Iveco EuroCargo Tector 12t-26t Repair Manual – PDF DOWNLOAD
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Iveco EuroCargo Tector 12t-26t Repair Manual – PDF DOWNLOAD
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Language: English
Brand: Iveco
DESCRIPTION:
Iveco EuroCargo Tector 12t-26t Repair Manual – PDF DOWNLOAD
EUROCARGO TECTOR
12 TO 26 t
REPAIR MANUAL
- This publication describes the characteristics, data and correct methods for repair operations on each component of the vehicle. If the instructions provided are followed and the specified equipment is used, correct repair operations in the programmed time will be ensured, safeguarding against possible accidents. Before starting to perform whatever type of repair, ensure that all accident prevention equipment is available and efficient.
- All protections specified by safety regulations, i.e.: goggles, helmet, gloves, boot, etc. must be checked and worn. All machining, lifting and conveying equipment should be inspected before use. The data contained in this publication was correct at the time of going to press but due to possible modifications made by the Manufacturer for reasons of a technical or commercial nature or for adaptation to the legal requirements of the different countries, some changes may have occurred. No part of this publication, including the pictures, may be reproduced in any form or by any means.
TABLE OF CONTENTS:
Iveco EuroCargo Tector 12t-26t Repair Manual – PDF DOWNLOAD
EUROCARGO TECTOR 12 TO 26 t 1
REPAIR MANUAL 1
SPECIAL REMARKS 3
Graph and symbols 4
UPDATING DATE 5
INDEX OF SECTIONS 7
SECTION 1 – General Specifications 9
General Specifications 9
COMPOSITION OF THE MODELS 11
IDENTIFICATION DATA AND LOCATION ON VEHICLE 19
FILLING UP 20
INTERNATIONAL LUBRICANT DESIGNATION 21
SECTION 2 – Engine 23
Engine 23
ENGINE IDENTIFICATION CODES 25
MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE 26
WARNINGS 26
High pressure CP3 pump 26
Rail and fittings 26
Injector 26
Low pressure tubing 26
High pressure tubing 26
ENGINE REMOVAL-REFITTING 27
Removal 27
Refitting 29
Tests and checks 29
Engine cooling filling system 29
Air bleeding from fuel system 30
Air bleeding from hydraulic power steering system 30
INJECTORS REPLACEMENT 31
Removal 31
Refitting 31
Tests and checks 33
REPLACING SEAL RING FRONT COVER DRIVING SHAFT 33
REPLACING SEAL RING FLYWHEEL HOUSING BOX 34
CYLINDER HEAD REM OVAL/REFITTING 35
Removal 35
Refitting 37
Tests and checks 37
Engine F4 AE 0481 41
GENERAL SPECIFICATIONS 43
ASSEMBLY DATA – CLEARANCES 46
TIGHTENING TORQUE 52
AUXILIARY COMPONENTS 54
TOOLS 55
ENGINE OVERHAUL 62
DISASSEMBLY OF THE ENGINE AT THE BENCH 62
REPAIR INTERVENTIONS 70
CYLINDER GROUP 70
Controls and measurements 70
Head face check on the cylinder group 71
TIMING SYSTEM 71
Camshaft 71
Cam lift check and pin alignment check 72
BUSHES 72
Bush replacement 73
Tappets 73
Fitting tappets – camshaft 73
OUTPUT SHAFT 74
Measuring journals and crankpins 74
Replacing oil pump control gear 76
Fitting main bearings 76
Finding journal clearance 76
Checking output shaft shoulder clearance 77
CONNECTING ROD – PISTON ASSEMBLY 77
Pistons 78
Measuring piston diameter 78
Piston pins 79
Conditions for proper pin-piston coupling 79
Split rings 79
Connecting rods 80
Bushes 80
Checking connecting rods 81
Checking torsion 81
Checking bending 81
Fitting connecting rod-piston assembly 81
Connecting rod-piston coupling 81
Fitting split rings 82
Fitting connecting rod-piston assembly into cylinder barrels 82
Finding crankpin clearance 83
Checking piston protrusion 84
Timing gear case 84
Timing 85
Flywheel housing 85
ENGINE FLYWHEEL 86
Replacing engine flywheel ring gear 86
CYLINDER HEAD 90
Removing the valves 90
Checking cylinder head wet seal 91
Checking cylinder head supporting surface 91
VALVES 92
Removing carbon deposits, checking and grinding valves 92
Checking clearance between valve stem and valve guide and valve centering 92
VALVE GUIDE 93
VALVE SEATS 93
Regrinding – replacing the valve seats 93
VALVE SPRINGS 95
FITTING CYLINDER HEAD 95
Refitting the cylinder head 95
Fitting injectors 96
RODS 97
Rocker assembly 97
Tappet clearance adjustment 98
Intake manifold 99
Wiring support 101
LUBRICATION 105
OIL PUMP 107
HEAT EXCHANGER 107
Oil pressure relief valve 108
Oil vapour recycling 109
COOLING SYSTEM 111
Water Pump 113
Viscous fan 113
Thermostat 114
BOOSTER 114
Turbosupercharger 114
Description 114
TURBOSUPERCHARGER ACTUATOR 115
Check and adjustment 115
Actuator replacement 115
TURBOSUPERCHARGER LAYOUT 117
COMMON RAIL 119
General Specifications 119
FEED SYSTEM 121
FEED SYSTEM LAYOUT 123
FUEL PREFILTER 125
FUEL FILTER 125
MECHANICAL SUPPLY PUMP 126
Normal operating conditions 126
Overpressure condition at outlet 126
Drain conditions 126
CP3 HIGH-PRESSURE PUMP 127
HIGH-PRESSURE PUMP – INSIDE STRUCTURE 128
Operating principle 129
Operation 131
RAIL 131
OVERPRESSURE VALVE 132
FLOWLIMITERS 132
INJECTOR 133
Injector in rest position 133
Injection start 133
Injection end 133
PRESSURE LIMITER FOR FUEL RETURN 133
Engine F4 AE 0681 137
GENERAL SPECIFICATIONS 139
ASSEMBLY DATA – CLEARANCES 142
ENGINE F4AE0681 OVERHAUL 150
Engine removal at the bench 150
TIMING SYSTEM 151
Camshaft 151
BUSHES 151
CYLINDER HEAD VALVE SEATS 153
Cylinder head fastening screw tightening 155
LUBRICATION 157
COOLING SYSTEM 158
BOOSTER 159
Turbosupercharger 159
TURBOSUPERCHARGER ACTUATOR 159
Check and adjustment 159
TURBOSUPERCHARGER LAYOUT 161
Troubleshooting Guide 163
FOREWORD 165
Diagnosis through instruments 165
DIAGNOSTICS 167
SECTION 3 – Clutch 177
Clutch 177
DESCRIPTION 179
Clutch 179
SPECIFICATIONS AND DATA 179
DIAGNOSTICS 183
TIGHTENING TORQUES 186
TOOLS 186
REMOVAL AND REFITTING 187
Removal 187
Refitting 187
DRIVEN PLATE OVERHAUL 187
Damper hub check 187
Friction gaskets 187
BLEEDING AIR FROM CLUTCH CIRCUIT 188
THRUST BEARING REMOVAL – REFITTING 188
REPLACING CLUTCH SHAFT SUPPORT BEARING 188
HYDRAULIC CONTROL 189
Servo-assisted master cylinder (14” – 13”/14” clutches) 189
Connections 189
Master cylinder (15”/16” clutches) 190
Slave cylinder (14” – 13”/14” clutches) 190
Clutch wear layout (13”/14” – 14” clutches) 191
Operating cylinder (15”/16” clutches) 191
WEAR INDICATOR REFITTING AND ADJUSTMENT (15/16” clutches) 192
ADJUSTING OPERATING CYLINDER PUSH ROD (New 15/16” clutch) 193
CHECKING AND ADJUSTING THE CLUTCH PEDAL (14” – 13”/14” clutches) 194
Clutch pedal stop 194
Clutch pedal idle stroke 194
CHECKING AND ADJUSTING THE CLUTCH PEDAL (15”/16” clutches) 195
Clutch pedal stop 195
Clutch pedal idle stroke 195
SECTION 4 – Gearbox 197
Gearbox 197
DIAGNOSTICS 199
Gears control connection 201
Gearbox control tie-rods adjustment 201
Gearbox 2855 6 205
DESCRIPTION 207
SPECIFICATIONS AND DATA 208
TIGHTENING TORQUES 211
TOOLS 212
GEARBOX 2855 6 DISENGAGEMENT/RE-ENGAGEMENT 217
Disengagement 217
Re-engagement 217
GEARBOX DISASSEMBLY 219
Checks 222
GEARBOX ASSEMBLY 223
Bearings pre-load adjustment for secondary shaft 223
PRIMARY SHAFT DISASSEMBLY 229
PRIMARY SHAFT ASSEMBLY 231
MOTION INLET SHAFT DISASSEMBLY 234
MOTION INLET SHAFT ASSEMBLY 234
Motion inlet shaft bearing adjustment 234
SECONDARY SHAFT DISASSEMBLY 235
SECONDARY SHAFT ASSEMBLY 235
INTERNAL DRIVE SHAFT DISASSEMBLY 235
INTERNAL DRIVE SHAFY ASSEMBLY 235
EXTERNAL CONTROL SHAFT DISASSEMBLY 236
EXTERNAL CONTROL BOX ASSEMBLY 237
Idle-R M switch adjustment 239
Gearbox 2865 6 241
DESCRIPTION 243
SPECIFICATIONS AND DATA 245
TIGHTENING TORQUES 247
TOOLS 248
GEARBOX 2865 5 DISENGAGEMENT/ RE-ENGAGEMENT 253
Disengagement 253
Re-engagement 253
GEARBOX DISASSEMBLY 255
Rear cover sealing gasket replacement 258
Checks 259
GEARBOX ASSEMBLY 259
Bearings pre-loading adjustment for secondary shaft 260
PRIMARY SHAFT DISASSEMBLY 264
PRIMARY SHAFT ASSEMBLY 267
MOTION ENTRY SHAFT DISASSEMBLY 269
MOTION ENTRY SHAFT ASSEMBLY 270
SECONDARY SHAFT DISASSEMBLY 270
SECONDARY SHAFT ASSEMBLY 270
INTERNAL CONTROL SHAFT DISASSEMBLY 271
INTERNAL CONTROL SHAFT ASSEMBLY 271
EXTERNAL CONTROL SHAFT DISASSEMBLY 271
EXTERNAL CONTROL BOX ASSEMBLY 272
Idle-R M switch adjustment 274
Gearbox 2870 9 275
DESCRIPTION 277
SPECIFICATIONS AND DATA 278
TIGHTENING TORQUES 281
TOOLS 282
GEARBOX 2870 9 DISENGAGEMENT/RE-ENGAGEMENT 287
Disengagement 287
Re-engagement 287
GEARBOX DISASSEMBLY 289
Checks 293
GEARBOX ASSEMBLY 294
Bearings pre-load adjustment for secondary shaft 294
Idle-Reverse Gear switch adjustment 300
PRIMARY SHAFT DISASSEMBLY 301
PRIMARY SHAFT ASSEMBLY 303
MOTION INLET SHAFT DISASSEMBLY 303
MOTION INLET SHAFT ASSEMBLY 304
Motion inlet shaft bearing adjustment 304
SECONDARY SHAFT DISASSEMBLY 304
SECONDARY SHAFT ASSEMBLY 304
INTERNAL DRIVE SHAFT DISASSEMBLY 304
INTERNAL DRIVE SHAFT ASSEMBLY 305
EXTERNAL DRIVE CASE DISASSEMBLY 305
EXTERNAL DRIVE CASE ASSEMBLY 306
EPICYCLIC REDUCTION GEAR ASSEMBLY 309
Operating diagrams about pneumatic epicyclic reduction gear drive circuit 309
DISASSEMBLY 311
Checks 313
ASSEMBLY 314
Gearbox 2895 9 319
DESCRIPTION 321
SPECIFICATIONS AND DATA 322
TIGHTENING TORQUE 325
TOOLS 326
GEARBOX DISENGAGEMENT/ RE-ENGAGEMENT 331
Disengagement 331
Re-engagement 331
GEARBOX DISASSEMBLING 331
Checks 335
GEARBOX ASSEMBLING 335
Adjusting transmission shaft bearing pre – load 335
Idle-R M switch adjustment 340
MAIN SHAFT DISASSEMBLING 341
MAIN SHAFT ASSEMBLING 343
INPUT SHAFT DISASSEMBLING 344
INPUT SHAFT ASSEMBLING 344
TRANSMISSION SHAFT 344
Bearing replacement 344
INTERNAL CONTROL SHAFT DISASSEMBLING 345
INTERNAL CONTROL SHAFT ASSEMBLING 345
EXTERNAL CONTROL BOX DISASSEMBLING 345
EXTERNAL CONTROL BOX ASSEMBLY 346
EPICYCLIC REDUCTION GEAR ASSEMBLY 349
Operating diagrams about pneumatic epicyclic reduction gear drive circuit 349
DISASSEMBLY 351
Checks 353
ASSEMBLY 354
Allison gearbox MD 3060P 359
DESCRIPTION 361
CHARACTERISTICS AND DATA 364
MAIN OPERATION ANOMALIES 365
TIGHTENING TORQUES 373
TOOLS 373
DISCONNECTING AND CONNECTING GEARBOX CONTROL MODULE AGAIN 375
Disconnecting Figure 375
Refitting 375
REPLACING SPEED SENSORS 375
Replacing turbine speed sensor 375
Engine revolutions sensor replacement 376
Replacing the output speed sensor 376
REPLACING OIL LEVEL SENSOR 376
REPLACING OIL SUCTION FILTER 377
REPLACING THE SOLENOID VALVES 377
REPLACING PLANE GASKETS IN GEARBOX CONTROL MODULE 378
REPLACING PRESSURE SWITCH F3 379
REPLACING THE SEAL RING ON THE OUTPUT SHAFT 379
Gearbox EATON FSO 5206B 381
DESCRIPTION 383
POSITION OF GEARSHIFT IDENTIFICATION TAG 384
SPECIFICATIONS AND DATA 385
Gear selection and engagement grid 388
TIGHTENING TORQUES 389
TOOLS 391
EXPERIMENTAL TOOLS 395
GEARSHIFT OVERHAUL 396
Checks 396
GEAR DRIVE CASE 396
Disassembling 396
Assembling 397
Refitting 399
Disassembling the gearbox 400
MOTION INLET SHAFT 403
Disassembling 403
Assembling 403
OUTPUT SHAFT 403
Disassembling 403
Assembling 407
INTERNAL DRIVING SHAFT 411
Disassembling 411
Assembling 412
Gearbox assembling 413
Adjusting the axial play of countershaft bearings 416
SECTION 5 – Propeller shafts 419
Propeller shafts 419
DESCRIPTION 421
PROPELLER SHAFT LAYOUT ON VEHICLES 426
PROPELLER SHAFT SPECIFICATIONS AND DATA 427
DIAGNOSTICS 429
TIGHTENING TORQUES 429
SLIDING PROPELLER SHAFT REMOVAL-REFITTING 430
Removal 430
Refitting 430
FIXED PROPELLER SHAFT REMOVAL- REFITTING 430
CHECKING PROPELLER SHAFTS ON VEHICLE 430
SECTION 6 – Rear axles 431
Rear axles 431
AXLES IN TANDEM Meritor SP 145 E 433
Axles in tandem (Intermediate) Meritor PD 145 E (R 2468) 435
DESCRIPTION 437
SPECIFICATIONS AND DATA 437
TIGHTENING TORQUES 439
TOOLS 442
EXPERIMENTAL TOOLS 448
INTERMEDIATE AXLE DISCONNECTION/ RECONNECTION (with Hendrickson suspensions) 451
Disconnection 451
Reconnection 451
SERVICING INTERMEDIATE AXLE ASSEMBLY PD 145 E (R 2468) 453
AIR BREATHER REMOVAL-REFITTING 453
SERVICING WHEEL HUBS 453
Checking wheel hub components 454
ASSEMBLING WHEEL HUBS 455
REMOVING DIFFERENTIAL GEAR – TRANSFER BOX (with rear axle on stand 99322215) 458
REFITTING DIFFERENTIAL GEAR – TRANSFER BOX (with rear axle on stand 99322215) 458
REPAIRING INTER-AXLE UNIT 459
Dismantling inter-axle unit 459
Checking inter-axle unit components 461
Fitting inter-axle unit 461
Adjusting drive input shaft bearing end float 463
Adjusting differential lock and inter-axle control pin end-stop 464
REPAIRING MAIN DIFFERENTIAL DISMANTLING DIFFERENTIAL CASING 464
Dismantling gear cage 468
Checking differential components 468
Assembling gear cage 469
ASSEMBLING DIFFERENTIAL CASING 470
Calculating bevel pinion position in differential casing 470
COMPUTATIONAL EXAMPLES 471
Adjusting the cap gap 474
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY) 476
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT 479
Tandem axles (Rear) Meritor PR 140 E (R 0868) 483
DESCRIPTION 485
SPECIFICATIONS AND DATA 485
TIGHTENING TORQUES 487
TOOLS 489
SERVICING REAR AXLE ASSEMBLY PR 140 E (R 0868) 494
AIR BREATHER REMOVAL/ INSTALLATION 494
OVERHAULING WHEEL HUBS 494
REMOVING DIFFERENTIAL (with axle on stand 99322215) 494
REFITTING DIFFERENTIAL (with axle on stand 99322215) 494
REPAIRING DIFFERENTIAL 495
Removing differential lock 495
Dismantling differential casing 496
Dismantling gear cage 497
Dismantling bevel pinion support 497
Checking differential components 501
Assembling gear cage 501
Specimen calculations 503
Assembling differential casing 503
ADJUSTING THE CAP GAP 505
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY) 508
SECTION 7 – Front Axles 511
Front Axles 511
Front axle 5845 513
DESCRIPTION 515
Characteristic angles 518
SPECIFICATIONS AND DATA 520
DIAGNOSTICS 522
TIGHTENING TORQUES 525
TOOLS 526
AXLE DETACHMENT AND REATTACHMENT 530
Front axle detachment 530
Front axle reattachment 531
CHECKS ON THE VEHICLE 531
Tie rods 531
Articulated joints 531
Check clearance of articulated joints 531
FRONT WHEEL SET UP 532
Setting of clips and headlights 532
Electronic compensation for rim maladjustment 533
Wheel alignment 533
Toe-in check 534
Check of wheel inclination (Camber) 534
Check upright angle of inclination (King Pin) and clearance angle (Caster) 534
Check steering angles 535
OVERHAUL OF THE FRONT AXLE ASSY 536
DETACHMENT ANDREATTACHMENT OFWHEEL HUBS 536
Detachment 536
Replacement of sealing ring 537
Replacement of wheel stud bolts 538
Wheel hub reattachment 538
Check wheel hub end play 539
Rolling torque survey 539
Cross tie rod detachment and reattachment 540
Replacement of cross tie rod articulated pins 540
Cross tie rod lever detachment and reattachment 541
Longitudinal tie rod lever detachment and reattachment 541
Steering knuckle pin detachment and reattachment 541
Detachment 541
Steering knuckle pin bearing replacement 542
Reattachment 542
Check and adjustment of clearance between steering knuckle and axle 543
CHECKS AND MEASUREMENTS OF THE AXLE UNIT 544
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins 544
Check hole inclination for steering knuckle pins 545
Front axles 5842/5 – 5851/5 547
DESCRIPTION 549
Characteristic angles 551
SPECIFICATIONS AND DATA 553
DIAGNOSTICS 555
TIGHTENING TORQUES 558
TOOLS 559
FRONT WHEEL SET UP 563
Setting of clips and headlights 563
Electronic compensation for rim maladjustment 564
Wheel alignment 564
Toe-in check 565
Check of wheel inclination (Camber) 565
Check upright angle of inclination (King Pin) and clearance angle (Caster) 565
Check steering angles 566
OVERHAUL OF THE FRONT AXLE ASSY 567
Removal and refitting of wheel hubs 567
Sealing ring replacement 567
Wheel hubs refitting 568
End play adjustment of wheel hub bearings 568
Rolling torque survey 568
REPLACEMENT OFWHEEL HUB BEARINGS 569
REPLACEMENT OF STUD BOLTS FOR WHEEL CLAMPING 570
CROSS TIE ROD REMOVAL AND REFITTING 570
REPLACEMENT OF CROSS TIE ROD ARTICULATED JOINTS 571
CROSS TIE ROD LEVER REMOVAL AND REFITTING 571
LONGITUDINAL TIE ROD LEVER REMOVAL AND REFITTING 571
STEERING KNUCKLE PIN REMOVAL AND REFITTING 571
Removal 571
Refitting 572
Check and adjustment of clearance between steering knuckle and axle 573
STEERING KNUCKLE PIN BEARING REPLACEMENT 574
CHECKS AND MEASUREMENTS OF THE AXLE UNIT 575
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins 575
Check hole inclination for steering knuckle pins 576
Front axle 5871/5 577
DESCRIPTION 579
Characteristic angles 581
SPECIFICATIONS AND DATA 583
DIAGNOSTICS 585
TIGHTENING TORQUES 588
TOOLS 589
FRONT WHEEL SET UP 593
Setting of clips and headlights 593
Electronic compensation for rim maladjustment 594
Wheel alignment 594
Toe-in check 595
Check of wheel inclination (Camber) 595
Check upright angle of inclination (King Pin) and clearance angle (Caster) 595
Check steering angles 596
OVERHAULING THE FRONT AXLE ASSEMBLY (Mechanical and pneumatic suspension) 597
OVERHAULING THE FRONT AXLE ASSEMBLY 597
Removing the wheel hubs 597
Replacing the wheel hub bearings 597
Replacing seal 598
Replacing wheel studs 598
Refitting wheel hubs 599
Adjusting wheel hub bearing end play 599
Checking the rolling torque 599
REMOVING AND REFITTING TRACK ROD 600
REPLACING TRACK ROD BALL JOINT 600
CHECKING BALL JOINT END PLAY FOR TRACK ROD AND DRAG LINK 600
Replacing ball joint 600
REMOVING AND REFITTING TRACK ROD ARMS 601
REMOVING AND REFITTING DRAG LINK ARM 601
REMOVING AND REFITTING THE KINGPIN 601
Removing 601
Refitting 602
Checking and adjusting play between stub axle and axle 602
STEERING KNUCKLE PIN BEARING REPLACEMENT 603
CHECKS AND MEASUREMENTS ON AXLE BODY 604
Checking surface flatness of leaf spring seating with respect to holes for kingpins 604
Checking inclination of holes for kingpins 605
SECTION 8 – Suspensions 607
Suspensions 607
Front and rear mechanical suspensions 609
DESCRIPTION 611
FRONT LEAF SPRINGS 611
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA 613
FRONT SUSPENSION – Models 110EL -120EL 613
FRONT SUSPENSION – Models 120E -130E 614
FRONT SUSPENSION – Models 120E -120E D-130E -130E D-130E18RS-150E -150E RS 615
FRONT SUSPENSION – Models 180E -260E 616
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA 617
FRONT SUSPENSION – Models 120E -130E 617
FRONT SUSPENSION – Models 120E D-130E D-150E 618
FRONT SUSPENSION – Models 180E 619
FRONT SHOCK ABSORBERS 620
Assembly diagrams 620
SPECIFICATIONS AND DATA 621
REAR LEAF SPRINGS 623
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA 625
REAR SUSPENSION – Models 110EL -120EL 625
REAR SUSPENSION – Models 120E -130E 626
REAR SUSPENSION – Models 120E -130E – 130E18RS 627
REAR SUSPENSION – Models 120E -120E D-130E -130E D-150E -150E18RS 628
REAR SUSPENSION – Models 180E 629
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA 630
REAR SUSPENSION 120E -130E 630
REAR SUSPENSION – Models 120E D-130E D-150E 631
REAR SUSPENSION 180E 632
HENDRICKSON REAR SUSPENSION Models 260E 633
Disconnection 633
Reconnection 633
REAR SHOCK ABSORBERS 635
Assembly diagrams 635
SPECIFICATIONS AND DATA 636
Shock absorber features and data – Models 260E 637
DIAGNOSTICS 638
TIGHTENING TORQUES 642
FRONT MECHANICAL SUSPENSION REMOVAL-REFITTING 643
Removal 643
Refitting 643
REAR MECHANICAL SUSPENSION REMOVAL-REFITTING 644
Removal 644
Refitting 644
FRONT SHOCK ABSORBERS 645
Removal 645
Refitting 645
REAR SHOCK ABSORBERS 645
Removal 645
Refitting 645
FRONT SWAY BAR 645
Removal 645
Refitting 645
REAR SWAY BAR 646
Removal 646
Refitting 646
REPAIRS 646
Leaf spring disassembly 646
Checks 646
BUSHING REPLACEMENT 647
Removal 647
Refitting 647
Leaf spring assembly 647
Front and rear pneumatic suspensions 649
PNEUMATIC SUSPENSIONS 651
INTRODUCTION 651
PNEUMATIC SUSPENSION ASSEMBLIES 651
FRONT PNEUMATIC SUSPENSION 651
LEAF SPRING SPECIFICATIONS AND DATA 652
FRONT SUSPENSION – MODELS 120E FP/130E FP/150E FP 652
FRONT SHOCK ABSORBERS 653
Assembly diagrams 653
SPECIFICATIONS AND DATA 653
REAR PNEUMATIC SUSPENSION 654
REAR SHOCK ABSORBERS 657
Assembly diagrams 657
SPECIFICATIONS AND DATA 658
Electronically controlled rear pneumatic suspension diagram (NEWAY for Models 110EL P-120EL P) 659
Cable-and-trunk diagram of pneumatic rear suspensions (For Models 120E P-130E P-150E P-180E P) 660
Electronically controlled FULL PNEUMATIC suspension diagram (For Model 120E FP-130E FP-150E FP) 661
Rear pneumatic suspension vehicle wiring diagram 662
Front and rear pneumatic suspension vehicle wiring diagram 663
CHASSIS LIFTING/LOWERING AND LEVELLING 664
Remote control 664
REMOTE CONTROL DESCRIPTION AND OPERATION 665
Lifting/lowering the chassis 665
Chassis self-leveling 665
Level ”M1” – ”M2” 665
VEHICLE MAIN COMPONENT ARRANGEMENT 666
SPECIFICATIONS AND DATA 667
DIAGNOSTICS 668
TIGHTENING TORQUES 670
TOOLS 671
MAIN PNEUMATIC SYSTEM COMPONENTS 672
Controlled-pressure valve 672
Low pressure indicator 672
Check valve 672
Electro-pneumatic front axle distributor for 4 x 2 FP vehicles 672
Operation 673
Front axle lifting 673
Front axle lowering 673
Self-leveling 673
Electro-pneumatic rear axle distributor for 4 x 2 P/FP vehicles 674
Operation 674
Rear axle lifting 674
Rear axle lowering 674
Self-leveling 674
Level sensor 675
Air springs 675
ECU 675
REAR PNEUMATIC SUSPENSIONS REMOVAL-REFITTING 676
Removal 676
Refitting 676
REAR SHOCK ABSORBERS 677
Removal 677
Refitting 677
REAR SWAY BAR 677
Removal 677
Refitting 677
REAR AIR SPRINGS 677
Removal 677
Refitting 677
FRONT SHOCK ABSORBERS 678
Removal 678
Refitting 678
FRONT AIR SPRINGS 678
Removal 678
Refitting 678
FRONT PNEUMATIC SUSPENSION REMOVAL-REFITTING 679
Removal 679
Refitting 679
FRONT SWAY BAR 679
Removal 679
Refitting 679
REAR PNEUMATIC SUSPENSION REMOVAL-REFITTING 680
Removal 680
Refitting 680
REAR AIR SPRINGS 681
Removal 681
Refitting 681
REAR SHOCK ABSORBERS 681
Removal 681
Refitting 681
REAR SWAY BAR 682
Removal 682
Refitting 682
SECTION 9 – Wheels and Tires 683
Wheels and Tires 683
DESCRIPTION 685
SPECIFICATIONS AND DATA 685
Tire pressure values 685
TOOLS 686
DIAGNOSTICS 686
STATIC WHEELS BALANCING 689
CORRECTION OF RESIDUAL STATIC UNBALANCE 690
TIRE PRESSURE 690
TIRE BEHAVIOUR DEPENDING ON PRESSURE 691
SECTION 10 – Steering 693
Steering 693
DESCRIPTION 695
SPECIFICATIONS AND DATA 696
DIAGNOSTICS 696
TIGHTENING TORQUES 701
TOOLS 701
ZF HYDRAULIC POWER STEERING (8095-8098) 702
Description 702
Hydraulic steering limiting 705
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (ZF 8095-8098) 706
Disconnection 706
Reconnection 707
HYDRAULIC STEERING LIMITER ADJUSTMENT 708
TRW TAS 55 HYDRAULIC POWER STEERING 709
Description 709
Rectilinear running neutral position 710
Right steering position 711
Left steering position 712
HYDRAULIC STEERING LIMITATION 713
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (TRW TAS 55) 714
Automatic adjustment setting of hydraulic steering limitation for TRW TAS 55 hydraulic power steering 714
Automatic adjustment check 714
Hydraulic drops adjustment 715
AIR DRAIN FROM HYDRAULIC POWER STEERING CIRCUIT 716
Hydraulic power steering oil level restoration 716
MEASURE OF DRIVE CASE CLEARANCES DETECTED ON STEERING WHEEL 716
MAXIMUM PRESSURE CHECK IN HYDRAULIC POWER STEERING SYSTEM 716
SECTION 11 – Pneumatic System – Brakes 717
Pneumatic System – Brakes 717
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (MISCELLANEOUS AND GENERATORS) 721
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (VALVES) 722
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (TANKS AND ACCUMULATORS) 728
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS) 729
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CYLINDERS AND CALIPERS) 730
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (COUPLING HALF-JOINTS AND HEADS) 731
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (SIGNALING DEVICES AND SWITCHES) 733
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (BRAKES) 734
PIPINGS AND FITTINGS 735
In general 735
Rigid pipings reflanging 735
Rigid pipings bending 736
Rigid pipings cutting 736
Flexible pipings replacement with threaded fittings 737
Flexible pipings replacement with quick connection fittings 738
BRAKING SYSTEM 740
Principle diagram for single vehicles (Models 110 EL – 120 EL ) 740
Principle diagram for vehicles adapted for towing (Models 110 EL – 120 EL ) 741
Principle diagram for single vehicles (Models 120 E – 130 E – 150 E ) 742
Principle diagram for vehicles adapted for towing (Models 120 E – 130 E – 150 E ) 743
Principle diagram for single vehicles (Model 180 E ) 744
Principle diagram for vehicles adapted for towing (Model 180 E ) 745
Principle diagram for single vehicles (Model 260E) (with Hendrickson suspensions) 746
ARRANGEMENT ON A VEHICLE OF MAIN BRAKING SYSTEM COMPONENTS 747
DESCRIPTION 748
Service braking 748
Safety braking 748
Engine brake 748
Operation 748
Parking braking 748
BRAKES 748
Front brakes 748
Rear brakes 748
DIAGNOSTIC 749
TIGHTENING TORQUES 760
TOOLS 762
SPECIFICATIONS AND DATA – PNEUMATIC SYSTEM 769
SPECIFICATIONS AND DATA – BRAKES 774
CHECKS OF MAIN BRAKE SYSTEM COMPONENTS 776
MAIN BRAKE SYSTEM COMPONENTS 779
COMPRESSOR 779
Diagnostics 779
A P U (Air Processing Unit) 780
Operation 781
Diagnostics 782
ENGINE BRAKE SWITCH 783
ENGINE BRAKE SOLENOID VALVE 783
ENGINE BRAKE CONTROL OPERATING CYLINDER 783
MANUAL DISCHARGE VALVE 783
SAFETY VALVE (Optional) 784
DUPLEX DISTRIBUTOR 784
Unbraking 785
Diagnostics 785
PRESSURE RELIEF VALVE 786
Operation 786
Pressure limitation 786
Bench calibration 786
Diagnostics 786
RELAY VALVE 787
Diagnostics 787
CHECK VALVE 787
Operation 787
PARKING BRAKE CONTROL MANUAL DISTRIBUTOR (Single vehicles) 788
Diagnostics 788
PARKING BRAKE CONTROL MANUAL DISTRIBUTOR (Vehicles adapted for towing) 789
Diagnostics 789
QUICK DISCHARGE VALVE 790
TRIPLE CONTROL SERVODISTRIBUTOR 790
Predominance adjustment 790
Diagnostics 790
COUPLING HEADS 791
Operation 791
PRESSURE PLUG VALVE 791
MEMBRANE BRAKE CYLINDER (for disc brakes and drum brakes) 791
COMBINED BRAKE CYLINDER 792
Combined cylinder emergency unbraking device 792
Repair interventions 792
Diagnostics 792
ABS SYSTEMWITH EBL FUNCTION 793
”ABS” Anti-Lock Brake System 793
”EBL” (Electronic Brake Limiter) anti-skid device 793
ELECTRONIC UNIT 793
Operation 793
REVOLUTIONS SENSORS 793
PHONIC WHEELS 793
Operation 793
ELECTRO-PNEUMATIC VALVE 794
Operation 794
BRAKE REPAIRS MODELS ML 110 EL / 120 EL ) 795
Front Brakes (Brake calipers of the PAN 17 type) 795
Rear Brakes (Brake calipers of the PAN 17 type) 795
Description 795
Brake locking system and brake operation 795
Automatic braking gaskets wear recovering device 795
Efficiency check for braking gaskets/brake disc wear recovering device 797
Braking gaskets replacement 797
Brake calipers disconnection and reconnection 798
Disconnection 798
Reconnection 798
BRAKE CALIPERS REVISION 798
Disassembly 798
Check of component parts 799
Assembly 799
BRAKE DISCS REVISION 802
Brake discs turning and grinding 802
BRAKE REPAIRING 803
Front brakes (Brake caliper KNORR SB6 type) 803
Front and rear brakes (Brake caliper KNORR SN6-SN7 type) 804
Operation (See previous figure) 805
CHECKS 805
Checking the automatic play recovery system efficiency 805
Check of braking gaskets thickness 806
REAR BRAKES REVISION 808
Braking gaskets replacement 808
Brake calipers disconnection and reconnection 810
Disconnection 810
Reconnection 811
Wheel hubs disconnection and reconnection 811
Disconnection 811
Reconnection 811
BRAKE CALIPERS REVISION TYPES B6 812
Disassembly 812
Cleaning and check of component parts 813
Assembly 813
BRAKE CALIPER OVERHAUL TYPE SN6-SN7 815
Disassembly 815
Component part cleaning and check 816
Assembly 816
REAR DISC BRAKES REVISION (12-18 t) 818
BRAKE DISCS REVISION 818
BRAKE DISCS TURNING AND GRINDING 818
REAR DRUM BRAKES – Model 260E28KE 819
Brake position with Hendrickson suspension 819
REAR BRAKES REVISION (26 t) 820
Disassembly 820
Check of component parts 822
DRUM TURNING 823
BRAKING GASKETS REPLACEMENT 824
BRAKING GASKETS TURNING 824
Assembly 825
SECTION 12 – Body – Chassis 831
Body – Chassis 831
CAB 833
General information 833
PROTECTIVE BODY TREATMENTS 834
Protective treatment 834
Preparing the sheet metal (bonderizing) 835
Applying the protective paint (electrophoresis) 835
CHECKING THE GEOMETRY OF THE CHASSIS FRAME 835
GENERAL RULES FORWORKING ON THE CHASSIS FRAME 835
Preparing the chassis frame for maintenance, checking and repair work authorized by IVECO 835
Spot welding 836
Welding instructions 836
Bodybuilder work on the structural members of the IVECO chassis frame 836
Drilling the chassis frame 836
PRECAUTIONS 837
Welds on the chassis frame 838
CHASSIS FRAME 839
REPAIRS AND CHECKS 839
Measuring the side bend of the chassis frame 840
Measuring the bend of the chassis frame downwards or upwards 840
Measuring the movement of the chassis frame 840
Measuring the torsion of the chassis frame 841
CHASSIS REFERENCE DIMENSIONS 842
CAB GEOMETRY 849
SEAL APPLICATION DIAGRAM 850
CAB ANCHORINGCAB ANCHORING AND TIGHTENING TORQUES 853
TOOLS 856
REPAIRS 857
Cab anchoring 857
Replacing cab suspension front and rear shock absorbers 857
Removing-refitting front mounts and cab stabilizer bar 857
HYDRAULIC CAB LIFTING SYSTEM 858
Replacing hydraulic cylinder for cab tilting 859
REPLACING WINDSCREEN WINDOW 859
General 859
Vibration knife 859
Harmonic wire 860
Removal (with harmonic wire) 860
Preparing the windscreen opening 860
Preparing the windscreen 861
Refitting 861
Replacing the winding window 863
Replacing the window winder 864
Replacing the fixed window 864
INSTRUMENT PANEL 866
Removal 866
Refitting 866
MIDDLE INSTRUMENT PANEL 866
Removal 866
Refitting 867
INSTRUMENT PANEL COVERING 867
Removal 867
Refitting 872
HEATING AND VENTILATION 872
Removal 872
Refitting 872
SECTION 13 – Service plan 873
Service plan 873
SERVICING 875
Service plan 875
SERVICE FREQUENCY 875
EXTRA PLAN OPERATIONS 875
Extra plan operations (to be carried out possibly at the same time as a planned service operation) 875
SCHEDULED MAINTENANCE OPERATIONS 876
EXTRA-PLAN OPERATIONS 876
SCHEDULED MAINTENANCE OPERATIONS 879
EXTRA-PLAN OPERATIONS 879
M1 SERVICE 880
M2 SERVICE 881
M3 SERVICE 884
EXTRA-PLAN MAINTENANCE 884
EP1 SERVICE 884
EP2 SERVICE 885
EP3 SERVICE 885
EP4 SERVICE 886
EP5 SERVICE 886
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