Iveco Stralis AT/AD. Manual

Figure 9

70692

70693

43974

Figure 10

Figure 11

Figure 12

Using a rope and the movable lift, put the retarder (3) on the
rotary stand 99322205 (4) together with the mount
99322225 (5). Unscrew the screws (2) and remove the
electropneumatic valve (1).

Take out the screws (1) and disconnect the hydraulic
accumulator (2).

Take out the water temperature sensor (2). Take out the
nuts (3 and 4) and remove the heat exchanger (1).

70966

Take off the seals (3). Take out the screws (1) and remove
the pump casing (2).
Remove the rotor (5) and the ring (4) of the oil pump.

Fitting

Hydraulic accumulator
Removal

70694

Figure 13

Take out the screws (1) and remove the solenoid valve (2).
Take out the screws (4 and 11) and remove the side covers
(5 and 10). Extract the piston (7) from the body (8).

For fitting, carry out the steps described for removal
in reverse order with the precaution to fit new seals
(3 - 6 - 9) and tighten the screws (1 - 4 - 11) to the
required torque.

Removing hydraulic retarder

534230

OVERHAULING THE INTARDER
HYDRAULIC RETARDER

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Base - January 2003

- Take out the plug (6) with the washer (5).

- Take out the plug (7) with the washer (8) and extract the

cup (9), springs (10 and 11) and the pressure relief valve
(12).

- Take out the plug (13) with the washer (14) and extract

the spring (15) and safety ball valve (16).

Do not take off the cover (6) so as not to tamper
with the adjustment device (7).

43988

70967

70969

Figure 14

Figure 15

Figure 16

Take the circlip (2) and the roller bearing (3) out of the pump
casing (1).

Take the seals (2 and 3) out of the rear box (1). Remove the
circlip (4) and extract the roller bearing (5).

From the rear half box (1):

- Take out the screw (5) and remove the proportional

solenoid valve (4) with the seal (3) and the pressure
control valve (2).

- The adjustment device (7) and extract the cup (8), spring

(9) and pressure adjustment valve (10).

Figure 17

70968

Figure 18

From the rear half box (17):

- Take out the plug (1) with the washer (2) and extract the

spring (3) and switchover valve (4).

70971

Take out the screws (2) and remove the rear half box (1)
from the front half box (3).

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Figure 19

70972

70973

Figure 20

Take the plug (2) with the washer (3) out of the front box
(1); extract the spring (4) and the valve (5).
Take out the plug (6) with the washer (7).

COMPONENT PARTS OF THE REAR BOX

1. Plug - 2. Washer - 3. Spring - 4. Switchover valve - 5. Gasket - 6. Rear half box - 7. Washer - 8. Plug - 9. Screw -

10. Pressure adjustment valve - 11. Spring - 12. Cup - 13. Adjustment device - 14. Cover - 15. Screw -

16. Proportional solenoid valve - 17. Seal - 18. Pressure control valve - 19. Screw - 20. Screw - 21. Screw -

22. Oil pump cover - 23. Grub screw - 24. Seal - 25. Roller bearing - 26. Rotor - 27. Ring gear - 28. Seal -

29. Split ring - 30. Roller bearing - 31. Washer - 32. Plug - 33. Safety ball valve - 34. Spring - 35. Washer -

36. Plug - 37. Pressure relief valve - 38. Spring - 39. Spring - 40. Cup - 41. Washer - 42. Plug

Figure 21

70970

Take off the gasket (1).

Lift the notches in the safety cover (2) and remove the half
rings (3) from the shaft of the rotor (4).

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Base - January 2003

Remove the plug and check that the spring (24, Figure 34) of
the friction reducing valve is present.

70974

43983

43985

Figure 22

Figure 23

Figure 24

Transfer the front half box (1) together with the rotor and
stator to the press. Put the half box on mounts (2) and take
the rotor shaft together with the stator (3) out of the internal
ring (4) of the tapered roller bearing and extract this from the
half box (1).

Unscrew the screw (1) and take off the washer (2).

Transfer the rotor and stator assembly to the press. Put the
stator (1) on the mounts and extract the rotor (2).

Figure 25

85841

Figure 26

Transfer the rotor and stator assembly to the bench and lock
it in the vice. Using the bridge 99341003 (1), tie rods
99341009 (2) and reaction block 99345058 (3), extract the
gear (4).

Figure 27

For hydraulic retarders equipped with a friction
reducing valve, proceed as follows.

For hydraulic retarders without friction reducing
valves, proceed as follows.

78331

85808

Remove the bolt (1) and the washer (2); using yoke
99341003 (3), and block 99345058 (4), extract the gear (5).

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Content .. 130 131 132 133 ..

Iveco Stralis AT/AD. Manual - part 132