DOWNLOAD PDF ZF AS Tronic Trucks Repair Manual (Level 1 - 2) 1327 751 101a

REPAIR MANUAL

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

1327 751 101a

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

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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

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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

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ZF-AS Tronic

Fig. no.

Test device diagnosis tool

Special tools

Order no.

Application

Qty.

Remarks

1X56 099 063 Adapter for shaft seal in release flange

1

1

1X56 137 124 Adapter for 105x125x12 shaft seal on output

2

1

1X56 138 189 Spacer ring (used in conjunction with adapter 1X56 137 124) for Intarder version, 105x125x12 shaft seal on output

3

1

1X56 138 215 Adapter for release for shaft seal

4

2

240

Simplifies assembly

11

15

74

M10

M10

75 60.5

1X56 138 244 64 112

ø9H7

10±0.1

25

14

ø9r6

ø8.7±0.1

20±0.1

2x45°

2x45° 40

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212±0.1

Setting fixture for piston rods on transmission actuator

37.5±0.1

5

ø9H7

15

1

ZF-AS Tronic

Fig. no.

Special tools

Test device diagnosis tool

Order no.

Application

6008 208 503

Remarks Only for ZF sales and service organizations

TestmanPro, complete 6

Scope of supply - 6008 208 013 TestmanPro with DPA04i + cable - 6008 208 015 Application CD - 6008 208 016 Licence 6008 208 501

Only for ZF sales and service organizations

Set for converting Testman to TestmanPro 7 Scope of supply - 6008 208 011 Update CD - 6008 208 015 Application CD - 6008 208 016 Licence 6008 307 009

8

Electrical adapter cable MobiDig 2001

To supply voltage in vehicle via cigarette lighter

0501 211 104 SAE 1708 cable 9

6008 208 003 TestmanPro for ZF customers 10

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Scope of supply: • 6008 308 601 Cable RS 232 • 0501 211 103 Cable ISO 9141 • 6008 308 600 DPA04i • 6008 208 900 TestmanPro software user interface

16

Following agreement with ZF Friedrichshafen AG

ZF-AS Tronic

Fig. no.

Special tools

Test device diagnosis tool

Order no.

Application

Application software ZF-AS Tronic 2 11

Single station licence

6008 308 019 de 6008 308 119 en 6008 308 219 fr 6008 308 319 es 6008 308 419 it 0501 301 068

12

Remarks

Simple programming device EPD1

6008 298 029 + details of program item no.

Programming tool for control unit programming

Memory card for control unit programming (depends on parts list)

13 PlugIn

6008 207 003 Table mode adapter for AS Tronic 14

Terminal test 6008 006 002 (68-pin) 15

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17

Adapter cable for programming and configuration purposes as well as diagnosis outside vehicle

The terminal tester can be used to interrupt all PINs and/or to take measurements on all PINs

ZF-AS Tronic

Fig. no.

Special tools

Test device diagnosis tool

Order no.

Application

UNIVERSAL

Remarks

Connection: terminal tester

6008 307 025 16 Universal diagnosis connection for use with terminal tester

6008 206 007

17

6008 307 026 (5-pin) 6008 307 031 (30-pin) Diagnosis connection for transmission and Intarder

MAN

20

6008 207 007 for MAN TGA 6008 207 006 for MAN F2000 + Bus Diagnosis connection for transmission and Intarder

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Adapter cable for pin end, bus and truck

Adapter cable with 68-pin pin for 18/20-pin bush

IVECO

19

Adapter cable for bush end, bus and truck

Adapter cable with 68-pin bush for 18/20-pin pin

6008 206 006

18

WARNING: PIN assignment depends on control unit

18

Connection: 5-pin diagnosis connection plug under flap in front of range selector Connection: 30-pin diagnosis connection plug near fuse box

Connection: diagnosis connection plug near fuse box.

ZF-AS Tronic

Fig. no.

Special tools

Test device diagnosis tool

Order no.

Application

RVI 6008 207 009 21

1327 751 101 - 2003-04

Diagnosis connection for transmission and Intarder

19

Remarks

Connection: diagnosis connection plug near fuse box or bottom left of driver’s cab

ZF-AS Tronic

Fig. no.

Special tools

ZF-Intarder diagnosis tool

Order no.

Application

Terminal tester adaptation

Remarks

Adapter cable for bush end, bus and truck

6008 206 011 for EST 42 1 Adapter cable with 68-pin pin for 88pin bush

Terminal tester adaptation

Adapter cable for pin end, bus and truck

6008 206 012 for EST 42 2 Adapter cable with 68-0 bush for 88pin pin

6008 207 005 EST 42 table mode adapter 3

AS Tronic 2 APPLICATION SOFTWARE 4

6008 308 011 de 6008 308 111 en 6008 308 211 fr 6008 308 311 es 6008 308 411 it Terminal tester adaptation 6008 206 024 for EST 48

5 Adapter cable with 68-pin pin for 88pin bush

1327 751 101 - 2003-04

20

Adapter cable for programming and configuration purposes as well as diagnosis outside the vehicle

Application software for Intarder EST42/48 (individual station licence)

Adapter cable for bush end, bus and truck

ZF-AS Tronic

Fig. no.

Special tools

ZF-Intarder diagnosis tool

Order no.

Application

Terminal tester adaptation

Remarks

Adapter cable for pin end, bus and truck

6008 206 025 for EST 48 6 Adapter cable with 68-pin pin for 88pin bush

6008 207 010 EST 48 table mode adapter 7

1327 751 101 - 2003-04

21

Adapter cable for programming and configuration purposes as well as diagnosis outside the vehicle

ZF-AS Tronic

Maintenance

1

Maintenance

1.3

–

Please also note any information provided by the vehicle manufacturer

–

Regular maintenance increases the transmission’s level of operational safety.

The type plate contains the most important pieces of data.

It can be found on the left-hand side of the transmission, when viewed from the output.

–

Visual inspection for oil leaks as part of vehicle servicing check.

1.1

Visual inspection of wiring

–

Check wiring for damage as part of vehicle servicing check.

–

Type plate

The following details must always be provided when making enquires or undertaking repair work: – transmission type – parts list no. of transmission – transmission volume production no.

ZF FRIEDRICHSHAFEN AG MADE IN GERMANY

AS Tronic

Ensure that connectors are seated correctly, connectors must be fitted with traction relief.

12 AS 2330 TO MODEL

PARTS LIST NO.

1327 036 001

1.2

Maintenance of pneumatic system

–

The maintenance instructions of the vehicle

CUSTOMER SPEC. NO TOTAL RATIO P.T.O.

SPEEDO RATIO

12.33 - 0.78 xxxxx

n=

11

xxx

xxxxx

OIL GRADE SEE LUBRIC. LIST TE-ML

xn ENGINE

02L 019 311

The pneumatic tank should be drained once a week, in winter this should be done once a day.

Type plate (example)

NOTE When draining the pneumatic tank, the pneumatic cleaner and water separator should also be drained provided that the cleaner does not function automatically.

–

xxxxxx

OIL CAPACITY IN LTS.

manufacturer must be observed.

–

N

SERIAL - NO.

00247443

1.4 Approved oil grades Only those lubricants which are listed in ZF List of Lubricants TE-ML 02 may be used. ZF List of Lubricants TE-ML 02 is available from all ZF agents or on the Internet at http://www.zf.com

The interval for changing cartridges must be observed in vehicles which are fitted with an air dryer.

1.5 Oil volume The oil volume is noted on the type plate.

Oil filling must be undertaken accurately if the correct volume of oil is to be filled into the transmission. (Refer to Sections 1.9 and 1.10).

1327 751 101 - 2003-04

1-1

ZF-AS Tronic

Maintenance

5

1 4

3

2

1 Tighten oil drain plug to 60 Nm 2 Tighten oil drain plug to 60 Nm 3 Tighten oil fill plug to 60 Nm

4 Type plate 5 Transmission breather

018 799

1.6

1.8

Transmission breather

The transmission oil heats up during travel. Overpressure therefore builds up and is continuously removed through a breather valve.

Ensure that the breather valve is functioning at all times.

Do not spray directly with pressurized water (water in transmission – risk of corrosion). The breather (5) must be clean and not have a plastic cover.

Oil change check (ZF-AS Tronic without ZF-Intarder)

! DANGER !

Too little oil in the transmission results in transmission damage. RISK OF ACCIDENT

Check the transmission oil level as part of vehicle servicing: –

Undertake oil level check with vehicle on level ground.

–

Do not check oil level immediately after travel (incorrect measurement result). Only undertake check once the transmission oil has cooled down (<40 °C).

–

Remove oil filler plug (3).

–

If the oil level has fallen below the oil filler aperture, the oil must be topped up (refer to 1.9.1).

1.7 Oil change intervals In order to retain the transmission’s level of operating safety, the oil change intervals, as specified in ZF List of Lubricants TE-ML 02, must be observed.

NOTE Whenever checking the oil level, the transmission should also be checked for leaks.

1327 751 101 - 2003-04

1-2

ZF-AS Tronic

Maintenance 1.9.1 Filling oil

1.9 Oil change (ZF-AS Tronic without ZFIntarder)

–

Fill oil through oil filler aperture (3).

The oil may only be changed when the vehicle is on level ground and the engine is switched off.

–

Always change the oil after a long period of travel while the transmission oil is still at operating temperature and is still thin.

The oil level is correct when the oil has reached the bottom edge of the oil filler aperture and/or if oil is already escaping from the oil filler aperture.

–

Tighten oil filler plug (3) to 60 Nm.

! DANGER !

Touching hot parts and transmission oil may result in burns.

–

Remove oil drain and oil filler plugs (1, 2 and 3) from transmission and collect transmission oil in a suitable container and dispose of in accordance with environmental guidelines.

–

Clean magnetic plug of oil drain plug (2) and replace seal.

–

Tighten oil drain plugs (1 and 2) to 60 Nm.

ZF FRIEDRICHSHAFEN AG

019248

2

3

1

Fig.: Transmission without Intarder 1 Oil drain plug 2 Oil drain plug 3 Oil filler plug Oil filler aperture or overflow measurement

1327 751 101 - 2003-04

1-3

ZF-AS Tronic with Intarder

Maintenance

1 Tighten oil drain plug to 60 Nm 2 Tighten oil drain plug to 60 Nm 3 Tighten oil filler plug or oil overflow to 60 Nm 4 Type plate

5 Transmission breather 9 After repairs, tighten oil filler plug to 60 Nm 10 Tighten screw to 23 Nm 11 Filter cover

019 368

NOTE – In order to gain a correct measurement result, the oil level must be checked when • the vehicle is on level ground.

• the engine is switched off • the transmission oil has cooled (< 40 °C).

– Check the oil level as part of vehicle servicing.

– When checking the oil level, also check for leaks in the following places: • transmission, • Intarder, • oil/water heat exchanger, • associated coolant pipes.

1.10 Oil level check (transmission with ZFIntarder) ! DANGER !

Too little oil in the transmission results in transmission damage. Risk of accident.

CAUTION To check the oil level, the Intarder must not be activated just before stopping the vehicle.

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

CHECK: – Stop the vehicle without activating the Intarder.

– When checking the oil level, the oil filler plug (3) should be removed.

– If the oil level has fallen below the edge of the oil overflow aperture, the oil must be topped up (refer to 1.14).

1327 751 101 - 2003-04

1-4

ZF-AS Tronic with Intarder

Maintenance

1.11 Instruction plate for oil change

! DANGER !

Touching hot parts and transmission oil may result in burns.

The instruction plate for oil changes, on the oil filler plug (3), must not be removed.

–

Switch off engine

–

Remove oil drain plug (2) from transmission and oil drain plug (1) from oil filter housing.

–

Clean solenoids of oil drain plug and replace the seals.

–

Replace oil filter (refer to 1.13).

–

Then, screw in oil drain plugs and tighten to 60 Nm.

OEL WECHSEL List SAEof30lubricants

TE-ML 02 1.

EINFUELLEN BIS UEBERLAUF

2.

PROBEFAHRT OHNE RETARDERBETRIEB

3.

NACHFUELLEN BIS UEBERLAUF

001 269

CAUTION Note the specified tightening torque for the oil drain plugs; otherwise the transmission may be damaged.

1.12 Oil change (transmission with ZF-Intarder) CAUTION The ZF-Intarder must NOT be activated just before stopping the vehicle for an oil change.

This ensures that the correct oil change volume is set in the transmission.

NOTE – When changing the oil, collect the oil drained out in an appropriate container and dispose of in accordance with environmental guidelines.

–

Always change oil after a long period of travel while the transmission oil is still at operating temperature and is still thin.

–

Only ever change the oil when the vehicle is on level ground.

1327 751 101 - 2003-04

1-5

ZF-AS Tronic with Intarder

Maintenance

1.13 Oil filter change NOTE Whenever changing the oil filter, always use a new oil filter. !

DANGER! With hot transmission oil: risk of burns.

1

Remove screw (10) from filter cover (11).

10

11 1

000529

2

Pull off filter cover (11) with attached filter.

Take oil filter of filter cover.

CAUTION There will be some oil left in the oil filter housing.

000552

3

On filter cover (11), check O-ring (8) for damage, replace and grease in if necessary.

4

Securely attach solenoid (12) to new filter.

5

Grease in O-ring (7).

6

Place filter cover (11) on new filter (6). Insert complete unit in filter housing until firmly home.

7

11

3

88

77

66

512

Tighten screw (10) to 23 Nm.

004467

1327 751 101 - 2003-04

1-6

ZF-AS Tronic with Intarder

Maintenance

1.14 Oil filling (transmission with ZF-Intarder) 9

WARNING When working on transmissions with ZF-Intarders, a distinction is made between oil filling during an oil change (1.14.1) and oil filling after transmission repairs (1.14.2)

1.14.1 Oil filling during an oil change NOTE The oil may only be filled when the vehicle is on level ground and the engine is switched off. Oil grade in accordance with TE-ML 02.

3

019 367

–

Remove oil filler plug (3).

–

Fill transmission until oil overflows.

–

Screw in oil filler plug (3) with new seal and tighten to 60 Nm.

1.14.2 Oil filling after transmission repairs NOTE The oil may only be filled when the vehicle is on level ground and the engine is switched off. Oil grade in accordance with TE-ML 02.

Carry out test run: distance 2 - 5 km Do NOT activate Intarder during test run.

End of test run: vehicle at standstill.

Do NOT activate Intarder.

–

–

Remove oil filler plugs (3 and 9).

–

Fill with oil at pos. 9 until oil overflows at pos. 3

–

Screw in oil filler plugs (3 and 9) with new seal and tighten to 60 Nm

Remove oil filler screw (3).

NOTE The instruction plate on the oil filler screw (3) must not be removed.

Carry out test run: distance 2 - 5 km Test run: at start, BRIEFLY activate Intarder (stage 6) ONCE

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

End of test run: vehicle at standstill.

Do NOT activate Intarder.

–

–

Screw in oil filler plug (3) with new seal and tighten to 60 Nm.

Remove oil filler plug (3).

NOTE The instruction plate on the oil filler screw (3) must not be removed.

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

–

1327 751 101 - 2003-04

1-7

Screw in oil filler plug (3) with new seal and tighten to 60 Nm.

ZF-AS Tronic with Intarder

Maintenance

1.15 Engine coolant

1.16 ZF-Intarder type plate

CAUTION When topping up the engine coolant, the specifications of the vehicle manufacturer MUST be observed. Otherwise the oil/water heat exchanger may be damaged.

The type plate contains the most important pieces of data.It can be found to the side of the Intarder housing.

–

–

–

–

The following items must always be provided when making enquires or undertaking repair work: 1. parts list no. of Intarder 2. volume production no. of Intarder

Engine coolant (mixture of fresh water and anti-corrosive antifreeze) – Recommended volume of anti-corrosive antifreeze, 35 - 50 vol. %, should be checked using coolant tester.

ZF FRIEDRICHSHAFEN AG MADE IN GERMANY

Intarder PARTS LIST NO.

Anti-corrosive antifreeze Base fluid: ethylene glycol with anti-corrosive inhibitors.

6085 020 028

P.T.O.

N OIL CAPACITY IN LTS.

Example of type plate

Change interval for engine coolant: max. every 2 years (fill in pre-mixed state)

NOTE If sludge forms or if the concentration suddenly falls, the coolant must be replaced immediately.

1-8

SERIAL - NO.

XXX XXX

CUSTOMER SPEC. NO TOTAL RATIO

Fresh water pH value of 6.5 -8.0; total hardness 3-10° dH

1327 751 101 - 2003-04

IT AS Tronic MODEL

SPEEDO RATIO n=

xn ENGINE

OIL GRADE SEE LUBRIC. LIST TE-ML 019527

ZF-AS Tronic

Diagnosis Calling up the error numbers*:

2

Diagnosis

2.1

Diagnosis for vehicles with ZF display and ZF range selector

• Switch on ignition • Turn rotary switch to «N» • Hold control lever in « + » position

For vehicles with their own display, refer to details provided in vehicle manufacturer’s description

A number shown on the display corresponds to the error number.

If 4 bars are displayed in addition to the number shown on a two-digit display, this means:

002 686

ZF display

Error no. + 100 e.g.: error no. 74 error no. 174

003 930

ZF range selector

013 587

When using standard ZF software, system errors are shown on the ZF display.

If 4 bars and 2 arrows are displayed in addition to the number shown, this means:

If a «screwdriver symbol» appears on the display, there is a system error.

Only limited operations are 008 026 possible.

For example: with certain system errors, automatic driving mode is deactivated and the transmission system remains in manual mode.

If a «STOP» appears on the display together with a «screwdriver symbol», there is a serious system error. The vehicle cannot be driven any further. The vehicle usually has to be towed away.

Error no. + 200 e.g.: error no. 27 error no. 227 018 470

008 027

* also refer to vehicle manufacturer operating manual

1327 751 101 - 2003-04

2-1

ZF-AS Tronic 2.2

Diagnosis

Diagnosis with TestmanPro

Interrogating error memory

Deleting error memory

1.

Open Testman

1.

Open Testman

2.

Commercial vehicle/special driveline technology

2.

Commercial vehicle/special driveline technology

3.

Main menu for AS Tronic 2

3.

Main menu for AS Tronic 2

4.

Licensing

4.

Licensing

5.

Safety information

5.

Safety information

6.

Diagnosis product menu

6.

Diagnosis product menu

7.

Laptop connection information

7.

Laptop connection information

8.

Communication structure

8.

Communication structure

9.

Logbook (is automatically saved in GDS3000 directory under transmission number)

9.

Logbook (is automatically saved in GDS3000 directory under transmission number)

10.

Interrogate diagnosis error memory (transmission actuator in vehicle, connection via vehicle end diagnoses interface)

10.

Del diagnosis error memory

11.

Del error memory yes/no

12.

Error memory has been deleted

11.

Interrogate/save error memory

12.

Select error (e.g. here error 191 EOL error)

13.

Interrogate error data (save if possible)

Working with checklists When handling complaints, it is important that the checklist is worked through in full and that the data required is determined. This is the only way in which the problem can be localized.

1327 751 101 - 2003-04

2-2

ZF-AS Tronic

Transmission actuator data sheet

TECHNICAL DATA / TECHNISCHE DATEN / CARACTERISTIQUES TECHNIQUES / CARATTERISTICHE TECNICHE WORKING MEDIUM: AIR ARBEITSMEDIUM: LUFT FLUIDE D'UTILISATION: AIR FLUIDO DI ESERCIZIO: ARIA

61/X1A

62/X1B TERMAL RANGE OF APPLICATION: THERMISCHER ANWENDUNGSBERREICH: PLAGE DE TEMPERATURE EN UTILISATION: CAMPO TERMICO DI APPLICAZIONE:

U

W

AMBIENT AIR TEMPERATURE: UMGEBUNGSLUFTTEMPERATUR: -30° C . . . MAX. 95°C TEMPERATURE AIR AMBIANTE: TEMPERATURA ARIA AMBIENTE:

32

FLANGE TEMPERATURE: FLANSCHTEMPERATUR: MAX 0,5h ... 130°C -30°C BIS 110°C BRIDE TEMPERATURES: FLANGIA TEMPERATURA: WORKING PRESSURE (SUPPLY): BETRIEBSDRUCK (VORRAT): pe = 5,5...12 bar PRESSION D'UTILISATION (ALIMENTATION): PRESSIONE DI ESERCIZIO (ALIMENTAZIONE): DEGREE OF PROTECTION ACCORDING TO IE C 529: SCHUTZART NACH IEC 529: IP 6K9K NACH DIN 40050 T9 DEGRE DE PROTECTION SUIVANT IEC 529: GRADO DI PROTEZIONE SECONDO IEC 529 : VOLTAGE: SPANNUNG:

24V -6V DC +8V DC

TENSION : TENSIONE: GROUPING OF WIRES (ON THE PLUG) STECKERBELEGUNG GROUPEMENT DE CABLES RAGGRUPPAMENTO DEI CAVI (SULLA CALOTTA)

HARDWARE: 446 180 101 2 DOC 610 SOFTWARE: 446 180 101 2 DOC 690 MIT SOFTWAREVERSION 201

STECKER 61/X1A 1 VPI 2 SDDK 3 CANF2-H 4 VPE1 5 VPE2 6 CANF2-L 7 SDEF 8 CANF1-H 9 SD 10 SDP 11 ADVP 12 CANF1-L 13 CANF1-L+ 14 CANF1-H+ 15 CANF1-T 16 VM1 17 VM2 18 VMHF1 19 VMHF2 20 VM3

M = TORQUE M = ANZUGSMOMENT M = COUPLE DE SERRAGE M = COPPIA DI SERRAGGIO SUPPLY OF ENERGY: ENERGIEZUFLUSS: 1 (ø 8mm) APPORT D'ENERGIE: ALIMENTAZIONE DI ENERGIA: DELIVERY: ARBEITSLEITUNG: 2 (ø 4mm) UTILISATION: MANDATA: EXHAUST: ENTLUEFTUNG: 31> 32 , 33 ø 16mm) ECHAPPEMENT: SCARICO: ELECTRICAL CONTROL: ELEKTRISCHER STEUERANSCHLUSS: 61, 62 COMMANDE ELECTRIQUE: COMANDO ELETTRICO:

61/X1A 1

2

3

5

4

6

7

8

61/X1A

U

STECKER 62/X1B 1 2 VM4 3 VM3 4 5 6 VMGA2 7 ADS1 8 ADS3 9 ADS2 10 EU 11 EF2 12 ADS4 13 ADS4+ 14 ADS3+ 15 AU 16 VM1 17 VM2 18 ADVP 19 ADVP+ 20 VMGA1

W

62/X1B

62/X1B

9 10 11 12 13 14 15 16 17 18 19 20

1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18 19 20

ECU STEUERELEKTRONIK

Y3

Y2

Y1

Y4

Y6

Y5

Y8

Y7

Y9

Y10

1

2 )(

)(

)(

)(

)(

)(

)(

)(

33 31

32 K1 - K2 SPLIT-GV

1/2-R-3/4 SELECT-WAEHLEN

2/4/R-N-1/3 SHIFT-SCHALTEN

H - L RANGE-GP

019 067

1327 751 101 - 2003-04

2-3

ZF-AS Tronic 3

Component replacement / transmission actuator

Component replacement 74.140*

3.1

Transmission actuator

74.120*

74.130*

74.030

3.1.1 Removing transmission actuator 74.070

74.090

! DANGER Only work on transmission actuator when ignition is off.

1

Switch off ignition 74.050 74.010

CAUTION If vehicle-specific parts (e.g. fuel pump, exhaust pipe or steering pump) have to be removed, please contact the vehicle manufacturer.

2

34.140 34.130

Disconnect electric plug connections from transmission actuator.

! DANGER Protective glasses should be worn when removing compressed air line from transmission actuator.

Compressed air will escape. Risk of injury from particles of dirt.

3

Remove compressed air line from pressure limitation valve of transmission actuator.

4

Remove breather (74.120) and/or bracket piece (74.140) and cannon socket (74.130) from transmission actuator (74.030) if these parts are being replaced.

5

Remove 15 M8 hex bolts (74.090; 74.070) from transmission actuator (74.030).

1327 751 101 - 2003-04

74.050

12.090 12.080 06.050 06.040

06.080

Loctite 262

* depending on parts list

3-1

015166

ZF-AS Tronic

Component replacement / transmission actuator

CAUTION The rubber gaskets (/170) may fall into transmission housing.

7

Remove compression springs (06.050; 34.140 and 12.090) and detent pins (06.040; 34.130 and 12.080). Remove the two cylindrical pins (74.050) if damaged.

8

Remove gasket (74.010) and clean sealing faces on transmission housing and transmission actuator.

/170

b

Take transmission actuator (74.030) off transmission housing and note down dimensions “a” and “b” for subsequent installation. a

6

018774

9

NOTE There is a transmission actuator kit. This con sists of transmission actuator (74.030), gasket (74.010) and breather (74.120).

74.140*

Remove ball pin (06.080) if damaged.

74.090

74.120*

74.130*

74.030 74.070

74.050 74.010

34.140 34.130

74.050

12.090 12.080 06.050 06.040

06.080

Loctite 262

* depending on parts list

1327 751 101 - 2003-04

3-2

015166

ZF-AS Tronic

Component replacement / transmission actuator

3.1.2 Fitting If the ball pin is replaced, spray thread of ball pin (06.080) with Loctite no. 262. Tighten ball pin to 23 Nm. On transmission actuator, move piston rod (4) into central position (Neutral). The correct position is reached if slight resistance can be felt when removing the piston rod (4).

3

Transfer dimensions “a” and “b” from the removed transmission actuator to the piston rods (3 and 5).

4

Selection gate (6) and piston rod (4) must be in line one another (flush). Ensure that rubber gaskets (/170) are used on transmission actuator.

b

2

/170

a

1

018774

NOTE Piston rod (3) Piston rod (4) Piston rod (5)

= shifts splinter group (GV) = shifts basic transmission = shifts range change group (GP) Selection gate (6) = shifts shift gate NOTE With 12-speed version, do not slide central selector rail too far into transmission otherwise selection finger may fall into transmission.

Alternative: If dimensions “a” and “b” can no longer be determined, the transmission actuator can be fitted using the setting aid (34) 1X56 138 244.. For in-house production following sketch, refer to special tools. On request, tool 1X56 138 244 can also be supplied by ZF. Adjust piston rods (3, 4 and 5) of transmission actuator so that they are in contact with the setting aid (34).

Move GV and GP selector rails in transmission towards output. Move central selector rail into neutral position. Selection gate (6) and piston rod (4) must be in line with one another (flush). Ensure that rubber gaskets (/170) are used on transmission actuator.

017908

7 34

017907

1327 751 101 - 2003-04

3-3

ZF-AS Tronic 5

Component replacement / transmission actuator

Place new gasket (74.010) on transmission housing.

74.140* 74.120*

74.130*

6

Insert detent pins (06.040; 34.130 and 12.080) and compression springs (06.050; 34.140 and 12.090).

74.030 74.070

74.090

NOTE The compression springs (06.050; 34.140 and 12.090) must be of the same length (approx.

50 mm). If variances are found, replace compression springs.

7

8

74.050

Attach transmission actuator (74.030), in so doing piston rods of transmission actuator must mesh in transmission selector rails. The vertical ball pin (06.080) meshes in the selection gate.

74.010

34.140 34.130

Tighten M8 hex bolts (74.090 and 74.070) to 23 Nm.

74.050

12.090 12.080 06.050 06.040

06.080

9

Depending on parts list: Tighten canon socket (74.130) to 18 Nm and secure bracket piece (74.140) and/or tighten breather (74.120) to 10 Nm

CAUTION If transmission actuator is replaced, note the following.

• Reprogram transmission actuator, refer to Section 3.1.5 • Take vehicle parameters from removed transmission actuator or enter new parameters.

10

11

Connect air line onto pressure limitation valve of transmission actuator.

Tightening torque 34 Nm Reconnect wiring harness at transmission and vehicle end otherwise function tests cannot be undertaken.

NOTE Fit connector with traction relief. Check for detent.

1327 751 101 - 2003-04

Loctite 262

* depending on parts list

015166

Final check: Has transmission actuator been reprogrammed?

Vehicle-specific parts should be refitted wherever possible. The transmission actuator can only be tested using the diagnosis device once the engine is running and there is a sufficient reserve of air. The system then undertakes a number of calibration processes. This can take up to 5 minutes. The following errors may then for example be displayed: piston rod not attached with error 132, 134 etc. teach-in error of sensors for gear, gate, GP, GV with ignition on.

3-4

ZF-AS Tronic

Component replacement / transmission actuator

3.1.3 Dismantling transmission actuator 1

Remove both screws (/150-1).

2

Left upper section (/110) of pressure limitation valve (/180) and use both straps (1) to carefully move sideways into grooves (2). Disconnect plug connections (7 and 8).

3

Remove gaskets (/150-3 and /170)

4

Remove gasket (/150-2) and clean sealing faces.

1

/150-1

/110

74.030

3.1.4 Assembling transmission actuator 1

Insert gasket (/150-3).

2

Place gasket (/150-2) on lower section (/130).

3

Re-establish plug connections (7 and 8). Again check that plug connection is secure.

4

Place upper section (/110) on lower section (/130).

Ensure gasket (/150-2) is positioned correctly, if necessary fix with two screws (74.090 or 74.070). Tighten both screws (/150-1) to 9.5 Nm.

/180

/150-2

2 /150-3 /130

5

/170

019352

Insert gaskets (/170).

8 7

018205

1327 751 101 - 2003-04

3-5

ZF-AS Tronic

Component replacement / transmission actuator

3.1.5 Programming transmission actuator When replacing the transmission actuator and/or upper section, customer-specific programming and/or setting of parameters (enter EOL data) is required.

10

The table mode adapter (6008 207 003), programming device EPD1 (0501 301 068) and corresponding “PlugIN cards” are needed for programming.

When setting parameters, the EOL data is entered into the transmission actuator electronics using the TestmanPro and corresponding software.

CAUTION • Reprogram transmission actuator • Take vehicle parameters from removed transmission actuator or enter new parameters.

019251

3.1.6 Replacing pressure limitation valve

74.030

NOTE Mark installation position of pressure limitation valve (180) for subsequent fitting.

1

Remove 4 nuts (10) and take off pressure limitation valve (/180) and O-ring (12). /180 12

CAUTION Do not fit O-ring (12) with grease.

2

Insert new O-ring (12), use 4 nuts to secure pressure limitation valve (/180) to transmission actuator (74.030). Tighten the 4 nuts (10) to 7 Nm.

1327 751 101 - 2003-04

019252

3-6

ZF-AS Tronic

Component replacement / clutch actuator

7

8

68.300

68.010

6

68.330 68.320 68.060 68.210*

/120 /130 68.150

68.154

/020

/030

/010

/110

68.020

68.210* * depending on parts list 018484

3.2

Clutch actuator

3

Disconnect plug connection (7) from transmission actuator and (8) from output speed sensor.

4

Remove wiring harness from cable terminal (68.300, 68.320 and 68.330).

5

Remove 4 M8 hex nuts with washers (/030) and take off clutch actuator (68.010).

6

Remove 4 M8 hex bolts (68.154) and take off cover (68.150).

7

Take push rod (68.210) full out of release fork (68.060).

3.2.1 Removal ! DANGER! • Switch off ignition • Wear protective glasses when removing compressed air line. Compressed air will escape.

Risk of injury from particles of dirt.

1

Once ignition has been switched off, compressed air line should be removed from clutch actuator.

2

Vent clutch actuator, to do so, release screw (6).

1327 751 101 - 2003-04

NOTE For removal and fitting of release fork, refer to section 3.4

3-7

ZF-AS Tronic

Component replacement / clutch actuator

3.2.2 Push rod Length “A” of push rod (68.210), depending on parts list version: 68.210

OEM

ZF no.

Length in mm

DAF

1328 302 033

119.1

RVI

1328 368 008

123.1

Hyundai, KIA

1314 268 002

124

MAN TGA

1328 368 003

127.1

Meritor

1328 368 004

133.6

Meritor

1328 368 009

144.9

A

018485

Adjustable push rod e.g. IVECO ZF-no.

Push rod (68.210) cpl. (with variable adjustment)

1314 268 002

Ball pins (/110)

1314 368 008

Push rod (/120)

1314 368 004

Hex nut (/130)

0637 002 051

68.210

/110

Loosen hex nut (/130)

2.

Screw ball pins (/110) to dimension required.

3.

Tighten hex nut (/130) to 52 Nm.

1327 751 101 - 2003-04

/120

A

Set push rod to set dimension “A”.

1.

/130

019622

3-8

ZF-AS Tronic

Component replacement

6 68.210

68.020

68.060 B

C

019 357

2

3.2.3 IVECO push rod setting

Calculate from dimension “C”: Dimension “B” + 33 mm = dimension “C”

The old push rod dimensions are used if only the clutch actuator is replaced.

Example: Dimension “B” = 57 mm

If driver disc or pressure plate is replaced, push rod (68.210) has to be reset.

57 mm + 33 mm = 90 mm (dimension “C”) CAUTION If working on vehicles with an AS Tronic transmission, it is not the wear dimension which is set, as is usually the case, but the release travel. If not set correctly, the pressure plate is damaged.

1

3

Insert push rod (68.210) in clutch actuator (68.020). Loosen screw (6) on clutch actuator (68.020) until cylinder moves out.

Measure dimension “C” between ball head of push rod and contact face of clutch actuator.

Set push rod accordingly until dimension “C” is reached.

Dimension “B”

Push release fork (68.060) forwards and measure dimension “B”.

1327 751 101 - 2003-04

Set dimension “C”:

3-9

ZF-AS Tronic

Component replacement / clutch actuator

3.2.4 Fitting Venting clutch actuator 1

Loosen screw (6) M12x1.5.

If seal on screw is worn, replace seal.

6

2

Push piston back.

018475

3

Hold down piston and tighten screw (6).

018476

6 018477

1327 751 101 - 2003-04

3-10

ZF-AS Tronic 4

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

5

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

Component replacement / clutch actuator

68.010 6

68.210*

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

/130

/120

/020

/030

/010

/110

68.020 68.210*

6

Loosen screw (6) and wait until piston is forced out. In so doing, ensure push rod (68.210) is seated correctly in release fork (68.060) and clutch actuator.

Retighten screw (6) to 22 Nm.

7

Secure cover (68.150) using 4 M8 hex bolts (68.154).

Tightening torque M8 = 23 Nm

018481

CAUTION Do not bend cable and do not tighten hard.

Avoid chafing points.

Fit connectors with traction relief and check detent.

8

9

6 68.060 68.150

68.154

If damaged, replace cable terminals (68.300, 68.320 and 68.330).

018482

Press wiring harness into cable terminals.

7

10

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

11

Connect compressed air line to clutch actuator.

68.060

68.300

8

68.330 68.320 018483

1327 751 101 - 2003-04

3-11

ZF-AS Tronic 3.3

Component replacement / driver disc

Replacement of driver disc (not ZF scope of supply)

If the driver disc is replaced, note the following: • Coat spline of input shaft with grease OLISTA LONGTIME 3EP (ZF no. 0671 190 050).

NOTE Avoid dirtying driver disc with grease, oil etc.

3.3.1 Fitting engine, clutch and transmission NOTE The release fork is fitted when the transmission is supplied. The transmission is supplied in Neutral or in the highest gear.

1

Fit clutch disc and pressure plate (use a mandrel to centre pressure plate).

2

Slide profile of input shaft into clutch disc.

3

Screw transmission and engine together.

4

Vent clutch actuator (refer to section 3.2.3).

5

Push release bearing forwards (engine end) so that clutch snaps into release bearing snap ring.

014794

WARNING The driver disc, pressure plate and friction lining are part of the customer specification (basic document for drawing up parts list).

The shift program software is co-ordinated to the characteristics of the clutch components.

Modifications to the components (from the customer specification) will result in poor clutch characteristics and/or component damage.

NOTE This happens if you place a short lever through the transmission bell housing and use this to press the bottom end of the release fork towards the rear (transmission end).

CAUTION Do not damage pressure plate.

6

Insert push rod.

7

Close opening on transmission bell housing (refer to section 3.2).

1327 751 101 - 2003-04

3-12

ZF-AS Tronic 3.4

Component replacement / clutch release mechanism

Clutch release mechanism

68.050

3.4.1 Removal of release fork 1

Remove 2 M12 hex bolts (68.130) from release shaft (68.110).

2

Take release bearing (68.050) and release fork (68.060) off input shaft.

68.060 018472

3

Take push rod (68.210) out of release fork (68.060).

68.210

68.060

018473

4

Slide release shaft (68.110) out of release fork (68.060).

68.060

/140

5

Dismantle release fork (68.060).

Use suitable tool to remove shaft seal (/140) and bush (/130). Replace ball cup (/120) if damaged or worn.

/130

/110

/130 /140 68.110

/120 68.130 018474

1327 751 101 - 2003-04

3-13

ZF-AS Tronic

Component replacement / clutch release mechanism

/110

/140

/130

68.060

/140 /130

/110

68.210

/130 /140 68.110

68.050

/120 68.130 018487

3.4.2 Fitting release fork 1

Assemble release fork (68.060).

An adapter 1X56 138 215 is needed as support for the release fork. The other adapter 1X56 138 215 is used to press both bushes (/130) flush into the release fork (/110).

3

Guide release shaft (68.110) into release fork (68.060) taking care not damage the shaft seals.

4

Position release bearing (68.050) on release flange. Do not grease sliding seat between release bearing and release flange.

5

Grease contact face of release bearing (68.050) to release fork (68.060) with OLISTA LONGTIME 3EP (ZF no. 0671 190 050). Mesh release fork (68.060) with release bearing (68.050). Ensure push rod (68.210) correctly.

6

Secure release shaft (68.110) to housing I with 2 M12 hex bolts (68.130).

Tightening torque M12 = 79 Nm

NOTE Coat the outer circumference of the shaft seals with methylated spirits.

2

Press in both shaft seals (/140) with adapter 1X56 138 215 until firmly home.

Grease sealing lip of shaft seals (/140) with OLISTA LONGTIME 3EP (ZF no. 0671 190 050).

1327 751 101 - 2003-04

3-14

ZF-AS Tronic 3.5

Component replacement / output flange

Output flange

3.5.1 Removal 1 2

Remove 2 hex bolts (32.550) and take off washer (32.540).

32.550 32.540 32.530

Use commercially available three-arm extractor to extract output flange (32.510) and remove Oring (32.530).

32.510

NOTE When extracting flange, use intermediate piece to protect shaft.

015171

3.5.2 Fitting 1

Heat output flange (32.510) to max. 70 °C and slide onto planetary carrier spline until firmly home. If working with Intarder version, ensure that screws* (32.520) are inserted.

32.540 32.510

32.550 32.530

! DANGER Only touch hot output flange if wearing protective gloves.

2

3

Once output flange has cooled down, insert Oring (32.530) in groove between shaft and output flange.

32.520 015169

Secure washer (32.540) with 2 M12 hex bolts (32.550).

Tightening torque M12 = 120 Nm

1327 751 101 - 2003-04

3-15

ZF-AS Tronic

Component replacement / output flange

3.5.3 Removing output cover NOTE Sections 3.5.3 and 3.5.4 do not apply to transmission versions with Intarders because the parts are not present.

31.080 31.050

31.030

1

Remove 10 M10 hex bolts (31.070) and take off output cover (31.050).

2

Take off shim (31.030).

3

Use appropriate tool to remove shaft seal (31.080) taking care not to damage output cover.

31.070 Loctite 574

015170

3.5.4 Fitting output cover 1

Coat outer circumference of shaft seal (31.080) methylated spirits and press adapter 1X56 137 124 together with ring 1X56 138 189 into output cover (31.050) until firmly home. Apply grease to sealing lip.

2

Coat sealing face of output cover with Loctite no. 574.

NOTE Sealing faces must be clean and free of all oil and grease.

3

Attach output cover (31.050) with shim (31.030).

4

Tighten 10 M10 hex bolts (31.070) to 46 Nm.

1327 751 101 - 2003-04

3-16

ZF-AS Tronic 3.6

Component replacement / speed sensor, output

Speed sensor (impulse sensor), output, depends on vehicle manufacturer

CAUTION If the Kitas sensor is changed, parameters must be set for the new sensor (and/or taught-in) because otherwise there will no longer be any tacho functions.

31.260*

3.6.1 Removal ZF FRIEDRICHSHAFEN AG

1

Pull out connector.

2

Remove impulse sensor (31.260).

014813

3.6.2 Fitting CAUTION • Fit connector with traction relief and check detent.

• Impulse sensor may be confused with other parts, therefore check ZF number.

1

Screw in impulse sensor (31.260).

(Setting is not required) Tightening torque = 45 Nm

3.6.3 Connector replacement 31.260*

If a connector has to be replaced, please use the AMP standard tool (for connection diagram, refer to parts list).

019249

Transmission without Intarder Impulse sensor* (DIN bayonet) length 90 mm Version Hall 0501 210 859 Kitas 0501 211 735

voltage supply ZF 6.5 - 30V vehicle end 6.5 - 9 V

Transmission with Intarder Impulse sensor* (DIN bayonet) length 19.8 mm Version Hall 0501 210 855 Kitas 0501 213 668

voltage supply ZF 6.5 - 30V vehicle end 6.5 - 9 V

* depending on parts list

1327 751 101 - 2003-04

3-17

ZF-AS Tronic 3.7

Component replacement / neutral switch

Replacing neutral switch*

06.260*

3.7.1 Removal 1

06.250

Remove neutral switch (06.260) with seal.

3.7.2 Fitting 1

Apply some grease to tappet of neutral switch.

Screw in neutral switch (06.260) with seal.

Tightening torque = 50 Nm NOTE Pin (06.250) must be fitted.

019250

3.7.3 Connector replacement If a connector has to be replaced, please use the AMP standard tool (for connection diagram, refer to parts list).

NameZF no.

Neutral switch (DIN bayonet) Seal Pin

0501 210 059 0634 801 062 1328 306 024

* Option (refer to parts list)

1327 751 101 - 2003-04

3-18

ZF-AS Tronic

Component replacement / Intarder

05.400*

7 1

05.440

05.110 02.180

2 02.170

05.100 02.190

05.020 05.030*

05.030*

019068

3.8

Replacing components on Intarder

CAUTION Fit all connectors with traction relief and check detent.

3.8.3 Solenoid valve 1

Grease O-ring (02.180) (only use a little grease) and insert in solenoid valve (02.170) and tighten using 2 cylindrical bolts (02.190) M8x22.

Tightening torque M8 = 23 Nm

3.8.1 Speed sensor, output 3.8.4 Temperature sensor 1

Screw in impulse sensor (1).

Tightening torque = 45 Nm

3.8.2 Tacho sensor 1

1

Screw in temperature sensor (05.030) with seal.

Tightening torque = 40 Nm

2

Tighten drain plug (05.020) for residual coolant to 34 Nm.

Screw in impulse sensor (2).

Tightening torque = 45 Nm

CAUTION Tacho sensor must be calibrated and lead sealed.

1327 751 101 - 2003-04

* depending on parts list

3-19

ZF-AS Tronic

Component replacement / Intarder

05.400*

7 1

05.440

05.110 02.180

2 02.170

05.100 02.190

05.020 05.030*

05.030*

019068

3.8.5 Removing 3/2-way valve 1

2

Pull connector off 3/2-way valve (05.100) and remove air connection (7).

Remove 2 M8 hex bolts (05.110).

Take off 3/2-way valve (05.100) with O-ring (ZF no. 0634 313 028).

3.8.6 Removing / fitting Intarder wiring harness

1

Remove 3 cable connectors (05.440).

2

Disconnect plug connectors.

Fit Intarder wiring harness Fitting 3/2-way valve 1

2

Secure new O-ring (ZF no. 0634 313 028) and 3/2-way valve (05.100) with 2 M8 hex bolts (05.110).

Tightening torque M8 = 23 Nm

1

Fit connector with traction relief. Ensure connector snaps in.

2

Secure wiring harness (05.400) to Intarder using 3 cable connectors (05.440).

Connect up air connection (7).

Tightening torque: Union screw M16X1.5 = 45 Nm

1327 751 101 - 2003-04

* depending on parts list

3-20

ZF-AS Tronic 3.9

Additional cooling connection

1

Remove screw plugs (01.030 and 01.040).

Component replacement / additional cooling

01.030

01.040

2

Insert O-rings (47.020 and 47.030) and union screws (47.050 and 47.060) in valve block (41.010).

018479

47.030

47.020

47.010

47.060 47.050

3

Screw union screws (47.050 and 47.060) into transmission housing and tighten to 60 Nm.

018478

47.050

47.010

47.030

47.050 47.060 47.020

47.060 018480

1327 751 101 - 2003-04

3-21

ZF-AS Tronic

Component replacement / display

3.10 Display ZF display 0501 211 422, CAN-compatible CAUTION Only work on display if ignition is off.

1

NOTE The display must be accessible from below.

2

3.10.1Disassembly 1

Pull connector (2) out of display.

Press on retaining clamps (see arrow) and move display (1) up and out.

014651

3.10.2Installation 1

Slide display (1) into opening.

CAUTION Fit connector (2) with traction relief and check detent.

3.10.3Connection diagram 0501 211 422, refer to Annex Plug assignment PIN 1: 58 (light on /off) on = GND PIN 2: AD (Piezo) Imax = 200 mA PIN 3: 58d (light dimmed) on = VP PIN 4: SD (ZF-BUS) PIN 5: CAN H PIN 6: VM (GND) PIN 7: CAN L PIN 8: VP (Batt): 9V......32V Max. current capacity 60mA Type of protection: at front IP54, at rear IP30

3.10.4Connector replacement If the connector has to be replaced, please use the AMP standard tool.

For vehicle-specific connection diagram, refer to parts list.

1327 751 101 - 2003-04

3-22

ZF-AS Tronic

Component replacement / Annex

Documents attached • Connector and mating connector designations • ZF standard pneumatics diagram • List of lubricants TE-ML02 1205 754 002 for current List of Lubricants, refer to: http://www.zf.com/defaultz.asp?lang=2&id=522

Drawings attached Drawing no.

0501 210 059c 0501 210 854b 0501 211 185a 0501 211 422e 1327 600 015b 1327 600 016a 1328 600 015c 1328 600 016b 1328 600 019 6006 629 024 6006 700 579c 6006 700 586a 6029 713 016a 6029 713 021 6029 713 022 6029 713 025a 6041 622 023c 6090 601 031 6090 604 024 6091 610 003d 6091 615 007

1327 751 101 - 2003-04

Name Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing Circuit diagram Circuit diagram Circuit diagram Connection diagram Connection diagram Circuit diagram Installation drawing Installation drawing Installation drawing Installation drawing Installation drawing

Techn. information Signal switch Impulse sensor Steering wheel switch Display 12 AS ZF-Standard 12 AS with Intarder and ZF-Standard cable tip 16 AS ZF-Standard 16 AS with Intarder ZF-Standard Clutch Range selector Range selector Range selector ZF-AS Tronic general Central consumer, ZF-AS Tronic general End consumer, ZF-AS Tronic general On-board computer ZF E module PTO NH/1 PTO NH/4 PTO NAS/10 PTO with emergency steering pump

3-23

Component replacement / connector and mating connector designations

ZF-AS Tronic Connector

Use

Type

Manuf.

ZF number

Manufacturer no.

CKD no.

Protection class

X1

GS3 on-site electronics

20-pin Bu

Kostal

6029 201 675

Conn. housing: 09432001 Bush contact: 22124472200 Gasket: 10800444521 Blind plug: 10800472632 Adapter bracket (folding part) ZF 0501 318 143

6029 199 090

IP 67/ 69

IP 67/ 69

X1

GS3 on-site electronics Bus actuator

18-pin Bu

Kostal

6029 201 752 0501 317 367

Conn. housing: 09432691 Bush contact: 22124472200 Gasket: 10800444521 Blind plug: 10800472632”

6029 199 125

X36

E-module

35-pin

AMP

6029 201 262

Conn. housing: 925379-1 Bracket: 928544-1 Cap: 925380-1 ISO-1481 screw ST 2,9X9,5-F Gasket ZF 6020 303 013 Contact bush 925590-1

6029 199 091

X21

Diagnosis

6-pin ST MNL

AMP

6029 201 121

Conn. housing 926682-3 Contact pin: 926887-1 6029 199 027

Open connector system, no details of protection class

X21

Diagnosis Mating connector

6-pin Bu MNL

AMP

6029 201 120

Conn. housing350715-1 Contact bush: 926882-3

6029 199 092

refer to 6-pin ST MNL”

Range selector

14-pin Bu J.P.T.

AMP

Conn. housing 929504-5 Contact bush: 927771-3

6029 199 042

refer to 6-pin ST MNL”

6-pin Bu J.P.T.

AMP

Conn. housing 929504-2 Contact bush: 927771-3

6029 199 109

refer to 6-pin ST MNL

4-pin St MNL

AMP

Conn. housing 350780-1 Contact pin: 926887-1

6029 199 028

refer to 6-pin ST MNL

Contact bush: 927771-3 Conn. housing 929504-3

6029 199 108

refer to 6-pin ST MNL

X2 X5 X5 X5

Display Display Display

8-pin Bu

AMP

6029 201 403 6029 201 367 6029 201 130 6029 201 676

A11/A14

Output sensor

4-pin BU DIN Bay.. angled

AMP

6029 201 618

Conn. housing 1-967325-1 Cap: 965783 Bush contact: 0-929974-1 Gasket: 828920-1 Blind plug: 828922-1

6029 199 111

IP 67/ 69K

S12

Neutral switch

4-pin BU DIN Bay.. straight

AMP

6029 201 619

Conn. housing 1-967325-1 Cap: 965786 Bush contact: 0-929974-1 Gasket: 828920-1 Blind plug: 828922-1

6029 199 088

IP 67/ 69K

S12

Neutral switch

4-pin BU DIN Bay.. angled

AMP

6029 201 618

Conn. housing 1-967325-1 Cap: 965783 Bush contact: 0-929974-1 Gasket: 828920-1 Blind plug: 828922-1

6029 199 111

IP 67/ 69K

6029 201 336 Conn. housing 929504-7 Contact bush: 927771-3

6029 199 043

refer to 6-pin ST MNL

X17

Junction for 22-pin Bu JPT vehicle power supply

AMP

X17 A M. conn.

Junction for vehicle power supply 22-pin St JPT

AMP

6029 201 354

Conn. housing 929505-7 Pin contact: 928930-5

6029 199 025

refer to 6-pin ST MNL

X18

Junction for vehicle power supply 18-pin Bu JPT

AMP

6029 201 361

Conn. housing 929504-6 Contact bush: 927771-3

6029 199 084

refer to 6-pin ST MNL

X18 A M. conn.

Junction for vehicle power supply 18-pin St JPT

AMP

6029 201 365

Conn. housing 929505-6 Pin contact: 928930-5

6029 199 026

refer to 6-pin ST MNL

X18 A M. conn.

Junction for CAN veh. p supply

6-pin Bu JPT

AMP

6029 201 367

Conn. housing 929504-2 Contact bush: 927771-3

6029 199 109

refer to 6-pin ST MNL

X18 A M. conn.

Junction for CAN veh. p supply

6-pin St JPT

AMP

6029 201 366

Conn. housing 926682-3 Contact pin: 928930-5

6029 199 110

refer to 6-pin ST MNL

X19

Junction for cab

18-pin Bu JPT

AMP

6029 201 361

Conn. housing 929504-6 Contact bush: 927771-3

6029 199 084

refer to 6-pin ST MNL

Junction for cab

18-pin St JPT

AMP

6029 201 365

Conn. housing 929505-6 Pin contact: 928930-5

6029 199 026

refer to 6-pin ST MNL

X20 m. conn. for X19

Connector replacement: If a connector has to be replaced, please use the AMP standard tool (for connection diagram, refer to parts list).

1327 751 101 - 2003-04

3-24

ZF-AS Tronic

Component replacement / pneumatics diagram

Example 1

Compressor Air dryer

Four-circuit protection valve

5 bar overcurrent valve

Transmission actuator with pressure sensor

20 litres Non-return valve

Clutch actuator

014885

014 885

Example 2

Compressor Air dryer

Four-circuit protection valve

Transmission actuator with pressure sensor

20 litres Non-return valve

Clutch actuator 014 886

1327 751 101 - 2003-04

5 bar overAuxiliary concurrent sumers valve 014886

3-25

Translation only for your information. German text is binding.

Commercial Vehicle and Special Driveline Technology

Manual and automatic transmissions for trucks and buses

x List of lubricants TE-ML 02

Product groups (1)

Lubricant classes for service fills (2)

Transmission types see page 2!

Transmissions without ZF-Intarder

Transmissions with ZF-Intarder

Ecolite _ VAN + bus 1

02D / 02F(3) / 02G alternative recommended (4): 02A / 02B / 02H

x ---

x

02G alternative recommended (4): 02A / 02B / 02C / 02H

x ---

truck + bus 2 bus 3 Ecomid / Ecomid with NMV truck + bus

_

_ 02A / 02B / 02C / 02D / 02H / 02L

02C / 02D / 02H / 02L

Transmatic

02C(5)

02C(5)

ASTRONiC 1 truck

x 02A(5) / 02B / 02C / 02H

02C / 02H

ASTRONiC 2 truck, bus + crane vehicle

x 02A(5) / 02H / 02L

02H / 02L

TC-Tronic Transmission ASTRONiC 2

x 02A(5) / 02H / 02L

---

02C(5) / ATF in accordance with TE-ML 14

---

Ecosplit / Ecosplit with NMV New ECOSPLIT / New ECOSPLIT with NMV

Torque converter lock-up clutches TC 2 x (1)

Approved lubricant classes for models not listed here: - Torque converter lock-up clutches (WSK) with separate oil circuit: 02C, ATF in accordance with TE-ML 14x - Constant-mesh and synchronised transmissions for commercial vehicles: 02A / 02B / 02C / 02H

(2)

See overleaf for approved trade products, oil drain intervals and low temperature limits.

(3)

Product group Ecolite - VAN + bus 1: TE-ML 02 applies only after the transmission has reached a total of 2,500 km. This also applies to repairs.

(4)

Product group Ecolite: In moderate climate zones, shift quality is impaired if oils of the lubricant classes 02A / 02B / 02C / 02H are used.

(5) The lubricants listed overleaf and marked thus (*) may not be used.

Comments: 1.

Instructions for transmission ventilation in accordance with Installation Guidelines 1203 765 010 and 1328 765 001 must be followed.

2.

A saponified lithium mineral oil-based multigrade grease of the NLGI class 2 should be used at greasing points (grease code KP2K-30 in accordance with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO/DIS 6743-9).

The list of lubricants TE-ML 02, Edition 01.07.2003 replaces all previous editions. The current list can always be obtained from all After-Sales Service points and on the Internet under www.zf.com / Information / Technical Information. x Page 1 of 14

ZF Friedrichshafen AG D-88038 Friedrichshafen phone: + 49 7541 77 3505x fax: + 49 7541 77 7319 1205 754 102g / 07.2003

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Transmission classification in accordance to product groups x Product groups

List of lubricants TE-ML 02

Transmission types (type in bold/italic are available with ZF Intarder)

Ecolite VAN + bus 1

S5-42, S6-36, S6-36/2, 5S200, 6S300, 5S250VO, 5S510VO, 5S640VO, 6S320VD, 6S720VO, 5S600BO, 6S300BD

truck

6S850

bus 2

6S890, 6S700BO

bus 3

S6-85, 6S1600, 6S1000BD, 6S1200BD, 6S1000BO, 6S1200BO, 6S1600BD, 6S1700BO

Ecomid / Ecomid with NMV truck bus

9S75, 9S109, 16S109 8S180, 8S2100BD, 8S2100BO

Ecosplit / Ecosplit with NMV truck

8S151, 16S151, 8S181, 16S181, 16S221, 16S251

New ECOSPLIT / New ECOSPLIT with NMV truck (7)

16S162XTD, 16S192XTD, 16S222XTD, 16S182XTO, 16S222XTO, 16S252XTO, 16S272XTO, 8S162XTD, 8S182XTO, 8S192XTD, 8S222XTO (7)

Transmatic (Ecosplit with WSK / New Ecosplit with WSK)

16S151 + WSK, 16S221+WSK400, 16S251+WSK440, 16S1623TD + WSK, 16S1823TO + WSK, 16S2223TD+WSK, 16S2523TO + WSK, 16S2720TO + WSK

ASTRONiC 1 truck

12AS1800, 16AS2200

ASTRONiC 2 truck (8)

12AS2301, 16AS2601; 12AS163XTD, 12AS193XTD, 12AS193XTO, 12AS213XTO, 12AS233XTO, 16AS223XTD, 16AS263XTO (8) 12AS234XTD, 12AS254XTD, 12AS254XTO, 12AS274XTO (8)

bus

10AS2301, 12AS2000B, 12AS2300B, 10AS2310B, 10AS200XBD, 10AS200XBO, 10AS230XBD, 10AS230XBO, 10AS270XBD, 10AS270XBO, 12AS2001BO, 12AS2301BO, 12AS2701BO

crane vehicle

12AS2302, 16AS2602

TC-Tronic 12TC2740TO, TC 2 x (7) X refers to transmission version 0 = without Intarder, 1 = Intarder, 2 = NMV, 3 = 100% overrun, 4 = servoshift (8)

X refers to transmission version 0 = without Intarder, 1 = Intarder

x

Page 2 of 14

1205 754 102g / 07.2003

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

_

Oil drain intervals

List of lubricants TE-ML 02

x x Product group (9)

x Lubricant class

Transmission types see page 2!

Operating conditions

Ecolite - without ZF-Intarder

x Short-distance transport (trucks) x Scheduled routes (buses)x x Tough operatingx conditionstions

Ecomid / Ecosplit / Transmatic (10) / ASTRONiC / TC-Tronic (10) - without ZF-Intarder - with ZF-Intarder Ecolite / Ecomid / Ecosplit / ASTRONiC - without ZF Intarder - with ZF-Intarder

Long-distance transport (trucks) x Long-distance coach journeys (buses)

x 02A

x 02B

x 02C/02H

x 02D/02L

02F/02G (Ecolite only)

oil drain interval

_ _ 60.000 km 120.000 1 year km 1 year

_ 120.000 km 1 year

_ 240.000 km 2 years

120.000 km 1 year _ ---

---

---

90.000 km 1 year

160.000 km 1 year

---

---

x 160.000 kmx 1 year

x 300.000 kmx 2 years

160.000 km 1 year ---

x

Comment: (9)

Please observe assignment product groups to approved lubricant classes on page 1!

(10) ATF in accordance with TE-ML 14 in torque converter lock-up clutches with separate oil circuit (WSK, TC 2): 120.000 km or 1 year. x

Low temperatures limits x Lubricant classes

Oil type / SAE viscosity grade

02B / 02D / 02F / 02G / 02L

75W / 75W-80 / 75W-85 / 75W-90 / ATF

above -40°C

02A / 02B / 02H

80W / 80W-85 / 80W-90

above -25°C

02C

30

above -15°C

20W (Transmatic only)

below -15°C

Page 3 of 14

Use at oil sump temperatures

1205 754 102g / 07.2003

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02A Gear oil of viscosity grades: SAE 80W / 80W-85 / 80W-90 (not applicable for Intarder) x Note: 1. In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are used.

2. Product group ASTRONiC: The lubricants marked thus (*) may not be used. x Manufacturer (02A)

Trade name (02A)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B COMP.BRASIL. D. PETRO. IPIRANGA, RIO DE JANEIRO/BR CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F GULF OIL INTERNATIONAL, PITTSBURG/USA HAFA, PARIS/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MOL-LUB LTD., ALMASFUZITO/H MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E

ADDINOL GETRIEBEÖL GS 80W ADDINOL GETRIEBEÖL GS 80W-90 AUTOL GETRIEBEÖL 80W-90 ARAL GETRIEBEÖL EP SAE 80W AVIA GEAR OIL MZ 80 BAYWA MEHRZWECKGETRIEBEÖL SAE 80 EP-GETRIEBEÖL 80W-100 EP-GETRIEBEÖL 80W-68 EP-GETRIEBEÖL 80W90 BP ENERGEAR EP 80W BP ENERGEAR EP 80W-90 FRONTOL MEHRZWECKGETRIEBEÖL SAE 80W MOTOREX GEAR OIL EP 80W MOTOREX GEAR OIL EP 80W/90 CALPAM MP GEAR OIL 80W GL 4 CASTROL EP80W CASTROL UNITRON 80W CEPSA TRANSMISIONES 80W-90 ERTOIL TRANSMISIONES 80W-90 ERTOIL TRANSMISIONES F SAE 80 GEARTEX EP-A 80W (*) GEARTEX EP-A 80W-90 IPIRGEROL EP 80W GEAR A ( 80W ) TOR MULTIPURPOSE GEAR OIL SAE 80W90 ROTRA HY 80W-90 ROTRA HY DB 80W ESSO GEAR OIL GP-D 80W MOBILUBE GX-A 80W TITAN GEAR MP SAE 80W YORK 791 SAE 80W85 GULF GEAR MZ 80W HAFA MPB SAE 80W HRD EP 80W HRD EP 80W-90 TRANS EPA SAE80W-85W KOMPRESSOL-MEHRZWECK-GETRIEBEOEL SAE 80W-90 HIDROIL SAE 80W90 Q8 T 35 SAE 80 W Q8 T 35 SAE 80W-90 LIQUI MOLY GETRIEBEÖL GL 4 SAE 80W INA TRANSMOL DB 80W INA TRANSMOL HD 80W-90 MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE 80W MOL HYKOMOL 80W MOTUL GEAR MB 80W EP GEAROIL SAE 80W OEST MEHRZWECK-GETRIEBEÖL SAE 80W OEST MEHRZWECK-GETRIEBEÖL SAE 80W-90 OMV GEAR OIL MP SAE 80W-85 PAKELO GEAR OIL EP/FZ SAE 80W PAKELO GEAR OIL EP/FZ SAE 80W/90 PANOLIN EP GEAR 80W PANOLIN EP GEAR 80W/90 HIPOL 10 ZF HIPOL SUPER GL-4 80W HIPOL SUPER GL-4 80W-90 CS EP M SAE 80W GULF GEAR LUBRICANT 80W-85

Page 4 of 14

Continued

SHELL & DEA OIL GMBH, HAMBURG/D SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F

Page 5 of 14

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

DEAGEAR EP-A SAE 80W ASEOL GEPRESS 80W ASEOL GEPRESS 80W-90 SHELL SPIRAX G 80W SHELL SPIRAX MA 80W WINTERSHALL WIOLIN MEHRZWECK-GETRIEBEÖL 80 WINTERSHALL WIOLIN MEHRZWECK-GETRIEBEÖL 80W-90 UNIVERSAL EP SAE 80W ANTAR EP 80W ANTAR EP 80W-90 FINA PONTONIC N 80W-85 FINA PONTONIC N 80W-90 TOTAL EP 80W-85 TOTAL EP 80W-90 TRANSELF EP 80W TRANSELF EP 80W-90 UNIL OPAL GEAR EP SAE 80W85W HIGH PERFORMANCE GEAR OIL GL-4 80W VEEDOL MULTIGEAR SAE 80W BVX M 100 80W85

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02B Gear oil of viscosity grades: SAE 80W / 80W-85 / 80W-90 / 75W-80 / 75W-85 / 75W-90x (not applicable for Intarder) _

Note: In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are used.x x Manufacturer (02B)

Trade name (02B)

ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARMORINE S.A., LANESTER CEDEX/F AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALTEX (UK) LIMITED, LONDON/GB CALTEX (UK) LIMITED, LONDON/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FALCON OIL COMPANY LTD., SHARJAH/UAE FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F HAFA, PARIS/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MODRICA OIL REFINERY, MODRICA/BIH MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB NEW PROCESS AG, TÜBACH/CH OEL-BRACK AG, HUNZENSCHWIL/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH

ADDINOL GETRIEBEÖL GX 80 W 90 ML AGIP ROTRA TRUCK GEAR S, SAE 75W-90 ARAL GETRIEBEÖL EP PLUS SAE 80W-90 BM 80 AVIA SYNTOGEAR FE 75W-90 EP AVIA SYNTOGEAR FE 80W-90 BAYWA SUPER 8090 MC BP ENERGEAR DL 80W BP ENERGEAR DL 80W-90 BP ENERGEAR HT 80W BP ENERGEAR HT 80W-90 ENERGEAR SHX-M SAE 75W-90 FRONTOL GETRIEBEÖL FE SAE 80W-90 MOTOREX UNISYNT TX CALPAM MULTI GEAR OIL FE 80W90 CALTEX TRANSLUBE LD SAE 80W CALTEX TRANSLUBE LD SAE 80W-90 CASTROL AGRI GEAR ULTRA CASTROL DYNADRIVE 80W-90 CASTROL SUPERDRIVE 80W CEPSA TRANSMISIONES EP FE+LD 75W-90 MULTIGEAR 80W-90 MULTIGEAR S 75W-90 TOR UNIGEAR 75W90 LD ROTRA LSX 75W-90 ROTRA TRUCK GEAR 80W-90 ESSO GEAR OIL TDL 75W-90 ESSO GEAR OIL TDL 80W-90 MOBILUBE 1 SHC 75W-90 MOBILUBE S 80W-90 FALCON SUPER EP GEAR OIL 80W/90 GL-4 TITAN SUPERGEAR MC 80W-90 GENOL GEAR-SYN 80W-90 YORK 896 EUROGEAR SAE 75W-90 HRD LONGEVIA P 80W-90 HRD LONGEVIA PXD 75W-90 SYNTHEGEAR SAE75W90 Q8 GEAR OIL XG SAE 80W-90 HYPOID GETRIEBEÖL TDL SAE 80W-90 MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90 MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90 SYNTRAN FE/MILLERS TRX SYNTH 75W/90 PENNASOL LONGLIFE GEAR GL 4 SAE 80W PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 80W TRANSLUBE GL-4 SAE 80W LODEXOL SS 80W SERVOL EP 80W/90 GEAROIL SYNTH QUAKER STATE SUPER Q 5 SAE 80W-90 OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90 OEST SYNTH GETRIEBEÖL SAE 75W-90 OMV GEAR OIL XD-4 SAE 80W-85 OMV UNIGEAR S SAE 75W-90 OMV UNIGEAR SAE 80W-90 PAKELO GLOBAL GEAR CBS SAE 75W/85 PAKELO GLOBAL GEAR SA SAE 80W PAKELO GLOBAL GEAR SA SAE 80W/85 PAKELO GLOBAL GEAR SA SAE 80W/90 PAKELO GLOBAL MULTIGEAR TS SAE 75W/90 PANOLIN SUPER DUTY SYNTH 75W/90

Page 6 of 14

Continued

PANOLIN AG, MADETSWIL/CH RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL S.A.E.L., MADRID/E SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHELL & DEA OIL GMBH, HAMBURG/D SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STRUB + CO AG, REIDEN/CH STRUB + CO AG, REIDEN/CH TEDEX OIL SP.Z.O.O., PIASECZNO/PL TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL YACCO, ST PIERRE LES ELBEUF/F ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D

Page 7 of 14

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

PANOLIN TOPGEAR 80W/90 HIPOL EXTRA GL-4 80W-90 HIPOL EXTRA GL-5 80W-90 GULF SYTHETIC GEAR LUBRICANT 75W-90 SHARLU EP GEAR LUBE 80W/90 (GL-4) DEAGEAR MZ 80W-90 SHELL SPIRAX GX 80W SHELL SPIRAX GX 80W-90 SHELL SPIRAX MX 80W-90 WINTERSHALL GETRIEBEFLUID SML 80W-90 GEARWAY G4 80W STRUB MULTIGEAR SGO 80W-90 VULCOGEAR SYNT SGX 75W-90 TEDEX SUPER GEAR OIL (3343ML) SAE 80W90 ANTAR EPS 75W-90 ANTAR UNIVERSAL FE 80W-90 FINA PONTONIC FDL 75W-90 FINA PONTONIC MDL 80W-90 TOTAL TRANSMISSION MDL 80W-90 TOTAL TRANSMISSION RS FE 80W-90 TOTAL TRANSMISSION SYN FE 75W-90 TRANSELF SYNTHESE FE 75W-90 TRANSELF UNIVERSAL FE 80W-90 SYNPOWER GEAR OIL TDL 75W-90 VALVOLINE STX GEAR OIL GL-5 80W-90 BVX 1000 DIVINOL GEAR OIL STO SAE 80W-90 ZEPPELIN SPEZIALGETRIEBEÖL GL-4/GL-5 80W-90

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02C Monograde engine oil of viscosity grades: SAE 30 / 40 (mineral oil-based, applicable for Intarder)x x Note: 1. In moderate climate zones, shift quality is impaired if viscosity grade SAE 40 is used.

2. Product group Transmatic: At ambient temperatures below -15°C, engine oil of viscosity grade SAE 20W (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL specifications or ACEA categories A/B/E) must be used. If possible, any one of the below-mentioned commercial products in the viscosity class SAE 20W is to be used.

3. Product group Transmatic/TC-Tronic: The lubricants marked thus (*) may not be used. x Manufacturer (02C)

Trade name (02C)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B FUCHS LUBRICANTS (UK) PLC, HANLEY/GB FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F IGOL FRANCE SA, AMIENS/F INA MAZIVA RIJEKA, RIJEKA/HR INA MAZIVA RIJEKA, RIJEKA/HR INA MAZIVA RIJEKA, RIJEKA/HR INA MAZIVA RIJEKA, RIJEKA/HR KRAFFT S.A., ANDOAIN/E LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LUBRICATION ENGINEERS, INC., FORT WORTH, TEXAS/USA MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D NEW PROCESS AG, TÜBACH/CH OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH SHELL & DEA OIL GMBH, HAMBURG/D SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S

ADDINOL TURBO DIESEL MD 305 SAE 30 ADDINOL TURBO DIESEL MD 405 SAE 40 (*) ARAL BASICTURBORAL SAE 30 AVIA SPECIAL HDC SAE 30 BLASOL 30 BLASOL 40 (*) BP VANELLUS C3 MONO SAE 30 BP VANELLUS C3 MONO SAE 40 (*) MOTOREX EXTRA 30 MOTOREX MULTI DF 30 CASTROL ASSURON T PLUS SAE 30 CASTROL ASSURONT PLUS SAE 40 (*) CASTROL TROPICAL TURBO 40 ZF (*) CRF 30 CRF 40 (*) URSA SUPER LA 30 URSA SUPER LA 40 (*) TITAN TXE 30 TITAN UNIVERSAL HD 30 GENOL MULTI-TURBO 30 YORK 730 SAE 30 YORK 730 SAE 40 (*) TRANS TURBO 4 SAE30 INA GORGONELA S 30 INA SAGARTIA 30 INA SUPER 3 30 INA SUPER 5 30 MONOGRADO SUPER S-3 SAE 40 (*) LIQUI MOLY TOURING HIGH TECH HD 40 (*) TOURING HIGH TECH MOTOROIL SAE 30 MONOLEC GFS ENGINE OIL SAE 30 OMEGA 643 SAE 40 (*) MEGOL MOTORENOEL HD-C3 SG SAE 30 MEGOL MOTORENOEL HD-C3 SG SAE 40 (*) PENNASOL MOTOR OIL EXTRA C SAE 40 (*) MONO DIESEL SAE 30 OMV TRUCK SAE 30 OMV TRUCK SAE 40 (*) ORLY DRACO 3001 SAE 30 ORLY DRACO 3001 SAE 40 (*) PAKELO PKO HD 4 SAE 30 PAKELO PKO HD 4 SAE 40 (*) PANOLIN EXTRA DIESEL 30 PANOLIN EXTRA DIESEL 40 (*) DEA CRONOS SUPER SAE 30 ASEOL MONOGRADE CF 30 ASEOL MONOGRADE CF 40 (*) SHELL GADINIA 30 SHELL GADINIA 40 (*) SHELL RIMULA X 30 WINTERSHALL REKORD 30 WINTERSHALL REKORD 40 (*) DIESELWAY 30 DIESELWAY 40 (*)

Page 8 of 14

Continued

STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL YACCO, ST PIERRE LES ELBEUF/F

Page 9 of 14

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

TURBO HD SAE 30 TEBOIL POWER D SAE 30 URSA LA 3 SAE 40 (*) TOTAL RUBIA S 30 ALL FLEET PLUS 30 ALL FLEET PLUS 40 (*) YACCO TRANSPRO MAS3 SAE 30

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02D Gear oil of viscosity grades: SAE 75W-80 / SAE 75W-85 / 75W-90 (semi-synthetic, applicable for Intarder)x x Note: In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 75W-80 are used. x Manufacturer (02D)

Trade name (02D)

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D BUCHER AG LANGENTHAL, LANGENTHAL/CH CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B DE OLIEBRON B.V., ZWIJNDRECHT/NL EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL ITALIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL HUILES BERLIET S.A., SAINT PRIEST/F KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL MAZIVA ZAGREB D.O.O, ZAGREB/HR OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH S.A.E.L., MADRID/E SHELL & DEA OIL GMBH, HAMBURG/D SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F

AUTOL GETRIEBEÖL VSL-4 75W-80 ARAL GETRIEBEÖL SNS SAE 75W-80 MOTOREX PRISMA TF 75W/80 CEPSA TRANSMISIONES FE+LD 75W-80 MULTIGEAR MTF 75W-80W TOR MT/LD GEAR OIL 75W80 MOBILTRANS SHC 30 MOBILUBE XHP 75W-80 TUTELA TRUCK GEARLITE SAE 75W80 TITAN CYTRAC LD 75W-80 YORK 894 75W-80 KENNOCO FLEET TRANSMISSION LUBE ED SAE 75W-80W HRD LONGEVIA 75W-80 Q8 T 60 SAE 75W-80 INA TRANSMOL HD 75W-80 OMV GEAR OIL LDI SAE 75W-80 PAKELO GOLDENGEAR LD SAE 75W/80 PANOLIN TRANSGEAR 75W/80W GULF INTARDER GEAR OIL 75W-80 DEAGEAR LD 75W-80 SHELL TRANSMISSION OIL ZFLD 75W-80 ANTAR LD 75W-80 FINA PONTONIC TI 75W-80 TOTAL TRANSMISSION TI 75W-80 TRANSELF LD 75W-80 GERION LD 75W80

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ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02F ATF in accordance with Group standard ZFN 13015 and special requirements x Manufacturer (02F)

Trade name (02F)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D CALTEX (UK) LIMITED, LONDON/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CHEVRONTEXACO, GHENT/B FL ITALIA S.P.A., VILLASTELLONE/I FL ITALIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL MORRIS LUBRICANTS, SHREWSBURY/GB OMV AG, SCHWECHAT/A PANOLIN AG, MADETSWIL/CH PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PRZEDSIEBIORSTWO MODEX-OIL, KWIDZYN/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL S.A.E.L., MADRID/E SHELL & DEA OIL GMBH, HAMBURG/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZELLER + GMELIN GMBH & CO., EISLINGEN/D

ADDINOL ATF D II D ADDINOL ATF D III ARAL GETRIEBEÖL ATF 55 F-30589 AVIA FLUID ATF 98 CALTEX ATF-HDM CASTROL TQ DEXRON III (F-30520) TEXTRAN PSM TUTELA CAR GI/E TUTELA GI/A TITAN ATF 4000 YORK 686 HRD STARMATIC 3 ATF 420 ATF 430 Q8 AUTO 14 Q8 AUTO 15 LIQUIMATIC SUPER ATF OMV ATF III PANOLIN ATF DEXRON III MERCON V ATF VECO MATIC IID HIPOL ATF II D HIPOL ATF III GULF ATF HIGH TECH DEAFLUID 3003 WINTERSHALL ATF III TEXAMATIC 7045E ELFMATIC G3 FINAMATIC HP TOTAL FLUIDE AT 42 VEEDOL ATF DEXRON III (F-30521) YACCO ATF III DIVINOL FLUID III F

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ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02G Gear oil in accordance with ZF order specification ZFB 864 (ZF number 0671 071 010)x Viscosity grade: SAE 75W (mineral oil-based, not applicable for Intarder)x x Manufacturer (02G)

Trade name (02G)

CHEVRONTEXACO, GHENT/B FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D

MULTIGEAR MTF LT TITAN EG 75 ZF TITAN GEAR ZF

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ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02H Gear oil of viscosity grade: SAE 80W-90x (mineral oil-based, applicable for Intarder)x x Manufacturer (02H)

Trade name (02H)

FL ITALIA S.P.A., VILLASTELLONE/I

TUTELA TRUCK ZC 90 SAE80W-90

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ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.07.2003

Lubricant class 02L Gear oil of viscosity grade: SAE 75W-85x (synthetic, applicable for Intarder)x x Manufacturer (02L)

Trade name (02L)

BP INTERNATIONAL, PANGBOURNE, READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB

BP ENERGEAR SHX 30 CASTROL SYNTRANS VEEDOL SYNMESH

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