ZF Industrial AS Tronic Manual (EN)

ZF AS Tronic

Subject to alterations in design Copyright by ZF This operating manual is protected by copyright. Reproduction and dissemination in any form, either wholly or in part especially as a reproduction, photomechanical or electronic copies or storage in data processing equipment or data networks without the approval of the legal owner is expressly prohibited and any violation will be pursued vigorously in the civil and criminal courts. Printed in Germany Edition: 2000 - 09

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Foreword

Foreword Please read this operating manual carefully before driving your vehicle. When operating the shift system, please note the special instructions provided in the vehicle manufacturer's operating manual. Your vehicle is fitted with a ZF- AS TRONIC automatic shift system. The more you familiarize yourself with this system, the more economically you can drive your vehicle. This operating manual will provide you with all the information you require to be able to make full use of the advanced technical features of the ZF- AS TRONIC. To ensure operating safety, please note the maintenance specifications.

Specialists employed by ZF After-Sales Service are always available to help with maintenance work on the transmission and are there to assist you should any other problems occur. The relevant addresses can be obtained from ZF in Friedrichshafen. We would like to wish you pleasant driving with your ZF- AS TRONIC ZF Friedrichshafen AG Truck Transmissions Division D-88038 Friedrichshafen Telefon: (0 75 41) 77-0 Telefax: (0 75 41) 77-90 80 00 3

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Important work safety notice

Important work safety notice The following safety instructions appear in this manual: ! ENVIRONMENTAL HAZARD ! Lubricants and cleaning agents must not be allowed to enter the ground, the water table or the sewage system. Request safety information for the products concerned from your local environmental protection authority and follow any instructions herein at all times. Always collect used oil in a suitably large container. Always dispose of used oil, clogged filters, lubricants and cleaning agents in accordance with environmental protection laws. Always observe manufacturer instructions when dealing with lubricants and cleaning agents.

NOTE Refers to special processes, techniques, data, etc. CAUTION This is used when incorrect, unprofessional working practices could damage the product. ! DANGER! ! This is used when lack of care could lead to personal injury and damage to property. 4

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Table of contents

Table of contents 16 AS 2601 with ZF-Intarder (Photo) . . . . . . . . . 1-1 2.6 Changing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.6.1 Changing gear in automatic mode . . . . . . . . . . . . 2-5 1 Description of system . . . . . . . . . . . . . . . . . . . . . 1-2 2.6.2 Changing gear in manual mode . . . . . . . . . . . . . . 2-5 1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 2.7 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 1.3 Range selector . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4 2.7.1 Changing direction of travel . . . . . . . . . . . . . . . . . 2-7 1.4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2.8 Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 1.5 Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2.9 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 1.6 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2.10 Switching off engine/ parking vehicle . . . . . . . . . 2-9 2.11 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 1.7 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6 2.12 Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 1.8 ZF auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 2.13 Clutch protection . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.14 Overspeed protection . . . . . . . . . . . . . . . . . . . . . . 2-11 2.1 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.14.1 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.2 Setting off, forwards travel . . . . . . . . . . . . . . . . . . 2-2 2.2.1 Correcting the starting gear . . . . . . . . . . . . . . . . .

2-2 2.14.2 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.3 Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.4 Starting to roll on slopes . . . . . . . . . . . . . . . . . . . . 2-4 2.5 Changing between manual and automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.16 Roller test rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 5

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