ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual PDF

Repair Manual

Maintenance, Diagnosis, Component Replacement Repair Level 1 - 2

Bus

1337 751 101b_en

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CAUTION The ZF order numbers listed in the manual apply to the ZF standard.

Variances may occur depending on the vehicle manufacturer.

The binding ZF order numbers can be found in the relevant parts list – parts list numbers are specified on the transmission type plate.

Subject to technical changes

Copyright by ZF Friedrichshafen AG 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 dept. / 2003-09

Edition: 2009-09

1337 751 101b

ZF-AS Tronic

Table of Contents Page

List of Changes .....................................................................................................................................

Preface .................................................................................................................................................

Important Information .........................................................................................................................

Instructions for Repairs .......................................................................................................................

Tightening Torques ..............................................................................................................................

Conversion Factors for Units of Measurement (EU - USA) .................................................................

Special Tools .........................................................................................................................................

Test Equipment, ZF-AS Tronic Diagnosis Tools...................................................................................

ZF-Intarder Diagnosis Tools .................................................................................................................

5 6 7 8 10 11 13 15 18

General maintenance ..........................................................................................................................

Visual Inspection of Wiring..................................................................................................................

Pneumatic System Maintenance..........................................................................................................

Clutch Actuator and Transmission Actuator .......................................................................................

Transmission Bleeding .........................................................................................................................

Note When Changing Oil .....................................................................................................................

Approved Oil Grades ............................................................................................................................

Oil Volume ............................................................................................................................................

Oil-Change Intervals ............................................................................................................................

Oil Change (ZF-AS Tronic Without ZF-Intarder) ...............................................................................

- Filling Oil .........................................................................................................................................

- Oil-Level Check ...............................................................................................................................

- Type Plate.........................................................................................................................................

Oil Change (ZF-AS Tronic With ZF-Intarder) ....................................................................................

- Oil Filter Replacement ....................................................................................................................

- Oil Filling ........................................................................................................................................

- Oil Filling in Case of Oil Change ...................................................................................................

- Oil Filling After Transmission Repair ............................................................................................

- Oil-Level Check ...............................................................................................................................

- Visual Inspection .............................................................................................................................

- Engine Coolant ................................................................................................................................

- ZF-Intarder Type Plate ....................................................................................................................

21 21 21 21 22 23 24 24 24 25 25 26 26 27 28 29 29 29 30 30 31 31

Diagnosis .......................................................................................................................................................

- Diagnosis on Vehicles With ZF Display and ZF Range Selector ....................................................

- Diagnosis With Testman pro ...........................................................................................................

- Data Sheet: 20-pin Transmission Actuator......................................................................................

- Pin Assignment ................................................................................................................................

- Data Sheet: 18-pin Transmission Actuator......................................................................................

32 32 33 34 35 36

Transmission Actuator ..................................................................................................................................

- Removing Transmission Actuator ..................................................................................................

- Removing the Upper Section from the Lower Section ..................................................................

- Reattaching the Upper Section to the Lower Section ....................................................................

- Mounting Transmission Actuator....................................................................................................

- Replacing Pressure Relief Valve .....................................................................................................

- Programming Transmission Actuator ............................................................................................

37 37 39 39 40 43 44

1337 751 101 - 2009-09

3

ZF-AS Tronic

Table of Contents Page

Clutch Actuator ...................................................................................................................................

- Removing Clutch Actuator .............................................................................................................

- Clutch Actuator Maintenance ........................................................................................................

- Bleeding and Assembling Clutch Actuator ....................................................................................

Clutch ..................................................................................................................................................

- Replace Clutch ................................................................................................................................

Clutch Release Mechanism .................................................................................................................

- Removing Release Fork ...................................................................................................................

- Fitting Release Fork .........................................................................................................................

Output Flange.......................................................................................................................................

- Removing and Mounting Output Flange.........................................................................................

- Removing and Mounting Yoke ........................................................................................................

Output Cover .......................................................................................................................................

- Removing and Mounting Output Cover ..........................................................................................

Output Impulse Sensor (Speed Sensor) ..............................................................................................

- Removing and Mounting Impulse Sensor.......................................................................................

Replacing Neutral Switch....................................................................................................................

- Remove and Install Neutral Switch ................................................................................................

Replace Intarder Components ...........................................................................................................

- Output Speed Sensor, Speedo Sensor, Solenoid Valve, Temperature Sensor ...............................

- Removing and Mounting 3/2 Directional Valve..............................................................................

- Removing and Mounting Intarder Cable Harness ..........................................................................

Additional Cooling ..............................................................................................................................

- Assembling the Valve Block of the Additional Cooling Unit..........................................................

ZF-Display ............................................................................................................................................

- Removing and Mounting the Display..............................................................................................

- Wiring Diagram ...............................................................................................................................

- Connector Assignment, Connector Replacement...........................................................................

Range Selector......................................................................................................................................

- Removing and Mounting Console-Type Range Selector.................................................................

- Removing and Mounting Steering-Column Switch ........................................................................

- Removing and Mounting Pushbutton Range Selector ....................................................................

- ZF Lever-Type Range Selector.........................................................................................................

Electronic Control Unit .......................................................................................................................

- Removing and Mounting E-Module ................................................................................................

- Removing and Mounting E-Module 2 .............................................................................................

- Removing and Mounting ZMTEC ...................................................................................................

- ZMTEC Pin Assignment ..................................................................................................................

Type Designations and Order Numbers .............................................................................................

Pneumatic Diagram ............................................................................................................................

45 45 46 47 49 49 50 50 52 55 55 56 57 57 58 58 59 59 60 60 61 61 62 62 63 63 63 63 64 64 65 66 68 69 69 70 71 72 73 74

Appendix ..............................................................................................................................................

- Attached Documents .......................................................................................................................

- Attached Drawings .........................................................................................................................

75 75 75

1337 751 101 - 2009-09

4

List of Changes: 1337 751 101

Index

Date of issue

Initiator

Comment

2003-09

BKS-R dept.

First version

a

2008-05

BKS-R dept.

Complete revision, the following has been added, among other: - New clutch release - Hose breather - Conversion factors - Maintenance of clutch and transmission actuator - Oil fill volume, ZF-AS Tronic Bus - E-module 2

b

2009-09

BKS-R dept.

- Maintenance of compressed-air system: Information added - Venting clutch actuator: Caution omitted - Disengagement: Lubrication instruction added - Keypad-type selector: Sticker included

1337 751 101 - 2009-09

Chapter

5

Preface Preface

Warranty

This manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products.

The work described below may only be performed by authorized, trained, and instructed staff. It is the responsibility of the user’s company or repair company to ensure that their repair staff is properly trained.

Repair work carried out at ZF Service Points is subject to the contractual conditions prevailing in the individual case.

Direct and/or subsequent costs are not covered by this contractual liability when: • work has been performed improperly or by unskilled personnel, by non-ZF-personnel, and/or

This manual deals with a ZF series product in accordance with the state of development on the date of issue.

• use of “non” genuine ZF parts.

In case of failure it is mandatory to act immediately, so to ensure the complete function of the ZF unit and minimize the scope of damage.

However, due to continuing technical advancements of the product, repair work might require work practices and test or adjustment data which are not contained in this manual.

We therefore recommend that work done on your ZF product is carried out only by skilled mechanics and fitters who have their practical and theoretical knowledge updated on a regular basis at our Service Training Center.

In case of proven unfounded delay in repair we reserve the right of partial acceptance or even a rejection of warranty claims.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continuously trained personnel, 2. Specified equipment, e.g.: special tools, 3. Genuine ZF spare parts in accordance with the latest volume production specifications.

All work performed at these service locations is carried out conscientiously and with care.

ZF Friedrichshafen AG Driveline and Chassis Technology

2008-06

6

0000_99D_010_en 2009-09

Safety Instructions The following safety instructions are used in this repair manual:

!

DANGER to the health!

Ensure confident handling with supplies.

Manufacturer’s instructions must be observed.

NOTE Refers to special working procedures, methods, information, use of auxiliary equipment, etc.

!

DANGER to the environment!

Lubricants, consumables, and cleaning agents must not be allowed to enter the soil, ground water, or sewage system.

• Ask your local environment agency for safety information on the relevant products and adhere to their requirements.

• Collect used oil in a suitably large container.

• Dispose of used oil, dirty filters, lubricants, and cleaning agents in accordance with environmental protection regulations.

• When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.

CAUTION Is used when the instructions are not complied with or not followed precisely and could lead to the product being damaged.

!

DANGER! Is used when lack of care could result in personal injury or danger to life.

CAUTION The transmission must NOT be suspended by the input shaft OR by the output flange/add-on parts.

Safety Instructions As a rule, repair technicians for ZF units are responsible for their own workplace safety.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to.

Before starting work, mechanics must therefore familiarize themselves with these regulations.

Incorrect

Personnel required to carry out repairs on ZF products must receive appropriate training in advance.

Compulsory training is the responsibility of the repair staff.

Correct

! DANGER! Do not walk under suspended load during parts transportation with a hoist.

2008-06

7

0000_99D_020_en 2009-09

Instructions for Repairs General Information

Cleaning Parts

Read this manual carefully before starting tests or repair work.

Remove old sealing compound residues from all sealing faces. Carefully remove burrs or other uneven patches using an oil stone.

Lube bores and grooves must be free from anticorrosion grease and foreign matter. Check that the passage is free.

Carefully cover opened transmissions to prevent the entry of foreign matter.

The ZF-Service Information details must be observed. These are available from all ZF Service Centers or from the ZF-ServiceLine.

In any cases of doubt, always contact the relevant expert departments at ZF-Service.

Whenever working on the transmission, ensure cleanliness and carry out the work as instructed.

Use specified tools to dismantle and assemble transmissions.

Reusing Parts Parts such as antifriction bearings, multidisks, thrust washers etc., must be inspected by a specialist, who should decide whether they can be re-used or not.

Replace parts which are damaged or have suffered from excessive wear.

CAUTION The pictures, drawings, and components shown do not always represent the original object, but are used to illustrate working practices.

The pictures, drawings, and components are not to scale and no conclusions must be drawn about size and weight (not even within a complete illustration).

All work must be performed as described in the text.

• Gaskets, locking plates Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

Gaskets are installed without the use of sealing compound or grease. When measuring coated gaskets/seals proceed as specified.

After repair work and tests performed, skilled personnel must make sure that the product is working properly again.

• Shaft seals Always replace shaft sealing rings with rough, ripped, or hardened sealing lips. Seal contact surfaces must be totally clean and in perfect condition.

Conversions and modifications may impact the transmission’s operational safety. Therefore, customer-specific deviations must be agreed with ZF in writing.

Reworking

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the recesses of housings and covers when cleaning.

2008-06

If rework is needed on spacer washers and shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.

8

0000_99D_030_en 2009-09

Instructions for Repairs Transmission Assembly

• Shaft Sealing Rings Press in shaft sealing ring with fixture or face plate until firmly home at relevant installation depth.

Assemble the transmission in a clean workplace.

Adhere to all adjustment data and tightening torques specified in the repair manual.

a) Apply a thin coat of sealing agent* to outer circumference of shaft sealing rings with a «steel surround».

• Bearings If the bearings are fitted while warm, these should be warmed up evenly (e.g. 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.

b) Never apply sealing agent to shaft sealing with a «rubber surround» but apply a thin coat of Vaseline 8420 or spirit to the outer circumference, or wet with a lubricant, e.g. a water-soluble concentrated washing-up liquid. c) Shaft sealing rings with steel and rubber surrounds should be treated on the outer circumference of the rubber surround as described for shaft seal (b).

• Sealing If a sealant* is recommended for sealing, then it is essential to adhere to the manufacturer’s directions for use. A thin layer of sealing agent should be applied to the surfaces and coat them evenly. Do not allow sealing agent to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the parts are pressed together.

d) Duo shaft sealing rings have two sealing lips. The dust protection sealing lip (X) must face outwards.

Fill the space between the sealing lips up to 60% with grease*.

X

• Transmission Oil After completing repairs, fill the transmission with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and the List of Lubricants TE-ML (refer to type plate). These are available from all ZF Service Centers or 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.

• Retaining Agents Retaining agents* may only be used where specified by the parts list.

When using retaining agents (e.g. Loctite) always comply with the manufacturer’s directions for use.

During assembly, comply with all adjustment data, inspection data, and tightening torques.

* refer to consumable material

2008-06

9

0000_99D_040_en 2009-09

Tightening torques Tightening torques for screws/bolts and nuts, extract from ZFN 148 Surface condition of screws/bolts/ nuts: Heat-treated blackened finish and oiled or galvanized and oiled.

This standard applies to bolts according to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and for nuts according to DIN 934 and ISO 4032, ISO 8673.

The bolts are tightened using a calibrated torque wrench.

This standard contains data on tightening torques for screws/bolts and nuts of strength categories 8.8, 10.9, and 12.9, as well as nuts of strength categories 8, 10, and 12.

NOTE Differing tightening torques are listed separately in the repair manual.

Coarse thread Measurement Screw/Bolt Nut

Fine thread Tightening torque in Nm for 8.8 10.9 12.9 8 10 12

Measurement Screw/Bolt Nut

Tightening torque in Nm for 8.8 10.9 12.9 8 10 12

M4 M5 M6

2,8 5,5 9,5

4,1 8,1 14

4,8 9,5 16,5

M8x1 M9x1 M10x1

24 36 52

36 53 76

43 62 89

M7 M8 M10

15 23 46

23 34 68

28 40 79

M10x10.25 M12x10.25 M12x1.5

49 87 83

72 125 120

84 150 145

M12 M14 M16

79 125 195

115 185 280

135 215 330

M14x1.5 M16x1.5 M18x1.5

135 205 310

200 300 440

235 360 520

M18 M20 M22

280 390 530

390 560 750

460 650 880

M18x2 M20x1.5 M22x1.5

290 430 580

420 620 820

490 720 960

M24 M27 M30

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 Status: August 1991

2008-06

10

0000_99D_050_en 2009-09

ZF-AS Tronic

Conversion Factors

Conversion Factors: from

to

x

Factor

Examples:

mm inch

inch mm

x x

0.03937 25.4

20.0 mm 0.4 inch

= 0.7874 inch = 10.16 mm

Nm ft.lb.

ft.lb.

Nm

x x

0.7376 1.356

60 Nm 35 ft.lb.

= 44.256 ft.lb. = 47.46 Nm

°C

°F

9 x °C 5

90 °C

= 194 °F

°F

°C

5(°F-32) 9

248 °F

= 120 °C

bar psi

psi bar

x x

14.513 0.06894

10 bar 200 psi

= 145.13 psi = 13.78 bar

liter US gallons

US gallons liter

x x

0.2642 3.7854

20 liters = 3 US gallons =

1337 751 101 - 2009-09

+ 32

11

5.284 US gallons 11.3562 liters

0000_99D_060_en 2009-09

ZF-AS Tronic

Fig. no.

Figure

Special Tools

Order no.

Application

Qty.

Remark

Chapter

1X56 138 215

“Clutch Release

1

Adapter for assembly of bushes and shaft sealing rings of release fork

Mechanism”

2

(Version A) Release fork with cams.

Chapter

1X56 138 546

“Clutch Release

2

Press-in mandrel for assembly of bearing bushes and cam rollers of the release fork

1

Mechanism” (Version B) Release fork with cam rollers.

Chapter

1X56 138 547

“Clutch Release

3

Support ffor the release fork

1

Mechanism” (Version B) Release fork with cam rollers.

1X56 137 124

Chapter “Output Cover”

4

Adapter for installing the shaft sealing ring at the output cover (in connection with a spacer ring 1X56 138 189)

1

1X56 138 189

Chapter “Output Cover”

5

Spacer ring for shaft sealing ring 105 x 125 x 12 at output cover (in connection with adapter 1X56 137 124)

1

NOTE: Please inquire as to packaging unit before ordering.

1337 751 101 - 2009-09

13

1327_91D_010_en 2008-03

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DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL