Iveco Stralis AT/AD. Manual — part 240
32795
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AIR SYSTEM - BRAKES
Base - January 2003
DESCRIPTION
SYMBOL
SINGLE CYLINDER HYDRAULIC
BRAKE
TWIN CYLINDER HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
WITH PARKING BRAKE
SINGLE CAM OPERATED BRAKE
TWIN DUAL CAM OPERATED BRAKE
A
B
C
Hydraulic system pipings for industrial vehicles are currently of
two types:
- Flexible ones made of polyamide with single-layered or
double-layered structure and in the following diameters
(
∅ 6-8-10-12-16 mm) equipped with spares in meters.
- Rigid metal pipings in the following diameters (
∅
4.75-6.35-8-10-12 mm). Pipings from
∅ 4.75 to ∅
10 mm are supplied as spares in straight 4-5-6 m crop
ends, while those exceeding 10 mm are supplied as spares
already cut, bent and reflanged.
RIGID PIPINGS REFLANGING REPRESENTATION
Reflanging type A
In general
Burr piping (1), insert union (2) and place it between small
blocks (3) abutting pin (5). Lock piping (1) with screw (4).
31971
31974
31973
Take back pin (4) to its neutral position. Screw screw (1) till
matrix die (2) comes to abut against small blocks (3) thereby
shaping the piping (5) end.
31972
31975
Arrange on a press 99386523 (3) small blocks (1) so that the
punched numbers, showing the piping number to be worked,
are facing the matrix die (2). The choice of the matrix die (2)
depends on the diameter of the piping to be reflanged.
Moreover, on every matrix die (2) the diameter of the piping
is punched for which the same one can be used.
Assemble matrix die (2) on press 99386523 (1).
For the reflanging process comply with what has been stated
above for reflanging type A.
Rigid pipings reflanging
Reflanging type B
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
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799512
PIPINGS AND FITTINGS
Rigid pipings bending
Reflanging type C
31979
Key on piping (1) nut (2) and ring (3).
Place piping (1) into tool (3) and operating on lever (2) bend
the piping.
31976
31977
Assemble union (2) and tighten so that ring (3, Figure 6) is
locked on piping (1).
31980
In order to free piping (2) from tool (3), operate on lever (1).
31978
31981
Assemble tool (1) 99386523 choosing parts (2) and (3)
depending on the diameter of pipings to be bent.
Place piping (2) into tool (3) 99386523 and tighten screw (1).
Keeping piping (2) still, rotate tool (3) till the piping is
completely cut.
Rigid pipings cutting
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
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20
AIR SYSTEM - BRAKES
Base - January 2003
- Use homologated pipes only;
- Check the spare pipe status, on which no cracks, cuts or
nickings must be detected;
- Cut the pipe at 90
° with respect to the axis through a
suitable pipe-cutting pliers 99387050 at the necessary
length;
Insert on the pipe in the following order:
- nut (3), pressure ring (2) (its greater thickness must be
facing nut (3) and reinforcement bush (1));
- the bush must be in perfect conditions (it must not have
either distortions or hammering traces).
- Carry out abutment ring reflanging upon assembly on the
vehicle or work bench on a fitting.
- The exerted pressure and the final distance from front
pressure ring edge to reinforcement bush edge must be
those mentioned in the table below.
Strictly comply with the following instructions:
Flexible pipings replacement with traditional
fittings
10398
10399
- Key the reinforcement bush with tool 99372219
guaranteeing the contact between its flange and the pipe
end;
- make sure that the pipe end penetrates into the suitable
rake groove obtained in the flange.
1. Reinforcement bush - 2. Pressure ring -
3. Nut - 4. Fitting - 5. Pipe -
h. Distance between bush edge and ring edge (see table).
After having cut the piping, burr and shape the end as
previously described.
Rotating tool (3) around piping (2), screw (1) is
loosened. In order to completely cut the piping, it is
then necessary to tighten screw (1) when it
loosening.
REINFORCEMENT BUSH ASSEMBLY
A
=
CORRECT ASSEMBLY
B
=
WRONG ASSEMBLY
Pipe
mm
Distance between
bush edge and ring
mm (*)
Assembling
pressure
N/mm
2
6 x 1
8 x 1
10 x 1.5
12 x 1.6
16 x 2.34
from 1 to 1.5
from 2 to 2.5
from 2 to 2.5
from 2 to 2.5
from 3 to 3.5
0.040
0.050
0.050
0.060
0.060
Insert the thereby-prepared piping end into the fitting body till
the reinforcement bush flange rests within the suitable seat:
- For closing the nut on the fitting, initially screw it manually
and then complete the tightening with a suitable box
wrench (complete series 99372221) inserted into the
dynamometric wrench, to be calibrated according to the
required tightening torque.
Double-
layered
Single-
layered
(*) See reference h, Figure 14.
Figure 12
Figure 13
Figure 14
!
10397
!
In case of a bad assembly, never use the pipe after
having extracted bush and abutment ring.
AIR SYSTEM - BRAKES
21
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AT/AD
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