ZFEcomat_35p.pptneevia

7/24/2019 ZFEcomat_35p.pptneevia

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BELL Articulated Dump Truck (ADT)

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ZF-Ecomat 2 - BELL-ADTPB_001_en

B 25 C B 30 C017322 017323

017320 017321

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ZF-Ecomat Advantages in the BELL-ADT

Ecomat

is compact and has a low weight

is off-road proven in civil and military application

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has a primary retarder system that brakes perfect in highand low speed ranges

has two engine dependent PTO connections for shiftable

or live PTO

has secondary steering pump system

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ZF-EcomatSpecial Vehicles Application

Articulated Dumper

12 000 units

NAFTA 30 %Germany 15 %Great Britain 10 %France 10 %Europe (others) 15 %International 20 %

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Military Vehicles 6 800 units20 international OEM

Rail Vehicles

1 088 units

3 international OEM Duewag 97

Adtranz 987 AEG 4

19 888 units

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200 000 Ecomat are already on the road

Most of them in City-bus application - a very hard job

Other bus applications line service coaches

Civil Vehicles with ZF-Ecomat

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ZF-Ecomat 2 - BELL-ADT

concrete mixers dumpers road sweepers garbage collectors

fire tenders oil rig carriers airport lift launches crane vehicles

PB_004_en

017199

017231

012633

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Military Vehicles with ZF-Ecomat

ZF-Ecomat applications in military vehicles

Application in heavy weight vehicles up to 25 / 30 tons

Extreme off-road capability

Fulfills the national or / and the extreme NATO-test for thedrive line

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011099

Proven in the Operation Desert Storm and in UN-Balkansmissions

Full military / NATO logistics

Emergency shift and steering device Simple service

Perfect diagnosis tools

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ZF-Ecomat

Military Application

OEM-name

Wheeled vehicles

HenschelSteyr EnasaElboKruppPanhard

Units produced

2 896324

1 56562

35

OEM-name Units produced

Tracked vehiclesOTO-MelaraKrauss Maffei

57

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Sibmas / MANTimoneyFaun (crane)RVITalbotSidesKomatsuFodenEWKMowagUnipower

Astra

4232233376110

991

4288536

1367

6 800Total

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T r a n s m

i s s

i o n s

/ y e a r

011740

ZF-Ecomat

Production Figures

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Year 017109

PB_007_en

Share of Ecomat 2

Share of 5-speedtransmissions

Total

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ZF-Ecomat 2

HP 502 C / HP 592 C / HP 602 CIn recent years Articulated Dump Truck (ADT)transmission technology has developed intointelligent systems. These systems (engine,

transmission, brakes, etc.) depend on theexchange of information for perfect function.This exchange of information is based on thetransmission of electronic signals by meansof CAN* technology.

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The ZF-Ecomat 2 meets the requirements for the use of the latest technology

for Articulated Dump Trucks (ADT).Advantages: Reduced operating costs Optimized fuel consumption Increased reliability Easy diagnosis

Together with vehicle manufacturers, ZF hasdeveloped the software for the common interfaces.

*CAN = Controller Area Network

012326

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ZF-Ecomat 2

CAN CommunicationThe new electronic control units EST 46 C and EST 47 C

EST 46 C: Communication (CAN)

Diagnosis

EST 47 C: Communication (CAN)Diagnosis

SAE J1939 or

IES-CANISO 9141

SAE J1939SAE J1587 / J1708 010167

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Advantages of CAN communication:

Reduces number of cables and plugged connections

Communicates constantly with all components of the drive train

Allows optimum engine and brake management minimum brake wear

optimum gearshifts due to engine and pressure control

Diagnoses the drive train system and facilitates service

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ZF-Ecomat 2

Modular System1 Converter module

2 Oil supply module

3 Retarder module

4 Planetary gearmodule

6

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5 Transmissioncontrol module

6 PTO module

1 2 3 4

5Transmission layoutat i = 5.60 - 1.00

i = 5.60 - 0.83

017326

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ZF-Ecomat 2

Planetary Transmission ModuleThe planetary transmission consistsof an interconnected system foursimple planetary gear sets.Different clutch combinations give a

transmission either 5 or 6 forwardspeeds.For each gear change, only oneclutch or brake is actuated. Gearchanges can therefore be madewithout interrupting tractive force.This is the secret of their

Neutral

1st gear

4th gear

5th gear

L U CB C D E F G

A

L U CB C D E F G

A

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excellent shift quality.

The main features of the planetarytransmission are:

Close ratio stepsThis feature enables you to driveconsistently in the most fuel-efficient

speed range.

Shift comfortThis enhances the safety of thedriver and is also gentle on thedriveline.

017341

2nd gear

3rd gear

017340

6th gear

Reverse

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ZF-Ecomat 2

Technical Data

015257

500

900 1100 1200

HP 502 C

HP 592 C

HP 602 C

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Range

5 HP 592 C502 C

602 C

6 HP 592 C502 C

602 C

Ratios

5.60 3.43 2.01 1.42 1.0 - 4.84

1st 2nd 3rd 4th 5th 6th Rev.Installed length

in mm L

795

approx. mass in kg(without PTOs)

344

5.60 3.43 2.01 1.42 1.0 0.83 4.84 795 366

Input torque [Nm]

354364

356

376

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ZF-Ecomat 2

Transmission and ShiftingZF-Ecomat 2 offers:Optimum shift quality and tailored shift programs Longevity of the drive train and satisfied drivers

The shift program is set according to the following criteria: to the respective engine characteristics (Euro 2 / 3 / [4] / gas engines) to the most economical speed range to the drive train - engine / transmission / axle / tires

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current load condition through constant sensing of accelerator pedal position and engine torque acceleration condition brake condition (Retarder operation) changing transmission parameters through shift pressure control

ZF-Ecomat 2: perfect for any use

Program variants:Up to 6 program variants (POWER - ECONOMY) are stored adjustment to individual application profile

} through torque adjustment during shift process

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ZF-Ecomat 2

Transmission Control ModuleThe transmission range

HP 502 C HP 592 C HP 602 C

is equipped with a tried-and-tested electro-hydraulictransmission control system.

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017042

e s mpu ses requ re

for control are supplied bythe electronic control unitEST 46C / 47C.

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ZF-Ecomat 2

Speed range Selector Operation:

Depending on the numberof speeds of the transmissionand the customers choice,the selector is available forZF-Ecomat 2 operation.

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rror s gna :

To prevent transmissiondamage, malfunctions aresignaled to the driver viaflash signals in the displayof the selector (flashing of

the shift drive range).

017329

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ZF-Ecomat 2

Primary Retarder

Stator

ZF-Ecomat 2 primary retarder combines optimum safety witheconomy :

No Articulated Dump Truck should be without the benefits of a

primary retarder

ZF-Ecomat 2 is equipped with an independent, integrated retardermodule.

Advanta es of this desi n:

Rotor

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Patented ZF grid minimum drag

loss

011817

The integrated primary retarder operates at engine speed andprovides smooth deceleration for any drive situation until near-standstill of the vehicle

The primary retarder module is much more effective in ArticulatedDump Truck than secondary retarder systems or converter brakesystems

Longevity of the brake system is maximized at least threefold lifetime as opposed to transmissions w/o retarder at least twofold lifetime as opposed to secondary retarders or con-

verter brakes

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ZF-Ecomat 2

Primary Retarder - Retarder ControlZF-Ecomat 2 primary retarder is continuously controlled by anelectric proportional valve.

brake performance adjustment to vehicle weight

brake performance adjustment to:

present brake management system

vehicle application

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Electrical retarder controlvia proportional valve

017113

The EST 46 C / EST 47 C controls transmission functions and theprimary retarder. The following control and protective functionsare integrated:

twofold oil temperature control in transmission smooth brake torque and limitation

Due to these protective functions thermal load peaks are avoidedand transmission lifetime secured.

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ZF-Ecomat

Primary Retarder - Retarder Control1 EST 46 C electronic

shift control unit

2 Speed range selectorconsole lever

3 Vehicle circuit

4 Retarder control,

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e.g. us ng ra e

pedal or lever onsteering column

5 Retarder temperaturesenor

6 Retarder proportionalvalve

7 Retarder Accumulator

5

6

7

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ZF-Ecomat

Engine-driven Power Take-offsVersions:

permanently-

driven

engagable

Installation position:

Direction of rotation

of the output shaft:

Output speed:nout = 0.97 x n eng

11 and/or 1oclock

11 o`clockpos.

1 o`clock pos. Direct installation of hydr. pump

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017349

017350

017352

Versions:engagable withspur gear drive

017355

Installation position:

Direction of rotationof the output shaft:

11 and/or 1oclock

Possible operating anglein install.

position

(o`clock)

11

1

60 90 300

(viewed facing transmission output)

Output speed (optional):nout = n eng x 0.68, 1.38

1.43, 2.12

11 o`clock pos. 60

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ZF-Ecomat - Comfortable Single Lever

Operation for Transmission and Power Take-off

1 Console speed rangeselector

2 On / off switch for PTO unit

3 Vehicle electric circuit

4 Engine-driven PTO(1 o`clock position)

1

2 4

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Function:

PTO switch (2)on and

Selector lever (1)in position ...

... N (neutral)

Vehicle stationaryPTO in operation

... D, 1, 2, 3 or R

Vehicle in motion,PTO disengaged

3017356

017357 017358

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ZF-Ecomat

Auxiliary UnitsSecondary pump (1)

Takes on function of primarypump when engine is stationary

and vehicle is in motion this makes it possible to

tow-start or tow the vehicle

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Emergency steering pump (2)

Takes on function of steeringpump when engine is stationaryand vehicle is in motion

maintains servo-assistance

to the power steering unit 0047192

1

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ZF-Ecomat

Coolant CircuitPreferred coolant circuit designs: Transmission oil cooler in main circuit ...

... arranged on

Plan view Side view

Heating

Transmissionoil connection

Transmissionoil cooler

Coolantexpansiontank

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pressure side

of cold watercircuit

Coolantwater pump

Transmissionoil cooler

Ecomattransmission

In-line engineCooler

015271

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ZF-Ecomat 2

Maintenance Regular maintenance is a prerequisite for transmission

longevity and low operating costs

Pay attention to the following 7 points:

1. Outgoing Done by truck manufacturer, ZF-Serviceinspection: or by yourself?

(see check list / ZF order no. 4149 754 101*)

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. ype: ransm ss on o re ease

(compare lube list / ZF order no. 1205 754 114*)

3. Coolant: Trucks specifications must be observed(no tap water)

4. Training: Your workshop staff are trained by ZF?(free service for your ZF agency)

ocumen s are ava a e

free of charge from:ZF Friedrichshafen AGWerk II / Abt. MKS-KD4Leutholdstr.

88038 Friedrichshafen

Fax: + 49 (0) 7541 77 5380e-mail: [email protected]

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5. Regular acc. to operating instructionsmaintenance: (ZF order no. 4149 758 101*) Section 4.5 / 4.6

For oil change intervals see ZF lube list

6. Operating Available to you and known?instructions: Can be a part of the operating instructions of the

truck manufacturer or ordered from ZF

ZF-Ecomat 2

Maintenance

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7. Customer: When problems occur - who analyzes and repairs?service Do you want to repair yourself?

Contact your ZF agent.

ocumen s are ava a e

free of charge from:ZF Friedrichshafen AGWerk II / Abt. MKS-KD4Leutholdstr.

88038 Friedrichshafen

Fax: + 49 (0) 7541 77 5380e-mail: [email protected]

PB_025_en

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ZF-Ecomat 2

Diagnosis - ZF-TestmanThe ZF Diagnosis Software Testman is configured as follows.It is installed on a commercial PC or Laptop.

Electronic diagnosisZF-Testman

Testinputs and

out utsDiagnosisRepair aid

Vehicleconfiguration

ZF-Diagnosis - adapter DPA 04I

RS 232-cable

017104

017105

017106

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Functions: Choice of language Automatic determination of vehicle configuration

transmission identification (O.D. / D.D. / converter / etc.) Test of signal outputs and inputs Readout of error memory (w/ error search tips)

allows identification of the conditions leading to the error Maintenance and repair instructions System check with vehicle standing still or moving

Enhanced diagnosis withZF-Testman fast, easy, efficient

ZF Diagnosis SoftwareTestman on 3 floppy disks

-ca e

SAE-cable

017107

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ZF-Ecomat

Versatile Product with an International Track Record

017359010897

017230

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017231011109

011108

017199

015142

017360

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ZF-Ecomat 2

Quality AssuranceZF-Ecomat 2 - housing inspection

Quality assurance has a very high ranking at ZF.To ensure frictionless functioning of our productsfor their entire lifetime, considerable efforts aremade. Modern quality assurance systems directlyinfluence processes in design, production, andassembly.

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Housing inspection - ZF-Ecomat 2

These efforts aim at achieving and maintaining 100% customer satisfaction.

015125

PB_028_en

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ZF-Ecomat 2

Transmission AssemblyCentral assembly line

At modern assembly cells the individualcomponents are pre-assembled, inspected andthen move on to the central assembly line.

There the ZF-Ecomat 2 transmission housings arecompleted by qualified staff in several assemblysteps in which the order-specific components are

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Central assembly line ZF-Ecomat 2

moun e .

017043

017043

PB_029_en

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ZF-Ecomat 2

Functional Check Before DeliveryFunctional check on load test bench

Before a ZF transmission is dispatched, alltransmission functions are checked on a loadtest bench. This way errors can be detectedand immediately rectified.

Benefit for the customer:Only inspected transmissions are dispatched.

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Functional test on load test bench

017044

017044

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ZF-Ecomat

Production LocationThe ZF-Ecomat ismanufactured in theCommercial VehicleTransmissions Division inFriedrichshafen, also hometo many other successfulmodels of truck and bustransmission.

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Plant II

supp es a w e range o

driveline, steering andsuspension products.

PB_031_en

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ZF-Service Network

Europe

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= ZF-Service for ZF-Ecomat transmissions

PB_032_en

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ZF-Service Network

Worldwide

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= ZF-Service for ZF-Ecomat transmissions

PB_033_en

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ZF-Service Offers ...

Technicalassistance

Field ServicePersonnel

Training

Documentation

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Warranty Long-term maintenance

back-up

Repairs Exchange

transmissions

Spare partproposals

Special tools Testers

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