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Technical Manual

For Installation, Functions,


And Initial Start-Up

HP 502 / HP 592 / HP 602


for city buses, buses running in line service, and coaches
4149 765 103
Subject to alterations in design

Copyright by ZF

This documentation is protected by copyright.


Any reproduction or dissemination in whatever
form which does not comply fully with the intended
purpose of this documentation is prohibited without
the consent of ZF Friedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, MC-C

Edition: 2004-12

4149 765 103


ZF-Ecomat 2 plus Important Information

Important Information Safety instructions

This Ecomat Technical Manual provides a technical The following safety instructions appear in this
basis for the Ecomat 2 plus system and has been manual:
produced for the benefit of vehicle and body manu-
facturers as well as ZF employees. NOTE
This manual contains answers to questions ranging Refers to special processes, techniques, data, use of
from specifications to installation inspection and auxiliary, etc.
commissioning.
CAUTION
This manual provides the basis for specifications of This is used when incorrect, unprofessional wor-
the transmission and peripheral units. king practices could damage the product.

Optimum procedure leading up to volume produc-


tion delivery: ! DANGER
Specification of transmission, automatic electronic This is used when lack of care could lead to personal
shift control unit and peripheral units performed injury or death.
by vehicle manufacturer and ZF using the
Questionnaire for parts list preparation.
Documentation by ZF.
Initial installation. ! THREATS to the environment !
Initial installation inspection carried out by ZF Lubricants and cleaning agents must not be allowed
staff. to enter the soil, ground water, or sewage system.
Start-up carried out by ZF staff. Request safety information for the products
ZF release certificate. concerned from your local environmental protec-
Authorization conform to certificate release. tion authority, and follow any instructions herein
at all times.
ZF can bear responsibility for any errors in the Collect used oil in a suitably large container.
initial installation only if sign-off has been perfor- Dispose of waste oil, used filters, lubricants, and
med by authorized ZF personnel and if all defects detergents in compliance with the stipulations of
found by ZF have been rectified by the vehicle or the environmental protection laws.
bodywork manufacturer. The vehicle or bodywork Always observe manufacturer instructions when
manufacturer shall bear sole responsibility for any dealing with lubricants and cleaning agents.
damage caused by defects attributable to the
vehicle or body manufacturer which could not be
detected by ZF personnel during initial sign-off.

If you require additional information concerning


installation and the installation inspection, we have
prepared an "Installation Guidelines" manual in
addition to the Ecomat technical manual. When
installing the transmission, these installation guide-
lines must be observed. If you have any questions or
improvement suggestions, please contact our depart-
ment: BPE1 - ECOMAT Application Engineering
department.

4149 765 103 - 2004-12 3


ZF-Ecomat 2 plus Contents

1 System solution Ecomat 2 plus

2 Description of transmission and technical data

3 Ecomat 2 plus installation position in vehicle

4 Installation arrangement and mountings

5 Guidelines for propshaft installation

6 Engine connection

7 Converter

8 Retarder

9 Cooling system

10 Transmission specification

11 Hydraulic circuit diagrams

12 Periperal equipment

13 Neutral at standstill

14 Temperature monitoring

15 Electronic automatic control system EST 146 / 147

16 Wiring

17 ZF documentation

18 Calculations and conversion tables

19 Oil grades and oil filters

4149 765 103 - 2004-12 5


ZF-Ecomat 2 plus Contents

1 System solution Ecomat 2 plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1


1.1 System solution Ecomat 2 plus (with CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 System solution Ecomat 2 plus (with load sensor, without CAN) . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 System solution Ecomat 2 plus (with PWM signal, without CAN) . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 Description of transmission and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


2.1 Transmission brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Transmission structure and auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Transmission ratios and powerflow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Torque assignment - vehicle weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Torsional vibration in driveline - inertia torques - vibration substitution model . . . . . . . . . . . . 2-8
2.6 Weights and inertia torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.1 Coaxial output without heat exchanger J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.2 Coaxial output with heat exchanger J01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.6.3 Coaxial output with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.6.4 Coaxial output with heat exchanger J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6.5 Angle drive 80 without offset, with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.6 Angle drive 80 without offset, with heat exchanger J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6.7 Angle drive 80 RHD (with right offset), with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.6.8 Angle drive 80 RHD (with right offset), without heat exchanger J08 . . . . . . . . . . . . . . . . . . . . 2-19
2.7 Clutch combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

3 Ecomat installation position in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 Installation arrangement and mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


4.1 Transmission flange-mounted on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 Guidelines for propshaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1


5.1 Permissible rotational irregularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Permitted resultant deflection angle for each joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 The permitted resultant flexure angle for all joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Single-section propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Multi-section propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6 Maximum permissible propshaft length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6 Engine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1


6.1 ZF Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2 Engine connection inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 Engine connection drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Overview converter-circuit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

7 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Torque converter: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Converter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Getting the right torque converter for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Torque converter diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Torque converter basic curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

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ZF-Ecomat 2 plus Contents

8 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Structure and function of retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Retarder action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 Retarder and engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Retarder activation variants hand and foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Permitted variants foot request without hand request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.2 Permitted variants foot request without hand request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.5.3 Permissible retarder activation variants "Foot" and "Hand" combined . . . . . . . . . . . . . . . . . . . . 8-7

9 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1


9.1 Design of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Release criteria for temperature measurements (max. ambient temperature = 40 C) . . . . . . . . 9-1
9.1.1.1 According to List of Lubricants TE-ML 14 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1.2 According to List of Lubricants TE-ML 14 A / B / C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2 Limit temperature values for oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.3 Cooling system with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.3.1 Cooling system graph of shell type cooler SBK 279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.4 Cooling system without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.4.1 Delivery volume of the primary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Position of transmission oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Cooler fitted on transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Layout with oil cooler separate fromtransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Oil line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Cooling water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.6 Specification for transmission heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7 Required performance of cooling water and antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.2 Fresh water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.3 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.4 Cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.8 Transmission fill with auxiliary cooling
(applicable to all transmissions approved for use with auxiliary cooling) . . . . . . . . . . . . . . . . . 9-9
9.9 Transmission oil sump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.9.1 System diagram, transmission oil sump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.10 Temperature measurements in bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.1 Measurement conditions / Retarder test cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.2 Measurement retarder cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.3 Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.4 Explanation of water temperature Retarder cycle (worst case) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.10.5 Temperature measuring points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

10 Transmission specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1


10.1 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.1.1 Flange-mounted installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2 Heat exchanger arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.1 Coaxial output, heat exchanger at rear, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . 10-5
10.2.2 Coaxial output, heat exchanger at rear, accumulator rear transverse . . . . . . . . . . . . . . . . . . . . . 10-6

4149 765 103 - 2004-12 7


ZF-Ecomat 2 plus Contents

10.2.3 Coaxial output or 80 angle drive RHD (with axial offset), heat exchanger
vertical on left, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2.4 Angle drive 80 LHD (without axial offset), heat exchanger horizontal on left,
accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.5 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left . . . . . . . . . . . 10-9
10.2.6 Coaxial output, vertical heat exchanger on right, accumulator rear transverse . . . . . . . . . . . . . 10-10
10.2.7 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting . . . 10-11
10.2.7.1 Cooler connection piece with threaded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.3 Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3.1 Deep oil pan, 4149 131 002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3.2 Deep oil pan; left- and right-hand connection prepared, 4149 131 006 . . . . . . . . . . . . . . . . . . . 10-14
10.3.3 Deep oil pan, auxiliary cooling, 4149 131 024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10.3.4 Flat oil pan, 4149 131 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.3.5 Flat oil pan; left- and right-hand connection prepared, 4149 131 009 . . . . . . . . . . . . . . . . . . . . 10-17
10.4 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.4.1 Oil filling <K 01> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.4.2 Oil filling <K 02>, <K 04>, <K 05> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.4.3 Oil filling <K03>, <K 06> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
10.4.4 Oil filling <K 09> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10.5 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.5.1 Coaxial output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.5.2 80 angle drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.5.3 Output flange 80 angle drive LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.4 Ecomat output flange; coaxial and angle drive 80 RHD with axial offset . . . . . . . . . . . . . . . . . 10-27

11 Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1


11.1 Hydraulic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2 Hydraulic diagram (with Bus Stop Neutral / NBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

12 Peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1


12.1 Speed range selector - push button switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.2 CAN range selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.3 Load sensor A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.3.2 Load sensor drawing, Drawing no.: 0501 209 635 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.4 PWM-Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.4.1 Calibration of the PWM Signal, Positive Impulse Flank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.4.2 Sensing ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
12.4.3 Signal Spezification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
12.5 Additional temperature sensor A6 for temperature display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
12.6 Temperature display A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
12.7 Kick down switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
12.7.1 Kick down switch S1 (Holding switch - high holding force), Drawing no.: 6007 603 030 . . . . . 12-13
12.8 Pressure switch S7 - NBS (Neutral when Stationary), Drawing no.: 0501 311 584 (a) . . . . . . . . 12-15
12.9 Changeover relay, e.g. range selector relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

13 Neutral at standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1


13.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.2 Connection diagram (electric), Drawing no.: 4139 720 045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

4149 765 103 - 2004-12 8


ZF-Ecomat 2 plus Contents

13.3 Neutral at Bus Stop - display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3


13.3.1 NBS active display via digital signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.3.2 NBS Active Display via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

14 Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1


14.1 Temperature information via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.2 Temperature information via temperature sensor A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.3 Temperature information from DM1 note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.4 Temperature warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.5 Addtional temperature sensor A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
14.6 Temperature display gauge A5, Drawing no.: 0501 204 074 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
14.7 Resistance characteristics - Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4

15 Electronic automatic control system EST 146/147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1


15.1 Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.2 Intended standard functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.3 Functions available on request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
15.4 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
15.5 Technical data of EST 146 / 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
15.6 Installation drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
15.6.1 Installation drawing EST 146, Drawing no.: 6009 690 001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
15.6.2 Installation drawing EST 147, Drawing no.: 6009 691 001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
15.7 Current circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
15.7.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector,
Drawing no.: 6029 729 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
15.7.2 Current circuit diagram EST 146 / EST 147 with CAN, with CAN range selector,
Drawing no.: 6029 729 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
15.7.3 Current circuit diagram EST 146 / EST 147 without CAN(NEng), with digital range selector,
Drawing no.: 6029 729 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
15.8 Pin pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
15.9 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
15.9.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector,
Drawing no.: 6029 729 156A / Pages 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
15.9.2 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector,
Drawing no.: 6029 729 233 / Pages 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
15.9.3 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range,
Drawing no.: 6029 729 216 / Pages 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
15.10 Function description EST 146 / 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23
15.11 ZF-Diagnosis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.1 ZF-Diagnosis protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.2 ZF-Diagnosis tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.2.1 ZF-Testman pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.2.2 Flash code output EST 146/147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-33
15.12 HST 46 auxiliary control unit EST 146 and EST 147 versions without CAN range selector . . . 15-35
15.12.1 Operating manual for HST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35
15.12.2 Technical data of HST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35
15.12.3 Dimensions of HST 46, Drawing no.: 6009 678 003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-36
15.13 Block diagram EST 146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-37
15.14 Block diagram EST 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-38

4149 765 103 - 2004-12 9


ZF-Ecomat 2 plus Contents

16 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.1 Complete wiring - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2 Complete wiring - With junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.3 Wiring connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.4 Wiring specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2

17 ZF documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1 ZF documentation with CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1.2 Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
17.2 ZF documentation without CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
17.2.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
17.2.2 Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
17.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5
17.3.1 Oil level check prior to first commissioning; transmission without oil filling . . . . . . . . . . . . . . 17-5
17.3.2 Oil level check prior to first commissioning; Transmission oil filing at plant . . . . . . . . . . . . . . 17-6
17.3.3 Oil level check prior to first commissioning;
Transmission with additional cooling system, with or without oil filling at plant . . . . . . . . . . . 17-7

18 Calculations and conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1


18.1 Driveline design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.2 Collective formulae for retarder and cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
18.3 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.3.1 Units of length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.3.2 Units of area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.3.3 Units of volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4
18.3.4 Units of energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4
18.3.5 Masseeinheiten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
18.3.6 Force units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-6
18.3.7 Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-7
18.3.8 Temperature conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-7
18.3.9 Moment of inertia conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8
18.4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8
18.5 List of dynamic tire radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8

19 Oil grades and oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1


19.1 List of Lubricants TE-ML 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.2 Purity of medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.3 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

4149 765 103 - 2004-12 10


ZF-Ecomat 2 plus System solution

1 System solution Ecomat 2 plus

1.1 System solution Ecomat 2 plus (with CAN)

8 Brake
Accelerator
1 2
3D
NR
16 Engine
Displays
13 12 2 ....
17 ....
CAN-Bus
20
11
6
7
10

1
4 9
21

14
15 18
5
19

023778_en

Key to drawing
1 Transmission electrical unit connector 11 Accelerator pedal
2 EST 146- / EST 147-connector 12 Retarder OFF - ON switch
3 Retarder connector 13 Main power supply
4 Accumulator connector 14 Pushbutton for NBS (Neutral when stationary)
5 Temperature sensor connector 15 Pushbutton for gear release
6 Kick down switch 16 Automatic electronic shift control unit
7 ZF diagnosis connection plug EST 146 / EST 147
8 Range selector (pushbutton) 17 Retarder manual lever, electrical
9 Dipstick (oil level check, oil status) 18 Impulse sensor for tachometer
10 Footplate brake valve for activating the 19 Connections for cooling water circuit
service brake and continuously variable 20 CAN connector
retarder activation 21 Auxiliary consumer from air supply

4149 765 103 - 2004-12 1-1


ZF-Ecomat 2 plus System solution

1.2 System solution Ecomat 2 plus


(with load sensor, without CAN)

8
NR
3D
1 2
16
13 12 2
17

11 20
6
7
10
21
1
4 9
22

14
15 18
5
19

023777

Key to drawing
1 Transmission electrical unit connector 11 Accelerator pedal
2 EST 146- / EST 147-connector 12 Retarder OFF - ON switch
3 Retarder connector 13 Main power supply
4 Accumulator connector 14 Pushbutton for NBS (Neutral when stationary)
5 Temperature sensor connector 15 Pushbutton for gear release
6 Kick down switch 16 Automatic electronic shift control unit
7 ZF diagnosis connection plug EST 146 / EST 147
8 Range selector (pushbutton) 17 Retarder manual lever, electrical
9 Dipstick (oil level check, oil status) 18 Impulse sensor for tachometer
10 Footplate brake valve for activating the 19 Connections for cooling water circuit
service brake and continuously variable 20 Linkage for injection pump
retarder activation 21 Load sensor for engine load detection
22 Auxiliary consumer from air supply

4149 765 003 - 2004-07 1-2


ZF-Ecomat 2 plus System solution

1.3 System solution Ecomat 2 plus


(with PWM signal, without CAN)

8
20
NR
3D
1 2
16
13 12 2
17

11
6
7
10

1
4 9
21

14
15 18
5
19

023779

Key to drawing 11 Accelerator pedal


1 Transmission electrical unit connector 12 Retarder OFF - ON switch
2 EST 146- / EST 147-connector 13 Main power supply
3 Retarder connector 14 Pushbutton for NBS (Neutral when stationary)
4 Accumulator connector 15 Pushbutton for gear release
5 Temperature sensor connector 16 Automatic electronic shift control unit
6 Kick down switch EST 146 / EST 147
7 ZF diagnosis connection plug 17 Retarder manual lever, electrical
8 Range selector (pushbutton) 18 Impulse sensor for tachometer
9 Dipstick (oil level check, oil status) 19 Connections for cooling water circuit
10 Footplate brake valve for activating the 20 PWM from EDC or E-gas
service brake and continuously variable 21 Auxiliary consumer from air supply
retarder activation

4149 765 003 - 2004-07 1-3


ZF-Ecomat 2 plus System solution

System solution Ecomat 2 plus Oil temperature is monitored using temperature


sensors. Data from temperature sensors is trans-
The Ecomat 2 plus system diagram illustrates one mitted via CAN bus system, EST 146 / 147 digital
of the possible Ecomat system set-ups using all output or direct wiring and displayed by means of
necessary individual components. display or warning lamp.
Retarder torque will be reduced as defined tem-
All electrical connections required between the Eco- perature limits are exceeded.
mat 2 plus system and automatic electronic control
unit are located in the interface to the vehicle electri- Engine load data will be transmitted from the
cal system (13) and in case of the CAN bus applica- engine electronic system to the EST 146 / 147
tion at the vehicle CAN bus system. (15) via CAN and/or PWM signal or from injec-
tion pump via load sensor.
The EST 146 / 147 (15) automatic electronic control Pressures for operating the clutch elements are
unit controls the transmission and monitors all func- modulated according to the engine load condition
tions. The automatic shift control unit gathers input using a proportional solenoid valve in the electri-
parameters from vehicle and transmission and pro- cal/hydraulic control unit.
cesses these to produce signals used for controlling
the transmission hydraulic system.

The driver may intervene in the Ecomat control sys-


tem using the following equipment:
- Speed range selector (push-button switch) (8)
- Kick-down (6)
- Accelerator pedal (11)
- Brake pedal (10)
- Switch for retarder operation (12/16)

The desired speed range can be pre-selected


using the speed range selector (8).
The button pressed is illuminated (continuously
lit).

The kickdown switch (6) enables the shift points


to be moved up to higher engine speed settings.
This means more time is spent in each gear
[during upshifts] and, conversely, that downshifts
occur sooner.

For retarder activation, please consult vehicle


manual.

4149 765 103 - 2004-12 1-4


ZF-Ecomat 2 plus Description of transmission and technical data

2 Description of transmission and Basic transmissions from ranges HP 502, HP 592,


technical data and HP 602 consist of a hydrodynamic torque con-
verter with a lock-up clutch and rear-mounted multi-
2.1 Transmission brief description speed planetary transmission.

ZF Ecomat transmissions from ranges HP 502, Torque converter


HP 592, and HP 602 can be used in multiple appli- The hydrodynamic torque converter, which uses the
cations in commercial and special vehicles. It is Trilok operating principle is a wear-free setting-off
possible to select between 5 or 6-speed transmissions system and is equipped with a stator mounted on a
to cover all requirements - from fitting in a city bus freewheel and a lock-up clutch. The converter opera-
to use in a long-distance coach. To ensure the tes only when the vehicle is starting and is then
broadest possible range of applications, Ecomat automatically locked up.
transmissions can be fitted with many auxiliaries. A lock-up clutch installed in the torque converter
They have been designed to comply fully with establishes a direct mechanical connection between
today's requirement of traffic safety and optimum the engine and planetary transmission after the set-
economy. ting-off phase. The power losses incurred by conver-
ter transmissions are therefore eliminated.
ZF Ecomat transmissions from ranges HP 502,
HP 592, and HP 602 offer the following advantages: Retarder
The hydrodynamic retarder, is integrated in the
Smooth starting with no mechanical wear, even transmission and no housing extension is necessary.
on extremely rough terrain. No clutch wear. The retarder is located between the torque converter
and planetary transmission. This means the full
The automatic shift program and smooth shift braking effect is available without interruption, even
characteristics do a great deal to protect the in lower gears.
engine and driveline. The retarder braking torque can be continuously
varied using a manual lever-operated or pedal brake
The integrated hydrodynamic retarder contri- valve. If required, the braking torque can be divided
butes to road safety and vehicle performance. into one or several stages, all limited to a value
Substantial cost savings are also achieved by specified by the customer.
extending the service life of wheel brake linings.
Planetary transmission
Increased fuel economy due to close ratio step- The planetary transmission, arranged behind the
ping, carefully chosen shift points and restriction torque converter, is designed as a 5- or 6-speed unit.
of converter operation to the initial driving phase. The planetary transmission is a combination of indi-
vidual planetary gear sets (no modular design).
Greater ease of operation for the driver, The gears in the planetary transmission are selected
enhancing driver performance and contributing automatically and without any interruption to trac-
to road safety. tion. The automatic electronic shift control unit
EST 146 / 147 provides signals for the gear selec-
Reduction of vehicle operation and maintenance tions. The EST 146 / 147 shifts the appropriate
costs, especially under demanding road and traf- multi-disc clutches and/or brakes via the electro-
fic conditions or even with drivers who have no hydraulic transmission control unit in accordance
practice with it. with various parameters from the vehicle and trans-
mission.

4149 765 103 - 2004-12 2-1


ZF-Ecomat 2 plus Description of transmission and technical data

Transmission control
The electro-hydraulic control system used in these
transmissions has given excellent results in practice.
It receives shift signals from the EST 146 / 147. This
modern automatic electronic control unit has a dia-
gnostics capacity and is designed to suit the number
of ratios, type of transmission, engine and vehicle.

ZF automatic transmissions
5 and 6 HP 502, 592, 602

3 4 5 6

1 7

013467
8

Key to drawing
1 Input 5 Clutches (A, B, C)
2 Torque converter lock-up clutch 6 Brakes (D, E, F)
3 Converter 7 Output
4 Retarder 8 Oil pump

4149 765 103 - 2004-12 2-2


ZF-Ecomat 2 plus Description of transmission and technical data

2.2 Transmission structure and auxiliaries

Using the basic transmission, auxiliary units can be


used to make the following variants.

Coaxial transmission with fitted oil cooler


The basic transmission is fitted with coaxial
output and oil cooler at the output end. The heat
exchanger module contains the oil cooler connec-
tion piece and cooler connection lines.

Coaxial transmission with separate cooler


Here, the basic transmission is fitted with a
cooler connection piece. A ZF cooler is available
for separate attachment or a cooler produced by
an external manufacturer can be used following
approval from ZF.

Transmission with flange-mounted 80 angle


drives
A 80 angle drive can be attached to the basic
transmission without axial offset or a 80 angle
drive can be attached to the right with axial off-
set. Cooler attachments (see Chap. 10) or a cooler
connection piece are available for this as for the
coaxial transmission version with separate
cooler.

Non-ZF oil cooler


If customers provide their own oil cooler:
- ZF fits the oil cooler connection for non-ZF oil
coolers to the basic transmission
- The oil cooler must comply with specifications
in Section 9, Cooling system,
- The associated piping must be provided by the
customer and must comply with Section 9,
Cooling system.

Retarder
All transmission versions are supplied with a
retarder as standard. The retarder is fitted in the
basic transmission between converter and plane-
tary transmission. The retarder does not increase
transmission length and adds only 11 kg to the
transmission weight.

4149 765 103 - 2004-12 2-3


ZF-Ecomat 2 plus Description of transmission and technical data

2 5

6
7

021765

Key to drawing
1 Basic transmission
2 Retarder
3 Coaxial output
4 80 angle drive left with offset (LHD)
5 80 angle drive right with offset (RHD)
6 Oil cooler, fitted at output end
7 Oil cooler connection piece for non-ZF oil
cooler

4149 765 103 - 2004-12 2-4


ZF-Ecomat 2 plus Description of transmission and technical data

2.3 Transmission ratios and powerflow diagram

Transmission ratio:
This table gives the mechanical transmission ratios in individual gears (without torque converter).

Ratios
No. of
gears 1st 2nd 3rd 4th 5th 6th Rev.
Total
gear gear gear gear gear gear gear

5 3.43 2.01 1.42 1.00 0.83 -- 4.84 4.14

6 3.43 2.01 1.42 1.00 0.83 0.59 4.84 5.82

Powerflow
WK WK B C D E F
B C D E F

Neutral 1st gear


A A
hydraul.

WK B C D E F

1st gear
(mechan.) A

WK
3 4 5 6 B C D E F

2nd gear A
2

WK B C D E F

3rd gear
A

1 7
WK B C D E F

4th gear A

WK B C D E F

013467 5th gear


8 A

WK B C D E F

6th gear
A

1 Input 5 Clutches (A, B, C)


2 Torque converter lock- 6 Brakes (D, E, F) WK B C D E F

up-clutch (WK) 7 Output


Reverse
3 Torque converter 8 Oil pump gear
A

4 Retarder
016362

4149 765 103 - 2004-12 2-5


ZF-Ecomat 2 plus Description of transmission and technical data

Power flow diagram:


The power flow diagram illustrates which clutches and combinations of clutches are closed when individual
gears are engaged, depending on transmission ratio.

5-speed version: i = 3.43 - 0.83


6-speed version: i = 3.43 - 0.59

Power flow
WK WK B C D E F
B C D E F

Neutral 1st gear


A A
hydraul.

WK B C D E F

1st gear
(mechan.) A

WK
3 4 5 6 B C D E F

2nd gear A
2

WK B C D E F

3rd gear
A

1 7
WK B C D E F

4th gear A

WK B C D E F

013467 5th gear


8 A

WK B C D E F

6th gear
A

1 Input 5 Clutches (A, B, C)


WK B C D E F
2 Torque converter lock- 6 Brakes (D, E, F)
up-clutch (WK) 7 Output Reverse
A
3 Torque converter 8 Oil pump gear
4 Retarder
016362

4149 765 103 - 2004-12 2-6


ZF-Ecomat 2 plus Description of transmission and technical data

2.4 Torque assignment - vehicle weight

Trans- No. of Max. permissible Coach City bus


Ratio
missions gears input speed (rpm) 26 t 13 t 19 t up to 28 t
HP 502 5 3.43 - 0.83 2800
for i = 0.59
6 1) 3.43 - 0.59 2800 nmax = 2000

Max. permissible
engine torque ISO 1585
1100 Nm 850 Nm1) 1100 Nm 1100 Nm 2)

HP 592 5 3.43 - 0.83 2800


for i = 0.59
6 1) 3.43 - 0.59 2800 nmax = 2000

Max. permissible
1250 Nm -- 1250 Nm 1250 Nm
engine torque ISO 1585
HP 602 5 3.43 - 0.83 2650
for i = 0.59
6 1) 3.43 - 0.59 2650 nmax = 2000

Max. permissible
engine torque ISO 1585 1600 Nm 3) -- 1600 Nm 4) 1600 Nm 4)

1) Only in conjuction with engine version CAN TSC1 TE


2) Max. torque in 1st gear: 1050 Nm
3) Max. torque in 1st gear: 1400 Nm
4) Max. torque in 1st gear: 1250 Nm

4149 765 103 - 2004-12 2-7


ZF-Ecomat 2 plus Description of transmission and technical data

2.5 Torsional vibration in driveline inertia


torques vibration substitution model

CAUTION
Generally speaking, torsional vibration is due to
more than one component. The natural frequencies
are determined by the distribution of inertia torques
and the torsional rigidity of the entire driveline.
The vehicle manufacturer must ensure that the
entire driveline does not apply any excessive vibra-
tion loadings on the transmission.
Limit values for angle acceleration amplitude at the
output flange: max = 2000 rad/sec2

For the purpose of mathematical investigations into


vibration, the transmission is divided into three
discrete rotating masses connected by (zero mass)
torsion springs:

Mass 1: Torque converter without engine


flywheel and connection parts

Mass 2: Clutch carrier


A, B, C for i = 3.43 - 0.83 (0.59)

Mass 3: Manual transmission including


output flange

Rigid body 1: Turbine shaft

Rigid body 2: Input shaft and/or hollow shaft.

Half the moment of inertia of the shafts is assigned


to the relevant adjoining masses.

The following tables give the corresponding data


(moments of inertia and torsional rigidity) for
individual transmission variants.

4149 765 103 - 2004-12 2-8


ZF-Ecomat 2 plus Description of transmission and technical data

Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)

5/6 HP 502 / 592 - W 360*TPC... 6 HP 602 - W 390*TPC...

WK
B C D E F
J1 J2 J3

C1 C2

1 2 3
016364

J1 C1 J2 C2 J3
The moment of inertia J1, oil capacity included
[kgm2] [Nm/rad] [kgm2] [Nm/rad] [kgm2]

1st gear 5/6 HP 502 / 592 1.51 19000 0.78 39760 0.23
i = 3.43 5/6 HP 602 2.07 39000 0.78 100300 0.24

2nd gear 5/6 HP 502 / 592 1.51 19000 0.78 58350 0.10
i = 2.01 5/6 HP 602 2.07 39000 0.78 136700 0.10

3rd gear 5/6 HP 502 / 592 1.51 19000 0.78 70760 0.14
i = 1.42 5/6 HP 602 2.07 39000 0.78 151200 0.15

4th gear 5/6 HP 502 / 592 1.51 19000 0.82 108500 0.50
i = 1.00 5/6 HP 602 2.07 39000 0.82 985000 0.53

5th gear 5/6 HP 502 / 592 1.51 19000 0.79 105700 0.46
i = 0.83 5/6 HP 602 2.07 39000 0.79 814100 0.46

6th gear 6 HP 502 / 592 1.51 19000 0.79 105700 0.46


i = 0.59 6 HP 602 2.07 39000 0.79 814100 0.46

Neutral position (lock-up clutch and clutches A, B, C open) 5/6 HP 502 / 592: J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
5/6 HP 602: J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2

Remarks: Figures are based on pump or turbine speed of converter.


Torque converter lock-up clutch closed.
Engine connecting parts must be assigned to first rotating mass.
Connecting parts fitted on output side must be assigned to third rotating mass.
The moment of inertia for neutral position applies in the following conditions:
- On input side, lock-up clutch and clutches A, B, and C opened
- Primary mass J1.1 of the converter (circuit cover, pump wheel, lock-up clutch) is hydro-
dynamically connected to the secondary mass J1.2 (turbine wheel, clutch carriers
A, B and C) through the oil in the converter. However, these masses are regarded as
separate for vibration purposes.

4149 765 103 - 2004-12 2-9


ZF-Ecomat 2 plus Description of transmission and technical data

Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)

5/6 HP 502 / 592 - W 360*TPC... / W 390*TPC...


incl. angle drive 80 RHD (i = 0.98) with right offset

J1 J2 J3
C 1 C 2

WK
B C D E F
Output RHD

1 2 3
021766

The moment of inertia J1 J1 C1 J2 C2 J3


Torque converter
oil capacity included [kgm2] [Nm/rad] [kgm2] [Nm/rad] [kgm2]

1st gear W 360*TPC... 1.51


5/6 HP 502 / 592 19000 0.78 39760 0.26
i = 3.43 W 390*TPC... 2.07

2nd gear W 360*TPC... 1.51


5/6 HP 502 / 592 19000 0.78 58350 0.18
i = 2.01 W 390*TPC... 2.07

3rd gear W 360*TPC... 1.51


5/6 HP 502 / 592 19000 0.78 70760 0.29
i = 1.42 W 390*TPC... 2.07

4th gear W 360*TPC... 1.51


5/6 HP 502 / 592 19000 0.82 108500 0.77
i = 1.00 W 390*TPC... 2.07

5th gear W 360*TPC... 1.51


5/6 HP 502 / 592 19000 0.79 105700 0.88
i = 0.83 W 390*TPC... 2.07

6th gear W 360*TPC... 1.51


6 HP 502 / 592 19000 0.79 105700 0.88
i = 0.59 W 390*TPC... 2.07

Neutral position (lock-up clutch and clutches A, B, C open) W 360*TPC... : J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
W 390*TPC... : J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2

Remarks: Figures are based on pump or turbine speed of converter.


Torque converter lock-up clutch closed.
Engine connecting parts must be assigned to first rotating mass.
Connecting parts fitted on output side must be assigned to third rotating mass.
The moment of inertia for neutral position applies in the following conditions:
- On input side, lock-up clutch and clutches A, B, and C opened
- Primary mass J1.1 of the converter (circuit cover, pump wheel, lock-up clutch) is hydro-
dynamically connected to the secondary mass J1.2 (turbine wheel, clutch carriers
A, B, and C) through the oil in the converter. However, these masses are regarded as
separate for vibration purposes.

4149 765 103 - 2004-12 2-10


ZF-Ecomat 2 plus Description of transmission and technical data

Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)

5/6 HP 502 / 592 - W 360*TPC... 5/6 HP 602 - W 390*TPC...


incl. angle drive 80 LHD (i = 0.97) without offset

J1 J2 J3
WK
B C D E F C 1 C 2

Output LHD

1 2 3 019213

The moment of inertia J1 J1 C1 J2 C2 J3


oil capacity included [kgm2] [Nm/rad] [kgm2] [Nm/rad] [kgm2]

1st gear 5/6 HP 502 / 592 1.51 19000 0.78 39760 0.25
i = 3.43 5/6 HP 602 2.07 39000 0.78 100300 0.26

2nd gear 5/6 HP 502 / 592 1.51 19000 0.78 58350 0.14
i = 2.01 5/6 HP 602 2.07 39000 0.78 136700 0.14

3rd gear 5/6 HP 502 / 592 1.51 19000 0.78 70760 0.20
i = 1.42 5/6 HP 602 2.07 39000 0.78 151200 0.21

4th gear 5/6 HP 502 / 592 1.51 19000 0.82 108500 0.62
i = 1.00 5/6 HP 602 2.07 39000 0.82 985000 0.65

5th gear 5/6 HP 502 / 592 1.51 19000 0.79 105700 0.65
i = 0.83 5/6 HP 602 2.07 39000 0.79 814100 0.65

6th gear 6 HP 502 / 592 1.51 19000 0.79 105700 0.65


i = 0.59 6 HP 602 2.07 39000 0.79 814100 0.65

Neutral position (lock-up clutch and clutches A, B, C open) 5/6 HP 502 / 592: J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
5/6 HP 602: J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2

Remarks: Figures are based on pump or turbine speed of converter.


Torque converter lock-up clutch closed.
Engine connecting parts must be assigned to first rotating mass.
Connecting parts fitted on output side must be assigned to third rotating mass.
The moment of inertia for neutral position applies in the following conditions:
- On input side, lock-up clutch and clutches A, B, and C opened
- Primary mass J1.1 of the converter (circuit cover, pump wheel, lock-up clutch) is hydro-
dynamically connected to the secondary mass J1.2 (turbine wheel, clutch carriers
A, B, and C) through the oil in the converter. However, these masses are regarded as
separate for vibration purposes.

4149 765 103 - 2004-12 2-11


ZF-Ecomat 2 plus Description of transmission and technical data

2.6 Weights and inertia torque values

2.6.1 Coaxial output without heat exchanger J08

Transmission type Total weight Position of center of gravity Inertia torque values

(with retarder) without oil with oill S [mm] oil included JS [kgm2] oil included

J08 (oil cooler separate) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 280 307 265 - 46 6 9.61 15.45 16.53

5/6 HP 592 285 312 265 - 46 6 9.61 15.45 16.53

5/6 HP 602 300 327 265 - 45 6 9.61 15.45 16.53

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021772

z z

4149 765 103 - 2004-12 2-12


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.2 Coaxial output with heat exchanger J01

Transmission type Total weight Position of center of gravity Inertia torque values
(without retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J01 (oil cooler,
installed at the rear) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 305 337 291 - 56 5 10.50 20.43 21.84

5/6 HP 592 310 342 291 - 56 5 10.51 20.44 21.85

5/6 HP 602 325 357 299 - 58 4 10.52 20.43 21.85

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021773

z z

4149 765 103 - 2004-12 2-13


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.3 Coaxial output with heat exchanger J05

Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J05 (oil cooler,
installed on the left side) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 305 337 297 - 43 25 11.69 24.21 23.31

5/6 HP 592 310 342 297 - 43 25 11.70 24.22 23.32

5/6 HP 602 325 357 295 - 42 24 11.71 24.26 23.36

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021774

z
z

4149 765 103 - 2004-12 2-14


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.4 Coaxial output with heat exchanger J10

Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the right side) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 305 337 292 - 42 - 11 11.48 22.06 21.42

5/6 HP 592 310 342 291 - 42 - 11 11.48 22.07 21.43

5/6 HP 602 325 357 290 - 42 - 11 11.48 22.10 21.44

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021780

z z

4149 765 103 - 2004-12 2-15


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.5 Angle drive 80 without offset, with heat exchanger J05

Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the left side) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 397 430 374 - 45 44 15.57 39.82 37.59

5/6 HP 592 402 435 373 - 45 44 15.58 39.93 37.69

5/6 HP 602 417 450 368 - 44 43 15.61 40.23 37.97

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021775

z
z

4149 765 103 - 2004-12 2-16


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.6 Angle drive 80 without offset, with heat exchanger J10

Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the right side) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 397 430 347 - 29 8 14.10 34.51 33.38

5/6 HP 592 402 435 345 - 21 8 14.10 34.56 33.43

5/6 HP 602 417 450 342 - 29 8 14.10 34.72 33.59

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021777

z
z

4149 765 103 - 2004-12 2-17


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.7 Angle drive 80 RHD (with right offset), with heat exchanger J05

Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the left side) m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 420 454 425 - 53 -9 17.11 45.79 43.68

5/6 HP 592 425 459 424 - 53 -9 17.11 45.88 43.77

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021778

z z

4149 765 103 - 2004-12 2-18


ZF-Ecomat 2 plus Description of transmission and technical data

2.6.8 Angle drive 80 RHD (with right offset), without heat exchanger J08

Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J08 (oil cooler separate)
m [kg] m [kg] xS yS zS Jx S JyS JzS

5/6 HP 502 387 416 394 - 52 - 34 13.56 37.58 38.50

5/6 HP 592 392 421 393 - 52 - 33 13.57 37.68 38.59

Center of gravity S refers to engine connection surface.


Inertia torque JS refers to the position of the center of gravity.

y x

021779

z z

4149 765 103 - 2004-12 2-19


ZF-Ecomat 2 plus Description of transmission and technical data

2.7 Clutch combinations

The tables shown which clutches are activated


depending on the gear selected and the ratio.

5th gear i = 3.43 - 0.83


6th gear i = 3.43 - 0.59

A B C D E F1 F2

Reverse gear

Neutral

Neutral (NBS) 1) *

1st gear

2nd gear

3rd gear

4th gear

5th gear

6th gear

* Reduced pressure
1) Standard version
F1 = external piston area brake F
F2 = internal piston area brake F

4149 765 103 - 2004-12 2-20


ZF-Ecomat 2 plus Ecomat installation position in vehicle

3 Ecomat installation position in vehicle

T-Drive Transverse installation at rear 80

The conventional installation position in buses is the To further optimize available space, various angle
mid-axle T-drive with the transmission fitted in the drive versions (WTR) are used to allow transverse
direction of travel. installation.
80 angle drive version with right offset

4139 S 2010 015996

The introduction of drop-center axles for low-floor Another advantage of the 80 WTR with axial offset
buses means the driveline is displaced, for example, is that the output is moved 217.5 mm downwards.
to the left.

80 angle drive version without left offset

4139 S 2011 4139 S 2014

4149 765 103 - 2004-12 3-1


ZF-Ecomat 2 plus Installation arrangement and mountings

4 Installation arrangement and mountings If the forces acting on each side are offset longitudi-
nally, please consult our Application Engineering
The transmission must not be supported other than department.
at the bolt attachment faces provided for this purpose
on the transmission housing and auxiliary unit.
Transmission mountings on the chassis must be 4.1 Transmission flange-mounted on engine
designed in consultation with ZF in such a way that
no additional forces resulting from twisting of the ZF recommended mounting points
chassis may be transmitted to the transmission
housing.

The connection dimensions for transmission moun-


C
tings, the transmission weight, and centre of gravity Engine
A Ecomat
are indicated in the individual installation drawings. B D
The bolts used to attach the transmission to its
mountings must be of quality 8.8. Specified tighte-
ning torque for mounting points see C + E + D = Mounting points at A + B or A + C or A + C/D
225 Nm.
If a flange-mounted angle drive is fitted, mounting
point E may be used for stabilization. However,
whenever mounting E is in rest position , ensure that
no forces are transmitted and that the rigidity of E is
C
less than the rigidity of mounting A + C or A + C/D
A B
and/or A + B. D

! DANGER
The bending torque exerted by mounting blocks at Ecomat with 80angle drive
Mounting points at A + B or A + C or A + C/D
mounting flange face C and/or D must not exceed the
following limit: MC 3500 Nm / MD 1500 Nm

E
The bending torque can be calculated from the C
bracing force (F) at the rubber mounting and lateral A B D
lever length (L) of bearing block. Take into account
any simultaneous vertical acceleration and torque E
021769
loading from the transmission or powerpack.
Ecomat with 80angle drive
Mounting points at A + B or A + C or A + C/D
Additional mounting point at E possible, either above or
L L below housing.

F F

4139 S 0028

4149 765 103 - 2004-12 4-1


ZF-Ecomat 2 plus Guidelines for propshaft installation

5 Guidelines for propshaft installation Relationship between and :

A propshaft may be the cause of torsional and rad [] n2 [1/min2]


per. 2000 2
=
bending vibrations in the driveline. Compliance s 1306
should therefore be maintained with the following
approximate values. The vehicle manufacturer is
responsible for this. 1.8

Rotational angle
Exceptions from the values specified must be 1.6 ,=
approved. 1.4

1.2
1 rev.

1.0 Limit curve for measurement


0.8 per. 2000 rad
s2
5.1 Permissible rotational irregularity
0.6

0.4
The maximum permissible angle-acceleration ampli-
0.2
tudes () in the driveline are 2000 rad/s2. Smaller
values do not result in vibration damage. S 0014
1000 2000 3000

Rotational acceleration in the driveline can be Propshaft speed n (rpm)


checked using a calculation or measurement. Alter-
natively, the rotary angle error () can also be
used for this purpose.
The following sub-chapters indicate limit values for
the permissible bending angle. If compliance is
,= maintained with these limits, the vibration ampli-
tudes excited by the propshafts will not exceed the
0.2
,= maximum value.
+0.1
0
S 0013
The limit values for the bending angle are used in
0.1 particular if there are no calculations or measure-
0.2
1 rev. ments of the vibration amplitudes.

4149 765 103 - 2004-12 5-1


ZF-Ecomat 2 plus Guidelines for propshaft installation

5.2 Permitted resultant deflection angle for Calculation example:


each joint
Plan view Front view
When using a spatial propshaft layout, the resultant
deflection angle R must first be determined using >V =13 >H =9
the following formula:
021846

tan R = tan2 H + tan2 V


tan R = 0.162 + 0.232 = 0.28 R = 15.6
where H - deflection angle when viewed horizontal-
ly (plan view) According to diagram: R 15

where V - deflection angle when viewed vertically


(front view). The acceptability of R depends on the type, size,
and speed of the propshaft.
The deflection angle is therefore defined as the
angle between the axes of rotation in front of and
20
Deflection anlgle R

behind the joint in the appropriate view. R


18
16
14
Product range
12 max. 7 at PTO
10
8 Flange 150
007927 6
Flange 165/180/225
4
2

As a rough guide, the angle R can be determined 0


500 1000 1500 2000 2500 3000 3500 4000
from the following diagram.
Propshaft speed n (rpm)
007098_en

25

20 30

25
15
13 20

10 15 >R
10
5
>V

0
5 9 10
>H 15 20
25
021847

Resultant deflection R with spatial propshaft


arrangement.

4149 765 103 - 2004-12 5-2


ZF-Ecomat 2 plus Guidelines for propshaft installation

5.3 The permitted resultant flexure angle for all


joints

The resultant flexure angle E is calculated from the


angles of individual joints using the following formula:

E = | R12 R22 R32 . . . |

The individual angles should be given the follo-


wing positive or negative values:

+ If the journal cross 90

is perpendicular to Input Output


the driven yoke

90
if the journal cross
is perpendicular to Input Output
the driving yoke 4139 S 0010

Limit value: E < 3

Examples illustrating the effect of deflection angle 1 and 2 on resultant flexure angle E

Z arrangement W arrangement Angle error Resultant flexure angle


= 1 - 2 E = | - 12 + 22 |

Example 1 >1 = 12 >1 = 12


(Precise
>2 = 12 >2 = 12
Z or W 0 0
arrangement)

Example 2
(Small >1 = 5 >1 = 5

deflection
>2 = 4 >2 = 4 1 3
angle with
angle error)

>1 = 15 >1 = 15
Example 3 >2 = 14
(Large >2 = 14

deflection 1 5,4
angle with
angle error)
021848

Example 3 shows that, in the case of large deflection angles, angle errors of as little as 1 can cause an impermissibly large resultant flexure angle.

4149 765 103 - 2004-12 5-3


ZF-Ecomat 2 plus Guidelines for propshaft installation

5.4 Single-section propshafts 5.5 Multi-section propshafts

Best efforts must be taken to configure the axle sus- In multi-section propshaft configurations, the drive-
pension suitably to ensure the propshaft remains in a line can be optimized by suitable choice of crosslink
precise Z pattern (1 = 2) under all vehicle loading. orientations and by varying height h of the inter-
mediate bearing ( angle distribution).

>1 Unfavorable arrangement


Transmission
>2 Axle
E = | - 12 + 22 - 32 | = (13,6)

4139 S 0015
1 = 9.5
h
= 5 Axle
2

Leaf springs give a good Z position due to parallel


Transmission
axle movement. 3 = 11

1 = 2 is more-or-less maintained across whole 4139 S 0017

range of suspension travel.


Optimized arrangement
1 (by changing position of crosslink)
Spring travel

2 loaded
E = | - 12 - 22 + 32 | = (2,4)
unloaded
4139 S 0016
Axle movement
1 = 9.5
h
= 5
Axle
2

Floating axle gives a poor Z position due to the


Transmission
pivoting movement of the axle. = 11
3
4139 S 0017
1 = 2 is only maintained at the middle point.
Suspension movements upwards or downwards
make the angles unequal.

1

2 Swing travel
loaded

-0 + Centre position
Axle Movement 4139 S 0016

4149 765 103 - 2004-12 5-4


ZF-Ecomat 2 plus Guidelines for propshaft installation

5.6 Maximum permissible propshaft length

NOTE
The maximum length is limited to 1500 mm to pre-
vent the bending vibrations being activated by the
propshaft, if necessary, a multiple arrangement with
intermediate bearing will have to be selected.

Further information

Balancing: The propshaft must be dynamically


balanced in quality 16 in accordance with VDI
guideline 2060.

250
4139 S 0018

200

150
Perm. residual imbalance per
balancing mass [gmm/kg]

100
80
Q1
6

60

40

30
300 500 700 900 1500 3000 4000
Propshaft speed n (1/min)

Permissible concentricity and runout errors of


the connection flange:

Max. Concentricity and Centering


speed runout deviation fit
[min-1] [mm]

500 0.10 h8

1500 0.07 h7

3500 0.06 h7

Lubrication:
The specifications of the propshaft manufacturer
should be observed for lubrication.
The sliding piece must move easily under load.

4149 765 103 - 2004-12 5-5


ZF-Ecomat 2 plus Engine connection

6 Engine connection NOTE


Before fitting together the engine and Ecomat,
Before the Ecomat transmission is connected to the always check that the following points are complied
engine, the Application Engineering dept. and engine with:
manufacturer must perform an engine connection
There must be an assembly access hole (4) in the
study. This involves determining all important
flywheel housing and flywheel.
dimensions and tolerances for the connection and
preparing an engine connection drawing. See Sec- The bolts must be of the quality specified in the
tion 5.2, Engine connection study for an example engine connection drawing.
of this and additional information.
Observe specified tightening torques when
tightening all bolts.

There are two methods for connecting the trans- Use only hardened, flat washers (DIN 125-13-
mission to the engine: 300 HV or DIN 125-10.5-300 HV), or stop screws
according to DIN 961, quality 8.8. Never use
Method 1: The engine flywheel (2) is retained toothed lock screws or similar.
and carries the starter ring gear (5). The flex
Check the following tolerances:
plates (10) are connected directly to the converter
- Max. deflection of flex plates
(7).
= 1.2 mm (important for flex plate life)
- Flex plate thickness (D)
Method 2: Remove engine flywheel (2). Fit a
= 4 x 0.5 mm 0.04 mm
starter ring gear carrier (8) between the flex
= 2 mm 0.16 mm
plates (10) and converter (7).
- Runout tolerance (A) of flywheel inner bore
and/or centring ring to centring spigot on
flywheel housing = max. 0.3 mm
- Permitted tolerance for dimension (C) for
for Method 1 = 0.66 mm
for Method 2 = + 0.66 mm
0.96 mm
(Dimension (B) is set by ZF to 0.5 mm)

Clean torque converter circuit cover.

4149 765 103 - 2004-12 6-1


ZF-Ecomat 2 plus Engine connection

Assembly sequence for variant 1


(with flywheel)

Check dimensions (A) and (C) comply with Bolt together transmission housing (6) and fly-
engine connection drawing. If dimensions exceed wheel housing (3) as shown in engine connection
tolerance, contact our Application Engineering drawing. Tightening torque for bolt quality 8.8:
dept. urgently. TA = 49 Nm for screws M10
TA = 79 Nm for screws M12.
Bolt together crankshaft (1), flywheel (2), flex
plates (10), and clamping ring (11). Consult engine Using assembly access hole (4) in flywheel
manufacturer to establish correct tightening housing and flywheel, bolt flex plates (10) onto
torque. converter (7). Tightening torque TA = 81 Nm for
bolt quality 8.8.

Variant 1 Drawing no.: 4139 530 064

A A

023809

4149 765 103 - 2004-12 6-2


ZF-Ecomat 2 plus Engine connection

Assembly sequence for variant 2


(without flywheel)

Check dimensions (A) and (C) comply with Bolt together transmission housing (6) and fly-
engine connection drawing. If dimensions exceed wheel housing (3) as shown in engine connection
tolerance, contact our Application Engineering drawing. Tightening torque for bolt quality 8.8:
dept. urgently. TA = 49 Nm for screws M10
TA = 79 Nm for screws M12.
Bolt together crankshaft (1), centering ring (11),
flex plates (10), and clamping ring (9). Consult Using assembly access hole (4) in flywheel
engine manufacturer to establish correct tighten- housing bolt flex plates (10) onto converter (7).
ing torque. Tightening torque TA = 81 Nm for bolt quality 8.8.

Using two bolts (12), bolt gear ring carrier (8)


with integral ring gear (5) onto converter (7).

Variant 2 Drawing no.: 4139 530 065

SECTION A-A

SECTION A-A
A

SECTION B-B
ASSEMBLY ACCESS HOLE

023810

4149 765 103 - 2004-12 6-3


ZF-Ecomat 2 plus Engine connection

6.1 ZF Scope of delivery 6.3 Engine connection: Further information

The flex plates and bolts for fastening 4 flex plates to Attempts should be made to undertake all engine
the converter are supplied by ZF. connections following variant 1 with a complete
flywheel.
NOTE
Vehicle manufacturer should establish whether the 4 Since there is no flywheel in the version following
diaphragms variant 2, the inertia torque of the engine is
are ordered form the engine manufacturer and changed. Under unfavorable circumstances, this
fitted there onto the engine with the connection may result in resonance vibrations and finally
parts required or diaphragm failure.
are to be included in the transmission scope of
supply for the vehicle manufacturer. CAUTION
Variant 2 (segregated design) may only be used
once the Application Engineering department has
been contacted.
6.2 Engine connection inspection
The following applies in general:
If no engine connection drawing has been prepared,
the following documents are required for the engine Engine connection drawings are already available
connection inspection: for popular engines.

Detailed drawing of flywheel housing The engine connection must be designed to


ensure that the torque converter is centered on
Detailed drawing of flywheel
the crankshaft.
Detailed drawing of end of crankshaft
For clamping disc and centering ring version, see
Drawing of engine output assembly showing axial detail W.
and radial tolerance range for crankshaft and For ring gear carrier version, see detail V (see
distance between end of crankshaft and flanging drawing 4139 601 171 overleaf).
face of flywheel housing.
A vibration damper between the engine and
For Method 2, pay particular attention to the transmission is not required when using the
markings for the fuel injection point. direct engine-transmission construction.

If the engine and transmission are installed sepa-


rately, a vibration damper should be fitted bet-
ween the crankshaft and propshaft. The choice of
such a damper should be made with the assistan-
ce of the Application Engineering department.
Responsibility for the correct damper design lies
with the vehicle manufacturer. The vehicle
manufacturer must provide the damper.

4149 765 103 - 2004-12 6-4


ZF-Ecomat 2 plus Engine connection

6.4 Engine connection drawings

Detailed drawing of engine connection Drawing no.: 4139 601 171

ZF-ECOMAT 2 plus

DETAIL V
5:1

4 FLEX PLATES
0.5 MM THICK

56 1.9

min. 7 mm 50 H7
e8
max. 8 mm 0.3 A
Contact surface
oKntaktfl
che
63.50.5
86.0 +0.5
1.0 DETAIL W
5:1

min. 4 021682

4149 765 103 - 2004-12 6-5


ZF-Ecomat 2 plus Engine connection

Detailed drawing of engine connection

Variant with flywheel

ZF-ECOMAT 2 plus
A

561.9

min. 7 mm 50 H7
e8
max. 8 mm
oKntaktfl
che 0.3 A
Contact surface

63.50.5
86.0 +-0.5
1.0

DETAIL W
5:1
5

R 201
5

R 201

min. 4 021683

4149 765 103 - 2004-12 6-6


ZF-Ecomat 2 plus Engine connection

6.5 Overview converter-circuit cover

W360 A [mm] LKR [mm]

0501 320 294 77.00 380

0501 320 293 81.25 380

0501 320 298 71.25 402

0501 320 295 71.25 380

0501 320 299 68.00 402

0501 320 297 77.00 402

0501 320 296 81.25 402

0501 320 300 86.25 326

W390 A [mm] LKR [mm]

0501 318 581 81.25 380

0501 318 583 77.00 402

0501 318 582 81.25 402

0501 319 971 71.25 380

0501 320 321 71.25 402

4149 765 103 - 2004-12 6-7


ZF-Ecomat 2 plus Converter

7 Converter freewheel when torque multiplication takes place


and thus remains stationary.
7.1 Torque converter: Description
To ensure economical operation, the torque conver-
The torque converter is mounted on the input end of ter lock-up clutch is closed as soon as this is possible.
the planetary transmission. The torque converter When the lock-up clutch is closed, the level of slip
consists of the impeller, turbine, and reaction mem- between the impeller and turbine wheel and there-
ber (stator) and the oil needed for torque transmis- fore the loss of hydraulic energy in the converter is
sion. "zero".

Torque is transmitted from the engine flywheel to The close ratios and optimum gear step adjustment
the torque converter by means of a connection of the 5th and 6th mechanical gears in the trans-
comprising flex plates. mission allow the converter to be locked up at a very
early stage. This makes use of the advantages of
mechanical power transmission early on high
efficiency and low power losses.
7.2 Converter functions

The impeller driven by the engine displaces the oil


in a circular pattern. This oil flow strikes the turbine
wheel and is deflected back.

The stator downstream of the turbine is used to


deflect the oil flowing out of the turbine back into
the impeller at an appropriate angle. This change in
direction generates a torque on the stator, which in
turn boosts the turbine torque. The ratio of turbine
torque to impeller torque is referred to as torque
conversion. The greater the difference in the speeds
of the impeller and turbine, the higher the torque
multiplication. In other words, maximum multiplica-
tion occurs when the turbine is stationary, and falls
as the turbine speed rises.

The converter adjusts the output speed to achieve


the required output torque using a continuous, auto-
matic process. The torque of the stator is always
equal to the difference between the turbine and
impeller torque.

When the turbine speed approaches approx. 80% of


the impeller speed, torque multiplication drops to a
ratio of 1, i.e. turbine torque equals impeller torque.
From this point on, the converter acts purely as a
fluid coupling. Under such conditions the stator,
which is linked to the housing by a roller freewheel
unit ("Trilok" principle) begins to rotate freely in the
oil flow, whereas it is held against the housing by the

4149 765 103 - 2004-12 7-1


ZF-Ecomat 2 plus Converter

Impeller Turbine wheel

From engine

TP TT
TR

To transmission

Condition at nT = O
instant of Stator Vehicle stationary
starting off

Intermediate nT < nEng


condition
nT = 0.8nEng
Condition immedia- nT = nEng
tely before lock-up After lock-up
clutch closes clutch closes
4139 S 2015

TP = Torque of impeller
TT = Torque of turbine wheel
TR = Torque of stator

4149 765 103 - 2004-12 7-2


ZF-Ecomat 2 plus Converter

7.3 Getting the right torque converter for your Refer to torque converter diagram for details of
engine appropriate engine-converter combinations, see
example of torque converter diagram on page 7-5.
In cooperation with vehicle manufacturers, the ZF
Application Engineering dept. has specified an To determine the operating points between torque
appropriate torque converter for every engine trans- converter and engine under full-throttle conditions,
mission combination. the net engine torque curve needs to be entered in
the primary parabolic characteristics field for the
The torque converter selection criteria are: torque converter.
Engine type (naturally-aspirated engine or turbo-
charged engine). There are converter models for the 5/6 HP 502 / 592 /
Torque conversion when starting off. 602 C transmissions which vary according to the
Speed reduction when starting off. impeller torque pickup, hydraulic diameter, and
Fuel economy or power increase. torque multiplication when starting off.
Heat build-up when driving for long periods with
lock-up clutch open.

Torque converter TP1000 0 Basic curve ID no. for


[Nm] [-] Drawing no. ANKE (P22500N)

W360*TPC145*MUE2.22 145 2.215 4166 711 150 01 14500 16300 1000 221 970Z

W360*TPC210*MUE2.43 210 2.430 4166 703 227 01 41210 41210 1400 243 1000Z

W360*TPC262*MUE2.40 262 2.400 4166 703 147 01 26200 26200 1000 240 1000Z

W360*TPC300*MUE2.36 300 2.360 4166 703 149 01 30000 30050 1000 236 1000Z

W360*TPC342*MUE2.27 342 2.270 4166 703 148 01 34200 34200 1000 227 1000Z

W360*TPC390*MUE2.17 390 2.165 4166 703 150 01 39000 39000 1000 216 1000Z

W390*TPC392*MUE2.20 392 2.195 4166 711 145 01 39200 41800 1000 219 1000Z

W390*TPC487*MUE1.98 487 1.982 4166 711 146 01 48700 49000 1000 198 1000Z

W390*TPC615*MUE1.83 615 1.829 4166 711 147 01 61500 63900 1000 183 1000Z

4149 765 103 - 2004-12 7-3


ZF-Ecomat 2 plus Converter

7.4 Torque converter diagram Calculation formulae


Formula for calculating torque pick-up for any
The following information can be read from the speed ratio.
torque converter graph (see drawing on next page): n12 T1
Stall torque = max. turbine torque TT = impeller ------ = ------
torque TP x max. multiplication o (Mue) at turbi- n22 T2
ne speed = 0. Calculation of HEAT REJECTION for a given
Stall speed = impeller speed nP at turbine speed tractive force: Refer to example.
nT = 0 rpm.
Engine power Peng gross (kW) Example:
Engine power Peng net (kW) Heat build-up for tractive force = 60% vehicle weight
Torque curve Teng gross (Nm) Tractive force:
Torque curve Teng net (Nm) F [N] = K G [kg] 9.81 [m/s2] K = 0.6
T2 (Nm) subtraction for auxiliaries such as auxi- F [N] = 0.6 G [kg] 9.81 [m/s2] G = weight [kg]
liary steering pump, generator etc.; approximate
value of T2 = 50 Nm may be assumed. If units TT [Nm] iG iA ges
with especially high power requirements are F [N] = -----------------------------------------
rdyn [m]
planned, e.g. a compressor, torque must be
calculated according to impeller speed,
F [N] rdyn [m]
TT turbine torque (Nm) against turbine speed TT [Nm] = -------------------------------
PV (kW) torque converter power losses against iG iA A G
turbine speed nT
Example: K G [kg] 9.81 [m/s2] rdyn [m]
nT = 800 rpm PV = 55 kW = -----------------------------------------------------------
iG iA A G
nP impeller speed against turbine speed nT
Example:
Using value of TT consult torque converter diagram
nT = 1200 rpm nP = 1800 rpm;
TT -- curve TT -- PV -- axis P -- heat build-up P (kW)
nT = 0 rpm nP = 1550 rpm
(stall speed)
Example:
Mue (torque multiplication) = TT / TP ber
TT = 1200 Nm PV = 49 kW
Nue (speed ratio) = nT / nP
TT = Turbine torque
Example:
F = Tractive force
=0 max. torque multiplica-
iG = Transmission ratio
tion = 2.165
iA = Rear axle ratio
= 0.78 torque multiplica-
G = Transmission efficiency approx. 0.95
tion = 1.0
A = Axle efficiency approx. 0.95
rdyn = Dynamic tire radius
Torque converter efficiency rating W
The torque converter efficiency rating is deter-
NOTE
mined by the product of torque conversion m and
When defining engine cooling constant, take
speed ratio n.
account of additional heat build-up during torque
W =
converter operation (20% torque converter drag)!
The efficiency rating of 80% is achieved at
= 0.8.

4149 765 103 - 2004-12 7-5


ZF-Ecomat 2 plus Converter

Torque converter diagram

014 914

Key to diagram
TengGr [Nm] = Engine torque curve (gross) Mue [-] = Torque multiplication ration
PengGr [kW] = Engine power curve (gross) m = TT/TP against speed ratio
nP [1/min] = Impeller speed against turbine Nue = nT/nP
speed nT TP [Nm] = Parabolae of impeller torque
TT [Nm] = Turbine torque against turbine pick-up against impeller speed
speed nT nP for speed ratio Nue = nT/nP
PV [kW] = Torque converter power losses A = Stall torque
against turbine speed nT B = Stall speed
Engine data = According to ISO 1585 (average
values)
Converter = According to VDI Guideslines
figures 2153 figures (average values)

4149 765 103 - 2004-12 7-6


ZF-Ecomat 2 plus Converter

7.5 Torque converter basic curves

W360*TPC145*MUE2.22
Basic curve: 4166 711 150
Impeller constants: nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft]
= TT/TP Converter torque ratio
0 2.215 0 145 107 70.0 81.5
0.10 2.062 0.206 149 110 69.3 80.7 = Torque converter efficiency
0.20 1.892 0.378 154 114 68.7 80.0
0.30 1.707 0.512 161 119 68.7 80.0 TPC Pump torque at constant pump speed nPC
0.40 1.546 0.618 163 120 69.2 80.5 nPC
0.50 1.396 0.698 162 119 70.0 81.5 K= Factor at constant pump speed nPC
TPC
0.60 1.252 0.751 158 117 72.0 83.8
0.70 1.118 0.783 146 108 75.8 88.3 TP Pump torque at pump speed nP
0.80k 1.004 0.803 124 91 82.8 96.4
0.85 0.995 0.846 102 75 92.5 107.6 TT Turbine torque at turbine speed nT
0.90 0.995 0.896 71 52 109.8 127.8
0.95 0.995 0.945 46 34 138.7 161.5 Torque converter values: acc. to VDI Guidelines 2153
0.97 0.995 0.965 29 21 179.6 209.1 mean values

1100 1500
T (Nm)

1000

.40
1300

=0

=0
T (ft.lb.)



1200
TP TP

k
800 1100
.80
=0
1000

700 TP
900

600
800
3.0

2.8 700
500
2.6
2.4 600
w(%)
2.2 400
2.0 500 100

1.8 90
1.6 300 80
400
1.4 70
1.2 300 60
200
1.0 50

0.8 200 TPC1000 40


0.6 30
100
0.4 100 20

0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
016 675
0 0.2 0.4 0.6 0.8 1.0

4149 765 103 - 2004-12 7-7


ZF-Ecomat 2 plus Converter

W360*TPC210*MUE2.43

Basic curve: 4166 703 227


Impeller constants: nPC = 1400 rpm

= nT/nP Torque converter speed ratio


TPC1400 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 2.430 0 412 304 69.0 80.3 = Torque converter efficiency


0.10 2.220 0.222 412 304 69.0 80.3
0.20 2.010 0.402 410 302 69.1 80.5 TPC Pump torque at constant pump speed nPC
0.30 1.790 0.537 405 299 69.6 81.0
0.40 1.610 0.644 394 291 70.5 82.1 nPC
K= Factor at constant pump speed nPC
0.50 1.420 0.710 376 277 72.2 84.1 TPC
0.60 1.260 0.756 354 261 74.4 86.6 TP Pump torque at pump speed nP
0.70 1.120 0.784 322 238 78.0 90.8
0.78k 1.000 0.780 282 208 83.4 97.1 TT Turbine torque at turbine speed nT
0.86 0.970 0.834 194 143 100.5 117.0
0.94 0.960 0.902 98 72 141.4 164.7
Torque converter values: Acc. to VDI Guidelines 2153
mean values

1800 2400

1700
2200
1600
1500 2000
T (Nm)

1400
T (ft.lb.)

=0

1600
TP
1100
1400
1000

900 8k
0.7
1200
800 =
3.0 1000 TP
2.8 700
2.6
2.4 600
2.2
800
w(%)
2.0 500 100
1.8 600 90
1.6 400 TPC1400 80
1.4 70
1.2 300 400 60
1.0 50
0.8 200 40
0.6 200 30
0.4 100 20
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0
016 670

4149 765 103 - 2004-12 7-8


ZF-Ecomat 2 plus Converter

W360*TPC262*MUE2.40

Basic curve: 4166 703 147


Impeller constants nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 2.400 0 262 193 61.8 71.9 = Torque converter efficiency


0.10 2.150 0.215 262 193 61.8 71.9
0.20 1.915 0.383 260 192 62.0 72.2 TPC Pump torque at constant pump speed nPC
0.30 1.705 0.512 256 189 62.5 72.8
0.40 1.520 0.608 248 183 63.5 74.0 nPC
K= Factor at constant pump speed nPC
0.50 1.365 0.683 235 173 65.2 76.0 TPC
0.60 1.235 0.741 218 160 67.8 79.0 TP Pump torque at pump speed nP
0.70 1.097 0.768 195 144 71.6 83.4
0.76k 1.000 0.760 175 129 75.6 88.0 TT Turbine torque at turbine speed nT
0.80 0.980 0.784 152 112 81.1 94.4
0.90 0.979 0.881 82 60 110.4 128.6
Torque converter values: Acc. to VDI Guidelines 2153
mean values

1800 2400

1700
2200
1600

1500 2000
T (Nm)

1400
T (ft.lb.)

=0

1600
TP
1100
k
1400
7 6
1000 0.
900
=
1200
TP
800
3.0 1000
2.8 700
2.6
2.4 600 800 w(%)
2.2
2.0 500 100
1.8 600 90
1.6 400 80
1.4 70
1.2 300 400 60
1.0 TPC1000 50
0.8 200 40
0.6 200 30
0.4 100 20
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0
016 671

4149 765 103 - 2004-12 7-9


ZF-Ecomat 2 plus Converter

W360*TPC300*MUE2.36

Basic curve: 4166 703 149


Impeller constants nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 2.360 0 300 221 57.7 67.2 = Torque converter efficiency


0.10 2.130 0.213 300 221 57.7 67.2
0.20 1.920 0.384 297 219 58.0 67.5 TPC Pump torque at constant pump speed nPC
0.30 1.720 0.516 290 214 58.8 68.4
0.40 1.540 0.616 278 205 60.0 69.8 nPC
K= Factor at constant pump speed nPC
0.50 1.380 0.690 264 194 61.6 71.7 TPC
0.60 1.250 0.750 245 181 63.9 74.4 TP Pump torque at pump speed nP
0.70 1.110 0.777 222 164 67.1 78.1
0.78k 1.000 0.780 192 142 72.2 84.0 TT Turbine torque at turbine speed nT
0.80 0.978 0.782 180 133 74.5 86.8
0.90 0.960 0.864 96 71 102.1 118.8
Torque converter values: Acc. to VDI Guidelines 2153
0.95 0.950 0.903 56 41 133.6 155.6 mean values

2600
1900

1800 2400

1700
2200
1600

1500 2000
T (Nm)

1400
T (ft.lb.)

0
=

1600
78

TP
0.

3.0 1100
=

2.8 1400
1000 TP
2.6
2.4 900 1200
w(%)
2.2 800

2.0 1000 100
700
1.8 90

1.6 600 800 80

1.4 500
70

1.2 600 60
400 50
1.0
0.8 300 400 TPC1000 40

0.6 30
200
0.4 200 20
100
0.2 10

0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0
016 672

4149 765 103 - 2004-12 7-10


ZF-Ecomat 2 plus Converter

W360*TPC342*MUE2.27

Basic curve: 4166 703 148


Impeller constants nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 2.270 0 342 252 54.1 63.0 = Torque converter efficiency


0.10 2.072 0.207 340 251 54.2 63.1
0.20 1.890 0.378 334 246 54.7 63.7 TPC Pump torque at constant pump speed nPC
0.30 1.704 0.511 324 239 55.6 64.7
0.40 1.540 0.616 312 230 56.6 65.9 nPC
K= Factor at constant pump speed nPC
0.50 1.390 0.695 295 217 58.2 67.8 TPC
0.60 1.260 0.756 274 202 60.4 70.3 TP Pump torque at pump speed nP
0.70 1.133 0.793 249 184 63.4 73.8
0.80k 1.000 0.800 206 152 69.7 81.1 TT Turbine torque at turbine speed nT
0.85 0.980 0.833 164 121 78.1 90.9
0.90 0.978 0.880 119 87 91.9 107.0
Torque converter values: Acc. to VDI Guidelines 2153
mean values

2600
1900

1800 2400

1700
2200
1600

1500 2000
T (Nm)

1400
=0
T (ft.lb.)

1600
0k

TP
0 .8

3.0 1100
=

2.8 1400

1000
2.6
TP
2.4 900 1200
w(%)
2.2
800
2.0 1000 100
700
1.8 90

1.6 600 800 80

1.4 70
500
1.2 600 60
400 50
1.0
TPC1000
0.8 300 400 40

0.6 30
200
0.4 200 20
100
0.2 10

0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0 016673

4149 765 103 - 2004-12 7-11


ZF-Ecomat 2 plus Converter

W360*TPC390*MUE2.17

Basic curve: 4166 703 150


Impeller constants: nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 2.165 0 390 288 50.6 59.0 = Torque converter efficiency


0.10 2.010 0.201 385 284 51.0 59.3
0.20 1.830 0.366 376 277 51.6 60.0 TPC Pump torque at constant pump speed nPC
0.30 1.645 0.494 363 268 52.5 61.1
0.40 1.480 0.592 347 256 53.7 62.5 nPC
K= Factor at constant pump speed nPC
0.50 1.350 0.675 326 240 55.4 64.5 TPC
0.60 1.230 0.738 300 221 57.7 67.2 TP Pump torque at pump speed nP
0.70 1.110 0.777 268 198 61.1 71.1
0.78k 1.000 0.780 234 173 65.4 76.1 TT Turbine torque at turbine speed nT
0.85 0.980 0.833 180 133 74.5 86.8
0.90 0.970 0.873 128 94 88.4 102.9
Torque converter values: Acc. to VDI Guidelines 2153
mean values

2600
1900

1800 2400

1700
2200
1600

1500 2000
T (Nm)

1400
T (ft.lb.)

=0

8k

1600

0 .7

TP
=

1100

1400
1000 TP
2.6
2.4 900 1200
2.2 w(%)
800
2.0 1000 100

1.8
700 90

1.6 600 800 80

1.4 70
500
1.2 600 60
400 50
1.0
0.8 300 400 TPC1000 40

0.6 30
200
0.4 200 20
100
0.2 10

0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0 016 674

4149 765 103 - 2004-12 7-12


ZF-Ecomat 2 plus Converter

W390*TPC392*MUE2.20

Basic curve: 4166 711 145


Impeller constants nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 2.195 0 392 289 50.5 58.8 = Torque converter efficiency


0.10 2.062 0.206 400 295 50.0 58.2
0.20 1.929 0.386 407 300 49.6 57.7 TPC Pump torque at constant pump speed nPC
0.30 1.768 0.530 414 305 49.1 57.2
0.40 1.602 0.641 418 308 48.9 57.0 nPC
K= Factor at constant pump speed nPC
0.50 1.450 0.725 403 297 49.8 58.0 TPC
0.60 1.292 0.775 376 277 51.6 60.0 TP Pump torque at pump speed nP
0.70 1.125 0.788 320 236 55.9 65.1
0.78k 1.000 0.780 260 192 62.0 72.2 TT Turbine torque at turbine speed nT
0.85 0.995 0.846 186 137 73.7 85.4
0.90 0.995 0.896 143 105 83.6 97.4
Torque converter values: Acc. to VDI Guidelines 2153
0.94 0.995 0.935 96 71 102.1 118.8
mean values.

3000
2200

2100 2800

2000
2600
1900

1800 2400

1700
2200
1600
2000
k

1500
.40

.78
=0
=0

=0
T (Nm)

1400


T (ft.lb.)

TP TP
TP
1600
1100
1400
1000

2.4 900 1200
2.2 w(%)
800
2.0 1000 100
700
1.8 90
1.6 600 800 80
1.4 70
500 TPC1000
1.2 600 60
400 50
1.0
0.8 300 400 40

0.6 30
200
0.4 200 20
100
0.2 10

0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0 016 676

4149 765 103 - 2004-12 7-13


ZF-Ecomat 2 plus Converter

W390*TPC487*MUE1.98

Basic curve: 4166 711 146


Impeller constants: nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 1.982 0 487 359 45.3 52.8 = Torque converter efficiency


0.10 1.894 0.189 490 361 45.2 52.6
0.20 1.804 0.361 490 361 45.2 52.6 TPC Pump torque at constant pump speed nPC
0.30 1.692 0.508 486 358 45.4 52.8
0.40 1.571 0.628 484 357 45.5 52.9 nPC
K= Factor at constant pump speed nPC
0.50 1.440 0.720 469 346 46.2 53.8 TPC
0.60 1.303 0.782 439 324 47.7 55.6 TP Pump torque at pump speed nP
0.70 1.159 0.811 387 285 50.8 59.2
0.80k 1.000 0.800 318 235 56.1 65.3 TT Turbine torque at turbine speed nT
0.85 0.995 0.846 271 200 60.7 70.7
0.90 0.995 0.896 204 150 70.0 81.5
Torque converter values: Acc. to VDI Guidelines 2153
0.95 0.995 0.945 114 84 93.7 109.1
mean values.

3000
2200

2100 2800
2000
2600
1900

1800 2400
1700
2200
1600

1500 2000
1400
T (Nm)
T (ft.lb.)

.1 0

=0

k
=0

.80

1600

TP
=0

1100 TP

1400
1000 TP

2.4 900 1200
w(%)
2.2 800
2.0 1000 100
700
1.8 90

1.6 600 800 80

1.4 500 TPC1000 70

1.2 600 60
400
1.0 50

0.8 300 400 40

0.6 30
200
0.4 200 20
100
0.2 10

0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0 016 677

4149 765 103 - 2004-12 7-14


ZF-Ecomat 2 plus Converter

W390*TPC615*MUE1.83

Basic curve: 4166 711 147


Impeller constants: nPC = 1000 rpm

= nT/nP Torque converter speed ratio


TPC1000 K
[] [] [] [Nm] [lbft] [Nm] [lbft] = TT/TP Converter torque ratio

0 1.829 0 615 454 40.3 47.0 = Torque converter efficiency


0.10 1.736 0.174 629 464 39.9 46.4
0.20 1.646 0.329 639 471 39.6 46.1 TPC Pump torque at constant pump speed nPC
0.30 1.551 0.465 634 468 39.7 46.2
0.40 1.447 0.579 625 461 40.0 46.6 nPC
K= Factor at constant pump speed nPC
0.50 1.337 0.669 609 449 40.5 47.2 TPC
0.60 1.228 0.737 560 413 42.3 49.2 TP Pump torque at pump speed nP
0.70 1.116 0.781 479 353 45.7 53.2
0.80k 1.000 0.800 379 280 51.4 59.8 TT Turbine torque at turbine speed nT
0.85 0.995 0.846 316 233 56.3 65.5
0.90 0.995 0.896 247 182 63.6 74.1
Torque converter values: Acc. to VDI Guidelines 2153
0.94 0.995 0.935 158 117 79.6 92.6
mean values.

3000
2200

2100 2800
2000
2600
1900

1800 2400

1700
2200
1600

1500 2000
T (Nm)

1400
k
T (ft.lb.)

0
0

.80
=
0.2

=0
=

1600

TP
1100 TP TP
1400
1000

2.4 900 1200
2.2 w(%)
800
2.0 1000 100
700
1.8 TPC1000 90

1.6 600 800 80

1.4 500
70

1.2 600 60
400
1.0 50

0.8 300 400 40

0.6 30
200
0.4 200 20
100
0.2 10

0 0 0 0
1000 2000 nT, nP (1/min) 3000

0 0.2 0.4 0.6 0.8 1.0
016 678

4149 765 103 - 2004-12 7-15


ZF-Ecomat 2 plus Retarder

8 Retarder Additionally, the ZF retarder has a special feature in


that a vane ring is rotatably fixed in the stator. This
8.1 Structure and function of retarder reduces losses when the retarder is not engaged to
less than 25% of the amount of loss without such a
The ZF Retarder integrated in the Ecomat is a single- division of the stator.
staged hydro-dynamic continuous brake fitted
between the torque converter and selector trans- A proportional solenoid which receives a voltage sig-
mission. nal from the transmission electronic unit determines
the piston position of the retarder valve. The higher
This means that braking force is directly dependent the voltage signal, the greater the oil pressure pres-
on the gear engaged. Even at low speeds, full ented by the control valve in the retarder cycle.
braking effect is available (characteristic for the
primary retarder). The retarder torque can be controlled depending on
The retarder consists of the following components: the piston position and the oil pressure determined
A rotor and a stator, both of which are fitted with by this. The maximum retarder torque is programmed
blades. The rotor (the rotating part of the retarder) is in the electronic unit.
connected to the input shaft of the transmission and The basic advantage of the ZF retarder is its infinite-
therefore also to the vehicles drive axle when a gear ly variable control. If required, the braking torque
is selected. The stator on the other hand is rigidly can be divided into one or several stages, all limited
connected to the Ecomat housing. to a value specified by the customer.

Grid

Stator
Rotor

023780

4149 765 103 - 2004-12 8-1


ZF-Ecomat 2 plus Retarder

8.2 Retarder action

There are various activation options for a braking


procedure using the retarder (see diagram, chapter
8.5). Depending on the type of activation, it may be
undertaken in stages or a gradual manner during
which a voltage value equivalent to the retarder
torque is sent from the appropriate activation ele-
ment to the proportional solenoids. Depending on
the strength of this signal, the piston of the retarder
control valve is moved into a certain position which
sets an appropriate level of oil pressure in the retar-
der circuit.

The oil filling experiences centrifugal acceleration


as a result of the rotors rotary motion, which is dri-
ven by the coasting vehicle via the axle, propshaft,
and transmission in overrun mode. The rotor forces
the oil into blades in the non-rotating stator. The
direction of oil flow is reversed and slowed (braked).
Due to the reverse of oil flow direction in the stator,
the rotation of the rotor is also slowed, as is the
vehicle speed.

The friction of the oil flow is converted into heat.


This heat is conveyed to the cooling water by the
heat exchanger in liquid cooled engines or radiated
into the cooling air in air-cooled engines.

4149 765 103 - 2004-12 8-2


ZF-Ecomat 2 plus Retarder

8.4 Retarder and engine brake

Max. braking torques

Trans- Total of all


mission Max. Torque brake torques Max. TRotor [Nm]
type max. [Nm] at nT = 1900 rpm

650 Nm 900 750

HP 502 C 850 Nm * 950 * 850 *

1100 Nm 1300 1050

HP 592 C 1250 Nm 1300 1050

1400 Nm 1500 1250


HP 602 C
1600 Nm 1500 1250

* up to max. 13 to

4149 765 103 - 2004-12 8-3


ZF-Ecomat 2 plus Retarder

8.5 Retarder activation variants


hand and foot

Overview of permitted Retarder activation variants

Hand

TSC1 Bed elem


TSC1 primary
No function

TSC1 sec
Analog
ED

1 2 3 4 5 6

No function 1/2 1/3 1/6


1

ED 2/1 2/2 2/3 2/6


2

Analog 3/1 3/2 3/3 3/6


3
Foot

EBC1 brake pedal 4/1 4/2 4/3 4/6


4

TSC1 primary 5/4


5

TSC1 sec 6/5


6

TSC1 primary = % of nominal rotor torque


TSC1 sec = % from 1st support point on characteristics field
M_output for retarder operation
TSC1 operating element = % of M_output during retarder operation

4149 765 103 - 2004-12 8-4


ZF-Ecomat 2 plus Retarder

8.5.1 Permitted variants foot request without


hand request

Variants 2/1

Activation via footplate in digital manner with max.


3 stages. Any parameters can be set for the retarder
request percentage.

Standard:
3-stage: 50 %, 75 %, and 100 %.

Inputs:
Pin 65 (ED 2), Pin 12 (ED 15), and Pin 36 (ED 7)

Footplate deactivation via S9.

Variants 3/1

Activation using footplate with analog voltage signal


on input EU3 EST 146/147 PIN 39.

Voltage spectrum 0 - 5 volts, percentage value of


retarder request in ECU 146/147 can be configured.

NOTE
To compensate for pedal zero setting variances, the
automatic footplate adjustment function in ECU
146/147 can be activated.

Footplate disengagement using S9 is advisable.

Variants 4/1

Retarder request using brake pedal value output via


CAN signal EBC1 brake pedal position as percent
of brake pedal travel. Retarder request can be con-
figured as % of pedal travel in ECU 146/147.

Footplate disengagement using S9 is advisable.

4149 765 103 - 2004-12 8-5


ZF-Ecomat 2 plus Retarder

8.5.2 Permitted variants foot request


without hand request

Variant 1/2

Digital activation using hand lever with max. 3


stages. Percentage value for retarder request can be
configured to desired level.

Standard:
3-stage: 50 %, 75 %, and 100 %.

Inputs:
Pin 65 (ED 2), Pin 12 (ED 15), and Pin 36 (ED 7)

Variant 1/3

Hand lever analog, stepped or continuously variable


with analog voltage signal on input EU2.
ECU 146/147 PIN 61.

For additional protection of hand lever zero setting


(retarder OFF), a digital input can be used. Standard
EDM2.

Variant 1/6

Retarder request via TSC 1 as a percentage of the


setting of a control element via CAN. The retarder
request value is specified by the CAN signal.

For further calculation of the retarder request, the


percentage for a given control element can be scaled
progressively from software Step 3.

4149 765 103 - 2004-12 8-6


ZF-Ecomat 2 plus Retarder

8.5.3 Permissible retarder activation variants


"Foot" and "Hand" combined

Variant 2/2 Variant 5/4

If possible, use different digital inputs for the pedal Retarder request via TSC 1 via CAN as direct specifi-
plate and manual lever. cation for rotor torque.

Reasoning: Additional linking of the TSC1 rotor torque specifi-


Requests made by foot and hand may differ and are cation with other controls should not be applied.
used for additional logic in the shift program.
Reasoning:
Recommendation: The rotor torque specified e.g. by brake management
Foot: ED2, ED15, ED7 would no longer be clear. As a consequence, this
Hand: Use three unused EDs. may affect the control process for a brake system.

Footplate disengagement using S9 is advisable. NOTE


The TSC1 cannot be assigned to foot or hand. A
distinction in the shift program would not then be
Variant combination of possible.
2/3 for explanation, refer to 2/1 and 1/3
2/6 for explanation, refer to 2/1 and 1/6
3/2 for explanation, refer to 3/1 and 1/2
3/3 for explanation, refer to 3/1 and 1/3
3/6 for explanation, refer to 3/1 and 1/6
4/2 for explanation, refer to 4/1 and 1/2
4/3 for explanation, refer to 4/1 and 1/3
4/6 for explanation, refer to 4/1 and 1/6

4149 765 103 - 2004-12 8-7


Retarder activation variants

1 2 3 4
Trittplatte Handhebel 0 1 2 3 n

4149 765 103 - 2004-12


S9 Foot plate Manual lever EDM 1
St St St St St St
1 2 3 1 2 3
ZF-Ecomat 2 plus

EU 2 EU 3

% % % %

V V

max. Berechnung Rotor-Ist-Moment


Trittplattenabschaltung Retarderabschaltung
Max. Caleulation Rotor-actual-torque
Foot plate deactivation

8-8
Retarder deactivation

8
%
Rotor-Ist-
EBC1 TSC1 Anforderung [%]
Moment [Nm]
Bedienelement EBC1 ABS aktiv
ABS not fully Rotor-actual-
TSC1 EBC1 ABS active
operational Request Control ellement torque [Nm]
EBC1
Break Pedal Pos.
5 6
Anforderung [%]
Request [%]

TSC1
Anforderung[%]
CAN (Retarderreferenzmoment [Nm])
TSC1
7
Request [%]
(Retarder reference torque [Nm])

016 707
Retarder
ZF-Ecomat 2 plus Cooling system

9 Cooling system Determination of max. permissible water


temperature
9.1 Design of cooling system
100
Ecomat 2 plus mit/w
ith
Special attention should be paid to the following
Ecofluid A plus

max [C]
points when designing the cooling system:
95
- Heat build-up due to torque converter

awc_in_
(see Torque converter diagram PV) 93C

t_
- Heat build-up due to retarder
90

The values calculated during the design of the


cooling system must be checked by ZF applications 85
engineers and monitored using the measurements
which must be taken during commissioning (see
9.11 Temperature measurements in bus). 80
10 20 30 40 50
delta_
ts_pec [K]
The cooling system should be designed in 021744

accordance with the requirements of the vehicle


type and site of use to ensure that the following Example:
approval criteria are satisfied: Measurement values during retarder cycles

Approximate values for engine cooling constant* t_sump = 75 C


for service temperatures t_amb = 10 C t_spec = 25 K
up to 30 C = 55 K/60 K t_wa_cin = 50 C
above 30 C = 50 K/55 K

Determination of permissible water temperature


9.1.1 Release criteria for temperature measure- from diagram
ments (max. ambient temperature = 40 C)
Result
9.1.1.1 According to List of Lubricants TE-ML 14 E
- In service applications, water temperature must
Thermostat and fan feedback control must be set not exceed 93 C line and the same applies to
so that the max. water temperature T_wa_cin at coolant temperatures in a feedback control
the max. admissible ambient temperature in line system subject to an ambient temperature of up
service applications corresponds to the diagram. to 40 C.
Transmission cooling constant max. 75 K (other- - Vehicle cooling capacity is sufficient
wise, vehicle cooling capacity insufficient). (GCC < 75 K)

* Engine cooling constant = difference between water temperature


upstream of radiator and ambient temperature.
For example: Ambient temperature 30 C, water temperature
upstream of radiator 85 C, engine cooling constant = 55 K

4149 765 103 - 2004-12 9-1


ZF-Ecomat 2 plus Cooling system

9.1.1.2 According to List of Lubricants TE-ML 14 9.1.2 Limit temperature values for oil temperature
A/B/C
Oil temperature in transmission oil sump
Thermostat and fan feedback control must be set
so that the max. water temperature T_wa_cin at The following sump temperature values must not be
max. admissible ambient temperature in line exceeded:
service applications corresponds to the diagram.
Transmission cooling constant max. 70 K With oil according to List of Lubricants TE-ML 14 E
(otherwise, vehicle cooling capacity insufficient). - Operating temperature and/or stabilized tempera-
ture max. 105 C.
- In exceptional cases and only for short periods
of time (max. 5 min. per 1 hour) 115 C are
permitted.
Determination of max. permissible water
temperature With oil according to List of Lubricants
TE-ML 14 A / B / C
100 - Operating temperature and/or stabilized tempera-
Ecomat 2 ture max. 100 C.
Ecomat 2 plus
max [C]

- In exceptional cases, 105 C are permissible for


95 short periods (max. 5 min. per 1 hour).
awc_in_
t_

90

87.5C 9.1.3 Cooling system with retarder


85
The transmission oil cooler is designed for cyclic
operation (no instances of long constant travel with
80 full retarder performance).
10 20 30 40 50 This results in a cooling capacity of 190 kW at
021 743 delta_
ts_pec [K] 250 dm3/min flow rate at water and oil end under
the marginal conditions represented on the Diagram
9.1.4.1.
For extreme Retarder applications note design
criteria described at item 9.1.

Recommended minimum water quantity


- Min. water flow rate
250 dm3/min = 15 m3/h - 350 m3/h per vehicle
at engine speed nmot = 2000 rpm
- Min. water flow rate
50 dm3/min = 3 m3/h
at idling speed nmot = 550 ... 600 rpm

4149 765 103 - 2004-12 9-2


ZF-Ecomat 2 plus Cooling system

9.1.3.1 Cooling system graph of shell type cooler kW

SBK 279 300 . .


Vw = f (Voil) = 416.7 dm3/min

. .
Vw = f (Voil) = 333.3 dm3/min
For an example of calculation for the braking
250
rating of a vehicle fitted with an Ecomat . .
Vw = f (Voil) = 250.0 dm3/min
transmission and retarder, see Chapter 18.
200
. .
Vw = f (Voil) = 166.7 dm3/min

Oil input temperature: 135 C


150
Water input temperature: 85 C Pw Poil

bar bar
. .
Vw = f (Voil) = 83.3 dm3/min
100 0.20 4
Poil
Pw
0.15 3

50 0.10 2

0.05 1

0 0

0 83.3 166.7 250 333.3 416.7 500

. .
Vw, Voil dm3/min 014985

9.1.4 Cooling system without retarder

The design of the heat exchanger must be based on As a guide value for light-duty operation, cooling
the Pv torque converter diagram and the flow rate of power of at least 30 kW should be available.
the primary pump. On versions without a retarder,
the oil quantity requiring to be cooled is determined
by the flow rate of the primary pump.

9.1.4.1 Delivery volume of the primary pump


Delivery volume of the primary pump

Input speed
4139 S 2107

4149 765 103 - 2004-12 9-3


ZF-Ecomat 2 plus Cooling system

9.2 Position of transmission oil cooler 9.4.2 Installation instructions

Depending on vehicle spatial requirements, the oil The oil cooler should not be installed above the
cooler can be installed transmission to avoid erroneous oil level readings
- Transverse behind the transmission or laterally or caused by return oil with engine at standstill.
- separately fitted from the transmission (installa- (See installation guidelines, section 8.3.3:
tion by vehicle manufacturer). Checking oil level on version with separate heat
exchanger installed higher than the center line of
CAUTION the transmission).
Connect waterline in contra-flow! 50 mm nominal The oil cooler must be installed close to the trans-
width must be ensured on the entire length. mission to reduce as much as possible the length
of hoses used and thus keep pressure losses at oil
side as low as possible.
Preferably fit the oil cooler on transmission
9.3 Cooler fitted on transmission engine block. Avoid unnecessary stress on hoses
by means of relative motion. Hoses must be
Specification heat exchanger group secured by brackets so that they cannot be
damaged in case of vibrations.
Chapter 10 Transmission specification can be used
to specify the heat exchanger group. The following should be noted in case of separate
external coolers:
The lines between transmission and oil cooler
9.4 Layout with oil cooler separate from must be routed carefully.
transmission Lines must be routed so to avoid contact or
chafing (relative motion must be considered).
9.4.1 Oil line connections Lines must be suitably fixed.
(Avoid vibrations).
Transmission with retarder: The distance between the transmission and
Internal diameter of connection lines at least exhaust should be at least 100 mm. If the distance
32 mm, hose lines heat resistant to at least 160 C, is not large enough, a screening plate must be
pressure resistant to 20 bar (test pressure 50 bar) and fitted.
not subject to corrosion by oils in the TE-ML 14 List
of Lubricants.

Transmission without retarder:


Internal diameter of connection lines at least
19 mm,hose lines heat resistant to at least 140 C,
pressure resistant to 20 bar (test pressure 50 bar) and
not subjectto corrosion by oils in the TE-ML 14 List
of Lubricants.

4149 765 103 - 2004-12 9-4


ZF-Ecomat 2 plus Cooling system

9.5 Cooling water circuit

Full-flow transmission oil cooler on cold water pressure side. This configuration is preferred.

Top view Transmission oil connection Side view

Cooling water
expansion tank
Heater
Transmission
oil cooler

Ther-
mostat

Radiator
Ecomat
Engine
trans-
mission

Transmission oil cooler Cooling water pump 015 618

Full-flow transmission oil cooler on cold water suction side.

Top view Transmission oil connection Side view

Cooling water
expansion tank
Heater

Ther-
mostat
Transmission
oil cooler
Radiator

Ecomat Engine
trans-
mission

Transmission oil cooler Cooling water pump


015 619

4149 765 103 - 2004-12 9-5


ZF-Ecomat 2 plus Cooling system

Full-flow transmission oil cooler on hot water pressure side.

Top view Transmission Side view


oil connection

Cooling water
Heater expansion tank

Transmission
oil cooler Thermostat
Vent pipe

Radiator
Ecomat
Engine
trans-
mission

Transmission oil cooler Cooling water pump 015 615

NOTE Transmission oil cooling water circuit for V-engines


When thermostat is closed, ensure the cooling water
still flows through the transmission oil cooler. If possible, the water required for cooling the trans-
(50 ltr/min at idling speed mission oil should be fed through the transmission
250 ltr/min at rated engine speed) oil cooler from both banks of cylinders (full cooling
water flow). After installation of the transmission oil
cooler, the distribution of the water flow between
the two banks of cylinders must be checked, and
corrected if necessary.

NOTE
If for some specific reason cooling water for the
transmission oil cooler can only be taken from one
bank of cylinders, consultation between the engine
and transmission manufacturers is essential.

4149 765 103 - 2004-12 9-6


ZF-Ecomat 2 plus Cooling system

Full-flow transmission oil cooler on hot water suction side.

Cooling water
expansion tank
Thermostat

2nd cylinder bank

Ecomat
transmission V-engine

Radiator
1st cylinder bank

Transmission
oil cooler
Cooling
water pump
Heater

015 617

By-pass transmission oil cooler on hot water suction side.

Cooling water
expansion tank
Thermostat

2nd cylinder bank

Ecomat
transmission V-engine
Radiator

1st cylinder bank

Transmission
oil cooler
Cooling
water pump
Heater

015 616

4149 765 103 - 2004-12 9-7


ZF-Ecomat 2 plus Cooling system

9.6 Specification for transmission heat If no water capable of meeting these requirements is
exchanger available, different grades of water can be mixed
together in order to achieve the specified water
Requirement specification 4139 761 004 is binding. quality (e.g. a mixture of hard and fully desalinated
water).

9.7 Required performance of cooling water and 9.7.3 Antifreeze


antifreeze
Ethylene glycol base with corrosion inhibitors.
Requirement specification for heat exchanger Antifreeze must not contain the following: Amines,
(LR94011) is binding. chlorides, phosphates, sulphates, carbonates, and
chromates.

9.7.1 General Specific gravity (20C): 1.11 - 1.14 (g/ml) DIN 51757
Flashpoint: > 110C DIN 51758
Antifreeze consists of ethylene glycol and anti- Boiling point: 160 C ASTM-D-1120
corrosion additives. Mix water and antifreeze to
make the cooling water. Ethylene glycol raises the
boiling point and lowers the freezing point, thus 9.7.4 Cooling fluid
extending the operating range. Anti-corrosion
additives must protect the cooling system from Cooling fluid is a mixture of fresh water and anti-
corrosion. Antifreeze must be prepared in such a freeze and must have the following properties
way that it retains its properties over a storage Minimum proportion of antifreeze: 35 vol.% test
period of at least two years. using antifreeze tester (areometer or hydrometer)
pH value: 7.5 to 9.0
test using pH meter or indicator paper
9.7.2 Fresh water Residual alkalinity: 10 ml 0.1n HCL
ASTM-D-1121
Only use clean water to produce cooler fluid. It must Flocculation point of 50%-solution: < -35C
comply with the following quality and analysis values: ASTM-D-1177
Color: Transparent, clear Foam volume after 5 min.: 150 ml
Smell: Neutral ASTM-D-1881
Particles in suspension (sediment): None Foam killer time after 5 min.: 5 sec.
pH value (at 20 C): 6.5 - 8.0 ASTM-D-1881
Total hardness: 3 - 10 dH
Ammonia content: Not traceable Reactivity against metal materials:
Aggressive carbon dioxide: Not traceable Removal rate: < 2 g/m2 on test sheets made of L-
Iron and manganese content: Max. 0.2 mg/l PbSn30, CuZn37, GG25, G-AlSi10Mgwa, A1Mn1
Chloride content: Max. 75 mg/l tested according to ASTM-D-1384 and guidelines
Sulphate content: Max. 50 mg/l in "Test of suitability of cooling water additives
Nitrate content: Max. 50 mg/l for combustion engine cooling water" by the
Nitrite content: Not traceable Verbrennungskraftmaschinen e. V. Research
Solid residue after evaporation: Max. 500 mg/l Institute, Frankfurt, Booklet R 315 (1977) or later
Potassium permanganate edition where valid.
consumption: Max. 10 mg/l
Balance index: 0, if possible

4149 765 103 - 2004-12 9-8


ZF-Ecomat 2 plus Cooling system

Reactivity against elastomers (NBR, EPDM): 5. Place selector lever in position N, start up the
- 50 vol.% antifreeze engine and then, after a brief period at idle speed,
- 100 hour aging at boiling point run for about 4 minutes in the speed range of 1000
- Shore A hardness modification = -10 to +10 SHA - 1500 rpm. Then run the engine until the oil sump
- Volume change V = -10 to +10% temperature reaches approx. 85 C (Section 4.4 of
- Residual pressure deformation < 30% the Operating Manual). The auxiliary cooling
system is then filled and drained automatically.
Cooling water storage limit: 1 - 2 years, after this 6. Check and adjust the oil level in accordance with
time, replace. If sediment forms or concentration the hot marks on the dipstick (refer to Operating
drops considerably, also replace cooling water. Manual, Section 4.3.1 Inspection at Operating
Temperature, with vehicle on level ground,
selector lever in N and engine at idling speed of
9.8 Transmission fill with auxiliary cooling 500 - 700 rpm).
(applicable to all transmissions approved
for use with auxiliary cooling)

This filling specification applies in addition to the


Operating Manual.
ACHTUNG CAUTION
Getriebe mit Zusatzkuehlung. Transmission iwth auxiliary cooling.

When an ECOMAT transmission is being operated Getriebe hat nicht die erforderliche Oelmenge.
A) Vor Erstinbetriebnahme die eGsamtlaenge
aller oKmponenten der Zusatzkuehlung ausserhalb
il volume insufficient for the transmission.
O
A) Determine total lenght of all auxiliary
cooling components outside of the transmission
prior to initial startup.

with auxiliary cooling, always ensure that the


des Getriebes ermitteln.
Aus der G esamtlaenge und eL itungs DN(Innendurchmesser) Determine additional oil volume on the basis of
die Zusatzoelmenge ermitteln. total lenght and line - DN(inner diameter).
m m m
m m
6 =24 =22m 0mm
6 =24m =22m 0mm
correct oil level is maintained at all times. Trans- DN DN DN=2 DN DN DN=2

il volume [Litre]
elvolumen [Liter]

5 5 8mm
8mm DN=1
DN=1
4 m 4 m
DN=16m DN=16m
3
missions cannot be supplied with the total oil fill
3

O
O

2 2
1 1

quantity required for this purpose. Once the trans- 0


2 4 6 8 10 12 14 16
eGsamtlaenge [m]
0
2 4 6 8 10 12 14 16
Total lenght[m]
eOlfuellvolumen des O elkuehlers ermitteln. Determine oil-fill volume of the oil cooler.

mission and auxiliary cooling system have been Die erforderliche uZsatzoelmenge einfuellen.

B) Vor Erstinbetriebnahme eOlstandskontrolle durchfuehren.


Fill in extra amount of oil reguired.

B) Prior to running transmission for the first


Motor starten,nach 30 Sekunden bei Leerlauf-Drehzahl time,carry out oil level check.

installed in the vehicle, the oil level must be set with eOlstand am Messstab pruefen,ewnn noetig O
bis Marke "CD
LO"bzw
Die massgebende O
.3" 0Ce" rreicht iwrd.
elstandskontrolle
el nachfuellen, Start engine,after 30 secs. check oil level at
dipstick iwth engine idling. If necessary,
add oil to "CO
LD/30C"mark.
ist die Pruefung bei The oil level check carried out

the transmission at operating temperature (85 C). Betriebstemperatur 80 - 90C.

Bei Motorleerlauf-Drehzahl Standbereich (n Mot=0) STO


P
at 80
C to 90C operating
temperature gives the
conclusive reading. engine stop zone STO
P
aWrmbereich 80-90C HO
T hot zone 80-90C HO
T
und eGtriebe Neutral
muss O elstand im O
il level must be in
aWrmbereich "85C" awrm range 8" 5CH
/ TO"
bzw
.H
" TOl"iegen. Kaltbereich 30C CO
D
L ith engine idling and
w cold zone 30C CO
D
L
transmission in neutral.

021684
Filling:
1. With the engine stationary, top up with ATF until 6
Oil quantity [litre]

you reach the STOP mark on the dipstick


m
2. Establish the correct line length for auxiliary 5 4m m mm
N=
2
=22m DN=20
cooling (all components outside the transmission: D DN 18m
m
hoses, pipes, cooler).
4
DN=
6mm
3. From the line length and internal diameter of the 3 DN=1
hoses (DN), determine the approximate volume
2
of additional oil required (refer to adjacent
diagram). 1
4. Fill the required additional volume of oil to above
0
the STOP mark on the dipstick, but do not add 2 4 6 8 10 12 14 16
more than 5 liters. If the additional volume of oil Line entire length [m]
exceeds 5 liters, do not top up beyond this level 021770

until the engine has been run for a while and you 7. If service work is required: Before working on the
have checked the oil level once again (refer to auxiliary cooling system, first drain off the trans-
Operating Manual, Section 4.3). Failure to do this mission oil!
could result in ATF overflowing from the trans- DN = internal diameter (tube or hose)
mission.
See also Chapter 17, ZF Specification

4149 765 103 - 2004-12 9-9


ZF-Ecomat 2 plus Cooling system

9.9 Transmission oil sump cooling

For applications which fail to comply with ZF


temperature acceptance criteria, and for specific
application profiles, e.g. extended braking phases
on downhill gradients, it is advisable to have the
capability for cooling the transmission oil sump.
In all cases, first consult a ZF applications engineer.

9.9.1 System diagram, transmission oil sump


cooling

The range of individual components included in the


scope of supply is defined jointly with the OEM.

Cooler connecting part

ECOMAT Vehicle cooling


Engine system
(not modified)
Oil sump
cooler SBK
Suction
pump

Oil pan

ATF
Cooling agent

Additional breather in case of


additional cooling system

From additional cooler

Towards additional cooler


019616; 021741

4149 765 103 - 2004-12 9-10


ZF-Ecomat 2 plus Cooling system

9.10 Temperature measurements in bus 9.10.3 Calculation

9.10.1 Measurement conditions / Retarder test Difference between oil sump temperature and
cycles water inlet temperature on transmission oil cooler:
_t_spec = t_sump - t_wa_cin
Load vehicle to maximum permissible weight. Difference between oil sump temperature and
Level test track. ambient temperature:
Dry road surface, no rain and if possible no wind GCC = t_sump - t_amb
or gentle wind at the most. If the temperatures (oil and water) change in a
Vehicle heating switched off. cyclical manner, you should calculate the average
Undertake retarder braking with 100% retarder temperature from the values derived from the last
torque without assistance from the wheel brakes. five cycles:
Cooling system under open-loop control
(Lock thermostats open, fan running continuously).
t1u t2u t3u t4u t5u
Ambient temperature > 0 C.
taverage
t1d t2d t3d t4d t5d
021742
- 50 km/h for city bus
- 80 km/h for interurban buses and coaches
v [km/h]

t1u + t2u + t3u + t4u + t5u t1d + t2d + t3d + t4d + t5d
taverage = ( 5
+
5
) :2

10 s Zeit
Time

021745

9.10.2 Measurement retarder cycles

Measurement points
- Water temperature at
transmission cooler inlet: t_wa_cin
- Transmission sump oil
temperature: t_sump
- Ambient temperature: t_amb

Following conditions must be met:


- Length of all test cycles until such time as all
temperatures have stabilized.

4149 765 103 - 2004-12 9-11


ZF-Ecomat 2 plus Cooling system

9.10.4 Explanation of water temperature 9.10.5 Temperature measuring points


Retarder cycle (worst case)
1) Ambient Temperature
With oil acc. to List of Lubricants TE-ML 14 E 2) Oil temperature transmission oil sump
GCC max. 75 C + 40 C ambient temperature 3) Water temperature at inlet end of transmission
yields under test conditions (retarder cycle) cooler
115 C max. permitted transmission oil sump
temperature
t_spec characterizes the oil/water heat exchange
process
GCC characterizes the cooling capacity of the
vehicle cooling system

NOTE
- During normal service operation, the max. per-
mitted oil sump temperature of 105 C must not
be exceeded on a long-term basis.
- Isolated, brief periods of peak sump temperatures
(max. 5 minutes within a 1 hour period) are per-
missible up to max. 115 C.

With oil acc. to List of Lubricants TE-ML 14 A / B / C

Under test conditions (retarder cycle), GCC max.


70 C + 40 C ambient temperature yields, max.
transmission oil sump temperature of 110 C
t_spec characterizes the oil/water heat exchange
process
GCC characterizes the cooling capacity of the
vehicle cooling system

NOTE
- During normal service operation, the max. per-
mitted oil sump temperature of 100 C must not
be exceeded over extended periods.
- Isolated, brief periods of peak sump temperatures
(max. 5 minutes within 1 hour period) are per-
missible up to max. 105 C.

4149 765 103 - 2004-12 9-12


ZF-Ecomat 2 plus Cooling system

Position of temperature measuring points

Oil in transmission sump (measurement probe)


2 Cooling water
output

Cooling water
input

Oil in transmission sump 2 021648


023783
(measurement probe)

Top view Side view


Transmission
oil connection

Cooling water
Transmission Heater expansion tank
oil cooler

3 Ther-
Water input at mostat
transmission and
heat exchanger
Radiator

Ecomat Engine
trans-
mission

Transmission oil cooler Cooling water pump


015 619

NOTE
M14x1.5 threaded connections must be fitted in the
measuring vehicle for the measurement point no. 5.

4149 765 103 - 2004-12 9-13


ZF-Ecomat 2 plus Transmission specification

10 Transmission specification From drawing no.: 4149 602 059

4149 765 103 - 2004-12 10-1


ZF-Ecomat 2 plus Transmission specification

10.1 Installation position

10.1.1 Flange-mounted installation position

04
187.5

68.6

68.6
12
256
187.5

68.6
68.6

03
68.6

68.6
187.5

187.5
256

68.6
68.6

187.5
187.5
Anzugsmomment 225 Nm

256
256
M16x1.5
24 tief

136
89

30
63.5

0
4
16
35
02
6.5

511.2h7
553

015 008

4149 765 103 - 2004-12 10-3


ZF-Ecomat 2 plus Transmission specification

10.2 Heat exchanger arrangement

10.2.1 Coaxial output, heat exchanger at rear, accumulator horizontal on left

DIN 72585-A1-2.1

019216
DIN 72585-A1-2.1
TEMPERATURGEBER
BAJONETTSTECKER
sensor
plug
Temperature
Bajonet

O4
O3

4149 765 103 - 2004-12 10-5


ZF-Ecomat 2 plus Transmission specification

10.2.2 Coaxial output, heat exchanger at rear, accumulator rear transverse

019217
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor

72585-A1-2.1
DIN72585-A1-2.1
Bajonet plug
DIN

O4
O3

4149 765 103 - 2004-12 10-6


ZF-Ecomat 2 plus Transmission specification

10.2.3 Coaxial output or 80 angle drive RHD (with axial offset),


heat exchanger vertical on left, accumulator horizontal on left

DIN 72585-A1-2.1
plug DIN 72585-A1-2.1

023800
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
Bajonet

O4
O3

4149 765 103 - 2004-12 10-7


ZF-Ecomat 2 plus Transmission specification

10.2.4 Angle drive 80 LHD (without axial offset), heat exchanger horizontal on left,
accumulator horizontal on left

DIN 72585-A1-2.1
plug DIN 72585-A1-2.1

023801
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
Bajonet

O4
O3

4149 765 103 - 2004-12 10-8


ZF-Ecomat 2 plus Transmission specification

10.2.5 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left

DIN 72585-A1-2.1

023802
plug DIN 72585-A1-2.1
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
Bajonet

O4
O3

4149 765 103 - 2004-12 10-9


ZF-Ecomat 2 plus Transmission specification

10.2.6 Coaxial output, vertical heat exchanger on right, accumulator rear transverse

023803
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor

72585-A1-2.1
DIN72585-A1-2.1
Bajonet plug
DIN

O4
O3

4149 765 103 - 2004-12 10-10


ZF-Ecomat 2 plus Transmission specification

10.2.7 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting

023813
DIN 72585-A1-2.1
DIN 72585-A1-2.1
sensor
TEMPERATURGEBER
BAJONETTSTECKER
plug
Temperature
Bajonet

O4
O3

4149 765 103 - 2004-12 10-11


ZF-Ecomat 2 plus Transmission specification

10.2.7.1 Cooler connection piece with threaded connection

M 14x1.5

II

Part no. I II III


I

4139 347 367 M42x2 M14x1.5 M14x1.5


III

4139 347 403 1-5/8-12 UN 28 1/8 -27 NPTF M14x1.5


I

4139 347 404 1-5/8-12 UN 28 M16x1.5 M16x1.5

4139 347 405 1-5/8-12 UN 28 3/8 -18 NPTF -

M 10x1
015 613

4149 765 103 - 2004-12 10-12


ZF-Ecomat 2 plus Transmission specification

10.3 Oil pan

10.3.1 Deep oil pan, 4149 131 002

015089

4149 765 103 - 2004-12 10-13


ZF-Ecomat 2 plus Transmission specification

10.3.2 Deep oil pan; left- and right-hand connection prepared, 4149 131 006

015090

4149 765 103 - 2004-12 10-14


ZF-Ecomat 2 plus Transmission specification

10.3.3 Deep oil pan, auxiliary cooling, 4149 131 024


Caution: Flat version with auxiliary cooling not possible!

400.5

02
2850.5
0.3
15-0.5

M26x1.5
21-0.5

01 01
M27x2
508-0.5

M26x1.5
2850.5
0.3

02
450.5

019931

4149 765 103 - 2004-12 10-15


ZF-Ecomat 2 plus Transmission specification

10.3.4 Flat oil pan, 4149 131 010

015092

4149 765 103 - 2004-12 10-16


ZF-Ecomat 2 plus Transmission specification

10.3.5 Flat oil pan; left- and right-hand connection prepared, 4149 131 009

015091

4149 765 103 - 2004-12 10-17


ZF-Ecomat 2 plus Transmission specification

10.4 Oil filling

10.4.1 Oil filling <K 01>

479
192

023784

4149 765 103 - 2004-12 10-19


ZF-Ecomat 2 plus Transmission specification

10.4.2 Oil filling <K 02>, <K 04>, <K 05>


AUSBAUHOEHE
Ca. A

479

A B 023786

K 02 380 132
K 04 843 584
K 05 597 330

4149 765 103 - 2004-12 10-20


ZF-Ecomat 2 plus Transmission specification

10.4.3 Oil filling <K03>, <K 06>

Ausbauhhe
ca. A

B
bezogen auf Linie O4

023805

A B C

K 03 445 198 35 15 0 / 90 / 135 / 150 / 180 / 225 / 270

K 06 517 339 134 30 0 / 90 / 135 / 180 / 250 / 270 / 315

4149 765 103 - 2004-12 10-21


ZF-Ecomat 2 plus Transmission specification

10.4.4 Oil filling <K 09>

477

131

49

023811

4149 765 103 - 2004-12 10-22


ZF-Ecomat 2 plus Transmission specification

10.5 Output

10.5.1 Coaxial output

Possible installation positions


of the impulse sensor (tighten


46
torque: 35 Nm)

280

110

X
MA
.6
K1
30 1

700.2
.5

16
M18x1

81.8-0.2
016 862

Overview of VDO impulse sensor variant

Sensor generation Inductive Hall Hall KITAS I KITAS I


impulse sensor impulse sensor impulse sensor Hall Inductive

Plug connection Renk Renk Bajonet Bajonet Bajonet


DIN 72585 DIN 72585 DIN 72585
Collective drawing 0501 208 790 0501 209 398 0501 210 854 0501 213 667 0501 213 674
Sensor length: 35 mm 0501 208 793 0501 209 401 0501 210 857 0501 213 672 0501 213 676
External part number 2159.50.103.01 2159.20.103.00 2159.04.103.00 2170.01.203.03 2170.01.503.01

NOTE
The transmission is supplied without an impulse sensor as standard.
Sensor wheel: 6 impulses per revolution.

4149 765 103 - 2004-12 10-23


ZF-Ecomat 2 plus Transmission specification

10.5.2 80 angle drives

Various angle drives (WTR) are available for the transverse installation of the engine and transmission unit:

WTR Ratios Max. engine Weight To the


torque (Nm) (approx. kg) right left

80 LHD 0.97 1 600* 97 ( = 3; 6; 9)


without axial offset

80 RHD
0.98 1 250 125 ( = 5)
with axial offset

Max. angle drives (WTR) input speed 3400 rpm ^ = in 6th gear 2000 rpm
* Following agreement with ZF

80 angle drive LHD 80 angle drive RHD


without axial offset with axial offset

1 2 2 1

80
019924
80

1 Output ( various flange versions available)


2 Ecomat transmission

4149 765 103 - 2004-12 10-24


ZF-Ecomat 2 plus Transmission specification

10.5.3 Output flange 80 angle drive LHD

Abbildung
Figure I I

Abbildung
Figure IV IV

47-0.3 85

161 JS8

90+0.5

131.9
178
C

C-C
M12

13
C
178

21.5+1
80

Abbildung
Figure II II Abbildung
Figure III III

(Intersection point of flange 023806

centre and spline pitch circle

x = screws must be pre-fitted

Included in
ZF no. the drawing A B Ch6 D E F G L M Fig.
x 4139 303 087 (1269 339 040) 150 130 90 12.2 2.3 10 110 45 8x45 I/II
x 4139 303 181 150 130 - 13.0 - - 110 - - I/III
4139 303 172 180 150 - 14.5 - - 127.5 - - I/III
4139 303 215 Yoke I/IV

4149 765 103 - 2004-12 10-25


ZF-Ecomat 2 plus Transmission specification

10.5.4 Ecomat output flange; coaxial and angle drive 80 RHD with axial offset

Fig. I Fig. IV Fig. VI

AUSSEN
FLANKEN
KERN

Fig. V

Fig. VII

Fig. II
NOTE
Clean output flangebefore
propshaft installation.

x = Screws must be pre-fitted

Included in
ZF no. A B Ch6 NH7 D E F G L M L Fig. Coaxial <) 80 RHD
the drawing
x 4139 303 087 (1269 339 040) 150 130 90 12.2 2.3 10 110 45 8x45 696 I/II X X
Fig. III
x 4139 303 072 (1269 338 079) 165 140 95 16.2 2.3 11 115 45 8x45 693 I/II X X
4139 303 074 (4139 303 073) 180 155.5 110 16.1 2.3 12 130 36 10x36 693 I/II X
4139 303 235 (4139 303 073) 180 155.5 110 14.1 2.3 12 133.3 45 8x45 693 I/II X
4139 303 081 (4139 303 038) 203 155.52 169.5 10.15 12.1 141 704 I/III X
4139 303 101 (4139 303 038) 203 155.52 169.5 9.65 9.8 141 704 I/III X
4139 303 109 (4139 303 038) 203 155.52 167.9 11.2 12.1 139.3 704 I/III X X
4139 303 207 Yoke 1710 Half round I/IV X
4139 303 153 (4139 303 038) 203 165 11.2 12.1 139.3 704 I/III X
4139 303 192 Yoke 1810 I/V X
x 4139 303 181 150 130 13.0 110 700 I/VI X X
4139 303 172 180 150 14.5 127.5 712.5 I/VI X X
4139 303 166 Yoke 1710 Full round I/VII X
017031

4149 765 103 - 2004-12 10-27


ZF-Ecomat 2 plus Hydraulic circuit diagrams

11 Hydraulic circuit diagrams

4149 700 026, Pages 1 and 2

4149 765 103 - 2004-12 11-1


ZF-Ecomat 2 plus Hydraulic circuit diagrams

11.1 Hydraulic description The amount of pressure R3 adjusts the retarder


effect.
Pump 14 and Filter 13 Pressure R3 passes through the cooler change-
Pump 14 draws oil from the oil pan through filter over valve and heat exchanger into the retarder.
13; this only works when the engine is running.
Pressure accumulator 4
Main pressure valve 12 To reduce retarder response time, air pressure is
The main pressure valve 12 sets the necessary used to feed the oil accumulator volume into the
system pressure depending on whether the lock- retarder circuit.
up clutch is open or closed.
Throttle pressure valve 17
Torque converter safety valve 3 Pressure D1 is set via the proportional solenoid
The torque converter safety valve 3 limits valve in accordance with the torque to be trans-
pressure D2 towards the torque converter to a ferred (from calculation) and fed to the pressure
specified value. control valve 9.2.

Converter counter-pressure valve 16 Valve unit 9 (clutches, brakes)


Pressure oil from the torque converter flows to After the solenoid valve 9.1 and shut-off valve 9.3
the converter counter-pressure valve 16. This are energized, a shift pressure is created from
valve sets converter internal pressure A8 to a main pressure P in the pressure control valve 9.2.
specified value. A8 pressure is transmitted to the The amount of pressure during the pressure con-
torque converter lock-up clutch valve unit 8. trol process is controlled by the pressure control
spring and throttle pressure D1.
Lubrication pressure valve 15 After the pressure control process is complete,
(retarder not operating). main pressure P is available at the clutches and
Pressure D4 downstream of the converter counter brakes 10.
pressure valve is transmitted through the cooler
change-over valve and heat exchanger to the Torque converter lock-up clutch valve unit 8
lubrication pressure valve 15 and reduced there This control process is identical to that of valve
to a specified lubrication pressure. Pressure D7 is unit 9 (clutches, brakes), with one exception:
fed to the manual transmission. During the pressure control process, the amount
of shift pressure is controlled by the pressure con-
Lubrication pressure valve 15 trol spring and A8 pressure (torque converter
(during retarder operation). internal pressure).
A proportional solenoid valve 18 is used to actuate
the retarder control valve 11. The piston space in When the clutches, brakes, and lock-up clutch
the cooler change-over valve 5 is evacuated (WK) are deactivated, the pressure lines of the
through control line D8 and spring force forces appropriate selector elements are vented using
the valve to switch over. Pressure D4 downstream solenoid valves 8.1 and 9.1 and deactivation
of the converter counter pressure valve 16 is valves 8.3 and/or 9.3.
transmitted through the cooler change-over valve
to the lubrication pressure valve 15 as pressure Torque converter drain valve 19
D7 and fed to the manual transmission. When the oil drain plug is removed from the oil
pan, the drain valve is activated. The oil in the
Retarder control valve 11 torque converter is therefore also drained when
Pressure D2 is a supply pressure at the retarder emptying the transmission oil.
control valve. Pressure R3 is set according to the
position of the proportional solenoid valve 18. Retarder activation valve 20

4149 765 103 - 2004-12 11-2


ZF-Ecomat 2 plus Hydraulic circuit diagrams

11.2 Hydraulic diagram (with Bus Stop Neutral / NBS)

A B 2 C D E F 1 F 2 A B 2 C D E F 1 F 2

5 GANG i = 3.43 BIS 0.83


6 GANG i = 3.43 BIS 0.59
5 GANG TO 6 GANG TO
RUECKWAERTS RUECKWAERTS
REVERSE REVERSE
NEUTRAL * NEUTRAL *
8 NEUTRAL NBS * NEUTRAL NBS *
1. GANG 1. GANG
1st GEAR 1st GEAR
WK 2. GANG 2. GANG
2nd GEAR 2nd GEAR
3. GANG 3. GANG
3rd GEAR 3rd GEAR
4. GANG 4. GANG
8.2 8.1 8.3 4th GEAR 4th GEAR
5. GANG
5. GANG
10 5th GEAR 5th GEAR
6. GANG
6th GEAR
A
B 1 = INNERE KOLBENFLAECHE KUPPLUNG B
INNER PISTON FACE CLUTCH B
B 2 = AEUSSERE KOLBENFLAECHE KUPPLUNG B
OUTER PISTON FACE CLUTCH B
9.2 9.1 9.3 F 1 = AEUSSERE KOLBENFLAECHE BREMSE F
10 OUTER PISTON FACE BRAKE F
B2 F 2 = INNERE KOLBENFLAECHE BREMSE F
B1 INNER PISTON FACE BRAKE F
B
* = REDUZIERTER DRUCK
REDUCED PRESSURE

9.2 9.1 9.3 ZUM SCHALTGETRIEBE


10 TO REDUCTION GEARBOX
WANDLER- SPEICHER
C B2 ENTLEERVENTIL ACCUMULATOR
C
19 A8

9.2 9.1 9.3 WANDLER-


SICHERHEITS
10 VENTIL-
4 15 SCHMIERDRUCK-
VENTIL
CONVERTER WAERMETAUSCHER TEMP.-
WANDLER- LUBRICATING
SAFETY VALVE
D GEGENDRUCK- OIL COOLER MESS- PRESSURE VALVE
VENTIL STELLE

D2
3 CONVERTER TEMPERATUR
COUNTER- SWITCH
PRESSURE SENSOR
9.2 9.1 9.3 VALVE 16
10
R3
E
11 D4 D6 D5 D7
RR3
X R3
F1
D2
F 1 -VENTIL 9.2 9.1 9.3 RETARDER-
REGELVENTIL
18 5 KUEHLER-
10 HAUPTDRUCK-
RETARDER
CONTROL VALVE UMSCHALT-
F1 VENTIL VENTIL
F MAIN PRESSURE
VALVE 12
COOLER
CHANGEOVER
D8 D8 R1 DETAIL X
VALVE
AUSFUEHRUNG
P HAUPTDRUCKVENTIL
F 2 -VENTIL 9.2 9.1 9.3 MIT DRUCKABSENKUNG
F2 VERSION
MAIN PRESSURE VALVE
D9 R2 WITH PRESSURE REDUCER
RETARDER
RETARDER-
20 EINSCHALTVENTIL
RETARDER
ENGAGEMENT VALVE
WK D2
P PRIMAER-
PUMPE
D1 PRIMARY PUMP
14
DROSSELDRUCKVENTIL A2
THROTTLE PRESSURE
SAUGFILTER
021767 VALVE 13 SUCTION FILTER
P 17
A1
P

4149 765 103 - 2004-12 11-3


ZF-Ecomat 2 plus Peripheral equipment

12 Peripheral equipment

12.1 Speed range selector - push button switch

Variants with 3, 5, and 6 push-buttons.

NOTE The D N R push-button speed range selector is recommended.


A speed range selector with 5 or 6 buttons should only be used in special cases.

Variant with 3 push-buttons From drawing no.: 6006 617 099 (b)

Z view Z
ANSICHT
Dashboard cut-out section
Armaturenbrett-Ausschnitt

.5
x0
ma
R

R
D
N
C
N
D
R B

5-4
Version vertical
Ausfhrung SenkrechtRR- -N
N -- DD VersionSenkrecht
Ausfhrung verticalD D- N-- NR - R

Standard Combined
D N R R N D cover plate cover plate

A A 102 + 1 153 + 1
Ausfhrung Waagrecht D - N - R Ausfhrung Waagrecht R - N - D B 99 + 0.5 151 + 0.5
Version horizontal D - N - R Version horizontal R - N - D
C 31 + 0.5 31 + 0.5

30.9 -1 93 -1 300 -30 X


b b
INTAKE HOUSING
AUFNAHMEGEHAEUSE
12 PIN AMP MATE-N-LOK
12-POL. AMP MATE-N-LOK
NO. 926681-3
NR.926681-3
0659 055 323
89.5 -0.5

0659 055 323


CONTACT PIN
KONTAKTSTIFT
NO. 926898-1
NR.926898-1
X viewX
ANSICHT 0659055
0659 055294
294

1 4 7 10
AMP MATE-N-LOK
MATE-N-LOK
3.5

b 2 5 8 11 12-POL.
12 PINSSTIFT
Z 3 6 9 12 AUFNAHMEGEHAEUSE
INTAKE HOUSING
33 +1 98 +0.5
014900

Technical data Standard Combined


Rated voltage: UN = 24 V cover plate cover plate
Operating voltage: UN = 20 - 32 V Version Parts list no. Parts list no.
Current rating: IAmax = 1 A Horizontal D-N-R 6006 017 192 6006 017 188
Operating temperature: - 20 C ... +70 C Horizontal R-N-D 6006 017 194 6006 017 189
Storage temperature: - 40 C ... +80 C Vertical D-N-R 6006 017 195 6006 017 190
Vertical R-N-D 6006 017 196 6006 017 191

4149 765 103 - 2004-12 12-1


ZF-Ecomat 2 plus Peripheral equipment

Variant with 5 push buttons From drawing no.: 6006 617 103 (b)

ANSICHT
Z view Z
Dashboard cut-out section
Armaturenbrett-Ausschnitt

.5
x0
ma
R

R
1
N

31+0,5
2
D
D 151+0.5
2
N
1
R

5-4
Ausfhrung Senkrecht
Version vertical Ausfhrung Senkrecht
Version vertical
R-N-D-2-1 1-2-D-N-R
R-N-D-2-1 1-2-D-N-R

1 2 D N R R N D 2 1
153 1

Ausfhrung
VersionWaagrecht 1 - 21 --D2- -ND- R- N - R
horizontal Ausfhrung
Version Waagrecht
horizontal R - N R- -DN--2D -- 12 - 1

30.9 -1 150 -1 300 -30


b b
X
INTAKE HOUSING
AUFNAHMEGEHAEUSE
12-PIN AMP
12-POL. AMPMATE-N-LOK
MATE-N-LOK
NO. 926681-3
NR.926681-3
89.5-0.5

0659 055 323


0659 055 323
CONTACT PIN
KONTAKTSTIFT
NO. 926898-1
NR.926898-1
ANSICHT
X viewX 0659 055
0659 055 294
294

1 4 7 10 AMP
AMP MATE-N-LOK
MATE-N-LOK
3.5

b 2 5 8 11 12-PIN
12-POL.STIFT
STIFT
INTAKE HOUSING
AUFNAHMEGEHAEUSE
33 +1 150 +0.5
Z 3 6 9 12
014 902

Technical data
Rated voltage: UN = 24 V Version Parts list no.
Operating voltage: UN = 20 - 32 V Horizontal 1-2-D-N-R 6006 017 200
Current rating: IAmax = 1 A Horizontal R-N-D-2-1 6006 017 203
Operating temperature: - 20 C ... +70 C Vertical 1-2-D-N-R 6006 017 204
Storage temperature: - 40 C ... +80 C Vertical R-N-D-2-1 6006 017 202

4149 765 103 - 2004-12 12-2


ZF-Ecomat 2 plus Peripheral equipment

Variant with 6 push buttons From drawing no.: 6006 617 107

ANSICHT
Z view Z

Dashboard cut-out section


Armaturenbrett-Ausschnitt
R

.5
1

x0
N

ma
R
2
D

31+0,5
3 3
2 D
151+0.5

1 N
R

5 -4
Version vertical
Ausfhrung Senkrecht VersionSenkrecht
Ausfhrung vertical
R - NN- -DD- 3- 3-2 -- 21 - 1 11- 2- -23 - 3
D -- ND- -RN - R

1 2 3 D N R R N D 3 2 1
153 1

Ausfhrung Waagrecht 1 1- 2- -23-- 3D -- D


Version horizontal N -- RN - R Ausfhrung
Version Waagrecht
horizontal R - NR- -DN-- 3D -- 32 --21- 1

30.9 -1 150 -1 300 -30


b b
X
INTAKE HOUSING
AUFNAHMEGEHAEUSE
12-PIN
12-POL.AMP
AMPMATE-N-LOK
MATE-N-LOK
NO. 926681-3
NR.926681-3
89.5 -0.5

0659
0659055
055323
323
CONTACT PIN
KONTAKTSTIFT
NO. 926898-1
NR.926898-1
X viewX 0659
0659055
055294
294
ANSICHT
1 4 7 10 AMP
AMPMATE-N-LOK
MATE-N-LOK
3.5

b 2 5 8 11 12-PIN STIFT
12-POL. STIFT
INTAKE HOUSING
AUFNAHMEGEHAEUSE
33 +1 150 +0,5
Z 3 6 9 12
014 903

Technical data
Rated voltage: UN = 24 V Version Parts list no.
Operating voltage: UB = 20-32 V Horizontal 1-2-3-D-N-R 6006 017 208
Current rating: IAmax = 1 A Horizontal R-N-D-3-2-1 6006 017 210
Operating temperature: -20C ...+70C Vertical 1-2-3-D-N-R 6006 017 211
Storage temperature: -40C ...+80C Vertical R-N-D-3-2-1 6006 017 212

4149 765 103 - 2004-12 12-3


Technische Daten
passender Kabelstecker: AMP 929 504 -5 Technical Features
suitable cable plug: AMP 929 504 -5

4149 765 103 - 2004-12


1. KUNDENSPEZIFIKATION
Ausfhrliche Technische Daten entnehmen Sie bitte
der Spezifikation Nr. 6006.740.001
CUSTOMER SPEZIFIKATION
Please find detailed technical Data
150 +/-1 in ZF-Spec. 6006.740.001
ZF-Ecomat 2 plus

2. ALLGEMEINE TECHN. DATEN

4.5+/-0.5

12.6+/-0.5
GENERAL TECHNICAL DATA:
Armaturenbrett-Ausschnitt

29.2+/-0,1
Nennspannung: U = 24V
12.2 CAN range selector

Nominal Voltage

5-1
Cutout instrument panel
Variant with 6 push buttons.

Stromaufnahme, max.: I = 1 Amp


Supply current, max.:

Betriebstemperatur: -40C bis +70C


Operating Temperature

Lagertemperatur: -40C bis 125C


Storage Temperature

70 +/-2
Schutzart (eingebaut): IP5K0

31+0,5

97.5+/-1
Protection class (installed):

3. CAN
CAN-Schnittstelle: ISO 11898
151+0.5 CAN-Interface:
45 Baudrate: 250 kBit / sec

CAN-Verkabelung: verdrilltes Leitungspaar


Bauraum fr Gegenstecker Anschlussplan CAN-cabling: ca. 30 Schlge pro Meter
und Kabel Connection Diagram twisted Pair
required space for circa 30 turns per meter
connector and cable

min. 30
E2 E4 E6

12-4
E1 E3 E5

8 9 10 11 12 13
EU1 EU2 EU3 EU4 EU5 EU6

1 56
Waagrechter Einbau: 1-2-3-D-N-R KL15 ADVP

A2 4
horizontally mounted CANL

3 48
CANL CANB_L
Twisted Pair A1
5 47

9 10
7 8
5 6
3 4
1 2

13 14
11 12
CANH CANB_H

33 +/-1
6
120 Ohm CANH

152,5 +/-1 7
CANT
VM
2 14
Senkrechter Einbau: 1-2-3-D-N-R
KL31 KL31
vertically mounted
ZF-Bestell-Nr.
A1 Elektr Steuerung EST146/147 ECU EST146/147 ZF-Part Number
Ausfhrung
A2 CAN-Tastenschallter CAN-Pushbotton switch
Version mit Blende
E1 Schalter (plus- / minus-) switch (highside / lowside) with cover
E2 Schalter (plus- / minus-) switch (highside / lowside)
E3 Schalter (plus- / minus-) switch (highside / lowside) Waagrecht 6006.340.014
1 2 3 D N R
E4 Schalter (plus- / minus-) switch (highside / lowside) horiz. mounted
E5 Schalter (plus- / minus-) switch (highside / lowside)
1
2
3
D
N
R

E6 Schalter (plus- / minus-) switch (highside / lowside) Senkrecht 6006.340.016


vertic. mounted
Applies to all CAN range selectors: For circuit diagram and technical data refer to following drawing.

6006 640 006


Peripheral equipment
ZF-Ecomat 2 plus Peripheral equipment

12.3 Load sensor A 3

Use either a PWM signal or a load sensor signal as


load signal for the Ecomat 2 plus NENG transmission
type.

12.3.1 Function
Us(V)
Automatic gear engagement is dependent on vehicle
speed and engine load.. The engine load is deter- 4,4 + 0,3

mined by accelerator pedal position and/or sensor 3,985


3,785
control lever on the injection pump. The engine load
and/or the position of the sensor control lever of the
injection pump are mechanically sensed and con-
1,215
verted into an electronic signal. 1,015
0,3 + 0,3
This load signal is then sent to the electronic shift 45 1
0 Lever position
control unit (ECU 146 / ECU 147) where it is con- Stop Stop
verted into a pressure signal using an appropriate Low High
4139 S 0034
characteristics curve for the installed engine.
The pressure modulation unit in the transmission
then ensures that the clutch engagement pressure is
appropriate for the level of engine load.

OC

Load sensor Pressure regulator

4139 S 0035

NOTE
The sensor control lever must not be drawn in the
load direction when coasting or when the engine is
over-revving. Refer to Chapters 11.2 to 11.5 for
instructions on how to install the load sensor.

4149 765 103 - 2004-12 12-5


ZF-Ecomat 2 plus Peripheral equipment

12.3.2 Load sensor drawing From drawing no.: 0501 209 635

Technical data
Funktion
Erfassung eines Winkels und Umsetzung in ein analoges Signal

Allgemeine Anforderungen 4
Kennlinie fr Betriebspannung UD = 5,00 V
Nennarbeitsbereich
U (V) 4.7
4.5 4.1 1
4
3.5
3
2,5
2
1.5
1
0.6
1 0.50.3
0
-30 -20 -10 0 10 20 30 40 50 60 70 Winkel
(Grad)
Nennarbeitsbereich: 0 bis 45
Gesamter Winkelbereich: +105 +5/-3
Referenzmarke LOW 0: U = 1,115 V 150 mV
Referenzmarke HIGH 45: U = 3,885 V 150 mV
Toleranzbereich: 150 mV

Elektrische Kenngren
Betriebsspannung: 5 V 5%
berspannungsfestigkeit: 32 V
Verpolschutz: 32 V
Betriebsstrme: 15 mA
Isolationswiderstand: 5 MOhm (gegenber Masse)
Isolationsfestigkeit: 500 V Wechselspannung
700 V Gleichspannung
Kurzschlussfestigkeit: 32 V
EMV-Festigkeit: DIN 40839 Teil 3 250 V
DIN 40839 Teil 4 150 V/m

Lebensdauer
2.000.000 Zyklen davon 60% bei +90 C
20% bei +120 C
20% bei -30 C

Schutzart
IP 66 A nach DIN 40050 Bl. 9

Betriebstemperatur
Betriebstemperaturbereich: -40 C bis +125 C 2
Max. Dauerbetriebstemperatur: +120 C
Referenztemperatur: Technische Daten spezifiziert bei +20 C 2 C

Mechanische Beanspruchung
Schockfestigkeit: nach DIN 40046 BL7; a = 100 g, t = 11 ms, z = 50
Vibration: nach DIN 40040 BL8
siehe Pflichtenheft Berichts-Nr. 472 4139 045
Medienbestndigkeit: Motor und Getriebele; Benzin, Diesel;
Reinigungsmittel (z.B. Kaltreiniger)

Umweltbeanspruchung
Korrosionsbestndigkeit
Spritzwasser: DIN 50017 KFW (4 Zyklen a 24h)
Salzsprhnebel: DIN 50017 KFW (4 Zyklen a 24h)

Klima
Klte: Prfung Aa nach DIN 40046 BL3 (-55 C, 16 h)
Trockene Wrme: Prfung Eb nach DIN 40046 BL4 (+125 C, 16 h)
Temperaturwechsel: Prfung Na nach DIN 40046 BL14 (-40 C, +120 C)
Feuchte Wrme: Prfung Ca nach DIN 40046 BL5 (+40 C, 16 h)
Feuchte Wrme zykl.: Prfung Dd nach DIN 40046 BL31 (+40 C, 6 Zyklen)

Dampfstrahl siehe ZF-Pflichtenheft Berichts-Nr. 472 4139 045

Einbauvorschriften
4149 765 103 - 2004-12 Schraubenanzugsmoment: 8 Nm + 4 Nm 12-7
ZF-Ecomat 2 plus Peripheral equipment

12.4 PWM-Signal

The PWM signal is a pulse-width modulated signal The PWM signal is a rectangular signal with a fixed
providing information on the current load status of frequency but a variable time share of high and low
the engine rather than the load sensor voltage pre- levels.
viously used. This signal is processed by ECU 146 / ECU 147.

12.4.1 Calibration of the PWM Signal, Positive


Impulse Flank

Periode T = 1f
1
Perod T = f

untere Ausfallschwelle obere Ausfallschwelle


Lower failure threshold Upper failure threshold
Minimalwert = SCHUB Maximalwert = VOLLLAST
Minimum value = COASTING Maximum value = FULL THROTTLE

24

PWM - Arbeitsbereich
PWM operating range
t
U
[v] t
t
9 2 2
3 1
0
0 1 2 3 4 5 6 7 8 9 10 abs. Pulsweite [ms]
pulse width [ms]

0 10 20 30 40 50 60 70 80 90 100 proz. Pulsweite [% von T]


Proc. pulse width [% von T]
023 788

0 10 20 30 40 45 Lastzustand EST 146 / EST 147 [Grad]


Load status of ECU 146 / ECU 147 [degree]

4149 765 103 - 2004-12 12-9


ZF-Ecomat 2 plus Peripheral equipment

12.4.2 Sensing ratio

This value ist the ratio


( Pulse width t
period T ) x 100 %.

12.4.3 Signal Spezification

Hardware:
Indexing threshold from low to high +9 V
Indexing threshold from high to low +2 V
Input resistance in ECU 146/ECU 147 10k 2k (pull-up supply positive)

Software:
Adaptive adjustment to the PWM frequency (period) whereby a range of 50 Hz to 500 Hz is considered
favorable.

Programming parameters:
Signal amplitude, positive or negative
Lower failure threshold %
Upper failure threshold %
Minimum value %
Maximum value %

The difference between the maximum and minimum values must be greater than 50% of the period length.

T_Mot
TV T_Eng
[%] [Nm]
1000

100 Obere Motor-Ausfallschwelle/Upper engine failure threshold 900

90 Kick-Down 800
100% red. Drehmoment
Vollast konstante Red. torque
80 Full throttle Gaspedalstellung (%) 700

70 600
75%
60 500
Constant accelerator
50 position (%) 400

40 50% 300

30 200
25%
20 100

Gaspedal Leerlauf = 0% / Accelerator idling = 0%


10
Untere Motor-Ausfallschwelle / Lower engine failure threshold
0
300 600 900 1200 1500 1800 2100 2400 2700 N_Mot
Volllastkurve / Full throttle curve N_Eng
red. Drehmomentkurve / Red. Torque curve [rpm]
TV Tastverhltnis / sensing ratio

023 787

4149 765 103 - 2004-12 12-10


ZF-Ecomat 2 plus Peripheral equipment

12.5 Additional temperature sensor A6 for


temperature display
From drawing no.: 0501 317 260
(For details see chapter 14)

M27x1
8 0.2
4-0.1 Technical data
Permiss. tight. torque: max. 30 Nm
Operating voltage: 6 - 24 V
Operating temperature: -30C to +150C
briefly (1 h) 180C
16.4 0.8

on sensor
2 +0.2

Gewinderille Storage temperature: -40C to +150C


DIN 3852,
Form A NOTE
10 0.2

72.8 0.1

Groove DIN Use seal ring A 14x18 DIN 7603 Cu


3852, form A no. 0634 801 038.
38 +0.5

19 h14
M14x1.5

10

83 +- 1
SW27 h13

014 991

4149 765 103 - 2004-12 12-11


ZF-Ecomat 2 plus Peripheral equipment

12.6 Temperature display A5


From drawing no.: 0501 204 074

Eichmarkierung weier Punkt 0,5 Klemmbereich


Calibration mark white point 0.5 Clamping area

passend fr Steckhlse 6,3


DIN 42247, Steckeranordnung
im Gehuse vertieft
approprinte for pin bushing 6.3
014 905
DIN 42247, plug set
deeper into housing

Technical data ZF no. 0501 204 074


Operating temperature: -5C to +70C
Storage temperature: -30C to +70C Connection codes
(+85C max. 1 h) G Sensor
Rated voltage: 24 V Earth
Operating voltage: 21.5 V to 30 V + Battery positive
S Buzzer
For further technical details see Chapter 14.

4149 765 103 - 2004-12 12-12


ZF-Ecomat 2 plus Peripheral equipment

12.7 Kick down switch

12.7.1 Kick down switch S1 (Holding switch - high holding force) From drawing no.: 6007 603 030

014 908

A Switch-off point Parts list no. 6007 203 181


B Stroke
C Holding force
D Actuating force at
switch point = 150 N 20 N
E Shift pattern

4149 765 103 - 2004-12 12-13


ZF-Ecomat 2 plus Peripheral equipment

12.8 Pressure switch S7 - NBS (Neutral when


Stationary
From drawing no.: 0501 311 584 (a)

4139 S 2056

Key to drawing
A Sealed with red safety coating
B Breather opening with filter
C Stamped on: Manufacturers code,
ZF no.
Date of manufacture:
Month, Year

Technical data
Switch point: ON at 0,9 bar 0,2 bar at
room temperature
beginning from
Operating pressure: 10 bar
Pressure resistant up to: 30 bar
Tightg. torque: Max. 30 Nm
Pressure medium: Air
Rated voltage: 12/24 V
Operating temperature: -30C to +100C
Storage temperature: -40C to +100C
Protection acc. to
DIN 40 050: Connctions acc. to IP-00
With customer-specific
plug: Contact space IP-64

4149 765 103 - 2004-12 12-15


ZF-Ecomat 2 plus Peripheral equipment

12.9 Changeover relay, e.g. range selector relay

014 912

ZF no.: 6041 312 019 Key to drawing


A Plug arrangement
Bosch no.: A 332 203 003 B Order no.
C Plug pin end 6.3x0.8 DIN 46 247
Appropriate relay socket: 6041 313 005 D Switch pattern imprinted

Technical data
Rated voltage: 24 V
Load : 10/20 A
Type of protection: IP 33 - IP 20 terminal -
DIN 40 050
when using plug sockets
ensure connection plug
points downwards!

4149 765 103 - 2004-12 12-16


ZF-Ecomat 2 plus Neutral at standstill

13 Neutral at standstill 5.3.31 CCVS Cruise Control/Vehicle Speed RX


5.2.6.8 Parking Brake Switch
13.1 Description

5.3.4 EBC1 Electronic Brake Controller #1 RX


Neutral at Bus Stop (NBS) has been developed in
order to save fuel in city bus applications with 5.2.1.18 Brake Pedal Position
frequent stops.
5.3.4 EBC3 Electronic Brake Controller #3 RX
The transmission automatically shifts into Neutral
5.2.5.176 Brake application pressure,
(i.e. the powerflow from the engine to the rear axle front axle, left wheel
is interrupted) whenever the following conditions
5.2.5.176 Brake application pressure,
are met:
front axle, left wheel

Accelerator pedal in idling position 5.2.5.176 Brake application pressure,


Signal from brake pressure switch (p 0.9 bar) front axle, left wheel
and / or signal from bus stop holding brake* 5.2.5.176 Brake application pressure,
front axle, left wheel
! DANGER
The pneumatic pressure in the brake system must be 5.3.2 TC1 Transmission Control #1 RX
selected to ensure that the vehicle is braked safety from Source Address
on uphill and downhill gradients.
5.2.3.6 Disengage Driveline Request

Road speed almost zero (< approx. 3 km/h)


1st gear engaged

Once all these conditions are met, the transmission


automatically shifts into Neutral after a delay time.

As soon as any of these conditions is no longer met,


1 st gear is engaged again.
Recommendation: brake is held in accordance with
wiring diagram 4139 720 045.

! DANGER
The driver and vehicle manufacturer must be infor-
med without fail of the correct method of operating
the vehicle on uphill and downhill inclines. Rolling
backwards on hills must be prevented in the usual
way, by using the parking brake or bus stop holding
brake. To move away from stationary, depress the
accelerator lightly - transmission engages - release
brake.
When NBS is used in connection with a door closing
device, the vehicle must never be able to begin
moving when not under control.
The bus stop holding brake must only be released
following "active intervention" by the driver, e.g.
* NBS activation via push button or alternatively via CAN J 1939, see
accelerating or releasing the brakes by hand. Table above.

4149 765 103 - 2004-12 13-1


Front axle

4149 765 103 - 2004-12


(+)

Air compressor
ZF-Ecomat 2 plus

Bus stop holding


brake switch Multi-circuit protection valve

Pressure
regulator Rear axle
13.2 Connection diagram (electric)

NBS pressure switch from


front axle brake circuit Solenoid shut-off valve
(bus stop holding brake)
(+) (+)
~ 0.3 bar
Bus stop holding NBS pushbutton
Pressure limiting

13-2
brake The pushbutton
should ensure that
valve
Solenoid the vehicle ist pre-
valve vented from rolling Non-return
P
backwards. valve
NBS Signal to
transmission
Manual parking
range brake valve
NBS signal to
transmission
NBS signal to
Footbrake
transmission
Bus stop holding brake solenoid valve and NBS pressure switch control valve
must be installed in separate brake circuits.
ADVANTAGE: Brake remains applied approx. 0.3 s after bus stop
holding brake release.
Combination
Diaphragm cylinder cylinder

014 990
From drawing no.: 4139 720 045
Neutral at standstill
ZF-Ecomat 2 plus Neutral at standstill

13.3 Neutral at Bus Stop - display Electronic Transmission Controller

Driveline Current
13.3.1 NBS active display via digital signal engaged gear
Neutral 00b* 0
We recommend as standard: NBS 00b* 1
NBS active digital display via AD10 Pin 52. Quit NBS 01b* in the beginning 1
Gear 01b* 1-6
Signal definition: Gear shifts 01b* see below
Signal is active if NBS is activated. Engage gear 01b* in the beginning see below
*b = Binary coding

13.3.2 NBS Active Display via CAN Position of selector switch Requested driving range

The display can be provided via a combination of Upshift: Signal change


the following CAN messages: at the beginning selected gear
at the end current gear
5.3.5 ETC1 Electronic Transmission Controller
5.2.2.6 Driveline engaged

and

5.3.8 ETC2 Electronic Transmission Controller


5.2.1.22 Current gear

The information listed in the matrix can be depicted


by combining the two CAN messages.

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ZF-Ecomat 2 plus Temperature monitoring

14 Temperature monitoring 14.4 Temperature warnings

The temperature thresholds and the customers'


B4 A6
names for errors and their priorities are defined in
the application meeting.

B14 021648

B4 - temperature sensor at retarder outlet


B14 - temperature sensor at transmission oil sump
A6 - temperature sensor at retarder outlet
(optional, for external temperature display)

14.1 Temperature information via CAN

The oil sump temperature 3.2.5.17 (transmission oil


temperature) and the oil temperature at the retarder
outlet 3.2.5.7 (hydraulic retarder oil temperature) are
transmitted via CAN.

14.2 Temperature information via temperature


sensor A6

For customers without access to the aforementioned


CAN messages, the temperature sensor A6 and dis-
play device A5 supply the appropriate retarder outlet
temperature.

14.3 Temperature information from DM1 note

The temperature warnings and temperature displays


can be displayed via CAN diagnosis in the form of
DM1 messages.

4149 765 103 - 2004-12 14-1


ZF-Ecomat 2 plus Temperature monitoring

14.5 Addtional temperature sensor A6


From drawing no.: 0501 317 260

M27x1
8 0.2
4-0.1

16.4 0.8
2 +0.2
Gewinderille
DIN 3852,
Form A
10 0.2

72.8 0.1
Groove DIN
3852, form A
38 +0.5

19 h14
M14x1.5

10

83 +- 1
SW27 h13

014 991

Technical data
Permiss. tight. torque: max. 30 Nm
Operating voltage: 6 - 24 V
Operating temperature: -30C to +150C
briefly (1 h) 180C
on sensor
Storage temperature: -40C to +150C

NOTE
Use seal ring A 14x18 DIN 7603 Cu
no. 0634 801 038.

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ZF-Ecomat 2 plus Temperature monitoring

14.6 Temperature display gauge A5 From drawing no.: 0501 204 074

Information from the temperature sensor is sent to a temperature display gauge. The gauge scale is divided
into 3 colored sections:
Green: All normal driving conditions
Green-red: Braking operations with retarder only
Red: Oil temperature excessive (warning lamp resp. acoustic signal at 145 C)

Eichmarkierung weier Punkt 0,5 Klemmbereich


Calibration mark white point 0.5 Clamping area

passend fr Steckhlse 6,3


DIN 42247, Steckeranordnung
im Gehuse vertieft
014 905
approprinte for pin bushing 6.3
DIN 42247, plug set
deeper into housing

Technical data Connection code


Operating temperature: -25C to +70C G Sensor
Storage temperature: -30C to +70C Earth
(+85C max. 1 h) + Battery positive terminal
Rated voltage: 24 V S Buzzer
Operating voltage: 21.5 V to 30 V
Output S on the temperature display may be loaded
(+) to Imax = 250 mA, that means, if temperature reaches
excessive levels (145C) a warning lamp / or acoustic
warning signal can be switched on.

K9

A5

014913

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ZF-Ecomat 2 plus Temperature monitoring

14.7 Resistance characteristics - Temperature sensor


R [Ohm]

Temp. [C] R [] Tolerance [%]


Average Necessary
measured
value
104 20 1108.9 1140.0 10
8 60 223.4 223.9 8
6 90 83.03 80.0 7
120 35.3 5.3
4 130 27.45 27.9 5

103
8
6

102
8
6

101
-10 0 10 20 30 40 50 60 70 80 100 120 140 C
015 088

4149 765 103 - 2004-12 14-4


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15 Electronic automatic control system Various failsafe mechanisms preventing incorrect


EST 146/147 operation and incorrect behavior increase driving
safety.
15.1 Function description
The control system is capable of self-diagnosis. Inte-
The new electronic automatic control system gration in the on-board diagnosis system is achieved
EST 146 / 147 is used to control and monitor the via interfaces to ISO 9141, KWP 2000 and/or SAEJ
function of the ZF Ecomat transmission HP 502 / 1587 and SAEJ 1939. New diagnosis systems with
592 / 602. The EST 146 / 147 can communicate with menu guidance make rapid and simple system
other control units via a CAN interface. checks possible in the vehicle.

The CAN connection makes simple integration in The electronic automatic control system makes a sig-
new vehicle concepts possible. Joint use of sensors is nificant contribution to
possible and connectors and cables numbers can be increasing shift quality and safety
reduced. improved cost-effectiveness, also thanks to
further reduction of fuel consumption levels
Various vehicle and transmission parameters increased reliability and
(direction of travel, drive range, engine load, engine simplification of installation and service
speeds, transmission temperature, driving speed
etc.) are recorded in the control system and proces-
sed into signals for activating the transmission
hydraulic unit. Furthermore, transmission-specific
information and requests are communicated to the
vehicle management via the CAN and/or main
power system interface.

The control system EST 146 / 147 ensures gradual


acceleration-dependent selector speed and simple
electrical retarder activation.
On request, up to six shift programs are available,
each independent of the others. 015 284

Whenever a gear change takes place, the electronic


unit controls the shift pressure so that a constant
shift time and therefore a constant shift comfort 15.2 Intended standard functions
over the entire service life is attained.
If the specified shift time can no longer be observed Drive programs optimized in terms of cost
via governing functions (e.g. due to damaged trans- effectiveness
mission parts, insufficient oil quantities etc.), this is Statistics memory for recording operating data
signaled to the driver via a status warning. Possible Acceleration and engine load-dependent shift
secondary damage can therefore be avoided. The points
torque converter lock-up clutch installed in the Increased shift comfort thanks to shift pressure
transmission is opened and closed by the control and shift time adjustment
system in accordance with the load and speed. The Transmission protection through engine manage-
engine may only be started in the neutral shift ment
position; a suitable starter inhibit should be installed Various failsafe mechanisms preventing incorrect
by the vehicle manufacturer. operation and incorrect behavior increase driving
safety.

4149 765 103 - 2004-12 15-1


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Non-volatile error memory to save error status in For these reasons, the EST 146 / 147 should be
transmission system located in a dry compartment. Recommended
Automatic electronic control unit capable of self installation locations:
diagnosis - In the driver's cab
Diagnosis with various devices in accordance - Inside the vehicle
with ISO standard 9141 or SAE J 1587 - In the switch box
EOL configuration of application parameters to The permitted installation positions MUST be
reduce the number of variants and adaptation to complied with (* refer to chapter 15.6). Other
customer requirements positions can only be approved after consultation
EEPROM parameter setting: selection of suitable with the ZF Application Engineering dept.
drive programs and range change assignments. The EST 146 / 147 housing should be easily
accessible. No earthing cable required.
Ensure min. 150 mm disassembly space for the
68 pin plug so it can also be removed from the
15.3 Functions available on request installed EST 146 / 147 housing for service
purposes.
Gear approval via additional button (2nd reverse In the following cases, the EST 146 / 147 must
gear button) not be energized. Switch ignition OFF and
Driving programs: remove the ignition key:
The automatic electronic control system can be - When connecting the EST 146 / 147 to the
fitted with up to six different shift programs and vehicle circuit.
four different customer blocks. - When disconnecting the 68-pin connector.
Program adaptation, i.e. selection of two suitable - When disconnecting the battery from the
shift programs is undertaken by the vehicle vehicle circuit.
manufacturer via end-of-line configuration
(EOL). NOTE
The drive program requested can be called up Do not install the EST 146 / 147 on vibration
during driving e.g. via a switch on the dashboard. dampers!
Status monitoring: Errors which may result in
damage in the transmission are indicated by the The positive (+) supply (terminal 15 or ignition)
depressed range change selector flashing must only be switched on or off with the vehicle
stationary.
For the following work, the ignition must be
switched OFF and the plug connector must be
15.4 Installation requirements disconnected from the EST 146 / 147:
- For electrical repairs to the vehicle and
When installing the EST 146 / 147, attention should especially for electric-arc welding!
be paid to the following points: - For insulation tests on the electrical equip-
The EST 146 / 147 must be installed in the ment.
vehicle in a suitable location where it is protected Jump-starting the engine:
from: To prevent excess voltages, we recommend using
- excessive atmospheric humidity a buffered jump starting unit, or connecting an
(max. +40C / 95% humidity) adequately charged battery in parallel.
- extreme temperatures
(min. -40C /max. +70C)
- dust build-up
- water splash

4149 765 103 - 2004-12 15-2


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.5 Technical data of EST 146 / 147 Interference impulse link to signal lines.
The capacity of the interference impulse should be
Rated voltage: U = 24 V coupled to the sensor and signal lines using coupling
Operating voltage: U = 18 - 32 V (36 V for 5 min) tongs.
Full load current: I=6A
High-energy, cap. connected negative impulse.
Resistance to interference impulses Acc. to ISO 7637, Part 2, test impulse 1
Interference impulse connection to vehicle's Us = -250 V, td = 2 ms, tl = 5 s, Ri = 10
voltage supply. Function criterion: a)
Unless otherwise specified, the interference impulses
should be superimposed on a vehicle voltage supply High-energy, cap. connected positive impulse.
of Ub = +28 V. Acc. to ISO 7637, Part 2, test impulse 2
Vs = +250 V, td = 0.05 ms, tl = 5 s, Ri = 10
High-energy, negative impulse. Function criterion: a)
Acc. to ISO 7637, Part 2, test impulse 1a
Us = -300 V, td = 2 ms, tl = 0.5 s, Ri = 4 Groups of short cap. connected negative impulses.
Function criterion: c) Acc. to ISO 7637, Part 2, test impulse 3a
Vs = -250 V, td = 0.1 s, Ri = 50
High-energy, negative impulse. Function criterion: a)
Acc. to ISO 7637, Part 2, test impulse 1b
Us = -600 V, td = 2 ms, tl = 5 s, Ri = 50 Groups of short cap. connected positive impulses.
Function criterion: c) Acc. to ISO 7637, Part 2, test impulse 3b
Vs = + 250 V, td = 0.1 s, Ri = 50
High-energy, positive impulse. Function criterion: a)
Acc. to ISO 7637, Part 2, test impulse 2
Vs = +300 V, td = 0,05 ms, tl = 5 s, Ri = 10 Electrostatic discharge
Function criterion: c)
Interference impulse through electrostatic
Groups of short negative impulses. discharge.
Acc. to ISO 7637, Part 2, test impulse 3a Acc. to EN 61000-4-2
Vs = +200 V, td = 0.1 s , Ri = 50 Us = 8 kV housing, / Us = 5 kV connector pins
Function criterion: a) C = 150 pF, Ri = 330
Function criterion (housing): a)
Groups of short positive impulses. (connector pin): d)
Acc. to ISO 7637, Part 2, test impulse 3b
Vs = +200 V, td = 0.1 s, Ri = 50 Electromagnetic compatibility (EMC)
Function criterion: a)
System measurements
Fall in voltage when starting.
Acc. to ISO 7637, Part 2, test impulse 4 Resistance to induced interferences (CS)
Us = -16 V, Ua = -12 V, t6 = 100 ms, Structure in accordance with
t8 = 20 s, tf = 100 ms, Ri = 0.01 MIL-STD-462, NOTICE 3
Function criterion: b) The vehicle voltage supply should be super-
imposed with a sine-wave AC current of 3 Vss .
Load-dump impulse Frequency range: 30 Hz to 120 kHz
acc. to ISO 7637, Part 2, test impulse 5 Function criterion: a)
Us = 200 V
Td = 150 ms, W = 800 J, Ri = 2.0
Function criterion: b)

4149 765 103 - 2004-12 15-3


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Resistance to radiated interferences ( RS ) Function criteria


Based on EC guideline 95/54/EG Annex 9 and/or
ISO/DIS 11452- 1 / 2 / 5 a) Full function capability
Frequency range: 1 MHz - 1 GHz E field No noticeably impaired drive function of control
Modulation type: - No modulat. unit under the conditions specified.
- AM 80% / 1 kHz
Polarization (from 220 MHz): vertical / horizontal b) Restricted operation (load-dump impulse)
Interference field strength: 100 V/m The control unit adopts a defined status during
Function criterion: a) the condition specified. When using control units
with MC, all data is retained. Once the condition
Induced interference emissions ( CE ) specified has ceased to apply, the control unit
Based on BDE 0879 Part 3 returns to its initial status.
With extended frequency range of up to 200 MHz
Degree of interference suppression: 5 c) No destruction
The control unit adopts a defined status under
Radiated interference emissions ( RE ) the condition specified (all outputs disengaged).
When using control units with MC, data is not
Wide band interference source retained. Once the condition specified has dis-
In accordance with EC guideline 95/54/EC appeared, the control unit is available in an
unrestricted operation (MC undertakes cold start).
Frequency range: 30 MHz - 1 GHz
d) No destruction
Narrow band interference source No noticeably impaired drive function of control
In accordance with EC guideline 95/54/EC unit under the conditions specified.

Frequency range: 30 MHz - 1 GHz

Temperature range: Operation: -40C ... +70C


Resistance to dampness: In acc. DIN/EC 68-2-30
(damp heat) Upper temperature: + 55 C
Function criterion a)
Resistance against
vibrations: 5 g (10 Hz...1 kHz)
Shock resistance: 25 g
Type of protection: IP 54
Weight: 0.9 kg

4149 765 103 - 2004-12 15-4


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.6 Installation drawings

15.6.1 Installation drawing EST 146 From drawing no.: 6009 690 001

4149 765 103 - 2004-12 15-5


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.6.2 Installation drawing EST 147 From drawing no.: 6009 691 001

4149 765 103 - 2004-12 15-6


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.7 Current circuit diagrams

15.7.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector From drawing no.: 6029 729 155

4149 765 103 - 2004-12 15-7


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.7.2 Current circuit diagram EST 146 / EST 147 with CAN, with CAN range selector From drawing no.: 6029 729 232

4149 765 103 - 2004-12 15-8


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.7.3 Current circuit diagram EST 146 / EST 147 without CAN(NEng), with digital range selector From drawing no.: 6029 729 215

4149 765 103 - 2004-12 15-9


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.8 Pin pattern From drawing no.: 6029 729 073

4149 765 103 - 2004-12 15-10


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.9 Connection diagrams

15.9.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 1 From drawing no.:. 6029 729 156A / Page 1

4149 765 103 - 2004-12 15-11


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 2 From drawing no.: 6029 729 156A / Page 2

4149 765 103 - 2004-12 15-12


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 3 From drawing no.: 6029 729 156A / Page 3

4149 765 103 - 2004-12 15-13


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 4 From drawing no.: 6029 729 156A / Page 4

4149 765 103 - 2004-12 15-14


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.9.2 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 1 From drawing no.: 6029 729 233 / Page 1

4149 765 103 - 2004-12 15-15


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 2 From drawing no.: 6029 729 233 / Page 2

4149 765 103 - 2004-12 15-16


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 3 From drawing no.: 6029 729 233 / Page 3

4149 765 103 - 2004-12 15-17


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 4 From drawing no.: 6029 729 233 / Page 4

4149 765 103 - 2004-12 15-18


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.9.3 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 1 From drawing no.: 6029 729 216 / Page 1

4149 765 103 - 2004-12 15-19


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 2 From drawing no.: 6029 729 216 / Page 2

4149 765 103 - 2004-12 15-20


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 3 From drawing no.: 6029 729 216 / Page 3

4149 765 103 - 2004-12 15-21


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 4 From drawing no.: 6029 729 216 / Page 4

4149 765 103 - 2004-12 15-22


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.10 Function description EST 146 / 147 PIN 5 (AD5) Digital output
accoding to Function: Activation of shift element C
Current circuit diagram 6029 729 155 / 215 The C shift element is activated via solenoid valve
- Application with/without CAN + FS without Y15.
CAN
Circuit diagram 6029 729 156 / 216 PIN 6 (AIP3) PWM current output
- Application with/without CAN + FS without Function: Activation of retarder proportional
CAN solenoid valve Y1
NOTE Same as current activation of retarder proportional
Separate current circuit diagram/connection valve Y1 in accordance with retarder torque
diagram for CAN range selector 6029 729 232/ requested.
6029 729 233
Pin pattern 6029 729 073 PIN 7 (CANF-T) CAN Full Termination
Function: Terminal resistance 120 Ohm
Voltage supply 24 V If EST 146 / 147 is defined as an end participant, the
terminal resistance must be activated in the EST by
Voltage supply limits: installing a jumper between PIN 26 and PIN 7.
Full functional capability between 18 V and 32 V
PIN 8 (AD9) ) Digital output
NOTE Function: Activation of solenoid valve Y2 for
At voltage levels < 18 V (terminal 30) the control retarder accumulator
device actively switches into a safe status (neutral).
PIN 9 (AD4) Digital output
RESET: Via range selector neutral Function: Activation of shift element D
The D shift element is activated via solenoid valve
Current consumption: Y14.
Standby: 1 mA
Idling: < 300 mA PIN 10 (AD7) Digital output
Full load: 6A Function: Activation of shift element A
Test period: 1h The A shift element is activated via solenoid valve
Y17.
PIN 1 (VM1) Earth/Ground supply
Function: Earth/ground supply for control unit PIN 11 (AD16) Digital output
(-) terminal 31 (vehicle earth/ground) Function: Activation of lock-up clutch shift
element
PIN 2 (VMG1) Sensor earth/ground supply The loch-up clutch shift element is activated via
Function: Earth/ground supply for sensors solenoid valve Y18.

PIN 3 (ER1) Input for resistance 1 PIN 12 (ED15) Digital input


Function: Input resistance for temperature sensor, Function: Digital retarder request
retarder output on cooler connection Standard: Stage 2 (2/3 of retarder torque) (function
piece can also be implemented via CAN, see Chap.
Retarder)
PIN 4 (AD6) Digital output
Function: AActivation of shift element B
The B shift element is activated via solenoid valve
Y16.

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ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

PIN 13 (ADM1) Digital earth/ground output PIN 20 (ED3) Digital input


Function: Status monitoring Function: NBS (Neutral at Bus Stop)
Issues a flashing signal when errors of maximum Input of BN (+) if the NBS function is desired.
priority occur. (Function can also be implemented via CAN)

Application example: Application example for city bus:


Activating an operating lamp with BN(-), optional for Transmission shifts to NBS status if:
vehicles without on-board diagnosis a) BN(+) is on PIN 20 (e.g. via pushbutton in braking
circuit), and
NOTE b) speed less than approx. 3 km/h and
See Chap. Diagnosis c) accelerator in idle position and
d) 1st gear is selected.
PIN 14 (SD1) Interface digital
Function: Not assigned for version with CAN. If one of the above conditions is no longer satisfied,
1st gear is immediately re-selected.
PIN 14 (SD1) Digital interface
Function: PWM interface for version without CAN. NOTE
For reference value of pushbutton in braking circuit,
PIN 15 (SDDK) Interface for digital diagnosis see Chap. NBS.
communication
Function: Communication line (K line) in Alternative assignment: Engine brake request
accordance with ISO 9141 (for EST 146) Input of BN (+) if the engine brake is to be engaged.
Function can also be implemented via CAN).
NOTE With ABS active: Input of BN (+) interrupted.
See Chap. Diagnosis
Alternative assignment for EST 147:
A line according to SAE J 1587/1708 PIN 21 (ED10) Digital input
Function: Range selector input
PIN 16 (EF2) Frequency input Refer to range selector matrix function.
Function: Input output speed
PIN 22 (VMHF) High frequency earth/ground
PIN 17 (EF4) Frequency input supply
Function: Not assigned Function: CAN earth/ground
Connection of sheath when wiring sheathed CAN
PIN 18 (EUPR) Programming voltage input lines.
Function: Voltage input for control unit
programming

PIN 19 (EDM1) Earth/Ground digital input


Function: ABS input for retarder deactivation
When the ABS is active input for retarder deactiva-
tion.
(Earth/Ground is interrupted).
(Function can also be implemented via CAN).

4149 765 103 - 2004-12 15-24


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

PIN 23 (VPE1) External positive supply PIN 30 (AD1) Digital output


Function: Terminal 30 (permanent +) Function: Activation of shift element G
Used to ensure a control unit overrun, i.e. to enter The G shift element is activated via solenoid valve
error and adaptation data once terminal 15 has been Y11.
disengaged.
The EST 146/147 automatically switches itself off PIN 31 (AD13) Digital output
once the voltage supply time lag has expired, i.e. Function: Activation of solenoid valve Y3 PTO unit
once the vehicles voltage supply is no longer being
drained. PIN 32 (AD12) Digital output
Function: V-signal
CAUTION Output of BN(+) if a programmed driving speed has
PINs 23 and 68 must be disengaged following been reached.
ignition Off (terminal 15) after 5 seconds at the Standard: : Output of BN (+) at operating frequency
earliest. > 20 Hz.
Application example: Preventing door from opening
PIN 24 (VMGA) Analog sensor earth/ground while vehicle in motion.
Function: Earth/ground sensor for temperature
sensor and optional analog retarder PIN 33 (EDM2) ) Digital earth/ground input
control element. Function: Redundancy signal for retarder control
hand lever
Alternative assignment: Load sensor A3 Example: Zero position recognition (retarder off).

PIN 25 (CANF-H) CAN F High PIN 34 (VMG2) Sensor earth/ground supply


Function : CAN-High Function: Earth/ground supply for sensors

PIN 26 (CANF-L) CAN F Low PIN 35 (SD3) Digital interface


Function : CAN-Low Function: Not assigned

PIN 27 (ER2) Resistance input PIN 36 (ED7) Digital input


Function: Resistance input of temperature sensor Function: Digital retarder request
transmission oil sump Standard: Stage 3 (2/3 of retarder torque) (function
Retarder torque will be reduced as defined oil sump can also be implemented via CAN, see Chap.
temperature limits are exceeded. Retarder)

PIN 28 (ED12) Digital input


Function: Range selector input
Refer to range selector matrix function.

PIN 29 (AD2) Digital output


Function: Activation of shift element F
The F shift element is activated via solenoid valve
Y12.

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ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

PIN 37 (AU) Voltage output PIN 44 (ED8) Digital input


Function: Sensor supply 5 V Function: External neutral
Voltage supply for analog retarder operating (Function can also be implemented via
elements and for load sensor (without CAN). CAN)

PIN 38 (EU1) Voltage input NOTE


Function: Voltage input of load sensor Only in agreement with ZF!
(without CAN) Interruption of BN(+) if transmission is to be shifted
to neutral.
PIN 39 (EU3) Voltage input If the safety switch is not used, a jumper must be
Function: Analog input for analog retarder control permanently installed to positive (terminal 15).
element
(retarder foot pedal, 0 - 5 V) PIN 45 (VIP) Positive terminal
Function: Terminal 15 (positive engaged) activated
NOTE via ignition switch
Retarder activation A13 can be deactivated via S9. Voltage supply activated via key-operated switch.

PIN 40 (EF3) Frequency input NOTE


Function: Input input speed sensor (application To ensure perfect booting and shutdown of the con-
without CAN). trol units communicating with the EST, ensure that
e.g. the engine, ABS, and transmission control units
PIN 41 (ED14) Digital input are activated and deactivated within 1.5 s.
Function: Range selector input
Refer to range selector matrix function. PIN 46 (VM2) Earth/ground supply
Function: Earth/ground supply for control unit (-)
PIN 42 (ED11) Digital input terminal 31 (vehicle earth/ground)
Function: Range selector input
Refer to range selector matrix function. PIN 47 (CANB-H) CAN B High
Function: Communication with CAN-FS
PIN 43 (ED4) Digital input
Function: Lock-up clutch open / upshift inhibit PIN 48 (CANB-L) CAN B Low
(Lock-up clutch open / upshift inhibit can also be Function: Communication with CAN-FS
implemented via CAN).
Input of BN(+) if: PIN 49 (ER3) Resistance input
Lock-up clutch open and upshift inhibit are to be Function: Resistance input for retarder classifica-
activated tion
Application example of lock-up clutch open:
ABS to disconnect engine drag torque PIN 50 (ED13) Digital input
Application example of upshift inhibit: Function: Range selector input
ASR to prevent shifts during ASR feedback Refer to range selector matrix function.
control cycle
PIN 51 (AD8) Digital output
Function: Retarder On solenoid valve Y19

NOTE
Relay K10 for brake light activation.

4149 765 103 - 2004-12 15-26


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

PIN 52 (AD10) Digital output PIN 58 (ADMR) Tracing digital earth/ground


Function: Engine brake output output
Output of BN(+) if engine brake is engaged via the Function: Transmission encoding
control unit. The electronic unit uses the transmission encoding
to distinguish between transmission versions with
PIN 53 (AD14) Digital output direct drive and overdrive ratios.
Function: Warning lamp: Oil temperature exceeded Negative on PIN 58 means overdrive.
on retarder output or in transmission oil (See Chap. Diagnosis)
sump
Output of BN(+) if a certain temperature limit is PIN 59 (SD2) Digital interface
exceeded. Function: Speedo signal
Standard: 16 Imp./rev
PIN 54 (AD3) Digital output
Function: Activation of shift element E PIN 60 (SDDL) Digital L line diagnosis interface
The E shift element is activated via solenoid valve Function: Communication line (L line) in
Y13. accordance with ISO 9141
Option: Enable line for diagnosis pushbutton for
PIN 55 (AD11) Digital output flash code output of error memory during FS
Function: Gear signal without CAN.
Output of BN(+) if a certain gear or gear range (can
be programmed) is selected. NOTE
Standard: Output in 1st or 2nd gear as well as R gear See Chap. Diagnosis
Alternative assignment for EST 147:
PIN 56 (ADVP) Digital output supply plus B line according to SAE J 1587/1708
Function: Range selector button lighting at FS
without CAN. PIN 61 (EU2) Voltage input
Output of BN(+) for activation or lighting of range Function: Voltage input for analogue retarder con-
selector. trol element (retarder hand lever)
Option: Status monitoring Signal input (0 to 5 V) for retarder control element.
The button pressed is illuminated (continuously lit).
Top priority errors are indicated by the flashing of NOTE
the button lighting. Retarder activation A12 cannot be deactivated via
S9. If deactivation is required, the power supply to
PIN 57 (AIP1) PWM current output A12 must be interrupted by an external switch.
Function: Same as current activation of throttle
pressure valve for adaptation of shift
pressure

4149 765 103 - 2004-12 15-27


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

PIN 62 (EF1) Frequency input PIN 67 (ED6) Digital input


Function: Turbine speed sensor input Function: Gear approval
If a driving range is selected from NEUTRAL
PIN 63 (ED1) Digital input (forwards or reverse), BN(+) must be in place via the
Function: Input of BN(+) for kick down function braking system and/or must be in place within 2
BN(+) at this input means that the shift points are seconds.
shifted towards higher speeds. If this is not the case, the driving range must be
(Function can also be implemented via CAN). selected again via the neutral range selector. If the
safety switch is not used, a jumper must be perma-
NOTE nently installed to positive (terminal 15).
To protect against accidental activation, the system
must be able to clearly feel the increase in actuation Application example:
force when depressing the accelerator for the kick Approval of shift via a switch in the braking circuit.
down function to be activated. Gear is only selected once the brake has been
Option: Additional button for gear approval, depressed.
application example: 2nd R gear button
PIN 68 (VPE2) External positive supply
PIN 64 (ED5) Digital input Function: Terminal 30 (permanent +).
Function: Program change-over Used to ensure a control unit overrun, i.e. to enter
Input of BN(+) if a change is to be made to the error and adaptation data once terminal 15 has been
second drive program. disengaged.
The EST 146/147 automatically switches itself off
PIN 65 (ED2) Digital input once the voltage supply time lag has expired, i.e.
Function: Digital retarder request once the vehicles voltage supply is no longer being
(Function can also be implemented via CAN, refer to drained.
chap. Retarder) Also see PIN 23
Standard: Stage 1 (1/3 of retarder torque)

PIN 66 (ED9) Digital input


Function: Retarder deactivation
Input of BN(+)
Deactivation of retarder function only during
request via foot control elements S12 (PIN 65/12/36)
or A13 (PIN 39) and 5.3.4 EBC1 (Brake Pedal Posi-
tion).
No retarder deactivation with retarder request via
CAN (TSC1).

4149 765 103 - 2004-12 15-28


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Vehicle range selector interface:

A2: PIN 5 (AD6) Digital output


Function: Starter inhibit
When in position N, there is an electrical connection
(switch) between ED1 and AD6.
The engine may only be started when the range
selector is in the neutral position.
This function must not be implemented via CAN but
via the digital output of the range selector.
Reason: It must also be possible for the engine to be
started even if the CAN connection is not available,
i.e. during a line interrupt or if no transmission con-
trol units are connected.

A2: PIN 10 (AD7) Digital output


Function: Range selector in neutral
Output of BN(+) if N is pressed. Do not use as a
starter inhibit.
For optional use.

A2: PIN 11 (AD8) Digital output


Function: Reverse headlight relay.
Output of BN(+) if R is pressed. For optional use.

A2: PIN 3 (ED1) Digital input


Function: Input supply for AD6
must have separate fuses!

A2: PIN 2 (VP) Positive supply


Function: Supply BN(+), see range selector func-
tion matrix (AD1 to AD5) and range
selector neutral (K7) as well as reverse
headlight signal (K8).

A2: PIN 1 (VM) Earth/ground supply


Function: Earth/ground
Earth/ground supply for lighting.

4149 765 103 - 2004-12 15-29


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.11 ZF-Diagnosis systems 15.11.2 ZF-Diagnosis tools

15.11.1 ZF-Diagnosis protocols 15.11.2.1 ZF-Testman pro

with EST 18 ISO 9141 System requirements:


with EST 46 ISO 9141 Windows 95 / 98 / NT 4.0, Windows 2000, ME
with EST 146 ISO 9141 or XP
with EST 47 SAE J 1587 Pentium 233 Mhz
Hardware acc. to SAE J 1708 RAM 16 MB / NT 4.0 32 MB
with EST 147 SAE J 1587 HD capacity 20 MB
Hardware acc. to SAE J 1708 Serial interface Com 1 or Com 2
Colours: High Color
CD-ROM drive
Modem for data transfer via mobile phone

1 2 3 4

023736

6 5

Scope of supply
Customer version 6009 208 003 including:

1 T adapter 9/6/3 pins


2 ZF level converter DPA 05
3 USB cable
4 Connection cable SAE J 1587 + ISO 9141
5 RS 232 cable
6 ZF Diagnosis Software Testman pro on CD-ROM
(wihout PC)

4149 765 103 - 2004-12 15-30


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Individual applications (CD) depending on trans-


mission system (Diagnosis software):

Ecomat 1 EST 18 6008 208 813

Ecomat 2 EST 46/47 6008 208 814

Ecomat 2 EST 146/147 6008 208 814

Level converter DPA05

Laptop with COM interface or USB interface with


COM adapter
ISO: on DPA 05 at botton
SAE: on DPA 05 at top

019215

Cable to diagnosis interface in vehicle wiring harness.

Diagnosis / EOL programming Ecomat 2 plus

Diagnosis: U Prog. off / term. 30 or term. 15


EOL: U Prog. on / term. 30 at SAE on;
at ISO term. 30 or term. 15

4149 765 103 - 2004-12 15-31


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Contents of diagnosis software 5. Vehicle configuration


1. Parameterization
1. Documentation 1. Driving programs
1. Repair Manual 2. Data field for information
2. List of Lubricants 3. EEPROM-Data configuration
3. OEM Supply Inspection 7. EEPROM/Customer-copy data
4. Ecomat Service Check 8. EEPROM-Load/save data
5. Testman documentation 9. Load/save customer data SAEJ1587

2. Statistics memory 2. Flashing/vehicle adaptation


1. Obtain statistics data from vehicle 1. Flash programming
2. Obtain statistics data from file 2. Flashing documentation
3. EEPROM parameter correction
3. Diagnosis 4. Data recording
1. Read out error memory 5. Display list of variables
2. Clearing the error memory. 6. Factory settings for customer data
3. Read out identification block
6. Read out error memory 6. ZF Service telephone directory
9. Logbook
7. Settings
4. Test inputs/outputs 1. Address code
1. Outputs (components) control 2. Modify baud rate
2. Check inputs 3. Change PC baud rate
3. Standstill system check 4. High-speed mode
4. Driving system check 1. Release
5. Test equipment
6. Speeds, currents, load signals, temperatures 9. Abort communication
7. CAN connections
8. Preventive maintenance
9. Internal parameters

Statistics data for recording operating data

Serves as a requirement for providing OEMs and Statistis data:


end customers with optimum advice on driveline e.g.
configuration. Vehicle and customer specification
Usage reference to SORT cycles
The statistics data is only ever recorded when the Speed duty cycle
engine is running and the operating mode corres- Gear cycle
ponds to normal operations. Exceptions are: Standstill periods (N; D; NBS)
Number of times ignition is switched on/off Temperature cycles
Recording operating voltage U_Kl30 Retarder use data
Saving the current kilometer reading (under- Gear-dependant torque cycle
taken via CAN, TCO message) Temperature comparison (fleet comparison)
Load classes comparison (fleet comparison)

4149 765 103 - 2004-12 15-32


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.11.2.2 Flash code output EST 146/147 Lamp status


t4
Start of flash code output On
t7 t1 t3 t8
Off
t2 t5
EST 146 via L line (pin 60, 68-pin connector) or
thousands hundreds
via assigned ED (digital input) 2 3
On
t6 L line signal earth/ground
EST 147 via assigned ED (digital input) Off
015004

Route L line or assigned ED to ground/earth for


more than 2 sec. Programmed standard times:

t1 1 sec Thousands on
t2 0.3 sec Thousands off
AError display (read out error memory) t3 1 sec Lamp off separation
t4 0.3 sec Hundreds on
Display via range selector lighting (only available t5 0.3 sec Hundreds off
on range selectors without CAN) t6 2 sec Minus on L line
t7 1.5 sec Lamp off start
Display via assigned AD (digital output), lamp t8 4 sec Lamp off end

Only flashing of error path (thousand and hund-


red digits of external ZF error no.)

Example: Flashing of error path no. 23


(C clutch)

4149 765 103 - 2004-12 15-33


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

Connection cable SAE J 1587 + ISO 9141 From drawing no.: (= Order no.) : 6008 207 023

ca. 2.4 m

2 9-pin Mate-N-Lok 9-pin DSUB-bush


3
1 Pin 1: Term. 30 Pin 1: CAN B Low
6
4 Pin 2: J 1708-L Pin 2: J 1708-H
5 Pin 3: VM Pin 3: CAN B High
7
9 Pin 4: J 1708-H Pin 4: J 1708-L
8 Pin 5: Uprog Pin 5: Uprog 015007

Pin 6: CAN B High Pin 6: Term. 15 (vehicle)


Pin 7: CAN B Low Pin 7: Term. 30
Pin 8: Term. 15 (ECU) Pin 8: Term. 15 (ECU)
Pin 9: Term. 15 (vehicle) Pin 9: VM
015 007

Adapter From drawing no.: (= Order no.) : 6008 207 024

X2
1
2
3

X1
1
2
3 0.3 m
4
5
023808
6 n.b.
7 n.b.
8 n.b. X3
9 n.b. 1
2
3
4
5
6 n.b.

4149 765 103 - 2004-12 15-34


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.12 HST 46 auxiliary control unit ! DANGER


EST 146 and EST 147 versions
All safety functions are de-activated when using the
without CAN range selector
HST 46 auxiliary control unit. Therefore, the following
points must be observed without exception:
NOTE
Never shift from N to D or from N to R unless the
No auxiliary control unit possible with combination
engine is at idling speed and the vehicle stationary.
EST 146 / 147 and CAN range selector.
The transmission can be shifted at higher speeds,
The HST 46 auxiliary control unit was developed in
but this will cause transmission damage.
order to move the vehicle during assembly and to
Before shifting from forwards to reverse or vice
provide an emergency control function should the
versa, ensure that the vehicle is stationary.
EST 146 / 147 electric control unit malfunction.
After shifting to D or R, wait approx. 2 seconds for
The HST 46 auxiliary control unit is fitted to the
positive engagement before accelerating.
68-pin plug instead of the EST 146 / 147 electronic
control unit and allows forwards and reverse gears
to be engaged as shown in the table below. Gear
shifts whilst driving are no longer possible.
15.12.2 Technical data of HST 46

The following versions are available:


Rated voltage: UN = 24 V
Operating voltage: UB = 21 to 30 V
HST 46 / 24 V Codierung Ecomat transmission
Parts no. 5 and 6 gears (32 V - 1 h, 45 V - 5 min)
6009 078 009 A+E 2nd gear Current consumption: Imax. = 3 A
C+F Reverse gear Test voltage: UPR = 28 V 0.5 V
Outputs load: Imax. = 1 A
Level of outputs: UA = UB -1.0 V
Operating temperature: -20C to +70C
15.12.1 Operating manual for HST 46
Storage temperature: -40C to +85C
Resistance to transient
Apply parking brake to prevent vehicle from
voltages: 2ms: 200V (DIN 40839)
rolling away.
0.1ms: 150V (DIN 57839)
Speed range selector shifted to "N" (Neutral).
150ms: 122V
Switch off engine and ignition.
Resistance to vibrations: 5 g at 10 Hz to 1 kHz
Remove plug from EST 146 / 147 control unit.
Resistance to shock loads: 10 g
Connect plug to HST 46 auxiliary control unit
Protection type: IP 40
and secure.
Start engine.

Engage gear using speed range selector.


Shift position N = Neutral
Shift position D = Forwards (gear is shifted no
up- or downshift occurs)
Shift position R = Reverse

4149 765 103 - 2004-12 15-35


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.12.3 Dimensions of HST 46 From drawing no.: 6009 678 003

173 81 Zulssige
Perm. Einbaulagen
installation positions
64
A
53

46 68
24 45

XX
D
1 2 22 23

N
R
1
6.2

1020.2
35
15

XX
XX
N D R

D R
135
100

min 15

Minimum distancezum
Mindestabstand for disconnecting
Abstecken desplugSteckers

014 998

4149 765 103 - 2004-12 15-36


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.13 Block diagram EST 146

VP
Power
VM supply AU

Safety
switch

AD1
AD2
ED1 AD3
ED2 AD4
ED3 AD5
ED4 AD6
ED5 AD7
ED6 Digital AD8
Digital AD9
ED7 outputs
ED8 inputs AD10
ED9 AD11
ED10 AD12
ED11 AD13
ED12 AD14
ED13 ADVP
ED14 ADM1
ED15
EDM1
EDM2
Micro Status
Computer monitoring
EF1
EF2 Speed
EF3 inputs
EF4
Current AIP1
AIP2
output AIP3
ER1
ER2
ER3
EU1 Analog SD1
High Speed SD2
EU2 inputs
EU3 SD3
ADM2
EUPR CANF-T
Full CAN- CANF-H
CANF-L
Interface CANB-H
CANB-L

ISO- SDOK
Interface SDOL

Program
EEPROM RAM
memory
019863

4149 765 103 - 2004-12 15-37


ZF-Ecomat 2 plus Electronic automatic control system EST 146 / 147

15.14 Block diagram EST 147

VP
Power
VM supply AU

Safety
switch

AD1
AD2
ED1 AD3
ED2 AD4
ED3 AD5
ED4 AD6
ED5 AD7
ED6 Digital Digital AD8
ED7 outputs AD9
inputs AD10
ED8
ED9 AD11
ED10 AD12
ED11 AD13
ED12 AD14
ED13 ADVP
ED14 ADM1
ED15
EDM1
EDM2 Micro
Status
Computer
monitoring
EF1 Speed
EF2
EF3 inputs
EF4
Current AIP1
output AIP2
AIP3
ER1
ER2
ER3 Analog
EU1 High Speed SD1
EU2 inputs SD2
EU3 SD3
ADM2
EUPR CANF-T
Full CAN- CANF-H
Interface CANF-L
CANB-H
CANB-L

SAE J1708-H
J1708 J1708-L

Program
EEPROM RAM
memory
019864

4149 765 103 - 2004-12 15-38


ZF-Ecomat 2 plus Wiring

16 Wiring

16.1 Complete wiring - Standard


CAUTION: Wiring only in Standard lengths Lengths
dry area (Special lengths requested
ZF-Diagnosis Speed range on request)
device selector

LX1 0.5; 1.0; 1.5; 2.0


Lx25
Lx2 LX2 -
LM1 LM2 Lx7 Temp. sensor LX3 -
Lx1 KN1 KN2 Lx6 LX6 1.0; 1.5; 2.0
Transmission
Lx3 Lx8 LX7 1.0; 1.5; 2.0
Prop. solenoid
BN1 Change-
Lx9 LX8 1.0; 1.5; 2.0
Lx21 Y1 (retarder)
Electronic over to Solenoid valve LX9 1.0; 1.5; 2.0
control unit Silfirtex Y2 (accumulator) LX21 0.5; 1.0
BN2 net hose
CAN connection LX25 0.35
013 579
LM1 -
LM2 2; 4; 6; 8; 10

16.2 Complete wiring - with junctions

CAUTION: Wiring only in Standard lengths Lengths


dry area
(Special lengths requested
ZF-Diagnosis Speed range on request)
device selector

LX1 0.5; 1.0; 1.5; 2.0


Lx25
ion

LX2 -
Opt

W4
LM1 LM3 LM2 Lx7 Temp. sensor LX3 -
2

W1 W3 W2 LX6 1.0; 1.5; 2.0


Lx

KN1 KN2 Lx6


Transmission
Lx1 Option LX7 1.0; 1.5; 2.0
Lx3 Lx8
Prop. solenoid LX8 1.0; 1.5; 2.0
BN1
Lx21 Lx9 Y1 (retarder)
Electronic LX9 1.0; 1.5; 2.0
control unit Solenoid valve
Y2 (accumulator) LX21 0.5; 1.0
BN2
CAN connection integrated plug-in LX25 0.35
013580
connectors LM1 -
Is the EST 146/147 CAN end user? No Yes LM2 2; 4; 6; 8; 10
(Terminator 120 ) LM3 -

Integrated plug-in connector 16.3 Wiring connection


4 M5
24 50.8
A Cap nut M27x1
46.7

39.7

L Following lengths are available:


1 m; 2 m; 3 m; 4 m; 5 m; 6 m; 8 m; 10 m; 12 m
70

023782

013578

4149 765 103 - 2004-12 16-1


ZF-Ecomat 2 plus Wiring

16.4 Wiring specifications

The wiring should be routed in the vehicle ensuring Do not fasten wiring
that it harness to oil, water, or
a) is not damaged pressure hoses.
b) can be accessed again at all times.

The wiring should be routed and secured in a


protected part of the vehicle.

Loose hanging wiring is not permitted.


006 700

Plug in transmission Install wiring harness at


connector correctly. sufficient distance from
exhaust pipe.
The maximum permissi-
ble ambient temperature
max 105C ist 105 C.

006 745 005 286

Plug-in connector of The minimum distance


EST 146 / 147 correctly. between the wiring
harness to generator
and to starter is
200 mm.
min 200 mm

006 746 006 703

The wiring harness Do not connect


must not be damaged by earth/ground cables to
drilling, grinding, flying the transmission.
sparks during welding
work etc.

005 282 006 704

4149 765 103 - 2004-12 16-2


ZF-Ecomat 2 plus Wiring

Connect negative pin of The plug connections


electrical start via must be removed for
earth/ground strap to service purposes.
vehicle chassis.
OK

005 279 006 740

Current must not flow Do not route wiring


through the trans- directly next to high
mission during electrical frequency lines.

!
welding work.

006 701 005 295

The cables must be R 20 mm min


The cable may be routed
routed so that they are in loops to compensate
ca. 500 mm

1 3 5
protected from the for differences in length.
effects of heat (install
2 4 6 max 6 x
Max. 3m cable length
max 3m Kabel
heat shield, if necessary) with 6 loops, curve
and chafing points. radius at least 20 mm.

005 280 006 741

The wiring must be When routing the


routed so that the plug cable, observe EMC
connections are never compatibility.

!
subject to tension
(especially in the bend
OK area of articulated
buses).

005 288 005 295

4149 765 103 - 2004-12 16-3


ZF-Ecomat 2 plus ZF documentation

17 ZF documentation

17.1 ZF documentation with CAN

17.1.1 Components

The engine, transmission, and electronic control CAUTION


unit (EST 146/147 ) of the Ecomat series micro- Before installing any Ecomat transmission, check
processor controlled automatic transmissions are the Parts List numbers on the identification plates
individually matched to each other. These three to ensure that the engine, transmission, and ECU
components may only be installed in a vehicle in a are as shown in the documentation, i.e. that the
combination which has been documented by ZF. details agree with the computer printout.
Every application is documented at ZF under a Parts In correspondence and inquiries, please always
List (specification) number and is available as a quote the Parts Lists Nos. and Serial Nos. of the
computer printout (see example below). Ecomat and the electronic control unit
(EST 146/147)!
Computer printout (scope of delivery)

4143 Z F F PA R T S L I S T O R G A N I Z AT I O N
MODULAR PARTS LIST TECHNICAL INF/MODIFICATION NO. *DISPLAY* SHEET 001
---------------------------------------------------------------------------------

a SNR(Z): 4149 080 XXX BEN: 6 HP 602 C T-INFO:


DEPT: BPE1 RESPONSIBLE: L: K3 AEI: ZB: STEP2
POS VKF PART NO. DESCRIPTION TECHNICAL INFORMATION AN/AU AE-NR
A10 CUSTOMER: XXXXXXX *COUNTRY: XX
A14 ORDER NO.: XXXXXXXXX
S02 VEHICLE DATA 1:
S04 MODEL: BUS (GELENK) *XXX
S06 MAX. G.V.W: SOLO 28T
S08 R DYN: 466*V MAX: CA. 100 KM/H
S10 HA: I = 5,74
S12
S14 XXXX / XXXX E3*KW265/1900*N.M1600/1530
S16 ENGINE: EDC BOSCH MS 5.5
S30 DRAWINGS:
S32 ENG.INSTALL.: 4139 500 798(0)
S34 CONVERTER DIAGRAMM: 4166 706 166
S46 CONNECT. DIAGRAM: 6029 729 XXX
S48 CURRENT CIRC. DIAGRAM 6029 729 XXX
930 SUPERIMPOSED PRODUCT CONSISTING OF:
932 1 4149 064 XXX 6 HP 602 C 24V*FLANGED*COAXIAL*NBS
b
*RETARDER*ECOMAT2PLUS
950 1 6009 090 XXX EST 146 STEP2
c
970 1 4139 130 126 CONNECTION
984 1 4149 196 164 PERIPHERALS 9416A
a = Parts List No. for computer printout (supply specification)
b = Parts List No. for Ecomat transmission
c = Parts List No. for electronic control unit EST 146 / 147

4149 765 103 - 2004-12 17-1


ZF-Ecomat 2 plus ZF documentation

17.1.2 Identification and engine compatibility data

ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY

ECOMAT 2 6 HP - 602 C 2
MODEL 3 CONTROL MIT EST 146 24 VDC 4
PARTS LIST NO. SERIAL NO. 7 TRANSMISSION 6HP602C
1 4149 064 XXX XXXXXX 3 1 ZF-NO. 6009090XXX SER. NO. XXXXX 2
5 PROGRAMMIER 6009390XXX
CUSTOMER
SPEC. NO
XX XXXXX XXXX 4 6 CUSTOMER NO. XXXXXXX
TOTA L 3.43 - 0.59 SPEEDO
6
5 R AT I O
RATIO IMP/U6.00
xn
P.T.O. N - n= - ENGINE e1 022 486
OIL CAPACITY OIL GRADE SEE
7 IN LITERS 20 LUBRIC. LIST TE-ML 14 8
9 A 10

D
019942 023812

Description of fiels on type plate

Transmission: Electronic control unit EST 146 / 147:

1 Transmission Parts List No. 1 EST 146 / 147 Parts List No.
(for matching EST 146 / 147, check documen- (for matching transmission, check documenta-
tation) tion)
2 Transmission model designation, including 2 EST 146 / 147 serial no.
number of gear ratios 3 ECU designation
3 Transmission serial no. 4 Rated voltage
4 Client's order no., if known to ZF 5 Programming
5 Transmission ratio range 6 Client's order no., if known to ZF
6 Speedo signals 6 impulses/revolutions 7 Transmission model designation, including
7 PTO model number of gear ratios
8 PTO ratio (Check that number of ratios is correct!)
9 Approx. oil quantity required for first filling
10 ZF List of Lubricants No.

4149 765 103 - 2004-12 17-2


ZF-Ecomat 2 plus ZF documentation

17.2 ZF documentation without CAN

17.2.1 Components

The engine, transmission, and electronic control CAUTION


unit (EST 146/147 ) of the Ecomat series micro- Before installing any Ecomat transmission, check
processor controlled automatic transmissions are the Parts List numbers on the identification plates
individually matched to each other. These three to ensure that the engine, transmission, and ECU
components may only be installed in a vehicle in a are as shown in the documentation, i.e. that the
combination which has been documented by ZF. details agree with the computer printout.
Every application is documented at ZF under a Parts In correspondence and inquiries, please always
List (specification) number and is available as a quote the Parts Lists Nos. and Serial Nos. of the
computer printout (see example below). Ecomat and the electronic control unit
(EST 146/147)!

Computer printout (scope of delivery)

4143 Z F F PA R T S L I S T O R G A N I Z AT I O N
MODULAR PARTS LIST TECHNICAL INF/MODIFICATION NO. *DISPLAY* SHEET 001
--------------------------------------------------------------------------------

a SNR(Z): 4149 080 XXX BEN: 6 HP 602 T-INFO:


DEPT: BPE1 RESPONSIBLE: L: K3 AEI: ZB: STEP2
POS VKF PART NO. DESCRIPTION TECHNICAL INFORMATION AN/AU AE-NR
A10 CUSTOMER: XXXXXXX *COUNTRY: XX
A14 ORDER NO.: XXXXXXXXX
S02 VEHICLE DATA 1:
S04 MODEL: BUS (GELENK) *XXX
S06 MAX. G.V.W: SOLO 28T
S08 R DYN: 466*V MAX: CA. 100 KM/H
S10 HA: I = 5,74
S12
S14 XXXX / XXXX E3*KW265/1900*N.M1600/1530
S16 ENGINE: EDC BOSCH MS 5.5
S30 DRAWINGS:
S32 ENG.INSTALL.: 4139 500 798(0)
S34 CONVERTER DIAGRAMM: 4166 706 166
S46 CONNECT. DIAGRAM: 6029 729 XXX
S48 CURRENT CIRC. DIAGRAM 6029 729 XXX
930 SUPERIMPOSED PRODUCT CONSISTING OF:
932 1 4149 064 XXX 6 HP 602 24V*FLANGED*COAXIAL*NBS
b
*RETARDER*ECOMAT2PLUS
950 1 6009 090 XXX EST 146 STEP2
c
970 1 4139 130 126 CONNECTION
984 1 4149 196 164 PERIPHERALS 9416A

a = Parts List No. for computer printout (supply specification)


b = Parts List No. for Ecomat transmission
c = Parts List No. for electronic control unit EST 146 / 147

4149 765 103 - 2004-12 17-3


ZF-Ecomat 2 plus ZF documentation

17.2.2 Identification and engine compatibility data

ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY

ECOMAT 2 6 HP - 602 N MOT 2


MODEL 3 CONTROL MIT EST 146 24 VDC 4
SERIAL NO.
PARTS LIST NO. 7 TRANSMISSION 6HP602
1 4180 064 XXX XXXXXX 3 1 ZF-NO. 6009090XXX SER. NO. XXXXX 2
CUSTOMER
XX XXXXX XXXX 4 5 PROGRAMMIER 6009390XXX
SPEC. NO 6 CUSTOMER NO. XXXXXXX
TOTA L 3.43 - 0.59 SPEEDO
6
5 R AT I O
RATIO IMP/U6.00
xn
P.T.O. N - n= - ENGINE e1 022 486
OIL CAPACITY OIL GRADE SEE
7 IN LITERS 20 LUBRIC. LIST TE-ML 14 8
9 A 10

D
019923 019399

Description of fiels on type plate

Transmission: Electronic control unit EST 146 / 147:

1 Transmission Parts List No. 1 EST 146 / 147 Parts List No.
(for matching EST 146 / 147, check documen- (for matching transmission, check documenta-
tation) tion)
2 Transmission model designation, including 2 EST 146 / 147 serial no.
number of gear ratios 3 ECU designation
3 Transmission serial no. 4 Rated voltage
4 Client's order no., if known to ZF 5 Programming
5 Transmission ratio range 6 Client's order no., if known to ZF
6 Speedo signals 6 impulses/revolutions 7 Transmission model designation, including
7 PTO model number of gear ratios
8 PTO ratio (Check that number of ratios is correct!)
9 Approx. oil quantity required for first filling
10 ZF List of Lubricants No.

4149 765 103 - 2004-12 17-4


ZF-Ecomat 2 plus ZF documentation

17.3 Oil level check

17.3.1 Oil level check prior to first commissioning;


transmission without oil filling

ACHTUNG CAUTION ATTENTION ATTENZIONE


Vor Erstinbetriebnahme Prior to running transmission Avant la premire mise en Prima della messa in eser-
Oelstandskontrolle for the first time, carry out service il faut effectuer le cizio si deve controllare
durchfuehren oil level check. contrle du niveau d'huile. il livello dell'olio
A) Fuellmenge 15-20 Liter A) Capacity 15-20 Liters A) Quantit verser: A) Quantit di riempimento
bei stehendem Motor. engine stopped. 15 20 l, moteur a motore fermo: 15-20
arrt. litri
B) Motor starten; nach 30 B) Start engine; after 30 B) Dmarrer le moteur; aprs B) Avviare il motore;
Sekunden bei Leerlauf- secs. check oil level 30 secondes vrifier le dopo 30 secondi e con
Drehzahl Oelstand am on dipstick with engine niveau de l'huile avec la il motore al minimo con-
Messstab pruefen. Wenn idling. If necessary, auge au rgime de ralenti trollare con l'asta il
noetig Oel nachfuellen, add oil to "COLD/30C" du moteur.Si ncessaire, livello dell'olio.
bis Marke "COLD" bzw. mark. complter le niveau d'huile Aggiungere olio, se
"30C"erreicht wird. The oil level check jusqu' la zone marque necessario, fino al segno
Die massgebende Oel- carried out at operating "COLD" ou "30C". "COLD" o "30C".
standskontrolle ist temperature 80C to 90C
die Pruefung bei Be- gives the finally deter- Le contrle du niveau Il controllo determinante
triebstemperatur mining reading. With d'huile la temprature del livello dell'olio
80C - 90C. engine idling and trans- de service de 80-90C quello a temperatura
Bei Motorleerlauf-Dreh- mission in neutral, oil est la mthode de mesure valable. d'esercizio di 80-90C.
zahl und Getriebe Neu- level must be in hot Au rgime de ralenti et Con il motore al minimo
tral muss Oelstand im range "85C/HOT". avec la bote de vitesses e il cambio in folle il
Warmbereich "85C" au point mort, le niveau livello dell'olio deve
bzw. "HOT"liegen doit se trouver dans la trovarsi nella zona di
zone chaude "85C" ou "HOT" caldo di "85C" o "HOT".

Standbereich (nMot=0) STOP zone engine stopped STOP niveau l'arrt(nmot=0) STOP Zona di fermo(nmot=0) STOP
Warmbereich 80-90C HOT hot zone 80-90C HOT moteur chaud 80-90C HOT Zona di caldo 80-90C HOT

Kaltbereich 30C COLD cold zone 30C COLD moteur froid 30C COLD Zona di freddo 30C COLD

019 891

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17.3.2 Oil level check prior to first commissioning;


Transmission oil filing at plant

ACHTUNG CAUTION ATTENTION ATTENZIONE


Getriebe ist mit Transmission La bote de vitesses Cambio riempito
Oel befuellt with oil fill est remplie d'huile con olio
A) Vor Erstinbetriebnahme A) Prior to running trans- A) Avant la premire mise A) Prima della messa in
Oelstandskontrolle mission for the first en service, il faut esercizio si deve
durchfuehren time, carry out oil level check. effectuer le contrle controllare il
du niveau d'huile. livello dell'olio
B) Motor starten, nach 30 B) Start engine, after 30
secs. check oil level B) Dmarrer le moteur; aprs B) Avviare il motore;
Sekunden bei Leerlauf-
30 secondes, vrifier le dopo 30 secondi e con
Drehzahl Oelstand am at dipstick with engine
niveau de l'huile avec la il motore al minimo con-
Messstab pruefen,wenn idling. If necessary, jauge au rgime de ralenti trollare con l'asta il
noetig Oel nachfuellen, add oil to "COLD/30C" mark. du moteur.Si ncessaire, livello dell'olio.
bis Marke "COLD" bzw. The oil level check complter le niveau d'huile Aggiungere olio, se
"30C"erreicht wird. carried out at 80C to jusqu'a ce que la zone necessario, fino a toccare
Die massgebende Oel- 90C operating temp- marque "COLD" ou "30C" il segno "COLD" o "30C".
standskontrolle ist erature gives the soit atteinte. Il controllo determinante
die Pruefung bei Be- conclusive reading. Le contrle du niveau del livello dell'olio
triebstemperatur 80 - 90C. Oil level must be in d'huile la temprature quello a temperatura
Bei Motorleerlauf-Dreh- warm range "85C/HOT" de service de 80-90C d'esercizio di 80-90C.
with engine idling and est la mthode de mesure valable. Con il motore al minimo
zahl und Getriebe Neu-
Au rgime de ralenti et e il cambio in folla il
tral muss Oelstand im transmission in neutral.
avec la bote de vitesses livello dell'olio deve
Warmbereich "85C" au point mort, le niveau trovarsi in questo caso
bzw. "HOT"liegen doit se trouver dans la nella zona di caldo di
zone chaude "85C" ou "HOT" "85C" o "HOT".

Standbereich (nMOT=0) STOP engine stop zone STOP niveau l'arrt(nmot=0) STOP Zona di fermo(nmot=0) STOP
Warmbereich 80-90C HOT hot zone 80-90C HOT moteur chaud 80-90C HOT Zona di caldo 80-90C HOT

Kaltbereich 30C COLD cold zone 30C COLD moteur froid 30C COLD Zona di freddo 30C COLD

019 892

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17.3.3 Oil level check prior to first commissioning;


Transmission with additional cooling
system, with or without oil filling at plant

ACHTUNG CAUTION
Getriebe mit Zusatzkuehlung. Transmission with auxiliary cooling.
Getriebe hat nicht die erforderliche Oelmenge. Oil volume insufficient for the transmission.
A) Vor Erstinbetriebnahme die Gesamtlaenge A) Determine total lenght of all auxiliary
aller Komponenten der Zusatzkuehlung ausserhalb cooling components outside of the transmission
des Getriebes ermitteln. prior to initial startup.
Aus der Gesamtlaenge und Leitungs DN(Innendurchmesser) Determine additional oil volume on the basis of
die Zusatzoelmenge ermitteln. total lenght and line - DN(inner diameter).
m
4m mm mm mm
6 =2 =22 m 6 =24 =22
m
Oelvolumen [Liter]

20m 20m

Oil volume [Litre]


DN DN DN = DN DN DN =
5 m 5 m
18m 18m
D N= DN=
4 6m m 4 6mm
DN=1 DN=1
3 3
2 2
1 1
0 0
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Gesamtlaenge [m] Total lenght[m]
Oelfuellvolumen des Oelkuehlers ermitteln. Determine oil-fill volume of the oil cooler.
Die erforderliche Zusatzoelmenge einfuellen. Fill in extra amount of oil reguired.

B) Vor Erstinbetriebnahme Oelstandskontrolle durchfuehren. B) Prior to running transmission for the first
Motor starten, nach 30 Sekunden bei Leerlauf-Drehzahl time, carry out oil level check.
Oelstand am Messstab pruefen,wenn noetig Oel nachfuellen, Start engine, after 30 secs. check oil level at
bis Marke "COLD" bzw."30C"erreicht wird. dipstick with engine idling. If necessary,
Die massgebende Oelstandskontrolle add oil to "COLD/30C" mark.
ist die Pruefung bei The oil level check carried out
Betriebstemperatur 80 - 90C. at 80C to 90C operating
temperature gives the
Bei Motorleerlauf-Drehzahl Standbereich (n Mot=0) STOP conclusive reading. engine stop zone STOP
Warmbereich 80-90C HOT hot zone 80-90C HOT
und Getriebe Neutral
muss Oelstand im Oil level must be in
Warmbereich "85C" warm range "85C/HOT"
bzw. "HOT"liegen. Kaltbereich 30C COLD with engine idling and cold zone 30C COLD
transmission in neutral.

021 684

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ZF-Ecomat 2 plus Calculations and conversion tables

18 Calculations and conversion tables Please observe the following points concerning
gradability:
18.1 Driveline design
Gradability in the 1 st mechanical gear must be
the criterium, because the torque converter
Use the following vehicle performance formulae to
should only be used as start-up assistance.
select driveline design. They enable you to select the
Reference value is S > 11 %.
best components to suit your special requirements In difficult terrain, a larger S value should be
(e.g. required top speed, gradability etc. as a function selected.
of axle ratios, transmission ratios, tire radii etc.).
The following is valid in practice for extreme
The formulae can either be solved using the para- applications: Starting capacity, e.g. starting off is
meters required or by iteration. still possible up to max = 0.8 Smax..
(Smax. = gradability at stall-point.)

Calculation formulae:

Driving speed vF [km/h]


0.377 rdyn [m] nT [min-1] 0.0714 rdyn [ft] nT [min-1]
vF = ________________________ vF = ________________________
iG iH iG iH

Max. gradability Smax [%]


(Resistance WL 0)

TT [Nm] iG iH tot TT [lbft] iG iH tot


Smax = 100 tan [arc sin( ____________________ fR)] Smax = 100 tan [arc sin( ____________________ fR)]
m [kg] 9.81 rdyn [m] G [lbft] rdyn [ft]

Gradability S at higher speeds vF


For inclines S 10% is sin tan ; Error 0.5 %

1 TT [Nm] iG iH tot
S = 100 [ ___________ ( ___________________ 0.0473 CW A VF2 [(km/h)2]) fR]
m [kg] 9.81 rdyn [m]

TT [lbft] iG iH tot 0.002529 CW A [ft2] VF2 [(mph)2]


S = 100 [ __________________ _ ________________________________ fR]
G [lbft] rdyn [ft] G [lbft]

rdyn[m], [ft] Rolling radius tot [] Overall efficiency = G H


m [kg] = 0.95 0.95 0.9

G [lbft] } Vehicle weight


fR [] Rolling resistance
Asphalt, concrete, fR = 0.010 0.012
9.81 [m/s2] Acceleration due to gravity
Beaten earth, fR = 0.020 0.040
nT [1/min] Turbine speed
CW [] Coefficient of air resistance Bus CW 0.6
TT [Nm], [lbft] Turbine wheel torque Truck CW 0.8
iG [] Transmission ratio A [m2], [ft2] Front section area Bus A 6m2
iH [] Axle ratio Lkw A 8m2
VF [km/h], [mph] Driving speed
Once the key data has been established, a computer program can be used, if required, to perform the vehicle
performance calculation.

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18.2 Collective formulae for retarder and cooler


1. Braking rating PB

G [kg] 9.81 [m/s2] v [km/h] s [%]


PB [kW] = __________________________ [sin (arc tan _____) + fR]
3600 100

2. Engine speed nMot = nRet (only applies when lock-up clutch closed)

v [km/h] iG iH
nT [1/min] = nMot [1/min] = ______________
0.377 rdyn [m]

3. Retarder rating PRet for nRet

TRet [Nm] nRet [1/min]


PRet [kW] = _____________________
9550

Calculation example

Braking rating of a city bus with 5 HP 502 C and Retarder

Data: G = 18 000 kg; fR = 0.01; v = 30 km/h; s = 7%

18 000 9.81 30 7
Brake rating PB = ________________ [sin (arc tan _____ ) + 0.01]
3600 100

Brake rating PB = 88 kW = 120 PS (Dauerbetrieb)

Calculation of engine and/or retarder speed at v = 30 km/h in 2nd gear


(only applies when lock-up clutch closed nMot = nRet)

30 2.01 5.92
nT [1/min] = nEng [1/min] = ______________ = 2032 1/min
0.377 0.466

Braking ability S on downhill inclines with braking torque T = 1300 Nm at nRet = 2200/min in 2nd gear and
v = 30 km/h

TBr [Nm] iG iH TBr = 1300 Nm


S = 100 tan [arc sin ( ______________________________ fR)]
m [kg] 9.81 [m/s2] rdyn [m] H at nT = 2032 rpm

1300 2.01 5.92


S = 100 tan [arc sin ( _________________________ 0.01)] = 21.25%
18 000 9.81 0.466 0.95

S = 21.25% incline can be driven with continual braking.

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ZF-Ecomat 2 plus Calculations and conversion tables

18.3 Conversion tables

18.3.1 Units of length

Unit in ft yd mile n mile mm m km

1 in = 1 0.08333 0.02778 25.4 0.0254


1 ft = 12 1 0.33333 304.8 0.3048
1 yd = 36 3 1 914.4 0.9144
1 mile = 63360 5280 1760 1 0.86898 1609.34 1.609
1 n mile1) = 72913 6076.1 2025.4 1.1508 1 1852 1.852

1 mm = 0.03937 3.281 10-3 1.094 10-3 1 0.001 10-6


1 m = 39.3701 3.2808 1.0936 1000 1 0.001
1 km = 39370 3280.8 1093.6 0.62137 0.53996 106 1000 1

in = inch, ft = foot, yd = yard, mile = statute mile, n mile = nautical mile


1) 1 n mile = 1 sm = 1 international nautical mile = 1/60th of a degree of latitude 1

In UK 1 n mile (UK) = 6080 ft 1853 m.


1 Knot = 1 n mile/h = 1852 km/h

18.3.2 Units of area

Unit in2 ft2 yd2 mile2 cm2 dm2 m2 a ha km2

1 in2 = 1 6.452 0.06452


1 ft2 = 144 1 0.1111 929 9.29 0.0929
1 yd2 = 1296 9 1 8361 83.61 0.8361
1 mile2 = 1 259 2.59

1 cm2 = 0.155 1 0.01


1 dm2 = 15.5 0.1076 0.01196 100 1 0.01
1 m2 = 1550 10.76 1.196 10000 100 1 0.01
1 a = 1076 119.6 10000 100 1 0.01
1 ha = 10000 100 1 0.01
1 km2 = 0.3861 10000 100 1

in2 = square inch (sq in),


ft2 = square foot (sq ft),
yd2 = square yard (sq yd),
mile2 = square mile (sq mile).

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18.3.3 Units of volume

Unit in3 ft3 yd3 gal (UK) gal (US) cm3 dm3 1) m3

1 in3 = 1 16.3871 0.01639


1 ft3 = 1728 1 0.03704 6.229 7.481 28.3168 0.02832
1 yd3 = 46656 27 1 168.18 201.97 764.555 0.76456
1 gal (UK) = 277.42 0.16054 1 1.20095 4546.09 4.54609
1 gal (US) = 231 0.13368 0.83267 1 3785.41 3.78541

1 cm3 = 0.06102 1 0.001


1 dm3 1) = 61.0236 0.03531 0.00131 0.21997 0.26417 1000 1 0.001
1 m3 = 61023.6 35.315 1.30795 219.969 264.172 106 1000 1

in3 = cubic inch (cu in),


ft3 = cubic foot (cu ft),
yd 3 = cubic yard (cu yd),
gal = gallon,
1) dm3 = 1 (Liter).

18.3.4 Units of energy

Unit J kw h kp m PS h kcal ft lbf Btu

Statutory units

1 J = 1 277.8 10-9 0.10197 377.7 10-9 238.8 10-6 0.73756 947.8 10-6
1 kWh = 3.6 10-6 1 367098 1.3596 859.84 2.6553 106 3412.14

Units to be converted

1 kp m = 9.80665 2.724 10-6 1 3.704 10-6 2.342 10-3 7.2330 9.295 10-3
1 PS h = 2.6476 106 0.73550 269980 1 632.369 1.9528 106 2509.4
1 kcal 1) = 4186.8 1.163 10-3 426.93 1.581 10-3 1 3088 3.9683

Anglo American units

1 ft lbf = 1.3558 376.6 10-9 0.13826 512.1 10-9 323.8 10-6 1 1.285 10-3
1 Btu 2) = 1055.06 293.1 10-6 107.59 398.6 10-6 0.252 778.17 1

1) 1 kcal = Amount of heat required to raise temperature of 1 kg water at 15C by 1C.


2) 1 Btu = Amount of heat required to raise temperature of 1 lb water by 1F.
1 therm = 105 Btu

4149 765 103 - 2004-12 18-4


Units of mass

Avoirdupois System (standard trading weights in UK and US)

Unit gr dram oz lb long cwt sh cwt long tn sh tn g kg t

4149 765 103 - 2004-12


1 gr = 1 0.03657 0.00229 1/7000 0.064799
1 dram = 27.344 1 0.0625 0.00391 1.77184
18.3.5 Units of mass
ZF-Ecomat 2 plus

1 oz = 437.5 16 1 0.0625 - 28.3495


1 lb = 7000 256 16 1 0.00893 0.01 0.0005 453.592 0.45359

1 long cwt1) = 112 1 1.12 0.05 50.8023


1 sh cwt1) = 100 0.8929 1 0.04464 0.05 45.3592
1 long tn1) = 2240 20 22.4 1 1.12 1016.05 1.01605
1 sh tn1 = 2000 17.857 20 0.8929 1 907.185 0.90718

1 g = 15.432 0.5644 0.03527 1 0.001


1 kg = 35.274 2.2046 0.01968 0.02205 1000 1 0.001
1 t = 2204.6 19.684 22.046 0.9842 1.1023 106 1000 1

18-5
UK = Great Britain, US = United States of America

gr = grain, oz = ounze, lb = pound


long cwt = long hundredweight, sh cwt = short hundredweight,
long tn long ton, sh tn = short ton.
1 slug = 14.5939 kg = Mass, accelerated by a force of 1 lbf at the rate of 1 ft/s2.
1 st (stone) = 14 lb = 6.35 kg (only UK)
1 qr (quarter) = 28 lb = 12.7006 kg (only UK, rare application).
1 quintal = 100 lb = 1 sh cwt = 45.3592 kg
1 tdw (ton dead weight) = 1.016 t. In tdw, the load-bearing ability of freight dampers (load + ballast + fuel + lubrication) is indicated.

1) If cwt and tn are used with prefix long or sh, this indicates that the reference is to the UK long cwt and long tn, or to the US short (sh) cwt and short
tn respectively.
Calculations and conversion tables
Force units

1 kp = 9.80665 N 10N
1 lbf (pound-force) = 4.44822 N 1 N = 0.101972 kp 0.1 kp
1 pdl (poundal) = 0.138255 N = Kraft. die eine Masse von 1 lb um 1 ft/s2 beschleunigt 1 N = 0.224809 lbf

4149 765 103 - 2004-12


1 sh (sthne)* = 103 N 1 N = 7.233011 pdl
Pressure and voltage units
18.3.6 Force units
ZF-Ecomat 2 plus

Unit N/m2 bar mbar bar N/mm2 kp/mm2 at kp/m2 Torr atm lbf/in2 lbf/ft2 tonf/in2

Statutory units

1 N/m2 = 1 Pa = 1 10 0.01 10-5 10-6 0.10197 0.0075


1 bar = 0.1 1 0.001 10-6 10-7 0.0102
1 mbar = 100 1000 1 0.001 0.0001 10.197 0.7501 0.0145 2.0886
1 bar = 105 106 1000 1 0.1 0.0102 1.0197 10197 750.06 0.9869 14.5037 2088.6
1 N/mm2 = 106 107 10000 10 1 0.10197 10.197 101972 7501 9.8692 145.037 20886 0.06475

Units to be converted

18-6
1 kp/mm2 = 98066.5 98.0665 9.80665 1 100 106 73556 96.784 1422.33 0.63497
1 at = 1 kp/cm2 = 98066.5 980.665 0.98066 0.0981 0.01 1 10000 735.56 0.96784 14.2233 2048.16
1 kp/m2 = 1mmWS = 9.80665 98.0665 0.0981 10-6 10-4 1 0.2048
1 Torr = 1mmHg = 133.322 1333.22 1.33322 0.00136 13.5951 1 0.00132 0.01934 2.7845
1 atm = 101325 1013.25 1.01325 1.03323 10332.3 760 1 14.695 2116.1

Anglo American units

1 lbf/in2 = 6894.76 68948 68.948 0.0689 0.00689 0.07031 703.07 51.715 0.06805 1 144
1 lbf/ft2 = 47.8803 478.8 0.4788 4.8824 0.35913 1
1 tonf/in2 = 154.443 15.4443 1.57488 157.488 152.42 2240 1

lbf/in2 = pound-force per square inch (psi), lbf/ft2 = pound-force per square foot (psf), tonf/in2 = (long) ton-force per square inch
1 pdl/ft2 (pound per square foot) = 1.48816 N/m2
1 barye* = 1 bar; 1 pz (pice)* = 1 sn/m2 (sthne/m2)* = 103; 1 dyn/cm = 1 bar.
Normen: DIN 66 034 Kilopond Newton, Newton Kilopond, Conversion tables DIN 66 037 Kilopond/cm2 Bar, Bar Kilopond/cm2,
Conversion tables, DIN 66 038 Torr Millibar, Millibar Torr, Conversion tables
* french units
Calculations and conversion tables
ZF-Ecomat 2 plus Calculations and conversion tables

18.3.7 Power units

Unit W kW kpm/s PS kcal/s kcal/h hp Btu/s

Statutory units

1 W = 1 0.001 0.10197 1.360 10-3 238.8 10-6 0.86 1.341 10-3 947.8 10-6
1 kW = 1000 1 101.97 1.3596 238.8 10-3 860 1.3410 947.8 10-3

Units to be converted

1 kpm/s = 9.80665 9.807 10-3 1 13.33 10-3 2.342 10-3 8.434 13.15 10-3 9.295 10-3
1 PS 1) = 735.499 0.7355 75 1 0.17567 632.53 0.98632 0.69712
1 kcal/s = 4186.8 4.1868 426.935 5.6925 1 3600 5.6146 3.9683

Anglo American units

1 hp1) = 745.70 0.7457 76.0402 1.0139 0.17811 641.302 1 0.70678


1 Btu/s = 1055.06 1.05506 107.586 1.4345 0.2520 907.35 1.4149 1

hp = horsepower 1)
bhp = brake horsepower (brake power), dhp = drawbar horsepower (Power on drawbar hook).

1 ft lbf/s = 1.35582 W
1 ch (cheval vapeur) (French) = 1 PS = 0.7355 W
1 poncelet (French) = 100 kpm/s = 0.981 kW

Standards: DIN 66035 calorie - joule, joule - calorie, conversion tables


DIN 66036 horsepower-kilowatt, kilowatt-horsepower conversion tables
DIN 66039 kilocalorie-Watthour, Watthour-kilocalorie conversion tables

1) Note different test conditions by SAE and DIN for hp and/or PS units or power for vehicle engines.

18.3.8 Temperature conversions

Conversion to
Unit
F R K

Degrees Celsius C 1 9 9 K = 273 + C


F = C + 32 R = C + 491.7
5 5
Degrees 5 5 + 273
C = (F 32) 1 R = F + 459.7 K = (F 32)
Fahrenheit F 9 9

Degrees Rankine R 5 F = R 459.7 1 5


C = (R 491.7) K = R
9 9

Kelvin K C = K 273 9 9 1
F = (K 273) + 32 R = K
5 5

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ZF-Ecomat 2 plus Calculations and conversion tables

18.3.9 Moment of inertia conversion factors

1 kg m2 = (3.2808)2 kg sq.ft = (3.2808)2 (2.2046 lb) sq.ft = 23.73 lb sq.ft


1 kg m2 = (39.3701)2 kg sq.inch = (39.3701)2 (2.2046 lb) sq.inch = 3417 lb sq.inch
1 kg m2 = (1.0936)2 kg sq.yard = (1.0936)2 (2.2046 lb) sq.yard = 2.636 lb sq.yard

18.4 Torque

1 Nm = 0.738 lbft

T [Nm] n [min-1] T [lbft] n [min-1]


P [kW] = ________________ P [kW] = ________________
9552 7045

18.5 List of dynamic tire radii

Tire dimensions S

S Tire width
D Outer diameter
Rim diameter

024254

Conversion of tire dimensions

5280
rdyn [rev/mile] = ___________
2 rdyn [ft]

4149 765 103 - 2004-12 18-8


ZF-Ecomat 2 plus Calculations and conversion tables

Standard tires Tapered bead seat, Nominal 22.5 (tubeless)

ETRTO-Normmae ETRTO Standard dimensions


Tube Outer Tire-tread Tube Outer Tire-tread
Type / Width diameter circum- Type / Width diameter circum-
Tire Tube- max. max. ference Tire Tube- max. max. ference
dimension less (mm) (mm) (mm) dimension less (mm) (mm) (mm)
6.00 R 9 166 553 1647 8 R 22.5 TL 216 950 2855
7.00 R 12 200 687 2050 9 R 22.5 TL 239 986 2959
205/80 R 15 213 723 2162 10 R 22.5 TL 264 1038 3111
7.50 R 15 220 787 2355 11 R 22.5* TL 290 1070 3203
8.25 R 15 243 855 2550 11 R 22.5** TL 287 1064 3203
10.00 R 15 286 939 2800 12 R 22.5 TL 312 1104 3306
7.00 R 16 TL 214 792 2361 13 R 22.5 TL 326 1146 3428
225/75 R 16C TL 232 758 2269 255/70 R 22.5 TL 265 944 2837
225/75 R 16 TL 232 758 2269 275/70 R 22.5 TL 287 974 2922
7.50 R 16 TL 218 818 2446 275/80 R 22.5 TL 287 1030 3087
8.25 R 16 239 878 2623 295/60 R 22.5 TL 304 940 2806
9.00 R 16 256 932 2782 295/80 R 22.5 TL 310 1062 3184
7.50 R 20 TL 218 944 2830 305/70 R 22.5 TL 317 1018 3050
8.25 R 20 239 980 2934 315/60 R 22.5 TL 326 966 2879
9.00 R 20 268 1038 3105 315/70 R 22.5 TL 318 1032 3093
10.00 R 20 286 1074 3209 315/80 R 22.5 TL 318 1096 3282
11.00 R 20 TL 297 1104 3300 385/55 R 22.5 TL 401 1012 3018
12.00 R 20 TL 319 1146 3422 385/65 R 22.5 TL 405 1092 3248
14.00 R 20 TL 377 1268 3776 425/65 R 22.5 TL 447 1146 3406
445/65 R 22.5 TL 472 1174 3485
455/45 R 22.5 TL 471 1008 2975
495/45 R 22.5 TL 519 1046 3085
* Operational code: 148/145L; 148/145J; 148/145K
** Operational code: 142/142J

4149 765 103 - 2004-12 18-9


ZF-Ecomat 2 plus Oil grades and oil filters

19 Oil grades and oil filters

19.1 List of Lubricants TE-ML 14

Current list of lubricants can be obtained on the


Internet ZF-WORLD under:
> N divisions > Friedrichshafen location >
Materials
> ZF List of Lubricants

Current list of lubricants can be obtained on the


Internet under:
www.zf.com
> products for > Techn. Informationen

19.2 Purity of medium

NOTE
The oil must not contain any visible solid impurities.

19.3 Oil filter

Only ZF oil filters with a mesh width of 60 m may


be used.

4149 765 103 - 2004-12 19-1