CV H-Step I

Manual Transmission
System Layout CV H-Step I

Power Train

2
Structure CV H-Step I

Clutch Operation

3
Gears and Shaft CV H-Step I

Hub gear and clutch

4th gear 5th gear 3rd gear 2nd gear Reverse gear 1th gear

Drive (Input) shaft and gear

Reverse idle gear

Reverse idle gear shaft

Main (Output) shaft

Counter shaft

4
Gears and shaft CV H-Step I

Synchronizer Ring

Synchronizer Sleeve

Synchronizer Key

Gear
Synchronizer Hub

Main shaft
Synchronizer Ring

Synchronizer Key CLICK 1,2 : lower picture

Gear CLICK 3,4 : upper picture

Sleeve -> Key -> Ring

 Sleeve Shifting

Synchronizer Sleeve
Gear clutching

5
Neutral Position CV H-Step I

Drive pinion Main gears and shaft

(Input shaft and gear)

4th gear 5th gear 3rd gear 2nd gear Reverse gear 1th gear

R 2 4

1 3 5

Counter gear Reverse idle gear

(Output shaft and gear)

Free rotation

Power Transmission

6
1st and Reverse Speed CV H-Step I

R 2 4

1 3 5

R 2 4

1 3 5

7
2nd and 3rd Speed CV H-Step I

R 2 4

1 3 5

R 2 4

1 3 5

8
4th and 5th Speed CV H-Step I

R 2 4

1 3 5

R 2 4

1 3 5

9
Key Points CV H-Step I

1. Counter shaft and their gears are one piece to be rotated together.
2. Main shaft is composed of two section, the one is input shaft (drive) and
the other one is outputshaft.
3. Inputshaft always rotates the countershaft.
4. All of the counter gear and all of the main gear are always matched and
move each other.
5. All of the gears in the gear box always rotate same direction.
6. Drive pinion gear (Inputshaft gear) is the Direct Drive (1:1).
7. Gear ratio is number of drive gear rotation/ number of driven gear rotation
or number of driven gear teeth / number of drive gear teeth
8. Final gear ratio is the value of multiplied each gear ratio.
9. Greater ratio means greater reduction ratio.
10.In case of insufficient oil quantity, the inputshaft gear(drive pinion gear)
teeth can be damaged during going up stiff hill road.
11.Gear shifting effort is great in the cold condition because of sticky
movement between synchronizer ring and gear taper face caused by the
high oil viscosity.
12.Idle noise is getting bigger as the oil temperature rising up because of
lighter fluctuation.

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Differential Gear CV H-Step I

Forward straight Turning

11
 CV H-Step II

ZF-Ecosplit(16S151)
Transmission
Contents CV H-Step II

◈ General
◈ Shift Pattern
◈ Internal Structure
◈ Power Flow
◈ Shift Lever
◈ Operation
◈ Schematic Diagram

13
General CV H-Step II

Features
▷ Increased power to weight ratio through the use of light alloy

housings and more compact design

▷ Optimized gearbox ratio range - 16 forward and 2 reverse speed

▷ Lubrication by oil pump

▷ Increased durability of gears by using surface hardening

▷ Quieter operation by using computer-optimized housing design and

low-noise gearing

▷ Adaptable P.T.O in many cases

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General CV H-Step II

Specification
Model 16 S 151

16 : 16 forward speed
S : Synchromesh type, K:Constantmesh Type
151: Max. input torque (1,700 Nm)

Weigh 290 kg(dry condition)

t

Oil API GL-4 or SAE 80W (90 : Tropical zones only)

Oil capacity : 11ℓ(dry condition)
8ℓ(oil change)

15
General CV H-Step II

Specification
Gear
Ratio

Range 1st 2nd 3rd 4th 5th 6th 7th 8th R

High 11.59 7.96 5.48 3.83 2.53 1.74 1.20 0.84 10.85

Low 13.86 9.52 6.56 4.58 3.02 2.08 1.43 1.00 12.97

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General CV H-Step II

Reverse S/W Neutral S/W Shut off valve

(range control)

Shift Range-
housing change group
cylinder
Mechanical
speedometer
Name plate Oil fill and Indicator S/W for
splitter group shift Impulse transmitter
level 5/2 Way Valve(splitter control valve)
check
Bell housing Main housing Rear housing
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General CV H-Step II

System Lay Out High/Low

High/Low relay
switch

Instrument
cluster

Clutch switch

Shift
Air tank cylinder
5/2 way
T/M High/Low valve
Split control switch
magnetic valve Low magnetic valve
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General CV H-Step II

Flow of Lubricant

1.When long hauling, rear axle shaft

should be disconnected from T/M.
(Not enough oil circulation) Oil pump
Pipe line
2.Oil pump is driven by engine. Drain plug
Oil passage
3.Steel oil filer can be used permanently.

Oil spray

Oil pump(driven by engine)

Oil filter Sump

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General CV H-Step II

Technical Terms in ZF T/M

*Bell Housing(Clutch Housing) *Rear Housing(Range-change Group)
- Oil pump - Planetary type Range-change Group
- Release fork

*Main Housing(Splitter Group)

- Constant Ratio Gear Set #2 (High Gear)
- Constant Ratio Gear Set #1 (Low Gear)
- #3 / #7 Gear Set
- #2 / #6 Gear Set
- #1 / #5 Gear Set
- Reverse Gear Set
- Gear Set #4, #8 (Direct Drive)

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General CV H-Step II

Technical Terms in ZF T/M

*Splitter
*SplitterGroup
Group *Shift
*ShiftHousing
Housing
--“High”
“High”or
or“Low”
“Low”atateach
eachspeed
speed --Shut
Shutoff
offValve
Valve: :Shift
Shiftvalve
valve
--5-2
5-2Way
WayValve(Pre
Valve(Preselecting
selectingvalve
valve))
--Splitter
Splitterindicator
indicatorswitch
switch
--Neutral
Neutralindicator
indicatorswitch
*Range-change
*Range-changeGroup
Group switch
--Reverse
Reverseindicator
indicatorswitch
switch
--11 22 33 44 Speed
st
st
nd
nd
rd
rd
th
th
Speed --Detent
Detentpin
pin
--55thth 66thth 77thth 88ththSpeed
Speed

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Shift Pattern CV H-Step II

15
14 13.86
13
12 11.59
11
10 9.52
9 7.96
8
6.56
7
6 5.48
5
4 4.58 3.83
3.02
3 2.53 2.08
1.74 1.43
2 1.20 1.00
0.84
1
L H L H L H L H L H L H L H L H L H
1st 2nd 3rd 4th 5th 6th 7th 8th Revers
e 22
Internal Structure CV H-Step II

Constant ratio gear set #1

Constant ratio gear set #2
Planetary gear set

Reverse gear set

3 / 7 gear set
rd th 1st / 5th gear set
2nd / 6th gear set
23
Power Flow CV H-Step II

Splitter
Group
L
1
H
L
2
H
L
3
H
L
4
H
24
Power Flow CV H-Step II

Splitter
Group
L
5
H
L
6
H
L
7
H
L
8
H
L
R
H
25
Power Flow CV H-Step II

31
4
32 Low
High
Low
2ndHigh
st
th
rdnd
rd
High
Low

26
Power Flow CV H-Step II

5thth High
8th
6
Reverse
7
8 Low
Low High

27
Double H-Shift Lever CV H-Step II

Range Change Group

1 3 5 7
90~100mm 12k
g 3~4kg 3~4kg
High N N
40 40 50 40
90~100mm
R 2 4 6 8
Low
Splitter group

Shift lever

28
Operation CV H-Step II

High - Splitter (1st Gear “High”) Air bleeder

Shift rail

Switching to “High”

From split control

magnetic valve

From low magnetic valve

29
Operation CV H-Step II

Low - Splitter (1st Gear “Low”) Air bleeder

Shift rail

Switching to “Low”

From split control

magnetic valve
From low magnetic valve

30
Operation CV H-Step II

Splitter Group Operation by Magnetic Valve

Range-change group : Air supply at all times

H
L T/M
Hi Lo

Tank
Air
Knob assembly

Clutch
Pedal

Clutch
Pedal s/w
Connector
Split control Low
magnetic valve magnetic
valve 31
Operation CV H-Step II

Range-change Group
Low speed(1st , 2nd , 3rd , 4th)

n
Pisto
Housing
Shift

Shut-off
valve

High speed(5th , 6th , 7th , 8th)

From air tank

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Schematic Diagram CV H-Step II

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