4149 - 765 - 103 - Ecomat 2 +
4149 - 765 - 103 - Ecomat 2 +
4149 - 765 - 103 - Ecomat 2 +
Copyright by ZF
Printed in Germany
Edition: 2004-12
This Ecomat Technical Manual provides a technical The following safety instructions appear in this
basis for the Ecomat 2 plus system and has been manual:
produced for the benefit of vehicle and body manu-
facturers as well as ZF employees. NOTE
This manual contains answers to questions ranging Refers to special processes, techniques, data, use of
from specifications to installation inspection and auxiliary, etc.
commissioning.
CAUTION
This manual provides the basis for specifications of This is used when incorrect, unprofessional wor-
the transmission and peripheral units. king practices could damage the product.
6 Engine connection
7 Converter
8 Retarder
9 Cooling system
10 Transmission specification
12 Periperal equipment
13 Neutral at standstill
14 Temperature monitoring
16 Wiring
17 ZF documentation
7 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Torque converter: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Converter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Getting the right torque converter for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Torque converter diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Torque converter basic curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
8 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Structure and function of retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Retarder action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 Retarder and engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Retarder activation variants hand and foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Permitted variants foot request without hand request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.2 Permitted variants foot request without hand request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.5.3 Permissible retarder activation variants "Foot" and "Hand" combined . . . . . . . . . . . . . . . . . . . . 8-7
10.2.3 Coaxial output or 80 angle drive RHD (with axial offset), heat exchanger
vertical on left, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2.4 Angle drive 80 LHD (without axial offset), heat exchanger horizontal on left,
accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.5 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left . . . . . . . . . . . 10-9
10.2.6 Coaxial output, vertical heat exchanger on right, accumulator rear transverse . . . . . . . . . . . . . 10-10
10.2.7 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting . . . 10-11
10.2.7.1 Cooler connection piece with threaded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.3 Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3.1 Deep oil pan, 4149 131 002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3.2 Deep oil pan; left- and right-hand connection prepared, 4149 131 006 . . . . . . . . . . . . . . . . . . . 10-14
10.3.3 Deep oil pan, auxiliary cooling, 4149 131 024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10.3.4 Flat oil pan, 4149 131 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.3.5 Flat oil pan; left- and right-hand connection prepared, 4149 131 009 . . . . . . . . . . . . . . . . . . . . 10-17
10.4 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.4.1 Oil filling <K 01> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.4.2 Oil filling <K 02>, <K 04>, <K 05> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.4.3 Oil filling <K03>, <K 06> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
10.4.4 Oil filling <K 09> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10.5 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.5.1 Coaxial output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.5.2 80 angle drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.5.3 Output flange 80 angle drive LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.4 Ecomat output flange; coaxial and angle drive 80 RHD with axial offset . . . . . . . . . . . . . . . . . 10-27
16 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.1 Complete wiring - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2 Complete wiring - With junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.3 Wiring connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.4 Wiring specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
17 ZF documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1 ZF documentation with CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1.2 Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
17.2 ZF documentation without CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
17.2.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
17.2.2 Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
17.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5
17.3.1 Oil level check prior to first commissioning; transmission without oil filling . . . . . . . . . . . . . . 17-5
17.3.2 Oil level check prior to first commissioning; Transmission oil filing at plant . . . . . . . . . . . . . . 17-6
17.3.3 Oil level check prior to first commissioning;
Transmission with additional cooling system, with or without oil filling at plant . . . . . . . . . . . 17-7
8 Brake
Accelerator
1 2
3D
NR
16 Engine
Displays
13 12 2 ....
17 ....
CAN-Bus
20
11
6
7
10
1
4 9
21
14
15 18
5
19
023778_en
Key to drawing
1 Transmission electrical unit connector 11 Accelerator pedal
2 EST 146- / EST 147-connector 12 Retarder OFF - ON switch
3 Retarder connector 13 Main power supply
4 Accumulator connector 14 Pushbutton for NBS (Neutral when stationary)
5 Temperature sensor connector 15 Pushbutton for gear release
6 Kick down switch 16 Automatic electronic shift control unit
7 ZF diagnosis connection plug EST 146 / EST 147
8 Range selector (pushbutton) 17 Retarder manual lever, electrical
9 Dipstick (oil level check, oil status) 18 Impulse sensor for tachometer
10 Footplate brake valve for activating the 19 Connections for cooling water circuit
service brake and continuously variable 20 CAN connector
retarder activation 21 Auxiliary consumer from air supply
8
NR
3D
1 2
16
13 12 2
17
11 20
6
7
10
21
1
4 9
22
14
15 18
5
19
023777
Key to drawing
1 Transmission electrical unit connector 11 Accelerator pedal
2 EST 146- / EST 147-connector 12 Retarder OFF - ON switch
3 Retarder connector 13 Main power supply
4 Accumulator connector 14 Pushbutton for NBS (Neutral when stationary)
5 Temperature sensor connector 15 Pushbutton for gear release
6 Kick down switch 16 Automatic electronic shift control unit
7 ZF diagnosis connection plug EST 146 / EST 147
8 Range selector (pushbutton) 17 Retarder manual lever, electrical
9 Dipstick (oil level check, oil status) 18 Impulse sensor for tachometer
10 Footplate brake valve for activating the 19 Connections for cooling water circuit
service brake and continuously variable 20 Linkage for injection pump
retarder activation 21 Load sensor for engine load detection
22 Auxiliary consumer from air supply
8
20
NR
3D
1 2
16
13 12 2
17
11
6
7
10
1
4 9
21
14
15 18
5
19
023779
Transmission control
The electro-hydraulic control system used in these
transmissions has given excellent results in practice.
It receives shift signals from the EST 146 / 147. This
modern automatic electronic control unit has a dia-
gnostics capacity and is designed to suit the number
of ratios, type of transmission, engine and vehicle.
ZF automatic transmissions
5 and 6 HP 502, 592, 602
3 4 5 6
1 7
013467
8
Key to drawing
1 Input 5 Clutches (A, B, C)
2 Torque converter lock-up clutch 6 Brakes (D, E, F)
3 Converter 7 Output
4 Retarder 8 Oil pump
Retarder
All transmission versions are supplied with a
retarder as standard. The retarder is fitted in the
basic transmission between converter and plane-
tary transmission. The retarder does not increase
transmission length and adds only 11 kg to the
transmission weight.
2 5
6
7
021765
Key to drawing
1 Basic transmission
2 Retarder
3 Coaxial output
4 80 angle drive left with offset (LHD)
5 80 angle drive right with offset (RHD)
6 Oil cooler, fitted at output end
7 Oil cooler connection piece for non-ZF oil
cooler
Transmission ratio:
This table gives the mechanical transmission ratios in individual gears (without torque converter).
Ratios
No. of
gears 1st 2nd 3rd 4th 5th 6th Rev.
Total
gear gear gear gear gear gear gear
Powerflow
WK WK B C D E F
B C D E F
WK B C D E F
1st gear
(mechan.) A
WK
3 4 5 6 B C D E F
2nd gear A
2
WK B C D E F
3rd gear
A
1 7
WK B C D E F
4th gear A
WK B C D E F
WK B C D E F
6th gear
A
4 Retarder
016362
Power flow
WK WK B C D E F
B C D E F
WK B C D E F
1st gear
(mechan.) A
WK
3 4 5 6 B C D E F
2nd gear A
2
WK B C D E F
3rd gear
A
1 7
WK B C D E F
4th gear A
WK B C D E F
WK B C D E F
6th gear
A
Max. permissible
engine torque ISO 1585
1100 Nm 850 Nm1) 1100 Nm 1100 Nm 2)
Max. permissible
1250 Nm -- 1250 Nm 1250 Nm
engine torque ISO 1585
HP 602 5 3.43 - 0.83 2650
for i = 0.59
6 1) 3.43 - 0.59 2650 nmax = 2000
Max. permissible
engine torque ISO 1585 1600 Nm 3) -- 1600 Nm 4) 1600 Nm 4)
CAUTION
Generally speaking, torsional vibration is due to
more than one component. The natural frequencies
are determined by the distribution of inertia torques
and the torsional rigidity of the entire driveline.
The vehicle manufacturer must ensure that the
entire driveline does not apply any excessive vibra-
tion loadings on the transmission.
Limit values for angle acceleration amplitude at the
output flange: max = 2000 rad/sec2
Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)
WK
B C D E F
J1 J2 J3
C1 C2
1 2 3
016364
J1 C1 J2 C2 J3
The moment of inertia J1, oil capacity included
[kgm2] [Nm/rad] [kgm2] [Nm/rad] [kgm2]
1st gear 5/6 HP 502 / 592 1.51 19000 0.78 39760 0.23
i = 3.43 5/6 HP 602 2.07 39000 0.78 100300 0.24
2nd gear 5/6 HP 502 / 592 1.51 19000 0.78 58350 0.10
i = 2.01 5/6 HP 602 2.07 39000 0.78 136700 0.10
3rd gear 5/6 HP 502 / 592 1.51 19000 0.78 70760 0.14
i = 1.42 5/6 HP 602 2.07 39000 0.78 151200 0.15
4th gear 5/6 HP 502 / 592 1.51 19000 0.82 108500 0.50
i = 1.00 5/6 HP 602 2.07 39000 0.82 985000 0.53
5th gear 5/6 HP 502 / 592 1.51 19000 0.79 105700 0.46
i = 0.83 5/6 HP 602 2.07 39000 0.79 814100 0.46
Neutral position (lock-up clutch and clutches A, B, C open) 5/6 HP 502 / 592: J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
5/6 HP 602: J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2
Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)
J1 J2 J3
C 1 C 2
WK
B C D E F
Output RHD
1 2 3
021766
Neutral position (lock-up clutch and clutches A, B, C open) W 360*TPC... : J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
W 390*TPC... : J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2
Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)
J1 J2 J3
WK
B C D E F C 1 C 2
Output LHD
1 2 3 019213
1st gear 5/6 HP 502 / 592 1.51 19000 0.78 39760 0.25
i = 3.43 5/6 HP 602 2.07 39000 0.78 100300 0.26
2nd gear 5/6 HP 502 / 592 1.51 19000 0.78 58350 0.14
i = 2.01 5/6 HP 602 2.07 39000 0.78 136700 0.14
3rd gear 5/6 HP 502 / 592 1.51 19000 0.78 70760 0.20
i = 1.42 5/6 HP 602 2.07 39000 0.78 151200 0.21
4th gear 5/6 HP 502 / 592 1.51 19000 0.82 108500 0.62
i = 1.00 5/6 HP 602 2.07 39000 0.82 985000 0.65
5th gear 5/6 HP 502 / 592 1.51 19000 0.79 105700 0.65
i = 0.83 5/6 HP 602 2.07 39000 0.79 814100 0.65
Neutral position (lock-up clutch and clutches A, B, C open) 5/6 HP 502 / 592: J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
5/6 HP 602: J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder) without oil with oill S [mm] oil included JS [kgm2] oil included
y x
021772
z z
Transmission type Total weight Position of center of gravity Inertia torque values
(without retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J01 (oil cooler,
installed at the rear) m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021773
z z
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J05 (oil cooler,
installed on the left side) m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021774
z
z
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the right side) m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021780
z z
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the left side) m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021775
z
z
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the right side) m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021777
z
z
2.6.7 Angle drive 80 RHD (with right offset), with heat exchanger J05
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J10 (oil cooler,
installed on the left side) m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021778
z z
2.6.8 Angle drive 80 RHD (with right offset), without heat exchanger J08
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder)
without oil with oil S [mm] oil included JS [kgm2] oil included
J08 (oil cooler separate)
m [kg] m [kg] xS yS zS Jx S JyS JzS
y x
021779
z z
A B C D E F1 F2
Reverse gear
Neutral
Neutral (NBS) 1) *
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
* Reduced pressure
1) Standard version
F1 = external piston area brake F
F2 = internal piston area brake F
The conventional installation position in buses is the To further optimize available space, various angle
mid-axle T-drive with the transmission fitted in the drive versions (WTR) are used to allow transverse
direction of travel. installation.
80 angle drive version with right offset
The introduction of drop-center axles for low-floor Another advantage of the 80 WTR with axial offset
buses means the driveline is displaced, for example, is that the output is moved 217.5 mm downwards.
to the left.
4 Installation arrangement and mountings If the forces acting on each side are offset longitudi-
nally, please consult our Application Engineering
The transmission must not be supported other than department.
at the bolt attachment faces provided for this purpose
on the transmission housing and auxiliary unit.
Transmission mountings on the chassis must be 4.1 Transmission flange-mounted on engine
designed in consultation with ZF in such a way that
no additional forces resulting from twisting of the ZF recommended mounting points
chassis may be transmitted to the transmission
housing.
! DANGER
The bending torque exerted by mounting blocks at Ecomat with 80angle drive
Mounting points at A + B or A + C or A + C/D
mounting flange face C and/or D must not exceed the
following limit: MC 3500 Nm / MD 1500 Nm
E
The bending torque can be calculated from the C
bracing force (F) at the rubber mounting and lateral A B D
lever length (L) of bearing block. Take into account
any simultaneous vertical acceleration and torque E
021769
loading from the transmission or powerpack.
Ecomat with 80angle drive
Mounting points at A + B or A + C or A + C/D
Additional mounting point at E possible, either above or
L L below housing.
F F
4139 S 0028
Rotational angle
Exceptions from the values specified must be 1.6 ,=
approved. 1.4
1.2
1 rev.
0.4
The maximum permissible angle-acceleration ampli-
0.2
tudes () in the driveline are 2000 rad/s2. Smaller
values do not result in vibration damage. S 0014
1000 2000 3000
25
20 30
25
15
13 20
10 15 >R
10
5
>V
0
5 9 10
>H 15 20
25
021847
90
if the journal cross
is perpendicular to Input Output
the driving yoke 4139 S 0010
Examples illustrating the effect of deflection angle 1 and 2 on resultant flexure angle E
Example 2
(Small >1 = 5 >1 = 5
deflection
>2 = 4 >2 = 4 1 3
angle with
angle error)
>1 = 15 >1 = 15
Example 3 >2 = 14
(Large >2 = 14
deflection 1 5,4
angle with
angle error)
021848
Example 3 shows that, in the case of large deflection angles, angle errors of as little as 1 can cause an impermissibly large resultant flexure angle.
Best efforts must be taken to configure the axle sus- In multi-section propshaft configurations, the drive-
pension suitably to ensure the propshaft remains in a line can be optimized by suitable choice of crosslink
precise Z pattern (1 = 2) under all vehicle loading. orientations and by varying height h of the inter-
mediate bearing ( angle distribution).
4139 S 0015
1 = 9.5
h
= 5 Axle
2
1
2 Swing travel
loaded
-0 + Centre position
Axle Movement 4139 S 0016
NOTE
The maximum length is limited to 1500 mm to pre-
vent the bending vibrations being activated by the
propshaft, if necessary, a multiple arrangement with
intermediate bearing will have to be selected.
Further information
250
4139 S 0018
200
150
Perm. residual imbalance per
balancing mass [gmm/kg]
100
80
Q1
6
60
40
30
300 500 700 900 1500 3000 4000
Propshaft speed n (1/min)
500 0.10 h8
1500 0.07 h7
3500 0.06 h7
Lubrication:
The specifications of the propshaft manufacturer
should be observed for lubrication.
The sliding piece must move easily under load.
There are two methods for connecting the trans- Use only hardened, flat washers (DIN 125-13-
mission to the engine: 300 HV or DIN 125-10.5-300 HV), or stop screws
according to DIN 961, quality 8.8. Never use
Method 1: The engine flywheel (2) is retained toothed lock screws or similar.
and carries the starter ring gear (5). The flex
Check the following tolerances:
plates (10) are connected directly to the converter
- Max. deflection of flex plates
(7).
= 1.2 mm (important for flex plate life)
- Flex plate thickness (D)
Method 2: Remove engine flywheel (2). Fit a
= 4 x 0.5 mm 0.04 mm
starter ring gear carrier (8) between the flex
= 2 mm 0.16 mm
plates (10) and converter (7).
- Runout tolerance (A) of flywheel inner bore
and/or centring ring to centring spigot on
flywheel housing = max. 0.3 mm
- Permitted tolerance for dimension (C) for
for Method 1 = 0.66 mm
for Method 2 = + 0.66 mm
0.96 mm
(Dimension (B) is set by ZF to 0.5 mm)
Check dimensions (A) and (C) comply with Bolt together transmission housing (6) and fly-
engine connection drawing. If dimensions exceed wheel housing (3) as shown in engine connection
tolerance, contact our Application Engineering drawing. Tightening torque for bolt quality 8.8:
dept. urgently. TA = 49 Nm for screws M10
TA = 79 Nm for screws M12.
Bolt together crankshaft (1), flywheel (2), flex
plates (10), and clamping ring (11). Consult engine Using assembly access hole (4) in flywheel
manufacturer to establish correct tightening housing and flywheel, bolt flex plates (10) onto
torque. converter (7). Tightening torque TA = 81 Nm for
bolt quality 8.8.
A A
023809
Check dimensions (A) and (C) comply with Bolt together transmission housing (6) and fly-
engine connection drawing. If dimensions exceed wheel housing (3) as shown in engine connection
tolerance, contact our Application Engineering drawing. Tightening torque for bolt quality 8.8:
dept. urgently. TA = 49 Nm for screws M10
TA = 79 Nm for screws M12.
Bolt together crankshaft (1), centering ring (11),
flex plates (10), and clamping ring (9). Consult Using assembly access hole (4) in flywheel
engine manufacturer to establish correct tighten- housing bolt flex plates (10) onto converter (7).
ing torque. Tightening torque TA = 81 Nm for bolt quality 8.8.
SECTION A-A
SECTION A-A
A
SECTION B-B
ASSEMBLY ACCESS HOLE
023810
The flex plates and bolts for fastening 4 flex plates to Attempts should be made to undertake all engine
the converter are supplied by ZF. connections following variant 1 with a complete
flywheel.
NOTE
Vehicle manufacturer should establish whether the 4 Since there is no flywheel in the version following
diaphragms variant 2, the inertia torque of the engine is
are ordered form the engine manufacturer and changed. Under unfavorable circumstances, this
fitted there onto the engine with the connection may result in resonance vibrations and finally
parts required or diaphragm failure.
are to be included in the transmission scope of
supply for the vehicle manufacturer. CAUTION
Variant 2 (segregated design) may only be used
once the Application Engineering department has
been contacted.
6.2 Engine connection inspection
The following applies in general:
If no engine connection drawing has been prepared,
the following documents are required for the engine Engine connection drawings are already available
connection inspection: for popular engines.
ZF-ECOMAT 2 plus
DETAIL V
5:1
4 FLEX PLATES
0.5 MM THICK
56 1.9
min. 7 mm 50 H7
e8
max. 8 mm 0.3 A
Contact surface
oKntaktfl
che
63.50.5
86.0 +0.5
1.0 DETAIL W
5:1
min. 4 021682
ZF-ECOMAT 2 plus
A
561.9
min. 7 mm 50 H7
e8
max. 8 mm
oKntaktfl
che 0.3 A
Contact surface
63.50.5
86.0 +-0.5
1.0
DETAIL W
5:1
5
R 201
5
R 201
min. 4 021683
Torque is transmitted from the engine flywheel to The close ratios and optimum gear step adjustment
the torque converter by means of a connection of the 5th and 6th mechanical gears in the trans-
comprising flex plates. mission allow the converter to be locked up at a very
early stage. This makes use of the advantages of
mechanical power transmission early on high
efficiency and low power losses.
7.2 Converter functions
From engine
TP TT
TR
To transmission
Condition at nT = O
instant of Stator Vehicle stationary
starting off
TP = Torque of impeller
TT = Torque of turbine wheel
TR = Torque of stator
7.3 Getting the right torque converter for your Refer to torque converter diagram for details of
engine appropriate engine-converter combinations, see
example of torque converter diagram on page 7-5.
In cooperation with vehicle manufacturers, the ZF
Application Engineering dept. has specified an To determine the operating points between torque
appropriate torque converter for every engine trans- converter and engine under full-throttle conditions,
mission combination. the net engine torque curve needs to be entered in
the primary parabolic characteristics field for the
The torque converter selection criteria are: torque converter.
Engine type (naturally-aspirated engine or turbo-
charged engine). There are converter models for the 5/6 HP 502 / 592 /
Torque conversion when starting off. 602 C transmissions which vary according to the
Speed reduction when starting off. impeller torque pickup, hydraulic diameter, and
Fuel economy or power increase. torque multiplication when starting off.
Heat build-up when driving for long periods with
lock-up clutch open.
W360*TPC145*MUE2.22 145 2.215 4166 711 150 01 14500 16300 1000 221 970Z
W360*TPC210*MUE2.43 210 2.430 4166 703 227 01 41210 41210 1400 243 1000Z
W360*TPC262*MUE2.40 262 2.400 4166 703 147 01 26200 26200 1000 240 1000Z
W360*TPC300*MUE2.36 300 2.360 4166 703 149 01 30000 30050 1000 236 1000Z
W360*TPC342*MUE2.27 342 2.270 4166 703 148 01 34200 34200 1000 227 1000Z
W360*TPC390*MUE2.17 390 2.165 4166 703 150 01 39000 39000 1000 216 1000Z
W390*TPC392*MUE2.20 392 2.195 4166 711 145 01 39200 41800 1000 219 1000Z
W390*TPC487*MUE1.98 487 1.982 4166 711 146 01 48700 49000 1000 198 1000Z
W390*TPC615*MUE1.83 615 1.829 4166 711 147 01 61500 63900 1000 183 1000Z
014 914
Key to diagram
TengGr [Nm] = Engine torque curve (gross) Mue [-] = Torque multiplication ration
PengGr [kW] = Engine power curve (gross) m = TT/TP against speed ratio
nP [1/min] = Impeller speed against turbine Nue = nT/nP
speed nT TP [Nm] = Parabolae of impeller torque
TT [Nm] = Turbine torque against turbine pick-up against impeller speed
speed nT nP for speed ratio Nue = nT/nP
PV [kW] = Torque converter power losses A = Stall torque
against turbine speed nT B = Stall speed
Engine data = According to ISO 1585 (average
values)
Converter = According to VDI Guideslines
figures 2153 figures (average values)
W360*TPC145*MUE2.22
Basic curve: 4166 711 150
Impeller constants: nPC = 1000 rpm
1100 1500
T (Nm)
1000
.40
1300
=0
=0
T (ft.lb.)
1200
TP TP
k
800 1100
.80
=0
1000
700 TP
900
600
800
3.0
2.8 700
500
2.6
2.4 600
w(%)
2.2 400
2.0 500 100
1.8 90
1.6 300 80
400
1.4 70
1.2 300 60
200
1.0 50
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
016 675
0 0.2 0.4 0.6 0.8 1.0
W360*TPC210*MUE2.43
1800 2400
1700
2200
1600
1500 2000
T (Nm)
1400
T (ft.lb.)
=0
1600
TP
1100
1400
1000
900 8k
0.7
1200
800 =
3.0 1000 TP
2.8 700
2.6
2.4 600
2.2
800
w(%)
2.0 500 100
1.8 600 90
1.6 400 TPC1400 80
1.4 70
1.2 300 400 60
1.0 50
0.8 200 40
0.6 200 30
0.4 100 20
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0
016 670
W360*TPC262*MUE2.40
1800 2400
1700
2200
1600
1500 2000
T (Nm)
1400
T (ft.lb.)
=0
1600
TP
1100
k
1400
7 6
1000 0.
900
=
1200
TP
800
3.0 1000
2.8 700
2.6
2.4 600 800 w(%)
2.2
2.0 500 100
1.8 600 90
1.6 400 80
1.4 70
1.2 300 400 60
1.0 TPC1000 50
0.8 200 40
0.6 200 30
0.4 100 20
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0
016 671
W360*TPC300*MUE2.36
2600
1900
1800 2400
1700
2200
1600
1500 2000
T (Nm)
1400
T (ft.lb.)
0
=
1600
78
TP
0.
3.0 1100
=
2.8 1400
1000 TP
2.6
2.4 900 1200
w(%)
2.2 800
2.0 1000 100
700
1.8 90
1.4 500
70
1.2 600 60
400 50
1.0
0.8 300 400 TPC1000 40
0.6 30
200
0.4 200 20
100
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0
016 672
W360*TPC342*MUE2.27
2600
1900
1800 2400
1700
2200
1600
1500 2000
T (Nm)
1400
=0
T (ft.lb.)
1600
0k
TP
0 .8
3.0 1100
=
2.8 1400
1000
2.6
TP
2.4 900 1200
w(%)
2.2
800
2.0 1000 100
700
1.8 90
1.4 70
500
1.2 600 60
400 50
1.0
TPC1000
0.8 300 400 40
0.6 30
200
0.4 200 20
100
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0 016673
W360*TPC390*MUE2.17
2600
1900
1800 2400
1700
2200
1600
1500 2000
T (Nm)
1400
T (ft.lb.)
=0
8k
1600
0 .7
TP
=
1100
1400
1000 TP
2.6
2.4 900 1200
2.2 w(%)
800
2.0 1000 100
1.8
700 90
1.4 70
500
1.2 600 60
400 50
1.0
0.8 300 400 TPC1000 40
0.6 30
200
0.4 200 20
100
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0 016 674
W390*TPC392*MUE2.20
3000
2200
2100 2800
2000
2600
1900
1800 2400
1700
2200
1600
2000
k
1500
.40
.78
=0
=0
=0
T (Nm)
1400
T (ft.lb.)
TP TP
TP
1600
1100
1400
1000
2.4 900 1200
2.2 w(%)
800
2.0 1000 100
700
1.8 90
1.6 600 800 80
1.4 70
500 TPC1000
1.2 600 60
400 50
1.0
0.8 300 400 40
0.6 30
200
0.4 200 20
100
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0 016 676
W390*TPC487*MUE1.98
3000
2200
2100 2800
2000
2600
1900
1800 2400
1700
2200
1600
1500 2000
1400
T (Nm)
T (ft.lb.)
.1 0
=0
k
=0
.80
1600
TP
=0
1100 TP
1400
1000 TP
2.4 900 1200
w(%)
2.2 800
2.0 1000 100
700
1.8 90
1.2 600 60
400
1.0 50
0.6 30
200
0.4 200 20
100
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0 016 677
W390*TPC615*MUE1.83
3000
2200
2100 2800
2000
2600
1900
1800 2400
1700
2200
1600
1500 2000
T (Nm)
1400
k
T (ft.lb.)
0
0
.80
=
0.2
=0
=
1600
TP
1100 TP TP
1400
1000
2.4 900 1200
2.2 w(%)
800
2.0 1000 100
700
1.8 TPC1000 90
1.4 500
70
1.2 600 60
400
1.0 50
0.6 30
200
0.4 200 20
100
0.2 10
0 0 0 0
1000 2000 nT, nP (1/min) 3000
0 0.2 0.4 0.6 0.8 1.0
016 678
Grid
Stator
Rotor
023780
* up to max. 13 to
Hand
TSC1 sec
Analog
ED
1 2 3 4 5 6
Variants 2/1
Standard:
3-stage: 50 %, 75 %, and 100 %.
Inputs:
Pin 65 (ED 2), Pin 12 (ED 15), and Pin 36 (ED 7)
Variants 3/1
NOTE
To compensate for pedal zero setting variances, the
automatic footplate adjustment function in ECU
146/147 can be activated.
Variants 4/1
Variant 1/2
Standard:
3-stage: 50 %, 75 %, and 100 %.
Inputs:
Pin 65 (ED 2), Pin 12 (ED 15), and Pin 36 (ED 7)
Variant 1/3
Variant 1/6
If possible, use different digital inputs for the pedal Retarder request via TSC 1 via CAN as direct specifi-
plate and manual lever. cation for rotor torque.
1 2 3 4
Trittplatte Handhebel 0 1 2 3 n
EU 2 EU 3
% % % %
V V
8-8
Retarder deactivation
8
%
Rotor-Ist-
EBC1 TSC1 Anforderung [%]
Moment [Nm]
Bedienelement EBC1 ABS aktiv
ABS not fully Rotor-actual-
TSC1 EBC1 ABS active
operational Request Control ellement torque [Nm]
EBC1
Break Pedal Pos.
5 6
Anforderung [%]
Request [%]
TSC1
Anforderung[%]
CAN (Retarderreferenzmoment [Nm])
TSC1
7
Request [%]
(Retarder reference torque [Nm])
016 707
Retarder
ZF-Ecomat 2 plus Cooling system
max [C]
points when designing the cooling system:
95
- Heat build-up due to torque converter
awc_in_
(see Torque converter diagram PV) 93C
t_
- Heat build-up due to retarder
90
9.1.1.2 According to List of Lubricants TE-ML 14 9.1.2 Limit temperature values for oil temperature
A/B/C
Oil temperature in transmission oil sump
Thermostat and fan feedback control must be set
so that the max. water temperature T_wa_cin at The following sump temperature values must not be
max. admissible ambient temperature in line exceeded:
service applications corresponds to the diagram.
Transmission cooling constant max. 70 K With oil according to List of Lubricants TE-ML 14 E
(otherwise, vehicle cooling capacity insufficient). - Operating temperature and/or stabilized tempera-
ture max. 105 C.
- In exceptional cases and only for short periods
of time (max. 5 min. per 1 hour) 115 C are
permitted.
Determination of max. permissible water
temperature With oil according to List of Lubricants
TE-ML 14 A / B / C
100 - Operating temperature and/or stabilized tempera-
Ecomat 2 ture max. 100 C.
Ecomat 2 plus
max [C]
90
. .
Vw = f (Voil) = 333.3 dm3/min
For an example of calculation for the braking
250
rating of a vehicle fitted with an Ecomat . .
Vw = f (Voil) = 250.0 dm3/min
transmission and retarder, see Chapter 18.
200
. .
Vw = f (Voil) = 166.7 dm3/min
bar bar
. .
Vw = f (Voil) = 83.3 dm3/min
100 0.20 4
Poil
Pw
0.15 3
50 0.10 2
0.05 1
0 0
. .
Vw, Voil dm3/min 014985
The design of the heat exchanger must be based on As a guide value for light-duty operation, cooling
the Pv torque converter diagram and the flow rate of power of at least 30 kW should be available.
the primary pump. On versions without a retarder,
the oil quantity requiring to be cooled is determined
by the flow rate of the primary pump.
Input speed
4139 S 2107
Depending on vehicle spatial requirements, the oil The oil cooler should not be installed above the
cooler can be installed transmission to avoid erroneous oil level readings
- Transverse behind the transmission or laterally or caused by return oil with engine at standstill.
- separately fitted from the transmission (installa- (See installation guidelines, section 8.3.3:
tion by vehicle manufacturer). Checking oil level on version with separate heat
exchanger installed higher than the center line of
CAUTION the transmission).
Connect waterline in contra-flow! 50 mm nominal The oil cooler must be installed close to the trans-
width must be ensured on the entire length. mission to reduce as much as possible the length
of hoses used and thus keep pressure losses at oil
side as low as possible.
Preferably fit the oil cooler on transmission
9.3 Cooler fitted on transmission engine block. Avoid unnecessary stress on hoses
by means of relative motion. Hoses must be
Specification heat exchanger group secured by brackets so that they cannot be
damaged in case of vibrations.
Chapter 10 Transmission specification can be used
to specify the heat exchanger group. The following should be noted in case of separate
external coolers:
The lines between transmission and oil cooler
9.4 Layout with oil cooler separate from must be routed carefully.
transmission Lines must be routed so to avoid contact or
chafing (relative motion must be considered).
9.4.1 Oil line connections Lines must be suitably fixed.
(Avoid vibrations).
Transmission with retarder: The distance between the transmission and
Internal diameter of connection lines at least exhaust should be at least 100 mm. If the distance
32 mm, hose lines heat resistant to at least 160 C, is not large enough, a screening plate must be
pressure resistant to 20 bar (test pressure 50 bar) and fitted.
not subject to corrosion by oils in the TE-ML 14 List
of Lubricants.
Full-flow transmission oil cooler on cold water pressure side. This configuration is preferred.
Cooling water
expansion tank
Heater
Transmission
oil cooler
Ther-
mostat
Radiator
Ecomat
Engine
trans-
mission
Cooling water
expansion tank
Heater
Ther-
mostat
Transmission
oil cooler
Radiator
Ecomat Engine
trans-
mission
Cooling water
Heater expansion tank
Transmission
oil cooler Thermostat
Vent pipe
Radiator
Ecomat
Engine
trans-
mission
NOTE
If for some specific reason cooling water for the
transmission oil cooler can only be taken from one
bank of cylinders, consultation between the engine
and transmission manufacturers is essential.
Cooling water
expansion tank
Thermostat
Ecomat
transmission V-engine
Radiator
1st cylinder bank
Transmission
oil cooler
Cooling
water pump
Heater
015 617
Cooling water
expansion tank
Thermostat
Ecomat
transmission V-engine
Radiator
Transmission
oil cooler
Cooling
water pump
Heater
015 616
9.6 Specification for transmission heat If no water capable of meeting these requirements is
exchanger available, different grades of water can be mixed
together in order to achieve the specified water
Requirement specification 4139 761 004 is binding. quality (e.g. a mixture of hard and fully desalinated
water).
9.7.1 General Specific gravity (20C): 1.11 - 1.14 (g/ml) DIN 51757
Flashpoint: > 110C DIN 51758
Antifreeze consists of ethylene glycol and anti- Boiling point: 160 C ASTM-D-1120
corrosion additives. Mix water and antifreeze to
make the cooling water. Ethylene glycol raises the
boiling point and lowers the freezing point, thus 9.7.4 Cooling fluid
extending the operating range. Anti-corrosion
additives must protect the cooling system from Cooling fluid is a mixture of fresh water and anti-
corrosion. Antifreeze must be prepared in such a freeze and must have the following properties
way that it retains its properties over a storage Minimum proportion of antifreeze: 35 vol.% test
period of at least two years. using antifreeze tester (areometer or hydrometer)
pH value: 7.5 to 9.0
test using pH meter or indicator paper
9.7.2 Fresh water Residual alkalinity: 10 ml 0.1n HCL
ASTM-D-1121
Only use clean water to produce cooler fluid. It must Flocculation point of 50%-solution: < -35C
comply with the following quality and analysis values: ASTM-D-1177
Color: Transparent, clear Foam volume after 5 min.: 150 ml
Smell: Neutral ASTM-D-1881
Particles in suspension (sediment): None Foam killer time after 5 min.: 5 sec.
pH value (at 20 C): 6.5 - 8.0 ASTM-D-1881
Total hardness: 3 - 10 dH
Ammonia content: Not traceable Reactivity against metal materials:
Aggressive carbon dioxide: Not traceable Removal rate: < 2 g/m2 on test sheets made of L-
Iron and manganese content: Max. 0.2 mg/l PbSn30, CuZn37, GG25, G-AlSi10Mgwa, A1Mn1
Chloride content: Max. 75 mg/l tested according to ASTM-D-1384 and guidelines
Sulphate content: Max. 50 mg/l in "Test of suitability of cooling water additives
Nitrate content: Max. 50 mg/l for combustion engine cooling water" by the
Nitrite content: Not traceable Verbrennungskraftmaschinen e. V. Research
Solid residue after evaporation: Max. 500 mg/l Institute, Frankfurt, Booklet R 315 (1977) or later
Potassium permanganate edition where valid.
consumption: Max. 10 mg/l
Balance index: 0, if possible
Reactivity against elastomers (NBR, EPDM): 5. Place selector lever in position N, start up the
- 50 vol.% antifreeze engine and then, after a brief period at idle speed,
- 100 hour aging at boiling point run for about 4 minutes in the speed range of 1000
- Shore A hardness modification = -10 to +10 SHA - 1500 rpm. Then run the engine until the oil sump
- Volume change V = -10 to +10% temperature reaches approx. 85 C (Section 4.4 of
- Residual pressure deformation < 30% the Operating Manual). The auxiliary cooling
system is then filled and drained automatically.
Cooling water storage limit: 1 - 2 years, after this 6. Check and adjust the oil level in accordance with
time, replace. If sediment forms or concentration the hot marks on the dipstick (refer to Operating
drops considerably, also replace cooling water. Manual, Section 4.3.1 Inspection at Operating
Temperature, with vehicle on level ground,
selector lever in N and engine at idling speed of
9.8 Transmission fill with auxiliary cooling 500 - 700 rpm).
(applicable to all transmissions approved
for use with auxiliary cooling)
When an ECOMAT transmission is being operated Getriebe hat nicht die erforderliche Oelmenge.
A) Vor Erstinbetriebnahme die eGsamtlaenge
aller oKmponenten der Zusatzkuehlung ausserhalb
il volume insufficient for the transmission.
O
A) Determine total lenght of all auxiliary
cooling components outside of the transmission
prior to initial startup.
il volume [Litre]
elvolumen [Liter]
5 5 8mm
8mm DN=1
DN=1
4 m 4 m
DN=16m DN=16m
3
missions cannot be supplied with the total oil fill
3
O
O
2 2
1 1
mission and auxiliary cooling system have been Die erforderliche uZsatzoelmenge einfuellen.
installed in the vehicle, the oil level must be set with eOlstand am Messstab pruefen,ewnn noetig O
bis Marke "CD
LO"bzw
Die massgebende O
.3" 0Ce" rreicht iwrd.
elstandskontrolle
el nachfuellen, Start engine,after 30 secs. check oil level at
dipstick iwth engine idling. If necessary,
add oil to "CO
LD/30C"mark.
ist die Pruefung bei The oil level check carried out
021684
Filling:
1. With the engine stationary, top up with ATF until 6
Oil quantity [litre]
until the engine has been run for a while and you 7. If service work is required: Before working on the
have checked the oil level once again (refer to auxiliary cooling system, first drain off the trans-
Operating Manual, Section 4.3). Failure to do this mission oil!
could result in ATF overflowing from the trans- DN = internal diameter (tube or hose)
mission.
See also Chapter 17, ZF Specification
Oil pan
ATF
Cooling agent
9.10.1 Measurement conditions / Retarder test Difference between oil sump temperature and
cycles water inlet temperature on transmission oil cooler:
_t_spec = t_sump - t_wa_cin
Load vehicle to maximum permissible weight. Difference between oil sump temperature and
Level test track. ambient temperature:
Dry road surface, no rain and if possible no wind GCC = t_sump - t_amb
or gentle wind at the most. If the temperatures (oil and water) change in a
Vehicle heating switched off. cyclical manner, you should calculate the average
Undertake retarder braking with 100% retarder temperature from the values derived from the last
torque without assistance from the wheel brakes. five cycles:
Cooling system under open-loop control
(Lock thermostats open, fan running continuously).
t1u t2u t3u t4u t5u
Ambient temperature > 0 C.
taverage
t1d t2d t3d t4d t5d
021742
- 50 km/h for city bus
- 80 km/h for interurban buses and coaches
v [km/h]
t1u + t2u + t3u + t4u + t5u t1d + t2d + t3d + t4d + t5d
taverage = ( 5
+
5
) :2
10 s Zeit
Time
021745
Measurement points
- Water temperature at
transmission cooler inlet: t_wa_cin
- Transmission sump oil
temperature: t_sump
- Ambient temperature: t_amb
NOTE
- During normal service operation, the max. per-
mitted oil sump temperature of 105 C must not
be exceeded on a long-term basis.
- Isolated, brief periods of peak sump temperatures
(max. 5 minutes within a 1 hour period) are per-
missible up to max. 115 C.
NOTE
- During normal service operation, the max. per-
mitted oil sump temperature of 100 C must not
be exceeded over extended periods.
- Isolated, brief periods of peak sump temperatures
(max. 5 minutes within 1 hour period) are per-
missible up to max. 105 C.
Cooling water
input
Cooling water
Transmission Heater expansion tank
oil cooler
3 Ther-
Water input at mostat
transmission and
heat exchanger
Radiator
Ecomat Engine
trans-
mission
NOTE
M14x1.5 threaded connections must be fitted in the
measuring vehicle for the measurement point no. 5.
04
187.5
68.6
68.6
12
256
187.5
68.6
68.6
03
68.6
68.6
187.5
187.5
256
68.6
68.6
187.5
187.5
Anzugsmomment 225 Nm
256
256
M16x1.5
24 tief
136
89
30
63.5
0
4
16
35
02
6.5
511.2h7
553
015 008
DIN 72585-A1-2.1
019216
DIN 72585-A1-2.1
TEMPERATURGEBER
BAJONETTSTECKER
sensor
plug
Temperature
Bajonet
O4
O3
019217
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
72585-A1-2.1
DIN72585-A1-2.1
Bajonet plug
DIN
O4
O3
DIN 72585-A1-2.1
plug DIN 72585-A1-2.1
023800
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
Bajonet
O4
O3
10.2.4 Angle drive 80 LHD (without axial offset), heat exchanger horizontal on left,
accumulator horizontal on left
DIN 72585-A1-2.1
plug DIN 72585-A1-2.1
023801
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
Bajonet
O4
O3
10.2.5 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left
DIN 72585-A1-2.1
023802
plug DIN 72585-A1-2.1
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
Bajonet
O4
O3
10.2.6 Coaxial output, vertical heat exchanger on right, accumulator rear transverse
023803
TEMPERATURGEBER
BAJONETTSTECKER
Temperature sensor
72585-A1-2.1
DIN72585-A1-2.1
Bajonet plug
DIN
O4
O3
10.2.7 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting
023813
DIN 72585-A1-2.1
DIN 72585-A1-2.1
sensor
TEMPERATURGEBER
BAJONETTSTECKER
plug
Temperature
Bajonet
O4
O3
M 14x1.5
II
M 10x1
015 613
015089
10.3.2 Deep oil pan; left- and right-hand connection prepared, 4149 131 006
015090
400.5
02
2850.5
0.3
15-0.5
M26x1.5
21-0.5
01 01
M27x2
508-0.5
M26x1.5
2850.5
0.3
02
450.5
019931
015092
10.3.5 Flat oil pan; left- and right-hand connection prepared, 4149 131 009
015091
479
192
023784
479
A B 023786
K 02 380 132
K 04 843 584
K 05 597 330
Ausbauhhe
ca. A
B
bezogen auf Linie O4
023805
A B C
477
131
49
023811
10.5 Output
46
torque: 35 Nm)
280
110
X
MA
.6
K1
30 1
700.2
.5
16
M18x1
81.8-0.2
016 862
NOTE
The transmission is supplied without an impulse sensor as standard.
Sensor wheel: 6 impulses per revolution.
Various angle drives (WTR) are available for the transverse installation of the engine and transmission unit:
80 RHD
0.98 1 250 125 ( = 5)
with axial offset
Max. angle drives (WTR) input speed 3400 rpm ^ = in 6th gear 2000 rpm
* Following agreement with ZF
1 2 2 1
80
019924
80
Abbildung
Figure I I
Abbildung
Figure IV IV
47-0.3 85
161 JS8
90+0.5
131.9
178
C
C-C
M12
13
C
178
21.5+1
80
Abbildung
Figure II II Abbildung
Figure III III
Included in
ZF no. the drawing A B Ch6 D E F G L M Fig.
x 4139 303 087 (1269 339 040) 150 130 90 12.2 2.3 10 110 45 8x45 I/II
x 4139 303 181 150 130 - 13.0 - - 110 - - I/III
4139 303 172 180 150 - 14.5 - - 127.5 - - I/III
4139 303 215 Yoke I/IV
10.5.4 Ecomat output flange; coaxial and angle drive 80 RHD with axial offset
AUSSEN
FLANKEN
KERN
Fig. V
Fig. VII
Fig. II
NOTE
Clean output flangebefore
propshaft installation.
Included in
ZF no. A B Ch6 NH7 D E F G L M L Fig. Coaxial <) 80 RHD
the drawing
x 4139 303 087 (1269 339 040) 150 130 90 12.2 2.3 10 110 45 8x45 696 I/II X X
Fig. III
x 4139 303 072 (1269 338 079) 165 140 95 16.2 2.3 11 115 45 8x45 693 I/II X X
4139 303 074 (4139 303 073) 180 155.5 110 16.1 2.3 12 130 36 10x36 693 I/II X
4139 303 235 (4139 303 073) 180 155.5 110 14.1 2.3 12 133.3 45 8x45 693 I/II X
4139 303 081 (4139 303 038) 203 155.52 169.5 10.15 12.1 141 704 I/III X
4139 303 101 (4139 303 038) 203 155.52 169.5 9.65 9.8 141 704 I/III X
4139 303 109 (4139 303 038) 203 155.52 167.9 11.2 12.1 139.3 704 I/III X X
4139 303 207 Yoke 1710 Half round I/IV X
4139 303 153 (4139 303 038) 203 165 11.2 12.1 139.3 704 I/III X
4139 303 192 Yoke 1810 I/V X
x 4139 303 181 150 130 13.0 110 700 I/VI X X
4139 303 172 180 150 14.5 127.5 712.5 I/VI X X
4139 303 166 Yoke 1710 Full round I/VII X
017031
A B 2 C D E F 1 F 2 A B 2 C D E F 1 F 2
D2
3 CONVERTER TEMPERATUR
COUNTER- SWITCH
PRESSURE SENSOR
9.2 9.1 9.3 VALVE 16
10
R3
E
11 D4 D6 D5 D7
RR3
X R3
F1
D2
F 1 -VENTIL 9.2 9.1 9.3 RETARDER-
REGELVENTIL
18 5 KUEHLER-
10 HAUPTDRUCK-
RETARDER
CONTROL VALVE UMSCHALT-
F1 VENTIL VENTIL
F MAIN PRESSURE
VALVE 12
COOLER
CHANGEOVER
D8 D8 R1 DETAIL X
VALVE
AUSFUEHRUNG
P HAUPTDRUCKVENTIL
F 2 -VENTIL 9.2 9.1 9.3 MIT DRUCKABSENKUNG
F2 VERSION
MAIN PRESSURE VALVE
D9 R2 WITH PRESSURE REDUCER
RETARDER
RETARDER-
20 EINSCHALTVENTIL
RETARDER
ENGAGEMENT VALVE
WK D2
P PRIMAER-
PUMPE
D1 PRIMARY PUMP
14
DROSSELDRUCKVENTIL A2
THROTTLE PRESSURE
SAUGFILTER
021767 VALVE 13 SUCTION FILTER
P 17
A1
P
12 Peripheral equipment
Variant with 3 push-buttons From drawing no.: 6006 617 099 (b)
Z view Z
ANSICHT
Dashboard cut-out section
Armaturenbrett-Ausschnitt
.5
x0
ma
R
R
D
N
C
N
D
R B
5-4
Version vertical
Ausfhrung SenkrechtRR- -N
N -- DD VersionSenkrecht
Ausfhrung verticalD D- N-- NR - R
Standard Combined
D N R R N D cover plate cover plate
A A 102 + 1 153 + 1
Ausfhrung Waagrecht D - N - R Ausfhrung Waagrecht R - N - D B 99 + 0.5 151 + 0.5
Version horizontal D - N - R Version horizontal R - N - D
C 31 + 0.5 31 + 0.5
1 4 7 10
AMP MATE-N-LOK
MATE-N-LOK
3.5
b 2 5 8 11 12-POL.
12 PINSSTIFT
Z 3 6 9 12 AUFNAHMEGEHAEUSE
INTAKE HOUSING
33 +1 98 +0.5
014900
Variant with 5 push buttons From drawing no.: 6006 617 103 (b)
ANSICHT
Z view Z
Dashboard cut-out section
Armaturenbrett-Ausschnitt
.5
x0
ma
R
R
1
N
31+0,5
2
D
D 151+0.5
2
N
1
R
5-4
Ausfhrung Senkrecht
Version vertical Ausfhrung Senkrecht
Version vertical
R-N-D-2-1 1-2-D-N-R
R-N-D-2-1 1-2-D-N-R
1 2 D N R R N D 2 1
153 1
Ausfhrung
VersionWaagrecht 1 - 21 --D2- -ND- R- N - R
horizontal Ausfhrung
Version Waagrecht
horizontal R - N R- -DN--2D -- 12 - 1
1 4 7 10 AMP
AMP MATE-N-LOK
MATE-N-LOK
3.5
b 2 5 8 11 12-PIN
12-POL.STIFT
STIFT
INTAKE HOUSING
AUFNAHMEGEHAEUSE
33 +1 150 +0.5
Z 3 6 9 12
014 902
Technical data
Rated voltage: UN = 24 V Version Parts list no.
Operating voltage: UN = 20 - 32 V Horizontal 1-2-D-N-R 6006 017 200
Current rating: IAmax = 1 A Horizontal R-N-D-2-1 6006 017 203
Operating temperature: - 20 C ... +70 C Vertical 1-2-D-N-R 6006 017 204
Storage temperature: - 40 C ... +80 C Vertical R-N-D-2-1 6006 017 202
Variant with 6 push buttons From drawing no.: 6006 617 107
ANSICHT
Z view Z
.5
1
x0
N
ma
R
2
D
31+0,5
3 3
2 D
151+0.5
1 N
R
5 -4
Version vertical
Ausfhrung Senkrecht VersionSenkrecht
Ausfhrung vertical
R - NN- -DD- 3- 3-2 -- 21 - 1 11- 2- -23 - 3
D -- ND- -RN - R
1 2 3 D N R R N D 3 2 1
153 1
0659
0659055
055323
323
CONTACT PIN
KONTAKTSTIFT
NO. 926898-1
NR.926898-1
X viewX 0659
0659055
055294
294
ANSICHT
1 4 7 10 AMP
AMPMATE-N-LOK
MATE-N-LOK
3.5
b 2 5 8 11 12-PIN STIFT
12-POL. STIFT
INTAKE HOUSING
AUFNAHMEGEHAEUSE
33 +1 150 +0,5
Z 3 6 9 12
014 903
Technical data
Rated voltage: UN = 24 V Version Parts list no.
Operating voltage: UB = 20-32 V Horizontal 1-2-3-D-N-R 6006 017 208
Current rating: IAmax = 1 A Horizontal R-N-D-3-2-1 6006 017 210
Operating temperature: -20C ...+70C Vertical 1-2-3-D-N-R 6006 017 211
Storage temperature: -40C ...+80C Vertical R-N-D-3-2-1 6006 017 212
4.5+/-0.5
12.6+/-0.5
GENERAL TECHNICAL DATA:
Armaturenbrett-Ausschnitt
29.2+/-0,1
Nennspannung: U = 24V
12.2 CAN range selector
Nominal Voltage
5-1
Cutout instrument panel
Variant with 6 push buttons.
70 +/-2
Schutzart (eingebaut): IP5K0
31+0,5
97.5+/-1
Protection class (installed):
3. CAN
CAN-Schnittstelle: ISO 11898
151+0.5 CAN-Interface:
45 Baudrate: 250 kBit / sec
min. 30
E2 E4 E6
12-4
E1 E3 E5
8 9 10 11 12 13
EU1 EU2 EU3 EU4 EU5 EU6
1 56
Waagrechter Einbau: 1-2-3-D-N-R KL15 ADVP
A2 4
horizontally mounted CANL
3 48
CANL CANB_L
Twisted Pair A1
5 47
9 10
7 8
5 6
3 4
1 2
13 14
11 12
CANH CANB_H
33 +/-1
6
120 Ohm CANH
152,5 +/-1 7
CANT
VM
2 14
Senkrechter Einbau: 1-2-3-D-N-R
KL31 KL31
vertically mounted
ZF-Bestell-Nr.
A1 Elektr Steuerung EST146/147 ECU EST146/147 ZF-Part Number
Ausfhrung
A2 CAN-Tastenschallter CAN-Pushbotton switch
Version mit Blende
E1 Schalter (plus- / minus-) switch (highside / lowside) with cover
E2 Schalter (plus- / minus-) switch (highside / lowside)
E3 Schalter (plus- / minus-) switch (highside / lowside) Waagrecht 6006.340.014
1 2 3 D N R
E4 Schalter (plus- / minus-) switch (highside / lowside) horiz. mounted
E5 Schalter (plus- / minus-) switch (highside / lowside)
1
2
3
D
N
R
12.3.1 Function
Us(V)
Automatic gear engagement is dependent on vehicle
speed and engine load.. The engine load is deter- 4,4 + 0,3
OC
4139 S 0035
NOTE
The sensor control lever must not be drawn in the
load direction when coasting or when the engine is
over-revving. Refer to Chapters 11.2 to 11.5 for
instructions on how to install the load sensor.
12.3.2 Load sensor drawing From drawing no.: 0501 209 635
Technical data
Funktion
Erfassung eines Winkels und Umsetzung in ein analoges Signal
Allgemeine Anforderungen 4
Kennlinie fr Betriebspannung UD = 5,00 V
Nennarbeitsbereich
U (V) 4.7
4.5 4.1 1
4
3.5
3
2,5
2
1.5
1
0.6
1 0.50.3
0
-30 -20 -10 0 10 20 30 40 50 60 70 Winkel
(Grad)
Nennarbeitsbereich: 0 bis 45
Gesamter Winkelbereich: +105 +5/-3
Referenzmarke LOW 0: U = 1,115 V 150 mV
Referenzmarke HIGH 45: U = 3,885 V 150 mV
Toleranzbereich: 150 mV
Elektrische Kenngren
Betriebsspannung: 5 V 5%
berspannungsfestigkeit: 32 V
Verpolschutz: 32 V
Betriebsstrme: 15 mA
Isolationswiderstand: 5 MOhm (gegenber Masse)
Isolationsfestigkeit: 500 V Wechselspannung
700 V Gleichspannung
Kurzschlussfestigkeit: 32 V
EMV-Festigkeit: DIN 40839 Teil 3 250 V
DIN 40839 Teil 4 150 V/m
Lebensdauer
2.000.000 Zyklen davon 60% bei +90 C
20% bei +120 C
20% bei -30 C
Schutzart
IP 66 A nach DIN 40050 Bl. 9
Betriebstemperatur
Betriebstemperaturbereich: -40 C bis +125 C 2
Max. Dauerbetriebstemperatur: +120 C
Referenztemperatur: Technische Daten spezifiziert bei +20 C 2 C
Mechanische Beanspruchung
Schockfestigkeit: nach DIN 40046 BL7; a = 100 g, t = 11 ms, z = 50
Vibration: nach DIN 40040 BL8
siehe Pflichtenheft Berichts-Nr. 472 4139 045
Medienbestndigkeit: Motor und Getriebele; Benzin, Diesel;
Reinigungsmittel (z.B. Kaltreiniger)
Umweltbeanspruchung
Korrosionsbestndigkeit
Spritzwasser: DIN 50017 KFW (4 Zyklen a 24h)
Salzsprhnebel: DIN 50017 KFW (4 Zyklen a 24h)
Klima
Klte: Prfung Aa nach DIN 40046 BL3 (-55 C, 16 h)
Trockene Wrme: Prfung Eb nach DIN 40046 BL4 (+125 C, 16 h)
Temperaturwechsel: Prfung Na nach DIN 40046 BL14 (-40 C, +120 C)
Feuchte Wrme: Prfung Ca nach DIN 40046 BL5 (+40 C, 16 h)
Feuchte Wrme zykl.: Prfung Dd nach DIN 40046 BL31 (+40 C, 6 Zyklen)
Einbauvorschriften
4149 765 103 - 2004-12 Schraubenanzugsmoment: 8 Nm + 4 Nm 12-7
ZF-Ecomat 2 plus Peripheral equipment
12.4 PWM-Signal
The PWM signal is a pulse-width modulated signal The PWM signal is a rectangular signal with a fixed
providing information on the current load status of frequency but a variable time share of high and low
the engine rather than the load sensor voltage pre- levels.
viously used. This signal is processed by ECU 146 / ECU 147.
Periode T = 1f
1
Perod T = f
24
PWM - Arbeitsbereich
PWM operating range
t
U
[v] t
t
9 2 2
3 1
0
0 1 2 3 4 5 6 7 8 9 10 abs. Pulsweite [ms]
pulse width [ms]
Hardware:
Indexing threshold from low to high +9 V
Indexing threshold from high to low +2 V
Input resistance in ECU 146/ECU 147 10k 2k (pull-up supply positive)
Software:
Adaptive adjustment to the PWM frequency (period) whereby a range of 50 Hz to 500 Hz is considered
favorable.
Programming parameters:
Signal amplitude, positive or negative
Lower failure threshold %
Upper failure threshold %
Minimum value %
Maximum value %
The difference between the maximum and minimum values must be greater than 50% of the period length.
T_Mot
TV T_Eng
[%] [Nm]
1000
90 Kick-Down 800
100% red. Drehmoment
Vollast konstante Red. torque
80 Full throttle Gaspedalstellung (%) 700
70 600
75%
60 500
Constant accelerator
50 position (%) 400
40 50% 300
30 200
25%
20 100
023 787
M27x1
8 0.2
4-0.1 Technical data
Permiss. tight. torque: max. 30 Nm
Operating voltage: 6 - 24 V
Operating temperature: -30C to +150C
briefly (1 h) 180C
16.4 0.8
on sensor
2 +0.2
72.8 0.1
19 h14
M14x1.5
10
83 +- 1
SW27 h13
014 991
12.7.1 Kick down switch S1 (Holding switch - high holding force) From drawing no.: 6007 603 030
014 908
4139 S 2056
Key to drawing
A Sealed with red safety coating
B Breather opening with filter
C Stamped on: Manufacturers code,
ZF no.
Date of manufacture:
Month, Year
Technical data
Switch point: ON at 0,9 bar 0,2 bar at
room temperature
beginning from
Operating pressure: 10 bar
Pressure resistant up to: 30 bar
Tightg. torque: Max. 30 Nm
Pressure medium: Air
Rated voltage: 12/24 V
Operating temperature: -30C to +100C
Storage temperature: -40C to +100C
Protection acc. to
DIN 40 050: Connctions acc. to IP-00
With customer-specific
plug: Contact space IP-64
014 912
Technical data
Rated voltage: 24 V
Load : 10/20 A
Type of protection: IP 33 - IP 20 terminal -
DIN 40 050
when using plug sockets
ensure connection plug
points downwards!
! DANGER
The driver and vehicle manufacturer must be infor-
med without fail of the correct method of operating
the vehicle on uphill and downhill inclines. Rolling
backwards on hills must be prevented in the usual
way, by using the parking brake or bus stop holding
brake. To move away from stationary, depress the
accelerator lightly - transmission engages - release
brake.
When NBS is used in connection with a door closing
device, the vehicle must never be able to begin
moving when not under control.
The bus stop holding brake must only be released
following "active intervention" by the driver, e.g.
* NBS activation via push button or alternatively via CAN J 1939, see
accelerating or releasing the brakes by hand. Table above.
Air compressor
ZF-Ecomat 2 plus
Pressure
regulator Rear axle
13.2 Connection diagram (electric)
13-2
brake The pushbutton
should ensure that
valve
Solenoid the vehicle ist pre-
valve vented from rolling Non-return
P
backwards. valve
NBS Signal to
transmission
Manual parking
range brake valve
NBS signal to
transmission
NBS signal to
Footbrake
transmission
Bus stop holding brake solenoid valve and NBS pressure switch control valve
must be installed in separate brake circuits.
ADVANTAGE: Brake remains applied approx. 0.3 s after bus stop
holding brake release.
Combination
Diaphragm cylinder cylinder
014 990
From drawing no.: 4139 720 045
Neutral at standstill
ZF-Ecomat 2 plus Neutral at standstill
Driveline Current
13.3.1 NBS active display via digital signal engaged gear
Neutral 00b* 0
We recommend as standard: NBS 00b* 1
NBS active digital display via AD10 Pin 52. Quit NBS 01b* in the beginning 1
Gear 01b* 1-6
Signal definition: Gear shifts 01b* see below
Signal is active if NBS is activated. Engage gear 01b* in the beginning see below
*b = Binary coding
13.3.2 NBS Active Display via CAN Position of selector switch Requested driving range
and
B14 021648
M27x1
8 0.2
4-0.1
16.4 0.8
2 +0.2
Gewinderille
DIN 3852,
Form A
10 0.2
72.8 0.1
Groove DIN
3852, form A
38 +0.5
19 h14
M14x1.5
10
83 +- 1
SW27 h13
014 991
Technical data
Permiss. tight. torque: max. 30 Nm
Operating voltage: 6 - 24 V
Operating temperature: -30C to +150C
briefly (1 h) 180C
on sensor
Storage temperature: -40C to +150C
NOTE
Use seal ring A 14x18 DIN 7603 Cu
no. 0634 801 038.
14.6 Temperature display gauge A5 From drawing no.: 0501 204 074
Information from the temperature sensor is sent to a temperature display gauge. The gauge scale is divided
into 3 colored sections:
Green: All normal driving conditions
Green-red: Braking operations with retarder only
Red: Oil temperature excessive (warning lamp resp. acoustic signal at 145 C)
K9
A5
014913
103
8
6
102
8
6
101
-10 0 10 20 30 40 50 60 70 80 100 120 140 C
015 088
The CAN connection makes simple integration in The electronic automatic control system makes a sig-
new vehicle concepts possible. Joint use of sensors is nificant contribution to
possible and connectors and cables numbers can be increasing shift quality and safety
reduced. improved cost-effectiveness, also thanks to
further reduction of fuel consumption levels
Various vehicle and transmission parameters increased reliability and
(direction of travel, drive range, engine load, engine simplification of installation and service
speeds, transmission temperature, driving speed
etc.) are recorded in the control system and proces-
sed into signals for activating the transmission
hydraulic unit. Furthermore, transmission-specific
information and requests are communicated to the
vehicle management via the CAN and/or main
power system interface.
Non-volatile error memory to save error status in For these reasons, the EST 146 / 147 should be
transmission system located in a dry compartment. Recommended
Automatic electronic control unit capable of self installation locations:
diagnosis - In the driver's cab
Diagnosis with various devices in accordance - Inside the vehicle
with ISO standard 9141 or SAE J 1587 - In the switch box
EOL configuration of application parameters to The permitted installation positions MUST be
reduce the number of variants and adaptation to complied with (* refer to chapter 15.6). Other
customer requirements positions can only be approved after consultation
EEPROM parameter setting: selection of suitable with the ZF Application Engineering dept.
drive programs and range change assignments. The EST 146 / 147 housing should be easily
accessible. No earthing cable required.
Ensure min. 150 mm disassembly space for the
68 pin plug so it can also be removed from the
15.3 Functions available on request installed EST 146 / 147 housing for service
purposes.
Gear approval via additional button (2nd reverse In the following cases, the EST 146 / 147 must
gear button) not be energized. Switch ignition OFF and
Driving programs: remove the ignition key:
The automatic electronic control system can be - When connecting the EST 146 / 147 to the
fitted with up to six different shift programs and vehicle circuit.
four different customer blocks. - When disconnecting the 68-pin connector.
Program adaptation, i.e. selection of two suitable - When disconnecting the battery from the
shift programs is undertaken by the vehicle vehicle circuit.
manufacturer via end-of-line configuration
(EOL). NOTE
The drive program requested can be called up Do not install the EST 146 / 147 on vibration
during driving e.g. via a switch on the dashboard. dampers!
Status monitoring: Errors which may result in
damage in the transmission are indicated by the The positive (+) supply (terminal 15 or ignition)
depressed range change selector flashing must only be switched on or off with the vehicle
stationary.
For the following work, the ignition must be
switched OFF and the plug connector must be
15.4 Installation requirements disconnected from the EST 146 / 147:
- For electrical repairs to the vehicle and
When installing the EST 146 / 147, attention should especially for electric-arc welding!
be paid to the following points: - For insulation tests on the electrical equip-
The EST 146 / 147 must be installed in the ment.
vehicle in a suitable location where it is protected Jump-starting the engine:
from: To prevent excess voltages, we recommend using
- excessive atmospheric humidity a buffered jump starting unit, or connecting an
(max. +40C / 95% humidity) adequately charged battery in parallel.
- extreme temperatures
(min. -40C /max. +70C)
- dust build-up
- water splash
15.5 Technical data of EST 146 / 147 Interference impulse link to signal lines.
The capacity of the interference impulse should be
Rated voltage: U = 24 V coupled to the sensor and signal lines using coupling
Operating voltage: U = 18 - 32 V (36 V for 5 min) tongs.
Full load current: I=6A
High-energy, cap. connected negative impulse.
Resistance to interference impulses Acc. to ISO 7637, Part 2, test impulse 1
Interference impulse connection to vehicle's Us = -250 V, td = 2 ms, tl = 5 s, Ri = 10
voltage supply. Function criterion: a)
Unless otherwise specified, the interference impulses
should be superimposed on a vehicle voltage supply High-energy, cap. connected positive impulse.
of Ub = +28 V. Acc. to ISO 7637, Part 2, test impulse 2
Vs = +250 V, td = 0.05 ms, tl = 5 s, Ri = 10
High-energy, negative impulse. Function criterion: a)
Acc. to ISO 7637, Part 2, test impulse 1a
Us = -300 V, td = 2 ms, tl = 0.5 s, Ri = 4 Groups of short cap. connected negative impulses.
Function criterion: c) Acc. to ISO 7637, Part 2, test impulse 3a
Vs = -250 V, td = 0.1 s, Ri = 50
High-energy, negative impulse. Function criterion: a)
Acc. to ISO 7637, Part 2, test impulse 1b
Us = -600 V, td = 2 ms, tl = 5 s, Ri = 50 Groups of short cap. connected positive impulses.
Function criterion: c) Acc. to ISO 7637, Part 2, test impulse 3b
Vs = + 250 V, td = 0.1 s, Ri = 50
High-energy, positive impulse. Function criterion: a)
Acc. to ISO 7637, Part 2, test impulse 2
Vs = +300 V, td = 0,05 ms, tl = 5 s, Ri = 10 Electrostatic discharge
Function criterion: c)
Interference impulse through electrostatic
Groups of short negative impulses. discharge.
Acc. to ISO 7637, Part 2, test impulse 3a Acc. to EN 61000-4-2
Vs = +200 V, td = 0.1 s , Ri = 50 Us = 8 kV housing, / Us = 5 kV connector pins
Function criterion: a) C = 150 pF, Ri = 330
Function criterion (housing): a)
Groups of short positive impulses. (connector pin): d)
Acc. to ISO 7637, Part 2, test impulse 3b
Vs = +200 V, td = 0.1 s, Ri = 50 Electromagnetic compatibility (EMC)
Function criterion: a)
System measurements
Fall in voltage when starting.
Acc. to ISO 7637, Part 2, test impulse 4 Resistance to induced interferences (CS)
Us = -16 V, Ua = -12 V, t6 = 100 ms, Structure in accordance with
t8 = 20 s, tf = 100 ms, Ri = 0.01 MIL-STD-462, NOTICE 3
Function criterion: b) The vehicle voltage supply should be super-
imposed with a sine-wave AC current of 3 Vss .
Load-dump impulse Frequency range: 30 Hz to 120 kHz
acc. to ISO 7637, Part 2, test impulse 5 Function criterion: a)
Us = 200 V
Td = 150 ms, W = 800 J, Ri = 2.0
Function criterion: b)
15.6.1 Installation drawing EST 146 From drawing no.: 6009 690 001
15.6.2 Installation drawing EST 147 From drawing no.: 6009 691 001
15.7.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector From drawing no.: 6029 729 155
15.7.2 Current circuit diagram EST 146 / EST 147 with CAN, with CAN range selector From drawing no.: 6029 729 232
15.7.3 Current circuit diagram EST 146 / EST 147 without CAN(NEng), with digital range selector From drawing no.: 6029 729 215
15.9.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 1 From drawing no.:. 6029 729 156A / Page 1
Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 2 From drawing no.: 6029 729 156A / Page 2
Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 3 From drawing no.: 6029 729 156A / Page 3
Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 4 From drawing no.: 6029 729 156A / Page 4
15.9.2 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 1 From drawing no.: 6029 729 233 / Page 1
Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 2 From drawing no.: 6029 729 233 / Page 2
Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 3 From drawing no.: 6029 729 233 / Page 3
Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 4 From drawing no.: 6029 729 233 / Page 4
15.9.3 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 1 From drawing no.: 6029 729 216 / Page 1
Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 2 From drawing no.: 6029 729 216 / Page 2
Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 3 From drawing no.: 6029 729 216 / Page 3
Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 4 From drawing no.: 6029 729 216 / Page 4
15.10 Function description EST 146 / 147 PIN 5 (AD5) Digital output
accoding to Function: Activation of shift element C
Current circuit diagram 6029 729 155 / 215 The C shift element is activated via solenoid valve
- Application with/without CAN + FS without Y15.
CAN
Circuit diagram 6029 729 156 / 216 PIN 6 (AIP3) PWM current output
- Application with/without CAN + FS without Function: Activation of retarder proportional
CAN solenoid valve Y1
NOTE Same as current activation of retarder proportional
Separate current circuit diagram/connection valve Y1 in accordance with retarder torque
diagram for CAN range selector 6029 729 232/ requested.
6029 729 233
Pin pattern 6029 729 073 PIN 7 (CANF-T) CAN Full Termination
Function: Terminal resistance 120 Ohm
Voltage supply 24 V If EST 146 / 147 is defined as an end participant, the
terminal resistance must be activated in the EST by
Voltage supply limits: installing a jumper between PIN 26 and PIN 7.
Full functional capability between 18 V and 32 V
PIN 8 (AD9) ) Digital output
NOTE Function: Activation of solenoid valve Y2 for
At voltage levels < 18 V (terminal 30) the control retarder accumulator
device actively switches into a safe status (neutral).
PIN 9 (AD4) Digital output
RESET: Via range selector neutral Function: Activation of shift element D
The D shift element is activated via solenoid valve
Current consumption: Y14.
Standby: 1 mA
Idling: < 300 mA PIN 10 (AD7) Digital output
Full load: 6A Function: Activation of shift element A
Test period: 1h The A shift element is activated via solenoid valve
Y17.
PIN 1 (VM1) Earth/Ground supply
Function: Earth/ground supply for control unit PIN 11 (AD16) Digital output
(-) terminal 31 (vehicle earth/ground) Function: Activation of lock-up clutch shift
element
PIN 2 (VMG1) Sensor earth/ground supply The loch-up clutch shift element is activated via
Function: Earth/ground supply for sensors solenoid valve Y18.
NOTE
Relay K10 for brake light activation.
1 2 3 4
023736
6 5
Scope of supply
Customer version 6009 208 003 including:
019215
t1 1 sec Thousands on
t2 0.3 sec Thousands off
AError display (read out error memory) t3 1 sec Lamp off separation
t4 0.3 sec Hundreds on
Display via range selector lighting (only available t5 0.3 sec Hundreds off
on range selectors without CAN) t6 2 sec Minus on L line
t7 1.5 sec Lamp off start
Display via assigned AD (digital output), lamp t8 4 sec Lamp off end
Connection cable SAE J 1587 + ISO 9141 From drawing no.: (= Order no.) : 6008 207 023
ca. 2.4 m
X2
1
2
3
X1
1
2
3 0.3 m
4
5
023808
6 n.b.
7 n.b.
8 n.b. X3
9 n.b. 1
2
3
4
5
6 n.b.
173 81 Zulssige
Perm. Einbaulagen
installation positions
64
A
53
46 68
24 45
XX
D
1 2 22 23
N
R
1
6.2
1020.2
35
15
XX
XX
N D R
D R
135
100
min 15
Minimum distancezum
Mindestabstand for disconnecting
Abstecken desplugSteckers
014 998
VP
Power
VM supply AU
Safety
switch
AD1
AD2
ED1 AD3
ED2 AD4
ED3 AD5
ED4 AD6
ED5 AD7
ED6 Digital AD8
Digital AD9
ED7 outputs
ED8 inputs AD10
ED9 AD11
ED10 AD12
ED11 AD13
ED12 AD14
ED13 ADVP
ED14 ADM1
ED15
EDM1
EDM2
Micro Status
Computer monitoring
EF1
EF2 Speed
EF3 inputs
EF4
Current AIP1
AIP2
output AIP3
ER1
ER2
ER3
EU1 Analog SD1
High Speed SD2
EU2 inputs
EU3 SD3
ADM2
EUPR CANF-T
Full CAN- CANF-H
CANF-L
Interface CANB-H
CANB-L
ISO- SDOK
Interface SDOL
Program
EEPROM RAM
memory
019863
VP
Power
VM supply AU
Safety
switch
AD1
AD2
ED1 AD3
ED2 AD4
ED3 AD5
ED4 AD6
ED5 AD7
ED6 Digital Digital AD8
ED7 outputs AD9
inputs AD10
ED8
ED9 AD11
ED10 AD12
ED11 AD13
ED12 AD14
ED13 ADVP
ED14 ADM1
ED15
EDM1
EDM2 Micro
Status
Computer
monitoring
EF1 Speed
EF2
EF3 inputs
EF4
Current AIP1
output AIP2
AIP3
ER1
ER2
ER3 Analog
EU1 High Speed SD1
EU2 inputs SD2
EU3 SD3
ADM2
EUPR CANF-T
Full CAN- CANF-H
Interface CANF-L
CANB-H
CANB-L
SAE J1708-H
J1708 J1708-L
Program
EEPROM RAM
memory
019864
16 Wiring
LX2 -
Opt
W4
LM1 LM3 LM2 Lx7 Temp. sensor LX3 -
2
39.7
023782
013578
The wiring should be routed in the vehicle ensuring Do not fasten wiring
that it harness to oil, water, or
a) is not damaged pressure hoses.
b) can be accessed again at all times.
!
welding work.
1 3 5
protected from the for differences in length.
effects of heat (install
2 4 6 max 6 x
Max. 3m cable length
max 3m Kabel
heat shield, if necessary) with 6 loops, curve
and chafing points. radius at least 20 mm.
!
subject to tension
(especially in the bend
OK area of articulated
buses).
17 ZF documentation
17.1.1 Components
4143 Z F F PA R T S L I S T O R G A N I Z AT I O N
MODULAR PARTS LIST TECHNICAL INF/MODIFICATION NO. *DISPLAY* SHEET 001
---------------------------------------------------------------------------------
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
ECOMAT 2 6 HP - 602 C 2
MODEL 3 CONTROL MIT EST 146 24 VDC 4
PARTS LIST NO. SERIAL NO. 7 TRANSMISSION 6HP602C
1 4149 064 XXX XXXXXX 3 1 ZF-NO. 6009090XXX SER. NO. XXXXX 2
5 PROGRAMMIER 6009390XXX
CUSTOMER
SPEC. NO
XX XXXXX XXXX 4 6 CUSTOMER NO. XXXXXXX
TOTA L 3.43 - 0.59 SPEEDO
6
5 R AT I O
RATIO IMP/U6.00
xn
P.T.O. N - n= - ENGINE e1 022 486
OIL CAPACITY OIL GRADE SEE
7 IN LITERS 20 LUBRIC. LIST TE-ML 14 8
9 A 10
D
019942 023812
1 Transmission Parts List No. 1 EST 146 / 147 Parts List No.
(for matching EST 146 / 147, check documen- (for matching transmission, check documenta-
tation) tion)
2 Transmission model designation, including 2 EST 146 / 147 serial no.
number of gear ratios 3 ECU designation
3 Transmission serial no. 4 Rated voltage
4 Client's order no., if known to ZF 5 Programming
5 Transmission ratio range 6 Client's order no., if known to ZF
6 Speedo signals 6 impulses/revolutions 7 Transmission model designation, including
7 PTO model number of gear ratios
8 PTO ratio (Check that number of ratios is correct!)
9 Approx. oil quantity required for first filling
10 ZF List of Lubricants No.
17.2.1 Components
4143 Z F F PA R T S L I S T O R G A N I Z AT I O N
MODULAR PARTS LIST TECHNICAL INF/MODIFICATION NO. *DISPLAY* SHEET 001
--------------------------------------------------------------------------------
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
D
019923 019399
1 Transmission Parts List No. 1 EST 146 / 147 Parts List No.
(for matching EST 146 / 147, check documen- (for matching transmission, check documenta-
tation) tion)
2 Transmission model designation, including 2 EST 146 / 147 serial no.
number of gear ratios 3 ECU designation
3 Transmission serial no. 4 Rated voltage
4 Client's order no., if known to ZF 5 Programming
5 Transmission ratio range 6 Client's order no., if known to ZF
6 Speedo signals 6 impulses/revolutions 7 Transmission model designation, including
7 PTO model number of gear ratios
8 PTO ratio (Check that number of ratios is correct!)
9 Approx. oil quantity required for first filling
10 ZF List of Lubricants No.
Standbereich (nMot=0) STOP zone engine stopped STOP niveau l'arrt(nmot=0) STOP Zona di fermo(nmot=0) STOP
Warmbereich 80-90C HOT hot zone 80-90C HOT moteur chaud 80-90C HOT Zona di caldo 80-90C HOT
Kaltbereich 30C COLD cold zone 30C COLD moteur froid 30C COLD Zona di freddo 30C COLD
019 891
Standbereich (nMOT=0) STOP engine stop zone STOP niveau l'arrt(nmot=0) STOP Zona di fermo(nmot=0) STOP
Warmbereich 80-90C HOT hot zone 80-90C HOT moteur chaud 80-90C HOT Zona di caldo 80-90C HOT
Kaltbereich 30C COLD cold zone 30C COLD moteur froid 30C COLD Zona di freddo 30C COLD
019 892
ACHTUNG CAUTION
Getriebe mit Zusatzkuehlung. Transmission with auxiliary cooling.
Getriebe hat nicht die erforderliche Oelmenge. Oil volume insufficient for the transmission.
A) Vor Erstinbetriebnahme die Gesamtlaenge A) Determine total lenght of all auxiliary
aller Komponenten der Zusatzkuehlung ausserhalb cooling components outside of the transmission
des Getriebes ermitteln. prior to initial startup.
Aus der Gesamtlaenge und Leitungs DN(Innendurchmesser) Determine additional oil volume on the basis of
die Zusatzoelmenge ermitteln. total lenght and line - DN(inner diameter).
m
4m mm mm mm
6 =2 =22 m 6 =24 =22
m
Oelvolumen [Liter]
20m 20m
B) Vor Erstinbetriebnahme Oelstandskontrolle durchfuehren. B) Prior to running transmission for the first
Motor starten, nach 30 Sekunden bei Leerlauf-Drehzahl time, carry out oil level check.
Oelstand am Messstab pruefen,wenn noetig Oel nachfuellen, Start engine, after 30 secs. check oil level at
bis Marke "COLD" bzw."30C"erreicht wird. dipstick with engine idling. If necessary,
Die massgebende Oelstandskontrolle add oil to "COLD/30C" mark.
ist die Pruefung bei The oil level check carried out
Betriebstemperatur 80 - 90C. at 80C to 90C operating
temperature gives the
Bei Motorleerlauf-Drehzahl Standbereich (n Mot=0) STOP conclusive reading. engine stop zone STOP
Warmbereich 80-90C HOT hot zone 80-90C HOT
und Getriebe Neutral
muss Oelstand im Oil level must be in
Warmbereich "85C" warm range "85C/HOT"
bzw. "HOT"liegen. Kaltbereich 30C COLD with engine idling and cold zone 30C COLD
transmission in neutral.
021 684
18 Calculations and conversion tables Please observe the following points concerning
gradability:
18.1 Driveline design
Gradability in the 1 st mechanical gear must be
the criterium, because the torque converter
Use the following vehicle performance formulae to
should only be used as start-up assistance.
select driveline design. They enable you to select the
Reference value is S > 11 %.
best components to suit your special requirements In difficult terrain, a larger S value should be
(e.g. required top speed, gradability etc. as a function selected.
of axle ratios, transmission ratios, tire radii etc.).
The following is valid in practice for extreme
The formulae can either be solved using the para- applications: Starting capacity, e.g. starting off is
meters required or by iteration. still possible up to max = 0.8 Smax..
(Smax. = gradability at stall-point.)
Calculation formulae:
1 TT [Nm] iG iH tot
S = 100 [ ___________ ( ___________________ 0.0473 CW A VF2 [(km/h)2]) fR]
m [kg] 9.81 rdyn [m]
2. Engine speed nMot = nRet (only applies when lock-up clutch closed)
v [km/h] iG iH
nT [1/min] = nMot [1/min] = ______________
0.377 rdyn [m]
Calculation example
18 000 9.81 30 7
Brake rating PB = ________________ [sin (arc tan _____ ) + 0.01]
3600 100
30 2.01 5.92
nT [1/min] = nEng [1/min] = ______________ = 2032 1/min
0.377 0.466
Braking ability S on downhill inclines with braking torque T = 1300 Nm at nRet = 2200/min in 2nd gear and
v = 30 km/h
Unit in3 ft3 yd3 gal (UK) gal (US) cm3 dm3 1) m3
Statutory units
1 J = 1 277.8 10-9 0.10197 377.7 10-9 238.8 10-6 0.73756 947.8 10-6
1 kWh = 3.6 10-6 1 367098 1.3596 859.84 2.6553 106 3412.14
Units to be converted
1 kp m = 9.80665 2.724 10-6 1 3.704 10-6 2.342 10-3 7.2330 9.295 10-3
1 PS h = 2.6476 106 0.73550 269980 1 632.369 1.9528 106 2509.4
1 kcal 1) = 4186.8 1.163 10-3 426.93 1.581 10-3 1 3088 3.9683
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
18-5
UK = Great Britain, US = United States of America
1) If cwt and tn are used with prefix long or sh, this indicates that the reference is to the UK long cwt and long tn, or to the US short (sh) cwt and short
tn respectively.
Calculations and conversion tables
Force units
1 kp = 9.80665 N 10N
1 lbf (pound-force) = 4.44822 N 1 N = 0.101972 kp 0.1 kp
1 pdl (poundal) = 0.138255 N = Kraft. die eine Masse von 1 lb um 1 ft/s2 beschleunigt 1 N = 0.224809 lbf
Unit N/m2 bar mbar bar N/mm2 kp/mm2 at kp/m2 Torr atm lbf/in2 lbf/ft2 tonf/in2
Statutory units
Units to be converted
18-6
1 kp/mm2 = 98066.5 98.0665 9.80665 1 100 106 73556 96.784 1422.33 0.63497
1 at = 1 kp/cm2 = 98066.5 980.665 0.98066 0.0981 0.01 1 10000 735.56 0.96784 14.2233 2048.16
1 kp/m2 = 1mmWS = 9.80665 98.0665 0.0981 10-6 10-4 1 0.2048
1 Torr = 1mmHg = 133.322 1333.22 1.33322 0.00136 13.5951 1 0.00132 0.01934 2.7845
1 atm = 101325 1013.25 1.01325 1.03323 10332.3 760 1 14.695 2116.1
1 lbf/in2 = 6894.76 68948 68.948 0.0689 0.00689 0.07031 703.07 51.715 0.06805 1 144
1 lbf/ft2 = 47.8803 478.8 0.4788 4.8824 0.35913 1
1 tonf/in2 = 154.443 15.4443 1.57488 157.488 152.42 2240 1
lbf/in2 = pound-force per square inch (psi), lbf/ft2 = pound-force per square foot (psf), tonf/in2 = (long) ton-force per square inch
1 pdl/ft2 (pound per square foot) = 1.48816 N/m2
1 barye* = 1 bar; 1 pz (pice)* = 1 sn/m2 (sthne/m2)* = 103; 1 dyn/cm = 1 bar.
Normen: DIN 66 034 Kilopond Newton, Newton Kilopond, Conversion tables DIN 66 037 Kilopond/cm2 Bar, Bar Kilopond/cm2,
Conversion tables, DIN 66 038 Torr Millibar, Millibar Torr, Conversion tables
* french units
Calculations and conversion tables
ZF-Ecomat 2 plus Calculations and conversion tables
Statutory units
1 W = 1 0.001 0.10197 1.360 10-3 238.8 10-6 0.86 1.341 10-3 947.8 10-6
1 kW = 1000 1 101.97 1.3596 238.8 10-3 860 1.3410 947.8 10-3
Units to be converted
1 kpm/s = 9.80665 9.807 10-3 1 13.33 10-3 2.342 10-3 8.434 13.15 10-3 9.295 10-3
1 PS 1) = 735.499 0.7355 75 1 0.17567 632.53 0.98632 0.69712
1 kcal/s = 4186.8 4.1868 426.935 5.6925 1 3600 5.6146 3.9683
hp = horsepower 1)
bhp = brake horsepower (brake power), dhp = drawbar horsepower (Power on drawbar hook).
1 ft lbf/s = 1.35582 W
1 ch (cheval vapeur) (French) = 1 PS = 0.7355 W
1 poncelet (French) = 100 kpm/s = 0.981 kW
1) Note different test conditions by SAE and DIN for hp and/or PS units or power for vehicle engines.
Conversion to
Unit
F R K
Kelvin K C = K 273 9 9 1
F = (K 273) + 32 R = K
5 5
18.4 Torque
1 Nm = 0.738 lbft
Tire dimensions S
S Tire width
D Outer diameter
Rim diameter
024254
5280
rdyn [rev/mile] = ___________
2 rdyn [ft]
NOTE
The oil must not contain any visible solid impurities.