ZF Passau GmbH

Construction Machinery Systems

D-94030 Passau
Germany
Phone +49 8 51 4 94-2732
Fax +49 8 51 4 94-2191
[email protected]

www.zf.com

Driveline Technology and Axle Systems

for Construction Machinery and
Construction Site Vehicles

The right is reserved to modify products and technical data.

Innovations
of Great Value.

AC / CONSTRUCTION 10 / EN

Driveline and Chassis Technology

U1
 ZF Innovations add up! They offer ad-
vantages for driver, carrier and manu-
facturer in equal measure. The industry
of construction machinery and con-
struction site vehicles is more and
more focused on topics like reduced
fuel consumption, comfort or environ-
mental compatibility. ZF driveline and
chassis technology is significantly
involved in this development.
Reducing fuel consumption, lower
wear and emission, increase productiv-
ity, extend service intervals, easier and
ZF – Innovations of Great Value 3
better handling and more automation
Make visions come true. With ZF technology.

Together we move the earth.

4
are all topics in the focus of ZF engi-
Transmission technology from ZF. 6

Best performance on all grounds.

Axle technology from ZF. 12
neers.
ZF – The technological leader.
Increased efficiency for your driveline. 18

Future driveline technology 28

ZF – The systems supplier 30

Technical glossary 32

Having partners. Beyond purchase. 43

3
Make visions come true.
With ZF technology.

„Offering new, downstream products will enable ZF to main-

tain its market position as a technology leader in the long run
and to stand out against competitors. With the development
of the continuously variable transmission for off-highway
applications and the hybrid solution on the basis of
Ergopower technology, the sector driveline and chassis tech-
nology for construction machinery has made decisive steps in
this direction.“

Hermann Beck
Vice President Business Unit Construction Machinery Systems

In order to take account of the optimum adaption to different working condi-

demand for more productivity and tions enables considerable increase of productiv-
efficiency as well as for enhanced ity, efficiency and driving comfort together with
driving comfort, ZF has concen- easy and safe operation.
trated over the last years on the Today, both hydrostatic and hydrodynamic fully
development of alternative trans- automatic powershift transmissions are equally
missions and used this knowledge established in the market. The hydrostatic-
for the production of construction, mechanical powersplit CVT offers the possibility
material handling and agricultural to combine the excellent efficiency of the hydro-
machinery. The combination of statics for low speeds with the excellent efficien-
ZF is a partner to the construction machinery mechanical and hydrostatic drive- cy of the mechanics for high speeds. This way it
industry throughout the world. line concepts, as in the powersplit becomes possible to combine the advantages of
n n n
ASTRA n
AUSA n
Bell n
Caterpillar n
Chengong
CV transmission, has proved par- two systems – hydrostatics and hydrodynamics-
n
CNH n
Dahua Doosan Doosan-Moxy
n n n
HAMM n

ticularly sustainable. in the CVT technology.

HBM-Nobas n
Heli n
Hitachi n
Huddig AB n
Hyundai
New ZF technologies enable to With the already considerably improved ZF
n
Hua Dong n
JCB n
JLG n
John Deere n
Kalmar n

operate the vehicle with reduced Efficiency Package (5-speed + converter lockup
Liugong n
Liebherr n
Linyi n
Longgong n
McNeilus
consumption and lower exhaust clutch and fully hydrostatic transmission) a fur-
n
Omniquip n
Sany n
Shangong n
Stetter n
TCM n

emissions and therefore spare the ther consumption and productivity advantage
Telcon n
Terex n
Tianjin n
Volvo/VCE n
Xiagong n

wallet and the environment. The will occur.

Xugong n
Xingma n n n

In addition to the CVT technology ZF will bring

a highly efficient and environmentally friendly
hybrid transmission on the market. Being the
market leader of the sector, ZF is of course also
profiting from the established and successful
hybrid solutions in passenger cars, busses and
commercial vehicles.

5
Together we move the earth.
Transmission technology from ZF.

ZF transmissions for construction and material handling machinery have been pro-
duced for more than 40 years with more than 200,000 transmissions thereof more
than 100,000 ERGOPOWER transmissions. ZF transmissions for the off-highway
applications are used by worldwide customers based on a wide range of applica-
tions such as wheel loaders, dump trucks, graders, wheel excavators, backhoe load-
ers and many more. ZF transmissions are tailor-made for all kinds of different appli-
cations.
 Transmission technology

ZF is a renowned specialist for driveline technology and recog-

nized worldwide as innovative systems supplier for off-road
machinery. The demands on these vehicle types are high: fast
work with millimeter accuracy and highest productivity com-
bined with reduced operating costs.

1 ZF-ERGOPOWER: ZF in wheel loaders handling, high shifting quality and flexibility. tooth contact reduce the noise level. 2 ZF-ERGOPOWER LII: ZF in dump trucks Well known and accepted design criteria
The tried and tested powershift transmis- Moreover, the operating costs can be fur- Extremely short shafts reduce deflection 8 speeds forward for 45 tons payload like rotational pressure compensation, set
sion system ther reduced. The ZF-ERGOPOWER pro- and tooth contact faults. This transmission is a complete new coun- right bearings or short and stiff shafts are
This tried and tested transmission system vides additional possibilities for connecting The vertical arrangement of the spur gear tershaft design for the application specially combined now with a remarkably reduced
has been optimized for different construc- an electronic driveline management, thus ratios bridges the height difference between in dump trucks, motor graders and heavy internal speed which results in less fuel
tion machinery types and offers the innova- enabling vehicle-specific controls. the input and output shafts. Consequently, wheel loaders. The main features for this consumption. The new transmission fea-
tive, optional feature of 5 instead of 4 gears. With the modular construction and opti- the axle differential can be integrated into new development are high efficiency, high- tures onboard electronics, an integrated
Therefore, the noise-optimized transmission mized design operating costs are kept as the housing. An additional transfer box is er speed, higher tractive effort and less retarder and can optionally be mounted to
allows even more comfortable and easier low as possible. Helical gears with high then unnecessary. noise emissions. the axle drive.

1 2 3

3 4 WG 94/98: 4 ZF-HYDROSTAR HL:

ZF in backhoe loaders ZF in mobile excavators
This powershift transmission is specially This transmission mainly used in wheel
designed for the application backhoe excavators is produced in 3 capacity
loader up to an engine power of approx. ranges and can be mounted directly to the
80 kW and a gross vehicle weight of up to ZF rigid axle MT-E 3000 range or mounted
9,000 kg. Engineered by ZF in Germany, separately to the chassis.
this transmission is produced in the USA This transmission can be used for an input
by ZF Gainesville, Georgia. torque from 550 Nm up to 950 Nm for an
empty vehicle weight from 15 to 25 tons.

8 9
 Transmission technology

5 ZF-HYDROSTAR 2 HC 85: 7 WG 98 TC / WG 98 TSC: 7

ZF in compact loaders ZF in telescopic handlers
This stepless hydrostatic transmission is a com- 4 WG 98 TC (Telehandler center mount)
plete new design and technology including the and 4 WG 98 TSC (Telehandler side mount-
crankshaft radial piston motors. The one speed ed compact) are designed for a max.
version is designed for approx. 20 km/h, the engine power of 90 kW. These transmis-
two speed version for 40 km/h. sions in connection with our telehandler
Through the continuously variable shifting the axles MS-T 3000 series allow the installation
riding comfort and handling performance has of different mountings of the boom (low
been increased. The electronically controlled and high, middle and center mounted boom
driveline management enables a low start up to a payload of 5.6 tons). More than 15
speed. 5 years of experience and a production of
Due to the integration of the hydro motors into more than 42,000 transmissions show the
the transmission system, interfaces to the vehi- success of our design and quality.
cle could be reduced. The low frequencies of
the slower hydro motor speeds helped reducing
noice emission.
This transmission can be mounted directly to
the MT-L 3060 ZF rigid axle or separately to the
chassis.

8 ZF-ECOMIX II: ZF in concrete mixers 8

20 % less weight
This transmission is the new generation for
concrete mixers up to 10 m³ (13 yd³) drum
capacity and an output torque up to 62,000
Nm (45,700 lb-ft). The compact lightweight
construction makes ECOMIX II 20 % lighter
and 50 % shorter in comparison to previous
models.
The use of patented elastomer units de-
signed by ZF allow an increase of the axial
run-out at drum bottom and an increase of
misalignment of the drum.
The acoustic and mechanical decoupling of
drum and vehicle frame leads to consider-
able noise reduction during operation and
6 improved driving comfort.
Serviceability has been improved thanks to
separate oil for transmission and hydrostatic
system as well as an improved accessibility.

9 WG 90-311: 9
ZF in material handling vehicles
ZF fully automatic powershift transmissions
are specially designed as a short drop ver-
sion and are used mainly in IC (internal
combustion) lift trucks and reach stacker
applications up to 60 tons lifting capacity
6 WG 160-310: ZF in graders and cranes (140 tons gross vehicle weight) but also in
Graders are specialists for flat terrain. In For mobile cranes ZF-ERGOPOWER terminal Trucks, RoRo trucks, yard tractors
rough conditions, for construction-site road- transmissions are used in various dimen- and aircraft tow tractors. These transmis-
ways or laser controlled levelling of large sions according to the necessary per- sions are used in the range of 65 to 330 kW.
areas, a grader is ideal. formance of the individual vehicles.
ZF develops innovative system transmis- ZF-ERGOPOWER transmissions offer
sions representing a high added value for completely new standards to the market.
any construction machine. Maximum Helical gears with high tooth contact
power utilization, optimum shifting quality errors. Vertical arrangements of spur
without tractive effort interruption, easy gear ratios bridge the difference in
maintenance and diagnostics combined height between input and output shaft,
with low noise emission delivers transmis- allowing the axle differencial to be inte-
sion technology being of equal benefit to grated into the housing. No additional
the vehicle owner and the driver. transfer box is required.

10 11
Best performance on all grounds.
Axle technology from ZF.

Over the last years ZF was able to develop basic optimization in axle technology.
Especially according to efficiency and power dissipation our engineers could achieve
major improvements.
As demonstrated in numerous tests in the company’s own development center, a
very long service life is ensured by ZF axles, as well as loading capability. The low-
speed brake of the ZF-MULTITRAC axles and the other sophisticated ZF design fea-
tures form the basis of a highly efficient driveline.
13
 Axle technology

2 ZF-MULTITRAC MT-L 3000 II series: 2

ZF axle systems form a solid basis for any vehicle design. Through ZF in wheel loaders
consistent systemization, steering axles in the series ZF-MULTISTEER The new generation of ZF axle systems for
wheel loaders offers an increased power-
and the powered rigid axles of the ZF-MULTITRAC series can be inte- and fuel efficiency due to low speed wheel
brake, the differential lock management
grated like a modular kit into almost all vehicle and application pro- ERGOTRACTION and an improved planetary
files – both an economical and performance-optimized solution. Slim drive. The ERGOPOWER transmission con-
trol provides automatic engagement and
axle housings, small axle center drives and high ratios in the wheel disengagement of the powershift differen-
tials. Cylindrical roller bearings in the final
heads are the essential parts of these innovative axle ranges. drive account for less heat generation and
less power losses and consequently
reduced fuel consumption.

1 3 3 ZF-MULTITRAC MT-D 3000 II series:

ZF in dump trucks
The new axle generation MT-D 3000 II has
implemented partly new standards as well
as new optional features. For example the
wet multi disc brakes are now standard,
optionally various differentials are available,
like limited slip or even HASR (Hydraulically
Applied Spring Released) multi disc diff-lock.
A big gain is the optimized brake manage-
ment between engine brake, transmission
retarder, transmission and axle service brake
in order to avoid the need for external axle
cooling. The new diff-lock management
makes it easier for the operator.
Also new is the use of metal face sealings
and an improved oil flow for the brake.
Finally we achieved a design with higher life-
time and improved efficiency.

1 ZF-MULTITRAC: Highest possible 4 4 ZF-MULTITRAC MT-B 3065:

reliability and efficiency ZF in backhoe loaders
Strong, but light. High torque transmission, The new axle generation MT-B 3000 results
but in a compact size. Adaptable, but at from a permanent development and consis-
costs acceptable to the market. ZF axles are tent research work. These rigid axles are
based on well-established major product specially developed for backhoe loader
lines and offer all options to fulfill individual applications. The robust design stands for
demands. severe applications and high lifetimes.
Precise gear meshing in all transmissions Service brakes with automatic brake clear-
and axles ensures low-noise power trans- ance adjustment, spring applied hydraulic
mission. released mechanical differential lock and an
integrated SAHR multi disc park brake on
the axle input are the key features.

14 15
 Axle technology

5 5 ZF-MULTITRAC MT-L 3060: 8 ZF-MULTISTEER MS-T 3000:

ZF in compact loaders ZF in telescopic handlers
The MT-L axles being provided by ZF are In order to be able to maintain flexibility in a
optimally suited for the on-site operation of tight space, ZF axles for telescopic handlers
compact loaders. The enormous durability have a steering angle of up to 55°. The
and robustness have been tested at the in- noise from the axles has been reduced
house test bench both alone and in connec- through optimum adaptation to the trans-
tion with the relating compact loader trans- mission requirements.
missions. As a result of this these axles are ZF axles feature particularly slim axle hous-
not only characterized by their long life. The ings. The design has been optimized with
high ratio in the wheel heads’ final drive the aid of finite element methods such that
allows a compact axle drive thus providing the axles are substantially stronger, but nev-
increased ground clearance. ertheless lighter compared to conventional
The system comprises a directly mounted design. The integrated, low-wear multi-disk
transfer box for hydrostatic drive and two brakes are protected against the dust and
different brake modules. dirt of construction site operation. In addi-
tion, a spring-operated, hydraulically
released parking brake is available as stan-
dard.

6 6 ZF-MULTITRAC MT-C 3000: 8

ZF in compactors
The new designed compactor axle is
equipped with an integrated spring applied
brake which is opened by hydraulic pres-
sure while engine is running. This safety
feature is the ideal solution. The axle is
designed for different sizes and is using
common parts.
By using parts from existing ZF axles high
lifetime and flexibility are the main advan-
tages.

7 ZF-MULTITRAC MT-G 3085: ZF in graders 7 9 9 OPTISTEER: less fuel consumption

The ZF MT-G 3000 axle systems are built and less tire wear
very robustly and orientated to performance. OPTISTEER is an additional feature for the
ZF offers axle systems up to 125,000 Nm MULTISTEER MS-T 3000 axle that improves
output torque and 27 t vehicle weight. steering and reduces tire wear while still
Speed ranges up to 50 km/h are no prob- maintaining a tight turning radius. An im-
lem for the various drivelines. provement in tracking characteristic and a
The biggest advantage for vehicle manufac- reduction in the rolling resistance is also
turers is however the available kit/delivery noticed.
system: Depending on the depth of produc- The steering angle error can be reduced by
tion, ZF alternatively offers the central part more than 50 % resulting in a reduction of
of the axle with the differential, with or tire side force by minimum of approx.40 %
without planetary drives. Additional wheel and consequently a corresponding reduc-
ends with planetary drives and even a com- tion of tire wear.
plete system (including tandem box) for Improved fuel efficiency, increased tire life,
which the customer only needs to specify and reduced stress on tie rods, wheel bear-
the connecting dimensions to the rims. ings, and other axle components are addi-
tional benefits of the new feature.

16 17
ZF – The technological leader.
Increased efficiency for your driveline.

During hard, practical application the driver and the construction machine form one
unit. It is only when each is perfectly matched to the other that the heaviest work
can be carried out. ZF offers a variety of systems, which are improving comfort,
operation and efficiency of construction machines for the driver and at the same
time enable vehicle owners to reduce their operating costs. The optimally matched
system components – ZF transmissions and axles – already provide a high level of
efficiency and ease of handling which is brought to perfection with new additional
features and functions. The ZF Efficiency Package.
ZF is a renowned specialist for driveline
technology and recognized worldwide
as an innovative systems supplier for
off-road machinery. ZF underlines its
systems competence with the EFFI-
-20%
Save operating costs
The fuel consumption of a vehicle gets more
and more important as the costs for fuel will
CIENCY PACKAGE: increase due to shortage of resources.

Less fuel consumption

ZF consolidates its competence in the
transmission, axle and functions devel-
+40%
Reduce production costs
The productivity of man and machine is the
opment, thus offering more than the most important factor for the costs per ton of
moved dirt.

sum of individual advantages. Higher productivity

The options of the EFFICIENCY PACK-

AGE provide increased productivity and
-15%
Reduce down time and service costs
A machine in the work shop costs money
and is not productive.

enhanced operating and driving com- Less service costs

fort for the operator associated with a

reduction of the operating and mainte-
+60%
Save transit time
Save material handling time
The amount of material the machine can move

nance costs for the vehicle owner. per liter fuel indicates the fuel efficiency. With
ZF this efficiency is increasing extremely due to
high performance, comfort for the driver and
More fuel efficiency high flexibility.
Full utilization of the EFFICIENCY PACK-
AGE allows fuel savings of up to 20%.

20 21
 ZF Efficiency Package

ZF Efficiency Package

Following are the modules of the ZF EFFICIENCY PACKAGE in detail:

For many years already, ZF driveline and chassis systems have n The MULTITRAC and MULTISTEER axles featuring lightness, stability

proven themselves in meeting the challenges of the market. and high transmission power.
n The ERGOPOWER transmission with 5 instead of standard 4 gears.
With the EFFICIENCY PACKAGE ZF consolidates its competence n The ERGOLOCKUP which engages the torque converter lock-up clutch

by modulation in low gears already.

in the transmission, axle and functions development, thus offering n The ERGOTRACTION which optimizes the engagement and

more than the sum of individual advantages. disengagement of the powershift differentials.
n The POWERINCH function which is an operating condition dependent

clutch cut-off with fully automated adjustment.

n Engine de-rating allows overload protection and tractive effort control.
n Operating mode selection enables shift point adjustment depending

on operating mode and selected engine rating.

ZF underlines its systems competence with the EFFI- This approach makes it possible to
Save fuel with ZF EFFICIENCY PACKAGE !
CIENCY PACKAGE which includes many benefits due reconcile the frequently conflicting
refuel refuel
to perfectly matched components. demands for: +
The options of the EFFICIENCY PACKAGE provide n less fuel and oil consumption
Standard
increased productivity and enhanced operating and n reduced component wear

Fuel consumption
Fuel savings
driving comfort for the operator associated with a n increased productivity up to 20 %

reduction of the operating and maintenance costs for n enhanced comfort

the vehicle owner. Full utilization of the EFFICIENCY n extended service intervals with
PACKAGE allows fuel savings of up to 20 %. n noise reduction ZF Efficiency
Package
n higher levels of automation
n improved shift quality
n easier operation
0
Distance / Time

The components of the Efficiency

Package in detail: ZF-ERGOPOWER ZF-ERGOLOCKUP
The core element of the Efficiency 5-speed automatic transmission Torque converter
Package is a 5-speed transmission and lock-up clutch
ERGOLOCKUP, a lock-up converter
which enables direct drive already at
low speeds. Further features are the
automated differential lock (ERGO-
TRACTION) and the new clutch cut-off Low speed brake
function POWERINCH. Additional func-
tions are improved tractive and power
management via engine
de-rate and operating
mode selection.

ZF-ERGOCONTROL
Transmission Control Unit

ZF-ERGOTRACTION
Differential lock management

23
22
 ZF Efficiency Package

ZF Efficiency Package

ZF-ERGOPOWER
This proven transmission system has been optimized
for different construction machinery types and offers
the innovative feature of 5 instead of 4 gears.
ZF-ERGOLOCKUP: Torque converter
lock-up clutch W 400 WK TD
With ZF-ERGOLOCKUP the torque con-
verter lock-up clutch (WK) is already
applied in low gears, controlled by
ERGOPOWER software.

More power and efficiency with 5-speeds Optimized power transfer with ZF-ERGOLOCKUP
A five-speed transmission is at the heart of the The ERGOLOCKUP ensures that at low speeds already
Efficiency Package, meaning fuel savings can be guar- the ERGOPOWER converter lock-up clutch is applied
anteed due to engine speed reduction, higher produc- by pressure modulation via the software. The optimum
tivity through better driving performance and higher effect of this function is of particular benefit to trans-
shift quality, noise reduction and, last but not least, a missions with 5 gears, since in this case the converter
higher number of gears which is the future standard. lock-up clutch can be kept closed when shifting gears.
Moreover, the operating costs can be further reduced. Advantage: Depending on the application conditions,
The ZF-ERGOPOWER provides additional possibilities the fuel consumption can be reduced by 10 % to 20 %.
for connecting an electronic driveline management, A realistic fuel consumption reduction of 5 liters per
thus enabling vehicle-specific controls. operating hour would mean a saving of 100,000 liters
for a fleet of 10 wheel loaders with an average of just
2000 h per year.

ZF Direct-Drive: Efficiency with torque converter ZF 5-speed with lock-up: Efficiency with torque converter
no losses, increased efficiency 100 % torque already in 2nd gear
ZF-ERGOLOCKUP features Direct Drive Since any kind of hydraulic power trans-
whenever possible. The torque convert- fer generates high levels of fuel con-
er is only in operation when really need- 5 100 % sumption, it must only be used where
ed through automatic t/c-mode selec- explicitly required. Therefore, after the 100 %
tion and proportional pressure modula- setting off process, a torque converter
tion. Hence the ZF-ERGOPOWER 5- lock-up clutch (German abbreviation:
4 max. 90 % 100 %
speed transmission with lock-up can be WK), such as the W340-4WK, ensures
transmission gear

operated in 100% direct drive mode at that the torque flow between the

operating time
almost all driving conditions which engine and the transmission can be
means no losses in the torque convert- max. 90 % 100 % designed in a loss-free and thus, com-
3
er. In first gear work mode t/c is applied pletely direct way (Direct Drive).
automatically. This design makes a considerable con-
tribution to fuel consumption reduction
2 max. 90 % max. 90/100 % and the economic viability of construc-
tion machinery. 100 %

1 max. 90 % max. 90 % max. 90 % max. 90 % max. 90 %

4-speed transmission ZF 5-speed transmission 4-speed standard ZF 5-speed transmission

with lock-up transmission lock-up with lock-up

open T/C lock-up open T/C lock-up

24 25
 ZF Efficiency Package

ZF Efficiency Package

The differential lock management is another core function of To make construction machinery and construction site vehicles with the ZF
Efficiency Package core functions even more efficient and powerful ZF offers
the ZF EFFICIENCY PACKAGE. Traction in all situations and on additional functions as option.
all surfaces is decisive to reduce component wear and increase
productivity. ZF POWERINCH
– Intelligent Clutch Cut-Off Function
The POWERINCH is an advanced drive-

Average brake power

line management feature to improve
loader application such as truck loading without POWERINCH
and tight corner operation by limiting
vehicle tractive effort in hydraulic stall
conditions to the minimum required to
More savings and comfort with the automatic differential lock ZF-ERGOTRACTION hold the vehicle and not to the maxi-
This feature for axle control mum available. The POWERINCH
management ZF-ERGOTRACTION
offers a differential lock dynamically adjusts the clutch cut-off
Standard self-locking differentials are purely torque management which gov- point depending on transmission output
reduction in
dependent and interfere in many drive conditions. Manual erns the interwheel differ- torque and brake pressure. It enables
brake power
ential locks in wheel load- the control of the vehicle drawbar pull
operated diff-locks are fully operator dependent hence mis-
ers. The ERGOPOWER via the brake pedal, independent of
used in many cases. ZF-ERGOTRACTION, the automatic transmission control pro- engine speed.
diff-lock control and ZF hydraulic power-shift differentials, vides automatic engage- The result is improved productivity and
ment and disengagement reduced fuel consumption as well as with POWERINCH
is the state of the art solution for wheel loaders.
of the powershift differen- reduced loading of the service brakes.
Advantages: This innovation protects the drive system com- tials. ZF offers the full range
ponents and the tires whilst offering 100 % tractive effort. of MT-L 3000 axles for
wheel loaders up to 35 t
It also contributes to a significant fuel saving. Moreover,
with the optional hydraulic
ERGOTRACTION improves the cross-country mobility and power-shift differential. ZF ENGINE DE-RATING

torque
Prevention of torque spikes through cut-off by engine de-rating
increases the performance. Vehicle handling is comfortable
active engine control via CAN.
and easy. Protection against misuse is also guaranteed. Torque reduction in first gear (particular- limit
ly in stall conditions) can be provided,
so that the maximum desired drawbar
pull is not exceeded. The engine de-
rating during shuttle shift reduces the
energy dissipation in the clutches and
100% traction on all grounds with ZF-ERGOTRACTION without ZF-ERGOTRACTION
contributes to lower fuel consumption.
ZF-ERGOTRACTION ensures that the
solid ground solid ground Engine de-rating leads to reduced fuel
diff-lock is always engaged when needed and
consumption, overload protection, bet-
automatically switches off when it is not nec-
ter controlled drawbar pull and
essary. Therefore optimal traction is guaran-
improved service life of the driveline. time
teed under all driving conditions.
Customer benefits:
Less tire wear
n no slipping tires esp. with unskilled operator
n no tire slippage on solid ground due to open
Operating Mode Selection

n_Engine [rpm]
differentials This additional function provides a
self locking selection of shift-point curves to accom- ECONOMY MODE POWER MODE
Fuel savings no engagement differential modate various operating conditions or
n no internal wind-up (open differential) multiple engine curves. Its advantages
- internal losses gear X
n no internal friction losses - no losses in differential include reduced fuel consumption and
- internal wind-up
Higher productivity - increased tire wear noise emissions, as well as optimised

downshift
travelling performance.

upshift
n 100% traction due to diff-lock soft ground soft ground
Reduced load on driveline components gear X+1
n no wind-up
n over-speeding

Higher operator comfort velocity [mph]

n automated diff-lock actuation
n prevention of tire rut holes due to - high traction - low traction
slipping tires - automatic engagement - wheel slip

26 traction 27
 Future driveline technology

Future driveline technology

Alternative drivelines are popular when it comes to preserving the

environment and resources and when new legal standards and
the demand for greater efficiency are to be met. In this regard, ZF
has set two milestones in transmission technology for construc-
tion machinery: ZF cPower, the new continuously variable trans-
mission and the ZF-ERGOPOWER hybrid transmission.

Electric
motor
Accumulator Hybrid Transmission Engine
control battery control control unit
ZF is one of the few independent automotive suppliers, the construction- and agricultural machin-
whose hybrid technology is already being used as a ery market. Hydrostatic technology is Power
electronics
standard. The Group has adjusted its product program more and more displacing hydrodynamic
Electric motor
to the increasing demand for hybrid technology and (torque converter) transmissions especial- 24 V
control unit
battery
DC/DC converter
thus covers the entire range: components, modules, ly in construction machinery systems. At
and complete hybrid systems based on the parallel customer’s option lower engine speed and
hybrid design. They can be used as a basis for all slowdown of the engine through a contin-
hybrid designs, from the micro and mild hybrid to the uous drive concept are in the focus. ZF
full hybrid, which leads to roughly 30 percent fuel sav- cPOWER meets all these demands. ZF hybrid technology Component Operational hybrid Strategy function
ings compared to a conventional driveline. Hydrostatic power-split CVTs can achieve ZF offers hybrid technology covering functions functions of the vehicle
electric machines and complete
With the development of the cPower transmission, ZF decisive consumption savings compared hybrid systems from one source. The
follows a trend to continuous variable transmissions in to hydrodynamic transmissions. ZF hybrid system is suitable for all ZF Hybrid modules under
transmission forms and can be imple- the responsibility of
mented for direct and separate trans- ZF (with partners)
mission mounting. Automotive manufacturers

ZF cPower: The new continuously ZF-ERGOPOWER Hybrid:

variable transmission Highly efficient future technology
The new ZF cPOWER offers full power The ZF hybrid component on the basis of
split and perfectly combines hydrostati- the well-proven ERGOPOWER series is
cal and mechanical advantages the logical evolutionary step towards an
throughout the whole range. It benefits electric drive and is keeping pace with
from the high degree of hydrostatical the trend towards more environmental
efficiency at low speeds and at the protection and preservation of resources.
same time from the great mechanical The ZF-ERGOPOWER hybrid works as a
efficiency at high speeds. parallel hybrid with an efficient electric
machine, providing up to 85 or 120 kW
Reduced fuel consumption of more than performance, depending on the size.
20 % and an increase of productivity of The complete hybrid system comprises
more than 40 % are possible. The high a power electronics for the electric
tech continuously variable transmission machine and a lithium ion battery as
(CVT) is 100 % assembly-compatible well as a hybrid control unit.
with ZF-ERGOPOWER transmissions.
ZF hybrid technology allows a reduction
of operating costs through less con-
sumption and simplified exhaust after-
treatment systems. Furthermore exhaust
emissions are reduced while the per-
formance output is increased by per-
formance boost.

28 29
 ZF – The systems supplier

TCU

Heavy-duty transmissions, precision axles and intelligent electronic systems are the Interfaces are reduced and the manufacturer of the construction machine receives
components that give a superior driveline package – right at the heart of every con- from a single source a perfectly tuned system ready for fitting. At the same time,
struction machine. attention is always paid to the requirements of the fleet operator and driver, both in
Apart from the basic orientation to various types of construction machine, ZF drive- their work with the machine as well as with upkeep and maintenance.
line components are matched more precisely to the relevant vehicle requirements in An innovative spirit, quality consciousness and smooth co-operation with vehicle
co-operation with the manufacturers. The modular system structure allows lots of manufacturers come together to make ZF a valuable and dependable system partner
ways of achieving the best driveline design through co-ordinated development. who will help you share the load.
ZF driveline technology for wheel loaders ZF driveline technology for compact loaders

The wheel loaders have the highest share of construction machinery worldwide. For the smaller range of articulated wheel loaders up to 11 tons empty vehicle
A high quantity of the wheel loaders are equipped with ZF Ergopower driveline. weight ZF can offer the axle range MT-L 3055 in connection with the transmis-
Easy shifting and shift quality by the electronic device is a derivate from the pas- sion AVG 185 or the new CVT transmission 2HC85 for the adaption of the
senger car application with automatic ZF transmissions. hydrostatic engine.
Efficiency and safety features are our main targets for the improvement of these A steering axle for this range is also available if it is not an articulated loader.
transmission ranges. These axles in connection with a possible mounted service and parking brake
(BHF) have a very compact design.

ZF driveline technology: Products and performance classes for wheel loaders

Empty vehicle Front Rear Electronics / Trans- Engine

weight1) axle axle gear selector mission power
max.

Class up to 9 t MT-L 3065-II MT-L 3065-II EST-37 A / DW 3 WG 115 90 kW

Class up to 10 t MT-L 3065-II MT-L 3065-II EST-37 A / DW 3 WG 130 130 kW
Class up to 12 t MT-L 3075-II MT-L 3075-II EST-37 A / DW 3 WG 160 160 kW
Class up to 14 t MT-L 3085 MT-L 3075-II EST-37 A / DW 3 WG 190 190 kW
Class up to 17 t MT-L 3095 MT-L 3085 EST-37 A / DW 3 WG 210 210 kW
ZF driveline technology: Products and performance classes for compact loaders
Class up to 21 t MT-L 3105 MT-L 3095 EST-37 A / DW 3 WG 230 230 kW
Class up to 24 t MT-L 3105 MT-L 3105 EST-37 A / DW 3 WG 260 270 kW Empty vehicle Front Rear Transmission Input torque
Class up to 27 t MT-L 3115 MT-L 3105 EST-37 A / DW 3 WG 310 320 kW weight1) axle axle max.
Class up to 28 t MT-L 3115 MT-L 3115 EST-37 A / DW 3 WG 310 320 kW
Class up to 31 t MT-L 3125 MT-L 3115 EST-37 A / DW 3 WG 310 320 kW Class up to 4.9 t MT-L 3015 MT-L 3015 AVG 150 / AVG 185 550 / 1,000 Nm
Class up to 35 t MT-L 3125 MT-L 3125 EST-37 A / DW 3 WG 310 320 kW Class up to 6.0 t MT-L 3020 MT-L 3020 AVG 150 / AVG 185 550 / 1,000 Nm

1) Empty vehicle weight without additional equipment 1) Empty vehicle weight without additional equipment

32 33
ZF driveline technology for dump trucks ZF driveline technology for mobile excavators

To be able to satisfy these requirements in routine use, maximum ground con- The wheel drive enables a rapid change of position without disturbing the sub-
tact, uniform distribution of the drive power to all wheels and uniform load strate. Easy tool changing makes the mobile excavator into a multifunction
distribution are important for a high level of safety. working machine which however needs to be moved precisely. Along with the
Apart from these viewpoints for reduced cycle times and more operator comfort, skill of the excavator operator, well-conceived mechanical driveline technology
economic efficiency and service life should not be forgotten. The stresses which is required to provide smooth movements when swiveling and braking. With the
come into play demand the highest level of ruggedness and reliability from all ZF driveline technology high power transmission and millimeter positioning
components in the transmission chain. are perfectly combined. Depending on the application, the axles are in this
respect stressed differently. In tight construction sites a precise response
of the steering axle should also support accurate positioning.
ZF driveline technology: Products and performance classes for dump trucks

Vehicle Front Wheel Rear Rear Electronics / Trans- Engine

payload axle head axle 1 axle 2 gear selector mission power
max.

Class up to 12 t MT-L 3075 -- MT-L 3075-II -- EST-37 A / VTS 3 WG 115 90 kW

Class up to 18 t MT-L 3085 -- MT-L 3085 -- EST-37 A / VTS 3 WG 160 160 kW
Class up to 18 t MT-D 3085 – MT-D 3085 MT-D 3085 EST-37 A / VTS 3 WG 160 160 kW
ZF driveline technology: Products and performance classes for mobile excavators
Class up to 25 t MT-D 3085 – MT-D 3085 MT-D 3085 EST-37 A / VTS 3 WG 210 230 kW
Class up to 27 t MT-D 3095 – MT-D 3095 MT-D 3095 EC II1) / VTS 3 EP 320 250 kW Empty vehicle Front Rear Transmission Swing Input
Class up to 30 t MT-D 3095 – MT-D 3095 MT-D 3095 1)
EC II / VTS 3 EP 320 250 kW weight1) axle axle drives torque
max.
Class up to 35 t MT-D 3105 WH 3105 MT-D 3105 MT-D 3105 EC II1) / VTS 3 EP 370 300 kW
Class up to 40 t MT-D 3105 WH 3105 MT-D 3105 MT-D 3105 1)
EC II / VTS 3 EP 420 350 kW Class up to 15 t MS-E 3050 MT-E 3050 HL-250 DR-140 550 Nm
Class up to 45 t 1)
EC II / VTS 3 EP 470 375 kW Class up to 19.5 t MS-E 3060 MT-E 3060 HL-270 DR-250 770 Nm
Class up to 50 t 1)
EC II / VTS 3 EP 520 400 kW Class up to 25 t MS-E 3070 MT-E 3070 HL-290 DR-350 950 Nm

1) EC II: ErgoControl II onboard electronics 1) Empty vehicle weight without additional equipment

34 35
ZF driveline technology for backhoe loaders ZF driveline technology for telehandlers

Backhoe loaders are a combination of wheel excavators and wheel loaders: The telescopic handler can be quickly fitted with shovel, fork, grab, working
loading at the front, digging at the back – and in between a power drive, platform and other tool attachments for the most varied jobs. This means
embedded in a maneuverable vehicle design. versatility in application in a wide variety of fields, from the construction site,
As genuine all rounders they can also be combined with various hydraulic industrial to agriculture.
attachments, for example for drilling, digging, pumping, breaking, compacting The ZF driveline versions for telescopic handlers are also versatile. Depending
or cutting. Consequently, backhoe loaders are seen where the most varied work on the type, low-boom or high-boom, center or side mounted boom designs are
has to be done and special machines would not be economical. possible. Special telescopic handler axles support the 4-wheel steering system.
In particular a lot is demanded from the front axle. It has to overcome the con-
flict between high loadability and high steering precision. The universal axle ZF driveline technology: Products and performance classes for telescopic handlers
concept facilitates front-wheel and four-wheel steering.
Empty vehicle Payload Front Rear Gear Transmission Engine power
weight1) max. axle axle selector max.

Class up to 10.6 t 3.2 t MS-T 3045 MS-T 3045 DW WG 98 TSC 105 kW

WG 98 TC
Class up to 12.9 t 3.9 t MS-T 3055 MS-T 3045 DW WG 98 TSC 105 kW
WG 98 TC
ZF driveline technology: Products and performance classes for backhoe loaders
Class up to 13.3 t 4.0 t MS-T 3060 MS-T 3045 DW WG 98 TSC 105 kW
WG 98 TC
Empty vehicle Front Rear Gear Transmission Engine power
weight1) axle axle selector max. Class up to 15.3 t 4.6 t MS-T 3060 MS-T 3055 DW WG 98 TSC 105 kW
WG 98 TC
Class up to 16.2 t 4.9 t MS-T 3070 MS-T 3055
Class up to 7.7 t MS-B 3025 MT-B 3065 DW 3 WG 90 65 kW
Class up to 9.2 t MS-B 3035 MT-B 3070 DW 3 WG 94 75 kW
Class up to 19.2 t 5.7 t MS-T 3070 MS-T 3060
Class up to 11.5 t MS 2045 MT 2085 DW 3 WG 98 90 kW

1) Empty vehicle weight without additional equipment 1) Empty vehicle weight without additional equipment

36 37
ZF driveline technology for graders ZF driveline technology for compactors

Graders must adapt to the most varied ground conditions quickly and impressively. Compactors are found in road building and on large construction sites. For the
Optimum weight distribution for achieving maximum tractive effort is one of the best compacting results the maximum transfer of power to the substrate is just
primary requirements. To master difficult conditions in the working routine, smooth as important as a stepless change of the driving speed. For use on uneven ter-
movements in conjunction with a high pulling power are decisive for excellent rain optimum weight distribution is also essential for increasing the tractive
working performance and for overcoming high material resistances. effort.
The optional lock-up clutch offers Direct-Drive condition with 8 forward / 4 reverse The ZF compactor axle profits from the application of well-proven components
speeds. from other axle ranges, particularly with regard to service life and flexibility.
Very good mounting methods can be realized due to the compact modular
design. For example, various hydraulic motor connections for direct mounting,
the mounting of a transfer box and also a number of different differential sys-
tems are possible. The internal stored-spring brakes are released by the
hydraulic operating pressure.

ZF driveline technology: Products and performance classes for graders ZF driveline technology: Products and performance classes for compactors

Empty vehicle Tandem Tandem Electronics / Transmission3) Engine power Vehicle Axle Axle output
weight1) System I2) System II + III2) gear Selector max. weight torque max.

Class up to 12 t WG 115 100 kW Class up to 10 t MT-C 3045 25,000 Nm

Class up to 17 t MT-G 3075 EST-37 A / VTS 3 WG 160 135 kW Class up to 14 t MT-C 3055 32,000 Nm
Class up to 21 t MT-G 3080 MT-G 3085 EST-37 A / VTS 3 WG 190 170 kW Class up to 18 t MT-C 3065 42,000 Nm
Class up to 27 t MT-G 3090 EST-37 A / VTS 3 WG 210 200 kW Class up to 25 t MT-C 3075 52,000 Nm

1) Empty vehicle weight without additional equipment

2) System I: center axle, System II: center axle and wheel heads, System III: center axle, wheel heads and tandem
3) Standard: 6/3 speeds, optional 8/4 speeds

38 39
ZF driveline technology for transport mixers ZF driveline technology for material handling vehicles

Fleet operators and superstructure manufacturers are placing increasing requirements on the The whole range of the ZF-ERGOPOWER automatic transmission
drive of the mixer drum. Higher power and harder duty cycles are only one aspect here. With is also available in a short-drop version specially designed for the
two series ZF has established a remarkable capability in mixer drivelines. application in lift-trucks, reach stackers, Ro-Ro trucks, terminal
ZF has developed the new generation of the ECOMIX range type CML (Concrete Mixer trucks and yard tractors.
Lowspeed) for transport mixers up to 10 m³ mixing capacity and an output torque up to These short-drop versions are derivates from the long-drop version
62,000 Nm. The new CML transmissions of the ECOMIX II range are based on the achieve- used in construction machinery.
ments of the first Ecomix generation, however, they are smaller, lighter, tougher, more flexible, This design allows a very compact assembly in the vehicle.
quieter, more noise reduced and easier to service.
The driveline of the P/PK range consists of a two-stage planetary drive which is driven by an
external hydraulic motor. Both ranges offer economical and well-proven technology along with
low-maintenance and low-wear operation also under high stress conditions. ZF driveline technology: Products and performance classes for material handling vehicles

Lifting capacity Transmission Electronics / Engine power

(Vehicle weight) (short-drop) gear selector max.
ZF driveline technology: Products and performance classes for transport mixers

Mixing Transmission Total ratio Output Installation Hydraulic 1.5-3.5 t (9 t) WG 90 65 kW

capacity torque max. angle max. motor 10 t (23 t) WG 94 EST-65 A / DW 3 90 kW
16 t (36 t) WG 131 EST-37 A / DW 3 130 kW
Class up to 7 m3 P 3301 141.0 48.000 Nm 15° none 22 t (44 t) WG 161 EST-37 A / DW 3 160 kW
Class up to 9 m3 P 4300 135.3 54.000 Nm 12° none 32 t (72 t) WG 171 EST-37 A / DW 3 180 kW
Class up to 10 m3 P 5300 135.3 60.000 Nm 11° none 37 t (80 t) WG 191 EST-37 A / DW 3 200 kW
Class up to 12 m3 P 7300 144.3 72.000 Nm 10° none 42 t (98 t) WG 211 EST-37 A / DW 3 240 kW
Class up to 8 m3 CML 8 7.8 52.000 Nm 20° adapted 50 t (120 t) WG 261 EST-37 A / DW 3 280 kW
3
Class up to 10 m CML 10 7.8 62.000 Nm 20° adapted 60 t (140 t) WG 311 EST-37 A / DW 3 330 kW

40 41
ZF driveline technology for tow tractors

Having partners.
Beyond purchase.

The ZF-ERGOPOWER transmission in tow bar airplane tractors enables soft shifts without tractive
interruption. This feature prevents shocks to the front wheel of the airplane which is a very impor-
tant safty aspect for this application.
A control system for a second driver cabin for easy manoevering in both directions can be installed
optionally. Further more, for ground service transports of the airplane, a converter lock-up clutch in
combination with the 5- or 6-speed version is available to increase fuel savings and productivity.

ZF driveline technology: Products and performance classes for tow tractors

Vehicle weight Transmission Electronics / Engine power

(short-drop/ gear selector max.
long-drop)

10 t WG 94/WG 94 EST-65 A / DW 3 75 kW
16 t WG 115 EST-37 A / DW 3 90 kW
20 t WG 131/WG 130 EST-37 A / DW 3 115 kW
25 t WG 161/WG 160 EST-37 A / DW 3 130 kW
30 t WG 191/WG 190 EST-37 A / DW 3 175 kW
45 t WG 211/WG 210 EST-37 A / DW 3 190 kW
60 t WG 261/WG 260 EST-37 A / DW 3 250 kW
70 t WG 311/WG 310 EST-37 A / DW 3 300 kW

Innovative products, quick availability, and global customer proximity

Overall, the ZF Services business unit has 76 separate facilities in 36
countries and 650 service partners worldwide. This dense service net-
ZF driveline technology for mobile cranes work means customers will have support wherever they expand
throughout the world. Of the 4,200 employees, about 2,000 work in
Germany at 15 locations. The main administrative offices are pooled
in Friedrichshafen and Schweinfurt. The fields of activity are diversified:
on- and off-highway, rails, industry, marine and wind power.

ZF Testman Pro – knowing the vehicle’s condition anytime, anywhere Like new – with ZF Reman aggregates
In modern driveline systems, an ever increasing number of functions are ZF Reman aggregates ensure a minimum of vehicle
ZF offers various transmissions for the entire range of mobile cranes. Depending on market controlled electronically. System complexity, which in fact increases per- downtimes and attractive prices for products like new.
and customer requirements, either transmissions from ZF Friedrichshafen, the AS Tronic or formance and driving comfort. On the other hand, however, mainte- The ZF Reman program assures a „long life“for your
from ZF Passau, the ERGOPOWER could be suitable for the crane application. All transmis- nance and fault detection are becoming more and more difficult – with- machines also in future.
sions from ZF will offer state-of-the-art technology and reliability. High efficiency with less out a suitable diagnosis tool. The solution: ZF-Testman Pro. With the ZF reman program we offer our customers
fuel consumption will reduce the emission in order to also meet environmental goals. ZF-Testman Pro checks the functionality of all electronically controlled remanufactured exchange units for all ZF Passau prod-
ZF products by means of telemetry or a notebook, online while driving ucts used in tractors, construction machinery and in
ZF driveline technology: Products and performance classes for mobile cranes or when the vehicle is at rest. busses. ZF Services has the experienced personnel,
technical resources, spare parts, exchange units and
RT cranes AT cranes Transmission Electronics / Engine power The diagnostic package ZF-Testman Pro avoids: the logistics required to provide your business with a
(Gross vehicle (Number of gear selector max. n Time-consuming fault detection top-notch and fast product support. The ZF remanu-
weight) axles) n Repairs for unspecified reason facturing process is more than just a repair. All reman-
n Expensive damage ufactured ZF products are completely disassembled,
31 t 2 WG 160 EST-37 A / DW 3 160 kW
n Expenditure of time and money cleaned and thoroughly inspected. When reassem-
63 t 2/3 WG 210 EST-37 A / DW 3 230 kW bled, the units are updated to the latest ZF service
90 t 3/4 WG 260 EST-37 A / DW 3 270 kW information and specification. The final testing is con-
ducted according to the same protocol as new produc-
120 t 4 WG 310 EST-37 A / DW 3 320 kW
tion units. If any units or components fail to meet
these exact specifications and standards, then they
are replaced.

42