Complete workshop manual contains service, maintenance, and troubleshooting information for the 1992-2002 Iveco EuroTech, EuroStar. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for 1992-2002 Iveco EuroTech, EuroStar is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

MAKE: Iveco
MODEL: EuroTech, EuroStar
YEAR: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

'92-'02 EuroTech Cursor, EuroStar Cursor (603.43.391).pdf
EUROTECH CURSOR EUROSTAR CURSOR REPAIR MANUAL; 944 pages

EuroTrakker_EuroTech_EuroStar Cursor 8-10-13 EWD (603.93.121).pdf
EUROTRAKKER EUROTECH EUROSTAR CURSOR 8/10/13 REPAIR MANUAL ELECTRIC/ELECTRONIC SYSTEM; 396 pages

EXCERPT:
INDEX
Section
General 1
Engine 2
Clutch 3
Transmission* 4
Intarder - ZF hydraulic retarder 5
Propeller shafts 6
Rear axles 7
Axles 8
Suspension 9
Wheels and tyres 10
Steering system 11
Hydraulic system - Brakes 12
Scheduled Maintenance 13

603.43.391 - Iveco Trucks EuroTech Cursor, EuroStar Cursor Repair Manual ('92-'02)....2
  EUROTECH CURSOR -  EUROSTAR CURSOR....2
    REPAIR MANUAL....2
      NOTE....4
        Graphs and symbols....5
      INDEX....6
        SECTION 1 -  General....7
          General....7
            COMPOSITION OF MODELS....9
            P.I.C. CODE NUMBER....13
              Vehicle Identification Data (EUROTECH)....17
              Vehicle Identification Data (EUROSTAR)....18
            FILLING UP....19
              International designations of lubricants and fluids....20
        SECTION 2 -  Engine....21
          Engine....21
            VIEWS OF THE ENGINE....27
            TECHNICAL DESIGNATION....29
            GENERAL CHARACTERISTICS....32
            ASSEMBLY CLEARANCE DATA....35
            FAULT DIAGNOSIS....41
            DESCRIPTION....41
            DIAGNOSTIC INSTRUMENTS....41
            CONTROL UNIT TEST....42
            ENGINE TEST....42
            AUXILIARY FUNCTIONS....42
            DETECTION OF MECHANICAL FAILURE....43
            TIGHTENING TORQUE....46
            TOOLS....51
            ENGINE REMOVAL - REFITTING....61
              Removal....61
              Refitting....62
            DISMANTLING THE ENGINE ON THE BENCH....65
            REPAIR OPERATIONS....72
            CYLINDER BLOCK....72
              Checks and measurements....72
            CYLINDER LINERS....73
              Replacing cylinder liners....74
              Removal....74
              Fitting and checking protrusion....74
            CRANKSHAFT....75
              Measuring main journals and crank pins....76
              Preliminary measurement of main and big end bearing shell selection data....77
              Replacing the timing control gear and oil pump....85
              Checking main journal installation clearance....85
              Checking crankshaft end float....86
            PISTON-CONNECTING ROD ASSEMBLY....87
              Removal....87
              Measuring the diameter of the pistons....88
              Conditions for correct gudgeon pin-piston coupling....88
              Piston rings....89
            CONNECTING ROD....90
              Bushings....91
              Checking connecting rods....91
              Mounting the piston rings piston assembly....92
              Mounting the piston rings....92
              Fitting the big end bearing shells....92
              Fitting connecting rod - piston assemblies in the cylinder liners ....93
              Checking piston protrusion....93
              Checking assembly clearance of big end pins....95
            CYLINDER HEAD....95
              Taking down the valves....95
              Checking the planarity of the head on the cylinder block....95
            VALVES....95
              Removing deposits and checking the valves....95
            VALVE GUIDES....96
              Replacing of valve guides....97
              Replacing - Reaming the valve seats....97
            REPLACING INJECTOR HOLDER CASES....97
              Removal....97
              Checking protrusion of injectors....99
            TIMING GEAR....100
              Checking cam lift and pin alignment....100
              Camshaft....101
              Bushes....101
              Replacing camshaft bushes using beater 99360499....102
              Valve springs....103
              Fitting the valves and oil seal ring....103
            ROCKER SHAFT....104
            ROCKERS....104
            LUBRICATION....105
              Oil pump....107
              Overpressure valve....107
              Oil pressure control valve....108
              Heat exchanger....108
              Engine oil filters....109
            COOLING....110
              Water pump....110
              Thermostat....110
            TURBOCHARGING....113
              Turbocharger....113
              Holset HX55V turbocharger....115
            ACTUATOR ADJUSTMENT....118
              VGT Control solenoid valve....118
              Holset HY55V turbocharger....119
              Actuator....120
              Solenoid valve for VGT control....120
            FEEDING....121
              Fuel pump....122
              Injector-pump....122
              Pumping element....122
              Nozzle....122
              Solenoid valve....122
              Replacing injectors-pump....122
            INJECTOR PHASES....123
              Filling phase....123
              Injection phase....124
              Pressure Reduction phase....124
            ASSEMBLING THE ENGINE ON THE BENCH....125
            DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER....127
              Fitting the connecting rod-piston assembly into the cylinder liners....128
            ENGINE FLYWHEEL....131
              Fitting engine flywheel....131
              Fitting camshaft....132
              Fitting pump-injectors....133
              Fitting rocker-arm shaft assembly....133
              Camshaft timing....134
              Phonic wheel timing....136
              Adjusting rocker armclearance, intake, exhaust and pre-load of pump injector governing rocker arms....137
            ENGINE COMPLETION....139
        SECTION 3 -  Clutch....141
          Clutch....141
            DESCRIPTION....143
              Clutch....143
            CHARACTERISTICS AND DATA....143
            DIAGNOSTICS....144
            TIGHTENING TORQUES....147
            TOOLS....147
            REMOVING AND REFITTING....148
              Removal....148
              Refitting....148
            REMOVING AND FITTING BACK THE THRUST BEARING ....148
            REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT....148
            DRIVEN PLATE CONTROL....149
              Damping hub control....149
              Friction seal....149
            BLEEDING AIR FROM THE CLUTCH SYSTEM....149
            HYDRAULIC CONTROL....150
            CLUTCH ACTUATOR FOR ZF 16 S151/181/221 GEARBOX....151
              Fitting and adjusting the clutch wear indicator....151
              Push rod adjustment (new clutch)....152
            CLUTCH ACTUATOR FOR EUROTRONIC GEARBOX....153
              Clutch actuator push rod adjustment (new clutch)....153
              Fitting the clutch actuator....153
              Replacing the clutch actuator....153
            CHECKING AND ADJUSTING THE CLUTCH PEDAL STOPS (excluded vehicles with EuroTronic gearbox)....154
              Clutch stop....154
              Clutch pedal idle stroke....154
              Pedal timing gear stroke....154
        SECTION 4 - Gearbox....155
          Gearbox....155
            Gearboxes: ZF 16 S 181 D.D. ZF 16 S 181 O.D. ZF 16 S 221 D.D....158
              LOCATION OF GEARBOX DESCRIPTION PLATE....160
              DESCRIPTION....161
              OPERATION....163
                Slow range....163
                Fast range....164
              EPICYCLIC REDUCTION GEAR CONTROL....165
                Reduced speeds....165
                Normal speeds....166
              SPECIFICATIONS AND DATA....167
              TIGHTENING TORQUES....171
              TOOLS....172
              GEARBOX FAULT DIAGNOSIS....177
              REMOVING-REFITTING THE GEARBOX....180
                Removal....180
                Refitting....181
              OVERHAULING THE GEARBOX....182
                Servoshift gear box....182
                Removal....182
                Refitting....182
                Disassembly....182
                Assembly....184
                Removing the rear box....187
                Removing the epicyclic reduction gear unit (ERG)....187
                Fitting the epicyclic reduction gear unit (ERG)....190
                Refitting the epicyclic reduction gear unit (ERG) rear box ....193
                Removing the gearbox....193
                Removing the main shaft....196
                Removing the drive input shaft....199
                Removing the transmission shaft....200
              CHECKS....200
                Gearbox....200
                Hubs - sliding sleeves - forks....200
                Bearings....200
                Shafts - gears....200
                Synchronizing devices....200
                BK-type single-cone synchronizing devices....200
                Fitting the transmission shaft....201
                Fitting the drive input shaft....201
                Fitting the main shaft....202
                Adjusting the main shaft....204
                Fitting the gearbox....205
                Oil pump....206
                Adjusting the transmission shaft bearing end float....206
                Drive input shaft cover....207
              PNEUMATIC CONTROL OF GEARBOX....209
            ZF gearboxes with INTARDER hydraulic retarder, types: 16 S 151 D.D. 16 S 181 D.D. 16 S 221 D.D....211
              SPECIFICATIONS AND DATA....213
              TOOLS....214
                Removing the hydraulic retarder from the gearbox on the stand....221
                Refitting the hydraulic retarder....221
                Removing the epicyclic reduction gear unit (ERG) rear box....222
                Removing the epicyclic reduction gear unit (ERG)....222
                Component parts of the epicyclic reduction gear unit....225
                Fitting the epicyclic reduction gear unit (ERG)....226
                Refitting the epicyclic reduction gear unit (ERG) rear box....228
            Gearbox EUROTRONIC 1800....230
              DESCRIPTION....232
              CHARACTERISTICS AND DATA....234
              TIGHTENING TORQUES....237
              EQUIPMENT....238
              DIAGNOSIS OF MECHANICAL TYPE FAULTS....244
              EUROTRONIC 1800 TRANSMISSION REMOVAL-REFITTING....247
                Removal....247
                Refitting....248
              REPAIRS....249
                Disassembly of front box....249
                Disassembling the intermediate casing....250
                Disassembly of rear box and epicyclic reduction unit....252
                Installation of rear box and epicyclic reduction unit....254
                Axial clearance regulation on epicyclic reduction gear bearing....254
                Removal of primary shaft....258
                Primary shaft installation....259
                Removal of Splitter synchroniser....261
                Installation of Splitter synchroniser....261
                Forks installation-disinstallation....261
                Secondary shafts....261
                Central box installation....262
                Shafts timing....264
                Disinstallation of movement input shaft....265
                Installation of movement input shaft....266
                Installation of front box....266
                Disinstallation of front cover....267
                Installation of front cover....267
                Regulation of axial clearance on movement input shaft bearing ....268
                Regulation of axial clearance on secondary shaft bearings....268
              EUROTRONIC IT (INTARDER)....272
                CHARACTERISTICS AND DATA....272
                REPAIRS....273
                  Disinstallation of rear box....273
                  Rear box installation....274
                  Regulation of axial clearance on epicyclic reduction gear bearing....274
                  Regulation of axial clearance on stator....275
                CLUTCH ACTUATOR....276
                  Description....276
                CHARACTERISTICS AND DATA....276
                SAFETY RULES....277
                  Disinstallation....278
                  Installation....280
                  Operating checks....281
                  Measure of piston stroke....281
            Gearbox EuroTronic 12 AS 2301 D.D....283
              DESCRIPTION....285
              SPECIFICATIONS AND DATA....286
              TIGHTENING TORQUES....289
              TOOLS....290
              OVERHAULING THE GEARBOX ....295
                Checks....295
                Gearbox actuator....295
                Removal....295
                Refitting....296
                Removing the rear box....296
                Removing the rear box....297
                Removing the epicyclic reduction gear train (E.R.G.)....298
                Fitting the epicyclic reduction gear train (E.R.G.)....300
                Adjusting epicyclic reduction gear train bearing end float....301
                Adjusting main shaft end float....302
                Synchronizing device assembly for engaging normal or reduced gears....304
                Removal....304
                Removing the middle box....307
                Removing the main shaft....309
                Removing the drive input shaft....311
                Removing the splitter synchronizing device....312
                Fitting the splitter synchronizing device....313
                Fitting the main shaft....314
                Fitting the drive input shaft....314
                Splitter control fork....317
                Disassembly - Assembly....317
                Gear control forks....317
                Removal....317
                Fitting....318
                Transmission shafts....319
                Disassembly - Assembly....319
                Fitting the middle box....319
                Fitting the front box....322
                Front cover....324
                Removal....324
                Fitting the front cover....324
                Adjusting drive input shaft bearing end float....324
                Adjusting transmission shaft bearing end float....325
                Clutch release lever....327
            Gearbox EuroTronic 12 AS 2301 D.D. with Intarder (IT)....330
              SPECIFICATION AND DATA....332
              OVERHAULING THE GEARBOX....333
                Removing the hydraulic retarder....333
                Refitting the hydraulic retarder....334
                Adjusting epicyclic reduction gear train bearing end float....334
                Adjusting stator end float....335
                Removing the rear box....336
                Removing the E.R.G....337
                Fitting the E.R.G....338
              EXPERIMENTAL TOOLS....343
        SECTION 5 - Intarder - ZF hydraulic retarder....344
          Intarder - ZF hydraulic retarder....344
            LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE....346
            GENERAL INFORMATION....347
            OPERATION....347
              Retarder engaged....348
              Retarder disengaged....349
            LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER....350
            REMOVING AND REFITTING THE RETARDER ON THE ZF S 181/221-OD GEARBOX....351
              Removal....351
              Refitting....352
              Filling with oil....352
            SPECIFICATIONS AND DATA....353
            TIGHTENING TORQUES....354
            TOOLS....355
            FAULT DIAGNOSIS....357
            OVERHAULING THE INTARDER HYDRAULIC RETARDER....361
              Hydraulic accumulator....361
              Removal....361
              Fitting....361
              Removing hydraulic retarder....361
              Checking the component parts of the hydraulic retarder....366
              Fitting the hydraulic retarder....367
              For hydraulic retarders without friction reducing valves only....367
              For both types of hydraulic retarder....368
              Stator end float adjustment....372
        SECTION 6 - Propeller shafts....374
          Propeller shafts....374
            SPECIFICATIONS AND DATA....376
            SPECIFICATIONS AND DATA (Vehicles 4x2)....378
            SPECIFICATIONS AND DATA (Vehicles 6 x 2)....379
            DIAGNOSTIC....380
            TIGHTENING TORQUES....382
            REMOVING AND REASSEMBLING THE PROPELLER SHAFT....383
              Removal....383
              Reassembly....383
            CHECKING THE PROPELLER SHAFT ON THE VEHICLE....384
            REMOVING AND FITTING BACK THE UNIVERSAL JOINTS ....385
            REMOVING AND REASSEMBLING THE SUPPORT....385
        SECTION 7 - Rear axles....386
          Rear axles....386
            Rear axle MERITOR U 177 E whit drum brakes....388
              DESCRIPTION....390
              SPECIFICATIONS AND DATA....390
              DIAGNOSTIC....393
              TIGHTENING TORQUES....395
              TOOLS....397
              REMOVING THE REAR AXLE....402
              FITTING BACK THE REAR AXLE....402
              REAR AXLE ASSEMBLY OVERHAULING....404
              WHEEL HUB OVERHAULING....404
                Removal....404
                Wheel hub component check....405
              REPLACING THEWHEEL HUB BOLTS....406
                Wheel hub reassembly....406
              REMOVINGANDREASSEMBLING THE DIFFERENTIAL (with axle on stand 99322215) ....408
                Removal....408
                Axle casing check....408
                Reassembly....409
              REPAIRING THE DIFFERENTIAL....409
                Removing the differential....409
                Removing the gearcase....411
              REMOVING THE BEVEL PINION FROM THE SUPPORT....413
                Differential component check....413
                Ressembling the gearcase....414
              REASSEMBLING THE BEVEL PINION SUPPORT....415
                Reassembling the differential housing....417
              CAP OPENING ADJUSTMENT....419
              CROWNWHEEL AND PINION CONTACT CORRECTION (AFTER ASSEMBLY)....422
                Instructions for the adjustment and operation check of the transmitter for the differential block operation control....425
            Rear Axle MERITOR U 177 E with disc brakes....426
              DESCRIPTION....428
              CHARACTERISTICS AND DATA....429
              TIGHTENING TORQUES....430
              TOOLS....432
              OVERHAULING THE REAR AXLE ASSEMBLY....436
              OVERHAULING THEWHEEL HUBS....436
                Removal....436
                Replacing wheel hub bearings....438
                Checking the parts forming the wheel hubs....438
                Replacing the wheel fixing pins....438
              REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215)....442
                Removal....442
                Checking axle housing....442
            Rear axle MERITOR MS 13-175 with drum brakes....444
              DESCRIPTION....446
              CHARACTERISTICS AND DATA....446
            Rear Axle MERITOR MS 13-175 with disc brakes....448
              DESCRIPTION....450
              CHARACTERISTICS AND DATA....450
            Rear axle 451391/1 (R 8284)....452
              DESCRIPTION....454
              SPECIFICATIONS AND DATA....455
              TIGHTENING TORQUES....456
              TOOLS....458
              REAR AXLES ASSEMBLY OVERHAUL....464
                Disassembly....464
                Epicycloid reduction gear disassembly....464
                Wheel hub disassembly....465
              CLEANING AND CHECKING WHEEL HUB AND EPICYCLOID GEAR PARTS....467
              WHEEL HUB ASSEMBLY....468
                Assembling the epicycloid reduction gear....470
              REMOVING-REFITTING THE DIFFERENTIAL....473
              REFITTING....474
              REPAIRING THE DIFFERENTIAL....475
                Removal....475
                Gear housing disassembly....476
                Removing the bevel pinion from the support....477
              CHECKING THE DIFFERENTIAL COMPONENTS....479
                Gear housing assembly....480
                Assembling the bevel pinion support....481
                Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring....481
                Differential housing assembly....483
                Gear housing bearings rolling torque adjustment....484
            Axles in Tandem....488
              Axles in Tandem (Intermediate) Meritor RP 160 E (R 2478)....490
                DESCRIPTION....492
                SPECIFICATIONS AND DATA....492
                TIGHTENING TORQUES....494
                TOOLS....498
                EXPERIMENTAL TOOLS....505
                SERVICING INTERMEDIATE AXLEASSEMBLY RP 160 E (R2478) ....508
                AIR BREATHER REMOVAL-REFITTING....508
                SERVICINGWHEEL HUBS....508
                  Checking wheel hub components....509
                ASSEMBLINGWHEEL HUBS....510
                REMOVING DIFFERENTIAL GEAR . TRANSFER BOX(with rear axle on stand 99322215) ....513
                REFITTING DIFFERENTIAL GEAR . TRANSFER BOX (with rear axle on stand 99322215)....513
                REPAIRING INTER-AXLE UNIT....514
                  Dismantling inter-axle unit....514
                  Checking inter-axle unit components....516
                  Fitting inter-axle unit....516
                  Adjusting drive input shaft bearing end float....518
                  Adjusting differential lock and inter-axle control pin end-stop....518
                REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING....519
                  Dismantling gear cage....522
                  Checking differential components....522
                  Assembling gear cage....523
                ASSEMBLING DIFFERENTIAL CASING....524
                  Calculatingbevel pinion positionin differential casing ....524
                COMPUTATIONAL EXAMPLES....525
                  Determining the thickness of the bevel pinion bearing clearance adjustment rings ....525
                  Adjusting the cap gap....528
                CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)....530
                REMOVING-SERVICING-REFITTIN G INTER-AXLEOUTPUT SHAFT....533
              Axles in Tandem (Rear) Meritor RR 160 E (R 0878)....536
                DESCRIPTION....538
                SPECIFICATIONS AND DATA....538
                TIGHTENING TORQUE....540
                TOOLS....542
                SERVICING REAR AXLE ASSEMBLY RR 160 E (R 0878)....547
                AIR BREATHER REMOVAL/ INSTALLATION....547
                SERVICINGWHEEL HUBS....547
                REMOVING DIFFERENTIAL (with axle on stand 99322215) ....547
                REFITTING DIFFERENTIAL (with axle on stand 99322215)....547
                REPAIRING DIFFERENTIAL....548
                  Removing differential lock....548
                  Dismantling differential casing....549
                  Dismantling gear cage....550
                  Dismantling bevel pinion support....550
                  Checking differential components....554
                  Assembling gear cage....554
                  Specimen calculations....556
                  Assembling differential casing....556
                ADJUSTING THE CAP GAP....558
                CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)....561
              Axles in Tandem (Rear) Meritor RR 167 E (R 0878)....564
                DESCRIPTION....566
                CHARACTERISTICS AND DATA....566
                TIGHTENING TORQUES....568
                TOOLS....570
                OVERHAULING REAR AXLE ASSEMBLY RR 167 E (R 0878)....576
        SECTION 8 -  Axles....578
          Axles....578
            Front axle....580
              Front axle 5876/4 (F 8021) 5876/5 (F 8021) Steering central added axle 5876/2 (F 8021)....580
                DESCRIPTION....582
                SPECIFICATIONS AND DATA....583
                FAULT DIAGNOSIS....585
                TIGHTENING TORQUES....587
                TOOLS....590
                REMOVING AND REFITTING FRONT AXLE....594
                  Vehicles with mechanical front suspension....594
                  Removal....594
                  Refitting....594
                REMOVING AND REFITTING FRONT AXLE....595
                  Vehicles with pneumatic front suspension and longitudinal bars....595
                  Removal....595
                  Refitting....596
                VEHICLE CHECKS....597
                  Tie rods....597
                  Swivel heads....597
                CHECKING SWIVEL HEAD PLAY....597
                FRONT AXLE ASSEMBLY OVER- HAUL....598
                REMOVING - REFITTINGWHEEL HUBS....598
                  Removal....598
                  Replacing wheel hub bearings....599
                  Replacing wheel fixing pins....600
                  Refitting wheel hubs....600
                  Checking wheel hub bearing end float....600
                  Measuring rolling torque....601
                REMOVING AND REFITTING TRANSVERSE TIE ROD ....601
                REPLACING TRANSVERSE TIE ROD SWIVEL HEADS ....602
                REMOVING AND REFITTING LEVERS FOR LONGITUDINAL TIE ROD ....602
                REMOVING - REFITTING LEVER FOR TRANSVERSE TIE ROD....602
                REMOVING AND REFITTING PIN FOR STUB AXLE....602
                  Removal....602
                  Replacing kingpin bearing....603
                  Checking and adjusting clearance between stub axle and axle....604
                CHECKING AND MEASURING THE AXLE BODY....605
                  Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins....605
                  Checking angle of holes for kingpins....606
              Axle 5876 (F 8021)....608
                DESCRIPTION....610
                SPECIFICATIONS AND DATA....611
                TIGHTENING TORQUE....612
                TOOLS....613
                FRONT AXLE ASSEMBLY OVERHAUL....617
                REMOVING - REFITTINGWHEEL HUBS....617
                  Removal....617
                  Refitting wheel hubs....618
            Rear axle....620
              Additional rigid rear axle 55080....620
                DESCRIPTION....622
                CHARACTERISTICS AND DATA....622
                TIGHTENING TORQUES....623
                TOOLS....624
                REPAIR OPERATIONS....626
              Additional rigid rear axle 56082/1....628
                CHARACTERISTICS AND DATA....630
                TIGHTENING TORQUES....631
                TOOLS....632
              Pneumaically lifted steering additional rear axle (57080)....634
                CHARACTERISTICS AND DATA....636
                TIGHTENING TORQUES....638
                TOOLS....639
                REPAIR OPERATIONS....643
                PNEUMATIC LIFT GENERAL....643
                GENERAL INFORMATION....643
                LOCATION OF THE MAIN HYDRAULIC SYSTEM COMPONENTS ON THE VEHICLE....644
                HYDRAULIC SYSTEM....645
                HYDRAULIC SYSTEM OUTLINE DIAGRAM....646
                VEHICLESWITH REAR AIR SPRING SUSPENSIONS AND PNEUMATIC LIFT....647
                  Location of the main components on the vehicle....647
                  Pneumatic principle diagram, rear air spring suspensions and pneumatic lift for additional axles with single wheels....648
                    FAULT DIAGNOSIS....649
                    TIGHTENING TORQUES (Steering and lifting device linkage)....652
                    CHARACTERISTICS AND DATA....653
                      Steering and third axle hydraulic system....653
                    MAIN HYDRAULIC SYSTEM COMPONENTS....654
                    HYDRAULIC ACCUMULATOR....654
                      Nitrogen pressure checking and recharging....654
                    OPERATOR CYLINDER....654
                      Disassembly....655
                      Assembly....655
                      Checking cylinder oil sealing on the vehicle....655
                    CENTRING CYLINDER....655
                      Disassembly....656
                      Assembly....656
                      Checking cylinder oil sealing on the vehicle....656
                    ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING....657
                      Removal....657
                      Refitting....657
                    AIR BLEEDING FROM THE HYDRAULIC CIRCUIT....658
                      Filling up and bleeding the power steering hydraulic circuit (circuit 1)....659
                      Filling up and bleeding the power steering hydraulic circuit (circuit 2)....659
            Wheel geometry....660
              GENERAL INFORMATION....662
                Steering wheel angles....662
              FRONTWHEEL GEOMETRY (4X2 vehicles)....663
                Positioning clips and headlights....663
                Electronic compensation of rim eccentricity....664
                Wheel alignment....664
                Checking wheel toe-in....665
                Checking wheel deviation....665
                Checking camber....665
                Checking kingpin angle and caster....666
                Checking rear axle alignment....667
              VEHICLE WHEEL GEOMETRY WITH CENTRAL ADDED AXLE (6X2 C)....667
                Checking steering angles....669
                Vehicle wheel geometry with steering rear added axle and pneumatic lifting....669
        SECTION 9 - Suspensions....672
          SUSPENSIONS....676
            DESCRIPTION....676
              Mechanical front suspension....676
              Air spring front suspension....676
              Air spring rear suspension....676
              Mechanical rear suspension....676
            FRONT SUSPENSION CHARACTERISTICS AND DATA....677
              Front leaf spring (vehicles with mechanical suspension)....677
              Front leaf spring (vehicles with air spring suspension)....678
              Leaf spring for additional central axle (vehicles with air spring suspension)....679
              Rear leaf spring (6x4 vehicles)....680
              Front shock absorbers....682
              Rear shock absorbers....683
            CHECKING SHOCK ABSORBERS BRAKING CAPACITY....684
            MECHANICAL FRONT SUSPENSION ASSEMBLY....686
            MECHANICAL REAR SUSPENSION ASSEMBLY....688
            REAR CANTILEVER SUSPENSION (6X2 - 6X4 vehicles) ....689
              Removing-reassembling the central support....689
              Removing-reassembling the central support shaft....689
              Replacing the bearings....689
              Removing-reassembling the bracket....689
              Removing the central support....689
              Removing the central support shaft....689
              Replacing the bracket....689
              Replacing the half bearings....689
              Reassembling the bracket....690
              Reassembling the central support shaft....691
              Reassembling the central support....691
            AIR SUSPENSION....693
              Chassis frame lifting, lowering and self-levelling with remote control ....693
              Saving Levels....693
            AIR SPRING SUSPENSION ASSEMBLIES....694
              Front air spring suspension for 4x2 vehicles: MP190E39/FP, LD440E43T/FP....694
              Front air spring suspension for 6x2P vehicles: LD260E43Y/FS - 43Y/FP....694
              Additional central axle air spring suspension for 6x2C vehicles: LD440E43TX/P....695
              Rear air spring suspension for 4x2 vehicles: LD190E39/P - 43/P, MP190E39/FP....695
              Rear air spring suspension for 4x2 vehicles: MP440E39T/P, LD440E43T/P....696
              Rear air spring suspension for 4x2 vehicles: LD440E43T/FP....696
              Rear air spring suspension for 6x2C vehicles: LD440E43TX/P....697
              Rear air spring suspension for 6x2P vehicles: MP-LD260E43Y/P....697
              Rear air spring suspension for 6x2P vehicles: LD260E43Y/FS-43Y/FP....698
              Rear air spring suspension for 6x4 vehicles: 260E..Z/P - 440E..TZ/P....698
            ATTITUDE VALUES....699
              In self-levelling conditions....699
            AIR SUSPENSION SYSTEM DIAGRAMS....701
              Rear air suspension main diagram for 4X2P vehicles....701
              Air suspension main diagram for 4x2FP vehicles....702
              Rear air suspension main diagram for 4X2T/P vehicles....703
              Air suspension main diagram for 4x2T/FP vehicles....704
              Suspension main diagram for 4x2 FP-CT/FP-GV/FP-D vehicles....705
              Suspension main diagram for 4x2FP-CM vehicles....706
              Rear air suspension main diagram for 6x2Y/PS vehicles....707
              Rear air suspension main diagram for 6x2Y/PT vehicles....708
              Air suspension main diagram for 6x2Y/FP/FS/FT vehicles....710
              Air suspension main diagram for 6x2TX/P vehicles....711
              Air suspension main diagram for 6x2Y/FP/FS-GV/FS-D vehicles....712
              Air suspension main diagram for 6x2Y/FP/FS-CM vehicles....713
              Air suspension main diagram for 6x4 Z/P - HM vehicles....714
              Air suspension main diagram for 6x4 TZ/P - HM vehicles....715
            TIGHTENING TORQUES....716
              Mechanical front suspension....716
              Pneumatic front suspension....717
              Pneumatic front suspension with bars....718
              Additional central axle air suspension 6x2C vehicles....719
              Rear air suspensions 4x2 + 6x2 C vehicles....720
              Rear air suspensions 6x2 P/PT/FT vehicles....722
              Rear air suspensions 6x2 P/PF/FS vehicles....723
              Rear air suspensions 6x2 P vehicles....724
              Rear air suspensions 6x4 vehicles....725
            TOOLS....727
            CHARACTERISTICS AND DATA....731
              Relief valve....732
            IDRAULIC SYSTEM MAIN COMPONENTS....732
              Pneumatic system....731
              Diagnostic....732
              Level sensor....732
              Electropneumatic distributor....733
              Suspension pressure gauge....733
              Air low pressure manometer switch....733
              Air spring....733
            DIAGNOSTIC....734
              Diagnosis Instruments....734
              Blink code table for ECAS .4X2 /6X4. suspension control unit....736
              Blink code table for ECAS 6X2C suspension control unit....737
              Blink code table for air-operated hoist ECAS 6X2 suspension control unit....738
            REAR SUSPENSIONS....744
              Removal....744
              Refitting....744
            REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM....745
            REMOVING-REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM....745
            REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM....745
            REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM....745
              Removal....745
              Refitting....745
            REPLACING THE SUSPENSION ARM FLEXIBLE PIN....746
              Removal....746
              Refitting....746
            STABILIZER BAR....747
            FRONT STABILIZER BAR....747
            CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)....747
            REAR STABILIZER BAR....747
            REAR ADDED AXLE STABILIZER BAR (6x2P vehicles)....747
              Removal....747
              Refitting....747
            RUBBER BUSHINGS....750
              Replacing front stabilizer bar rubber bushings....750
              Replacing rear stabilizer bar rubber bushings....750
            SHOCK ABSORBERS....751
              Removal-refitting....751
              Front axle shock absorbers (6x2 C vehicles)....751
              Central added axle shock absorbers....751
              Rear axle shock absorbers....751
              Rear added axle shock absorbers (6x2 P vehicles)....751
              Removal....751
              Refitting....751
        SECTION 10 - Wheels and tyres....752
          Wheels and tyres....752
            DESCRIPTION....754
            CHARACTERISTICS AND DATA....754
              Tyre inflation pressures....754
            TOOLS....755
            FAULT DIAGNOSIS....755
            STATIC BALANCING OF THE WHEELS....758
            CORRECTING RESIDUAL STATIC IMBALANCE....759
            TYRE PRESSURE....759
            HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE....760
        SECTION 11 - Steering system....762
          Steering system....762
            DESCRIPTION....764
              4x2 vehicle control diagram (mechanical front suspension)....765
              4x2 FP - 6x2 FP Vehicle steering control diagram with front air suspension and leaf spring....766
              4x2 - 6x2 FP Vehicle steering control diagram with front air suspension and longitudinal bars....767
              6x2 C Vehicle steering control diagram with auxiliary central axle....768
              6x2p (steering rear axle) Vehicle steering control diagram with front mechanical suspension....769
              6x2p (steering rear axle) Vehicle steering control diagram with front air suspension and longitudinal bars....770
              6x2p (steering rear axle) Vehicle steering control diagramwithfront air suspension andand leaf spring....771
            CHARACTERISTICS AND DATA....775
            FAULT DIAGNOSIS....776
            TIGHTENING TORQUES....781
            TOOLS....782
            REMOVING AND REFITTING THE POWER STEERING UNIT....784
              Removal....784
              Refitting....785
              Removing-Fitting the Steering Lever....785
            REMOVING AND REFITTING THE STEERING CONTROL ASSEMBLY....786
              Removal....786
              Refitting....787
            BLEEDING AIR FROM THE POWER STEERING CIRCUIT....788
            MEASURING PLAYS IN THE STEERING BOX DETECTED ON THE STEERINGWHEEL ....788
            CHECKING THE POWER STEERING SYSTEM MAXIMUM PRESSURE....788
            ADJUSTING THE HYDRAULIC STEERING LIMITING DEVICE....788
              Checking the hydraulic limiting of steering with vehicle running....789
              Setting the automatic hydraulic steering limit....789
              Checking....789
        SECTION 12 - Pneumatic system - Brakes....790
          Pneumatic system - Brakes....790
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)....794
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)....795
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)....801
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)....802
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)....803
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)....804
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)....805
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)....806
            SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)....807
            PIPES AND COUPLINGS....808
              In general....808
              End forming on rigid pipes....808
              Bending rigid pipes....809
              Cutting rigid pipes....809
              Replacing flexible hoses with threaded couplings....810
              Replacing flexible hoses with quick-connection couplings....811
            BRAKING SYSTEM....813
              Outline diagram for 4x2 vehicles 190 E...P/FP....813
              Outline diagram for 4x2 vehicles 440 E...T/P-T/FP....814
              Outline diagram for 6x2C vehicles 440 E...TX/P....815
              Outline diagram for 6x2P vehicles 260 E...Y/PS - Y/FS - Y/FP....816
              Outline diagram for 6x2P vehicles 260 E...Y/TN....817
              Outline diagram for 6x4 vehicles 260 E...Z/P-HM....818
              ABS-ASR system wiring diagram (for 4x2 vehicles)....819
              ABS-ASR system wiring diagram (for 6x2C vehicles)....820
              ABS-ASR system wiring diagram (for 6x2P vehicles)....821
              ABS-ASR system wiring diagram (for 6x2P Y/TN vehicles)....822
              ABS-ASR system wiring diagram (for 6x4 vehicles)....823
              EBS system wiring diagram (for 4x2 vehicles) 440 E... T/P-T/FP....824
              EBS system wiring diagram (for 6x2C vehicles) 440 E... TX/P....825
              Layout of the main brake system components on the vehicle....826
              Layout of the main ABS-ASR system components on the vehicle....827
              Layout of the main EBS system components on the vehicle....828
            DESCRIPTION....829
              Service braking....829
              Emergency braking....829
              Exhaust braking....829
              Parking brake....829
            BRAKES....829
              Front brakes (KNORR SB7 - SN7 type)....829
              Rear brakes (PERROT type dia. 410 x 180 - 410 x 200) ....829
            DIAGNOSTICS....830
              Diagnosis Instruments....830
              ABS Troubleshooting....832
              EBS Troubleshooting....840
            TIGHTENING TORQUES....876
            TOOLS....879
            SPECIFICATIONS AND DATA - AIR SYSTEM....889
            CHARACTERISTICS AND DATA - BRAKES....896
            CHECKING MAIN BRAKE SYSTEM COMPONENTS....900
            BRAKING SYSTEM MAIN COMPONENTS....902
              Compressor....902
              Head locking screw tightening....902
              Fault diagnosis....903
            A.P.U. (Air Processing Unit)....903
              Distributor with electric (vehicles not fitted with EBS)....904
              Duplex Distributor with electric (vehicles not fitted with EBS) ....904
              Fault diagnosis (vehicles not fitted with EBS)....904
              Triple-control servo-distributor (vehicles not fitted with EBS)....905
              Predominance adjustment....905
            KNORR - BREMSE AC 567 B....905
            WABCO 973009013....905
              Fault Diagnosis....906
              Trailer control servo-distributor (vehicles fitted with EBS ....906
              Relief valve (towing vehicles)....906
              Coupling heads....906
              Parking brake control hand distributor (towing vehicles)....907
              Parking brake control hand distributor (towing vehicles)....907
              Fault Diagnosis (Parking brake control hand distributor (towing vehicles)....907
              Rear axle electro-pneumatic modulator (for vehicles with EBS)....908
              Fault Diagnosis....908
              Relay valve (vehicles not fitted with EBS) ....909
              Axle proportional relay valve (vehicles fitted with EBS)....909
              Fault Diagnosis (vehicles not fitted with EBS)....909
              Exhaust brake control pedal valve....909
              Low-pressure switch....909
              Controlled pressure valve....910
              Fault Diagnosis....910
              Dual stop valve....910
              Pressure test point valve....910
              Diaphragm brake cylinder (for front and added front axle disc brake) ....911
              Diaphragm brake cylinder (for front and added front axle drum brake)....911
              (for front and added front axle Combined brake cylinder ....911
              Combined brake cylinder (for drum brake)....912
              Combined cylinder emergency brake release device ....912
            ANTI-SKID SYSTEMS....913
              Antilock braking system (ABS)....913
              Anti-skid system (ASR)....913
              EBS (Electronic Brake System)....913
              Electronic control unit....914
              Brake antilock distributor....914
              ASR electropneumatic valve....914
              Revolution sensor....914
              Phonic wheels....914
            BRAKE REPAIR....915
              KNORR SB7 type front disk brakes (vehicles not fitted with EBS)....915
              KNORR SBY type front disk brakes (vehicles fitted with EBS)....916
            KNORR SB7 type front disk brakes (vehicles not fitted with EBS)....915
              Operation....919
            CHECKS....919
            KNORR SBY type front disk brakes (vehicles fitted with EBS)....916
            SN7 TYPE DISK BRAKES....917
            CHECKS....919
              Checking the automatic play recovery system efficiency....919
              Checking brake lining thickness....920
              Brake lining replacement....921
            Remov.-fitting back the brake calipers Remover....924
              Remover....924
              Refitting....925
            Removing-fitting the wheel hubs....925
              Removing....925
              Refitting....926
            SB7 BRAKE CALLIPER OVERHAULING....927
              Disassembly....927
              Cleaning and checking the components....927
              Assembly....928
            BRAKE DISC OVERHAULING....929
            BRAKE DISCS TURNING AND GRINDING....929
            FRONT DRUM BRAKES....930
            REAR BRAKES....930
              Disassembly....930
              Assembly....930
            REAR DISK BRAKES....930
            REAR DRUM BRAKES....931
            REAR DRUM BRAKES OVERHAULING....931
              Disassembly....931
              Turning drums....934
              Replacing brake linings....934
        SECTION 13 -  Scheduled Maintenance....938
          SCHEDULED MAINTENANCE....940
          DESCRIPTION....940
            Service plan....940
          OPERATIONS....941
          DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCEWORK....944
603.93.121 - Iveco Trucks EuroTrakker, EuroTech, EuroStar Cursor 8-10-13 Electrical Wiring Diagrams....946
  EUROTRAKKER - EUROTECH - EUROSTAR CURSOR 8/10/13....946
    REPAIR MANUAL ELECTRIC/ELECTRONIC SYSTEM....946
      FOREWORD....948
      GENERAL LIST OF CONTENTS....950
        Introduction....952
          General cautions for electric/electronic components....955
          Concept of earth and electromagnetic compatibility....957
          Concept of CAN LINE....962
          Technical Codes....966
          Graphic symbols and abbreviations....972
        General....978
          DESCRIPTION OF BASE SYSTEM....980
            Technical and electric specifications....980
            Cab structure....980
            Components on the engine F2B....982
            Frame structure....986
            Complete vehicle with cab tilted....987
            Vehicle transparency (Euro Tech/EuroStar)....988
          POWER NETWORK....990
            Negative network....990
            Earth points on the vehicle....991
            Positive network....1002
            Starting....1006
          MAIN COMPONENTS....1009
            Interconnecting Control Unit (UCI)....1009
            Central panel - Cursor 8 (On Road)....1027
            Starter motor....1035
            Alternator....1039
            Steering column lever unit....1041
            Ignition switch....1047
            Front wall connectors (A) (EuroTech - EuroStar)....1048
            Rear wall connector ( " )....1059
            Connectors between cables (Base vehicle) Cursor 8/10/13....1066
        Specific circuits....1094
          ABS OPERATION DIAGRAM (CURSOR 8 - 10 - 13)....1096
          EDC MS6.2 (Cursor 8 - 10 - 13)....1157
          ECAS....1188
          IMMOBILIZER....1229
        Circuit Charts....1248
          Keys....1250
            Chart No. 1: Start up from driver’s seat....1251
            Chart No. 2: Start up from engine compartment....1252
            Chart No. 3: Pre-heating....1253
            Chart No. 4: Recharge....1254
            Chart No. 5: Instruments (fuel level - water temperature)....1255
            Chart No. 6: Instruments (engine oil and brake air pressure)....1256
            Chart No. 7a: Instruments (tachograph - rev counter) F2B (on)....1257
            Chart No. 7b: Instruments (tachograph - rev counter) F3A/F3B (on) - F2B/F3B (off)....1258
            Chart No. 8a: Warning lights (iveco control)....1259
            Chart No. 8b: Warning lights F2B (on)....1260
            Chart No. 8c: Warning lights F3A/F3B (on)....1261
            Chart No. 8d: Warning lights F2B/F3B (off)....1262
            Chart No. 9: Sidelights (cabin interior)....1263
            Chart No. 10: Sidelights (vehicle exterior)....1264
            Chart No. 11: Main/dipped beam headlights....1265
            Chart No. 12: Additional headlights and rear foglights....1266
            Chart No. 13: Direction indicators - hazard lights....1267
            Chart No. 14: Brake lights - Reverse light - Horn....1268
            Chart No. 15: Windscreen wiper....1269
            Chart No. 16a: Interior lighting and service F2B (on)....1270
            Chart No. 16b Interior lighting and service F3A/F3B (on)....1271
            Chart No. 16c: Interior lighting and service F2B/F3B (off)....1272
            Chart No. 17: Rearview mirrors....1273
            Chart No. 18a: Window winders F2B (on) F2B/F3B (off)....1274
            Chart No. 18b: Window winders F3A/F3B (on)....1275
            Chart No. 19a: ABS / ASR F2B (on)....1276
            Chart No. 19b: ABS / ASR F3A/F3B (on)....1277
            Chart No. 19c: ABS / ASR F2BF3B (off)....1278
            Chart No. 20: EBS F3A/F3B (on)....1279
            Chart No. 21a: EDC (connector B) F2B (on)....1280
            Chart No. 21b: EDC (connector B) F3A/F3B (on) F2B/F3B (off)....1281
            Chart No. 22a: EDC (connector a - F2B)....1282
            Chart No. 22b: EDC (connector A - F3B)....1283
            Chart No. 23a: EUROTRONIC 1 F2B (on)....1284
            Chart No. 23b: EUROTRONIC I I F3A/F3B (on) F2B/F3B (off)....1285
            Chart No. 24: Manual climate control system....1286
            Chart No. 25: Automatic climate control system....1287
            Chart No. 26: Additional air heating manual mode....1288
            Chart No. 27: Additional air heating manual mode (GGVS)....1289
            Chart No. 28: Independent heating unit manual control for cabin and engine....1290
            Chart No. 29: Independent heating unit manual control for cabin and engine (TMP)....1291
            Chart No. 30: Main remote control switch....1292
            Chart No. 31: ADR electronic main remote control switch....1293
            Chart No. 32: Air TMP emergency switch....1294
            Chart No. 33: Air TMP emergency switch (French)....1295
            Chart No. 34: Ground startup and recharge....1296
            Chart No. 35: 15-Pole socket....1297
            Chart No. 36: 2X7 Pole socket (only tractor)....1298
            Chart No. 37: Heated windscreen....1299
            Chart No. 38: Drier heating heated pre-filter....1300
            Chart No. 39: Trip computer level 1....1301
            Chart No. 40: Trip computer level1 (with main current switch)....1302
            Chart No. 41A: Electronic speedometer F2B (ON)....1303
            Chart No. 41B: Electronic speedometer F3A/F3B (ON) F2B/F3B (OFF)....1304
            Chart No. 42: Hour counter....1305
            Chart No. 43: Economy Power....1306
            Chart No. 44: Central door lock....1307
            Chart No. 45: Multipower takeoff....1308
            Chart No. 46: Right and left beacon light....1309
            Chart No. 47: Sunroof....1310
            Chart No. 48: Central lubrication “Lincoln” - “Vogel”....1311
            Chart No. 49: Hydraulic power steering circuit....1312
            Chart No. 50: Hydraulic power steering circuit (northern countries)....1313
            Chart No. 51: Headlight washer and windscreen wiper....1314
            Chart No. 52: Trailer braking system....1315
            Chart No. 53: Immobilizer....1316
            Chart No. 54: Intarder ZF....1317
            Chart No. 55: ECAS for 4X2 and 6X2 (ON)....1318
            Chart No. 56: ECAS for 4X2 and tractor (ON)....1319
            Chart No. 57: ECAS for 6X2 P/FP and PT/FT with additional hydraulic steering axis (ON)....1320
...
Iveco EuroTech, EuroStar Trucks Workshop Repair Service Manual 1992-2002