Betriebsanleitung

Operating Instructions
Manuel d’Utilisation
Manual de Servicio
Istruzioni per l’Uso

Iveco
ZF-6 AS 300 VD
ZF-6 AS 320 VD
ZF-6 AS 380 VO
ZF-6 AS 400 VO
1323 758 104
Subject to technical changes

Copyright by ZF

The present documentation is protected by copyright.

Any kind of reproduction or dissemination in
whatever form that does not exclusively correspond
to documentation objectives will be prosecuted if no
prior approval by ZF Friedrichshafen AG was granted.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2004-11

Edition: 2006-05
 Preface

Your vehicle is equipped with an automatic transmission

of the 6 AS 300-/400- series. The more familiar you are
with the transmission, the more economically you will be
able to drive with it. These operating instructions tell you
how to make the best use of the technological advantages
of the ZF transmission. Therefore please carefully read
these operating instructions, and any
special instructions given by the vehicle manufacturer,
before driving the vehicle for the first time. To ensure
safe and reliable operation, please comply with all
maintenance instructions. Skilled ZF After-Sales Service
personnel are available to maintain your transmission and
to assist you with any problems.

We wish you safe and pleasant driving with your

ZF transmission.

ZF FRIEDRICHSHAFEN AG
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and Special Driveline Technology
D-88038 Friedrichshafen
Phone +49 (0) 7541 77-0
Fax +49 (0) 7541 77-90 80 00
Internet: www.zf.com

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Safety Instructions
The following safety instructions appear in this manual:
NOTE
Refers to special processes, methods, information, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
! DANGER !
This is used when lack of care could lead to
personal injury or material damage.
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! THREATS TO THE ENVIRONMENT !
Lubricants and cleaning agents must not be allowed to
enter the soil, ground water, or sewage system.
• Ask your local environment agency for safety
information on the relevant products and adhere
to their requirements.
• Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
• When working with lubricants and cleaning agents
always refer to the manufacturer's instructions.
4
 Contents

Page Page

1 Technical data ZF transmission 6 AS 300 VD / 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 AS 320 VD / 6 AS 380 VO / 6 AS 400 VO . . . . . . 7 4.1 Transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1.2 Oil fill quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1.3 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.2 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Auxiliary unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.2.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Selector lever positions . . . . . . . . . . . . . . . . . . . . 11 4.4 Transmission breather . . . . . . . . . . . . . . . . . . . . . 24
3.2 Start engine in Neutral, Manual, or 4.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Driving in Automatic mode «A» . . . . . . . . . . . . . . 14 5 Error responses . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Driving in manual mode «M» . . . . . . . . . . . . . . . . 15 5.1 Limp Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5 Switching between Automatic
and Manual modes . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.1 Changing from Automatic mode
into Manual mode . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.2 Changing from Manual mode
into Automatic mode . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.9 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 Technical data

1 Technical data ZF transmission 6 AS 300 VD / 6 AS 320 VD / 6 AS 380 VO / 6 AS 400 VO

Max. input torque Standard ratios

Nm 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse
6 AS 300/320 VD 6.73 3.95 2.56 1.78 1.29 1.00 6.06
6 AS 380/400 VO 5.38 3.15 2.04 1.37 1.00 0.79 4.84

Installation vertical

Shift mechanism all forward gears lock-synchronized; reverse gear with constant mesh
(6 AS 400 VO synchronized)

Actuation electro-mechanical

Weight without oil without auxiliaries approx. 72 kg

Oil fill
quantity approx. litres 2.7 (6 AS 300 / 320) / 2.2 (6 AS 380 / 400)

Ölsorte TRANSELF LD 75W 80

Oil change intervals 1st oil change after 240 000 km and all following changes after 240 000 km.

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Transmission diagram

Fig. 1
Example: 6 AS 300 VD transmission range
023970

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 Description

2 Description «A» = Automatic mode

«M» = Manual mode
The synchromesh transmission has been specially «N» = Neutral Central position
developed for commercial vehicles up to 150 kW. «R» = Reverse
«+» = Upshift
«–» = Downshift -
2.1 Construction
« + »; « – »; Tip positions: A/M N
The ZF-6 AS 300/400 model range fitted in the vehicle has « A/M »; Lever returns to
a tried and tested countershaft design. central position.
+ R
The gear pairs on the 6 forwards gears are helical-cut. « R»; « N »; Central position:
027565
The gear pair on the reverse gear has constant mesh, i.e. Lever remains in
is synchronized. respective positions. Fig. 2

2.2 Shift mechanism

The transmission is shifted automatically. The automatic 2.3 Auxiliary unit

transmission allows for an Automatic mode « A» and a
Manual mode « M» n which the gears can be selected by Possible connection point for lateral PTO unit
“tipping” the selector lever towards « + » (Upshift) or « –» on left-hand side, viewed in direction of travel:
(Downshift). Drivers can switch between Automatic and - 6 AS 300 VD
Manual mode at any time. - 6 AS 320 VD
- 6 AS 380 VO
- 6 AS 400 VO

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Operation

3 Operation

If the following operating instructions are obeyed, you

will be able to drive economically and save fuel:

Manual mode

• Ensure the needle is always in the

middle range on the rev counter.

n/1000 • Use the highest possible gear.

• Anticipate traffic conditions

024212
ahead.
Footbrake Accelerator pedal Selector lever Display
• Avoid unnecessary braking or
Fig. 3
acceleration.

ZF recommendation:
To drive economically, select Automatic mode.

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 Operation

3.1 Selector lever positions If the maneuvering threshold (approx. 5 km/h) is

«N» Neutral
When in this selector lever position, no power is
being transmitted from the engine to the wheels of
the vehicle. When the brakes are released, the
vehicle is free to move (e.g. pushing, towing).
not reached within 5 sec., the transmission auto-
matically shifts to « N ».
Display shows flashing « N »
For further shift operations, the selector lever has
to be put to « N » position first.

NOTE
A signal is emitted if a door remains open while the
engine is not running and the neutral position is
engaged without having the parking break engaged.

«R» Reverse
The reverse gear is engaged up to a speed of
approx. 5 km/h. The gear request is ignored beyond
this threshold. If the reverse gear is engaged after « + »; « –»; Tip positions:
having exceeded the maneuvering threshold while « A/M »; Lever returns to
driving forward, the previously engaged gear is central position.
kept.
Display shows flashing « R » « R»; « N »; Central position:
Lever remains in
If the maneuvering threshold (approx. 5km/h) is
respective positions.
reached within 5 sec. by decelerating, the reverse
gear is engaged.
Fig. 4
Display shows « R » 024210

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Operation

« M » Manual mode
Only gear shifts which do not exceed the maximum
engine speed limits or fall below the minimum
limits are permitted.

« + »; « –»; Tip positions:

«A» Automatic mode « A/M »; Lever returns to
The optimum gear is automatically selected each central position.
time.
« R»; « N »; Central position:
«+» Upshifts in Manual mode Lever remains in
respective positions.
«–» Downshifts in Manual mode
Fig. 4
Drivers can switch between Automatic and Manual modes 024210

at any time.

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 Operation

3.2 Start engine in Neutral, Manual, or Automatic • Display shows: « N », « A1 » or

mode «R»

• Apply parking brake (prevents vehicle from starting to (« A1 » also appears when in 027567
roll accidentally). Manual mode because after the
start, Automatic mode is always
• Ignition ON. present initially)

• Display shows: « BRAKE » 027568

(Engine cannot be started).

• Apply brake. 027576

• Display shows: « OK » NOTE 027569

In case of the non-synchronized reverse gear,

• Engine can be started the following applies:
027566 If the vehicle is parked with selector switch in « R »
position, the engine has to be started just after switching
NOTE on the ignition and engaging the foot brake to be able to
A signal is emitted if a door remains open while the engage the non-synchronized reverse gear.
engine is running, a forward or reverse gear is engaged,
and the neutral position is engaged without having the
parking break engaged. ! DANGER !
It is absolutely forbidden to leave the vehicle while the
engine is running and a gear is engaged in order to
prevent an unintentional setting off.
In this case, an audio warning resounds!

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Operation
3.3 Driving in Automatic mode « A »
The selector lever is placed in central position.
• After starting, 1st gear (« A1 »)
is automatically selected.
• Release hand brake and at the
same time
• set off by pressing the accelerator pedal gently and
carefully.
- Vehicle automatically undertakes subsequent gear
changes. The gear currently selected is shown on the
display.
- Gentle throttle = upshifts occur earlier
- Strong throttle = upshifts occur later
• Kickdown
When the accelerator pedal is fully depressed, the
gear ratio offering maximum acceleration capacity is
selected.
1323 758 104 - 2006-05
• Braking
When the service brake is pressed, Automatic mode
changes down whenever the lower engine speed limit
defined for each gear is reached.
- If the engine speed drops (e.g. when driving uphill or
when vehicle is coasting), Automatic mode changes
down whenever the lower engine speed limit defined
027568
for each gear is reached.
- The clutch opens just before the vehicle comes to a
stop. 1st gear remains selected.
NOTE
When on uphill inclines, do not use the accelerator to
prevent the vehicle from rolling backwards: Instead apply
the service brake. This avoids excessive clutch wear.
If the vehicle is not held using the service brake, the
clutch may overheat. A signal then sounds and the clutch
closes slowly.
The driver must decide whether he wants to depress the
accelerator and set off or depress the service brake and
remain stationary.
14
 Operation

3.4 Driving in manual mode « M » - The driver can select the timing of the gear change at
any point between the lower and upper engine speed
The selector lever is placed in central position. limits.
- If the driver does not make a manual selection before
• After starting, 1st gear is
the upper or lower engine speed limit is reached, the
automatically selected
most appropriate gear ratio is selected automatically.
Display shows: « A1 »
027568
• Braking
• Tipping selector lever once
To gain maximum possible benefit from the engine
to the left or to « + » or « – »
brake when coasting and when depressing the brake
Display shows: « M1 »
pedal, the driver must change down into the optimum
gear at the right time.
027570
• Release hand brake and at the same time set - The clutch opens just before the vehicle comes to a
off by pressing the accelerator pedal gently and stop. 1st gear remains selected.
carefully.

• Subsequent selections are made by tipping the selector

lever in the following directions
« + » - upshift or
« – » - downshift
- Gear jumps can be made to « + » or « – »
(e.g. « M2 » - « M4 », « M5» - « M3 »).
The gear currently selected is shown on the display.

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Operation

3.5 Switching between Automatic and Manual Alternatively: Simultaneous change of modes and gear.
modes
Modes and gear are changed
Once the engine has been started, the vehicle is stationary by directly tipping to « + » or « – »
and the selector lever is in the central position, 1st gear from central position.
« A1 » is generally selected. Drivers can switch between 027573
these modes at any time. E.g.:
Tipping once to « + » A2 to M3.

3.5.1 Changing from Automatic mode into Manual

027572
mode

A shift from the automatic mode

« A » into manual mode « M » is
effected by tipping the selector
lever once to the left from central
position.
The engaged gear is accepted.
3.5.2 Changing from Manual mode into Automatic
mode
027571
A shift from the manual mode « M »
into automatic mode « A » is effected
by tipping the selector lever once to
the left out of central position. 027574

027572
Subsequent selections are made by tipping the If necessary, the automatic unit
selector lever in either the « + » or « – ». The current shifts into the gear which is opti-
gear is shown in the display. mally apt to the driving situation.
027575

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 Operation

3.6 Reversing 3.7 Parking

• Bring the vehicle to a complete
stop.
• Press the footbrake.
• Move selector lever out of
central position to the right
into position « N ».
Display shows « N ».
• Move selector lever out of
position « N » and down into
position « R ».
Display shows « R »
If the reverse gear is engaged,
a signal is emitted.
• Release the footbrake. Reverse
by pressing the accelerator pedal
gently and carefully.
-
NOTE
Only if the ignition is switched on, gears are engaged.
A/M N
The vehicle can be parked in the automatic or manual
+ R mode, in the neutral position, or in the reverse gear.
027565
• Press foot brake and bring the vehicle to a complete
Central position
stop.
- Transmission automatically selects « A1 » or « M1 » or
is in « R» position depending on the mode selected.
- If the vehicle has to be parked in neutral, the selector
lever must be set to « N».
027567
• Turn ignition off and apply the parking brake.
- The vehicle is now parked in the 1st gear, the reverse
gear or in neutral.
Engage gear as additional parking interlock:
027569 • In case the vehicle is parked uphill: Forward gear
• In case the vehicle is parked downhill: Reverse Gear
NOTE
Loaded vehicles should also be secured by placing chocks
under the wheels.

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Operation

3.8 Tow starting • Max. permitted towing distance: 100 km (60 miles)
- select Neutral.
Press selector lever into position « N ». The transmission - max. permitted towing speed: 60 km/h (35 mph)!
must engage position « N ». Display shows: « N ».
• Towing distances above 100 km (60 miles):
As the vehicle rolls forwards, press selector lever to the - disconnect propshaft from the rear axle.
left and into position « A». When traveling forwards, the
optimum gear for the vehicle speed is automatically • If transmission is damaged:
selected and the clutch is then engaged. Once the engine - disconnect propshaft from the rear axle.
starts, immediately move the selector lever to the right
and into position « N ». NOTE
When towing, also follow vehicle manufacturer instruc-
tions at all times.
3.9 Towing
CAUTION
• The transmission can only be Observe national regulations when towing.
towed when in position « N ».
If the transmission cannot be
shifted to « N », the flange 027567
fittings for the propshaft on the
rear axle must be removed.

• The transmission can only be shifted once the ECU is

supplied with sufficient power. If the battery is not
powerful enough, use an external battery to provide
sufficient electrical current.

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 Maintenance

4 Maintenance 4.1 Transmission oil

Regular maintenance improves the operating safety and 4.1.1 Oil type
reliability of the transmission. Therefore it is particularly
important to comply with the correct maintenance Only use the following grade of oil:
intervals. TRANSELF LD 75W 80

! DANGER ! 4.1.2 Oil fill quantity

The vehicle maintenance has to be exclusively carried
out with engine being stationary. Secure the vehicle
against unintentional rolling off.
NOTE
The maintenance operations have to be carried out only
when vehicle is stationary and in horizontal position.
• The exact quantity of oil required can only be
obtained by following the oil fill instructions
correctly (see Section 4.2.2).
• For oil level check, see Section 4.3).
• Oil fill quantities for normal installations
(0° - 3° inclination).

NOTE Transmission Oil volume in dm3 *

At each maintenance operation also check the trans- ZF - 6 AS 300 VD
mission for seal integrity. approx. 2.7
ZF - 6 AS 320 VD
ZF - 6 AS 380 VO
approx. 2.2
ZF - 6 AS 400 VO
* 1dm3 ˆ= 1 litre

The oil quantity is shown on the type plate (affixed to the

transmission) and in the Technical Data (see Section 1).

1323 758 104 - 2006-05 19

Maintenance

4.1.3 Oil change intervals

Always observe the following oil change intervals:

Class of Lubricants First Oil Change subsequently

Tranself 75 W 80 240 000 km 240 000 km

Construction site work, 50 000 km or if the distances driven are much less,
tropical climates every 1000 operating hours,
but at least once every year

CAUTION
If the oil change intervals indicated are not observed, the operating safety and
reliability of the transmission may be impaired!

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 Maintenance

4.2 Oil change
With the 6 AS 300 VD / 6 AS 320 VD / 6 AS 380 VO /
6 AS 400 VO transmissions, the oil drain plug, item 5, and
the screw for oil filling and oil overflow measurements,
item 8, are located on the righthand side of the trans-
mission when viewed in the direction of travel (Fig. 5).
• Unscrew oil drain plug (5) from transmission (Fig. 5)
and drain oil into a suitable container. Dispose of
correctly.
• Clean oil drain plug (5) and magnet.
• Tighten oil drain plug (5) to 50 Nm.

4.2.1 Oil drain

NOTE
When oil changes are due, always change the oil after a
long journey, while the transmission oil is still warm and
thin.

! DANGER ! 019031
Hot transmission oil can cause SERIOUS BURNS! 8 5

Fig. 5 Six-speed synchromesh transmission

5 = Oil drain plug
8 = Oil fill and oil overflow measuring

1323 758 104 - 2006-05 21

Maintenance

4.2.2 Oil filling

• Remove screw plug (8) of oil filling point.

• Top up oil through oil fill aperture.

• The oil level is correct if the oil level has reached the
bottom edge of the oil filling point and/or if oil is
already escaping from the oil fill aperture.

• Tighten screw plug (8) of oil filling point to 50 Nm.

019031
8 5

Fig. 6 Six-speed synchromesh transmission

5 = Oil drain plug
8 = Oil fill and oil overflow measuring

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 Maintenance

4.3 Oil level check

! DANGER !
Insufficient oil in the transmission can lead to damage.
RISK OF ACCIDENTS!
Check the transmission oil level at regular intervals.
Hot transmission oil can cause SERIOUS BURNS!

• Always check the oil level while the vehicle is on level

ground.
019031
• Do not check the oil level immediately after a journey 8 5
(or incorrect results will be obtained). Only check the
level once the transmission oil has cooled down Fig. 7 Six-speed synchromesh transmission
(< 40 °C / 105 °F). 5 = Oil drain plug
8 = Oil fill and oil overflow measuring
• Remove the screw plug (8) (see Fig. 7).

• If the oil level has fallen below the edge of the oil fill
hole, more oil must be added (see Section 4.2.2).

• Tighten screw plug (8) in oil fill hole (see Fig. 7) to

50 Nm.

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Maintenance

4.4 Transmission breather 4.5 Type plate

The oil in the transmission heats up when the vehicle is The type plate contains the most important transmission
driven. This causes overpressure, which is continuously data. It is located on the side of the transmission.
reduced thanks to a breather valve.
Ensure that the valve is always in good working order. Please always quote the following information in the
The breather valve (Fig. 8) must be clean and have its event of queries or repairs:
plastic cover removed. Do not directly spray with waterjet 1. Transmission type
(water in transmission - risk of corrosion). 2. Transmission parts list no. (spec. no.)
3. Transmission serial no.
Transmission breather 4. Oil quantity
5. List of Lubricants

ZF FRIEDRICHSHAFEN AG
MADE IN HUNGARY
1 6 AS . . .
MODEL
PARTS LIST NO. SERIAL - NO.
2 1323 . . . . . . ............. 3
CUSTOMER
SPEC. NO
TOTAL SPEEDO
RATIO RATIO
xn
P.T.O. N n= ENGINE
OIL CAPACITY OIL GRADE SEE
IN LTS. ... LUBRIC. LIST TE-ML
019318
4 5
023970
Fig. 8 Transmission breather Fig. 9 Type plate

1323 758 104 - 2006-05 24

 Error responses

5 Error responses

Do not park the vehicle if still operational in danger A signal is emitted in the following cases:
areas. Properly secure the vehicle after having parked it • When serious errors are made.
(observe the instructions by vehicle manufacturer and the • In case of clutch overload.
operating instructions). • When reverse gear is engaged
Observe national laws and provisions!

Display Description of error

N Incorrect operation detected by system (R gear selected without engine running)

N Limited further travel possible. No need to abort journey.

Safety jeopardized. Take vehicle to safe place as quickly as possible and switch off
engine straight away. Further travel not possible.

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Error responses

5.1 Limp Home

Different types of operating errors exist:

1. Slight errors 4. Transmission error

The vehicle can only be driven in the 1st to 4th gear. The vehicle can be hardly moved with an engaged gear
or the gears 1/2, 3/4, 5/6.
2. Acceleration pedal loss
The vehicle slowly sets off by moving the selector lever CAUTION
out of « N» to the central position or to « R». « N» is Frequently starting the vehicle in gears other than the
engaged when braking to the point of standstill. 1st gear can damage the clutch.
Restart the vehicle by actuating « N» and pushing the
selector lever in the central position or « R» position. 5. Serious errors
Warning buzzer activated. Slowly brake the vehicle
3. Selector lever error and bring it to standstill outside danger areas. It is
While driving, the vehicle can be operated normally impossible to move the vehicle.
in the automatic mode. If the vehicle comes to a
standstill, « N» is engaged and the vehicle must be
towed. Do not park then the vehicle in danger areas.

1323 758 104 - 2006-05 26