Technical Manual 4139 - 765 - 121a

T E C H N I C A L M A N UA L
HP 500 HP 590 HP 600

FOR BUSES AND COACHES
STAGE II
ZF FRIEDRICHSHAFEN AG
Bereich Nkw-Antriebstechnik
D-88038 Friedrichshafen
Telephone (07541) 77-0 • Telefax (07541) 77-908000
4139 765 121a

Automatic transmissions from ranges
HP 500 HP 590 HP 600
Ecomat Technical Manual

for buses and coaches
Stage II
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IMPORTANT NOTICE
This Ecomat Technical Manual provides a technical basis for the Ecomat system and has been
produced for the benefit of vehicle and coachwork manufacturers as well as ZF employees.
This manual contains answers to questions ranging from specifications to installation inspection
and commissioning.
This manual provides the basis for specifications of the transmission and peripheral units.
Optimum procedure leading up to series production delivery:
% Specification of transmission and peripheral units performed by vehicle manufacturer and

ZF
% Documentation by ZF
% Initial installation
% Initial installation inspection performed by ZF personnel
% Commissioning performed by ZF personnel
% Certificate of Release granted by ZF
% Correction work if required by Certificate of Release
ZF can bear responsibility for any initial installation only if sign-off has been performed by
authorised ZF personnel and if all defects found by ZF have been rectified by the vehicle or
bodywork manufacturer. The vehicle or bodywork manufacturer shall bear sole responsibility
for any damage caused by defects attributable to the vehicle or coachwork 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 guidelines must be observed.
If you have any questions or suggestions, please contact our department: NE-3A - ECOMAT
Application Engineering Department.
2
The complete Ecomat system 1
Description of transmission and technical data 2
Ecomat installation position in vehicle 3
Installation position and mountings, propshaft connection 4
Connection to engine 5
Converter 6
Retarder 7
Cooling system 8
Transmission specifications 9
Hydraulic systems 10
Engine governing system 11
Peripherals 12
Neutral at Bus Stop (NBS) 13
Temperature monitoring 14
EST 18 electronic control unit 15
Cable harness and cable fitting requirements 16
ZF documents 17
Ecomat questionnaire - preparation of parts list 18
Calculations and conversion tables 19
Oil grades, oil filters 20
Pin patterns 21
Index of key words 22
3
Contents
Page
1 The complete Ecomat system .................................................................................................................... 8
2 Description of transmission and technical data ...................................................................................... 10

2.1 Brief description of transmission ................................................................................................ 10
2.2 Transmission structure and auxiliaries ........................................................................................ 12
2.2.1 Other auxiliaries ........................................................................................................................... 14.1
2.3 Transmission ratios and powerflow diagram ............................................................................... 15
2.3.1 Further ratios to those listed in Section 2.3 ................................................................................ 16.1
2.4 Maximum engine torques and vehicle weights ........................................................................... 17
2.4.1 Max. engine torques and vehicle weights (expanded version of table in Section 2.4) ................ 18.1
2.4.2 Load reduction ............................................................................................................................. 18.2
2.5 Moments of inertia and vibration substitution model ................................................................. 19
2.5.1 Moments of inertia and vibration substitution model
(for ratios i = 2.81-1.00 or i = 2.81-0.80) .................................................................................... 20.1
2.6 Transmission weights .................................................................................................................. 21
2.6.1 Transmission weights (expanded version of table in Section 2.6) ............................................... 22.1
2.7 Installation drawing ..................................................................................................................... 23
2.8 Clutch activation combinations ................................................................................................... 24.1
3 Ecomat installation position in vehicle ..................................................................................................... 25

3.1 Other Ecomat installation positions in vehicle ............................................................................ 26.1
4 Installation position and mountings, propshaft connection ................................................................... 27

4.1 Installation position and mountings ............................................................................................ 27
4.1.1 Ecomat with flange-mounted 63° angle drive - U.S.A. ............................................................... 28.1
4.1.2 Ecomat with flange-mounted STU 8000 spur gear drive ............................................................ 28.1
4.1.3 Transmission mounted separately from engine ........................................................................... 28.1
4.2 Propshaft connection ................................................................................................................... 29
4.2.1 Permitted propshaft angles .......................................................................................................... 29
4.2.2 Single-section propshafts ............................................................................................................ 32
4.2.3 Multi-section propshafts .............................................................................................................. 33
4.2.4 Other information ........................................................................................................................ 33
5 Connection to engine ................................................................................................................................. 34

5.1 ZF equipment supplied ................................................................................................................ 36
5.2 Engine connection study ............................................................................................................. 36
5.3 Engine connection - further instructions ..................................................................................... 38.1
5.3.1 Engine connection drawings HP 500 / HP 590 / HP 600 ............................................................ 38.3
6 Converter .................................................................................................................................................... 39
6.1 Description of torque converter ................................................................................................... 39
6.2 How the torque converter works .................................................................................................. 39
6.3 Getting the right torque converter for your engine ...................................................................... 40
6.4 Torque converter graph ................................................................................................................ 42
6.5 Basic torque converter graph curves ........................................................................................... 44.1
4
Page
7 Retarder ...................................................................................................................................................... 45
7.1 Structure and function of retarder ............................................................................................... 46
7.2 How the retarder works ............................................................................................................... 46
7.3 Control of the retarder ................................................................................................................. 47
7.4 Retarder and engine brake ........................................................................................................... 47
7.5 Pre-set retarder braking force ...................................................................................................... 47
7.6 Different variants for controlling the retarder ............................................................................. 47
7.7 Diagrams of retarder control systems .......................................................................................... 48
7.8 Using Ecomat in vehicles with Anti-Lock Brakes (ABS) ........................................................... 54
7.9 Using Ecomat in vehicles with engine brake .............................................................................. 54
7.10 Retarder control device ................................................................................................................ 54
7.11 Other retarder control devices ..................................................................................................... 56.1
7.12 Retarder torque in Ecomat ........................................................................................................... 56.6
7.13 Idling speed losses ....................................................................................................................... 56.6
7.14 Retarder control characteristics ................................................................................................... 56.7
7.15 R3 pressure vs. applied air pressure Pair ..................................................................................... 56.7
7.16 Retarder response time ................................................................................................................. 56.7
8 Cooling system ............................................................................................................................................ 57

8.1 Position of oil cooler .................................................................................................................... 57
8.2 Layout with oil cooler separate from transmission ...................................................................... 57
8.2.1 Oil line connections...................................................................................................................... 57
8.2.2 Installation guidelines................................................................................................................... 57
8.3 Specifications for < J.. > group heat exchanger ........................................................................... 57
8.4 Choice of oil cooler ...................................................................................................................... 57
8.4.1 Cooling system with retarder ....................................................................................................... 58
8.4.1.1 Cooling system graph................................................................................................................... 58
8.4.2 Cooling system without retarder .................................................................................................. 58
8.4.2.1 Cooling system without retarder - further instructions ................................................................ 58.1
8.5 Cooling water circuit .................................................................................................................... 59
8.6 Oil cooler specifications............................................................................................................... 62
8.6.1 Required performance of cooler version ...................................................................................... 62
8.6.2 Technical inspections.................................................................................................................... 62
8.6.3 Technical supply conditions ......................................................................................................... 62
8.7 Required performance of cooling water and antifreeze ............................................................... 63
8.7.1 General ......................................................................................................................................... 63
8.7.2 Fresh water ................................................................................................................................... 63
8.7.3 Antifreeze ..................................................................................................................................... 63
8.7.4 Cooling water ............................................................................................................................... 63
8.8 Collected formulae - retarder cooling system .............................................................................. 64.1
8.9 Heat exchanger with hard-coat lining........................................................................................... 64.3
9 Transmission specifications ....................................................................................................................... 65

9.1 Maximum engine torques and vehicle weights ........................................................................... 66
9.2 Installation position < L.. > ......................................................................................................... 67
9.3 Retarder version < G... > ............................................................................................................. 69
9.4 Heat exchanger position < J.. > ................................................................................................... 71
9.5 Oil sump < F.. > ........................................................................................................................... 75
5
Page
9.6 Oil fill < K.. > .............................................................................................................................. 79

9.7 Transmission output < A.. > ........................................................................................................ 81
9.8 Ecomat output flange ................................................................................................................... 83
9.9 Engine connection components supplied .................................................................................... 85
9.10 Auxiliaries ................................................................................................................................... 86
10 Hydraulic systems ...................................................................................................................................... 93

10.1 Hydraulic system 1 ...................................................................................................................... 94
10.2 How the hydraulic system works.................................................................................................. 95
10.3 Hydraulic system 2 ...................................................................................................................... 96
10.4 Hydraulic diagram........................................................................................................................ 96.1
10.5 Hydraulic diagram for version with NBS .................................................................................... 96.2
11 Engine governing system ........................................................................................................................... 97

11.1 Engine governor .......................................................................................................................... 97
11.2 Load reduction ............................................................................................................................. 97
11.3 Load response characteristics of engine ...................................................................................... 97
11.4 Engine governor - further instructions ........................................................................................ 98.1
11.4.1 Governor characteristics .............................................................................................................. 98.1
11.4.2 Using two-speed (RQ) or all-speed (RQV) governed engines with automatic transmissions .... 98.2
12 Peripherals .................................................................................................................................................. 99
12.1 Speed range selection system ...................................................................................................... 100
12.1.1 Push-button speed range selector ................................................................................................ 100
12.2 Load sensor A3 ............................................................................................................................ 103
12.3 Program change-over switch S5 .................................................................................................. 105
12.4 Temperature sensor A6 ................................................................................................................ 105
12.5 Temperature gauge A5 ................................................................................................................. 106
12.6 Accelerator interlock (antigas) .................................................................................................... 107
12.7 Kickdown switch ......................................................................................................................... 109
12.8 Retarder ....................................................................................................................................... 110
12.8.1 Reduction valves RV1, RV2, RV3 ............................................................................................... 110
12.8.2 Solenoid valve Y11 ..................................................................................................................... 111
12.8.3 Solenoid valves Y5, Y12, Y13 .................................................................................................... 112
12.8.4 2-way valve .................................................................................................................................. 113
12.8.5 Pressure switch S2 ....................................................................................................................... 113
12.9 Pressure switch S7 - Neutral at Bus Stop (NBS) ......................................................................... 114
12.10 Change-over contact and relay .................................................................................................... 115
13 Neutral at Bus Stop (NBS) ........................................................................................................................ 116

13.1 Neutral at Bus Stop, restrictions on application ........................................................................... 118.1
14 Temperatur monitoring ............................................................................................................................. 119

14.1 Temperature sensor A6 ................................................................................................................ 119
14.2 Temperature gauge A5 ................................................................................................................. 120
14.3 Resistance curve for temperature sensor ..................................................................................... 120.1
6
Page
15 EST 18 electronic control unit ................................................................................................................... 121

15.1 How the EST 18 works ................................................................................................................ 121
15.2 Standard functions ....................................................................................................................... 122
15.3 Optional functions ....................................................................................................................... 122
15.4 Installation requirements ............................................................................................................. 123
15.5 EST 18 dimensions ...................................................................................................................... 124
15.6 Circuit diagram ............................................................................................................................ 125
15.7 Wiring diagram ............................................................................................................................ 126
15.8 Functional description of vehicle electrical system ..................................................................... 127
15.9 EST 18 diagnostics system .......................................................................................................... 130
15.10 HST 18 auxiliary control unit ...................................................................................................... 131
16 Cable harness and cable fitting requirements ......................................................................................... 133

16.1 Complete cable harness - standard - ............................................................................................ 133
16.1.1 Complete cable harness; assembly drawing ................................................................................. 134.1
16.2 Complete cable harness - with in-line connections - ................................................................... 133
16.3 Cable connections......................................................................................................................... 134
16.4 Bushing......................................................................................................................................... 134
16.5 Electrical system sockets for plugs BN 1 and BN 2..................................................................... 134
16.6 Cable harness and cable fitting requirements............................................................................... 135
17 ZF documents ............................................................................................................................................. 136

7.1 Components ................................................................................................................................. 136
17.2 Identification and engine compatibility data ............................................................................... 137
17.3 Notes concerning ZF documents ................................................................................................. 138
18 Ecomat questionnaire - preparation of parts list .................................................................................... 141
19 Calculations and conversion tables ........................................................................................................... 151

19.1 Selection of driveline components ............................................................................................... 151
19.2 Conversion tables ........................................................................................................................ 152
19.2.1 Units of length ............................................................................................................................. 152
19.2.2 Units of area ................................................................................................................................ 152
19.2.3 Units of volume ........................................................................................................................... 153
19.2.4 Units of energy ............................................................................................................................ 153
19.2.5 Units of mass ............................................................................................................................... 154
19.2.6 Units of force ............................................................................................................................... 155
19.2.7 Units of power ............................................................................................................................. 156
19.2.8 Temperature conversions ............................................................................................................. 156
19.2.9 Moment of inertia conversion factors .......................................................................................... 157
19.3 List of dynamic tyre radii (Michelin) .......................................................................................... 157
20 Oil grades, oil filters ................................................................................................................................... 159

20.1 List of lubricants TE - ML 14 ..................................................................................................... 161
20.2 Oil filters ..................................................................................................................................... 165
21 Pin patterns ................................................................................................................................................ 167
22 Index of key words ..................................................................................................................................... 169

7
1 The complete Ecomat system
4139 S 2001
Key to diagram
1 Interface to vehicle electrical system 15 Pressure switch S2 for retarder control

2 Temperature gauge A5 16 Pedal brake valve BV with modulation valve for
3 Push-button speed range selector A2 service brake actuation and infinitely-variable retar-
der operation
4 Identification plate
17 Lever-operated valve HV for infinitely-variable re-
5 EST 18 electronic control unit A1 tarder operation
6 Connection for MOBiDIG 200 18 Kickdown switch S1
7 From auxiliary air supply, 19 Accelerator pedal
internal diameter of pressure lines = 6 - 8 mm
20 Linkage to injection pump
8 Cooling water connections
21 Load sensor A3 for detection of engine load condi-
9 Solenoid valve Y2 for accumulator tion
10 ZF Ecomat 22 Compressed air line for retarder control (optionally
11 Solenoid valve Y1 for retarder controlled by 16 and/or 17). Pressure line for mo-
12 Temperature sensor A6 dulated pressure (0 - 3 bar), internal diameter
= 4 mm
13 Pressure reduction valve RV1 (1.2 bar)
23 2-way valve WV
14 Solenoid valve Y5 for retarder reduction
24 Cable harness
8
The complete Ecomat system

The Ecomat system diagram illustrates one of the possi- % With the complete Ecomat system, the driver can use
ble Ecomat system set-ups using all necessary compo- the pedal brake valve BV (16) and lever-operated
nents. valve HV (17) to control infinitely-variable retarder
operation.
All electrical connections required between the Ecomat
system and the vehicle electronic system are located in Both valves function using compressed air and when
the interface to the vehicle electrical system (1). operated, send compressed air (0 to 3 bar) towards
the 2-way valve WV (23). At the 2-way valve, air
The EST 18 electronic control unit A1 (5) controls the with higher pressure is sent to the retarder control
transmission and monitors all functions. The automatic pressure switch S2 (15), pressure reduction valve
control unit gathers data from the vehicle and trans-mis- RV1 (1.2 bar) (13) and solenoid valve Y5 (14) for re-
sion (speed range, engine load condition, etc.) and pro- tarder torque reduction.
cesses these to produce signals used for controlling the
transmission hydraulic system. The pressure switch S2 for retarder control (15) swit-
ches at 0.35 bar and sends this signal to the
The driver may intervene in the Ecomat control system EST 18 A1 (5).
using the following equipment:
– Speed range selector (push-button unit) A2 (3) % Oil temperature is monitored using temperature sen-
sor A6 (12) fitted in the oil cooler connection. Data
– Kickdown switch S1 (18) from temperature sensor A6 is sent to the temperatu-
re gauge A5 from where the oil tempera-ture may be
– Accelerator pedal (19)
read.
– Pedal brake valve (16) and lever-operated valve for
% The oil temperature may be read on temperature
infinitely-variable retarder operation (17).
gauge A5 (2). In addition, a switch point for "excess
% The desired speed range can be pre-selected using temperature" (145°C) is built in. This contact switch
the speed range selector A2 (3). is used to activate the retarder torque reduction
The button pressed is illuminated (continuously lit). process.
During the retarder torque reduction process, the re-

tarder reduction solenoid valve Y5 (14) is energized.
DANGER
Compressed air flows through the pres-sure reduc-
% If a button flashes, transmission damage is immi- tion valve RV1 (13) and solenoid valve Y5 (14) to
nent. the retarder solenoid valve Y1 (11). If com-pressed
% The transmission monitoring system can no longer air pressures from the pedal brake valve or lever ope-
monitor all functions! rated valve (16, 17) are greater than 1.2 bar, these are
reduced to give a maximum 1.2 bar air pressure at
If this occurs, immediately drive to nearest service the solenoid valve (11).
station. Drive slowly to reduce transmission loading.
% Load sensor A3 (21) monitors the engine load condi-
% The kickdown switch S1 (18) is used to move the tion at the pump filling control lever of the injection
shift points towards higher engine speeds, so the pump and transmits this information to the EST 18
transmission remains in each gear longer when acce- A1 (5).
lerating and shifts out of each gear sooner when de-
Pressures for operating the clutch elements are mo-
celerating.
dulated according to the engine load condition using
a proportional solenoid valve in the electrical/hy-
draulic control unit.
9
2 Description of transmission and technical data
2 Description of transmission and tech- Basic transmissions from ranges HP 500, HP 590 and
nical data HP 600 consist of a hydrodynamic torque converter with
a lock-up clutch and rear-mounted multi-speed plane-
2.1 Brief description of transmission tary gear train.
ZF Ecomat transmissions from ranges HP 500, HP 590 Torque converter

and HP 600 can be used in multiple applications in com-
mercial and special vehicles. It is possible to select bet- The hydrodynamic torque converter, which uses the
ween 4, 5 or 6-speed transmissions to cover all require- TRILOK operating principle, is equipped with a stator
ments - from fitting in a city bus to use in a long-di- mounted on a freewheel and a lock-up clutch. The con-
stance coach. To ensure the broadest possible range of verter operates only when the vehicle is starting and is
applications, Ecomat transmissions can be fitted with then automatically locked up.
many auxiliaries. They have been designed to comply
fully with today's requirement of traffic safety and opti- Retarder
mum economy.
The single-flow hydrodynamic retarder, available as an
ZF Ecomat transmissions from ranges HP 500, HP 590 option, is integrated in the gearbox and no housing ex-
and HP 600 offer the following advantages: tension is necessary. The retarder is located between the
torque converter and planetary gear train. This means
% Smooth starting with no mechanical wear, even on the full braking effect is available without interruption,
extremely rough terrain. even in lower gears.
No clutch wear.
The retarder braking torque can be continuously varied
% The automatic shift program and smooth shift cha- using a lever-operated or pedal brake valve. If required,
racteristics do a great deal to protect the engine and the braking torque can be divided into one or several
driveline. stages, all limited to a value specified by the customer.
% The integral hydrodynamic retarder contributes to
road safety and vehicle performance. Substantial cost Planetary gear train
savings are also achieved by extending the service The planetary gear train, arranged behind the torque
life of wheel brake linings. converter, is designed as a 4, 5 or 6-speed unit. The pla-
% Increased fuel economy due to close ratio stepping, netary gear train is a combination of individual plane-
carefully chosen shift points and restriction of con- tary gear sets (i.e. not a range system)
verter operation to the initial driving phase.
Gear shift control
% Greater ease of operation for the driver, enhancing
driver performance and contributing to road safety. The electro-hydraulic control system used in these trans-
missions has given excellent results in practice. It recei-
% Reduction of vehicle operation and maintenance ves shift signals from the EST 18. This modern electro-
costs, especially under demanding road and traffic nic control unit has a diagnostics capacity and is
conditions or in cases where drivers are changed fre- designed to suit the number of ratios, type of transmis-
quently. sion, engine and vehicle.
10
ZF automatic transmission 5 and 6 HP 500
4139 S 2002
Key to drawing:
1 Input 5 Clutches (A, B, C)

2 Torque converter lock-up clutch (ÜK) 6 Brakes (D, E, F)
3 Torque converter 7 Output
4 Retarder 8 Oil pump
11
2.2 Transmission structure and auxiliaries
Using the basic transmission, add-on components can be

used to make the following variants.
% Coaxial transmission with fitted oil cooler % Non-ZF oil cooler

The basic transmission is fitted with coaxial output If customers provide their own oil cooler:
and oil cooler at the output end. The heat exchanger – ZF fits the oil cooler connection for non-ZF oil
module contains the oil cooler connection and cooler coolers to the basic transmission.
connection lines. – The oil cooler must comply with specifications in
Section 8, Cooling system.
% Coaxial transmission with non-ZF cooler
– The associated pipework must be provided by the
In this case, the basic transmission, coaxial output
customer and must comply with Section 8, Cool-
and oil cooler connection for the non-ZF cooler are
ing system.
assembled. Customers must provide their own oil
cooler. % Retarder
All transmission versions can be supplied with or
% Transmission with flange-mounted 60°, 65° and
without retarder. The retarder is fitted in the basic
80° angle drive
transmission between the converter and planetary
A 60°, 65° and 80° angle drive can be fitted to the
gear section. The retarder does not increase transmis-
basic transmission. The oil cooler connection for a
sion length and adds only 11 kg to the transmission
non-ZF oil cooler is mounted on the transmission.
weight.
12

4139 S 2003
Key to drawing:
1 Basic transmission
2 Retarder
3 80° angle drive
4 60°/65° angle drive
5 Coaxial output
6 Oil cooler, fitted at output end
7 Oil cooler connection for non-ZF oil cooler
13
14
2.2.1 Other auxiliaries
% Transmission with flange-mounted 63° angle drive. % A special STU 8000 spur gear drive was developed
The angle drive was specially developed for the re- for a specific application.
quirements of the U.S. bus market. The angle drive is
for direct mounting onto the transmission, as
with the 60°, 65° and 80° units.

4139 S 2024
Key to drawing:
1 Transmission
8 Cover for separate installation
9 63° angle drive
10 STU 8000 spur gear drive
14.1
2.3 Transmission ratios and powerflow diagram
Transmission ratios:
This table gives the mechanical transmission ratios in individual gears (without torque converter).
No. of Ratios
gears
1st 2nd 3rd 4th 5th 6th 7th R Total
3.43 2.01
4 1.42 1.00 – – – 4.84 3.43
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 diagram:
The powerflow diagram illustrates which clutches and combinations of clutches are closed when individual gears
are engaged, depending on transmission ratio.
Powerflow h.
% ' ( )
Neutral
$
h. % ' ( )
1st gear
$
h. % ' ( )
2nd gear
$
h. % ' ( )
3rd gear
$
h. % ' ( )
4th gear
4139 S 2004
$
1 Input 5 Clutches (A, B,) h. % ' ( )

2 Torque converter lock-up- 6 Brakes (D, E, F) Reverse
clutch (ÜK) 7 Output gear
3 Torque converter 8 Oil pump $
4 Retarder indicates lock-up clutch is
disengaged
4139 S 2005
15
4-speed version: i = 3.43 - 1.0 5-speed version: i = 3.43 - 0.83

6-speed version: i = 3.43 - 0.59
Powerflow
h.
% & ' ( )
Neutral
$
h. % & ' ( )
1st gear
$
h. % & ' ( )
2nd gear
$
h. % & ' ( )

3rd gear
$
h. % & ' ( )
4th gear
$
h. % & ' ( )

5th gear
$
4139 S 2006
h. % & ' ( )

6th gear
$
1 Input 5 Clutches (A, B, C)

h. % & ' ( )
2 Torque converter lock-up 6 Brakes (D, E, F)
clutch (ÜK) 7 Output Reverse
3 Torque converter 8 Oil pump gear $
4 Retarder indicates lock-up clutch is
disengaged
4139 S 2007
16
2.3.1 Further ratios to those listed in Section 2.3
This table gives the mechanical transmission ratios in individual gears (without torque converter).
No. of Ratios
gears
1st 2nd 3rd 4th 5th 6th 7th R Total
2.81
1.84 1.36 1.00 – – – 3.97 2.81
4
3.43 2.01 1.42 1.00 – – – 4.84 3.43
2.81 1.84 1.36 1.00 0.80 – – 3.97 3.52

5
3.43 2.01 1.42 1.00 0.83 – – 4.84 4.14
3.43
6 2.01 1.42 1.00 0.83 0.59 – 4.84 5.82
16.1
2.4 Maximum engine torques and vehicle weights
Transmis- No. of Max. permissible input

Ratio Artic. bus Coach City bus
sion gears speed [rpm]
HP 500 4 3.43 – 1.0 2800
5 3.43 – 0.83 2800
for i= 0.59
6 3.43 – 0.59 2800 nmax = 1600*
Max. permissible
1050 Nm 1100 Nm 1100 Nm
Engine torque DIN 70020
Max. weight 28 t 26 t 18.5 t
HP 590 4 3.43 – 1.0 2800

5 3.43 – 0.83 2800
6 3.43 – 0.59 2800 for i = 0.59
nmax = 1600*
Max. permissible
1250 Nm 1250 Nm 1250 Nm
Max. weight 28 t 26 t 28 t
HP 600 4 3.43 – 1.0 2650

5 3.43 – 0.83 2650
6 3.43 – 0.59 2650 for i = 0.59
nmax = 1600*
Max. permissible
1400 Nm 1400 Nm 1400 Nm
HP 600* 4 3.43 – 1.0 2650

5 3.43 – 0.83 2650
for i = 0.59
6 3.43 – 0.59 2650 nmax = 1600*
Max. permissible
1600 Nm
Max. weight 26 t
* Only after consultation with ZF Application Engineering Department
17
18
2.4.1 Max. engine torques and vehicle weights (expanded version of table in Section 2.4)
Trans- No. of Max. permissible input

mission gears speed (rpm)
HP 500 4 3.43 – 1.0 2800
4 2.81 – 1.0 2800
5 3.43 – 0.83 2800
5 2.81 – 0.8 2800
for i = 0.59
6 3.43 – 0.59 2800 nmax = 1600*
Max. permissible
1050 Nm 1100 Nm 1100 Nm
Max. weight 28 t 26 t 18,5 t
HP 590 4 3.43 – 1.0 2800

4 2.81 – 1.0 2800
5 3.43 – 0.83 2800
5 2.81 – 0.8 2800
for i = 0.59
6 3.43 – 0.59 2800 nmax = 1600*
Max. permissible
1250 Nm 1250 Nm 1250 Nm
HP 600 4 3.43 – 1.0 2650

4 2.81 – 1.0 2650
5 3.43 – 0.83 2650
5 2.81 – 0.8 2650
6 3.43 – 0.59 2650 for i = 0.59
nmax = 1600*
Max. permissible
1400 Nm 1400 Nm 1400 Nm
4
HP 600* 3.43 – 1.0 2650
4 2.81 – 1.0 2650
5 3.43 – 0.83 2650
5 2.81 – 0.8 2650
6 3.43 – 0.59 2650 for i = 0.59
nmax = 1600*
Max. permissible
1600 Nm
Max. weight 26 t
18.1
Please note the following information for engines with 2.4.2 Load reduction
max. torque greater than 1400 Nm (to DIN 70020):
Basic requirement
% Modified main pressure 13/22 bar
Load reduction must be effective in the following condi-
% Modified D1 pressure max. 8 bar
tions:
% ZFW 380-30/1.1.2 B converter (µo = 2.25)
– In 1st gear and in reverse
– During all up- and downshifts

Load reduction for coaches
– When the torque converter lock-up clutch is open
> 1400 Nm < 1600 Nm
Load reduction should be requested in all cases. ZF in-

ternal departments can study exceptional cases. Ensure
Load reduction equipment requirements
a suitable WK pressure control valve is fitted for < 1400
Nm to maintain shift quality when load reduction is – The engine manufacturer shall provide a mechanical
used. Take the lower torque curve when determining the detent to restrict engine torque to max. 1400 Nm, in
specific transmission components. accordance with DIN 70020.
– Load reduction shall be effective in passive condition

(low torque at rest or when unenergized).
The engine shall not develop full torque unless
prompted by the EST 18, and only then by means of
a +24V active electrical signal. See "Pos. 722, type
OUT, Function: Detent solenoid/Load reduction"
(Section 15).
A method shall be provided to ensure that the engine
torque cannot exceed 1400 Nm in case any load re-
duction element malfunctions, e.g. cable breakage,
loss of pneumatic supply, defective relay, etc.
– The engine manufacturer is responsible for demon-

strating the reaction speed of the load reduction devi-
ce.
The maximum reaction time of the load reduction
device shall not exceed 0.10 seconds. The reaction
time starts when the electrical signal changes (chan-
ge from 24 volts to 0 volt) at full engine torque and
finishes when the engine torque is reduced.
– Load reduction using the electronic accelerator inter-

face (reduction via DKR signal) is not permissible
because there is no mechanical stop.
– The load reduction device usually takes the form of

a twin lever injector pump.
– The vehicle manufacturer shall be responsible for the

entire installation procedure and supply of all com-
ponents required. ZF only supplies the necessary
signal to control the load reduction function.
18.2
2.5 Moments of inertia and vibration substitution

model
For the purpose of mathematical investigations into vi- % Rigid body 1: Turbine shaft
bration, the transmission is divided into three distinct ro-
tating masses connected by (zero mass) torsion springs: % Rigid body 2: Input shaft or quill shaft.
% Mass 1: Torque converter without engine flywheel Half the moment of inertia of the shafts is assigned to
and connection parts the relevant adjoining masses.
% Mass 2: Clutch carrier The following tables give the corresponding data (mo-
A, B for i = 3.43 – 1.00 ments of inertia and torsional rigidity) for individual
A, B, C for i = 3.43 – 0.83 transmission variants.
% Mass 3: Planetary gear section including output

flange
4 HP 500 / 4 HP 590 – ZFW 360-10/... 4 HP 600 – ZFW 380-30/...

% ' ( )
- - -
& &
$
4139 S 2008
J1 C1 J2 C2 J3
[kgm2] [Nm/rad] [kgm2] [Nm/rad] [kgm2]
1st gear 4 HP 500 / 4 HP 590 1.85 19000 0.67 39760 0.29

i = 3.43 4 HP 600 2.47 39000 0.67 100300 0.30
2nd gear 4 HP 500 / 4 HP 590 1.85 19000 0.67 58350 0.10

i = 2.01 4 HP 600 2.47 39000 0.67 136700 0.10
3rd gear 4 HP 500 / 4 HP 590 1.85 19000 0.67 70760 0.12

i = 1.42 4 HP 600 2.47 39000 0.67 151200 0.13
4th gear 4 HP 500 / 4 HP 590 1.85 19000 0.77 122850 0.42

i = 1.00 4 HP 600 2.47 39000 0.77 985000 0.45
Neutral position 4 HP 500 / 4 HP 590: J = 2.50 kgm2

(lock-up clutch and clutches A, B open) 4 HP 600: J = 3.10 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 of output flange must be assigned to the third rotating
mass.
% The moment of inertia for neutral position applies in the following conditions:
– on input side, lock-up clutch and clutches A and B opened,
– converter slip should correspond to drag torque of opened clutches.
19
5 HP 500 / 5 HP 590 – ZFW 360-10/... 5 HP 600 – ZFW 380-30/...

% & ' ( )
- - -
& &
$
4139 S 2009
J1 C1 J2 C2 J3
1st gear 5 HP 500 / 5 HP 590 1.85 19000 0.78 39760 0.23

i = 3.43 5 HP 600 2.47 39000 0.78 100300 0.24
2nd gear 5 HP 500 / 5 HP 590 1.85 19000 0.78 58350 0.10

i = 2.01 5 HP 600 2.47 39000 0.78 136700 0.10
3rd gear 5 HP 500 / 5 HP 590 1.85 19000 0.78 70760 0.14

i = 1.42 5 HP 600 2.47 39000 0.78 151200 0.15
4th gear 5 HP 500 / 5 HP 590 1.85 19000 0.82 108500 0.50

i = 1.00 5 HP 600 2.47 39000 0.82 985000 0.53
5th gear 5 HP 500 / 5 HP 590 1.85 19000 0.79 105700 0.46

i = 0.83 5 HP 600 2.47 39000 0.79 814100 0.46

(lock-up clutch and clutches A, B, C open) 5 HP 600: J = 3.20 kgm2

% Engine connecting parts must be assigned to first rotating mass.
% Connecting parts fitted on output side of output flange must be assigned to the third rotating
mass.
– on input side, lock-up clutch and clutches A, B and C opened,
– converter slip should correspond to drag torque of opened clutches.
20
2.5.1 Moments of inertia and vibration substitution

model
(for ratios i = 2.81 – 1.00 or i = 2.81 – 0.80)
For the purpose of mathematical investigations into vi- % Rigid body 1: Turbine shaft
bration, the transmission is divided into three distinct ro-
tating masses connected by (zero mass) torsion springs: % Rigid body 2: Input shaft or quill shaft.
% Mass 1: Torque converter without engine flywheel Half the moment of inertia of the shafts is assigned to
and connection parts the relevant adjoining masses.
% Mass 2: Clutch carrier A, B for i = 2.81 - 1.00 The following tables give the corresponding data (mo-
A, B, C for i = 2.81 - 0.80 ments of inertia and torsional rigidity) for individual
transmission variants.
% Mass 3: Planetary gear section incl. output flange
4 HP 500 / 4 HP 590 – ZFW 360-10/... 4 HP 600 – ZFW 380-30/...

% ' ( )
- - -
& &
$
4139 S 2008
J1 C1 J2 C2 J3
1st gear 4 HP 500 / 4 HP 590 1.85 19000 0.67 39760 0.29

i = 2.81 4 HP 600 2.47 39000 0.67 100300 0.29
2nd gear 4 HP 500 / 4 HP 590 1.85 19000 0.67 58350 0.10

i = 1.84 4 HP 600 2.47 39000 0.67 136700 0.10
3rd gear 4 HP 500 / 4 HP 590 1.85 19000 0.67 70760 0.13

i = 1.36 4 HP 600 2.47 39000 0.67 151200 0.13
4th gear 4 HP 500 / 4 HP 590 1.85 19000 0.77 122850 0.42

i = 1.00 4 HP 600 2.47 39000 0.77 985000 0.45

(lock-up clutch and clutches A, B open) 4 HP 600: J = 3.10 kgm2

% Engine connecting parts must be assigned to the first rotating mass.
% Connecting parts fitted on output side of output flange must be assigned to the third rotating mass.
– On input side, lock-up clutch and clutches A and B opened,
– Converter slip should correspond to drag torque of opened clutches.
20.1
5 HP 500 / 5 HP 590 – ZFW 360-10/... 5 HP 600 – ZFW 380-30/...

% & ' ( )
- - -
& &
$
4139 S 2009
J1 C1 J2 C2 J3
1st gear 5 HP 500 / 5 HP 590 1.85 19000 0.78 39760 0.24

i = 2.81 5 HP 600 2.47 39000 0.78 100300 0.24
2nd gear 5 HP 500 / 5 HP 590 1.85 19000 0.78 58350 0.10

i = 1.84 5 HP 600 2.47 39000 0.78 136700 0.10
3rd gear 5 HP 500 / 5 HP 590 1.85 19000 0.78 70760 0.14

i = 1.36 5 HP 600 2.47 39000 0.78 151200 0.15
4th gear 5 HP 500 / 5 HP 590 1.85 19000 0.82 108500 0.50

i = 1.00 5 HP 600 2.47 39000 0.82 985000 0.53
5th gear 5 HP 500 / 5 HP 590 1.85 19000 0.79 105700 0.46

i = 0.80 5 HP 600 2.47 39000 0.79 814100 0.47

(lock-up clutch and clutches A, B, C open) 5 HP 600: J = 3.20 kgm2

% Engine connecting parts must be assigned to the first rotating mass.
% Connecting parts fitted on output side of output flange must be assigned to the third rotating mass.
– On input side, lock-up clutch and clutches A, B and C opened.
– Converter slip should correspond to drag torque of opened clutches.
20.2
2.6 Transmission weights
Depending on transmission type and auxiliaries, refer to the table below and appropriate installation drawing to find
transmission weight and position of centre of gravity.
Mass of basic transmission

Transmission
No. of gears Ratio (without oil fill, heat exchanger or
type
retarder)
4 3.43 – 1.00 259 kg
HP 500 5 3.43 – 0.83 269 kg
6 3.43 – 0.59 269 kg
4 3.43 – 1.00 264 kg

HP 590 5 3.43 – 0.83 274 kg
6 3.43 – 0.59 274 kg
4 3.43 – 1.00 279 kg

HP 600 5 3.43 – 0.83 289 kg
6 3.43 – 0.59 289 kg
Weights of auxiliaries (without oil fill):
Retarder approx. 11 kg
Oil cooler for direct fitting approx. 30 kg
60°/65° angle drive approx. 97 kg
80° angle drive approx. 92 kg
21
22
2.6.1 Transmission weights (expanded version of table in Section 2.6)
Depending on transmission type and auxiliaries, refer to the table below and appropriate installation drawing to find
transmission weight and position of centre of gravity.
Mass of basic transmission

Trans. type No. of gears Ratio (without oil fill, heat exchanger
or retarder)
4 3.43 – 1.00 259 kg
4 2.81 – 1.00 259 kg
HP 500 5 3.43 – 0.83 269 kg
5 2.81 – 0.80 269 kg
6 3.43 – 0.59 269 kg
4 3.43 – 1.00 264 kg

4 2.81 – 1.00 264 kg
HP 590 5 3.43 – 0.83 274 kg
5 2.81 – 0.80 274 kg
6 3.43 – 0.59 274 kg
4 3.43 – 1.00 279 kg

4 2.81 – 1.00 279 kg
HP 600 5 3.43 – 0.83 289 kg
5 2.81 – 0.80 289 kg
6 3.43 – 0.59 289 kg
Weights of auxiliaries (without oil fill):
Retarder approx. 11 kg
Oil cooler for direct fitting approx. 30 kg
60°/65° angle drive approx. 97 kg
80° angle drive approx. 92 kg
63° angle drive 150 kg

STU 8000
+ accumulator + special oil cooler 145 kg
22.1
2.7 Installation drawing From drawing no.: 4139 601 127(a)
Clearance for
dipstick
Clearance for oil filter

2 Lower part of Cannon plug cable connection code B2-20 A48-Pn VG 95234
3 Protective cap for lower part of plug
4 Transmission mounting M16x1.5; 24 deep
Tightening torque 225Nm
8 Pressure measurement point, input side of converter M10x1; 12 deep
9 Measurement point for shift throttle pressure M10x1; 12 deep
10 Measurement point for retarder pressure M10x1; 12 deep
11 Measurement point for main pressure M10x1; 12 deep
12 Identification plate
13 Speedo connection for speedo rpm = 0.65 x output rpm
18 Cable connection for shift magnet for retarder operation
"COSTAL" plug M27 x 1
19 Compressed air line connection for retarder operation
M12 x 1.5; 12 deep
20 Oil drain plug (internal hex head) 10mm AF (Tightening torque= 50Nm)
21 Compressed air line connection for accumulator M12x1.5; 12 deep
22 Cable connection for shift magnet for accumulator "COSTAL" plug M27x1
23 Cooling water inlet Ø 50x4
24 Cooling water outlet Ø 50x4
25 Connection for temperature sensor M14x1.5 14 deep
("COSTAL" M27x1 cable connection)
S Centre of gravity
28 Oil fill pipe with dipstick and breather
Weight Centre of gravity S 29 Measurement point for lubricating oil pressure P = 0.4 to 2.5bar
Voltage 24 V Type
Initial oil fill approx. 17L without oil x y z 36 Water drain plug (internal hex head) 8 mm AF
Oil volume for oil change 10 to 15L 5 HP 500 310 kg 316 –46 –10 39 Connection face for peripherals M16x1.5 24 deep
Tightening torque = 225 Nm
5 HP 600 330 kg 291 –37 –6 4139 S 2108
23
24
2.8 Clutch activation combinations
The tables below show which clutches are activated de-

pending on the gear engaged and the ratio.
4-speed i = 3.43 - 1.00 5-speed i = 3.43 - 0.83 and i = 2.81 - 0.80

4-speed i = 2.81 - 1.00 6-speed i = 3.43 - 0.59
A B1 B2 D E F1 F2 A B C D E F1 F2
Reverse ● ● ● Reverse ● ● ●
Neutral Neutral
Neutral (NBS) ● ●* Neutral (NBS) ● ●*
1st gear ● ● 1st gear ● ●

2nd gear ● ● 2nd gear ● ●
3rd gear ● ● 3rd gear ● ●
4th gear ● ● 4th gear ● ●
5th gear ● ●
* Reduced pressure
6th gear ● ●
* Reduced pressure
B1 = inner piston surface of clutch B

B2 = outer piston surface of clutch B
F1 = outer piston surface of brake F
F2 = inner piston surface of brake F
24.1
3 Ecomat installation position in vehicle
3 Ecomat installation position in vehicle Transverse installation at rear 60°, 65°, 80°
To further optimize available space, various angle drive

T-drive
versions are used to allow transverse installation.
The conventional installation position in buses is the
mid-axle T-drive with the transmission fitted in the di- 60°, 65° angle drive
rection of travel.
4139 S 2012
60°, 65° angle drive

4139 S 2010
The introduction of drop-centre axles for low-floor

buses means the driveline is displaced e.g. to the left.
4139 S 2013
80° angle drive
4139 S 2011
4139 S 2014
An additional advantage of the 80° angle drive is the

helical gear stage allowing output shaft to be displaced
217.5 mm downwards.
25
26
3 Ecomat installations in vehicle
3.1 Other Ecomat installation positions in vehicle
Transverse installation at rear with 63° angle drive
A 63° angle drive has been developed for the American

market for use of the Ecomat transmission in vehicles
fitted with "63° rear axles".
63° angle drive
4139 S 2025
26.1
4 Installation position and mountings, propshaft connection
4 Installation position and mountings,

propshaft connection
4.1 Installation position and mountings ZF recommended mounting points

The transmission must not be supported other than at
Transmission flange-mounted on engine
the bolt attachment faces provided for this purpose on
the transmission housing and auxiliary unit.
Transmission mountings on the chassis must be de-

signed in consultation with ZF in such a way that no ad-
ditional forces resulting from twisting of the chassis
&
may be transmitted to the transmission housing. ENGINE
$
ECOMAT
%
The connection dimensions for transmission mountings,
the transmission weight and centre of gravity are indica-
ted in the individual installation drawings. Mounting points at A + B or A + C
The bolts used to attach the transmission to its moun-
tings must be of quality 8.8. Specified tightening torque
for mounting points see C + E = 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 less than the rigi-
dity of mountings A + C or A + B.
Ecomat with 80° angle drive
DANGER
Mounting points at A + B or A + C
The bending torque exerted by mounting blocks at
mounting flange face C must not exceed the following
limit:
(
MC ) 3500 Nm
&
The bending torque can be calculated from the bracing $ %

force (F) at the rubber mounting and lateral lever length
(
(L) of bearing block. Take into account any simultane-
ous vertical acceleration and torque loading from the Ecomat with 60°/65° angle drive
transmission or powerpack. Mounting points at A + B or A + C
Additional mounting point at E possible,
either above or below housing
/ / 4139 S 0019
) )
4139 S 0028
If the forces acting on each side are offset longitudi-nal-

ly, please consult our Application Engineering Dept.
27
28
4.1.1 Ecomat with flange-mounted 4.1.2 Ecomat with flange-mounted STU 8000 spur
63° angle drive - U.S.A. gear drive
Mounting point K can be used with the flange-mounted

Viewed from the rear of the vehicle
STU 8000 spur gear drive for better stability. However,
ensure that no forces are transmitted when the rubber
mounting at mounting point K is in the zero position
(rest position). Mounting point K must be less rigid
than mounting points A+B.
$
%
$
%
Viewed from the front of the vehicle

Mounting points at A + B + K
4139 S 0071
4.1.3 Transmission mounted separately from engine
A torsional vibration damper (X) must be fitted if the

, $
% transmission is installed separately from the engine.
The propshaft between engine and transmission must be
provided with length compensation.
Mounting points at A + B + I
The flexure angle must not exceed 8°.
The vehicle manufacturer is responsible for selecting

4139 S 0070
and providing the torsional vibration damper.
Mounting point I can be used for better stability. ZF particulary recommends low-maintenance propshafts
with plastic-coated spline profiles.
Ensure that no forces are transmitted when the rubber
mounting at mounting point I is in the zero position DANGER
(rest position). Mounting point I must be less rigid than Ensure the bending torque of the bearing blocks at mo-
mounting points A+B. unting points C and D does not exceed the following li-
mits:
MC ) 3500 Nm; MD ) 1500 Nm
&
ENGINE
$ ECOMAT
%
'
Mounting points at A + B + C + D
4139 S 0072
28.1
4.2 Propshaft connection 4.2.1 Permitted propshaft angles
The vehicle manufacturer is entirely responsible for Excessive flexure angles ß and incorrect angular align-
determining the propshaft installation position. ment 6 ß (ß1 - ß2) lead to incorrect rotational angles
6 _, which may cause harmful vibrations in the prop-
The flexure angles of both universal joints should be the shaft.
same in both Z and W installation positions (ß1 = ß2).
To avoid such vibrations, comply with the following
permitted propshaft angles:
– max. permitted flexure angle ß for each joint,
Z position
– max. permitted resultant flexure angle ßE and

– permitted resulting incorrect rotational angle 6 _
% The permitted flexure angle ß for each joint de-

pends on the type, size and rotational speed of the
propshaft - see Diagram below.

W position
Permitted propshaft flexure angle ß
4139 S 0008
(max. shaft length Lz = 1500 mm)

Flexure angle ß

D
E
F

Rotation of propshaft (rpm) 4139 S 0009
a) Flange Ø 150 mm
b) Flange Ø 165/180/225 mm
c) Yoke 1710, 1810
29
% The permitted resultant flexure angle ßE for all The individual angles ß should
joints ) 3°. be given the following positive
or negative values: 90°

The diagram below shows how the amount of flexure Input
angle effects the resultant flexure angle. + if the crosslink is perpen-
The resultant flexure angle is calculated from the angles dicular to the driven yoke.
90°

of individual joints using the following formula: – if the crosslink is perpen- Input
ßE = 3, ± ß12 ± ß22 ± ß32 ± ..., dicular to the driving yoke.
4139 S 0010
Examples showing the use of this formula are given in

the diagram below and in Section 4.2.3, Multi-section CAUTION
propshafts. For the purposes of the calculation, assume the most un-
favourable condition, i.e. the largest flexure angles.
Examples of how the amount of flexure angles ß1 and ß2 affects the resultant flexure angle ßE
Z position W position
Example 1 (exact Z or W position)

Example 2 (small flexure angles with angular error)

Example 3 (large flexure angles with angular error)

Angular error Resultant flexure angle

Example 6ß = ß1 – ß2 ßE = 3 , – ß12 + ß22 ,
1 0° 0°
2 1° 3°
3 1° 5.4°
Example 3 shows that with large flexure angles, even an angular error
as small as 1° produces an unacceptably large resultant flexure angle. 4139 S 0011
30
For propshafts with both vertical and horizontal % Maximum permitted resultant rotational angle error
offsets 6 _ (measured at transmission output flange).
first find resultant angle ßR from the diagram below
which is used in the formula at the bottom of this co- Use this limiting value if measurement values for ro-
lumn. tational angle error are available as shown in the
graph below. If you know the rotational angle error,
Resultant flexure angle ßR for propshafts limiting value ßE can be disregarded.
with both vertical and horizontal offsets
Rotational 6_
angle error

6_

1 rev.

4139 S 0013
The maximum permitted angle 6 _ is based on the con-

9

sideration that damage to the driveline is caused by a
combination of vibration amplitudes and frequencies.

Therefore if vibration frequencies are low, i.e. low rota-
tional speeds, the angular error can be larger than at
higher frequencies.

+ The limit curve shown on the graph below is generated
as follows:
Example:
Side-view Top view
rad 6 _ (°) · n2(1/min2)

(vertical offset)+ (horizontal offset) ¡perm ) 2000 =
s2 1306
9 +

¡perm is the permitted limit. Values below this curve do
not cause vibrational damage.

Rotational angle 6_
Reading from the graph, ßR = 15°

6_
4139 S 0012

1 rev.

The general formula for calculating the resultant flexure Limit curve for measured
angle is: values

¡perm is ) 2000 rad
s2
tan ßR = 3 tan2 ßH + tan2 ßV

Rotation of propshaft n (rpm)
4139 S 0014
31
4.2.2 Single-section propshafts
You should aim to configure the axle suspension suita-

bly to ensure the propshaft remains in a precise Z pat-
tern (ß1 = ß2) under all vehicle loading conditions.
Axle

Transmission
4139 S 0015
Influence of axle suspension on universal joint flexure angles
Leaf springs give a good Z position due to parallel axle Floating axle gives a poor Z position due to the pivoting
movement. movement of the axle.
ß1 = ß2 is more-or-less maintained across whole range of ß1 = ß2 is only maintained at the middle point. Suspension
suspension travel. movements upwards or downwards make the angles
unequal.
Spring movement

Laden Pivoting movement
Unladen Laden
Middle position
Axle movement Axle movement
4139 S 0016
32
4.2.3 Multi-section propshafts
In multi-section propshaft configurations, the driveline

can be optimized by suitable choice of crosslink orienta-
tions and by varying height h of the centre bearing (re-
distribution of ß angle values).
Optimizing the driveline by varying the crosslink position
Unfavourable arrangement

K Axle

ßE = 3 , – ß12 + ß22 – ß32 , (= 13.6°)
Transmission

Optimized arrangement
(by changing position of crosslink) K Axle

ßE = 3 , – ß12 – ß22 + ß32 , (= 2.4°)

Transmission

4139 S 0017
4.2.4 Other information
% The propshaft must be dynamically balanced accor- % The tubular outer section of the sliding joint in
ding to Quality 16, VDI Guidelines 2060. the propshaft must be inclined downwards.
Balancing quality Q16, VDI Guidelines 2060 % We recommend using propshafts with coated
spline profiles.

Permitted residual imbalance per unit

mass of balanced body [gmm/kg]

4

Rotation of propshaft (rpm)
4139 S 0018
33
5 Connection to engine
5 Connection to engine – Permitted tolerance for dimension (C)
Before the Ecomat transmission is connected to the en- for Method 1 = ± 0.66 mm
gine, ZF must perform an "engine connection study".
for Method 2 = + 0.66 mm
This involves determining all important dimensions and – 0.96 mm
tolerances for the connection and preparing an engine
connection drawing. See Section 5.2, Engine connection (Dimension (B) is set by ZF to ± 0.5 mm.)
study for an example of this and additional information.
There are two methods for connecting the transmission

to the engine: Assembly sequence for Method 1
(with flywheel)
% Method 1: The engine flywheel (2) is retained and
carries the starter ring gear (5). The flex plates (10) % Check dimensions (B) and (C) comply with engine
are connected directly to the converter (7). connection drawing. If dimensions exceed tolerance,
contact our Application Engineering Dept. urgently.
% Method 2: Remove engine flywheel (2). Fit a starter
ring gear carrier (8) between the flex plates (10) and % Bolt together crankshaft (1), flywheel (2), flex plates
converter (7). (10), and clamping ring (11). Consult engine manu-
facturer to establish correct tightening torque.
NOTE
Before fitting together the engine and Ecomat, always % Bolt together transmission housing (6) and flywheel
check that the following points are complied with: housing (3) as shown in engine connection drawing.
Tightening torque TA = 49 Nm for bolt quality 8.8.
% There must be an assembly access hole (4) in the
flywheel housing and flywheel. % Using assembly access hole (4) in flywheel housing
and flywheel, bolt flex plates (10) onto converter (7).
% The bolts must be of the quality specified in the en- Tightening torque TA = 81 Nm for bolt quality 8.8.
gine connection drawing.
% Observe specified tightening torques when tigh-

tening all bolts. Assembly sequence for Method 2
(without flywheel)
% Use only hardened, flat washers (DIN 125-13-300
HV or DIN 125-10.5-300 HV). Never use toothed % Check dimensions (B) and (C) comply with engine
lock screws or similar. connection drawing. If dimensions exceed tolerance,
contact our Application Engineering Dept. urgently.
% Wherever possible, always connect transmission to
engine using Method 1 with complete flywheel. % Bolt together crankshaft (1), centring ring (11), flex
plates (10), and clamping ring (9). Consult engine
% Only use Method 2 after consultation with our Appli- manufacturer to establish correct tightening torque.
cation Engineering Dept.
% Using two bolts (12), bolt gear ring carrier (8) with
% Check the following tolerances: integral ring gear (5) onto converter (7).
– Max. deflection of flex plates % Bolt together transmission housing (6) and flywheel
= ± 1.2 mm (important for flex plate life) housing (3) as shown in engine connection drawing.
– Flex plate thickness (D) = 4 x (0.5 mm ± 0.04 mm) Tightening torque TA = 49 Nm for bolt quality 8.8.
= 2 mm ± 0.16 mm
– Runout tolerance (A) of flywheel inner bore
% Using assembly access hole (4) in flywheel housing,
bolt flex plates (10) onto converter (7). Tightening
and/or centring ring to centring spigot on
torque TA = 81 Nm for bolt quality 8.8.
flywheel housing = max.0.3 mm
34
Method 1 Drawing no.: 4139 530 064
4139 S 0003
Method 2 Drawing no.: 4139 530 065
4139 S 0004
35
5.1 ZF equipment supplied 5.2 Engine connection study
The flex plates and bolts for fastening flex plates to the If no engine connection drawing has been prepared, the
converter are supplied by ZF. following documents are required for the engine
connection study:
– Detailed drawing of flywheel housing
– Detailed drawing of flywheel
– Detailed drawing of end of crankshaft
– Drawing of engine output assembly showing axial

and radial tolerance range for crankshaft and dis-
tance between end of crankshaft and flanging face of
flywheel housing.
– For Method 2, pay particular attention to the mar-

kings for the fuel injection point.
36
5.2 Engine connection study

Engine connection drawing example (Method 2) From drawing no.: 4139 530 041 (b)
4139 S 0005a
37
38
5 Engine connection
5.3 Engine connection – further instructions
We recommend Variant 1 for engine connections, using

the complete flywheel.
In Variant 2, the inertia torque of the engine is altered

because the flywheel is not used. In unfavourable con-
ditions, this can lead to resonance vibration, possibly
causing flex plate failures.
CAUTION
Contact the Applications Design Department before
using Variant 2 (without flywheel).
General instructions:
% Engine connection drawings have been prepared for

all currently available engines.
% Always arrange the engine connection so the conver-

ter is centred on the crankshaft.
% See detail "W" for clamping ring and centring ring.

See detail "V" for version with starter ring gear carri-
er (refer to drawing 4139 601 171 overleaf).
% There is no need for a vibration damper between the

engine and transmission if you mount the transmis-
sion directly onto the engine.
% Fit a vibration damper between the crankshaft and

propshaft if you install the engine and transmission
separately. Contact the Applications Design Depart-
ment to discuss what type of damper to use.
The vehicle manufacturer shall be responsible for
choosing the correct damper and must provide the
damper itself.
38.1
5 Engine connection
Detailed engine connection drawing Drawing no.: 4139 601 171
)/(;3/$7(6
007+,&.
4139 S 2026
38.2
5 Engine connection
5.3.1 Engine connection drawings HP 500/HP 590
AEC 760 4139 500 673 KHD BF 6L 913 4139 500 891
BFL 413 FR 4139 500 767
CATERPILLAR 3116 ATAAC 4139 530 001 F 8/F 10L 413 4139 500 732
3176 4139 530 008 F 8/6 L 413 4139 500 749
3208 NA 4139 500 751 F 8/6 L 413,ang. drive 4139 500 783
3306 4139 500 832
LEYLAND E 0 0510 4139 500 784
E 06 TL 11
CHRYSLER BS 16 4139 500 753 Leyland Engine 4139 500 836
E 06 TL 11
Leyland DAB 4139 500 763
CUMMINS LT 10-250/L10-H 4139 500 755
NT, NH series 4139 500 753
LIAZ ML 635/637 4139 500 840
V 903 4139 500 757
V/VT 555 4139 500 785
MACHIMPEX Type 6120 4139 500 752
B series 4139 500 856
C series 4139 500 887
MACK ET (8) 673 4139 500 780
DAF DK series / LT 4139 500 671 MAN D 0226 MKF 4139 500 746
DH 825 4139 500 675 D 0846 Daewoo 4139 500 742
DNT 620 4139 500 857 D 0826 F 4139 500 900
DT 615 4139 500 878 D 2156/D 2356 4139 500 816
D 2156 (SAE 1) 4139 500 810
D 2356 (SAE 1) 4139 500 810
DAIMLER BENZ OM 352 T 4139 500 815
D 2866/D 2566 4139 500 676
OM 355 A/LA 4139 500 862
D 2566 with flange 4139 500 787
OM 360/360 A 4139 500 733
D 0826 4139 530 066
OM 366 A/LA 4139 530 011
OM 400 series 4139 500 676
MITSUBISHI 8 DC 81A/8DD 90A 4139 500 745
OM 432 A 4139 530 007
NISSAN PE6H 4139 500 754
DDA 6V-71 4139 500 774 PE6T 4139 530 009
6V-92 4139 500 762
6V-53 T 4139 500 739 PEGASO 9152/3 4139 500 674
8.2 T 4139 500 741
PERKINS V8.640/540 4139 500 747
FIAT 8200.12.028 4139 500 744
RABA D 1246 4139 500 846
8210 4139 500 760
8220 12/13 4139 500 669
ROLLS ROYCE EAGLE 4139 500 778
8220.12 with flange 4139 500 737
8260 4139 500 672
RVI MID 620-30/45 4139 500 764
8361 SI 4139 500 765
MIDR 0602.12 4139 500 811
GARDNER 6HLXCT 4139 500 850 SAURER C2KT 4139 500 670
6LXCT 4139 500 886
SCANIA DS 11/DS 14 4139 500 796
HINO EK 200/EK 100 4139 500 829
STEYR 9 FUA 4139 500 756
HO 6C 4139 500 740
WD 615 4139 500 777
M 10U 4139 500 827
VOLVO TD 70E 4139 500 817
IHC DD 466 4139 500 826 TD 71 4139 500 888
TD 100 A/120 A 4139 500 738
ISUZU 6 RA 1 4139 500 750
10 PC 1 4139 500 748
38.3
5 Engine connection
Engine connection drawings HP 600
ADE 407/422 4139 500 798

CUMMINS L10-270 4139 500 792
L10 vertical 4139 500 794
NH/NT 4139 500 793
DAF DK series 4139 500 806
DAIMLER BENZ OM 400 series 4139 500 798
DDA 6V-92 4139 500 762

6V-92 with flange 4139 500 892
GARDNER 6LYT 4139 500 797
HINO GT 31A
Gas turbine 4139 500 847
IVECO 8210 4139 500 760

8280 4139 500 800
KHD F8/10L 413 F 4139 500 732

F10/12L 413 F 4139 500 804
KOMATSU SA 6D 125 4139 500 803
LEYLAND TL 11 4139 500 813
LIAZ ML 637 4139 500 844
MACK EM 6.275 4139 500 807
MAN D 25 series 4139 500 798
MITSUBISHI 6 D 22T2 4139 500 841
NISSAN RE 10 4139 500 632
RABA D 11 UTL 4139 500 814
ROLLS ROYCE PR 350 E 4139 500 808
RVI MIDR 063045 4139 500 799
SCANIA DS 9 / DS 11 4139 530 055
VOLVO THD 101 4139 500 738
38.4
6 Converter
6 Converter The converter adjusts output speed to achieve the requi-

red torque by a continuous, automatic process.
6.1 Description of torque converter Stator torque is always equal to the difference between
torque at the turbine and impeller.
The torque converter is mounted on the input end of the
When the turbine speed reaches approx. 80% of the im-
planetary gear train. It consists of the impeller, turbine,
peller speed, torque multiplication drops to a ratio of 1,
stator (reaction member) and the oil needed for torque
i.e. turbine torque = impeller torque. From this point on,
transmission. Torque is transmitted from the engine
the converter acts purely as a fluid coupling. Under such
flywheel to the torque converter by means of a connec-
conditions the stator, which is linked to the housing by a
tion comprising flex plates.
roller freewheel unit ("Trilok" principle) begins to rotate
6.2 How the torque converter works freely in the oil flow, whereas it is held against the hou-
sing by the freewheel when torque multiplication takes
The impeller driven by the engine displaces the oil in a place and thus remains stationary.
circular flow. This oil flow strikes the turbine and is de-
To ensure economical operation, the torque converter
flected back. The stator located between the turbine and
lock-up clutch (ÜK) is closed as soon as this is possible.
impeller is used to deflect the oil flowing out of the tur-
When the torque converter lock-up clutch is closed,
bine again, and direct it back to the impeller at an appro-
there is no slip between the impeller and turbine and
priate input angle. The deflection creates a torque at the
therefore no loss of hydraulic energy in the converter.
stator and thus boosts the torque at the turbine.
The ratio between turbine and impeller torque is refer- The close ratios and optimum gear step adjustment of
red to as torque multiplication. The greater the differen- the 4th, 5th and 6th mechanical gears in the transmis-
ce in the speeds of the impeller and turbine, the higher sion allow the converter to be locked up at a very early
the torque multiplication. In other words, max- stage. This makes use of the advantages of mechanical
imum multiplication occurs when the turbine is station- power transmission early on - high efficiency and low
ary, and falls as the turbine speed rises. power losses.
TP = Torque of
Turbine
Impeller impeller
TT = Torque of
turbine
From engine TR = Torque of stator
TP TT
TR
To transmission
Condition at nT = O
instant of Stator Vehicle stationary
starting off
nT < nEng
Intermediate
condition
nT 5 0.8nEng
Condition
immediately nT = nEng
before lock-up After lock-up clutch
clutch closes 4139 S 2015 closes
39
6 Converter
6.3 Getting the right torque converter for your

engine
In cooperation with vehicle manufacturers, the ZF Ap-

plication Engineering Dept. has specified an appropriate
torque converter for every engine-transmission combi-
nation.
The torque converter selection criteria are:
% Engine type (naturally-aspirated engine or turbo-

charged engine)
% Torque conversion when starting off
% Speed reduction when starting off
% Fuel economy or power increase
% Heat build-up when driving for long periods with

lock-up clutch open.
Refer to torque converter graph, e.g. drawing no. 4166

704 398 for details of appropriate engine-converter
combinations.
Plot the net engine torque curve and basic torque con-
verter curves. The intersection points on the graph show
the characteristic converter/engine relation points in full
load condition.
There are six converter models for the HP 500/HP590/

HP 600 transmissions which vary according to the im-
peller torque pickup, hydraulic diameter and torque mul-
tiplication when starting off.
Impeller torque Tp1000
at turbine speed = 0 and Torque multiplication
Torque converter impeller speed when starting off with Basic curve
np1000 = 1000 rpm turbine locked
Tp1000 [Nm] +o (Mu) Drawing no.
ZFW 360-10/1 A.1.7. 157 2.14 4166 704 462
ZFW 360-10/1/1/.1.1. 262 2.40 4166 703 147
ZFW 360-10/1.1.1/1/. 390 2.17 4166 703 150
ZFW 380-30/2.1.1. 376 2.54 4166 711 089
ZFW 380-30/1.1.2 B 500 2.25 4166 704 567
ZFW 380-30/1.1.2. 515 2.44 4166 711 090
40
41
6 Converter
6.4 Torque converter graph
The following information can be read from the torque Formulae

converter graph (see drawing 4166 704 398):
– Formula for calculating torque pick-up for any speed
– Stall torque = max. turbine torque TT = impeller tor- ratio
que TP x max. multiplication +o (Mu) at turbine n12 T
speed = 0. ––– = ––1
n22 T2
– Stall speed = impeller speed nP at turbine speed
nT = 0 rpm. – Calculation of "HEAT REJECTION" for a given
tractive effort: see Example.
– Engine power Peng gross (kW)
– Engine power Peng net (kW) Example:

Heat build-up for tractive effort = 60% vehicle weight
– Torque curve Teng gross (Nm)
Tractive effort:
– Torque curve Teng net (Nm)
F [N] = K x G [kg] x 9.81 [m/s2] K = 0.6
– T2 (Nm) subtraction for auxiliaries such as auxiliary F [N] = 0.6 x G [kg] x 9.81 [m/s2] G = mass [kg]
steering pump, generator etc.; approximate value of
T2 = 50 Nm may be assumed. If units with especially TT [Nm] x iG x iA x dtot
high power requirements are planned, e.g. a com- F [N] = –––––––––––––––––––
rdyn [m]
pressor, torque must be calculated according to im-
peller speed,
F [N] x rdyn [m]
– TT turbine torque (Nm) against turbine speed TT [Nm] = ––––––––––––––
iG x iA x dA x dG
– PV (kW) torque converter power losses against turbi-
ne speed nT K x G [kg] x 9.81 [m/s2] x rdyn [m]
Example: = –––––––––––––––––––––––––––
iG x iA x dA x dG
nT = 800 rpm PV = 55 kW
– nP impeller speed against turbine speed nT Using value of TT consult torque converter graph
Example:
TTA curve TTA PVA axis PA heat build-up P (kW)
nT = 1200 rpm nP = 1800 rpm;
nT = 0 rpm nP = 1550 rpm

Example:
(stall speed)
TT = 1200 Nm PV = 49 kW
– Mu torque multiplication + = TT / TP against speed
ratio Nu = nT / nP TT = Turbine torque
Example: F = Tractive effort
Nu = 0 max. torque iG = Transmission ratio
multiplication = 2.165 iA = Rear axle ratio
Nu = 0.78 torque multipli- dG = Transmission efficiency approx. 0.95
cation = 1.0 dA = Axle efficiency approx. 0.95
rdyn = Dynamic tyre radius
NOTE
When selecting engine cooler, take account of additional
heat build-up during torque converter operation!
42
6 Converter
Torque converter graph Drawing no.: 4166 704 398
4139 S 2039
Key to graph
TengGr/Net [Nm] = Engine torque curve Mu [–] = Torque multiplication ratio
(Gross/Net) + = TT/TP against speed ratio
PengGr/Net [kW] = Engine power curve Nu = nT/nP
(Gross/Net) TP [Nm] = Parabolae of impeller torque
nP [1/min] = Impeller speed against pick-up against impeller speed nP
turbine speed nT for speed ratio Nu = nT/nP
TT [Nm] = Turbine torque against T2 [Nm] = Subtraction for auxiliaries (e.g. auxi-
turbine speed nT liary steering pump, generator etc.)
PV [kW] = Torque converter power losses A = Stall torque

against turbine speed nT B = Stall speed
Engine data: = According to DIN 70 020 (average
values)
Converter = According to VDI Guidelines
figures: 2153 (average values)
43
44
6 Torque converter
6.5 Basic torque converter graph curves
Converter diagram Drawing no.: 4166 704 462

4139 S 2090
CONVERTER: ZFW 360-10/1 A.1.7. Converter characteristics

i + d TPC1500
STARTING TORQUE MULTIPL.: MUEstart = 2.137 [Nm] [LBFT]
0 2.137 0 352 260
0.10 2.009 0.201 347 255
Engine data: acc. to DIN 70 020 (average values) 0.20 1.863 0.373 343 252
0.30 1.720 0.516 335 247
Converter values: acc. to VDI Guidelines 2153 (average values) 0.40 1.545 0.618 327 241
0.50 1.404 0.702 313 230
0.55 1.333 0.733 307 226
0.60 1.249 0.749 301 222
0.65 1.176 0.764 291 215
0.70 1.098 0.769 277 205
0.72 1.073 0.773 269 199
0.74 1.045 0.773 259 191
0.77 1.000 0.770 248 183
IDENT. NO. 1 35200 35200 1500 213 1000 Z
44.1
6 Wandler
4139 S 2092
CONVERTER: ZFW 360-10/1/1/.1.1.

Converter characteristics
STARTING TORQUE MULTIPL.: MUEstart = 2.400 TPC1000
i + d
0 2.4 0 262
Engine data: acc. to DIN 70 020 (average values)
0.2 1.915 0.383 260
0.4 1.52 0.608 247.7
Converter values: acc. to VDI Guidelines 2153 (average values)
0.6 1.235 0.741 217.5
0.7 1.097 0.768 195
0.76 1.0 0.76 175
0.8 0.98 0.784 152
0.85 0.98 0.833 116
0.9 0.979 0.881 82
0.95 0.97 0.921 46
0.975 0.93 0.907 22.7
1.0 0 0 0
44.2
6 Converter
4139 S 2094
CONVERTER: ZFW 360-10/1.1.1/1/.

START. TORQUE MULTIPL.: MUEstart = 2.165 TPC1000
i + d
0 2.165 0 390
Engine data: acc. to DIN 70 020 (average values)
0.2 1.83 0.366 375.5
0.4 1.48 0.592 347
Converter values: acc. to VDI Guidelines 2153 (average values)
0.6 1.23 0.738 300
0.7 1.107 0.775 268
0.78 1.0 0.78 234
0.8 0.98 0.784 222
0.85 0.978 0.831 180
0.9 0.967 0.87 128
0.95 0.95 0.902 64
0.975 0.927 0.904 28
1.0 0 0 0
44.3
6 Converter
Converter diagram Drawing no.: 4166 711 089 (a)
4139 S 2095
CONVERTER: ZFW 380-30/2.1.1.

i + d
0 2.54 0 376.3
Engine data: acc. to DIN 70 020 (average values) 0.1 2.284 0.23 381.8
0.2 2.036 0.41 382.3
Converter values: acc. to VDI Guidelines 2153 (average values) 0.3 1.812 0.54 375.4
0.4 1.608 0.64 367.8
0.5 1.417 0.71 352.7
0.6 1.262 0.76 330.5
0.7 1.114 0.78 298
0.77 1.0 0.77 259
0.8 0.962 0.77 226.2
0.875 0.95 0.83 134.9
0.9 0.948 0.85 105.3
0.94 0.929 0.87 66.9
0.96 0.88 0.84 42.3
0.99 0.75 0.74 9.4
1.0 0 0 0
44.4
6 Converter
4139 S 2096
CONVERTER: ZFW 380-30/1.1.2 B

i + d
Engine data: acc. to DIN 70 020 (average values) 0 2.251 0 404.3

0.1 2.063 0.206 407.8
Converter values: acc. to VDI Guidelines 2153 (average values) 0.2 1.884 0.377 405
0.3 1.712 0.514 396.2
0.4 1.546 0.618 383
0.5 1.377 0.689 363.8
0.6 1.244 0.746 335.3
0.7 1.117 0.782 292.9
0.74 1.069 0.791 272.4
0.78 1.0 0.78 248.5
0.84 0.978 0.822 175.4
0.86 0.974 0.838 152.7
0.90 0.967 0.87 108.5
0.94 0.950 0.893 67.4
1.0 0 0 0
44.5
6 Converter
Converter diagram Drawing no.: 4166 711 090 (a)
4139 S 2097
CONVERTER: ZFW 380-30/1.1.2.

i + d
0 2.438 0 417.6
Engine data: acc. to DIN 70 020 (average values) 0.1 2.206 0.22 415.6
0.2 1.983 0.4 406.4
Converter values: acc. to VDI Guidelines 2153 (average values) 0.3 1.766 0.53 392.8
0.4 1.585 0.63 379.7
0.5 1.393 0.70 359.8
0.6 1.25 0.75 331.2
0.7 1.115 0.78 291.3
0.78 1.0 0.78 244.2
0.8 0.976 0.78 226.8
0.86 0.971 0.83 160.2
0.9 0.963 0.87 115
0.94 0.954 0.9 69.5
0.96 0.944 0.91 43.3
0.99 0.771 0.76 8.5
1.0 0 0 0
44.6
7 Retarder
7 Retarder
Seite
7.1 Structure and function of retarder ............................................................... 46
7.2 How the retarder works ............................................................................... 46
7.3 Control of the retarder ................................................................................. 47
7.4 Retarder and engine brake ........................................................................... 47
7.5 Pre-set retarder braking force ...................................................................... 47
7.6 Different variants for controlling the retarder ............................................. 47
7.7 Diagrams of retarder control system ........................................................... 48
7.8 Using Ecomat in vehicles with Anti-Lock Brakes (ABS) ........................... 54
7.9 Using Ecomat in vehicles with engine brake .............................................. 54
7.10 Retarder control device................................................................................. 54
7.11 Other retarder control devices ..................................................................... 56.1
7.12 Retarder torque in Ecomat ........................................................................... 56.6
7.13 Idling speed losses ....................................................................................... 56.6
7.14 Retarder control characteristics ................................................................... 56.7
7.15 R3 pressure vs. applied air pressure Pair ...................................................... 56.7
7.16 Response time of retarder without accumulator .......................................... 56.7
45
7 Retarder
7 Retarder Additionally, the ZF retarder has a special feature in that

a vane ring is rotatably fixed in the stator. This reduces
7.1 Structure and function of retarder losses when the retarder is not engaged to less than 25%
of the amount of loss without such a division of the sta-
The ZF retarder integrated in your Ecomat transmission tor.
is a single-flow hydrodynamic continuous brake located
between the torque converter and planetary gear section. The rotor (turning part of the retarder) is connected to
the transmission input shaft, and so when a gear is en-
This means that braking force is directly dependent on gaged, the rotor is also connected to the driving axle of
the gear engaged. Even at low speeds, full braking effect the vehicle. In contrast, the stator is firmly fixed to the
is available (primary retarder). Ecomat housing.
The retarder consists of the following conventional main The basic advantage of the ZF retarder is its infinitely-
components: rotor, stator and valves required for pneu- variable control. The braking force can be divided into
matic and hydraulic control. The rotor and stator are one or several levels.
both constructed as impellers.
1 Connection for control

compressed air
2 Regulator
3 Outlet spiral
4 Oil line to transmission
oil cooler
5 Stator
6 Rotor
7 Oil line from transmisson
oil cooler
Drawing shows simplified view without vane ring

4139 S 2016
7.2 How the retarder works The rotor forces the oil into blades in the non-rotating
(Shows simplified view without vane ring) stator. The direction of oil flow is reversed and slowed
(braked). Due to the reverse of oil flow direction in the
During braking, a hand or foot-operated control valve stator, the rotation of the rotor is also slowed, as is the
causes compressed air to open the retarder regulator vehicle speed.
valve. This allows oil to flow freely in the retarder cir-
cuit. The rotor is driven by the vehicle through its axle, The friction of the oil flow is converted into heat. This
propshaft, transmission and clutch and its rotation cau- heat is conveyed to the cooling water by the heat ex-
ses the retarder oil to undergo centrifugal acceleration, changer in liquid cooled engines or radiated into the
making the oil circulate in the retarder. cooling air in air-cooled engines.
46
7 Retarder
7.3 Control of the retarder 7.6 Different variants for controlling the retarder
The different variants for controlling the retarder are The following different variants are available for con-
listed in Section 7.6 and illustrated in Section 7.7, Dia- trolling the retarder:
grams of retarder control systems.
% Infinitely-variable retarder control using foot pedal
Refer to Section 10, Hydraulic systems to see how the brake valve
retarder control system functions. (See Section 7.7, drawing no.: 4139 720 018)
7.4 Retarder and engine brake

% Three-step retarder control using hand-lever
(See Section 7.7, drawing no.: 4139 720 019)
Maximum permissible retarder torque including engine
drag torque is:
% Infinitely-variable foot and hand-operated retarder
control
1300 +50 Nm for the HP 500/HP 590 (See Section 7.7, drawing no.: 4139 720 020)
1500 +50 Nm for the HP 600
% Infinitely-variable foot operated and stepped hand-
When the retarder and an engine brake are combined, operated retarder control
ZF restricts the retarder torque to prevent the limiting (See Section 7.7, drawing no.: 4139 720 021)
values given above being exceeded.
% Stepped foot and hand-operated retarder control
Braking force at transmission output during retarder (See Section 7.7, drawing no.: 4139 720 022)
operation is made up of:
% One-step retarder control using brake pressure switch
Retarder braking force + internal transmission losses + or proximity switch or mechanical switch on brake
engine drag torque. pedal
(See Section 7.7, drawing no.: 4139 720 044)
7.5 Pre-set retarder braking force
The pre-set retarder braking force is listed in the parts

list. During commissioning before delivery from ZF, this
is pre-set assuming a constant 150 Nm engine drag
torque.
When using the engine brake, ensure that the total brake
force (engine brake + retarder brake force) does not ex-
ceed the maximum permissible retarder braking force,
see Section 7.4.
47
7 Retarder
7.7 Diagrams of retarder control systems
See Section 12, Peripherals for individual components (except retarder control elements).
Pneumatic diagram From drawing no.: 4139 720 018 (b)
Vehicle electrical system Pos. 644 Pos. 632

cable harness "Retarder "Gear signal
input" output"
Retarder Accumulator
Infinitely-variable retarder control using foot

pedal brake valve/hand-lever valve with gear
and temperature-dependent retarder reduction
4139 S 2017
Key to drawing:
A5 Temperature gauge RV1 Pressure reduction valve 1.2 bar

BV Foot pedal brake valve/hand-lever valve S2 Pressure switch for retarder control 0.35 bar
H2 Retarder indicator lamp SG Retarder control "OFF"
K2 Gear signal relay Y1 Retarder solenoid valve
K9 Temperature control relay Y2 Accumulator solenoid valve
P1 Compressed air supply Y5 Retarder reduction solenoid valve
48
7 Retarder
Pneumatic diagram From drawing no.: 4139 720 019 (c)
Vehicle electrical Pos. 644 Pos. 632

system cable harness "Retarder "Gear signal
input" output"
Retarder
switch
Three-step retarder control using hand-lever

valve/foot pedal brake valve with gear and
temperature-dependent retarder reduction
4139 S 2018
Key to drawing:

H2 Retarder indicator lamp Y1 Retarder solenoid valve
K2 Gear signal relay Y2 Accumulator solenoid valve
K9 Temperature control relay Y12 Pressure control solenoid valve
P1 Compressed air supply Y13 Pressure control solenoid valve
RV1 Pressure reduction valve 1.2 bar K12/13 Solenoid valve pressure control relay
RV2 Pressure reduction valve 2.0 bar
49
7 Retarder
Vehicle electrical
system cable harness Pos. 632
Pos. 644
"Retarder "Gear signal
input" output"
Infinitely-variable foot and hand-operated retar-

der control with gear and temperature-dependent
retarder reduction
4139 S 2019
Key to drawing:

BV Foot pedal brake valve S2 Pressure switch for retarder control 0.35 bar
HV Retarder hand-lever valve SG Retarder control "OFF"
K9 Temperature control relay Y5 Retarder reduction solenoid valve
P1 Compressed air supply WV Change-over valve
50
7 Retarder
Vehicle electrical Pos. 632

Pos. 644
system cable harness "Gear signal
"Retarder
input" output"
Retarder
switch
Infinitely-variable foot-operated and stepped hand-ope-

rated retarder control with gear and temperature-depen-
dent retarder reduction
4139 S 2020
Key to drawing:
A5 Temperature gauge S2 Pressure switch for retarder control 0.35 bar
BV Foot pedal brake valve SG Retarder control "OFF"
K9 Temperature control relay Y5 Retarder reduction solenoid valve
RV1 Pressure reduction valve 1.2 bar Y12 Pressure control solenoid valve
RV3 Pressure reduction valve 3.0 bar WV Change-over valve
RV4 Pressure reduction valve 1.2 bar K11-13 Solenoid valve pressure control relay
51
7 Retarder
Pneumatic diagram From drawing no.: 4139 720 022 (c)
Vehicle electrical
system cable harness Pos. 644 Pos. 632
"Retarder "Gear signal
input" output"
Hand lever
Foot pedal
Stepped foot and hand-operated retarder control

with gear and temperature-dependent retarder re-
duction
4139 S 2021
Key to drawing:

H2 Retarder indicator lamp SG Retarder control "OFF"
K2 Gear signal relay Y1 Retarder solenoid valve
K9 Temperature control relay Y2 Accumulator solenoid valve
RV2 Pressure reduction valve 2.0 bar K12/13 Solenoid valve pressure control relay
52
7 Retarder
Pneumatic diagram From drawing no.: 4139 720 044 (a)
Vehicle electrical
system cable harness
Pos. 644 Pos. 632
"Retarder- "Gear signal-
input" output"
Brake pressure switch or

proximity switch or me-
chanical switch
One-step retarder control using brake pres-

sure switch or proximity switch or mechanical
switch on brake pedal with gear and tempera-
ture-dependent retarder reduction.
4139 S 2022
Key to drawing:

H2 Retarder indicator lamp RV3 Pressure reduction valve 3.0 bar
K2 Gear signal relay SG Retarder control "OFF"
K9 Temperature control relay Y1 Retarder solenoid valve
P1 Compressed air supply Y2 Accumulator solenoid valve
Y5 Retarder reduction solenoid valve
53
7 Retarder
7.8 Using Ecomat in vehicles with Anti-Lock 7.10 Retarder control device
Brakes (ABS)
The foot pedal brake valve (BV), drawing no. 0501 203
Observe the following conditions with active ABS: 995 is used as the retarder control device for infinitely-
variable retarder operation.
% The retarder must be switched off.
(Interruption of input signal Pos. 644, see Section
7.7.)
% The engine drag torque can be disconnected from ou-

tput (see "Functional description of vehicle electrical
system" in Section 15.8.). To do this, we can offer an
optional function, "Lock-up clutch open".
% The engine brake must be disengaged, see "Func-

tional description of vehicle electrical system" in
Section 15.8.
7.9 Using Ecomat in vehicles with engine brake
CAUTION
To avoid engine stalling, engine brake control must be
handled electronically via the EST 18.
The engine brake is disengaged if
– the lock-up clutch opens,
– a gear shift occurs (approx. 1 sec)
– the accelerator pedal is depressed.
– the EST 18 emergency control function is activated.
54
7 Retarder
Foot pedal brake valve From drawing no.: 0501 203 995(a)
I = Brake valve (service brake)

II = Modulator valve (retarder operation)
3 = Vent (service brake)
11 = Air supply connection (Circuit 1)
12 = Air supply connection (Circuit 2)
13 = Air supply connection for auxiliary units
21 = Service brake connection (Circuit 1)
22 = Service brake connection (Circuit 2)
23 = Retarder operation connection (modulated pressure)
Max. operating pressure: 10 bar
Medium: air ZF no.: 0501 203 995 (a)
Temperature range: - 40°C to + 80°C Wabco no.: 461 324 008 0
4139 S 2023
55
56
7 Retarder
7.11 Other retarder control devices Foot pedal brake valve for continuously-variable retar-
der operation (BV)
Manually operated lever valve for continuously-variable
retarder operation (HV) 0501 203 829 Brake valve
0501 203 832 Manually operated brake valve Brake valve for 3-level retarder control
0501 203 833 Manually operated brake valve 0501 206 153 Brake valve
Manually operated lever valve for continuously-variable Switch for 3-level retarder control
retarder operation with integrated electrical switch (HV)
0501 205 041 Switch
0501 203 556 Manually operated brake valve 0501 205 042 Switch
Manually operated brake valve From drawing no.: 0501 203 832 and 0501 203 833 (b)
Pressure-stroke diagram
Resulting pressure
Lever stroke
1 Supply line connection

2 Cylinder line connection
3 Vent
Medium: Air
Temperature range: –40°C to +80°C
Connection drawing
A B
4139 S 2027
WABCO No. Drawing No. Lever length Connection diagram

461 709 006 0 0501 203 832 250 mm A
461 709 005 0 0501 203 833 (b) 125 mm B
56.1
7 Retarder
Manually operated brake valve From drawing no.: 0501 203 556 (d)
Resulting pressure Pressure-stroke diagram
Switch: OFF
Lever stroke
Switch: ON
1 Supply line connection

2 Cylinder line connection
3 Vent
Medium: Air
Installation position: Any
Connection diagram
ZF No.: 0501 203 556

WABCO No.: 461 709 502 0
4139 S 2028
56.2
7 Retarder
Foot pedal brake valve From drawing no.: 0501 203 829 (c)
oke
dal str
e
Foot p
Connection diagram
I = Brake valve (service brake)

II = Modulation valve (retarder actuation)
3 = Vent (service brake)
11 = Connection from air reservoir (circuit 1)
12 = Connection from air reservoir (circuit 2)
13 = Connection from air reservoir auxiliaries
21 = Connection to service brakes (circuit 1)
22 = Connection to service brakes (circuit 2)
23 = Connection to retarder actuation (modulated pressure)
ZF No.: 0501 203 829
Medium: Air Wabco No : 461 324 001 0
4139 S 2029
56.3
7 Retarder
Foot pedal brake valve From drawing no.: 0501 206 153
9,(:;
3RLQWRIFORVXUHVZLWFK,,,
3RLQWRIFORVXUHVZLWFK,,
3RLQWRIFORVXUHVZLWFK, 3UHVVXUHSRLQWPHFKDQLFDO
3 = Vent
11/12 = Supply
21/22 = Output
Medium: Air
Max. nominal width: 78.5 mm2 = ^ ø 10 mm
Installation location: Vent pointing downwards (max. de-
viation of central axis of the unit from the vertical 90°)
Switch loading I, II, III: at 24 V – 1A (inductive load)
ZF No.: 0501 206 153 Wabco No.: 461 318 001 0

4139 S 2068
56.4
7 Retarder
Braking level switch From drawing no.: 0501 205 041 (a) and 0501 205 042 (a)
0RXQWLQJVXUIDFH
PD[PP
0RXQWLQJQXW
0[6:
$)
¡

0RXQWLQJDSHUWXUH

6HDOLQJJDLWHU
,QIRUPDWLRQSODWH
0[ 6WRSSRVLWLRQ

[
PP
[$ $

0[
)

6:

$

003 900
Technical data
No. of switch positions: 7 (1 off (0) position + 6 closed)
The switching range must be subsequently limited externally for 3,
4, 5 or 6 switch positions. Do this by inserting one or two stop pins
&RQQHFWLRQSRVLWLRQV (2 x 18 DIN 6325).
IRUWKHVZLWFKOD\RXW
Switch sequence: Short-circuiting, e.g. when switching
from one level to the next, the level al-
ready engaged shall not be interrupted.
Connection: 6.3 x 0.8 flat pin plug at the rear, e.g.

8-pin receptacle housing AMP

No. 163007-0
Mounting: Central mounting using nut M 22 x 1

thread element M 22 x 1 made of pres-

sure-die cast zinc alloy ZnA14Cu1 in a

moulded plastic casing
Tightening torque max. 15 Ncm
Voltage: max. 30 V

Switching current: max. 0.5 A

Continuous current: max. 1 A
6ZLWFKOD\RXW Peak current: max. 2 A (momentary)
Switch cycles: 106

ROBERT-SEUFFER No.: ZF No.: Lever length [mm]

635.1001 0501 205 041 (a) 80
635.1002 0501 205 042 (a) 120
56.5
7 Retarder
7.12 Retarder torque in Ecomat
Braking torque of the retarder in the transmission

HP 500/590/600
6HWWLQJ
%UDNLQJWRUTXH
6HWWLQJ
6HWWLQJ
5HWDUGHUVSHHG >USP@ 4139 S 2098
Measurements were taken in direct drive at input speed NOTE

nin = 2200 – 800 rpm (itot = 1) on the series production The braking torque TBr includes a constant engine drag
test rig. torque Teng.drag = 150 Nm
Oil temperature: 80 – 85°C Braking torque: TBr = TRet + Teng.drag
Flywheel mass: Brake A 1000 + additional mass

(corresponding to approx. 18 t vehi-
cle mass)
7.13 Idling speed losses
&RQYHQWLRQDO
5HWDUGHU
>USP@
4139 S 2099
56.6
7 Retarder
7.14 Retarder control characteristics 7.16 Retarder response time
The measurements were taken on an HP 500 transmissi- The retarder can be supplied with or without an accu-
on in direct drive at 2000 rpm on the series production mulator.
test rig.
The retarder cut-off time is approx. 0.2–0.3 sec.
Oil temperature: 80 – 85°C
Response time of retarder with accumulator
4 HP 500 No. 9608 B
7RXW>1P@
VHF

Time until 900 Nm braking torque

Piston Control Tout Time when braking
torque effect starts
Ø start end [Nm]
[bar] [bar]

17 0.6 2.8 1300

19 0.6 2.8 1100

QLQ>USP@
003 895

Test rig motor braking torque
Response time of retarder without accumulator
3DLU>EDU@
003 897 4 HP 500 No. 9608 B
7.15 R3 pressures vs. applied air pressure

VHF
Pair
Measurements were taken in direct drive at input speed Time until 900 Nm braking torque
2000 rpm on the series production test rig.

Oil temperature: 80 – 85°C
35>EDU@
Time when braking tor-

que effect starts

1P

QLQ>USP@
1P 003 896

3DLU>EDU@
003 898
56.7
8 Cooling system
8 Cooling system % Lines must not touch transmission or engine or chafe

(avoid relative movement).
8.1 Position of oil cooler
% Fix lines adequately (prevent vibration).
The oil cooler should be fitted according to space
available in the vehicle. % Maintain 100 mm gap between lines and exhaust; use
heat shield if distance is less.
– Transverse behind transmission or side-mounted or
– fitted separately from the transmission (installation 8.3 Specifications for <J..> group heat exchanger
by vehicle manufacturer). Refer to Section 9, Transmission specifications in order
to specify the <J..> group heat exchanger.
8.2 Layout with oil cooler separate from trans-
mission 8.4 Choice of oil cooler
8.2.1 Oil line connections When choosing the oil cooler, take the following into
account:
Transmission with retarder:
Internal diameter of connection lines at least 32 mm, – heat build-up due to torque converter (see Torque
hose lines heat resistant to at least 160°C, pressure resi- converter diagram PV)
stant to 20 bar (test pressure 50 bar) and not subject to – heat build-up due to retarder
corrosion by oils in the TE-ML 14 List of Lubricants.
During the installation check it is essential to check the
Transmission without retarder: values calculated when selecting the cooling system.
Internal diameter of connection lines at least 19 mm,
hose lines heat resistant to at least 140°C, pressure resi- The cooling system should be designed to maintain the
stant to 20 bar (test pressure 50 bar) and not subject to following oil temperature limits (measured at the trans-
corrosion by oils in the TE-ML 14 List of Lubricants. mission oil cooler input). This design should also take
into account vehicle type requirements and the geogra-
8.2.2 Installation guidelines phical location where the vehicle will be used.
% The oil cooler should not be above the transmission, Transmission oil temperature at oil cooler input
otherwise the transmission oil level will be incorrect
due to oil running back after the engine is stopped. If During retarder operation:
the cooler is mounted above the transmission, the oil – The switch point of the temperature gauge warning
level can only be measured with the engine running. contact is 145°C.
(See Installation Guidelines Section 8.3.3: Oil level
check with separate heat exchanger installed higher – Exceptionally, temperatures up to 150°C are permis-
than centre line of transmission) sible for short periods (max. 5 minutes).
% The oil cooler must be mounted near the transmis- – Ensure the alarm contact is connected to a warning
sion to reduce oil side pressure losses caused by ex- lamp and/or alarm buzzer.
cessively long hoses/pipes to a minimum.
– It is possible to specify that the alarm contact signal
% The oil cooler is best mounted on the transmission/ should also reduce retarder braking torque (e.g. in
engine block. Avoid unnecessary strain on hoses/ coaches).
pipes caused by relative movement. Fix the hoses/
During torque converter operation:
pipes using flexible clips so they are not destroyed by
vibration. – Max. temperature, continuous operation is 110°C.
Observe the following with non-ZF coolers: – Exceptionally, temperatures up to 130°C are permis-
sible for short periods (max. 5 minutes).
% Lay lines between transmission and oil cooler
carefully. During normal driving:
– Permissible temperature range is between 90 to
100°C.
57
8 Cooling system
Oil temperature in transmission oil sump 8.4.1.1 Cooling system graph
The following sump temperatures must not be exceeded

(measured through the oil fill pipe):
– Operating temperature/continuous temperature
80/90°C.
– Exceptionally, temperatures up to 105°C are permit-

ted for short periods (max. 5 minutes).
8.4.1 Cooling system with retarder
The oil cooler fitted to the transmission is designed for

cyclic operation (not for long periods of driving at full
retarder power).
The limiting conditions shown on the graph in Figure

8.4.1.1 give a cooling power of 150 kW.
For extreme retarder applications, observe limiting tem-

peratures in Section 8.4, or fit a larger heat exchanger.
% Water flow at least 250 ltr/min = 15 m3/h at nominal

speed
% Water flow at least 50 ltr/min = 3 m3/h at idling

speed
% Max. water input temperature 85°C. Oil input temperature: 135°C

Water input temperature: 85°C 4139 S 2030
8.4.2 Cooling system without retarder
The heat exchanger must be designed in accordance

with the torque converter diagram PV and the delivery
volume of the primary pump. In versions without retar-
der, the oil volume to be cooled depends on the delivery
volume of the primary pump.
In undemanding applications, use a cooling power of

at least 30 kW as a guideline.
% Water flow at least 250 ltr/min = 15 m3/h at nominal

speed
% Water flow at least 50 ltr/min = 3 m3/h at idling

speed
Permissible pressures for oil flow of 60 ltr/min.:

6Poil max. 0.3 bar
6 Pwater at water flow of 250 ltr/min. must be
approx. 0.5 bar.
58
8 Cooling system
8.4.2.1 Cooling system without retarder - further instructions
Oil flow rate through cooler across the speed range
HP 500 Neutral (torque converter lock-up clutch open), 90° sump temperature, mean values for series production
>OPLQ@
QLQ >USP@
4139 S 2106
HP 600 Neutral (torque converter lock-up clutch open) 90° sump temperature, mean values for series production
>OPLQ@
QLQ >USP@
4139 S 2107
58.1
8 Cooling system
8.5 Cooling water circuit
Full-flow transmission oil cooler on cold water pressure side. This configuration is preferred.
Top view Side view
Transmission oil connection
Cooling water
expansion tank
Transmission Heater
oil cooler
Ther-
mostat
Radiator
Ecomat-
Engine
transmis-
sion
Transmission oil cooler Cooling water pump

4139 S 0044
Full-flow transmission oil cooler on cold water suction side.
Top view Side view

Cooling water
expansion tank
Transmission Heater
oil cooler
Ther-
mostat
Radiator
Ecomat-
Engine
transmis-
sion

4139 S 0045
59
8 Cooling system
Full-flow transmission oil cooler on hot water pressure side.
Top view Side view

Cooling water
Heater expansion tank
Thermostat
Transmission Vent pipe
oil cooler
Radiator
Ecomat-
Engine
transmis-
sion

4139 S 0046
With this cooling water circuit configuration, a reduced Transmission oil cooling water circuit for V-engines
cooling capacity is available for retarder cooling. The
retarder braking power must therefore be restricted If possible, the water required for cooling the transmis-
accordingly. sion oil should be fed through the transmission oil
cooler from both banks of cylinders (full cooling water
NOTE flow). After installation of the transmission oil cooler,
When thermostat is closed, ensure the cooling water still the distribution of the water flow between the two banks
flows through the transmission oil cooler. of cylinders must be checked, and corrected if
(50 ltr/min at idling speed necessary.
250 ltr/min at rated engine speed)
NOTE
If for some specific reason cooling water for the trans-
mission oil cooler can only be taken from one bank of
cylinders, consultation between the engine and transmis-
sion manufacturers is essential.
60
8 Cooling system
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
4139 S 0047
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
4139 S 0048
61
8 Cooling system
8.6 Oil cooler specifications Cooler/transmission; perm. movement ± 1 mm

Frequency range = 0 to 50 Hz
8.6.1 Required performance of cooler version Movement amplitude = ± 0.8 mm
The following requirements must be fulfilled for techni- % Rigidity pipe assembly
cal release to be granted: – oil circuit
Static test over-pressure P = 50 bar
Design data
% Over-pressures during operation % Leak test
– Water circuit P = 2.5 bar – Water circuit
– Oil circuit P = 10 bar Static test over-pressure P = 3.2 bar
% Flow rates – Oil circuit

– Water circuit: vmax = 24 m3/h = 400 ltr/min Static test over-pressure P = 20 bar
– Oil circuit: vmax = 21 m3/h = 350 ltr/min % Proof of heat exchanger capacity established by
% Pressure losses - water circuit means of measurement values corresponding to the
Medium: cooling water with antifreeze to – 25°C above conditions.
Water temperature = 85°C Endurance strength tests
Flow rate vwater = 20 m3/h = 333 ltr/min % Cooler mountings
Perm. pressure loss P = 0.075 bar – Endurance test
Cooler mounted on transmission
Flow rate vwater = 15 m3/h = 250 ltr/min
Frequency = 30 Hz
Perm. pressure loss P = 0.045 bar
Movement amplitude = ± 2 mm
% Pressure losses - oil circuit Test duration = 100 h
Medium: ATF DEXRON II or
SAE 10 W mono-grade engine oil % Housing (water circuit)
– Pressure puls endurance test
Oil temperature = 115°C
Medium = water
Flow rate voil = 20 m3/h = 333 ltr/min Over-pressure P1 = 2.5 bar
Perm. pressure loss P = 2.3 bar Over-pressure P2 = 0 bar
Flow rate voil = 15 m3/h = 250 ltr/min Frequency f = 3 Hz
Perm. pressure loss P = 1.4 bar Pressure gradient = 2.5 bar / 0.05 sec.
No. of pressure changes * 106
% Heat exchanger capacity
Heat dissipation = 170 kW under the following con- % Pipe assembly (oil circuit)
ditions: – Pressure puls endurance test
– Cooling water without additives Medium = ATF DEXRON II or
– Flow rate vwater = 20 m3/h SAE 10 W mono-grade engine oil
= 333 ltr/min Over-pressure P1 = 7 bar
– Water inlet temperature twater = 85°C Over-pressure P2 = 0 bar
– Medium: ATF DEXRON II or Frequency f = 3 Hz
SAE 10 W mono-grade engine oil Pressure gradient = 7 bar / 0.05 sec.
– Flow rate voil = 15 m3/h = 250 ltr/min No. of pressure changes * 106
– Oil inlet temperature toil = 135°C
8.6.3 Technical supply conditions
8.6.2 Technical inspections
% Cleaning
Functional checks The cooler must be clean inside and must not contain
% Rigidity – cooler mounting contaminating particles.
– Measurement of relative movement – Water and oil circuits
Cleaning with anti-corrosion oil
62
8 Cooling system
% Corrosion prevention – internal: 8.7.3 Antifreeze

Rinse with anti-corrosion oil (water and oil circuits)
Ethylene glycol base with corrosion inhibitors. Antifre-
% Corrosion protection – external: eze must not contain the following: Amines, chlorides,
The housing must be painted according to ZF Stan- phosphates, sulphates, carbonates and chromates.
dard 915.
Specific gravity (20°C): 1.11 – 1.14 (g/ml)
% Plugs to DIN 51757
All in- and outlets (water and oil circuits) must be Flashpoint: > 110°C to DIN 51758
sealed with protective caps. Boiling point: * 160°C to ASTM-D-1120
8.7 Required performance of cooling water and 8.7.4 Cooling water

antifreeze
Cooling water is a mixture of fresh water and antifreeze
and must have the following properties:
8.7.1 General
% Minimum proportion of antifreeze: 35% vol. Test
Antifreeze consists of ethylene glycol and anti-corrosion
using antifreeze tester (areometer or hydrometer)
additives. Mix water and antifreeze to make the cooling
water. Ethylene glycol raises the boiling point and lo- % pH value: 7.5 – 9.0
wers the freezing point, thus extending the operating Test using pH meter or indicator paper
range. Anti-corrosion additives protect the cooling sy-
stem from corrosion. % Residual alkalinity: * 10 ml 0.1 and HCL
ASTM-D-1121
Antifreeze must be prepared in such a way that it retains
its properties over a storage period of at least two years. % Flocculation point of 50%-solution: < –35°C
ASTM-D-1177
8.7.2 Fresh water % Foam volume after 5 min.: ) 150 ml
Only use pure water to make up cooling water. The wa- ASTM-D-1881
ter must correspond to the following quality and analy- % Foam killer time after 5 min.: ) 5 sec.
sis values: ASTM-D-1881
Colour: Colourless, clear % Reactivity against metal materials:
Smell: Neutral Removal rate: < 2 g/m2 on test sheets made of
Particles in suspension (sediment): None L-PbSn30, CuZn37, GG25, G-AlSi2
pH value (20°C): 6.5 to 8.0 tested to ASTM-D-1384 and guidelines in "Test of
Total hardness: 3 to 10° dH suitability of coolant additives for combustion engine
Ammonia content: Not traceable cooling water" by the Verbrennungskraftmaschinen
Iron and manganese content: max. 0.2 mg/ltr e. V. Research Institute, Frankfurt, Booklet R 315
Chloride content: max. 75 mg/ltr (1977) or later edition where valid.
Sulphate content: max. 50 mg/ltr
Nitrate content: max. 50 mg/ltr % Reactivity against elastomers (NBR, EPDM):
Nitrite content: Not traceable – 50% vol. antifreeze
Solid residue after evaporation: max. 500 mg/ltr – 100 hour aging at boiling point
Potassium permanganate – Shore A hardness modification = –10 to +10
consumption: max. 10 mg/ltr SHA
– Volume change V = –10 to +10%
If no suitable water is available in accordance with these
conditions, different water types may be mixed to achie- – Residual pressure deformation < 30%
ve the required water quality (e.g. mixture of hard and % Cooling water storage limit: 1 - 2 years, after this
fully desalinated water). time, replace. If sediment forms or concentration
drops considerably, also replace cooling water.
63
64
8 Cooling system
8.8 Collected formulae - retarder cooling system
1. Braking power PB
G [kg] · 9.81 [m/s2] · v [km/h] s [%]

PB [kW] = ––––––––––––––––––––––––– [sin (arc tan –––––) + fR]
3600 100
2. Engine speed neng = nRet (applies only when lock-up clutch is closed)
v [km/h] · iG · iH
nRet [rpm] = neng [rpm] = –––––––––––––––
0.377 · rdyn [m]
3. Retarder power PRet for nRet
TRet [Nm] · nRet [rpm]

PRet [kW] = ––––––––––––––––––––
9550
Sample calculation
Braking power of a truck with Ecomat 6 HP 600 and retarder
Data: G = 45 000 kg; fR = 0.01; v = 30 km/h

s = 7% for trucks to STVO §41 (German traffic regulations), continuous braking system
45 000 · 9.81 · 30 –7
Braking power PB = –––––––––––––––– [sin (arc tan –––– ) + 0.01]
3600 100
Braking power PB = -220 kW = 300 PS (continuous operation)
Calculation of engine or retarder speed at v = 30 km/h in 3rd gear

(neng = nRet only when converter lock-up clutch is closed)
30 · 2.01 · 5.92
nRet [rpm] = neng [rpm] = –––––––––––––– = 1815 rpm
0.377 · 0.519
Braking capacity S on downhill slope with braking torque T = 1300 Nm at n = 2200/min in 3rd gear and
v = 30 km/h
TBr = –1250 Nm
TBr [Nm] · iG · iH
S = 100 tan [arc sin (––––––––––––––––––––––––––––– –fR)] at nT = 1815 rpm
G [kg] · 9.81 [m/s2] · rdyn [m] · dH
–1250 · 2.01 · 5.92

S = 100 tan [arc sin (––––––––––––––––––––––– – 0.01)] = –7.85%
45 000 · 9.81 · 0.519 · 0.95
S = –7.85% downhill slopes can be negotiated using continuous braking.

64.1
8 Cooling system
Braking power of a vehicle with ZF retarder
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UG\Q >P@

9HKLFOHVSHHGY>NPK@

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7WRXW>1P@DWWUDQVPLVVLRQUDWLRLW

d
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6SHHGDWWUDQVPLVVLRQRXWSXWQWLQ >USP@ 7\UHVSHHGQW\UH >USP@ 3% Ã>VLQDUFWDQI
5@

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015 246
64.2
8 Cooling system
8.9 Heat exchangers with hard-coat lining
For special applications and in locations where the water

quality is suspected not to reach the requirements listed
in Section 8.7, the transmission must be fitted with a
heat exchanger with a hard-cost lining.
In these heat exchangers, all surfaces of covers and hou-

sings which may come into contact with water are provi-
ded with a hard-coat lining (lining thickness
25 ± 5 +m).
64.3
9 Transmission specifications
Page
9.1 Maximum engine torques and vehicle weights ........................................... 66
9.2 Installation position < L .. > ........................................................................ 67
9.3 Retarder version < G .. > ............................................................................. 69
9.4 Heat exchanger position < J .. > .................................................................. 71
9.5 Oil sump < F .. > ......................................................................................... 75
9.6 Oil fill < K .. > ............................................................................................. 79
9.7 Transmission output < A .. > ....................................................................... 81
9.8 Ecomat output flange ................................................................................... 83
9.9 Engine connection components supplied .................................................... 85
9.10 Auxiliaries ................................................................................................... 86
In addition to this section, see also Section 18, Ecomat parts list preparation
questionnaire.
Please use Section 18 when specifying a transmission, this provides a systematic pro-
cedure for each assembly requiring documentation.
Section 9, Specifications and Section 18, Questionnaire are constructed to allow easy
cross-referencing.
65
9.1 Maximum engine torques and vehicle weights

mission gears speed [rpm]
HP 500 4 3.43 – 1.0 2800
5 3.43 – 0.83 2800
for i = 0.59
6 3.43 – 0.59 2800 nmax = 1600*
Max. permissible
1050 Nm 1100 Nm 1100 Nm
HP 590 4 3.43 – 1.0 2800

5 3.43 – 0.83 2800
for i = 0.59
6 3.43 – 0.59 2800 nmax = 1600*
Max. permissible
1250 Nm 1250 Nm 1250 Nm
HP 600 4 3.43 – 1.0 2650

5 3.43 – 0.83 2650
for i = 0.59
6 3.43 – 0.59 2650 nmax = 1600*
Max. permissible
1400 Nm 1400 Nm 1400 Nm
HP 600* 4 3.43 – 1.0 2650

5 3.43 – 0.83 2650
for i = 0.59
6 3.43 – 0.59 2650 nmax = 1600*
Max. permissible
1600 Nm
Max. weight 26 t
66
9.1.1 Maximum engine torques and vehicle weights (expanded version of table in Section 9.1)

mission gears speed (rpm)
HP 500 4 3.43 – 1.0 2800
4 2.81 – 1.0 2800
5 3.43 – 0.83 2800
5 2.81 – 0.8 2800
6 3.43 – 0.59 2800 at i = 0.59
nmax = 1600*
Max. permissible
1050 Nm 1100 Nm 1100 Nm
HP 590 4 3.43 – 1.0 2800

4 2.81 – 1.0 2800
5 3.43 – 0.83 2800
5 2.81 – 0.8 2800
at i = 0.59
6 3.43 – 0.59 2800 nmax = 1600*
Max. permissible
1250 Nm 1250 Nm 1250 Nm
HP 600 4 3.43 – 1.0 2650

4 2.81 – 1.0 2650
5 3.43 – 0.83 2650
5 2.81 – 0,8 2650
at i = 0.59
6 3.43 – 0.59 2650 nmax = 1600*
Max. permissible
1400 Nm 1400 Nm 1400 Nm
4
HP 600* 3.43 – 1.0 2650
4 2.81 – 1.0 2650
5 3.43 – 0.83 2650
5 2.81 – 0.8 2650
6 3.43 – 0.59 2650 at i = 0.59
nmax = 1600*
Max. permissible
1600 Nm
Max. weight 26 t
*Only after consultation with ZF Application Engineering Department
66.1
9 Getriebespezifikation
Seite
9.2 < L ... > Installation position ..........................................................68
9.2.1 < L 01 > Flange-mounted installation position..................................68
9.2.2 < L 02 > Separate installation position .............................................68.1
9.2.3 Input flange ............................................................................................68.2
67
9.2 Installation position < L .. >
9.2.1 Flange-mounted installation position < L 01 > From drawing no.: 4139 601 143
Tightening torque
Depth 24
M16x1.5
225 Nm
4139 S 2031
68
9.2.2 Separate installation position < L 02 > From drawing no.: 4139 601 143
21%27+6,'(6
4139 S 2069
68.1
9 Transmission specification
9.2.3 Input flange, Fig. I From drawing no.: 4139 601 144
Pos. A A
Con- B C D
verter Fig. II Fig. III
360 200 204 178 105 57
380 215 219 193 120 72
21%27+6,'(6
4139 S 2070
68.2
Input flange, Fig. II From drawing no.: 4139 601 144
Flange 4130 302 117

4139 S 2071
Input flange, Fig. III From drawing no.: 4139 601 144
Flange 4139 302 016

4139 S 2072
68.3
Seite
9.3 < G ... > Retarder version .................................................................... 70
9.3.1 < G 01 > Flange-mounted solenoid valve .............................................. 70
9.3.2 < G 02 > Cover plate for version without retarder ................................. 70.1
< G 03 > Separate solenoid valve .......................................................... 70.1
69
9.3 Retarder version < G.. >
9.3.1 Flange-mounted solenoid valve < G 01 > From drawing no.: 4139 601 145
Vent
M12x1.5; depth 12
Alternative
P connections
4139 S 2032
< G 01 > US version From drawing no.: 4139 601 145
Vent
1/4" - 18 NPTF depth 10

Alternative
P connections
4139 S 2062
70
9.3.2 Cover plate for version without retarder <G02>

Separate solenoid valve <G03> From drawing no.:4139 601 145
6&5(:3/8*
0[
4139 S 2073
70.1
Page
9.4 < J ... > Heat exchanger position ....................................................... 72
9.4.1 < J 01 > Rear-mounted heat exchanger ................................................ 72
9.4.2 < J 08 > Heat exchanger, mounted separately from transmission ........ 73
Direct-mounted accumulator
9.4.3 < J 05 > Side-mounted heat exchanger, with retarder .......................... 74.1
9.4.4 < J 07 > Heat exchanger, mounted separately from transmission ........ 74.2
Without accumulator or with separate accumulator
9.4.5 < J 10 > Right-mounted heat exchanger ............................................... 74.3
CAUTION
Ensure correct water quality in
all versions.
71
9.4 Heat exchanger position < J .. >
9.4.1 Rear-mounted heat exchanger < J 01 > From drawing no.: 4139 601 154 (a)
Optional temperature
sensor connection
M14x1.5
14 deep
Thread 1 Thread 2
Standard version None None
US version M 14 x 1.5 1/8.27 DRYSEAL NPTF SAEJ 476a

4139 S 2033
72
9.4.2 Heat exchanger <J 08> mounted separately from transmission

Direct-mounted accumulator From drawing no. : 4139 601 154 (a)
Detail Y Section B-B Section J-J

Standard version F M K
US version H P O
Special version H M L
Version F Version H
Version M Version P
Version K Version O Version L
4139 S 2034
73
74
9.4.3 Side-mounted heat exchanger, with retarder < J 05 > From drawing no.: 4139 601 154 (a)
4139 S 2074
74.1
9.4.4 Heat exchanger mounted separately from transmission < J 07 >

Without accumulator or with separate accumulator From drawing no.: 4139 601 154 (a)
Detail Y Section B-B Section J-J

Standard Version F M K
US Version H P O
Special version H M K
9(56,21) 9(56,21+
&211(&7,21
'((3
9(56,210
9(56,21. 9(56,212
9(56,213
%%
4139 S 2075
74.2
9.4.5 Right-mounted heat exchanger < J 10 > From drawing no.: 4139 601 154 (a)
237,21$/7(03(5$785(
6(1625&211(&7,21
['((3
72+($7(;&+$1*(5
)520+($7(;&+$1
*(5
4139 S 2076
74.3
Seite
9.5 < F ... > Oil sump.................................................................................. 76
9.5.1 < F 02 > Deep oil sump .......................................................................... 76
9.5.2 < F 04 > Deep oil sump, left and right-hand connections prepared ....... 77
9.5.3 < F 01 > Shallow oil sump ..................................................................... 78.1
9.5.4 < F 05 > Shallow oil sump, left and right-hand connections prepared... 78.2
9.5.5 < F 08 > Deep oil sump, left-hand connection prepared ........................ 78.3
9.5.6 < F 15 > Deep oil sump, inch thread, left and right-hand
connections prepared .............................................................. 78.4
9.5.7 < F 11 > Deep oil sump, 15° tilt; same design as < F 02 >
but with oil intake for 15° transverse angle
75
9.5 Oil sump < F.. >
9.5.1 Deep oil sump < F 02 > From drawing no.: 4139 601 155 (a)
Filter Clearance for removal of valve body
Oil drain M22x1.5
4139 S 2035
76
9.5.2 Deep oil sump < F 04 >; left and right-hand connection prepared From drawing no.: 4139 601 155 (a)
Clearance for removal of valve body

Filter
Oil drain M22x1.5
4139 S 2036
77
78
9.5.3 Shallow oil sump < F 01 > From drawing no.: 4139 601 155 (a)
&/($5$1&()255(029$/2)9$/9(%2'<
2,/'5$,1
4139 S 2077
78.1
9.5.4 Shallow oil sump < F 05 >; Left and right-hand connections prep. From drawing no.: 4139 601 155 (a)
&/($5$1&()255(029$/2)9$/9(%2'<
2,/'5$,1
4139 S 2078
78.2
9.5.5 Deep oil sump < F 08 >; Left-hand connection prepared From drawing no.: 4139 601 155 (a)
&/($5$1&()255(029$/2)9$/9(%2'<
2,/'5$,1
4139 S 2079
78.3
9.5.6 Deep oil sump < F 15 >; Left and right-hand connec- From drawing no.: 4139 601 155 (a)
tions prepared; inch thread, including magnetic drain plug
&/($5$1&()255(029$/2)9$/9(%2'<
)/$1.
(;7(51$/
&25(
2,/'5$,1
4139 S 2080
78.4
Seite
9.6 < K ... > Oil fill ..................................................................................... 80
9.6.1 < K 01 > Oil fill ..................................................................................... 80
9.6.2 < K 02 > Oil fill ..................................................................................... 80.1
< K 04 > Oil fill ..................................................................................... 80.1
< K 05 > Oil fill ..................................................................................... 80.1
9.6.3 < K 03 > Oil fill ..................................................................................... 80.2
< K 06 > Oil fill ..................................................................................... 80.2
9.6.4 < K 09 > Oil fill ..................................................................................... 80.3
9.6.5 < K 10 > Oil fill ..................................................................................... 80.4
9.6.6 Transmission with oil fill point on side – Oil level marks – ....................... 80.5
79
9.6 Oil fill < K .. >
9.6.1 Oil fill < K 01 > From drawing no.: 4139 601 156 (b)
Clearance
4139 S 2037
80
9.6.2 Oil fill < K 02 > < K 04 > < K 05 > From drawing no.: 4139 601 156 (b)
)255(029$/
&/($5$1&(
$3352;
A B
K02 380 109
K04 843 561
K05 597 307
4139 S 2088
80.1
9.6.3 Oil fill < K 03 > < K 06 > From drawing no.: 4139 601 156 (b)
&/($5$1&()255(029$/
$3352;$
5(/$7('72/,1(
A B C ß _
K03 445 175 35 15 0° / 90° / 135° / 150° / 180° / 225° / 270°
K06 517 316 134 30° 0° / 90° / 135° / 180° / 250° / 270° / 315°
4139 S 2085
80.2
4139 S 2086
80.3
4139 S 2087
80.4
9.6.6 Transmission with oil fill point on side

– oil level marks –
Oil fill 4139 500 734 (c) CAUTION

The special oil fill tube must not have a vent and must
For this application, vehicle manufacturers must make be oil tight!
the special oil fill tube themselves. Use the remaining standard oil fill tube <K01> for vent-
ing or, in special cases, vent through the PTO aperture
ZF supplies the transmission with an oil sump, e.g. cover.
< F04 > see Section 9.5.2 For initial installation, specify the oil level marks on the
The oil measurement components 4139 131 808 can be special oil dipstick based on the markings on the stan-
obtained from ZF as a loose delivery. dard oil dipstick, e.g. <K01>.

615= '(6&5',367,&.3$576 7,1)26(,7/
'(371($%35(367(13 / . $(, =%
326 47< 3$57180%(5 =6 '(6&5,37,21 7(&+1,&$/,1)250$7,21 .$.&30/
+%0(1*($'=.=0/($1$8602'1202''$7(

25,1* ; =)1
+(;%2/7 0; ',1
&211(&7,213$57
*$6.(7

&29(5
)811(/
),//(51(&. '+2(+( )$
6 +(;6&5(: 0; ',1)(=1& %$/

2,/',367,&. .3/ ,1

02'
(1'2)02'8/$53$576/,67
3$5712 02'12BB326BB
80.5
Oil fill 4139 500 901 (b) U.S.A. version Specifying the oil level markings on the oil dipstick
for oil fill < K 10 >
The transmissions are supplied with deep oil sump
<F15>, prepared for LH and RH connection; inch % The vehicle manufacturer makes the oil fill tube
thread, including oil drain plug with magnet. which is connected to the <K10>.
The vehicle manufacturer replaces the sealing compo- % Specify the oil level markings on the special oil dip-
nents with a 90° adapter, special oil fill tube and oil dipstick during initial installation.
stick.
% Insert an unmarked oil dipstick into the oil filler tu-
CAUTION be. Mark the oil dipstick at the end of the tube.
The special oil fill tube must not have a vent and must
be oil tight! % Take the length from the flange surface of the tube to
Use the remaining standard oil fill tube <K01> for vent- the centre of the transmission (= 100) and the dimen-
ing or, in special cases, vent through the PTO aperture sion from the centre of the transmission to the oil le-
cover. vels (see drawing 4139 500 901). Add these dimen-
For initial installation, specify the oil level marks on the sions to the length measured in the previous step to
special oil dipstick based on the markings on the stan- obtain the final oil level markings on the oil dipstick.
dard oil dipstick, e.g. <K01>. % ZF will then document the oil dipstick.
% ZF supplies the oil dipstick as a loose part.
80.6
Oill fill
Standard oil fill point Standard oil

with breather fill point
with breather
6WDWLRQDU\UDQJH 6WDWLRQDU\UDQJH
+RWUDQJH +RWUDQJH
%RWWRPHGJHRI %RWWRPHGJHRI
KRXVLQJ KRXVLQJ
&ROGUDQJH &ROGUDQJH
Extract from drawing no.: 4139 500 734 Extract from drawing no.: 4139 500 901
4139 S 0073
★ NOTE: ★★ CAUTION
Oil sump deep deep shallow shallow A breather is fitted here in the standard oil fill point. Special oil fill point without
Transmission installation angle
0° – 4° 4° – 7° 0° – 4° 4° – 7° It is especially important that the transmission vents breather, oil-tight.
- output lower than input -
through this tube if the transmission is installed at an
A (mm) 124 109 107 98 angle.
In special cases, the transmission can also vent through
B (mm) 40 40 40 40 the PTO aperture cover.
C (mm) 164 149 147 138
D (mm) 182 164 162 153
E (mm) 234 225 227 209
F (mm) 255 238 240 222
80.7
Seite
9.7 < A ... > Transmission output ............................................................. 82
9.7.1 < A01 > Coaxial output ......................................................................... 82
9.7.2 < A06 > Output; angle drive 60° right,

see Section 9.10.1, Auxiliaries ................................................ 86
9.7.3 < A08 > Output, angle drive 65° left,

see Section 9.10.1, Auxiliaries ............................................... 86
9.7.4 < A09 > Output, angle drive 65° right

9.7.5 < A11 > Output, angle drive 80° left

9.7.6 < A07 > Output, spur gear drive,

see Section 9.10.6, Auxiliaries ............................................... 92.3
9.7.7 < A10 > Output, angle drive 63° right,

see Section 9.10.7, Auxiliaries ............................................... 92.4
9.8 Ecomat output flange ................................................................................. 83
81
9.7 Transmission output <A..>
9.7.1 Coaxial output <A 01> From drawing no.: 4139 601 157
Ecomat
output
M16x1.5 flange
Depth 24
Speedometer connection E2
similar to DIN 75 532
4139 S 2038
82
9.8 Ecomat output flange From drawing no.: 4139 601 158 (a)
Fig. I Fig. IV Fig. VI
Fig. VII
Fig. II
Fig. V
x = Bolts must be pre-fitted 4139 S 2040
ZF No. In drawing ØA ØB ØCh6 ØNH7 ØD E F ØG L° M L Fig.
x 4139 303 087 (1269 339 040) 150 130 90 – 12.2 2.3 10 110 45° 8x45° 696 I/II
x 4139 303 072 (1269 338 079) 165 140 95 – 16.2 2.3 11 115 45° 8x45° 693 I/II
4139 303 074 (4139 303 073) 180 155.5 110 – 16.1 2.3 12 130 36° 10x36° 693 I/II
4139 303 075 (4139 303 073) 180 155.5 110 – 14.1 2.3 12 133.3 45° 8x45° 693 I/II
4139 303 081 (4139 303 038) 203 155.52 – 169.5 10.15 – 12.1 141 – – 704 I/III
4139 303 101 (4139 303 038) 203 155.52 – 169.5 9.65 – 9.8 141 – – 704 I/III
Fig. III 4139 303 109 (4139 303 038) 203 155.52 – 167.9 11.2 – 12.1 139.3 – – 704 I/III
4139 303 155 (4139 303 038) 203 155.52 – 166.5 11.2 – 12.1 137.9 – – 704 I/III
4139 303 150 – Yoke 1710 – half round – I/IV
4139 303 153 (4139 303 038) 203 – – 165 11.2 – 12.1 139.3 – – 704 I/III
0501 311 089 – Yoke 1810 – I/V
x 4139 303 181 150 130 – – 13.0 – – 110 – – 700 I/VI
4139 303 172 180 150 – – 14.5 – – 127.5 – – 712.5 I/VI
4139 303 166 – Yoke 1710 – full round – I/VII
83
Seite
9.9 Engine connection components supplied ................................................. 86
9.10 Auxiliaries ................................................................................................... 86
9.10.1 60°/65°/80° angle drives .............................................................................. 86
9.10.2 Output flange 60°– angle drive .................................................................... 89
9.10.5 Other auxiliaries .......................................................................................... 92.1
9.10.6 STU 8000 spur gear drive < A 07 > ........................................................... 92.3
9.10.7 63° angle drive < A 10 > ............................................................................ 92.4
85
9.9 Engine connection components supplied Angle drives are flange-mounted on the output of the
Ecomat transmission. They can be fitted in the follo-
ZF supplies the flex plates and bolts to fasten the flex wing positions (angle _)
plates onto the torque converter circuit cover (see Sec-
tion 5). 60° angle drive : output left or right,
tilted 3.5°, 5° and 10°.
9.10 Auxiliaries
65° angle drive : output right tilted 3.5°; 5° und 10°,
output left tilted 5°
9.10.1 60°/65°/80° angle drives
80° angle drive : installation position and output
Various angle drives (WTR) are available for transverse
left as shown in installation drawing.
engine/transmission blocks.
WTR Ratio Max. engine torque Weight

CAUTION
Max. permissible input speed when angle drive fitted:
nmax. = 2400 rpm
60° 0.97 max. 1400 Nm 97 kg
65° 1.03 max. 1400 Nm 97 kg
80° 0.91 max. 1250 Nm 92 kg
60°/65° angle drive 80° angle drive
X view Y view
Key to drawing
1 Mounting faces
Values in brackets ( ) are for 65° angle drive
2 Output
Ø A and Y see Table in Section 9.10.2 / 9.10.3
(various flanges available)
3 Speedometer connection
4 Ecomat transmission
4139 S 2046
86
Ecomat with 60°/65° angle drive
4139 S 2041
Ecomat with 80° angle drive
4139 S 2042
87
88
9.10.2 Output flange 60°-angle drive From drawing no.: 4139 601 162 (a)
Fig. VI
Fig. I Fig. IV
Fig. VII
Fig. II Fig. V
x = Bolts must be pre-fitted 4139 S 2043
ZF No. In drawing ØA ØB ØCh6 ØNH7 ØD E F ØG L° M Y Fig.
x 4139 303 087 (1269 339 040) 150 130 90 – 12.2 2.3 10 110 45° 8x45° 387 I/II
x 4139 303 072 (1269 338 079) 165 140 95 – 16.2 2.3 11 115 45° 8x45° 384 I/II
4139 303 074 (4139 303 073) 180 155.5 110 – 16.1 2.3 12 130 36° 10x36° 384 I/II
4139 303 075 (4139 303 073) 180 155.5 110 – 14.1 2.3 12 133.3 45° 8x45° 384 I/II
4139 303 081 (4139 303 038) 203 155.52 – 169.5 10.15 – 12.1 141 – – 395 I/III
4139 303 101 (4139 303 038) 203 155.52 – 169.5 9.65 – 9.8 141 – – 395 I/III
4139 303 109 (4139 303 038) 203 155.52 – 167.9 11.2 – 12.1 139.3 – – 395 I/III
Fig. III
4139 303 155 (4139 303 038) 203 155.52 – 166.5 11.2 – 12.1 137.9 – – 395 I/III
4139 303 150 – Yoke 1710 – half round – I/IV
4139 303 153 (4139 303 038) 203 – – 165 11.2 – 12.1 139.3 – – 395 I/III
0501 311 089 – Yoke 1810 – I/V
x 4139 303 181 150 130 – – 13.0 – – 110 – – 391 I/VI
4139 303 172 180 150 – – 14.5 – – 127.5 – – 403.5 I/VI
4139 303 166 – Yoke 1710 – full round – I/VII
89
90
9.10.3 Output flange 65° angle drive From drawing no.: 4139 601 163 (a)
Fig. II
Fig. I
Fig. III
Fig. IV
4139 S 2044
ZF No. In drawing ØA ØB ØC ØN ØD E F ØG Y Fig.
4139 303 114 (4139 303 111) 203 155.52/184.12 – 169.5 9.7 1.2 12.1 141 405.8 I/II
4139 303 112 (4139 303 111) 203 155.52/184.12 – 169.5 10.1 1.2 12.1 141 405.8 I/II
4139 303 116 (4139 303 111) 203 155.52/184.12 – 164.5 11.2 1.2 12.1 139.3 405.8 I/II
4139 349 122 150 130 – – 13 – – 104 406.5 I/IV
4139 349 117 (4139 349 116) 150 130 90 – 12.1 2.5 10 110.3 397.8 I/III
91
9.10.4 Output flange 80° angle drive From drawing no.: 4139 601 164 (a)
Fig. I
Fig. II Fig. III
(Intersection of flange centre

and gear teeth reference circle) 4139 S 2045
x = Bolts must be pre-fitted
Point R
ZF No. In drawing ØA ØB ØCh6 ØD E F ØG L° M Fig.
(x, y, z)
x 4139 303 087 (1269 339 040) 150 130 90 12.2 2.3 10 110 45° 8x45° 730 -215 33 I/II
x 4139 303 072 (1269 338 079) 165 140 95 16.2 2.3 11 115 45° 8x45° 730 -215 36 I/II
4139 303 074 (4139 303 073) 180 155.5 110 16.1 2.3 12 130 36° 10x36° 730 -215 36 I/II
4139 303 075 (4139 303 073) 180 155.5 110 14.1 2.3 12 133.3 45° 8x45° 730 -215 36 I/II
x 4139 303 181 150 130 – 13.0 – – 110 – – 729 -215 29 I/III
4139 303 172 180 150 – 14.5 – – 127.5 – – 727 -216 17 I/III
92
9.10.5 Other auxiliaries CAUTION

(supplement to Section 9.10.1) Max. permissible input speed when angle drive fitted:
Other auxiliaries can be fitted to the engine/transmis- nmax. = 2400 rpm

sion unit. These are indicated in the shaded rows of the
table below.
WTR Ratio max. engine torque Weight
60° 0.97 max. 1400 Nm 97 kg
65° 1.03 max. 1400 Nm 97 kg
80° 0.91 max. 1250 Nm 92 kg
63° 1.017 max. 1200 Nm 440 kg*

STU
1.03 max. 1050 Nm 415 kg**
8000
* Overall weight of 4 HP 590 + accumulator + PTO

(3.43 – 1.00)
** Overall weight of 4 HP 500 + accumulator + heat
exchanger (2.81 – 1.00)
Angle drives (WTR) are flange-mounted on the output

of the Ecomat transmission. They can be fitted in the
following positions (angle _):
60° Angle drive : Output left or right, tilted

3.5°; 5° and 10°.
65° Angle drive : Output right, tilted 3.5°; 5° and 10°

output left, tilted 5°.
80° Angle drive : Installation position and output left

as shown in Section 9.10.1.
63° Angle drive : Installation position as shown in

Section 9.10.7
Drawing no. 4139 601 107
Spur gear drive Installation position as shown in

STU 8000: Section 9.10.6
Drawing no. 4139 601 177
92.1
92.2
9.10.6 STU 8000 spur gear drive < A 07 > Drawing no.: 4139 601 177 (a)
63$&()255(02
9,1*',367,&.
00
63$&()255(02
9,1*2,/),/7(5
&$1121&$%/(&211(&725/2:(53$57
5()%$319*
3527(&7,9(&$3)253/8*
*($5%2;6863(16,210['((3
7,*+7(1,1*72548(1P
35(6685(0($685,1*32,17$+($'2)&219(57(5
0['((3
9(17 0($685,1*32,17)256+,)75(675,&72535(6685(
0['((3
0($685,1*32,17)255(7$5'(535(6685(
0['((3
0($685,1*32,17)2535,0$5<35(6685(
0['((3
,'(17,),&$7,213/$7(
63(('2&211(&7,21
Q 63(('2 JQ 287387
237,21$/(/(&75,&$/63(('2'5,9(
0[
&$%/(&211(&7,21)2562/(12,'2)5(7$5'(5
$&78$7,1*&,5&8,7
&267$/
3/8*0J
&211(&7,21)25&2035(66('$,5/,1()255(7$5'(5
$&78$7,210J'((3
2,/'5$,13/8*$),17(51$/+(;+($'7D 1P
&211(&7,21)25&2035(66('$,5/,1()25
5(6(592,5(0J'((3
&$%/(&211(&7,215(6(592,562/(12,'

&267$/
3/8*0J
&211(&7,21)257(03(5$785(6(16250J
'((3&$%/(&211(&7,21
&267$/
0J
2,/),//(5:,7+',367,&.$1'%5($7+(5
0($685,1*32,17)25/8%5,&$7,1*2,/35(6685(
3 72EDU0 J
6833/(0(17$5<6863(16,21)25*($5%2;0 J
'((37,*+7(1,1*72548(1P
&(175(2)*5$9,7<
6(&7,21
92/7$*(9
0(&+$1,&5$7,26 0$66
&$3$&,7<)25,1,7,$/2,/),//$3352;/
0$,1*($5%2; 6385*($5 :,7+287
7<3( *($5 2,/ &$3$&,7<)252,/&+$1*(672/
4139 S 2101
92.3
9.10.7 63° angle drive < A 10 > Drawing no.: 4139 601 107 (b)
4139 S 2102
92.4
10 Hydraulic systems
Seite
10.1 Hydraulic system 1....................................................................................... 94
10.2 How the hydraulic system works.................................................................. 95
10.3 Hydraulic system 2....................................................................................... 96
10.4 Hydraulic diagram........................................................................................ 96.1
10.5 Hydraulic diagram........................................................................................ 96.2
93
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
D2 A8
Säkerhetsventil • Koppel-omvormer-
2 Veiligheidsventiel
4 Druckspeicher • Accumulator • Ackumulator •
Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
R2
6 Wärmetauscher • Heat exchanger •
WK R1 Värmeväxlare • Koeler
5
D7
R3 7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
8 WK-Ventileinheit • WK valve unit •
1 Ventilenhet WK • WK-ventielunit
12 D2 15 8.1 Magnetventil • Solenoid valve • Magnetventil •
R2 A8 D7 Magneetventiel
8.2 Drucksteuerventil • Pressure control valve •
P
Tryckregleringsventil • Drukregelventiel
8.3 Ausschaltventil • Shutoff valve •
16 Urkopplingsventil • Afschakelventiel
WK
9 Ventileinheit Kupplung/Bremse • valve unit
Clutches/Brakes • Ventilenhet Lamellkoppling •
R3 ventielunit Koppeling\Rem
D4
9.1 Magnetventil • Solenoid valve • Magnetventil •
PP R3
Magneetventiel
14 D8
18 Tryckregleringsventil • Drukregelventiel
Urkopplingsventil • Afschakelventiel
18 PVW PSCHM 10 Kupplung/Bremse A, B, C, D, E, F, G •
13
7 4 Clutches/Brakes • Lamellkoppling •
Koppeling\Rem
11 D2
10 11 Retarderregelventil • Retarder control valve •

Retarderstyrventil • Retarderregelventiel
3 D6 D5 12 Hauptdruckventil • Main pressure valve •
WK
8.1 9.1 Huvudtryckventil • Hoofddrukventiel
P
13 Filter • Filter • Filter • Filter
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 15
6 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
D1 16 Wandlergegendruck • Converter counterpressure •

8.3 9.3
Momentomvandlarens mottrycksventil •
17 Koppelomvormertegendruk
P D1 D1 R2 P
17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
Technische Änderungen vorbehalten • Subject to
technical change without notice • Rätt till tekniska 18 Luft • Air • Luft • Lucht
ändrigar förbehålles • Technische veranderingen
voorbehouden
WK
Ausschaltstellung
ECOMAT - HYDRAULIC 1 Position opened
Läge från
Uitschakelstand 4139 753 704 NK-A 02.92
10 Hydraulic systems – Retarder control valve 11 – HYDRAULIC 2 –

Pressure D2 is a supply pressure at the retarder con-
10.2 How the hydraulic system works trol valve. Pressure R3 is set according to air pressu-
re 18 introduced from outside the system. The amo-
Please refer to the hydraulic system diagrams unt of pressure R3 adjusts the retarder effect.
"ECOMAT – HYDRAULIC 1 – disengaged" or Pressure R3 passes through the cooler change-over
"ECOMAT – HYDRAULIC 2 – engaged" valve and heat exchanger into the retarder.
for clarification of how the components are connected.
This text explains the function of individual compo- – Accumulator 4
nents. To reduce retarder response time, air pressure 18 is
used to feed the oil accumulator volume into the re-
Description of hydraulic system tarder circuit.
– Pump 14 and filter 13 – Throttle pressure valve 17

The pump 14 draws oil from the sump through filter Normal operation: – HYDRAULIC 1 –
13. This only works when engine is running. Depending on the engine load condition, pressure D1
is created at this proportional solenoid valve and fed
– Main pressure valve 12 to pressure control valve 9.2.
The main pressure valve 12 sets the necessary
system pressure depending on whether the lock-up Retarder operation: – HYDRAULIC 2 –
clutch is open or closed. Depending on the R2 pressure (retarder braking tor-
que), pressure D1 is created and fed to the pressure
– Torque converter safety valve 3 control valve 9.2.
The torque converter safety valve 3 limits pressure
D2 towards the torque converter to a specified value. – Valve unit 9 (clutches, brakes)
After the solenoid valve 9.1 and shut-off valve 9.3
– Converter counter-pressure valve 16 are energized, a shift pressure is created from main
Pressure oil from the torque converter flows to the pressure P in the pressure control valve 9.2.
converter counter-pressure valve 16. This valve sets The amount of pressure during the pressure control
converter internal pressure A8 to a specified value. process is controlled by the pressure control spring
A8 pressure is transmitted to the torque converter and throttle pressure D1.
lock-up clutch valve unit 8. After the pressure control process is complete, main
pressure P is available at the clutches and brakes 10.
– Lubrication pressure valve 15 – HYDRAULIC 1 –
(retarder not operating) – Torque converter lock-up clutch valve unit 8
Pressure D4 downstream of the converter counter- This control process is identical to that of valve unit
pressure valve is transmitted through the cooler 9 (clutches, brakes), with one exception:
change-over valve and heat exchanger to the lubrica- During the pressure control process, the amount of
tion pressure valve 15 and reduced there to a speci- shift pressure is controlled by the pressure control
fied lubrication pressure. Pressure D7 is fed to the spring and A8 pressure (torque converter internal
planetary gear section 7. pressure).
– Lubrication pressure valve 15 – HYDRAULIC 2 – – HYDRAULIC 1 – During disengagement of clut-
(retarder operating) ches, brakes and torque converter lock-up clutch, so-
Air pressure 18 is used to actuate the retarder control lenoid valves 8.1 und 9.1 and shut-off valves 8.3 and
valve 11. The piston space in the cooler change-over 9.3 vent pressure lines to the various shift elements.
valve 5 is evacuated through control line D8 and
spring force forces the valve to switch over. Pressure
D4 downstream of the converter counter pressure
valve 16 is transmitted through the cooler change-
over valve to the lubrication pressure valve 15 as
pressure D7 and fed to the planetary gear section 7.
95
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
D2 A8 Säkerhetsventil • Koppel-omvormer-
2 Veiligheidsventiel
4 Druckspeicher • Accumulator • Ackumulator •
Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
R2
6 Wärmetauscher • Heat exchanger •
WK R1 Värmeväxlare • Koeler
5
D7
R3
7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
8 WK-Ventileinheit • WK valve unit •
1 Ventilenhet WK • WK-ventielunit
12 D2 15 8.1 Magnetventil • Solenoid valve • Magnetventil •
R2 A8 D7
Magneetventiel
P Tryckregleringsventil • Drukregelventiel
16 Urkopplingsventil • Afschakelventiel
WK 9 Ventileinheit Kupplung/Bremse • valve unit
Clutches/Brakes • Ventilenhet Lamellkoppling •
R3 ventielunit Koppeling\Rem
D4
9.1 Magnetventil • Solenoid valve • Magnetventil •
PP R3 Magneetventiel
14 D8 9.2 Drucksteuerventil • Pressure control valve •
18 Tryckregleringsventil • Drukregelventiel
Urkopplingsventil • Afschakelventiel
18 PVW PSCHM 10 Kupplung/Bremse A, B, C, D, E, F, G •
13 Clutches/Brakes • Lamellkoppling •
7 4 D5
Koppeling\Rem
11 D2
11 Retarderregelventil • Retarder control valve •
10 Retarderstyrventil • Retarderregelventiel
3 D6 D5 12 Hauptdruckventil • Main pressure valve •
WK Huvudtryckventil • Hoofddrukventiel
8.1 9.1
8 9 13 Filter • Filter • Filter • Filter
P
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 6 15 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
D1 16 Wandlergegendruck • Converter counterpressure •

Momentomvandlarens mottrycksventil •
8.3 9.3 Koppelomvormertegendruk
17
P D1 D1 R2 P
17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
Technische Änderungen vorbehalten • Subject to 18 Luft • Air • Luft • Lucht
technical change without notice • Rätt till tekniska
ändrigar förbehålles • Technische veranderingen
WK
voorbehouden
Einschaltstellung
ECOMAT - HYDRAULIC 2 Position locked
Läge till
Inschakelstand
4139 753 705 NK-A 02.92
10.4 Hydraulic diagram Drawing no.: 4139 700 957 (b)
4139 S 2103
96.1
10.5 Hydraulic diagram Drawing no.: 4139 700 988 (b)

Version for NBS
5('8&('35(6685(
Version for NBS
4139 S 2105
96.2
11 Engine governing system
11 Engine governing system 11.3 Load response characteristics of engine
D1 - course of curve (up- and downshifts)

11.1 Engine governor
Classification: load response characteristics of engine
An RQ governor (idling speed and top speed governor)
is required as standard for the following reasons:
Pressure differential X between idling speed
% to improve shift quality in all part-load ranges,
Code
and full-load [%]
at load sensor angle:
% to allow smoother driving.
0° 10° 20° 30° 40° 45°
In special cases, an RQV governor (all-speed governor) L01 0 0 33.33 66.66 100.00 100.00
may be necessary. This can lead to the following pro- P01 0 0 20.00 60.00 100.00 100.00
blems:
P02 0 0 0 50.00 100.00 100.00
% reduced shift quality in part-load range and P03 0 0 0 33.33 100.00 100.00
% less smooth drive characteristics. at load sensor angle:
The type of governor fitted is shown on the type plate of 0° 4° 16° 20° 35° 40°
the injection pump or governor. C01 0 0 75.00 80.00 100.00 100.00
at load sensor angle:
11.2 Load reduction
0° 5° 22° 30° 40° 45°
In special cases, load reduction can be used for engines
with torques above permissible values for the HP 600. C02 0 0 80.00 90.00 100.00 100.00
In such cases, please contact the ZF Application En-
gineering Dept. The following characteristic curves can be used to clas-
Load reduction or engine torque reduction in certain sify the load acceptance characteristics of engines:
transmission conditions prevents transmission overload. L01 (linear) Naturally aspirated engine
Control: The EST 18 produces output signal no. 722: P01 (Progressive 1) Turbo-charged engine
"max. torque release" (see also Section 15).
P02 (Progressive 2) High-powered turbo-charged
DANGER engine
For safety reasons, the control system must fulfil the P03 (Progressive 3) High-powered turbo-charged
following condition: engine with intercooler
If any control element malfunctions, there must be no
possibility that the maximum permissible transmission C01 Cummins specific
input torque for the HP 600 can be exceeded. characteristics
C02 Cummins specific

characteristics
97
98
11 Engine governor
11.4 Engine governor - further instructions All-speed governor (RQV)
11.4.1 Governor characteristics The all-speed governor sets an almost constant engine
speed depending on the setting of the control lever on
Idling speed and top speed governor (RQ) the fuel injection pump. We recommend using all-speed
The characteristic area of the two-speed governor shows governors for commercial vehicles with PTOs, for con-
that the governor only operates at idling speed and when struction equipment, tractors, boats and fixed machinery.
the engine reaches max. rpm. In the area between these
limits, engine torque is solely dependent on the accele-
rator pedal setting.
Governing linkage travel

Application: – On-road vehicles.
In order to improve driving characteristics, the dotted
part-load lines are often at an angle (fuel volume in-
directly proportional to engine speed).
Governing linkage travel
Engine speed
4139 S 0076
Characteristic graph of the all-speed governor

1 Idling speed set point
2 Full-load line
a Positive compensation at higher speed range
Engine speed
4139 S 0075
Characteristic graph of the idling speed and top Mixed governor

speed governor
1 Idling speed set point The mixed governor usually has all-speed governor
2 Full-load line characteristics up to 1200 rpm and two-speed
a Positive compensation at higher speed range characteristics above 1200 rpm.
b Ungoverned area
Determining the governor type

The governor type is shown on the injection pump or
governor identification plate,
or
you can check the governor type as follows:
Idling speed and top speed governor: with the vehicle in

Neutral, accelerate slowly. The engine speed rises to its
rated level after reaching a specific point.
All-speed governor: any specific engine speed can be
maintained at a stable level.
98.1
11 Engine governor
11.4.2 Using idling speed and top speed (RQ) or all-speed (RQV) governed engines with automatic transmis-
sions
Idling speed and top speed governor All-speed governor

Part-load upshifts Part-load upshifts
The accelerator pedal sets the engine torque. The accelerator pedal sets the rated engine speed.
The governor gives a proportion of the fuel injection The engine regulates the speed and the governor gives
volume corresponding to the proportion of the torque. full-load when the speed changes (upshift).
Consequence: slow acceleration, no torque jolt during Consequence: slow acceleration to the shift point, strong
the gearshift and generally restrained driving shift jolt, strong acceleration up to rated speed.
characteristics.
QHQJLQH
QHQJLQH 7RXWSXW
7RXWSXW
QRXWSXW
QRXWSXW
4139 S 0079 4139 S 0077
Part-load downshifts Part-load downshifts
Shift quality improved because the engine accelerates to Poor shift quality due to negative torque peaks.
synchronizing speed even under part-load. Cause: the engine does not accelerate to synchronizing
speed.
7RXWSXW QHQJLQH
QHQJLQH 7RXWSXW
7RXWSXW
QRXWSXW QRXWSXW
4139 S 0080 4139 S 0078
98.2
12 Peripherals
12 Peripherals
Page
12.1 Speed range selection system ...................................................................... 100

12.1.1 Push-button speed range selector ................................................................ 100
12.2 Load sensor A3 ............................................................................................ 103
12.2.1 Function ....................................................................................................... 103
12.2.2 Dimensions and technical data .................................................................... 104
12.3 Program change-over switch S5 .................................................................. 105
12.4 Temperature sensor A6 ................................................................................ 105
12.5 Temperature gauge A5 ................................................................................. 106
12.6 Accelerator interlock (anti-gas) ................................................................... 107
12.6.1 Y4 solenoid valve ......................................................................................... 107
12.6.2 Anti-gas cylinder ......................................................................................... 108
12.7 Kickdown switch .......................................................................................... 109
12.7.1 S1 kickdown switch (strong holding force) ................................................. 109
12.7.2 S1 kickdown switch (low holding force) ..................................................... 109
12.8 Retarder ....................................................................................................... 110
12.8.1 Reduction valves RV1, RV2, RV3 ............................................................... 110
12.8.2 Solenoid valve Y11 ..................................................................................... 111
12.8.3 Solenoid valves Y5, Y12, Y13 .................................................................... 112
12.8.4 2-way valve .................................................................................................. 113
12.8.5 Pressure switch S2 ....................................................................................... 113
12.9. Pressure switch S7 - Neutral at Bus Stop (NBS) ......................................... 114
12.10 Changeover contact and relay ...................................................................... 115
Please use Section 18 when specifying peripherals, this provides a systematic procedure
for each peripheral component.
Section 12, Peripherals and Section 18, Questionnaire are constructed to allow easy
cross-referencing.
99
12 Peripherals
12 Peripherals
12.1 Speed range selection system
12.1.1 Push-button speed range selector
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 617 103
Z view
Version Vertical R-N-D Version Vertical D-N-R
Version Horizontal D-N-R Version Horizontal R-N-D
AMP Mate-N-Lok
12 pin socket
Intake housing
Intake housing
AMP 12 pin socket
Mate-N-Lok 4139 S 2063
no. 926681-3 0659
055 323 Standard Combined
Contact pin cover plate cover plate
no. 926898-1
0659 055 294 A 102 + 1 153 ± 1
B 99 + 0.5 151 ± 0.5
C 31 + 0.5 31 + 0.5
Technical data
Rated voltage UN = 24 V Standard cover plate Combined cover plate

Operating voltage UB = 20–32 V Version Parts list no. Parts list no.
Current IAmax = 1 A Horizontal D-N-R 6006 017 192 6006 017 188
Operating temperature –20°C to +70°C Horizontal R-N-D 6006 017 194 6006 017 189
Vertical D-N-R 6006 017 195 6006 017 190
Storage temperature –40°C to +80°C Vertical R-N-D 6006 017 196 6006 017 191
100
12 Peripherals
Dashboard cut-out section
View Z
Version: Vertical R-N-D-2-1 Version: Vertical 1-2-D-N-R
Version: Horizontal 1-2-D-N-R Version: Horizontal R-N-D-2-1
Intake housing
AMP 12 pin socket
Mate-N-Lok
no. 926681-3
X
Contact pin
no. 926898-1
0659 055 294 AMP Mate-N-Lok
12 pin socket
Intake housing
4139 S 2064
Technical data Version Parts list no.

Rated voltage UN = 24 V Horizontal 1-2-D-N-R 6006 017 200
Horizontal R-N-D-2-1 6006 017 203
Operating voltage UB = 20–32 V
Vertical 1-2-D-N-R 6006 017 204
Current IAmax = 1 A Vertical R-N-D-2-1 6006 017 202
Operating temperature –20°C to +70°C
Storage temperature –40°C to +80°C
101
12 Peripherals
Dashboard cut-out section
View Z
Version: Vertical R-N-D-3-2-1 Version: Vertical 1-2-3-D-N-R
Version: Horizontal 1-2-3-D-N-R Version: Horizontal R-N-D-3-2-1
Intake housing
AMP 12 pin socket
Mate-N-Lok
no. 926681-3 X
Contact pin
no. 926898-1
0659 055 294 AMP Mate-N-Lok
12 pin socket
Intake housing
4139 S 2065
Technical data Version Parts list no.

Rated voltage UN = 24 V Horizontal 1-2-3-D-N-R 6006 017 208
Horizontal R-N-D-3-2-1 6006 017 210
Operating voltage UB = 20–32 V
Vertical 1-2-3-D-N-R 6006 017 211
Current IAmax = 1 A Vertical R-N-D-3-2-1 6006 017 212
Operating temperature –20°C to +70°C
Storage temperature –40°C to +80°C
102
12 Peripherals
12.2 Load sensor A3
12.2.1 Function
Gears are changed automatically depending on road

speed and engine load. Engine load is determined by the 8V9
position of the accelerator pedal and the control lever on
the injection pump.
The load sensor senses engine load mechanically by the

position of the control lever on the injection pump, and
converts this into an electronic signal.
This load signal is transmitted to the electronic control

unit (EST 18) where it is converted into a pressure sig-

nal on the basis of a characteristic curve which is
"High" Lever position _
matched to the engine. "Low"
stop
stop
The pressure modulation device in the transmission
ensures that the clutch engagement pressure is matched 4139 S 0034
to the engine load.
EST 18
2&
Load sensor Pressure regulator
4139 S 0035
NOTE
The pump filling control lever must not be pulled
towards Load during coasting or over-revving.
See Installation Guidelines Sections 11.2 to 11.5 for
installation of the load sensor.
103
12 Peripherals
12.2.2 Dimensions and technical data From drawing no.: 0501 311 587 (d)
Y view
4139 S 0037
Technical data ZF No. 0501 311 587 (d)
Operating temperature: –30°C to +120°C Key to drawing:

Storage temperature: –40°C to +120°C
Load on end stops: max. 55 Ncm (0.55 Nm) 8 Markings (for setting full-load/idling)
(stops must only be reached 9 Load sensor lever
at engine shut-off point) 10 ITT Cannon connector
11 Shrink-fit sheath
Protection type: IP 66 DIN 40050
Mounting bolts: Strength class 8.8 DIN 267 12 Connecting cable
Tightening torque: 8 (+ 4) Nm 13 PTFE membrane
Deep water fordability: Water column 1m
14 Identification, Model No.
Test duration 5h
Load reversals 50 15 Safety stops
Installation drawing: 0501 311 587 (d)
104
12 Peripherals
12.3 Program change-over switch S5 12.4 Temperature sensor A6

From drawing no.: 0501 204 926 (b) From drawing no.: 0501 308 844 (c)
Base of contact
Colour: white
4139 S 2049
Groove to DIN 3852,
shape A
ZF-No. 0501 204 926 (b)
Protection type: IP 65 before plug board
Standard shift element with clutch

Contacts Connection Switch pattern
1 opening
and
Plug connection
1 closing
switch
4139 S 2050
The key operated or locking switch is used to turn on
and off the switch elements (briefly or permanently)
which are currently connected in the circuit. ZF No. 0501 308 844 (c)
Locking switch position 3 (lock stop position at start or

finish of turn) can only be moved from the start to the Technical data
stop position if the key is inserted. The key can then be Perm. tightening torque: max. 30 Nm
turned to the right.
Operating voltage: 6 – 24 V
The key may be removed in each lock position. Operating temperature: –30°C to +150°C
for short periods (1 hour)
180°C at gauge
NOTE
Use sealing ring A 14x18 DIN 7603 Cu
Use no. 0634 801 038.
105
12 Peripherals
12.5 Temperature gauge A5 From drawing no.: 0501 204 074 (h)
Calibration
mark: white 0 - 4 clamping area
point Ø 0.5
Appropriate for pin

bushing 6.3
DIN 46247, plug set
deeper into housing
4139 S 2051
Technical data ZF No. 0501 204 074 (h)
Operating temperature: –25°C to +70°C Connection codes

Storage temperature: –30°C to +70°C G Sensor
(+85°C max. 1 hour)
Earth
Rated voltage: 24 V
+ Battery positive terminal
Operating voltage: 21.5 V to 30 V
S Buzzer
See Section 14 for further technical information.
106
12 Peripherals
12.6 Accelerator interlock (anti-gas)
12.6.1 Y4 solenoid valve From drawing no.: 0501 001 471 (c)

0[

0[

=

0[

Detail Z

5

5

¡

5

4139 S 2109
Technical data ZF No.: 0501 001 471 (c)

Nominal width: 2
Operating pressure: min. 0 kp/cm2 Key to drawing
max. 10 kp/cm2
Valve seat seal: Viton 1 Air inlet from supply
Temperature range: Medium +70°C 2 Air outlet to working line
Ambient –55°C to +100°C 3 Vent
Installation position: As required
X Order no. and delivery date stamped on
Voltage: min. 18 V DC
max. 28 V DC
Current: 0.430 A
Switch-on time: 100%
Power consumption: approx. 10 W
Magnet: With built-in Varistor
Leakage: max. 4 cm3/min.
107
12 Peripherals
12.6.2 Anti-gas cylinder From drawing no.: 6038 311 026 (c)

[

0

0

¡

¡K
¡

%
¡

&

$ ¡
1
1
'

(
4139 S 2111
Technical data ZF No.: 6038 311 026 (c)
Medium: Air WABCO no.: 421 410 039 0

Operating pressure: max. 8 bar Key to drawing
Thermal application range: – 40°C to +80°C
A Rubber sleeve
Effective piston Ø: 30 mm
B 19 mm AF
C Spring area on graph
D Working area on graph at 4.5 bar
E Stroke
108
12 Peripherals
12.7 Kickdown switch
12.7.1 S1 kickdown switch (strong holding force) From drawing no.: 6007 603 030
4139 S 2112
A Switch-off point D Actuating force at switch point Parts list no.: 6007 203 181
B Stroke = 150 ± 20 N
C Holding force E Switch pattern
12.7.2 S1 kickdown switch (low holding force) From drawing no.: 6007 603 007 (e)
4139 S 2113
A Plug connections of various C Switch point 2 ± 1 mm Parts list no.: 6007 203 105
lengths according to collective D Over-pressure force 130 ± 20 N
drawing 0501 202 785
E Holding force 55 N ± 10 N
B Stroke
F Switch pattern
109
12 Peripherals
12.8 Retarder
See Section 7.10 for retarder control elements
12.8.1 Reduction valves RV1, RV2, RV3
¡

0$;
WABCO

0
¡
0[

0,1
0,1

¡
4139 S 2052
Modulated
ZF No. WABCO no.
pressure P2
RV1: 1.2 +0.1/–0.2 bar 0501 206 150 (a) 475 009 0210
RV2: 2 +0.1/–0.2 bar 0501 206 151 (a) 475 009 022 0
RV3: 3 +0.3 bar 0501 207 558 (a) 475 009 026 0
Technical data
Medium: Air 3
EDU
Max. operating pressure: Pe = 10 bar

Nominal width:: 12.5 mm2 = Ø 4 mm

Operating temperature: –40°C to +80°C

Installation position: As drawn

Key to drawing $
3
EDU59
1 Input pressure P1 %

2 Modulated pressure P2 3
EDU59

3 Vent 3
EDU59

Graph: 3
EDU

A Pressure limit at first fill
4139 S 2114
B Pressure limit after use
110
12 Peripherals
12.8.2 Solenoid valve Y11 From drawing no.: 0501 206 143

0 1P
¡
¡

0 1P

¡
WABCO

0[

0[

¡
( '
0[
: $%&2
$

9

4139 S 2053
Technical data ZF No.: 0501 206 143

Voltage: 24 +4.8/–2.4 V Key to drawing
Current type: DC
1 Air inlet
Rated current: 430 mA
2 Air outlet
Operating pressure: ) 10 bar
3 Vent
Thermal application range: –40°C to +100°C
4 Electronic control connection
** Material: Cu Zn 38 Pb 1 F 42
Surface protection Gal Ag 1 µm
5 After loosening knurled nut, magnet can be moved
to desired position.
111
12 Peripherals
12.8.3 Solenoid valves Y5, Y12, Y13 From drawing no.: 0501 206 144 (a)
¡
¡

$

0 1P

0 1P

¡

$

¡
WABCO

0[

0[ R

0[

¡
[

¡%
¡
100% E D
8

0[

843A
W ABC O

24 V

$$
¡
4139 S 2054
Technical data ZF No.: 0501 206 144 (a)

Voltage: 24 +4.8/–2.4 V Key to drawing
Current type: DC
1 Air inlet from supply
Rated current: 430 mA
2 Air outlet to working line
Operating pressure: ) 10 bar
3 Vent
Thermal application range: –40°C to +100°C
4 Electronic control connection
5 After loosening knurled nut, magnet can be moved
Protection type: IP 68 (JED-370) to desired position.
(acc. to DIN 40050)
* Material: JED -076 M1
Surface protection Gal Ag 1µm
112
12 Peripherals
12.8.4 2-way valve 12.8.5 Pressure switch S2

From drawing no.: 0501 203 261 From drawing no.: 0501 204 411 (c)
4139 S 2055 4139 S 2056
ZF No.: 0501 203 261 ZF No.: 0501 204 411 (c)
Westinghouse No.: A 434 208 000 0 Key to drawing:
Key to drawing: A Sealed with red safety coating
V = Supply B Breather opening with filter
Z = Cylinder C Stamped on: Manufacturer's code,

ZF No.
Technical data Date of manufacture: month, year
Nominal width: Ø 12 mm
Operating pressure: max. 8 kp/cm2 Technical data
Differential closing pressure: * 0.15 kp/cm2 Switch point: ON at 0.35 bar ± 0.15 bar
Medium: Air pressure relative to atmos-
Thermal application range: –40°C to +80°C phere
Weight: 0.25 kg Operating pressure: 10 bar
Pressure resistant up to: 30 bar
Tightening torque: max. 30 Nm
Pressure medium: Air
Rated voltage: 12/24 V
Protection type
to DIN 40 050: Connection acc. to IP-00
With customer-
specific plug: Contact space IP-64
113
12 Peripherals
12.9 Pressure switch S7 - Neutral at Bus Stop (NBS)

From drawing no.: 0501 311 584
4139 S 2056
ZF No.: 0501 311 584
Key to drawing:
A Sealed with red safety coating
B Breather opening with filter
C Stamped on: Manufacturer's code,
ZF No.
Date of manufacture: month, year
Technical data
Switch point: ON at 0.9 bar ± 0.2 bar

pressure relative to atmos-
phere
Operating pressure: 10 bar
Pressure resistant up to: 30 bar
Tightening torque: max. 30 Nm
Pressure medium: Air
Rated voltage: 12/24 V
Protection type
to DIN 40 050: Connection acc. to IP-00
With customer-specific plug: Contact space IP-64
114
12 Peripherals
12.10 Changeover contact and relay

From drawing no.: 6041 312 019
Key to drawing:
A Plug arrangement
B Order No.
C Plug pin end 6.3 x 0.8
DIN 46 247
D Switch pattern imprinted
Technical data
Rated voltage: 24 V
Load: 10/20 A
Protection type: IP 33 – IP 20 terminal
– DIN 40 050 when using
plug sockets
Ensure connection plug
points downwards!
4139 S 2059
ZF No.: 6041 312 019
Bosch No.: A 332 203 003
Appropriate relay socket: 6041 313 005
115
13 Neutral at Bus Stop (NBS)

Neutral at Bus Stop (NBS) has been developed with the
new EST 18 electronic control unit in order to save fuel
in city bus applications with frequent stops.
The transmission automatically shifts into Neutral (i.e.

the powerflow from the engine to the rear axle is inter-
rupted) whenever the following conditions are met:
% Accelerator pedal in idling position
% Signal from brake pressure switch (p * 0.9 bar) and /

or signal from bus stop holding brake
% Road speed almost zero (< approx. 3 km/h)
% 1st gear engaged
Once all these conditions are met, the transmission auto-

matically shifts into Neutral after a delay of 2 seconds.
As soon as any of these conditions is no longer met, 1st

gear is engaged again.
DANGER
The driver and vehicle manufacturer must be informed
without fail of the correct method of operating the ve-
hicle on uphill and downhill inclines.
Rolling backwards on hills must be prevented in the
usual way, by using the parking brake or bus stop hol-
ding 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. acce-
lerating or releasing the brakes by hand.
For connection diagram, see drawing 4139 720 045
116
Electrical connection diagram Pneumatic connection diagram Connection diagram
Bus stop holding

Multi-circuit
brake switch
protection valve
Pressure regulator
NBS pressure
Bus stop switch in front
holding brake axle brake circuit Solenoid shut-off valve ~ 3.0 bar
– Bus stop holding brake –
Air compressor
Solenoid Pressure limiting valve
valve NBS signal to
transmission Non-return valve
NBS
pressure
NBS signal to switch Manual
transmission 0.9 bar parking
brake valve
Bus stop holding brake solenoid valve and

Foot brake Combination
NBS pressure switch must be installed in Diaphragm
control valve cylinder
separate brake circuits. brake
Advantage: cylinder
Brake remains applied approx. 0.3 sec. af- NBS signal to
ter bus stop holding brake released. transmission
VA = Front axle
HA = Rear axle
4139 S 0074
117
From drawing no.: 4139 720 045 (a)
118
13 Neutral at Bus Stop
13.1 Neutral at Bus Stop

Application restrictions
The Neutral at Bus Stop (NBS) application was develo-

ped for city buses.
NBS is not available with the HP 600.
Neutral shift “F” Drawing no.: 4139 601 167 (a)
4139 S 2089
Key to drawing NBS activated:

For NBS operation, piston chambers F1 and F2 are initi-
F Piston ally vented, then piston chamber F2 is filled with redu-
F1 External piston chamber ced pressure to move the piston into "Ready position".
F2 Internal piston chamber With the piston in "Ready position", the clutch can be
closed immediately for starting off.
118.1
14 Temperature monitoring
In order to monitor oil temperatures downstream of the
converter and retarder, a temperature sensor or tempera-
ture switch is fitted in the cooler connection.
14.1 Temperature sensor A6

From drawing no.: 0501 308 844 (c)
Base of contact
Colour: white
Groove to DIN 3852,

shape A
Switch pattern
4139 S 2050
Technical data
Perm. tightening torque: max. 30 Nm

Operating voltage: 6 – 24 V
for short periods (1 hour)
180°C at gauge
NOTE
Use sealing ring A 14x18 DIN 7603 Cu
Use no. 0634 801 038.
119
14.2 Temperature gauge A5 From drawing no.: 0501 204 074 (h)
Information from the temperature sensor is sent to a temperature display gauge. The gauge scale is divided into 3
coloured 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)
Calibration mark:
white point Ø 0.5
0 - 4 clamping area
Appropriate for 6.3

plug terminal DIN 46247,
plug set deeper into housing
4139 S 2051
Technical data Connection codes
Operating temperature: –25°C to +70°C G Sensor

Storage temperature: –30°C to +70°C Earth
(+85°C max. 1 hour) + 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, e.g. if temperature reaches excessive le-
vels (145°C) a warning lamp and/or acoustic warning
signal can be switched on.
Retarder
Retarder torque reduction can also be activated by the
temperature gauge.
Key to drawing:
Y5 Retarder torque reduction solenoid valve

Y1 Retarder solenoid valve
K9 Temperature control relay
RV1 Pressure reduction valve 1.2 bar
A5 Temperature gauge
4139 S 2057
S Output S
See Section 7.7 diagrams of retarder control systems
120
14.3
5>2KP

323.805/14/1

U = 6.3; Rv = 83 Ohm
Test medium: Marlotherm-S

Temperature sensor resistance curve

Temp. Res. (1 ) Tol. (%)
0.0 3219.7 12.5
10.0 1887.8 12.5
20.0 1162.6 12.7
30.0 728.8 13.6

40.0 473.3 14.4
50.0 315.8 14.7
60.0 216.1 14.7
70.0 152.0 14.6

80.0 109.8 13.9
90.0 81.3 13.3
100.0 61.2 10.3
110.0 46.8 11.5

120.0 36.5 10.6
130.0 28.9 10.8
140.0 28.1 11.6
150.0 18.7 12.1

$&
120.1
15 EST 18 electronic control unit
15 EST 18 electronic control unit This guarantees a constantly high level of shift comfort
throughout the transmission service life.
15.1 How the EST 18 works
If the specified shift time cannot be obtained using this
The electronic control unit controls and monitors the self adjustment facility (e.g. damage to transmission
function of the ZF Ecomat transmission. components, insufficient oil etc.), the driver is informed
of this condition. This helps to prevent further transmis-
The electronic control unit receives various data from sion damage.
the vehicle and transmission (direction of travel, drive
range, engine load, turbine speed, vehicle speed etc.) The torque converter lock-up clutch fitted in the trans-
and processes these into signals used for controlling the mission is opened and closed by the electronic control
transmission hydraulics. unit depending on load and speed. A starting interlock
prevents the engine being started if the transmission is
The electronic control unit selects from a range of gear not in Neutral.
shift speeds which can be adapted to suit the vehicle
drive resistance. This guarantees economical driving and Driving safety is increased by various protection devices
good performance. to prevent operator error and incorrect driving styles.
Gear shift characteristics are specified by ZF in coope-
The electronic control unit is capable of self-diagnosis
ration with the vehicle manufacturer.
(ZF MOBIDIG 200 diagnosis device) and is compatible
If desired, it is possible to have two independently selec- with all diagnosis devices fitted with ISO Standard DIS
table drive programs. 9141 interfaces. Sporadic and continuous faults are sto-
red in a permanent memory and may be called up any ti-
The electronic control unit recognizes incorrect adjust- me using the diagnosis device. In addition, it is possible
ments and load sensor changes, and compensates for to display faults using the central warning display as
these automatically within a specified range. well as using a flashing code lamp in the vehicle.
During each gear shift, the electronic control unit regu-
lates shift pressure so as to ensure standard shift times
independently of temperature or external influences.
Block circuit diagram (example)
Power Safety cir- Data inputs/ communication

supply cuit outpus ports
Speed range
selector
Shift
solenoids
Digital
PTO signal inputs
Digital ou- Converter lock-up
Kickdown clutch solenoid
signal tputs
Microcomputer Retarder control
Brake signal Exhaust brake
control
Starter interlock
nturbine Antigas control
Speed
Active preselect
noutput inputs interlock
etc.
Diagnosis
Diagnosis Diagnosis
Program Diagnostic
memory memory Rheostat Shift pressure re-
Load condi- Analog gulator
tion etc. inputs Diagnosis
4139 S 2058e
121
15.2 Standard functions 15.3 Optional functions
% Economical drive program % Neutral at Bus Stop (NBS)
% Adaption to vehicle and engine using load-dependent % PWM interface for load signal from electronic acce-
shift points lerator or EDC equipment (in connection with
EST 18 E)
% Adaption to drive resistance using speed-dependent
shift points % Second drive program
The electronic control unit can be fitted with two
% Shift comfort and transmission protection using pres- different drive programs. The drive program required
sure controlled shift sequences can be selected using a switch fitted to the dashboard
% Self-adjustment function if load sensor misadjusted or the vehicle power supply junction box (see Section
(± 10%) 12, Program change-over switch S5).
% Increased driving safety using various functions to

prevent operator error and incorrect driving style
% Permanent error memory to store transmission sy-

stem faults
% On-board diagnosis using flashing code
% Electronic control unit with self-diagnosis facility,

compatible with various diagnosis devices to ISO
Standard 9141.
4139 S 2061
122
15.4 Installation requirements
When installing the EST 18, attention should be paid to % The positive (+) supply (terminal 15 or ignition)
the following points: must only be switched on or off with the vehicle sta-
tionary.
% The EST 18 must be installed in the vehicle in a
suitable location where it is protected from: % For the following work, the ignition must be
switched OFF and the plug connector must be dis-
– excessive atmospheric humidity connected from the EST 18:
(max. +40°C / 95% humidity)
– extreme temperatures – For electrical repairs to the vehicle and especially
(min. –40°C /max. +70°C) for electric-arc welding!
– dust build-up – For insulation tests on the electrical equipment.
– water splash
% Jump-starting the engine:
% For these reasons, the EST 18 should be located in a To prevent excess voltages, we recommend using a
dry compartment. Recommended locations are: buffered jump starting unit, or connecting an adequa-
tely charged battery in parallel.
– In the driver's cab
– Inside the vehicle
– In the electrical junction box
EST 18 technical data
% The permitted installation points must be complied
with (See Section 15.5). Other positions can only be Rated voltage: U = 24 V
approved after consultation with the ZF Application Operating voltage: U = 21-30 V
Engineering Dept. (32 V – 1 h, 45 V – 5 min)
% EST 18 housing requirements: Power consumption: Imax. = 6 A

Resistance to ) 2 ms: ± 200 V (DIN 40839)
– Ease of access, transient voltages: ) 0.1 ms: ± 150 V (DIN57839)
– In single-pole vehicle electronic systems (negati- ) 150 ms: 122 V
ve battery terminal connected to vehicle chassis),
Resistance to electro-
good earth connection to the vehicle chassis
magnetic radiation: 100 V/m (10 kHz – 1 GHz)
(otherwise an earthing cable - minimum cross
section area 2.5 mm2 and max. length 0.5 m - Emitted interference: Conducted = VDE 0879 T3
must be installed). Grade 5
Radiated = 0.5 mV/m
– In dual pole vehicle electronic systems (negative
Temperature range: Operating: –40°C to +70°C
terminal of battery isolated from vehicle chassis)
Storage: –40°C to +85°C
the EST 18 housing must be isolated from the ve-
hicle. Humidity: + 40° at 95% relative atmos-
phere humidity
% Ensure min. 150 mm movement arc for 55 pin plug
Resistance to vibrations: 5 g (10 Hz to 1 kHz)
so it can also be removed from the installed EST 18
housing for servicing. Resistance to
shock loads: 10 g
% In the following cases, the EST 18 must not be ener-
Protection type: IP 54, DIN 40050 Sheet 8
gized. Switch ignition OFF and remove the ignition
key:
– when connecting the EST 18 to the vehicle circuit

– when disconnecting the 55-pin connector
– when disconnecting the battery from the vehicle
circuit.
NOTE
Do not install the EST 18 on vibration dampers!
123
15.5 EST 18 dimensions
I II
Road surface
4139 S 0043
Key to drawing: Installation drawing:
I = view in direction X 6009 633 001 (b)

II = installation positions
A = horizontal
B = vertical (standard installation)
C = permissible inclination
* minimum distance for disconnecting plug including
test adapter.
124
15.6 Circuit diagram Drawing no.: 4139 720 001 (c)
Key to drawing:
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
A1 ELECTR. CONTROL UNIT EST 18 K1 RELAY, ENGINE BRAKE S1 SWITCH, KICKDOWN

A2 SPEED RANGE SELECTOR K2 RELAY, GEAR SIGNAL S2 SWITCH, RETARDER-CONTROL
A3 LOAD SENSOR K3 RELAY, SPEED SIGNAL S3 SWITCH, ENGINE BRAKE
A4 TRANSMISSION HP 500/590/600 K4 RELAY, DETENT SOLENOID S4 SWITCH, LOCK-UP CLUTCH OPEN/UPSHIFT INTERLOCK
A5 TEMPERATURE GAUGE K6 RELAY, STARTER INTERLOCK S5 SWITCH, PROGRAM SELECTION For pin patterns, see last page
A6 TEMPERATURE SENSOR K7 RELAY, NEUTRAL S6 SWITCH, EXTERNAL GEAR INTERLOCK
A7 DIAGNOSIS UNIT (SPEED RANGE SELECTOR) S7 SWITCH, NEUTRAL AT BUS STOP (NBS)
A8 PWM INTERFACE (OPTIONAL) K8 RELAY, REVERSING LAMP S8 SWITCH, NEUTRAL EXTERNAL
K9 RELAY, TEMPERATURE WARNING
F1 FUSE 8 AMPS K10 RELAY, RETARDER "ON" Y1 SOLENOID VALVE, RETARDER MV1
F2 FUSE 8 AMPS Y2 SOLENOID VALVE, RETARDER ACCUMULATOR MV2
F3 FUSE 8 AMPS Y3 SOLENOID VALVE, PTO
Y4 SOLENOID VALVE, ANTI-GAS
H1 LAMP, STATUS MONITORING Y5 SOLENOID VALVE, RETARDER TORQUE REDUCTION
4139 S 0032
125
15.7 Wiring diagram Drawing no.: 4139 720 002 (c)
Key to drawing
ITEM DESCRIPTION ITEM DESCRIPTION
A1 ELECTR. CONTROL UNIT EST-18 K8 RELAY, REVERSING LAMP

A2 SPEED RANGE SELECTOR K9 RELAY, TEMPERATURE WARNING
A3 LOAD SENSOR K10 RELAY, RETARDER "ON"
A4 TRANSMISSION HP 500/590/600
A5 TEMPERATURE GAUGE S1 SWITCH, KICKDOWN
A6 TEMPERATURE SENSOR S2 SWITCH, RETARDER CONTROL
A7 DIAGNOSIS UNIT S3 SWITCH, ENGINE BRAKE
Locate open connector systems in dry A8 PWM INTERFACE (OPTIONAL) S4 SWITCH, LOCK-UP CLUTCH
OPEN/UPSHIFT INTERLOCK
compartment
F1 FUSE 8 AMPS S5 SWITCH, PROGRAM SELECTION
F2 FUSE 8 AMPS S6 SWITCH, EXTERNAL GEAR INTERLOCK
F3 FUSE 8 AMPS S7 SWITCH, NEUTRAL AT BUS STOP (NBS)
For pin patterns, see last page S8 SWITCH, EXTERNAL NEUTRAL
LENGTH INCLUDING CONNECTORS H1 LAMP, STATUS MONITORING
FROM TO LENGTH H2 LAMP, RETARDER OPERATION Y1 SOLENOID VALVE, RETARDER MV1
X CAUTION Y2 SOLENOID VALVE, RETARDER
X1 KN1 L1 1.0 m K1 RELAY, ENGINE BRAKE
For numbers 672 and 680, line routing to chassis KN1 KN2 L2 ......m ACCUMULATOR MV2
must be divided into two lines. KN1 X2 L3 ......m K2 RELAY, GEAR SIGNAL Y3 SOLENOID VALVE, PTO
KN1 X3/X4 L4 ......m K3 RELAY, SPEED SIGNAL Y4 SOLENOID VALVE, ANTI-GAS
X1 X25 L5 0.2 m K4 RELAY, DETENT SOLENOID Y5 SOLENOID VALVE, RETARDER TORQUE
KN2 X6 L7 1.5 m
K6 RELAY, STARTER INTERLOCK REDUCTION
KN2 X5 L8 2.0 m K7 RELAY, NEUTRAL (SPEED RANGE
KN2 X7 L9 1.5 m SELECTOR)
KN2 X8 L10 1.5 m
KN2 X9 L11 ..... m
4139 S 0033a
126
15.8 Functional description of vehicle electrical sy- Pos. 632 Type: OUT Function: Gear signal
stem 4139 720 043 (b) Output of BN(+) when a specific gear or gear range is
(based on wiring diagram engaged (programmable). Standard: output in 1st, 2nd
4139 720 002 and circuit diagram 4139 720 001) and Reverse gears. E.g. in order to reduce retarder
Abbreviations used: power in 1st and 2nd gears.
Pos: Item number of electrical lead (printed on Pos. 636 Type: OUT Function: Speed signal
the relevant lead or indicated in the circuit Output of BN(+) when a programmed road speed has
diagram) been reached.
Type: Type of signal (input, output, communi- Standard: output of BN(+) whenever the output
cation) frequency is > 40 Hz.
Example of use: interlock to prevent doors from opening
BN(+) Positive voltage in vehicle electrical system while the vehicle is in motion.
(control unit supply)
BN (Earth) Negative voltage in vehicle electrical Pos. 640 Type: IN Function: Kickdown
system (earth/ground) Input of BN(+) when the kickdown switch is actuated.
IN: Input signal to the ZF system The kickdown switch is a Normally-Open Contact.
BN(+) at this input moves the shift points towards
OUT: Output signal from the ZF system higher engine speeds.
COM: Signal intended for communication with
other equipment or with the driver; may be Pos. 644 Type: IN Function:
either an input or output signal Retarder request
RES: Free (reserve) lead Input of BN(+) whenever the retarder is to be engaged,
e.g. via a pressure switch in the retarder's pneumatic
circuit.
Vehicle electrical system 1
Pos. 648 Type: COM Function:
Pos. 620 Type: IN Function: Starter interlock Diagnosis lead K
Provides the starter interlock circuit with power at the Communication lead to ISO 9141 for linking up to intel-
vehicle electrical system's voltage. In order to allow the ligent test instruments.
engine to be started even if the control unit fuse has Can be connected to a central diagnostics system.
blown, this lead should be protected by a separate fuse.
Pos. 652 Type: OUT Function:
Pos. 624 Type: OUT Function: Starter interlock Temperature sensor output
Output of BN(+) when the speed range selector is in the Temperature signal output for connection of temperature
N position. display unit.
Example of use: controlling a relay that prevents the en- Note: this requires protection by additional fuse F3 only
gine from starting whenever the selector is not in the if the transmission has emergency control. Otherwise
NEUTRAL position. protected by F1.
Pos. 628 Type: OUT Function: Pos. 656 Type: IN Function:
Reversing light Vehicle circuit - positive
Output of BN(+) when the speed range selector is in the Power supply to the control unit. This supply lead is in
R position. parallel with Pos. 660 and is protected by an 8 Ampere
Example of use: the reversing light can be controlled via fuse.
this relay.
Pos. 660 Type: IN Function:
Vehicle circuit - positive
Supply voltage input for the control unit. This supply
lead is in parallel with Pos. 656.
127
Pos. 664 Type: IN Function: Vehicle electrical system 2

External gear interlock
Pos. 690 Type: OUT Function: Retarder output
Safety circuit - whenever a speed range (forward or re-
verse) is preselected from NEUTRAL, there must be a Output of BN(+) whenever the retarder is operating.
positive voltage BN(+) from the brake circuit, or one Examples of use: actuating an indicator lamp when re-
must appear within 2 seconds. tarder is operating; controlling advance pressurization of
Otherwise, the required speed range must be selected retarder pneumatic lines if they are of substantial length.
from NEUTRAL once more.
If the safety circuit is not used, a jumper to positive must CAUTION
be permanently installed (Pos. 656/Pos. 660). The retarder is switched off when changing gear and at
Example of use: acceptance of gear change via a switch low speeds. If a brake lamp is connected, this goes out.
in the brake circuit. The gear does not engage until the
brake is actuated.
Pos. 694 Type: OUT Function: Speed range selec-
Pos. 668 Type: OUT Function: tor in Neutral
Status monitoring Output of BN(+) whenever the speed range selector is in
Flashing signal output for status monitoring. This lead NEUTRAL position.
is in parallel with the speed range selector lamps. Example of use: locking the speed range selector if
Example of use: to supply BN(+) to a telltale lamp. there are two sets of driver controls.
Pos. 672 Type: IN Function: Pos. 698 Type: IN Function: External Neutral
Vehicle circuit - negative Switching off BN(+) when the transmission is switched
Vehicle earth. This pin is in parallel with Pos. 680. to NEUTRAL or is to be held in Neutral.
Pos. 680 Type: IN Function:

Vehicle circuit - negative CAUTION
If this function is not used, a permanent jumper to Pos. 656
Vehicle earth. This pin is in parallel with Pos. 672. or Pos. 660 must be installed.
CAUTION
Pos. 672 and 680 must be connected to the chassis via Example of use:
2 separate leads. a) Standard: external Neutral with self-holding feature:
Further gear selection is only possible after the speed
range selector has first been switched to NEUTRAL
position.
b) Optional: external Neutral without self-holding feature:

gear actuated as soon as BN(+) is present on Pos. 698.
DANGER
Suitable measures must be taken in the vehicle to
prevent gears being engaged accidentally.
Pos. 702 Type: OUT Function: Accelerator in-

terlock (anti-gas)
Output of BN(+) when the accelerator pedal and injec-
tion pump must be returned to or held in idling setting.
Example of use: if a gear is selected from NEUTRAL,
the anti-gas signal is emitted for 1 second to ensure that
the engine is at idling speed.
128
Alternative pin allocations for buses: CAUTION

The earth connection required must never be made
Pos. 702 Type: OUT Function: Speed signal II
using makeshift laboratory test cables or similar.
Second speed signal
Pos. 706 Type: IN Function: Lock-up clutch

open/upshift interlock A. To erase error memory
1. Switch off ignition
Input of BN(+) whenever:
2. Press diagnostics button and hold down
– Lock-up clutch is to be opened and upshift interlock 3. Switch on ignition
is to be activated, 4. Hold down diagnostics button for a further 3 seconds
– PTO is to be engaged. 5. Release diagnostics button A the error memory is
erased.
Pos. 710 Type: OUT Function: PTO release
Output of BN(+) when a signal requesting the PTO is
B. To call up flashing code
present and certain engagement conditions are met.
1. Ignition must already be switched on
then:
CAUTION 2. Depress diagnostics button for at least 2 seconds and
Signal output continues, even when engagement release.
conditions are no longer fulfilled. 3. The first error recorded in the error memory is
Standard engagement conditions are: shown as a flashing code.
accelerator pedal at idling position and engine speed
< 900 rpm. Each time the button is pressed again, the next error in
the memory is shown.
Pos. 714 Type: OUT Function: If there are no errors stored in the memory, the lamp
Speedometer signal goes out for as long as the diagnostics button is held
down. This applies in the case of standard programming,
Speedometer signal output from ECU (not allocated at
i.e. the diagnostics lamp is continuously lit during
present).
normal functioning.
Pos. 718 Type: COM Function: Diagnosis lead L Further modes are obtainable by using data field
(diagnostics push-button) programming.
Communication interface for test units complying with Pos. 722 Type: OUT Function: Detent solenoid
ISO 9141, which use lead L (initialization lead) in
Output of BN(+) when conditions for engagement are
addition to lead K.
fulfilled.
General notes:
Standard engagement conditions:
In order to carry out the following functions, the dia-
Accelerator pedal depressed, so that it is not in idling
gnostics lead (L) must be earthed briefly via a push-
position, and engine speed > 900 rpm.
button switch.
To prevent short circuits, one of the two variants
suggested below should be used:
a) Permanent installation of a push-button switch.

This switch should be installed in such a way that it
is not immediately accessible.
b) Push-button switch connected to the vehicle elec-
trical circuit connector via a connecting cable and
then removed after work has finished.
129
Alternative pin allocations for special-purpose vehicles: Pos. 738 Type: RES Function:
Pos. 722 Type: OUT Function: Load reduction Reserve (free) lead to transmission.
Output of BN(+) whenever engine torque is to be re- Pos. 742 Type: IN Function: NBS (Neutral at
leased. Bus Stop)
Pos. 726 Type: IN Function: Input of BN(+) if the NBS function is desired.
Program change-over Example of use on a city bus:
The transmission enters NBS mode whenever:
Input of BN(+) when switching over to the 2nd drive
program is required. a) BN(+) is present at Pos. 742 (e.g. via pressure switch
in brake circuit), and
Pos. 730 Type: IN Function: b) speed is less than approx. 3 km/h, and
Request engine brake c) the accelerator pedal is at idling position, and
Input of BN(+) when engine brake is to be engaged. d) 1st gear is selected.
If ABS is activated: interrupt input of BN(+). As soon as any of the above conditions is not fulfilled,
Pos. 734 Type: OUT Function: 1st gear is re-engaged immediately.
Engine brake output Pos. 746 Type: IN Function: PWM interface
Output of BN(+) when the engine brake is engaged by Input of engine load condition in the form of a pulse-
the control unit. width modulated signal which meets the relevant speci-
Whenever the engine brake is used, the lock-up clutch is fications.
closed and the downshift points are altered.
15.9 EST 18 diagnostics system Depending on their seriousness, errors are divided into 3
risk categories, defined as follows:
The EST 18 diagnostics system comprises self-diagno-
sis and condition-diagnosis. Category1: No immediate action necessary.
Category2: Have fault repaired in workshop as soon as
% Self-diagnosis possible.
The EST 18 self-diagnosis function is active each time Category 3: Return to workshop under part-load and
the vehicle electrical supply is turned on and during ve- rectify fault.
hicle operation.
DANGER
The self-diagnosis function monitors
• Category 3 indicates imminent danger of transmis-
– all analog and digital outputs
sion damage.
– vehicle electrical supply voltage
• The transmission monitoring system can no longer
– load sensor reference voltage
monitor all functions.
– speed sensor
– speed range selector (SRS) • Category 3 errors are automatically brought to the
– load sensor adjustment driver's attention by the button pressed on the push-
button switch flashing.
% Condition monitoring
Continuous monitoring of the following:
In order to read and delete entries in the error memory,
– transmission slip and to locate faults, the following equipment is available
– clutch slip time at ZF After Sales Service Centres:
– turbine speed sensor
% MOBiDIG 200 Diagnosis Device,
All error conditions registered by self-diagnosis and % PR 87 Test Device,
condition monitoring are stored in a permanent error
memory (EE PROM).
% Terminal box and test cables.
130
15.10 HST 18 auxiliary control unit

DANGER
The HST 18 auxiliary control unit was developed in or- All safety functions are de-activated when using the
der to move the vehicle during assembly and to provide HST 18 auxiliary control unit. Therefore, the following
an emergency control function should the EST 18 elec- points must be observed without exception:
tronic control unit malfunction.
% Never shift from N to D or from N to R unless the
The HST 18 auxiliary control unit is fitted to the 55-pin engine is at idling speed and the vehicle stationary.
plug instead of the EST 18 electronic control unit and
allows forwards and reverse gears to be engaged as The transmission can be shifted at higher speeds, but
shown in the table below. Gear shifts whilst driving are this will cause transmission damage.
no longer possible.
% Before shifting from Forwards to Reverse or vice
The following versions are available: versa, ensure that the vehicle is stationary.
HST 18/24 V Ecomat transmission % After shifting to D or R, wait approx. 2 seconds for
Code positive engagement before accelerating.
Parts list no. 4-,5- and 6-speed
6009 038 111 A+F 1st gear
6009 038 110 A+E 2nd gear
6009 038 112 A+D 3rd gear HST 18 technical data
6009 038 113 A+B 4th gear
Rated voltage: UN = 24 V
C + F* Rev. gear Operating voltage: UB = 21 to 30 V
(32 V - 1 h, 45 V - 5 min)
* for all HST 18 control systems Power consumption: Imax. = 3 A
Test voltage: UPR = 28 V ±0.5 V
Operating instructions for the HST 18 Load at outputs: Imax. = 1 A
Level of outputs: UA = UB -1.0 V
% Apply parking brake to prevent vehicle from rolling
away. Operating temperature: -20°C to +70°C
Storage temperature: -40°C to +85°C
% Move speed range selector to position N.
Resistance to
% Switch off engine and ignition. transient voltages: )2ms: ±200V (DIN 40839)
)0.1ms: ±150V (DIN 57839)
% Remove plug from EST 18 control device.
)150ms: 122V
% Connect plug to HST 18 auxiliary control unit and Resistance to vibrations: 5 g at 10 Hz to 1 kHz
secure.
Resistance to
% Start engine. shock loads: 10 g
Protection type: IP 4X
Engage gear using speed range selector.
N= Neutral
D= Forwards (gear is shifted

no up- or downshift occurs)
R= Reverse
131
Dimensions of HST 18
4139 S 2084
Key to drawing: Installation drawing:
* Minimum distance for disconnecting plug including 6009 638 002 (a)
test adapter.
Installation positions:
A = vertical (standard)
B = horizontal
C = permissible inclination
132
16 Cable harness and cable fitting requirements
16.1 Complete cable harness - standard - From drawing no.: 4139 720 030 (a)
Diagnosis Speed range

device selector
Load sensor
Transmission
Temperature
sensor
Solenoid valve
Electronic Y1 (retarder)
control unit
Solenoid valve
Y2
(accumulator)
See Section 15.7,

Wiring diagram for plug types
4139 S 2066
16.2 Complete cable harness - with in-line connections - From drawing no.: 4139 720 030 (a)

device selector Load sensor
Transmission
Temperature
sensor
Solenoid valve
Y1 (retarder)
Electronic
control unit
Solenoid valve
Y2
(accumulator)
See Section 15.7,

Wiring diagram for plug types
4139 S 2067
133
16.3 Cable connections 16.4 Wall duct disconnect

From drawing no.: 4139 720 030 (a)
When using complete cable system with in-line connec-
tions, the following bushing is required:
C1 - 28 - 21 PSN
VG 95 234
ZF No.: 0659 050 300
Housing shape to VG 95234
4139 S 2081
A Connection nut M 27 x 1
L The following lengths are available:
1 m, 2 m, 3 m, 4 m, 5 m, 6 m, 8 m, 10 m, 12 m
Shape C1 4139 S 2082
Dimensions:
VG 95234 - shape C1 or TBF-B
4139 S 2083
A = Bush side
B = O - ring
C = Pin side
16.5 Electrical system sockets for plugs BN 1 and BN 2
% 15-pin plug; MATE - N - LOK Bu

- Contact part for BN 1 -
ZF No.: 6029 199 005
% 15-pin plug; MATE - N - LOK St

- Contact part for BN 2 -
ZF No.: 6029 199 006
134
16.1.1 Complete cable harness, assembly drawing
&$87,21 35,17326126%/$&.,1.

21$///($'6
326,7,21180%(5
7$5*(7$''5(66
$77$&+$//&$%/(0$5.,1*
7$*672&0)5203/8*
&211(&7,21
3,13$77(51
352'8&7,21',0(16,21 &+(&.',0(16,21/,1(
*,9(1/,1(/(1*7+ /(1*7+,1&/86,9(3/8*
120',0 72/(5$1&(
3,13$77(5166+2:19,(:('2172&$%/(,16(57,216,'(2)3/8* &21'8&725/223,1*
&2,/0(7(5
4139 S 2100
134.1
Drawing no.: 6029 209 008(a)
16.6 Cable harness and cable fitting requirements From drawing no.: 6029 209 035
Technical data
3$5$0(7(56
7(03(5$785(
,1)250$7,21
&855(173(5
5(6,67$1&(
&211(&7('
3527(&7,21
72 ',1
,168/$7,21
0$;5$7('
5(6,67$1&(
7<3(:+(1
,16(57,21
&217$&7
&217$&7
6+((7
5$1*(
)25&(
27+(5
0$;
&20321(17
&211(&7257<3(6
$
$5($6'5<&20
& $335;1 P1 01 ,3 $ ,16(57,21&<&/(6

)253527(&7('
%26&+
'
3$570(176
& $335;1 P1 01 ,3 $ ,16(57,21&<&/(6

0$7(1/2.
1
63/,&(
& ² P1 01 ,3 $ ²
.
,55$',$7('39&
)/;/($'
P1P 01 ,168/$7,21
& ² ² $
PP 2876,'(²PP
/
%5$,'('
27+(5
² ² ² ² ² +$/2*(1 )5((
6/((9,1* &
0 ²
² ² ² ² ²
&$%/(675$3 &
*
&$%/(675$3 ²
² ² ² ² ²
:,7+/$%(/ &
&211(&7,217<3(6
)25813527(&7('
% ,16(57,21&<&/(6
&$1121 & $335;1 P1 01 ,3 $ :$7(53522)72 %$5
&
&267$/ & $335;1 P1 01 ,3 $ ,16(57,21&<&/(6
)
$5($6
685(6($/ & $335;1 P1 01 ,3 $ ,16(57,21&<&/(6
&RUURVLRQUHVLVWDQFHFRQQHFWRUV%&)
6DOWVSUD\WR',166K
&RQGHQVDWLRQZDWHUFOLPDWHWR',1.):K
8QSURWHFWHGSDUWVUHVLVWDQWWRSHWUROHXPVSLULWGLHVHOIXHOFROGVDIHW\
FOHDQLQJVROYHQWVDQGFRPPHUFLDOFOHDQLQJDJHQWV
4139 S 0031
135
17 ZF documents
17 ZF documents
17.1 Components
The engine, transmission and electronic control unit

(EST 18) of the Ecomat series microprocessor-con-
trolled automatic transmissions are individually matched
to each other. These three components may only be in-
stalled in a vehicle in a combination which has been do-
cumented by ZF.
Every application is documented at ZF under a Parts
List (specification) number and is available as a com-
puter printout (see example below).
CAUTION
Before installing any Ecomat transmission, check the
Parts List numbers on the identification plates to ensure
that the engine, transmission and ECU are as shown in
the documentation, i.e. that the details agree with the
computer printout.
In correspondence and inquiries, please always quote
the Parts Lists Nos. and Serial Nos. of the Ecomat and
the electronic control unit (EST 18)!
Computer printout (supply specification)
=))3$576/,6725*$1,6$7,21
02'8/$53$576:,7+7(&+1,&$/,1)250$7,2102',),&$7,2112 6+((7

D 615=6'(6&5+3 7,1)2

'(371('35(367(13/.$(, =%
326 9.) 3$57180%(5 '(6&5,37,21 7(&+1,&$/,1)250$7,21 $1$8$(
$ 3$576/,67(;75$&7$9$,/$%/(
$ &86720(5;;;;
$ &86763(&12 121(
6 9(+,&/('$7$
6 02'(/;;;;;; ;;;; ;
6 0$;*9: 7
6 5'<1 90$; $3352;.0+
6 5$ ,
6 ;;; 20+ .: 10
6 '5$:,1*6
6 (1*,1(,167$//$7,21
6 &219(57(5*5$3+
6 &211(&7,21',$*5$0
+,*+(5352'8&7&216,67,1*2)
E +3 9 )/$1*(02817(' &2$;,$/ 1%6
5(7$5'(5
F (67 (&8+3
+67 9 &/87&+(6$(
(
&211(&7,21
3(5,3+(5$/6 ;;;;
(1'2)02'8/$53$576/,67
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 18
136
17 ZF documents
17.2 Identification and engine compatibility data
4139 S 0001a 4139 S 0002
Description of fields on data plate
Transmission: Electronic control unit EST 18:
1 = Transmission Parts List No. (for matching 1 = EST 18 Parts List No. (for matching transmission,
EST 18, check documentation) check documentation)
2 = Transmission model designation, including 2 = EST 18 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 = Software no.
5 = Transmission ratio range 6 = Client's order no., if known to ZF
6 = Speedometer drive ratio 7 = Transmission model designation, including
7 = PTO model number of gear ratios
8 = PTO ratio Caution: check that number of ratios is correct!
9 = Approx. oil quantity required for first filling 8 = Transmission ratio range
10 = ZF List of Lubricants No. 9 = Engine model or name

10 = Rated output power of engine
137
17 ZF documents
17.3 Notes concerning ZF documents
A parts list is drawn up according to the specification of the ZF automatic transmission produced by the vehicle
manufacturer and ZF.
The parts list defines the complete list of parts to be supplied by ZF. See the example below.
Parts list no.: 4139 070 800 (example), -Transaction 4152-
$ 3$576/,67(;75$&7$9$,/$%/(
$ &86720(5;;;;
$ &86763(&12 121(
6 9(+,&/('$7$
6 02'(/%86&,7< ;
6 0$;*9062/2 7
6 5 '<1 9 0$; $335; .0+
6 5$ ,
6 ;;;; 0+ .: 10
6 '5$:,1*6
6 (1*,1(,167$//$7,21
6 &219(57(5',$*5$0
6 :,5,1*',$*5$0
6 9(+,&/('$7$

6 02'(/%86&,7< ;
6 0$;*90 7
6 5'<1 90$; $335;.0+
6 5$ ,
6 ;;;; 20+$ .: 10
6 '5$:,1*6
6 (1*,1(,167$//$7,21
6 &219(57(5',$*5$0
66+3 9 )/$1*( 02817(' &2$;,$/ 1%6
5(7$5'(5
$ 3$576/,67(;75$&7$9$,/$%/(
$ &86720(5;;;;
$ &86763(&12&2'(
$ $
) /!,167$/326,7,21 )/$1*(02817('
) 5!5$7,26
) + 5
) 6+,)7,1721(875$/:+(167$7,21$5<
) 6<67(035(6685( %$5
) $!287387&2$;,$/
) 38/6(6(1625= 1287387138/6(1625
) 2873)/$1*(5$2' %2/7 ;0;;
) 5$7('92/7$*( 92/732/(6

* !63(('2'5,9( ,
* 0!35(6685(02'8/$7,21(/(&75,&$/
* *!62/(12,'9$/9()255(7$5'(5&21752/)/$1*( 02817('
* 5(7$5'(55(7$5'$7,21 10
* -!+($7(;&+$1*(55($502817('
* )!2,/6803'((3
* .!2,/),// %
* &219(57(5 =):
0 '5$:,1*6
0 ,167$//$7,21
138
17 ZF documents
0 75$160,66,21 ',$*5$0

0 +<'5$8/,&6<67(0
0 6(&7,21

0 6(&7,21
0 6(&7,21
0 6(&7,21
0 6(&7,21
0 6(&7,21
0 2,/&$3$&,7< $335; /
0 2,/*5$'($&&72=) 7(0/
0 0$66 &$ .*
0 3$,17,1* 121(
0 3527(&7,9(&2$7,1* .$7., =)1
66(67 +3 1%6
$ &86720(5;;;;
$ &86763(&12&2'(
$ .=
63(('5$1*(
) 5$7('92/7$*( 92/7

) 7(03(5$785(5$1*(
) 23(5$7,21 72'(*&
) 6725$*( 72'(*&
0 '5$:,1*6
0 ,167$//$7,21
0 6(&7,21
0 '$7$'5$:,1*
0 $66(0%/<,16758&7,216
0 77% 10 530
0 0$66 $335; .*
6+67 9 &/87&+$(
$ &86720(5*(1(5$/ 0$5.(7,1*

$ &86763(&12 ,1&$7$/2*8(21'$7$6+((7
0 '5$:,1*6
0 ,167$//$7,21
0 6(&7,21
0 &,5&8,7',$*5$0
66&211(&7,21
63(5,3+(5$/6 ;;;;
$ &86720(5;;;;
$ &86763(&12&2'(
$ .=
0 '5$:,1*6
0 ,167$//$7,21
0 ,167$//$7,21
0 &,5&8,7',$*5$0
(1'2)3$576/,67(;75$&7
3$5712 '% 02'12 326B 0/( . 56
139
140
18 Ecomat questionnaire - preparation of parts lists
ECOMAT
PARTS LIST PREPARATION
QUESTIONNAIRE
Vehicle manufacturer: ...................................................

Customer contact: ................................................... Tel.: ...........................................
Telefax: .....................................
ZF contact: ................................................... Dept.: ........................................
Tel.: ...........................................
ZF parts list no.:
Customer code no.:
VEHICLE DATA:
Vehicle: .............................................................................
Type: .............................................................................
Topography: .............................................................................
Application: .............................................................................
Gross vehicle weight (GVW): ................................................... kg

Unladen weight: ................................................... kg
Trailer: ................................................... kg
Tyre size and make: .............................................................................

Dynamic tyre radius: rdyn = .......................................... m
Axle ratio: iA = ...........................................
Axle (make and type): .............................................................................
Axle combination: .............................................................................
Transfer gearbox: front-mounted iv = .............................................
rear-mounted iv = .............................................
Frontal area: A =.................. m2

Air drag coefficient: cd =..................
Rolling resistance: fR =.................. Standard values:
On-road, tarmac: fR = 0.010
On-road, concrete: fR = 0.012
Off-road, firm unsurfaced road: fR = 0.020
Off-road, soft unsurfaced road: fR = 0.040
141
ENGINE:
Make: .............................................................................
Type: .............................................................................
Model: .............................................................................
Max. engine power: P = ................... kW n = ................... rpm
Max. torque: T = ................... Nm n = ................... rpm
❐ ❐ ❐
Normally-aspirated Turbo-charged Turbo-charged with intercooler
Rating as per: ❐ DIN70 020

❐ ISO 15 85
❐ SAE 13 49
❐ ..................
Idling speed: ......................... rpm

Permissible max. speed: ......................... rpm
Injection pump
(make and type): .............................................................................
Governor characteristics: .............................................................................
Curve shape (load characteristics of engine; ☞ see Technical Manual, Section 11):
❐ L01
❐ P01
❐ P02
❐ P03
❐ C01
❐ C02
Particular remarks: .............................................................................

.............................................................................
.............................................................................
PERFORMANCE CALCULATION:
Torque converter diagram ...................................................

Traction diagram ...................................................
Acceleration diagram ...................................................
Braking diagram ...................................................
Top speed ................................................... km/h
142
ENGINE COOLING SYSTEM:

❐ Water ❐ Air
Cooling capacity, radiator: ................................................... kW
Water pump delivery: .............................. dm3/min at n = ......................... rpm
Flow rate through
transmission oil cooler: .............................. dm3/min at n = ......................... rpm
Water thermostat adjustment: Opening begins at ................................................ °C
Fully open at ................................................... °C
TRANSMISSION VERSION:
Decription ☞ see Technical Manual, Section 9
Installation drawing: .............................................................................
Customer order no.: .............................................................................
Transmission type: ................ HP ...........................
Neutral at Bus Stop (NBS): ❐ YES ❐ NO
Gear 1 2 3 4 5 6 R
Ratio
Vehicle electrical system voltage ❐ 12V ❐ 24V
❐ Earth via chassis 1-pin
❐ Positive via chassis 2-pin
❐ Floating chassis 2-pin
Transmission capable of fording ❐ YES NO ❐

☞ See Technical Manual for commercial vehicles, Section 9, Retarder type
INSTALLATION POSITION :
<L01> flange-mounted ❐ Engine interface drawing .........................................

Longitudinal inclination angle ...............................°
Engine interface, low .............................................°
Output low ..............................................................°
<L02> separate ❐ Input flange: Type: ..............................................

Outside dia.:....................................
Pitch circle dia.: .............................
Hole dia.: ........................................
No. of bores: ..................................
Centring dia.: ..................................
Transverse inclination permitted ± 3.0°
143
RETARDER
VERSION <G ......................> max. brake torque (incl. engine drag torque)
for direct drive
...................................................... Nm
ENGINE BRAKE ❐ YES ❐ NO

T =..................................................Nm
HEAT EXCHANGER
ARRANGEMENT <J........................>
................................................................................................................................................
COOLING WATER CIRCUIT:

❐
Cooler arrangement Full flow
❐ Part flow
¬
❐ ☞
Cold water side
❐ Hot water side
See Technical Manual
Section 8.5
❐ Pressure side
❐ Suction side ®
OIL SUMP <F ......................>
................................................................................................................................................
OIL FILL <K ......................>

................................................................................................................................................
OUTPUT <A ......................>

................................................................................................................................................
Output flange: Type: ....................................................

Outside dia.: ........................................
Pitch circle dia.: ..................................
Hole dia.: .............................................
No. of bores: .......................................
Centring dia.: ... ...................................
SPEEDO DRIVE ❐ YES ❐ NO
144
PTO <D..................> Application: ...................................................

........................................................................
PTO alignment ❐ 1 o'clock ❐ 11 o'clock
Ratio i = ..........x nEngine i = ..........x nEngine
Propshaft connection components:

% PTO flange
Type:...............................................................
Outside dia.: ..................................................
Pitch circle dia.: .............................................
Hole dia.: .......................................................
No. of bores:...................................................
Centring dia.: ... .............................................
Connection components for

direct connection of units:
% Adapter flange:
Connection to: ................................................
Centring dia.:..................................................
Hole pattern:...................................................
Hole dia.:........................................................
Centring depth:...............................................
% Bush:
Internal spline: ..............................................
Length: ..........................................................
........................................................................
........................................................................
........................................................................
ENGINE CONNECTION
DRAWING .................................................................................................
ENGINE CONNECTION .................................................................................................
COMPONENTS SUPPLIED .................................................................................................
.................................................................................................
SPECIAL TRANSMISSION
FEATURES .................................................................................................
.................................................................................................
.................................................................................................
.................................................................................................
145
PERIPHERAL COMPONENTS Parts list ..............

☞ See Technical Manual, Section 12
......................................................................................................................................
......................................................................................................................................
Wiring diagram: 4139 720 ....................... Pneumatic diagram: 4139 720.......................

☞ See Technical Manual, Section 7.7
PUSH-BUTTON SWITCH A2:
Parts list ...................................................
CONSOLE SWITCH:
Parts list ...................................................
CABLE CONNECTION: From .......................... To .......................................

Plug connection type: ..................................................................................
Length: ..................................................................................
PROGRAM CHANGE-OVER SWITCH S5: ..................................................................................
CABLE HARNESS: ☞ See Figs. I and II

Parts list ...................................................................
WALL DUCT DISCONNECT: ..................................................................................

(☞ See Technical Manual, Section 16.4)
VEHICLE ELECTRICAL SUPPLY: BN 1: ..................................................................................

BN 2: ..................................................................................
MATE-N-LOK contact parts ..................................................................................
(☞ See Technical Manual, Section 16.5)
LOAD SENSOR A3: ..................................................................................

TEMPERATURE SENSOR A6: ..................................................................................
TEMPERATURE GAUGE A5: ..................................................................................
TEMPERATURE SWITCH: ..................................................................................
ANTI-GAS: ❐ YES ❐ NO
❐ Solenoid valve Y4 ......................................................................
❐ Anti-gas cylinder.........................................................................
Cable connection: Length = ..................................................................................

(☞ See Fig. III)
146
KICK-DOWN SWITCH S1: S1 ❐ YES ❐ NO

Closing switch: ❐ YES ❐ NO
Parts list ........................................................................
Cable connection: Length = ........................................................................

(☞ See Fig. III)
RETARDER CONTROL ELEMENTS:

Hand-lever valve ............................................................ ¬
Foot pedal valve ............................................................ ☞ See Technical Manual, Section 7
Switch ............................................................. ®
REDUCTION VALVES
❐ 1.2 bar (RV1 retarder) ....................................................................... No.: ................
3/2-WAY VALVE (Y11) ........................................................................

Cable connection Length = .......................................................................
☞ See Fig. III
3/2-WAY VALVE (Y5, Y12, Y13) ........................................................................

No.: ........................................................................
Cable connection Length = ......................................................................
☞ See Fig. III No.: ........................................................................
☞ See
Technical
2-WAY VALVE (WV) ........................................................................ Manual,
Section 12
PRESSURE SWITCH S2 ........................................................................

☞ See Fig. III ........................................................................
PRESSURE SWITCH S7 ........................................................................

– NBS –
☞ See Fig. III ........................................................................
RELAYS ........................................................................
........................................................................
147
Fig. I Complete cable harness – Standard –

device selector Load sensor
L 1 = .........................
L 2 = .........................
Transmission
L 3 = .........................
Temp. sensor L 4 = .........................
Solenoid valve
Electronic Y1 (retarder)
control unit
Solenoid valve
Y2 (accumulator)
Notes: .........................................................................................
4139 S 2066
Fig. II Complete cable harness - with in-line connections -

device selector Load sensor L 1 = .......................
L 2 = .......................
Transmission
L 3 = .......................
Temp. sensor L 4 = .......................
L 6 = .......................
Solenoid valve
Electronic Y1 (retarder) L 13 = .......................
control unit
Solenoid valve
Y2 (accumulator)
Notes: ......................................................................................... 4139 S 2067
Fig. III Cable connection
A Connection nut M 27 x 1
L The following lengths are available:

1 m, 2 m, 3 m, 4 m, 5 m, 6 m,
8 m, 10 m, 12 m
4139 S 2081
148
ELECTRONIC CONTROL UNIT
Description: EST: .......................................
Customer reference no.:
Particular features: ............................................................................

Voltage: ❐ 12 V ❐ 24 V
Program change-over: ❐ YES ❐ NO
1 2 3 D N R
Drive ranges 1
Drive ranges 2
STANDARD EST PROGRAMS
P1 P2
❐ ❐ SUPER ECONOMY
❐ ❐ ECONOMY
❐ ❐ NORMAL
❐ ❐ POWER
SPECIAL PROGRAMS
Full-load conditions
P1
P2
Special customer requests: ............................................................................................................

............................................................................................................
149
LOAD REDUCTION: ❐ YES ❐ NO
STANDARD INTERLOCK: PTO output control at turbine speed nT < 900 min-1
and load threshold < S11
❐ Standard not required
Particular features: ..................................................................
..................................................................
..................................................................
GEAR SIGNAL:
% City bus/truck standard version gears 1 and 2:
% Coach standard version gear 1:
..................................................................
..................................................................
SPEED SIGNAL: Standard version: 40 Hz at output (except truck)

..................................................................
..................................................................
STATUS MONITORING: Activated by flashing code

❐ YES ❐ NO
EXTERNAL NEUTRAL: ❐ Standard with self-holding function

❐ Special request without self-holding function
150
19 Calculations and conversion tables
19 Calculations and conversion tables Please observe the following points concerning gradability:
% Gradability in the 1st mechanical gear must be the

19.1 Selection of driveline components
criterium, because the torque converter should only
Use the following vehicle performance formulae to used to help start the vehicle moving.
select driveline components. They enable you to select Reference value is S > 11%.
the best components to suit your special requirements In difficult terrain, a larger S value should be selected.
(e.g. required top speed, gradability etc. as a function of
% The following is valid in practice for extreme applications:
axle ratios, transmission ratios, tyre radii etc.).
Starting capacity, e.g. starting off is still possible up
The formulae can either be solved using the parameters to max. = 0.8 · Smax..
required or by iteration. (Smax. = gradability at stall-point).
Formulae:
Vehicle speed vF [km/h]
0.377 x rdyn x nT
vF = –––––––––––––
iG x iH
Maximum gradability Smax [%]

(air resistance WL 5 0)
TT x iG x iH x dtot
Smax = 100 x tan [arc sin ( –––––––––––––– – fR)]
G x 9.81 x rdyn
Gradability S at higher speeds vF

For inclines of S ) 10%, sin _ 5 tan _; error ) 0.5 %
1 TT x iG x iH x dtot
S = 100 [ ––––––– ( –––––––––––––– – 0.0473 x CW x A x VF2) – fR]
G x 9.81 rdyn
rdyn[m] Rolling radius fR [–] Rolling resistance

G [kg] Vehicle weight Asphalt, concrete, fR = 0.010 – 0.012
Beaten earth fR = 0.020 – 0.040
9.81 [m/s2] Acceleration due to gravity
CW [–] Coefficient of air Bus CW 5 0.6
nT [1/min] Turbine speed resistance Truck CW 5 0.8
TT [Nm] Turbine torque A [m2] Front section area Bus A 5 6m2
iG [–] Transmission ratio Truck A 5 8m2
iH [–] Axle ratio VF [km/h] Vehicle speed
dtot [–] Overall efficiency = dG x dH
= 0.95 x 0.95 5 0.9
Once the key data has been established, a computer program can be used if required to perform the vehicle perfor-
mance calculation.
151
19.2 Conversion tables
19.2.1 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 Knot = 1 nautical mile per hour = 1.852 km/h

In UK 1 nauticalmile (UK) = 6080 ft 5 1853 m.
19.2.2 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).
152
19.2.3 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),
yd3 = cubic yard (cu yd),
gal = gallon,
1) dm3 = 1 (liter).
19.2.4 Units of energy
Unit J kw h kp m PS h kcal ft lbf Btu
International standard 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
Non-international standard units
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 15°C by 1°C.

2) 1 Btu = Amount of heat required to raise temperature of 1 lb of water by 1°F.
1 therm = 105 Btu
153
Units of mass
154
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
1 gr = 1 0.03657 0.00229 1/7000 – – – – 0.064799 – –

1 dram = 27.344 1 0.0625 0.00391 – – – – 1.77184 – –
19.2.5 Units of mass
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
UK = United Kingdom, US = United States
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 = the mass of a body which when acted upon by a force of 1 lbf will accelerate at 1 ft/s2.
1 st (stone) = 14 lb = 6.35 kg (UK only)
1 qr (quarter) = 28 lb = 12.7006 kg (UK only, rare).
1 quintal = 100 lb = 1 sh cwt = 45.3592 kg
1 tdw (ton dead weight) = 1.016 t. The tonnage of freighters is measured in tdw (cargo + ballast + fuel + supplies).
1) Whenever cwt and tn appear without prefix long or short, they refer to the long cwt and long tn in the UK and short cwt and short tn in the US.
Units of force
1 kp = 9.80665 N 5 10N
1 lbf (pound-force) = 4.44822 N 1 N = 0.101972 kp 5 0.1 kp
1 pdl (poundal) = 0.138255 N = force which will produce an acceleration of 1 ft/s2 in a mass of 1 lb on which it acts 1 N = 0.224809 lbf
1 sh (sthène)* = 103 N 1 N = 7.233011 pdl
Units of pressure and stress
19.2.6 Units of force
Unit N/m2 +bar mbar bar N/mm2 kp/mm2 at kp/m2 Torr atm lbf/in2 lbf/ft2 tonf/in2
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
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 = 1mmWC = 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 –
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 (pièce)* = 1 sn/m2 (sthène/m2)* = 103; 1 dyn/cm = 1 +bar.
Standards: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
155
19.2.7 Units of power
Unit W kW kpm/s PS kcal/s kcal/h hp Btu/s
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
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
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, dhp = drawbar horsepower.
1 ft lbf/s = 1.35582 W
1 ch (cheval vapeur) (French) = 1 PS = 0.7355 kW
1 poncelet (French) = 100 kpm/s = 0.981 kW
Standards: DIN 66035 calorie - joule, joule - calorie, conversion tables

DIN 66036 Pferdestärke-kilowatt, kilowatt-Pferdestärke 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.
19.2.8 Temperature conversions
Conversion to
Unit
°C °F °R K
Degrees Celsius °C 1 °F = 9 °C + 32 °R = 9 °C + 491.7 K = 273 + °C

5 5
Degrees Fahrenheit °F °C = (°F – 32) · 5 1 °R = °F + 459.7 K = (°F – 32)

5 + 273
9 9
Degrees Rankine °R °C = (°R – 491.7) · 5 °F = °R – 459.7 1 K = 5 °R

9 9
Kelvin K °C = K – 273 9 9 1
°F = (K – 273) + 32 °R = K
5 5
156
19.2.9 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
19.3 List of dynamic tyre radii (Michelin)
Code Rdyn Code Rdyn
9.00 R 20 0.4934 m 9 R 22.5 0.4730 m

10.00 R 20 0.5077 m 10 R 22.5 0.4949 m
11.00 R 20 0.5252 m 11 R 22.5 0.5090 m
12.00 R 20 0.5443 m 12/80 R 22.5 0.5026 m
13.00 R 20 0.5459 m 12 R 22.5 0.5260 m
14.00 R 20 0.6008 m 13 R 22.5 0.5451 m
16.00 R 20 0.6493 m 11/70 R 22.5 0.4671 m
12/80 R 20 0.4894 m 275/80 R 22.5 0.4909 m
13/80 R 20 0.5085 m 295/80 R 22.5 0.5069 m
14/80 R 20 0.5283 m 315/70 R 22.5 0.4925 m
245/70 R 19.5 0.4060 m
265/70 R 19.5 0.4200 m
157
158
20 Oil grades, oil filters
Page
20.1 List of Lubricants TE - ML 14 .................................................................... 161
20.2 Oil filters ..................................................................................................... 165
159
160
Translation only for your information. German text is binding.
Commercial Vehicle and

Special Driveline Technology Division
Powershift transmissions for commercial vehicles List of lubricants TE-ML 14
x Approved lubricants x
Product groups for service fills Recommended alternatives
x x x
Ecomat Lubricant class 14A / 14B / 14C / 14E Monograde engine oils SAE 10W (2)
x Automatic Transmission Fluids (ATF)x
HP500, HP590, HP600x x
HP502C, HP552C,x See overleaf for approved trade products
HP592C, HP602C and oil change intervals
x
Particularly recommended:
ZF Ecofluid A PLUS (14E) (1)
x
(1) The fully synthetic ATF known as ZF Ecofluid A PLUS was developed specifically for use in Ecomat transmissions.
This combination of a synthetic base oil with a specially balanced additive package delivers superlative oxidation
stability and consistent friction characteristics. The viscosity level is ideally suited to this transmission and this
factor, combined with high resistance to scuffing and pitting, assures the unit of extremely valuable protection and a
correspondingly long service life for its bearings and gears. Another positive feature of ZF Ecofluid A PLUS is its flat
viscosity characteristics curve which makes it particularly well suited to operation in cold as well as hot climate
zones.
(2) SAE 10W monograde engine oils which satisfy one of the following specifications may be used under exceptional
circumstances: API CD/CE/CF-4/CF/CG-4/CH-4/SF/SG/SH/SJ or ACEA category A, B or E. The shift elements and
friction linings are coordinated to ATF. There is a risk that levels of shift comfort will suffer as a result of using
engine oil.
x
The list of lubricants TE-ML 14, Edition 01.04.2003 replaces all ZF Friedrichshafen AG
previous editions. The current list can always be obtained from D-88038 Friedrichshafen
all After-Sales Service points and on the Internet under phone: + 49 7541 77 7461x
www.zf.com / information / technical information. fax: + 49 7541 77 7319
x
Page 1 of 7 1205 754 114g / 04.2003
Continued ZF Friedrichshafen AG / List of lubricants TE-ML 14, edition 01.04.2003
Table 1: Recommended oil and filter change intervals for Ecomat transmissions:
Lubricant class Oil and filter change interval [km/year] Operating hours data
(See overleaf for approved trade for construction
products) Normal operating Tough operating machines
conditions conditions (3)
x x x
14A 30.000 km 20.000 km _
(also applies for monograde 1 x year 1 x year 1000 h
engine oils SAE 10W)
x x
_ 60.000 km 45.000 km _
14B 1 x every 2 years 1 x every 2 years 2000 h
x x
x x
_ 120.000 km 90.000 km _
14C 1 x every 2 years 1 x every 2 years 3000 h
x
x x
_ 150.000 km 120.000 km _
14E 1 x every 3 years 1 x every 3 years 4000 h
x
x
Table 2: The oil change intervals of Table 1 (above) apply to complete fills only. When a
different class of lubricant is to be used for the first time, the oil and filter change intervals of
the table below apply. After that, the change intervals of Table 1 apply again.
x Oil and filter change interval [km/year] Operating hours data
Changing class of lubricant for construction
from Normal operating Tough operating machines
conditions conditions (3)
x x
_ 45.000 km 30.000 km _
14A => 14B 1 x year 1 x year 1000 h
x
x x
_ 60.000 km 45.000 km _
14A => 14C 1 x every 2 years 1 x every 2 years 1500 h
x
x x
_ 75.000 km 60.000 km _
14A =>14E 1 x every 2 years 1 x every 2 years 2000 h
x
x x
_ 90.000 km 70.000 km _
14B => 14C 1 x every 2 years 1 x every 2 years 2500 h
x
x x
_ 120.000 km 90.000 km _
14B => 14E 1 x every 2 years 1 x every 2 years 3000 h
x
x x
_ 150.000 km 120.000 km _
14C => 14E 1 x every 3 years 1 x every 3 years 4000 h
x
x
(3) Average speed < 25 km/h and vehicle weight > 23 t or
average transmission oil sump temperatures > 95 °C.
Page 2 of 7 1205 754 114g / 04.2003

Lubricant class 14A

Mineral oil-based ATFs in accordance with Group standard ZFN 13015
x
Manufacturer (14A) Trade name (14A)
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL ATF D II D
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL ATF D III
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP ATF D 309
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL ATF 22
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL ATF 55 F-30589
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 86
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 98
BAYWA AG, MÜNCHEN/D BAYWA ATF 3000
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH ATF GM
BP INTERNATIONAL, PANGBOURNE, READING/GB BP AUTRAN MBX
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX ATF SUPER
CALTEX (UK) LIMITED, LONDON/GB CALTEX ATF-HDM
CALTEX (UK) LIMITED, LONDON/GB CALTEX TEXAMATIC 1322S
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TQ DEXRON III (F-30520)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TQ-D (21289)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TQ-D (22765)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TRANSMAX T
CHEVRONTEXACO, GHENT/B TEXAMATIC 4291
CHEVRONTEXACO, GHENT/B TEXTRAN PSM
CYCLON HELLAS S.A., MAROUSSI ATHENS/GR ATF TYPE D
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO ATF D2
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL ATF 220
FL ITALIA S.P.A., VILLASTELLONE/I TUTELA CAR GI/E
FL ITALIA S.P.A., VILLASTELLONE/I TUTELA GI/A
FUCHS PETROLUB AG, MANNHEIM/D TITAN ATF 3000
FUCHS PETROLUB AG, MANNHEIM/D TITAN ATF 4000
GENOL GMBH & CO., WIEN/A GENOL ATF MULTIFLUID
GINOUVES GEORGES SA, LA FARLEDE/F YORK 686
HUILES BERLIET S.A., SAINT PRIEST/F HRD STARMATIC 3
HYDROTEX, CARROLLTON, TEXAS/USA HY-TORQUE Z (ATF)
IGOL FRANCE SA, AMIENS/F ATF 420
IGOL FRANCE SA, AMIENS/F ATF 430
KRAFFT S.A., ANDOAIN/E ATF SYNTHETIC D3
KRAFFT S.A., ANDOAIN/E KRAFFT ATF 21247
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 14
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 15
LIQUI MOLY GMBH, ULM/D LIQUI MOLY ATF DEXRON IID
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA ATF SUPER
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYDRAULIKOEL ATF DEXRON II D
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL FLUID GETRIEBEOEL TYP P/CN
MORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC D II
MORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC SUPER ATF
OEL-BRACK AG, HUNZENSCHWIL/CH QUAKER STATE ATF Q3 PLUS
OMV AG, SCHWECHAT/A OMV ATF D II (D22427)
OMV AG, SCHWECHAT/A OMV ATF III
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MULTIPURPOSE TRANSMISSION FLUID II D
PANOLIN AG, MADETSWIL/CH PANOLIN ATF DEXRON III
PETROGAL S.A., LISBOA/P GALP TRANSMATIC D II
PRZEDSIEBIORSTWO MODEX-OIL, KWIDZYN/PL VECO MATIC IID
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL ATF II D
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL ATF III
S.A.E.L., MADRID/E GULF ATF D II D
SHELL & DEA OIL GMBH, HAMBURG/D DEAFLUID 3003
SHELL & DEA OIL GMBH, HAMBURG/D DEAFLUID 4011
SHELL & DEA OIL GMBH, HAMBURG/D DEAMATIC
SHELL ASEOL AG, BERN 5/CH ASEOL ATF DB UNIVERSAL
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TA (D-21631)
SLOVNAFT VURUP A.S., BRATISLAVA/SK MADIT AUTOMATIC
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL ATF III
STATOIL LUBRICANTS, STOCKHOLM/S STATOIL TRANSWAY DX III
SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B SUNAMATIC 149
SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B SUNAMATIC 153
TEDEX OIL SP.Z.O.O., PIASECZNO/PL TEDEX ATF DEXRON II D
TERPEL BUCARAMANGA S.A., BUCARAMANGA /CO TERMATIC HD
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F ELFMATIC G3
Page 3 of 7
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F FINAMATIC II D

TOTALFINAELF LUBRIFIANTS S.A., PARIS/F TOTAL FLUIDE ATX
UNIL S.A., SAUMUR CEDEX/F MATIC D
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE ATF TYPE D
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE DURABLEND ATF
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL ATF DEXRON III (F-30521)
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL ATF-M (22764)
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL UNITRANS S PLUS (F30359)
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL FLUID III F
Page 4 of 7
Lubricant class 14B

Semi-synthetic ATFs in accordance with Group standard ZFN 13015x
x
Manufacturer (14B) Trade name (14B)
CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRON SYNTHETIC ATF HEAVY DUTY
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA AAMCO SYNTHETIC BLEND ATF
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO ATF LT 71141
FL ITALIA S.P.A., VILLASTELLONE/I TUTELA HP 20
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 15 ED
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN MERCON V ATF
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN VHVI DEXRON III ATF
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TX (G-32003)
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TX (G-34077)
STATOIL LUBRICANTS, STOCKHOLM/S SYNTOMATIC
STATOIL LUBRICANTS, STOCKHOLM/S TRANSWAY S DX II
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F ELFMATIC G3 SYN
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F TOTAL FLUIDEMATIC SYN
Page 5 of 7
Lubricant class 14C

Synthetic ATFs in accordance with Group standard ZFN 13015x
x
(*) Not approved for special transmissions with ratio i=5.6-0.83/1.0
x
Manufacturer (14C) Trade name (14C)
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL ATF E-S (*)
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 92 S (*)
BP INTERNATIONAL, PANGBOURNE, READING/GB BP AUTRAN LTF (*)
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX ATF II E SYNTHETIC (*)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TRANSMAX Z
CEPSA LUBRICANTS S.A., MADRID/E CEPSA ATF SYNTHETIC (*)
CHEVRONTEXACO, GHENT/B TEXAMATIC S (*)
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ATF II E (*)
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL ATF SHC (*)
FL ITALIA S.P.A., VILLASTELLONE/I TUTELA TRUCK ATF 90 (*)
FUCHS PETROLUB AG, MANNHEIM/D TITAN ATF 5000 SL (*)
HUILES BERLIET S.A., SAINT PRIEST/F HRD STARMATIC S2 (*)
KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KOMPRESSOL-DEXRON SYNTH LTF (*)
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 14 SYNTHETIC (*)
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA ATF EKSTRA (*)
MOL-LUB LTD., ALMASFUZITO/H MOL ATF SYNT (*)
NEW PROCESS AG, TÜBACH/CH ATF SYNTH (*)
OMV AG, SCHWECHAT/A OMV ATF-S (*)
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY MATIC ATF DEXRON II E (*)
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO AUXON II E (*)
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO DX FLUID II TS (*)
PANOLIN AG, MADETSWIL/CH PANOLIN ATF SYNTH (*)
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL ATF II E (*)
REPSOL LUBRICANTES, MADRID/E MATIC SINTETICO (*)
S.A.E.L., MADRID/E GULF ATF SYNT (*)
SHELL & DEA OIL GMBH, HAMBURG/D DEAFLUID S
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL ATF XS (*)
SLOVNAFT VURUP A.S., BRATISLAVA/SK MADIT AUTOMATIC II E (*)
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL ATF DEXRON S (*)
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL FLUID ES-MAX (*)
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F ELFMATIC G2 SYN (*)
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F FINAMATIC S 6726 (*)
TOTALFINAELF LUBRIFIANTS S.A., PARIS/F TOTAL FLUIDE SYN FE (*)
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE SYNPOWER ATF (*)
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL UNITRANS Z
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF ECOFLUID A
Page 6 of 7
Lubricant class 14E

Synthetic ATFsx
x
Manufacturer (14E) Trade name (14E)
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF ECOFLUID A PLUS
Page 7 of 7
20.2 Oil filters
Only use ZF oil filters with 60+ mesh width.
165
166
21 Pin patterns
(VIEW ONTO FACE-

OF EQUIPMENT)
PIN PATTERNS
Item no. A1 A2 A3 A4 A5
DESCRIPTION AMP AMP CANNON CANNON VDO

55-PIN CONNECTOR MATE-N-LOK 4-PIN SS 19-PIN VG 3-PIN CONNECTOR
12-PIN CONTACT CONNECTOR CONNECTOR
PART CAP
A6,Y1,Y2,
Item no. Y3,Y4,Y5 A7 X3 X4 X25
DESCRIPTION ROUND INSTRUMENT AMP AMP AMP

CONNECTOR SOCKET MATE-N-LOK MATE-N-LOK MATE-N-LOK
2-PIN, K27 5-PIN, SOCKET 15-PIN CONTACT 15-PIN CONTACT 3-PIN CONTACT
PART CAP PART PLUG PART CAP
4139 S 0082
167
22 Index of key words
A
Accelerator pedal ...................................................... 8, 9, 129 Clutch activation combinations ....................................... 24.1
Accumulator ....................................................................... 95 Clutches ................................................ 11, 15, 16, 19, 20, 95
Add-on unit ....................................................... 65, 81, 85, 86 Coaxial transmission .......................................................... 12
Air resistance, coefficient of ............................................. 151 Code .................................................................................. 131
All-speed governor .......................................................... 98.1 Collected formulae – retarder cooling system ................. 64.1
Angle drive ...................... 12, 13, 14.1, 21, 81, 85, 86, 87, 89 Components ............................................................ 9, 10, 136
91, 92, 92.4 Compressed air supply ......................... 48, 49, 50, 51, 52, 53
Angle drive 60°/65°/80° ................................ 81, 85, 86, 92.4 Compressed air ............................................................... 9, 46
Angle drive 63° ........................................... 14.1, 81, 85, 92.4 Computer print-out ........................................................... 136
Angular alignment, incorrect .............................................. 29 Connection for temperature sensor ..................................... 23
Antifreeze ........................................................................... 63 Connection diagram .................................................. 117, 126
Anti-gas cylinder ................................................ 99, 108, 128 Continuous brake ................................................................ 46
Anti-gas ...................................................................... 99, 107 Continuous temperature ...................................................... 58
Anti-lock brakes (ABS) ........................................ 45, 54, 130 Conversion tables ..................................................... 151, 152
Automatic shift system ................................... 9, 10, 121, 131 Conversion factors ............................................................ 157
Auxiliary control unit ....................................................... 131 Converter .......................................... 10, 11, 15, 16, 39 - 44.6
Auxiliaries .............................................14.1, 42, 43, 85, 92.1 Converter counter-pressure valve ....................................... 95
Axle ratio .......................................................................... 151 Converter diagram ............................... 40, 42, 43, 44.1 - 44.6
Converter lock-up clutch ........................................ 15, 16, 39
Converter power losses ................................................. 42, 43
Converter slip ............................................................... 19, 20
B Cooler ..................................................................... 12, 57, 62
Balancing quality ................................................................ 33 Cooler change-over valve ................................................... 95
Basic torque converter graph curve ................. 40, 44.1 - 44.6 Cooler connection ......................................................... 9, 119
Basic transmission .......................... 10, 12, 13, 14.1, 21, 22.1 Cooler, separate, non-ZF .................................................... 57
Basic curve ......................................................................... 40 Cooling power .................................................................... 58
Block diagram .................................................................. 121 Cooling system ....................................................... 12, 57, 58
Brakes ....................................................... 11, 15, 16, 94, 116 Cooling water ..................................................................... 63
Braking capacity S on downhill slope ............................. 64.1 Cooling system graph ......................................................... 58
Braking level switch ........................................................ 56.5 Cooling water ..................................................... 8, 46, 62, 63
Braking power ........................................................ 64.1, 64.2 Cooling water pump ............................................... 59, 60, 61
Braking torque ...................................... 10, 46, 47, 56.6, 64.1 Cooling water inlet ............................................................. 23
Bus stop holding brake ..................................................... 116 Cooling water circuit .......................................................... 59
Bushing ..................................................................... 134, 146 Cooling system with retarder .............................................. 58
Cooling system without retarder .............................. 58., 58.1
Cooling water outlet ........................................................... 23
C Corrosion prevention .......................................................... 63
Cover for separate installation ......................................... 14.1
Cable connection ...................................................... 134, 148
Cross-link position ...............................................................33
Cable harness fitting requirements ........................... 133, 135
Current .............................................. 100, 101, 102, 107, 131
Cable harness .............8, 48, 49, 50, 51, 52, 53, 133, 135, 148
Cut-off time of the retarder .............................................. 56.7
Cable harness, Complete, assembly drawing ................ 134.1
Cyclic operation .................................................................. 58
Calculations ...................................................................... 151
Calculation of engine or retarder speed ........................... 64.1
Cannon plug cable connection ............................................ 23
Centre of gravity, position of .............................................. 23 D
Centring ring ....................................................................... 34 D2 pressure ......................................................................... 95
Change-over valve ................................................ 50, 51, 147 Description of hydraulic system ......................................... 95
Change-over contact and relay ................................... 99, 115 Diagnosis line (L-line) ...................................................... 129
Chassis ...................................................................... 126, 128 Diagnosis .................................................................. 121, 130
Choice of oil cooler ............................................................ 57 Diagnosis device ....................................................... 121, 130
Circuit cover (for torque converter) .................................... 86 Diagnosis switch ................................................................129
Circuit diagram ......................................................... 125, 127 Diagrams ......................................................... 45, 47, 48, 120
Clamping disk ..................................................................... 34 Dissipable heat .................................................................... 62
Climbing ability ................................................................ 151 Documentation ................................................... 65, 136, 138
169
Door closing device .......................................................... 116 H

Drive angles ........................................................................ 29
Drive program .................................................................. 122 Hand-lever valve ............................................ 8, 9, 48, 49, 50
Drive program, second ..................................................... 122 Heat build-up .......................................................... 40, 42, 57
Driveline components ....................................................... 151 Heat exchanger ............. 12, 46, 57, 58, 64.3, 71, 72, 73, 74.1
Dynamic radius ................................................... 42, 151, 157 74.2, 74.3, 95
Dynamic tyre radii .................................................... 141, 157 Heat exchanger capacity ..................................................... 62
Heat exchanger position ......................................... 65, 71, 72
Heat exchangers with hard-coat lining ............................ 64.3
Heat rejection ...................................................................... 42
E Holding force .............................................................. 99, 109
Ecomat system, complete ................................................. 8, 9 Hot water side ..................................................................... 60
Efficiency ..................................................................... 39, 42 HST 18 .............................................................................. 131
Efficiency, total ................................................................ 151 HST 18 dimensions .......................................................... 132
Electronic accelerator ....................................................... 122 HST 18 installation ........................................................... 123
Electronic control unit ...................... 8, 9, 121, 122, 131, 149 Hydraulic diagram ..................................................... 93, 96.1
Emergency control function ....................................... 54, 131 Hydraulic diagram (Version for NBS) ...................... 93, 96.2
Engine ........................................................... 40, 97, 137, 142 Hydraulic systems ...................................... 47, 93, 94, 95, 96
Engine brake ................................................... 45, 47, 54, 130
Engine connection .................................................... 34 - 38.4
Engine connection components .................. 19, 20, 65, 85, 86 I
Engine connection drawing ............... 35, 37, 38.2, 38.3, 38.4
Engine connection investigation ......................................... 36 Identification plate .................................................. 8, 23, 137
Engine drag torque .................................................... 47, 56.6 Idling speed ........................................................ 58, 131, 142
Engine flywheel ................................................... 19, 20.1, 34 Idling speed and top speed governor ............................... 98.1
Engine governor ........................................................ 97, 98.1 Idling speed losses ........................................................... 56.6
Engine power ...................................................................... 42 Impeller ............................................................................... 46
Engine power curve ............................................................ 43 Inertia, Moment of ....................................... 19, 20, 20.1, 157
Engine speed .................................................................... 64.1 Initial installation .................................................................. 2
Error memory ........................................................... 122, 130 Injector pump ........................................................................ 8
Error memory, deletion .................................................... 129 Input ........................................................................ 11, 15, 16
EST 18 .................... 8, 9, 10, 54, 97, 121, 123, 124, 130, 131 Input flange ............................................................. 68.2, 68.3
EST 18 diagnosis system .................................................. 130 Input fork ............................................................................ 30
Input speed ................................... 17, 18.1, 66, 66.1, 86, 92.1
Input temperature, oil ......................................................... 62
Input temperature, water ..................................................... 62
F Installation drawing for Ecomat ......................................... 23
Filters .................................................................................. 95 Installation guidelines ......................................................... 57
Flashing code ............................................................ 121, 122 Installation position ....... 65, 67, 68, 68.1, 107, 110, 112, 124
Flashing code, call up ....................................................... 129 Installation position and mountings .................................... 27
Flex plates ............................................................... 34, 39, 86
Floating axle ....................................................................... 32
Flow volume ....................................................................... 62 K
Fluid coupling ..................................................................... 39
Flywheel ............................................................................. 39 Kickdown ........................................... 8, 9, 99, 109, 127, 147
Foot pedal brake valve ............ 8, 9, 10, 48, 49, 50, 51, 54, 55
56.1, 56.3, 56.4
Formulae ..................................................................... 42, 151 L
Fresh water ......................................................................... 63 Leaf springs ........................................................................ 32
Full flow ................................................................. 59, 60, 61 List of lubricants ............................... 159, 161, 162, 163, 164
Load acceptance characteristics .......................................... 97
Load reduction ........................................... 18.2, 97, 130, 150
G Load sensor ........................................... 8, 9, 97, 99, 103, 121
Gear release ...................................................................... 128 Load sensor adjustment .................................................... 130
Gear signal ................................................................ 127, 150 Lock-up clutch ............................................ 10, 11, 19, 20, 39
Governor ............................................................................. 97 Lubricating oil pressure, measurement ............................... 23
Governor characteristics .................................................. 98.1 Lubricating oil pressure valve ............................................ 95
170
M Peripherals .......................................................... 99, 100, 146

Pin patterns ....................................................................... 167
Main pressure, measurement point ..................................... 23 Planetary gear section ............................................. 19, 46, 95
Main pressure valve ............................................................ 94 Planetary gear train ....................................................... 10, 39
Manually operated brake valve ............................... 56.1, 56.2 Pneumatic diagram ............................... 48, 49, 50, 51, 52, 53
Maximum engine torques ..................... 17, 18.1, 65, 66, 66.1 Powerflow ........................................................................... 15
Mixed governor ............................................................... 98.1 PR 87 test device .............................................................. 130
MOBiDIG ............................................................. 8, 121, 130 Pressure control valve ......................................................... 95
Modulator valve .................................................................... 8 Pressure measurement point, input side of converter ......... 23
Mountings ........................................................................... 27 Pressure modulation ..............................................................8
Multiplication ............................................................... 39, 42 Pressure reduction valve ....... 8, 9, 48, 49, 50, 51, 52, 53, 120
Multiplication ratio ....................................................... 42, 43 Pressure switch ........... 8, 9, 47, 48, 50, 51, 99, 113, 114, 117
Multi-section propshafts ..................................................... 33 Primary pump ..................................................................... 58
Primary retarder .................................................................. 46
Program change-over switch ...................... 99, 105, 122, 146
N Proportional solenoid valve ............................................ 9, 95
Neutral at Bus Stop (NBS) .............. 99, 114, 116, 117, 118.1 Propshaft angles, permitted ................................................ 29
122, 130 Propshaft connection .................................................... 27, 29
Neutral position .................................. 19, 20, 20.1, 20.2, 116 Proximity switch ........................................................... 47, 53
Pump ................................................................................... 95
Pump filling control lever ............................................. 9, 103
Pump speed ................................................................... 40, 42
O Pump torque ............................................................ 39, 40, 42
Oil connections ................................................................... 57 Pump wheel ........................................................................ 39
Oil cooler .............................................. 12, 13, 21, 46, 57, 58 Push-buttons ..................................................... 100, 101, 102
Oil cooler connection ................................................... 12, 13 Push-button switch ..................................... 8, 9, 99, 100, 130
Oil cooler, non-ZF ........................................................ 12, 13 PWM interface .......................................................... 122, 130
Oil cooler specifications ..................................................... 62
Oil dipstick ...................................................................... 80.6
Oil dipstick parts .............................................................. 80.5
Oil drain plug ...................................................................... 23
Q
Oil fill ................................................................ 65, 79 – 80.7 Questionnaire ........................................................ 65, 99, 141
Oil fill using dipstick .......................................................... 23 Questionnaire -
Oil filters .................................................................. 159, 165 Vehicle data ........................................................... 141
Oil flow rate through cooler ............................................ 58.1 Engine ................................................................... 142
Oil grades .......................................................................... 159 Vehicle power calculation ..................................... 142
Oil level check .................................................................... 57 Engine cooling system .......................................... 143
Oil level marks ................................................. 79, 80.5, 80.6 Transmission model .............................................. 143
Oil pumps ............................................................... 11, 15, 16 Peripherals ............................................................. 146
Oil sump ..................................... 65, 75 - 78.4, 80.5, 80.6, 95 Cable connections ................................................. 148
Onboard diagnosis ............................................................ 122 Electronic control unit ........................................... 149
Operating pressure ............ 107, 108, 110, 111, 112, 113, 114
Operating temperature ........58, 100, 101, 102, 105, 106, 110,
113, 114, 119, 120, 131 R
Output ................................................... 11, 12, 13, 15, 81, 82 R3 pressure .......................................................... 45, 56.7, 95
Output flange ............................ 19, 65, 81, 83, 85, 89, 91, 92 Rated voltage .... 100, 101, 102, 106, 113, 114, 115, 120, 131
Output flange, Ecomat ............................................ 65, 81, 83 Ratios, number of ......................................................... 10, 21
Output flange, 60° angle drive ...................................... 85, 89 Reaction member ................................................................ 39
Output fork .......................................................................... 30 Reaction time ................................................................... 18.2
Output speed ....................................................................... 39 Rear axle ratio ..................................................................... 42
Output torque ...................................................................... 39 Reduction valve .................................................. 99, 110, 147
Relay ....................................... 48, 49, 50, 51, 52, 53, 99, 115
Release, Certificate of ........................................................... 2
P Resistance to shock load ........................................... 123, 131
Parking brake .................................................................... 131 Resultant flexure angle ................................................. 29, 30
Part-load downshifts ........................................................ 98.2 Retarder ................. 9, 10, 11, 12, 13, 15, 16, 45 - 53, 58, 110
Part-load upshifts ............................................................. 98.2 Retarder control ........ 8, 9, 45, 47, 48, 49, 50, 51, 52, 53, 120
Parts list ...................................................................... 47, 138 Retarder control characteristics ................................. 45, 56.7
Parts list preparation ................................................... 65, 141 Retarder control elements .................... 45, 54, 56.1, 110, 147
Retarder control valve ........................................................ 95
171
Retarder control variants .............................................. 45, 47 T

Retarder operating lamp ....................... 48, 49, 50, 51, 52, 53
Retarder operation .......................................................... 8, 54 T-drive ................................................................................ 25
Retarder power ................................................................ 64.1 Technical data .............. 10, 99, 100, 101, 102, 104, 105, 106,
Retarder pressure, measuring point .................................... 23 107,108,110, 111, 112, 113, 114,
Retarder response time .............................................. 45, 56.7 115, 119, 120, 131
Retarder torque ....................................................... 45, 47, 95 Temperature display ................ 8, 9, 48 - 53, 57, 99, 106, 120
Retarder torque in Ecomat ......................................... 45, 56.6 Temperature display gauge ............................................... 120
Retarder torque reduction ........... 8, 9, 48, 49, 50, 51, 53, 120 Temperature conversion ................................................... 156
Retarder version ............................................................ 69, 70 Temperature monitoring ................................................... 119
Reversing lamp ................................................................. 127 Temperature sensor ............................ 8, 9, 99, 105, 119, 120
Rigid body ................................................................. 19, 20.1 Temperature sensor resistance curve ............................. 120.1
Risk categories .................................................................. 130 Temperature switch .......................................................... 119
Rolling radius ................................................................... 151 Terminal box .................................................................... 130
Rolling resistance ............................................................. 151 Throttle pressure ................................................................. 95
Rotational angles, incorrect ................................................ 29 Throttle pressure valve ....................................................... 95
Rotor ................................................................................... 46 Tightening torque ............................... 34, 105, 113, 114, 119
RQ governor .................................................................... 98.2 Torque ........................................................................... 42, 97
RQV governor ................................................................. 98.2 Torque converter .............................................. 10, 39, 40, 86
Rubber bearing ................................................................... 27 Torque converter clutch ...... 11, 15, 16, 19, 20, 39, 40, 54, 95
Torque curve ....................................................................... 42
Torque multiplication ................................................... 39, 40
Torque multiplication (starting off) .................................... 40
S Torque reduction ................................................................ 97
Self-diagnosis ................................................................... 130 Torque, stator ...................................................................... 39
Service brake ........................................................................ 8 Torsion springs ................................................................... 19
Shift pressure ...................................................................... 95 Total hardness of cooling water .......................................... 63
Shift throttle pressure measurement ................................... 23 Transfer gearbox ................................................................. 10
Shut-off valve ..................................................................... 95 Transmission, brief description .......................................... 10
Single-section propshaft ..................................................... 32 Transmission control .......................................................... 10
Solenoid valves ...................... 8, 9, 48, 49, 50, 51, 52, 53, 69, Transmission, description of .......................................... 9, 10
70, 95, 99,107, 111, 112, 120 Transmission, hydraulic system ................................... 9, 121
Special oil dipstick .................................................. 80.5, 80.6 Transmission mounting ................................................ 23, 27
Special oil fill .......................................................... 80.5, 80.6 Transmission oil cooler ................................................ 57, 60
Special oil fill tube .................................................. 80.5, 80.6 Transmission oil temperature ............................................. 57
Specification ............................................... 2, 12, 57, 65, 138 Transmission ratio ..................................................... 15, 16.1
Speed ............................................................................ 42, 43 Transmission specification ................................................. 65
Speedometer connection ............................................... 23, 82 Transmission type ............................................................... 21
Speed range selector ............................... 9, 99, 100, 130, 131 Transverse installation at rear 60°, 65°, 80° ....................... 25
Speed ratio .................................................................... 42, 43 Transverse installation at rear with 63° angle drive ........ 26.1
Speed sensor ..................................................................... 130 Turbine ......................................................................... 39, 40
Speed signal ...................................................................... 127 Turbine shaft ............................................... 19, 20, 20.1, 20.2
Stall point .......................................................................... 151 Turbine speed ......................... 19, 20, 20.1, 20.2, 40, 42, 121
Stall speed ..................................................................... 42, 43 Turbine speed sensor ........................................................ 130
Stall torque .................................................................... 42, 43 Turbine wheel ............................................................... 39, 42
Standard oil fill ................................................................ 80.7 Turbine wheel speed ....................................... 39, 42, 43, 151
Starter interlock ................................................................ 127 Turbine wheel torque ...................................... 39, 42, 43, 151
Starting ring gear ................................................................ 34 Twin lever injector pump ................................................ 18.2
Stator ............................................................................. 39, 46 2-way valve ................................................ 8, 9, 99, 113, 147
Stator mounted on freewheel .............................................. 10 Tyre radius .................................................................. 42, 151
Status monitoring ...................................................... 128, 130
Storage temperature ................. 100, 101, 102, 105, 106, 113,
114, 119, 120, 131
STU 8000 spur gear drive ..................... 14.1, 22.1, 92.1, 92.3
Sump temperature ...................................................... 58, 58.1
Supply pressure .................................................................. 95
System monitoring ........................................................ 9, 130
172
U
Units of area ..................................................................... 152
Units of energy ................................................................. 153
Units of force .................................................................... 155
Units of length .................................................................. 152
Units of mass .................................................................... 154
Units of power .................................................................. 156
Units of volume ................................................................ 153
Upshift interlock ............................................................... 129
V
Vehicle electrical system .................................. 8, 9, 127, 134
Vehicle electrical system plug .......................................... 134
Vehicle power calculation ................................................ 151
Vehicle speed .................................................................... 151
Vehicle weight .............................. 17, 18.1, 65, 66, 66.1, 151
Vibration ....................................................................... 29, 57
Vibration dampers ................................................... 28.1, 123
Vibration stability ..................................................... 123, 131
Vibration substitution model ..................................... 19, 20.1
W
W-position of propshaft connection ................................... 30
Wall duct disconnect .................................................134, 146
Warning buzzer .................................................................. 57
Warning contact .................................................................. 57
Warning lamp ............................................................. 57, 120
Water drain plug ................................................................. 23
Water inlet temperature ...................................................... 58
Water quality ................................................................ 63, 71
Water through-flow ............................................................ 58
Weight .............................................................. 21, 22.1, 92.1
Wiring diagram ................................................................. 126
Y
Yoke ....................................................................... 29, 83, 89
Z
Z position of propshaft connection ..................................... 30
173

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T E C H N I C A L M A N UA L

HP 500 HP 590 HP 600

4139 765 121a

Ecomat Technical Manual

Optimum procedure leading up to series production delivery:

% Specification of transmission and peripheral units performed by vehicle manufacturer and

% Initial installation inspection performed by ZF personnel

% Commissioning performed by ZF personnel

% Certificate of Release granted by ZF

% Correction work if required by Certificate of Release

1 The complete Ecomat system .................................................................................................................... 8

2 Description of transmission and technical data ...................................................................................... 10

3 Ecomat installation position in vehicle ..................................................................................................... 25

4 Installation position and mountings, propshaft connection ................................................................... 27

5 Connection to engine ................................................................................................................................. 34

8 Cooling system ............................................................................................................................................ 57

9 Transmission specifications ....................................................................................................................... 65

9.6 Oil fill < K.. > .............................................................................................................................. 79

10 Hydraulic systems ...................................................................................................................................... 93

11 Engine governing system ........................................................................................................................... 97

13 Neutral at Bus Stop (NBS) ........................................................................................................................ 116

14 Temperatur monitoring ............................................................................................................................. 119

15 EST 18 electronic control unit ................................................................................................................... 121

16 Cable harness and cable fitting requirements ......................................................................................... 133

17 ZF documents ............................................................................................................................................. 136

18 Ecomat questionnaire - preparation of parts list .................................................................................... 141

19 Calculations and conversion tables ........................................................................................................... 151

20 Oil grades, oil filters ................................................................................................................................... 159

21 Pin patterns ................................................................................................................................................ 167

22 Index of key words ..................................................................................................................................... 169

1 The complete Ecomat system

1 Interface to vehicle electrical system 15 Pressure switch S2 for retarder control

The complete Ecomat system

During the retarder torque reduction process, the re-

ZF Ecomat transmissions from ranges HP 500, HP 590 Torque converter

ZF automatic transmission 5 and 6 HP 500

1 Input 5 Clutches (A, B, C)

2.2 Transmission structure and auxiliaries

Using the basic transmission, add-on components can be

% Coaxial transmission with fitted oil cooler % Non-ZF oil cooler

2.2.1 Other auxiliaries

2.3 Transmission ratios and powerflow diagram

6 3.43 2.01 1.42 1.00 0.83 0.59 – 4.84 5.82

1 Input 5 Clutches (A, B,) h. % ' ( )

4-speed version: i = 3.43 - 1.0 5-speed version: i = 3.43 - 0.83

h. % & ' ( )

h. % & ' ( )

h. % & ' ( )

h. % & ' ( )

h. % & ' ( )

h. % & ' ( )

1 Input 5 Clutches (A, B, C)

2.3.1 Further ratios to those listed in Section 2.3

2.81 1.84 1.36 1.00 0.80 – – 3.97 3.52

2.4 Maximum engine torques and vehicle weights

Transmis- No. of Max. permissible input

Max. weight 28 t 26 t 18.5 t

HP 590 4 3.43 – 1.0 2800

HP 600 4 3.43 – 1.0 2650

HP 600* 4 3.43 – 1.0 2650

* Only after consultation with ZF Application Engineering Department

Trans- No. of Max. permissible input

Max. weight 28 t 26 t 18,5 t