Driveline Technology for

Heavy Material Handling Vehicles

Innovations
of Great Value.
Driveline Technology for Heavy Material Handling

High precision with heavy

loads and fully automatic
gear shift
Material handling vehicles with internal combus-
tion engines are real “all-rounders”. In outdoor
applications, for example, they must not only be
able to quickly transport extremely heavy loads
over long distances, but they must also be able to
precisely maneuver their load and set it down in
the tightest of spaces. ZF offers a wide range of fully
ZF transmissions meet all demands automatic transmissions in the
The widely varying functions make the highest ERGOPOWER® series to pro-
demands on the driveline, in particular on the
transmission: It must be designed for strong vide driveline systems techno-
engines with a high input torque and smooth
gear shifts that take place under full load, with-
logy for combustion driven
out interruption to the tractive effort. material handling machinery.
Important for the manufacturer and the end user This applies to lift-trucks,
The transmissions must however not take up reachstackers, yard-tractors
much space. Manufacturers who want to keep
their products small and maneuvrable are and RoRo-/terminal-trucks in
restricted with installation space.
the full range from 6 to 60 tons
Specially designed range of transmissions
lifting capacity. ZF systems
With Ergopower ZF is offering a complete range
of transmissions which feature this variety of technology, tailored to users,
functions: Apart from high flexibility and com-
pact design, the transmissions from this range,
represents excellent quality
which were specially conceived for material han- and reliability.
dling vehicles with combustion engines, also
have a highly developed electro-hydraulic control.

Conclusion ZF is a partner to manufacturers of material handling

vehicles throughout the world.
Consequently, the transmissions are easy to oper-    Autopogrutschik (UA)  CMHA (ROK)  CVS (I) 

ate and have finely graded gears. Manufacturers Doosan (ROK)  Douglas (GB)  Fantuzzi (I)  FMC (USA)
and users also appreciate the low operating costs  Fresia (I)  Godrej (IND)  Hangzhou (CN)  Heli (CN) 

and the customer-orientated service friendliness Hyundai (ROK)  Indital (IND)  Kalmar (S)  Kamag (D) 

of the lift-truck, RoRo-tractor, straddle carrier or Mafi (D)  Meclift (FIN)  Milan (BR)  MOL (B)  Noell (D)
reachstacker transmissions “Made in Passau,  Pimespo (I)  Sahand (IR)  Schopf (D)  Svetruck (S) 

Germany”. Taylor (USA)  Terberg (NL)  TIL (IND)  TLD (F)   

ZF-ERGOPOWER fully automatic Transmissions
WG 311
WG 161
Power packs for material handling
The products of the ZF-ERGOPOWER
series extend over a wide range of
input torques: from 800 Nm for the
WG 115 to 2,750 Nm for the WG 311,
respectively 750 Nm for the fully auto-
matic transmission WG 94, and thus
match many different vehicles. The
shifting can be fully automatic and
without interrupting the tractive force
or with powershift.
WG 211
WG 94
Special design for material handling
vehicles
The ZF-ERGOPOWER transmissions
WG 115 up to WG 311 as well as the
fully automatic transmission WG 94
have been specially designed for the
most versatile applications in material
handling with combustion engines. By
optimum matching of transmission
hardware and electronic control, the
ZF-ERGOPOWER units assure soft
shift transitions in operation – a deci-
sive criteria in practical applications.
User-friendly with electronic assistance
A new, particularly user-friendly fea-
ture of the latest, compact ZF trans-
missions is the electronic inching. This
offers a “creep function” which makes
it easier to position loads with highest
levels of accuracy.
 Main product advantages
Easy handling, short cycling time,  Electronical inching possibility available

(no mechanical linkages)

exact positioning of the material  No tractive effort interruption by using

proportional valves
are just some requirements for  Logistic advantages, less different parts

 High sophisticated shift quality (soft and smooth

modern material handling vehicles. shifting), developed with the know-how from
ZF passenger car automatic
 Low noise level (high contact helical gears)

 Various torque converters for different engines

With ZF driveline technology for available

 Stiff and short rotating shafts – less deflexion

 Special design for material handling application

material handling, moving heavy (ratios, center drop, installation dimensions)
 Durable clutch packs with increased oil flow
loads could not be easier. (optimized cooling)
 For WG 261 - WG 311 up to three PTO possible

 For WG 94 - WG 211 one PTO is standard

 Electronic system with self diagnostic

 Easy maintenance and repair

(set right bearings, no shiming)

 Short and long drop gear boxes available

Precise positioning with electronic inching

Also available in the ZF-ERGOPOWER

series: Electronic inching.
Pressure

By actuating a pedal the driver can reduce Inching

the speed during operation to maneuver in
Max. clutch pressure
a “creeper mode” without himself having to
declutch or shift gear. This enables loads
to be positioned sensitively and accurately
to the millimeter.
Gradient =
The system f(engine speed)

The expansion of functions to include elec-

tronic inching has become possible by the Inching pressure =
f(inch pedal position) Direction clutch
electro-hydraulic ZF-ERGOCONTROL which
is also supplied by ZF and which ideally
matches the functions of engine, converter
and transmission.
ZF-Ergocontrol works without mechanical
linkage, but by a load sensor and the con-
trol unit. The CANbus-compatible transmis-
sion control unit has a diagnostic interface
Inching on Slipping Inching off Time
which simplifies service and maintenance.
The controller software can be programmed
not only specifically to the vehicle, but also
according to the application, which makes
the overall transmission package even more The inching pressure depends on the inch pedal position in the range between min. and
user-friendly. max. inching pressure. When leaving the inching mode the closing pressure gradient is
dependent on the engine speed.
 ERGOPOWER ERGOPOWER ERGOPOWER
2 WG 94 / 3 WG 94 WG 115/130/131/160/161/171 WG 190/191/210/211 WG 260/261/310/311

Applications Applications Applications Applications

Lift-trucks Lift-trucks, terminal- and RoRo-, terminal- and yard-tractors, Lift-trucks, reachstackers, RoRo-
yard- tractors lift-trucks, straddle carriers tractors, straddle carriers

Product features Product features Product features Product features

 2 WG 94  For vehicles up to approx. 72 t  For vehicles up to approx. 98 t  For vehicles up to approx. 140 t

 2 forward and 2 reverse gears GVW (32 tons lifting capacity) GVW (42 tons lifting capacity) GVW (60 tons lifting capacity)
 Engine dependent PTO  3 forward and 3 reverse gears  3-6 forward and 3 reverse gears  3-5 forward and 3 reverse gears

 Electronics package including  Hydrodynamic converter  Full / semi-automatic gear  Up to 2,750 Nm transmission

inching only in combination (without free-wheel) shift control turbine torque

with CAN and rotation angle  6 shafts and 5 clutches  Various hydrodynamic torque  Fully automatic gear shift

sensor  Powershiftable with converters, lock-up clutch control

 3 WG 94 proportional control available  Various hydrodynamic torque

 3 forward and 3 reverse gears  Inching electronically controlled  Drop input / output converters, lock-up clutch
 Engine dependent in-line PTO by EST-37 A, 24 V 190 mm (short drop) available
 Electronics package including  Drop input / output 540 mm (long drop)  Drop input / output

inching only in combination 300 mm (short drop)  1 PTO, co-axial 380 mm (short drop)
with CAN and rotation angle 500 mm (long drop)  Proportional controlled 575 mm (long drop)
sensor or with engine speed  1 PTO, co-axial, powershift  Max. 3 PTO possible:

sensor (integrated in the non-disconnectable  Electronic inching 1 co-axial PTO, 2 side PTO
transmission) and rotation  Integrated oil lines

angle sensor
 Electronic control = 24 V

 Free-wheel torque converter

For various requirements and numerous 330 2750 60 140

classes of material handling equipment, 280 2500 50 120

ZF offers a finely graded range of trans-
240 1700 42 98
missions.
200 1500 37 80

180 1300 32 72
Gross vehicle weight (tons)
160 1100 22 44
Lifting capacity (tons)
Turbine torque (Nm)
Engine power (kW)

130 950 16 36

90 800 12 23

WG 94 WG 115 WG 131 WG 161 WG 171 WG 191 WG 211 WG 261 WG 311

Technichal data ZF-ERGOPOWER

Transmission short-drop WG 94 – WG 131 WG 161 WG 171 WG 191 WG 211 WG 261 WG 311

long-drop WG 94 WG 115 WG 130 WG 160 – WG 190 WG 210 WG 260 WG 310

Engine power (kW) 90 90 130 160 180 200 240 280 330
Engine speed (rpm) 2,600 2,600 2,600 2,600 2,600 2,600 2,600 2,500 2,500
T/M input torque (Nm) 750 800 950 1,100 1,300 1,500 1,700 2,500 2,750
PTO torque (Nm) 400 800 800 800 800 800 800 1,500 1,500
GVW (to) 23 23 36 44 72 80 98 120 140
Lifting capacity (to) 10 12 16 22 32 37 42 50 60
Center distance (mm)
short-drop 155 – 300 300 300 190 190 380 380
long-drop 306 500 500 500 – 540 540 575 575

Engine Power Control via CAN possible (individual application process)

ZF Passau GmbH
Driveline Technology
for Material Handling Vehicles
D-94030 Passau
Germany
Phone +49 8 51 4 94-2732
Fax +49 8 51 4 94-2191
sales.ac@zf.com

www.zf.com

The right is reserved to modify products and technical data.

AC / HEAVY MATERIAL HANDLING 08 / E

Driveline and Chassis Technology