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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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Important 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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Table of Contents
1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2Transmission configuration and add-on parts . . . . 8
1.3 System solution ZF-EcoLife . . . . . . . . . . . . . . . . . . 10
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.1Pushbutton 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
2.4.2.2Additional 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 |
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3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.1 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.2 Oil quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1Initial check of the oil level in order to ensure
a minimum oil quantity . . . . . . . . . . . . . . . . . . . . . 30
3.3.2Relevant 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 |
3.6Variant 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
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Description
1Description
1.1Assemblies
These EcoLife transmissions consist of a hydrodynamic torque converter with a lockup clutch and a downstream 6-speed planetary transmission.
Torque converter
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.
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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.
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Description
1.2Transmission 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
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Description
•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.
035560 |
Fig. 1.2 Transmission with flange-mounted angle drive of 80° (RHD)
•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.
035561
Fig. 1.3 Transmission with flange-mounted angle drive of 80° (LHD)
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Description
1.3 System solution ZF-EcoLife
Key to drawing |
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Accelerator pedal |
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Vehicle-CAN |
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Cable connection between |
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Engine |
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On-board computer |
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the electronic control unit and |
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the transmission |
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Brake system |
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Electronic control unit |
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ZF-CAN |
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Electronic control unit's |
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connector |
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E-Modul |
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Oil filler tube with oil |
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Speed range selector |
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dipstick |
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2 3 D N |
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Tachometer impulse sensor |
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Diagnosis Tool |
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(optionally 10 o’clock/ |
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14 o’clock) |
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• EOL |
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• Diagnosis |
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6 |
Cooling water connections |
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• Measuring |
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Pressure filter |
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Signal |
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• Parameterization |
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Oil pan |
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converter |
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Oil drain plug |
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Vent |
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Vehicle electric system |
“Vehicle CAN” |
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– Speed range selector |
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– Engine/On-board |
computer/ |
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(pushbutton range selector) |
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brake system |
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– Inputs |
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– Accelerator pedal |
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–Kickdown, retarder lever, |
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– Kickdown, retarder lever, |
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foot pedal |
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foot pedal |
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– Outputs |
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12 |
ZF peripheries “ZF CAN” |
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– Diagnosis interface ZF (12.1) |
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– E module 2 (optional) |
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Diagnosis tools ZF-Testman |
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– Inputs |
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– Diagnosis |
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–Kickdown, retarder lever, |
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– EOL |
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foot pedal |
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– Measuring |
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– Outputs |
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– Parameterization |
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10 |
1 |
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7 |
4 |
5 |
6 |
035558_en
8 |
9 |
4181 758 101 - 2013-01 |
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Description
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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Operation
2Operation
2.1Pushbutton 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
029415
Pushbutton control with diagnostics connector, variant with 6 pushbuttons, horizontally arranged (details may be different from illustration).
029416
Cover for diagnostics connector open
029417
Diagnostic cable connected
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