ZF TraXon gearbox, repair e-manual

Content

Index of chapters

Table of contents

Preface

Safety instructions

Brief description TRAXON

• Transmission system
• Type key
• Segmentation / torque gradation
• Transmission program
• Technical data

Transmission system and its components

• System design
• Transmission and shift system
• Transmission components
• Peripheral components
• INTARDER system description

Function description

• Basic function
• Start-up and shut-off behavior
• Shifting during standstill
• Setting off
• Gear engagement during travel
• Maneuvering
• Protection functions
• Automatic drive program
• Engaging the automatic drive program
• Automatic starting gear selection
• Automatic gear change
• Disengaging the automatic drive program
• ZF rolling function (optional)
• ZF GPS PREVISION: predictive driving strategy (optional)
• TRAXON incident concep
• System analyses conducted
• Clutch actuation concept
• Transmission control unit concept
• Interface concept
• Layout criteria and testing of the transmission system
• Error responses
• Diagnosis

Installation

• Transmission installation inspection
• Standard transmission installation drawings
• This chapter is not available for bus versions
• Input shaft
• Bell housing
• Clutch
• Design of the clutch actuation unit (ConAct)
• Engine connection
• Transmission suspension
• Transmission installation angle
• Propshaft connection
• Torsional vibrations
• Vertical vibrations caused by road bumps
• Cover / step protection plate
• Brackets on the transmission
• Fordability
• Accessibility
• Guidelines for body builders
• Vehicle wiring
• Temperatures
• Permissible ambient temperatures at the transmission
• Permissible oil temperatures
• Causes for excessive oil temperatures
• Initial start-up of the vehicle at low temperatures
• Storage of the transmissions
• Oil supply
• Oil grade and oil change intervals
• Oil quality
• Oil fill quantity
• Oil change
• Draining oil
• Replacing the oil filter
• Filling oil
• Checking the oil level
• Transmission bleeding
• Electrics
• System layout and circuit diagrams
• Plug description for the vehicle
• Vehicle supply voltages and currents
• CAN bus installation
• Wiring
• Plug and mating plug designations
• Other electrical interfaces on the TRAXON
• CAN signals
• EMC
• Pneumatics
• Air supply design
• Air reservoir
• Air pressure
• Air consumption
• Air connection
• Air lines
• Air quality
• Pressure display / pressure warning
• Functional area diagram of the air supply
• Auxiliary power units
• Transmission installation on the assembly line
• Transport
• Main transmission delivery
• Corrosion protection
• Subsequent paintwork
• Guidelines for the installation of transmissions with INTARDER
• Installation and connection of electronic devices
• Assembly of engine, clutch and transmission
• Transmission installation checklist
• End-of-line programming (EOL programming)
• TRAXON operating concept
• Starting the engine
• Setting off, forward driving
• Maneuvering
• Moving off downhill
• Changing the operating mode: manual / automatic
• Changing gears
• Reversing
• Engine brake
• Stopping
• Switching off the engine / parking the vehicle
• Towing
• Tow starting
• Clutch protection
• Engine overspeed protection
• Roller test bench
• System failures (error messages)
• Calibrating the inclination sensor
• Maintenance
• Visual inspection of the wiring
• Compressed air system maintenance

Intarder

• Intarder technical data
• Intarder operating method
• Intarder brake diagram
• Intarder design
• Overview of standard application EST
• Intarder operating functions
• Braking step lever
• E-module
• Intarder main switch
• Intarder check display signal
• Speedo sensor
• ECU plug connections
• Intarder power supply connector

Cooling

• Cooling system
• Braking power / cooling power
• Pressures in the cooling system
• Coolant tubes
• Coolant flow
• Coolant quantity
• Oil / coolant heat exchanger
• Coolant thermostat
• Vehicle radiator
• Vehicle fan
• Engine coolant
• Cooling water
• Coolant additive (antifreeze / corrosion protection agent)
• Monitoring and change intervals

Application and documentation

• Application
• ZF documentation
• Customer specification
• Parts list [BoM] number and type plates
• Initial start-up
• Installation release Application limits
• Vehicle handover to end customer

Body builder

• Responsibilities
• Notes for body builders

Annex

• List of abbreviations
• Overview of revisions
• Other applicable documents
• Attached documents and drawings

Repair instructions

• Diagnosis
• Diagnosis tool
• Truck transmission overview
• Bus transmission overview
• Transmission version
• Transmission interfaces
• Transmission setup
• Bleeding the conact
• Transmission control
• Valve block
• Sensor module
• Selector actuator
• Speed sensor
• Impulse sensor for speedometer
• Oil / coolant heat exchanger
• Oil / air heat exchanger
• PTO cover
• Adapter plate
• Compressed-air connection
• Conact
• Output flange
• Overview of revisions
• Attached documents
• Assembling the transmission

Customers reviews