Iveco Stralis AT/AD. Manual

43985

Figure 46

Figure 47

Heat the internal ring of the bearing (1) to approximately
85ºC and mount it on the shaft of the rotor (2).

Figure 48

43984

Transfer the assembly to the bench and lock (2) the gear
mounted on the rotor shaft in a vice so as to support the
assembly.
Heat the seating of the outer race (1) of the taper roller
bearing and install the outer race.

70975

Leave the bearing to cool and fit the front half box (5) on the
rotary stand 99322205 (3) together with the mount
99322225 (4).
Fit the tool 99370047 (2) for pre-loading the bearing.
Pre-load the bearing so that the rolling torque that can be
measured with the torque wrench (1) is 2

±0.5 Nm.

Using a feeler gauge (6) measure the thickness of the half
rings (2, Figure 49): distance A.

Figure 49

For both types of hydraulic retarder

71272

Insert the half rings (2) of the thickness measured
beforehand.
Mount the cover (1).
Dent cap (1) using a suitable tool.

Apply sealant on the thread of the plug (6) and screw it down
with a new washer (7) and tighten it to the required torque.
Insert the valve (5) and the spring (4) into the front box (1).
Apply sealant on the thread of the plug (2), screw it down
with a new gasket (3) and tighten it to the required torque.

70973

Figure 50

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Base - January 2003

70971

Figure 51

Figure 52

Put a new gasket on the front box (3).
Mount the rear box (1), screw down the screws (2) and
tighten them to the required torque.

Figure 53

70969

In the rear box (1), insert:

- Pressure adjustment valve (10), spring (9) and cup (8).

Apply sealant on the thread of the adjustment device (7),
screw it down with a new washer, tightening it to the
required torque.

- Pressure control valve (2) and mount the proportional

solenoid valve (4) with a new seal (3).
Screw down the screws (5) and tighten them to the
required torque.

Figure 54

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

70698

In the rear box (17), insert:

- Safety ball valve (16), spring (15) and plug (13) with

washer (14).

- Pressure relief valve (12), springs (10-11), cup (9) and

screw down the plug (7) with the washer (8).

- Screw down the plug (6) with the washer (5).

- Switchover valve (4), spring (3) and screw down the plug

(1) with the washer (2).

Fit the roller bearing (5) and circlip (4) in the rear half box (1).
Position the seals (2 and 3) on it.

70967

Before mounting the plugs (13-7-5 and 1), apply
sealants on their threads.
The plugs have to be tightened to the required
torque.

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Figure 55

Figure 56

Mount the roller bearing (3) in the pump casing (1) and
secure it with the circlip (2).

Figure 57

70966

Mount the ring gear (4), the rotor (5) and the pump casing (2).
Screw down the screws (1) and tighten them to the required
torque.
Position the seals (3).

Figure 58

43988

71287

Refit the heat exchanger (1) to the hydraulic retarder and
tighten the fixing nuts (3 and 5).
Mount the temperature sensor (2). Mount the seal (4).

Refit the hydraulic accumulator (1) together with the
electropneumatic valve (3).
Screw down the screws (2 and 4) and tighten them to the
required torque.

70963

Figure 59

44003

Using installation tool 99374221 (1), install a new oil seal (2)
in the hydraulic retarder casing.

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Base - January 2003

Figure 60

Determine the thickness H of the stator end float adjustment
ring.

- With a depth gauge (1) and calibrated rule (2), measure

the distance between the supporting surface of the
stator (distance A).

- Measure the thickness of the gasket between the

retarder and the gearbox (distance B).

The thickness H of the stator end float adjustment ring is
given by the following equation:

H = A + B + C

Where,

- A and B = measurements made

- C

= 0.05 mm: pre-load of stator end float

adjustment ring (-0.05 - +0.05 mm).

Refit the hydraulic retarder as described under the relevant
heading of gearbox overhauling.

70946

Stator end float adjustment

INTARDER - ZF HYDRAULIC RETARDER

TRALIS

AT/AD

Content .. 132 133 134 135 ..

Iveco Stralis AT/AD. Manual - part 134