Iveco Stralis AT/AD. Manual

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.

CLUTCH

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

32.5 mm

CLUTCH

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

CLUTCH

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

TRALIS

AT/AD

5052 CLUTCH ACTUATOR FOR ZF 16 S

151/181/221 GEARBOXES

Fitting and adjusting the clutch wear indicator

Content .. 62 63 64 65 ..

Iveco Stralis AT/AD. Manual - part 64