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Iveco Stralis AT/AD. Manual - part 240

32795

TRALIS

AT/AD

AIR SYSTEM - BRAKES

Base - January 2003

DESCRIPTION

SYMBOL

SINGLE CYLINDER HYDRAULIC
BRAKE

TWIN CYLINDER HYDRAULIC BRAKE

DUAL SERVO HYDRAULIC BRAKE

DUAL SERVO HYDRAULIC BRAKE
WITH PARKING BRAKE

SINGLE CAM OPERATED BRAKE

TWIN DUAL CAM OPERATED BRAKE

Hydraulic system pipings for industrial vehicles are currently of
two types:

- Flexible ones made of polyamide with single-layered or

double-layered structure and in the following diameters
(

∅ 6-8-10-12-16 mm) equipped with spares in meters.

- Rigid metal pipings in the following diameters (

∅

4.75-6.35-8-10-12 mm). Pipings from

∅ 4.75 to ∅

10 mm are supplied as spares in straight 4-5-6 m crop
ends, while those exceeding 10 mm are supplied as spares
already cut, bent and reflanged.

RIGID PIPINGS REFLANGING REPRESENTATION

Reflanging type A

In general

Burr piping (1), insert union (2) and place it between small
blocks (3) abutting pin (5). Lock piping (1) with screw (4).

31971

31974

31973

Take back pin (4) to its neutral position. Screw screw (1) till
matrix die (2) comes to abut against small blocks (3) thereby
shaping the piping (5) end.

31972

31975

Arrange on a press 99386523 (3) small blocks (1) so that the
punched numbers, showing the piping number to be worked,
are facing the matrix die (2). The choice of the matrix die (2)
depends on the diameter of the piping to be reflanged.
Moreover, on every matrix die (2) the diameter of the piping
is punched for which the same one can be used.

Assemble matrix die (2) on press 99386523 (1).
For the reflanging process comply with what has been stated
above for reflanging type A.

Rigid pipings reflanging

Reflanging type B

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

AIR SYSTEM - BRAKES

TRALIS

AT/AD

799512

PIPINGS AND FITTINGS

Rigid pipings bending

Reflanging type C

31979

Key on piping (1) nut (2) and ring (3).

Place piping (1) into tool (3) and operating on lever (2) bend
the piping.

31976

31977

Assemble union (2) and tighten so that ring (3, Figure 6) is
locked on piping (1).

31980

In order to free piping (2) from tool (3), operate on lever (1).

31978

31981

Assemble tool (1) 99386523 choosing parts (2) and (3)
depending on the diameter of pipings to be bent.

Place piping (2) into tool (3) 99386523 and tighten screw (1).
Keeping piping (2) still, rotate tool (3) till the piping is
completely cut.

Rigid pipings cutting

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

TRALIS

AT/AD

AIR SYSTEM - BRAKES

Base - January 2003

- Use homologated pipes only;

- Check the spare pipe status, on which no cracks, cuts or

nickings must be detected;

- Cut the pipe at 90

° with respect to the axis through a

suitable pipe-cutting pliers 99387050 at the necessary
length;

Insert on the pipe in the following order:

- nut (3), pressure ring (2) (its greater thickness must be

facing nut (3) and reinforcement bush (1));

- the bush must be in perfect conditions (it must not have

either distortions or hammering traces).

- Carry out abutment ring reflanging upon assembly on the

vehicle or work bench on a fitting.

- The exerted pressure and the final distance from front

pressure ring edge to reinforcement bush edge must be
those mentioned in the table below.

Strictly comply with the following instructions:

Flexible pipings replacement with traditional
fittings

10398

10399

- Key the reinforcement bush with tool 99372219

guaranteeing the contact between its flange and the pipe
end;

- make sure that the pipe end penetrates into the suitable

rake groove obtained in the flange.

1. Reinforcement bush - 2. Pressure ring -

3. Nut - 4. Fitting - 5. Pipe -

h. Distance between bush edge and ring edge (see table).

After having cut the piping, burr and shape the end as
previously described.

Rotating tool (3) around piping (2), screw (1) is
loosened. In order to completely cut the piping, it is
then necessary to tighten screw (1) when it
loosening.

REINFORCEMENT BUSH ASSEMBLY
A

CORRECT ASSEMBLY

WRONG ASSEMBLY

Pipe

Distance between

bush edge and ring

mm (*)

Assembling

pressure

N/mm

6 x 1

8 x 1

10 x 1.5

12 x 1.6

16 x 2.34

from 1 to 1.5

from 2 to 2.5

from 3 to 3.5

0.040

0.050

0.060

Insert the thereby-prepared piping end into the fitting body till
the reinforcement bush flange rests within the suitable seat:

- For closing the nut on the fitting, initially screw it manually

and then complete the tightening with a suitable box
wrench (complete series 99372221) inserted into the
dynamometric wrench, to be calibrated according to the
required tightening torque.

Double-

layered

Single-

layered

(*) See reference h, Figure 14.

Figure 12

Figure 13

Figure 14

10397

In case of a bad assembly, never use the pipe after
having extracted bush and abutment ring.

AIR SYSTEM - BRAKES

TRALIS

AT/AD

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