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The automated transmission system

for modern cranes

GB
 Introduction

In recent years vehicle manufacturers have been directing a substantial

share of their activities at relieving drivers of some of their workload
so that they can fully concentrate on safe and economical goods transport.

To this end, mechanical transmissions were used, automated with add-on

technology such as shift cylinders, valves, sensors and so on.

ZF has abandoned this approach and developed a new transmission

concept which is setting standards. ZF´s tried-and-tested transmission
technology wedded with state-of-the-art electronics have brought forth the
promising ZF-AS Tronic system – and, sure enough, at reasonable cost.

All transmission functions have been integrated in one single unit.

The driver can choose in favor of the automatic mode or opt for manual
shifting of gears. In any case, he has been relieved of any clutch work and
can fully concentrate on steering his truck.

The ZF-AS Tronic stands for:

➽ Economic efficiency
➽ Reliabilitiy
➽ Environmental acceptability

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 ZF-AS Tronic – A means to what end?

New technological solutions open up a whole world of novel

opportunities of design for the entire driveline:

➽ EDC-engines have gone into production

➽ Standard dry clutches have become fully automatable
➽ EDC and other electronics systems can communicate
(CAN-communication)

Increased reliability and raised economic efficiency of vehicles have been

and still are core issues in development work. ZF fully supports these
objectives and has made a major contribution with the ZF-AS Tronic.

➽ The entire driveline is relieved of substantial load by the fact that gear
changes are automatic and shift processes automated.
➽ Reduction of the number of sources for malfunction by integral
construction.
➽ The new automatic ZF-shift strategy permits operation of the engine in
the most economical range (automatic mode).
➽ Simple operation (also facilitates change of drivers).
➽ If needed, the driver can intervene in any traffic situation and initiate
gear changes at his own discretion (easy correction by means of
a tip lever).

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 ZF-AS Tronic – By all means!

It is the optimum drive system for trucks with electronically

controlled diesel engines (EDC) and modern CAN-technology.

009399

➽ Automatically shifting transmission system on the basis of a robust,

mechanical transmission.
➽ If needed, semiautomatic operation (manual gear selection).
➽ Alternative operating concepts (e.g. console selector, steering
column/steering wheel selector).
➽ Electronic/pneumatic clutch control; no clutch pedal.
➽ Electric/pneumatic shifting
➽ Speed adjustment of the gears (synchronization) in the main gear
during gear shifts performed via EDC-engine and transmission brake.

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 ZF-AS Tronic – By all means!

A perfectly communicating driveline.

Engine

integrated
Transmission
EDC Control ABS/ASR

3
01046
565
000

The ZF-AS Tronic offers:

➽ CAN-system network
➽ continuous monitoring of vehicle condition
➽ info readout for driver via display
➽ Selection of drive program and correction option
via tip lever (joystick)
➽ Diagnosis possible direct on vehicle

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 This is ZF-AS Tronic

T he first completely integrated transmission system.

clutch shifting module with
integrated electronics

clutch actuator

➽ No "add-on" operating elements.

➽ Only few central connections for compressed air and electric system.
➽ Electronic control system integrated in shifting module.
➽ Space and weight-saving construction:
Two countershafts and 2-speed planetary gear.
➽ The basic gear is dog clutch-operated (non-synchronized);
Splitter and range-change group are synchronized.
➽ Simpler, shorter, lighter and more versatile than anything else
the market can offer today.

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 ZF-AS Tronic – Two Performance Classes

Optimum installation space, weight and costs.

➽ 12 AS 2301
12-speed transmission

for vehicles up to 2 300 Nm (ca. 450 HP)

Specifically for this price-conscious vehicle class!

➽ 16 AS 2601
16-speed transmission

for vehicles up to 2 600 Nm (ca. 550 HP)

Ideal for demanding transport tasks

in international transportation!

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 Transmission Design

009931

Double-countershaft transmission with

• integrated splitter group and
• planetary-designed range-change group

Splitter Main Range-change

group transmission group

12 AS 2301 = 2 x 3 x 2

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 Installation Dimensions

953 (910)
622.5 (579.5) 221
5 395
5 3 7

(109)
278

116.5
32

Ø180
Ø511
Ø25
301

9 7 6 1 4 9 8 10 2
011524

Legend:
1 Input 6 Connection site for clutch-dependent PTO
2 Output 7 Compressed-air connection

3 Shifting module 8 Oil fill opening and oil level check

4 Clutch actuator 9 Oil drain opening

5 Breather 10 Speedo sensor

( ) Dimensions in parentheses for 12 AS 2301

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 Technical Data

12 AS 2301
Nm 1 900 2 300
kg 250
L 11

Direct Drive Overdrive

Gear 1 15.86 12.33
2 12.33 9.59
3 9.57 7.44
4 7.44 5.78
5 5.87 4.57
6 4.57 3.55
7 3.47 2.70
8 2.70 2.10
9 2.10 1.63
10 1.63 1.27
11 1.29 1.00
12 1.00 0.78
R 1 14.68 11.41
R 2 11.41 8.88

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 Internal Structure and Function
16 AS 2601
Sp
litte
rg
rou
K1 p
K2

R-gear
transmission reversing gear
brake
4
3 Range-change
2
1 group

16
(12 AS 26
AS 01
230 : four
1: t -
hre speed R-gear
e-s
pee sectio reversing Output flange
ds n
ect gear
ion
)
➽ Housing: Light alloy, three parts; integrated clutch bell.

➽ Power distribution: Constant K1 or K2 on both countershafts.

➽ Return of power distribution in 4-speed section onto main shaft in

corresponding gear (or reverse gear).

➽ Drive via range-change group. In slow driving range speed 1 to 8

(12 AS 2301: 1-6) with range group ratio.

➽ In fast driving range speed 9 to 16 (7 to 12) direct to universal shaft.

➽ The 12-speed transmission 12 AS 2301 has no gear set 1
Therefore, the transmission is about 43 mm shorter.

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 Gear Shifting

Shifting module
Shift Cylinder for
range group section Selector cylinder for
main transmission

Shift cylinder for

main transmission
section
Shift cylinder for
splitter group

e ed
-sp
12
GV 2/3
1/R
GP

➽ Gearshifts are perfomed by the shifting module (pneumatically)

➽ For splitter and range groups one shift cylinder each

➽ One shift cylinder for actuation of main transmission section

➽ One shift cylinder for gear selector of main transmission section

➽ Valves, cylinders, sensors and external connections integrated in transmission

shifting module

➽ Shifting commands from the electronic system or, if needed, from the driver

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 Clutch Actuation

Clutch Transmission travel

Control Unit sensor

valves
clutch open

0108
valves
42
clutch closed
actuator
piston
control
electronics

clutch air 010833

actuator supply

➽ No clutch pedal or hydraulic system

➽ Electro-pneumatic control of clutch processes
• when starting-off and when stopping
• when shifting gears
• when maneuvering
➽ Standard dry clutch actuated by clutch actuator
➽ Automatic clutch re-adjustment
➽ Driver automatically warned (display) if clutch is overloaded
➽ Display readout if clutch needs to be replaced

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 Shifting Module

Shifting module with Integrated

integrated Transmission electronics Transmission
Control Unit

010833

010291

Vehicle plug Transmission

(CAN) plug

The shifting module is installed on the top of the transmission,

and easily accessible

It contains:
➽ the integrated transmission electronics
➽ the valves for "shifting", "selecting", "transmission brake"
➽ the shift cylinders
➽ sensors for speed, pressure, etc.
➽ pressure relief valve
➽ the electric and pneumatic connections
for vehicle and transmission

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 Transmission Control Unit

CAN-communikation
with EDC, ABS, ASR

Clutch control

Transmission control,
gear changes

Automatic system
010832 (Driving strategy)

The transmission electronic system controls all processes in the trans-

mission and continuously communicates with linked-up vehicle systems.

7 8

1 2 9

3 4

6
5

air supply

1 Electronic Diesel Control (EDC) 5 Clutch actuator

2 Shifting module with integrated 6 Intarder electronics
Transmission Control Unit 7 Display Electrics
3 EDC-engine 8 Range selector Pneumatics
4 Dry clutch 9 ABS / ASR CAN-communication

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 Operating Concept
Console Range Selector
Several
upshifts upshifting
(several taps) (1 gear)

A/M reverse
shifting
switch over (1 gear)
(only whilst driving)
several
downshifts
(several taps)

63
0104

D ... Drive (forward,

automatic or manual)
N ... Neutral
R ... Reverse
A ... Automatic
M ... Manual 010464

The display keeps the driver informed:

➽ Operational mode (Drive mode, actual gear, etc.)
➽ Warnings
565

➽ Info on system malfunctions

000

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 Display Readouts
Warning
Operating mode System malfunction

System self-check Air pressure insufficient

(when ignition on) (airless)

Transmission in
Foot off pedal
Neutral position

Automatic mode Clutch overloaded

Select lower gear

Engaged starting-off or Communication error

driving gear (here: 5th gear). to display
Versions : 12-speed
Start. speed: 1st - 6th
Drive speed: 1st - 12th Clutch wear indicator

Gear selected,
downshift options
System error. Journey
can be continoued with
Reverse gear "Low" restrictions
engaged
System error.
Stop!
Reverse gear "High"
engaged
Example error code: 153
(Lines = "1")
PTO 1
ist activated (P). Auxiliary gear shift system:
Transmission Neutral (N). L1 = forward speed engaged
L2 = higher forward
PTO 1 und 2 are
LN = Neutral
activated (P). Starting-off
LR = Reverse gear
gear 3 engaged (3) speed

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 Operating modes

Automatic Mode 010832

➽ Transmission shifts automatically

➽ Both hands always on steering wheel
➽ Optimum gearshifts in any situation
"Dynamic" or "economical" drive style: the electronic system
recognizes the style and responds
➽ If needed, correction of gear selected via tip lever
➽ The electronic system preselects a starting gear;
the driver may adjust it to the situation given
➽ Maneuvering and PTO-operation only in manual mode

M anual Mode 010463

➽ Gearshifts at driver´s discretion (via tip lever)

➽ Automatic clutch operation of transmission
➽ Shifting of transmission by
repeated tapping: 1x = 1 gear; 2x = 2 gears
➽ The electronic system preselects a starting gear;
the driver may adjust it to the situation given
➽ Wrong gearshifts are precluded

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 Features
Technology and Function

➽ High-performance helical gears - new technology

➽ Central hydraulic oil supply
➽ Customary dry clutch
➽ Central cable harness; few external connections
➽ Robust housing with integrated clutch bell
➽ Full integration of all components
➽ Low temperature level for long service life of components
➽ Automated transmission functions for swift gearshifts
➽ Shifting in a manner that relieves the driveline of peak loads
➽ Jolt-free gear changes due to controlled clutch
➽ Display warning in case of clutch overload or if clutch needs
to be replaced
➽ Diagnostic mode recognizes and indicates malfunctions on display,
activates alternative functions and allows journey to be continued
➽ Simple trouble-shooting on vehicle by means of system-immanent
error memory and ZF-diagnosis unit

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 Benefits for the Driver

➽ Optimum relief for the driver:

• No clutch pedal
• Swift, automatic gear changes
• No operating errors
(electronic overspeed protection etc.)
• Continuously updated info via display
• All concentration focused on traffic
• Suitable starting gear always available
• Economical driving supported by most modern drive
strategies provided by transmission electronics
• Low noise level
➽ Smooth clutch control for maneuvering and reversing
➽ At any time – depending on the traffic situation – the driver can
change from the automatic mode to manual gear selection.
The driver remains "in command" of his vehicle.
➽ Easy vehicle operation, promptly understood by rotating drivers;
vehicle and driver are ready to go within a short time.

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 Benefits for the
Vehicle Manufacturer
➽ No shift lever with shift block and shifting linkage.
➽ No connections and lines for clutch pedal (hydraulics, kinematics).
➽ Spatial flexibility regarding installation of display and range selector.
➽ Flexible driver cabin arrangement.
➽ Noise encapsulation not necessary (simple, robust basic transmission with
helical gears).
➽ Long service life and high functional safety of the transmission through
integration of all components.
➽ Complete system with final inspection from a single supplier
(only one supplier).
➽ Improved economic efficiency of the transmission due to automatic
program (more favorable operating costs).
➽ No operating errors
➽ Simple check of electronic components and interfaces on the assembly
line by means of electronic diagnosis.
➽ Error memory integrated.

Benefits for vehicle manufacturer:

• Less installation costs
• Parts and systems omitted
• Less diagnosis and repair costs
• Less training costs

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 Benefits for the
Fleet Owner

➽ More payload
(ca. 60 kg more as opposed to Ecosplit transmissions)
➽ The driveline is relieved of peak loads; therefore less clutch wear
➽ Economic efficiency improved by automatic program
(Rental vehicle, etc.)
➽ Simple operation, no operating errors
➽ No clutch pedal, driver stays fit and motivated
➽ Ideal for unskilled drivers (driver rotation)
➽ High brake efficiency due to ZF-Intarder
➽ Only one contact partner for queries regarding
entire transmission / Intarder system
➽ Easy procurement of spare parts

Benefits for fleet owner:

• Less training costs
• Less maintenance and repair costs
• Less operating costs
(fuel, clutch, brake linings, brake drums)

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 Benefits
for the Environment

➽ Promotes fuel-saving drive style

= less exhaust / particulate emission

➽ Optimum efficiency
= low power loss

➽ 95% of all system components can be recyled

= raw material savings

➽ No environment-critical material such as asbestos, cadmium

= eco-friendly

➽ No hydraulic oil for clutch actuation

= eco-friendly

➽ Prolonged oil change intervals

= less waste oil

➽ Reduced transmission weight

= increased transport efficiency

➽ Varnishing with water varnish

= Savings in solvents
= eco-friendly

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 Self-Diagnosis

The AS Tronic system continuously performs self-diagnosis.

It recognizes malfunctions, activates alternative functions and ensures
continuance of journey.
For the driver this means:
➽ In case of malfunction:
• info by means of a symbol shown in display
• in addition: buzzing signal
• the driver can react accordingly

➽ The driver is informed whether he has to stop

immediately or whether the malfunction permits
to continue the journey to a suitable checking point. 011707
3
01046

➽ There he can activate the check mode to define

the malfunction (error code). Any measures to be taken
will be found in the operating manual.

➽ There are several options:

• Journey can be continued without any restrictions
• Journey can be continued with restrictions
• Journey can be continued with severe restrictions
(auxiliary control system)
• Journey cannot be continued.
ZF comes to the driver´s aid: in the operating manual he will find
hot lines, addresses and actions to take.

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