CAPÍTULO 3: ANÁLISIS DE LOS RESULTADOS
3.4 Validación del Sistema
17 ZF documentation
17.1 ZF documentation with CAN 17.1.1 Components
The engine, transmission, and electronic control unit (EST 146/147 ) of the Ecomat series micro-processor controlled automatic transmissions are individually matched to each other. These three components may only be installed in a vehicle in a combination which has been documented by ZF.
Every application is documented at ZF under a Parts List (specification) number and is available as a computer printout (see example below).
Computer printout (scope of delivery)
CAUTION
Before installing any Ecomat transmission, check the Parts List numbers on the identification plates to ensure that the engine, transmission, and ECU are as shown in the documentation, i.e. that the details agree with the computer printout.
In correspondence and inquiries, please always quote the Parts Lists Nos. and Serial Nos. of the Ecomat and the electronic control unit
(EST 146/147)!
4143 Z F F PA R T S L I S T O R G A N I Z AT I O N
MODULAR PARTS LIST TECHNICAL INF/MODIFICATION NO. *DISPLAY* SHEET 001
SNR(Z): 4149 080 XXX BEN: 6 HP 602 C T-INFO:
DEPT: BPE1 RESPONSIBLE: L: K3 AEI: ZB: STEP2
POS VKF PART NO. DESCRIPTION TECHNICAL INFORMATION AN/AU AE-NR
A10 CUSTOMER: XXXXXXX *COUNTRY: XX
A14 ORDER NO.: XXXXXXXXX
S02 VEHICLE DATA 1:
S04 MODEL: BUS (GELENK) *XXX
S06 MAX. G.V.W: SOLO 28T
S08 R DYN: 466*V MAX: CA. 100 KM/H
S10 HA: I = 5,74
S12
S14 XXXX / XXXX E3*KW265/1900*N.M1600/1530
S16 ENGINE: EDC BOSCH MS 5.5
S30 DRAWINGS:
S32 ENG.INSTALL.: 4139 500 798(0)
S34 CONVERTER DIAGRAMM: 4166 706 166
S46 CONNECT. DIAGRAM: 6029 729 XXX
S48 CURRENT CIRC. DIAGRAM 6029 729 XXX
930 SUPERIMPOSED PRODUCT CONSISTING OF:
932 1 4149 064 XXX 6 HP 602 C 24V*FLANGED*COAXIAL*NBS
*RETARDER*ECOMAT2PLUS
950 1 6009 090 XXX EST 146 STEP2
970 1 4139 130 126 CONNECTION
984 1 4149 196 164 PERIPHERALS 9416A
a = Parts List No. for computer printout (supply specification) b = Parts List No. for Ecomat transmission
c = Parts List No. for electronic control unit EST 146 / 147
a
b c
-ZF documentation ZF-Ecomat 2 plus
17-2
4149 765 103 - 2004-12
Description of fiels on type plate
Transmission:
1 Transmission Parts List No.
(for matching EST 146 / 147, check documen-tation)
2 Transmission model designation, including number of gear ratios
3 Transmission serial no.
4 Client's order no., if known to ZF 5 Transmission ratio range
6 Speedo signals 6 impulses/revolutions
7 PTO model
8 PTO ratio
9 Approx. oil quantity required for first filling 10 ZF List of Lubricants No.
Electronic control unit EST 146 / 147:
1 EST 146 / 147 Parts List No.
(for matching transmission, check documenta-tion)
2 EST 146 / 147 serial no.
3 ECU designation 4 Rated voltage 5 Programming
6 Client's order no., if known to ZF
7 Transmission model designation, including number of gear ratios
(Check that number of ratios is correct!) 17.1.2 Identification and engine compatibility data
B
A
C
D
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
ECOMAT 2 6 HP - 602 C
4149 064 XXX XXXXXX
XX XXXXX XXXX
3.43 - 0.59 IMP/U6.00
-
-20 14
MODEL
PARTS LIST NO. SERIAL NO.
CUSTOMER
OIL GRADE SEE LUBRIC. LIST TE-ML
2
ZF documentation ZF-Ecomat 2 plus
17.2 ZF documentation without CAN 17.2.1 Components
The engine, transmission, and electronic control unit (EST 146/147 ) of the Ecomat series micro-processor controlled automatic transmissions are individually matched to each other. These three components may only be installed in a vehicle in a combination which has been documented by ZF.
Every application is documented at ZF under a Parts List (specification) number and is available as a computer printout (see example below).
Computer printout (scope of delivery)
CAUTION
Before installing any Ecomat transmission, check the Parts List numbers on the identification plates to ensure that the engine, transmission, and ECU are as shown in the documentation, i.e. that the details agree with the computer printout.
In correspondence and inquiries, please always quote the Parts Lists Nos. and Serial Nos. of the Ecomat and the electronic control unit
(EST 146/147)!
4143 Z F F PA R T S L I S T O R G A N I Z AT I O N
MODULAR PARTS LIST TECHNICAL INF/MODIFICATION NO. *DISPLAY* SHEET 001
SNR(Z): 4149 080 XXX BEN: 6 HP 602 T-INFO:
DEPT: BPE1 RESPONSIBLE: L: K3 AEI: ZB: STEP2
POS VKF PART NO. DESCRIPTION TECHNICAL INFORMATION AN/AU AE-NR
A10 CUSTOMER: XXXXXXX *COUNTRY: XX
A14 ORDER NO.: XXXXXXXXX
S02 VEHICLE DATA 1:
S04 MODEL: BUS (GELENK) *XXX
S06 MAX. G.V.W: SOLO 28T
S08 R DYN: 466*V MAX: CA. 100 KM/H
S10 HA: I = 5,74
S12
S14 XXXX / XXXX E3*KW265/1900*N.M1600/1530
S16 ENGINE: EDC BOSCH MS 5.5
S30 DRAWINGS:
S32 ENG.INSTALL.: 4139 500 798(0)
S34 CONVERTER DIAGRAMM: 4166 706 166
S46 CONNECT. DIAGRAM: 6029 729 XXX
S48 CURRENT CIRC. DIAGRAM 6029 729 XXX
930 SUPERIMPOSED PRODUCT CONSISTING OF:
932 1 4149 064 XXX 6 HP 602 24V*FLANGED*COAXIAL*NBS
*RETARDER*ECOMAT2PLUS
950 1 6009 090 XXX EST 146 STEP2
970 1 4139 130 126 CONNECTION
984 1 4149 196 164 PERIPHERALS 9416A
a = Parts List No. for computer printout (supply specification) b = Parts List No. for Ecomat transmission
c = Parts List No. for electronic control unit EST 146 / 147
a
b c
-ZF documentation ZF-Ecomat 2 plus
17-4
4149 765 103 - 2004-12
Description of fiels on type plate
Transmission:
1 Transmission Parts List No.
(for matching EST 146 / 147, check documen-tation)
2 Transmission model designation, including number of gear ratios
3 Transmission serial no.
4 Client's order no., if known to ZF 5 Transmission ratio range
6 Speedo signals 6 impulses/revolutions
7 PTO model
8 PTO ratio
9 Approx. oil quantity required for first filling 10 ZF List of Lubricants No.
Electronic control unit EST 146 / 147:
1 EST 146 / 147 Parts List No.
(for matching transmission, check documenta-tion)
2 EST 146 / 147 serial no.
3 ECU designation 4 Rated voltage 5 Programming
6 Client's order no., if known to ZF
7 Transmission model designation, including number of gear ratios
(Check that number of ratios is correct!) 17.2.2 Identification and engine compatibility data
B
A
C
D
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
ECOMAT 2 6 HP - 602 N MOT
4180 064 XXX XXXXXX
XX XXXXX XXXX
3.43 - 0.59 IMP/U6.00
-
-20 14
MODEL
PARTS LIST NO. SERIAL NO.
CUSTOMER
OIL GRADE SEE LUBRIC. LIST TE-ML
2
ZF documentation ZF-Ecomat 2 plus
17.3 Oil level check
17.3.1 Oil level check prior to first commissioning;
transmission without oil filling
ACHTUNG CAUTION
Vor Erstinbetriebnahme Oelstandskontrolle durchfuehren
Prior to running transmission for the first time, carry out oil level check.
A) Fuellmenge 15-20 Liter bei stehendem Motor.
B) Motor starten; nach 30 Sekunden bei Drehzahl Oelstand am Messstab pruefen. Wenn noetig Oel nachfuellen, bis Marke "COLD" bzw.
"30°C"erreicht wird.
Die massgebende standskontrolle ist die Pruefung bei triebstemperatur 80°C - 90°C.
Bei zahl und Getriebe tral muss Oelstand im Warmbereich "85°C"
bzw. "HOT"liegen
zone engine stopped hot zone 80-90°C
cold zone 30°C A) Capacity 15-20 Liters engine stopped.
B) Start engine; after 30 secs. check oil level
Avant la première mise en service il faut effectuer le contrôle du niveau d'huile.
A) Quantité à verser:
15 à 20 l, moteur arrêté.
B) Démarrer le moteur; après 30 secondes vérifier le
Prima della messa in eser-cizio si deve controllare il livello dell'olio
Zona di fermo(nmot=0) Zona di caldo 80-90°C
Zona di freddo 30°C niveau à l'arrêt(nmot=0)
moteur chaud 80-90°C
moteur froid 30°C
A) Quantitá di riempimento a motore fermo: 15-20 litri B) Avviare il motore;
dopo 30 secondi e con
ZF documentation ZF-Ecomat 2 plus
17-6
4149 765 103 - 2004-12
17.3.2 Oil level check prior to first commissioning;
Transmission oil filing at plant
ACHTUNG CAUTION
Getriebe ist mit Oel befuellt
Transmission with oil fill A) Vor Erstinbetriebnahme
Oelstandskontrolle durchfuehren B) Motor starten, nach 30 Sekunden bei
A) Prior to running mission for the first time, carry out oil level check.
B) Start engine, after 30 secs. check oil level transmission in neutral.
STOP
engine stop zone hot zone 80-90°C
cold zone 30°C STOP HOT
COLD
ATTENTION ATTENZIONE
La boîte de vitesses est remplie d'huile
Cambio riempito con olio A) Avant la première mise
en service, il faut effectuer le contrôle du niveau d'huile.
B) Démarrer le moteur; après 30 secondes, vérifier le
A) Prima della messa in esercizio si deve controllare il livello dell'olio B) Avviare il motore;
dopo 30 secondi e con
Il controllo determinante del livello dell'olio è
Zona di fermo(nmot=0) Zona di caldo 80-90°C
Zona di freddo 30°C niveau à l'arrêt(nmot=0)
moteur chaud 80-90°C
moteur froid 30°C
STOP
ZF documentation ZF-Ecomat 2 plus
17.3.3 Oil level check prior to first commissioning;
Transmission with additional cooling system, with or without oil filling at plant
ACHTUNG
Getriebe mit Zusatzkuehlung.
Getriebe hat nicht die erforderliche Oelmenge.
STOP HOT
COLD Standbereich (n Mot=0)
Kaltbereich 30°C Warmbereich 80-90°C A) Vor Erstinbetriebnahme die Gesamtlaenge
aller Komponenten der Zusatzkuehlung ausserhalb des Getriebes ermitteln.
Aus der Gesamtlaenge und Leitungs DN(Innendurchmesser) die Zusatzoelmenge ermitteln.
Oelvolumen [Liter]
Gesamtlaenge [m]
Oil volume [Litre]
Total lenght[m]
Transmission with auxiliary cooling.
Oil volume insufficient for the transmission.
A) Determine total lenght of all auxiliary cooling components outside of the transmission prior to initial startup.
Determine additional oil volume on the basis of total lenght and line - DN(inner diameter).
CAUTION
engine stop zone hot zone 80-90°C
cold zone 30°C STOP HOT
COLD Oelfuellvolumen des Oelkuehlers ermitteln.
Die erforderliche Zusatzoelmenge einfuellen.
B) Vor Erstinbetriebnahme Oelstandskontrolle durchfuehren.
Motor starten, nach 30 Sekunden bei Leerlauf-Drehzahl Oelstand am Messstab pruefen,wenn noetig Oel nachfuellen, bis Marke "COLD" bzw."30°C"erreicht wird.
Die massgebende Oelstandskontrolle ist die Pruefung bei Betriebstemperatur 80 - 90°C.
Bei Motorleerlauf-Drehzahl und Getriebe Neutral muss Oelstand im Warmbereich "85°C"
bzw. "HOT"liegen.
Determine oil-fill volume of the oil cooler.
Fill in extra amount of oil reguired.
B) Prior to running transmission for the first time, carry out oil level check.
Start engine, after 30 secs. check oil level at dipstick with engine idling. If necessary, add oil to "COLD/30°C" mark.
The oil level check carried out at 80ÔC to 90°C operating temperature gives the conclusive reading.
Oil level must be in warm range "85°C/HOT"
with engine idling and transmission in neutral.
DN=16mDN=18mmm DN=20mm DN=22mm DN=24mm
DN=24mm DN=22mm DN=20mm DN=18mm DN=16mm
021 684
18 Calculations and conversion tables 18.1 Driveline design
Use the following vehicle performance formulae to select driveline design. They enable you to select the best components to suit your special requirements (e.g. required top speed, gradability etc. as a function of axle ratios, transmission ratios, tire radii etc.).
The formulae can either be solved using the para-meters required or by iteration.
Please observe the following points concerning gradability:
• Gradability in the 1 st mechanical gear must be the criterium, because the torque converter should only be used as start-up assistance.
Reference value is S > 11 %.
In difficult terrain, a larger S value should be selected.
• The following is valid in practice for extreme applications: Starting capacity, e.g. starting off is still possible up to max = 0.8•Smax..
(Smax.= gradability at stall-point.)
Calculation formulae:
Driving speed vF[km/h]
Max. gradability Smax[%]
(Resistance WL≈ 0)
Gradability S at higher speeds vF
For inclines S ≤ 10% is sin α ≈ tan α; Error ≤ 0.5 % S = 100 [ __________________ _ ________________________________ – fR]
G [lbft] •rdyn [ft] G [lbft]
TT[lbft]•iG•iH•ηtot
Smax= 100 •tan [arc sin( ____________________ – fR)]
G [lbft] •rdyn [ft]
0.0714 •rdyn [ft] •nT [min-1] vF= ________________________
iG•iH
rdyn[m], [ft] Rolling radius m [kg]
G [lbft]
9.81 [m/s2] Acceleration due to gravity nT[1/min] Turbine speed
TT[Nm], [lbft] Turbine wheel torque iG[–] Transmission ratio iH[–] Axle ratio
Once the key data has been established, a computer program can be used, if required, to perform the vehicle performance calculation.
0.377 •rdyn [m] •nT [min-1] vF= ________________________
iG•iH
Vehicle weight
}
ηtot[–] Overall efficiency = ηG•ηH
= 0.95 •0.95 ≈ 0.9 fR[–] Rolling resistance
Asphalt, concrete, fR= 0.010 – 0.012 Beaten earth, fR= 0.020 – 0.040 CW[–] Coefficient of air resistance Bus CW≈ 0.6
Truck CW≈ 0.8 A [m2], [ft2] Front section area Bus A ≈ 6m2
Lkw A ≈ 8m2 VF[km/h], [mph] Driving speed