Betriebsanleitung

Operating Instructions
Manuel dUtilisation
Manual de Servicio
Istruzioni per lUso

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 instructions, 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

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 manufacturers instructions.

Table of Contents
Page

Page
1

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2.1
2.2
2.3
2.4

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Power Units . . . . . . . . . . . . . . . . . . . . .

7
7
7
8
10

3
3.1
3.2
3.3
3.3.1
3.3.2
3.4
3.4.1
3.4.2
3.5
3.6
3.7
3.8
3.9
3.9.1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Engine and Setting Off . . . . . . . . . . . . .
Actuating the Clutch . . . . . . . . . . . . . . . . . . . . . .
Shifting of Transmission . . . . . . . . . . . . . . . . . . .
Transmission Shift Pattern . . . . . . . . . . . . . . . . .
Selecting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engaging the PTOs . . . . . . . . . . . . . . . . . . . . . . .
Clutch-Dependent PTOs . . . . . . . . . . . . . . . . . . .
Engine-Dependent PTOs . . . . . . . . . . . . . . . . . . .
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tow Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limp Home Operation . . . . . . . . . . . . . . . . . . . .
Starting Up the Vehicle at Low Temperatures . .
Parking Vehicle at Low Temperatures . . . . . . . .

11
11
11
12
12
13
15
15
16
16
16
17
18
19
19

1341 758 101 - 2006-02

4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . .........
Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Fill Quantity . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . .
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Maintenance for Version With
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Clutch . . . . . . . . . . . . . . . . . . . . . .
Check of the Release Valve on Clutch Pedal . . .
Bleeding the Transmission . . . . . . . . . . . . . . . . .
Pneumatic System Maintenance . . . . . . . . . . . .
Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20
20
20
20
20
21
21
22
22
23
24
25
26
27
27

Technical Data
1

Technical Data

Model

for standard drive

Direct drive 16 S 1620 TD

16 S 1920 TD

16 S 2220 TD

Overdrive 16 S 1820 TO

16 S 2220 TO

16 S 2520 TO

1900 / 2200

2200 / 2500

max. Nm 1)

Input torque
Ratios

1600 / 1850

Forwards gears
R gears

Speedometer

16 S 2723 TO
2300

TD = 16.41 - 1.00

TO = 13.80 - 0.84

TD = 15.36 - 12.92

TO = 12.92 -10.80

electronic

Installation2)

16 S 2320 TD
2700

z=6
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

4-speed chapter Via horizontal turning shaft control 3) with superimposed H shift pattern

Shift actuation

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)
Oil volume

289

315

319

334

approx. l

11

13

13

13.5

when changing oil approx. l

10

10

11

standard

Oil grade
1)
2)
3)
4)
5)

approx. kg

install.5)

According to relevant ZF List of Lubricants, TE-ML 02

Approximate value (depends on type of vehicle and vehicle data as well as the prevailing operating conditions).
Observe the ZF guidelines for installing mechanical transmissions (1203 765 110) for this point.
The turning shaft control connection can be adapted to most installation circumstances encountered in vehicles.
For air pressure required, refer to the ZF guidelines for installing mechanical transmissions (1203 765 110)
Transmission inclination of between 0 and 3

1341 758 101 - 2006-02

Description
2

Description

2.1

Setup

5
1

The ZF-NewEcosplit transmission consists of a 4-speed

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

2.2

Shift pattern I

Version

2
6

4
8
027415

4-speed chapter:
Synchronized, reverse gear with constant mesh
Mechanical actuation (turning shaft control)
Superimposed H shift mechanism
Servoshift

Fig. 1
Superimposed H shift pattern
R
1-4
5-8
N

Range change group, rear-mounted:

Synchronized
Changeover with preselector switch on shift lever with
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
3

Reverse gear
Low range change group
High range change group
Neutral position

Description
2.3
7
5

Range-Change Group Superimposed H Shift

Mechanism

N
6

The shift mechanism is divided into 3 adjacent gates.

In gates 3/4 and 7/8, there is a spring-loaded return to
Neutral function.
The pneumatic changeover of the range change group
from gate 3/4 to gate 5/6 and vice versa is performed by a
preselector switch on the shift lever (Fig. 2).

8
4

2
R

high

high

5
1

splitter group

range change group

low

Shift Actuation

7
3
N

low

027416_en

2
6

4
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

Description
Splitter group

Control of the range change group shift function comprises a shift module (35) and the dual-action pneumatic
cylinder in the transmission (34).

35

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.

34

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

Description
2.4

Auxiliary Power Units

+ engine-dependent PTO

Depending on the vehicle version, the Ecosplit

transmissions can be fitted with the following auxiliary
power units (Fig. 5):

WSK
Drivedependent
PTO
N ... PL

Separate heat exchanger

for transmission oil cooling
Voith and Telma retarders
can be fitted on request

Clutch-dependent
PTOs
N1, N4 and N10

Integrated
ZF-Intarder

011359

Enginedependent
PTO NMV 221

Fig. 5
1341 758 101 - 2006-02

10

Operation
3

Operation

3.1

Cost-effective driving with good fuel economy is assured

when the following operating instructions are observed:

15

25

5
0

rpm x 100

Apply parking brake (to prevent the vehicle from

starting to roll accidentally)
Shift transmission into Neutral.
Start engine.
Select gear (preferably: 1st gear to conserve the clutch)

Drive in the mid-speed range.

20

10

Starting Engine and Setting Off

Release parking brake and gently engage clutch.

Also observe information provided by the vehicle
manufacturer.

Use the highest gear available.

30

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.

3.2

Avoid unnecessary use of the

brakes and the accelerator.

Actuating the Clutch

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 synchromesh mechanism is one which enables all gears to rotate
in the same direction at synchronous speeds. This system
makes the shift process quicker and more reliable:

7
5

No double-declutching during upshifts,

No intermediate throttle application and no declutching

when shifting down, even when driving downhill and
in difficult situations.

Switch at top:
Hi splitter group (H)

3.3.1 Superimposed H
The superimposed H shift pattern (Fig. 6) has a springloaded return to neutral in gates 3/4 (low range) and 7/8
(high range) (idle setting).
To select gates 1/2 and/or 5/6, the shift lever needs to be
guided in the correct direction, then held against this
spring force while the gear change takes place. The
selector lever jumps back to the neutral, when released
from the mid-position of the gate.

1341 758 101 - 2006-02

Switch at bottom:
Lo splitter group (L)
027411

Fig. 6
Shift lever with super-imposed H shift pattern and splitter
switch and lever for range change group

12

Operation
3.3.2 Selecting Gears

Must preselect high ratio (high range group) on the

selector switch
Depress the clutch pedal
Shift into neutral at which point the range change
group starts to change over
Select gate 1/2
Shift the basic transmission into 1st gear - the range
change group will by now have shifted into high ratio.
Engage the clutch
Leave preselector switch in selected range group

CAUTION
In order to prevent damage from occurring at the
transmissions synchronization, the clutch should
always be fully depressed.
During upshifts and downshifts, two gear steps may be
shifted at maximum in one go (e.g. from 4L to 6L).
Shifts encompassing more than two gear steps will lead
to wear at the transmissions synchronization.
To prevent transmission and engine damage, only select
the next lowest gear if the maximum speed of the
intended gear is reached through deceleration.
When operating the PTO, gear changes must never be
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 vehicles speed, then, the PTO must be
disengaged in advance.

NOTE
Only actuate preselector switch if the range change group
is to be engaged immediately afterwards.

7
5

high
N

Superimposed H

Changing the range change group is effected via a switch

at the shift lever. This means that the driver, if she/he
wishes to shift from 4th gear into the 5th gear in the basic
transmission.

splitter group

2
R

Fig. 7

1341 758 101 - 2006-02

13

low

027412_en

Operation
CAUTION
Continuously selecting gears with a high level of manual
force will result in increased wear to the synchronizer
components.

Reverse gear

CAUTION
In order to prevent damage from occurring at the transmissions 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 transmissions synchronization.

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.

CAUTION
Only select reverse gear when the vehicle is stationary.

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 engagement or investigate the separating characteristics of the
clutch (also refer to chapter 4.5).
Slowly engage clutch.

1341 758 101 - 2006-02

14

Operation
3.4

Engaging the PTOs

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).

3.4.1 Clutch-Dependent PTOs

Operation with vehicle in stationary position and in
motion.

Slowly engage the clutch and increase the speed to

operating speed.

Engagement / Disengagement

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.

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.

Gear Interlock (Option)

NOTE
Depending on operating conditions, retardation times will
differ and can be shortened by brief initial synchromesh
engagement, preferably of 1st gear.

the vehicle must not be moved at all while the PTO

engaged,

1341 758 101 - 2006-02

The gear interlock function becomes necessary if

PTO engagement must be prevented while vehicle is in

motion.

15

Operation
3.4.2 Engine-Dependent PTOs

3.5

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
max. engine speed 2000 rpm
The engine-dependent PTO can be operated when the
vehicle is stationary and in motion.

Parking

Close parking brake.

Select gear as additional parking protection:

NOTE
The following engine speeds must not be exceeded when
engaging the engine-dependent PTO:
2000 rpm at engine-dependent PTO ratio of 0.98
1300 rpm at engine-dependent PTO ratio of 1.55
depending on the inertia and drag torque to be shifted.

Vehicle facing uphill:

Forward gear!

Vehicle facing downhill:

Reverse gear!

Heavily laden vehicles should also be secured by

placing chocks under the wheels.

3.6

NOTE
Refer to Operating Manual 1315 758 150.

Tow Starting

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

conditions:

Rdyn 0.6 [m] (z.B. F24)

6.0

Emergency steering pump fitted

High range selected, shift lever in neutral position
Towing distance of max. 100 km
The max. permissible towing speed should be defined
depending on axle ratio and tire size using the diagram
provided (also refer to Fig. 8).

Rdyn 0.4 [m] (z.B. 245/70R19.5)

5.0
4.0
3.0
2.0
10

NOTE
Vehicle manufacturer specifications MUST be observed.

15

20

25

30

35

40

45
50
V [km/h]
027279_en

Fig. 8
Example (reading): iAxle = 6, Rdyn = 0.5 m
Towing speed from diagram:
Vmax = 25 km/h

CAUTION
If one of the aforementioned conditions is not satisfied,
the propshaft must always be deflanged from the rear
axle or the stub shafts must be removed in order to
prevent transmission damage from occurring.
If you suspect transmission damage, the propshaft must
also be deflanged from the rear axle or the stub shafts
must be removed.

1341 758 101 - 2006-02

Rdyn 0.5 [m] (z.B. 275/80R22.5)

7.0

NOTE
Relevant local legislation relating to max. towing speeds
must be observed.

17

Operation
3.8

Limp Home Operation

Faults occurring when changing the range change group

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

35

34

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
Further travel only possible if the low range change
group (gears 1 - 4) is selected.
If the high range change group remains selected, the
vehicle will have to be towed.

018971_1

Fig. 9
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
15 C, the suitability of the oil should be checked
according to List of Lubricants TE-ML 02. If necessary,
change the oil type in the transmission.
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.

When parking the vehicle at outside temperatures of less

than 0 C, ensure that the low range change group is
selected in the transmission (shift lever in position for
1st gear or in neutral position for gate 3/4).

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 1820 TO 16 S 2220 TO

Regular maintenance increases the transmissions

operational reliability. It is therefore particularly
important for the maintenance intervals to be observed.

4.1

16 S 1620 TD 16 S 1920 TD 16 AS TO

16 S 2220 TD
16 S 2520 TO
16 S 2320 TD

Transmission Oil

4.1.1 Oil Grade

NOTE
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
Service Centers or can be downloaded from the Internet at www.zf.com.
We recommend that you use ZF-Ecofluid M.

11

13

13.5

Oil changes. approx.

08

10

11.0

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

4.1.3 Oil Change Interval

Refer to ZF lists of lubricants for oil change intervals
TE-ML 02.
NOTE
To ensure that the transmission achieves the required
level of operational safety and reliability, the oil change
intervals must be observed as specified.

4.1.2 Oil Fill Quantity

Correctly undertaking the oil fill process is crucial for
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

At initial fill

20

Maintenance
4.2

Oil Change

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

4.2.1 Draining Oil

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

Unscrew oil drain plug from transmission

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

017850

Clean oil drain plug (1), replace sealing ring and tighten
to specified torque.

Fig. 10
View from below,
1 Drain plug (60 Nm)
2 Oil drain plug with magnetic plug (60 Nm)

1341 758 101 - 2006-02

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

Clean oil drain plug with magnetic plug (2) replace

sealing ring, and tighten to specified torque.

21

Maintenance
4.2.2 Oil Filling

4.3

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

The oil level is correct when it has reached the bottom

edge of the filler hole and/or when oil is already
escaping out of the filler hole.

Oil Level Check

DANGER !
Too little oil in the transmission will result in
transmission damage. Risk of accident!

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
must be topped up (refer to chapter 4.2.2).

018971_2

Fig. 11
Position of the oil filler bore and overflow measurement

1341 758 101 - 2006-02

NOTE
Whenever checking the oil level, also check the manual
transmission for seal integrity.

22

Maintenance
4.4

Transmission Maintenance for Version with Heat

Exchanger

Check:
- Let engine run at idle speed for approx. 3 minutes.
- Shift transmission into Neutral.
- Switch off engine.
- Undertake oil level check as described in chapter 4.3.

NOTE
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.
This must be done so that the heat exchanger and
connecting lines are filled completely with oil.
- Switch off engine.
- Top up oil again until it overflows.

1341 758 101 - 2006-02

000 508

Fig. 12
Sketch: Ecosplit transmission with heat exchanger

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

The clutch must be fully separated before the splitter

group is engaged via the release valve (37).

c
d

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

17

Check

37

clearance of
at least 1 mm

21

The clutch must be adjusted according to the

manufacturers instructions.

027413_en

Fig. 13
a
Position Clutch closed
b
Position Clutch fully separated
c
Clutch excess travel range
d
End stop
17 Master cylinder for hydraulic clutch operation
19 From pneumatic tank
21 To clutch slave cylinder
32 To splitter group relay valve
37 Splitter group release valve

Setting screw on clutch pedal must be set such that the

release valve (37) is only activated in the excess travel
range (c).
In position (b) the clutch is completely separated (for
checking see chapter 4.5). Ensure there is clearance
between the release valve (37) and the operating device
in the pedal position (clearance of at least 1 mm).

1341 758 101 - 2006-02

25

19
32

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.

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).

NOTE
Ventilation must be checked on the occasion of each
individual vehicle inspection.

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

Fig. 14; Vent

1341 758 101 - 2006-02

018971_3

Fig. 15; Hose breather

26

Maintenance
4.8

Pneumatic System Maintenance

4.9

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).

Type Plate

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

NOTE
When draining the compressed air reservoirs, the
compressed air cleaner and water separator should also be
drained if this doesnt happen automatically.

ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY

ECOSPLIT

Note the vehicle manufacturers details for this process.

MODEL

PARTS LIST NO.

16 S 1920 TD

1342 001 001

XXXXXXX

011356

16,41-1,0

SPEEDO
RATIO

CUSTOMER
SPEC. NO
TOTAL
RATIO
P.T.O. N

OIL CAPACIT
IN LITERS

SERIAL NO.

IMP/U 6,0

xn
ENGINE

n=

13

OIL GRADE SEE

LUBRIC. LIST TE-ML

02
027417

Fig. 16; Type plate (example)

1341 758 101 - 2006-02

27

2
3