Iveco EuroCargo Tector 12-26t Repair Manual – PDF DOWNLOAD
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Iveco EuroCargo Tector 12-26t Repair Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Iveco
DESCRIPTION:
Iveco EuroCargo Tector 12-26t Repair Manual – PDF DOWNLOAD
”This document provides data, characteristics, instructions and methodology to perform repair interventions on the vehicle and its components. Anyhow, this document is addressed to qualified and specialised personnel. Iveco commercial and assistance network personnel as well as all Iveco authorised points of assistance are specifically qualified and equipped to perform the repair interventions that are indicated in this document. Before performing any intervention, check to have available the document relating to the vehicle model on which the intervention is being performed and also make sure that all accident prevention devices, such as, as a rough guide, goggles, helmet, gloves, shoes, as well as work tooling, lifting and transport tooling, etc., are available and efficient, and further make sure that the vehicle is put such a way that an intervention can be made in safety conditions.
Making interventions strictly observing the indications given here, as well as using specific tooling indicated, assures a correct repair intervention, execution timing observance and operators’ safety. Each repair intervention must be finalised to the recovery of functionality, efficiency and safety conditions that are provided by Iveco. Each intervention, on the vehicle, that is finalised to a modification, alteration or else, which is not authorised by Iveco, involves the exclusion of any responsibility for Iveco, and, in particular, where the vehicle is covered by a guarantee, each such intervention involves an immediate lapse of the guarantee.
Responsibility for Iveco in repair intervention execution is excluded. Iveco is available to provide all clarifications necessary tomake interventions, as well as to provide indications in cases and situations not included in this document. Data and information contained in this document could result not to be updated owing to modifications made by Iveco at any moment for technical or commercial reasons, or because of the need to adapt the vehicle to law requirements in different countries.
In the case of a difference between what contained here and what actually found on the vehicle, please contact Iveco network before making any intervention.” The data contained in this publication might fail to reflect the latest changes which the Manufacturer may introduce at any time, for technical or sales purposes, or to meet the requirements of local legislation. Copy, even partial, of text and drawings is forbidden.
TABLE OF CONTENTS:
Iveco EuroCargo Tector 12-26t Repair Manual – PDF DOWNLOAD
EUROCARGO TECTOR 12 TO 26 t 1
REPAIR MANUAL 1
PRELIMINARY REMARKS 3
SYMBOLS -WARNINGS 3
SYMBOLS – ASSISTANCE OPERATIONS 4
PRODUCT CODE 5
GENERAL WARNINGS 6
GENERAL WARNINGS ON THE ELECTRIC SYSTEM 8
Bonding and screening 9
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS 10
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES 10
UPDATE DATA 11
INDEX OF SECTIONS 13
SECTION 1 – General Specifications 15
General Specifications 15
COMPOSITION OF THE MODELS 17
IDENTIFICATION DATA AND LOCATION ON VEHICLE 27
FILLING UP 28
INTERNATIONAL LUBRICANT DESIGNATION 29
SECTION 2 – Engine 31
Engine 31
ENGINE IDENTIFICATION CODES 33
MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE 34
WARNINGS 34
High pressure CP3 pump 34
Rail and fittings 34
Injector 34
Low pressure tubing 34
High pressure tubing 34
ENGINE REMOVAL/REFITTING 35
Removal 35
Refitting 37
Tests and checks 37
Engine cooling filling system 37
Air bleeding from fuel system 38
Air bleeding from hydraulic power steering system 38
INJECTORS REPLACEMENT 39
Removal 39
Refitting 39
Tests and checks 41
REPLACING SEAL RING FRONT COVER DRIVING SHAFT 41
REPLACING SEAL RING FLYWHEEL HOUSING BOX 42
CYLINDER HEAD REMOVAL/REFITTING 43
Removal 43
Refitting 45
Tests and checks 45
Engine F4 AE 0481 49
GENERAL SPECIFICATIONS 51
ASSEMBLY DATA – CLEARANCES 54
TIGHTENING TORQUE 60
AUXILIARY COMPONENTS 62
TOOLS 62
ENGINE OVERHAUL 70
DISASSEMBLY OF THE ENGINE AT THE BENCH 70
REPAIR INTERVENTIONS 78
CYLINDER GROUP 78
Controls and measurements 78
Head face check on the cylinder group 79
TIMING SYSTEM 79
Camshaft 79
Cam lift check and pin alignment check 80
BUSHES 80
Bush replacement 81
Tappets 81
Fitting tappets – camshaft 81
OUTPUT SHAFT 82
Measuring journals and crankpins 82
Replacing oil pump control gear 84
Fitting main bearings 84
Finding journal clearance 84
Checking output shaft shoulder clearance 85
CONNECTING ROD – PISTON ASSEMBLY 85
Pistons 86
Measuring piston diameter 86
Piston pins 87
Conditions for proper pin-piston coupling 87
Split rings 87
Connecting rods 88
Bushes 88
Checking connecting rods 89
Checking torsion 89
Checking bending 89
Fitting connecting rod-piston assembly 89
Connecting rod-piston coupling 89
Fitting split rings 90
Fitting connecting rod-piston assembly into cylinder barrels 90
Finding crankpin clearance 91
Checking piston protrusion 92
Timing gear case 92
Timing 93
Flywheel housing 93
ENGINE FLYWHEEL 94
Replacing engine flywheel ring gear 94
CYLINDER HEAD 98
Removing the valves 98
Checking cylinder head wet seal 99
Checking cylinder head supporting surface 99
VALVES 100
Removing carbon deposits, checking and grinding valves 100
Checking clearance between valve stem and valve guide and valve centering 100
VALVE GUIDE 101
VALVE SEATS 101
Regrinding – replacing the valve seats 101
VALVE SPRINGS 103
FITTING CYLINDER HEAD 103
Refitting the cylinder head 103
Fitting injectors 104
RODS 105
Rocker assembly 105
Tappet clearance adjustment 106
Intake manifold 107
Wiring support 109
LUBRICATION 113
OIL PUMP 115
HEAT EXCHANGER 115
Oil pressure relief valve 116
Oil vapour recycling 117
COOLING SYSTEM 119
Water Pump 121
Viscous fan 121
Thermostat 122
BOOSTER 122
Turbosupercharger 122
Description 122
TURBOSUPERCHARGER ACTUATOR 123
Check and adjustment 123
Actuator replacement 123
TURBOSUPERCHARGER LAYOUT 125
SYSTEM OF INJECTION FEEDING ELECTRONIC TALL PRESSURE COMMON RAIL 127
General Specifications 127
FEED SYSTEM 129
FEED SYSTEM LAYOUT 131
FUEL PREFILTER 133
FUEL FILTER 133
MECHANICAL SUPPLY PUMP 134
Normal operating conditions 134
Overpressure condition at outlet 134
Drain conditions 134
CP3 HIGH-PRESSURE PUMP 135
HIGH-PRESSURE PUMP – INSIDE STRUCTURE 136
Operating principle 137
Operation 139
RAIL 139
DOUBLE STAGE OVERPRESSURE VALVE 140
INJECTOR 141
Injector in rest position 141
Injection start 141
Injection end 141
PRESSURE LIMITER FOR FUEL RETURN 141
Engine F4 AE 0681 145
GENERAL SPECIFICATIONS 147
ASSEMBLY DATA – CLEARANCES 150
ENGINE F4AE0681 OVERHAUL 158
Engine removal at the bench 158
TIMING SYSTEM 159
Camshaft 159
BUSHES 159
CYLINDER HEAD VALVE SEATS 161
Cylinder head fastening screw tightening 163
LUBRICATION 165
COOLING SYSTEM 166
BOOSTER 167
Turbosupercharger 167
TURBOSUPERCHARGER ACTUATOR 167
Check and adjustment 167
TURBOSUPERCHARGER LAYOUT 169
Troubleshooting Guide 171
FOREWORD 173
Diagnosis through instruments 173
DIAGNOSTICS 175
SECTION 3 – Clutch 185
Clutch 185
DESCRIPTION 187
Clutch 187
SPECIFICATIONS AND DATA 187
DIAGNOSTICS 191
TIGHTENING TORQUES 194
TOOLS 194
REMOVAL AND REFITTING 195
Removal 195
Refitting 195
DRIVEN PLATE OVERHAUL 195
Damper hub check 195
Friction gaskets 195
THRUST BEARING REMOVAL – REFITTING 196
REPLACING CLUTCH SHAFT SUPPORT BEARING 196
HYDRAULIC CONTROL 197
Mini-servoclutch (13” – 13”/14” clutches) 197
Clutch disengagement cylinder (13” – 13”/14” clutches) 197
13” – 13”/14” clutch mounting assembly 198
13” – 13”/14” clutch wear check 198
Midi-servoclutch cylinder (15”/16” clutches) 199
Clutch disengagement cylinder (15”/16” clutches) 199
15”/16” clutch wear check 200
15”/16” clutch mounting assembly 200
CLUTCH DISENGAGEMENT CYLINDER TIP ADJUSTMENT (New 15”/16” clutch) 201
ADJUSTMENT OF STOP AND PEDAL POSITIONING SCREWON THE CLUTCH PEDAL 202
Clutch pedal clearance 202
Clutch pedal travel 202
CLUTCH CONTROL SYSTEM BLOW-OFF PROCEDURE 202
SECTION 4 – Gearbox 203
Gearbox 203
DIAGNOSTICS 205
Gears control connection 207
Gearbox control tie-rods adjustment 207
Gearbox 2855S 6 211
DESCRIPTION 213
SPECIFICATIONS AND DATA 214
TIGHTENING TORQUES 217
TOOLS 218
GEARBOX 2855S 6 REMOVAL/REFITTING 223
Removal 223
Refitting 223
GEARBOX DISASSEMBLY 225
Checks 228
GEARBOX ASSEMBLY 229
Bearings pre-load adjustment for secondary shaft 229
PRIMARY SHAFT DISASSEMBLY 235
PRIMARY SHAFT ASSEMBLY 237
MOTION INLET SHAFT DISASSEMBLY 240
MOTION INLET SHAFT ASSEMBLY 240
Motion inlet shaft bearing adjustment 240
SECONDARY SHAFT DISASSEMBLY 241
SECONDARY SHAFT ASSEMBLY 241
INTERNAL DRIVE SHAFT DISASSEMBLY 241
INTERNAL DRIVE SHAFT ASSEMBLY 241
EXTERNAL CONTROL SHAFT DISASSEMBLY 242
EXTERNAL CONTROL BOX ASSEMBLY 243
Idle-R M switch adjustment 245
Gearbox 2865S 6 247
DESCRIPTION 249
SPECIFICATIONS AND DATA 251
TIGHTENING TORQUES 253
TOOLS 254
GEARBOX 2865S 5 REMOVAL/ REFITTING 259
Removal 259
Refitting 259
GEARBOX DISASSEMBLY 261
Rear cover sealing gasket replace-ment 264
Checks 265
GEARBOX ASSEMBLY 265
Bearings pre-loading adjustment for secondary shaft 266
PRIMARY SHAFT DISASSEMBLY 270
PRIMARY SHAFT ASSEMBLY 273
MOTION ENTRY SHAFT DISASSEMBLY 275
MOTION ENTRY SHAFT ASSEMBLY 276
SECONDARY SHAFT DISASSEMBLY 276
SECONDARY SHAFT ASSEMBLY 276
INTERNAL CONTROL SHAFT DISASSEMBLY 277
INTERNAL CONTROL SHAFT ASSEMBLY 277
EXTERNAL CONTROL SHAFT DISASSEMBLY 277
EXTERNAL CONTROL BOX ASSEMBLY 278
Idle-R M switch adjustment 280
Gearbox 2870S 9 281
DESCRIPTION 283
SPECIFICATIONS AND DATA 284
TIGHTENING TORQUES 287
TOOLS 288
GEARBOX 2870S 9 REMOVAL/ REFITTING 293
Removal 293
Refitting 293
GEARBOX DISASSEMBLY 295
Checks 299
GEARBOX ASSEMBLY 300
Bearings pre-load adjustment for secondary shaft 300
Idle-Reverse Gear switch adjustment 306
PRIMARY SHAFT DISASSEMBLY 307
PRIMARY SHAFT ASSEMBLY 309
MOTION INLET SHAFT DISASSEMBLY 309
MOTION INLET SHAFT ASSEMBLY 310
Motion inlet shaft bearing adjustment 310
SECONDARY SHAFT DISASSEMBLY 310
SECONDARY SHAFT ASSEMBLY 310
INTERNAL DRIVE SHAFT DISASSEMBLY 310
INTERNAL DRIVE SHAFT ASSEMBLY 311
EXTERNAL DRIVE CASE DISASSEMBLY 311
EXTERNAL DRIVE CASE ASSEMBLY 312
EPICYCLIC REDUCTION GEAR ASSEMBLY 315
Operating diagrams about pneumatic epicyclic reduction gear drive circuit 315
DISASSEMBLY 317
Checks 319
ASSEMBLY 320
Gearbox 2895S 9 325
DESCRIPTION 327
SPECIFICATIONS AND DATA 328
TIGHTENING TORQUE 331
TOOLS 332
GEARBOX REMOVAL/REFITTING 337
Removal 337
Refitting 337
GEARBOX DISASSEMBLING 337
Checks 341
GEARBOX ASSEMBLING 341
Adjusting transmission shaft bearing pre – load 341
Idle-R M switch adjustment 346
MAIN SHAFT DISASSEMBLING 347
MAIN SHAFT ASSEMBLING 349
INPUT SHAFT DISASSEMBLING 350
INPUT SHAFT ASSEMBLING 350
TRANSMISSION SHAFT 350
Bearing replacement 350
INTERNAL CONTROL SHAFT DISASSEMBLING 351
INTERNAL CONTROL SHAFT ASSEMBLING 351
EXTERNAL CONTROL BOX DISASSEMBLING 351
EXTERNAL CONTROL BOX ASSEMBLY 352
EPICYCLIC REDUCTION GEAR ASSEMBLY 355
Operating diagrams about pneumatic epicyclic reduction gear drive circuit 355
DISASSEMBLY 357
Checks 359
ASSEMBLY 360
Allison gearbox MD 3060P 365
DESCRIPTION 367
CHARACTERISTICS AND DATA 370
MAIN OPERATION ANOMALIES 371
TIGHTENING TORQUES 379
TOOLS 379
REMOVAL/ REFITTING (ALLISON) GEARBOX 381
Removal 381
Refitting 382
REMOVAL AND REFITTING GEARBOX CONTROL MODULE AGAIN 383
Disconnecting 383
Refitting 383
REPLACING SPEED SENSORS 383
Replacing turbine speed sensor 383
Engine revolutions sensor replacement 384
Replacing the output speed sensor 384
REPLACING OIL LEVEL SENSOR 384
REPLACING OIL SUCTION FILTER 385
REPLACING THE SOLENOID VALVES 385
REPLACING PLANE GASKETS IN GEARBOX CONTROL MODULE 386
REPLACING PRESSURE SWITCH F3 387
REPLACING THE SEAL RING ON THE OUTPUT SHAFT 387
Gearbox EATON FSO 5206B 389
DESCRIPTION 391
POSITION OF GEARSHIFT IDENTIFICATION TAG 392
SPECIFICATIONS AND DATA 393
Gear selection and engagement grid 396
TIGHTENING TORQUES 397
TOOLS 399
REMOVAL/REFITTING (EATON FSO5206B) GEARBOX 403
Removal 403
Refitting 403
EXPERIMENTAL TOOLS 405
GEARSHIFT OVERHAUL 406
Checks 406
GEAR DRIVE CASE 406
Disassembling 406
Assembling 407
Refitting 409
Disassembling the gearbox 410
MOTION INLET SHAFT 413
Disassembling 413
Assembling 413
OUTPUT SHAFT 413
Disassembling 413
Assembling 417
INTERNAL DRIVING SHAFT 421
Disassembling 421
Assembling 422
Gearbox assembling 423
Adjusting the axial play of countershaft bearings 426
SECTION 5 – Propeller shafts 429
Propeller shafts 429
DESCRIPTION 431
PROPELLER SHAFT LAYOUT ON VEHICLES 436
PROPELLER SHAFT SPECIFICATIONS AND DATA 437
DIAGNOSTICS 439
TIGHTENING TORQUES 439
SLIDING PROPELLER SHAFT REMOVAL-REFITTING 440
Removal 440
Refitting 440
FIXED PROPELLER SHAFT REMOVAL-REFITTING 440
CHECKING PROPELLER SHAFTS ON VEHICLE 440
SECTION 6 – Rear axle 441
Rear axles 441
Axles in tandem ArvinMeritor SP 145 E 443
Axles in tandem (Intermediate) – ArvinMeritor PD 145 E (R 2468) 445
DESCRIPTION 447
LOCATION OF DIFFERENTIAL UNIT PLATES – REAR AXLE 448
SPECIFICATIONS AND DATA 449
TIGHTENING TORQUES 451
TOOLS 454
EXPERIMENTAL TOOLS 460
INTERMEDIATE AXLE DISCONNECTION/ RECONNECTION (with Hendrickson suspensions) 463
Disconnection 463
Reconnection 463
SERVICING INTERMEDIATE AXLE ASSEMBLY PD 145 E (R 2468) 465
AIR BREATHER REMOVAL-REFITTING 465
SERVICING WHEEL HUBS 465
Checking wheel hub components 466
ASSEMBLING WHEEL HUBS 467
REMOVING DIFFERENTIAL GEAR – TRANSFER BOX (with rear axle on stand 99322215) 470
REFITTING DIFFERENTIAL GEAR – TRANSFER BOX (with rear axle on stand 99322215) 470
REPAIRING INTER-AXLE UNIT 471
Dismantling inter-axle unit 471
Checking inter-axle unit components 473
Fitting inter-axle unit 473
Adjusting drive input shaft bearing end float 475
Adjusting differential lock and inter-axle control pin end-stop 476
REPAIRING MAIN DIFFERENTIAL-DISMANTLING DIFFERENTIAL CASING 476
Dismantling gear cage 480
Checking differential components 480
Assembling gear cage 481
ASSEMBLING DIFFERENTIAL CASING 482
Calculating bevel pinion position in differential casing 482
COMPUTATIONAL EXAMPLES 483
Adjusting the cap gap 486
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY) 488
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT 491
Axles in tandem (Rear) – ArvinMeritor PR 140 E (R 0868) 495
DESCRIPTION 497
LOCATION OF DIFFERENTIAL UNIT – COMPLETE REAR AXLE DESCRIPTION PLATES 498
SPECIFICATIONS AND DATA 499
TIGHTENING TORQUES 501
TOOLS 503
SERVICING REAR AXLE ASSEMBLY PR 140 E (R 0868) 508
AIR BREATHER REMOVAL/INSTALLATION 508
OVERHAULING WHEEL HUBS 508
REMOVING DIFFERENTIAL (with axle on stand 99322215) 508
REFITTING DIFFERENTIAL (with axle on stand 99322215) 508
REFITTING DIFFERENTIAL (with axle on stand 99322215) 508
REPAIRING DIFFERENTIAL 509
Removing differential lock 509
Dismantling differential casing 510
Dismantling gear cage 511
Dismantling bevel pinion support 511
Checking differential components 515
Assembling gear cage 515
Specimen calculations 517
Assembling differential casing 517
ADJUSTING THE CAP GAP 519
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY) 522
ArvinMeritor Axle MS 08-125 525
DESCRIPTION 527
LOCATION OF DIFFERENTIAL UNIT – COMPLETE REAR AXLE DESCRIPTION PLATES 528
TECHNICAL NAME 528
FEATURES AND DATA 529
DIAGNOSTICS 531
TIGHTENING TORQUES 533
TOOLS 536
REAR AXLE DISCONNECTION-RECONNECTION 540
Rear axle disconnection Vehicles with a mechanical suspension 540
Rear axle disconnection Vehicles with a pneumatic suspension 542
Axle reconnection 543
DIFFERENTIAL DISCONNECTION-RECONNECTION WITH THE AXLE ON THE VEHICLE 544
Disconnection 544
Reconnection 544
REAR AXLE ASSEMBLY OVERHAUL 545
Air vent disconnection and reconnection 545
Wheel hub overhaul 545
Check parts making up the wheel hubs 549
Replacement of wheel holding down studs 549
Wheel hub mounting 549
FIXING THE DIFFERENTIAL 553
Dismounting the differential box 553
DISMOUNTING THE WHEELWORK BOX 554
BEVEL PINION SUPPORT DISASSEMBLING 555
Check of parts making up the differential 558
MOUNTING THE WHEELWORK BOX 558
MOUNTING BEVEL PINION SUPPORT 559
CALCULATION EXAMPLES 562
MOUNTING THE DIFFERENTIAL BOX 562
Adjusting cap opening out 563
FIXING CROWN WHEEL AND PINION ASSEMBLY CONTACTS (AFTER MOUNTING) 566
Directions to adjust and check the operation of the transmitter for checking differential locking device insertion 570
ArvinMeritor Axle MS10 – 144 571
DESCRIPTION 573
LOCATION OF DIFFERENTIAL UNIT – COMPLETE REAR AXLE DESCRIPTION PLATES 574
TECHNICAL NAME 574
SPECIFICATIONS AND DATA 575
DIAGNOSTICS 577
TIGHTENING TORQUES 579
TOOLS 581
REAR AXLE REMOVAL/ REFITTING (vehicles with pneumatic suspensions) 587
Removal 587
Refitting 587
REAR AXLE REMOVAL/ REFITTING (vehicles with mechanical suspensions) 588
Removal 588
Refitting 588
OVERHAULING THE REAR AXLE ASSEMBLY 589
OVERHAULING THE WHEEL HUBS 589
Disassembly 589
Replacing wheel hub bearings 590
Checking the parts forming the wheel hubs 591
Replacing the wheel fixing pins 591
REMOVAL THE DIFFERENTIAL (with axle on stand no 99322215) 594
REFITTING THE DIFFERENTIAL (with axle on stand no 99322215) 594
FIXING THE DIFFERENTIAL 595
Disassembly the differential box 595
Disassembly the wheelwork box 597
Disassembly bevel pinion support 598
Check of parts making up the differential 599
Assembly the wheelwork box 599
Assembly bevel pinion support 601
Assembly the differential box 605
Adjusting cap opening out 607
BEVEL TORQUE CONTACTS CORRECTION (AFTER ASSEMBLY) 609
AXLES WITH DIFFERENTIAL LOCKING DEVICE 612
Description 612
TIGHTENING TORQUES 613
REMOVAL THE DIFFERENTIAL (with axle on stand no 99322215) 614
FIXING THE DIFFERENTIAL 614
Disassembly of the differential locking device 614
Assembly of the differential locking device 615
Directions to adjust and check the operation of the transmitter for checking differential locking insertion 616
ArvinMeritor Axle MS10 – 164 617
DESCRIPTION 619
LOCATION OF DIFFERENTIAL UNIT – COMPLETE REAR AXLE DESCRIPTION PLATES 620
TECHNICAL NAME 620
SPECIFICATIONS AND DATA 621
DIAGNOSTICS 622
TIGHTENING TORQUES 624
TOOLS 626
REAR AXLE REMOVAL/ REFITTING (with pneumatic suspensions) 631
Removal 631
Refitting 631
REAR AXLE REMOVAL/ REFITTING (with mechanical suspensions) 632
Removal 632
Refitting 632
OVERHAULING THE REAR AXLE ASSEMBLY 633
OVERHAULING THE WHEEL HUBS 633
Disassembly 633
Replacing wheel hub bearings 634
Checking the parts forming the wheel hubs 635
Replacing the wheel fixing pins 635
DIFFERENTIAL GEAR REMOVAL AND REFITTING (with rear axle on stand 99322215) 638
Removal 638
Refitting 638
DIFFERENTIAL GEAR REPAIR 639
Differential gear disassembly 639
Gearing case disassembly 640
BEVEL PINION DISASSEMBLY FROM SUPPORT 642
Check of parts composing differential gearing assembly 642
Gearing case assembly 643
FITTING THE SUPPORT ON THE BEVEL PINION 644
Differential case assembly 647
CAP RETRACTION ADJUSTMENT 649
BEVEL TORQUE CONTACTS CORRECTION (AFTER ASSEMBLY) 652
Instructions for adjusting and verifying transmitter operation to check insertion of differential gear locking 655
WORK ON THE VEHICLE 656
REPLACING THE BEVEL PINION SUPPORT SEAL RING 656
Disassembly 656
Assembly 657
ArvinMeritor Axle MS13 – 165 659
DESCRIPTION 661
LOCATION OF DIFFERENTIAL UNIT – COMPLETE REAR AXLE DESCRIPTION PLATES 662
TECHNICAL NAME 662
SPECIFICATIONS AND DATA 663
DIAGNOSTICS 664
TIGHTENING TORQUES 666
TOOLS 668
OVERHAULING THE REAR AXLE ASSEMBLY 673
OVERHAULING THE WHEEL HUBS 673
Removal 673
Replacing wheel hub bearings 675
Checking the parts forming the wheel hubs 675
Replacing the wheel fixing pins 675
REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215) 679
Removal 679
Refitting 679
REPAIRING THE DIFFERENTIAL 680
Removing the differential 680
Removing the gearcase 681
REMOVING THE BEVEL PINION FROM THE SUPPORT 683
Differential component check 683
Fitting the gear housing 684
FITTING THE MOUNT ON THE BEVEL PINION 685
Reassembling the differential housing 687
ADJUSTING THE CAP GAP 689
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY) 692
Instructions for adjusting and verifying transmitter operation to check insertion of differential gear locking 695
WORK ON THE VEHICLE 696
REPLACING THE BEVEL PINION MOUNT SEAL 696
Disassembly 696
Assembly 697
SECTION 7 – Front Axle 699
Front Axles 699
Front axle 5845 701
DESCRIPTION 703
Characteristic angles 706
SPECIFICATIONS AND DATA 708
DIAGNOSTICS 710
TIGHTENING TORQUES 713
TOOLS 714
AXLE REMOVAL AND REFITTING 718
Front axle removal 718
Front axle refitting 719
CHECKS ON THE VEHICLE 719
Tie rods 719
Articulated joints 719
Check clearance of articulated joints 719
FRONT WHEEL SET UP 720
Setting of clips and headlights 720
Electronic compensation for rim maladjust-ment 721
Wheel alignment 721
Toe-in check 722
Check of wheel inclination (Camber) 722
Check upright angle of inclination (King Pin) and clearance angle (Caster) 722
Check steering angles 723
OVERHAUL OF THE FRONT AXLE ASSY 724
REMOVAL AND REFITTING OF WHEEL HUBS 724
Removal 724
Replacement of sealing ring 725
Replacement of wheel stud bolts 726
Wheel hub reattachment 726
Check wheel hub end play 727
Rolling torque survey 727
Cross tie rod removsl and refitting 728
Replacement of cross tie rod articulated pins 728
Cross tie rod lever removal and refit-ting 729
Longitudinal tie rod lever removal and refitting 729
Steering knuckle pin removal and re-fitting 729
Removal 729
Steering knuckle pin bearing replacement 730
Refitting 730
Check and adjustment of clearance between steering knuckle and axle 731
CHECKS AND MEASUREMENTS OF THE AXLE UNIT 732
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins 732
Check hole inclination for steering knuckle pins 733
Front axles 5842/5 – 5851/5 735
DESCRIPTION 737
Characteristic angles 739
SPECIFICATIONS AND DATA 741
DIAGNOSTICS 743
TIGHTENING TORQUES 746
TOOLS 747
FRONT AXLE REMOVAL – REFITTING (Mechanical suspension) 751
Removal 751
Refitting 751
FRONT AXLE REMOVAL – REFITTING (Pneumatic suspension) 752
Removal 752
Refitting 752
FRONT WHEEL SET UP 753
Setting of clips and headlights 753
Electronic compensation for rim maladjustment 754
Wheel alignment 754
Toe-in check 755
Check of wheel inclination (Camber) 755
Check upright angle of inclination (King Pin) and clearance angle (Caster) 755
Check steering angles 756
OVERHAUL OF THE FRONT AXLE ASSY 757
Removal and refitting of wheel hubs 757
Sealing ring replacement 757
Wheel hubs refitting 758
End play adjustment of wheel hub bearings 758
Rolling torque check 758
REPLACEMENT OF WHEEL HUB BEARINGS 759
REPLACEMENT OF STUD BOLTS FOR WHEEL CLAMPING 760
CROSS TIE ROD REMOVAL AND REFITTING 760
REPLACEMENT OF CROSS TIE ROD ARTICULATED JOINTS 761
CROSS TIE ROD LEVER REMOVAL AND REFITTING 761
LONGITUDINAL TIE ROD LEVER REMOVAL AND REFITTING 761
STEERING KNUCKLE PIN REMOVAL AND REFITTING 761
Removal 761
Refitting 762
Check and adjustment of clearance between steering knuckle and axle 763
STEERING KNUCKLE PIN BEARING REPLACEMENT 764
CHECKS AND MEASUREMENTS OFTHE AXLE UNIT 765
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins 765
Check hole inclination for steering knuckle pins 766
Front axle 5871/5 767
DESCRIPTION 769
Characteristic angles 771
SPECIFICATIONS AND DATA 773
DIAGNOSTICS 775
TIGHTENING TORQUES 778
TOOLS 779
FRONT WHEEL SET UP 783
Setting of clips and headlights 783
Electronic compensation for rim maladjustment 784
Wheel alignment 784
Toe-in check 785
Check of wheel inclination (Camber) 785
Check upright angle of inclination (King Pin) and clearance angle (Caster) 785
Check steering angles 786
FRONT AXLE REMOVING AND REFITTING (Mechanical and pneumatic suspension) 787
OVERHAULING THE FRONT AXLE ASSEMBLY 787
Removing the wheel hubs 787
Replacing the wheel hub bearings 787
Replacing seal 788
Replacing wheel studs 788
Refitting wheel hubs 789
Adjusting wheel hub bearing end play 789
Checking the rolling torque 789
REMOVING AND REFITTING TRACK ROD 790
REPLACING TRACK ROD BALL JOINT 790
CHECKING BALL JOINT END PLAY FOR RACK ROD AND DRAG LINK 790
Replacing ball joint 790
REMOVING AND REFITTING TRACK ROD ARMS 791
REMOVING AND REFITTING DRAG LINK ARM 791
REMOVING AND REFITTING THE KINGPIN 791
Removing 791
Refitting 792
Checking and adjusting play between stub axle and axle 792
STEERING KNUCKLE PIN BEARING REPLACEMENT 793
CHECKS AND MEASUREMENTS ON AXLE BODY 794
Checking surface flatness of leaf spring seating with respect to holes for kingpins 794
Checking inclination of holes for kingpins 795
Front axle 5860 797
DESCRIPTION 799
Characteristic angles 800
SPECIFICATIONS AND DATA 802
DIAGNOSTICS 804
TIGHTENING TORQUES 807
FRONT WHEEL SET UP 808
Setting of clips and headlights 808
Electronic compensation for rim maladjustment 809
Wheel alignment 809
Toe-in check 810
Check of wheel inclination (Camber) 810
Check upright angle of inclination (King Pin) and clearance angle (Caster) 810
Check steering angles 811
OVERHAUL OF THE FRONT AXLE ASSY 812
Wheel hub (flanged unit-bearing) removal and refitting 812
Removal 812
Replacing the wheel fastening studs 813
Wheel hubs refitting 813
CROSS TIE ROD REMOVAL AND REFITTING 814
REPLACEMENT OF CROSS TIE ROD ARTICULATED JOINTS 814
CROSS TIE ROD LEVER REMOVAL AND REFITTING 814
LONGITUDINAL TIE ROD LEVER REMOVAL AND REFITTING 815
STEERING KNUCKLE PIN REMOVAL AND REFITTING 815
Removal 815
Steering knuckle pin removal and refitting 815
Refitting 816
Checking and adjusting the play between the kingpin and the front axle 817
CHECKS AND MEASUREMENTS OFTHE AXLE UNIT 818
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins 818
Check hole inclination for steering knuckle pins 819
SECTION 8 – Suspensions 821
Suspensions 821
Front and rear mechanical suspensions 823
DESCRIPTION 825
FRONT LEAF SPRINGS 825
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA 827
FRONT SUSPENSION – Models 110EL -120EL 827
FRONT SUSPENSION – Models 120E -130E 828
FRONT SUSPENSION – Models 120E -120E D-130E -130E D-130E18RS-140E -140E RS-150E -150E RS 829
FRONT SUSPENSION – Models 160E -160E RS 830
FRONT SUSPENSION – Models 180E -190EL -260E 831
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA 832
FRONT SUSPENSION – Models 120E -130E 832
FRONT SUSPENSION – Models 120E D-130E D-140E -140E RS-150E 833
FRONT SUSPENSION – Models 180E 834
FRONT SHOCK ABSORBERS 835
Assembly diagrams 835
SPECIFICATIONS AND DATA 836
REAR LEAF SPRINGS 838
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA 840
REAR SUSPENSION – Models 110EL -120EL 840
REAR SUSPENSION – Models 120E -130E 841
REAR SUSPENSION – Models 120E -130E – 130E18RS 842
REAR SUSPENSION -Models 120E -120E D-130E -130E D-140E -140E RS-150E -150E18RS-160E -160E RS 843
REAR SUSPENSION – Models 180E 844
REAR SUSPENSION – Models 190EL 845
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA 846
REAR SUSPENSION 120E -130E 846
REAR SUSPENSION – Models 120E D-130E D-140E -140E RS-150E 847
REAR SUSPENSION 180E 848
HENDRICKSON REAR SUSPENSION Models 260E 849
Removal 849
Refitting 849
REAR SHOCK ABSORBERS 851
Assembly diagrams 851
SPECIFICATIONS AND DATA 852
Shock absorber features and data – Models 260E 853
DIAGNOSTICS 854
TIGHTENING TORQUES 858
TOOLS 858
EXPERIMENTAL TOOLS 859
FRONT MECHANICAL SUSPENSION REMOVAL- REFITTING 861
Removal 861
Refitting 861
REAR MECHANICAL SUSPENSION REMOVAL- REFITTING 862
Removal 862
Refitting 862
FRONT SHOCK ABSORBERS 863
Removal 863
Refitting 863
REAR SHOCK ABSORBERS 863
Removal 863
Refitting 863
FRONT SWAY BAR 863
Removal 863
Refitting 863
REAR SWAY BAR 864
Removal 864
Refitting 864
REPAIRS 864
REPLACING LEAF-SPRING BUSHINGS 864
DISCONNECTING AND RECONNECTING REAR LEAF-SPRING BUSHINGS 864
Disconnecting rear bushings 864
Reconnecting rear bushings 867
Disconnecting front bushings 868
Reconnecting front bushings 868
DISCONNECTING AND RECONNECTING FRONT LEAF-SPRING BUSHINGS 869
Disconnecting front bushings 869
Reconnecting front bushings 870
Disconnecting rear bushings 870
Reconnecting front bushings 871
Front and rear pneumatic suspensions 873
PNEUMATIC SUSPENSIONS 875
INTRODUCTION 875
PNEUMATIC SUSPENSION ASSEMBLIES 875
FRONT PNEUMATIC SUSPENSION 875
LEAF SPRING SPECIFICATIONS AND DATA 876
FRONT SUSPENSION – MODELS 120E FP/130E FP/140E FP/150E FP 876
FRONT SHOCK ABSORBERS 877
Assembly diagrams 877
SPECIFICATIONS AND DATA 877
REAR PNEUMATIC SUSPENSION 878
REAR SHOCK ABSORBERS 882
Assembly diagrams 882
SPECIFICATIONS AND DATA 883
Electronically controlled rear pneumatic suspension diagram (For Models 110EL P-120EL P) 884
Cable-and-trunk diagram of pneumatic rear suspensions (For Models 120E P-130E P-140E P-150E P-160E P-180E P-190EL P) 885
Electronically controlled FULL PNEUMATIC suspension diagram (For Models 120E FP-130E FP-140E FP-150E FP) 886
CHASSIS LIFTING/LOWERING AND LEVELLING 887
Remote control 887
REMOTE CONTROL DESCRIPTION AND OPERATION 888
Lifting/lowering the chassis 888
Chassis self-leveling 888
Level ”M1” – ”M2” 888
VEHICLE MAIN COMPONENT ARRANGEMENT 889
SPECIFICATIONS AND DATA 890
DIAGNOSTICS 891
TIGHTENING TORQUES 893
Rear pneumatic suspension of the HENDRICKSON type (Models 110EL P – 120EL P) 894
TOOLS 895
MAIN PNEUMATIC SYSTEM COMPONENTS 896
Controlled-pressure valve 896
Low pressure indicator 896
Check valve 896
Electro-pneumatic front axle distributor for 4 x 2 FP vehicles 896
Operation 897
Front axle lifting 897
Front axle lowering 897
Self-leveling 897
Electro-pneumatic rear axle distributor for4 x 2 P/FP vehicles 898
Operation 898
Rear axle lifting 898
Rear axle lowering 898
Self-leveling 898
Level sensor 899
Air springs 899
ECU 899
REAR PNEUMATIC SUSPENSIONS REMOVAL-REFITTING 900
Removal 900
Refitting 900
REAR SHOCK ABSORBERS 901
Removal 901
Refitting 901
REAR SWAY BAR 901
Removal 901
Refitting 901
REAR AIR SPRINGS 901
Removal 901
Refitting 901
FRONT SHOCK ABSORBERS 902
Removal 902
Refitting 902
FRONT AIR SPRINGS 902
Removal 902
Refitting 902
FRONT PNEUMATIC SUSPENSION REMOVAL-REFITTING 903
Removal 903
Refitting 903
FRONT SWAY BAR 903
Removal 903
Refitting 903
REAR PNEUMATIC SUSPENSION REMOVAL-REFITTING 904
Removal 904
Refitting 904
REAR AIR SPRINGS 905
Removal 905
Refitting 905
REAR SHOCK ABSORBERS 905
Removal 905
Refitting 905
REAR SWAY BAR 906
Removal 906
Refitting 906
SECTION 9 – Wheels and Tires 907
Wheels and Tires 907
DESCRIPTION 909
SPECIFICATIONS AND DATA 909
Tire pressure values 909
TOOLS 910
DIAGNOSTICS 910
STATIC WHEELS BALANCING 913
CORRECTION OF RESIDUAL STATIC UNBALANCE 914
TIRE PRESSURE 914
TIRE BEHAVIOUR DEPENDING ON PRESSURE 915
SECTION 10 – Steering 917
Steering 917
DESCRIPTION 919
SPECIFICATIONS AND DATA 920
DIAGNOSTICS 920
TIGHTENING TORQUES 925
TOOLS 925
ZF HYDRAULIC POWER STEERING (8095-8098) 926
Description 926
Hydraulic steering limiting 929
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (ZF 8095-8098) 930
Disconnection 930
Reconnection 931
HYDRAULIC STEERING LIMITER ADJUSTMENT 932
TRW TAS 55 HYDRAULIC POWER STEERING 933
Description 933
Rectilinear running neutral position 934
Right steering position 935
Left steering position 936
HYDRAULIC STEERING LIMITATION 937
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (TRW TAS 55) 938
Automatic adjustment setting of hydraulic steering limitation for TRWTAS 55 hydraulic power steering 938
Automatic adjustment check 938
Hydraulic drops adjustment 939
AIR DRAIN FROM HYDRAULIC POWER STEERING CIRCUIT 940
Hydraulic power steering oil level restoration 940
MEASURE OF DRIVE CASE CLEARANCES DETECTED ON STEERING WHEEL 940
MAXIMUM PRESSURE CHECK IN HYDRAULIC POWER STEERING SYSTEM 940
SECTION 11 – Pneumatic System – Brakes 941
Pneumatic System – Brakes 941
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (MISCELLANEOUS AND GENERATORS) 945
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (VALVES) 946
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (TANKS AND ACCUMULATORS) 952
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS) 953
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CYLINDERS AND CALIPERS) 954
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (COUPLING HALF-JOINTS AND HEADS) 955
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (SIGNALING DEVICES AND SWITCHES) 957
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (BRAKES) 958
PIPINGS AND FITTINGS 959
In general 959
Rigid pipings reflanging 959
Rigid pipings bending 960
Rigid pipings cutting 960
Flexible pipings replacement with threaded fittings 961
Flexible pipings replacement with quick connection fittings 962
BRAKING SYSTEM 964
Principle diagram for single vehicles (Models 110 EL – 120 EL ) 964
Principle diagram for vehicles adapted for towing (Models 110 EL – 120 EL ) 965
Principle diagram for single vehicles (Models 120 E – 130 E – 140E – 150 E – 160E ) 966
Principle diagram for vehicles adapted for towing (Models 120 E – 130 E – 140E – 150 E – 160E ) 967
Principle diagram for single vehicles (Model 180 E – 190EL ) 968
Principle diagram for vehicles adapted for towing (Model 180 E – 190EL ) 969
Principle diagram for single vehicles (Model 260E) (with Hendrickson suspensions) 970
ARRANGEMENT ON A VEHICLE OF MAIN BRAKING SYSTEM COMPONENTS 971
DESCRIPTION 972
Service braking 972
Safety braking 972
Engine brake 972
Operation 972
Parking braking 972
BRAKES 972
Front brakes 972
Rear brakes 972
DIAGNOSTIC 973
TIGHTENING TORQUES 984
TOOLS 986
SPECIFICATIONS AND DATA – PNEUMATIC SYSTEM 993
SPECIFICATIONS AND DATA – BRAKES 998
CHECKS OF MAIN BRAKE SYSTEM COMPONENTS 1000
MAIN BRAKE SYSTEM COMPONENTS 1003
COMPRESSOR 1003
Diagnostics 1003
A P U (Air Processing Unit) 1004
Operation 1005
Diagnostics 1006
ENGINE BRAKE SWITCH 1007
ENGINE BRAKE SOLENOID VALVE 1007
ENGINE BRAKE CONTROL OPERATING CYLINDER 1007
MANUAL DISCHARGE VALVE 1007
SAFETY VALVE (Optional) 1008
DUPLEX DISTRIBUTOR 1008
Unbraking 1009
Diagnostics 1009
PRESSURE RELIEF VALVE 1010
Operation 1010
Pressure limitation 1010
Bench calibration 1010
Diagnostics 1010
RELAY VALVE 1011
Diagnostics 1011
CHECK VALVE 1011
Operation 1011
PARKING BRAKE CONTROL MANUAL DISTRIBUTOR (Single vehicles) 1012
Diagnostics 1012
QUICK DISCHARGE VALVE 1014
TRIPLE CONTROL SERVODISTRIBUTOR AC 597 B 1014
Predominance adjustment 1014
Diagnostics 1014
COUPLING HEADS 1015
Operation 1015
PRESSURE PLUG VALVE 1015
MEMBRANE BRAKE CYLINDER (for disc brakes and drum brakes) 1015
COMBINED BRAKE CYLINDER 1016
Combined cylinder emergency unbraking device 1016
Repair interventions 1016
Diagnostics 1016
ABS SYSTEM WITH EBL FUNCTION 1017
”ABS” Anti-Lock Brake System 1017
”EBL” (Electronic Brake Limiter) anti-skid device 1017
ELECTRONIC UNIT 1017
Operation 1017
REVOLUTIONS SENSORS 1017
PHONIC WHEELS 1017
Operation 1017
ELECTRO-PNEUMATIC VALVE 1018
Operation 1018
BRAKE REPAIRS (Models ML 110 EL / 120 EL ) 1019
Front Brakes (Brake calipers of the PAN 17 type) 1019
Rear Brakes (Brake calipers of the PAN 17 type) 1019
Description 1019
Brake locking system and brake operation 1019
Automatic braking gaskets wear recovering device 1019
Efficiency check for braking gaskets/brake disc wear recovering device 1021
Braking gaskets replacement 1021
Checks 1021
Brake calipers disconnection and reconnection 1022
Disconnection 1022
Reconnection 1022
BRAKE CALIPERS REVISION 1022
Disassembly 1022
Check of component parts 1023
Assembly 1023
BRAKE DISCS REVISION 1026
Brake discs turning and grinding 1026
BRAKE REPAIRING 1027
Front brakes (Brake caliper KNORR SB6 type) 1027
Front and rear brakes (Brake caliper KNORR SN6-SN7 type) 1028
Operation (See previous figure) 1029
CHECKS 1029
Checking the automatic play recovery system efficiency 1029
Check of braking gaskets thickness 1030
REAR BRAKES REVISION 1032
Braking gaskets replacement 1032
Brake calipers disconnection and re-connection 1034
Disconnection 1034
Reconnection 1035
Wheel hubs disconnection and re-connection 1035
Disconnection 1035
Reconnection 1035
BRAKE CALIPERS REVISION TYPE SB6 1036
Disassembly 1036
Cleaning and check of component parts 1037
Assembly 1037
BRAKE CALIPER OVERHAUL TYPE SN6-SN7 1039
Disassembly 1039
Component part cleaning and check 1040
Assembly 1040
REAR DISC BRAKES REVISION (12-18 t) 1042
BRAKE DISCS REVISION 1042
BRAKE DISCS TURNING AND GRINDING 1042
REAR DRUM BRAKES – Model 260E28KE 1043
Brake position with Hendrickson suspension 1043
REAR BRAKES REVISION (26 t) 1044
Disassembly 1044
Check of component parts 1046
DRUM TURNING 1047
BRAKING GASKETS REPLACEMENT 1048
BRAKING GASKETS TURNING 1048
Assembly 1049
SECTION 12 – Body – Chassis 1055
Body – Chassis 1055
CAB 1057
General information 1057
PROTECTIVE BODY TREATMENTS 1058
Protective treatment 1058
Preparing the sheet metal (bonderizing) 1059
Applying the protective paint (electrophoresis) 1059
CHECKING THE GEOMETRY OF THE CHASSIS FRAME 1059
GENERAL RULES FOR WORKING ON THE CHASSIS FRAME 1059
Preparing the chassis frame for maintenance, checking and repair work authorized by IVECO 1059
Spot welding 1060
Welding instructions 1060
Bodybuilder work on the structural members of the IVECO chassis frame 1060
Drilling the chassis frame 1060
PRECAUTIONS 1061
Welds on the chassis frame 1062
CHASSIS FRAME 1063
REPAIRS AND CHECKS 1063
Measuring the side bend of the chassis frame 1064
Measuring the bend of the chassis frame downwards or upwards 1064
Measuring the movement of the chassis frame 1064
Measuring the torsion of the chassis frame 1065
CHASSIS REFERENCE DIMENSIONS 1066
CAB GEOMETRY 1073
SEAL APPLICATION DIAGRAM 1074
CAB ANCHORING AND TIGHTENING TORQUES 1077
TOOLS 1080
REPAIRS 1081
Cab anchoring 1081
Replacing cab suspension front and rear shock absorbers 1081
Removing-refitting front mounts and cab stabilizer bar 1081
HYDRAULIC CAB LIFTING SYSTEM 1082
Replacing hydraulic cylinder for cab tilting 1083
REPLACING WINDSCREEN WINDOW 1083
General 1083
Vibration knife 1083
Harmonic wire 1084
Removal (with harmonic wire) 1084
Preparing the windscreen opening 1084
Preparing the windscreen 1085
Refitting 1085
Replacing the winding window 1087
Replacing the window winder 1088
Replacing the fixed window 1088
INSTRUMENT PANEL 1090
Removal 1090
Refitting 1090
MIDDLE INSTRUMENT PANEL 1090
Removal 1090
Refitting 1091
INSTRUMENT PANEL COVERING 1091
Removal 1091
Refitting 1096
HEATING AND VENTILATION 1096
Removal 1096
Refitting 1096
SECTION 13 – Service plan 1097
Service plan 1097
SERVICING 1099
Service plan 1099
SERVICE FREQUENCY 1099
EXTRA PLAN OPERATIONS 1099
Extra plan operations (to be carried out possibly at the same time as a planned service operation) 1099
SCHEDULED MAINTENANCE OPERATIONS 1100
EXTRA-PLAN OPERATIONS 1100
SCHEDULED MAINTENANCE OPERATIONS 1103
EXTRA-PLAN OPERATIONS 1103
M1 SERVICE 1104
M2 SERVICE 1105
M3 SERVICE 1108
EXTRA-PLAN MAINTENANCE 1108
EP1 SERVICE 1108
EP2 SERVICE 1109
EP3 SERVICE 1109
EP4 SERVICE 1110
EP5 SERVICE 1110
SECTION 14 – Electric/Electronic system 1111
Electric/Electronic system 1111
PRELIMINARY REMARKS 1113
SYMBOLS – WARNINGS 1113
SYMBOLS – ASSISTANCE OPERATIONS 1114
PRODUCT CODE 1115
GENERAL WARNINGS 1116
GENERAL WARNINGS ON THE ELECTRIC SYSTEM 1118
CONCEPT OF GROUND AND ELECTROMAGNETIC COMPATIBILITY 1119
Practical tips 1120
CAN LINE 1121
Efficiency tests on the CAN line 1122
DESCRIPTION OF BASIC SYSTEM 1123
ELECTRICAL CHARACTERISTICS 1123
ENGINE COMPONENTS 1124
Engine F4AE0481 1124
Engine F4AE0681 1125
POWER NETWORK 1126
Positive network 1126
Power cable sections 1126
Negative network 1127
Ground point identification 1128
STARTING 1135
General remarks 1135
Starting from the driver’s seat (Cab hooked) 1135
Starting from the engine compartment (Cab tilted) 1136
ALTERNATOR 1137
STARTER MOTOR 1138
COMPONENT CODE 1139
JUNCTION CONNECTOR 1144
BULKHEAD 1189
INSTRUMENT PANEL 1205
CENTRAL DASHBOARD 1206
INSTRUMENT CLUSTER 1208
Description 1208
Models available 1210
OPTICAL INDICATORS ON THE CLUSTER 1211
(FAILURE) INDICATORS ON THE DISPLAY 1212
“POP-UP” EVENTS 1214
CLUSTER (PIN-OUT) 1215
CENTRAL INTERCONNECTING UNIT 1216
REMOTE-CONTROL SWITCH ASSEMBLY 1217
FUSE ASSEMBLY 1218
CONNECTOR ASSEMBLY 1220
STEERING COLUMN STALK 1227
POSITION OF ELECTRONIC CONTROL UNITS 1228
BODY CONTROLLER 1229
Linking connectors 1229
CONNECTOR PIN-OUT 1234
TACHOGRAPH 1235
DESCRIPTION OF EDC 7 INJECTION SYSTEM 1236
ABS 1260
ECAS 1267
ENGINE BRAKE 1280
IMMOBILIZER 1282
AUTOMATIC GEARBOX ALLISON WTEC III 1293
ELECTRONIC CENTRAL UNIT DMI (DATA MANAGEMENT INTERFACE) (OPT 5626) 1341
AUXILIARY HEATER WEBASTO 1343
FAULT DIAGNOSIS 1356
Diagnosis Instruments 1356
System initialization screen 1357
DIAGNOSTIC screen (oly for Highline versions) 1358
Meanings of anomaly codes 1358
Description of fault codes (SPN) 1359
TROUBLESHOOTING 1361
Instrument Body Controller (IBC) 1361
Instrument Cluster (IC) 1376
“EDC 7″ injection system 1381
MAINTENANCE SCHEDULE 1649
CIRCUIT CARDS 1651
Card 1: Positive direct to the batteries 1653
Card 2: Positive after main current switch 1654
Card 3: Positive after main current switch 1655
Card 4: Service power supply (+15/1) 1656
Card 5: Service power supply (+15/1) 1657
Card 6: Service power supply (+15/2) 1658
Card 7: Body Controller 1659
Card 8: Body Controller 1660
Card 9: Body Controller 1661
Card 10: EDC (Connector B) 1662
Card 11: EDC (Connector B) 1663
Card 12: EDC (Connectors A and C – 6 cylinders) 1664
Card 13: EDC (Connectors A and C – 4 cylinders) 1665
Card 14: Instrument Cluster / Tachograph prearrangement 1666
Card 15: Immobilizer 1667
Card 16: ABS (4X2) 1668
Card 17: ABS (6X4) 1669
Card 18: ECAS 4X2 P 1670
Card 19: ECAS 4X2 FP 1671
Card 20: Additional heater prearrangement AIRTOP2000 1672
Card 21: Additional heater prearrangement AIRTOP2000 with ADR 1673
Card 22: Manually controlled air-conditioning prearrangement 1674
Card 23: CAN line 1675
Card 24: Cigar lighter/Horns/Electric heater 1676
Card 25: Rotating lamps/Bed lights/ Emergency light/Headlamp washer 1677
Card 26: Electric window regulator/Sunroof (with and without the Bed Module) 1678
Card 27: Heated prefilter/Brake air drier/Pneumatic, heated seats 1679
Card 28: Central closing prearrangement/Adjustable, heated rearview mirrors 1680
Card 29: Main current remote-control switch (TGC) 1681
Card 30: Current Main Remote Control Switch (TGC) prearrangement (TGC)/ Compliance to rules ADR (TMP) 1682
Card 31: Cab tipping/Overall power takeoff 1683
Card 32: Fridge/Voltage reducer/Car radio 1684
Card 33: Loading board preset 1685
Card 34: Body builder connectors 1686
Card 35: Side- rear – total PTO /Transverse and longitudinal differential lock 1687
Card 36: Allison gearbox 1688
Card 37: Retarder (Allison gearbox) 1689
Card 38: Centrali unit (DMI) (opt 5626) 1690
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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