Iveco EuroCargo/Tector 2002-2008 Workshop Repair & Service Manual
Catalog:
Model:
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the 2002-2008 Iveco EuroCargo/Tector. 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 2002-2008 Iveco EuroCargo/Tector 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
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MODEL: EuroCargo / Tector
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YEAR: 2002, 2003, 2004, 2005, 2006, 2007, 2008
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LANGUAGE: English/Italian
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FORMAT: PDF (272 MB)
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EXCERPT:
INDEX OF SECTIONS
Section
General Specifications 1
Engine 2
Clutch 3
Gearbox 4
Propeller shafts 5
Rear axles 6
Front Axles 7
Suspensions 8
Wheels and tyres 9
Steering 10
Pneumatic system — brakes 11
Body and chassis 12
Service plan 13
Electric/electronic system 14
Print 603.93.391 Base - October 2004
32 FRONT AXLE 5845 EUROCARGO TECTOR 12-26 t
520615 Steering knuckle pin bearing replacement
Figure 56
Steering knuckle bearing replacement (5) is made using for their disassembly and assembly beater’s elements (1-2-3) 99374527 and handle 99370007 (4).
Use element (1) and handle (4) to disassemble the sealing ring (8) and the roller bearings (6-7) on the upper side.
Use element (3) and handle (4) to disassemble the sealing ring (9) and the roller bearings (10-11) on the lower side.
Figure 57
Roller bearing assembly (7): use element (1 and 2) and handle (4).
Roller bearing assembly (6): use element (2) and handle (4).
Roller bearing assembly (8): use elements (3 and 2) and handle (4).
Roller bearing assembly (9): use element (2) and handle (4).
Figure 58
Use beater 99374171 (4) and handle 99370007 (3) to place sealing rings (2 and 5) in the steering knuckle (1).
Refitting
Figure 59
Set on the axle (2) the steering knuckle (3) and place the articulated pin (1).
Set tool 99374400 (4) on the steering knuckle (3) and fasten it by using the same lower cover lock screws (5), clamping them with the right torque.
Place the pin (1) in the axle conical housing, screwing the pressure screw (6) with a torque having 10 ÷ 11 daNm.
Remove tool 99374400 (4) from the steering knuckle (3).
Before placing the pin (1), it is necessary to check that the conical housing on the axle and the pin surface are perfectly cleaned and dry, in order to avoid oil layers which could foster the pin rotation in its place during its introduction.
...
12-26T (603.93.111)....2
12-26T (603.93.391)....888
EUROCARGO TECTOR 12 TO 26 t....888
REPAIR MANUAL....888
PRELIMINARY REMARKS....890
SYMBOLS -WARNINGS....890
SYMBOLS - ASSISTANCE OPERATIONS....891
PRODUCT CODE....892
GENERAL WARNINGS....893
GENERAL WARNINGS ON THE ELECTRIC SYSTEM....895
Bonding and screening....896
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS....897
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES....897
UPDATE DATA....898
INDEX OF SECTIONS....900
SECTION 1 - General Specifications....902
General Specifications....902
COMPOSITION OF THE MODELS....904
IDENTIFICATION DATA AND LOCATION ON VEHICLE....914
FILLING UP....915
INTERNATIONAL LUBRICANT DESIGNATION....916
SECTION 2 - Engine....918
Engine....918
ENGINE IDENTIFICATION CODES....920
MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE....921
WARNINGS....921
High pressure CP3 pump....921
Rail and fittings....921
Injector....921
Low pressure tubing....921
High pressure tubing....921
ENGINE REMOVAL/REFITTING....922
Removal....922
Refitting....924
Tests and checks....924
Engine cooling filling system....924
Air bleeding from fuel system....925
Air bleeding from hydraulic power steering system....925
INJECTORS REPLACEMENT....926
Removal....926
Refitting....926
Tests and checks....928
REPLACING SEAL RING FRONT COVER DRIVING SHAFT....928
REPLACING SEAL RING FLYWHEEL HOUSING BOX....929
CYLINDER HEAD REMOVAL/REFITTING....930
Removal....930
Refitting....932
Tests and checks....932
Engine F4 AE 0481....936
GENERAL SPECIFICATIONS....938
ASSEMBLY DATA - CLEARANCES ....941
TIGHTENING TORQUE....947
AUXILIARY COMPONENTS....949
TOOLS....949
ENGINE OVERHAUL....957
DISASSEMBLY OF THE ENGINE AT THE BENCH....957
REPAIR INTERVENTIONS....965
CYLINDER GROUP....965
Controls and measurements....965
Head face check on the cylinder group....966
TIMING SYSTEM....966
Camshaft....966
Cam lift check and pin alignment check....967
BUSHES....967
Bush replacement....968
Tappets....968
Fitting tappets - camshaft....968
OUTPUT SHAFT....969
Measuring journals and crankpins....969
Replacing oil pump control gear....971
Fitting main bearings....971
Finding journal clearance....971
Checking output shaft shoulder clearance....972
CONNECTING ROD - PISTON ASSEMBLY....972
Pistons....973
Measuring piston diameter....973
Piston pins....974
Conditions for proper pin-piston coupling....974
Split rings....974
Connecting rods....975
Bushes....975
Checking connecting rods....976
Checking torsion....976
Checking bending....976
Fitting connecting rod-piston assembly....976
Connecting rod-piston coupling....976
Fitting split rings....977
Fitting connecting rod-piston assembly into cylinder barrels....977
Finding crankpin clearance....978
Checking piston protrusion....979
Timing gear case....979
Timing....980
Flywheel housing....980
ENGINE FLYWHEEL....981
Replacing engine flywheel ring gear....981
CYLINDER HEAD....985
Removing the valves....985
Checking cylinder head wet seal....986
Checking cylinder head supporting surface....986
VALVES....987
Removing carbon deposits, checking and grinding valves....987
Checking clearance between valve stem and valve guide and valve centering....987
VALVE GUIDE....988
VALVE SEATS....988
Regrinding - replacing the valve seats....988
VALVE SPRINGS....990
FITTING CYLINDER HEAD....990
Refitting the cylinder head....990
Fitting injectors....991
RODS....992
Rocker assembly....992
Tappet clearance adjustment....993
Intake manifold....994
Wiring support....996
LUBRICATION....1000
OIL PUMP....1002
HEAT EXCHANGER....1002
Oil pressure relief valve....1003
Oil vapour recycling....1004
COOLING SYSTEM....1006
Water Pump....1008
Viscous fan....1008
Thermostat....1009
BOOSTER....1009
Turbosupercharger....1009
Description....1009
TURBOSUPERCHARGER ACTUATOR....1010
Check and adjustment....1010
Actuator replacement....1010
TURBOSUPERCHARGER LAYOUT....1012
SYSTEM OF INJECTION FEEDING ELECTRONIC TALL PRESSURE COMMON RAIL....1014
General Specifications....1014
FEED SYSTEM....1016
FEED SYSTEM LAYOUT....1018
FUEL PREFILTER....1020
FUEL FILTER....1020
MECHANICAL SUPPLY PUMP....1021
Normal operating conditions....1021
Overpressure condition at outlet....1021
Drain conditions....1021
CP3 HIGH-PRESSURE PUMP....1022
HIGH-PRESSURE PUMP - INSIDE STRUCTURE....1023
Operating principle....1024
Operation....1026
RAIL....1026
DOUBLE STAGE OVERPRESSURE VALVE....1027
INJECTOR....1028
Injector in rest position....1028
Injection start....1028
Injection end....1028
PRESSURE LIMITER FOR FUEL RETURN....1028
Engine F4 AE 0681....1032
GENERAL SPECIFICATIONS....1034
ASSEMBLY DATA - CLEARANCES....1037
ENGINE F4AE0681 OVERHAUL....1045
Engine removal at the bench....1045
TIMING SYSTEM....1046
Camshaft....1046
BUSHES....1046
CYLINDER HEAD VALVE SEATS....1048
Cylinder head fastening screw tightening....1050
LUBRICATION....1052
COOLING SYSTEM....1053
BOOSTER....1054
Turbosupercharger....1054
TURBOSUPERCHARGER ACTUATOR....1054
Check and adjustment....1054
TURBOSUPERCHARGER LAYOUT....1056
Troubleshooting Guide....1058
FOREWORD....1060
Diagnosis through instruments....1060
DIAGNOSTICS....1062
SECTION 3 - Clutch....1072
Clutch....1072
DESCRIPTION....1074
Clutch....1074
SPECIFICATIONS AND DATA....1074
DIAGNOSTICS....1078
TIGHTENING TORQUES....1081
TOOLS....1081
REMOVAL AND REFITTING....1082
Removal....1082
Refitting....1082
DRIVEN PLATE OVERHAUL....1082
Damper hub check....1082
Friction gaskets....1082
THRUST BEARING REMOVAL - REFITTING....1083
REPLACING CLUTCH SHAFT SUPPORT BEARING....1083
HYDRAULIC CONTROL....1084
Mini-servoclutch (13” - 13”/14” clutches)....1084
Clutch disengagement cylinder (13” - 13”/14” clutches)....1084
13” - 13”/14” clutch mounting assembly....1085
13” - 13”/14” clutch wear check....1085
Midi-servoclutch cylinder (15”/16” clutches)....1086
Clutch disengagement cylinder (15”/16” clutches)....1086
15”/16” clutch wear check....1087
15”/16” clutch mounting assembly....1087
CLUTCH DISENGAGEMENT CYLINDER TIP ADJUSTMENT (New 15”/16” clutch)....1088
ADJUSTMENT OF STOP AND PEDAL POSITIONING SCREWON THE CLUTCH PEDAL....1089
Clutch pedal clearance....1089
Clutch pedal travel....1089
CLUTCH CONTROL SYSTEM BLOW-OFF PROCEDURE....1089
SECTION 4 - Gearbox....1090
Gearbox....1090
DIAGNOSTICS....1092
Gears control connection....1094
Gearbox control tie-rods adjustment....1094
Gearbox 2855S.6....1098
DESCRIPTION....1100
SPECIFICATIONS AND DATA....1101
TIGHTENING TORQUES....1104
TOOLS....1105
GEARBOX 2855S.6 REMOVAL/REFITTING....1110
Removal....1110
Refitting....1110
GEARBOX DISASSEMBLY....1112
Checks....1115
GEARBOX ASSEMBLY....1116
Bearings pre-load adjustment for secondary shaft....1116
PRIMARY SHAFT DISASSEMBLY....1122
PRIMARY SHAFT ASSEMBLY....1124
MOTION INLET SHAFT DISASSEMBLY....1127
MOTION INLET SHAFT ASSEMBLY....1127
Motion inlet shaft bearing adjustment....1127
SECONDARY SHAFT DISASSEMBLY....1128
SECONDARY SHAFT ASSEMBLY....1128
INTERNAL DRIVE SHAFT DISASSEMBLY....1128
INTERNAL DRIVE SHAFT ASSEMBLY....1128
EXTERNAL CONTROL SHAFT DISASSEMBLY....1129
EXTERNAL CONTROL BOX ASSEMBLY....1130
Idle-R.M. switch adjustment....1132
Gearbox 2865S.6....1134
DESCRIPTION....1136
SPECIFICATIONS AND DATA....1138
TIGHTENING TORQUES....1140
TOOLS....1141
GEARBOX 2865S. 5 REMOVAL/ REFITTING....1146
Removal....1146
Refitting....1146
GEARBOX DISASSEMBLY....1148
Rear cover sealing gasket replace-ment....1151
Checks....1152
GEARBOX ASSEMBLY....1152
Bearings pre-loading adjustment for secondary shaft....1153
PRIMARY SHAFT DISASSEMBLY....1157
PRIMARY SHAFT ASSEMBLY....1160
MOTION ENTRY SHAFT DISASSEMBLY....1162
MOTION ENTRY SHAFT ASSEMBLY....1163
SECONDARY SHAFT DISASSEMBLY....1163
SECONDARY SHAFT ASSEMBLY....1163
INTERNAL CONTROL SHAFT DISASSEMBLY....1164
INTERNAL CONTROL SHAFT ASSEMBLY....1164
EXTERNAL CONTROL SHAFT DISASSEMBLY....1164
EXTERNAL CONTROL BOX ASSEMBLY....1165
Idle-R.M. switch adjustment....1167
Gearbox 2870S.9....1168
DESCRIPTION....1170
SPECIFICATIONS AND DATA....1171
TIGHTENING TORQUES....1174
TOOLS....1175
GEARBOX 2870S. 9 REMOVAL/ REFITTING....1180
Removal....1180
Refitting....1180
GEARBOX DISASSEMBLY....1182
Checks....1186
GEARBOX ASSEMBLY....1187
Bearings pre-load adjustment for secondary shaft....1187
Idle-Reverse Gear switch adjustment....1193
PRIMARY SHAFT DISASSEMBLY....1194
PRIMARY SHAFT ASSEMBLY....1196
MOTION INLET SHAFT DISASSEMBLY....1196
MOTION INLET SHAFT ASSEMBLY....1197
Motion inlet shaft bearing adjustment....1197
SECONDARY SHAFT DISASSEMBLY....1197
SECONDARY SHAFT ASSEMBLY....1197
INTERNAL DRIVE SHAFT DISASSEMBLY....1197
INTERNAL DRIVE SHAFT ASSEMBLY....1198
EXTERNAL DRIVE CASE DISASSEMBLY....1198
EXTERNAL DRIVE CASE ASSEMBLY....1199
EPICYCLIC REDUCTION GEAR ASSEMBLY....1202
Operating diagrams about pneumatic epicyclic reduction gear drive circuit....1202
DISASSEMBLY....1204
Checks....1206
ASSEMBLY....1207
Gearbox 2895S.9....1212
DESCRIPTION....1214
SPECIFICATIONS AND DATA....1215
TIGHTENING TORQUE....1218
TOOLS....1219
GEARBOX REMOVAL/REFITTING....1224
Removal....1224
Refitting....1224
GEARBOX DISASSEMBLING....1224
Checks....1228
GEARBOX ASSEMBLING....1228
Adjusting transmission shaft bearing pre - load....1228
Idle-R.M. switch adjustment....1233
MAIN SHAFT DISASSEMBLING....1234
MAIN SHAFT ASSEMBLING....1236
INPUT SHAFT DISASSEMBLING....1237
INPUT SHAFT ASSEMBLING....1237
TRANSMISSION SHAFT....1237
Bearing replacement....1237
INTERNAL CONTROL SHAFT DISASSEMBLING....1238
INTERNAL CONTROL SHAFT ASSEMBLING....1238
EXTERNAL CONTROL BOX DISASSEMBLING....1238
EXTERNAL CONTROL BOX ASSEMBLY....1239
EPICYCLIC REDUCTION GEAR ASSEMBLY....1242
Operating diagrams about pneumatic epicyclic reduction gear drive circuit....1242
DISASSEMBLY....1244
Checks....1246
ASSEMBLY....1247
Allison gearbox MD 3060P....1252
DESCRIPTION....1254
CHARACTERISTICS AND DATA....1257
MAIN OPERATION ANOMALIES....1258
TIGHTENING TORQUES....1266
TOOLS....1266
REMOVAL/ REFITTING (ALLISON) GEARBOX....1268
Removal....1268
Refitting....1269
REMOVAL AND REFITTING GEARBOX CONTROL MODULE AGAIN....1270
Disconnecting....1270
Refitting....1270
REPLACING SPEED SENSORS....1270
Replacing turbine speed sensor....1270
Engine revolutions sensor replacement....1271
Replacing the output speed sensor....1271
REPLACING OIL LEVEL SENSOR....1271
REPLACING OIL SUCTION FILTER....1272
REPLACING THE SOLENOID VALVES....1272
REPLACING PLANE GASKETS IN GEARBOX CONTROL MODULE....1273
REPLACING PRESSURE SWITCH F3....1274
REPLACING THE SEAL RING ON THE OUTPUT SHAFT....1274
Gearbox EATON FSO 5206B....1276
DESCRIPTION....1278
POSITION OF GEARSHIFT IDENTIFICATION TAG....1279
SPECIFICATIONS AND DATA....1280
Gear selection and engagement grid....1283
TIGHTENING TORQUES....1284
TOOLS....1286
REMOVAL/REFITTING (EATON FSO5206B) GEARBOX....1290
Removal....1290
Refitting....1290
EXPERIMENTAL TOOLS....1292
GEARSHIFT OVERHAUL....1293
Checks....1293
GEAR DRIVE CASE....1293
Disassembling....1293
Assembling....1294
Refitting....1296
Disassembling the gearbox....1297
MOTION INLET SHAFT....1300
Disassembling....1300
Assembling....1300
OUTPUT SHAFT....1300
Disassembling....1300
Assembling....1304
INTERNAL DRIVING SHAFT....1308
Disassembling....1308
Assembling....1309
Gearbox assembling....1310
Adjusting the axial play of countershaft bearings....1313
SECTION 5 - Propeller shafts....1316
Propeller shafts....1316
DESCRIPTION....1318
PROPELLER SHAFT LAYOUT ON VEHICLES....1323
PROPELLER SHAFT SPECIFICATIONS AND DATA....1324
DIAGNOSTICS....1326
TIGHTENING TORQUES....1326
SLIDING PROPELLER SHAFT REMOVAL-REFITTING....1327
Removal....1327
Refitting....1327
FIXED PROPELLER SHAFT REMOVAL-REFITTING....1327
CHECKING PROPELLER SHAFTS ON VEHICLE....1327
SECTION 6 - Rear axle....1328
Rear axles....1328
Axles in tandem ArvinMeritor SP 145 E....1330
Axles in tandem (Intermediate) - ArvinMeritor PD 145 E (R 2468)....1332
DESCRIPTION....1334
LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE....1335
SPECIFICATIONS AND DATA....1336
TIGHTENING TORQUES....1338
TOOLS....1341
EXPERIMENTAL TOOLS....1347
INTERMEDIATE AXLE DISCONNECTION/ RECONNECTION (with Hendrickson suspensions)....1350
Disconnection....1350
Reconnection....1350
SERVICING INTERMEDIATE AXLE ASSEMBLY PD 145 E (R 2468)....1352
AIR BREATHER REMOVAL-REFITTING....1352
SERVICING WHEEL HUBS....1352
Checking wheel hub components....1353
ASSEMBLING WHEEL HUBS....1354
REMOVING DIFFERENTIAL GEAR - TRANSFER BOX (with rear axle on stand 99322215)....1357
REFITTING DIFFERENTIAL GEAR - TRANSFER BOX (with rear axle on stand 99322215)....1357
REPAIRING INTER-AXLE UNIT....1358
Dismantling inter-axle unit....1358
Checking inter-axle unit components....1360
Fitting inter-axle unit....1360
Adjusting drive input shaft bearing end float....1362
Adjusting differential lock and inter-axle control pin end-stop....1363
REPAIRING MAIN DIFFERENTIAL-DISMANTLING DIFFERENTIAL CASING....1363
Dismantling gear cage....1367
Checking differential components....1367
Assembling gear cage....1368
ASSEMBLING DIFFERENTIAL CASING....1369
Calculating bevel pinion position in differential casing....1369
COMPUTATIONAL EXAMPLES....1370
Adjusting the cap gap....1373
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)....1375
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT....1378
Axles in tandem (Rear) - ArvinMeritor PR 140 E (R 0868)....1382
DESCRIPTION....1384
LOCATION OF DIFFERENTIAL UNIT - COMPLETE REAR AXLE DESCRIPTION PLATES....1385
SPECIFICATIONS AND DATA....1386
TIGHTENING TORQUES....1388
TOOLS....1390
SERVICING REAR AXLE ASSEMBLY PR 140 E (R 0868)....1395
AIR BREATHER REMOVAL/INSTALLATION....1395
OVERHAULING WHEEL HUBS....1395
REMOVING DIFFERENTIAL (with axle on stand 99322215)....1395
REFITTING DIFFERENTIAL (with axle on stand 99322215)....1395
REFITTING DIFFERENTIAL (with axle on stand 99322215)....1395
REPAIRING DIFFERENTIAL....1396
Removing differential lock....1396
Dismantling differential casing....1397
Dismantling gear cage....1398
Dismantling bevel pinion support....1398
Checking differential components....1402
Assembling gear cage....1402
Specimen calculations....1404
Assembling differential casing....1404
ADJUSTING THE CAP GAP....1406
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)....1409
ArvinMeritor Axle MS 08-125....1412
DESCRIPTION....1414
LOCATION OF DIFFERENTIAL UNIT - COMPLETE REAR AXLE DESCRIPTION PLATES....1415
TECHNICAL NAME....1415
FEATURES AND DATA....1416
DIAGNOSTICS....1418
TIGHTENING TORQUES....1420
TOOLS....1423
REAR AXLE DISCONNECTION-RECONNECTION....1427
Rear axle disconnection Vehicles with a mechanical suspension....1427
Rear axle disconnection Vehicles with a pneumatic suspension....1429
Axle reconnection....1430
DIFFERENTIAL DISCONNECTION-RECONNECTION WITH THE AXLE ON THE VEHICLE....1431
Disconnection....1431
Reconnection....1431
REAR AXLE ASSEMBLY OVERHAUL....1432
Air vent disconnection and reconnection....1432
Wheel hub overhaul....1432
Check parts making up the wheel hubs....1436
Replacement of wheel holding down studs....1436
Wheel hub mounting....1436
FIXING THE DIFFERENTIAL....1440
Dismounting the differential box....1440
DISMOUNTING THE WHEELWORK BOX....1441
BEVEL PINION SUPPORT DISASSEMBLING....1442
Check of parts making up the differential....1445
MOUNTING THE WHEELWORK BOX....1445
MOUNTING BEVEL PINION SUPPORT....1446
CALCULATION EXAMPLES....1449
MOUNTING THE DIFFERENTIAL BOX....1449
Adjusting cap opening out....1450
FIXING CROWN WHEEL AND PINION ASSEMBLY CONTACTS (AFTER MOUNTING)....1453
Directions to adjust and check the operation of the transmitter for checking differential locking device insertion.....1457
ArvinMeritor Axle MS10 - 144....1458
DESCRIPTION....1460
LOCATION OF DIFFERENTIAL UNIT - COMPLETE REAR AXLE DESCRIPTION PLATES....1461
TECHNICAL NAME....1461
SPECIFICATIONS AND DATA....1462
DIAGNOSTICS....1464
TIGHTENING TORQUES....1466
TOOLS....1468
REAR AXLE REMOVAL/ REFITTING (vehicles with pneumatic suspensions)....1474
Removal....1474
Refitting....1474
REAR AXLE REMOVAL/ REFITTING (vehicles with mechanical suspensions)....1475
Removal....1475
Refitting....1475
OVERHAULING THE REAR AXLE ASSEMBLY....1476
OVERHAULING THE WHEEL HUBS....1476
Disassembly....1476
Replacing wheel hub bearings....1477
Checking the parts forming the wheel hubs....1478
Replacing the wheel fixing pins....1478
REMOVAL THE DIFFERENTIAL (with axle on stand no. 99322215)....1481
REFITTING THE DIFFERENTIAL (with axle on stand no. 99322215)....1481
FIXING THE DIFFERENTIAL....1482
Disassembly the differential box....1482
Disassembly the wheelwork box....1484
Disassembly bevel pinion support....1485
Check of parts making up the differential....1486
Assembly the wheelwork box....1486
Assembly bevel pinion support....1488
Assembly the differential box....1492
Adjusting cap opening out....1494
BEVEL TORQUE CONTACTS CORRECTION (AFTER ASSEMBLY)....1496
AXLES WITH DIFFERENTIAL LOCKING DEVICE....1499
Description....1499
TIGHTENING TORQUES....1500
REMOVAL THE DIFFERENTIAL (with axle on stand no. 99322215)....1501
FIXING THE DIFFERENTIAL....1501
Disassembly of the differential locking device....1501
Assembly of the differential locking device....1502
Directions to adjust and check the operation of the transmitter for checking differential locking insertion.....1503
ArvinMeritor Axle MS10 - 164....1504
DESCRIPTION....1506
LOCATION OF DIFFERENTIAL UNIT - COMPLETE REAR AXLE DESCRIPTION PLATES....1507
TECHNICAL NAME....1507
SPECIFICATIONS AND DATA....1508
DIAGNOSTICS....1509
TIGHTENING TORQUES....1511
TOOLS....1513
REAR AXLE REMOVAL/ REFITTING (with pneumatic suspensions)....1518
Removal....1518
Refitting....1518
REAR AXLE REMOVAL/ REFITTING (with mechanical suspensions)....1519
Removal....1519
Refitting....1519
OVERHAULING THE REAR AXLE ASSEMBLY....1520
OVERHAULING THE WHEEL HUBS....1520
Disassembly....1520
Replacing wheel hub bearings....1521
Checking the parts forming the wheel hubs....1522
Replacing the wheel fixing pins....1522
DIFFERENTIAL GEAR REMOVAL AND REFITTING (with rear axle on stand 99322215)....1525
Removal....1525
Refitting....1525
DIFFERENTIAL GEAR REPAIR....1526
Differential gear disassembly....1526
Gearing case disassembly....1527
BEVEL PINION DISASSEMBLY FROM SUPPORT....1529
Check of parts composing differential gearing assembly....1529
Gearing case assembly....1530
FITTING THE SUPPORT ON THE BEVEL PINION....1531
Differential case assembly....1534
CAP RETRACTION ADJUSTMENT....1536
BEVEL TORQUE CONTACTS CORRECTION (AFTER ASSEMBLY)....1539
Instructions for adjusting and verifying transmitter operation to check insertion of differential gear locking....1542
WORK ON THE VEHICLE....1543
REPLACING THE BEVEL PINION SUPPORT SEAL RING....1543
Disassembly....1543
Assembly....1544
ArvinMeritor Axle MS13 - 165....1546
DESCRIPTION....1548
LOCATION OF DIFFERENTIAL UNIT - COMPLETE REAR AXLE DESCRIPTION PLATES....1549
TECHNICAL NAME....1549
SPECIFICATIONS AND DATA....1550
DIAGNOSTICS....1551
TIGHTENING TORQUES....1553
TOOLS....1555
OVERHAULING THE REAR AXLE ASSEMBLY....1560
OVERHAULING THE WHEEL HUBS....1560
Removal....1560
Replacing wheel hub bearings....1562
Checking the parts forming the wheel hubs....1562
Replacing the wheel fixing pins....1562
REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215)....1566
Removal....1566
Refitting....1566
REPAIRING THE DIFFERENTIAL....1567
Removing the differential....1567
Removing the gearcase....1568
REMOVING THE BEVEL PINION FROM THE SUPPORT....1570
Differential component check....1570
Fitting the gear housing....1571
FITTING THE MOUNT ON THE BEVEL PINION....1572
Reassembling the differential housing....1574
ADJUSTING THE CAP GAP....1576
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)....1579
Instructions for adjusting and verifying transmitter operation to check insertion of differential gear locking....1582
WORK ON THE VEHICLE....1583
REPLACING THE BEVEL PINION MOUNT SEAL....1583
Disassembly....1583
Assembly....1584
SECTION 7 - Front Axle....1586
Front Axles....1586
Front axle 5845....1588
DESCRIPTION....1590
Characteristic angles....1593
SPECIFICATIONS AND DATA....1595
DIAGNOSTICS....1597
TIGHTENING TORQUES....1600
TOOLS....1601
AXLE REMOVAL AND REFITTING....1605
Front axle removal....1605
Front axle refitting....1606
CHECKS ON THE VEHICLE....1606
Tie rods....1606
Articulated joints....1606
Check clearance of articulated joints....1606
FRONT WHEEL SET UP....1607
Setting of clips and headlights....1607
Electronic compensation for rim maladjust-ment....1608
Wheel alignment....1608
Toe-in check....1609
Check of wheel inclination (Camber)....1609
Check upright angle of inclination (King Pin) and clearance angle (Caster)....1609
Check steering angles....1610
OVERHAUL OF THE FRONT AXLE ASSY....1611
REMOVAL AND REFITTING OF WHEEL HUBS....1611
Removal....1611
Replacement of sealing ring....1612
Replacement of wheel stud bolts....1613
Wheel hub reattachment....1613
Check wheel hub end play....1614
Rolling torque survey....1614
Cross tie rod removsl and refitting....1615
Replacement of cross tie rod articulated pins....1615
Cross tie rod lever removal and refit-ting....1616
Longitudinal tie rod lever removal and refitting....1616
Steering knuckle pin removal and re-fitting....1616
Removal....1616
Steering knuckle pin bearing replacement....1617
Refitting....1617
Check and adjustment of clearance between steering knuckle and axle....1618
CHECKS AND MEASUREMENTS OF THE AXLE UNIT....1619
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins....1619
Check hole inclination for steering knuckle pins....1620
Front axles 5842/5 - 5851/5....1622
DESCRIPTION....1624
Characteristic angles....1626
SPECIFICATIONS AND DATA....1628
DIAGNOSTICS....1630
TIGHTENING TORQUES....1633
TOOLS....1634
FRONT AXLE REMOVAL - REFITTING (Mechanical suspension)....1638
Removal....1638
Refitting....1638
FRONT AXLE REMOVAL - REFITTING (Pneumatic suspension)....1639
Removal....1639
Refitting....1639
FRONT WHEEL SET UP....1640
Setting of clips and headlights....1640
Electronic compensation for rim maladjustment....1641
Wheel alignment....1641
Toe-in check....1642
Check of wheel inclination (Camber)....1642
Check upright angle of inclination (King Pin) and clearance angle (Caster)....1642
Check steering angles....1643
OVERHAUL OF THE FRONT AXLE ASSY....1644
Removal and refitting of wheel hubs....1644
Sealing ring replacement....1644
Wheel hubs refitting....1645
End play adjustment of wheel hub bearings....1645
Rolling torque check....1645
REPLACEMENT OF WHEEL HUB BEARINGS....1646
REPLACEMENT OF STUD BOLTS FOR WHEEL CLAMPING....1647
CROSS TIE ROD REMOVAL AND REFITTING....1647
REPLACEMENT OF CROSS TIE ROD ARTICULATED JOINTS....1648
CROSS TIE ROD LEVER REMOVAL AND REFITTING....1648
LONGITUDINAL TIE ROD LEVER REMOVAL AND REFITTING ....1648
STEERING KNUCKLE PIN REMOVAL AND REFITTING....1648
Removal....1648
Refitting....1649
Check and adjustment of clearance between steering knuckle and axle....1650
STEERING KNUCKLE PIN BEARING REPLACEMENT ....1651
CHECKS AND MEASUREMENTS OFTHE AXLE UNIT....1652
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins....1652
Check hole inclination for steering knuckle pins....1653
Front axle 5871/5....1654
DESCRIPTION....1656
Characteristic angles....1658
SPECIFICATIONS AND DATA....1660
DIAGNOSTICS....1662
TIGHTENING TORQUES....1665
TOOLS....1666
FRONT WHEEL SET UP....1670
Setting of clips and headlights....1670
Electronic compensation for rim maladjustment ....1671
Wheel alignment....1671
Toe-in check....1672
Check of wheel inclination (Camber)....1672
Check upright angle of inclination (King Pin) and clearance angle (Caster)....1672
Check steering angles....1673
FRONT AXLE REMOVING AND REFITTING (Mechanical and pneumatic suspension)....1674
OVERHAULING THE FRONT AXLE ASSEMBLY....1674
Removing the wheel hubs....1674
Replacing the wheel hub bearings....1674
Replacing seal....1675
Replacing wheel studs....1675
Refitting wheel hubs....1676
Adjusting wheel hub bearing end play....1676
Checking the rolling torque....1676
REMOVING AND REFITTING TRACK ROD....1677
REPLACING TRACK ROD BALL JOINT....1677
CHECKING BALL JOINT END PLAY FOR RACK ROD AND DRAG LINK....1677
Replacing ball joint....1677
REMOVING AND REFITTING TRACK ROD ARMS ....1678
REMOVING AND REFITTING DRAG LINK ARM....1678
REMOVING AND REFITTING THE KINGPIN....1678
Removing....1678
Refitting....1679
Checking and adjusting play between stub axle and axle....1679
STEERING KNUCKLE PIN BEARING REPLACEMENT....1680
CHECKS AND MEASUREMENTS ON AXLE BODY....1681
Checking surface flatness of leaf spring seating with respect to holes for kingpins.....1681
Checking inclination of holes for kingpins....1682
Front axle 5860....1684
DESCRIPTION....1686
Characteristic angles....1687
SPECIFICATIONS AND DATA....1689
DIAGNOSTICS....1691
TIGHTENING TORQUES....1694
FRONT WHEEL SET UP....1695
Setting of clips and headlights....1695
Electronic compensation for rim maladjustment....1696
Wheel alignment....1696
Toe-in check....1697
Check of wheel inclination (Camber)....1697
Check upright angle of inclination (King Pin) and clearance angle (Caster)....1697
Check steering angles....1698
OVERHAUL OF THE FRONT AXLE ASSY ....1699
Wheel hub (flanged unit-bearing) removal and refitting....1699
Removal....1699
Replacing the wheel fastening studs....1700
Wheel hubs refitting....1700
CROSS TIE ROD REMOVAL AND REFITTING....1701
REPLACEMENT OF CROSS TIE ROD ARTICULATED JOINTS ....1701
CROSS TIE ROD LEVER REMOVAL AND REFITTING....1701
LONGITUDINAL TIE ROD LEVER REMOVAL AND REFITTING....1702
STEERING KNUCKLE PIN REMOVAL AND REFITTING....1702
Removal....1702
Steering knuckle pin removal and refitting....1702
Refitting....1703
Checking and adjusting the play between the kingpin and the front axle....1704
CHECKS AND MEASUREMENTS OFTHE AXLE UNIT....1705
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins....1705
Check hole inclination for steering knuckle pins....1706
SECTION 8 - Suspensions....1708
Suspensions....1708
Front and rear mechanical suspensions....1710
DESCRIPTION....1712
FRONT LEAF SPRINGS....1712
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA....1714
FRONT SUSPENSION - Models 110EL..-120EL......1714
FRONT SUSPENSION - Models 120E..-130E......1715
FRONT SUSPENSION - Models 120E..-120E..D-130E..-130E..D-130E18RS-140E..-140E.. RS-150E..-150E..RS....1716
FRONT SUSPENSION - Models 160E..-160E..RS....1717
FRONT SUSPENSION - Models 180E..-190EL..-260E......1718
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA.....1719
FRONT SUSPENSION - Models 120E..-130E......1719
FRONT SUSPENSION - Models 120E..D-130E..D-140E..-140E..RS-150E......1720
FRONT SUSPENSION - Models 180E......1721
FRONT SHOCK ABSORBERS....1722
Assembly diagrams....1722
SPECIFICATIONS AND DATA....1723
REAR LEAF SPRINGS....1725
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA....1727
REAR SUSPENSION - Models 110EL..-120EL......1727
REAR SUSPENSION - Models 120E..-130E......1728
REAR SUSPENSION - Models 120E..-130E..- 130E18RS....1729
REAR SUSPENSION -Models 120E..-120E..D-130E..-130E..D-140E..-140E..RS-150E..-150E18RS-160E..-160E..RS....1730
REAR SUSPENSION - Models 180E......1731
REAR SUSPENSION - Models 190EL......1732
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA....1733
REAR SUSPENSION 120E..-130E......1733
REAR SUSPENSION - Models 120E..D-130E..D-140E..-140E..RS-150E......1734
REAR SUSPENSION 180E......1735
HENDRICKSON REAR SUSPENSION Models 260E......1736
Removal....1736
Refitting....1736
REAR SHOCK ABSORBERS....1738
Assembly diagrams....1738
SPECIFICATIONS AND DATA....1739
Shock absorber features and data - Models 260E......1740
DIAGNOSTICS....1741
TIGHTENING TORQUES....1745
TOOLS....1745
EXPERIMENTAL TOOLS....1746
FRONT MECHANICAL SUSPENSION REMOVAL- REFITTING....1748
Removal....1748
Refitting....1748
REAR MECHANICAL SUSPENSION REMOVAL- REFITTING....1749
Removal....1749
Refitting....1749
FRONT SHOCK ABSORBERS....1750
Removal....1750
Refitting....1750
REAR SHOCK ABSORBERS....1750
Removal....1750
Refitting....1750
FRONT SWAY BAR....1750
Removal....1750
Refitting....1750
REAR SWAY BAR....1751
Removal....1751
Refitting....1751
REPAIRS....1751
REPLACING LEAF-SPRING BUSHINGS....1751
DISCONNECTING AND RECONNECTING REAR LEAF-SPRING BUSHINGS....1751
Disconnecting rear bushings....1751
Reconnecting rear bushings....1754
Disconnecting front bushings....1755
Reconnecting front bushings....1755
DISCONNECTING AND RECONNECTING FRONT LEAF-SPRING BUSHINGS....1756
Disconnecting front bushings....1756
Reconnecting front bushings....1757
Disconnecting rear bushings....1757
Reconnecting front bushings....1758
Front and rear pneumatic suspensions....1760
PNEUMATIC SUSPENSIONS....1762
INTRODUCTION....1762
PNEUMATIC SUSPENSION ASSEMBLIES....1762
FRONT PNEUMATIC SUSPENSION....1762
LEAF SPRING SPECIFICATIONS AND DATA....1763
FRONT SUSPENSION - MODELS 120E..FP/130E..FP/140E..FP/150E..FP....1763
FRONT SHOCK ABSORBERS....1764
Assembly diagrams....1764
SPECIFICATIONS AND DATA....1764
REAR PNEUMATIC SUSPENSION....1765
REAR SHOCK ABSORBERS....1769
Assembly diagrams....1769
SPECIFICATIONS AND DATA....1770
Electronically controlled rear pneumatic suspension diagram (For Models 110EL..P-120EL..P)....1771
Cable-and-trunk diagram of pneumatic rear suspensions (For Models 120E..P-130E..P-140E..P-150E..P-160E..P-180E..P-190EL..P)....1772
Electronically controlled FULL PNEUMATIC suspension diagram (For Models 120E..FP-130E..FP-140E..FP-150E..FP)....1773
CHASSIS LIFTING/LOWERING AND LEVELLING....1774
Remote control....1774
REMOTE CONTROL DESCRIPTION AND OPERATION....1775
Lifting/lowering the chassis....1775
Chassis self-leveling....1775
Level ”M1” - ”M2”....1775
VEHICLE MAIN COMPONENT ARRANGEMENT....1776
SPECIFICATIONS AND DATA....1777
DIAGNOSTICS....1778
TIGHTENING TORQUES....1780
Rear pneumatic suspension of the HENDRICKSON type (Models 110EL..P - 120EL..P)....1781
TOOLS....1782
MAIN PNEUMATIC SYSTEM COMPONENTS....1783
Controlled-pressure valve....1783
Low pressure indicator....1783
Check valve....1783
Electro-pneumatic front axle distributor for 4 x 2 FP vehicles....1783
Operation....1784
Front axle lifting....1784
Front axle lowering....1784
Self-leveling....1784
Electro-pneumatic rear axle distributor for4 x 2 P/FP vehicles....1785
Operation....1785
Rear axle lifting....1785
Rear axle lowering....1785
Self-leveling....1785
Level sensor....1786
Air springs....1786
ECU....1786
REAR PNEUMATIC SUSPENSIONS REMOVAL-REFITTING....1787
Removal....1787
Refitting....1787
REAR SHOCK ABSORBERS....1788
Removal....1788
Refitting....1788
REAR SWAY BAR....1788
Removal....1788
Refitting....1788
REAR AIR SPRINGS....1788
Removal....1788
Refitting....1788
FRONT SHOCK ABSORBERS....1789
Removal....1789
Refitting....1789
FRONT AIR SPRINGS....1789
Removal....1789
Refitting....1789
FRONT PNEUMATIC SUSPENSION REMOVAL-REFITTING....1790
Removal....1790
Refitting....1790
FRONT SWAY BAR....1790
Removal....1790
Refitting....1790
REAR PNEUMATIC SUSPENSION REMOVAL-REFITTING....1791
Removal....1791
Refitting....1791
REAR AIR SPRINGS....1792
Removal....1792
Refitting....1792
REAR SHOCK ABSORBERS....1792
Removal....1792
Refitting....1792
REAR SWAY BAR....1793
Removal....1793
Refitting....1793
SECTION 9 - Wheels and Tires ....1794
Wheels and Tires....1794
DESCRIPTION....1796
SPECIFICATIONS AND DATA....1796
Tire pressure values....1796
TOOLS....1797
DIAGNOSTICS....1797
STATIC WHEELS BALANCING....1800
CORRECTION OF RESIDUAL STATIC UNBALANCE....1801
TIRE PRESSURE....1801
TIRE BEHAVIOUR DEPENDING ON PRESSURE....1802
SECTION 10 - Steering....1804
Steering....1804
DESCRIPTION....1806
SPECIFICATIONS AND DATA....1807
DIAGNOSTICS....1807
TIGHTENING TORQUES....1812
TOOLS....1812
ZF HYDRAULIC POWER STEERING (8095-8098)....1813
Description....1813
Hydraulic steering limiting....1816
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (ZF 8095-8098)....1817
Disconnection....1817
Reconnection....1818
HYDRAULIC STEERING LIMITER ADJUSTMENT....1819
TRW TAS 55 HYDRAULIC POWER STEERING....1820
Description....1820
Rectilinear running neutral position....1821
Right steering position....1822
Left steering position....1823
HYDRAULIC STEERING LIMITATION....1824
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (TRW TAS 55)....1825
Automatic adjustment setting of hydraulic steering limitation for TRWTAS 55 hydraulic power steering....1825
Automatic adjustment check....1825
Hydraulic drops adjustment....1826
AIR DRAIN FROM HYDRAULIC POWER STEERING CIRCUIT....1827
Hydraulic power steering oil level restoration....1827
MEASURE OF DRIVE CASE CLEARANCES DETECTED ON STEERING WHEEL....1827
MAXIMUM PRESSURE CHECK IN HYDRAULIC POWER STEERING SYSTEM....1827
SECTION 11 - Pneumatic System - Brakes....1828
Pneumatic System - Brakes....1828
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (MISCELLANEOUS AND GENERATORS)....1832
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (VALVES)....1833
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (TANKS AND ACCUMULATORS)....1839
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS)....1840
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CYLINDERS AND CALIPERS)....1841
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (COUPLING HALF-JOINTS AND HEADS)....1842
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (SIGNALING DEVICES AND SWITCHES)....1844
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (BRAKES)....1845
PIPINGS AND FITTINGS....1846
In general....1846
Rigid pipings reflanging....1846
Rigid pipings bending....1847
Rigid pipings cutting....1847
Flexible pipings replacement with threaded fittings....1848
Flexible pipings replacement with quick connection fittings....1849
BRAKING SYSTEM....1851
Principle diagram for single vehicles (Models 110 EL.. - 120 EL..)....1851
Principle diagram for vehicles adapted for towing (Models 110 EL.. - 120 EL..)....1852
Principle diagram for single vehicles (Models 120 E.. - 130 E.. - 140E.. - 150 E.. - 160E..)....1853
Principle diagram for vehicles adapted for towing (Models 120 E.. - 130 E.. - 140E.. - 150 E.. - 160E..)....1854
Principle diagram for single vehicles (Model 180 E.. - 190EL..)....1855
Principle diagram for vehicles adapted for towing (Model 180 E.. - 190EL..)....1856
Principle diagram for single vehicles (Model 260E) (with Hendrickson suspensions)....1857
ARRANGEMENT ON A VEHICLE OF MAIN BRAKING SYSTEM COMPONENTS....1858
DESCRIPTION....1859
Service braking....1859
Safety braking....1859
Engine brake....1859
Operation....1859
Parking braking....1859
BRAKES....1859
Front brakes....1859
Rear brakes....1859
DIAGNOSTIC....1860
TIGHTENING TORQUES....1871
TOOLS....1873
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM....1880
SPECIFICATIONS AND DATA - BRAKES....1885
CHECKS OF MAIN BRAKE SYSTEM COMPONENTS....1887
MAIN BRAKE SYSTEM COMPONENTS....1890
COMPRESSOR....1890
Diagnostics....1890
A.P.U. (Air Processing Unit)....1891
Operation....1892
Diagnostics....1893
ENGINE BRAKE SWITCH....1894
ENGINE BRAKE SOLENOID VALVE....1894
ENGINE BRAKE CONTROL OPERATING CYLINDER....1894
MANUAL DISCHARGE VALVE....1894
SAFETY VALVE (Optional)....1895
DUPLEX DISTRIBUTOR....1895
Unbraking....1896
Diagnostics....1896
PRESSURE RELIEF VALVE....1897
Operation....1897
Pressure limitation....1897
Bench calibration....1897
Diagnostics....1897
RELAY VALVE....1898
Diagnostics....1898
CHECK VALVE....1898
Operation....1898
PARKING BRAKE CONTROL MANUAL DISTRIBUTOR (Single vehicles)....1899
Diagnostics....1899
QUICK DISCHARGE VALVE....1901
TRIPLE CONTROL SERVODISTRIBUTOR AC 597 B....1901
Predominance adjustment....1901
Diagnostics....1901
COUPLING HEADS....1902
Operation....1902
PRESSURE PLUG VALVE....1902
MEMBRANE BRAKE CYLINDER (for disc brakes and drum brakes)....1902
COMBINED BRAKE CYLINDER....1903
Combined cylinder emergency unbraking device....1903
Repair interventions....1903
Diagnostics....1903
ABS SYSTEM WITH EBL FUNCTION....1904
”ABS” Anti-Lock Brake System....1904
”EBL” (Electronic Brake Limiter) anti-skid device....1904
ELECTRONIC UNIT....1904
Operation....1904
REVOLUTIONS SENSORS....1904
PHONIC WHEELS....1904
Operation....1904
ELECTRO-PNEUMATIC VALVE....1905
Operation....1905
BRAKE REPAIRS (Models ML 110 EL.. / 120 EL..)....1906
Front Brakes (Brake calipers of the PAN 17 type)....1906
Rear Brakes (Brake calipers of the PAN 17 type)....1906
Description....1906
Brake locking system and brake operation....1906
Automatic braking gaskets wear recovering device....1906
Efficiency check for braking gaskets/brake disc wear recovering device....1908
Braking gaskets replacement....1908
Checks....1908
Brake calipers disconnection and reconnection....1909
Disconnection....1909
Reconnection....1909
BRAKE CALIPERS REVISION....1909
Disassembly....1909
Check of component parts....1910
Assembly....1910
BRAKE DISCS REVISION....1913
Brake discs turning and grinding....1913
BRAKE REPAIRING....1914
Front brakes (Brake caliper KNORR SB6 type)....1914
Front and rear brakes (Brake caliper KNORR SN6-SN7 type)....1915
Operation (See previous figure)....1916
CHECKS....1916
Checking the automatic play recovery system efficiency....1916
Check of braking gaskets thickness....1917
REAR BRAKES REVISION....1919
Braking gaskets replacement....1919
Brake calipers disconnection and re-connection....1921
Disconnection....1921
Reconnection....1922
Wheel hubs disconnection and re-connection....1922
Disconnection....1922
Reconnection....1922
BRAKE CALIPERS REVISION TYPE SB6....1923
Disassembly....1923
Cleaning and check of component parts....1924
Assembly....1924
BRAKE CALIPER OVERHAUL TYPE SN6-SN7....1926
Disassembly....1926
Component part cleaning and check....1927
Assembly....1927
REAR DISC BRAKES REVISION (12-18 t)....1929
BRAKE DISCS REVISION....1929
BRAKE DISCS TURNING AND GRINDING....1929
REAR DRUM BRAKES - Model 260E28KE....1930
Brake position with Hendrickson suspension....1930
REAR BRAKES REVISION (26 t)....1931
Disassembly....1931
Check of component parts....1933
DRUM TURNING....1934
BRAKING GASKETS REPLACEMENT....1935
BRAKING GASKETS TURNING....1935
Assembly....1936
SECTION 12 - Body - Chassis....1942
Body - Chassis....1942
CAB....1944
General information....1944
PROTECTIVE BODY TREATMENTS....1945
Protective treatment....1945
Preparing the sheet metal (bonderizing)....1946
Applying the protective paint (electrophoresis)....1946
CHECKING THE GEOMETRY OF THE CHASSIS FRAME....1946
GENERAL RULES FOR WORKING ON THE CHASSIS FRAME....1946
Preparing the chassis frame for maintenance, checking and repair work authorized by IVECO....1946
Spot welding....1947
Welding instructions....1947
Bodybuilder work on the structural members of the IVECO chassis frame....1947
Drilling the chassis frame....1947
PRECAUTIONS....1948
Welds on the chassis frame....1949
CHASSIS FRAME....1950
REPAIRS AND CHECKS....1950
Measuring the side bend of the chassis frame....1951
Measuring the bend of the chassis frame downwards or upwards....1951
Measuring the movement of the chassis frame....1951
Measuring the torsion of the chassis frame....1952
CHASSIS REFERENCE DIMENSIONS....1953
CAB GEOMETRY....1960
SEAL APPLICATION DIAGRAM....1961
CAB ANCHORING AND TIGHTENING TORQUES....1964
TOOLS....1967
REPAIRS....1968
Cab anchoring....1968
Replacing cab suspension front and rear shock absorbers....1968
Removing-refitting front mounts and cab stabilizer bar....1968
HYDRAULIC CAB LIFTING SYSTEM....1969
Replacing hydraulic cylinder for cab tilting....1970
REPLACING WINDSCREEN WINDOW....1970
General....1970
Vibration knife....1970
Harmonic wire....1971
Removal (with harmonic wire)....1971
Preparing the windscreen opening....1971
Preparing the windscreen....1972
Refitting....1972
Replacing the winding window....1974
Replacing the window winder....1975
Replacing the fixed window....1975
INSTRUMENT PANEL....1977
Removal....1977
Refitting....1977
MIDDLE INSTRUMENT PANEL....1977
Removal....1977
Refitting....1978
INSTRUMENT PANEL COVERING....1978
Removal....1978
Refitting....1983
HEATING AND VENTILATION....1983
Removal....1983
Refitting....1983
SECTION 13 - Service plan....1984
Service plan....1984
SERVICING....1986
Service plan....1986
SERVICE FREQUENCY....1986
EXTRA PLAN OPERATIONS....1986
Extra plan operations (to be carried out possibly at the same time as a planned service operation)....1986
SCHEDULED MAINTENANCE OPERATIONS....1987
EXTRA-PLAN OPERATIONS....1987
SCHEDULED MAINTENANCE OPERATIONS....1990
EXTRA-PLAN OPERATIONS....1990
M1 SERVICE....1991
M2 SERVICE....1992
M3 SERVICE....1995
EXTRA-PLAN MAINTENANCE....1995
EP1 SERVICE....1995
EP2 SERVICE....1996
EP3 SERVICE....1996
EP4 SERVICE....1997
EP5 SERVICE....1997
SECTION 14 - Electric/Electronic system....1998
Electric/Electronic system....1998
PRELIMINARY REMARKS....2000
SYMBOLS - WARNINGS....2000
SYMBOLS - ASSISTANCE OPERATIONS....2001
PRODUCT CODE....2002
GENERAL WARNINGS....2003
GENERAL WARNINGS ON THE ELECTRIC SYSTEM....2005
CONCEPT OF GROUND AND ELECTROMAGNETIC COMPATIBILITY....2006
Practical tips....2007
CAN LINE....2008
Efficiency tests on the CAN line....2009
DESCRIPTION OF BASIC SYSTEM....2010
ELECTRICAL CHARACTERISTICS....2010
ENGINE COMPONENTS....2011
Engine F4AE0481....2011
Engine F4AE0681....2012
POWER NETWORK....2013
Positive network....2013
Power cable sections....2013
Negative network....2014
Ground point identification....2015
STARTING....2022
General remarks....2022
Starting from the driver’s seat (Cab hooked)....2022
Starting from the engine compartment (Cab tilted)....2023
ALTERNATOR....2024
STARTER MOTOR....2025
COMPONENT CODE....2026
JUNCTION CONNECTOR....2031
BULKHEAD....2076
INSTRUMENT PANEL....2092
CENTRAL DASHBOARD....2093
INSTRUMENT CLUSTER....2095
Description....2095
Models available....2097
OPTICAL INDICATORS ON THE CLUSTER....2098
(FAILURE) INDICATORS ON THE DISPLAY....2099
“POP-UP” EVENTS....2101
CLUSTER (PIN-OUT)....2102
CENTRAL INTERCONNECTING UNIT....2103
REMOTE-CONTROL SWITCH ASSEMBLY....2104
FUSE ASSEMBLY....2105
CONNECTOR ASSEMBLY....2107
STEERING COLUMN STALK....2114
POSITION OF ELECTRONIC CONTROL UNITS....2115
BODY CONTROLLER....2116
Linking connectors....2116
CONNECTOR PIN-OUT....2121
TACHOGRAPH....2122
DESCRIPTION OF EDC 7 INJECTION SYSTEM....2123
ABS....2147
ECAS....2154
ENGINE BRAKE....2167
IMMOBILIZER....2169
AUTOMATIC GEARBOX ALLISON WTEC III....2180
ELECTRONIC CENTRAL UNIT DMI (DATA MANAGEMENT INTERFACE) (OPT. 5626)....2228
AUXILIARY HEATER WEBASTO....2230
FAULT DIAGNOSIS....2243
Diagnosis Instruments....2243
System initialization screen....2244
DIAGNOSTIC screen (oly for Highline versions)....2245
Meanings of anomaly codes....2245
Description of fault codes (SPN)....2246
TROUBLESHOOTING....2248
Instrument Body Controller (IBC)....2248
Instrument Cluster (IC)....2263
“EDC 7" injection system....2268
MAINTENANCE SCHEDULE....2536
CIRCUIT CARDS....2538
Card 1: Positive direct to the batteries....2540
Card 2: Positive after main current switch....2541
Card 3: Positive after main current switch....2542
Card 4: Service power supply (+15/1)....2543
Card 5: Service power supply (+15/1)....2544
Card 6: Service power supply (+15/2)....2545
Card 7: Body Controller....2546
Card 8: Body Controller....2547
Card 9: Body Controller....2548
Card 10: EDC (Connector B)....2549
Card 11: EDC (Connector B)....2550
Card 12: EDC (Connectors A and C - 6 cylinders)....2551
Card 13: EDC (Connectors A and C - 4 cylinders)....2552
Card 14: Instrument Cluster / Tachograph prearrangement....2553
Card 15: Immobilizer....2554
Card 16: ABS (4X2)....2555
Card 17: ABS (6X4)....2556
Card 18: ECAS 4X2 P....2557
Card 19: ECAS 4X2 FP....2558
Card 20: Additional heater prearrangement AIRTOP2000....2559
Card 21: Additional heater prearrangement AIRTOP2000 with ADR....2560
Card 22: Manually controlled air-conditioning prearrangement....2561
Card 23: CAN line....2562
Card 24: Cigar lighter/Horns/Electric heater....2563
Card 25: Rotating lamps/Bed lights/ Emergency light/Headlamp washer....2564
Card 26: Electric window regulator/Sunroof (with and without the Bed Module)....2565
Card 27: Heated prefilter/Brake air drier/Pneumatic, heated seats....2566
Card 28: Central closing prearrangement/Adjustable, heated rearview mirrors....2567
Card 29: Main current remote-control switch (TGC)....2568
Card 30: Current Main Remote Control Switch (TGC) prearrangement (TGC)/ Compliance to rules ADR (TMP)....2569
Card 31: Cab tipping/Overall power takeoff....2570
Card 32: Fridge/Voltage reducer/Car radio....2571
Card 33: Loading board preset....2572
Card 34: Body builder connectors....2573
Card 35: Side- rear - total PTO /Transverse and longitudinal differential lock....2574
Card 36: Allison gearbox....2575
Card 37: Retarder (Allison gearbox)....2576
Card 38: Centrali unit (DMI) (opt. 5626)....2577
6-10T (603.93.101)....2578
EUROCARGO TECTOR 6 TO 10 t....2578
REPAIR MANUAL....2578
SPECIAL REMARKS....2580
Graphs and symbols....2581
INDEX OF SECTIONS....2584
SECTION 1 - General Specifications....2586
General Specifications....2586
COMPOSITION OF THE MODELS....2588
IDENTIFICATION DATA AND LOCATION ON VEHICLE....2596
FILLING UP....2597
INTERNATIONAL LUBRICANT DESIGNATION....2598
SECTION 2 - Engine....2600
Engine....2600
ENGINE IDENTIFICATION CODE....2602
MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE....2603
WARNINGS....2603
CP3 high pressure pump....2603
Rail and fittings....2603
Injector....2603
Low pressure pipes....2603
High pressure pipes....2603
ENGINE REMOVAL/REFITTING....2604
Removal....2604
Refitting....2606
Checks and inspections....2606
Topping up the engine cooling system....2606
Bleeding from the fuel system....2607
Bleeding air from the power steering system....2607
INJECTOR REPLACEMENT....2608
Removal....2608
Refitting....2608
Checks and inspections....2610
REPLACEMENT OF ENGINE FRONT SHAFT COVER SEALING RING....2610
REPLACEMENT OF FLYWHEEL CASE SEALING RING....2611
CYLINDER HEAD REMOVAL/REFITTING....2612
Removal....2612
Refitting....2614
Checks and inspections....2614
Engine F4 AE 0481....2618
GENERAL SPECIFICATIONS....2620
CLEARANCE DATA....2623
TIGHTENING TORQUE....2629
AUXILIARY COMPONENTS....2631
TOOLS....2632
ENGINE OVERHAUL....2639
ENGINE REMOVAL AT THE BENCH....2639
REPAIR OPERATIONS....2647
CYLINDER UNIT....2647
Checks and measurements....2647
Checking cam lift and pin alignment....2649
BUSHES....2649
Bush replacement....2650
Tappets....2650
Fitting tappets - camshaft....2650
OUTPUT SHAFT....2651
Measuring journals and crankpins....2651
Replacing oil pump control gear....2653
Fitting main bearings....2653
Finding journal clearance....2653
Checking output shaft shoulder clearance....2654
CONNECTING PISTON ASSEMBLY....2654
Pistons....2655
Measuring piston diameters....2655
Piston pins....2656
Conditions for proper pin-piston coupling....2656
Split rings....2656
Connecting rods....2657
Bushes....2657
Checking connecting rods....2658
Checking torsion....2658
Checking bending....2658
Fitting connecting rod-piston assembly....2658
Connecting rod-piston coupling....2658
Fitting split rings....2659
Fitting connecting rod-piston assembly into cylinder barrels....2659
Finding crankpin clearance....2660
Checking piston protrusion....2661
Timing gear case....2661
Timing....2662
Flywheel housing....2662
ENGINE FLYWHEEL....2663
Replacing engine flywheel ring gear....2663
CYLINDER HEAD....2667
Removing the valves....2667
Checking cylinder head wet seal....2668
Checking cylinder head supporting surface....2668
VALVES....2669
Removing carbon deposits, checking and grinding valves....2669
Checking clearance between valve stem and valve guide and valve centering....2669
VALVE GUIDE....2670
VALVE SEATS....2670
Regrinding - replacing the valve seats....2670
VALVE SPRINGS....2672
FITTING CYLINDER HEAD....2672
Refitting the cylinder head....2672
Assembling electro-injectors....2673
RODS....2674
Rocker assembly....2674
Adjusting tappet clearance....2675
Intake manifold....2676
Wiring support....2678
LUBRICATION....2682
OIL PUMP....2684
HEAT EXCHANGER....2684
Oil pressure relief valve....2685
Oil vapour recycling....2686
COOLING SYSTEM....2688
Water Pump....2690
Viscous fan....2690
Thermostat....2691
BOOSTER....2691
Turbosupercharger....2691
Description....2691
TURBOSUPERCHARGER ACTUATOR....2692
Check and adjustment....2692
Actuator replacement....2692
TURBOSUPERCHARGER LAYOUT....2694
COMMON RAIL....2696
General Specifications....2696
HYDRAULIC SYSTEM....2698
HYDRAULIC SYSTEM LAYOUT....2700
FUEL PREFILTER....2702
FUEL FILTER....2702
MECHANICAL SUPPLY PUMP....2703
Normal operating conditions....2703
Overpressure condition at outlet....2703
Drain conditions....2703
CP3 HIGH-PRESSURE PUMP....2704
HIGH-PRESSURE PUMP - INSIDE STRUCTURE....2705
Operating principle....2706
Operation....2708
RAIL....2708
OVERPRESSURE VALVE....2709
FLOW LIMITERS....2709
INJECTOR....2710
Injector in rest position....2710
Injection start....2710
Injection end....2710
PRESSURE LIMITER FOR FUEL RETURN....2710
Engine F4 AE 0681....2714
GENERAL SPECIFICATIONS....2716
ASSEMBLY DATA - CLEARANCES....2719
ENGINE F4AE0681 OVERHAUL....2727
Engine removal at the bench....2727
TIMING SYSTEM....2728
Camshaft....2728
BUSHES....2728
CYLINDER HEAD VALVE SEATS....2730
Cylinder head fastening screw tightening....2732
LUBRICATION....2734
COOLING SYSTEM....2735
BOOSTER....2736
Turbosupercharger....2736
TURBOSUPERCHARGER LAYOUT....2738
Troubleshooting guide....2740
FOREWORD....2742
Diagnosis through instruments....2742
DIAGNOSTICS....2744
SECTION 3 - Clutch....2754
Clutch....2754
DESCRIPTION....2756
Clutch....2756
SPECIFICATIONS AND DATA....2756
DIAGNOSTICS....2759
TIGHTENING TORQUES....2762
TOOLS....2762
REMOVAL AND REFITTING....2763
Removal....2763
Refitting....2763
DRIVEN PLATE OVERHAUL....2763
Damper hub check....2763
Friction gaskets....2763
BLEEDING AIR FROM CLUTCH CIRCUIT....2764
THRUST BEARING REMOVAL - REFITTING....2764
REPLACING CLUTCHSHAFT SUPPORT BEARING....2764
HYDRAULIC CONTROL....2765
Power-assisted master cylinder....2765
Connections....2765
Operating cylinder....2766
Clutch wear layout....2766
CHECKING AND ADJUSTMENT OF CLUTCH PEDAL TRAVEL....2767
Clutch pedal stop....2767
Clutch pedal idle stroke....2767
SECTION 4 - Gearboxes....2768
Gearboxes....2768
DIAGNOSTICS....2770
Gears control connection....2772
Gearbox control tie-rods adjustment....2772
Gearbox 2855.5 - 2855.6....2774
DESCRIPTION....2776
SPECIFICATIONS AND DATA....2777
TIGHTENING TORQUES....2780
TOOLS....2781
GEARBOX 2855.6 REMOVAL - REFITTING....2786
Removal....2786
Refitting....2786
GEARBOX DISASSEMBLY....2788
Checks....2791
GEARBOX ASSEMBLY....2792
Bearings pre-load adjustment for secondary shaft....2792
PRIMARY SHAFT DISASSEMBLY....2798
PRIMARY SHAFT ASSEMBLY....2800
MOTION INLET SHAFT DISASSEMBLY....2803
MOTION INLET SHAFT ASSEMBLY....2803
Motion inlet shaft bearing adjustment....2803
SECONDARY SHAFT DISASSEMBLY....2804
SECONDARY SHAFT ASSEMBLY....2804
INTERNAL DRIVE SHAFT DISASSEMBLY....2804
INTERNAL DRIVE SHAFY ASSEMBLY....2804
EXTERNAL CONTROL SHAFT DISASSEMBLY....2805
EXTERNAL CONTROL BOX ASSEMBLY....2806
Idle-R.M. switch adjustment....2808
Gearbox 2865.6....2810
DESCRIPTION....2812
SPECIFICATIONS AND DATA....2814
TIGHTENING TORQUES....2816
TOOLS....2817
GEARBOX 2865.5 DISENGAGEMENT/RE-ENGAGEMENT....2822
Disengagement....2822
Re-engagement....2822
GEARBOX DISASSEMBLY....2824
Rear cover sealing gasket replacement....2827
Checks....2828
GEARBOX ASSEMBLY....2828
Bearings pre-loading adjustment for secondary shaft....2829
PRIMARY SHAFT DISASSEMBLY....2833
PRIMARY SHAFT ASSEMBLY....2836
MOTION ENTRY SHAFT DISASSEMBLY....2838
MOTION ENTRY SHAFT ASSEMBLY....2839
SECONDARY SHAFT DISASSEMBLY....2839
SECONDARY SHAFT ASSEMBLY....2839
INTERNAL CONTROL SHAFT DISASSEMBLY....2840
INTERNAL CONTROL SHAFT ASSEMBLY....2840
EXTERNAL CONTROL SHAFT DISASSEMBLY....2840
EXTERNAL CONTROL BOX ASSEMBLY....2841
Idle-R.M. switch adjustment....2843
Gearbox 2870.9....2844
DESCRIPTION....2846
SPECIFICATIONS AND DATA....2847
TIGHTENING TORQUES....2850
TOOLS....2851
GEARBOX 2870.9 DISENGAGEMENT/RE-ENGAGEMENT....2856
Disengagement....2856
Re-engagement....2856
GEARBOX DISASSEMBLY....2858
Checks....2862
GEARBOX ASSEMBLY....2863
Bearings pre-load adjustment for secondary shaft....2863
Idle-Reverse Gear switch adjustment....2869
PRIMARY SHAFT DISASSEMBLY....2870
PRIMARY SHAFT ASSEMBLY....2872
MOTION INLET SHAFT DISASSEMBLY....2872
MOTION INLET SHAFT ASSEMBLY....2873
Motion inlet shaft bearing adjustment....2873
SECONDARY SHAFT DISASSEMBLY....2873
SECONDARY SHAFT ASSEMBLY....2873
INTERNAL DRIVE SHAFT DISASSEMBLY....2873
INTERNAL DRIVE SHAFT ASSEMBLY....2874
EXTERNAL DRIVE CASE DISASSEMBLY....2874
EXTERNAL CONTROL BOX ASSEMBLY....2875
EPICYCLIC REDUCTION GEAR ASSEMBLY....2878
Operating diagrams about pneumatic epicyclic reduction gear drive circuit....2878
DISASSEMBLY....2880
Checks....2882
ASSEMBLY....2883
SECTION 5 - Propeller shafts....2888
Propeller shafts....2888
DESCRIPTION....2890
SPECIFICATIONS AND DATA FOR ”FIXED” AND ”SLIDING” PROPELLER SHAFTS....2894
SPECIFICATIONS AND DATA FOR ”SINGLE-SECTION” PROPELLER SHAFTS....2895
DIAGNOSTICS....2896
TIGHTENING TORQUES....2896
SINGLE-SECTION PROPELLER SHAFT DISENGAGEMENT - RE-ENGAGEMENT....2897
Disengagement....2897
Re-engagement....2897
SLIDINGPROPELLERSHAFT DISENGAGEMENT - RE-ENGAGEMENT....2898
Disengagement....2898
Re-engagement....2898
TWO-SECTION PROPELLER SHAFT DISENGAGEMENT - RE-ENGAGEMENT....2898
CHECK OF VEHICLE PROPELLER SHAFTS....2898
SECTION 6 - Rear axles 4517 and 4521....2900
Rear axles 4517 and 4521....2900
DESCRIPTION....2902
SPECIFICATIONS AND DATA....2904
DIAGNOSTICS....2906
TIGHTENING TORQUES....2908
TOOLS....2912
REAR AXLE DISENGAGEMENT/RE-ENGAGEMENT (with mechanical suspensions)....2916
Disengagement....2916
Re-engagement....2916
REAR AXLE DISENGAGEMENT/RE-ENGAGEMENT ( with pneumatic suspensions)....2917
Disengagement....2917
Re-engagement....2917
REARAXLEASSEMBLY REVISION....2918
AIR VENT DISENGAGEMENT — RE-ENGAGEMENT....2918
WHEEL HUB REVISION....2919
Disassembly....2919
Check of parts composing wheel hubs....2920
Rear axle case check....2921
Assembly....2922
DIFFERENTIAL GEAR REPAIR....2924
Disassembly pertaining to rear axle 4517....2925
Disassembly pertaining to rear axle 4521....2925
Gearing case disassembly....2925
Disassembly of bevel pinion assembly....2926
Check of parts composing the differential gear....2927
Gearing case assembly....2928
Assembly pertaining to rear axle 4521....2931
Assembly pertaining to rear axle 4521....2933
Gearing case assembly on rear axle case....2933
Assembly pertaining to rear axle 4517....2933
Assembly pertaining to rear axle 4521....2933
VARIATION WITH DIFFERENTIAL LOCKING....2937
Disassembly....2938
Checks....2938
Assembly....2938
ANTISKID DEVICE SENSOR....2938
Assembly....2938
SECTION 7 - Front axles 5833 - 5833/1....2940
Front axles 5833 - 5833/1....2940
DESCRIPTION....2942
Front axle....2942
Characteristic angles....2944
SPECIFICATIONS AND DATA....2946
DIAGNOSTICS....2948
TIGHTENING TORQUES....2951
TOOLS....2952
FRONT AXLE DISENGAGEMENT/RE-ENGAGEMENT (with mechanical suspensions)....2956
Disengagement....2956
Re-engagement....2956
FRONT AXLE DISENGAGEMENT/RE-ENGAGEMENT (with pneumatic suspensions)....2957
Disengagement....2957
Re-engagement....2957
FRONT WHEEL ATTITUDE....2958
Claws and projectors placement....2958
Electronic rim misalignment compensation....2959
Wheel alignment....2959
Wheel toe-in check....2960
Wheel camber check....2960
King pin and caster angle check....2960
Steering angles check....2961
FRONT AXLE ASSEMBLY REVISION....2962
WHEEL HUBS DISENGAGEMENT AND RE-ENGAGEMENT....2962
Disengagement....2962
Sealing ring replacement....2963
Wheel hubs re-engagement....2963
Axial clearance adjustment for wheel hub bearings....2963
Rolling torque measure....2964
WHEEL HUB BEARINGS REPLACEMENT....2964
WHEEL SECURING RISERS REPLACEMENT....2965
TRANSVERSE TIE-ROD DETACHMENT AND RE-ATTACHMENT....2965
Detachment....2965
Re-attachment....2965
TRANSVERSE TIE-ROD STUB AXLE REPLACEMENT....2966
TRANSVERSE TIE-ROD LEVERS DETACHMENT AND RE-ATTACHMENT....2966
LONGITUDINAL TIE-ROD LEVER DETACHMENT AND RE-ATTACHMENT....2966
STUB AXLE PIN DETACHMENT AND RE-ATTACHMENT....2966
Detachment....2966
Re-attachment....2967
Check and adjustment of clearance between stub axle and front axle....2968
STEERING KNUCKLE PIN BEARING REPLACEMENT....2969
FRONT AXLE BODY CHECKS AND MEASURES....2970
Planarity check of leaf springs bearing surfaces with respect to stub axle pin holes....2970
Check of stub axle pin holes camber....2971
SECTION 8 - Suspensions....2972
Suspensions....2972
Front and rear mechanical suspensions....2974
DESCRIPTION....2976
FRONT LEAF SPRINGS....2976
FRONT PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA....2977
Models 60E.. - 100E.. with axle load up to 3200 kg....2977
Models 65E.. - 100E.. with axle load over 3200 kg....2978
FRONT HALF-ELLIPTIC LEAF SPRING SPECIFICATIONS AND DATA....2979
Models 60E..K....2979
Models 65E..K - 75E..K....2980
Models 75E15K....2981
Models 80E..K - 100E..K....2982
REAR LEAF SPRINGS....2983
REAR PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA....2985
Models 60E.. - 65E.. - 75E.. - 80E......2985
Models 100E......2986
REAR HALF-ELLIPTIC LEAF SPRING SPECIFICATIONS AND DATA....2987
Models 60E..K - 65E..K....2987
Models 75E..K....2988
Models 80E..K....2989
Models 100E..K....2990
SHOCK ABSORBERS....2991
Assembly diagrams....2991
SHOCK ABSORBER SPECIFICATIONS AND DATA....2992
Front shock absorbers (with parabolic leaf springs)....2992
Front shock absorbers (with half-elliptic leaf springs)....2992
Rear shock absorbers (with parabolic leaf springs)....2993
Rear shock absorbers (with half-elliptic leaf springs)....2993
DIAGNOSTICS....2994
TIGHTENING TORQUES....2998
FRONT MECHANICAL SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3000
Disengagement....3000
Re-engagement....3000
REAR MECHANICAL SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3001
Disengagement....3001
Re-engagement....3001
FRONT SHOCK ABSORBERS....3002
Disengagement....3002
Re-engagement....3002
REAR SHOCK ABSORBERS....3002
Disengagement....3002
Re-engagement....3002
FRONT STABILISING BAR....3002
Disengagement....3002
Re-engagement....3002
REAR STABILISING BAR....3003
Disengagement....3003
Re-engagement....3003
REPAIR INTERVENTIONS....3003
Leaf springs disassembly....3003
Checks....3003
BUSH REPLACEMENT....3004
Disassembling....3004
Assembling....3004
Leaf springs assembling....3004
Front and rear pneumatic suspensions....3006
PNEUMATIC SUSPENSIONS....3008
IN GENERAL....3008
PNEUMATIC SUSPENSIONS ASSEMBLIES....3009
Principle layout for rear pneumatic suspensions....3010
Principle layout for FULL pneumatic suspensions....3011
Electric layout with rear pneumatic suspensions....3012
Electric layout for vehicles with front and rear pneumatic suspensions....3013
MAIN COMPONENTS ARRANGEMENT ON VEHICLE....3014
REMOTE CONTROL DESCRIPTION AND OPERATION....3016
Chassis lifting/lowering....3016
Chassis self-leveling....3016
”M 1” - ”M 2” level....3016
DIAGNOSTICS....3017
TIGHTENING TORQUES....3019
TOOLS....3019
SPECIFICATIONS AND DATA....3020
Pneumatic system....3020
FRONT LEAF SPRING (MODELS ML 80E18FP/21FP - ML90E18FP/21FP - ML 100E18FP/21FP)....3021
Front shock absorbers....3022
Rear shock absorbers....3022
MAIN PNEUMATIC SYSTEM COMPONENTS....3023
Controlled-pressure valve....3023
Level sensor....3023
Front axle electro-pneumatic distributor for 4 x 2 FP vehicles....3024
Operation....3024
Front axle lifting....3024
Front axle lowering....3024
Self-leveling....3024
Rear axle electropneumatic distributor for 4 x 2 P/FP vehicles....3025
Operation....3025
Rear axle lifting....3025
Rear axle lowering....3025
Self-leveling....3025
MANOMETRIC LOW AIR PRESSURE SWITCH....3026
AIR SPRINGS....3026
Electronic unit.....3026
FRONT PNEUMATIC SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3028
Disengagement....3028
Re-engagement....3028
REAR PNEUMATIC SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT ....3029
Disengagement....3029
Re-engagement....3029
FRONT SHOCK ABSORBERS....3030
Disengagement....3030
Re-engagement....3030
FRONT AIR SPRINGS....3030
Disengagement....3030
Re-engagement....3030
REAR SHOCK ABSORBERS....3030
Disengagement....3030
Re-engagement....3030
REAR AIR SPRINGS....3031
Disengagement....3031
Re-engagement....3031
FRONT STABILISING BAR....3031
REAR STABILISING BAR....3031
SECTION 9 - Wheels and tyres....3032
Wheels and tyres....3032
DESCRIPTION....3034
SPECIFICATIONS AND DATA....3034
Tire pressure values....3034
TOOLS....3035
DIAGNOSTICS....3035
STATICWHEEL BALANCING....3038
CORRECTION OF RESIDUAL STATIC UNBALANCE....3039
TIRE PRESSURE....3039
TIRE BEHAVIOUR DEPENDING ON PRESSURE....3040
SECTION 10 - Steering system....3042
Steering system....3042
DESCRIPTION....3044
Hydraulic guide system installation view....3044
SPECIFICATION AND DATA....3044
STEERING WHEEL CONTROL SCHEME....3045
DIAGNOSTIC....3046
TIGHTENING TORQUE....3051
TOOLS....3051
POWER STEERING PUMP ZF FN4 Integral....3052
Description....3052
ZF 8090 HYDRAULIC POWER STEERING....3053
Description....3053
Hydraulic steering limiting device....3056
REMOVING AND REFITTING THE HYDRAULIC POWER STEERING (ZF 8090)....3057
Removal....3057
Refitting....3058
ADJUSTING THE HYDRAULIC STEERING LIMITING DEVICE....3059
TRW TAS 30 HYDRAULIC POWER STEERING....3060
Description....3060
Neutral position - straight running....3061
Steering to the right....3062
Steering to the left....3063
HYDRAULIC STEERING LIMITING DEVICE....3064
Setting the TRW TAS 30 power steering limiting device automatic adjustment....3065
Checking the automatic adjustment....3065
Fluid leaking manual adjustment....3066
BLEEDING THE AIR FROM THE HYDRAULIC POWER STEERING CIRCUIT....3067
MEASURING CLEARANCE IN STEERING BOX AT STEERING WHEEL....3067
CHECKING MAXIMUM PRESSURE OF POWER STEERING SYSTEM....3067
SECTION 11 - Pneumatic System - Brakes....3068
Pneumatic System - Brakes....3068
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS)....3072
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)....3073
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)....3079
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)....3080
SYMBOLS FORAIR/HYDRAULIC SYSTEMCIRCUITDIAGRAMS(CYLINDERSANDCALLIPERS)....3081
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (HALF-JOINTS AND COUPLING HEADS)....3082
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)....3084
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)....3085
PIPES AND COUPLINGS....3086
Overview....3086
End forming on rigid pipes....3086
Bending rigid pipes....3087
Cutting rigid pipes....3087
Replacing flexible hoses with threaded couplings....3088
Replacing flexible hoses with quick connection couplings....3089
BRAKING SYSTEM....3091
General layout for stand-alone vehicles....3091
General layout for towing vehicles....3092
BRAKING SYSTEM MAIN COMPONENTS LAYOUT ON VEHICLE....3093
Description....3094
Service braking....3094
Exhaust brake....3094
Operation....3094
Parking brake....3094
Brakes....3094
Front and rear brakes....3094
DIAGNOSTIC....3095
TIGHTENING TORQUE....3106
TOOLS....3107
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM....3110
Compressor....3110
A.P.U. (drier/4 ways)....3110
Drier....3110
4-way protection valve....3110
Air tanks....3110
Duplex distributor....3110
Pressure limiting valve (for towable vehicles)....3110
Augmenter valve (towing vehicles)....3111
Triple control servo distributor (towing vehicles)....3111
Variable and automatic coupling heads....3111
Air/hydraulic converters....3111
Manual discharge valve....3111
Parking brake distributor (single vehicles)....3112
Parking brake distributor (vehicles adapted for towing)....3112
Dump valve....3112
Spring cylinder....3112
ABS electronic control unit....3112
ABS solenoid valve....3112
SPECIFICATIONS AND DATA - BRAKES....3113
BRAKE SYSTEM MAIN COMPONENT CHECKS....3114
BRAKING SYSTEM MAIN COMPONENTS....3117
COMPRESSOR....3117
Diagnostic....3117
A.P.U. (Air Processing Unit)....3118
Operation....3119
Diagnostics....3120
ENGINE BRAKE SWITCH....3121
ENGINE BRAKE SOLENOID VALVE....3121
ENGINE BRAKE CONTROL OPERATING CYLINDER....3121
MANUAL DISCHARGE VALVE....3121
SAFETY VALVE (Optional)....3122
DUPLEX DISTRIBUTOR....3122
Brake release....3123
Diagnostic....3123
PRESSURE LIMITING VALVE....3124
Operation....3124
Pressure limiting....3124
Setting at the bench....3124
Diagnostic....3124
TRIPLE CONTROL SERVO DISTRIBUTOR....3125
Predominance regulation....3125
Diagnostic....3125
COUPLING HEADS....3126
Operation....3126
CHECK VALVE....3126
Operation....3126
AIR/HYDRAULIC CONVERTERS....3127
Master cylinder....3127
Checks....3127
Refitting....3127
Diagnostic....3128
AUGMENTER VALVE (towing vehicles)....3128
Diagnostic....3128
ANTI-SKID SYSTEMS....3129
Antilock braking system (ABS)....3129
ELECTROPNEUMATIC VALVE....3129
Operation....3129
ELECTRONIC CONTROL UNIT....3130
Operation....3130
RPM SENSORS....3130
PHONIC WHEELS....3130
Operation....3130
AIR BLEEDING FROM HYDRAULIC CIRCUIT....3131
Front brake circuit....3131
Rear brake circuit....3131
Air bleeding from the hydraulic circuit using the deaerating device....3131
PARKING BRAKE CONTROL HAND DISTRIBUTOR (stand-alone vehicles)....3132
Diagnostic....3132
PARKING BRAKE CONTROLHAND DISTRIBUTOR (Towing vehicles)....3133
Diagnostic....3133
SPRING BRAKE CYLINDER....3134
Operation....3134
Spring cylinder emergency brake release device....3134
Resetting the rear brakes in running condition....3135
Repair operations....3135
Diagnostic....3135
REPAIRING BRAKES....3136
Front brakes....3136
Operation....3136
REPLACING FRONT BRAKE LININGS....3136
For 5833/1 front axle....3137
For any model....3137
For 5833 front axle....3138
For 5833/1 front axle....3138
REMOVING FRONT BRAKE CALLIPERS....3139
For any model....3139
REMOVING FRONTWHEEL HUBS....3139
OVERHAULING THE BRAKE DISCS....3140
TURNING AND GRINDING THE BRAKE DISCS....3140
Rear brakes....3141
Operation....3141
REAR BRAKE CALLIPER HYDRAULIC OPERATION DIAGRAM (GIRLING)....3141
Parking brake device operation....3141
Automatic backlash take up device operation....3141
Operation of the system for taking up wear....3143
First operation stage (F1 < F2) - Low pressure....3144
Second operation stage (F1 > F2) - High pressure....3145
Third operation stage (Pressure resetting to zero) - Resting position....3146
Parking braking....3147
Parking brake operation....3147
REPLACING THE REAR BRAKE LININGS....3148
Removal....3148
For rear axle 4517....3148
For any model....3149
Refitting....3150
For rear axle 4521....3150
For rear axle 4517....3150
REMOVING THE REAR BRAKE CALLIPERS....3150
REMOVING REARWHEEL HUBS....3151
OVERHAULING THE BRAKE CALLIPERS....3152
Brake callisper removal....3154
For rear calliper....3154
For front and rear calliper....3155
For rear calliper....3155
For Girling rear calliper....3155
For Brembo rear calliper....3155
For front and rear calliper....3156
Component cleaning and checking....3156
Brake calliper refitting....3156
For rear calliper (Girling)....3156
For rear calliper (Brembo)....3156
For front and rear calliper....3157
For front calliper....3157
For rear calliper....3157
For front and rear calliper....3158
For rear calliper....3158
REFITTING BRAKES....3158
REFITTING THE FRONT WHEEL HUBS....3158
REFITTING THE REAR WHEEL HUBS....3160
REFITTING THE BRAKE CALLIPERS....3161
REFITTING THE REAR BRAKE CALLIPERS....3162
SECTION 12 - Body - Chassis....3164
Body - Chassis....3164
CAB....3166
General information....3166
CHARACTERISTICS AND DATA....3167
PROTECTIVE BODY TREATMENTS....3171
Protective treatment....3171
Preparing the sheet metal (bonderizing)....3172
Applying the protective paint (electrophoresis)....3172
CHECKING THE GEOMETRY OF THE CHASSIS FRAME....3172
GENERAL RULES FORWORKING ON THE CHASSIS FRAME....3172
Preparing the chassis frame for maintenance, checking and repair work authorized by IVECO....3172
Spot welding....3173
Welding instructions....3173
Bodybuilder work on the structural members of the IVECO chassis frame....3173
Drilling the chassis frame....3173
PRECAUTIONS....3174
Welds on the chassis frame....3175
CHASSIS FRAME....3176
REPAIRS AND CHECKS....3176
Measuring the side bend of the chassis frame....3177
Measuring the bend of the chassis frame downwards or upwards....3177
Measuring the movement of the chassis frame....3177
Measuring the torsion of the chassis frame....3178
CHASSIS REFERENCE DIMENSIONS....3179
CAB GEOMETRY....3184
SEAL APPLICATION DIAGRAM....3185
CAB ANCHORINGCAB ANCHORING AND TIGHTENING TORQUES....3188
TOOLS....3193
REPAIRS....3194
Cab anchoring....3194
Replacing cab suspension front and rear shock absorbers....3194
Removing-refitting front mounts and cab stabilizer bar....3194
HYDRAULIC CAB LIFTING SYSTEM....3195
Replacing hydraulic cylinder for cab tilting....3196
REPLACINGWINDSCREENWINDOW....3196
General....3196
Vibration knife....3196
Harmonic wire....3197
Removal (with harmonic wire)....3197
Preparing the windscreen opening....3197
Preparing the windscreen....3198
Refitting....3198
Replacing the winding window....3200
Replacing the window winder....3201
Replacing the fixed window....3201
INSTRUMENT PANEL....3203
Removal....3203
Refitting....3203
MIDDLE INSTRUMENT PANEL....3203
Removal....3203
Refitting....3204
INSTRUMENT PANEL COVERING....3204
Removal....3204
Refitting....3209
HEATING AND VENTILATION....3209
Removal....3209
Refitting....3209
SECTION 13 - Programmed maintenance....3210
Programmed maintenance....3210
SERVICING....3212
Service plan....3212
SERVICE FREQUENCY....3212
EXTRA PLAN OPERATIONS....3212
Extra plan operation (to be carried out possibly at the same time as a planned service operation)....3212
PROGRAMMED MAINTENANCE OPERATIONS....3213
OPERATIONS NOT INCLUDED IN THE PLAN....3213
PROGRAMMED MAINTENANCE OPERATIONS....3216
OPERATIONS NOT INCLUDED IN THE PLAN....3216
M1 SERVICE....3217
M2 SERVICE....3218
M3 SERVICE....3221
M4 SERVICE....3221
MAINTENANCE NOT INCLUDED IN THE SERVICE....3221
EP1 SERVICE....3221
EP2 SERVICE....3221
EP3 SERVICE....3221
EP4 SERVICE....3222
EP5 SERVICE....3223
OIL REPLACEMENT AND BRAKE HYDRAULIC SYSTEM BLEEDING....3223
Front brake circuit....3223
Rear brake circuit....3223
Air bleeding from the hydraulic circuit using the deaerating device....3223
6-10T (603.93.381)....3226
EUROCARGO TECTOR 6 TO 10 t....3226
REPAIR MANUAL....3226
PRELIMINARY REMARKS....3228
SYMBOLS -WARNINGS....3228
SYMBOLS - ASSISTANCE OPERATIONS....3229
PRODUCT CODE....3230
GENERAL WARNINGS....3231
GENERAL WARNINGS ON THE ELECTRIC SYSTEM....3233
Bonding and screening....3234
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS....3235
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES....3235
UPDATE DATA....3236
INDEX OF SECTIONS....3238
SECTION 1 - General Specifications....3240
General Specifications....3240
COMPOSITION OF THE MODELS....3242
IDENTIFICATION DATA AND LOCATION ON VEHICLE....3250
FILLING UP....3251
INTERNATIONAL LUBRICANT DESIGNATION....3252
SECTION 2 - Engine....3254
Engine....3254
Engine....3254
ENGINE IDENTIFICATION CODE....3256
MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE....3257
WARNINGS....3257
High pressure CP3 pump....3257
Rail and fittings....3257
Injector....3257
Low pressure tubing....3257
High pressure tubing....3257
ENGINE REMOVAL/REFITTING....3258
Removal....3258
Refitting....3260
Checks and inspections....3260
Topping up the engine cooling system....3260
Bleeding air from the fuel system....3261
Bleeding air from the power steering system....3261
INJECTOR REPLACEMENT....3262
Removal....3262
Refitting....3262
Checks and inspections....3264
REPLACEMENTOFENGINE FRONTSHAFT COVER SEALING RING....3264
REPLACEMENT OF FLYWHEEL CASE SEALING RING....3265
CYLINDER HEAD REMOVAL/REFITTING....3266
Removal....3266
Refitting....3268
Checks and inspections....3268
Engine F4 AE 0481....3272
GENERAL SPECIFICATIONS....3274
CLEARANCE DATA....3277
TIGHTENING TORQUE....3283
AUXILIARY COMPONENTS....3285
TOOLS....3285
ENGINE OVERHAUL....3293
ENGINE REMOVAL AT THE BENCH....3293
REPAIR OPERATIONS....3301
CYLINDER UNIT....3301
Checks and measurements....3301
Checking head supporting surface on cylinder unit....3302
TIMING SYSTEM....3302
Camshaft....3302
Checking cam lift and pin alignment....3303
BUSHES....3303
Bush replacement....3304
Tappets....3304
Fitting tappets — camshaft....3304
OUTPUT SHAFT....3305
Measuring journals and crankpins....3305
Replacing oil pump control gear....3307
Fitting main bearings....3307
Finding journal clearance....3307
Checking output shaft shoulder clearance....3308
CONNECTING ROD - PISTON ASSEMBLY....3308
Pistons....3309
Measuring piston diameters....3309
Piston pins....3310
Conditions for proper pin-piston coupling....3310
Split rings....3310
Connecting rods....3311
Bushes....3311
Checking connecting rods....3312
Checking torsion....3312
Checking bending....3312
Fitting connecting rod-piston assembly....3312
Connecting rod-piston coupling....3312
Fitting split rings....3313
Fitting connecting rod-piston assembly into cylinder barrels....3313
Finding crankpin clearance....3314
Checking piston protrusion....3315
Timing gear case....3315
Timing....3316
Flywheel housing....3316
ENGINE FLYWHEEL....3317
Replacing engine flywheel ring gear....3317
CYLINDER HEAD....3321
Removing the valves....3321
Checking cylinder head wet seal....3322
Checking cylinder head supporting surface....3322
VALVES....3323
Removing carbon deposits, checking and grinding valves....3323
Checking clearance between valve stem and valve guide and valve centering....3323
VALVE GUIDE....3324
VALVE SEATS....3324
Regrinding - replacing the valve seats....3324
VALVE SPRINGS....3326
FITTING CYLINDER HEAD....3326
Refitting the cylinder head....3326
Assembling electro-injectors....3327
RODS....3328
Rocker assembly....3328
Adjusting tappet clearance....3329
Intake manifold....3330
Wiring support....3332
LUBRICATION....3336
OIL PUMP....3338
HEAT EXCHANGER....3338
Oil pressure relief valve....3339
Oil vapour recycling....3340
COOLING SYSTEM....3342
Water Pump....3344
Viscous fan....3344
Thermostat....3345
BOOSTER....3345
Turbosupercharger....3345
Description....3345
TURBOSUPERCHARGER ACTUATOR....3346
Check and adjustment....3346
Actuator replacement....3346
TURBOSUPERCHARGER LAYOUT....3348
COMMON RAIL....3350
General Specifications....3350
HYDRAULIC SYSTEM....3352
HYDRAULIC SYSTEM LAYOUT....3354
FUEL PREFILTER....3356
FUEL FILTER....3356
MECHANICAL SUPPLY PUMP....3357
Normal operating conditions....3357
Overpressure condition at outlet....3357
Drain conditions....3357
CP3 HIGH-PRESSURE PUMP....3358
HIGH-PRESSURE PUMP - INSIDE STRUCTURE....3359
Operating principle....3360
Operation....3362
RAIL....3362
DOUBLE STAGE OVERPRESSURE VALVE....3363
INJECTOR....3364
Injector in rest position....3364
Injection start....3364
Injection end....3364
PRESSURE LIMITER FOR FUEL RETURN....3364
Engine F4 AE 0681....3368
GENERAL SPECIFICATIONS....3370
ASSEMBLY DATA - CLEARANCES....3373
ENGINE F4AE0681 OVERHAUL....3381
Engine removal at the bench....3381
TIMING SYSTEM....3382
Camshaft....3382
BUSHES....3382
CYLINDER HEAD VALVE SEATS....3384
Cylinder head fastening screw tightening....3386
LUBRICATION....3388
COOLING SYSTEM....3389
BOOSTER....3390
TURBOSUPERCHARGER LAYOUT....3392
Troubleshooting guide....3394
FOREWORD....3396
Diagnosis through instruments....3396
DIAGNOSTICS....3398
SECTION 3 - Clutch....3408
Clutch....3408
DESCRIPTION....3410
Clutch....3410
SPECIFICATIONS AND DATA....3410
DIAGNOSTICS....3413
TIGHTENING TORQUES....3416
TOOLS....3416
REMOVAL AND REFITTING....3417
Removal....3417
Refitting....3417
DRIVEN PLATE OVERHAUL....3417
Damper hub check....3417
Friction gaskets....3417
THRUST BEARING REMOVAL - REFITTING....3418
REPLACING CLUTCH SHAFT SUPPORT BEARING....3418
HYDRAULIC CONTROL....3419
Mini servo-clutch....3419
Connections....3419
Clutch disengaging cylinder....3419
Clutch mounting assembly....3420
Clutch wear control....3420
ADJUSTING PEDAL AND STOP POSITION SCREWS....3421
Clutch pedal clearance....3421
Clutch pedal travel....3421
CLUTCH CONTROL DRAIN PROCEDURE....3421
SECTION 4 - Gearboxes....3422
Gearboxes....3422
DIAGNOSTICS....3424
Gears control connection....3426
Gearbox control tie-rods adjustment....3426
Gearbox 2855S.5 - 2855S.6....3428
DESCRIPTION....3430
SPECIFICATIONS AND DATA....3431
TIGHTENING TORQUES....3434
TOOLS....3435
GEARBOX 2855S.6 REMOVAL - REFITTING....3440
Removal....3440
Refitting....3440
GEARBOX DISASSEMBLY....3442
Checks....3445
GEARBOX ASSEMBLY....3446
Bearings pre-load adjustment for secondary shaft....3446
PRIMARY SHAFT DISASSEMBLY....3452
PRIMARY SHAFT ASSEMBLY....3454
MOTION INLET SHAFT DISASSEMBLY....3457
MOTION INLET SHAFT ASSEMBLY....3457
Motion inlet shaft bearing adjustment....3457
SECONDARY SHAFT DISASSEMBLY....3458
SECONDARY SHAFT ASSEMBLY....3458
INTERNAL DRIVE SHAFT DISASSEMBLY....3458
INTERNAL DRIVE SHAFY ASSEMBLY....3458
EXTERNAL CONTROL SHAFT DISASSEMBLY....3459
EXTERNAL CONTROL BOX ASSEMBLY....3460
Idle-R.M. switch adjustment....3462
Gearbox 2865S.6....3464
DESCRIPTION....3466
SPECIFICATIONS AND DATA....3468
TIGHTENING TORQUES....3470
TOOLS....3471
GEARBOX 2865S.5 DISENGAGEMENT/ RE-ENGAGEMENT....3476
Disengagement....3476
Re-engagement....3476
GEARBOX DISASSEMBLY....3478
Rear cover sealing gasket replacement....3481
Checks....3482
GEARBOX ASSEMBLY....3482
Bearings pre-loading adjustment for secondary shaft....3483
PRIMARY SHAFT DISASSEMBLY....3487
PRIMARY SHAFT ASSEMBLY....3490
MOTION ENTRY SHAFT ASSEMBLY....3493
SECONDARY SHAFT DISASSEMBLY....3493
SECONDARY SHAFT ASSEMBLY....3493
INTERNAL CONTROL SHAFT DISASSEMBLY....3494
INTERNAL CONTROL SHAFT ASSEMBLY....3494
EXTERNAL CONTROL SHAFT DISASSEMBLY....3494
EXTERNAL CONTROL BOX ASSEMBLY....3495
Idle-R.M. switch adjustment....3497
Gearbox 2870S.9....3498
DESCRIPTION....3500
SPECIFICATIONS AND DATA....3501
TIGHTENING TORQUES....3504
TOOLS....3505
GEARBOX 2870S.9 DISENGAGEMENT/RE-ENGAGEMENT....3510
Disengagement....3510
Re-engagement....3510
GEARBOX DISASSEMBLY....3512
Checks....3516
GEARBOX ASSEMBLY....3517
Bearings pre-load adjustment for secondary shaft....3517
Idle-Reverse Gear switch adjustment....3523
PRIMARY SHAFT DISASSEMBLY....3524
PRIMARY SHAFT ASSEMBLY....3526
MOTION INLET SHAFT DISASSEMBLY....3526
MOTION INLET SHAFT ASSEMBLY....3527
Motion inlet shaft bearing adjustment....3527
SECONDARY SHAFT DISASSEMBLY....3527
SECONDARY SHAFT ASSEMBLY....3527
INTERNAL DRIVE SHAFT DISASSEMBLY....3527
INTERNAL DRIVE SHAFT ASSEMBLY....3528
EXTERNAL DRIVE CASE DISASSEMBLY....3528
EXTERNAL CONTROL BOX ASSEMBLY....3529
EPICYCLIC REDUCTION GEAR ASSEMBLY....3532
Operating diagrams about pneumatic epicyclic reduction gear drive circuit....3532
DISASSEMBLY....3534
Checks....3536
ASSEMBLY....3537
SECTION 5 - Propeller shafts....3542
Propeller shafts....3542
DESCRIPTION....3544
SPECIFICATIONS AND DATA FOR ”FIXED” AND ”SLIDING” PROPELLER SHAFTS....3548
SPECIFICATIONS AND DATA FOR ”SINGLE-SECTION” PROPELLER SHAFTS....3549
DIAGNOSTICS....3550
TIGHTENING TORQUES....3550
SINGLE-SECTION PROPELLER SHAFT DISENGAGEMENT - RE-ENGAGEMENT....3551
Disengagement....3551
Re-engagement....3551
SLIDING PROPELLER SHAFT DISENGAGEMENT - RE-ENGAGEMENT....3552
Disengagement....3552
Re-engagement....3552
TWO-SECTION PROPELLER SHAFT DISENGAGEMENT - RE-ENGAGEMENT....3552
CHECK OF VEHICLE PROPELLER SHAFTS....3552
SECTION 6 - Rear axles 4517 and 4521....3554
Rear axles 4517 and 4521....3554
DESCRIPTION....3556
SPECIFICATIONS AND DATA....3558
DIAGNOSTICS....3560
TIGHTENING TORQUES....3562
TOOLS....3566
REAR AXLE DISENGAGEMENT/RE-ENGAGEMENT (with mechanical suspensions)....3570
Disengagement....3570
Re-engagement....3570
REAR AXLE DISENGAGEMENT/RE-ENGAGEMENT (with pneumatic suspensions)....3571
Disengagement....3571
Re-engagement....3571
REAR AXLE ASSEMBLY REVISION....3572
AIR VENT DISENGAGEMENT - RE-ENGAGEMENT....3572
WHEEL HUB REVISION....3573
Disassembly....3573
Check of parts composing wheel hubs....3574
Rear axle case check....3575
Assembly....3576
DIFFERENTIAL GEAR REPAIR....3578
Disassembly pertaining to rear axle 4517....3579
Disassembly pertaining to rear axle 4521....3579
Gearing case disassembly....3579
Disassembly of bevel pinion assembly....3580
Check of parts composing the differential gear....3581
Gearing case assembly....3582
Assembly pertaining to rear axle 4521....3585
Assembly pertaining to rear axle 4521....3587
Gearing case assembly on rear axle case....3587
Assembly pertaining to rear axle 4517....3587
Assembly pertaining to rear axle 4521....3587
VARIATION WITH DIFFERENTIAL LOCKING....3591
Disassembly....3592
Checks....3592
Assembly....3592
ANTISKID DEVICE SENSOR....3592
Assembly....3592
SECTION 7 - Front axles 5833 - 5833/1....3594
DESCRIPTION....3596
Front axle....3596
Characteristic angles....3598
SPECIFICATIONS AND DATA....3600
DIAGNOSTICS....3602
TIGHTENING TORQUES....3605
TOOLS....3606
FRONT AXLE DISENGAGEMENT/RE-ENGAGEMENT (with mechanical suspensions)....3610
Disengagement....3610
Re-engagement....3610
FRONT AXLE DISENGAGEMENT/RE-ENGAGEMENT (with pneumatic suspensions)....3611
Disengagement....3611
Re-engagement....3611
FRONT WHEEL ATTITUDE....3612
Claws and projectors placement....3612
Electronic rim misalignment compensation....3613
Wheel alignment....3613
Wheel toe-in check....3614
Wheel camber check....3614
King pin and caster angle check....3614
Steering angles check....3615
FRONT AXLE ASSEMBLY REVISION....3616
WHEEL HUBS DISENGAGEMENT AND RE-ENGAGEMENT....3616
Disengagement....3616
Sealing ring replacement....3617
Wheel hubs re-engagement....3617
Axial clearance adjustment for wheel hub bearings....3617
Rolling torque measure....3618
WHEEL HUB BEARINGS REPLACEMENT....3618
WHEEL SECURING RISERS REPLACEMENT....3619
TRANSVERSE TIE-ROD DETACHMENT AND RE-ATTACHMENT....3619
Detachment....3619
Re-attachment....3619
TRANSVERSE TIE-ROD STUB AXLE REPLACEMENT....3620
TRANSVERSE TIE-ROD LEVERS DETACHMENT AND RE-ATTACHMENT....3620
LONGITUDINAL TIE-ROD LEVER DETACHMENT AND RE-ATTACHMENT....3620
STUB AXLE PIN DETACHMENT AND RE-ATTACHMENT....3620
Detachment....3620
Re-attachment....3621
Check and adjustment of clearance between stub axle and front axle....3622
STEERING KNUCKLE PIN BEARING REPLACEMENT....3623
FRONT AXLE BODY CHECKS AND MEASURES....3624
Planarity check of leaf springs bearing surfaces with respect to stub axle pin holes....3624
Check of stub axle pin holes camber....3625
SECTION 8 - Suspensions....3626
Front and rear mechanical suspensions....3628
DESCRIPTION....3630
FRONT LEAF SPRINGS....3630
FRONT PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA....3631
Models 60E.. - 100E.. with axle load up to 3400 kg....3631
Models 65E.. - 100E.. with axle load over 3400 kg....3632
FRONT HALF-ELLIPTIC LEAF SPRING SPECIFICATIONS AND DATA....3633
Models 60E..K....3633
Models 65E..K - 75E..K....3634
Models 75E15K....3635
Models 80E..K - 100E..K....3636
REAR LEAF SPRINGS....3637
REAR PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA....3639
Models 60E.. - 65E.. - 75E.. - 80E......3639
Models 100E......3640
REAR HALF-ELLIPTIC LEAF SPRING SPECIFICATIONS AND DATA....3641
Models 60E..K - 65E..K....3641
Models 75E..K....3642
Models 80E..K....3643
Models 100E..K....3644
SHOCK ABSORBERS....3645
Assembly diagrams....3645
SHOCK ABSORBER SPECIFICATIONS AND DATA....3646
Front shock absorbers (with parabolic leaf springs)....3646
Front shock absorbers (with half-elliptic leaf springs)....3646
Rear shock absorbers (with parabolic leaf springs)....3647
Rear shock absorbers (with half-elliptic leaf springs)....3647
DIAGNOSTICS....3648
TIGHTENING TORQUES....3652
TOOLS....3652
FRONT MECHANICAL SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3654
Disengagement....3654
Re-engagement....3654
REAR MECHANICAL SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3655
Disengagement....3655
Re-engagement....3655
FRONT SHOCK ABSORBERS....3656
Disengagement....3656
Re-engagement....3656
REAR SHOCK ABSORBERS....3656
Disengagement....3656
Re-engagement....3656
FRONT STABILISING BAR....3656
Disengagement....3656
Re-engagement....3656
REAR STABILISING BAR....3657
Disengagement....3657
Re-engagement....3657
REPAIR INTERVENTIONS....3657
REPLACING LEAF-SPRING BUSHINGS (For vehicles with leaf-springs provided with bushings having a metal shell)....3657
DISCONNECTING AND RECONNECTING REAR LEAF-SPRING BUSHINGS....3657
Disconnecting rear bushings....3657
Reconnecting rear bushings....3660
Disconnecting front bushings....3661
Reconnecting front bushings....3661
DISCONNECTING AND RECONNECTING FRONT LEAF-SPRING BUSHINGS....3662
Disconnecting front bushings....3662
Reconnecting front bushings....3663
Disconnecting rear bushings....3663
Reconnecting front bushings....3664
Front and rear pneumatic suspensions....3666
PNEUMATIC SUSPENSIONS....3668
IN GENERAL....3668
PNEUMATIC SUSPENSIONS ASSEMBLIES....3669
Principle layout for rear pneumatic suspensions....3670
Principle layout for FULL pneumatic suspensions....3671
MAIN COMPONENTS ARRANGEMENT ON VEHICLE....3672
CHASSIS LIFTING, LOWERING AND SELF-LEVELING....3673
Remote control....3673
REMOTE CONTROL DESCRIPTION AND OPERATION....3674
Chassis lifting/lowering....3674
Chassis self-leveling....3674
”M 1” - ”M 2” level....3674
DIAGNOSTICS....3675
TIGHTENING TORQUES....3677
HENDRICKSON type rear pneumatic suspension....3677
TOOLS....3678
SPECIFICATIONS AND DATA....3679
Pneumatic system....3679
FRONT LEAF SPRING (MODELS ML 80E18FP/21FP - ML90E18FP/21FP - ML 100E18FP/21FP)....3680
Front shock absorbers....3681
Rear shock absorbers....3681
MAIN PNEUMATIC SYSTEM COMPONENTS....3682
Controlled-pressure valve....3682
Level sensor....3682
Front axle electro-pneumatic distributor for 4 x 2 FP vehicles....3683
Operation....3683
Front axle lifting....3683
Front axle lowering....3683
Self-leveling....3683
Rear axle electropneumatic distributor for 4 x 2 P/FP vehicles....3684
Operation....3684
Rear axle lifting....3684
Rear axle lowering....3684
Self-leveling....3684
MANOMETRIC LOW AIR PRESSURE SWITCH....3685
AIR SPRINGS....3685
Electronic unit....3685
FRONT PNEUMATIC SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3686
Disengagement....3686
Re-engagement....3686
NEWAY TYPE REAR PNEUMATIC SUSPENSIONS DISENGAGEMENT - RE-ENGAGEMENT....3687
Disengagement....3687
Re-engagement....3687
FRONT SHOCK ABSORBERS....3688
Disengagement....3688
Re-engagement....3688
FRONT AIR SPRINGS....3688
Disengagement....3688
Re-engagement....3688
REAR SHOCK ABSORBERS....3688
Disengagement....3688
Re-engagement....3688
REAR AIR SPRINGS....3689
Disengagement....3689
Re-engagement....3689
FRONT STABILISING BAR....3689
REAR STABILISING BAR....3689
SECTION 9 - Wheels and tyres....3690
Wheels and tyres....3690
DESCRIPTION....3692
SPECIFICATIONS AND DATA....3692
Tire pressure values....3692
TOOLS....3693
DIAGNOSTICS....3693
STATIC WHEEL BALANCING....3696
CORRECTION OF RESIDUAL STATIC UNBALANCE....3697
TIRE PRESSURE....3697
TIRE BEHAVIOUR DEPENDING ON PRESSURE....3698
SECTION 10 - Steering system....3700
Steering system....3700
DESCRIPTION....3702
Hydraulic guide system installation view....3702
SPECIFICATION AND DATA....3702
STEERING WHEEL CONTROL SCHEME....3703
DIAGNOSTIC....3704
TIGHTENING TORQUE....3709
TOOLS....3709
POWER STEERING PUMP ZF FN4 Integral....3710
Description....3710
ZF 8090 HYDRAULIC POWER STEERING....3711
Description....3711
Hydraulic steering limiting device....3714
REMOVING AND REFITTING THE HYDRAULIC POWER STEERING (ZF 8090)....3715
Removal....3715
Refitting....3716
ADJUSTING THE HYDRAULIC STEERING LIMITING DEVICE....3717
TRW TAS 30 HYDRAULIC POWER STEERING....3718
Description....3718
Neutral position - straight running....3719
Steering to the right....3720
Steering to the left....3721
HYDRAULIC STEERING LIMITING DEVICE....3722
Setting the TRW TAS 30 power steering limiting device automatic adjustment....3723
Checking the automatic adjustment....3723
Fluid leaking manual adjustment....3724
BLEEDING THE AIR FROM THE HYDRAULIC POWER STEERING CIRCUIT....3725
MEASURING CLEARANCE IN STEERING BOX AT STEERING WHEEL....3725
CHECKING MAXIMUM PRESSURE OF POWER STEERING SYSTEM....3725
SECTION 11 - Pneumatic System - Brakes....3726
Pneumatic System - Brakes....3726
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS)....3730
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)....3731
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)....3737
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)....3738
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CYLINDERS AND CALLIPERS)....3739
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (HALF-JOINTS AND COUPLING HEADS)....3740
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)....3742
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)....3743
PIPES AND COUPLINGS....3744
Overview....3744
End forming on rigid pipes....3744
Bending rigid pipes....3745
Cutting rigid pipes....3745
Replacing flexible hoses with threaded couplings....3746
Replacing flexible hoses with quick connection couplings....3747
BRAKING SYSTEM....3749
General layout for stand-alone vehicles....3749
General layout for towing vehicles....3750
BRAKING SYSTEM MAIN COMPONENTS LAYOUT ON VEHICLE....3751
Description....3752
Service braking....3752
Exhaust brake....3752
Operation....3752
Parking brake....3752
Brakes....3752
Front and rear brakes....3752
DIAGNOSTIC....3753
TIGHTENING TORQUE....3764
TOOLS....3765
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM....3768
Compressor....3768
A.P.U. (drier/4 ways)....3768
Drier....3768
4-way protection valve....3768
Air tanks....3768
Duplex distributor....3768
Pressure limiting valve (for towable vehicles)....3768
Augmenter valve (towing vehicles)....3769
Triple control servo distributor (towing vehicles)....3769
Variable and automatic coupling heads....3769
Air/hydraulic converters....3769
Manual discharge valve....3769
Parking brake distributor (single vehicles)....3770
Parking brake distributor (vehicles adapted for towing)....3770
Dump valve....3770
Spring cylinder....3770
ABS electronic control unit....3770
ABS solenoid valve....3770
SPECIFICATIONS AND DATA - BRAKES....3771
BRAKE SYSTEM MAIN COMPONENT CHECKS....3772
BRAKING SYSTEM MAIN COMPONENTS....3775
COMPRESSOR....3775
Diagnostic....3775
A.P.U. (Air Processing Unit)....3776
Operation....3777
Diagnostics....3778
ENGINE BRAKE SWITCH....3779
ENGINE BRAKE SOLENOID VALVE....3779
ENGINE BRAKE CONTROL OPERATING CYLINDER....3779
MANUAL DISCHARGE VALVE....3779
SAFETY VALVE (Optional)....3780
DUPLEX DISTRIBUTOR....3780
Brake release....3781
Diagnostic....3781
PRESSURE LIMITING VALVE....3782
Operation....3782
Pressure limiting....3782
Setting at the bench....3782
Diagnostic....3782
TRIPLE CONTROL SERVO DISTRIBUTOR....3783
Predominance regulation....3783
Diagnostic....3783
COUPLING HEADS....3784
Operation....3784
CHECK VALVE....3784
Operation....3784
AIR/HYDRAULIC CONVERTERS (diaphragm)....3785
Master cylinder....3785
Checks....3785
Refitting....3785
Diagnostic....3786
AUGMENTER VALVE (towing vehicles)....3786
Diagnostic....3786
ANTI-SKID SYSTEMS....3787
Antilock braking system (ABS)....3787
ELECTROPNEUMATIC VALVE....3787
Operation....3787
ELECTRONIC CONTROL UNIT....3788
Operation....3788
RPM SENSORS....3788
PHONIC WHEELS....3788
Operation....3788
AIR BLEEDING FROM HYDRAULIC CIRCUIT....3789
Front brake circuit....3789
Rear brake circuit....3789
Air bleeding from the hydraulic circuit using the deaerating device....3789
PARKING BRAKE CONTROL HAND DISTRIBUTOR (stand-alone vehicles)....3790
Diagnostic....3790
PARKING BRAKE CONTROL HAND DISTRIBUTOR (Towing vehicles)....3791
Diagnostic....3791
SPRING BRAKE CYLINDER....3792
Operation....3792
Spring cylinder emergency brake release device....3792
Resetting the rear brakes in running condition....3793
Repair operations....3793
Diagnostic....3793
REPAIRING BRAKES....3794
Front brakes....3794
Operation....3794
REPLACING FRONT BRAKE LININGS....3794
For 5833/1 front axle....3795
For any model....3795
For 5833 front axle....3796
For 5833/1 front axle....3796
REMOVING FRONT BRAKE CALLIPERS....3797
For any model....3797
REMOVING FRONT WHEEL HUBS....3797
OVERHAULING THE BRAKE DISCS....3798
TURNING AND GRINDING THE BRAKE DISCS....3798
Rear brakes....3799
Operation....3799
REAR BRAKE CALLIPER HYDRAULIC OPERATION DIAGRAM (GIRLING)....3799
Parking brake device operation....3799
Automatic backlash take up device operation....3799
Operation of the system for taking up wear....3801
First operation stage (F1 < F2) - Low pressure....3802
Second operation stage (F1 > F2) - High pressure....3803
Third operation stage (Pressure resetting to zero) - Resting position....3804
Parking braking....3805
Parking brake operation....3805
REPLACING THE REAR BRAKE LININGS....3806
Removal....3806
For rear axle 4517....3806
For any model....3807
Refitting....3808
For rear axle 4521....3808
For rear axle 4517....3808
REMOVING THE REAR BRAKE CALLIPERS....3808
REMOVING REAR WHEEL HUBS....3809
OVERHAULING THE BRAKE CALLIPERS....3810
Brake callisper removal....3812
For rear calliper....3812
For front and rear calliper....3813
For rear calliper....3813
For Girling rear calliper....3813
For Brembo rear calliper....3813
For front and rear calliper....3814
Component cleaning and checking....3814
Brake calliper refitting....3814
For rear calliper (Girling)....3814
For rear calliper (Brembo)....3814
For front and rear calliper....3815
For front calliper....3815
For rear calliper....3815
For front and rear calliper....3816
For rear calliper....3816
REFITTING BRAKES....3816
REFITTING THE FRONT WHEEL HUBS....3816
REFITTING THE REAR WHEEL HUBS....3818
REFITTING THE BRAKE CALLIPERS....3819
REFITTING THE REAR BRAKE CALLIPERS....3820
SECTION 12 - Body - Chassis....3822
Body - Chassis....3822
CAB....3824
General information....3824
CHARACTERISTICS AND DATA....3825
PROTECTIVE BODY TREATMENTS....3829
Protective treatment....3829
Preparing the sheet metal (bonderizing)....3830
Applying the protective paint (electrophoresis)....3830
CHECKING THE GEOMETRY OF THE CHASSIS FRAME....3830
GENERAL RULES FOR WORKING ON THE CHASSIS FRAME....3830
Preparing the chassis frame for maintenance, checking and repair work authorized by IVECO....3830
Spot welding....3831
Welding instructions....3831
Bodybuilder work on the structural members of the IVECO chassis frame....3831
Drilling the chassis frame....3831
PRECAUTIONS....3832
Welds on the chassis frame....3833
CHASSIS FRAME....3834
REPAIRS AND CHECKS....3834
Measuring the side bend of the chassis frame....3835
Measuring the bend of the chassis frame downwards or upwards....3835
Measuring the movement of the chassis frame....3835
Measuring the torsion of the chassis frame....3836
CHASSIS REFERENCE DIMENSIONS....3837
CAB GEOMETRY....3842
SEAL APPLICATION DIAGRAM....3843
CAB ANCHORING AND TIGHTENING TORQUES....3846
TOOLS....3851
REPAIRS....3852
Cab anchoring....3852
Replacing cab suspension front and rear shock absorbers....3852
Removing-refitting front mounts and cab stabilizer bar....3852
HYDRAULIC CAB LIFTING SYSTEM....3853
Replacing hydraulic cylinder for cab tilting....3854
REPLACING WINDSCREEN WINDOW....3854
General....3854
Vibration knife....3854
Harmonic wire....3855
Removal (with harmonic wire)....3855
Preparing the windscreen opening....3855
Preparing the windscreen....3856
Refitting....3856
Replacing the winding window....3858
Replacing the window winder....3859
Replacing the fixed window....3859
INSTRUMENT PANEL....3861
Removal....3861
Refitting....3861
MIDDLE INSTRUMENT PANEL....3861
Removal....3861
Refitting....3862
INSTRUMENT PANEL COVERING....3862
Removal....3862
Refitting....3867
HEATING AND VENTILATION....3867
Removal....3867
Refitting....3867
SECTION 13 - Programmed maintenance....3868
Programmed maintenance....3868
SERVICING....3870
Service plan....3870
SERVICE FREQUENCY....3870
EXTRA PLAN OPERATIONS....3870
Extra plan operation (to be carried out possibly at the same time as a planned service operation)....3870
PROGRAMMED MAINTENANCE OPERATIONS....3871
OPERATIONS NOT INCLUDED IN THE PLAN....3871
PROGRAMMED MAINTENANCE OPERATIONS....3874
OPERATIONS NOT INCLUDED IN THE PLAN....3874
M1 SERVICE....3875
M2 SERVICE....3876
M3 SERVICE....3879
M4 SERVICE....3879
MAINTENANCE NOT INCLUDED IN THE SERVICE....3879
EP1 SERVICE....3879
EP2 SERVICE....3879
EP3 SERVICE....3879
EP4 SERVICE....3880
EP5 SERVICE....3881
OIL REPLACEMENT AND BRAKE HYDRAULIC SYSTEM BLEEDING....3881
Front brake circuit....3881
Rear brake circuit....3881
Air bleeding from the hydraulic circuit using the deaerating device....3881
SECTION 14 - Electric/Electronic system....3884
Electric/Electronic system....3884
PRELIMINARY REMARKS....3886
SYMBOLS-WARNINGS....3886
SYMBOLS-ASSISTANCE OPERATIONS....3887
PRODUCT CODE....3888
GENERAL WARNINGS....3889
GENERAL WARNINGS ON THE ELECTRIC SYSTEM....3891
CONCEPT OF GROUND AND ELECTROMAGNETIC COMPATIBILITY....3892
Practical tips....3893
CAN LINE....3894
Efficiency tests on the CAN line....3895
DESCRIPTION OF BASIC SYSTEM....3896
ELECTRICAL CHARACTERISTICS....3896
ENGINE COMPONENTS....3897
Engine F4AE0481....3897
POWER NETWORK....3898
Positive network....3898
Power cable sections....3898
Negative network....3899
Ground point identification....3900
STARTING....3907
General remarks....3907
Starting from the driver’s seat (Cab hooked)....3907
Starting from the engine compartment (Cab tilted)....3908
ALTERNATOR....3909
STARTER MOTOR....3910
COMPONENT CODE....3911
JUNCTION CONNECTOR....3916
BULKHEAD....3961
INSTRUMENT PANEL....3977
CENTRAL DASHBOARD....3978
INSTRUMENT CLUSTER....3980
Description....3980
Models available....3982
OPTICAL INDICATORS ON THE CLUSTER....3983
(FAILURE) INDICATORS ON THE DISPLAY....3984
“POP-UP” EVENTS....3986
CLUSTER (PIN-OUT)....3987
CENTRAL INTERCONNECTING UNIT....3988
REMOTE-CONTROL SWITCH ASSEMBLY....3989
FUSE ASSEMBLY....3990
CONNECTOR ASSEMBLY....3992
STEERING COLUMN STALK....3999
POSITION OF ELECTRONIC CONTROL UNITS....4000
BODY CONTROLLER....4001
Linking connectors....4001
CONNECTOR PIN-OUT....4006
TACHOGRAPH....4007
DESCRIPTION OF EDC 7 INJECTION SYSTEM....4008
ABS....4032
ECAS....4039
ENGINE BRAKE....4052
IMMOBILIZER....4054
ELECTRONIC CENTRAL UNIT DMI (DATA MANAGEMENT INTERFACE) (OPT. 5626)....4065
AUXILIARY HEATERWEBASTO....4067
DIAGNOSTIC INSTRUMENTS....4080
Diagnosis instruments....4080
System initialization screen....4081
DIAGNOSTIC screen (oly for Highline versions)....4082
Meanings of anomaly codes....4082
Description of fault codes (SPN)....4083
TROUBLESHOOTING....4084
Instrument Body Controller (IBC)....4084
Instrument Cluster (IC)....4099
“EDC 7” injection system....4104
MAINTENANCE SCHEDULE....4372
Circuit cards....4374
Card 1: Positive direct to the batteries....4376
Card 2: Positive after main current switch....4377
Card 3: Positive after main current switch....4378
Card 4: Service power supply (+15/1)....4379
Card 5: Service power supply (+15/1)....4380
Card 6: Service power supply (+15/2)....4381
Card 7: Body Controller....4382
Card 8: Body Controller....4383
Card 9: Body Controller....4384
Card 10: EDC (Connector B)....4385
Card 11: EDC (Connector B)....4386
Card 12: EDC (Connector A/C - 4 cylinders)....4387
Card 13: Instrument Cluster / Tachograph....4388
Card 14: Immobilizer....4389
Card 15: ABS....4390
Card 16: ECAS P....4391
Card 17: ECAS FP....4392
Card 18: Additional heater prearrangement AIRTOP2000....4393
Card 19: Additional heater prearrangement AIRTOP2000 with ADR....4394
Card 20: Manual-control air-conditioning....4395
Card 21: CAN line....4396
Card 22: Cigar lighter/Horns/Electric heater....4397
Card 23: Rotating lamps/Bed lights/ Emergency light/Headlamp washer....4398
Card 24: Electric window regulator/Sunroof (with and without the Bed Module)....4399
Card 25: Heated windscreen/Heated prefilter/Brake air drier/Pneumatic, heated seats....4400
Card 26: Central closing prearrangement/Adjustable, heated rearview mirrors....4401
Card 27: Main current remote-control switch (TGC)....4402
Card 28: Current Main Remote Control Switch (TGC) prearrangement (TGC)/ Compliance to rules ADR (TMP)....4403
Card 29: Cab tipping/Overall power takeoff....4404
Card 30: Fridge/Voltage reducer/Car radio....4405
Card 31: Loading board preset....4406
Card 32: Body builder connectors....4407
Card 33: PTO lateral - trasero - total /Bloqueo diferencial transversal y longitudinal....4408
Card 34: Central unit (DMI) (opt. 5626)....4409
6-10T (EURO 4_5) (603.93.613) (IT)....4410
EUROCARGO EURO 4/5 DA 6 A 10 t....4410
MANUALE PER LE RIPARAZIONI....4410
PREMESSA....4412
SIMBOLI - AVVERTENZE....4412
SIMBOLI - OPERAZIONI DI ASSISTENZA....4413
CODICE PRODOTTO....4414
AVVERTENZE GENERALI....4415
AVVERTENZE GENERALI SULL’IMPIANTO ELETTRICO....4417
Masse e schermature....4418
INSTALLAZIONI OPTIONAL ELETTRO-MECCANICI....4419
CONVERSIONI TRA LE PRINCIPALI UNITÀ DI MISURA DEL SISTEMA INTERNAZIONALE E LE GRANDEZZE DERIVATE DI PIÙ COMUNE IMPIEGO....4419
DATI DI AGGIORNAMENTO....4420
INDICE DELLE SEZIONI....4422
SEZIONE 1 - Generalità....4424
Generalità....4424
COMPOSIZIONE DEI MODELLI....4426
DATI DI IDENTIFICAZIONE E LORO UBICAZIONE SUL VEICOLO....4432
RIFORNIMENTI....4433
DENOMINAZIONE INTERNAZIONALE DEI LUBRIFICANTI....4434
SEZIONE 2 - Motore....4436
Motore....4436
CODIFICA IDENTIFICAZIONE MOTORE....4438
PRINCIPALI INTERVENTI SU MOTORE MONTATO SUL VEICOLO....4439
AVVERTENZE....4439
Pompa alta pressione CP3....4439
Accumulatore idraulico (rail) e accessori....4439
Elettroiniettore....4439
Tubazioni bassa pressione....4439
Tubazione alta pressione....4439
STACCO/RIATTACCO MOTORE....4440
Stacco....4440
Riattacco....4442
Verifiche e controlli....4442
Riempimento impianto di raffreddamento motore....4442
Spurgo aria dall’impianto d'alimentazione....4443
Spurgo aria dall’impianto idroguida....4443
SOSTITUZIONE ELETTROINIETTORI....4444
Stacco....4444
Riattacco....4444
Verifiche e controlli....4446
SOSTITUZIONE ANELLO DI TENUTA COPERCHIO ANTERIORE ALBERO MOTORE....4446
SOSTITUZIONE ANELLO DI TENUTA SCATOLA COPRIVOLANO....4447
STACCO/RIATTACCO TESTA CILINDRI....4448
Stacco....4448
Riattacco....4450
Verifiche e controlli....4450
MOTORE F4 AE 3481....4454
CARATTERISTICHE GENERALI....4456
DATI - GIUOCHI DI MONTAGGIO....4459
COPPIE DI SERRAGGIO....4465
ORGANI AUSILIARI....4467
ATTREZZATURA....4468
REVISIONE MOTORE....4475
SMONTAGGIO DEL MOTORE AL BANCO....4475
INTERVENTI RIPARATIVI....4483
GRUPPO CILINDRI....4483
Controlli e misurazioni....4483
Controllo superficie appoggio testa su gruppo cilindri....4484
DISTRIBUZIONE....4484
Albero distribuzione....4484
Controllo alzata eccentrici e controllo allineamento perni....4485
BOCCOLE....4485
Sostituzione delle boccole....4486
Punterie....4486
Montaggio punterie - Albero distribuzione....4486
ALBERO MOTORE....4487
Misurazione perni di banco e di biella....4487
Sostituzione ingranaggio comando pompa olio ....4489
Montaggio cuscinetti di banco....4489
Rilievo giuoco di montaggio perni di banco....4489
Controllo giuoco di spallamento albero motore....4490
COMPLESSIVO BIELLA-STANTUFFO....4490
Stantuffi....4491
Misurazione diametro stantuffi....4491
Perni stantuffi....4492
Condizioni per un corretto accoppiamento perni-stantuffi....4492
Anelli elastici....4492
Bielle....4493
Boccole....4493
Controllo bielle....4494
Controllo torsione....4494
Controllo flessione....4494
Montaggio complessivo biella-stantuffo....4494
Accoppiamento bielle-stantuffi....4494
Montaggio anelli elastici....4495
Montaggio complessivi biella stantuffo nelle canne cilindri....4495
Rilievo giuoco di montaggio perni di biella....4496
Controllo sporgenza stantuffi....4497
Scatola ingranaggi distribuzione....4497
Messa in fase distribuzione....4498
Scatola coprivolano....4498
VOLANO MOTORE....4499
Sostituzione corona dentata volano motore....4499
TESTA CILINDRI....4503
Smontaggio valvole....4503
Controllo tenuta idraulica testa cilindri....4504
Controllo superficie di appoggio testa cilindri....4504
VALVOLE....4505
Disincrostazione controllo e rettifica valvole....4505
Controllo giuoco fra stelo valvola guidavalvole e centratura valvole....4505
GUIDAVALVOLE....4506
SEDI VALVOLE....4506
Ripassatura - sostituzione sedi valvole....4506
MOLLE VALVOLE....4508
MONTAGGIO TESTA CILINDRI....4508
Riattacco testa cilindri....4508
Montaggio elettroiniettori....4509
ASTE....4510
Gruppo bilancieri....4510
Registrazione giuoco punterie....4511
Collettore di aspirazione....4512
Supporto cablaggio....4514
LUBRIFICAZIONE....4518
POMPA OLIO....4520
SCAMBIATORE DI CALORE....4520
Valvola di regolazione pressione olio....4521
Ricircolo vapori olio....4522
RAFFREDDAMENTO....4524
Pompa acqua....4526
Ventilatore viscostatico....4526
Termostato....4527
SOVRALIMENTAZIONE....4527
Turbocompressore....4527
Descrizione....4527
ATTUATORE TURBO COMPRESSORE....4528
Controllo e registrazione....4528
Sostituzione attuatore....4528
SISTEMA DI ALIMENTAZIONE AD INIEZIONE ELETTRONICA ALTA PRESSIONE (COMMON RAIL)....4529
Generalità....4529
IMPIANTO IDRAULICO....4531
SCHEMA IDRAULICO....4532
PREFILTRO COMBUSTIBILE....4534
FILTRO COMBUSTIBILE....4534
POMPA MECCANICA DI ALIMENTAZIONE....4535
Normale condizione di funzionamento....4535
Condizione di sovrappressione in uscita....4535
Condizioni di spurgo....4535
POMPA AD ALTA PRESSIONE CP3....4536
STRUTTURA INTERNA POMPA ALTA PRESSIONE....4537
Principio di funzionamento....4538
Funzionamento....4540
RAIL (ACCUMULATORE DI PRESSIONE)....4540
VALVOLA DI SOVRAPPOSIZIONE A DOPPIO STADIO....4540
ELETTROINIETTORE....4541
Iniettore in posizione di riposo....4541
Inizio iniezione....4541
Fine iniezione....4541
LIMITATORE DI PRESSIONE PER RITORNO COMBUSTIBILE....4541
MOTORE F4 AE 3681....4544
CARATTERISTICHE GENERALI....4546
DATI - GIUOCHI DI MONTAGGIO....4549
REVISIONE MOTORE F4AE3681....4557
Smontaggio del motore al banco....4557
DISTRIBUZIONE....4558
Albero distribuzione....4558
BOCCOLE....4558
TESTA CILINDRI SEDI VALVOLE....4560
Serraggio viti fissaggio testa cilindri....4562
LUBRIFICAZIONE....4564
RAFFREDDAMENTO....4565
SISTEMA DENOX 2....4566
SISTEMA DENOX 2....4568
Generalità....4568
Serbatoio....4570
Comando indicatore di livello liquido AdBlue....4570
Modulo pompa....4570
Modulo di dosaggio....4570
Sensore di temperatura gas di scarico....4571
Sensore di rilevamento umidità....4572
GUIDA ALLA RICERCA GUASTI....4574
PREMESSA....4576
Diagnosi mediante strumenti....4576
DIAGNOSTICA....4578
SEZIONE 3 - Frizione....4588
Frizione....4588
DESCRIZIONE....4590
Frizione....4590
CARATTERISTICHE E DATI....4590
DIAGNOSTICA....4591
COPPIE DI SERRAGGIO....4594
ATTREZZATURA....4594
STACCO E RIATTACCO....4595
Stacco....4595
Riattacco....4595
REVISIONE DISCO CONDOTTO....4595
Controllo mozzo smorzatore....4595
Guarnizioni d’attrito....4595
STACCO-RIATTACCO CUSCINETTO REGGISPINTA....4596
SOSTITUZIONE DEL CUSCINETTO DI SUPPORTO ALBERO FRIZIONE....4596
COMANDO IDRAULICO....4597
Mini-Servofrizione....4597
Collegamenti....4597
Cilindro disinnesto frizione....4597
Complessivo montaggio frizioni....4598
Controllo usura frizioni....4598
REGOLAZIONE DELLE VITI DI POSIZIONE PEDALE E FINE CORSA....4599
Gioco pedale frizione....4599
Corsa del pedale frizione....4599
PROCEDURA DI SPURGO DEL COMANDO FRIZIONE....4599
SEZIONE 4 - Cambi di velocità....4600
Cambi di velocità....4600
DIAGNOSTICA....4602
COMANDO MARCE....4604
REGISTRAZIONE CAVI BOWDEN....4605
Cambio di velocità ZF S5-42....4608
DESCRIZIONE....4610
UBICAZIONE TARGHETTA DESCRITTIVA CAMBIO DI VELOCITÀ....4611
CARATTERISTICHE E DATI....4612
Cambio di velocità 2855B.6....4614
DESCRIZIONE....4616
CARATTERISTICHE E DATI....4617
COPPIE DI SERRAGGIO....4620
ATTREZZATURA....4621
STACCO/RIATTACCO CAMBIO 2855B.6....4626
Stacco....4626
Riattacco....4626
SMONTAGGIO DEL CAMBIO DI VELOCITÀ....4628
Controlli....4631
MONTAGGIO DEL CAMBIO DI VELOCITÀ....4632
Registrazione precarico cuscinetti per albero secondario....4632
SMONTAGGIO ALBERO PRIMARIO....4639
MONTAGGIO DELL’ALBERO PRIMARIO....4641
SMONTAGGIO ALBERO ENTRATA MOTO....4644
MONTAGGIO ALBERO ENTRATA MOTO....4644
Registrazione cuscinetto albero entrata moto....4644
SMONTAGGIO ALBERO SECONDARIO....4645
MONTAGGIO ALBERO SECONDARIO....4645
SMONTAGGIO ALBERO DEL COMANDO INTERNO....4645
MONTAGGIO ALBERO DEL COMANDO INTERNO....4645
Registrazione interruttore Folle-R.M.....4646
Cambio di velocità 2865B.6....4648
DESCRIZIONE....4650
CARATTERISTICHE E DATI....4652
COPPIE DI SERRAGGIO....4654
ATTREZZATURA....4655
SMONTAGGIO DEL CAMBIO DI VELOCITÀ....4660
Sostituzione guarnizione di tenuta coperchio posteriore....4663
Controlli....4664
MONTAGGIO DEL CAMBIO DI VELOCITÀ....4664
Registrazione precarico cuscinetti per albero secondario....4665
SMONTAGGIO ALBERO PRIMARIO....4669
MONTAGGIO DELL’ALBERO PRIMARIO....4671
SMONTAGGIO ALBERO ENTRATA MOTO....4674
MONTAGGIO ALBERO ENTRATA MOTO....4674
SMONTAGGIO ALBERO SECONDARIO....4675
MONTAGGIO ALBERO SECONDARIO....4675
SMONTAGGIO ALBERO DEL COMANDO INTERNO....4675
MONTAGGIO ALBERO DEL COMANDO INTERNO....4675
Registrazione interruttore Folle-R.M.....4676
Cambio di velocità 2870B.9....4678
DESCRIZIONE....4680
CARATTERISTICHE E DATI....4681
COPPIE DI SERRAGGIO....4684
ATTREZZATURA....4685
SMONTAGGIO DEL CAMBIO DI VELOCITÀ....4690
Controlli....4694
MONTAGGIO DEL CAMBIO DI VELOCITÀ....4695
Registrazione precarico cuscinetti per albero secondario....4695
Registrazione interruttore Folle-R.M.....4701
SMONTAGGIO ALBERO PRIMARIO....4702
MONTAGGIO ALBERO PRIMARIO....4704
SMONTAGGIO ALBERO ENTRATA MOTO....4704
MONTAGGIO ALBERO ENTRATA MOTO....4705
Registrazione cuscinetto albero entrata moto....4705
SMONTAGGIO ALBERO SECONDARIO....4705
MONTAGGIO ALBERO SECONDARIO....4705
SMONTAGGIO ALBERO COMANDO INTERNO....4705
MONTAGGIO ALBERO COMANDO INTERNO....4706
GRUPPO RIDUTTORE EPICICLOIDALE....4707
Schemi di funzionamento circuito pneumatico comando riduttore epicicloidale....4707
SMONTAGGIO....4709
Controlli....4711
MONTAGGIO....4712
SEZIONE 5 - Alberi di trasmissione....4716
Alberi di trasmissione....4716
DESCRIZIONE....4718
CARATTERISTICHE E DATI ALBERI DI TRASMISSIONE "FISSI" E " SCORREVOLI"....4722
CARATTERISTICHE E DATI ALBERI DI TRASMISSIONE "MONOTRONCO"....4723
DIAGNOSTICA....4724
COPPIE DI SERRAGGIO....4724
STACCO-RIATTACCO ALBERO DI TRASMISSIONE MONOTRONCO....4725
Stacco....4725
Riattacco....4725
STACCO-RIATTACCO ALBERO DI TRASMISSIONE SCORREVOLE....4726
Stacco....4726
Riattacco....4726
STACCO- RIATTACCO ALBERO DI TRASMISSIONE IN DUE TRONCHI....4726
CONTROLLO ALBERI DI TRASMISSIONE SU VEICOLO....4726
SEZIONE 6 - Ponti 4517 e 4521....4728
Ponti 4517 e 4521....4728
DESCRIZIONE....4730
CARATTERISTICHE E DATI....4732
DIAGNOSTICA....4734
COPPIE DI SERRAGGIO....4736
ATTREZZATURA....4740
STACCO/RIATTACCO PONTE (con sospensioni meccaniche)....4744
Stacco....4744
Riattacco....4744
STACCO/RIATTACCO PONTE (con sospensioni pneumatiche)....4745
Stacco....4745
Riattacco....4745
REVISIONE COMPLESSIVO PONTE POSTERIORE....4746
STACCO - RIATTACCO SFIATO ARIA....4746
REVISIONE MOZZI RUOTE....4747
Smontaggio....4747
Controllo dei particolari componenti i mozzi ruote....4748
Controllo scatola ponte....4749
Montaggio....4750
RIPARAZIONE DIFFERENZIALE....4752
Smontaggio inerente al ponte posteriore 4517....4753
Smontaggio inerente al ponte posteriore 4521....4753
Smontaggio scatola ruotismi....4753
Smontaggio gruppo pignone conico....4754
Controllo dei particolari componenti il differenziale....4755
Montaggio scatola ruotismi....4756
Montaggio gruppo pignone conico....4757
Montaggio inerente al ponte posteriore 4521....4759
Montaggio inerente al ponte posteriore 4521....4761
Montaggio scatola ruotismi sulla scatola ponte....4761
Montaggio inerente al ponte posteriore 4517....4761
Montaggio inerente al ponte posteriore 4521....4761
VARIANTE CON BLOCCAGGIO DIFFERENZIALE....4765
Smontaggio....4766
Controlli....4766
Montaggio....4766
SENSORE DISPOSITIVO ANTISKID....4766
Montaggio....4766
SEZIONE 7 - Assali anteriori 5833 - 5833/1....4768
Assali anteriori 5833 - 5833/1....4768
DESCRIZIONE....4770
Assale anteriore....4770
Angoli caratteristici....4772
CARATTERISTICHE E DATI....4774
DIAGNOSTICA....4776
COPPIE DI SERRAGGIO....4779
ATTREZZATURA....4780
STACCO/RIATTACCO ASSALE (con sospensioni meccaniche)....4784
Stacco....4784
Riattacco....4784
STACCO/RIATTACCO ASSALE (con sospensioni pneumatiche)....4785
Stacco....4785
Riattacco....4785
ASSETTO RUOTE ANTERIORI....4786
Posizionamento graffe e proiettori....4786
Compensazione elettronica della scentratura del cerchio....4787
Allineamento delle ruote....4787
Controllo convergenza delle ruote....4788
Controllo inclinazione delle ruote (Camber)....4788
Controllo angolo di inclinazione montante (King Pin) e angolo di incidenza (Caster)....4788
Controllo angoli di sterzata....4789
REVISIONE DEL COMPLESSIVO ASSALE ANTERIORE....4790
STACCO E RIATTACCO MOZZI RUOTE....4790
Stacco....4790
Sostituzione dell’anello di tenuta....4791
Riattacco mozzi ruote....4791
Registrazione giuoco assiale cuscinetti mozzi ruote....4791
Rilievo della coppia di rotolamento....4792
SOSTITUZIONE CUSCINETTI MOZZI RUOTE....4792
SOSTITUZIONE COLONNETTE FISSAGGIO RUOTE....4793
STACCO E RIATTACCO TIRANTE TRASVERSALE....4793
Stacco....4793
Riattacco....4793
SOSTITUZIONE SNODI TIRANTE TRASVERSALE....4794
STACCO E RIATTACCO LEVA PER TIRANTE LONGITUDINALE....4794
STACCO E RIATTACCO DEL PERNO PER FUSO A SNODO....4794
Stacco....4794
Riattacco....4795
Controllo e registrazione del giuoco tra fuso a snodo e assale....4796
SOSTITUZIONE CUSCINETTO PERNO FUSO....4797
CONTROLLI E MISURAZIONI DEL CORPO ASSALE....4798
Controllo inclinazione dei fori per perni fuso a snodo....4799
SEZIONE 8 - Sospensioni....4800
Sospensioni....4800
SOSPENSIONI MECCANICHE ANTERIORI E POSTERIORI....4802
DESCRIZIONE....4804
MOLLE A BALESTRA ANTERIORI....4804
CARATTERSTICHE E DATI MOLLE A BALESTRA PARABOLICHE ANTERIORI....4805
Modelli 60E.. - 100E.. con carico sull’assale fino a 3400 kg....4805
Modelli 65E.. - 100E.. con carico sull’assale superiore a 3400 kg....4806
CARATTERISTICHE E DATI MOLLE A BALESTRA SEMIELLITTICHE ANTERIORI....4807
Modelli 60E..K....4807
Modelli 65E..K - 75E..K....4808
Modelli 75E 16K....4809
Modelli 80E..K - 100E..K....4810
MOLLE A BALESTRA POSTERIORI....4811
CARATTERISTICHE E DATI MOLLE A BALESTRA PARABOLICHE POSTERIORI....4813
Modelli 60E.. - 65E.. - 75E.. - 80E......4813
Modelli 100E......4814
CARATTERISTICHE E DATI MOLLE A BALESTRA SEMIELLITTICHE POSTERIORI....4815
Modelli 60E..K - 65E..K....4815
Modelli 75E..K....4816
Modelli 80E..K....4817
Modelli 100E..K....4818
AMMORTIZZATORI....4819
Schemi di montaggio....4819
CARATTERISTICHE E DATI AMMORTIZZATORI....4820
Ammortizzatori anteriori (con modello a balestra paraboliche)....4820
Ammortizzatori anteriori (con molle a balestra semiellittiche)....4820
Ammortizzatori posteriori (con molle a balestra paraboliche)....4821
Ammortizzatori posteriori (con molle a balestra semiellittiche)....4821
DIAGNOSTICA....4822
COPPIE DI SERRAGGIO....4826
ATTREZZATURA....4826
ATTREZZATURA SPERIMENTALE....4827
STACCO-RIATTACCO SOSPENSIONI MECCANICHE ANTERIORI....4828
Stacco....4828
Riattacco....4828
STACCO-RIATTACCO SOSPENSIONI MECCANICHE POSTERIORI....4829
Stacco....4829
Riattacco....4829
AMMORTIZZATORI ANTERIORI....4830
Stacco....4830
Riattacco....4830
AMMORTIZZATORI POSTERIORI....4830
Stacco....4830
Riattacco....4830
BARRA STABILIZZATRICE ANTERIORE....4830
Stacco....4830
Riattacco....4830
BARRA STABILIZZATRICE POSTERIORE....4831
Stacco....4831
Riattacco....4831
INTERVENTI RIPARATIVI....4831
SOSTITUZIONE BOCCOLE MOLLE A BALESTRA....4831
STACCO E RIATTACCO BOCCOLE MOLLE A BALESTRA POSTERIORI....4831
Stacco boccole posteriori....4831
Riattacco boccole posteriori....4834
Stacco boccole anteriori....4835
Riattacco boccole anteriori....4835
STACCO E RIATTACCO BOCCOLE MOLLE A BALESTRA ANTERIORI....4836
Stacco boccole anteriori....4836
Riattacco boccole anteriori....4837
Stacco boccole posteriori....4837
Riattacco boccole posteriori....4837
SOSPENSIONI PNEUMATICHE ANTERIORI E POSTERIORI....4838
SOSPENSIONI PNEUMATICHE....4840
GENERALITÀ....4840
COMPLESSIVI SOSPENSIONI PNEUMATICHE....4840
Schema di principio sospensioni pneumatiche posteriori....4841
Schema di principio sospensioni FULL pneumatic....4842
DISPOSIZIONE DEI PRINCIPALI COMPONENTI SUL VEICOLO....4843
SOLLEVAMENTO ABBASSAMENTO E AUTOLIVELLAMENTO DEL TELAIO....4844
Telecomando....4844
DESCRIZIONE E FUNZIONAMENTO DEL TELECOMANDO....4845
Sollevamento/Abbassamento del telaio....4845
Autolivellamento del telaio....4845
Livello “M 1” - “M 2”....4845
DIAGNOSTICA....4846
COPPIE DI SERRAGGIO....4848
Sospensione pneumatica anteriore....4848
Sospensione pneumatica posteriore tipo HENDRICKSON....4848
ATTREZZATURA....4849
CARATTERISTICHE E DATI....4850
Impianto pneumatico....4850
MOLLA A BALESTRA ANTERIORE (MODELLI ML 80E18FP/21FP - ML90E18FP/21FP - ML 100E18FP/21FP)....4851
Ammortizzatori anteriori....4852
Ammortizzatori posteriori....4852
PRINCIPALI COMPONENTI DELL’IMPIANTO PNEUMATICO....4853
Valvola a pressione controllata....4853
Sensore di livello....4853
Distributore elettropneumatico assale per veicoli 4 x 2 FP....4854
Funzionamento....4854
Sollevamento assale....4854
Abbassamento assale....4854
Autolivellamento....4854
Distributore elettropneumatico ponte per veicoli 4 x 2 P/FP....4855
Funzionamento....4855
Sollevamento ponte....4855
Abbassamento ponte....4855
Autolivellamento....4855
INTERRUTTORE MANOMETRICO BASSA PRESSIONE ARIA....4856
MOLLE AD ARIA....4856
Centralina elettronica....4856
STACCO-RIATTACCO SOSPENSIONI PNEUMATICHE ANTERIORI....4858
Stacco....4858
Riattacco....4858
STACCO - RIATTACCO SOSPENSIONI PNEUMATICHE POSTERIORI TIPO HENDRICKSON....4859
Stacco....4859
Riattacco....4859
AMMORTIZZATORI ANTERIORI....4860
Stacco....4860
Riattacco....4860
MOLLE AD ARIA ANTERIORI....4860
Stacco....4860
Riattacco....4860
AMMORTIZZATORI POSTERIORI....4860
Stacco....4860
Riattacco....4860
MOLLE AD ARIA POSTERIORI....4861
Stacco....4861
Riattacco....4861
BARRA STABILIZZATRICE ANTERIORE....4861
BARRA STABILIZZATRICE POSTERIORE....4861
SEZIONE 9 - Ruote e Pneumatici....4862
Ruote e Pneumatici....4862
DESCRIZIONE....4864
CARATTERISTICHE E DATI....4864
Valori di pressione dei pneumatici....4864
ATTREZZATURA....4865
DIAGNOSTICA....4865
EQUILIBRATURA STATICA DELLE RUOTE....4868
CORREZIONE DELLO SQUILIBRIO STATICO RESIDUO....4869
PRESSIONE DEI PNEUMATICI....4869
COMPORTAMENTO DEL PNEUMATICO IN FUNZIONE DELLA PRESSIONE....4870
SEZIONE 10 - Sterzo....4872
Sterzo....4872
DESCRIZIONE....4874
Vista installazione dell’impianto idroguida....4874
CARATTERISTICHE E DATI....4874
SCHEMA COMANDO STERZO....4875
DIAGNOSTICA....4876
COPPIE DI SERRAGGIO....4881
ATTREZZATURA....4882
POMPA SERVOSTERZO ZF FN4 INTEGRAL....4882
Descrizione....4882
IDROGUIDA ZF 8090....4883
Descrizione....4883
Limitazione idraulica della sterzata....4886
STACCO E RIATTACCO IDROGUIDA (ZF 8090)....4887
Stacco....4887
Riattacco....4888
IDROGUIDA TRW TAS 30....4889
Descrizione....4889
Posizione neutra marcia rettilinea....4890
Posizione di sterzata a destra....4891
Posizione di sterzata a sinistra....4892
LIMITAZIONE IDRAULICA DELLA STERZATA....4893
Impostazione della regolazione automatica della limitazione idraulica della sterzata dell’idroguida TRW TAS 30....4894
Controllo regolazione automatica....4894
Regolazione delle cadute idrauliche....4895
SPURGO DELL’ARIA DAL CIRCUITO IDROGUIDA....4896
MISURAZIONE DEI GIUOCHI NELLA SCATOLA GUIDA RILEVATI SUL VOLANTE....4896
CONTROLLO DELLA PRESSIONE MASSIMA DELL’IMPIANTO IDROGUIDA....4896
SEZIONE 11 - Impianto Pneumatico - Freni....4898
Impianto Pneumatico - Freni....4898
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (VARI E GENERATORI)....4902
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (VALVOLE)....4903
SIMBOLIGRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SERBATOI EACCUMULATORI)....4909
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (CONVERTITORI, CILINDRI E PINZE)....4910
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (PINZE E CILINDRI)....4911
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SEMI GIUNTI E TESTE D’ACCOPPIAMENTO)....4912
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (SEGNALATORI E INTERRUTTORI)....4914
SIMBOLI GRAFICI PER SCHEMI IMPIANTI IDROPNEUMATICI (FRENI)....4915
TUBAZIONI E RACCORDI....4916
Generalità....4916
Ribordatura delle tubazioni rigide....4916
Piegatura delle tubazioni rigide....4917
Taglio delle tubazioni rigide....4917
Sostituzione delle tubazioni flessibili con raccordi filettati....4918
Sostituzione delle tubazioni flessibili con raccordi ad innesto rapido....4919
IMPIANTO DI FRENATURA....4921
Schema di principio per veicoli isolati....4921
Schema di principio per veicoli atti al traino....4922
DISPOSIZIONE SUL VEICOLO DEI PRINCIPALI COMPONENTI DELL’IMPIANTO DI FRENATURA....4923
Descrizione....4924
Frenatura di servizio....4924
Freno motore....4924
Funzionamento....4924
Freno di stazionamento....4924
Freni....4924
Freni anteriori e poteriori....4924
DIAGNOSTICA....4925
COPPIE DI SERRAGGIO....4936
ATTREZZATURA....4937
CARATTERISTICHE E DATI - IMPIANTO PNEUMATICO....4940
Compressore....4940
A.P.U. (essiccatore/4 vie)....4940
Essiccatore....4940
Valvola di protezione a 4 vie....4940
Serbatoi aria....4940
Distributore duplex....4940
Valvola limitatrice di pressione (per veicoli atti al traino)....4940
Valvola potenziatrice (per veicoli atti al traino)....4941
Servo distributore a triplo comando (per veicoli atti al traino)....4941
Teste d’accoppiamento moderabile e automatico....4941
Convertitori pneumoidraulici....4941
Valvola di scarico manuale....4941
Distributore freno di stazionamento (veicoli isolati)....4942
Distributore freno di stazionamento (veicoli atti al traino)....4942
Valvola di scarico rapido....4942
Cilindro a molla....4942
Centralina elettronica ABS....4942
Elettrovalvola per ABS....4942
CARATTERISTICHE E DATI - FRENI....4943
CONTROLLI DEI PRINCIPALI COMPONENTI DELL’IMPIANTO FRENI....4944
PRINCIPALI COMPONENTI DELL’IMPIANTO FRENI....4947
COMPRESSORE....4947
Diagnostica....4947
A.P.U. (Air Processing Unit)....4948
Funzionamento....4949
Diagnostica....4950
INTERRUTTORE FRENO MOTORE....4951
ELETTROVALVOLA FRENO MOTORE....4951
CILINDRO OPERATORE COMANDO FRENO MOTORE....4951
VALVOLA DI SCARICO MANUALE....4951
VALVOLA DI SICUREZZA (Optional)....4952
DISTRIBUTORE DUPLEX....4952
Sfrenatura....4953
Diagnostica....4953
VALVOLA LIMITATRICE DI PRESSIONE....4954
Funzionamento....4954
Limitazione della pressione....4954
Taratura al banco....4954
Diagnostica....4954
SERVODISTRIBUTORE A TRIPLO COMANDO....4955
Regolazione della predominanza....4955
Diagnostica....4955
TESTE DI ACCOPPIAMENTO....4956
Funzionamento....4956
VALVOLA DI RITENUTA....4956
Funzionamento....4956
CONVERTITORI PNEUMOIDRAULICI....4957
Cilindro maestro....4957
Controlli....4957
Montaggio....4957
Diagnostica....4958
VALVOLA POTENZIATRICE....4958
Diagnostica....4958
SISTEMI ANTISLITTAMENTO....4959
Dispositivo antibloccaggio ruote (ABS)....4959
VALVOLA ELETTROPNEUMATICA....4959
Funzionamento....4959
CENTRALINA ELETTRONICA....4960
Funzionamento....4960
SENSORI GIRI....4960
RUOTE FONICHE....4960
Funzionamento....4960
SPURGO ARIA DAL CIRCUITO IDRAULICO....4961
Circuito freni anteriori....4961
Circuito freni posteriori....4961
Spurgo aria dal circuito idraulico mediante dispositivo disaereatore....4961
DISTRIBUTORE A MANO COMANDO FRENO DI STAZIONAMENTO (Veicoli isolati)....4962
Diagnostica....4962
DISTRIBUTORE A MANO COMANDO FRENO DI STAZIONAMENTO (Veicoli atti al traino)....4963
Diagnostica....4963
CILINDRO FRENO A MOLLA....4964
Funzionamento....4964
Dispositivo di sfrenatura di emergenza del cilindro a molla....4964
Ripristino dei freni posteriori nella condizione di marcia....4965
Interventi riparativi....4965
Diagnostica....4965
RIPARAZIONE FRENI....4966
Freni anteriori....4966
Funzionamento....4966
SOSTITUZIONE GUARNIZIONI FRENANTI ANTERIORI....4966
Per assale 5833/1....4967
Per tutti i modelli....4967
Per assale 5833....4968
Per assale 5833/1....4968
STACCO PINZE FRENO ANTERIORI....4969
Per tutti i modelli....4969
STACCO MOZZI RUOTE ANTERIORI....4969
REVISIONE DISCHI FRENO....4970
TORNITURA E RETTIFICA DEI DISCHI FRENO....4970
Freni posteriori....4971
Funzionamento....4971
SCHEMA DI FUNZIONAMENTO IDRAULICO DELLA PINZA FRENO POSTERIORE (GIRLING)....4971
Funzionamento del dispositivo del freno di stazionamento....4971
Funzionamento del dispositivo di recupero automatico del gioco....4971
Funzionamento del sistema di recupero usura....4973
Prima fase di funzionamento (F1 = F2) - Bassa pressione....4974
Seconda fase di funzionamento (F1 > F2) - Alta pressione....4975
Terza fase di funzionamento (Ritorno della pressione a zero) - Posizione di riposo....4976
Frenatura di stazionamento....4977
Funzionamento della frenatura di stazionamento....4977
SOSTITUZIONE GUARNIZIONI FRENANTI POSTERIORI Figura 99....4978
Smontaggio....4978
Per ponte 4517....4978
Per tutti i modelli....4979
Montaggio....4980
Per ponte 4521....4980
Per ponte 4517....4980
STACCO PINZE FRENO POSTERIORE....4980
STACCO MOZZI RUOTE POSTERIORI....4981
REVISIONE PINZE FRENO....4982
Smontaggio pinze freno....4984
Per pinza posteriore....4984
Per pinza anteriore e posteriore....4985
Per pinza posteriore....4985
Per pinza posteriore Girling....4985
Per pinza posteriore Brembo....4985
Per pinza anteriore e posteriore....4986
Pulizia e controllo dei Particolari componenti....4986
Montaggio pinze freno....4986
Per pinza posteriore (Girling)....4986
Per pinza posteriore (Brembo)....4986
Per pinza anteriore e posteriore....4987
Per pinza anteriore....4987
Per pinza posteriore....4987
Per pinza anteriore e posteriore....4988
Per pinza posteriore....4988
MONTAGGIO FRENI....4988
RIATTACCO MOZZI RUOTE ANTERIORI....4988
RIATTACCO MOZZI RUOTE POSTERIORI....4990
RIATTACCO PINZE FRENO....4991
RIATTACCO DELLE PINZE FRENO POSTERIORI....4992
SEZIONE 12 - Carrozzeria Telaio....4994
Carrozzeria - Telaio....4994
CABINA....4996
Generalità....4996
TRATTAMENTI PROTETTIVI SCOCCA....4997
Trattamento protettivo....4997
Trattamento di preparazione delle lamiere (bonderizzazione)....4998
Applicazione delle vernice protettiva (cataforesi)....4998
VERIFICA DELLA GEOMETRIA DEL TELAIO....4998
NORME GENERALI PER GLI INTERVENTI SUL TELAIO....4998
Preparazione del telaio agli interventi di manutenzione, verifica e riparazione dei casi autorizzati da IVECO....4998
Saldatura per punti....4999
Prescrizioni sulla saldatura....4999
Interventi da parte del carrozziere sui longheroni del telaio IVECO....4999
Forature sul telaio....4999
PRECAUZIONI....5000
Saldature sul telaio....5001
TELAIO....5002
INTERVENTI RIPARATIVI CONTROLLI....5002
Rilievo del piegamento laterale del telaio....5003
Rilievo del piegamento del telaio verso il basso o verso l’alto....5003
Rilievo dello spostamento del telaio....5003
Rilievo della torsione del telaio....5004
QUOTE DI RIFERIMENTO TELAIO....5005
GEOMETRIA DELLA CABINA....5010
SCHEMA ZONE DI APPLICAZIONE SIGILLANTE....5011
ANCORAGGIO CABINA E COPPIE DI SERRAGGIO....5014
ATTREZZATURA....5019
INTERVENTI RIPARATIVI....5020
Ancoraggio cabina....5020
Sostituzione ammortizzatori anteriori e posteriori sospensione cabina....5020
Stacco e riattacco supporti anteriori e barra stabilizzatrice cabina....5020
IMPIANTO DI SOLLEVAMENTO IDRAULICO CABINA....5021
Sostituzione cilindro idraulico per ribaltamento cabina....5022
SOSTITUZIONE CRISTALLO PARABREZZA....5022
Generalità....5022
Coltello a vibrazione....5022
Filo armonico....5023
Stacco (con filo armonico)....5023
Preparazione del vano parabrezza....5023
Preparazione del parabrezza....5024
Riattacco....5024
Sostituzione cristallo scendente porte....5026
Sostituzione dispositivo alza cristallo....5027
Sostituzione cristallo fisso....5027
PLANCIA STRUMENTI....5029
Stacco....5029
Riattacco....5029
PLANCIA STRUMENTI CENTRALE....5029
Stacco....5029
Riattacco....5030
RIVESTIMENTO PLANCIA STRUMENTI....5030
Stacco....5030
Riattacco....5035
RISCALDAMENTO E VENTILAZIONE....5035
Stacco....5035
Riattacco....5035
SEZIONE 13 - Manutenzione programmata....5036
Manutenzione programmata....5036
PIANO DI MANUTENZIONE ELETTRONICO....5038
COLLEGAMENTO STRUMENTI DI DIAGNOSI....5039
MANUTENZIONE....5040
Prospetto dei servizi di manutenzione....5040
INTERVALLI MANUTENZIONE....5040
SERVIZIO DI MANUTENZIONE FUORI PIANO E OPERAZIONI TEMPORALI....5040
Operazioni fuori piano/temporali (possibilmente in concomitanza con un servizio di manutenzione)....5040
OPERAZIONI DI MANUTENZIONE PROGRAMMATA....5044
OPERAZIONI FUORI PIANO/TEMPORALI....5044
SERVIZIO M1....5045
SERVIZIO M2....5046
SERVIZIO M3....5048
SERVIZIO M4....5048
MANUTENZIONE FUORI PIANO....5049
SERVIZIO EP1....5049
SERVIZIO EP2....5049
SERVIZIO T1....5049
SERVIZIO T2....5049
SERVIZIO T3....5049
SERVIZIO T4....5050
SERVIZIO T5....5050
SOSTITUZIONE OLIO E SPURGO IMPIANTO IDRAULICO FRENI....5051
Circuito freni anteriori....5051
Circuito freni posteriori....5051
Spurgo aria dal circuito idraulico mediante dispositivo disaereatore....5051
SERVIZIO T6....5052
SEZIONE 14 - Impianto Elettrico/Elettronico....5054
Impianto Elettrico/Elettronico....5054
PREMESSA....5056
SIMBOLI - AVVERTENZE....5056
SIMBOLI - OPERAZIONI DI ASSISTENZA....5057
CODICE PRODOTTO....5058
AVVERTENZE GENERALI....5059
AVVERTENZE GENERALI SULL’IMPIANTO ELETTRICO....5061
CONCETTO DI MASSA E COMPATIBILITÀ ELETTROMAGNETICA....5062
Consigli pratici....5063
CAMBIAMENTI PRINCIPALI....5064
LINEA CAN VDB - EURO 3....5065
Prove di efficienza sulla linea CAN A B....5066
LINEE CAN - EURO 4....5067
COMPLESSIVO LINEE CAN....5071
RETE DI POTENZA....5072
Rete positiva....5072
Sezioni cavi di potenza....5072
Rete negativa....5073
Identificazione dei punti di massa....5074
AVVIAMENTO....5081
Generalità....5081
Avviamento da posto guida (Cabina agganciata)....5081
Avviamento da vano motore (Cabina ribaltata) ....5082
ALTERNATORE....5083
MOTORINO DI AVVIAMENTO....5084
CODICI COMPONENTI....5085
PASSAPARETE....5090
PLANCIA PORTASTRUMENTI....5097
PLANCIA CENTRALE....5098
INSTRUMENT CLUSTER....5100
INDICATORI OTTICI SU CLUSTER....5103
INDICATORI (AVARIE) SU DISPLAY....5104
CLUSTER (PIN-OUT)....5107
UNITÀ CENTRALE DI INTERCONNESSIONE....5108
COMPLESSIVO MINITELERUTTORI....5109
COMPLESSIVO FUSIBILI....5111
FUSIBILI SUPPLEMENTARI....5113
DEVIOGUIDA....5114
UBICAZIONE CENTRALINE ELETTRONICHE....5115
BODY CONTROLLER (IBC3)....5116
MODULO ELETTRONICO TELAIO (M.E.T.)....5122
TACHIGRAFO DIGITALE (DTCO)....5125
COMPONENTI CENTRALINA ECM (EDC7)....5133
COMPONENTI CENTRALINA VCM....5142
CENTRALINA ELETTRONICA VCM (VEHICLE CONTROL MODULE)....5146
FRENO MOTORE....5149
IMMOBILIZER....5151
SISTEMA SCR (SELECTIVE CATALYTIC REDUCTION) - DENOX 2....5153
ABS 6....5156
ECAS....5163
CENTRALINA ELETTRONICA DMI (DATA MANAGEMENT INTERFACE) (OPT. 5626)....5173
RISCALDATORE WEBASTO....5175
SISTEMA DI CHIUSURA CENTRALIZZATA CON TELECOMANDO....5188
STRUMENTI DIAGNOSTICI....5190
PIANO DI MANUTENZIONE....5194
SCHEDE CIRCUITALI....5196
Scheda 1: Positivo diretto batterie (+Batt)....5198
Scheda 2: Positivo dopo interruttore generale di corrente (+30)....5199
Scheda 3: Positivo dopo interruttore generale di corrente (+30)....5200
Scheda 4: Positivo dopo interruttore generale di corrente (+30)....5201
Scheda 5: Positivo dopo interruttore generale di corrente (+30)....5202
Scheda 6: Alimentazione servizi (+15)....5203
Scheda 7: Alimentazione servizi (+15)....5204
Scheda 8: Alimentazione servizi (+15/1)....5205
Scheda 9: Body Controller....5206
Scheda 10: Body Controller....5207
Scheda 11: Body Controller....5208
Scheda 12: Body Controller....5209
Scheda 13: Instrument Cluster....5210
Scheda 14: Tachigrafo....5211
Scheda 15: Centralina VCM....5212
Scheda 16: Centralina VCM....5213
Scheda 17: EDC (connettore B)....5214
Scheda 18: EDC (Connettore A/C - 4 cilindri)....5215
Scheda 19: Centralina UDS....5216
Scheda 20: Centralina MET (connettore A)....5217
Scheda 21: Centralina MET (connettore P)....5218
Scheda 22: Centralina MET (connettore C)....5219
Scheda 23: ABS....5220
Scheda 24: ECAS P....5221
Scheda 25: ECAS FP....5222
Scheda 26: Riscaldatore supplementare AIRTOP2000....5223
Scheda 27: Climatizzazione a comando manuale....5224
Scheda 28: Linee CAN (BCB / VDB / EDB / ECB)....5225
Scheda 29: Accendisigari/Avvisatori acustici/Elettroriscaldatore....5226
Scheda 30: Fari rotanti/Luci lettini/Lampada di emergenza/Lavaproiettori....5227
Scheda 31: Alzacristalli elettrici/Tetto apribile (con e senza Bed Module)....5228
Scheda 32: Parabrezza riscaldato/Prefiltro riscaldato/Essicatore aria freni/ Sedili pneumatici riscaldati....5229
Scheda 33: Frigorifero/Riduttore di tensione/Autoradio....5230
Scheda 34: Ribaltamento cabina/Predisposizione sponda caricatrice....5231
Scheda 35: Chiusura centralizzata/Specchi retrovisori termici regolabili....5232
Scheda 36: Chiusura centralizzata con telecomando....5233
Scheda 37: PTO laterale - posteriore - totale/Cambio meccanico....5234
Scheda 38: Teleruttore Generale di corrente (TGC)....5235
Scheda 39: Teleruttore Generale di corrente (TGC)/Adeguamento normativa ADR (TMP)....5236
Scheda 40: Centralina DMI....5237
6-26T EWD (603.93.181) (EN)....5238
EUROCARGO TECTOR 6 TO 26 t....5238
REPAIR MANUAL ELECTRIC/ELECTRONIC SYSTEM....5238
PREFACE....5240
UPDATE DATA....5242
GENERAL LIST OF CONTENTS....5244
Introduction....5246
General warnings for electrical/electronic components....5248
General warnings for electrical/electronic components....5249
Concept of ground and electromagnetic compatibility....5250
Practical tips....5252
CAN Line....5253
Efficiency tests on the CAN line....5255
General....5258
Description of basic system....5260
Engine mounted components....5261
POWER NETWORK....5266
Identification of earth points....5268
ENGINE STARTING....5273
Alternator....5275
Starting....5276
Main components....5278
Instrument panel....5280
Central dashboard....5281
INSTRUMENT CLUSTER....5283
Models available....5285
OPTICAL INDICATORS ON THE CLUSTER....5286
(FAILURE) INDICATORS ON THE DISPLAY....5287
“POP-UP” EVENTS....5289
CLUSTER (PIN-OUT)....5290
CENTRAL INTERCONNECTING UNIT....5291
REMOTE-CONTROL SWITCH ASSEMBLY....5292
FUSE ASSEMBLY....5293
CONNECTOR ASSEMBLY....5295
STEERING COLUMN STALK....5302
POSITION OF ELECTRONIC CONTROL UNITS....5303
BODY CONTROLLER....5304
CONNECTOR PIN-OUT....5309
BULKHEAD....5310
DIAGNOSIS CONNECTOR....5316
TACHOGRAPH....5318
Electronic systems....5320
EDC 7....5322
ABS....5346
ECAS....5356
Engine Brake....5370
Immobilizer....5372
AIR TOP 2000 auxiliary heater....5385
Circuit cards....5398
Card 1: Positive direct to the batteries....5400
Card 2: Positive after main current switch....5401
Card 3: Positive after main current switch....5402
Card 4: Service power supply (15/1)....5403
Card 5: Service power supply (+15/1)....5404
Card 6: Service power supply (+15/2)....5405
Card 7: Body Controller....5406
Card 8: Body Controller....5407
Card 9: Body Controller....5408
Card 10: EDC (Connector B)....5409
Card 11: EDC (Connector B)....5410
Card 12: EDC (Connector A)....5411
Card 13: Instrument Cluster / Tachograph....5412
Card 14: Immobilizer....5413
Card 15: ABS (4X2)....5414
Card 16: ABS (6X2)....5415
Card 17: ECAS 4X2 Pneumatic....5416
Card 18: ECAS 4X2 Full Pneumatic....5417
Card 19: Auxiliary heater AIRTOP2000....5418
Card 20: Manual-control air-conditioning....5419
Card 21: CAN lines....5420
Card 22: Cigar lighter/Horns/Electric heater....5421
Card 23: Rotating lamps/Bed lights/ Emergency light/Headlamp washer....5422
Card 24: Electric window regulator/Sunroof (with and without the Bed Module)....5423
Card 25: Heated windscreen/Heated prefilter/Brake air drier/Pneumatic, heated seats....5424
Card 26: Central locking/Adjustable, heated rearview mirrors....5425
Card 27: Main current remote-control switch (TGC)/ Compliance to rules ADR (TMP)....5426
Card 28: Main current remote-control switch (TGC) / Compliance to rules ADR (TMP)....5427
Card 29: Cab tipping/Overall power takeoff....5428
Card 30: Fridge/Voltage reducer/Car radio....5429
6-26T EWD (603.93.183) (IT)....5430
EUROCARGO TECTOR DA 6 A t....5430
MANUALE PER LE RIPARAZIONI IMPIANTO ELETTRICO/ELETTRONICO....5430
PREMESSA....5432
DATI DI AGGIORNAMENTO....5434
INDICE GENERALE....5436
Introduzione....5438
Avvertenze generali per i componenti elettrici/elettronici....5440
Avvertenze generali per i componenti elettronici....5441
Concetto di massa e compatibilità elettromagnetica....5442
Consigli pratici....5444
Linea CAN....5445
Prove di efficienza sulla linea CAN....5447
Generalità....5450
Descrizione impianto base....5452
Componenti sul motore....5453
RETE DI POTENZA....5458
Identificazione punti di massa....5460
AVVIAMENTO....5465
Alternatore....5467
Motorino di avviamento....5468
Componenti principali....5470
Plancia portastrumenti....5472
Plancia centrale....5473
INSTRUMENT CLUSTER....5475
Versioni disponibili....5477
INDICATORI OTTICI SU CLUSTER....5478
INDICATORI (AVARIE) SU DISPLAY....5479
EVENTI DI “POP-UP”....5481
CLUSTER (PIN-OUT)....5482
UNITÀ CENTRALE D’INTERCONNESSIONE....5483
COMPLESSIVO TELERUTTORI....5484
COMPLESSIVO FUSIBILI....5485
COMPLESSIVO CONNETTORI....5487
DEVIOGUIDA....5494
UBICAZIONE CENTRALINE ELETTRONICHE....5495
BODY CONTROLLER....5496
PIN-OUT CONNETTORI....5501
PASSAPARETE....5502
CONNETTORE DIAGNOSI....5508
TACHIGRAFO....5510
Sistemi elettronici....5512
EDC 7....5514
ABS....5538
ECAS....5548
Freno motore....5562
Immobilizer....5564
Riscaldatore Air Top 2000 WEBASTO....5577
Schede circuitali....5590
Scheda 1: Positivo diretto batterie....5592
Scheda 2: Positivo dopo interruttore generale di corrente....5593
Scheda 3: Positivo dopo Interruttore Generale di corrente....5594
Scheda 4: Alimentazione servizi (15/1)....5595
Scheda 5: Alimentazione servizi (+15/1)....5596
Scheda 6: Alimentazione servizi (+15/2)....5597
Scheda 7: Body Controller....5598
Scheda 8: Body Controller....5599
Scheda 9: Body Controller....5600
Scheda 10: EDC (Connettore B)....5601
Scheda 11: EDC (Connettore B)....5602
Scheda 12: EDC (Connettore A)....5603
Scheda 13: Instrument Cluster / Tachigrafo....5604
Scheda 14: Immobilizer....5605
Scheda 15: ABS (4X2)....5606
Scheda 16: ABS (6X2)....5607
Scheda 17: ECAS 4X2 Pneumatic....5608
Scheda 18: ECAS 4X2 Full Pneumatic....5609
Scheda 19: Riscaldatore supplementare AIRTOP2000....5610
Scheda 20: Climatizzazione a comando manuale....5611
Scheda 21: Linee CAN....5612
Scheda 22: Accendisigari/Avvisatori acustici/Elettroriscaldatore....5613
Scheda 23: Fari rotanti/Luci Lettini/Lampada di emergenza/Lavaproiettori....5614
Scheda 24: Alzacristalli elettrici/Tetto apribile (con e senza Bed Modul)....5615
Scheda 25: Parabrezza riscaldato/Prefiltro riscaldato/Essicatore aria freni/Sedili pneumatici riscaldati....5616
Scheda 26: Chiusura centralizzata/Specchi retrovisori termici regolabili....5617
Scheda 27: Teleruttore Generale di corrente (TGC)/Adeguamento normativa ADR (TMP)....5618
Scheda 28: Teleruttore Generale di corrente (TGC)/Adeguamento normativa ADR (TMP)....5619
Scheda 29: Ribaltamento cabina/Presa di forza totale....5620
Scheda 30: Frigorifero/Riduttore di tensione/Autoradio....5621
603.93.183 EuroCargo Electrical Service Manual....5622
EUROCARGO TECTOR DA 6 A t....5622
MANUALE PER LE RIPARAZIONI IMPIANTO ELETTRICO/ELETTRONICO....5622
PREMESSA....5624
DATI DI AGGIORNAMENTO....5626
INDICE GENERALE....5628
Introduzione....5630
Avvertenze generali per i componenti elettrici/elettronici....5632
Avvertenze generali per i componenti elettronici....5633
Concetto di massa e compatibilità elettromagnetica....5634
Consigli pratici....5636
Linea CAN....5637
Prove di efficienza sulla linea CAN....5639
Generalità....5642
Descrizione impianto base....5644
Componenti sul motore....5645
RETE DI POTENZA....5650
Identificazione punti di massa....5652
AVVIAMENTO....5657
Alternatore....5659
Motorino di avviamento....5660
Componenti principali....5662
Plancia portastrumenti....5664
Plancia centrale....5665
INSTRUMENT CLUSTER....5667
Versioni disponibili....5669
INDICATORI OTTICI SU CLUSTER....5670
INDICATORI (AVARIE) SU DISPLAY....5671
EVENTI DI “POP-UP”....5673
CLUSTER (PIN-OUT)....5674
UNITÀ CENTRALE D’INTERCONNESSIONE....5675
COMPLESSIVO TELERUTTORI....5676
COMPLESSIVO FUSIBILI....5677
COMPLESSIVO CONNETTORI....5679
DEVIOGUIDA....5686
UBICAZIONE CENTRALINE ELETTRONICHE....5687
BODY CONTROLLER....5688
PIN-OUT CONNETTORI....5693
PASSAPARETE....5694
CONNETTORE DIAGNOSI....5700
TACHIGRAFO....5702
Sistemi elettronici....5704
EDC 7....5706
ABS....5730
ECAS....5740
Freno motore....5754
Immobilizer....5756
Riscaldatore Air Top 2000 WEBASTO....5769
Schede circuitali....5782
Scheda 1: Positivo diretto batterie....5784
Scheda 2: Positivo dopo interruttore generale di corrente....5785
Scheda 3: Positivo dopo Interruttore Generale di corrente....5786
Scheda 4: Alimentazione servizi (15/1)....5787
Scheda 5: Alimentazione servizi (+15/1)....5788
Scheda 6: Alimentazione servizi (+15/2)....5789
Scheda 7: Body Controller....5790
Scheda 8: Body Controller....5791
Scheda 9: Body Controller....5792
Scheda 10: EDC (Connettore B)....5793
Scheda 11: EDC (Connettore B)....5794
Scheda 12: EDC (Connettore A)....5795
Scheda 13: Instrument Cluster / Tachigrafo....5796
Scheda 14: Immobilizer....5797
Scheda 15: ABS (4X2)....5798
Scheda 16: ABS (6X2)....5799
Scheda 17: ECAS 4X2 Pneumatic....5800
Scheda 18: ECAS 4X2 Full Pneumatic....5801
Scheda 19: Riscaldatore supplementare AIRTOP2000....5802
Scheda 20: Climatizzazione a comando manuale....5803
Scheda 21: Linee CAN....5804
Scheda 22: Accendisigari/Avvisatori acustici/Elettroriscaldatore....5805
Scheda 23: Fari rotanti/Luci Lettini/Lampada di emergenza/Lavaproiettori....5806
Scheda 24: Alzacristalli elettrici/Tetto apribile (con e senza Bed Modul)....5807
Scheda 25: Parabrezza riscaldato/Prefiltro riscaldato/Essicatore aria freni/Sedili pneumatici riscaldati....5808
Scheda 26: Chiusura centralizzata/Specchi retrovisori termici regolabili....5809
Scheda 27: Teleruttore Generale di corrente (TGC)/Adeguamento normativa ADR (TMP)....5810
Scheda 28: Teleruttore Generale di corrente (TGC)/Adeguamento normativa ADR (TMP)....5811
Scheda 29: Ribaltamento cabina/Presa di forza totale....5812
Scheda 30: Frigorifero/Riduttore di tensione/Autoradio....5813
Iveco EuroCargo/Tector 2002-2008 Workshop Repair & Service Manual
