AS-Tronic Reparaturstufe 1-2 PDF

Repair Manual
Maintenance, Diagnosis,
Component Replacement
Repair Level 1 - 2
Bus 1337 751 101b_en

CAUTION
The ZF order numbers listed in the manual apply to
the ZF standard.
Variances may occur depending on the vehicle
manufacturer.
The binding ZF order numbers can be found in the
relevant parts list – parts list numbers are specified
on the transmission type plate.
Subject to technical changes
Copyright by ZF Friedrichshafen AG
This documentation is protected by copyright. Any

reproduction or dissemination in whatever form
which does not comply fully with the intended
purpose of this documentation is prohibited without
the consent of ZF Friedrichshafen AG.
Printed in Germany
ZF Friedrichshafen AG, MC-C dept. / 2003-09
Edition: 2009-09
1337 751 101b

ZF-AS Tronic Table of Contents
Page
List of Changes ..................................................................................................................................... 5

Preface ................................................................................................................................................. 6
Important Information ......................................................................................................................... 7
Instructions for Repairs ....................................................................................................................... 8
Tightening Torques .............................................................................................................................. 10
Conversion Factors for Units of Measurement (EU - USA) ................................................................. 11
Special Tools ......................................................................................................................................... 13
Test Equipment, ZF-AS Tronic Diagnosis Tools................................................................................... 15
ZF-Intarder Diagnosis Tools ................................................................................................................. 18
General maintenance .......................................................................................................................... 21

Visual Inspection of Wiring.................................................................................................................. 21
Pneumatic System Maintenance.......................................................................................................... 21
Clutch Actuator and Transmission Actuator ....................................................................................... 21
Transmission Bleeding ......................................................................................................................... 22
Note When Changing Oil ..................................................................................................................... 23
Approved Oil Grades ............................................................................................................................ 24
Oil Volume ............................................................................................................................................ 24
Oil-Change Intervals ............................................................................................................................ 24
Oil Change (ZF-AS Tronic Without ZF-Intarder) ............................................................................... 25
- Filling Oil ......................................................................................................................................... 25
- Oil-Level Check ............................................................................................................................... 26
- Type Plate......................................................................................................................................... 26
Oil Change (ZF-AS Tronic With ZF-Intarder) .................................................................................... 27
- Oil Filter Replacement .................................................................................................................... 28
- Oil Filling ........................................................................................................................................ 29
- Oil Filling in Case of Oil Change ................................................................................................... 29
- Oil Filling After Transmission Repair ............................................................................................ 29
- Oil-Level Check ............................................................................................................................... 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
1337 751 101 - 2009-09 3

ZF-AS Tronic Table of Contents
Page
Clutch Actuator ................................................................................................................................... 45

- Removing Clutch Actuator ............................................................................................................. 45
- Clutch Actuator Maintenance ........................................................................................................ 46
- Bleeding and Assembling Clutch Actuator .................................................................................... 47
Clutch .................................................................................................................................................. 49
- Replace Clutch ................................................................................................................................ 49
Clutch Release Mechanism ................................................................................................................. 50
- Removing Release Fork ................................................................................................................... 50
- Fitting Release Fork ......................................................................................................................... 52
Output Flange....................................................................................................................................... 55
- Removing and Mounting Output Flange......................................................................................... 55
- Removing and Mounting Yoke ........................................................................................................ 56
Output Cover ....................................................................................................................................... 57
- Removing and Mounting Output Cover .......................................................................................... 57
Output Impulse Sensor (Speed Sensor) .............................................................................................. 58
- Removing and Mounting Impulse Sensor....................................................................................... 58
Replacing Neutral Switch.................................................................................................................... 59
- Remove and Install Neutral Switch ................................................................................................ 59
Replace Intarder Components ........................................................................................................... 60
- Output Speed Sensor, Speedo Sensor, Solenoid Valve, Temperature Sensor ............................... 60
- Removing and Mounting 3/2 Directional Valve.............................................................................. 61
- Removing and Mounting Intarder Cable Harness .......................................................................... 61
Additional Cooling .............................................................................................................................. 62
- Assembling the Valve Block of the Additional Cooling Unit.......................................................... 62
ZF-Display ............................................................................................................................................ 63
- Removing and Mounting the Display.............................................................................................. 63
- Wiring Diagram ............................................................................................................................... 63
- Connector Assignment, Connector Replacement........................................................................... 63
Range Selector...................................................................................................................................... 64
- Removing and Mounting Console-Type Range Selector................................................................. 64
- Removing and Mounting Steering-Column Switch ........................................................................ 65
- Removing and Mounting Pushbutton Range Selector .................................................................... 66
- ZF Lever-Type Range Selector......................................................................................................... 68
Electronic Control Unit ....................................................................................................................... 69
- Removing and Mounting E-Module ................................................................................................ 69
- Removing and Mounting E-Module 2 ............................................................................................. 70
- Removing and Mounting ZMTEC ................................................................................................... 71
- ZMTEC Pin Assignment .................................................................................................................. 72
Type Designations and Order Numbers ............................................................................................. 73
Pneumatic Diagram ............................................................................................................................ 74
Appendix .............................................................................................................................................. 75
- Attached Documents ....................................................................................................................... 75
- Attached Drawings ......................................................................................................................... 75
1337 751 101 - 2009-09 4

List of Changes: 1337 751 101
Index Date of issue Chapter Initiator Comment
2003-09 BKS-R dept. First version
a 2008-05 BKS-R dept. Complete revision, the following has been added, among other:
- New clutch release
- Hose breather
- Conversion factors
- Maintenance of clutch and transmission actuator
- Oil fill volume, ZF-AS Tronic Bus
- E-module 2
b 2009-09 BKS-R dept. - Maintenance of compressed-air system: Information added

- Venting clutch actuator: Caution omitted
- Disengagement: Lubrication instruction added
- Keypad-type selector: Sticker included
1337 751 101 - 2009-09 5

Preface
Preface Warranty
This manual is intended for skilled personnel Repair work carried out at ZF Service Points is
trained by ZF Friedrichshafen AG to carry out subject to the contractual conditions prevailing
maintenance and repair work on ZF products. in the individual case.
The work described below may only be performed
by authorized, trained, and instructed staff. It is Direct and/or subsequent costs are not covered by
the responsibility of the user’s company or repair this contractual liability when:
company to ensure that their repair staff is properly
• work has been performed improperly or by
trained.
unskilled personnel, by non-ZF-personnel,
and/or
This manual deals with a ZF series product in
accordance with the state of development on the • use of “non” genuine ZF parts.
date of issue.
In case of failure it is mandatory to act immediately,
However, due to continuing technical advancements so to ensure the complete function of the ZF unit
of the product, repair work might require work and minimize the scope of damage.
practices and test or adjustment data which are not
contained in this manual. In case of proven unfounded delay in repair we
We therefore recommend that work done on your reserve the right of partial acceptance or even a
ZF product is carried out only by skilled mechanics rejection of warranty claims.
and fitters who have their practical and theoretical
knowledge updated on a regular basis at our Service
Training Center.
Service points equipped by ZF Friedrichshafen AG

all over the world offer you:
1. Continuously trained personnel,
2. Specified equipment,
e.g.: special tools,
3. Genuine ZF spare parts in accordance

with the latest volume production
specifications.
All work performed at these service locations

is carried out conscientiously and with care.
ZF Friedrichshafen AG
Driveline and Chassis Technology
0000_99D_010_en
2008-06 6 2009-09
Safety Instructions
The following safety instructions are used ! DANGER to the health!

in this repair manual:
Ensure confident handling with supplies.
Manufacturer’s instructions must be observed.
NOTE
Refers to special working procedures, methods,
information, use of auxiliary equipment, etc. ! DANGER to the environment!
Lubricants, consumables, and cleaning agents must
CAUTION
not be allowed to enter the soil, ground water, or
Is used when the instructions are not complied
sewage system.
with or not followed precisely and could lead to
• Ask your local environment agency for safety
the product being damaged.
information on the relevant products and adhere
to their requirements.
• Collect used oil in a suitably large container.
! • Dispose of used oil, dirty filters, lubricants, and
DANGER!
cleaning agents in accordance with environmental
Is used when lack of care could result in personal
protection regulations.
injury or danger to life.
• When working with lubricants and cleaning agents
always refer to the manufacturer’s instructions.
CAUTION
Safety Instructions
The transmission must NOT be suspended by the
input shaft OR by the output flange/add-on parts.
As a rule, repair technicians for ZF units are
responsible for their own workplace safety.
To avoid injury to personnel and damage to

products, all safety regulations and legal
Incorrect
requirements which apply to repair and
maintenance work must be adhered to.
Before starting work, mechanics must therefore
familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF

Correct
products must receive appropriate training in
advance.
Compulsory training is the responsibility of the
repair staff.
! DANGER!
Do not walk under suspended load during parts
transportation with a hoist.
0000_99D_020_en
2008-06 7 2009-09
Instructions for Repairs
General Information Cleaning Parts
Read this manual carefully before starting tests or Remove old sealing compound residues from all
repair work. sealing faces. Carefully remove burrs or other
uneven patches using an oil stone.
The ZF-Service Information details must be Lube bores and grooves must be free from anti-
observed. These are available from all ZF Service corrosion grease and foreign matter. Check that the
Centers or from the ZF-ServiceLine. passage is free.
Carefully cover opened transmissions to prevent the
In any cases of doubt, always contact the relevant entry of foreign matter.
expert departments at ZF-Service.
Whenever working on the transmission, ensure
cleanliness and carry out the work as instructed. Reusing Parts
Use specified tools to dismantle and assemble
transmissions. Parts such as antifriction bearings, multidisks,
thrust washers etc., must be inspected by a
specialist, who should decide whether they can
CAUTION be re-used or not.
The pictures, drawings, and components shown Replace parts which are damaged or have suffered
do not always represent the original object, but are from excessive wear.
used to illustrate working practices.
The pictures, drawings, and components are not to • Gaskets, locking plates
scale and no conclusions must be drawn about size Parts which cannot be removed without being
and weight (not even within a complete illustration). damaged must always be replaced with new
All work must be performed as described in the parts (e.g. gaskets and locking plates).
text. Gaskets are installed without the use of sealing
compound or grease. When measuring coated
After repair work and tests performed, skilled gaskets/seals proceed as specified.
personnel must make sure that the product is
working properly again. • Shaft seals
Always replace shaft sealing rings with rough,
Conversions and modifications may impact the ripped, or hardened sealing lips. Seal contact
transmission’s operational safety. Therefore, surfaces must be totally clean and in perfect
customer-specific deviations must be agreed with condition.
ZF in writing.
After removing the transmission from the vehicle, Reworking

clean thoroughly with a suitable cleaning agent
before opening. Pay particular attention to the If rework is needed on spacer washers and shims
recesses of housings and covers when cleaning. etc. because of clearance settings, ensure that the
reworked areas contain no face runout and have
the same surface quality.
0000_99D_030_en
2008-06 8 2009-09
Instructions for Repairs
Transmission Assembly • Shaft Sealing Rings

Press in shaft sealing ring with fixture or face
Assemble the transmission in a clean workplace. plate until firmly home at relevant installation
Adhere to all adjustment data and tightening depth.
torques specified in the repair manual.
a) Apply a thin coat of sealing agent* to outer
circumference of shaft sealing rings with a
• Bearings
«steel surround».
If the bearings are fitted while warm, these
should be warmed up evenly (e.g. heating b) Never apply sealing agent to shaft sealing
cabinet). with a «rubber surround» but apply a thin
The temperature should be approx. 85°C and coat of Vaseline 8420 or spirit to the outer
must not exceed 120°C. All bearings fitted must circumference, or wet with a lubricant, e.g. a
be coated with operating oil after assembly. water-soluble concentrated washing-up liquid.
c) Shaft sealing rings with steel and rubber

• Sealing
surrounds should be treated on the outer
If a sealant* is recommended for sealing, then
circumference of the rubber surround as
it is essential to adhere to the manufacturer’s
described for shaft seal (b).
directions for use. A thin layer of sealing agent
should be applied to the surfaces and coat them d) Duo shaft sealing rings have
evenly. Do not allow sealing agent to enter oil two sealing lips. The dust
ducts and bores. On oil-carrying ducts and bores, protection sealing lip (X)
wipe off the sealing agent on the surfaces to be must face outwards.
sealed near apertures to ensure that no sealing Fill the space between the X
agent enters the oil feeds when the parts are sealing lips up to 60% with
pressed together. grease*.
• Retaining Agents • Transmission Oil

Retaining agents* may only be used where After completing repairs, fill the transmission
specified by the parts list. with transmission oil. For the procedure and
When using retaining agents (e.g. Loctite) always approved oils, refer to the transmission operating
comply with the manufacturer’s directions for manual and the List of Lubricants TE-ML (refer
use. to type plate). These are available from all
During assembly, comply with all adjustment ZF Service Centers or on the Internet at
data, inspection data, and tightening torques. www.zf.com. After filling the transmission with
oil, tighten the screw plugs at the oil filling point
and the oil overflow to the specified torques.
* refer to consumable material
0000_99D_040_en
2008-06 9 2009-09
Tightening torques
Tightening torques for screws/bolts and nuts,

extract from ZFN 148
This standard applies to bolts according to DIN 912, Surface condition of screws/bolts/ nuts:
DIN 931, DIN 933, DIN 960, DIN 961 as well as Heat-treated blackened finish and oiled or
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, galvanized and oiled.
and for nuts according to DIN 934 and ISO 4032,
ISO 8673. The bolts are tightened using a calibrated torque
wrench.
This standard contains data on tightening torques
for screws/bolts and nuts of strength categories 8.8, NOTE
10.9, and 12.9, as well as nuts of strength categories Differing tightening torques are listed separately
8, 10, and 12. in the repair manual.
Coarse thread Fine thread
Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

Screw/Bolt 8.8 10.9 12.9 Screw/Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M4 2,8 4,1 4,8 M8x1 24 36 43

M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M10x1 52 76 89
M7 15 23 28 M10x10.25 49 72 84
M8 23 34 40 M12x10.25 87 125 150
M10 46 68 79 M12x1.5 83 120 145
M12 79 115 135 M14x1.5 135 200 235

M14 125 185 215 M16x1.5 205 300 360
M16 195 280 330 M18x1.5 310 440 520
M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1.5 430 620 720
M22 530 750 880 M22x1.5 580 820 960
M24 670 960 1100 M24x1.5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1.5 1100 1600 1850
M27x2 1050 1500 1800

M30x1.5 1550 2200 2550
M30x2 1500 2100 2500
Status: August 1991

0000_99D_050_en
2008-06 10 2009-09
ZF-AS Tronic Conversion Factors
Conversion Factors:
from to x Factor Examples:
mm inch x 0.03937 20.0 mm = 0.7874 inch

inch mm x 25.4 0.4 inch = 10.16 mm
Nm ft.lb. x 0.7376 60 Nm = 44.256 ft.lb.

ft.lb. Nm x 1.356 35 ft.lb. = 47.46 Nm
°C °F 9 x °C 90 °C = 194 °F
+ 32
5
°F °C 5(°F-32) 248 °F = 120 °C

9
bar psi x 14.513 10 bar = 145.13 psi

psi bar x 0.06894 200 psi = 13.78 bar
liter US gallons x 0.2642 20 liters = 5.284 US gallons

US gallons liter x 3.7854 3 US gallons = 11.3562 liters
0000_99D_060_en
1337 751 101 - 2009-09 11 2009-09
ZF-AS Tronic Special Tools
Fig. Figure Order no. Application Qty. Remark

no.
1X56 138 215 Chapter

“Clutch Release
Adapter Mechanism”
1 for assembly of bushes and 2 (Version A)
shaft sealing rings of release fork Release fork
with cams.

“Clutch Release
Press-in mandrel 1 Mechanism”
2 for assembly of bearing bushes and (Version B)
cam rollers of the release fork Release fork with
cam rollers.

“Clutch Release
Support 1 Mechanism”
3 ffor the release fork (Version B)
Release fork with
cam rollers.

“Output Cover”
Adapter
4 for installing the shaft sealing ring at 1
the output cover (in connection with
a spacer ring 1X56 138 189)

“Output Cover”
Spacer ring
5 for shaft sealing ring 105 x 125 x 12 1
at output cover (in connection
with adapter 1X56 137 124)
NOTE: Please inquire as to packaging unit before ordering.
1327_91D_010_en
1337 751 101 - 2009-09 13 2008-03
ZF-AS Tronic Special Tools

no.
240
Sketch Chapter
“Transmission
M10
64
75
11
60.5
M10
112
74 Actuator”
1
15
100.1 ø9H7 ø9H7
Setting aid Assembly aid
6 200.1 14
2120.1 for piston rods on
ø8.70.1
transmission actuator
ø9r6
25
2x45 2x45
37.50.1
40
1327_91D_010_en
1337 751 101 - 2009-09 14 2008-03
ZF-AS Tronic Diagnosis Tools

no.
6008 208 503 Only for

ZF-Testman pro complete ZF Sales
and Service
Organizations
Scope of supply:
1 - 6008 208 100 ZF-Testman pro 1
with DPA05 + cable
- 6008 208 015 Application CD
- 6008 208 016 License
6008 208 501 Only for

ZF-Testman pro diagnosis software ZF Sales
and Service
Organizations
Scope of supply:
2 - 6008 208 011 ZF-Testman pro 1
Update CD
- 6008 208 015 Application CD
- 6008 208 016 License
6008 208 003 following

ZF-Testman pro for ZF customers agreement with
ZF Friedrichs-
Scope of supply:
hafen AG
- 6008 208 100 ZF-Testman pro
3 with DPA05 + cable 1
- 6008 208 900 ZF-Testman pro
software for user interface
(CD basic installation)
6008 208 819 Single user

license
Diagnosis software
ZF-AS Tronic 2
4 1
6008 207 003 Adapter cable for

programming and
configuration
Table mode adapter
purposes and for
ZF-AS Tronic 2 diagnosis outside
5 1 the vehicle
1327_91D_050_en
1337 751 101 - 2009-09 15 2008-03

No.
6008 006 002 The terminal

tester can be
used to interrupt
Terminal tester all PINs and
1 68-pin 1 to take
measurements
at all PINs.
6008 307 025 Connection:

Terminal tester
Diagnosis Connection CAUTION:

2 Universal for 1 PIN asignment
use with terminal tester. depends on
control unit.
6008 206 007 Adapter cable

at socket end for
bus and truck
Adapter cable
3 68-pin socket to 18/20-pin pin 1

at pin end for
bus and truck
Adapter cable
4 68-pin pin to 18/20-pin socket 1
6008 307 009 Voltage supply

in vehicle via
cigarette lighter
Main power system cable
5 for MobiDig 2001 1
1327_91D_040_en
1337 751 101 - 2009-09 16 2008-03

No.
6008 207 006 for MAN F2000 + Bus The diagnosis

connector is near
6008 207 007 for MAN TGA
the fuse box.
6 Diagnosis connection 1
for transmission and Intarder
0501 211 104
Cable SAE 1708

7 (USA) 1
1327_91D_040_en
1337 751 101 - 2009-09 17 2008-03
ZF-AS Tronic ZF-Intarder Diagnosis Tools

no.
6008 206 011 Adapter cable at

socket end for
Adapter cable for EST 42 terminal bus and truck
tester
1 1
Adapter cable, 68-pin pin to
88-pin socket

pin end for bus
Adapter cable for EST 42 terminal and truck
tester
2 1
Adapter cable, 68-pin socket to
88-pin pin

for programming
Table mode adapter EST 42 and
configuration
purposes and
3 1 for diagnosis
outside
the vehicle
6008 208 811 Diagnosis

software cpl. CD
Diagnosis software EST42/48
(single user
for ZF-Intarder license)
4 1

socket end for
tester
5 1
88-pin socket
1327_91D_030_en
1337 751 101 - 2009-09 18 2008-03
ZF-AS Tronic ZF-Intarder Diagnosis Tools

no.

at pin end for
tester
6 1
88-pin socket

for program-
Table mode adapter EST 48 ming and
configuration
purposes and
7 1 for diagnosis
outside the
vehicle
1327_91D_030_en
1337 751 101 - 2009-09 19 2008-03
1337 751 101 - 2009-09
ZF-AS Tronic Maintenance
General Maintenance Clutch Actuator and Transmission Actuator
• Please also note the details provided by the are to be replaced and/or overhauled after 2.4
vehicle manufacturer million gear shifts. The number of gear shifts can
be found in the statistics memory.
• Regular maintenance increases the transmission’s
operational reliability.
• If “TC” appears frequently on the display, the
• Conduct a visual check for oil leaks during compressed-air supply is possibly defective and
vehicle servicing checks. therefore has to be checked.
- Check pressure with Testman pro:
• All transmission maintenance work may only
Operating pressure (reservoir) 5.5 to 12 bar
be carried out when the vehicle is on horizontal
If the system pressure is below 6.2 bar or
ground and the engine is switched off.
greater than 7.2 bar (display via Testman pro
• With all screw plugs it must be ensured that the pressure sensor) the pressure relief valve must
sealing ring is renewed before every assembly. be replaced.
If the system pressure is greater than 7.2 bar,
preliminary transmission damage is possible
Visual Inspection of Wiring and no error is saved in the error memory.
• Check wiring for damage as part of vehicle • If the “CC” (clutch check phase) takes very long,
servicing. the compressed-air supply to clutch actuator is
possibly defective (soiling of valve screw);
• Check that connectors are seated correctly,
therefore, check the clutch actuator valve screw.
connectors must be fitted strain-relieved.
Pneumatic System Maintenance
• The vehicle manufacturer’s maintenance

instructions must be observed.
• The pneumatic tank should be drained once

a week, in winter every day.
- During draining of the pneumatic tank, the
pneumatic cleaners and water separators should
also be drained if this is not done automatically.
NOTE
Water in compressed air indicates defect water
separator.
• If vehicles are fitted with an air dryer, the

interval for replacing the cartridge must be
observed.
1348_53D_010_en
21 2009-09
Transmission Bleeding
The transmission is fitted with a vent on the The following should be noted when fitting the hose
transmission actuator as a standard. The vent should (also refer to sketch):
be protected from the ingress of large amounts of
water. The vent must be clean; ensure that the • Ensure that the hose exits the transmission vent
plastic cover is not fitted. horizontally (use angle screw connection if
necessary).
In the case of vehicles which are frequently cleaned
• Route hose so that it rises continuously. A siphon
using a water jet, moisture or moist air may be
effect should be avoided (see sketch).
drawn into the vent as a result of sudden
transmission cooling, causing condensation to form • No kinks, chafing points. Route hose in the
inside the transmission. Also applications where the largest radius possible.
transmission is located in the surface water spray
• Max. permissible hose temperature (e.g. near
zone from the rear wheels may be affected by this.
exhaust pipes, exhaust turbocharger) must not be
exceeded.
Since the proportion of water in the transmission
oil must not exceed 1 000 ppm, rather than the • End of hose lowered by approx. 150 mm.
standard vent, ZF recommends that a a hose-type
• Inside width of hose should be at least Ø 4 mm.
vent be installed in the vehicle’s dry compartment.
The interface on the transmission to the hose may be • The vehicle manufacturer is responsible for the
factory-installed and supplied this way. correct fitting and routing of the hose.
A retrofit kit for hose venting is available under ZF
number 1315 298 021 from ZF-Service.
This provides the best possible protection for the

transmission against water ingress. When using this ca. 150 mm
form of hose venting, the oil change interval for correct
ECOFLUID M transmission oil increases. incorrect
More information on this can be found in the List of
Lubricants TE-ML 02.
Notes on the “dry compartment” and routing of the

hose:
“Dry compartment” is defined as follows:
• Splash-protected
• Low air humidity

027524
Fig.: Guideline for routing a hose-type
Example: trunk, battery compartment
vent to the dry compartment
1348_53D_010_en
22 2009-09
For oil changes, please note the following:

Old New
The screw plug with tag 0768 409 494 at the oil
filling point must be replaced by the new screw plug
without tag 0768 409 498. The screw plug with tag
has a recess between collar and hexagon (see arrow)
and must therefore not be used any more.
Tightening torque:
screw plug with sealing ring: 60 Nm
AC
HT
U NG
SYN
TH
ET
BE OEL- IK-
FU
ELL
UN
GE G
Repair solution, only in agreement with ZF: AE
OE NDE
LW RT
INT ECHS ER
ER EL-
VA
LL
• Tapered screw plug without solenoid 029486

0736 303 005
• Tapered screw plug with solenoid

0736 305 016
Use Loctite 222 to coat tapered screw plug thread

before assembly.
Tightening torque:
tapered screw plugs: 50 Nm
1348_53D_010_en
23 2009-09
Approved Oil Grades Oil-Change Intervals
Only those lubricants listed in ZF List of Lubricants To ensure that the transmission achieves the
TE-ML 02 may be used. The ZF List of Lubricants required level of operational safety and reliability,
TE-ML 02 can be obtained from all ZF Service the oil change intervals must be observed as
Centers or via the Internet: http://www.zf.com. specified in List of Lubricants TE-ML 02!
Oil Volume
The oil volume is noted on the type plate. It is crucial

for the correct oil volume in the transmission to
carry out the oil fill accurately (see Chapter “Oil
Filling”).
Oil fill quantities ZF-AS Tronic Bus
Oil change Initial fill or after transmission repair

approx. quantity in liters approx. quantity in liters
Transmission type with Intarder without Intarder with Intarder without Intarder
10 AS 2000 BD * 12 * 12
10 AS 2000 BO * 12 * 12
10 AS 2001 BD 12 * 21 *
10 AS 2001 BO 12 * 21 *
10 AS 2010 B IT 12 * 21 *
10 AS 2300 BD * 12 * 12
10 AS 2300 BO * 12 * 12
10 AS 2301 BD 12 * 21 *
10 AS 2301 BO 12 * 21 *
10 AS 2310 B * 12 * 12
10 AS 2310 B IT 12 * 21 *
10 AS 2700 BO * 12 * 12
10 AS 2701 BO 12 * 21 *
12 AS 1601 BO 12 * 21 *
12 AS 2000 B IT 12 * 21 *
12 AS 2000 BO * 12 * 12
12 AS 2001 BO 12 * 21 *
12 AS 2300 B IT 12 * 21 *
12 AS 2300 BO * 12 * 12
12 AS 2301 BO 12 * 21 *
12 AS 2700 BO * 12 * 12
12 AS 2701 BO 12 * 21 *
* not available
1348_53D_010_en
24 2009-09
1 Screw plug with solenoid 4 Type plate

2 Screw plug with solenoid 5 Transmission bleeding
3 Remove screw plug
028456
Oil Change (ZF-AS Tronic Without ZF-Intarder) Filling Oil
Oil may only be changed when the vehicle is • Fill in oil through oil filler hole (3).
horizontal and the engine is switched off.
• The oil level is correct when the oil has reached
the bottom edge of the oil filler hole and/or when
Always change the oil after a long journey while
oil is already escaping out of the oil filler hole.
the transmission oil is still at operating temperature
and thin. • Tighten screw plug (3) to 60 Nm.
! DANGER !
Touching hot parts and transmission oil may cause
burns.
• Remove screw plugs (1, 2 and 3) from

transmission and collect transmission oil in a
suitable container and dispose of in accordance
with environmental regulations.
• Clean screw plug solenoid and replace sealing

rings.
• Screw in and tighten screw plugs (1 and 2) to

60 Nm.
1348_53D_010_en
25 2009-09
Oil-Level Check Type Plate

(ZF-AS Tronic Without ZF-Intarder)
The type plate contains the key data.
It is located on the left of the transmission when
! DANGER ! viewed from the output.
Too little oil in the transmission will result in
transmission damage. Risk of accident! The following details must always be given when
making inquiries or for repairs:
1. Transmission type (model)
Check the transmission oil level as part of vehicle 2. Transmission parts list no.
servicing: 3. Transmission serial no.
• Undertake oil level check when vehicle is on

horizontal ground. ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
• Do not check the oil level right after travel AS Tronic 12 AS 2301 BO 1
(incorrect measurement result). Only check once PARTS LIST NO. MODEL SERIAL NO.
the transmission oil has cooled down (< 40 °C). 2 1348 045 004 00247443 3
CUSTOMER xxxxxx
• Remove screw plug (3). SPEC. NO.
TOTAL 12.33 - 0.78 SPEEDO xxx
RATIO
• If the oil level has fallen below the oil filler hole, RATIO
n= xxxxx xn
P.T.O. N xxxxx ENGINE
the oil must be topped up (refer to chapter on OIL CAPACIT OIL GRADE SEE
IN LITERS 21 LUBRIC. LIST TE-ML 02
“Filling Oil”).
029367
NOTE Fig.: Type plate (example)

Whenever checking the oil level, also inspect the
transmission for leaks.
1348_53D_010_en
26 2009-09
ZF-AS Tronic with Intarder Maintenance
4
3
2
11 1 10
1 Oil drain location, Intarder 9 Oil filler hole after repairs

2 Oil drain location, transmission 10 Tighten screw to 23 Nm.
3 Oil filler hole and/or oil overflow point 11 Filter cover
4 Type plate Tighten screw plugs (1, 2, 3 and 9) to 60 Nm.
5 Transmission vent
029437_1
Oil Change (ZF-AS Tronic With ZF-Intarder) ! DANGER !

Touching hot parts and transmission oil may cause
CAUTION
burns.
The ZF-Intarder must NOT be actuated shortly
before parking the vehicle to change oil!
• Switch off engine.
This ensures that the correct oil volume is
measured in the transmission. • Remove screw plugs (1 and 2) from transmission
and Intarder and collect transmission oil in a
NOTES suitable container.
• In the case of an oil change, the oil must be Dispose of transmission oil in accordance with
drained into a suitable container and disposed environmental guidelines.
of in an environmentally-friendly manner.
• Clean solenoid on screw plugs
• Always change the oil after a long journey while and replace sealing rings.
the transmission oil is still at operating
• Screw in screw plugs (1 and 2) and tighten to
temperature and thin.
60 Nm.
• Change the oil only when the vehicle is parked
on horizontal ground. CAUTION
Observe the specified tightening torque for screw
plugs; otherwise transmission damage may occur!
• Replace oil filter.
1348-53D-020_en
1337 751 101 - 2009-09 27 2008-05
Oil Filter Replacement
NOTE
Use new oil filter for each oil change.
11
! DANGER !
When transmission oil is hot: Danger of burns!
1 Remove screw (10) from filter cover (11).
10
000529_1
2 Remove filter cover (11) with mounted

filter. Remove oil filter from filter cover.
CAUTION
There is residual oil left in the oiI filter housing!
000552
3 Check O-ring (8) on filter cover (11), for

damage, replace and grease, if necessary.
4 Safely attach solenoid (12) to the new filter.
5 Grease O-ring (7).
6 Fit filter cover (11) onto new filter (6). Insert

the complete unit in the filter housing until
complete abutment.
11 8 7 6 12
7 Tighten screw (10) to 23 Nm.
004467
1348-53D-020_en
1337 751 101 - 2009-09 28 2008-05
Oil Filling (ZF-AS Tronic With ZF-Intarder)
CAUTION 9
In case of transmission with ZF-Intarder, a
distinction is made between oil fill during oil
change and oil fill after transmission repair.
Oil Filling in Case of Oil Change 3
NOTE
The oil fill may only take place when the vehicle
is parked on horizontal ground and the engine is
switched off. Oil grade according to TE-ML 02. 029437_2
• Remove screw plug (3). Oil Filling After Transmission Repair

• Fill oil into transmission until it overflows.
NOTE
• Insert screw plug (3) and new sealing ring and The oil fill may only take place when the vehicle
tighten to 60 Nm. is parked on horizontal ground and the engine is
switched off. Oil grade according to TE-ML 02.
Undertake test drive: Distance of 2 - 5 km
During the test drive, disengage Intarder activation • Remove screw plugs (3 and 9).
via the footbrake.
• Fill with oil at pos. 9 until oil flows over at pos. 3.
DO NOT engage the Intarder during the test drive.
• Insert screw plugs (3 and 9) and new sealing ring
and tighten to 60 Nm.
End of test drive: Vehicle is parked.
DO NOT engage Intarder! Undertake test drive: Distance of 2 - 5 km
During the test drive, disengage Intarder activation
• Remove screw plug (3). via the footbrake.
Test drive: At the beginning, BRIEFLY activate the
CAUTION Intarder (Stage 6) ONCE.
Check oil level again and if necessary, top up with
oil until it overflows. End of test drive: Vehicle is parked.
Do NOT engage Intarder!
• Insert screw plug (3) and new sealing ring and
tighten to 60 Nm. • Remove screw plug (3).
CAUTION
Check oil level again and if necessary, top up with
oil until it overflows.
• Tighten screw plug (3) to 60 Nm.
1348-53D-020_en
1337 751 101 - 2009-09 29 2008-05
Oil-Level Check (ZF-AS Tronic With ZF-Intarder) Visual Inspection
If the accumulator charge valve is seriously leaking,

! DANGER ! then replace the entire accumulator.
Too little oil in the transmission will result in
transmission damage.
Risk of accident!
CAUTION
To check the oil level, the Intarder must not be
activated just before parking the vehicle.
This ensures that the correct oil volume is
measured in the transmission.
NOTES
• In order to get a correct measurement, the oil
level check is to be effected with
- Vehicle parked on horizontal ground,
- Engine turned off,
- Transmission oil cooled down (< 40 °C).
• Check the transmission oil level as part of vehicle

servicing.
• Pay particular attention to possible leakages:

- Transmission,
- Intarder,
- Oil/Water heat exchanger,
- The corresponding cooling water pipes.
CHECK
• Park your vehicle in stationary position without
actuating the Intarder.
• Remove the screw plug at the oil filler hole (3)
during oil level check.
• If the oil level has dropped below the edge of the
oil filler hole, refill oil until overflow.
• Insert screw plug (3) and new sealing ring and
tighten to 60 Nm.
1348-53D-020_en
1337 751 101 - 2009-09 30 2008-05
Engine Coolant ZF-Intarder Type Plate
CAUTION The type plate contains the important key data of

When refilling the engine coolant, please pay strict the Intarder. It is located on the side of the Intarder
attention to the instructions given by the vehicle housing.
manufacturer! Otherwise, damage may occur at the
oil/water heat exchanger! The following information must always be given
when making inquiries, placing orders, or carrying
• Engine coolant out repairs:
(mixture made from fresh water and
anti-freeze/anti-corrosion agent) 1. Parts list no. of the Intarder
- Recommended volume for anti-freeze/anti- 2. Serial no. of the Intarder
corrosion agent: 40 -50 Vol.%, to be checked
with coolant inspector.
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
• Anti-freeze and anti-corrosion agents INTARDER AS Tronic
PARTS LIST NO. MODEL SERIAL NO.
Basic fluid: Ethylenglycol with corrosion
1 6085 020 028 XXX XXX 2
inhibitors.
CUSTOMER
SPEC. NO.
TOTAL SPEEDO
• Fresh water RATIO
RATIO
xn
P.T.O. N n=
pH value 6.5 -8.0; overall hardness < 20° dH ENGINE
OIL CAPACIT OIL GRADE SEE
IN LITERS LUBRIC. LIST TE-ML
Change interval of the engine coolant: 029367
• At max. every 2 years Fig.: Type plate (example)

with aluminum heat exchanger (for premixed fill).
• At max. every 4 years
with stainless steel heat exchanger
(for premixed fill).
• Deviating information
(shorter change intervals) given by the vehicle
and/or engine manufacturer are to be complied
with.
NOTE
The entire cooling system must always be rinsed
with water prior to new fills.
The coolant must also be replaced immediately if
sludge forms or if the coolant’s concentration falls
suddenly.
1348-53D-020_en
1337 751 101 - 2009-09 31 2008-05
ZF-AS Tronic Diagnosis
Diagnosis on Vehicles with ZF Display and Call up error numbers*:

ZF Range Selector
• Switch on the ignition.
NOTE • Turn rotary switch to «N».

Depending on the manufacturer and vehicle type,
• Hold control lever in « + » position.
you may have operating processes other than those
described in this manual. Therefore, also observe
The number shown in the display is the error
the operating instructions provided by the vehicle
number.
manufacturer.
If 4 bars are displayed in addition to the number

shown on a two-digit display, this means:
Error no. +100

e. g.: Error no. 74
002686 003930
Error no. 174
013587
ZF display ZF range selector
If 4 bars and 2 arrows are displayed in addition to

the number shown, this means:
The ZF standard software displays system errors on
the ZF display.
Error no. + 200
e.g.: Error no. 27
If a “wrench symbol”
Error no. 227
appears on the display,
there is a system error. 018470
Only restricted operations 008026

may be available.
For example: With certain system errors, automatic
Show error memory contents and delete error
mode is deactivated and the transmission system
memory*:
remains in manual mode.
• on vehicles with ZF display,
If a «STOP» and a «wrench refer to annex 1337 754 101
symbol» appear on the
• on vehicles with ZF range selector button,
display, there is a serious
refer to annex 1337 754 105
system error. 008027
You must not continue driving.

The vehicle usually has to be towed away.
* also refer to vehicle manufacturer’s operating instructions
1327-93D-011_en
1337 751 101 - 2009-09 32 2008-03
ZF-AS Tronic Diagnosis
Diagnosis With Testman pro
Reading Error Memory Clearing Error Memory
1. Open Testman 1. Open Testman
2. Commercial Vehicle / Special Driveline 2. Commercial Vehicle / Special Driveline

Technology Technology
3. Main menu AS Tronic 2 3. Main menu AS Tronic 2
4. Licensing 4. Licensing
5. Safety information 5. Safety Information
6. Diagnosis product menu 6. Diagnosis product menu
7. Information regarding laptop connection 7. Information regarding laptop connection
8. Communication structure 8. Communication structure
9. Description 9. Description
(is automatically saved in GDS3000 directory (is automatically saved in GDS3000 directory
under the transmission number) under the transmission number)
10. Read diagnosis error memory 10. Clear diagnosis error memory
(transmission actuator in vehicle, connection
11. Clear error memory yes/no
via diagnosis interface on vehicle)
12. Error memory erased
11. Read/Save error memory
12. Select error

(e.g. in this case, error 191 EOL error) Working with checklists
(For checklist AS Tronic cf. ZF-ServiceLine or Annex)
13. Read out error data
(save if possible)
When reporting complaints, it is important that
you have fully worked through the check list and
provided the data required. This is the only way in
which the problem can be localized.
Resistance measurement on CAN BUS with digital

multimeter see Annex.
1327_93D_021_en
1337 751 101 - 2009-09 33 2009-09
ZF-AS Tronic Data Sheet: 20-pin Transmission Actuator
TECHNICAL DATA TECHNISCHE DATEN CARACTERISTIQUES TECHNIQUES CARATTERISTICHE TECNICHE
WORKING MEDIUM: AIR

ARBEITSMEDIUM: LUFT
FLUIDE D'UTILISATION: AIR
FLUIDO DI ESERCIZIO: ARIA 62/X1B 61/X1A
W U
TERMAL RANGE OF APPLICATION:
THERMISCHER ANWENDUNGSBERREICH:
PLAGE DE TEMPERATURE EN UTILISATION:
CAMPO TERMICO DI APPLICAZIONE:
AMBIENT AIR TEMPERATURE: 32

UMGEBUNGSLUFTTEMPERATUR: -30˚ C . . . MAX. 95˚C
TEMPERATURE AIR AMBIANTE:
TEMPERATURA ARIA AMBIENTE:
FLANGE TEMPERATURE:
FLANSCHTEMPERATUR: MAX 0,5h ... 130˚C -30˚C BIS 110˚
BRIDE TEMPERATURES:
FLANGIA TEMPERATURA:
WORKING PRESSURE (SUPPLY):

BETRIEBSDRUCK (VORRAT): pe = 5,5...12 bar
PRESSION D'UTILISATION (ALIMENTATION):
PRESSIONE DI ESERCIZIO (ALIMENTAZIONE): GROUPING OF WIRES (ON THE PLUG)
STECKERBELEGUNG
DEGREE OF PROTECTION ACCORDING TO IE C 529: GROUPEMENT DE CABLES
RAGGRUPPAMENTO DEI CAVI (SULLA CALOTTA) 61/X1A
SCHUTZART NACH IEC 529: IP 6K9K NACH DIN 40050 T9
DEGRE DE PROTECTION SUIVANT IEC 529: STECKER 61/X1A STECKER 62/X1B U
GRADO DI PROTEZIONE SECONDO IEC 529 : 1 VPI 1 -
2 SDDK 2 VM4
3 CANF2-H 3 VM3
VOLTAGE: 4 VPE1 4 -
SPANNUNG: 24V -6V DC 5 VPE2 5 -
TENSION : +8V DC 6 CANF2-L 6 VMGA2
TENSIONE: 7 SDEF 7 ADS1
8 CANF1-H 8 ADS3
9 SD 9 ADS2
HARDWARE: 446 180 101 2 DOC 610
10 SDP 10 EU 62/X1B
SOFTWARE: 446 180 101 2 DOC 690 MIT SOFTWAREVERSION 201 11 ADVP 11 EF2 W
12 CANF1-L 12 ADS4
M = TORQUE 13 CANF1-L+ 13 ADS4+
M = ANZUGSMOMENT 14 CANF1-H+ 14 ADS3+
M = COUPLE DE SERRAGE 15 CANF1-T 15 AU
16 VM1 16 VM1
M = COPPIA DI SERRAGGIO 17 VM2 17 VM2
18 VMHF1 18 ADVP
SUPPLY OF ENERGY: 19 VMHF2 19 ADVP+
ENERGIEZUFLUSS: 1 (ø8mm) 20 VM3 20 VMGA1
APPORT D'ENERGIE:
ALIMENTAZIONE
DI ENERGIA: 61/X1A 62/X1B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DELIVERY: ECU STEUERELEKTRONIK

ARBEITSLEITUNG:
2 (ø 4mm)
UTILISATION:
Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10
MANDATA:
EXHAUST: 1
ENTLUEFTUNG: 2
31> 32 , 33 ø 16mm) )( )( )( )( )( )( )( )(
ECHAPPEMENT:
33
SCARICO:
31
ELECTRICAL CONTROL:
ELEKTRISCHER
STEUERANSCHLUSS: 61, 62
COMMANDE
32
ELECTRIQUE: K1 - K2 1/2-R-3/4 2/4/R-N-1/3 H - L
COMANDO ELETTRICO: SPLIT-GV SELECT-WAEHLEN SHIFT-SCHALTEN RANGE-GP
019 067
1327-74D-021_en
1337 751 101 - 2009-09 34 2008-03
ZF-AS Tronic
Assignment
Pinbelegung Pin Assignment
1337 D0 0071
Pin
1327-74D-022_en
1337 751 101 - 2009-09 35 2008-03
ZF-AS Tronic Data Sheet: 18-pin transmission actuator
TECHNICAL DATA TECHNISCHE DATEN CARACTERISTIQUES TECHNIQUES CARAT

WORKING MEDIUM: AIR
ARBEITSMEDIUM: LUFT
FLUIDE D'UTILISATION: AIR
FLUIDO DI ESERCIZIO: ARIA
TERMAL RANGE OF APPLICATION:

THERMISCHER ANWENDUNGSBERREICH:
PLAGE DE TEMPERATURE EN UTILISATION:
CAMPO TERMICO DI APPLICAZIONE:
AMBIENT AIR TEMPERATURE :

UMGEBUNGSLUFTTEMPERATUR : -30° C MAX. 95°C
TEMPERATURE AIR AMBIANTE:
TEMPERATURA ARIA AMBIENTE:
FLANGE TEMPERATURE:
FLANSCHTEMPERATUR: -30°C BIS 110°C
BRIDE TEMPERATURES: MAX 0,5h BEI 130°C
FLANGIA TEMPERATURA:
62/X1B 62/X1A
WORKING PRESSURE (SUPPLY):
BETRIEBSDRUCK (VORRAT): pe = 5,5...12 bar
PRESSION D'UTILISATION (ALIMENTATION):
PRESSIONE DI ESERCIZIO (ALIMENTAZIONE): GROUPING OF WIRES
(ON THE PLUG)
STECKERBELEGUNG
DEGREE OF PROTECTION ACCORDING TO IEC 529 : GROUPMENT DE CABLES
SCHUTZART NACH IEC 529 : IP 6K9K NACH DIN 40050 T9 RAGGRUPPAMENTO DEI CAVI
DEGRE DE PROTECTION SUIVANT IEC 529: (SULLA CALOTTA)
GRADO DI PROTEZIONE SECONDO IEC 529: STECKER STECKER
61/X1A 62/X1B
VOLTAGE: -6V DC
SPANNUNG: 24V +8V DC 1 VP 1 1
TENSION : 2 SDDK 2 VMGA1
3 CANF 2 - H 3
TENSIONE: 4 VPE 1 4
5 VPE 2 5
SOFTWARE-VERSION 203 6 CANF 2 - L 6 VMGA2
SOFTWARE MASTER: 446 180 544 4 / DOC CODE 690 7 SDEF 7 ADS1
8 CANF 1 - H 8 ADS3
SOFTWARE SLAVE: 446 180 545 4 / DOC CODE 690 9 SD 9 ADS2
HARDWARE: 446 180 101 2 DOC 610 INDEX F 10 SDP 10 EU
11 ADVP 11 EF2
M = TORQUE 12 CANF 1 - L 12 ADS4
13 CANF 1 - L + 13
M = ANZUGSMOMENT 14 CANF 1 - H + 14
M = COUPLE DE SERRAGE 15 CANF 1 - T 15 AU
M = COPPIA DI SERRAGGIO 16 VM1 16 VM1
17 VM2 17 VM2
18 VMHF 1 18 ADVP
SUPPLY OF ENERGY:
ENERGIEZUFLUSS: 1 (Ø 8mm)
APPORT D'ENERGIE:
ALIMENTAZIONE DI ENERGIA :
DELIVERY: 61/X1A 62/X1B

ARBEITSLEITUNG: 2 (Ø 4mm) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
UTILISATION: ECU STEUERELEKTRONIK
MANDATA:
Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10
EXHAUST:
ENTLUEFTUNG: 31 (> Ø 16mm) 32, 33
1
ECHAPPEMENT: 2
SCARICO: )( )( )( )( )( )( )( )(
33
ELECTRICAL CONTROL: 31
ELEKTR. STEUERANSCHL. : 61, 62
COMMANDE ELECTRIQUE:
COMANDO ELETTRICO:
32
K1 - K2 1/2-R-3/4 2/4/R-N-1/3 H - L
SPLIT-GV SELECT-WAEHLEN SHIFT-SCHALTEN RANGE-GP
019646
1327-74D-022_en
1337 751 101 - 2009-09 36 2008-03
ZF-AS Tronic Transmission Actuator
Removing Transmission Actuator
!DANGER
74.140*
Only work on the transmission actuator
74.130* 74.120*
when the ignition is off. Risk of accident!
74.030
74.090 74.070
1 Switch off ignition
CAUTION
If vehicle-specific parts (e.g. fuel pump, exhaust
pipe, or steering pump) have to be removed,
please contact the vehicle manufacturer.
74.050
2 Disconnect electric plug connection from
74.010
transmission actuator.
12.090
74.050
!DANGER 34.140 12.080
34.130 06.050
Protective glasses must be worn when removing 06.040
the compressed air line from the transmission
06.080
actuator. Compressed air will escape!
Risk of injury from dirt particles.
Loctite
262
* depends on the parts list 015166

3 Remove compressed air line from
transmission actuator’s pressure relief valve.
4 Remove breather 74.120 or angle piece

74.140 and cannon plug 74.130 from
transmission actuator 74.030 if these parts
are being replaced.
5 Remove 15 M8 hex bolts 74.090, 74.070

from transmission actuator 74.030.
1327_74D_031_en
1337 751 101 - 2009-09 37 2008-05
CAUTION
The rubber seals /170 may fall into the
transmission housing.
/170
6 Remove transmission actuator 74.030
from transmission housing and ensure that
the rubber seals /170 are also removed,
otherwise they could fall into the
transmission housing.
b
a
Note of dimensions “a” and “b” for later
installation.
7 Remove the pressure springs 06.050, 34.140

and 12.090 and detent pins 6.040, 34.130
and 12.080. Replace the two cylinder pins
74.050 if they are damaged. 018774
8 Remove seal 74.010 and clean sealing

surfaces on transmission housing and 74.140*
transmission actuator. 74.130* 74.120*
74.030
NOTE
A transmission actuator kit is available. 74.090 74.070
It consists of transmission actuator 74.030,
seal 74.010, and breather 74.120.
9 Remove ball pin 06.080 if damaged.
74.050
74.010
12.090
74.050
34.140 12.080
34.130 06.050
06.040
06.080
Loctite
262
1327_74D_031_en
1337 751 101 - 2009-09 38 2008-05
Removing the Upper Section from the Lower

Section 6009 274 069
NOTE 09 03 43872
Seal kit 0501 319 863 contains both screws /150-1, 4213 550 110
the flat seal /150-2, and the profile seal /150-3.
024361
CAUTION
1
Note down the data on the type plate. You will /150-1
need them for ordering spare parts and for
correspondence.
/110
1 Remove both screws /150-1.
2 Raise upper section /110 at the pressure

relief valve /180 and use both tabs (1) to
74.030
carefully move it sideways into the grooves* /180
(2). Disconnect plug connections (7, 8).
3 Remove seals /150-3 and /170. /150-2

2
4 Remove seal /150-2 and clean sealing faces.
/150-3
* not possible with the 18-pin variant
/130
Reattaching the Upper Section to the Lower

Section /170
019352
1 Insert seal /150-3.
2 Place seal /150-2 on lower section /130.
3 Re-connect plug connections (7 and 8).

Again check fit of plug connection.
4 Place upper section /110 on lower section 8

/130. Ensure that the seal /150-2 does not
7
slip, fix if necessary. Tighten the two screws
/150-1 to 9.5 Nm.
5 Insert seals /170.
018205
1327_74D_005_en
1337 751 101 - 2009-09 39 2007-05
Mounting Transmission Actuator
1 If the ball pin is being replaced, coat the

thread of ball pin 06.080 with Loctite no. 262. /170
Tighten ball pin to 23 Nm.
2 Move piston rod (4) on transmission actuator

into central position (Neutral). The correct
position is reached when slight resistance can
b
a
be felt when pulling out the piston rod (4).
3 Transfer dimensions “a” and “b” from the

removed transmission actuator to the piston
rods (3 and 5).
4 Selector gate (6) and piston rod (4) must be

one above the other (flush). Ensure that the 018774
rubber seals /170 have been inserted on the
transmission actuator. /170
5 4 3
Legend
Piston rod (3) = shifts the splitter group (SG)
Piston rod (4) = shifts the basic transmission
Piston rod (5) = shifts the range change group (RC)
Selector gate (6) = selects the shift gate
NOTE
6
With the 12-speed version, do not slide the
shift rail 06.010 in the middle too far into the
transmission, otherwise the shift finger could
fall into the transmission.
017908
Legend
12.010 Splitter group (GV) shift rail
34.010 06.080 06.010 12.010
06.010 Shift rail for basic transmission
34.010 Range change group (GP) shift rail
06.080 Ball pin
015019
1327_74D_041_en
1337 751 101 - 2009-09 40 2008-03
Alternative: If dimensions “a” and “b” can no

longer be established, the transmission actuator
can be fitted using setting aid (34) 1X56 138 244.
In-house production following sketch, see special 34
tools. On request, tool 1X56 138 244 can also be
supplied by ZF.
Adjust the transmission actuator’s piston rods (3, 4,
and 5) so that they are in contact with the setting
aid (34). Engage SG and RC shift rails in the trans-
mission in output direction.
Move the central gear shift rail into Neutral.
Selector gate (6) and piston rod (4) must be one
above the other (flush). Ensure that the rubber seals
/170 on the transmission actuator are inserted.
017907
5 Place new seal 74.010 on transmission
housing.
74.140*
6 Insert detent pins 06.040, 34.130 and 12.080
74.130* 74.120*
and compression springs 06.050, 34.140 and
12.090. 74.030
74.090 74.070
NOTE
The compression springs 06.050, 34.140 and
12.090 must be of the same length (approx.
50 mm). If deviations are found, replace
pressure springs.
7 Attach transmission actuator 74.030 ensuring

that piston rods of transmission actuator 74.050
reach into gearshift rails of transmission. 74.010
The vertical ball pin 06.080 reaches into the
selector gate.
12.090
74.050
34.140 12.080
8 Tighten M8 hex bolts 74.090 and 74.070 to 34.130 06.050
06.040
23 Nm.
06.080
9 Depending on parts list:
Tighten cannon plug 74.130 to 18 Nm and
Loctite
secure angle piece 74.140 and/or tighten 262
breather 74.120 to 10 Nm.
* depending on parts list 015166
1327_74D_041_en
1337 751 101 - 2009-09 41 2008-03
CAUTION
If the transmission actuator is replaced, the
following should be noted.
• To reprogram the transmission actuator,
please refer to chapter
• Take over vehicle parameters from removed
transmission or re-enter.
10 Connect air line to transmission actuator’s

pressure relief valve.
Tightening torque: 34 Nm
11 Re-connect cable harness at transmission

and vehicle end, otherwise functions
cannot be tested.
NOTE
Connectors must be fitted strain-relieved.
Plug must snap in.
Final check:
Has the transmission actuator been reprogrammed?
Refit vehicle-specific parts as far as possible.

The diagnosis unit can only be used to test the
transmission actuator once the engine is running
and there is a sufficient air reserve. The system
then carries out a number of calibration processes.
This may take up to 5 minutes. The following errors
might be displayed, e.g.: Piston rod not attached
with errors 132, 134, etc. or teaching-in error for
gear, gate, RC, SG sensors with ignition on.
1327_74D_041_en
1337 751 101 - 2009-09 42 2008-03
Replacing Pressure Relief Valve

(repair kit 0501 320 849) 10
NOTE
Mark the installation position of the pressure relief
valve /180 for fitting later on.
1 Remove 4 nuts (10) and take off pressure

relief valve /180 and O-ring (12).
CAUTION
Do not use grease to fit O-ring (12).
2 Insert new O-ring (12), use 4 nuts (10)

to attach pressure relief valve /180 to
transmission actuator 74.030. 019251
New O-ring (12) available on request at ZFF

dept. LKS or BKS.
/180 12 74.030
019252
1327_74D_110_en
1337 751 101 - 2009-09 43 2007-09
Programming Transmission Actuator
When replacing the transmission actuator and/or 21

upper section, customer-specific programming
and/or parameter setting (entering EOL data) will
be required.
20
During parameter setting, the EOL data are enter-

22
ed in the transmission actuator’s electronics using
ZF-Testman pro and the corresponding software.
Diagram of transmission actuator programming

Item 20.1 23
20 Table mode adapter
20.1 Power supply connection
21 Cable from table mode adapter to the DPA05 028537
22 DPA05
23 Cable to laptop and/or PC
CAUTION
When reprogramming a transmission actuator,
transfer the vehicle parameters from the removed
transmission actuator or re-enter them.
1327_74D_012_en
1337 751 101 - 2009-09 44 2007-05
ZF-AS Tronic Clutch Actuator
7 68.300 8
68.010
6
68.330 68.320
68.060
68.210*
68.020*
/030
/020
68.150 /010
68.020*
68.154
* depending on parts list 029 482
Removing Clutch Actuator
!DANGER! 5 Remove 4 M8 hex-head bolts 68.154 and take

• Switch off ignition. off the cover 68.150.
• Protective glasses must be worn when removing the
compressed air line. Compressed air will escape! 6 Remove 4 M8 hex-head bolts /030 with shims
Risk of injury from particles of dirt. and/or 4 M8 hex-head bolts 68.020.
1 Once the ignition has been switched off, the 7 Remove the clutch actuator 68.010.
compressed air line should be removed from
the clutch actuator. 8 Take pushrod 68.210 completely out
of the release fork 68.060.
2 Bleed clutch actuator. Loosen screw (6) for
this purpose.
NOTE
3 Disconnect plug connection (7) from For removal and fitting of release fork, refer to the
transmission actuator and (8) from output chapter “Clutch Release Mechanism”.
speed sensor.
4 Remove cable harness from cable clamps

68.300, 68.320, 68.330 and, if necessary,
remove the fixing devices 68.360, 68.370.
1327_68D_021_en
1337 751 101 - 2009-09 45 2008-03
22
024537
Clutch Actuator Maintenance

(repair kit 0501 322 365)
! DANGER! Inspect valve screw (2) for dirt, replace if necessary.

• Only work on clutch actuator when the ignition is off. If the clutch actuator is very dirty it has to be
• Protective glasses must be worn when removing replaced or cleaned after consultation with ZF
the compressed air line. Compressed air will Service.
escape!
Risk of injury caused by dirt particles! NOTE
If the transmission system remains too long in
“CC” (teach-in clutch) this indicates that the clutch
The repair kit consists of a screw (6) with sealing actuator is dirty.
ring and a valve screw (2) with O-ring.
Visual Inspection
Tightening torque (MA): Check whether cable routing is correct. Ensure that
Screw plug (6) MA = 22 Nm there are no chafings.
Valve screw (2) MA = 70 Nm
1327_68D_071_en
1337 751 101 - 2009-09 46 2008-03
Bleeding and Assembling Clutch Actuator
1 Loosen screw (6) M12x1.5.

If sealing ring is worn at screw, replace
sealing ring.
018475
2 Push piston back.
018476
3 Hold piston pushed down and tighten screw

(6).
018477
1327_68D_032_en
1337 751 101 - 2009-09 47 2009-09
4 Place pushrod 68.210 in socket of release

fork 68.060.
5 Secure clutch actuator 68.010 with 4 M8

hex nuts (/030) and 4 washers (/020) and/or
4 M8 hex screws 68.020. In so doing, ensure
68.010
that the connections are positioned correctly
and that the pushrod 68.210 is seated 68.210* 6
correctly in the release fork and clutch
actuator. 68.020*
/030
Tightening torque: /020
Hexagon nut (/030) M8 = 23 Nm /010
Stud bolt (/010) M8 = 10 Nm
68.020*
Hex-head bolts 68.020 M8 = 23 Nm
6 Loosen bolt (6) and wait until piston has

extended. In so doing, ensure that pushrod
68.210 is seated correctly in release fork
68.060 and clutch actuator.
Tighten bolt (6) again to 22 Nm.
7 Secure cover 68.150 with 4 M8 hex-head

bolts 68.154.
Tightening torque M8 = 23 Nm 6
68.060
CAUTION 68.150
Do not bend cable or put under tensile load.
Avoid chafing points.
Fit connectors strain-relieved and check detent.
68.154
018482
8 Replace cable clamps 68.300, 68.320, and
68.330 if damaged.
7 68.300 8
9 Press cable harness into cable clamps.
10 Connect 18 or 20-pin connector (7) to

transmission actuator and then attach
connector (8) to output speed sensor.
11 Connect compressed air line to clutch

actuator.
68.060 68.330 68.320
018483
1327_68D_032_en
1337 751 101 - 2009-09 48 2009-09
ZF-AS Tronic Clutch*
Replace Clutch*
If the clutch disk is replaced, the following must be

considered:
• Grease the spline of the input shaft with

OLISTA LONGTIME 3EP (ZF no. 0671 190 050).
• Slide clutch disk onto input shaft, remove it

again and, if necessary, wipe off excess grease.
NOTE
Avoid soiling of clutch disk with grease, oil, etc.
014794
Fitting Engine, Clutch, and Transmission CAUTION

(also refer to Instructions for transmission/clutch Do not damage pressure plate!
removal and installation, 1327 754 104 and/or
1327 754 106). 6 Insert pushrod.
NOTE 7 Close opening on transmission bell housing

The release bearing is fitted when the transmission (refer to Chapter “Bleeding and assembling
is delivered. The transmission is in Neutral or in clutch actuator”).
the highest gear available.
CAUTION
1 Fit clutch disk and pressure plate (use a • The clutch disk, pressure plate, and friction
mandrel to center the pressure plate). lining are part of the customer specification
(basic document for drawing up parts list).
2 Slide profile of input shaft into profile of • The software of the shift program is adapted to
clutch disk. the characteristics of the clutch components.
• Changing the components contrary to the
3 Screw transmission and engine together. customer specification results in poor clutch
characteristics and/or damage to the
4 Blede clutch actuator (refer to Chapter components.
“Bleeding and assembling clutch actuator”).
5 Press release bearing forwards (engine end)

so that the clutch snaps into snap ring of the
release bearing.
NOTE
This is done by using a short lever to push
the lower end of the release fork to the back
(transmission end) through the opening in
the transmission bell housing. * ZF scope of supply depends on spare parts version
1327_68D_061_en
1337 751 101 - 2009-09 49 2008-03
ZF-AS Tronic Clutch Release Mechanism
Clutch Release Mechanism
68.060
/140 68.050
/130 /110
68.210
/130
68.110
68.130
/120
68.050 /140
68.130 68.110
68.060
Clutch Release Mechanism: Version A
028365
Removing Release Fork Version A: Release fork with cams
1 Remove 2 M12 hex-head bolts 68.130 from 4 Dismantling the release fork 68.060:
release shaft 68.110. Remove the two shaft sealing rings /140 and
bearing bushes /130 with suitable tools.
2 Take release bearing 68.050 and release fork Replace the ball cup /120 if damaged or worn.
68.060 off the input shaft.
3 Slide the release shaft 68.110 out of the

release fork 68.060. If necessary, take out the
pushrod 68.210 from the release fork.
1327_68D_010_en
1337 751 101 - 2009-09 50 2007-05
Version B: Release fork with cam rollers

68.060
CAUTION
Do not wash the following parts:
68.110
- Release fork 68.060
/150
- Release bearing 68.050 /160
68.130
4 Disassemble the release fork 68.060:
Remove the bearing bush /130 with suitable /130 /110
tools.
68.210
Drive out cam rollers /150 and /160 from the
release fork 68.060 (e. g. with a punch).
Replace ball cups /120 if damaged or worn. /120
68.050
028231
1327_68D_010_en
1337 751 101 - 2009-09 51 2007-05
Mounting Release Fork
/110
/140 /130
68.050 68.060
68.110
/140
/130 /110
68.130
68.130 68.210
/120
/130
68.060 68.050
68.110
/140
Clutch Release Mechanism: Version A
028366
CAUTION 4 Guide release shaft 68.110 into release fork

The release fork 68.060 and the release bearing 68.060, do not damage shaft sealing rings in
68.050 of the versions A and B cannot be combined. the process.
The release shaft 68.110 however is identical for
both versions. 5 Position release bearing 68.050 on release
flange (guide tube).
Version A: Clutch release mechanism with cams
NOTE
1 Assembling the release fork 68.060. Do not grease the bearing fit
An adapter 1X56 138 215 is needed as support “release bearing – release flange”.
for the release fork /110. Another adapter
1X56 138 215 is used to press in the two 6 Apply OLISTA LONGTIME 3EP (ZF no.
bushes /130 and shaft sealing rings /140 (pay 0671 190 050) grease to contact face to the
attention to the installation position) one after release bearing 68.050 at the release fork
the other. 68.060. Engage release fork 68.060 with
release bearing 68.050.
2 Fill the shaft sealing rings /140 with grease
between the sealing lips. 7 Fasten the release shaft 68.110 with 2 M12
Grease bearing bushes /130 with OLISTA hex-head bolts 68.130 to the connection plate.
LONGTIME 3EP (ZF no. 0671 190 050). Tightening torque: 95 Nm
3 Press in ball cup /120 and grease with OLISTA

LONGTIME 3EP (ZF no. 0671 190 050).
1327_68D_100_en
1337 751 101 - 2009-09 52 2009-09
1X56 138 546
1X56 138 547
/110 /130
Clutch Release Mechanism: Version B
028244
Version B: Release fork with cam rollers NOTE

Press in the bearing bush – rim facing the
CAUTION press-in mandrel.
Always press in the bearing bush /130 first, then
the cam rollers /150 and /160. Use the press-in mandrel 1X56 138 546 for
pressing in the bearing bush /130 until firmly
home in the release fork /110 so that the
1 Assemble the release fork 68.060 using bush’s rim fully engages in the groove of the
assembly fixture 1X56 138 547 as a support. release fork.
2 Use the press-in mandrel 1X56 138 546 in

order to press in the cam rollers /150 and /160
until firmly home in the release fork /110.
1327_68D_100_en
1337 751 101 - 2009-09 53 2009-09
CAUTION
Do not grease the following parts: 68.050
- Cam rollers
- Bearing fit “Release bearing – release flange”
- Release shaft
- Bearing bush (greased ex works)
NOTE
"Release shaft must not be greased" applies to new
components as they are already factory-greased.
However, maintenance should include a lubrication 68.110
check followed by greasing if necessary.
68.060
028239
3 If necessary, press in ball cup /120 and grease

with OLISTA LONGTIME 3EP
68.060
(ZF no. 0671 190 050).
68.110
4 Slide release shaft 68.110 into release fork
/150
68.060. /160
68.130
NOTE
The release shaft in the bearing bush has /130 /110
clearance.
68.210
5 Grease the front end of the cams of the release

bearing with OLISTA LONGTIME 3EP /120
(ZF no. 0671 190 050).
68.050
6 Position release bearing 68.050 on release 028233

flange (guide tube).
7 Engage release fork 68.060 with release

bearing 68.050. Ensure correct fit of pushrod
68.210.
8 Attach release shaft 68.110 to the clutch

housing with 2 M12 hex-head bolts 68.130.
1327_68D_100_en
1337 751 101 - 2009-09 54 2009-09
ZF-AS Tronic Output Flange
Output Flange
Removing the Output Flange
1 Remove two hex-head bolts 32.550 and take off

32.550
washer 32.540. 32.540
32.530
2 Pull off the output flange 32.510 using a stan- 32.510
dard three-armed puller and remove the O-ring
32.530.
NOTE
The shaft must not be damaged during pull-off
process; therefore, use a thrust piece.
015171
Mounting the Output Flange

(06.260)
(06.250) 32.550
1 Heat output flange 32.510 to max. 70 °C and 32.540
(06.220)
slide onto spline of planetary carrier until (06.200) 32.530
32.510
firmly home (axial abutment). Ensure that in
the case of the Intarder version, the screws
32.520 have been inserted.
!
DANGER
Only touch hot output flange when wearing protective
gloves.
(06.210)
32.520 (with Intarder)
2 Once the output flange has cooled down, press
015169_1
the O-ring 32.530 into the groove between the
shaft and the output flange.
3 Fasten washer 32.540 with 2 M12 hex-head

bolts 32.550.
1327_32D_010_en
1337 751 101 - 2009-09 55 2009-09
ZF-AS Tronic Output Flange
Removing the Yoke
32.550
1 Remove 2 hex bolts 32.550 and take off
washer 32.540. 32.540
2 Use a suitable standard extractor to remove

yoke 32.510.
NOTE
When removing, use interim piece to protect
the shaft.
32.510
018733
Mounting the Yoke
1 Heat yoke 32.510 to max. 70 °C and slide

onto spline of planetary carrier until firmly
home.
!DANGER
Always wear protective gloves when handling
heated output flange.
2 Once the yoke has cooled down, secure

washer 32.540 with 2 M12 hex-head bolts
32.550.
018732
Tightening torque M12 = 120 Nm.
1327_32D_011_en
1337 751 101 - 2009-09 56 2008-03
ZF-AS Tronic Output Cover
Removing the Output Cover
NOTE 31.080
In the case of transmissions equipped with an 31.050
Intarder, these parts are not available.
31.030*
1 Remove 10 M10 hex-head screws 31.070 and
lift off output cover 31.050.
2 If necessary, remove the shim 31.030.

31.070
NOTE
The shim 31.030 is no longer needed for modern Loctite
574
transmissions since the output cover 31.050 has been
modified accordingly.
* depending on parts list 028255
3 Use a suitable tool to remove shaft sealing

ring 31.080; do not damage output cover in
the process.
1X56 137 124
Mounting the Output Cover
1 Coat the outer circumference of the shaft

sealing ring 31.080 with spirit and press into 1X56 138 189
output cover 31.050 using the mounting
adapter 1X56 137 124 in connection with the
ring 1X56 138 189 and ensure that it is firmly
home (axial abutment). Slightly grease sealing
lip.
028678
2 Coat the sealing surface of the output cover
with Loctite Nr. 574.
NOTE
Sealing surfaces must be clean and free of oil
and grease.
3 Fit output cover 31.050 – with shim 31.030 –

if necessary.
4 Tighten 10 M12 hex-head bolts 31.070

to 46 Nm.
1327_31D_070_en
1337 751 101 - 2009-09 57 2008-03
ZF-AS Tronic Impulse sensor
Output impulse sensor (speed sensor)
CAUTION
When the KITAS sensor 31.230 is replaced, the
parameters for the new sensor must be set (or
taught in) otherwise there will no longer be a
speedo function.
Remove impulse sensor 31.260
1 Pull out connector.
2 Remove impulse sensor 31.260.

31.230
028457
Fit impulse sensor
1 Screw in impulse sensor 31.260.

(Setting is not required)
2 Connect plug with impulse sensor and ensure

that it snaps in.
3 Screw in impulse sensor 31.230.

CAUTION 31.230
• Connector must be fitted strain-relieved.
Plug must snap in. 31.260
• The impulse sensor can be mixed up.
Always check the ZF number. * depending on the parts list 014814_1
Connector Replacement
If a connector has to be replaced, please use the AMP

standard tool (for wiring diagram, refer to parts list).
Transmission without Intarder Transmission with Intarder 2

Impulse sensor* (DIN bayonet) Length 90 mm Impulse sensor* (DIN bayonet) Length 19.8 mm
Version Supply voltage Version Supply voltage
Hall 0501 210 859 ZF 6.5 - 30 V Hall 0501 210 855 ZF 6.5 - 30 V
Kitas I 0501 211 735 At vehicle end 6.5 - 9 V Kitas I 0501 213 668 At vehicle end 6.5 - 9 V
Kitas II 0501 214 769 At vehicle end 6.5 - 9 V Kitas II 0501 214 768 At vehicle end 6.5 - 9 V
*depending on parts list
1327_31D_061_en
1337 751 101 - 2009-09 58 2009-09
ZF-AS Tronic Neutral switch
Replacing Neutral Switch*

Pay attention to Service Information no. 26_05 06.260*
and no. 08_06 which can be obtained via the 06.250
ZF-ServiceLine or at all ZF representative offices.
Remove Neutral switch
1 Remove Neutral switch 06.260 with sealing

ring.
Install Neutral switch
1 Slightly grease the tappet of the Neutral 014815
switch. Screw in Neutral switch 06.260 with

sealing ring.
NOTE
Pin 06.250 must be fitted.
Designation ZF no.
Neutral switch (DIN bayonet) 0501 216 474
Sealing ring 0634 801 062
Pin 1328 306 024
* Option (refer to parts list)
1327_06D_021_en
1337 751 101 - 2009-09 59 2009-09
ZF-AS Tronic Intarder
05.100 7
05.110
05.030
31.260
05.400
02.180 05.430
02.170 05.440
05.410
05.420
31.230
02.190
014738_1
Replace Intarder Components Speedo Sensor
NOTE 1 Screw in impulse sensor 31.230.

- Replace aluminum heat exchanger by stainless-steel Tightening torque: 45 Nm
heat exchanger, see Modification Instructions
6085 754 104. CAUTION
- Accumulator replacement is described in the Speedo sensor must be calibrated and lead-sealed.
ZF-Intarder Repair Manual 6085 751 122.
Solenoid Valve
CAUTION
Fit all connectors in a strain-relieved way and 1 Slightly grease O-ring 02.180 and insert
check detent. into solenoid valve 02.170 and fasten with
2 M8x22 fillister head screws 02.190.
Tightening torque M8: 23 Nm
Output Speed Sensor
1 Screw in impulse sensor 31.260. Temperature Sensor

1 Screw in temperature sensor 05.030 with
sealing ring.
1348_81D_010_en
1337 751 101 - 2009-09 60 2009-09
ZF-AS Tronic Intarder
05.100 7
05.110
05.030
31.260
05.400
02.180 05.430
02.170 05.440
05.410
05.420
31.230
02.190
014738_1
Removing 3/2 Directional Valve (accumulator Removing Intarder Cable Harness

charge valve)
1 Remove 3 cable clips 05.440.
1 Pull out connector from the 3/2 directional
valve 05.100 and remove air connection (7). 2 Remove 4 screws 05.430 M4 and detach the
plug connections.
2 Remove 2 M8 hex-head bolts 05.110.
Remove the 3/2 directional valve 05.100 with
O-ring (ZF no. 0634 313 028). Mounting Intarder Cable Harness
1 If the angles 05.410 are damaged, replace

Mounting 3/2 Directional Valve them.
Tighten M8 hexagon screw 05.420 to 23 Nm.
1 Use 2 M8 hex-head bolts 05.110 to fasten the
new O-ring (ZF no. 0634 313 028) and the 2 Cable harness assembly: Position nose to the
3/2 directional valve 05.100. top – attach to angle with 4 screws 05.430 M4.
Tightening torque M8:23 Nm Tightening torque M4: 2 Nm
2 Connect air connection (7). 3 Use 3 cable clips 05.440 to fasten

Tightening torque: the cable harness to the Intarder.
Hollow screw M16X1.5 = 45 Nm
1348_81D_010_en
1337 751 101 - 2009-09 61 2009-09
ZF-AS Tronic Additional Cooling
Assembling the Valve Block of the Additional

Cooling Unit
NOTE 01.030
Manuals, such as 1327 751 105 are made available
for the the assembly/removal of the heat
exchanger.
1 Remove screw plugs 01.030 and 01.040.
01.040
018479
2 Insert O-rings 47.020 and 47.030 as well as

hollow screws 47.050 and 47.060 into the 47.030 47.020
valve block 41.010.
47.010
47.060
47.050
018478
3 Screw in hollow screws 47.050 and 47.060 47.050 47.010 47.030

into the transmission housing and tighten to
60 Nm.
47.050 47.060 47.020
47.060
018480
1327_47D_050_en
1337 751 101 - 2009-09 62 2008-03
ZF-AS Tronic Display
ZF Display
(0501 211 422 CAN capable)
CAUTION
1
Only work on the display when the ignition is off.
NOTE
You must be able to access the display from below.
2
Removal
Remove connector (2) from display.

Force out retaining brackets (see arrow) and move
display (1) up and out.
014651
Installation
Slide display (1) into opening.
CAUTION
Fit connectors (2) in strain-relieved manner and
check detent.
Wiring Diagram
0501 211 422, see Annex
Connector Assignment
PIN 1: 58 (light on /off) on = GND

PIN 2: AD (Piezo) Imax = 200 mA
PIN 3: 58d (light dimmed) on = VP
PIN 4: SD (ZF-BUS)
PIN 5: CAN H
PIN 6: VM (GND)
PIN 7: CAN L
PIN 8: VP (Batt): 9V......32V
max. power consumption 60mA
Type of protection: front IP54, rear IP30
If the connector has to be replaced, please use the

AMP standard tool. For vehicle-specific wiring
diagram, refer to parts list.
1327_80D_070_en
1337 751 101 - 2009-09 63 2008-03
ZF-AS Tronic Range selector
Console-type range selector

(ZF-Nr. 6006 029 018)
CAUTION
Only work on the display if the ignition is off.
Removal 3
1 Pull off connector (1) and remove 4 screws

M8 (2).
2
2
1
Installation
1 Snap in connector (1). 014 650
2 Fasten console-type range selector (3) with

4 screws M8 (2).
Tightening torque M8: 23 Nm
CAUTION
If the connector has to be replaced,

please use the AMP standard tool.
Circuit diagram 6006 700 579, refer to annex
1327_80D_010_en
1337 751 101 - 2009-09 64 2008-05
Steering-column switch*
CAUTION
Only work on the range selector when the
ignition is off. 7
8
• Steering-column switch (9) ZF no. 0501 211 185

Circuit diagram: 0501 211 185, see Annex 6
5
• Rotary switch (8) ZF no. 6006 199 031

Circuit diagram: 6006 700 586, see Annex
4
• EVOBUS version
ZF no. 6006 199 030 9
separate rotary switch and separate
range selector ZF no. 6006 235 012 014652
Removal
1 Pull out connector (4) from cable harness

and remove 2 screws M5 (5).
2 Remove 4 screws M4 (6) from rotary switch

(8) and pull out connector (7) from cable
harness.
Installation Connector Replacement
1 Plug connector (7) to cable harness and If a connector has to be replaced, please use the
fasten rotary switch (8) with 4 screws M4 AMP standard tool.
(6). For wiring diagram, refer to parts list.
Tightening torque M4: 2.8 Nm
2 Plug connector (4) to cable harness and

fasten steering column switch (9) with 2
screws M5 (5).
Tightening torque M5: 5.5 Nm
CAUTION
Fit connector strain-relieved and check detent.
NOTE
Access to other components (e.g. brake step
switch) must be ensured.
* Special version
1327_80D_020_en
1337 751 101 - 2009-09 65 2008-05
Pushbutton Range Selector*

(ZF no. 0501 214 599)
3
NOTE
The order no. 6006 039 006 include a pushbutton
range selector and a sticker. R
CAUTION N
Only work on the speed range selector if the
1
D Fn
ignition is off.
Removal
1 Pull out connector (1). 019519
Installation CAUTION
Electromagnetic influences (EMC) can cause
1 Snap in connector (1). malfunctioning or even failure of electronic devices
(e.g. cell phones, radio sets...). This sticker should
2 Attach pushbutton range selector (3).
therefore be within the field of vision of the driver.
CAUTION
Fit connectors in strain-relieved manner and
check detent.

AMP standard tool.
Use of
electronic equipment
in the proximity of the shifter
may cause malfunction
031577_en
Sticker
* Special version
1327_80D_030_en
1337 751 101 - 2009-09 66 2009-09
The following installation specifications apply to the

pushbutton range selector 6006 039 006:
• A minimum distance of 50 cm must be kept

between installed radio sets and the ZF pushbutton
range selector.
• Transmitting antennas must be mounted at a

minimum distance of 1.5 m from the ZF push-
button range selector. The type of antenna must be
selected in accordance with the specs of the sender
and the installation location of the antenna.
• A minimum distance of 20 cm must be kept

between the wiring of senders (e.g. power supply,
microphone, antenna cables) and the ZF push-
button range selector.
• Power supply lines of senders according to

installation instruction (short lines, correct cable
cross-section, good contacts on voltage supply and
vehicle minus or chassis).
• The ZF pushbutton range selector must be installed

in such a manner that a distance to senders (e.g.
cell phones, radio sets) greater than 50 cm is
ensured. If necessary, the installation locations of
senders must be changed.
• Avoid horizontal installation of the ZF pushbutton

range selector to prevent senders (e.g. cell phones )
from being placed on the ZF pushbutton range
selector. This prevents direct EM influence in the
nearfield range of the cellular radio antenna on
the selector electronics.
• Cellular radio holders next to or on the ZF push-

button range selector must be avoided.
1327_80D_030_en
1337 751 101 - 2009-09 67 2009-09
D N
A/M
R
+ Shift up 2 gears (spring stop)

+ Shift up 1 gear (first spring stop)
A/M Switching from automatic into manual mode
(and vice versa)
D= Driving (Drive)
N= Neutral (Detent)
R= Reverse (Detent)
– Shift down 1 gear (first spring stop)
– Shift down 2 gears (spring stop)
024528
ZF Lever-Type Range Selector
Order no. with knob: 6006 039 003

Order no. without knob: 0501 322 394
Drawing no. 0501 322 394
Operating instructions: 1348 758 101
NOTE
The range selector is designed fordashboard or con-
sole installation. The cover (cap) and the leather
sack required for the knob connection are not part
of the ZF scope of supply.
The installation location of the range selector has to
be chosen in such a way that the range selector is
not damaged when the driver gets on or off.
More range selector data can be found in drawing

6006 039 003.
1348_80D_020_en
68 2008-03
ZF-AS Tronic Electronic Control Unit
E-module*
(ZF no.: 6041 322 023)
1
CAUTION 2
Work on the E-module only when the ignition is 1
off. 1
4
NOTE
The E-module is located in the E-compartment of
the vehicule.
3
Removal
1 Pull out 35-pin connector (3) from E-module

(2). 014700
2 Remove 3 screws (1) and earthing strap (4).
Installation
Installation instructions:
The E-module housing must be connected with an
earthing strap to the chassis ground.
The E-module must be installed in a protected loca-
tion, in accordance with the approved installation
position.
1 Screw on E-module (2) and earthing strap (4).

Tighten screws M5 (1) to 5.5 Nm.
2 Fit connector (3) to E-module (2).
CAUTION
Fit connector in a strain-relieved manner and
check detent.

AMP standard tool.
For wiring diagram, refer to parts list.
* depending on parts list version
1327_80D_040_en
1337 751 101 - 2009-09 69 2008-05
E-module 2*
(ZF no.: 6041 322 044) 1
2 1
CAUTION
Work on the E-module only when the ignition is
off. 4
NOTE
5
The E-module is located in the E-compartment of
the vehicle.
Removal
3
1 Remove 15-pin and 18-pin connectors
(5 and 3) from E-module (2). 029484
2 Remove 2 screws (1) and ground strap (4).
Installation
Installation instructions:
The E-module housing must be connected with a
ground strap to the chassis ground.
The E-Modul must be installed in a protected
location, paying attention to permitted installation
position.
1 Screw on E-module (2) and ground strap (4).

Tighten screws M5 (1) to 5.5 Nm.
2 Snap in connectors (5 and 3) on E-module (2).
CAUTION

AMP standard tool.
* depending on spare parts version
1327_80D_041_en
1337 751 101 - 2009-09 70 2008-05
ZMTEC
(ZF Meritor Transmission Electronic Control,
ZF no. 0501 320 211, refer to annex)
CAUTION
Work on ZMTEC only when the ignition is off.
Removal 1
2
1 Remove screw (1) from connector (2).
2 Pull 35-pin connector(2) off ZMTEC (3).
3 Remove 4 screws (4) and take off ZMTEC (3).

019503
Installation
Installation instruction:
The ZMTEC must be installed at a protected
location in accordance with the released
installation positions.
2
1 Attach ZMTEC (3) with 4 screws (4). 3
2 Snap in connector (3) on ZMTEC (2) and 4

tighten screw (1).
CAUTION
019502

AMP standard tool.
1327_80D_050_en
1337 751 101 - 2009-09 71 2008-05
ZMTEC pin assignment
1337 D1 0074
1327_80D_050_en
1337 751 101 - 2009-09 72 2008-05
ZF-AS Tronic Wiring
Type Designations and Order Numbers
Plut Usage Type Manufacturer Manufacturer no. CKD no. Protection

class
X1 Transmission actuator 20-pin bush Kostal Connector housing: 09432001 6029 199 090 IP 67/ 69
(TCU) Bush contact: 22124472200
Seal: 10800444521
Blind plug: 10800472632
X1 Transmission actuator 18-pin bush Kostal Connector housing: 09432691 6029 199 125 IP 67/ 69
(TCU) Bush contact: 22124472200
Special version Seal: 10800444521
Blind plug: 10800472632
X21 Diagnosis 6-pin plug MNL AMP Connector housing: 926682-3 6029 199 027
Contact pin: 926887-1
X21 Diagnosis 6-pin bush MNL AMP Connector housing:350715-1 6029 199 092
Mating connector Contact bush: 926882-3
X2 Lever-type range selector 21-pin bush AMP Connector housing: 8-968975-1 6029 199 160
3-reihig Contact bush: 927771-3
X2 Lever-type range selector 21-pin plug AMP Connector housing: 1-967630-1 -
(speed range selec. conn.) 3-reihig Contact bush: 926887-1
X2 Pushbutton range selector 14-pin bush AMP Connector housing: 776273-1 6029 199 133
AMPSEAL Contact bush: 770854-3
X2 Range selector (with 14-pin bush JPT AMP Connector housing: 929504-5 6029 199 042
seperate E-module) Contact bush: 927771-3
X36 E-module in the case 35-pin AMP Connector housing: 925379-1 6029 199 091
of console-type range Bracket: 928544-1
selector with separate Cap: 925380-1
E-module ISO-1481-screw ST 2,9X9.5-F
Seal ZF 6020 303 013
Contact bush 925590-1
X36a E-module 2 15-pin bush AMP Connector housing: 964561-2 6029 199 143
Contact bush: 927771-3
X36b E-module 2 18-pin bush AMP Connector housing: 8-968974-1 6029 199 144
X5 Display JPT 8-pin bush AMP Connector housing: 929504-3 6029 199 108
A11/A14 Output sensor 4-pin bush DIN AMP Connector housing: 1-967325-1 6029 199 111 IP 67/ 69K
Bay. angle Cap: 965783
Bush contact: 0-929974-1
Seal: 828920-1
Blind plug: 828922-1
X17 Main power system 22-pin bush JPT AMP Connector housing: 929504-7 6029 199 043
junction Contact bush: 927771-3
X17 A Main power system 22-pin plug JPT AMP Connector housing: 929505-7 6029 199 025
Mating connector junction Pin contact: 928930-5
junction Contact bush: 927771-3
X17 A Main power system 18-pin plug JPT AMP Connector housing:929505-6 6029 199 026
Mating connector junction Pin contact: 928930-5
junction CAN Contact bush: 927771-3
X18 A Main power system 6-pin plug JPT AMP Connector housing: 926682-3 6029 199 110
Mating connector junction CAN Contact pin: 928930-5
X18 Main power system 3-pin plug Fa. Deutsch Connector housing: DT06-3S-CE04 - IP69H
junction CAN Series DT Contact pin: 0462-202-16141
X18 A Main power system 3-pin bush Fa. Deutsch Connector housing: DT06-3S-CE04 - IP69H
Mating connector junction CAN Series DT Contact bush: 0462-201-16141
X19 Cab junction 18-pin bush JPT AMP Connector housing: 929504-6 6029 199 084
X20 Mating Cab junction 18-pin plug JPT AMP Connector housing: 929505-6 6029 199 026
connector to X19 Pin contact: 928930-5
X19 Cab junction 31-pin plug Fa.Deutsch Connector housing: ZF no. 6029 301 114 - IP69H
Series WT Clutch: WTC06B-24-31PN
Pin contact: 0460-202-16141
X20 Mating Cab junction 31-pin bush Fa.Deutsch Connector housing: WT06B-24-31SN - IP69H
connector to X19 Series WT Contact bush: 0462-201-16141
Plug replacement: If a plug needs to be replaced, please use the AMP standard tool.
Refer to parts list for wiring diagram.
1348-80D-010_en
1337 751 101 - 2009-09 73 2008-03
ZF-AS Tronic Pneumatic Diagram
Example
Compressor
4-circuit
Air drier protection
valve 21
23
1
24
22
Transmission actuator
with pressure sensor
D-I = 9 mm
20 L
Clutch Non-
actuator return Overflow
valve valve
D-I = 9 mm
Auxiliary
> 5 bar*
consumer
max. 4 m
Intarder
* The pressure set at the pressure relief valve must be higher than the closing
pressure of the corresponding output at the 4-circuit protection valve.
027526
1327_80D_060_en
1337 751 101 - 2009-09 74 2008-02
ZF-AS Tronic Annex
Annex
Attached Documents
Order no. Designation
1337 754 101 ZF-AS Tronic – Show contents of error memory and delete error memory
1337 754 105 ZF-AS Tronic – ZF pushbutton range selector: Show error memory contents and delete error
memory
1327 D1 0031 CAN bus measurements with digital multimeter
– ZF-AS Tronic / ZF-AS Tronic mid checklist
– ZF-AS Tronic / ZF-AS Tronic mid NAFTA checklist
1337 D1 0130a Testman pro programming instructions
– Service Information No. 26_05 Neutral switch

– Service Information No. 08_06 Neutral switch
Attached Drawings
Drawing no. Designation Techn. information

0501 210 854d Installation drawing Impulse sensor
0501 211 185a Installation drawing Steering-column switch
0501 211 422e Installation drawing Display
0501 320 211 Installation drawing ZMTEC
6041 322 045d Installation drawing ZF E-module 2
6041 622 023d Installation drawing ZF E-module
1327 600 007i Installation drawing BUS, ZF-ASTronic with Intarder
1328 600 019 Installation drawing Clutch release
1328 600 043 Installation drawing Clutch release
6006 629 024 Installation drawing Console-type range selector
6006 700 579c Circuit diagram Console-type range selector
6006 700 586a Circuit diagram Console-type range selector
0501 214 599 Installation drawing Pushbutton Range Selector
6029 713 148a Circuit diagram ZF pushbutton range selector with E-module 2
6006 639 003a Installation drawing ZF Lever-Type Range Selector
6029 713 149 Circuit diagram ZF Lever-Type Range Selector
6029 713 168 Wiring Diagram ZF Lever-Type Range Selector
6029 711 038a Circuit diagram EST 42 Bremsomat CAN
6029 713 025b Circuit diagram Main computer
1337_55D_010_en
1337 751 101 - 2009-09 75 2009-09
How to display and delete error memory
This document applies to vehicles with ZF display and ZF-AS TRONIC transmission system.
For vehicles with other displays refer to description of manufacturer.
Display error memory (read-out):
• Engine OFF
• Turn ignition ON
• Turn control switch to «N», actuate service brake and hold.
• Push tip lever forward and hold in front position.
• This allows read-out of error memory on display.
Have faults repaired in authorized ZF Service Center. Delete errors from memory before test run.
Delete error memory:
• Engine OFF and ignition OFF

• Push tip lever forward and hold in front position.
• Wait for 3 seconds to release tip lever. Tip lever returns to center position.
• Wait for another 3 seconds, push tip lever forward and hold in front position.
• Turn ignition OFF after another 2 or 3 seconds.
• This deletes error memory.
Read-out error memory once more after test run and have faults repaired, if any. Then delete any further errors form
error memory.
ZF Friedrichshafen AG Tel. ++49 (7541) 77-0

Fax. ++49 (7541) 77-908000
Subject to technical changes. D 88038 Friedrichshafen Internet www.zf.com
Order No. 1337 754 101 Printed in Federal Republic of Germany/Imprimé en République Fédérale d'Allemagne; ZF-Druckerei, Friedrichshafen
ZF range selector keypad:
How to display and delete error memory
This document applies to vehicles with a ZF range selector keypad (ZF part no.: 0501 219 979) and a ZF-AS tronic
transmission system.
Display error memory (read-out):
• Engine OFF
• Move range selector into «N» position
• Actuate service brake
• With service brake actuated, press «↑» button on range selector and hold down
• This allows read-out of error memory on display.
Have faults repaired in authorized ZF Service Center. Delete errors from memory before test run.
Delete error memory:
• Engine OFF and ignition OFF

• Press «↑» button on range selector and hold down
• After approx. 3 seconds, release button.
• Wait approx. 3 seconds and press «↑» button on range selector and hold down
• Turn ignition OFF after another 2 or 3 seconds
• This deletes error memory.
Read-out error memory once more after test run and have faults repaired, if any. Then delete any further errors form
error memory.
ZF Friedrichshafen AG Tel. ++49 (7541) 77-0

Fax. ++49 (7541) 77-908000
Subject to technical changes. D 88038 Friedrichshafen Internet www.zf.com
Order No. 1337 754 105 Printed in Federal Republic of Germany/Imprimé en République Fédérale d'Allemagne; ZF-Druckerei, Friedrichshafen
ZF-AS Tronic CAN BUS Measurements
CAN BUS Measurements With Digital Multimeter
NOTE
All measurements described below are taken with
the terminal tester and a multimeter.
The actual values are measured between the

respective terminals and compared with the
specified target values (red measuring peak « + »,
black measuring peak « – ».)
The cabling and the plug connection are also

included in this measurement:
1. Set multimeter to resistance measurement.
2. Ignition OFF (all control units must be

connected).
3. Connect terminal tester.
Measurement between Target value Actual value Possible cause
CAN H
approx. 0 Ω Short circuit from CAN H to CAN L
red measuring peak
and approx. 60 Ω Connection to terminator is interrupted or resistor

approx. 120 Ω
damaged.
CAN L
black arrow pointer Both terminators are not connected and/or damaged
approx. ∞ Ω
or CAN interrupted.
1327_D1_0031_en
77 2008-04
Checklist AS-Tronic / AS – Mid
Editor: ________________________ Date: __________________
Vehicle data:
Vehicle operator: ________________________________________________________
Vehicle manufacturer: ________________________________________________________
Chassis number (VIN): ________________________________________________________
Engine type: ________________ Engine power : _________________
Mileage: ________________ Date in service: _________________
Model type : ________________ License no.: _________________
Transmission data:
Transmission type: ________________ Spec. list: _________________
Serial number: ________________
TCU No. (ZF): ________________ Wabco GS No.: _________________
Clutch actuator no.: ________________
Software: 6009 ____ ____ P1: ___________.hex P2: ___________.hex
Complaint: _________________________________________________________________
_________________________________________________________________
Exception:
Oil temperature by complain resp. error warning: ______C
Problem with communication: Communication in order
No communication via vehicle diagnose interface
No communication via table modus adapter
Interruption during programming P1
Interruption during programming P2
Error memory:
Error code Frequency Countdown Text
!! Do not delete the error memory of the replaced transmission actuators !!
Seite 1 von 5 Stand: 12.02.07 LKS-T Pricha
1348 D1 0030a
Clutch data: (Necessary if the transmission is removed due to clutch problems)

Clutch type: ______________________________
Clutch disc: ______________________________
Pressure plate: ______________________________
Release bearing: ______________________________
Release fork: ______________________________
10-Speed DD 10-Speed OD 12 - Speed 16 - Speed

Limit positions (GS 3):
Action Signal Nominal Actual

4-7-1-3 GS 3 GS 3.3 AS-Tronic
10 – speed DD
1st gear engaged High value Front left < 590 Ink
3rd gear engaged Low value Rear right > 80 Ink
5th gear engaged High value Front right < 590 Ink
1st reverse engaged Low value Rear left > 80 Ink
Difference 1st gear – 1st reverse < 500 Ink
Difference 5th gear – 3rd gear < 500 Ink

10 – speed OD
5th gear engaged High value Front left < 590 Ink
1st gear engaged Low value Rear right > 80 Ink
3rd gear engaged High value Front right < 590 Ink
1st reverse engaged Low value Rear left > 80 Ink
Difference 5th gear – 1st reverse < 500 Ink
Difference 3rd gear – 1st gear < 500 Ink

4-7-1-3 GS 3 GS 3.3 AS-Tronic AS-Mid
12 – speed
1st gear engaged High value Front left < 590 Ink < 520
3rd gear engaged Low value Rear right > 80 Ink > 120
5th gear engaged High value Front right < 590 Ink < 520
1st reverse engaged Low value Rear left > 80 Ink > 120
Difference 1st gear – 1st reverse < 500 Ink < 390
Difference 5th gear – 3rd gear < 500 Ink < 390

16 – speed
1st gear engaged Low value Rear left > 80 Ink
3rd gear engaged High value Front left < 590 Ink
5th gear engaged Low value Rear right > 80 Ink
7th gear engaged High value Front right < 590 Ink
1st reverse engaged High value none < 590 Ink
Difference 3rd gear – 1st gear < 500 Ink
Difference 7th gear – 5th gear < 500 Ink
1348 D1 0030a

4-7-1-3 AS-Tronic AS - Mid AS - Tronic AS - Mid
Limit positions
gate, group, split
Gate (1/2) (1/R) Low value 70 – 120 Ink 70 - 120
Gate (3/4) (2/3) High value 500 – 580 Ink 500 - 580
Group low Low value High value 80 – 130 Ink 515 - 590
Group high High value Low value 490 – 590 Ink 100 - 145
Splitter low (overdrive) Low value 70 – 140 Ink 120 - 170
Splitter high (overdrive) High value 500 – 650 Ink 500 - 550
Splitter low (direct drive) High value 500 – 650 Ink 500 - 550
Splitter high (direct drive) Low value 70 – 140 Ink 120 - 170

4-7-2
Clutch actuator
Input speed (low idle aktiv) Clutch engaged = engine
N_sek ___ 1/min
speed (1/min)
Relative clutch stroke (%) in neutral
S_kup (%) In neutral = 100%
to absolute clutch travel (mm) ___% Ù ___ mm
S_Kup_abs (mm) 100% = 27 – 60mm
(clutch is engaged)
Absolute clutch transfer point Between 12 and 45mm
S_kup_ap_abs ___ mm
(depend of wear / milage) (= 0% S_Kup)
Difference between absolute clutch Difference
transfer point and clutch engaged S_kup_abs app. 14 – 19 mm ___ mm
(DAF: 14 – 21mm)
Relative clutch travel (%) gear S_kup (%) Clutch open = app. 0%
engaged to absolute clutch stroke S_kup_abs (mm) ___% = ___mm ___ % Ù___ mm
(mm)
Length of pressing rod Part list no. Length (mm)

Measurement is only necessary if the absolute clutch travel (mm) is out of tolerance.
Bova, DAF, Dennis, Evobus, Neoplan, VDL 1328 302 033 119,1
RVI, Irisbus 1328 368 008 123,1
Deawoo, HMC, KIA 1314 268 002 124
MAN (Bus/truck) 1328 368 003 127,1
MAN TC-Tronic 1328 368 007 130
Irisbus (Cursor 10 F3A) 1314 268 002 136
Meritor, MCI, Prevost, Spartan, , Van Hool (USA) 1328 368 009 144,9
IVECO 1314 268 002 adjustable

4-7-4
Operating voltage
Terminal 30 18V – 29,5V
Terminal 15 (ignition) 18V – 29,5V
1348 D1 0030a

4-7-1-1
Check term 30 / 15
Vehicle stop with engaged gear and During ignition off with engaged gear the
ignition off: transmission must shift hearable into Neutral
Range group position high GPS (AS-Tronic) 490 Ink – 590 Ink
GPS (AS – Mid) 100 Ink – 145 Ink
Gear position neutral Gear sensor 300 Ink – 345 Ink
4-7-5
Acc. pedal (MAN FFR)
Not activ = 0%
Accelerator position Alpha_fp
Depressed pedal = 100%
Kickdown feeling point Alpha_fp 88 – 92 %
Kickdown activ Z_Sonder_status Accelerator > app. 95%
Decrease of KD-signal by
Kickdown inactiv Z_Sonder_status
accelerator < 80 %
Low idle switch aktiv Z_Sys_Status_1_UFB Accelerator < 8%
Accelerator pedal (without FFR)
Not activ = 0%
Accelerator position Alpha_fp
Depressed pedal = 100%
Kickdown activ Z_Sonder_status Accelerator 100%
Decrease of KD-signal by
Kickdown inactiv Z_Sonder_status
accelerator < 100 %
Low idle switch activ Z_sys_Status_1_UFB Accelerator < 13%
4-7-7
System pressure (GS3)
System pressure Druck_Luft 7,0 – 7,8 bar
4-5-1
Sig. brake pedal switch
Z_sys_Status_1_UFB
7-5-1
Signal exhaust brake
Z_sys_Status_1_UFB
4-5-1
Power take off (PTO)
Measurement of this signal is only necessary if there are any problems regarding PTO
Request PTO switch SN1A Signal activ 1
check signal ECU Astronic SN1F Signal activ 1
PTO engaged (feedback) SN1R Signal activ 1
2-1-9
Statistic memory
Data get of vehicle value memory
123456.sta
(Filename = serial number gearbox)
1348 D1 0030a
CAN - measurement
Measurement of the CAN is only necessary if there are any problems regarding CAN-errors
Measurement CAN H and CAN L 59 - 61 Ohm
Short circuit H to L
Interrupt connection to resistance actual app. 0 Ohm
Interrupt both resistances actual app. 120 Ohm
app. infinite Ohm
Remarks / Measures:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Note: You have to add the checklist to the replaced parts!
Protokoll of Datalogger Recordings
Filename Remarks
.dat
.dat
.dat
.dat
.dat
.dat
.dat
.dat
.dat
Remarks:
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
1348 D1 0030a
Checklist ASTRONIC 2 / ASTRONIC-mid
North America - 10 and 12 speed transmissions
Technician: Date:
Customer: Vehicle fleet no.:
Vehicle manufacturer: Vehicle model:
In service date: Vehicle mileage:
Chassis number – VIN (all 17 digits):
Engine manufacturer & model:
ZF Testman-pro action buttons
Transmission information 3-9

Transmission type:
Transmission serial number:
Transmission combination product no. (Transmission Spec/Part No.):
Transmission actuator no. (GS3 / GS3.3): Wabco number (GS / GS3.3):
ZF Programming: 6009 P1: .hex P2: .hex
Cutch actuator serial number (only available on the actuator data decal):
Complaint
Error memory 3-1

Text description Failure (FNr.) Count (Cnt) Current ** Countdown
0
1
2
3
4
5
6
7
8
9
DO NOT DELETE THE ERROR MEMORY FROM THE REPLACED TRANSMISSION ACTUATOR
** Click on the failure action button(s) – 0, 1, 2, 3 …etc. Read: “Countdown unit” for each failure
Page 1 of 4 ASTRONIC2/ASTRONIC mid_08.2008 ZFSSNA_MT

1348_D1_0041
(Inc = Increments ≈ 0.06 mm)
10 – Speed OD (Gears on the display) Signal Signal Nominal Actual
Limit positions 4-7-1-3 GS 3 GS 3.3 AS-Tronic
5th gear engaged Odd gears Front left < 590 Inc
1st gear engaged Even gears Rear right > 80 Inc
3rd gear engaged Odd gears Front right < 590 Inc
Reverse engaged Even gears Rear left > 80 Inc
Difference 5th gear – Reverse < 500 Inc
Difference 3rd gear – 1st gear < 500 Inc
12 – Speed OD (Gears on the display) Signal Nominal Actual Nominal Actual

Limit positions 4-7-1-3 GS 3 GS 3.3 AS-Mid AS-Tronic
1st gear engaged Odd gears Front left < 520 Inc < 590 Inc
3rd gear engaged Even gears Rear right > 120 Inc > 80 Inc
5th gear engaged Odd gears Front right < 520 Inc < 590 Inc
Reverse engaged Even gears Rear left > 120 Inc > 80 Inc
Difference 1st gear – Reverse < 390 Inc < 500 Inc
Difference 5th gear – 3rd gear < 390 Inc < 500 Inc
Clutch actuator limit positions 4-7-2 Signal Nominal Values Actual Values
Clutch engaged =
Transmission input speed (Low idle active) N_sek rpm
engine speed (1/min)
Relative clutch stroke (%) in neutral to S_kup (%) Clutch closed = 100%
A %Ù mm
Absolute clutch stroke (mm) S_Kup_abs(mm) 100% = 27 – 60mm
Conditions:
Engine: idle speed - Transmission: neutral - Clutch: engaged = 100%
100% = value in mm „set value“ between 27 and 60 mm (e.g. 41mm) depending on wear
Absolute transfer point (mm) (wear depended) S_kup_ap_abs Between 12 and 45mm mm
Conditions:
Engine: idle speed - Transmission: neutral - Clutch check passed at engine start-up, clutch engaged.
B Actual value in mm: between 12 and 45 mm means 0% clutch travel
“Absolute transfer point” ( “kissing point”): Clutch will disengage (open) until the transmission input rpm drops down to 0 rpm
(If not, fault code 117/124 will be logged). Next, the clutch will engage until a specific transmission input rpm is being recognized (“kissing point”)
and then slightly open back to fully disengaged position and engine rpm is zero again. (0% = e.g.: 25mm)
Difference
Difference between absolute clutch stroke
S_kup_abs app. 14 – 19 mm mm
and absolute clutch transfer point
C (DAF: 14 – 21 mm)
Calculation:
Actual value to be between: 15 and 19mm. This is the working stroke of the clutch actuator between clutch engaged and disengaged.
E.g.: clutch position in neutral = 41mm and kissing point at 25mm (41mm – 25mm = 16mm), the result is the working stroke: 16mm
Relative clutch stroke (%) gear engaged to S_kup (%) Clutch open = app. 0%
%Ù mm
Absolute clutch stroke (mm) S_kup_abs(mm) 0% = XXX mm
D Conditions:
Engine: idle speed - Transmission: gear engaged - Clutch status: disengaged
The actual value is a control value and to be approx. the “kissing point” (e.g.: 25mm).
Length of pressing rod Part list no. Length (mm) Select

1348_D1_0041
Note: Measurement is only necessary if the absolute
clutch travel (mm) is out of tolerance.
1328 302 033 119.1
1328 368 008 123.1
N. America–Truck (Mack, Volvo, MBE4000 engines) 1328 368 004 133.6
1328 368 003 127.1
1328 368 007 130.1
1328 368 015 138.6
N. America Bus / Truck (CAT, DDC, Cummins eng.) 1328 368 009 144.9
1328 302 026 111.6
1314 268 002 adjustable
Clutch information:
Clutch manufacturer (if available):
Clutch part number (if available):
Pressure plate part number (if available):
Clutch fork type: Standard: Roller Fork:
Value /
Operating voltage check 4-7-4 Nominal Values Actual Values
Description
Operating voltage (term.30) V - Battery V (Volt) 18.0 V – 29.5 V
Operating voltage (term.15) V - Ignition V (Volt) 18.0 V – 29.5 V
Make sure the vehicle is stationary! While monitoring term. 30 and term. 15 switch the ignition to OFF.
Read: “Operating voltage (term 30) V”. Voltage must remain in range 18V – 29.5V. YES NO
Read: “Operating voltage (term 15) V”. Voltage must go to approx. 0 V – 2 V YES NO
Transmission neutral check 4-7-1-1 Confirm / value

During ignition off with gear engaged the
Vehicle stopped with gear engaged. Switch
transmission must shift audible into Neutral YES NO
ignition to “OFF”!
and Range Group to High
Gear Position Neutral
Gear Sensor (Inc) 300 Inc – 345 Inc
Read: “Gear sensor (INC)“
Range Group Position GPS (ASTRONIC) 490 Inc – 590 Inc
Read: “GP sensor (INC)“ GPS (AS-Mid) 100 Inc – 145 Inc
Accelerator pedal check 4-7-5 Confirm / value
Idle = 0% %
Accelerator pedal position % Alpha_fp
Full Throttle = 100% %
Idle Validation Switch active Accelerator < 13%
Read: “Accelerator pedal position %“ Z_low_idle Idle Switch OFF before %
Read: “Idiling switch test“ 13% of throttle position
Kickdown switch test Depressed pedal 100%
Z_kd ON OFF N/A
Read: “Kickdown switch” Kickdown ON
System pressure (GS 3 / GS 3.3) 4-7-7 Actual value
Read: „System pressure (mBar)“ 1000 mBar= 1 Bar Druck_Luft 7.0 – 7.8 Bar Bar
Inputs check 4-5-1 Confirm

1348_D1_0041
Signal brake pedal switch (stationary & driving) Z_FBR Pin SBS signal active YES NO N/A
Signal exhaust brake
Z_mbr_an Pin SMB signal active YES NO N/A
Read: SMB pin
Signal PTO (power take off) Request switch Pin SN1A signal active YES NO N/A
Note: Measurement of this signal is only necessary if Signal check ECU Pin SN1F signal active YES NO N/A
there are any problems regarding PTO Engaged/feedback Pin SN1R signal active YES NO N/A
Statistical data GS 3 2-1-9 Confirm
Retrieve and save statistical data
File type .sta (Trans S/N).sta YES NO
(File name = gearbox serial number)
Statistical data GS 3 or GS 3.3 4-9-8-1 Confirm
Save_EEprom_Hex_File
File type .hex (Trans S/N).hex YES NO
(File name = gearbox serial number)
CAN measurement Value Nominal Value Actual Value

Measure between CAN_H and CAN_L
(All controllers / ECU-s must be connected)
OHM (Ω) 59-61Ω
Note: Measurement of this signal is only necessary if
there are any problems regarding CAN errors
“EASY START“ function check Description Reaction Confirm
o Vehicle stopped
Vehicle service brakes
o Starting gear engaged
Rollback prevent realise after approx. 2 YES NO
o Service brake engaged
sec.
o Service brake disengaged
Remarks / Measures:
INCLUDE CHECKLIST COPY WITH REPLACED TRANSMISSION OR TRANSMISSION ACTUATOR

1348_D1_0041
Programming Instruction for Testman Pro
Connect the DPA05 as follows:
• Connect the serial interface cable between DPA05 (V24 - RS232)

and the serial interface on the PC (Com1)
• Connect diagnosis cable (3) to DPA05 on the “ISO 9141“ (2)
interface
• Connect 6-pin diagnosis plug with the diagnosis connector in the
vehicle
• Switch on ignition
• Green lamp on DPA05 must light up
Programming Instuctions 1
Testman Pro
1337 D1 0130a
Double-click the Testman - Icon
Click mouse on green square with tick

in bottom right-hand corner
Alternatively:
Activate window with mouse;
Confirm Start window with Enter
Click mouse on „2 ASTRONIC 2“
Alternatively:
Press button 2
License is being checked.

Wait untill window closes automatically
Testman Pro
1337 D1 0130a
Read safety notice and click mouse on
green box in bottom right-hand corner
to confirm.
Alternatively:
Confirm by pressing Enter key
Click mouse on „5 Vehicle Configuration“
Alternatively:
Press button 5
Click mouse on
„2 Flash/Vehicle “
Alternatively:
Press button 2
Click mouse on „1 Flash Programming“
Alternatively:
Press button 1
Testman Pro
1337 D1 0130a
click mouse on green box with thick in
bottom right-hand corner
(note for MAN - Vehicles)
Alternatively:
Confirm notic window with Enter
Click mouse on „1 loud up Part List“
Alternatively:
Press button 1
Software Update:
Open „Update_V31_13j“ file
with double click
Programming of replacement tranmissions

or replacement of transmission actuator:
Open “Cpl_Programming_V31_13j“
file with double click.
Selct corresponing “A“ item no.
(refer to summary list for “AS Tronic

Assigment: Vehicle - Engine - Software“)
Testman Pro
1337 D1 0130a
Check that correct software is louded;
Click mouse on green box with tick in
Bottom right-hand corner.
Alternatively:
Confirm notice window with Enter
Click mouse on „Yes (y)“
Alternatively:
Press botton „y“
Programming now starts. The time required for programming depends on the
processing power of your PC (approximately 20 minutes).
Note: During programming operation, never switch off ignition

The programming operation is complete once a message reading „Programming
successfully completed!“ appears on screen.
Abortion of communication:
If during programming, an abortion of communication occurs, please, go
through the following steps:
- Ignition off
- Check connections
- CloseTestman Pro
- Ignition on
- RE-start programming
Contacts for Testman Pro:
Roland Aicher: +49 (0) 7541 / 77-4312

Paul Lanz: +49 (0) 7541 / 77-5481
Testman Pro
1337 D1 0130a
SERVICE INFORMATION
Nr. 26_05
Type: ASTRONIC Model: 1327, 1328, 1339 Date: 2005-09-30
CC list SSO: all + USA Assembly: Electrics Page 1 of 4
CC list OEM: DAF, RVI, IVECO
CC list customer: --
Modification Regarding Neutral Switch in ASTRONIC Transmissions
In isolated cases, neutral signal transmission in ASTRONIC transmissions was disturbed (due to
unfavorable tolerance characteristics of the neutral switch).
For optimization, the pin between neutral switch and selector shaft was shortened. This modifica-
tion coincided with a drawing amendment, i.e. the item number for this modified pin has not
changed.
Components affected:
Designation Item number Comment

Neutral switch 0501 210 059 No change
Pin 1328 306 024 Total length changed
Damage coding:
Damaged part Damage

Designation Item number Location Type Cause
Pin 1328 306 024 559 224 230
Launch data:
Production launch of the modified pin on May 2, 2005, and starting with transmission serial
number 330,000.
Measures:
1. Repair of a transmission due to a different damage pattern requires replacement of
“old” pin by shorter “modified” pin

(see page 2 for identification features of “old” and “modified” pin);
aluminum sealing washer (under the neutral switch).
Ersteller: W. Ammann, Abt. LKS-T

07541 - 77 55 52
Fax 07541 - 77 90 55 52
Email: [email protected] i.V. Stauber i.A. Stemme
ZF Friedrichshafen AG, LKW– Bus-Antriebstechnik Kundendienst Technischer Service
88038 Friedrichshafen
© ZF Friedrichshafen AG
SERVICE INFORMATION
Nr. 26_05 Page 2 of 4
2. Complaints regarding the neutral switch require replacement of
“old” pin by shorter “modified” pin;

neutral switch;
aluminum sealing washer (under the neutral switch).
Please return the defective neutral switch to ZF Friedrichshafen if it is designated as a return-

able part (see page 4 for address).
Distinguishing features of “old” and “modified” pin:
Total length A
OLD 59 – 0.5 mm MODIFIED 58.5 – 0.5 mm
Detail X
OLD MODIFIED
SERVICE INFORMATION
Nr. 26_05 Page 3 of 4
Photos of neutral switch, pin, and sealing washer:
Pin
1328 306 024
Neutral switch
0501 210 059
Sealing washer 0634 801

062 between housing
and neutral switch
Note
When screwing in the neutral switch, ensure that
• the thread is dry (free of oil);
• the correct tightening torque is applied to the neutral switch (45 Nm);
• a new aluminum sealing washer is used.
SERVICE INFORMATION
Nr. 26_05 Page 4 of 4
Sketch of installation situation for switch and pin
Neutral switch
0501 210 059
Sealing washer
0634 801 062
between housing
and neutral switch
Pin
1328 306 024
Returning defective neutral switches:
Neutral switches must be returned with completed tags to:
Plant 2
After-Sales Service (Building 4)
Mr. Siegfried Zoll, Dept. LKS-GR
Zeppelin-Werftgelände 70
Germany
Validity:
This Service Information is valid as of now and unlimited in time.

SERVICE INFORMATION
Nr. 08_06c
Type: ECOSPLIT,ECOMID,ECOLITE,ASTRONIC Model: All models Date: 2007-02-20
Mailing list SSO: All Page 1 of 5
Mailing list OEM: -- Subassembly: Electrics
Mailing list customer: --
Neutral Switch in Mechanical Transmissions
Supplements/Changes (marked with arrow )
The neutral switch was re-designed and introduced with a new parts number via a parts list change
/ change of BoM.
Components affected:
NEW OLD
Name Part number Part number Remarks
Switch 0501 215 297 0501 210 059
Substantially similar to 297, however,
Switch 0501 215 298 0501 214 642
different plug connection.
Measures:
While considering Service Information No. 26_05 dating May 30, 2005, in the case of a complaint,
the following components must be replaced:
The neutral switch (no preventive replacement).
“Old” pin by “modified” one with reduced total length (see images 1 to 5).
Aluminum sealing disk between housing and neutral switch in line with parts list (see im-
age 7).
Ersteller: W. Ammann, Abt. LKS-T i.A. Ammann geprüft: i.V. Stauber gesehen: i.V. Leibinger
07541 - 77 55 52 Fax 07541 - 77 90 55 52 Email: [email protected]

ZF Friedrichshafen AG Kundendienst Technischer Service LKW-, Bus-Antriebstechnik
88045 Friedrichshafen, Zeppelin-Werftgelände 70
© ZF Friedrichshafen AG
SERVICE INFORMATION
Nr. 08_06c Page 2 of 5
Differentiation characteristics for “old” vs. “modified” pin:
Total length A
OLD 59 – 0.5 mm MODIFIED 58.5 – 0.5 mm
Illustration 1
Detail X
OLD MODIFIED
Illustration 2 Illustration 3
Illustration 4 Illustration 5
SERVICE INFORMATION
Use of old parts:
Old switches on stock must not be installed any longer.
Swing units on stock, already repaired and/or reworked, must be retrofit with the switch in accor-
dance to the new version. When reworking swing units, it must be ensured that these are equipped
with a new switch in line with the new version.
* No return delivery of defective or used switches, old version!
* If the case of non-expected failure of a switch, new version, occurs, then it is manda-
tory to return the switch for defective part investigations to the address below. Please
add note: New neutral switch!
Return address:
LKS-GR dept.
Mr. Siegfried Zoll
Zeppelin-Werftgelände 70
D - 88045 Friedrichshafen
SERVICE INFORMATION
Modification data:
For all models affected: Parts list changes are documented with the following notification numbers.
Parts list Introduced as of

modifica- Model affected Transmission family Serial number Date
tion *)
6525E 1324 -- May 15,
NEW ECOMID
2006
6526E 1314 AS TRONIC 862.565 April 10,
1342,1344 NEW ECOSPLIT 2006
6529E 1290,1310, 1340, -- June 15,
ECOLITE
1349,1350,1351 2006
6530E 1304 ECOMID -- June 15,
6038 Shift System 2006
6531E 1307 -- April 15,
ECOLITE
2006
6532E 1312 ECOSPLIT 2 -- --
1315,1316, ECOSPLIT 3 861.981 April 12,
4130 Torque converter and 2006
6533E
clutch system (German
abbreviation: WSK)
1327,1328,1329, 376.345 April 10,
6545E AS TRONIC
1336,1338,1339,1353 2006
1316, ECOSPLIT 3 861.893 April 11,
6546E
1341 NEW ECOSPLIT 2006
1290, 1323,1332, ECOLITE -- April 15,
6547E 1295,1297 ECOSPLIT 2 2006
1346 NEW ECOLITE
Parts list modification *) = Notification number regarding parts list modification

SERVICE INFORMATION
Switches no.: 0501 215 297, 0510 215 298
Illustration 6 Illustration 7 Illustration 8
Sealing ring Differentiation characteristic

In accordance with parts list Parts number at socket
Damage coding:
In the case of a neutral switch primary damage, the latter must be encoded as follows:
Defective part Damage

Designation Part number Location Type Cause
0501 210 059
0501 214 642 546 224 206
Switch
0501 215 297 (contact) (No contact) (Electric defect)
0501 215 298
Validity:
This Service Information is valid as of February 20, 2007 for an unlimited period.
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Nur zur Information / For information only
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1 2 3 4 5 6 7 8 60 90 036 02 9
Material
35 +-0,5
40 +-1
Gehaeuse PA6.6GF30 schwarz

Blende PA6.6GF30 schwarz
Stecker ST1(18)(2.8x0.8) Cu Sn 6 bleifrei verzinnt
Stecker ST1(15)(2.8x0.8) Cu Sn 6 bleifrei verzinnt
Stecker ST1 (15) Stecker ST1(18) Halter St 12 blau verzinkt
passend zu passend zu
ly
Gegenstecker Gegenstecker
AMP 8-968973-1 AMP 8-968974-1
on
Technische Daten
130
n
Nennspannung 12/24V
112,5+-1
Betriebsspannung 9V....32V
io
Betriebstemperatur -40....+85 C
at
Ruhestrom <1mA
6,5+-0,2
Schutzklasse IP20
6,5+-0,2
m
Pflichtenheft Wehrle SP-0801-43 E-Modul 2-60 031 001
or
ZF Spezifikation Nr. 6041 722 039
8+-0,5
85+-0,5
nf
97,6+-1
i
8+-0,5 Barcode Barcode:
6041322044 xxxx
ZF-Nummer+Serien-Nummer
or
6041.322.044
Fertigungsdatum E-Modul2 ZF-Nummer
YYYY-MM-TT HW: xx
Serien-Nummer xxxx SW: xx
/F
E24 10R-020166
Nominal- 12/24V
Spannung Hardware-Stand
Software-Stand
E1-Nummer
n
Name g. ZF-Nummer Muster Info
io
95+-0,5 6041 322 041 A Funktionsprototyp
at
6041 322 042 B Entwicklungsprototyp
6041 322 043 C Serienprototyp
m
6041 322 044 D Serie
or
Stecker ST1(18)
nf
Pos. Funktion Bez.

1 Klemme 15 (Geschaltetes Plus) EDVP
Stecker ST1 (15) 2 Klemme 30 (Dauerplus)
rI
VPE
Pos. Funktion Bez. 3 Zentrale Abschalteinrichtung VPS1
1 Sensor Versorgungsspannung ADVP 4 Zentrale Abschalteinrichtung VPS2
zu
2 Eingang digital1(low-aktiv) EDM1 5 Zentrale Abschalteinrichtung VPS3

3 Eingang digital 2 (low-aktiv) EMD2 6 CANF1-Schnittstelle H-Leitung CANF1-H
4 Eingang digital 3 (low-aktiv) EMD3 7 CANF1-Schnittstelle H+-Leitung CANF1-H+
5 Eingang digital 4 (low-aktiv) EMD4 8 CANF1-Schnittstelle L-Leitung CANF1-L
ur
6 Eingang digital 5 (low-aktiv) EMD5 9 CANF1-Schnittstelle L+-Leitung CANF1-L+

7 Eingang digital 6 (low -aktiv)/ reserve EMD6 10 Analogeingang EU
Gewicht: 170g
8 Eingang digital 7 (low-aktiv)/ reserve EMD7 11 CANF1 Ausgang Abschlusswiderstand CANF1-T H i n w e i s z u r l e t z t e n A e n d .G 4 3 8 - K e n n z e i c h n u n g d e r E - T y p - N u m m e r h i n z u
g.
N
9 Eingang digital 8 (low-aktiv)/ reserve EMD8 12 Schirmung CAN1-Schnittstelle VMHF1

ja ja
10Eingang digital 1 (high-aktiv) ED1 13 Schirmung CAN2-Schnittstelle VMHF2 DmbA A
nein COP nein
11 Eingang digital 2 (high-aktiv) ED2 14 Ausgang digital 1 (sink) Reversing light relay ADM1
g G438 12.01.05 Datum Name
12Eingang digital 3 (high-aktiv) ED3 15 Ausgang digital 2 (sink) ADM2 f G429 10.12.04 g e z e i c h n e t1 6 . 0 6 . 0 4 Sitter
13Eingang digital 4 (high-aktiv) ED4 16 Ausgang digital 3 (sink) ADM3 e G417 10.11.04 geprueft 60 031 001
14Eingang digital 5 (high-aktiv) ED5 17 Versorgung Masse 1 VM1 d G397 23.09.04
15Masseversorgung Peripherie VMG 18 Versorgung Masse 2 VM2 c G385 1.09.04 Masstab Zeichnungs-Nr.
b
a
G378
G375
16.07.04
13.07.04
1:1 E-Modul 2 60 90 036 02
Werkzeug-Nr.
Aus- A2
Aenderung Datum Name
gabe
Computer-Zeichnung Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
Ähnl. Zeichnung Similar Draw. ZF Friedrichshafen AG
Original This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
nicht verändern Techn. Information Technical Information Benennung / Description Zeichnungs-Nr. Drawing-No. Ind. Blatt von DIN
D 05-04-05 Mollnau Bearbeit. Drawn 04-06-08 Mollnau
Computer drawing. Sheet of
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 04-06-08 F18641
E-Modul 2 Fahrschalter ELEKTRON.BAUST.
original copy
Änderungen / Modifications 6041.322.045_D 1 1 2
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Nur zur Information / For information only F17994 01.10.2007 15:01:57
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Nur zur Information / For information only F17994 01.10.2007 15:01:57

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1 2 3 4 5 6 7 8 9
1 2 KL.30
KL.30
F1 10A
1 2 Kl.30
KL.15
KL.15
F2 10A
display
8
3 light dimmed (0V..VP)
clutch actuator
with clutch
ly
A5 position sensor
11 1 4 5
on
5 7 6
ADVP1 VPI VPE1 VPE2
8 clutch engage quick
ADS3 Y14
6 7 1
speed sensor
n
UE 9 7 clutch engage slow
VPE EDVP output vehicle SD ECU ADS1 Y15
io
4 7 12 clutch disengage quick
A14 A2 SDEF A1 ADS4 Y16
at
3
A1 2 20 9 clutch disengage slow
U0 VM3 ADS2 Y17
4
m
CANF-H+
2 sensor A4
CANF-L+
conector X1a
conector X1b
output speed (optional)
or
3 3 15 power supply sensor
CANF-H CANF2-H AU 5V
1 6
A2 CANF-L CANF2-L
10 signal clutch sensor
20 pin Kostal
20 pin Kostal
nf
EU1 0-5V
14 10
CANF-Ra SDP
i
15
CANF-Rb
Shift lever (-) (-) (-)
or
5
VMHF
/F
16 ground
VM1
AD1 AD2 AD3 AD4 AD5 EDM1 EDM2 EDM3 EDM4 EDM5 VM VM
17 ground
9 18 19 20 21 10 12 13 16 17 11 8 VM2
n
optional 18 2 sensor ground
VMHF1 VMGA1
io
19
VMHF1
8
at
CANF1-H
12
CANF1-L
A23 14
H8 E43 S17 S8
details shown
on page 2
m 13
CANF1-H+
CANF1-L+
ADVP
EF
18
11 4
1
UE
A2
or
15
CANF1-T 3
switch switch A1
warning vehicle
manoevering state
nf
lamp speed 6 2
mode prohibit vehicle driveline CAN VMGA2 U0
threshold signal (nonlocking
rI
easy switch)
start
E77 E48 A11

zu
E13 E17 E42 Kl.30 output

P
speed sensor
signal signal 2
reverse
ur
neutral Programm service 1

light
switch brake
(easy VP K
N
start)
2 2
SDDK
A21
VM1 VM2
3
16 17
diagnosis interface
Kl.31 KL31
KL.31
Bearbeit. Drawn 06-05-31 Mollnau
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 06-05-31 Mollnau
ASTronic Bus Standard Stromlaufplan
original copy Joystick Shifter
Änderungen / Modifications Circuit Diagram 6029.713.149__ 1 2 2
1 2 3 4 5 6 7 8 9
A 1 ZF Getriebesteller-Elektronik ZF transmission actuator electronic unit

A 2 Fahrschalter Shift lever
Gerät Stecker
A 4 Kupplungssteller mit Sensorik Clutch actuator with Clutch position sensor

A ..
A11 Drehzahlgeber Abtrieb Sensor Output Speed
A21 Diagnoseschnittstelle nach DIN ISO 9141 Diagnostic Interface DIN ISO 9141
ly
Dargestellte Polbilder: A23 Fahrzeug Antriebsstrang CAN Vehicle driveline CAN
on
Sicht auf Gegenstecker des Gerätes
F 1 Sicherung 10A (Kl.30) Fuse 10A
F 2 Sicherung 10A (Kl.15) Fuse 10A
n
Polbild zu A1 POLBILD POLBILD POLBILD POLBILD
io
X1A/X1B plug view plug view plug view plug view
H 8 Warnlampe Warning lamp
at
zu A21 zu A2 zu A11,A14 zu A5
1 2 E13 Rueckfahrscheinwerfer Revers Light
3 5
6 4 9 6 3 21 18 15 12 9 6 3 8 7 E17 Neutral Signal Signal Neutral
m
7 8 2 6 5
10 12 14 5 2 20 17 14 11 8 5 2 4 3 E42 Easy Start Easy Start
11 13 4 3
15 16 17
4 1
19 16 13 10 7 4 1 1 2 1 E43 Geschwindigkeitsschwelle Vehicle Speed Treshold
or
18 19 20 E48 Signal 2 Bertiebsbremse Signal 2 Service Brake(easy start)
AMP M-N-L DIN Baj. AMP JPT E77 Programm Schalter Program switch
JPT 3-reihig
nf
6-pin 4-pin 8-pin
21-pin
Kostal
20-pin S 8 Schaltverhinderung Switch State Prohibit
i
S17 Schalter Rangieren Manoevering Mode Switch
or
Y14 MV Kuppl. schliessen schnell (Entlueften) Sol. Valve Clutch Engage Fast
/F
Y15 MV Kuppl. schliessen langsam (Entlueften) Sol. Valve Clutch Engage Slow
Y16 MV Kuppl. oeffnen schnell (Belueften) Sol. Valve Clutch Disengage Fast
Y17 MV Kuppl. oeffnen langsam (Belueften) Sol. Valve Clutch Disengage Slow
n
io
at
Getriebestellerelektronik Transmission ECU
m Getriebestellerelektronik Transmission ECU
or
konfiguriert CAN end-user konfiguriert CAN mid-user
als CAN-Bus-Endteilnehmer als CAN-Bus-Mittelteilnehmer
nf
*
rI
*
8 CANF1-H CAN-H CANF1-H CAN-H (ECU A)
zu
8
CAN-H A23
A23 14 CANF1-H+ frei/ spare CAN-H 14 CANF1-H+ CAN-H (ECU B)
Busabschluß- 120
Fahrzeug-
Busabschluß- 120 Fahrzeug-
ur
widerstand/ Ohm widerstand/ Ohm

terminating
15 CANF1-T verkabelung/ terminating
CANF1-T frei/ spare
verkabelung/
resistor resistor 15
N
vehicle harness vehicle harness

13 CANF1-L+ 12 CANF1-L CAN-L (ECU A)
CAN-L 12 CANF1-L CAN-L CAN-L 13 CANF1-L+ CAN-L+ (ECU B)
18 VMHF1 HF-ground optional 18 VMHF1 HF-ground optional

HF-ground 19 VMHF2 HF-ground optional HF-ground 19 VMHF2 HF-ground optional
Bearbeit. Drawn 06-05-31 Mollnau
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 06-05-31 Mollnau
ASTronic Bus Standard Stromlaufplan
Änderungen / Modifications Circuit Diagram 6029.713.149__ 2 2 2
1 2 3 4 5 6 7 8 9
A5
1
2
WA:+Z/1.2 900
LX 5 3 +Bel
4
Wr:CH/1.1 -RT
5 CAN H
WE:-/1.2 902
X5 6 VM
Ws:CL/1.1 -SW
7 CAN L
WJ:+A/1.1 906
8 VP
X5
Display
WX:+B/1.2 901
1 (+) Diagnose
WK:K/1.2 907
ly
2 K Diagnosis
WY:-/1.2 902
3 (-)
-SW
on
Ws:CL/1.1
CANF-L 1 LX21 X21 4 L
2 5 Pog
-RT Wr:CH/1.1
CANF-H 3 6
4
n
905 WI:-H/1.2
VMHF 5
901 WX:+B/1.2
X21
A21
io
VPE 6
906 WJ:+A/1.1
EDVP 7
902 WE:-/1.2
at
VM 8
409 X17:13/2.2
9
410 X17:16/2.2
10
m
411 X17:18/2.2
A2 VM 11
412 X17:14/2.2 WK:K/1.2 907 907 X1:2/1.8 X20:7/1.6 900
EDM2 12 1 1 1 VPI
or
413 X17:15/2.2 WC:+B/1.1 901 901 X1:4/1.8 X20:1/1.6 907
EDM3 13 2 2 2 SDDK
950 X2:15/1.1 Wr:CH/1.1 -RT -RT X1:3/1.8 X20:3/1.6 -RT
CANF-Ra 14 3 3 3 CANF2-H
950 X2:14/1.1 WX:+B/1.2 901 901 X1:5/1.8 X20:2/1.6 901
nf
CANF-Rb 15 4 4 4 VPE1
416 X17:11/2.2 WU:EF/1.1 918 918 X1:7/1.8 X20:4/1.6 901
16 5 5 5 VPE2
417 X17:7/2.2 Ws:CL/1.1 -SW -SW X1:6/1.8 LX 1 X20:6/1.6 -SW
i
17 6 6 6 CANF2-L
418 X17:17/2.2 WA:+Z/1.2 900 900 X1:1/1.8 X20:5/1.6 918
18 LX 19 7 7 7 SDEF
or
AD3 19
419 X17:10/2.2 LX 2 WR:CH/1.1 -GE1
8 8
-GE1 X1:8/1.8 X20:8/1.6 -GE1
8 CANF1-H
420 X17:9/2.2 917 X1:9/1.8 X20:9/1.6 917
AD4 20 9 9 X20 X1 9 SD
421 919
/F
21 X17:12/2.2 10 10 X20:14/1.6 10 SDP
X19
X2 WI:-H/1.2 905
11 11
905 X1:18/1.8 X20:15/1.6 906
11 ADVP A1
WY:-/1.2 902 902 X1:16/1.8 X20:13/1.6 -GN1
X2 WS:CL/1.1 -GN1
12 12
-GN1 X1:12/1.8 X20:18/1.6 -GN2
12 CANF1-L
13 13 13 CANF-1L+
Fahrschalter 919 919 -GE2
n
WD:SDP/1.2 14 14 X1:10/1.8 X20:17/1.6 14 CANF1-H+
WJ:+A/1.1 906 906 X1:11/1.8
15 15 15 CANF1-T
io
WE:-/1.2 902 902 X1:17/1.8 X20:12/1.6 902
918 X19:5/1.6 919 X19:14/1.6 16 16 16 VM1
WU WD WP:H+/1.1 -GE2
17 17
-GE2 X1:14/1.8 X20:16/1.6 902
17 VM2
at
X17:8/2.2 EF X17:6/2.2 SDP -GN2 -GN2 905
WQ:L+/1.1 18 18 X1:13/1.8 X20:11/1.6 18 VMHF1
X2:3/1.1
Wr 907 X21:2/1.6
WK
19 VMHF2
X19:3/1.6
X5:5/1.5
CH X19:1/1.6 K
m X19 X20 20 VM3
or
X2:1/1.1
Ws X5:3/1.5
WA X1
X19:6/1.6 CL X19:7/1.6 +Z
nf
X5:7/1.5 X17:3/2.2
X2:7/1.1 X17/2.1
WJ 901
rI
X17:1/2.2
X19:15/1.6 +A 901 X19:4/1.6
WX LX17 Polbild Polbild Polbild POLBILD POLBILD POLBILD
X5:8/1.5 +B zu X19 zu X20 zu A1 zu X2 zu A21 zu A5
901 X2:6/1.1
zu
X17:4/2.2 901 X21:1/1.6 3 6 9 12 15 18 21 8 7

17 18 18 17 6 3
1 2 6 5
901 X17:2/2.2 15 16 16 15 3 5 2 5 8 11 14 17 20
901 X19:2/1.6
WC X17:21/2.2
WE
13 14
11 12
14
12
13
11
6 4 9 1 4 7 10 13 16 19
5
4
2
1
4
2
3
1
+B 7 8
ur
X19:16/1.6 - 9 10 10 9 10 12 14
7 8 11 13
-GE1 X5:6/1.5 5 6
8 7
15 16 17 AMP JPT
X19:8/1.6
WR X2:8/1.1 3 4 6 5 JPT 3-reihig AMP M-N-L
8-pin
N
-GE1 18 19 20
X18:1/2.2 CH 1 2 4 3 21-pin 6-pin
2 1
902 X17:22/2.2
-GN1 X19:13/1.6
WS X19:12/1.6
WY X18/2.1
AMP JPT
18-pin
AMP JPT
-GN1 X18:3/2.2 - 18-pin
Kostal
CL X21:3/1.6
LX18 20-pin
-GE2 X19:17/1.6
-GE2 X18:2/2.2
WP
H+ 905 X2:5/1.1
905 X19:11/1.6
WI STROMLAUFPLAN:
-GN2 X19:18/1.6 -H
WQ 905 X18:5/2.2
-GN2 X18:4/2.2 L+ 905 X18:6/2.2 6029.713.149
Bearbeit. Drawn 06-09-06 Döbell
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 06-09-06 Döbell
ASTRONIC BUS ANSCHLUSSPLAN
Änderungen / Modifications CONNECTION DIAG. 6029.713.168__ 1 2 2
1 2 3 4 5 6 7 8 9
Kl.30
Kl.15
F1 10A F2 10A
WX:+B/1.2 901
1 BORDNETZ(Kl.30) VEHICLE ELECTR.CIRCUIT(+30) 1
WC:+B/1.1 901
WA:+Z/1.2 900
WJ:+A/1.1 906
4 ADVP 4
5 5
919
ly
WD:SDP/1.2 6 6
X2:17/1.1 417
7 Gang einlegen verhindern Switch State Prohibit 7
918 D3orB7
on
WU:EF/1.1 8 Abtriebsdrehzahl Signal Output Speed 8
X2:20/1.1 420
9 Geschwindigkeitsschw. Speedthreschold 9
X2:19/1.1 419
10 Neutral Signal 10
X2:16/1.1 416
11 Signal 2 Service Brake Bremssignal 11 A13 A14
n
X2:21/1.1 421
12 Easy Start Easy Start 12
X2:9/1.1 409 Tachograph Sensor
io
X17/1.5 13 Rückfahrscheinwerfer Reverse Light 13
X2:12/1.1 412 output speed
"X17/BN" 14 Programm Schalter Switch Rrogram 14
X2:13/1.1 413
at
15 Rangier Taster Manovering Mode Switch 15
X2:10/1.1 410
16 16
X2:18/1.1 418
17 Warnlampe Warning Lamp 17
m
X2:11/1.1 411
18 Signal Masse Signal Ground 18
19 19
or
20 20
WE:-/1.2 902
21 BORDNETZ(Kl.31) VEHICLE ELECTR.CIRCUIT(-) 21
WY:-/1.2 902
nf
22 BORDNETZ(Kl.31) VEHICLE ELECTR.CIRCUIT(-) 22
S17 E13 E48 P E43
X17 X17A
i
A23
or
E77 E17 S8
/F
H8 E42
WR:CH/1.1 -GE1
1 CANF1-H 1
WP:H+/1.1 -GE2
X18/1.5 2 CANF1-H+ 2
-GN1
n
WS:CL/1.1 3 CANF1-L 3
"X18/CAN" -GN2
WQ:L+/1.1 4 CANF1-L+ 4
io
WI:-H/1.2 905
5 VMHF-1 5
WI:-H/1.2 905
6 VMHF-2 6
at
X18 X18A
m
or
nf
POLBILD POLBILD POLBILD POLBILD A23

rI
zu X17A zu X17 zu X18 zu X18A

zu
21 22 22 21
19 20 20 19
17 18 6 5 5 6
18 17
15 16 4 3 3 4
16 15
13 14 2 1 1 2
14 13
ur
11 12
9 10 12 11
10 9
AMP JPT AMP JPT
7 8
5 6 8 7 6-pin 6-pin Kl.31
N
3 4 6 5
1 2 4 3
2 1
AMP JPT
22-pin
AMP JPT
22-pin
STROMLAUFPLAN:
6029.713.149
Bearbeit. Drawn 06-09-06 Döbell
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 06-09-06 Döbell
ASTRONIC BUS ANSCHLUSSPLAN
Änderungen / Modifications CONNECTION DIAG. 6029.713.168__ 2 2 2
1 2 3 4 5 6 7 8 9
10A
Kl.30 F1
10A
Kl.15 F2
Hauptschalter
Main switch
1
S10 2
Pinbelegung
nach Stecker
8 4 30 45 31 53 55 54
ly
Polbild
AD4 ED8 VPI2 VPI1 VPE2 VPE1

7 15 4
on
Bremsstufen- St1 ED1 AIP
schalter 6 42
St2 ED2 Prop-
5 16 1
A6 Brake
level
St3
3 43
ED3 ventil
Y1
St4 ED4 Proportional
n
selector 2 17 2
St5 ED5 Valve
1 44 3
io
St6 ED6 ADM1
1
at
AD1
Speicher
1
ventil
m
Accumulator Y2
2
charge valve
or
AF1 8 34
A13 Tachograph nAb EF1 VM3
A1 29
nf
Wenn nAb nicht über CAN (TCO1) AD2 1
if nAb not via CAN (TCO1) Intarder-
EST 42
i
Kontrolleuchte
+
Intarder P7
or
Diagnose- Pilot-light
2 14 6 2
schnittstelle K SDDK VM4
4 41
/F
L SDDL
A21 Uprog
5 12
EUPR
2
Diagnostic AD3
Interface Ausgabe
n
Bremslicht- 1
-
keine Unterbrechungsdiagnose
io
Ansteuerung
Output E18 no interrupt diagnostic
Stop-light 2
at
33
VM5
CAN-System
schnitt
CANF-H
CANF-H+
22
23
CANF-H
CANF-H+
m AD6
52
or
CANF-L 49
stelle CANF-L Abschaltung 1
CANF-L+ 50
A23 VMHF1 24
CANF-L+ Tempomat
E10
nf
Can VMHF1 cruise control

VMHF2 51 2
Interface VMHF2 switch off
CANF-T 21 5
CANF-T VM6
rI
CANF-T+ 48
CANF-T+
zu
9
ER1
VM1 VM2 VMG1
ur
28 27 37
Temperatur-
geber
N
Temperature B13
Sensor
Kl.31
a 4220/01 01-10-08 Mollnau Bearbeit. Drawn
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 17.04.01 Boike
EST 42 Bremsomat CAN Stromlaufplan
original copy
Änderungen / Modifications Wiring Diagram 6029.711.038_A 1 1 2
1 2 3 4 5 6 7 8 9
1 2 KL.30
KL.30
F 1 ?1 0 A
1 2 KL.15
KL.15
F 2 ?1 0 A
clutch actuator
with clutch
11 1 4 5
position sensor
ly
ADVP1 VPI VPE1 VPE2 clutch engage quick
8
ADS3 Y14
on
clutch engage slow
7
ADS1 Y15
clutch disengage quick
9 12
SD ADS4 Y16
n
clutch disengage slow
9
io
ADS2 Y17
10 A4
at
SDP
TCU 15
power supply sensor
AU 5V
m
signal clutch sensor
10
A1 EU1 0-5V
or
7
SDEF
Connector X1b
connector X1a
3
nf
CANF2-H (-) (-) (-)
6
20 pin Kostal
20 pin Kostal
CANF2-L
i
ground
or
16
VM1
ground
17
/F
VM2
sensor ground
20
VMGA1
n
io
18 1
ADVP UE
at
18
19
VMHF1
11 4 A11
VMHF2 EF A1
m
A23
CANF-H
?
?
8
12
CANF1-H VMGA2
6 2 U0
or
CANF-L CANF1-L
sensor output speed
? 14
nf
CANF-H+ CANF1-H+
? 13
CANF-L+ CANF1-L+
15
CANF1-T
rI
CAN-vehicle interface ( ZF-TCU mid-user)

zu
A21 VP
ur
? 2
K SDDK
VM
N
VM1 VM2 VM3

?
16 17 20
diagnosis interface
KL31 KL.31
b 08.08.07 Nal Bearbeit. Drawn 28.01.98 MOLLNAU
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 14.01.98 NAULIN
ASTRONIC 2 MAN NT STROMLAUFPLAN
original copy
Änderungen / Modifications CIRCUIT DIAGRAM 6029.713.025_B 1 2 2
1 2 3 4 5 6 7 8 9
Stecker/Plug
ZF-Kabel
ZF-Harness A 1 ZF Getriebesteller Elektronik TCU transmission control unit
A 4 Kupplungssteller mit Sensorik clutch actuator with clutch position sensor
Polbildansicht
View of pin pattern
ly
A11 Drehzahlgeber Abtrieb sensor output speed
on
Polbild zu A1
POLBILD A21 Diagnoseschnittstelle nach DIN ISO 9141 diagnostic interface DIN ISO 9141
X1A/X1B
zu A11/A14 A23 Fahrzeug CAN-Schnittstelle CAN vehicle interface
n
io
1 2
3 5 2
6 4 9 4 3 F 1 Sicherung 10A (Kl.30) Fuse 10A
7 8 1 F 2 Sicherung 10A (Kl.15) Fuse 10A
at
10 12 14
11 13
15 16 17
18 19 20 DIN Baj. Y14 MV Kuppl. schliessen schnell (Entlueften) sol. valve clutch engage fast
m
4-pin Y15 MV Kuppl. schliessen langsam (Entlueften) sol. valve clutch engage slow
Y16 MV Kuppl. oeffnen schnell (Belueften) sol. valve clutch disengage fast
or
Kostal Y17 MV Kuppl. oeffnen langsam (Belueften) sol. valve clutch disengage slow
20-pin
i nf
or
/F
n
io
at
m
or
nf
rI
zu
ur
N
b 08.08.07 Nal Bearbeit. Drawn 28.01.98 MOLLNAU
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 15.01.98 NAULIN
ASTRONIC 2 MAN NT STROMLAUFPLAN
original copy
Änderungen / Modifications CIRCUIT DIAGRAM 6029.713.025_B 2 2 2
Hauptverwaltung
Telefon +49 7541 77-0
Telefax +49 7541 77-908000
www.zf.com
Antriebs- und Fahrwerktechnik

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Repair Manual

Bus 1337 751 101b_en

Subject to technical changes

This documentation is protected by copyright. Any

ZF Friedrichshafen AG, MC-C dept. / 2003-09

1337 751 101b

List of Changes ..................................................................................................................................... 5

General maintenance .......................................................................................................................... 21

Transmission Actuator .................................................................................................................................. 37

1337 751 101 - 2009-09 3

Clutch Actuator ................................................................................................................................... 45

1337 751 101 - 2009-09 4

Index Date of issue Chapter Initiator Comment

2003-09 BKS-R dept. First version

b 2009-09 BKS-R dept. - Maintenance of compressed-air system: Information added

1337 751 101 - 2009-09 5

Service points equipped by ZF Friedrichshafen AG

1. Continuously trained personnel,

3. Genuine ZF spare parts in accordance

All work performed at these service locations

The following safety instructions are used ! DANGER to the health!

To avoid injury to personnel and damage to

Personnel required to carry out repairs on ZF

General Information Cleaning Parts

After removing the transmission from the vehicle, Reworking

Transmission Assembly • Shaft Sealing Rings

c) Shaft sealing rings with steel and rubber

• Retaining Agents • Transmission Oil

* refer to consumable material

Tightening torques for screws/bolts and nuts,

Coarse thread Fine thread

Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

M4 2,8 4,1 4,8 M8x1 24 36 43

M12 79 115 135 M14x1.5 135 200 235

M18 280 390 460 M18x2 290 420 490

M24 670 960 1100 M24x1.5 760 1100 1250

M27x2 1050 1500 1800

Status: August 1991

from to x Factor Examples:

mm inch x 0.03937 20.0 mm = 0.7874 inch

Nm ft.lb. x 0.7376 60 Nm = 44.256 ft.lb.

°F °C 5(°F-32) 248 °F = 120 °C

bar psi x 14.513 10 bar = 145.13 psi

liter US gallons x 0.2642 20 liters = 5.284 US gallons

Fig. Figure Order no. Application Qty. Remark

1X56 138 215 Chapter

1X56 138 546 Chapter

1X56 138 547 Chapter

1X56 137 124 Chapter

1X56 138 189 Chapter

NOTE: Please inquire as to packaging unit before ordering.

Fig. Figure Order no. Application Qty. Remark

NOTE: Please inquire as to packaging unit before ordering.

Fig. Figure Order no. Application Qty. Remark

6008 208 503 Only for

6008 208 501 Only for

6008 208 003 following

6008 208 819 Single user

6008 207 003 Adapter cable for