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TRANSCRIPT
Driveline Technology for Heavy Material Handling
Material handling vehicles with internal combus-tion engines are real “all-rounders”. In outdoorapplications, for example, they must not only beable to quickly transport extremely heavy loadsover long distances, but they must also be able toprecisely maneuver their load and set it down inthe tightest of spaces.
ZF transmissions meet all demands
The widely varying functions make the highestdemands on the driveline, in particular on thetransmission: It must be designed for strongengines with a high input torque and smoothgear shifts that take place under full load, with-out interruption to the tractive effort.
Important for the manufacturer and the end user
The transmissions must however not take upmuch space. Manufacturers who want to keeptheir products small and maneuvrable arerestricted with installation space.
Specially designed range of transmissions
With Ergopower ZF is offering a complete rangeof transmissions which fea ture this variety offunctions: Apart from high flexibility and com-pact design, the transmis sions from this range,which were specially conceived for material han-dling vehicles with combustion engines, alsohave a highly deve loped electro-hydraulic control.
Conclusion
Consequently, the transmissions are easy to oper -ate and have finely graded gears. Manu facturersand users also appreciate the low operating costsand the customer-orientated service friendlinessof the lift-truck, RoRo-tractor, straddle carrier orreachstacker transmissions “Made in Passau,Germany”.
High precision with heavyloads and fully automaticgear shift
ZF offers a wide range of fullyautomatic transmissions in theERGOPOWER® series to pro-vide driveline systems techno -logy for combustion drivenmaterial handling machinery.This applies to lift-trucks,reachstackers, yard-tractorsand RoRo-/terminal-trucks inthe full range from 6 to 60 tonslifting capacity. ZF systemstechnology, tailored to users,represents excellent quality and reliability.
ZF is a partner to manufacturers of material handling vehicles throughout the world.� � � Autopogrutschik (UA) � CMHA (ROK) � CVS (I) �
Doosan (ROK) � Douglas (GB) � Fantuzzi (I) � FMC (USA) � Fresia (I) � Godrej (IND) � Hangzhou (CN) � Heli (CN) �
Hyundai (ROK) � Indital (IND) � Kalmar (S) � Kamag (D) �
Mafi (D) � Meclift (FIN) � Milan (BR) � MOL (B) � Noell (D) � Pimespo (I) � Sahand (IR) � Schopf (D) � Svetruck (S) �
Taylor (USA) � Terberg (NL) � TIL (IND) � TLD (F) � � �
Power packs for material handling
The products of the ZF-ERGOPOWERseries extend over a wide range ofinput torques: from 800 Nm for theWG 115 to 2,750 Nm for the WG 311,respectively 750 Nm for the fully auto-matic transmission WG 94, and thusmatch many different vehicles. Theshifting can be fully automatic andwithout interrupting the tractive forceor with powershift.
Special design for material handling vehicles
The ZF-ERGOPOWER transmissions WG 115 up to WG 311 as well as thefully automatic transmission WG 94have been specially designed for themost versatile applications in materialhandling with combustion engines. Byoptimum matching of transmissionhardware and electronic control, theZF-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. Thisoffers a “creep func tion” which makesit easier to position loads with highestlevels of accuracy.
WG 211
WG 94
WG 311
WG 161
ZF-ERGOPOWER fully automatic Transmissions
Precise positioning with electronic inching
Also available in the ZF-ERGOPOWERseries: Electronic inching. By actuating a pedal the driver can re ducethe speed during operation to maneuver ina “creeper mode” without himself having todeclutch or shift gear. This enables loads to be positioned sensitively and accuratelyto the milli meter.
The system
The expansion of functions to include elec-tronic inching has become possible by theelectro-hydraulic ZF-ERGO CONTROL whichis also supplied by ZF and which ideallymatches the functions of engine, converterand transmis sion. ZF-Ergocontrol works without mechanicallinkage, but by a load sensor and the con-trol unit. The CANbus-compatible transmis-sion control unit has a diagnostic interfacewhich simplifies service and maintenance.The controller software can be programmednot only specifically to the vehicle, but alsoaccording to the application, which makesthe overall transmission package even moreuser-friendly.
The inching pressure depends on the inch pedal position in the range between min. andmax. inching pressure. When leaving the inching mode the closing pressure gradient isdependent on the engine speed.
Easy handling, short cycling time,exact positioning of the materialare just some requirements formodern material handling vehicles.
With ZF driveline technology formaterial handling, moving heavyloads could not be easier.
Pres
sure
TimeInching on Slipping Inching off
Inching pressure =f(inch pedal position)
Gradient =f(engine speed)
Direction clutch
Max. clutch pressure
Inching
Main product advantages� Electronical inching possibility available
(no mechanical linkages)� No tractive effort interruption by using
proportional valves� Logistic advantages, less different parts� High sophisticated shift quality (soft and smooth
shifting), developed with the know-how from ZF passenger car automatic
� Low noise level (high contact helical gears)� Various torque converters for different engines
available� Stiff and short rotating shafts – less deflexion� Special design for material handling application
(ratios, center drop, installation dimensions)� Durable clutch packs with increased oil flow
(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
For various requirements and numerousclasses of material handling equipment,ZF offers a finely graded range of trans-missions.
2 WG 94 / 3 WG 94
ApplicationsLift-trucks
Product features� 2 WG 94� 2 forward and 2 reverse gears� Engine dependent PTO � Electronics package including
inching only in combinationwith CAN and rotation anglesensor
� 3 WG 94 � 3 forward and 3 reverse gears� Engine dependent in-line PTO� Electronics package including
inching only in combinationwith CAN and rotation anglesensor or with engine speedsensor (integrated in thetransmission) and rotationangle sensor
� Electronic control = 24 V� Free-wheel torque converter
ERGOPOWERWG 115/130/131/160/161/171
ApplicationsLift-trucks, terminal- and yard- tractors
Product features� For vehicles up to approx. 72 t
GVW (32 tons lifting capacity)� 3 forward and 3 reverse gears� Hydrodynamic converter
(without free-wheel)� 6 shafts and 5 clutches� Powershiftable with
proportional control� Inching electronically controlled
by EST-37 A, 24 V� Drop input / output
300 mm (short drop)500 mm (long drop)
� 1 PTO, co-axial, non-disconnectable
ERGOPOWERWG 190/191/210/211
ApplicationsRoRo-, terminal- and yard-tractors,lift-trucks, straddle carriers
Product features� For vehicles up to approx. 98 t
GVW (42 tons lifting capacity)� 3-6 forward and 3 reverse gears� Full / semi-automatic gear
shift control� Various hydrodynamic torque
converters, lock-up clutch available
� Drop input / output 190 mm (short drop)540 mm (long drop)
� 1 PTO, co-axial� Proportional controlled
powershift� Electronic inching� Integrated oil lines
ERGOPOWERWG 260/261/310/311
ApplicationsLift-trucks, reachstackers, RoRo-tractors, straddle carriers
Product features� For vehicles up to approx. 140 t
GVW (60 tons lifting capacity)� 3-5 forward and 3 reverse gears� Up to 2,750 Nm transmission
turbine torque� Fully automatic gear shift
control� Various hydrodynamic torque
converters, lock-up clutch available
� Drop input / output 380 mm (short drop)575 mm (long drop)
� Max. 3 PTO possible:1 co-axial PTO, 2 side PTO
Engi
ne p
ower
(kW
)
Turb
ine
torq
ue (
Nm
)
Lift
ing
capa
city
(to
ns)
Gro
ss v
ehic
le w
eigh
t (t
ons)
140
120
98
80
72
44
36
23
60
50
42
37
32
22
16
12
330
280
240
200
180
160
130
90
2750
2500
1700
1500
1300
1100
950
800
WG 94 WG 115 WG 131 WG 161 WG 171 WG 191 WG 211 WG 261 WG 311
Technichal data ZF-ERGOPOWER
Engine power (kW)
Engine speed (rpm)
T/M input torque (Nm)
PTO torque (Nm)
GVW (to)
Lifting capacity (to)
Center distance (mm)short-droplong-drop
90
2,600
750
400
23
10
155306
WG 94WG 94
Transmission short-droplong-drop
130
2,600
950
800
36
16
300500
WG 131WG 130
90
2,600
800
800
23
12
–500
–WG 115
160
2,600
1,100
800
44
22
300500
WG 161WG 160
180
2,600
1,300
800
72
32
300–
WG 171–
200
2,600
1,500
800
80
37
190540
WG 191WG 190
240
2,600
1,700
800
98
42
190540
WG 211WG 210
280
2,500
2,500
1,500
120
50
380575
WG 261WG 260
330
2,500
2,750
1,500
140
60
380575
WG 311WG 310
Engine Power Control via CAN possible (individual application process)
Driveline and Chassis Technology
ZF Passau GmbHDriveline Technologyfor Material Handling VehiclesD-94030 PassauGermanyPhone +49 851 494-2732Fax +49 851 [email protected]
www.zf.com
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