ZF Transmission ZF-AS Tronic Trucks Repair Level 1-2 Repair Manual 1327751101a – PDF DOWNLOAD

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ZF Transmission ZF-AS Tronic Trucks Repair Level 1-2 Repair Manual 1327751101a – PDF DOWNLOAD

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ZF Transmission ZF-AS Tronic Trucks Repair Level 1-2 Repair Manual 1327751101a – PDF DOWNLOAD

Language : English
Pages : 96
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

ZF Transmission ZF-AS Tronic Trucks Repair Level 1-2 Repair Manual 1327751101a – 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 Trucks Repair Level 1-2 Repair Manual 1327751101a – PDF DOWNLOAD

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
Drawing...............................................................................72
	0501 210 059......................................................................72
	0501 210 854......................................................................73
	0501 211 185......................................................................74
	0501 211 422......................................................................75
	1327 600 015......................................................................76
	1327 600 016......................................................................77
	1328 600 015......................................................................78
	1328 600 016......................................................................79
	1328 600 019......................................................................80
	6006 629 024......................................................................81
	6006 700 579......................................................................82
	6006 700 586......................................................................83
	6029 713 016......................................................................84
	6029 713 021......................................................................86
	6029 713 022......................................................................88
	6029 713 025......................................................................90
	6041 622 023......................................................................92
	6090 601 031......................................................................93
	6090 604 024......................................................................94
	6091 610 003......................................................................95
	6091 615 007......................................................................96

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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