Complete service repair manual for Iveco Stralis Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Iveco Stralis 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.
...
603.43.671 - Iveco Stralis Euro 3 (18-44T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('02-'06) (EN).pdf
603.93.141 - Iveco Stralis AT_AD REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('02-'06) (EN).pdf
603.93.321 - Iveco Stralis AT_AD_AS Electronically Controlled Braking System EBS 2_ESP_EBL (EN).pdf
603.93.333 - Iveco Stralis AT_AD REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('02-'06) (EN).pdf
603.93.531 - Iveco Stralis AS Euro 4-5 (18-44T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('06-'13).pdf
603.93.746 - Iveco Stralis Circuit Diagrams (BC2) (EN).pdf

PRODUCT DETAILS:
Total Pages: 7,301 pages
File Format: PDF
Language: English

603.43.671 - Iveco Stralis Euro 3 (18-44T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('02-'06) (EN)...2
  STRALIS...2
    REPAIR MANUAL - MECHANICAL ELECTRIC / ELECTRONIC...2
      SPECIAL REMARKS...4
        Graphs and symbols...5
      UPDATE DATA...6
      INDEX OF SECTIONS...8
        SECTION 1 - General...10
          General...10
            VEHICLE IDENTIFICATION DATA...12
              Vehicle Identification Plate...13
              Production identification plate...13
            COMPOSITION OF MODELS...14
            P.I.C. NUMBER CODING...20
            REPLENISHING FLUIDS...24
        SECTION 2 - Engine...28
          Engine...28
            F3A Engine...32
              VIEWS OF THE ENGINE...34
              TECHNICAL DESIGNATION...38
              CHARACTERISTIC CURVES...39
              GENERAL CHARACTERISTICS...41
              ASSEMBLY CLEARANCE DATA...44
              TIGHTENING TORQUE...50
              TOOLS...56
              ENGINE REMOVAL - REFITTING...66
                Removal...66
                Refitting...67
                Filling the cooling system...68
                Bleeding air from the supply system...69
                Checks and tests...69
              ELECTRO-MAGNETIC JOINT REPLACEMENT...70
                Removal...70
                Refitting...71
              DISMANTLING THE ENGINE ON THE BENCH...74
              REPAIR OPERATIONS...81
              CYLINDER BLOCK...81
                Checks and measurements...81
                Cylinder liners...82
                Replacing cylinder liners...83
                Crankshaft...84
                Measuring the main journals and crankpins...85
                Preliminary measurement of main and big end bearing shell selection data...86
                Selecting the main and big end bearing shells...87
                Replacing the timing gear and oil pump...93
                Checking main journal assembly clearance...93
                Checking crankshaft end float...94
                Piston connecting rod assembly...95
                Piston rings...97
                Connecting rods...98
                Bushings...99
                Checking connecting rods...99
                Fitting the big end bearing shells...100
                Mounting the piston rings...100
                Fitting the big end bearing shells...100
                Fitting connecting rod - piston assemblies in the cylinder liners...101
                Checking piston protrusion...101
                Checking crankpin assembly clearance...102
              CYLINDER HEAD...102
                Removing valves...102
                Checking the planarity of the head on the cylinder block...102
                Valves...102
                Removing deposits and checking the valves...102
                Valve seats...103
                Checking clearance between valve-stem and associated valve guide...104
                Valve guides...104
                Replacing injector cases...104
                Checking injector protrusion...106
              TIMING GEAR...108
                Camshaft drive...108
                Idler gear pin...108
                Idler gear...108
                Twin intermediate gear pin...108
                Twin idler gear...108
                Replacing the bushings...108
                Timing system...109
                Checking cam lift and pin alignment...109
                Bushings...110
                Valve springs...112
                Fitting valves and oil seal...113
              ROCKER SHAFT...113
                Rocker arms...114
                Shaft...114
              ENGINE ASSEMBLY ON BENCH...115
                Fitting connecting rod - piston assemblies in cylinder liners...118
              ENGINE FLYWHEEL...121
                Fitting engine flywheel...121
                Fitting camshaft...122
                Fitting pump-injectors...123
                Fitting rocker-arm shaft assembly...123
                Camshaft timing...124
                Phonic wheel timing...126
                Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors...127
                Completing Engine Assembly...128
              LUBRICATION...130
                Oil pump...132
                Overpressure valve...132
                Oil pressure control valve...133
                Heat exchanger...133
                By-pass valve...135
                Thermostatic valve...135
                Engine oil filters...135
              COOLING...136
                Water pump...138
                Thermostat...138
                Electromagnetic coupling...138
              TURBOCHARGING...139
                Turbocharger HOLSET HY55V...139
              REPAIRING ACTIONS...143
                Actuator...143
                Solenoid valve for VGT control...143
              FEEDING...145
                Fuel pump...146
                Injector-pump...146
                Replacing injectors-pump...146
                Injector Phases...147
            F3B Engine...152
              VIEWS OF THE ENGINE...154
              TECHNICAL DESCRIPTION...157
              CHARACTERISTIC CURVES...158
              GENERAL SPECIFICATIONS...161
              ASSEMBLY DATA - CLEARANCE...164
              TIGHTENING TORQUES...170
              DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS...173
              TOOLS...177
              ENGINE REMOVAL-REFITTING...188
                Removal...188
                Refitting...191
                Filling the cooling system...192
                Bleeding air from the system...192
                Checks and tests...193
              ELECTRO-MAGNETIC JOINT REPLACEMENT...194
                Removal...194
                Refitting...195
              STRIPPING THE ENGINE ON THE BENCH...198
              REPAIRS...205
              CYLINDER BLOCK...205
                Checks and measurements...205
                Cylinder liners...206
                Replacing the cylinder liners...207
                Crankshaft...208
                Measuring the main journals and crankpins...209
                Preliminary measurement of data to select main bearing and big end bearing shells...210
                Selecting the main bearing and big end bearing shells...211
                Replacing the timing gear and oil pump...217
                Checking main journal assembly clearance...217
                Checking crankshaft end float...218
                Connecting rod piston assembly...219
                Piston rings...221
                Connecting rod...222
                Bushings...223
                Checking connecting rods...223
                Mounting the connecting rod — piston assembly...224
                Mounting the piston rings...224
                Fitting the big end bearing shells...224
                Fitting connecting rod - piston assemblies in the cylinder liners...225
                Checking piston protrusion...225
                Checking crankpin assembly clearance...226
              CYLINDER HEAD...226
                Checking head bearing surface on cylinder block...226
                Valves...226
                Valve seats...227
                Checking clearance between valve-stem and associated valve guide...228
                Valve guides...228
                Replacing injector cases...228
                Checking injector protrusion...230
              TIMING GEAR...232
                Camshaft drive...232
                Idler gear pin...232
                Idler gear...232
                Twin intermediate gear pin...232
                Twin idler gear...232
                Replacing the bushings...232
                Timing system...233
                Checking cam lift and pin alignment...233
                Bushings...234
                Valve springs...236
              ROCKER SHAFT...237
                Shaft...238
                Rocker arms...238
              ENGINE ASSEMBLY ON BENCH...239
                Fitting connecting rod - piston assemblies in cylinder liners...242
                Fitting the cylinder head...243
                Fitting flywheel box...244
              ENGINE FLYWHEEL...245
                Fitting engine flywheel...245
                Fitting camshaft...246
                Fitting pump-injectors...247
                Fitting rocker-arm shaft assembly...247
                Camshaft timing...248
                Phonic wheel timing...250
                Adjusting rocker armclearance, intake, exhaust and pre-load of pump injector governing rocker arms...251
                Completing assembly...252
              LUBRICATION...254
                Oil pump...256
                Overpressure valve...256
                Oil pressure control valve...257
                Heat exchanger...257
                By-pass valve...259
                Thermostatic valve...259
                Engine oil filters...259
              COOLING...260
                Water pump...262
                Thermostat...262
                Electromagnetic coupling...262
              TURBOCHARGING...263
                Turbocharger HOLSET HY 55 V...263
              REPAIRING ACTIONS...267
                Actuator...267
                Solenoid valve for VGT control...267
              FEEDING...269
                Fuel pump...270
                Injector-pump...270
                Replacing injectors-pump...270
                Injector Phases...271
            Hydrocar pressure take-off on timing system...276
              HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)...278
                Description...278
              SPECIFICATIONS AND DATA...279
              TIGHTENING TORQUES...280
              ENGAGING POWER TAKE-OFF...281
              REMOVING-REFITTING POWER TAKE-OFF...281
            Fault Diagnosis...284
              FAULT DIAGNOSIS...286
                Diagnosis Instruments...286
                Cluster Diagnosis...288
                Troubleshooting via DTC-FMI codes...290
        SECTION 3 - Clutch...318
          Clutch...318
            DESCRIPTION...320
              Clutch...320
            SPECIFICATIONS AND DATA...320
            FAULT DIAGNOSIS...321
            TIGHTENING TORQUES...324
            TOOLS...324
            REMOVING AND REFITTING THE CLUTCH...325
              Removal...325
              CHECKS...325
              Refitting...326
            REMOVING-REFITTING THE THRUST BEARING...326
            REMOVING-REFITTING THE PEDAL UNIT...327
              Removal (vehicles with EuroTronic Automated gearbox)...327
              Removal (vehicles with ZF 16 S... gearbox)...328
              Refitting...329
            PEDAL...329
            UNIT REMOVAL-ASSEMBLY...329
            CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ZF 16 S... gearboxes)...330
              Clutch stop...330
              Idle travel of clutch pedal...330
              Pedal control valve stroke...330
            HYDRAULIC CONTROL (vehicles with ZF 16 S... gearboxes)...331
            CLUTCH ACTUATOR FOR ZF 16 S... GEARBOXES...332
              Fitting and adjusting the clutch wear indicator...332
            OPERATOR CYLINDER PUSH ROD ADJUSTMENT (new clutch)...333
            CLUTCH ACTUATOR FOR EUROTRONIC AUTOMATED GEARBOX...334
              Clutch actuator push rod adjustment (new clutch)...334
              Fitting the clutch actuator...334
              Replacing the clutch actuator...334
        SECTION 4 - Gearbox...336
          Gearbox...336
            Gearboxes: ZF 16 S 181 D.D. - ZF 16 S 181 O.D. - ZF 16 S 221 D.D...340
              LOCATION OF GEARBOX DESCRIPTION PLATE...342
              DESCRIPTION...343
              OPERATION...345
                Slow range...345
                Fast range...346
              EPICYCLIC REDUCTION GEAR CONTROL...347
                Reduced speeds...347
                Normal speeds...348
              SPECIFICATIONS AND DATA...349
              TIGHTENING TORQUES...353
              TOOLS...354
              GEARBOX FAULT DIAGNOSIS...359
              REMOVING-REFITTING THE GEARBOX...362
                Removal...362
                Refitting...363
              OVERHAULING THE GEARBOX...364
                Servoshift gear box...364
                Removal...364
                Refitting...364
                Disassembly...364
                Assembly...366
                Removing the rear box...370
                Removing the epicyclic reduction gear unit (ERG)...370
                Fitting the epicyclic reduction gear unit (ERG)...372
                Refitting the epicyclic reduction gear unit ERG) rear box...375
                Removing the gearbox...375
                Removing the main shaft...378
                Removing the drive input shaft...381
                Removing the transmission shaft...382
              CHECKS...382
                Gearbox...382
                Hubs - sliding sleeves - forks...382
                Bearings...382
                Shafts - gears...382
                Synchronizing devices...382
                BK-type single-cone synchronizing devices...382
                Fitting the transmission shaft...383
                Fitting the drive input shaft...383
                Fitting the main shaft...384
                Adjusting the main shaft...386
                Fitting the gearbox...387
                Oil pump...388
                Adjusting the transmission shaft bearing end float...388
                Drive input shaft cover...389
              PNEUMATIC CONTROL OF GEARBOX...391
              CONNECTING DIAGRAM FOR GEARBOXWITH SERVOSHIFT...392
            ZF gearboxes with INTARDER hydraulic retarder, types: 16 S 181 D.D./O.D. - 16 S 221 D.D...396
              SPECIFICATIONS AND DATA...398
              TOOLS...399
                Removing the hydraulic retarder from the gearbox on the stand...406
                Refitting the hydraulic retarder...406
                Removing the epicyclic reduction gear unit (ERG) rear box...407
                Removing the epicyclic reduction gear unit (ERG)...407
                Component parts of the epicyclic reduction gear unit...410
                Fitting the epicyclic reduction gear unit (ERG)...411
                Refitting the epicyclic reduction gear unit (ERG) rear box...413
            Gearboxes: EuroTronic Automated 12 AS 2301 D.D./O.D. EuroTronic Automated 16 AS 2601 D.D./O.D...416
              DESCRIPTION...418
              SPECIFICATIONS AND DATA...419
              FAULT DIAGNOSIS...423
                Diagnosis Instruments...423
                Cluster Diagnosis...425
                Troubleshooting via DTC-FMI codes...427
              TIGHTENING TORQUES...461
              TOOLS...464
              OVERHAULING THE GEARBOX...470
                Checks...470
                Gearbox actuator...470
                Removal...470
                Refitting...471
                Removing the rear box...471
                Removing the rear box...472
                Removing the epicyclic reduction gear train (E.R.G.)...473
                Fitting the epicyclic reduction gear train (E.R.G.)...475
                Adjusting epicyclic reduction gear train bearing end float...476
                Adjusting main shaft end float...477
                Synchronizing device assembly for engaging normal or reduced gears...479
                Removal...479
                Fitting...479
                Removing the middle box...482
                Removing the main shaft...484
                Removing the drive input shaft...486
                Removing the splitter synchronizing device...487
                Fitting the splitter synchronizing device...488
                Fitting the main shaft...489
                Fitting the drive input shaft...489
                Splitter control fork...492
                Disassembly - Assembly...492
                Gear control forks...492
                Removal...492
                Fitting...493
                Transmission shafts...494
                Disassembly - Assembly...494
                Fitting the middle box...494
                Fitting the front box...497
                Front cover...499
                Removal...499
                Fitting the front cover...499
                Adjusting drive input shaft bearing end float...499
                Adjusting transmission shaft bearing end float...500
                Clutch release lever...502
            Gearboxes: EuroTronic Automated 12 AS 2301 D.D./O.D. with Intarder EuroTronic Automated 16 AS 2601 D.D./O.D. with Intarder...506
              EuroTronic Automated 12 AS 2301 D.D./O.D. — 16 AS 2601 D.D./O.D. with intarder...508
              SPECIFICATIONS AND DATA...508
              EXPERIMENTAL TOOLS...509
              REMOVING-REFITTING GEARBOX...510
                Removal...510
                Refitting...510
              OVERHAULING THE GEARBOX...512
                Removing the hydraulic retarder...512
                Refitting the hydraulic retarder...513
                Adjusting epicyclic reduction gear train bearing end float...513
                Adjusting stator end float...514
                Removing the rear box...515
                Disassembling the E.R.G...516
                Fitting the E.R.G...517
            Power take-offs...522
              POWER TAKE-OFFS ZF-TYPE...524
              CHARACTERISTICS AND DATA...524
              POWER TAKE-OFFS HIDROCAR TYPE...530
              CHARACTERISTICS AND DATA...530
            Transmission external control (except for vehicles equipped with Eurotronic gearshift)...536
              TRANSMISSION EXTERNAL CONTROL...538
                Transmission tie rod adjustment...538
              SIDE TIE ROD...539
                Removal...539
                Refitting...540
              TELESCOPIC TIE ROD...540
                Removal...540
                Refitting...540
              TRANSMISSION IDLER ARM...540
                Removal...540
                Disassembly...541
                Assembly...541
                Refitting...541
              CROSS TIE ROD...541
                Removal...541
                Refitting...541
        SECTION 5 - Intarder - ZF hydraulic retarder...542
          Intarder - ZF hydraulic retarder...542
            LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE...544
            GENERAL INFORMATION...545
            OPERATION...545
              Retarder engaged...546
              Retarder disengaged...547
            LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER...548
            REMOVING AND REFITTING THE RETARDER ON THE ZF S 181/221-OD GEARBOX...549
              Removal...549
              Refitting...550
              Filling with oil...550
            SPECIFICATIONS AND DATA...551
            TIGHTENING TORQUES...552
            TOOLS...553
            FAULT DIAGNOSIS...555
            OVERHAULING THE INTARDER HYDRAULIC RETARDER...559
              Hydraulic accumulator...559
              Removal...559
              Fitting...559
              Removing hydraulic retarder...559
              Checking the component parts of the hydraulic retarder...564
              Fitting the hydraulic retarder...565
              Stator end float adjustment...570
        SECTION 6 - Propeller shafts...572
          Propeller shafts...572
            CHARACTERISTICS AND DATA...574
            STRALIS ( Tractors) CHARACTERISTICS AND DATA ( vehicles 4x2/6x2C/6x4)...576
            STRALIS ( Cabs) CHARACTERISTICS AND DATA ( vehicles 4x2/6x2P/6x4)...577
            DIAGNOSTIC...578
            TIGHTENING TORQUES...580
            TOOLS...580
            REMOVING AND REASSEMBLING THE PROPELLER SHAFT...581
              Removal...581
              Reassembly...581
            CHECKING THE PROPELLER SHAFT ON THE VEHICLE...582
            REMOVING AND FITTING BACK THE UNIVERSAL JOINTS...583
            REMOVING AND REASSEMBLING THE SUPPORT...583
        SECTION 7 - Rear axles...584
          Rear axles...584
            FAULT DIAGNOSIS...586
            REMOVING-REFITTING THE REAR AXLE...588
              Removal...588
              Refitting...588
            REMOVING-REFITTING THE DIFFERENTIAL FROM THE REAR AXLE ON THE VEHICLE...589
              Removal...589
              Refitting...589
          Rear Axle ARVINMERITOR U 177 E with disc brakes...592
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...594
            DESCRIPTION...596
            CHARACTERISTICS AND DATA...597
            TIGHTENING TORQUES...598
            TOOLS...600
            OVERHAULING THE REAR AXLE ASSEMBLY...606
            OVERHAULING THE WHEEL HUBS...606
              Removal...606
              Replacing wheel hub bearings...608
              Checking the parts forming the wheel hubs...608
              Replacing the wheel fixing pins...608
            REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215)...612
              Removal...612
              Checking axle housing...612
              Refitting...612
            REPAIRING THE DIFFERENTIAL...613
              Removing the differential...613
              Removing the gearcase...614
            REMOVING THE BEVEL PINION FROM THE SUPPORT...616
              Differential component check...616
              Fitting the gear housing...617
            FITTING THE MOUNT ON THE BEVEL PINION...618
              Reassembling the differential housing...620
            ADJUSTING THE CAP GAP...622
            CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...625
            WORK ON THE VEHICLE...628
            REPLACING THE BEVEL PINION MOUNT SEAL...628
              Disassembly...628
              Assembly...629
          Rear axle ARVINMERITOR U 177 E whit drum brakes...632
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...634
            DESCRIPTION...636
            CHARACTERISTICS AND DATA...637
            TIGHTENING TORQUES...640
            TOOLS...642
            OVERHAULING THE REAR AXLE ASSEMBLY...648
            OVERHAULING THE WHEEL HUBS...648
              Removal...648
              Wheel hub component check...649
            REPLACING THEWHEEL HUB BOLTS...650
              Wheel hub reassembly...650
            REMOVING AND REASSEMBLING THE DIFFERENTIAL...652
              Removal...652
              Axle casing check...652
          Rear Axle ARVINMERITOR MS 13-175 (R 1783) with disc brakes...656
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...658
            DESCRIPTION...660
            CHARACTERISTICS AND DATA...660
          Rear axle ARVINMERITOR MS 13-175 (R 1783) whit drum brakes...664
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...666
            DESCRIPTION...668
            CHARACTERISTICS AND DATA...668
          Axles in Tandem...672
          Axles in Tandem (Intermediate) ARVINMERITOR RP 160 E (R 2478)...674
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...676
            DESCRIPTION...677
            SPECIFICATIONS AND DATA...678
            TIGHTENING TORQUES...680
            TOOLS...684
            EXPERIMENTAL TOOLS...691
            SERVICING INTERMEDIATE AXLE ASSEMBLY RP 160 E (R2478)...694
            AIR BREATHER REMOVAL-REFITTING...694
            SERVICINGWHEEL HUBS...694
              Checking wheel hub components...695
            ASSEMBLING WHEEL HUBS...696
            REMOVING DIFFERENTIAL GEAR — TRANSFER BOX (with rear axle on stand 99322215)...699
            REFITTING DIFFERENTIAL GEAR — TRANSFER BOX (with rear axle on stand 99322215)...699
            REPAIRING INTER-AXLE UNIT...700
              Dismantling inter-axle unit...700
              Checking inter-axle unit components...702
              Fitting inter-axle unit...702
              Adjusting drive input shaft bearing end float...704
              Adjusting differential lock and inter-axle control pin end-stop...704
              REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING...705
                Dismantling gear cage...708
                Checking differential components...708
                Assembling gear cage...709
              ASSEMBLING DIFFERENTIAL CASING...710
                Calculating bevel pinion positionin differential casing...710
              COMPUTATIONAL EXAMPLES...711
                Determining the thickness of the bevel pinion bearing clearance adjustment rings...711
                Adjusting the cap gap...714
              CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...716
              REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT...719
          Axles in Tandem (Rear) ARVINMERITOR RR 160 E (R 0878)...722
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...724
            DESCRIPTION...725
            SPECIFICATIONS AND DATA...726
            TIGHTENING TORQUE...728
            TOOLS...730
            SERVICING REAR AXLE ASSEMBLY RR 160 E (R 0878)...735
            AIR BREATHER REMOVAL/ INSTALLATION...735
            SERVICING WHEEL HUBS...735
            REMOVING DIFFERENTIAL (with axle on stand 99322215)...735
            REFITTING DIFFERENTIAL (with axle on stand 99322215)...735
            REPAIRING DIFFERENTIAL...736
              Removing differential lock...736
              Dismantling differential casing...737
              Dismantling gear cage...738
              Dismantling bevel pinion support...738
              Checking differential components...742
              Assembling gear cage...742
              Assembling differential casing...744
            ADJUSTING THE CAP GAP...746
            CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...749
          Axles in Tandem (Rear) ARVINMERITOR RR 167 E (R 0878)...752
            LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...754
            DESCRIPTION...756
            CHARACTERISTICS AND DATA...756
            TIGHTENING TORQUES...758
            TOOLS...760
            OVERHAULING REAR AXLE ASSEMBLY RR 167 E (R 0878)...766
          Rear axle 451391 HR (R 8284)...770
            DESCRIPTION...772
            SPECIFICATIONS AND DATA...773
            TIGHTENING TORQUES...774
            TOOLS...776
            REAR AXLES ASSEMBLY OVERHAUL...782
              Disassembly...782
              Epicycloid reduction gear disassembly...782
              Wheel hub disassembly...783
            CHECKING THE WHEEL HUB AND EPICYCLOID REDUCTION GEAR UNIT PARTS...785
            WHEEL HUB ASSEMBLY...786
              Assembling the epicycloid reduction gear...788
            REMOVING-REFITTING THE DIFFERENTIAL...791
            REPAIRING THE DIFFERENTIAL...793
              Disassembly...793
              Gear housing disassembly...794
              Removing the bevel pinion from the support...795
            CHECKING THE DIFFERENTIAL COMPONENTS...797
              Gear housing assembly...798
              Assembling the bevel pinion support...799
              Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...799
              Differential housing assembly...801
              Gear housing bearings rolling torque adjustment...802
        SECTION 8 - Axles...806
          Axles...806
            Front axle 5876/4 (F 8021) 5876/5 (F 8021) Steering central added axle 5876/2 (F 8021)...810
              DESCRIPTION...812
              SPECIFICATIONS AND DATA...813
              FAULT DIAGNOSIS...815
              TIGHTENING TORQUES...818
              TOOLS...820
              REMOVING AND REFITTING FRONT AXLE...824
                Vehicles with mechanical front suspension...824
                Removal...824
                Refitting...824
              REMOVING AND REFITTING FRONT AXLE...825
                Vehicles with pneumatic front suspension and longitudinal bars...825
                Removal...825
                Refitting...826
              VEHICLE CHECKS...827
                Tie rods...827
                Swivel heads...827
              CHECKING SWIVEL HEAD PLAY...827
              FRONT AXLE ASSEMBLY OVERHAUL...828
              REMOVING - REFITTINGWHEEL HUBS...828
                Removal...828
                Replacing wheel hub bearings...829
                Replacing wheel fixing pins...830
                Refitting wheel hubs...830
                Checking wheel hub bearing end float...830
                Measuring rolling torque...831
              REMOVING AND REFITTING TRANSVERSE TIE ROD...831
              REPLACING TRANSVERSE TIE ROD SWIVEL HEADS...832
              REMOVING AND REFITTING LEVERS FOR LONGITUDINAL TIE ROD...832
              REMOVING - REFITTING LEVER FOR TRANSVERSE TIE ROD...832
              REMOVING AND REFITTING PIN FOR STUB AXLE...832
                Removal...832
                Replacing kingpin bearing...833
                Checking and adjusting clearance between stub axle and axle...834
              CHECKING AND MEASURING THE AXLE BODY...835
                Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins...835
                Checking angle of holes for kingpins...836
            Axle 5876 (F 8021)...840
              DESCRIPTION...842
              SPECIFICATIONS AND DATA...843
              TIGHTENING TORQUE...844
              TOOLS...845
              FRONT AXLE ASSEMBLY OVERHAUL...849
              REMOVING - REFITTINGWHEEL HUBS...849
                Removal...849
                Refitting wheel hubs...850
            Rigid rear added axle 55080/DI (N 8071)...854
              DESCRIPTION...856
              CHARACTERISTICS AND DATA...857
              TIGHTENING TORQUE...858
              TOOLS...859
              REMOVING-REFITTING...861
                Removal...861
                Refitting...862
              REPAIRS...862
            Rigid rear added axle 55080/TI (N 8071)...866
              DESCRIPTION...868
              CHARACTERISTICS AND DATA...869
              TIGHTENING TORQUES...870
              TOOLS...871
              REPAIRS...872
            Rigid rear added axle 56082/D1 (N 9171)...876
              DESCRIPTION...878
              CHARACTERISTICS AND DATA...879
              TIGHTENING TORQUE...880
              TOOLS...881
            Rigid rear added axle 56082/T1 (N 9171)...886
              DESCRIPTION...888
              CHARACTERISTICS AND DATA...889
              TIGHTENING TORQUE...890
              TOOLS...891
              REMOVING-REFITTING...893
              REPAIR OPERATIONS...893
            Steering rear added axle 57080/DI (N 8072)...896
              DESCRIPTION...898
              CHARACTERISTICS AND DATA...899
              TIGHTENING TORQUES...901
              TOOLS...902
              REPAIRS...906
              PNEUMATIC LIFT...906
              GENERAL...906
              LOCATION ON THE VEHICLE OF THE MAIN COMPONENTS OF THE HYDRAULIC SYSTEM...907
              HYDRAULIC SYSTEM...908
              HYDRAULIC SYSTEMWORKING DIAGRAM...909
              VEHICLESWITH PNEUMATIC REAR SUSPENSIONS AND PNEUMATIC LIFTING...910
                Location on the vehicle of the main components...910
                Pneumatic working diagram, rear air suspensions and air lift for added axles with single wheels...911
              FAULT DIAGNOSIS...912
              TIGHTENING TORQUES (Steering and lifting device linkage)...915
              CHARACTERISTICS AND DATA...916
              Steering and third axle hydraulic system...916
              MAIN HYDRAULIC SYSTEM COMPONENTS...917
              HYDRAULIC ACCUMULATOR...917
                Nitrogen pressure checking and recharging...917
              OPERATOR CYLINDER...917
                Disassembly...918
                Assembly...918
                Checking cylinder oil sealing on the vehicle...918
              CENTRING CYLINDER...918
                Disassembly...919
                Assembly...919
                Checking cylinder oil sealing on the vehicle...919
              ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING...920
                Removal...920
                Refitting...920
              AIR BLEEDING FROM THE HYDRAULIC CIRCUIT...921
                Filling up and bleeding the power steering hydraulic circuit (circuit 1)...922
                Filling up and bleeding the power steering hydraulic circuit (circuit 2)...922
            Steering rear added axle 57080/TI (N 8072)...926
              DESCRIPTION...928
              CHARACTERISTICS AND DATA...929
              TIGHTENING TORQUES...931
              TOOLS...932
              REPAIR OPERATIONS...935
            Wheel geometry...938
              GENERAL INFORMATION...940
                Steering wheel angles...940
              FRONTWHEEL GEOMETRY (4X2 vehicles)...941
                Positioning clips and headlights...941
                Electronic compensation of rim eccentricity...942
                Wheel alignment...942
                Checking wheel toe-in...943
                Checking wheel deviation...943
                Checking camber...943
                Checking kingpin angle and caster...944
                Checking rear axle alignment...945
              VEHICLE WHEEL GEOMETRY WITH CENTRAL ADDED AXLE (6X2 C)...945
                Checking steering angles...947
                Vehicle wheel geometry with steering rear added axle and pneumatic lifting...947
        SECTION 9 - Suspensions...950
          Suspensions...950
            SUSPENSIONS...952
            DESCRIPTION...952
              Mechanical front suspension...952
              Pneumatic front suspension...952
              Pneumatic rear suspension...952
            SPECIFICATIONS AND DATA...953
              Leaf spring for central added axle (vehicles with air suspension)...958
            MECHANICAL FRONT SUSPENSION ASSEMBLY DRAWING...959
              Front shock absorbers...962
              Rear shock absorbers...963
            AIR SUSPENSION...964
              Chassis frame lifting, lowering and self-levelling with remote control...964
              Saving Levels...964
              Working diagram of pneumatic rear suspensions for 4x2T/P tractors...965
              Working diagram of suspensions for 4x2T/FP/FP-CT/FP-GV tractors...966
              Working diagram of air suspensions for 4x2FP vehicles...967
              Working diagram of air suspensions for 6x2Y/FP/FS-GV vehicles...968
              Working diagram of air suspensions for 6x2Y/FP/FS-CM vehicles...969
              Working diagram of air suspensions for 6x2Y/FP/FS-GV vehicles...970
              Working diagram of air suspensions for 6x2Y/FP/FS-CM vehicles...971
              Working diagram of rear air suspensions for 6x2Y/PT vehicles...972
              Working diagram of rear air suspensions for 6x2Y/PS vehicles...973
              Working diagram of rear air suspensions for 6x2Y/PS vehicles...974
              Working diagram of air suspensions for 6x2TX/P vehicles...975
              Working diagram of rear air suspensions for 6x2Y/FT vehicles...976
              Working diagram of rear air suspensions for 6x2Y/FT vehicles...977
              Working diagram of pneumatic rear suspensions for 6x4 Z/P - HM - 6x4 TZ/P - HM vehicles...978
              Rear air suspension main diagram for 4X2 P vehicles...979
            CHARACTERISTICS AND DATA...980
              Pneumatic System...980
            MAIN COMPONENTS OF THE PNEUMATIC SYSTEM...981
              Fault Diagnosis...981
              Controlled pressure valve...981
              Level sensor...981
              Electro-Pneumatic Control Valve...982
              Load detector pressure sensor...983
              Low air pressure switch...983
              Air spring...983
              ECAS Control Unit...983
            FAULT DIAGNOSIS...984
              Diagnosis Instruments...984
              Cluster Diagnosis...986
              Troubleshooting via DTC-FMI codes...988
            TOOLS...1013
            TIGHTENING TORQUES...1015
              Mechanical front suspension...1015
              Pneumatic front suspension...1016
              Pneumatic front suspension with bars...1017
              Central added axle pneumatic suspensions 6x2 C vehicles...1018
              Pneumatic rear suspension 4x2 — 6x2 C vehicles...1019
              Pneumatic rear suspension 6x2 P/PT/FT vehicles...1020
              Pneumatic rear suspension 6x2 P/FP/FS vehicles...1021
              Pneumatic rear suspension 6x2 P vehicles...1022
              Pneumatic rear suspension 6x2 P/PS vehicles...1023
              Pneumatic rear suspension 6x4 P vehicles...1024
            REMOVAL-REFITTING OF FRONT LEAF SPRING...1025
              Removal...1025
              Refitting...1025
            REMOVING-REFITTING FRONT SUSPENSION BARS...1026
              Removing longitudinal bars...1026
              Removing transverse bar...1026
              Refitting...1026
            REAR SUSPENSIONS...1028
              Removal...1028
              Refitting...1028
            REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM...1029
            REMOVING-REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM...1029
            REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM...1029
            REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM...1029
              Removal...1029
              Refitting...1029
            REPLACING THE SUSPENSION ARM FLEXIBLE PIN...1030
              Removal...1030
              Refitting...1030
            STABILIZER BAR...1031
            FRONT STABILIZER BAR...1031
            CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)...1031
            REAR STABILIZER BAR...1031
            REAR ADDED AXLE STABILIZER BAR (6x2P vehicles)...1031
              Removal...1031
              Refitting...1031
            RUBBER BUSHINGS...1034
              Replacing front stabilizer bar rubber bushings...1034
              Replacing rear stabilizer bar rubber bushings...1034
            SHOCK ABSORBERS...1035
              Removal-refitting...1035
              Front axle shock absorbers (6x2 C vehicles)...1035
              Central added axle shock absorbers...1035
              Rear axle shock absorbers...1035
              Rear added axle shock absorbers (6x2 P vehicles)...1035
              Removal...1035
              Refitting...1035
            CHASSIS FRAME ADJUSTMENT...1036
        SECTION 10 - Wheels and tyres...1042
          Wheels and tyres...1042
            DESCRIPTION...1044
            CHARACTERISTICS AND DATA...1044
              Tyre inflation pressures...1044
            TOOLS...1045
            FAULT DIAGNOSIS...1045
            STATIC BALANCING OF THE WHEELS...1048
            CORRECTING RESIDUAL STATIC IMBALANCE...1049
            TYRE PRESSURE...1049
            HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE...1050
        SECTION 11 - Steering...1052
          Steering...1052
            DESCRIPTION...1054
              Vehicle steering control diagram...1055
              Vehicle steering control diagram with front air suspension and longitudinal bars...1056
              Vehicle steering control diagram with front air suspension and leaf springs...1057
              6x2 Vehicle steering control diagram with front mechanical suspension...1058
              6x2c (right-hand drive) Vehicle steering control diagram with front air suspension and leaf springs...1059
              6x2p (steering rear axle) Vehicle steering control diagram with front mechanical ...1060
              6x2p (steering rear axle) Vehicle steering control diagram with front air suspension and leaf springs...1061
              6x2p (steering rear axle) Vehicle steering control diagram with front air suspension and longitudinal bars...1062
            SPECIFICATIONS AND DATA...1063
            FAULT DIAGNOSIS...1064
            TIGHTENING TORQUES...1069
            TOOLS...1070
            REMOVING-REFITTING THE POWER STEERING SYSTEM...1072
              Removal...1072
              Refitting...1074
              Removing-Fitting the Steering Lever...1074
            STEERING CONTROL...1075
            REMOVING-REFITTING THE STEERING CONTROL ASSEMBLY...1076
              Removal...1076
              Refitting...1078
              Changing the pneumatic cylinder...1078
              Removal...1078
              Refitting...1079
            BLEEDING THE POWER STEERING SYSTEM...1081
            MEASURING STEERING BOX PLAY AT THE STEERINGWHEEL...1081
            CHECKING THE MAXIMUM PRESSURE OF THE POWER STEERING SYSTEM...1081
              Setting the automatic hydraulic steering limit...1081
        SECTION 12 - Air system - Brakes...1082
          Air system - Brakes...1082
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...1086
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)...1087
            SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)...1093
            Print 603.43.671 SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)...1094
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)...1095
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...1096
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...1097
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)...1098
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)...1099
            PIPINGS AND FITTINGS...1100
              In general...1100
              Rigid pipings reflanging...1100
              Rigid pipings bending...1101
              Rigid pipings cutting...1101
              Flexible pipings replacementwith traditional fittings...1102
              Flexible pipings replacement with quick connection fittings...1103
            EBS (ELECTRONIC BRAKE SYSTEM)...1105
            EBS Benefits...1105
              Tractor and trailer compatibility at any time...1105
              Complete fault-diagnosis structures...1105
            OPERATING LOGIC...1106
            BRAKE SYSTEM...1107
            AUXILIARY BRAKE INTEGRATION...1108
            “ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)...1109
              “ABS” (Anti-Lock Brake System)...1109
              EBL (Electronic Brakes Limiter)...1110
              Operating Logic...1110
            BRAKE SYSTEM WITH EBS DEVICE...1111
              EBS working diagram for 4x2 vehicles (tractors)...1111
              EBS working diagram for 6x2 vehicles (tractors)...1112
              EBS working diagram for 4x2 vehicles (trucks)...1113
              EBS working diagram for 6x2 vehicles (trucks)...1115
            BRAKE SYSTEM WITH ABS-EBL DEVICE...1119
              Working diagram for 4x2 vehicles...1119
              Working diagram for 6x2 vehicles (trucks)...1121
              Working diagram for 6x2 vehicles (tractors)...1123
              ABS-EBL working diagram for 6x2 vehicles (tractors)...1124
              Working diagram for 6x4 vehicles...1125
            DESCRIPTION...1127
              Service braking...1127
              Emergency braking...1127
              Parking brake...1127
              Exhaust brake...1127
            BRAKES...1127
              Disc Brakes...1127
              Drum Brakes...1127
            FAULT DIAGNOSIS...1128
              Diagnosis Instruments...1128
              Cluster Diagnosis...1130
              System ABS - Troubleshooting via DTC-FMI codes...1132
              System EBS - Troubleshooting via DTC-FMI codes...1156
            TIGHTENING TORQUES...1234
            TOOLS...1237
            SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM...1245
            SPECIFICATIONS AND DATA - BRAKES...1253
            CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM...1255
            MAIN COMPONENTS OF THE BRAKING SYSTEM...1257
              Compressor...1257
              Head locking screw tightness...1257
              Fault diagnosis...1258
              A.P.U. (Air Processing Unit)...1258
              Duplex control valve vehicles without EBS)...1259
              Duplex control valve with electric transmitter (vehicles with EBS)...1259
              Fault Diagnosis (vehicles without EBS)...1259
              Relay valve (vehicles without EBS)...1260
              Proportional relay valve for front axle (vehicles with EBS)...1260
              Fault Diagnosis (vehicles without EBS)...1260
              Coupling heads...1260
              Rear axle electro-pneumatic modulator (for vehicles with EBS)...1261
              Fault Diagnosis...1261
              Redundancy valve (for 4x2 and 6x2 trucks)...1262
              ABS-EBS solenoid valve...1262
              Dual stop valve...1262
              Triple servo control valve (vehicles without EBS)...1262
              Predominance control...1263
              Fault Diagnosis...1263
              Trailer servo control valve (vehicles with EBS)...1264
              Parking brake hand control valve (vehicles suited to towing)...1264
              Pressure test point valve...1264
              Manual control valve to slow down the trailer (optional extra)...1264
              Fault Diagnosis (parking brake control valve)...1264
              Controlled pressure valve...1265
              Fault Diagnosis...1265
              Check valve (vehicles suited to towing)...1265
              Low-pressure switch...1265
              Electro-pneumatic valve for ASR...1266
              Speed sensor...1266
              Electronic control unit...1266
              Pressure sensor...1266
              Diaphragm brake cylinder for front and added front axle disc brake)...1267
              Diaphragm brake cylinder (for front and added front axle drum brake)...1267
              Combined brake cylinder (for front and rear disc brake)...1267
              Combined brake cylinder (for front and rear drum brake)...1267
              Combined cylinder emergency brake release device...1268
              Repairs...1268
              Fault Diagnosis...1268
            DISC BRAKES TYPE KNORR SB7 (vehicles without EBS)...1269
            DISC BRAKES TYPE KNORR SB7 (vehicles with EBS)...1270
            DISC BRAKES KNORR TYPE (CALIPER SN7)...1271
              Brake caliper components...1272
              Operation...1273
            CHECKS...1273
              Efficiency of automatic clearance recovery...1273
              Brake lining thickness...1274
            OVERHAULING FRONT DISC BRAKES...1275
              Replacing brake linings...1275
              Removing and refitting brake callipers...1278
              Removal...1278
              Refitting...1279
              Removing and refitting wheel hubs...1279
              Removal...1279
              Refitting...1280
            BRAKE CALIPER OVERHAUL...1281
              Disassembly...1281
              Component part cleaning and check...1282
              Assembly...1282
            OVERHAULING BRAKE CALLIPERS SB7...1285
              Removal...1285
              Cleaning and checking component parts...1285
              Assembly...1286
            OVERHAULING BRAKE DISCS...1287
            TURNING AND GRINDING BRAKE DISCS...1287
            OVERHAULING REAR DISC BRAKES...1288
              Replacing brake linings...1288
            OVERHAULING THE DRUM BRAKES...1291
              Removing/fitting the front drum brakes...1291
              Removing the rear drum brakes...1291
              Turning drums...1294
              Replacing brake linings...1294
              Assembly...1295
        SECTION 13 - Bodywork - Chassis frame...1298
          Bodywork - Chassis frame...1298
            CAB...1302
              General information...1302
            FEATURES AND DATA...1302
            TOOLS...1302
            TIGHTENING TORQUE...1303
            REPAIRS REMOVING-REFITTING THE CAB...1306
              Removal...1306
              Removing the bumpers...1308
              Refitting...1310
            REPLACING THE FRONT SHOCK ABSORBER...1311
              Removal...1311
              Refitting...1311
            REPLACING THE CAB SUSPENSION FRONT MOUNTING RUBBER-TYPE BUSHINGS...1311
              Removal...1311
              Refitting...1312
            REPLACING THE CAB FRONT MOUNT BUSHINGS...1312
              Removal...1312
              Refitting...1312
            REMOVING — REFITTING THE STABILIZER BAR...1312
              Removal...1312
              Refitting...1312
            CHANGING THE REAR SHOCK ABSORBER...1314
              Removal...1314
              Refitting...1314
            CHANGING THE CAB LOCK...1314
              Removal...1314
              Refitting...1314
            CHANGING THE SWINGING BRACKET BUSHING...1314
              Removal...1314
              Refitting...1315
              Adjusting the front levelling valve linkwork...1316
            CAB TILTING...1318
            CAB TILTING UNIT...1319
              Removal...1319
              Refitting...1319
              Checking the oil level...1319
              Periodic level check...1319
            REPLACING THEWINDSHIELD...1320
              Removal...1320
              Refitting...1320
            REPLACING THEWINDING WINDOW...1321
              Removal...1321
              Refitting...1322
            REPLACING THEWINDOWWINDER...1322
              Removal...1322
              Refitting...1323
            REPLACING THE DOOR LOCK...1323
              Removal...1323
              Refitting...1323
            REPLACING THE OUTSIDE HANDLE OF THE DOOR...1324
              Removal...1324
              Refitting...1324
            CHANGING THE INSIDE HANDLE...1324
              Removal...1324
              Refitting...1324
            CHANGING THE SIDE MIRRORS...1325
              Removal...1325
              Refitting...1325
            CHANGING THE DOOR...1325
              Removal...1325
              Refitting...1325
            REPLACING THE FIXED WINDOW...1326
              Removal...1326
              Preparing the window bay...1326
              Preparing the window...1326
              Refitting...1326
            REPLACEMENT OF SIDE LID OPENING CONTROL...1328
              Removing...1328
              Fitting...1329
              Lid opening control adjustment...1329
            DRIVER’S SEAT...1330
              Removal...1330
              Refitting...1330
              Component layout...1331
            REMOVING THE DRIVER’S SEAT...1332
              Removing-fitting the cushion...1332
              Removing-fitting the cushion slider...1332
              Removing-fitting the seatbelt...1333
              Removing-fitting seatbelt connection and right-hand side upholstery...1333
              Removing — fitting the left-hand side upholstery, IPS valve and heating switch...1334
              Removing - fitting the back...1334
              Removing - fitting the back adjustment lever...1335
              Removing - fitting the height adjustment device...1335
              Removing - fitting the seat angle adjustment device...1335
              Removing — fitting the flexible cable of the shock absorber adjustment device...1335
              Removing — fitting the back adjustment lever segment...1336
              Removing - fitting the air spring...1336
              Removing - fitting the shock absorber...1336
              Removing - fitting the height adjustment valve...1337
              Removing - fitting the height locking system...1337
              Removing — fitting the flexible cable of the horizontal lever suspension...1337
              Removing - fitting the fast lowering magnetic valve...1338
              Removing - fitting the fast lowering switch...1338
              Removing - fitting the lumbar support device...1338
              Removing - fitting the back upholstery...1339
              Removing - fitting the cushion upholstery...1339
            AIR INTAKE LID REMOVAL AND REFITTING...1340
              Removal...1340
              Refitting...1340
            AIR INTAKE LID MOTOR REPLACEMENT...1340
              Removing...1340
              Refitting...1341
            WINDSCREEN SUN VISOR REEL REMOVAL/REFITTING...1341
              Removal...1341
              Refitting...1342
            WINDSCREEN SUN VISOR REEL MOTOR REPLACEMENT...1342
              Removing...1342
              Refitting...1342
            CABIN REFRIGERATOR...1342
              Preliminary checks...1342
              Removal...1343
              Refitting...1343
            OVERHAULING...1343
              Removing...1343
              Fan disassembling...1343
              Disassembling the anti-tipping probe with electronic circuit on the control unit...1344
              Electronic control unit disassembling...1345
              Checks...1345
              Fitting...1345
            INSTRUMENT PANEL...1346
            CENTRAL INSTRUMENT PANEL...1346
            FASCIA COVERING...1347
            CAB AIR-CONDITIONING...1352
              General...1352
            VENTILATION...1352
              Description...1352
            AIR-CONDITIONING AND HEATING...1353
              Description...1353
              Air-conditioning...1353
              Heating...1353
              Air-conditioning controls assembly...1353
              Automatic...1353
              Manual...1353
              Heating and ventilation...1353
            COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)...1354
            HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)...1355
            MAIN COMPONENTS OF AIR CONDITIONER AND HEATER (WEBASTO)...1356
              Outside temperature sensor...1357
              Inside temperature sensor...1357
              Three-way solenoid valve (WEBASTO)...1358
              Compressor...1358
              Dehumidifier filter and safety pressure switches...1359
              Geared motors...1360
              Evaporator temperature sensor...1361
              Blown air temperature sensor...1361
              Expansion valve...1362
            PROCEDURE FOR EMPTYING AND REFILLING THE AIR-CONDITIONING SYSTEMS WITH R134A REFRIGERANT...1363
              R134A refrigerant recovery and refilling station (99305146)...1363
            SAFETY STANDARDS...1364
            CONTROL FASCIA...1365
            OPERATION FLOW CHART...1367
            RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM...1368
            CREATING A VACUUM IN THE SYSTEM...1370
            RESTORING OIL IN THE SYSTEM...1372
            FILLING THE SYSTEMWITH REFRIGERANT...1373
            CHECKINGTHEPRESSURES INTHESYSTEM...1375
            OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM...1375
            LEAK FINDER FOR AIR-CONDITIONING SYSTEMSWITH HFC R134A (9905147)...1375
            REPAIR OPERATIONS...1376
            HEATER...1376
              Removal...1376
              Refitting...1376
            ADDITIONAL AIR HEATER SYSTEM...1377
              Removal...1377
              Refitting...1377
            DEFROST CONTROL MOTOR...1377
              Removal...1377
              Refitting...1378
            AIR RECIRCULATION DOOR CONTROL MOTOR...1379
              Removal...1379
              Refitting...1379
            AIR MIXING DOOR CONTROL MOTOR...1379
              Removal...1379
              Refitting...1379
            HEATER RADIATOR TEMPERATURE SENSOR...1380
              Removal...1380
              Refitting...1380
            FLOOR AIR DOOR CONTROL MOTOR...1380
              Removal...1380
              Refitting...1380
            ELECTRIC FAN...1381
              Removal...1381
              Refitting...1381
            HEATER RADIATOR...1381
              Removal...1381
              Refitting...1382
            POLLEN FILTER...1383
              Removal...1383
              Refitting...1383
            AIR-CONDITIONER COMPRESSOR...1383
              Removal...1383
              Refitting...1383
            AIR-CONDITIONER CONDENSER...1384
              Removal...1384
              Refitting...1384
            OUTSIDE AIR TEMPERATURE SENSOR...1384
              Removal...1384
              Refitting...1384
            DIAGNOSTICS INSTRUMENTS...1385
            MODUS - IWT - IT 2000...1385
            MODUS...1385
            IWT...1385
            IT 2000...1385
            Troubleshooting the air-conditioner system...1386
            Troubleshooting the additional air heater system...1390
        SECTION 14 - Scheduled maintenance...1398
          Scheduled maintenance...1398
            MAINTENANCE...1400
              Maintenance services chart...1400
            CHECKS AND/OR MAINTENANCEWORK...1401
            DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCEWORK...1402
            CHECKS AND/OR MAINTENANCEWORK...1404
            MAINTENANCEWORK...1405
            M1 SERVICE...1405
            M2 SERVICE...1409
            EXTRA PLAN MAINTENANCE...1411
            EP1 SERVICE...1411
            EP2 SERVICE...1411
            EP3 SERVICE...1411
            T1 SERVICE...1412
            T2 SERVICE...1412
            T3 SERVICE...1413
            T4 SERVICE...1414
        SECTION 15 - Electric/electronic system...1416
          Electric/electronic system...0
            UPDATE DATA...1418
            GENERAL LIST OF CONTENTS...1420
              INTRODUCTION...1422
                General warnings for electrical/electronic components...1424
                Component Code...1426
                Vehicle technical data...1431
              GENERAL...1432
                Description of the Multiplex system...1434
                Power Network...1453
                Mass points...1454
                List of st junction connector on board the vehicle...1458
              COMPONENTS...1498
                Remote control/fuse holder center...1500
                Supplementary remote switches...1502
                Supplementary fuses...1505
                Instrument panel...1507
                Controls on central panel...1508
                Controls on left panel frame...1509
                Controls on right panel frame...1510
                Light setting adjustment...1511
                Controls on the steering wheel...1512
                Heat rearview mirror adjustment...1513
                Left light control...1514
                External light rotating switch...1518
                Emergency switch...1519
                Tire selectors...1520
                Diagnosis connector...1521
                VDI electronic center...1522
                Wall pass...1523
                Alternator...1528
                Starter motor...1530
              ELECTRONIC SYSTEMS...1532
                MULTIPLEX SYSTEM...1534
                  Cluster...1536
                  Body Computer...1545
                  Front Frame Computer (FFC)...1557
                  Rear Frame Computer (RFC)...1560
                  Passenger Door Module (PDM)...1565
                  Driver Door Module (DDM)...1566
                  Cabin Module (CB)...1567
                  Steering Wheel Interface (SWI)...1569
                  Spiraled contact...1572
                  Bed Module...1577
                CONDITIONER...1578
                HYDRONIC D 10 WATER HEATER...1593
                IMMOBILIZER...1600
                EDC 6.2...1604
                EBS...1641
                ABS — EBL...1659
                ECAS...1685
                EUROTRONIC AUTOMATED...1706
                INTARDER...1726
              DIAGNOSIS...1734
                DIAGNOSTIC METHOD...1736
                DIAGNOSTICS...1737
                  Example of anomaly...1738
                DIAGNOSIS TOOLS...1740
                MULTIPLEX SYSTEM ERROR CODES...1742
              CIRCUIT CHARTS...1884
                CHART 1...1886
                CHART 2/1...1887
                CHART 2/2...1888
                CHART 2/3...1889
                CHART 3/1...1890
                CHART 3/2...1891
                CHART 4/1...1892
                CHART 4/2...1893
                CHART 4/3...1894
                CHART 4/4...1895
                CHART 5...1896
                CHART 6/1...1897
                CHART 6/2...1898
                CHART 7/1...1899
                CHART 7/2...1900
                CHART 8...1901
                CHART 9...1902
                CHART 10...1903
                CHART 11...1904
                CHART 12...1905
                CHART 13...1906
                CHART 14...1907
                CHART 15...1908
                CHART 16...1909
                CHART 17...1910
                CHART 18...1911
                CHART 19...1912
                CHART 20...1913
                CHART 21...1914
                CHART 22...1915
                CHART 23...1916
                CHART 24...1917
                CHART 25...1918
                CHART 26...1919
                CHART 27...1920
                CHART 28...1921
                CHART 29...1922
                CHART 30...1923
                CHART 31...1924
                CHART 32...1925
                CHART 33...1926
                CHART 34...1927
                CHART 35...1928
              BLOCK CHARTS...1930
                CHART 1...1932
                CHART 2...1933
                CHART 3...1934
                CHART 4...1935
                CHART 5...1936
                CHART 6...1937
                CHART 7...1938
                CHART 8...1939
                CHART 9...1940
                CHART 10...1941
                CHART 11...1942
                CHART 12...1943
                CHART 13...1944
                CHART 14...1945
                CHART 15...1946
                CHART 16...1947
                CHART 17...1948
                CHART 18...1949
                CHART 19...1950
                CHART 20...1951
                CHART 21...1952
                CHART 22...1953
                CHART 23...1954
                CHART 24...1955
                CHART 25...1956
                CHART 26...1957
603.93.141 - Iveco Stralis AT_AD REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('02-'06) (EN)...1958
  STRALIS AT/AD...1958
    REPAIR MANUAL :...1958
      MECHANICAL...1959
        SPECIAL REMARKS...1961
          Graphs and symbols...1962
        INDEX OF SECTIONS...1965
          SECTION 1 - General...1967
            General...1967
              VEHICLE IDENTIFICATION DATA...1969
                Vehicle Identification Plate...1970
                Production identification plate...1970
              COMPOSITION OF MODEL...1971
              P.I.C. NUMBER CODING...1975
              REPLENISHING FLUIDS...1979
          SECTION 2 - Engine...1983
            Engine...1983
              F2B Engine...1985
                GENERAL CHARACTERISTICS...1995
                VIEWS OF THE ENGINE...1990
                ASSEMBLY CLEARANCE DATA...1998
                TIGHTENING TORQUES...2004
                TOOLS...2010
                DISMANTLING THE ENGINE ON THE BENCH...2022
                REPAIR OPERATIONS...2029
                CYLINDER BLOCK...2029
                  Checks and measurements...2029
                CYLINDER LINERS...2030
                  Replacing cylinder liners...2031
                  Removal...2031
                  Fitting and checking protrusion...2031
                CRANKSHAFT...2032
                  Measuring main journals and crank pins...2033
                PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA...2034
                  Replacing the timing control gear and the oil pump...2041
                  Checking main journal installation clearance...2041
                  Checking crankshaft end float...2042
                PISTON-CONNECTING ROD ASSEMBLY...2043
                  Removal...2043
                  Measuring the diameter of the pistons...2044
                  Conditions for correct gudgeon pin-piston coupling...2044
                  Piston rings...2045
                CONNECTING ROD...2046
                  Checking connecting rod alignment...2047
                  Mounting the connecting rod - piston assembly...2047
                  Mounting the piston rings...2047
                  Fitting the connecting rod-piston assembly into the piston liners...2048
                  Piston protrusion check...2048
                  Checking assembly clearance of big end pins...2049
                CYLINDER HEAD...2049
                  Valve removal...2049
                  Checking the planarity of the head on the cylinder block...2049
                VALVE...2049
                  Removing deposits and checking the valves...2049
                VALVE GUIDES...2050
                  Replacing of valve guides...2051
                  Replacing - Reaming the valve seats...2051
                REPLACING INJECTOR HOLDER CASES...2051
                  Removal...2051
                  Checking protrusion of injectors...2053
                TIMING GEAR...2054
                  Checking cam lift and pin alignment...2054
                  Camshaft...2055
                  Bushes...2055
                  Replacing camshaft bushes using beater 99360487...2056
                  Removal...2056
                  Assembly...2056
                VALVE SPRINGS...2057
                  Fitting the valves and oil seal ring...2057
                ROCKER SHAFT...2058
                  Shaft...2058
                  Rocker...2058
                ASSEMBLING THE ENGINE ON THE BENCH...2059
                DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER...2061
                  Fitting the connecting rod-piston assembly into the cylinder liners...2062
                ENGINE FLYWHEEL...2065
                  Fitting engine flywheel...2065
                  Fitting camshaft...2066
                  Fitting pump-injectors...2067
                  Fitting rocker-arm shaft assembly...2067
                  Camshaft timing...2068
                  Phonic wheel timing...2070
                  Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors...2071
                ENGINE COMPLETION...2072
                LUBRICATION...2075
                  Oil pump...2077
                  Overpressure valve...2077
                  Oil pressure control valve...2078
                  Heat exchanger...2078
                  By-pass valve...2079
                  Thermostatic valve...2079
                  Engine oil filters...2079
                COOLING...2081
                  Description...2081
                  Operation...2081
                  Water pump...2083
                  Thermostat...2083
                  Electromagnetic coupling...2083
                TURBOCHARGING...2084
                TURBOCHARGER...2084
                TURBO COMPRESSOR HOLSET HX 40V...2086
                  Actuator...2089
                  Solenoid valve for VGT control...2089
                FUEL FEED...2090
                  Fuel pump...2091
                  Injector-pump...2091
                  Replacing injectors-pump...2091
                  Injector Phases...2092
              F3A Engine...2095
                VIEWS OF THE ENGINE...2097
                TECHNICAL DESIGNATION...2101
                CHARACTERISTIC CURVES...2102
                GENERAL CHARACTERISTICS...2104
                ASSEMBLY CLEARANCE DATA...2107
                TIGHTENING TORQUE...2113
                TOOLS...2119
                DISMANTLING THE ENGINE ON THE BENCH...2131
                REPAIR OPERATIONS...2138
                CYLINDER BLOCK...2138
                  Checks and measurements...2138
                CYLINDER LINERS...2139
                  Replacing cylinder liners...2140
                CRANKSHAFT...2141
                  Measuring the main journals and crankpins...2142
                  Preliminary measurement of main and big end bearing shell selection data...2143
                  Selecting the main and big end bearing shells...2144
                  Replacing the timing gear and oil pump...2150
                  Checking main journal assembly clearance...2150
                  Checking crankshaft end float...2151
                PISTON CONNECTING ROD ASSEMBLY...2152
                  Piston rings...2154
                CONNECTING RODS...2155
                  Bushings...2156
                  Checking connecting rods...2156
                  Mounting the connecting rod - piston assembly...2157
                  Mounting the piston rings...2157
                  Fitting the big end bearing shells...2157
                  Fitting connecting rod - piston assemblies in the cylinder liners...2158
                  Checking piston protrusion...2158
                  Checking crankpin assembly clearance...2159
                CYLINDER HEAD...2159
                  Removing valves...2159
                  Checking the planarity of the head on the cylinder block...2159
                  Valves...2159
                  Removing deposits and checking the valves...2159
                  Valve seats...2160
                  Checking clearance between valve-stem and associated valve guide...2161
                  Valve guides...2161
                  Replacing injector cases...2161
                  Checking injector protrusion...2163
                  Timing system...2164
                  Camshaft...2165
                  Bushings...2165
                  Valve springs...2167
                  Fitting valves and oil seal...2168
                ROCKER SHAFT...2168
                  Shaft...2169
                  Rocker arms...2169
                ENGINE ASSEMBLY ON BENCH...2170
                  Fitting connecting rod - piston assemblies in cylinder liners...2173
                ENGINE FLYWHEEL...2176
                  Fitting engine flywheel...2176
                  Fitting camshaft...2177
                  Fitting pump-injectors...2178
                  Fitting rocker-arm shaft assembly...2178
                  Camshaft timing...2179
                  Phonic wheel timing...2181
                  Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors...2182
                  Completing Engine Assembly...2183
                LUBRICATION...2185
                  Oil pump...2187
                  Overpressure valve...2187
                  Oil pressure control valve...2188
                  Heat exchanger...2188
                  By-pass valve...2189
                  Thermostatic valve...2189
                  Engine oil filters...2189
                COOLING...2191
                  Description...2191
                  Operation...2191
                  Water pump...2193
                  Thermostat...2193
                  Electromagnetic coupling...2193
                TURBOCHARGING...2194
                  Turbocharger HOLSET HY55V...2194
                  Actuator...2198
                  Solenoid valve for VGT control...2198
                FEEDING...2200
                  Fuel pump...2201
                  Injector-pump...2201
                  Replacing injectors-pump...2201
                  Injector Phases...2202
              Hydrocar pressure take-off on timing system...2205
                HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)...2207
                  Description...2207
                SPECIFICATIONS AND DATA...2208
                TIGHTENING TORQUES...2209
                ENGAGING POWER TAKE-OFF...2210
                REMOVING-REFITTING POWER TAKE-OFF...2210
          SECTION 3 - Clutch...2211
            Clutch...2211
              DESCRIPTION...2213
                Clutch...2213
              CHARACTERISTICS AND DATA...2213
              DIAGNOSTICS...2216
              TIGHTENING TORQUES...2219
              TOOLS...2219
              REMOVING AND REFITTING THE CLUTCH...2220
                Removal...2220
              CHECKS...2220
                Refitting...2221
              REMOVING-REFITTING THE THRUST BEARING...2221
              REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT...2221
              REMOVING-REFITTING THE PEDAL UNIT...2222
                Removal (vehicles with EuroTronic Automated gearbox)...2222
                Removal (vehicles with ZF 16 S... gearbox)...2223
                Refitting...2224
              PEDAL...2224
                Unit removal-assembly...2224
              CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL...2225
              HYDRAULIC CONTROL (Vehicles with ZF 9 S 109 - ZF 16S 151/181/221 gearboxes)...2226
              CLUTCH ACTUATOR FOR ZF 16 S 151/181/221 GEARBOXES...2227
                Fitting and adjusting the clutch wear indicator...2227
              PUSH ROD ADJUSTMENT...2228
                Operator cylinder (new clutch)...2228
              BLEEDING CLUTCH CIRCUIT...2228
              CLUTCH ACTUATOR FOR EUROTRONIC AUTOMATED GEARBOX...2229
                Clutch actuator push rod adjustment (new clutch)...2229
                Fitting the clutch actuator...2229
                Replacing the clutch actuator...2229
          SECTION 4 - Gearboxes...2231
            Gearboxes...2231
              Gearbox ZF 9 S 109 D.D...2233
                GENERAL SPECIFICATIONS...2235
                  Description of gearbox 9 S 109 D.D...2235
                SPECIFICATIONS AND DATA...2237
                DIAGNOSTICS...2240
                TIGHTENING TORQUE...2243
                EQUIPMENT...2244
                REMOVAL...2247
                  Removing the E.R.U.box...2247
                  Reassembling the E.R.U.box...2247
                DISASSEMBLING THE E.R.U. BOX...2248
                DISASSEMBLING THE E.R.U...2248
                CHECKS...2250
                ASSEMBLING THE E.R.U...2252
                ASSEMBLING THE E.R.U. BOX...2253
                DISASSEMBLING THE GEARBOX...2255
                REMOVING THE INPUT SHAFT...2258
                REMOVING THE MAIN SHAFT...2258
                REMOVING THE TRANSMISSION SHAFT...2261
                REMOVING THE GEARCHANGE CASE OF GEARBOX...2261
                OIL PUMP...2263
                CHECKS...2264
                ASSEMBLING THE GEARCHANGE CASE...2264
                ASSEMBLING THE TRANSMISSION SHAFT...2266
                ASSEMBLING THE INPUT SHAFT...2269
                ASSEMBLING THE GEARBOX...2269
                ADJUSTING THE TRANSMISSION SHAFT BEARINGS...2271
                  Adjusting the main shaft bearings...2272
              Gearboxes: ZF 16 S 181 D.D. - ZF 16 S 181 O.D. - ZF 16 S 221 D.D...2275
                LOCATION OF GEARBOX DESCRIPTION PLATE...2277
                DESCRIPTION...2278
                OPERATION...2280
                  Slow range...2280
                  Fast range...2281
                EPICYCLIC REDUCTION GEAR CONTROL...2282
                  Reduced speeds...2282
                  Normal speeds...2283
                SPECIFICATIONS AND DATA...2284
                TIGHTENING TORQUES...2288
                TOOLS...2289
                GEARBOX FAULT DIAGNOSIS...2294
                REMOVING-REFITTING THE GEARBOX...2297
                  Removal...2297
                  Refitting...2298
                OVERHAULING THE GEARBOX...2299
                  Servoshift gear box...2299
                  Removal...2299
                  Refitting...2299
                  Disassembly...2299
                  Assembly...2301
                  Removing the rear box...2305
                  Removing the epicyclic reduction gear unit (ERG)...2305
                  Fitting the epicyclic reduction gear unit (ERG)...2307
                  Refitting the epicyclic reduction gear unit (ERG) rear box...2310
                  Removing the gearbox...2310
                  Removing the main shaft...2313
                  Removing the drive input shaft...2316
                  Removing the transmission shaft...2317
                CHECKS...2317
                  Gearbox...2317
                  Hubs - sliding sleeves - forks...2317
                  Bearings...2317
                  Shafts - gears...2317
                  Synchronizing devices...2317
                  BK-type single-cone synchronizing devices...2317
                  Fitting the drive input shaft...2318
                  Fitting the drive input shaft...2318
                  Fitting the main shaft...2319
                  Adjusting the main shaft...2321
                  Fitting the gearbox...2322
                  Oil pump...2323
                  Adjusting the transmission shaft bearing end float...2323
                  Drive input shaft cover...2324
                PNEUMATIC CONTROL OF GEARBOX...2326
              ZF gearboxes with INTARDER hydraulic retarder, types: 16 S 151 D.D. 16 S 181 D.D. 16 S 221 D.D...2327
                SPECIFICATIONS AND DATA...2329
                TOOLS...2330
                  Removing the hydraulic retarder from the gearbox on the stand...2337
                  Refitting the hydraulic retarder...2337
                  Removing the epicyclic reduction gear unit (ERG) rear box...2338
                  Removing the epicyclic reduction gear unit (ERG)...2338
                  Component parts of the epicyclic reduction gear unit...2341
                  Fitting the epicyclic reduction gear unit (ERG)...2342
                  Refitting the epicyclic reduction gear unit (ERG) rear box...2344
              Gearbox EuroTronic 12 AS 2301 D.D./O.D...2345
                DESCRIPTION...2347
                SPECIFICATIONS AND DATA...2348
                TIGHTENING TORQUES...2351
                TOOLS...2352
                OVERHAULING THE GEARBOX...2357
                  Checks...2357
                  Gearbox actuator...2357
                  Removal...2357
                  Refitting...2358
                  Removing the rear box...2358
                  Removing the rear box...2359
                  Removing the epicyclic reduction gear train (E.R.G.)...2360
                  Fitting the epicyclic reduction gear train (E.R.G.)...2362
                  Adjusting epicyclic reduction gear train bearing end float...2363
                  Adjusting main shaft end float...2364
                  Synchronizing device assembly for engaging normal or reduced gears...2366
                  Removal...2366
                  Fitting...2366
                  Removing the middle box...2369
                  Removing the main shaft...2371
                  Removing the drive input shaft...2373
                  Removing the splitter synchronizing device...2374
                  Fitting the splitter synchronizing device...2375
                  Fitting the main shaft...2376
                  Fitting the drive input shaft...2376
                  Splitter control fork...2379
                  Disassembly - Assembly...2379
                  Gear control forks...2379
                  Removal...2379
                  Fitting...2380
                  Transmission shafts...2381
                  Disassembly - Assembly...2381
                  Fitting the middle box...2381
                  Fitting the front box...2384
                  Front cover...2386
                  Removal...2386
                  Fitting the front cover...2386
                  Adjusting drive input shaft bearing end float...2386
                  Adjusting transmission shaft bearing end float...2387
                  Clutch release lever...2389
              Gearbox EuroTronic 12 AS 2301 D.D./O.D. with Intarder (IT)...2391
                SPECIFICATIONS AND DATA...2393
                OVERHAULING THE GEARBOX...2394
                  Removing the hydraulic retarder...2394
                  Refitting the hydraulic retarder...2395
                  Adjusting epicyclic reduction gear train bearing end float...2395
                  Adjusting stator end float...2396
                  Removing the rear box...2397
                  Removing the E.R.G...2398
                  Fitting the E.R.G...2399
                EXPERIMENTAL TOOLS...2404
              Gearboxes Allison MD 3060 PR - Allison MD 3066 PR...2405
                DESCRIPTION...2407
                TECHNICAL DESIGNATION...2410
                  Identification plate...2410
                CHARACTERISTICS AND DATA...2411
                MAIN OPERATION ANOMALIES...2412
                TIGHTENING TORQUES...2420
                TOOLS...2420
                REMOVAL AND REFITTING OF THE TRANSMISSION...2421
                  Removal...2421
                  Refitting...2421
                DISCONNECTING AND CONNECTING GEARBOX CONTROL MODULE AGAIN...2424
                  Disconnecting...2424
                  Refitting...2424
                REPLACING SPEED SENSORS...2424
                  Replacing turbine speed sensor...2424
                  Engine revolutions sensor replacement...2425
                  Replacing the output speed sensor...2425
                REPLACING OIL LEVEL SENSOR...2425
                REPLACING OIL SUCTION FILTER...2426
                REPLACING THE SOLENOID VALVES...2426
                REPLACING PLANE GASKETS IN GEARBOX CONTROL MODULE...2427
                REPLACING PRESSURE SWITCH F3...2428
                REPLACING THE SEAL RING ON THE OUTPUT SHAFT...2428
              Transmission external control (except for vehicles equipped with Eurotronic - Allison gearshift)...2429
                TRANSMISSION EXTERNAL CONTROL...2431
                  Transmission tie rod adjustment...2431
                SIDE TIE ROD...2432
                  Removal...2432
                  Refitting...2433
                TELESCOPIC TIE ROD...2433
                  Removal...2433
                  Refitting...2433
                TRANSMISSION IDLER ARM...2433
                  Removal...2433
                  Disassembly...2434
                  Assembly...2434
                  Refitting...2434
                CROSS TIE ROD...2435
                  Removal...2435
                  Refitting...2435
              Power take-off...2437
                ZF POWER TAKE-OFF...2439
                HYDROCAR POWER TAKE-OFF...2459
              Power take off (Optional 2395)...2465
                DESCRIPTION...2467
                FEATURES AND DATA...2468
                TIGHTENING TORQUE...2469
                EQUIPMENT...2470
                  Operation (power take off disengaged)...2474
                  Operation (power take off engaged)...2475
                REMOVING - REFITTING TOTAL POWER TAKE-OFF ASSEMBLY...2476
                  Removal...2476
                  Refitting...2476
                OVERHAULING...2477
                  Removing main box...2477
                  Removing drive assembly...2477
                  Removing bearing for shaft with gear wheel...2477
                  Removing oil pump...2478
                  Cleaning and checking parts...2479
                  Fitting the oil pump...2479
                  Fitting bearing for shaft with gear wheel...2480
                  Fitting drive assembly...2480
                  Adjusting drive output shaft tapered bearings...2482
                  Fitting the main housing...2483
                  Adjusting ball bearing...2483
          SECTION 5 - Intarder - ZF hydraulic retarder...2485
            Intarder - ZF hydraulic retarder...2485
              LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE...2487
              GENERAL INFORMATION...2488
              OPERATION...2488
                Retarder engaged...2489
                Retarder disengaged...2490
              LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER...2491
              REMOVING AND REFITTING THE RETARDER ON THE ZF S 181/221-OD GEARBOX...2492
                Removal...2492
                Refitting...2493
                Filling with oil...2493
              SPECIFICATIONS AND DATA...2494
              TIGHTENING TORQUES...2495
              TOOLS...2496
              FAULT DIAGNOSIS...2498
              OVERHAULING THE INTARDER HYDRAULIC RETARDER...2502
                Hydraulic accumulator...2502
                Removal...2502
                Fitting...2502
                Removing hydraulic retarder...2502
                Checking the component parts of the hydraulic retarder...2507
                Fitting the hydraulic retarder...2508
                Stator end float adjustment...2513
          SECTION 6 - Propeller shafts...2515
            Propeller shafts...2515
              CHARACTERISTICS AND DATA...2517
              DIAGNOSTIC...2519
              TIGHTENING TORQUES...2521
              TOOLS...2521
              REMOVING AND REASSEMBLING THE PROPELLER SHAFT...2522
                Removal...2522
                Reassembly...2522
              CHECKING THE PROPELLER SHAFT ON THE VEHICLE...2523
              REMOVING AND FITTING BACK THE UNIVERSAL JOINTS...2524
              REMOVING AND REASSEMBLING THE SUPPORT...2524
          SECTION 7 - Rear axles...2525
            Rear axles...2525
              FAULT DIAGNOSIS...2527
              REMOVING-REFITTING THE REAR AXLE...2529
                Removal...2529
                Refitting...2529
              REMOVING-REFITTING THE DIFFERENTIAL FROM THE REAR AXLE ON THE VEHICLE...2530
                Removal...2530
                Refitting...2530
              Rear Axle MERITOR MS 13-175 with disc brakes...2531
                DESCRIPTION...2533
                CHARACTERISTICS AND DATA...2534
                TIGHTENING TORQUES...2535
                TOOLS...2537
                OVERHAULING THE REAR AXLE ASSEMBLY...2542
                OVERHAULING THEWHEEL HUBS...2542
                  Removal...2542
                  Replacing wheel hub bearings...2544
                  Checking the parts forming the wheel hubs...2544
                  Replacing the wheel fixing pins...2544
                REMOVING AND REFITTING THE DIFFERENTIAL...2548
                  Removal...2548
                  Refitting...2548
                REPAIRING THE DIFFERENTIAL...2549
                  Removing the differential...2549
                  Removing the gearcase...2550
                REMOVING THE BEVEL PINION FROM THE SUPPORT...2552
                  Differential component check...2552
                  Fitting the gear housing...2553
                FITTING THE MOUNT ON THE BEVEL PINION...2554
                  Reassembling the differential housing...2556
                ADJUSTING THE CAP GAP...2558
                CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...2561
                WORK ON THE VEHICLE...2564
                REPLACING THE BEVEL PINION MOUNT SEAL...2564
                  Disassembly...2564
                  Assembly...2565
              Rear axle MERITOR MS 13-175 whit drum brakes...2567
                DESCRIPTION...2569
                CHARACTERISTICS AND DATA...2570
                TIGHTENING TORQUES...2573
                TOOLS...2575
                OVERHAULING THE REAR AXLE ASSEMBLY...2580
                OVERHAULING THEWHEEL HUBS...2580
                  Removal...2580
                  Wheel hub component check...2581
                REPLACING THEWHEEL HUB BOLTS...2582
                  Wheel hub reassembly...2582
                REMOVING AND REASSEMBLING THE DIFFERENTIAL...2584
                  Removal...2584
                  Axle casing check...2584
              Rear axle 451391 (R 8284)...2585
                DESCRIPTION...2587
                SPECIFICATIONS AND DATA...2588
                TIGHTENING TORQUES...2589
                TOOLS...2591
                REAR AXLES ASSEMBLY OVERHAUL...2597
                  Disassembly...2597
                  Epicycloid reduction gear disassembly...2597
                  Wheel hub disassembly...2598
                CHECKING THE WHEEL HUB AND EPICYCLOID REDUCTION GEAR UNIT PARTS                                        ...2600
                WHEEL HUB ASSEMBLY...2601
                  Assembling the epicycloid reduction gear...2603
                REMOVING-REFITTING THE DIFFERENTIAL...2606
                REPAIRING THE DIFFERENTIAL...2608
                  Disassembly...2608
                  Gear housing disassembly...2609
                  Removing the bevel pinion from the support...2610
                CHECKING THE DIFFERENTIAL COMPONENTS...2612
                  Gear housing assembly...2613
                  Assembling the bevel pinion support...2614
                  Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...2614
                  Differential housing assembly...2616
                  Gear housing bearings rolling torque adjustment               ...2617
              Axles in Tandem MERITOR RT 160 E/1...2621
                Axles in Tandem (Intermediate) Meritor RP 160 E (R 2478)...2623
                  DESCRIPTION...2625
                  SPECIFICATIONS AND DATA...2625
                  TIGHTENING TORQUES...2627
                  TOOLS...2631
                  EXPERIMENTAL TOOLS...2638
                  SERVICING INTERMEDIATE AXLEASSEMBLY RP 160 E (R2478)...2641
                  AIR BREATHER REMOVAL-REFITTING...2641
                  SERVICING WHEEL HUBS...2641
                    Checking wheel hub components...2642
                  ASSEMBLING WHEEL HUBS...2643
                  REMOVING DIFFERENTIAL GEAR — TRANSFER BOX(with rear axle on stand 99322215)...2646
                  REFITTING DIFFERENTIAL GEAR — TRANSFER BOX (with rear axle on stand 99322215)...2646
                  REPAIRING INTER-AXLE UNIT...2647
                    Dismantling inter-axle unit...2647
                    Checking inter-axle unit components...2649
                    Fitting inter-axle unit...2649
                    Adjusting drive input shaft bearing end float...2651
                    Adjusting differential lock and inter-axle control pin end-stop...2652
                  REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING...2652
                    Dismantling gear cage...2656
                    Checking differential components...2656
                    Assembling gear cage...2657
                  ASSEMBLING DIFFERENTIAL CASING...2658
                    Calculating bevel pinion positionin differential casing...2658
                  COMPUTATIONAL EXAMPLES...2659
                    Determining the thickness of the bevel pinion bearing clearance adjustment rings...2659
                    Adjusting the cap gap...2662
                  CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...2664
                  REMOVING-SERVICING-REFITTING INTER-AXLEOUTPUT SHAFT...2667
                Axles in Tandem (Rear) MERITOR RR 167 E (R 0878)...2671
                  DESCRIPTION...2673
                  CHARACTERISTICS AND DATA...2673
                  TIGHTENING TORQUES...2675
                  TOOLS...2677
                  OVERHAULING REAR AXLE ASSEMBLY RR 167 E (R 0878)...2683
          SECTION 8 - Axles...2685
            Axles...2685
              Front axle 5876/4 (F 8021) 5876/5 (F 8021) 5886/5 (F9021) Steering central added axle 5876/2 (F 8021)...2687
                DESCRIPTION...2689
                SPECIFICATIONS AND DATA...2690
                FAULT DIAGNOSIS...2692
                TIGHTENING TORQUES...2695
                TOOLS...2697
                REMOVING AND REFITTING AXLE...2701
                  Removal       ...2701
                  Refitting        ...2701
                REMOVING AND REFITTING AXLE...2702
                  Vehicles with pneumatic front suspension and longitudinal bars...2702
                  Removal...2702
                  Refitting...2703
                VEHICLE CHECKS...2704
                  Tie rods...2704
                  Swivel heads...2704
                CHECKING SWIVEL HEAD PLAY...2704
                FRONT AXLE ASSEMBLY OVERHAUL...2705
                REMOVING - REFITTING WHEEL HUBS...2705
                  Removal...2705
                  Replacing wheel hub bearings...2706
                  Replacing wheel fixing pins...2707
                  Refitting wheel hubs...2707
                  Checking wheel hub bearing end float...2707
                  Measuring rolling torque...2708
                REMOVING AND REFITTING TRANSVERSE TIE ROD...2708
                REPLACING TRANSVERSE TIE ROD SWIVEL HEADS...2709
                LONGITUDINAL TIE ROD LEVER REMOVAL/REFITTING...2709
                CROSS TIE ROD LEVER REMOVAL/REFITTING...2709
                REMOVING AND REFITTING PIN FOR STUB AXLE...2709
                  Removal...2709
                  Replacing kingpin bearing...2710
                  Checking and adjusting clearance between stub axle and axle...2711
                CHECKING AND MEASURING THE AXLE BODY...2712
                  Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins...2712
                  Checking angle of holes for kingpins...2713
              Rigid rear added axle 55080/DI (N 8071)...2715
                DESCRIPTION...2717
                CHARACTERISTICS AND DATA...2718
                TIGHTENING TORQUE...2719
                TOOLS...2720
                REMOVING-REFITTING...2722
                  Removal...2722
                  Refitting...2723
                REPAIRS...2723
              Rigid rear added axle 55080/TI (N 8071)...2725
                DESCRIPTION...2727
                CHARACTERISTICS AND DATA...2728
                TIGHTENING TORQUES...2729
                TOOLS...2730
                REMOVING - REFITTING WHEEL HUBS...2732
                  Removal...2732
                  Replacing wheel hub bearings...2733
                  Replacing wheel fixing pins...2734
                  Refitting wheel hubs...2734
              Rigid rear added axle with hydraulic lifting 56082/D1 (N 9171)...2735
                DESCRIPTION...2737
                CHARACTERISTICS AND DATA...2738
                TIGHTENING TORQUE...2739
                TOOLS...2740
                REMOVING-REFITTING...2741
                REPAIRS...2741
              Rigid rear added axle with hydraulic lifting 56082/T1 (N 9171)...2743
                DESCRIPTION...2745
                CHARACTERISTICS AND DATA...2746
                TIGHTENING TORQUE...2747
                TOOLS...2748
                REMOVING-REFITTING...2749
                REPAIR OPERATIONS...2749
                VEHICLES WITH MECHANICAL SUSPENSION AND HYDRAULIC LIFTING...2750
                  Location of main system components...2750
                  Hydraulic system circuit diagram...2751
                FAULT DIAGNOSIS...2752
                SPECIFICATIONS...2754
                ELECTRO-HYDRAULIC PUMP...2755
                  Removal...2755
                  Refitting...2755
                LIFTING CYLINDERS (VEHICLESWITH MECHANICAL SUSPENSION)...2756
                  Removal...2756
                  Refitting...2756
              Steering rear added axle 57080/DI (N 8072)...2757
                DESCRIPTION...2759
                CHARACTERISTICS AND DATA...2760
                TIGHTENING TORQUES...2762
                TOOLS...2763
                REPAIRS...2767
                PNEUMATIC LIFT...2767
                GENERAL...2767
                LOCATION ON THE VEHICLE OF THE MAIN COMPONENTS OF THE HYDRAULIC SYSTEM...2768
                HYDRAULIC SYSTEM...2769
                HYDRAULIC SYSTEM WORKING DIAGRAM...2770
                VEHICLES WITH PNEUMATIC REAR SUSPENSIONS AND PNEUMATIC LIFTING...2771
                  Location on the vehicle of the main components...2771
                  Pneumatic working diagram, rear air suspensions and air lift for added axles with single wheels...2772
                TIGHTENING TORQUES (Steering and lifting device linkage)...2776
                CHARACTERISTICS AND DATA...2777
                  Steering and third axle hydraulic system...2777
                MAIN HYDRAULIC SYSTEM COMPONENTS...2778
                HYDRAULIC ACCUMULATOR...2778
                  Nitrogen pressure checking and recharging...2778
                OPERATOR CYLINDER...2778
                  Disassembly...2779
                  Assembly...2779
                  Checking cylinder oil sealing on the vehicle...2779
                CENTRING CYLINDER...2779
                  Disassembly...2780
                  Assembly...2780
                  Checking cylinder oil sealing on the vehicle...2780
                ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING...2781
                  Removal...2781
                  Refitting...2781
                AIR BLEEDING FROM THE HYDRAULIC CIRCUIT...2782
                  Filling up and bleeding the power steering hydraulic circuit (circuit 1)...2783
                  Filling up and bleeding the power steering hydraulic circuit (circuit 2)...2783
              Steering rear added axle 57080/TI (N 8072)...2785
                DESCRIPTION...2787
                CHARACTERISTICS AND DATA...2788
                TIGHTENING TORQUES...2790
                TOOLS...2791
                REPAIR OPERATIONS...2794
              Wheel geometry...2795
                GENERAL INFORMATION...2797
                  Steering wheel angles...2797
                FRONTWHEEL GEOMETRY (4X2 vehicles)...2798
                  Positioning clips and headlights...2798
                  Electronic compensation of rim eccentricity...2799
                  Wheel alignment...2799
                  Checking wheel toe-in...2800
                  Checking wheel deviation...2800
                  Checking camber...2800
                  Checking kingpin angle and caster...2801
                  Checking rear axle alignment...2802
                VEHICLE WHEEL GEOMETRY WITH CENTRAL ADDED AXLE (6X2 C)...2802
                  Checking steering angles...2804
                  Vehicle wheel geometry with steering rear added axle and pneumatic lifting...2804
          SECTION 9 - Suspensions...2807
            Suspensions...2807
              SUSPENSIONS...2809
              DESCRIPTION...2809
                Mechanical front suspension...2809
                Pneumatic front suspension...2809
                Pneumatic rear suspension...2809
                Rear mechanical suspension...2809
              SPECIFICATIONS AND DATA...2810
              MECHANICAL FRONT SUSPENSION ASSEMBLY DRAWING...2820
              REAR MECHANICAL SUSPENSION ASSEMBLY...2824
              “CANTILEVER” REAR SUSPENSION (Vehicles 6X2)...2826
                Procedure for assembly of the slipper block and mounting brackets for the longitudinal bars...2826
                Tightening the U-bolts clamping the leaf spring to the central pivot...2826
                Removing the central support...2827
                Removing the central support shaft...2827
                Replacing the bracket...2827
                Replacing the half bearings...2827
                Reassembling the bracket...2828
                Reassembling the central support shaft...2829
                Reassembling the central support...2829
                Front shock absorbers...2831
                Additional axle shock absorbers...2832
                Rear shock absorbers...2833
              AIR SUSPENSION...2834
                Chassis frame lifting, lowering and self-levelling with remote control...2834
                Saving Levels...2834
              AIR SUSPENSION SYSTEM DIAGRAMS...2835
                Rear air suspension main diagram for 4X2P vehicles...2835
                Working diagram of pneumatic rear suspensions for 4x2T/P tractors...2836
                Suspension diagram for tractors and cabin vehicles 4x2T/FP...2837
                Working diagram of air suspensions for 6x2Y/FP/FS-D/FP-D vehicles...2838
                Working diagram of air suspensions for 6x2Y/FP/FS-D/FP-D vehicles (without lifting the additional axle)...2839
                Working diagram of air suspensions for 6x2Y/FP/FS-CM vehicles...2840
                Working diagram of air suspensions for 6x2Y/FP/FS-CM vehicles (without lifting the additional axle)...2841
                Working diagram of rear air suspensions for 6x2Y/PT vehicles...2842
                Working diagram of rear air suspensions for 6x2Y/PT vehicles (without lifting the additional axle)...2843
                Working diagram of rear air suspensions for 6x2Y/PS vehicles...2844
                Working diagram of rear air suspensions for 6x2Y/PS vehicles (without lifting the additional axle)...2845
                Working diagram of air suspensions for 6x2TX/P vehicles...2846
                Working diagram of pneumatic rear suspensions for 6x4 TZ/P vehicles...2847
              CHARACTERISTICS AND DATA...2848
                Pneumatic System...2848
              MAIN COMPONENTS OF THE PNEUMATIC SYSTEM...2849
                Controlled pressure valve...2849
                Fault Diagnosis...2849
                Level sensor...2849
                Electro-Pneumatic Control Valve...2850
                Load detector pressure sensor...2851
                Low air pressure switch...2851
                Air spring...2851
                ECAS Control Unit...2851
              FAULT DIAGNOSIS...2852
                Diagnosis Instruments...2852
                Cluster Diagnosis...2853
              TOOLS...2858
              TIGHTENING TORQUES...2862
                Mechanical front suspension...2862
                Pneumatic front suspension...2863
                Pneumatic front suspension with bars...2864
                Central added axle pneumatic suspensions 6x2 C vehicles...2865
                Pneumatic rear suspension 4x2 - 6x2 C vehicles...2866
                Pneumatic rear suspension 6x2 P/PT/FT vehicles...2867
                Pneumatic rear suspension 6x2 P/FP/FS vehicles...2868
                Pneumatic rear suspension 6x2 P/PS vehicles...2869
                Pneumatic rear suspension 6x4 P vehicles...2870
              REMOVAL-REFITTING OF FRONT LEAF SPRING...2871
                Removal...2871
                Refitting...2871
              REMOVING-REFITTING FRONT SUSPENSION BARS...2872
                Removing longitudinal bars...2872
                Removing transverse bar...2872
                Refitting...2872
              REAR SUSPENSIONS...2873
                Removal...2873
                Refitting...2873
              REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM...2874
              REMOVING REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM...2874
              REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM...2874
              REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM...2874
                Removal...2874
                Refitting...2874
              REPLACING THE SUSPENSION ARM FLEXIBLE PIN...2875
                Removal...2875
                Refitting...2875
              STABILIZER BAR...2876
              FRONT STABILIZER BAR...2876
              CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)...2876
              REAR STABILIZER BAR...2876
                Removal...2876
                Refitting...2876
              RUBBER BUSHINGS...2879
                Replacing front stabilizer bar rubber bushings...2879
                Replacing rear stabilizer bar rubber bushings...2879
              SHOCK ABSORBERS...2880
                Removal-refitting...2880
                Front axle shock absorbers (6x2 C vehicles)...2880
                Central added axle shock absorbers...2880
                Rear axle shock absorbers...2880
                Rear added axle shock absorbers (6x2 P vehicles)...2880
                Removal...2880
                Refitting...2880
              CHASSIS FRAME ADJUSTMENT...2881
          SECTION 10 - Wheels and tyres...2885
            Wheels and tyres...2885
              DESCRIPTION...2887
              CHARACTERISTICS AND DATA...2887
                Tyre inflation pressures...2887
              TOOLS...2888
              FAULT DIAGNOSIS...2888
              STATIC BALANCING OF THE WHEELS...2891
              CORRECTING RESIDUAL STATIC IMBALANCE...2892
              TYRE PRESSURE...2892
              HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE...2893
          SECTION 11 - Steering...2895
            Steering...2895
              DESCRIPTION...2897
              SPECIFICATIONS AND DATA...2898
              FAULT DIAGNOSIS...2899
              TIGHTENING TORQUES...2904
              TOOLS...2905
              REMOVING-REFITTING THE POWER STEERING SYSTEM...2907
                Removal...2907
                Refitting...2909
                Removing-Fitting the Steering Lever...2909
              STEERING CONTROL...2910
              REMOVING-REFITTING THE STEERING CONTROL ASSEMBLY...2911
                Removal...2911
                Refitting...2913
                Changing the pneumatic cylinder...2913
                Removal...2913
                Refitting...2914
              BLEEDING THE POWER STEERING SYSTEM...2916
              MEASURING STEERING BOX PLAY AT THE STEERING WHEEL...2916
              CHECKING THE MAXIMUM PRESSURE OF THE POWER STEERING SYSTEM...2916
                Setting the automatic hydraulic steering limit...2916
          SECTION 12 - Air system - Brakes...2917
            Air system - Brakes...2917
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...2921
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)...2922
              SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)...2928
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)...2929
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)...2930
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...2931
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...2932
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)...2933
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)...2934
              PIPINGS AND FITTINGS...2935
                In general...2935
                Rigid pipings reflanging...2935
                Rigid pipings bending...2936
                Rigid pipings cutting...2936
                Flexible pipings replacementwith traditional fittings...2937
                Flexible pipings replacement with quick connection fittings...2938
              EBS (ELECTRONIC BRAKE SYSTEM)...2940
                EBS Benefits...2940
                Tractor and trailer compatibility at any time...2940
                Complete fault-diagnosis structures...2940
              OPERATING LOGIC...2941
              BRAKE SYSTEM...2942
              AUXILIARY BRAKE INTEGRATION...2943
              “ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)...2944
                “ABS” (Anti-Lock Brake System)...2944
                EBL (Electronic Brakes Limiter)...2945
                Operating Logic...2945
                EBS working diagram for 4x2 vehicles (tractors)...2946
                EBS working diagram for 4x2 vehicles (models: AT440S.. /FP-CT/FP-LT)...2947
                EBS working diagram for 6x2 vehicles (tractors)...2948
                EBS working diagram for 6x2 vehicles (trucks)...2949
                EBS working diagram for 6x2 vehicles (trucks)...2950
                ABS-EBL working diagram for 4x2 vehicles (trucks and tractors)...2954
                ABS-EBL working diagram for 6x2C vehicles...2955
                ABS-EBL working diagram for 6x4 vehicles...2956
                ABS-EBL working diagram for stand alone 4x2 vehicles (trucks)...2957
                ABS-EBL working diagram for 6x2 vehicles (trucks)...2958
                ABS-EBL working diagram for stand alone 6x2 vehicles (trucks)...2960
              DESCRIPTION...2961
                Service braking...2961
                Emergency braking...2961
                Exhaust brake...2961
                Parking brake...2961
              BRAKES...2961
                Disc Brakes...2961
                Drum Brakes...2961
              FAULT DIAGNOSIS...2962
                Diagnosis Instruments...2962
                Cluster Diagnosis...2963
              TIGHTENING TORQUES...2977
              TOOLS...2980
              SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM...2989
              SPECIFICATIONS AND DATA - BRAKES...2995
              CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM...2998
              MAIN COMPONENTS OF THE BRAKING SYSTEM...3000
                Compressor...3000
                Head locking screw tightness...3000
                Fault diagnosis...3001
                A.P.U. (Air Processing Unit)...3001
                Duplex control valve (vehicles without EBS)...3002
                Duplex control valve with electric transmitter (vehicles with EBS)...3002
                Fault Diagnosis (vehicles without EBS)...3002
                Relay valve (vehicles without EBS)...3003
                Proportional relay valve for front axle (vehicles with EBS)...3003
                Fault Diagnosis (vehicles without EBS)...3003
                Coupling heads...3003
                Rear axle electro-pneumatic modulator (for vehicles with EBS)...3004
                Fault Diagnosis...3004
                Redundancy valve (for 4x2 and 6x2 trucks)...3005
                ABS-EBS solenoid valve...3005
                Dual stop valve...3005
                Triple servo control valve (vehicles without EBS)...3005
                Predominance control...3006
                Fault Diagnosis...3006
                Trailer servo control valve (vehicles with EBS)...3007
                Pressure test point valve...3007
                Parking brake hand control valve (vehicles suited to towing)...3007
                Fault Diagnosis (parking brake control valve)...3007
                Parking brake control manual distributor (standby vehicles)...3008
                Manual control valve to slow down the trailer (optional extra)...3008
                Fault Diagnosis (parking brake control valve)...3008
                Controlled pressure valve...3009
                Fault Diagnosis...3009
                Check valve (vehicles suited to towing)...3009
                Low-pressure switch...3009
                Electro-pneumatic valve for ASR...3010
                Speed sensor...3010
                Phonic wheels...3010
                Electronic control unit...3010
                Pressure sensor...3010
                Diaphragm brake cylinder (for front and added front axle disc brake)...3011
                Diaphragm brake cylinder (for front and added front axle drum brake)...3011
                Combined brake cylinder (for front and rear disc brake)...3011
                Combined brake cylinder (for front and rear drum brake)...3011
                Combined cylinder emergency brake release device...3012
                Repairs...3012
                Fault Diagnosis...3012
              DISC BRAKES KNORR TYPE (CALIPER SN7)...3013
                Operation (See previous figure)...3014
              CHECKS...3014
                Checking the automatic play recovery system efficiency...3014
                Brake caliper components...3015
                Check of braking seals thickness...3016
              OVERHAULING FRONT DISC BRAKES...3017
                Replacing brake linings...3017
                Removing and refitting brake callipers...3020
                Removal...3020
                Refitting...3021
                Removing and refitting wheel hubs...3021
                Removal...3021
                Refitting...3022
              BRAKE CALIPER OVERHAUL...3023
                Disassembly...3023
                Component part cleaning and check...3024
                Assembly...3024
              OVERHAULING REAR DISC BRAKES...3026
                Replacing brake linings...3026
              OVERHAULING BRAKE DISCS...3029
              TURNING AND GRINDING BRAKE DISCS...3029
              DRUM BRAKES...3030
              OVERHAULING THE DRUM BRAKES...3031
                Removing the rear drum brakes...3031
                Turning drums...3035
                Replacing brake linings...3036
                Assembly...3036
          SECTION 13 - Bodywork - Chassis frame...3041
            Bodywork - Chassis frame...3041
              CAB...3043
                General information...3043
              CAB TILTING...3043
                Cab mechanic suspension...3044
                Cab driving position adjustment...3044
                Cab pneumatic suspension...3045
                Adjusting the levelling valve linkage...3045
              CAB AIR-CONDITIONING...3046
                General...3046
              VENTILATION...3046
                Description...3046
              AIR-CONDITIONING AND HEATING...3047
                Description...3047
                Air-conditioning...3047
                Air-conditioning controls assembly...3047
                Manual...3047
                Heating and ventilation...3047
                Heating...3047
              COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)...3048
              HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)...3049
                Outside temperature sensor...3050
                Compressor...3050
                Condenser and safety pressure switches...3051
                Geared motors...3052
                Evaporator temperature sensor...3053
                Expansion valve...3053
              PROCEDURE FOR EMPTYING AND REFILLING THE AIR-CONDITIONING SYSTEMS WITH R134A REFRIGERANT...3054
                R134A refrigerant recovery and refilling station (99305146)...3054
              SAFETY STANDARDS...3055
              CONTROL FASCIA...3056
              OPERATION FLOW CHART...3058
              RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM...3059
              CREATING A VACUUM IN THE SYSTEM...3061
              RESTORING OIL IN THE SYSTEM...3063
              FILLING THE SYSTEM WITH REFRIGERANT...3064
              CHECKING THE PRESSURES IN THE SYSTEM...3066
              OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM...3066
              LEAK FINDER FOR AIR-CONDITIONING SYSTEMS WITH HFC R134A (9905147)...3066
              REPAIR OPERATIONS...3067
              HEATER...3067
                Removal...3067
                Refitting...3067
              ADDITIONAL AIR HEATER SYSTEM...3068
                Removal...3068
                Refitting...3068
              DEFROST CONTROL MOTOR...3068
                Removal...3068
                Refitting...3069
              AIR RECIRCULATION DOOR CONTROL MOTOR...3070
                Removal...3070
                Refitting...3070
              ELECTRIC FAN...3070
                Removal...3070
                Refitting...3070
              HEATER RADIATOR...3070
                Removal...3070
                Refitting...3071
              POLLEN FILTER...3072
                Removal...3072
                Refitting...3072
              AIR-CONDITIONER COMPRESSOR...3072
                Removal...3072
                Refitting...3072
              AIR-CONDITIONER CONDENSER...3073
                Removal...3073
                Refitting...3073
              OUTSIDE AIR TEMPERATURE SENSOR...3073
                Removal...3073
                Refitting...3073
          SECTION 14 - Scheduled maintenance...3075
            Scheduled maintenance...3075
              VEHICLE WITH MOTOR Cursor 8 (F2B)...3077
              MAINTENANCE...3077
                Maintenance services chart...3077
              CHECKS AND/OR MAINTENANCEWORK...3078
              OFF-PLANE OPERATIONS...3079
              MAINTENANCE WORK...3083
              M1 SERVICE...3083
              M2 SERVICE...3085
              M3 SERVICE...3089
              M4 SERVICE...3089
              EP1 SERVICE...3089
              T1 SERVICE...3090
              T2 SERVICE...3090
              T3 SERVICE...3090
              T4 SERVICE...3090
              T5 SERVICE...3091
              T6 SERVICE...3091
              VEHICLE WITH MOTOR Cursor 10 (F3A)...3093
              MAINTENANCE...3093
                Maintenance services chart...3093
              CHECKS AND/OR MAINTENANCE WORK...3094
              OFF-PLANE OPERATIONS...3095
              MAINTENANCE WORK...3099
              M1 SERVICE...3099
              M2 SERVICE...3103
              EXTRA PLAN MAINTENANCE...3105
              EP1 SERVICE...3105
              EP2 SERVICE...3105
              EP3 SERVICE...3105
              T1 SERVICE...3106
              T2 SERVICE...3106
              T3 SERVICE...3107
              T4 SERVICE...3108
      ELECTRIC/ELECTRONIC SYSTEM...3109
        UPDATE DATA...3111
        GENERAL LIST OF CONTENTS...3113
          Introduction...3115
            General warnings for electrical/electronic components...3117
            Component Code...3119
            VARIATIONS WITH RESPECT TO STRALIS “AS”...3124
          General...3125
            GENERAL DESCRIPTION OF THE MULTIPLEX SYSTEM...3127
            POWER NETWORK...3146
            MASS POINTS...3147
            LIST OF ST JUNCTION CONNECTOR ON BOARD THE VEHICLE...3151
          Components...3163
            REMOTE CONTROL/FUSE HOLDER CENTER...3165
            SUPPLEMENTARY REMOTE SWITCHES...3167
            SUPPLEMENTARY FUSES...3170
            INSTRUMENT-HOLDER DASHBOARD...3172
            CENTRAL DASHBOARD CONTROLS...3173
            CONTROLS ON THE STEERING WHEEL...3174
            REARVIEW MIRRORS AND WINDOW REGULATOR CONTROL ADJUSTMENT (OPT)...3175
            LEFT LIGHT CONTROL...3176
            DIAGNOSIS CONNECTOR...3180
            “VDI” ELECTRONIC CENTER...3181
            WALL PASS...3182
            ALTERNATOR...3187
            STARTER MOTOR...3189
          Elektronic systems...3191
            LOCATION OF MULTIPLEX SYSTEM COMPONENTS ON BOARD THE VEHICLE...3193
              Cluster...3195
              Body computer...3202
              Front Frame Computer (F.F.C.)...3214
              Rear Frame Computer (R.F.C.)...3217
              Driver door module (D.D.M.)...3221
              Passanger Door Module (P.D.M.)...3221
              C.B. (Cab module) Opt...3224
              S.W.I. (Steering wheel / steervator interface)...3226
            SPIRALED CONTACT...3229
            B.M. (BED MODULE) OPT...3234
            AUTOMATIC AIR CONDITIONER...3236
            MANUAL AIR CONDITIONER...3251
            HYDRONIC D 10 WATER HEATER...3256
            IMMOBILIZER...3263
            EDC...3267
            EBS...3298
            ABS-EBL...3316
            ECAS SUSPENSIONS...3341
            EUROTRONIC AUTOMATIC TRANSMISSION...3362
            INTARDER...3381
          Diagnosis...3389
          Circuit charts...3391
            Card 1: Battery positive...3393
            Card 2: Positive after TGC (+30)...3394
            Card 3: Positive after TGC (+30)...3395
            Card 4: Positive after TGC (+30)...3396
            Card 5: Services supply (+15)...3397
            Card 6: Services supply (+15)...3398
            Card 7: BC unit (J7)...3399
            Card 8: BC unit (J6)...3400
            Card 9: BC unit (J4-J5)...3401
            Card 10: BC unit (J2-J3)...3402
            Card 11: SWI unit...3403
            Card 12: FFC unit (J2)...3404
            Card 13: FFC unit (J1)...3405
            Card 14: RFC unit (J1)...3406
            Card 15: RFC unit (J2)...3407
            Card 16: CM unit...3408
            Card 17: DDM-BM unit...3409
            Card 18: PDM unit...3410
            Card 19: IC unit...3411
            Card 20: CAN-ICB/IDB line...3412
            Card 21: CAN-SB (EBS/ABS) line...3413
            Card 22: CAN-BCB line...3414
            Card 23: VDI unit / CAN-VDB line...3415
            Card 24: ECAS 4x2 FP...3416
            Card 25: ECAS 6x4 P...3417
            Card 26: ECAS 6x2 P/FP...3418
            Card 27: ECAS 4x2 Tractor...3419
            Card 28: ECAS 6x2C...3420
            Card 29: ZF retarder...3421
            Card 30: ABS...3422
            Card 31: EBS...3423
            Card 32: EuroTronic II...3424
            Card 33: Immobilizer...3425
            Card 34: Manually controlled air conditioning system...3426
            Card 35: Automatically controlled air conditioning system...3427
            Card 36: Automatically controlled supplementary water heater...3428
            Card 37: Manually controlled supplementary water heater...3429
            Card 38: Manually controlled supplementary air heater...3430
            Card 39: EDC (Connector A) for F3A engines...3431
            Card 40: EDC (Connector A) for F2B engines...3432
            Card 41: EDC (Connector B)...3433
            Card 42: PTO with mechanical gearbox...3434
            Card 43: Radioreceiver...3435
          Block diagrams...3437
            Chart 1: Start-up - recharge warning light...3439
            Chart 2: EDC power supply - Immobilizer -Warning light - EDC Blink code - (warning light) - Four wheel drive on warning light...3440
            Chart 3: Cruise Control - Accelerator pedal sensor (potentiometer) - Pre-post heating warning light...3441
            Chart 4: Intarder...3442
            Chart 5: Voltmeter - Rev counter - Engine water temperature - Fuel level...3443
            Chart 6: Engine oil pressure - Engine oil level - window winder level - Hydraulic power steering fluid level - Engine water level...3444
            Chart 7: Chock wear indicator - Pad wear indicator - Reduced gear on indicator- Clogged oil filter indicator - Clogged air filter indicator...3445
            Chart 8: Differential block -Water presence in fuel indicator...3446
            Chart 9: Exterior lights...3447
            Chart 10: Exterior lights...3448
            Chart 11: Exterior lights - Reverse light...3449
            Chart 12: Hazard lights - Headlight beam orientation...3450
            Chart 13: Internal lights...3451
            Chart 14: Windscreen wiper - Horn - Hour counter...3452
            Chart 15: TGC...3453
            Chart 16: Sunroof - Windscreen washer...3454
            Chart 17: Tachograph...3455
            Chart 18: Engine electric fan...3456
            Chart 19: Rearview mirror control - Power windows...3457
            Chart 20: Central door lock...3458
            Chart 21: ECAS (warning lights) - ABS (warning lights)...3459
            Chart 22: EBS (warning lights) - Heated windscreen - PTO...3460
            Chart 23: Retarder (warning light) - Cabin tilting...3461
            Chart 24: Brake air pressure - ECAS - Outside temperature...3462
            Chart 25: Trip odometer / Total odometer - Speed limiter...3463
            Chart 26: Engine oil temperature - Beacon lights - Sun visor...3464
603.93.321 - Iveco Stralis AT_AD_AS Electronically Controlled Braking System EBS 2_ESP_EBL (EN)...3465
  ELECTRONICALLY CONTROLLED BRAKING SYSTEM EBS 2/ESP/EBL...3465
    Pneumatic system - EBS 2/ESP/EBL brakes...3467
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...3471
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)...3472
      SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)...3478
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)...3479
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)...3480
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...3481
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...3482
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)...3483
      SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)...3484
      PIPINGS AND FITTINGS...3485
        In general...3485
        Rigid pipings reflanging...3485
        Rigid pipings bending...3486
        Rigid pipings cutting...3486
        Flexible pipings replacementwith traditional fittings...3487
        Flexible pipings replacement with quick connection fittings ...3488
      EBS 2 (ELECTRONIC BRAKE SYSTEM)...3490
        EBS Benefits...3490
        Tractor and trailer compatibility at any time...3490
        Complete fault-diagnosis structures...3490
      OPERATING LOGIC...3491
      AUXILIARY BRAKE INTEGRATION...3493
        ESP (Electronic Stability Program)...3494
      “ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM - ELECTRONIC BRAKE LIMITER)...3494
        “ABS” (Anti-Lock Brake System)...3494
        EBL (Electronic Brakes Limiter)...3495
        Operating Logic...3495
        Braking system evolution...3495
      BRAKING SYSTEMS...3496
        ABS-EBL working diagram for 4x2 vehicles (trucks and tractors, not including HR) with CURSOR 8 (F2B) engine...3496
        Working diagram for 6x2 vehicles (tractors) with CURSOR 8 (F2B) engine...3497
        ABS-EBL working diagram for 6x2 vehicles (tractors) with CURSOR 8 (F2B) engine...3498
        Working diagram for 6x2 vehicles (trucks) with CURSOR 8 (F2B) engine and with CURSOR 10 engine (F3A with mechanical suspensions)...3499
        ABS-EBL working diagram for 6x2 vehicles (trucks) with CURSOR 8 (F2B) engine and with CURSOR 10 engine (F3A with mechanical suspensions)...3500
        ABS-EBL working diagram for stand alone 4x2 vehicles (trucks) with CURSOR 8 (F2B) engine...3501
        ABS-EBL working diagram for 6x2C vehicles (trucks) with CURSOR 8 (F2B) engine...3502
        EBS 2 working diagram for 4x2 vehicles (tractors) with CURSOR 10/13 engine...3504
        EBS 2 working diagram for 4x2 T/FP-CT vehicles (tractors) with CURSOR 10/13 engine...3505
        EBS 2 working diagram for 6x2 vehicles (tractors) with CURSOR 10/13 engine...3506
        EBS 2 working diagram for 4x2 vehicles (trucks) with CURSOR 10/13 engine...3507
        EBS 2 working diagram for 6x2 vehicles (trucks) with CURSOR 10/13 engine...3508
        EBS 2 working diagram for 6x2 vehicles (trucks) with CURSOR 10/13 engine...3509
        EBS 2 system components location on vehicle (tractors variant)...3510
        ABS-EBL system components location (tractors variant)...3511
      DESCRIPTION...3512
        Service braking...3512
        Emergency braking...3512
        Exhaust brake...3512
        Parking brake...3512
      BRAKES...3512
        Front and rear disk brakes  (Knorr sn7 type)...3512
      FAULT DIAGNOSIS...3513
        Diagnosis Instruments...3513
        Cluster Diagnosis...3514
         EBS 2Working diagram...3529
      TIGHTENING TORQUES...3534
      TOOLS...3536
      SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM...3543
      SPECIFICATIONS AND DATA - BRAKES...3548
      CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM...3549
      MAIN COMPONENTS OF THE BRAKING SYSTEM...3551
        Compressor...3551
        Head locking screw tightness...3551
        Fault diagnosis...3552
        A.P.U. (Air Processing Unit)...3552
      OPERATION...3554
        Duplex control valve (vehicles without EBS)...3558
        Fault Diagnosis (vehicles without EBS)...3558
        CBU (Central Brake Unit) (vehicles with EBS 2)...3559
        Relay valve (vehicles without EBS)...3561
        Fault Diagnosis (vehicles without EBS)...3561
        Coupling heads...3561
        Electropneumatic modulator (vehicles with EBS 2)...3562
        Operation...3564
        Redundancy valve (for 4x2 and 6x2 trucks)...3565
        ABS solenoid valve...3565
        Dual stop valve...3565
        Triple servo control valve (vehicles without EBS)...3565
        Predominance control...3566
        Fault Diagnosis...3566
        Pressure test point valve...3570
        Operation...3568
        Trailer drive servo-assisted distributor (vehicles with EBS 2)...3567
         Parking brake hand control valve (vehicles suited to towing)...3570
        Fault Diagnosis (parking brake control valve)...3570
        Parking brake control manual distributor (standby vehicles)...3571
        Manual control valve to slow down the trailer (optional) ...3571
        Fault Diagnosis (parking brake control valve)...3571
        Controlled pressure valve...3572
        Check valve (vehicles suited to towing)...3572
        Low-pressure switch...3572
        Electro-pneumatic valve for ASR...3573
        Diaphragm brake cylinder (for front and added front axle disc brake) ...3574
        Electro-pneumatic valve for ASR...3573
        Speed sensor...3573
        Phonic wheels...3573
        Electronic control unit...3573
        Diaphragm brake cylinder (for front and added front axle disc brake) ...3574
         Combined brake cylinder (for front and rear disc brake) ...3574
        Combined cylinder emergency brake release device ...3575
        Repairs...3575
        Fault Diagnosis...3575
      DISC BRAKES KNORR TYPE (CALIPER SN7)...3576
        Operation (See previous figure)...3577
      CHECKS...3577
        Checking the automatic play recovery system efficiency...3577
        Brake caliper components...3578
        Check of braking seals thickness...3579
      OVERHAULING FRONT DISC BRAKES...3580
        Replacing brake linings...3580
        For vehicles without EBS...3581
        For all vehicles ...3581
        For vehicles with EBS...3583
        Removing and refitting brake callipers...3583
        Refitting...3584
        Removing and refitting wheel hubs...3584
        Removal ...3584
        Refitting...3585
      BRAKE CALIPER OVERHAUL...3586
        Disassembly...3586
        Component part cleaning and check...3587
        Assembly...3587
      OVERHAULING REAR DISC BRAKES...3589
        Replacing brake linings...3589
      OVERHAULING BRAKE DISCS...3592
       TURNING AND GRINDING BRAKE DISCS...3592
603.93.333 - Iveco Stralis AT_AD REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('02-'06) (EN)...3593
  STRALIS AT/AD...3593
    MANUALE PER LE RIPARAZIONI...3593
      PREMESSA...3595
      SIMBOLI - AVVERTENZE...3595
      SIMBOLI - OPERAZIONI DI ASSISTENZA...3596
      CODICE PRODOTTO...3597
      AVVERTENZE GENERALI...3598
      AVVERTENZE GENERALI SULL’IMPIANTO ELETTRICO...3600
        Masse e schermature...3601
      INSTALLAZIONI OPTIONAL ELETTRO-MECCANICI...3602
      CONVERSIONI TRA LE PRINCIPALI UNITÀ DI MISURA DEL SISTEMA INTERNAZIONALE E LE GRANDEZZE DERIVATE DI PIÙ COMUNE IMPIEGO...3602
      DATI DI AGGIORNAMENTO...3603
      INDICE DELLE SEZIONI...3605
        SEZIONE 1 - Generalità...3607
          Generalità...3607
            DATI DI IDENTIFICAZIONE VEICOLO...3609
              Targhetta identificazione veicolo...3610
              Targhetta identificazione prodotto...3610
            COMPOSIZIONE DEI MODELLI...3611
            CODIFICAZIONE NUMERO P.I.C...3615
            RIFORNIMENTI...3619
        SEZIONE 2 - Motore...3623
          Motore...3623
            Motore F2B...3625
              DENOMINAZIONE TECNICA...3630
              CARATTERISTICHE GENERALI...3635
              DATI - GIUOCHI DI MONTAGGIO...3638
              COPPIE DI SERRAGGIO...3646
              ATTREZZATURA...3654
              STACCO-RIATTACCO MOTORE...3665
                Stacco...3665
                Riattacco...3666
                Riempimento impianto di raffreddamento...3667
                Spurgo aria dall’impianto d’alimentazione...3668
                Verifiche e controlli...3668
              SOSTITUZIONE GIUNTO ELETTROMAGNETICO...3669
                Stacco...3669
                Riattacco...3670
              SMONTAGGIO MOTORE AL BANCO...3673
              INTERVENTI RIPARATIVI...3680
              GRUPPO CILINDRI...3680
                Controlli e misurazioni...3680
              CANNE CILINDRI...3681
                Sostituzione canne cilindri...3682
                Smontaggio...3682
                Montaggio e controllo sporgenza...3682
              ALBERO MOTORE...3683
                Misurazione perni di banco e di biella...3684
              RILIEVO PRELIMINARE DEI DATI PER LA SELEZIONE DEI SEMICUSCINETTI DI BANCO E DI BIELLA...3685
                Sostituzione ingranaggio comando distribuzione e pompa olio...3692
                Controllo giuoco di montaggio perni di banco...3692
                Controllo giuoco di spallamento albero motore...3693
              COMPLESSIVO STANTUFFO BIELLA...3694
                Smontaggio...3694
                Misurazione diametro stantuffi...3695
                Condizioni per un corretto accoppiamento perno-stantuffo...3695
                Anelli elastici...3696
              BIELLA...3697
                Controllo bielle...3698
                Montaggio complessivo biella-stantuffo...3698
                Montaggio anelli elastici...3698
                Montaggio complessivi biella stantuffo nelle canne cilindri...3699
                Controllo sporgenza stantuffi...3699
                Controllo giuoco di montaggio perni di biella...3700
              TESTA CILINDRI...3700
                Smontaggio valvole...3700
                Controllo superficie appoggio testa sul gruppo cilindri...3700
              VALVOLE...3701
                Disincrostazione e controllo valvole...3701
              GUIDAVALVOLE...3701
                Sostituzione dei guidavalvole...3702
                Sostituzione - Ripassatura sedi valvole...3702
              SOSTITUZIONE ASTUCCI PORTA INIETTORI...3702
                Smontaggio...3702
                Controllo sporgenza iniettori...3704
              DISTRIBUZIONE...3705
                Comando distribuzione...3705
                Perno per ingranaggi di rinvio...3705
                Ingranaggio di rinvio...3705
                Ingranaggio doppio di rinvio...3705
                Sostituzione boccole...3705
                Albero distribuzione...3706
                Controllo alzata eccentrici e allineamento perni...3706
                Boccole...3707
                Sostituzione boccole per albero distribuzione mediante battitoio 99360487...3708
                Smontaggio...3708
                Montaggio...3708
              MOLLE VALVOLE...3709
                Montaggio valvole e anello paraolio...3709
              ALBERO BILANCIERI...3710
                Albero...3710
                Bilancieri...3710
              MONTAGGIO MOTORE AL BANCO...3711
              SCHEMA DELL’ORDINE DI SERRAGGIO DELLE VITI DI FISSAGGIO SOTTOBASAMENTO...3713
                Montaggio complessivi biella stantuffo nelle canne cilindri...3714
              VOLANO MOTORE...3717
                Montaggio volano motore...3717
                Montaggio albero distribuzione...3718
                Montaggio iniettori pompa...3719
                Montaggio albero bilancieri...3719
                Messa in fase albero della distribuzione...3720
                Fasatura della ruota fonica...3722
                Registrazione giuoco bilancieri aspirazione scarico e precarico bilancieri comando iniettori pompa...3723
              COMPLETAMENTO MOTORE...3724
              LUBRIFICAZIONE...3727
                Pompa olio...3729
                Valvola di sovrapressione...3729
                Valvola di regolazione pressione olio...3730
                Scambiatore di calore...3730
                Valvola by-pass...3731
                Valvola termostatica...3731
                Filtro olio motore...3731
              RAFFREDDAMENTO...3733
                Descrizione...3733
                Funzionamento...3733
                Giunto elettromagnetico...3735
                Pompa acqua...3735
                Termostato...3736
              SOVRALIMENTAZIONE...3739
              TURBOCOMPRESSORE...3739
              TURBO COMPRESSORE HOLSET HY40V...3741
                Attuatore...3744
                Elettrovalvola per comando VGT...3744
              INTERVENTI RIPARATIVI...3744
                Controllo movimento della geometria variabile...3745
                Controllo attuatore...3745
                Controllo corsa attuatore...3746
                Pulizia corpo turbina...3746
              ALIMENTAZIONE...3749
                Valvola di sovrapressione...3751
                Pompa di alimentazione...3751
                Iniettore pompa...3752
                Sostituzione iniettori-pompa...3752
                Fasi dell’iniettore...3753
            Motore F3A...3755
              VISTE DEL MOTORE...3757
              DENOMINAZIONE TECNICA...3761
              CURVE CARATTERISTICHE...3762
              CARATTERISTICHE GENERALI...3764
              DATI - GIUOCHI DI MONTAGGIO...3767
              COPPIE DI SERRAGGIO...3775
              ATTREZZATURA...3781
              STACCO - RIATTACCO MOTORE...3791
                Stacco...3791
                Riattacco...3792
              SOSTITUZIONE GIUNTO ELETTROMAGNETICO...3793
                Stacco...3793
                Riattacco...3794
              SMONTAGGIO MOTORE AL BANCO...3797
              INTERVENTI RIPARATIVI...3804
              GRUPPO CILINDRI...3804
                Controlli e misurazioni...3804
              CANNE CILINDRI...3805
                Sostituzione canne cilindri...3806
              ALBERO MOTORE...3807
                Misurazione perni di banco e di biella...3808
                Rilievo preliminare dei dati per la selezione dei semicuscinetti di banco e di biella...3809
                Selezione semicuscinetti di banco e di biella...3810
                Sostituzione ingranaggio comando distribuzione e pompa olio...3816
                Controllo giuoco di montaggio perni di banco...3816
                Controllo giuoco di spallamento albero motore...3817
              COMPLESSIVO STANTUFFO BIELLA...3818
                Anelli elastici...3820
              BIELLA...3821
                Boccole...3822
                Controllo bielle...3822
                Montaggio complessivo biella-stantuffo...3823
                Montaggio anelli elastici...3823
                Montaggio semicuscinetti di biella...3823
                Montaggio complessivi biella stantuffo nelle canne cilindri...3824
                Controllo sporgenza stantuffi...3824
                Controllo giuoco di montaggio perni di biella...3825
              TESTA CILINDRI...3825
                Smontaggio valvole...3825
                Controllo superficie appoggio testa sul gruppo cilindri...3825
                Valvole...3826
                Disincrostazione e controllo valvole...3826
                Sedi valvole...3826
                Controllo giuoco fra stelo-valvola e relativa guidavalvola...3827
                Guidavalvole...3827
                Sostituzione astucci porta iniettori...3827
                Controllo sporgenza iniettori...3829
              DISTRIBUZIONE...3830
                Comando distribuzione...3830
                Perno ingranaggio di rinvio...3830
                Ingranaggio di rinvio...3830
                Perno ingranaggio doppio di rinvio...3830
                Ingranaggio doppio di rinvio...3830
                Sostituzione boccole...3830
                Albero distribuzione...3831
                Controllo alzata eccentrici e allineamento perni...3831
                Boccole...3832
                Molle valvole...3834
                Montaggio valvole e anello paraolio...3835
              ALBERO BILANCIERI...3835
                Albero...3836
                Bilancieri...3836
              MONTAGGIO MOTORE AL BANCO...3837
                Montaggio complessivi biella stantuffo nelle canne cilindri...3840
              VOLANO MOTORE...3843
                Montaggio volano motore...3843
                Montaggio albero distribuzione...3844
                Montaggio iniettori-pompa...3845
                Montaggio alberi bilanceri...3845
                Messa in fase albero della distribuzione...3846
                Fasatura della ruota fonica...3848
                Registrazione giuoco bilancieri aspirazione scarico e precarico bilancieri comando iniettori pompa...3849
                Completamento motore...3850
              LUBRIFICAZIONE...3853
                Pompa olio...3855
                Valvola di sovrapressione...3855
                Valvola di regolazione pressione olio...3856
                Scambiatore di calore...3856
                Valvola by-pass...3857
                Valvola termostatica...3857
                Filtri olio motore...3857
              RAFFREDDAMENTO...3859
                Descrizione...3859
                Funzionamento...3859
                Pompa acqua...3861
                Termostato...3861
                Giunto elettromagnetico...3861
              SOVRALIMENTAZIONE...3862
                Turbocompressore HOLSET HY55V...3862
                Attuatore...3867
                Elettrovalvola per comando VGT...3867
              INTERVENTI RIPARATIVI...3867
                Controllo movimento della geometria variabile...3868
                Controllo attuatore...3868
                Controllo corsa attuatore...3869
                Pulizia corpo turbina...3869
              ALIMENTAZIONE...3872
                Valvola di sovrapressione...3874
                Pompa di alimentazione...3874
                Iniettore pompa...3875
                Sostituzione iniettori-pompa...3875
                Fasi dell’iniettore...3876
            Presa di forza Hydrocar sulla distribuzione...3879
              PRESA DI FORZA HYDROCAR SULLA DISTRIBUZIONE - (P.T.O. OPTIONAL)...3881
                Descrizione...3881
              CARATTERISTICHE E DATI...3882
              COPPIE DI SERRAGGIO...3883
              INSERIMENTO PRESA DI FORZA...3884
              STACCO-RIATTACCO PRESA DI FORZA...3884
        SEZIONE 3 - Frizione...3885
          Frizione...3885
            DESCRIZIONE...3887
              Frizione...3887
            CARATTERISTICHE E DATI...3887
            DIAGNOSTICA...3890
            COPPIE DI SERRAGGIO...3893
            ATTREZZATURA...3893
            STACCO E RIATTACCO FRIZIONE...3894
              Stacco...3894
            CONTROLLI...3894
              Riattacco...3895
            STACCO-RIATTACCO CUSCINETTO REGGISPINTA...3895
            SOSTITUZIONE DEL CUSCINETTO SUPPORTO ALBERO FRIZIONE...3895
            STACCO-RIATTACCO PEDALIERA SATA...3896
              Stacco (veicoli con cambio di velocità EuroTronic Automated)...3896
              Stacco (veicoli con cambio di velocità ZF 16 S...)...3897
              Riattacco...3898
            PEDALIERA TIPO SATA...3898
              Smontaggio-montaggio...3898
            CONTROLLO E REGISTRAZIONE ARRESTI PEDALE FRIZIONE...3899
              Arresto frizione...3899
              Corsa a vuoto pedale frizione...3899
              Corsa distributore a pedale...3899
            PEDALIERA TIPOWABCO...3900
              Arresto frizione...3900
              Corsa distributore a pedale...3900
            COMANDO IDRAULICO (Veicoli con cambi di velocità: ZF 9 S/16 S 109 - ZF 16S 151/181/221)...3901
            ATTUATORE FRIZIONE PER CAMBI DI VELOCITÀ ZF 16 S 109/151/181/221 CON SEGNALATORE USURA FRIZIONE...3903
              Montaggio e registrazione segnalatore di usura frizione...3903
            ATTUATORE FRIZIONE SENZA SEGNALATORE USURA FRIZIONE...3904
            REGISTRAZIONE PUNTALE...3905
              Attuatore frizione (frizione nuova)...3905
            SPURGO ARIA DEL CIRCUITO FRIZIONE...3905
            ATTUATORE FRIZIONE PER CAMBIO DI VELOCITÀ EUROTRONIC AUTOMATED...3906
              Registrazione puntale attuatore frizione (Frizione nuova)...3906
              Montaggio attuatore frizione...3906
              Sostituzione attuatore frizione...3906
        SEZIONE 4 - Cambi di velocità...3907
          Cambi di velocità...3907
            Cambio di velocità ZF 9 S 109 D.D...3909
              GENERALITÀ...3911
              Descrizione...3911
              CARATTERISTICHE E DATI...3913
              DIAGNOSTICA...3916
              COPPIE DI SERRAGGIO...3919
              ATTREZZATURA...3920
              SMONTAGGIO...3923
                Stacco della scatola G.R.E...3923
                Riattacco della scatola G.R.E...3923
              SMONTAGGIO SCATOLA G.R.E...3924
              SMONTAGGIO DEL G.R.E...3924
              CONTROLLI...3926
              MONTAGGIO G.R.E...3928
              MONTAGGIO SCATOLA G.R.E...3929
              SMONTAGGIO SCATOLA CAMBIO...3931
              SMONTAGGIO ALBERO ENTRATA MOTO...3934
              SMONTAGGIO ALBERO PRIMARIO...3934
              SMONTAGGIO ALBERO SECONDARIO...3937
              SMONTAGGIO SCATOLA COMANDO CAMBIO...3937
              POMPA OLIO...3939
              CONTROLLI...3940
              MONTAGGIO SCATOLA COMANDO CAMBIO...3940
              MONTAGGIO ALBERO SECONDARIO...3942
              MONTAGGIO ALBERO ENTRATA MOTO...3945
              MONTAGGIO SCATOLA CAMBIO...3945
              REGISTRAZIONE GIUOCO ASSIALE CUSCINETTI ALBERO SECONDARIO...3947
                Registrazione giuoco assiale cuscinetti albero primario...3948
            Cambio di velocità ZF 16 S 109 D.D...3951
              DESCRIZIONE...3953
              CARATTERISTICHE E DATI...3955
              DIAGNOSTICA...3958
              COPPIE DI SERRAGGIO...3961
              ATTREZZATURA...3962
              SMONTAGGIO...3965
                Stacco della scatola G.R.E...3965
                Riattacco della scatola G.R.E...3965
                Smontaggio scatola G.R.E...3966
                Smontaggio del G.R.E...3966
              CONTROLLI...3968
                Montaggio G.R.E...3970
                Montaggio scatola G.R.E...3971
                Registrazione giuoco assiale cuscinetto posteriore...3971
                Smontaggio scatola cambio...3973
                Smontaggio albero entrata moto...3976
                Montaggio albero entrata moto...3976
                Smontaggio albero primario...3977
              CONTROLLI...3978
                Montaggio albero primario...3979
                Smontaggio albero secondario...3982
                Smontaggio scatola comando cambio...3982
              POMPA OLIO...3984
              CONTROLLI...3985
                Montaggio scatola comando cambio...3985
                Montaggio albero secondario...3987
                Montaggio scatola cambio...3987
                Registrazione cuscinetti albero secondario...3989
                Registrazione cuscinetti albero primario...3990
            Cambi di velocità: ZF 9 S 109 con Intarder ZF 16 S 109 con Intarder...3993
              CARATTERISTICHE E DATI...3995
            Cambio di velocità: ZF 16 S 151 D.D. - ZF 16 S 181 D.D./O.D. - ZF 16 S 221 D.D...3997
              UBICAZIONE TARGHETTA DESCRITTIVA CAMBIO DI VELOCITÀ...3999
              DESCRIZIONE...4000
              FUNZIONAMENTO...4002
                Gamma lenta...4002
                Gamma veloce...4003
              COMANDO GRUPPO RIDUTTORE EPICICLOIDALE...4004
                Marce ridotte...4004
                Marce normali...4005
              CARATTERISTICHE E DATI...4006
              COPPIE DI SERRAGGIO...4010
              ATTREZZATURA...4011
              DIAGNOSTICA CAMBI DI VELOCITÀ...4016
              STACCO-RIATTACCO CAMBIO...4019
                Stacco...4019
                Riattacco...4020
              REVISIONE CAMBIO DI VELOCITÀ...4021
                Scatola comando marce servoshift...4021
                Stacco...4021
                Riattacco...4021
                Smontaggio...4021
                Montaggio...4023
                Stacco scatola posteriore...4027
                Smontaggio gruppo riduttore epicicloidale (G.R.E.)...4027
                Montaggio gruppo riduttore epicicloidale (G.R.E.)...4029
                Determinazione spessore anello di registro giuoco assiale cuscinetto posteriore...4031
                Riattacco scatola posteriore gruppo riduttore epicicloidale (G.R.E.)...4032
                Smontaggio scatola cambio...4032
                Smontaggio albero primario...4035
                Smontaggio albero entrata moto...4040
                Smontaggio albero secondario...4041
              CONTROLLI...4041
                Scatola cambio...4041
                Mozzi - manicotti scorrevoli - forcelle...4041
                Cuscinetti...4041
                Alberi - ingranaggi...4041
                Sincronizzatori...4041
                Sincronizzatori monocono tipo BK...4041
                Montaggio albero secondario...4042
                Montaggio albero entrata moto...4042
                Montaggio albero primario...4043
                Registrazione albero primario...4049
                Montaggio scatola cambio...4050
                Pompa olio...4051
                Registrazione giuoco assiale cuscinetto albero secondario...4051
                Coperchio albero entrata moto...4052
              COMANDO PNEUMATICO CAMBIO...4054
            Cambio di velocità ZF con rallentatore idraulico Intarder, tipo:16 S 151 D.D. - 16 S 181 D.D./O.D. - 16 S 221 D.D...4055
              CARATTERISTICHE E DATI...4057
              ATTREZZATURA...4058
                Stacco rallentatore idraulico dal cambio sul cavalletto...4065
                Riattacco rallentatore idraulico...4065
                Stacco scatola posteriore gruppo riduttore epiciloidale (G.R.E.)...4066
                Smontaggio gruppo riduttore epicicloidale (G.R.E.)...4066
                Particolari componenti il gruppo riduttore epicicloidale...4069
                Montaggio gruppo riduttore epicicloidale (G.R.E.)...4070
                Riattacco scatola posteriore gruppo riduttore epicicloidale (G.R.E.)...4072
            Cambio di velocità EuroTronic 12 AS 2301 D.D./O.D...4073
              DESCRIZIONE...4075
              UBICAZIONE TARGHETTA DESCRITTIVA CAMBIO DI VELOCITÀ...4075
              CARATTERISTICHE E DATI...4076
              COPPIE DI SERRAGGIO...4079
              ATTREZZATURA...4080
              REVISIONE CAMBIO DI VELOCITÀ ...4085
                Controlli...4085
                Attuatore cambio...4085
                Stacco...4085
                Riattacco...4086
                Stacco scatola posteriore...4086
                Smontaggio scatola posteriore...4087
                Smontaggio gruppo riduttore epicicloidale (G.R.E.)...4088
                Montaggio gruppo riduttore epicicloidale (G.R.E.)...4090
                Registrazione giuoco assiale cuscinetto gruppo riduttore epicicloidale...4091
                Registrazione giuoco assiale albero primario...4092
                Gruppo sincronizzatori innestomarce normali o ridotte...4094
                Smontaggio...4094
                Montaggio...4094
                Smontaggio scatola centrale...4097
                Smontaggio albero primario...4099
                Smontaggio albero entrata moto...4101
                Smontaggio sincronizzatore splitter...4102
                Montaggio sincronizzatore splitter...4103
                Montaggio albero entratamoto...4104
                Montaggio albero primario...4104
                Forcella comando splitter...4107
                Smontaggio - montaggio...4107
                Forcelle comando marce...4107
                Smontaggio...4107
                Montaggio...4108
                Alberi secondari...4109
                Smontaggio - Montaggio...4109
                Montaggio scatola centrale...4109
                Montaggio scatola anteriore...4112
                Coperchio anteriore...4114
                Smontaggio...4114
                Montaggio coperchio anteriore...4114
                Registrazione giuoco assiale cuscinetto albero entrata moto...4114
                Registrazione giuoco assiale cuscinetti alberi secondari...4115
                Leva disinnesto frizione...4117
                Sostituzione centralina elettronica...4118
                Smontaggio...4118
                Montaggio...4118
                Sostituzione valvola limitatrice di pressione stacco...4118
                Stacco...4118
                Riattacco...4118
            Cambio di velocità EuroTronic 12 AS 2301 D.D./O.D. con Intarder (IT)...4119
              CARATTERISTICHE E DATI...4121
              REVISIONE CAMBIO DI VELOCITÀ...4122
                Stacco rallentatore idraulico...4122
                Riattacco rallentatore idraulico...4123
                Registrazione giuoco assiale cuscinetto gruppo riduttore epicicloidale...4123
                Registrazione giuoco assiale statore...4124
                Stacco scatola posteriore...4125
                Smontaggio G.R.E...4126
                Montaggio G.R.E...4127
              ATTREZZATURA SPERIMENTALE...4132
            Cambi di velocità Allison MD 3060 PR - Allison MD 3066 PR...4135
              GENERALITÀ...4137
              DENOMINAZIONE TECNICA...4140
                Targhetta di identificazione...4140
              CARATTERISTICHE E DATI...4141
              PRINCIPALI ANOMALIE DI FUNZIONAMENTO...4142
              COPPIE DI SERRAGGIO...4150
              ATTREZZATURA...4150
              STACCO - RIATTACCO CAMBIO DI VELOCITÀ...4151
                Stacco...4151
                Riattacco...4151
              STACCO E RIATTACCO DEL MODULO DI CONTROLLO...4154
                Stacco...4154
                Riattacco...4154
              SOSTITUZIONE DEI SENSORI DI VELOCITÀ...4154
                Sostituzione del sensore velocità turbina...4154
                Sostituzione del sensore giri motore...4155
                Sostituzione del sensore velocità di uscita...4155
              SOSTITUZIONE DEL SENSORE LIVELLO OLIO...4155
              SOSTITUZIONE DEL FILTRO DI ASPIRAZIONE DELL’OLIO...4156
              SOSTITUZIONE DELLE ELETTROVALVOLE...4156
              SOSTITUZIONE DELLE GUARNIZIONI PIANE DEL MODULO DI CONTROLLO...4157
              SOSTITUZIONE DEL PRESSOSTATO F3...4158
              SOSTITUZIONE DELL’ANELLO DI TENUTA SULL’ALBERO DI USCITA...4158
            Comando esterno cambio di velocità (escluso veicoli con cambio di velocità: Eurotronic - Allison)...4159
              COMANDO ESTERNO CAMBIO DI VELOCITÀ...4161
                Regolazione tiranteria comando cambio...4161
              TIRANTE LONGITUDINALE...4162
                Stacco...4162
                Riattacco...4163
              TIRANTE TELESCOPICO...4163
                Stacco...4163
                Riattacco...4163
              LEVA RINVIO COMANDO CAMBIO...4163
                Stacco...4163
                Smontaggio...4164
                Montaggio...4164
                Riattacco...4164
              TIRANTE TRASVERSALE...4165
                Stacco...4165
                Riattacco...4165
            Prese di forza...4167
              PRESE DI FORZA TIPO ZF...4169
              PRESE DI FORZA HIDROCAR...4189
            Presa di forza totale (Optional 2395)...4195
              DESCRIZIONE...4197
              CARATTERISTICHE E DATI...4198
              COPPIE DI SERRAGGIO...4199
              ATTREZZATURA...4200
              ATTREZZATURA SPERIMENTALE...4202
                Funzionamento (presa di forza disinserita)...4205
                Funzionamento (presa di forza inserita)...4206
              STACCO RIATTACCO COMPLESSIVO PRESA DI FORZA TOTALE...4207
                Stacco...4207
                Riattacco...4208
              REVISIONE...4209
                Smontaggio scatola principale...4209
                Smontaggio gruppo presa di moto...4209
                Smontaggio cuscinetto per albero con ruota dentata...4209
                Smontaggio pompa olio...4210
                Pulizia-verifica e controllo deiparticolari...4211
                Montaggio pompa olio...4211
                Montaggio cuscinetto per albero con ruota dentata...4212
                Montaggio gruppo presa di moto...4212
                Registrazione cuscinetti conici albero uscita moto...4214
                Montaggio scatola principale...4215
                Registrazione cuscinetto a sfere...4215
        SEZIONE 5 - Rallentatore idraulico ZF - Intarder...4217
          Rallentatore idraulico ZF - Intarder...4217
            UBICAZIONE TARGHETTA DESCRITTIVA RALLENTATORE IDRAULICO INTARDER...4219
            GENERALITÀ...4220
            FUNZIONAMENTO...4220
              Rallentatore inserito...4221
              Rallentatore disinserito...4222
            DISPOSIZIONE SUL RALLENTATORE DEI PRINCIPALI COMPONENTI DEGLI IMPIANTI...4223
            STACCO E RIATTACCO DEL RALLENTATORE DAL CAMBIO DI VELOCITÀ ZF 16 S 181/221...4224
              Stacco...4224
              Riattacco...4225
              Riempimento dell’olio...4225
            CARATTERISTICHE E DATI...4226
            COPPIE DI SERRAGGIO...4227
            ATTREZZATURA...4228
            DIAGNOSTICA...4230
            REVISIONE RALLENTATORE IDRAULICO INTARDER...4234
              Accumulatore idraulico...4234
              Smontaggio...4234
              Montaggio...4234
              Smontaggio rallentatore idraulico...4234
              Controllo dei particolari componenti il rallentatore idraulico...4239
              Montaggio rallentatore idraulico...4240
              Registrazione giuoco assiale dello statore...4245
        SEZIONE 6 - Alberi di trasmissione...4247
          Alberi di trasmissione...4247
            CARATTERISTICHE E DATI...4249
            STRALIS AT/AD (Trattori) CARATTERISTICHE E DATI (Veicoli 4x2/6x2C/6x2p/6x4)...4251
            STRALIS AT/AD (Cabinati) CARATTERISTICHE E DATI (Veicoli 4x2/6x2P/6x2C)...4252
            DIAGNOSTICA...4253
            COPPIE DI SERRAGGIO...4255
            ATTREZZATURA...4255
            STACCO-RIATTACCO ALBERO DI TRASMISSIONE...4256
              Stacco...4256
              Riattacco...4256
            CONTROLLO ALBERI DI TRASMISSIONE SU VEICOLO...4257
            SMONTAGGIO E MONTAGGIO DEI GIUNTI CARDANICI...4258
            SMONTAGGIO E MONTAGGIO DEL SUPPORTO...4258
        SEZIONE 7 - Ponti...4259
          Ponti...4259
            DIAGNOSTICA...4261
            STACCO-RIATTACCO PONTE POSTERIORE...4263
              Stacco...4263
              Riattacco...4263
            STACCO-RIATTACCO DEL DIFFERENZIALE DAL PONTE SU VEICOLO...4264
              Stacco...4264
              Riattacco...4264
            Ponte Posteriore ARVINMERITOR MS 13-175 con freni a disco...4265
              UBICAZIONE TARGHETTE DESCRITTIVE GRUPPO DIFFERENZIALE - PONTE...4267
              DESCRIZIONE...4268
              CARATTERISTICHE E DATI...4269
              COPPIE DI SERRAGGIO...4270
              ATTREZZATURA...4272
              REVISIONE COMPLESSIVO PONTE...4277
              REVISIONE MOZZI RUOTE...4277
                Smontaggio...4277
                Sostituzione cuscinetti mozzi ruote...4279
                Controllo dei particolari componenti mozzi ruote...4279
                Sostituzione colonnette fissaggio ruote...4279
              STACCO E RIATTACCO DIFFERENZIALE...4283
                Stacco...4283
                Riattacco...4283
              RIPARAZIONE DIFFERENZIALE...4284
                Smontaggio differenziale...4284
                Smontaggio scatola ruotismi...4285
              SMONTAGGIO PIGNONE CONICO DAL SUPPORTO...4287
                Controllo dei particolari componenti il differenziale...4287
                Montaggio scatola ruotismi...4288
              MONTAGGIO SUPPORTO SUL PIGNONE CONICO ...4289
                Montaggio scatola differenziale...4291
              REGISTRAZIONE DIVARICAMENTO DEI CAPPELLI...4293
              CORREZIONI CONTATTI COPPIE CONICHE (DOPO MONTAGGIO)...4296
              INTERVENTI SU VEICOLO...4299
              SOSTITUZIONE ANELLO DI TENUTA DEL SUPPORTO PIGNONE CONICO...4299
                Smontaggio...4299
                Montaggio...4300
            Ponte Posteriore ARVINMERITOR MS 13-175 con freni a tamburo...4301
              UBICAZIONE TARGHETTE DESCRITTIVE GRUPPO DIFFERENZIALE - PONTE...4303
              DESCRIZIONE...4304
              CARATTERISTICHE E DATI...4305
              COPPIE DI SERRAGGIO...4308
              ATTREZZATURA...4310
              REVISIONE COMPLESSIVO PONTE POSTERIORE...4315
              REVISIONE MOZZI RUOTE...4315
                Smontaggio...4315
                Controllo dei particolari componenti mozzi ruote...4316
              SOSTITUZIONE COLONNETTE MOZZI RUOTE...4317
                Montaggio mozzi ruote...4317
              STACCO E RIATTACCO DIFFERENZIALE...4319
                Stacco...4319
                Controllo scatola ponte...4319
            Ponte posteriore 451391 (R 8284)...4321
              DESCRIZIONE...4323
              CARATTERISTICHE E DATI...4324
              COPPIE DI SERRAGGIO...4325
              ATTREZZATURA...4327
              REVISIONE COMPLESSIVO PONTE POSTERIORE...4333
                Smontaggio...4333
                Smontaggio riduttore epicicloidale...4333
                Smontaggio mozzi ruote...4334
              CONTROLLO DEI PARTICOLARI COMPONENTI MOZZI RUOTE E DI RIDUTTORI EPICICLOIDALI...4336
              MONTAGGIO MOZZI RUOTE...4337
                Montaggio riduttore epicicloidale...4339
              STACCO E RIATTACCO DIFFERENZIALE...4342
              RIPARAZIONE DIFFERENZIALE...4344
                Smontaggio...4344
                Smontaggio scatola ruotismi...4345
                Smontaggio supporto per pignone conico...4346
              CONTROLLO DEI PARTICOLARI COMPONENTI IL DIFFERENZIALE...4348
                Montaggio scatola ruotismi...4349
                Montaggio supporto per pignone conico...4350
                Procedura per la determinazione dello spessore dell’anello di registro coppia di rotolamento pignone conico...4350
                Montaggio scatola differenziale...4352
                Registrazione coppia rotolamento cuscinetti scatola ruotismi...4353
            Ponti in Tandem ARVINMERITOR RT 160 E/1...4357
              Ponti in Tandem (Intermedio) ARVINMERITOR RP 160 E (R 2478)...4359
                UBICAZIONE TARGHETTE DESCRITTIVE GRUPPO DIFFERENZIALE - PONTE...4361
                DESCRIZIONE...4362
                CARATTERISTICHE E DATI...4363
                COPPIE DI SERRAGGIO...4365
                ATTREZZATURA...4369
                ATTREZZATURA SPERIMENTALE...4376
                REVISIONE COMPLESSIVO PONTE INTERMEDIO RP 160 E (R 2478)...4379
                STACCO-RIATTACCO SFIATO ARIA...4379
                REVISIONE MOZZI RUOTE...4379
                  Controllo dei particolari componenti i mozzi ruote...4380
                MONTAGGIO MOZZI RUOTE...4381
                STACCO DIFFERENZIALE - RIPARTITORE (con ponte su cavalletto 99322215) ...4384
                RIATTACCO DIFFERENZIALE - RIPARTITORE (con ponte su cavalletto 99322215)...4384
                RIPARAZIONE GRUPPO RIPARTITORE...4385
                  Smontaggio ripartitore...4385
                  Controllo particolari componenti il gruppo ripartitore...4387
                  Montaggio gruppo ripartitore...4387
                  Registrazione giuoco assiale cuscinetti albero entrata moto...4389
                  Registrazione fine corsa perno di comando bloccaggio differenziale-ripartitore...4390
                RIPARAZIONE DIFFERENZIALE PRINCIPALE - SMONTAGGIO SCATOLA DIFFERENZIALE...4390
                  Smontaggio scatola ruotismi...4394
                  Controllo dei particolari componenti il differenziale...4394
                  Montaggio scatola ruotismi...4395
                MONTAGGIO SCATOLA DIFFERENZIALE...4396
                  ...4396
                ESEMPI DI CALCOLO...4397
                  Determinazione spessore anelli di registro giuoco cuscinetti pignone conico...4397
                  Registrazione divaricamento dei cappelli...4400
                CORREZIONI CONTATTI COPPIE CONICHE (DOPO MONTAGGIO)...4402
                STACCO-REVISIONE-RIATTACCO ALBERO USCITA RIPARTITORE...4405
              Ponti in Tandem (Posteriore) ARVINMERITOR RR 167 E (R 0878)...4409
                UBICAZIONE TARGHETTE DESCRITTIVE GRUPPO DIFFERENZIALE - PONTE COMPLETO...4411
                DESCRIZIONE...4412
                CARATTERISTICHE E DATI...4413
                COPPIE DI SERRAGGIO...4414
                ATTREZZATURA...4416
                REVISIONE COMPLESSIVO PONTE POSTERIORE RR 167 E (R 0878)...4422
        SEZIONE 8 - Assali...4423
          Assali...4423
            Assale anteriore 5876/4 (F 8021) 5876/5 (F 8021) 5886/5 (F 9021) - Assale aggiunto centrale sterzante 5876/2 (F 8021)...4425
              DESCRIZIONE...4427
              CARATTERISTICHE E DATI...4428
              DIAGNOSTICA...4430
              COPPIE DI SERRAGGIO...4433
              ATTREZZATURA...4435
              STACCO E RIATTACCO ASSALE...4439
                Veicoli con sospensione anteriore meccanica...4439
                Stacco...4439
                Riattacco...4439
                Veicoli con sospensione anteriore pneumatica e barre longitudinali...4440
                Stacco...4440
                Riattacco...4441
              STACCO E RIATTACCO ASSALE AGGIUNTO CENTRALE STERZANTE (veicoli cabinati 6x2C)...4442
                Stacco...4442
                Riattacco...4443
              CONTROLLI SU VEICOLO...4444
                Tiranti...4444
                Teste a snodo...4444
              CONTROLLO GIUOCO TESTA A SNODO...4444
              REVISIONE DEL COMPLESSIVO ASSALE ANTERIORE...4445
              STACCO - RIATTACCO MOZZI RUOTE...4445
                Stacco...4445
                Sostituzione cuscinetti mozzi ruote...4446
                Sostituzione colonnette fissaggio ruote...4447
                Riattacco mozzi ruote...4447
                Controllo giuoco assiale cuscinetti mozzi ruote...4447
                Rilievo della coppia di rotolamento...4448
              STACCO E RIATTACCO TIRANTE TRASVERSALE...4448
              SOSTITUZIONE TESTE A SNODO TIRANTE TRASVERSALE ...4449
              STACCO E RIATTACCO LEVE PER TIRANTE LONGITUDINALE...4449
              STACCO E RIATTACCO LEVA PER TIRANTE TRASVERSALE...4449
              STACCO E RIATTACCO DEL PERNO PER FUSO A SNODO...4449
                Stacco...4449
                Sostituzione cuscinetto perno fuso...4450
                Controllo e registrazione del giuoco tra fuso a snodo e assale...4451
              CONTROLLI E MISURAZIONI DEL CORPO ASSALE...4452
                Controllo planarità superfici appoggio molle a balestra rispetto ai fori per perni fuso a snodo...4452
                Controllo inclinazione dei fori per perni fuso a snodo...4453
            Assale aggiunto posteriore rigido 55080/DI (N 8071)...4455
              DESCRIZIONE...4457
              CARATTERISTICHE E DATI...4458
              COPPIE DI SERRAGGIO...4459
              ATTREZZATURA...4460
              STACCO-RIATTACCO...4462
                Stacco...4462
                Riattacco...4463
              INTERVENTI RIPARATIVI...4463
            Assale aggiunto posteriore rigido 55080/TI (N 8071)...4465
              DESCRIZIONE...4467
              CARATTERISTICHE E DATI...4468
              COPPIE DI SERRAGGIO...4469
              ATTREZZATURA...4470
              STACCO - RIATTACCO MOZZI RUOTE...4472
                Stacco...4472
                Sostituzione cuscinetti mozzi ruote...4473
                Sostituzione colonnette fissaggio ruote...4474
                Riattacco mozzi ruote...4474
            Assale aggiunto posteriore rigido a sollevamento idraulico 56082/D1 (N 9171)...4475
              DESCRIZIONE...4477
              CARATTERISTICHE E DATI...4478
              COPPIE DI SERRAGGIO...4479
              ATTREZZATURA...4480
              STACCO-RIATTACCO...4481
              INTERVENTI RIPARATIVI...4481
            Assale aggiunto posteriore rigido a sollevamento idraulico 56082/T1 (N 9171)...4483
              DESCRIZIONE...4485
              CARATTERISTICHE E DATI...4486
              COPPIE DI SERRAGGIO...4487
              ATTREZZATURA...4488
              STACCO-RIATTACCO...4489
              INTERVENTI RIPARATIVI...4489
              VEICOLI CON SOSPENSIONI MECCANICHE E SOLLEVAMENTO IDRAULICO...4490
                Ubicazione sul veicolo dei principali componenti...4490
                Schema di principio impianto idraulico...4491
                Registrazione...4492
                Legenda schema elettrico...4494
              DIAGNOSTICA...4496
              CARATTERISTICHE E DATI...4498
              POMPA ELETTROIDRAULICA...4499
                Stacco...4499
                Riattacco...4499
              CILINDRI DI SOLLEVAMENTO (SOSPENSIONI MECCANICHE)...4500
                Stacco...4500
                Riattacco...4500
            Assale aggiunto posteriore sterzante a sollevamento pneumatico 57080/DI (N 8072)...4501
              DESCRIZIONE...4503
              CARATTERISTICHE E DATI...4504
              COPPIE DI SERRAGGIO...4506
              ATTREZZATURA...4507
              INTERVENTI RIPARATIVI...4511
              SOLLEVAMENTO PNEUMATICO...4511
              GENERALITÀ...4511
              UBICAZIONE SUL VEICOLO DEI PRINCIPALI COMPONENTI DELL’IMPIANTO IDRAULICO...4512
              IMPIANTO IDRAULICO...4513
              SCHEMA DI PRINCIPIO IMPIANTO IDRAULICO...4514
              VEICOLI CON SOSPENSIONI POSTERIORI PNEUMATICHE E SOLLEVAMENTO PNEUMATICO...4515
                Ubicazione sul veicolo dei principali componenti...4515
                Schema di principio pneumatico, sospensioni pneumatiche posteriori e sollevatore pneumatico per assali aggiunti con ruote singole...4516
              DIAGNOSTICA...4517
              COPPIE DI SERRAGGIO (Tiranteria sterzo e dispositivo di sollevamento)...4520
              CARATTERISTICHE E DATI...4521
                Impianto idraulico sterzo e terzo asse...4521
              PRINCIPALI COMPONENTI DELL’IMPIANTO IDRAULICO...4522
              ACCUMULATORE IDRAULICO...4522
                Controllo e ricarica pressione di azoto...4522
              CILINDRO OPERATORE...4522
                Stacco...4523
                Riattacco...4523
                Controllo tenuta olio del cilindro sul veicolo...4523
              CILINDRO DI CENTRAGGIO...4523
                Stacco...4524
                Riattacco...4524
                Controllo tenuta olio del cilindro sul veicolo...4524
              STACCO E RIATTACCO DISPOSITIVO DI SOLLEVAMENTO PNEUMATICO ASSALE AGGIUNTO...4525
                Stacco...4525
                Riattacco...4525
              SPURGO DELL’ARIA DAL CIRCUITO IDRAULICO...4526
                Riempimento e spurgo del circuito idraulico idroguida (circuito 1)...4527
                Riempimento e spurgo del circuito idraulico del terzo asse (circuito 2)...4527
            Assale aggiunto posteriore sterzante a sollevamento pneumatico 57080/TI (N 8072)...4529
              DESCRIZIONE...4531
              CARATTERISTICHE E DATI...4532
              COPPIE DI SERRAGGIO...4534
              ATTREZZATURA...4535
              INTERVENTI RIPARATIVI...4538
            Assetto ruote...4539
              GENERALITÀ...4541
                Angoli caratteristici ruote sterzanti...4541
              ASSETTO RUOTE ANTERIORI (veicoli 4x2)...4542
                Posizionamento graffe e proiettori...4542
                Compensazione elettronica della scentratura del cerchio...4543
                Allineamento delle ruote...4543
                Controllo convergenza ruote...4544
                Controllo scostamento ruote...4544
                Controllo inclinazione delle ruote (Camber)...4544
                Controllo angolo di inclinazione montante (King Pin) e angolo di incidenza (Caster)...4545
                Controllo allineamento ponte posteriore...4546
              ASSETTO RUOTE VEICOLI CON ASSALE AGGIUNTO CENTRALE (6X2 C)...4546
                Controllo angoli di sterzata...4548
                Assetto ruote veicoli con assale aggiunto posteriore sterzante e sollevamento pneumatico...4548
        SEZIONE 9 - Sospensioni...4551
          Sospensioni...4551
            SOSPENSIONI...4555
            DESCRIZIONE...4555
              Sospensione anteriore meccanica...4555
              Sospensione anteriore pneumatica...4555
              Sospensione posteriore pneumatica...4555
              Sospensione posteriore meccanica...4555
            CARATTERISTICHE E DATI...4556
            COMPLESSIVO SOSPENSIONE ANTERIORE MECCANICA...4566
            COMPLESSIVO SOSPENSIONE POSTERIORE MECCANICA...4570
            SOSPENSIONE POSTERIORE “CANTILEVER” (Veicoli 6X2)...4572
              Procedure per il montaggio pattino di supporto molla a balestra e supporto di ancoraggio barre longitudinali...4572
              Serraggio staffe di fissaggio molla a balestra al supporto centrale...4572
              Stacco supporto centrale...4573
              Smontaggio albero per supporto centrale...4573
              Sostituzione della mensola...4573
              Sostituzione semicuscinetti...4573
              Riattacco mensola...4574
              Riattacco albero per supporto centrale...4575
              Riattacco supporto centrale...4575
              Ammortizzatori anteriori...4577
              Ammortizzatori assali aggiunti...4578
              Ammortizzatori posteriori...4579
            SOSPENSIONI PNEUMATICHE...4580
              Sollevamento, abbassamento e autolivellamento telaio mediante telecomando ...4580
              Memorizzazione dei livelli...4580
            MISURATORE CARICO ASSI...4581
            CALIBRAZIONE (indicazione su display)...4581
            SCHEMI IMPIANTI SOSPENSIONI PNEUMATICHE...4583
              Schema di principio sospensioni pneumatiche posteriori per cabinati 4x2P...4583
              Schema di principio sospensioni posteriori pneumatiche per trattori 4x2T/P...4584
              Schema di principio sospensioni per trattori e cabinati 4x2/FP...4585
              Schema di principio sospensioni pneumatiche per veicoli 6x2Y/FP/FS-D/FP-D (con sollevatore assale aggiunto)...4586
              Schema di principio sospensioni pneumatiche per veicoli 6x2Y/FP/FS-D/FP-D (senza sollevatore assale aggiunto)...4587
              Schema di principio sospensioni pneumatiche per cabinati 6x2Y/FP/FS-CM (con sollevatore assale aggiunto)...4588
              Schema di principio sospensioni pneumatiche per cabinati 6x2Y/FP/FS-CM (senza sollevatore assale aggiunto)...4589
              Schema di principio sospensioni pneumatiche posteriori per cabinati 6x2Y/PT e trattori 6X2TY/PT (con sollevatore assale aggiunto)...4590
              Schema di principio sospensioni pneumatiche posteriori per cabinati 6x2Y/PT e trattori 6X2TY/PT (senza sollevatore assale aggiunto)...4591
              Schema di principio sospensioni pneumatiche posteriori per veicoli 6x2Y/PS...4592
              Schema di principio sospensioni pneumatiche posteriori per veicoli 6x2Y/PS (senza sollevatore assale aggiunto)...4593
              Schema di principio sospensioni pneumatiche per veicoli 6x2TX/P...4594
              Schema di principio sospensioni pneumatiche per veicoli 6x2X/P...4595
              Schema di principio sospensioni pneumatiche per veicoli 6x2X/FP...4596
              Schema di principio sospensioni posteriori pneumatiche per veicoli 6x4 TZ/P...4597
            CARATTERISTICHE E DATI...4598
              Impianto pneumatico...4598
            PRINCIPALI COMPONENTI DELL’IMPIANTO PNEUMATICO...4599
              Valvola a pressione controllata...4599
              Diagnostica...4599
              Sensore di livello...4599
              Distributore elettropneumatico...4600
              Sensore di pressione rilevatore di carico...4601
              Interruttore manometrico bassa pressione aria...4601
              Molla ad aria...4601
              Centralina ECAS...4601
            DIAGNOSTICA...4602
              Strumenti di diagnosi...4602
              Diagnosi su Cluster...4603
            ATTREZZATURA...4608
            COPPIE DI SERRAGGIO...4612
              Sospensione anteriore meccanica...4612
              Sospensione anteriore pneumatica...4613
              Sospensione anteriore pneumatica con barre...4614
              Sospensioni pneumatiche assale aggiunto centrale Veicoli 6x2 TX/P...4615
              Sospensione pneumatiche assale aggiunto centrale Veicoli 6x2 X/P - X/FP...4616
              Sospensione posteriore pneumatica Veicoli 4x2 + 6x2 C...4617
              Sospensione posteriore pneumatica Veicoli 6x2 P/PT/FT...4619
              Sospensione posteriore pneumatica Veicoli 6x2 P/FP/FS...4620
              Sospensione posteriore pneumatica Veicoli 6x2 P/PS...4621
              Sospensione posteriore pneumatica Veicoli 6x4 P...4622
            STACCO-RIATTACCO MOLLA A BALESTRA ANTERIORE...4623
              Stacco...4623
              Riattacco...4623
            STACCO-RIATTACCO BARRE SOSPENSIONE ANTERIORE...4624
              Stacco barre longitudinali...4624
              Stacco barra trasversale...4624
              Riattacco...4624
            STACCO - RIATTACCO MOLLA A BALESTRA ASSALE AGGIUNTO CENTRALE (veicoli cabinati 6x2C)...4625
              Stacco...4625
              Riattacco...4625
            SOSPENSIONI POSTERIORI...4626
              Stacco...4626
              Riattacco...4626
            STACCO-RIATTACCO BRACCIO OSCILLANTE LONGITUDINALE PONTE POSTERIORE...4627
            STACCO-RIATTACCO BRACCIO OSCILLANTE LONGITUDINALE ASSALE AGGIUNTO POSTERIORE...4627
            STACCO-RIATTACCO BRACCIO OSCILLANTE TRIANGOLARE PONTE POSTERIORE...4627
            STACCO-RIATTACCO BRACCIO OSCILLANTE TRIANGOLARE ASSALE AGGIUNTO POSTERIORE...4627
              Stacco...4627
              Riattacco...4627
            SOSTITUZIONE PERNO ELASTICO BRACCIO OSCILLANTE...4628
              Smontaggio...4628
              Montaggio...4628
            SOSTITUZIONE SNODO SFERICO BRACCIO OSCILLANTE TRIANGOLARE...4628
              Smontaggio...4629
              Montaggio...4629
            BARRA STABILIZZATRICE...4631
            BARRA STABILIZZATRICE ANTERIORE...4631
            BARRA STABILIZZATRICE ASSALE AGGIUNTO CENTRALE (veicoli 6x2 C)...4631
            BARRA STABILIZZATRICE POSTERIORE...4631
            BARRA STABILIZZATRICE ASSALE AGGIUNTO POSTERIORE (veicoli 6x2 P)...4631
              Stacco...4631
              Riattacco...4631
            BOCCOLE ELASTICHE...4634
              Sostituzione boccole elastiche barra stabilizzatrice anteriore...4634
              Sostituzione boccole elastiche barra stabilizzatrice posteriore...4634
            AMMORTIZZATORI...4635
              Stacco-riattacco...4635
              Ammortizzatori assale anteriore (veicoli 6x2 C)...4635
              Ammortizzatori assale aggiunto centrale...4635
              Ammortizzatori ponte posteriore...4635
              Ammortizzatori assale aggiunto posteriore (veicoli 6x2 P)...4635
              Stacco...4635
              Riattacco...4635
            REGOLAZIONE DEL TELAIO...4636
        SEZIONE 10 - Ruote e Pneumatici...4641
          Ruote e Pneumatici...4641
            DESCRIZIONE...4643
            CARATTERISTICHE E DATI...4643
              Valori di pressione dei pneumatici...4643
            ATTREZZATURA...4644
            DIAGNOSTICA...4644
            EQUILIBRATURA STATICA DELLE RUOTE...4647
            CORREZIONE DELLO SQUILIBRIO STATICO RESIDUO...4648
            PRESSIONE DEI PNEUMATICI...4648
            COMPORTAMENTO DEL PNEUMATICO IN FUNZIONE DELLA PRESSIONE...4649
        SEZIONE 11 - Sterzo...4651
          Sterzo...4651
            DESCRIZIONE...4653
            CARATTERISTICHE E DATI...4654
              Schema comando sterzo veicoli con sospensione anteriore meccanica...4655
              Schema comando sterzo veicoli con sospensione anteriore pneumatica e barre longitudinali...4656
              Schema comando sterzo veicoli con sospensione anteriore pneumatica e molle a balestra...4657
              Schema comando sterzo trattori 6x2 C con sospensione anteriore meccanica...4658
              Schema comando sterzo trattori 6x2C(guida destra) con sospensione anteriore pneumatica e molle a balestra...4659
              Schema comando sterzo cabinati 6x2C...4660
              Schema comando sterzo veicoli 6x2 p-assale posteriore sterzante - con sospensione anteriore meccanica...4661
              Schema comando sterzo veicoli 6x2 p - assale posteriore sterzante - con sospensione anteriore pneumatica...4662
              Schema comando sterzo veicoli 6x2 p - assale posteriore sterzante - con sospensione anteriore pneumatica e barre longitudinali...4663
              Schema del circuito idraulico comando sterzo veicoli cabinati 6x2C...4664
            DIAGNOSTICA...4665
            COPPIE DI SERRAGGIO...4670
            ATTREZZATURA...4671
            STACCO-RIATTACCO IDROGUIDA...4673
              Stacco...4673
              Riattacco...4675
              Smontaggio-montaggio leva sterzo...4675
            COMANDO STERZO...4676
            STACCO-RIATTACCO COMPLESSIVO COMANDO STERZO...4677
              Stacco...4677
              Riattacco...4679
              Sostituzione del cilindro pneumatico...4679
              Smontaggio...4679
              Montaggio...4680
              Sostituzione interruttore indicatore di direzione...4682
              Stacco...4682
              Montaggio...4683
            SPURGO DELL’ARIA DAL CIRCUITO IDROGUIDA...4683
            MISURAZIONE DEI GIUOCHI NELLA SCATOLA GUIDA RILEVATI SUL VOLANTE...4683
            CONTROLLO DELLA PRESSIONE MASSIMA DELL’IMPIANTO IDROGUIDA...4684
              Impostazione della regolazione automatica della limitazione idraulica della sterzata dell’idroguida...4684
              Controllo...4684
            CALIBRAZIONE ESP (Electronic Stability Program)...4684
        SEZIONE 12 - Impianto pneumatico - Freni...4685
          Impianto pneumatico - Freni...4685
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (VARI E GENERATORI)...4689
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (VALVOLE)...4690
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SERBATOI E ACCUMULATORI)...4696
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (CONVERTITORI, CILINDRI E PINZE)...4697
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (PINZE E CILINDRI)...4698
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SEMI GIUNTI E TESTE D’ACCOPPIAMENTO)...4699
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SEMI GIUNTI E TESTE D’ACCOPPIAMENTO)...4700
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SEGNALATORI E INTERRUTTORI)...4701
            SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (FRENI)...4702
            TUBAZIONI E RACCORDI...4703
              Generalità...4703
              Ribordatura delle tubazioni rigide...4703
              Piegatura delle tubazioni rigide...4704
              Taglio delle tubazioni rigide...4704
              Sostituzione delle tubazioni flessibili con raccordi tradizionali...4705
              Sostituzione delle tubazioni flessibili con raccordi ad innesto rapido...4706
            SISTEMA EBS (ELECTRONIC BRAKE SYSTEM)...4708
              Vantaggi dell’ EBS...4708
              Compatibilità tra motrice e rimorchio in qualsiasi momento...4708
              Strutture diagnostiche complete...4708
            LOGICA DEL FUNZIONAMENTO...4709
            IMPIANTO DI FRENATURA...4710
            INTEGRAZIONE FRENI AUSILIARI...4711
            ESP (ELECTRONIC STABILITY PROGRAM)...4712
            SISTEMA “ABS-EBL” (ANTI-LOCK BRAKE SYSTEM) (ELECTRONIC BRAKE LIMITER)...4713
              Sistema “ABS” (Anti-Lock Brake)...4713
              EBL (Electronic Brakes Limiter)...4714
              Logica del Funzionamento...4714
              Schema di principio impianto EBS per veicoli 4x2 (trattori)...4715
              Schema di principio impianto EBS per veicoli 4x2 (mod. AT440S.. /FP-CT/FP-LT)...4716
              Schema di principio impianto EBS per veicoli 6x2 (trattori)...4717
              Schema di principio impianto EBS per veicoli 4x2 (carri)...4718
              Schema di principio impianto EBS per veicoli 6x2 (carri)...4719
              Ubicazione componenti dell’impianto EBS sul veicolo (variante trattori)...4721
              Ubicazione componenti dell’impianto EBS sul veicolo (variante carri 6x2)...4722
              Schema di principio impianto EBS2 per veicoli 4x2 (trattori)...4723
              Schema di principio impianto EBS2 per veicoli 4x2 T/FP-CT...4724
              Schema di principio impianto EBS2 per veicoli 6x2 (trattori)...4725
              Schema di principio impianto EBS2 per veicoli 4x2 (carri)...4726
              Schema di principio impianto EBS2 per veicoli 6x2 (carri)...4727
              Schema di principio impianto EBS2 per veicoli 4x2p (trattori)...4729
              Ubicazione componenti dell’impianto EBS2 sul veicolo (variante carri)...4730
              Ubicazione componenti dell’impianto EBS2 sul veicolo (variante trattori)...4731
              Schema di principio impianto ABS-EBL per veicoli 4x2 (carri e trattori esclusi veicoli con ponte HR)...4732
              Schema di principio impianto ABS-EBL per veicoli 6x2C (trattori)...4733
              Schema di principio impianto ABS-EBL per veicoli 6x2C (carri)...4734
              Schema di principio impianto ABS-EBL per veicoli 6x4...4735
              Schema di principio impianto ABS-EBL per veicoli isolati 4x2 (carri)...4736
              Schema di principio impianto ABS-EBL per veicoli 6x2P (carri)...4737
              Schema di principio impianto ABS-EBL per veicoli isolati 6x2 (carri)...4739
            DESCRIZIONE...4740
              Frenatura di servizio...4740
              Frenatura di soccorso...4740
              Freno motore...4740
              Frenatura di stazionamento...4740
            FRENI...4740
              Freni a disco...4740
              Freni a tamburo...4740
            DIAGNOSTICA...4741
              Strumenti di diagnosi...4741
              Diagnosi su Cluster...4742
            COPPIE DI SERRAGGIO...4756
            ATTREZZATURA...4759
            CARATTERISTICHE DATI - IMPIANTO PNEUMATICO...4768
            CARATTERISTICHE E DATI - FRENI...4775
            CONTROLLI DEI PRINCIPALI COMPONENTI DELL’IMPIANTO FRENI...4778
            PRINCIPALI COMPONENTI DELL’ IMPIANTO FRENI...4780
              Compressore...4780
              Serraggio viti bloccaggio testa...4780
              Diagnostica...4781
              A.P.U. (Air Processing Unit)...4781
              Distributore Duplex (veicoli senza EBS)...4782
              Distributore Duplex con trasmettitore Elettrico (veicoli con EBS) ...4782
              CBU - Central Brake Unit (veicoli con EBS2)...4782
              Diagnostica distributore Duplex (veicoli senza EBS)...4782
              Valvola a relè (veicoli senza EBS)...4783
              Valvola a relè proporzionale per assale (veicoli con EBS)...4783
              Diagnostica (veicoli senza EBS)...4783
              Teste d’accoppiamento...4783
              Modulatore elettropneumatico ponte (per veicoli con EBS-EBS2)...4784
              Diagnostica (per veicoli con EBS)...4784
              Valvola di ridondanza (per carri 4x2 e 6x2)...4785
              Elettrovalvola ABS-EBS...4785
              Doppia valvola di arresto...4785
              Servodistributore a triplo comando (veicoli senza EBS)...4785
              Regolazione della predominanza...4786
              Diagnostica...4786
              Servodistributore comando rimorchio (veicoli con EBS - EBS2)...4787
              Valvola presa di controllo pressione...4787
              Distributore a mano comando freno di stazionamento (veicoli atti al traino)...4787
              Diagnostica (distributore di comando freno di stazionamento)...4787
              Distributore a mano comando freno di stazionamento (veicoli isolati)...4788
              Distributore a mano per rallentamento rimorchio (optional) ...4788
              Diagnostica (distributore di comando freno di stazionamento)...4788
              Valvola a pressione controllata...4789
              Diagnostica...4789
              Valvola di ritenuta (veicoli atti al traino) ...4789
              Interruttore di bassa pressione...4789
              Valvola elettropneumatica per ASR...4790
              Sensore giri...4790
              Ruote foniche...4790
              Centralina elettronica...4790
              Sensore di pressione...4790
              Cilindro freno a membrana (per freno a disco anteriore e assale aggiunto)...4791
              Cilindro freno a membrana (per freno atamburo anteriore e assale aggiunto)...4791
              Cilindro freno combinato (per freno a disco anteriore e posteriore)...4791
              Cilindro freno combinato (per freno a tamburo posteriore)...4791
              Dispositivo di sfrenatura di emergenza del cilindro combinato per freni a disco posteriori e freni a tamburo...4792
              Dispositivo di frenatura di emergenza del cilindro combinato per freni a disco anteriori...4792
              Interventi riparativi...4792
              Diagnostica...4792
            FRENI A DISCO TIPO KNORR (PINZA SN7)...4793
              Funzionamento...4794
            CONTROLLI...4794
              Verifica efficienza del recuperatore automatico del gioco...4794
              Componenti pinza freno...4795
              Controllo spessore guarnizioni frenanti...4796
            REVISIONE FRENI ANTERIORI A DISCO...4797
              Sostituzione guarnizioni frenanti...4797
              Stacco e riattacco pinze freno...4800
              Stacco...4800
              Riattacco...4801
              Stacco e riattacco mozzi ruote...4801
              Stacco...4801
              Riattacco...4802
            REVISIONE PINZE FRENO...4803
              Smontaggio...4803
              Pulizia e controllo dei particolari componenti...4804
              Montaggio...4804
            REVISIONE FRENI A DISCO POSTERIORI...4806
              Sostituzione guarnizioni frenanti...4806
            REVISIONE DISCHI FRENO...4809
            TORNITURA E RETTIFICA DEI DISCHI FRENO...4809
            FRENI A TAMBURO...4810
            REVISIONE FRENI A TAMBURO...4811
              Smontaggio freni posteriori a tamburo...4811
              Tornitura tamburi...4815
              Sostituzione guarnizioni frenanti...4816
              Montaggio...4816
            SISTEMA ESP...4821
              Modulo ESP...4821
              Ubicazione modulo ESP...4821
              Sensore angolo di sterzatura...4822
              Autoapprendimento e Calibrazione del sistema ESP...4822
        SEZIONE 13 - Carrozzeria - Telaio...4823
          Carrozzeria - Telaio...4823
            CABINA...4829
              Generalità...4829
            CARATTERISTICHE E DATI...4829
            ATTREZZATURA...4829
            COPPIE DI SERRAGGIO...4830
            INTERVENTI RIPARATIVI...4835
            PARAURTI...4835
              Stacco...4835
              Riattacco...4835
            CABINA...4836
              Stacco...4836
              Riattacco...4840
            CABINA STRALIS AT CAR TRANSPORTER (CT)...4841
              Stacco...4841
              Riattacco...4841
            SOSTITUZIONE AMMORTIZZATORE ANTERIORE...4842
              Stacco...4842
              Riattacco...4842
            SOSTITUZIONE BOCCOLE ELASTICHE SOPPORTI ANTERIORI SOSPENSIONE CABINA...4842
              Stacco...4842
              Riattacco...4843
            SOSTITUZIONE BOCCOLE SOPPORTO ANTERIORE CABINA ...4843
              Stacco...4843
              Riattacco...4843
            STACCO RIATTACCO BARRA STABILIZZATRICE...4843
              Stacco...4843
              Riattacco...4843
            SOSTITUZIONE BOCCOLE MENSOLE ANCORAGGIO CABINA VEICOLO CAR TRANSPORT...4845
              Stacco...4845
              Smontaggio - montaggio boccola...4845
              Riattacco...4845
            SOSTITUZIONE AMMORTIZZATORE POSTERIORE ...4846
              Stacco...4846
              Riattacco...4846
            SOSTITUZIONE BOCCOLE TIRANTE TRASVERSALE...4846
              Stacco...4846
              Smontaggio - montaggio boccole...4846
              Riattacco...4846
            VALVOLA LIVELLATRICE...4847
              Stacco...4847
              Riattacco...4847
            SOSTITUZIONE SERRATURA BLOCCAGGIO CABINA...4847
              Stacco...4847
              Riattacco...4847
            RIBALTAMENTO CABINA...4847
            SOSTITUZIONE CILINDRO IDRAULICO RIBALTAMENTO CABINA...4847
              Stacco...4847
              Riattacco...4847
              Controllo livello olio...4849
              Spurgo aria impianto ribaltamento cabina...4849
              Sospensione meccanica cabina...4851
              Registrazione dell’assetto cabina...4851
              Sospensione pneumatica cabina...4852
              Registrazione della tiranteria valvole livellatrici...4852
            SOSTITUZIONE DEL PARABREZZA...4853
              Stacco...4853
              Riattacco...4853
            SOSTITUZIONE CRISTALLO SCENDENTE PORTA...4854
              Stacco...4854
              Riattacco...4855
            SOSTITUZIONE DISPOSITIVO ALZA CRISTALLO ...4856
              Stacco...4856
              Riattacco...4856
            SOSTITUZIONE SERRATURA PORTA...4856
              Stacco...4856
              Riattacco...4857
            SOSTITUZIONE MANIGLIA ESTERNA PORTA...4857
              Stacco...4857
              Riattacco...4857
            SOSTITUZIONE MANIGLIA INTERNA...4858
              Stacco...4858
              Riattacco...4858
            SOSTITUZIONE SPECCHIETTI LATERALI...4858
              Stacco...4858
              Riattacco...4858
            SOSTITUZIONE PORTA...4858
              Stacco...4858
              Riattacco...4858
            SOSTITUZIONE CRISTALLO FISSO...4859
              Stacco...4859
              Preparazione del vano cristallo...4859
              Preparazione del cristallo...4859
              Riattacco...4859
            PLANCIA STRUMENTI...4861
              Stacco...4861
              Riattacco...4861
            PLANCIA INTERRUTTORI CENTRALE...4861
              Stacco...4861
              Riattacco...4862
            RIVESTIMENTO PLANCIA...4862
              Stacco...4862
              Riattacco...4865
            ARROTOLATORE PARASOLE PARABREZZA...4865
              Stacco...4865
              Riattacco...4866
            SOSTITUZIONE MOTORINO ARROTOLATORE PARASOLE PARABREZZA...4866
              Stacco...4866
              Riattacco...4866
            BOTOLA PRESA ARIA...4867
              Stacco...4867
              Riattacco...4867
            SOSTITUZIONE MOTORINO BOTOLA PRESA ARIA...4867
              Smontaggio...4867
              Montaggio...4868
            SOSTITUZIONE CAVO COMANDO APERTURA SPORTELLO LATERALE...4868
              Smontaggio...4868
              Montaggio...4870
              Registrazione cavo comando apertura sportello...4870
            SEDILE CONDUCENTE...4871
              Stacco...4871
              Riattacco...4871
              Ubicazioni componenti...4872
            SMONTAGGIO SEDILE CONDUCENTE...4873
              Smontaggio-montaggio cuscino...4873
              Smontaggio...4873
              Montaggio...4873
              Smontaggio-montaggio pattini per cuscino...4873
              Smontaggio...4873
              Montaggio...4873
              Smontaggio-montaggio cintura di sicurezza...4874
              Montaggio...4874
              Smontaggio-montaggio attacco cintura di sicurezza e rivestimento laterale destro...4874
              Montaggio...4874
              Smontaggio-montaggio rivestimento laterale sinistro, valvola IPS e interruttore per il riscaldamento...4875
              Smontaggio...4875
              Montaggio...4875
              Smontaggio - montaggio schienale...4875
              Smontaggio...4875
              Montaggio...4875
              Smontaggio - montaggio leva per regolazione schienale...4876
              Smontaggio...4876
              Montaggio...4876
              Smontaggio - montaggio dispositivo regolazione in altezza...4876
              Smontaggio...4876
              Montaggio...4876
              Smontaggio - montaggio dispositivo per regolazione inclinazione sedile...4876
              Smontaggio...4876
              Montaggio...4876
              Smontaggio - montaggio cavo flessibile dispositivo regolazione ammortizzatore ...4876
              Smontaggio...4876
              Montaggio...4877
              Smontaggio - montaggio segmento per leva regolazione schienale...4877
              Smontaggio...4877
              Montaggio...4877
              Smontaggio - montaggio molla ad aria...4877
              Smontaggio...4877
              Montaggio...4877
              Smontaggio - montaggio ammortizzatore...4877
              Smontaggio...4877
              Montaggio...4878
              Smontaggio - montaggio valvola per regolazione altezza...4878
              Smontaggio...4878
              Montaggio...4878
              Smontaggio - montaggio sistema di blocco altezza...4878
              Smontaggio...4878
              Montaggio...4878
              Smontaggio - montaggio cavo flessibile sospensione orizzontale leva ...4878
              Smontaggio...4878
              Montaggio...4879
              Smontaggio - montaggio valvola magnetica per abbassamento veloce...4879
              Smontaggio...4879
              Montaggio...4879
              Smontaggio - montaggio interruttore per abbassamento veloce...4879
              Smontaggio...4879
              Montaggio...4879
              Smontaggio - montaggio dispositivo per appoggio lombare...4879
              Smontaggio...4879
              Montaggio...4879
              Smontaggio - montaggio rivestimento schienale...4880
              Smontaggio...4880
              Montaggio...4880
              Smontaggio - montaggio rivestimento cuscino...4880
              Smontaggio...4880
              Montaggio...4880
            SCHEMA PNEUMATICO SEDILE AUTISTA...4881
            SCHEMA PNEUMATICO SEDILE PASSEGGERO...4882
            FRIGORIFERO CABINA...4883
              Controlli preliminari...4883
              Stacco...4883
              Riattacco...4883
            REVISIONE...4884
              Smontaggio...4884
              Smontaggio ventilatore...4884
              Smontaggio sonda antiribaltamento con circuito elettronico su centralina...4884
              Smontaggio centralina elettronica...4885
              Controlli...4885
              Montaggio...4885
            CLIMATIZZAZIONE INTERNO CABINA...4886
              Generalità...4886
            VENTILAZIONE...4886
              Descrizione...4886
            CLIMATIZZAZIONE...4887
              Descrizione...4887
              Condizionamento...4887
              Riscaldamento...4887
              Gruppo comandi climatizzazione...4887
              Manuale...4887
              Riscaldamento e ventilazione...4887
            UBICAZIONE COMPONENTI (CLIMATIZZATORE WEBASTO)...4888
            UBICAZIONE COMPONENTI GRUPPO RISCALDATORE (WEBASTO)...4889
              Sensore temperatura esterna...4890
              Compressore...4890
              Condensatore e pressostati di sicurezza...4891
              Motoriduttori...4892
              Sensore temperatura evaporatore...4893
              Valvola di espansione...4893
            RISCALDATORE SUPPLEMENTARE AD ARIA (a richiesta)...4894
              Descrizione...4894
              Funzionamento...4894
            DIAGNOSTICA...4895
              Guida alla ricerca guasti...4895
              Premessa...4895
              Ricerca guasti per sintomi...4895
              Riscaldatore supplementare ad aria...4898
            CARATTERISTICHE E DATI...4904
            AVVERTENZE GENERALI...4905
            COPPIE DI SERRAGGIO...4905
            INTERVENTI RIPARATIVI...4906
            RISCALDATORE...4906
              Stacco...4906
              Riattacco...4906
            RISCALDATORE SUPPLEMENTARE ARIA...4907
              Stacco...4907
              Riattacco...4907
            MOTORE COMANDO SPORTELLO RICIRCOLO ARIA...4907
              Stacco...4907
              Riattacco...4907
            ELETTROVENTILATORE...4908
              Stacco...4908
              Riattacco...4908
            RADIATORE RISCALDATORE...4908
              Stacco...4908
              Riattacco...4909
            RUBINETTO...4909
              Stacco...4909
              Riattacco...4910
            FILTRO ANTIPOLLINE...4910
              Stacco...4910
              Riattacco...4910
            COMPRESSORE CONDIZIONATORE...4910
              Stacco...4910
              Riattacco...4911
            CONDENSATORE CONDIZIONATORE...4911
              Stacco...4911
              Riattacco...4911
            SENSORE TEMPERATURA ARIA ESTERNA...4911
              Stacco...4911
              Riattacco...4911
            SOSTITUZIONE DELLA FRIZIONE ELETTROMAGNETICA ...4912
            PROCEDURA PER LO SVUOTAMENTO E LA RICARICA DEGLI IMPIANTI DI CONDIZIONAMENTO CON REFRIGERANTE RI34A ...4914
              Stazione di ricarica e recupero refrigerante R134A (99305146)...4914
            NORME DI SICUREZZA...4915
            PLANCIA COMANDI...4916
            DIAGRAMMA DI FLUSSO OPERAZIONI...4918
            RECUPERO REFRIGERANTE DALL’IMPIANTO SU VEICOLO...4919
            CREAZIONE DEL VUOTO NELL’IMPIANTO...4921
            RIPRISTINO DELL’OLIO NELL’IMPIANTO...4923
            CARICA DEL REFRIGERANTE NELL’IMPIANTO...4924
            CONTROLLO DELLE PRESSIONI NELL’IMPIANTO...4926
            OPERAZIONI PRIMA DELLO STACCO DELLA STAZIONE DALL’IMPIANTO...4926
            CERCAFUGHE PER IMPIANTI DI CONDIZIONAMENTO CON HFC RI34A (9905147)...4926
            TELAIO...4927
            COPPIE DI SERRAGGIO...4927
            INTERVENTI RIPARATIVI...4928
            CONTROLLI...4928
              Rilievo del piegamento del telaio verso il basso o verso l’alto...4929
              Rilievo del piegamento laterale del telaio...4929
              Rilievo dello spostamento del telaio...4929
              Rilievo della torsione del telaio...4930
            PRECAUZIONI...4930
              Saldature sul telaio...4932
        SEZIONE 14 - Manutenzione programmata...4933
          Manutenzione programmata...4933
            VEICOLI CON MOTORE Cursor 8 (F2B)...4935
            MANUTENZIONE...4935
              Prospetto dei servizi di manutenzione...4935
            INTERVENTI DI CONTROLLO E/O MANUTENZIONE...4936
            OPERAZIONI FUORI PIANO...4937
            INTERVENTI DI MANUTENZIONE...4941
            SERVIZIO M1...4941
            SERVIZIO M2...4943
            SERVIZIO M3...4947
            SERVIZIO M4...4947
            SERVIZIO EP1...4947
            SERVIZIO T1...4948
            SERVIZIO T2...4948
            SERVIZIO T3...4948
            SERVIZIO T4...4948
            SERVIZIO T5...4949
            SERVIZIO T6...4949
            VEICOLI MOTORE Cursor 10 (F3A)...4951
            MANUTENZIONE...4951
              Prospetto dei servizi di manutenzione...4951
            INTERVENTI DI CONTROLLO E/O MANUTENZIONE...4952
            OPERAZIONI FUORI PIANO...4953
            INTERVENTI DI MANUTENZIONE...4957
            SERVIZIO M1...4957
            SERVIZIO M2...4961
            MANUTENZIONE FUORI PIANO...4963
            SERVIZIO EP1...4963
            SERVIZIO EP2...4963
            SERVIZIO EP3...4963
            SERVIZIO T1...4964
            SERVIZIO T2...4964
            SERVIZIO T3...4965
            SERVIZIO T4...4966
        SEZIONE 15 - Impianto Elettrico/Elettronico...4967
          Impianto Elettrico/Elettronico...4967
            AVVERTENZE GENERALI PER I COMPONENTI ELETTRICI/ELETTRONICI...4969
            CODIFICA COMPONENTI...4971
            SISTEMA MULTIPLEX...4976
            DESCRIZIONE...4977
            RETE DI POTENZA...4996
            PUNTI DI MASSA...4997
              Elenco connettori di giunzione (st) presenti sul veicolo...5001
            CENTRALINA PORTA FUSIBILI / TELERUTTORI...5041
            TELERUTTORI SUPPLEMENTARI...5043
            FUSIBILI SUPPLEMENTARI...5046
            PLANCIA PORTA STRUMENTI...5048
            COMANDI SU PLANCIA CENTRALE...5049
            COMANDI SU VOLANTE...5050
            REGOLAZIONE SPECCHI RETROVISORI E COMANDO ALZACRISTALLI...5051
            DEVIOGUIDA ...5052
            PRESA DIAGNOSI...5056
            CENTRALINA ELETTRONICA “VDI”...5057
            PASSAPARETE...5058
            ALTERNATORE...5063
            MOTORINO DI AVVIAMENTO...5065
            SISTEMA MULTIPLEX...5067
              Cluster...5069
              Body computer...5077
              Front Frame Computer F.F.C. (Servizi / Motore)...5089
              Rear Frame Computer (R.F.C.)...5092
              Passenger Door Module (P.D.M.)...5097
              Driver Door Module (D.D.M.)...5098
              C.B. (Cabin module) Opt...5099
              Steering Wheel Interfaces SWI (Centralina interfaccia volante / devioguida)...5101
              Contatto spiralato...5104
              Bed Module (BM ) OPT...5109
            CLIMATIZZATORE AUTOMATICO...5111
            CLIMATIZZATORE MANUALE...5126
            RISCALDATORE AD ACQUA HYDRONIC D 10...5131
            IMMOBILIZER...5138
            EDC...5142
            EBS...5178
            EBS2...5196
            ABS-EBL...5204
            SOSPENSIONI ECAS...5230
            EUROTRONIC AUTOMATED...5253
            INTARDER...5272
            CAMBIO AUTOMATICO ALLISON WTEC III...5279
            DIAGNOSTICA...5315
              Strumenti di diagnosi...5315
              Diagnosi su Cluster...5316
            INFORMAZIONI SU CLUSTER...5318
            TROUBLESHOOTING...5321
              Body Computer (BC)...5321
              Passenger door module (PDM-CDM)...5346
              Driver door module (DDM)...5348
              Front Frame Computer (FFC)...5351
              Rear Frame Computer (RFC)...5362
              EBS...5375
              EBS2...5396
              Allison...5463
              Eurotronic 2...5654
            SCHEDE CIRCUITALI...5741
              Scheda 1: Positivo batteria...5743
              Scheda 2/1: Positivo dopo TGC (+30) ...5744
              Scheda 2/2: Positivo dopo TGC (+30)...5745
              Scheda 2/3: Positivo dopo TGC (+30)...5746
              Scheda 3/1: Alimentazione servizi (+15)...5747
              Scheda 3/2: Alimentazione servizi (+15)...5748
              Scheda 4/1: Centralina BC (J7)...5749
              Scheda 4/2: Centralina BC (J6)...5750
              Scheda 4/3: Centralina BC (J4-J5)...5751
              Scheda 4/4: Centralina BC (J2-J3)...5752
              Scheda 5: Centralina SWI...5753
              Scheda 6/1: Centralina FFC (J2)...5754
              Scheda 6/2: Centralina FFC (J1)...5755
              Scheda 7/1: Centralina RFC (J1)...5756
              Scheda 7/2: Centralina RFC (J2)...5757
              Scheda 8: Centralina CM...5758
              Scheda 9: Centralina DDM-BM-Chiusura centralizzata con telecomando...5759
              Scheda 10: Centralina PDM...5760
              Scheda 11: Centralina IC / tachigrafo (MTCo - DTCO)...5761
              Scheda 12: Linea CAN-ICB/IDB/Centralina VDI  Telematik - Navigation...5762
              Scheda 13: Linea CAN-SB (EBS/ABS)...5763
              Scheda 14: Linea CAN-BCB...5764
              Scheda 15: Linea CAN-VDB...5765
              Scheda 16: ECAS 4x2 P Trattore...5766
              Scheda 17: ECAS 4x2 FP Trattore...5767
              Scheda 18: ECAS 4x2 P/FP Carro...5768
              Scheda 19: ECAS 6X4 P...5769
              Scheda 20: ECAS 6x2 P/FP/C (terzo asse sollevabile)...5770
              Scheda 20/1: ECAS 6x2 P/FP (terzo asse non sollevabile)...5771
              Scheda 20/2: ECAS 6x2 C (terzo asse non sollevabile)...5772
              Scheda 21: Rallentatore ZF...5773
              Scheda 22: ABS...5774
              Scheda 23: EBS...5775
              Scheda 24: EBS2...5776
              Scheda 25: EuroTronic II...5777
              Scheda 26: Cambio Allison...5778
              Scheda 27: Rallentatore Cambio Allison...5779
              Scheda 28: Immobolizer...5780
              Scheda 29: Raffreddamento motore...5781
              Scheda 30: Ventilazione...5782
              Scheda 31: Impianto di climatizzazione a comando manuale...5783
              Scheda 32: Impianto di climatizzazione a comando manuale (Car Transporter)...5784
              Scheda 33: Impianto di climatizzazione a comando automatico...5785
              Scheda 34: Riscaldatore supplementare ad acqua a comando automatico...5786
              Scheda 35: Riscaldatore supplementare ad acqua a comando manuale...5787
              Scheda 36: Riscaldatore supplementare ad aria a comando manuale/automatico...5788
              Scheda 37: EDC (Connettore B)...5789
              Scheda 38: EDC (Connettore A) per motori F3A...5790
              Scheda 39: EDC (Connettore A) per motori F2B...5791
              Scheda 40: PTO Multipower...5792
              Scheda 41: Radioricevitore...5793
              Scheda 42: ADR (2001 94/9/EG)...5794
              Scheda 43: ADR (opt. 0129)...5795
              Scheda 44: IGC Meccanico...5796
            SCHEMI A BLOCCHI...5797
              Schema 1: A. Avviamento - B. Ricarica...5799
              Schema 2: A. Alimentazione EDC - B. Avaria EDC / Immobilizer - C. Catene neve inserite - E. Trazione integrale inserita...5800
              Schema 3: A. Cruise control - B. Sensore pedale acceleratore - C. Preriscaldo...5801
              Schema 4: ABS/EBS...5802
              Schema 5: A. Voltmetro - B. Contagiri - C. Temperatura acqua motore - D. Livello combustibile...5803
              Schema 6: A. Indicazione pressione olio motore - B. Indicazione livello olio motore - C. Indicazione livello liquido lavacristallo - D. Indicazione livello olio idroguida - E. Indicazione acqua motore...5804
              Schema 7: A. Segnalazione usura freni (ABS) - B. Segnalazione usura freni (EBS) - C. Segnalazione marce ridotte inserite - D. Segnalazione filtro olio intasato - E. Segnalazione filtro aria intasato...5805
              Schema 8: A. Segnalazione freno a mano inserito - B. Bloccaggio differenziale trasversale (on road) - C. Bloccaggio differenziale trasversale (off road) - D. Bloccaggio differenziale longitudinale - E. Segnalazione presenza acqua filtro gasolio...5806
              Schema 9: Luci esterne...5807
              Schema 10: A. Luci anabbaglianti - B. Luci abbaglianti - C. Luci fendinebbia/retronebbia...5808
              Schema 11: A. Luci stop (EBS) - B. Luci stop - C. Luci retromarcia - D. Illuminazione ralla...5809
              Schema 12: A. Luci direzione/emergenza - B. Orientamento proiettori...5810
              Schema 13: Luci interne...5811
              Schema 14: A. Tergicristallo - B. Avvisatore acustico - C. Contatore...5812
              Schema 15: TGC...5813
              Schema 16: A. Tetto apribile - B. Lavaproiettori...5814
              Schema 17: Tachigrafo...5815
              Schema 18: A. Comando ventilatore motore - B. Comando riscaldatore supplementare ad acqua...5816
              Schema 19: A. Comando specchi retrovisori - B. Comando alzavetri...5817
              Schema 20: A. Comando chiusura centralizzata...5818
              Schema 21: A. ECAS (indicatori ottici) - B. ABS (indicatori ottici)...5819
              Schema 22: A. EBS (indicatori ottici) - B. Parabrezza termico - C. P.T.O...5820
              Schema 23: A. Rallentatore (indicatore ottico) - B. Filtro gasolio intasato...5821
              Schema 24: A. Indicazione pressione aria freni - B. Indicazione temperatura esterna...5822
              Schema 25: A. Visualizzazione km totali/parziali - B. Visualizzazione marcia inserita - C. Speed limiter...5823
              Schema 26: A. Segnalazione temperatura olio motore - B. Comando fanali rotanti...5824
603.93.531 - Iveco Stralis AS Euro 4-5 (18-44T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC ('06-'13)...5825
  STRALIS AS EURO 4/5...5825
    REPAIR MANUAL...5825
      MECHANICAL ELECTRIC/ELECTRONIC...5825
        PRELIMINARY REMARKS...5827
        SYMBOLS -WARNINGS...5827
        SYMBOLS - ASSISTANCE OPERATIONS...5828
        PRODUCT CODE...5829
        GENERAL WARNINGS...5830
        GENERAL WARNINGS ON THE ELECTRIC SYSTEM...5832
          Bonding and screening...5834
        OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS...5835
        CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES...5835
        UPDATE DATA...5837
        INDEX OF SECTIONS...5839
          SECTION 1 - General...5841
            General...5841
              VEHICLE IDENTIFICATION DATA...5843
                Vehicle Identification Plate...5844
                Production identification plate...5844
              COMMERCIAL CODES...5845
              COMPOSITION OF MODELS...5847
              P.I.C. NUMBER CODING...5849
              REPLENISHING FLUIDS...5853
                International lubricant designation...5855
          SECTION 2 - Engine...5857
            Engine...5857
              F3A Engine...5859
                VIEWS OF THE ENGINE...5861
                TECHNICAL DESIGNATION...5865
                CHARACTERISTIC CURVES...5866
                GENERAL CHARACTERISTICS...5868
                ASSEMBLY CLEARANCE DATA...5871
                TIGHTENING TORQUE F3A ENGINE...5878
                TOOLS...5885
                ENGINE REMOVAL - REFITTING...5895
                  Removal...5895
                  Refitting...5896
                  Filling the cooling system...5897
                  Bleeding air from the supply system...5898
                  Checks and tests...5898
                ELECTRO-MAGNETIC JOINT REPLACEMENT...5899
                  Removal...5899
                  Refitting...5900
                DISMANTLING THE ENGINE ON THE BENCH...5903
                REPAIR OPERATIONS...5910
                CYLINDER BLOCK...5910
                  Checks and measurements...5910
                  Cylinder liners...5911
                  Replacing cylinder liners...5912
                  Crankshaft...5913
                  Measuring the main journals and crankpins...5914
                  Preliminary measurement of main and big end bearing shell selection data...5915
                  Selecting the main and big end bearing shells...5916
                  Replacing the timing gear and oil pump...5922
                  Checking main journal assembly clearance...5922
                  Checking crankshaft end float...5923
                  Piston connecting rod assembly...5924
                  Piston rings...5926
                  Connecting rods...5927
                  Bushings...5928
                  Checking connecting rods...5928
                  Mounting the connecting rod — piston assembly...5929
                  Mounting the piston rings...5929
                  Fitting the big end bearing shells...5929
                  Fitting connecting rod - piston assemblies in the cylinder liners...5930
                  Checking piston protrusion...5930
                  Checking crankpin assembly clearance...5931
                CYLINDER HEAD...5931
                  Disassembly the valves...5931
                  Checking head bearing surface on cylinder block...5931
                  Valves...5932
                  Removing deposits and checking the valves...5932
                  Valve seats...5932
                  Checking clearance between valve-stem and associated valve guide...5933
                  Valve guides...5933
                  Replacing injector cases...5933
                  Checking injector protrusion...5935
                TIMING GEAR...5936
                  Camshaft drive...5936
                  Idler gear pin...5936
                  Idler gear...5936
                  Twin intermediategearpin...5936
                  Twin idler gear...5936
                  Replacing the bushings...5936
                  Timing system...5937
                  Checking cam lift and pin alignment...5937
                  Bushings...5938
                  Replacing camshaft bushings with drift 99360499...5939
                  Removal...5939
                  Assembly...5939
                  Valve springs...5940
                ROCKER SHAFT...5941
                  Shaft...5942
                  Rocker arms...5942
                ENGINE ASSEMBLY ON BENCH...5943
                  Fitting connecting rod - piston assemblies in cylinder liners...5946
                ENGINE FLYWHEEL...5949
                  Fitting engine flywheel...5949
                  Fitting camshaft...5950
                  Fitting pump-injectors...5951
                  Fitting rocker-arm shaft assembly...5951
                  Camshaft timing...5952
                  Phonic wheel timing...5954
                  Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors...5955
                  Completing Engine Assembly...5956
                LUBRICATION...5959
                  Oil pump...5961
                  Overpressure valve...5961
                  Oil pressure control valve...5962
                  Heat exchanger...5962
                  By-pass valve...5963
                  Thermostatic valve...5963
                  Engine oil filters...5963
                  Valve integrated in piston cooling nozzle...5964
                COOLING...5965
                  Description...5965
                  Operation...5965
                  Electromagnetic coupling...5967
                  Water pump...5967
                  Thermostat...5967
                  View of thermostat operation for versions with Intarder...5968
                TURBOCHARGING...5969
                  Turbocharger HOLSET HE 531 V...5969
                  Actuator...5970
                  Solenoid valve for VGT control...5970
                REPAIRING ACTIONS...5970
                  Variable geometry movement control...5971
                  Checking the actuator...5971
                  Checking actuator travel...5972
                  Cleaning turbine body...5972
                FEEDING...5975
                  Overpressure valve...5976
                  Feed pump...5976
                  Injector-pump...5976
                  Replacing injectors-pump...5977
                  Pressure damper...5977
              F3B Engine...5979
                VIEWS OF THE ENGINE...5981
                TECHNICAL DESCRIPTION...5984
                CHARACTERISTIC CURVES...5985
                GENERAL SPECIFICATIONS...5987
                ASSEMBLY DATA - CLEARANCE...5990
                TIGHTENING TORQUE...5997
                DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS...6000
                TOOLS...6004
                ENGINE REMOVAL-REFITTING...6015
                  Removal...6015
                  Refitting...6018
                  Filling the cooling system...6019
                  Bleeding air from the supply system...6020
                  Checks and tests...6020
                ELECTRO-MAGNETIC JOINT REPLACEMENT...6021
                  Removal...6021
                  Refitting...6022
                DISASSEMBLY THE ENGINE ON THE BENCH...6025
                REPAIRS...6033
                CYLINDER BLOCK...6033
                  Checks and measurements...6033
                  Cylinder liners...6034
                  Replacing the cylinder liners...6035
                  Crankshaft...6036
                  Measuring the main journals and crankpins...6037
                  Preliminary measurement of data to select main bearing and big end bearing shells...6038
                  Selecting the main bearing and big end bearing shells...6039
                  Replacing the timing gear and oil pump...6045
                  Checking main journal assembly clearance...6045
                  Checking crankshaft end float...6046
                  Connecting rod piston assembly...6047
                  Piston rings...6049
                  Connecting rod...6050
                  Bushings...6051
                  Checking connecting rods...6051
                  Mounting the connecting rod — piston assembly...6052
                  Mounting the piston rings...6052
                  Fitting the big end bearing shells...6052
                  Fitting connecting rod - piston assemblies in the cylinder liners...6053
                  Checking piston protrusion...6053
                  Checking crankpin assembly clearance...6054
                CYLINDER HEAD...6054
                  Disassembly the valves...6054
                  Checking head bearing surface on cylinder block...6054
                  Valves...6055
                  Valve seats...6055
                  Checking clearance between valve-stem and associated valve guide...6056
                  Valve guides...6056
                  Replacing injector cases...6056
                  Checking injector protrusion...6058
                TIMING GEAR...6059
                  Camshaft drive...6059
                  Idler gear pin...6059
                  Idler gear...6059
                  Twin intermediate gear pin...6059
                  Twin idler gear...6059
                  Replacing the bushings...6059
                  Timing system...6060
                  Checking cam lift and pin alignment...6060
                  Bushings...6061
                  Valve springs...6063
                ROCKER SHAFT...6064
                  Shaft...6065
                  Rocker arms...6065
                ENGINE ASSEMBLY ON BENCH...6066
                  Fitting connecting rod - piston assemblies in cylinder liners...6069
                  Fitting the cylinder head...6070
                  Fitting flywheel box...6071
                ENGINE FLYWHEEL...6072
                  Fitting engine flywheel...6072
                  Fitting camshaft...6073
                  Fitting pump-injectors...6074
                  Fitting rocker-arm shaft assembly...6074
                  Camshaft timing...6075
                  Phonic wheel timing...6077
                  Adjusting rocker arm clearance, intake, exhaust and pre-load of pump injector governing rocker arms...6078
                  Completing Engine Assembly...6079
                LUBRICATION...6083
                  Oil pump...6085
                  Overpressure valve...6085
                  Oil pressure control valve...6086
                  Heat exchanger...6086
                  By-pass valve...6087
                  Thermostatic valve...6087
                  Engine oil filters...6087
                  Valve integrated in piston cooling nozzle...6088
                COOLING...6089
                  Description...6089
                  Operation...6089
                  Electromagnetic coupling...6091
                  Water pump...6091
                  Thermostat...6091
                  View of thermostat operation for versions with Intarder...6092
                TURBOCHARGING...6093
                  Turbocharger HOLSET HE 551 V...6093
                  Actuator...6094
                  Solenoid valve for VGT control...6094
                REPAIR...6094
                  Variable geometry movement control...6095
                  Checking the actuator...6095
                  Checking actuator travel...6096
                  Cleaning turbine body...6096
                FEEDING...6099
                  Overpressure valve...6100
                  Feed pump...6100
                  Injector-pump...6100
                  Pressure damper...6100
              Hydrocar pressure take-off on timing system...6101
                HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)...6103
                  Description...6103
                SPECIFICATIONS AND DATA...6104
                TIGHTENING TORQUES...6105
                ENGAGING POWER TAKE-OFF...6106
                REMOVING-REFITTING POWER TAKE-OFF...6106
              Denox System 2...6107
                DeNOx2 SYSTEM...6109
                  General remarks...6109
                  Tank...6111
                  Ad Blue fluid level gauge control...6111
                  By-pass valve...6111
                  Pump module...6112
                  Dosing module...6112
                  Catalyst...6112
                  Exhaust gas temperature sensor...6113
                  Humidity detecting sensor...6114
                REPAIR INTERVENTIONS ON DeNox SYSTEM...6115
                  Ad Blue tank...6115
                  Disconnection...6115
                  Reconnection...6115
                  Tank level indicator...6116
                  Disconnection...6116
                  Reconnection...6116
                  Pump module...6116
                  Disconnection...6116
                  Filter + Pre-Filter...6117
                  Disconnection...6117
                  Reconnection...6117
                  Deflecting valve...6117
                  Disconnection...6117
                  Inlet exhaust gas temperature sensor...6117
                  Disconnection...6117
                  Reconnection...6118
                  Outlet exhaust gas temperature sensor...6118
                  Disconnection...6118
                  Reconnection...6118
                  Nitrogen oxides detecting sensor (IF PRESENT)...6118
                  Disconnection...6118
                  Reconnection...6119
                  Sucked air humidity detecting sensor...6119
                  Disconnection...6119
                  Reconnection...6119
                  Measuring out module...6119
                  Disconnection...6119
                  Reconnection...6119
              Fault Diagnosis...6121
                FAULT DIAGNOSIS...6123
                  Diagnosis Instruments...6123
                  Cluster Diagnosis...6125
                  DTC - FMI error codes...6127
          SECTION 3 - Clutch...6151
            Clutch...6151
              DESCRIPTION...6153
                Clutch...6153
              SPECIFICATIONS AND DATA...6153
              DIAGNOSTICS...6155
                Main operating faults of a mechanical nature...6155
              TIGHTENING TORQUES...6156
              TOOLS...6156
              REMOVING AND REFITTING THE CLUTCH...6157
                Removal...6157
              CHECKS...6157
                Refitting...6158
              REMOVING-REFITTING THE THRUST BEARING...6158
              REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT...6158
              REMOVING-REFITTING THE PEDAL UNIT SATA...6159
                Removal (vehicles with EuroTronic Automated gearbox)...6159
                Removal (vehicles with ZF 16 S... gearbox)...6160
                Refitting...6161
              PEDAL TYPE SATA (Vehicles with ABS)...6161
                Unit removal-assembly...6161
              CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ABS)...6162
                Clutch stop...6162
                Idle travel of clutch pedal...6162
                Pedal control valve stroke...6162
              PEDAL TYPE WABCO vehicles with EBS)...6163
                Clutch stop...6163
                Clutch pedal idle travel...6163
                Pedal control valve stroke...6163
              HYDRAULIC CONTROL vehicles with ZF 16 S... gearboxes)...6164
                Clutch actuator...6165
              SPECIFICATIONS FOR MANUAL GEARBOX PREASSEMBLY...6166
                Spring pin adjustment...6166
              BLEEDING CLUTCH CIRCUIT...6167
              SPECIFICATIONS FOR AUTOMATIC TRANSMISSION ASSEMBLY...6168
          SECTION 4 - Gearboxes...6169
            Gearboxes...6169
              Gearboxes: ZF 16 S 1920 T.D., ZF 16 S 2220 T.D./T.O., ZF 16 S 2320 T.D., ZF 16 S 2520 T.O...6171
                DESCRIPTION...6173
                LOCATION OF GEARBOX DESCRIPTION PLATE...6174
                SPECIFICATIONS AND DATA...6175
                SPECIFICATIONS AND DATA...6176
                TIGHTENING TORQUES...6177
                TOOLS...6178
                REMOVING-REFITTING THE GEARBOX...6179
                Removal...6179
                Refitting...6180
              ZF gearboxes with Intarder (IT), hydraulic retarder, types: ZF 16 S 1921 T.D., ZF 16 S 2221 T.D./T.O., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O...6181
                SPECIFICATIONS AND DATA...6183
                TOOLS...6184
                OVERHAULING THE GEARBOX...6191
                  Removing the hydraulic retarder from the gearbox on the stand...6191
                  Refitting the hydraulic retarder...6192
                  Adjusting stator end float...6192
                  Removing the epicyclic reduction gear unit ERG) rear box...6194
                  Removing the epicyclic reduction gear unit (ERG)...6194
                  Refitting the epicyclic reduction gear unit (ERG) rear box...6199
              Gearboxes EuroTronic Automated: - 12 AS 1930 T.D. - 12 AS 2330 T.D./T.O. - 12 AS 2530 T.O...6201
                DESCRIPTION...6203
                LOCATION OF GEARBOX DESCRIPTION PLATE...6203
                GEARBOX ELECTRONIC MANAGEMENT...6204
                  Theoretical scheme...6204
                SPECIFICATIONS AND DATA...6206
                TIGHTENING TORQUES...6207
                TOOLS...6208
                REMOVING-REFITTING GEARBOX...6209
                  Removal...6209
                  Refitting...6209
              Gearboxes EuroTronic Automated with Intarder: - 12 AS 1931 T.D. - 12 AS 2331 T.D./T.O. - 12 AS 2531 T.O...6211
                SPECIFICATIONS AND DATA...6213
                TOOLS...6214
                EXPERIMENTAL TOOLS...6215
                OVERHAULING THE GEARBOX...6216
                  Removing the hydraulic retarder...6216
                  Refitting the hydraulic retarder...6217
                  Adjusting epicyclic reduction gear train bearing end float...6217
                  Adjusting stator end float...6218
                  Adjusting stator end float...6219
                  Removing the rear box...6220
                  Disassembling the E.R.G...6220
                  Assembling the E.R.G...6222
              EuroTronic gearboxes diagnostics...6227
                DIAGNOSTICS...6229
                  Diagnosis Instruments...6229
                  Cluster Diagnosis...6231
                  Troubleshooting via DTC-FMI codes...6233
          SECTION 5 - Intarder - ZF hydraulic retarder...6325
            Intarder - ZF hydraulic retarder...6325
              LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE...6327
              GENERAL INFORMATION...6328
              OPERATION...6328
                Retarder engaged...6329
                Retarder disengaged...6330
              LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER...6331
              REMOVING AND REFITTING THE RETARDER ON THE ZF 16 S 1621/1921/2221 GEARBOX...6332
                Removal...6332
                Refitting...6333
                Filling with oil...6333
              SPECIFICATIONS AND DATA...6334
              TIGHTENING TORQUES...6335
              TOOLS...6336
              DIAGNOSTICS...6338
                Main operating faults of a mechanical nature...6338
              OVERHAULING THE INTARDER HYDRAULIC RETARDER...6340
                Hydraulic accumulator...6340
                Removal...6340
                Fitting...6340
                Removing hydraulic retarder...6340
                Checking the component parts of the hydraulic retarder...6345
                Fitting the hydraulic retarder...6346
                Stator end float adjustment...6351
                Only for EuroTronic Automated gearboxes, operate as below...6351
          SECTION 6 - Propeller shafts...6353
            Propeller shafts...6353
              CHARACTERISTICS AND DATA...6355
              STRALIS (Tractors) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2C/6x4/6x2p)...6357
              STRALIS AS (Cabs) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2P/6x4)...6358
              DIAGNOSTIC...6359
                Main operating faults of a mechanical nature...6359
              TIGHTENING TORQUES...6360
              TOOLS...6360
              REMOVING AND REASSEMBLING THE PROPELLER SHAFT...6361
                Removal...6361
                Reassembly...6361
              CHECKING THE PROPELLER SHAFT ON THE VEHICLE...6362
              REMOVING AND FITTING BACK THE UNIVERSAL JOINTS...6363
              REMOVING AND REASSEMBLING THE SUPPORT...6363
          SECTION 7 - Rear axles...6365
            Rear axles...6365
              DIAGNOSTICS...6367
                Main operating faults of a mechanical nature...6367
              REMOVING-REFITTING THE REAR AXLE...6369
                Removal...6369
                Refitting...6369
              REMOVING-REFITTING THE DIFFERENTIAL FROM THE REAR AXLE ON THE VEHICLE...6370
                Removal...6370
                Refitting...6370
              Rear Axle ARVINMERITOR MS 13-175 with disc brakes...6371
                LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...6373
                DESCRIPTION...6374
                CHARACTERISTICS AND DATA...6375
                TIGHTENING TORQUES...6376
                TOOLS...6378
                OVERHAULING THE REAR AXLE ASSEMBLY...6383
                OVERHAULING THE WHEEL HUBS...6383
                  Removal...6383
                  Replacing wheel hub bearings...6385
                  Checking the parts forming the wheel hubs...6385
                  Replacing the wheel fixing pins...6385
                REMOVING AND REFITTING THE DIFFERENTIAL with axle on stand 99322215)...6389
                  Removal...6389
                  Refitting...6389
                REPAIRING THE DIFFERENTIAL...6390
                  Removing the differential...6390
                  Removing the gearcase...6391
                REMOVING THE BEVEL PINION FROM THE SUPPORT...6393
                  Differential component check...6393
                  Fitting the gear housing...6394
                FITTING THE MOUNT ON THE BEVEL PINION...6395
                  Reassembling the differential housing...6397
                ADJUSTING THE CAP GAP...6399
                CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...6402
                WORK ON THE VEHICLE...6405
                REPLACING THE BEVEL PINION MOUNT SEAL...6405
                  Disassembly...6405
                  Assembly...6406
              Rear axle 451391...6407
                DESCRIPTION...6409
                SPECIFICATIONS AND DATA...6410
                TIGHTENING TORQUES...6411
                TOOLS...6413
                REAR AXLES ASSEMBLY OVERHAUL...6419
                  Disassembly...6419
                  Epicycloid reduction gear disassembly...6419
                  Wheel hub disassembly...6420
                CHECKING THE WHEEL HUB AND EPICYCLOID REDUCTION GEAR UNIT PARTS...6422
                WHEEL HUB ASSEMBLY...6423
                  Assembling the epicycloid reduction gear...6425
                REMOVING-REFITTING THE DIFFERENTIAL...6428
                REPAIRING THE DIFFERENTIAL...6430
                  Disassembly...6430
                  Gear housing disassembly...6431
                  Removing the bevel pinion from the support...6432
                CHECKING THE DIFFERENTIAL COMPONENTS...6434
                  Gear housing assembly...6435
                  Assembling the bevel pinion support...6436
                  Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...6436
                  Differential housing assembly...6438
                  Gear housing bearings rolling torque adjustment...6439
              Axles in tandem ARVINMERITOR MT23-155/2D...6443
                Axles Intermediate ARVINMERITOR MD11-155/2D...6445
                  DESCRIPTION...6447
                  SPECIFICATIONS ANDA DATA...6447
                  LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...6448
                  SPECIFICATIONS AND DATA...6449
                  TIGHTENING TORQUES...6451
                  TOOLS...6453
                  SPECIAL PURPOSE TOOLS...6459
                  INTERMEDIATE REAR AXLE ASSEMBLY OVERHAUL...6460
                  OVERHAULING THEWHEEL HUBS...6460
                    Removal...6460
                    Replacing wheel hub bearings...6462
                    Checking the parts forming the wheel hubs...6462
                    Replacing the wheel fixing pins...6462
                    Wheel hub reassembly...6463
                  DIFFERENTIAL CASE REMOVAL...6466
                    Case removal...6466
                    Gearing case removal...6472
                    Checking the differential components...6473
                    Gearing case refitting...6473
                  ASSEMBLING DIFFERENTIAL CASING...6475
                    Calculating bevel pinion position in differential casing...6475
                  EXAMPLES...6475
                    Adjust the limit switch of the differential - distributor lock control pin...6479
                    Adjusting drive input shaft bearing end float...6480
                  ADJUSTING THE CAP ANGLE...6481
                  CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)...6484
                  REMOVAL-OVERHAUL-REFITTING OF DISTRIBUTOR OUTPUT SHAFT...6487
                    Adjustment of motion output shaft bearing end play...6488
                Rear axles ARVINMERITOR MR11-155/D...6489
                  DESCRIPTION...6491
                  LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE...6492
                  CHARACTERISTICS AND DATA...6493
                  TIGHTENING TORQUES...6494
                  REPAIR OPERATIONS...6496
          SECTION 8 - Axles...6497
            Axles...6497
              Front axles...6497
                Front axle 5876 5876/4 5876/5 Steering central added axle 5876/4...6499
                  DESCRIPTION...6501
                  SPECIFICATIONS AND DATA...6502
                  DIAGNOSTICS...6504
                    Main operating faults of a mechanical nature...6504
                  TIGHTENING TORQUES...6505
                  TOOLS...6507
                  REMOVING AND REFITTING AXLE...6511
                    Vehicles with mechanical front suspension...6511
                    Removal...6511
                    Refitting...6511
                  REMOVING AND REFITTING AXLE...6512
                    Vehicles with pneumatic front suspension and longitudinal bars...6512
                    Removal...6512
                    Refitting...6513
                  HYDRAULIC SYSTEM FOR CENTRAL ADDED AXLE STEERING (vehicles 6X2C)...6514
                    Hydraulic system working diagram...6514
                  CHARACTERISTICS AND DATA...6515
                  CENTRING CYLINDER OPERATING DIAGRAM...6516
                    Added central axle...6516
                    Location on the vehicle of the main components of the hydraulic system...6517
                    Hydraulic system...6518
                  AIR BLEEDING FROM THE HYDRAULIC CIRCUIT...6519
                    Filling up and bleeding the power steering hydraulic circuit (circuit 1)...6520
                    Filling up and bleeding the power steering hydraulic circuit (circuit 2)...6520
                  REPAIRS...6521
                  CENTRAL ADDED AXLE AIR LIFT, 6X2C VEHICLES...6521
                  GENERAL...6521
                    Location on the vehicle of the main components...6522
                    Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for central added axle with single wheels...6523
                  VEHICLE CHECKS...6524
                    Tie rods...6524
                    Swivel heads...6524
                  CHECKING SWIVEL HEAD PLAY...6524
                  FRONT AXLE ASSEMBLY OVERHAUL...6525
                  REMOVING - REFITTING WHEEL HUBS...6525
                    Removal...6525
                    Replacing wheel hub bearings...6526
                    Replacing wheel fixing pins...6527
                    Refitting wheel hubs...6527
                    Checking wheel hub bearing end float...6527
                    Measuring rolling torque...6528
                  REMOVING AND REFITTING TRANSVERSE TIE ROD...6528
                  REPLACING TRANSVERSE TIE ROD SWIVEL HEADS...6529
                  LONGITUDINAL TIE ROD LEVER REMOVAL/REFITTING...6529
                  CROSS TIE ROD LEVER REMOVAL/REFITTING...6529
                  REMOVING AND REFITTING PIN FOR STUB AXLE...6529
                    Removal...6529
                    Replacing kingpin bearing...6530
                    Checking and adjusting clearance between stub axle and axle...6531
                  CHECKING AND MEASURING THE AXLE BODY...6532
                    Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins...6532
                    Checking angle of holes for kingpins...6533
              Additional rear axle...6497
                Rigid rear added axle 55080/DI...6535
                  DESCRIPTION...6537
                  CHARACTERISTICS AND DATA...6538
                  TIGHTENING TORQUE...6539
                  TOOLS...6540
                  REMOVING-REFITTING...6542
                    Removal...6542
                    Refitting...6543
                  REPAIRS...6543
                Rigid rear added axle with hydraulic lifting 56082/D1 (N 9171)...6545
                  DESCRIPTION...6547
                  CHARACTERISTICS AND DATA...6548
                  TIGHTENING TORQUE...6549
                  TOOLS...6550
                  REMOVING-REFITTING...6551
                  REPAIRS...6551
                Steering rear added axle with pneumatic lifting 57080/DI...6553
                  DESCRIPTION...6555
                  CHARACTERISTICS AND DATA...6556
                  TIGHTENING TORQUES...6558
                  TOOLS...6559
                  REPAIRS...6563
                  PNEUMATIC LIFT...6563
                  GENERAL...6563
                  LOCATION ON THE VEHICLE OF THE MAIN COMPONENTS OF THE HYDRAULIC SYSTEM...6564
                  HYDRAULIC SYSTEM...6565
                  HYDRAULIC SYSTEM WORKING DIAGRAM...6566
                  VEHICLES WITH PNEUMATIC REAR SUSPENSIONS AND PNEUMATIC LIFTING...6567
                    Location on the vehicle of the main components...6567
                    Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for rear added axle with single wheels...6568
                  DIAGNOSTICS...6569
                    Main operating faults of a mechanical nature...6569
                  TIGHTENING TORQUES (Steering and lifting device linkage)...6570
                  CHARACTERISTICS AND DATA...6571
                    Steering and third axle hydraulic system...6571
                  MAIN HYDRAULIC SYSTEM COMPONENTS...6572
                  HYDRAULIC ACCUMULATOR...6572
                    Nitrogen pressure checking and recharging...6572
                  OPERATOR CYLINDER...6572
                    Disassembly...6573
                    Assembly...6573
                    Checking cylinder oil sealing on the vehicle...6573
                  CENTRING CYLINDER...6573
                    Disassembly...6574
                    Assembly...6574
                    Checking cylinder oil sealing on the vehicle...6574
                  ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING...6575
                    Removal...6575
                    Refitting...6575
                  AIR BLEEDING FROM THE HYDRAULIC CIRCUIT...6576
                    Filling up and bleeding the power steering hydraulic circuit (circuit 1)...6577
                    Filling up and bleeding the power steering hydraulic circuit (circuit 2)...6577
                Wheel geometry...6579
                  GENERAL INFORMATION...6581
                    Steering wheel angles...6581
                  FRONT WHEEL GEOMETRY (4X2 vehicles)...6582
                    Positioning clips and headlights...6582
                    Electronic compensation of rim eccentricity...6583
                    Wheel alignment...6583
                    Checking wheel toe-in...6584
                    Checking wheel deviation...6584
                    Checking camber...6584
                    Checking kingpin angle and caster...6585
                    Checking rear axle alignment...6586
                    Vehicle wheel geometry with steering rear added axle and pneumatic lifting...6586
                    Wheel setup for vehicles with additional centralsteering axle and pneumatic lift...6587
          SECTION 9 - Suspensions...6589
            Suspensions...6589
              SUSPENSIONS...6593
              DESCRIPTION...6593
                Mechanical front suspension...6593
                Pneumatic front suspension...6593
                Pneumatic rear suspension...6593
              SPECIFICATIONS AND DATA...6594
                Models front suspension: 4x2 (tractors)...6594
                Models front suspension: 4x2 (tractors) - 6x4 (tractors and cab-equipped vehicles)...6595
                Models front suspension: 4x2 (tractors) - 6x4 (tractors and cab-equipped vehicles)...6596
                Models front suspension: 4x2 (cab-equipped vehicles) - 6x2C (tractors) - 6x2P (tractors and cab-equipped vehicles)...6597
                Models front suspension: 4x2 (tractors and lorries) - 6x2P (tractors and lorries)...6599
                Models front suspension: 4x2 (tractors and cab-equipped vehicles) - 6x2P (cab-equipped) vehicles with pneumatic front suspension...6600
              MECHANICAL FRONT SUSPENSION ASSEMBLY DRAWING...6601
              PNEUMATIC FRONT SUSPENSION ASSEMBLY...6604
              CENTRAL ADDED AXLE SUSPENSION ASSEMBLY...6605
                Leaf spring for central added axle (vehicles with air suspension) 6x2C vehicles...6606
                Front shock absorbers...6607
                Additional axle shock absorbers...6608
                Rear shock absorbers...6609
              PNEUMATIC SUSPENSION...6610
                Chassis frame lifting, lowering and self-levelling with remote control...6610
                Saving Levels...6610
              AXLE LOAD METER...6611
                Activating function...6611
              CALIBRATION (indication on display unit)...6611
              SCHEMES OF AIR SPRING SUSPENSIONS SYSTEMS...6613
                Principle scheme of rear air spring suspensions for lorries 4x2/P...6613
                Principle scheme of suspensions for lorries 4x2/FP...6614
                Principle scheme of air spring suspensions for lorries 4x2FP-CM...6615
                Working diagram of pneumatic rear suspensions for 4x2T/P tractors...6616
                Working diagram of suspensions for 4x2T/FP-LT...6617
                Working diagram of pneumatic suspensions for tractors 6x2TX/P (without added axle lifter)...6618
                Working diagram of pneumatic suspensions for tractors 6x2TX/P (with added axle lifter)...6619
                Principle scheme of rear air spring suspensions for lorries 6x2Y/PS (with added axle lifter)...6620
                Principle scheme of rear air spring suspensions for lorries 6x2Y/PS (without added axle lifter)...6621
                Principle scheme of rear air spring suspensions for lorries 6x2Y/PT and tractors 6x2TY/PT (with added axle lifter)...6622
                Principle scheme of rear air spring suspensions for lorries 6x2Y/PT and tractors 6x2TY/PT (without added axle lifter)...6623
                Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-CM (with added axle lifter)...6624
                Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-CM (without added axle lifter)...6625
                Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-GV (with added axle lifter)...6626
                Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-GV (without added axle lifter)...6627
                Working diagram of pneumatic rear suspensions for 6x4 tractors and lorries...6628
              CHARACTERISTICS AND DATA...6629
                Pneumatic System...6629
              MAIN COMPONENTS OF THE PNEUMATIC SYSTEM...6630
                Fault Diagnosis...6630
                Controlled pressure valve...6630
                Level sensor...6630
                Electro-Pneumatic Control Valve...6631
                Load detector pressure sensor...6632
                Low air pressure switch...6632
                Air spring...6632
                ECAS Control Unit...6632
              DIAGNOSTICS...6633
                Diagnosis Instruments...6633
                Cluster Diagnosis...6635
                Troubleshooting via DTC-FMI codes...6637
              TOOLS...6666
              SPECIAL PURPOSE TOOLS...6668
              TIGHTENING TORQUES...6669
                Mechanical front suspension...6669
                Pneumatic front suspension...6670
                Pneumatic front suspension with bars...6671
                Central added axle pneumatic suspensions 6x2 C vehicles...6672
                Pneumatic rear suspension 4x2 - 6x2 C vehicles...6673
                Pneumatic rear suspension 6x2 P/PT vehicles...6675
                Pneumatic rear suspension 6x2 P/PS vehicles...6676
                Pneumatic rear suspension 6x2 P/FP/FS vehicles (version for 3800 to 5500 wheel bases)...6677
                Pneumatic rear suspension 6x2 P/FP/FS vehicles (version for 5700 to 6050 wheel bases)...6678
                Pneumatic rear suspension 6x4 P vehicles...6679
              REMOVAL-REFITTING OF FRONT LEAF SPRING...6680
                Removal...6680
                Refitting...6680
              REMOVING-REFITTING FRONT SUSPENSION BARS...6681
                Removing longitudinal bars...6681
                Removing transverse bar...6681
                Refitting...6681
              REAR SUSPENSIONS...6683
                Removal...6683
                Refitting...6683
              REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM...6684
              REMOVING-REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM...6684
              REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM...6684
              REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM...6684
                Removal...6684
                Refitting...6684
              REPLACING THE SUSPENSION ARM FLEXIBLE PIN...6685
                Dismounting...6685
                Mounting...6685
              REPLACING TRIANGULAR SWINGING ARM BALL ARTICULATED JOINT...6685
                Dismounting...6686
                Mounting...6686
              STABILIZER BAR...6688
              FRONT STABILIZER BAR...6688
              CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)...6688
              REAR STABILIZER BAR...6688
              REAR ADDED AXLE STABILIZER BAR (6x2P vehicles)...6688
                Removal...6688
                Refitting...6688
              RUBBER BUSHINGS...6691
                Replacing front stabilizer bar rubber bushings...6691
                Replacing rear stabilizer bar rubber bushings...6691
              SHOCK ABSORBERS...6692
                Removal-refitting...6692
                Central added axle shock absorbers...6692
                Rear axle shock absorbers...6692
                Rear added axle shock absorbers 6x2 P vehicles)...6692
                Removal...6692
                Refitting...6692
              CHASSIS FRAME ADJUSTMENT...6693
          SECTION 10 - Wheels and tyres...6699
            Wheels and tyres...6699
              DESCRIPTION...6701
              CHARACTERISTICS AND DATA...6701
                Tyre inflation pressures...6701
              TOOLS...6702
              DIAGNOSTICS...6702
                Main operating faults of a mechanical nature...6702
              STATIC BALANCING OF THE WHEELS...6704
              CORRECTING RESIDUAL STATIC IMBALANCE...6705
              TYRE PRESSURE...6705
              HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE...6706
          SECTION 11 - Steering...6707
            Steering...6707
              DESCRIPTION...6709
              SPECIFICATIONS AND DATA...6710
                Scheme of the steering control of vehicles with mechanical front suspension...6711
                Vehicle steering control diagram with front air suspension and longitudinal bars...6712
                Vehicle steering control diagram with front air suspension and leaf springs...6713
                Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with mechanical front suspension...6714
                Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with pneumatic front suspension...6715
                Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with pneumatic front suspension and longitudinal bars...6716
                Scheme of the steering control of 6x2 c vehicles - having a steering central axle -with mechanical front suspension...6717
              DIAGNOSTICS...6718
                Main operating faults of a mechanical nature...6718
              TIGHTENING TORQUES...6720
              TOOLS...6721
              REMOVING-REFITTING THE POWER STEERING SYSTEM...6723
                Removal...6723
                Refitting...6725
                Removing-Fitting the Steering Lever...6725
              STEERING CONTROL...6726
              REMOVING-REFITTING THE STEERING CONTROL ASSEMBLY...6727
                Removal...6727
                Refitting...6729
                Changing the pneumatic cylinder...6729
                Removal...6729
                Refitting...6730
                Replacing direction indicator switch...6732
                Removal...6732
              BLEEDING THE POWER STEERING SYSTEM...6733
              MEASURING STEERING BOX PLAY AT THE STEERING WHEEL...6733
              CHECKING THE MAXIMUM PRESSURE OF THE POWER STEERING SYSTEM...6734
                Setting the automatic hydraulic steering limit...6734
                Check...6734
              ESP (Electronic Stability Program) CALIBRATION...6734
          SECTION 12 - Air system - Brakes...6735
            Air system - Brakes...6735
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...6739
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)...6740
              SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)...6746
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)...6747
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)...6748
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...6749
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)...6751
              SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)...6752
              PIPINGS AND FITTINGS...6753
                In general...6753
                Flexible pipings replacementwith traditional fittings...6753
                Flexible pipings replacement with quick connection fittings...6754
              EBS (ELECTRONIC BRAKE SYSTEM)...6756
                EBS Benefits...6756
                Tractor and trailer compatibility at any time...6756
                Complete fault-diagnosis structures...6756
              OPERATING LOGIC...6757
              BRAKE SYSTEM...6758
              AUXILIARY BRAKE INTEGRATION...6759
              ESP (ELECTRONIC STABILITY PROGRAM)...6760
              “ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)...6761
                “ABS” (Anti-Lock Brake System)...6761
                EBL (Electronic Brakes Limiter)...6762
                Operating Logic...6762
              EBS SYSTEM COMPONENTS LOCATION ON VEHICLE (TRACTORS VARIANT)...6763
              LOCATION OF EBS SYSTEM COMPONENTS ON THE VEHICLE (TRUCKS VARIANT)...6764
              BRAKING SCHEMES OF EBS SYSTEMS...6765
                Theoretical scheme of EBS system for 4x2 vehicles (tractors)...6765
                EBS working diagram for 6x2p vehicles (tractors)...6766
                Theoretical scheme of EBS system for 6x2p vehicles (tractors)...6767
                Theoretical scheme of EBS system for 6x2 C vehicles (tractors)...6768
                Theoretical scheme of EBS system for 4x2 vehicles (trucks)...6769
                EBS working diagram for 6x2p vehicles (trucks)...6770
                Working diagram of EBS system for 6x2p vehicles (trucks)...6771
              LOCATION OF ABS - EBL SYSTEM COMPONENTS (TRACTOR VARIANT)...6772
              BRAKING SCHEMES OF ABS - EBL - ASR SYSTEMS...6773
                Working diagram of ABS-EBL-ASR system for 4x2 vehicles (trucks and tractors)...6773
                Working diagram of ABS-EBL-ASR system for 6x2p vehicles (trucks)...6774
                Working diagram of ABS-EBL-ASR system for 6x2p vehicles (trucks)...6775
                Working diagram of ABS-EBL-ASR system for 6x2C vehicles (tractors)...6776
                Working diagram of ABS-EBL-ASR system for 6x4 vehicles (trucks and tractors)...6777
              BRAKING SCHEMES OF ABS - EBL SYSTEMS...6778
                Working diagram of ABS-EBL system for 4x2 vehicles (trucks and tractors)...6778
                Working diagram of ABS-EBL system for 6x2C vehicles (tractors)...6779
                Working diagram of ABS-EBL system for 6x2p vehicles (trucks)...6780
                Working diagram of ABS-EBL system for 6x2p vehicles (trucks)...6781
                Working diagram of ABS-EBL system for 6x4 vehicles (trucks and tractors)...6782
              DESCRIPTION...6783
                Service braking...6783
                Emergency braking...6783
                Exhaust brake...6783
                Parking brake...6783
              BRAKES...6783
                Disc Brakes...6783
                Drum Brakes...6783
              DIAGNOSTICS...6784
                Diagnosis Instruments...6784
                Cluster Diagnosis...6786
                Troubleshooting via DTC-FMI codes...6788
              TIGHTENING TORQUES...6893
              TOOLS...6895
              SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM...6904
              SPECIFICATIONS AND DATA - BRAKES...6909
              CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM...6911
              MAIN COMPONENTS OF THE BRAKING SYSTEM...6913
                Compressor...6913
                Head locking screw tightness...6913
                Fault diagnosis...6914
                A.P.U. (Air Processing Unit)...6914
                Duplex control valve (vehicles without EBS)...6915
                Fault Diagnosis (vehicles without EBS)...6915
                CBU - Central Brake Unit (vehicles with EBS)...6915
                Relay valve (vehicles without EBS)...6916
                Proportional relay valve for front axle (vehicles with EBS)...6916
                Fault Diagnosis (vehicles without EBS)...6916
                Coupling heads...6916
                Redundancy valve (for 4x2 and 6x2 trucks)...6917
                ABS-EBS solenoid valve...6917
                Dual stop valve...6917
                Triple servo control valve (vehicles without EBS)...6917
                Predominance control...6918
                Fault Diagnosis...6918
                Trailer servo control valve (vehicles with EBS)...6919
                Parking brake hand control valve (vehicles suited to towing)...6919
                Pressure test point valve...6919
                Manual control valve to slow down the trailer (optional extra)...6919
                Fault Diagnosis (parking brake control valve)...6919
                Controlled pressure valve...6920
                Fault Diagnosis...6920
                Check valve (vehicles suited to towing)...6920
                Low-pressure switch...6920
                Electro-pneumatic valve for ASR...6921
                Speed sensor...6921
                Phonic wheels...6921
                Electronic control unit...6921
                Pressure sensor...6921
                Diaphragm brake cylinder (for front and added front axle disc brake)...6922
                Combined brake cylinder (for front and rear disc brake)...6922
                Combined brake cylinder (for front and rear drum brake)...6922
                Combined cylinder emergency brake release device...6923
                Repair operations...6923
                Fault diagnosis...6923
              ESP SYSTEM COMPONENTS...6924
              ESP SYSTEM SELF-LEARNING AND CALIBRATION...6925
              DISC BRAKES KNORR TYPE (CALIPER SN7)...6926
                Operation (See previous figure)...6927
              CHECKS...6927
                Checking the automatic play recovery system efficiency...6927
                Brake caliper components...6928
                Check of braking seals thickness...6929
              OVERHAULING FRONT DISC BRAKES...6930
                Replacing brake linings...6930
                Removing and refitting brake callipers...6933
                Removal...6933
                Refitting...6934
                Removing and refitting wheel hubs...6934
                Removal...6934
                Refitting...6935
              BRAKE CALIPER OVERHAUL...6936
                Disassembly...6936
                Component part cleaning and check...6937
                Assembly...6937
              OVERHAULING REAR DISC BRAKES...6939
                Replacing brake linings...6939
              OVERHAULING BRAKE DISCS...6942
              TURNING AND GRINDING  BRAKE DISCS...6942
              DRUM BRAKES...6943
              OVERHAULING THE DRUM BRAKES...6944
                Removing the rear drum brakes...6944
                Turning drums...6947
                Replacing brake linings...6948
                Assembly...6949
          SECTION 13 - Bodywork - Chassis frame...6953
            Bodywork - Chassis frame...6953
              CAB...6959
                General information...6959
              FEATURES AND DATA...6959
              TOOLS...6959
              TIGHTENING TORQUES...6960
              REPAIR WORK...6963
              BUMPER...6963
                Removal...6963
                Refitting...6963
              CABIN...6963
                Removal...6963
                Refitting...6968
              REPLACING THE FRONT SHOCK ABSORBER...6969
                Removal...6969
                Refitting...6969
              REPLACING THE CAB SUSPENSION FRONT MOUNTING RUBBER-TYPE BUSHINGS...6969
                Removal...6969
                Refitting...6970
              REPLACING THE CAB FRONT MOUNT BUSHINGS...6970
                Removal...6970
                Refitting...6970
              REMOVING - REFITTING THE STABILIZER BAR...6970
                Removal...6970
                Refitting...6970
              CHANGING THE REAR SHOCK ABSORBER...6972
                Removal...6972
                Refitting...6972
              CHANGING THE CAB LOCK...6972
                Removal...6972
                Refitting...6972
              CHANGING THE SWINGING BRACKET BUSHING ...6972
                Removal...6972
                Refitting...6973
                Adjusting the front levelling valve linkwork...6974
              ELECTRICALLY DRIVEN CAB TILT...6975
              MANUALLY DRIVEN CAB TILT...6976
                Removal...6976
                Refitting...6976
                Checking the oil level...6976
                Periodic level check...6976
              MANUALLY DRIVEN CAB TILT...6977
              REPLACING HYDRAULIC CAB TILT CYLINDER...6977
                Removal...6977
                Refitting...6977
                Checking oil level...6978
                Bleeding cab tilt system...6978
                Bleeding air frommanual drive pump (point 1)...6978
                Bleeding air from cab tilting cylinder (point 2)...6978
                Bleeding air from secondary circuit (point 3)...6978
                Bleeding air fully...6978
              REPLACING THE WIND SHIELD...6979
                Removal...6979
                Refitting...6979
              REPLACING THE WINDING WINDOW...6980
                Removal...6980
                Refitting...6981
              REPLACING THE WINDOW WINDER...6981
                Removal...6981
                Refitting...6982
              REPLACING THE DOOR LOCK...6982
                Removal...6982
                Refitting...6982
              REPLACING THE OUTSIDE HANDLE OF THE DOOR...6983
                Removal...6983
                Refitting...6983
              CHANGING THE INSIDE HANDLE...6983
                Removal...6983
                Refitting...6983
              CHANGING THE SIDE MIRRORS...6984
                Removal...6984
                Refitting...6984
              CHANGING THE DOOR...6984
                Removal...6984
                Refitting...6984
              REPLACING THE FIXED WINDOW...6985
                Removal...6985
                Preparing the window bay...6985
                Preparing the window...6985
                Refitting...6985
              INSTRUMENT PANEL...6987
                Removal...6987
                Refitting...6987
              CENTRAL INSTRUMENT PANEL...6987
                Removal...6987
                Refitting...6988
              FASCIA COVERING...6988
                Removal...6988
                Refitting...6992
              AIR INTAKE LID REMOVAL AND REFITTING...6993
                Removal...6993
                Refitting...6993
              AIR INTAKE LID MOTOR REPLACEMENT...6993
                Removing...6993
                Refitting...6994
              WINDSCREEN SUN VISOR REEL REMOVAL/REFITTING...6994
                Removal...6994
                Refitting...6995
              WINDSCREEN SUN VISOR REEL MOTOR REPLACEMENT...6995
                Removing...6995
                Refitting...6995
              REPLACING SIDE DOOR OPENING CONTROL CABLE...6995
                Removing...6995
                Fitting...6997
                Lid opening control adjustment...6997
              CABIN REFRIGERATOR...6997
                Preliminary checks...6997
                Removal...6998
                Refitting...6998
              OVERHAULING...6998
                Removing...6998
                Fan disassembling...6998
                Disassembling the anti-tipping probe with electronic circuit on the control unit...6999
                Electronic control unit disassembling...7000
                Checks...7000
                Fitting...7000
              DRIVER’S SEAT...7001
                Removal...7001
                Refitting...7001
                Component layout...7002
              REMOVING THE DRIVER’S SEAT...7003
                Removal...7003
                Fitting...7003
                Removing-fitting the cushion slider...7003
                Removal...7003
                Fitting...7003
                Removing-fitting the seatbelt...7004
                Fitting...7004
                Removing-fitting seatbelt connection and right-hand side upholstery...7004
                Fitting...7004
                Removing - fitting the left-hand side upholstery, IPS valve and heating switch...7005
                Removal...7005
                Fitting...7005
                Removing - fitting the back...7005
                Removal...7005
                Fitting...7005
                Removing - fitting the back adjustment lever...7006
                Removal...7006
                Fitting...7006
                Removing - fitting the height adjustment device...7006
                Removal...7006
                Fitting...7006
                Removing - fitting the seat angle adjustment device...7006
                Removal...7006
                Fitting...7006
                Removing - fitting the flexible cable of the shock absorber adjustment device...7006
                Removal...7006
                Fitting...7007
                Removing - fitting the back adjustment lever segment...7007
                Removal...7007
                Fitting...7007
                Removing - fitting the air spring...7007
                Removal...7007
                Fitting...7007
                Removing - fitting the shock absorber...7007
                Removal...7007
                Fitting...7008
                Removing - fitting the height adjustment valve...7008
                Removal...7008
                Fitting...7008
                Removing - fitting the height locking system...7008
                Removal...7008
                Fitting...7008
                Removing - fitting the flexible cable of the horizontal lever suspension...7008
                Removal...7008
                Fitting...7009
                Removing - fitting the fast lowering magnetic valve...7009
                Removal...7009
                Fitting...7009
                Removing - fitting the fast lowering switch...7009
                Removal...7009
                Fitting...7009
                Removing - fitting the lumbar support device...7009
                Removal...7009
                Fitting...7009
                Removing - fitting the back upholstery...7010
                Removal...7010
                Fitting...7010
                Removing - fitting the cushion upholstery...7010
                Removal...7010
                Fitting...7010
              CAB AIR-CONDITIONING...7011
                General...7011
              VENTILATION...7011
                Description...7011
              AIR-CONDITIONING AND HEATING...7012
                Description...7012
                Air-conditioning...7012
                Heating...7012
                Air-conditioning controls assembly...7012
                Automatic...7012
                Manual...7012
                Heating and ventilation...7012
              COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)...7013
              HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)...7014
              MAIN COMPONENTS OF AIR CONDITIONER AND HEATER (WEBASTO)...7015
                Outside temperature sensor...7016
                Inside temperature sensor...7016
                Three-way solenoid valve (WEBASTO)...7017
                Compressor...7017
                Dehumidifier filter and safety pressure switches...7018
                Geared motors...7019
                Evaporator temperature sensor...7020
                Blown air temperature sensor...7020
                Expansion valve...7021
              ADDITIONAL AIR HEATER SYSTEM (on request)...7022
                Description...7022
                Operation...7022
              DIAGNOSTICS...7023
                Troubleshooting...7023
                Introduction...7023
              CHARACTERISTICS AND DATA...7027
              GENERAL WARNINGS...7028
              TIGHTENING TORQUES...7028
              REPAIR OPERATIONS...7029
              HEATER...7029
                Removal...7029
                Refitting...7029
              ADDITIONAL AIR HEATER SYSTEM...7030
                Removal...7030
                Refitting...7030
              DEFROST CONTROL MOTOR...7030
                Removal...7030
                Refitting...7031
              AIR RECIRCULATION DOOR CONTROL MOTOR...7032
                Removal...7032
                Refitting...7032
              AIR MIXING DOOR CONTROL MOTOR...7032
                Removal...7032
                Refitting...7032
              HEATER RADIATOR TEMPERATURE SENSOR...7033
                Removal...7033
                Refitting...7033
              FLOOR AIR DOOR CONTROL MOTOR...7033
                Removal...7033
                Refitting...7033
              ELECTRIC FAN...7034
                Removal...7034
                Refitting...7034
              HEATER RADIATOR...7034
                Removal...7034
                Refitting...7035
              TAP...7035
                Removal...7035
                Refitting...7036
              POLLEN FILTER...7036
                Removal...7036
                Refitting...7036
              AIR-CONDITIONER COMPRESSOR...7036
                Removal...7036
                Refitting...7037
              AIR-CONDITIONER CONDENSER...7037
                Removal...7037
                Refitting...7037
              OUTSIDE AIR TEMPERATURE SENSOR...7037
                Removal...7037
                Refitting...7037
              REPLACING THE ELECTROMAGNETIC CLUTCH...7038
              PROCEDURE FOR DRAINING AND RECHARGING AIR CONDITIONING SYSTEMS WITH RECHARGING STATION 99305146 AND RECOVERY OF R134A COOLANT...7040
              SAFETY STANDARDS...7041
              CONTROL FASCIA...7042
              OPERATION FLOW CHART...7044
              RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM...7045
              CREATING A VACUUM IN THE SYSTEM...7047
              RESTORING OIL IN THE SYSTEM...7049
              FILLING THE SYSTEM WITH REFRIGERANT...7050
              CHECKING THE PRESSURES IN THE SYSTEM...7052
              OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM...7052
              PROCEDURE FOR DRAINING AND RECHARGING AIR CONDITIONING SYSTEMS WITH RECHARGING STATION 99305148 AND RECOVERY OF R134A COOLANT...7053
                Main components...7053
              SAFETY STANDARDS...7054
              CONTROL PANEL...7055
                Keypad functions...7055
                Emergency warning light panel...7055
              PRELIMINARY CHECKS...7056
              AUTOMATIC PROCEDURE...7056
              ASSISTED PROCEDURE...7058
              LEAK FINDER FOR AIR-CONDITIONING SYSTEMS WITH HFC R134A (99305147)...7060
              DIAGNOSTICS INSTRUMENTS...7060
              MODUS - IT 2000 - E.A.SY...7060
              MODUS...7060
              IT 2000...7060
              E.A.SY...7060
              CHASSIS...7061
              TIGHTENING TORQUES...7061
              CHASSIS FRAME...7062
              REPAIRS...7062
              CHECKS...7062
                Measuring the bend of the chassis frame downwards or upwards...7063
                Measuring the side bend of the chassis frame...7063
                Measuring the movement of the chassis frame...7063
                Measuring the torsion of the chassis frame...7064
              PRECAUTIONS...7064
                Welds on the chassis frame...7066
          SECTION 14 - Scheduled maintenance...7067
            Scheduled maintenance...7067
              MAINTENANCE SERVICES CHART...7069
              CHECKS AND/OR MAINTENANCEWORK...7070
              DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCEWORK...7071
              MAINTENANCE WORK...7073
              CHECKS AND/OR MAINTENANCE WORK...7073
              M1 SERVICE...7074
              M2 SERVICE...7079
              EXTRA PLAN MAINTENANCE...7079
              EP1 SERVICE...7079
              EP2 SERVICE...7080
              EP3 SERVICE...7080
              EP4 SERVICE...7080
              T1 SERVICE...7082
              T2 SERVICE...7082
              T3 SERVICE...7083
              T4 SERVICE...7083
          SECTION 15 - Electric/Electronic system...7085
            Electric/Electronic system...7085
              GENERAL WARNINGS FOR ELECTRICAL/ELECTRONIC COMPONENTS...7087
              COMPONENT CODE...7091
              MAIN CHANGES...7095
              CAN LINES...7096
              CAN LINE ASSEMBLY DRAWING...7102
              POWER NETWORK...7103
              MASS POINTS...7104
              ELECTRICAL EQUIPOTENTIAL BRAID...7105
              28 V - 40 A ÷ 90 A “BOSCH”ALTERNATOR...7108
              24V - 5,5 KW “NIPPONDENSO” STARTER MOTOR...7110
              JUNCTION CONNECTORS...7112
              CONNECTOR FOR BODYBUILDERS (CAB)...7125
              CONNECTOR FOR BODYBUILDERS (CHASSIS)...7141
              CONNECTOR FOR BODYBUILDERS (CHASSIS-TRUCK)...7150
              DIAGNOSIS OUTLET...7160
              OBD CONNECTOR...7161
              RECEPTACLE CONNECTOR...7162
              REMOTE-CONTROL SWITCH / FUSE HOLDER CONTROL UNIT...7167
              FUSES...7167
              SUPPLEMENTARY REMOTE SWITCHES...7169
              SUPPLEMENTARY FUSES (70000)...7171
              INSTRUMENT BOARD...7173
              CONTROLS ON THE CENTRAL BOARD...7174
              CONTROLS ON THE STEERING WHEEL...7175
              REARVIEW MIRRORS AND WINDOW REGULATOR CONTROL ADJUSTMENT...7176
              EXTERNAL REARVIEW MIRRORS HEATING...7176
              LIGHT CONTROL...7177
              ENGINE BRAKE CONTROL AND INTARDER...7180
              GEAR SELECTION FUNCTION...7181
              FUNCTION ENGAGING EMERGENCY MODE (LIMP HOME)...7183
              MULTIPLEX SYSTEM...7185
                Cluster...7186
                Cluster (optical indicators)...7187
                Pin-out connectors...7189
                Display operation...7190
                Display structure...7191
                Optical status indicators on display...7192
                Display instruments...7194
                Body computer...7195
              F.F.C. - R.F.C. (Front Frame Computer - Rear Frame Computer)...7206
              F.F.C. (Services / Engine)...7207
              R.F.C...7210
              D.D.M. / P.D.M. / Cab module...7213
              D.D.M. / P.D.M...7214
              P.D.M...7215
              D.D.M...7216
              C.B. (Cab module) Opt...7217
              S.W.I. (Steering wheel / steervator interface)...7219
              SPIRALED CONTACT...7222
              STEERING COLUMN (COMPONENT LOCATION)...7223
              B.M. (BED MODULE)...7227
              TACHOGRAPH...7228
              EDC (ECM) SYSTEMS...7230
              SYSTEM COMPONENTS...7234
              VCM (VEHICLE CONTROL MODULE) ELECTRONIC CONTROL UNIT...7255
              IMMOBILIZER...7258
              ABS-EBL ANTI—LOCK BRAKE SYSTEM - ELECTRONIC BRAKE LIMITER SYSTEM...7260
              BRAKE SYSTEM EBS2 (ELECTRONIC BRAKE SYSTEM - 2)...7267
              COMMON COMPONENTS...7275
              AXLE LOAD METER...7293
              PRESSURE SENSORS...7294
              EUROTRONIC AUTOMATIC TRANSMISSION...7300
              ELECTRONIC CENTER...7308
              TRANMSISSION ACTUATOR...7310
              LOCATION ON THE VEHICLE...7311
              CLUTCH ACTUATOR...7312
              INTARDER...7316
              DMI (DATA MANAGEMENT INTERFACE) (PTO) ELECTRONIC CONTROL UNIT...7322
              AUTOMATIC AIR CONDITIONER...7323
              MANUAL AIR CONDITIONER...7338
              HYDRONIC D 10 WATER HEATER...7342
              COMPONENTS LOCATION...7343
              SYSTEM COMPONENTS...7344
              SCR (SELECTIVE CATALYTIC REDUCTION) SYSTEM - DENOX 2...7349
              CENTRAL LOCKING WITH REMOTE CONTROL...7352
              DIAGNOSTIC...7354
              INFORMATION ON CLUSTER...7357
              CIRCUIT CARD...7359
                Card 1 Power supply voltage (+30)...7361
                Card 2 Power supply voltage (+30) after TGC...7362
                Card 3 Power supply voltage (+30) after TGC...7363
                Card 4 Power supply voltage (+30) after TGC...7364
                Card 5 Power supply voltage (+15)...7365
                Card 6 Power supply voltage (+15)...7366
                Card 7 Body Computer (BC)...7367
                Card 8 Body Computer (BC)...7368
                Card 9 Body Computer (BC)...7369
                Card 10 Body Computer (BC)...7370
                Card 11 Steering Wheel Interface (SWI)...7371
                Card 12 Front Frame Computer (FFC)...7372
                Card 13 Front Frame Computer (FFC)...7373
                Card 14 Rear Frame Computer (RFC)...7374
                Card 15 Rear Frame Computer (RFC)...7375
                Card 16 Cabin Module (CM)...7376
                Card 17 Driver Dool Module (DDM) / Bed Module (BM)...7377
                Card 18 Passenger Door Module (PDM)...7378
                Card 19 Instrument Cluster (IC) / Tachograph...7379
                Card 20 Can lines “ICB” - “IDB” - “FMB”...7380
                Card 21 Can lines “SB” (EBS2-ABS)...7381
                Card 22 Can lines “BCB”...7382
                Card 23 Can lines “VDB”...7383
                Card 24 Can lines “ECB”...7384
                Card 25 Ecas 4x2 P (Tractor)...7385
                Card 26 Ecas 4x2 FP (Tractor)...7386
                Card 27 Ecas 4x2 P / FP (Truck)...7387
                Card 28 Ecas 6x4 P...7388
                Card 29 Ecas 6x2 P / FP / C (3rd axle liftable)...7389
                Card 30 Ecas 6x2 P / FP (3rd axle not liftable)...7390
                Card 31 Ecas 6x2 C (Tractor - 3rd axle not liftable)...7391
                Card 32 Retarder ZF...7392
                Card 33 ABS...7393
                Card 34 EBS2...7394
                Card 35 Eurotronic II...7395
                Card 36 Cooling / Engine ventilation...7396
                Card 37 Hand-operated conditioning system...7397
                Card 38 Automatic conditioning system...7398
                Card 39 Automatically controlled supplementary water heater...7399
                Card 40 Hand-operated supplementary water heater...7400
                Card 41 Supplementary air -operated heater (manual / automatic)...7401
                Card 42 EDC (connector B)...7402
                Card 43 EDC (connector A)...7403
                Card 44 DMI PTO control unit...7404
                Card 45 Radio receiver...7405
                Card 46 ADR (2001 94/9/EG)...7406
                Card 47 ADR (OPT. 0129)...7407
                Card 48 Electronic Control Unit VCM...7408
                Card 49 Electronic Control Unit DCU 15 (System SCR)...7409
              BLOCK DIAGRAM...7411
                Diagram 1: A. Start-up B. Engine revs signal for body builders C. Recharge...7413
                Diagram 2: A. EDC power supply B. EDC / VCM failure C. Snow chains fitted D. All-wheel drive ON...7414
                Diagram 3: A. Cruise Control B. Accelerator pedal sensor C. Preheating...7415
                Diagram 4: ABS/EBS...7416
                Diagram 5: A. Voltmeter B. Revs counter C. Engine water temperature D. Fuel level...7417
                Diagram 6: A. Engine oil level indication B. Engine oil pressure indication C. windscreen washer fluid level indication D. Power steering oil level indication E. Engine water indication...7418
                Diagram 7: A. Brake wear signal (ABS) B. Brake wear signal (EBS) C. Geared-down speed ON signal D. Oil filter clogging signal E. Air filter clogging signal...7419
                Diagram 8: A. Hand brake ON signal B. Transverse differential lock (on-road) C. Transverse differential lock (off-road) D. Longitudinal differential lock E. Signalling the presence of water in the diesel fuel filter...7420
                Diagram 9: External lights...7421
                Diagram 10: A. Low-beam headlights B. High-beam headlights C. Fog lights/rear fog lights...7422
                Diagram 11: A. Brake lights B. Brake lights C. Reversing lights D. Fifth wheel lighting...7423
                Diagram 12: A. Indicator/emergency lights B. Headlamp adjustment...7424
                Diagram 13: Internal lights...7425
                Diagram 14: A. Windscreen wiper B. Horn C. Counter...7426
                Diagram 15: TGC...7427
                Diagram 16: A. Sunroof B. Headlamp washer...7428
                Diagram 17: Tachograph...7429
                Diagram 18: A. Diagnosis B. Diagnosis (optical indicators) C. Engine fan control D. Manual air conditioner control...7430
                Diagram 19: A. Rear-view mirror control B. Window regulator control...7431
                Diagram 20: A. Central locking control...7432
                Diagram 21: A. ECAS (optical indicators) B. ABS (optical indicators)...7433
                Diagram 22: A. EBS (optical indicators) B. Heated windscreen C. P.T.O...7434
                Diagram 23: A. Decelerator (optical indicator) B. Diesel fuel filter clogged C. Cabin tilting...7435
                Diagram 24: A. Brake air pressure indication B. Front/rear axle load indication C. External temperature indication...7436
                Diagram 25: A. Full/partial km displaying B. Gear engaged displaying C. Speed limiter D. Clutch switch signal...7437
                Diagram 26: A. Engine oil temperature signal B. Rotary lamp control C. Sun visor control...7438
603.93.746 - Iveco Stralis Circuit Diagrams (BC2) (EN)...7439

Iveco Stralis Trucks Repair & Service Manual