Technical characteristics of the ZF gearbox
Technical characteristics of the gearbox 16 S 151
Rice. 71. Connection diagram for pneumatic control for the divider and multiplier.
] — clutch reservoir; 2 — clutch pedal; 3 — gear shift lever; 4 — reverse sensor; 5 — valve for switching on the range multiplier; b — neutral sensor; 7 — sensor for switching on the low range of the demultiple licator; 8 — range switching cylinder; 9 — first gear sensor; 10 — air distributor of the divider; 11 — sensor for switching on the low range of the divider; 12 — top gear engagement sensor; 13 - to the clutch slave cylinder; 14 — valve for switching on the divider; 15 — clutch master cylinder.
Gearbox type
Mechanical sixteen-speed, consisting of a main four-stage gearbox, a front two-stage gear divider and a multiplier
Max, input torque. N.m
Gear ratios (in brackets for gearboxes with highest direct drive)
Roller needles with cages without rings
Inertial type, coupling with steel friction rings coated with molybdenum
With helical teeth, constant mesh
Non-contact, 6-prong inductor
Lubrication system
All parts are splash lubricated; the bearings of the gearbox, divider and range gears also have additional feed from the oil pump
Behind the end of the main gearbox intermediate shaft
Mechanical, with remote drive for the main gearbox
(possible option with servo amplifier), pneumatic preselector -
new for divider, pneumatic for range multiplier
Shift lever force
The gearbox consists of the following main components: a main four-stage gearbox, a front two-stage gear divider and a range-shifter. All forward gears in the main gearbox are activated by synchronizers, and the reverse gear is engaged by a gear clutch. The multiplier is planetary, it is automatically switched using a pneumatic valve by a clutch synchronizer when the lever is moved in neutral from the 3-4 gear position to 5-6 and vice versa.
The gear divider is mechanical and consists of one pair of cylindrical gears and a synchronizer. The divider control is pneumatic.
The gears are engaged mechanically, through a double H-shift. It is divided into 5 tracks located next to each other. On tracks 3-4 or 5-6 there is
neutral position of the lever.
Rice. 72. Gear shift diagram.
a - the lowest range of the range; b is the highest range of the range.
Spring clamps constantly press the lever to the neutral position. Pneumatic switching of the range multiplier occurs automatically when the lever is moved in neutral from the 3-4 gear position to 5-6 and vice versa.
The preliminary selection of a gear in the divider is made by moving the pneumatic valve switch installed in the handle of the gear shift lever to position B or H. The gear in the divider is switched after pressing the clutch pedal. Depending on the conditions of use of the vehicle, you can use a divider in any gear.
The servo amplifier consists of a control unit and a two-position cylinder. The gears in the gearbox are engaged as described above, only with pneumatic assistance.
Advantage: Reduced gear shifting effort.
Prolonged engagement of gears with high manual force contributes to increased wear of the synchronizers.
Depending on the vehicle model, the gearbox may be equipped with a power take-off.
GEARBOX OPERATION
By observing the following operating instructions, fuel economy and trouble-free driving are guaranteed:
• You should drive in the middle engine speed range (Fig. 74)
Use the highest gear
Fig.74. Average engine speed range
Start the engine and move off
• Set the parking brake (prevents the vehicle from moving spontaneously)
. Turn on neutral in the gearbox
• Engage gear (preferably first, to save the clutch)
• Release the parking brake and smoothly depress the clutch
CAUTION: Shifting gears while the clutch is not fully disengaged will result in accelerated wear of the transmission synchronizers.
• If you leave your vehicle running, you must set the parking brake. This prevents the vehicle from moving spontaneously.
• Do not start the engine with the cab raised
Ecosplit - ZF gearboxes are synchronized. The synchronizer makes gear changes quick, safe and silent:
• Without pressing the clutch twice when upshifting.
• Without intermediate gas supply and double clutch release when switching from higher to lower gears.
Rice. 75. Gearbox shift diagram
In the diagram (Fig. 72) for switching on gears N on the tracks for switching on gears 3-4 (reduced gear of the range multiplier) and 5-6 (direct gear of the range multiplier) there is a neutral position (idling state).
To select tracks 1-2 or 7-8 gears, you need to move the lever to the appropriate position overcoming the spring force and hold it in this position when turning it on. The transition from the low gear position of the range multiplier to the direct gear position of the range multiplier and back is separated by a more powerful spring clamp.
Engaging reverse gear is blocked by an additional lock and requires increased effort.
• Move the shift lever smoothly, without much effort and with an open hand, as shown in Fig. 5.
• When engaging a gear, keep pressure on the lever while the synchronizer performs the shifting process.
• Changing tracks from 3-4 gears to 5-6 gears or vice versa is done with a short half of the palm of the lever and smoothly moving it into the desired gear.
• Shift smoothly to minimize effort. This is especially important when the transmission oil is still cold.
If the operating temperature of the gearbox has not yet reached normal, then shifting requires increased effort.
Rice. 76. Gear shift
Shift gears correctly:
1-2-3-4 - low gears (lowest range of the multiplier);
5-6-7-8 - higher gears (highest range of the multiplier). When slowing down, change gears only sequentially: 8-7-6-5-4-3-2-1. Always keep the gear engaged when driving.
— switch from the highest range of the range to the lowest at a speed of more than 30 km/h;
— coast and go downhill with the gear shift lever in neutral position.
• Engage reverse gear when the vehicle is stationary and the engine is idling.
• To avoid damage to the transmission and engine, engage a nearby low gear first if the engine speed reaches a minimum in that gear when braking.
Switching on the power take-off.
The power take-off must only be turned on and off when the vehicle is stationary.
When parking the vehicle for a long time (for example, overnight parking), the power take-off must be turned off. Parking:
• Switch the gearbox to the lowest range position (1st-4th gears)
• Set the parking brake.
• For additional safety, engage the gear: If the car is uphill - forward gear;
from the mountain - reverse gear.
Towing (to start the engine):
Start the engine by towing in direct range gear (5-8 gears).
Towing (defective vehicle):
Towing is possible only under the following conditions: neutral position of the gearbox with direct transmission of the tipplikator (track 5-6 or 7-8 gears). Towing distance is no more than 100 km. The maximum permissible speed is no more than 20 km/h.
If one of the above conditions is not met, the driveshaft must be disconnected from the rear axle.
If damage to the gearbox is suspected, the driveshaft must be disconnected from the rear axle.
Problems when changing range positions (for example, tracks 3-4 gears to 5-6 gears or vice versa) may have the following reasons:
• damage to the pneumatic system.
• The switching valve or the switching cylinder of the range multiplier has defects (condensation or contamination).
• Continuation of movement is possible only when the lowest range of the multiplier is switched on (1-4 gears).
• If the direct transmission of the range gear remains switched on, the vehicle can be towed.
Operating the vehicle at low temperatures:
The gearbox is filled with oil according to the chemical chart. The gearbox can operate at external temperatures down to -30°C. The following points need to be taken into account:
• at external temperatures down to -20°С
After starting the engine, a period is required to warm up the gearbox. Warming up of the transmission oil should be carried out with partial (incomplete) load at low speed.
• at external temperatures down to -30°С
Before starting the engine, it is necessary to warm up the gearbox with warm air. You should also pay attention to the fact that the temperature in the gearbox should not exceed 150°C.
It is not allowed to heat the box with an open flame!
Use of the vehicle at prolonged temperatures between 0 and - 60°C.
The gearbox must be supplied with oils that meet the technical requirements and the list of oils recommended by ZF.
Parking the car at low temperatures.
When the external temperature is below 0°C, it should be taken into account that the lower range of the range is switched on in the gearbox (shift lever in position 1 of gear or in the neutral position of tracks 3-4).
Regular maintenance increases the reliability of the gearbox. It is especially important to observe the intervals between technical inspections.
Only oils that comply with the ZF lubricant list are allowed to fill the gearbox.
Amount of oil to be filled
The required amount of oil is shown on the rating plate attached to the gearbox.
— When first filling, -11l
— When changing oil, -8 l
— Amount of filling oil for normal installation (tilt 0 - 3°).
Man TGA gearbox shift diagram
The MAN gear shift diagram may seem quite complicated. 16 forward gears and two reverse. How to manage them? However, you get used to it very quickly. And then you begin to understand that this is all “stuffed” for a reason. The gears are very easy to engage thanks to the pneumatic booster. The noise from the box is minimal due to its special design.
This MAN gear shift scheme allows you to optimally use the power of the power unit, both when starting, accelerating, driving, and braking, right up to a complete stop. Correctly selected gears enable high-performance operation of all equipment, without compromising reliability and efficiency. In addition, it can be connected to a variety of power take-offs.
The gearbox itself consists of three parts. Main with four gears, two-stage divider and range multiplier. The multiplier automatically switches when moving from 3-4 rows to 5-6 rows. The lever located on the gearshift lever is a divider with which you can select a slow or fast group. These groups are activated by depressing the clutch and shifting the lever.
In order for the MAN gearbox to serve for a long time, it is necessary to carry out timely maintenance and replace worn parts. It is better not to skimp on oil and fill it with special oil, although the one filled at the factory is enough for 300,000 km when transporting goods over long distances, and for 100 thousand when the car is operating in difficult conditions, both road and climatic. Among other things, as follows from the prospectus, it allows you to save 1 percent of fuel. It doesn’t seem like much, but if you convert it into liters and money, you get a noticeable figure.
The MAN SE company is a mechanical engineering factory Maschinenfabrik Augsburg-Nurnberg SE. Main shareholder of Volkswagen AG. The company's headquarters are located in Munich.
Currently, the company is engaged in the production of medium and heavy-duty trucks, light-duty vehicles, as well as trucks for the armed forces and various types of civilian buses.
In this article we will take a closer look at MAN TGA tractors, consider what the MAN TGA gearbox is, the MAN TGA gear shift pattern, etc.
Read in this article
What's the result?
The MAN TGA gearbox is durable in operation with qualified technical maintenance (oil change using high-quality lubricating fluid, timely replacement of worn gearbox parts, etc.).
We also recommend reading the article on how to properly ride a robot box. From this article you will learn about the features, as well as recommendations regarding the operation of cars with a robotic gearbox. At the same time, an important factor in the durability of the gearbox lies in the qualifications of the driver operating the vehicle with this type of transmission. More precisely, the MAN TGA gearbox is very demanding in terms of timely gear shifting at the required speed, taking into account large weight loads.
MAN TGA gearbox: gearbox features and shift pattern
The main model of MAN is the TGA tractor, which became the basis for another new MAN TGH series. By the way, MAN vehicle markings are assigned to a tractor depending on its load capacity. There are such series:
- TGM, TGL;
- TGA - basic model;
- TGS TGX - heavyweights;
- TGM - medium-duty trucks;
- TGL - light-duty vehicles.
The tractors of this series are mainly equipped with six-cylinder engines of our own production with a volume of 10.5 to 12.8 liters, the power of which can vary from 310 to 530 horsepower, depending on the vehicle configuration.
These engines can be coupled with a 12-speed automatic transmission, a 16-speed manual ZF ComfortShift with ServoShift hydrostatic gearshift system (HGS), a 16-speed manual ZF 16 S NEW ECOSPLIT, etc. Let's use the ZF manual gearbox as an example 16 S NEW ECOSPLIT let's look at the main features and switching diagram.
Features of the manual transmission of the MAN TGA ZF 16 S NEW ECOSPLIT
So, the MAN TGA gearbox ZF 16 S NEW ECOSPLIT, depending on the configuration, comes in three types:
- Gearbox with NMV (power take-off mechanism from the internal combustion engine) and intarder (hydrodynamic non-wearing retarder with intense heat exchange);
- Gearbox with intarder (hydrodynamic non-wearing retarder with intense heat exchange);
- Gearbox without intarder.
The main common components of all three types of MAN TGA gearbox ZF 16 S NEW ECOSPLIT:
MAN TGA gearbox: shift diagram
The basic MAN gearbox switching scheme may seem quite complicated at first glance, since it has sixteen forward gears and two reverse gears. But this is only at first glance. You can get used to driving such a box very quickly. Having studied all the nuances and features, it is possible to appreciate a lot of advantages.
For example, thanks to the pneumatic booster, gear shifts smoothly and easily. And the design features of the box allow it to create minimal noise when turned on.
Even on the MAN TGA gearbox, the switching pattern is implemented in such a way as to optimally use the power of the vehicle’s internal combustion engine at the beginning of movement, when accelerating or braking almost to a complete stop. There is another advantage of the gearbox - the ability to connect different power take-offs.
The MAN TGA gear shift diagram consists of three main parts:
- main part with four gears;
- two-stage divider (using the divider located on the gearshift lever, you can select a slow or fast group (the groups are activated when the driver depresses the clutch and switches the lever);
- demultiplier (automatic switching when moving from 3-4 rows to 5-6 rows).
Working space
I climb into the cabin. Despite the fact that it is called “middle”, the engine tunnel is small and you can move freely throughout the considerable internal space. A fairly wide sleeping shelf (2005 mm in length and 745 in width) hides drawers for personal belongings and a built-in refrigerator. Plus three drawers above the windshield and two glove compartments... The main thing here is not to forget what you put where.
Excellent seats with all possible adjustments, a steering wheel with many buttons, adjustable in two planes. The familiar graphics of the instrument board, where two main dials are separated by a built-in on-board computer display... Of course, the climate control panel is in its place. In general, if you have driven a MAN before, then don’t expect any revolutionary discoveries. True, the abundance of buttons makes you regret that you were not diligent at school: you still need to learn how to operate all this, and you can be sure that the MAN TGS operating instructions will become your favorite book in the first months of work.
A detail has appeared in the interior, hinting that MAN belongs to the Volkswagen concern: the usual Volkswagen media system with navigation, SD cards and the ability to connect two mobile phones - not only the driver, but also his partner will not be left without attention. I would like to note that three-dimensional maps with tips on how to save fuel taking into account the terrain are available for Europe, but for Russia, unfortunately, there are no such maps yet.
The ergonomics of the main controls are familiar, including a truly Manov-style TipMatic automated gearbox selector in the form of a rotary handle and a “handbrake” on a separate podium to the right of the driver’s seat. However, previous complaints about ergonomics also remain valid. This concerns visibility: huge side mirrors leave virtually no blind spots along the sides, but steal a fairly large sector in the front hemisphere of vision. And not only a cyclist, but also a medium-sized car can hide there. But the mirror above the windshield helps when maneuvering - you can see everything that is in front of the bumper.
general information
Manual transmission ZF 16 S New Ecosplit
Gearbox with NMV and intarder:
- Engine-dependent power take-off.
- Rocker mechanism housing.
- Working cylinder.
- Heat exchanger.
- Pneumatic accumulator.
- Intarder.
- Typical intarder plate.
- Kitas sensor.
- Pneumatic servo drive.
- Gearbox type plate.
- Bearing mounting flange.
- Clutch slave cylinder.
- Clutch release fork.
- Power take-off drive shaft.
- Gearbox input shaft.
Gearbox with intarder:
- Rocker mechanism housing.
- Transmission blocking.
- Working cylinder.
- Heat exchanger.
- Pneumatic accumulator.
- Intarder.
- Typical intarder plate.
- Kitas sensor.
- Pneumatic servo drive.
- Gearbox type plate.
- Clutch slave cylinder.
- Clutch release fork.
Gearbox without intarder:
- Shift mechanism housing.
- Working cylinder.
- Pneumatic servo drive.
- Typical plate.
- Clutch slave cylinder.
- Release fork.
The gearbox consists of a four-speed unit, a pre-engaged splitter group and a sequentially engaged rear planetary splitter. 4-speed synchronized gearbox with claw clutch and servo drive. The divider group and rear divider are similarly synchronized. Synchronization is carried out using motor control.
The divider group is activated by the corresponding switch on the gear lever. With this switch, the driver first calls the lower or higher divider group and then completes the process by pressing the clutch pedal.
The Servoshift device consists of a mechanical-pneumatic control part and a double-acting pneumatic cylinder.
Ecosplit transmissions can be equipped with engine-, transmission- and mode-dependent power take-offs.
Some Ecosplit transmissions are equipped with engine-dependent power take-offs. The Ecosplit transmission can be additionally equipped with a mode-linked and transmission-dependent power take-off.
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