Iveco Stralis AT/AD. Manual — part 106
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
161
S
TRALIS
AT/AD
SPECIFICATIONS AND DATA
GEARBOX
EuroTronic Automated 12 AS 2301 D.D./O.D.
Type
EuroTronic Automated 12 AS 2301 D.D./O.D.
with intarder
Maximum braking
torque
Nm
3000
Braking capacity
Kw
520
Type of oil
Quantity after overhauling
gearbox and retarder drained
completely
litres
kg
Tutela Truck FE-Gear
Tutela ZC 90
21
19
Figure 1
70831
!
This differs from the 12 AS 2301 D.D./O.D. gearbox in the following:
EuroTronic Automated 12 AS 2301 D.D./O.D. with intarder
D.D. = Direct Drive
O.D. = Over Drive (Multiplied)
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Unscrew the ring nut (1 and 5) and disconnect the electric
wiring (2) from the speed sensor (6 and 7).
Detach the wiring (2) from the clips (
→) securing it to the
middle box.
Remove the nuts (4) and detach the actuator (3) from the
front box.
Fir spacers SP. 2396 (2) and fasten the gearbox (1) to
brackets 99322225 (3) on the rotating stand 99322205 (4).
Drain off the lubricating oil by removing the plugs from the
Intarder and from the gearbox.
If applicable, remove the four nuts (2) fixing the heat
exchanger (1) to the hydraulic retarder (3) and detach the
heat exchanger (1).
Remove the screw (1) and the washer (2) beneath. Extract
the plug (3) with the seal (4), oil filter (5) and magnet (6).
Block rotation of the sleeve (2) by applying the lever
99370317 (1) to it and remove the screws (3), disc (4) and
underlying seal (5).
78649
70934
70936
78324
78652
Removing the hydraulic retarder
162
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
S
TRALIS
AT/AD
Base - January 2003
OVERHAULING THE GEARBOX
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Using an extractor composed of the bridge 99341003 (3),
brackets 99341018 (2) and reaction block 993410134 (4),
remove the sleeve (1) from the shaft (5).
Remove the screws (1) fixing the hydraulic retarder (2) to the
rear box (3).
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2).
With special ropes and lifter, detach the hydraulic retarder
(2) from the rear box.
Remove the adjustment rings (3 and 4) and the gasket (6).
Determine the ball bearing end float adjustment thickness (1)
by proceeding as follows:
- measure the protrusion of the bearing (1) from the
surface of the rear box (2): distance A;
- measure the distance between the sealing surface (1) of
the half box of the retarder and the supporting surface
of the bearing (1, Figure 10): distance B;
- measure the thickness of the gasket between the
retarder and gearbox: distance C.
The thickness S of the adjustment ring is given by the
following equation:
S = [ B + C - A ] - G
where:
- B - C - A = measurements
- G = 0.1 mm: end float of the ball bearing (1 Figure 10)
(0
÷ 0.1 mm)
Before refitting, determine the thickness of the adjustment
rings (3 and 4 Figure 9) as follows:
Adjusting
epicyclic
reduction
gear
train
bearing end float
78344
78321
78325
44005
78326
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
163
S
TRALIS
AT/AD
Refitting the hydraulic retarder
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Determine the thickness S of the stator end float adjustment
ring:
- using a depth gauge (1) and calibrated rule (2), measure
the distance between the sealing surface of the half
boxes and the supporting surface of the stator (3):
distance A;
- measure the thickness of the gasket between the
retarder and gearbox: distance B.
The thickness S of the stator end float adjustment ring is given
by the following sum: S = A+B+C
- A and B
= measurements
- C
= 0.05 mm: stator end float adjustment ring
pre-load. (- 0.05
÷ 0.05 mm)
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2)
and lift it with a hoist.
Position the adjustment rings (3 and 5) of the thickness
determined in the preceding measurements on the bearing
(4) and on the seat (
→) of the stator.
Fit a new gasket (6) on the rear box.
Mount the hydraulic retarder (2) on the rear box (7) making
sure that the gasket (6) gets positioned correctly.
Screw down the screws (2) fixing the hydraulic retarder (1) to
the rear box (3) and tighten them to the prescribed torque.
Heat the flange (2) to approx. 80
°C and fit it onto the spider
shaft (1).
Fit on a new seal (5), the disc (4), screw down the screws (3)
and tighten them to the prescribed torque.
Block rotation of the sleeve (1) by applying the lever
99370317 (3) and tighten the fixing screws (2) to the
prescribed torque.
70946
70948
70949
78327
70954
164
GEARBOX EuroTronic 12 AS 2301 D.D./O.D. with Intarder
S
TRALIS
AT/AD
Base - January 2003
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