OPERATING INSTRUCTIONS

ZF synchromesh transmissions
16 S 151, 16 S 181
16 S 221, 16 S 251

1315 758 101e

Subject to alterations in design

Copyright by ZF

This document is protected by copyright. Any repro-

duction and dissemination in whatever form – even in adapted,
paraphrased or extracted form – in particular as a reprint, pho-
tomechanical or electronic reproduction or as storage in data
processing equipment or data networks without approval by
the holder of the copyright is prohibited and will be prosecuted
under civil and criminal law.

Printed in Germany

ZF Friedrichshafen AG, MKS-K / 1992

Edition: 10.2001
 Preface

Your vehicle is equipped with a synchromesh transmis- To ensure safe and reliable operation, please comply
sion of the ZF-ECOSPLIT model range. with all maintenance instructions. Skilled ZF After-
Sales Service personnel are available to maintain your
The more familiar you are with the Ecosplit transmis- transmission and to assist you with any problems.
sion, the more economically you will be able to drive
with it. These operating instructions inform you of how
to make the best use of the technical advantages of the We wish you safe and pleasant driving with your ZF
ZF transmission. Therefore, please carefully read these transmission
operating instructions and any special instructions
provided by the ZF Friedrichshafen AG
vehicle manufacturer before driving the vehicle for the Commercial Vehicles/Special Transmissions
first time. Division
D-88038 Friedrichshafen
Germany
Tel.: + 49 7541 77-0
Fax: + 49 7541 77-90 80 00
Internet: www.zf.com

1
Important safety information

The following safety instructions are used in this

operating manual:
! DANGER
Non-observance of safety instructions may lead to
operational errors, damage to or destruction of the
NOTE unit. As a consequence, operators or other persons
Refers to special processes, techniques, data, use of auxiliary may be injured or their life may be at risk.
equipment, etc.
! THREATS TO THE ENVIRONMENT!
CAUTION Lubricants and cleaning agents must not be allowed to
This is used when incorrect, unprofessional working prac- enter the soil, ground water or sewage system.
tices may damage the product. • 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.
! DANGER • Dispose of used oil, dirty filters, lubricants
This is used when lack of care may lead to and cleaning agents in accordance with
personal injury or death or damage to property. environmental protection guidelines.
• When working with lubricants and cleaning
agents, always refer to the manufacturer’s
instructions.

2
 Contents

Page Page

1 Technical data ....................................................... 4 3.8 Emergency operation ............................................... 19

3.9 Starting the vehicle at
2 Description sub-zero temperatures.............................................. 20
2.1 Design ..................................................................... 5 3.9.1 Parking the vehicle at sub-zero temperatures .......... 20
2.2 Configuration .......................................................... 5
2.3 Gearshift system ...................................................... 7 4 Maintenance
2.4 Servoshift................................................................. 9 4.1 Transmission oil....................................................... 21
2.5 Auxiliary units ......................................................... 9 4.1.1 Oil grades................................................................. 21
4.1.2 Oil fill quantities...................................................... 21
3 Operation 4.1.3 Oil change intervals ................................................. 21
3.1 Starting the engine and setting off........................... 10 4.2 Oil change................................................................ 22
3.2 Operating the clutch ................................................ 10 4.2.1 Draining off old oil ................................................. 22
3.3 Gear selection .......................................................... 11 4.2.2 Oil fill ...................................................................... 23
3.3.1 Shift pattern ............................................................. 11 4.3 Oil level check ......................................................... 23
3.3.2 Changing gear.......................................................... 13 4.4 Maintenance of transmission (version
3.3.3 Changing gear with servoshift................................. 15 with heat exchanger)................................................ 24
3.4 Engaging and disengaging PTOs............................. 16 4.5 Checking clutch operation ....................................... 25
3.4.1 Clutch-dependent PTOs........................................... 16 4.6 Checking release valve at the clutch pedal ............. 26
3.4.2 Engine-dependent PTOs .......................................... 17 4.7 Transmission breather.............................................. 27
3.5 Parking..................................................................... 17 4.8 Maintenance of the pneumatic system .................... 27
3.6 Tow-starting............................................................. 17 4.9 Type plate................................................................. 28
3.7 Towing away ............................................................ 18

3
Technical data

Model for standard drive

16 S 151 16 S 181 16 S 221 16 S 251
Input torque max. Nm 1) 1600 / 1850 1900 / 2200 2200 / 2500 2700
Ratios Forwards gears 16.41 - 1.00 / 13.80 - 0.84 13.80 - 0.84
Reverse gears 15.36 - 12.92 / 12.92 - 10.80 12.92 - 10.80
Speedometer electronic z=6
Installation2) Horizontal, to the left with integrated clutch bell housing
Gearshift 4-speed section Forwards gears with synchromesh, reverse gear with constant mesh
Range change and splitter group With synchromesh
Shift actuation 4-speed section Via horizontal turning shaft control 3) with double H shift pattern
or superimposed H shift pattern
Range change group4) Double H: changeover conducted automatically with appropriate selection
Superimposed H: changeover using preselection switch on shift lever
Splitter group4) Preselector valve on shift lever
Weight (without auxiliaries) approx. kg 289 315 319 334
Oil vol. for standard install. 5) approx. l 11 13 13 13,5
for oil change approx. l 8 10 10 11
Oil grade In accordance with the current ZF List of Lubricants TE-ML 02
1) Approximate value (depends on vehicle type and vehicle data as well as relevant application).
2) Here, the ZF Guidelines for installing manual transmissions (1203 765 110) should also be noted.
3) Turning shaft control connection can be adapted to the installation conditions in the vehicle.
4) Air pressure required = 6.2 to max. 10 bar; pressure red. valve (ZF no. 0501 204 036) must be fitted for higher pressure levels.
5) Transmission inclination 0 to 3°
4 1315 758 101e
 Description

2 Description Fig. 2 Double H shift pattern

2.1 Design

ZF-Ecosplit transmissions comprise a 4-speed section, a

range-change group and a splitter group.

2.2 Configuration

4-speed section: Selector pattern I Selector pattern II

• synchromesh, reverse gear with constant mesh
• manual shift control (turning shaft control)
• double H shift pattern or superimposed H shift pattern Automatic changeover (double H)
• Servoshift R Reverse gear
1-4 Low range-change group
Range change group, rear-mounted: 5-8 High range-change group
• synchromesh N Neutral
• automatic changeover (pneumatic) when shifting
between gates 3/4 and 5/6 or vice versa (Fig. 2)
with double H pattern
• changeover using preselector switch on shift
lever with superimposed H pattern (Fig. 3a)

Splitter group, front-mounted:

• synchromesh
• pneumatic changeover by preselector valve on
shift lever for (Fig. 3 and 3a), then actuating Selector pattern I Selector pattern II
clutch.
Fig. 2a Superimposed H shift pattern
1315 758 101e 5
Description

Fig. 3 Fig. 3a
Double-H * high Superimposed H *
shift lever shift lever
Range-change
group

high
low

high
high
tter
Spli
p
grou
Range-change
Splitter group group
low

7
low
low
7 N
5 8 3
3 5 8
N
6 N 4
N 1
1 4 6
2
2

R
R
* Please note vehicle manufacturer data

6 1315 758 101e


2.3 Gearshift system
Range-change group, double H shift pattern
The shift system is divided into 5 adjacent gates. There is
a spring-loaded neutral position in gates 3/4 and 5/6.
Unequal spring detent strengths mean that all
positions can be easily located in the shift pattern.
The pneumatic changeover of the range-change group is
performed automatically when shifting from gate 3/4 to
5/6 or vice versa.
Fig. 4
ZF double H shift pattern
1315 758 101e
Description
Range-change group, superimposed H shift pattern
The shift system is divided into 3 adjacent gates. There
is a spring-loaded neutral position in gates 3/4 and 7/8.
The pneumatic changeover of the range-change group
for gate 3/4 to 5/6 or vice versa is performed using a
preselector switch on the shift lever (Fig. 3a).
Fig. 4a
ZF superimposed H shift pattern
7
Description

The range-change group shift control system comprises Splitter group

a shift valve (35) and a double-action pneumatic cylin-
der (34) fitted in the transmission.
35
The splitter group is operated by means of a toggle
switch fitted to the shift lever (Fig. 3 and 3a). The low or
high splitter group is preselected by the driver using this
switch and shifted when the clutch is depressed.

NOTE
34 Changeover is performed when the clutch is fully
depressed.

Any gear can be split depending on the application

conditions of the vehicle.
Please also refer to vehicle manufacturer’s instructions.

017853

Fig. 5
34 Pneumatic cylinder
35 Shift valve

8 1315 758 101e

 Description

2.4 Servoshift 2.5 Auxiliary units

The Servoshift system consists of a mechanical-pneu- Depending on the vehicle configuration, the Ecosplit
matic control unit and a double-action transmission may be equipped with the following
pneumatic cylinder. auxiliary units (Fig. 7):

Shifting Ecosplit transmissions with Servoshift is per- Fig. 7

formed as described under 2.3 (Fig. 4 and 4a), but with + NMV
pneumatic support.
Clutch-dependent
Advantages are: • considerably shorter gear lever Vehicle-
PTOs
travel, WSK depen-
N1, N4 and N10
• reduced shift forces dent
PTO
Fig. 6 N ... PL

Integrated
ZF-Intarder
011359

Engine-
dependent
PTO
017083
NMV 221

1315 758 101e 9

Operation

3 Operation 3.1 Starting the engine and setting off

Follow the operating information provided below to • Apply the parking brake (to prevent the vehicle
drive economically and save fuel: from accidentally starting to move).
• Shift the transmission into neutral.
• Start the engine.
• Engage gear (preferably 1st gear to protect clutch)
15
• Release parking brake and gently engage clutch. Also
20
10
note manufacturer’s instructions.
25
• Drive in the medium engine
5
30 speed range.
!
rpm x 100
0
DANGER
• Drive in the highest possible When leaving the vehicle with the engine running,
gear. activate parking brake. This prevents undesired vehicle
rolling.

3.2 Operating the clutch

• React to traffic conditions • Always fully depress the clutch.

well in advance.
CAUTION
• Avoid unnecessary braking Changing gear when the clutch is not fully disengaged
and accelerating. causes additional wear to the synchronizers in the trans-
mission.

10 1315 758 101e

 Operation

3.3 Gear selection The gate for reverse gear is safeguarded by a spring-
loaded stop and requires a greater amount of force to
ZF-Ecosplit transmissions are synchromesh trans- overcome.
missions.
Synchronizers ensure that the meshing gears for the Unequal spring detent strengths mean that all positions
required gear are rotating at the correct speed and in the can be easily located in the shift pattern, i.e. the gates
correct direction before the gear is engaged. You can can be found easily.
therefore change gear quicker and more reliably:
7
• without double-declutching when changing up, “GP changeover” 5
8
• without blipping the throttle and double-declutching 3
N
when changing down, even when driving downhill N 6
1
and in difficult traffic situations. 4

2
3.3.1 Shift pattern
R
Double H
The double H shift pattern (Fig. 8) includes a spring-
loaded neutral position (idling position) in gates 3/4 (low Toggle switch up:
range-change group) and 5/6 (high range-change group). High splitter group (H)
In order to select gears 1/2 or 7/8, move the selector lever
against the spring force in the required direction and hold Toggle switch down:
the lever against this force when making the engagement Low splitter group (L)
stroke. The gear lever returns to the neutral position if 010876/017855
released in the central area. The slow range-change group
is separated with a stronger spring force (“GP Fig. 8 Shift lever with double H shift pattern and splitter lever
changeover”) than the high range-change group.
1315 758 101e 11
Operation

Superimposed H
The superimposed H shift pattern (Fig. 8a) has a spring- 7 N
loaded neutral position (idling position) in gates 3/4 3
(low range-change) and 7/8 (high range-change). 5 8
In order to select gears 1/2 or 5/6, move the 1 N
4
selector lever against the spring force in the required 6
direction and hold the lever against this force when 2
making the engagement stroke. The gear lever returns to
the neutral position if released in the central area. R

The reverse gate is fitted with a spring loaded stop

which must be overcome by deliberate effort.

Toggle switch up:

High splitter group (H)

Toggle switch down:

Low splitter group (L)(L)
010877/017857

Fig. 8a Shift lever with superimposed H shift patter and

splitter switch and range-change lever

12 1315 758 101e

 Operation

3.3.2 Changing gear NOTE

CAUTION
• To protect the transmission, always fully disengage the
clutch.
• To avoid causing severe damage to the transmission and
engine, only change down a gear if the vehicle has been
braked to below the maximum speed for the intended
gear.
When the transmission is cold, gearshifting requires
increased shift effort. If the range-change group does
not change over when changing down from gate 5/6 into
gate 3/4, slow your vehicle and engage the appropriate
gear at a lower speed
Fig. 9
002 694

• Move gear lever quickly but gently. This is particularly Changing gates
important when the transmission oil is cold. It is best when
to move the gear lever with the open palm of your upshifting
002 701

hand, as shown in Fig. 9. downshifting

• When engaging a gear, hold the selector lever against

the pressure point until the synchronization process is
complete and the gear is engaged.
Double H
• To move between gates 3/4 and 5/6, strike the gear
lever briefly with a palm of your hand, then moved
swiftly onwards into the desired gear (Fig. 9).
CAUTION
Changing between gates 5/6 and 3/4 at a vehicle speed of
more than approx. 28 km/h is not permitted.
A gate change causes the rear-mounted range-change
group synchromesh to switch ranges and at vehicle speeds
of more than approx. 28 km/h, this will result in premature
wear.

1315 758 101e 13

Operation

Superimposed H 7 N
The range-change shift is pre-selected on the switch on 3 high
5 8
the shift lever. If, for example, drivers want to shift from 1
N 4
4th gear in the basic trans- 6
mission into 5th gear, he must 2 Range-change group
R
• preselect the high group on the switch
• disengage the clutch low
017856/010877
• shift the transmission to neutral – the range-
Fig. 9a
change group then begins to change over
• select gate 1/2
Reverse gear
• shift the basic transmission into 1st gear – the range-
change group has in the meantime changed over to
CAUTION
high
Only engage reverse gear when the vehicle is at a standstill.
• engage clutch
• Reverse gear may only be selected or deselected
• leave preselection switch in selected group
when the clutch is open.
NOTE • The clutch should be disengaged at idling engine
Only actuate preselection switch if the range-change speed.
group is to be shifted directly afterwards.
• Only select reverse gear once the countershaft
has come to a standstill. If the countershaft is not
at a standstill, grating will occur when selecting
reverse gear.

14 1315 758 101e

 Operation

NOTE 3.3.3 Changing gears with Servoshift

Service life periods differ depending on the
operating mode and may be reduced by short initial Changing gears with Servoshift is performed as
synchromesh speed-matching, preferably of 1st gear. described under Section 3.3.2.

• Selecting and deselecting reverse gear. Grating when CAUTION

selecting reverse gear is not permissible. Permanent shifting at high manual shift forces may result
If necessary, lengthen waiting time before engagement in increased wear of synchronizer parts.
or investigate separating characteristics of clutch (refer
to Section 4.5). • Only perform shifts when the clutch is fully separated.

• Slowly engage clutch. NOTE

Should the Servoshift fail, shifting may be performed at
considerably raised manual shift force.

1315 758 101e 15

Operation

3.4 Engaging and disengaging PTOs
3.4.1 Clutch-dependent PTOs
Operation when the vehicle is stationary or
moving
Engaging / disengaging
• PTO may only be engaged or disengaged when the
clutch is open.
• Clutch disengagement should be conducted at idling
engine speed.
• Only engage PTO once countershaft has come to
standstill. If the countershaft is not at a standstill,
grating will occur when engaging the PTO.
NOTE
Service life periods differ depending on the operating
mode and may be reduced by short initial synchromesh
speed-matching, preferably of 1st gear.
• Selecting and deselecting PTO. Grating when
selecting the PTO is not permissible.
If necessary, lengthen waiting time before engagement
or investigate separating characteristics of clutch (refer
to Section 4.5).
• Slowly engage clutch.
CAUTION
• Gear changes are not permitted during PTO operation.
• If parking the vehicle for a long period of time (e.g.
overnight) always disengage the PTO.
Gear blocking (option)
Gear blocking is required if
• the PTO is engaged and the vehicle MUST not move
• during travel, PTO engagement must be prevented.

16 1315 758 101e

 Operation

3.4.2 Engine-dependent PTOs 3.5 Parking

This type of PTO is engaged regardless of the vehicle • Shift transmission into low range-change group
clutch. (1st - 4th gear).

• The PTO must always be engaged or disengaged when • Apply the parking brake.
the engine is running: For extra safety, engage a gear:
min. engine speed 600 rpm
max. engine speed 2000 rpm • Vehicle facing uphill: a forwards gear
• Engine-dependent PTOs can be operated when the
vehicle is moving or stationary. • Vehicle facing downhill: reverse gear

NOTE • Loaded vehicles should also be secured by placing

When engaging the PTO, the following engine speeds chocks under the wheels.
must not be exceeded:
2000 rpm for PTO ratio of 0.98
1300 rpm for PTO ratio of 1.55 3.6 Tow-starting
depending on the inertia and drag torque levels to be
engaged. Start the engine by towing with a gear engaged in the
high range-change group.
NOTE
Refer to operating manual 1315 758 150. CAUTION
To prevent damage inside the transmission, only tow-start
the vehicle in the high range-change group (gears 5-8).
Furthermore, the vehicle must not be tow-started in
reverse gear.

1315 758 101e 17

Operation

3.7 Towing away

[i axle]
Vehicles can only be towed away under the
following conditions: 8.0
Rdyn 0.5[m](e.g.275/80R22.5)
• vehicle fitted with emergency steering pump 7.0
Rdyn 0.6[m](e.g.F24)
• high range-change group selected, shift lever in
neutral position 6.0 Rdyn 0.4[m](e.g.245/70R19.5)
• max. towing distance 100 km
• the max. permissible towing speed has to be deter- 5.0
mined using the diagram shown (Fig. 10) and 4.0
depending on the axle ratio and tyre size.
3.0
NOTE
Always observe instructions provided by the 2.0
vehicle manufacturer. 10 15 20 25 30 35 40 45 50
V [km/h]
Fig. 10
CAUTION Example: iaxle= 6. Rdyn = 0.5 m
If any of the above conditions are not fulfilled, the prop- Towing speed according to diagram Vmax = 25 km/h
shaft must be disconnected at the rear axle the stub shafts
must be removed.
If there is reason to suspect that the transmission unit is NOTE
damaged, disconnect the propeller shaft at the rear shaft Observe the relevant national legislation relating to
or remove the stub shafts. max. towing speeds.

18 1315 758 101e

 Operation

3.8 Emergency operation 35

If a fault occurs when changing the range-change group

(e.g. when shifting up or down between gates 3/4 and 34
5/6), this may be due to one of the following reasons:

• damage to pipework in pneumatic system.

• shift valve (35) or shift cylinder (34) serving range-

change group is defective (condensate or contamina-
tion).

017083
NOTE
• Vehicle can then only be driven if the low range-
change group (1st – 4th gear) is engaged. Fig. 11
• If the high range-change group is engaged when the 34 Shift cylinder for range-change group
fault occurs, the vehicle must be towed away. 35 Shift valve for range-change group

1315 758 101e 19

Operation

3.9 Starting the vehicle at sub-zero temperatures 3.9.1 Parking the vehicle at sub-zero temperatures

The transmission is filled with oil in accordance with

ZF List of Lubricants TE-ML 02. At outside tempera- When parking the vehicle at outdoor temperatures
tures of less than –15 °C, the suitability of the oil should below 0 °C, ensure that the low range-change group is
be checked in accordance with the List of Lubricants engaged in the transmission (shift lever in 1st gear
TE-ML 02. If necessary, change the oil in the transmis- position or neutral position in gate 3/4).
sion.
Alternatively, before starting the engine, heat up the oil.
This can be done, e.g. using warm air which must not
exceed 130 °C on the trans-
mission itself.

! DANGER
When leaving vehicle with engine running, activate
parking brake. This prevents undesired vehicle
rolling.

NOTE
• For engine starting and driving away, refer to
Section 3.1
• The vehicle manufacturer specifications MUST
be observed.

20 1315 758 101e

 Maintenance

4 Maintenance Oil quantity/ Transm. 16 S 151 16 S 181/221 16 S 251

Regular maintenance improves the operating safety and First fill l 11 13 13.5
reliability of the transmission. It is therefore particularly Oil changes l 8 10 11
important that compliance is maintained with the cor-
rect maintenance intervals.
Oil fill quantity for normal installation (0° – 3° inclination)

4.1 Transmission oil

4.1.1 Oil grades 4.1.3 Oil change interval

NOTE For oil change intervals, refer to ZF List of

• Only oils contained in the valid ZF List of Lubricants
TE-ML 02 are authorized for use in the transmission.
• The List of Lubricants can be obtained from all the ZF
After-Sales Service Centres or on the Internet under
www.zf.com.
Lubricants TE-ML 02.
NOTE
The oil change intervals indicated must be complied
with as the operating safety and reliability of the
transmission may otherwise be impaired.

4.1.2 Oil fill quantities

Fill the transmission with oil correctly in order to ensure

the precise oil quantity in the transmission (refer to
Section 4.2.2). The oil quantity is shown on the type
plate (fitted to side of transmission) and in the technical
data (Page 4).
Refer to Section 4.3 for instructions on checking the oil
level.
1315 758 101e 21
Maintenance

4.2 Oil change CAUTION

Oil must not be allowed to drain into the ground, into the
4.2.1 Draining off old oil water table or into the sewage system. Any excess oil must
be collected in an appropriate
container and properly disposed of in accordance with
environment regulations.

NOTE
Always change the oil after a long journey so that the
transmission oil is still warm and thin.

! DANGER
Contact with the transmission or the trans-
mission oil may lead to skin burns.

017850
• Unscrew oil drain plugs from transmission
2 (Fig. 12, items 1 and 2) and collect used oil in suitable
1
container.
Fig. 12
View from below, • Tighten the oil drain plugs (1) to the indicated torque.
1 Oil drain plug (60 Nm)
2 Oil drain plug with magnetic plugs (60 Nm) • Clean oil drain plug and magnetic plugs (2), replace
seal ring and tighten to the indicated torque.

22 1315 758 101e

 Maintenance

4.2.2 Oil fill 4.3 Oil level check

• Pour in the oil through the oil filler hole (Fig. 13).
! DANGER
• The oil level is correct when the oil reaches the lower Insufficient oil in the transmission causes
edge of the filler hole or when oil is already escaping damage. Risk of accident.
out of the oil filler hole.

Check the transmission oil level at regular

intervals:

• Check oil level with vehicle standing on level ground.

• Do not check oil level immediately after a journey (or

incorrect results will be obtained). Only check the oil
level after the oil in the transmission has cooled down
(<40 °C).

• Unscrew oil filler plug (Section 4.2.2).

017083
• If the oil level has fallen below the edge of the oil
filler hole, more oil must be added (Section 4.2.2).
Fig. 13
Position of oil filler hole and overflow measurement NOTE
Every time you check the oil, also check the
transmission for any oil leaks.

1315 758 101e 23

Maintenance

4.4 Transmission maintenance (version with heat • Check:

exchanger) - Allow engine to run at idling speed for approx.
3 minutes.
NOTE - Shift transmission into neutral.
Maintenance work relevant for the standard transmis- - Switch off engine.
sion version should be carried out. - Conduct oil level check has described under 4.3.

The following points should also be noted:

• Oil draining:
- Unscrew oil drain screw from heat exchanger.

• Oil filling:
- After the oil overflow test (Section 4.2.2), screw in
the oil fill hole screw.
Tightening torque = 60 Nm.
- Shift transmission into neutral.
- Allow engine to run at approx. 1200 rpm for around
2 - 3 minutes. This is required to ensure that the heat
exchanger and connection pipes are filled completely
with oil.
000 508
- Switch off engine. Fig. 14
- Again top up with oil until it overflows. Diagram: Ecosplit transmission with heat exchanger

24 1315 758 101e

 Maintenance

4.5 Checking clutch operation

To guarantee the service life and trouble-free operation

of the synchromesh system, it is absolutely essential
that the clutch disengages without any difficulties. This
is also important for operation of clutch-dependent
PTOs.

Perfect clutch disengagement can be checked as

follows:

• Allow the engine to run at idling speed and depress

clutch;

• After max. 20 sec. *, slowly engage reverse gear.

In the event of any “grating” noise from the

selector teeth (scraping noise from the shift dogs)
during this check, the clutch MUST be reset and/or
checked.

* Depending on mass of the flywheel and temperature

1315 758 101e 25

Maintenance

4.6 Checking the release valve at the clutch pedal a

b
c
The clutch must be fully disengaged before the splitter d
group is shifted by the release valve (37).

CAUTION
The lock synchronizer may be irreparably damaged if the 17 37
splitter group is engaged and the release valve is incorrectly
set.

To check min. 1mm clearance 19

32
21
000 340
• The clutch must be set according to the vehicle
manufacturer’s instructions. Fig. 15
a “Clutch engaged” position
• The adjusting screw on the clutch pedal must be set b “Clutch fully disengaged” position
so that the release valve (37) is only activated in the c Overtravel range of clutch
overtravel range (c). d End stop
17 Master cylinder for hydraulic clutch operation
• The clutch is fully disengaged when in position (b) (to 19 From compressed air tanker
check this, see Section 4.5). There must be clearance 21 To clutch slave cylinder
of at least 1 mm between the release valve (37) and 32 To relay valve for splitter group
pedal stop screw in this position. 37 Release valve for splitter group

26 1315 758 101e

 Maintenance

4.7 Transmission breather 4.8 Maintenance of the pneumatic system

The transmission oil heats up during travel. This
causes overpressure in the transmission which must be
continually vented through a breather valve.
Check that this valve is always operating correctly. The
breather (Fig. 16) must be kept clean. Do not cover with
a cap.
All pneumatic systems suffer from a buildup of conden-
sate. Service the pneumatic system at regular intervals
to prevent condensate, rust and other impurities from the
compressed air tanks from entering the valves or shift
cylinders. The compressed air tanks must be drained
weekly. This should be done daily in winter.

NOTE
Drain the compressed air scrubber and water separator
when draining the compressed air tanks, unless these are
automatic units.

For this operation, observe the vehicle manufacturer’s

instructions.

017083
Fig. 16
Transmission breather valve

1315 758 101e 27

Maintenance

4.9 Type plate

The type plate contains the most important transmission

data. It is located on the left side of the transmission (in
direction of drive).

Please always quote the following information in the

event of queries or repairs:
1. Transmission parts list no.
2. Transmission type
3. Transmission serial no.

ECOSPLIT 16 S 181 2

1 1316 055 106 011356 3

XXXXXXX
16.41 - 1.0 IMP/U6.00

13 02
005001
Fig. 17
Sample type plate

28 1315 758 101e