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 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
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.
4
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.
Table of Contents Page
Page 1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
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
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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
5
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
8
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
6
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
N
R
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.
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7 3
7
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
3
1
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
R
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
8
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
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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 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.
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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
3
N
1
N
• No double-declutching during upshifts,
6
4
2
• No intermediate throttle application and no declutching when shifting down, even when driving downhill and in difficult situations.
R
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.
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8
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 transmission’s 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 transmission’s 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 vehicle’s 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
3
1
Superimposed H
N
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.
6
4
splitter group
2 R
Fig. 7
1341 758 101 - 2006-02
8
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 transmission’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.
• 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.
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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.
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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.
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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.
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19
Maintenance 4
Maintenance
Oil quantity/Transm.
16 S 1820 TO 16 S 2220 TO
Regular maintenance increases the transmission’s 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
2
1
• 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.
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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
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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 manufacturer’s 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).
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a
b
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 doesn’t happen automatically.
ZF FRIEDRICHSHAFEN AG MADE IN GERMANY
ECOSPLIT
Note the vehicle manufacturer’s details for this process.
1
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
