Ecomat Opertors Manual

4182 758 101

BetriebsanleitungOperating Instructions

Manuel d’UtilisationManual de ServicioIstruzioni per l’Uso

4HP 504 C HP 594 C HP 604 C

for city buses, intercity buses and coaches

Subject to alteration in design

Copyright by ZF

This documentation is protected by copyright. Any reproduction or dissemination in whatever form whichdoes not comply fully with the intended purpose of this documentation is prohibited without the consent of ZFFriedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, 2006-06

Edition: 2006-06

Preface

Before the vehicle first enters service, please note the following points:

• Read this operating manual carefully and take due noteof all safety instructions.

• To ensure that the transmission achieves the requiredlevel of operational safety and reliability, always paycareful attention to the maintenance instructions.

The ZF Customer Service specialists are available to assistyou. in carrying out maintenance work or to help if anyother problems arise.These addresses are listed in the “ZF Company Directory”(order number 0000 762 703) or on the Internet underwww.zf.com/ servicenetz.You will find more product information on the Internet bylogging on to www.zf.com (Products/Product World Bus).

NOTEAll details in these Operating Instructions refer to thebasic version of the ZF-Ecomat transmission.Due to the large number of installation options, no preciseinformation can be provided for any specific vehicle.If there are any differences in operation between theinstructions in this brochure and the Operating Instruc-tions specific to an individual vehicle manufacturer, thevehicle-specific instructions are the ones to follow.

Motoring pleasure with the ZF-Ecomat is brought to youby

ZF Friedrichshafen AGCommercial Vehicle and Special Driveline TechnologyD-88038 FriedrichshafenPhone: +49 (0) 7541 77-0Fax: +49 (0) 7541 77-90 80 00Internet: www.zf.com

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The following safety instructions appear in this manual:

NOTERefers to special processes, techniques, information, etc.

CAUTIONThis is used when incorrect, unprofessional working practices could damage the product.

DANGER! This is used when lack of care could lead to personalinjury or material damage.

THREATS TO THE ENVIRONMENT! Lubricants and cleaning agents must not be allowedto enter the soil, ground water, or sewage system. • Ask your local environment agency for safety

information on the relevant products and adhereto their requirements.

• Collect used oil in a suitably large container.• Dispose of used oil, dirty filters, lubricants, and

cleaning agents in accordance with environmental protection guidelines.

• When working with lubricants and cleaning agentsalways refer to the manufacturer’s instructions.

NOTE on cleaning the vehicle / transmission

CAUTIONWhen cleaning, always ensure that the steam cleaner orhigh-pressure cleaner does not make direct contact withthe screw cap of the dipstick. Any water ingress throughthe breather can damage the transmission!

!

!

Safety Instructions

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1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.1 Structure of Basic ZF-Ecomat 4 Transmission . . . 71.2 ZF-Ecomat 4 System Solution . . . . . . . . . . . . . . 81.3 Auxiliary Transmission . . . . . . . . . . . . . . . . . . .11

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.1 Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.1.1 Digital Speed Range Selector . . . . . . . . . . . . . . .122.1.2 CAN Speed Range Selector . . . . . . . . . . . . . . . .122.1.2.1 Lighting of the CAN Speed Range

Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . .132.1.2.2 Pushbutton Settings . . . . . . . . . . . . . . . . . . . . . .132.2 Starting the Engine . . . . . . . . . . . . . . . . . . . . . .142.3 Selecting Gear . . . . . . . . . . . . . . . . . . . . . . . . . .142.4 Setting Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152.5 Driving Ranges . . . . . . . . . . . . . . . . . . . . . . . . . .162.5.1 Downhill Travel . . . . . . . . . . . . . . . . . . . . . . . . .162.5.2 Change in Direction of Travel . . . . . . . . . . . . . .162.5.3 Kickdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172.5.4 Retarder Operating Mode . . . . . . . . . . . . . . . . .182.6 Stopping, Parking . . . . . . . . . . . . . . . . . . . . . . . .202.7 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212.7.1 Towing Away Vehicle with

Operational Transmission . . . . . . . . . . . . . . . . .212.7.2 Towing a Vehicle with Suspected

Transmission Damage. . . . . . . . . . . . . . . . . . . . .212.8 Temperature Monitoring . . . . . . . . . . . . . . . . . .22

2.9 Limit Values for Oil Temperature . . . . . . . . . . .222.9.1 Transmission Oil Temperature

Before Heat Exchanger . . . . . . . . . . . . . . . . . . .222.9.2 Oil Temperature in Transmission Oil Sump . . . .232.9.3 Actions to be Taken When the Relevant

Permissible Oil Temperature is Exceeded . . . . . .242.10 Status Monitoring / Warning Lamps . . . . . . . . .242.11 Transmission Response to a Malfunction . . . . .252.11.1 Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . .252.12 Auxiliary Control Unit . . . . . . . . . . . . . . . . . . . .262.12.1 Operating Instructions for the

Auxiliary Control Unit . . . . . . . . . . . . . . . . . . . .26

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .283.1 Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283.2 Oil Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . .283.3 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . .293.3.1 Guide Value Measurement . . . . . . . . . . . . . . . . .303.3.1.1 Checking Before the Engine is Switched On . .303.3.1.2 Checking After Starting the Engine . . . . . . . . . .313.3.2 Checking at Operating Temperature . . . . . . . . .313.3.3 Option for Heating Up the Transmission Oil . .323.4 Oil Change Intervals . . . . . . . . . . . . . . . . . . . . .333.5 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333.5.1 Draining Transmission Oil . . . . . . . . . . . . . . . . .333.5.2 Draining Oil From ZF Angle Drive . . . . . . . . .343.5.3 Filling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Table of Contents

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1 Description

The Ecomat range of transmissions comprises a hydro-dynamic torque converter (Föttinger t/c) with lock-upclutch, a hydrodynamic retarder and a downstream, multi-ratio planetary transmission.

The torque converter is a starting unit which operateswithout mechanical wear and which adapts its settingacross an infinitely variable range to suit prevailing conditions (delivering the required level of input torque).

The gears in the planetary transmission are selected automatically and without any interruption to traction.Signals for gear shifts are supplied by the electronic controlunit. Depending on various parameters obtained fromvehicle and transmission, this automatic controllerengages the appropriate multi-disc clutches and brakes via the electro-hydraulic transmission control unit.

A lock-up clutch installed in the torque converter estab-lishes a direct mechanical connection between engine andplanetary transmission after the starting phase. This eliminates the power losses normally associated withtorque converter transmissions.

The hydrodynamic retarder is installed between torque converter and planetary transmission. This means that the level of retarder braking force on the output shaft isgear-dependent. As a consequence, full braking action isavailable, even at the lower end of the speed range. Thebraking torque can be controlled across an infinitelyvariable range or can be sub-divided into several steps.

Braking action while driving downhill or in city traffic canbe delivered by the retarder without mechanical wear,thereby extending the life of the service brakes.

Description

Description

1

1.1 Structure of Basic ZF-Ecomat 4 Transmission

Key to items1 Drive2 Torsion damper (optional)3 Torque converter4 Hydrodynamic retarder5 Rotating multi-disc clutches6 Stationary multi-disc brakes

7 Output8 Heat exchanger9 Auxiliary cooling, short-circuit bracket (optional)10 Transmission type plate (possible positions)11 Transmission electrical unit connector12 Serial number (embossed)

024744

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026741

2 3 4 5 6 7 9

8

10

11

10

10

12

1.2 ZF-Ecomat 4 System Solution

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Description

027591

Key to drawing1 Transmission electrical

unit connector2 ECU 146 / ECU 147 connector3 Retarder connector4 Retarder accumulator connector*5 Temp.sensor connector (B4/A6) 6 Kickdown Switch7 ZF diagnosis connection plug8 Speed range selector9 Transmission breather, oil filler

tube, oil dipstick10 Footplate brake valve for activation

of service brake and infinitely variable retarder operation

11 Accelerator pedal12 Retarder switch OFF - ON*13 Main Power System

14 Pushbutton for NBS*15 Pushbutton for gear release*16 ECU 146/147

Electronic Control Unit 17 Retarder manual lever, electrical*18 Impulse sensor for speedometer*19 Coolant connections20 CAN connection21 From air supply to auxiliary

consumers*22 Type plate ECU 146/14723 Temperature display A5*

*optional

6 7

9

2

8

10

14

11

1216

22

3

4

BrakeAccelerator

EngineDisplays

CAN-Bus

........17

1 2 3 D N R

20

1815

13 13

23

1

5 19

21

Ecomat 4 System Solution

This system diagram illustrates one of the possible systemsolutions for Ecomat 4 with ECU 146/147 and individualcomponents.

The electrical wiring from the Ecomat 4 system is routed tothe electronic automatic shift controller ECU 146/147 (16)and to the CAN bus (20) in the vehicle via the vehicle circuit interface (13).

The electronic shift controller is used to control and monitor transmission functions. The electronic controlunit ECU 146/147 records input parameters from vehicleand transmission sent via CAN or as digital signals andprocesses these into signals to control the transmission’shydraulic system.

The driver can intervene actively in the Ecomat controlsystem using:

• Speed range selector (8)

• Kickdown (6)

• Accelerator pedal (11)

• Brake pedal (10)

• Switch for retarder operation (12/17)

The desired speed range can be pre-selected using thespeed range selector. The button pressed is illuminated(continuously lit).

The kick-down switch is used to move the shift pointstowards higher engine speeds, so the transmission remainsin each gear longer when accelerating and shifts out ofeach gear sooner when decelerating.

The retarder (zero-wear service brake) is activated by thebrake pedal (10) and/or hand lever (17).The retarder ON - OFF switch (12) can be used to enable/disable the retarder function.

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Description

Temperature sensors (5) are installed to monitor the oil temperature (also refer to Section 2.8). Data from temperature sensors is transmitted via CAN bus system,ECU 146/147 digital output or direct wiring and displayedby means of display or warning lamp.

Whenever defined temperature limits are exceeded,retarder torque is reduced continuously.Engine load information is transmitted from the enginecontrol unit to the ECU 146/147 using CAN.

A proportional solenoid valve in the hydraulic shift control system modulates clutch actuation pressures inaccordance with engine load.

Ecomat 4 Innovations

For temperature-critical applications, transmissions in the Ecomat 4 ranges are prepared for connection of a separateheat exchanger (auxiliary cooler). To connect up the additional heat exchanger, the short-circuit bracket isremoved and flexible hoses are used to create a link to theheat exchanger. Short-circuit bracket, see Section 1.1, Pos. 9.

Description

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11

1

4 3

2

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Description

027511

Key to drawing1 Basic transmission2 Coaxial output (standard)3 80° angle drive left without offset (LHD)4 80° angle drive right with offset (RHD)

1.3 Auxiliary Transmission

Depending on vehicle version and application, theZF-Ecomat transmission can be equipped with an 80° angle drive.

12

2 Operation

2.1 Pushbutton

The vehicle is either equipped with a digital pushbutton ora CAN speed range selector switch.

Installation variants with 3, 4, 5 or 6 pushbuttons,installed horizontally or vertically:

R = Reverse

N = Neutral

D = Automatic forwards driving range (Drive)

1, 2, 3 = Limited forward driving ranges

2.1.1 Digital Speed Range Selector

• The button pressed is illuminated (continuously lit).

• The button pushed flashes if it is not accepted by the transmission control unit.

Digital speed range selector, installed horizontally

2.1.2 CAN Speed Range Selector

Distinguishing features between CAN pushbutton anddigital pushbutton speed range selector switches:

• Convex keys

• Neutral button does not lock

• ZF logo located on side of Neutral button

CAN speed range selector, installed horizontally

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Operation

005624

027768 027769

13

2.1.2.1 Lighting of the CAN Speed Range SelectorSwitch

Button lighting colors:

• Neutral button: bernstein

• 1, 2, 3, D and R: yellow

All buttons light up for approx. 1.2 s:

• Lighting test at system startup

All keys light up dimly:

• Search lighting: To make it easier to find the buttons inthe dark.

Individual buttons light up brightly:

• Function lighting: Identifies the active, pressed push-button.

Individual buttons flashes:

• The active (pushed) button flashes if it is not acceptedby the transmission control unit.

All buttons flash:

• Serious internal fault in pushbutton

• Malfunction in CAN communication. Once this defecthas been remedied, the light stops flashing.

Exceptions:

• If the transmission control unit is not providing the information required for lighting purposes, the lampsonly light up in search mode. Nevertheless, the vehiclecan still be driven in this status.

• The lighting is also deactivated if the pushbutton position can no longer be correctly established as aresult of a hardware defect and the buttons only lightup with search lighting.

NOTEThe brightness settings for search and function lightingcan, if required, be adjusted independently. They arecorrected as a function of operating voltage.

2.1.2.2 Pushbutton Settings

NOTEIf several buttons are selected at the same time, the smallest gear inhibit button selected is chosen.e.g. if buttons 1, 2, 3 and D are selected at the same time,button 1 is activated.

Operation

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14

2.2 Starting the Engine

Engine can only be started if:

• Vehicle is stationary (brake applied).

• Speed range selector is in Neutral position (“N”)

NOTEStarter inhibit: If the speed range selector is not inNeutral, the engine cannot be started.

CAUTIONOnly jump-start on the battery, never on the starter!Ignition OFF/ON but not while vehicle is in motion!

2.3 Selecting Gear

Standard:

• Speed range selector in Neutral

• Accelerator pedal at idle setting and neng < 900 rpm

• Select desired driving range or direction of travel.

CAUTIONNever actuate speed range selector and throttle at thesame time!

Transmission with additional “gear release” function

(Additional installation by vehicle manufacturer, recommended by ZF)



• Select desired driving range and apply the brake.System only engages the appropriate gear while thebrake is being applied.

Operator errors when engaging gear

• Accelerator pedal actuated or neng > 900 rpm

• If “gear enable” is installed, but brake not applied

• “R” direction of travel selected at a vehicle speed of > approx. 3 km/h

After selecting the desired driving range, the system does not engage a gear.

Transmission with auxiliary function “2nd Reverse gearbutton”

• To reverse the vehicle, press the R button on the speedrange selector and also the R button on the dashboard.

Operation

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2.4 Setting Off

After selecting the appropriate speed range, wait forapprox. 1 to 2 seconds, release brake (if applied) andaccelerate.

DANGER !On steep uphill gradients, always accelerate as soonas you release the brake! RISK OF ACCIDENT fromvehicle rolling backwards!

CAUTIONDo not set off immediately at temperatures below -15 °C.Instead, allow engine to warm up for approx. 5 minutes.Speed range selector in Neutral.

!

Operation

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2.5 Driving Ranges

Please refer to the vehicle’s Operating Instructions forprecise information about the gears engaged in each of thespeed ranges.

A defined range of gears / ratios is assigned to each speedrange. Shifts are only executed at shift points defined bythe electronic shift control unit.

Manual intervention in the automatic shift sequence(shifting right through the speed ranges) is not advisable.

DANGER !If the transmission is shifted into “N” while the vehicleis in motion, the powerflow between engine and out-put is interrupted. This prevents the engine brake andretarder from being able to operate.Risk of accident! – Apply the brake!For safety reasons, when faults occur in the electronicshift control unit or whenever there is a power failure,the transmission automatically selects “N”.

2.5.1 Downhill Travel

When driving down steep gradients, depending on requirements, you should select setting 1, 2 or 3 on thespeed range selector. This restricts upshifts.

DANGER !In extreme cases, to protect the engine, the upshift inhibit is cancelled. When this happens, it is possible for the transmissionto shift up independently from the selected drivingrange to the highest gear. RISK OF ACCIDENT!Note tachometer!

2.5.2 Change in Direction of Travel

Before changing from Forwards to Reverse or vice versa:

• Vehicle stationary


• Speed range selector in Neutral position, depress brakepedal if necessary

• Move speed range selector to D, 1, 2, 3 or R

!

!

Operation

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2.5.3 Kickdown

To utilize max. engine power, higher shift points can becalled up using the kick-down switch (see illustration) orthe CAN system (to accelerate or to use the acceleratorpedal on uphill gradients).

• Depress accelerator pedal beyond its full throttle pressure point (kickdown setting)

Operation

Acceleratorpedal

Full load (pressure point)

Kickdown

Kickdown switch

023629

184182 758 101 - 2006-06

2.5.4 Retarder Operating Mode

The retarder is a ratio-dependent hydrodynamic brakewhich operates without mechanical wear. The retardershould be employed every time the brakes are applied.This extends the life of the service brake. The retarder can be activated by hand and/or using the foot controls.

Conditions for retarder operation(retarder engaged/actuated)

• Accelerator pedal in idle speed setting

• A forwards gear must be engaged

• Vehicle speed > approx. 3 km/h

If these conditions are met, the system prevents upshifts(upshift inhibit).

CAUTIONIf the accelerator pedal is actuated, the retarder disengages. The upshift inhibit is cancelled.

Operation

Brak

e ped

al

Retarder ra

nge

Service brake range + retarder

013186

6

5

4

3

2

1

0023630

19

Operation

4182 758 101 - 2006-06

The retarder is disengaged automatically by the electronic shift controller:

• When “ABS is active”.

• Whenever the permitted oil temperature is exceeded, asdefined in Section 2.9.

If a retarder ON-OFF switch is fitted, the retarder mustbe switched off:

• On icy roads.

• Whenever the permitted oil temperature is exceeded, asdefined in Section 2.9.

The max. permitted oil temperature for retarder operationis 150 °C (max. 5 mins). Note temperature indicator or temperature warning, refer to section 2.8 or vehicle manufacturer’s OperatingInstructions.

• Retarder activation using foot pedal, de-activation usingtoggle switch on dashboard.

• Switch off hand lever whenever the brake has beenapplied!

DANGER !The retarder is feedback-controlled by a specifiedtemperature characteristics curve.Risk of accident due to reduced braking power!

!

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2.6 Stopping, Parking

NOTEOnly apply the parking brake when vehicle is stationary.

Stopping

The vehicle can be stopped at any time, regardless of thesetting of the speed range selector. The electronic shiftcontrol unit then engages the appropriate gear for settingoff.

With short stops:

• Speed range can remain selected

• Apply brake

At extended stops:


• Apply brake

Transmission with special “Bus Stop Neutral” (NBS)feature

The transmission automatically selects Neutral when thefollowing conditions are in place simultaneously:

• Vehicle stationary

• Brake applied

• Accelerator pedal in idle speed setting

The range selected with the speed range selector is thenretained. As soon as one of the three conditions ceases to apply, 1st gear is selected immediately and automatically.

Parking


• Apply parking brake

DANGER !Before leaving the vehicle, always apply the parkingbrake. When the engine is switched off, there is nodirect connection between engine and axle. The vehicle can therefore start to roll!

!

Operation

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2.7 Towing

2.7.1 Towing Away Vehicle with Operational Transmission


• Max. towing time: 2 hours

• Max. towing speed:City and intercity buses: 25 km/hCoaches: 35 km/h

NOTEAt an ambient temperature of less than -15 °C the towingspeed is 5 km/h.

2.7.2 Towing a Vehicle with Suspected Transmission Damage

CAUTIONIf transmission damage is suspected, the propshaft flangebetween transmission and drive shaft needs to be disconnected.

Exception: In a dangerous situation, towing is permitteduntil the vehicle leaves the immediate danger area (e.g.road junction/intersection, tunnel etc.), without firstdisconnecting the driveline.

Operation

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2.8 Temperature Monitoring

Monitoring of transmission temperature is performed bythe ECU 146/147 electronic shift controller. The oil sump temperature and oil temperature at the retarder outlet aretransmitted by CAN to the vehicle control unit. For customers with no access to these CAN messages, temperature sensor A6 and temperature indicator A5 deliver the corresponding retarder outlet temperature

The switch point for the warning contact on the tempera-ture display unit is 145 °C.

2.9 Limit Values for Oil Temperature

2.9.1 Transmission Oil Temperature Before HeatExchanger

During retarder operation:

• In exceptional cases, short periods of operation (max. 5 mins. within a 1 hour period) at 150 °C are permissible.

During torque converter operation:

• The temperature limit for continuous operation is 110 °C.

• In exceptional cases, short periods of operation (max. 5 mins. within a 1 hour period) at 130 °C are permissible.

During normal driving:

• The permitted temperature range is between 90 - 100 °C.

Operation

2.9.2 Oil Temperature in Transmission Oil Sump

The following sump temperatures must not be exceeded(not even at high ambient temperatures):

Transmission oil sump temperatures Ecomat 4

Operatingtemperature max. max.or endurance 100 °C 105 °Ctemperature

Exception:max. 5 mins. within 105 °C 115 °C1 hour

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

with oil acc. to List of Lubricants TE-ML 14 E

NOTE80° angle drive with axial offset is not approved for endurance sump temperatures of 105 °C!

B14: Temperature sensor in transmission sump

Pos 120/124: Temperature sensor on retarder outlet (B4) or temperature sensor (A6) for temperature indicator (A5) see Section 1.2 ZF-Ecomat 4 System Solution

21

21

Operation

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Pos. 120

B14

Pos. 124

021648

24

2.9.3 Actions to be Taken When the Relevant Permissible Oil Temperature is Exceeded

• Driving at partial load

• Switch off retarder

If this does NOT cause the oil temperature to drop:

• Stop the vehicle


• Run engine at raised idle speed

NOTEIf the temperature does not drop back into its permittedrange within a few minutes, the possible causes are:

• Oil level too low or too high

• Contaminated heat exchange in vehicle

• Coolant circuit defective

• Transmission damage

Inform ZF Service Center without delay!

2.10 Status Monitoring / Warning Lamps

The diagnostics system of the electronic shift control unitECU 146/147 monitors the transmission status every timethe vehicle circuit is switched on and continuously whilethe vehicle is in motion.

Warning lampsFaults are displayed by warning lamps lighting up (red oryellow) and by warning messages which appear on thedriver’s display panel (refer to the vehicle manufacturer’sOperating Instructions).

If a selected gear or speed range is not accepted by theECU, the button pressed on the speed range selector startsto flash.

Operation

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25

2.11 Transmission Response to a Malfunction

To protect the transmission in the event of a malfunction,the following responses are provided:

Shift into Neutral:In the event of major malfunctions in the power supply tothe transmission, e.g. short circuit.

Shift into Limp-Home Mode:If there is an interruption to CAN communication or a lossof shaft speed information.

DANGER !If a malfunction occurs in the transmission system,the following applies: • Greatest danger of transmission damage• Restricted system monitoring RISK OF ACCIDENT!

2.11.1 Limp-Home Mode

The ECU is set up with specific time and pressure settingsfor pressure control in limp-home mode. Please also notethat:

• The retarder function is not available

• The “Bus Stop Neutral” (NBS) function is not available

• The engine brake cannot be activated

• “Torque converter lock-up clutch” (WK) is open

• Engine torque is limited to protect the transmission (no engine management)

!

Operation

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2.12 Auxiliary Control Unit

This auxiliary control unit was developed to help withmoving the vehicle during the production process and toact as a limp-home facility in the event of ECU failure.

Auxiliary control unit HST 46 The HST 46 auxiliary control unit is fitted to the 68-pin connector instead of the ECU 145/147-pin connector. Thisallows the driver to select one forwards and one reversegear. Gear shifts whilst driving are no longer possible.

NOTEAuxiliary control unit not available with the ECU 146/147 and CAN pushbutton combination.

2.12.1 Operating Instructions for the Auxiliary Control Unit

• Apply parking brake to prevent vehicle from rolling accidentally.

• Speed range selector is in “N” position.

• Switch off engine and ignition.

• Remove connector from electronic shift controller.

• Connect plug to HST 46 auxiliary control unit andsecure.

• Start engine.

• Engage gear on pushbutton:

Shift setting “N” = Neutral

Shift setting “D” = Drive (forwards gear is engaged, no upshifts or downshifts occur)

Shift setting “R” = Reverse

Operation

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DANGER !When operating via the auxiliary control unit, none ofthe safety functions are enabled. RISK OF ACCIDENT!

The following points must therefore be taken intoaccount at all times: • Shifting from “N“ to “D“ or from “N“ to “R“ only

ever at idle speed and with the vehicle stationary.The transmission can also change gear at higher shaft speeds – but this can lead to transmission damage.

• Before every change from forwards to reversetravel or vice versa, always ensure that the vehicle is completely stationary.

• After shifting into “D” or “R”, always wait for2 seconds to enable the transmission to engagebefore starting to accelerate.

!

Operation

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3 Maintenance

Regular and correctly performed maintenance is essentialto safeguard the operational safety of the transmission. Itis therefore particularly important for the maintenanceintervals to be observed.

THREATS TO THE ENVIRONMENT!Lubricants and cleaning agents must not be allowedto enter the soil, ground water, or sewage system.• Ask your local environment agency for safety

information on the relevant products and adhere to their requirements.

• Collect used oil in a suitably large container.• Dispose of used oil, dirty filters, lubricants, and

cleaning agents in accordance with environmental protection guidelines.

• When working with lubricants and cleaning agentsalways refer to the manufacturer’s instructions.

3.1 Oil Grade

CAUTIONWhen filling Ecomat transmissions, always use oils specified on the latest version of the ZF List of Lubricants TE-ML 14.

The latest List of Lubricants can be obtained from all ZFSales & Service Centers or can be downloaded from theInternet at: www.zf.com (Service / Technical Information /ZF List of Lubricants) and viewed.

3.2 Oil Volumes

• During oil changes (drain lasts approx. 10 min.) approx. 18 liters

• After installation of new/replacement transmissions approx. 20 liters

• When first filling the dry transmission approx. 28 liters

NOTEThese figures are guide values and refer to the standard version of the Ecomat 4. Depending on the version of heatexchanger fitted, oil quantities can rise by as much asapprox. 5 liters.The definitive oil volume is the one obtained after the oillevel check and at operating temperature (see Section3.3.2).

!

Maintenance

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3.3 Oil Level Check

CAUTIONAlways maintain the correct oil level:

• Insufficient oil leads to transmission malfunctions and damage

• Too much oil causes the transmission to overheat

DANGER !Insufficient oil in the system leads to partial or com-plete failure of the retarder, i.e. braking action isimpaired or non-existent.

The following applies in general:

• Check the oil level at operating temperature (80 to 90 °C) to obtain a definitive figure.

• The vehicle must be parked on level ground whenchecking the oil level.

• Shift range selector (pushbutton) to Neutral.

• Run engine at idle speed. Idle speed should be set to 500 to 700 rpm. It must never drop below 450 rpm.

• Undertake oil level check at least once a quarter.

• Conduct regular visual inspections of the transmission forsigns of leakage.

• In exceptional cases the oil level may need to bechecked while the transmission oil is cold – refer toSection 3.3.1.Then always check the oil again at normal operating temperature.

!

Maintenance

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Maintenance

3.3.1 Guide Value Measurement

This oil level measurement, carried out while the transmission oil is cold, is applied under the followingexceptional circumstances:

• When a transmission enters service for the first time.

• If the engine has not run in a long time or if the vehiclehas been transferred or purchased.

• After in situ transmission repair, e.g. removal of the oilpan, hydraulic control unit, heat exchanger etc.

• After oil or filter changes.

Calculation of the flat rate (labor charge) can be dividedinto steps:

• Checking before the engine is switched on.

• Checking after the engine has been switched on.

Then check again at operating temperature.

3.3.1.1 Checking Before the Engine is Switched On

• Vehicle stationary and on horizontal ground.

• Oil level must reach the “STOP” mark.

NOTEIf the oil level is higher than this, do not drain any oil!

} HOT

} COLD

- STOP

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3.3.1.2 Checking After Starting the Engine

Oil level check with cold transmission oil (approx. 30 °C):

• Vehicle stationary and on horizontal ground

• Shift range selector (pushbutton) to Neutral

• Leave engine running at 1200 - 1500 rpm for 15 - 20 seconds

• Run engine at idle speed and measure oil level within30 seconds

• Oil level must be in the “COLD” range

NOTEIf the oil level is higher than this, do not drain any oil!

CAUTIONAfter cold starts below 0 °C, the dipstick must be immersed at least 10 mm below the surface of the oil to enable the unit to heat up properly to operating temperature.

Then check again at operating temperature (see Section3.3.2).

3.3.2 Checking at Operating Temperature

Oil level check with hot transmission oil (80 to 90 °C):


• Shift range selector (pushbutton) to Neutral

• Run engine for 15 - 20 seconds at 1200 - 1500 rpm (not required with directly mounted heat exchanger)

• Let engine run at idle speed

CAUTIONThe engine idle speed should be set to between 500 and700 rpm. It must never drop below 450 rpm.

• Oil level must be in the ‘HOT’ range.

For the options available for heating up transmission oil,see Section 8.3.3.

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Maintenance

} HOT

} COLD

- STOP

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3.3.3 Option for Heating Up the Transmission Oil

The transmission oil can be heated up to its specified operating temperature for oil check purposes by runningthe vehicle normally with retarder cycles until the oilsump temperature reaches 80 - 90 °C.

If normal operation of the vehicle is not possible, the oilneeds to be heated up in one of the following ways:

• Apply parking brake

• Select speed range ‘D’

• Apply service brake

• Run engine several times at part throttle (as required)for 15 to 20 seconds at 1200 to 1500 rpm.

CAUTIONThe maximum permitted oil temperature defined in Section 2.9 must not be exceeded!

After every heating-up phase and with the transmission in Neutral, run engine at 1500 to 2000 rpm for 15 to 30 seconds.

Once the operating temperature has been reached, acheck must be carried out in accordance with Section3.3.2.

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3.4 Oil Change Intervals

The oil change intervals defined in ZF List of LubricantsTE-ML 14 are binding.

The latest List of Lubricants can be obtained from all ZFSales & Service Centers or can be downloaded from theInternet at: www.zf.com (Service / Technical Information /ZF List of Lubricants) and viewed.

NOTEWhen changing oil from ATF in lubricant class 14A or 14Bto an ATF grade with longer oil change intervales, an intermediate oil change is required to comply with List ofLubricants TE-ML 14.

3.5 Oil Change

3.5.1 Draining Transmission Oil

NOTEDrain oil at operating temperature for at least 10 minutes:


• Engine must be stationary

• Unscrew oil drain plug (1) and drain oil

• Remove filter cover (2)

CAUTIONThe oil filter must be replaced at every oil change.

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3.5.2 Draining Oil From ZF Angle Drive

The ZF angle drive shares an oil supply with the ZF-Ecomat. Only drain oil at operating temperature.

ZF 80° angle drive LHD without offset

• Engine must be stationary

• Unscrew and remove oil drain plug (1) from angle driveand drain residual oil from angle drive

ZF 80° angle drive LHD without offset

ZF 80° angle drive RHD with offset

This angle drive does not have its own oil drain plug.Drain oil through drain plug in main transmission as described in Section 3.5.

ZF 80° angle drive RHD with offset

Maintenance

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Maintenance

3.5.3 Filling Oil

• Replace filter cartridge, copper rings and O-ring

• Screw down filter cover (2), tightening torque: 25 Nm

• Screw in oil drain plug (1) :Tightening torque - oil pan: 50 Nm- Tightening torque - 80° angle drive LHD without offset: 60 Nm

• Remove dipstick (3)

• Fill with oil and check oil level in accordance withSection 3.3

NOTEThe angle drive (optional) is filled via the transmission. Use oil grade in accordance with List of Lubricants TE-ML 14 Oil volume, see Section 3.2.

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Troubleshooting Instructions

Error Possible cause Remedial action

Engine will not start. Speed range selector not in “Neutral” Select “Neutral” on speed range selector

Electronic control unit connector loose. Tighten ECU plug connection

Starter inhibit relay defective or missing Replace relay or check CAN CAN signal signal

Transmission does not Accelerator pedal not in idle speed position or Check accelerator pedal / injection pump engage any gears load signal too high or adjust it

Engine idle speed > 900 rpm Set engine idle speed

Only on transmissions with auxiliary function “Gear release”:Service brake not applied Apply the service brake

ECU in malfunction setting Switch ignition on/off

Vehicle does not move Oil level too low Check / correct oil level

Transmission defective Call ZF Service

Oil temperature too high Oil level too high Check / correct oil level

Retarder engaged Switch off retarder using hand lever

Transmission damage Call ZF Service

Radiator dirty Clean the radiator

Retarder not responding Oil level too low Check / correct oil level

Retarder proportional valve or solenoid valve Check CAN signal and retarder connectornot operating, CAN signal not present

Documents

Ecomat Opertors Manual