Driveline Technology and Axle Systems for Construction Equipment. Fit for Function

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1 Driveline Technology and Axle Systems for Construction Equipment Fit for Function

2 There is a suitable construction machine for every application. Our flexible systems technology accompanies and supports our customers on their way to specialization. We provide solutions delivering high standards of functionality for your headstart into the future. Global Competence You must be global player for holding your ground in this dynamic world. Since its foundation in 1915, ZF has been setting worldwide standards in the construction of vehicle components. ZF manufactures transmissions, steering systems, axles, chassis components and complete systems for cars, commercial vehicles and off-road machinery. ZF is also the leading driveline expert for special vehicles, rail-bound equipment, marine crafts and helicopters. A dense network of production sites, assembly plants as well as sales and service locations ensures worldwide ZF presence in all market regions for full customer support. Hermann Beck Vice President A - Construction Machinery Systems Fit for Function Innovation and absolute customer focusing are the central pillars of our company philosophy. Consistent awareness of customer requirements is the prerequisite for taking decisive steps into function-orientated development and for setting new standards in mobile construction machinery. ZF driveline components stand for the ultimate in performance, economy and comfort. Focal points of our technical development are the requirements of vehicle owners and drivers. Reliability and easy operation provide maximum efficiency. This is our understanding of Fit for Function! Concentration of expertise within the ZF group generates extensive synergies. ZF basic research, state-of-the-art tools for simultaneous engineering as well as materials and surface technology are essential elements of our know-how pool. Moving Innovation Modern construction machines perform a large variety of complex jobs. ZF s main focus is always concentrated on the specific requirements of the customer. Whatever your conditions, we offer tailor-made technology for any application, making our systems the core of every efficient construction machine and providing safe, comfortable and economic operation. This approach has made us worldwide market leader which in turn means that you can count on having a strong partner. Hermann Beck 2 3

3 Success Factor Innovation The systems partner and innovation leader ZF offers its customers the full range of R & D and product knowhow. One source for everything, minimized interfaces, perfect matching of all modules for optimum performance and reserves. You get a fully tuned and quality-proven system for integration into your construction machinery. Anyone who just responds to requirements is late. Therefore, innovation all over the world is our home. ZF driveline and chassis technology is your reliable partner for worldwide success. ZF The Systems Partner Systems for Winners There is only restricted scope for further functional improvements at the component level. Concentrated activities are centered around quality optimization and increase of reliability. However, the only way to achieve quantum leaps in terms of functionality is to network the components with their central control systems. Outstanding Solutions for any Application Heavy-duty transmissions, precision axles and intelligent electronic systems are the components any sophisticated total package is composed of. Tailor-made solutions of ultimate technological level are the secret of our company s worldwide market leadership! One thing is certain though: The whole is greater than the sum of its parts. Buying in individual components long ceased to be all that it takes. Cooperation with an efficient systems partner is your decisive advantage. The target we are striving for is quite simple: Combining sophisticated modules to a perfect system to offer the decisive plus in productivity and reliability for your construction machinery. Example Dumper Driveline: Transmissions and axles in dumpers are continuously exposed to maximum loading factors. What makes ZF products stand out for these requirements are high levels of reliability and low wear and tear. 4 5

4 A consistently applied systematic approach to our axle ranges enables us to deliver a cost-effective, optimum performance solution for virtually any vehicle or application profile by drawing on our pool of modular designs. This multi-faceted flexibility is symbolized by the brand names we have chosen for our axle series. ZF Axles Ground Clearance Ground Contact ZF Multisteer and ZF Multitrac High technology for proper ground contact with maximum ground clearance. ZF axle systems place firm ground under any vehicle concept. The modular design allows coming up to all customer requirements. Slim axle housings, small axle center drives and high ratios in the wheel heads do not represent a conflicting engineering target for us but are already part of our innovative axle ranges ZF-Multisteer and ZF-Multitrac. A policy of sharing experience gained in engineering, testing and practice this is how we are able to directly focus our development efforts on the specific needs of our customers. The outcome of this meticulous work guarantees production units offering considerably increased performance, extended service life and decisive economy. ZF-Multisteer and ZF-Multitrac fully meet the most diverging targets: They are robust but also lightweight, capable of delivering a great deal of power from a compact shape, they are versatile while remaining cost-effective in line with the market. Every ZF construction equipment axle is based on the mature status of long production runs, thus offering the full range of options needed to comply with your individual demands. Sectional view of wheel head The total efficiency of the brake is optimized by synchronized RPM of wet multi-disc brake and wheel. ZF Multisteer Multisteer front axle systems were designed for extreme loadings. The steering cylinder is integrated in the axle housing and is positioned in a protected location behind the axle. Combined with the negative scrub radius this allows high maneuverability even with large front wheels. ZF Multitrac Multitrac rear axles are equipped with internal wet multidisc brakes which ensure high levels of braking torque, require minimum maintenance and are self-adjusting. They are fitted with SAHR park brakes. 6 7

5 ZF Ergopower transmissions offer completely new standards to the market. Helical gears with high tooth contact reduce the noise level. Extremely short shafts prevent deflection and tooth contact errors. Vertical arrangement of spur gear ratios bridges the difference in height between input and output shaft, allowing the axle differential to be integrated into the housing. No additional transfer box is required. ZF Transmissions Maximum efficiency The world of construction machines is extremely versatile. ZF driveline technology constantly bears in mind these complex requirements. When we supply transmissions to our customers, they not only receive a superlative technical product, they also take a major step forward. We develop innovative system transmissions representing a high added value for any construction machine. Maximum power utilization, optimum shifting quality without tractive effort interruption, easy maintenance and diagnostics combined with low noise emission delivers transmission technology being of equal benefit to the vehicle owner and the driver. ZF Ergopower You can materialize completely new construction machinery concepts with ZF. Extreme low-noise operation and considerably reduced load peaks increase both service life and reliability to a great extent, resulting in your construction machines offering even more comfort and economy. The modular configuration combined with a cost-optimized design is cutting your operating costs down to an absolute minimum and ensures excellent tuning to vehicle and application. The helical gears with high tooth contact, the extremely short, stiff shaft and the noise-optimized housing design allow a considerable noise reduction. The compact clutch package offers improved shifting quality and a high level of handling comfort. 8 9

6 Controllable power ZF-Ergocontrol stands for the central brain of the drive system. Microprocessors are networking and controlling all vehicle functions on a central basis. For axles and transmissions. For individual pressure build-up. For the right shifting point. For smooth gear change without tractive effort interruption. For optimized driving performance and traction. To prevent operating errors. Altogether, this saves fuel and allows the driver to fully concentrate on his job. ZF Electronics Permanent intelligence everything under control The decisive criterion: All-In-One-Motion Control can only be achieved by ingenious electronic systems. ZF-Ergocontrol and ZF-Ergoshift The Power of Data applies to modern company management just as much as it does to the interaction of forces in construction machinery. ZF electronics handle the total management of the vehicle and control engine, retarder, clutches, interaxle differentials, brakes and axle differentials. The advantages are obvious: easy operation, reduced wear and low consumption levels. This is how modern driveline management permanently guarantees optimum power utilization. ZF-Ergocontrol The electronic ZF-Ergocontrol combines the components to an efficiently functioning system. The software carefully matches the machine to the individual application to ensure optimum utilization of the power produced under the hood. ZF-Ergoshift The interface between man and machine, with gear selectors designed in accordance with stateof-the-art ergonomic know-how. They guarantee fatigue-proof working, ensure excellent efficiency and operating safety and highly increase the productivity of your construction machine

7 A spare part might be needed within 24 hours in the remotest corner of the African bush: no problem for our ingenious logistics system! We can deliver rapid support anywhere on earth to keep your business on the move. We train your staff, provide you with professional equipment, help you to set up your own workshops and advise you on all matters relating to technical modifications and updates. ZF After-Sales Service Worldwide. Hand-in-Glove. Technology leadership is one side of the coin. However, it is our unique standard of customer service, delivered round the clock and right around the globe that has given ZF an international name as a dynamic partner with a highly responsible attitude towards its customers. Always a decisive step ahead With this extensive service network, we can satisfy your expectations even before you approach us with an issue. We are always one step ahead and have the best solution on hand. Wherever our customers might be, you have the reassurance of knowing that you are in good hands. You can also benefit from the decisive added value which ZF is able to contribute: access to the expertise of the manufacturer. The decentralized management structure of ZF enables us to stay in close contact with our markets, our customers and their specific needs. This flexibility and our global network of development and production sites not only offer outstanding products, they also deliver superlative standards of service. This combination assures us of a competitive edge in all our markets, safeguarding our future success. Our range of services is available long before our customers start to make their purchasing decisions, examples being analysis, fine-tuning and consultancy support on all aspects of your application. Once your product has left our production facilities, ZF continues to provide support with expert advice and action. This extends right through the lifetime of each product and beyond, with theoretical as well as practical support

8 Innovation, high quality thinking and ready service are focused on the central target of increased customer benefit. Therefore, we have chosen the leading principle of consistently persuading our customers by supporting them with competence and excellent performance. We count on ZF 14 15

9 ZF axle systems and ZF gear units are designed for specific application conditions. Optimised for power and flexibility, ZF components form the basis of any dependable and profitable construction machine. ZF technology adds decisive value at the highest level. ZF Driveline Technology: Vehicles and Performance Classes Dump Truck Vehicle Payload Front Axles Rear Axles 1 Rear Axles 2 Electronic / Gear Selector Transmission Engine Power max. Class to 12 t MT-L 3075 MT-L 3075 WG 115 Compact Loader Class to 18 t MT-L 3085 MT-L 3085 WG kw Empty Vehicle Front Axles Rear Axles Transmission Input Torque Weight 1) max. Class to 4.9 t Class to 6.0 t Class to 6.3 t Class to 7.5 t MT-L 715 MT-L 720 MT-L 230 MT-L 745 MT-L 715 MT-L 720 MT-L 230 MT-L 745 AVG 150 AVG 150 AVG 185 AVG Nm 660 Nm 1300 Nm 1300 Nm Class to 18 t Class to 25 t Class to 27 t Class to 27 t WG 160 WG 210 WG 260 WG kw 230 kw 230 kw 270 kw Class to 30 t WG kw Wheel Loader Empty Vehicle Front Axles Rear Axles Electronic Gear Weight 1) Selector Transmission Engine Power max. Class to 35 t Class to 40 t WG 310 WG kw 320 kw Class to 9 t MT-L 3065 MT-L 3065 Ergo II/ WG 115 Mobile Excavator Class to 10 t Class to 12 t Class to 14 t MT-L 3065 MT-L 3075 MT-L 3085 MT-L 3065 MT-L 3075 MT-L 3075 Ergo II/ Ergo II/ Ergo II/ WG 130 WG 160 WG kw 160 kw 1 Empty Vehicle Front Axles Rear Axles Transmission Swing Drives Input Torque Weight 1) max. Class to 18 t MT-L 3095 MT-L 3085 Ergo II/ WG kw Class to 15 t MS-E 3050 MT-E 3050 HL-250 DR Nm Class to 24 t MT-L 3105 MT-L 3105 Ergo II/ WG kw Class to 19 t MS-E 3060 MT-E 3060 HL-270 DR Nm Class to 30 t AP 420/R AP 420/R Ergo II/ WG kw Class to 25 t MS-E 3070 MT-E 3070 HL-290 DR Nm 1) Empty vehicle weight without additional equipment 1) Empty vehicle weight without additional equipment 16 17

10 To be able to fulfil our promise Fit for Function also in the future, we are alreade working on tomorrow s system solutions just as you would expect from the world s market leader! ZF Driveline Technology: Vehicles and Performance Classes Backhoe Loader Empty Vehicle Front Axles Rear Axles Gear Selector Transmission Engine Power Weight 1) max. Class to 7,0 t MT 2075 WG 92 Class to 7,0 t MS 2025 MT 2075 WG 92 Class to 8,5 t MT 2075 WG 92 Telescopic Handler Class to 8,5 t Class to 12,0 t MS 2035 MT 2075 MT 2085 WG 92 WG 98 Empty Vehicle Weight 1) Front Axles Rear Axles Gear Selector Transmission Engine Power Class to 12,0 t MS 2045 MT 2085 WG 98 (Lift Capacity) max. Class to 6.5 t (2.7 t) Class to 8.0 t (3.0 t) Class to 9.0 t (3.5 t) MS-T 3035 MS-T 3045 MS-T 3045 MS-T 3025 MS-T 3035 MS-T 3045 WG 92 TSC WG 92 TC WG 92 TSC WG 92 TC WG 92 TSC WG 92 TC Grader Empty Vehicle Tandem Gear Selector Transmission Engine Power Weight 1) max. Class to 12.0 t (4.0 t) Class to 13.0 t (4.5 t) MS-T 3055 MS-T 3060 MS-T 3045 MS-T 3045 WG 98 TSC WG 98 TC WG 98 TSC WG 98 TC Class to 11,0 t Class to 15,0 t Class to 18,5 t AP-G 6 AP-G 8 AP-G 12 WG 115 WG 160 WG kw 135 kw 135 kw Class to 14.0 t (5.0 t) MS-T 3060 MS-T 3055 WG 98 TSC WG 98 TC Class to 18,5 t Class to 18,5 t AP-G 12 AP-G 12 WG 190 WG kw 200 kw 1) Empty vehicle weight without additional equipment 1) Empty vehicle weight without additional equipment Subject to technical modifications 18 19

11 ZF Passau GmbH D Passau Phone Fax Driveline and Chassis Technology AC/CONSTRUCTION 04/E - Design: Atelier & Friends, Passau - Print: Ostler-Druck, Passau