Professional Documents
Culture Documents
ZF-AS Tronic
Trucks
Repair level 1 - 2
Maintenance, diagnosis, replacement of components
CAUTION
The ZF order numbers listed in this document apply
to standard ZF products.
Variances are possible depending on the vehicle
manufacturer.
The binding ZF order numbers are listed in the
relevant parts list parts list no. can be found on the
transmission type plate.
Copyright by ZF Friedrichshafen AG
This document is protected by copyright. Any form of
reproduction or dissemination not wholly corresponding
to the intended use of this documentation is prohibited
without the approval of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C / 2000-02
Edition: 2003-05
ZF-AS Tronic
Table of contents
Page
5
7
8
9
11
13
15
20
1
Maintenance ..............................................................................................................................................
1.1 Visual inspection of wiring .........................................................................................................................
1.2 Maintenance of pneumatic system .............................................................................................................
1.3 Type plate ....................................................................................................................................................
1.4 Approved oil grades ....................................................................................................................................
1.5 Oil volume ..................................................................................................................................................
1.6 Transmission breather .................................................................................................................................
1.7 Oil change intervals ....................................................................................................................................
1.8 Oil level check.............................................................................................................................................
1.9 Oil change (transmission without ZF-Intarder) ..........................................................................................
1.9.1 Filling oil.....................................................................................................................................................
1.10 Oil level check.............................................................................................................................................
1.11 Instruction plate for oil change ...................................................................................................................
1.12 Oil change (transmission with ZF-Intarder) ...............................................................................................
1.13 Oil filter change ..........................................................................................................................................
1.14 Oil filling ....................................................................................................................................................
1.14.1 Oil filling during an oil change ..................................................................................................................
1.14.2 Oil filling after transmission repairs...........................................................................................................
1.15 Engine coolant ............................................................................................................................................
1.16 ZF-Intarder type plate .................................................................................................................................
1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-4
1-5
1-5
1-6
1-7
1-7
1-7
1-8
1-8
2
2.1
2.2
2.3
Diagnosis ....................................................................................................................................................
Diagnosis for vehicles with ZF display and ZF range selector....................................................................
Diagnosis with TestmanPro.........................................................................................................................
Transmission actuator data sheet.................................................................................................................
2-1
2-1
2-2
2-3
3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.2
3.2.1
3.2.2
3.2.3
3.2.4
Component replacement...........................................................................................................................
Transmission actuator .................................................................................................................................
Removing transmission actuator .................................................................................................................
Fitting..........................................................................................................................................................
Dismantling transmission actuator..............................................................................................................
Assembling transmission actuator ..............................................................................................................
Programming transmission actuator............................................................................................................
Replacing pressure limitation valve ............................................................................................................
Clutch actuator ............................................................................................................................................
Removal ......................................................................................................................................................
Push rod ......................................................................................................................................................
IVECO push rod setting ..............................................................................................................................
Fitting..........................................................................................................................................................
3-1
3-1
3-1
3-3
3-5
3-5
3-6
3-6
3-7
3-7
3-8
3-9
3-10
ZF-AS Tronic
Table of contents
Page
3-12
3-12
3-13
3-13
3-14
3-15
3-15
3-15
3-16
3-16
3-17
3-17
3-17
3-17
3-18
3-18
3-18
3-18
3-19
3-19
3-19
3-19
3-19
3-20
3-20
3-21
3-22
3-22
3-22
3-22
3-22
Annex
Documents / drawings attached................................................................................................................... 3-23
Connector and mating connector designations............................................................................................ 3-24
Pneumatics diagram .................................................................................................................................... 3-25
ZF-AS Tronic
Chapter Initiator
BKS/LKS
Comments
Complete revision:
Maintenance included, diagnosis extended,
repair work updated. Repair manual, level 1-2 divided
up into truck 1327 751 101 and bus 1337 751 101
ZF-AS Tronic
Preface
This document has been written for skilled staff who
have been trained by ZF Friedrichshafen AG to carry
out maintenance and repair work on ZF products.
This manual refers to a volume production ZF product in accordance with the state of development on
the date of issue.
However, due to further technical developments, repair
work on your unit may require other work practices and
other test or adjustment data which are not contained in
this manual.
We therefore recommend that you entrust your ZF product to supervisors and fitters who have had their practical and theoretical knowledge updated on a regular basis
at our Service-Training-Center.
ZF-AS Tronic
Important information
SAFETY NOTICE
GENERAL INFORMATION
CAUTION
Pictures, drawings and components shown do not
always represent the original object but are simply
used to illustrate working procedures. Pictures,
drawings and components are not to scale and no
information about size and weight should be inferred
(even within a complete drawing).
Always follow the working steps as described in the
text.
NOTE
Refers to special process, techniques, data, use of
auxiliary equipment etc.
CAUTION
This is used if other incorrect, unprofessional working practices could damage the product.
! DANGER
This is used when lack of care could lead to personal
injury or death.
CAUTION
The transmission must NOT be hung on the input
shaft NOR on the output flange.
ZF-AS Tronic
SHAFT SEALS
Always change shaft seals with rough, ripped or hardened seal lips. Seal contact surfaces must be totally clean
and in perfect condition.
REWORKING
Parts held on with Loctite can be slightly loosened if
warmed with a hot air blower.
Rework may only be carried out on the seal contact surfaces using plunge-cut grinding. Never use an emery
cloth. Ensure there are no traces of grinding or rifling
from grinding.
CLEANING PARTS
Remove old remains of gaskets from all sealing faces.
Carefully remove burrs or other similar patches of
roughness using an oil stone.
TRANSMISSION ASSEMBLY
Find a clean site to assemble the transmission.
Gaskets are fitted without the use of sealing compound
or grease. When measuring silicon-coated gaskets, take
care not to include the silicon layer in the
measurement.
During transmission assembly, comply with all
adjustment data and tightening torques specified in the
repair manual.
REUSING PARTS
A competent person must inspect parts such as ball or
roller bearings, multi-discs, thrust washers etc. to decide
whether they can be reused or not.
Replace parts which are damaged or have suffered from
excessive wear.
ZF-AS Tronic
BEARINGS
If the bearings are fitted while hot, these should be heated accordingly (e.g. in a heating cabinet).
The temperature should be approx. 85 C and must not
exceed 120 C. All bearings fitted must be coated with
operating oil after assembly.
SEALING
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturers directions for use. The
sealing agent should be applied to the surfaces in thin
layers and must be spread evenly. Do not allow sealing
agent to enter oil ducts and bores. The sealing agent
should be wiped off oil-carrying ducts and bores from
the surfaces to be sealed near apertures to ensure that no
sealing agent penetrates the oil feeds when the surfaces
are sealed.
RETAINING AGENTS
Retaining agents* may only be used in those places
specified in the parts list.
Always comply with the manufacturers directions of
use when using retaining agents (e.g. Loctite).
During assembly, observe all adjustment data, checking
data and tightening torques.
SHAFT SEALS
a) Apply a thin coat of sealing agent* on outer edge of
shaft seals with steel surround.
TRANSMISSION OIL
After completing repairs, fill the transmission with
transmission oil. For the procedure and approved oils,
refer to the transmission operating manual and List of
Lubricants TE-ML (refer to type plate). These
documents are available from all ZF After-Sales Service
points and can be found on the Internet at www.zf.com.
After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
specified torques.
b) Never apply sealing agent to shaft seals with rubber surround but apply a thin coat of Vaseline 8420
to the outer edge or spray with a lubricant, such as a
water-soluble, concentrated washing-up liquid (e.g.
Pril, Coin, Palmolive).
c) Shaft seals with steel and rubber surrounds should be
treated as shaft seals (described above in section (b))
on the outer edge of the rubber surround.
* refer to consumables
10
ZF-AS Tronic
Tightening torques
NOTE
Divergent tightening torques are listed separately in the
repair manual.
Size
Size
Bolt
Nut
Tightening torque
in Nm for
8.8
10.9
8
10
12.9
12
M4
M5
M6
2.8
5.5
9.5
4.1
8.1
14
4.8
9.5
16.5
M7
M8
M10
15
23
46
23
34
68
M12
M14
M16
79
125
195
M18
M20
M22
M24
M27
M30
Bolt
Nut
Tightening torque
in Nm for
8.8
10.9
8
10
12.9
12
M8x1
M9x1
M10x1
24
36
52
36
53
76
43
62
89
28
40
79
M10x1.25
M12x1.25
M12x1.5
49
87
83
72
125
120
84
150
145
115
185
280
135
215
330
M14x1.5
M16x1.5
M18x1.5
135
205
310
200
300
440
235
360
520
280
390
530
390
560
750
460
650
880
M18x2
M20x1.5
M22x1.5
290
430
580
420
620
820
490
720
960
670
1000
1350
960
1400
1900
1100
1650
2250
M24x1.5
M24x2
M27x1.5
760
730
1100
1100
1050
1600
1250
1200
1850
M27x2
M30x1.5
M30x2
1050
1550
1500
1500
2200
2100
1800
2550
2500
11
ZF-AS Tronic
Tightening torques
M8x1
M10x 1
M12x1.5
M14x1.5
M16x1.5
M18x1.5
M20x1.5
M22x1.5
M24x1.5
M26x1.5
M27x2
M30x1.5
M30x2
M33x2
M36x1.5
M38x1.5
M42x1.5
M42x2
M45x1.5
M45x2
M48x1.5
M48x2
M52x1.5
M60x2
M64x2
Tightening torque
in Nm screwed into
steel/grey cast Al alloy
20*
25 / 30*
35
35
40
50
55
60 / 80*
70
80 / 105*
80
100 / 130*
95
120
130
140
150
145
160
150
170
160
180
195
205
Pipe
outer
diameter
10*
15 / 20*
25
25
30
35
45
50 / 65*
60
70 / 90*
70
90 / 130*
85
110
115
120
130
125
140
130
145
135
150
165
175
Thread
Tightening
torque
in Nm
4-5
M8x1
20 - 25
M10x1
25 - 35
M12x1.5
30 - 40
10
M14x1.5
35 - 40
12
M16x1.5
45
15
M18x1.5
50
18
M22x1.5
60
22
M26x1.5
90
28
M30x1.5
130
35
M38x1.5
140
12
ZF-AS Tronic
Withdrawn Title
DIN
DIN 1
Tapered pins
ISO 2339
DIN 7
Cylinder pin
ISO 2338
DIN 84
Cylindrical
screws
ISO 1207
DIN 85
Flat head
screws
ISO 1580
DIN 94
Split pins
ISO 1234
DIN 417
Threaded pins
ISO 7435
DIN 439-1
DIN 439-2
Hex nuts
Hex nuts
ISO 4036
ISO 4035
ISO 8675
DIN 551
Threaded pins
ISO 4766
DIN 553
Threaded pins
ISO 7434
DIN 555
Hex nuts
ISO 4034
DIN 558
Hex bolts
ISO 4018
DIN 601
Hex bolts
ISO 4016
DIN 912
Cylindrical
screws
ISO 4762
DIN 931-1
Hex bolts
ISO 4014
DIN 933
Hex bolts
ISO 4017
DIN 934
Hex nuts
ISO 4032
ISO 8673
DIN 960
Hex bolts
ISO 8765
DIN 961
Hex bolts
ISO 8676
DIN 963
Countersunk
bolts
ISO 2009
DIN 964
Countersunk
bolts
ISO 2010
13
ZF-AS Tronic
Withdrawn Title
DIN
DIN 965
DIN 980
Lock nuts
ISO 7042
ISO 10513
DIN 985
Lock nuts
ISO 10511
DIN 1440
Washers
ISO 8738
DIN 1443
Bolts
ISO 2340
DIN 1444
Bolts
ISO 2341
DIN 1471
Grooved pins
ISO 8744
DIN 1472
Grooved pins
ISO 8745
DIN 1473
Grooved pins
ISO 8740
DIN 1474
Grooved pins
ISO 8741
DIN 1475
Grooved pins
ISO 8742
DIN 1476
Grooved studs
ISO 8746
DIN 1477
Grooved studs
ISO 8747
DIN 1481
Slotted pins
ISO 8752
DIN 6325
Cylinder pins
ISO 8734
DIN 7346
Slotted pins
Flange
ISO 13337
DIN 7976
DIN 7978
Tapered pins
ISO 8736
DIN 7979
Cylinder pins
ISO 8733
ISO 8735
DIN 7981
DIN 7982
DIN 7985
Cheese head
screws
ISO 7045
14
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
Qty.
Remarks
240
Simplifies
assembly
11
15
74
M10
M10
75
60.5
9H7
100.1
25
14
9r6
8.70.1
200.1
2x45
2x45
40
2120.1
Setting fixture
for piston rods on transmission actuator
37.50.1
9H7
15
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
Remarks
Only for ZF sales and
service organizations
TestmanPro, complete
6
Scope of supply
- 6008 208 013 TestmanPro with
DPA04i + cable
- 6008 208 015 Application CD
- 6008 208 016 Licence
6008 208 501
To supply voltage in
vehicle via cigarette
lighter
Scope of supply:
6008 308 601 Cable RS 232
0501 211 103 Cable ISO 9141
6008 308 600 DPA04i
6008 208 900 TestmanPro software
user interface
16
Following agreement
with ZF Friedrichshafen
AG
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
Application software
ZF-AS Tronic 2
11
de
en
fr
es
it
12
Remarks
Programming tool
for control unit
programming
13
PlugIn
Terminal test
6008 006 002 (68-pin)
15
17
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
UNIVERSAL
Remarks
Connection:
terminal tester
17
MAN
20
IVECO
19
18
WARNING:
PIN assignment depends
on control unit
18
Connection: 5-pin
diagnosis connection
plug under flap in front
of range selector
Connection: 30-pin
diagnosis connection
plug near fuse box
Connection:
diagnosis connection
plug near fuse box.
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
RVI
6008 207 009
21
19
Remarks
Connection:
diagnosis connection
plug near fuse box or
bottom left of drivers
cab
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
Remarks
AS Tronic 2 APPLICATION
SOFTWARE
4
de
en
fr
es
it
20
Application software
for Intarder EST42/48
(individual station
licence)
ZF-AS Tronic
Fig.
no.
Special tools
Order no.
Application
Remarks
21
ZF-AS Tronic
Maintenance
Maintenance
1.3
1.1
Type plate
AS Tronic
12 AS 2330 TO
MODEL
1.2
CUSTOMER
SPEC. NO
TOTAL
RATIO
P.T.O.
SPEEDO
RATIO
12.33 - 0.78
xxxxx
n=
11
xxx
xxxxx
xn
ENGINE
02L
019 311
NOTE
When draining the pneumatic tank, the pneumatic
cleaner and water separator should also be drained
provided that the cleaner does not function
automatically.
xxxxxx
OIL CAPACITY
IN LTS.
SERIAL - NO.
00247443
1-1
ZF-AS Tronic
Maintenance
1
4
4 Type plate
5 Transmission breather
018 799
1.6
1.8
Transmission breather
The transmission oil heats up during travel. Overpressure therefore builds up and is continuously removed
through a breather valve.
Ensure that the breather valve is functioning at all times.
Do not spray directly with pressurized water (water in
transmission risk of corrosion). The breather (5) must
be clean and not have a plastic cover.
! DANGER !
Too little oil in the transmission results in transmission damage. RISK OF ACCIDENT
NOTE
Whenever checking the oil level, the transmission
should also be checked for leaks.
1-2
ZF-AS Tronic
Maintenance
1.9.1 Filling oil
! DANGER !
Touching hot parts and transmission oil may result
in burns.
ZF FRIEDRICHSHAFEN AG
019248
1-3
1
2
3
4
Maintenance
5
9
10
11
Transmission breather
After repairs, tighten oil filler plug to 60 Nm
Tighten screw to 23 Nm
Filter cover
019 368
NOTE
CAUTION
To check the oil level, the Intarder must not be activated just before stopping the vehicle.
This ensures that the correct oil volume is set in the
transmission.
CHECK:
When checking the oil level, the oil filler plug (3)
should be removed.
If the oil level has fallen below the edge of the oil
overflow aperture, the oil must be topped up
(refer to 1.14).
1-4
Maintenance
! DANGER !
Touching hot parts and transmission oil may result
in burns.
OEL WECHSEL
List
SAEof30lubricants
TE-ML 02
1.
EINFUELLEN BIS
UEBERLAUF
2.
PROBEFAHRT OHNE
RETARDERBETRIEB
3.
NACHFUELLEN BIS
UEBERLAUF
001 269
CAUTION
Note the specified tightening torque for the oil drain
plugs; otherwise the transmission may be damaged.
1-5
Maintenance
DANGER!
With hot transmission oil: risk of burns.
11
1
000529
CAUTION
There will be some oil left in the oil filter housing.
000552
On filter cover (11), check O-ring (8) for damage, replace and grease in if necessary.
11
88
77
66
512
004467
1-6
Maintenance
WARNING
When working on transmissions with ZF-Intarders, a
distinction is made between oil filling during an oil
change (1.14.1) and oil filling after transmission
repairs (1.14.2)
019 367
NOTE
The instruction plate on the oil filler screw (3) must not
be removed.
CAUTION
Check oil level again and if necessary, top up with oil
until it overflows.
Screw in oil filler plug (3) with new seal and tighten to 60 Nm.
NOTE
The instruction plate on the oil filler screw (3) must not
be removed.
CAUTION
Check oil level again and if necessary, top up with oil
until it overflows.
1-7
Screw in oil filler plug (3) with new seal and tighten to 60 Nm.
Maintenance
CAUTION
When topping up the engine coolant, the specifications of the vehicle manufacturer MUST be
observed. Otherwise the oil/water heat exchanger
may be damaged.
Engine coolant
(mixture of fresh water and anti-corrosive
antifreeze)
Recommended volume of anti-corrosive
antifreeze, 35 - 50 vol. %, should be checked
using coolant tester.
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
Intarder
PARTS LIST NO.
Anti-corrosive antifreeze
Base fluid: ethylene glycol with anti-corrosive
inhibitors.
P.T.O.
N
OIL CAPACITY
IN LTS.
NOTE
If sludge forms or if the concentration suddenly falls, the
coolant must be replaced immediately.
1-8
SERIAL - NO.
XXX XXX
CUSTOMER
SPEC. NO
TOTAL
RATIO
Fresh water
pH value of 6.5 -8.0; total hardness 3-10 dH
IT AS Tronic
MODEL
SPEEDO
RATIO
n=
xn
ENGINE
ZF-AS Tronic
Diagnosis
Calling up the error numbers*:
Diagnosis
2.1
Switch on ignition
Turn rotary switch to N
Hold control lever in + position
For vehicles with their own display, refer to details provided in vehicle manufacturers description
002 686
ZF display
003 930
ZF range selector
013 587
If a screwdriver symbol
appears on the display, there is a
system error.
Only limited operations are
008 026
possible.
For example: with certain system errors, automatic driving mode is deactivated and the transmission system
remains in manual mode.
If a STOP appears on the display together with a screwdriver symbol, there is a serious
system error. The vehicle cannot be driven any further. The vehicle usually
has to be towed away.
008 027
2-1
ZF-AS Tronic
2.2
Diagnosis
1.
Open Testman
1.
Open Testman
2.
2.
3.
3.
4.
Licensing
4.
Licensing
5.
Safety information
5.
Safety information
6.
6.
7.
7.
8.
Communication structure
8.
Communication structure
9.
9.
10.
10.
11.
12.
11.
12.
13.
2-2
ZF-AS Tronic
61/X1A
62/X1B
TERMAL RANGE OF APPLICATION:
THERMISCHER ANWENDUNGSBERREICH:
PLAGE DE TEMPERATURE EN UTILISATION:
CAMPO TERMICO DI APPLICAZIONE:
32
FLANGE TEMPERATURE:
FLANSCHTEMPERATUR: MAX 0,5h ... 130C
-30C BIS 110C
BRIDE TEMPERATURES:
FLANGIA TEMPERATURA:
WORKING PRESSURE (SUPPLY):
BETRIEBSDRUCK (VORRAT): pe = 5,5...12 bar
PRESSION D'UTILISATION (ALIMENTATION):
PRESSIONE DI ESERCIZIO (ALIMENTAZIONE):
DEGREE OF PROTECTION ACCORDING TO IE C 529:
SCHUTZART NACH IEC 529: IP 6K9K NACH DIN 40050 T9
DEGRE DE PROTECTION SUIVANT IEC 529:
GRADO DI PROTEZIONE SECONDO IEC 529 :
VOLTAGE:
SPANNUNG:
24V -6V DC
+8V DC
TENSION :
TENSIONE:
GROUPING OF WIRES (ON THE PLUG)
STECKERBELEGUNG
GROUPEMENT DE CABLES
RAGGRUPPAMENTO DEI CAVI (SULLA CALOTTA)
STECKER 61/X1A
1
VPI
2
SDDK
3
CANF2-H
4
VPE1
5
VPE2
6
CANF2-L
7
SDEF
8
CANF1-H
9
SD
10 SDP
11 ADVP
12 CANF1-L
13 CANF1-L+
14 CANF1-H+
15 CANF1-T
16 VM1
17 VM2
18 VMHF1
19 VMHF2
20 VM3
M = TORQUE
M = ANZUGSMOMENT
M = COUPLE DE SERRAGE
M = COPPIA DI SERRAGGIO
SUPPLY OF ENERGY:
ENERGIEZUFLUSS: 1 ( 8mm)
APPORT D'ENERGIE:
ALIMENTAZIONE DI ENERGIA:
DELIVERY:
ARBEITSLEITUNG: 2 ( 4mm)
UTILISATION:
MANDATA:
EXHAUST:
ENTLUEFTUNG: 31> 32 , 33 16mm)
ECHAPPEMENT:
SCARICO:
ELECTRICAL CONTROL:
ELEKTRISCHER STEUERANSCHLUSS: 61, 62
COMMANDE ELECTRIQUE:
COMANDO ELETTRICO:
61/X1A
1
61/X1A
STECKER 62/X1B
1
2
VM4
3
VM3
4
5
6
VMGA2
7
ADS1
8
ADS3
9
ADS2
10 EU
11 EF2
12 ADS4
13 ADS4+
14 ADS3+
15 AU
16 VM1
17 VM2
18 ADVP
19 ADVP+
20 VMGA1
62/X1B
62/X1B
9 10 11 12 13 14 15 16 17 18 19 20
9 10 11 12 13 14 15 16 17 18 19 20
ECU STEUERELEKTRONIK
Y3
Y2
Y1
Y4
Y6
Y5
Y8
Y7
Y9
Y10
2
)(
)(
)(
)(
)(
)(
)(
)(
33
31
32
K1 - K2
SPLIT-GV
1/2-R-3/4
SELECT-WAEHLEN
2/4/R-N-1/3
SHIFT-SCHALTEN
H - L
RANGE-GP
019 067
2-3
ZF-AS Tronic
3
Component replacement
74.140*
3.1
Transmission actuator
74.120*
74.130*
74.030
74.090
! DANGER
Only work on transmission actuator when ignition
is off.
CAUTION
If vehicle-specific parts (e.g. fuel pump, exhaust
pipe or steering pump) have to be removed, please
contact the vehicle manufacturer.
2
34.140
34.130
! DANGER
Protective glasses should be worn when removing
compressed air line from transmission actuator.
Compressed air will escape. Risk of injury from
particles of dirt.
74.050
12.090
12.080
06.050
06.040
06.080
Loctite
262
3-1
015166
ZF-AS Tronic
CAUTION
The rubber gaskets (/170) may fall into transmission housing.
/170
Take transmission actuator (74.030) off transmission housing and note down dimensions
a and b for subsequent installation.
a
018774
NOTE
There is a transmission actuator kit. This con
sists of transmission actuator (74.030), gasket
(74.010) and breather (74.120).
74.140*
74.090
74.120*
74.130*
74.030
74.070
74.050
74.010
34.140
34.130
74.050
12.090
12.080
06.050
06.040
06.080
Loctite
262
3-2
015166
ZF-AS Tronic
3.1.2 Fitting
If the ball pin is replaced, spray thread of ball
pin (06.080) with Loctite no. 262. Tighten ball
pin to 23 Nm.
On transmission actuator, move piston rod (4)
into central position (Neutral). The correct
position is reached if slight resistance can be
felt when removing the piston rod (4).
/170
018774
NOTE
Piston rod (3)
Piston rod (4)
Piston rod (5)
017908
7
34
017907
3-3
ZF-AS Tronic
5
74.140*
74.120*
74.130*
74.030
74.070
74.090
NOTE
The compression springs (06.050; 34.140 and
12.090) must be of the same length (approx.
50 mm). If variances are found, replace compression springs.
7
74.050
74.010
34.140
34.130
74.050
12.090
12.080
06.050
06.040
06.080
CAUTION
If transmission actuator is replaced, note the following.
Reprogram transmission actuator, refer to Section 3.1.5
Take vehicle parameters from removed transmission actuator or enter new parameters.
10
11
Loctite
262
015166
Final check:
Has transmission actuator been reprogrammed?
Vehicle-specific parts should be refitted wherever possible. The transmission actuator can only be tested using
the diagnosis device once the engine is running and
there is a sufficient reserve of air. The system then
undertakes a number of calibration processes. This can
take up to 5 minutes. The following errors may then for
example be displayed: piston rod not attached with error
132, 134 etc. teach-in error of sensors for gear, gate, GP,
GV with ignition on.
3-4
ZF-AS Tronic
/150-1
/110
74.030
/180
/150-2
2
/150-3
/130
/170
019352
8
7
018205
3-5
ZF-AS Tronic
10
The table mode adapter (6008 207 003), programming device EPD1 (0501 301 068) and
corresponding PlugIN cards are needed for
programming.
When setting parameters, the EOL data is entered
into the transmission actuator electronics using the
TestmanPro and corresponding software.
CAUTION
Reprogram transmission actuator
Take vehicle parameters from removed transmission actuator or enter new parameters.
019251
74.030
NOTE
Mark installation position of pressure limitation valve
(180) for subsequent fitting.
1
CAUTION
Do not fit O-ring (12) with grease.
2
019252
3-6
ZF-AS Tronic
68.300
68.010
68.330 68.320
68.060
68.210*
/120
/130
68.150
68.154
/020
/030
/010
/110
68.020
68.210*
* depending on parts list
018484
3.2
Clutch actuator
Disconnect plug connection (7) from transmission actuator and (8) from output speed sensor.
3.2.1 Removal
! DANGER!
Switch off ignition
Wear protective glasses when removing compressed
air line. Compressed air will escape.
Risk of injury from particles of dirt.
NOTE
For removal and fitting of release fork, refer to
section 3.4
3-7
ZF-AS Tronic
OEM
ZF no.
Length in mm
DAF
119.1
RVI
123.1
Hyundai, KIA
124
MAN TGA
127.1
Meritor
133.6
Meritor
144.9
018485
68.210
/110
2.
3.
/120
/130
019622
3-8
ZF-AS Tronic
Component replacement
6
68.210
68.020
68.060
B
019 357
The old push rod dimensions are used if only the clutch
actuator is replaced.
Example:
Dimension B = 57 mm
57 mm + 33 mm = 90 mm (dimension C)
CAUTION
If working on vehicles with an AS Tronic transmission, it is not the wear dimension which is set, as is
usually the case, but the release travel. If not set correctly, the pressure plate is damaged.
Dimension B
Set dimension C:
3-9
ZF-AS Tronic
3.2.4 Fitting
Venting clutch actuator
1
018475
018476
6
018477
3-10
ZF-AS Tronic
4
68.010
6
68.210*
Tightening torque
Hex nut (/030) M8 = 23 Nm
Stud bolt (/010) M8 = 10 Nm
/130
/120
/020
/030
/010
/110
68.020
68.210*
018481
CAUTION
Do not bend cable and do not tighten hard.
Avoid chafing points.
Fit connectors with traction relief and check
detent.
8
6
68.060
68.150
68.154
018482
10
11
68.060
68.300
68.330 68.320
018483
3-11
ZF-AS Tronic
3.3
014794
WARNING
The driver disc, pressure plate and friction lining are
part of the customer specification (basic document for
drawing up parts list).
The shift program software is co-ordinated to the
characteristics of the clutch components.
Modifications to the components (from the customer
specification) will result in poor clutch
characteristics and/or component damage.
NOTE
This happens if you place a short lever through
the transmission bell housing and use this to
press the bottom end of the release fork towards
the rear (transmission end).
CAUTION
Do not damage pressure plate.
6
3-12
ZF-AS Tronic
3.4
68.050
68.060
018472
68.210
68.060
018473
/140
/130
/110
/130
/140
68.110
/120
68.130
018474
3-13
ZF-AS Tronic
/110
/140
/130
68.060
/140
/130
/110
68.210
/130
/140
68.110
68.050
/120
68.130
018487
NOTE
Coat the outer circumference of the shaft seals
with methylated spirits.
2
3-14
ZF-AS Tronic
3.5
Output flange
3.5.1 Removal
1
2
32.550
32.540
32.530
32.510
NOTE
When extracting flange, use intermediate piece
to protect shaft.
015171
3.5.2 Fitting
1
32.540
32.510
32.550
32.530
! DANGER
Only touch hot output flange if wearing protective
gloves.
Once output flange has cooled down, insert Oring (32.530) in groove between shaft and output flange.
32.520
015169
3-15
ZF-AS Tronic
31.080
31.050
31.030
31.070
Loctite
574
015170
3-16
ZF-AS Tronic
3.6
CAUTION
If the Kitas sensor is changed, parameters must be
set for the new sensor (and/or taught-in) because
otherwise there will no longer be any tacho functions.
31.260*
3.6.1 Removal
ZF FRIEDRICHSHAFEN AG
014813
3.6.2 Fitting
CAUTION
Fit connector with traction relief and check
detent.
Impulse sensor may be confused with other parts,
therefore check ZF number.
1
019249
voltage supply
ZF
6.5 - 30V
vehicle end 6.5 - 9 V
voltage supply
ZF
6.5 - 30V
vehicle end 6.5 - 9 V
3-17
ZF-AS Tronic
3.7
06.260*
3.7.1 Removal
1
06.250
3.7.2 Fitting
1
NameZF no.
Neutral switch (DIN bayonet)
Seal
Pin
3-18
ZF-AS Tronic
05.400*
7
1
05.440
05.110
02.180
2
02.170
05.100
02.190
05.020
05.030*
05.030*
019068
3.8
CAUTION
Fit all connectors with traction relief and check
detent.
CAUTION
Tacho sensor must be calibrated and lead sealed.
3-19
ZF-AS Tronic
05.400*
7
1
05.440
05.110
02.180
2
02.170
05.100
02.190
05.020
05.030*
05.030*
019068
3-20
ZF-AS Tronic
3.9
01.030
01.040
018479
47.030
47.020
47.010
47.060
47.050
018478
47.050
47.010
47.030
47.060
018480
3-21
ZF-AS Tronic
3.10 Display
ZF display 0501 211 422, CAN-compatible
CAUTION
Only work on display if ignition is off.
NOTE
The display must be accessible from below.
2
3.10.1Disassembly
1
3.10.2Installation
1
CAUTION
Fit connector (2) with traction relief and check
detent.
3.10.3Connection diagram
0501 211 422, refer to Annex
Plug assignment
PIN 1:
PIN 2:
PIN 3:
PIN 4:
PIN 5:
PIN 6:
PIN 7:
PIN 8:
3.10.4Connector replacement
If the connector has to be replaced, please use the
AMP standard tool.
For vehicle-specific connection diagram, refer to parts
list.
3-22
ZF-AS Tronic
Documents attached
Connector and mating connector designations
ZF standard pneumatics diagram
List of lubricants TE-ML02 1205 754 002
for current List of Lubricants, refer to: http://www.zf.com/defaultz.asp?lang=2&id=522
Drawings attached
Drawing no.
0501 210 059c
0501 210 854b
0501 211 185a
0501 211 422e
1327 600 015b
1327 600 016a
1328 600 015c
1328 600 016b
1328 600 019
6006 629 024
6006 700 579c
6006 700 586a
6029 713 016a
6029 713 021
6029 713 022
6029 713 025a
6041 622 023c
6090 601 031
6090 604 024
6091 610 003d
6091 615 007
Name
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Circuit diagram
Circuit diagram
Circuit diagram
Connection diagram
Connection diagram
Circuit diagram
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Techn. information
Signal switch
Impulse sensor
Steering wheel switch
Display
12 AS ZF-Standard
12 AS with Intarder and ZF-Standard cable tip
16 AS ZF-Standard
16 AS with Intarder ZF-Standard
Clutch
Range selector
Range selector
Range selector
ZF-AS Tronic general
Central consumer, ZF-AS Tronic general
End consumer, ZF-AS Tronic general
On-board computer
ZF E module
PTO NH/1
PTO NH/4
PTO NAS/10
PTO with emergency steering pump
3-23
Component replacement /
connector and mating connector designations
ZF-AS Tronic
Connector
Use
Type
Manuf.
ZF number
Manufacturer no.
CKD no.
Protection class
X1
GS3 on-site
electronics
20-pin Bu
Kostal
IP 67/ 69
IP 67/ 69
X1
GS3 on-site
electronics
Bus actuator
18-pin Bu
Kostal
X36
E-module
35-pin
AMP
X21
Diagnosis
6-pin ST MNL
AMP
Open connector
system, no details
of protection
class
X21
Diagnosis
Mating connector
6-pin Bu MNL
AMP
Conn. housing350715-1
Contact bush: 926882-3
refer to
6-pin ST MNL
Range selector
14-pin Bu
J.P.T.
AMP
refer to
6-pin ST MNL
6-pin Bu
J.P.T.
AMP
refer to
6-pin ST MNL
4-pin St MNL
AMP
refer to
6-pin ST MNL
refer to
6-pin ST MNL
X2
X5
X5
X5
Display
Display
Display
8-pin Bu
AMP
A11/A14
Output sensor
4-pin BU DIN
Bay.. angled
AMP
IP 67/ 69K
S12
Neutral switch
4-pin BU DIN
Bay.. straight
AMP
IP 67/ 69K
S12
Neutral switch
4-pin BU DIN
Bay.. angled
AMP
IP 67/ 69K
refer to
6-pin ST MNL
X17
Junction for
22-pin Bu JPT
vehicle power supply
AMP
X17 A
M. conn.
Junction for
vehicle power supply 22-pin St JPT
AMP
refer to
6-pin ST MNL
X18
Junction for
vehicle power supply 18-pin Bu JPT
AMP
refer to
6-pin ST MNL
X18 A
M. conn.
Junction for
vehicle power supply 18-pin St JPT
AMP
refer to
6-pin ST MNL
X18 A
M. conn.
Junction for
CAN veh. p supply
6-pin Bu JPT
AMP
refer to
6-pin ST MNL
X18 A
M. conn.
Junction for
CAN veh. p supply
6-pin St JPT
AMP
refer to
6-pin ST MNL
X19
Junction for
cab
18-pin Bu JPT
AMP
refer to
6-pin ST MNL
Junction for
cab
18-pin St JPT
AMP
refer to
6-pin ST MNL
X20 m. conn.
for X19
Connector replacement: If a connector has to be replaced, please use the AMP standard tool (for connection diagram, refer to parts list).
3-24
ZF-AS Tronic
Example 1
Compressor
Air dryer
Four-circuit
protection
valve
5 bar overcurrent
valve
Transmission
actuator
with pressure sensor
20 litres
Non-return
valve
Clutch actuator
014885
014 885
Example 2
Compressor
Air dryer
Four-circuit
protection
valve
Transmission
actuator
with pressure sensor
20 litres
Non-return
valve
Clutch actuator
014 886
5 bar
overAuxiliary concurrent
sumers
valve
014886
3-25
x
List of lubricants TE-ML 02
Lubricant classes for service fills (2)
(1)
Transmissions without
ZF-Intarder
Transmissions with
ZF-Intarder
Ecolite
_
VAN + bus 1
x
---
02G
alternative recommended (4):
02A / 02B / 02C / 02H
x
---
truck + bus 2
bus 3
Ecomid / Ecomid with NMV
truck + bus
_
02A / 02B / 02C / 02D /
02H / 02L
02C(5)
02C(5)
x
02A(5) / 02B / 02C / 02H
02C / 02H
ASTRONiC 2
truck, bus + crane vehicle
x
02A(5) / 02H / 02L
02H / 02L
TC-Tronic
Transmission ASTRONiC 2
x
02A(5) / 02H / 02L
---
02C(5) / ATF in
accordance with TE-ML 14
---
(2)
See overleaf for approved trade products, oil drain intervals and low temperature limits.
(3)
Product group Ecolite - VAN + bus 1: TE-ML 02 applies only after the transmission has reached a total of 2,500
km. This also applies to repairs.
(4)
Product group Ecolite: In moderate climate zones, shift quality is impaired if oils of the lubricant classes
02A / 02B / 02C / 02H are used.
(5) The lubricants listed overleaf and marked thus (*) may not be used.
Comments:
1.
Instructions for transmission ventilation in accordance with Installation Guidelines 1203 765 010 and
1328 765 001 must be followed.
2.
A saponified lithium mineral oil-based multigrade grease of the NLGI class 2 should be used at greasing points
(grease code KP2K-30 in accordance with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO/DIS 6743-9).
ZF Friedrichshafen AG
D-88038 Friedrichshafen
phone: + 49 7541 77 3505x
fax:
+ 49 7541 77 7319
1205 754 102g / 07.2003
Continued
Transmission classification
in accordance to product groups
x
Product groups
Transmission types
(type in bold/italic are available with ZF Intarder)
Ecolite
VAN + bus 1
truck
6S850
bus 2
6S890, 6S700BO
bus 3
ASTRONiC 1
truck
12AS1800, 16AS2200
ASTRONiC 2
truck (8)
bus
crane vehicle
12AS2302, 16AS2602
TC-Tronic
12TC2740TO, TC 2
x
(7) X refers to transmission version
0 = without Intarder, 1 = Intarder, 2 = NMV, 3 = 100% overrun, 4 = servoshift
(8)
Page 2 of 14
Continued
x
x
Product group (9)
x
Lubricant class
Operating conditions
Ecolite
- without ZF-Intarder
x
Short-distance transport
(trucks)
x
Scheduled routes
(buses)x
x
Tough operatingx
conditionstions
Ecomid / Ecosplit /
Transmatic (10) /
ASTRONiC / TC-Tronic (10)
- without ZF-Intarder
- with ZF-Intarder
Ecolite / Ecomid /
Ecosplit / ASTRONiC
- without ZF Intarder
- with ZF-Intarder
Long-distance transport
(trucks)
x
Long-distance coach
journeys (buses)
x
02A
x
02B
x
02C/02H
x
02D/02L
02F/02G
(Ecolite
only)
_
_
60.000 km
120.000
1 year
km
1 year
_
120.000
km
1 year
_
240.000
km
2 years
120.000
km
1 year
_
---
---
---
90.000 km
1 year
160.000
km
1 year
---
---
x
160.000
kmx
1 year
x
300.000
kmx
2 years
160.000
km
1 year
---
Comment:
(9)
(10) ATF in accordance with TE-ML 14 in torque converter lock-up clutches with separate oil circuit
(WSK, TC 2): 120.000 km or 1 year.
x
above -40C
above -25C
02C
30
above -15C
below -15C
Page 3 of 14
Continued
Page 4 of 14
Continued
Page 5 of 14
Continued
Note:
In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are
used.x
x
Manufacturer (02B)
ADDINOL GETRIEBEL GX 80 W 90 ML
AGIP ROTRA TRUCK GEAR S, SAE 75W-90
ARAL GETRIEBEL EP PLUS SAE 80W-90
BM 80
AVIA SYNTOGEAR FE 75W-90 EP
AVIA SYNTOGEAR FE 80W-90
BAYWA SUPER 8090 MC
BP ENERGEAR DL 80W
BP ENERGEAR DL 80W-90
BP ENERGEAR HT 80W
BP ENERGEAR HT 80W-90
ENERGEAR SHX-M SAE 75W-90
FRONTOL GETRIEBEL FE SAE 80W-90
MOTOREX UNISYNT TX
CALPAM MULTI GEAR OIL FE 80W90
CALTEX TRANSLUBE LD SAE 80W
CALTEX TRANSLUBE LD SAE 80W-90
CASTROL AGRI GEAR ULTRA
CASTROL DYNADRIVE 80W-90
CASTROL SUPERDRIVE 80W
CEPSA TRANSMISIONES EP FE+LD 75W-90
MULTIGEAR 80W-90
MULTIGEAR S 75W-90
TOR UNIGEAR 75W90 LD
ROTRA LSX 75W-90
ROTRA TRUCK GEAR 80W-90
ESSO GEAR OIL TDL 75W-90
ESSO GEAR OIL TDL 80W-90
MOBILUBE 1 SHC 75W-90
MOBILUBE S 80W-90
FALCON SUPER EP GEAR OIL 80W/90 GL-4
TITAN SUPERGEAR MC 80W-90
GENOL GEAR-SYN 80W-90
YORK 896
EUROGEAR SAE 75W-90
HRD LONGEVIA P 80W-90
HRD LONGEVIA PXD 75W-90
SYNTHEGEAR SAE75W90
Q8 GEAR OIL XG SAE 80W-90
HYPOID GETRIEBEL TDL SAE 80W-90
MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
SYNTRAN FE/MILLERS TRX SYNTH 75W/90
PENNASOL LONGLIFE GEAR GL 4 SAE 80W
PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 80W
TRANSLUBE GL-4 SAE 80W
LODEXOL SS 80W
SERVOL EP 80W/90
GEAROIL SYNTH
QUAKER STATE SUPER Q 5 SAE 80W-90
OEST MEHRZWECK-GETRIEBEL FE SAE 80W-90
OEST SYNTH GETRIEBEL SAE 75W-90
OMV GEAR OIL XD-4 SAE 80W-85
OMV UNIGEAR S SAE 75W-90
OMV UNIGEAR SAE 80W-90
PAKELO GLOBAL GEAR CBS SAE 75W/85
PAKELO GLOBAL GEAR SA SAE 80W
PAKELO GLOBAL GEAR SA SAE 80W/85
PAKELO GLOBAL GEAR SA SAE 80W/90
PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN SUPER DUTY SYNTH 75W/90
Page 6 of 14
Continued
Page 7 of 14
Continued
Page 8 of 14
Continued
Page 9 of 14
TURBO HD SAE 30
TEBOIL POWER D SAE 30
URSA LA 3 SAE 40 (*)
TOTAL RUBIA S 30
ALL FLEET PLUS 30
ALL FLEET PLUS 40 (*)
YACCO TRANSPRO MAS3 SAE 30
Continued
Page 10 of 14
Continued
ADDINOL ATF D II D
ADDINOL ATF D III
ARAL GETRIEBEL ATF 55 F-30589
AVIA FLUID ATF 98
CALTEX ATF-HDM
CASTROL TQ DEXRON III (F-30520)
TEXTRAN PSM
TUTELA CAR GI/E
TUTELA GI/A
TITAN ATF 4000
YORK 686
HRD STARMATIC 3
ATF 420
ATF 430
Q8 AUTO 14
Q8 AUTO 15
LIQUIMATIC SUPER ATF
OMV ATF III
PANOLIN ATF DEXRON III
MERCON V ATF
VECO MATIC IID
HIPOL ATF II D
HIPOL ATF III
GULF ATF HIGH TECH
DEAFLUID 3003
WINTERSHALL ATF III
TEXAMATIC 7045E
ELFMATIC G3
FINAMATIC HP
TOTAL FLUIDE AT 42
VEEDOL ATF DEXRON III (F-30521)
YACCO ATF III
DIVINOL FLUID III F
Page 11 of 14
Continued
CHEVRONTEXACO, GHENT/B
FUCHS PETROLUB AG, MANNHEIM/D
FUCHS PETROLUB AG, MANNHEIM/D
MULTIGEAR MTF LT
TITAN EG 75 ZF
TITAN GEAR ZF
Page 12 of 14
Continued
Page 13 of 14
Continued
BP ENERGEAR SHX 30
CASTROL SYNTRANS
VEEDOL SYNMESH
Page 14 of 14