Unification of gearboxes for trucks

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Unification of gearboxes for trucks

In Europe, it is Mercedes-Benz, Volvo, Scania that have retained the production of their boxes, but, as they say, ZF is still involved in the design of many models. And sometimes these three automakers use pure ZF boxes. Volvo Trucks has enough boxes for large engines of heavy trucks; they have not worked with “small forms” for a long time. Volvo FL/FE medium-tonnage trucks are equipped with six-speed ZF EcoLite 6S1000 series gearboxes, which are manufactured in Hungary. They used to produce boxes for Ikarus there - they also had licensed ZF gearboxes. In addition, 9-speed ZF 9S1110 or EcoMid ZF 9S109 gearboxes are used. The Volvo FL recently began installing mechanical robotic six-speed ZF As-Tronic gearboxes, but they were given their own name - Volvo I-Sync. Automatic gearboxes with GMT manufactured by Alisson are often installed. Because there are transmission parts that connect not only gearboxes from two different families, like the ZF 16-speed Ecosplit and 9-speed EcoMid gearboxes, but also gearboxes from different manufacturers altogether. This is the flywheel housing, or in other words, the clutch housing.

All over the world, the fastening of truck and bus gearboxes to the engine is unified, made according to several standardized sizes, designated SAE 1, SAE 2, SAE 3, etc. SAE - Society of Automotive Engineers translated from English as “community of automotive engineers”. Back in the 30s, the Americans not only systematized the requirements for automobile oils, but also brought order to the diverse dimensions of the clutch housing, flywheel diameters, the size of the input shaft splines, and clutch connecting parameters. That's why everything is measured in inches. Over time, SAE standards have become international, and on any engine with a flange made, say, according to SAE 1 (in other words, ISO 7648, size code 1), you can install even a German ZF gearbox, even an American Eaton Fuller, or a Chinese Fast Gear, at least our YaMZ-1809/1909 (modifications of YaMZ-239) or KAMAZ-154/152 with the corresponding crankcase. The Smolensk Automotive Aggregate Plant, which produces gearboxes for ZIL, also makes gearboxes with a crankcase according to the SAE 3 standard, this is the standard for four-cylinder “liter” diesel engines and five- and six-speed gearboxes. Just remember that the crankcases of the previous “Soviet” boxes were made according to their own special standards. Unification allows you to have backup boxes, thereby reducing downtime in case of major repairs. Or, conversely, with any gearbox, if it has a clutch housing according to the SAE standard, you can connect any suitable engine of a different, non-original make and model. There is a known case when a carrier suffered terribly with a weak, exotic in Russia and worn out Renault engine on a Van Hooll tourist bus that was in very good condition, while having the opportunity to replace it with the common MAN D2866 diesel engine. Now such a replacement of engines may become relevant if the carrier wants to modernize part of the vehicle fleet to comply with more stringent toxicity standards, to switch from Euro-0 almost to Euro-4. It is important that the flanges of the secondary shaft of foreign-made boxes are also made according to a single standard with holes for four bolts and end splines that transmit the lion's share of the torque. For example, such a flange with a diameter of 180 mm on a KAMAZ box is designated 154.1701240, but smaller flanges are used on smaller boxes. They are also standardized. When replacing the original gearbox, it is necessary to take into account not only the amount of torque, but also the gear ratios. On ZF boxes, the numbers are indicated on a plate; each model of German boxes has two rows of gear ratios: with a higher direct transmission or with an overdrive. Moreover, these options are created only due to the divider gears; the remaining parts of the boxes are the same. It is desirable that the box with overdrive be replaced with the same one, although a gearbox with direct drive can also be installed. On the most modern tractors, just such boxes are installed, but the number of final drives is reduced - it is believed that this saves fuel due to the higher efficiency of the transmission. The difference in numbers between the 12+2-speed Swedish gearbox and the 16-speed ZF gearbox is small, but you shouldn’t count on a successful replacement with, say, a 16S181 9-speed gearbox. In combination with a drive axle gearbox that has a low gear ratio, the clutch may burn when starting off with a loaded vehicle. Putting a 9 or 10-speed gearbox instead of a 6-speed gearbox is an option that our understanding carriers have been successfully practicing for a long time. Suffice it to remember how boxes with a divider were installed on KAMAZ trucks independently. A car with such a gearbox is easier to drive and saves fuel. There are known cases when the much more reliable ZIL-130 was installed on PAZ-3205 buses instead of the “Gazonovskaya” gearbox.

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Switching gears on a truck

On a classic manual transmission, speeds are switched as follows:

1. Start the truck and make sure that the high/low shift button and the distributor switch are at the bottom.
2. Depress the clutch pedal (far left).
3. With your right hand, move the transmission selector to the lowest position.
4. Slowly release the clutch and press the gas pedal.
5. Depress the clutch again when the tachometer reaches first gear.
6. Move the transmission selector to the neutral position and release the clutch pedal.
7. Depress the clutch and set the selector to the first speed position.

The transition to all other levels works in a similar way. If you have reached the limit of low speeds, switch the selector to high (move the button to the upper position) and work according to the same scheme.

If there is a need to divide some of the transmission values ​​in half, use a distributor (demultiplier or divider) for this. This function is especially relevant when driving on hilly terrain, transporting very heavy loads, when it is important to control the level of engine speed in the desired range. To separate the gear, move the distributor button forward, release the gas, squeeze and release the clutch.

A video of a Scania truck shifting gears on the move can be seen here:

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Gearbox ZF 16S.151 for KamAZ

Description

The 16-speed gearbox of the ZF 16S.151 / 16S.1820 TO model is installed on chassis, dump trucks, and heavy-duty KAMAZ long-haul vehicles.
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 highest gear is overdrive.

The gear divider is mechanical, consists of 2 pairs of cylindrical gears and a synchronizer. The divider control is pneumatic.

Gear ratios

Gearboxes 16S.151 from the following main parts: • a four-speed base with a gear for reversing • a planetary rear splitter connected behind it • a built-in Splitter group for pre-selecting the gear ratio

Technical characteristics of gearbox 16S.151

Gearbox configurations 16S.151

Possible gearbox malfunctions, causes and methods for eliminating them

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Useful tips

Before driving, it is recommended to study the gear shift pattern in as much detail as possible. You can do this while standing still, you need to constantly look at the box. As a rule, a special diagram is indicated on the selector regarding the position of each speed . Low gears have one color, high gears have another color. The speeds responsible for rear movement (letter R) are highlighted separately. Remember how many gears there are on the selector, as well as the positions of all the switches and what they do.

So, it is important to pay attention to the transmission characteristics on your truck. The more advanced the gearbox, the easier it is to drive the car. The presence of a multiplier and divider makes it easier to drive in the mountains and save fuel. And using an automatic transmission makes driving a truck even easier.

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Device diagram

The design of the gearbox consists of the following components:

• main 4-speed gearbox,
• front 2-speed gear divider,
• demultiplier.

Transmission diagram
The forward speeds in the main gearbox are activated using synchronizers, the rear speeds are activated by a gear clutch. The multiplier has a planetary design; switching occurs automatically using a pneumatic valve. The weight of the ZF 16S151 gearbox is 290 kilograms. The maximum torque is 1850 Nm.

The speed divider has a mechanical design; it includes a pair of spur gears and a synchronizer.

The gears are engaged mechanically, through a double H-shift, which is divided into five adjacent ones.

The lever is pressed to the neutral position using spring clamps. Pneumatic switching of the range multiplier occurs automatically when the lever moves in neutral.

The choice of speed in the divider occurs as a result of moving the pneumatic valve switch, which is located in the shift lever handle, to position B or H. Switching occurs after depressing the clutch pedal. Depending on the conditions of use of the vehicle, a divider can be used at any speed.

ZF 16S151 for car Man

The servo amplifier includes a control unit and a 2-position cylinder. The speed in the ZF 16S151 gearbox is switched on as a result of pneumatic reinforcement.

The main advantage of this type of transmission is the reduction in gear shifting effort.

Many drivers who use such transmissions note not only significant fuel savings, but also ease of maintenance. Fuel is also saved significantly.