Iveco Stralis as Tronic

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GEARBOX EuroTronic 12 AS 2301 D.D./O.D.

113

Gearbox EuroTronic 12 AS 2301 D.D./O.D.

Page

Print 603.93.141

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .

1 15

SPECIFICATIONS AND DATA . . . . . . . . . . . . .

11 6

TIGHTENING TORQUES . . . . . . . . . . . . . . . . .

1 19

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

OVERHAULING THE GEARBOX . . . . . . . . . . .

125

- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 25

- Gearbox actuator . . . . . . . . . . . . . . . . . . . . . .

125

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 25

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

- Removing the rear box . . . . . . . . . . . . . . . . . .

12 6

- Removing the rear box . . . . . . . . . . . . . . . . . .

12 7

- Removing Removing the epicyclic epicyclic reduction reduction gear train (E.R.G.) . . . . . . . . . . . . . . . . . . . . . .

128

epicyclic reduction reduction gear train (E.R.G.) G.) - Fitting the epicyclic

130

- Adjusting epicyclic reduction gear train bearing end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131

- Adjusting main shaft end float . . . . . . . . . . . . .

132

- Synchronizing device assembly assembly for engaging normal or reduced gears . . . . . . . . . . . . . . . . .

134

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 34

- Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

- Removing the middle box . . . . . . . . . . . . . . . .

1 37

- Removing the main shaft . . . . . . . . . . . . . . . . .

139

- Removing the drive input shaft . . . . . . . . . . . .

1 41

- Remo Removi ving ng the split splitte terr synchr synchron onizi izing ng devi device ce . . .

142

- Fitti itting ng the the spli splitt tte er sync synchr hron oniz izin ingg device vice . . . . . .

143 143

- Fitting the drive input shaft . . . . . . . . . . . . . . .

144

Base - January 2003

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114

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GEARBOX EuroTronic 12 AS 2301 D.D./O.D. D.D./O.D.

Page

- Fitting the main shaft . . . . . . . . . . . . . . . . . . . .

144

- Splitter control fork . . . . . . . . . . . . . . . . . . . .

147

- Disassembly - Assembly . . . . . . . . . . . . . . . . .

1 47

- Gear control forks . . . . . . . . . . . . . . . . . . . . .

14 7

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147

- Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148

- Transmission shafts . . . . . . . . . . . . . . . . . . . . .

149

- Disassembly - Assembly . . . . . . . . . . . . . . . . .

1 49

- Fitting the middle box . . . . . . . . . . . . . . . . . . .

149

- Fitting the front box . . . . . . . . . . . . . . . . . . . .

152

- Front cover . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 54

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

- Fitting the front cover . . . . . . . . . . . . . . . . . . .

154

- Adju Adjusti sting ng drive drive input input shaft shaft bear bearing ing end end float float . .

154

- Adjusti Adjusting ng transm transmissi ission on shaft shaft beari bearing ng end float float

155

- Clutch release lever . . . . . . . . . . . . . . . . . . . .

157















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DESCRIPTION The EuroTronic gearbox 12 AS 2301 D.D./O.D. is mechanical with electro-pneumatic control. The driver can choose whether to program gear selection/engagement manually or automatically. The shafts and gears have helical toothing that reduces reduces operating noise. The main shaft gear coupling is obtained with sleeves with front toothing. The splitter and epicyclic epicyclic reduction reduction gear unit engagement engagement is synchronized synchronized.. The speed speedss are selecte selected d with fine finely ly stagger staggered ed ratios ratios and can be be engage engaged d in success succession ion with the the couplin couplingg of the epicycl epicyclic ic reducti reduction on gear unit ”ERG” and the ”Splitter” slow or fast speed unit. On engaging the ”ERG”, the speeds of the main shaft are doubled. The ratios obtained in this way are further doubled with the engagement of the ”Splitter”. Each single ratio is thus divided into a fast or slow ratio. D.D. = Direct Direct drive drive O.D. = Over Drive Drive (Multiplied) (Multiplied)

Figure 1

000418t















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SPECIFICATIONS AND DATA GEARBOXES

EuroTronic Automated 12 AS 2301 2301 D.D.

Type Torque activated

12 AS 2301 2301 O.D. O.D.

Mechanical Nm

1900

2500

Forward gears Reverse gears

12 2

Type ype of runni unning ng cont contrrol

ele electr ctronic onical ally ly-o -op perate rated d sem semi-aut -auto omati maticc

Rear power takeoff

optional

Gear engagement:

by front engagement sleeves

E.R.U.* and splitter engagement

free ring synchroniser

Gears

constantly engaged straight toothed

Gear ratios 1a 2a 3a 4a 5a 6a 7a 8a 9a 10a 11a 12a a 1 RM 2a RM ERG* = Epicyclic Reduction Reduction Gearin Gearingg D.D. D.D. = Dire Direct ct driv drive e O.D. O.D. = Over Over Driv Drive e (Mult (Multipl iplied ied))

15.85 12.32 9.56 7.43 5.87 4.56 3.47 2.70 2.09 1.62 1.28 1.00 14.68 11.41

12.33 9.59 7.44 5.78 4.57 3.55 2.70 2.10 1.63 1.27 1.00 0.78 11.41 8.88















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SPECIFICATIONS AND DATA EuroTronic Automated 12 AS 2301 D.D./O.D. Bearings driv drive e inpu inputt shaf shaftt ERG* sha shaft tran transm smis issio sion n shaft shaftss

with balls with cylindrical rollers rollers with tapered rollers

Bearing end float: driv drive e inpu inputt shaf shaftt ERG* ERG* plan planet et shaf shaftt tran transm smis issio sion n shaft shaftss

0  0.1 mm 0  0.1 mm - 0.05  + 0.05 mm

End float: main sha shaft driv drive e input input shaft shaft split split ring ring

0.2 mm 0  0.1 mm

Temperatu Temperature re for fitting bearings bearings or bearing bearing seats on the boxes Forced lubrication with positive displacement pump flow rate (with 12 th speed engaged and oil at a temperature of 80ºC)

120  C

50 dm3/min

pressure with 12 th speed speed engage engaged d at 2400 2400 rpm and oil at a temperature of: 40ºC 80ºC Oil type

Tutela Truck Fe-Gear Tutela ZC 90 litres kg

ERG* = Epicyclic Reduction Reduction Gearing Gearing D.D. D.D. = Dire Direct ct driv drive e O.D. O.D. = Over Over Driv Drive e (Mul (Multip tiplied lied))

1.7 bar 1.2 bar

12 11

117















118


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Figure 2

001396t

LONGITUDINAL CROSS-SECTION OF EUROTRONIC 12AS 2301 GEARBOX

















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TIGHTENING TORQUES Figure 3

70824

TORQUE

Screws fixing drive input shaft cover

Nm 23 10 23

kgm 2.3 1 2.3

4

Screw fixing clutch uncoupling lever control pin: - M 12 8.8 - M 12 10.9

79 115

7.9 11.5

5

Screws fixing cover (spread LOCTITE 241 on the thread)

79

7.9

1 2 3

Screws fixing gearbox actuator Screw fixing oil pump

















120

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TOOLS TOOL NO.

DESCRIPTION

99305121

Hot air device

99322205

Rotary stand for overhauling assemblies

99322225

Mount to support support assemblies assemblies (to fit onto stand 99322205) 99322205)

99341003

Single-acting bridge

















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121

TOOLS TOOL NO.

DESCRIPTION

99341018

Pair of brackets with hole

99345057

Extractor reaction block

99345078

993450998

Extractor to remove drive input shaft bearing (use with 99345105)

Inse Inserte rterr to fit fit beari bearing ng on main main shaf shaft, t, rear rear side side and and to inse insert rt rear rear flan flange ge of gearbox

















122


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TOOLS TOOL NO.

DESCRIPTION

99347132

Ring grips to extract gearbox transmission shaft bearings (use with 99345057 - 99347100) 99347100)

99360323

Tool Tool to turn drive drive input input shaft shaft when when refitti refitting ng the gearbo gearbox x to the engine

99360526

99360527

Tool to extract and insert main shaft (use with 99360527) and to drive in gearbox drive input shaft bearing (use with 99345098)

Tool retaining retaining gearbox gearbox main shaft forks (use with 99360526) 99360526)

















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TOOLS TOOL NO.

DESCRIPTION

99370007

Grip for interchangeable drifts

99370153

Tool for positioning main shaft when removing the transmission shafts and for retaining gearbox reverse gear pins

99370172

Tool Toolss (6) to mount mount gear gearbo box x epic epicyc yclic lic reduc reductio tion n gear gear train train synchronizer rings

99370317

Reaction Reaction lever with extension to fasten drive output flange



















124

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TOOLS TOOL NO.

DESCRIPTION

99370629

Mount Mount to supp support ort gear gearbo box x when when remov removing ing and and fitti fitting ng it back back on the the vehicle

99374092

Drift Drift to mount mount oute outerr races races of bear bearing ingss (69 99370007)

99374221

Driver to mount seals on back cover

 91)

(use (use with with



















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530210 530210


OVERH OVERHAU AULIN LING G THE THE GEARBOX

Wash the assembly thoroughly before overhauling.

!

125

530520 530520 Gearb Gearbox ox actuat actuator or Removal Figure 4

The specific and/or general tools must be used in the way for which they were designed. To facilit facilitate ate assemb assembly, ly, put the removed removed parts parts away away on the specific tray in their order of removal. Upon Upon asse assemb mbly ly,, the the follo followi wing ng must must alwa always ys be replaced with new parts: the gaskets and seals, spring pins, safety plates and springs. Nuts and screws must be tighten tightened ed to the prescribe prescribed d torque torque with with their their thread dry and degreased. Keep to the specific regulations when disposing of lubricant and detergents.

78649

Unscrew the ring nut (1 and 5) and disconnect the electric wiring (2) from the speed sensor (6 and 7).

Checks The gears, gears, synchr synchroniz onizer er rings, rings, coupli coupling ng bodies bodies and slidin slidingg couplings must show no sign of failure or excessive toothing wear. The main shaft must have no indentation, especially on the sliding sliding surfaces surfaces of the gear rotation rotation and coupling sleeves. The reverse idle gear shafts must have a polished surface free from scoring. The gearboxes must show no sign of cracking and the bearing seat seatss must must be neit neither her dama damage ged d nor nor worn, worn, so as to preve prevent nt the the

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.



















126

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Removing the rear box Figure 8

Figure 6

78651

Take out the screws (2) and detach the actuator (1) with its gasket.

!

The The elect electron ronic ic contr control ol unit unit is integ integrat rated ed in the the actuator and these cannot be overhauled. See under the diagnosis heading for the check.

Check that the oil vapour vent (3) is not clogged; clogged; if it is, clean it.

70863

Disconnect Disconnect speed actuators actuators (1) as described described in the relevant chapter. Extract the springs (6-7-8) and the pawls (6).

!

The springs (7 and 8) are of equal length, the spring (6) is larger.

Refitting Figure 7

Remove the pin (4) from the rod (5). Remove the switch (1) together with the gasket (2) and extract the cap (3).



















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Figure 10

127

Figure 12

70833 70831

Remove the screws (1) fixing the plates (2) fastening the pins (4) and extract these together with the seal (3) from the rear box (7). Extract the two centring pins (5). Remove the screws (6). Fit the eyebolt 99366811 to the sleeve (8) and, using special ropes and lifter, detach the rear box (7) from the middle one (9).

Remove the adjustment ring (3) and the plate (1) together with the coupling body (2).

Removing the rear box Figure 13



















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Figure 15

Figure 18

45946

70838

Using a press, extract the spider shaft (1) from the supporting roller bearing (2). Turn the rear box (3) upside-down and extract the roller bearing (2).

Using pliers (2), tighten tighten the ends of the circlip (3) and remove remove the coupling body (4) ( 4) from the E.R.G. shaft (1).

Removing Removing the epicyclic epicyclic reduction reduction gear train (E.R.G.) Figure 16

Figure 19





















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Figure 21

129

Figure 22

70842

70841

Extract one of the pins (1) from the toothed shaft (2) and extract the rings (3) from this.

Figure 23

Using a suitable extractor, remove the roller bearing ring (1) from the spider shaft (2). Usin Usingg a punc punch, h, extra extract ct the the disc(3) disc(3) from from theinside theinside of the the spid spider er shaft (2).





















130

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Fitting the epicyclic reduction gear train (E.R.G.) Figure 24

Figure 27

70982 70844

Heat the inside ring (2) of the roller bearing to 120C and fit it on the spider shaft (3). Fit on the circlip (1). Fit on the disc (4).

Figure 25

Smea Smearr grea grease se into into the the hole hole of the plan planeta etary ry gear gear (5) (5) and and insert insert the rollers (3) with the associated shim adjustment rings (2 and 4). Fit the planetar planetaryy gears gears (5) onto onto the spider spider shaft shaft (6), fastening them to it with the pins (1).

Figure 28





















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131

Adjusting epicyclic reduction gear train bearing end float

Figure 30

Figure 32

45951

70847

Heat the seat of the bearing (1) of the rear box (2) to 120C and mount the bearing (1).

Determine the ball bearing end float adjustment thickness (3) by proceeding as follows: measure the depth of the seat on the cover (1) of the - measure bearing (3), distance distance A; measure the protrusio protrusion n of the bearing bearing (3) from the - measure





















132

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Figure 33

Figure 35

45954

70849

Using Using the the drive driverr 9937 9937422 4221 1 (1), (1), fit the the seal seal (2) (2) in the the cove coverr (3). (3).

Heat Heat the the slee sleeve ve (1) (1) to 90C and fit itit onto onto the spider spider shaf shaftt (1). (1). Fit on a new seal (4), the disc (3) and screws (2) and tighten them to the prescribed torque.





















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133

Using a depth gauge (3), measure the distance between the top end of the circlip (5) and the top side of the calibrated rule (1), distance B .

Figure 37

The thickness S of the main shaft end float adjustment ring is determined by the following equation:

S = (A - B) - 2 For your your informa information(see tion(see Figure Figure 39), 39), subtra subtractin ctingg the thickn thickness ess of the calibrated blocks and rule:

- from the distance A gives the distance X corresponding to the distance between the end of the spider shaft (2) from the mating surface of the rear box (1).

70851

Fit the connecting sleeve (7) together with the circlip (5) on the main shaft (6). Position two calibrated blocks (2) on the middle box (4) and place a calibrated rule (1) on them. Th

librat librated ed bl ks

d rul

st be th

- from the distance B gives the distance Y corresponding to the distance between the circlip (4) and the mating surface of the middle box (3).























134

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Fitting Figure 39

Figure 41























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Figure 44


135

Insert the rod (3) of appropriat appropriate e diameter in the hole for the screw (4, Figure 45) and in the oil pipe (5) to guide this into its seat, while lowering the rear box (4). Lower the rear box (4), paying attention that the spider shaft, oil pipe (5) and rod (7) go into their seat correctly.

Figure 47























136

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Figure 49

Figure 50























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Removing the middle box Figure 52

Figure 54

137























138

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Figure 57

Figure 60

























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Figure 63


Figure 65

139

























140

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Fi re 67

Fi re 68

























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Figure 69


Figure 72

141

























142

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Removing the splitter synchronizing device Figure 73

Figure 75

























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Fitting the splitter synchronizing device


Figure 77

143





























































































































































































































































































































































Iveco Stralis as Tronic

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