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Transmission Tests ZF

This document provides instructions for performing a stall test on a ZF ECOMAT 2 transmission to diagnose engine and transmission problems. It describes how to check stall speed and what the results may indicate. Stall protection software prevents transmission damage by limiting stalling to 15 seconds and requiring cooling off periods. Troubleshooting guidance is given for issues like a freewheeling or stuck stator.

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Bassie
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685 views3 pages

Transmission Tests ZF

This document provides instructions for performing a stall test on a ZF ECOMAT 2 transmission to diagnose engine and transmission problems. It describes how to check stall speed and what the results may indicate. Stall protection software prevents transmission damage by limiting stalling to 15 seconds and requiring cooling off periods. Troubleshooting guidance is given for issues like a freewheeling or stuck stator.

Uploaded by

Bassie
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Chapter 2 ZF ECOMAT 2 TRANSMISSION B25D / B30D Mk I

STALL TESTING

Stall testing is performed to determine whether a power complaint is due to an engine problem
or transmission malfunction.
Stall speed is the maximum engine RPM attainable when the engine is at full throttle and
when the torque converter turbine is not moving, or “stalled.”
A Stall test can be done to confirm a fault code from the engine diagnostics or to confirm a
fault from the Transmission diagnostics.

STALL PROTECTION

The D Series machines have been fitted with stall protection software to protect the
transmission Torque convertor / oil Pump from Damage.
The Software installed allows the operator to stall only when certain conditions have been
met.Firstly the vehicle must be in the stationary position for more than 6 seconds
The Engine torque must be more than 50 % for 6 Seconds
The Park brake or service brake must be applied (Or Both) for more than 6 seconds
If these parameters are active for more than 6 seconds the CCU Knows that the vehicle is in a
stall condition and will allow the stall to continue up till a total of 15 seconds have past
After 15seconds the CCU will command the ADM to 0% Torque or Low Idle for 50 Seconds.If
Neutral is selected while in the 50 Second cool off period is active the CCU will command a
speed restriction of 1250 rpm for the remainder of the 50 Seconds.

IF A STALL TEST IS NECESSARY


1. Before starting check that the oil on the dipstick is within the safe operating band.
2. Place chocks in front and behind wheels.
3. Ensure that no person is working on or under the machine.
4. Start the engine and let it idle.
MDU can be used by selecting “Actual Values “ and pressing “Select” and then “Next”,
taking you to “Transmission values” . Press “select” and this will bring you to “Transmission
Temp”.The transmission sump temperature must be monitered at all times during stall test.
6. Apply the park brake.
7. Let the air pressure build up until the low air pressure buzzer goes off.
8. Push the service brake pedal down and keep it down.
9. Select first gear.
10. Push accelerator pedal until engine is running at 1000RPM and keep at this RPM
for 15 Seconds, After 15 seconds the CCU will limit the engine torque to 0% for a cool of
period of 50 seconds.
11. Remove foot from accelerator pedal and select neutral.
12. Push the accelerator ,the CCU will only allow 1200 rpm for the remainder of the cool
off period.
13. Repeat steps 9 to 13 until the sump temperature stabilizes around 70 ºC (160 ºF).

CHECKING THE STALL RPM


1. Bring sump temperature as described above.
2. Select first gear and apply foot brake pedal and keep it down.
3. Push accelerator pedal all the way down.
4. After +- 5 seconds the RPM will stabilize. After 15 Seconds The CCU will Initailize the
Cool off period OF 0% Torque or Low Idle, If Neutral is selected while in the 50 Second
cool Off the CCU Will still Limit the Rpm To 1200
5. This stabilised RPM will be the stall RPM. (Refer to B30D/B25D Stall Speeds.)

NOTE: THE STALL WILL ONLY TAKE PLACE FOR 15 SECONDS.


NOTE: ALWAYS REFER TO LATEST SERVICE BULLETIN FOR

Bell Training Center Revision 0.1 117


Chapter 2 ZF ECOMAT 2 TRANSMISSION B25D / B30D Mk I
STALL SPEED SPECIFICATIONS B30D/B25D STALL SPEEDS

Model Low idle High idle Stall speed


B30D 600 rpm 2800 rpm 2092 rpm
B25D 600 rpm 2800 rpm 1851 rpm

ANALYZING STALL TEST RESULTS

If stall test readings are 150 RPM higher or lower than specifications....

• The stall test readings are acceptable.

• Stall test readings may vary slightly above or below specifications, depending on ambient
temperature, altitude, tachometer variations and other conditions.

If stall test readings are 200 RPM or more below specifications....

• The engine may be down on power


• The engine may not be attaining full fuel

• If stall test readings are extremely low (about 30% lower than specifications...)

• The engine may be severely down on power

• The engine may not be attaining full fuel

• The converter stator may be freewheeling

If stall test readings are 200 RPM or more above specifications...

• The transmission may have slipping clutches

• Transmission oil level might be too low or high

• Converter out pressure may be too low due to internal transmission problem.

If stall test readings are normal, but there are high converter out temperatures after cool
down...

• The converter stator may be stuck

• The transmission cooling system may not be operating properly

• The engine cooling system may not be operating properly.

Bell Training Center Revision 0.1 118


Chapter 2 ZF ECOMAT 2 TRANSMISSION B25D / B30D Mk I
TROUBLE SHOOTING A FREEWHEELING STATOR

A freewheeling stator can cause extremely low stall speeds.

• To verify a freewheeling stator prior to tear down, road test the vehicle.

• If the vehicle has no power at low speed, but performs normally at high speeds, the stator
may be freewheeling.

• Elevated oil temperatures or no full-throttle upshifts can also indicate a freewheeling stator.

TROUBLESHOOTING A STUCK STATOR

• A stuck stator can cause high converter out temperatures after cool down, despite normal
stall test readings.

• A stuck stator can also prevent the vehicle from reaching its top speed and/or transmission
overheating at highway speeds.

• To verify a stuck stator prior to tear down, stall test as follows:

• Stall until converter out temperature reaches 120-130°C (250- 270 degrees Fahrenheit.)

• Place the transmission in neutral, then accelerate the engine to between 1200 and 1500-
RPM for 2 to 3 minutes.

• If the converter out temperature doesn’t drop, the stator may be stuck or the engine/
transmission cooling system may be malfunctioning.

If tests confirms that the converter stator is suspect, remove the transmission, disassemble the
torque converter and inspect the stator, springs, rollers and race

STALL TORQUE RATIO

Stall torque ratio reflects the amount of turbine shaft torque the converter developes compared
to the amount of torque the engine developes.

Example - if the converter configuration provides a 2 : 1 stall torque ratio, the torque converter
is capable of delivering twice the engine’s torque to the transmission gearing.

Bell Training Center Revision 0.1 119

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