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Transmission improves comfort and reliability

A ZF Great Britain product story
Edited by the Engineeringtalk editorial team Mar 31, 2008

The noise-optimised transmission allows smoother, more comfortable and easier handling, high shifting quality and flexibility.

ZF's efficiency package provides perfectly matched components for driveline systems, providing the wheel loader and diesel lift truck markets with fuel savings of up to 20%.

The package improves the comfort of the driver and reduces operating and maintenance costs for the vehicle owner.

Five basic modules are integrated into the efficiency package: a ZF-Ergopower transmission, an Ergolockup convertor lock-up clutch, the Ergotraction inter-wheel differential lock management, the Ecotraction and the Multitrac axle.

The Ergopower transmission system major component in the efficiency package, and it has been optimised for different construction machinery types and now offers five instead of four gears.

As a result, the noise-optimised transmission allows smoother, more comfortable and easier handling, high shifting quality and flexibility.

Moreover, operating costs can be further reduced, as the ZF Ergopower provides additional capabilities for connecting an electronic driveline management system, thus enabling vehicle-specific controls.

Integrated into the five-speed transmission, the Ergolockup function ensures that, at low speeds, the Ergopower's torque convertor lock-up clutch is applied by modulation via software.

This function is of particular benefit to transmissions with five gears, since it allows the convertor lock-up clutch to be closed when shifting gears.

The major advantage of this design is that, depending upon the application conditions, fuel consumption can be reduced by 10% to 15%.

This corresponds to a saving of approximately 2.5 litres/hour.

Considering an average annual performance of 2000 operating hours and a fleet of 10 vehicles, this equates to 50,000 litres of fuel saving per year.

In addition, a lower engine speed further reduces noise emissions.

The Ergotraction for axle control offers differential lock management, with inter-wheel differential locks in wheel loaders and the inter-axle differential locks in dumpers.

Previously, differential locks were only engaged when they were required.

Ergotraction is always engaged, unless this would disturb the operation of the vehicle.

The protects the drive system components and the vehicle tyres and provides 100% tractive effort.

The vehicle user also benefits from significant fuel savings, increased cross-country mobility and improved vehicle performance.

Handling is easier and more comfortable as a result and security of operation is ensured as safeguards against misuse are built-in.

The final Ergopower option, Ecotraction, offers automatic axle disconnect at the transmission.

The transmission control identifies changes from rough terrain to the road or situations in which the all-wheel-drive function is no longer required.

In these cases, it automatically disengages the all-wheel-drive or re-engages it for on-site operation.

The major benefit of automatic axle disconnect is that it contributes significantly to a reduction in fuel consumption during on-road operation.

Furthermore, the driving performance of the vehicle is improved and driveline components and tyres are protected.

Ecotraction increases cross-country mobility, improves handling and protects the vehicle against misuse.

ZF Multitrac axles match the Ergopower functions for maximum performance at the output stage of the efficiency package.

These steering axle systems for construction machinery provide both stability and lightness.

The axles are equipped with integrated, wet multidisk brakes and deliver low-noise power transmission through precise meshing of their gearing.

The Multitrac axles require a minimum of maintenance and have a long service life.

Their design allows for connection of an electronic driveline management system and direct transmission mount.

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