Betriebsanleitung

Operating Instructions
Manuel d’Utilisation
Manual de Servicio
Istruzioni per l’Uso

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:
• 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.
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 Instruc-
tions specific to an individual vehicle manufacturer, the
vehicle-specific instructions are the ones to follow.

The ZF Customer Service specialists are available to assist

you. in carrying out maintenance work or to help if any Motoring pleasure with the ZF-Ecomat is brought to you
other problems arise. by
These addresses are listed in the “ZF Company Directory”
(order number 0000 762 703) or on the Internet under ZF Friedrichshafen AG
www.zf.com/ servicenetz. Commercial Vehicle and
You will find more product information on the Internet by Special Driveline Technology
logging on to www.zf.com (Products/Product World Bus). D-88038 Friedrichshafen
Phone: +49 (0) 7541 77-0
Fax: +49 (0) 7541 77-90 80 00
Internet: www.zf.com

4182 758 101 - 2006-06 3

Safety Instructions

The following safety instructions appear in this manual:

! THREATS TO THE ENVIRONMENT!
NOTE
Refers to special processes, techniques, information, etc.
CAUTION
This is used when incorrect, unprofessional
working practices could damage the product.
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 manufacturer’s instructions.

! DANGER!
This is used when lack of care could lead to personal
injury or material damage. 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 4


1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Structure of Basic ZF-Ecomat 4 Transmission . . . 7
1.2 ZF-Ecomat 4 System Solution . . . . . . . . . . . . . . 8
1.3 Auxiliary Transmission . . . . . . . . . . . . . . . . . . .11
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.1 Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.1.1 Digital Speed Range Selector . . . . . . . . . . . . . . .12
2.1.2 CAN Speed Range Selector . . . . . . . . . . . . . . . .12
2.1.2.1 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
Table of Contents
2.9 Limit Values for Oil Temperature . . . . . . . . . . .22
2.9.1 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
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.1 Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.2 Oil Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.3 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . .29
3.3.1 Guide Value Measurement . . . . . . . . . . . . . . . . .30
3.3.1.1 Checking Before the Engine is Switched On . .30
3.3.1.2 Checking After Starting the Engine . . . . . . . . . .31
3.3.2 Checking at Operating Temperature . . . . . . . . .31
3.3.3 Option for Heating Up the Transmission Oil . .32
3.4 Oil Change Intervals . . . . . . . . . . . . . . . . . . . . .33
3.5 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.5.1 Draining Transmission Oil . . . . . . . . . . . . . . . . .33
3.5.2 Draining Oil From ZF Angle Drive . . . . . . . . .34
3.5.3 Filling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5
Description

1 Description The hydrodynamic retarder is installed between torque

The Ecomat range of transmissions comprises a hydro-
dynamic torque converter (Föttinger 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).
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.
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 estab-

lishes 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 6

 Description

1.1 Structure of Basic ZF-Ecomat 4 Transmission

1 2 3 4 5 6 7 12 9 10

11

024744 10

026741
8
10
Key to items
1 Drive 7 Output
2 Torsion damper (optional) 8 Heat exchanger
3 Torque converter 9 Auxiliary cooling, short-circuit bracket (optional)
4 Hydrodynamic retarder 10 Transmission type plate (possible positions)
5 Rotating multi-disc clutches 11 Transmission electrical unit connector
6 Stationary multi-disc brakes 12 Serial number (embossed)
4182 758 101 - 2006-06 7
Description

1.2 ZF-Ecomat 4 System Solution

8 22 Brake
23
Accelerator
1 2
3 D
N R Engine
16 Displays
13 12 2 ....
13 17 ....
CAN-Bus
20
11
6
7
10

Key to drawing 1
4
1 Transmission electrical 21 9
unit connector
2 ECU 146 / ECU 147 connector 14
15 18
3 Retarder connector
4 Retarder accumulator connector* 14 Pushbutton for NBS* 19
5
5 Temp.sensor connector (B4/A6) 15 Pushbutton for gear release*
6 Kickdown Switch 16 ECU 146/147
7 ZF diagnosis connection plug Electronic Control Unit
8 Speed range selector 17 Retarder manual lever, electrical* 3
9 Transmission breather, oil filler 18 Impulse sensor for speedometer*
tube, oil dipstick 19 Coolant connections
027591
10 Footplate brake valve for activation 20 CAN connection
of service brake and infinitely 21 From air supply to auxiliary
variable retarder operation consumers*
11 Accelerator pedal 22 Type plate ECU 146/147
12 Retarder switch OFF - ON* 23 Temperature display A5*
13 Main Power System *optional
4182 758 101 - 2006-06 8

Ecomat 4 System Solution
This system diagram illustrates one of the possible system
solutions for Ecomat 4 with ECU 146/147 and individual
components.
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).
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 transmission’s
hydraulic system.
4182 758 101 - 2006-06
Description
The driver can intervene actively in the Ecomat control
system using:
• Speed range selector (8)
• Kickdown (6)
• Accelerator pedal (11)
• Brake pedal (10)
• Switch for retarder operation (12/17)
The desired speed range can be pre-selected using the
speed range selector. The button pressed is illuminated
(continuously lit).
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.
9
Description

Temperature sensors (5) are installed to monitor the oil Ecomat 4 Innovations
temperature (also refer to Section 2.8). Data from
For temperature-critical applications, transmissions in the
temperature sensors is transmitted via CAN bus system,
Ecomat 4 ranges are prepared for connection of a separate
ECU 146/147 digital output or direct wiring and displayed
heat exchanger (auxiliary cooler). To connect up the
by means of display or warning lamp.
additional heat exchanger, the short-circuit bracket is
removed and flexible hoses are used to create a link to the
Whenever defined temperature limits are exceeded,
heat exchanger.
retarder torque is reduced continuously.
Short-circuit bracket, see Section 1.1, Pos. 9.
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 4 3

ZF-Ecomat transmission can be equipped with an
80° angle drive.

1 2

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)
027511

4182 758 101 - 2006-06 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
• Convex keys
a CAN speed range selector switch.
• Neutral button does not lock
Installation variants with 3, 4, 5 or 6 pushbuttons,
• ZF logo located on side of Neutral button
installed horizontally or vertically:
R = Reverse
N = Neutral
D = Automatic forwards driving range (Drive) 027768
027769
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.

005624
Digital speed range selector, installed horizontally

4182 758 101 - 2006-06 12

 Operation

2.1.2.1 Lighting of the CAN Speed Range Selector Exceptions:

Switch • If the transmission control unit is not providing the
information required for lighting purposes, the lamps
Button lighting colors:
only light up in search mode. Nevertheless, the vehicle
• Neutral button: bernstein can still be driven in this status.
• 1, 2, 3, D and R: yellow • The lighting is also deactivated if the pushbutton
position can no longer be correctly established as a
All buttons light up for approx. 1.2 s:
result of a hardware defect and the buttons only light
• Lighting test at system startup up with search lighting.
All keys light up dimly:
NOTE
• Search lighting: To make it easier to find the buttons in The brightness settings for search and function lighting
the dark. can, if required, be adjusted independently. They are
corrected as a function of operating voltage.
Individual buttons light up brightly:
• Function lighting: Identifies the active, pressed push-
button.
2.1.2.2 Pushbutton Settings
Individual buttons flashes:
• The active (pushed) button flashes if it is not accepted NOTE
by the transmission control unit. If several buttons are selected at the same time, the
smallest gear inhibit button selected is chosen.
All buttons flash:
e.g. if buttons 1, 2, 3 and D are selected at the same time,
• Serious internal fault in pushbutton button 1 is activated.
• 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

Engine can only be started if: (Additional installation by vehicle manufacturer,

recommended by ZF)
• 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
• Select desired driving range and apply the brake.
Starter inhibit: If the speed range selector is not in
System only engages the appropriate gear while the
Neutral, the engine cannot be started.
brake is being applied.
CAUTION
Operator errors when engaging gear
Only jump-start on the battery, never on the starter!
Ignition OFF/ON but not while vehicle is in motion! • 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
• Speed range selector in Neutral
does not engage a gear.
• Accelerator pedal at idle setting and neng < 900 rpm
Transmission with auxiliary function “2nd Reverse gear
• Select desired driving range or direction of travel.
button”
CAUTION
• To reverse the vehicle, press the R button on the speed
Never actuate speed range selector and throttle at the
range selector and also the R button on the dashboard.
same time!

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
Please refer to the vehicle’s Operating Instructions for
precise information about the gears engaged in each of the
speed ranges.
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 out-
put 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”.
4182 758 101 - 2006-06
2.5.1 Downhill Travel
When driving down steep gradients, depending on
requirements, you should select setting 1, 2 or 3 on the
speed range selector. This restricts upshifts.
! DANGER !
In extreme cases, to protect the engine, the upshift
inhibit is cancelled.
When this happens, it is possible for the 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
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 Accelerator
the CAN system (to accelerate or to use the accelerator pedal
pedal on uphill gradients).
Full load
• Depress accelerator pedal beyond its full throttle (pressure point)
pressure point (kickdown setting) Kickdown

Kickdown switch
023629

4182 758 101 - 2006-06 17

Operation

2.5.4 Retarder Operating Mode

l
da
pe
The retarder is a ratio-dependent hydrodynamic brake
ge

e
which operates without mechanical wear. The retarder

ak
ran

Br
should be employed every time the brakes are applied. r
de
This extends the life of the service brake. The retarder etar
R r
rde
can be activated by hand and/or using the foot controls.
+ reta
e
ang
rake r
b
Conditions for retarder operation vice
(retarder engaged/actuated) Ser

• 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
4
If the accelerator pedal is actuated, the retarder
3
disengages. The upshift inhibit is cancelled.
2

1
023630
0

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 manufacturer’s 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
• Accelerator pedal in idle speed setting
setting of the speed range selector. The electronic shift
control unit then engages the appropriate gear for setting
The range selected with the speed range selector is then
off.
retained.
As soon as one of the three conditions ceases to apply,
With short stops:
1st gear is selected immediately and automatically.
• 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
! 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!

4182 758 101 - 2006-06 20

 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
• Speed range selector in Neutral between transmission and drive shaft needs to be
disconnected.
• Max. towing time: 2 hours
• Max. towing speed: Exception: In a dangerous situation, towing is permitted
City and intercity buses: 25 km/h until the vehicle leaves the immediate danger area (e.g.
Coaches: 35 km/h road junction/intersection, tunnel etc.), without first
disconnecting the driveline.
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
The switch point for the warning contact on the tempera-
ture display unit is 145 °C.
2.9.1 Transmission Oil Temperature Before Heat
Exchanger
During retarder operation:
• In exceptional cases, short periods of operation
(max. 5 mins. within a 1 hour period) at 150 °C are
permissible.
During torque converter operation:
• The temperature limit for continuous operation is
110 °C.
• In exceptional cases, short periods of operation
(max. 5 mins. within a 1 hour period) at 130 °C are
permissible.
During normal driving:
• The permitted temperature range is between
90 - 100 °C.

4182 758 101 - 2006-06 22

 Operation

2.9.2 Oil Temperature in Transmission Oil Sump Pos. 120 Pos. 124

The following sump temperatures must not be exceeded

(not even at high ambient temperatures):

Transmission oil sump temperatures Ecomat 4

Operating 1 2
temperature max. max.
or endurance 100 °C 105 °C
temperature
B14
Exception: 021648
max. 5 mins.
within 105 °C 115 °C
1 hour B14: Temperature sensor in transmission sump

1 with oil acc. to List of Lubricants TE-ML 14 A / B / C / E Pos 120/124: Temperature sensor on retarder outlet (B4)
2 with oil acc. to List of Lubricants TE-ML 14 E or temperature sensor (A6) for temperature indicator (A5)
see Section 1.2 ZF-Ecomat 4 System Solution

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
• Driving at partial load
• Switch off retarder
If this does NOT cause the oil temperature to drop:
• Stop the vehicle
• Speed range selector in Neutral
• Run engine at raised idle speed
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.
Warning lamps
Faults are displayed by warning lamps lighting up (red or
yellow) and by warning messages which appear on the
driver’s display panel (refer to the vehicle manufacturer’s
Operating Instructions).

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

NOTE
ECU, the button pressed on the speed range selector starts
If the temperature does not drop back into its permitted
to flash.
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:
Shift into Neutral:
In the event of major malfunctions in the power supply to
the transmission, e.g. short circuit.
Shift into Limp-Home Mode:
If there is an interruption to CAN communication or a loss
of shaft speed information.
The ECU is set up with specific time and pressure settings
for pressure control in limp-home mode. Please also note
that:
• The retarder function is not available
• The “Bus Stop Neutral” (NBS) function is not available
• The engine brake cannot be activated
• “Torque converter lock-up clutch” (WK) is open
• Engine torque is limited to protect the transmission
(no engine management)

! 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 • Apply parking brake to prevent vehicle from rolling
act as a limp-home facility in the event of ECU failure. 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 • Switch off engine and ignition.
connector instead of the ECU 145/147-pin connector. This
• Remove connector from electronic shift controller.
allows the driver to select one forwards and one reverse
gear. Gear shifts whilst driving are no longer possible. • Connect plug to HST 46 auxiliary control unit and
secure.
NOTE
• Start engine.
Auxiliary control unit not available with the
ECU 146/147 and CAN pushbutton combination. • Engage gear on pushbutton:
Shift setting “N” = Neutral
Shift setting “D” = Drive (forwards gear is
engaged, no upshifts or
downshifts occur)
Shift setting “R” = Reverse

4182 758 101 - 2006-06 26

 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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Maintenance

3 Maintenance The latest List of Lubricants can be obtained from all ZF

Sales & Service Centers or can be downloaded from the
Regular and correctly performed maintenance is essential Internet at: www.zf.com (Service / Technical Information /
to safeguard the operational safety of the transmission. It ZF List of Lubricants) and viewed.
is therefore particularly important for the maintenance
intervals to be observed.
3.2 Oil Volumes
! THREATS TO THE ENVIRONMENT!
• During oil changes (drain lasts approx. 10 min.)
Lubricants and cleaning agents must not be allowed
approx. 18 liters
to enter the soil, ground water, or sewage system.
• Ask your local environment agency for safety • After installation of new/replacement transmissions
information on the relevant products and adhere approx. 20 liters
to their requirements.
• When first filling the dry transmission
• Collect used oil in a suitably large container.
approx. 28 liters
• Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
NOTE
protection guidelines.
These figures are guide values and refer to the standard
• When working with lubricants and cleaning agents
version of the Ecomat 4. Depending on the version of heat
always refer to the manufacturer’s instructions.
exchanger fitted, oil quantities can rise by as much as
approx. 5 liters.
The definitive oil volume is the one obtained after the oil
3.1 Oil Grade level check and at operating temperature (see Section
3.3.2).
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:

CAUTION
Always maintain the correct oil level:
• Insufficient oil leads to transmission malfunctions
and damage
• Too much oil causes the transmission to overheat
! DANGER !
Insufficient oil in the system leads to partial or com-
plete failure of the retarder, i.e. braking action is
impaired or non-existent.
• Check the oil level at operating temperature (80 to
90 °C) to obtain a definitive figure.
• The vehicle must be parked on level ground when
checking the oil level.
• Shift range selector (pushbutton) to Neutral.
• Run engine at idle speed.
Idle speed should be set to 500 to 700 rpm.
It must never drop below 450 rpm.
• Undertake oil level check at least once a quarter.
• Conduct regular visual inspections of the transmission 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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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 • Vehicle stationary and on horizontal ground.
transmission oil is cold, is applied under the following
• Oil level must reach the “STOP” mark.
exceptional circumstances:
NOTE
• When a transmission enters service for the first time.
If the oil level is higher than this, do not drain any oil!
• 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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3.3.1.2 Checking After Starting the Engine
Oil level check with cold transmission oil (approx. 30 °C):
• Vehicle stationary and on horizontal ground
• Shift range selector (pushbutton) to Neutral
• Leave engine running at 1200 - 1500 rpm for
15 - 20 seconds
• Run engine at idle speed and measure oil level within
30 seconds
• Oil level must be in the “COLD” range
NOTE
If the oil level is higher than this, do not drain any oil!
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.
Then check again at operating temperature (see Section
3.3.2).
4182 758 101 - 2006-06
Maintenance
3.3.2 Checking at Operating Temperature
Oil level check with hot transmission oil (80 to 90 °C):
• Vehicle stationary and on horizontal ground
• Shift range selector (pushbutton) to Neutral
• Run engine for 15 - 20 seconds at 1200 - 1500 rpm
(not required with directly mounted heat exchanger)
• Let engine run at idle speed
- STOP
} HOT
} COLD
024885
CAUTION
The engine idle speed should be set to between 500 and
700 rpm. It must never drop below 450 rpm.
• Oil level must be in the ‘HOT’ range.
For the options available for heating up transmission oil,
see Section 8.3.3.
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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 Maintenance

3.4 Oil Change Intervals 3.5 Oil Change

The oil change intervals defined in ZF List of Lubricants 3.5.1 Draining Transmission Oil
TE-ML 14 are binding.
NOTE
The latest List of Lubricants can be obtained from all ZF Drain oil at operating temperature for at least 10 minutes:
Sales & Service Centers or can be downloaded from the
• Vehicle stationary and on horizontal ground
Internet at: www.zf.com (Service / Technical Information /
ZF List of Lubricants) and viewed. • Engine must be stationary
• Unscrew oil drain plug (1) and drain oil
NOTE
When changing oil from ATF in lubricant class 14A or 14B • Remove filter cover (2)
to an ATF grade with longer oil change intervales, an
intermediate oil change is required to comply with List of
Lubricants TE-ML 14.

1
027485

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

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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
• Engine must be stationary
• Unscrew and remove oil drain plug (1) from angle drive
and drain residual oil from angle drive
ZF 80° angle drive RHD with offset
This angle drive does not have its own oil drain plug.
Drain oil through drain plug in main transmission
as described in Section 3.5.

027488
1
027487

ZF 80° angle drive LHD without offset ZF 80° angle drive RHD with offset

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 Maintenance

3.5.3 Filling Oil

• Replace filter cartridge, copper rings and O-ring

• Screw down filter cover (2), 3
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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Troubleshooting Instructions

Error Possible cause Remedial action

Engine will not start. Speed range selector not in “Neutral” Select “Neutral” on speed range selector
Electronic control unit connector loose. Tighten ECU plug connection
Starter inhibit relay defective or missing Replace relay or check CAN
CAN signal signal
Transmission does not Accelerator pedal not in idle speed position or Check accelerator pedal / injection pump
engage any gears load signal too high or adjust it
Engine idle speed > 900 rpm Set engine idle speed
Only on transmissions with auxiliary function
“Gear release”:
Service brake not applied Apply the service brake
ECU in malfunction setting Switch ignition on/off
Vehicle does not move Oil level too low Check / correct oil level
Transmission defective Call ZF Service
Oil temperature too high Oil level too high Check / correct oil level
Retarder engaged Switch off retarder using hand lever
Transmission damage Call ZF Service
Radiator dirty Clean the radiator
Retarder not responding Oil level too low Check / correct oil level
Retarder proportional valve or solenoid valve Check CAN signal and retarder connector
not operating, CAN signal not present

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