Iveco EuroTrakker & Trakker Trucks Repair & Service Manual
Catalog:
Model:
Complete service repair manual for Iveco EuroTrakker & Trakker Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Iveco EuroTrakker & Trakker Trucks workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
03.43.461 - Iveco EuroTrakker Cursor 8 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('93-'04 ).pdf
03.43.811 - Iveco EuroTrakker Cursor 13 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('93-'04).pdf
03.93.121 - Iveco EuroTrakker_EuroTech_EuroStar Cursor 8-10-13 REPAIR MANUAL_ELECTRIC_ELECTRONIC_SYSTEM.pdf
03.93.641 - Iveco Trakker Euro 4-5 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('04-'13).pdf
03.93.641 - Iveco Trakker Euro 4-5 ELECTRIC_ELECTRONIC SYSTEM.pdf
PTO GUIDE FOR DEEC 2_2008_EN.pdf
TABLE OF CONTENTS
General 1
Engines 2
Clutch 3
Gearboxes 4
Power take-off 5
Transfer box TC 1800-TC 2200 6
Propeller shafts 7
Axles 8
Front axles 9
Suspensions 10
Wheels and tyres 11
Steering 12
Pneumatic system - Brakes 13
Bodywork and Chassis frame 14
Programmed maintenance 15
Electric/electronic system 16
PRODUCT DETAILS:
Total Pages: 4,021 pages
File Format: PDF
Language: English
603.43.461 - Iveco EuroTrakker Cursor 8 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('93-'04 )...2
EUROTRAKKER CURSOR...2
REPAIR MANUAL...2
NOTE...4
Graphs and symbols...5
INDEX...6
SECTION 1 - General...7
General...7
GENERAL...9
COMPOSITION OF THE MODELS...9
P.I.C. CODE NUMBERS...14
VEHICLE IDENTIFICATION DATA...20
FILLING UP...21
International designations of lubricants and fluids...22
SECTION 2 - Engine...23
Engine...23
VIEWS OF THE ENGINE...28
TECHNICAL DESIGNATION...31
GENERAL CHARACTERISTICS...37
ASSEMBLY CLEARANCE DATA...40
FAULT DIAGNOSIS...46
DESCRIPTION...46
DIAGNOSTIC INSTRUMENTS...46
CONTROL UNIT TEST...47
ENGINE TEST...47
AUXILIARY FUNCTIONS...47
TIGHTENING TORQUES (PROVISIONAL)...51
TOOLS...55
ENGINE REMOVAL - REFITTING...65
Removal...65
Refitting the engine...66
DISMANTLING THE ENGINE ON THE BENCH...69
REPAIR OPERATIONS...75
CYLINDER BLOCK...75
Checks and measurements...75
CYLINDER LINERS...76
Replacing cylinder liners...77
Removal...77
Fitting and checking protrusion...77
CRANKSHAFT...78
Measuring main journals and crank pins...79
SELECTING THE MAIN HALF-BEARINGS AND BIG END HALF-BEARINGS...81
DETERMINATION OF PRELIMINARY DATA FOR SELECTION...82
Replacing the timing control gear and the oil pump...91
Checking main journal installation clearance...91
Checking crankshaft end float...93
PISTON-CONNECTING ROD ASSEMBLY...94
Removal...94
Measuring the diameter of the pistons...95
Conditions for correct gudgeon pin-piston coupling...95
Piston rings...96
CONNECTING ROD...97
Checking connecting rod alignment...98
Mounting the connecting rod - piston assembly...98
Mounting the piston rings...98
Fitting the connecting rod-piston assembly into the piston liners...99
Piston protrusion check...99
Checking assembly clearance of big end pins...100
CYLINDER HEAD...100
Taking down the valves...100
Checking the planarity on cylinder head...100
VALVE...100
Removing deposits and checking the valves...100
VALVE GUIDES...101
Replacing of valve guides...102
Replacing - Reaming the valve seats...102
REPLACING INJECTOR HOLDER CASES...102
Removal...102
Checking protrusion of injectors...104
TIMING GEAR...105
Checking cam lift and pin alignment...105
Camshaft...106
Bushes...106
Replacing camshaft bushes using beater 99360487...107
VALVE SPRINGS...108
Fitting the valves and oil seal ring...108
ROCKER SHAFT...109
ROCKERS...109
LUBRICATION...110
Oil pump...110
Overpressure valve...110
Oil pressure control valve...113
Heat exchanger...113
By-pass valve...114
Thermostatic valve...114
Engine oil filters...114
COOLING...115
Water pump...115
Thermostat...115
TURBOCHARGING...119
Turbocharger HOLSET HX40V...121
Actuator adjustment...122
VGT control solenoid valve...122
Turbocharger HOLSET HY40V...127
Actuator...130
Working principle...130
Solenoid valve for VGT control...130
FUEL FEED...131
Fuel pump...132
Injector-pump...132
Pumping element...132
Nozzle...132
Solenoid valve...132
Replacing injectors-pump...132
Injector Phases...133
Filling phase...133
Injection phase...134
Pressure Reduction phase...134
ASSEMBLING THE ENGINE ON THE BENCH...135
DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER...137
Fitting the connecting rod-piston assembly into the cylinder liners...138
ENGINE FLYWHEEL...141
Replacing the toothed crown of the engine flywheel...141
Fitting engine flywheel...141
Fitting camshaft...142
Fitting pump-injectors...143
Fitting rocker-arm shaft assembly...143
Camshaft timing...144
Phonic wheel timing...146
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors...147
ENGINE COMPLETION...148
SECTION 3 - Clutch...149
Clutch...149
DESCRIPTION...151
Clutch...151
SPECIFICATIONS AND DATA...151
DIAGNOSTICS...153
TIGHTENING TORQUES...156
REMOVAL AND REFITTING...157
Removal...157
Refitting...157
REMOVING-REFITTING THE THRUST BEARING...157
REPLACING CLUTCH SHAFT SUPPORT BEARING ...157
CHECKS...158
CLUTCH DISENGAGEMENT CONTROL...159
REMOVING-REFITTING THE PEDAL ASSY ...159
Removal...159
Refitting...159
STRIP-DOWN AND REASSEMBLY...160
CHECKING AND ADJUSTING CLUTCH PEDAL STOPS (excluded vehicles with EuroTronic gearbox)...162
Clutch stop...162
Clutch pedal idle stroke...162
Pedal timing gear stroke...162
HYDRAULIC CONTROL vehicles with gearboxes: 2895.9-ZF 9/16 S 109-ZF 16 S 151...163
CLUTCH ACTUATOR FOR ZF 16 S 151 GEARBOXES...164
Refitting and adjusting thewear clutch indicator...164
Push rod adjustment (new clutch)...165
CLUTCH ACTUATOR FOR EUROTRONIC AUTOMATED GEARBOX...166
Clutch actuator push rod adjustment (new clutch)...166
Fitting the clutch actuator...166
Replacing the clutch actuator...166
SECTION 4 - Gearboxes...167
Gearboxes...167
Gearbox 2895.9...170
DESCRIPTION...172
Gearbox...172
CHARACTERISTICS AND DATA...173
FAULT DIAGNOSIS...174
TIGHTENING TORQUES...176
TOOLS...177
DISMANTLING TRANSMISSION...184
CHECKS...187
ASSEMBLING THE TRANSMISSION...188
ADJUSTING SECONDARY SHAFT BEARING PRELOAD...188
DISMANTLING PRIMARY SHAFT...193
FITTING THE PRIMARY SHAFT...195
TAKING DOWN THE INPUT SHAFT...195
ASSEMBLING INPUT SHAFT...196
SECONDARY SHAFT...196
Replacing the bearings...196
DISMANTLING INTERNAL GEAR CHANGE SHAFT...196
ASSEMBLING INTERNAL GEAR CHANGE SHAFT...197
DISMANTLINGEXTERNALGEARCHANGE CASING...197
Assembly...198
EPICYCLIC REDUCTION GEAR UNIT...200
DISMANTLING...202
CHECKS...206
INSTALLATION...207
Gearbox ZF 9 S 109...213
GENERAL SPECIFICATIONS...215
Description of gearbox 9 S 109...215
SPECIFICATIONS AND DATA...217
DIAGNOSTICS...220
TIGHTENING TORQUE...223
EQUIPMENT...224
REMOVAL...227
Removing the E.R.U.box...227
Reassembling the E.R.U.box...227
DISASSEMBLING THE E.R.U. BOX...228
DISASSEMBLING THE E.R.U...228
CHECKS...230
ASSEMBLING THE E.R.U...232
ASSEMBLING THE E.R.U. BOX...233
ADJUSTING THE AXIAL BACKLASH OF THE REAR BEARING...233
DISASSEMBLING THE GEARBOX...235
REMOVING THE INPUT SHAFT...238
REMOVING THE MAIN SHAFT...238
REMOVING THE TRANSMISSION SHAFT...241
REMOVING THE GEARCHANGE CASE OF GEARBOX...241
OIL PUMP...243
CHECKS...244
ASSEMBLING THE GEARCHANGE CASE...244
ASSEMBLING THE TRANSMISSION SHAFT...246
ASSEMBLING THE INPUT SHAFT...249
ASSEMBLING THE GEARBOX...249
ADJUSTING THE TRANSMISSION SHAFT BEARINGS...251
Adjusting the main shaft bearings...252
Gearbox ZF 16 S 109...256
DESCRIPTION...258
CHARACTERISTICS AND DATA...260
FAULT DIAGNOSIS...263
TIGHTENING TORQUES...266
TOOLS...267
DISMANTLING...270
Removing E.R.U. case...270
Refitting E.R.U. case...270
Dismantling E.R.U. case...271
Dismantling E.R.U...271
CHECKS...273
Assembling E.R.U. case...276
Dismantling transmission case...278
Dismantling the input shaft...281
Assembling the drive input shaft...281
Dismantling the main shaft...282
CHECKS...283
Assembling the main shaft...284
Dismantling the countershaft...287
Taking down the gear change control case...287
OIL PUMP...289
CHECKS...290
Assembling gear change control case...290
Assembling the countershaft...292
Assembling transmission case...292
Adjusting the countershaft bearings...294
Adjusting the main shaft bearings...295
Gearbox ZF 16 S 151...299
DESCRIPTION...301
OPERATION...303
CHARACTERISTICS AND DATA...307
FAULT DIAGNOSIS...311
TIGHTENING TORQUES...314
TOOLS...315
REMOVING-FITTING THE ZF GEAR CHANGE...320
Removal...320
Reassembly...321
DISMANTLING...322
Removing Epicyclic Reduction Unit (E.R.U.) assembly...322
Taking down the transmission case...323
Dismantling countershaft...326
Dismantling main shaft and drive input shaft...326
Dismantling Epicyclic Reduction Unit (E.R.U.)...330
CHECKS AND INSPECTIONS...334
Cleanliness and inspection of bearings...334
Refitting...336
Assembling Epicyclic Reduction Unit (E.R.U.)...338
Assembling main shaft and input shaft...341
Assembling the countershaft...344
Assembling the transmission case...344
Refitting Epicyclic Reduction Unit (E.R.U.)...347
Gearbox EUROTRONIC...350
INTRODUCTION...352
CHARACTERISTICS AND DATA...354
TIGHTENING TORQUE...357
EQUIPMENT...358
MECHANICAL FAULTS DIAGNOSIS...364
REPAIRS...367
Removal of front box removal...367
Removal of central box...368
Removal of rear box and epicyclic reduction unit...370
Installation of rear box and epicyclic reduction unit...372
Axial clearance regulation on epicyclic reduction gear bearing...372
Removal of primary shaft...376
Primary shaft installation...377
Removal of Splitter synchroniser...379
Installation of Splitter synchroniser...379
Forks installation-disinstallation...379
Secondary shafts...379
Central box installation...380
Shafts timing...382
Disinstallation of movement input shaft...383
Installation of movement input shaft...384
Installation of front box...384
Disinstallation of front cover...385
Installation of front cover...385
Regulation of axial clearance on movement input shaft bearing...386
Regulation of axial clearance on secondary shaft bearings...386
EUROTRONIC IT (INTARDER)...390
CHARACTERISTICS AND DATA...390
REPAIRS...391
Disinstallation of rear box...391
Rear box installation...392
Regulation of axial clearance on epicyclic reduction gear bearing...392
Regulation of axial clearance on stator...393
CLUTCH ACTUATOR...394
Description...394
CHARACTERISTICS AND DATA...394
SAFETY RULES...395
Disinstallation...396
Installation...398
Operating checks...399
Measure of piston stroke...399
Gearbox EuroTronic 12 AS 2301 D.D...401
DESCRIPTION...403
SPECIFICATIONS AND DATA...404
TIGHTENING TORQUES...407
TOOLS...408
OVERHAULING THE GEARBOX...413
Checks...413
Gearbox actuator...413
Removal...413
Refitting...414
Removing the rear box...414
Removing the rear box...415
Removing the epicyclic reduction gear train (E.R.G.)...416
Fitting the epicyclic reduction gear train (E.R.G.)...418
Adjusting epicyclic reduction gear train bearing end float...419
Adjusting main shaft end float...420
Synchronizing device assembly for engaging normal or reduced gears...422
Removal...422
Removing the middle box...425
Removing the main shaft...427
Removing the drive input shaft...429
Removing the splitter synchronizing device...430
Fitting the splitter synchronizing device ...431
Fitting the main shaft...432
Fitting the drive input shaft...432
Splitter control fork...435
Disassembly - Assembly...435
Gear control forks...435
Removal...435
Fitting...436
Transmission shafts...437
Disassembly - Assembly...437
Fitting the middle box...437
Fitting the front box...440
Front cover...442
Removal...442
Fitting the front cover...442
Adjusting drive input shaft bearing end float...442
Adjusting transmission shaft bearing end float...443
Clutch release lever...445
Gearbox EuroTronic 12 AS 2301 D.D. with Intarder (IT)...448
SPECIFICATIONS AND DATA...450
OVERHAULING THE GEARBOX...451
Removing the hydraulic retarder...451
Refitting the hydraulic retarder...452
Adjusting epicyclic reduction gear train bearing end float...452
Adjusting stator end float...453
Removing the rear box...454
Removing the E.R.G...455
Fitting the E.R.G...456
EXPERIMENTAL TOOLS...461
Epicyclic reduction gear unit TC 700...463
DESCRIPTION...465
SPECIFICATIONS AND DATA...465
REDUCTION GEAR UNIT OPERATION...467
On road...467
Off road...468
Motion transmission diagram: on road...469
Motion transmission diagram: off road...470
TIGHTENING TORQUES...471
EQUIPMENT...472
REMOVING AND REFITTING THE REDUCTION GEAR UNIT...474
Removal...474
Refitting...474
DISASSEMBLING THE REDUCTION GEAR UNIT AT THE BENCH...475
DISASSEMBLING THE INPUT SHAFT (Operation to be performed under hydraulic press)...476
DISASSEMBLING THE COUNTERSHAFT...477
DISASSEMBLING THE EPICYCLIC REDUCTION GEAR UNIT...477
CLEAN OUT AND CHECKS...478
REPLACING THE SEALING RINGS ON DRIVING AND INPUT SHAFT COVERS...478
REFITTING THE COUNTERSHAFT...480
REFITTING THE EPICYCLIC REDUCTION GEAR UNIT (Differential)...480
SHAFT BEARINGS PRELOAD ADJUSTMENT...482
DRIVING SHAFT...482
Indicator switch adjustment...483
Pulse transmitter adjustment...484
Transfer case TC 1800...486
DESCRIPTION...488
SPECIFICATIONS AND DATA...488
TRANSFER CASE OPERATION...490
On-road...490
Off road...491
Transmission of motion pictorial diagram: on-road...492
Transmission of motion pictorial diagram: off-road...493
TIGHTENING TORQUE...494
EQUIPMENT...495
TRANSFER CASE REMOVALRE- FITTING IN PLACE...498
Removal...498
Re-fitting in place...498
DISMANTLING THE TRANSFER CASE AT THE BENCH...498
DISMANTLING THE INPUT SHAFT...500
DISMANTLING THE COUNTERSHAFT...501
DISMANTLING THE EPICYCLIC TRANSFER CASE...501
REPLACING THE SEAL RINGS ON THE DRIVING SHAFT COVERS...502
CLEAN OUT AND CHECK...502
FITTING IN PLACE THE INPUT SHAFT...502
FITTING IN PLACE THE COUNTERSHAFT...503
FITTING IN PLACE THE EPICYCLIC TRANSFER CASE...503
ASSEMBLING THE TRASFER CASE AT THE BENCH...504
ADJUSTING SHAFT BEARING PRELOADING...506
Prod switch adjustment...508
Pulse sender adjustment...508
Power take off...511
Power take off HYDROCAR...514
POWER TAKE OFF HYDROCAR...516
SPECIFICATIONS AND DATA...516
TIGHTENING TORQUES...518
Power take off ZF...521
POWER TAKE OFF ZF...523
SPECIFICATIONS AND DATA...523
TIGHTENING TORQUES...525
Power take off (Optional 2395)...528
DESCRIPTION...530
FEATURES AND DATA...531
TIGHTENING TORQUE...532
EQUIPMENT...533
Operation (power take off disengaged)...537
REMOVING - REFITTING TOTAL POWER TAKE-OFF ASSEMBLY...539
Removal...539
Refitting...539
OVERHAULING...540
Removing main box...540
Removing drive assembly...540
Removing bearing for shaft with gear wheel...540
Removing oil pump...541
Cleaning and checking parts...542
Fitting bearing for shaft with gear wheel...543
Fitting drive assembly...543
Adjusting drive output shaft tapered bearings...545
Adjusting ball bearing...546
SECTION 5 - Intarder - ZF hydraulic retarder...548
Intarder - ZF hydraulic retarder...548
LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE...550
GENERAL INFORMATION...551
OPERATION...551
Retarder engaged...552
Retarder disengaged...553
LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER...554
REMOVING AND REFITTING THE RETARDER ON THE ZF S 151-OD GEARBOX...555
Removal...555
Refitting...556
Filling with oil...556
SPECIFICATIONS AND DATA...557
TIGHTENING TORQUES...558
TOOLS...559
FAULT DIAGNOSIS...561
OVERHAULING THE INTARDER HYDRAULIC RETARDER...565
Hydraulic accumulator...565
Removal...565
Fitting...565
Removing hydraulic retarder...565
Checking the component parts of the hydraulic retarder...570
Fitting the hydraulic retarder...571
Stator end float adjustment...576
SECTION 6 - Propeller shafts...578
Propeller shafts...578
SPECIFICATIONS AND DATA...580
DIAGNOSTIC...585
TIGHTENING TORQUES...587
EQUIPMENT...587
REMOVING AND RE-FITTING IN PLACE THE PROPELLER SHAFT...588
REPAIR OPERATIONS...588
REMOVING THE UNIVERSAL JOINT...588
FITTING IN PLACE THE UNIVERSAL JOINT...588
CHECKING THE PROPELLER SHAFTS ON THE VEHICLE...589
SECTION 7 - Axles...590
Axles...590
AXLES...592
DIAGNOSTIC...594
REMOVING - RE-FITTING IN PLACE THE FRONT DRIVE AXLE (4x4 - 6x6 Vehicles)...596
Removal...596
Re-fitting in place...597
REMOVING REAR AXLES (4x2 - 4x4 Vehicles)...598
REMOVING THE REAR AXLE 6x4 - 6x6 - 8x4x4 Vehicles...600
REMOVING THE INTERMEDIATE AXLE 6x4 - 6x6 - 8x4x4 Vehicles...601
Instructions to adjust and check the functioning of the transmitter that controls the engagement of differential and reduction gear unit locking...602
REFITTING IN PLACE THE AXLE - Vehicles : all versions...602
Front drive axleD 1385 (5985) D 8185 (5985/2D)...605
DESCRIPTION...607
SPECIFICATIONS AND DATA...609
TIGHTENING TORQUE...611
EQUIPMENT...615
REPAIRING THE AXLE ANDWHEEL HUBS...620
Removal...620
Removing the fork support...627
Removing the stub axle...627
Removing the epicyclic reduction gear...628
CLEAN-OUT AND CHECKS...629
CHECKING THE AXLE CASING CAMBER ANGLE AND CASTER ANGLE...629
Fitting in place the fork support...632
Fitting in place the stub axle...633
Fitting in place the epicyclic reduction gear support...638
GREASING THE STUB AXLE PINS...639
EPICYCLIC UNITS LUBRICATION...639
REMOVING THE DIFFERENTIAL (with axle on stand 99322215)...640
Axle casing check...640
RE-FITTING IN PLACE THE DIFFERENTIAL (with axle on stand 99322215)...640
REPAIRING THE DIFFERENTIAL...642
Removal...642
REMOVING THE BEVEL PINION SUPPORT...644
REMOVING THE GEAR HOUSING...644
CHECKING THE DIFFERENTIAL COMPONENTS...644
FITTING IN PLACE THE GEAR HOUSING...645
FITTING IN PLACE THE BEVEL PINION SUPPORT...646
FITTING IN PLACE THE DIFFERENTIAL HOUSING...648
Adjusting the gear housing bearings rolling torque...649
Intermediate axles R 9274 (452191) R 9189 (453291) R 9274 (452191/2D) R 9189 (453291/2D)...654
DESCRIPTION...656
SPECIFICATIONS AND DATA...658
TIGHTENING TORQUES...659
EQUIPMENT...663
REMOVAL-RE-FITTING IN PLACE THE DIFFERENTIAL-REDUCTION GEAR UNIT (with axle on vehicle) ...671
Removal...671
Re-fitting...671
INTERMEDIATE AXLE ASSEMBLY REPAIR OPERATIONS...673
Removal...673
Dis-assembling the epicyclic reduction unit...673
Removing the wheel hubs...674
CHECKS ON THEWHEEL HUBS AND EPICYCLIC REDUCTION GEAR COMPONENTS...676
Fitting in place the wheel hubs...676
Fitting in place the epicyclic reduction unit...679
REMOVAL-RE-FITTING IN PLACE OF THE DIFFERENTIALREDUCTION GEAR UNIT (with axle on stand 99322215)...681
Removal...681
Refitting in place...681
DIFFERENTIAL-REDUCTION GEAR UNIT REPAIR OPERATIONS ...682
Removal...682
Removing the gear housing...687
Removing the differential-reduction gear unit...689
CHECKS ON DIFFERENTIAL-REDUCTION GEAR UNIT COMPONENTS...690
FITTING IN PLACE THE BEVEL PINION HOUSING...693
Procedure to determine the adjusting ring thickness for the bevel pinion rolling torque...693
FITTING IN PLACE THE DIFFERENTIAL HOUSING...695
FITTING IN PLACE THE GEAR HOUSING...696
Adjusting gearing box bearing rolling torque...697
DRIVING SHAFT...701
Removal...701
Checks...702
Refitting in place...702
Intermediate axle R 9174 (452146) R 9174 (452146/2D)...705
DESCRIPTION...707
REPAIRS...707
SPECIFICATIONS AND DATA...709
TIGHTENING TORQUES...710
EQUIPMENT...714
DIFFERENTIAL - REDUCTION GEAR UNIT REPAIR OPERATIONS...722
Removing the bevel pinion support...724
Removing the gear housing...724
Removing the differential - reduction gear unit...725
DIFFERENTIAL - REDUCTION GEAR UNIT COMPONENTS CHECK...728
Assembling the differential - reduction gear unit...728
Assembling the gear housing...730
Assembling the bevel pinion support...731
Procedure to determine the adjusting ring thickness for the bevel pinion rolling torque...731
DIFFERENTIAL HOUSING ASSEMBLY...733
Adjusting the rolling torque for the gear housing bearings...735
Rear axles R 8284 (451391) R 8274 (452191) R 8298 (453291) R 8284 (451391/2D) R 8274 (452191/2D) R 8298 (453291/2D)...740
DESCRIPTION...742
SPECIFICATIONS AND DATA...745
TIGHTENING TORQUE...746
DRIVING TORQUES...747
EQUIPMENT...750
REAR AXLE ASSEMBLY OVERHAUL OPERATIONS...756
Removing the epicyclic reduction gear...756
Removing the wheel hubs...759
CHECKING WHEEL HUB AND EPICYCLIC REDUCTION GEARCOMPONENTS...760
FITTING IN PLACE THEWHEEL HUBS...760
Fitting in place the epicyclic reduction gear...763
REMOVAL AND RE-FITTING IN PLACE THE DIFFERENTIAL...766
RE-FITTING IN PLACE...767
REMOVING THE DIFFERENTIAL HOUSING...768
Removing the gear housing...769
REMOVING THE BEVEL PINION SUPPORT...770
DIFFERENTIAL COMPONENTS CHECK...772
FITTING IN PLACE THE GEAR HOUSING...773
FITTING IN PLACE THE BEVEL PINION SUPPORT...774
Procedure to determine the thickness of the bevel pinion rolling torque adjusting ring...774
FITTING IN PLACE THE DIFFERENTIAL HOUSING...776
Adjusting the rolling torque of the gear housing bearings...777
Rear axle R 8174 (452146) R 8174 (452146/2D)...783
DESCRIPTION...785
REPAIR OPERATIONS...785
SPECIFICATIONS AND DATA...787
TIGHTENING TORQUES...788
EQUIPMENT...792
DIFFERENTIAL REPAIR OPERATIONS...797
Removal...797
REMOVING THE GEAR HOUSING...798
REMOVING THE BEVEL PINION SUPPORT...799
DIFFERENTIAL COMPONENTS CHECK...799
FITTING IN PLACE THE GEAR HOUSING...800
FITTING IN PLACE THE BEVEL PINION SUPPORT...801
FITTING IN PLACE THE DIFFERENTIAL HOUSING...803
Adjusting the rolling torque of the gear housing bearings...804
Axles in Tandem Meritor SR 145 E/2D...807
Axles in tandem (Intermediate) Meritor RD 145 E (R 2478)...809
DESCRIPTION...811
SPECIFICATIONS AND DATA...811
TIGHTENING TORQUES...813
TOOLS...817
EXPERIMENTAL TOOLS...824
! SERVICING INTERMEDIATE AXLEASSEMBLYRD145E(R2478)...827
AIR BREATHER REMOVAL-REFITTING...827
SERVICINGWHEEL HUBS...827
Checking wheel hub components...828
ASSEMBLINGWHEEL HUBS...829
REMOVING DIFFERENTIAL GEAR — TRANSFER BOX(with rear axle on stand 99322215) ...832
REFITTING DIFFERENTIAL GEAR — TRANSFER BOX (with rear axle on stand 99322215)...832
REPAIRING INTER-AXLE UNIT...833
Dismantling inter-axle unit...833
Checking inter-axle unit components...835
Fitting inter-axle unit...835
Adjusting drive input shaft bearing end float...837
Adjusting differential lock and inter-axle control pin end-stop...837
REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING...838
Dismantling gear cage...841
Checking differential components...841
Assembling gear cage...842
ASSEMBLING DIFFERENTIAL CASING...843
Calculatingbevel pinion positionin differential casing...843
COMPUTATIONAL EXAMPLES...844
Adjusting the cap gap...847
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...849
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT...852
Axles in tandem (Rear) Meritor RR 140 E (R 0878)...855
DESCRIPTION...857
SPECIFICATIONS AND DATA...857
TOOLS...861
SERVICING REAR AXLE ASSEMBLY RR 140 E (R 0878)...866
AIR BREATHER REMOVAL/ INSTALLATION...866
REMOVING DIFFERENTIAL (with axle on stand 99322215) ...866
REFITTING DIFFERENTIAL (with axle on stand 99322215)...866
REPAIRING DIFFERENTIAL...867
Removing differential lock...867
Dismantling differential casing...868
Dismantling gear cage...869
Dismantling bevel pinion support...869
Checking differential components...873
Assembling gear cage...873
Specimen calculations...875
Assembling differential casing...875
ADJUSTING THE CAP GAP...877
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...880
Axles in Tandem Meritor RT 153 E/2D...883
Axles in Tandem (Intermediate) Meritor RP 153 E...885
DESCRIPTION...887
SPECIFICATIONS AND DATA...887
TIGHTENING TORQUES...889
TOOLS...893
EXPERIMENTAL TOOLS...900
SERVICING INTERMEDIATE AXLE ASSEMBLY RP 153 E...903
WHEEL HUB OVERHAULING...903
Removing...903
Checks on wheel hub components...904
Refitting...904
REMOVING DIFFERENTIAL ...908
REFITTING DIFFERENTIAL (axle on stand 99322215) ...908
REPAIRING INTER-AXLE UNIT...909
Dismantling inter-axle unit...909
Checking inter-axle unit components...911
Fitting inter-axle unit...911
Adjusting drive input shaft bearing end float...913
Adjusting differential lock and inter-axle control pin end-stop...913
REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING...914
Removing the gear housing...917
Checking the differential components...918
Refitting the gear housing...918
ASSEMBLING DIFFERENTIAL CASING...920
Calculating bevel pinion position in differential casing...920
EXAMPLES...920
ADJUSTING THE CAP ANGLE...923
CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)...926
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT...930
Axles in tandem (rear) MERITOR RR 167...933
DESCRIPTION...935
CHARACTERISTICS AND DATA...936
TIGHTENING TORQUES...937
TOOLS...938
REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215) ...944
Removal...944
Checking axle housing...944
Refitting...944
REPAIRING THE DIFFERENTIAL...945
Removing the differential...945
Removing the gearcase...946
REMOVING THE BEVEL PINION FROM THE SUPPORT...948
Differential component check...948
Fitting the gear housing...949
FITTING THE MOUNT ON THE BEVEL PINION...950
Reassembling the differential housing...952
ADJUSTING THE CAP GAP...954
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...957
WORK ON THE VEHICLE...960
REPLACING THE BEVEL PINION MOUNT SEAL...960
Disassembly...960
Assembly...961
SECTION 8 - Axles...963
Axles...963
Axles 5886 (F9021) 5886/2D (F9021)...965
DESCRIPTION...967
Front axle...967
SPECIFICATIONS AND DATA...968
DIAGNOSTIC...970
TIGHTENING TORQUE...973
TOOL...975
REMOVING AND RE-FITTING THE AXLE...981
Removal...981
Refitting in place...982
VEHICLE CHECKS...983
Kingpins...983
Tie rods...983
TRACK ROD AND DRAG LINK KINGPINS SLACK CHECK...983
FRONT AXLE ASSEMBLY OVERHAUL...984
REMOVING AND RE -FITTING IN PL ACE THE WHEEL HUBS...984
Removal...984
Re-fitting in place the wheel hubs...986
Wheel hub bearings end play adjustment...986
Finding the rolling torque...986
WHEEL HUB BEARINGS REPLACEMENT...987
Wheel bolts replacement...988
REMOVAL AND RE-FITTING IN PLACE THE TRACK ROD...988
REPLACING TRANSVERSE TIE ROD SWIVEL HEADS...989
REMOVING AND REFITTING LEVERS FOR TRANSVERSE TIE ROD...989
REMOVING AND REFITTING LEVER FOR LONGITUDINAL TIE ROD...989
REMOVING AND REFITTING PIN FOR STUB AXLE...989
Removal...989
REMOVAL AND RE-FITTING IN PLACE THE DRAG LINK...990
Replacing kingpin bearing...990
Re-fitting...991
Stub axle-axle end play check and adjustment...992
AXLE BODY CHECKS AND MEASUREMENTS...992
Checking leaf spring supporting surface levelness with reference to kingpin holes using proper equipment...992
Kingpin holes camber angle check...994
Front axle 5886/D (F9021)...995
DESCRIPTION...997
Front axle 5886 / D...997
SPECIFICATIONS AND DATA...998
TIGHTENING TORQUES...1000
FRONT AXLE ASSEMBLY OVERHAUL...1001
REMOVING - REFITTINGWHEEL HUBS...1001
Removal...1001
Refitting wheel hubs...1002
Wheel geometry...1003
GENERAL INFORMATION...1005
Steering wheel angles...1005
FRONTWHEEL GEOMETRY (4X2 VEHICLES)...1006
Positioning clips and headlights...1006
Electronic compensation of rim eccentricity...1007
Wheel alignment...1007
Checking wheel toe-in...1008
Checking wheel deviation...1008
Checking camber...1008
Checking kingpin angle and caster...1009
Checking rear axle alignment...1010
WHEEL GEOMETRY OF VEHICLES WITH ADDED CENTRAL AXLE (8X4X4)...1010
Checking steering angles...1012
SECTION 9 - Suspensions...1013
Suspensions...1013
FRONT AND REAR SUSPENSIONS...1015
Description...1015
SPECIFICATIONS AND DATA FRONT SUSPENSIONS 4X2 - 6X4 - 6X6 - 4X4 MODELS...1025
FRONT SHOCK ABSORBERS...1030
REAR SHOCK ABSORBERS...1031
AIR SUSPENSION...1032
Chassis frame lifting, lowering and self-levelling with remote control ...1032
Saving Levels...1032
AIR SUSPENSION SYSTEM DIAGRAMS...1033
Rear air suspension main diagram for 4x4W/P vehicles...1033
Working diagram of pneumatic rear suspensions for 6x4 HB/P, 8x4 H/P, 8x4 HB/P vehicles...1034
CHARACTERISTICS AND DATA...1035
Pneumatic system...1035
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM...1036
Relief valve...1036
Fault diagnosis...1036
Level sensor...1036
Electropneumatic distributor...1037
Air low pressure manometer switch...1037
Air spring...1037
Pneumatic rear suspension 4x4W/P vehicles...1038
Pneumatic rear suspension 8x4 H/P - HB/P vehicles...1039
FAULT DIAGNOSIS...1041
Diagnosis Instruments...1041
TIGHTENING TORQUE...1047
EQUIPMENT...1048
REMOVAL-REFITTING OF FRONT LEAF SPRING...1053
Removal...1053
Refitting...1053
REMOVAL-REFITTING OF INTERMEDIATE AXLE LEAF SPRING (8X4 VEHICLES)...1054
Removal...1054
Refitting...1054
REMOVAL-REFITTING OF REAR LEAF SPRING (4X2 - 4X4 vehicles)...1055
Removal...1055
Refitting...1055
REMOVAL-REFITTING OF REAR LEAF SPRING ON CANTILEVER TYPE SUSPENSIONS (6X4 - 6X6 - 8X4 vehicles)...1056
Removal...1056
Refitting...1056
Procedure for assembly of the slipper block and mounting brackets for the longitudinal bars...1057
Tightening theU-bolts clamping the leaf spring to the central pivot...1057
REAR CANTILEVER SUSPENSION (6x4 - 6x6 - 8x4 vehicles)...1058
Removal-refitting of central pivot...1058
Removal-refitting of central pivot shaft !...1058
Renewal of bearings...1058
Removal-refitting of hanger bracket...1058
Removal of the central pivot...1058
Removal of the central pivot shaft...1058
Removal of the hanger bracket...1058
Renewal of the bearings...1058
Refitting the hanger bracket...1059
Refitting the central pivot shaft...1060
Refitting the central pivot...1060
REMOVAL-REFITTING OF REAR AXLE LONGITUDINAL ARM...1062
REMOVAL-REFITTING OF INTERMEDIATE AXLE LONGITUDINAL ARM...1062
REMOVAL-REFITTING OF REAR AXLE TRIANGULAR ARM FOR VEHICLES WITH AIR SUSPENSION...1062
Removal...1062
Refitting...1062
REPLACEMENT OF THE FLEXIBLE PINS OF LONGITUDINAL/TRIANGULAR ARMS...1063
Disassembly...1063
Assembly...1063
SHOCK ABSORBERS...1064
Removal...1064
Refitting...1064
ANTI-ROLL BARS...1064
ANTI-ROLL BAR...1065
FRONT ANTI-ROLL BAR...1065
AUXILIARY AXLE ANTI-ROLL BAR (8X4 VEHICLES)...1065
REAR ANTI-ROLL BAR ...1065
INTERMEDIATE AXLE ANTI-ROLL BAR (6X4 - 6X6 - 8X4 VEHICLES)...1065
Removal...1065
Refitting...1065
SECTION 10 - Wheels and tyres...1069
Wheels and tyres...1069
DESCRIPTION...1071
CHARACTERISTICS AND DATA...1071
Tyre inflation pressure data...1071
TOOLS...1072
DIAGNOSTIC...1072
WHEEL STATIC BALANCING...1075
CORRECTING RESIDUAL STATIC UNBALANCE...1076
TYRE PRESSURE...1076
BEHAVIOUR OF TYRES DEPENDING ON INFLATION PRESSURE...1077
SECTION 11 - Steering gear...1079
Steering gear...1079
DESCRIPTION...1081
SPECIFICATIONS AND DATA...1082
DIAGNOSTIC...1083
TIGHTENING TORQUE...1088
EQUIPMENT...1089
Steering control diagram for 4x2 - 6x4 vehicles (ZF 8098 power steering)...1091
Steering control diagram for 4x4 - 6x6 vehicles (ZF 8098 power steering)...1092
Steering control diagram for 8x4x4 vehicles (ZF 8099/1 power steering)...1093
Steering hydraulic control circuit diagram for 8x4x4 vehicles (8099/1 power steering)...1095
HYDRAULIC GUIDE...1097
Mounting steering wheel lever...1097
REMOVING AND REFITTING IN PLACE THE STEERING CONTROL ASSEMBLY...1098
Removal...1098
Fitting in place...1099
MAIN OPERATIONS...1100
Bleeding the air from the power steering circuit...1100
Measuring plays in the steering box detected on the steering wheel ...1100
Checking the power steering system maximum pressure...1100
Adjusting the hydraulic steering limiting device...1100
Checking the steering hydraulic modulation device with the vehicle running...1102
Setting the automatic hydraulic steering limit...1102
Check...1102
SECTION 12 - Pneumatic system - Brakes...1103
Pneumatic system - Brakes...1103
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS)...1106
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)...1107
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...1113
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALIPERS AND CYLINDERS)...1114
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (HALF-JOINTS AND COUPLING HEADS)...1116
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)...1118
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)...1119
PIPES AND COUPLINGS...1120
General...1120
End forming on rigid pipes...1120
Bending rigid pipes...1121
Cutting rigid pipes...1121
Replacing flexible hoses with threaded couplings ...1122
Replacing flexible hoses with quick-connection couplings...1123
BRAKING SYSTEM...1125
Wiring diagram for 4x2 - 4x4 vehicles...1125
6x4 vehicles wiring diagram (the tractor version)...1126
6x4 vehicles wiring diagram (only outside Europe)...1127
6x6 vehicles wiring diagram...1128
8x4x4 vehicles wiring diagram...1129
ABS system wiring diagram (for 4x2 - 4x4 vehicles)...1130
ABS - ASR system wiring diagram (for 4x2 - 4x4 vehicles)...1131
ABS system wiring diagram (for 6x4 - 6x6 vehicles)...1132
ABS - ASR system wiring diagram (for 6x4 - 6x6 vehicles)...1133
ABS system wiring diagram (for 8x4x4 vehicles)...1134
ABS - ASR system wiring diagram (for 8x4x4 vehicles)...1135
Working diagram for 4x2 - 4x4 vehicles designed for towing with EBL device...1136
Working diagram for 6x4 vehicles isolated with an EBL device...1137
Working diagram for 6x4 - 6x6 vehicles designed for towing with EBL device...1138
Working diagram for 8x4x4 vehicles isolated with an EBL device...1139
Working diagram for 8x4x4 vehicles designed for towing with EBL device...1140
BRAKING SYSTEM...1141
Working diagram for 4x2 - 4x4 vehicles designed for towing with ABS-ASR device (without braking corrector)...1141
Working diagram for 6x4 - 6x6 vehicles designed for towing with ABS-ASR device (without braking corrector)...1142
Working diagram for isolated 6x4 vehicles with ABS-ASR device (without braking corrector)...1143
Working diagram for isolated 8x4x4 vehicles with ABS-ASR device (without braking corrector)...1144
Working diagram for 8x4x4 vehicles designed for towing with ABS-ASR device (without braking corrector)...1145
Braking system main components layout on the vehicle...1146
ABS - ASR system main components layout on the vehicle...1147
DESCRIPTION...1148
Service braking...1148
Emergency braking...1148
Retarding braking...1148
Parking braking...1148
BRAKES...1148
Front disc brakes SB7 - SN7 type (for vehicles with partial traction)...1148
Drum brakes...1148
FAULT DIAGNOSIS...1149
Diagnosis Instruments...1149
ABS Troubleshooting...1151
TIGHTENING TORQUES...1169
TOOLS...1172
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM...1181
SPECIFICATIONS AND DATA - BRAKES...1186
BRAKING SYSTEM MAIN COMPONENTS CHECK...1193
BRAKING SYSTEM MAIN COMPONENTS...1196
Compressor...1196
Head fastening screws tightening torque...1196
Diagnostic...1196
Drier...1197
Diagnostic...1197
Four-way safety valve...1197
Diagnostic...1197
Duplex distributor...1198
Diagnostic...1198
Pressure reducer...1199
Diagnostic...1199
Setting at the bench...1199
Triple control servo distributor...1199
Diagnostic...1199
Predominance adjustment...1199
KNORR BREMSE AC 597B...1200
KNORR BREMSE AC 597B WABCO 973 009 013...1200
Diagnostic...1200
Coupling heads...1201
Check valve (towing vehicles)...1201
Parking brakes control hand distributor (for towing vehicles)...1201
Diagnostic...1201
Parking brakes control hand distributor (stand-alone vehicles)...1202
Diagnostic...1202
Relay valves...1203
Diagnostic...1203
Engine brake control pedal valve...1203
Diaphragm brake cylinder...1203
Combined brake cylinder...1204
Combined cylinder emergency relief device...1204
REPAIR OPERATIONS...1204
Diagnostic...1204
BRAKING CONTROL...1205
For 6x4 - 6x6 - 8x4x4 vehicles...1206
Diagnostic...1207
ANTI-SKID SYSTEM...1207
ABS (Anti-Lock Brake System)...1207
ASR (Anti-Slip Regulator) system...1207
EBL (Electronic Brakes Limiter)...1207
Electronic control unit...1208
Brake anti-lock distributor...1208
Electropneumatic valve for ASR...1208
Rpm sensors...1208
Phonic wheels...1208
BRAKE REPAIRS...1209
FRONT DISC BRAKES SB7 TYPE (VEHICLESWITH PARTIAL TRACTION)...1209
DISC BRAKES SN7 TYPE...1210
Brakes SB7 type operation...1211
CHECKS...1211
Efficiency of automatic clearance recovery...1211
Brake lining thickness...1212
Replacing brake linings...1213
Removing and refitting SB7 brake callipers...1215
Removal...1215
Refitting...1215
Removing and refitting wheel hubs...1216
Removal...1216
Refitting...1216
OVERHAULING SB7 BRAKECAL - LIPERS...1217
Cleaning and checking component parts...1218
Assembly...1218
OVERHAULING BRAKE DISCS...1219
TURNING AND GRINDING BRAKE DISCS ON THE BENCH ...1220
TURNING AND GRINDING BRAKE DISCS ON THE VEHICLE...1220
DRUM BRAKES...1221
FRONT BRAKES...1222
REAR BRAKES...1222
Disassembly...1222
Drum turning...1227
Replacing brake linings...1227
Turning brake linings...1228
Assembly...1228
SECTION 13 - Body work - Chassis...1235
Body work - Chassis...1235
CAB...1237
Specifications...1237
TIGHTENING TORQUE...1237
EQUIPMENT...1237
ANCHORAGE CAB...1238
REPAIR OPERATIONS...1240
REPLACING CAB SUSPENSION FRONT AND REAR SHOCK ABSORBERS ...1240
REMOVING AND RE-FITTING INPLACE THEFRONTSUPPORTS AND CAB STABILIZER BARS...1240
REPLACING THE CAB TIPPING HYDRAULIC CYLINDER...1241
REPLACING THEWINDSCREEN...1241
REPLACING LOWERABLE DOOR WINDOWS...1242
REPLACING THEWINDOW CLOSING DEVICE...1243
REPLACINGTHEFIXEDWINDOW...1243
Replacing the roof air vent hatch...1245
CAB HEATING AND VENTILATION UNIT...1245
CHASSIS...1246
REPAIR OPERATIONS...1246
CHECKS...1246
Finding chassis bending up and down...1247
Finding chassis lateral bending...1247
Finding chassis displacement...1247
Finding chassis twist...1248
PRECAUTIONS...1248
Welds on the chassis...1250
SECTION 14 - Scheduled maintenance...1251
SCHEDULED MAINTENANCE...1253
Description...1253
Maintenance services specifications...1253
EXTRA PLAN OPERATIONS...1253
Maintenance servicing table (time intervals)...1257
CHECK AND/OR MAINTENANCE POINTS SCHEME...1259
603.43.811 - Iveco EuroTrakker Cursor 13 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('93-'04)...1261
EUROTRAKKER CURSOR 13...1261
REPAIR MANUAL...1261
NOTE...1263
Graphics and Symbols...1264
CONTENTS OF SECTIONS...1265
SECTION 1 - General...1266
General...1266
VEHICLE IDENTIFICATION DATA...1268
Vehicle Identification Plate...1269
Production identification plate...1269
P.I.C. NUMBER CODING...1270
COMPOSITION OF MODELS...1274
REPLENISHING FLUIDS...1280
International lubricant and fluid names...1282
SECTION 2 - Engine...1284
Engine...1284
VIEWS OF THE ENGINE...1288
TECHNICAL DESCRIPTION...1291
CHARACTERISTIC CURVES...1292
GENERAL SPECIFICATIONS...1296
ASSEMBLY DATA - CLEARANCE...1299
FAULT DIAGNOSIS...1305
Blink Code...1305
Check procedures / troubleshooting...1305
Procedures to delete faultmemory fromdriving seat...1305
EDC MS 6.2 control unit blink code table...1306
FAULT DIAGNOSIS INSTRUMENTS...1307
MODUS - IT2000...1307
I.W.T...1308
TROUBLESHOOTING...1309
Introduction...1309
Troubleshooting with Blink Code...1310
Troubleshooting by symptoms...1318
TIGHTENING TORQUES...1325
DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS...1328
TOOLS...1332
ENGINE REMOVAL-REFITTING...1342
Removal...1342
Refitting...1345
Filling the cooling system...1346
Bleeding air from the supply system...1347
Checks and tests...1347
STRIPPING THE ENGINE ON THE BENCH...1350
REPAIRS...1358
Cylinder block...1358
Checks and measurements...1358
Cylinder liners...1359
Replacing the cylinder liners...1360
Crankshaft...1361
Measuring the main journals and crankpins...1362
Selecting the main bearing and big end bearing shells...1363
Preliminary measurement of data to select main bearing and big end bearing shells...1364
Replacing the timing gear and oil pump...1371
Checking main journal assembly clearance...1371
Checking crankshaft end float...1372
Connecting rod piston assembly...1373
Piston rings...1375
Connecting rod...1376
Checking connecting rods...1377
Mounting the connecting rod - piston assembly...1377
Mounting the piston rings...1377
Fitting connecting rod piston assembly in the cylinder liners to check assembly clearances...1378
Checking assembly clearance of big end pins...1379
Cylinder head...1379
Removing valves...1379
Checking head bearing surface on cylinder block...1379
Valves...1379
Decarbonizing and checking valves...1379
Valve guides...1380
Replacing valve guides...1381
Replacing - Regrinding valve seats...1381
Replacing injector cases...1381
Checking injector protrusion...1383
Timing system...1384
Checking cam lift and pin alignment...1384
Camshaft...1385
Bushings...1385
Valve springs...1388
Rocker arm shaft...1389
Rocker arms...1389
ENGINE ASSEMBLY ON BENCH...1390
Fitting connecting rod piston assemblies in cylinder liners...1393
Fitting cylinder head...1394
Fitting flywheel box...1395
ENGINE FLYWHEEL...1396
Fitting engine flywheel...1396
Fitting camshaft...1397
Fitting pump-injectors...1398
Rocker arm holder shaft assembly...1398
Camshaft timing...1399
Phonic wheel timing...1401
Adjusting rocker armclearance, intake, exhaust and pre-load of pump injector governing rocker arms...1402
Completing assembly...1403
LUBRICATION...1405
Oil pump...1405
Overpressure valve...1405
Oil pressure control valve...1406
Heat exchanger...1406
By-pass valve...1407
Thermostatic valve...1407
Engine oil filters...1407
Lubrication circuit...1408
COOLING...1410
Water pump...1410
View of thermostat operation...1410
Cooling circuit...1412
TURBOCHARGING...1414
Turbocharger...1414
HOLSET HY55V (VGT Turbine)...1415
Actuator...1418
Working principle...1418
Solenoid valve for VGT control...1418
HOLSET HX 50W (Wastegate Turbine)...1420
Pressure relief valve...1420
FEEDING...1422
Fuel pump...1423
Injector-pump...1423
Replacing injectors-pump...1423
Injector Phases...1424
HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)...1426
Specifications and data...1427
Tightening torques...1428
Engaging power take-off...1429
Removing-refitting power take-off...1429
SECTION 3 - Clutch...1430
Clutch...1430
DESCRIPTION...1432
Clutch...1432
SPECIFICATIONS AND DATA...1432
FAULT DIAGNOSIS...1434
TIGHTENING TORQUES...1437
TOOLS...1437
REMOVING AND REFITTING THE CLUTCH...1438
Removal...1438
CHECKS...1438
Refitting...1439
REMOVING-REFITTING THE THRUST BEARING...1439
CLUTCH DISENGAGEMENT CONTROL (vehicles with ZF 16 S 151/181/221 O.D. gearboxes)...1440
REMOVING-REFITTING THE PEDAL UNIT...1440
Removal...1440
Refitting...1440
PEDAL UNIT...1441
REMOVAL-ASSEMBLY...1441
CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ZF 16 S 151 O.D./181 O.D./221 O.D. gearboxes)...1442
Clutch stop...1442
Idle travel of clutch pedal...1442
Pedal control valve stroke...1442
HYDRAULIC CONTROL (vehicles with ZF 16 S 151 O.D./181 O.D./221 O.D. gearboxes)...1443
CLUTCH ACTUATOR FOR ZF 16 S 151 O.D./181 O.D./221 O.D. GEARBOXES...1444
Fitting and adjusting the clutch wear indicator...1444
Push rod adjustment (new clutch)...1445
Push rod adjustment (vehicles with PTO opt. 2395 only)...1445
BLEEDING THE AIR FROM THE CLUTCH CIRCUIT...1445
CLUTCH ACTUATOR FOR THE EUROTRONIC 16 A S 2601 O.D. GEARBOX...1446
Clutch actuator push rod adjustment (new clutch)...1446
Fitting the clutch actuator...1446
Replacing the clutch actuator...1446
SECTION 4 - Gearbox...1448
Gearbox...1448
Gearboxes ZF 16 S 151 O.D. - ZF 16 S 181 O.D. - ZF 16 S 221 O.D...1450
LOCATION OF GEARBOX DESCRIPTION PLATE...1452
DESCRIPTION...1453
GEARBOX AIR-OPERATED CONTROL...1455
OPERATION...1456
Slow range...1456
Fast range...1457
EPICYCLIC REDUCTION GEAR CONTROL...1458
Reduced speeds...1458
Normal speeds...1459
SPECIFICATIONS AND DATA...1460
TIGHTENING TORQUES...1464
TOOLS...1465
GEARBOX FAULT DIAGNOSIS...1470
REMOVING-REFITTING THE GEARBOX...1474
Removal...1474
Refitting...1475
OVERHAULING THE GEARBOX...1476
Servoshift gear box...1476
Removal...1476
Refitting...1476
Disassembly...1476
Assembly...1478
Removing the rear box...1482
Removing the epicyclic reduction gear unit (ERG)...1482
Fitting the epicyclic reduction gear unit (ERG)...1484
Refitting the epicyclic reduction gear unit (ERG) rear box ...1487
Removing the gearbox...1487
Removing the main shaft...1490
Removing the drive input shaft...1493
Removing the transmission shaft...1494
CHECKS...1494
Gearbox...1494
Hubs - sliding sleeves - forks...1494
Bearings...1494
Shafts - gears...1494
Synchronizing devices...1494
BK-type single-cone synchronizing devices...1494
Fitting the transmission shaft...1495
Fitting the drive input shaft...1495
Fitting the main shaft...1496
Adjusting the main shaft...1498
Fitting the gearbox...1499
Oil pump...1500
Adjusting the transmission shaft bearing end float...1500
Drive input shaft cover...1501
ZF gearboxes with INTARDER hydraulic retarder, types: 16 S 151 O.D. - 16 S 181 O.D. - 16 S 221 O.D...1504
SPECIFICATIONS AND DATA...1506
TOOLS...1507
Removing the hydraulic retarder from the gearbox on the stand...1514
Refitting the hydraulic retarder...1514
Removing the epicyclic reduction gear unit (ERG) rear box...1515
Removing the epicyclic reduction gear unit (ERG)...1515
Component parts of the epicyclic reduction gear unit...1518
Fitting the epicyclic reduction gear unit (ERG)...1519
Refitting the epicyclic reduction gear unit (ERG) rear box...1521
Gearbox: EuroTronic 16 AS 2601 O.D...1523
DESCRIPTION...1525
SPECIFICATIONS AND DATA...1526
TIGHTENING TORQUES...1529
TOOLS...1530
OVERHAULING THE GEARBOX...1535
Checks...1535
Gearbox actuator...1535
Removal...1535
Refitting...1536
Removing the rear box...1536
Removing the rear box...1537
Removing the epicyclic reduction gear train (E.R.G.)...1538
Fitting the epicyclic reduction gear train (E.R.G.)...1540
Adjusting epicyclic reduction gear train bearing end float...1541
Adjusting main shaft end float...1542
Synchronizing device assembly for engaging normal or reduced gears...1544
Removal...1544
Removing the middle box...1547
Removing the main shaft...1549
Removing the drive input shaft...1551
Removing the splitter synchronizing device...1552
Fitting the splitter synchronizing device...1553
Fitting the main shaft...1554
Fitting the drive input shaft...1554
Splitter control fork ...1557
Disassembly - Assembly...1557
Gear control forks...1557
Removal...1557
Fitting...1558
Transmission shafts...1559
Disassembly - Assembly...1559
Fitting the middle box...1559
Fitting the front box...1562
Front cover...1564
Removal...1564
Fitting the front cover...1564
Adjusting drive input shaft bearing end float...1564
Adjusting transmission shaft bearing end float...1565
Clutch release lever...1567
Gearbox: EuroTronic 16 AS 2601 O.D. with Intarder...1570
EuroTronic Automated 16 AS 2601 O.D. with intarder...1572
SPECIFICATIONS AND DATA...1572
OVERHAULING THE GEARBOX...1573
Removing the hydraulic retarder...1573
Refitting the hydraulic retarder...1574
Adjusting epicyclic reduction gear train bearing end float...1574
Adjusting stator end float...1575
Removing the rear box...1576
Removing the E.R.G...1577
Fitting the E.R.G...1578
EXPERIMENTAL TOOLS...1583
SECTION 5 - Intarder - ZF hydraulic retarder...1584
Intarder - ZF hydraulic retarder...1584
LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE...1586
GENERAL INFORMATION...1587
OPERATION...1587
Retarder engaged...1588
Retarder disengaged...1589
LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER...1590
REMOVING AND REFITTING THE RETARDER ON THE ZF S 151/181/221-OD GEARBOX...1591
Removal...1591
Refitting...1592
Filling with oil...1592
SPECIFICATIONS AND DATA...1593
TIGHTENING TORQUES...1594
TOOLS...1595
FAULT DIAGNOSIS...1597
OVERHAULING THE INTARDER HYDRAULIC RETARDER...1601
Hydraulic accumulator...1601
Removal...1601
Fitting...1601
Removing hydraulic retarder...1601
Checking the component parts of the hydraulic retarder...1606
Fitting the hydraulic retarder...1607
Stator end float adjustment...1612
SECTION 6 - Total power take-off (Option 2395)...1614
Total power take-off (Option 2395)...1614
DESCRIPTION...1616
SPECIFICATIONS AND DATA...1617
TIGHTENING TORQUES...1618
TOOLS...1619
Operation (power take off disengaged)...1623
Operation (power take off engaged)...1624
REMOVING - REFITTING TOTAL POWER TAKE-OFF ASSEMBLY...1625
Removal...1625
Refitting...1625
OVERHAULING...1626
Removing main box...1626
Removing drive assembly...1626
Removing bearing for shaft with gear wheel...1626
Removing oil pump...1627
Cleaning and checking parts...1628
Fitting oil pump...1628
Fitting bearing for shaft with gear wheel...1629
Fitting drive assembly...1629
Adjusting drive output shaft tapered bearings...1631
Fitting main box...1632
Adjusting ball bearing...1632
SECTION 7 - Reduction gear - Divider TC 1800-TC 2200...1634
Reduction gear - Divider TC 1800-TC 2200...1634
DESCRIPTION OF REDUCTION GEAR - DIVIDER ASSEMBLY TC 1800 - TC 2200...1636
SPECIFICATIONS AND DATA...1636
VERSION WITH P.T.O. (OPT. 391-392)...1638
P.T.O. SPECIFICATIONS...1638
USING THE REDUCTION GEAR - DIVIDER...1639
On-road driving (normal ratio)...1639
Diagram of drive transmission with normal ratio...1640
Off-road driving (reduced ratio)...1641
Diagram of drive transmission with reduced ratio...1642
Version with P.T.O...1643
TORQUE DIVIDER...1646
Division ratio calculation...1646
Control locking divider and differential gears...1647
TIGHTENING TORQUES...1649
TOOLS...1653
LUBRICATION...1656
REMOVING AND REFITTING REDUCTION GEAR - DIVIDER ...1657
Removal...1657
Refitting...1657
REMOVING THE REDUCTION GEAR - DIVIDER ON THE BENCH...1657
CLEANING AND CHECKING PARTS...1661
REPLACING OUTPUT SHAFT COVER SEALS...1661
REPLACING INPUT SHAFT COVER SEAL...1661
INPUT SHAFT...1662
Removal...1662
Fitting...1662
EPICYCLIC DIVIDER UNIT...1663
Removal...1663
Fitting...1664
COUNTERSHAFT...1664
Removal...1664
Fitting...1664
FITTING THE REDUCTION GEAR - DIVIDER ON THE BENCH...1665
ADJUSTING THE BEARING PRE-LOAD...1668
Input shaft...1668
Countershaft...1668
Output shaft...1669
COMPLETING ASSEMBLY...1670
Adjusting push-rod switch signalling divider locking and P.T.O. engagement (if applicable)...1671
Adjusting pulse transmitter...1671
Replenishing oil...1671
SECTION 8 - Propeller shafts...1672
Propeller shafts...1672
SPECIFICATIONS AND DATA...1674
FAULT DIAGNOSIS...1674
TIGHTENING TORQUES...1676
TOOLS...1676
PROPELLER SHAFT REMOVAL AND REFITTING...1677
Removal...1677
Refitting...1677
REPAIRS...1677
Removing the universal joint...1677
Fitting the universal joint...1677
CHECKING PROPELLER SHAFTS ON VEHICLES...1678
SECTION 9 - Axles...1680
Axles...1680
FAULT DIAGNOSIS...1682
REAR AXLE REMOVAL - REFITTING...1684
Removing the intermediate axle ( 6x4 - 8x4 - 8x8 vehicles)...1684
Removing the rear axle ( 6x4 - 8x4 - 8x8 vehicles) ...1685
Refitting the rear axle...1686
Instructions for adjustments and checks on differential lock and flow divider engagement transmitter operation...1686
Front Axle 5985/2D (D1385)...1689
DESCRIPTION...1691
SPECIFICATIONS AND DATA...1692
TIGHTENING TORQUES...1694
TOOLS...1696
OVERHAULING THE FRONT AXLEE...1702
Wheel hub disassembly...1702
Stub axle disassembly...1703
Drive shaft disassembly...1705
Fork support disassembly...1705
Stub axle disassembly...1706
Wheel hub disassembly...1706
Epicycloid gear disassembly...1706
CLEANING AND CHECKING PARTS...1707
CHECKING THE AXLE HOUSING ANGLE AND INCIDENCE...1707
ASSEMBLY...1710
Fork support assembly...1711
Drive shaft assembly...1712
Stub axle assembly...1712
Epicycloid reduction gear assembly...1717
Greasing the stub axle pins...1718
Epicycloid gear unit lubrication...1718
REMOVING THE DIFFERENTIAL (with the rear axle mounted on stand 99322215)...1719
Checking the axle housing...1719
REFITTING THE DIFFERENTIAL (with the axle mounted on stand 99322215)...1719
DIFFERENTIAL REPAIR...1721
Disassembly...1721
Disassembling the gear housing...1722
Disassembling the bevel pinion support...1723
CHECKING THE DIFFERENTIAL COMPONENTS...1723
Assembling the gear housing...1724
Assembling the bevel pinion support...1725
Differential...1727
Adjusting the rolling torque on the gear housing bearings...1728
Intermediate axles 452191/2D (R 9274) 453291/2D (R 9189)...1732
DESCRIPTION...1734
SPECIFICATIONS AND DATA...1735
TIGHTENING TORQUES...1736
TOOLS...1738
REMOVING-REFITTING THE FLOW DIVIDER DIFFERENTIAL (with the axle mounted on the vehicle)...1745
Removal...1745
Refitting...1745
INTERMEDIATE AXLE ASSEMBLY REPAIRS...1746
Disassembly...1746
Epicycloid reduction gear disassembly...1746
Wheel hub disassembly...1747
Wheel hub disassembly...1750
Assembling the epicycloid reduction gear...1752
REMOVING-REFITTING THE FLOW DIVIDER DIFFERENTIAL (with the axle mounted on stand 99322215)...1754
Removal...1754
Refitting...1754
REPAIRING THE FLOW DIVIDER-DIFFERENTIAL...1755
Flow divider differential unit disassembly...1755
Gear housing disassembly...1758
Flow divider-differential disassembly...1760
Flow divider differential unit assembly...1764
Gear housing assembly...1765
Flow divider differential unit assembly...1767
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...1767
Adjusting the rolling torque on the gear housing bearings...1771
DRIVE SHAFT...1775
Disassembly...1775
Checking parts...1776
Assembly...1776
Intermediate axle 452146/2D (R 9174)...1779
DESCRIPTION...1781
SPECIFICATIONS AND DATA...1782
TIGHTENING TORQUES...1783
TOOLS...1785
REPAIRING THE FLOW DIVIDERDIFFERENTIAL ASSEMBLY...1791
Disassembly...1791
REPAIRING THE FLOW DIVIDER DIFFERENTIAL...1791
Flow divider differential unit disassembly...1791
Removing the bevel pinion from the support...1794
Gear housing disassembly...1794
Differential - flow divider disassembly...1795
CHECKING THE DIFFERENTIAL - FLOW DIVIDER COMPONENTS...1799
Flow divider - differential unit assembly...1799
Gear housing assembly...1801
Assembling the bevel pinion support...1802
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...1802
Differential housing assembly...1804
Gear housing bearings rolling torque adjustment...1806
Rear axles 451391/2D (R 8284) 452191/2D (R 8274) 453291/2D (R 8298)...1812
DESCRIPTION...1814
SPECIFICATIONS AND DATA...1815
TIGHTENING TORQUES...1816
TOOLS...1818
REAR AXLES ASSEMBLY OVERHAUL...1823
Disassembly...1823
Epicycloid reduction gear disassembly...1823
Wheel hub disassembly...1824
CLEANING AND CHECKING WHEEL HUB AND EPICYCLOID GEAR PARTS...1826
WHEEL HUB ASSEMBLY...1827
Assembling the epicycloid reduction gear...1829
REMOVING-REFITTING THE DIFFERENTIAL...1832
REFITTING...1833
REPAIRING THE DIFFERENTIAL...1834
Removal...1834
Gear housing disassembly...1835
Removing the bevel pinion from the support...1836
CHECKING THE DIFFERENTIAL COMPONENTS...1838
Gear housing assembly...1839
Assembling the bevel pinion support...1840
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...1840
Differential housing assembly...1842
Gear housing bearings rolling torque adjustment...1843
Rear axle 452146/2D (R 8174)...1849
DESCRIPTION...1851
SPECIFICATIONS AND DATA...1852
TIGHTENING TORQUES...1853
TOOLS...1855
REAR AXLE ASSEMBLY OVERHAUL...1860
REPAIRING THE DIFFERENTIAL...1860
Disassembly...1860
Disassembling the gear housing...1861
Disassembling the bevel pinion support...1862
CHECKING THE DIFFERENTIAL COMPONENTS...1862
Assembling the gear housing...1863
Assembling the bevel pinion support...1864
Differential housing assembly...1866
Adjusting the rolling torque on the gear housing bearings...1867
Axles in Tandem MERITOR RT 153E/2D...1872
Axles in Tandem (Intermediate) Meritor RP 153E...1874
DESCRIPTION...1876
SPECIFICATIONS AND DATA...1876
TIGHTENING TORQUES...1878
TOOLS...1882
EXPERIMENTAL TOOLS...1889
SERVICING INTERMEDIATE AXLE ASSEMBLY RP 153E...1892
WHEEL HUB OVERHAULING...1892
Removing...1892
Checks on wheel hub components...1893
Refitting...1893
REMOVING DIFFERENTIAL (AXLE ON STAND 99322215) ...1897
REFITTING DIFFERENTIAL (axle on stand 99322215)...1897
REPAIRING INTER-AXLE UNIT...1898
Dismantling inter-axle unit...1898
Checking inter-axle unit components...1900
Fitting inter-axle unit...1900
Adjusting drive input shaft bearing end float...1902
REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING...1903
Removing the gear housing...1906
Checking the differential components...1907
Refitting the gear housing...1907
ASSEMBLING DIFFERENTIAL CASING...1909
Calculating bevel pinion position in differential casing...1909
ADJUSTING THE CAP ANGLE...1912
CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)...1915
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT...1919
Rear Axle MERITOR U 177 E...1922
DESCRIPTION...1924
CHARACTERISTICS AND DATA...1925
TIGHTENING TORQUES...1926
TOOLS...1927
REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215) ...1933
Removal...1933
Checking axle housing...1933
Refitting...1933
REPAIRING THE DIFFERENTIAL...1934
Removing the differential...1934
Removing the gearcase...1935
REMOVING THE BEVEL PINION FROM THE SUPPORT...1937
Differential component check...1937
Fitting the gear housing...1938
FITTING THE MOUNT ON THE BEVEL PINION...1939
Reassembling the differential housing...1941
ADJUSTING THE CAP GAP...1943
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...1946
WORK ON THE VEHICLE...1949
REPLACING THE BEVEL PINION MOUNT SEAL...1949
Disassembly...1949
Assembly...1950
SECTION 10 - Front axles...1952
Front axles...1952
Front axle 5886/D (F9021)...1955
DESCRIPTION...1957
Front axle 5886 / D...1957
SPECIFICATIONS AND DATA...1958
TIGHTENING TORQUES...1960
FAULT DIAGNOSIS...1961
TOOLS...1964
REMOVING AND REFITTING FRONT AXLE...1969
Removal...1969
Refitting...1969
REMOVING AND REFITTING MIDDLE AXLE (8X4 - 8X8 VEHICLES)...1970
Removal...1970
Refitting...1970
VEHICLE CHECKS...1971
Tie rods...1971
Swivel heads...1971
CHECKING SWIVEL HEAD PLAY...1971
FRONT AXLE ASSEMBLY OVERHAUL...1972
REMOVING - REFITTINGWHEEL HUBS...1972
Removal...1972
Replacing wheel hub bearings...1973
Replacing wheel fixing pins...1974
Refitting wheel hubs...1974
Checking wheel hub bearing end float...1974
Measuring rolling torque...1975
REMOVING AND REFITTING TRANSVERSE TIE ROD...1975
REPLACING TRANSVERSE TIE ROD SWIVEL HEADS ...1976
REMOVING AND REFITTING PIN FOR STUB AXLE ...1976
Removal...1976
Replacing kingpin bearing...1977
Checking and adjusting clearance between stub axle and axle...1978
CHECKING AND MEASURING THE AXLE BODY...1979
Checking angle of holes for kingpins...1980
Front axle 5886/2D (F9021)...1982
DESCRIPTION...1984
Front axle 5886 / 2D...1984
SPECIFICATIONS AND DATA...1985
TIGHTENING TORQUES...1987
FRONT AXLE ASSEMBLY OVERHAUL...1988
REMOVING - REFITTING WHEEL HUBS...1988
Removal...1988
Refitting wheel hubs...1989
Wheel geometry...1992
GENERAL INFORMATION...1994
Steering wheel angles...1994
FRONT WHEEL GEOMETRY (4X2 VEHICLES)...1995
Positioning clips and headlights...1995
Electronic compensation of rim eccentricity...1996
Wheel alignment...1996
Checking wheel toe-in...1997
Checking wheel deviation...1997
Checking camber...1997
Checking kingpin angle and caster...1998
Checking rear axle alignment...1999
WHEEL GEOMETRY OF VEHICLES WITH ADDED CENTRAL AXLE (8X4X4)...1999
Checking steering angles...2001
SECTION 11 - Suspensions...2002
Suspensions...2002
FRONT AND REAR MECHANICAL SUSPENSIONS...2004
Description...2004
SPECIFICATIONS AND DATA...2015
FRONT SHOCK ABSORBERS...2025
REAR SHOCK ABSORBERS...2026
AIR SUSPENSION...2027
Chassis frame lifting, lowering and self-levelling with remote control ...2027
Saving Levels...2027
Working diagram of pneumatic rear suspensions for 8x4 H/P, 8x4 HB/P vehicles...2028
CHARACTERISTICS AND DATA...2029
Pneumatic system...2029
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM...2030
Relief valve...2030
Fault diagnosis...2030
Level sensor...2030
Electropneumatic distributor...2031
Air low pressure manometer switch...2031
Air spring...2031
Rear pneumatic suspension for vehicles 8x4 H/P - HB/P...2032
FAULT DIAGNOSIS...2033
Diagnosis Instruments...2033
TIGHTENING TORQUES...2038
TOOLS...2039
REMOVAL-REFITTING OF FRONT LEAF SPRING...2044
Removal...2044
Refitting...2044
REMOVAL-REFITTING OF INTERMEDIATE AXLE LEAF SPRING (8X4 VEHICLES)...2045
Removal...2045
Refitting...2045
REMOVAL-REFITTING OF REAR LEAF SPRING (4X2 - 4X4 VEHICLES)...2046
Removal...2046
Refitting...2046
REMOVAL-REFITTING OF REAR LEAF SPRING ON CANTILEVER TYPE SUSPENSIONS (6X4 - 6X6 - 8X8 VEHICLES)...2047
Removal...2047
Refitting...2047
Procedure for assembly of the slipper block and mounting brackets for the longitudinal bars...2048
Tightening theU-bolts clamping the leaf spring to the central pivot...2048
REAR CANTILEVER SUSPENSION (6x4 - 6x6 - 8x4 - 8x8 vehicles)...2049
Removal-refitting of central pivot...2049
Removal-refitting of central pivot...2049
Renewal of bearings...2049
Removal-refitting of hanger bracket...2049
Removal of the central pivot...2049
Removal of the central pivot shaft...2049
Removal of the hanger bracket...2049
Renewal of the bearings...2049
Refitting the hanger bracket...2050
Refitting the central pivot shaft...2051
Refitting the central pivot...2051
REMOVAL-REFITTING OF REAR AXLE LONGITUDINAL ARM...2053
REMOVAL-REFITTING OF INTERMEDIATE AXLE LONGITUDINAL ARM...2053
REMOVAL-REFITTING OF REAR AXLE TRIANGULAR ARM FOR VEHICLES WITH AIR SUSPENSION...2053
Removal...2053
Refitting...2053
REPLACEMENT OF THE FLEXIBLE PINS OF LONGITUDINAL/TRIANGULAR ARMS...2054
Disassembly...2054
Assembly...2054
SHOCK ABSORBERS...2055
Removal...2055
Refitting...2055
ANTI-ROLL BARS...2055
ANTI-ROLL BAR...2056
FRONT ANTI-ROLL BAR...2056
AUXILIARY AXLE ANTI-ROLL BAR (8X4 VEHICLES)...2056
REAR ANTI-ROLL BAR...2056
INTERMEDIATE AXLE ANTI-ROLL BAR (6X4 - 6X6 - 8X4 - 8X8 VEHICLES)...2056
Removal...2056
Refitting...2056
SECTION 12 - Wheels and tyres...2060
Wheels and tyres...2060
DESCRIPTION...2062
SPECIFICATIONS AND DATA...2062
Tyre inflation pressures...2062
TOOLS...2063
FAULT DIAGNOSIS...2063
STATICWHEEL BALANCING...2066
CORRECTION OF RESIDUAL STATIC IMBALANCE...2067
TYRE INFLATION PRESSURES...2067
RELATIONSHIP OF INFLATION PRESSURE TO TYRE BEHAVIOUR...2068
SECTION 13 - Steering...2070
Steering...2070
DESCRIPTION...2072
STEERING BOX/VEHICLE COMBINATIONS...2073
SPECIFICATIONS AND DATA...2074
Vehicles: 4X2 - 4X4 - 6X4 - 6X6...2074
Vehicles: 8x4x4 - 8x8...2074
FAULT DIAGNOSIS...2075
TOOLS...2080
TIGHTENING TORQUES...2081
Steering gear arrangement for 4x2 - 6x4 vehicles (ZF 8098 steering box)...2082
Steering gear arrangement for 4x4 - 6x6 vehicles (ZF 8098 steering box)...2083
Steering gear arrangement for 8x4x4 - 8x8 vehicles (ZF 8099/1.5 steering box)...2084
Hydraulic circuit diagram for 8x4x4 - 8x8 vehicles (ZF 8099/1.5 steering box)...2085
HYDRAULIC POWER STEERING...2086
Steering lever assembly...2086
REMOVAL AND REFITTING OF COMPLETE STEERING COLUMN...2087
Removal...2087
Refitting...2088
MAIN OPERATIONS...2089
Bleeding the power steering system...2089
Measuring steering box play at the steering wheel ...2089
Checking the maximum pressure of the power steering wheel...2089
Adjustment of hydraulic steering limiting valves...2089
Testing the hydraulic steering limiting valves with the vehicle in motion...2090
Setting the automatic hydraulic steering limit...2090
Checking...2090
SECTION 14 - Air system - Brakes...2092
Air system - Brakes...2092
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (MISCELLANEOUS AND GENERATORS)...2096
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (VALVES)...2097
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)...2103
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)...2104
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (CALLIPERS AND CYLINDERS)...2105
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (HALF-COUPLINGS AND COUPLING HEADS)...2106
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (HALF-COUPLINGS AND COUPLING HEADS)...2107
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (INDICATORS AND SWITCHES)...2108
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (BRAKES)...2109
PIPES AND FITTINGS...2110
General information...2110
Flaring rigid pipes...2110
Bending rigid pipes...2111
Cutting rigid pipes...2111
Replacing the flexiblehoses withconventional fittings ...2112
Replacing flexible hoses with quick-coupling fittings...2113
BRAKING SYSTEM...2115
Working diagram for 4x2 - 4x4 vehicles designed for towing with ABS-ASR device...2115
Working diagram for isolated 6x4 vehicles with ABS-ASR device...2116
Working diagram for 6x4 - 6x6 vehicles designed for towing with ABS-ASR device...2117
Working diagram for isolated 8x4x4 - 8x8x4 vehicles with ABS-ASR device...2118
Working diagram for 8x4x4 - 8x8x4 vehicles designed for towing with ABS-ASR device...2119
BRAKING SYSTEM...2120
Working diagram for 4x2 - 4x4 vehicles designed for towing with ABS-ASR device...2120
Concept diagram for 6x4 vehicles isolated with EBL devices...2121
Working diagram for 6x4 - 6x6 vehicles designed for towing with EBL device...2122
Concept diagram for 8x4x4 - 8x8x4 vehicles isolated with EBL devices...2123
Working diagram for 8x4x4 - 8x8x4 vehicles designed for towing with EBL device...2124
Layout on vehicle of main components of braking system...2126
Layout on vehicle of main components of ABS-ASR system...2127
DESCRIPTION...2128
Service braking...2128
Emergency braking...2128
Retarding braking...2128
Parking brake...2128
ABS (Anti-Lock Brake System)...2128
ASR (Anti-Slip Regulator) system...2129
EBL (Electronic Brakes Limiter)...2129
BRAKES...2129
Front disc brakes type KNORR: SB7; SN7 (for vehicles with partial traction)...2129
Front brakes (for four-wheel drive vehicles) and rear brakes type MERITOR Duo - duplex Ø 410x180 and 410x200 ...2129
FAULT DIAGNOSIS...2130
Diagnosis Instruments...2130
ABS Troubleshooting...2132
TIGHTENING TORQUES...2152
TOOLS...2155
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM...2163
SPECIFICATIONS AND DATA - BRAKES...2168
CHECKS ON MAIN COMPONENTS OF THE BRAKING SYSTEM...2171
CHECKS ON MAIN COMPONENTS OF THE BRAKING SYSTEM...2172
MAIN COMPONENTS OF THE BRAKING SYSTEM...2174
Compressor...2174
Head locking screw tightness...2174
Electronic control unit...2175
A.P.U. (Air Processing Unit)...2175
Triple servo control valve...2176
Predominance control...2176
Predominance control...2176
Knorr Bremse AC 597B...2176
Wabco 973 009 013...2176
Duplex control valve...2177
Coupling heads...2178
Check valve (vehicles suited to towing)...2178
Parking brake hand control valve (vehicles suited to towing)...2178
Safety valve (”for Sweden”)...2179
Parking brake hand control valve (isolated vehicles)...2179
Diaphragm brake cylinder...2180
Combined brake cylinder...2180
Combined cylinder emergency braking device...2180
Repairs...2180
Relay valve...2181
Pressure reduction unit...2181
Engine brake switch...2182
Dual servo control valve...2182
Brake anti-lock control valve...2183
ASR electropneumatic valve...2183
Speed sensor...2183
Phonic wheels...2183
BRAKE REPAIRS...2184
FRONT DISC BRAKES SB7 TYPE (VEHICLESWITH PARTIAL TRACTION)...2184
TYPE SN7 DISK BRAKES...2185
SB7 type brake operation...2187
CHECKS...2187
Efficiency of automatic clearance recovery...2187
Brake lining thickness...2188
Replacing brake linings...2189
Removing and refitting brake callipers SB7...2191
Removal...2191
Refitting...2191
Removing and refitting wheel hubs...2192
Removal...2192
Refitting...2192
OVERHAULING BRAKE CALLIPERS SB7...2193
Disassembly...2193
Cleaning and checking component parts...2194
Assembly...2194
OVERHAULING BRAKE DISCS...2195
TURNING AND GRINDING BRAKE DISCS ON THE BENCH ...2196
TURNING AND GRINDING BRAKE DISCS ON THE VEHICLE...2196
DRUM BRAKES...2196
FRONT BRAKES...2197
REAR BRAKES...2197
Disassembly...2197
Turning drums...2200
Replacing brake linings...2200
Turning brake linings...2201
Assembly...2201
SECTION 15 - Bodywork - Chassis frame...2204
Bodywork - Chassis frame...2204
CAB...2206
General information...2206
TIGHTENING TORQUES...2206
Cab front suspensions...2206
Cab rear suspension...2206
TOOLS...2206
CAB ANCHORING...2207
REPAIRS...2209
REPLACING CAB SUSPENSION FRONT AND REAR SHOCK ABSORBERS...2209
REMOVING-REFITTING FRONT MOUNTS AND CAB STABILIZER BAR...2209
REPLACING HYDRAULIC CYLINDER FOR CAB TILTING...2209
Removal...2209
Refitting...2209
REPLACING THE WINDSHIELD...2210
REPLACING THE WINDING WINDOW...2211
REPLACING THE WINDOW WINDER...2212
REPLACING THE FIXED WINDOW...2212
Removal...2212
Preparing the window bay...2212
Preparing the window...2212
Refitting...2213
REPLACING SUNROOF...2214
Removal...2214
Preparing the sunroof bay...2214
Preparing the sunroof...2214
Refitting...2215
Replacing the roof air inlet door...2215
CAB VENTILATION AND HEATING UNIT...2215
CHASSIS FRAME...2216
REPAIRS AND CHECKS...2216
Measuring the bend of the chassis frame downwards or upwards...2217
Measuring the side bend of the chassis frame...2217
Measuring the movement of the chassis frame...2217
Measuring the torsion of the chassis frame...2218
PRECAUTIONS...2218
Welds on the chassis frame...2220
SECTION 16 - Scheduled maintenance...2222
Scheduled maintenance...2222
SCHEDULED MAINTENANCE...2224
Description...2224
Maintenance services specifications...2224
EXTRA PLAN OPERATIONS...2224
CHECKS AND/OR MAINTENANCE WORK...2227
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE WORK...2228
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE WORK...2229
CHECKS AND/OR MAINTENANCE WORK...2230
M1 SERVICE...2231
M2 SERVICE...2236
M3 SERVICE...2239
M4 SERVICE (Only for kilometric intervals)...2239
EXTRA PLAN MAINTENANCE...2239
EP2 SERVICE...2239
EP3 SERVICE...2240
EP4 SERVICE...2241
EP5 SERVICE...2241
603.93.121 - Iveco EuroTrakker_EuroTech_EuroStar Cursor 8-10-13 REPAIR MANUAL_ELECTRIC_ELECTRONIC_SYSTEM...2242
EUROTRAKKER - EUROTECH - EUROSTAR CURSOR 8/10/13...2242
REPAIR MANUAL ELECTRIC/ELECTRONIC SYSTEM...2242
FOREWORD...2244
GENERAL LIST OF CONTENTS...2246
Introduction...2248
General cautions for electric/electronic components...2251
Concept of earth and electromagnetic compatibility...2253
Concept of CAN LINE...2258
Technical Codes...2262
Graphic symbols and abbreviations...2268
General...2274
DESCRIPTION OF BASE SYSTEM...2276
Technical and electric specifications...2276
Cab structure...2276
Components on the engine F2B...2278
Frame structure...2282
Complete vehicle with cab tilted...2283
Vehicle transparency (Euro Tech/EuroStar)...2284
POWER NETWORK...2286
Negative network...2286
Earth points on the vehicle...2287
Positive network...2298
Starting...2302
MAIN COMPONENTS...2305
Interconnecting Control Unit (UCI)...2305
Central panel - Cursor 8 (On Road)...2323
Starter motor...2331
Alternator...2335
Steering column lever unit...2337
Ignition switch...2343
Front wall connectors (A) (EuroTech - EuroStar)...2344
Rear wall connector ( " )...2355
Connectors between cables (Base vehicle) Cursor 8/10/13...2362
Specific circuits...2390
ABS OPERATION DIAGRAM (CURSOR 8 - 10 - 13)...2392
EDC MS6.2 (Cursor 8 - 10 - 13)...2453
ECAS...2484
IMMOBILIZER...2525
Circuit Charts...2544
Keys...2546
Chart No. 1: Start up from driver’s seat...2547
Chart No. 2: Start up from engine compartment...2548
Chart No. 3: Pre-heating...2549
Chart No. 4: Recharge...2550
Chart No. 5: Instruments (fuel level - water temperature)...2551
Chart No. 6: Instruments (engine oil and brake air pressure)...2552
Chart No. 7a: Instruments (tachograph - rev counter) F2B (on)...2553
Chart No. 7b: Instruments (tachograph - rev counter) F3A/F3B (on) - F2B/F3B (off)...2554
Chart No. 8a: Warning lights (iveco control)...2555
Chart No. 8b: Warning lights F2B (on)...2556
Chart No. 8c: Warning lights F3A/F3B (on)...2557
Chart No. 8d: Warning lights F2B/F3B (off)...2558
Chart No. 9: Sidelights (cabin interior)...2559
Chart No. 10: Sidelights (vehicle exterior)...2560
Chart No. 11: Main/dipped beam headlights...2561
Chart No. 12: Additional headlights and rear foglights...2562
Chart No. 13: Direction indicators - hazard lights...2563
Chart No. 14: Brake lights - Reverse light - Horn...2564
Chart No. 15: Windscreen wiper...2565
Chart No. 16a: Interior lighting and service F2B (on)...2566
Chart No. 16b Interior lighting and service F3A/F3B (on)...2567
Chart No. 16c: Interior lighting and service F2B/F3B (off)...2568
Chart No. 17: Rearview mirrors...2569
Chart No. 18a: Window winders F2B (on) F2B/F3B (off)...2570
Chart No. 18b: Window winders F3A/F3B (on)...2571
Chart No. 19a: ABS / ASR F2B (on)...2572
Chart No. 19b: ABS / ASR F3A/F3B (on)...2573
Chart No. 19c: ABS / ASR F2BF3B (off)...2574
Chart No. 20: EBS F3A/F3B (on)...2575
Chart No. 21a: EDC (connector B) F2B (on)...2576
Chart No. 21b: EDC (connector B) F3A/F3B (on) F2B/F3B (off)...2577
Chart No. 22a: EDC (connector a - F2B)...2578
Chart No. 22b: EDC (connector A - F3B)...2579
Chart No. 23a: EUROTRONIC 1 F2B (on)...2580
Chart No. 23b: EUROTRONIC I I F3A/F3B (on) F2B/F3B (off)...2581
Chart No. 24: Manual climate control system...2582
Chart No. 25: Automatic climate control system...2583
Chart No. 26: Additional air heating manual mode...2584
Chart No. 27: Additional air heating manual mode (GGVS)...2585
Chart No. 28: Independent heating unit manual control for cabin and engine...2586
Chart No. 29: Independent heating unit manual control for cabin and engine (TMP)...2587
Chart No. 30: Main remote control switch...2588
Chart No. 31: ADR electronic main remote control switch...2589
Chart No. 32: Air TMP emergency switch...2590
Chart No. 33: Air TMP emergency switch (French)...2591
Chart No. 34: Ground startup and recharge...2592
Chart No. 35: 15-Pole socket...2593
Chart No. 36: 2X7 Pole socket (only tractor)...2594
Chart No. 37: Heated windscreen...2595
Chart No. 38: Drier heating heated pre-filter...2596
Chart No. 39: Trip computer level 1...2597
Chart No. 40: Trip computer level1 (with main current switch)...2598
Chart No. 41A: Electronic speedometer F2B (ON)...2599
Chart No. 41B: Electronic speedometer F3A/F3B (ON) F2B/F3B (OFF)...2600
Chart No. 42: Hour counter...2601
Chart No. 43: Economy Power...2602
Chart No. 44: Central door lock...2603
Chart No. 45: Multipower takeoff...2604
Chart No. 46: Right and left beacon light...2605
Chart No. 47: Sunroof...2606
Chart No. 48: Central lubrication “Lincoln” - “Vogel”...2607
Chart No. 49: Hydraulic power steering circuit...2608
Chart No. 50: Hydraulic power steering circuit (northern countries)...2609
Chart No. 51: Headlight washer and windscreen wiper...2610
Chart No. 52: Trailer braking system...2611
Chart No. 53: Immobilizer...2612
Chart No. 54: Intarder ZF...2613
Chart No. 55: ECAS for 4X2 and 6X2 (ON)...2614
Chart No. 56: ECAS for 4X2 and tractor (ON)...2615
Chart No. 57: ECAS for 6X2 P/FP and PT/FT with additional hydraulic steering axis (ON)...2616
603.93.641 - Iveco Trakker Euro 4-5 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('04-'13)...2618
603.93.641 - Iveco Trakker Euro 4-5 ELECTRIC_ELECTRONIC SYSTEM...4320
PTO GUIDE FOR DEEC 2_2008_EN...4610
Iveco EuroTrakker & Trakker Trucks Repair & Service Manual
