Professional Documents
Culture Documents
Copyright by ZF
These operating instructions are protected by copyright. Any
reproduction and dissemination in whatever form also in
adapted, paraphrased or extracted form in particular as a
reprint, photomechanical or electronic reproduction or as a
storage in data-processing equipment or data networks without
approval by the holder of the copyright is prohibited and will be
prosecuted under civil and criminal law.
Printed in Germany
Automatic transmission
HP 500, HP 590, HP 600
for trucks and special vehicles
Connection for
emergency steering pump
Secondary
pump
004 718
PTO
Emergency
steering pump
004 719
Secondary
pump
3
PREFACE
NOTE
All data in this booklet refer to the basic version of the Ecomat transmission. Due to the large number of installation
options, no precise data for any specific vehicle can be given.
If there are any differences between the operating instructions given in this booklet and those given in the vehicles
own operating manual, please follow the instructions in
the vehicle operating manual.
We wish you pleasant driving with the ZF Ecomat.
ZF Friedrichshafen AG
Commercial Vehicle Transmissions Division
D-88038 Friedrichshafen
Telephone: (0 75 41) 77-0 Telefax: (0 75 41) 77-8000
SAFETY NOTES
NOTE
Refers to special processes, techniques, data, use of auxiliary
equipment etc.
CAUTION
This is used when incorrect, unprofessional working practices
could damage the product.
! DANGER
This is used when lack of care could lead to personal injury
or death.
CONTENTS
1. TECHNICAL DATA
2. DESCRIPTION
3. OPERATION
4. MAINTENANCE
5. TROUBLESHOOTING NOTES
TABLE OF CONTENTS
1.
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.
2.1
2.2
2.3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ecomat system solution . . . . . . . . . . . . . . . . . . . .
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A 800/3D transfer case . . . . . . . . . . . . . . . . . . . . .
10
10
14
16
3.
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.3
3.4
3.5
3.6
3.7
3.7.1
3.7.2
3.8
3.8.1
3.8.2
3.8.3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving instructions . . . . . . . . . . . . . . . . . . . . . . .
Speed range selector . . . . . . . . . . . . . . . . . . . . . . .
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . .
Gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulling away . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kickdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator interlock . . . . . . . . . . . . . . . . . . . . . .
Retarder operation . . . . . . . . . . . . . . . . . . . . . . . .
Stopping, parking . . . . . . . . . . . . . . . . . . . . . . . . .
Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tow-starting without secondary pump . . . . . . . . .
Tow-starting with secondary pump . . . . . . . . . . .
Towing away . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing away without secondary pump . . . . . . . .
Towing away with secondary pump . . . . . . . . . . .
Emergency steering pump . . . . . . . . . . . . . . . . . .
18
18
18
18
19
20
20
21
22
22
23
24
24
24
25
25
26
26
3.9
3.10
3.11
3.12
3.13
Temperature monitoring . . . . . . . . . . . . . . . . . . . .
Status monitoring . . . . . . . . . . . . . . . . . . . . . . . . .
PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Twin cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HST 18 auxiliary control unit . . . . . . . . . . . . . . .
27
28
28
28
29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ecomat oil quantities . . . . . . . . . . . . . . . . . . . . . .
Ecomat oil level check . . . . . . . . . . . . . . . . . . . . .
Oil level check at operating temperature . . . . . . .
Reference measurements . . . . . . . . . . . . . . . . . . .
Check procedure if heat exchanger is separately
installed above transmission centre . . . . . . . . . . .
4.4
Transmission oil heating methods . . . . . . . . . . . .
4.5
Oil change intervals . . . . . . . . . . . . . . . . . . . . . . .
4.6
Ecomat oil drain, oil fill . . . . . . . . . . . . . . . . . . . .
4.7
Oil fill for A 800/3D transfer case . . . . . . . . . . . .
4.7.1 Initial fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8
Checking load sensor adjustment . . . . . . . . . . . . .
4.9
Electronic accelerator equipment and EDC units
30
30
30
30
31
32
Troubleshooting notes . . . . . . . . . . . . . . . . . . . .
41
4.
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
5.
33
33
34
35
36
36
37
38
40
TECHNICAL DATA
Max. perm.
Max. weight (t)
input
at engine torque DIN 70020/ISO 1585
Series No. of
speed
Fire service Refuse Construction
gears
(rpm)
vehicles
vehicles machinery 1stgear 2nd
4
HP 500
HP 590
1)
2)
3)
4)
3rd
4th
5th
6th .
R.
Weight 3) Install.
length
[mm]
(kg)
L
3.43
2.01
1.43
1.00
4.84
300
693
28 t
28 t
1)
3.43
2.01
1.43
1.00
0.83
4.84
310
693
1150 Nm
1050 Nm
1050 Nm
5.60
3.43
2.01
1.43
1.00
4.84
344
795
5.60
3.43
2.01
1.43
1.00
0.83
4.84
356
795
3.43
2.01
1.43
1.00
4.84
305
693
5
5
2 800
28 t
28 t
1)
3.43
2.01
1.43
1.00
0.83
4.84
315
693
1250 Nm
1250 Nm
1)
5.60
3.43
2.01
1.43
1.00
4.84
354
795
5.60
3.43
2.01
1.43
1.00
0.83
4.84
366
795
3.43
2.01
1.43
1.00
4.84
320
693
3.43
2.01
1.43
1.00
0.83
4.84
330
693
5.60
3.43
2.01
1.43
1.00
4.84
364
795
3.43
2.01
1.43
1.00
0.83
0.59
4.84
330
693
5.60
3.43
2.01
1.43
1.00
0.83
4.84
376
795
5
5
5
HP 600
Ratios
2 800
2 650
5
6
2650 2)
2650
28 t
28 t
1600 4)
1400
DESCRIPTION
Description
2.1
NOTE
The components shown in the following system diagram can
be found in the text under the same numbers.
10
Fig. 1
004 887
DESCRIPTION
Key to drawing
1
15
Temperature sensor
16
Temperature gauge
17
Console selector
18
Identification plate
19
20
Brake pedal
21
Antigas cylinder
Wiring
22
Kickdown switch
23
Accelerator pedal
10
24
25
11
26
12
27
13
ZF-Ecomat
28
14
10
11
DESCRIPTION
All electrical connections required between the Ecomat system and the vehicle electronic system are located in the interface to the vehicle electrical system (1).
The EST 18 electronic control unit (6) controls the transmission and monitors all functions. The automatic control
unit gathers data from the vehicle and transmission (speed
range, engine load condition, etc.) and processes these to produce signals used for controlling the transmission hydraulic
system.
For special applications, the EST 21 is available instead of the
EST 18.
The driver may intervene in the Ecomat control system using
the following equipment:
12
u The lamp (2) is used for status monitoring. The lamp does
! DANGER
If this lamp flashes (frequency 0.2 sec), transmission
damage is imminent and danger of accidents!
Restricted system monitoring!
If this occurs, immediately drive to the nearest service
station. Drive slowly to reduce transmission loading.
u The kickdown switch (22) is used to move the shift points
DESCRIPTION
connection piece to monitor oil temperature. The information from the temperature sensor is sent to the temperature gauge (3) from where the oil temperature may be
read.
u The oil temperature may be read on temperature gauge (3).
13
DESCRIPTION
2.2
Design
2
The torque converter provides smooth starting without
mechanical wear and compensates automatically for various
load conditions by providing the necessary input torque.
The various gears in the planetary transmission are engaged
automatically with no interruption in traction. Gearshifts are
performed in response to signals from the EST 18 electronic
control unit. In response to various variables in the vehicle
and transmission, the EST 18 sends signals to the hydraulic
solenoid valves which actuate the corresponding clutches and
brakes.
A lock-up clutch in the torque converter provides a direct
mechanical link between engine and planetary transmission
after the vehicle start-up phase, thus eliminating the power
losses seen in conventional automatic transmissions where the
torque converter remains in operation all the time.
14
DESCRIPTION
2
Fig. 2: Transmission design for i = 3.43 0.83
3.43 0.59
L = 102 mm
004
114
004 114
004 113
004 113
15
DESCRIPTION
2.3
Key to drawing
a
Ecomat connection
The A 800/3D transfer case is available for all-wheel drive vehicles and has a pneumatically engaged lockable transfer differential. The transfer case can be flange-mounted on the Ecomat or separately installed.
2
u Torque distribution between front/rear axles optionally
1 : 1.83 or 1 : 3.35
16
DESCRIPTION
e
d
f/g
c
004 945
Fig. 4
17
OPERATION
Operation
3.1
Driving instructions
R
N
D
1, 2, 3
= Reverse
= Neutral
= Automatic forward drive (Drive)
= Restricted automatic forward speed ranges
CAUTION
If the specified clutch slip times are exceeded during gear
change, the lamp (2) on the dashboard (status monitoring)
begins to flash.
Risk of transmission damage!
004 715
Fig. 5
3.1.2 Starting the engine
18
OPERATION
CAUTION
Jump starting only permitted on battery, never on starter
motor!
CAUTION
Never move the selector lever whilst accelerator pedal is
depressed!
19
OPERATION
-15
CAUTION
Do not pull away at temperatures below -15 C.
Warm up the engine for approx. 5 mins. with
selector lever in neutral position.
3
3.2
Speed ranges
20
! DANGER!
If the transmission is shifted into N whilst the vehicle is
moving, the connection between engine and transmission is
broken. This means engine and retarder braking power
is lost.
Risk of accident! Actuate brake!
For safety reasons, the transmission is automatically shifted
into N if a fault occurs in the EST 18 or if current in the
transmission is lost.
Driving downhill
When descending steep hills, select speed range 1, 2 or 3 as
required to limit upshifts.
! DANGER!
In extreme cases, the upshift interlock cuts out to protect
the engine.
In this case, the transmission can shift up into the
highest gear whatever speed range is selected. Risk of
accidents!
OPERATION
3.3
Kickdown
Accelerator
Full-load
(Pressure point
Kickdown
Kickdown switch
004 886
Fig. 6
Installation example:
Pneumaticallyactuated accelerator
interlock device
21
OPERATION
3.4
Retarder actuation
The retarder can be activated using a hand-operated lever or a
foot pedal. It is actuated via electronic switch contacts or
pressure switches in the braking circuit (refer to vehicle
operating manual / instructions).
NOTE
All special vehicles such as refuse collection trucks, dumpers,
mobile cranes, fire service vehicles etc. are equipped with an
accelerator interlock.
3.5
Retarder operation
22
CAUTION
If the accelerator pedal is depressed, the retarder disengages.
The upshift interlock cuts out.
OPERATION
! DANGER!
If the permissible oil temperature of 145 C is exceeded,
the retarder is automatically reset.
Risk of accident due to reduced braking power!
3.6
Stopping, parking
Stopping
The vehicle can be stopped at any time, regardless of the
selector lever position. The EST 18 selects the appropriate
starting gear.
During short stops:
The selector lever can be left in gear
Apply brakes
During longer stops:
! DANGER!
When the engine is stopped, there is no direct mechanical
link between the engine and the axle. Vehicle may roll
away.
23
OPERATION
3.7
Tow-starting
NOTES
The necessary tow-starting speed depends on
Transmission ratio
Programmed starting gear
Axle ratio
Tyre size
Temperature
Therefore, fixed values cannot be given. Please refer to your
Vehicle Operating Instructions for the correct tow-starting
speed for your vehicle.
CAUTION
Check whether your Ecomat transmission is equipped with a
secondary pump * which provides the transmission clutches
with the necessary oil pressure if tow-starting is required.
Always use a tow bar
Move the speed range selector to position D
Keep accelerator pedal in full-load position
Switch off retarder, if installed
Accelerate the vehicle quickly to prescribed tow-starting
speed
* Refer to pages 2 and 3
24
CAUTION
Tow-starting at temperatures below -15 C is not permissible
risk of transmission damage.
3.8
Towing away
Axle ratio
OPERATION
12
CAUTION
If you suspect the transmission may be damaged, disconnect
the propshafts between the Ecomat and drive axles before
towing.
Exception: In dangerous situations, it is permissible to tow
away before disconnecting the drive line (e.g. on cross-roads
or in tunnels etc.).
10
rdyn m
6
3.8.1 Towing away without secondary pump
Towing away at temperatures down to -15 C
10
20
0,4
0,5
30
40
0,6
50
Abschleppgeschwindigkeit
v km/h
Towing speed
v [km/h]
Towing away at temperatures below -15 C
Selector lever in neutral position
Max. towing time 2 hours
Max. towing speed 5 km/h
000 855
iA = 7.6
rdyn = 0.490
18 km/h
25
OPERATION
! DANGER!
If the propshafts are disconnected, the assistance provided
by the emergency steering pump is no longer available.
OPERATION
3.9
Temperature monitoring
Operating temperature:
Normal driving:
Retarder operation:
Converter operation:
approx. 85 C
max. 100 C
max. 145 C
max. 110 C
! DANGER!
If oil temperature exceeds 145 C, the retarder is
automatically reset.
Risk of accidents due to reduced braking power!
Temperature gauge
transmission damage
Please inform the nearest ZF Service Point!
004 717
Fig. 10
Green range
Green/red range
Red range
OPERATION
3.10
Status monitoring
3.11
PTOs
Engagement conditions:
Accelerator pedal in idling position
Engine speed < 900 rpm
! DANGER!
If the status monitoring lamp (2) is flashing, there is grave
danger of transmission damage and system monitoring is
only restricted.
Risk of accidents!
3
In this case, the vehicle must be driven under part-load to the
nearest workshop so that the fault can be corrected!
Selector lever in N
(see vehicle operating manual / instructions)
NOTE
If these conditions are not fulfilled, PTO engagement is
blocked. When the PTO is engaged, the converter lock-up
clutch remains disengaged and an upshift interlock comes into
operation.
3.12
Twin cabs
28
OPERATION
3.13
= Neutral
Position D
Position R
= Reverse
DANGER!
29
MAINTENANCE
Maintenance
4.1
Oil grades
CAUTION
Ecomat transmissions with flange-mounted A800/3D
transfer case have a separate oil circuit!
Only oils as per the applicable ZF List of Lubricants can be
used for filling the transmission / transfer case:
Ecomat transmission:
TE-ML 14
A 800/3D transfer case:
TE-ML 02
The latest Lists of Lubricants can be requested from all ZF
After-Sales Centres.
4.2
approx. 30 ltr
approx. 20 ltr
At oil changes
approx. 15 ltr
4.3
30
MAINTENANCE
CAUTION
The oil level must be checked regularly at operating
temperature. This is the only way of ensuring that the
level is correct.
Check oil level once weekly see Section 4.3.1.
Under certain circumstances, the oil level must first be
checked when the transmission oil is cold see Section
4.3.2. Always recheck afterwards at operating
temperature.
If the heat exchanger is located higher than the centre line
of transmission (separate installation), the oil level should
be checked as described in Section 4.3.3.
Hot range 80 - 90 C
4.3.1 Oil level check at operating temperature
S 0024
For correct results, the oil level must be checked when the
transmission oil is hot (80 - 90C).
We recommend that this check is performed once weekly,
preferably after finishing a journey.
Fig. 12
Conditions:
Park vehicle on level ground
Switch speed range selector to neutral
Run engine at idling speed
31
MAINTENANCE
4.3.2
Reference measurements
S 0025
Fig. 13
32
MAINTENANCE
CAUTION
After cold-starting at sub-zero temperatures, the dipstick must
dip at least 10 mm into the oil before it is permissible to run
the transmission up to temperature.
An accurate oil level check at operating temperature must
then be made as soon as possible (see Section 4.3.1).
Cold range 30 C
4.4
S 0026
Fig. 14
33
MAINTENANCE
4
4.5
CAUTION
The filter must be renewed after every oil change.
every 30 000 km
every 90 000 km
34
MAINTENANCE
4.6
S 0020
S 0022
Fig. 15
Fig. 16
35
MAINTENANCE
4.7
CAUTION
Separate oil circuit!
The lubrication for the A800/3D transfer case is independent
of that for the Ecomat basic transmission.
NOTE
The vehicle must be level before oil fill can take place.
Oil quantity:
approx. 6.5 l
Oil grade:
see ZF List of Lubricants TE-ML 02
Oil change interval: see Section 4.5 Ecomat
This list can be requested from all ZF Service points.
36
MAINTENANCE
004 720
Fig. 17
2
1
37
MAINTENANCE
4.8
CAUTION
Do not use stops on load sensor housing for setting.
Do not loosen bolts on load sensor housing or nut on shaft.
Check ball heads for wear (too much backlash) and grease
filling.
Check procedure
(The engine must be at the correct setting before the check is
begun).
The check can be carried out using marks on the front (Fig. 18)
or the top of the housing (Fig. 19).
Stops
38
000 822
Fig. 18
low
high
MAINTENANCE
low
000 824
Fig. 19
high
Accelerator pedal
Kickdown overtravel plunger
Kickdown switch
Antigas cylinder
Load sensor
Injection pump on engine
Injection pump full-load stop
A
B
C
D
Idling position
Full-load position
Stop position
Air supply
S 0093
Fig. 20
39
MAINTENANCE
4.9
The engine load signal is not recorded by the load sensor but
electronically.
For electronic accelerator
equipment units:
If problems occur
please contact the nearest vehicle manufacturer service
point.
40
TROUBLESHOOTING NOTES
Fault
Possible cause
Remedy
Select neutral.
Connect plug.
Exchange relay.
Transmission fault
Request ZF service.
Retarder engaged
Internal fault
Request ZF service.
41