Professional Documents
Culture Documents
Instructions
Bus
Lever-Type Range Selector
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 / 2005-09
Edition: 2005-09
Preface
Safety Instructions
The following safety instructions appear in this manual:
NOTE
Refers to special processes, techniques, information, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
DANGER!
This is used when lack of care could lead to personal
injury or material damage.
Table of Contents
1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.7
1.8
Description of System . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Selector . . . . . . . . . . . . . . . . . . . . . . . . .
Display (ZF Display) . . . . . . . . . . . . . . . . . . . .
Display: Automatic Mode . . . . . . . . . . . . . . . .
Display: Manual Mode . . . . . . . . . . . . . . . . . .
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . .
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . .
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . .
ZF-Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-3
1-4
1-5
1-5
1-5
1-5
1-6
1-6
1-6
2
2.1
2.2
2.2.1
2.2.1
2.2.3
2.2.2
2.3
2.4
2.5
2.6
2.6.1
2.6.2
2.6.3
2.7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine . . . . . . . . . . . . . . . . . . . . .
Setting Off . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Off, Forward Travel . . . . . . . . . . . . . . .
Setting Off, Reverse Travel . . . . . . . . . . . . . . .
Starting Gear Correction . . . . . . . . . . . . . . . . .
Setting Off with Starting Aid (Optional) . . . . .
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving Off Downhill . . . . . . . . . . . . . . . . . . .
Changing Operating Mode: Manual/Automatic
Gear Changes . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Changes during automatic mode . . . . . .
Gear Changes during Manual Operations . . .
Function of Engine Brake when Changing Gear
Change in Direction of Travel . . . . . . . . . . . . .
2-1
2-1
2-2
2-2
2-2
2-3
2-3
2-4
2-5
2-5
2-6
2-6
2-6
2-7
2-8
2.8
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
Stopping Engine / Vehicle . . . . . . . . . . . . . . . .
2.10 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 Tow Starting . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12 Clutch Protection . . . . . . . . . . . . . . . . . . . . . . .
2.13 Engine Overspeed Protection . . . . . . . . . . . . .
2.13.1 Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13.2 Automatic mode . . . . . . . . . . . . . . . . . . . . . . .
2.14 Roller Test Rig . . . . . . . . . . . . . . . . . . . . . . . . .
2.15 Displays for ZF-AS Tronic . . . . . . . . . . . . . . . .
2.16 System Faults (Error Messages) . . . . . . . . . . .
2.17 Use in Sub-Zero Temperatures . . . . . . . . . . . .
2.17.1 Parking Vehicle at Low Temperatures . . . . . .
2-8
2-9
2-9
2-9
2-10
2-10
2-10
2-10
2-11
2-12
2-15
2-17
2-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Fluid . . . . . . . . . . . . . . . . . . . . .
Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Fill Quantity . . . . . . . . . . . . . . . . . . . . . . . .
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Change Intervals . . . . . . . . . . . . . . . . . . . .
Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . .
Filling With Oil . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the Transmission . . . . . . . . . . . . . . .
Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Inspection of Wiring . . . . . . . . . . . . . . .
Pneumatic System Maintenance . . . . . . . . . . .
3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-3
3-4
3-4
3-5
3-5
3-5
3
3.1
3.1.1
3.1.2
3.2
3.2.1
3.2.2
3.2.3
3.3
3.4
3.5
3.6
3.7
1-1
DANGER!
The brake must be applied to prevent the vehicle from
unintentionally moving either forwards or backwards.
1-2
1.2
Overview
1
A/M
2
D
S
T
O
P
Key
1 ZF range selector
2 ZF display
3 Transmission actuator with integrated
electronic transmission control
4 Clutch actuator
5
6
7
8
Transmission
Accelerator
Brake pedal
ZF-Intarder
1-3
024527
024527
1.3
You can use the range selector to select gears and change
operating mode.
Range Selector
A/M D
A/M
+
+
024528
N
R
= Drive
= Neutral
= Reverse
= Downshift 1 gear (first spring point)
= Downshift 2 gears (spring point stop)
024529/024528
1348 758 101 - 2005-09
1-4
1.4
Only descriptions of the displays for transmission functions are provided in this operating manual. Refer to
vehicle manufacturers operating instructions for other
displays.
023664
The transmission is
in automatic mode
(4 bars and 2 arrows).
1.5
023665
Accelerator Pedal
023663
1-5
1.6
Automatic Mode
1.7
Manual Mode
If A/M is selected using the range selector, the transmission system changes into manual mode. The driver
can use the range selector to propose a starting gear other
than that proposed by the system.
If you press the accelerator pedal, the clutch closes
automatically and the vehicle starts to move.
The driver uses the range selector to select the gears
required.
The driver can use the range selector to intervene manually at any time for example, in difficult driving situations
without having to come off the gas. The mode then
changes from automatic to manual.
1.8
ZF-Intarder
1-6
Operation
Operation
2.1
NOTE
Depending on the manufacturer and vehicle type, you
may have controls and operating processes other than
those described in this manual.
Therefore, also observe the operating instructions provided
by the vehicle manufacturer.
N
R
024688
Switch on ignition
-
A/M
DANGER!
The vehicle must not be left with the engine running
and a gear selected.
023666
Self-check is complete.
N appears on display,
transmission is in Neutral
023667
NOTE
Gears cannot be selected when engine is stationary.
2-1
Operation
2.2
Setting off
A/M
N
R
A/M
N
R
024678
023668
024684
023669
DANGER!
The vehicle may start to roll away if you do not
depress the accelerator.
When setting off on an incline, select gear and only
release parking brake once accelerator has been
depressed otherwise the vehicle will roll backwards.
2-2
DANGER!
If the vehicle is rolling, a shift is not made into reverse
gear!
Immediately bring the vehicle to a standstill.
Only the display provides definitive information on
the direction of travel selected in the transmission.
Operation
A/M
N
R
024679
DANGER !
Once the brake pedal is released, the brake is only
engaged for a short time. The vehicle may roll.
NOTE
The time to release the brake depends on the accelerator position, clutch position and roadspeed.
The brake is released even if the transmission is shifted
to Neutral.
2-3
Operation
2.3
Maneuvering
023670
CAUTION
If the driver does not respond to
the CL display, the clutch may be
damaged from overload.
DANGER!
The system changes from maneuvering mode to setting off mode depending on the accelerator position
and vehicle speed.
The vehicle may accelerate suddenly.
2-4
023669
023671
DANGER!
If the driver does not respond to the CL display, the
system changes from maneuvering mode to setting
off. The vehicle may accelerate.
RISK OF ACCIDENT!
Operation
2.4
2.5
DANGER!
When the vehicle moves off without a gear selected
range selector in position N the engine brake
will not work.
Do not allow vehicle to roll in direction opposite to
that of the gear selected.
A/M
N
R
024685
A/M
NOTE
If + or is selected using the range selector lever, the
operating mode changes briefly into manual.
N
R
024678
023668
2-5
Operation
2.6
Gear Changes
A/M
Drive situation
Loading
Accelerator position
Velocity
Engine speed
N
R
024679
A/M
N
R
024685
2-6
Operation
Jumping gears
!
NOTE
You can shift from any gear to Neutral at anytime using
the range selector. This shift takes priority.
The accelerator position must not be changed during
the shift process because the engine is controlled
automatically.
A shift command is not undertaken if the shift would
result in the maximum engine speed (governing speed)
being exceeded.
DANGER !
Shifts to Neutral can also be made during travel. If a
shift is made to Neutral, the driveline is interrupted.
The engine brake then no longer functions.
2-7
DANGER !
The engine brake function is interrupted during the
gear shift. The vehicle may accelerate when traveling
downhill.
Operation
2.7
A/M
N
R
A/M
CAUTION
To preserve the mechanical parts of the clutch release
mechanism, you should shift the transmission to Neutral
when stopping for long periods (more than approx. 1 to
2 min., e.g. in queuing traffic, traffic jam, at railway
crossings etc.). The clutch is thereby closed and the
clutch release mechanism relieved.
N
R
024686/024680
2.8
DANGER!
Changing direction of travel from R to D and vice
versa from D to R may only be undertaken when
the vehicle is stationary, otherwise the transmission
shifts to Neutral.
The display is definitive for the direction of travel
selected in the transmission.
Stopping
2-8
DANGER !
When the vehicle is stationary with the engine
running and a gear selected, you need simply press
the accelerator in order to move the vehicle!
Before leaving the vehicle with the engine running,
the transmission must be shifted into Neutral
and the parking brake engaged.
Activating the parking brake during travel and on a
smooth surface may bring the engine to a standstill. Steering assistance is then no longer available!
Operation
2.9
2.10 Towing
CAUTION
When towing, the propshaft flange must always be
disconnected from the rear axle. If this is not possible,
remove both stub shafts.
Prevent pollution through possible oil loss.
024681
024687
DANGER!
The engine cannot be switched off if a gear is
selected. The vehicle may roll away if no brakes
are engaged.
NOTE
If the transmission is not shifted to Neutral before the
engine is switched off, this is done automatically when
the ignition is moved to Off .
1348 758 101 - 2005-09
2-9
Operation
NOTE
Select an operating mode in which there is no risk of
clutch overloading, for example:
2-10
DANGER!
The vehicle may speed up when traveling downhill.
To protect the engine from damage in the overspeed
range (red range), the system undertakes an upshift.
Operation
DANGER!
The vehicle may leave the rollers even if the accelerator is not depressed.
2-11
Operation
023672
Transmission in Neutral
023667
Manual mode
4th gear is engaged in the
transmission
023664
023665
023669
Manual mode
8th gear is engaged in the
transmission. Option of downshifting by up to 3 gear steps
available (one gear per bar) .
CH = System self-check.
Display appears during Ignition
ON.
023666
2-12
Operation
TC = Transmission check
Transmission positions cannot be
learnt.
Warning information:
AL = Airless.
Appears in turn with the normal
display. The transmission systems
pneumatic system does not have
sufficient pressure.
023673
NOTE
Only start once sufficient air pressure is reached. If the
clutch doesnt open when stopping as a result of insufficient air pressure, the engine is stalled.
DANGER!
If gear shifts are undertaken with insufficient air
pressure, the transmission may remain in Neutral so
that there is no direct drive and no engine brake
effect.
024722
023674
023675
023676
FP = Accelerator pedal
Move accelerator pedal into idling
position.
If the display doesnt go out, there
is a system fault. Further travel
not possible.
CL = Clutch
Appears in turn with the normal
display. Clutch is overloaded.
Remedy: Chapter 2.13 Clutch
Protection
CW = Clutch wear indicator
Take vehicle to nearest specialist
workshop to have the clutch
replaced.
CC = Clutch check
Clutch position cannot be learnt.
HT = High temperature
(excessive transmission temperature).
024721
023677
2-13
Operation
023678
EE = Electronic Error
Appears if communication
between the display and transmission electronics is interrupted.
System faults:
ES = Easy Start
Electronic starting aids are
temporarily unavailable.
023679
NOTE
With certain system faults, automatic mode is deactivated
and the transmission system remains in manual mode.
023761
DANGER !
The vehicle may roll.
NS = Neutral Shift
N Use range selector to select
Neutral
S
T
O
P
023680
STOP + Screwdriver
= Serious system fault
Stop the vehicle. You must not
continue driving. You must take
the vehicle to a workshop.
023762
NOTE
Depending on the vehicle type, after a certain time, the
transmission may automatically switch to Neutral in order
to protect the mechanical components of the clutch
release mechanism.
DANGER!
Whenever possible do not stop the vehicle in
hazardous places.
2-14
Operation
Switch on ignition
NOTE
The error numbers can only be called up when the engine
is switched off.
A/M
N
R
A/M
N
R
024678/024743
2-15
Operation
Switch on ignition
023682
NOTE
The error numbers can only be called up from the error
memory when the engine is switched off.
018470
2-16
Operation
Down to 20 C
20 C to 35 C
35 C to 40 C
Oil grade
Engine start
permitted
permitted
When starting,
note
Limitations
None
At transm, temperatures in
excess of 30 C, transm. is
operable and all functions are
provided. Longer shift times
should be expected.
At transmission temperatures in
excess of 30 C, transmission
is operable and all functions are
provided. Longer shift times
should be expected.
2-17
2-18
Maintenance
Maintenance
3.1
Oil Change
Transmission Fluid
3-1
Initial fill
after repairs
with
Intarder
without
Intarder
with
Intarder
without
Intarder
12 liters
11 liters
21 liters
11 liters
Maintenance
3.2
Oil Change
NOTE
Change the oil when the vehicle is on horizontal ground.
DANGER!
Touching hot parts and transmission oil may cause
burns.
Remove oil drain plugs (items 1 and 2) from transmission and collect transmission oil in a suitable container
and dispose of in accordance with environmental
regulations.
Clean oil drain plug with magnetic plug and replace
seal.
Tighten oil drain plugs to the specified torque.
3-2
Maintenance
Key
1 Oil drain plug
tightening torque TA = 60 Nm
2 Oil drain plug
tightening torque TA = 60 Nm
3 Oil fill and overflow measurement
tightening torque TA = 60 Nm
2 3
010768
014783
3 2
3-3
Maintenance
3.3
3.4
DANGER !
Too little oil in the transmission will result in transmission damage. Risk of accident!
013583
1 Transmission bleeding
2 Type plate
3 Oil fill plug
4 Initial fill and/or oil fill after repairs, only for Intarder
version
3-4
Maintenance
3.5
Type Plate
3.6
Check that connectors are seated correctly, connectors must be fitted without traction relief.
3.7
200 010
XXXXX
21
NOTE
When draining the pneumatic tank, the pneumatic
cleaners and water separate should also be drained if
this is not done automatically.
02
3-5
3-6