The ZF 4WG-200 Control System Testing Point: Overseas Training

The ZF 4WG-200 control system testing point Overseas Training -pengzhifeng (arrange) Updated:2013-2-26

Transmission control system 1.

2. 3. 4. 5. 6.

Transmission control unit EST117T Transmission WG range Speed selector switch DW-2 Connection to vehicle circuit Transmission wiring Solenoid value

2

4WG-200 transmission control valve.

4

0.7mm

3 mm C4 1mm

M4 M3 M5 M2 M1

•

Five solenoid valves on transmission control valve Check solenoid valves from X1. 35-14 35-15

35-31 35-32 35-33

From 85 ohm to 100 ohm.

35-14: Y4, 35-15: Y2, 35-31: Y5, 35-32: Y3, 35-33: Y1

Diagnostic system

N

•Speed sensor The resistance between core 17 & 27 should be 920-1120 Ohm Otherwise, check: if connector X10 is secured properly observe the pins on speed sensor if they are rusted or dirty

X10

Speed sensor

Speed sensor exterior and principle drawing symbol

Speed sensor work principle

Speed sensor measurement

•Transmission system voltage and earth Core 18 and 35 are earthed On the ignition, 24V should be detected between core 1 & 2, otherwise Check if the 7.5A transmission control fuse melts

Diagnostic system

For speed sensor

For solenoid valve

For gear selector

X5

X10 X1

X2 X9

Positions of ZF connectors

selector testing table gear

wire connected red: power, black: earth

neutral 1

grey,black and blue

neutral 2

grey and black

neutral 3

grey,black and green

neutral 4

grey, black,green and blue

forward 1

yellow,black and blue

forward 2

yellow and black

forward 3

yellow black and green

forward 4

yellow,black,green and blue

reverse 1

pink,black and blue

reverse 2

pink and black

reverse 3

pink, black and green

reverse 4

pink, black, green and blue

core

solenoid valve on/off

clutch on/off

23-25-26

M2、M3、M4

KV+K1

23-25

M3、M4

KV+K2

23-25-8

M3

KV+K3

23-25-8-26

M5

K4+K3

5-25-26

M1、M2、M4

KR+K1

5-25-

M1、M4

KR+K2

5-25-08

M1

KR+K3

5-25-8-26

none

19-25 29-25-26 29-25 29-25-8 29-25-8-26

-Oil level at 80℃ on the upper oil dipstick mark “HOT”

First step :starting engine at a speed 1000rmp and waiting few minutes. Used : SAE15W-40 CH (about 34-36L) Pressure:16+2bar Working temperature: 80℃-100℃.

What is problem?

What is problem?

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