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ZF – ERGOPOWER
4/6 WG 260-310
REFERENCE
For information concerning description, installation instructions, operation and maintenance, see
respective Operating Instructions, ZF-Ordering-No. 5872 196 002.
_____________________________________________
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
PREFACE
This documentation has been developed for skilled staff trained by the ZF Passau for the repair and
maintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of
the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.
ZF Passau GmbH
Off-Road Transmissions
and Axle Systems
Division
Off-Road Transmissions
Repair Instruction and Axle Systems
Division
GENERAL
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
By no means, Molykote is permitted to be used.
Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
Off-Road Transmissions
Repair Instruction and Axle Systems
Division
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
___________________________________________________
REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description..
REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again. .
Off-Road Transmissions
Repair Instruction and Axle Systems
Division
25,40 mm = 1 in ( inch)
1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per square inch lbf/in2 )
=
0,070 bar ( 0,071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4,456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )
1.1 Filter
Figure 144
Figure 481
Figure 482
1.1
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich
Inductiv sensor Arbeitsmaschinen-Antriebe
und Achssysteme
14
39
Figure 1
31
Figure 2
2.0
Geschäftsbereich
Inductiv sensor Arbeitsmaschinen-Antriebe
und Achssysteme
)
The following Figures describe the assembly, resp. setting of
the inductive transmitter n-Engine (14) !
The assembly of the inductive transmitter n-Turbine (6) and
n-Central gear train (39) has to be carried out accordingly !
+ 0,3
Inductive transmitter n-Engine (14) X = 0,5 mm
+ 0,3
X
Figure 3
Figure 4
Rotate counting disk radially until one tooth tip is central to the
inductive transmitter bore.
Figure 5
Figure 6
2.1
Geschäftsbereich
Inductiv sensor Arbeitsmaschinen-Antriebe
und Achssysteme
Screw the plug gauge out and determine Dimension II (see also
Figure 533).
Figure 7
EXAMPLE „ M1“:
Dimension II e.g. ............................... 30,10 mm
+ 0,3
Dimension X (0,5 mm) .......... e.g. - 0,60 mm
gives Installation dimension A = 29,50 mm
EXAMPLE „M2“:
Dimension I e.g. ................................ 30,00 mm
Installation dimension A e.g. ............ - 29,50 mm
Gives Adjusting disk(s) s = 0,50 mm
Figure 8
Figure 9
2.2
Geschäftsbereich
Inductiv sensor Arbeitsmaschinen-Antriebe
und Achssysteme
Figure 10
The Figure on the left shows the speed sensor (Hall sensor).
1 1 = Speed sensor
2 = O-ring
3 = Setting plate(s)
2 3
Figure 11
Figure 12
Figure 13
2.3
Geschäftsbereich
Inductiv sensor Arbeitsmaschinen-Antriebe
und Achssysteme
EXAMPLE „ N1„:
Example „N2“
Figure 14 Line up setting plates (2x, s = 0,5 mm) and grease O-ring.
Figure 15
2.4
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich
HSG 94 Arbeitsmaschinen-Antriebe
und Achssysteme
4.0
Geschäftsbereich
HSG 94 Arbeitsmaschinen-Antriebe
und Achssysteme
4.1 DISASSEMBLY
Loosen socket head screws and remove selector housing.
Figure 1
Clean screens
Figure 2
4.2 ASSEMBLY
Figure 3
Figure 4
4.1
Geschäftsbereich
HSG 94 Arbeitsmaschinen-Antriebe
und Achssysteme
Figure 5
Figure 6
Figure 7
Figure 8
4.2
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich
Lock Up Arbeitsmaschinen-Antriebe
und Achssysteme
5.1 WK-Valve
5.1.1 DISASSEMBLY
Figure 1
Figure 2
5.1.2 ASSEMBLY
Figure 3
7 5 3 1 1 = Solenoid valve
2 = Socket head screw + Spring washer (2x)
3 = Selector housing
4 = Spool
5 = Shim rings (empirical value, 6 units/0,5 mm thick, each)
8 6 4 2 6 = Compression spring
7 = Stop (optional, empirical value A = 3,0 mm)
8 = Connecting fitting (install new O-ring)
Figure 4 With the shim rings 5 and the stop 7, the WK pressure
12 + 2 bar will be determined!
Install stop 7, with the stepped plane face facing the com-
pression spring!
Figure 5
Figure 6
5.1
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich
Output Arbeitsmaschinen-Antriebe
und Achssysteme
Figure1
Install shaft seal, with the sealing lip facing the oil chamber.
) At application of the prescribed driver (S), the exact installa-
tion position is obtained !
Grease sealing lip !
According to the version, different shaft seals can have been
applied !
Outer diameter rubber-coated – wet with spirit !
Outer diameter metallic - wet with sealing compound
(Loctite, Type-No. 574) !
Figure 3
Figure 4
6.0
Geschäftsbereich
Output Arbeitsmaschinen-Antriebe
und Achssysteme
Figure 5
Remove lock plate, loosen hex. head screws and pull off output
flange.
Figure6
6.4 Assembly
Install shaft seal (Arrow), with the sealing lip facing the oil
(S) chamber.
) At application of the prescribed driver (S), the exact instal-
lation position is obtained !
Grease sealing lip !
According to the version, different shaft seals may be ap-
plied:
Outer diameter rubber-coated – wet with spirit !
Outer diameter metallic - wet with sealing
compound Loctite (Type-No. 574) !
6.1
Geschäftsbereich
Output Arbeitsmaschinen-Antriebe
und Achssysteme
Figure 8
Figure 9
Figure 10
6.2
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
Geschäftsbereich - A
Werkstatthandbuch Arbeitsmaschinen-Antriebe
und Achssysteme
L A Y O U T 4 W G -2 6 0 1 2 3
T A B L E -1 4
1 2
9
1 1
1 0
IN S T A L L A T IO N V IE W 4 W G -2 6 0 - D IR E C T M O U N T IN G
F R O N T V IE W 1 2 3 4 5
T A B L E -2
1 = L iftin g lu g s
2 = B re a th e r
3 = E le c tro h y d ra u lic s h ift c o n tro l 6
4 = D ia p h ra g m s D ire c t m o u n tin g
5 = 4 th P o w e r t a k e - o f f
6 = C o n v e rte r
7 = O u tp u t fla n g e (c o n v e rte r-s id e )
8 = C o a rs e filte r
9 = O il d ra in p lu g
1 0 = A tta c h m e n t p o s s ib ility fo r O il fille r tu b e w ith O il d ip s tic k (c o n v e rte r-s id e )
1 1 = O il fille r tu b e w ith O il d ip s tic k (re a r-s id e )
1 1
7
1 0 9
IN S T A L L A T IO N V IE W 4 W G -2 6 0 S E P A R A T E IN S T A L L A T IO N
F R O N T V IE W 1 2 3 4 5
T A B L E -3
1 = L iftin g lu g
2 = B re a th e r
3 = E le c tro h y d ra u lic s h ift c o n tro l
4 = In p u t fla n g e In p u t v ia U n iv e rs a l s h a ft
6 6
th
5 = 4 P o w e r ta k e -o ff
6 = T ra n s m is s io n s u s p e n s io n M 2 0
7 = O u tp u t fla n g e (c o n v e rte r-s id e )
8 = C o a rs e filte r
9 = O il d ra in p lu g
1 0 = A tta c h m e n t p o s s ib ility fo r a n O il fille r tu b e w ith O il d ip s tic k (c o n v e rte r-s id e )
1 0 9
IN S T A L L A T IO N V IE W 4 W G -2 6 0 S E P A R A T E IN S T A L L A T IO N
S ID E V IE W 1 2 3 4 5 6
T A B L E -4
1 = In p u t fla n g e (In p u t v ia U n iv e rs a l s h a ft)
2 = C o v e r
7
3 = C o n v e rte r b e ll
4 = L iftin g lu g 1 6
5 = B re a th e r
6 = E le c tro h y d ra u lic s h ift c o n tro l 8
7 = M o u n tin g f a c e 3 rd . P o w e r ta k e - o f f
8 = L u b r i c a t i n g o i l l i n e 3 rd a n d 4 th P o w e r t a k e - o f f
9 = O u tp u t fla n g e (re a r-s id e )
1 0 = O il fille r tu b e w ith O il d ip s tic k (re a r-s id e ) 1 5
1 1 = C o v e r
1 2 = G e a rb o x h o u s in g
1 3 = O u tp u t fla n g e (c o n v e rte r-s id e )
1 4 = T ra n s m is s io n s u s p e n s io n M 2 0
1 5 = A s s e m b ly o p e n in g
1 6 = M o u n t i n g f a c e 4 th P o w e r t a k e - o f f
9
1 4
1 0
1 3 1 2 1 1
IN S T A L L A T IO N V IE W 4 W G -2 6 0 W IT H 3 R D
A N D 4 R D
P O W E R
T A K E -O F F - R E A R V IE W 1 2 3 4
T A B L E -5
st
5
2 = 1 P o w e r ta k e -o ff
n d
3 = 2 . P o w e r ta k e -o ff 6
4 = L iftin g lu g
5 = P re s s u re o il lin e C lu tc h K 1
6 = P re s s u re o il lin e C lu tc h K 2 1 7 7
7 = P re s s u re o il lin e C lu tc h K 3
K 1
8 = P re s s u re o il lin e C lu tc h K R 1 6 K V
9 = P re s s u re o il lin e C lu tc h K 4
8
K 2
1 3 = M o d e l Id e n tific a tio n P la te 1 5
1 4 = L u b ric a tin g o il lin e S 1 C lu tc h K R /K 2
K 4
1 5 = L u b ric a tin g o il lin e S 2 C lu tc h K 4 /K 3
1 6 = P re s s u re o il lin e C lu tc h K V 1 4
1 7 = L u b r i c a t i n g o i l l i n e 3 rd a n d 4 th P o w e r ta k e -o ff 1 0
1 1
1 2
1 3
IN S T A L L A T IO N V IE W 4 W G -2 6 0 W IT H 3 RD A N D 4 R D
P O W E R
T A K E -O F F A N D E M E R G E N C Y S T E E R IN G P U M P
R E A R V IE W 1 2 3 4
T A B L E - 6 1 6
1 = 1 P o w e r ta k e -o ff
5
2 = P re s s u re o il lin e C lu tc h K V
3 = 2 n d
P o w e r ta k e -o ff 1 5 6
4 = L iftin g lu g
5 = P re s s u re o il lin e C lu tc h K 1 K 1
6 = P re s s u re o il lin e C lu tc h K 4 K V
7 = P re s s u re o il lin e C lu tc h K 3
8 = L u b ric a tin g o il lin e S 1 C lu tc h K R /K 2 1 4 K 2
7
9 = E m e rg e n c y s te e rin g p u m p
D = C o n n e c tio n P re s s u re lin e M 2 2 x 1 ,5 K R
1 0
1 1
IN S T A L L A T IO N V IE W 4 W G -2 6 0 W IT H D IS C B R A K E
R E A R V IE W 1 2 3 4
T A B L E -7
1 = 1 P o w e r ta k e -o ff
2 = P re s s u re o il lin e C lu tc h K 2 5
3 = P re s s u re o il lin e C lu tc h K R
4 = L iftin g lu g
5 = P re s s u re o il lin e C lu tc h K 1 6
6 = P re s s u re o il lin e C lu tc h K 3
7 = P re s s u re o il lin e C lu tc h K 4 1 5 K 1
8 = P re s s u re o il lin e C lu tc h K V
9 = B ra k e d is c K V
7
1 0 = A tta c h m e n t p o s s ib ility fo r O il fille r tu b e w ith O il d ip s tic k (re a r-s id e )
1 1 = M o d e l Id e n tific a tio n P la te K 3
1 3 = D is c b ra k e K R
1 3
9
1 2
1 0
1 1
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 4 W G -2 6 0
T A B L E -8
T h e m a r k e d p o s itio n s (e .g . 5 3 ) c o r r e s p o n d w ith th e p o s itio n s o n th e ta b le - 9 !
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n (a b o u t 8 0 ° - 9 5 ° C ) !
N o . D e n o m in a tio n o f th e p o s itio n C o n n e c tio n M a r k in g o n th e
v a lv e b lo c k
M e a s u r in g p o in ts fo r h y d r a u lic o il a n d te m p e r a tu r e : 2 8 2 9
5 1 = In fro n t o f th e c o n v e rte r o p e n in g p re s s u re 8 ,5 b a r M 1 0 x 1 H Y
5 2 = B e h in d th e c o n v e rte r o p e n in g p re s s u re 5 ,0 b a r M 1 0 x 1
5 3 = C lu tc h F o rw a rd 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C lu tc h R e v e rs e 1 6 + 2 b a r K R M 1 0 x 1 E
5 6 = C lu tc h 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C lu tc h 1 6 + 2 b a r K 2 M 1 0 x 1 A
5 8 = C lu tc h 1 6 + 2 b a r K 3 M 1 0 x 1 C
6 0 = C lu tc h 1 6 + 2 b a r K 4 M 1 0 x 1 F
6 3 = B e h in d th e c o n v e rte r M 1 4 x 1 ,5 K 1
T e m p e ra tu re 1 0 0 ° C ; s h o rt-tim e 1 2 0 ° C
6 5 = S y s te m p re s s u re 1 6 + 2 b a r M 1 0 x 1 K 3 1 K 2
K V
1 6
C o n n e c tio n s
1 0 = B re a th e r M 1 0 x 1
1 5 = C o n n e c tio n to th e h e a t e x c h a n g e r ---- --- ----
K R K 3
1 3
1 6 = C o n n e c tio n fro m th e h e a t e x c h a n g e r ---- --- ---- K 4
2 8 = T o file r M 4 2 x 2
2 9 = F ro m filte r M 4 2 x 2
3 0 = F ro m filte r p re s s u re d iffe re n tia l v a lv e (O p tio n ) M 4 2 x 2
3 1 = T o b ra k e v a lv e (O p tio n ) M 1 6 x 1 ,5
3 2 = R e tu rn p ip e fro m b ra k e v a lv e M 2 6 x 1 ,5
3 6 = O il fille r p lu g M 4 2 x 2
4 9 = P lu g c o n n e c tio n o n th e e le c tro -h y d ra u lic c o n tro l u n it
6 8 = S y s te m p re s s u re (O p tio n ) M 1 6 x 1 ,5 G
6 9 = C o n tro l (O p tio n ) M 1 6 x 1 ,5 J
I n d u c tiv e tr a n s m itte r s a n d s p e e d s e n s o r
5 = In d u c tiv e tra n s m itte r n C e n tra l g e a r tra in M 1 8 x 1 ,5
9 = In d u c tiv e tra n s m itte r n E n g in e M 1 8 x 1 ,5
1 3 = S p e e d se n so r n O u p u t a n d S p e e d o m e te r ---- --- ----
1 4 = In d u c tiv e tra n s m itte r n T u rb in e M 1 8 x 1 ,5 P a g e 1 fro m 2
VIEW X X
28
56
60 58
D C
53
10
E B 31
55 57
F
G
A
9
30 J H K
69
49 14
29
32
68 51 36 65 28
Legend:
CODING
WT = Heat exchanger
WGV = Converter back pressure valve 5,0 bar
• Pressure regulator active Engaged clutches
WSV = Converter safety valve 8,5 bar Driving direction SPEED Y1 Y2 Y3 Y4 Y5 Y6
HDV = Main pressure valve 16+2 bar Forward 1 • • K1 KV
RV-9 = Pressure reducing valve 9 bar 2 • • KV K2
NFS = Follow-on slide 3 • • K3 KV
4 • • K4 K3
D = Vibration damper Reverse 1 • • KR K1
B = Orifice 2 • • KR K2
P1 = Proportional valve K4 3 • • KR K3
P2 = Proportional valve KR Neutral
P3 = Proportional valve K1 Engaged clutch KR K4 K1 K3 KV K2
Positions ons on the valve block F E D C B A
P4 = Proportional valve K3 Consec. No. of the measurement 55 60 56 58 53 57
P5 = Proportional valve KV points
P6 = Proportional valve K2
Y1...Y6 = Pressure regulators
TEMP = Temperature sensor
FDV = Filter pressure differential valve (Bypass-valve) ∆p=5,7 +1,5
- 0,5 bar
K R K 4 K 1 K 3 K V K 2
F 5 5 E 6 0 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
D D D D D D
B B B B B B
Y 1 Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6
N F S N F S N F S N F S
R V -9
T E M P
H D V K 6 5
V a lv e b lo c k c o n tro l c irc u it
M a in p re s s u re v a lv e 1 6 + 2 b a r P re s s u re re d u c in g v a lv e 9 b a r
H o u s in g
P lu g (C a b le h a rn e s s )
A Y 6 Y 1 A
Y 5 Y 2
B B
Y 4 Y 3
C o v e r C o v e r
H o u s in g V a lv e b lo c k
S E C T IO N A - A
M a in p re s s u re v a lv e 1 6 + 2 b a r V a lv e b lo c k P re s s u re re d u c in g v a lv e 9 b a r
P lu g (C a b le h a rn e s s )
D u c tp la te In te rm e d ia te p la te
S E C T IO N B - B
P ro p o rtio n a l v a lv e P 5
Y 5
V ib ra tio n d a m p e r
P re s s u re re g u la to r
F o llo w -o n s lid e
IN D U C T IV E T R A N S M IT T E R A N D S P E E D S E N S O R (H A L L S E N S O R )
T A B L E -1 1
IN D U C T IV E T R A N S M IT T E R
H o u s in g
T h e s p e e d s re q u ire d fo r th e E le c tro n ic c o n tro l E S T -3 7
w ill b e p ic k e d -u p b y th e fo llo w in g s e n s o rs :
In d u c tiv e tra n s m itte r
5 = In d u c tiv e tra n s m itte r n C e n tra l g e a r tra in S
9 = In d u c tiv e tra n s m itte r n E n g in e
1 3 = S p e e d se n so r n O u tp u t a n d S p e e d o m e te r G e a r w h e e l
1 4 = In d u c tiv e tra n s m itte r n T u rb in e
O n th e S c h e d u le o f m e a s u rin g p o in ts , T a b le -8 ,
th e in s ta lla tio n p o s itio n s o f th e s e n s o rs a re illu s tra te d .
A tte n tio n :
C lu tc h a x le K 4 /K 3
4 W G -2 6 0 F U L L Y -A U T O M A T IC C O N T R O L E S T -3 7
C IR C U IT D IA G R A M S T A N D A R D (6 0 2 9 7 1 7 0 4 0 )
T A B L E -1 2
IT E M L E G E N D IT E M L E G E N D
A 1 E L E C T R O N IC C O N T R O L U N IT T C U S 2 S W IT C H P R E S S U R E C U T -O F F
A 2 C O N T R O L L E R D W -3 S 3 S W IT C H D R IV IN G P R O G R A M A U T O M A T IC /M A N U A L
A 3 E L E C T R O H Y D R A U L IC C O N T R O L U N IT 4 W G -2 6 0 S 9 S W IT C H P A R K IN G B R A K E R E L E A S E (O P T IO N )
A 5 D IA G N O S IS IN T E R F A C E (P L U G ) S 1 0 S W IT C H F IL T E R C O N T A M IN A T IO N
A 6 D IS P L A Y S 3 1 S W IT C H A C H N O W L E D G M E N T P A R K IN G B R A K E
A 7 C A N -IN T E R F A C E (P L U G ) S 3 4 S W IT C H D IS P L A Y IL L U M IN A T IO N *
K 1 R E L A IY S T A R T E R IN T E R L O C K *
B 1 S P E E D S E N S O R n E N G IN E K 2 R E L A IY R E V E R S E D R IV E *
B 2 S P E E D S E N S O R n T U R B I N E
B 3 S P E E D S E N S O R n C E N T R A L G E A R T R A IN
B 4 S P E E D S E N S O R n O U T P U T
B 1 5 S E N S O R T E M P E R A T U R E B E H I N D C O N V E R T E R
F 1 F U S E 7 ,5 A *
F 2 F U S E 7 ,5 A *
H 3 A C O U S T IC - / O P T IC A L W A R N IN G *
F 1
K l.3 0 /1 .1 2 K l.3 0 /1 .1
K l.1 5 /1 .1 2 K l.1 5 /1 .1
F 2
L E
P 1 1 1
8 6
D 2
M
P P
2 2 2 6 3
K 2
A
8 5
S 2 S 3 S 9 S 3 1 H 3
5 2
4 1
S 3
2 6 2
4 5 2 3 6 8
V P I V P E 1 V P E 2
6 6
E D 8 E D 9
4 4 2 9 2 1 3 0 3 1 5 2
E D 1 1 E D 1 0 E D 1 2 E D 1 3 A D M 1 A D M 2
7
1 5
M N L 6 -p in
6 0 2 9 1 9 9 0 7 4
2
1 8
6
4
2
7
5
3
1
B 4 E F 4 S D D K
A 5 A M P J P T 8 -p in
1 8 4 6 0 2 9 1 9 9 1 0 8
E U P R
1 2 3 1 0 4
V M G 2 4 6
1
0 6
S u p e rs e a l 3 -p in
2 4
2 A D M 3
A D M 4 0 5 3 8 A 6
6 0 2 9 1 9 9 0 7 1 A D M 8 3 3 4 1
V P S D 1
1 4
K D 2 2 E D 7
4 3 6
F
N 6 4
E D 4
E D 6
S 3 4
A 2 B 1
R 6 4
6 3
E D 5
E D 1 0 1
B 2 6 5 E D 2 A IP 1 5 6 Y 1 = K R
2 0 1 0 0 2
B 3 E D 3 A 1 A IP
A IP
3
2
3 2 0 3 Y 2 =
Y 3 =
K 4
K 1
8 6 5 5 0 4
A IP 4 0 5 Y 4 = K 3
1 1 9 A IP 5 0 9
D 1 B 1 2 0 3
E F 1
V M G 1 A IP 6 5 1 0 6
0 7
Y 5 =
Y 6 =
K V
K 2 A 3
V P S 1 1 2
K 1 8 5
1 V P S 1 1 3
0 8
V P S 1 (+ )
4 1 E R 1 3 9
E F 2 T E M P
B 2 2
6 8
4 5
2 3
2 2
V M G A 2 4 6 0 9
T E M P
E R 2 4 9 1 B 1 5 2
1
B 3 2 4 2 E F 3
6 8 -p in
6 0 2 9 1 9 9 0 6 3 1 2 1 2
E R 3 1 7 3 4 5
C A N _ H C A N _ L C A N _ T V G S 6 7 8 9
V M 1 V M 2 V P S 2 V P S 2 A D M 5 A D M 6 A D M 7 M in i T im e r 2 -p in
M in i T im e r
2 -p in 2 5 2 6 2 7 2 8 1 2 8 5 3 5 7 1 1 3 4
S 1 0 6 0 2 9 1 9 9 0 1 1 1 0 1 1 1 2 1 3
1 2 1 4 1 5 1 6
6 0 2 9 1 9 9 0 1 1 S u p e rse a l
2 -p in 1 2
6 0 2 9 1 9 9 0 4 5 K o s ta l 1 6 -p in
6 0 2 9 1 9 9 0 7 2
1 2 4
4
2
3
1 A 7
J P T 4 -p in
6 0 2 9 1 9 9 0 7 6
K l.3 1 K l.3 1 /1 .6
P o lb ild e r e n ts p re c h e n d e n S te c k e rn a n d e r V e rk a b e lu n g !
V E R D R IL L T E L E IT U N G E N (3 0 S C H L Ä G E /M ) A B L > 2 M
A L L E R E L A IS M IT S C H U T Z D IO D E N 1 A /4 0 0 V
B U S A B S C H L U S S W E N N P IN 2 6 U N D 2 7 V E R B U N D E N .
C O N T R O L L E R D W -3
T A B L E -1 3
L E V E R F O R M E C H A N IC A L C O N N E C T IO N D IA G R A M C O N T R O L L E R
N E U T R A L IN T E R L O C K C O D IN G C O N T R O L L E R
(+ )
O U T P U T K D
S P E E D F O R W A R D R E V E R S E N E U T R A L
X 2 : A
1 2 3 4 1 2 3 4 1 2 3 4
N D (+ )
A D 1 B 1
B 1 X 1 :C
A D 2 B 2
A 2 B 2
B 3 X 1
X 1 : B
: A A 1
A D 3 B 3 X 1 : B
IN P O S IT IO N (N E U T R A L ), V
A D 4 X 1 : C
F -R N O T S W IT C H A B L E V R
X 1 : D
A S
A D 5 R
A D 6 A S
A D 7
E K 1 K 2
L
P
(-)
A B C D
M
A B C D
X 2 X 1 K 1 = R E L A Y S T A R T E R IN T E R L O C K
A
K 2 = R E L A Y R E V E R S IN G L IG H T S
S
F G E A R P O S IT IO N S T Y P E N S C H IL D A 1 = E L E C T R O N IC U N IT E S T -3 7
C IR C U IT D IA G R A M C O N T R O L L E R A 2 = C O N T R O L L E R
F
S W A
A D 3 (B 3 )
N N N D
S 6 1 S 4 1 1 S 5
R 2 2 2 G N B
A D 2 (B 2 )
B L C
A D 1 (B 1 )
V I D
A D 7 (K D )
R X 1
R T A
E D 1 (+ /V P )
F = F O R W A R D S 1 1
N = N E U T R A L 3 2 G R D
A D 6 (N )
R = R E V E R S E T Y P E P L A T E
S 2 1
D = M E C H A N IC A L N E U T R A L IN T E R L O C K C O N T R O L D W - 3
3 2 G E B
A D 4 (F O R W A R D )
1 = 1 st S P E E D V 1 2 / 2 4 N R .
S 3 1
2 = 2 n d S P E E D
3 2 R S C
3 = 3 rd S P E E D S T U E C K L . 0 5 0 1 2 1 0 1 4 8 A D 5 (R E V E R S E )
4 = 4 th S P E E D X 2
C O N T R O L L E R E R G O II
T A B L E -1 4 C O D IN G C O N T R O L E R C O N N E C T IO N D IA G R A M C O N T R O L L E R
O U T P U T
V R N T + T - K D / S N
+ E
-
N A D 1 B 1 (+ ) V P (+ )
A D 2 B 2 K D /E (A D 8 ) E D 7
A D 3 B 3 T + (A D 1 ) E D 1 A 1
T - (A D 2 ) E D 2
A D 5 V
A 2 C (A
(A
D 3 )
D 5 )
E D 3
E D 4
A D 6 R A D 7
K D (A D 6 ) E D 5
A D 7 N N (A D 7 ) E D 6 A D 9
S N (A D 9 )
A D 8 K D
V M (-)
A D 9 S N (-)
K 3 K 1 K 2
: = U O U T P U T = O V (A C T IV E L O W )
: = U S E R V IC E - 0 ,3 V
K 1 = R E L A Y S T A R T E R IN T E R L O C K
K 2 = R E L A Y R E V E R S IN G L IG H T S
K 3 = R E L A Y S H O V E L N E U T R A L (C U S T O M IZ E D )
A 1 = E L E C T R O N IC U N IT E S T -1 7 T /E S T -2 5
A 2 = C O N T R O L L E R E R G O II
C IR C U IT D IA G R A M C O N T R O L L E R
R T + /V P
2
M E A N IN G O F P U S H B U T T O N S
S 1 G E
4
A D 5 V (F O R W A R D ) P O S L E G E N D
W S
S 2 A D 3 B 3 /C (C O N T R O L -S IG N A L )
R S 9
A D 6 R (R E V E R S E ) S 1 P U S H B U T T O N D R IV IN G D I R E C T I O N
6
= D R IV IN G D IR E C T IO N F O R W A R D S 1 '
( ) V ' S 2
F O R
P U S
W A R D
H B U T T O N
A N D C -S IG N
D R IV IN G
A L
D I
F O
R E
R W
C T I
A R D
O N
= D R IV IN G D IR E C T IO N R E V E R S E S 2 '
( ) R '
S 3
R E V
P U S
E R S E A
H B U T T O N
N D C -S IG N A
N E U T R A L
L R E V E R S E
N = N E U T R A L S 3
S 4
B R
5
A D 7 A S /N S 4 P U S H B U T T O N U P S H IF T IN G
B L S 5 P U S H B U T T O N D O W N S H IF T IN G
+ = U P S H IF T IN G S 5 O G
7
A D 1 B 1 /T +
S 6 P U S H B U T T O N K IC K D O W N /R E L E A S E
A D 2 B 2 /T - P U S H B U T T O N S H O V E L N E U T R A L
- = D O W N S H IF T IN G 8 S 7
:
S 6
(S N ) = S H O V E L -N E U T R A L V I
1 0
A D 8 K D /E
(S H O V E L H O R IZ O N T A L ) S 7 S W
1 1
A D 9 S N
K D /E = K IC K D O W N C O N T R O L A N D (1 )
V M (-)
S A F E T Y R E L E A S E X 1
L A Y O U T 6 W G -3 1 0
1 2 3 4 5 6 7
T A B L E -1
1 = In p u t fla n g e D riv e v ia u n iv e rs a l s h a ft 8
2 = R e ta rd e r
3 = W K
4 = C o n v e rte r 9
5 = B re a th e r
6 = E le c tro h y d ra u lic c o n tro l u n it
7 = 2 nd P o w e r ta k e -o f f
8 = T ra n s m is s io n p u m p 1 0
9 = 1 st P o w e r ta k e -o ff
1 0 = C lu tc h a x le K V /K 1
1 1 = C lu tc h a x le K R /K 2
1 2 = C lu tc h a x le K 4 /K 3 1 1
1 3 = O u tp u t fla n g e (re a r-s id e )
1 4 = C ra w le r s p e e d
1 5 = O u tp u t fla n g e (c o n v e rte r-s id e ) 1 2
1 6 = C o u n te rs h a ft
1 6
1 3
1 5 1 4
IN S T A L L A T IO N V IE W 6 W G -3 1 0 W IT H R E T A R D E R
(1 0 -o ' C L O C K P O S IT IO N )
F R O N T V IE W 1 2 3 4
T A B L E -2 A
1 = L iftin g lu g
2 = B re a th e r
3 = E le c tro h y d ra u lic s h if t c o n tro l
4 = P re s s u re o il lin e fro m in fro n t o f th e c o n v e rte r to th e re ta rd e r v a lv e 1 0 5
5 = In p u t fla n g e D riv e v ia u n iv e rs a l s h a ft
6 = O u tp u t fla n g e (c o n v e rte r-s id e )
7 = C o a rs e filte r
8 = O il d ra in p lu g
9 = P n e u m a tic o r h y d ra u lic e n g a g e m e n t a n d d is c o n n e c tio n
1 0 = R e ta rd e r v a lv e
7
9
8
IN S T A L L A T IO N V IE W 6 W G -3 1 0 W IT H R E T A R D E R
1 0 -o ' C L O C K P O S IT IO N
S ID E V IE W
T A B L E -2 B
P a g e 1 fro m 2
3 6 4 2 1 5 1 6 1 2 3 4 5 6 7
1 0
1 1 1 2 1 3 1 4 1 3 1 2 1 1
P a g e 2 fro m 2
IN S T A L L A T IO N V IE W 6 W G -3 1 0 W IT H R E T A R D E R
(1 0 -o ' C L O C K P O S T IO N )
R E A R V IE W 1 2 3 4 5
T A B L E -2 C
1 = 1 P o w e r ta k e -o ff
2 = P re s s u re o il lin e fro m th e e le c tro h y d ra u lic s h ift c o n tro l to th e W K -V a lv e
1 8
3 = P re s s u re lin e C lu tc h K V
4 = 2 n d
P o w e r ta k e -o ff 1 7 6
5 = L iftin g lu g
6 = P re s s u re o il lin e C lu tc h K 1 7
7 = P re s s u re o il lin e C lu tc h K 3 K 1
1 2
IN S T A L L A T IO N V IE W 6 W G -3 1 0 W IT H R E T A R D E R (3 -o C L O C K P O S IT IO N )
F R O N T V IE W 1 2
T A B L E 3 A
1 1
5
7
1 0 9 8
IN S T A L L A T IO N V IE W 6 W G -3 1 0 W IT H R E T A R D E R (3 -o C L O C K P O S IT IO N )
S ID E V IE W
1 2 3 4 5 6 7
T A B L E 3 B
8
1 = In p u t fla n g e In p u t th ro u g h p ro p sh a ft
2 = S ta to r
3 = C o n v e rte r b e ll h o u s in g 9
4 = L iftin g lu g s
5 = P re s s u re o il lin e fro m c o n v e rte r c lu tc h v a lv e to c o n v e rte r c lu tc h
6 = P re s s u re o il lin e fro m e le c tro -h y d ra u lic s h ift c o n tro l to c o n v e rte r c lu tc h v a lv e
7 = E le c tro -h y d ra u lic s h ift c o n tro l
8 = C o n v e rte r c lu tc h v a lv e
9 = B re a th e r lin e C o n v e rte r c lu tc h
1 0 = T ra n s m is s io n s u s p e n s io n th re a d s M 2 0
1 1 = O u tp u t fla n g e (re a r s id e ) 1 0
1 2 = O il d ra in p lu g w ith m a g n e tic in s e r t M 3 8 x 1 ,5
1 3 = O u tp u t fla n g e F ro n t a x le L H
1 4 = A x le in s e rt " L K "
1 1
1 4
1 3 1 2
IN S T A L L A T IO N V IE W 6 W G -3 1 0 W IT H R E T A R D E R (3 -o ' C L O C K P O S IT IO N
R E A R V IE W 1 2 3 4 5 6
T A B L E -3 C
1 = C o n v e rte r c lu tc h v a lv e 2 0 7
2 = P re s s u re o il lin e fro m e le c tro -h y d ra u lic s h ift c o n tro l to c o n v e rte r c lu tc h v a lv e
3 = 1 s t P o w e r ta k e -o ff
4 = P re s s u re o il lin e C lu tc h K R 1 9 8
5 = E le c tro -h y d ra u lic s h ift c o n tro l K V
K 1
6 = 2 n d P o w e r ta k e -o ff 9
7 = P re s s u re o il lin e C lu tc h K 1
1 8
8 = P re s s u re o il lin e C lu tc h K 4 K 2
1 0
9 = P re s s u re o il lin e K 3 1 7 K R 1 1
1 0 = C o n n e c tio n lu b ric a tin g o il lin e fro m re ta rd e r v a lv e K 4
1 1 = L u b e o il lin e S 1 C lu tc h K R /K 2
1 2 = L u b e o il lin e S 2 C lu tc h K 4 /K 3
D K 3
1 2
1 3 = A tta c h m e n t p o s s ib ility fo r o il fille r tu b e w ith o il d ip s tic k 1 6 S
1 4 = T y p e p la te
1 5 = O u tp u t fla n g e (re a r s id e )
1 6 = E m e rg e n c y s te e rin g p u m p
S = S u c tio n p ip e c o n n e c tio n M 2 6 x 1 ,5 1 5
D = P re s s u re c o n n e c tio n M 2 2 x 1 ,5
1 7 = P re s s u re o il lin e C lu tc h K 2
1 8 = P re s s u re o il lin e C lu tc h K V 1 4
1 9 = R e ta rd e r v a lv e
2 0 = B re a th e r lin e C o n v e rte r c lu tc h
1 3
S C H E D U L E O F M E A S U R IN G P O IN T S A N D C O N N E C T IO N S 6 W G -3 1 0
T A B L E -4
T h e m a rk e d p o s itio n s (e .g . 5 3 ) a re c o r re s p o n d in g to th e p o s itio n s o n th e T a b le -5
T h e m e a s u re m e n ts h a v e to b e c a rrie d o u t a t h o t tra n s m is s io n (a b o u t 8 0 ° - 9 0 ° C )!
V IE W X
(se e P a g e 3 )
6 0 5 6
K V K 1
1 0
1 4
3 0 5 8 In p u t 1 s t P o w e r ta k e -o f f
D C P u m p
K R K 2
E B 6
F A 5 3
G R T W K 1 3 3 1
5 5 K
H
J K 4 K 3
5 7
E m e rg e n c y ste e rin g p u m p
3 9
6 5
O u tp u t O u tp u t
2 9
I n te r a x le d if f e re n tia l
6 7 2 7 5 1
P a g e 1 fro m 3
N o . D E N O M IN A T IO N O F T H E P O S IT IO N C O N N E C T I O N M A R K I N G O N T H E
V A L V E B L O C K
M E A S U R IN G P O IN T S F O R P R E S S U R E O IL A N D T E M P E R A T U R E
5 1 = IN F R O N T O F T H E C O N V E R T E R O P E N I N G P R E S S U R E 8 ,5 b a r M 1 0 x 1 H
5 2 = B E H IN D T H E C O N V E R T E R O P E N IN G P R E S S U R E 5 b a r M 1 0 x 1
5 3 = C L U T C H F O R W A R D 1 6 + 2 b a r K V M 1 0 x 1 B
5 5 = C L U T C H R E V E R S E 1 6 + 2 b a r K R M 1 0 x 1 F
5 6 = C L U T C H 1 6 + 2 b a r K 1 M 1 0 x 1 D
5 7 = C L U T C H 1 6 + 2 b a r K 2 M 1 0 x 1 A
5 8 = C L U T C H 1 6 + 2 b a r K 3 M 1 0 x 1 C
6 0 = C L U T C H 1 6 + 2 b a r K 4 M 1 0 x 1 E
6 3 = T E M P E R A T U R E 1 0 0 ° C B E H IN D T H E C O N V E R T E R , S H O R T -T IM E 1 2 0 ° C (M A X . 5 M IN U T E S )M 1 0 x 1
6 5 = S Y S T E M P R E S S U R E 1 6 + 2 b a r M 1 0 x 1 K
6 6 = T E M P E R A T U R E 1 4 5 ° C B E H IN D R E T A R D E R , S H O R T -T IM E 1 5 0 ° C (M A X . 5 M IN U T E S ) M 1 4 x 1 ,5
6 7 = W K -C O N T R O L P R E S S U R E 1 2 + 2 b a r M 1 0 x 1
C O N N E C T IO N S
1 0 = B R E A T H E R M 1 0 x 1
1 5 = T O T H E H E A T E X C H A N G E R ---------
1 6 = F R O M T H E H E A T E X C H A N G E R ---------
2 7 = O IL F IL L E R P L U G M 4 2 x 2
2 8 = T O T H E Z F -F IL T E R M 4 2 x 2
2 9 = F R O M T H E Z F -F IL T E R M 4 2 x 2
3 0 = F R O M T H E F IL T E R B Y P A S S T O T H E C O N V E R T E R M 4 2 x 2
3 6 = R E T A R D E R V A L V E A C T U A T IO N (C O M P R E S S E D A IR ) 5 ,5 b a r M 1 2 x 1 ,5
3 7 = A X L E D IS C O N N E C T IO N (C O M P R E S S E D A IR ) 6 b a r M 1 2 x 1 ,5
3 8 = F R O M H E A T E X C H A N G E R T O L U B R IC A T IO N IN T O T R A N S M . ( V IA R E T A R D E R V A L V E ) M 3 0 x 1 ,5
3 9 = IN F R O N T O F T H E C O N V E R T E R T O T H E H E A T E X C H A N G E R (V IA R E T AR D E R V A L V E ) M 3 0 x 1 ,5
4 0 = B E H IN D T H E C O N V E R T E R T O T H E H E A T E X C H A N G E R (V IA R E T A R D E R V A L V E ) M 3 0 x 1 ,5
4 9 = P L U G C O N N E C T IO N O N T H E E L E C T R O H Y D R A U L I C C O N T R O L U N IT ---------
-- = S Y T E M P R E S S U R E (O P T IO N ) M 1 6 x 1 ,5 G
-- = P IL O T P R E S S U R E (O P T IO N ) M 1 6 x 1 ,5 J
7 0 = E M E R G E N C Y S T E E R IN G P U M P - P R E S S U R E L IN E M 2 2 x 1 ,5
7 1 = E M E R G E N C Y S T E E R IN G P U M P - S U C T IO N L IN E M 3 3 x 1 ,5
IN D U C T IV E T R A N S M IT T E R , S P E E D S E N S O R A N D S W IT C H
6 = IN D U C T IV E T R A N S M IT T E R n T U R B I
N E M 1 8 x 1 ,5
1 3 = IN D U C T IV E T R A N S M IT T E R n C E N T R A L G E A R T R A IN M 1 8 x 1 ,5
1 4 = IN D U C T IV E T R A N S M IT T E R n E N G IN
E M 1 8 x 1 ,5
3 1 = S P E E D S E N S O R n O U T P U T ------- ----
3 5 = A X L E D IS C O N N E C T IO N IN D IC A T O R /A C K N O W L E D G E M E N T M 1 8 x 1 ,5
P a g e 2 fro m 3
V IE W Z
4 0 1 5 1 6
V IE W Y
5 2
6 3
3 6
X 4 0
(se e P a g e 1 )
6 6 3 8 3 9
6 7 1 4
Y 1 6
Z 1 5
2 8
6 6 K 1
K V
K 2
7 0
K R
KK 33 3 1
6 K 4
7 1
3 7 1 3
3 5 3 5
P a g e 3 fro m 3
K R K 4 K 1 K 3 K V K 2
F 5 5 E 6 0 D 5 6 C 5 8 B 5 3 A 5 7
P 1 P 2 P 3 P 4 P 5 P 6
D D D D D D
B B B B B B
Y 1 Y 2 N F S Y 3 N F S Y 4 Y 5 Y 6
N F S N F S N F S N F S
R V -9
T E M P
H D V K 6 5
V A L V E B L O C K
C O N T R O L C IR C U IT
L E G E N D E :
= M A IN P R E S S U R E
= R E G U L A T E D M A I N P R E S S U R E
= P IL O T P R E S S U R E
= C O N V E R T E R IN P U T P R E S S U R E
= C O N V E R T E R O U T P U T P R E S S U R E
= L U B R IC A T IO N
= R E T U R N IN T O T H E S U M P
P a g e 2 fro m 3
M A IN O IL C IR C U IT
N O T S C O P E O F S U P P L Y -Z F
A IR R E S E R V O IR 8 b a r W K M
W K V
S C O P E O F S U P P L Y -Z F
C O N V E R T E R
P R E S S U R E R E D U C IN G 6 7 W K
V A L V E 5 1
5 .5 b a r
3 0
S O L E N O ID V A L V E 2 9
H
W S V
6 3 5 2
Z F -F IN E F IL T E R
F F F IL T E R G R A D E A C C O R D IN G IS O 4 5 7 2 :
ß 30 ³ 7 5 ß 15 ³ 2 5 ß 10 ³ 5 .0
W G V
D U S T C A P A C I T Y A C C O R D IN G IS O 4 5 7 2 :
B Y P A S S V A L V E : D p = 2 + 3
b a r
F D V m in . 1 7 g
2
F IL T E R S U R F A C E c m :
3 9 2 x 6 7 0 0 = 1 3 4 0 0
W T (S C O P E O F S U P P L Y C U S T O M E R )
W S
1 6 1 5
F IL L U N G P O S IT IO N 2 8
R T V
T R A N S M IS S IO N P U M P
O N T H E D R I V E R 'S C A B I N
W IT H R E T A R D E R p = 1 6 + 2 b a r
6 6 Q p = 1 1 5 l/m i n -1 a t
-1
n = E N G IN E 2 0 0 0 m in
W IT H O U T R E T A R D E R
C O A R S E F IL T E R :
M E S H S IZ E m m : 4 5 0
L U B R IC A T IO N 2
F I L T E R S U R F A C E: c m 1 0 0 0
3 8
4 0
R T Ö L S U M P F P a g e 3 fro m 3
E L E C T R O H Y D R A U L IC C O N T R O L W IT H P R O P O R T IO N A L V A L V E S
T A B L E - 6
M A IN P R E S S U R E V A L V E 1 6 + 2 b a r P R E S S U R E R E D U C IN G V A L V E 9 b a r
H O U S IN G
P L U G (C A B L E H A R N E S S )
A Y 6 Y 1 A
Y 5 Y 2
B B
Y 4 Y 3
C O V E R C O V E R
H O U S IN G V A L V E B L O C K
P a g e 1 fro m 2
S E C T IO N A - A
M A IN P R E S S U R E V A L V E P R E S S U R E R E D U C IN G V A L V E
1 6 + 2 b a r V A L V E B L O C K 9 b a r
P L U G (C A B L E H A R N E S S )
D U C T P L A T E
IN T E R M E D IA T E P L A T E
S E C T IO N B - B
P R O P O R T IO N A L V A L V E P 5
Y 5
V IB R A T IO N D A M P E R
P R E S S U R E R E G U L A T O R
F O L L O W -O N S L ID E
P a g e 2 fro m 2
6 W G -3 1 0 F U L L Y -A U T O M A T IC C O N T R O L E S T -3 7
C IR C U IT D IA G R A M S T A N D A R D (6 0 2 9 7 1 7 0 3 9 )
T A B L E - 7
IT E M L E G E N D IT E M L E G E N D
A 1 E L E C T R O N IC C O N T R O L U N IT T C U S 1 S W IT C H R E T A R D E R
A 2 C O N T R O L L E R S 4 S W IT C H K IC K D O W N (O P T IO N )
A 3 E L E C T R O H Y D R A U L IC C O N T R O L U N IT 6 W G -3 1 0 S 5 S W IT C H R E Q U E S T E N G IN E B R A K E
A 5 D I A G N O S IS IN T E R F A C E (P L U G ) S 1 0 S W IT C H F IL T E R C O N T A M IN A T IO N
A 6 D I S P L A Y S 2 8 S W IT C H P R E S E L E C T IO N D IF F E R E N T IA L L O C K
A 7 C A N -IN T E R F A C E (P L U G ) S 3 2 S W IT C H T R O U G H O N T O P *
A 9 S P E E D O M E T E R W IT H F R E Q U E N C Y D IV ID E R * S 3 4 S W IT C H D IS P L A Y IL L U M IN A T IO N *
B 1 S P E E D S E N S O R n E N G I N E Y 7 S O L E N O ID V A L V E W K
B 2 S P E E D S E N S O R n T U R B IN E Y 8 S O L E N O ID V A L V E R E T A R D E R
B 3 S P E E D S E N S O R n C E N T R A L G E A R T R A IN Y 9 S O L E N O ID V A L V E D IF F E R E N T IA L L O C K
B 4 S P E E D S E N S O R n O U T P U T
B 6 L O A D S E N S O R K 1 R E L A Y S T A R T E R IN T E R L O C K *
B 9 S E N S O R T E M P E R A T U R E R E T A R D E R K 2 R E L A Y R E V E R S E D R IV E *
F 1 F U S E 7 ,5 A *
F 2 F U S E 7 ,5 A *
H 3 A C O U S T IC - / O P T IC A L W A R N IN G *
H 7 P IL O T L A M P R E S T R IC T E D S P E E D R A N G E *
N O T E : * = S C O P E O F S U P P L Y C U S T O M E R
P a g e 1 fro m 2
K l.3 0
F 1
E
L
K l.3 0
K l.1 5 K l.1 5
F 2
P
M 1 1 1 8 6
A D 2
1
2 2 2 2 6 3
S K 2 8 5
S 1 S 4 S 5 S 2 8 S 3 2 H 3
5 2
4 1
H 7 M N L 6 -p in
6 0 2 9 1 9 9 0 7 4 1 8 7
3 6 5
4 3
V P I V P E 1 V P E 2 E D 1 0 E D 7 E D 8 E D 1 2 E D 9 A D M 1 E D 1 3 A D M 2 2
2 1
2
B 4 E F 4 S D D K
A 5 A M P J P T 8 -p in
4 6 0 2 9 1 9 9 1 0 8
E U P R
1 2 3 1
V M G 2 4 6
1
1
S u p e rs e a l 3 -p in
1
A U 1
2 4
2
S D 4 A 9 3 8 A 6
2
V P
6 0 2 9 1 9 9 0 7 1 B 6 3 E U 1
S D 1
4 1
V M G A 1
A D M 3
* K D E D 7 A D M 4
6
F
N
E D 4
E D 6
A D M 8 S 3 4
A 2 T +
R E D 5
E D 1 0 1
T - E D 2 A IP 1 0 2 Y 1
* N -R e le a s e
C h a n g e -o v e r A u to m a tic
E D 1 1
E D 3
A 1 A IP
A IP
3
2 0 3 Y 2
Y 3
0 4
8 6 1
A IP 4 0 5 Y 4
E F 1 A IP 5 Y 5
K 1 8 5
B 1 2
V M G 1 A IP 6
0 6
0 7 Y 6 A 3
* = O P T IO N A L V P S 1 V P S 1 (+ )
1 V P S 1 0 8
E F 2 E R 1 T E M P
B 2 2
6 8
4 5
2 3
2 2
V M G A 2
0 9
T E M P
1 2
1 E R 2 B 9
B 3 2
E F 3
6 8 -p in
6 0 2 9 1 9 9 0 6 3
3
1 2
5
E R 3 4
C A N _ H C A N _ L C A N _ T V G S 6 7 8 9
V M 1 V M 2 V P S 2 V P S 2 A D M 7 A D M 5 A D M 6
M in i T im e r
2 -p in
S 1 0 1 0 1 1 1 2 1 3
1 2 1 4 1 5 1 6
6 0 2 9 1 9 9 0 1 1 S u p e rse a l
1 1 2 -p in 1 2
6 0 2 9 1 9 9 0 4 5 K o s ta l 1 6 -p in
2 2 6 0 2 9 1 9 9 0 7 2
1 2 4 Y 7 Y 9
1
1 2
4
2
3
1 A 7 Y 8 2 K o s ta l M 2 7
2 -p in
J P T 4 -p in 6 0 2 9 1 9 9 0 0 3
6 0 2 9 1 9 9 0 7 6
K l.3 1 K l.3 1
IN D U K T IV E T R A N S M IT T E R
6 = In d u c tiv e tra n s m itte r n -C e n tra l g e a r tra in
1 4 = In d u c tiv e tra n s m itte r n -E n g in e S
3 9 = In d u c tiv e tra n s m itte r n -T u rb in e
3 1 = S p e e d se n so r n -O u tp u t a n d s p e e d o m e te r G E A R W H E E L
(H a ll se n s o r)
S P E E D S E N S O R
A tte n tio n :
(H A L L S E N S O R )
F o r th e in d u c tiv e tra n s m itte rs , th e fo llo w in g d iffe re n t
s e ttin g d im e n s io n s b e tw e e n th e c o n ta c t a re a -in d u c tiv e S = 1 .0 - 1 ,5 m m S P E E D S E N S O R
tra n s m itte r a n d th e to o th tip h a v e to b e o b s e rv e d :
(H A L L S E N S O R )
S P U R G E A R K 3
n -E n g in e (1 4 ) A = 0 ,5
+ 0 ,3
m m H O U S IN G
+ 0 ,3
n -T u rb in e (3 9 ) A = 0 ,5 m m C L U T C H A X L E K 4 /K 3
± 0 ,1
n - C e n tra l g e a r tra in A = 0 ,3 m m