ZF Transmission ZF-AS Tronic Trucks Repair Level 1-2 Repair Manual 1327751101a – PDF DOWNLOAD

REPAIR MANUAL

ZF-AS Tronic Trucks Repair level 1 - 2 Maintenance, diagnosis, replacement of components

1327 751 101a

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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.

Subject to technical modifications.

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

1327 751 101a

ZF-AS Tronic

Table of contents Page

Overview of amendments ...........................................................................................................................

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

Important information.................................................................................................................................

Instructions for carrying out repairs............................................................................................................

Tightening torques ......................................................................................................................................

Changing from DIN to ISO standard codes ................................................................................................

Test device, diagnosis tool...........................................................................................................................

ZF-Intarder diagnosis tool...........................................................................................................................

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

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 Component replacement...........................................................................................................................

3.1 Transmission actuator .................................................................................................................................

3.1.1 Removing transmission actuator .................................................................................................................

3.1.2 Fitting..........................................................................................................................................................

3.1.3 Dismantling transmission actuator..............................................................................................................

3.1.4 Assembling transmission actuator ..............................................................................................................

3.1.5 Programming transmission actuator............................................................................................................

3.1.6 Replacing pressure limitation valve ............................................................................................................

3.2 Clutch actuator ............................................................................................................................................

3.2.1 Removal ......................................................................................................................................................

3.2.2 Push rod ......................................................................................................................................................

3.2.3 IVECO push rod setting ..............................................................................................................................

3.2.4 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

2 2.1 2.2 2.3

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ZF-AS Tronic

Table of contents Page

3.3 Replacement of driver disc.......................................................................................................................... 3-12 3.3.1 Fitting engine, clutch and transmission....................................................................................................... 3-12 3.4 Clutch release mechanism........................................................................................................................... 3-13 3.4.1 Removal of release fork .............................................................................................................................. 3-13 3.4.2 Fitting release fork ...................................................................................................................................... 3-14 3.5 Output flange .............................................................................................................................................. 3-15 3.5.1 Removal ..................................................................................................................................................... 3-15 3.5.2 Fitting ......................................................................................................................................................... 3-15 3.5.3 Removing output cover ............................................................................................................................... 3-16 3.5.4 Fitting output cover ..................................................................................................................................... 3-16 3.6 Speed sensor (impulse sensor), output, depends on vehicle manufacturer ................................................. 3-17 3.6.1 Removal ..................................................................................................................................................... 3-17 3.6.2 Fitting ......................................................................................................................................................... 3-17 3.6.3 Connector replacement ............................................................................................................................... 3-17 3.7 Replacing Neutral switch ............................................................................................................................ 3-18 3.7.1 Removal ..................................................................................................................................................... 3-18 3.7.2 Fitting ......................................................................................................................................................... 3-18 3.7.3 Connector replacement ............................................................................................................................... 3-18 3.8 Replacing components on Intarder ............................................................................................................. 3-19 3.8.1 Speed sensor, output.................................................................................................................................... 3-19 3.8.2 Tacho sensor................................................................................................................................................ 3-19 3.8.3 Solenoid valve............................................................................................................................................. 3-19 3.8.4 Temperature sensor ..................................................................................................................................... 3-19 3.8.5 Removing 3/2-way valve............................................................................................................................. 3-20 3.8.6 Removing / fitting Intarder wiring harness ................................................................................................. 3-20 3.9 Additional cooling connection .................................................................................................................... 3-21 3.10 Display ....................................................................................................................................................... 3-22 3.10.1 Disassembly................................................................................................................................................ 3-22 3.10.2 Installation.................................................................................................................................................. 3-22 3.10.3 Connection diagram ................................................................................................................................... 3-22 3.10.4 Connector replacement............................................................................................................................... 3-22 Annex Documents / drawings attached................................................................................................................... 3-23 Connector and mating connector designations............................................................................................ 3-24 Pneumatics diagram .................................................................................................................................... 3-25

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ZF-AS Tronic

Index Issue date a

1327 751 101 - 2003-04

Overview of amendments: 1327 751 101

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

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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.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained staff 2. Specified equipment, e.g: special tools 3. Genuine ZF spares, to our latest specifications

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

Warranty: Repair work carried out at ZF service points is covered by warranty in accordance with the prevailing contractual conditions.

ZF FRIEDRICHSHAFEN AG Commercial Vehicle and Special Driveline Technology Division Service Werk 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-908000 Internet: www.zf.com

1327 751 101 - 2003-04

Damage resulting from work performed by non-ZF staff in an improper and unprofessional manner, together with any follow-on costs caused by such work, is not covered by the contractual liability.

This also applies to instances in which genuine ZF spares have not been used.

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ZF-AS Tronic

Important information

SAFETY NOTICE

GENERAL INFORMATION

Companies who repair ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

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

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

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

It is the responsibility of each company to ensure that their repair staff are properly trained.

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.

The following safety instructions appear in this manual

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly. ! THREATS TO THE ENVIRONMENT Lubricants 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 guidelines.

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

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.

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ZF-AS Tronic

Instructions for carrying out repairs GASKETS, LOCKING PLATES

In any instances of doubt, always contact the relevant specialist department within ZF After-Sales Service for advice.

Ensure cleanliness and professional work whenever working on the transmission.

The intended tools must be used to dismantle and assemble the transmission.

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

SHAFT SEALS Always change shaft seals with rough, ripped or hardened seal lips. Seal contact surfaces must be totally clean and in perfect condition.

After removing the transmission from the vehicle, clean thoroughly with appropriate washing agent before opening.

Pay particular attention to the corners and angles of housings and covers when cleaning with appropriate washing agent.

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.

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

Lube bores and grooves must be free of anti-corrosion agents and foreign bodies. Check that they can move freely.

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.

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

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.

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ZF-AS Tronic

Instructions for carrying out repairs d) Duo shaft seals have two sealing lips. The dust protection sealing lip (X) must face outwards.

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.

X

e) Fill the gap between the sealing lips so that it is 60 % filled with grease* (use a grease e.g. produced by Aral such as Aralub HL2 or produced by DEA such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (this makes fitting easier).

Press the shaft seal with mounting or face plate evenly into the relevant installation depth.

SEALING If a sealing agent* is to be used for carrying out sealing, comply with the manufacturer’s 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 manufacturer’s 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

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ZF-AS Tronic

Tightening torques

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

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

The bolts are tightened using a calibrated snap torque wrench or torque display wrench.

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

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

Metric standard pitch thread

Metric course pitch thread

Size

Size

Bolt Nut

Tightening torque in Nm for 8.8 10.9 8 10

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

M10x1.25 M12x1.25 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

12.9 12

Bolt Nut

Tightening torque in Nm for 8.8 10.9 8 10

12.9 12

Edition: August 1991

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ZF-AS Tronic

Tightening torques

Screw plugs DIN 908, 910 and 7604

Union screws DIN 7643

The values of the screw plug tightening torques were determined according to DIN 7604 for screwing into steel, grey cast and aluminium alloys.

The values are based on experience and are only intended as reference values for the fitter.

The values for the tightening torque should also be used for screw plugs as defined in DIN 908 and DIN 910 as the thread geometries are almost identical.

General rule: Screw class 5, ZFN 148-1 Screw material: steel acc. to DIN 7604 Surface condition: as manufactured (no surface protection) and lightly oiled or galvanized, chrome-plated and lightly oiled.

The tightening torques were determined for screwing into steel, grey cast and aluminium alloys.

The values are based on experience and are only intended as reference values for the fitter.

General rule: Screw class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: as manufactured (no surface protection) and lightly oiled or galvanized, chrome-plated and lightly oiled.

Screw plugs (DIN 908, 910, 7604) Dimensions

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

Union screws (DIN 7643)

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

* DIN 7604 Form C

1327 751 101 - 2003-04

Thread

Tightening torque in Nm

4-5

M8x1

20 - 25

6

M10x1

25 - 35

8

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

Edition: October 1995

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ZF-AS Tronic

Changing from DIN to ISO standard codes

Withdrawn Title DIN

Replacement Result of testing/measures 1) ISO standard

DIN 1

Tapered pins

ISO 2339

- some can be interchanged → changed to ISO 2339 - parts cannot be interchanged (e.g. when 1 = 36 mm), documented on DIN 1-ALT

DIN 7

Cylinder pin

ISO 2338

- some can be interchanged → changed to ISO 2338 - parts cannot be interchanged (e.g. → 13 and 14 and/or 1 = 36 mm), documented on DIN 7-ALT

DIN 84

Cylindrical screws

ISO 1207

- some can be interchanged → changed to ISO 1207 - parts cannot be interchanged (e.g. M2.6), doc. on DIN 84-ALT

DIN 85

Flat head screws

ISO 1580

- can be interchanged → changed to ISO 1580

DIN 94

Split pins

ISO 1234

- can be interchanged → changed to ISO 1234

DIN 417

Threaded pins

ISO 7435

- can be interchanged → changed to ISO 7435

DIN 439-1 DIN 439-2

Hex nuts Hex nuts

ISO 4036 ISO 4035 ISO 8675

- cannot be interchanged → documented on DIN 439-ALT

DIN 551

Threaded pins

ISO 4766

- can be interchanged → changed to ISO 4766

DIN 553

Threaded pins

ISO 7434

- can be interchanged → changed to ISO 7434

DIN 555

Hex nuts

ISO 4034

- cannot be interchanged → documented on DIN 555-ALT

DIN 558

Hex bolts

ISO 4018

- some can be interchanged → changed to ISO 4018 - parts cannot be interch. (e.g. M12, new waf), doc. on DIN 558-ALT

DIN 601

Hex bolts

ISO 4016

- some can be interchanged → changed to ISO 4016 - parts cannot be interchanged (e.g. M10 and M12, new waf), documented on DIN 601-ALT

DIN 912

Cylindrical screws

ISO 4762

- some can be interchanged → changed to ISO 4762 - parts cannot be interchanged (e.g. M18, M22, M27 and M33), documented on DIN 912-ALT

DIN 931-1

Hex bolts

ISO 4014

- some can be interchanged → changed to ISO 4014 - parts cannot be interchanged (e.g. M10, M12, M14 and M22 with new waf), documented on DIN 931-ALT

DIN 933

Hex bolts

ISO 4017

- some can be interchanged → changed to ISO 4017 - parts cannot be interchanged (e.g. M10, M12, M14 and M22 with new waf), documented on DIN 933-ALT

DIN 934

Hex nuts

ISO 4032 ISO 8673

- cannot be interchanged as a result of different nut heights and - for M10, M12, M14 and M22 with new waf.

DIN 960

Hex bolts

ISO 8765

- some can be interchanged → changed to ISO8765 - parts cannot be interchanged (e.g. M10, M12, M14 and M22 with new waf), documented on DIN 960-ALT

DIN 961

Hex bolts

ISO 8676

- some can be interchanged → changed to ISO 8676 - parts cannot be interchanged (e.g. M10, M12, M14 and M22 with new waf), documented on DIN 961-ALT

DIN 963

Countersunk bolts

ISO 2009

- cannot be interchanged due to different head dimensions, documented on DIN 963-ALT

DIN 964

Countersunk bolts

ISO 2010

- cannot be interchanged due to different head dimensions, documented on DIN 964-ALT

1) refers to the product parts numbered by ZF

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ZF-AS Tronic

Withdrawn Title DIN

Changing from DIN to ISO standard codes

Replacement Result of testing/measures 1) ISO standard

DIN 965

Countersunk bolts ISO7046

- cannot be interchanged due to different head dimensions documented on DIN 965-ALT

DIN 980

Lock nuts

ISO 7042 ISO 10513

- cannot be interchanged → documented on DIN 980-ALT

DIN 985

Lock nuts

ISO 10511

- cannot be interchanged → documented on DIN 985-ALT

DIN 1440

Washers

ISO 8738

- some can be interchanged → changed to ISO 8738 - parts cannot be interchanged, documented on DIN 1440-ALT

DIN 1443

Bolts

ISO 2340

- can be interchanged → changed to ISO 2340

DIN 1444

Bolts

ISO 2341

- can be interchanged → changed to ISO 2340

DIN 1471

Grooved pins

ISO 8744

- some can be interchanged → changed to ISO 8744 - parts cannot be interchanged (e.g. 1 = 6 mm), documented on DIN 1471-ALT

DIN 1472

Grooved pins

ISO 8745

- some can be interchanged → changed to ISO 8745 - parts cannot be interchanged (e.g. 1 = 6 and 25 mm), documented on DIN 1472-ALT

DIN 1473

Grooved pins

ISO 8740

- some can be interchanged → changed to ISO 8740 - parts cannot be interchanged (e.g. 1 = 4, 5, 6, 25 and 50 mm), documented on DIN 1473-ALT

DIN 1474

Grooved pins

ISO 8741

- can be interchanged → changed to ISO 8741

DIN 1475

Grooved pins

ISO 8742

- can be interchanged → changed to ISO 8742

DIN 1476

Grooved studs

ISO 8746

- can be interchanged → changed to ISO 8746

DIN 1477

Grooved studs

ISO 8747

- can be interchanged → changed to ISO 8747

DIN 1481

Slotted pins

ISO 8752

- some can be interchanged → changed to ISO 8752 - parts cannot be interchanged (e.g. 1 = 36), documented on DIN 1481-ALT

DIN 6325

Cylinder pins

ISO 8734

- some can be interchanged → changed to ISO 8734 - parts cannot be interchanged (e.g. 1 = 36), documented on DIN 6325-ALT

DIN 7346

Slotted pins Flange

ISO 13337

- some can be interchanged → changed to ISO 13337 - parts cannot be interchanged (→ 7, 11 and 23 mm), documented on DIN 6325-ALT

DIN 7976

Tapping screws ISO 1479

- can be interchanged → changed to ISO 1479

DIN 7978

Tapered pins

ISO 8736

- some can be interchanged → changed to ISO 8736 - parts cannot be interchanged (e.g. 1 = 36), documented on DIN 7978-ALT

DIN 7979

Cylinder pins

ISO 8733 ISO 8735

- some can be interchanged → changed to ISO 8733/8735 - parts cannot be interchanged, documented on DIN 7979-ALT

DIN 7981

Tapping screws ISO 7049

- can be interchanged → changed to ISO 1479

DIN 7982

Tapping screws ISO 7050

- cannot be interchanged → documented on DIN 7982-ALT

DIN 7985

Cheese head screws

- can be interchanged → changed to ISO 7045

ISO 7045

1) refers to the product parts numbered by ZF

1327 751 101 - 2003-04

14

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