DOWNLOAD PDF ZF-AS Tronic + Intarder + System Components & PDI Installation Manual 1327 754 106

Installation Manual

Installation Manual for ZF-AS Tronic + Intarder + System Components For Installation and PDI (Delivery Check) 1327 754 106

Subject to technical changes

Copyright by ZF The present documentation is protected by copyright.

Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.

Printed in Germany ZF Friedrichshafen AG, MC-C / 2004-08

Edition: 2004-08

1327 754 106

Contents Page Preface ...........................................................................................................................................................

Safety notice ..................................................................................................................................................

General information ......................................................................................................................................

Instructions for repairs ..................................................................................................................................

List of changes 1327 754 106 ........................................................................................................................

5 6 6 7 9

Preparations ...................................................................................................................................................

Preparing for ZF-AS Tronic Installation ........................................................................................................

Checks Before Installation .............................................................................................................................

Preparations for Clutch Installation ..............................................................................................................

11 11 13 14

Clutch Installation ..........................................................................................................................................

17

Transmission Installation ...............................................................................................................................

Lifting and Transporting ................................................................................................................................

20 20

Fitting Clutch Actuator...................................................................................................................................

Venting Clutch Actuator.................................................................................................................................

25 25

Connections to the Vehicle ............................................................................................................................

28

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

Oil level check for transmission versions without an Intarder ....................................................................

Oil Level Check and Oil Filling for Transmission Versions with an Intarder..............................................

30 30 31

OEM Delivery Check ...........................................................................................................................................

33

OEM Delivery Check for ZF-ASTronic Transmissions in the NAFTA Market.............................................

35

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

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

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

We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 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 utmost care.

Warranty: Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case.

ZF Friedrichshafen AG Nutzfahrzeug- und Sonder-Antriebstechnik Commercial Vehicle and Special Driveline Technology Service Werk 2 Tel. +49 (0)7541 77-0 Fax +49 (0)7541 77-908000 Internet: www.zf.com

2003-08

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.

5

Important information Safety notice

General information

Companies repairing ZF units are responsible for their own work safety.

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

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 familiarize themselves with these regulations.

CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures.

Pictures, drawings and components are not to scale.

Conclusions about size and weight should not be drawn (even within a complete illustration).

Always follow the working steps as described in the text.

Personnel 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 is properly trained.

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.

The following safety instructions appear in this manual:

! THREATS TO THE ENVIRONMENT !

NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.

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.

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 or death.

CAUTION The transmission must NOT be hung by the input shaft NOR by the output flange.

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Instructions for repairs In case of doubt always turn to the relevant department within ZF After-Sales Services for advice.

All work on transmissions is to be performed expertly and under clean conditions.

Use specified tools to dismantle and assemble transmissions.

Gaskets, locking plates

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening.

Pay particular attention to the projections and recesses of housings and covers when cleaning.

Shaft seals

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

Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.

Parts joined with Loctite are easier to separate if warmed with a fan heater.

Reworking Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling.

Cleaning parts Remove remains of old gaskets on all seal-faces.

Carefully remove burrs or similar patches of roughness using an oil-stone.

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

Lube bores and grooves must be free of anticorrosion agents and foreign matter; check for perfect passage.

Carefully cover opened transmissions to prevent foreign matter from entering.

Transmission assembly Find a clean site to assemble the transmission.

Gaskets are installed without the use of sealing compound or grease. When measuring siliconcoated gaskets, take care not to include the silicon layer in the measurement.

During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.

Reusing parts Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used.

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

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Instructions for repairs d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.

Bearings If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet).

Temperature should be at approx. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.

X

e) Fill the gap between the sealing lips so it is 60 % filled with grease (e.g. produced

by Aral such as Aralub HL2 or by DEA such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

Sealing If a specific sealing agent* is to be used for sealing, comply with the manufacturer’s directions for use.

Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing 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 surfaces are sealed.

Retaining agents Retaining agents* may only be used in places as specified in the parts list.

Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite).

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

Shaft seals a) Apply a light coat of sealing agent* on outer edge of shaft seals with “steel surround”.

Transmission oil After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point and on the internet under 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 wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b).

* refer to expendable material

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List of changes: 1327 754 106

Index

Issue date

1327 754 106 - 2004-08

Section

Originator

Comment

9

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10

ZF-AS Tronic

Preparations

Preparing for ZF-ASTronic Installation ZF’s scope of supply is documented in the parts list.

The parts list number is noted on the type plate (01.150).

01.150 018799

ZF-ELCAT - (technical information sheet)

Information such as the following for installing the ZF-AS Tronic can be found on the cover sheet.

parts list

1328 097 036 ASTRONIC IT

DAF TRUCKS NV

item

Illustration using a sample parts list:

Pos. A98 Pos. S46 Pos. S48

Customer specification Circuit diagram System plan (only for the ZF-AS Tronic with Intarder)

A10 A14 A90 A98 S02

CUSTOMER: DAF TRUCKS NV *COUNTRY: NL CUST. SPEC. NO. NONE RELEASE.FIRST INSTALLATION CHECK NECESSARY SPECIFICATION: 1328 761 050 VEHICLE DATA 1:

S04 S06 S14 S30 S46 S48

MODEL. TRUCK *F95XF MAX. G.V.M. T*MAX. G.C.M. 44T DAF /XE280C1E3 *KW280/1900*N.M1750/1000 DRAWING: WIRING DIAGRAM: 6029 713 061 WIRING DIAGRAM: 6029 711 035 SYSTEM DIAGRAM: 6009 771 031

S52 S54 S56 S64 T02 T04 T06 T14

VEHICLE DATA 2: MODEL: TRUCK *F95XF MAX. G.V.M. T*MAX. G.C.M. 44T DAF /XE315C1E3 *KW315/1900*N.M1900/1100 VEHICLE DATA 3: MODEL. TRUCK *F95XF MAX. G.V.M. T*MAX. G.C.M. 44T DAF /XE355C1E3 *KW355/1900*N.M2100/1200

023515en

Pos. M02 Pos. M52

Pos. M94

ZF-ELCAT - (technical information sheet)

Installation drawing Condition on delivery: Neutral (NG) or highest gear (HG) selected Weight

parts list

1328 040 037 16 AS 2601 IT *02-12-04S DAF TRUCKS NV

item A10 A14 A16 A86 A90

CUSTOMER: DAF TRUCKS NV *COUNTRY: NL CUST. SPEC. NO: CODE 1448145 RELEASE: CLEANNESS 20/14MYM*ZFN 5015 RELEASE: FIRST INSTALLATION CHECK NECESSARY

F52 G64 M00 M02 M50 M52

OUTP. FLANGE RA:OD=180 *BOLT=4XM14X50 L=109,5* HEAT EXCHANGER: BACK UNDERSIDE *WITH DRAWING: INSTALLATION: 1328 600 016 ASSEMBLY INSTRUCTIONS: TESTING: ENGAGE HIGH GEAR AFTER FUNC. TEST

M54 M90 M92 M94 M96 M98 Q50

INSPECTION PROGRAM: 6009 374 278 (16G.DD) OIL CAPACITY: EX WORKS * 23.00L GEARBOX OIL GRADE ACC. TO ZF: TE-ML02L MASS: CA. 340,0KG PAINT: NO PAINT * PRESERVATION: KA1+2T/K12/ *ZFN 916 QUALITY INSTRUCTION:

023516en

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1327 51D 010_en

ZF-AS Tronic Pos. F40 Pos. F44 Pos. G78

Preparations

Input shaft Engine connection Clutch release mechanism and length of push rod

ZF-ELCAT - (technical information sheet) Datei

Suche

Extras

parts list

Hilfe 1328 001 067 16 AS TD/TO

DAF TRUCKS NV

item A10

CUSTOMER: DAF TRUCKS NV

A14

CUST. SPEC. NO: AT FINAL PRODUCT

F06 F10

INSTAL. POSITION *FLANGE MOUNTED* RATIO: 17,03-1,00*DG GEARING: HELICAL GEAR

F34 F38 F40 F44 F46 G32

G50 G60 G78 H50 H78

*COUNTRY: NL

17,03*14,12*11,50*9,54*7,86*6,52*5,51 4,57*3,73*3,01*2,52*2,01*1,72*1,43 1,21*1,00 *R1=15,77*R2=13,07 CONTROL: SFI * SEPARAT. CLUTCH: AUTOMATED DOG CLUTCH VERS. INPUT SHAFT : L=109,0*SAE 10C 2 INCH JOURNAL :D=25 F7*SCHAFT:D=50,30*BUSH: WITHOUT ENGINE CONNECTION: SAE 1*CENTERING D=511,175 LZ=12*D=11,0 REL. BRG. CARRIER: L=23,3*D=62,611 SWITCH: NG*OPENING * PROTECTING CAP: WITH * AUXILIARY UNITS: IT AS TRONIC * REDUCTION DEVICE AUXILIARY UNITS/ACCESSORIES RELEASE BRG:D=62,3*L=102,0*FORK WIDTH 85,8 PRESSING ROD:L=119*LEVER: WITH ELECTRONIC: PULSE TRANSMITTER SFI:IMP/U 8,14*

M00 M14

TRANSMITTER: WITH * PROTECTING CAP: WITHOUT PULSE TRANSMITTER TACHO: IMP/U 8,14* TRANSMIT: WITH *IT * PROTECT CAP: WITH BAYONET * VERSION: KITAS I ADR-PROTECTED EXPLOSION DRAWING: SECTION: 1328 192 002

M16

SECTION:

H80

1328 030 026

023517en

The customer specification contains definitions, in particular of the vehicle’s system components, such as engine type, clutch, electronics.

80.350 80.360

Check components using the customer specification, e.g. pressure plate (80.350), clutch disc (80.360).

023518

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ZF-AS Tronic

Preparations

Checks Before Installation Cleanliness • Remove preserving agent from input shaft (02.010).

• Flywheel, pressure plate, release bearing, and guide pipe must be free of preserving agent and dirt.

NOTE When cleaning, use an appropriate cleaning agent (e.g. brake cleaner) and a fluff-free cloth.

02.010

• Clutch must be free of dirt, oil, and grease.

023519

• Do not touch the driver disc lining with greasy fingers.

Flywheel

• If the clutch disc lining is dirtied with oil or grease, the clutch disc (driver disc) should be replaced because this cannot be used any more and may result in comfort and/or functional limitations.

023520

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ZF-AS Tronic

Preparations

Preparations for Clutch Installation 80.350

• Flywheel (1), clutch disc, or driver disc (80.360) and pressure plate, incl. tangential flat springs (80.350) must be free of damage.

80.360

The service instructions issued by the engine manufacturer should also be noted.

023518

• Check installed pilot bearing (2) for clearance 2

• The junction between the flywheel housing (3) and clutch housing must not be damaged in any way.

• Avoid alignment errors; • The pilot bearing (2) is self-centering but can only compensate for limited alignment errors

1

3 023520

• Splined shaft profile on input shaft (02.010) must be free of damage and corrosion preventative.

• Clutch disc (80.360) must slide easily over splined shaft profile

02.010

68.050

• The release fork components (68.060) must rotate freely and easily around their point of attachment.

• Release bearing (68.050) must slide easily over guide pipe of input shaft (02.010).

68.060

023521

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1327 68D 050_en

ZF-AS Tronic

Preparations

CAUTION • Do not apply grease to guide pipe!

• If hub profile of clutch disc has been lubricated previously, splined shaft profile of input shaft must not be lubricated any more.

• Apply grease to journal (seat of pilot bearing) on input shaft (see arrow). Use Optimol Olista Longtime 3 EP (ZF order number 0671 190 050).

023522

CAUTION If hub profile (see arrow) of clutch disc has not been lubricated previously, excess volumes of grease must not be applied. Excess grease must be removed, otherwise once rotated it may be flung onto the clutch lining and thereby cause clutch problems.

023523

• The release bearing requires no maintenance, no lubrication is needed.

• Remove transport protection (20).

20

023522

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ZF-AS Tronic

Preparations

If the release bearing has been supplied loose.

02.520 • If working with new or replacement transmissions, preserving agents must be removed (degreased) from the guide pipe (release flange) and input shaft.

68.050

• Do not apply grease to release bearing (68.050) – release flange (02.520) sliding seat!

68.060 023524

• Apply grease to locating face of release bearing (68.050) with release fork (68.060). Use OLISTA LONGTIME 3EP (ZF no. 0671 190 050) (see arrow).

While release bearing is being slid onto release flange, slide release fork into release bearing.

023525

• Slide release bearing back until stop is reached.

68.050

68.060

023526

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ZF-AS Tronic

Clutch Installation

Clutch Installation

Guide pins

• Screw guide pins into upper screw holes in flywheel.

023527

• Fit driver disc and pressure plate - without using any grease.

If necessary, remove any corrosion preventative used with a suitable cleaner (e.g. brake cleaner).

!

DANGER During the installation process, the input shaft must not be used to hold or support the clutch. Otherwise, the pilot bearing could be damaged or the clutch could fall out and cause injury to staff or damage to clutch components, use centering mandrel if necessary.

018422

• Insert the clutch, secured to a clutch trolley or a corresponding support (e.g. centering mandrel and lifting fixture 1T66 159 068), in the flywheel.

CAUTION The driver disc is marked as “Flywheel side” and this side must face the flywheel (engine end).

If there is no “Flywheel side” marking, check the clearance (torsion spring, main damper) to the flywheel.

023528

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ZF-AS Tronic

Clutch Installation

• Slide pressure plate and driver disc over guide pins.

In so doing, ensure that the pressure plate is firmly home and parallel on the flywheel.

Guide pins

CAUTION If you do not ensure that the pressure plate is centered in the flywheel or that your retaining bolts are fitted as described here, this may result in the pressure plate being preloaded.

The clutch function is not then ensured.

• Insert 12 bolts and tighten slightly by hand.

CAUTION Do not use a pneumatic screwdriver.

023543

• Remove guide pins.

• Insert the 2 remaining bolts.

023529

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ZF-AS Tronic

Clutch Installation

• Further tighten the bolts crosswise in several steps (each of approx. 1 rotation) until all bolts are tight.

During this process again check that the centering is correct.

• Use torque wrench to tighten bolts to the specified torque.

Tightening torque: Refer to specification of engine or vehicle manufacturer CAUTION Pneumatic screwdrivers must not be used when fitting the pressure plate.

CAUTION The centering mandrel should slide out easily.

023529

• Before installing the transmission, ensure that the ends of the snap-on ring are hooked together.

Snap-on ring closed (hooked together)

023544

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ZF-AS Tronic

Transmission Installation

Transmission Installation Lifting and Transporting • Do not attach the ZF-AS Tronic to the input shaft or output flange.

INCORRECT 023530

• Only use the suspension points authorized on the transmission, refer to installation drawing.

• For the TC Tronic, refer to THB 4190 765 001 • To lift and transport, only use secure lifting tackle, such as a 3-strand chain.

CORRECT 019529

! DANGER Safely secure the transmission to a trolley. The transmission may otherwise fall over and cause injury to staff or damage to transmission components.

018412

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ZF-AS Tronic

Transmission Installation

• Align the transmission so that the input shaft is in line with the pilot bearing and align the flywheel housing and transmission housing in parallel (if necessary, use centering pins).

018432

CAUTION Carefully guide the transmission input shaft into the clutch disc (driver disc) hub. Do not violently force or push input shaft into hub. Otherwise the clutch disc will be damaged.

NOTE If the transmission is in Neutral, the input shaft can be turned slightly with the aid of a long pair of tongues etc. so that the spline profiles of the input shaft and clutch disc hub slide into one another easily.

• Slide transmission towards engine-flywheel housing.

018433

CAUTION Transmission must be firmly home against flywheel housing. Only then should the retaining bolts be tightened.

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ZF-AS Tronic

Transmission Installation

• Use 12 bolts to secure transmission to flywheel housing.

Tighten bolts crosswise in accordance with vehicle manufacturer’s instructions.

Securing to Flywheel Housing • Use bolts with a high strength class (8.8) • Calculation in accordance with VDI 2230 • Use shims according to ISO 7089/7090 • Observe specified tightening torque M10 46 ± 5 Nm M12 79 ± 8 Nm • Note additional thermal load (e.g. using 10.9 bolt with tightening torque for a 8.8 bolt)

Retaining bolts 023531

CAUTION Do not lock-head bolts!

Securing with Stud Bolts If the ZF-AS Tronic is secured to the flywheel housing using threaded pins fitted at the engine end, the projection length of the stud bolts at the transmission end must be no longer than 62 mm.

Reason: If the projection length is any longer, this may make it very difficult to remove the transmission for servicing work. In extreme cases, the transmission has to be removed for such purposes.

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ZF-AS Tronic

Transmission Installation

• If necessary, secure rear transmission suspension.

018411

• Remove trolley from transmission.

018412

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ZF-AS Tronic

Transmission Installation

• Clutch release mechanism is visible.

• Unfasten breather screw (6) on clutch actuator (68.010), or remove clutch actuator.

• Push release bearing forwards (engine end) by using a short lever (prybar) inserted through aperture in transmission bell housing to push lower end of release fork backwards (transmission end) so that clutch snaps into snap-on ring of release bearing.

CAUTION Do not damage pressure plate!

023532

68.010 6

68.210*

/120 /130

/010

/020

/030

/110 68.020 68.210* 018481

NOTE You must be able to feel and hear the clutch snapping in.

Press release fork towards engine to check that the connection has snapped in correctly.

Engine end

Transmission end

023533

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ZF-AS Tronic

Transmission Installation

Fitting Clutch Actuator Venting Clutch Actuator • Loosen M12x1.5 bolt (6).

• Check sealing ring on bolt for wear and replace if necessary.

6

018475

• Force piston back.

018476

• Hold piston in forced back position and tighten bolt (6).

Tightening torque: 22 Nm

6 018477

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ZF-AS Tronic

Transmission Installation

• Insert push rod (68.210) in recess of release fork (68.060).

• Secure clutch actuator (68.010) and 4 washers (/020) with 4 M8 hex nuts (/030). In so doing, ensure that the connections are positioned correctly and that push rod (68.210) is seated correctly in the release fork and clutch actuator.

Tightening torque Hex nut (/030) M8 = 23 Nm Stud bolt (/010) M8 = 10 Nm

68.010 6

68.210*

/120 /130

/010

/020

/030

/110 68.020 68.210* 018481

• Loosen bolt (6) and wait until piston has extended.

In so doing, ensure that push rod (68.210) is seated correctly in release fork (68.060) and clutch actuator.

Tighten bolt (6) again to 22 Nm. • Secure cover (68.150) with 4 M8 hex bolts (68.154).

Tightening torque M8 = 23 Nm

6 68.060

CAUTION • Do not bend cable or tighten hard.

• Avoid chafing points.

• Fit connectors with traction relief and check detent.

68.150

68.154 018482

• Replace cable clips (68.300, 68.320, and 68.330) if damaged.

7

8

68.300

• Press wiring harness into cable clips.

• Connect 18 or 20-pin connector (7) to transmission actuator and connect connector (8) to output speed sensor.

68.060

68.330 68.320

018483

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ZF-AS Tronic

Transmission Installation

• Connect air supply lines to clutch actuator and transmission actuator.

023534

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ZF-AS Tronic

Connections to the Vehicle

Connections to the Vehicle

2

• Connect up vehicle connector (1) for vehicle circuit wiring (“Vehicle” side) until you hear it snap in (lock).

1

• Connect up transmission’s connector (2) (“Transmission” side) for central wiring to clutch actuator until you hear it snap in (lock).

023535

• Connect up transmission’s output speed sensor connector (nab1).

• Connect up vehicle’s output speed sensor connector (nab2).

nab1

CAUTION Some vehicle manufacturers use speedo-specific output sensors with different operating voltages (e.g. Kitas sensor with 9 - 12 V; this sensor is beige and approx. 10 mm longer than the black ZF output sensor operated at 24 V).

You must ensure that this sensor is only used at the nab2 (speedo) point.

nab2

023536 R

NOTE When used with a ZF-Intarder, the following actions must also be undertaken: • Fit water pipes (at top and bottom) (1).

• Top up coolant and if necessary, vent • Fit electrical plug connector: - accumulator charge valve (2) - proportional solenoid valve (3) • Connect air connection (4) to accumulator.

1 4

2

3

023537

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ZF-AS Tronic

Connections to the Vehicle

• Connect cardan shaft to transmission’s output flange.

NOTE Note connection specifications issued by vehicle manufacturer!

018410

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ZF-AS Tronic

Oil Level Check

Oil Level Check Oil level check for transmission versions without an Intarder • Remove oil filler plug (3) from transmission.

• Check oil level.

• The oil level must be at the lower edge of the oil filler aperture.

3

• If necessary, top up with oil according to ZF List of Lubricants TE-ML 02.

• Screw oil filler plug (3) back in.

018799

• Start engine and idle for approx. 30 seconds.

• Remove oil filler plug (3) and check oil level again.

• If necessary, top up oil until level reaches lower edge of oil filler aperture.

• Insert oil filler plug (3) and tighten to 60 Nm.

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ZF-AS Tronic

Oil Level Check

Oil Level Check and Oil Filling for Transmission Versions with an Intarder 9 NOTE The oil level check and oil filling process for AS Tronic transmissions with a ZF-Intarder are as follows: • Vehicle stationary and on horizontal ground • Engine switched off

a) Oil filling after oil change • Open oil filler plug (3).

• Fill transmission until oil overflows.

• Screw in oil filler plug (3) with new sealing ring. Tightening torque 60 Nm. • Fill up pneumatic system externally.

• Start engine.

• Undertake test run: Do NOT engage Intarder for 2 - 5 km.

• Continue from: c) At the end of the test run.

3

013610

a) Oil filling after repairs • Open oil filler plug (9).

• Fill with oil at pos. 9 until oil escapes from pos. 3.

• Screw in oil filler plug (9) with new sealing ring. Tightening torque 60 Nm. • Fill up pneumatic system externally.

• Start engine.

• Undertake test run: Distance of 2 - 5 km • At start of test run, BRIEFLY engage Intarder ONCE (stage 6).

• Continue from: c) At the end of the test run.

CAUTION To check the oil level, the Intarder must not be activated straight after the vehicle is shut down.

This ensures that the correct oil volume is measured in the transmission.

• Open oil filler plug (3).

Do not remove information plate.

CAUTION Check oil level again and if necessary, top up with oil until it overflows.

• Screw oil filler plug (3) back in with new sealing ring.

Tightening torque 60 Nm

c) At the end of the test run • Vehicle stationary • Do not engage Intarder.

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1327_52D_020_en

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ZF-AS Tronic

OEM Delivery Check

Vehicle manufacturer: ..............................................

End customer: ..............................................................

Vehicle type: ............................................................

Acceptance/ name:........................................................

Location: ..................................................................

Tel. / Fax /Dept.: .............................................................

Truck

Bus

Crane

Rail

Chassis no.: ..................................................................................................... km reading: .....................................................................................................

Transmission parts list no.: ..............................................................................

Transmission no.: ............................................................................................

R

Transmission actuator parts list no.: ................................................................

Transmission actuator no.: ..............................................................................

Error memory deleted?

Yes

No

Report / Comments / Special info.: Vehicle parameters:

Rear axle ratio

(irear axle) ........................................................................................

Central vehicle computer Intarder Engine type/Rating

........................................................................................

(yes/no) ........................................................................................ .........................................................................................

IMPORTANT! Please, complete this page in full and return to ZFF, dept. LML, OEM support, Fax: 0049-7541-77-5171 NOTE: All warranty requirements only come into force once the fully completed OEM delivery check form has been returned!

Date: ............................. Location: ............................ Signature:...................................................................

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1327 52D 030_en

34

11

level ◆ Transmission and pneumatic circuit sealed?

◆ Transmission oil

Test after test run

12

Vehicle safety check ☞ Undertake according to details provided by vehicle manufacturer

1

Oil grade according to ZF List of Lubricants TE-ML 02

Oil check ◆ Oil level (+ operating instructions)

2

7

another test run ◆ Delete

◆ If necessary, undertake

◆ Read out

10

3

Check plug-in connections ◆ Correct installation position ◆ Fully snapped in

20

6

D N R

12

9b

◆ Vibrations

◆ Noise

◆ Gearshift quality

4

8

3

1

11

14

5

9a

during “vehicle test run”

◆ Undertake test

ZF-TESTMAN pro - test

Test run

10

ZF-AS Tronic – OEM Delivery Check *

Error memory

2

Transmission actuator ◆ Connector (11) ➢ Connector plugged in ➢ Connector output not at top ➢ Access to transmission actuator and connector ➢ Load compensation

4

8

ZF-TESTMAN pro - test ◆ Undertake test with “vehicle stationary”

Undertake all checks with parking brake applied .

NOTE: Note the vehicle manufacturer’s details for starting the engine. !

* Option

1 Shift lever 2 Display 3 Transmission actuator 4 Clutch actuator 5 Transmission 6 Accelerator 7 Brake pedal 8 Rotary switch 10 Neutral switch 11 Central connector from vehicle 12 Bleed screw 14 Connector (Intarder) 20 Pneumatic tank 20 dm3

Check wiring harness routing ☞ Manual for installation, functions, and initial start-up

7

☞ Observe safety specifications

Connect up test device ZF-TESTMAN pro Interrogate and clear error memory

6

50*

* Please keep access to the transmission actuator’s removal / installation space free for service purposes .

Free access to transmission actuator

5

◆ Damage, chafing points

◆ Correct cross-section

to pneumatic diagram

◆ Installation corresponds

Check air lines ☞ refer to pneumatic diagram

150*

1327 754 106 - 2004-08

1327 52D 030_en

OEM Delivery Check for ZF-ASTronic Transmissions in the NAFTA Market

ZF-AS Tronic Manufacturer/OEM: ..........................................................

Transmission type: ................................................................

Chassis serial no.: ..............................................................

Transmission serial no.: ........................................................

Location: ............................................................................

Tel./Fax/Department: ..........................................................

Section

Process

1

Inspection before initial start-up 1.1 1.2

Yes

No

Is the cover (access to clutch release mechanism) screwed on?

Is the plug on the clutch actuator tightened to the specified torque? (nominal: 22 Nm) NOTE: This test is required if the clutch actuator has had to be vented with an incorrectly fitted release bearing.

(If the transmission is energized before the clutch release bearing is in contact with the circlip, the clutch actuator is subjected to pressure and prevents the clutch release bearing from engaging until the clutch actuator has been vented via this plug.)

1.3

All plug connections and wiring on the transmission (i.e. transmission connection cable, vehicle-end connection, ABS cable SAE 1939/1587 cable) checked?

1.4

Are the air lines on the transmission actuator and clutch actuator connected up?

1.5

Is there enough oil in the transmission?

Remove oil filler plug and check that the oil level reaches up to the lower edge of the oil filler aperture. If necessary, top up oil and screw in oil filler plug. (Tan: 60 Nm

1.6*

Is the transmission de-energized when the ignition key is in the ACC position?

Move ignition key to ACC. If the LED on the range selector button does not light up, the control unit (TCU) is not energized.

2

Check the start/setting off function 2.1*

Does “CH” (CH/AL) appears on the display when the ignition key is turned to ON/EIN? Turn ignition key to ON/EIN without starting the engine. “CH” appears on the display (if necessary, alternate between “CH” and “AL” if the transmission has not yet reached the 85 PSI level of air pressure required).

2.2*

Initial system tests after starting the engine (display showing N).

NOTE: When the vehicle is first being started during assembly, the transmission runs through one automatic clutch adjustment procedure. The teach-in process for the clutch is carried out during this initial adjustment procedure. The engine idling speed changes during the adjustment. This behavior is normal.

2.3 2.4

Once full operating pressure has been reached, check the pneumatic system for air loss.

Reverse travel light on vehicle checked?

Reverse travel light is switched on when the foot-operated brake and the R. button on the vehicle are pressed.

2.5

Errors saved in error memory deleted?

“Some” error displays are normal during the first start and can be put down to possible assembly factors encountered during chassis wiring. Check errors of this kind, if necessary rectify the cause.

DELETE ERRORS: Park vehicle and apply parking brake. Switch engine and ignition to OFF/AUS. Connect up diagnosis system and delete error memory.

2.6*

Check that all errors have been deleted?

• Switch on ignition, shift transmission into Neutral. Active errors can be called up at any time by pressing (holding down) the upshift button and can be shown on the range selector button display.

NOTE: The transmission shifts into Neutral when the Neutral button is pressed.

• Inactive errors can be displayed when the upshift button and foot-operated brake are pressed at the same time.

* depending on vehicle manufacturer, the displays and controls may differ from those described here.

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OEM Delivery Check for ZF-ASTronic Transmissions in the NAFTA Market

ZF-AS Tronic Section

Process

Yes

3

Performance test rig (dyno testing) – Press the “FN” function button until the transmission changes over to manual.

No

NOTE: The dyno test can only be undertaken manually. The transmission needs roadspeed information from the front wheels in order to change over to automatic mode. If this information is not provided, the transmission remains in the same gear until a change is made to manual. All automatic test must therefore be undertaken on a test track or similar environment.

3.1

Starting gears checked?

Select forwards and reverse starting gears and check Neutral. The LED displays on the range selector button (D, N, and R) must display the transmission status.

3.2

Clutch checked when setting off?

Ensure that the clutch engages without juddering, note down all noticeable problems which arise when shifting / engaging the clutch. The clutch should be checked when accelerating gently in the forwards and reverse starting gears and when accelerating assertively.

3.3

Pressure checked on secondary pneumatic tank after ten rapid shifts?

Upshift and downshift transmission rapidly ten times (for example 2-3, 3-2, 2-3 etc.). Ensure that the system pressure is 6.5 bar or higher (95 PSI or more).

3.4

Upshifts / downshifts checked?

Shift through all gears on the transmission, including R gear. The transmission status must be visible on the display.

3.5

Jumping of gears during upshifts and downshifts checked?

Jump gears when upshifting and downshifting by pressing the upshift and downshift buttons.

3.6

Engine brake function checked?

If the vehicle has an engine brake, this should be activated. Jump gears when accelerating (engine brake function can be heard during the upshift).

NOTE: The engine brake can be activated by the transmission electronics for faster and comfortable upshifts.

Once the vehicle has reached the necessary speed, request a single downshift. The engine brake must not interfere with the gearshift process.

3.7 4*

Speedo function checked?

Test run – Press the “FN” function button, the transmission shifts to automatic mode NOTE: Test runs should be undertaken on a test track or another suitable environment.

4.1

Drive program for automatic function checked?

Appropriate shift points must be reached during slow and fast acceleration. All the gears must be passed through in automatic mode.

4.2**

Easy start function checked? (Aid for setting off on slopes) When using the Easy start function, the vehicle is held on a slope for a max. of 2 sec via the braking pressure initiated by the foot brake. During this time, you must move from the brake pedal to the accelerator to improve setting off on a slope. The vehicle must not roll backwards.

5

Delivery check 5.1

Before switching off the ignition, note down any active and/or inactive errors which may have arisen.

5.2

Check transmission for leaks (oil/air), if necessary rectify leak.

5.3

Transmission oil level checked?

Open filler plug and undertake visual check to establish that the oil level is at the lower edge of the oil filler aperture. If necessary, top up oil and screw in filler plug and tighten to the torque specified. (Tan: 60 Nm

5.4**

Is the ZF-AS Tronic operating manual 1337 758 001 available in the vehicle?

5.5**

Has the “Setting off on slope” sticker (1337 753 001) been stuck to the windscreen?

* depending on vehicle manufacturer, the displays and controls may differ from those described here. ** Option

Signature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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36

Date of final testing: . . . . . . . . . . . . . . . . . . . . . . . . . .

1327 52D 040_en

ZF Friedrichshafen AG Hauptverwaltung 88038 Friedrichshafen Telefon +49 7541 77-0 Telefax +49 7541 77-90 80 00 www.zf.com

Antriebs- und Fahrwerktechnik