ZF AS Tronic Transmission/Gearbox Service & Repair Manual

GEARBOX EuroTronic 16 AS 2601 O.D. 1 EUROTRAKKER CURSOR 13 Print 603.43.671/A Gearbox: EuroTronic 16 AS 2601 O.D. Page DESCRIPTION 3 .......................... SPECIFICATIONS AND DATA 4 ............. TIGHTENING TORQUES 7 ................. TOOLS 8 ................................ OVERHAULING THE GEARBOX 13 ........... - Checks 13 .............................. - Gearbox actuator 13 ...................... - Removal 13 ............................. - Refitting 14 .............................. - Removing the rear box 14 .................. - Removing the rear box 15 .................. - Removing the epicyclic reduction gear train (E.R.G.) 16 .............................. - Fitting the epicyclic reduction gear train (E.R.G.) 18 - Adjusting epicyclic reduction gear train bearing end float 19 ............................. - Adjusting main shaft end float 20 ............. - Synchronizing device assembly for engaging normal or reduced gears 22 ....................... - Removal 22 ............................. - Removing the middle box 25 ................ - Removing the main shaft 27 ................. - Removing the drive input shaft 29 ............ - Removing the splitter synchronizing device 30 ... - Fitting the splitter synchronizing device 31 ...... - Fitting the drive input shaft 32 ............... - Fitting the main shaft 32 ....................

2 GEARBOX EuroTronic 16 AS 2601 O.D. EUROTRAKKER CURSOR 13 Page - Splitter control fork 35 ..................... - Disassembly - Assembly 35 ................. - Gear control forks 35 ...................... - Removal 35 ............................. - Fitting 36 ............................... - Transmission shafts 37 ..................... - Disassembly - Assembly 37 ................. - Fitting the middle box 37 ................... - Fitting the front box 40 .................... - Front cover 42 ........................... - Removal 42 ............................. - Fitting the front cover 42 ................... - Adjusting drive input shaft bearing end float 42 .. - Adjusting transmission shaft bearing end float 43 . - Clutch release lever 45 .....................

DESCRIPTION The EuroTronic Automated gearbox in its 16 AS 2601 O.D. versions 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 operating noise. The main shaft gear coupling is obtained with sleeves with front toothing. The splitter and epicyclic reduction gear unit engagement is synchronized. The speeds are selected with finely staggered ratios and can be engaged in succession with the coupling of the epicyclic reduction 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. O.D. = Geared up Figure 1 000418t GEARBOX EuroTronic 16 AS 2601 O.D. 3 EUROTRAKKER CURSOR 13 Print 603.43.671

4 GEARBOX EuroTronic 16 AS 2601 O.D. EUROTRAKKER CURSOR 13 Print 603.43.671/A SPECIFICATIONS AND DATA GEARBOXES EuroTronic 16 AS 2601 O.D. Type Mechanical Torque activated Nm 2200 Nm Forward gears Reverse gears 16 2 Type of running control electronically-operated semi-automatic Side rear power takeoff optional Gear engagement: E.R.U.* and splitter engagement by front engagement sleeves free ring synchroniser Gears constantly engaged straight toothed Gear ratios 1 st 2 nd 3 rd 4 th 5 th 6 th 7 th 8 th 9 th 10 th 11 th 12 th 13 th 14 th 15 th 16 th 1 st RM 2 nd RM 14.12 11.68 9.54 7.89 6.52 5.39 4.57 3.78 3.09 2.56 2.09 1.73 1.43 1.8 1.00 0.83 13.07 10.81 ERG* = Epicyclic Reduction Gearing O.D. = Geared up

GEARBOX EuroTronic 16 AS 2601 O.D. 5 EUROTRAKKER CURSOR 13 SPECIFICATIONS AND DATA GEARBOXES EuroTronic 16 AS 2601 .OD Bearings - drive input shaft - ERG* shaft - transmission shafts with balls with cylindrical rollers with tapered rollers Bearing end float: - drive input shaft - ERG* planet shaft - transmission shafts 0 0.1 mm 0 0.1 mm - 0.05 + 0.05 mm End float: - main shaft - drive input shaft split ring 0.2 mm 0 0.1 mm Temperature for fitting bearings or bearing seats on the boxes 120 C Forced lubrication with positive displacement pump flow rate (with 12 th speed engaged and oil at a temperature of 80ºC) pressure with 12 th speed engaged at 2400 rpm and oil at a temperature of: 40ºC 80ºC 50 dm 3 /min 1.7 bar 1.2 bar Oil type Tutela ZC 90 litres kg 12 11 ERG* = Epicyclic Reduction Gearing O.D. = Geared up

000979t Figure 2 LONGITUDINAL CROSS-SECTION OF EUROTRONIC 16AS 2601 D.D./O.D. GEARBOX O.D. = Geared up 6 GEARBOX EuroTronic 16 AS 2601 O.D. EUROTRAKKER CURSOR 13

70824 Figure 3 GEARBOX EuroTronic 16 AS 2601 O.D. 7 EUROTRAKKER CURSOR 13 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Screws fixing gearbox actuator 23 2.3 2 Screw fixing oil pump 10 1 3 Screws fixing drive input shaft cover 23 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 6 Screws fixing clutch actuator 23 2.3 7 Screw cap to discharge air from clutch actuator 22 2.2 8 Screws fixing rear box to middle box 46 4.6 9 Screws fixing flange retaining plate 120 12 10 Screws fixing rear cover 5 4.6 11 Speed sensor 45 4.5 12 Screws fixing middle box to front box 50 5 Pin on rod (spread LOCTITE 262 on the thread) 23 2.3 Oil vapour vent 10 1 Screw plug M 10x1 on rear box 15 1.5 Screw plug M 24x1 on rear box 60 6 Screw M12 fixing power take-off bay cover 79 7.9 Screw plug M 24x1.5 on middle box 60 6 Screw fixing plates retaining fork joint pins on rear box 23 2.3

8 GEARBOX EuroTronic 16 AS 2601 O.D. EUROTRAKKER CURSOR 13 TOOLS TOOL NO. DESCRIPTION Hot air device 99305121 99322205 Rotary stand for overhauling assemblies 99322225 Mount to support assemblies (to fit onto stand 99322205) 99341003 Single-acting bridge 99341013 Reaction block 99341015 Clamp

GEARBOX EuroTronic 16 AS 2601 O.D. 9 EUROTRAKKER CURSOR 13 TOOLS TOOL NO. DESCRIPTION 99341018 Pair of brackets with hole 99345057 Extractor reaction block 99345078 Extractor to remove drive input shaft bearing (use with 99345105) 993450998 Inserter to fit bearing on main shaft, rear side and to insert rear flange of gearbox 99345105 Extractor for gearbox drive input shaft bearing (use with 99345078) 99347100 Small extractor (use with specific rings with 99347132)

10 GEARBOX EuroTronic 16 AS 2601 O.D. EUROTRAKKER CURSOR 13 TOOLS TOOL NO. DESCRIPTION 99347132 Ring grips to extract gearbox transmission shaft bearings (use with 99345057 - 99347100) 99360323 Tool to turn drive input shaft when refitting the gearbox to the engine 99360526 Tool to extract and insert main shaft (use with 99360527) and to drive in gearbox drive input shaft bearing (use with 99345098) 99360527 Tool retaining gearbox main shaft forks (use with 99360526) 99366811 Set of M10 eyebolts (3) to remove and refit gearboxes 99370006 Grip for interchangeable drifts

ZF AS Tronic Transmission/Gearbox Service & Repair Manual

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