to TCU speed sensor has an internal defect connector pin is contacted to battery voltage or has no contact S.C. TO GROUND AT ENGINE SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin cable / connector is defective and is contacted to vehicle ground speed sensor has an internal defect reaction of the TCU possible steps to repair remarks TCU uses default value OP-Mode: normal OP-Mode: substitute clutch control OP-Mode: substitute clutch control check the DLM STEERING ANGLE SENSOR check the cable from TCU to the sensor check the connectors check the DLM STEERING ANGLE SENSOR check the cable from TCU to the sensor check the connectors check the speed sensor check the cable from TCU to the sensor check the connectors check the speed sensor Seite 12 von 38

83 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection LOGICAL ERROR AT ENGINE SPEED INPUT TCU measures a engine speed over a threshold and the next moment the measured speed is zero cable / connector is defective and has bad contact speed sensor has an internal defect sensor gap has the wrong size S.C. TO BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT TCU measures a voltage higher than 7.00 V at speed input pin cable is defective and is contacted to battery voltage cable has no connection to TCU speed sensor has an internal defect connector pin is contacted to battery voltage or has no contact S.C. TO GROUND AT TURBINE SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin cable / connector is defective and is contacted to vehicle ground speed sensor has an internal defect LOGICAL ERROR AT TURBINE SPEED INPUT TCU measures a turbine speed over a threshold and at the next moment the measured speed is zero cable / connector is defective and has bad contact speed sensor has an internal defect sensor gap has the wrong size reaction of the TCU possible steps to repair remarks OP-Mode: substitute clutch control OP-Mode: substitute clutch control if a failure is existing at output speed, TCU shifts to neutral OP-Mode: limp home OP-Mode: substitute clutch control if a failure is existing at output speed, TCU shifts to neutral OP-Mode: limp home OP-Mode: substitute clutch control if a failure is existing at output speed, TCU shifts to neutral OP-Mode: limp home check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap check the cable from TCU to the sensor check the connectors check the speed sensor check the cable from TCU to the sensor check the connectors check the speed sensor check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap This fault is reset after power up of TCU This fault is reset after power up of TCU Seite 13 von 38

84 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT TCU measures a voltage higher than 7.00 V at speed input pin cable is defective and is contacted to battery voltage cable has no connection to TCU speed sensor has an internal defect connector pin is contacted to battery voltage or has no contact S.C. TO GROUND AT INTERNAL SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin cable / connector is defective and is contacted to vehicle ground speed sensor has an internal defect LOGICAL ERROR AT INTERNAL SPEED INPUT TCU measures a internal speed over a threshold and at the next moment the measured speed is zero cable / connector is defective and has bad contact speed sensor has an internal defect sensor gap has the wrong size 3A S.C. TO BATTERY VOLTAGE OR O.C. AT OUTPUT SPEED INPUT TCU measures a voltage higher than 12.5 V at speed input pin cable is defective and is contacted to battery voltage cable has no connection to TCU reaction of the TCU possible steps to repair remarks OP-Mode: substitute clutch control OP-Mode: substitute clutch control OP-Mode: substitute clutch control special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home check the cable from TCU to the sensor check the connectors check the speed sensor check the cable from TCU to the sensor check the connectors check the speed sensor check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap check the cable from TCU to the sensor check the connectors check the speed sensor This fault is reset after power up of TCU Seite 14 von 38

85 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection speed sensor has an internal defect connector pin is contacted to battery voltage or has no contact 3B S.C. TO GROUND AT OUTPUT SPEED INPUT TCU measures a voltage less than 1.00V at speed input pin cable / connector is defective and is contacted to vehicle ground speed sensor has an internal defect 3C LOGICAL ERROR AT OUTPUT SPEED INPUT TCU measures a output speed over a threshold and at the next moment the measured speed is zero cable / connector is defective and has bad contact speed sensor has an internal defect sensor gap has the wrong size 3E OUTPUT SPEED ZERO DOESN T FIT TO OTHER SPEED SIGNALS if transmission is not neutral and the shifting has finished, TCU measures outputspeed zero and turbine speed or internal speed not equal to zero. speed sensor has an internal defect sensor gap has the wrong size ENGINE CONF TIMEOUT Timeout of CAN-message ENGINE CONF from engine controller interference on CAN-Bus CAN wire/connector is broken reaction of the TCU possible steps to repair remarks special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home OP-Mode: substitute clutch control check the cable from TCU to the sensor check the connectors check the speed sensor check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap check the sensor signal of output speed sensor check the sensor gap of output speed sensor check the cable from TCU to the sensor check engine controller check wire of CAN-Bus check cable to engine controller This fault is reset after power up of TCU This fault is reset after power up of TCU Seite 15 von 38

86 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection CAN wire/connector is defective and has contact to vehicle ground or battery voltage EEC1 TIMEOUT Timeout of CAN-message EEC1 from EEC controller interference on CAN-Bus CAN wire/connector is broken CAN wire/connector is defective and has contact to vehicle ground or battery voltage EEC3 TIMEOUT Timeout of CAN-message EEC3 from EEC controller interference on CAN-Bus CAN wire/connector is broken CAN wire/connector is defective an has contact to vehicle ground or battery voltage ENGINGE TORQUE SIGNAL CAN signal for engine torque is defective engine controller is defective interference on CAN-Bus REFERENCE ENGINE TORQUE SIGNAL CAN signal for reference of engine torque is defective engine controller is defective interference on CAN-Bus 6A ACTUAL ENGINE TORQUE SIGNAL CAN signal for actual engine torque is reaction of the TCU possible steps to repair remarks OP-Mode: substitute clutch control OP-Mode: substitute clutch control OP-Mode:substitute clutch control OP-Mode:substitute clutch control check EEC controller check wire of CAN-Bus check cable to EEC controller check EEC controller check wire of CAN-Bus check cable to EEC controller check engine controller check wire of CAN-Bus check cable to engine controller check engine controller check wire of CAN-Bus check cable to engine controller OP-Mode:substitute clutch control check engine controller check wire of CAN-Bus Seite 16 von 38

87 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection defective engine controller is defective interference on CAN-Bus 6B NOM FRICTION TORQUE SIGNAL CAN signal for nominal friction torque is defective engine controller is defective interference on CAN-Bus 6E EEC2 TIMEOUT Timeout of CAN-message EEC2 from EEC controller interference on CAN-Bus CAN wire/connector is broken CAN wire/connector is defective and has contact to vehicle ground or battery voltage S.C. TO BATTERY VOLTAGE AT CLUTCH K1 the measured resistance value of the valve is out of limit, the voltage at K1 valve is too high. cable / connector is defective and has contact to battery voltage regulator has an internal defect S.C. TO GROUND AT CLUTCH K1 the measured resistance value of the valve is out of limit, the voltage at K1 valve is too low. cable / connector is defective and has contact to vehicle ground cable / connector is defective and has contact to another regulator output of reaction of the TCU possible steps to repair remarks OP-Mode:substitute clutch control no reaction, TCU uses default signal accelerator pedal in idle position OP-Mode: normal TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown check cable to engine controller check engine controller check wire of CAN-Bus check cable to engine controller check EEC controller check wire of CAN-Bus check cable to EEC controller check the cable from TCU to the gearbox check the connectors from TCU to the gearbox check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox 1) see chapter 4 1) see chapter 4 Seite 17 von 38

88 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection the TCU regulator has an internal defect O.C. AT CLUTCH K1 the measured resistance value of the valve is out of limit. cable / connector is defective and has no contact to TCU regulator has an internal defect S.C. TO BATTERY VOLTAGE AT CLUTCH K2 the measured resistance value of the valve is out of limit, the voltage at K2 valve is too high. cable / connector is defective and has contact to battery voltage regulator has an internal defect S.C. TO GROUND AT CLUTCH K2 the measured resistance value of the valve is out of limit, the voltage at K2 valve is too low. cable / connector is defective and has contact to vehicle ground cable / connector is defective and has contact to another regulator output of the TCU regulator has an internal defect O.C. AT CLUTCH K2 the measured resistance value of the valve is out of limit. cable / connector is defective and has no contact to TCU regulator has an internal defect reaction of the TCU possible steps to repair remarks TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the 1) see chapter 4 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 18 von 38

89 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection S.C. TO BATTERY VOLTAGE AT CLUTCH K3 the measured resistance value of the valve is out of limit, the voltage at K3 valve is too high. cable / connector is defective and has contact to battery voltage regulator has an internal defect S.C. TO GROUND AT CLUTCH K3 the measured resistance value of the valve is out of limit, the voltage at K3 valve is too low. cable / connector is defective and has contact to vehicle ground cable / connector is defective and has contact to another regulator output of the TCU regulator has an internal defect O.C. AT CLUTCH K3 the measured resistance value of the valve is out of limit. cable / connector is defective and has no contact to TCU regulator has an internal defect S.C. TO BATTERY VOLTAGE AT CLUTCH K4 the measured resistance value of the valve is out of limit, the voltage at K4 valve is too high. cable / connector is defective and has contact to battery voltage regulator has an internal defect reaction of the TCU possible steps to repair remarks TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox 1) see chapter 4 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 19 von 38

90 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection S.C. TO GROUND AT CLUTCH K4 the measured resistance value of the valve is out of limit, the voltage at K4 valve is too low. cable / connector is defective and has contact to vehicle ground cable / connector is defective and has contact to another regulator output of the TCU regulator has an internal defect O.C. AT CLUTCH K4 the measured resistance value of the valve is out of limit. cable / connector is defective and has no contact to TCU regulator has an internal defect S.C. TO BATTERY VOLTAGE AT CLUTCH KV the measured resistance value of the valve is out of limit, the voltage at KV valve is too high. cable / connector is defective and has contact to battery voltage regulator has an internal defect S.C. TO GROUND AT CLUTCH KV the measured resistance value of the valve is out of limit, the voltage at KV valve is too low. cable / connector is defective and has contact to vehicle ground cable / connector is defective and has contact to another regulator output of the TCU reaction of the TCU possible steps to repair remarks TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox 1) see chapter 4 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 20 von 38

91 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection regulator has an internal defect O.C. AT CLUTCH KV the measured resistance value of the valve is out of limit. cable / connector is defective and has no contact to TCU regulator has an internal defect S.C. TO BATTERY VOLTAGE AT CLUTCH KR the measured resistance value of the valve is out of limit, the voltage at KR valve is too high. cable / connector is defective and has contact to battery voltage regulator has an internal defect S.C. TO GROUND AT CLUTCH KR the measured resistance value of the valve is out of limit, the voltage at KR valve is too low. cable / connector is defective and has contact to vehicle ground cable / connector is defective and has contact to another regulator output of the TCU regulator has an internal defect O.C. AT CLUTCH KR the measured resistance value of the valve is out of limit. cable / connector is defective and has no contact to TCU regulator has an internal defect reaction of the TCU possible steps to repair remarks TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1) check internal wire harness of the gearbox 1) see chapter 4 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 21 von 38

92 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection 8A S.C. TO GROUND AT DLM TRANSVERSAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground device has an internal defect connector pin is contacted to vehicle ground 8B S.C. TO BATTERY VOLTAGE AT DLM TRANSVERSAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage device has an internal defect connector pin is contacted to battery voltage 8E S.C. TO BATTERY VOLTAGE AT DLM INDICATOR LAMP OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage device has an internal defect connector pin is contacted to battery voltage reaction of the TCU possible steps to repair remarks output will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal no reaction OP-Mode: normal no reaction OP-Mode: normal 8F O.C. DLM INDICATOR LAMP OUTPUT no reaction OP-Mode: normal check the cable from TCU to the valve check the connectors check the resistance of valve check the cable from TCU to the valve check the connectors check the resistance of valve check the cable from TCU to the device check the connectors check the resistance of device check the cable from TCU to the device check the connectors 1) see chapter 4 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 22 von 38

93 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU device has an internal defect connector has no connection to TCU O.C. AT RELAY REVERSE WARNING ALARM TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU backup alarm device has an internal defect connector has no connection to TCU S.C. TO GROUND AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground starter interlock relay has an internal defect connector pin is contacted to vehicle ground S.C. TO BATTERY VOLTAGE AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage reaction of the TCU possible steps to repair remarks no reaction OP-Mode: normal no reaction OP-Mode: normal no reaction OP-Mode: normal check the resistance of device check the cable from TCU to the backup alarm device check the connectors from backup alarm device to TCU check the resistance 1) of backup alarm device check the cable from TCU to the starter interlock relay check the connectors from starter interlock relay to TCU check the resistance 1) of starter interlock relay check the cable from TCU to the starter interlock relay check the connectors from starter interlock relay to TCU check the resistance 1) of starter 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 23 von 38

94 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection cable is defective and is contacted to battery voltage starter interlock relay has an internal defect connector pin is contacted to battery voltage O.C. AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU starter interlock relay has an internal defect connector has no connection to TCU 9A S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground converter clutch solenoid has an internal defect connector pin is contacted to vehicle ground 9B O.C. AT CONVERTER LOCK UP CLUTCH SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no reaction of the TCU possible steps to repair remarks no reaction OP-Mode: normal no reaction OP-mode: normal converter clutch always open, retarder not available OP-mode: normal interlock relay check the cable from TCU to the starter interlock relay check the connectors from starter interlock relay to TCU check the resistance 1) of starter interlock relay check the cable from TCU to the converter clutch solenoid check the connectors from converter clutch solenoid to TCU check the resistance 1) of converter clutch solenoid check the cable from TCU to the converter clutch solenoid check the connectors from converter clutch solenoid to TCU check the resistance 1) of converter clutch solenoid 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 24 von 38

95 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection connection to TCU converter clutch solenoid has an internal defect connector has no connection to TCU 9C S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage converter clutch solenoid has an internal defect connector pin is contacted to battery voltage 9D S.C. TO GROUND AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground retarder solenoid has an internal defect connector pin is contacted to vehicle ground 9E O.C. AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU retarder solenoid has an internal reaction of the TCU possible steps to repair remarks no reaction OP-mode: normal no reaction OP-mode: normal no reaction OP-mode: normal check the cable from TCU to the converter clutch solenoid check the connectors from converter clutch solenoid to TCU check the resistance 1) of converter clutch solenoid check the cable from TCU to the retarder solenoid check the connectors from retarder solenoid to TCU check the resistance 1) of retarder solenoid check the cable from TCU to the retarder solenoid check the connectors from retarder solenoid to TCU check the resistance 1) of retarder solenoid 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 25 von 38

96 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection defect connector has no connection to TCU 9F S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage retarder solenoid has an internal defect connector pin is contacted to battery voltage A S.C. TO GROUND AT DIFFLOCK OR AXLE CONNECTION SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground difflock solenoid has an internal defect connector pin is contacted to vehicle ground A S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR AXLE CONNECTION SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage difflock solenoid has an internal defect connector pin is contacted to battery reaction of the TCU possible steps to repair remarks no reaction OP-mode: normal no reaction OP-mode: normal no reaction OP-mode: normal check the cable from TCU to the retarder solenoid check the connectors from retarder solenoid to TCU check the resistance 1) of retarder solenoid check the cable from TCU to the difflock solenoid check the connectors from difflock solenoid to TCU check the resistance 1) of difflock solenoid check the cable from TCU to the difflock solenoid check the connectors from difflock solenoid to TCU check the resistance 1) of difflock solenoid 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 26 von 38

97 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection voltage A O.C. AT DIFFLOCK OR AXLE CONNECTION SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU difflock solenoid has an internal defect connector has no connection to TCU A S.C. TO GROUND AT WARNING SIGNAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground warning device has an internal defect connector pin is contacted to vehicle ground A O.C. AT WARNING SIGNAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU warning device has an internal defect connector has no connection to TCU A S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT TCU detected a wrong voltage at the reaction of the TCU possible steps to repair remarks no reaction OP-mode: normal no reaction OP-mode: normal no reaction OP-mode: normal check the cable from TCU to the difflock solenoid check the connectors from difflock solenoid to TCU check the resistance 1) of difflock solenoid check the cable from TCU to the warning device check the connectors from warning device to TCU check the resistance 1) of warning device check the cable from TCU to the warning device check the connectors from warning device to TCU check the resistance 1) of warning device no reaction OP-mode: normal check the cable from TCU to the warning device check the connectors from warning 1) see chapter 4 1) see chapter 4 1) see chapter 4 1) see chapter 4 Seite 27 von 38

98 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage warning device has an internal defect connector pin is contacted to battery voltage B SLIPPAGE AT CLUTCH K1 TCU calculates a differential speed at closed clutch K1. If this calculated value is out of range, TCU interprets this as slipping clutch. low pressure at clutch K1 low main pressure wrong signal at internal speed sensor wrong signal at output speed sensor wrong size of the sensor gap clutch is defective B SLIPPAGE AT CLUTCH K2 TCU calculates a differential speed at closed clutch K2. If this calculated value is out of range, TCU interprets this as slipping clutch. low pressure at clutch K2 low main pressure wrong signal at internal speed sensor wrong signal at output speed sensor wrong size of the sensor gap clutch is defective B SLIPPAGE AT CLUTCH K3 TCU calculates a differential speed at closed clutch K3. If this calculated value is reaction of the TCU possible steps to repair remarks TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown device to TCU check the resistance 1) of warning device check pressure at clutch K1 check main pressure in the system check sensor gap at internal speed sensor check sensor gap at output speed sensor check signal at internal speed sensor check signal at output speed sensor replace clutch check pressure at clutch K2 check main pressure in the system check sensor gap at internal speed sensor check sensor gap at output speed sensor check signal at internal speed sensor check signal at output speed sensor replace clutch TCU shifts to neutral OP-Mode: limp home if failure at another clutch is check pressure at clutch K3 check main pressure in the system check sensor gap at internal speed Seite 28 von 38

99 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection out of range, TCU interprets this as slipping clutch. low pressure at clutch K3 low main pressure wrong signal at internal speed sensor wrong signal at output speed sensor wrong size of the sensor gap clutch is defective B SLIPPAGE AT CLUTCH K4 TCU calculated a difference speed at TCU calculates a differential speed at closed clutch K4. If this calculated value is out of range, TCU interprets this as slipping clutch. low pressure at clutch K4 low main pressure wrong signal at internal speed sensor wrong signal at turbine speed sensor wrong size of the sensor gap clutch is defective B SLIPPAGE AT CLUTCH KV TCU calculates a differential speed at closed clutch KV. If this calculated value is out of range, TCU interprets this as slipping clutch. low pressure at clutch KV low main pressure wrong signal at internal speed sensor wrong signal at turbine speed sensor wrong size of the sensor gap clutch is defective reaction of the TCU possible steps to repair remarks pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown sensor check sensor gap at output speed sensor check signal at internal speed sensor check signal at output speed sensor replace clutch check pressure at clutch K4 check main pressure in the system check sensor gap at internal speed sensor check sensor gap at turbine speed sensor check signal at internal speed sensor check signal at turbine speed sensor replace clutch check pressure at clutch KV check main pressure in the system check sensor gap at internal speed sensor check sensor gap at turbine speed sensor check signal at internal speed sensor check signal at turbine speed sensor replace clutch Seite 29 von 38

100 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection B SLIPPAGE AT CLUTCH KR TCU calculates a differential speed at closed clutch KR. If this calculated value is out of range, TCU interprets this as slipping clutch. low pressure at clutch KR low main pressure wrong signal at internal speed sensor wrong signal at turbine speed sensor wrong size of the sensor gap clutch is defective B OVERTEMP SUMP TCU measured a temperature in the oil sump that is over the allowed threshold. B OVERTEMP RETARDER TCU measured a temperature in the retarder oil that is over the allowed threshold. reaction of the TCU possible steps to repair remarks TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown no reaction OP-Mode: normal TCU disables retarder OP-Mode: normal B OVERSPEED ENGINE retarder applies if configured OP-Mode: normal BA DIFFERENTIAL PRESSURE OIL FILTER no reaction TCU measured a voltage at differential OP-Mode: normal pressure switch out of the allowed range oil filter is polluted cable/connector is broken or cable/connector is contacted to battery voltage or vehicle ground differential pressure switch is defective BB SLIPPAGE AT CONVERTER LOCKUP CLUTCH TCU calculates a differential speed at closed converter lockup clutch. If this check pressure at clutch KR check main pressure in the system check sensor gap at internal speed sensor check sensor gap at turbine speed sensor check signal at internal speed sensor check signal at turbine speed sensor replace clutch cool down machine check oil level check temperature sensor cool down machine check oil level check temperature sensor check oil filter check wiring from TCU to differential pressure switch check differential pressure switch (measure resitance) check pressure at converter lockup clutch check main pressure in the system - Seite 30 von 38

101 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection calculated value is out of range, TCU interprets this as slipping clutch. low pressure at converter lockup clutch low main pressure wrong signal at engine speed sensor wrong signal at turbine speed sensor wrong size of the sensor gap clutch is defective BC OVERSPEED OUTPUT TCU messures an transmission output speed above the defined threshold BD S.C. TO GROUND AT ENGINE BRKAE SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground engine brake solenoid has an internal defect connector pin is contacted to vehicle ground BE S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage engine brake solenoid has an internal defect connector pin is contacted to battery reaction of the TCU possible steps to repair remarks No reaction OP-Mode: normal no reaction OP-mode: normal no reaction OP-mode: normal check sensor gap at engine speed sensor check sensor gap at turbine speed sensor check signal at engine speed sensor check signal at turbine speed sensor replace clutch check the cable from TCU to the engine brake solenoid check the connectors from engine brake solenoid to TCU check the resistance 1) of engine brake solenoid check the cable from TCU to the engine brake solenoid check the connectors from engine brake solenoid to TCU check the resistance 1) of engine brake solenoid 1) see chapter 4 1) see chapter 4 Seite 31 von 38

102 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection voltage BF O.C. AT ENGINE BRAKE TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU engine brake solenoid has an internal defect connector has no connection to TCU C ENGINE TORQUE OR ENGINE POWER OVERLOAD TCU calculates an engine torque or engine power above the defined thresholds C TRANSMISSION OUTPUT TORQUE OVERLOAD TCU calculates an transmission output torque above the defined threshold C TRANSMISSION INPUT TORQUE OVERLOAD TCU calculates an transmission input torque above the defined threshold C S.C. TO GROUND AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground joystick status indicator has an internal defect connector pin is contacted to vehicle ground reaction of the TCU possible steps to repair remarks no reaction OP-mode: normal OP-Mode: normal OP-Mode: normal programmable :No reaction or shift to neutral OP-Mode: normal no reaction OP-Mode: normal check the cable from TCU to the engine brake solenoid check the connectors from engine brake solenoid to TCU check the resistance 1) of engine brake solenoid check the cable from TCU to joystick status indicator check the connectors from joystick status indicator to TCU check the resistance 1) of joystick status indicator 1) see chapter 4 Seite 32 von 38

103 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection C S.C. TO BATTERY VOLTAGE AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage joystick status indicator has an internal defect connector pin is contacted to battery voltage C O.C. AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin cable is defective and has no connection to TCU joystick status indicator has an internal defect connector has no connection to TCU CA ENGINE_RETARDER CONFIG_TIMEOUT Timeout of CAN-message ENGINE_RETARDER CONFIG from EEC controller interference on CAN-Bus CAN wire/connector is broken CAN wire/connector is defective an has contact to vehicle ground or battery voltage CB ERC1 TIMEOUT Timeout of CAN-message ERC1 from reaction of the TCU possible steps to repair remarks no reaction OP-Mode: normal no reaction OP-Mode: normal OP-Mode: substitute clutch control check the cable from TCU to joystick status indicator check the connectors from joystick status indicator to TCU check the resistance 1) of joystick status indicator check the cable from TCU to joystick status indicator check the connectors from joystick status indicator to TCU check the resistance 1) of joystick status indicator check EEC controller check wire of CAN-Bus check cable to EEC controller OP-Mode: substitute clutch control check EEC controller check wire of CAN-Bus Seite 33 von 38

104 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection EEC controller interference on CAN-Bus CAN wire/connector is broken CAN wire/connector is defective an has contact to vehicle ground or battery voltage D S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS TCU measures more than 6V at the pin AU1 (5V sensor supply) D S.C. TO GROUND AT POWER SUPPLY FOR SENSORS TCU measures less than 4V at the pin AU1 (5V sensor supply) D LOW VOLTAGE AT BATTERY measured voltage at power supply is lower than 10 V (12V device) lower than 18 V (24V device) D HIGH VOLTAGE AT BATTERY measured voltage at power supply is higher than 18 V (12V device) higher than 32.5 V (24V device) D ERROR AT VALVE POWER SUPPLY VPS1 TCU switched on VPS1 and measured VPS1 is off or TCU switched off VPS1 and measured VPS1 is still on cable or connectors are defect and are contacted to battery voltage cable or connectors are defect and are contacted to vehicle ground permanent power supply KL30 missing TCU has an internal defect reaction of the TCU possible steps to repair remarks see fault codes no. 21 to 2C see fault codes no. 21 to 2C shift to neutral OP-Mode: TCU shutdown shift to neutral OP-Mode: TCU shutdown shift to neutral OP-Mode: TCU shutdown check cable to EEC controller check cables and connectors to sensors, which are supplied from AU1 check the power supply at the pin AU1 (should be appx. 5V) check cables and connectors to sensors, which are supplied from AU1 check the power supply at the pin AU1 (should be appx. 5V) check power supply battery check cables from batteries to TCU check connectors from batteries to TCU check power supply battery check cables from batteries to TCU check connectors from batteries to TCU check fuse check cables from gearbox to TCU check connectors from gearbox to TCU replace TCU fault codes no. 21 to no. 2C may be a reaction of this fault fault codes no. 21 to no. 2C may be a reaction of this fault Seite 34 von 38

105 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection D ERROR VALVE POWER SUPPLY VPS2 TCU switched on VPS2 and measured VPS2 is off or TCU switched off VPS2 and measured VPS2 is still on cable or connectors are defect and are contacted to battery voltage cable or connectors are defect and are contacted to vehicle ground permanent power supply KL30 missing TCU has an internal defect D S.C. TO GROUND AT DLM LONGITUDINAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground cable is defective and is contacted to vehicle ground device has an internal defect connector pin is contacted to vehicle ground D S.C. TO BATTERY VOLTAGE AT DLM LONGITUDINAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage cable is defective and is contacted to battery voltage device has an internal defect connector pin is contacted to battery voltage reaction of the TCU possible steps to repair remarks shift to neutral OP-Mode: TCU shutdown output will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal no reaction OP-Mode: normal check fuse check cables from gearbox to TCU check connectors from gearbox to TCU replace TCU check the cable from TCU to the valve check the connectors check the resistance of valve check the cable from TCU to the valve check the connectors check the resistance of valve 1) see chapter 4 1) see chapter 4 Seite 35 von 38

106 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection E S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT TCU sends data to the display and measures allways a high voltage level on the connector cable or connectors are defective and are contacted to battery voltage display has an internal defect E S.C. TO GROUND AT DISPLAY OUTPUT TCU sends data to the display and measures allways a high voltage level on the connector cable or connectors are defective and are contacted to vehicle ground display has an internal defect F GENERAL EEPROM FAULT TCU can't read non volantile memoy TCU is defective F APPLICATION ERROR something of this application is wrong F CLUTCH FAILURE AEB was not able to adjust clutch filling parameters One of the AEB-Values is out of limit F CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL CALIBRATION DATA LOST TCU was not able to read correct clutch adjustment parameters interference during saving data on non reaction of the TCU possible steps to repair remarks no reaction OP-Mode: normal no reaction OP-Mode: normal no reaction OP-Mode: normal transmission stay neutral OP-Mode: TCU shutdown transmission stay neutral OP-Mode: TCU shutdown default values = 0 for AEB offsets used OP-Mode: normal no Inchmode available check the cable from TCU to the display check the connectors at the display change display check the cable from TCU to the display check the connectors at the display change display replace TCU replace TCU!! check clutch execute AEB often shown together with fault code F2 This fault occurs only if an test engineer did something wrong in the application of the vehicle TCU shows also the affected clutch on the Display Seite 36 von 38

107 ZF Friedrichshafen AG description of fault codes for ERGO-Control Fault Code (hex) SPN FMI MEANING OF THE FAULT CODE possible reason for fault detection volatile memory TCU is brand new reaction of the TCU possible steps to repair remarks Seite 37 von 38

108 ZF Friedrichshafen AG description of fault codes for ERGO-Control measuring of resistance at actuator/sensors and cable 4.1 actuator: 1 2 R G open circuit: R 12 R 1G R 2G short cut to ground: R 12 R; R 1G 0, R 2G R or R 1G R, R 2G 0 (for s.c. to ground, G is connected to vehicle ground) short cut to battery: R 12 R; R 1G 0, R 2G R or R 1G R, R 2G 0 (for s.c. to battery, G is connected to battery voltage) 4.2 cable: TCU U Bat 1 2 open circuit: R 12 R 1P R 1C R 2P R 2C short cut to ground: R 12 0; R 1C R 2C 0, R 1P R 2P short cut to battery: R 12 0, R 1C R 2C, R 1P R 2P 0 Gnd P (power supply) Actuator / Sensor C (chassis) Seite 38 von 38

109 Ersatzteilkatalog Spare-parts catalog 4 WG 190 ZF-Stücklisten-Nr. / ZF parts-list number: Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted

110 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafelübersicht zu / Overview of figures for: Materialnr. / Material number Benennung / Description Technische Info / Technical info WG 190 n/a Bildtafel Figure Sachnummer Product number Benennung Technische Info Technical info Description MOTORANSCHLUSS SAE3/W340/CLIP ENGINE CONNECT. 1 Stk WANDLER CONVERTER 1 Stk ANTRIEB DRIVE 1 Stk GETR.GEHAEUSE ACHSDIFFERENT/WK/TACHO TRANSM.HOUSING 1 Stk GETR.GEHAEUSE KURZER ENTLUEFTER TRANSM.HOUSING 1 Stk KUPPLUNG COUPLING 1 Stk KUPPLUNG COUPLING 1 Stk KUPPLUNG COUPLING 1 Stk KUPPLUNG COUPLING 1 Stk KUPPLUNG COUPLING 1 Stk KUPPLUNG COUPLING 1 Stk ACHSABSCHALTUNG MECHANIC 7C, ANTRIEBSSE ITE VERSCHIEBBAR AXLE DISCONNECTION 1 Stk DIFFERENTIAL DIFFERENTIAL 1 Stk FESTSTELLBREMSE MIT BREMSSCH. OHNE BREM SE PARKING BRAKE 1 Stk FESTSTELLBREMSE MECH.7C DIFF. PARKING BRAKE 1 Stk NEBENABTRIEB SAE-C 12/24 DP, 14Z, OH NE WK, NICHT SCHALTB. POWER TAKE-OFF 1 Stk SCHALTUNG GEARSHIFT SYST. 1 Stk SCHALTUNG MIT DIFF.DRUCKSCHALTER /SCHLIESSER STANDARD GEARSHIFT SYST. 1 Stk SCHALTUNG HSG-94/24V GEARSHIFT SYST. 1 Stk STEUERUNG VERSCHL.TEILE(WK) CONTROL UNIT 1 Stk DRUCKREGLER WSV 11BAR, WGV 4,3 BAR PRESSURE REGULATOR 1 Stk DRUCKOELPUMPE SHW/GLEITLAGER PRESSURE OIL PUMP 1 Stk NOTLENKPUMPE VERSCHLUSST. OHNE ANBAU MOEGLICHK. EMERGENCY STEERING PUMP 1 Stk TACHO VERSCHL.TEILE SPEEDOMETER 1 Stk INDUKTIVGEBER STANDARD INDUCTIVE TRANSMITTER 1 Stk Menge Quantity Einheit Unit Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 2-75

111 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafelübersicht zu / Overview of figures for: Materialnr. / Material number Benennung / Description Technische Info / Technical info WG 190 n/a Bildtafel Figure Sachnummer Product number Benennung Technische Info Technical info Description TEMPERATURGEBER EST/CAN TEMP.SENSOR 1 Stk FILTER DIREKTANBAU WG ( D.F.) FILTER 1 Stk EINFUELLSTUTZEN LANG / WANDLERSEITE FILLER NOZZLE 1 Stk LOSTEILE LOOSE PARTS 1 Stk LOSTEILE LOOSE PARTS 1 Stk Menge Quantity Einheit Unit Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 3-75

112 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT MOTORANSCHLUSS SAE3/W340/CLIP ENGINE CONNECT Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 4-75

113 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info MOTORANSCHLUSS / ENGINE CONNECT. SAE3/W340/CLIP Pos. Sachnummer Product number Benennung Technische Info Technical info Description WANDLERGLOCKE CONVERTER BELL 1 Stk KT.SCHRAUBE HEXAGON SCREW 18 Stk MEMBRANE DIAPHRAGM 1 Stk KT.SCHRAUBE HEXAGON SCREW 4 Stk ANLAUFSCHEIBE A=1,00 THRUST WASHER 8 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 5-75

114 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT WANDLER n/a CONVERTER 010 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 6-75

115 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info WANDLER / CONVERTER n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WANDLER CONVERTER 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 7-75

116 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT ANTRIEB n/a DRIVE Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 8-75

117 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info ANTRIEB / DRIVE n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description ANTRIEBSWELLE Z=54 INPUT SHAFT 1 Stk ANTRIEBSRAD Z=53 INPUT GEAR 1 Stk SICHERUNGSRING CIRCLIP 1 Stk TURBINENWELLE ZF6 WW. A ZFN417 TURBINE SHAFT 1 Stk SPRENGRING SB 38 SNAP RING 1 Stk ROLLENLAGER 60,0X95,0X27,0 B TIMKEN B ROLLER BEARING 1 Stk ROLLENLAGER 60,0X95,0X27,0 B TIMKEN B ROLLER BEARING 1 Stk R-RING 60 X 3 SH P KA R-RING 2 Stk LEITRADWELLE STATOR SHAFT 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 9-75

118 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT GETR.GEHAEUSE ACHSDIFFERENT/WK/TACHO TRANSM.HOUSING / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 10-75

119 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT GETR.GEHAEUSE ACHSDIFFERENT/WK/TACHO TRANSM.HOUSING Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 11-75

120 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info GETR.GEHAEUSE / TRANSM.HOUSING ACHSDIFFERENT/WK/TACHO Pos. Sachnummer Product number Benennung Technische Info Technical info Description GEH.VORDERTEIL HOUS.FRONT SECT 1 Stk GEH.HINTERTEIL HOUS.REAR SECTION 1 Stk Menge Quantity GEH.HINTERTEIL ET HOUS.REAR SECTION 1 Stk ZYLINDERSTIFT 10 M 6X 24 CYLINDRICAL PIN 2 Stk ZYL.SCHRAUBE CAP SCREW 40 Stk HALTEBLECH F270 FIXING PLATE 1 Stk ZYL.SCHRAUBE CAP SCREW 2 Stk ABSCHIRMBLECH WG 210 ZFN410-FU270 SCREEN SHEET 1 Stk ABSCHIRMBLECH ZFN410-FU270 SCREEN SHEET 1 Stk ZYL.SCHRAUBE CAP SCREW 5 Stk BAUMUSTERSCHILD TYPE PLATE 1 Stk OELZUF.GEHAEUSE OIL FEED.HOUSG. 1 Stk DICHTUNG GASKET 1 Stk TORXSCHRAUBE M8X45 TORX SCREW 21 Stk TORXSCHRAUBE M8X30 TORX SCREW 15 Stk TORXSCHRAUBE M8X60 TORX SCREW 4 Stk HALTEBLECH F270 FIXING PLATE 1 Stk ZYL.SCHRAUBE CAP SCREW 2 Stk OELROHR KPL. ROVET AG OIL TUBE 1 Stk O-RING O-RING 1 Stk ZYL.SCHRAUBE CAP SCREW 2 Stk OELROHR WG-210 E235 OIL TUBE 1 Stk ZYL.SCHRAUBE CAP SCREW 1 Stk O-RING O-RING 2 Stk OELROHR A3 ROVET OIL TUBE 1 Stk Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 12-75

121 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info GETR.GEHAEUSE / TRANSM.HOUSING ACHSDIFFERENT/WK/TACHO Pos. Sachnummer Product number Benennung Technische Info Technical info Description O-RING O-RING 1 Stk ZYL.SCHRAUBE CAP SCREW 2 Stk OELROHR WG-210 E235 OIL TUBE 1 Stk ZYL.SCHRAUBE CAP SCREW 1 Stk O-RING O-RING 2 Stk SAUGROHR SUCTION TUBE 1 Stk ZYL.SCHRAUBE CAP SCREW 1 Stk VERSCHL.SCHR. CM38X1,5 KPL.MIT O-RING SCREW PLUG 1 Stk / O-RING O-RING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 13-75

122 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT GETR.GEHAEUSE KURZER ENTLUEFTER TRANSM.HOUSING 140 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 14-75

123 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info GETR.GEHAEUSE / TRANSM.HOUSING KURZER ENTLUEFTER Pos. Sachnummer Product number Benennung Technische Info Technical info Description ENTLUEFTER BREATHER 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 15-75

124 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT KUPPLUNG n/a COUPLING / / /052/ /052/ / / / / / / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 16-75

125 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WELLE SHAFT 1 Stk VERSCHL.DECKEL B=4,5 SEALING CAP 1 Stk STIFTSCHRAUBE STUD 1 Stk KUPPLUNG COUPLING 1 Stk / LAMELLENTRAEGER DISC CARRIER 1 Stk / KOLBEN PISTON 1 Stk // O-RING O-RING 1 Stk // O-RING O-RING 1 Stk / TELLERFEDER 89X68,3X1,70 BAUER CUP SPRING 7 Stk / L-RING L-RING 1 Stk / REIBLAMELLE BSSP1446 KD BORG-WARNER FRICTION DISC 1 Stk / LAMELLE BRL 1246 KD BORG-WARNER DISC 9 Stk / INNENLAMELLE LD INNER CLUTCH DISC 9 Stk / ENDSCHEIBE K1/KV/KR Z=34 F500 END SHIM 1 Stk /0150 SPRENGRING SNAP RING 1 Stk S=2,1 NB S=2,25 NB S=2,4 NB S=2,55 NB S=2,7 NB S=2,85 NB S=3,0 NB S=3,15 NB S=3,30 NB S=3,45 NB Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 17-75

126 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description S=3,60 NB S=3,75 NB S=3,90 NB S=4,05 NB S=4,20 NB LOSRAD IDLER 1 Stk LAUFSCHEIBE LS X 78X5 RUNNING DISK 2 Stk AXIALNADELKRANZ AXIAL NEEDLE CAGE 2 Stk AXIALSCHEIBE AS5578 AXIAL WASHER 2 Stk NADELKRANZ NEEDLE CAGE 1 Stk SICHERUNGSRING X23001 SEEGER-ORBIS CIRCLIP 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk KOLBENRING RIKEN CORPORA PISTON RING 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 18-75

127 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT KUPPLUNG n/a COUPLING / /052/ /052/ / / / / / / / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 19-75

128 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WELLE SHAFT 1 Stk STIFTSCHRAUBE STUD 1 Stk KUPPLUNG COUPLING 1 Stk / LAMELLENTRAEGER DISC CARRIER 1 Stk / KOLBEN PISTON 1 Stk // O-RING O-RING 1 Stk // O-RING O-RING 1 Stk / TELLERFEDER 89X68,3X1,70 BAUER CUP SPRING 7 Stk / L-RING L-RING 1 Stk / AUSSENLAMELLE BSSP1416 KD BORG-WARNER KPL. OUTER CLUTCH DISC 1 Stk / LAMELLE BRL 1216 KD BORG-WARNER DISC 7 Stk / INNENLAMELLE LD INNER CLUTCH DISC 7 Stk / ENDSCHEIBE Z=44 HOERBIGER E380TM END SHIM 1 Stk /0150 SPRENGRING AEHNL. SB 153 SNAP RING 1 Stk S=2,1 NB S=2,25 NB S=2,4 NB S=2,55 NB S=2,7 NB S=2,85 NB S=3,00 NB S=3,15 NB S=3,30 NB S=3,45 NB S=3,60 NB Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 20-75

129 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description S=3,75 NB S=3,90 NB S=4,05 NB S=4,20 NB LOSRAD IDLER 1 Stk LAUFSCHEIBE LS X 78X5 RUNNING DISK 2 Stk AXIALNADELKRANZ AXIAL NEEDLE CAGE 2 Stk AXIALSCHEIBE AS5578 AXIAL WASHER 2 Stk NADELKRANZ NEEDLE CAGE 1 Stk SICHERUNGSRING X23001 SEEGER-ORBIS CIRCLIP 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk KOLBENRING RIKEN CORPORA PISTON RING 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 21-75

130 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT KUPPLUNG n/a COUPLING / / / / / / / /052/ /052/ / /042 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 22-75

131 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WELLE SHAFT 1 Stk STIFTSCHRAUBE STUD 1 Stk KUPPLUNG COUPLING 1 Stk / LAMELLENTRAEGER DISC CARRIER 1 Stk / KOLBEN PISTON 1 Stk // O-RING O-RING 1 Stk // O-RING O-RING 1 Stk / TELLERFEDER 89X68,3X1,70 BAUER CUP SPRING 7 Stk / L-RING L-RING 1 Stk / AUSSENLAMELLE BSSP1416 KD BORG-WARNER KPL. OUTER CLUTCH DISC 1 Stk / LAMELLE BRL 1216 KD BORG-WARNER DISC 7 Stk / INNENLAMELLE LD INNER CLUTCH DISC 7 Stk / ENDSCHEIBE Z=44 HOERBIGER E380TM END SHIM 1 Stk /0150 SPRENGRING AEHNL. SB 153 SNAP RING 1 Stk S=2,1 NB S=2,25 NB S=2,4 NB S=2,55 NB S=2,7 NB S=2,85 NB S=3,00 NB S=3,15 NB S=3,30 NB S=3,45 NB S=3,60 NB Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 23-75

132 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description S=3,75 NB S=3,90 NB S=4,05 NB S=4,20 NB LOSRAD IDLER 1 Stk LAUFSCHEIBE LS X 78X5 RUNNING DISK 2 Stk AXIALNADELKRANZ AXIAL NEEDLE CAGE 2 Stk AXIALSCHEIBE AS5578 AXIAL WASHER 2 Stk NADELKRANZ NEEDLE CAGE 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk KOLBENRING RIKEN CORPORA PISTON RING 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 24-75

133 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT KUPPLUNG n/a COUPLING / / / / / / / /052/ /052/ / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 25-75

134 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WELLE SHAFT 1 Stk ZAHNRAD GEAR 1 Stk SICHERUNGSRING CIRCLIP 1 Stk STIFTSCHRAUBE STUD 1 Stk KUPPLUNG CLUTCH 1 Stk / LAMELLENTRAEGER DISC CARRIER 1 Stk / KOLBEN PISTON 1 Stk // O-RING O-RING 1 Stk // O-RING O-RING 1 Stk / TELLERFEDER 89X68,3X1,70 BAUER CUP SPRING 7 Stk / L-RING L-RING 1 Stk / AUSSENLAMELLE BSSP1416 KD BORG-WARNER KPL. OUTER CLUTCH DISC 1 Stk / LAMELLE BRL 1216 KD BORG-WARNER DISC 6 Stk / INNENLAMELLE LD INNER CLUTCH DISC 6 Stk / ENDSCHEIBE Z=44 HOERBIGER E380TM END SHIM 1 Stk /0150 SPRENGRING SNAP RING 1 Stk S=2,1 NB S=2,25 NB S=2,4 NB S=2,55 NB S=2,7 NB S=2,85 NB S=3,00 NB S=3,15 NB S=3,30 NB Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 26-75

135 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description S=3,45 NB S=3,60 NB S=3,75 NB S=3,90 NB S=4,05 NB S=4,20 NB LOSRAD Z=38 IDLER 1 Stk LAUFSCHEIBE LS X 78X5 RUNNING DISK 1 Stk AXIALNADELKRANZ AXIAL NEEDLE CAGE 2 Stk AXIALSCHEIBE AS5578 AXIAL WASHER 3 Stk NADELKRANZ NEEDLE CAGE 1 Stk SICHERUNGSRING CIRCLIP 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk KOLBENRING RIKEN CORPORA PISTON RING 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 27-75

136 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT KUPPLUNG n/a COUPLING / / / / / / / / / /052/ /052/ / /042 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 28-75

137 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WELLE SHAFT 1 Stk VERSCHL.DECKEL B=4,5 SEALING CAP 1 Stk STIFTSCHRAUBE STUD 1 Stk KUPPLUNG CLUTCH 1 Stk / LAMELLENTRAEGER DISC CARRIER 1 Stk / KOLBEN PISTON 1 Stk // O-RING O-RING 1 Stk // O-RING O-RING 1 Stk / SCHEIBE F500 WASHER 1 Stk / STUETZSCHEIBE ZFN410-F500 SUPPORT DISC 1 Stk / DRUCKFEDER COMPRESSION SPRING 1 Stk / L-RING L-RING 1 Stk / REIBLAMELLE BSSP1446 KD BORG-WARNER FRICTION DISC 1 Stk / LAMELLE BRL 1246 KD BORG-WARNER DISC 10 Stk / INNENLAMELLE LD INNER CLUTCH DISC 10 Stk / ENDSCHEIBE K1/KV/KR Z=34 F500 END SHIM 1 Stk /0150 SPRENGRING SNAP RING 1 Stk S=2,1 NB S=2,25 NB S=2,4 NB S=2,55 NB S=2,7 NB S=2,85 NB S=3,0 NB S=3,15 NB Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 29-75

138 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description S=3,30 NB S=3,45 NB S=3,60 NB S=3,75 NB S=3,90 NB S=4,05 NB S=4,20 NB LOSRAD Z=52 IDLER 1 Stk NADELKRANZ NEEDLE CAGE 1 Stk KUGELLAGER WTB 55.0X90.0X18.0 DURCHGEHAERTET BALL BEARING 1 Stk SICHERUNGSRING CIRCLIP 1 Stk SICHERUNGSRING CIRCLIP 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk KOLBENRING RIKEN CORPORA PISTON RING 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 30-75

139 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT KUPPLUNG n/a COUPLING / / / / / / / / /052/ / /052/ / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 31-75

140 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description WELLE SHAFT 1 Stk VERSCHL.DECKEL B=4,5 SEALING CAP 1 Stk STIFTSCHRAUBE STUD 1 Stk KUPPLUNG CLUTCH 1 Stk / LAMELLENTRAEGER DISC CARRIER 1 Stk / KOLBEN PISTON 1 Stk // O-RING O-RING 1 Stk // O-RING O-RING 1 Stk / SCHEIBE F500 WASHER 1 Stk / STUETZSCHEIBE ZFN410-F500 SUPPORT DISC 1 Stk / DRUCKFEDER COMPRESSION SPRING 1 Stk / L-RING L-RING 1 Stk / REIBLAMELLE BSSP1446 KD BORG-WARNER FRICTION DISC 1 Stk / LAMELLE BRL 1246 KD BORG-WARNER DISC 10 Stk / INNENLAMELLE LD INNER CLUTCH DISC 10 Stk / ENDSCHEIBE K1/KV/KR Z=34 F500 END SHIM 1 Stk /0150 SPRENGRING SNAP RING 1 Stk S=2,1 NB S=2,25 NB S=2,4 NB S=2,55 NB S=2,7 NB S=2,85 NB S=3,0 NB S=3,15 NB Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 32-75

141 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info KUPPLUNG / COUPLING n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description S=3,30 NB S=3,45 NB S=3,60 NB S=3,75 NB S=3,90 NB S=4,05 NB S=4,20 NB LOSRAD Z=52 IDLER 1 Stk NADELKRANZ NEEDLE CAGE 1 Stk KUGELLAGER WTB 55.0X90.0X18.0 DURCHGEHAERTET BALL BEARING 1 Stk SICHERUNGSRING CIRCLIP 1 Stk SICHERUNGSRING CIRCLIP 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk ROLLENLAGER TIMKEN ROLLER BEARING 1 Stk KOLBENRING RIKEN CORPORA PISTON RING 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 33-75

142 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT ACHSABSCHALTUNG MECHANIC 7C, ANTRIEBSSE ITE VERSCHIEBBAR AXLE DISCONNECTION Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 34-75

143 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info ACHSABSCHALTUNG / AXLE MECHANIC 7C, ANTRIEBSSE ITE VERSCHIEBBAR DISCONNECTION Pos. Sachnummer Product number Benennung Technische Info Technical info Description ABTRIEBSFLANSCH KPL. OUTPUT FLANGE 1 Stk ABSCHIRMBLECH FU270 SCREEN SHEET 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 35-75

144 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT DIFFERENTIAL n/a Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 36-75

145 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info DIFFERENTIAL n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description ABTRIEBSWELLE Z=42 ZFN417-C OUTPUT SHAFT 1 Stk ABTRIEBSRAD OUTPUT GEAR 1 Stk ROLLENLAGER ROLLER BEARING 2 Stk SCHEIBE C45E WASHER 1 Stk ZYL.SCHRAUBE CAP SCREW 2 Stk O-RING O-RING 1 Stk WELLENDICHTRING SHAFT SEAL 1 Stk KUGELLAGER BALL BEARING 1 Stk SICHERUNGSRING CIRCLIP 1 Stk PLANETENTRAEGER IN GGG-60 PLANET CARRIER 1 Stk PLANETENRAD PLANETARY GEAR 6 Stk PLANETENBOLZEN 16MNCR5 A ZFN417 PLANET SHAFT 6 Stk ANLAUFSCHEIBE THRUST WASHER 12 Stk SPANNSTIFT SLOT. PIN 6 Stk NADELROLLE A 3 X29,8 G2 ISO NEEDLE ROLLER 162 Stk ANLAUFSCHEIBE IN ST2K50GBK F500 ZFN410 THRUST WASHER 1 Stk ANLAUFSCHEIBE IN ST2K50GBK F500 ZFN410 THRUST WASHER 1 Stk ZYL.SCHRAUBE CAP SCREW 18 Stk DIFF.DECKEL ZFN417-C DIFF.COVER 1 Stk SONNENRAD SUN GEAR 1 Stk NADELHUELSE HK2020 ST-KAEFIG NEEDLE SLEEVE 1 Stk NADELHUELSE HK5528 ST-KAEFIG NEEDLE SLEEVE 1 Stk HOHLWELLE Z=46 ZF7B QUILL SHAFT 1 Stk SPRENGRING SB 63 SNAP RING 1 Stk GEHAEUSE HOUSING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 37-75

146 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info DIFFERENTIAL n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description ZYL.SCHRAUBE CAP SCREW 2 Stk ZYL.SCHRAUBE CAP SCREW 7 Stk RUNDDICHTRING O-RING 1 Stk FEDERHUELSE SPRING SLEEVE 1 Stk DRUCKFEDER COMPRESSION SPRING 1 Stk KOLBEN PISTON 1 Stk RECHTECKRING OBLONG RING 1 Stk DICHTUNG GASKET 1 Stk ZYLINDER CYLINDER 1 Stk TORXSCHRAUBE M8X45 TORX SCREW 4 Stk RIEGEL IN C15 A ZFN413 BOLT 1 Stk SCHALTER KPL. SWITCH 1 Stk O-RING O-RING 1 Stk SCHALTGABEL ZF50 GEAR SHIFT FORK 1 Stk GLEITSTEIN SLIDING PAD 2 Stk BOLZEN KPL. STUD 2 Stk O-RING O-RING 2 Stk KT.SCHRAUBE HEXAGON SCREW 2 Stk SCHIEBEMUFFE ZF6 A ZFN413 SLIDING SLEEVE 1 Stk ABTRIEBSWELLE OUTPUT SHAFT 1 Stk KUGELLAGER BALL BEARING 1 Stk SICHERUNGSRING CIRCLIP 1 Stk WELLENDICHTRING SHAFT SEAL 1 Stk BUCHSE Z=34 BUSH 1 Stk ZWISCHENSCHEIBE INTERMEDIATE WASHER 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 38-75

147 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info DIFFERENTIAL n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description SCHEIBE 16MNCR5 WASHER 1 Stk ZYL.SCHRAUBE CAP SCREW 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 39-75

148 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT FESTSTELLBREMSE MIT BREMSSCH. OHNE BREM SE PARKING BRAKE Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 40-75

149 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info FESTSTELLBREMSE / PARKING BRAKE MIT BREMSSCH. OHNE BREM SE Pos. Sachnummer Product number Benennung Technische Info Technical info Description BREMSSCHEIBE IN F500 BRAKE DISC 1 Stk KT.SCHRAUBE HEXAGON SCREW 8 Stk SCHEIBE 10,5 WASHER 8 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 41-75

150 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT FESTSTELLBREMSE MECH.7C DIFF PARKING BRAKE Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 42-75

151 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info FESTSTELLBREMSE / PARKING BRAKE MECH.7C DIFF. Pos. Sachnummer Product number Benennung Technische Info Technical info Description FLANSCH FLANGE 1 Stk ABSCHIRMBLECH SCREEN SHEET 1 Stk KT.SCHRAUBE HEXAGON SCREW 6 Stk SCHEIBE 10,5 WASHER 6 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 43-75

152 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT NEBENABTRIEB SAE-C 12/24 DP, 14Z, OH NE WK, NICHT SCHALTB POWER TAKE-OFF Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 44-75

153 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info NEBENABTRIEB / POWER TAKE-OFF SAE-C 12/24 DP, 14Z, OH NE WK, NICHT SCHALTB. Pos. Sachnummer Product number Benennung Technische Info Technical info Description PUMPENWELLE Z=21 ZF6 A ZFN417 PUMP SHAFT 1 Stk SICHERUNGSRING CIRCLIP 1 Stk R-RING 60 X 3 SH P KA R-RING 1 Stk KUGELLAGER BALL BEARING 1 Stk ABDECKPLATTE COVER PLATE 1 Stk O-RING O-RING 1 Stk KT.SCHRAUBE HEXAGON SCREW 4 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 45-75

154 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT SCHALTUNG n/a GEARSHIFT SYST / /010 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 46-75

155 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info SCHALTUNG / GEARSHIFT SYST. n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description DICHTUNG GASKET 1 Stk KANALPLATTE DUCT PLATE 1 Stk DICHTBLECH SEALING PLATE 1 Stk TORXSCHRAUBE M8X30 TORX SCREW 36 Stk STIFTSCHRAUBE STUD 14 Stk KT.MUTTER HEXAGON NUT 14 Stk TORXSCHRAUBE M6X76 TORX SCREW 23 Stk KOLBEN EN AW-6082[ALSI1MGMN] PISTON 1 Stk DRUCKFEDER DRAHT D=1,6 FEDERSTAHL COMPRESSION SPRING 1 Stk VERSCHL.SCHR. M10X1 KPL.MIT O-RING SCREW PLUG 8 Stk / O-RING O-RING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 47-75

156 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT SCHALTUNG MIT DIFF.DRUCKSCHALTER /SCHLIESSER STANDARD GEARSHIFT SYST. 770 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 48-75

157 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info SCHALTUNG / GEARSHIFT SYST. MIT DIFF.DRUCKSCHALTER /SCHLIESSER STANDARD Pos. Sachnummer Product number Benennung Technische Info Technical info Description STOESS.SCHALTER TAPPET SWITCH 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 49-75

158 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT SCHALTUNG HSG-94/24V GEARSHIFT SYST / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 50-75

159 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT SCHALTUNG HSG-94/24V GEARSHIFT SYST Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 51-75

160 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info SCHALTUNG / GEARSHIFT SYST. HSG-94/24V Pos. Sachnummer Product number Benennung Technische Info Technical info Description VENTILBLOCK VALVE BLOCK 1 Stk BLENDE D=0,8 ORIFICE 6 Stk KOLBEN NACHFOLGESCHIEBER EN AW-ALSIMGMN T6 PISTON 6 Stk DRUCKFEDER COMPRESSION SPRING 6 Stk KOLBEN EN AW-ALSIMGMN T6 WW. PISTON 6 Stk DRUCKFEDER COMPRESSION SPRING 6 Stk KOLBEN EN AW-ALSIMGMN T6 PISTON 1 Stk DRUCKFEDER COMPRESSION SPRING 1 Stk REGELKOLBEN EN AW-ALSIMGMN T6 WW. CONTROL PISTON 1 Stk DRUCKFEDER COMPRESSION SPRING 1 Stk DICHTUNG GASKET 1 Stk GEHAEUSE GD-ALSI9CU3 HOUSING 1 Stk TORXSCHRAUBE M5 TORX SCREW 18 Stk DRUCKREGLER VR030AA032D03 MAGNET-SCHULT PRESSURE REGULATOR 3 Stk / RUNDDICHTRING O-RING 1 Stk HALTEBLECH FIXING PLATE 3 Stk TORXSCHRAUBE M5X12 TORX SCREW 3 Stk DICHTUNG GASKET 1 Stk GEHAEUSE GD-ALSI9CU3 HOUSING 1 Stk TORXSCHRAUBE M5 TORX SCREW 18 Stk DRUCKREGLER VR030AA032D03 MAGNET-SCHULT PRESSURE REGULATOR 3 Stk / RUNDDICHTRING O-RING 1 Stk HALTEBLECH FIXING PLATE 3 Stk TORXSCHRAUBE M5X12 TORX SCREW 3 Stk KABELBAUM KPL.HSG-94 SERIE 1 WIRING HARNESS 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 52-75

161 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info SCHALTUNG / GEARSHIFT SYST. HSG-94/24V Pos. Sachnummer Product number Benennung Technische Info Technical info Description DICHTUNG GASKET 1 Stk DECKEL AUSF.I COVER 1 Stk TORXSCHRAUBE M5 TORX SCREW 14 Stk DICHTUNG GASKET 1 Stk DECKEL AUSF.II COVER 1 Stk HALTEKLAMMER RETAINING CLAMP 1 Stk TORXSCHRAUBE M5 TORX SCREW 14 Stk DICHTBLECH ELRINGKLINGER ALMG4,5MN0,7 H24 SEALING PLATE 1 Stk SIEB MASCHENW.200MY KUEFNER KG KUEF.NR.97NE028.1 SCREEN 6 Stk KANALPLATTE GD-ALSI9CU3 DUCT PLATE 1 Stk TORXSCHRAUBE M6X23 TORX SCREW 18 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 53-75

162 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT STEUERUNG VERSCHL.TEILE(WK) CONTROL UNIT / / / / / / / /010 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 54-75

163 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info STEUERUNG / CONTROL UNIT VERSCHL.TEILE(WK) Pos. Sachnummer Product number Benennung Technische Info Technical info Description 0490 VERSCHL.SCHR. M26X1,5 KPL.MIT O-RING SCREW PLUG 1 Stk / VERSCHL.SCHR. SCREW PLUG 1 Stk / O-RING O-RING 1 Stk VERSCHL.SCHR. M16X1,5 KPL.MIT O-RING SCREW PLUG 1 Stk / O-RING O-RING 1 Stk VERSCHL.SCHR. M16X1,5 KPL.MIT O-RING SCREW PLUG 2 Stk / O-RING O-RING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 55-75

164 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT DRUCKREGLER WSV 11BAR, WGV 4,3 BAR PRESSURE REGULATOR Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 56-75

165 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info DRUCKREGLER / PRESSURE REGULATOR WSV 11BAR, WGV 4,3 BAR Pos. Sachnummer Product number Benennung Technische Info Technical info Description VENTIL VALVE 1 Stk DRUCKPLATTE ALMGSI0,5F13 PRESSURE PLATE 1 Stk SICHERUNGSBLECH F270 LOCK PLATE 1 Stk KOLBEN ALSIMGMN T6 PISTON 1 Stk DRUCKFEDER FEDERSTAHL COMPRESSION SPRING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 57-75

166 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT DRUCKOELPUMPE SHW/GLEITLAGER PRESSURE OIL PUMP / / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 58-75

167 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info DRUCKOELPUMPE / PRESSURE OIL PUMP SHW/GLEITLAGER Pos. Sachnummer Product number Benennung Technische Info Technical info Description ZAHNRADPUMPE GEAR PUMP 1 Stk / WELLENDICHTRING 75 X 95X10 A+R SHAFT SEAL 1 Stk 0020 ZYL.SCHRAUBE M10X75 KPL.MIT O-RING CAP SCREW 10 Stk / ZYL.SCHRAUBE CAP SCREW 1 Stk / O-RING O-RING 1 Stk O-RING O-RING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 59-75

168 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT NOTLENKPUMPE VERSCHLUSST. OHNE ANBAU MOEGLICHK EMERGENCY STEERING PUMP Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 60-75

169 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info NOTLENKPUMPE / EMERGENCY STEERING VERSCHLUSST. OHNE ANBAU MOEGLICHK. PUMP Pos. Sachnummer Product number Benennung Technische Info Technical info Description DECKEL F270 COVER 1 Stk DICHTUNG GASKET 1 Stk KT.SCHRAUBE HEXAGON SCREW 23 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 61-75

170 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT TACHO VERSCHL.TEILE SPEEDOMETER 480/ / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 62-75

171 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info TACHO / SPEEDOMETER VERSCHL.TEILE Pos. Sachnummer Product number Benennung Technische Info Technical info Description VERSCHL.SCHR. SCREW PLUG 1 Stk / O-RING O-RING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 63-75

172 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT INDUKTIVGEBER STANDARD INDUCTIVE TRANSMITTER 010/ / / Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 64-75

173 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info INDUKTIVGEBER / INDUCTIVE TRANSMITTER STANDARD Pos. Sachnummer Product number Benennung Technische Info Technical info Description INDUKTIVGEBER INDUCTIVE TRANSMITTER 3 Stk / RUNDDICHTRING O-RING 1 Stk DREHZAHLGEBER SPEED TRANSMITT 1 Stk / O-RING O-RING 1 Stk ZYL.SCHRAUBE CAP SCREW 1 Stk VERSCHL.DECKEL D=20 SEALING CAP 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 65-75

174 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT TEMPERATURGEBER EST/CAN TEMP.SENSOR /010 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 66-75

175 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info TEMPERATURGEBER / TEMP.SENSOR EST/CAN Pos. Sachnummer Product number Benennung Technische Info Technical info Description TEMPERATURGEBER TEMP.SENSOR 1 Stk / O-RING ET O-RING 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 67-75

176 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT FILTER DIREKTANBAU WG ( D.F.) Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 68-75

177 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info FILTER DIREKTANBAU WG ( D.F.) Pos. Sachnummer Product number Benennung Technische Info Technical info Description DRUCKFILTER PRESSURE FILTER 1 Stk FILTERKOPF KPL. FILTER HEAD 1 Stk O-RING O-RING 2 Stk TORXSCHRAUBE M8X60 TORX SCREW 2 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 69-75

178 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT EINFUELLSTUTZEN LANG / WANDLERSEITE FILLER NOZZLE Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 70-75

179 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info EINFUELLSTUTZEN / FILLER NOZZLE LANG / WANDLERSEITE Pos. Sachnummer Product number Benennung Technische Info Technical info Description OELSTANDSROHR KPL. OIL LEVEL TUBE 1 Stk OELMESSSTAB KPL. OIL DIPSTICK 1 Stk DICHTUNG GASKET 2 Stk KT.SCHRAUBE HEXAGON SCREW 2 Stk KT.SCHRAUBE HEXAGON SCREW 2 Stk ABDECKBLECH COVER PLATE 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 71-75

180 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT LOSTEILE n/a LOOSE PARTS 010/ / / / / / / / / / / / / / / / / /030 Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 72-75

181 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info LOSTEILE / LOOSE PARTS n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description BREMSE BRAKE 1 Stk / DICHTUNGSSATZ SEAL KIT 1 Stk / REPARATURSATZ REPAIR KIT 1 Stk / REPARATURSATZ REPAIR KIT 1 Stk / REPARATURSATZ REPAIR KIT 1 Stk / REPARATURSATZ REPAIR KIT 1 Stk / REPARATURSATZ REPAIR KIT 1 Stk / BREMSBELAGSATZ BRAKE LINING KIT 1 Stk / REPARATURSATZ REPAIR KIT 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 73-75

182 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Bildtafel / Figure: Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info PLT LOSTEILE n/a LOOSE PARTS Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Seite / Page: 74-75

183 Produkt / Product: WG 190 Ersatzteilkatalog / Spare-parts catalog Ersatzteilliste zu Bildtafel / Spare-parts list for figure: Bildtafel / Figure Materialnr. / Material number Benennung / Description Technische Info / Technical info LOSTEILE / LOOSE PARTS n/a Pos. Sachnummer Product number Benennung Technische Info Technical info Description FS VTS 3 FS VTS 3 1 Stk KABEL ARBMASCH EST37 OFFENE STECKER LANG CABLE OFF-ROAD 1 Stk DISPLAY KPL.2 X 4POL.MATE-N-LOK DISPLAY 1 Stk STECKERSATZ STECKER 4POL M-N-L BU PLUG KIT 1 Stk STECKERSATZ STECKER 22POL BU JUN.P.T. PLUG KIT 1 Stk STEUERUNG CONTROL UNIT 1 Stk Menge Quantity Einheit Unit ww = wahlweise / optional NB = nach Bedarf / as required ET = Ersatzteil / spare part Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Seite / Page: 75-75

184

185 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG Design and function Bild 1-1: Brake components 1 Housing 2 Pressure ring 3 Pressure bolt 4 Setting screw 5 Plate spring pack 6 Piston 7 Lining pad 8 Lining pad 9 Guiding pin 10 Rubber buffer 11 Adjusting screw 12 Lining spring 13 Counter nut The two identical lining pads (7)(8) slide on the guide surfaces on the top of the housing and are held in position by a lining spring (12). The brake itself is directly fixed on the gearbox or onto the axle of a vehicle with the two guide pins (9). The brake is positioned axially using the rubber buffers (10) between the brake housing and the guide pins (9), and the setting screw (11). When the brake is actuated (= closed) a clamping force is created on the lining pads (7)(8) which is transmitted to the brake disc. Under the force of the plate spring pack (5), the piston (6), together with the adjusting screw (4), the pressure bolt (3) and the lining pad (7) are moved towards the brake disc. When the lining pad (7) comes into contact with the brake disc, the reaction force displaces the brake on the guide pins (9), against the spring force of the rubber buffers (10), until the second lining pad (8) is also pressed against the brake disc. The braking effect (braking torque) is dependent upon the frictional values of the brake linings. The brake is released by complete pretensioning of the plate spring pack (5). The piston (6) is moved back by the required minimum release pressure to the stop on the pressure ring (2). During this process the brake positions itself, depending upon the setting, by the two rubber buffers (10) up to contact with the setting screw (11). An equal air gap must be guaranteed on both sides of the brake disc when set correctly. The clamping force is reduced by wear of the lining pads (7)(8) and the brake disc. The brake must then be re-adjusted Maintenance and repair manual TM 99/07 1

186 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG Fitting and setting instructions Bild 2-1: Fitting and setting instructions 1 Locknut (SW 24) 2 Setting screw (SW 8) 3 Adjusting screw (SW 6) 4 Counter nut (SW 13) 5 Screw cap 6 Pressure bolt 7 Guiding bolt 8 Bleeding screw (SW 11) 9 Piston (SW 11) 2.1. Fitting the brake The brake is supplied by KNOTT GmbH in accordance with the drawing. The method of fitting the brake to the axle housing or gearbox is to be taken from the fitting instructions provided by the manufacturers of the axle housing or gearbox. Note: The fitting or adjusting must always be carried out when the brake is cold. 1. Rotate the screw cap (5) in a counter-clockwise direction and unscrew it. 2. Release the locknut (1) and turn the adjusting screw (2) counter-clockwise until the pressure bolt (6) contacts the piston (9) with the flat surface. 3. Slide the brake over the brake disc in this condition. Note: The point at which the brake disc is fitted is determined by the customer. 4. Screw the two guide pins (7) into the axle housing or gearbox in accordance with the fitting instructions provided by the manufacturers of the axles or gearboxes. 5. Connect the pressure. 6. Apply the required release pressure (min. 120 bar) to the brake in order to pre-tension the plate spring pack (10) completely, up to the stop. 7. Carry out bleeding of the brake using the bleed valve (8) Maintenance and repair manual TM 99/07

187 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG Clearance adjusting 1. Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold them in position. Note: The thickness of the setting gauge must be adjusted to the desired air gap. 2. Turn the adjusting screw (2) in a clockwise direction until the two setting gauges are clamped between the brake lining carriers and the brake disc. 3. Hold the adjusting screw (2) in position and lock using the locknut (1). Caution! Type FSG88 Clearance in mm Setting gauge in mm min. 0,5 0,25 Nominal clearance 1,0 0,50 max. 1,5 0,75 The application pressure for clamping the setting gauges must be selected so that both gauges can be removed using a small amount of force after locking in position. 4. Release the locknut (4) and then turn the setting screw (3) in a clockwise direction until the end surface of the setting screw (3) is in contact with the surface provided for setting. 5. Hold the setting screw (3) in position and lock using the locknut (4). 6. Remove the setting gauges from both sides of the brake disc. Note: The fitting procedure for the brake and the setting of the desired air gap is now complete. The brake is ready for use. 7. Turn the screw cap (5) in a clockwise direction and tighten hand-tight. Note: The brake should be actuated and released several times to check that it is functioning properly. Maintenance and repair manual TM 99/07 3

188 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG Adjusting instructions 1. Place the vehicle on flat ground and secure against rolling away. 2. Release the parking brake by application of the required release pressure (min. 120 bar). 3. Rotate the screw cap (5) in a counter-clockwise direction and unscrew it. 4. Release the locknut (1) of the adjusting screw (2) 5. Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold them in position. Note: The setting gauge must be selected in accordance with the table under 2.2 "Air gap setting"! 6. Turn the adjusting screw (2) in a clockwise direction until the two setting gauges are clamped between the brake lining carriers and the brake disc. 7. Apply the locknut (1) to the adjusting screw (2). Caution! The application pressure for clamping the setting gauges must be selected so that both gauges can be removed using a small amount of force after locking in position. 8. Release the locknut (4) and then turn the setting screw (3) in a clockwise direction until the end surface of the setting screw (3) is in contact with the surface provided for setting. 9. Hold the setting screw (3) in position and lock using the locknut (4). 10. Remove the setting gauge from both sides of the brake disc. Note: The adjustment of the desired air gap is now complete. The brake is ready for use. 11. Turn the screw cap (5) in a clockwise direction and tighten hand-tight. Note: Actuate the brake valve several times and check the holding effect of the parking brake on a suitable incline or a suitable gradient. 4 Maintenance and repair manual TM 99/07

189 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG Emergency release of the parking brake Bild 3-1: Emergency release of the parking brake 1 Locknut (SW 24 2 Setting screw (SW 8) S Peg spanner G Ring spanner In the event of a failure in pressure supply the parking brake can be released mechanically in the following way: 1. Secure the vehicle against rolling away. 2. Rotate the screw cap in a counter-clockwise direction and unscrew it. 3. Release the locknut (1) and unscrew it back to the end of the setting screw (2). 4. Rotate the setting screw (2) in a clockwise direction until the brake disc is completely free. Caution! For emergency release a torque of min. 70 Nm is required on the setting screw (2)! 5. Screw on the locknut (1) up to contact with the piston and apply a slight locking force to the setting screw (2). 6. Screw on the screw cap in a clockwise direction by a few threads. (dirt ingress protection) Caution! 2 1 S In this condition the vehicle has no parking brake facility and thus must be protected from rolling away by different means. The brake must be adjusted before re-commissioning. Siehe (Maintenance and repair manual) G Maintenance and repair manual TM 99/07 5

190 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG Maintenance and repair work 4.1. Maintenance and replacement of the lining pads Bild 4-1: Replace the lining pads 1 Locknut (SW 24) 2 Setting screw (SW 8) 3 Pressure bolt 4 Piston S Peg spanner S1 Screwdriver R Ring spanner The brake, particularly the brake lining carriers, must be visually inspected at regular intervals, depending upon the application and the type of vehicle (maintenance interval to be specified by the vehicle manufacturer). If the remaining lining thickness is too thin, these intervals must be reduced accordingly to prevent extensive damage to the brake or the brake disc. Once the minimum remaining lining thickness of mm per brake lining carrier is reached, the brake lining carrier must be replaced in accordance with the following instructions: S1 Caution! 4 2 Use only genuine KNOTT spare parts. If any other spare parts are used, KNOTT accepts no warranty or guarantee for the brake or its function. 1. Place the vehicle on flat ground and secure against rolling away. 2. Release the parking brake by application of the required release pressure (min. 120 bar). 3. Rotate the screw cap in a counter-clockwise direction and unscrew it. 4. Release the locknut (1) of the setting screw screw (2). 5. Rotate the setting screw (2) in an counter-clockwise direction until the pressure bolt (3) can be pushed completely into the piston (4). 6. Unscrew (lever) the pressure bolt (3) with a suitable screwdriver until it contacts the piston (4). S 3 1 R 6 Maintenance and repair manual TM 99/07

191 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG 88 Bild 4-2: Replace the lining pads 1 Counter nut (SW 13) 2 Adjusting screw (SW 6) 3 Lining pad 4 Lining pad 5 Lining spring. 7. Release the counter nut (1) and unscrew the setting screw (2) from the brake housing Caution! The lining spring (5) is pre-tensioned. The lining spring (5) must be held in position with a suitable tool whilst removing the setting screw (2). 8. Remove the lining spring (5). 9. Remove the two lining pads (3)(4) from the lining compartment in the brake housing. Note: If there is no possibility of changing the brake lining carriers (3)(4) as described above (not enough space), the brake must be removed completely. The procedure for removing the brake from the axle housing or gearbox can be taken from the fitting instructions provided by the manufacturer of the axles or gearboxes. Caution! Check the pressure line. A pressure line which is too short must be unscrewed in order to permit removal of the brake. An emergency release of the parking brake must be carried out before releasing the pressure line. 10. Replace the lining pads (3)(4). 5 Maintenance and repair manual TM 99/07 7

192 Maintenance and repair manual TM 99/07 Spring applied hydro released sliding caliper FSG The lining spring (5) must be pushed in position with a suitable tool whilst screwing in the adjusting screw (2). Note: If you removed the brake completely because of a lack of space you must carry out fitting of the brake in accordance with the fitting instructions provided by the manufacturers of the axles or gearboxes. Note: 4.2. Replacing the seals Bild 4-3: Replacing the sealrings 1 Piston 2 Setting screw (SW 8) 3 Setting nut (SW 24) 4 Housing 5 Circlip 6 Sealring 7 Pressure ring 8 Pressure bolt 9 Plate spring pack 10 Dust protection cap A Detail sealring B Detail sealring After changing the lining pads (3)(4), or repair to them, the brake must be adjusted in accordance with 2.1 "Fitting the brake" from Point 4 "connect the pressure". 10 Leaking seals must be replaced in accordance with the following instructions: 1. Place the vehicle on flat ground and secure against rolling away. 2. Release the parking brake by application of the required release pressure (min. 120 bar). Caution! If the brake cannot be pressurised with the required release pressure (min. 120 bar) because of excessive leaks, the parking brake MUST be released using the emergency procedure. (see "3. Emergency release of the parking brake") 3. Rotate the screw cap in a counter-clockwise direction and unscrew it. 4. Release the setting nut (3) of the setting screw (2) A B 8 Maintenance and repair manual TM 99/07