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Today’s 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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Technical Information

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AS Tronic Technical Data

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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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Components

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Communication in the Driveline
AS Tronic 2 Shift selector
additional interfaces keypad
(e.g. buzzer, PTO, ...)

E-Modul
E-Module/ZMTEC
Fahrschalter-Elektronik
(Basis-Modul)
ZF System CAN

Other Vehicle Interfaces


ECU
AS Tronic 2
(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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
AS Tronic Mechanical Structure

Shift Control Module ( GS3 )


Planetary Range
Change Group

Input Splitter

• 12 Forward Gears
• Synchronization
via CAN Three Speed Clutch Control
• All Controls in GS3 Main Gear Box Module

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Shift System

Splitter Group
Splitter Group
Countershaft Constant 1
Input Shaft Constant 2

Countershaft Range Change


Group
Transmission Brake

3-Speed 3 2 1 R
Transmission Component
R Gear, Reversing Gear
Output Shaft / Flange

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Transmission Actuator (GS3)

The Shift Module


(Mechatronics Module)

Replaceable
Input Speed Sensor

Compressed-air Replaceable
Electronic Temp Sensor Replaceable
Transmission Transmission Connection
Control Unit Plug Air Regulator
Vehicle
Plug
(CAN)
Rebuildable
Cylinders,
Valves and
Sensors

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Mechatronics Module
• Valves
Integrated Pressure - Shifting
Transmission ECU Regulator - Selecting
Valve - Gearbox
Brake

Transmission
Connector

Vehicle Connector
(CAN)
• Sensors • Shift cylinder
- Travel - Splitter Group (GV)
- Temperature - Range Group (GP)
- Speed - Main Transmission
- Pressure

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Intelligent Transmission Control

Driving comfortably
safely, and economically
all the
– Fully-automatic time
shifting and clutch actuation
• Fully-automatic shifting and
–clutch actuation
Drive strategy
• –Drive strategy
Protection function
• –Protection function
Maneuvering function
• Maneuvering function
– Starting support function
• Starting support function
– Shift dynamics
• Shift dynamics
• –Automatic neutral
Automatic neutral shift
shift function
function during standstill
during standstill

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Clutch Module
Control Electronics
Travel Sensor

Clutch Module Compressed Air Connection


Valves for
Clutch Control

Actuation Piston

010842

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
ZF-SACHS Clutch

• Microprocessor
controlled self-
adjusting system
• Lifetime in inter-
city duty cycle
250,000 to 350,000
miles
• Lifetime in over-
the-road duty
cycle 500,000 to
750,000 miles
• System will warn
driver of clutch
overload or need
of replacement

17” DIA Single Disk Diaphragm Style, Lube-For-Life, Sealed,


Dry Clutch With Pull-Type Self-Centering Release
Organic Facing Pressure Plate Bearing
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
Clutch Components Greasing Procedure

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Status: Intro of the New Roller Release Mechanism

Wear

Anti-Rotation
Device

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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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


New Clutch Fork

• New clutch fork


1328.268.012
with modified
contact surface
• Compatible
with previous
release bearings
for roller forks

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Quiz #1

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


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?
B–2

4. How many air system connections are on the ZF


transmission in the MCI application?
B-2

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Driving Modes

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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.
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
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

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Easy Start Cont’d
• 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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
Easy Start - Operation
Brake pedal depressed, vehicle stopped

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Easy Start – Operation
Brake pedal released, two second timer activated

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Easy Start – Operation
Valve opens after two seconds time-out or clutch engagement

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Maintenance

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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 017568


017568

FAX: (828) 322-8712


E-MAIL: sales@nelsonlubricants.com
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
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
transmission’s service life
- Improving shift comfort
- Compatible if mixed with
other oils

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Diagnostics and Troubleshooting

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AS Tronic Shifter
Manual/Automatic Mode Indicator:
Auto – Green Arrows Present 2 Digit Alphanumeric Display (Gear Attained,
Manual – No Arrows Present Warning Indications And Diagnostic Information)

”Upshift”

RND – Status "Downshift"


Indicator
Warning Indications on display:
3 Red LED‘s
CH - Self Diagnostic Check
”Reverse” AL - Air Less (low air)
CL - Clutch Load
CW - Clutch Wear
FP - Foot Pedal (accelerator pedal error)
”Neutral” SM - System Malfunction
HT - High Temperature (gearbox ≥ 130°C, TCU ≥ 125°C)
NS - Neutral Shift (auto neutral)
TC - Transmission Check (position learning error)
”Drive” 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)

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Failure Identification Philosophy
Level I
- Missing non-critical signal from non-transmission system
- Error is logged in memory, but driver is not alerted
Level II
- 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 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.
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
Diagnostic Options

The PC-based diagnostic software for all transmissions,


On-Board Diagnosis axles and steering systems by ZF

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
Displays active and • Suitable for laptop and PC
stored error codes • Access to service documentation

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


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 Fault Reaction Codes: 100 – Fault Reaction Codes: 200
– 99 (Example: Code 27) 199 (Example: Code 127) and UP (Example: Code 227)

Two Digit Two Digit Number + Two Digit Number +


Number Two Green Bars Two Green Bars +
Arrows Up & Down

Active Failures: Historical Failures:


1) Ignition On 1) Ignition On
2) Transmission in Neutral 2) Transmission in Neutral
3) Press and Hold Up Arrow Key 3) Hold down service brake
4) Error Codes will scroll until all faults 4) Press and Hold Up Arrow Key
are displayed 5) Error Codes will scroll until all
faults are displayed
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
Driving Tips

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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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
Driving Tips Cont’d
• 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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
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
© 2011 Motor Coach Industries, Inc. All Rights Reserved.
Service and Support

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Support and Service

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Support and Service

Regional Service Manager Regional Service Manager


Western Region North-East Region
Dan Danielsen Jeff Henning
2290 Snowdrift Road ZF Services North America
Helena, Montana 59602 777 Hickory Hill Drive
(406) 458-0142 Vernon Hills, IL 60061
(847) 478-6845 (847) 478-6736
Fax: (406) 458-0226 Fax: (847) 478-6843
Cell: 847-951-2908 jeff.henning@zf.com
dan.danielsen@zf.com
Regional Service Manager
South-East Region
Misha Todorovic
ZF Services North America
777 Hickory Hill Drive
Vernon Hills, IL 60061
(847) 478-6728
Fax: (847) 478-6843
miodrag.todorovic@zf.com

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


2011 Current

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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Summary

You should now know the following:


• History of ZF
• Technical Information
• Components
• Driving Modes
• Maintenance
• Diagnostics and Troubleshooting
• Driving Tips
• Service and Support

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Quiz #2

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


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

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Questions and Answers

Click on the hand to ask your question with your voice

© 2011 Motor Coach Industries, Inc. All Rights Reserved.


Thank you for your business

© 2011 Motor Coach Industries, Inc. All Rights Reserved.