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Stage 1-2
Preface 7
Validity and Field of Application 7
Product Designation 8
Safety 10
Signal Words and Symbols 10
General Safety Instructions 11
Product-Specific Safety Instructions, 13
ESD Protection 13
Instructions for Repair and Assembly 14
Diagnosis Tool 17
TruckTransmission Overview 19
Bus Transmission Overview 20
Transmission Version 21
TraXon Basic Transmission 21
TraXon with InTArDEr 21
Transmission Interfaces 22
Transmission Setup 23
Type Plate 24
TraXon Type Plate 24
InTArDEr Type Plate 25
Control Unit Type Plate 25
Maintenance26
Visual Inspection of Wiring 26
Compressed Air System Maintenance 26
Oil Grade and Oil Change Intervals 26
Oil Quality 26
Oil Quantity 26
Transmission Bleeding 26
Oil Change (TraXon without InTArDEr) 27
Draining Oil 27
Filling Oil 28
Checking the Oil Level (TraXon without InTArDEr) 28
Oil Change (TraXon with InTArDEr) 29
Draining Oil 30
Oil Filter Change 31
Filling Oil (TraXon with InTArDEr) 32
Filling Oil During an Oil Change 32
Filling Oil After a Transmission repair 33
Checking the Oil Level (TraXon with InTArDEr) 34
Visual Inspection 34
Engine Coolant 35
Engine Coolant Change Interval 35
Diagnosis 36
General 36
ZF-TESTMAn 36
Working with Checklists 37
Bleeding the ConAct 38
Bleeding the ConAct with the Diagnostic Unit 38
Manually Bleeding the ConAct 39
Transmission Control 40
removing the Transmission Control 40
Installing the Transmission Control 45
Valve Block 51
removing the Valve Block 51
Installing the Valve Block 52
Sensor Module 53
removing the Sensor Module 53
Installing the Sensor Module 54
Selector Actuator 55
removing the Selector Actuator 55
Installing the Selector Actuator 56
Speed Sensor 57
removing the Speed Sensor 57
Installing the Speed Sensor 58
Impulse Sensor for Speedometer 59
removing the Impulse Sensor 59
Installing the Impulse Sensor 59
Oil/Coolant Heat Exchanger 60
removing the Heat Exchanger 60
Heat Exchanger Kit 61
Installing the Heat Exchanger Kit 62
Oil/Air Heat Exchanger 64
removing the Heat Exchanger 64
Heat Exchanger Kit 65
Installing the Heat Exchanger Kit 66
PTO Cover 68
removing the PTO Cover 68
Installing the PTO Cover 68
Adapter Plate 69
removing the Adapter Plate 69
Installing the Adapter Plate 72
Compressed-Air Connection 75
removing the Connecting nozzle 75
Installing the Connecting nozzle 75
ConAct 76
removing the ConAct 76
Installing the ConAct 79
Output Flange 82
removing the Output Flange 82
Installing the Output Flange 84
Overview of Revisions 86
Attached Documents 88
Páginas 114 PDF em Inglês
Stage 3
Preface 7
Validity and field of application 7
Product designation8
Safety 10
Signal words and symbols 10
General safety instructions 11
Product-specific safety instructions 13
ESD protection 13
Instructions for Repair and Assembly 14
Consumables 17
Settings 18
Workshop Equipment 19
Special tools 19
Diagnosis Tool 30
Truck Transmission Overview 32
Bus Transmission Overview 33
Transmission Version 34
TRAXON basic transmission 34
TRAXON with INTARDER 34
Transmission Interfaces 35
Transmission Setup 36
Type Plate 37
TRAXON type plate 37
INTARDER type plate 38
Control unit type plate 38
Transport 39
Preparatory Work 40
Bleeding the ConAct 43
Bleeding the ConAct with the diagnostic unit 43
Manually bleeding the ConAct 44
Disassembling the Transmission 45
Removing the transmission control 46
Removing the valve block 50
Removing the sensor module 51
Removing the selector actuator 52
Removing the speed sensor 53
Removing the impulse sensor 54
Removing the heat exchanger 55
Removing the PTO cover 57
Removing the adapter plate 58
Compressed-air connection (removing the connecting nozzle) 61
Removing the ConAct 62
Rotating the transmission without assembly stand 65
Removing the output flange 66
Removing the output cover 68
Removing the steering pump 70
Removing the INTARDER 72
Removing the transmission housing 75
? Removing the transmission housing (version with INTARDER) 76
? Removing the transmission housing (version without INTARDER) 77
Disassembling the planet carrier 80
Disassembling the sun gear 87
Removing the range change group 88
Rotating the transmission 94
Removing the connection plate 96
? Disassembling the R/C piston 104
? Disassembling the S/G piston 105
? Disassembling the MT piston 106
? Disassembling the plain bearing 107
Removing the clutch housing 108
Disassembling the clutch housing 111
Removing the shaft package 112
Disassembling the countershaft 116
Disassembling the input shaft 118
Disassembling the synchronizer unit 124
Disassembling the main shaft, 12-speed, model range 121 126
Disassembling the main shaft, 12-speed, model range 122 130
Disassembling the main shaft, 16-speed 134
Disassembling the shift system 139
Disassembling the bearing support 144
Assembling the Transmission 146
Assembling the bearing support 146
Assembling the shift system 150
Assembling the main shaft, 12-speed, model range 121 156
Assembling the main shaft, 12-speed, model range 122 161
Assembling the main shaft, 16-speed 167
Assembling the synchronizer unit 174
Assembling the input shaft 178
Assembling the countershaft 185
Installing the shaft package 186
Assembling the clutch housing 191
Installing the clutch housing 192
Pre-assembling the connection plate 196
Measuring the connection plate 205
Connection plate 209
? Overview gear shift pistons 209
? Pre-assembling the R/C piston 211
? Pre-assembling the S/G piston 212
? Pre-assembling the MT piston 214
? Pre-assembling the plain bearing 217
? Fitting the connection plate 218
Installing the ConAct 225
Rotating the transmission by 180° 228
Installing the range change group 231
Assembling the sun gear 237
Pre-assembling the planetary gearset 238
Assembling the transmission housing 245
Measuring the range change group 247
? Clearance setting main shaft - sun gear 247
Fitting the transmission housing 249
? Fitting the transmission housing (version without INTARDER) 250
? Fitting the transmission housing (version with INTARDER) 251
Installing the INTARDER housing 252
Fitting the steering pump 254
Installing the adapter plate 256
Installingthe PTO Cover 259
Fitting the output cover 260
Installing the output flange 262
Installing the impulse sensor 264
Installing the speed sensor 265
Fitting the heat exchanger 266
Compressed-air connection (fitting the connecting nozzle) 269
Installing the selector actuator 270
Installing the sensor module 271
Installing the valve block 272
Installing the transmission control 273
Final assembly 279
Checking leak tightness 280
Annex 281
Overview of revisions 282
Comparison table for grease quantities 283
Installation instructions 0000702644 285
Páginas 288 PDF em Inglês
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