ZF-ECOMAT 2 plus HP 502 HP 592 HP 602 Installation, Functions, & Initial Start-Up Technical Manual

Technical Manual For Installation, Functions, And Initial Start-Up

HP 502 / HP 592 / HP 602 for city buses, buses running in line service, and coaches 4149 765 103

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Subject to alterations in design

Copyright by ZF This documentation is protected by copyright.

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

Edition: 2004-12

4149 765 103

ZF-Ecomat 2 plus

Important Information

Important Information

Safety instructions

This Ecomat Technical Manual provides a technical basis for the Ecomat 2 plus system and has been produced for the benefit of vehicle and body manufacturers as well as ZF employees.

This manual contains answers to questions ranging from specifications to installation inspection and commissioning.

The following safety instructions appear in this manual: NOTE Refers to special processes, techniques, data, use of auxiliary, etc.

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

This manual provides the basis for specifications of the transmission and peripheral units.

Optimum procedure leading up to volume production delivery: • Specification of transmission, automatic electronic shift control unit and peripheral units performed by vehicle manufacturer and ZF using the “Questionnaire for parts list preparation”.

• Documentation by ZF. • Initial installation.

• Initial installation inspection carried out by ZF staff.

• Start-up carried out by ZF staff.

• ZF release certificate.

• Authorization conform to certificate release.

! DANGER This is used when lack of care could lead to personal injury or death.

! THREATS to the environment !

Lubricants and cleaning agents must not be allowed to enter the soil, ground water, or sewage system.

• Request safety information for the products concerned from your local environmental protection authority, and follow any instructions herein at all times.

• Collect used oil in a suitably large container.

• Dispose of waste oil, used filters, lubricants, and detergents in compliance with the stipulations of the environmental protection laws.

• Always observe manufacturer instructions when dealing with lubricants and cleaning agents.

ZF can bear responsibility for any errors in the initial installation only if sign-off has been performed by authorized ZF personnel and if all defects found by ZF have been rectified by the vehicle or bodywork manufacturer. The vehicle or bodywork manufacturer shall bear sole responsibility for any damage caused by defects attributable to the vehicle or body manufacturer which could not be detected by ZF personnel during initial sign-off.

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

4149 765 103 - 2004-12

3

ZF-Ecomat 2 plus

4149 765 103 - 2004-12

Contents

1

System solution Ecomat 2 plus

2

Description of transmission and technical data

3

Ecomat 2 plus installation position in vehicle

4

Installation arrangement and mountings

5

Guidelines for propshaft installation

6

Engine connection

7

Converter

8

Retarder

9

Cooling system

10

Transmission specification

11

Hydraulic circuit diagrams

12

Periperal equipment

13

Neutral at standstill

14

Temperature monitoring

15

Electronic automatic control system EST 146 / 147

16

Wiring

17

ZF documentation

18

Calculations and conversion tables

19

Oil grades and oil filters

5

ZF-Ecomat 2 plus

Contents

1 1.1 1.2 1.3

System solution Ecomat 2 plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System solution Ecomat 2 plus (with CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System solution Ecomat 2 plus (with load sensor, without CAN) . . . . . . . . . . . . . . . . . . . . . . . .

System solution Ecomat 2 plus (with PWM signal, without CAN) . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-1 1-2 1-3

2 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 2.7

Description of transmission and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission structure and auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission ratios and powerflow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque assignment - vehicle weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torsional vibration in driveline - inertia torques - vibration substitution model . . . . . . . . . . . .

Weights and inertia torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coaxial output without heat exchanger J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coaxial output with heat exchanger J01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coaxial output with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coaxial output with heat exchanger J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle drive 80° without offset, with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle drive 80° without offset, with heat exchanger J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Clutch combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-3 2-5 2-7 2-8 2-12 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20

3

Ecomat installation position in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

4 4.1

Installation arrangement and mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission flange-mounted on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1

5 5.1 5.2 5.3 5.4 5.5 5.6

Guidelines for propshaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permissible rotational irregularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permitted resultant deflection angle for each joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The permitted resultant flexure angle for all joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single-section propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multi-section propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum permissible propshaft length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-2 5-3 5-4 5-4 5-5

6 6.1 6.2 6.4 6.5

Engine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine connection inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine connection drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview converter-circuit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-4 6-4 6-5 6-7

7 7.1 7.2 7.3 7.4 7.5

Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque converter: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Getting the right torque converter for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque converter diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque converter basic curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-1 7-1 7-3 7-5 7-7

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Contents

8 8.1 8.2 8.4 8.5 8.5.1 8.5.2 8.5.3

Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Structure and function of retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retarder action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retarder and engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retarder activation variants hand and foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permitted variants “foot request” without “hand request” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permitted variants “foot request” without “hand request” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permissible retarder activation variants "Foot" and "Hand" combined . . . . . . . . . . . . . . . . . . . .

8-1 8-1 8-2 8-3 8-4 8-5 8-6 8-7

9 9.1 9.1.1 9.1.1.1 9.1.1.2 9.1.2 9.1.3 9.1.3.1 9.1.4 9.1.4.1 9.2 9.3 9.4 9.4.1 9.4.2 9.5 9.6 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.8

9-1 9-1 9-1 9-1 9-2 9-2 9-2 9-3 9-3 9-3 9-4 9-4 9-4 9-4 9-4 9-5 9-8 9-8 9-8 9-8 9-8 9-8

9.9 9.9.1 9.10 9.10.1 9.10.2 9.10.3 9.10.4 9.10.5

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Release criteria for temperature measurements (max. ambient temperature = 40 °C) . . . . . . . .

According to List of Lubricants TE-ML 14 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

According to List of Lubricants TE-ML 14 A / B / C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limit temperature values for oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system graph of shell type cooler SBK 279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery volume of the primary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Position of transmission oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooler fitted on transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Layout with oil cooler separate fromtransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification for transmission heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required performance of cooling water and antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fresh water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission fill with auxiliary cooling (applicable to all transmissions approved for use with auxiliary cooling) . . . . . . . . . . . . . . . . .

Transmission oil sump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System diagram, transmission oil sump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature measurements in bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measurement conditions / Retarder test cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measurement retarder cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of water temperature Retarder cycle (worst case) . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature measuring points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-9 9-10 9-10 9-11 9-11 9-11 9-11 9-12 9-12

10 10.1 10.1.1 10.2 10.2.1 10.2.2

Transmission specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flange-mounted installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat exchanger arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

10-1 10-3 10-3 10-5 10-5 10-6

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Contents

10.2.5 10.2.6 10.2.7 10.2.7.1 10.3 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.4 10.4.1 10.4.2 10.4.3 10.4.4 10.5 10.5.1 10.5.2 10.5.3 10.5.4

Coaxial output or 80° angle drive RHD (with axial offset), heat exchanger vertical on left, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Angle drive 80° LHD (without axial offset), heat exchanger horizontal on left, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left . . . . . . . . . . . 10-9 Coaxial output, vertical heat exchanger on right, accumulator rear transverse . . . . . . . . . . . . . 10-10 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting . . . 10-11 Cooler connection piece with threaded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Deep oil pan, 4149 131 002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Deep oil pan; left- and right-hand connection prepared, 4149 131 006 . . . . . . . . . . . . . . . . . . . 10-14 Deep oil pan, auxiliary cooling, 4149 131 024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Flat oil pan, 4149 131 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Flat oil pan; left- and right-hand connection prepared, 4149 131 009 . . . . . . . . . . . . . . . . . . . . 10-17 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Oil filling <K 01> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Oil filling <K 02>, <K 04>, <K 05> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Oil filling <K03>, <K 06> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Oil filling <K 09> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Coaxial output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 80° angle drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 Output flange 80° angle drive LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Ecomat output flange; coaxial and angle drive 80° RHD with axial offset . . . . . . . . . . . . . . . . . 10-27

11 11.1 11.2

Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Hydraulic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Hydraulic diagram (with Bus Stop Neutral / NBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

12 12.1 12.2 12.3 12.3.1 12.3.2 12.4 12.4.1 12.4.2 12.4.3 12.5 12.6 12.7 12.7.1 12.8 12.9

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

13 13.1 13.2

Neutral at standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Connection diagram (electric), Drawing no.: 4139 720 045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

10.2.4

4149 765 103 - 2004-12

8

ZF-Ecomat 2 plus

Contents

13.3 13.3.1 13.3.2

Neutral at Bus Stop - display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 NBS active display via digital signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 NBS Active Display via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

14 14.1 14.2 14.3 14.4 14.5 14.6 14.7

Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature information via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature information via temperature sensor A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature information from DM1 note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Addtional temperature sensor A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature display gauge A5, Drawing no.: 0501 204 074 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistance characteristics - Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15.1 15.2 15.3 15.4 15.5 15.6 15.6.1 15.6.2 15.7 15.7.1

14-1 14-1 14-1 14-1 14-1 14-2 14-3 14-4

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

4149 765 103 - 2004-12

9

ZF-Ecomat 2 plus

Contents

16 16.1 16.2 16.3 16.4

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete wiring - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete wiring - With junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16-1 16-1 16-1 16-1 16-2

17 17.1 17.1.1 17.1.2 17.2 17.2.1 17.2.2 17.3 17.3.1 17.3.2 17.3.3

ZF documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF documentation with CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF documentation without CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil level check prior to first commissioning; transmission without oil filling . . . . . . . . . . . . . .

Oil level check prior to first commissioning; Transmission oil filing at plant . . . . . . . . . . . . . .

Oil level check prior to first commissioning; Transmission with additional cooling system, with or without oil filling at plant . . . . . . . . . . .

17-1 17-1 17-1 17-2 17-3 17-3 17-4 17-5 17-5 17-6 17-7

18 18.1 18.2 18.3 18.3.1 18.3.2 18.3.3 18.3.4 18.3.5 18.3.6 18.3.7 18.3.8 18.3.9 18.4 18.5

Calculations and conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driveline design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Collective formulae for retarder and cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Masseeinheiten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Force units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moment of inertia conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of dynamic tire radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18-1 18-1 18-2 18-3 18-3 18-3 18-4 18-4 18-5 18-6 18-7 18-7 18-8 18-8 18-8

19 19.1 19.2 19.3

Oil grades and oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Lubricants TE-ML 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purity of medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19-1 19-1 19-1 19-1

4149 765 103 - 2004-12

10

ZF-Ecomat 2 plus

System solution

1

System solution Ecomat 2 plus

1.1

System solution Ecomat 2 plus (with CAN)

Brake Accelerator Engine Displays .... ....

CAN-Bus

8 1 2

13

3D

NR

17

16 12

2

20

6

11 7

10 1 21

4

9

14 15

18

5

19

3 023778_en

Key to drawing 1 Transmission electrical unit connector 2 EST 146- / EST 147-connector 3 Retarder connector 4 Accumulator connector 5 Temperature sensor connector 6 Kick down switch 7 ZF diagnosis connection plug 8 Range selector (pushbutton) 9 Dipstick (oil level check, oil status) 10 Footplate brake valve for activating the service brake and continuously variable retarder activation

4149 765 103 - 2004-12

11 12 13 14 15 16 17 18 19 20 21

1-1

Accelerator pedal Retarder OFF - ON switch Main power supply Pushbutton for NBS (Neutral when stationary) Pushbutton for gear release Automatic electronic shift control unit EST 146 / EST 147 Retarder manual lever, electrical Impulse sensor for tachometer Connections for cooling water circuit CAN connector Auxiliary consumer from air supply

ZF-Ecomat 2 plus 1.2

System solution

System solution Ecomat 2 plus (with load sensor, without CAN) 8 1 2

13

17

6

11

3D

NR

16 12

2

20

7

10 21 1 22

4

9

14 15

18

5

19

3 023777

Key to drawing 1 Transmission electrical unit connector 2 EST 146- / EST 147-connector 3 Retarder connector 4 Accumulator connector 5 Temperature sensor connector 6 Kick down switch 7 ZF diagnosis connection plug 8 Range selector (pushbutton) 9 Dipstick (oil level check, oil status) 10 Footplate brake valve for activating the service brake and continuously variable retarder activation

4149 765 003 - 2004-07

11 12 13 14 15 16 17 18 19 20 21 22

1-2

Accelerator pedal Retarder OFF - ON switch Main power supply Pushbutton for NBS (Neutral when stationary) Pushbutton for gear release Automatic electronic shift control unit EST 146 / EST 147 Retarder manual lever, electrical Impulse sensor for tachometer Connections for cooling water circuit Linkage for injection pump Load sensor for engine load detection Auxiliary consumer from air supply

ZF-Ecomat 2 plus 1.3

System solution

System solution Ecomat 2 plus (with PWM signal, without CAN) 8

20

1 2

13

17

6

3D

NR

16 12

2

11 7

10 1 21

4

9

14 15

18

5

19

3 023779

11 12 13 14 15 16

Key to drawing 1 Transmission electrical unit connector 2 EST 146- / EST 147-connector 3 Retarder connector 4 Accumulator connector 5 Temperature sensor connector 6 Kick down switch 7 ZF diagnosis connection plug 8 Range selector (pushbutton) 9 Dipstick (oil level check, oil status) 10 Footplate brake valve for activating the service brake and continuously variable retarder activation

4149 765 003 - 2004-07

17 18 19 20 21

1-3

Accelerator pedal Retarder OFF - ON switch Main power supply Pushbutton for NBS (Neutral when stationary) Pushbutton for gear release Automatic electronic shift control unit EST 146 / EST 147 Retarder manual lever, electrical Impulse sensor for tachometer Connections for cooling water circuit PWM from EDC or E-gas Auxiliary consumer from air supply

ZF-Ecomat 2 plus

System solution • Oil temperature is monitored using temperature sensors. Data from temperature sensors is transmitted via CAN bus system, EST 146 / 147 digital output or direct wiring and displayed by means of display or warning lamp.

Retarder torque will be reduced as defined temperature limits are exceeded.

System solution Ecomat 2 plus The Ecomat 2 plus system diagram illustrates one of the possible Ecomat system set-ups using all necessary individual components.

All electrical connections required between the Ecomat 2 plus system and automatic electronic control unit are located in the interface to the vehicle electrical system (13) and in case of the CAN bus application at the vehicle CAN bus system.

• Engine load data will be transmitted from the engine electronic system to the EST 146 / 147 (15) via CAN and/or PWM signal or from injection pump via load sensor.

Pressures for operating the clutch elements are modulated according to the engine load condition using a proportional solenoid valve in the electrical/hydraulic control unit.

The EST 146 / 147 (15) automatic electronic control unit controls the transmission and monitors all functions. The automatic shift control unit gathers input parameters from vehicle and transmission and processes these to produce signals used for controlling the transmission hydraulic system.

The driver may intervene in the Ecomat control system using the following equipment: - Speed range selector (push-button switch) (8) - Kick-down (6) - Accelerator pedal (11) - Brake pedal (10) - Switch for retarder operation (12/16) • The desired speed range can be pre-selected using the speed range selector (8).

The button pressed is illuminated (continuously lit).

• The kickdown switch (6) enables the shift points to be moved up to higher engine speed settings.

This means more time is spent in each gear [during upshifts] and, conversely, that downshifts occur sooner.

• For retarder activation, please consult vehicle manual.

4149 765 103 - 2004-12

1-4

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