Iveco Stralis AT/AD. Manual — part 235
77553
Figure 31
Figure 32
Figure 33
77554
77555
Position the steering gear shaft mount (2) in the mount (1).
Measure the distances B and C between the internal surface
of the mount (2) and the sliding surface (of the above) of the
mount (1) with a suitable instrument (3) (precision class 0.05
mm).
PARTS COMPRISING THE STEERING GEAR ASSEMBLY
1. Pneumatic cylinder - 2. Adjustment washer - 3. Coupling - 4. Mount - 5. Washer - 6. Screw - 7. Damper -
8. Steering gear shaft assembly - 9. Nut - 10. Washer - 11. Nut.
Determine the thickness of the adjustment washer (2,
Figure 31) as follows.
Measure the distance A between the sliding surfaces of the
mount (1) with a suitable instrument (precision class 0.05 mm).
20
STEERING
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Base - January 2003
77556
Figure 34
Figure 35
Figure 36
77558
Fit on a new screw (7) with the washer (8) positioning it at
the point marked during removal.
From the opposite side, fit on the washer (2). Apply Loctite
270 on the thread of the new nut (1) and screw it onto the
screw (3) to determine a clearance of 0.1
÷ 0.2 mm between
the washer (2) and the mount (3).
Check the travel of the mount (8) of the steering gear shaft
on the mount (3) in all directions.
Set the steering gear shaft mount (6) in the position of the
start of travel (minimum height of the steering wheel).
Remove the air coupling (4) from the pneumatic cylinder (5).
Screw a suitable coupling (2) into the air supply hole of the
new cylinder (3) and introduce air at a pressure of 8
÷ 12 bars.
!
The air pressure must be maintained throughout the
following measurement and assembly.
Place the pneumatic cylinder (3) on the plane and put the
adjustment washer (1) on its piston; measure the distance
(D) with a suitable instrument (4, precision class 0.05 mm).
S = A - (B + C + D + 0.2), where A - B - C - D are the
distances measured and 0.2 is the clearance.
77557
Put mount (2) in mount (1) and fit on the cylinder (4 supplied
with air at a pressure of 8
÷ 12 bars) positioning it with the
pin (5) in the guiding groove of the mount (2).
Choose the adjustment washer (3) from the ones supplied
as spares, with the thickness calculated in the preceding
measurement.
!
Washer thickness: 4.6 — 4.7 — 4.8 — 4.9 - 5-5 — 5.2 —
5.4 mm.
Lubricate the washer (3) with grease and insert it between
the cylinder (4) and the mount (1).
Figure 37
77551
Fit on the damper (1), screw down the fixing nuts (2 and 3)
tightening them to a torque of 23 Nm.
Check the locking of the cylinder (4): applying a tractive force
of 300 N (30 kg) to the steering gear shaft, in the direction
of the driver, this must not move in relation to the mount (3).
Then refit the steering gear assembly to the vehicle as
described under the relevant heading.
4
STEERING
21
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AT/AD
This adjustment is made after fitting the power steering
system on the vehicle, with the vehicle unloaded and the
front wheels raised or set on revolving platforms. In addition,
it is necessary to steer both right and left as follows.
Make sure the gearbox is in neutral.
Start the engine and run at a speed of
≤ 1500 rpm.
Turn the steering wheel in one direction to bring the stop
screw (2) on the stub axle (3) into contact with the axle (1).
60925
the two values in mm obtained for left and right steering: the
total should not exceed 40 mm.
Lower the axle.
CHECKING THE MAXIMUM PRESSURE OF
THE POWER STEERING SYSTEM
Using the pressure tester 99374393, connected as described
above, and the driver’s side wheel locked, start the engine and
run at idle. Apply a steering force of 10
÷20 kg to the steering
wheel and record the pressure reading on the 0
÷160 bar
gauge. Repeat the operation applying the same steering force
in the opposite direction; if the readings obtained are lower
than specified, locate the source of the problem.
!
The maximum pressure is given on the data plate
attached to the ZF steering box.
Setting the automatic hydraulic steering limit
In this position, apply an additional force on the steering
wheel to determine the automatic setting. Repeat this
procedure steering in the opposite direction.
If there is a reduction in the travel of the steering control
lever, it is necessary to replace the steering limiting screw
concerned with a new one, or both screws if the trouble
involves the opposite travel as well.
The screws are located on the top and bottom sides of the
power steering box. Make the adjustment as described
above.
Check
Connect a pressure gauge (minimum full-scale value 200 bar)
to the pressure test fitting on the delivery line from the pump
to the power steering and apply a steering force at the steering
wheel of 50
± 20 Nm (corresponding to 200 ± 80 N on a 500
mm diameter steering wheel), turning the wheel to the full lock
position. The pressure reading should be within the range of 35
to 70 bar. If the pressure is too high, replace the adjustment
screws with new ones and repeat the adjustment procedure.
If the pressure is too low, check that the hydraulic system is
operating properly and that there are no leaks.
For all vehicles
To bleed the power steering system, proceed as follows.
Fill the power steering fluid reservoir with the prescribed fluid
(Tutela GI/A)
Turn the engine over with the starter motor and top up the
fluid continually to prevent air being drawn into the pump.
Top up the fluid until the level remains constant above the
minimum mark on the dipstick.
Start the engine and run it idling, checking that the level of the
fluid does not fall under the minimum level marked on the
dipstick.
Turn the steering wheel from lock to lock several times to
force any air out of the power steering cylinder until no more
bubbles appear in the fluid in the reservoir.
Accelerate to maximum rpm, then stop the engine and check
that the fluid level does not rise more than 1 to 3 cm.
* For vehicles with a steering third axle with pneumatic
lifting.
See the description on page 98 under the heading
”STEERING REAR ADDED AXLE WITH PNEUMATIC
LIFTING” in section 8 of this manual.
33694
501430
MEASURING STEERING BOX
PLAY AT THE STEERING WHEEL
Check there is no mechanical play in the steering linkage.
Lock the left-hand wheel in the straight-ahead position using
the expanders 99374399; raise the axle.
Attach the fixed pointer (2) to the windscreen with suction
cups, and attach the graduated scale 99374398 (1) to the
steering wheel.
Position the pressure tester 99374393 (3) (0 to 10 bar and
0 to 160 bar, pressure gauges connected by a shunt valve).
Connect the pipe of the pressure tester to the fitting on the
power steering delivery pipe.
Top up the fluid level if necessary.
Start the engine and run at idle speed. Record the pressure
reading shown on the 0 to 10 bar gauge. Slowly turn the
steering wheel to the left until the previous pressure reading
is increased by 1 bar. Hold the steering wheel in this position
and record the value in mm reached on the graduated scale
99374398. Now turn the steering wheel to the right until the
pressure reading is again increased by 1 bar, and note the
value in mm on the graduated scale 99374398. Add together
501430
BLEEDING THE POWER
STEERING SYSTEM
Figure 38
Figure 39
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Base - January 2003
AIR SYSTEM - BRAKES
1
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SECTION 12
Air system - Brakes
Page
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
DIAGRAMS (TANKS AND ACCUMULATORS)
5
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS (VALVES)
6
. . . . . . . . . . .
SYMBOLS FOR AIR-HYDRAULIC SYSTEM
DIAGRAMS (TANKS AND ACCUMULATORS)
12
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS
(CONVERTERS, CYLINDERS AND CALLIPERS)
13
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
DIAGRAMS (CALLIPERS AND CYLINDERS)
14
.
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
DIAGRAMS (SEMI-COUPLINGS AND COUPLING
CONNECTORS)
15
. . . . . . . . . . . . . . . . . . . . . .
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
DIAGRAMS (SEMI-COUPLINGS AND COUPLING
CONNECTORS)
16
. . . . . . . . . . . . . . . . . . . . . .
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
DIAGRAMS (INDICATORS AND SWITCHES)
17
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
DIAGRAMS (BRAKES)
18
. . . . . . . . . . . . . . . . . .
PIPINGS AND FITTINGS
19
. . . . . . . . . . . . . . . . . . .
- In general
19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rigid pipings reflanging
19
. . . . . . . . . . . . . . . . . . .
- Rigid pipings bending
20
. . . . . . . . . . . . . . . . . . . .
- Rigid pipings cutting
20
. . . . . . . . . . . . . . . . . . . . .
- Flexible pipings replacement
with traditional fittings
21
. . . . . . . . . . . . . . . . . . .
- Flexible pipings replacement with quick
connection fittings
22
. . . . . . . . . . . . . . . . . . . . . .
EBS (ELECTRONIC BRAKE SYSTEM)
24
. . . . . . . . .
- EBS Benefits
24
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tractor and trailer compatibility at any time
24
. . .
- Complete fault-diagnosis structures
24
. . . . . . . . .
OPERATING LOGIC
25
. . . . . . . . . . . . . . . . . . . . . .
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