Daf ZF Ecosplit 181 & 221 Series Official Component Manual
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This is the COMPLETE Official Component manual for the Daf Trucks .
This manual contain high-quality diagrams, schematics, pictures, step-by-step instructions on how to service and repair your trucks DAF
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Models And Serials :
8 S 181
16 S 181
16 S 221
16 S 1920
16 S 2020
16 S 2220
16 S 2320
16 S 2520
CONTENTS :
Contents .....................................................................................................................................1-01
Preface..........................................................................................................................................1-03
General information ...............................................................................................................1-04
Safety instructions.................................................................................................................. 1-06
Tightening torques for nuts and bolts.............................................................................1-07
Spring table ...............................................................................................................................1-08
Adjustment data .....................................................................................................................1-09
Special tools .............................................................................................................................1-14
View of transmission...............................................................................................................1-16
1 Removing components/range-change ......................................................................2-01
1.1 Plastic pipes ..................................................................................................................... 2-01
1.2 Output flange ....................................................................................................................2-01
1.3 Cover ....................................................................................................................................2-01
1.4 5/2-way valve ...................................................................................................................2-02
1.5 Shift cylinder for range-change ...............................................................................2-02
1.6 Housing/range-change ...............................................................................................2-03
1.7 Planet gear train with synchronizer......................................................................... 2-04
1.8 Assembling planet gear train with range-change synchronizer ..................2-06
1.9Assembling range-change /housing/output flange/piston ......................... 2-09
2 Removing components from centre housing ...................................................... 2-12
2.1 Splitter (GV) cylinder ....................................................................................................2-12
2.2 Shift housing ................................................................................................................. 2-12
2.3 Shift housing, friction-optimized version ........................................................... 2-16
2.4 Shift mechanism/selector patterns ...................................................................... 2-21
3 Removing components from clutch housing......................................................... 2-24
3.1 Release fork ......................................................................................................................2-24
3.2 Connection plate with integral pump.................................................................. 2-25
3.3 Clutch housing ............................................................................................................. 2-26
4 Removing components ............................................................................................ 2-26
4.1 Removing components/clutch housing .......................................................... 2-26
4.2 Splitter shift rail /centre housing ....................................................................... 2-26
4.3 Removing shafts...........................................................................................................2-27
4.4 Removing components/centre housing .............................................................. 2-27
4.5 Input shaft .........................................................................................................................2-28
4.6 Mainshaft ...........................................................................................................................2-30
4.7 Assembling synchronizer...............................................................................................2-37
4.7.1 Version ZF-BK..................................................................................................................2-37
4.7.2 Version ZF-D ...................................................................................................................2-38
4.8 Layshaft.................................................................................................................................. 2-39
5 Installing components......................................................................................................... 2-41
5.1 Centre housing ...................................................................................................................2-41
5.2 Clutch housing ...................................................................................................................2-41
6 Synchronizer/wear limits.....................................................................................................2-42
6.1 Determining wear limit (except 1st and 2nd gears) ........................................... 2-42
6.2 Determining wear limit (1st and 2nd gears).................................................2-42
7 Adjusting mainshaft..................................................................................................................... 2-43
7.1 Selecting thrust washer and shim, straight-cut version................................2-43
7.1 Selecting thrust washer and shim, helical-cut version ..................................2-44
8 Installing shafts ................................................................................................................2-45
8.1 Installing input shaft, mainshaft, layshaft and shift rails ..............................2-45
9 Splitter shift fork .............................................................................................................. 2-46
9.1 Adjusting shift fork ................................................................................................... 2-46
10 Clutch housing/centre housing ............................................................................ 2-48
10.1 Fitting clutch housing to centre housing .......................................................2-48
11 Adjusting shafts............................................................................................................ 2-49
11.1 Input shaft .................................................................................................................. 2-49
11.2 Layshaft........................................................................................................................... 2-50
12 Fitting clutch housing components.........................................................................2-51
12.1 Connection plate with integral pump................................................................ 2-52
12.2 Release fork ...................................................................................................................2-53
13 Fitting centre housing components.......................................................................... 2-55
13.1 Reverse idler gear/reverse idler pin....................................................................... 2-55
13.2 Cylinder.............................................................................................................................. 2-55
13.3 5/2-way valve ................................................................................................................2-56
13.4 Compressed air test for piston and splitter cylinder.......................................2-56
13.5 Injection pipe ............................................................................................................... 2-57
14 Fitting complete range-change ................................................................................. 2-58
15 Fitting components..........................................................................................................2-60
15.1 Shift housing ..................................................................................................................2-60
15.3 Plastic pipes .................................................................................................................2-60
16 Compressed air test on breather ............................................................................ 2-61
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