Silvercrest SKAS 1000 A16 Especificaciones

Maintenance and Diagnostics Manual MM-0150ZF-FreedomLine TransmissionRevised 06-09

Section 1Introduction1Section 1IntroductionZF-FreedomLine Automated Two-Pedal TransmissionThis manual provides maintenance and service information for

Section 3Maintenance91PTO Requirements FlowchartNoticeThe ZF-FreedomLine transmission is delivered pre-programmed to accept both a stationary PTO (for

Section 4Wiring/Pneumatic Diagrams 92Section 4Wiring/Pneumatic DiagramsWiring/Pneumatic DiagramsResistance SpecificationsDiagnostic Connecto rConnecto

Section 4Wiring/Pneumatic Diagrams934005601aTRANSMISSIONHARNESSVOLTAGE DOUBLERZF TCUNEUTRALINTERLOCKSPEEDSENSORSEAT HARNESSZMTECZFM DISPLAYSHIFT MODU

Section 4Wiring/Pneumatic Diagrams 944005610a12345DEDICATEDTRANSMISSIONAIR TANKTANKS, DRYER,COMPRESSOR,PRESSUREPROTECTIONVALVES, ETC.AIR FITTINGSAIR L

Section 5Removal and Installation95Step 1Section 5Removal and InstallationWARNINGTo prevent serious eye injury, always wear safe eye protection when y

Section 5Removal and Installation 96Step 4Disconnect the air supply line from the air filter regulator. Disconnect the cooler lines as required.WARNIN

Section 5Removal and Installation97Step 7If the release bearing retainer clip is not visible, the starter may need to be bumped to turn clutch so that

Section 5Removal and Installation 98Step 10Disconnect the SAE J-1939 and the OEM connectors.앫GO TO THE NEXT STEP.SAE J-1939CONNECTOROEMCONNECTORStep 1

Section 5Removal and Installation99Step 13Remove the rear support if one is installed.앫GO TO THE NEXT STEP.Step 14WARNINGSupport the transmission secu

Section 5Removal and Installation 100Step 16With the transmission supported by a transmission jack, remove the transmission by carefully pulling it st

Section 1Introduction 2Approved Oil Lubricant Specifications for ZF-FreedomLine TransmissionsWARNINGUse of inappropriate oil may damage the transmissi

Section 5Removal and Installation101Step 1WARNINGTo prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance o

Section 5Removal and Installation 102Step 4Inspect the splines on the input shaft for wear and damage. Use an emery cloth to remove small scratches fr

Section 5Removal and Installation103Step 7Position the transmission so that the input shaft aligns with the pilot bearing.앫GO TO THE NEXT STEP.Step 8W

Section 5Removal and Installation 104Step 10Use 12 fasteners to secure the transmission to the flywheel. Tighten them in a star pattern to OEM specifi

Section 5Removal and Installation105Step 13Use a 13 mm socket and ratchet to remove the four fasteners that secure the clutch inspection cover.앫GO TO

Section 5Removal and Installation 106Step 16Use a 13 mm socket and ratchet to install the clutch inspection cover. Tighten the fasteners to 17 lb-ft (

Section 5Removal and Installation107Step 19Connect the SAE J-1939 connector and the OEM connector to the transmission.앫GO TO THE NEXT STEP.4002015bSAE

Section 5Removal and Installation 108Step 21Use a 22 mm wrench to remove the fill plug from the transmission. Check that the oil is even with the bott

Section 5Removal and Installation109Step 23Charge the air system to 120 psi.The vehicle may not start after installing the transmission due to low air

Section 5Removal and Installation 110Step 1ClutchRemovalRemove the transmission. Refer to Transmission in this section.앫GO TO THE NEXT STEP.Step 2WARN

Section 1Introduction3FUNCTION ButtonPress and release the FUNCTION button to switch between automatic and manual mode, move into Reverse from a stop,

Section 5Removal and Installation111Step 4Install guide pins.앫GO TO THE NEXT STEP.GUIDE PINSStep 5Remove the remaining fasteners from the clutch housi

Section 5Removal and Installation 112Step 1InstallationClean the flywheel and bell housing surface. 앫GO TO THE NEXT STEP.Step 2Check the flywheel and

Section 5Removal and Installation113Step 4Inspect the clutch housing, disc and release bearing for damage.앫 If the components are damaged: Call OnTrac

Section 5Removal and Installation 114Step 7NOTE: The flywheel side of the clutch disc is marked “Flywheel-Side.”Verify that the flywheel side of the

Section 5Removal and Installation115Step 10Remove the guide pins. Install the remaining fasteners.앫GO TO THE NEXT STEP.FASTENERSStep 11Use a torque wr

Section 5Removal and Installation 116Step 13Check that the release bearing retainer clip is closed before you install the transmission.앫GO TO THE NEXT

Section 5Removal and Installation117Step 1Voltage DoublerRemovalUnplug the voltage doubler connector.앫GO TO THE NEXT STEP.Step 2Use a 7/16-inch socket

Section 5Removal and Installation 118Step 1InstallationUse four fasteners with flat washers and a 7/16-inch socket and ratchet to install the voltage

Section 5Removal and Installation119Step 1ZF-FreedomLine Transmission Electronic Controller (ZMTEC)RemovalUse a 1/4-inch socket and ratchet to remove

Section 5Removal and Installation 120Step 1InstallationUse four fasteners with flat washers and a 7/16-inch socket and ratchet to install the ZMTEC to

Section 1Introduction 4System Malfunction WarningWARNINGIf a system malfunction occurs, the instrument panel display illuminates “SM” for system malfu

Section 5Removal and Installation121Step 1Transmission Yoke RemovalFollow the driveline manufacturer’s instructions to remove the driveshaft from the

Section 5Removal and Installation 122Step 4WARNINGDo not damage plug installed in center of output shaft!Refer to the Service Notes page on the front

Section 5Removal and Installation123Step 1Installation WARNINGDo not overheat the yoke. Damage to the output shaft seal can result.Heat the yoke to 17

Section 5Removal and Installation 124Step 4Tighten the fasteners to 89 lb-ft (120 N•m). 앫GO TO THE NEXT STEP.TStep 5Install the driveshaft. Refer to t

Section 5Removal and Installation125Step 1Output Shaft Seal RemovalRemove the transmission yoke. Refer to Transmission Yoke in this section.앫GO TO THE

Section 5Removal and Installation 126Step 1Installation Clean all loose debris from the output shaft seal area.앫GO TO THE NEXT STEP.Step 2Apply a thin

Section 5Removal and Installation127Step 1Input Shaft SealRemovalRemove the transmission: refer to Transmission Removal in this section. The release f

Section 5Removal and Installation 128Step 1Remove transmission yoke: reference Transmission Yoke Removal in this section.Output CoverRemovalRemove the

Section 5Removal and Installation129Step 1InstallationCoat the outer circumference of the shaft sealing ring with grease. Use an appropriate driver to

Section 5Removal and Installation 130Step 1Air Filter RegulatorNOTE: The repair kit contains four nuts, one O-ring and the air filter regulator. Befor

Section 1Introduction5WARNINGThis vehicle is equipped with ZF-FreedomLine automated manual transmission. The vehicle can roll backward when stopped on

Section 5Removal and Installation131Step 1TCU Top Half/Top CoverRemovalRemove the electrical wiring harness from the TCU connector marked “vehicle”.앫G

Section 5Removal and Installation 132Step 4Use a 13 mm socket to remove the 15 fasteners that secure the TCU to the transmission.앫GO TO THE NEXT STEP.

Section 5Removal and Installation133Step 7Disconnect the plug connections.앫GO TO THE NEXT STEP.Step 8Ensure the profile seal remains in the bottom par

Section 5Removal and Installation 134Step 1InstallationPlace the new gasket seal on the upper section.앫GO TO THE NEXT STEP.Step 2Reconnect the plug co

Section 5Removal and Installation135Step 3Check that the plug connections are tight and secure.앫GO TO THE NEXT STEP.Step 4Place the upper section on t

Section 5Removal and Installation 136Step 7Install the air fitting into the air regulator.앫GO TO THE NEXT STEP.Step 8Connect the electrical wiring har

Section 5Removal and Installation137Step 9Connect the transmission vehicle wiring harness to the TCU port marked “Vehicle.”4007234aELCIHEVTRANSMISSION

Section 5Removal and Installation 138Step 1Transmission Control Unit (TCU)RemovalUnplug the electrical wiring harness assembly from the TCU port marke

Section 5Removal and Installation139Step 4Use a 13 mm socket and ratchet to remove the 15 fasteners that secure the TCU to the transmission.앫GO TO THE

Section 5Removal and Installation 140Step 1InstallationInspect the sealing surfaces of the TCU and transmission for debris. If necessary, use a scrape

Section 1Introduction 6Adjust the Starting Gear1. Press and release the FUNCTION button as necessary to switch to manual mode.2. Move the joystick FOR

Section 5Removal and Installation141Step 4Transfer measurements for the shift rails from the removed transmission actuator to piston rods a, b, and c

Section 5Removal and Installation 142Step 6WARNINGUse care not to drop springs into the transmission.NOTE: The detent spring on the passenger side of

Section 5Removal and Installation143Step 8Place the shift module onto the transmission.앫GO TO THE NEXT STEP.Step 9Use a 13 mm socket and ratchet to se

Section 5Removal and Installation 144Step 11Connect the transmission vehicle wiring harness to the TCU port marked “Vehicle.”앫GO TO THE NEXT STEP.VEHI

Section 5Removal and Installation145Shift Rail/TCU Cylinder Adjustments for InstallationWARNINGThis procedure should only be performed if pistons on t

Section 5Removal and Installation 146Step 1Selector CylinderWARNINGThis procedure is to be performed only with out-of-warranty cases. During warranty

Section 5Removal and Installation147Step 1Disassembly Lower Section of TCUWARNINGThis procedure is to be performed only with out-of-warranty cases. Du

Section 5Removal and Installation 148Step 5Use a suitable tool to raise the cylinder cover slightly and remove.앫GO TO THE NEXT STEP.Step 6Take the pis

Section 5Removal and Installation149Step 1AssemblyUse a suitable tool to insert the low-friction bearings bushings flush with the bearing bore.앫GO TO

Section 5Removal and Installation 150Step 5Fit the cylinder covers in the same position from which you previously removed them and secure each one wit

Section 2Fault Code Diagnostics7Section 2Fault Code DiagnosticsWARNINGTo prevent serious eye injury, always wear safe eye protection when you perform

Section 5Removal and Installation151Travel Sensors Engage, Splitter, Range and SelectWARNINGThis procedure is to be performed only with out-of-warrant

Section 5Removal and Installation 152Step 1Air Pressure SensorRemovalWARNINGThis procedure is to be performed only for out-of-warranty repairs. During

Section 5Removal and Installation153Step 4Use a 13 mm socket to remove the 15 fasteners that secure the TCU to the transmission.앫GO TO THE NEXT STEP.S

Section 5Removal and Installation 154Step 7Disconnect plug connections.앫GO TO THE NEXT STEP.Step 8Ensure the profile seal remains in the bottom part o

Section 5Removal and Installation155Step 12Remove the old O-ring.4007244aO-RING

Section 5Removal and Installation 156Step 1InstallationInspect the sensor and ensure the O-ring is installed.Install the sensor.앫GO TO THE NEXT STEP.S

Section 5Removal and Installation157Step 4Reconnect the plug connections (7 and 8).Check that the plug connections are tight and secure.앫GO TO THE NEX

Section 5Removal and Installation 158Step 8Use a 13 mm socket and ratchet to secure the TCU to the transmission with 15 fasteners. Secure the wiring h

Section 5Removal and Installation159Step 11Connect the transmission vehicle wiring harness to the TCU port marked “Vehicle.”4007234aELCIHEVTRANSMISSIO

Section 5Removal and Installation 160Step 1Transmission Wiring Harness Assembly RemovalUnplug the wiring harness assembly from the TCU port marked “Ve

Section 2Fault Code Diagnostics 8Inactive Fault CodesNOTE: All inactive fault codes will steadily display for approximately 1-1/2 seconds each. Ignor

Section 5Removal and Installation161Step 4Unplug the OEM connector.앫GO TO THE NEXT STEP.4002016aStep 5Unplug the output shaft speed sensor connector.앫

Section 5Removal and Installation 162Step 7Remove the wiring harness from the clips.

Section 5Removal and Installation163Step 1InstallationConnect the wiring harness assembly to the TCU at the connector port marked “Vehicle.”앫GO TO THE

Section 5Removal and Installation 164Step 4Connect the wiring harness assembly to the OEM wiring harness.앫GO TO THE NEXT STEP.4002016aStep 5Connect th

Section 5Removal and Installation165Step 7Connect the wiring harness assembly to the Neutral switch connector.앫GO TO THE NEXT STEP.Step 8Secure the wi

Section 5Removal and Installation 166Step 1Cooler By-Pass Valve RemovalPlace a pan underneath the transmission to collect the oil. Remove the hoses fr

Section 5Removal and Installation167Step 1InstallationInstall the cooler by-pass valve as shown.앫GO TO THE NEXT STEP.O-RINGSStep 2Use a 27 mm socket a

Section 5Removal and Installation 168Step 4Fasten the hoses to the by-pass valve. Using a torque wrench, tighten the oil line fitting to the cooler-by

Section 5Removal and Installation169Step 1Neutral Switch RemovalUnplug the Neutral switch connector.앫GO TO THE NEXT STEP.Step 2Use a 1-1/16-inch (27 m

Section 5Removal and Installation 170Step 1InstallationUse a 1-1/16-inch (27 mm) socket and ratchet to install the Neutral switch and tighten to 33 lb

Section 2Fault Code Diagnostics93. The TCU will begin to list the inactive fault codes on the instrument panel display.4. Record the fault codes. When

Section 5Removal and Installation171Step 1Output Shaft Speed SensorRemovalNOTE: The transmission’s upper and lower output shaft speed sensors are ide

Section 5Removal and Installation 172Step 1InstallationNOTE: The transmissions upper and lower output shaft speed sensors are identical and use the s

Section 5Removal and Installation173Section 5Removal and InstallationStep 1WARNINGAlways remove the clutch actuator housing BEFORE you remove the tran

Section 5Removal and Installation 174Step 4Remove the transmission wiring harness from the clips.앫GO TO THE NEXT STEP.Step 5Remove the air supply line

Section 5Removal and Installation175Step 7Remove the clutch actuator housing.앫GO TO THE NEXT STEP.Step 8Use a 17 mm socket and ratchet to install the

Section 5Removal and Installation 176Step 1InstallationUse a 17 mm wrench to remove the vent plug from the clutch actuator housing. The plug is opposi

Section 5Removal and Installation177Step 4Use a 13 mm wrench to install the clutch actuator housing onto the transmission with four nuts and washers.앫

Section 5Removal and Installation 178Step 7Use a 17 mm wrench to install the vent plug. Use a torque wrench to tighten the vent plug to 16 lb-ft (22 N

Section 5Removal and Installation179Step 10Secure the wiring harness to the wiring harness clips.앫GO TO THE NEXT STEP.Step 11Secure the air supply lin

Section 5Removal and Installation 180Step 1Release Bearing RemovalNOTE: YOU MUST REMOVE THE TRANSMISSION FROM THE VEHICLE TO REMOVE THE RELEASE BEARI

Section 2Fault Code Diagnostics 107. Release up-shift button.8. Wait 3 seconds.9. Press up-shift button.10. Turn ignition “OFF”.11. Wait until all shi

Section 5Removal and Installation181Step 1InstallationRemove the clutch actuator housing. Refer to Clutch Actuator Housing and Wiring Harness in this

Section 5Removal and Installation 182 Step 4Operate the vehicle. Check for correct operation.

ZF Friedrichshafen AGCommercial Vehicle and SpecialDriveline TechnologyD-88038 Friedrichshafenwww.zf.comInformation contained in this publication was

Service NotesZF-FreedomLine TransmissionMaintenance and Diagnostics Manual MM-0150USING THIS MAINTENANCE MANUAL This maintenance manual addresses main

Section 2Fault Code Diagnostics11SAE Fault Code Repair InstructionsSAE J1587 Fault CodeInstrument Panel Display Fault Code Fault DescriptionRepair Ins

Section 2Fault Code Diagnostics 1231 7 PID 1F Range position sensor signal disengages during drivingUsing TransSoft, verify that the engagement positi

Section 2Fault Code Diagnostics1332 13 PID 20 Splitter position sensor self-adjustment faultNOTE: The gear engage position sensor is unable to cycle.I

Section 2Fault Code Diagnostics 1434 7 PID 22 Mechanical failure of the clutch actuator assembly solenoidsIf possible, retrieve ISO fault code using T

Section 2Fault Code Diagnostics1537 3 SID 25 Short circuit to positive at the output stage to the splitter direct solenoid (Y2)When submitting a warra

Section 2Fault Code Diagnostics 1639 5 SID 27 Open circuit at the output stage to the rail select #1 solenoid (Y4)When submitting a warranty claim und

Section 2Fault Code Diagnostics1748 5 SID 30 Open circuit of the gear engage position sensor signalWhen submitting a warranty claim under standard war

Section 2Fault Code Diagnostics 1850 5 SID 32 Open circuit at the output stage to the rail select #2 solenoid (Y5)When submitting a warranty claim und

Section 2Fault Code Diagnostics1954 6 SID 36 Short circuit to ground at the output stage to the inertia brake solenoid (Y1)When submitting a warranty

Section 2Fault Code Diagnostics 2057 14 SID 39 ZF CAN timeout Unplug the ZMTEC only and check for 58.0 to 62.0 ohms resistance across pins D1 and D2 o

Service Notes-vNOT RELEASED 06-18-09– PROPRIETARY –Before You BeginThis manual provides maintenance and diagnostic instructions for ZF-FreedomLine tra

Section 2Fault Code Diagnostics2160 5 PID 3C Open circuit of the rail select position sensorWhen submitting a warranty claim under standard warranty c

Section 2Fault Code Diagnostics 2263 14 SID 3F Error on output shaft speed sensor #2 (the lower one)NOTE: Output shaft speed sensor #2 is a four wirin

Section 2Fault Code Diagnostics23152 5 SID 98 Open circuit at the output stage to the main solenoid (Y1)When submitting a warranty claim under standar

Section 2Fault Code Diagnostics 24191 14 PID BF Output shaft speed sensor #1 faulty or both sources of vehicle speed are inoperative.NOTE: Output shaf

Section 2Fault Code Diagnostics25231 14 SID E7 The main TCU has not received expected SAE J1939 communicationsFrom the engine ECM, body controller, or

Section 2Fault Code Diagnostics 26254 14 SID FE Main TCU fault If issue occurs during transmission software upgrade, the TCU is incompatible with the

Section 2Fault Code Diagnostics27ISO Fault Code DiagnosticsNOTE: ISO display codes may not be available on vehicles built prior to January 2006.ISO Fa

Section 2Fault Code Diagnostics 288 8 Short circuit to ground at the output stage to the low range solenoid (Y8)When submitting a warranty claim under

Section 2Fault Code Diagnostics2921 15 Short circuit to ground at the output stage to fast engagement clutch valveMeasure the resistance between pin 8

Section 2Fault Code Diagnostics 3034 22 Open circuit at the output stage to the splitter direct solenoid (Y2)When submitting a warranty claim under st

Table of ContentsRegulatory Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2Fault Code Diagnostics3140 28 Open circuit at the output stage to the low range solenoid (Y8)When submitting a warranty claim under standard

Section 2Fault Code Diagnostics 3252 34 Open circuit at output stage to large disengagement clutch valveAdditional fault codes 51/52/53 also active, v

Section 2Fault Code Diagnostics3366 42 Short circuit to positive at the output stage to the splitter direct solenoid (Y2)When submitting a warranty cl

Section 2Fault Code Diagnostics 3472 48 Short circuit to positive at the output stage to the low range solenoid (Y8)When submitting a warranty claim u

Section 2Fault Code Diagnostics3585 55 Short circuit to positive at output stage to large engagement clutch valveMeasure the resistance between pin 8

Section 2Fault Code Diagnostics 3694 5E The main TCU has not received communication from the ABS. ASR brake control active message error: EBC1The TCU

Section 2Fault Code Diagnostics37100 64 Error on output speed signal 2 (the lower one)NOTE: Output shaft speed sensor #2 plugs into the ZF-FreedomLine

Section 2Fault Code Diagnostics 38108 6C Shift lever errorZF-FreedomLine shifter analog shift lever (Freightliner and Sterling vehicles only)First che

Section 2Fault Code Diagnostics39118 76 Clutch does not disengage Complete the pneumatic requirements flowchart.Verify air supply/air quality.Remove a

Section 2Fault Code Diagnostics 40122 7A Mechanical failure of small clutch engagement solenoidComplete the pneumatic requirements flowchart.Verify ai

Table of Contents How to Clear Inactive Fault Codes from the Instrument Panel Display Using a Steering Column-Mount Shift Lever . . . . . . . . . .

Section 2Fault Code Diagnostics41128 80 Oil temperature sensor fault When submitting a warranty claim under standard warranty conditions, the complete

Section 2Fault Code Diagnostics 42133 85 Short circuit to positive of the rail select position sensorWhen submitting a warranty claim under standard w

Section 2Fault Code Diagnostics43139 8B No range change group sensor signal (open circuit)When submitting a warranty claim under standard warranty con

Section 2Fault Code Diagnostics 44145 91 Range shift disengagement error Complete the pneumatic requirements flowchart.If no issues are found with the

Section 2Fault Code Diagnostics45149 95 Splitter selection fault during the splitter selection procedureComplete the pneumatic requirements flowchart.

Section 2Fault Code Diagnostics 46152 98 Rail selection fault during the rail selection procedureComplete the pneumatic requirements flowchart.The sel

Section 2Fault Code Diagnostics47155 9B Main transmission gear does not engageComplete the pneumatic requirements flowchart.The engagement actuator di

Section 2Fault Code Diagnostics 48159 9F Range position sensor signal leaves engaged position during drivingUsing TransSoft, verify that the range pos

Section 2Fault Code Diagnostics49166 A6 Permanent idle signalNOTE: The idle switch is built into the accelerator pedal and is wired into the engine co

Section 2Fault Code Diagnostics 50173 AD The main TCU has not received communication from the engine. Error on brake switch message: CCVSThe TCU recei

Regulatory GuidanceiRegulatory GuidanceRegulatory GuidanceAll persons working with, handling or exposed to the area where work on the transmission occ

Section 2Fault Code Diagnostics51190 BE EOL EEPROM parameter out of valid rangeThe EOL parameters need to be updated. This can be accomplished with Tr

Section 2Fault Code Diagnostics 52199 C7 The main TCU has not received communication from the ABS (CAN WSI timeout)Due to an issue with the vehicle’s

Section 3Maintenance53Section 3MaintenanceRelease Fork Greasing Procedure (Standard and Roller Fork Applications)Step 1 For Standard Fork Applications

Section 3Maintenance 54Section 3MaintenanceRelease Fork Greasing Procedure (Standard and Roller Fork Applications)Step 3With the clutch fork pried bac

Section 3Maintenance55Release Fork Greasing Procedure (Standard and Roller Fork Applications)Step 5Working through the clutch inspection cover, use a

Section 3Maintenance 56Release Fork Greasing Procedure (Standard and Roller Fork Applications)Step 7For Standard Fork Applications onlyNOTE: This proc

Section 3Maintenance57Release Fork Greasing Procedure (Standard and Roller Fork Applications)Step 8Install the clutch actuator rod into the ball joint

Section 3Maintenance 58Release Fork Greasing Procedure (Standard and Roller Fork Applications)Step 10Use a 13 mm wrench to install the clutch actuator

Section 3Maintenance59Release Fork Greasing Procedure (Standard and Roller Fork Applications)Step 12Use a 13 mm socket and torque wrench to tighten th

Section 3Maintenance 60SAE J1939 Requirements FlowchartNoticeThe ZF-FreedomLine transmission actively diagnoses SAE J1939 data bus faults and reacts a

Model Numbers and Ratios iiModel Numbers and Ratios12-Speed ZF-FreedomLine16-Speed ZF-FreedomLineM O – Z 12 A – A 16 Torque Ratin

Section 3Maintenance61SAE J1939 Requirements Flowchart4004245aAAre anyof them loggedand active?Check for thefollowing active codes.Are anyof the codes

Section 3Maintenance 62Electrical Requirements Flowchart4004157aUnplug the 21-pin OEMinterface connector, J7. Disconnect the batteries.Check the resis

Section 3Maintenance63Electrical Requirements Flowchart4004193cReconnect the outputshaft speed sensor #2connector, J5. Check the DC voltagebetween pi

Section 3Maintenance 64Electrical RequirementsStep 1Unplug the 21-pin OEM interface connector, J7.4002016aStep 2Disconnect the batteries. Use a discon

Section 3Maintenance65Electrical RequirementsStep 4Check the resistance between pin E of the OEM interface connector, J7, and the battery ground conne

Section 3Maintenance 66Electrical RequirementsStep 7NOTE: The voltage ranges referenced in the following steps are based on voltage ranges of a syste

Section 3Maintenance67Electrical RequirementsStep 10Check the DC voltage between pin B of the OEM interface connector, J7, and the battery ground conn

Section 3Maintenance 68Electrical RequirementsStep 13Check the DC voltage between pin A of the OEM interface connector, J7, and the battery ground con

Section 3Maintenance69Electrical RequirementsStep 16Reconnect the OEM interface connector, J7.4002016aStep 17Disconnect the TCU connector, J1 (this co

Section 3Maintenance 70Electrical RequirementsStep 19Reconnect the TCU connector, J1. GO TO STEP 20.Step 20Disconnect the output shaft speed sensor #1

iiiZF-FreedomLine Fasteners Tightening TorqueDescription SizeTorque Specification(lb-ft) (N•m)Drain plug M24 x 1.5 44 60Fill/Spill plug M24 x 1.5 44 6

Section 3Maintenance71Electrical RequirementsStep 22Reconnect the output shaft speed sensor #1. Step 23Turn the key off.Step 24Disconnect the output s

Section 3Maintenance 72Electrical RequirementsStep 25Turn the key on but do not start the engine.Step 26With the output shaft speed sensor #2 disconne

Section 3Maintenance73Electrical RequirementsStep 28Reconnect the output shaft speed sensor #2, J5.The transmission’s electrical system is operating c

Section 3Maintenance 74Pneumatic Requirements Flowchart4004158aMeasure the air pressure inthe air tank that suppliesthe transmission air tank. Verify

Section 3Maintenance75Pneumatic Requirements Flowchart4004194cVerify that the transmissionair tank is protected with aone-way check valve. The one-wa

Section 3Maintenance 76Pneumatic RequirementsStep 1Measure the air pressure in the vehicle air tanks.Is the air pressure 100 psi or more?앫YES ➞ GO TO

Section 3Maintenance77Pneumatic RequirementsStep 4Verify the presence of a 10 L (approximately) transmission air tank.Is the transmission air tank ins

Section 3Maintenance 78Pneumatic RequirementsStep 7Verify that the transmission is prioritized after the air brakes but before all other air options.I

Section 3Maintenance79Pneumatic RequirementsStep 10Verify that the transmission air tank is protected with a one-way check valve.Is a one-way check va

Section 3Maintenance 80No-Start Troubleshooting FlowchartWith the key off,disconnect the 21-pin OEMinterface connector, J7. Charge the airsystem and

AcronymsivAcronyms Referenced in ManualABS — Anti-Lock Braking SystemACC — AccessoryASR — Anti-Slip RegulationCAN — Controller Area NetworkCCVS — Crui

Section 3Maintenance81No-Start Troubleshooting Flowchart4004195bTurn the key on for 10 seconds and then bump the engine.DO NOT ATTEMPT TO STARTTHE EN

Section 3Maintenance 82No-Start TroubleshootingStep 1Is “AL” on the transmission display when the key is turned on?앫NO ➞ GO TO STEP 2.앫 YES ➞ CHARGE T

Section 3Maintenance83No-Start TroubleshootingStep 4With the key off, disconnect the 21-pin OEM interface connector, J7.4002016aStep 5WARNINGBefore pe

Section 3Maintenance 84No-Start TroubleshootingStep 7Remove the jumper wire from the OEM side of the OEM interface connector, J7.4004162bOEM INTERFACE

Section 3Maintenance85No-Start TroubleshootingStep 10Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT.Doe

Section 3Maintenance 86No-Start TroubleshootingStep 13Reconnect the neutral switch connector, J2.Step 14Attempt to bump the engine with the starter. D

Section 3Maintenance87No-Start TroubleshootingStep 16Attempt to bump the engine with the starter. DO NOT ATTEMPT TO START THE ENGINE, JUST BUMP IT.Doe

Section 3Maintenance 88No-Start TroubleshootingStep 19With the plunger of the neutral switch pushed in, measure the resistance across pins 1 and 2 of

Section 3Maintenance89No-Start TroubleshootingStep 22Reassemble and reconnect the neutral switch and neutral push pin. Tighten the neutral switch to 3

Section 3Maintenance 90No-Start TroubleshootingStep 25Disconnect the OEM interface connector, J7, the neutral switch connector, J2, and the ZMTEC conn