OperatingInstructions Bus Lever-Type Range Selector 1348 758 101 Subject to alterations in design Copyright by ZF 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 / 2005-09 Edition: 2005-09 Preface Your vehicle is fitted with an automatic transmission system from the ZF-AS Tronic range. The more familiar you are with the ZF-AS Tronic, the more cost-effectively you will be able to drive it. This operating manual will provide you with the necessary information to allow you to make full use of the technical advantages of the ZF-AS Tronic. Before first driving the vehicle, we would ask you to read this operating manual carefully. Note the special instructions provided in the vehicle manufacturer’s operating manual. To operate and maintain the ZF-Intarders, you will also need the ZF-Intarder operating manual, order number 6085 758 102. In order to ensure reliability in service, please note the specifications governing maintenance. The ZF Customer Service specialists are available to assist you in maintenance work or to help if any other problems arise. You can obtain their addresses from ZF in Friedrichshafen. Motoring pleasure with the ZF-AS Tronic is brought to you by ZF Friedrichshafen AG Bus Driveline Technology (SB) D-88038 Friedrichshafen Phone: +49 (0) 75 41 77-0 Fax: +49 (0) 75 41 77-90 80 00 Internet: www.zf.com 1348 758 101 - 2005-09 3 techniques. dirty filters. lubricants. and cleaning agents in accordance with environmental protection guidelines. ground water. 1348 758 101 . unprofessional working practices could damage the product. information. etc.Safety Instructions The following safety instructions appear in this manual: ! NOTE Refers to special processes. • When working with lubricants and cleaning agents always observe the manufacturer’s instructions. • Ask your local environment agency for safety information on the relevant products and ensure compliance with their requirements. .2005-09 4 THREATS TO THE ENVIRONMENT! Lubricants and cleaning agents must not be allowed to enter the soil. CAUTION This is used when incorrect. or sewage system. ! DANGER! This is used when lack of care could lead to personal injury or material damage. • Collect used oil in a suitably large container. • Dispose of used oil. . . . . . . . . . . . . . Automatic Mode . . . . . . . .1 3. .5 1. . . . . . . .3 2. . . . . . . . .3 3. . . . . . . . . . . . . . . . .6 1. . Oil Grade . .1 2. .17 Use in Sub-Zero Temperatures . . . . . . . . . ZF-Intarder . . . . . . . . .2. . .7 1. . . . . . . .8 Description of System . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . .1 3. . . . . . . . . . . . .6 2. . .4 2. . . . . . . . . . . . Starting Gear Correction . . . . . . Function of Engine Brake when Changing Gear Change in Direction of Travel . . . . . . . . . . . . . . . . .1 3. . . . . . . .2. . .13 Engine Overspeed Protection . . . . . . . . . . . . . .2. . . . . .2 Automatic mode . . . . . . . . . . . . . . .2 3.1 Parking Vehicle at Low Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling With Oil . . . . . . . . . . . . . . . . . . . . . Reverse Travel . . . . . . . . . . . . . . . . . . . . . 2-8 2-9 2-9 2-9 2-10 2-10 2-10 2-10 2-11 2-12 2-15 2-17 2-17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . Display: Manual Mode . . . . . . . . .17. . . . . . . Display: Automatic Mode . Display (ZF Display) . . . . .4 3. .3 2. . .6 3. . . .6. . 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-3 3-4 3-4 3-5 3-5 3-5 3 3. . . . . . . . . . . . . . . . .14 Roller Test Rig . . . . Maneuvering . Moving Off Downhill . . . . . . . . . Pneumatic System Maintenance . . . . .11 Tow Starting . . . . . . . . . . . . . . . . .16 System Faults (Error Messages) . . . . . . . . . . . . . . . . . . . . Oil Change Intervals .7 5 . . . . . . . . . . . . . . . . . . . . . . . .2. 2. . . . . . . . . . . . .13. . 2. .15 Displays for ZF-AS Tronic . . . . . . . . . . . 2. . Accelerator Pedal . . . . . . . . . . . . . . . Range Selector . . . . . . . . . . . . . . . . . . . Manual Mode .2 3. . . . . . . . . . . . . . . .2.1 2. . 2. . . . . . . . . .2 2. . . .3 2. . . . . . . . . Transmission Fluid . . . . . . .2 2. . . . . . . . . . . . . . . . Visual Inspection of Wiring . . . . . . . . . . .9 Stopping Engine / Vehicle . . . . .5 2. .6. . . . . . .2 2. . Starting the Engine . . . . . . . . . .4. . . . 2. . . . . . . . . . . . . . . . . . . . . . .1 1. . . . . . . . . .1 2. . . .7 Operation . .12 Clutch Protection . . Setting Off. . . . . . . . . . . . . . .1 Manual Mode . . . . . . . . . . . . . . . . . Setting Off . Setting Off. . . . . . . . . . . . .2.3 3. . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . .2. . . . . . . . 2. . . . . . . . . . . . . . . . .1 1. . . . . . . . 2. Type Plate . . . . . . . . . . . . . . . . . . . General Description . .2 3. . . . . . . . . . . .8 Stopping . . . . . . . . . . . . . . Setting Off with Starting Aid (Optional) . . . 2. . . . . . . .1. . . . . . . . . . .2005-09 2.4. . . .5 3. . 1-2 1-2 1-3 1-4 1-5 1-5 1-5 1-5 1-6 1-6 1-6 2 2. . . . .1 2. . . . . . .13. . . .2 1. . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-2 2-2 2-2 2-3 2-3 2-4 2-5 2-5 2-6 2-6 2-6 2-7 2-8 1348 758 101 . . . . . . . . . . . . . . . Oil Changes . . . . . . . Overview . . . . . .2 1. . . . . . . Gear Changes during automatic mode . . .Table of Contents 1 1. Draining the Oil . . . . . . . . . . . . . . . . . . . . . .3 1. . Bleeding the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . Gear Changes during Manual Operations . Changing Operating Mode: Manual/Automatic Gear Changes . Oil Level Check . . Oil Fill Quantity . . . . . . . . . .10 Towing . .4 1. . . . . . . 2. . . . . . . . . . . . . . . Forward Travel . . . . . . . . . . 2005-09 6 .1348 758 101 . 2005-09 1-1 .ZF-AS Tronic Transmission System ZF-AS Tronic with Intarder 012240 1348 758 101 . g. The transmission electronics process all incoming signals and initiate the gear shift using solenoid valves and shift cylinders. the splitter group and planetary group have synchromesh.2005-09 The ZF-Intarder is an additional hydro-dynamic brake integrated in the transmission which operates with no wear. and sensors. Unlike with powershift transmissions. The clutch actuator is controlled electro-pneumatically and handles all clutch actuation functions.Description of the System 1 The basic transmission has constant mesh.1 General Description Gear shifts are undertaken automatically by the transmission system. 1348 758 101 . and • when the vehicle is stationary. Description of the System 1. • at very low speeds. the driveline is open. DANGER! The brake must be applied to prevent the vehicle from unintentionally moving either forwards or backwards. gear step. The display on the dashboard displays all the system information required for the driver (e. malfunction etc.). ! The transmission actuator and clutch actuation unit (clutch actuator) are the most important components for complete automation of the transmission. with the ZF-AS Tronic • during gear shifts. shift valves. The transmission actuator consists of the transmission electronics. shift cylinders. in order not to stall the engine. The clutch is controlled by the transmission system and a clutch pedal is no longer fitted. 1-2 . This means that no drive force is transferred. The ZF-AS Tronic consists of a basic transmission and an integrated splitter and planetary group. The automatic ZF-AS Tronic transmission system is adapted to the engine by means of a standard dry clutch. 2 Overview 1 A/M 2 D 3 N R 5 S T O P 7 6 Key 1 ZF range selector 2 ZF display 3 Transmission actuator with integrated electronic transmission control 4 Clutch actuator 1348 758 101 .2005-09 8 4 5 6 7 8 Transmission Accelerator Brake pedal ZF-Intarder 1-3 024527 024527 .Description of the System 1. R R In the “N” and “R” positions. Range Selector After the positions “+”.2005-09 1-4 . “+”.Description of the System 1. the range selector snaps back to “D”. + + = Upshift 2 gears (spring point stop) = Upshift 1 gear (first spring point) 024528 A/M = Changeover from Automatic mode to Manual mode (and vice versa) D N R – – = Drive = Neutral = Reverse = Downshift 1 gear (first spring point) = Downshift 2 gears (spring point stop) 024529/024528 1348 758 101 . “–” and “A/M” have been selected. “–”. A/M D N A/M D N You can undertake manual upshifts or downshifts over more than 2 gear steps by tipping the speed selector several times.3 You can use the range selector to select gears and change operating mode. the range selector locks. Refer to vehicle manufacturer’s operating instructions for other displays.1 Display: Automatic Mode The transmission is in automatic mode (4 bars and 2 arrows). and error messages. The clutch is activated by the electronic transmission control unit depending on accelerator actuation.2005-09 1-5 . 4th gear is engaged in the transmission. The display shows the number of the gear selected. During gear shifts. neutral. Option of downshifting by up to 3 gear steps available (one gear per bar) 023664 1.4 Display (ZF Display) 1.4.5 023665 Accelerator Pedal 023663 The accelerator’s position must not be changed during the shift process. 8th gear is engaged in the transmission.2 Display: Manual Mode Only descriptions of the displays for transmission functions are provided in this operating manual. the engine is influenced by the electronic transmission control unit. downshifts available. 4th gear is engaged in the transmission. 1.Description of the System 1. 1348 758 101 .4. Description of the System 1. Manual Mode If “A/M” is selected using the range selector. 1. Overrevving the engine is not economical and should be prevented by the driver. The mode then changes from automatic to manual.2005-09 1-6 . The gear shift system selects the best gear for setting off. The driver can use the range selector to propose a starting gear other than that proposed by the system. the clutch closes automatically and the vehicle starts to move. the engine may stall. If you press the accelerator pedal.8 ZF-Intarder ZF operating manual 6085 758 102 is provided for operating and maintaining the ZF-Intarder.7 Range selector in position “ D”. The shift system performs upshifts and downshifts automatically during travel. 1348 758 101 . The driver uses the range selector to select the gears required. in difficult driving situations – without having to come off the gas.6 Automatic Mode 1. If the accelerator is pressed when in too high a gear. The driver can use the range selector to intervene manually at any time – for example. the transmission system changes into manual mode. the clutch closes automatically and the vehicle starts to move. are prevented by the shift system when in automatic mode. Downshifts which would result in overrevving or stalling the engine. If you press the accelerator pedal. Operation 2 Operation 2. also observe the operating instructions provided by the vehicle manufacturer. you may have controls and operating processes other than those described in this manual.1 • NOTE Depending on the manufacturer and vehicle type.2005-09 2-1 . Therefore. • Shift system self-check (display shows “CH ”) Start the engine - 023666 Self-check is complete. Starting the Engine Apply parking brake • The range selector must be in “N ” (transmission in Neutral) D N R 024688 • Switch on “ignition” - ! A/M DANGER! The vehicle must not be left with the engine running and a gear selected. transmission is in Neutral 023667 NOTE Gears cannot be selected when engine is stationary. “N ” appears on display. 1348 758 101 . When setting off on an incline.“R ” appears on the display (clutch remains separated N R A/M D N R 024678 • Depress accelerator and release brake at the same time (clutch closes automatically).2.) A/M D • Use range selector to select “R ” . .Operation 2. Forward Travel • Move range selector from “N” to “D”.2. (The system selects the starting gear itself.The display shows the starting gear selected. .Vehicle sets off (clutch closes automatically). 1348 758 101 . 023668 024684 023669 • Depress accelerator and at the same time release the parking brake.Automatic mode is activated .1 Setting Off. . Reverse Travel • Vehicle must be stationary. .2 Setting Off.Vehicle moves backwards. clutch remains separated.2 Setting off 2. Only the display provides definitive information on the direction of travel selected in the transmission. a shift is not made into reverse gear! Immediately bring the vehicle to a standstill. ! ! DANGER! The vehicle may start to roll away if you do not depress the accelerator.2005-09 2-2 DANGER! If the vehicle is rolling. 2. select gear and only release parking brake once accelerator has been depressed otherwise the vehicle will roll backwards. Corrections can be made between the minimum and maximum starting gears.Operation 2. • Press the accelerator.2.2005-09 DANGER ! Once the brake pedal is released. .Automatic mode is activated.3 Starting Gear Correction • Use range selector to select “ D” or “ R ”. clutch position and roadspeed. .4 Setting Off with Starting Aid (Optional) As an option. . • Start engine (see 2. The starting aid should prevent the vehicle from rolling away when starting on an uphill or downhill incline. 1348 758 101 . • Release service brake. The system proposes a starting gear.Vehicle sets off. Undertaking correction: • Press range selector lever in “ + ” or “ –” direction.The display shows the starting gear selected. the vehicle can be equipped with an electronic starting aid (Easy Start). the brake is only engaged for a short time.2. 2-3 . • The brake is released even if the transmission is shifted to Neutral.The display shows the starting gear selected.The brake remains engaged briefly thanks to the starting aid. . The vehicle may roll.Brake is released . A/M D N R ! 024679 2. • Apply service brake and release parking brake. . NOTE • The time to release the brake depends on the accelerator position.1). Operation 2. ! DANGER! The system changes from maneuvering mode to setting off mode depending on the accelerator position and vehicle speed. 023670 CAUTION If the driver does not respond to the “ CL” display. 1st gear (depending on vehicle.2005-09 2-4 023669 023671 DANGER! If the driver does not respond to the “ CL” display. 2nd gear may also be intended as a maneuvering gear. The system recognizes maneuvering mode from the accelerator position and the low travel speed. ! The “CL” display appears when the clutch is overloaded. In maneuvering mode. Maneuvering mode is not available in other gears. the system changes from maneuvering mode to setting off. possibly 1st and 2nd gear) and R gear are provided as maneuvering gears for very slow travel. 1348 758 101 . The vehicle may accelerate suddenly. A change is made from maneuvering mode into setting off mode. The length of time spent maneuvering in this gear is restricted. correct the current gear by pressing the range selector lever in the “ – ” direction. RISK OF ACCIDENT! . the vehicle (accelerator) is more sensitive and clutch activation differs from how it is in normal mode. If necessary. The vehicle may accelerate. the clutch may be damaged from overload. Maneuvering in 2nd gear Depending on the vehicle type.3 Maneuvering in 1st gear or R gear Maneuvering The time spent maneuvering is not limited in 1st gear. • Use the range selector to select “A/M”. the system selects a gear appropriate for the roadspeed.4 Moving Off Downhill 2.2005-09 2-5 . the driveline is now closed. ! Changing Operating Mode: Manual / Automatic Can be undertaken at any time.Operation 2. N R 024678 023668 1348 758 101 . even during travel. • Use the range selector to select “A/M”. Changing operating mode from manual to automatic: DANGER! When the vehicle moves off without a gear selected – range selector in position “N ” – the engine brake will not work. A/M D NOTE If “ + ” or “ –” is selected using the range selector lever. A/M Changing operating mode from automatic to manual: D N R 024685 If the vehicle rolls forwards – transmission in Neutral – once the brake has been released and you shift from “N ” to “D ”.5 Requirements: Engine is running. The clutch closes without the accelerator being pressed. the operating mode changes briefly into manual. Do not allow vehicle to roll in direction opposite to that of the gear selected. 6 Gear Changes 2. D N R 024685 1348 758 101 .2 Gear Changes during Manual Operations • Press range selector lever in “+” or “– ” direction.Operation 2.6.2005-09 2-6 . 8th gear is engaged. • If you use the range selector lever to select “ A/M ”.6. 2. automatic mode is re-activated.1 Gear Changes during Automatic Mode All upshifts and downshifts are undertaken automatically. 023672 A/M 2 arrows and 4 bars = automatic mode. This depends on: • • • • • A/M D Drive situation Loading Accelerator position Velocity Engine speed N R 024679 The shift system exits automatic mode when a manual shift is undertaken. the engine brake is automatically reactivated. the system downshifts into automatic mode so that the maximum engine effect is reached. The vehicle may accelerate when traveling downhill. the driveline is interrupted.3 Function of Engine Brake when Changing Gear Jumping one gear: • Press range selector lever in “+” or “–” direction until stop is reached. The engine brake then no longer functions.Operation Jumping gears 2. The engine brake is deactivated by the system during gear shifts. pressing once all the way to the first spring point and once to the stop in quick succession. ! NOTE • You can shift from any gear to Neutral at anytime using the range selector. • A shift command is not undertaken if the shift would result in the maximum engine speed (governing speed) being exceeded. . • The accelerator position must not be changed during the shift process because the engine is controlled automatically. Once the gear shift is complete. 1348 758 101 . ! DANGER ! Shifts to “Neutral” can also be made during travel. If a shift is made to “Neutral”. This shift takes priority.6. Jumping two gears: • Press range selector lever in the direction required.2005-09 2-7 DANGER ! The engine brake function is interrupted during the gear shift. By activating the engine brake. ).. 1348 758 101 . at railway crossings etc. you should shift the transmission to Neutral when stopping for long periods (more than approx. N R 024686/024680 ! 2. • Activating the parking brake during travel and on a smooth surface may bring the engine to a standstill.Operation 2.g. e. in queuing traffic.8 • Always engage the service or parking brake when the vehicle is stationary.2005-09 2-8 DANGER ! • When the vehicle is stationary with the engine running and a gear selected. Steering assistance is then no longer available! . you need simply press the accelerator in order to move the vehicle! • Before leaving the vehicle with the engine running.The clutch opens automatically before the vehicle reaches a standstill so that the engine does not “stall”. ! Stopping • With the accelerator untouched. Change in Direction of Travel Reverse travel “R ” to forwards travel “D ” and vice versa. the transmission must be shifted into Neutral and the parking brake engaged. The display is definitive for the direction of travel selected in the transmission. A/M D N R A/M D CAUTION To preserve the mechanical parts of the clutch release mechanism. The clutch is thereby closed and the clutch release mechanism relieved. 1 to 2 min. otherwise the transmission shifts to Neutral. slow down the vehicle using the service brake until it reaches a standstill.7 . traffic jam. DANGER! Changing direction of travel from “R” to “D” and vice versa from “D” to “R” may only be undertaken when the vehicle is stationary. the propshaft flange must always be disconnected from the rear axle.10 Towing • Bring the vehicle to a complete stop When towing. NOTE If the transmission is not shifted to Neutral before the engine is switched off.2005-09 2-9 . 1348 758 101 . ensure that you observe the vehicle manufacturer’s instructions! A/M • Apply parking brake D N CAUTION When towing. R • Move range selector to “N” 024681 • Switch off engine via ignition key A/M D N 2. The vehicle may roll away if no brakes are engaged.9 Stopping Engine / Vehicle 2. If this is not possible. Prevent pollution through possible oil loss. this is done automatically when the ignition is moved to “Off ”. 024687 ! DANGER! The engine cannot be switched off if a gear is selected. remove both stub shafts.11 Tow Starting R The engine cannot be tow started.Operation 2. we would recommend always selecting the lowest gear possible when setting off.Operation 2. • If the vehicle speeds up when traveling downhill. . NOTE Select an operating mode in which there is no risk of clutch overloading. CAUTION The engine may be damaged if the vehicle speeds up when traveling downhill and the engine enters the overspeed range. To protect the engine from damage in the overspeed range (red range). • Stop. To keep clutch wear levels as low as possible.2005-09 2-10 DANGER! The vehicle may speed up when traveling downhill. the driver still has considerable influence on the clutch’s service life. • Ensure that the engine does not exceed the permissible speed range.13.13. the electronics only permit gear shifts which are within the range of engine speeds laid down by the vehicle manufacturer. 2. for example: 2. there is no automatic shift into a higher gear.13 Engine Overspeed Protection If there is a risk of the clutch being overloaded by several starting procedures undertaken one after another in short succession or by crawling in too high a gear.1 Manual Mode • Accelerate vehicle (to close the clutch).2 Automatic Mode ! 1348 758 101 . To protect the engine and transmission. the system undertakes an upshift.12 Clutch Protection 2. • Set off quickly in a lower gear Despite the clutch being automated. the “ CL” display appears. If you select a gear. • When the rollers are running. the clutch closes. reverse gear can no longer be selected.Operation 2.When the rollers are running. the system recognizes the R “driving vehicle” function. A/M D N . 1348 758 101 .14 Roller Test Rig • Drive onto the roller test rig (brake test rig) • Move range selector to “N” . 024688 If only the driving axle is on the roller.2005-09 2-11 . the AS Tronic detects an ABS error because the front wheels will not turn. ! DANGER! The vehicle may leave the rollers even if the accelerator is not depressed. 023666 2-12 . Operating displays: 023672 • Automatic mode is shown in the display by 4 bars with 2 arrows. (8th gear is engaged in the transmission) • Transmission in Neutral 023667 • Reverse gear is engaged in the transmission • Manual mode • 4th gear is engaged in the transmission 023664 023665 1348 758 101 .Operation 2.15 Displays for ZF-AS Tronic The display provides information about the transmission status. • Display appears during “Ignition ON”. • “CH ” = System self-check. Option of downshifting by up to 3 gear steps available (one gear per bar) .2005-09 023669 • Manual mode • 8th gear is engaged in the transmission. Further travel not possible. there is a system fault. Clutch is overloaded. • “HT ” = High temperature (excessive transmission temperature). If the clutch doesn’t open when stopping as a result of insufficient air pressure. • Appears in turn with the normal display.13 Clutch Protection • “CW” = Clutch wear indicator • Take vehicle to nearest specialist workshop to have the clutch replaced. the transmission may remain in Neutral so that there is no direct drive and no engine brake effect. the engine is “stalled”.Operation • “TC ” = Transmission check • Transmission positions cannot be learnt. • “CL” = Clutch • Appears in turn with the normal display.2005-09 2-13 . 023673 NOTE Only start once sufficient air pressure is reached. Warning information: • “AL ” = Airless. 024721 023677 1348 758 101 . • Remedy: Chapter 2. • “CC ” = Clutch check • Clutch position cannot be learnt. 024722 023674 023675 023676 • “FP” = Accelerator pedal • Move accelerator pedal into idling position. ! DANGER! If gear shifts are undertaken with insufficient air pressure. The transmission system’s pneumatic system does not have sufficient pressure. • If the display doesn’t go out. • Also refer to section 2. 023761 ! • “Screwdriver” = System fault • Appears when only restricted operations are available.16 1348 758 101 . • Take vehicle to specialist workshop as soon as possible.2005-09 2-14 . DANGER! Whenever possible do not stop the vehicle in hazardous places. You must not continue driving.Operation 023678 • “EE ” = Electronic Error • Appears if communication between the display and transmission electronics is interrupted. the transmission may automatically switch to Neutral in order to protect the mechanical components of the clutch release mechanism. • “NS ” = Neutral Shift • “ N ” Use range selector to select Neutral S T O P 023680 • “STOP ” + “Screwdriver” = Serious system fault • Stop the vehicle. after a certain time. DANGER ! The vehicle may roll. System faults: • “ES ” = Easy Start • Electronic starting aids are temporarily unavailable. 023679 NOTE With certain system faults. You must take the vehicle to a workshop. automatic mode is deactivated and the transmission system remains in manual mode. 023762 ! NOTE Depending on the vehicle type. switch off the system by means of the master battery switch. please specify the error number(s).16 System Faults (Error Messages) • If a “screwdriver symbol” appears on the display. A/M D N R A/M D N R 024678/024743 Depending on the version. • Switch on ignition • The range selector must be in “N” • Use the range selector to select “D ” • Hold range selector lever in “+” NOTE The error numbers can only be called up when the engine is switched off. Shut down the vehicle. 1348 758 101 . there is a system fault. Switch the ignition back on.Operation Calling up error number(s): 2. there is a serious system fault. wait until the display goes out. This corresponds to the error currently active. you must not continue driving. If the display does not go out after “Ignition OFF”. If the fault message is still present. • The fault message and the resultant error response can be cancelled when the vehicle is stationary via “Ignition OFF”. you will have to go to a service center. If a “ STOP ” and “ Screwdriver symbol ” appear on the display.2005-09 2-15 . a 2 or 3-digit error number will appear on the display. When contacting the service center. Only restricted operations may be available. : Error no.2005-09 2-16 . 018470 e.: Error no. 174 If 4 bars and 2 arrows are displayed in addition to the number shown. g. + 100 (only on a two-digit display) Calling up error numbers from the error memory: • Switch on ignition • The range selector must be in “N” • Move range selector to “D ” and at the same time depress the foot brake. 227 1348 758 101 . 023681 023682 e. this means: Error no.Operation If 4 bars are displayed in addition to the number shown. g. 74 Error no. The errors saved are displayed one after another on the display. this means: Error no. +200 (only on a two-digit display) • Hold range selector lever in “+” NOTE The error numbers can only be called up from the error memory when the engine is switched off. 2005-09 2-17 . 1348 758 101 . Longer shift times should be expected. 1500 rpm This can be done e. note – Warm-up phase of at least 10 minutes.17 Use in Sub-Zero Temperatures Vehicle manufacturer specifications MUST be observed. temperatures in excess of –30 °C. is operable and all functions are provided. Outside temperature Down to –20 °C –20 °C to –35 °C –35 °C to –40 °C Oil grade in accordance with ZF-List of Lubricants TE-ML 02 in accordance with ZF-List of Lubricants TE-ML 02 in accordance with ZF-List of Lubricants TE-ML 02 Engine start permitted permitted Transmission must be preheated before the engine is started.Operation 2. with warm air which must not exceed 130 °C on the transm. with increased idling speed of approx. Limitations None At transm.17. 2.1 Parking Vehicle at Low Temperatures The vehicle may be parked or the transmission stored for long periods down to an outside temperature of –40 °C.g. Longer shift times should be expected. transm. CAUTION Do not heat on transmission and clutch actuator. When starting. transmission is operable and all functions are provided. At transmission temperatures in excess of –30 °C. 1348 758 101 .2005-09 2-18 . 2005-09 3-1 Initial fill after repairs with Intarder without Intarder with Intarder without Intarder 12 liters 11 liters 21 liters 11 liters . The ZF List of Lubricants TE-ML 02 is available from all ZF agencies or on the Internet http://www. Oil Change Transmission Fluid 3. Visual inspection for oil leaks as part of vehicle inspection.1.3).1 Oil grade In accordance with ZF List of Lubricants TE-ML 02. the ZF-Intarder operating manual 6085 758 102 will also be needed.2. 1348 758 101 .zf.1.1 Correctly filling the oil is essential to the precise oil volume when changing oil (refer to Chapter 3. 3.Maintenance 3 Maintenance 3.2 Oil Fill Quantity Regular maintenance increases the transmission’s operational reliability. If the transmission has a ZF-Intarder.com. 2 Oil Change 3. the oil change intervals must be observed as specified in List of Lubricants TE-ML 02! DANGER! Touching hot parts and transmission oil may cause burns. • Tighten oil drain plugs to the specified torque.Maintenance 3. • Remove oil drain plugs (items 1 and 2) from transmission and collect transmission oil in a suitable container and dispose of in accordance with environmental regulations.2.1 Oil Change Intervals To ensure that the transmission achieves the required level of operational safety and reliability.2Draining the Oil Always change the oil after a long journey while the transmission oil is still at operating temperature and thin. ! 3.2. NOTE Change the oil when the vehicle is on horizontal ground. 1348 758 101 .2005-09 3-2 . • Clean oil drain plug with magnetic plug and replace seal. .Maintenance Key 1 Oil drain plug tightening torque TA = 60 Nm 2 Oil drain plug tightening torque TA = 60 Nm 3 Oil fill and overflow measurement tightening torque TA = 60 Nm 1 2 3 010768 Version: Standalone transmission 3. - 014783 1 3 2 Version: Transmission with Intarder 1348 758 101 .2005-09 3-3 The oil level is correct when it has reached the bottom edge of the filler hole and/or when oil is already escaping out of the filler hole.2.3 Filling With Oil • Top up oil through oil filler aperture (item 3). • If the oil level has fallen below the oil fill aperture.3). NOTE Whenever checking the oil level.4 Check the transmission oil level at regular intervals: Bleeding the Transmission The transmission oil heats up during travel. Only check once the transmission oil has cooled down (<40 °C). The breather (item 1) must be clean and must not have its plastic cover fitted (transport protection). only for Intarder version 3-4 . also inspect the transmission for leaks. ! 2 3 DANGER ! Too little oil in the transmission will result in transmission damage.3 Oil Level Check 3.2. Ensure that the breather valve is fully functional at all times.Maintenance 3. This results in the formation of excess pressure which is continuously removed via a breather valve. Risk of accident! 013583 1 Transmission bleeding 2 Type plate 3 Oil fill plug 4 Initial fill and/or oil fill after repairs. • Check oil level when vehicle is on horizontal ground. the oil must be topped up (chapter 3. • Do not undertake the oil level check right after travel (this will produce an incorrect measurement). 1 4 • Remove oil filler plug (item 3). The following details must always be given when making inquires or undertaking repairs: 1 Parts list no.7 Pneumatic System Maintenance The vehicle manufacturer’s maintenance instructions must be observed.5 Type Plate 3.6 The type plate contains the key data. connectors must be fitted without traction relief.2005-09 3-5 . of transmission Visual Inspection of Wiring • Check wiring for damage. of transmission 2 Type of transmission 3 Serial no. 12 AS 2301 BO 1348 044 xxx • The pneumatic tank should be drained every week. the pneumatic cleaners and water separate should also be drained if this is not done automatically. 02 Type plate (example) 1348 758 101 .Maintenance 3. It is located on the left side of the transmission when viewed from the output. • Check that connectors are seated correctly. 3. in the winter every day. 200 010 XXXXX 21 NOTE When draining the pneumatic tank. 1348 758 101 .2005-09 3-6 .