ZF Transmission ZF-AS Tronic & ZF-AS Tronic mid Technical Manual 1328765101h – PDF DOWNLOAD

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ZF Transmission ZF-AS Tronic & ZF-AS Tronic mid Technical Manual 1328765101h – PDF DOWNLOAD

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ZF Transmission ZF-AS Tronic & ZF-AS Tronic mid Technical Manual 1328765101h – PDF DOWNLOAD

Language : English
Pages : 176
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

ZF Transmission ZF-AS Tronic & ZF-AS Tronic mid Technical Manual 1328765101h – PDF DOWNLOAD

Preface:

ZF-AS Tronic and ZF-AS Tronic mid are automatic transmission systems.
To avoid
• Damage or failure of the transmission and vehicle,
• Functional limitations for the transmission system,
• Limitations in terms of operating quality,
the details on the function, installation, and initial start-up of the transmission system MUST be
noted.

This technical manual serves as a technical guide for the ZF-AS Tronic system for both vehicle and
vehicle body manufacturers as well as ZF staff.

This manual describes the standard ZF application. Customer-specific deviations must be agreed on
in writing with ZF.
A ZF-AS Tronic application contains the following stages:

• Writing of customer specification for the trans- mission system by vehicle manufacturer and ZF,
• Documentation by ZF,
• Initial installation,
• First installation check and initial setup by ZF staff,
• Approval on the basis of the customer specifica-
tion and parts list.

TABLE OF CONTENTS:

ZF Transmission ZF-AS Tronic & ZF-AS Tronic mid Technical Manual 1328765101h – PDF DOWNLOAD

Technical Manual ZF-AS Tronic, ZF-AS Tronic mid..........................................................  1
	Copyright by ZF......................................................................................  2
	Preface..............................................................................................  3
	List of Chapters.....................................................................................  5
	Table of Contents....................................................................................  6
	List of Documents.................................................................................... 13
	List of Abbreviations................................................................................ 14
	Overview of Amendments: 1328 765 101................................................................. 15
1 Brief Description of the ZF-ASTronic................................................................... 17
	1.1 General.......................................................................................... 19
	1.2 Interfaces....................................................................................... 20
2 Transmission System and its Components................................................................. 23
	2.1 System Design.................................................................................... 25
	2.2 Transmission and Shift System.................................................................... 26
		2.2.1 Description of Transmission................................................................ 26
		2.2.2 Description of Shift System................................................................ 28
		2.2.3 Overview of Product Families............................................................... 29
		2.2.4 PF1: Technical Data 12-Speed / Direct Drive................................................ 30
		2.2.5 PF1: Technical Data 12-Speed / Overdrive................................................... 31
		2.2.6 PF2: Technical Data 12-Speed / Direct Drive................................................ 32
		2.2.7 PF2: Technical Data 12-Speed / Overdrive................................................... 33
		2.2.8 PF3: Technical Data 12-Speed / Direct Drive................................................ 34
		2.2.9 PF3: Technical Data 12-Speed / Overdrive................................................... 35
		2.2.10 PF3: Technical Data 16-Speed / Direct Drive............................................... 36
		2.2.11 PF3: Technical Data 16-Speed / Overdrive.................................................. 37
		2.2.12 PF4: Technical Data 12-Speed / Direct Drive............................................... 38
		2.2.13 PF4: Technical Data 12-Speed / Overdrive.................................................. 39
	2.3 Transmission Components.......................................................................... 40
		2.3.1 Transmission Actuator...................................................................... 40
		2.3.2 Clutch Actuator............................................................................ 41
	2.4 Peripheral Components............................................................................ 42
		2.4.1 ZF Selector Lever With Integrated E-Module and Additional ZF Extension Module.............. 42
			2.4.1.1 ZF selector lever with integrated E-module........................................... 42
			2.4.1.2 ZF Extension Module.................................................................. 44
		2.4.2 ZF Range Selector Module + ZF Extension Module............................................. 45
			2.4.2.1 ZF Range Selector Module............................................................. 45
			2.4.2.2 ZF Extension Module.................................................................. 45
		2.4.3 Display.................................................................................... 46
			OPERATING DISPLAYS........................................................................... 46
			WARNING INFORMATION.......................................................................... 47
			SYSTEM ERROR................................................................................. 48
	2.5 Auxiliaries...................................................................................... 49
		2.5.1 Intarder................................................................................... 49
			2.5.1.1 General.............................................................................. 49
			2.5.1.2 Mechanical Interface................................................................. 49
			2.5.1.3 Oil Grade and Oil Fill............................................................... 49
			2.5.1.4 Coolant Connection................................................................... 49
			2.5.1.5 Pneumatic Interface.................................................................. 49
			2.5.1.6 Electrical Interface................................................................. 50
			2.5.1.7 Communication Interface.............................................................. 50
			2.5.1.8 Speedo Signal........................................................................ 50
		2.5.2 PTOs....................................................................................... 50
			2.5.2.1 Clutch-Dependent PTOs................................................................ 50
			2.5.2.2 Vehicle Driven PTOs.................................................................. 51
			2.5.2.3 Engine-Dependent PTOs................................................................ 51
			2.5.2.4 Retrofitting......................................................................... 51
3 Description of Function................................................................................ 53
	3.1 Basic Function................................................................................... 55
		3.1.1 Shift Engagement Characteristics / Ignition On............................................. 56
		3.1.2 Gear Selection With Vehicle Stationary..................................................... 56
			3.1.2.1 Shifting from Neutral................................................................ 56
			3.1.2.2 Shifting From One Gear to Another.................................................... 56
			3.1.2.3 Shifting to Neutral.................................................................. 56
		3.1.3 Setting Off................................................................................ 57
		3.1.4 Gear Selection during Travel............................................................... 59
			3.1.4.1 Upshifts............................................................................. 59
			3.1.4.2 Downshifts........................................................................... 60
		3.1.6 Protective Functions....................................................................... 62
			3.1.6.1 Engine Protection Function........................................................... 62
			3.1.6.2 Clutch Overload Protection........................................................... 62
		3.1.7 Control of PTOs............................................................................ 63
			3.1.7.1 PTO Activation....................................................................... 63
			3.1.7.2 PTO Deactivation..................................................................... 64
		3.1.8 Ignition Off............................................................................... 64
	3.2 Automatic Drive Program.......................................................................... 65
		3.2.1 Activating Automatic Drive Program......................................................... 66
		3.2.2 Automatic Selection of Setting Off Gear.................................................... 66
		3.2.3 Automatic Gear Change...................................................................... 66
		3.2.4 Deactivating Automatic Drive Program....................................................... 68
	3.3 ZF-AS Tronic Malfunction Concept................................................................. 69
		3.3.1 Principles................................................................................. 69
		3.3.2 System Analyses Undertaken................................................................. 69
		3.3.3 Clutch Actuator Concept.................................................................... 70
		3.3.4 Transmission Control Unit Concept.......................................................... 70
		3.3.5 Interface Concept.......................................................................... 71
		3.3.6 Driving Modes Investigated................................................................. 71
	3.4 Error Responses.................................................................................. 72
	3.5 Diagnosis........................................................................................ 73
		3.5.1 Error Memory............................................................................... 73
		3.5.2 On-Board Diagnosis......................................................................... 73
		3.5.3 Off-Board Diagnosis........................................................................ 73
4 Installation........................................................................................... 75
	4.1 Transmission Installation Investigation.......................................................... 79
		4.1.1 Standard Transmission Installation Drawings................................................ 79
		4.1.2 PTO + Emergency Steering Pump Installation Drawings........................................ 79
		4.1.3 Input Shafts............................................................................... 79
		4.1.4 Clutch Bell Housing........................................................................ 80
		4.1.5 Clutch..................................................................................... 80
		4.1.6 Clutch Release Unit........................................................................ 82
		4.1.7 Engine Connection.......................................................................... 83
		4.1.8 Suspension................................................................................. 84
		4.1.9 Transmission Installation Angle............................................................ 87
		4.1.10 Propshaft Connection...................................................................... 88
		4.1.11 Torsional vibrations...................................................................... 92
			4.1.11.1 Permissible vibrations at transmission input........................................ 92
			4.1.11.2 Uniformity of rotation.............................................................. 92
		4.1.12 Bending Vibrations........................................................................ 93
		4.1.13 Cover / Protective Floor Panels........................................................... 93
		4.1.14 Additional Brackets....................................................................... 93
		4.1.15 Fording Ability........................................................................... 93
		4.1.16 Accessibility............................................................................. 94
		4.1.17 Additional Guidelines for Vehicle Body Manufacturer....................................... 95
		4.1.18 Vehicle Wiring............................................................................ 95
	4.2 Temperatures..................................................................................... 96
		4.2.1 Permissible Ambient Temperatures on Transmission........................................... 96
		4.2.2 Permissible Oil Temperatures............................................................... 96
		4.2.3 Causes of Excess Oil Temperatures.......................................................... 96
		4.2.4 Additional Transmission Cooling............................................................ 97
		4.2.5 Use in Sub-Zero Temperatures............................................................... 98
		4.2.6 Storing the Transmission................................................................... 98
	4.3 Filling With Oil................................................................................. 99
		4.3.1 Oil Grade and Oil Change Interval.......................................................... 99
		4.3.2 Oil Fill Quantity.......................................................................... 99
		4.3.3 Draining the Oil...........................................................................100
		4.3.4 Filling With Oil...........................................................................100
		4.3.5 Oil Level Check............................................................................100
		4.3.6 General Information........................................................................101
		4.3.7 Information about Bleeding the Transmission................................................101
		4.3.8 Venting by Means of Hose Line in Dry Compartment...........................................102
	4.4 Electrics........................................................................................103
		4.4.1 System Layout and Circuit Diagrams.........................................................103
		4.4.2 Description of Connectors..................................................................104
		4.4.2.1 Connector on Transmission................................................................104
		4.4.2.2 Power Supply Connector to Vehicle........................................................105
		4.4.3 Power Supply Voltages......................................................................106
		4.4.4 CAN Bus Installation.......................................................................107
		4.4.5 Quality Requirements of Wiring.............................................................109
		4.4.6 Connector and Mating Connector Designations................................................110
		4.4.7 Other Electrical Interfaces on the ZF-AS Tronic............................................111
			4.4.7.1 Neutral Switch (S12).................................................................111
			4.4.7.2 Speedo Sensor........................................................................111
		4.4.8 CAN Signals................................................................................112
		4.4.9 EMC Compatibility..........................................................................112
	4.5 Pneumatics.......................................................................................113
	4.6 Auxiliaries......................................................................................115
		4.6.1 ZF-Intarder................................................................................115
		4.6.2 Third Party Retarder.......................................................................115
		4.6.3 ZF Power Take Off Units (PTOs).............................................................115
		4.6.4 Third Party PTOs...........................................................................116
		4.6.5 Heat Exchanger.............................................................................116
	4.7 Transmission Installation on Assembly Belt.......................................................116
		4.7.1 Transport..................................................................................116
		4.7.2 Supplying the Main Transmission............................................................117
		4.7.3 Corrosion Protection.......................................................................117
		4.7.4 Subsequent Paintwork.......................................................................117
		4.7.5 Assembly of Engine, Clutch, and Transmission...............................................117
		4.7.6 EOL Programming............................................................................118
		4.7.7 Delivery Check.............................................................................119
	4.8 Additional Information...........................................................................120
		4.8.1 Operation..................................................................................120
			4.8.1.1 Starting Engine......................................................................120
			4.8.1.2 Setting Off, Forward Travel..........................................................121
			4.8.1.3 Maneuvering..........................................................................121
				4.8.1.3.1 Maneuvering via the accelerator pedal with rotary switch in D or R position....121
				4.8.1.3.2 Maneuvering acc. to rotary switch position DM or RM............................122
			4.8.1.4 Moving off Downhill..................................................................122
			4.8.1.5 Changing Operating Mode: Manual / Automatic..........................................122
			4.8.1.6 Changing Gear........................................................................123
			4.8.1.7 Reverse Travel.......................................................................123
			4.8.1.8 Engine Brake.........................................................................124
			4.8.1.9 Stopping.............................................................................124
			4.8.1.10 Switching Off Engine / Stopping Vehicle.............................................124
			4.8.1.11 Towing..............................................................................124
			4.8.1.12 Tow Starting........................................................................125
			4.8.1.13 Clutch Protection...................................................................125
			4.8.1.14 Engine Overspeed Protection.........................................................126
			4.8.1.15 Operations with Clutch-Driven PTO...................................................126
			4.8.1.16 Roller test rig.....................................................................127
		4.8.2 Maintenance................................................................................128
		4.8.2.1 Visual Inspection of Wiring..............................................................128
		4.8.2.2 Maintenance of Pneumatic System..........................................................128
		4.8.3 Vehicle Handover to End Customer...........................................................128
	4.9 Application and Documentation....................................................................129
		4.9.1 Application................................................................................129
		4.9.2 ZF Documentation...........................................................................129
		4.9.3 Type Plate.................................................................................129
		4.9.4 Explanation for ZF Documentation...........................................................130
5 Annex..................................................................................................131
	5.1 Designations for AS Transmission.................................................................133
	5.2 AS Transmission Program..........................................................................134
		5.2.1 AS Transmission Program for Trucks.........................................................134
		5.2.2 AS Transmission Program for Special Applications...........................................135
		5.2.3 AS Transmission Program for Rail Vehicles..................................................135
	5.3 Attached Documents (only for information)........................................................136
		0000 210 854c....................................................................................137
		0501 211 422e....................................................................................138
		0501 214 767b....................................................................................139
		0501 215 297.....................................................................................140
		1327 600 015e....................................................................................141
		1327 600 016g....................................................................................142
		1328 600 015f....................................................................................143
		1328 600 016g....................................................................................144
		1328 600 019.....................................................................................145
		1328 600 043.....................................................................................146
		1328 600 044.....................................................................................147
		1336 600 019c....................................................................................148
		1336 600 020c....................................................................................149
		1336 600 021b....................................................................................150
		1336 600 022b....................................................................................151
		1336 600 041a....................................................................................152
		6006 629 032.....................................................................................153
		6006 639 002.....................................................................................154
		6029 713 025.....................................................................................155
			Blatt 2......................................................................................156
		6029 713 157.....................................................................................157
			Blatt 2......................................................................................158
		6029 713 158.....................................................................................159
			Blatt 2......................................................................................160
		6029 713 163.....................................................................................161
			Blatt 2......................................................................................162
		6029 713 166.....................................................................................163
			Blatt 2......................................................................................164
		6041 622 026.....................................................................................165
		6090 601 031.....................................................................................166
		6090 601 045a....................................................................................167
		6090 604 024.....................................................................................168
		6090 604 036a....................................................................................169
		6091 610 003e....................................................................................170
		6091 611 001b....................................................................................171
			Blatt 2......................................................................................172
		6091 615 007.....................................................................................173
		6091 618 001.....................................................................................174

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