TraXon Training_Print to MAN_12-2019

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Internal
TraXon Training
Nilson Marques | Field Support | TTB
© ZF Friedrichshafen AGInternal
System Soden
Manual 
pre-selection system
AVS
Automatic 
pre-selection system
AS Tronic
Automatic
transmission control
TraXon
Anticipatory 
driving strategy
Application Cars Coach
Heavy truck /
coach
Heavy truck /
coach
Operation 3 pedals 3 pedals 2 pedals 2 pedals
Automation Prefix Semi-automatic Fully automatic Fully automatic 
Special feature Mechanical Add-on
Fully integrated 
transmission modules
PreVision GPS
Start of volume 
production
1921 1989 1997 2015
Development of 
ZF Transmission Systems 
2018-07-12 | Field Support | TraXon Training 2
© ZF Friedrichshafen AGInternal
TraXon
Productio figures
3
2017: 57.286
2016: 8.297
2018: 
172.045
Stand: 04/2019
© ZF Friedrichshafen AGInternal
H 10,5 x B 15,43 cm
Position H 8,97 x 3,0 cm
• High input torques 
(up to 3,400 Nm)
• Benchmark: highest torque-mass ratio 
(12.83 Nm/kg, 12-speed version)
• Benchmark: highest transmission spread 
(DD 16.69-1.00 / OD 12.92-0.77)
• Benchmark: highest efficiency 99.7 %
• Long service life
• Low-noise
• Concentric clutch actuation system ConAct
The Highlights 
(Technology)
2018-07-12 | Field Support | TraXon Training 4
TraXon – Best values for the global market
© ZF Friedrichshafen AGInternal
TraXon – A Step into the Future
Customer Values
2018-07-12 | Field Support | TraXon Training 5
• Excellent smooth-running transmission 
• Driving in ECO program mode
• Reduced engine speeds at cruising speed
• Fuel-efficient transmission control unit
Fuel-efficient
© ZF Friedrichshafen AGInternal
The Transmission System
2018-07-12 | Field Support | TraXon Training 6
Dry separating 
clutch 
(SAE 1)
Mechatronics modules
Integrated 
bell housing
Intarder
(option)
Control elements
Power take-offs (PTOs) (option)
Additional
modules
Concentric
clutch actuation system
ConAct
3
© ZF Friedrichshafen AGInternal
TraXon
Mechatronics • ConAct ® Clutch Actuation System
2018-07-12 | Field Support | TraXon Training 7
• Concentric clutch actuation (on 
input shaft)
• Push-type clutch
• Protected inside the bell housing 
• Compressed air actuation
Plug-in termination to 
electronic control unit 
(TCU)
Travel sensor
Features
© ZF Friedrichshafen AGInternal
H 10,5 x B 7,45 cm
Position H 1,0 x 3,0 cm
TraXon
Extension Modules 
2018-07-12 | Field Support | TraXon Training 8
Available auxiliary devices:
• Single/twin plate dry clutch
• ZF-Intarder
• Clutch-dependent and driving-
dependent power take-offs (PTOs)
• NMV PTO module
• Additional heat exchanger 
for non-Intarder transmissions
In preparation:
Hybrid module
The starting module for the electric 
drive
Dual clutch module 
For shift systems without tractive 
force interruption
WSK torque converter clutch
The starting module for heavy goods 
vehicle traffic
Individuality through diversity 
© ZF Friedrichshafen AGInternal
For driving: Hydraulic pumps for example
Design: b = with output flange
c = for direct pump attachment
Operating mode: Continuous duty
Axle offset: Without
Possible installation 
positions:
Output torque: 1,000 Nm
TraXon
Clutch-Dependent PTO
9
ZF NH/1 PTO 
with integrated shift cylinder
© ZF Friedrichshafen AGInternal
For driving: Hydraulic pumps for example
Design: b = with output flange
c = for direct pump attachment
Operating mode: Short-term operation
Axle offset: 80 mm
Possible installation 
positions:
Output torque: 430 Nm
TraXon
Clutch-Dependent PTO
10
ZF NH/4 PTO 
with integrated shift cylinder
© ZF Friedrichshafen AGInternal
TraXon
Clutch-Dependent PTO
11
For driving: Compressors, hydraulic pumps, rotodynamic
pumps (fire service) for example
Design: (applies for out-
put point "1" and/or "2")
b = with output flange
c = for direct pump mounting
Operating mode: Continuous duty
Axle offset: +133 mm upwards
to the center of the 
transmission -70 mm 
downwards
+149.7 mm upwards
to the center of the 
transmission -54 mm 
downwards
Possible installation 
positions:
Output torque: “Fast” (at top or bottom) = 360 - 600 Nm
“Slow” (at bottom or top = 630 - 730 Nm)
ZF N TX/10 PTO 
with integrated shift cylinder
"1" = fast top
"2" = slow bottom
"1" = slow top
"2" = fast bottom
„1“
„2“
© ZF Friedrichshafen AGInternal
N TX/10
TraXon
Retrofitting of PTOs
12
PTOs can fundamentally be retrofitted.
Requirement:
• The mounting face on the transmission is machined and sealed by a cover.
Special features:
• TraXon transmissions
The control electronics of these transmissions must be "reprogrammed" 
when PTOs are retrofitted (by ZF or vehicle manufacturer).
• TraXon with N TX/10 
The retrofitting of a second output point and/or the relocation of the output 
point from the "top" to the "bottom" is extremely laborious!
© ZF Friedrichshafen AGInternal
38
Connecting Dimensions
13
TraXon
38
15°
140
© ZF Friedrichshafen AGInternal2018-07-12 | Field Support | TraXon Training 14
Operating modes
© ZF Friedrichshafen AGInternal
Starting and Setting Off
2018-07-12 | Field Support | TraXon Training 15
Rotary switchOperation
N
3
• Parking brake is engaged. Rotary 
switch in position "N"
• Start the engine. After the 
system check, the display shows:
Display
Danger: Vehicle may roll (as with any manual transmission)!
e.g.: automatic + 3rd gear
• Use rotary switch to select "D".
The starting gear will be engaged 
automatically (if required, the 
starting gear can be corrected).
• Accelerate and release the brake 
in parallel
© ZF Friedrichshafen AGInternal
Operating Modes
2018-07-12 | Field Support | TraXon Training 16
Manual mode
• The transmission system determines:
• Starting gear 
• Gear changes
• Clutch actuation and gear changes are always 
performed automatically
• Manual gear correction possible with control lever (tip 
function)
• Incorrect gear changes excluded
Automatic mode
• Automatic selection of the starting gear
• Manual gear selection with the control lever – automatic 
clutch actuation and gear changes
• Search function and maneuvering mode
• Incorrect gear changes excluded
• Maneuvering and PTO operation only 
in the manual mode.
© ZF Friedrichshafen AGInternal
TraXon
Convenience Shifts
2018-07-12 | Field Support | TraXon Training 17
• Soft clutch actuation and gear 
changes
• Precise speed recording due to 
high-resolution sensors
Characteristics
• Improved driving comfort
• Optimum acceleration when 
setting off
Benefits
© ZF Friedrichshafen AGInternal
TraXon
Fast Gear Changes
2018-07-12 | Field Support | TraXon Training 18
• Improved shift sequence in case 
of demanding topographies
• Minimum shifting time
• Adapted driving strategy
Fast gear changes
Advantages
• Fuel economy
(driving at lower engine speeds)
© ZF Friedrichshafen AGInternal
Sample display
Manual mode, 5th gear engaged, 
downshift option: max. 2 gears
Use manual mode only to avoid unnecessary shifting on 
gradients or in frequently changing topography!
Manual Mode
2018-07-12 | Field Support | TraXon Training 19
Manual mode – only for exceptional 
situations!
Driver shifts actively by using the control 
lever (tip function)!
5
© ZF Friedrichshafen AGInternal
TraXon
Maneuvering Function
2018-07-12 | Field Support | TraXon Training 20
• Smooth closing of drive clutch
• Excellent adjustment control via 
the accelerator pedal
Features
• Perfect control over the vehicle
• Even with difficult track conditions
Benefits
© ZF Friedrichshafen AGInternal
Maneuvering forward
Maneuvering backwards
Activation: Depress 
accelerator pedal in the 
upper range.
Activation: rotary switch to 
DM/RM position
Maneuvering Mode
2018-07-12 | Field Support | TraXon Training 21
Activation Display
DM
RM
© ZF Friedrichshafen AGInternal2018-07-12 | Field Support | TraXon Training 22
Software & funcionalidades
© ZF Friedrichshafen AGInternal
• Allows the vehicle to perform 
rocking movements• Purpose-built clutch actuation
• Manual activation by the driver
Features
• Easy to free the vehicle from 
troughs and trenches etc. 
Advantages
TraXon
Rock-Free Function
2018-07-12 | Field Support | TraXon Training 23
© ZF Friedrichshafen AGInternal
• Setting off with optimum engine 
torque
• Determines vehicle weight and 
track gradient
Features
• Easy and safe setting off on 
mountains and on difficult terrain
Advantages
TraXon
Hill Holder
2018-07-12 | Field Support | TraXon Training 24
© ZF Friedrichshafen AGInternal
TraXon
Rolling Function
2018-07-12 | Field Support | TraXon Training 25
• Calculates driving resistance for 
track gradient
• Activates the rolling function: 
transmission in neutral position
Features
• Reduces the drag losses
• Fuel economy
Benefits
© ZF Friedrichshafen AGInternal
TraXon
Offroad Mode
2018-07-12 | Field Support | TraXon Training 26
• Adapts the driving functions to 
difficult terrain / ground:
• Optimum calculation of driving 
resistance
• Adapted shifting speed
• Special clutch functions
• Manual activation by the driver
Features
• Safer driving on difficult terrain, 
also with high loads
Benefits
© ZF Friedrichshafen AGInternal
TraXon • PreVision/GPS 
Anticipatory Driving Strategy
2018-07-12 | Field Support | TraXon Training 27
Ideal shifting points
Consumption-optimized rolling
Prevent unnecessary gear changes
Early upshift 
into the most economical gear
Selects the right gear –
before the uphill gradient increases
Optimally uses the omentum
on downhill gradients 
Identifies the upcoming 
uphill gradient
Here, PreVision does not shift into the top gear:
no downshifting is required for the coming uphill gradients
• Reduces the shift frequency
• Fuel consumption savings
• Increased comfort 
thanks to fewer gearshifts
• Increase of rolling phases
• Optimized calculation of the 
driving resistance and the vehicle 
mass to increase driving quality 
and effectivity
PreVision GPS
Rolling activated
No rolling
No rolling
© ZF Friedrichshafen AGInternal
Communication in the Driveline
2018-07-12 | Field Support | TraXon Training 28
Brake control 
ABS/EBS
TraXon
(TCU)
Engine control 
(EDC)
GPS 
module
Intarder
control
© ZF Friedrichshafen AGInternal
The TraXon TECU does not have it´s own GPS sensor. 
For vehicles which are provided with the signal via CAN then the GPS signal could be used to support the shift strategy.
GPS – Signalverarbeitung
GPS – Signal Processing
© ZF Friedrichshafen AGInternal2018-07-12 | Field Support | TraXon Training 30
Astronic review
© ZF Friedrichshafen AGInternal
Astronic
Esquema Fluxo de força Direct
Drive
1ª vel.
2ª vel.
3ª vel.
4ª vel.
5ª vel.
6ª vel.
7ª vel.
8ª vel.
9ª vel.
10ª vel.
11ª vel.
12ª vel.
R1-marcha atrás
R2-marcha atrás
K1 K2/3 2 1 R GP
grupo reductor
lento
grupo reductor
rápido
© ZF Friedrichshafen AGInternal
1ª marcha
1ª engrenagemK 1
© ZF Friedrichshafen AGInternal
2ª marcha
1ª engrenagemK 2
© ZF Friedrichshafen AGInternal
3ª marcha
2ª 
engrenagem
K 1
© ZF Friedrichshafen AGInternal
4ª marcha
2ª engrenagemK2
© ZF Friedrichshafen AGInternal
5ª marcha
3ª engrenagemK1
© ZF Friedrichshafen AGInternal
6ª marcha
3ª 
engrenagem
K2
© ZF Friedrichshafen AGInternal
7ª marcha
4ª engrenagemK1
© ZF Friedrichshafen AGInternal
8ª marcha
4ª engrenagemK2
© ZF Friedrichshafen AGInternal
9ª marcha
Tudo se repete com GP rápido 
(desconectado)
Luva na 
direção da 
saída 
© ZF Friedrichshafen AGInternal
10ª marcha
© ZF Friedrichshafen AGInternal
11ª marcha
© ZF Friedrichshafen AGInternal
12ª marcha
© ZF Friedrichshafen AGInternal
13ª marcha
© ZF Friedrichshafen AGInternal
14ª marcha
© ZF Friedrichshafen AGInternal
15ª marcha
© ZF Friedrichshafen AGInternal
16ª marcha
© ZF Friedrichshafen AGInternal
Marcha ré lenta
© ZF Friedrichshafen AGInternal
Marcha ré rápida


file:///C:/Alle Trainerleitfaden/07 AS Tronic/AS Tronic 1/AS 1 Trainerleitfaden.pps#2. Lieferumfang
file:///C:/Trainerleitfaden/07 AS Tronic/AS Tronic 1/AS 1 Trainerleitfaden.pps#7. Kraftflußschema
file:///C:/Trainerleitfaden/07 AS Tronic/Trainerleitfaden Deutsch/2 AS_Tronic_2_Teil_1_Mechanik/AS_Tronic_2_Teil_1_Mechanik2.ppt#9. 16 AS 2601
© ZF Friedrichshafen AGInternal
1
AS Tronic design interno
© ZF Friedrichshafen AGInternal2018-07-12 | Field Support | TraXon Training 51
TraXon overview
© ZF Friedrichshafen AGInternal
Electronic transmission control unit (TCU)
TraXon
Electronic Control Unit
2018-07-12 | Field Support | TraXon Training 52
• PreVision GPS anticipatory driving strategy
• Fully automatic driving with automatic adaptation 
of the driving programs (Eco to Power)
Driving strategy
Software-based transmission functions
• Rolling function
• Maneuvering function
• Fast gear changes
• Convenience shifts
• Start-stop assistance
• Hill holder
• Offroad mode
• Rock-free function
Safely hidden behind 
the cladding of the 
housing 
cover – the TCU
Central connection 
for vehicle electronics
© ZF Friedrichshafen AGInternal
TraXon
Basic Transmission
2018-07-12 | Field Support | TraXon Training 53
Countershaft
Countershaft
Input shaft
and main shaft
Splitter group
Constant 1
Splitter group
Constant 2
3-speed main 
transmission section
Range change group
R
Output shaft
Output flange
123
Deflection gear of R gear
© ZF Friedrichshafen AGInternal
TraXon
Mechatronics
2018-07-12 | Field Support | TraXon Training 54
• Module
Mechatronics
"Select" actuation module
Valve module
Sensor module
• Exchangeable modules
• Vibration stability
• Temperature-resistant
• Internal wiring
• Digital signal transmission
• Designed for many gearshifts, 
long service life
© ZF Friedrichshafen AGInternal
TraXon
Shift System (12-Speed)
2018-07-12 | Field Support | TraXon Training 55
Integrated pneumatic 
shift cylinders
(valve module)
Gear 2/3
Splitter group
Gear 1/R
Range change group
Shift forks:
Shift system
© ZF Friedrichshafen AGInternal
TraXon
Connection Plate
2018-07-12 | Field Support | TraXon Training 56
• The complete pneumatic
transmission actuation system is 
integrated in the connection plate:
• all pneumatics channels
• shift cylinders for:
• splitter group
• range change group
• main transmission 
• transmission brake
• oil pump
• Direct connection surface for valve 
actuation module (on top)
Separator plate 
between bell 
housing/exhaust 
air chamber 
Direct connection 
surface for valve 
module
Connection plate
Transmission brake
Oil pump
Connection plate
© ZF Friedrichshafen AGInternalVisualisierung des TraXon 12.2 / 16, Stand: 19.03.2013
Mechanik TraXon 12.2
Schaltung HG mit Wählaktuator / Gearshift
with selection actuator
Wählaktuator
Selection actuator
Wählhülse
Selection sleeve
Mitnahme- &
Verriegelungs-
codierung
Moving and
Locking coding
Schaltgabel HG 2G-3G
Shift fork HG 2G-3G
Schaltgabel HG 1G-RG
Shift fork HG 1G-RG
Schaltgabel HG 2G-3G
Shift fork HG 2G-3G
Schaltgabel HG 1G-RG
Shift fork
Anschlussplatte
Connection plate
3-Stellungszylinder mit 2 Schleppkolben
3-position cylinder with 2 trailer pistons
Gebermagnet Wegsensor HG
Transmitter magnet for position sensor HG
Schaltschiene HG
Shift rail HG
© ZF Friedrichshafen AGInternal
TraXon
Exhaust Air Chamber and Oil Filter
2018-07-12 | Field Support | TraXon Training 58
New
Central air
connection
Oil filter with collecting magnets
Protected exhaust 
air chamber
• Oil filter with collecting 
magnet
Permanent oil cleaning
• ZF-ECOFLUID M transmission 
oil (initial fill)
• Internal exhaust air chamber
Low-noise
• One central air connection
Reliable
© ZF Friedrichshafen AGInternalVisualisierung des TraXon 12.2, Stand: 19.03.2013
Ölversorgung TraXon / 
Oil supply TraXon
Ölführung Gehäuse
Oil conduit housing
Ansaugung im Ölsumpf
Oil suction in the sump
© ZF Friedrichshafen AGInternalVisualisierung des TraXon12.2, Stand: 19.03.2013
Saugfilter
Suction filter
Ölführung Gehäuse
Oil conduit housing
Ölversorgung TraXon / 
Oil supply TraXon
© ZF Friedrichshafen AGInternalVisualisierung des TraXon 12.2, Stand: 19.03.2013
Pumpe
pump
Saugkanal
Suction channel
Druckkanal
Pressure channel
Ölführung Gehäuse
Oil conduit housing
Ölversorgung TraXon / 
Oil supply TraXon
© ZF Friedrichshafen AGInternal
Ölversorgung / Oil supply
Vorstellung TraXon, 19.03.2013
breitere Pumpe
broadened pump
Druckölfilter
Pressure oil filter
Spritzrohrdichtungen
Seal for injection pipe 
Zwangsschmierung 
VGW Lager
Lubrication Countershaft bearing
95% Ölvolumen durch 
den by-pass
95% of the oil volume
will pass the by-pass
Drucköl
Pressure oil
Druckfilter
Pressure filter
Ölführung Gehäuse
Oil conduit housing Übergabe Wärmetauscher (optional)
Transfer to oil cooler (option)
© ZF Friedrichshafen AGInternalVisualisierung des TraXon 12.2, Stand: 19.03.2013
Spritzrohr PTO
Spray tube to PTO
Ölführung Gehäuse
Oil conduit housing
Ölversorgung TraXon / 
Oil supply TraXon
Dichtung für Spritzrohr 
Sealing for spray tube
© ZF Friedrichshafen AGInternal
Daten
Data
Wert
/ Value
Betriebsdruck max. Kuehlmittel.
Operation pressure max. coolant. 4 bar
Betriebsdruck max. öl. 
Operation pressure max. oil. 5 bar
Kuehlmittel volumen
Coolant volume 0,220 L
Ölvolumen
Oil Volume 0,320 L
Volumenstrom Öl
Flow rate oil 26 L/min
Volumenstrom Kuehlmittel
Flow rate coolant 20 L/min
Exchanger Heat Technical Data
© ZF Friedrichshafen AGInternal 65
© ZF Friedrichshafen AGInternal 66
© ZF Friedrichshafen AGInternal
Variant 12.1 and 12.2
67
Kurzer Lagerträger 12.1
Short bearing carrier 12.1 
langerLagerträger 12.2
Long bearing carrier 12.2 & 16 
21,15 53,15
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Getriebesteuerung (Knorr Bremse)
Transmission Control (Knorr Bremse)
Getriebesteuerung / 
Transmission control
© ZF Friedrichshafen AGInternal
Anschlüsse / Bauteile der Getriebesteuerung
Connectors / Parts of Transmission Control
Ventilblock / Valve block
Sensormodul / Sensor module
Wählaktuator / Selction module
Kabel Drehzahlgeber / Wiring speed sensor
Anschluss Fahrzeug / Connector vehicle
Verschluss Entlüftung Conact / Cover Conact bleeding
ECU mit Neigungssensor / ECU incl. inclination sensor
Druckausgleich / pressure balance
© ZF Friedrichshafen AGInternal
Funktion Neigungssensor
Function of inclination sensor
Feste Platten links und rechts.
Federnd gelagerte Platte in der Mitte.
Diese Platte schwingt als gefederte Masse nach 
links oder rechts (je nach Neigung).
Fixed panels on the left and right side.
Spring loaded panel in the middle.
This plate swings as spring loaded mass to the left
or right side (depends on the inclination)
Das Feder-Masse-System ist mikromechanisch 
integriert und als Chip auf der Leiterplatte des 
Steuergerätes eingelötet
The spring mass system is micromechanical
integrated and placed on the circuit board as a chip.
© ZF Friedrichshafen AGInternal
Mit Änderung des Abstandes der Platten ändern sich die Kapazitäten welche
mittels der Elektronik erfasst werden. Somit kann die jeweilige Neigung erkannt 
werden.
By changing the distance of the panels the capacity changes which is detected
by the electronics. Thus, the respective inclination can be recognized.
Funktion Neigungssensor
Function of inclination sensor
© ZF Friedrichshafen AGInternal
Druckausgleichselement
Pressure balance element
Druckanpassung an 
abgedichtenen Raum 
mittels Druck-
ausgleichselement.
Pressure adjustment of
sealed area by pressure
balance element.
Abgedichteter Raum
Sealed area
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Conact (ZF Sachs)
Conact (ZF Sachs)
© ZF Friedrichshafen AGInternal
Daten
Data
Wert
/ Value
Pneumatischer Querschnitt des Zylinders
/ pneumatic cylinder cross section
23910 mm²
Maximaler Arbeitsdruck 
/ max. working pressure
13,5 bar
Arbeitsmedium
/ working agent
Fahrzeugdruckluft
/ compressed air from vehicle
Berstdruck
/ Bursting pressure
20 bar
Maximaler Hub 
/ max. travel
38 mm
Sensorversorgungsspannung 
/ Sensor power supply
5V
Hersteller
/Manufacturer
ZF Sachs
Conact Technische Daten
Conact Technical Data
© ZF Friedrichshafen AGInternal
Pin 
Term
Bezeichnung
Description
Aderfarbe
Strand colour
1 AU2
Versorgung Kupplungswegsensor
Sensor power supply
Weiss
white
2 SD1
Signal Kupplungswegsensor
Signal sensor
Gelb
yellow
3 VMG1
Masse Kupplungswegsensor
Ground sensor
Schwarz
black
Conact Sensor
Conact Sensor
© ZF Friedrichshafen AGInternal
Conact
Conact
Ausrücklager
/release bearing
Gehäuse
/housing
Vorlastfeder
/preload spring
Druckraum
/pressure area
Kolben
/piston
© ZF Friedrichshafen AGInternal
Wirkweise Kupplung gezogene Kupplung (AS2)
Clutch Action Mode pulled clutch (AS2)
Gedrückte Kupplung (TraXon)
pressed clutch (TraXon)
Gezogene Kupplung (AS2) 
pulled clutch (AS2)
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Wählaktuator (MSM)
Selector Actuator (MSM)
© ZF Friedrichshafen AGInternal
Pin 
Term
Bezeichnung
Description
1 und 3
Plus (+) auf Pin 1; Minus (-) auf Pin 3: Bewegung in Richtung (+)
Minus (-) auf Pin 1; Plus (+) auf Pin 3: Bewegung in Richtung (-)
Plus (+) on term 1; Minus (-) on term 3: movement in direction (+)
Minus (-) on term 1; Plus (+) on term 3: movement in direction (-)
2
Brücke zur Positionsberechnung
Bridge for travel calculation
Wählaktuator (12-Gang)
Selection actuator (12-speed)
(+
)
(-)
© ZF Friedrichshafen AGInternal
Bewegen /move:Halten /hold:
Halten durch Permanentmagneten realisiert ➔ Kein Strom benötigt
„Hold“: realised due to permanent magnetic flux: => no current
needed
Bewegung: Spulen & Permanentmagnet ➔ Höhere Kräfte
„Move“: Implemented due to permanent magnetic & coil flux: => 
Higher forces generated
Fluß Permanentmagnet
Permanent magnetic flux Spulenfluß
Coil flux
N
S
N
S
N
S
N
S
F F
S S S S
Wählaktuator (12-Gang)
Selector Actuator (12-speed)
© ZF Friedrichshafen AGInternal
Wählaktuator (16-Gang)
Selection actuator (16-speed)
(+)(-)
Pin 
Term
Bezeichnung
Description
1, 2, 3 und 4
Minus (-) auf Pin 1; Plus (+) auf Pin 3, 2 und 4 gemeinsam: Bewegung in Richtung (+)
Plus (+) auf Pin 1; Minus (-) auf Pin 3, 2 und 4 gemeinsam: Bewegung in Richtung (-)
Plus (+) auf Pin 4; Minus (-) auf Pin 1, 2 und 3 gemeinsam: Bewegung in Richtung Mitte
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Sensormodul (Knorr Bremse)
Sensor Module (Knorr Bremse)
© ZF Friedrichshafen AGInternal
Position
Position
Wert
/ Value
1
Sensor (PLCD) Nachschaltgruppe (GP)
Sensor (PLCD) range (GP)
2
Sensor (PLCD) Vorschaltgruppe (GV)Sensor (PLCD) splitter (GV)
3
Sensor (PLCD) Hauptgetriebe (HG)
Sensor (PLCD) Gear (HG)
4
Temperatursensor / Drehzahlsensor
Temperatur sensor / Speed sensor
Sensormodul
Sensor Module
1 2 3
4
123
4
© ZF Friedrichshafen AGInternal
Sensormodul Anschluss
Sensor Modul Connector
Pin
Term
Beschreibung
/ Description
1
Frequenz Drehzahlgeber
Frequency speed sensor
2
Signal Temperatursensor
Signal temperature sensor
3
Spannungsversorgung 5V (GV,GP, HG, Temperatur)
Power supply 5V (GV, GP, HG, temperature)
4
Ausgang Signal Digital Vorschaltgruppe (GV)
Output signal digital splitter (GV)
5
Ausgang Signal Digital Nachschaltgruppe (GP)
Output signal digital range (GP)
6
Sensormasse (GV, GP, HG)
Ground sensors (GV, GP, HG)
7
Ausgang Signal Digital Schalten (HG)
Output signal digital gearshift (HG)
8
Spannungsversorgung 8 – 10V (Drehzahlgeber)
Power supply 8 – 10V (speed sensor)
© ZF Friedrichshafen AGInternal
Ausgleich Abstand Drehzahlsensor
Compensation of different distance (speed sensor)
Because of the distance to the impulse wheel and in 
relationship to the two transmission housings, there is a 
difference, this is within the speed sensor module. This 
sensor is loosely attached. This allows for automatic
adjustment of the speed sensor.
Speedsensor:
Sensor positon onto the layshaft.
TCU calculates the inputshaft speed.
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Ventilmodul
Valve Module
© ZF Friedrichshafen AGInternal
Ventil
/ 
Valve
Beschreibung Description
Y1 Getriebebremse Einlass Transmission Brake (Input)
Y2 Vorschaltgruppe (GV) K2 Splittergroup (GV) K2
Y3 Vorschaltgruppe (GV) K1 Splittergroup (GV) K1
Y6 Schalten (HG) R/2 Gear (HG) R/2
Y7 Schalten (HG) 1/3 Gear (HG) 1/3
Y8 Nachschaltgruppe (GPL) Langsam Range (GPL) slow
Y9 Nachschaltgruppe (GPS) Schnell Range (GP) fast
Y10 Hauptabschaltventil2 (HAV2) Main cut valve2 (HAV2)
Y11 Hauptabschaltventil1 (HAV1) Main cut valve2 (HAV1)
Y12 Getriebebremse Auslass Transmission Brake (Output)
Y14 Kupplung schließen (groß) Clutch close (fast)
Y15 Kupplung schließen (klein) Clutch close (slow)
Y16 Kupplung Öffnen (groß) Clutch open (fast)
Y17 Kupplung Öffnen (klein) Clutch open (slow)
Ventilbezeichnungen
Valve description
Bemerkung:
Ventilbezeichnungen sind an AS2 
orientiert. Daher ist Y4/5 sowie Y13 
nicht belegt.
Note:
Valve description is mirrored to the
AS2 application.
Other than the Y4/5 and Y13 are not 
assigned!
© ZF Friedrichshafen AGInternal
Pin / Term Beschreibung 
/ Description
Pin / Term Beschreibung 
/ Description
1 (+) Y12 17 (-) Y15
2 (-) 18 (+) Y8 / Y2
3 (+) Y7 / Y14
Y7 
19 (-) Y6
4 (-) 20 (-) Y2
5 (-) Y16 21 (+) Y6
6 (-) Y14 22 (+) Y15 / Y1
7 (-) Y3 23 (-) Y1
8 (+) Y16 24 (+)
Drucksensor / 
Pressure sensor
9 (+) Y9 / Y11 25 (-)
10 (+) Y3 26 Signal
11 (-) Y10
12 (-) Y11
13 (+) Y10 / Y17
14 (-) Y9
15 (-) Y17
16 (-) Y8
Ventilblock-Anschluss
Valve Block Connector
© ZF Friedrichshafen AGInternal
Y1
Y12
Y8 Y10 Y17Y2 Y15 Y6
Y9 Y11 Y3 Y16 Y14 Y7
Magnete Identifikation
Solenoids Identification
© ZF Friedrichshafen AGInternal
Ventilblock
Valve Block
© ZF Friedrichshafen AGInternal
Air Channel Supply
Luftversorgung
Air Supply
Druckluft Fahrzeug 
Pressure supply vehicle
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
© ZF Friedrichshafen AGInternal
Druckluft Fahrzeug 
Pressure supply vehicle
Pressure Sensor
Drucksensor
Drucksensor
Pressure Sensor
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
Druck steht an Drucksensor an
Pressure sensor is pressurized
© ZF Friedrichshafen AGInternal
Split
Vorschaltgruppe
Split Group - GV
Druckluft Fahrzeug 
Pressure supply vehicle
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
Y2: Schalten Vorschaltgruppe GV K2
Y2: Engage splitter GV K2
Y3: Schalten Vorschaltgruppe GV K1
Y3: Engage splitter GV K1
© ZF Friedrichshafen AGInternal
Range Group
Nachschaltgruppe
Range Group - GP
Druckluft Fahrzeug 
Pressure supply vehicle
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
Y8: Schalten Nachschaltgruppe GPL
Y8: Engage range GPL
Y9: Schalten Nachschaltgruppe GPS
Y9: Engage range GPS
© ZF Friedrichshafen AGInternal
Schaltung (HG)
Shift Group
Druckluft Fahrzeug 
Pressure supply vehicle
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
Y6: Schalten Hauptgetriebe R/2
Y6: Engage gear R/2
Y7: Schalten Hauptgetriebe 1/3
Y7: Engage gear 1/3
© ZF Friedrichshafen AGInternal
Schaltung (HG)
Shift Group
Y6+7: Schalten Hauptgetriebe N
Y6+7: Engage gear N
Druckluft Fahrzeug 
Pressure supply vehicle
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
© ZF Friedrichshafen AGInternal
Getriebebremse
Transmission Brake
Druckluft Fahrzeug 
Pressure supply vehicle
Y10 / Y11: Luftfreigabe
Y10 / Y11: Air release
Y1 : Aktivieren Getriebebremse
Y1 : Activate transmission brake
Y12 : Entlüften Getriebebremse
Y12 : Exhaust transmission brake
© ZF Friedrichshafen AGInternal
IN OUT
Kupplung (Conact)
Clutch (Conact)
Druckluft Fahrzeug 
Pressure supply vehicle
Y16 /17 : Kupplung öffnen
Y16 /17 : Open clutch
Y14 /15 : Kupplung schließen
Y14 /15 : Close clutch
© ZF Friedrichshafen AGInternal
Only proceed within this manual
process. Under emergency cases the
normal clutch bleeding must be
executed through the ZF Testman or
OEM Diagnosis tool.
Manuelles Kupplungsentlüftung
Manual Clutch Bleeding
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Entlüftung 3/2-Wege Ventile
Exhausting 3/2 Way Valve
Entlüftung GP
Exhausting Range (GP)
Entlüftung GV
Exhausting Splitter (GV)
Entlüftung HG
Exhausting Gear (HG)
© ZF Friedrichshafen AGInternal
Entlüftung 2/2-Wegeventil (NO; Getriebebremse)
Exhausting 2/2 Way Valve (NO; Transmission brake)
Entlüftung Getriebebremse
Exhausting transmission brake
© ZF Friedrichshafen AGInternal
Entlüftung 2/2-Wegeventil (NC; Conact)
Exhausting 2/2 Way Valve (NC; Conact)
Entlüftung Conact
Exhausting Conact
© ZF Friedrichshafen AGInternal
Entlüftung nach Aussen
Exhausting to Environment
Luft gelangt durch Nut in 
Anschlussplatte in den 
Zwischenraum zwischen 
Anschlussplatte und 
Gehäusedeckel
Air comes through the
groove into the
intermediate space between
connection plate and
housing cover
Luft tritt an den unten 
gelegenen Bohrungen im 
Kupplungsgehäuse aus
Air gets out at the holes in 
the connection plate on the
bottom side.
© ZF Friedrichshafen AGInternal
Entlüftung Getriebe
Breather Transmission
© ZF Friedrichshafen AGInternal
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
Conact
Wählaktuator / Selector Actuator
Sensormodul / Sensor Module
Ventilmodul / Valve Module
Entlüftung / Breathing
Getriebesteuerung / Transmission control
Software
FAQ
© ZF Friedrichshafen AGInternal
Softwarestruktur
Software Structure
Knorr Bootloader
OEM Bootloader
Flashfile Datenfeld EEprom
© ZF Friedrichshafen AGInternal © ZF Friedrichshafen AG2018-07-12 | Field Support | TraXon Training 115
ZF Friedrichshafen AG behält sich sämtliche Rechte an den gezeigten
technischen Informationen einschließlich der Rechte zur Hinterlegung von 
Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im
In- und Ausland vor.
ZF Friedrichshafen AG reserves all rights regarding the shown technical 
information including the right to file industrial property right applications and 
the industrial property rights resulting from these in Germany and abroad.
Thank you 
© ZF Friedrichshafen AGInternal
Risk of damage when fitting the transmission control unit
116
© ZF Friedrichshafen AGInternal
Riskof damage when fitting the transmission control unit
117