Iveco Stralis AT/AD. Manual — part 68
Main operating troubles of the gearbox are the following:
1 - Noise
2 - Spontaneous speed disengagment and uneven engagement
3 - Difficult and bound speed engagement
4 - Faulty or inefficient pneumatic system
YES
Too much backlash of gears
Check the gearbox and replace the gears worn out
Gears, bearings, synchronizer rings and coupling el-
ements worn out.
Replace the shaft and the driven disc, if required.
Inadequate oil level in the box
Fill with Tutela ZC 90 or Tutela Truck Fe-Gear
oil up to required level.
Uncorrect engagement operation
Engage the gears to bottom before releasing the clutch
pedal.
YES
YES
1
NOISE
NO
NO
YES
2
SPONTANEOUS DISENGAGEMENT
OR UNEVEN ENGAGEMENT OF
GEARS
Forks broken
Remove the gearbox, check the elements and replace
where required.
Synchronizer rings worn out.
Check the engaging gears and sliding sleeves, replace
those worn out, replace the synchronizer rings.
YES
YES
NO
NO
8
GEARBOX ZF 9 S 109 D.D.
S
TRALIS
AT/AD
Base - January 2003
4
PNEUMATIC CONTROL SYSTEM
FAULTY OR INEFFICIENT *
Rod forks bound.
Remove the gearbox and find cause of binding; carry
out the required repair operations.
DIFFICULT AND BOUND GEAR
ENGAGEMENT
3
Move of sliding sleeves hindered.
Check and repair.
Not suitable type of oil in the box.
Drain the oil and fill with Tutela ZC 90 or Tutela
Truck Fe-Gear oil.
YES
YES
NO
NO
YES
Clutch engagement missing.
Adjust or replace the control device.
YES
NO
YES
NO
Air pipe fittings faulty
Check pipe fittings and replace where required.
Air pipe bent and/or squeezed.
Replace the pipe.
YES
NO
Air leaks from the pipe
Check that there are no leaks from pipes and pipe fit-
tings; use an acoustic tester or suds. Replace or seal
where required.
YES
GEARBOX ZF 9 S 109 D.D.
9
S
TRALIS
AT/AD
Air leaks from the pressure reducing valve.
Replace the valve or the sealing rings.
Faulty adjustment of the pressure reducing valve.
Check the valve pressure. Replace where required.
YES
NO
YES
Air leaks from the inlet valve. Inlet valves not operating.
Check the inlet valves. Replace the valves or the valve
sealing rings where required.
YES
NO
Air leaks from control cylinders.
Replace the gaskets and the sealing rings in the control
cylinder.
YES
NO
* Checks are to be carried out with the engine off and air tanks filled up.
10
GEARBOX ZF 9 S 109 D.D.
S
TRALIS
AT/AD
Base - January 2003
GEARBOX ZF 9 S 109 D.D.
11
S
TRALIS
AT/AD
TIGHTENING TORQUE
DESCRIPTION
TORQUE
Nm
Kgm
Hexagonal head screw M5
6
(0.6)
Bleeder in the gearbox
10
(1)
Diaphragm in the disengaging valve (according to version)
20
(2)
Hollow screws M 10 x 1 in ”tecalan” pipes
20
(2)
Hexagonal screws M 8
25
(2.5)
Hollow screws M 12x 1.5 in ”tecalan”pipes
35
(3.5)
Locking screws M 14 x 1.5 in the gearbox
38
(3.8)
Hollow screws M 14 x 1.5 in ”tecalan” pipes
38
(3.8)
Locking screws M 16 x 1.5 in gear box and control box
45
(4.5)
Pressure switches in gearbox and covers
45
(4.5)
Safety nuts M10 x 1 in linkage and ball joint
46
(4.6)
Hexagonal nuts M 10 or hexagonal head screws
49
(4.9)
Locking screws M 18 x 1.5 in gear box and control box
50
(5)
Hexagonal nuts M 12 in the bearing linkage
50
(5)
Locking stop in gearbox and control box
50
(5)
Locking screw M 24 x 1.5 9 (bevel) in the gearbox
50
(5)
Pulse transmitter for the tachometer
50
(5)
Driving torque for the hexagonal head screws M 12 in the output flange
60
(6)
Hexagonal head screws M 12
86
(8.6)
Magnetic screw plug M 38 x 1.5 in the gearbox
140
(14)
Knuckle screw in the gearbox control case
160
(16)
Safety nut M 16 x 1.5 in splitter and epicyclic unit pistons
180
(18)
Knuckle screws for the epicyclic reduction gear unit
180
(18)
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