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Construction : Components Accessories Spares Hardware | November 2015 | Source : Equipment India

ZF transmissions are tailor-made for different applications

Suresh KV, President for ZF in India

ZF has recently strengthened its business development footprint for the Indian market through establishing a local engineering resource. Suresh KV, President for ZF in India elaborates on the company´s solutions to the CE industry.

How does ZF transmission systems help in the smooth operation of hydraulically driven accessories in equipment?
ZF transmission has the provision for mounting of the hydraulic pumps which are used to power most of the hydraulically driven accessories. ZF´s electrically controlled transmission has an option for advanced inching feature which lets the hydraulic pump use the engine power for operation of equipment hydraulics and then remaining power gets transferred to the driveline.

How do your transmission systems help in productivity and safety of the equipment on uneven or unpaved terrain or extremely hazardous underfoot conditions? How does it achieve ground traction in high gradients and slushy or muddy or loose soils conditions?
ZF-ERGOPOWER: This tried and tested transmission system has been optimised for different construction machinery types and offers the innovative, optional feature of five instead of four gears. Therefore, the noise-optimised transmission allows even more comfortable and easier handling, high shifting quality and flexibility. Moreover, the operating costs can be further reduced. The ZF-ERGOPOWER provides additional possibilities for connecting an electronic driveline management, thus enabling vehicle-specific controls. With the modular construction and optimised design, operating costs are kept as low as possible. Helical gears with high tooth contact reduce the noise level. Extremely short shafts reduce deflection and tooth contact faults.

Transmission for heavy loads: The ZF-ERGOPOWER LII transmission is a completely new countershaft design for the application specially in dump trucks, motor graders and heavy wheel loaders. The main features for this new development are high efficiency, higher speed, higher tractive effort and less noise emissions. Well known and accepted design criteria like rotational pressure compensation, set right bearings or short and stiff shafts are combined now with a remarkably reduced internal speed which results in less fuel consumption. The new transmission features onboard electronics, an integrated retarder and can optionally be mounted to the axle drive. The vertical arrangement of the spur gear ratios bridges the height difference between the input and output shafts. Consequently, the axle differential can be integrated into the housing. An additional transfer box is then unnecessary.

ZF-Ergotraction: This feature for axle control offers a differential lock management which governs the inter-wheel differential locks in wheel loaders. The ERGOPOWER transmission control provides automatic engagement and disengagement of the power shift differentials. ZF offers the full range of MT-L 3000 axles for wheel loaders up to 35 t with the optional hydraulic power-shift differential. Ergotraction improves the cross-country mobility and increases the performance. Vehicle handling is comfortable and easy. Protection against misuse is also guaranteed.

How do the transmission systems vary for different applications/equipment like construction and earthmoving, mining and material handling applications?
Heavy-duty transmissions/axles and intelligent electronic systems are the components that give a superior driveline package for the variety of applications.

ZF technology, mobility and driving comfort can be combined with reduced fuel consumption, preservation of resources, high efficiency, and additional safety. The technology company supplies driveline, electronic, and software technology for all kinds of construction machinery.

Apart from the basic orientation to various types of construction machines, ZF driveline components are matched more precisely to the relevant vehicle requirements in co-operation with the manufacturers. The modular system structure allows lots of ways of achieving the best driveline design through co-ordinated development.

The whole range of the ZF-ERGOPOWER automatic transmission is available in long-drop and short-drop versions to meets the requirement of different vehicle structure of construction equipment, mining equipment and material handling equipment. Long-drop version specially designed for the mining and construction equipment and short-drop version specially designed for the application in lift-trucks, reach stackers, Ro-Ro trucks, terminal trucks and yard tractors. These short-drop versions are derivate from the long-drop. This design allows a very compact assembly in the material handling equipment.

What are the latest transmission solutions from ZF?
ZF-ERGOPOWER: This proven and tested fully automatic power shift transmission system has been optimised for different construction machinery types and offers the innovative feature of five instead of four gears for wheel loader applications. Therefore, the noise-optimised transmission allows even more comfortable and easier handling, high shifting quality and flexibility. Moreover, the operating costs can be further reduced. The ZF-ERGOPOWER provides additional possibilities for connecting an electronic driveline management, thus enabling vehicle-specific controls.

High loads at low speeds in combination with a high dynamics are the outstanding requirements for construction machinery. These criteria are met optimally by the new ZF CVT technology which possesses a degree of efficiency that was inconceivable up to now. The rising demands for fuel reduction and increased productivity require new technologies such as the CVT in construction machines. A trend towards lower engine speeds and the demand for engine stabilization by a constant speed concept are the future challenges in the construction machinery market. The continuously varying cPOWER from ZF meets both these requirements.

ECOMIX II: ZF has developed the new generation of the ECOMIX range type CML (Concrete Mixer Lowspeed) for transport mixers. Mixer transmissions ECOMIX II are based on the achievements of the first ECOMIX generation, however, they are smaller, lighter, tougher, more flexible, quieter, more noise reduced and easier to service.

The ECOMIX II transmission in comparison to previous models is approx. 24 per cent lighter and 50 per cent shorter. However, the special design of the new mixer transmission range ECOMIX II also offers a wide range of further advantages. Thanks to a tough bearing concept it was possible to significantly increase the output bearing strength, which leads to less sensibility at off-road operation. The use of patented Elastomer units from ZF Boge Elastmetall allows an increase of the axial run out at drum bottom and an increase of misalignment of the drum. With the new bearing concept the installation angle is no longer dependent on drum size and drum filling. An installation angle up to 20¦ is always possible. Acoustic and mechanic decoupling of drum and vehicle frame leads to considerable noise reduction during operation and improved driving comfort.

The service-friendliness has been improved by an adapted, weight-optimised slow running radial-piston motor and a separate oil volume for the transmission, as well as better accessibility. Instead of the previous sealing collar, a cassette seal is used, making the transmission more robust and increasing the service life. The transmission is fitted with lifetime oil lubrication.

Who are your major customers? Do you provide customised solutions?
ZF transmissions are tailor-made for all kinds of different applications. In India we supply to most of the leading OEMs, i.e. Tata Hitachi, Leyland Deere, Hyundai Construction Equipment Co, Tractors India Ltd, LeeBoy, JCB, BEML, etc.

What is the growth potential for transmission products?
We foresee good growth potential for our products in line with the growth of the overall off highway market in India. ZF has also recently strengthened it´s business development footprint for the Indian market through establishing a local engineering resource. The engineering team in India will focus on product strategies in order to address better product positioning for the local market through design-to-market exercises. Furthermore, the local resource will support our OEM customers in their new projects, linking the geographic divide between India and Germany and thereby reducing lead times for a faster response and effective project to business conversions.

ZF´s electrically controlled transmission has an option for advanced inching feature which lets the hydraulic pump use the engine power for operation of equipment hydraulics and then remaining power gets transferred to the driveline.

ZF PRODUCTS AND SOLUTIONs
Gear boxes:

  • ZF-Ergopower for wheel loaders, graders and cranes
  • Power CVT for wheel loaders
  • ZF-Ergopower LII for dump trucks
  • 4WG94/98 for backhoe loaders, mobile cranes and airport tow tractors
  • ZF-Hydrostar 2HC85 for compact loaders
  • ZF Ecomix II for concrete mixers

  • Axles:

  • ZF Multitrack MT-L 3085 for Wheel Loaders
  • ZF Multitrack MT-B 3065 for Backhoe Loaders
  • ZF Multisteer MS-T 3000 for Telescopic handlers  
  • ZF Multitrack MT-G 3000 for Graders

  • Transaxles:
  • CVT < 400 PS Terramatic
  • CVT > 400 PS ECCOM
  • TerraPower T-7000
  • Terrasteer / Agrosteer – Sterring Axles
  • Terrashift / T-500
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