KAMAZ 5490 Operation Manual Download Page 280

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1341 758 001 - 2012-05

4.9 Type plate

The type plate contains the key data. It is fitted on the left of

the transmission when viewed in the direction of travel.

The following information must always be stated when making

inquiries, placing orders, or carrying out repairs:

1. Transmission parts list number

2. Transmission type

3. Transmission serial no.

Fig. 16 Type plate (example)

Maintenance

ZF FRIEDRICHSHAFEN AG

MADE IN GERMANY

MODEL

PARTS LIST NO. SERIAL NO.

SPEEDO

RATIO

OIL CAPACIT

IN LITERS

OIL GRADE SEE

LUBRIC. LIST TE-ML

CUSTOMER

SPEC. NO
TOTAL
RATIO
P.T.O. N

n =

ENGINE

ECOSPLIT

1342 001 001

16,41-1,0

IMP/U 6,0

XXXXXXX

011356

16 S 1920 TD

027417

Summary of Contents for 5490

Page 1: ...KAMAZ PUBLICLY TRADED COMPANY Operation manual Z 5490 vehicle 5490 3902203 01 Naberezhnye Chelny 2017...

Page 2: ...s of version to be supplied to re gions and countries with moderate climate are designed to operate at ambient air temperatures from minus 40 C to plus 40 C the air relative humidity up to 75 at plus...

Page 3: ...ntation supplied with vehicle 2 4 Vehicle marking 2 6 Engine marking 2 8 Scheme of sealing 2 9 3 BRIEF DESCRIPTION OF VEHICLE SYSTEMS AND MECHANISMS 3 1 Engine 3 1 Transmission 3 1 Frame and fifth whe...

Page 4: ...djustment of headlamp inclination angle 4 14 Light shifter 4 15 Light for movement in the daytime 4 15 End outline and side marker lamps 4 15 Low beam 4 15 High beam 4 15 Auxiliary illumination headla...

Page 5: ...view mirrors 4 23 Mirror heating 4 23 Seat position adjustment 4 24 Safety belts 4 27 The upper bunk 4 28 The lower bunk 4 29 Steering wheel adjustment 4 30 Air conditioning system control 4 31 Venti...

Page 6: ...n modes 4 42 Driving the vehicle 4 43 Safety requirements 4 43 Safety requirements during operation of vehicle with electronic systems 4 45 New vehicle operation running in 4 46 Main rules of operatio...

Page 7: ...switch 4 65 Electronic brake system EBS 4 66 Control of service and auxiliary brake systems with the aid of brake pedal Brake Management 4 66 Antilock brake system 4 66 Antiskid system ASR 4 67 Vehicl...

Page 8: ...s 6 8 Vehicle care 6 14 To care the windscreen 6 15 Air filter replacement 6 16 Checking receivers for condensation 6 17 Tire maintenance 6 17 When inflating the tires 6 18 Checking the oil level in e...

Page 9: ...dangerous goods 7 26 Steering system faults 7 27 Steering play 7 27 Power steering unit does not provide required force 7 27 Parking brake release in hazard situations 7 28 Fuses and relays 7 29 Arra...

Page 10: ...dix 3 Service materials 3 1 Appendix copy Diesel Engine Pre heaters 14 10 Appendix copy Liquid small size pre starting heater PROMOTRONIK 16 24 Appendix copy Service instruction AIRTRONIC D2 Independe...

Page 11: ...ure trouble free operation use only genu ine spare parts Installation of different equipment and devices on a vehicle and its chassis is to be agreed with design documentation developer and owner Scie...

Page 12: ...s Benz OM 457LA V 3 Mercedes Benz OM 457LA V 3 Mercedes Benz OM 457 LA EEV 3 Mercedes Benz OM 457 LA EEV 4 Maximum climbability train not less 18 10 Disk wheels 9 00 22 5 Tires tubeless 315 60 R22 5 3...

Page 13: ...ed 40 km h m not more vehicle 33 8 Outer vehicle turning radius between walls front buffer m not more 8 Fuel tanks capacity5 l 400 2 665 ____________________________ 1 Parameters are given for vehicle...

Page 14: ...5 0 2 ENGINE TECHNICAL DATA Engine model Mercedes Benz OM 457LA V 4 Mercedes Benz OM 457 LA EEV 4 Mercedes Benz OM 457LA V 3 Mercedes Benz OM 457 LA EEV 3 Mercedes Benz OM 457LA V 2 Engine type Four s...

Page 15: ...key starter and instruments switch key 2 sets In a toolbox1 or in a pallet for accessories2 kit for tire inflation tow yoke minimum set of tools Hydraulic jack for certain configurations 1 set 2 pcs...

Page 16: ...a cost an oil transfer pump 1 pc Truck chassis is to be equipped with tools ac cessories and appropriate operation documentation for purchased products A list of additional equipment may be defined du...

Page 17: ...weight ex ceeds the corresponding permissible maximum weight then the weight values are indicated in two columns Technically permissible maximum weights m vehicle technically permissible maximum weigh...

Page 18: ...gross weight m1 train gross weight for tractors 1 permissible front axle load 2 permissible second axle load 3 permissible third axle load 4 permissible fourth axle load manufacturer s trade mark In...

Page 19: ...ntal boom of the right side member at front part of the frame and includes XTC manufacturer s code 3 marks digit 0 frame model designation 6 marks production year code 1 mark ordinal production number...

Page 20: ...of ZF gear box power steering of RBL ZF companies are not sealed If tachograph is installed in vehicle manufacturer s plant the tachograph is sealed temporarily Tachograph Supplier s seal Z seal view...

Page 21: ...on manual see in Appendix Op eration manual for ZF INTARDER Inbuilt retarder in tarder for trucks and buses with gear box ZF Axles Axle DAIMLER HL6 is used on the vehicle Provision is made on the vehi...

Page 22: ...g functions control of serice and secondary brake systems Brake Management anti lock braking system ABS anti skid system ASS electronic stability programme ESP Brake mechanisms disk type HALDEX KNORR...

Page 23: ...ve terminal the field winding lead the phase terminal and the pilot lamp contact between themselves and to ground using the jumpers 3 Do not test the operability of electric equipment circuit and of s...

Page 24: ...receiver fixed position The audio system and other auxiliary power consumers work with the key in position ON Movement position fuel supply to all vehi cle systems fixed position START Start of engine...

Page 25: ...ment panel 15 parking brake 16 central part of instrument panel 18 combination switch 19 starting preheater control console panel 20 clutch panel 21 control selector switch of automated gearbox and au...

Page 26: ...modes dangerous for engine if admissible engine crankshaft speed is exceeded 3 pilot lamps 4 information display 5 electronic speedometer 6 speedometer indicator lights up red color if vehicle set max...

Page 27: ...ature pilot lamp is located in the indicator zone it lights up color red at over temperature of cooling liquid 10 tank fuel level indicator Fuel reserve pilot lamp is located in the zone of in dicator...

Page 28: ...ent Engagement of interwheel differential lock color orange Engine failure color orange Malfunction in exhaust gas aftertreatment system and or engine color orange Right turn indicator color green int...

Page 29: ...nt color orange Malfunction of steering control color red Attention Number of pilot lamps can change depending on vehicle configuration Information display At each activation of ignition switch key in...

Page 30: ...vehicle with a parking brake engaged Turn over the information screens by buttons or To leave the screen press the button Screen control on the display 1 information display 2 buttons of screen contr...

Page 31: ...ed R reverse motion is engaged 4 current time 5 current value of ambient air temperature 6 total distance covered by the vehicle 7 daily vehicle mileage resettable 8 the number of the gear engaged war...

Page 32: ...urrent data on motor hours for the trip covering period Average speed current data on average speed for the trip covering period Average consumption current data on average fuel consumption for the tr...

Page 33: ...ress the button The symbol will flash on and off in front of the scale Adjust display light brightness by buttons and Press the button adjusted screen light brightness will be saved in memory Brightne...

Page 34: ...t disengagement of strorage batteries Button is locked when ignition key is in ON position ASR mode selection Engagement disengagement of air condi tioner Engagement disengagement of warning indicatio...

Page 35: ...of hydraulic motor for certain vehicle configurations Engagement disengagement of PTO box Engagement disengagement of flashing lights for certain vehicle configurations Emergency storage battery switc...

Page 36: ...gagement of reading lamp on passenger s side Pos Application of shifters 1 Opening closing of the top hatch 2 Engagement disengagement of driver s reading lamp 3 Engagement disengagement of night time...

Page 37: ...juster position 0 Vehicle is not loaded 1 3 From partial vehicle load to loaded vehicle Headlamp inclination angle is to be adjusted in such a way when headlamp beam doesn t blind the drivers of oncom...

Page 38: ...late light and switch illumination are energized LOW BEAM Turn the light switch to position HIGH BEAM 1 Turn on the low beam turn the light switch to position 2 Shift combination switch forward till f...

Page 39: ...ght switch At trailer semitrailer connection the rear fog lamps of truck tractor are not active TRAIN LAMPS Train lamps are switched on automatically when trailer semitrailer electric equipment is con...

Page 40: ...rtly pull the combination switch up to position 3 For a short period of time the pilot lamp on instru ment panel and high beam light up HORN Giving of audible warning is carried out through 6 button p...

Page 41: ...until the first movement of wipers and turn the switch 1 to position or 3 Maintain the interval required but not more than 20 sec 4 Turn the switch 1 to position or Time passed between disengagement a...

Page 42: ...windscreen wiper blades can suddenly start mooving when starting WINDSCREEN WASHER To switch on the windscreen washer press the shifter 1 located on combination switch up to stop see Fig Windscreen wa...

Page 43: ...er Vehicle doors can be lock released and locked by means of door locking shifters located in switch block on driver s and passenger s door see Fig Door locking shifter To release the door lock press...

Page 44: ...w during its opening During the window movement there is a hazard of drawing in and jamming between side window and door frame In case of danger release the shifter or press on its upper part to close...

Page 45: ...rewdriver in the drive port 4 Rotate the screwdriver counter clockwise till full closing of the hatch 5 Install the plug in the port SAFETY SCREEN OF THE HATCH The hatch is equipped with a safety scre...

Page 46: ...il the time when the mirror occu pies necessary position One must bear in mind the reflection in external mirrors is always undersized that is why the objects seem more away than it is in reality MIRR...

Page 47: ...osition the longitudinal damper is locked in the lower position it is unlocked Seat heating Seat heating is engaged at pressing on the upper or lower part of the button 7 Heating is en gaged at air te...

Page 48: ...button 12 the seat raises and is automatically fixed in position set by the lever 11 The lever 13 is used to adjust the seat suspension stiffness Adjustment of the seat lateral position With the leve...

Page 49: ...With the button 7 shifted up the front edge of cushion raises with it shifted down the edge lowers down With the button lowering down the seat cushion is fixed in selected position Adjustment of the...

Page 50: ...of breast if belt is unfastened for complete reeling and also to avoid seizure it is suggested to hold the belt strap on Safety belt performs protection function if seat back is arranged almost verti...

Page 51: ...tton of retaining belt lock see Fig Re taining belt of the upper bunk 3 Unhook the belts 4 Lower the bunk down For installation of guard mesh hang the hooks of guard mesh in the eye ring see Fig Insta...

Page 52: ...g belt 3 from the rear wall 3 Raise up the bunk 4 Stretch the retaining belt 3 and fix it on the hook 4 on the lower side of the bunk Installation of guard mesh Before starting the trip fix the hook 1...

Page 53: ...is unlocked 4 Adjust position of steering wheel by height and inclination 5 Press on the upper part of steering wheel posi tion adjustment switch Steering column is locked If the steering column locki...

Page 54: ...i tioning system you can regulate air distribution air tem perature air flow Attention In case of air conditioning system elements mal function it is not recommended to switch the conditioner on Proce...

Page 55: ...the temperature regulator to the right to decrease to the left It is recommended to engage the temperature regulator not less fre quently than once twice a month to maintain its operation reliability...

Page 56: ...on mode 3 Close the side windows and ventilation hatch Attention It is suggested to use the recircu lation mode during short period of time as the glass misting over can occur It is necessary to shift...

Page 57: ...indscreen defrosting 1 Set the shifter and regulators as it is shown in the Fig Windscreen defrosting 2 Close ventilation deflectors 3 Switch on if necessary the autonomous cab heater Windscreen defro...

Page 58: ...witch LED color red built into switch comes ON 2 Set the temperature regulator on a required tem perature Conditioner switching off Press on the lower part of conditioner switch LED built into switch...

Page 59: ...independent heater is engaged and disengaged by remote switch Attention Before going to the dangerous zone fuel filling station petroleum processing plant and so on the heat er should be disengaged I...

Page 60: ...the shifters in neutral position the lighting is disengaged Engagement and disengagement of reading lamp on passenger s side 1 engagement of reading lamp on passenger s side 2 disengagement of read in...

Page 61: ...switching on the electric equipment with the voltage 12 V it is necessary to switch on the voltage converter to shift the electrical socket to 12 V To engage the voltage converter depress the voltage...

Page 62: ...be switched on by short pressing of operation button From the moment of pressing the button the smoke alarm deactivates roughly for 20 min When the signal is switched off roughly every 40 sec a short...

Page 63: ...t is not recommended to carry over heavy things in the compartments Attention In order to prevent injury of people by things falling at hard vehicle braking all glove boxes and ad ditional compartment...

Page 64: ...sts of the following components ERA GLONASS BLOCK two blocks of user interface located on instru ment panel see Fig User s interface block loudspeaker block is located in an overhead con sole or over...

Page 65: ...e system does not respond to emergency call SOS button pressing and there is no illumination of emergency call SOS button Emergency call SOS Emergency call can be made under condition that ignition ke...

Page 66: ...while it works 8 It is strictly forbidden to perform any works in the zone of cooling system fan while engine works 9 Do not open the expansion tank cap of an over heated engine let the engine cool do...

Page 67: ...ner heating may cause it failure or explosion It is forbidden to connect ground conductors to any sensors items of wiring or to engine electronic con trol module arranged on engine It is strictly forb...

Page 68: ...hours With this be sure to disconnect the storage bat teries 8 Be sure to change the fuses pilot lamps and dis connect connect the cables and other commutation devic es only with power storage battery...

Page 69: ...y to warm up oil in steer ing system see Section 5 Vehicle operation in cold season It is prohibited to rotate the steering wheel before the oil in the steering system is warmed up 6 For mechanical ge...

Page 70: ...with automated control the neutral position should be fitted forcefully if necessary Make sure that N illuminates on the display shut down the engine put the chocks under rear wheels of vehicle and se...

Page 71: ...and descending it is suggested to move in automatic mode Gearbox itself selects the re quired gear appropriate for certain driving speed To slow down the truck train when descending use the auxiliary...

Page 72: ...sure to prime the tank and bleed fuel system before the engine is started see section 7 Possible malfunctions of vehicle units and systems Self help Fuel the vehicle in accordance with recommenda tion...

Page 73: ...k to tank is enough in the process of vehicle motion Sequence of filling in the tanks is free but the left tank is considered to be the main as a fuel suction pipe is installed in it If at fuel tank o...

Page 74: ...message signals on the display of the instrument cluster see Section 5 Vehicle operation in the cold period of time At ambient air temperature minus 20 prelim inarily warm up the engine with the aid o...

Page 75: ...wer source see section 7 Potential failures of vehicle units and sys tems Self help Engine shutdown 1 Stop the vehicle 2 Install neutral in the gear box 3 Engage the parking brake 4 At coolant high te...

Page 76: ...arget idle speed To increase the crankshaft speed depress the but ton to reach necessary idle speed To decrease the crankshaft speed depress the but ton to reach necessary idle speed Return to preset...

Page 77: ...the system keeps run ning in the mode of speed maintaining while the speed value restores till that prior to pedal depression To increase the speed of cruise control press the button To decrease the s...

Page 78: ...oper road and in hard conditions it is suggested to engage all gears successively pursuant to gearshift scheme Operation manual for gearbox see in Appendix Operation manual Auto trucks ZF NewEcosplit...

Page 79: ...late is rotating The gears shift automatically in the splitter high gear engagement with lever shifting from the forth gear position to the fifth gear position low gear engage ment when shifting from...

Page 80: ...rried out depend ing on the engine crankshaft speed fuel feed pedal posi tion vehicle load service brake operational state road conditions Manual gear shifting and gear shift point are de fined by the...

Page 81: ...eering col umn against stop Warning messages Display Description Self checking of the system after ignition key rotation to N position Insufficient pressure in circuit IV of pneu matic system Gear shi...

Page 82: ...gear for start ing from standstill 2 Shift the rotary switch from N position to D position see Fig Gear shifter 3 Depress the fuel feed pedal and release the park ing brake With fuel feed pedal depres...

Page 83: ...de is displayed corresponding to the rotary switch position so the shifting is executed Motion modes Direct maneuvering DM and reverse maneuvering RM modes are meant for very slow motion It is recomme...

Page 84: ...lly engages the gear convenient for starting from standstill The vehicle can start moving Stopping the vehicle always set the service or parking brake Engagement of reverse gear Reverse gear is engage...

Page 85: ...ne only after vehicle stop With differential locked it is necessary to move linearly with speed not exceeding 10 km h without stops preventing the wheel skidding The lock should be disengaged immediat...

Page 86: ...rol valve has two fixed positions in the upper position 1 the parking brake is dis engaged position Movement in the lower position 2 the parking brake is en gaged position Stop With the parking brake...

Page 87: ...upon the engine crankshaft speed With increase of revolutions the braking power and efficiency increase Maximum engine crankshaft speed for engine brake operation for a short period of time 2500 min...

Page 88: ...essed position of the switch the auxil iary brake system is controlled by function Brake Management Attention If pilot lamps and light up on the in strument panel along with indication of the brake sy...

Page 89: ...s of vehicle units and systems Self help After failure elimination the pilot lamp of truck tractor EBS ABS dies out at motion start when the vehi cle achieves the speed 5 7 km h Similarly the lamp of...

Page 90: ...ram ESP is a combina tion of two systems stabilizing the vehicle movement systems controlling vehicle stability defining the steering wheel turning degree compensate control loss by means of selective...

Page 91: ...ument panel 3 Engage the gear in the gearbox 4 Release the vehicle parking brake and start the motion When starting from standstill the vehicle is auto matically taken off from the hill start assist c...

Page 92: ...fault lightens on the instrument panel Air suspension electronic control system does not require special maintenance except control inspection of operability in the service center Air suspension contr...

Page 93: ...ont part of vehicle is jacked for repair for example when removing and installing tires The chocks are also intended to prevent vehicle run away in case of emergency stop See section Main opera tion r...

Page 94: ...en to open and to close the facing panel pulling it only by one edge For fixation of the upper facing panel in the upper position pull the thrust from the holder and install it into the bracket slot T...

Page 95: ...of the vehi cle under the cover of the cab instep hatch see Fig Ac cess to the inflation valve It is forbidden to open the hatch of the foot step shield for more than 90 to make the tire inflation va...

Page 96: ...iler pursuant to re quirements of Operation manual of the fifth wheel manu facturer 5 During operation of hydroficated tractor with hydroficated semi trailer remove plugs from locking means of oil duc...

Page 97: ...ing device is practically un loaded 5 During operation of hydroficated tractor with hydroficated semi trailer unscrew the nut and disconnect hydraulic locking devices of tractor and trailer disconnect...

Page 98: ...on the upper part of hydraulic motor switch located on the instrument panel LED built into switch comes ON The message appears on the display see Fig The hydraulic distribution valve is engaged 7 Afte...

Page 99: ...two steps connect the hose to check outlet valve in parking brake receiver inflate tires till maximum possible pres sure recorded by pressure regulator connect hose to tire inflation cock top up tire...

Page 100: ...mperature of ambient air is indicated in Table Engine operating time neces sary for oil heating in the steering system versus ambient air temperature Engine operating time necessary for oil heating in...

Page 101: ...eating at engine start If the ambient air temperature is below 30 an unstable operation of display is possible and the temperature of 40 can cause an erratic instrument cluster operation Extreme tempe...

Page 102: ...ts and starter switch key to the ON position position of motion In ambient temperatures below minus 5 the pre heating of EFU plugs switches on automatically whereby the following information is displa...

Page 103: ...ipped with an independ ent fuel tank for preheater 14 Observe the fuel level in a tank as independent tank is not included into engine fuel system see Section 6 Maintenance FUEL HEATING The fuel is he...

Page 104: ...parture or in stations after prolonged work Weekly maintenance is performed once a week by a driver It is tolerable to perform weekly mainte nance in a service center by demand of vehicel owner Attent...

Page 105: ...and eliminate troubles see section 7 Possible faults in vehi cle systems and units Self help 3 Check condition and leak proof of items and pipes of fuel supply system of lubricating system of cooling...

Page 106: ...must be no perceptible clearance between semi trailer kingpin and bolster lock Damage of hoses is not admissible inspect visually Connection cables must be secured reliably 6 Check the state and secu...

Page 107: ...s and cracks Avoid brake pipes deformation By ear test the air drive for leakage Air leakage is not permissible The air drive should be tested for leakage at a nominal pressure with activated compress...

Page 108: ...ormal opera tion Replace faulty lamps Check the operability of front headlamps and lights direction indicators left right marker and end outline lamps low beam high beam train lamps additional illumin...

Page 109: ...rator is not permitted 17 Check the tightness of rear sus pension Check visually the state of rear suspension Not permissible cuts on rubber cord casings of air springs loosening of bolted connections...

Page 110: ...see Fig Hy draulic oil tank If necessary add oil through the filling neck Greases are used in accord with suggestions of Appendices 2 3 21 Check the state and cottering of pins of auxiliary brake air...

Page 111: ...re no cotters put them on their place 2 Inspect condition and operation of hydraulic locks and hydrau lic cylinder for raising and lowering the cab The locking mechanism must retain the cab securely f...

Page 112: ...Check the fastening of brake chambers Check the fastening ofbrake chambers The tightening torque for fastening brake chambers 180 220 N m 18 to 22 kgf m 6 Inspect visually the state and fastening of t...

Page 113: ...s are tolerable Crossing of trans verse and longitudinal cracks is not permissible Be sure to change belt if any pit ting 9 Inspect the integrity of electric contacts in the air conditioning system Ch...

Page 114: ...leaning bleeding the compressed air from on board or autonomous network 12 Clean the gearbox and drive axle breathers The breathers must be clean Remove breathers prior to blowing to prevent the ingre...

Page 115: ...the bolster kingpin Grease the bolster through grease cups Apply an even layer of grease to the bol ster support plate and mouth by brushing see Fig To grease bolster Greases are used in accord with s...

Page 116: ...Top up to norm the fluid level in tank of clutch master cylin der Inspect visually the liquid level in a tank of clutch master cylinder see Fig Tank of the clutch master cylinder The clutch master cy...

Page 117: ...nd tool box with compressed air For washing use neutral detergents water jet ap plication pressure is to be not more 118 kP 1 2 kgf cm2 To preserve paint coating avoid prolonged effect of salts acids...

Page 118: ...air temperature below zero the work of windshield wiper with brushes frozen to the window is prohibited If the information about the low liquid level in a washer tank is displayed prime the tank with...

Page 119: ...ert the new main filter element as far as it can go 4 Place cover on air filter body The nipple valve in this case should be mounted vertically downwards 5 Fasten the latches on air filter cover To ch...

Page 120: ...the service center Maintenance of a dryer supposes a regular change of a filter element as soon as it becomes dirty approxi mately once a year If any oil emissions by compressor causing the filter el...

Page 121: ...on the air delivery valve is on pres sure regulator valve is closed by cap 1 see Fig Air dry er with pressure regulator To deliver air using a tire inflation hose from tools set connect it instead of...

Page 122: ...ith the help of dipstick with the cab raised The oil level should be between the lower and upper dipstick marks 4 If necessary add oil through a filling neck see Fig Checking the oil level in the Merc...

Page 123: ...add coolant of the same grade through a filling neck after removing expansion tank cover see Fig Expansion tank cover Use the coolant in accord with suggestions of Appendix 3 5 Tighten the cover till...

Page 124: ...sition by turning it clockwise 6 Tighten the vent plug with the torque of 1 0 to 2 0 N m 7 Close the expansion tank cover 8 Start the engine The air will be released from the fuel feed system automati...

Page 125: ...filter 3 Tighten the water drain screw witch a torque of 1 5 to 2 0 N m 4 Remove the filter cap and take out the filter el ement 5 Replace the filter cap sealing ring 6 Grease sealing rings of the fil...

Page 126: ...tion the fuel tank air filter should be replaced To replace fuel tank air filter 1 Stop the vehicle shut off the engine engage the parking brake the gearshift lever should be in neutral position place...

Page 127: ...in the tank is equipped with mag net valve which allow the fuel nozzle to switch off au tomatically after the maximum Adblue level has been reached Attention Do not over pour AdBlue above the max leve...

Page 128: ...o rinse the surface immediately It is prohibited to re use liquid drained during repair Be sure to use only plastic or stainless steel cans for AdBlue storage If agent is stored in cans produced from...

Page 129: ...from inde pendent fuel tank After fuel is drained and the hose is placed back the heater should work until all fuel burns Fuel is drained as follows 1 Close the fuel cock 4 2 Slacken the clip of hose...

Page 130: ...The body surface should be clean without leak age traces dirt or dust otherwise excessive self discharge may take place For maitenance wipe the up per battery cover to clean it from dirt and dust Pre...

Page 131: ...rage remove the batteries from the truck if the truck is going to be out of use for more than 1 month charge them and keep if possible in a dry cool room at temperature not higher than 0 The minimum s...

Page 132: ...5 7 km h If any critical faults STOP pilot lamp comes ON in addition to message At that moment the buzzer sounds If the hazard signal system or direction indicators are ON the sound signals are not em...

Page 133: ...instru ment panel With this all direction indicators lighten and the signal lamp LED built into the button flashes To disengage hazard signal system depress the corresponding button again With this a...

Page 134: ...ic system and eliminate trouble After the fault has been corrected the pilot lamp dies out The displays are controlled by using the buttons located on the left steering wheel side see Fig Display scre...

Page 135: ...appears Depress the Menu key button The menu bar of diagnostics system selection becomes highlighted 4 With buttons or pressed select the ve hicle system if available for diagnostics engine brake sys...

Page 136: ...errors the further errors can be viewed only after elimination of those that are already displayed 8 After viewing the errors you can return to the main screen by keeping the button pressed for a long...

Page 137: ...er road users Never use the mode for diagnostics of operation al parameters on public roads because reading and evaluating information from the screens will cause the driver to pay less attention to t...

Page 138: ...n coolant oil Screen 5 Controls the actuating force applied to accelerator pedal per cent the actuating force applied to brake pedal per cent clutch pedal effort pressed not pressed parking brake actu...

Page 139: ...a tion stop the engine engage the parking brake check the level of oil in crankcase see section 6 Maintenance If oil level in crankcase is OK but pilot lamp of hazard oil pressure fails to die out be...

Page 140: ...N If any air in fuel injection system be sure to prime fuel tank and eliminate air prior to engine start color red Alternator charging current is absent Vehicle motion is permitted with special care C...

Page 141: ...ault correction Immidiately stop the vehicle paying attention to the road situation engage the parking brake let the engine running at an increased crankshaft speed let the gearbox cool down If the oi...

Page 142: ...ot be determined Vehicle driving is prohibited till fault correction Address the service center on the display Clutch is overloaded Select the lowest gear or stop the vehicle on the display limit clut...

Page 143: ...rouble color orange Buzzer sounds Engine hazard state Vehicle driving is prohibited till fault correction Address the service center color orange Trouble after treat ment system and or in engine Vehic...

Page 144: ...taking into account the traffic situa tion stop the engine engage the parking brake check the coolant level in expansion tank see section 6 Maintenance If coolant level is OK but pilot lamp and indic...

Page 145: ...akage of pipelines and elastic hoses connec tions Check the brake system devices for operability eliminate trouble after faults correction with vehicle being stationary let engine working to restore t...

Page 146: ...stem of the vehicle Vehicle motion is permitted with special care Stop the vehicle engage the parking brake perform the system diagnostics Be sure to address the service center to eliminate troubles A...

Page 147: ...r accumulation not more than 50 and further system operation blockage To erase passive er rors address the service center color orange Failure of EBS semi trailer Vehicle motion is permitted paying at...

Page 148: ...shing light code or if the fault is not resolved by yourself contact the service center color red Intermittent horn Safety belt is not fastened Fasten the safety belt color red Buzzer sounds Malfuncti...

Page 149: ...ank with ready made washing liq uid The water detection sensor has tripped in the coarse fuel filter Drain sediment from coarse fuel filter see section 6 Maintenance Pressure in the tire s is below or...

Page 150: ...front right side marker lights Trouble of the front left direction indicator Trouble of the front right direction indicators Trouble of the front left bulb of the additional lighting for poor visibil...

Page 151: ...ft high beam headlamp Trouble of the right high beam headlamp Trouble of the left low beam headlamp Trouble of the right low beam headlamp Trouble of the left daytime running lamp Trouble of the right...

Page 152: ...rear right marker lights Trouble of the rear left direction indicator Trouble of the rear right direction indicator Trouble of tail fog lamps located on both sides of the vehicle Trouble of brake lig...

Page 153: ...ts of the trailer semi trailer Trouble of all right marker lights of the trailer semi trailer Trouble of the left direction indicator of the trailer semi trailer Trouble of the right direction indicat...

Page 154: ...7 23 Trouble of stop lights brake lights located on both sides of the trailer semi trailer Trouble of reverse lights located on both sides of the trailer semi trailer...

Page 155: ...l lowing characteristics rated voltage from 24 to 30 V the recommended starting current is more than 1000 A If power source has weaker starting current then prior to starting wait for some 10 15 minut...

Page 156: ...positive clips of positive and negative connection cables 6 On the vehicle with discharged batteries turn the ignition switch key to the position O everything is off 7 In vehicle with charged storage...

Page 157: ...GEROUS GOODS The vehicle for carrying dangerous goods is equipped with an emergency stop switch installed on its instrument panel see Fig Emergency stop switch which intention is to switch the battery...

Page 158: ...g mechanism for play and to repair it contact the service center POWER STEERING UNIT DOES NOT PROVIDE REQUIRED FORCE If power steering unit does not ensure sufficient effort or operates irregularly wi...

Page 159: ...eumatic drive then after the mechanical release of parking brake the truck will have no brakes at all Prior to parking spring brake release place the chocks under wheels 2 Besides with no compressed a...

Page 160: ...nstalled on the instrument panel on the passenger side see Fig Access to the fuse box To provide access to the fuse box remove fasteners and take off the fuse box cover see Fig Fuse and relay box Acce...

Page 161: ...y K2 Wiper stop relay wipers K3 Towing hitch light relay K4 Horn relay K5 Fuel heating relay K6 Cab tilting lock relay K7 Relay for locking storage battery switch off K8 Conditioner relay K9 Emergency...

Page 162: ...ystem ON FU1 7 10A Control unit for MR2 engine ON FU1 8 10 Control unit for gearbox ON FU1 9 10A Retarder control unit ON FU1 10 5A OBD diagnostics connector ON FU1 11 5A Tachograph instrument cluster...

Page 163: ...15A EBS control unit ON 0 FU3 2 15A Trailer EBS ON 0 FU3 3 15A Air suspension control module ON 0 FU3 4 15A Flash beacons ON 0 FU3 5 10 Control unit for gearbox ON 0 FU3 6 10A Retarder control unit ON...

Page 164: ...10A 24V Socket ON 0 FU4 9 10A Buzzer sound ON 0 FU4 10 5A Remote switch off relay of storage batteries ON 0 FU4 11 ON 0 FU4 12 5 Steering wheel mounted paddle shifters ON 0 FU5 1 15A Fuel heating in t...

Page 165: ...r electric equipment MUX4 P Is not dependent 0 FU6 2 15A Control module for electric equipment MUX4 P Is not dependent 0 FU6 3 15A Control module for electric equipment MUX4 P Is not dependent 0 FU6 4...

Page 166: ...cause of trip then switch on the automatic fuse again Check the circuit leading from the fuse to the consumer Replace fuses circuit breakers after the short circuit is eliminated Breaks in the circui...

Page 167: ...arrangement of sealing gaskets When replacing blown bulbs their type and pow er must be considered Replacement of lighting products with LEDs should be carried out at the service center REPLACING THE...

Page 168: ...the fastening screw 1 remove the bulb in upward direction see Fig Searchlight bulb of the hitch lighting 2 Take out the plug 4 3 Disconnect the clamping spring 6 take out the halogen lamp holding it b...

Page 169: ...ct the plug with the bulb contact close the cover 5 Install the headlamp cluster secure it with bolts 3 Open the covers 9 and 11 Headlamp cluster 1 high beam light 2 low beam light 3 direction indicat...

Page 170: ...ode 3 5 tail fog lamp Light diode 7 9 rear light Light diode 3 9 rear marker and end outline lamps Light diode 0 3 stop signal lamp Light diode 3 5 License plate light bulb Light diode 0 8 Train lamps...

Page 171: ...ion relay comes to operation Poor contact between starter body and truck frame Ensure good contact Address the service center Motor oil used does not correspond to season in cold Change the motor oil...

Page 172: ...into pump tank body Prior to raising the cab 1 Zone of cab tilting must be free 2 Apply the vehicle parking brake 3 Shift the gearshift lever to neutral 4 Rotate the ignition switch key to position 0...

Page 173: ...position Arrow downwards bo rotating it counterclock wise until it stops To lower the cab swing the pump handle 3 using tire iron when installing electric pump press the electric pump control button...

Page 174: ...tention During cab accelerated lowering there s danger of injure do not keep the cab by hands You can stay under the cab only after it is entire ly set into a tilted position With engine working and c...

Page 175: ...ace the jack 3 in bracket 6 secure the jack with clamping plates 2 and 4 and drive in the nuts 1 and 2 In storage the screw head should be driven in working plungers lowered and lock needle should be...

Page 176: ...at the end of raising stop raising To lower the vehicle 1 Slowly screw out the locking needle 3 2 Screw out the filling orifice plug 5 to release air and screw it in with cargo lowering over Attentio...

Page 177: ...e With further rotation of the shaft the rope is reeled up and the support is rising along with the wheel 4 Secure the wheel with two nuts with washers in raised position To lower the spare wheel 1 Un...

Page 178: ...e Fig Lifting the front wheel for the rear shaft of the thrust journal see Fig Lifting the rear wheel 7 Lift the wheel using a jack Place trestles 8 Undo ten nuts attaching wheels to hubs Take down th...

Page 179: ...specified WHEEL WITH TUBELESS TIRE DISASSEMBLY AND ASSEMBLY Assemble and disassemble wheels in a special site of enterprise equipped with required tools and applianc es When assembling and disassembl...

Page 180: ...ire bead withdraw the bead outside the rim end face in that very place and further working around the wheel circumference sink the rim end face inside the tire see Fig Sequence of wheel with tubeless...

Page 181: ...ions should be performed with the serviceable tools To mount a tubeless tire on a wheel rim 1 Place the gate onto a wheel rim 2 Place the tire horizontally 3 The wheel is disposed with disk up insert...

Page 182: ...d too high Install the support plate on one level or 50 mm below Bolster fails to open Train is on rough ground or bolster is un der action of stretching forces Release the bolster locking means Bolst...

Page 183: ...The trucks chassis purchased but not introduced into operation may be stored in storehouses without preservation for not more than three months from the date of sale If after storage period expired t...

Page 184: ...ssia dd 16 06 2003 N 19 2 Rules for highway transportation of goods approved by RF Government Regulation dd 15 04 2011 N 272 3 Guideline for goods transportation on domes tic airlines of USSR approved...

Page 185: ...10 1 10 MANUFACTURER S WARRANTY The guarantee terms are agreed upon in a pur chase sale agreement...

Page 186: ...rking with greases and cleaning agents be sure to observe the manufacturer s prescriptions When using cleaning agents oils greases in the process of product operation or washing do not pollute the amb...

Page 187: ...t in accordance with Service book Table 1 Values for maintenance intervals Types of maintenance Vehicle maintenance intervals Daily Maintenance Daily mnt daily Weekly maintenance Weekly mnt weekly Mai...

Page 188: ...T 32511 2013 590 2009 EN 590 2009 Pre starting heater power supply sys tem independent Diesel fuel EURO GOST 52368 2005 590 2004 grade III Diesel fuel EURO complant with the standards of the environme...

Page 189: ...e with the ZF gearbox opera tion manual Rear hypoid axle case Daimler HL6 See Appendix 3 section Transmission oils MB Sheet No 235 8 11 0 l 3 maintenance 1 time in 3 years Change oil Plate support sur...

Page 190: ...e Litol 24 GOST 21150 87 KP2N 20 on DIN 51502 lithium basis 0 070 kg Mnt Lubricate through grease cups Kingpins of the front axle steering knuckles Grease Litol 24 GOST 21150 87 KP2N 20 on DIN 51502 l...

Page 191: ...nections on a frame Power Packer hydraulic cab tilter including cab hydrau lic lock Exxon Mobil UNIVIS HVI 26 1 2 l _ In case of depressurization change the oil Steering control equipped with ZF pump...

Page 192: ...cation sheets No 326 0 325 0 326 3 325 5 Of the Mercedes Benz prescriptions for operat ing materials MB Sheet No 325 0 2 MB Sheet No 325 3 MB Sheet No 326 0 2 MB Sheet No 326 3 50 0 l In accordance wi...

Page 193: ...ge htpp bevo mercedes benz com DIESEL FUEL Apply fuel compliant with EURO EN 590 stand ard where the sulfur content is no more than 10 million 1 MOTOR OILS For complete information about motor oils se...

Page 194: ...age during this pe riod exceeds the limit values for operation according to the list of lubricants TE ML 02 it is neccessary to change the oil Attention Note it is allowed to mix different lubricant c...

Page 195: ...ive Catalytic Reduction system SCR Adblue liquid is an aqueous solution of urea with solidification temperature of minus 11 5 C The tank heating system prevents the liquid freez ing At ambient tempera...

Page 196: ...It is highly recommended to use oil cooler when operating at temperatures above 65 Note the specified temperature ranges refer to the oil temperature and not to the ambient air temperature Note For h...

Page 197: ...60 minus 13 16 65 AW46 46 100 46 6 90 minus 4 25 77 65 Cygnus 32 32 115 32 5 40 minus 10 17 68 65 Cygnus 46 46 109 46 6 90 minus 4 25 77 65 LT5606G 14 372 14 5 13 minus 45 minus 25 48 ESSO Univis Ext...

Page 198: ...s 32 32 108 32 5 52 minus 18 18 69 65 Tellus 46 46 98 46 6 70 6 25 75 65 Tellus Artic 34 300 34 9 89 minus 38 7 87 65 Tellus TX 32 162 32 6 50 minus 18 13 73 65 TOTAL ELF Eguivis ZS 15 15 151 15 3 70...

Page 199: ...Limited Liability Company 443100 Samara Lesnaya str 11 Tel 846 270 65 09 270 68 64 Fax 846 270 65 09 E mail advers ts yandex ru Copy Diesel Engine Pre heaters 14 10 User Manual 14TC 451 00 00 00 000...

Page 200: ...istics 4 3 Safety measures 5 4 Description of pre heater set up and operation 6 5 Pre heater control unit 11 6 Control panel 11 7 Faults 13 8 Pre heater control system faults 13 9 Maintenance 16 10 Re...

Page 201: ...ration under low ambient temperature conditions 2 Additional heating of engine and passenger compartment with the engine running under hard frost conditions 3 Warming up passenger s compartment and wi...

Page 202: ...duty 4 2 3 Fuel diesel fuel meeting requirements of GOST305 Standard depending on ambient air temperature 2 4 Fuel consumption l h full duty 2 medium duty 1 2 low duty 0 54 2 5 Heat carrier ntifreeze...

Page 203: ...aired in service centers authorized by the manufacturer 3 10 The pre heater shall be disconnected from the accumulator battery when being repaired or welding is performed with the truck 3 11 It is pro...

Page 204: ...med functional test of its components such as flame detector heat and overheating sensors pump air pump motor glow plugs fuel pump and corresponding electric circuits In case of nonfailed status there...

Page 205: ...e fuel supply stops and the combustion chamber is purged with air Peculiarities of the pre heater automatic control under emergency conditions and in contingencies 1 If the pre heater has not started...

Page 206: ...8 Figure 1 Pre heater electric circuit...

Page 207: ...9 Figure 2 Pre heater main components...

Page 208: ...10 Figure 3 Pre heater basic components...

Page 209: ...the limits when flameout in the combustion chamber is arise 6 Control panel Control panel further on panel is a part of the pre heater meant for manual control of the device The panel functions are t...

Page 210: ...f the knob is in a position when the heater fan is ON for 4min then it will be ON again only in 6min for 4min Thus it will continue cycling unless the knob is turned or the heater is switched off Afte...

Page 211: ...faults of the pre heater are indicated by panel LED blinking 7 3 Refer to Section 8 for typical faults of the pre heater and trouble shooting procedures 7 4 If malfunctions occur during the operation...

Page 212: ...t sensor and replace with a new one if necessary Check circulation pump for correct operation 2 No more tries to start the pre heater left In case there is no more tries to start the pre heater left c...

Page 213: ...g of the circulation pump for the short circuit check the circulation pump itself and replace if necessary Check the electric wiring of the fuel pump for the short circuit check the pumping capacity a...

Page 214: ...ice object description of activities and maintenance technique Requirement specification Instruments materials tools Type of maintenance daily Seasonal lectrical equipment Check of security of attachm...

Page 215: ...cetone screwdriver Every 500h Combustion chamber Clean up the 1 5 mm hole for air supply to the ignition plug Visual inspection 13 wrench screwdriver Every 500h Fuel system Check the fuel pipe for lea...

Page 216: ...with requirements 5 GOST 15150 69 and from mechanical effects in conformity with category C requirements GOST 23216 78 11 2 As concerns the climatic factors transportation and storage conditions of t...

Page 217: ...characteristics in Chart 1 are given under the ambient air temperature 20 and the nominal voltage Admissible fluctuations are 10 Chart 1 Items of characteristics Heater PRAMOTRONIC 16WD24 Nominal Volt...

Page 218: ...osive and highly inflammable liquids 3 11 It s not allowed to use the heater when the vehicle is parked in enclosed spaces in a garage in a workshop etc to prevent poisoning by the exhaust 3 12 When f...

Page 219: ...Frame position 1 Heat exchanger position 2 Air pump position 3 Control unit position 4 Glow plug position 5 Flame indicator position 6 Heat sensor of incoming liquid overheating sensor position 7 Heat...

Page 220: ...4 Fig 2 The main parts of the liquid heater PRAMOTRONIC 16WD 24...

Page 221: ...odes are also output on the front board of the panel see figure 3 They show the condition of the heater it doesn t glow the heater doesn t work it glows green the heater works it flickers with interva...

Page 222: ...es a quick preparation heating of the motor for starting up that is the heater reaches the FULL mode and in this mode heats the liquid up to the temperature 70 Then it goes to the MEDIUM mode and brin...

Page 223: ...k in this mode until the moment when the incoming heat exceeds the outgoing heat In this condition the rising of the temperature of the cooling liquid starts and when the temperature reaches 70 the he...

Page 224: ...ssible level of the cooling liquid 5 6 The connecting hydraulic hookups hose pipes must be laid with pitches and without excessive bends in which air locks can occur 5 7 The assembly of the exhaust pi...

Page 225: ...a short time to fill the inner volume of the hose pipe with the fuel In assembling the fuel system short radius bends of sleeves and hose pipes are not allowed as a bite fracture of the flow passage o...

Page 226: ...10 Fig 6 The diagram of the assembly of the fuel system of the heater with an individual fuel tank...

Page 227: ...11 Fig 7 The diagram of the assembly of the fuel system of the heater with the fuel intake from the motor vehicle fuel tank...

Page 228: ...h a sharp knife as in figure 8 The restriction of the flow passage of the heater as well as hollows and barbs are not allowed Attention The hose pipe and the fuel pump should be protected from heating...

Page 229: ...13 Fig 9 The diagram of the fuel pump assembly...

Page 230: ...red air tightness of the fuel system and tightening of the clips reliability of electrical connection 6 2 Mount the protective device buttons 2 and 3 on the control panel will glow 6 3 Firmly turn the...

Page 231: ...0 Below minus 20 Diesel fuel 0 4 State Standard Specification 305 82 or mixture of diesel fuel 0 2 minus 45 State Standard Specification 305 82 50 and kerosene 25 or 20 Technical Specifications 38 401...

Page 232: ...ws Check the presence of the fuel in the fuel tank and the work of the fuel pump 9 2 All possible malfunctions that may occur during the heater operation are displayed as malfunction codes on the cont...

Page 233: ...n or failed Resistance between the terminals must be 1ohm 5 The fuel pump failure Not connecting the fuel pump harness from the pump check if it is broken or failed Resistance between the terminals mu...

Page 234: ...1 APPENDIX SERVICE INSTRUCTION AIRTRONIC D2 INDEPENDENT DEVICE FOR HEATING AND MAINTENANCE OF AIR TEMPERATURE IN THE CAB...

Page 235: ...on guidelines 7 6 Maintenance advice 7 6 1 Reliability control before starting 7 6 2 Heating operation on high ground 8 7 Technical details and functional description 8 7 1 Actuation 8 7 2 Start 8 7 3...

Page 236: ...ctions of push buttons 11 9 2 Menu bar 11 9 3 Data entry field 11 9 4 HEATING 12 9 5 VENTILATION 12 9 6 PROGRAM 12 9 7 SETTINGS 14 9 8 Factory setting 14 9 9 Error codes their description and remedial...

Page 237: ...ned device for heating air 2 exhaust system 3 air supply tube in combustion chamber 4 air conduct 5 rotating outlet vent 6 control panel timing device 7 metering pump assembly with fuel filter 8 T con...

Page 238: ...TIONS Danger Safety hazard burn hazard and toxic hazard The heater must only be switched on when in spection cover is closed and outlet pipes are installed Do not open the inspection cover while the a...

Page 239: ...air supply system to combus tion chamber and exhaust system When repairing it is allowed to use only original accessories or original spare parts When performing electric welding operations on the ve...

Page 240: ...separate fuel tank the following rules must be observed at a temperature above 0 C use diesel fuel in accordance with DIN EN 590 at a temperature from 0 C to 20 C use winter diesel fuel in accordance...

Page 241: ...emaining time of operation or symbol in continuous mode Pin electrode is switched on and fan works at low speed Please note If temperature after previous heating cycle is still too high only fan cold...

Page 242: ...xt start at minimum speed recirculate mode or turns off fresh air mode 7 5 MODE OF VENTILATION To activate the mode of ventilation select the function Ventilation on display screen of control panel an...

Page 243: ...ce is not provided if changes in design of the heater have been made by an unauthorized party or if parts of third party manufacturers are built in the device 8 3 Maintenance instructions Switch on th...

Page 244: ...u items and to make settings 9 2 MENU BAR Symbol Function Heating On Off Ventilation On Off Program Settings 9 3 DATA ENTRY FIELD Symbol Function Time setting Time display format Weekday setting Batte...

Page 245: ...eating Off SHORTPRESS Press and hold the button for less than 2 sec onds the function Heating On will be completed 9 5 VENTILATION Ventilation On On the menu bar use the buttons to select the symbol a...

Page 246: ...ays of the week day of the week Using buttons select a group of days of the week Monday Friday Mo Fr Saturday Sunday Sa So Monday Sunday Mo So or a day of the week Monday Tuesday Wednesday Thursday Fr...

Page 247: ...buttons select time display format and confirm using the button 9 8 FACTORY SETTING Program presetting Group of days of the week Monday Friday Mo Fr Time of beginning of trip 7 00 Language DE Time dis...

Page 248: ...switched on again Wait until the machine recognition finishes then set the exact time and day of the week NO SIGNAL The device does not respond to commands Check the heater fuse replace if necessary...

Page 249: ...Operating Instructions Trucks ZF NewEcosplit...

Page 250: ...tected by copyright Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG Infringements lead to civil and criminal prosecution T...

Page 251: ...these operating instructions you will learn how to derive maximum benefit from the technical advantages of the ZF transmission Therefore we kindly ask the driver to carefully read these operating ins...

Page 252: ...d material damage THREATS FOR THE ENVIRONMENT Lubricants consumables and cleaning agents must not be allowed to enter the soil ground water or sewage system Ask your local environmental protection age...

Page 253: ...me operation 22 3 8 1 Servoshift 22 3 9 Initial startup of vehicle at low temperatures 23 3 9 1 Parking the vehicle at low temperatures 23 Page 4 Maintenance 24 4 1 Transmission fluid 24 4 1 1 Oil gra...

Page 254: ...00 TO 13 80 0 84 Reverse gears TD 15 36 12 92 TO 12 92 10 80 Speedometer electronic z 6 Installation2 horizontal with integrated clutch housing to the left Shift system 4 speed section forward gears s...

Page 255: ...ver with superimposed H shift pattern Fig 1 Automatic changeover when switching between shift gates 3 4 and 5 6 with double H shift pattern Fig 1a Splitter group upstream Synchronized Changeover via p...

Page 256: ...shift patterns are possible As example the standard design is shown Also note the details provided by the vehicle manufacturer R 2 4 1 3 N N 6 8 5 7 Range change group high low Splitter group high lo...

Page 257: ...ed H shift pattern Range change group of double H shift pattern The shift system is divided into 5 parallel shift gates Shift gates 3 4 and 5 6 have each a spring mounted neutral position Spring locki...

Page 258: ...e shift lever Fig 2 and 2a The driver uses this preselection switch to preselect the low or high splitter group which is then triggered by depressing the clutch pedal NOTE Changeover is triggered when...

Page 259: ...ary power units Fig 5 Separate heat exchanger for cooling the transmission oil Voith and Telma retarder can be built in upon request Fig 5 Description Torque con verter clutch PTO Engine dependent PTO...

Page 260: ...ift transmission to neutral position Start engine Fully depress clutch pedal Engage gear preferably 1st gear to protect the clutch Release parking brake and carefully engage the clutch Note vehicle ma...

Page 261: ...es 3 4 low range change group and 7 8 high range change group In order to select shift gates 1 2 and 5 6 move the shift lever in the desired direction pressing against the spring force and hold agains...

Page 262: ...leased from the central position of the shift gate The low range change group is separated from the high range change group by a stronger spring locking mechanism RC hump The shift gate for the revers...

Page 263: ...ached the maximum speed of the intended gear When operating the clutch dependent PTO the gears shall not be changed this applies also to a splitter group change since this leads to wear of the transmi...

Page 264: ...nge NOTE Only operate preselector switch when you want to engage the range change group directly afterwards CAUTION Constant shifting with high manual shifting force can cause increased wear on the sy...

Page 265: ...back into the previous shift gate and repeat the gear shifting again at a lower speed CAUTION It is not permitted to change between shift gates 5 6 and 3 4 when the driving speed is higher than approx...

Page 266: ...e Engage reverse gear smoothly and without force Engage clutch slowly NOTE Grating noise when activating the reverse gear is not permissible Only engage reverse gear once the countershaft is standing...

Page 267: ...e PTO Runout times differ depending on the operating mode and may be reduced by short initial synchronization of 1st gear If required wait longer before actuation CAUTION Gear changes are not permissi...

Page 268: ...transmission ratio of 1 55 The engine speeds depend on the inertia and drag torques to be shifted NOTES Please refer to operation instructions 1315 758 150 3 5 Parking Change transmission to the low...

Page 269: ...ed conditions is not met the propshaft must be disconnected from the rear axle flange or the axle half shafts must be removed in order to avoid transmission damage If you suspect transmission damage t...

Page 270: ...ontamination NOTE Continuation of journey is only possible when the low range change group 1st 4th gear is selected The vehicle must be towed if the high range change group remains engaged 3 8 1 Servo...

Page 271: ...r which must not exceed a temperature of 130 C on the transmission DANGER When leaving the vehicle when the engine is running the vehicle might start rolling unintentionally Engage parking brake NOTE...

Page 272: ...4 1 Transmission fluid 4 1 1 Oil grade NOTE When filling transmissions only the oils specified in the latest applicable version of the ZF List of Lubricants TE ML 01 or TE ML 02 are authorized The Lis...

Page 273: ...hange oil after a longer journey while the transmission oil is still at operating temperature and of low viscosity DANGER Touching the hot transmission and transmission fluid may result in burns Unscr...

Page 274: ...smission leads to transmission damages Check the transmission oil level at regular intervals Check oil level when vehicle is on level ground Do not perform oil level check right after travel this will...

Page 275: ...g torque 60 Nm Shift transmission to neutral position Let the engine run for approx 2 3 minutes at around 1200 rpm This is necessary for the heat exchanger and the connecting lines to be fully filled...

Page 276: ...the synchronizers it is absolutely required that the clutch separates completely This is also true for the clutch dependent PTOs The correct separation of the clutch is checked as follows Engine at op...

Page 277: ...roup Inspection Clutch must be set according to the provisions of the vehicle manufacturer Adjusting screw on the clutch pedal must be set in such a way as to prevent the release valve 1 from respondi...

Page 278: ...like for instance milk tankers concrete mixers etc have to be cleaned frequently due to their application For this reason these vehicles should be equipped with a hose breather The hose must be routed...

Page 279: ...condensate rust water and other impurities of the compressed air reservoirs from entering the valves or shift cylinders regular maintenance of the compressed air system is required The compressed air...

Page 280: ...placing orders or carrying out repairs 1 Transmission parts list number 2 Transmission type 3 Transmission serial no Fig 16 Type plate example Maintenance ZF FRIEDRICHSHAFEN AG MADE IN GERMANY MODEL...

Page 281: ...Deutschland Germany Telefon Phone 49 7541 77 0 Telefax Fax 49 7541 77 908000 www zf com EN 1341 758 101b 2012 05 ZF Friedrichshafen AG 88038 Friedrichshafen Deutschland Germany Telefon Phone 49 7541 7...

Page 282: ...085 758 102c The Integrated Retarder for Trucks and Buses With ZF Transmissions ECU 42 Control Unit Betriebsanleitung Operating Instructions Manuel d Utilisation Manual de Servicio Istruzioni per l Us...

Page 283: ...yright 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...

Page 284: ...omid 9 S 109 IT 16 S 109 IT 16 S 1621 TD 16 S 1821 TO 16 S 1921 TD 16 S 2221 TD TO 16 S 2521 TO 16 S 2721 TO 9 S 1111 TD TO 9 S 1311 TO ZF AS Tronic 12 AS 2301 IT 16 AS 2601 IT 12 AS 1631 TD 12 AS 193...

Page 285: ...exchanger on the right 10 AS 2010 B IT 10 AS 2310 B IT 12 AS 2000 B IT 12 AS 2300 B IT 8 S 2101 BD 8 S 2101 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 6 S 1601 BD 6 S...

Page 286: ...able to assist you in carrying out maintenance work or to help if any other problems arise with the transmission and the ZF Intarder The individual addresses are listed in the ZF Company Directory ord...

Page 287: ...jury or material damage THREATS TO THE ENVIRONMENT Lubricants consumables and cleaning agents must not be allowed to enter the soil ground water or sewage system Ask your local environment agency for...

Page 288: ...on the vehicle 20 3 6 1 ZF Braking Step Lever Bremsomatic 21 3 7 Deleting the Flash Code Output and the Error Memory 22 3 8 Flash Code Error List 24 4 Maintenance 27 4 1 Oil Level Check 27 4 2 Type Pl...

Page 289: ......

Page 290: ...altered with depressed clutch pedal for gear change If your vehicle is equipped with an engine brake then these can be activated in addition to the Intarder CAUTION Prior to and during downhill travel...

Page 291: ......

Page 292: ...tes to a smoother and more economic driving style The advantages of the ZF Intarder are High level of braking performance Short response times Joint oil circuit with the manual transmission and thus j...

Page 293: ......

Page 294: ...ansmission is operable and all functions are provided Longer shift times should be expected 30 C to 40 C In accordance with ZF List of Lubricants TE ML 02 Transmission must be preheated before the eng...

Page 295: ...omat operation i e when the Intarder is active as well as during the consistent braking steps NOTE Please check whether the Intarder functions correspond with the subsequently described illuminated di...

Page 296: ...58 102b 2006 10 15 Error code output via the flash code also refer to 3 7 In addition to the normal functions the Intarder check display outputs the flash code error number also refer to Chapter 3 7 f...

Page 297: ...eving the service brake system Activation of the constant braking step operation Set the braking step lever in the position from 1 to max In line with the preselected position the vehicle is consisten...

Page 298: ...cle manufacturer NOTES If the required braking performance is greater than the maximum braking performance of the Intarder then additionally the engine or service brakes must be actuated Please consid...

Page 299: ...the case of downhill travel the required braking performance is greater than the maximum braking performance of the Intarder then additionally the engine or service brakes must be actuated If the cur...

Page 300: ...in step B NOTE If the braking step lever is set back into position B after engaging constant braking step operation and the automatic speed control becomes effective with the current speed Deleting t...

Page 301: ...r the respectively current speed is set after releasing the accelerator pedal the brake pedal or the engine brake Advantages Bremsomatic Cruise control and Bremsomatic may not operate against one anot...

Page 302: ...is only working in step B NOTE If the braking step lever is after engagement of the constant braking step operation set back into position B then the automatic speed control becomes effective with th...

Page 303: ...le error number 23 4 Within 5 seconds time the braking step lever is set to two stages below the max braking step here position 3 and subsequently again to the position of one stage below the max brak...

Page 304: ...5 All errors displayed via the flash code output are deleted for the flash code output With the flash code output only error which do not impede functions can be read out of the control unit Errors wh...

Page 305: ...defect accumulator charge valve 12 El defect control engine brake 13 El defect control Intarder check display 14 El defect control performance reduction warning light 15 El defect control brake lights...

Page 306: ...ect engine speed sensor 41 CAN message EEC2 defective 42 CAN message TSC1 defective 43 Sending error of CAN messages 44 CAN BUS off 45 CAN message EBC1 defective 46 Communication error CAN messages 47...

Page 307: ...ge FMR2 defective IES ID 593 62 CAN message EPS1 defective IES ID 556 63 CAN message BC_DR 64 ExtensionBox CAN message TSC1 65 Adaptive Cruise Control ACC CAN message TSC1 66 Transmission 2 CAN messag...

Page 308: ...o be effected with Vehicle in stationary position Engine turned off and Transmission oil cooled down 40 C Check the transmission s oil level at regular intervals Please pay particular attention to pos...

Page 309: ...or undertaking repairs 1 Transmission type 2 Parts list no of the Intarder 3 Volume production no of the Intarder 4 Oil volume 5 List of Lubricants Type plate example ZF FRIEDRICHSHAFEN AG MADE IN GER...

Page 310: ...g journey while the transmission oil is still hot and thin Park vehicle on horizontal ground and turn off engine For draining the oil the oil drain plug is to be unscrewed at the transmission position...

Page 311: ...exchanger can be mounted at the bottom end horizontally to the truck transmission Oil maintenance items in line with the transmission type 1 Oil drain location transmission 2 Oil drain location Intard...

Page 312: ...can be mounted to the bottom end horizontally to the truck transmission Oil maintenance locations in line with the transmission type 1 Oil drain location transmission 2 Oil drain location Intarder ho...

Page 313: ...unted to the bottom end horizontally to the truck transmission Oil maintenance locations in line with the transmission type 1 Oil drain location transmission 2 Oil drain location Intarder housing 3 Oi...

Page 314: ...l Overflow Plugs Fig 4 Transmissions 8 S 2101 BD BO with ZF Intarder 1 Oil drain location transmission 2 Oil drain location Intarder housing 3 Oil filter cover Intarder housing 4 Oil overflow and oil...

Page 315: ...ssion 6 S 1600 IT 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO alu heat exchanger at bottom 1 Oil drain location transmission 3 Oil filter cover Intarder housing 4 Oil overflow and oil fill after oil change 9...

Page 316: ...n 6 S 1600 IT 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO stainless steel heat exchanger at bottom 1 Oil drain location transmission 3 Oil filter cover Intarder housing 4 Oil overflow and oil fill after oil c...

Page 317: ...S 1601 BD 6 S 1701 BO 6 S 1901 BO alu heat exchanger on the right 1 Oil drain location transmission 2 Oil drain location Intarder housing 3 Oil filter cover Intarder housing 4 Oil overflow and oil fi...

Page 318: ...601 BD 6 S 1701 BO 6 S 1901 BO stainless steel heat exchanger on the right 1 Oil drain location transmission 2 Oil drain location Intarder housing 3 Oil filter cover Intarder housing 4 Oil overflow an...

Page 319: ...ist at start of page 4 stainless steel heat exchanger on the right 1 Oil drain location transmission 2 Oil drain location Intarder housing below the oil filter 3 Oil filter cover Intarder housing 4 Oi...

Page 320: ...O ring 7 of the new filter Mount cover 3 with screws 10 For tightening torques refer to table on pages 45 and 46 004467 10 3 5 6 7 019485 3 004707 6 8 004467 Remove cover 3 with plugged on filter Remo...

Page 321: ...erflows Screw oil overflow plug 4 back in with new sealing ring Fill transmission until oil overflows Screw oil overflow plug 4 back in with new sealing ring Test run Do NOT engage Intarder Test run A...

Page 322: ...on agents Basic fluid Ethylenglycol with anti corrosion inhibitors Fresh Water pH value 6 5 8 5 overall hardness 20 dH Change interval of the engine coolant At max every 2 years with aluminum heat exc...

Page 323: ...After draining the residual coolant screw in the drain plug 11 with the new sealing ring Tightening torque Also refer to table on pages 45 and 46 Maintenance 6085 758 102b 2004 03 42 110 11 027986 11...

Page 324: ...ensor 110 is also the residual coolant drain plug NOTE After draining the residual coolant screw in the temperature sensor with the new sealing ring Tightening torque Also refer to table on pages 45 a...

Page 325: ...the Intarder Pressure differences are compensated for at the transmission s vent valve To this end please consult the respective chapter of the transmission s Operating Instructions Maintenance 6085 7...

Page 326: ...icants TE ML 02 In line with the transmission type with the ZF Intarder Oil change ca 11 0 dm3 12 0 dm3 12 5 dm3 12 0 dm3 12 5 dm3 12 0 dm3 13 5 dm3 13 0 dm3 Repair approx 18 5 dm3 21 5 dm3 22 0 dm3 2...

Page 327: ...02 Oil change intervals According to List of Lubricants TE ML 02 In line with the transmission type with the ZF Intarder Oil change ca 12 0 dm3 13 5 dm3 19 0 dm3 12 0 dm3 Repair approx 21 0 dm3 21 5 d...

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