ZFEcomat 35p.pptneevia

Ne
ev
ia
Do
cu
The Automatic Transmission for

BELL Articulated Dump Truck
en
tC
on
ve
rte
rP
4149 763 103a
ro
v6
.0
Ne
ev
ia
BELL
Articulated Dump Truck (ADT)
Do
cu
en
tC
B 25 D
017320
on
B 20 C
017321
ve
rte
rP
4149 763 103a
ro
B 25 C
017322
PB_001_en
B 30 C
017323
ZF-Ecomat 2 - BELL-ADT
v6
.0
Ne
ev
ia
Ecomat
4149 763 103a
ZF-Ecomat
Advantages in the BELL-ADT
Do
cu
m
is compact and has a low weight
en
is off-road proven in civil t
and military application
Co
has a primary retarder system that
brakes perfect in high
n
ve
and low speed ranges
r
te for shiftable
has two engine dependent PTO connections
rP
or live PTO
r
o
has secondary steering pump system
v6
.0
PB_002_en
Ne
ev
ia
ZF-Ecomat
Special Vehicles Application
Do
cu
Articulated Dumper
NAFTA
Germany
Great Britain
France
Europe (others)
International
30 %
15 %
10 %
10 %
15 %
20 %
en
tC
12 000 units
on
20 international OEM
Rail Vehicles
3 international OEM
Duewag
97
Adtranz
987
AEG
4
4149 763 103a
Military Vehicles
6 800 units
ve
rte
rP
ro
1 088 units
v6
19 888 units
PB_003_en
.0
Ne
ev
ia
Civil Vehicles with ZF-Ecomat
Do
200 000 Ecomat are already on the road
cu
Most of them in City-bus application - a very hard job
4149 763 103a
Other bus applications

line service
coaches
en
Trucks with Ecomat

concrete mixers
dumpers
road sweepers
garbage collectors
fire tenders
oil rig carriers
airport lift launches
crane vehicles
PB_004_en
tC
on
012633
ve
rte
rP
017199
ro
v6
.0
017231
Ne
ev
ia
Military Vehicles with ZF-Ecomat
Do
ZF-Ecomat applications in military vehicles
cu
Application in heavy weight vehicles up to 25 / 30 tons
en
Extreme off-road capability
tC
Fulfills the national or / and the extreme NATO-test for the

drive line
on
Proven in the Operation Desert Storm and in UN-Balkans

missions
ve
Full military / NATO logistics

Emergency shift and steering device
4149 763 103a
Simple service
Perfect diagnosis tools
PB_005_en
rte
rP
ro
v6
.0
011099
Ne
ev
ia
ZF-Ecomat
Military Application
Do
4149 763 103a
OEM-name
Wheeled vehicles
Henschel
Steyr
Enasa
Elbo
Krupp
Panhard
Sibmas / MAN
Timoney
Faun (crane)
RVI
Talbot
Sides
Komatsu
Foden
EWK
Mowag
Unipower
Astra
PB_006_en
Units produced
cu
OEM-name
2 896
324
1 565
62
3
5
423
2
233
376
110
99
1
428
85
36
136
7
Units produced
Tracked vehicles
OTO-Melara
Krauss Maffei
en
5
7
tC
on
ve
Total
6 800
rte
rP
ro
v6
.0
Ne
ev
ZF-Ecomat
Production Figures
Do
Transmissions / year
ia
cu
en
tC
011740
on
ve
rte
rP
Total
4149 763 103a
Share of 5-speed
transmissions
ro
Share of Ecomat 2
017109
PB_007_en
Year
v6
.0
Ne
ev
ia
ZF-Ecomat 2
HP 502 C / HP 592 C / HP 602 C
Do
In recent years Articulated Dump Truck (ADT)

transmission technology has developed into
intelligent systems. These systems (engine,
transmission, brakes, etc.) depend on the
exchange of information for perfect function.
This exchange of information is based on the
transmission of electronic signals by means
of CAN* technology.
Together with vehicle manufacturers, ZF has
developed the software for the common interfaces.
cu
en
tC
on
*CAN = Controller Area Network
012326
ve
rte
rP
The ZF-Ecomat 2 meets the requirements for the use of the latest technology
for Articulated Dump Trucks (ADT).
Advantages:
Reduced operating costs
Optimized fuel consumption
Increased reliability
Easy diagnosis
4149 763 103a
ro
PB_008_en
v6
.0
Ne
ev
ia
ZF-Ecomat 2
CAN Communication
Do
The new electronic control units EST 46 C and EST 47 C

EST 46 C:
cu
Communication (CAN)
Diagnosis
EST 47 C:
en
SAE J1939 or
IES-CAN
ISO 9141
tC
Communication (CAN)
Diagnosis
Advantages of CAN communication:
SAE J1939
SAE J1587 / J1708
on
010167
ve
rte
Reduces
number of cables and plugged connections
Communicates
constantly with all components of the drive train
Allows
optimum engine and brake management

minimum brake wear
rP
ro
4149 763 103a
optimum gearshifts due to engine and pressure control

Diagnoses
PB_009_en
the drive train system and facilitates service
v6
.0
Ne
ev
ia
ZF-Ecomat 2
Benefits for the Customer
Do
4, 5 or 6 speeds
for any kind of ADT and truck
Starting converter
prompt activation - fast lockup
cu
Smooth gearshifts
en
tC
Primary retarder
high brake performance - to near-standstill
on
CAN electronics
4149 763 103a
high driving quality
communication and control for all drive

train components
ve
rte
Longevity and easy maintenance
high degree of availability of vehicle

lowering of operating expenses
Diagnostic capability of the system
easy service
Extensive ZF service network
quick support and advice
Constant model policy
consistent modular system
PB_010_en
rP
ro
v6
.0
Ne
ev
ia
ZF-Ecomat 2
Modular System
Do
1 Converter module
cu
2 Oil supply module

3 Retarder module
4 Planetary gear
module
en
tC
on
ve
5 Transmission
control module
rte
4149 763 103a
6 PTO module
Transmission layout
at
i = 5.60 - 1.00
i = 5.60 - 0.83
PB_011_en
rP
ro
017326
v6
5
.0
Ne
ev
ia
ZF-Ecomat 2
Planetary Transmission Module
Do
The planetary transmission consists

of an interconnected system four
simple planetary gear sets.
Different clutch combinations give a
transmission either 5 or 6 forward
speeds.
For each gear change, only one
clutch or brake is actuated. Gear
changes can therefore be made
without interrupting tractive force.
This is the secret of their
excellent shift quality.
cu
LUC
en
tC
5th gear
on
2nd gear
ve
rte
4149 763 103a
6th gear
rP
3rd gear
Reverse
017341
PB_012_en
E F G
BC D
Close ratio steps

This feature enables you to drive
consistently in the most fuel-efficient
speed range.
Shift comfort
This enhances the safety of the
driver and is also gentle on the
driveline.
4th gear
1st gear
The main features of the planetary

transmission are:
LUC
E F G
BC D
Neutral
ro
v6
.0
017340
Ne
ev
ia
ZF-Ecomat 2
Technical Data
Do
cu
HP 502 C
en
500
015257
Range
4149 763 103a
HP 602 C
tC
2nd
3rd
900
on
4th
5 HP
1.0
6 HP
502 C
592 C 5.60 3.43 2.01 1.42
602 C
1.0
1200
Input torque [Nm]
rte
Installed length approx. mass in kg

6th Rev.
in mm L
(without PTOs)
5th
502 C
592 C 5.60 3.43 2.01 1.42
602 C
1100
ve
Ratios
1st
PB_013_en
HP 592 C
rP
4.84
795
0.83 4.84
795
ro
344
354
364
v6
356
366
376
.0
Ne
ev
ia
ZF-Ecomat 2
Transmission and Shifting
Do
ZF-Ecomat 2 offers:
Optimum shift quality and tailored shift programs
Longevity of the drive train and satisfied drivers
cu
The shift program is set according to the following criteria:

to the respective engine characteristics (Euro 2 / 3 / [4] / gas engines)
to the most economical speed range
to the drive train - engine / transmission / axle / tires
en
tC
on
The shift program provides intelligent response to:

current load condition through constant sensing of accelerator pedal position and engine torque
acceleration condition
through torque adjustment during shift process
brake condition (Retarder operation)
changing transmission parameters through shift pressure control
4149 763 103a
ZF-Ecomat 2: perfect for any use

Program variants:
Up to 6 program variants (POWER - ECONOMY) are stored
adjustment to individual application profile
PB_014_en
ve
rte
rP
ro
v6
.0
Ne
ev
ia
ZF-Ecomat 2
Transmission Control Module
Do
The transmission range

HP 502 C
HP 592 C
HP 602 C
cu
is equipped with a tried-andtested electro-hydraulic

transmission control system.
The shift impulses required
for control are supplied by
the electronic control unit
EST 46C / 47C.
en
tC
on
ve
rte
rP
ro
v6
4149 763 103a
017042
.0
PB_015_en
Ne
ev
ia
Operation:
ZF-Ecomat 2
Speed range Selector
Do
cu
Depending on the number

of speeds of the transmission
and the customers choice,
the selector is available for
ZF-Ecomat 2 operation.
Error signal:
To prevent transmission
damage, malfunctions are
signaled to the driver via
flash signals in the display
of the selector (flashing of
the shift drive range).
en
tC
on
ve
rte
rP
4149 763 103a
017329
ro
v6
.0
PB_016_en
Ne
ev
ia
ZF-Ecomat 2
Primary Retarder
Do
ZF-Ecomat 2 primary retarder combines optimum safety with

economy:
cu
No Articulated Dump Truck should be without the benefits of a

primary retarder
Stator
Rotor
en
ZF-Ecomat 2 is equipped with an independent, integrated retarder

module.
tC
on
Advantages of this design:
011817
Patented ZF grid
minimum drag
loss
The integrated primary retarder operates at engine speed and

provides smooth deceleration for any drive situation until nearstandstill of the vehicle
ve
rte
The primary retarder module is much more effective in Articulated

Dump Truck than secondary retarder systems or converter brake
systems
rP
ro
4149 763 103a
Longevity of the brake system is maximized

at least threefold lifetime as opposed to transmissions w/o retarder
at least twofold lifetime as opposed to secondary retarders or converter brakes
v6
.0
PB_017_en
Ne
ev
ia
ZF-Ecomat 2
Primary Retarder - Retarder Control
Do
ZF-Ecomat 2 primary retarder is continuously controlled by an

electric proportional valve.
cu
brake performance adjustment to vehicle weight
en
brake performance adjustment to:

present brake management system
tC
vehicle application
on
The EST 46 C / EST 47 C controls transmission functions and the

primary retarder. The following control and protective functions
are integrated:
ve
rte
twofold oil temperature control in transmission

smooth brake torque and limitation
4149 763 103a
017113
ro
Due to these protective functions thermal load peaks are avoided

and transmission lifetime secured.
Electrical retarder control

via proportional valve
PB_018_en
rP
v6
.0
Ne
ev
ia
ZF-Ecomat
Primary Retarder - Retarder Control
Do
1 EST 46 C electronic
shift control unit
2 Speed range selector

console lever
3 Vehicle circuit
4 Retarder control,
e.g. using brake
pedal or lever on
steering column
cu
en
tC
on
ve
rte
5 Retarder temperature
senor
4149 763 103a
rP
6 Retarder proportional
valve
7 Retarder Accumulator
ro
v6
.0
PB_019_en
Ne
ev
ia
11 o`clock
pos.
ZF-Ecomat
Engine-driven Power Take-offs
Do
1 o`clock pos.
Direct installation of
hydr. pump
Versions:
cu
Installation position:
permanentlydriven
017349
11 o`clock pos. 60
Direction of rotation
of the output shaft:
en
engagable
Versions:
engagable with
spur gear drive
tC
Output speed:
nout = 0.97 x neng
on
017352
ve
300
4149 763 103a
rP
ro
Output speed (optional):

nout = neng x 0.68, 1.38
1.43, 2.12
(o`clock)
1
017355
11 and/or 1
oclock
Direction of rotation
of the output shaft:
11
017350
Installation position:
rte
Possible operating angle

in install. 60
90
position
PB_020_en
11 and/or 1
oclock
v6
.0
(viewed facing transmission output)
Ne
ev
ia
ZF-Ecomat - Comfortable Single Lever

Operation for Transmission and Power Take-off
Do
1 Console speed range

selector
cu
2 On / off switch for PTO unit

3 Vehicle electric circuit
4 Engine-driven PTO
(1 o`clock position)
en
tC
on
017356
... N (neutral)
PTO switch (2)

on and
Vehicle stationary
PTO in operation
Selector lever (1)

in position ...
4149 763 103a
ve
Function:
017357
PB_021_en
rte
rP
... D, 1, 2, 3 or R
Vehicle in motion,
PTO disengaged
ro
017358
v6
.0
Ne
ev
ia
ZF-Ecomat
Auxiliary Units
Do
Secondary pump (1)
cu
Takes on function of primary

pump when engine is stationary
and vehicle is in motion
this makes it possible to
tow-start or tow the vehicle
en
tC
on
ve
Emergency steering pump (2)
rte
Takes on function of steering

pump when engine is stationary
and vehicle is in motion
maintains servo-assistance
to the power steering unit
2
004719
4149 763 103a
rP
ro
v6
.0
PB_022_en
Ne
ev
ia
ZF-Ecomat
Coolant Circuit
Do
Preferred coolant circuit designs: Transmission oil cooler in main circuit ...
Plan view
cu
Side view
Transmission
oil connection
Transmission
oil cooler
en
Coolant
expansion
tank
tC
Heating
on
... arranged on
pressure side
of cold water
circuit
ve
rte
Cooler
Ecomat
transmission
In-line engine
rP
4149 763 103a
ro
Transmission
oil cooler
PB_023_en
Coolant
water pump
015271
v6
.0
Ne
ev
ia
ZF-Ecomat 2
Maintenance
Do
Regular maintenance is a prerequisite for transmission

longevity and low operating costs
cu
en
Pay attention to the following 7 points:

1. Outgoing
inspection:
* Documents are available
free of charge from:
ZF Friedrichshafen AG
Werk II / Abt. MKS-KD4
Leutholdstr.
2. Oil type:
3. Coolant:
Done by truck manufacturer, ZF-Service

or by yourself?
(see check list / ZF order no. 4149 754 101*)
tC
on
Transmission oil released?

(compare lube list / ZF order no. 1205 754 114*)
ve
rte
Trucks specifications must be observed

(no tap water)
88038 Friedrichshafen
4. Training:
ro
Your workshop staff are trained by ZF?

(free service for your ZF agency)
4149 763 103a
Fax:
+ 49 (0) 7541 77 5380
e-mail: documentation.zff@zf.com
rP
v6
.0
PB_024_en
Ne
ev
ia
ZF-Ecomat 2
Maintenance
Do
5. Regular
maintenance:
cu
en
6. Operating
instructions:
* Documents are available

free of charge from:
ZF Friedrichshafen AG
Werk II / Abt. MKS-KD4
Leutholdstr.
7. Customer:
service
acc. to operating instructions

(ZF order no. 4149 758 101*) Section 4.5 / 4.6
For oil change intervals see ZF lube list
Available to you and known?

Can be a part of the operating instructions of the
truck manufacturer or ordered from ZF
tC
on
ve
When problems occur - who analyzes and repairs?

Do you want to repair yourself?
Contact your ZF agent.
rte
rP
88038 Friedrichshafen
ro
4149 763 103a
Fax:
+ 49 (0) 7541 77 5380
e-mail: documentation.zff@zf.com
v6
.0
PB_025_en
Ne
ev
ia
ZF-Ecomat 2
Diagnosis - ZF-Testman
Do
RS 232cable
The ZF Diagnosis Software Testman is configured as follows.

It is installed on a commercial PC or Laptop.
cu
017104
017105
ZF-Diagnosis - adapter
DPA 04I
ISO-cable
Repair aid
017106
SAE-cable
017107
4149 763 103a
ZF Diagnosis Software
Testman on 3 floppy disks
Enhanced diagnosis with

ZF-Testman
fast, easy, efficient
PB_026_en
en
Electronic diagnosis
ZF-Testman
tC
Diagnosis
on
Test
inputs and
outputs
Vehicle
configuration
ve
Functions:
Choice of language
Automatic determination of vehicle configuration
transmission identification (O.D. / D.D. / converter / etc.)
Test of signal outputs and inputs
Readout of error memory (w/ error search tips)
allows identification of the conditions leading to the error
Maintenance and repair instructions
System check with vehicle standing still or moving
rte
rP
ro
v6
.0
Ne
ev
ZF-Ecomat
ia
Versatile Product with an International Track Record
Do
cu
m
017230
010897
en
tC
017359
on
ve
rte
017199
017360
rP
011108
4149 763 103a
ro
011109
PB_027_en
015142
v6
.0
017231
Ne
ev
ia
ZF-Ecomat 2
Quality Assurance
Do
ZF-Ecomat 2 - housing inspection
cu
Quality assurance has a very high ranking at ZF.

To ensure frictionless functioning of our products
for their entire lifetime, considerable efforts are
made. Modern quality assurance systems directly
influence processes in design, production, and
assembly.
en
tC
These efforts aim at achieving and maintaining 100

% customer satisfaction.
on
ve
rte
rP
4149 763 103a
Housing inspection - ZF-Ecomat 2
ro
015125
v6
.0
PB_028_en
Ne
ev
ia
ZF-Ecomat 2
Transmission Assembly
Do
Central assembly line
cu
At modern assembly cells the individual

components are pre-assembled, inspected and
then move on to the central assembly line.
en
tC
There the ZF-Ecomat 2 transmission housings are

completed by qualified staff in several assembly
steps in which the order-specific components are
mounted.
on
ve
rte
017043
rP
4149 763 103a
Central assembly line ZF-Ecomat 2
ro
017043
v6
.0
PB_029_en
Ne
ev
ia
ZF-Ecomat 2
Functional Check Before Delivery
Do
Functional check on load test bench
cu
Before a ZF transmission is dispatched, all

transmission functions are checked on a load
test bench. This way errors can be detected
and immediately rectified.
en
tC
Benefit for the customer:

Only inspected transmissions are dispatched.
on
ve
rte
017044
rP
4149 763 103a
Functional test on load test bench
ro
017044
v6
.0
PB_030_en
Ne
ev
ia
ZF-Ecomat
Production Location
Do
The ZF-Ecomat is
manufactured in the
Commercial Vehicle
Transmissions Division in
Friedrichshafen, also home
to many other successful
models of truck and bus
transmission.
cu
en
tC
on
ZF supplies a wide range of

driveline, steering and
suspension products.
ve
rte
rP
4149 763 103a
Plant II
ro
v6
.0
PB_031_en
Ne
ev
ia
ZF-Service Network
Europe
Do
cu
en
tC
on
ve
rte
rP
4149 763 103a
ro
= ZF-Service for ZF-Ecomat transmissions

PB_032_en
v6
.0
Ne
ev
ia
ZF-Service Network
Worldwide
Do
cu
en
tC
on
ve
rte
rP
4149 763 103a
ro
= ZF-Service for ZF-Ecomat transmissions
PB_033_en
v6
.0
Ne
ev
ia
ZF-Service Offers ...
Do
cu
Technical
assistance
Training
en
Field Service
Personnel
tC
on
Warranty
Long-term maintenance
back-up
Repairs
Exchange
transmissions
4149 763 103a
Documentation
ve
rte
Spare part
proposals
rP
ro
Special tools
Testers
v6
.0
PB_034_en

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The Automatic Transmission for

4149 763 103a

4149 763 103a

4149 763 103a

4149 763 103a

Civil Vehicles with ZF-Ecomat

200 000 Ecomat are already on the road

Most of them in City-bus application - a very hard job

4149 763 103a

Other bus applications

Trucks with Ecomat

Military Vehicles with ZF-Ecomat

ZF-Ecomat applications in military vehicles

Application in heavy weight vehicles up to 25 / 30 tons

Extreme off-road capability

Fulfills the national or / and the extreme NATO-test for the

Proven in the Operation Desert Storm and in UN-Balkans

Full military / NATO logistics

4149 763 103a

4149 763 103a

In recent years Articulated Dump Truck (ADT)

*CAN = Controller Area Network

4149 763 103a

The new electronic control units EST 46 C and EST 47 C

Advantages of CAN communication:

number of cables and plugged connections

constantly with all components of the drive train

optimum engine and brake management

4149 763 103a

optimum gearshifts due to engine and pressure control

the drive train system and facilitates service

for any kind of ADT and truck

prompt activation - fast lockup

high brake performance - to near-standstill

4149 763 103a

high driving quality

communication and control for all drive

Longevity and easy maintenance

high degree of availability of vehicle

Diagnostic capability of the system

Extensive ZF service network

quick support and advice

Constant model policy

consistent modular system

2 Oil supply module

4149 763 103a

The planetary transmission consists

4149 763 103a

Close ratio steps

The main features of the planetary

4149 763 103a

Input torque [Nm]

Installed length approx. mass in kg

The shift program is set according to the following criteria:

The shift program provides intelligent response to:

4149 763 103a

ZF-Ecomat 2: perfect for any use

The transmission range

is equipped with a tried-andtested electro-hydraulic

4149 763 103a

Depending on the number

4149 763 103a