4149 - 751 - 608c - Part - 1 (1) - Reparatii Stagiul 1-2

Reparaturanleitung
Repair Manual
Manuel de Réparation
Manual de Reparaciones
Manuale di Riparazione
HP 502/504, HP 592/594, HP 602/604

ECU 146 / ECU 147
4149 Ecomat 2 plus, 4180 Ecomat 2 NMOT
4182 Ecomat 4
Stages 1-2 4149 751 608c
Subject to alterations in design
Copyright by ZF
This documentation is protected by copyright. Any

reproduction or dissemination in whatever form
which does not comply fully with the intended pur-
pose of this documentation is prohibited without the
consent of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C / 2005-06
Edition: 2006-03
4149 751 608c

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Table of Contents
Page
Preface ........................................................................................................................................................... 5
Safety Instructions ......................................................................................................................................... 6
Instructions for Repairs ................................................................................................................................. 7
Tightening Torques ........................................................................................................................................ 9
Consumables .................................................................................................................................................. 11
Adjustment Data ............................................................................................................................................ 12
Special Tools .................................................................................................................................................. 15
Arrangement of Peripheral Equipment ......................................................................................................... 19
Sectional view, Ecomat 2 plus ....................................................................................................................... 20
Sectional view, Ecomat 4 ............................................................................................................................... 22
Shift elements, clutch and brake combinations, Ecomat 2 plus ................................................................... 23

Shift elements, clutch and brake combinations, Ecomat 4 .......................................................................... 24
1 Maintenance......................................................................................................................................... 1-1
1.1 Oil Change Intervals ............................................................................................................................ 1-1

1.2 Oil Capacities ....................................................................................................................................... 1-1
1.3 Oil Grade .............................................................................................................................................. 1-1
1.4 Check Oil level ..................................................................................................................................... 1-2
1.5 Operating Temperature ....................................................................................................................... 1-2
1.6 Adding Oil ............................................................................................................................................ 1-2
1.7 Checking Oil Level at Operating Temperature ................................................................................... 1-2
1.8 Checking Oil Level when Cold ............................................................................................................ 1-3
1.9 Checking Oil Level with Engine Off ................................................................................................... 1-3
1.10 Checking Oil Level on Versions with Heat Exchanger Higher than Center Line of Transmission ... 1-3
1.11 Changing Oil at Operating Temperature ............................................................................................. 1-4
1.12 Adjustment of Load Sensor ...................................................................................................... ........... 1-5
2 Servicing............................................................................................................................................... 2-1
2.1 Replacing Filter .................................................................................................................................... 2-1

2.2 Replacing Retarder Solenoid Valve ..................................................................................................... 2-3
2.3 Replacing Accumulator Solenoid Valve .............................................................................................. 2-4
2.4 Replacing the Accumulator ................................................................................................................. 2-5
2.5 Replacing Temperature Sensor ........................................................................................................... 2-6
2.6 Replacing the “Output” Sensor ............................................................................................................ 2-7
2.6.1 Replacing Retarder Resistor ................................................................................................................ 2-11
2.7 Removing and Assembling Oil Pan ..................................................................................................... 2-13
2.8 Replacing Inductive Sensor “Turbine” ................................................................................................ 2-16
2.9 Replacing Inductive Sensor “NMOT” ................................................................................................. 2-22
2.10 Replacing Complete Hydraulic Transmission Control Unit ............................................................... 2-26
2.11 Replacing Impulse Sensor for Speedometer ....................................................................................... 2-31
2.12 Replacing Output Flange and/or Radial Seal Ring ............................................................................. 2-32
2.13 Pressure Tests ...................................................................................................................................... 2-36
4149 751 608b - 2005-10 3

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Table of Contents
Page
3 Troubleshooting..................................................................................................................................... 3-1
3.1 Inspection with Test Cable 1P01 138 153 ........................................................................................... 3-1
Table of Resistance Measurement Nominal Values ............................................................................ 3-2
Tolerance Table of Temperature Sensor NTC - Sensor B14 ................................................................ 3-3
Table – Retarder Alignment ................................................................................................................. 3-4
3.2 Annex
Installation Instructions for “ZF-TESTMAN pro” Diagnostic Tool
4 Plans .................................................................................................................................................... 4-1

Ecomat 2 plus - Hydraulic Diagrams
Hydraulic circuit diagram without NBS, from drawing no.: 4149 700 026/1 ..................................... 4-1
Hydraulic circuit diagram with NBS, from drawing no.: 4149 700 026/2 .......................................... 4-2
Ecomat 4 - Hydraulic circuit diagram, from drawing no.: 4182 700 001 .......................................... 4-3
Ecomat 2 plus - circuit diagrams:
Current circuit diagram ECU 146 / ECU 147 with CAN and digital range selector;
From drawing no.: 6029 729 155 ........................................................................................................ 4-4
Current circuit diagram ECU 146 / ECU 147 with CAN range selector;
From drawing no.: 6029 729 232 ........................................................................................................ 4-5
Current circuit diagram ECU 146 / ECU 147 without CAN (NMot), with digital range selector;
From drawing no.: 6029 729 215 ........................................................................................................ 4-6
Ecomat 4 - Current circuit diagram:
Current circuit diagram ECU 146 / ECU 147 with CAN and digital range selector;
From drawing no.: 6029 749 008 ....................................................................................................... 4-7
Current circuit diagram ECU 146 / ECU 147 with CAN range selector;
From drawing no.: 6029 749 010 ........................................................................................................ 4-8
EST 146 / EST 147 contact patterns: 6029 729 073 ........................................................................... 4-9
Ecomat 2 plus - wiring diagrams:
Connection diagram ECU 146 / ECU 147 with CAN and digital range selector;
From drawing no.: 6029 729 156A / Sheet 1-4 .................................................................................... 4-10
Connection diagram ECU 146 / ECU 147 with CAN and CAN range selector;
From drawing no.: 6029 729 233 / Sheet 1-4....................................................................................... 4-14
Connection diagram ECU 146 / ECU 147 without CAN(NMot), with digital range selector;
From drawing no.: 6029 729 216 / Sheet 1-4 ...................................................................................... 4-18
Ecomat 4 - Wiring diagrams:
Connection diagram ECU 146 / ECU 147 with CAN and digital range selector;
From drawing no.: 6029 749 009 / Sheet 1-4 ................................................................................... 4-22
Connection diagram ECU 146 / ECU 147 with CAN and CAN range selector;
From drawing no.: 6029 749 011 / Sheet 1-4 .................................................................................... 4-26
Annex
ZF-Ecomat 2 plus HYDRAULIC 1 - Off Position
ZF-Ecomat 2 plus HYDRAULIC 2 - On Position
4149 751 608c - 2006-03 4

Preface
This repair manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF products

in accordance with the state of development on the
date of issue.
However, due to continuing development of the

product, repair work might require work practices
and test or adjustment data not contained in this
manual.
We recommend that work done on your ZF product

is carried out only by skilled mechanics who have
had their practical and theoretical knowledge up-
dated on a regular basis at our After-Sales Service
training centers.
Service Points equipped by ZF Friedrichshafen AG

all over the world offer you:
1. Continually trained personnel,
2. Specified equipment, e.g. special tools,
3. Genuine ZF spares, according to our latest

specifications.
All work performed at these Service Points is carried

out conscientiously and with utmost care.
Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
ZF Friedrichshafen AG the individual case.
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and Damage resulting from work performed by non-ZF
Special Driveline Technology personnel in an improper and unprofessional
Service Werk 2 (Plant 2) manner and any consequential costs are excluded
Phone: +49 (0)7541 77-0 from the contractual liability agreement. Exclusion
Fax: +49 (0)7541 77-908000 of liability also applies if genuine ZF spares are
Internet: www.zf.com not used.
2003-08 5
Important Information
Safety Instructions General Information
Companies repairing ZF units are responsible for Read this manual carefully before starting any tests
their own work safety. or repair work.
To avoid injury to personnel and damage to

products, all safety regulations and legal require- CAUTION
ments which apply to repair and maintenance work Pictures, drawings, and components do not always
must be adhered to. represent the original object, but are used to illus-
Before starting work, mechanics must familiarize trate working procedures.
themselves with these regulations. Pictures, drawings, and components are not to scale.
Conclusions about size and weight should not be
Personnel required to carry out repairs on ZF drawn (even within a complete illustration).
products must receive appropriate training in Always follow the working steps as described in the
advance. It is the responsibility of each company to text.
ensure that their repair staff is properly trained.
After completion of repair work and testing, skilled

staff must check whether the product is functioning
The following safety instructions appear in this correctly.
manual:
! THREATS TO THE ENVIRONMENT !

NOTE Lubricants, consumables, and cleaning agents must
Refers to special processes, techniques, data, use of not be allowed to enter the soil, ground water, or
auxiliary equipment, etc. sewage system.
• Ask your local environment agency for safety
information on the relevant products and adhere to
CAUTION their requirements.
This is used when incorrect, unprofessional work- • Collect used oil in a suitably large container.
ing practices could damage the product. • Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
! DANGER • When working with lubricants and cleaning agents
This is used when lack of care could lead to personal always refer to the manufacturer’s instructions.
injury or death.
CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.
2003-08 6
Instructions for Repairs
ZF Service Information must be observed. This Gaskets, Locking plates

information is available at all ZF Service Centers or
via the ZF-ServiceLine. Parts which cannot be removed without being
damaged must always be replaced with new parts
In case of doubt always turn to the relevant depart- (e.g. gaskets and locking plates).
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed by
experts only and under clean conditions.
Use specified tools to dismantle and assemble Shaft Seals
transmissions.
Always change shaft seals with rough, ripped or
hardened sealing lips. Seal contact surfaces must be
After removing the transmission from the vehicle, totally clean and in perfect condition.
clean it thoroughly with a suitable cleaning agent
before opening.
Pay particular attention to the projections and
recesses of housings and covers when cleaning. Reworking
Parts joined with Loctite are easier to separate if Rework may be carried out on seal contact surfaces
warmed with a fan heater. using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.
Cleaning parts If rework is needed on spacer discs, shims etc.

because of clearance adjustment, ensure that the
Remove remains of old gaskets on all sealing sur- reworked areas contain no face runout and have
faces. Carefully remove burrs or similar patches of the same surface quality.
roughness using an oilstone.
Lube bores and grooves must be free of anti-

corrosion agents and foreign matter; check for Transmission Assembly
perfect passage.
Find a clean work area to assemble the transmission.
Carefully cover opened transmissions to prevent for- Gaskets are installed without sealing compound or
eign matter from entering. grease. When measuring silicon-coated gaskets, do
not include the silicon layer.
During assembly, comply with all adjustment data
and tightening torques in the Repair Manual.
Reusing parts
Parts such as roller bearings, discs, thrust washers

etc., must be inspected by a competent person who
should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered
from excessive wear.
2003-08 7
Instructions for Repairs
Bearings d) Duo shaft sealing rings have two

sealing lips. The dust protection
f the bearings are fitted while warm, these should be sealing lip (X)
warmed up evenly (e.g. in a heating cabinet). must face outwards. X
The temperature should be approx. 85 °C and must
not exceed 120 °C. Each mounted bearing must be
oiled with operating oil.
e) If possible, heat shaft sealing ring’s bore to
between 40 and 50 °C (this makes fitting easier).
Press the shaft sealing ring on to the relevant
Sealing installation depth with mounting or face plate.
If a specific sealing agent* is to be used for carrying

out sealing, comply with the manufacturer’s direc-
tions for use. Apply a thin layer of sealing agent to Retaining Agents
the surfaces and spread evenly. Do not allow sealing
agent to enter oil ducts and bores. On oil-carrying Retaining agents* may only be used in the places
ducts and/or bores specified in the parts list.
, wipe off the sealing agent on the surfaces to be When using retaining agents (e.g. Loctite), always
sealed near apertures to ensure that no sealing agent comply with the manufacturer’s directions for use.
enters the oil feeds when the surfaces are sealed. During assembly, comply with all specified adjust-
ment values, checking data and tightening torques.
Shaft Sealing Rings

Transmission Oil
a) Apply a thin coat of sealing agent* to outer edge
of shaft sealing rings with a “steel surround”. After completing repairs, fill the transmission with
transmission oil. For the procedure and approved
b) Never apply sealing agent to shaft sealing rings oils, refer to the transmission operating manual and
with a “rubber surround” but apply a thin coat of the List of Lubricants TE-ML (refer to type plate).
Vaseline 8420 to the outer edge or wet with a These are available from all ZF Service Centers or on
lubricant, e.g. a water-soluble, concentrated the Internet at www.zf.com. After filling the trans-
washing-up liquid (e.g. Pril, Coin, Palmolive). mission with oil, tighten the screw plugs at the oil
filling point and the oil overflow to the specified
c) Shaft sealing rings with steel and rubber sur- torques.
rounds
should be treated on the outer edge of the rubber
surround as described above in section (b).
* refer to consumables
2003-08 8
ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Overview of Amendments: 4149 751 608
Index Date of issue Chapter Initiator Remark
a 2005-06 2.9 BKS-T Replacing inductive sensor “NMOT”, model 4180. . . . . .
b 2005-10 Title BKS-T with model 4182, ECOMAT 4
Sectional BKS-T Ecomat 4, 5, and 6-speed version with

view Torsional vibration damper
Shift BKS-T Ecomat 4 - clutch and brake combinations

elements
c 2006-03 4 BKS-T Ecomat 4 - Hydraulic circuit diagram 4182 700 001

Ecomat 4 - current circuit diagram 6029 749 008,
6029 749 010
Ecomat 4 - Wiring diagram 6029 749 009,
6029 749 011
4149 751 608c - 2006-03 9

Tightening Torques
Tightening torques for bolts and nuts, excerpt

from ZFN 148
This standard applies to bolts according to DIN 912, Surface condition of bolts/nuts: Heat-treated black-
DIN 931, DIN 933, DIN 960, DIN 961, as well as ened finish and oiled or galvanized and oiled or gal-
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, vanized, chromated, and oiled.
and for nuts according to DIN 934 and ISO 4032,
ISO 8673. The bolts are tightened using an appropriate snap
torque wrench or torque display wrench.
This standard contains data on tightening torques
for bolts and nuts of strength categories 8.8, 10.9, NOTE
and 12.9, as well as nuts of strength categories 8, 10, Divergent tightening torques are listed separately in
and 12. the repair manual.
Coarse-pitch thread Fine screw thread
Size Tightening torque in Nm for Dimension Tightening torque in Nm for

Screw/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M4 2.8 4.1 4.8 M8x1 24 36 43

M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14 16.5 M10x1 52 76 89
M7 15 23 28 M10x1.25 49 72 84
M8 23 34 40 M12x1.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520
M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960
M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850
M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500
Edition: August 1991
2003-08 10
Tightening Torques
Screw plugs DIN 908, 910, and 7604 Union Screws DIN 7643
The screw plug tightening torques were determined The tightening torques were determined for screw-
according to DIN 7604 for screwing into steel, gray ing into steel, gray cast, and aluminum alloys.
cast, and aluminum alloys. The values are based on The values are based on experience and are
experience and are intended as reference values for intended as reference values for the fitter.
the fitter.
The values for tightening torque apply analogously General rule:
to screw plugs according to DIN 908 and DIN 910, as Screw / Bolt class 5, ZFN 148-1
the thread geometries are almost identical. Material: 9SMnPb28K acc. to DIN 1651
General rule: Surface condition: As manufactured (without sur-
Screw / Bolt class 5, ZFN 148-1 face protection) and lightly oiled or galvanized, chro-
Screw / Bolt material: Steel acc. to DIN 7604 mated, and lightly oiled.
Surface condition: As manufactured (without sur-
face protection) and lightly oiled or galvanized, chro-
mated, and lightly oiled.
Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)
Dimension Tightening torque in Nm Pipe Thread Tightening

screwed into outer torque
steel / gray cast Al alloy diameter in Nm
M8x1 20* 10*
M10x 1 25 / 30* 15 / 20* 4-5 M8x1 20 - 25
M12x1.5 35 25
M14x1.5 35 25 6 M10x1 25 - 35
M16x1.5 40 30
M18x1.5 50 35 8 M12x1.5 30 - 40
M20x1.5 55 45
M22x1.5 60 / 80* 50 / 65* 10 M14x1.5 35 - 40
M24x1.5 70 60
M26x1.5 80 / 105* 70 / 90* 12 M16x1.5 45
M27x2 80 70
M30x1.5 100 / 130* 90 / 130* 15 M18x1.5 50
M30x2 95 85
M33x2 120 110 18 M22x1.5 60
M36x1.5 130 115
M38x1.5 140 120 22 M26x1.5 90
M42x1.5 150 130
M42x2 145 125 28 M30x1.5 130
M45x1.5 160 140
M45x2 150 130 35 M38x1.5 140
M48x1.5 170 145
M48x2 160 135
M52x1.5 180 150
M60x2 195 165
M64x2 205 175
* DIN 7604 Form C Edition: October 1995
2003-08 11
ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Consumables
Designation Name Volume Application Comments

ZF item number Approx.
Grease For example: Assembly aids in general

0750 199 001 Spectron FO 20
Sealing compound Loctite no. 574 Screw connection output flange

0666 790 017
Grease techn. Vaseline 8420 Assembly aids in general

0671 190 016
Transmission oil Refer to TE-ML14 Assembly aid in general

List of Lubricants
NOTE: Inquire size of containers before placing any orders!
4149 751 608a - 2005-06 12

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Adjustment Data
Designation Dimension Measurement device Remark
01. Inner resistances of R = approx. 67 Ohm Ohmmeter and test Resistance increases
solenoid valves for at 20 °C cable 1P01 138 153 depending on temp. up to
transmission clutches and or terminal tester around 74 Ohm when transm.
brakes 6008 006 002 is at operating temperature.
02. Internal resistance of induc- R = 850 ± 100 Ohm Ohmmeter Resistance increases
tive sensors (speed sen- at 20 °C depending on temperature.
sors) nT and nOut.
03. Tightening torque of the 30 Nm Torque Renew copper sealing ring.

temperature sensor wrench
M14x1.5
04. Tightening torque of the oil 50 Nm Torque Renew copper sealing ring.
drain plug wrench
M22x1.5 in the oil pan
05. Distance between the 0.5 to 0.7 mm Depth gage Adjust clearance with shims.
inductive sensor - output Gage (meas. stick)
and face end gears on 1X56 138 149
planetary carrier 1X56 138 150
06. Distance between the 0.6 to 0.8 mm Depth gage Adjust clearance with shims.
inductive sensor - turbine Gage (meas. stick)
and pulse sensor ring 1X56 138 149
1X56 138 150
07. Tightening torque for M6 9.5 Nm Torque Do not overtighten.

fixing bolts on inductive wrench
sensor
08. Distance between speedo- 0.7 to 1.4 mm Depth gage Clearance is specified;
meter impulse sensor & check value.
annular gear on output
09. Tightening torque for 35 Nm Torque Do not overtighten.

speedo sensor wrench
10. Installation dimension of 14 to 15 mm Use adapter 1X56 136 824

shaft sealing ring in output
cover When using the adapter, the
installation dimension is
specified.
4149 751 608a - 2005-06 13

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Adjustment Data
Designation Dimension Measurement device Remark
11.Tightening torque for M6 6 Nm Torque Do not overtighten.

hex nuts on inductive wrench
sensor cover-output
12. Tightening torque of the 60 Nm Torque Secure with lock plate.

hexagon bolts M12 at the wrench Use Adapter 1X56 136 471.
output flange
13. Tightening torque of the 90 up to 100 Nm Torque

screw plug M42x2 in the wrench
duct plate
14. Tightening torque of the 12 Nm Torque Do not exceed value.

screw plugs M10x1 at the wrench
pressure measurement
locations
4149 751 608a - 2005-06 14

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Special Tools
Figure Illustration Order no. Application Qty. Comment

no.
1X56 136,471 1
Mounting adapter
1 for safety plate on output flange
1X56 136 824 1
Attachment
2 for the installation of the radial seal
ring at the output flange
1P01 136 670 1
Test gage
3 0 – 25 bar with connecting piece
M10x1
1P01 137 856 1
Test gage
4 0 – 10 bar with connecting piece
M10x1
1X56 137 126 1
Lifting device
5 for transmissions
4149 751 608a - 2005-06 15

ZF-Ecomat: 4149 / 4180 / 4182

no.
1X56 138 149 1
Measuring stick
6 to determine distance between
inductive sensor and pulse sensor on
turbine and output.
(in conjunction with text fixture
1X56 138 150)
1X56 138 150 1
Test device
7 to determine distance between
inductive sensor and pulse sensor on
turbine and output.
(in conjunction with measuring stick
1X56 138 149)
1X56 103 755 1
Gripper
8 for winding up the output flange
(in conjunction with mounting fixture
1X56 136 512)
1X56 136 512 1
Mounting fixture
9 for winding up the output flange
(in conjunction with gripper
1X56 103 755)
1X56 136 513 (220 V) 1 Options

or available:
1X56 137 575 (110 V) for 220 volts
10 or 110 volts
Hot air blower
to heat various parts
4149 751 608a - 2005-06 16

ZF-Ecomat: 4149 / 4180 / 4182

no.
1P01 138 153 1
Test cable
11 for testing solenoid valves
6008 006 002 1
68-pin terminal tester

12 For troubleshooting
in the electrical sector
6008 208 003 1
Diagnostic system Complete

ZF-TESTMAN pro system
Windows 95, 98, 2000, NT, and XP without
PC
Complete system without PC
for
13 This includes: Windows
95, 98, 2000,
ZF-TESTMAN pro Software NT, and XP
on CD ROM (1)
DPA 05 ZF-Diagnostic adapter

with adapter cable
6008 208 814 1
Application software
14 ZF-TESTMAN pro
for Ecomat 2 plus

on CD ROM
4149 751 608a - 2005-06 17

4149 751 608a - 2005-06 18
ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Arrangement of Peripheral Equipment
Arrangement of Peripheral Equipment
Anzeige-Instrumente
Bremse
Gaspedal
Motor
NR
8
3D
1 2
15
.........
12
2
.......
13
16
CAN-Bus
11
6 22 21 7
10
14
20 4 1
9
17
19 20
18
023514
Key to drawing
1 Transmission electrical power plug 11 Accelerator pedal

2 ECU 146- / ECU 147 plug 12 Retarder switch OFF - ON
3 Proportional solenoid retarder 13 Main Power System
4 Solenoid valve retarder accumulator 14 Pushbutton for NWS
5 Temperature Sensor 15 Electronic automatic shift control ECU 146 /
6 Kickdown switch ECU 147
7 ZF-MOBiDIG connection plug and 16 Retarder manual lever, electrical
ZF-TESTMAN pro 17 Impulse sensor for speedometer
8 Speed range selector (push-button switch) 18 Coolant connection
9 Dipstick (oil level check, oil condition) 19 Retarder accumulator
10 Pedal-operated brake valve for actuation of the 20 Type plate
service brake and continuously variable retarder 21 Load sensor
actuation via CAN 22 Linkage for injection pump
4149 751 608a - 2005-06 19

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Cross-Section Diagram
ZF-Ecomat 2 plus
4-speed version
1 2 4 5 6 7 9 10 11 12 13
013468
26 25 24 23 22 21 20 19 18 17 16 15 14
013468
Key to drawing
1 Input 15 Inductive sensor “Output“

2 Cover plate 16 Brake “F”
4 Control element 17 Brake “E”
5 Oil feed flange 18 Brake “D”
6 Clutch “A” 19 Shift control
7 Clutch “B” 20 Inductive sensor “Turbine”
9 Housing 21 Oil pan
10 Planetary gear set I 22 Retarder
11 Planetary gear set II 23 Primary pump
12 Planetary gear set III 24 Converter
13 Speedo sensor 25 Torque converter lock-up clutch “WK”
14 Output 26 Turbine shaft
4149 751 608a - 2005-06 20

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Cross-Section Diagram
ZF-Ecomat 2 plus
5 and 6-speed version
1 2 4 5 6 7 8 9 10 11 12 13
013467
26 25 24 23 22 21 20 19 18 17 16 15 14
013467
Key to drawing
1 Input 15 Inductive sensor “Output”

2 Cover plate 16 Brake “F”
4 Control element 17 Brake “E”
5 Oil feed flange 18 Brake “D”
6 Clutch “A” 19 Shift control
7 Clutch “B” 20 Inductive sensor “Turbine”
8 Clutch “C” 21 Oil pan
9 Housing 22 Retarder
10 Planetary gear set I 23 Primary pump
11 Planetary gear set II 24 Converter
12 Planetary gear set III 25 Torque converter lock-up clutch “WK”
13 Speedo sensor 26 Turbine shaft
14 Output
4149 751 608a - 2005-06 21

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Cross-section Diagram
ZF-Ecomat 4
5 and 6-speed version with torsional damper
024744
Key to drawing
1 Hydrodynamic torque converter

2 Torsional damper
4149 751 608b - 2005-10 22

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Shift elements
Clutch and Brake Combinations, Ecomat 2 plus
The tables shown which shift elements are activated depending on the gear selected and the ratio.
Number Transmission model and parts list

of gears HP 502 HP 592 HP 602 Ratio
4-speed 4149 006 . . . 4149 056 . . . 4149 066 . . . 3,43 - 1,00
5-speed 4149 003 . . . 4149 053 . . . 4149 063 . . . 3,43 - 0,83
6-speed 4149 004 . . . 4149 054 . . . 4149 064 . . . 3,43 - 0,59
5-speed 4180 003 . . . 4180 053 . . . 3,43 - 0,83
6-speed 4180 004 . . . 4180 054 . . . 4180 064 . . . 3,43 - 0,59
Ecomat 2 without NBS Ecomat 2 with NBS

Clutch / Brake A B1 B2 D E F1 F2 Clutch / Brake A B1 B2 D E F1 F2
4-speed i = da 3,43 to 1,00 4-speed i = da 3,43 to 1,00
Reverse • • • Reverse • • •
Neutral Neutral •*
1st gear • • Neutral NBS • •*
2nd gear • • 1st gear • •
3rd gear • • 2nd gear • •
4th gear • • 3rd gear • •
4th gear • •
Ecomat 2 without NBS Ecomat 2 with NBS

Frizione / freno A B2 C D E F1 F2 Frizione / freno A B2 C D E F1 F2
5-speed 5-speed
and i = da 3,43 to 0,83 and i = da 3,43 to 0,83
6-speed i = da 3,43 to 0,59 6-speed i = da 3,43 to 0,59
Reverse • • • Reverse • • •
Neutral Neutral •*
1st gear • • Neutral NBS • •*
2nd gear • • 1st gear • •
3rd gear • • 2nd gear • •
4th gear • • 3rd gear • •
5th gear • • 4th gear • •
6th gear • • 5th gear • •
6th gear • •
B1 = Inner piston face clutch B
B2 = Outer piston face clutch B
F1 = Outer piston face brake F
F2 = Inner piston face brake F
* = Reduced pressure (only for transmissions with NBS)
4149 751 608b - 2005-10 23

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Shift elements
Clutch and Brake Combinations, Ecomat 4
The tables shown which shift elements are activated depending on the gear selected and the ratio.
Number Transmission model and parts list

of gears HP 504 HP 554 HP 594 HP 604 Ratio
5-speed 4182 003 . . . 3,43 - 0,83
6-speed 4182 004 . . . 4182 044 . . . 4182 054 . . . 4182 064 . . . 3,43 - 0,59
Ecomat 4
Clutch / Brake A B C D E F1 F2
5-speed i = 3,43 to 0,83

6-speed i = 3,43 to 0,59
Reverse • • •
Neutral
Neutral NBS • •*
1st gear • •
2nd gear • •
3rd gear • •
4th gear • •
5th gear • •
6th gear • •
F1 = Outer piston face brake F

F2 = Inner piston face brake F
* = Reduced pressure (only for transmissions with NBS)
4149 751 608b - 2005-10 24

ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Maintenance
1. Maintenance
1.1 Oil Change Intervals
NOTE: The suction filter must be replaced at each oil change. To do this, first drain the oil (at
operating temperature). The complete filter set (filter and sealing rings) can be obtained under
ZF order number 4139 298 936.
Transmission oil change Mileage Operating hours
Oil change after transmission repair. 1 000 km 50 h
Mineral-oil-basic ATF according to Group Standard ZFN 13015,

TE-ML 14, lubricant class 14A / 14D:
Oil change in normal use. 30 000 km
Oil change in heavy use*. 20 000 km
Construction machinery or special vehicles
cranes, refuse vehicles, etc. 1 000 h
but at least 1x per year.
Partly synthetic ATF according to Group Standard ZFN 13015,

TE-ML 14, lubricant class 14B:
but at least 1x every 2 years.
Synthetic ATF according to Group Standard ZFN 13015,

TE-ML 14, lubricant class 14C:
Synthetic ATF according to Group Standard ZFN 13015,

TE-ML 14, lubricant class 14E:
*Average speed < 25 km/h and vehicle weight > 23 t.
1.2 Oil Quantities
When first filling the dry transmission (with oil cooler) approx. 30 liters
Upon oil change approx. 14 - 17 liters
New fill after installation of transmission in vehicle approx. 20 liters
The amounts given are only approximate values; always
use the dipstick to check the final oil level.
1.3 Oil Grade
Refer to ZF List of Lubricants TE-ML 14. Internet: http://www.zf.com

This list can also be requested from all ZF-Service Centers.
4149 751 608a - 2005-06 1-1

ZF-Ecomat: 4149 / 4180 / 4182
1.4 Checking Oil Level

Dipstick (check – oil
! DANGER level/oil condition)
Reduced or no braking effect because of insufficient
oil level!
Risk of accident!
Because of a too low oil level, the retarder may fail Oil pipe (oil filling)
partially or totally.
The full braking effect can only be guaranteed by -
regularly checking and maintaining the correct oil
level.
CAUTION
It is very important to maintain the correct oil level
in the transmission. Oil levels which are too low
lead to malfunctions and transmission failure. Too
much oil causes the transmission to overheat.
021060
• The oil level must be checked quarterly

within the context of the safety inspections.
• The vehicle is horizontal for this purpose.
• The engine is idling.
• Shift to neutral before measuring.
150
1.5 Operating Temperature
130 c
The correct operating temperature for
checking the oil level can be read out on the
indicator device’s display in the vehicle. 110
NOTE 80
The transmission oil must have reached the 50
VDO
operating temperature of 80 - 90 °C for check-
ing the oil level.
1.6 Adding Oil 001683
The transmission oil is poured in through the

same aperture where the dipstick measure-
ment is taken.
1 liter changes the oil level by approx. 10 mm.
1.7 Oil Inspection at Operating Temperature

Conditions: Warm range } 80–90 °C
• Vehicle: level position
• Speed range selector shifted to “N” (Neutral)
• The engine is idling. (approx. 2 min.)
• Transmission oil at 80 - 90 °C
The oil level must be between the upper and
lower marking of the hot area. If the oil level is
not in this area, repeat the test and ensure that
the dipstick cap fits tightly in the bayonet lock
when the dipstick is inserted.
011577
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ZF-Ecomat: 4149 / 4180 / 4182
1.8 Checking Oil Level when Cold
Conditions:
• Vehicle: level position.
• Speed range selector shifted to “N” (Neutral).
• The engine is idling.
• Transmission fluid at approx. 30 °C.
After 3 up to 5 minutes operation in idling, the

transmission’s oil level must be between the
upper and lower marking of the cold oil area.
If the oil does not reach the minimum marking,
Cold range } Approx. 30 °C
add oil immediately. Correct the final oil level

after another inspection during operating
temperature.
011577
1.9 Checking Oil Level with Engine Off
Conditions:
• Engine stopped. Engine stopped } (nEngine = 0)
The oil level must be in-between the lower

and upper marking of the engine stopped
range. If the oil level is slightly higher than
this, do not drain any oil! This option is only
available for transmissions with directly
mounted heat exchanger or such transmissions
where the heat exchanger is located below the
transmission.
011577
1.10 Inspection for Version: Heat Exchanger

Above Centerline of Transmission
Conditions:
• Speed range selector in neutral position.
• Leave engine running at 1 200 up to
1 500 rpm for 15 to 20 seconds.
Afterwards, perform “Inspection of cold oil

level” at engine idling speed within 3 minutes
time and then, carry out “Oil level inspection at
operating temperature”.
4149 751 608a - 2005-06 1-3

ZF-Ecomat: 4149 / 4180 / 4182
dip stick
1.11 Changing Oil at Operating Temperature
! DANGER
Transmission oil is hot!
Risk of burns!
*1
When loosening the oil drain plug, wear protective
gloves. Do not put your hand into the draining oil
stream.
! DANGER
Used oil may pollute the environment when draining
oil!
Threat to the environment!
Collect used oil in a suitably large container and
dispose of in accordance with environmental *1) Bypass line for additional cooling, only with ZF-Ecomat 4 024886
• Switch the engine off.

• Drain transmission oil at the drain hole of the Screws (23 Nm)
oil pan.
• Screw-off filter cover and replace suction
filter according to description, Section 2.1.
Filter cover
• Screw-in drain plug (50 Nm) and mount filter
cover according to Section 2.1. Oil drain plug (50 Nm)
CAUTION
Always use original oil drain plugs on transmis-
sions with a converter drain valve. The drain plug
controls and closes the converter’s drain valve.
021113
• Remove oil dipstick and fill with max.
10 liters of transmission oil.
• Start engine and once idling, immediately
and slowly top up with 4 liters of transmis-
sion oil.
• Insert dipstick and check the cold oil level in
accordance with Section 1.8. Correct oil level
Warm range } 80 -90 °C
if necessary.
• Heat transmission oil to operating tempera-
ture (80 - 90 °C). Check oil level at operating
temperature in accordance with Section 1.7
and correct if necessary.
011577
4149 751 608c - 2006-03 1-4

ZF-Ecomat: 4149 / 4180 / 4182
1.12 Adjustment of Load Sensor
Check of load sensor setting

! DANGER
Do not perform this setting process with the • After maintenance jobs performed on the
engine running! transmission and engine.
The vehicle can start moving unintentionally! • In the case of harsh shifting.
Engine and ignition must be turned off and the • At least once every 3 months.
parking brake must be engaged.
CAUTION
Incorrect setting may cause harsh shifting or
damage due to slipping times that are too long!
Accelerator pedal
Pump filling control lever Idle running
Kickdown Full throttle
Full throttle Idle running excess travel bush Kickdown
Full throttle Idling
Injection pump Kickdown

at the engine switch
Load sensor
001 652
001652
Checking the load sensor with the markings

on the top front face or top housing side.
Selector lever
• Switch off engine.
• Engage parking brake.
• Keep accelerator pedal pressed down until
full throttle limit stop. Idle running Full throttle
• Maintain position. marking marking
• Selector lever marking must be aligned with
the full throttle marking at the housing.
• Let go of accelerator pedal up to idling.
• Selector lever marking must be aligned with Full throttle Idle running
the idling marking at the housing. marking marking
001415
4149 751 608a - 2005-06 1-5

4149 751 608a - 2005-06 1-6
ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Servicing
2. Servicing
2.1 Replacing the Filter 2
!DANGER
When draining oil, used oil can leak out and get into
the environment!
Threat to the environment!
1
Collect used oil in a suitably large container and
dispose of in accordance with the environment
Dispose of soiled filters in accordance with the
environment protection guidelines.
019661
1 Drain oil at oil drain plug (1) in accordance

with description, Section 1.11.
31
2 Remove filter cover (2).
3 Pull out used filter element (3).
NOTE
Check filter with reference to contamination.
019662
4 Insert a new filter element (no. 0750 131 003).

4
NOTE
Filters must always be renewed. Cleaning is
not permissible.
5 Check that the filter’s (4) O-ring is correctly

seated and undamaged.
6 Lubricate O-Ring with transmission fluid.
008513
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ZF-Ecomat: 4149 / 4180 / 4182
7 Replace O-ring (1) in the filter cover (2).
12
11
010483
8 Put filter cover (1) back on.
9 Screw in four hex screws (2) and tighten. 1

Tightening torque: 23 Nm
12
019661
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ZF-Ecomat: 4149 / 4180 / 4182
2.2 Replacing Retarder Solenoid Valve

1
1 Undo cable connection (1) at solenoid valve.
2 Unscrew and remove two hex screws M8 (2).
12
019715
3 Remove solenoid valve (1) and insert new

solenoid valve with a new O-ring (2).
11
21
019716
4 Screw in two hex screws M8x22 with shims

(1) and tighten. 12
5 Reconnect cable connection (2).
019715
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ZF-Ecomat: 4149 / 4180 / 4182
2.3 Replacing Accumulator Solenoid Valve
1 Undo cable connection (1) at solenoid valve.
2 Separate air line.
12 1
3 Unscrew and remove two hexagon bolts M8
(2).
021173
4 Grease the new O-ring (1) with technical

Vaseline and insert it into the solenoid valve’s
groove.
019651
5 Mount valve.
6 Screw in hex screws M8x55 with shims (1) and

tighten.
11
7 Re-connect air line and cable connection.
021173
4149 751 608a - 2005-06 2-4

ZF-Ecomat: 4149 / 4180 / 4182
2.4 Replacing the Accumulator

12
1 Remove the accumulator’s solenoid valve (1)
according to Section 2.3.
2 Unscrew the two hex screw M8 at the

mounting plate (2) of the output cover’s screw
connection . 11
021173
3 Remove the two M8 socket-head bolts (1) from

the input end of the accumulator.
021175
4 Grease the new O-ring (1) with technical

Vaseline and insert it into the accumulator’s
groove.
5 Insert accumulator, insert the two socket head

bolts M8x25 with disks. At the output-end,
insert the two hexagon bolts M8 with shims
and nuts M8 at the mounting plate of the
output cover’s screw connection.
Tighten all screws.
Tightening torque: 23 Nm 1
021176
4149 751 608a - 2005-06 2-5

ZF-Ecomat: 4149 / 4180 / 4182
2.5 Replacing Temperature Sensor
1 Undo cable connection at temperature sensor.

11
2 Unscrew temperature sensor (1).
019830
3 Slide new copper sealing ring (1) on

temperature sensor and screw in temperature
sensor.
11
019831
4 Reconnect cable connection with the

identification “TG” to the temperature sensor
11
(1).
019831
4149 751 608a - 2005-06 2-6

ZF-Ecomat: 4149 / 4180 / 4182
2.6 Replacing Inductive Sensor - Output
1 Screw-off two hexagon nuts M6 (1) with shims

and remove cover (2) of the inductive sensor.
12
021115
2 Disconnect cable connectors (1) from inductive

sensor.
These are blade connectors which should be
pulled off straight.
1
CAUTION
Using suitable pliers, pull on the connectors and not
on the cable.
3 Unscrew TORX screw (2) and remove

inductive sensor.
12
021201
4 Remove O-ring (1), shim washers (2), and

TORX screw (3) from inductive sensor (4). 14
13
1 12
021193
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ZF-Ecomat: 4149 / 4180 / 4182
5 Turn output flange until the gear teeth (1) on

the planet carrier in the center of the drilled
hole for the inductive sensor are visible.
021202
6 Insert the 1X56 138 149 dipstick (1) into the

inductive sensor drilled hole and screw home
(2).
Tightening torque: 9.5 Nm 1
13
7 Push the probe (3) forward to the stop on the

gear teeth end face and secure by tightening
the screw (4).
8 Unscrew the dipstick fastening screw (2) and

pull out the dipstick carefully.
12
14
021203
9 Measure distance from face end of sensor to

the dipstick holder contact surface and note
down as dimension “b”.
019813
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ZF-Ecomat: 4149 / 4180 / 4182
10 Insert the new inductive sensor in the test

device 1X56 138 150 and screw home.
Tightening torque: 9.5 Nm
021197
11 Measure distance from contact surface of

inductive sensor to contact face of inductive
sensor holder and note it down as dimension
“c”.
Inductive sensor distance dimension “a” must

c
be 0.5 – 0.7 mm.
Adjust with shims.
Measurement formula:
c–b=d
d + a = thickness “S” of shim washer
Measurement example:
Measure “c” = 52.6 mm 021198
Measure “b” = 51.3 mm
Measure “a” = 0.6 mm (0.5 to 0.7 mm)
12 313
Example for calculation:
52.6 mm – 51.3 mm = 1.3 mm
1.3 mm + 0.6 mm = 1.9 mm
Determined thickness “S” of shim washer = 1.9 mm
Shims OTK 0769 143 377 are available from 0.80 to

6.00 mm in 0.1 mm gradations.
1 Gear teeth planet carrier

2 Housing output cover 1
aa
3 Inductive sensor 44 5
4 Shims
011620
5 Inductive sensor fixing bolt
4149 751 608a - 2005-06 2-9

ZF-Ecomat: 4149 / 4180 / 4182
12 Insert TORX screw (1) with shim in the drill

hole on the inductive sensor (2). Push the 2
selected shims (3) onto the TORX screw and
secure with O-ring (4).
4 3 1
021193
13 Connect cable plug (1) to inductive sensor.
14 Insert the inductive sensor and tighten with

TORX screw M6x45 (2).
1
021201
15 Test O-ring on cover (1), if required, renew and

fasten cover with two M6 hex bolts and
washers.
021115
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ZF-Ecomat: 4149 / 4180 / 4182
2.6.1 Replacing Retarder Resistor
1 Remove cover from inductive sensor output

according to Section 2.6.
2 Loosen cable plug at resistor.

pulled off straight.
3 Take out resistor.
CAUTION
Each resistance is allocated to the appropriate
transmission by retarder adjustment and is
inscribed with a part number. Read off part num-
ber. A new resistance may only be fitted with the 021122
identical part number of the old resistance.
NOTE
Of the ten-digit part number of the resistance,
2
eight digits (6029 201 6) are located on the end
face of the resistor (1). The last two digits of the
part number (2) are located as shown on the
perimeter.
Example: 6029 201 6(44) = Resistance of 22.10 kΩ
Resistor OTK = 1.96 –150.00 kΩ 1
Item number Designation Ret. adjustment

6029 201 652 Resistance 150.00 kΩ
6029 201 651 Resistance 100.00 kΩ
6029 201 650 Resistance 75.00 kΩ 021124
6029 201 649 Resistance 57.60 kΩ
6029 201 648 Resistance 46.40 kΩ
6029 201 647 Resistance 37.40 kΩ
6029 201 646 Resistance 31.60 kΩ
6029 201 645 Resistance 26.10 kΩ
6029 201 644 Resistance 22.10 kΩ
6029 201 643 Resistance 18.70 kΩ
6029 201 642 Resistance 15.80 kΩ
6029 201 641 Resistance 13.30 kΩ
6029 201 640 Resistance 11.30 kΩ
6029 201 639 Resistance 9.31 kΩ
6029 201 638 Resistance 7.68 kΩ
6029 201 637 Resistance 6.34 kΩ
6029 201 636 Resistance 5.11 kΩ
6029 201 635 Resistance 3.92 kΩ
6029 201 634 Resistance 2.94 kΩ
6029 201 633 Resistance 1.96 kΩ
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ZF-Ecomat: 4149 / 4180 / 4182
4 Plug on new resistor with identical parts

number (the one of the old resistor) and install
as depicted.
5 Mount cover according to Section 2.6.
021201
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ZF-Ecomat: 4149 / 4180 / 4182
2.7 Removing and assembling oil pan
! DANGER
Oil can get into the environment!
Threat to the environment!!
Collect used oil in a suitably large container. Drain the
oil thoroughly and dispose of it in accordance with the
regulations of the environmental protection laws.
1 Drain oil and disassemble oil filter according to

description, Section 2.1.
019661
!DANGER
Oil pan may fall down!
Risk of injury!
Support oil pan sufficiently prior to loosening the
screws.
2 Remove hex screws (1) on the oil pan. 1
3 Detach oil pan from the sealing face with light

blows of a plastic hammer.
019662
4 Remove oil pan.
CAUTION
If the transmission is fitted with a converter drain
valve, do not damage the operating pin (1) for the 1
converter drain valve when removing the oil pan.
016072
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ZF-Ecomat: 4149 / 4180 / 4182
5 Before mounting the oil pan, check if the

serrated ring ZA 5 (1) is securely engaged in
the operating pin groove of the converter drain 1
valve.
016073
6 Check operating pin (1) for the converter drain

valve for ease of movement.
016072
7 Place new gasket on the oil pan.
8 Position oil pan with two hex screws that are

plugged in opposite to one another (with steel
shims) at the transmission housing and tighten.
019664
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ZF-Ecomat: 4149 / 4180 / 4182
9 The two hex screws (1) at the input-end, in the

mid-center area of the screw connection, must
have copper washers underneath.
Steel washers are used on the other hexagon
screws of the oil pan.
011603
10 Tighten all hexagon screws M8x60 at the oil

pan.
11 Insert oil drain plug again according to Section

1 and tighten.
CAUTION
Always use original ZF oil drain plugs on transmis-
sions with a converter drain valve.
The converter drain valve is activated via the ZF oil
drain plug.
019662
12 Replace oil filter and fill up with transmission

oil according to Section 1.
011605
4149 751 608b - 2005-10 2-15

ZF-Ecomat: 4149 / 4180 / 4182
2.8 Replacing Inductive Sensor “Turbine”
1 Remove oil pan (1) according to Section 2.7.
019661
2 Remove M42x2 screw plug (1).
021200
3 Disconnect cable connectors (1) from inductive

sensor.
pulled off straight. 1
CAUTION
Using suitable pliers, pull on the connectors and not 2
on the cable.
4 Unscrew TORX screw (2) and remove

inductive sensor.
011608
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ZF-Ecomat: 4149 / 4180 / 4182
5 Remove O-ring (1), shims (2), and TORX screw

(3) from inductive sensor (4). 4
3
1 2
021193
6 Using a large screwdriver or similar tool, turn

the torque converter and at the same time use a
small screwdriver to find the raised points on
the pulse transmitter ring (1).
021194
7 When one of these raised points is in line with

the screw-in bore for the inductive sensor,
measure gap “a” between the inductive sensor 11 2 4
(3) and a raised point on the pulse encoder ring
(1).
CAUTION 55
For this case, it is important that the measurement
is taken on a raised point on the pulse transmitter
ring, otherwise the inductive sensor will be
3
damaged by the raised points on the sensor ring
when the engine is started.
aa
011622
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ZF-Ecomat: 4149 / 4180 / 4182
8 Insert the 1X56 138 149 dipstick into the

inductive sensor drilled hole and screw home
(1).
021195
9 Push the probe (1) forward to the stop on the

raised point of the pulse transmitter ring and
secure by tightening the screw (2).
1
10 Unscrew the dipstick fastening screw (3) and
pull out the dipstick carefully.
021196
11 Measure distance from face end of sensor to

the dipstick holder contact surface and note
down as dimension “b”.
019813
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ZF-Ecomat: 4149 / 4180 / 4182
12 Screw the inductive sensor into the test fixture

1X56138150.
021197
13 Measure distance from contact surface of

inductive sensor to contact face of inductive
sensor holder and note it down as dimension
“c”.
Inductive sensor distance dimension “a” must be

c
0.6 – 0.8 mm.
Adjust with shim washers.
Measurement formula:
c–b=d
d + a = thickness “S” of shim washer
Measurement example:
Measure “c” = 52.6 mm 021198
Measure “b” = 50.9 mm
Measure “a” = 0.7 mm (0.6 to 0.8 mm)
Example for calculation: 11 2 4

52.6 mm - 50.9 mm = 1.7 mm
1.7 mm + 0.7 mm = 2.4 mm
55
Determined thickness “S” of shim washer = 2.4 mm
Shims OTK 0769 143 377 are made available as of

0.80 up to 6.00 mm in 0.1 mm gradations. 3
1 Pulse transmitter ring

2 Retaining plate
aa
3 Inductive sensor
4 Shims
011622
5 TORX screw
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ZF-Ecomat: 4149 / 4180 / 4182
14 Insert TORX screw (1) with washer in the drill

hole on the inductive sensor (2). Push the 2
selected shim washers (3) onto the TORX
screw and secure with O-ring (4).
1
41 3
021193
15 Insert the inductive sensor and screw home

with TORX screw M6x45 (1).
16 Connect cable plug (2) to inductive sensor.

2
021199
17 Screw in screw plug M42x2 into duct plate and

tighten.
Tightening torque: 90 – 100 Nm
021200
4149 751 608a - 2005-06 2-20

ZF-Ecomat: 4149 / 4180 / 4182
18 Installing oil pan (1) according to Section 2.7.
19 Screw in oil drain plug according to Section

1.11.
CAUTION
Always use original oil drain plugs on
transmissions with a converter drain valve. The
drain plug controls and closes the converter’s drain
valve.
1
20 Replace oil filter and fill up with transmission
oil according to Section 1.
019661
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ZF-Ecomat: 4149 / 4180 / 4182
2.9 Replacing Inductive Sensor “NMOT”
NOTE:
For information on transmission version
Ecomat 2 NMOT, refer to type plate and model
4180 . . . . . . .
024238
019661
2 Loosen plug connection (1) at the bracket.
024223
4149 751 608a - 2005-06 2-22

ZF-Ecomat: 4149 / 4180 / 4182
3 Unscrew TORX screw and remove inductive

sensor with cable connection.
NOTE:
Tools (T30) for TORX screw,
for example by Facom, 89Tx.30
024220
4 Remove cable plug (1), O-ring (2), and TORX

screw (3) from inductive sensor NMOT.
024217
NOTE:
There is no need to enter in a setting for the
inductive sensor NMOT. The installation
dimensions are pre-determined by design.
024217
4149 751 608a - 2005-06 2-23

ZF-Ecomat: 4149 / 4180 / 4182
5 Pre-assemble the new inductive sensor NMOT.

Plug-on cable plug (1) on inductive sensor
NMOT, insert TORX screw (2) in inductive
sensor NMOT, and put on the O-ring (3) onto
the TORX screw.
NOTE:
4
For safe insertion of the inductive sensor, 1
position screw-in tool (4) on TORX screw.
024219
6 Insert the inductive sensor NMOT (1) as shown

into the drilled hole and position TORX screw.
024220
7 Tighten inductive sensor NMOT.

024221
4149 751 608a - 2005-06 2-24

ZF-Ecomat: 4149 / 4180 / 4182
Installation position:
1 Inductive sensor NMOT

2 TORX screw 1
3 Cable with plug
024224
8 Connect plug connection (1) at the bracket.
024224
9 Install oil pan, refer to Chapter 6.2.
019661
4149 751 608a - 2005-06 2-25

ZF-Ecomat: 4149 / 4180 / 4182
2.10 Replacing Complete Hydraulic Transmission

Control Unit
CAUTION
Remove dirt and dust from the transmission’s cable
harness connection before unscrewing the cable
harness.
1 Loosen the cable harness plug by turning the

locking ring anti-clockwise.
021136
2 Unscrew the two M8 hex screws (1) with

washers from the Kostal socket-outlet.
021401
019661
4149 751 608a - 2005-06 2-26

ZF-Ecomat: 4149 / 4180 / 4182
4 Using a screwdriver, unlatch the flat connector

for the inductive sensor output (1) and the flat
connector for the retarder resistance (2) on the 15
valve body and remove from the plug sockets.
NOTE
The sump temperature sensor is integrated into 14
the plug (3). Only remove if required.
12 13
5 Take the sump temperature sensor cable (4) out 1
of the protective sleeve (5).
019814
NOTE:
Working step no. 6 only in the case of the
transmission variant Ecomat 2 NMOT.
To be detected at the type plate under model
4180 . . . . . .
6 Loosen plug connection (1) at the bracket.
024223
! DANGER
If the shift control unit comes loose, oil sprays out.
Oil can get into the eyes! Danger of injury to eyes!
Wear safety goggles!
Let the oil drain out properly and observe information
about danger to the environment!
7 Unscrew 39 M8 TORX screws on the switching

control but do not screw out completely.
021432
4149 751 608a - 2005-06 2-27

ZF-Ecomat: 4149 / 4180 / 4182
!DANGER
The shift control unit weighs approx. 18 kg!
Risk of injury!
Pay attention to sharp edges.
Protect shift control unit from falling down.
8 Screw out the TORX screws M8 completely

and remove the shift control unit.
CAUTION
Make sure that electric lines are not damaged.
019814
NOTE:
View: Transmission variant Ecomat 2 NMOT
with additional wiring for inductive sensor
NMOT (1). To be detected at the type plate
under model 4180 . . . . . .
024226
9 During the installation of the shift control unit,

the above given description must be adhered to
in reversed order. The following points should
be noted here:
NOTE
Make sure that the Kostal socket-outlet (arrow)
must be inserted in the seat of the transmission
housing.
CAUTION
Make sure that electric lines are not damaged.
019666
4149 751 608a - 2005-06 2-28

ZF-Ecomat: 4149 / 4180 / 4182
NOTE:
Working step no. 10 only in the case of the
transmission variant Ecomat 2 NMOT.
10 Connect plug connection (1) for the inductive

sensor NMOT.
12
024223
11 Inductive sensor’s turbine clearance must only

be recalibrated if shift control unit is replaced.
021433
12 The 39 TORX screws M8 for the screw

connection of the shift control unit feature
varying lengths: 12
30 pieces M8x43 (1)
9 pieces M8x35 (2)
The nine shorter TORX screws are screwed in 1

at the recessed faces.
All TORX screws must be screwed in and

tightened.
021432
4149 751 608a - 2005-06 2-29

ZF-Ecomat: 4149 / 4180 / 4182
13 Plug flat connector in on the side of the shift

control unit as shown.
5
1
4
1
1 Inductive sensor-output plug
2 Retarder resistance plug
3 Sump temperature sensor
NOTE
The sump temperature sensor is integrated into 1 2
1
the plug (3).
3
1
14 Slide in temperature sensor cable (4) in
protective sleeve (5).
019814
15 Plug connection to be inserted in housing

recess and then, screw in the two hexagon
bolts M8x20 with shims (5).
021401
16 Measure inductive sensor’s “Turbine“

according to description, Section 2.8, and
screw in with new shim washers.
Afterwards, re-connect.
17 Fit oil pan and new filter in accordance with

the description in Section 2.7.
021200/019661
4149 751 608a - 2005-06 2-30

ZF-Ecomat: 4149 / 4180 / 4182
2.11 Replacing Impulse Sensor for Speedometer
1 Unscrew the pulse transmitter (1).
023539
2 Coat threads of new pulse transmitter with

service oil.
021236
3 Screw in new pulse transmitter.

021405
4149 751 608a - 2005-06 2-31

ZF-Ecomat: 4149 / 4180 / 4182
2.12 Replacing Output Flange and/or Shaft

Sealing Ring
!
DANGER
Danger of injury to the eyes!
Wear safety goggles!
1 Remove locking plate on output flange (1) (if

fitted).
NOTE
Volume produced transmissions are mounted
without locking plates.
1
021406
2 Unscrew the two M12 hexagon screws.
NOTE
When doing so secure the output flange against
1
twisting with a suitable lever.
3 Remove pressure disk (1), if necessary, with a

plastic hammer.
021407
4 Pull off output flange with a commercially

available two or three arm puller.
NOTE
Protect front face of output shaft with a shim or
a suitable pressure piece.
021421
4149 751 608a - 2005-06 2-32

ZF-Ecomat: 4149 / 4180 / 4182
5 Lever out the shaft sealing ring on the output

shaft with a suitable tool.
CAUTION
Do not damage the seal drill hole when pulling out
the sealing ring.
021422
6 Place shaft sealing ring (1) on the top part

1X56 136 824 with the sealing lip pointing to
the output cover.
CAUTION
The spring loading of the sealing lip must be visible
when the sealing ring is seated on the top part.
021423
7 Wet the shaft sealing ring at its outer

circumference with a lubricant (e.g.
concentrated washing-up liquid).
CAUTION
Do not use grease or transmission oil for the
exterior of the sealing ring since this can cause
leaks.
8 Drive in the shaft sealing ring with the top part

until firmly home.
021424
4149 751 608a - 2005-06 2-33

ZF-Ecomat: 4149 / 4180 / 4182
NOTE
The use of the top part 1X56 136 824 ensures 15-1
that sealing ring is installed at the correct
installation depth of 15-1 mm between face
end of inner bearing race and face end of
sealing ring.
001 654
001654
!DANGER
Material is getting hot !
Risk of burns!
Wear protective gloves.
9 Heat up output flange to 100 up to 110 °C.
CAUTION
Do not heat output flange to more than 110 °C,
otherwise the sealing ring will be damaged.
NOTE
Prior to assembly of the output flange, plug on
hexagon bolts if necessary.
021425
10 Screw gripper piece 1X56 103 755 onto the
output shaft, locate output flange, and pull on
as far as the axial installation with the
mounting tool 1X56 136 512.
CAUTION
Do not strike the output flange.
11 Coat pressure disk (1) at sealing face (plane

face without inclination) with surface sealant
(Loctite no. 574) and add on flange.
021426
4149 751 608a - 2005-06 2-34

ZF-Ecomat: 4149 / 4180 / 4182
12 Coat the hexagon screws M12x30 underneath

the bolt heads with a face sealant (Loctite no.
574), screw in, and tighten.
NOTE
Here, always use new hexagon screws.
021427
! DANGER
When driving up the securing plate (1), sharp burrs
may be created!
Risk of injury!
Carefully remove the burr with a file or a suitable tool.
13 Drive locking plate with adapter 1X56 136 471

onto the M12 hex screw until the locking plate
lies axially on the pressure disk.
CAUTION
Ensure cleanliness! Carefully remove swarf and
other abraded material.
021428
14 Retighten propeller shaft. Tighten hexagon

screws in accordance with the recommenda-
tion of the vehicle manufacturer.
021429
4149 751 608a - 2005-06 2-35

ZF-Ecomat: 4149 / 4180 / 4182
2.13 Pressure test
Pressure test with the transmission fitted in the

vehicle:
1 Establish the pressure measuring connections

14
planned for the testing. Unscrew the screw
plug and screw it into the test manometer
(gage).
Test manometer 1P01 136 670 (up to 25 bar)
Test manometer 1P01 137 856 (up to 10 bar) 15 13
1 = Main pressure PH
2 = Throttle pressure PD1
1 16 12
3 = Pressure upstream of torque converter PD2
4 = Pressure downstream of heat exchanger PD6 / PD7* 021430
5 = Retarder pressure PR3

6 = Retarder control pressure PRR3
* (4) with retarder “ON” = PD6

* (4) with retarder “OFF“ = PD6 / PD7 = lubricating
pressure
2 Carry out pressure testing as per table below.
3 After pressure measurement remove test

manometer.
4 Screw in screw plugs with new copper sealing

rings.
021431
4149 751 608a - 2005-06 2-36

ZF-Ecomat: 4149 / 4180 / 4182
Pressure measurement table:
A = Normal main pressure 4 = Pressure downstream of heat exchanger PD6 / PD7 *

B = Increased main pressure with engines larger * with retarder “ON” = PD6
than 1400 Nm * with retarder “OFF” = PD6 / PD7= Lubricating oil
pressure
Pressure measurement location: 5 = Retarder pressure PR3
1 = Main pressure PH 6 = Retarder control pressure PRR3
2 = Throttle pressure PD1 7 = Oil temperature toil
(PD1 = at zero current = 10 bar) neng = Engine speed
3 = Pressure upstream of torque converter PD2 WK= Torque converter lock-up clutch
Pressure measurement table A 7 1 2 3 4 5*/6*

NORMAL MAIN PRESSURE M10x1 M10x1 M10x1 M10x1 M10x1
nengine toil PH PD1 PD2 PD6/D7 PR3/PRR3
Load Gear WK (rpm) (°C) (bar) (bar) (bar) (bar) (bar)
Idle running N open 700 20 - 40 7 - 15 4±0,3 4.0 - 5.5 0.8 - 1.8
Idle run- N D
Cold
open 550 20 - 40 7 - 15 0.2 - 1.0 0.8 - 1.8
ning 4.0 - 5.5
for 2 sec.
Full throttle N open 2000-2500 20 - 40 18 - 21 4±0,3 6.0 - 8.5 1.8 - 2.5
Full throttle Shifted closed 2000-2500 20 - 40 10 - 12 4±0,3 6.0 - 8.5 1.8 - 2.8
Idle run- 0.2 - 1.0
N D open 80 - 90 7 - 15 3.0 - 4.5 0.1 - 0.8
Hot
550
ning for 2 sec.
Full throttle N open 2000-2500 80 - 90 ♦16 - 20 4±0,3 6.0 - 8.5 1.8 - 2.5
*Values are to be obtained from the appropriate parts list. Consult ZF if necessary.
♦ Values below the pressure point: Please contact the relevant ZF Service Center before removing the transmission.
Pressure measurement table B 7 1 2 3 4 5*/6*
INCREASED MAIN PRESSURE M10x1 M10x1 M10x1 M10x1 M10x1

nengine toil PH PD1 PD2 PD6/D7 PR3/PRR3
Load Gear WK (rpm) (°C) (bar) (bar) (bar) (bar) (bar)
Idle running N open 700 20 - 40 13 -22 4±0,3 4.0 - 5.5 0.8 - 1.8
Idle run- N D
Cold
open 550 20 - 40 13 - 22 0.2 -1.5 0.8 - 1.8

4.0 - 5.5
ning for 2 sec.
Idle run- 0.2 -1.5
N D open 80 - 90 10 - 17 3.0 - 4.5 0.1 - 0.8
Hot
550
ning for 2 sec.

*Values are to be obtained from the appropriate parts list. Consult ZF if necessary.
4149 751 608a - 2005-06 2-37

4149 751 608a - 2005-06 2-38
ZF-Ecomat: 4149 / 4180 / 4182
HP 502/504 / HP 592/594 / HP 602/604 Diagnosi s / Troubleshooting
3 Troubleshooting 2 Carry out resistance measurements according

to the nominal values table for solenoid valves
3.1 Inspection with Test Cable 1P01 138 153 and inductive sensors.
Tolerance table Temperature sensor NTC -
! DANGER sensor B14 Also refer to tolerance table and
Shifts can be triggered by the testing cable and the characteristic curve for temperature sensor.
vehicle can start moving unintentionally! Item number Retarder resistor B16 Also refer
Danger to life! to table on retarder alignment.
Only use testing cable with vehicle stationary and
switched-off engine! NOTE:
Resistance values can alter with a rise and/or
1 Insert the test cable Kostal plug into the fall in temperature.
transmission Kostal socket-outlet. On the solenoid valves the resistance value
increases with rising temperature.
CAUTION At the temperature sensor B14 the resistance
Do not apply any voltage to the emergency switch value decreases with rising temperature.
(yellow sockets) or the inductive sensor (green
sockets), or there will be a short-circuit and failure
of the switch (transmission removal) and/or the
inductive sensor.
4149 751 608a - 2005-06 3-1

ZF-Ecomat: 4149 / 4180 / 4182
Table of resistance measurement nominal values:
Measure resistances of solenoid valve coils and inductive sensor, see following listing.
Brake/Clutch A4 Ohmmeter (nominal

Test unit Inductive sensor Designation value)
Resistor Pin
Solenoid valve Y17 Clutch A A 13 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y16 Clutch B1 B 12 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y15 Clutch B2 C 11 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y14 Brake D D 22 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y13 Brake E E 24 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y12 Brake F F 19 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y11 Brake G / F2 G 6 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y18 Clutch WK WK 9 approx. 67 ± 4 Ω at 20°C
Solenoid valve Y19 Retarder RET 8 approx. 67 ± 4 Ω at 20°C
D1- Prop.
D1 Valve D1 10 approx. 8.6 ±0.5 Ω at 20 °C
solenoid valve Y20
Inductive n Output nAB 2 approx. 850 ± 100 Ω at 20°C
sensor B11
*Retarder
Retarder identifier RET.K 18 * 1.96 to 150 kΩ
resistance B16
♦ Temperature
Sump temperature TG 4 approx.125 ± 5 Ω at 20 °C
sensor B14
Inductive n Turbine nT 1 approx. 850 ± 100 Ω at 20°C
sensor B12
Inductive
n MOT nAN 3 approx. 850 ± 100 Ω at 20°C
sensor B13
Prop. sol. valve Y1 Retarder AIP3 6 approx. 25 ± 1.5 Ω at 20°C
Solenoid valve Y2 Accumulator AD9 8 approx. 131 ± 10 Ω at 20 °C
♦ Also refer to table on Ground/earth Term. 31

tolerances and characte-
ristic curve of temperatu- Ground/earth GM1 15
re sensor
Ground/earth GM2 17
* Refer to retarder align-
ment table VM1 21
Ground/earth
VM2 20
4149 751 608a - 2008-02 3-2

ZF-Ecomat: 4149 / 4180 / 4182
Tolerance table Temp. 2*Rt 2*Rt (min) 2*Rt (max)

Temperature sensor NTC - sensor B14 [°C] [Ohm] [Ohm] [Ohm]
Thermometrics DKS 4261
2 elements in line -20 957796 896080.6 1023353.4
-15 720948 676412 768108
-10 547652 515240.8 581880.2
Tolerance table – 20 °C to 150 °C
-5 419668 395880 444708
0 324282 306690.8 342746
5 252580.6 239476.2 266295.4
10 198235.8 188407 208494
15 156760.6 149700.6 164443.6
20 124765.8 119130 130615.8
25 99991 95685.8 104448
30 80649.2 77343 84063.2
35 65448.2 62896.4 68076.4
40 53425.2 51446.4 55457.8
45 43857 42316 45435.8
50 36197.6 34992.8 37428.8
55 30031.2 29086 30994.8
60 25040 24296 25796.4
65 20978.6 20391.2 21574
70 17657 17192.4 18127
75 14927.6 14559.2 15299.2
80 12674 12381.4 12968.2
85 10804.8 10572.4 11038.2
90 9248 9063 9433
95 7945.8 7775 8117
100 6852 6694.8 7010
105 5929.8 5785.4 6075.4
110 5149.4 5017 5283.2
115 4486.4 4365 4609.4
120 3921.6 3810 4034.2
125 3438 3336 3541.6
130 3023.2 2929.8 3118.4
135 2666.2 2580.6 2753.6
140 2357.8 2279.4 2438.2
Characteristic Curve 145 2090.8 2018.8 2164.6
150 1858.8 1792.8 1926.8
Resistance / Temperature 023540
DKS 4261 (*in series)

100000
90000
80000 2*Rt [Ohm]
Resistance [Ohm]
70000
60000
50000
40000
30000
20000
10000
0
20 30 40 50 60 70 80 90 100 110 120
Temperature [°C] 023541
4149 751 608a - 2005-06 3-3

ZF-Ecomat: 4149 / 4180 / 4182
Table – retarder alignment
CAUTION
Each resistance is allocated to the appropriate 2
transmission by retarder adjustment and is
inscribed with a part number. Read off part num-
ber. A new resistance may only be fitted with the
identical part number of the old resistance.
NOTE
Of the ten-digit part number of the resistance, 1
eight digits (6029 201 6) are located on the end
face of the resistor (1). The last two digits of
the part number (2) are located as shown on
the perimeter.
021124
Example:
6029 201 6(44) = Resistance 22.10 kΩ Item number Designation Retarder
alignment
6029 201 652 Resistance 150.00 kΩ

6029 201 651 Resistance 100.00 kΩ
6029 201 650 Resistance 75.00 kΩ
6029 201 649 Resistance 57.60 kΩ
6029 201 648 Resistance 46.40 kΩ
6029 201 647 Resistance 37.40 kΩ
6029 201 646 Resistance 31.60 kΩ
6029 201 645 Resistance 26.10 kΩ
6029 201 644 Resistance 22.10 kΩ
6029 201 643 Resistance 18.70 kΩ
6029 201 642 Resistance 15.80 kΩ
6029 201 641 Resistance 13.30 kΩ
6029 201 640 Resistance 11.30 kΩ
6029 201 639 Resistance 9.31 kΩ
6029 201 638 Resistance 7.68 kΩ
6029 201 637 Resistance 6.34 kΩ
6029 201 636 Resistance 5.11 kΩ
6029 201 635 Resistance 3.92 kΩ
6029 201 634 Resistance 2.94 kΩ
6029 201 633 Resistance 1.96 kΩ
4149 751 608a - 2005-06 3-4

Diagnosis Tool
Installation Manual
6008 758 104a

Subject to alterations in design
Copyright by ZF
This documentation is protected by copyright.

Any reproduction or dissemination in whatever form
which does not comply fully with the intended purpose
of this documentation is prohibited without the consent
of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C / 2003-12
Edition: 2005-08
ZF-TESTMAN pro Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 Starting ZF-TESTMAN pro . . . . . . . . . . . . . . . 17

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Auxiliaries for Telemetry . . . . . . . . . . . . . . . . . 18
1 System Components . . . . . . . . . . . . . . . . . . . . . 6 6.1 Telemetrics Data Transfer With the
1.1 Customer Version . . . . . . . . . . . . . . . . . . . . . . . 6 DPA05 Version ≥ V2.0 . . . . . . . . . . . . . . . . . . . . 18
1.2 SSO Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6.2 Telemetrics Data Transfer With the
1.3 OEM Version . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DPA05 Version < V2.0 . . . . . . . . . . . . . . . . . . . . 18
6.3 Telemetrics Data Transfer With the
2 Basic Installation of the ZF-TESTMAN pro DPA04i, all Versions . . . . . . . . . . . . . . . . . . . . . 19
Customer, OEM, and SSO Versions . . . . . . . . . 8 6.4 Parts Kit for Telemetry Without
2.1 Additional Installation . . . . . . . . . . . . . . . . . . . 9 ZF-TESTMAN pro at Vehicle-End . . . . . . . . . . 19
2.1.1 Customer Version . . . . . . . . . . . . . . . . . . . . . . . 9 6.5 Description and Setup of Connections . . . . . . . 20
2.1.2 SSO Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.5.1 DPA05 Version ≥ V2.0 . . . . . . . . . . . . . . . . . . . . 20
6.5.2 DPA05 Version < V2.0 . . . . . . . . . . . . . . . . . . . . 21
3 Description of Connection . . . . . . . . . . . . . . . . 10 6.5.3 DPA04i all Versions . . . . . . . . . . . . . . . . . . . . . . 22
3.1 DPA04: Description and Setup of Connections . 10 6.5.4 6008 207 031 Description of Adapter . . . . . . . . 23
3.2 DPA04: Connecting Programmer Tool . . . . . . . 11 6.6 Additional Telemetry Installation With
3.3 DPA05 Version < V2.0: GSM Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 24
Description and Setup of Connections . . . . . . . 12
3.4 DPA05 Version ≥ V2.0: 7 "Menu" Overview . . . . . . . . . . . . . . . . . . . . . . . 26
Description and Setup of Connections . . . . . . . 13
3.5 DPA05: Connecting Programmer Tool . . . . . . . 14 8 Additional Settings . . . . . . . . . . . . . . . . . . . . . . 27
4 Description of DPA Interface . . . . . . . . . . . . . . 15 9 Additional Information for DPA04s

4.1 Checking DPA, PC Driver, COM, and Operated with a USB Port . . . . . . . . . . . . . . . . 27
USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Flash Programming and Updating the DPA . . . 16 10 Technical Data / System Requirements . . . . . 28
6008 758 104 - 2005-08 3

ZF-TESTMAN pro Preface
This documentation is intended for specialized personnel Service locations equipped by ZF Friedrichshafen AG all
trained by ZF Friedrichshafen AG to carry out maintenance over the world offer you:
and repair work on ZF products.
1. Well-trained personnel,
This manual deals with a ZF product in accordance with
the state of development on the date of issue. 2. Specified equipment,
e.g. specialized tools,
However, due to the ongoing development of this unit,
repair work might require work practices and test or 3. Genuine ZF spares, to
adjustment data which are not contained in this manual. our latest specifications.
We therefore recommend that all work on your ZF pro-
duct is carried out only by skilled mechanics and fitters
who have had their practical and theoretical knowledge All work performed at these service locations is carried
updated on a regular basis at our Customer Service out conscientiously and with care.
training centers.
Warranty:
Repair work carried out at ZF service locations is subject
ZF Friedrichshafen AG to the contractual conditions prevailing in the individual
Bereich Nutzfahrzeug- und Sonder-Antriebstechnik case.
Vehicle and Special Driveline Technology division
Service Werk 2 / Plant 2 Damage resulting from work performed by non-ZF person-
D-88038 Friedrichshafen nel in an improper and unprofessional manner, together
Telephone: +49 7541 77-0 with follow-on costs caused by such work, is excluded
Telefax: +49 7541 77-5726 from the contractual warranty agreement.
Internet: www.zf.com This also applies where genuine parts have not been used.
6008 758 104 - 2005-08 4

ZF-TESTMAN pro Safety Instructions
Companies repairing ZF units are responsible for their

! DANGER !
own work safety.
This is used when lack of care could lead to personal
To avoid injury to personnel and damage to products, injury or material damage.
strict compliance with all safety regulations and legal
requirements applicable to repair and maintenance work
is mandatory.
! THREATS TO THE ENVIRONMENT!
Before starting work, mechanics must therefore
familiarize themselves with these regulations. Lubricants and cleaning agents must not be allowed to
enter the soil, ground water, or sewage system.
Personnel required to carry out repairs on ZF products • Ask your local environment agency for safety
must receive appropriate training in advance. It is the information on the relevant products and ensure
responsibility of each company to ensure that their repair compliance with their requirements.
staff is properly trained. • Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
The following safety instructions appear in this manual: protection guidelines.
• When working with lubricants and cleaning agents
always observe the manufacturer's instructions.
NOTE
Refers to special processes, techniques, data, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
6008 758 104 - 2005-08 5

ZF-TESTMAN pro System Components
1 System Components
1.1 Customer Version
Order number Part number Designation Note

6008 208 003 6008 208 100 Diagnosis tool (complete) Customer version
6008 208 900 Basic CD installation
Additional application software is needed.

More information on the diagnosis software required can be obtained from your ZF service location.
1.2 SSO Version

6008 208 503 6008 208 100 Diagnosis tool (complete) Total package
6008 208 009 Basic CD installation only for SSO
6008 208 015 Additional CD installation (applications)
6008 208 016 Diskette (license)
6008 207 025 Universal adapter
1.3 OEM Version

6008 208 7xx Basic and additional CD installation
6008 758 104 - 2005-08 6

ZF-TESTMAN pro Basic Installation
Content of diagnosis tool 6008 208 100

6008 208 100 6008 307 405 Box
– DPA05 (not sold individually)
6008 207 026 USB cable
6008 308 601 RS232 cable
6008 207 023 Diagnosis connection cable, universal 9-pin
6008 207 024 Diagnosis connection adapter, universal
9 6 3-pin
6008 758 704a Description
6008 758 104 - 2005-08 7

2 Basic Installation of the ZF-TESTMAN pro

Customer, OEM, and SSO Versions
NOTE
This software runs on Microsoft Windows 95 / 98 / ME /
NT / 2000, and XP operating systems.
You will need administrator rights to install the software
on Windows NT / 2000 / XP.
1. Insert CD-ROM 6008 208 900 (customer version),

6008 208 7xx (OEM version) or 6008 208 009
(VSO/SSO version) in the drive.
2. Wait until the installation program starts up automa-

tically. If this function has been deactivated on your
computer, manually start the 'setup.exe' file from the
root directory on the CD-ROM.
019941
3. Follow the instructions provided by the installation
program.
ZF-TESTMAN pro software on CD-ROM
NOTE Order number: 6008 208 900
• ZF-TESTMAN pro is written in German and English.
This only affects system responses but not the actual
diagnosis software.
• With OEM versions, only one CD is needed for basic
and additional installations. The parts lists for these
versions may differ.
6008 758 104 - 2005-08 8

2.1 Additional Installation 2.1.2 SSO Version
2.1.1 Customer Version 1. Insert CD-ROM 6008 208 009 in the drive.
1. Insert the CD-ROM containing the application soft- 2. Wait until the installation program starts up auto-
ware required in the drive. matically.
If this function has been deactivated on your
2. Wait until the installation program starts up auto- computer, manually start the 'setup.exe' file from
matically. the root directory on the CD-ROM.
If this function has been deactivated on your
computer, manually start the 'setup.exe' file from 3. Follow the instructions provided by the installation
the root directory on the CD-ROM. program.
3. Follow the instructions provided by the installation 4. Insert diskette 6008 208 016 when requested to do
program. so.
5. Once the setup is complete, insert CD 6008 208 015

and continue from point 2 - 3.
NOTE
After the installation, the software driver must be checked
and/or set as is described in section 4.1.
6008 758 104 - 2005-08 9

ZF-TESTMAN pro Description of Connection
3 Description of Connection
3.1 DPA04: Description and Setup of Connections 5 4 1
1 Indicating light for UBatt (battery voltage)

4 Indicating light for K line (DATA)
5 Indicating light for L line
8 RS232 connection to computer
10 Connection for control unit with ISO mode 021643

11 Connection for control unit with SAE mode 13 16 8
13 Programmer voltage ON/OFF switch

16 Terminal 15 ECU switch (for SAE mode)
10 11 021644
6008 758 104 - 2005-08 10

3.2 DPA04: Connecting Programmer Tool
1 Connect COM interface (1) and DPA04i adapter (3) 2

with the RS232 cable (2).
2 Connect ISO or SAE cable (4) to the relevant interface

(ISO 9141 / SAE J1708) on the DPA04i adapter (3) and
on the vehicle electronics.
1
3
4
Explanation of drawing
1 Your PC – with system requirements satisfied 021757
2 RS232 cable Order no.: 6008 308 601
3 DPA04i-Diagnosis adapter Order no.: 6008 308 600
4 ISO cable Order no.: 0501 211 103
or
SAE cable Order no.: 0501 211 104
6008 758 104 - 2005-08 11

3.3 DPA05 Version < V2.0: Description and

Setup of Connections
Indicating lights:
1 UBatt (battery voltage)
2 CPU-OK
3 BSL
4 DATA
5 L-LTG (L line)
6 CAN1 019944
7 CAN2
8 9 1 2 3 4 5 6 7
Cable connection to the computer:
8 RS232 (connection cable)
9 USB (connection cable)
Connection for control units: 10

10 ISO mode
11 SAE mode
12 I/0 + CAN
ON/OFF switch:
13 UPRG (programmer voltage)
14 R-CAN2
15 R-CAN1
019945
Term. 30 / Term. 15 switch:

16 Terminal for 15 ECU 11 13 16 14 15 12
6008 758 104 - 2005-08 12

3.4 DPA05 Version ≥ V2.0: Description and

Setup of Connections
Indicating lights:
1 UBatt (battery voltage)
2 CPU-OK
3 BSL
4 DATA
5 L-LTG (L line)
6 CAN1 024673
7 CAN2
Cable connection to the computer: 17 8 18 9 1 2 3 4 5 6 7
8 RS232 (connection cable)
9 USB (connection cable)
Cable connection to mobile phone:
17 RS232 10
18 UBatt
Connection for control units:
10 ISO mode
11 SAE mode
12 I/0 + CAN
ON/OFF switch:
13 UPRG (programmer voltage)
14 R-CAN2
019945
15 R-CAN1
Term. 30 / Term. 15 switch: 11 13 16 14 15 12
16 Terminal for 15 ECU
6008 758 104 - 2005-08 13
3.5 DPA05: Connecting Programmer Tool

2
1 Connect COM interface (1) and DPA05 adapter (3)
with CAN diagnosis cable or RS232 cable (2).
2 Connect ISO or SAE cable (4) to the relevant inter- 3

face (ISO 9141 / SAE J1708) on the DPA05 adapter
(3) and on the vehicle electronics. 1
4
1 Your PC – with system requirements satisfied
2 RS232 cable Order no.: 6008 308 601 or
019940
USB diagnosis cable Order no.: 6008 207 026
3 DPA05 diagnosis adapter
4 Diagnosis cable, 9-pin Order no.: 6008 207 023
Adapter 9 to 3-pin Order no.: 6008 207 024
(See Page 7)
6008 758 104 - 2005-08 14

ZF-TESTMAN pro Description of DPA Interface
4 Description of DPA Interface
ZF-TESTMAN pro has a central

1
display and allows users to set
021641
the various software drivers. 2
Once the ZF-TESTMAN pro 3
has been started, this dialogue
window is opened by clicking
once on the ZF icon.
1 PC driver version
2 DPA04i driver version
3 VUSB driver version
4 Choice of COM port, USB port, or modem*
5 If necessary, here you can select your COM interface
6 If necessary, here you can extend the period of the
timeout (for PCs with small amounts of RAM, this may be 4
necessary to avoid premature termination of a communi-
cation link). 5
7 Entry field for phone number
8 Start DPA05 update (if needed) 6
9 Download for DPA (if needed)
10 Close window 7
11 Restart connection to DPA
8 9
* Note: The “modem” selection opportunity depends upon the 10 11
application.
024670
6008 758 104 - 2005-08 15
ZF-TESTMAN pro Description of DPA Interface
4.1 Checking DPA, PC Driver, COM, and USB Port USB Update, Only for DPA05 Users:
After the installation, the PC and DPA and possibly the 1. Connect the DPA05 to the USB interface of your PC.
USB version must be available as shown in the diagram.
If that is not the case, then the DPA04/05 must be re- 2. Connect the DPA05 to a 24 V power source.
programmed.
3. Click on update DPA05.
NOTE
These versions may differ from that described.
Please refer to your installation CD or any accompanying Installation of USB Driver for DPA05 Users:
correspondence supplied for the correct program status.
NOTE
When first starting up the DPA05 with the USB point,
Windows points out new hardware. At this point, the USB
4.2 Flash Programming and Updating the DPA driver can be installed by following the software instruc-
tions provided.
Re-programming DPA04/05: This installation can be undertaken at a later time only via
the device manager (Start/Settings/System Control/
1. Connect the DPA04/05 to the COM interface of your System/Hardware/Hardware Assistant).
PC.
The path for the driver is GDS3000\usb_driver.
2. Connect the DPA04/05 to a 24 V power source.
3. Click on Load DPA.
6008 758 104 - 2005-08 16

ZF-TESTMAN pro Starting ZF-TESTMAN pro
5 Starting ZF-TESTMAN pro Starting Application - SSO Version

(SSO and Customer Versions)
Click on:
During the installation, an icon is automatically created on 1. Division 1- 4.
the desktop. ZF-TESTMAN pro can be started by double- 2. e.g. 1 AS Tronic AS Tronic 2.
clicking on this.
It can also be started under The program now starts the license check, and the
Start/Program/ZF-TESTMAN pro. security information then appears.
The main menu appears by pressing ENTER or clicking
Starting Application – Customer Version on .
Click on:
1. PAL2 Application
2. Run
3. Select
4. e.g. AS Tronic 2 D
5. Run
The program now starts and the security information

appears. The main menu appears by pressing ENTER or
clicking on .
6008 758 104 - 2005-08 17

ZF-TESTMAN pro Auxiliaries for Telemetry
6 Auxiliaries for Telemetry
Auxiliaries for telemetry if a DPA04i/05 is available.
6.1 Telemetrics Data Transfer With the DPA05 Version ≥ V2.0

6008 206 032 Adapter 9 to 9-pin SUB-D
6008 206 033 Adapter Main power system cable
6008 208 918 License For installation refer to 6.6
6.2 Telemetrics Data Transfer With the DPA05 Version < V2.0

6008 207 031 Adapter cable Connection via DPA/GSM
transmitter
6008 758 104 - 2005-08 18

6.3 Telemetrics Data Transfer With the DPA04i, all Versions

6008 207 031 Adapter cable Connection via DPA/GSM
transmitter
6.4 Parts Kit for Telemetry Without ZF-TESTMAN pro at Vehicle-End (only Transfer of Data, no Display)

6008 208 101 - DPA05 (not sold individually)
6008 206 032 Adapter 9 to 9-pin SUB-D
6008 206 033 Adapter Main power system cable
6008 758 104 - 2005-08 19

6.5 Description and Setup of Connections
6.5.1 DPA05 Version ≥ V2.0
1 3
1
024682
024683
4 5
2
1 Siemens GSM terminal (mobile phone)

2 ISO/SAE vehicle interface
3 6008 206 033 adapter for the main power system
4 6008 206 032 adapter
RS232 only for the mobile handset
5 Vehicle supply voltage
6008 758 104 - 2005-08 20

6.5.2 DPA05 Version < V2.0
1 2 3 3 1
024677 024676
5 7
1 Siemens GSM terminal (mobile phone) 5 RS232 to the DPA05 < V2.0
2 Connection to the GSM 6 ISO or SAE diagnostics connection to the
(operating voltage for the MC35) electronic control unit
3 6008 207 031 adapter 7 Connection from the adapter
4 RS232 for the mobile handset
6008 758 104 - 2005-08 21

6.5.3 DPA04i all Versions
1 2 3 3
1
6
4
024675
5
024674
1 Siemens GSM terminal (mobile phone) 5 RS232 to the DPA04i

2 Connection to the GSM 6 ISO or SAE diagnostics connection to the electronic
(operating voltage for the MC35) control unit
3 Adapter 7 Connection from the adapter
4 RS232 for the mobile handset
6008 758 104 - 2005-08 22

6.5.4 6008 207 031 Description of Adapter
for use in 6.5.2 and 6.5.3
1 2 3
024671
1 GSM mobile handset (vehicle supply voltage

depends upon model)
2 to the DPA04i/DPA05<V2.0 (RS232)
3 to the mobile phone
4 Connection: ISO or SAE at the DPA
6008 758 104 - 2005-08 23

6.6 Additional Telemetry Installation with GSM • System requirements for the receiver (receiving
Transmitter computer):
In order to receive and display the data sent, the
NOTE receiving computer must be equipped with an analog
• An GSM transmitter (sender) and a corresponding SIM or digital modem or a mobile radio phone.
card are not contained in ZF’s scope of supplies. We When using an ISDN installation, the latter must be
recommend to use the Siemens MC35 module since configured as “analog”.
comprehensive tests have been carried out with it. When using a digital modem or a mobile radio phone,
However, a standard GSM mobile phone can also be then the phone service provider has to guarantee that
used. Please pay attention to the fact that ZF can only the function for data transfer has been enabled.
provide technical support when the Siemens MC35 is
used. For further information about the device, please • The initial operation and configuration of the GSM
feel free to send your request to: testmanpro@zf.com transmitter are explained in the operating instruction’s
(ZF internally: also via the ZF-ServiceLine). The mobile “instructions.pdf” for license CD 6008 208 918.
telephone contract (SIM card) has to provide for data
transfer functionalities. Please ensure that this feature
is made available by contacting your mobile telephone IMPORTANT
system provider. This additional function can only be used by means of
further registration and/or licensing.
6008 758 104 - 2005-08 24

Installation procedure
1. Check the driver version of your ZF-TESTMAN pro 3. Order the CD license activation 6008 208 918 (if
and DPA (also refer to Section 4). needed, including hardware, also refer to 1.4.1 - 1.5).
These must be ≥ 3.00. If that is not the case,
please upgrade by means of the corresponding ZF- 4. Upon reception of the 6008 208 918 CD, the latter is
TESTMAN pro update. inserted into the disc drive.
5. Wait until the installation program starts up automa-

2. Carry out hardware registration process. The tically.
register.exe program required to this end is made If this function has been deactivated on your computer,
available in the Testman directory on your computer manually start the 'setup.exe' file from the root direc-
including instructions (path: GDS3000\register). tory on the CD-ROM.
In the case of older versions, this directory may be
missing. In such cases, feel free to send your registra- 6. Follow the instructions provided by the installation
tion software request to the following e-mail address: program.
testmanpro@zf.com (ZF internally: also via the ZF-
ServiceLine).
Please pay attention to making active use of the
“readme” file instructions during registration and type
in your SAP order number or your reference number
(also refer to Order under Item 3).
6008 758 104 - 2005-08 25

ZF-TESTMAN pro Flash Programming and Updating the DPA
7 "Menu" Overview 7. Settings
NOTE 8. - PDI check

The menu items listed below are product-dependent and - Brief check of system with error protocol.
may therefore differ.
9. Abort communication
1. Documentation - Link to control unit is ended.
- ZF-TESTMAN pro user manual.
- Transmission repair manual. Esc Esc Back to menu
- List of lubricants. - Jump back by 1 menu.
2. Statistics memory
3. Diagnosis
- Read error memory.
- Delete error memory.
- Read ID block.
4. Test inputs/outputs
- Test device
- Dynamic display
- Read, write internal values.
5. Vehicle configuration
- Flash ECU.
- Set ECU parameters.
6. Telephone directory
- ZF agencies around the world.
024690
6008 758 104 - 2005-08 26
ZF-TESTMAN pro Additional Settings
8 Additional Settings 9 Additional Information for DPA04s Operated with

a USB Port (USB-to-COM Adapter)
NOTE
Only with Windows 95 and Windows 98. Only for DPA04 users who use a computer with a USB
port but with no RS232 interface.
1. Use right-hand mouse key to click on
ZF-Testman pro symbol. In order to still be able to use this computer, an USB-to-
COM adapter must be used (not supplied by ZF).
2. Select characteristics. When buying one of these, we would recommend that you
test the adapter.
3. Select program and select "Close when exiting". Cable length should be less than 1 m.
4. Staticize and confirm by pressing "OK". Driver software which installs this on COM4 is usually
supplied with these adapters.
You can therefore no longer use this adapter to program
the DPA04 because COM1 or COM2 is needed for this
purpose.
The ‘dpaload_uni’ directory can however be copied onto a

computer which has a RS232 interface. It can then be
downloaded from this computer. ZF-TESTMAN pro does
not have to be installed for this to be done.
Path: GDS3000\dpaload_uni
6008 758 104 - 2005-08 27

ZF-TESTMAN pro Technical Data / System Requirements
10 Technical Data / System Requirements
System requirements:
• Pentium 233 MHZ or higher
• Microsoft operating system as of WIN95
• Screen resolution of at least 800x600 pixels
• 65536 colors (16-bit depth of color)
• 31/2 inch diskette drive
• CD-ROM drive
• RS232 interface, COM1 to COM4 (with DPA04 or

DPA05) or USB interface (with DPA05)
• Modem connection (when using the telemetry

functionality)
• Network connection (future projects)
6008 758 104 - 2005-08 28

ZF Friedrichshafen AG
Hauptverwaltung
88038 Friedrichshafen
Telefon +49 7541 77-0
Telefax +49 7541 77-908000
www.zf.com
Antriebs- und Fahrwerktechnik

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ZF Friedrichshafen AG, MC-C / 2005-06

4149 751 608c

Shift elements, clutch and brake combinations, Ecomat 2 plus ................................................................... 23

1.1 Oil Change Intervals ............................................................................................................................ 1-1

2.1 Replacing Filter .................................................................................................................................... 2-1

4149 751 608b - 2005-10 3

4 Plans .................................................................................................................................................... 4-1

4149 751 608c - 2006-03 4

This repair manual is intended for skilled personnel

This manual deals with the standard ZF products

However, due to continuing development of the

We recommend that work done on your ZF product

Service Points equipped by ZF Friedrichshafen AG

1. Continually trained personnel,

2. Specified equipment, e.g. special tools,

3. Genuine ZF spares, according to our latest

All work performed at these Service Points is carried

Safety Instructions General Information

To avoid injury to personnel and damage to

After completion of repair work and testing, skilled

! THREATS TO THE ENVIRONMENT !

ZF Service Information must be observed. This Gaskets, Locking plates

Cleaning parts If rework is needed on spacer discs, shims etc.

Lube bores and grooves must be free of anti-

Parts such as roller bearings, discs, thrust washers

Bearings d) Duo shaft sealing rings have two

If a specific sealing agent* is to be used for carrying

Shaft Sealing Rings

Index Date of issue Chapter Initiator Remark

a 2005-06 2.9 BKS-T Replacing inductive sensor “NMOT”, model 4180. . . . . .

b 2005-10 Title BKS-T with model 4182, ECOMAT 4

Sectional BKS-T Ecomat 4, 5, and 6-speed version with

Shift BKS-T Ecomat 4 - clutch and brake combinations

c 2006-03 4 BKS-T Ecomat 4 - Hydraulic circuit diagram 4182 700 001

4149 751 608c - 2006-03 9

Tightening torques for bolts and nuts, excerpt

Coarse-pitch thread Fine screw thread

Size Tightening torque in Nm for Dimension Tightening torque in Nm for

M4 2.8 4.1 4.8 M8x1 24 36 43

M12 79 115 135 M14x1.5 135 200 235

M18 280 390 460 M18x2 290 420 490

M24 670 960 1100 M24x1.5 760 1100 1250

M27x2 1050 1500 1800

Edition: August 1991

Dimension Tightening torque in Nm Pipe Thread Tightening

Designation Name Volume Application Comments

Grease For example: Assembly aids in general

Sealing compound Loctite no. 574 Screw connection output flange

Grease techn. Vaseline 8420 Assembly aids in general

Transmission oil Refer to TE-ML14 Assembly aid in general

NOTE: Inquire size of containers before placing any orders!

4149 751 608a - 2005-06 12

Designation Dimension Measurement device Remark

03. Tightening torque of the 30 Nm Torque Renew copper sealing ring.

07. Tightening torque for M6 9.5 Nm Torque Do not overtighten.

09. Tightening torque for 35 Nm Torque Do not overtighten.

10. Installation dimension of 14 to 15 mm Use adapter 1X56 136 824

4149 751 608a - 2005-06 13

Designation Dimension Measurement device Remark

11.Tightening torque for M6 6 Nm Torque Do not overtighten.