ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102a – PDF DOWNLOAD

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ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102a – PDF DOWNLOAD

FILE DETAILS:

ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102a – PDF DOWNLOAD

Language : English
Pages : 111
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102a – PDF DOWNLOAD

Preface:

• This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out
  maintenance and repair work on ZF products.
• This manual deals with the standard ZF product in accordance with the state of development on the date of
  issue.
• However, due to continuing development of the product, repair work might require work practices and test or
  adjustment data which are not contained in this manual.
• We therefore recommend that work done on your ZF
  product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on
  a regular basis at our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG all over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. specialized tools
3. Genuine ZF spares, to our latest specifications

• All work performed in these service points is carried out conscientiously and with care.
• Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual
  conditions.
• Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together
  with follow-on costs caused by such work, is excluded from the contractual warranty agreement. This also applies
  where genuine ZF spares have not been used.

TABLE OF CONTENTS:

ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102a – PDF DOWNLOAD

ZF-Ecosplit 16 S 251...............................................................................  1
	Copyright by ZF................................................................................  2
	Contents.......................................................................................  3
	Preface........................................................................................  5
	Important information..........................................................................  6
	Instructions for carrying out repairs..........................................................  7
	Tightening torques.............................................................................  9
	Consumables.................................................................................... 11
	Adjustment data................................................................................ 12
	Table of springs............................................................................... 17
	Special tools.................................................................................. 18
1 Removing components / range-change............................................................... 27
	1.1 Plastic pipes.............................................................................. 27
	1.2 Output flange.............................................................................. 28
	1.3 Cover...................................................................................... 29
	1.4 5/2-way valve.............................................................................. 31
	1.5 Shift cylinder for range-change............................................................ 32
	1.6 Housing/range-change....................................................................... 34
	1.7 Planetary drive with synchronization....................................................... 37
		1.7.1 Synchronization...................................................................... 37
		1.7.2 Ring gear............................................................................ 39
		1.7.3 Planet carrier....................................................................... 40
2 Servoshift....................................................................................... 43
	2.1 Non-integrated version..................................................................... 43
	2.2 Integrated version......................................................................... 44
3 Shift mechanism.................................................................................. 45
	3.1 Double “H” shift pattern Removing and dismantling shift housing 6.......................... 45
	3.2 Superimposed “H” shift pattern Removing and dismantling shift housing ..................... 48
	3.3 Shift mechanism for the integrated Servoshift Removing and dismantling of shift housing.... 53
	3.4 Shift patterns without Servoshift shift mechanism left or right............................ 58
		3.4.1 Horizontal torque shaft left / Selector pattern I.................................... 58
		3.4.2 Horizontal torque shaft left / Selector pattern II................................... 59
		3.4.3 Horizontal torque shaft right / Selector pattern I................................... 60
		3.4.4 Horizontal torque shaft right / Selector pattern II.................................. 61
	3.5 Shift patterns with Servoshift shift mechanism left or right............................... 62
		3.5.1 Horizontal torque shaft left / Selector pattern I.................................... 62
		3.5.2 Horizontal torque shaft left / Selector pattern II................................... 63
		3.5.3 Horizontal torque shaft right / Selector pattern I................................... 64
		3.5.4 Horizontal torque shaft right / Selector pattern II.................................. 65
	3.6 Assembling complete shift housing.......................................................... 66
		3.6.1 Shift without Servoshift............................................................. 66
		3.6.2 Shift with Servoshift................................................................ 66
4 Components / clutch housing...................................................................... 67
	4.1 Release fork and connection plate.......................................................... 67
		4.4.1 Removing release fork (pulled)....................................................... 67
		4.1.2 Removing release fork (pulled)....................................................... 69
		4.1.3 Removing release fork (pushed)....................................................... 71
		4.1.4 Removing release fork (pulled)....................................................... 73
	4.2 Pump housing with integral pump............................................................ 76
	4.3 Clutch housing............................................................................. 77
	4.4 Removing components........................................................................ 79
5 Components / centre housing...................................................................... 81
	5.1 Splitter (GV) cylinder..................................................................... 81
	5.2 Splitter shift rail........................................................................ 82
	5.3 Removing shafts and components............................................................. 84
		5.3.1 Installing components................................................................ 86
		5.3.2 Installing shafts.................................................................... 87
		5.3.3 Reverse idler gear................................................................... 88
	5.4 Injection pipe............................................................................. 88
	5.5 Attaching components....................................................................... 89
6 Input shaft...................................................................................... 91
7 Mainshaft........................................................................................ 93
8 Layshaft.........................................................................................101
9 Synchronizer.....................................................................................103
	9.1 Determining wear limit (except for 1st /2nd gear)..........................................103
	9.2 Determining wear limit (1st /2nd gear).....................................................103
	9.3 Assembling synchronizer....................................................................104
	9.4 Sectional view of synchronizer/ZF-BK.......................................................104
10 Adjusting shafts................................................................................105
	10.1 Mainshaft Determining ring and axial washer...............................................105
	10.2 Input shaft and connection plate..........................................................106
	10.3 Layshaft..................................................................................107
	10.4 Planetary drive...........................................................................108
11 Compressed air test.............................................................................109
	11.1 Compressed air test for piston and splitter cylinder .....................................109
	11.2 Compressed air test on breather...........................................................109
ZF Friedrichshafen AG..............................................................................111

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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