Operating_Instruction.pdf

Automatic transmissionHP 500, HP 590, HP 600for trucks and special vehicles

4139 758 130aTechnical modifications reserved.

Status: June 1995

Subject to alterations in design

Copyright by ZF

These operating instructions are protected by copyright. Anyreproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks withoutapproval by the holder of the copyright is prohibited and will beprosecuted under civil and criminal law.

Printed in Germany

2

Transmission version i = 3.43 (short)

Connection for emergency steering pump

Secondarypump

004 718

3

Transmission version i = 5.60 (long)

PTO

Emergency steering pump

Secondarypump

004 719

5

NOTEAll data in this booklet refer to the basic version of the Eco-mat transmission. Due to the large number of installationoptions, no precise data for any specific vehicle can be given.If there are any differences between the operating instruc-tions given in this booklet and those given in the vehicle’sown operating manual, please follow the instructions inthe vehicle operating manual.

We wish you pleasant driving with the ZF Ecomat.

ZF Friedrichshafen AGCommercial Vehicle Transmissions DivisionD-88038 Friedrichshafen Telephone: (0 75 41) 77-0 • Telefax: (0 75 41) 77-8000

Before starting the vehicle, please:

• read the operating instructions carefully, paying particularattention to the safety notes.

• follow the maintenance notes to guarantee transmissionoperating safety.

ZF Customer Service experts are available to assist you withmaintenance work on transmission and with any problemsthat may occur. The addresses are listed on the attached fold-out.

PREFACE

6

The following safety notes are used in these operatinginstructions:

NOTERefers to special processes, techniques, data, use of auxiliaryequipment etc.

CAUTIONThis is used when incorrect, unprofessional working practicescould damage the product.

SAFETY NOTES

DANGERThis is used when lack of care could lead to personal injuryor death.

!

7

CONTENTS

11. TECHNICAL DATA

22. DESCRIPTION

33. OPERATION

44. MAINTENANCE

55. TROUBLESHOOTING NOTES

8

TABLE OF CONTENTS

1. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.1 Ecomat system solution . . . . . . . . . . . . . . . . . . . . 102.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.3 A 800/3D transfer case . . . . . . . . . . . . . . . . . . . . . 16

3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.1 Driving instructions . . . . . . . . . . . . . . . . . . . . . . . 183.1.1 Speed range selector . . . . . . . . . . . . . . . . . . . . . . . 183.1.2 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 183.1.3 Gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.1.4 Pulling away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.2 Speed ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.3 Kickdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.4 Accelerator interlock . . . . . . . . . . . . . . . . . . . . . . 223.5 Retarder operation . . . . . . . . . . . . . . . . . . . . . . . . 223.6 Stopping, parking . . . . . . . . . . . . . . . . . . . . . . . . . 233.7 Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.7.1 Tow-starting without secondary pump . . . . . . . . . 243.7.2 Tow-starting with secondary pump . . . . . . . . . . . 243.8 Towing away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.8.1 Towing away without secondary pump . . . . . . . . 253.8.2 Towing away with secondary pump . . . . . . . . . . . 263.8.3 Emergency steering pump . . . . . . . . . . . . . . . . . . 26

3.9 Temperature monitoring . . . . . . . . . . . . . . . . . . . . 273.10 Status monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 283.11 PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.12 Twin cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.13 HST 18 auxiliary control unit . . . . . . . . . . . . . . . 29

4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.1 Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.2 Ecomat oil quantities . . . . . . . . . . . . . . . . . . . . . . 304.3 Ecomat oil level check . . . . . . . . . . . . . . . . . . . . . 304.3.1 Oil level check at operating temperature . . . . . . . 314.3.2 Reference measurements . . . . . . . . . . . . . . . . . . . 324.3.3 Check procedure if heat exchanger is separately

installed above transmission centre . . . . . . . . . . . 334.4 Transmission oil heating methods . . . . . . . . . . . . 334.5 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . 344.6 Ecomat oil drain, oil fill . . . . . . . . . . . . . . . . . . . . 354.7 Oil fill for A 800/3D transfer case . . . . . . . . . . . . 364.7.1 Initial fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.7.2 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . 374.8 Checking load sensor adjustment . . . . . . . . . . . . . 384.9 Electronic accelerator equipment and EDC units 40

5. Troubleshooting notes . . . . . . . . . . . . . . . . . . . . 41

9

TECHNICAL DATA

1Max. perm. Max. weight (t) Ratios Weight 3) Install.input at engine torque DIN 70020/ISO 1585 length

Series No. of speed Fire service Refuse Construction [mm]gears (rpm) vehicles vehicles machinery 1stgear 2nd 3rd 4th 5th 6th . R. (kg) L

4 3.43 2.01 1.43 1.00 - - 4.84 300 693

HP 5005

2 80028 t 28 t 1) 3.43 2.01 1.43 1.00 0.83 - 4.84 310 693

5 1150 Nm 1050 Nm 1050 Nm 5.60 3.43 2.01 1.43 1.00 - 4.84 344 795

6 5.60 3.43 2.01 1.43 1.00 0.83 4.84 356 795

4 3.43 2.01 1.43 1.00 - - 4.84 305 693

HP 5905

2 80028 t 28 t 1) 3.43 2.01 1.43 1.00 0.83 - 4.84 315 693

5 1250 Nm 1250 Nm 1) 5.60 3.43 2.01 1.43 1.00 - 4.84 354 795

6 5.60 3.43 2.01 1.43 1.00 0.83 4.84 366 795

4 3.43 2.01 1.43 1.00 - - 4.84 320 693

5 2 65028 t 28 t

3.43 2.01 1.43 1.00 0.83 - 4.84 330 693

HP 600 516004) 1400

5.60 3.43 2.01 1.43 1.00 - 4.84 364 795

6 26502) 3.43 2.01 1.43 1.00 0.83 0.59 4.84 330 693

6 2650 5.60 3.43 2.01 1.43 1.00 0.83 4.84 376 795

1) Only after consultation with ZF2) At i = 0.59; nmax = 1600 rpm _ only after consultation with ZF3) Transmission with retarder and oil cooler (without oil)4) For fire service vehicles above 1600 Nm, only after consultation

with ZF

Oil fill quantity for initial fill: approx. 30 l

10

DESCRIPTION

2 Description

2.1 Ecomat system solution

NOTEThe components shown in the following system diagram canbe found in the text under the same numbers.

004 887Fig. 1

10

DESCRIPTION

Key to drawing

1 Interface for vehicle electrical system

2 Status monitoring lamp

3 Temperature gauge

4 Console selector

5 Identification plate

6 EST 18 electronic control unit

7 Connector plug for MOBiDIG 200

8 Wiring

9 Engine speed-dependent PTO

10 From auxiliary air supply, internal diameter of pressure lines = 6 to 8 mm

11 Cooling water connections

12 Solenoid valve accumulator

13 ZF-Ecomat

14 Retarder solenoid valve

15 Temperature sensor

16 Pressure reduction valve (1.2 bar)

17 Retarder reduction solenoid valve

18 Accelerator interlock (Antigas) solenoid valve

19 Mechanical switch for retarder actuation

20 Brake pedal

21 Antigas cylinder

22 Kickdown switch

23 Accelerator pedal

24 Linkage to injection pump

25 Load sensor for detection of engine load condition

26 Pressure reduction valve (3.0 bar)

27 Retarder control „OFF“ switch

28 PTO switch (ON/OFF)

12

DESCRIPTION

Ecomat system solution

The Ecomat system diagram illustrates one of the possibleEcomat system set-ups using all necessary components.

All electrical connections required between the Ecomat sy-stem and the vehicle electronic system are located in the inter-face to the vehicle electrical system (1).

The EST 18 electronic control unit (6) controls the trans-mission and monitors all functions. The automatic controlunit gathers data from the vehicle and transmission (speedrange, engine load condition, etc.) and processes these to pro-duce signals used for controlling the transmission hydraulicsystem.

For special applications, the EST 21 is available instead of theEST 18.

The driver may intervene in the Ecomat control system usingthe following equipment:

• speed range selector (console switch) (4)• kickdown switch (22)• acelerator pedal (23)• mechanical switch for retarder actuation (19)

u The desired speed range can be preselected using thespeed range selector (4).

u The lamp (2) is used for status monitoring. The lamp doesnot light under normal operating conditions.

If this occurs, immediately drive to the nearest servicestation. Drive slowly to reduce transmission loading.

u The kickdown switch (22) is used to move the shift pointstowards higher engine speeds, so the transmission remainsin each gear longer when accelerating and shifts out ofeach gear sooner when decelerating.

u The air pressure in the “air supply to auxiliary consumers“(10) line is reduced to 3 bar by means of the pressurereduction valve (26). This corresponds to the maximumretarder torque.

2 DANGERIf this lamp flashes (frequency 0.2 sec), transmissiondamage is imminent and danger of accidents!Restricted system monitoring!

!

13

DESCRIPTION

u The mechanical switch for retarder actuation is operatedby pressing down the brake pedal and outputs a signal(+24 V) to the EST 18 (6) provided that switch (27) isclosed.

u The temperature sensor (15) is installed on the coolerconnection piece to monitor oil temperature. The infor-mation from the temperature sensor is sent to the temper-ature gauge (3) from where the oil temperature may beread.

u The oil temperature may be read on temperature gauge (3).In addition, a switch point for "excess temperature"(145°C) is built in. This contact switch is used to activatethe retarder torque reduction process.

During the retarder torque reduction process, the retarderreduction solenoid valve (17) is energized. Compressed airflows through the pressure reduction valve (16) andsolenoid valve (17) to the retarder solenoid valve (14).

u Load sensor (25) monitors the engine load condition at thepump filling control lever of the injection pump and sendsthis information to the EST 18 (6).

Pressures for operating the clutch elements are modulatedaccording to the engine load condition using a propor-tional solenoid valve in the electrical/hydraulic controlunit.

u The accelerator interlock cylinder (21) or pneumaticcylinder interrupts acceleration for 1 second when thetransmission is shifted from neutral into another speedrange. This protects the clutches as they should only beloaded with full engine torque after approx. 1 second.The accelerator interlock cylinder (21) is activated via theaccelerator interlock solenoid valve (18).

2

14

DESCRIPTION

2.2 Design

Transmissions in the Ecomat series consist of a hydrodynamictorque converter based on the Föttinger principle, with a lock-up clutch, a hydrodynamic retarder and a rear-mountedmultiple-speed planetary transmission.

The torque converter provides smooth starting withoutmechanical wear and compensates automatically for variousload conditions by providing the necessary input torque.

The various gears in the planetary transmission are engagedautomatically with no interruption in traction. Gearshifts areperformed in response to signals from the EST 18 electroniccontrol unit. In response to various variables in the vehicleand transmission, the EST 18 sends signals to the hydraulicsolenoid valves which actuate the corresponding clutches andbrakes.

A lock-up clutch in the torque converter provides a directmechanical link between engine and planetary transmissionafter the vehicle start-up phase, thus eliminating the powerlosses seen in conventional automatic transmissions where thetorque converter remains in operation all the time.

The hydrodynamic retarder is located between the torqueconverter and planetary transmission. This means that brakingforce is dependent on the gear engaged. Therefore, fullbraking power is available even at low speeds. Braking torquecan either be infinitely variable or divided into individualretardation steps.

Braking on downhill slopes or in city traffic can be carriedout wear-free using the retarder, as this is not a friction brake.

ZF also supplies high-performance PTOs for all truck andspecial vehicle operating systems. These are engine speed-dependent and are engageable or permanently engaged,depending on version. When the PTO is engaged, theconverter lock-up clutch is disengaged and an upshiftinterlock comes into operation.

2

15

DESCRIPTION

The ZF Ecomat transmission can be supplied as a shortversion (for ratios up to 3.43) and a long version (for ratios upto 5.60).

The long version contains an additional planetary gear trainfor ratios i = 5.60 with the length L = 102 mm.

Fig. 2: Transmission design for i = 3.43 – 0.833.43 – 0.59

Fig. 3: Transmission design for i = 5.60 – 0.83 (shown with PTO)

2

004 114

004 113

004 114 004 113

L = 102 mm

16

DESCRIPTION

2.3 A 800/3D transfer case

The A 800/3D transfer case is available for all-wheel drive ve-hicles and has a pneumatically engaged lockable transfer dif-ferential. The transfer case can be flange-mounted on the Eco-mat or separately installed.

u Torque distribution between front/rear axles optionally1 : 1.83 or 1 : 3.35

u Transfer case ratio i = 1.02

u The output direction of rotation is identical to the inputdirection. Lubrication is separate from the Ecomattransmission.

u Maximum input torque = 16000 Nm.

u Maximum permissible input speed on transfer case(without heat exchanger ) is 2650 rpm.

u For special applications, the maximum permissible inputspeed on the transfer case (with heat exchanger) is 3000 rpm.

Key to drawing

a Ecomat connection

b Output flange to front axle (DIN 165)

c Output flange to rear axle (DIN 165)

d Transmission mounting M16 x 1,5; 19 deep, Tightening torque 200 Nm

e Speedo connection E2 DIN 75532; i = 1.545

f Compressed air connection M12 x 1.5 for differentialinterlock

g Costal plug M27 x 1,5 for differential interlock

h Oil drain plug SW17

i Oil fill and oil overflow check SW17

k Connection for ventilation M10 x 1

Oil quantity approx. 6.5 l, oil as per List of LubricantsTE-ML 02

2

2

17

DESCRIPTION

k

i h a f/g b c

d

e

004 945

Fig. 4

18

OPERATION

3 Operation

3.1 Driving instructions

3.1.1 Speed range selector (4)

Selector lever position:

R = ReverseN = NeutralD = Automatic forward drive (Drive)1, 2, 3 = Restricted automatic forward speed ranges

CAUTIONIf the specified clutch slip times are exceeded during gearchange, the lamp (2) on the dashboard (status monitoring)begins to flash.

• Risk of transmission damage!

• Restricted system monitoring!

In this case, the vehicle must be driven to the nearestworkshop under part-load only.

004 715

Fig. 5

3.1.2 Starting the engine

It is only permissible to start the engine when:

• vehicle is stationary (brake „on“)

• selector lever is in neutral position

NOTEStarter interlock – If the selector lever is not in neutralposition, the engine cannot be started.

3

19

OPERATION

CAUTIONJump starting only permitted on battery, never on startermotor!

• Never switch ingition ON/OFF while vehicle is moving

3.1.3 Gear selection

Conditions:

• Selector lever in neutral position

• Vehicle stationary (brake „on“)

• Accelerator pedal in idling position nEng < 900 rpm

Then, select the desired speed range and direction of travelusing the selector lever.

Transmission with additional „External gear interlock“function(To be installed additionally by the vehicle manufacturer - asrecommended by ZF)

• Select the desired speed range . The system only engagesthe corresponding gear if the brakes are „on“.

CAUTIONNever move the selector lever whilst accelerator pedal isdepressed!

Accelerator interlock (Antigas)The accelerator interlock device prevents acceleration for 1second when shifting from neutral to another speed range.

Errors possible during gear selection

• Accelerator pedal depressed or nEng > 900 rpm

• Brake pedal not depressed - transmission with „gear selectinterlock“

• Selecting reverse „R“ when road speed > approx. 3 km/h

No further gear engages once the desired speed range hasbeen selected.

In this case:


• Select desired speed range again, ensuring conditionsdescribed above are met.

3

20

OPERATION

3.1.4 Pulling away

After selecting desired speed range, wait approx. 1 to 2seconds before releasing brake and depressing accelerator.

CAUTIONDo not pull away at temperatures below -15°C.Warm up the engine for approx. 5 mins. withselector lever in neutral position.

3.2 Speed ranges

Precise details of the speed range selector and the ratiosavailable in the various speed ranges can be found in thevehicle operating manual / instructions.

Each speed range is allocated certain range of gears. Gearsare only shifted at the shift points defined by the EST 18.

Manual override of the automatic shift cycles (by shiftingthrough the speed ranges) is of no advantage.

Driving downhillWhen descending steep hills, select speed range 1, 2 or 3 asrequired to limit upshifts.

3

-15°

DANGER!If the transmission is shifted into N whilst the vehicle ismoving, the connection between engine and transmission isbroken. This means engine and retarder braking poweris lost.Risk of accident! – Actuate brake!For safety reasons, the transmission is automatically shiftedinto N if a fault occurs in the EST 18 or if current in thetransmission is lost.

!

DANGER!In extreme cases, the upshift interlock cuts out to protectthe engine.In this case, the transmission can shift up into thehighest gear whatever speed range is selected. Risk ofaccidents!

!

21

OPERATION

Changing direction of travelBefore shifting from forwards to reverse or vice versa, ensure:

• Vehicle is stationary

• Engine is at idling speed

• Selector lever is in neutral position

Then, select gear as described in Section 3.1.3.

3.3 Kickdown

To make use of max. engine power, select higher gearshiftpoints using the kickdown switch (to accelerate or on uphillgradients).

• Depress the accelerator pedal past the full-load pressurepoint - kickdown position

Kickdown

004 886

Fig. 6

3Accelerator

Full-load(Pressure point

Kickdown

Installation example:Pneumatically-actuated acceleratorinterlock device

Kickdown switch

22

OPERATION

3.4 Accelerator interlock (Antigas)

The accelerator interlock device prevents acceleration for 1second when the transmission is shifted from neutral intoanother speed range.

This procedure protects the clutches as they should only beloaded with full engine torque after approx.1 second.

NOTEAll special vehicles such as refuse collection trucks, dumpers,mobile cranes, fire service vehicles etc. are equipped with an„accelerator interlock“.

3.5 Retarder operation

The retarder is a wear-free hydrodynamic brake. The brakingpower depends on which gear is engaged. The retarder shouldbe applied whenever braking is required. This saves wear onthe service brakes, as they do not become hot even whendriving downhill for long periods.

Retarder actuationThe retarder can be activated using a hand-operated lever or afoot pedal. It is actuated via electronic switch contacts orpressure switches in the braking circuit (refer to vehicleoperating manual / instructions).

Conditions for retarder operation(Retarder engaged/actuated)

• Accelerator in idling position

• Road speed > approx. 3 km/h

In this case, the system prevents upshifts(upshift interlock).

CAUTIONIf the accelerator pedal is depressed, the retarder disengages.The upshift interlock cuts out.

3

23

OPERATION

The retarder must be disengaged:

• on icy roads

• if oil temperature is too high (> 145°C)

During retarder operation, the oil temperature must notexceed 145°C. The oil temperature is monitored by a gaugeor a warning device (see Section 3.9, Temperaturemonitoring).

• The (foot) pedal control can be switched off using thetoggle switch on the dashboard

• Return the hand-operated lever to zero position after eachbraking operation

3.6 Stopping, parking

StoppingThe vehicle can be stopped at any time, regardless of theselector lever position. The EST 18 selects the appropriatestarting gear.

During short stops:

• The selector lever can be left in gear• Apply brakes

During longer stops:


Parking Always apply the parking brake if leaving the vehicle.

3

DANGER!If the permissible oil temperature of 145°C is exceeded,the retarder is automatically reset.Risk of accident due to reduced braking power!

!

DANGER!When the engine is stopped, there is no direct mechanicallink between the engine and the axle. Vehicle may rollaway.

!

24

OPERATION

3.7 Tow-starting

3.7.1 Tow-starting without secondary pump

CAUTIONIt is neither possible nor permissible to start the engine bytowing the vehicle if there is no secondary pump - risk oftransmission damage!

3.7.2 Tow-starting with secondary pump

CAUTIONCheck whether your Ecomat transmission is equipped with asecondary pump * which provides the transmission clutcheswith the necessary oil pressure if tow-starting is required.

• Always use a tow bar

• Move the speed range selector to position “D“

• Keep accelerator pedal in full-load position

• Switch off retarder, if installed

• Accelerate the vehicle quickly to prescribed tow-startingspeed

* Refer to pages 2 and 3

NOTESThe necessary tow-starting speed depends on – Transmission ratio– Programmed starting gear– Axle ratio– Tyre size– TemperatureTherefore, fixed values cannot be given. Please refer to yourVehicle Operating Instructions for the correct tow-startingspeed for your vehicle.

CAUTIONTow-starting at temperatures below -15°C is not permissible –risk of transmission damage.

3

25

OPERATION

3

3.8 Towing away

CAUTIONIf you suspect the transmission may be damaged, disconnectthe propshafts between the Ecomat and drive axles beforetowing.

Exception: In dangerous situations, it is permissible to towaway before disconnecting the drive line (e.g. on cross-roadsor in tunnels etc.).

3.8.1 Towing away without secondary pump

Towing away at temperatures down to -15°C


• Max. towing time 2 hours

• Max. towing speed, see graph

Towing away at temperatures below -15°C


• Max. towing time 2 hours

• Max. towing speed 5 km/h

000 855

Fig. 9: Towing speed graph

Example:Axle ratio: iA = 7.6Dynam. tyre radius: rdyn = 0.490Towing speed. max.: 18 km/h

0 10 20 30 40 50

4

6

8

10

12

rdyn m

0,60,50,4

Abschleppgeschwindigkeit v km/h

Axl

e r

atio

Towing speed v [km/h]

26

OPERATION

3.8.2 Towing away with secondary pump

CAUTIONCheck whether your Ecomat transmission is equipped with asecondary pump* which guarantees the lubrication oil supplyto the transmission when towing away.

Towing away at temperatures down to -15°C

• Move the speed range selector to position "N".

Always observe legal speed limits when towing a vehicle. ZFdoes not impose specific maximum towing speeds.

CAUTIONIf you suspect the transmission may be damaged, disconnectthe propshaft between the transmission and the driving axlesbefore towing.


Towing away at temperatures below -15°C

• Move the speed range selector to position “N“

• Max. towing speed 5 km/h

CAUTIONIf you suspect the transmission may be damaged, disconnectthe propshaft between the transmission and the driving axlesbefore towing.

3.8.3 Emergency steering pump

The emergency steering pump* attached to the output cover isconnected to the output shaft and therefore operated contin-uously when the vehicle is being driven. The emergencypump speed corresponds to the propshaft speed. Should theauxiliary steering pump fail, or if the vehicle is on tow, theemergency steering pump keeps the power steering opera-tional.


3

DANGER!If the propshafts are disconnected, the assistance providedby the emergency steering pump is no longer available.

!

27

OPERATION

3DANGER!If oil temperature exceeds 145°C, the retarder isautomatically reset.Risk of accidents due to reduced braking power!

!

3.9 Temperature monitoring

The temperature is monitored by a gauge or warning device.

Permissible oil temperatures:

– Operating temperature: approx. 85°C– Normal driving: max. 100°C– Retarder operation: max. 145°C– Converter operation: max. 110°C

Temperature gauge

What to do if the permissible oil temperatures areexceeded:

• Drive at part-load in low speed range

• Disengage the retarder (also refer to Section 3.5)

If this does not cause the oil temperature to drop:

• Stop the vehicle

• Move selector lever into neutral position

• Run engine at higher revs

If the temperature does not fall to within the permissiblerange within a few seconds, possible causes include:

• oil level too low

• defective coolant circuit

• transmission damage

Please inform the nearest ZF Service Point!

004 717

Fig. 10Green range – for all normal operating conditionsGreen/red range – only for braking operation with retarderRed range – oil temperature too high

3.10 Status monitoring

The transmission is monitored every time the vehicle circuitvoltage is switched on or during operation by the diagnosissystem in the EST 18 electronic control unit.

In this case, the vehicle must be driven under part-load to thenearest workshop so that the fault can be corrected!

3.11 PTOs

Engagement conditions:

• Accelerator pedal in idling position

• Engine speed < 900 rpm

• Selector lever in „N“(see vehicle operating manual / instructions)

NOTEIf these conditions are not fulfilled, PTO engagement isblocked. When the PTO is engaged, the converter lock-upclutch remains disengaged and an upshift interlock comes intooperation.

3.12 Twin cabs

Some applications have twin cabs. In these cases, when theselector lever is being used by one cab, the other cab isblocked by means of a detent solenoid.

28

OPERATION

3

DANGER!If the status monitoring lamp (2) is flashing, there is gravedanger of transmission damage and system monitoring isonly restricted. Risk of accidents!

!

29

OPERATION

3.13 HST18 auxiliary control unit

The HST 18 auxiliary control unit was developed in order tomove the vehicle during assembly and to provide an emer-gency control function should the EST 18 electronic controlunit malfunction.

The HST 18 auxiliary control unit is fitted to the 55-pin pluginstead of the EST 18 electronic control unit and allows 1 for-ward and the reverse gear to be engaged. Gear shifts whilstdriving are no longer possible.

Operation instructions for the HST18

• Apply parking brake to prevent vehicle from rolling awayunintentionally.

• Move speed range selector to position “N“ .

• Switch off engine and ignition.

• Remove plug from EST 18 control unit.

• Connect plug to HST 18 auxiliary control unit and secure.

• Start engine.

• Select gear using selector lever:

Position „N“ = Neutral

Position „D“ = Forwards (gear is engaged, neitherupshift nor downshift occurs.)

Position „R“ = Reverse

3

DANGER!

All safety functions are de-activated when using the HST 18auxiliary control unit.Danger of accidents!Therefore, the following points must be observed withoutexception:• Shifts from „N“ to „D“ or from „N“ to „R“ ;

must only be carried out at idling speed and when the vehicle is stationary.The transmission can also be shifted at higher speed. However, this leads to transmission damage.

• When switching between forwards and reverse operation or vice versa, ensure that the vehicle is stationary.

• After shifting to „D“ or „R“, always wait for approx. 2 seconds so that the transmission is engaged before accelerating.

!

30

MAINTENANCE

4

4 Maintenance

Good maintenance means safe transmission operation. It istherefore especially important to carry out any necessarymaintenance work in the correct manner.

4.1 Oil grades

Only oils as per the applicable ZF List of LubricantsTE-ML 14 can be used for filling the Ecomat transmission.

CAUTIONEcomat transmissions with flange-mounted A800/3Dtransfer case have a separate oil circuit!Only oils as per the applicable ZF List of Lubricants can beused for filling the transmission / transfer case:Ecomat transmission: – TE-ML 14A 800/3D transfer case: – TE-ML 02

The latest Lists of Lubricants can be requested from all ZFAfter-Sales Centres.

4.2 Ecomat oil quantities

For initial filling of dry transmission (without oil cooler) approx. 30 ltr

After installing new/exchange transmission approx. 20 ltr

At oil changes approx. 15 ltr

The above quantities are for guidance only, the precisequantity must always be determined by measuring with thedipstick.

Oil quantities for A800/3D see Section 4.7.

4.3 Ecomat oil level check

It is essential for the Ecomat transmission to be operated withthe correct oil level.Too little oil leads to mal-functions and damage.

Too much oil results in transmission overheating.

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CAUTION• The oil level must be checked regularly at operating

temperature. This is the only way of ensuring that thelevel is correct.Check oil level once weekly – see Section 4.3.1.

• Under certain circumstances, the oil level must first bechecked when the transmission oil is cold – see Section4.3.2. Always recheck afterwards at operatingtemperature.

• If the heat exchanger is located higher than the centre lineof transmission (separate installation), the oil level shouldbe checked as described in Section 4.3.3.

4.3.1 Oil level check at operating temperature

For correct results, the oil level must be checked when thetransmission oil is hot (80 - 90°C).We recommend that this check is performed once weekly,preferably after finishing a journey.

Conditions:

• Park vehicle on level ground

• Switch speed range selector to neutral

• Run engine at idling speed

After waiting approx. 2 minutes, the oil level must be withinthe warm range.

CAUTIONThe idling speed should be set between 500 and 700 rpm.On no account may it fall below 450 rpm.

Hot range 80 - 90°C

S 0024

Fig. 12

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4.3.2 Reference measurements

This approximate oil level check, which is performed with thetransmission oil cold, is used in the following exceptionalcases:

• When using a transmission for the first time

• After long periods out of use or before first operating avehicle received from elsewhere

• After in-vehicle repairs to the transmission: e.g. removal ofoil sump, hydraulic control module, oil cooler etc.

• After oil change or filter replacement

The oil level check should be carried out in two stages:

• Level check before starting engine

• Level check after starting engine

Oil level check before starting engine

The oil level must be within or above the stationary range„nEng = 0“.If the oil level is higher, do not drain off any oil!

Stationary range (nEng = 0)

S 0025

Fig. 13

Oil level check after starting engine

Run the engine at idling speed for approx. 3 to 5 minutes(speed range selector in neutral) and then check the oil level.The oil level should be within the cold range (30°C).If the oil level is higher, do not drain off any oil!

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CAUTIONAfter cold-starting at sub-zero temperatures, the dipstick mustdip at least 10 mm into the oil before it is permissible to runthe transmission up to temperature.An accurate oil level check at operating temperature mustthen be made as soon as possible (see Section 4.3.1).

Cold range 30°CS 0026

Fig. 14

4.3.3 Oil level check with separate heat exchangerinstalled higher than centre line of transmission

The oil level check must be carried out under the followingconditions:

• Run transmission in neutral position for 15 to 20 secondsand engine speed 1200 to 1500 rpm.

• Allow the engine to return to idling speed. Within 3 minutes, perform the “oil level check after startingengine” and then the “oil level check at operatingtemperature”.

4.4 Methods of heating up transmission oil

If the transmission oil cannot be heated up during normaloperation, it must be heated up as follows:

• Engage parking brake

• Select „D“ speed range

• Apply service brakes

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• If required, repeatedly run engine for between 15 to 20seconds under part-load at 1200 to 1500 rpm.

CAUTIONMax. permissible oil temperature 110 °C.

• After each heating-up phase, allow engine to run for 15 to 30 seconds at 1500 to 2000 rpm with transmission inneutral position.

Once operating temperature has been reached:

• Move transmission into neutral position

• Run engine at idling speed for 2 to 3 minutes

Then, carry out oil level check as per Section 4.3.1.

4.5 Oil change intervals

CAUTIONThe filter must be renewed after every oil change.

Mineral ATF (Automatic Transmission Fluids)

• For normal operation (max. 110°C) every 30000 km

• For heavy (high temperature) applications(110 – 150°C) every 20000 km

• In construction machinery or special vehicles(mobile cranes, refuse vehicles etc.) every 1000 hrs. of

operation• However, at least once every year

Synthetic ATF oils

• For normal operation (max. 110°C) every 90000 km

• For heavy (high temperature) applications(110 – 150°C) every 60000 km

• In construction machinery or special vehicles(mobile cranes, refuse vehicles etc.) every 3000 hrs. of

operation

• However, at least once every two years

If mineral ATF is replaced by synthetic ATF, the next oilchange interval is 45 000 km.All subsequent intervals are 90 000 km.

Oil change intervals for A800/3D see Section 4.7.

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4.6 Ecomat oil drain, oil fill

Drain oil – only at operating temperature!

• Engine stationary

• Unscrew oil drain plug (1) and drain oil.

• Remove filter cover (2).

• Renew filter cartridge, Cu rings and O-rings.

S 0020

Fig. 15

• Replace filter cover (tighten bolts to 25 Nm)

• Screw in oil drain plug (1) (tightening torque 50 Nm)

• Remove dipstick (3)

• Add oil (oil quantity, see Section 4.2)

• Check oil level as per Section 4.3

S 0022

Fig. 16

13

2

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4.7 Oil drain, oil fill for A800/3D transfer case

CAUTIONSeparate oil circuit!The lubrication for the A800/3D transfer case is independentof that for the Ecomat basic transmission.

NOTEThe vehicle must be level before oil fill can take place.

Oil quantity: approx. 6.5 lOil grade: see ZF List of Lubricants TE-ML 02Oil change interval: see Section 4.5 Ecomat

This list can be requested from all ZF Service points.

Drain oil – only at operating temperature!


• Unscrew oil drain plug (1) and drain oil.

• Screw in oil drain plug (1) (tightening torque 50 Nm)

4.7.1 Initial fill


• Unscrew oil fill plug (2).

• Fill in 5.5 litres of oil.

NOTEFill in oil slowly to avoid backflow and overflow at theopening.

• Screw in oil fill plug.

• Start engine and carry out a short test run (200 - 300 metres).

• Park vehicle on level ground.

• After 5 to 10 minutes:Remove oil fill plug (2) and fill in oil until it flows over atthe opening.

NOTEFill in oil slowly to avoid backflow.

• Screw in oil fill plug.(Tightening torque 50 Nm)

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4004 720

Fig. 17 2

1

4.7.2 Oil level check

• Start engine and carry out a short test run (200 - 300 metres).

• Park vehicle on level ground.

• After 5 to 10 minutes:Remove oil fill plug (2) and fill in oil until it flows over atthe opening.

NOTEFill in oil slowly to avoid backflow.

• Screw in oil fill plug. (Tightening torque 50 Nm)

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4.8 Checking load sensor adjustment

The load sensor adjustment must be checked:

• following maintenance work to the transmission or engine• following hard shifts• at least every 3 months

Check procedure (The engine must be at the correct setting before the check isbegun).

The check can be carried out using marks on the front (Fig. 18)or the top of the housing (Fig. 19).

• Switch off engine

• Engage parking brake

• Slowly depress accelerator pedal until pressure point isreached (injection pump full-load stop) – do not depresspedal beyond this point

• Retain accelerator pedal position – load sensor lever markmust correspond to full-load mark (high) on housing.

• Release accelerator pedal until idling position is reached

• Load sensor lever mark must correspond to idling mark(low) on housing.

CAUTION• Do not use stops on load sensor housing for setting.• Do not loosen bolts on load sensor housing or nut on shaft.• Check ball heads for wear (too much backlash) and grease

filling.

000 822

Fig. 18

low high

Stops

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000 824

Fig. 19

Key to drawing (Fig. 20)

1 Accelerator pedal

2 Kickdown overtravel plunger

3 Kickdown switch

4 Antigas cylinder

5 Load sensor

6 Injection pump on engine

7 Injection pump full-load stop

A Idling position

B Full-load position

C Stop position

D Air supply

S 0093

Fig. 20

lowhigh

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4.9 Electronic accelerator equipment and EDC units

The engine load signal is not recorded by the load sensor butelectronically.

• For electronic acceleratorequipment units: from the electronic system of

the electronic acceleratorequipment to the EST 18

• For EDC units: directly from the engine elec-tronic system to the EST 18

If problems occur

• please contact the nearest vehicle manufacturer servicepoint.

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Fault Possible cause Remedy

Engine will not start Selector lever not in “Neutral“ Select neutral.

Plug of electronic control unit loose Connect plug.

Starter interlock relay fault Exchange relay.

No gear engages in transmission Load sensor not in idling position Check and/or readjust the load sensor/injection pump.

Engine idling speed > 900 rpm Adjust the engine idling speed.

Only for transmissions with “External gear interlock“ function:Service brakes not applied Apply service brakes.

Electronic control unit in failure mode Switch ignition off/on.

Vehicle does not move Oil level too low Check/correct oil level.

Transmission fault Request ZF service.

Oil temperature too high Oil level too high Check/correct oil level.

Retarder engaged Disengage the retarder using hand lever.

Internal fault Request ZF service.

Retarder does not work Oil level too low Check/correct oil level.

Retarder solenoid valve not functioning Check solenoid valve/electrical connections.If necessary, request ZF service.

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