Iveco Stralis AT/AD. Manual — part 127
41041
41042
41043
41044
Figure 31
Figure 32
Figure 33
Figure 34
Using an appropriate drift, fit the seal (1) in the cover (2).
Apply LOCTITE 410 on the supporting surface. Mount the
cover (2) and tighten the screws to a torque of 18 Nm. Fit on
the flange (3) and screw down the nut (4) by hand.
Take the box (4) out of the vice and turn it over. Fit the roller
bearings (3), thrust washer (2) and tapered roller bearing (1)
on the shaft.
Fit the plates 99363241 (3) on the outer ring of the bearing.
Tighten the screws (2) to a torque of 18 Nm (1.8 kgm), corre-
sponding to an axial load of approx. 250 kg, and turn the out-
put shaft.
Using a feeler gauge (1), measure the distance between the
supporting surface and the outer ring of the bearing.
The measurement will correspond to the thickness of the ad-
justment ring.
Mount the adjustment ring (1). Apply LOCTITE 510 sealant
on the supporting surface (2). Mount the cover (3) and lock
the screws to a torque of 18 Nm (1.8 kgm).
Replace the seals on the fittings (2-12, Figure 4) then mount
them and position the split rings (1-13, Figure 4). Screw on the
transmitter (7, Figure 4).
!
Tightening the nut (4) to a torque of 380 Nm (38
kgm) has to be done on the vehicle, after fitting the
drive assembly on the main box.
!
The thickness of the adjustment ring will have to be
selected by rounding off.
For example, measurement 6 to 6.04 mm, select ring
of thickness 6 mm.
measurement 6.05 to 6.09, select ring
of thickness 6.1 mm.
250
POWER TAKE OFF
S
TRALIS
AT/AD
Base - January 2003
41045
41047
41046
41048
41049
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Slightly heat the seat (
⇓) for the ball bearing on the box and
mount the shaft (1) with the gear wheel together with the bea-
ring.
Measure the distance (A, Figure 38) on the main box (2) with
a feeler gauge (1).
Measure the distance (B, Figure 38) on the cover (2) for the
bearing with a feeler gauge (1).
PARTIAL SECTION OF BEARING AND SHAFT WITH
GEAR WHEEL
The value ”C” of the adjustment ring is given by the following
formula: A - B = C
Fit the middle gear (3) in the box, drive in (2) after replacing
the seals (1).
!
If the value of ”C” is the same as the nominal thickness
of the adjustment ring (see table on page 236), fit the
relevant ring.
Whereas, if ”C” is different, fit the adjustment ring for
the smaller value.
For example, ”C” = 4.14 to 4.11 mm, fit the ring of
4.1 mm.
Adjusting ball bearing
POWER TAKE OFF
251
S
TRALIS
AT/AD
Fitting the main housing
41020
41050
41019
Figure 40
Figure 41
Figure 42
Fit the setting ring (3), apply LOCTITE 510 sealant to the con-
tact surface; fit the cover (2) complete with choke ring and
tighten the screws (1) to torque 22 Nm (2.2 kg).
Fit tool 99395216 (1) to a box spanner and tighten the screws
by a further 60
°, 2
nd
stage
Fit the plate joint (2) with the flange, block it using tool
99370317 (1) and tighten the screws (3) to torque 95 Nm
(9.5 kg). 1
st
stage.
α
252
POWER TAKE OFF
S
TRALIS
AT/AD
Base - January 2003
INTARDER - ZF HYDRAULIC RETARDER
1
S
TRALIS
AT/AD
5342
Intarder - ZF hydraulic retarder
Page
LOCATION OF INTARDER HYDRAULIC
RETARDER DESCRIPTION PLATE
3
. . . . . . . .
GENERAL INFORMATION
4
. . . . . . . . . . . . . . . .
OPERATION
4
. . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Retarder engaged
5
. . . . . . . . . . . . . . . . . . . . . .
-
Retarder disengaged
6
. . . . . . . . . . . . . . . . . . . .
LAYOUT OF MAIN SYSTEM COMPONENTS
ON THE RETARDER
7
. . . . . . . . . . . . . . . . . . .
REMOVING AND REFITTING THE RETARDER ON
THE ZF S 151/181/221-OD GEARBOX
8
. . . .
-
Removal
8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Refitting
9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Filling with oil
9
. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA
10
. . . . . . . . . . . . .
TIGHTENING TORQUES
11
. . . . . . . . . . . . . . . . .
TOOLS
12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT DIAGNOSIS
14
. . . . . . . . . . . . . . . . . . . . . .
OVERHAULING THE INTARDER HYDRAULIC
RETARDER
18
. . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Hydraulic accumulator
18
. . . . . . . . . . . . . . . . . . .
-
Removal
18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Fitting
18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Removing hydraulic retarder
18
. . . . . . . . . . . . . .
-
Checking the component parts of the hydraulic
retarder
23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Fitting the hydraulic retarder
24
. . . . . . . . . . . . . .
-
Stator end float adjustment
29
. . . . . . . . . . . . . . .
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