EFFICIENCY PACKAGE

Fuel savings, lower emissions and a longer service life

ZF underscores its expertise in driveline and chassis technology with the EFFICIENCY PACKAGE, a carefully selected group of complementary components that create a vast array of benefits. The ZF torque converter lock-up clutch and other components of the EFFICIENCY PACKAGE work together seamlessly to save fuel, lower emissions and extend service life. The easy handling of ZF's fully automatic transmissions and high-tech axle systems support the driver in all work situations. The result is a considerable increase in productivity. Using the full scope of services can cut fuel consumption by up to 20%.

The goals of the EFFICIENCY PACKAGE

• Reduce fuel consumption
• Reduce wear
• Increase productivity
• Enhance comfort
• Reduce oil consumption
• Extend service intervals
• Reduce noise
• Increase automation
• Improve gear-shift quality
• Simplify operation

The EFFICIENCY PACKAGE components at a glance

• MULTITRAC and MULTISTEER axles, characterized by their light weight, stability and high transmission power
• ERGOPOWER transmission, with the standard number of gears increased from 4 to 5
• ERGOLOCKUP, which engages the torque converter lock-up by modulation even in low gears
• ERGOTRACTION, interwheel differential lock management which optimizes the engagement and disengagement of the powershift differentials
• POWERINCH, dynamically adjusts the clutch cut-off point depending on transmission output torque
• ENGINE DERATING, with overload protection and tractive force control
• OPERATING MODE SELECTION, offers shift point selection to accommodate different operating modes and engine ratings

ERGOPOWER
This proven, fully automatic powershift transmission system has been optimized for different types of construction machinery and features an innovative increase from 4 to 5 gears. The noise-optimized transmission thereby allows even more comfortable and easier handling, high shifting quality and flexibility. In addition, this enables a further reduction of operating costs. ERGOPOWER also offers the additional option of connecting an electronic driveline management, thus enabling vehicle-specific controls.

ERGOLOCKUP
ERGOLOCKUP enables the use of DIRECT DRIVE whenever possible. The torque converter is only engaged when it is actually needed and is activated automatically through t/c mode selection and proportional pressure regulation. This allows the ZF ERGOPOWER 5-speed transmission with integrated converter lock-up to be operated in full DIRECT DRIVE mode in almost all driving conditions, and without any losses in the torque converter. The t/c mode is automatically engaged in first gear, which cuts consumption by between 10% and 20% depending on operating conditions. Assuming a realistic reduction of around 5 liters per operating hour for a fleet of 10 vehicles operating an average of 2,000 hours a year, this would equate to a savings of 100,000 liters annually.

ERGOTRACTION
This feature for axle control offers a differential lock management which governs the axle differential locks in wheel loaders. The ERGOPOWER transmission control automatically engages and disengages the powershift differentials. ZF offers the full range of MT-L 3000 axles with an optional hydraulic powershift transmission for wheel loaders up to 35 tons. This innovation protects the drive components and tires while still supplying 100% tractive force and saving fuel. Moreover, ERGOTRACTION improves off-road mobility and increases performance. Vehicle handling is comfortable and easy, and protection against operating errors is guaranteed.

POWERINCH
POWERINCH dynamically adjusts the clutch cut-off point depending on transmission output torque and brake pressure. It controls the vehicle’s tractive force through the brake pedal, regardless of engine speed. POWERINCH is a highly advanced driveline management system which improves the operation of wheel loaders – for example, when loading trucks or turning tight corners. At full hydraulic performance, the tractive force needed to move the vehicle is limited to the minimum required instead of the maximum available. This principle reduces power loss in the torque converter and energy loss in the axle service brake, thus boosting productivity, as more power is available for the vehicle hydraulics and the driver is guaranteed smooth control at high engine and low driving speeds. This also allows better handling of the vehicle in general.

ENGINE DERATING
This prevents torque spikes through active engine control via CAN. Torque derating in first gear (particularly in stall conditions) can be integrated so that the maximum desired tractive force is not exceeded. Engine derating during SHUTTLE SHIFT reduces the dissipation of energy in the clutches. ENGINE DERATING reduces fuel consumption, provides overload protection, increases tractive force and extends service life.

OPERATING MODE SELECTION
This additional function provides a selection of shift-point curves to accommodate various operating conditions or multiple engine curves. Its advantages include reduced fuel consumption and noise emissions, as well as optimized handling and driving performance.