ZF AS Tronic & AS Tronic Mid Technical Manual 1328 765 101g PDF

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ZF AS Tronic & AS Tronic Mid Technical Manual 1328 765 101g – PDF DOWNLOAD

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ZF AS Tronic & AS Tronic Mid Technical Manual 1328 765 101g – PDF DOWNLOAD

Language : English
Pages : 176
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

ZF AS Tronic & AS Tronic Mid Technical Manual 1328 765 101g – PDF DOWNLOAD

Start Service CD 0
Technical Manual for Installation, Function, and Initial Start-Up ZF-ASTronic ZF-ASTronic mid 1
Copyright by ZF 2
Preface 3
List of Chapters 5
Table of Contents 6
Documents to which reference is made 13
List of Abbreviations 14
Overview of Amendments: 1328 765 101 15
1 Brief Description of the ZF-AS Tronic 19
1 1 General 19
1 2 Interfaces 20
2 Transmission System and its Components 25
2 1 System Design 25
2 2 Transmission and Shift System 26
2 2 1 Description of Transmission 26
2 2 2 Description of Shift System 28
2 2 3 Overview of Product Families 29
2 2 4 Trucks Product Family 1: 12-Speed / Direct Drive 30
2 2 5 Trucks Product Family 1: 12-Speed / Overdrive 31
2 2 6 Trucks Product Family 2: 12-Speed / Direct Drive 32
2 2 7 Trucks Product Family 2: 12-Speed / Overdrive 33
2 2 8 Trucks Product Family 3: 12-Speed / Direct Drive 34
2 2 9 Trucks Product Family 3: 12-Speed / Overdrive 35
2 2 10 Truck Product Family 3: 16-Speed / Direct Drive 36
2 2 11 Trucks Product Family 3: 16-Speed / Overdrive 37
2 2 12 Trucks Product Family 4: 12-Speed / Direct Drive 38
2 2 13 Trucks Product Family 4: 12-Speed / Overdrive 39
2 2 14 BUS: 12-Speed / Overdrive 40
2 2 15 BUS: 10-Speed / Direct Drive 41
2 2 16 BUS: 10-Speed / Overdrive 42
2 3 Transmission Components 43
2 3 1 Transmission Actuator 43
2 3 2 Clutch Actuator 44
2 4 Peripheral Components 45
2 4 1 ZF Selector Lever With Integrated E-Module and Additional ZF Extension Module 45
2 4 1 1 ZF selector lever with integrated E-module 45
2 4 1 2 ZF Extension Module 46
2 4 2 ZF Range Selector Module + ZF Extension Module 47
2 4 2 1 ZF Range Selector Module 47
2 4 2 2 ZF Extension Module 47
2 4 3 Display 48
2 5 Auxiliaries 51
2 5 1 Intarder 51
2 5 1 1 General 51
2 5 1 2 Mechanical Interface 51
2 5 1 3 Oil Grade and Oil Fill 51
2 5 1 4 Coolant Connection 51
2 5 1 5 Pneumatic Interface 51
2 5 1 6 Electrical Interface 52
2 5 1 7 Communication Interface 52
2 5 1 8 Speedo Signal 52
2 5 2 PTOs 52
2 5 2 1 Clutch-Dependent PTOs 52
2 5 2 2 Vehicle Driven PTOs 53
2 5 2 3 Engine-Dependent PTOs 53
2 5 2 4 Retrofitting 53
3 Function Description 57
3 1 Basic Function 57
3 1 1 Shift Engagement Characteristics / Ignition On 58
3 1 2 Gear Selection With Vehicle Stationary 58
3 1 2 1 Shifting from Neutral 58
3 1 2 2 Shifting From One Gear to Another 58
3 1 2 3 Shifting to Neutral 58
3 1 3 Setting Off 59
3 1 4 Gear Selection during Travel 61
3 1 4 1 Upshifts 61
3 1 4 2 Downshifts 62
3 1 5 Maneuvering 62
3 1 6 Protective Functions 64
3 1 6 1 Engine Protection Function 64
3 1 6 2 Clutch Overload Protection 64
3 1 7 Activating PTOs 65
3 1 7 1 Engaging PTO 65
3 1 7 2 Disengaging PTO 65
3 1 8 Ignition Off 66
3 2 Automatic Drive Program 67
3 2 1 Activating Automatic Drive Program 68
3 2 2 Automatic Selection of Setting Off Gear 68
3 2 3 Automatic Gear Change 68
3 2 4 Deactivating Automatic Drive Program 70
3 3 ZF-AS Tronic Malfunction Concept 71
3 3 1 Principles 71
3 3 2 System Analyses Undertaken 71
3 3 3 Clutch Actuator Concept 72
3 3 4 Transmission Control Unit Concept 72
3 3 5 Interface Concept 73
3 3 6 Driving Modes Investigated 73
3 4 Error Responses 74
3 5 Diagnosis 75
3 5 1 Error Memory 75
3 5 2 On-Board Diagnosis 75
3 5 3 Off-Board Diagnosis 75
4 Installation 81
4 1 Transmission Installation Investigation 81
4 1 1 Standard Transmission Installation Drawings 81
4 1 2 PTO + Emergency Steering Pump Installation Drawings 81
4 1 3 Input Shafts 81
4 1 4 Clutch Bell Housing 82
4 1 5 Clutch 82
4 1 6 Clutch Release Unit 84
4 1 7 Engine Connection 85
4 1 8 Suspension 86
4 1 9 Transmission Installation Angle 89
4 1 10 Propshaft Connection 90
4 1 11 Torsional vibrations 94
4 1 11 1 Permissible vibrations at transmission input 94
4 1 11 2 Uniformity of rotation 94
4 1 12 Bending Vibrations 95
4 1 13 Cover / Protective Floor Panels 95
4 1 14 Additional Brackets 95
4 1 15 Fording Ability 95
4 1 16 Accessibility 96
4 1 17 Additional Guidelines for Vehicle Body Manufacturer 97
4 1 18 Vehicle Wiring 97
4 2 Temperatures 98
4 2 1 Permissible Ambient Temperatures on Transmission 98
4 2 2 Permissible Oil Temperatures 98
4 2 3 Causes of Excess Oil Temperatures 98
4 2 4 Additional Transmission Cooling 99
4 2 5 Use in Sub-Zero Temperatures 100
4 2 6 Storing the Transmission 100
4 3 Filling With Oil 101
4 3 1 Oil Grade and Oil Change Interval 101
4 3 2 Oil Fill Quantity 101
4 3 3 Draining the Oil 102
4 3 4 Filling With Oil 102
4 3 5 Oil Level Check 102
4 3 6 General Information 103
4 3 7 Information about Bleeding the Transmission 103
4 3 8 Venting by Means of Hose Line in Dry Compartment 104
4 4 Electrics 105
4 4 1 System Layout and Circuit Diagrams 105
4 4 2 Description of Connectors 106
4 4 2 1 Connector on Transmission 106
4 4 2 2 Power Supply Connector to Vehicle 107
4 4 3 Power Supply Voltages 108
4 4 4 CAN Bus Installation 109
4 4 5 Quality Requirements of Wiring 111
4 4 6 Connector and Mating Connector Designations 112
4 4 7 Other Electrical Interfaces on the ZF-AS Tronic 113
4 4 7 1 Neutral Switch 113
4 4 7 2 Speedo Sensor 113
4 4 8 CAN Signals 114
4 4 9 EMC Compatibility 114
4 5 Pneumatics 115
4 6 Auxiliaries 117
4 6 1 ZF-Intarder 117
4 6 2 Third Party Retarder 117
4 6 3 ZF Power Take Off Units (PTOs) 117
4 6 4 Third Party PTOs 118
4 6 5 Heat Exchanger 118
4 7 Transmission Installation on Assembly Belt 118
4 7 1 Transport 118
4 7 2 Supplying the Main Transmission 119
4 7 3 Corrosion Protection 119
4 7 4 Subsequent Paintwork 119
4 7 5 Assembly of Engine, Clutch, and Transmission 119
4 7 6 EOL Programming 120
4 7 7 Delivery Check 121
4 8 Additional Information 122
4 8 1 Operation 122
4 8 1 1 Starting Engine 122
4 8 1 2 Setting Off, Forward Travel 123
4 8 1 3 Maneuvering 123
4 8 1 3 1 Maneuvering via the accelerator pedal with rotary switch in D or R position 123
4 8 1 3 2 Maneuvering acc to rotary switch position DM or RM 124
4 8 1 4 Moving off Downhill 124
4 8 1 5 Changing Operating Mode: Manual / Automatic 124
4 8 1 6 Changing Gear 125
4 8 1 7 Reverse Travel 125
4 8 1 8 Engine Brake 126
4 8 1 9 Stopping 126
4 8 1 10 Switching Off Engine / Stopping Vehicle 126
4 8 1 11 Towing 126
4 8 1 12 Tow Starting 127
4 8 1 13 Clutch Protection 127
4 8 1 14 Engine Overspeed Protection 128
4 8 1 15 Operations with Clutch-Driven PTO 128
4 8 1 16 Roller test rig 129
4 8 1 17 System Faults (Error Messages) 129
4 8 2 Maintenance 130
4 8 2 1 Visual Inspection of Wiring 130
4 8 2 2 Maintenance of Pneumatic System 130
4 8 3 Vehicle Handover to End Customer 130
4 9 Application and Documentation 131
4 9 1 Application 131
4 9 2 ZF Documentation 131
4 9 3 Type Plate 131
4 9 4 Explanation for ZF Documentation 132
5 Annex 135
5 1 Designations for AS Transmission 135
5 2 AS Transmission Program 136
5 2 1 AS Transmission Program for Trucks 136
5 2 2 AS Transmission Program for Buses 137
5 2 3 AS Transmission Program for Special Applications 137
5 2 4 AS Transmission Program for Rail Vehicles 137
5 3 Attached Documents 138
Drawings 0
0501 210 854b 139
0501 211 422e 140
0501 214 767 141
0501 215 297 142
1327 600 007f 143
1327 600 015e 144
1327 600 016f 145
1328 600 015f 146
1328 600 016g 147
1328 600 019 148
1328 600 038b 149
1328 600 043 150
1336 600 019a 151
1336 600 020a 152
1336 600 021a 153
1336 600 022a 154
6006 629 032 155
6006 639 002a 156
6029 713 025a, Sheet 1 157
6029 713 025a, Sheet 2 158
6029 713 157, Sheet 1 159
6029 713 157, Sheet 2 160
6029 713 158, Sheet 1 161
6029 713 158, Sheet 2 162
6029 713 163, Sheet 1 163
6029 713 163, Sheet 2 164
6029 713 166, Sheet 1 165
6029 713 166, Sheet 2 166
6041 622 026b 167
6090 601 031 168
6090 601 045a 169
6090 604 024 170
6090 604 036a 171
6091 610 003e 172
6091 611 001b, Sheet 1 173
6091 611 001b, Blatt 2 174
6091 615 007 175
6091 618 001 176

S.V 08/24