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ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual 1337751101b – PDF DOWNLOAD
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ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual 1337751101b – PDF DOWNLOAD
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Description
ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual 1337751101b – PDF DOWNLOAD
FILE DETAILS:
ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual 1337751101b – PDF DOWNLOAD
Language : English
Pages : 128
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual 1337751101b – PDF DOWNLOAD
Preface:
- This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products. - This manual deals with the standard ZF product in accordance with the state of development on the date of
issue. - However, due to continuing development of the product, repair work might require work practices and test or
adjustment data which are not contained in this manual. - We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on
a regular basis at our After-Sales Service training courses.
Service points equipped by ZF Friedrichshafen AG all over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. specialized tools
3. Genuine ZF spares, to our latest specifications
- All work performed in these service points is carried out conscientiously and with care.
TABLE OF CONTENTS:
ZF Transmission ZF-AS Tronic Bus Maintenance, Diagnosis, Component Replacement Repair Manual 1337751101b – PDF DOWNLOAD
Repair Manual ZF-AS Tronic Bus.................................................. 1 Maintenance, Diagnosis,Component Replacement................................ 1 Repair Level 1 - 2.......................................................... 1 Copyright................................................................... 2 Table of Contents........................................................... 3 List of Changes: 1337 751 101............................................... 5 Preface..................................................................... 6 Safety Instructions......................................................... 7 Instructions for Repairs.................................................... 8 Tightening torques.......................................................... 10 Conversion Factors.......................................................... 11 Special Tools............................................................... 13 Diagnosis Tools............................................................. 15 ZF-Intarder Diagnosis Tools................................................. 18 Maintenance..................................................................... 21 General Maintenance......................................................... 21 Visual Inspection of Wiring................................................. 21 Pneumatic System Maintenance................................................ 21 Clutch Actuator and Transmission Actuator................................... 21 Transmission Bleeding....................................................... 22 For oil changes, please note the following.................................. 23 Approved Oil Grades......................................................... 24 Oil Volume.................................................................. 24 Oil-Change Intervals........................................................ 24 Oil fill quantities ZF-AS Tronic Bus........................................ 24 Oil Change (ZF-AS Tronic Without ZF-Intarder)............................... 25 Filling Oil............................................................. 25 Oil-Level Check(ZF-AS Tronic Without ZF-Intarder)....................... 26 Type Plate.............................................................. 26 Oil Change (ZF-AS Tronic With ZF-Intarder).................................. 27 Oil Filter Replacement.................................................. 28 Oil Filling (ZF-AS Tronic With ZF-Intarder)............................. 29 Oil Filling in Case of Oil Change....................................... 29 Oil Filling After Transmission Repair................................... 29 Oil-Level Check (ZF-AS Tronic With ZF-Intarder)......................... 30 Visual Inspection........................................................... 30 Engine Coolant.............................................................. 31 ZF-Intarder Type Plate...................................................... 31 Diagnosis....................................................................... 32 Diagnosis on Vehicles with ZF Display and ZF Range Selector................. 32 Diagnosis With Testman pro.................................................. 33 Data Sheet: 20-pin Transmission Actuator.................................... 34 Pin Assignment.............................................................. 35 Data Sheet: 18-pin transmission actuator.................................... 36 Transmission Actuator........................................................... 37 Removing Transmission Actuator.............................................. 37 Removing the Upper Section from the Lower Section........................... 39 Reattaching the Upper Section to the Lower Section.......................... 39 Mounting Transmission Actuator.............................................. 40 Replacing Pressure Relief Valve............................................. 43 Programming Transmission Actuator........................................... 44 Clutch Actuator................................................................. 45 Removing Clutch Actuator.................................................... 45 Clutch Actuator Maintenance................................................. 46 Bleeding and Assembling Clutch Actuator..................................... 47 Replace Clutch.............................................................. 49 Clutch Release Mechanism........................................................ 50 Removing Release Fork....................................................... 50 Version A: Release fork with cams....................................... 50 Version B: Release fork with cam rollers................................ 51 Mounting Release Fork....................................................... 52 Version A: Clutch release mechanism with cams........................... 52 Version B: Release fork with cam rollers................................ 53 Output Flange................................................................... 55 Removing the Output Flange.................................................. 55 Mounting the Output Flange.................................................. 55 Removing the Yoke........................................................... 56 Mounting the Yoke........................................................... 56 Output Cover.................................................................... 57 Removing the Output Cover................................................... 57 Mounting the Output Cover................................................... 57 Impulse sensor.................................................................. 58 Output impulse sensor (speed sensor)........................................ 58 Remove impulse sensor....................................................... 58 Fit impulse sensor.......................................................... 58 Connector Replacement....................................................... 58 Neutral switch.................................................................. 59 Replacing Neutral Switch.................................................... 59 Remove Neutral switch....................................................... 59 Install Neutral switch...................................................... 59 Intarder........................................................................ 60 Replace Intarder Components................................................. 60 Output Speed Sensor......................................................... 60 Speedo Sensor............................................................... 60 Solenoid Valve.............................................................. 60 Temperature Sensor.......................................................... 60 Removing 3/2 Directional Valve (accumulator charge valve)................... 61 Mounting 3/2 Directional Valve.............................................. 61 Removing Intarder Cable Harness............................................. 61 Mounting Intarder Cable Harness............................................. 61 Additional Cooling.............................................................. 62 Assembling the Valve Block of the Additional Cooling Unit................... 62 ZF Display...................................................................... 63 Removal..................................................................... 63 Installation................................................................ 63 Wiring Diagram.............................................................. 63 Connector Assignment........................................................ 63 Connector Replacement....................................................... 63 Range selector.................................................................. 64 Console-type range selector................................................. 64 Removal................................................................. 64 Installation............................................................ 64 Connector Replacement................................................... 64 Steering-column switch...................................................... 65 Removal................................................................. 65 Installation............................................................ 65 Connector Replacement................................................... 65 Pushbutton Range Selector................................................... 66 Removal................................................................. 66 Installation............................................................ 66 Connector Replacement................................................... 66 ZF Lever-Type Range Selector................................................ 68 Electronic Control Unit......................................................... 69 E-module.................................................................... 69 Removal................................................................. 69 Installation............................................................ 69 Connector Replacement................................................... 69 E-module 2.................................................................. 70 Removal................................................................. 70 Installation............................................................ 70 Connector Replacement................................................... 70 ZMTEC....................................................................... 71 Removal................................................................. 71 Installation............................................................ 71 Connector Replacement................................................... 71 ZMTEC pin assignment.................................................... 72 Wiring.......................................................................... 73 Type Designations and Order Numbers......................................... 73 Pneumatic Diagram............................................................... 74 Annex........................................................................... 75 Attached Documents.......................................................... 75 1337 754 101 - ZF-AS Tronic............................................. 76 How to display and delete error memory.............................. 76 1337 754 105 - ZF-AS Tronic............................................. 77 ZF range selector keypad: How to display and delete error memory.... 77 CAN BUS Measurements With Digital Multimeter............................ 78 Checklist AS Tronic / AS Tronic mid..................................... 79 Checklist AS Tronic 2 / AS Tronic mid North America..................... 84 Programming Instruction for Testman Pro................................. 88 SERVICE INFORMATION Nr. 26_05........................................... 93 SERVICE INFORMATION Nr. 08_06c.......................................... 97 Attached Drawings........................................................... 75 0501 210 854d...........................................................103 0501 211 185a...........................................................104 0501 211 422e...........................................................105 0501 320 211............................................................106 6041 322 045d...........................................................107 6041 622 023d...........................................................108 1327 600 007i...........................................................109 1328 600 019............................................................110 1328 600 043............................................................111 6006 629 024............................................................112 6006 700 579c...........................................................113 6006 700 586a...........................................................114 0501 214 599............................................................115 6029 713 148a...........................................................116 Blatt 2.............................................................117 6006 639 003a...........................................................118 6029 713 149............................................................119 Blatt 2.............................................................120 6029 713 168............................................................121 Blatt 2.............................................................122 6029 711 038a...........................................................123 6029 713 025b...........................................................124 Blatt 2.............................................................125
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