ZF 4wg 200 will only move forward in 2nd gear. Displays codes B5 slippage clutch KV and B6 slippage clutch KR. Has no pressure on valve body ports for those two clutches. Could this be a relief valve or something stuck in the valve body? A link to a manual for trouble shooting?
ZF 4WG 210 or 200 tranny. Rather a 4 WG 210 with this kind of codes. Is this reaction after an action of maintenance or repair? Any action done on cables, connectors?
Assuming it is a 4WG210 gearbox: With ignition off and on, the fault codes must be gone. Start engine, then shift to 2F at standstill. Pressure on KV or KR? Ususally no slippage codes at standstill possible. Will B5 pop up when moving loader?
Thanks for the reply. Man I am working on it with said it is actually a 190, I got those numbers off some paper work. After some other tests we did decided to check out the valve body. Found oil supply screens for those two clutches totally stopped up and collapsed. Waiting on parts to come across the Atlantic and will update you in a week or two. It has had no recent work done to it. Trash from dirty funnels and such? Does it have an internal filter also or just the spin on? It has a yellow piece that looks like it is from a hydraulic piston seal.
Hi Tenwheeler, there is a coarse filter at bottom of suction pipe in transmission to hold back "rocks". Just a screen. Please renew main filter and check old one for clutch material. Usually the small screens at supply prop valves only can be polluted with stuff pressed through paper of main filter. Are you able to get a readout of fault and EE memory of TCU? JCB/ZF dealer? Could get us an idea about condition of clutches... br Bigbert
What is the part number of your TCU controller is under dash or seat should start with EST xxx
Hi Laycobeau, Bosch 0 260 001 034 GS6.12.3 ZF 6009 365 005 HOS612C3103 GBOY28083VG◊ 6009 365 002 Thanks, Tenwheeler
Hi Bigbert, Cut filter open, looks good, good idea. No codes other than display. Dealer is $600 service call just to show up due to location. We try not to do that. There are 6 screens in that picture (just in case anyone is wondering). Thanks
Hi Tenwheeler, condition of filter sounds promising. I'd recommend to pull all solenoids. Remove side covers and bolts, pull solenoids. There are (possibly) screens fitted, too. Clean those as well, fit new gaskets and try again. good luck Bigbert
If you still have an error after all cleaned that error can be from speed sensors in the transmission for the clutch speed. yeh bosch and zf go back and forth buying parts of each other
Bigbert and laycobeau: Thanks for the replies! I had ordered the gaskets before your posts but may well have talked myself out of going into the valve body. That would have been a mistake. It now has all speeds F & R but have not worked it. Surely need to change the fluid but with what? I have looked other places and here. Nige is a wealth of information but I don't know those numbers. AW32, AW46, 303 and Dextron III are commonly available here. Will one of those work or should I special order something?
Hi Tenwheeler, regular engine oil will do. No hydraulic fluid. See list of lubricants ZF TE_ML03. https://www.zf.com/corporate/de_de/.../lists_of_lubricants/lists_of_lubricants.jsp#
JCB 436 ZF 4 wg 190 PSI problems again. The torque converter drive plates broke. Replaced the converter due to damage on the drive lugs and all the bolts were broke off in them. Now the machine will not move. Pulls a little but eases forward when in reverse at times. No fault codes on dash display and shows it is in the gear selected. I have 15 pages of hand made wiring diagrams from the last time I worked on it but very little hydraulic information. A picture of the valve body has a plug on the top left letter K. I numbered it 65 for some reason and noted 240 PSI in neutral. Now it has 225 PSI. Port B-53 had pressure in F 1,2 & 3. Port E-55 had pressure in R 1,2 & 3. Now those two ports never have pressure. Is there a dump valve or something else to check?
Port 65 is system pressure for clutches, the other ports pressure to clutches when engaged. 225 psi instead 240 is okay, will raise with higher rpm. K1 (56), K2 (57), etc. got pressure? does 4th gear K4 (60) and K3 (58) move vehicle? Little drag to forward without KV, but K1 is normal at high engine speed. Could share an operators manual via email. Did you tighten bolts of control unit with 9.5 Nm? System will not throw slippage codes like B1, B2 etc at standstill. regards Bigbert
Thank You! I will check those and update. [email protected] Do not recall how tight bolts were installed. It has been over two years. I will run back over them at 9.5 Nm. I have service calls today. It will be Monday.
Checked the bolt torque. None were loose. Checked pressures stationary in shop. Pushed it out the door. Ground is a slight down grade. Shifted through f 1-4. All had fault code B5. Shifted back to F2 and drove it back to the building. Appeared to operate normally. Shifted to R1 it pulled forward but display says N. Fault Code B6. In R2 & R3 it also wants pull forward. Display says N with a fault code of B5. Also pulls forward in N with fault codes B5 and B6. Thanks for the operators manual. I will spend some time with that tonight.
Time to go back in the valve body?
We did not have a pressure gauge anywhere when pushed it out of the shop. Do not know what any pressures were but it would drive forward. Pulled the valve body. The screens were stopped up again and a spool was scored. Serviced it and it is still running. These ZF's are as tough as nails.