ZF Transmission ZF-AS Tronic Bus Repair Manual 1337751101 – PDF DOWNLOAD

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ZF Transmission ZF-AS Tronic Bus Repair Manual 1337751101 – PDF DOWNLOAD

FILE DETAILS:

ZF Transmission ZF-AS Tronic Bus Repair Manual 1337751101 – PDF DOWNLOAD

Language : English
Pages : 89
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

ZF Transmission ZF-AS Tronic Bus Repair Manual 1337751101 – PDF DOWNLOAD

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 prod- uct 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 prod- uct to supervisors and fitters who have had
  their practi- cal and theoretical knowledge updated on a regular basis at our
  Service-Training-Center.

TABLE OF CONTENTS:

ZF Transmission ZF-AS Tronic Bus Repair Manual 1337751101 – PDF DOWNLOAD

Start.................................................................................................. 0
ZF-AS Tronic Bus Repair level 1 - 2.................................................................... 1
Copyright Edition: 2003-09............................................................................. 2
Table of contents...................................................................................... 3
Overview of amendments................................................................................. 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.............................................................................18
1 Maintenance..........................................................................................20
	1.1 Visual inspection of wiring....................................................................20
	1.2 Maintenance of pneumatic system SPEC. NO.......................................................20
	1.3 Type plate.....................................................................................20
	1.4 Approved oil grades............................................................................20
	1.5 Oil volume.....................................................................................20
	1.6 Transmission breather..........................................................................21
	1.7 Oil change intervals...........................................................................21
	1.8 Oil change check (ZF-AS Tronic without ZF-Intarder)............................................21
	1.9 Oil change (ZF-AS Tronic without ZFIntarder)...................................................22
	1.10 Oil level check (transmission with ZFIntarder)................................................23
	1.11 Instruction plate for oil change..............................................................24
	1.12 Oil change (transmission with ZF-Intarder)....................................................24
	1.13 Oil filter change.............................................................................25
	1.14 Oil filling (transmission with ZF-Intarder)...................................................26
	1.15 Engine coolant................................................................................27
	1.16 ZF-Intarder type plate........................................................................27
2 Diagnosis............................................................................................28
	2.1 Diagnosis for vehicles with ZF display and ZF range selector ..................................28
	2.2 Diagnosis with TestmanPro......................................................................29
	Transmission actuator data sheet 20-pin............................................................30
	Pin assignment.....................................................................................31
	Transmission actuator data sheet 18-pin............................................................32
3 Component replacement................................................................................33
	3.1 Transmission actuator..........................................................................33
		3.1.2 Fitting..................................................................................35
		3.1.3 Dismantling transmission actuator........................................................38
		3.1.4 Assembling transmission actuator.........................................................38
		3.1.5 Programming transmission actuator........................................................39
		3.1.6 Replacing pressure limitation valve......................................................39
	3.2 Clutch actuator................................................................................40
		3.2.1 Removal..................................................................................40
		3.2.2 Fitting..................................................................................41
	3.3 Replacement of driver disc (not ZF scope of supply)............................................43
	3.4 Clutch release mechanism.......................................................................44
		3.4.2 Fitting release fork.....................................................................45
	3.5 Output flange..................................................................................46
		3.5.3 Removing output cover....................................................................47
		3.5.5 Removing yoke............................................................................48
	3.6 Speed sensor (impulse sensor), output, depends on vehicle manufacturer.........................49
	3.7 Replacing neutral switch*......................................................................50
	3.8 Replacing components on Intarder...............................................................51
		3.8.5 Removing 3/2-way valve...................................................................52
	3.9 Additional cooling connection..................................................................53
	3.10 Display.......................................................................................54
	3.11 Range selector................................................................................55
		3.11.2 Steering wheel switch*..................................................................56
		3.11.3 Range selector keypad...................................................................57
	3.12 Electronic control unit.......................................................................58
		3.12.2 ZMTEC...................................................................................59
	ZMTEC pin assignment...............................................................................60
	Component replacement..............................................................................61
	Component replacement / pneumatics diagram.........................................................62
Annex..................................................................................................63
	How to display and delete error memory.............................................................64
	ZF range selector keypad:..........................................................................65
	Measurements on CAN BUS with digital multimeter Measurements on CAN BUS with digital multimeter....66
	SERVICE INFORMATION................................................................................68
	List of lubricants TE-ML 02........................................................................71
	Programming Instruction for TestmanPro.............................................................85
Drawings............................................................................................... 0
Removal / Installation Instructions.................................................................... 0

Contact us: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V