Contents

Technical data

• Manual transmission control
• General information
• Tightening torques
• Pneumatic gearbox control (service movement)
• General information
• Tightening torques
• Pneumatic gearbox
• General information
• Tightening torques
• Gearbox ZF 6S-850
• General information
• Tightening torques
• Refueling tanks
• Gearbox ZF 8/9 / 16s-109
• General information
• Tightening torques
• Refueling tanks
• Gearboxes ZF8 / 16s-151/181 and 16s-221
• General information
• Tightening torques
• Refueling tanks
• EATON FS / 6309a gearbox
• General information
• Tightening torques
• Refueling tanks
• ALLISON automatic transmission
• General information
• Tightening torques
• Refueling tanks
• Clutch
• General information
• Tightening torques
• Refueling tanks
• Support shafts
• General information
• Tightening torques
• Refueling tanks
• ZF Intarder
• General information
• Tightening torques
• Power take-off shaft
• General information
• Tightening torques
• Refueling tanks
• AS TRONIC gearbox
• General information
• Tightening torques
• Refueling tanks

Diagnostics

• Manual transmission control
• Troubleshooting table
• Pneumatic gearbox control
• Troubleshooting table
• Pneumatic gearbox
• Troubleshooting table
• Manual transmission
• Troubleshooting table
• Automatic transmission
• Reading fault codes
• Fault code table
• Clutch
• Troubleshooting table
• Support shafts
• Troubleshooting table
• ZF Intarder
• Troubleshooting table
• AS TRONIC
• Troubleshooting table

Manual transmission control

• General information
• Manual Transmission Description
• Reducer
• Gear Lever
• Checking and adjusting the LHD / RHD gearbox control
• Removal and installation, complete unit
• Removal and installation, reducer
• Removal - Refitting, Shift Lever Inner Dust Cover
• Removal and installation, gears
• Removing and installing, control rod
• Removal and installation, ball joint control

Pneumatic transmission control (service movement)

• General information
• Description of the pneumatic transmission control system (servo shift)
• Component Description
• Servo Shift
• Emergency Selector Function
• Removal and Installation
• Repair and Installation, Servo Shiftoblock

Gearbox - pneumatic

• General information
• Location of underdrive protection components for ZF / EATON gearboxes
• System description, underdrive protection
• Location of protection components
• Description of the protection system
• Pneumatic diagram, transmission control
• Component Description
• Integrated air distribution unit
• Valve neutral
• Underdrive safety valve
• High / Low Range Cylinder
• Pressure Reducing Valve
• GV valve
• Divider Relay Valve
• Filter / Regulator, EATON FS / 6309a
• Speed ??Signal Simulation
• Inspect, underdrive relief valve
• Check and Adjust, ZF / EATON Gearbox GV Valve
• Test, filter / regulator, EATON FS / 6309a
• Removal and installation, reducer, reducer, valve
• Cleaning the filter / regulator, EATON FS / 6309a

Gearbox ZF 6S-850

• General information
• System Description
• Component Description
• Synchronizer
• Check and adjust
• Inspection, transmission oil level
• Checking and adjusting, axial clearance of the input shaft bearing
• Inspection and adjustment, output shaft axial play
• Removal - Refitting, transmission
• Removing and installing, entire gearbox
• Removal and Installation, Drive Flange
• Uninstallation and Installation, Exit
• Removing and installing, gearbox front cover o-ring
• Removing and installing, selector
• Draining and filling, reducer

Gearbox ZF 8/9 / 16s-109

• General information
• System Description
• Component Description
• Synchronizer
• Check and adjust
• Inspection, transmission oil level
• Checking and adjusting, axial clearance of the input shaft bearing
• Checking and adjusting, axial clearance of the output shaft bearing
• Checking and adjusting the shift shaft housing on the gearbox
• Removal - Refitting, transmission
• Removing and installing complete transmission
• Removal and Installation, Drive Flange
• Uninstallation and Installation, Exit
• Removing and installing, gearbox front cover o-ring
• Removing and installing, selector
• Draining and filling, reducer
• Gearbox ZF8 / 9 / 16s-109 with integrated retarder

Gearboxes ZF 8 / 16s-151/181 and 16s-221

• General information
• System Description
• Component Description
• Synchronizer
• Check and adjust
• Checking the transmission oil level
• Checking and adjusting, axial play of the input shaft bearing
• Inspection and adjustment, axial play of the gearbox output shaft bearing
• Checking and adjusting the shift shaft housing on the gearbox
• Gearbox removal and installation
• Removal and installation, complete gearbox with or without integrated retarder
• Removal and Installation, propshaft flange
• Uninstallation and Installation, Exit
• Removal - Refitting, Gearbox, Front Seal
• Removing and installing, selector
• Draining and filling, reducer

EATON FS / 6309a gearbox

• General information
• System Description
• Check and adjust
• Inspection, transmission oil level
• Inspection and adjustment, axial clearance of the input shaft bearing
• Removal - Refitting, transmission
• Removal and Installation, Drive Flange
• Uninstallation and Installation, Exit
• Removing and installing, gearbox front cover o-ring
• Removing and installing, selector
• Draining and filling, reducer

Automatic transmissions

• General information
• System Description
• Component Description
• Automatic transmission selector
• Check and adjust
• Inspection, oil level
• Removing and installing, installing gearbox
• Removing and installing oil filters
• Draining and filling, reducer

Clutch

• Safety Instructions
• General information
• System description, clutch
• Description of the clutch protection system
• Master cylinder
• Clutch CF 75/85
• Clutch CF 65
• AS Tronic clutch unit
• Automatic adjustment of clutch switch assembly
• Attaching the clutch lever to the gearbox
• Attaching the clutch lever to the clutch housing
• Component Description
• Master cylinder
• CF 75/85 clutch servo
• CF 65 clutch servo
• AS Tronic clutch
• Automatic clutch release
• CF 75/85 clutch wear indicator
• CF 65 clutch wear indicator
• Thrust bearing
• Check and adjust
• Inspection and adjustment, clutch pedal
• Inspection, clutch reservoir
• Inspect, clutch fluid level
• Removal and installation, clutch reservoir
• Removing and installing, AS Tronic clutch unit
• Removal and Installation, Traction Clutch Thrust Bearing.
• Removal - Refitting, thrust clutch thrust bearing
• Removal and installation, drawbar
• Removal - Refitting, clutch pressure lever
• Removal and Installation, Clutch Switch Assembly / Clutch Disc
• Removal and installation, automatic adjustment of clutch switch assembly / clutch disc
• Removing and installing, pilot bearing
• Removal and installation, master cylinder
• Draining and filling, clutch system
• Bleeding the clutch system

Support shafts

• General information
• Cardan shaft
• Center support
• Check and adjust
• Inspection, propeller shaft
• Removal - Refitting, propeller shaft / auxiliary shaft assembly
• Disassembly and assembly, universal joint
• Disassembly and assembly, center bearing
• Lubrication of the universal joint and auxiliary shafts

ZF Intarder

• Safety Instructions
• General information
• Intarder
• Hydraulic control unit
• Location of main components
• Checking and adjusting, axial play of the output shaft bearing
• Inspection and adjustment, static axial movement
• Inspection, transmission / oil level andntarder
• Removal and installation, installation inside
• Removal - Refitting, solenoid valve
• Removal and installation, battery
• Removal and Installation, Heat Exchanger
• Removal and installation, hydraulic valve
• Removal and installation, oil pump
• Removal and installation, oil filter
• Removal and installation, proportional valve
• Removal and Installation, Intarder Drive
• Disassembly and assembly, battery
• Draining and filling, reducer / intarder

Power take-off shaft

• Safety Instructions
• General information
• Side view of the drive
• Drive cross section
• Power take-off shaft of DAF engine without driven flange and control unit
• Power take-off shaft of DAF engine with driving flange and without control
• Power take-off shaft of DAF engine with drive flange and control
• Power take-off shaft for DAF engine with third gear for opposite direction of rotation of drive flange
• Modifications
• NL / 1ANDNH / 1PTO Version B
• NL / 1ANDNH / 1PTO C version
• NL / 4ANDNH / 4PTO Version B
• NL / 4ANDNH / 4PTO C version
• PTO N221 / 10 on gearbox without intarder
• PTO N221 / 10 on gearbox with intarder
• PTO NAS / 10
• Intermediate PTO for gearboxes without gear
• Intermediate PTO for gearboxes
• PTO Z81, version B
• PTO Z81, version C
• PTO 2266, version B
• PTO 2266, version C
• Pneumatic diagram, PTO control
• Checking and adjusting, axial play of the propeller shaft of the DAF engine
• Checking and adjusting, axial play of DAF engine PTO drive sprockets
• Inspection and adjustment, axial play of the gearbox output shaft without gearbox with PTO N221 / 10
• Checking and adjustment, PTO axial play Nl on PTO N221 / 10
• Removal and installation, all DAF engine PTO on flywheel
• Removing and installing, flywheel housing of PTO shaft for DAF engine
• Removal and installation, PTO NH / 1 and NL / 1, version B
• Removal and installation, PTO NH / 1 and NL / 1, version C
• Removal and installation, PTO NH / 4 and NL / 4, version B
• Removal and installation, PTO NH / 4 and NL / 4, version C
• Removal and installation, PTO N221 / 10 for gearboxes without intarder
• Removal and installation, PTO N221 / 10 on gearbox with intarder
• Removal and installation, PTO NL / 1 on PTO N221 / 10
• Removal and Installation, PTO NAS / 10
• Removing and installing an intermediate power take-off shaft on a gearbox without an intider
• Removal and installation, intermediate shaft of power take-off on gearbox with gearbox.
• Removal and installation, PTO Z81, version B
• Removal and installation, PTO Z81, version C
• Removing and installing PTO 2266, version B
• Removal and installation, PTO 2266, version C
• Disassembly and assembly, DAF engine PTO shaft
• Disassembly and disassembly, DAF engine PTO housing
• Manual versions without drive flange and shift control

AS Tronic gearbox

• General information
• System Description
• Component Description
• Reducer / modulator
• Operating unit
• Transmission / Brake
• Check and adjust
• Inspection and Adjustment, Transmission Oil Level
• Inspection and adjustment, axial play of the gearbox output shaft bearing
• Removal and installation, assembly of gearbox with or without integrated retarder
• Removing and installing, gearbox modulator
• Removal and installation, work unit
• Removal and Installation, Drive Flange
• Removal and Installation, Output Shaft Oil Seal
• Removing and installing, gearbox front cover oil seal
• Draining and filling, reducer