Operating

Instructions

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
manufacturers 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

Safety Instructions
The following safety instructions appear in this manual:

NOTE
Refers to special processes, techniques, information, 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 or material damage.

1348 758 101 - 2005-09

THREATS TO THE ENVIRONMENT!

Lubricants and cleaning agents must not be allowed to
enter the soil, ground water, or sewage system.
Ask your local environment agency for
safety information on the relevant products
and ensure compliance with their requirements.
Collect used oil in a suitably large container.
Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with
environmental protection guidelines.
When working with lubricants and cleaning agents
always observe the manufacturers instructions.

Table of Contents

1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.7
1.8

Description of System . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Selector . . . . . . . . . . . . . . . . . . . . . . . . .
Display (ZF Display) . . . . . . . . . . . . . . . . . . . .
Display: Automatic Mode . . . . . . . . . . . . . . . .
Display: Manual Mode . . . . . . . . . . . . . . . . . .
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . .
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . .
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . .
ZF-Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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
2.2
2.2.1
2.2.1
2.2.3
2.2.2
2.3
2.4
2.5
2.6
2.6.1
2.6.2
2.6.3
2.7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine . . . . . . . . . . . . . . . . . . . . .
Setting Off . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Off, Forward Travel . . . . . . . . . . . . . . .
Setting Off, Reverse Travel . . . . . . . . . . . . . . .
Starting Gear Correction . . . . . . . . . . . . . . . . .
Setting Off with Starting Aid (Optional) . . . . .
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving Off Downhill . . . . . . . . . . . . . . . . . . .
Changing Operating Mode: Manual/Automatic
Gear Changes . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Changes during automatic mode . . . . . .
Gear Changes during Manual Operations . . .
Function of Engine Brake when Changing Gear
Change in Direction of Travel . . . . . . . . . . . . .

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 - 2005-09

2.8
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
Stopping Engine / Vehicle . . . . . . . . . . . . . . . .
2.10 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 Tow Starting . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12 Clutch Protection . . . . . . . . . . . . . . . . . . . . . . .
2.13 Engine Overspeed Protection . . . . . . . . . . . . .
2.13.1 Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13.2 Automatic mode . . . . . . . . . . . . . . . . . . . . . . .
2.14 Roller Test Rig . . . . . . . . . . . . . . . . . . . . . . . . .
2.15 Displays for ZF-AS Tronic . . . . . . . . . . . . . . . .
2.16 System Faults (Error Messages) . . . . . . . . . . .
2.17 Use in Sub-Zero Temperatures . . . . . . . . . . . .
2.17.1 Parking Vehicle at Low Temperatures . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Fluid . . . . . . . . . . . . . . . . . . . . .
Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Fill Quantity . . . . . . . . . . . . . . . . . . . . . . . .
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Change Intervals . . . . . . . . . . . . . . . . . . . .
Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . .
Filling With Oil . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the Transmission . . . . . . . . . . . . . . .
Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Inspection of Wiring . . . . . . . . . . . . . . .
Pneumatic System Maintenance . . . . . . . . . . .

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
3.1
3.1.1
3.1.2
3.2
3.2.1
3.2.2
3.2.3
3.3
3.4
3.5
3.6
3.7

1348 758 101 - 2005-09

ZF-AS Tronic Transmission System

ZF-AS Tronic with Intarder

012240

1348 758 101 - 2005-09

1-1

Description of the System

The basic transmission has constant mesh, the splitter

group and planetary group have synchromesh.

Description of the System

1.1 General Description

Gear shifts are undertaken automatically by the transmission system.

The automatic ZF-AS Tronic transmission system is

adapted to the engine by means of a standard dry clutch.
The clutch is controlled by the transmission system and
a clutch pedal is no longer fitted.

The display on the dashboard displays all the system

information required for the driver (e.g. gear step,
malfunction etc.).

Unlike with powershift transmissions, with the

ZF-AS Tronic
during gear shifts,
at very low speeds, in order not to stall the engine, and
when the vehicle is stationary,
the driveline is open. This means that no drive force is
transferred.

The transmission actuator and clutch actuation unit

(clutch actuator) are the most important components for
complete automation of the transmission.
The transmission actuator consists of the transmission
electronics, shift valves, shift cylinders, and sensors.
The transmission electronics process all incoming signals
and initiate the gear shift using solenoid valves and shift
cylinders.

DANGER!
The brake must be applied to prevent the vehicle from
unintentionally moving either forwards or backwards.

The clutch actuator is controlled electro-pneumatically

and handles all clutch actuation functions.

The ZF-AS Tronic consists of a basic transmission and an

integrated splitter and planetary group.

1348 758 101 - 2005-09

The ZF-Intarder is an additional hydro-dynamic brake

integrated in the transmission which operates with no
wear.

1-2

Description of the System

1.2

Overview
1
A/M

2
D

S
T
O
P

Key
1 ZF range selector
2 ZF display
3 Transmission actuator with integrated
electronic transmission control
4 Clutch actuator

1348 758 101 - 2005-09

5
6
7
8

Transmission
Accelerator
Brake pedal
ZF-Intarder

1-3

024527

024527

Description of the System

1.3

You can use the range selector to select gears and change
operating mode.

Range Selector

After the positions +, +, , and A/M have been

selected, the range selector snaps back to D.

A/M D

A/M

You can undertake manual upshifts or downshifts over

more than 2 gear steps by tipping the speed selector
several times.

In the N and R positions, the range selector locks.

+
+

= 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 - 2005-09

1-4

Description of the System

1.4

Display (ZF Display)

1.4.2 Display: Manual Mode

Only descriptions of the displays for transmission functions are provided in this operating manual. Refer to
vehicle manufacturers operating instructions for other
displays.

4th gear is engaged in the

transmission.

The display shows the number of the gear selected,

neutral, downshifts available, and error messages.

8th gear is engaged in the

transmission. Option of downshifting by up to 3 gear steps
available (one gear per bar)

023664

1.4.1 Display: Automatic Mode

The transmission is
in automatic mode
(4 bars and 2 arrows).

1.5

023665

Accelerator Pedal

023663

The accelerators position must not be changed during the

shift process.

4th gear is engaged

in the transmission.

The clutch is activated by the electronic transmission

control unit depending on accelerator actuation.
During gear shifts, the engine is influenced by the electronic transmission control unit.

1348 758 101 - 2005-09

1-5

Description of the System

1.6

Automatic Mode

1.7

Range selector in position D. The gear shift system

selects the best gear for setting off.
If you press the accelerator pedal, the clutch closes
automatically and the vehicle starts to move.
The shift system performs upshifts and downshifts
automatically during travel.

Manual Mode

If A/M is selected using the range selector, the transmission system changes into manual mode. The driver
can use the range selector to propose a starting gear other
than that proposed by the system.
If you press the accelerator pedal, the clutch closes
automatically and the vehicle starts to move.
The driver uses the range selector to select the gears
required.

Downshifts which would result in overrevving or stalling

the engine, are prevented by the shift system when in
automatic mode.

Overrevving the engine is not economical and should be

prevented by the driver.

The driver can use the range selector to intervene manually at any time for example, in difficult driving situations
without having to come off the gas. The mode then
changes from automatic to manual.

If the accelerator is pressed when in too high a gear, the

engine may stall.

1.8

ZF-Intarder

ZF operating manual 6085 758 102 is provided for

operating and maintaining the ZF-Intarder.

1348 758 101 - 2005-09

1-6

Operation

Operation

2.1

NOTE
Depending on the manufacturer and vehicle type, you
may have controls and operating processes other than
those described in this manual.
Therefore, also observe the operating instructions provided
by the vehicle manufacturer.

Starting the Engine

Apply parking brake

The range selector must be

in N
(transmission in Neutral)

N
R
024688

Switch on ignition
-

A/M

DANGER!
The vehicle must not be left with the engine running
and a gear selected.

Shift system self-check

(display shows CH )

Start the engine

-

023666

Self-check is complete.
N appears on display,
transmission is in Neutral
023667

NOTE
Gears cannot be selected when engine is stationary.

1348 758 101 - 2005-09

2-1

Operation

2.2

Setting off

2.2.2 Setting Off, Reverse Travel

Vehicle must be stationary.

2.2.1 Setting Off, Forward

Travel
Move range selector from
N to D.
- Automatic mode is activated
- The display shows the starting
gear selected.
(The system selects the
starting gear itself, clutch
remains separated.)

A/M

Use range selector to select

R
- R appears on the display
(clutch remains separated

N
R

A/M

N
R

024678

Depress accelerator and release

brake at the same time
(clutch closes automatically).
- Vehicle moves backwards.

023668

024684

023669

Depress accelerator and at the same time release the

parking brake.
- Vehicle sets off (clutch closes automatically).

DANGER!
The vehicle may start to roll away if you do not
depress the accelerator.
When setting off on an incline, select gear and only
release parking brake once accelerator has been
depressed otherwise the vehicle will roll backwards.

1348 758 101 - 2005-09

2-2

DANGER!
If the vehicle is rolling, a shift is not made into reverse
gear!
Immediately bring the vehicle to a standstill.
Only the display provides definitive information on
the direction of travel selected in the transmission.

Operation

2.2.3 Starting Gear Correction

Use range selector to select D or R .

- Automatic mode is activated.
- The display shows the starting gear selected.

Release service brake.

- The brake remains engaged briefly thanks to the
starting aid.

Press the accelerator.

- Brake is released
- Vehicle sets off.

The system proposes a starting gear. Corrections can be

made between the minimum and maximum starting gears.
Undertaking correction:
Press range selector lever in +
or direction.
- The display shows the starting
gear selected.

A/M

N
R

024679

2.2.4 Setting Off with Starting Aid (Optional)

As an option, the vehicle can be equipped with an electronic starting aid (Easy Start). The starting aid should
prevent the vehicle from rolling away when starting on
an uphill or downhill incline.

Start engine (see 2.1).

Apply service brake and release parking brake.

1348 758 101 - 2005-09

DANGER !
Once the brake pedal is released, the brake is only
engaged for a short time. The vehicle may roll.

NOTE
The time to release the brake depends on the accelerator position, clutch position and roadspeed.
The brake is released even if the transmission is shifted
to Neutral.

2-3

Operation

2.3

Maneuvering in 1st gear or R gear

Maneuvering

The time spent maneuvering is not

limited in 1st gear.

1st gear (depending on vehicle, possibly 1st and 2nd gear)

and R gear are provided as maneuvering gears for very
slow travel. Maneuvering mode is not available in other
gears. If necessary, correct the current gear by pressing
the range selector lever in the direction.

023670

CAUTION
If the driver does not respond to
the CL display, the clutch may be
damaged from overload.

In maneuvering mode, the vehicle (accelerator) is more

sensitive and clutch activation differs from how it is in
normal mode.

Maneuvering in 2nd gear

Depending on the vehicle type, 2nd gear
may also be intended as a maneuvering
gear.
The length of time spent maneuvering in
this gear is restricted. A change is made
from maneuvering mode into setting off
mode.

The system recognizes maneuvering mode from the

accelerator position and the low travel speed.

DANGER!
The system changes from maneuvering mode to setting off mode depending on the accelerator position
and vehicle speed.
The vehicle may accelerate suddenly.

The CL display appears when the clutch is overloaded.

1348 758 101 - 2005-09

2-4

023669

023671

DANGER!
If the driver does not respond to the CL display, the
system changes from maneuvering mode to setting
off. The vehicle may accelerate.
RISK OF ACCIDENT!

Operation

2.4

Moving Off Downhill

2.5

Requirements: Engine is running.

Changing Operating Mode: Manual / Automatic

Can be undertaken at any time, even during travel.

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.
Do not allow vehicle to roll in direction opposite to
that of the gear selected.

Use the range selector to select

A/M.

A/M

Changing operating mode from

automatic to manual:

N
R
024685

If the vehicle rolls forwards

transmission in Neutral once the
brake has been released and you
shift from N to D , the system
selects a gear appropriate for the
roadspeed.
The clutch closes without the
accelerator being pressed, the
driveline is now closed.

Use the range selector to select A/M.

A/M

NOTE
If + or is selected using the range selector lever, the
operating mode changes briefly into manual.

N
R
024678

023668

1348 758 101 - 2005-09

2-5

Operation

2.6

Gear Changes

2.6.2 Gear Changes during Manual Operations

Press range selector lever in
+ or direction.

2.6.1 Gear Changes during Automatic Mode

All upshifts and downshifts are undertaken automatically.
This depends on:

A/M

Drive situation
Loading
Accelerator position
Velocity
Engine speed

N
R
024679

The shift system exits automatic

mode when a manual shift is
undertaken.
023672

A/M

2 arrows and 4 bars = automatic mode;

8th gear is engaged.

If you use the range selector

lever to select A/M , automatic
mode is re-activated.

N
R
024685

1348 758 101 - 2005-09

2-6

Operation

Jumping gears

2.6.3 Function of Engine Brake when Changing Gear

Jumping one gear:

Press range selector lever in + or direction until
stop is reached.

The engine brake is deactivated by the system during gear

shifts. Once the gear shift is complete, the engine brake is
automatically reactivated.

Jumping two gears:

Press range selector lever in the direction required,
pressing once all the way to the first spring point and
once to the stop in quick succession.

By activating the engine brake, the system downshifts into

automatic mode so that the maximum engine effect is
reached.

!
NOTE
You can shift from any gear to Neutral at anytime using
the range selector. This shift takes priority.
The accelerator position must not be changed during
the shift process because the engine is controlled
automatically.
A shift command is not undertaken if the shift would
result in the maximum engine speed (governing speed)
being exceeded.

DANGER !
Shifts to Neutral can also be made during travel. If a
shift is made to Neutral, the driveline is interrupted.
The engine brake then no longer functions.

1348 758 101 - 2005-09

2-7

DANGER !
The engine brake function is interrupted during the
gear shift. The vehicle may accelerate when traveling
downhill.

Operation

2.7

- The clutch opens automatically before the vehicle

reaches a standstill so that the engine does not
stall.

Change in Direction of Travel

Reverse travel R to forwards travel D and vice versa.

A/M

N
R

A/M

CAUTION
To preserve the mechanical parts of the clutch release
mechanism, you should shift the transmission to Neutral
when stopping for long periods (more than approx. 1 to
2 min., e.g. in queuing traffic, traffic jam, at railway
crossings etc.). The clutch is thereby closed and the
clutch release mechanism relieved.

N
R

024686/024680

2.8

Always engage the service or parking brake when the

vehicle is stationary.

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, otherwise the transmission
shifts to Neutral.
The display is definitive for the direction of travel
selected in the transmission.

Stopping

With the accelerator untouched, slow down the vehicle

using the service brake until it reaches a standstill.

1348 758 101 - 2005-09

2-8

DANGER !
When the vehicle is stationary with the engine
running and a gear selected, you need simply press
the accelerator in order to move the vehicle!
Before leaving the vehicle with the engine running,
the transmission must be shifted into Neutral
and the parking brake engaged.
Activating the parking brake during travel and on a
smooth surface may bring the engine to a standstill. Steering assistance is then no longer available!

Operation

2.9

Stopping Engine / Vehicle

2.10 Towing

Bring the vehicle to a complete

stop

When towing, ensure that you observe the vehicle

manufacturers instructions!
A/M

Apply parking brake

CAUTION
When towing, the propshaft flange must always be
disconnected from the rear axle. If this is not possible,
remove both stub shafts.
Prevent pollution through possible oil loss.

Move range selector to N

024681

Switch off engine via ignition

key
A/M

2.11 Tow Starting

The engine cannot be tow started.

024687

DANGER!
The engine cannot be switched off if a gear is
selected. The vehicle may roll away if no brakes
are engaged.

NOTE
If the transmission is not shifted to Neutral before the
engine is switched off, this is done automatically when
the ignition is moved to Off .
1348 758 101 - 2005-09

2-9

Operation

2.12 Clutch Protection

2.13 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, the CL
display appears.

To protect the engine and transmission, the electronics

only permit gear shifts which are within the range of
engine speeds laid down by the vehicle manufacturer.

NOTE
Select an operating mode in which there is no risk of
clutch overloading, for example:

2.13.1 Manual Mode

Accelerate vehicle (to close the clutch).

Stop.
Set off quickly in a lower gear
Despite the clutch being automated, the driver still has
considerable influence on the clutchs service life.
To keep clutch wear levels as low as possible, we would
recommend always selecting the lowest gear possible
when setting off.

If the vehicle speeds up when traveling downhill, there

is no automatic shift into a higher gear.
Ensure that the engine does not exceed the permissible
speed range.
CAUTION
The engine may be damaged if the vehicle speeds up
when traveling downhill and the engine enters the
overspeed range.

2.13.2 Automatic Mode

1348 758 101 - 2005-09

2-10

DANGER!
The vehicle may speed up when traveling downhill.
To protect the engine from damage in the overspeed
range (red range), the system undertakes an upshift.

Operation

2.14 Roller Test Rig

Drive onto the roller test rig
(brake test rig)
Move range selector to N .
A/M
D
N
- When the rollers are running,
the system recognizes the
R
driving vehicle function.
024688
If only the driving axle is on
the roller, the AS Tronic detects
an ABS error because the front wheels will not turn.
When the rollers are running, reverse gear can no
longer be selected.
If you select a gear, the clutch closes.

DANGER!
The vehicle may leave the rollers even if the accelerator is not depressed.

1348 758 101 - 2005-09

2-11

Operation

2.15 Displays for ZF-AS Tronic

The display provides information about the transmission
status.
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 - 2005-09

023669

Manual mode
8th gear is engaged in the
transmission. Option of downshifting by up to 3 gear steps
available (one gear per bar) .

CH = System self-check.
Display appears during Ignition
ON.
023666

2-12

Operation

TC = Transmission check
Transmission positions cannot be
learnt.

Warning information:
AL = Airless.
Appears in turn with the normal
display. The transmission systems
pneumatic system does not have
sufficient pressure.

023673

NOTE
Only start once sufficient air pressure is reached. If the
clutch doesnt open when stopping as a result of insufficient air pressure, the engine is stalled.

DANGER!
If gear shifts are undertaken with insufficient air
pressure, the transmission may remain in Neutral so
that there is no direct drive and no engine brake
effect.

024722

023674

023675

023676

FP = Accelerator pedal
Move accelerator pedal into idling
position.
If the display doesnt go out, there
is a system fault. Further travel
not possible.
CL = Clutch
Appears in turn with the normal
display. Clutch is overloaded.
Remedy: Chapter 2.13 Clutch
Protection
CW = Clutch wear indicator
Take vehicle to nearest specialist
workshop to have the clutch
replaced.

CC = Clutch check
Clutch position cannot be learnt.
HT = High temperature
(excessive transmission temperature).

024721

023677

1348 758 101 - 2005-09

2-13

Operation

023678

EE = Electronic Error
Appears if communication
between the display and transmission electronics is interrupted.

System faults:

ES = Easy Start
Electronic starting aids are
temporarily unavailable.

023679

NOTE
With certain system faults, automatic mode is deactivated
and the transmission system remains in manual mode.

023761

Screwdriver = System fault

Appears when only restricted
operations are available.
Take vehicle to specialist workshop as soon as possible.

DANGER !
The vehicle may roll.

NS = Neutral Shift
N Use range selector to select
Neutral

S
T
O
P

023680

STOP + Screwdriver
= Serious system fault
Stop the vehicle. You must not
continue driving. You must take
the vehicle to a workshop.

023762

NOTE
Depending on the vehicle type, after a certain time, the
transmission may automatically switch to Neutral in order
to protect the mechanical components of the clutch
release mechanism.

DANGER!
Whenever possible do not stop the vehicle in
hazardous places.

Also refer to section 2.16

1348 758 101 - 2005-09

2-14

Operation

Calling up error number(s):

2.16 System Faults (Error Messages)

If a screwdriver symbol appears on the display,
there is a system fault. Only restricted operations may
be available.
If a STOP and Screwdriver symbol appear on the
display, there is a serious system fault. Shut down the
vehicle, you must not continue driving.
The fault message and the resultant error response can
be cancelled when the vehicle is stationary via Ignition OFF, wait until the display goes out. If the display
does not go out after Ignition OFF, switch off the
system by means of the master battery switch. Switch
the ignition back on.
If the fault message is still present, you will have to go
to a service center.
When contacting the service center, please specify the
error number(s).

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.

A/M

N
R

A/M

N
R

024678/024743

Depending on the version, a 2 or 3-digit error number will

appear on the display.
This corresponds to the error currently active.

1348 758 101 - 2005-09

2-15

Operation

If 4 bars are displayed in addition to the number shown,

this means: Error no. + 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.
023681

023682

e. g.: Error no. 74

Error no. 174

If 4 bars and 2 arrows are displayed in addition to the

number shown, 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.

The errors saved are displayed one after another on the

display.

018470

e. g.: Error no. 227

1348 758 101 - 2005-09

2-16

Operation

2.17 Use in Sub-Zero Temperatures

Vehicle manufacturer specifications MUST be observed.
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.

When starting,
note

Warm-up phase of at least

10 minutes, with increased
idling speed of approx.
1500 rpm

This can be done e.g. with

warm air which must not
exceed 130 C on the transm.
CAUTION
Do not heat on transmission
and clutch actuator.

Limitations

None

At transm, temperatures in
excess of 30 C, transm. is
operable and all functions are
provided. Longer shift times
should be expected.

At transmission temperatures in
excess of 30 C, transmission
is operable and all functions are
provided. Longer shift times
should be expected.

2.17.1 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.
1348 758 101 - 2005-09

2-17

1348 758 101 - 2005-09

2-18

Maintenance

Maintenance

3.1.2 Oil Fill Quantity

Regular maintenance increases the transmissions

operational reliability.
Visual inspection for oil leaks as part of vehicle inspection.
If the transmission has a ZF-Intarder, the ZF-Intarder
operating manual 6085 758 102 will also be needed.

3.1

Correctly filling the oil is essential to the precise oil

volume when changing oil (refer to Chapter 3.2.3).

Oil Change

Transmission Fluid

3.1.1 Oil grade

In accordance with ZF List of Lubricants TE-ML 02. The
ZF List of Lubricants TE-ML 02 is available from all ZF
agencies or on the Internet http://www.zf.com.

1348 758 101 - 2005-09

3-1

Initial fill
after repairs

with
Intarder

without
Intarder

with
Intarder

without
Intarder

12 liters

11 liters

21 liters

11 liters

Maintenance

3.2

Oil Change

3.2.2Draining the Oil

Always change the oil after a long journey while the
transmission oil is still at operating temperature and thin.

NOTE
Change the oil when the vehicle is on horizontal ground.

3.2.1 Oil Change Intervals

To ensure that the transmission achieves the required
level of operational safety and reliability, 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.

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.
Clean oil drain plug with magnetic plug and replace
seal.
Tighten oil drain plugs to the specified torque.

1348 758 101 - 2005-09

3-2

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

2 3

010768

Version: Standalone transmission

3.2.3 Filling With Oil

Top up oil through oil filler aperture (item 3).
-

014783

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.

Maintenance

3.3

Oil Level Check

3.4

Check the transmission oil level at regular intervals:

Bleeding the Transmission

The transmission oil heats up during travel. This results

in the formation of excess pressure which is continuously
removed via a breather valve. Ensure that the breather
valve is fully functional at all times. The breather (item 1)
must be clean and must not have its plastic cover fitted
(transport protection).

Check oil level when vehicle is on horizontal ground.

Do not undertake the oil level check right after travel
(this will produce an incorrect measurement). Only
check once the transmission oil has cooled down
(<40 C).

Remove oil filler plug (item 3).

If the oil level has fallen below the oil fill aperture, the
oil must be topped up (chapter 3.2.3).
NOTE
Whenever checking the oil level, also inspect the transmission for leaks.

DANGER !
Too little oil in the transmission will result in transmission damage. Risk of accident!

013583

1 Transmission bleeding
2 Type plate
3 Oil fill plug
4 Initial fill and/or oil fill after repairs, only for Intarder
version
3-4

Maintenance

3.5

Type Plate

3.6

The type plate contains the key data.

It is located on the left side of the transmission when
viewed from the output.
The following details must always be given when making
inquires or undertaking repairs:
1 Parts list no. of transmission
2 Type of transmission
3 Serial no. of transmission

Visual Inspection of Wiring

Check wiring for damage.

Check that connectors are seated correctly, connectors must be fitted without traction relief.

3.7

Pneumatic System Maintenance

The vehicle manufacturers maintenance instructions

must be observed.
12 AS 2301 BO
1348 044 xxx

The pneumatic tank should be drained every week, in

the winter every day.

200 010

XXXXX

21

NOTE
When draining the pneumatic tank, the pneumatic
cleaners and water separate should also be drained if
this is not done automatically.

02

Type plate (example)

1348 758 101 - 2005-09

3-5

1348 758 101 - 2005-09

3-6