Iveco Stralis AT/AD. Manual — part 64
72838
38808
Figure 19
Figure 20
For refitting, carry out the steps described for removal in re-
verse order. Then adjust the travel of the pedals as described
under the relevant heading.
PEDAL
Unit removal-assembly
(see Figure 20)
Take out the springs (11) to return the pedals (13*-15).
Eject the spring pins (7) so as to free the levers (1* and 2)
from the pedals (13* and 15), which you should then extract
from the pedal unit mount (18). To replace the roller bear-
ings (9), use:
- the percussion extractor 99340205 to remove them;
- a suitable drift to fit them.
Refitting
1. Brake control lever — 2. Clutch control lever* - 3. Roller bearings — 4. Pin — 5. Fork — 6. Master cylinder* - 7. Spring pin —
8. Splitter control button* - 9. Roller bearings — 10. Washer — 11. Return spring — 12. Pedal cover — 13. Clutch pedal —
14. Control valve — 15. Brake pedal — 16. Brake pedal limit stop screw — 17. Brake pedal stop bracket — 18. Pedal unit mount —
19. Clutch pedal stop bracket — 20. Clutch pedal limit stop screw*
*
Excluding vehicles with the EuroTronic Automated gearbox.
The roller bearings and associated shafts have to be
lubricated with TUTELA MR3 grease.
Complete assembly by carrying out the steps per-
formed for removal in reverse order.
!
!
With each removal, the seals (1) of the coupling of
the control valve cover (2) have to be replaced with
new ones.
Tighten the screws and nuts to the required torque. After re-
fitting, check and if necessary adjust the travel of the pedal as
described under the relevant heading.
14
CLUTCH
S
TRALIS
AT/AD
Base - January 2003
Clutch stop
Check the distance A between the pedal unit mount (1) and
the end of the screw (2). It has to be 32.5 mm, turn the screw
appropriately if it is not.
Idle travel of clutch pedal
Work the clutch pedal (8) to take the cap (6) into contact
with the piston (5) of the master cylinder.
In this condition, check the distance B between the clutch
pedal (8) and the screw (7) that has to be 1 - 2 mm, turn the
screw (7) appropriately if it is not.
The distance B corresponds to the clearance of 0.5 - 1 mm
between the cap (6) and the piston (5) in the condition of
the clutch pedal (9) in contact with the screw (7).
Pedal control valve stroke
After adjusting the position of the bottom and top stop, ad-
just the travel of the piston of the pedal control valve (in the
case of the ZF gearbox).
Take the clutch pedal (8) into contact with the bottom stop
screw (2) and keep it in this position.
Press the button of the control valve (3) fully down and,
keeping it pressed, position the angle bracket (4) so that be-
tween it and the button there is a distance of 0.5 — 1 mm.
This is to prevent the pedal control valve from stopping the
clutch pedal.
39696
Figure 21
A
32.5 mm
B
CLUTCH
15
S
TRALIS
AT/AD
CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL
(vehicles with ZF 9S 109 - ZF 16S 151/181/221 gearboxes)
VIEW OF THE MASTER CYLINDER
The hydraulic control is composed of:
- master cylinder with oil reservoir built in;
- clutch actuator with full recovery of driven disc wear.
Figure 22
Figure 23
CLUTCH ACTUATOR SECTION
FOR GEARBOX ZF 9S109
Figure 24
CLUTCH ACTUATOR SECTION
FOR GEARBOX ZF 16S 151/181/221
HYDRAULIC CONTROL
(Vehicles with ZF 9 S 109 - ZF 16S 151/181/221
gearboxes)
85484
16
CLUTCH
S
TRALIS
AT/AD
Base - January 2003
Take out the plastic rod, rubber seal and metal clamp.
Turn the ”worn clutch” mark (3) on the new actuator from
the rest position to 90
° anticlockwise or clockwise; it depends
on the clutch supplier.
Position 1: wear/travel (Valeo) 25 mm.
61273
!
When the clutch plate wears, the plastic rod moves
towards the mark.
If replacing the clutch, it is necessary to mount a new
wear indicator KIT, setting it as described above.
Figure 25
Insert the plastic rod (1) against the actuator clamp.
Push the seal (2).
61274
Figure 26
Retract the plastic rod (1) away from the actuator, the rubber
seal (2) must not move.
Lock the seal (2) with the metal clamp (3).
61275
Figure 27
Cut off the rear section of the plastic rod (1).
61276
Figure 28
Insert the plastic rod (1) as far as the actuator clamp.
61277
Figure 29
CLUTCH
17
S
TRALIS
AT/AD
5052 CLUTCH ACTUATOR FOR ZF 16 S
151/181/221 GEARBOXES
Fitting and adjusting the clutch wear indicator
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