As Tronic

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Todays Topic:
Shifting Focus: Caring for your ZF AS Tronic Transmission
ZF Services North America, LLC
If you do not have an audio connection, dial 877-739-5904 and enter the Audio PIN number given to you on your screen
2011 Motor Coach Industries, Inc. All Rights Reserved.
Learning Objectives
During this presentation you will learn:
History of ZF
Technical Information
Components
Driving Modes
Maintenance
Diagnostics and Troubleshooting
Driving Tips
Service and Support
AS Tronic
Introduced to Global Coach Market in 2000; Introduced to
NA Coach Market in 2002.
Manual transmission - Automatic operation

Two-Pedal Simple Driver Interface
Single Disc Clutch Power Transfer
Pneumatic Shift and Clutch Control
Transmission electronics are integrated in the housing,
minimum wiring at the transmission
Manual Transmission Robust Hardware
ZF AS Tronic
12 AS 2301 BO
AS Tronic Technical Data
Fuel Economy Test Results

In Field Fuel Economy Data
DDC EPA02 and EPA04 Results
ZF 7.62 mpg (Nationally)
ZF 8.4 mpg (Midwest)
ZF 7.28 mpg (Western Region)
Tests with EPA 2007 Engines

Tests Winnipeg to Calgary (at GVW)
ZF/Cummins: 8.75 mpg
ZF/CAT: 7.89 mpg
ZF/DDC: 7.77 mpg
Tests with EPA 2010 Engines (Detroit Diesel)

ZF/DDC S60 EPA07: 7.83 MPG
ZF/DD13 EPA2010: 8.66 MPG
Components
Communication in the Driveline

Shift selector
keypad
AS Tronic 2
additional interfaces
(e.g. buzzer, PTO, ...)
E-Modul
E-Module/ZMTEC
Fahrschalter-Elektronik
(Basis-Modul)
ECU
AS Tronic 2
ZF System CAN
Other Vehicle Interfaces
(Integrated Electronic)
EDC
ABS
Vehicle CAN
The AS Tronic 2 offers:
CAN system network

Continuous monitoring of vehicle condition
Info readout via display
Selection of driving modes and correction option via ZF shifter
Diagnosis possible direct on vehicle
AS Tronic Mechanical Structure

Shift Control Module ( GS3 )
Planetary Range
Change Group
Input Splitter
12 Forward Gears
Synchronization
via CAN
All Controls in GS3
Three Speed
Main Gear Box
Clutch Control
Module
Shift System
Input Shaft
Countershaft
Splitter Group
Constant 1
Splitter Group
Constant 2
Countershaft
Range Change
Group
Transmission Brake
3-Speed
3
Transmission Component
R
R Gear, Reversing Gear
Output Shaft / Flange
Shift Layout
Shift cylinder for the
range change group (GP)
Selector cylinder for

main transmission section
Shift cylinder for

main transmission
section
Shift cylinder
for the
splitter
group (GV)
Actuation for the

gear pairs:
GV 2/3
1/R
GP
Transmission Actuator (GS3)

The Shift Module
(Mechatronics Module)
Replaceable
Input Speed Sensor
Electronic
Transmission Transmission
Control Unit Plug
Compressed-air
Connection
Replaceable
Temp Sensor
Vehicle
Plug
(CAN)
Rebuildable
Cylinders,
Valves and
Sensors
Replaceable
Air Regulator
Mechatronics Module
Integrated
Transmission ECU
Valves
- Shifting
- Selecting
- Gearbox
Brake
Pressure
Regulator
Valve
Transmission
Connector
Vehicle Connector
(CAN)
Sensors
- Travel
- Temperature
- Speed
- Pressure
Shift cylinder
- Splitter Group (GV)
- Range Group (GP)
- Main Transmission
Intelligent Transmission Control

Driving comfortably
safely, and economically
all the
time
Fully-automatic
shifting
and clutch actuation
Fully-automatic shifting and

clutch
Drive strategy
actuation
strategy
Drive
Protection
function
function
Protection
Maneuvering function
Maneuvering function
Starting support function
Starting support function
Shift dynamics
Shift dynamics
Automatic
Automatic neutral
shift function
neutral
shift
during standstill
function
during standstill
Clutch Module
Control Electronics
Travel Sensor
Clutch Module
Compressed Air Connection

Valves for
Clutch Control
Actuation Piston
010842
Clutch Actuator Filter

Complaint: Long CH check phase, long shifting times,
delay in the clutch learning process, bad shift quality
Cause: Air compressor contaminates the air system with hot
engine oil with the result of a carbonization of the air
hoses and all periphery components
Example: Air connection (check valve/filter, Kit No. 0501
322 365)
New:
Contaminated:
Remedy action: In case of contamination all devices which

are connected to the air system must be checked,
exchanged, and the root cause must be found
ZF-SACHS Clutch
Microprocessor
controlled selfadjusting system
Lifetime in intercity duty cycle
250,000 to 350,000
miles
Lifetime in overthe-road duty
cycle 500,000 to
750,000 miles
System will warn
driver of clutch
overload or need
of replacement
17 DIA Single Disk
Dry Clutch With
Organic Facing
Diaphragm Style,
Pull-Type
Pressure Plate
Lube-For-Life, Sealed,
Self-Centering Release
Bearing
Clutch Components Greasing Procedure
Status: Intro of the New Roller Release Mechanism
Wear
Anti-Rotation
Device
Status: Intro of the New Roller Release Mechanism

New Release
Fork
1328.268.012
Additional
Surface
Old Release
Fork
1328.268.011
Enlargement of the contact faces of the clutch

release fork's anti-rotation device
New Clutch Fork

New clutch fork
1328.268.012
with modified
contact surface
Compatible
with previous
release bearings
for roller forks
Quiz #1
Quiz #1 Answers
1. What transfers power between the engine and the ZF
transmission?
C SINGLE DISC DRY CLUTCH
2. How much fluid does the ZF transmission hold in the MCI
application?
D ALL OF THE ABOVE
3. How many electrical connections are on the ZF
transmission in the MCI application?
B2
4. How many air system connections are on the ZF
transmission in the MCI application?
B-2
Driving Modes
Driving Modes
Automatic Mode: Transmission shifts automatically.
Driver can override automatically selected gear by using
Up/Down Arrow Keys. Transmission will only allow shifts
which will not cause damage to itself or the engine.
Display Example
Manual Mode: Manual mode used to avoid unnecessary

shifting on inclines or strongly changing topography.
Transmission will only shift when prompted driver via the
Up/Down Arrow Keys. Again, the transmission will only
perform a shift that will not damage itself or the engine.
Display Example
Maneuvering Mode: 1st Gear and Reverse-Throttle pedal

acts like a clutch pedal for first 80% of throttle travel.
Available in both Automatic and Manual Modes.
Easy Start
The function aims to prevent the vehicle from rolling back
when starting off and to simplify the starting off process for
the driver
ES
Easy Start Contd

Activation logic
-
Brake pedal is pressed

Transmission is not in neutral
Vehicle speed is zero (vehicle stopped)
The current gear is lower or equal to the maximum start off
gear
When brake pedal is released Easy Start remains active

until:
-
Accelerator signal is detected

Defined clutch position is reached
Time of around 2s has lapsed and there is no accelerator signal
The speed, calculated from the transmission speed using two
redundant speed sensors, is found to be greater than a set
threshold value
The transmission is in Neutral
Brake pressure can be increased at any time; a soft touch on
the brake pedal keeps the vehicle still
Easy Start - Operation

Brake pedal depressed, vehicle stopped
Easy Start Operation

Brake pedal released, two second timer activated
Easy Start Operation

Valve opens after two seconds time-out or clutch engagement
Maintenance
Approved Clutch Components Service Lubricant
Optimol Olista Longtime

ZF P/N :
398 030 002 (400g)

0671 190 165 (100g)
North American Supplier:

NELSON OIL COMPANY
FIVE 20TH ST SW
PO BOX 1472
HICKORY, NC 28603
PHONE: (828) 322-9226
FAX: (828) 322-8712
E-MAIL: sales@nelsonlubricants.com
017568
017568
AS Tronic Lubrication
Oil Change Interval
- 300,000 km (186,000 miles) or 2 Years

- 500,000 km (300,000 miles) or 3 years with ZF
Ecofluid M and dry compartment breather kit
(ZF P/N: 1315 298 072)
Remote dry compartment breather is used by

MCI in 2007 production
Easy to install on existing product
Oil Capacity
- 11 Liter (3 Gallons) non-INTARDER version
- 18 Liter (5 Gallons) INTARDER version
ZF Recommended Fully Synthetic Oils
ZF Ecofluid M
Cognis Emgard Rebrand List (Shell, Texaco, Petro Canada, etc.)
Note: For more detailed description and additional selection refer to

ZF list of lubricants TE-ML 02**
**The most current version can be obtained at www.zf.com
ZF - Ecofluid M Transmission Fluid The Advantages

Why have ZF-Ecofluid M as
the transmission oil?
The advantages over
mineral and standard
synthetic oils/fluids:
-
New Low Price!

Reducing service costs
Environmentally friendly
Extending the
transmissions service life
Improving shift comfort
Compatible if mixed with
other oils
AS Tronic Shifter
Manual/Automatic Mode Indicator:
Auto Green Arrows Present
Manual No Arrows Present
2 Digit Alphanumeric Display (Gear Attained,

Warning Indications And Diagnostic Information)
Upshift
RND Status
Indicator
3 Red LEDs
Reverse
Neutral
Drive
"Downshift"
Warning Indications on display:
CH - Self Diagnostic Check
AL - Air Less (low air)
CL - Clutch Load
CW - Clutch Wear
FP - Foot Pedal (accelerator pedal error)
SM - System Malfunction
HT - High Temperature (gearbox 130C, TCU 125C)
NS - Neutral Shift (auto neutral)
TC - Transmission Check (position learning error)
CC - Clutch Check (clutch position can not be learned)
ES - Easy Start failure is detected
-- -- - Communication of the display with TCU is disturbed
EE - Communication of the display with TCU is disturbed
EX External signal active
BP Actuate brake pedal
SG Control unit reset
FS Shift selector fault
Function Key
(Toggles Between Auto/Manual Mode)
Failure Identification Philosophy

Level I
-
Missing non-critical signal from non-transmission system

Error is logged in memory, but driver is not alerted
Failure which may cause drivability issues, but further

driving is allowable
Some systems may not be available (Easy Start, Intarder,
Etc)
Check Trans Light Activated
Driver should proceed with caution
Level II
-
Level III
-
Critical system failure

Further driving not possible
SM on display and Check Trans Light Activated.
Driver must stop vehicle immediately (be aware that
once the vehicle stops, the transmission may not be able
to take a gear or close the clutch)
017568
Note:
After recording the active failure, always try to reset the system by
cycling the ignition key.
Diagnostic Options
On-Board Diagnosis
The PC-based diagnostic software for all transmissions,

axles and steering systems by ZF
Displays active and

stored error codes
1.
Laptop with TestMan-Pro

Diagnostic Software
2.
DPA 05 Interface
3.
Diagnostic Cable
Simple, menu-guided system check

Diagnosis while at rest (standstill) and in
motion (travel)
Check all input and output signals
Graphic depiction
Statistical data
Suitable for laptop and PC
Access to service documentation
Reading Error Memory Via ZF Shifter

Error Codes read from the ZF shifter are two digit numbers with green bars and arrows.
Fault Reaction Codes: 02
99 (Example: Code 27)
Two Digit
Number

199 (Example: Code 127)
Two Digit Number +

Two Green Bars

and UP (Example: Code 227)
Two Digit Number +

Two Green Bars +
Arrows Up & Down
Historical Failures:
Active Failures:
1) Ignition On
1) Ignition On
2) Transmission in Neutral
2) Transmission in Neutral
3) Hold down service brake
3) Press and Hold Up Arrow Key
4) Press and Hold Up Arrow Key
4) Error Codes will scroll until all faults
5) Error Codes will scroll until all
are displayed
faults are displayed
Driving Tips
Driving Tips
New Customers and Drivers Must Be Trained!
You cannot drive an AS Tronic vehicle like you drive a
Powershift!
Customer Comfort Directly Related to Driver Behavior

Throttle Pedal = Clutch Pedal
Abrupt Throttle Movement = Abrupt Clutch Movement
Use steady throttle position during shifts (do not lift!)
Low Speed Maneuvering

Utilize Maneuver Mode (1st and 2nd gear)
Clutch engagement much smoother in Maneuver Mode
Starting On Hills
Take advantage of Easy Start Use full brake apply after
stop
On Steep Grades, Downshift to 1st Gear (if not automatically
selected)
Use Parking Brake to Help Start-Off
Driving Tips Contd

Auto vs. Manual Mode
If gear Hunting is experienced, use Manual mode to hold
gear
Downshift before hill for better climbing performance
Driver may up and downshift while still in Auto Mode
Engine Brakes and Downshifting

Level of engine brakes selected affects how trans
downshifts
100% Engine Brake = 2 Gear Downshift (if possible)
<50% Engine Brake = 1 Gear Downshift
Higher Engine Speed = Higher Engine Brake Performance
Long Idle Times

If idling in gear for long periods, please shift to Neutral
If idling for 5 minutes in gear, Trans will automatically
shift to neutral
This helps prevent pressure plate and release bearing
wear
Driver Training DVD

ZF P/N: 1337.AST.DVD
Menu
-
Introduction
What is AS Tronic?
Your Driving Experience
Driving Tips
Automatic Mode
Comparison with
Powershift
Inclines
Maneuvering Mode
Engine Brakes
Operation & Warning
Indicators
ZF Diagnostic
Equipment
Conclusion
Service and Support
Support and Service
Support and Service

Regional Service Manager
Western Region
Dan Danielsen
2290 Snowdrift Road
Helena, Montana 59602
(406) 458-0142
(847) 478-6845
Fax: (406) 458-0226
Cell: 847-951-2908
dan.danielsen@zf.com

North-East Region
Jeff Henning
ZF Services North America
777 Hickory Hill Drive
Vernon Hills, IL 60061
(847) 478-6736
Fax: (847) 478-6843
jeff.henning@zf.com
South-East Region
Misha Todorovic
ZF Services North America
(847) 478-6728
Fax: (847) 478-6843
miodrag.todorovic@zf.com
2011 Current
2011 Current
Arizona
Cummins Rocky Mountain, LLC
651 N. 101st Avenue
Avondale, AZ 85323
(800) 800-2345
Palmer Johnson Power Systems
2060 S. 16th Street, Suite 113
Phoenix, AZ 85034
(800) 341-4334
California
HD Industries
537 W. Anaheim Street
Long Beach, CA 90813
(562) 591-5665
28970 Hopkins Street, Unit H
Hayward, CA 94545
(800) 341-4334
Colorado
8211 East 96th Avenue
Henderson, CO 80640
(800) 927-7201
Florida
Precision Transmission
4821 Waycross Road
Ft. Meyers, FL 33905
(888) 343-8912
Illinois
ZF Services North America, LLC
(800) 451-2595
Midwest Fuel Injection
1100 Holser Drive
Bolingbrook, IL 60490
(815) 886-1740
Georgia
Peach State Freightliner
100 Sterling Place
McDonough, GA 30253
(678) 583-8800
Kentucky
Republic Diesel
865 Nandino Boulevard
Lexington, KY 40511
(800) 432-9527
2011 Current
Kentucky
Republic Diesel
305 E. College Street
Louisville, KY 40203
(800) 292-5565
Michigan
Frontier Truck Parts
2019 Chicago Drive
Wyoming, MI 49519
(866) 241-2100
Louisiana
Louisiana Coaches, Inc.
5056 Taravella Rd.
Marrero, LA 70072
(888) 884-5226
Minnesota
3572 Hoffman Road East
White Bear Lake, MN, 55110
(800) 341-4334
Maine
Camerota (see Massachusetts)
Nebraska
Inland Truck Parts
5301 Alvo Ave.
Lincoln, NE 68514
(800) 243-9393
Maryland
Johnson Truck Center
3801 Ironwood Place
Landover, MD 20785
(877) 533-9878
Massachusetts
Camerota Truck Parts
35 Washington St.
Westborough, MA 01581
(800) 231-4005
New Jersey
Cummins Power Systems
41-85 Doremus Avenue
Newark, NJ 07105
(800) 433-7884
Foley Inc.
833 Centennial Avenue
Piscataway, NJ 08855
(800) 228-3406
2011 Current
Nevada
2750 Losee Road
Las Vegas, NV 89030
(800) 800-2345
New York
Cummins Power Systems
890 Zerega Avenue
Bronx, NY 10473
(800) 564-7373
Pennsylvania
Precision Transmission
159 Discovery Drive
Colmar, PA 18915
(215) 822-8300
Texas
Cummins Southern Plains
2614 Big Town Boulevard
Mesquite, TX 75150
(800) 297-2948
7045 N. Loop 610 East
Houston, TX 77028
(800) 474-7421
Texas
6226 Pan Am Expressway North
San Antonio, TX 78218
(800) 364-4884
Virginia
Johnson Truck Center
5509 Wellington Road
Gainesville, VA 20155
(877) 533-9878
Washington
Bowers Power Systems
22221 70th Avenue South
Kent, WA 98032
(800) 858-5881
Pacific Torque
18060 Des Moines Memorial Drive South
Seattle, WA 98148
(800) 726-5300
Wisconsin
1835 Haynes Drive
Sun Prairie, WI 53590
(800) 341-4334
2011 Current
Canada (Edmonton)
The Gear Centre
14605 116 Avenue
Edmonton, AB T5M3E8
(877) 450-4327
Canada (Dartmouth)
Cummins Eastern Canada, LP
50 Simmonds Drive
Dartmouth, NS B3B 1R3
(902) 468-7938
Canada (Calgary)
The Gear Centre
71710 Blackfoot Trail SE
Calgary, AB T2H2M1
(888) 252-3880
Canada (Mississauga)
Tarten Equipment
6199 Shawson Drive
Mississauga, ON L5T1E5
(888) 670-1704
Canada (Surrey)
Western Star & Sterling Trucks of
Vancouver, Inc.
9300 - 192 Street
Surrey, BC V4N3R8
(604) 882-0902
Canada (Mississauga)
The Gear Centre
#1 1235 Shawson Drive
Mississauga, ON L4W1C4
(888) 246-5077
Canada (Fredericton)
Atlantic Powertrain
827 Prospect Street
Fredericton, NB E3B5A6
(506) 453-1900
Summary
You should now know the following:

History of ZF
Components
Driving Modes
Maintenance
Driving Tips
Service and Support
Quiz #2
Quiz #2 Answers
1. How many driving modes are there?
D - AUTOMATIC, MANUAL AND MANEUVERING
2. Easy Start is a system to work the clutch more smoothly?
False
3. There are only 2 ways to accurately retrieve diagnostic
fault information?
TRUE
4. A "NS" on the ZF shifter means?
C NEUTRAL SHIFT
Questions and Answers

Click on the hand
to ask your question with your voice
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Visit www.mcicoach.

Welcome to the MCILEARN Series

Your Webinar Will Begin Shortly

2011 Motor Coach Industries, Inc. All Rights Reserved.

Manual transmission - Automatic operation

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

AS Tronic Technical Data

2011 Motor Coach Industries, Inc. All Rights Reserved.

Fuel Economy Test Results

Tests with EPA 2007 Engines

Tests with EPA 2010 Engines (Detroit Diesel)

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

Communication in the Driveline

Other Vehicle Interfaces

The AS Tronic 2 offers:

CAN system network

AS Tronic Mechanical Structure

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

Selector cylinder for

Shift cylinder for

Actuation for the

2011 Motor Coach Industries, Inc. All Rights Reserved.

Transmission Actuator (GS3)

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

Intelligent Transmission Control

Fully-automatic shifting and

2011 Motor Coach Industries, Inc. All Rights Reserved.

Compressed Air Connection

2011 Motor Coach Industries, Inc. All Rights Reserved.

Clutch Actuator Filter

Remedy action: In case of contamination all devices which

2011 Motor Coach Industries, Inc. All Rights Reserved.

Clutch Components Greasing Procedure

2011 Motor Coach Industries, Inc. All Rights Reserved.

Status: Intro of the New Roller Release Mechanism

Status: Intro of the New Roller Release Mechanism

Enlargement of the contact faces of the clutch

New Clutch Fork

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

Manual Mode: Manual mode used to avoid unnecessary

Maneuvering Mode: 1st Gear and Reverse-Throttle pedal

2011 Motor Coach Industries, Inc. All Rights Reserved.

Easy Start Contd

Brake pedal is pressed

When brake pedal is released Easy Start remains active

Accelerator signal is detected

Easy Start - Operation

2011 Motor Coach Industries, Inc. All Rights Reserved.

Easy Start Operation

2011 Motor Coach Industries, Inc. All Rights Reserved.

Easy Start Operation

2011 Motor Coach Industries, Inc. All Rights Reserved.

2011 Motor Coach Industries, Inc. All Rights Reserved.

Approved Clutch Components Service Lubricant

Optimol Olista Longtime

398 030 002 (400g)

North American Supplier:

- 300,000 km (186,000 miles) or 2 Years