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FUNCTIONAL DESCRIPTION
5 HP 19
Imprint:
Responsibility for the contents
ZF Getriebe GmbH, Department MKTD,
Saarbrcken, Germany
Printed by HAGER PAPPRINT GmbH, Kirkel
Printed in Germany
Reproduction, printing or translation either
wholly or in part isprohibited.
Published by ZF Getriebe GmbH,
Saarbrcken, Department MKTD
Printed in Germany by
HAGER PAPPRINT GmbH, Kirkel.
Item No. 1060 754 002
Introduction / Note
Function description 5 HP 19
Contents
Page
Introduction / note
Contents
Key
10
Converter
11
Oil pump
14
15
16
Overlap circuit
20
21
Position switch
26
Parking lock
27
28
34
35
36
46
47
48
51
Technical data
52
Notes
Function description 5 HP 19
ZFS, Department MKTD
March 1998
1
Function description 5 HP 19
ZFS, Department MKTD
53/54
March 1998
2
5 HP 19 transmission
7
10
11
12
13
14
15
16
17
18
19
5
4
3
2
1
31
20
21
22
23
24
25
26
27
28
29
30
Key
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Turbine
)
Converter lock-up clutch piston
)
Stator
) Torque converter
Converter cover
)
Pump
)
Transmission housing
Multi-disc brake C
Multi-plate clutch B
Multi-plate clutch E
Multi-disc brake A
Ravigneaux planetary gear set
Multi-disc brake D
Freewheel, 1st gear
Multi-disc brake G
Multi-plate clutch F
Single rear-mounted planetary gear set
Parking lock gear
Gearbox extension complete with preset bearing
Output flange
ATF pump - crescent-type
Flow control valve
ATF drain screw
Magnet
Oil pan
Oil filter
Speed sensor, gearbox rotating speed/turbine (Hall-effect generator)
EDS-1 pressure control valve for modulation/system pressure
Hydraulic control unit
Solenoid valves 1, 2 and 3 and pressure control valves EDS 2, 3 and 4
Speed sensor, gearbox output speed (inductive sensor)
ATF filler cap (at side of transmission housing)
Function description 5 HP 19
ZFS, Department MKTD
5
6
7
8
9
Oil filler
Breather
Selector lever connection
Plug connection for electronic control unit
Plug connection for electronic position switch
March 1998
5
Rear-wheel drive
Function description 5 HP 19
ZFS, Department MKTD
March 1998
6
Power is supplied to the transmission through a hydrodynamic torque converter with an integrated
converter lock-up clutch.
The transmissions capacity ratings are:
max. power input:
max. torque:
The 5 forward gears and 1 reverse gear are obtained by means of a Ravigneaux double planetary gear
set and a rear-mounted single planetary gear set with one spider.
Function description 5 HP 19
ZFS, Department MKTD
March 1998
7
1 sun wheel
4 matching planetary gears
1 planetary spider
1 annulus
The individual gear ratios are obtained by introducing torque at certain elements of the planetary gear
train, while other elements are braked.
Power is always transmitted to the output shaft via the annulus or ring gear (see power flow description).
The mechanical ratios are as follows:
Gear:
1st
2nd
3rd
4th
5th
Rev.
Ratio:
3.67
2.0
1.41
1.0
0.74
4.10
Function description 5 HP 19
ZFS, Department MKTD
March 1998
8
Function description 5 HP 19
ZFS, Department MKTD
March 1998
1
2
Multi-plate clutch E
Multi-plate clutch A
3
4
5
6
Multi-plate clutch F
Multi-disc brake G
Output shaft
Impeller
Turbine wheel
From
engine
To transmission
Condition at
moment of driving
off (stationary
stator)
Stator
nT < nP
nT < nP
Turbine wheel turns
slightly slower than
impeller
Status in so-called
coupling range
(stator rotating)
Function description 5 HP 19
ZFS, Department MKTD
nT = 0
Vehicle at a
standstill
March 1998
10
5 HP 19 torque converter
4
5
3
6
7
8
9
2
1
1
2
3
4
5
Converter cover
Lock-up clutch piston
Engine connection
Turbine
Pump
Function description 5 HP 19
ZFS, Department MKTD
6
7
8
9
Freewheel
Stator shaft
Turbine shaft (input shaft)
Stator
March 1998
11
n/engine
1
2
3
4
Function description 5 HP 19
ZFS, Department MKTD
5
6
7
Turbine
Pump
Stator
March 1998
12
Lock-up clutch/open
n/engine > n/turbine
Lock-up clutch/engaged
n/engine = n/turbine
Function description 5 HP 19
ZFS, Department MKTD
March 1998
13
Oil pump
The oil pump is a crescent-type pump with a delivery rate of about 24 cm3 per revolution; it is located
between the torque converter and the transmission housing.
The converter is located in the pump by a plain bearing. The pump is driven directly from the engine
via the converter shell, and supplies the transmission and selector unit with oil.
The pump draws in oil through a filter and pumps pressurized oil through the flow regulating valve,
which at higher operating speeds returns any excess pressurized oil directly to the pumps intake side.
The pressurized oil is pumped from the flow regulating valve through the main pressure valve in the
hydraulic selector unit, where the oil pressure is modified and the surplus oil returned to the sump.
1
8
1
2
3
4
Sealing ring
Disc
Shaft sealing ring
Bearing bush
Function description 5 HP 19
ZFS, Department MKTD
5 Pump housing
6 Pump ring gear
7 Impeller
8 Centering sleeve
March 1998
14
Intermediate plate
PUMP
Flow regulating valve
POSITION SWITCH
5 HP 19 pump charging
Function description 5 HP 19
ZFS, Department MKTD
March 1998
15
Shift elements
In addition to the converter lock-up clutch, the shift elements include a sprag-type freewheel:
freewheel for 1st gear, for shifting from 1 to 2 and 2 to 1, beneath brake D
four rotating multi-plate clutches A, B, E and F
three fixed multi-disc brakes C, D and G
Shifting from 1 to 2 and 2 to 1 is supported by the sprag-type freewheel, so that there is no overlapping of the two clutches or brakes.
Overlap occurs when shifting from 2-3, 3-4, 4-5 and 5-4, 4-3, 3-2. In other words, during the shift one
clutch must remain capable of transmitting the drive at a reduced main pressure until the corresponding clutch can accept the incoming torque.
The shift elements, clutches or brakes are engaged hydraulically. The pressurized oil reaches the space
between the cylinder and piston, as a result of which the plates are compressed. When the oil pressure
drops, the diaphragm spring acting on the piston presses the piston back to its initial position.
The shift elements are designed to permit gearshifts under load without interrupting the tractive force.
Muli-plate clutches A, B, E and F supply engine power to the planetary gear train, with multi-disc brakes C, D and G reacting to the torque at the housing.
Function description 5 HP 19
ZFS, Department MKTD
March 1998
16
Function description 5 HP 19
ZFS, Department MKTD
17
March 1998
1
2
3
4
5
6
7
Vent
Cylinder for brake G
Brake G
Transmission housing
Cylinder for clutch F
Clutch F
Cylinder for brake G (external plate carrier)
locked to the transmission housing (with screws)
2
3
7
1
10
1
2
3
4
5
6
Lubrication channel
Input (input shaft),
cylinder E
Main pressure, clutch E
Piston E
Cylinder E (external plate carrier)
Clutch assembly
Function description 5 HP 19
ZFS, Department MKTD
11
12
7
8
9
10
11
Baffle plate
Diaphragm spring
Output (interior plate carrier)
Space between piston and cylinder
Space for dynamic pressure
equalization
12 Bearing
March 1998
18
Example of a freewheel
Sprag-type freewheel
Purpose and operating principle of the freewheel:
The freewheel transfers torque in one direction only, and rotates freely in the other. Its purpose is to
simplify the shift operation in technical terms without interrupting the flow of the tractive force, and
to achieve consistent shift quality.
Direction of rotation:
The sprag blocks are located in the space between the inner and outer ring in such a way
that these can turn in relation to one another.
Locking direction:
The sprag blocks between the inner and outer
rings are asymmetrically shaped, and are raised upright when the rings turn in opposite
directions. They consequently become lodged
between the inner and outer rings, preventing
any relative movement of these two components. The sprag blocks are located in a special cage.
Function description 5 HP 19
ZFS, Department MKTD
March 1998
19
Overlap control
In the case of the overlap shift procedures 2-3, 3-4, 4-5 and 5-4, 4-3, 3-2, the place of the freewheel is
taken by suitable control of the clutches. The appropriate clutches are energized by electronic-hydraulic means. This saves both space and weight.
The electronic-hydraulic circuit is formed by various valves within the hydraulic selector unit, which
are energized by means of pressure regulators.
These elements cause the appropriate clutches or brakes to cut in or out at the right moment.
The electronic control unit is located away from the transmission, at a separate point
(see electronic control unit).
Speed
Engine speed
Speed
characteristic
Time
Pressure
Pressure
variation
Torque
characteristic
Pressure
cut-in clutch
Pressure
cut-out clutch
Function description 5 HP 19
ZFS, Department MKTD
Time
March 1998
20
Mechanical positions
P
R
N
Selector unit
Module connector
Function description 5 HP 19
ZFS, Department MKTD
March 1998
21
R
N
D
Position / function
P = Park, must only be engaged if the vehicle is at a standstill. Procedure: first apply handbrake,
then engage position P.
R = Reverse, must only be engaged if the vehicle is at a standstill and the engine idling.
N = Neutral, when the vehicle is at a standstill, apply the handbrake first to prevent the vehicle
from rolling away. When the vehicle is moving, only select Neutral in order to counteract
skidding.
D = Drive, automatic-shift position for normal driving. Automatic gearshifts from 1st to 5th and
5th to 1st and all intermediate gears.
The 5th, 4th, 3rd, 2nd and 1st gears are shifted up by moving the lever in the direction of the
plus (+) symbol or down by moving the lever in the direction of the minus (-) symbol in the
manual program (one-touch mode). The currently selected gear is retained (see M program).
4th gear: Select this position if the transmission tends to hunt between 5th-4th/4th-5th in
certain driving conditions (only possible in Steptronic mode).
3rd gear: Select this position if the transmission tends to hunt between 3rd and 5th in certain driving conditions. Also recommended for lengthy descents (only available in
Steptronic mode).
2nd gear: Select this position when driving over mountain passes with lengthy ascents and
descents (only available in Steptronic mode).
Advantages:
1. Gang:
Function description 5 HP 19
ZFS, Department MKTD
March 1998
22
M-program
- manual
up-shifts
- manual
down-shifts
N
D
XE-program
S-program
The individual programs are no longer selected by the program button, but by moving the selector
lever to the appropriate gate.
XE - program
Adaptive Transmission Control (AGS)
S - program
Adaptive Transmission Control (AGS)
Function description 5 HP 19
ZFS, Department MKTD
March 1998
23
XE-program (AGS)
Standard drive program in position D.
P
R
N
D
The programs are selected by the electronic control unit, which automatically modifies the transmissions shift characteristics according to rolling
resistance, load, accelerator pedal movement and
the road situation.
S/D gate
Kick-Fast
evaluation
Driving
operation
evaluation
Braking
evaluation
Evaluation of the
type of driver
Downhill
driving
recognition
Fast-Off
recognition
Selector lever
Corner
recognition
Gear selection
Function description 5 HP 19
ZFS, Department MKTD
March 1998
24
S-program 5 HP 19 BMW
S-program
The S program is a performance-oriented program with the transmissions shift characteristics
moved up to higher engine speeds. To select the
program the selector lever is moved across into
the left gate, but without moving farther to + or -.
P
R
N
M-program 5 HP 19 BMW
M-program (one-touch mode)
The M program is a manual shift program which is
activated by pushing the lever to + or - in the left
gate.
P
R
N
D
Function description 5 HP 19
ZFS, Department MKTD
March 1998
25
Coding table
L1
L2
L3
L4
P Z1 R Z2 N Z2 D Z3 4
1 1 1 1 1 1 0 0 0
1 0 0 0 1 0 0 0 0
0 0 0 1 1 1 1 0 0
1 1 0 0 0 0 0 0 1
Function description 5 HP 19
ZFS, Department MKTD
3
0
0
1
1
2
1
0
1
1
March 1998
26
1
2
3
4
Pawl
Connecting rod
Output shaft
Parking lock gear
Function description 5 HP 19
ZFS, Department MKTD
March 1998
27
In 1st gear, the power is introduced from the torque converter purely hydraulically to the front planetary gear train . The connection between the converter turbine and the sunwheel (2) in the planetary
gear set is established by a rotating multi-plate clutch, clutch A. The freewheel beneath the multi-disc
brake D locks the planetary gear sets spider when rotating to the left. Sunwheel 2 drives the planetary
gears that are meshed with planetary gears I. These in turn drive the ring gear which is connected to
the ring gear support and the ring gear (interior disc support brake G) of the in-series planetary gear
set by a spider shaft.
The multi-disc brake G blocks the sunwheel of the rear-mounted planetary gear set via the cylinder of
the multi-plate clutch F. This causes the spider to be driven.
The spider is connected with the output shaft.
Spider speed = output speed
In 1st gear, with braking effect when coasting, the multi-disc brake D is also engaged, i.e. the spider
of the front planetary gear set is blocked.
Ring gear
Short planetary gear
Long planetary gear
Sunwheel 1
Planet carrier
Sunwheel 2
Function description 5 HP 19
ZFS, Department MKTD
March 1998
28
In the same way as for the 1st gear, the sunwheel 2 of the front planetary gear set is driven via the turbine shaft and clutch A.
The sunwheel 1 is locked by the multi-disc brake C.
Planetary gears 2 drive planetary gears 1, which roll around the stationary sunwheel 1.
Output is as for 1st gear via the ring gear of the front and the in-series planetary gear set, the spider
and simultaneously the output shaft.
Ring gear
Short planetary gear
Long planetary gear
Sunwheel 1
Planet carrier
Sunwheel 2
Function description 5 HP 19
ZFS, Department MKTD
March 1998
29
The sunwheel 2 is once again, as for gears 1 and 2, driven via the converter turbine shaft and clutch
A. Multi-disc brake C blocks the sunwheel 1. The planet carriers 2 drive the planetary gears 1 which
roll around the stationary sunwheel 1. Output is then accomplished, as in gears 1 and 2, via the ring
gear of the front and the in-series planetary gear set. The planetary gears are driven via the ring gear
through the engaged multi-plate clutch F. Unlike in 1st and 2nd gears, through-drive in the rear-mounted planetary gear set is thus achieved.
Ring gear
Short planetary gear
Long planetary gear
Sunwheel 1
Planet carrier
Sunwheel 2
Function description 5 HP 19
ZFS, Department MKTD
March 1998
30
Power is transmitted via the turbine shaft with the multi-plate clutches A and E engaged.
Multi-plate clutch A drives the sunwheel 2 and multi-plate clutch E the spider of the front planetary
gear set at engine speed.
The ring gear is driven to the right (in the direction of engine rotation) as a result of the inertial thrust
of the vehicle mass thrust, thereby locking the planetary gears (through-drive at the front planetary
gear set). Consequently, the ring gear of the rear-mounted planetary gear set is driven at engine speed.
The planetary gear of the rear-mounted planetary gear set is driven by the engaged multi-plate clutch
F via the ring gear and the sun wheel. In this way, through-drive is achieved in the rear planetary gear
set as well.
Ring gear
Short planetary gear
Long planetary gear
Sunwheel 1
Planet carrier
Sunwheel 2
Function description 5 HP 19
ZFS, Department MKTD
March 1998
31
Power transmission is via the converters turbine shaft and the engaged multi-plate clutch E. The inner
plate carrier of the clutch E meshes with the planetary spider.
The sun wheel 1 is locked via the body of multi-disc brake C.
The planetary gears 1 then roll around the sunwheel 1 and thereby drive the ring gear of the rearmounted planetary gear set which is in the through-drive setting as in 3rd and 4th gear.
Ring gear
Short planetary gear
Long planetary gear
Sunwheel 1
Planet carrier
Sunwheel 2
Function description 5 HP 19
ZFS, Department MKTD
March 1998
32
Power transmission is via the turbine shaft and cylinder A (which is also the inner plate carrier of
clutch B) to the engaged multi-plate clutch B.
The engaged multi-plate clutch B transmits the power to the sunwheel 1 via the body.
Multi-plate clutch D is engaged and locks the planetary spider.
The planetary gears 1 thus cause the sunwheel 1 and the ring gear, which is connected via the spider
shaft to the ring gear carrier and the ring gear of the in-series planetary gear set (inner disc carrier,
brake G) , to reverse direction.
Ring gear
Short planetary gear
Long planetary gear
Sunwheel 1
Planet carrier
Sunwheel 2
Function description 5 HP 19
ZFS, Department MKTD
March 1998
33
Function description 5 HP 19
ZFS, Department MKTD
34
N = Neutral (DIN)
WK 3rd-5th
D, 5-4 traction
M, 1st
D, 5th
D, 4th
D, 3rd
D, 2nd
D, 1st
N = Neutral
R = Reverse
POS / GEAR
MV
*-*
MV + EDS LOGIC
EDS
*
*
CLUTCH
*-
*-
BRAKE
CLUTCH LOGIC
5 HP 19 E 18
1. G.
FREEWHEEL
March 1998
Power flow 5 HP 19
Power flow, 5 HP 19 version
Clutch
Brake
Freewheel
Ratio
i
Ratio
steps
PHI
Total
Function description 5 HP 19
ZFS, Department MKTD
March 1998
35
(MV)
(EDS) electronic pressure control
Turbine (turbine speed, transmission)
Output (output speed, transmission)
are arranged in such a way that they are accessible when the transmission is installed on the vehicle
(see drawing).
The temperature sensor is integrated into the wiring harness on the control-unit side.
Oil filter
Turbine
speed
sensor
Function description 5 HP 19
ZFS, Department MKTD
System pressure
control
Hydraulic
selector unit
Solenoid valves
and shift pressure
controls
Output speed
sensor
March 1998
36
(KV-C)
(KV-G)
(KV-A)
(KV-E)
(ZV5-4)
(HD-V)
(HV-C)
(HV-G)
(WS)
Function description 5 HP 19
ZFS, Department MKTD
March 1998
37
Selector valve
The driver of the vehicle selects the direction of travel (forward or reverse), the park position and the
neutral position via the selector valve.
Function description 5 HP 19
ZFS, Department MKTD
March 1998
38
Valve housing II
Solenoid valve 1
(MV1)
Solenoid valve 2
(MV2)
Solenoid valve 3
(MV3)
(EDS 2)
(EDS 3)
(EDS 4)
Traction/coasting valve
(ZS-V)
(SV-WD)
Shift valve 1
(SV-1)
Shift valve 2
(SV-2)
Shift valve 3
(SV-3)
Reverse-gear valve
(RG-V)
(DRV-1)
Function description 5 HP 19
ZFS, Department MKTD
March 1998
39
Type:
Pressure range:
Rated voltage:
Nom. diameter:
Starting current:
Plate-armature valve
0 to 5 bar
12 V
1.6 mm
166 mA
Tolerance range
for falling pressure
characteristic
Adjusting point
Hysteresis
for rising pressure characteristic
Function description 5 HP 19
ZFS, Department MKTD
March 1998
40
Dimension A
Gap:
Interior resistance:
Function description 5 HP 19
ZFS, Department MKTD
March 1998
41
Hall-effect sensor
Plug
V+
V-
Electronic circuit
Hall I. C.
- Bipolar mono-cell
- 75 G
Function description 5 HP 19
ZFS, Department MKTD
March 1998
42
Function description 5 HP 19
ZFS, Department MKTD
March 1998
43
(Schm.-V)
(WK-V)
(WD-V)
(ZV 4-> 5)
Function description 5 HP 19
ZFS, Department MKTD
(Mod-V)
(DRV II)
(DR-P)
March 1998
44
Function description 5 HP 19
ZFS, Department MKTD
March 1998
45
Function description 5 HP 19
ZFS, Department MKTD
March 1998
46
From transmission
Turbine speed
Output speed
Transmission temp.
From vehicle
Engine speed
Engine torque
Throttle butterfly
Engine temperature
(all engine
signals are
transmitted via
CAN bus)
Kick-down
P, R, N, D (4, 3, 2 -one-touch mode)
Program (manual)
Brake light
Signals from other vehicle systems
(digital)
(digital, encoded)
(digital)
(digital)
March 1998
47
Function description 5 HP 19
ZFS, Department MKTD
48
March 1998
Note
Bridge to pin 4.31
Modular plug inputs and outputs are divided according to functional groups.
Pin assignment
The middle row of contacts in the power circuits have a leading function, in
the signal circuits the upper and lower row of contacts have a leading function.
A modular plug contact system with 5 chambers is used at the control unit end
(BMW diagram x xxx xxx) as a pin contact system. The pin housing for the
transmission control is to be blue so it can be distinguished from other control
units. The connectors are not encoded. The drawing numbers have yet to be
defined.
Connector specifications
only 5 HP 24
only 5 HP 24
only 5 HP 24
Note
Function description 5 HP 19
ZFS, Department MKTD
49
March 1998
GE
GR
OR
WS
BL
WE
GE
GR
GN
GE
RT
VI
OR
WS
VI
yellow
grey
orange
white
blue
white
yellow
grey
green
yellow
red
violet
orange
white
violet
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Function description 5 HP 19
ZFS, Department MKTD
March 1998
50
Important!
Function description 5 HP 19
ZFS, Department MKTD
March 1998
51
TRANSMISSION TYPE:
TRANSMISSION POWER
HANDLING CAPACITY:
Tmax
Pmax
nmax
nmax
nmax
Tmax
CONVERTER:
RATIOS:
1st gear
2nd gear
3rd gear
4th gear
3.67
2.0
1.41
1.0
Gears:
= 300 Nm
= 150 kW (204 bhp)
= 6,540 min-1
= 5,000 min-1
= 6,400 min-1
= 540 Nm
POSITIONS:
P, R, N, D (4, 3, 2)
CONTROL:
Electro-hydraulic
Various shift programs available
4.10
Engine application
5HP18
5HP19
Difference
M52B28
M52B25
M52B20
84.0kg
84.0kg
79.8kg
79.5kg
78.9kg
76.6kg
4.5kg
5.1kg
3.2kg
TRANSMISSION OIL:
Function description 5 HP 19
ZFS, Department MKTD
March 1998
52
Notes
Function description 5 HP 19
ZFS, MKTD department
March 1998
53
Notes
Function description 5 HP 19
ZFS, Department MKTD
March 1998
54