Operating Instructions
Bus
ZF-EcoLife
for City Buses, Intercity Buses, and Coaches
Copyright © ZF Friedrichshafen AG
This document is protected by copyright.
Complete or partial reproduction or distribution of this document is not permitted
without the consent of ZF Friedrichshafen AG. Infringements lead to civil and criminal
prosecution.
This document is a translation of the German original.
Preface
Before operating the vehicle for the first time, please note the
following points:
• Read these Operating Instructions carefully and observe all
safety instructions.
• To ensure operational safety and reliability of the
transmission, always observe the maintenance instructions.
The ZF Customer Service specialists are available to assist you
in carrying out transmission maintenance work or to help if any
problems arise.
You will find the addresses in the “ZF Company Directory”
(order number 0000 762 703) or on the Internet under
www.zf.com (Company/ZF worldwide).
You will find more product information on the Internet by
logging on to www.zf.com (Products & Services/Product
Range Buses).
NOTE
All details in these Operating Instructions refer to the basic
version of the ZF-EcoLife transmission.
Due to the large number of installation options, no precise
information can be provided for any specific vehicle.
If there should be any deviating operating instructions as
regards this brochure and the Operating Instructions specific
to an individual vehicle manufacturer, the vehicle-specific
instructions will be binding.
Motoring pleasure with the ZF-EcoLife is brought to you by
ZF Friedrichshafen AG
D-88038 Friedrichshafen
Phone: +49 (0) 7541 77-0
Fax: +49 (0) 7541 77-90 80 00
Internet: www.zf.com
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Impor tant Safety Information
The following safety instructions are used with the present
operating instructions:
NOTE
Reference is made to special procedures, methods,
information, etc.
CAUTION
Used when deviating, unprofessional operation can damage
the product.
DANGER!
This is used when lack of care could lead to personal
injury or material damage.
THREATS TO THE ENVIRONMENT!
Lubricants, consumables and cleaning agents must
not be allowed to enter the soil, ground water, or
sewage system.
• Ask your local environmental protection agency
for safety data sheets on the relevant products
and adhere to their requirements.
• Collect oil in a suitably large container.
• Dispose of oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection regulations.
• When working with lubricants and cleaning agents
always observe the manufacturer’s instructions.
NOTE on cleaning the vehicle/transmission
CAUTION
When cleaning, make sure not to point the steam cleaner
or high-pressure cleaner directly at the breather, nor the
electronic control unit, or the plug-in connections. Ingress of
water may lead to operational malfunctions and transmission
damage!
– Breather, see Chapter 1.3, item 10
– Electronic control unit and connector, see Chapter 1.3,
items 1, 2, and 3
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1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Transmission configuration and add-on parts . . . . 8
1.3 System solution ZF-EcoLife . . . . . . . . . . . . . . . . . . 10
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.1 Pushbutton control with diagnostics connector . . 12
2.1.1 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.2 Pushbutton illumination . . . . . . . . . . . . . . . . . . . . 13
2.1.3 Pushbutton selector position . . . . . . . . . . . . . . . . . 14
2.2 Driving ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Engaging a gear . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.1 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Transmission with additional functions . . . . . . . . . 16
2.4.2.1 Additional function “gear release” . . . . . . . . . . . . . 16
2.4.2.2 Additional function “additional pushbutton
reverse gear” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Downhill driving . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Change in direction of travel . . . . . . . . . . . . . . . . . 17
2.8 Kickdown (forced downshift) . . . . . . . . . . . . . . . . 18
2.9 Retarder operation . . . . . . . . . . . . . . . . . . . . . . . . 18
2.10 Stopping, parking . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.11 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.11.1 Towing vehicle with coaxial transmission . . . . . . . . 21
2.11.1.1 Transmission is functioning . . . . . . . . . . . . . . . . . . 21
2.11.1.2 Transmission damage suspected . . . . . . . . . . . . . 21
2.11.2 Towing vehicle with angle drive transmission . . . . 22
2.12 Temperature monitoring . . . . . . . . . . . . . . . . . . . . 23
2.13 Status monitoring/warning lamps . . . . . . . . . . . . . 24
2.14 Transmission response to a malfunction . . . . . . . . 24
2.14.1 Emergency operation . . . . . . . . . . . . . . . . . . . . . . 25
2.15 Use at low temperatures and longer downtimes . . 26
2.15.1 Parking the vehicle at sub-zero temperatures . . . . 27
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Oil quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Initial check of the oil level in order to ensure
a minimum oil quantity . . . . . . . . . . . . . . . . . . . . . 30
3.3.2 Relevant oil level check at operating temperature . 30
3.3.3 Electric oil level check . . . . . . . . . . . . . . . . . . . . . 31
3.3.4 Option for heating-up the transmission oil . . . . . . 31
3.4 Oil-change intervals . . . . . . . . . . . . . . . . . . . . . . . 31
3.5 Variant 1 – Oil change with standard oil drain . . . 32
3.5.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.6 Variant 2 – Oil change with VRM special oil drain . 34
3.6.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting Instructions . . . . . . . . . . . . . . . . . 36
Table of Contents
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1 Description
1.1 Assemblies
These EcoLife transmissions consist of a hydrodynamic torque
converter with a lockup clutch and a downstream 6-speed
planetary transmission.
Torq u e c o nver t e r
The hydrodynamic torque converter, which uses the Trilok
principle, is a wear-free starting element equipped with a
stator freewheel and an integrated lockup clutch. The converter
operates only during the starting process and is automatically
bypassed when the clutch closes.
As a result, losses occurring in the converter are eliminated.
Torsional vibration dampers
All converter types are equipped with torsional vibration
dampers allowing not only better driving comfort but also
reduction of fuel consumption as a result of lowered shifting
speeds.
Retarder
Retarder equipment is standard for all transmission versions.
The integrated hydrodynamic retarder is arranged in the basic
transmission between converter and planetary transmission.
Due to the location of the retarder on the transmission input
(so-called primary retarder), the brake torque on the output is
increased by the respective transmission ratio. As a result, a
high retarder brake torque is available in the lower gears, and
can be used almost until vehicle standstill. As long as
permissible values are observed, this can be parameterized at
will, which permits adaptation to individual applications or the
wishes of customers.
Retarder control is normally managed through actuation of
the brake pedal. The electronic control unit converts the brake
signal is into a braking torque, either in steps or in a
continuously variable manner.
Via CAN, the retarder can be combined with other brake
systems. When this is done, the maximally permitted sum of
brake torques must be taken into account.
Optionally, or in combination with the brake pedal, the retarder
can also be operated via a hand lever.
Description
Planetary transmission
The planetary transmission, next in line after the torque
converter, is designed as a 6-speed unit. It represents a linked
system of simple planetary gear sets (not a group-type design).
The gears in the planetary transmission are selected
automatically and without any interruption of traction.
The signals for individual gearshifts are supplied by the
electronic control unit. Depending on various operating
variables of engine, vehicle, brake system, etc., the
corresponding multidisk clutches or brakes are controlled
via the electrohydraulic control unit.
Electrohydraulic control unit
The transmission is equipped with an electrohydraulic control
unit. The electro-hydraulic shift control unit obtains the shift
commands from the electronic control unit. Proportional
solenoid valves are used to modulate closing of the clutch
and brake elements in accordance with the engine load.
Description
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Description
1.2 Transmission configuration and add-on parts
Based on the basic transmission with attached electronic
control unit, the following variants exist:
• Coaxial transmission version with heat exchangers
directly attached.
On the coaxial standard transmission, the retarder heat
exchanger is mounted on the output end and the transmission
heat exchanger is arranged laterally.
035559
Fig. 1.1 Coaxial transmission
9
Description
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• Transmission with flanged-on angle drive 80° (RHD) and
directly attached heat exchangers.
An angle drive of 80° (RHD) can be flange-mounted to the
basic transmission. Special retarder heat exchanger
arrangements are made available for this purpose.
• Transmission with flanged-on angle drive 80° (LHD) and
directly attached heat exchangers.
An angle drive of 80° (LHD) can be flange-mounted to the
basic transmission. Special retarder heat exchanger
arrangements are made available for this purpose.
Fig. 1.2 Transmission with flange-mounted
angle drive of 80° (RHD)
Fig. 1.3 Transmission with flange-mounted
angle drive of 80° (LHD)
035560 035561
1
2
3
5
6
4
10
7
8 9
11
12
13
12.1
Kick-Down
Retarder l
ever
Brake pedal
Inputs and
outputs
Vehicle-CAN
ZF-CAN
Engine
Speed range selector
E-Modul
Brake system
On-board
computer
Diagnosis Tool
• Diagnosis
• EOL
• Measuring
•
Parameterization
Signal
converter
123DNR
Accelerator pedal
Description
1.3 System solution ZF-EcoLife
Key to drawing
1 Cable connection between
the electronic control unit and
the transmission
2 Electronic control unit
3 Electronic control unit's
connector
4 Oil filler tube with oil
dipstick
5 Tachometer impulse sensor
(optionally 10 o’clock/
14 o’clock)
6 Cooling water connections
7 Pressure filter
8 Oil pan
9 Oil drain plug
10 Vent
11 Vehicle electric system “Vehicle CAN”
– Engine/On-board computer/
brake system
– Accelerator pedal
– Kickdown, retarder lever,
foot pedal
12 ZF peripheries “ZF CAN”
– E module 2 (optional)
– Inputs
–Kickdown, retarder lever,
foot pedal
– Outputs
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– Speed range selector
(pushbutton range selector)
– Inputs
–Kickdown, retarder lever,
foot pedal
– Outputs
– Diagnosis interface ZF (12.1)
13 Diagnosis tools ZF-Testman
– Diagnosis
– EOL
– Measuring
– Parameterization
10
035558_en
11
Brief description
The system diagram illustrates possible system solutions for the
ZF-EcoLife with all requisite individual components.
The EcoLife transmission is connected to the vehicle power
supply via the vehicle CAN, and via the ZF CAN with the range
selector, the optional E-module 2, and the diagnosis tool.
The electronic control unit controls and monitors the EcoLife
transmission and features all standard diagnostic protocols. The
electronic control unit records vehicle and transmission input
variables communicated via CAN and converts them into
signals to control the transmission's hydraulic control elements.
The driver can intervene actively in the EcoLife control system
using:
– Speed range selector (pushbutton range selector)
– Kickdown
– Accelerator pedal
– Brake pedal
– Switch for retarder actuation
• The range selector can be used to preselect speed ranges.
Pushbuttons will shine when depressed (permant
illumination).
• The kickdown function can be used to move shift points
towards higher engine speeds, so the transmission remains
in each gear longer during acceleration and shifts out of
each gear sooner during deceleration.
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Description
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2 Operation
2.1 Pushbutton control with diagnostics connector
2.1.1 Variants
Variants: 3, 4, 5 or 6 pushbuttons for speed-range selection,
horizontally or vertically arranged:
R = Reverse
N = Neutral
D = automatic forward driving range (Drive)
optional:
1, 2, 3 = limited forward driving ranges
For a description of the driving ranges see Chapter 2.2
Pushbutton control with diagnostics connector,
variant with 6 pushbuttons, horizontally arranged
(details may be different from illustration).
Cover for diagnostics connector open
Diagnostic cable connected
Operation
029415
029416
029417
2.1.2 Pushbutton illumination
Brightness levels 1 (low) and 2 (high) are available for
pushbutton illumination.
Turning the vehicle key into driving position causes the system
to perform an automatic illumination test. All pushbuttons will
be illuminated for approx. 1.2 seconds at level 2 before the
system changes to level 1 for easier location of the
pushbuttons.
After pressing the pushbutton, it will be illuminated at level 2
as soon as it is accepted by the electronic control unit
(functional illumination).
Display of errors:
• Illumination level 1 is retained despite depressed
pushbutton
Possible causes:
– Information needed for illumination is not provided by the
electronic control unit.
In such a case, normal driving is still possible.
– Hardware defect on pushbutton selector
• Depressed pushbutton flashes
Cause: Pushbutton is not accepted by the electronic control
unit (for potential cases see Chapters 2.3 and 2.4)
• All pushbuttons flash
Possible causes:
– Serious internal fault of pushbutton selector
– Malfunction of CAN communication
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Operation
2.1.3 Pushbutton selector position
NOTE
If several pushbuttons are selected at the same time, the
smallest gear locking button selected will be activated.
Example: If pushbuttons 3 and D are accidentally depressed
at the same time, pushbutton 3 will be activated.
2.2 Driving ranges
Driving ranges are selected through depression of the
respective pushbuttons of the pushbutton range selector (cf.
Chapter 2.1). Consult the vehicle operating instructions for
precise information about the gears engaged in each of the
speed ranges.
A defined range of gears is assigned to each driving range.
The electronic control unit determines the shift points at which
gear changes are performed.
Manual intervention in the automatic shifting process
(shifting through driving ranges) is not expedient.
DANGER!
If the pushbutton “N” is depressed during driving
operation, the power flow between engine and output
will be interrupted.
Engine and retarder braking action are then lost.
Risk of accident! – Apply the brake!
For safety reasons, when faults occur in the electronic
control unit or whenever there is a power failure, the
transmission automatically selects "Neutral".
2.3 Starting the engine
The engine may only be started under the following conditions:
• Vehicle standstill
• Activated service or parking brake
• Pushbutton selector in Neutral position (“N”)
NOTE
Starting interlock: If the pushbutton selector is not in neutral
position, engine start will as a rule be prevented. For details
consult the vehicle operating instructions of the vehicle
manufacturer.
Operation
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It may be possible to start the engine when the pushbutton
selector is not in neutral position. In such a case, the
pushbutton depressed will flash after the engine starts (cf.
Chapter 2.1.2), and the transmission will remain in Neutral. To
drive off, the pushbutton “N” will then have to be depressed
and subsequently (acc. to Chapter 2.4) the desired drivingrange pushbutton on the pushbutton range selector.
CAUTION
Only jump-start on the battery, never on the starter! Do not
turn the vehicle key while driving!
2.4 Engaging a gear
CAUTION
Never operate the pushbutton range selector and step on
the accelerator at the same time!
2.4.1 Standard
• Accelerator pedal in idling position
• n
eng
< 900 rpm
• Vehicle standstill
• Activated service or parking brake
• Select desired driving range by depressing corresponding
pushbutton on pushbutton range selector.
In the following cases, engagement of a starting gear is
prevented by the electronic control unit in spite of a selected
driving range (pushbutton depressed). In such cases, the
pushbutton depressed will flash (cf. Chapter 2.1.2):
• Accelerator pedal operated
• n
eng
> 900 rpm
• Driving speed > approx. 3 km/h and driving range
selected do not correspond to actual driving direction.
• Transmission oil sump temperature below –20 °C.
– required measures see Chapter 2.15
Operation
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2.4.2 Transmission with additional functions
2.4.2.1 Additional function “gear release”
(Additional installation by vehicle manufacturer, recommended
by ZF!)
In addition to the cases mentioned under 2.4.1, engagement
of a starting gear is prevented by the electronic control unit in
spite of a selected driving range (pushbutton depressed) in the
following case. In this case, the push button depressed will
flash (cf. Chapter 2.1.2):
• Neither service nor parking brake activated
Operation of the service or parking brake will cause the
starting gear to engage and the depressed pushbutton will
change from flashing to functional illumination.
2.4.2.2 Additional function “additional pushbutton
reverse gear”
For engagement of the reverse gear, depress the R pushbutton
of the pushbutton range selector and promptly also the R
pushbutton on the instrument panel.
Remaining procedure as described under 2.4.1. In addition to
the cases mentioned under 2.4.1, engagement of the reverse
gear will be prevented by the electronic control unit in spite of
the depressed R pushbutton of the pushbutton range selector
in the following case. In this case, the R pushbutton depressed
will flash (cf. Chapter 2.1.2):
• Additional R pushbutton on instrument panel not depressed
Operation
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2.5 Starting
After selecting the appropriate driving range, wait for approx.
1 to 2 seconds, then release the brake and accelerate.
Depending on vehicle configuration and loading state, the
vehicle may start at low speed on a level track or on a slight
uphill grade after release of the brake. If a lower driving speed
is desired, this must be realized through operation of the brake
pedal.
DANGER!
• In the event of reduced grip of the front wheels, e.g.
due to black ice, locking of the front wheels may occur.
The vehicle can then no longer be steered.
• On major uphill grades, always accelerate with the
parking brake activated. Do not release the parking
brake before you can feel propulsion.
RISK OF ACCIDENT caused by vehicle rolling backwards!
• Fast rolling backwards in a forward gear, or rolling
forward in the reverse gear, is not permitted and may
result in stalling of the engine and loss of steering
support.
• Always start with great care and gentle acceleration
when starting near persons or obstacles in order to rule
out any risks.
2.6 Downhill driving
Before driving down steep gradients, select driving range 1, 2,
or 3 on the pushbutton speed range selector, as the situation
may require. This limits upshifts.
DANGER!
In an extreme case, the hold mode will be cancelled
to protect the engine.
In such a case, the transmission may shift up to the
highest gear irrespective of driving range selected.
RISK OF ACCIDENT!
Watch revmeter!
2.7 Change in direction of travel
Before changing from Forward to Reverse or vice versa:
• Bring the vehicle to a complete standstill.
• Depress pushbutton “N” on the pushbutton range selector
• Continue as described under Chapter 2.4.
Operation
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2.8 Kickdown (forced downshift)
To utilize maximum engine power, higher shift points can be
realized via the kickdown switch (see illustration) or the CAN
system (for acceleration or on uphill grades).
• Depress the accelerator pedal beyond the full-load action
point (kickdown position).
NOTE
Use of the kickdown function increases fuel consumption.
2.9 Retarder operation
The retarder is a gear-dependent hydrodynamic brake which
operates without wear. The retarder should be used for every
braking action. This extends the life of the service brake. The
retarder can be operated via a hand lever and/or the brake
pedal.
When control takes place exclusively via the brake pedal, there
is usually a rocker switch “Retarder ON/OFF” on the instrument
panel.
In the event of hand lever control, the lever must be returned to
zero position after each braking action.
Consult the vehicle operating instructions for more details on
retarder control.
Operation
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Kickdown switch
Accelerator pedal
Full load
(action point)
Kickdown
(forced
downshift)
023629
Conditions for retarder operation
Retarder operation is accepted by the electronic control unit
only under the following conditions:
• Accelerator pedal in idling position
• A forward gear is engaged
• The driving speed exceeds approx. 3 km/h
• The ABS system is not active
If any one of these conditions is not fulfilled with the retarder
engaged, the retarder will be deactivated.
When the maximally permitted oil temperature according to
Chapter 2.12 is approached, the retarder's performance will
be reduced or the retarder will be disabled by the electronic
control unit.
DANGER!
Risk of accident due to reduced braking power!
The retarder must be deactivated using the “Retarder ON/OFF”
switch in the following cases:
• On icy roads.
If an electronic braking system (EBS) and/or antilock system
(ABS) is available, manual retarder shutdown is not required.
• When the permitted oil temperature acc. to Chapter 2.12 is
exceeded.
Options for manually deactivating the retarder:
• Set the "Retarder ON/OFF" switch to the OFF position
(if available)
• Set hand lever to zero position (if available)
• Depress pushbutton "N" on the pushbutton range selector
and thus engage transmission neutral
CAUTION
Only in emergencies on black ice if there is no other
option for switching off the retarder available.
Operation
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2.10 Stopping, parking
Stopping
The vehicle can be stopped at any time through activation of
the service brake, irrespective of the position of the pushbutton
range selector. In such a case, the electronic control unit will
engage the appropriate starting gear. Owing to the propulsion
of the converter, the vehicle may come to a standstill on a
slight grade even without actuation of the brake.
• Activate service or parking brake
In the event of a prolonged halt, the pushbutton selector should
be set to the neutral position.
DANGER!
If the brake is not activated, the vehicle may start
moving even without actuation of the accelerator
pedal.
Transmission with function “Automatic Idle Shift” (AIS)
The electronic control unit will set the transmission to “Neutral”
if the following conditions prevail simultaneously:
• Vehicle approaching standstill
• Service or parking brake activated
• Accelerator pedal in idling position
The range selected last on the pushbutton selector will be
retained. As soon as one of the three conditions no longer
prevails, the appropriate starting gear will be engaged.
Parking
• Activate the parking brake
• Then depress pushbutton “N” on the pushbutton range
selector
DANGER!
Before leaving the vehicle, always activate the parking
brake. When the engine is switched off, there is no
direct connection between engine and axle. The
vehicle can start to roll!
Operation
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2.11 Towing
2.11.1 Towing vehicle with coaxial transmission
2.11.1.1 Transmission is functioning
• Engine idling, if possible
• Pushbutton range selector in Neutral position
• Max. towing time: 2 hours
• Max. towing speed:
Intercity and city buses: 25 km/h
Coaches: 35 km/h
NOTE
At an ambient temperature below –15 °C, the maximally
permitted towing speed is 5 km/h.
2.11.1.2 Transmission damage suspected
CAUTION
If transmission damage is suspected, the propshaft flange
between transmission and drive shaft must be disconnected.
As an alternative, the input shafts can be removed at both
ends of the rear axle. Ensure with each measure/action
taken that the provisions of the vehicle and component
manufacturer are met in terms of vehicle safety and
environmental protection.
Exception:
In a dangerous situation, towing without separation of the drive
train is permitted until the vehicle has left the danger area (e.g.
intersection, tunnel, etc.).
Operation
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2.11.2 Towing vehicle with angle drive transmission
CAUTION
When a vehicle with angle drive transmission is towed, the
propshaft between transmission and powered axle must
always be disconnected.
As an alternative, the input shafts can be removed at both
ends of the rear axle. Ensure with each measure/action
taken that the provisions of the vehicle and component
manufacturer are met in terms of vehicle safety and
environmental protection.
Exception:
In a dangerous situation, towing without separation of the drive
train is permitted until the vehicle has left the danger area (e.g.
intersection, tunnel, etc.).
In such a case the following conditions apply:
• Engine idling, if possible
• Pushbutton range selector in Neutral position
• Max. towing time: 10 minutes
• Max. towing speed: 15 km/h
NOTE
At an ambient temperature below –15 °C, the maximally
permitted towing speed is 5 km/h.
Operation
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23
2.12 Temperature monitoring
The electronic control unit monitors the transmission
temperature. Oil sump temperature and the oil temperature on
the retarder output are sent to the vehicle computer via CAN.
Depending on the vehicle application, alert signals will be
issued when the permissible temperature limit values are
exceeded.
Consult the vehicle operating instructions for more details.
When the permissible temperature limit values are approached
during retarder operation, retarder performance will be
reduced by the electronic control unit.
Action to be taken in the event of a temperature alert:
• Drive in partial-load range
• Using the “Retarder ON/OFF” switch:
Deactivate the retarder
If this does NOT cause the oil temperature to drop:
• Stop the vehicle
• Put pushbutton range selector in Neutral position
• Run engine at raised idle speed
NOTE
If, after a few seconds, the temperature does not decrease to
the permitted range, this may be due to:
• Oil level too low or too high
• Contaminated vehicle heat exchanger
• Defective cooling circuit
• Transmission damage
Inform ZF Service Center!
Operation
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2.13 Status monitoring/warning lamps
The diagnosis system of the electronic control unit monitors
the transmission status whenever the vehicle circuit is
switched on and during operation.
Warning lamps
Faults are indicated by warning lamps lighting up (red or
yellow) and/or by warning messages which appear on the
driver’s display panel (consult the vehicle operating
instructions).
If a selected driving range is not accepted by the electronic
control unit, the pushbutton pressed on the pushbutton speed
range selector will flash (see Chapter 2.1.2).
2.14 Transmission response to a malfunction
To protect the transmission in the event of a malfunction, the
following responses are provided:
Shift into Neutral:
In the event of serious malfunctions in the power supply to the
transmission, e.g. short circuit.
Engagement of emergency operation mode (see Chapter
2.14.1):
If there is an interruption of CAN communication or a loss of
speed information.
DANGER!
The following applies in the event of a malfunction
of the transmission system:
• Serious risk of transmission damage
• Limited system monitoring
RISK OF ACCIDENT!
• Continuation of the trip is only allowed if the
utmost care is practiced by driving as slowly and
foresighted as possible.
Operation
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25
2.14.1 Emergency operation
Depending on the fault prevailing, the following limitations may
occur during emergency operation:
• Retarder function limited or not available
• Automatic Idle Shift (AIS) function not available
• No activation of the engine brake
• Torque converter lockup clutch (WK) open
• Limitation of engine torque for transmission protection
(no engine control)
• Poorer shifting quality or no gearchanges
Operation
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26
2.15 Use at low temperatures and longer downtimes
Vehicle manufacturer specifications must definitely be observed.
NOTE: Depending on the downtime period and previous development of ambient temperature, the transmission oil sump
temperature might be higher or lower than the current ambient temperature.
Operation
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Outside temperature Down to –20 °C –20 °C to –30 °C –30 °C to –40 °C
Oil grade
In accordance with ZF List
of Lubricants TE-ML 20
In accordance with ZF List
of Lubricants TE-ML 20
In accordance with ZF List
of Lubricants TE-ML 20
Engine start
Permitted Permitted Transmission must be preheated
before the engine is started.
When starting, note
‒
Warm-up phase of at least
10 minutes, with increased
idling speed of approx.
1500 rpm.
Transmission in Neutral
This can be done e.g. with warm air
which must not exceed 130 °C on
the transmission.
CAUTION: Do not heat up directly
at the transmission and/or in the
vicinity of the electronic control
unit and the wiring.
Limitations None The different functional restrictions are activated by the electronic
control unit during the warm-up period (maintaining neutral position
despite selected drive range via pushbutton range selector,
limitation of speed and torque).
27
2.15.1 Parking the vehicle at sub-zero temperatures
The vehicle may be parked or the transmission stored for long
periods down to an outside temperature of –40 °C.
Operation
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28
4181 758 101 - 2013-01
3 Maintenance
Regular and correctly performed maintenance is essential to
safeguard the operational safety of the transmission. It is
therefore of particular importance that maintenance intervals
are observed.
THREATS TO THE ENVIRONMENT!
Lubricants and cleaning agents must not be allowed
to enter the soil, ground water, or sewage system.
• Ask your local environmental protection agency
for safety data sheets on the relevant products
and adhere to their requirements.
• Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection regulations.
• When working with lubricants and cleaning agents
always observe the manufacturer’s instructions.
3.1 Oil grade
Only oil as specified by the ZF List of Lubricants TE-ML 20 may
be used to fill up EcoLife transmissions.
For the classification of your vehicle in terms of the maximum
allowable oil sump temperature, please refer to the operating
instructions of your vehicle. Subsequently, please use the oil
grades as released in accordance with the ZF List of Lubricants
TE-ML 20 and adhere to the change intervals stipulated for oil
and pressure filter.
The latest List of Lubricants can be obtained from all ZF Sales
& Service Centers or can be downloaded from the Internet at:
www.zf.com (Products & Services/Service Center).
Maintenance
29
3.2 Oil quantities
• For oil change with standard oil drain
(draining time approx. 10 min.) approx. 24 liters
• For oil change with
VRM special oil drain system approx. 17 liters
• For initial fill of dry transmission
– 6 AP 1000 B/1200 B/1400 B approx. 38 liters
– 6 AP 1700 B/2000 B approx. 42 liters
– 6 AP 100x B/120x B/
6 AP 140x B/170x B approx. 43 liters
NOTE
These values are reference values!
The definitive oil quantity is the one determined by oil level
check at operating temperature (90 °C).
3.3 Oil level check
CAUTION
It is absolutely necessary to maintain the correct oil level:
• Insufficient oil leads to transmission malfunctions
and transmission damage.
• Too much oil causes overheating of the transmission.
DANGER!
Insufficient oil leads to partial or complete failure of
the retarder, i.e. braking action is impaired or not
available.
Valid in general:
• Top up transmissions that are supplied in non-oil-filled
condition with the status oil qualities prior to initial
operation
• In order to ensure minimum oil volumes for initial operation
or after an oil filling (e.g. oil change, repair), an initial check
is to be conducted with cold transmission oil, refer to
Chapter 3.3.1.
• The decisive oil level check is to be implemented at an
operating temperature (of 90 °C), see Chapter 3.3.2
• For transmission oil heating options, see Chapter 3.3.4
• At least, conduct quarterly oil level check
• Conduct regular visual inspections in terms of transmission
leakages
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Maintenance
30
4181 758 101 - 2013-01
Maintenance
3.3.1 Initial check of the oil level in order to ensure a minimum oil quantity
NOTE
For commissioning or after an oil filling (e.g. oil change,
repair), an initial check of the oil level has to be conducted
after engine start to ensure the minimum oil quantity.
Oil level check with cold transmission oil (30 °C):
• The vehicle must be parked on level ground.
• Shift the speed range selector (pushbutton range selector)
to "neutral".
• Let engine run for 15 to 20
seconds at 1200 – 1500 rpm.
• Let engine run with idling speed.
CAUTION
The idle speed should be set
to between 500 and 700 rpm.
It must never drop below
400 rpm.
• Oil level must be within
“30 °C (cold)” range
3.3.2 Relevant oil level check at operating temperature
Oil level check with hot transmission oil (90 °C):
• The vehicle must be parked on level ground.
•• Shift the speed range selector (pushbutton range selector)
to "neutral".
• Let engine run for 15 – 20 seconds at 1200 – 1 500 rpm.
• Let engine run with idling speed.
CAUTION
The idle speed should be set
to between 500 and 700 rpm.
It must never drop below
400 rpm.
• Oil level must be within
“90 °C (hot)” range.
031567
} 30 °C “cold”
031567
} 90 °C “hot”
31
3.3.3 Electric oil level check
The Technical Customer Information “Electric Oil Level Sensor
EcoLife, 4181 761 022” is obligatory.
3.3.4 Option for heating-up the transmission oil
The transmission oil can be heated up to its specified operating
temperature for oil check purposes by running the vehicle with
retarder cycles until the oil sump temperature reaches 90 °C.
CAUTION
The maximum admissible oil temperature in the oil sump
is determined by the classification of your vehicle in
accordance with the ZF List of Lubricants TE-ML 20.
For details, please consult the vehicle's operating
instructions.
When the operating temperature is reached carry out
“Check at operating temperature 90 °C” (Chapter 3.3.2).
3.4 Oil change intervals
• The specifications contained in the ZF List of Lubricants
TE-ML 20 are binding.
• For the respective classification of your vehicle, please refer
to the operating instructions of your vehicle.
CAUTION
The pressure filter must be renewed each time the oil is
exchanged.
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Maintenance
32
3.5 Variant 1 – Oil change with standard oil drain
3.5.1 Oil drain
(see Fig. 3.1)
NOTE
Only drain oil at operating temperature and for at least
10 minutes:
• Engine standstill
• Unscrew oil drain plug (1) and drain oil.
• Unscrew filter cover (2) and drain oil from the filter
chamber.
• Replace filter cartridge (pressure filter) and O-ring on filter
cover and on th oil drain plug.
NOTE
Pressure filter must be replaced during oil change.
ZF 80° angle drive RHD/LHD
The angle drive does not have its own oil drain plug.
Drain oil through main transmission’s oil drain plug as
described in Chapter 3.5.1.
3.5.2 Oil fill
(see Fig. 3.1 to 3.4)
• Tighten filter cover (2).
Tightening torque: 29 Nm
NOTE
Be aware of different screw lengths.
• Screw in oil drain plug (1):
Tightening torque: 35 Nm
CAUTION
Always use genuine ZF oil drain plugs.
The converter drain valve is activated via the ZF oil drain
plug.
• Fill in oil acc. to Chapter 3.2 on oil filler pipe (4).
• Check oil level on oil dipstick (5), see Chapter 3.3.
• For the oil grade, see Chapter 3.1.
Maintenance
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33
Maintenance
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Fig. 3.1 Coaxial transmission with standard oil drain
Fig . 3.3 Transmission with angle drive of 80°, RHD
Fig . 3.4 Transmission with angle drive of 80°, LHD
Fig . 3.2 Coaxial transmission
035580
035560_1 035561_1
035559_1
2
1
5
4
4/5
5
4
3.6 Variant 2 – Oil change with VRM special oil drain
3.6.1 Oil drain
NOTE
– Oil drain only at operating temperature
– For oil draining with the VRM special oil drain, a torque
converter draining is not performed
– For VRM special oil drain, a harmonization and approval from
the "Sales and Application" department is required for the
specification of the oil and filter change intervals.
• Engine standstill
• Unscrew special screw plug (6.1 or 6.2, depending on
installation position) and drain oil via quick plug system.
• Unscrew filter cover (2) and drain oil from the filter chamber.
• Replace filter cartridge (pressure filter) and O-ring at filter
cover and at oil drain plug.
NOTE
Pressure filter must be replaced when oil is changed.
3.6.2 Oil fill
(see Fig. 3.2 to 3.5)
• Tighten filter cover (2).
Tightening torque: 29 Nm
NOTE
Be aware of different screw lengths.
• Screw in special screw plug (6.1 or 6.2, depending on
installation position).
Tightening torque: 10 Nm
• Fill in oil at oil filler pipe (4) according to Chapter 3.2.
• Check oil level at oil dipstick (5), refer to Chapter 3.3.
• Oil grade, see Chapter 3.1.
34
Maintenance
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035581
Fig. 3.5 Coaxial transmission with VRM special oil drain
2
6.1
6.21
35
3.7 Engine coolant
The transmission's cooling system is connected to the engine's
cooling circuit. The composition of the engine coolant
specified by the vehicle manufacturer (water/coolant additive)
as well as the stipulated change intervals must be adhered to.
The respectively necessary information can be taken from the
vehicle's operating instructions.
CAUTION
Non-observance in this context may lead to corrosion
damage at the transmission's cooling system.
ZF's minimum requirements vis-à-vis the engine's coolant
for avoiding corrosion can be obtained, if required, via ZF
Services.
Maintenance
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36
4181 758 101 - 2013-01
Troubleshooting Instructions
Error Possible cause Remedial action
Engine will not start Pushbutton range selector not in “Neutral” Select “Neutral” on range selector
Connector of the electronic control unit is loose Establish plug connection
Starting interlock relay defective or missing Replace relay or check CAN signal
CAN signal via CAN
Transmission does not Accelerator pedal not in idle position or Check accelerator pedal/injection pump
engage any gears load signal too high or adjust it
Engine idle speed > 900 rpm Set engine idle speed
Transmission oil sump temperature below –20 °C Warm up engine for approx. 5 minutes
Only on transmissions with additional function
“Gear release”:
Neither service brake nor parking brake activated Activate ser vice or parking brake
Electronic control unit in malfunction setting Turn off the engine and start it again
Vehicle does not move Oil level too low Check/correct oil level
Transmission defective Call ZF Service
Oil temperature too high Oil level too high Check/correct oil level
Retarder engaged Deactivate retarder (via hand lever or
rocker switch)
Transmission damage Call ZF Service
Vehicle radiator dirty Clean the radiator
No retarder effect Oil level too low Check/correct oil level
Retarder proportional valve or solenoid valve Check CAN signal and retarder connector
not working, CAN signal not present signal
37
ZF Friedrichshafen AG
88038 Friedrichshafen
Deutschland · Germany
Telefon/Phone +49 7541 77-0
Telefax/Fax +49 7541 77-908000
www.zf.com
EN 4181 758 101c - 2013-01
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