ZF-ECOMAT 2 plus HP 502 HP 592 HP 602 Installation, Functions, & Initial Start-Up Technical Manual 4149765103 – PDF DOWNLOAD
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ZF-ECOMAT 2 plus HP 502 HP 592 HP 602 Installation, Functions, & Initial Start-Up Technical Manual 4149765103 – PDF DOWNLOAD
Language : English
Pages : 186
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
ZF-ECOMAT 2 plus HP 502 HP 592 HP 602 Installation, Functions, & Initial Start-Up Technical Manual 4149765103 – PDF DOWNLOAD
Transmission brief description:
ZF Ecomat transmissions from ranges HP 502,
HP 592, and HP 602 can be used in multiple appli- cations in commercial and special vehicles. It is
possible to select between 5 or 6-speed transmissions to cover all requirements – from fitting in a
city bus to use in a long-distance coach. To ensure the broadest possible range of applications,
Ecomat transmissions can be fitted with many auxiliaries.
They have been designed to comply fully with today’s requirement of traffic safety and optimum
economy.
HP 592, and HP 602 offer the following advantages:
engine and driveline.
Substantial cost savings are also achieved by extending the service life of wheel brake linings.
restriction of converter operation to the initial driving phase.
safety.
fic conditions or even with drivers who have no
practice with it.
TABLE OF CONTENTS:
ZF-ECOMAT 2 plus HP 502 HP 592 HP 602 Installation, Functions, & Initial Start-Up Technical Manual 4149765103 – PDF DOWNLOAD
Technical Manual ZF-ECOMAT 2 plus................................................................................... 1 4149 765 103.................................................................................................... 1 Copyright by ZF Edition: 2004-12................................................................................ 2 Important Information........................................................................................... 3 Contents........................................................................................................ 4 1 System solution Ecomat 2 plus................................................................................. 10 1.1 System solution Ecomat 2 plus (with CAN)................................................................ 10 1.2 System solution Ecomat 2 plus........................................................................... 11 1.3 System solution Ecomat 2 plus........................................................................... 12 2 Description of transmission and............................................................................... 14 2.1 Transmission brief description.......................................................................... 14 2.2 Transmission structure and auxiliaries.................................................................. 16 2.3 Transmission ratios and powerflow diagram............................................................... 18 2.4 Torque assignment - vehicle weight...................................................................... 20 2.5 Torsional vibration in driveline – inertia.............................................................. 21 2.6 Weights and inertia torque values....................................................................... 25 2.6.1 Coaxial output without heat exchanger J08......................................................... 25 2.6.2 Coaxial output with heat exchanger J01............................................................ 26 2.6.3 Coaxial output with heat exchanger J05............................................................ 27 2.6.4 Coaxial output with heat exchanger J10............................................................ 28 2.6.5 Angle drive 80° without offset, with heat exchanger J05........................................... 29 2.6.6 Angle drive 80° without offset, with heat exchanger J10........................................... 30 2.6.7 Angle drive 80° RHD (with right offset), with heat exchanger J05.................................. 31 2.6.8 Angle drive 80° RHD (with right offset), without heat exchanger J08............................... 32 2.7 Clutch combinations..................................................................................... 33 3 Ecomat installation position in vehicle....................................................................... 34 4 Installation arrangement and mountings........................................................................ 35 4.1 Transmission flange-mounted on engine................................................................... 35 5 Guidelines for propshaft installation......................................................................... 36 5.1 Permissible rotational irregularity..................................................................... 36 5.2 Permitted resultant deflection angle for................................................................ 37 5.3 The permitted resultant flexure angle for all........................................................... 38 5.4 Single-section propshafts............................................................................... 39 5.5 Multi-section propshafts................................................................................ 39 5.6 Maximum permissible propshaft length.................................................................... 40 6 Engine connection............................................................................................. 41 Variant 1................................................................................................... 42 Variant 2................................................................................................... 43 6.1 ZF Scope of delivery.................................................................................... 44 6.2 Engine connection inspection............................................................................ 44 6.3 Engine connection: Further information.................................................................. 44 6.4 Engine connection drawings.............................................................................. 45 6.5 Overview converter-circuit cover........................................................................ 47 7 Converter..................................................................................................... 48 7.1 Torque converter: Description........................................................................... 48 7.2 Converter functions..................................................................................... 48 7.3 Getting the right torque converter for your............................................................. 50 7.4 Torque converter diagram................................................................................ 51 7.5 Torque converter basic curves........................................................................... 53 W360*TPC210*MUE2.43..................................................................................... 54 W360*TPC262*MUE2.40..................................................................................... 55 W360*TPC300*MUE2.36..................................................................................... 56 W360*TPC342*MUE2.27..................................................................................... 57 W360*TPC390*MUE2.17..................................................................................... 58 W390*TPC392*MUE2.20..................................................................................... 59 W390*TPC487*MUE1.98..................................................................................... 60 W390*TPC615*MUE1.83..................................................................................... 61 8 Retarder...................................................................................................... 62 8.1 Structure and function of retarder...................................................................... 62 8.2 Retarder action......................................................................................... 63 8.4 Retarder and engine brake............................................................................... 64 8.5 Retarder activation variants............................................................................ 65 8.5.1 Permitted variants “foot request” without......................................................... 66 8.5.2 Permitted variants “foot request”................................................................. 67 8.5.3 Permissible retarder activation variants.......................................................... 68 Retarder activation variants........................................................................ 69 9 Cooling system................................................................................................ 70 9.1 Design of cooling system................................................................................ 70 9.1.1 Release criteria for temperature measurements..................................................... 70 9.1.2 Limit temperature values for oil temperature...................................................... 71 9.1.3 Cooling system with retarder...................................................................... 71 9.1.4 Cooling system without retarder................................................................... 72 9.2 Position of transmission oil cooler..................................................................... 73 9.3 Cooler fitted on transmission........................................................................... 73 9.4 Layout with oil cooler separate from.................................................................... 73 9.5 Cooling water circuit................................................................................... 74 9.6 Specification for transmission heat..................................................................... 77 9.7 Required performance of cooling water and............................................................... 77 9.8 Transmission fill with auxiliary cooling................................................................ 78 9.9 Transmission oil sump cooling........................................................................... 79 9.10 Temperature measurements in bus........................................................................ 80 9.10.1 Measurement conditions / Retarder test........................................................... 80 9.10.2 Measurement retarder cycles...................................................................... 80 9.10.3 Calculation...................................................................................... 80 9.10.4 Explanation of water temperature................................................................. 81 9.10.5 Temperature measuring points..................................................................... 81 10 Transmission specification................................................................................... 83 10.1 Installation position.................................................................................. 84 10.1.1 Flange-mounted installation position............................................................. 84 10.2 Heat exchanger arrangement............................................................................. 85 10.2.1 Coaxial output, heat exchanger at rear, accumulator horizontal on left........................... 85 10.2.2 Coaxial output, heat exchanger at rear, accumulator rear transverse.............................. 86 10.2.3 Coaxial output or 80° angle drive RHD (with axial offset),....................................... 87 10.2.4 Angle drive 80° LHD (without axial offset), heat exchanger horizontal on left,................... 88 10.2.5 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left................. 89 10.2.6 Coaxial output, vertical heat exchanger on right, accumulator rear transverse.................... 90 10.2.7 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting........... 91 10.2.7.1 Cooler connection piece with threaded connection........................................... 92 10.3 Oil pan................................................................................................ 93 10.3.1 Deep oil pan, 4149 131 002....................................................................... 93 10.3.2 Deep oil pan; left- and right-hand connection prepared, 4149 131 006............................. 94 10.3.3 Deep oil pan, auxiliary cooling, 4149 131 024.................................................... 95 10.3.4 Flat oil pan, 4149 131 010....................................................................... 96 10.3.5 Flat oil pan; left- and right-hand connection prepared, 4149 131 009............................. 97 10.4 Oil filling............................................................................................ 98 10.4.1 Oil filling <K 01>............................................................................... 98 10.4.2 Oil filling <K 02>, <K 04>, <K 05>............................................................... 99 10.4.3 Oil filling <K03>, <K 06>........................................................................100 10.4.4 Oil filling <K 09>...............................................................................101 10.5 Output.................................................................................................102 10.5.1 Coaxial output...................................................................................102 10.5.2 80° angle drives.................................................................................103 10.5.3 Output flange 80° angle drive LHD................................................................104 10.5.4 Ecomat output flange; coaxial and angle drive 80° RHD with axial offset..........................105 11 Hydraulic circuit diagrams...................................................................................106 11.1 Hydraulic description..................................................................................107 11.2 Hydraulic diagram (with Bus Stop Neutral / NBS)........................................................108 12 Peripheral equipment.........................................................................................109 12.1 Speed range selector - push button switch..............................................................109 12.2 CAN range selector.....................................................................................112 12.3 Load sensor A 3........................................................................................113 12.3.1 Function.........................................................................................113 12.3.2 Load sensor drawing..............................................................................114 12.4 PWM-Signal.............................................................................................115 12.4.1 Calibration of the PWM Signal, Positive..........................................................115 12.4.2 Sensing ratio....................................................................................116 12.4.3 Signal Spezification.............................................................................116 12.5 Additional temperature sensor A6 for...................................................................117 12.6 Temperature display A5.................................................................................118 12.7 Kick down switch.......................................................................................119 12.8 Pressure switch S7 - NBS (Neutral when.................................................................120 12.9 Changeover relay, e.g. range selector relay............................................................121 13 Neutral at standstill........................................................................................122 13.1 Description............................................................................................122 13.2 Connection diagram (electric)..........................................................................123 13.3 Neutral at Bus Stop - display..........................................................................124 13.3.1 NBS active display via digital signal............................................................124 14 Temperature monitoring.......................................................................................125 14.1 Temperature information via CAN........................................................................125 14.2 Temperature information via temperature................................................................125 14.3 Temperature information from DM1 note..................................................................125 14.4 Temperature warnings...................................................................................125 14.5 Addtional temperature sensor A6........................................................................126 14.6 Temperature display gauge A5...........................................................................127 14.7 Resistance characteristics - Temperature sensor........................................................128 15 Electronic automatic control system..........................................................................129 15.1 Function description...................................................................................129 15.2 Intended standard functions............................................................................129 15.3 Functions available on request.........................................................................130 15.4 Installation requirements.............................................................................130 15.5 Technical data of EST 146 / 147........................................................................131 15.6 Installation drawings..................................................................................133 15.6.1 Installation drawing EST 146.....................................................................133 15.6.2 Installation drawing EST 147.....................................................................134 15.7 Current circuit diagrams...............................................................................135 15.7.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector....................135 15.7.2 Current circuit diagram EST 146 / EST 147 with CAN, with CAN range selector......................136 15.7.3 Current circuit diagram EST 146 / EST 147 without CAN(NEng), with digital range selector.........137 15.8 Pin pattern............................................................................................138 15.9 Connection diagrams....................................................................................139 15.9.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 1............139 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 2...............140 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 3...............141 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, page 4...............142 15.9.2 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 1................143 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 2...................144 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 3...................145 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, page 4...................146 15.9.3 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 1....147 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 2.......148 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 3.......149 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, page 4.......150 15.10 Function description EST 146 / 147....................................................................151 15.11 ZF-Diagnosis systems..................................................................................158 15.11.1 ZF-Diagnosis protocols..........................................................................158 15.11.2.1 ZF-Testman pro................................................................................158 15.11.2.2 Flash code output EST 146/147.................................................................161 15.12 HST 46 auxiliary control unit.........................................................................163 15.12.1 Operating manual for HST 46.....................................................................163 15.12.2 Technical data of HST 46........................................................................163 15.12.3 Dimensions of HST 46............................................................................164 15.13 Block diagram EST 146.................................................................................165 15.14 Block diagram EST 147.................................................................................166 16 Wiring.......................................................................................................167 16.1 Complete wiring - Standard.............................................................................167 16.2 Complete wiring - with junctions.......................................................................167 16.3 Wiring connection......................................................................................167 16.4 Wiring specifications..................................................................................168 17 ZF documentation.............................................................................................170 17.1 ZF documentation with CAN..............................................................................170 17.1.1 Components.......................................................................................170 17.1.2 Identification and engine compatibility data.....................................................171 17.2 ZF documentation without CAN...........................................................................172 17.2.1 Components.......................................................................................172 17.2.2 Identification and engine compatibility data.....................................................173 17.3 Oil level check........................................................................................174 17.3.1 Oil level check prior to first commissioning;....................................................174 17.3.2 Oil level check prior to first commissioning;....................................................175 17.3.3 Oil level check prior to first commissioning;....................................................176 18 Calculations and conversion tables...........................................................................177 18.1 Driveline design.......................................................................................177 18.2 Collective formulae for retarder and cooler............................................................178 18.3 Conversion tables......................................................................................179 18.3.1 Units of length..................................................................................179 18.3.2 Units of area....................................................................................179 18.3.3 Units of volume..................................................................................180 18.3.4 Units of energy..................................................................................180 18.3.5 Units of mass....................................................................................181 18.3.6 Force units......................................................................................182 18.3.7 Power units......................................................................................183 18.3.8 Temperature conversions..........................................................................183 18.3.9 Moment of inertia conversion factors.............................................................184 18.4 Torque.................................................................................................184 18.5 List of dynamic tire radii.............................................................................184 19 Oil grades and oil filters...................................................................................186 19.1 List of Lubricants TE-ML 14............................................................................186 19.2 Purity of medium.......................................................................................186 19.3 Oil filter.............................................................................................186
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