Iveco Stralis AT/AD. Manual — part 92
104
GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER
S
TRALIS
AT/AD
Base - January 2003
TOOL No.
DESCRIPTION
99395604
Dial gauge (0
÷10 mm)
43196
Figure 2
Fit the brackets 99371050 (3) onto the assembly.
Using ropes with hooks and a movable lift, put the assembly
on the rotary stand 99322205 (2) together with the mount
99322225 (4).
Take off the plug (5) and drain the lubricating oil from the
gearbox.
Take off the plug (1) and drain the lubricating oil from the
hydraulic retarder.
Figure 3
61202
Lift the notch of the safety plate (3) and take it off.
Take out the screws retaining the drive output flange (2),
plate (4) and seal beneath.
Take out the screw (9) and extract the plug (7) with the seal
(8), the oil filter (6) and magnet (5).
Set the gearbox upright.
Take out the screws (
→) fixing the hydraulic retarder (1) to
the epicyclic reduction gear unit (10). Sling the heat
exchanger with a rope and, using the hydraulic lift, remove
the hydraulic retarder (1) from the epicyclic reduction gear
unit (10).
Figure 4
43797
Set the adjustment rings on the ERG bearing and on the
hydraulic retarder.
Fit the hydraulic retarder (1) back on the ERG box (10),
tightening the screws (
→) to the required torque.
Mount the magnet (5), oil filter (6), plug (7) with seal (8) and
tighten the screws (9) to the required torque.
Fit the flange (2) on the ERG shaft.
Lubricate the seal and fit it on.
Position the retaining plate (4) and tighten the fixing screws
to the required torque.
Fit the safety plate (3) on the screws and notch it with the
tool 99370465.
Figure 5
43821
Fit on the retarder drain plug (1) and the gearbox oil drain plug
(2).
Replenish the assembly with the required quantity and grade
of oil.
!
Recover the adjustment rings from the stator and
from the epicyclic assembly shaft bearing.
To overhaul the hydraulic retarder, see SECTION 5, Intarder
hydraulic retarder.
Refitting the hydraulic retarder
Replace the sealing elements with new parts.
Removing the hydraulic retarder from the
gearbox on the stand
GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER
105
S
TRALIS
AT/AD
43798
Figure 6
43799
Figure 7
Remove the hydraulic retarder as described under the
relevant heading.
Take off the fittings (
→) and disconnect the pipes (1 and 3)
from the cylinder (4). Remove the cylinder (4) from the ERG
rear box (2).
Remove the nut (1) and extract the piston (2) from the rod
(3).
37353
Figure 8
Using the percussion extractor 99340205 (2) and part
99342143 (3), extract two of the three centring pins from the
ERG rear box (1).
The arrows show the outside pins to extract; there is a third
pin inside.
43801
Figure 9
!
Here we describe the steps to remove and fit the
ERG epicyclic reduction gear unit that differ from the
ones given for gearboxes without the Intarder.
Remove the seal (5), gasket (4), switch (3), push rod (2) and
retaining push rod (6) from the ERG rear box (1).
Take out the screws fixing the ERG rear box (1) to the
gearbox (2). Fasten the retaining plate (3) to the shaft (4)
with two screws. Using a rope and hydraulic lift, remove the
ERG box (1) from the gearbox (2).
43802
Figure 10
Removing the epicyclic reduction gear unit
(ERG)
Removing the epicyclic reduction gear unit
(ERG) rear box
106
GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER
S
TRALIS
AT/AD
Base - January 2003
43803
Figure 11
Place the epicyclic reduction gear unit (2) on the workbench
and remove the pins (1) for the articulation of the fork (8,
Figure 12) controlling the ERG.
Figure 12
36804
Using the extractor composed of bridge (1), tie rods (3) and
block (2) fitted onto the ERG box, as shown in the figure,
extract the bearing (5) and the box (6) from the ERG shaft
(4).
Figure 13
61216
Using the extractor composed of bridge (1), brackets (2),
part (4) and clamp (3), extract the gear (6) from the ERG
shaft (5).
Take off the plate (7) with the tube (8) for lubrication.
Figure 14
61217
!
While extracting them, hold back the rod (7) to then
take it out of the box (6) when it is freed from the
fork (8).
Take the fork (8) with its blocks out of the sliding sleeve (9).
Remove the fifth wheel bearing (2) from the gear (1).
Figure 15
61218
Take the synchronizer ring (1) out of the sliding sleeve hub.
GEARBOX ZF 16 S 151 D.D. - 181 D.D. - 221 D.D. WITH INTARDER
107
S
TRALIS
AT/AD
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