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HP 502 / HP 592 / HP 602
for city buses, buses running in line service, and coaches
4149 765 103
Technical Manual
For Installation, Functions, 
And Initial Start-Up
Subject to alterations in design
Copyright by ZF
This documentation is protected by copyright. 
Any reproduction or dissemination in whatever 
form which does not comply fully with the intended
purpose of this documentation is prohibited without
the consent of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C
Edition: 2004-12
4149 765 103
Important InformationZF-Ecomat 2 plus
34149 765 103 - 2004-12
Important Information
This Ecomat Technical Manual provides a technical
basis for the Ecomat 2 plus system and has been 
produced for the benefit of vehicle and body manu-
facturers as well as ZF employees. 
This manual contains answers to questions ranging
from specifications to installation inspection and
commissioning.
This manual provides the basis for specifications of
the transmission and peripheral units.
Optimum procedure leading up to volume produc-
tion delivery:
• Specification of transmission, automatic electronic
shift control unit and peripheral units performed
by vehicle manufacturer and ZF using the 
“Questionnaire for parts list preparation”.
• Documentation by ZF.
• Initial installation.
• Initial installation inspection carried out by ZF
staff.
• Start-up carried out by ZF staff.
• ZF release certificate.
• Authorization conform to certificate release.
ZF can bear responsibility for any errors in the
initial installation only if sign-off has been perfor-
med by authorized ZF personnel and if all defects
found by ZF have been rectified by the vehicle or
bodywork manufacturer. The vehicle or bodywork
manufacturer shall bear sole responsibility for any
damage caused by defects attributable to the 
vehicle or body manufacturer which could not be
detected by ZF personnel during initial sign-off.
If you require additional information concerning
installation and the installation inspection, we have
prepared an "Installation Guidelines" manual in
addition to the Ecomat technical manual. When
installing the transmission, these installation guide-
lines must be observed. If you have any questions or
improvement suggestions, please contact our depart-
ment: BPE1 - ECOMAT Application Engineering
department.
Safety instructions
The following safety instructions appear in this
manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary, etc.
CAUTION
This is used when incorrect, unprofessional wor-
king practices could damage the product.
DANGER
This is used when lack of care could lead to personal
injury or death.
THREATS to the environment !
Lubricants and cleaning agents must not be allowed
to enter the soil, ground water, or sewage system.
• Request safety information for the products 
concerned from your local environmental protec-
tion authority, and follow any instructions herein 
at all times.
• Collect used oil in a suitably large container.
• Dispose of waste oil, used filters, lubricants, and 
detergents in compliance with the stipulations of 
the environmental protection laws.
• Always observe manufacturer instructions when
dealing with lubricants and cleaning agents.
!
!
1 System solution Ecomat 2 plus
2 Description of transmission and technical data
3 Ecomat 2 plus installation position in vehicle
4 Installation arrangement and mountings
5 Guidelines for propshaft installation
6 Engine connection
7 Converter
8 Retarder
9 Cooling system
10 Transmission specification
11 Hydraulic circuit diagrams
12 Periperal equipment
13 Neutral at standstill
14 Temperature monitoring
15 Electronic automatic control system EST 146 / 147
16 Wiring
17 ZF documentation
18 Calculations and conversion tables
19 Oil grades and oil filters
ContentsZF-Ecomat 2 plus
54149 765 103 - 2004-12
1 System solution Ecomat 2 plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 System solution Ecomat 2 plus (with CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 System solution Ecomat 2 plus (with load sensor, without CAN) . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 System solution Ecomat 2 plus (with PWM signal, without CAN) . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 Description of transmission and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Transmission brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Transmission structure and auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Transmission ratios and powerflow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Torque assignment - vehicle weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Torsional vibration in driveline - inertia torques - vibration substitution model . . . . . . . . . . . . 2-8
2.6 Weights and inertia torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.1 Coaxial output without heat exchanger J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.2 Coaxial output with heat exchanger J01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.6.3 Coaxial output with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.6.4 Coaxial output with heat exchanger J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6.5 Angle drive 80° without offset, with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.6 Angle drive 80° without offset, with heat exchanger J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6.7 Angle drive 80° RHD (with right offset), with heat exchanger J05 . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.6.8 Angle drive 80° RHD (with right offset), without heat exchanger J08 . . . . . . . . . . . . . . . . . . . . 2-19
2.7 Clutch combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
3 Ecomat installation position in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4 Installation arrangement and mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Transmission flange-mounted on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5 Guidelines for propshaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Permissible rotational irregularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Permitted resultant deflection angle for each joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 The permitted resultant flexure angle for all joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Single-section propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Multi-section propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6 Maximum permissible propshaft length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6 Engine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 ZFScope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2 Engine connection inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 Engine connection drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Overview converter-circuit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
7 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Torque converter: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Converter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Getting the right torque converter for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Torque converter diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Torque converter basic curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ContentsZF-Ecomat 2 plus
64149 765 103 - 2004-12
8 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Structure and function of retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Retarder action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 Retarder and engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Retarder activation variants hand and foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Permitted variants “foot request” without “hand request” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.2 Permitted variants “foot request” without “hand request” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.5.3 Permissible retarder activation variants "Foot" and "Hand" combined . . . . . . . . . . . . . . . . . . . . 8-7
9 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Design of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Release criteria for temperature measurements (max. ambient temperature = 40 °C) . . . . . . . . 9-1
9.1.1.1 According to List of Lubricants TE-ML 14 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1.2 According to List of Lubricants TE-ML 14 A / B / C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2 Limit temperature values for oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.3 Cooling system with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.3.1 Cooling system graph of shell type cooler SBK 279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.4 Cooling system without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.4.1 Delivery volume of the primary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Position of transmission oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Cooler fitted on transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Layout with oil cooler separate fromtransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Oil line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Cooling water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.6 Specification for transmission heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7 Required performance of cooling water and antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.2 Fresh water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.3 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7.4 Cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.8 Transmission fill with auxiliary cooling 
(applicable to all transmissions approved for use with auxiliary cooling) . . . . . . . . . . . . . . . . . 9-9
9.9 Transmission oil sump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.9.1 System diagram, transmission oil sump cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.10 Temperature measurements in bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.1 Measurement conditions / Retarder test cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.2 Measurement retarder cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.3 Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.10.4 Explanation of water temperature Retarder cycle (worst case) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.10.5 Temperature measuring points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
10 Transmission specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.1.1 Flange-mounted installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2 Heat exchanger arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.1 Coaxial output, heat exchanger at rear, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . 10-5
10.2.2 Coaxial output, heat exchanger at rear, accumulator rear transverse . . . . . . . . . . . . . . . . . . . . . 10-6
ContentsZF-Ecomat 2 plus
74149 765 103 - 2004-12
10.2.3 Coaxial output or 80° angle drive RHD (with axial offset), heat exchanger 
vertical on left, accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2.4 Angle drive 80° LHD (withoutaxial offset), heat exchanger horizontal on left, 
accumulator horizontal on left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.5 Coaxial output, heat exchanger vertical on right, accumulator horizontal on left . . . . . . . . . . . 10-9
10.2.6 Coaxial output, vertical heat exchanger on right, accumulator rear transverse . . . . . . . . . . . . . 10-10
10.2.7 Coaxial output, heat exchanger separate from transmission, accumulator direct mounting . . . 10-11
10.2.7.1 Cooler connection piece with threaded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.3 Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3.1 Deep oil pan, 4149 131 002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3.2 Deep oil pan; left- and right-hand connection prepared, 4149 131 006 . . . . . . . . . . . . . . . . . . . 10-14
10.3.3 Deep oil pan, auxiliary cooling, 4149 131 024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10.3.4 Flat oil pan, 4149 131 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.3.5 Flat oil pan; left- and right-hand connection prepared, 4149 131 009 . . . . . . . . . . . . . . . . . . . . 10-17
10.4 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.4.1 Oil filling <K 01> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.4.2 Oil filling <K 02>, <K 04>, <K 05> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.4.3 Oil filling <K03>, <K 06> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
10.4.4 Oil filling <K 09> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10.5 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.5.1 Coaxial output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.5.2 80° angle drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.5.3 Output flange 80° angle drive LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.4 Ecomat output flange; coaxial and angle drive 80° RHD with axial offset . . . . . . . . . . . . . . . . . 10-27
11 Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1 Hydraulic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2 Hydraulic diagram (with Bus Stop Neutral / NBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
12 Peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1 Speed range selector - push button switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.2 CAN range selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.3 Load sensor A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.3.2 Load sensor drawing, Drawing no.: 0501 209 635 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.4 PWM-Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.4.1 Calibration of the PWM Signal, Positive Impulse Flank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12.4.2 Sensing ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
12.4.3 Signal Spezification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
12.5 Additional temperature sensor A6 for temperature display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
12.6 Temperature display A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
12.7 Kick down switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
12.7.1 Kick down switch S1 (Holding switch - high holding force), Drawing no.: 6007 603 030 . . . . . 12-13
12.8 Pressure switch S7 - NBS (Neutral when Stationary), Drawing no.: 0501 311 584 (a) . . . . . . . . 12-15
12.9 Changeover relay, e.g. range selector relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
13 Neutral at standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.2 Connection diagram (electric), Drawing no.: 4139 720 045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
ContentsZF-Ecomat 2 plus
84149 765 103 - 2004-12
13.3 Neutral at Bus Stop - display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.3.1 NBS active display via digital signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.3.2 NBS Active Display via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
14 Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.1 Temperature information via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.2 Temperature information via temperature sensor A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.3 Temperature information from DM1 note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.4 Temperature warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.5 Addtional temperature sensor A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
14.6 Temperature display gauge A5, Drawing no.: 0501 204 074 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
14.7 Resistance characteristics - Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
15 Electronic automatic control system EST 146/147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.1 Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.2 Intended standard functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 15-1
15.3 Functions available on request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
15.4 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
15.5 Technical data of EST 146 / 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
15.6 Installation drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
15.6.1 Installation drawing EST 146, Drawing no.: 6009 690 001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
15.6.2 Installation drawing EST 147, Drawing no.: 6009 691 001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
15.7 Current circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
15.7.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector,
Drawing no.: 6029 729 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
15.7.2 Current circuit diagram EST 146 / EST 147 with CAN, with CAN range selector,
Drawing no.: 6029 729 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
15.7.3 Current circuit diagram EST 146 / EST 147 without CAN(NEng), with digital range selector,
Drawing no.: 6029 729 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
15.8 Pin pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
15.9 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
15.9.1 Current circuit diagram EST 146 / EST 147 with CAN and digital range selector, 
Drawing no.: 6029 729 156A / Pages 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
15.9.2 Current circuit diagram EST 146 / EST 147 with CAN and CAN range selector, 
Drawing no.: 6029 729 233 / Pages 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
15.9.3 Current circuit diagram EST 146 / 147 without CAN (NEng), with digital selector range, 
Drawing no.: 6029 729 216 / Pages 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
15.10 Function description EST 146 / 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23
15.11 ZF-Diagnosis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.1 ZF-Diagnosis protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.2 ZF-Diagnosis tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.2.1 ZF-Testman pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
15.11.2.2 Flash code output EST 146/147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-33
15.12 HST 46 auxiliary control unit EST 146 and EST 147 versions without CAN range selector . . . 15-35
15.12.1 Operating manual for HST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35
15.12.2 Technical data of HST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35
15.12.3 Dimensions of HST 46, Drawing no.: 6009 678 003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-36
15.13 Block diagram EST 146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-37
15.14 Block diagram EST 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-38
ContentsZF-Ecomat 2 plus
94149 765 103 - 2004-12
16 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.1 Complete wiring - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2 Complete wiring - With junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.3 Wiring connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.4 Wiring specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
17 ZF documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1 ZF documentation with CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
17.1.2 Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
17.2 ZF documentation without CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
17.2.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
17.2.2 Identification and engine compatibility data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
17.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5
17.3.1 Oil level check prior to first commissioning; transmission without oil filling . . . . . . . . . . . . . . 17-5
17.3.2 Oil level check prior to first commissioning; Transmission oil filing at plant . . . . . . . . . . . . . . 17-6
17.3.3 Oil level check prior to first commissioning; 
Transmission with additional cooling system, with or without oil filling at plant . . . . . . . . . . . 17-7
18 Calculations and conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.1 Driveline design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.2 Collective formulae for retarder and cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
18.3 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.3.1 Units of length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.3.2 Units of area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.3.3 Units of volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4
18.3.4 Units of energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4
18.3.5 Masseeinheiten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
18.3.6 Force units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-6
18.3.7 Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-7
18.3.8 Temperature conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-7
18.3.9 Moment of inertia conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8
18.4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8
18.5 List of dynamic tire radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8
19 Oil grades and oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.1 List of Lubricants TE-ML 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.2 Purity of medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.3 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
ContentsZF-Ecomat 2 plus
104149 765 103 - 2004-12
System solutionZF-Ecomat 2 plus
1-14149 765 103 - 2004-12
1 System solution Ecomat 2 plus
1.1 System solution Ecomat 2 plus (with CAN)
Key to drawing
1 Transmission electrical unit connector
2 EST 146- / EST 147-connector
3 Retarder connector
4 Accumulator connector
5 Temperature sensor connector
6 Kick down switch
7 ZF diagnosis connection plug
8 Range selector (pushbutton)
9 Dipstick (oil level check, oil status)
10 Footplate brake valve for activating the 
service brake and continuously variable 
retarder activation
11 Accelerator pedal
12 Retarder OFF - ON switch
13 Main power supply
14 Pushbutton for NBS (Neutral when stationary)
15 Pushbutton for gear release
16 Automatic electronic shift control unit 
EST 146 / EST 147
17 Retarder manual lever, electrical
18 Impulse sensor for tachometer
19 Connections for cooling water circuit
20 CAN connector
21 Auxiliary consumer from air supply
6 7
9
2
8
10
14
11
12
16
3
5
4
Brake
Accelerator
Engine
Displays
CAN-Bus
....
....17
1 2 3
 D N 
 R
20
1815
13
1
19
21
023778_en
System solutionZF-Ecomat 2 plus
1-24149 765 003 - 2004-07
1.2 System solution Ecomat 2 plus 
(with load sensor, without CAN)
Key to drawing
1 Transmission electrical unit connector
2 EST 146- / EST 147-connector
3 Retarder connector
4 Accumulator connector
5 Temperature sensor connector
6 Kick down switch
7 ZF diagnosis connection plug
8 Range selector (pushbutton)
9 Dipstick (oil level check, oil status)
10 Footplate brake valve for activating the 
service brake and continuously variable 
retarder activation
11 Accelerator pedal
12 Retarder OFF - ON switch
13 Main power supply
14 Pushbutton for NBS (Neutral when stationary)
15 Pushbutton for gear release
16 Automatic electronic shift control unit 
EST 146 / EST 147
17 Retarder manual lever, electrical
18 Impulse sensor for tachometer
19 Connections for cooling water circuit
20 Linkage for injection pump
21 Load sensor for engine load detection
22 Auxiliary consumer from air supply
6 7
9
2
8
10
14
11
12
16
3
5
1 4
17
1 2 3
 D N 
 R
20
21
1815
13
22
19
023777
System solutionZF-Ecomat 2 plus
1-34149 765 003 - 2004-07
1.3 System solution Ecomat 2 plus 
(with PWM signal, without CAN)
Key to drawing
1 Transmission electrical unit connector
2 EST 146- / EST 147-connector
3 Retarder connector
4 Accumulator connector
5 Temperature sensor connector
6 Kick down switch
7 ZF diagnosis connection plug
8 Range selector (pushbutton)
9 Dipstick (oil level check, oil status)
10 Footplate brake valve for activating the 
service brake and continuously variable 
retarder activation
11 Accelerator pedal
12 Retarder OFF - ON switch
13 Main power supply
14 Pushbutton for NBS (Neutral when stationary)
15 Pushbutton for gear release
16 Automatic electronic shift control unit 
EST 146 / EST 147
17 Retarder manual lever, electrical
18 Impulse sensor for tachometer
19 Connections for cooling water circuit
20 PWM from EDC or E-gas
21 Auxiliary consumer from air supply
6 7
9
2
8
10
14
11
12
16
3
5
4
17
1 2 3
 D N 
 R
1815
13
20
21
1
19
023779
System solutionZF-Ecomat 2 plus
1-44149 765 103 - 2004-12
System solution Ecomat 2 plus
The Ecomat 2 plus system diagram illustrates one 
of the possible Ecomat system set-ups using all
necessary individual components.
All electrical connections required between the Eco-
mat 2 plus system and automatic electronic control
unit are located in the interface to the vehicle electri-
cal system (13) and in case of the CAN bus applica-
tion at the vehicle CAN bus system.
The EST 146 / 147 (15) automatic electronic control
unit controls the transmission and monitors all func-
tions. The automatic shift control unit gathers input
parameters from vehicle and transmission and pro-
cesses these to produce signals used for controlling
the transmission hydraulic system.
The driver may intervene in the Ecomat control sys-
tem using the following equipment:
- Speed range selector (push-button switch) (8)
- Kick-down (6)
- Accelerator pedal (11)
- Brake pedal (10)
- Switch for retarder operation (12/16)
• The desired speed range can be pre-selected
using the speed range selector (8).
The button pressed is illuminated (continuously
lit).
• The kickdown switch (6) enables the shift points
to be moved up to higher engine speed settings.
This means more time is spent in each gear
[during upshifts] and, conversely, that downshifts
occur sooner.
• For retarder activation, please consult vehicle
manual.
• Oil temperature is monitored using temperature
sensors. Data from temperature sensors is trans-
mitted via CAN bus system, EST 146 / 147 digital
output or direct wiring and displayed by means of
display or warning lamp.
Retarder torque will be reduced as defined tem-
perature limits are exceeded.
• Engine load data will be transmitted from the
engine electronic system to the EST 146 / 147
(15) via CAN and/or PWM signal or from injec-
tion pump via load sensor.
Pressures for operating the clutch elements are
modulated according to the engine load condition
using a proportional solenoid valve in the electri-
cal/hydraulic control unit.
Description of transmission and technical dataZF-Ecomat 2 plus
2-14149 765 103 - 2004-12
2 Description of transmission and 
technical data
2.1 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.
ZF Ecomat transmissions from ranges HP 502, 
HP 592, and HP 602 offer the following advantages:
• Smooth starting with no mechanical wear, even
on extremely rough terrain. No clutch wear.
• The automatic shift program and smooth shift
characteristics do a great deal to protect the 
engine and driveline.
• The integrated hydrodynamic retarder contri-
butes to road safety and vehicle performance.
Substantial cost savings are also achieved by
extending the service life of wheel brake linings.
• Increased fuel economy due to close ratiostep-
ping, carefully chosen shift points and restriction
of converter operation to the initial driving phase.
• Greater ease of operation for the driver, 
enhancing driver performance and contributing
to road safety.
• Reduction of vehicle operation and maintenance
costs, especially under demanding road and traf-
fic conditions or even with drivers who have no
practice with it.
Basic transmissions from ranges HP 502, HP 592,
and HP 602 consist of a hydrodynamic torque con-
verter with a lock-up clutch and rear-mounted multi-
speed planetary transmission.
Torque converter
The hydrodynamic torque converter, which uses the
Trilok operating principle is a wear-free setting-off
system and is equipped with a stator mounted on a
freewheel and a lock-up clutch. The converter opera-
tes only when the vehicle is starting and is then
automatically locked up.
A lock-up clutch installed in the torque converter
establishes a direct mechanical connection between
the engine and planetary transmission after the set-
ting-off phase. The power losses incurred by conver-
ter transmissions are therefore eliminated.
Retarder
The hydrodynamic retarder, is integrated in the
transmission and no housing extension is necessary.
The retarder is located between the torque converter
and planetary transmission. This means the full 
braking effect is available without interruption, even
in lower gears.
The retarder braking torque can be continuously
varied using a manual lever-operated or pedal brake
valve. If required, the braking torque can be divided
into one or several stages, all limited to a value 
specified by the customer. 
Planetary transmission
The planetary transmission, arranged behind the
torque converter, is designed as a 5- or 6-speed unit.
The planetary transmission is a combination of indi-
vidual planetary gear sets (no modular design).
The gears in the planetary transmission are selected
automatically and without any interruption to trac-
tion. The automatic electronic shift control unit 
EST 146 / 147 provides signals for the gear selec-
tions. The EST 146 / 147 shifts the appropriate
multi-disc clutches and/or brakes via the electro-
hydraulic transmission control unit in accordance
with various parameters from the vehicle and trans-
mission.
Description of transmission and technical dataZF-Ecomat 2 plus
2-24149 765 103 - 2004-12
Transmission control
The electro-hydraulic control system used in these
transmissions has given excellent results in practice.
It receives shift signals from the EST 146 / 147. This
modern automatic electronic control unit has a dia-
gnostics capacity and is designed to suit the number
of ratios, type of transmission, engine and vehicle. 
ZF automatic transmissions 
5 and 6 HP 502, 592, 602
Key to drawing
1 Input
2 Torque converter lock-up clutch
3 Converter
4 Retarder
5 Clutches (A, B, C)
6 Brakes (D, E, F)
7 Output
8 Oil pump
1
2
3 4
8
5 6
7
013467
Description of transmission and technical dataZF-Ecomat 2 plus
2-34149 765 103 - 2004-12
2.2 Transmission structure and auxiliaries
Using the basic transmission, auxiliary units can be
used to make the following variants.
• Coaxial transmission with fitted oil cooler
The basic transmission is fitted with coaxial 
output and oil cooler at the output end. The heat
exchanger module contains the oil cooler connec-
tion piece and cooler connection lines.
• Coaxial transmission with separate cooler
Here, the basic transmission is fitted with a 
cooler connection piece. A ZF cooler is available
for separate attachment or a cooler produced by
an external manufacturer can be used following
approval from ZF.
• Transmission with flange-mounted 80° angle
drives
A 80º angle drive can be attached to the basic
transmission without axial offset or a 80º angle
drive can be attached to the right with axial off-
set. Cooler attachments (see Chap. 10) or a cooler
connection piece are available for this as for the
coaxial transmission version with separate 
cooler.
• Non-ZF oil cooler
If customers provide their own oil cooler:
- ZF fits the oil cooler connection for non-ZF oil
coolers to the basic transmission
- The oil cooler must comply with specifications
in Section 9, Cooling system,
- The associated piping must be provided by the
customer and must comply with Section 9,
Cooling system.
• Retarder
All transmission versions are supplied with a
retarder as standard. The retarder is fitted in the
basic transmission between converter and plane-
tary transmission. The retarder does not increase
transmission length and adds only 11 kg to the
transmission weight.
Description of transmission and technical dataZF-Ecomat 2 plus
2-44149 765 103 - 2004-12
Key to drawing
1 Basic transmission
2 Retarder
3 Coaxial output
4 80° angle drive left with offset (LHD)
5 80° angle drive right with offset (RHD)
6 Oil cooler, fitted at output end
7 Oil cooler connection piece for non-ZF oil 
cooler
1
6
7
2 5
4
3
021765
B C D E F
WK WK
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
WK
WK
WK
WK
WK
WK
WK
Powerflow
1st gear
(mechan.)
Neutral
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
1 Input
2 Torque converter lock-
up-clutch (WK)
3 Torque converter
4 Retarder
5 Clutches (A, B, C)
6 Brakes (D, E, F)
7 Output
8 Oil pump
1
3 4 5 6
7
2
8 013467
016362
1st gear
hydraul.
Description of transmission and technical dataZF-Ecomat 2 plus
2-54149 765 103 - 2004-12
2.3 Transmission ratios and powerflow diagram
Transmission ratio:
This table gives the mechanical transmission ratios in individual gears (without torque converter).
1st
gear
2nd
gear
3rd
gear
4th
gear
5th
gear
6th
gear
Rev.
gear
Total
Ratios
3.43 2.01 1.42 1.00 0.83 -- 4.84
3.43 2.01 1.42 1.00 0.83 0.59 4.84
4.14
5.82
No. of
gears
5
6
Description of transmission and technical dataZF-Ecomat 2 plus
2-64149 765 103 - 2004-12
Power flow diagram:
The power flow diagram illustrates which clutches and combinations of clutches are closed when individual
gears are engaged, depending on transmission ratio.
5-speed version: i = 3.43 - 0.83
6-speed version: i = 3.43 - 0.59
B C D E F
WK WK
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
B C D E F
A
WK
WK
WK
WK
WK
WK
WK
Power flow
1st gear
(mechan.)
Neutral
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
1 Input
2 Torque converter lock-
up-clutch (WK)
3 Torque converter
4 Retarder
5 Clutches (A, B, C)
6 Brakes (D, E, F)
7 Output
8 Oil pump
1
3 4 5 6
7
2
8 013467
016362
1st gear
hydraul.
Description of transmission and technical dataZF-Ecomat 2 plus
2-74149 765 103 - 2004-12
2.4 Torque assignment - vehicle weight
Trans-
missions
HP 502
No. of
gears
Ratio Max. permissible 
input speed (rpm)
Coach
26 t 13 t 19 t up to 28 t
City bus
5 3.43 - 0.83 2800
61) 3.43 - 0.59 2800 for i = 0.59nmax = 2000
Max. permissible 
engine torque ISO 1585 1100 Nm 850 Nm
1) 1100 Nm 1100 Nm2)
HP 592 5 3.43 - 0.83 2800
61) 3.43 - 0.59 2800 for i = 0.59nmax = 2000
Max. permissible 
engine torque ISO 1585 1250 Nm -- 1250 Nm 1250 Nm
HP 602 5 3.43 - 0.83 2650
61) 3.43 - 0.59 2650 for i = 0.59nmax = 2000
Max. permissible 
engine torque ISO 1585 1600 Nm
3) -- 1600 Nm4) 1600 Nm4)
1) Only in conjuction with engine version CAN TSC1 TE
2) Max. torque in 1st gear: 1050 Nm
3) Max. torque in 1st gear: 1400 Nm
4) Max. torque in 1st gear: 1250 Nm
Description of transmission and technical dataZF-Ecomat 2 plus
2-84149 765 103 - 2004-12
2.5 Torsional vibration in driveline – inertia 
torques – vibration substitution model
CAUTION
Generally speaking, torsional vibration is due to
more than one component. The natural frequencies
are determined by the distribution of inertia torques
and the torsional rigidity of the entire driveline.
The vehicle manufacturer must ensure that the 
entire driveline does not apply any excessive vibra-tion loadings on the transmission.
Limit values for angle acceleration amplitude at the
output flange: εmax = ± 2000 rad/sec2
For the purpose of mathematical investigations into
vibration, the transmission is divided into three 
discrete rotating masses connected by (zero mass)
torsion springs:
• Mass 1: Torque converter without engine
flywheel and connection parts
• Mass 2: Clutch carrier
A, B, C for i = 3.43 - 0.83 (0.59)
• Mass 3: Manual transmission including
output flange
• Rigid body 1: Turbine shaft
• Rigid body 2: Input shaft and/or hollow shaft.
Half the moment of inertia of the shafts is assigned
to the relevant adjoining masses.
The following tables give the corresponding data
(moments of inertia and torsional rigidity) for 
individual transmission variants.
Description of transmission and technical dataZF-Ecomat 2 plus
2-94149 765 103 - 2004-12
Remarks: • Figures are based on pump or turbine speed of converter.
• Torque converter lock-up clutch closed.
• Engine connecting parts must be assigned to first rotating mass.
• Connecting parts fitted on output side must be assigned to third rotating mass.
• The moment of inertia for neutral position applies in the following conditions: 
- On input side, lock-up clutch and clutches A, B, and C opened
- Primary mass J1.1 of the converter (circuit cover, pump wheel, lock-up clutch) is hydro-
dynamically connected to the secondary mass J1.2 (turbine wheel, clutch carriers 
A, B and C) through the oil in the converter. However, these masses are regarded as
separate for vibration purposes.
1 2 3
C 1 C 2
1 2 3
J J J
B
A
C D E FWK
5/6 HP 502 / 592 - W 360*TPC... 6 HP 602 - W 390*TPC...
The moment of inertia J1, oil capacity included
J1
[kgm2]
C1
[Nm/rad]
J2
[kgm2]
C2
[Nm/rad]
J3
[kgm2]
1st gear
i = 3.43
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.78
0.78
39760
100300
0.23
0.24
2nd gear
i = 2.01
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.78
0.78
58350
136700
0.10
0.10
3rd gear
i = 1.42
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.78
0.78
70760
151200
0.14
0.15
Neutral position (lock-up clutch and clutches A, B, C open) 5/6 HP 502 / 592: J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
5/6 HP 602: J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2
4th gear
i = 1.00
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.82
0.82
108500
985000
0.50
0.53
5th gear
i = 0.83
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.79
0.79
105700
814100
0.46
0.46
6th gear
i = 0.59
6 HP 502 / 592
6 HP 602
1.51
2.07
19000
39000
0.79
0.79
105700
814100
0.46
0.46
016364
Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)
Description of transmission and technical dataZF-Ecomat 2 plus
2-104149 765 103 - 2004-12
Remarks: • Figures are based on pump or turbine speed of converter.
• Torque converter lock-up clutch closed.
• Engine connecting parts must be assigned to first rotating mass.
• Connecting parts fitted on output side must be assigned to third rotating mass.
• The moment of inertia for neutral position applies in the following conditions: 
- On input side, lock-up clutch and clutches A, B, and C opened
- Primary mass J1.1 of the converter (circuit cover, pump wheel, lock-up clutch) is hydro-
dynamically connected to the secondary mass J1.2 (turbine wheel, clutch carriers 
A, B, and C) through the oil in the converter. However, these masses are regarded as
separate for vibration purposes.
1 2 3
C 1 C 2
1 2 3
J J J
B
A
C D E FWK
5/6 HP 502 / 592 - W 360*TPC... / W 390*TPC...
incl. angle drive 80° RHD (i = 0.98) with right offset
J1
[kgm2]
Torque converter
The moment of inertia J1
oil capacity included
C1
[Nm/rad]
J2
[kgm2]
C2
[Nm/rad]
J3
[kgm2]
1st gear
i = 3.43
5/6 HP 502 / 592
1.51
2.07
W 360*TPC...
W 390*TPC...
19000 0.78 39760 0.26
2nd gear
i = 2.01
5/6 HP 502 / 592
1.51
2.07
W 360*TPC...
W 390*TPC...
19000 0.78 58350 0.18
3rd gear
i = 1.42
5/6 HP 502 / 592
1.51
2.07
W 360*TPC...
W 390*TPC...
19000 0.78 70760 0.29
Neutral position (lock-up clutch and clutches A, B, C open) W 360*TPC... : J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
W 390*TPC... : J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2
4th gear
i = 1.00
5/6 HP 502 / 592
1.51
2.07
W 360*TPC...
W 390*TPC...
19000 0.82 108500 0.77
5th gear
i = 0.83
5/6 HP 502 / 592
1.51
2.07
W 360*TPC...
W 390*TPC...
19000 0.79 105700 0.88
6th gear
i = 0.59
6 HP 502 / 592
1.51
2.07
W 360*TPC...
W 390*TPC...
19000 0.79 105700 0.88
021766
Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)
Output RHD
Description of transmission and technical dataZF-Ecomat 2 plus
2-114149 765 103 - 2004-12
Remarks: • Figures are based on pump or turbine speed of converter.
• Torque converter lock-up clutch closed.
• Engine connecting parts must be assigned to first rotating mass.
• Connecting parts fitted on output side must be assigned to third rotating mass.
• The moment of inertia for neutral position applies in the following conditions: 
- On input side, lock-up clutch and clutches A, B, and C opened
- Primary mass J1.1 of the converter (circuit cover, pump wheel, lock-up clutch) is hydro-
dynamically connected to the secondary mass J1.2 (turbine wheel, clutch carriers
A, B, and C) through the oil in the converter. However, these masses are regarded as
separate for vibration purposes.
1 2 3
C 1 C 2
1 2 3
J J J
B
A
C D E FWK
5/6 HP 502 / 592 - W 360*TPC... 5/6 HP 602 - W 390*TPC... 
incl. angle drive 80° LHD (i = 0.97) without offset 
019213
Inertia torques and vibration substitution model for i = 3.43 - 0.83 (0.59)
The moment of inertia J1
oil capacity included
J1
[kgm2]
C1
[Nm/rad]
J2
[kgm2]
C2
[Nm/rad]
J3
[kgm2]
1st gear
i = 3.43
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.78
0.78
39760
100300
0.25
0.26
2nd gear
i = 2.01
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.78
0.78
58350
136700
0.14
0.14
3rd gear
i = 1.42
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.78
0.78
70760
151200
0.20
0.21
Neutral position (lock-up clutch and clutches A, B, C open) 5/6 HP 502 / 592: J1.1 = 1.32 kgm2 / J1.2 = 0.87 kgm2
5/6 HP 602: J1.1 = 1.70 kgm2 / J1.2 = 1.07 kgm2
4th gear
i = 1.00
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.82
0.82
108500
985000
0.62
0.65
5th gear
i = 0.83
5/6 HP 502 / 592
5/6 HP 602
1.51
2.07
19000
39000
0.79
0.79
105700
814100
0.65
0.65
6th gear
i = 0.59
6 HP 502 / 592
6 HP 602
1.51
2.07
19000
39000
0.79
0.79
105700
814100
0.65
0.65
Output LHD
2.6 Weights and inertia torque values
2.6.1 Coaxial output without heat exchanger J08
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity.
Description of transmission and technical dataZF-Ecomat 2 plus
2-124149 765 103 - 2004-12
Transmission type Total weight Position of center of gravity Inertia torque values
(with retarder) without oil with oill S [mm] oil included JS [kgm2] oil included
J08 (oil cooler separate) m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 280 307 265 - 46 6 9.61 15.45 16.53
5/6 HP 592 285 312 265 - 46 6 9.61 15.45 16.53
5/6 HP 602 300 327 265 - 45 6 9.61 15.45 16.53
z z
y x
021772
Description of transmission and technical dataZF-Ecomat 2 plus
2-134149 765 103 - 2004-12
2.6.2 Coaxial output with heat exchanger J01
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity.
z
y
z
x
021773
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 305 337 291 - 56 5 10.50 20.43 21.84
5/6 HP 592 310 342 291 - 56 5 10.51 20.44 21.85
5/6 HP 602 325 357 299 - 58 4 10.52 20.43 21.85
Transmission type 
(without retarder)
J01 (oil cooler, 
installed at the rear)Description of transmission and technical dataZF-Ecomat 2 plus
2-144149 765 103 - 2004-12
2.6.3 Coaxial output with heat exchanger J05
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity.
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 305 337 297 - 43 25 11.69 24.21 23.31
5/6 HP 592 310 342 297 - 43 25 11.70 24.22 23.32
5/6 HP 602 325 357 295 - 42 24 11.71 24.26 23.36
z
y
z
x
021774
Transmission type 
(with retarder)
J05 (oil cooler, 
installed on the left side)
Description of transmission and technical dataZF-Ecomat 2 plus
2-154149 765 103 - 2004-12
2.6.4 Coaxial output with heat exchanger J10
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity.
z
y
z
x
021780
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 305 337 292 - 42 - 11 11.48 22.06 21.42
5/6 HP 592 310 342 291 - 42 - 11 11.48 22.07 21.43
5/6 HP 602 325 357 290 - 42 - 11 11.48 22.10 21.44
Transmission type 
(with retarder)
J10 (oil cooler, 
installed on the right side)
Description of transmission and technical dataZF-Ecomat 2 plus
2-164149 765 103 - 2004-12
2.6.5 Angle drive 80° without offset, with heat exchanger J05
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity. 
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 397 430 374 - 45 44 15.57 39.82 37.59
5/6 HP 592 402 435 373 - 45 44 15.58 39.93 37.69
5/6 HP 602 417 450 368 - 44 43 15.61 40.23 37.97
z
y
z
x
021775
Transmission type 
(with retarder)
J10 (oil cooler, 
installed on the left side)
Description of transmission and technical dataZF-Ecomat 2 plus
2-174149 765 103 - 2004-12
2.6.6 Angle drive 80° without offset, with heat exchanger J10
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity. 
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 397 430 347 - 29 8 14.10 34.51 33.38
5/6 HP 592 402 435 345 - 21 8 14.10 34.56 33.43
5/6 HP 602 417 450 342 - 29 8 14.10 34.72 33.59
z
y
z
x
021777
Transmission type 
(with retarder)
J10 (oil cooler, 
installed on the right side)
Description of transmission and technical dataZF-Ecomat 2 plus
2-184149 765 103 - 2004-12
2.6.7 Angle drive 80° RHD (with right offset), with heat exchanger J05
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity. 
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 420 454 425 - 53 - 9 17.11 45.79 43.68
5/6 HP 592 425 459 424 - 53 - 9 17.11 45.88 43.77
z
y
z
x
021778
Transmission type 
(with retarder)
J10 (oil cooler, 
installed on the left side)
Description of transmission and technical dataZF-Ecomat 2 plus
2-194149 765 103 - 2004-12
2.6.8 Angle drive 80° RHD (with right offset), without heat exchanger J08
Center of gravity S refers to engine connection surface. 
Inertia torque JS refers to the position of the center of gravity.
Total weight Position of center of gravity Inertia torque values
without oil with oil S [mm] oil included JS [kgm2] oil included
m [kg] m [kg] xS yS zS JxS JyS JzS
5/6 HP 502 387 416 394 - 52 - 34 13.56 37.58 38.50
5/6 HP 592 392 421 393 - 52 - 33 13.57 37.68 38.59
z
y
z
x
021779
Transmission type 
(with retarder)
J08 (oil cooler separate)
Description of transmission and technical dataZF-Ecomat 2 plus
2-204149 765 103 - 2004-12
2.7 Clutch combinations
The tables shown which clutches are activated
depending on the gear selected and the ratio.
5th gear i = 3.43 - 0.83
6th gear i = 3.43 - 0.59
* Reduced pressure
1) Standard version
F1 = external piston area brake F
F2 = internal piston area brake F
A B C D E F1 F2
Reverse gear ● ● ●
Neutral
Neutral (NBS) 1) ● ● *
1st gear ● ●
2nd gear ● ●
3rd gear ● ●
4th gear ● ●
5th gear ● ●
6th gear ● ●
Ecomat installation position in vehicleZF-Ecomat 2 plus
3-14149 765 103 - 2004-12
3 Ecomat installation position in vehicle
T-Drive
The conventional installation position in buses is the
mid-axle T-drive with the transmission fitted in the
direction of travel.
The introduction of drop-center axles for low-floor
buses means the driveline is displaced, for example,
to the left.
Transverse installation at rear 80°
To further optimize available space, various angle
drive versions (WTR) are used to allow transverse
installation.
Another advantage of the 80° WTR with axial offset
is that the output is moved 217.5 mm downwards.
80° angle drive version with right offset
80° angle drive version without left offset
4139 S 2011
015996
4139 S 2014
4139 S 2010
Installation arrangement and mountingsZF-Ecomat 2 plus
4-14149 765 103 - 2004-12
4 Installation arrangement and mountings
The transmission must not be supported other than
at the bolt attachment faces provided for this purpose
on the transmission housing and auxiliary unit.
Transmission mountings on the chassis must be 
designed in consultation with ZF in such a way that
no additional forces resulting from twisting of the
chassis may be transmitted to the transmission 
housing.
The connection dimensions for transmission moun-
tings, the transmission weight, and centre of gravity
are indicated in the individual installation drawings.
The bolts used to attach the transmission to its
mountings must be of quality 8.8. Specified tighte-
ning torque for mounting points see C + E + D = 
225 Nm.
If a flange-mounted angle drive is fitted, mounting
point E may be used for stabilization. However, 
whenever mounting E is in rest position , ensure that
no forces are transmitted and that the rigidity of E is
less than the rigidity of mounting A + C or A + C/D
and/or A + B.
DANGER
The bending torque exerted by mounting blocks at
mounting flange face C and/or D must not exceed the
following limit: MC ≤ 3500 Nm / MD ≤ 1500 Nm
The bending torque can be calculated from the 
bracing force (F) at the rubber mounting and lateral
lever length (L) of bearing block. Take into account
any simultaneous vertical acceleration and torque
loading from the transmission or powerpack.
If the forces acting on each side are offset longitudi-
nally, please consult our Application Engineering
department.
4.1 Transmission flange-mounted on engine
ZF recommended mounting points
!
F
L L
F
4139 S 0028
A B
A
A
B
B
C
C
E
E
C
D
D
D
Engine
Mounting points at A + B or A + C or A + C/D
Ecomat with 80°angle drive
Mounting points at A + B or A + C or A + C/D
Ecomat with 80°angle drive
Mounting points at A + B or A + C or A + C/D
Additional mounting point at E possible, either above or
below housing.
Ecomat
021769
Guidelines for propshaft installationZF-Ecomat 2 plus
5-14149 765 103 - 2004-12
5 Guidelines for propshaft installation
A propshaft may be the cause of torsional and 
bending vibrations in the driveline. Compliance
should therefore be maintained with the following
approximate values. The vehicle manufacturer is 
responsible for this.
Exceptions from the values specified must be 
approved.
5.1 Permissible rotational irregularity
The maximum permissible angle-acceleration ampli-
tudes (∆ε) in the driveline are 2000 rad/s2. Smaller
values do not result in vibration damage.
Rotational accelerationin the driveline can be 
checked using a calculation or measurement. Alter-
natively, the rotary angle error (∆α) can also be
used for this purpose.
Relationship between ∆α and ∆ε: 
∆εper. ≤ 2000
rad 
=
∆α [°] • n2 [1/min2]
s2 1306
The following sub-chapters indicate limit values for
the permissible bending angle. If compliance is
maintained with these limits, the vibration ampli-
tudes excited by the propshafts will not exceed the
maximum value.
The limit values for the bending angle are used in
particular if there are no calculations or measure-
ments of the vibration amplitudes.0.2
+0.1
0
0.1
0.2
� �
� �
S 0013
1 rev.
1.2
1.8
1.6
1.4
1.0
0.8
0.6
0.4
0.2
1000 2000 3000
� �
Propshaft speed n (rpm)
Ro
ta
tio
na
l a
ng
le
∆
α
Limit curve for measurement
εper. ≤ 2000 rads2
S 0014
1 rev.
Guidelines for propshaft installationZF-Ecomat 2 plus
5-24149 765 103 - 2004-12
5.2 Permitted resultant deflection angle for
each joint
When using a spatial propshaft layout, the resultant
deflection angle βR must first be determined using
the following formula:
tan βR = tan2 βH + tan2 βV
where βH - deflection angle when viewed horizontal-
ly (plan view)
where βV - deflection angle when viewed vertically
(front view).
The deflection angle β is therefore defined as the
angle between the axes of rotation in front of and
behind the joint in the appropriate view.
As a rough guide, the angle βR can be determined
from the following diagram.
Resultant deflection βR with spatial propshaft 
arrangement.
Calculation example:
Plan view Front view
tan βR = 0.162 + 0.232 = 0.28 βR = 15.6°
According to diagram: βR ≈ 15°
The acceptability of βR depends on the type, size,
and speed of the propshaft.
β
007927
10˚
15˚
20˚
25˚
13˚
9˚ 10˚ 15˚
5˚
0˚
5˚
20˚ 25˚
�H
R�
�
V
5˚
10˚
15˚
20˚
25˚
30˚
021847
�V =13° �H =9°
021846
500 1000 1500 2000 2500 3000 3500 4000
18°
20°
16°
14°
12°
10°
max. 7° at PTO
8°
6°
4°
2°
0° 
De
fle
ct
io
n 
an
lg
le
 β
R
Product range
Propshaft speed n (rpm)
R
Flange Ø 165/180/225
Flange Ø 150
β
007098_en
Guidelines for propshaft installationZF-Ecomat 2 plus
5-34149 765 103 - 2004-12
5.3 The permitted resultant flexure angle for all
joints
The resultant flexure angle βE is calculated from the
angles of individual joints using the following formula:
βE = | ± βR12 ± βR22 ± βR32 ± . . . |
The individual angles β should be given the follo-
wing positive or negative values:
+ If the journal cross
is perpendicular to Input Output
the driven yoke
– if the journal cross
is perpendicular to Input Output
the driving yoke
Limit value: βE < 3°
90˚
90˚
4139 S 0010
Examples illustrating the effect of deflection angle β1 and β2 on resultant flexure angle βE
�1 = 12° �1 = 12°
�1 = 5°
�1 = 5°
�1 = 15° �1 = 15°
�2 = 14°
�2 = 14°
�2 = 4°
�2 = 4°
�2 = 12° �2 = 12°
Z arrangement W arrangement Angle error Resultant flexure angle
∆β = β1 - β2 βE = | - β12 + β22 |
0° 0°
1° 3°
1° 5,4°
Example 3 shows that, in the case of large deflection angles, angle errors of as little as 1° can cause an impermissibly large resultant flexure angle.
Example 3
(Large
deflection
angle with
angle error)
021848
Example 1
(Precise
Z or W
arrangement)
Example 2
(Small
deflection
angle with
angle error)
Guidelines for propshaft installationZF-Ecomat 2 plus
5-44149 765 103 - 2004-12
5.4 Single-section propshafts
Best efforts must be taken to configure the axle sus-
pension suitably to ensure the propshaft remains in a
precise Z pattern (β1 = β2) under all vehicle loading.
Leaf springs give a good Z position due to parallel
axle movement.
β1 = β2 is more-or-less maintained across whole
range of suspension travel.
Floating axle gives a poor Z position due to the 
pivoting movement of the axle.
β1 = β2 is only maintained at the middle point. 
Suspension movements upwards or downwards
make the angles unequal.
5.5 Multi-section propshafts
In multi-section propshaft configurations, the drive-
line can be optimized by suitable choice of crosslink
orientations and by varying height h of the inter-
mediate bearing (β angle distribution).
Unfavorable arrangement
βE = | - β12 + β22 - β32 | = (13,6°)
Optimized arrangement
(by changing position of crosslink)
βE = | - β12 - β22 + β32 | = (2,4°)
�1
�2
2
β
1β
-0 +
1β
2
β
Transmission
Axle
4139 S 0015
Spring travel
loaded
unloaded
Axle movement
Swing travel
loaded
Centre position
Axle Movement 4139 S 0016
4139 S 0016
β
3
= 5˚
= 9.5˚
= 11˚
h
1β
2
β
Transmission
Axle
4139 S 0017
= 11˚β 3
= 5˚
h
2
β
= 9.5˚
1β
Transmission
Axle
4139 S 0017
Guidelines for propshaft installationZF-Ecomat 2 plus
5-54149 765 103 - 2004-12
5.6 Maximum permissible propshaft length
NOTE
The maximum length is limited to 1500 mm to pre-
vent the bending vibrations being activated by the
propshaft, if necessary, a multiple arrangement with
intermediate bearing will have to be selected.
Further information
• Balancing: The propshaft must be dynamically
balanced in quality 16 in accordance with VDI
guideline 2060.
• Permissible concentricity and runout errors of
the connection flange:
• Lubrication: 
The specifications of the propshaft manufacturer
should be observed for lubrication.
The sliding piece must move easily under load.
Max. Concentricity and Centering 
speed runout deviation fit
[min-1] [mm]
500 0.10 h8
1500 0.07 h7
3500 0.06 h7
Pe
rm
. r
es
id
ua
l i
m
ba
la
nc
e 
pe
r 
ba
la
nc
in
g 
m
as
s 
[g
m
m
/k
g]
Propshaft speed n (1/min)
41
39
 S
 0
01
8
Q16
300 500 700 900 1500 3000 4000
30
40
60
80
100
150
200
250
Engine connectionZF-Ecomat 2 plus
6-14149 765 103 - 2004-12
6 Engine connection
Before the Ecomat transmission is connected to the
engine, the Application Engineering dept. and engine
manufacturer must perform an “engine connection
study”. This involves determining all important
dimensions and tolerances for the connection and
preparing an engine connection drawing. See Sec-
tion 5.2, “Engine connection study” for an example
of this and additional information.
There are two methods for connecting the trans-
mission to the engine:
• Method 1: The engine flywheel (2) is retained
and carries the starter ring gear (5). The flex 
plates (10) are connected directly to the converter
(7).
• Method 2: Remove engine flywheel (2). Fit a 
starter ring gear carrier (8) between the flex 
plates (10) and converter (7).
NOTE
Before fitting together the engine and Ecomat,
always check that the following points are complied
with:
• There must be an assembly access hole (4) in the
flywheel housing and flywheel.
• The bolts must be of the quality specified in the
engine connection drawing.
• Observe specified tightening torques when 
tightening all bolts.
• Use only hardened, flat washers (DIN 125-13-
300 HV or DIN 125-10.5-300 HV), or stop screws
according to DIN 961, quality 8.8. Never use 
toothed lock screws or similar.
• Check the following tolerances:
- Max. deflection of flex plates 
= ± 1.2 mm (important for flex plate life)
- Flex plate thickness (D)
= 4 x 0.5 mm ± 0.04 mm 
= 2 mm ± 0.16 mm
- Runout tolerance (A) of flywheel inner bore
and/or centring ring to centring spigot on
flywheel housing = max. 0.3 mm
- Permitted tolerance for dimension (C) for 
for Method 1 = ± 0.66 mm
for Method 2 = + 0.66 mm
– 0.96 mm
(Dimension (B) is set by ZF to ± 0.5 mm)
• Clean torque converter circuit cover.
Engine connectionZF-Ecomat 2 plus
6-24149 765 103 - 2004-12
Assembly sequence for variant 1 
(with flywheel)
• Check dimensions (A) and (C) comply with 
engine connection drawing. If dimensions exceed
tolerance, contact our Application Engineering
dept. urgently.
• Bolt together crankshaft (1), flywheel (2), flex 
plates (10), and clamping ring (11). Consult engine
manufacturerto establish correct tightening 
torque.
• Bolt together transmission housing (6) and fly-
wheel housing (3) as shown in engine connection
drawing. Tightening torque for bolt quality 8.8: 
TA = 49 Nm for screws M10
TA = 79 Nm for screws M12.
• Using assembly access hole (4) in flywheel 
housing and flywheel, bolt flex plates (10) onto
converter (7). Tightening torque TA = 81 Nm for
bolt quality 8.8.
Variant 1 Drawing no.: 4139 530 064
A A
023809
Engine connectionZF-Ecomat 2 plus
6-34149 765 103 - 2004-12
Assembly sequence for variant 2 
(without flywheel)
• Check dimensions (A) and (C) comply with 
engine connection drawing. If dimensions exceed
tolerance, contact our Application Engineering
dept. urgently.
• Bolt together crankshaft (1), centering ring (11),
flex plates (10), and clamping ring (9). Consult
engine manufacturer to establish correct tighten-
ing torque.
• Using two bolts (12), bolt gear ring carrier (8)
with integral ring gear (5) onto converter (7).
• Bolt together transmission housing (6) and fly-
wheel housing (3) as shown in engine connection
drawing. Tightening torque for bolt quality 8.8:
TA = 49 Nm for screws M10
TA = 79 Nm for screws M12.
• Using assembly access hole (4) in flywheel 
housing bolt flex plates (10) onto converter (7).
Tightening torque TA = 81 Nm for bolt quality 8.8.
Variant 2 Drawing no.: 4139 530 065
A
A
023810
SECTION A-A
SECTION A-A
SECTION B-B
ASSEMBLY ACCESS HOLE
Engine connectionZF-Ecomat 2 plus
6-44149 765 103 - 2004-12
6.1 ZF Scope of delivery
The flex plates and bolts for fastening 4 flex plates to
the converter are supplied by ZF.
NOTE
Vehicle manufacturer should establish whether the 4
diaphragms
• are ordered form the engine manufacturer and
fitted there onto the engine with the connection
parts required or
• are to be included in the transmission scope of
supply for the vehicle manufacturer.
6.2 Engine connection inspection
If no engine connection drawing has been prepared,
the following documents are required for the engine
connection inspection:
• Detailed drawing of flywheel housing
• Detailed drawing of flywheel 
• Detailed drawing of end of crankshaft 
• Drawing of engine output assembly showing axial
and radial tolerance range for crankshaft and 
distance between end of crankshaft and flanging
face of flywheel housing.
• For Method 2, pay particular attention to the 
markings for the fuel injection point.
6.3 Engine connection: Further information
Attempts should be made to undertake all engine
connections following variant 1 with a complete
flywheel.
Since there is no flywheel in the version following
variant 2, the inertia torque of the engine is 
changed. Under unfavorable circumstances, this
may result in resonance vibrations and finally 
diaphragm failure.
CAUTION 
Variant 2 (segregated design) may only be used
once the Application Engineering department has
been contacted.
The following applies in general:
• Engine connection drawings are already available
for popular engines.
• The engine connection must be designed to 
ensure that the torque converter is centered on
the crankshaft.
• For clamping disc and centering ring version, see
detail “W”.
For ring gear carrier version, see detail “V“ (see
drawing 4139 601 171 overleaf).
• A vibration damper between the engine and
transmission is not required when using the
direct engine-transmission construction.
• If the engine and transmission are installed sepa-
rately, a vibration damper should be fitted bet-
ween the crankshaft and propshaft. The choice of
such a damper should be made with the assistan-
ce of the Application Engineering department.
Responsibility for the correct damper design lies
with the vehicle manufacturer. The vehicle
manufacturer must provide the damper.
Engine connectionZF-Ecomat 2 plus
6-54149 765 103 - 2004-12
6.4 Engine connection drawings
Detailed drawing of engine connection Drawing no.: 4139 601 171
ZF-ECOMAT 2 plus
A
DETAIL V
5:1
DETAIL W
5:1
 50 H7e8
56 1.9
86.0 1.0
+ 0.5
63.5±0.5
0.3 A
min. 7 mm
max. 8 mm
Kontaktfläche
min. 4 021682
4 FLEX PLATES
0.5 MM THICK
Contact surface
Engine connectionZF-Ecomat 2 plus
6-64149 765 103 - 2004-12
Detailed drawing of engine connection
Variant with flywheel
5R 201
5
R 201
W
ZF-ECOMAT 2 plus
A
 50 H7e8
56±1.9
63.5±0.5
86.0
0.3 A
min. 7 mm
max. 8 mm
Kontaktfläche
DETAIL W
5:1
min. 4
+ 0.5
- 1.0
021683
Contact surface
Engine connectionZF-Ecomat 2 plus
6-74149 765 103 - 2004-12
6.5 Overview converter-circuit cover
W360 A [mm] LKR [mm]
0501 320 294 77.00 380
0501 320 293 81.25 380
0501 320 298 71.25 402
0501 320 295 71.25 380
0501 320 299 68.00 402
0501 320 297 77.00 402
0501 320 296 81.25 402
0501 320 300 86.25 326
W390 A [mm] LKR [mm]
0501 318 581 81.25 380
0501 318 583 77.00 402
0501 318 582 81.25 402
0501 319 971 71.25 380
0501 320 321 71.25 402
ConverterZF-Ecomat 2 plus
7-14149 765 103 - 2004-12
7 Converter
7.1 Torque converter: Description
The torque converter is mounted on the input end of
the planetary transmission. The torque converter
consists of the impeller, turbine, and reaction mem-
ber (stator) and the oil needed for torque transmis-
sion.
Torque is transmitted from the engine flywheel to
the torque converter by means of a connection 
comprising flex plates.
7.2 Converter functions
The impeller driven by the engine displaces the oil
in a circular pattern. This oil flow strikes the turbine
wheel and is deflected back.
The stator downstream of the turbine is used to
deflect the oil flowing out of the turbine back into
the impeller at an appropriate angle. This change in
direction generates a torque on the stator, which in
turn boosts the turbine torque. The ratio of turbine
torque to impeller torque is referred to as torque
conversion. The greater the difference in the speeds
of the impeller and turbine, the higher the torque
multiplication. In other words, maximum multiplica-
tion occurs when the turbine is stationary, and falls
as the turbine speed rises. 
The converter adjusts the output speed to achieve
the required output torque using a continuous, auto-
matic process. The torque of the stator is always
equal to the difference between the turbine and
impeller torque.
When the turbine speed approaches approx. 80% of
the impeller speed, torque multiplication drops to a
ratio of 1, i.e. turbine torque equals impeller torque.
From this point on, the converter acts purely as a
fluid coupling. Under such conditions the stator,
which is linked to the housing by a roller freewheel
unit ("Trilok" principle) begins to rotate freely in the
oil flow, whereas it is held against the housing by the
freewheel when torque multiplication takes place
and thus remains stationary.
To ensure economical operation, the torque conver-
ter lock-up clutch is closed as soon as this is possible.
When the lock-up clutch is closed, the level of slip
between the impeller and turbine wheel and there-
fore the loss of hydraulic energy in the converter is
"zero".
The close ratios and optimum gear step adjustment
of the 5th and 6th mechanical gears in the trans-
mission allow the converter to be locked up at a very
early stage. This makes use of the advantages of
mechanical power transmission early on high 
efficiency and low power losses.
ConverterZF-Ecomat 2 plus
7-24149 765 103 - 2004-12
4139 S 2015
Turbine wheelImpeller
From engine
Condition at 
instant of 
starting off
Stator
nT = O
Vehicle stationary
nT < nEng
nT = 0.8nEng
nT = nEng
After lock-up 
clutch closes
TP = Torque of impeller
TT = Torque of turbine wheel
TR = Torque of stator
Intermediate 
condition
Condition immedia-
tely before lock-up
clutch closes
To transmission
TP TR TT
4166 703 1502.165
Basic curve
Drawing no.
ID no. for
ANKE (P22500N)
TP1000
[Nm]
µ0
[ - ]
2.195
4166 703 147
4166 703 149
4166 703 148
01 14500 16300 1000 221 970Z
01 26200 26200 1000 240 1000Z
01 30000 30050 1000 236 1000Z
01 34200 34200 1000