Important work safety notice
The following safety instructions appear in this manual:
ENVIRONMENTAL HAZARD !
NOTE
Refers to special processes, techniques, data, etc.
CAUTION
This is used when incorrect,unprofessional working practices could damage the product.
DANGER! !
This is used when lack of care could lead to personal injury and damage to property.
Lubricants and cleaning agents must not be allowed to enter the ground,the water table or the sewage system.
Request safety information for the products concerned from your local environmental protection authority and follow any instructions herein at all times.
Always collect used oil in a suitably large container.
Always dispose of used oil,clogged filters, lubricants and cleaning agents in accordance with environmental protection laws. Always observe manufacturer instructions when dealing with lubricants and cleaning agents.
16 AS 2601 with ZF-Intarder (Photo)
1 Description of system
1.1 General description
1.2 Overview
1.3Range selector
1.4Display
1.5Accelerator
1.6Automatic mode
1.7Manual mode
1.8ZF auxiliary units .
2 Operation
2.1Starting the engine
2.2 Setting off, forwards travel
2.2.1Correcting the starting gear
2.3 Maneuvering . .
2.4Starting to roll on slopes
2.5Changing between manual and automatic mode
2.6Changing gear . . . . . . .
.1-2
.1-2
.1-4
.1-5
.1-5
.1-6
.1-6
.2-1
.2-1
.2-2
.2-2
.2-3
.2-4
.2-4
Table of contents
2.6.1Changing gear in automatic mode
2.6.2Changing gear in manual mode .
2.7Reversing .
2.7.1Changing direction of travel
2.8Engine brake
2.9Stopping
2.10 Switching off engine/ parking vehicle
2.11Towing
2.12 Tow-starting
2.13Clutch protection
2.14Overspeed protection
2.14.1Manual mode
2.14.2Automatic mode . . .
.2-11
2.16Roller test rig
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Table of contents
2.17 Display for ZF-AS TRONIC
2.18System errors (error messages) .
.2-13
.2-16
2.19Starting the vehicle at very low temperatures . . .2-17
2.19.1Operation of vehicle at sustained ambienttemperatures of between 0 °C and -40 °C .
2.19.2Parking the vehicle at low temperatures
3Maintenance .
3.1Transmission oil
3.1.1Oil grade
3.1.2Oil quantities
3.2Oil changes
3.2.1Oil change intervals
3.2.2Draining oil
3.2.3Oil fill
3.3Oil level check
3.4Transmission ventilation
3.5Type plate
3.6Visual inspection of wiring
3.7Pneumatic system maintenance
. .2-17
.2-17
.3-1
.3-1
.3-1
.3-1
.3-1
.3-1
4List of errors
.3-3
.3-5
.3-5
.3-5
View of unit installed by Deutsche Grove without intarder
Description of system
1Description of system
1.1General description
The ZF-AS TRONIC automatic transmission is adapted to the engine by means of a standard dry clutch. Since the clutch is also controlled by the ZF-AS TRONIC transmission system, the clutch pedal can be dispensed with.
The ZF-AS TRONIC consists of a basic transmission and an integrated splitter and planetary group.
The basic transmission is shifted using constant mesh gears. The splitter and planetary group are synchronized.
A display in the dashboard shows the driver all the system information required (e.g. gear stage, fault, etc.)
The transmission actuator and the clutch actuator are the components most crucial to complete transmission automation.
The transmission actuator consists of the transmission electronics, shift valves, shift cylinders and sensors.
The clutch actuator is electro-pneumatically controlled and is responsible for the entire clutch actuation process.
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Operation
2.2Setting off,forwards travel
Start the engine (see 2.1).
Turn rotary switch from « N » to « D ».
Automatic mode is activated.
The display shows the starting gear selected. (The system selects the starting gear itself, the clutch remains separated (disengaged)
Depress accelerator and at the same time release the parking brake.
DANGER!
The vehicle may roll away even if the accelerator is not depressed.
Vehicle sets off (clutch closes automatically).
2.2.1Correcting the starting gear
The driver may correct the starting gear selected by the system.
How to make a correction:
Press tip lever in the « – » or « + » direction.
The display shows the starting gear selected.
2.3Maneuvering
For extremely slow-speed travel (e.g. connecting or disconnecting a trailer or semi-trailer), a maneuvering option is provided.
For maneuvering purposes, the system can call on the first 2 forward gears and both reverse gears. In other gears, the maneuvering option is not available.
The system recognizes maneuvering status from the position of the accelerator pedal and the low roadspeed.
In maneuvering mode, the vehicle (accelerator) is more responsive and clutch actuation is different from normal status.
DANGER !
Depending on the accelerator position and vehicle roadspeed the system switches from maneuvering to startup mode.
The vehicle can accelerate.
RISK OF ACCIDENT!
Unlimited maneuvering time
In the event of clutch overload, the display shows « CL ».
Whenever clutch overload occurs, the display unit shows « CL ».
DANGER !
If the driver fails to respond to the display « CL », the system switches from maneuvering.
The vehicle can accelerate at this point.
RISK OF ACCIDENT!
2.4Starting to roll on slopes
Precondition: the engine must be running.
DANGER!
If the vehicle starts to roll and no gears are selected - rotary switch pointing to « N » - the engine brake is ineffective!
Do not allow the vehicle to roll in the opposite direction of travel to that of the gear selected.
If the vehicle rolls forwards - with transmission in neutral - once the brake is released and the driver shifts from « N » to « D », then the system selects a gear suitable for the roadspeed. The driveline is then fully engaged.
2.5Changing between manual and automatic mode
Always possible, even while the vehicle is in motion.
Changing from manual to automatic mode: tip lever to the left.
Changing from automatic to manual mode: tip lever to the left or push tip lever in the « + » or « – » direction.
2.6 Changing gear
2.6.1Changing gear in automatic mode
All upshifts and downshifts are performed automatically.
These depend on: driving resistance loading accelerator-position speed engine speed
The gear indication appears as a digit in the display during travel.
2.6.2Changing gear in manual mode
Push tip lever in « + » or « – » direction.
When a shift is performed manually, the shift system automatically exits automatic mode.
If the driver moves the tip lever to the left, automatic mode is reactivated.
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Jumping gears
Jumping one gear:
Twice in rapid succession, push tip lever in the direction required.
Jumping two gears:
Three times in rapid succession, push tip lever in the direction required.
NOTES
You can use the rotary switch to shift any gear to neutral at any time. This shift process always takes priority.
The position of the accelerator must not be changed during the shift process because the engine is automatically controlled.
A shift command is not carried out if this shift would lead to the maximum engine speed being exceeded.
DANGER !
The driver may shift to "Neutral" during travel.If the driver does shift to "Neutral",the driveline is interrupted.
The engine brake is then no longer effective.
2.7Reversing
DANGER !
If the vehicle is rolling,shifts cannot be made into reverse! Stop the vehicle immediately.
2.7.1Changing direction of travel
Changing from reverse « R » to forwards travel « D » and vice versa.
Turn rotary switch from « R » to « D ».
Selecting reversing gear:
The vehicle must be at a standstill.
Turn rotary switch to « R ».
« R » appears in the display (clutch remains separated/ disengaged).
Depress accelerator and at the same time, release brake (clutch closes automatically).
Vehicle moves backwards.
DANGER !
A change in the direction of travel,performed by moving the rotary switch from « R » to « D » and vice versa « D » to « R »,may only be undertaken when the vehicle is at a standstill otherwise the transmission will shift into neutral.
2.8Engine brake
DANGER !
The engine braking action is interrupted during the gear change process.The vehicle may accelerate when travelling downhill.
2.9Stopping
After releasing the accelerator pedal, retard the vehicle using the service brake, until it comes to a complete stop.
The clutch opens automatically before the vehicle comes to a complete stop, preventing the engine from stalling.
Manual driving mode
The engine brake is deactivated by the system during gear changes. After successful shifts, the engine brake is automatically re-engaged.
Automatic driving mode
When the engine brake is employed, the system changes down to deliver maximum braking torque.
If ever the vehicle is stationary for extended periods, ZF advises you to select transmission neutral.
DANGER !
If ever the vehicle is stationary with the engine run ning and the gear engaged,you only have to press the accelerator pedal for the vehicle to set off unless the parking brake is applied!
Before leaving the vehicle with the engine running, the transmission must be in neutral and the parking brake engaged.
The engine may stall if the parking brake is actuated while the vehicle is in motion on slippery road surfaces.If this happens,power steering assistance is NO LONGER available!
2.10Switching off engine/parking vehicle
Bring vehicle to a standstill.
Engage parking brake.
Move rotary switch to « N ».
Switch off engine via ignition key.
Place chocks under vehicle wheels (e.g. on gradients).
2.11Towing
Vehicle manufacturer instructions must be observed when towing!
CAUTION
For towing purposes,always disconnect the propeller shaft flange from the rear axle before setting off.If it cannot be disconnected,remove both stub shafts.
Avoid polluting the environment in the event of oil loss.
DANGER !
The ZF AS TRONIC automatically selects Neutral whenever the engine is switched off.The vehicle may roll away if brakes are not actuated.
2.12Tow-starting
The engine cannot be tow-started.
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2.13Clutch protection
« CL » appears in display if there is a risk of clutch overload resulting from several starting process occurring in rapid succession or of crawling in too a high starting gear.
NOTE
Select an operating mode in which the clutch will not be overloaded, for example: accelerate vehicle (to close the clutch). stop the vehicle. set off in a lower gear.
DANGER !
If the driver ignores the warning signal,the clutch will close when the accelerator is depressed. The clutch thereby avoids further loading.
This may cause the engine to "stall" and,if on an incline,it is possible that the vehicle will roll backwards.
The clutch opens again when speed is reduced.
To conserve the mechanical components of the clutch release device, the transmission should be shifted to neutral if the vehicle stops for long periods of time (for more than approx. 1 to 2 min., for example, in traffic jams, at railway crossings etc.).This closes the clutch and relieves the clutch release device.
Even though the clutch is automated, the driver still has considerable influence on clutch service life.
To keep levels of wear on the clutch low, we would recommend that when setting off, you always select the lowest gear possible.
2.14Overspeed protection
To protect the entire driveline from excessive speeds, the ZF-AS TRONIC only permits gear shifts which fall within the vehicle manufacturer's specified range of engine speeds.
2.14.1Manual mode
Ensure that the engine does not exceed the permitted speed range.
If the vehicle accelerates on downhill slopes, there is no automatic upshift into a higher gear.
CAUTION
The engine may be damaged if the vehicle is accelerated on downhill gradients and the engine thereby enters the overspeed range.
2.14.2Automatic mode
DANGER
!
The vehicle may accelerate on downhill slopes. The system will undertake upshifts to protect the engine from damage in the overspeed range (red range).
2.16Roller test rig
Having driven onto the roller test rig (brake test rig), shift transmission into "neutral".
When the roller is activated, the system recognizes the "driving vehicle" function. If the driver selects a gear, the clutch closes.
Reverse gear cannot be selected when the roller is activated.
DANGER !
The vehicle may drive off the roller even if the accelerator is not depressed.
2.17Display for ZF-AS TRONIC
The display provides information on the status of the transmission. It usually shows the gear selected (e.g.: 1 - 16 or « N », « R »).
Additional display information:
« CH » = system self-check.
Display appears when «ignition is ON ».
DANGER !
If shifts are undertaken when pneumatic pressure is too low,the transmission may remain in neutral to ensure that there is no direct drive and that the engine brake is ineffective.
« FP » = drive pedal (accelerator)
Bring accelerator to idling position. If the display does not go out, there is a system error. The vehicle cannot be driven!
« AL » = Airless (Luftmangel).
Alternates with the normal display. The transmission compressed air system hasinsufficient pressure.
« CL » = clutch (clutch)
Alternates with the normal display. Clutch is overloaded.
Remedy: chapter 2.11 Clutch protection.
NOTE
Only set off once there is sufficient air pressure in the system. If air pressure is too low when the vehicle stops, do not open the clutch otherwise the engine will "stall".
«CW» = clutch wear (clutch wear)
Proceed to approved workshop to have clutch exchanged at next opportunity.
Automatic mode is shown in the display by means of 4 bars and 2 arrows. (8th gear is selected in transmission)
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