Betriebsanleitung

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

ZF Synchromesh
Transmission
16 S 1620 TD, 16 S 1820 TO
16 S 1920 TD, 16 S 2220 TO
16 S 2220 TD, 16 S 2520 TO
16 S 2320 TD, 16 S 2723 TO
1341 758 101
Subject to alterations in design

Copyright by ZF

This documentation is protected by copyright. Any

reproduction or dissemination in whatever form which
does not comply fully with the intended purpose of this
documentation is prohibited without the consent of ZF
Friedrichshafen AG.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2006

Edition: 2006-02
 Preface

Your vehicle is fitted with a mechanical synchromesh

transmission from the ZF-ECOSPLIT range.

The more familiar you are with your ZF transmission, the

more cost-effectively 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 instruc-
tions, and any special instructions given by the vehicle
manufacturer, before driving the vehicle for the first time.

In order to ensure reliability in service, please note the

specifications governing maintenance. The ZF Customer
Service specialists are available to assist you in carrying
out maintenance work or to help if any other problems
arise.

Motoring pleasure with ZF transmissions is brought to you

by

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

1341 758 101 - 2006-02 3

Safety Instructions

The following safety instructions appear in this manual:
NOTE
Refers to special processes, techniques, 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.
! THREATS TO THE ENVIRONMENT!
Lubricants, consumables, 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
 Table of Contents

Page Page

1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . ......... 20

4.1 Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.1.1 Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.1.2 Oil Fill Quantity . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.1.3 Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Shift Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.2 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Auxiliary Power Units . . . . . . . . . . . . . . . . . . . . . 10 4.2.1 Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.3 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1 Starting Engine and Setting Off . . . . . . . . . . . . . 11 4.4 Transmission Maintenance for Version With
3.2 Actuating the Clutch . . . . . . . . . . . . . . . . . . . . . . 11 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Shifting of Transmission . . . . . . . . . . . . . . . . . . . 12 4.5 Checking the Clutch . . . . . . . . . . . . . . . . . . . . . . 24
3.3.1 Transmission Shift Pattern . . . . . . . . . . . . . . . . . 12 4.6 Check of the Release Valve on Clutch Pedal . . . 25
3.3.2 Selecting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.7 Bleeding the Transmission . . . . . . . . . . . . . . . . . 26
3.4 Engaging the PTOs . . . . . . . . . . . . . . . . . . . . . . . 15 4.8 Pneumatic System Maintenance . . . . . . . . . . . . 27
3.4.1 Clutch-Dependent PTOs . . . . . . . . . . . . . . . . . . . 15 4.9 Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4.2 Engine-Dependent PTOs . . . . . . . . . . . . . . . . . . . 16
3.5 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Tow Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Limp Home Operation . . . . . . . . . . . . . . . . . . . . 18
3.9 Starting Up the Vehicle at Low Temperatures . . 19
3.9.1 Parking Vehicle at Low Temperatures . . . . . . . . 19

1341 758 101 - 2006-02 5

Technical Data

1 Technical Data
Model for standard drive
Direct drive 16 S 1620 TD 16 S 1920 TD 16 S 2220 TD 16 S 2320 TD
Overdrive 16 S 1820 TO 16 S 2220 TO 16 S 2520 TO 16 S 2723 TO
Input torque max. Nm 1) 1600 / 1850 1900 / 2200 2200 / 2500 2300 2700
Ratios Forwards gears TD = 16.41 - 1.00 TO = 13.80 - 0.84
R gears TD = 15.36 - 12.92 TO = 12.92 -10.80
Speedometer electronic z=6
Installation2) Horizontal, to the left with integrated clutch bell housing
Shift system 4-speed chapter Forwards gears synchronized, reverse gear with constant mesh
Range change / splitter groups Synchronized
Shift actuation 4-speed chapter Via horizontal turning shaft control 3) with superimposed H shift pattern
Range change group4) Superimposed H: Changeover using preselector switch on shift lever
Splitter group4) Preselector valve fitted on the shift lever
Weight (no extra equipment) approx. kg 289 315 319 334
Oil volume standard install.5) approx. l 11 13 13 13.5
when changing oil approx. l 8 10 10 11
Oil grade According to relevant ZF List of Lubricants, TE-ML 02
1) Approximate value (depends on type of vehicle and vehicle data as well as the prevailing operating conditions).
2) Observe the ZF guidelines for installing mechanical transmissions (1203 765 110) for this point.
3) The turning shaft control connection can be adapted to most installation circumstances encountered in vehicles.
4) For air pressure required, refer to the ZF guidelines for installing mechanical transmissions (1203 765 110)
5) Transmission inclination of between 0 and 3°
1341 758 101 - 2006-02 6
 Description

2 Description
Shift pattern I
5 7
2.1 Setup 1 3

The ZF-NewEcosplit transmission consists of a 4-speed

section, a range change group, and a splitter group. N

2 4
R 6 8
2.2 Version
027415
4-speed chapter:
• Synchronized, reverse gear with constant mesh
• Mechanical actuation (turning shaft control) Fig. 1
• Superimposed H shift mechanism Superimposed H shift pattern
• Servoshift
R Reverse gear
Range change group, rear-mounted: 1-4 Low range change group
• Synchronized 5-8 High range change group
• Changeover with preselector switch on shift lever with N Neutral position
superimposed H shift pattern (Fig. 2)

Splitter group, upstream:

• Synchronized
• Pneumatic changeover via preselector valve on the shift
lever (Fig. 2) and then engage clutch.

1341 758 101 - 2006-02 7

Description

2.3 Shift Actuation

7
Range-Change Group Superimposed H Shift
5
3 N Mechanism
1
N 8 The shift mechanism is divided into 3 adjacent gates.
6 In gates 3/4 and 7/8, there is a spring-loaded return to
4
Neutral function.
2
The pneumatic changeover of the range change group
R
high from gate 3/4 to gate 5/6 and vice versa is performed by a
preselector switch on the shift lever (Fig. 2).

high splitter group 5 7

1 3

range change group low N

2 4
low 027416_en R 6 8

027415
Fig. 2
Shift lever * superimposed H Fig. 3
The ZF superimposed H-shift shift mechanism

* Please note any details provided by the vehicle manufacturer.

1341 758 101 - 2006-02 8

 Description

Control of the range change group shift function compris-
es a shift module (35) and the dual-action pneumatic
cylinder in the transmission (34).
35 34
Splitter group
The splitter group is shifted using a switch fitted on the
shift lever (Fig. 2). The driver uses this switch to preselect
the splitter group for low or high and then releases it by
depressing the clutch pedal.
NOTE
Change over when the clutch is fully depressed.

Depending on the operating conditions under which the

vehicle is being driven, the driver can split any gear.
Please also note any details provided by the vehicle
manufacturer.

018971_1

Fig. 4
34 Pneumatic cylinder
35 Shift module

1341 758 101 - 2006-02 9

Description

2.4 Auxiliary Power Units

+ engine-dependent PTO

Depending on the vehicle version, the Ecosplit

transmissions can be fitted with the following auxiliary Clutch-dependent
power units (Fig. 5): PTOs
WSK
Drive- N1, N4 and N10
• Separate heat exchanger
for transmission oil cooling dependent
PTO
• Voith and Telma retarders N ... PL
can be fitted on request

Integrated
ZF-Intarder

011359

Engine-
dependent
PTO NMV 221

Fig. 5

1341 758 101 - 2006-02 10

 Operation

3 Operation 3.1 Starting Engine and Setting Off

Cost-effective driving with good fuel economy is assured • Apply parking brake (to prevent the vehicle from
when the following operating instructions are observed: starting to roll accidentally)
• Shift transmission into Neutral.
• Start engine.
• Select gear (preferably: 1st gear to conserve the clutch)
15
• Drive in the mid-speed range.
20
10 • Release parking brake and gently engage clutch.
25
• Use the highest gear available. Also observe information provided by the vehicle
5
rpm x 100
30 manufacturer.
0

! DANGER !
If ever you leave the vehicle with the engine still
running, first apply the parking brake. This prevents
the vehicle from starting to roll away accidentally.

• Anticipate traffic conditions.

• Avoid unnecessary use of the 3.2 Actuating the Clutch

brakes and the accelerator.
• Always fully depress the clutch pedal.

CAUTION
Selecting gears before the clutch has fully separated will
cause premature wear to the transmission synchronizer
unit.

1341 758 101 - 2006-02 11

Operation

3.3 Shifting of Transmission The gate for reverse gear is protected by a pawl stop and
requires more force to be applied.
The ZF-Ecosplit transmissions are synchronized
transmissions (synchromesh transmissions). A synchro-
7
mesh mechanism is one which enables all gears to rotate
in the same direction at synchronous speeds. This system 5 3 N
makes the shift process quicker and more reliable: 1
N 8
• No double-declutching during upshifts, 6
4
• No intermediate throttle application and no declutching 2
when shifting down, even when driving downhill and R
in difficult situations.

Switch at top:
3.3.1 Superimposed H Hi splitter group (H)

The superimposed H shift pattern (Fig. 6) has a spring-

Switch at bottom:
loaded return to neutral in gates 3/4 (low range) and 7/8 Lo splitter group (L)
(high range) (idle setting).
To select gates 1/2 and/or 5/6, the shift lever needs to be 027411
guided in the correct direction, then held against this Fig. 6
spring force while the gear change takes place. The Shift lever with super-imposed H shift pattern and splitter
selector lever jumps back to the neutral, when released switch and lever for range change group
from the mid-position of the gate.

1341 758 101 - 2006-02 12

 Operation

3.3.2 Selecting Gears • Must preselect high ratio (high range group) on the
selector switch
CAUTION • Depress the clutch pedal
• In order to prevent damage from occurring at the • Shift into neutral – at which point the range change
transmission’s synchronization, the clutch should group starts to change over
always be fully depressed. • Select gate 1/2
• During upshifts and downshifts, two gear steps may be • Shift the basic transmission into 1st gear - the range
shifted at maximum in one go (e.g. from 4L to 6L). change group will by now have shifted into high ratio.
Shifts encompassing more than two gear steps will lead • Engage the clutch
to wear at the transmission’s synchronization. • Leave preselector switch in selected range group
• To prevent transmission and engine damage, only select
the next lowest gear if the maximum speed of the
NOTE
intended gear is reached through deceleration.
Only actuate preselector switch if the range change group
• When operating the PTO, gear changes must never be
is to be engaged immediately afterwards.
undertaken (even changes between splitter groups)
because this will result in transmission synchronizer
unit wear. If a gear change may be required in order to
adapt the vehicle’s speed, then, the PTO must be 7
disengaged in advance. high
5
3 N
1
N 8
Superimposed H
6 splitter group
Changing the range change group is effected via a switch 4
at the shift lever. This means that the driver, if she/he 2
wishes to shift from 4th gear into the 5th gear in the basic R
transmission. low 027412_en

Fig. 7

1341 758 101 - 2006-02 13

Operation
CAUTION
Continuously selecting gears with a high level of manual
force will result in increased wear to the synchronizer
components.
CAUTION
In order to prevent damage from occurring at the trans-
mission’s synchronization, change-over to the low range
change group may only be effected as of speeds below
approx. 28 km/h. During travel, the other range group
may only be preselected just before carrying out the next
shift sequence. If the other range group is selected too
early, then, because of the swiftly changing traffic
conditions, unintended gear shifts may occur during the
next gear change and wear will consequently be caused at
the transmission’s synchronization.
1341 758 101 - 2006-02
Reverse gear
CAUTION
Only select reverse gear when the vehicle is stationary.
• Reverse gear may only be engaged and disengaged
when the clutch is open!
• The clutch should be disengaged when the engine is at
idling speed.
• Only engage reverse gear once the countershaft has
come to a complete stop. If the countershaft is not
stationary, grating will be heard when engaging the
reverse gear.
NOTE
Depending on operating conditions, retardation times will
differ and can be shortened by brief initial synchromesh
engagement, preferably of 1st gear.
• Engage and disengage reverse gear. No grating is
permitted when engaging the reverse gear.
If necessary, extend the waiting time leading to engage-
ment or investigate the separating characteristics of the
clutch (also refer to chapter 4.5).
• Slowly engage clutch.
14

3.4 Engaging the PTOs
3.4.1 Clutch-Dependent PTOs
Operation with vehicle in stationary position and in
motion.
Engagement / Disengagement
• PTO may only be engaged and disengaged when the
clutch is open!
• The clutch should be disengaged when the engine is at
idling speed.
• Only engage PTO once the countershaft has come to a
complete stop. If the countershaft is not stationary,
grating will be heard when engaging the PTO.
NOTE
Depending on operating conditions, retardation times will
differ and can be shortened by brief initial synchromesh
engagement, preferably of 1st gear.
1341 758 101 - 2006-02
Operation
• Engage and disengage PTO. No grating is permitted
when engaging the PTO.
If necessary, extend the waiting time leading to
engagement or investigate the separating characteristics
of the clutch (also refer to chapter 4.5).
• Slowly engage the clutch and increase the speed to
operating speed.
CAUTION
• Gear changes are not permissible when operating the
PTO.
• If the vehicle is parked for an extended period (e.g.
over night), the PTO should always be disengaged.
Gear Interlock (Option)
The gear interlock function becomes necessary if
• the vehicle must not be moved at all while the PTO
engaged,
• PTO engagement must be prevented while vehicle is in
motion.
15
Operation

3.4.2 Engine-Dependent PTOs 3.5 Parking

Activation is not dependent on the vehicle clutch. • Shift transmission into low range change group
(gears 1 - 4).
• Only engage or disengage when the engine is running:
min. engine speed 600 rpm • Close parking brake.
max. engine speed 2000 rpm Select gear as additional parking protection:
• The engine-dependent PTO can be operated when the
vehicle is stationary and in motion. • Vehicle facing uphill: Forward gear!

NOTE • Vehicle facing downhill: Reverse gear!

The following engine speeds must not be exceeded when
engaging the engine-dependent PTO: • Heavily laden vehicles should also be secured by
2000 rpm at engine-dependent PTO ratio of 0.98 placing chocks under the wheels.
1300 rpm at engine-dependent PTO ratio of 1.55
depending on the inertia and drag torque to be shifted.
3.6 Tow Starting
NOTE
Refer to Operating Manual 1315 758 150. Start engine by tow starting in the high range change
group.

CAUTION
• To avoid damaging the transmission, the vehicle may
only be tow started in the high range change group
(gears 5 - 8).
• The vehicle must also not be tow started with reverse
gear selected.

1341 758 101 - 2006-02 16

 Operation

3.7 Towing [i Axle]

8.0
Vehicles may only be towed under the following Rdyn 0.5 [m] (z.B. 275/80R22.5)
conditions: 7.0
Rdyn 0.6 [m] (z.B. F24)
6.0
• Emergency steering pump fitted Rdyn 0.4 [m] (z.B. 245/70R19.5)
• High range selected, shift lever in neutral position 5.0
• Towing distance of max. 100 km
4.0
• The max. permissible towing speed should be defined
depending on axle ratio and tire size using the diagram 3.0
provided (also refer to Fig. 8).
2.0
10 15 20 25 30 35 40 45 50
NOTE
V [km/h]
Vehicle manufacturer specifications MUST be observed.
027279_en

CAUTION Fig. 8
If one of the aforementioned conditions is not satisfied, Example (reading): iAxle = 6, Rdyn = 0.5 m
the propshaft must always be deflanged from the rear Towing speed from diagram:
axle or the stub shafts must be removed in order to Vmax = 25 km/h
prevent transmission damage from occurring.
If you suspect transmission damage, the propshaft must
also be deflanged from the rear axle or the stub shafts NOTE
must be removed. Relevant local legislation relating to max. towing speeds
must be observed.

1341 758 101 - 2006-02 17

Operation

3.8 Limp Home Operation

Faults occurring when changing the range change group

35 34
(e.g. from gate 3/4 into 5/6 or vice versa) may be due to
one of the following:

• Line damage in the pneumatic system.

• Shift module (35) and/or shift cylinder (34) for the

range change group defective (build up of condensate or
dirt).

NOTE
018971_1
• Further travel only possible if the low range change
group (gears 1 - 4) is selected.
• If the high range change group remains selected, the Fig. 9
vehicle will have to be towed. 34 Shift cylinder for the range change group
35 Shift module for the range change group

3.8.1 Servoshift

If the Servoshift fails, the transmission can still change

gear, but much more force now has to be applied for each
shift action.

1341 758 101 - 2006-02 18

 Operation

3.9 Starting Up Vehicle at Low Temperatures 3.9.1 Parking Vehicle at Low Temperatures

The transmission is filled with oil according to ZF List of

Lubricants TE-ML 02. At outside temperatures of less than When parking the vehicle at outside temperatures of less
–15 °C, the suitability of the oil should be checked than 0 °C, ensure that the low range change group is
according to List of Lubricants TE-ML 02. If necessary, selected in the transmission (shift lever in position for
change the oil type in the transmission. 1st gear or in neutral position for gate 3/4).
Alternatively, it can be preheated before the engine is
started. This can be done e.g. with warm air which must
not exceed 130 °C on the transmission.

! DANGER
When exiting the vehicle with the engine running,
apply the parking brake. This prevents the vehicle
from starting to roll away accidentally.

NOTE
• Refer to chapter 3.1 for starting the engine and setting
off.
• Vehicle manufacturer specifications MUST be observed.

1341 758 101 - 2006-02 19

Maintenance

4 Maintenance Oil quantity/Transm. 16 S 1620 TD 16 S 1920 TD 16 AS … TO

Regular maintenance increases the transmission’s 16 S 1820 TO 16 S 2220 TO

operational reliability. It is therefore particularly 16 S 2220 TD
important for the maintenance intervals to be observed.
16 S 2520 TO

16 S 2320 TD
4.1 Transmission Oil
At initial fill 11 13 13.5
4.1.1 Oil Grade
Oil changes. approx. 08 10 11.0

NOTE Fill volumes in dm3 for normal installation (0° - 3° inclination)

• When filling transmissions, only those oils specified in
the latest version of the ZF List of Lubricants TE-ML 02
are authorized.
• The List of Lubricants can be obtained from all ZF 4.1.3 Oil Change Interval
Service Centers or can be downloaded from the Inter-
net at www.zf.com. Refer to ZF lists of lubricants for oil change intervals
• We recommend that you use ZF-Ecofluid M. TE-ML 02.

NOTE
4.1.2 Oil Fill Quantity
To ensure that the transmission achieves the required
level of operational safety and reliability, the oil change
Correctly undertaking the oil fill process is crucial for
intervals must be observed as specified.
ensuring the precise oil volume (refer to chapter 4.2.2).
The fill quantity is shown on the type plate (fitted on the
side of the transmission) and in the Technical Data (page 6).

Oil level check (refer to chapter 4.3).

1341 758 101 - 2006-02 20

 Maintenance

4.2 Oil Change CAUTION

Oil must not be allowed to enter the soil, ground water,
4.2.1 Draining Oil or sewage system. Collect overflowing oil in a suitable
container and dispose of in accordance with
environmental guidelines.

NOTE
Basics: Change the oil after a long journey while the
transmission oil is still thin and at operating temperature.

! DANGER
Touching the hot transmission and transmission oil
may result in burns!

• Unscrew oil drain plug from transmission

017850
(Fig. 10, pos. 1 and 2) and collect used oil in a suitable
2 1 container.

Fig. 10 • Clean oil drain plug (1), replace sealing ring and tighten
View from below, to specified torque.
1 Drain plug (60 Nm)
2 Oil drain plug with magnetic plug (60 Nm) • Clean oil drain plug with magnetic plug (2) replace
sealing ring, and tighten to specified torque.

1341 758 101 - 2006-02 21

Maintenance

4.2.2 Oil Filling 4.3 Oil Level Check

• Top up oil through oil filler aperture (Fig. 11).

! DANGER !
• The oil level is correct when it has reached the bottom Too little oil in the transmission will result in
edge of the filler hole and/or when oil is already transmission damage. Risk of accident!
escaping out of the filler hole.

Check the transmission oil level at regular intervals:

• Check oil level when vehicle is on horizontal ground.

• Do not undertake the oil level check right after travel

(this will produce an incorrect measurement). Only
undertake the check once the transmission oil has
cooled down (<40 °C).

• Unscrew and remove the oil filler plug (chapter 4.2.2).

• If the oil level has fallen below the oil filler hole, the oil
018971_2
must be topped up (refer to chapter 4.2.2).

Fig. 11 NOTE
Position of the oil filler bore and overflow measurement Whenever checking the oil level, also check the manual
transmission for seal integrity.

1341 758 101 - 2006-02 22

 Maintenance

4.4 Transmission Maintenance for Version with Heat • Check:

Exchanger - Let engine run at idle speed for approx. 3 minutes.
- Shift transmission into Neutral.
- Switch off engine.
NOTE - Undertake oil level check as described in chapter 4.3.
Maintenance work should be carried out as specified for
the standard transmission version.

The following points should also be noted here:

• Draining the oil:

- Unscrew oil drain plug from heat exchanger (as far as
available).

• Oil fill:
- After the oil overflow check (chapter 4.2.2), screw in oil
filler hole screw.
Tightening torque = 60 Nm.
- Shift transmission into Neutral.
- Idle engine at approx. 1200 rpm for around 2 - 3 minutes. 000 508
This must be done so that the heat exchanger and Fig. 12
connecting lines are filled completely with oil. Sketch: Ecosplit transmission with heat exchanger
- Switch off engine.
- Top up oil again until it overflows.

1341 758 101 - 2006-02 23

Maintenance

4.5 Checking the Clutch

In order to guarantee the service life and functional

efficiency of synchronizer units, it is essential that the
clutch separates perfectly. This also applies when
engaging fitted clutch-dependent PTOs.

You can check that the clutch is separating perfectly as

follows:

• Engine idling at operating temperature, depress clutch;

• After max. 20 sec.* slowly engage R gear.

Should you hear the selector teeth “grating” (scraping

noise of shift teeth), the clutch must be adjusted and/or
checked.

* Depending on the flywheel disk mass and temperature

1341 758 101 - 2006-02 24

 Maintenance

4.6 Check of the Release Valve on Clutch Pedal a

b
The clutch must be fully separated before the splitter c
group is engaged via the release valve (37). d

CAUTION
The synchronizer unit may be destroyed if the splitter
17 37
group is engaged with an incorrectly set release valve.

Check clearance of
19
at least 1 mm
32
• The clutch must be adjusted according to the 21 027413_en
manufacturer’s instructions.
Fig. 13
• Setting screw on clutch pedal must be set such that the a Position “Clutch closed”
release valve (37) is only activated in the excess travel b Position “Clutch fully separated”
range (c). c Clutch excess travel range
d End stop
• In position (b) the clutch is completely separated (for 17 Master cylinder for hydraulic clutch operation
checking see chapter 4.5). Ensure there is clearance 19 From pneumatic tank
between the release valve (37) and the operating device 21 To clutch slave cylinder
in the pedal position (clearance of at least 1 mm). 32 To splitter group relay valve
37 Splitter group release valve

1341 758 101 - 2006-02 25

Maintenance

4.7 Bleeding the Transmission 4.7.2 Hose Breather

The transmission oil heats up during travel. This results in
the formation of excess pressure which is continuously
removed via a bleed valve.
NOTE
Ventilation must be checked on the occasion of each
individual vehicle inspection.
Vehicles which require frequent cleaning should always
be equipped with a hose breather. Examples would be
milk collection vehicles, cement trucks etc.
The hose must be routed without any sharp bends or
chafing points. The end of the hose must terminate in a
dry area (e.g. in the engine compartment or in a chassis
cavity).

4.7.1 Vent

Ensure that the vent is fully functional at all times. The

vent must be clean and must not have its cover fitted. Do
not direct pressurized water directly at this valve (water in
the transmission: Risk of corrosion).

023684

018971_3
Fig. 14; Vent Fig. 15; Hose breather
1341 758 101 - 2006-02 26
 Maintenance

4.8 Pneumatic System Maintenance 4.9 Type Plate

Condensation builds up in all pneumatic systems. Regular
pneumatic system maintenance is essential to ensure that
condensation, rust, and other impurities do not pass from
the compressed air reservoirs into valves and gear change
cylinders.
The compressed air reservoirs must be drained once a
week (or daily in winter).
NOTE
When draining the compressed air reservoirs, the
compressed air cleaner and water separator should also be
drained if this doesn’t happen automatically.
The type plate contains the key data.
It is fitted on the left of the fitted transmission when
viewed in the direction of travel.
The following details must always be given when making
inquires or undertaking repairs:
1. Parts list no. of transmission
2. Type of transmission
3. Serial no. of transmission
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY

ECOSPLIT 16 S 1920 TD 2
Note the vehicle manufacturer’s details for this process. PARTS LIST NO. MODEL SERIAL NO.
1 1342 001 001 011356 3
CUSTOMER
SPEC. NOXXXXXXX
TOTAL SPEEDO
RATIO
16,41-1,0 RATIO IMP/U 6,0
P.T.O. N xn
n=
ENGINE
OIL CAPACIT OIL GRADE SEE
IN LITERS 13 LUBRIC. LIST TE-ML 02
027417

Fig. 16; Type plate (example)

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