ZF-Ecomat automatic gearbox for buses:

state of the art (B7)

ZF Italia S.r.l. - Reparto ST-T

Ecomat - State of the Art 1

 Ecomat Gearbox

Gearbo ECO MAT

x ECOnomy autoMATic

economy
automatic
hydrodynamic
with primary hydraulic retarder
modular
Ecomat - State of the Art 2
 Product development

System ZF-Ecomat ZF-Ecomat ZF-Ecomat 2 ZF-Ecomat ZF-Ecomat 4

Automatic gearbox Automatic gearbox Automatic gearbox 2 plus Automatic gearbox
Automatic gearbox

Use Urban and interurban buses, Tourist coaches, trucks

Automation Fully automated

Description Mechanical torque Regulated gear CAN 6-speed Optimised for Euro 4
transmission changes, Technology 6 in the City
diagnostics

ECU AEM 6 EST 18 EST 46/47 EST 146/147 EST 146/147

1978 1988 1998 2002 2006

Ecomat - State of the Art 3

ZF-Ecomat • Bus
 ZF-Ecomat in a constantly changing
landscape

ZF-Ecomat, EST18, ZF-Ecomat 2 for ZF-Ecomat 4,

ZF-Ecomat: regulated gear changes, EDC engines ZF-Ecomat 2 Plus, optimised for
series launch electronic diagnostics + CAN bus, EST 146/147 Euro 4
EST 46 C / 47C,
electronically-controlled
CityBus retarder

1978 1988 1998 2002 2006

1992 1995 2000 2003 2006 2009

Euro 1 Euro 2 Euro 3 Euro 4 Euro 5

EDC CAN Bus

SORT

Ecomat - State of the Art 4

ZF-Ecomat • Bus
 Internal structure

Hydrodynamic torque Gearbox ECU

converter

Primary retarder

Blade clutch
Blade brakes

Planetary gear train

Oil/water
heat exchanger

Ecomat - State of the Art Oil pump 5

 New in the Ecomat 2

ECOMAT 1 ECOMAT 2

New in the Ecomat 2:

 New EST46/47C ECU - compatible with the vehicle's CAN bus
 Improved software functionalities in the ECU and Statistical Records (New)
 Simplification of peripheral components
 Electronic control (rather than electro-pneumatic) for the retarder controls
 Two temperature sensors in the gearbox, connected to the ECU
 Latest generation of heat exchanger
 New torque converters
 New retarder control and engagement valves

Ecomat - State of the Art 6

 New in the

 EST 46/47C ECU

New, more powerful and faster hardware, software integrates new functions, identical installation, auto-adaptive functionalities,
improved statistical logging

 New MS torque converters

Optimised surface coating on the converter clutch, larger friction surface and improved torque transmission capacities (+40%)

 Innovative and optimised gearbox components

Primary oil pump, hollow stator shaft with axial seals, new main pressure valve, ball bearings on the input side, sealing gaskets on
clutch pistons A, B & C

 New gearbox oil: ECOFLUID A plus

Ecomat - State of the Art 7

 New in the Ecomat 4
ECOMAT 2 plus ECOMAT 4 Standard Optional Advantages

With a second pump Longer service life and

Additional oil
integrated into the No secondary pump   X improved performance levels
cooling
gearbox for the retarder

Yes, but only in X X

conjunction with the With input With input Fuel consumption reduced by
Torque damping
No converter torque levels torque levels 1 to 3 litres per 100 km
W390 >1600 Nm <1600 Nm

Engine applications
Engine torque Max. 1,600 Nm Max. 1 750 Nm X  
up to 1 750 Nm

Bus Stop Neutral

Cross section of Piston Cross section piston
function linked to X   Optimised gear changes
F2 and solenoid G F1
braking

ECU software Version 03 Versions 04 and 05 X Improved functionalities

Yes
Clutch control on
With new internal Optimisation of the torque
deactivation of the No X
valve and software converter deactivation phase
converter (WK)
version 05

Ecomat - State of the Art 8

 ZF-Ecomat 4
Product Range

5 HP 504 C

5 HP 594 C
5-speed
5 HP 604 C

6 HP 504 C
6-speed
6 HP 594 C

6 HP 604 C

Nm 600 800 1 000 1 200 1 400 1 600 1 800

Ecomat - State of the Art 9

ZF-Ecomat • Bus
 ZF-Ecomat 4
Technical Characteristics
Max. weight (t) with engine torque * Gear ratios
DIN 70020 / ISO 1585

Series Number Urban and Articulated Touring 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse
of gears Interurban buses coaches gear
buses

5 3,43 2,01 1,42 1,00 0,83 -------

19 t 28 t 26 t
HP 504 C 4,84
1 100 Nm 1 050 Nm 1 100
6 3,43 2,01 1,42 1,00 0,83 0,59

5 3,43 2,01 1,42 1,00 0,83 -------

24 t 28 t 26 t
HP 594 C 4,84
1 250 Nm 1 250 Nm 1 250 Nm
6 3,43 2,01 1,42 1,00 0,83 0,59

5 3,43 2,01 1,42 1,00 0,83 -------

24 t 28 t 26 t
HP 604 C 4,84
1 750 Nm1) 1)
1 750 Nm 1 750 Nm1)
6 3,43 2,01 1,42 1,00 0,83 0,59

* Combined with a torque damper (>1 600 Nm)

Ecomat - State of the Art 10