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

The document provides information about testing and maintenance of a ZF 4WG-200 transmission control system. It describes the main components of the system, including the transmission control unit, range selector, and solenoid valves. It also provides diagnostic instructions for checking the speed sensor resistance and transmission system voltage. Tables list the wire connections and solenoid valve states for each gear selector position. Maintenance instructions specify the proper oil level and grade when the transmission oil is at 80°C.

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2K views

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

The document provides information about testing and maintenance of a ZF 4WG-200 transmission control system. It describes the main components of the system, including the transmission control unit, range selector, and solenoid valves. It also provides diagnostic instructions for checking the speed sensor resistance and transmission system voltage. Tables list the wire connections and solenoid valve states for each gear selector position. Maintenance instructions specify the proper oil level and grade when the transmission oil is at 80°C.

Uploaded by

Abdellah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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The ZF 4WG-200 control system

testing point
Overseas Training
-pengzhifeng (arrange)
Updated:2013-2-26
Transmission control system

1. Transmission control unit EST-


117T
2. Transmission WG range
3. Speed selector switch DW-2
4. Connection to vehicle circuit
5. Transmission wiring
6. 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 From 85 ohm to 100 ohm.
35-32
35-33

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 Speed sensor work


principle drawing symbol 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 core solenoid valve on/off clutch on/off

red: power, black: earth 19-25


neutral 1 grey,black and blue 29-25-26

neutral 2 grey and black 29-25

neutral 3 grey,black and green 29-25-8

neutral 4 grey, black,green and blue 29-25-8-26

forward 1 yellow,black and blue 23-25-26 M2、M3、M4 KV+K1


forward 2 yellow and black 23-25 M3、M4 KV+K2
forward 3 yellow black and green 23-25-8 M3 KV+K3
forward 4 yellow,black,green and blue 23-25-8-26 M5 K4+K3
reverse 1 pink,black and blue 5-25-26 M1、M2、M4 KR+K1
reverse 2 pink and black 5-25- M1、M4 KR+K2
reverse 3 pink, black and green 5-25-08 M1 KR+K3
reverse 4 pink, black, green and blue 5-25-8-26 none
-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?

19

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