Betriebsanleitung

Operating Instructions
Manuel dUtilisation
Manual de Servicio
Istruzioni per lUso

4
HP 504 C HP 594 C HP 604 C
for city buses, intercity buses
and coaches

4182 758 101

Subject to alteration 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, 2006-06

Edition: 2006-06

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

NOTE
All details in these Operating Instructions refer to the
basic version of the ZF-Ecomat transmission.
Due to the large number of installation options, no precise
information can be provided for any specific vehicle.
If there are any differences in operation between the
instructions in this brochure and the Operating Instructions specific to an individual vehicle manufacturer, the
vehicle-specific instructions are the ones to follow.

Read this operating manual carefully and take due note

of all safety instructions.
To ensure that the transmission achieves the required
level of operational safety and reliability, always pay
careful attention to the maintenance instructions.
The ZF Customer Service specialists are available to assist
you. in carrying out maintenance work or to help if any
other problems arise.
These addresses are listed in the ZF Company Directory
(order number 0000 762 703) or on the Internet under
www.zf.com/ servicenetz.
You will find more product information on the Internet by
logging on to www.zf.com (Products/Product World Bus).

4182 758 101 - 2006-06

Motoring pleasure with the ZF-Ecomat is brought to you

by
ZF Friedrichshafen AG
Commercial Vehicle and
Special Driveline Technology
D-88038 Friedrichshafen
Phone: +49 (0) 7541 77-0
Fax:
+49 (0) 7541 77-90 80 00
Internet: www.zf.com

Safety Instructions
The following safety instructions appear in this manual:

NOTE
Refers to special processes, techniques, information, 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 material damage.

THREATS TO THE ENVIRONMENT!

Lubricants and cleaning agents must not be allowed
to enter the soil, ground water, or sewage system.
Ask your local environment agency for safety
information on the relevant products and adhere
to their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
When working with lubricants and cleaning agents
always refer to the manufacturers instructions.

NOTE on cleaning the vehicle / transmission

CAUTION
When cleaning, always ensure that the steam cleaner or
high-pressure cleaner does not make direct contact with
the screw cap of the dipstick. Any water ingress through
the breather can damage the transmission!

4182 758 101 - 2006-06

Table of Contents
1
1.1
1.2
1.3

2.9
2.9.1

Limit Values for Oil Temperature . . . . . . . . . . .22

Transmission Oil Temperature
Before Heat Exchanger . . . . . . . . . . . . . . . . . . .22
2.9.2
Oil Temperature in Transmission Oil Sump . . . .23
2.9.3
Actions to be Taken When the Relevant
Permissible Oil Temperature is Exceeded . . . . . .24
2.10
Status Monitoring / Warning Lamps . . . . . . . . .24
2.11
Transmission Response to a Malfunction . . . . .25
2.11.1 Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . .25
2.12
Auxiliary Control Unit . . . . . . . . . . . . . . . . . . . .26
2.12.1 Operating Instructions for the
Auxiliary Control Unit . . . . . . . . . . . . . . . . . . . .26

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Structure of Basic ZF-Ecomat 4 Transmission . . . 7
ZF-Ecomat 4 System Solution . . . . . . . . . . . . . . 8
Auxiliary Transmission . . . . . . . . . . . . . . . . . . .11

2
2.1
2.1.1
2.1.2
2.1.2.1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Digital Speed Range Selector . . . . . . . . . . . . . . .12
CAN Speed Range Selector . . . . . . . . . . . . . . . .12
Lighting of the CAN Speed Range
Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . .13
2.1.2.2 Pushbutton Settings . . . . . . . . . . . . . . . . . . . . . .13
2.2
Starting the Engine . . . . . . . . . . . . . . . . . . . . . .14
2.3
Selecting Gear . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.4
Setting Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.5
Driving Ranges . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.5.1
Downhill Travel . . . . . . . . . . . . . . . . . . . . . . . . .16
2.5.2
Change in Direction of Travel . . . . . . . . . . . . . .16
2.5.3
Kickdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.5.4
Retarder Operating Mode . . . . . . . . . . . . . . . . .18
2.6
Stopping, Parking . . . . . . . . . . . . . . . . . . . . . . . .20
2.7
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.7.1
Towing Away Vehicle with
Operational Transmission . . . . . . . . . . . . . . . . .21
2.7.2
Towing a Vehicle with Suspected
Transmission Damage. . . . . . . . . . . . . . . . . . . . .21
2.8
Temperature Monitoring . . . . . . . . . . . . . . . . . .22

4182 758 101 - 2006-06

3
3.1
3.2
3.3
3.3.1
3.3.1.1
3.3.1.2
3.3.2
3.3.3
3.4
3.5
3.5.1
3.5.2
3.5.3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Oil Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . .29
Guide Value Measurement . . . . . . . . . . . . . . . . .30
Checking Before the Engine is Switched On . .30
Checking After Starting the Engine . . . . . . . . . .31
Checking at Operating Temperature . . . . . . . . .31
Option for Heating Up the Transmission Oil . .32
Oil Change Intervals . . . . . . . . . . . . . . . . . . . . .33
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Draining Transmission Oil . . . . . . . . . . . . . . . . .33
Draining Oil From ZF Angle Drive . . . . . . . . .34
Filling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Description
1

Description

The hydrodynamic retarder is installed between torque

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

The Ecomat range of transmissions comprises a hydrodynamic torque converter (Fttinger t/c) with lock-up
clutch, a hydrodynamic retarder and a downstream,
multi-ratio planetary transmission.
The torque converter is a starting unit which operates
without mechanical wear and which adapts its setting
across an infinitely variable range to suit prevailing
conditions (delivering the required level of input torque).

Braking action while driving downhill or in city traffic can

be delivered by the retarder without mechanical wear,
thereby extending the life of the service brakes.

The gears in the planetary transmission are selected

automatically and without any interruption to traction.
Signals for gear shifts are supplied by the electronic control
unit. Depending on various parameters obtained from
vehicle and transmission, this automatic controller
engages the appropriate multi-disc clutches and brakes
via the electro-hydraulic transmission control unit.
A lock-up clutch installed in the torque converter establishes a direct mechanical connection between engine and
planetary transmission after the starting phase.
This eliminates the power losses normally associated with
torque converter transmissions.

4182 758 101 - 2006-06

Description
1.1 Structure of Basic ZF-Ecomat 4 Transmission
1 2 3

12

9 10

11
10

024744

10
Key to items
1 Drive
2 Torsion damper (optional)
3 Torque converter
4 Hydrodynamic retarder
5 Rotating multi-disc clutches
6 Stationary multi-disc brakes
4182 758 101 - 2006-06

7
8
9
10
11
12
7

Output
Heat exchanger
Auxiliary cooling, short-circuit bracket (optional)
Transmission type plate (possible positions)
Transmission electrical unit connector
Serial number (embossed)

026741

Description
1.2 ZF-Ecomat 4 System Solution
8

23

N R
3 D
1 2

13

13

12

17

Brake
Accelerator
Engine
Displays
....
....
CAN-Bus

22
16
2

20

11
7

10

Key to drawing
1 Transmission electrical
unit connector
2 ECU 146 / ECU 147 connector
15
3 Retarder connector
4 Retarder accumulator connector*
5 Temp.sensor connector (B4/A6)
6 Kickdown Switch
7 ZF diagnosis connection plug
8 Speed range selector
9 Transmission breather, oil filler
tube, oil dipstick
10 Footplate brake valve for activation
of service brake and infinitely
variable retarder operation
11 Accelerator pedal
12 Retarder switch OFF - ON*
13 Main Power System
4182 758 101 - 2006-06

1
21

14

9
18

14 Pushbutton for NBS*

5
15 Pushbutton for gear release*
16 ECU 146/147
Electronic Control Unit
17 Retarder manual lever, electrical* 3
18 Impulse sensor for speedometer*
19 Coolant connections
20 CAN connection
21 From air supply to auxiliary
consumers*
22 Type plate ECU 146/147
23 Temperature display A5*
*optional
8

19

027591

Description
Ecomat 4 System Solution

The driver can intervene actively in the Ecomat control

system using:

This system diagram illustrates one of the possible system

solutions for Ecomat 4 with ECU 146/147 and individual
components.

Speed range selector (8)

Kickdown (6)
Accelerator pedal (11)

The electrical wiring from the Ecomat 4 system is routed to

the electronic automatic shift controller ECU 146/147 (16)
and to the CAN bus (20) in the vehicle via the vehicle
circuit interface (13).

Brake pedal (10)

Switch for retarder operation (12/17)
The desired speed range can be pre-selected using the
speed range selector. The button pressed is illuminated
(continuously lit).

The electronic shift controller is used to control and

monitor transmission functions. The electronic control
unit ECU 146/147 records input parameters from vehicle
and transmission sent via CAN or as digital signals and
processes these into signals to control the transmissions
hydraulic system.

The kick-down switch is used to move the shift points

towards higher engine speeds, so the transmission remains
in each gear longer when accelerating and shifts out of
each gear sooner when decelerating.
The retarder (zero-wear service brake) is activated by the
brake pedal (10) and/or hand lever (17).
The retarder ON - OFF switch (12) can be used to
enable/disable the retarder function.

4182 758 101 - 2006-06

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

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

Whenever defined temperature limits are exceeded,

retarder torque is reduced continuously.
Engine load information is transmitted from the engine
control unit to the ECU 146/147 using CAN.
A proportional solenoid valve in the hydraulic shift
control system modulates clutch actuation pressures in
accordance with engine load.

4182 758 101 - 2006-06

10

Description
1.3 Auxiliary Transmission
Depending on vehicle version and application, the
ZF-Ecomat transmission can be equipped with an
80 angle drive.

Key to drawing
1 Basic transmission
2 Coaxial output (standard)
3 80 angle drive left without offset (LHD)
4 80 angle drive right with offset (RHD)
4182 758 101 - 2006-06

027511

11

Operation
2

Operation

2.1.2 CAN Speed Range Selector

2.1

Pushbutton

Distinguishing features between CAN pushbutton and

digital pushbutton speed range selector switches:

The vehicle is either equipped with a digital pushbutton or

a CAN speed range selector switch.

Convex keys
Neutral button does not lock

Installation variants with 3, 4, 5 or 6 pushbuttons,

installed horizontally or vertically:

ZF logo located on side of Neutral button

= Reverse

= Neutral

= Automatic forwards driving range (Drive)

027768

1, 2, 3 = Limited forward driving ranges

2.1.1 Digital Speed Range Selector

The button pressed is illuminated (continuously lit).

CAN speed range selector, installed horizontally

The button pushed flashes if it is not accepted by the

transmission control unit.

Digital speed range selector, installed horizontally

4182 758 101 - 2006-06

005624

12

027769

Operation
2.1.2.1 Lighting of the CAN Speed Range Selector
Switch

Exceptions:
If the transmission control unit is not providing the
information required for lighting purposes, the lamps
only light up in search mode. Nevertheless, the vehicle
can still be driven in this status.

Button lighting colors:

Neutral button:

bernstein

1, 2, 3, D and R:

yellow

The lighting is also deactivated if the pushbutton

position can no longer be correctly established as a
result of a hardware defect and the buttons only light
up with search lighting.

All buttons light up for approx. 1.2 s:

Lighting test at system startup
All keys light up dimly:

NOTE
The brightness settings for search and function lighting
can, if required, be adjusted independently. They are
corrected as a function of operating voltage.

Search lighting: To make it easier to find the buttons in

the dark.
Individual buttons light up brightly:
Function lighting: Identifies the active, pressed pushbutton.

2.1.2.2 Pushbutton Settings

Individual buttons flashes:

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

The active (pushed) button flashes if it is not accepted

by the transmission control unit.
All buttons flash:
Serious internal fault in pushbutton
Malfunction in CAN communication. Once this defect
has been remedied, the light stops flashing.

4182 758 101 - 2006-06

13

Operation
2.2

Starting the Engine

Transmission with additional gear release function

(Additional installation by vehicle manufacturer,
recommended by ZF)

Engine can only be started if:

Vehicle is stationary (brake applied).

Speed range selector in Neutral

Speed range selector is in Neutral position (N)

Accelerator pedal at idle setting and neng < 900 rpm

NOTE
Starter inhibit: If the speed range selector is not in
Neutral, the engine cannot be started.

Select desired driving range and apply the brake.

System only engages the appropriate gear while the
brake is being applied.

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

Operator errors when engaging gear

Accelerator pedal actuated or neng > 900 rpm
If gear enable is installed, but brake not applied

2.3

Selecting Gear

R direction of travel selected at a vehicle speed of

> approx. 3 km/h

Standard:

After selecting the desired driving range, the system

does not engage a gear.

Speed range selector in Neutral

Accelerator pedal at idle setting and neng < 900 rpm
Select desired driving range or direction of travel.

Transmission with auxiliary function 2nd Reverse gear

button

CAUTION
Never actuate speed range selector and throttle at the
same time!

To reverse the vehicle, press the R button on the speed

range selector and also the R button on the dashboard.

4182 758 101 - 2006-06

14

Operation
2.4 Setting Off
After selecting the appropriate speed range, wait for
approx. 1 to 2 seconds, release brake (if applied) and
accelerate.

DANGER !
On steep uphill gradients, always accelerate as soon
as you release the brake! RISK OF ACCIDENT from
vehicle rolling backwards!

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

4182 758 101 - 2006-06

15

Operation
2.5

Driving Ranges

2.5.1 Downhill Travel

Please refer to the vehicles Operating Instructions for

precise information about the gears engaged in each of the
speed ranges.

When driving down steep gradients, depending on

requirements, you should select setting 1, 2 or 3 on the
speed range selector. This restricts upshifts.

A defined range of gears / ratios is assigned to each speed

range. Shifts are only executed at shift points defined by
the electronic shift control unit.

Manual intervention in the automatic shift sequence

(shifting right through the speed ranges) is not advisable.

DANGER !
If the transmission is shifted into N while the vehicle
is in motion, the powerflow between engine and output is interrupted. This prevents the engine brake and
retarder from being able to operate.
Risk of accident! Apply the brake!
For safety reasons, when faults occur in the electronic
shift control unit or whenever there is a power failure,
the transmission automatically selects N.

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

2.5.2 Change in Direction of Travel

Before changing from Forwards to Reverse or vice versa:
Vehicle stationary
Accelerator pedal at idle setting and neng < 900 rpm
Speed range selector in Neutral position, depress brake
pedal if necessary
Move speed range selector to D, 1, 2, 3 or R

4182 758 101 - 2006-06

16

Operation
2.5.3 Kickdown
To utilize max. engine power, higher shift points can be
called up using the kick-down switch (see illustration) or
the CAN system (to accelerate or to use the accelerator
pedal on uphill gradients).

Accelerator
pedal
Full load
(pressure point)

Depress accelerator pedal beyond its full throttle

pressure point (kickdown setting)

Kickdown

Kickdown switch
023629

4182 758 101 - 2006-06

17

Operation

pe
da
l

2.5.4 Retarder Operating Mode

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

Br
ak
e

ge
an
r
r
de
tar
e
R
r
rde
reta
+
e
ang
ke r
a
r
b
vice
Ser

Conditions for retarder operation

(retarder engaged/actuated)
Accelerator pedal in idle speed setting
A forwards gear must be engaged
013186

Vehicle speed > approx. 3 km/h

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

6
5

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

4
3
2
1

023630

4182 758 101 - 2006-06

18

Operation
The retarder is disengaged automatically by the
electronic shift controller:
When ABS is active.
Whenever the permitted oil temperature is exceeded, as
defined in Section 2.9.
If a retarder ON-OFF switch is fitted, the retarder must
be switched off:
On icy roads.
Whenever the permitted oil temperature is exceeded, as
defined in Section 2.9.
The max. permitted oil temperature for retarder operation
is 150 C (max. 5 mins).
Note temperature indicator or temperature warning,
refer to section 2.8 or vehicle manufacturers Operating
Instructions.
Retarder activation using foot pedal, de-activation using
toggle switch on dashboard.
Switch off hand lever whenever the brake has been
applied!

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

4182 758 101 - 2006-06

19

Operation
2.6 Stopping, Parking

Transmission with special Bus Stop Neutral (NBS)

feature

NOTE
Only apply the parking brake when vehicle is stationary.

The transmission automatically selects Neutral when the

following conditions are in place simultaneously:
Vehicle stationary

Stopping

Brake applied

The vehicle can be stopped at any time, regardless of the

setting of the speed range selector. The electronic shift
control unit then engages the appropriate gear for setting
off.

Accelerator pedal in idle speed setting

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

With short stops:

Speed range can remain selected
Apply brake

Parking
Speed range selector in Neutral

At extended stops:

Apply parking brake

Speed range selector in Neutral

Apply brake

4182 758 101 - 2006-06

20

DANGER !
Before leaving the vehicle, always apply the parking
brake. When the engine is switched off, there is no
direct connection between engine and axle. The
vehicle can therefore start to roll!

Operation
2.7

Towing

2.7.2 Towing a Vehicle with Suspected

Transmission Damage

2.7.1 Towing Away Vehicle with Operational

Transmission

CAUTION
If transmission damage is suspected, the propshaft flange
between transmission and drive shaft needs to be
disconnected.

Speed range selector in Neutral

Max. towing time: 2 hours
Max. towing speed:
City and intercity buses:
Coaches:

Exception: In a dangerous situation, towing is permitted

until the vehicle leaves the immediate danger area (e.g.
road junction/intersection, tunnel etc.), without first
disconnecting the driveline.

25 km/h
35 km/h

NOTE
At an ambient temperature of less than -15 C the towing
speed is 5 km/h.

4182 758 101 - 2006-06

21

Operation
2.8

Temperature Monitoring

2.9

Limit Values for Oil Temperature

Monitoring of transmission temperature is performed by

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

2.9.1 Transmission Oil Temperature Before Heat

Exchanger

The switch point for the warning contact on the temperature display unit is 145 C.

During torque converter operation:

During retarder operation:

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

The temperature limit for continuous operation is

110 C.
In exceptional cases, short periods of operation
(max. 5 mins. within a 1 hour period) at 130 C are
permissible.
During normal driving:
The permitted temperature range is between
90 - 100 C.

4182 758 101 - 2006-06

22

Operation
Pos. 120

2.9.2 Oil Temperature in Transmission Oil Sump

Pos. 124

The following sump temperatures must not be exceeded

(not even at high ambient temperatures):

Transmission oil sump temperatures Ecomat 4

Operating
temperature
or endurance
temperature
Exception:
max. 5 mins.
within
1 hour
1
2

max.
100 C

max.
105 C
B14
021648

105 C

115 C

B14: Temperature sensor in transmission sump

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

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

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

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

4182 758 101 - 2006-06

23

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

2.10 Status Monitoring / Warning Lamps

The diagnostics system of the electronic shift control unit
ECU 146/147 monitors the transmission status every time
the vehicle circuit is switched on and continuously while
the vehicle is in motion.

Driving at partial load

Switch off retarder
If this does NOT cause the oil temperature to drop:

Warning lamps
Faults are displayed by warning lamps lighting up (red or
yellow) and by warning messages which appear on the
drivers display panel (refer to the vehicle manufacturers
Operating Instructions).

Stop the vehicle

Speed range selector in Neutral
Run engine at raised idle speed

If a selected gear or speed range is not accepted by the

ECU, the button pressed on the speed range selector starts
to flash.

NOTE
If the temperature does not drop back into its permitted
range within a few minutes, the possible causes are:
Oil level too low or too high
Contaminated heat exchange in vehicle
Coolant circuit defective
Transmission damage
Inform ZF Service Center without delay!

4182 758 101 - 2006-06

24

Operation
2.11 Transmission Response to a Malfunction

2.11.1 Limp-Home Mode

To protect the transmission in the event of a malfunction,

the following responses are provided:

The ECU is set up with specific time and pressure settings

for pressure control in limp-home mode. Please also note
that:

Shift into Neutral:

In the event of major malfunctions in the power supply to
the transmission, e.g. short circuit.

The retarder function is not available

The Bus Stop Neutral (NBS) function is not available
The engine brake cannot be activated

Shift into Limp-Home Mode:

If there is an interruption to CAN communication or a loss
of shaft speed information.

Torque converter lock-up clutch (WK) is open

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

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

4182 758 101 - 2006-06

25

Operation
2.12 Auxiliary Control Unit

2.12.1 Operating Instructions for the Auxiliary

Control Unit

This auxiliary control unit was developed to help with

moving the vehicle during the production process and to
act as a limp-home facility in the event of ECU failure.

Apply parking brake to prevent vehicle from rolling

accidentally.
Speed range selector is in N position.

Auxiliary control unit HST 46

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

Switch off engine and ignition.

Remove connector from electronic shift controller.
Connect plug to HST 46 auxiliary control unit and
secure.

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

4182 758 101 - 2006-06

Start engine.
Engage gear on pushbutton:

26

Shift setting N

= Neutral

Shift setting D

= Drive (forwards gear is

engaged, no upshifts or
downshifts occur)

Shift setting R

= Reverse

Operation

DANGER !
When operating via the auxiliary control unit, none of
the safety functions are enabled.
RISK OF ACCIDENT!
The following points must therefore be taken into
account at all times:
Shifting from N to D or from N to R only
ever at idle speed and with the vehicle stationary.
The transmission can also change gear at higher
shaft speeds but this can lead to transmission
damage.
Before every change from forwards to reverse
travel or vice versa, always ensure that the vehicle
is completely stationary.
After shifting into D or R, always wait for
2 seconds to enable the transmission to engage
before starting to accelerate.

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27

Maintenance
3

Maintenance

The latest List of Lubricants can be obtained from all ZF

Sales & Service Centers or can be downloaded from the
Internet at: www.zf.com (Service / Technical Information /
ZF List of Lubricants) and viewed.

Regular and correctly performed maintenance is essential

to safeguard the operational safety of the transmission. It
is therefore particularly important for the maintenance
intervals to be observed.

3.2 Oil Volumes

THREATS TO THE ENVIRONMENT!

Lubricants and cleaning agents must not be allowed
to enter the soil, ground water, or sewage system.
Ask your local environment agency for safety
information on the relevant products and adhere
to their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
When working with lubricants and cleaning agents
always refer to the manufacturers instructions.

During oil changes (drain lasts approx. 10 min.)

approx. 18 liters
After installation of new/replacement transmissions
approx. 20 liters
When first filling the dry transmission
approx. 28 liters
NOTE
These figures are guide values and refer to the standard
version of the Ecomat 4. Depending on the version of heat
exchanger fitted, oil quantities can rise by as much as
approx. 5 liters.
The definitive oil volume is the one obtained after the oil
level check and at operating temperature (see Section
3.3.2).

3.1 Oil Grade

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

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Maintenance
3.3 Oil Level Check

The following applies in general:

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

CAUTION
Always maintain the correct oil level:

The vehicle must be parked on level ground when

checking the oil level.

Insufficient oil leads to transmission malfunctions

and damage

Shift range selector (pushbutton) to Neutral.

Too much oil causes the transmission to overheat

Run engine at idle speed.

Idle speed should be set to 500 to 700 rpm.
It must never drop below 450 rpm.

DANGER !
Insufficient oil in the system leads to partial or complete failure of the retarder, i.e. braking action is
impaired or non-existent.

Undertake oil level check at least once a quarter.

Conduct regular visual inspections of the transmission for
signs of leakage.
In exceptional cases the oil level may need to be
checked while the transmission oil is cold refer to
Section 3.3.1.
Then always check the oil again at normal operating
temperature.

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29

Maintenance
3.3.1 Guide Value Measurement

3.3.1.1 Checking Before the Engine is Switched On

This oil level measurement, carried out while the

transmission oil is cold, is applied under the following
exceptional circumstances:

Vehicle stationary and on horizontal ground.

Oil level must reach the STOP mark.
NOTE
If the oil level is higher than this, do not drain any oil!

When a transmission enters service for the first time.

If the engine has not run in a long time or if the vehicle
has been transferred or purchased.
After in situ transmission repair, e.g. removal of the oil
pan, hydraulic control unit, heat exchanger etc.

- STOP

After oil or filter changes.

} HOT

Calculation of the flat rate (labor charge) can be divided

into steps:
} COLD

Checking before the engine is switched on.

024885

Checking after the engine has been switched on.

Then check again at operating temperature.

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30

Maintenance
3.3.1.2 Checking After Starting the Engine

3.3.2 Checking at Operating Temperature

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

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

Vehicle stationary and on horizontal ground

Vehicle stationary and on horizontal ground

Shift range selector (pushbutton) to Neutral

Shift range selector (pushbutton) to Neutral

Leave engine running at 1200 - 1500 rpm for

15 - 20 seconds

Run engine for 15 - 20 seconds at 1200 - 1500 rpm

(not required with directly mounted heat exchanger)

Run engine at idle speed and measure oil level within

30 seconds

Let engine run at idle speed

Oil level must be in the COLD range

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

- STOP
} HOT

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

} COLD
024885

CAUTION
The engine idle speed should be set to between 500 and
700 rpm. It must never drop below 450 rpm.

Then check again at operating temperature (see Section

3.3.2).

Oil level must be in the HOT range.

For the options available for heating up transmission oil,
see Section 8.3.3.
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31

Maintenance
3.3.3 Option for Heating Up the Transmission Oil
The transmission oil can be heated up to its specified
operating temperature for oil check purposes by running
the vehicle normally with retarder cycles until the oil
sump temperature reaches 80 - 90 C.
If normal operation of the vehicle is not possible, the oil
needs to be heated up in one of the following ways:
Apply parking brake
Select speed range D
Apply service brake
Run engine several times at part throttle (as required)
for 15 to 20 seconds at 1200 to 1500 rpm.
CAUTION
The maximum permitted oil temperature defined in
Section 2.9 must not be exceeded!
After every heating-up phase and with the transmission
in Neutral, run engine at 1500 to 2000 rpm for 15 to
30 seconds.
Once the operating temperature has been reached, a
check must be carried out in accordance with Section
3.3.2.
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32

Maintenance
3.4 Oil Change Intervals

3.5

Oil Change

The oil change intervals defined in ZF List of Lubricants

TE-ML 14 are binding.

3.5.1 Draining Transmission Oil

NOTE
Drain oil at operating temperature for at least 10 minutes:

The latest List of Lubricants can be obtained from all ZF

Sales & Service Centers or can be downloaded from the
Internet at: www.zf.com (Service / Technical Information /
ZF List of Lubricants) and viewed.

Vehicle stationary and on horizontal ground

Engine must be stationary
Unscrew oil drain plug (1) and drain oil

NOTE
When changing oil from ATF in lubricant class 14A or 14B
to an ATF grade with longer oil change intervales, an
intermediate oil change is required to comply with List of
Lubricants TE-ML 14.

Remove filter cover (2)

1
027485

2
CAUTION
The oil filter must be replaced at every oil change.
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33

Maintenance
3.5.2 Draining Oil From ZF Angle Drive
The ZF angle drive shares an oil supply with the
ZF-Ecomat. Only drain oil at operating temperature.
ZF 80 angle drive LHD without offset

ZF 80 angle drive RHD with offset

Engine must be stationary

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

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

027488
027487

ZF 80 angle drive RHD with offset

ZF 80 angle drive LHD without offset

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34

Maintenance
3.5.3 Filling Oil
Replace filter cartridge, copper rings and O-ring
Screw down filter cover (2),
tightening torque: 25 Nm

Screw in oil drain plug (1) :

Tightening torque - oil pan: 50 Nm
- Tightening torque - 80 angle drive LHD
without offset: 60 Nm

027486

Remove dipstick (3)

Fill with oil and check oil level in accordance with
Section 3.3
NOTE
The angle drive (optional) is filled via the transmission.
Use oil grade in accordance with List of Lubricants
TE-ML 14 Oil volume, see Section 3.2.

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35

Troubleshooting Instructions

Error

Possible cause

Remedial action

Engine will not start.

Speed range selector not in Neutral

Select Neutral on speed range selector

Electronic control unit connector loose.

Tighten ECU plug connection

Starter inhibit relay defective or missing

CAN signal

Replace relay or check CAN

signal

Accelerator pedal not in idle speed position or

load signal too high

Check accelerator pedal / injection pump

or adjust it

Engine idle speed > 900 rpm

Set engine idle speed

Only on transmissions with auxiliary function

Gear release:
Service brake not applied

Apply the service brake

ECU in malfunction setting

Switch ignition on/off

Oil level too low

Check / correct oil level

Transmission defective

Call ZF Service

Oil level too high

Check / correct oil level

Retarder engaged

Switch off retarder using hand lever

Transmission damage

Call ZF Service

Radiator dirty

Clean the radiator

Oil level too low

Check / correct oil level

Retarder proportional valve or solenoid valve

not operating, CAN signal not present

Check CAN signal and retarder connector

Transmission does not

engage any gears

Vehicle does not move

Oil temperature too high

Retarder not responding

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