ZF Automatic Transmission ZF-AS Tronic 12AS 2302 2530 2531 ZF 16AS 2602 Service Manual 899501708 –

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Automated power shift gear ZF-ASTronic Preamble The actual service manual is destined for the servicing personnel of LIEBHERRWERK EHINGEN GMBH and. ZF FRIEDRICHSHAFEN AG. The actual service manual comprises the descriptions of: In part I the ZF standard version and in part 11 the special Liebherr crane version.

The contents of the service manual are subdivided into the following sections: • Functional description • Test and setting instructions • Dismantling and fitting instructions • Trouble shooting Instructions for maintenance and maintenance intervals are stipulated in the operating instructions (BAL) of the respective Liebherr mobile crane.

In case of damages due to inproper and inexpert work performed by non Liebherr personnel, Liebherr-Werk-Ehingen GmbH decline any responsibility!

Equally any guarantee is declined for replacement parts which do not comply with the attribute "Original Liebherr Spare Part".

The national safety regulations must be absolutely respected during all maintenance and repair work!

• In Germany: Regulation for prevention of accidents (UW) • In other countries: Regulations of the country concerned • In the USA: National regulations, especially 1. OSHA (Occupational Safety and Health Administration) Regulation 1910.180 (for crawler locomotive and truck cranes) 2.OSHA Regulation 1926.550 (for cranes and derricks) 3.ASME (American Society of Mechanical Engineers) Regulation B30.5-1994

The actual service manual is not subject to any modification service.

Issued by LIEBHERR-WERK EHINGEN GMBH Department: Service - Training (KDNMS).

Reprints/copies, even extracts, or transmission to third parties are inadmissible without Liebherr's prior permission.

Subject to technical modifications !

Liebherr-Werk Ehingen GmbH, Service Department

IIIBHIIIII

Table of contents

ZF-~TROlliliC®

1

Brief description of the ZF-AS TRONIC

2

Transmission system and its components 2.1

System design

2.2

Transmission* and shift system Description of transmission Description of shift system Technical data, 16-speed - direct drive Technical data, 16-speed - overdrive Technical data, 12-speed, short- direct drive Technical data, 12-speed, short- overdrive Technical data, 12-speed, long- direct drive Technical data, 12-speed, long- overdrive Technical data, 10-speed, bus - direct drive Technical data, 10-speed, bus - overdrive Technical data, 12-speed, bus- overdrive

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11

2.3 2.3.1 2.3.2

2.4 2.4.1 2.4.2 2.4.3

2.5 2.5.1 2.5.1.1 2.5.1.2 2.5.1.3 2.5.1.4 2.5.1.5 2.5.1.6 2.5.1.7 2.5.1.8 2.5.2 2.5.2.1 2.5.2.2 2.5.2.3 2.5.2.4

3

Transmission components Transmission actuator Clutch actuator Peripheral components Range selector Electronic module (ZF E module) Display Auxiliaries Intarder General Mechanical interface Oil grade and oil volume Coolant connection Pneumatic interface Electrical interface Communications interface Speedo signal PTOs Clutch-dependent PTOs Roadspeed-dependent PTOs Engine-dependent PTOs Retrofitting

Description of function 3.1 3.1.1 3.1.2 3.1.2.1

Basic function Shift engagement characteristics / ignition on Gear selection when at a standstill Shifting from neutral

* For transmission designations, refer to Annex 1328 765 101c

2002-09

Zi-~TROJltliC®

3.1.2.2 3.1.2.3 3.1.3 3.1.4 3.1.4.1 3.1.4.2 3.1.5 3.1.6 3.1.6.1 3.1.6.2 3.1.7 3.1.7.1 3.1.7.2 3.1.8

Shifting from one gear to another Shifting to neutral Setting off Gear selection during travel Upshifts Downshifts Manoeuvring Protective functions Engine protection functions Clutch overload protection Activating PTOs Engaging PTO Disengaging PTO Ignition off

3.2

Automatic drive program Activating automatic drive program Automatic selection of setting off gear Automatic gear change Deactivating automatic drive program

3.2.1 3.2.2 3.2.3 3.2.4

3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6

ZF-AS TRONIC malfunction concept Principles System analyses undertaken Clutch actuator concept Transmission control concept Interface concept Driving modes investigated

3.4

Error responses

3.5

Diagnosis Error memory On-board diagnosis Off-board diagnosis

3.5.1 3.5.2 3.5.3

4

Table of contents

Installation 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.1.12

1328 765 101c

Transmission installation investigation Standard transmission installation drawings PTO + emergency steering pump installation drawings Input shafts Clutch bell housing Clutch Clutch release device Engine connection Suspension Transmission installation angle Propshaft connection Torsional vibrations Bending vibrations

2002-09

Table of contents

ZF-~TROlliliC®

4.1.13 4.1.14 4.1.15 4.1.16 4.1.17 4.1.18

Cover I protective floor panels Additional brackets Fording ability Accessibility Additional guidelines for vehicle body manufacturer Vehicle wiring

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6

Temperatures Permissible ambient temperatures on transmission Permissible oil temperatures Causes of excess oil temperatures Additional transmission cooling Use in sub-zero temperatures Storing the transmission

4.3

Oil fill

4.4 4.4.1 4.4.2 4.4.2.1 4.4.2.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.7.1 4.4.7.2 4.4.8 4.4.9

Electrics System layout and circuit diagrams Description of connectors Transmission end connector Power supply connector to vehicle Power supply voltages CAN bus installation Quality requirements of wiring Connector and mating connector designations Other electrical interfaces on the ZF-ASTRONIC Neutral switch (S12) Speedo sensor CAN signals EMC

4.5

Pneumatics

4.6 4.6.1 4.6.2 4.6.3 4.6.4

Auxiliaries ZF-Intarder Third party retarder ZFPTOs Third party PTOs

4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7

Transmission installation on assembly belt Transport Supplying the main transmission Anti-corrosive protection Subsequent paintwork Assembly of engine, clutch and transmission EOL (End Of Line) programming Delivery check

1328 765 101c

2002-09

Zi-~TROJltliC®

5

4.8 4.8.1 4.8.2

Additional information Operating and maintenance instructions Vehicle handover to end customer

4.9 4.9.1 4.9.2 4.9.3 4.9.4

Application and documentation Application ZF documentation Type plate Explanation for ZF documentation

Table of contents

Annex 5.1

Designations for AS-transmission

5.2 5.2.1 5.2.2

AS transmission program AS transmission program for trucks AS transmission program for buses

Attachment: attached documents

1328 765 101c

2002-09

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DOWNLOAD THE COMPLETE MANUAL