Operating Instructions

BusZF-EcoLifefor 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 criminalprosecution.This document is a translation of the German original.

Preface

Before operating the vehicle for the first time, please note thefollowing points:

• Read these Operating Instructions carefully and observe allsafety instructions.

• To ensure operational safety and reliability of thetransmission, always observe the maintenance instructions.

The ZF Customer Service specialists are available to assist youin carrying out transmission maintenance work or to help if anyproblems arise. You will find the addresses in the “ZF Company Directory”(order number 0000 762 703) or on the Internet underwww.zf.com (Company/ZF worldwide).You will find more product information on the Internet bylogging on to www.zf.com (Products & Services/ProductRange Buses).

NOTEAll details in these Operating Instructions refer to the basicversion of the ZF-EcoLife transmission.Due to the large number of installation options, no preciseinformation can be provided for any specific vehicle.If there should be any deviating operating instructions asregards this brochure and the Operating Instructions specific to an individual vehicle manufacturer, the vehicle-specificinstructions will be binding.

Motoring pleasure with the ZF-EcoLife is brought to you by

ZF Friedrichshafen AGD-88038 FriedrichshafenPhone: +49 (0) 7541 77-0Fax: +49 (0) 7541 77-90 80 00Internet: www.zf.com

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The following safety instructions are used with the presentoperating instructions:

NOTEReference is made to special procedures, methods,information, etc.

CAUTIONUsed when deviating, unprofessional operation can damagethe product.

DANGER!This is used when lack of care could lead to personalinjury or material damage.

THREATS TO THE ENVIRONMENT!Lubricants, consumables and cleaning agents must not be allowed to enter the soil, ground water, orsewage 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 agentsalways observe the manufacturer’s instructions.

NOTE on cleaning the vehicle/transmission

CAUTIONWhen cleaning, make sure not to point the steam cleaner or high-pressure cleaner directly at the breather, nor theelectronic control unit, or the plug-in connections. Ingress ofwater may lead to operational malfunctions and transmissiondamage! – Breather, see Chapter 1.3, item 10 – Electronic control unit and connector, see Chapter 1.3,items 1, 2, and 3

Important Safety Information

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1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 Transmission configuration and add-on parts . . . . 81.3 System solution ZF-EcoLife . . . . . . . . . . . . . . . . . . 10

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.1 Pushbutton control with diagnostics connector . . 122.1.1 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.1.2 Pushbutton illumination . . . . . . . . . . . . . . . . . . . . 132.1.3 Pushbutton selector position . . . . . . . . . . . . . . . . . 142.2 Driving ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.3 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 142.4 Engaging a gear . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4.1 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4.2 Transmission with additional functions . . . . . . . . . 162.4.2.1 Additional function “gear release” . . . . . . . . . . . . . 162.4.2.2 Additional function “additional pushbutton

reverse gear” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.5 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.6 Downhill driving . . . . . . . . . . . . . . . . . . . . . . . . . . 172.7 Change in direction of travel . . . . . . . . . . . . . . . . . 172.8 Kickdown (forced downshift) . . . . . . . . . . . . . . . . 182.9 Retarder operation . . . . . . . . . . . . . . . . . . . . . . . . 182.10 Stopping, parking . . . . . . . . . . . . . . . . . . . . . . . . . 202.11 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212.11.1 Towing vehicle with coaxial transmission . . . . . . . . 212.11.1.1 Transmission is functioning . . . . . . . . . . . . . . . . . . 212.11.1.2 Transmission damage suspected . . . . . . . . . . . . . 212.11.2 Towing vehicle with angle drive transmission . . . . 22

2.12 Temperature monitoring . . . . . . . . . . . . . . . . . . . . 232.13 Status monitoring/warning lamps . . . . . . . . . . . . . 242.14 Transmission response to a malfunction . . . . . . . . 242.14.1 Emergency operation . . . . . . . . . . . . . . . . . . . . . . 252.15 Use at low temperatures and longer downtimes . . 262.15.1 Parking the vehicle at sub-zero temperatures . . . . 27

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.2 Oil quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.3.1 Initial check of the oil level in order to ensure

a minimum oil quantity . . . . . . . . . . . . . . . . . . . . . 303.3.2 Relevant oil level check at operating temperature . 303.3.3 Electric oil level check . . . . . . . . . . . . . . . . . . . . . 313.3.4 Option for heating-up the transmission oil . . . . . . 313.4 Oil-change intervals . . . . . . . . . . . . . . . . . . . . . . . 313.5 Variant 1 – Oil change with standard oil drain . . . 323.5.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.5.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.6 Variant 2 – Oil change with VRM special oil drain . 343.6.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.6.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.7 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 torqueconverter with a lockup clutch and a downstream 6-speedplanetary transmission.

Torque converter

The hydrodynamic torque converter, which uses the Trilokprinciple, is a wear-free starting element equipped with astator freewheel and an integrated lockup clutch. The converteroperates only during the starting process and is automaticallybypassed when the clutch closes. As a result, losses occurring in the converter are eliminated.

Torsional vibration dampers

All converter types are equipped with torsional vibrationdampers allowing not only better driving comfort but alsoreduction of fuel consumption as a result of lowered shiftingspeeds.

Retarder

Retarder equipment is standard for all transmission versions.The integrated hydrodynamic retarder is arranged in the basictransmission 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 isincreased by the respective transmission ratio. As a result, ahigh retarder brake torque is available in the lower gears, andcan be used almost until vehicle standstill. As long aspermissible values are observed, this can be parameterized atwill, which permits adaptation to individual applications or thewishes of customers.

Retarder control is normally managed through actuation of the brake pedal. The electronic control unit converts the brakesignal is into a braking torque, either in steps or in acontinuously variable manner.

Via CAN, the retarder can be combined with other brakesystems. When this is done, the maximally permitted sum ofbrake torques must be taken into account. Optionally, or in combination with the brake pedal, the retardercan also be operated via a hand lever.

Description

Planetary transmission

The planetary transmission, next in line after the torqueconverter, is designed as a 6-speed unit. It represents a linkedsystem of simple planetary gear sets (not a group-type design).The gears in the planetary transmission are selectedautomatically and without any interruption of traction.

The signals for individual gearshifts are supplied by theelectronic control unit. Depending on various operatingvariables of engine, vehicle, brake system, etc., thecorresponding multidisk clutches or brakes are controlled via the electrohydraulic control unit.

Electrohydraulic control unit

The transmission is equipped with an electrohydraulic controlunit. The electro-hydraulic shift control unit obtains the shiftcommands from the electronic control unit. Proportionalsolenoid 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 electroniccontrol unit, the following variants exist:

• Coaxial transmission version with heat exchangersdirectly attached.

On the coaxial standard transmission, the retarder heatexchanger is mounted on the output end and the transmissionheat exchanger is arranged laterally.

035559Fig. 1.1 Coaxial transmission

9

Description

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• Transmission with flanged-on angle drive 80° (RHD) anddirectly attached heat exchangers.

An angle drive of 80° (RHD) can be flange-mounted to thebasic transmission. Special retarder heat exchangerarrangements are made available for this purpose.

• Transmission with flanged-on angle drive 80° (LHD) anddirectly attached heat exchangers.

An angle drive of 80° (LHD) can be flange-mounted to thebasic transmission. Special retarder heat exchangerarrangements are made available for this purpose.

Fig. 1.2 Transmission with flange-mountedangle drive of 80° (RHD)

Fig. 1.3 Transmission with flange-mountedangle drive of 80° (LHD)

035560 035561

10

1.3 System solution ZF-EcoLife

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Description

1 2

3

5 64

10

7

8 9

11

12

1312.1

Kick-Down

Retarder lever

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

1 2 3 D N R

Accelerator pedalKey to drawing

1 Cable connection between the electronic control unit and the transmission

2 Electronic control unit3 Electronic control unit's

connector4 Oil filler tube with oil

dipstick5 Tachometer impulse sensor

(optionally 10 o’clock/ 14 o’clock)

6 Cooling water connections7 Pressure filter8 Oil pan9 Oil drain plug10 Vent11 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

– 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

035558_en

11

Brief description

The system diagram illustrates possible system solutions for theZF-EcoLife with all requisite individual components.

The EcoLife transmission is connected to the vehicle powersupply via the vehicle CAN, and via the ZF CAN with the rangeselector, the optional E-module 2, and the diagnosis tool.

The electronic control unit controls and monitors the EcoLifetransmission and features all standard diagnostic protocols. Theelectronic control unit records vehicle and transmission inputvariables communicated via CAN and converts them intosignals to control the transmission's hydraulic control elements.

The driver can intervene actively in the EcoLife control systemusing:

– 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 (permantillumination).

• The kickdown function can be used to move shift pointstowards higher engine speeds, so the transmission remainsin each gear longer during acceleration and shifts out ofeach 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 forpushbutton illumination. Turning the vehicle key into driving position causes the systemto perform an automatic illumination test. All pushbuttons willbe illuminated for approx. 1.2 seconds at level 2 before thesystem changes to level 1 for easier location of thepushbuttons.

After pressing the pushbutton, it will be illuminated at level 2as soon as it is accepted by the electronic control unit(functional illumination).

Display of errors:

• Illumination level 1 is retained despite depressedpushbutton

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 controlunit (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

NOTEIf several pushbuttons are selected at the same time, thesmallest 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 therespective pushbuttons of the pushbutton range selector (cf.Chapter 2.1). Consult the vehicle operating instructions forprecise information about the gears engaged in each of thespeed ranges.

A defined range of gears is assigned to each driving range. The electronic control unit determines the shift points at whichgear 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 drivingoperation, the power flow between engine and outputwill be interrupted. Engine and retarder braking action are then lost.Risk of accident! – Apply the brake!For safety reasons, when faults occur in the electroniccontrol unit or whenever there is a power failure, thetransmission 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”)

NOTEStarting interlock: If the pushbutton selector is not in neutralposition, engine start will as a rule be prevented. For detailsconsult the vehicle operating instructions of the vehiclemanufacturer.

Operation

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It may be possible to start the engine when the pushbuttonselector is not in neutral position. In such a case, thepushbutton depressed will flash after the engine starts (cf.Chapter 2.1.2), and the transmission will remain in Neutral. Todrive off, the pushbutton “N” will then have to be depressedand subsequently (acc. to Chapter 2.4) the desired driving-range pushbutton on the pushbutton range selector.

CAUTIONOnly jump-start on the battery, never on the starter! Do notturn the vehicle key while driving!

2.4 Engaging a gear

CAUTIONNever operate the pushbutton range selector and step onthe accelerator at the same time!

2.4.1 Standard

• Accelerator pedal in idling position • neng < 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 isprevented by the electronic control unit in spite of a selecteddriving range (pushbutton depressed). In such cases, thepushbutton depressed will flash (cf. Chapter 2.1.2):

• Accelerator pedal operated • neng > 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, recommendedby ZF!)

In addition to the cases mentioned under 2.4.1, engagement of a starting gear is prevented by the electronic control unit inspite of a selected driving range (pushbutton depressed) in thefollowing case. In this case, the push button depressed willflash (cf. Chapter 2.1.2):

• Neither service nor parking brake activated

Operation of the service or parking brake will cause thestarting gear to engage and the depressed pushbutton willchange from flashing to functional illumination.

2.4.2.2 Additional function “additional pushbutton reverse gear”

For engagement of the reverse gear, depress the R pushbuttonof the pushbutton range selector and promptly also the Rpushbutton on the instrument panel.

Remaining procedure as described under 2.4.1. In addition tothe cases mentioned under 2.4.1, engagement of the reversegear will be prevented by the electronic control unit in spite ofthe depressed R pushbutton of the pushbutton range selectorin the following case. In this case, the R pushbutton depressedwill 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, thevehicle may start at low speed on a level track or on a slightuphill grade after release of the brake. If a lower driving speedis desired, this must be realized through operation of the brakepedal.

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 accelerationwhen starting near persons or obstacles in order to ruleout 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 situationmay 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 thehighest 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 berealized via the kickdown switch (see illustration) or the CANsystem (for acceleration or on uphill grades).

• Depress the accelerator pedal beyond the full-load actionpoint (kickdown position).

NOTEUse of the kickdown function increases fuel consumption.

2.9 Retarder operation

The retarder is a gear-dependent hydrodynamic brake whichoperates without wear. The retarder should be used for everybraking action. This extends the life of the service brake. Theretarder can be operated via a hand lever and/or the brakepedal.

When control takes place exclusively via the brake pedal, thereis usually a rocker switch “Retarder ON/OFF” on the instrumentpanel.

In the event of hand lever control, the lever must be returned tozero position after each braking action.

Consult the vehicle operating instructions for more details onretarder control.

Operation

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Kickdown switch

Accelerator pedal

Full load(action point)

Kickdown(forceddownshift)

023629

Conditions for retarder operation

Retarder operation is accepted by the electronic control unitonly 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 retarderengaged, the retarder will be deactivated.

When the maximally permitted oil temperature according toChapter 2.12 is approached, the retarder's performance will be reduced or the retarder will be disabled by the electroniccontrol 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 isexceeded.

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 selectorand thus engage transmission neutral

CAUTIONOnly in emergencies on black ice if there is no otheroption 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 ofthe service brake, irrespective of the position of the pushbuttonrange selector. In such a case, the electronic control unit willengage the appropriate starting gear. Owing to the propulsionof the converter, the vehicle may come to a standstill on aslight grade even without actuation of the brake.

• Activate service or parking brake

In the event of a prolonged halt, the pushbutton selector shouldbe set to the neutral position.

DANGER!If the brake is not activated, the vehicle may startmoving even without actuation of the acceleratorpedal.

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 beretained. As soon as one of the three conditions no longerprevails, 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 parkingbrake. When the engine is switched off, there is nodirect connection between engine and axle. Thevehicle 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/hCoaches: 35 km/h

NOTEAt an ambient temperature below –15 °C, the maximallypermitted towing speed is 5 km/h.

2.11.1.2 Transmission damage suspected

CAUTIONIf transmission damage is suspected, the propshaft flangebetween transmission and drive shaft must be disconnected.As an alternative, the input shafts can be removed at bothends of the rear axle. Ensure with each measure/actiontaken that the provisions of the vehicle and componentmanufacturer are met in terms of vehicle safety andenvironmental protection.

Exception:In a dangerous situation, towing without separation of the drivetrain 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

CAUTIONWhen a vehicle with angle drive transmission is towed, thepropshaft between transmission and powered axle mustalways be disconnected.As an alternative, the input shafts can be removed at bothends of the rear axle. Ensure with each measure/actiontaken that the provisions of the vehicle and componentmanufacturer are met in terms of vehicle safety andenvironmental protection.

Exception: In a dangerous situation, towing without separation of the drivetrain 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

NOTEAt an ambient temperature below –15 °C, the maximallypermitted towing speed is 5 km/h.

Operation

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23

2.12 Temperature monitoring

The electronic control unit monitors the transmissiontemperature. Oil sump temperature and the oil temperature onthe retarder output are sent to the vehicle computer via CAN.Depending on the vehicle application, alert signals will beissued when the permissible temperature limit values areexceeded.

Consult the vehicle operating instructions for more details.

When the permissible temperature limit values are approachedduring retarder operation, retarder performance will bereduced 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

NOTEIf, after a few seconds, the temperature does not decrease tothe 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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24

2.13 Status monitoring/warning lamps

The diagnosis system of the electronic control unit monitorsthe transmission status whenever the vehicle circuit isswitched on and during operation.

Warning lampsFaults are indicated by warning lamps lighting up (red oryellow) and/or by warning messages which appear on thedriver’s display panel (consult the vehicle operatinginstructions).

If a selected driving range is not accepted by the electroniccontrol unit, the pushbutton pressed on the pushbutton speedrange 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, thefollowing responses are provided:

Shift into Neutral:In the event of serious malfunctions in the power supply to thetransmission, e.g. short circuit.

Engagement of emergency operation mode (see Chapter2.14.1):If there is an interruption of CAN communication or a loss ofspeed 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 mayoccur 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 sumptemperature 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 gradeIn 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 preheatedbefore the engine is started.

When starting, note ‒ Warm-up phase of at least 10 minutes, with increasedidling speed of approx. 1500 rpm.Transmission in Neutral

This can be done e.g. with warm airwhich must not exceed 130 °C onthe transmission.CAUTION: Do not heat up directlyat the transmission and/or in thevicinity of the electronic controlunit and the wiring.

Limitations None The different functional restrictions are activated by the electroniccontrol unit during the warm-up period (maintaining neutral positiondespite 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 longperiods down to an outside temperature of –40 °C.

Operation

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3 Maintenance

Regular and correctly performed maintenance is essential tosafeguard the operational safety of the transmission. It istherefore of particular importance that maintenance intervalsare observed.

THREATS TO THE ENVIRONMENT!Lubricants and cleaning agents must not be allowedto 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 agentsalways observe the manufacturer’s instructions.

3.1 Oil grade

Only oil as specified by the ZF List of Lubricants TE-ML 20 maybe used to fill up EcoLife transmissions.For the classification of your vehicle in terms of the maximumallowable oil sump temperature, please refer to the operatinginstructions of your vehicle. Subsequently, please use the oilgrades as released in accordance with the ZF List of LubricantsTE-ML 20 and adhere to the change intervals stipulated for oiland 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).

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3.2 Oil quantities

• For oil change with standard oil drain(draining time approx. 10 min.) approx. 24 liters

• For oil change withVRM 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

NOTEThese values are reference values! The definitive oil quantity is the one determined by oil levelcheck at operating temperature (90 °C).

3.3 Oil level check

CAUTIONIt 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 ofthe retarder, i.e. braking action is impaired or notavailable.

Valid in general:

• Top up transmissions that are supplied in non-oil-filledcondition with the status oil qualities prior to initialoperation

• In order to ensure minimum oil volumes for initial operationor after an oil filling (e.g. oil change, repair), an initial checkis to be conducted with cold transmission oil, refer toChapter 3.3.1.

• The decisive oil level check is to be implemented at anoperating 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 transmissionleakages

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Maintenance

3.3.1 Initial check of the oil level in order to ensurea minimum oil quantity

NOTEFor commissioning or after an oil filling (e.g. oil change,repair), an initial check of the oil level has to be conductedafter 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 20seconds 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 operatingtemperature

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 – 1500 rpm.

• Let engine run with idling speed.

CAUTIONThe 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”

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3.3.3 Electric oil level check

The Technical Customer Information “Electric Oil Level SensorEcoLife, 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 operatingtemperature for oil check purposes by running the vehicle withretarder cycles until the oil sump temperature reaches 90 °C.

CAUTIONThe maximum admissible oil temperature in the oil sump is determined by the classification of your vehicle inaccordance with the ZF List of Lubricants TE-ML 20.For details, please consult the vehicle's operatinginstructions.

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 referto the operating instructions of your vehicle.

CAUTIONThe pressure filter must be renewed each time the oil isexchanged.

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3.5 Variant 1 – Oil change with standard oil drain

3.5.1 Oil drain(see Fig. 3.1)

NOTEOnly 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 filterchamber.

• Replace filter cartridge (pressure filter) and O-ring on filtercover and on th oil drain plug.

NOTEPressure filter must be replaced during oil change.

ZF 80° angle drive RHD/LHDThe angle drive does not have its own oil drain plug.Drain oil through main transmission’s oil drain plug asdescribed 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

NOTEBe aware of different screw lengths.

• Screw in oil drain plug (1):Tightening torque: 35 Nm

CAUTIONAlways use genuine ZF oil drain plugs. The converter drain valve is activated via the ZF oil drainplug.

• 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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Maintenance

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5

4

4/5

2

1

Fig. 3.1 Coaxial transmission with standard oil drain

Fig . 3.3 Transmission with angle drive of 80°, RHD

5

4

Fig . 3.4 Transmission with angle drive of 80°, LHD

Fig . 3.2 Coaxial transmission035580

035560_1 035561_1

035559_1

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 thespecification of the oil and filter change intervals.

• Engine standstill

• Unscrew special screw plug (6.1 or 6.2, depending oninstallation 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 filtercover and at oil drain plug.

NOTEPressure 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

NOTEBe aware of different screw lengths.

• Screw in special screw plug (6.1 or 6.2, depending oninstallation 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.

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Maintenance

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2

6.21

6.1

035581Fig. 3.5 Coaxial transmission with VRM special oil drain

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3.7 Engine coolant

The transmission's cooling system is connected to the engine'scooling circuit. The composition of the engine coolantspecified 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 thevehicle's operating instructions.

CAUTION Non-observance in this context may lead to corrosiondamage 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 ZFServices.

Maintenance

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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 signalCAN 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 service 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 orrocker 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 connectornot working, CAN signal not present signal

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ZF Friedrichshafen AG88038 FriedrichshafenDeutschland · GermanyTelefon/Phone +49 7541 77-0Telefax/Fax +49 7541 77-908000www.zf.com

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