ZF-FreedomLine Transmission Maintenance & Diagnostics Manual MM-0150 – PDF DOWNLOAD

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ZF-FreedomLine Transmission Maintenance & Diagnostics Manual MM-0150 – PDF DOWNLOAD

FILE DETAILS:

ZF-FreedomLine Transmission Maintenance & Diagnostics Manual MM-0150 – PDF DOWNLOAD

Language : English
Pages : 192
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

ZF-FreedomLine Transmission Maintenance & Diagnostics Manual MM-0150 – PDF DOWNLOAD

USING THIS MAINTENANCE MANUAL:

• This maintenance manual addresses maintenance, diagnostics and use issues that owners and users of
  ZF-FreedomLine transmissions may encounter. It is not intended as a discussion of every issue that
  may arise in those contexts but is illustrative of certain information that might be considered in
  conjunction with installation, maintenance, repair and use of the subject transmissions.
• Owners and users of ZF-FreedomLine transmissions are responsible for familiarizing themselves with
  the content of this maintenance manual and using the information (and following the warnings)
  contained herein for any function or condition covered. They are also responsible for communicating
  the information contained in this maintenance manual to any persons performing installation,
  maintenance or repair services with respect to the subject transmissions. Correct maintenance,
  diagnostics and use of the subject transmissions, and observance of the suggestions and directives
  contained in this maintenance manual, are integral requirements of continued warranty coverage for
  the subject transmissions.
• This maintenance manual is provided under the following limitations, restrictions and disclaimers,
  which are applicable to any person or entity using or relying on the same, as a condition to such
  usage or reliance:
• THESE MATERIALS PROVIDE SUGGESTIONS, AS WELL AS CERTAIN REQUIREMENTS, WITH RESPECT TO THE
  INSTALLATION, MAINTENANCE, REPAIR AND USAGE OF ZF-FREEDOMLINE TRANSMISSIONS.
  INSTALLATION, MAINTENANCE, REPAIR AND USAGE OF THE SUBJECT TRANSMISSIONS IS SOLELY THE
  RESPONSIBILITY OF THE OWNERS AND USERS OF THE SUBJECT TRANSMISSIONS, AND IMPROPER OR INCORRECT ACTIONS OR OMISSIONS IN THAT REGARD ARE NOT THE RESPONSIBILITY OF
  ZF FRIEDRICHSHAFEN AG.

TABLE OF CONTENTS:

ZF-FreedomLine Transmission Maintenance & Diagnostics Manual MM-0150 – PDF DOWNLOAD

Regulatory Guidance i
Model Numbers and Ratios ii
12-Speed ZF-FreedomLine
16-Speed ZF-FreedomLine
Torque Specifications iii
ZF-FreedomLine Fasteners Tightening Torque
Acronyms iv
Acronyms Referenced in Manual
Section 1: Introduction 1
ZF-FreedomLine Automated Two-Pedal Transmission
Features
ZF-FreedomLine Transmissions Use a Self-Adjusting Integral Clutch
Clutch Features
How the Clutch Operates
Tools Used in This Manual
Approved Oil Lubricant Specifications for ZF-FreedomLine Transmissions 2
Recommended Preventive Maintenance
ZF-FreedomLine Transmissions Fluid Capacities
How to Identify a ZF-FreedomLine Transmission
Shift Module and Joystick
NEUTRAL Button
FUNCTION Button 3
Shift-n-CruiseTM Speed Control
Instrument Panel and Shift Module Displays
Instrument Panel Display
System Malfunction Warning 4
What to do if a System Malfunction Occurs
System Self-Check Status
System Air is Low
Clutch Overload Status
Clutch Wear Warning
How to Shift the Transmission 5
Automatic Mode
Manual Mode
Parking a Vehicle 6
Shift Labels
Section 2: Fault Code Diagnostics 7
Before You Make a Warranty Repair on a ZF-FreedomLine Transmission
Fault Codes and Volt-Ohm Meter (VOM) Diagnostics
Fault Codes
How to Retrieve Active and Inactive SAE and ISO Fault Codes from the Instrument Panel Display
Using the ZF-FreedomLine Shifter
Active SAE and ISO Fault Codes
Inactive Fault Codes 8
To View Active or Inactive Fault Codes Again
How to Clear Inactive Fault Codes from TCU Memory
How to Retrieve Active and Inactive SAE and ISO Fault Codes from the Instrument Panel Display
Using a Steering Column-Mount Shift Lever
Active Fault Codes
Inactive Fault Codes
Table of Contents
How to Clear Inactive Fault Codes from the Instrument Panel Display Using a Steering
Column-Mount Shift Lever 9
How to Retrieve Active and Inactive ISO Fault Codes from the Instrument Panel Display
Using an SAE J1939 Push-Button Shift Lever
Active ISO Fault Codes
Inactive ISO Fault Codes
How to Clear Inactive Fault Codes from the Instrument Panel Display Using an SAE J1939
Push-Button Shift Lever
SAE Fault Code Repair Instructions 11
ISO Fault Code Diagnostics 27
Section 3: Maintenance 53
Release Fork Greasing Procedure (Standard and Roller Fork Applications)
SAE J1939 Requirements Flowchart 60
Electrical Requirements Flowchart 62
Pneumatic Requirements Flowchart 74
No-Start Troubleshooting Flowchart 80
PTO Requirements Flowchart 91
Section 4: Wiring/Pneumatic Diagrams 92
Resistance Specifications
Diagnostic Connector
Connector Pin Assignments
Section 5: Removal and Installation 95
Transmission
Clutch 110
Voltage Doubler 117
ZF-FreedomLine Transmission Electronic Controller (ZMTEC) 119
Transmission Yoke 121
Output Shaft Seal 125
Input Shaft Seal 127
Output Cover 128
Air Filter Regulator 130
TCU Top Half/Top Cover 131
Transmission Control Unit (TCU) 138
Shift Rail/TCU Cylinder Adjustments for Installation 145
Adjust the Cylinder Pistons
Selector Cylinder 146
Travel Sensors Engage, Splitter, Range and Select 151
Air Pressure Sensor 152
Transmission Wiring Harness Assembly 160
Cooler By-Pass Valve 166
Neutral Switch 169
Output Shaft Speed Sensor 171
Clutch Actuator Housing and Wiring Harness 173
Release Bearing 180

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