ZF Ecolife Operating Instructions
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
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