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

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

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

Language : English
Pages : 71
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

Start Service CD 0
REPAIR MANUAL ZF-AS Tronic 1
Trucks Repair level 1 – 2 1
1327 751 101a 1
Copyright Edition: 2003-05 2
Table of contents 3
Overview of amendments: 1327 751 101 5
Preface 6
Important information 7
Instructions for carrying out repairs 8
Tightening torques 10
Changing from DIN to ISO standard codes 12
Test device diagnosis tool 14
ZF-Intarder diagnosis tool 19
1 Maintenance 21
1 1 Visual inspection of wiring 21
1 2 Maintenance of pneumatic system 21
1 3 Type plate 21
1 4 Approved oil grades 21
1 5 Oil volume 21
1 6 Transmission breather 22
1 7 Oil change intervals 22
1 8 Oil change check (ZF-AS Tronic without ZF-Intarder) 22
1 9 Oil change (ZF-AS Tronic without ZFIntarder) 23
1 10 Oil level check (transmission with ZFIntarder) 24
1 11 Instruction plate for oil change 25
1 12 Oil change (transmission with ZF-Intarder) 25
1 13 Oil filter change 26
1 14 Oil filling (transmission with ZF-Intarder) 27
1 15 Engine coolant 28
1 16 ZF-Intarder type plate 28
2 Diagnosis 29
2 1 Diagnosis for vehicles with ZF display and ZF range selector 29
2 2 Diagnosis with TestmanPro 30
3 Component replacement 32
3 1 Transmission actuator 32
3 1 1 Removing transmission actuator 32
3 1 2 Fitting 34
3 1 3 Dismantling transmission actuator 36
3 1 4 Assembling transmission actuator 36
3 1 5 Programming transmission actuator 37
3 2 Clutch actuator 38
3 2 1 Removal 38
3 2 2 Push rod 39
3 2 3 IVECO push rod setting 40
3 2 4 Fitting 41
3 3 Replacement of driver disc (not ZF scope of supply) 43
3 3 1 Fitting engine, clutch and transmission 43
3 4 Clutch release mechanism 44
3 4 1 Removal of release fork 44
3 4 2 Fitting release fork 45
3 5 Output flange 46
3 5 1 Removal 46
3 5 2 Fitting 46
3 5 3 Removing output cover 47
3 6 Speed sensor (impulse sensor), output, depends on vehicle manufacturer 48
3 6 1 Removal 48
3 6 2 Fitting 48
3 6 3 Connector replacement 48
3 7 Replacing neutral switch* 49
3 7 1 Removal 49
3 7 2 Fitting 49
3 8 Replacing components on Intarder 50
3 8 1 Speed sensor, output 50
3 8 2 Tacho sensor 50
3 8 3 Solenoid valve 50
3 8 4 Temperature sensor 50
3 8 5 Removing 3/2-way valve 51
3 8 6 Removing / fitting Intarder wiring harness 51
3 9 Additional cooling connection 52
3 10 Display 53
3 10 1Disassembly 53
3 10 2Installation 53
3 10 3Connection diagram 53
3 10 4Connector replacement 53
Documents attached 54
Component replacement / connector and mating connector designations 55
Component replacement / pneumatics diagram 56
List of lubricants TE-ML 02 58
List of lubricants TE-ML 02 www 0

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