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Lotus Elise, Esprit Repair Service Manuals


INSTANT DOWNLOAD


Complete service repair manual with Electrical Wiring Diagrams for Lotus Elise, Esprit, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Lotus Elise, Esprit workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Lotus Elise Service Manual 2001-2007
Lotus Elise Service Manual 1996-2001
Lotus Esprit (S4, V-8) Service Manual & Parts Manual 1993-2004.pdf

PRODUCT DETAILS:
Total Pages: 1,032 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
Elise Service Manual ’01-’07
Body Fittings – BP3
Bodycare & Repair – BO30
Brakes – JI50
Chassis – AG68
Clutch – QG74
Electrics – MO88
Engine – EG124
Engine Cooling – KG264
Engine Management – EMO273
Front Suspension – CH317
Fuel System – LI327
Heating & Ventilation – PI339
Intro & Technical Data – TDN – TDO345
Maintenance & Lubrication – OH359
Rear Suspension – DG367
Steering HF377
Transmission – FI387
Wheels & Tyres – GG444
Elise Service Manual ’96-‘01449
A1111T0327J450
Front Cover450
Contents452
Introduction453
Technical Data – Engine (TDL)460
Technical Data – Vehicle (TDM)464
Chassis (AF)469
Bodycare & Repair (BM)475
Body Fittings (BN)493
Front Suspension (CG)528
Rear Suspension (DE)538
Engine (inc. Rover publication RCL 0057ENG) (EE)552
Engine Management (EMN)691
Transmission (inc. Rover publication RCL 0124ENG) (FH)718
Wheels & Tyres (GF)754
Steering (HE)759
Brakes (JH)769
Engine Cooling (KF)785
Fuel System (LH)794
Electrics (MN)806
Maintenance & Lubrication (OG)880
Heating & Ventilation (PF)888
Air Conditioning, Heating & Ventilation (2000 M.Y.) (PH)896
Clutch (QF)920
Motorsport (XA)932
340R Supplement (340R)983
Exige Supplement (Exige)1033
Update1074
Esprit (S4, V-8) Service Manual & Parts Manual ’93-‘041085
JF.25.pdf0
Section JF.252066
DM- ABS IIIA2066
ANTILOCK BRAKE SYSTEM2066
Some operations in this section require that the hydraulic lines, hoses and2066
System uses a hydraulic accumulator which, when fully charged, contains2066
Brake fluid at high pressure. Before disconnecting any hydraulic lines, hose2066
Component Locations .. 42066
System Operation . 62066
Circuit Operation .. 62066
ABS Controller . 62066
Front Enable Relay … 62066
Rear Enable Relay 72066
Front and rear Solenoids … 72066
Wheel Speed Sensor . 72066
Brake Switch . 72066
Pump Motor Circuit .. 72066
ABS Tell Tail 72066
Lamp Driver Module . 72066
Self Diagnostic Capabilities .. 72066
Diagnosis … 82066
Pre-Diagnosis Inspection … 82066
2066
Trouble Codes 82066
Additional Diagnostic Capabilities 82066
ABS Snapshot 82066
Manual Relay and Solenoid Control .. 82066
Enhanced Diagnostics 92066
Note On Intermittents 102066
Figure 1. Pre-Diagnosis Inspection 112066
Figure 3. Electric Schematic Diagram … 142066
Trouble Code 1.pdf0
Section JF2069
Trouble Code Diagnosis2069
2069
CODE Page2069
A033 Brake switch Open . 822069
A055 ABS Controller internal voltage fault … 1582069
Code Page 1.pdf0
Section JF2068
Trouble Code Diagnosis2068
2068
CODE Page2068
Turbo 93.pdf0
Turbo 93-961086
Esprit-V8 (OCRing).pdf0

Lotus Elise, Esprit Repair Service Manuals


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Lifan X50/X60/X70 Compact SUV Repair Service Manual


INSTANT DOWNLOAD


Complete service repair manual with Electrical Wiring Diagrams for LIFAN X50, X60, X70, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Lifan X50/X60/X70 Compact SUV workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

lifan-x50-rukovodstvo-po-remontu-_lf_20140923_RU.pdf
LIFAN X50 Wiring Diagram(LF-20161206).pdf
LIFAN X50 расположение точек массы.pdf
LIFAN X60 Service Manual(LF-20160620).pdf
LIFAN X60 Wiring Diagram(LF-20160620).pdf
LIFAN X60 Руководство по ремонту (LF-20110929).RU.pdf
LIFAN X60 точки масс.pdf
LIFAN X70 Service Manual(LF-20171021).EN.pdf
LIFAN X70 Wiring Diagram(LF-20180620).EN.pdf
LIFAN-X70-Rukovodstvo-po-remontu-_LF_20171021_(RU).pdf

PRODUCT DETAILS:
Total Pages: 7,421 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: Russian / English

TABLE OF CONTENTS
LIFAN X50 Wiring Diagram(LF-20161206)….1
1.Content….2
2.Introduction….6
3.Symbol….8
4.Circuit Diagnosis….9
5.Wiring Diagram….14
Charging System / Clock Power / Starting System….14
Charging System / Clock Power / Starting System(PEPS)….15
PEPS System-1….16
PEPS System-2….17
Ignition System / Fuel System….18
Electronic Control System….19
Cooling System / A/C compressor….20
Air Conditioning / Rear Defroster / RearView Mirror Heating….21
TCU System….22
Cigarette Lighter / Horn / Seat Heating….23
Headlamps / Daytime Running Lamp / Rear Fog Lamp….24
Left and Right Turn Lamp / Hazard Warning Lamp….25
Left and Right Turn Lamp / Hazard Warning Lamp(PEPS)….26
Dome Lamp / Trunk Lamp / Sunroof/ TPMS….27
Width Lamps / Interior Lighting….28
EPS System….29
Instrument Cluster(I) Reverse Radar….30
Instrument Cluster(II) Multi-Function Screen….31
Audio System….32
Power Window….33
Power RearView Mirror….34
Wiper / Washer System….35
Central Locking / Theft Deterrent System….36
Supplemental Restraint System….37
ESP System….38
ABS System / Brake Lamp / Reverse Lamp….39
Diagnose Interface System….40
6.Fuse and Relay….41
Engine Compartment Fuse and Relay Box….41
IP Fuse and Relay Box….42
IP Fuse and Relay Box….43
Engine Compartment Fuse and Relay Box Power Distribution….44
IP Fuse and Relay Box Power Distribution….45
7.Ground Distribution….46
Ground Distribution G01-G02-G03-G04-G05….46
Ground Distribution G11-G12-G13-G14….47
Ground Distribution G15-G21-G22….48
Ground Distribution G23-G24-G25….49
Ground Distribution G26-G27-G28-G31….50
8.Harness Connector Location View….51
Engine Harness Connector Location View….51
Engine Compartment Harness Connector Location View….52
IP Harness Connector Location View….53
Body Harness Connector Location View….54
Door Harness Connector Location View….55
Airbag (8 Return Circuit)and Rear Bump Harness Connector Location View….56
AC and Airbag(2 Return Circuit) Harness Connector Location View….57
Roof Harness Connector Location View….58
Tail Gate Harness Connector Location View….59
9.Ground Point Location View….60
Ground Point Location View-G01-G02-G03….60
Ground Point Location View-G05….61
Ground Point Location View-G11-G12-G13-G14-G15….62
Ground Point Location View-G21-G22-G23….63
Ground Point Location View-G24-G25-G28….64
Ground Point Location View-G26….65
Ground Point Location View-G27-G31….66
10.Harness Connector View….67
Engine Harness Connector (E–)….67
E01….67
E04….68
E05….68
E06….68
E07….68
E08….69
E09….69
E10….69
E11….69
E12….70
E13….70
E14….70
E15….70
E16….71
E17….71
E19….71
E21….71
E22….72
E23….72
E24….72
E25….72
E26….73
E27….73
E28….73
E29….73
E30….74
E31….74
EI1….74
EI2….75
EU….75
Engine Compartment Harness Connector (U–)….76
U01….76
U02….76
U03….76
U04….76
U05….77
U06….77
U07/U10….77
U08….78
U09….78
U13….78
U14….79
U15….79
U16….79
U17….79
U19….80
U20….80
U21….80
U23….80
U26….81
U27….81
U29….81
U30….82
U31….82
U32….83
UI1….83
UI2….84
UI2….84
UI3….85
UE….85
Instrument Harness Connector (I–)….86
I01….86
I02….86
I03….87
I04….87
I05….88
I06….88
I07….88
I08….89
I09….89
I10….89
I11….90
I12….90
I13….90
I14….91
I15….91
I16….91
I17/18….92
I19….92
I20….93
I20….93
I21….93
I22….94
I23….94
I24….94
I25….95
I26….95
I27….96
I28….96
I29….96
I30….97
I32….97
I33….98
I34….98
I35….98
I36….98
I37….99
I38….99
I39….100
I40….100
I41….100
I42….101
I44….101
I43….101
I45….102
IR….102
IA….102
ID1….103
ID2….103
ID3….104
IU1….104
IU2….105
IU2….105
IU3….106
IS….106
IB1….107
IB2….108
IE1….108
IE2….109
Body Harness Connector (B–)….110
B01….110
B02….110
B03….110
B04….110
B05….111
B06….111
B07….111
B08….111
B09….112
B10….112
B11….112
B12….112
B13….113
B14….113
B15….113
B17….113
B18….114
B19….114
B20….114
B21….114
B22….115
B23….115
B24….115
B25….115
B26….116
BD1….116
BD2….116
BI1….117
BI2….118
BM1….118
BM2….119
BT….119
T01….120
T02….120
TB….120
TL….121
Tail Gate Harness Connector (L–)….122
L01….122
L02….122
L03….122
L04….122
L05….123
L06….123
LT….123
D01….124
D02….124
D03….124
D04….124
D05….125
D06….125
D07….125
D08….125
D09….126
D10….126
D11….126
D12….126
D13….127
D14….127
D15….127
D16….127
D17….128
D18….128
D19….128
DB1….128
DB2….129
DI1….129
DI2….130
DI3….130
R01….131
R03….131
R02….131
RI….132
SRS Harness Connector(S–)….133
S01….133
S02….133
S03….134
S04….134
S05….134
S06….134
S07….135
S08….135
S09….135
S10….135
S11….136
SI….136
Rear Bumper Harness Connector(M–)….137
M01….137
M02….137
M03….137
M04….137
M05….138
M06….138
M07….138
M08….138
MB1….139
MB2….139
Air Conditioning Harness Connector(A–)….140
A01….140
A02….140
A03….141
A04….141
A05….141
A06….141
A07….142
A08….142
AI….142
LIFAN X50 расположение точек массы….145
LIFAN X60 Service Manual(LF-20160620)….160
Service Mnual of LIFANX60….160
Content….162
Chapter I Complete Vehicle’s Performance….163
Section 1 Overview….163
Section 2 Main Technical Parameters….169
Section 3 Maintenance Regulations….180
Chapter II Overview….185
Section 1 EFI system….185
Section 2 Daily Usage and Maintenance….264
Chapter III Mechanical Part….292
Section 1 Cylinder pressure check….292
Section 2 Check and Adjustment of Valve Clearance….299
Chapter IV Chassis….403
Section 1 Manual transmission (MT)….403
Section 2 Automatic Transmission (4AT)….532
Continuously Variable Transmission (CVT) ….588
Section 3 Suspension System….665
Section 4 Steering System….719
Section 5 Brake System….732
Section 6 Fuel Supply System….776
Section 7 Drive System….781
Chapter V Electrical Part….812
Section 1 Starting System….812
Section 2 Power Supply System….819
Section 3 Air Conditioning….841
Section 4 Lamps….882
Section 5 Electric Window….889
Section 6 Exterior Electric Rearview Mirror….898
Section 7 Wiper and Washer….903
Section 8 Instrument Cluster….909
Section 9 BCM Central Lock and Burglar Alarm System….929
Section 10 Reversing Radar System (optional)….951
Section 11 Audio System (option)….958
Section 12 Air Bag….968
Section 13 Other Electric Systems….997
Chapter VI Vehicle Body and Accessories….1005
Section 1 Vehicle Body….1005
Section 2 Accessories….1012
LIFAN X60 Wiring Diagram(LF-20160620)….1038
1.Content….1039
2.Introduction….1044
3.Symbol….1046
4.Circuit Diagnosis….1047
5.Wiring Diagram….1052
Charging System / Clock Power / Starting System(Delphi)….1052
Charging System / Clock Power / Starting System(UE)….1053
Charging System / Clock Power / Starting System(UE 1.4T)….1054
Ignition System / Fuel System(Delphi)….1055
Ignition System / Fuel System(UE)….1056
Ignition System / Fuel System(UE 1.4T)….1057
Electronic Control System(Delphi)….1058
Electronic Control System(UE)….1059
Electronic Control System(UE 1.4T)….1060
Cooling System / A/C compressor(Delphi)….1061
Cooling System / A/C compressor(UE)….1062
Cooling System / A/C compressor(UE 1.4T)….1063
TCU System….1064
Air Conditioning / Rear Defroster / RearView Mirror Heating….1065
Headlamps / Daytime Running Lamp / Rear Fog Lamp….1066
Cigarette Lighter / Horn / Seat Heating / TPMS….1067
Left / Right Turn Lamp / Hazard Warning Lamp….1068
Dome Lamp / Trunk Lamp / Sunroof / Sun Visor Lamp….1069
Width Lamps / Interior Lighting….1070
Instrument Cluster / Reverse Radar….1071
Audio System / Multi-Function Screen / MP5 System….1072
Power RearView Mirror….1073
Power Window….1074
Wiper / Washer System….1075
Central Locking / Theft Deterrent System….1076
Supplemental Restraint System….1077
ESP System….1078
ABS System / Brake Lamp / Parking Lamp / Reverse Lamp….1079
Diagnose Interface System….1080
6.Fuse and Relay….1081
Engine Compartment Fuse and Relay Box….1081
Battery Power Breaker Box….1082
IP Fuse and Relay Box….1083
IP Fuse and Relay Box….1084
Engine Compartment Fuse and Relay Box Power Distribution….1085
Engine Compartment Fuse and Relay Box Power Distribution(UE)….1086
Engine Compartment Fuse and Relay Box Power Distribution(UE 1.4T)….1087
IP Fuse and Relay Box Power Distribution….1088
7.Ground Distribution ….1089
Ground Distribution G01-G01a-G01b-G02-G02a-G02b-G03b….1089
Ground Distribution G03a-G04-G10-G11-G12….1090
Ground Distribution G15-G16-G17-G18….1091
Ground Distribution G21-G24-G26-G27-G28….1092
Ground Distribution G29-G31….1093
8.Harness Connector Location View….1094
Engine Harness Connector Location View….1094
Engine Harness Connector Location View(UE 1.4T)….1095
Engine Compartment Harness Connector Location View….1096
IP Harness Connector Location View….1097
Body Harness Connector Location View….1098
Door and Tail Gate Harness Connector Location View….1099
Airbag Harness Connector Location View….1100
Roof Harness Connector Location View….1101
9.Ground Point Location View….1102
Ground Point Location View-G01-G02-G01a-G02a-G03a….1102
Ground Point Location View-G01b-G02b-G03b….1103
Ground Point Location View-G10-G11-G12….1104
Ground Point Location View-G15-G16-G17-G18….1105
Ground Point Location View-G26-G27-G28-G29….1106
Ground Point Location View-G24….1107
Ground Point Location View-G21….1108
Ground Point Location View-G31….1109
10.Harness Connector View….1110
Engine Harness Connector (E–)-1.8VVT(Delphi)….1110
E01….1110
E02….1111
E03….1111
E04….1111
E05….1112
E06….1112
E07….1112
E08….1112
E09….1113
E10….1113
E11….1113
E12….1113
E13….1114
E14….1114
E15….1114
E16….1114
E17….1115
E18….1115
E19….1115
E20….1115
E21….1116
E22….1116
E23….1116
E24….1116
E25….1117
E26….1117
EI1….1117
EI2….1118
EU1….1118
Engine Harness Connector (E–)-1.8VVT(UE)….1119
E01a….1119
E02a….1120
E03a….1120
E04a….1121
E05a….1121
E06a….1121
E07a….1121
E08a….1122
E09a….1122
E10a….1122
E11a….1122
E12a….1123
E13a….1123
E14a….1123
E15a….1123
E16a….1124
E17a….1124
E18a….1124
E19a….1124
E20a….1125
E21a….1125
E22a….1125
E23a….1125
E24a….1126
EI1a….1126
EU1a….1127
Engine Harness Connector (E–)-1.4T(UE)….1127
E01b….1127
E02b….1129
E03b….1129
E04b….1130
E05b….1130
E06b….1130
E07b….1130
E08b….1131
E09b….1131
E10b….1131
E12b….1131
E13b….1132
E14b….1132
E15b….1132
E16b….1132
E17b….1133
E18b….1133
E19b….1133
E20b….1133
E21b….1134
E22b….1134
E23b….1134
E24b….1134
E25b….1135
EI2b….1135
EI1b….1135
EU1b….1136
EQ1….1136
Injector Harness Connector (Q–)….1137
Q01….1137
Q02….1137
Q03….1137
Q04….1137
Q05….1138
Q06….1138
Q07….1138
Q08….1138
QE1….1139
Engine Compartment Harness Connector (U–)….1140
U01….1140
U02….1140
U03….1140
U04….1140
U05….1141
U06….1141
U07….1141
U08….1141
U09….1142
U10….1142
U11….1142
U12….1143
U13….1143
U14….1144
U15….1144
U16….1144
U17….1144
U18….1145
U19….1145
U20….1145
U21….1145
U22….1146
U23….1147
U24….1147
UE1….1148
UI1….1148
UI2….1149
UI3….1149
UE1a….1150
UE1b….1150
Instrument Harness Connector (I–)….1151
I01….1151
I02….1151
I03….1152
I04….1152
I05….1152
I06….1152
I07….1153
I08….1153
I09….1154
I10….1154
I11….1155
I12….1155
I13….1155
I14….1156
I15….1156
I16….1156
I17….1157
I21….1157
I20….1157
I22….1157
I23….1158
I24….1158
I25….1158
I26….1159
I27….1159
I28….1160
I29….1160
I30….1161
I31….1161
I32….1161
I33….1161
I34….1162
I35….1162
I36….1162
I37….1162
I38….1163
I39….1163
I40….1164
I41….1164
I42….1165
I43….1165
I44….1165
I45….1166
I46….1166
I47….1166
I48….1166
I49….1167
I50….1167
I51….1167
IB1….1168
IB2….1168
IB3….1169
IU1….1169
IU2….1170
IU3….1170
ID1….1171
ID2….1171
ID3….1172
ID4….1172
IE2….1172
IE1….1173
IE1a….1173
IE1b….1174
IE2b….1174
IR1….1174
IS1….1175
IA1….1175
Body Harness Connector (B–)….1176
B01….1176
B02….1176
B03….1176
B04….1176
B05….1177
B06….1177
B07….1177
B08….1177
B09….1178
B10….1178
B11….1178
B12….1178
B13….1179
B14….1179
B15….1179
B16….1179
B17….1180
B18….1180
B19….1181
B20….1181
BI1….1181
BI2….1182
BI3….1182
BD1….1183
BD2….1183
BM1….1184
BT1….1184
Tail Gate Harness Connector (T–)….1185
T01….1185
T02….1185
T03….1185
T04….1185
T05….1186
T06….1186
TB1….1186
Door Harness Connector(D–)….1187
D01….1187
D02….1187
D03….1187
D04….1187
D05….1188
D06….1188
D08….1188
D09….1189
D10….1189
D11….1189
D12….1189
D13….1190
D14….1190
D15….1190
D16….1190
D17….1191
D18….1191
D19….1191
D20….1191
D21….1192
D22….1192
D23….1192
DI1….1193
DI2….1193
DI3….1194
DI4….1194
DB1….1195
DB2….1195
Roof Harness Connector(R–)….1196
R01….1196
R03….1196
R02….1196
R04….1196
R05….1197
R06….1197
RI1….1197
SRS Harness Connector(S–)….1198
S01….1198
S02….1198
S03….1198
S04….1198
S05….1199
SI1….1200
Rear Bumper Harness Connector(M–)….1201
M01….1201
M02….1201
M03….1201
M04….1201
MB1….1202
Air Conditioning Harness Connector(A–)….1203
A01….1203
A02….1203
A03….1203
A04….1203
A05….1204
A06….1204
A07….1204
AI1….1205
11.Abbreviations….1206
LIFAN X60 Руководство по ремонту (LF-20110929).RU….1208
LIFAN X60 точки масс….1628
LIFAN X70 Service Manual(LF-20171021).EN….1635
01-Overview….1635
OLE_LINK9….1653
OLE_LINK10….1653
Overview….1641
How to use this manual….1641
Vehicle parameters….1644
Logo….1648
Danger, warning, and caution signs….1649
Traction and Shipping ….1657
Vehicle Lift and Support….1658
Regular maintenance….1660
Abbreviations….1663
02-1Engine mechanical system….1667
Mechanical System….1669
Technical specifications….1669
Precautions….1674
Preparation….1675
Structure and installation location….1679
General Inspection….1686
Diagnostic Information and Procedures….1687
Removal and Installation….1710
02-2Engine control system (Delphi)….1773
Engine control system (Delphi)….1775
Precautions….1775
Preparation….1777
Structure and installation location….1778
Operating Principle….1779
Diagnostic Information and Procedures….1789
Removal and Installation….1939
02-2Engine control system (UAES)….1951
Engine control system (UMC)….1953
Precautions….1953
Preparation….1954
Structure and installation location….1955
Operating Principle….1956
Diagnostic Information and Procedures….1961
Removal and installation….2119
02-3Lubrication System….2131
Lubrication System….2133
Technical specifications….2133
Precautions….2135
Preparation….2136
Structure and installation location….2137
Electrical Schematic Diagram….2138
General Inspection….2139
Operating Principle….2141
Diagnostic Information and Procedures….2142
Removal and Installation….2148
02-4Fuel System….2157
Fuel System….2159
Mechanical systems….2159
Precautions….2160
Preparation….2161
Structure and installation location….2162
Functional diagram….2163
General Inspection….2164
Diagnostic Information and Procedures….2166
Removal and Installation….2172
02-5Intake system….2177
Intake system….2179
Structure and installation location….2179
Functional diagram….2181
Operating Principle….2182
Diagnostic Information and Procedures….2183
Removal and Installation….2186
02-6Exhaust system….2189
Exhaust system….2191
Precautions….2191
Structure and installation location….2192
Functional diagram….2193
Diagnostic Information and Procedures….2194
Removal and Installation….2197
02-7Cooling system….2199
Cooling system….2201
Mechanical systems….2201
Precautions….2202
Structure and installation location….2203
General Inspection….2206
Functional diagram….2207
Operating Principle….2208
Diagnostic Information and Procedures….2209
Removal and Installation….2225
02-8Start system….2239
OLE_LINK1….2252
OLE_LINK2….2252
Start system….2241
Technical specifications….2241
Precautions….2242
Preparation….2243
Structure and installation location….2244
General Inspection….2245
Operating Principle….2250
Diagnostic Information and Procedures….2251
Removal and Installation….2268
02-9Charging system….2269
Charging system….2271
Technical specifications….2271
Precautions….2272
Preparation….2273
General Inspection….2274
Operating Principle….2275
Structure and installation location….2276
Diagnostic Information and Procedures….2277
Removal and Installation….2286
02-10Ignition System….2289
Ignition System….2291
Technical specifications ….2291
Precautions….2292
Preparation….2293
Structure and installation location….2294
General Inspection….2295
Operating Principle….2296
Diagnostic Information and Procedures….2297
Removal and Installation….2304
02-11Emission control system….2307
Emission control system….2309
Technical specifications ….2309
Preparation….2311
Structure and installation location….2312
General Inspection….2313
Operating Principle….2314
Diagnostic Information and Procedures….2315
Removal and Installation….2320
02-12Power suspension device….2327
Power suspension device….2329
Technical specifications….2329
Structure and installation location….2331
Removal and Installation….2334
02-13Engine immobilizer….2343
Engine anti-theft system….2345
Preparation….2345
Structure and installation location….2346
Operating Principle….2347
Diagnostic Information and Procedures….2350
Removal and installation….2359
03-1Manual transmission….2361
Manual transmission assembly….2363
Technical specifications….2363
Precautions….2365
Preparation….2366
Structure and installation location….2368
General Inspection….2376
Operating Principle….2378
Diagnostic Information and Procedures….2381
Removal and Installation….2390
Disassembly and installation….2406
03-2Continuously variable transmission….2419
Continuously variable transmission….2421
Technical specifications….2421
Precautions….2422
Preparation….2423
Structure and installation location….2424
General Inspection….2427
Operating Principle….2430
Diagnostic Information and Procedures….2435
DTC diagnosis and testing….2446
Removal and Installation….2509
03-3Clutch….2523
Clutch….2525
Technical specifications….2525
Precautions….2526
Structure and installation location….2528
General Inspection….2530
Operating Principle….2531
Diagnostic Information and Procedures….2532
Removal and Installation….2547
04-Drive Train….2555
Drive Shaft….2557
Technical specifications….2557
Precautions….2558
Structure and installation location….2560
General Inspection….2561
Operating Principle….2562
Diagnostic Information and Procedures….2563
Removal and Installation….2572
05-1Front suspension….2577
Front suspension….2579
Technical specifications….2579
Precautions….2580
Preparation….2581
Structure and installation location….2582
General Inspection….2585
Operating Principle….2587
Diagnostic Information and Procedures….2589
Removal and Installation….2604
05-2Rear suspension….2617
Rear suspension….2619
Technical specifications….2619
Precautions….2620
Preparation….2621
Structure and installation location….2622
General Inspection….2624
Operating Principle….2625
Diagnostic Information and Procedures….2626
Removal and Installation….2631
05-3Wheels and tires….2639
Wheels and tires….2641
Technical specifications….2641
Precautions….2642
Preparation….2643
Structure and installation location….2645
General Inspection….2646
Operating Principle….2649
Diagnostic Information and Procedures….2651
Removal and Installation….2654
05-4Four-wheel alignment….2657
Four-wheel alignment….2659
Technical Specifications….2659
Precautions….2660
Preparation….2661
General Inspection….2662
Operating Principle….2663
Diagnostic Information and Procedures….2664
06-Hydraulic power steering system….2673
Hydraulic power steering system….2675
Technical Specifications….2675
Precautions….2676
Preparation….2677
Structure and installation location….2678
General Inspection….2680
Operating Principle….2681
Diagnostic Information and Procedures….2682
Removal and Installation….2694
07-1Service brake system….2711
07-2Parking system….2757
Mechanical parking system….2759
Technical specifications….2759
Precautions….2760
Preparation….2761
Structure and installation location….2762
General Inspection….2763
Operating Principle….2764
Diagnostic Information and Procedures….2765
Removal and installation….2771
07-3 ABS TCS EBD ESP….2775
08-Electric air conditioning system….2855
09-1Seatbelt….2919
_GoBack….2934
Seatbelt….2921
Technical specifications….2921
Precautions….2922
Preparation….2923
Structure and installation location….2924
General Inspection….2925
Operating Principle….2926
Diagnostic Information and Procedures….2927
Removal and Installation….2939
09-2Airbag system….2947
Airbag system….2949
Technical specifications….2949
Precautions….2950
Preparation….2951
Structure and installation location….2952
Operating Principle….2953
Diagnostic Information and Procedures….2955
Removal and Installation….2993
10-1Fender….3003
Fender….3005
Technical specifications….3005
Structure and installation location….3006
Removal and Installation….3007
10-2Engine cover….3009
Engine cover….3011
Removal and Installation….3011
10-3Car door….3019
Car door….3021
Operating Principle….3021
Removal and Installation….3022
10-4Glass….3029
Glass….3031
Operating Principle….3031
Removal and Installation….3032
10-5Door handles, door locks and doors….3041
Door handles, door locks and doors….3043
Removal and Installation….3043
10-6Filler cap….3053
Filler cap….3055
Removal and Installation….3055
10-7Shelf curtains….3057
Shelf curtains….3059
Removal and Installation….3059
11-1Dashboard and console….3061
Dashboard and console….3063
Technical specifications….3063
Precautions….3064
Structure and installation location….3065
Removal and installation….3067
11-2Seat….3079
Seat….3081
Technical specifications….3081
Precautions….3082
Operating Principle….3083
Diagnostic Information and Procedures….3084
Removal and installation….3094
11-3Interior trim….3105
Interior trim….3107
Precautions….3107
Preparation….3108
Removal and installation….3109
11-4Exterior trim….3131
Exterior trim….3133
Precautions….3133
Preparation….3134
Removal and installation….3135
12-1Lighting System….3147
Lighting System….3149
Technical specifications….3149
Precautions….3150
Preparation….3151
Structure and installation location….3152
General Inspection….3154
Operating Principle….3155
Diagnostic Information and Procedures….3158
Removal and Installation….3206
12-2Wiper and scrubber….3219
Wiper and scrubber….3221
Technical specifications….3221
Precautions….3222
Structure and installation location….3223
Operating Principle….3225
Diagnostic Information and Procedures….3226
Removal and Installation….3267
12-3Horn System….3277
12-4Instruments and displays….3291
Instrument and display….3293
Technical specifications….3293
Structure and installation location….3294
Operating Principle….3295
Diagnostic Information and Procedures….3296
Removal and installation….3356
12-5Electric rearview mirror….3359
Electric rearview mirror….3361
Precautions….3361
Structure and installation location….3362
Operating Principle….3363
Diagnostic Information and Procedures….3364
Removal and installation….3374
12-6Audio system….3377
Audio system….3379
Preparation….3379
Precautions….3380
Structure and installation location….3381
Diagnostic Information and Procedures….3382
Removal and installation….3390
12-7EPS system (keyless entry and one-key start system)….3399
PEPS system….3401
Technical specifications….3401
Structure and installation location….3404
General Inspection….3405
Operating Principle….3406
Diagnostic Information and Procedures….3409
Removal and installation….3447
12-8Central locking system….3455
Central lock system….3457
Precautions….3457
Preparation….3458
Structure and installation location….3459
Operating Principle….3460
Diagnosis Information and Procedures….3463
Removal and Installation….3473
12-9Roof….3479
Roof….3481
Technical specifications….3481
Operating Principle….3482
Diagnosis Information and Procedures….3483
Removal and Installation….3489
12-10Power window….3491
Power window….3493
Technical specifications….3493
Precautions….3494
Preparation….3495
Operating Principle….3496
Structure and installation location….3498
Diagnosis information and procedures….3499
Removal and Installation….3511
12-11Automobile reversing radar….3515
Rear reversing radar….3517
Precautions….3517
Preparation….3518
Structure and installation location….3519
Diagnosis Information and Procedures….3521
Removal and Installation….3527
12-12Constant-speed cruise control system….3531
Constant speed cruise….3533
Precautions….3533
Preparation….3534
Structure and installation location….3535
Operating Principle….3536
Diagnosis Information and Procedures….3537
Removal and Installation….3545
12-13Communication system….3547
Communication system….3549
Operating principle….3549
Diagnosis information and procedures….3550
12-14Body controller BCM….3559
Body controller (BCM)….3561
Technical specifications….3561
Structure and installation location….3562
Operating principle….3563
Diagnosis information and procedures….3564
Removal and installation….3601
12-15Defrosting….3603
Defrosting….3605
Structure and installation location….3605
Diagnosis information and procedures….3606
Removal and installation….3614
12-16Cigarette lighter….3617
Cigarette lighter….3619
Operating Principle….3619
Diagnosis information and procedures….3620
Removal and installation….3626
12-17PMS Tire pressure monitoring system….3631
TPMS (tire pressure monitoring system)….3633
Technical specifications….3633
Structure and installation location….3635
Electrical Schematic Diagram….3636
General Inspection….3637
Operating Principle….3638
Diagnosis information and procedures….3639
Removal and installation….3657
LIFAN X70 Wiring Diagram(LF-20180620).EN….3659
1 Circuit Diagram Description….3664
2 Circuit Diagnosis and Maintenance Description….3664
3 Element Symbol….3668
4 Wiring Diagram….3669
4.1A PEPS….3669
4.1A Wiring Diagram 1 of PEPS….3669
4.1A Wiring Diagram 2 of PEPS….3670
4.1A Wiring Diagram 3 of PEPS….3671
4.1A Wiring Diagram 4 of PEPS….3672
4.1A Wiring Diagram 5 of PEPS….3673
4.1B BCM….3674
4.1B Wiring Diagram 1 of BCM….3674
4.1B Wiring Diagram 2 of BCM….3675
4.1B Wiring Diagram 3 of BCM….3676
4.1B Wiring Diagram 4 of BCM….3677
4.2A Starting/Power Distribution System….3678
4.2B Starting/Power Distribution System (Engine Start Stop)….3679
4.3A EMS (Delphi)….3680
4.3A Wiring Diagram 1 of Engine Management System….3680
4.3A Wiring Diagram 2 of Engine Management System….3681
4.3B EMS (UAES)….3682
4.3B Wiring Diagram 1 of Engine Management System….3682
4.3B Wiring Diagram 2 of Engine Management System….3683
4.4A Cooling System (Delphi)….3684
4.4B Cooling System (UAES)….3685
4.5 TCU System….3686
4.6 ABS/ESP System….3687
4.7 Instrument Cluster System….3688
4.8 Wiper System….3689
4.9 Airbag System….3690
4.10 Power Seat System….3691
4.11 Seat Heating System….3692
4.12 Power Rearview Mirror System….3693
4.13 DVD/GPS Audio-visual System….3694
4.13 Wiring Diagram 1 of DVD/GPS Audio-visual System….3694
4.13 Wiring Diagram 2 of DVD/GPS Audio-visual System….3695
4.14 A/C System….3696
4.15 Horn/Cigarette Lighter/TPMS System….3697
4.16A Roof Light/Sunroof System….3698
4.16B Roof Light/Sunroof System….3699
4.17 OBD System….3700
4.18A Brake Lamp/Position Lamp System….3701
4.18B Brake Lamp/Position Lamp System….3702
4.19 GLONASS System (Overseas Only)….3703
5 Fuse and Relay Box….3704
5.1 Engine Compartment Fuse and Relay Box….3704
Relay….3704
Fuse….3704
5.2 Instrument Panel Fuse and Relay Box….3705
Relay….3705
Fuse….3705
Back View of Instrument Panel Electrical Box….3705
5.3 Three-way Fuse Box….3706
Fuse….3706
5.4 Power Distribution Diagram of Engine Compartment Electrical Box….3707
5.5A Power Distribution Diagram of Instrument Panel Electrical Box….3708
5.5B Power Distribution Diagram of Instrument Panel Electrical Box (Engine Start Stop)….3709
6 Ground Distribution….3710
6.1 Ground distribution G101-G102a-G103a-G102b-G103b….3710
6.2 Ground distribution G111-G112-G113….3711
6.3 Ground distribution G121….3712
6.4 Ground distribution G122-G123….3713
6.5 Ground distribution G124-G125-G126-G127-G128….3714
7 Harness Connector Location View….3715
7.1A Engine harness-2.0MT (Delphi)….3715
7.1B Engine harness-2.0CVT (UAES)….3716
7.2 Engine compartment harness….3717
7.3 Instrument harness….3718
7.4 Body harness….3719
7.5 LF door/LR door harness….3720
7.6 RF door/RR door harness….3721
7.7 Airbag harness….3722
7.8 Headlining harness….3723
7.9 Tail door/rear bumper harness….3724
8 Ground Point Location View….3725
8.1A G102a-G103a….3725
8.1B G102b-G103b….3726
8.2 G101-G111-G112-G113103a….3727
8.3 G121-G122-G123….3728
8.4 G124….3729
8.5 G125-G126-G127….3730
8.6 G128….3731
9 Harness Connector View….3732
9.1A Engine Harness-2.0MT (Delphi)….3732
ECU(E01a)….3732
Accelerator pedal position sensor (E03a)….3733
Front oxygen sensor (E04a)….3733
Power steering switch (E05a)….3733
Intake VVT valve (E06a)….3733
Knock sensor (E07a)….3734
Starter (E08a)….3734
Oil pressure alarm (E09a)….3734
Intake air temperature & pressure sensor (E10a)….3734
A/C field switch (E11a)….3735
Generator regulator (E12a)….3735
Fuel injector A (E13a)….3735
Fuel injector B (E14a)….3735
Fuel injector C (E15a)….3736
Fuel injector D (E16a)….3736
Ignition coil A (E17a)….3736
Ignition coil B (E18a)….3736
Ignition coil C (E19a)….3737
Ignition coil D (E20a)….3737
Intake camshaft sensor (E21a)….3737
Electric throttle valve (E22a)….3737
Coolant temperature sensor (E23a)….3738
Canister control valve (E24a)….3738
Crankshaft position sensor (E25a)….3738
Reversing Lamp Switch (E26a)….3738
Gear switch (E27a)….3739
9.1B Engine harness-2.0CVT (UAES)….3740
ECU(E01b)….3740
TCU(E02b)….3741
Accelerator Pedal Position Sensor (E03b)….3742
Front Oxygen Sensor (E04b)….3742
Power Steering Switch (E05b)….3742
Intake VVT Valve (E06b)….3742
Knock Sensor (E07b)….3743
Starter (E08b)….3743
Oil Pressure Alarm (E09b)….3743
Intake Air Temperature & Pressure Sensor (E10b)….3743
A/C Field Switch (E11b)….3744
Generator Regulator (E12b)….3744
Fuel Injector A (E13b)….3744
Fuel Injector B (E14b)….3744
Fuel Injector C (E15b)….3745
Fuel Injector D (E16b)….3745
Ignition Coil A (E17b)….3745
Ignition Coil B (E18b)….3745
Ignition Coil C (E19b)….3746
Ignition Coil D (E20b)….3746
Intake Camshaft Sensor (E21b)….3746
Electric Throttle Valve (E22b)….3746
Coolant Temperature Sensor (E23b)….3747
Canister Control Valve (E24b)….3747
Crankshaft Position Sensor (E25b)….3747
Output shaft speed sensor (E26b) ….3747
Gear switch (E27b)….3748
Turbine speed sensor (E28b) ….3748
Output shaft pressure sensor (E29b) ….3748
Input shaft pressure sensor (E30b) ….3748
Input shaft pressure sensor (E31b)….3749
Solenoid valve (E32b) ….3749
9.2 Engine compartment harness ….3750
Tweeter (U02) ….3750
Ambient temperature sensor (U03) ….3750
Electronic fan (U04) ….3750
LF anti-collision radar (U05)….3750
LF fog lamp (U06)….3751
LF wheel speed sensor (U07)….3751
LF combination lamp (U08)….3751
Liquid level switch, brake fluid (U09)….3751
ABS/ESP HCU (U10)….3752
Front wiper motor (U11)….3752
RF combination lamp (U12)….3752
High and low pressure switch (U13)….3753
RF anti-collision radar (U14)….3753
RF fog lamp (U15)….3753
RF wheel speed sensor (U16)….3753
Washer motor (U17)….3754
IP box (U18)….3754
9.3 Instrument harness ….3755
Left Tweeter (I01)….3755
Fuse box 1 (I03)….3755
Fuse box 2# (I04)….3755
Fuse box 3 (I05)….3755
Fuse box 4 (I06)….3756
Fuse box 5 (I07)….3756
Fuse box 6 (I08)….3757
Clutch bottom switch (I09)….3757
Clutch top switch (I10)….3757
Brake switch (I11)….3757
OBD diagnostic interface (I12)….3758
ESCL (I13)….3758
Light combination switch (I14)….3758
Clock spring 1 (I15)….3759
Driver’s Airbag (I16)….3759
Steering angle sensor (I17)….3759
Ignition switch (I19)….3759
Wiper combination switch (I18)….3760
Immobilizer identification coil (I20)….3760
Ignition switch light circle (I21)….3760
PEPS1(I23)-Black ….3761
PEPS2(I24)-Gray ….3761
PEPS3(I25)-Brown ….3762
PEPS4 (I26)….3762
Instrument panel switch (I28)….3763
Instrument cluster (I29)….3763
ENGINE START STOP button (I30)….3764
Cigarette lighter (I31)….3764
MP5 Player 1 (I32)….3764
MP5 player (brown protective sleeve) 2 (I33)….3765
MP5 player (black protective sleeve) 3 (I34)….3765
MP5 Player Screen 1 (I35)….3765
MP5 Player Screen 2 (I37)….3766
A/C control panel (I38)….3766
Front antenna, internal (I39)….3767
On-board power supply (I40)….3767
Rear oxygen sensor (I41)….3767
Ambient light sensor (I42)….3767
Front passenger’s airbag (I43)….3768
Right tweeter (I44)….3768
BCM1(I45)-Black….3768
BCM2(I46)-Gray….3769
BCM1(I47)-Brown….3769
9.4 Body harness….3770
PEPS5 (B01)….3770
Middle antenna, internal (B02)….3770
RF courtesy switch (B03)….3770
RR wheel speed sensor (B04)….3771
RR courtesy switch (B05)….3771
RR combination lamp (B06)….3771
LF courtesy switch (B07)….3771
Fuel pump (B08)….3772
Rear antenna, internal (B09)….3772
LR wheel speed sensor (B10)….3772
LR courtesy switch (B11)….3772
Trunk lamp (B12)….3773
LR combination lamp (B13)….3773
BCM4 (B14)….3773
9.5 LF door harness….3774
LF door loudspeaker (D01)….3774
Window regulator motor, LF door (D02)….3774
Left external rearview mirror (D03)….3774
Switch, LF door armrest (D04)….3775
Courtesy lamp, LF door (D05)….3775
LF door lamp (D06)….3775
Handle antenna, LF door (D07)….3776
Lock, LF door (D08)….3776
9.6 RF door harness….3777
RF door loudspeaker (D12)….3777
Window regulator motor, RF door (D13)….3777
Right Exterior rearview mirror(D14)….3777
Switch, RF door armrest (D15)….3777
RF door lamp (D16)….3778
Lock, RF door (D17)….3778
9.7 LR door harness….3778
LR door loudspeaker (D20)….3778
Window regulator motor, LR door (D21)….3778
Armrest switch, LR door (D22)….3779
LR door lock (D23)….3779
9.8 RR door harness….3779
RR door loudspeaker (D26)….3779
Window regulator motor, RR door (D27)….3779
Armrest switch, RR door (D28)….3780
RR door lock (D29)….3780
9.9 Airbag harness….3780
Left pre-warning seat belt(S01)….3780
Seat belt switch, driver’s side (S02)….3780
Heating, driver seat (S03)….3781
Driver’s power seat (S04)….3781
CVT gear selector (S05)….3781
Yaw rate sensor (S06)….3781
SRS ECU (four loops) (S07)….3782
Parking brake switch (S08)….3782
Heating, front passenger seat (S10)….3783
Seat belt switch, front passenger’s side (S11)….3783
TPMS (S12)….3783
Right pre-warning seat belt(S13)….3784
9.10 Roof harness ….3784
Left Make-up mirror lamp (R01)….3784
Right make-up mirror lamp (R02)….3784
Sunroof motor (R03)….3785
Microphone (R04)….3785
Front roof lamp (R06)….3785
Antenna 1/2 (R08)….3785
9.11 Tail door harness ….3786
High mount brake lamp (T01)….3786
Rear defroster (T02)….3786
LR combination lamp (T03)….3786
Rear wiper motor (T04)….3786
RR combination lamp (T05)….3787
LR license plate lamp (T06)….3787
Tail door lock (T07)….3787
Rear view camera (T08)….3787
Inching switch, trunk (T09)….3788
RR license plate lamp (T10)….3788
9.12 Rear bumper harness….3788
LR fog lamp (M01)….3788
LR anti-collision radar (M02)….3788
Trunk antenna (M03)….3789
RR anti-collision radar (M04)….3789
RR fog lamp (M05)….3789
9.13 A/C harness ….3790
Temperature sensor, evaporator (A01)….3790
Air mixing motor (A02)….3790
Mode motor (A03)….3790
Internal/external circulation motor (A04)….3790
Blower speed regulation module (A05)….3791
Blower (A06)….3791
A/C control module (A07)….3791
9.15 GLONASS harness (for Russia only) ….3792
GLONASS controller (G01)….3792
GLONASS loudspeaker (G02)….3792
GLONASS switch (G03)….3792
9.16 Connector ….3793
Connector 1, body harness and LF door harness (BD1/DB1)….3793
Connector 1, body harness and LR door harness (BD2/DB2)….3793
Connector 1, body harness and RR door harness (BD3/DB3)….3794
Connector 1, body harness and rear bumper harness (BM1/MB1)….3794
Connector 1, body harness and engine compartment harness (BU1/UB1)….3794
Connector 1, instrument harness and roof harness (IR1/RI1)….3795
Connector 1, body harness and tail door harness (BT1/TB1)….3795
Connector 1, instrument harness and body harness (IB1/BI1)….3796
Connector 2, instrument harness and body harness (IB2/BI2)….3796
Connector 1, instrument harness and LF door harness (ID1/DI1)….3797
Connector 1, instrument harness and RF door harness (ID3/DI3)….3797
Connector 1, instrument harness and engine compartment harness (IU1/UI1)….3798
Connector 1, instrument harness and A/C harness (IA1/AI1)….3798
Connector 1, instrument harness and airbag harness (IS1/SI1)….3799
Connector 2, instrument harness and airbag harness (IS2/SI2)….3799
Connector 3, instrument harness and Airbag harness (IS3/SI3)….3800
Connector 1, instrument harness and GLONASS harness (IG1/GI1)….3800
Connector 1, engine compartment harness and engine harness (MT condition) (UE1/EU1a)….3801
Connector 1, engine compartment harness and engine harness (CVT condition) (UE1/EU1b)….3801
Connector 1, instrument harness and engine harness (MT condition) (IE1/EI1a)….3802
Connector 1, instrument harness and engine harness (CVT condition) (IE1/EI1b)….3802
10 Abbreviation….3803
LIFAN-X70-Rukovodstvo-po-remontu-_LF_20171021_(RU)….3805
OLE_LINK9….3824
OLE_LINK10….3824
Общие сведения….3811
Пользование руководством….3811
Параметры автомобиля….3814
Эмблема….3818
Знаки опасности, предупреждения и предостережения….3819
Буксировка и транспортировка ….3828
Подъем автомобиля и установка опор….3829
Регулярное техническое обслуживание….3831
Сокращения….3834
Механическая система….3839
Технические характеристики….3839
Меры предосторожности….3844
Подготовка….3845
Конструкция и расположение узлов и деталей….3849
Общая проверка….3856
Диагностическая информация и процедуры….3857
Снятие и установка….3880
Система управления ….3947
Меры предосторожности….3947
Подготовка….3948
Конструкция и расположение узлов и деталей….3949
Принцип работы….3950
Диагностическая информация и процедуры….3955
Снятие и установка….4114
Система управления двигателем (Delphi)….4127
Меры предосторожности….4127
Подготовка….4129
Конструкция и расположение узлов и деталей….4130
Принцип работы….4131
Диагностическая информация и процедуры….4142
Снятие и установка….4294
Система смазки….4307
Технические характеристики….4307
Меры предосторожности….4309
Подготовка….4310
Конструкция и расположение узлов и деталей….4311
Принципиальная электрическая схема….4312
Общая проверка….4313
Принцип работы….4315
Диагностическая информация и процедуры….4316
Снятие и установка….4322
Топливная система….4333
Механические системы….4333
Меры предосторожности….4334
Подготовка….4335
Конструкция и расположение узлов и деталей….4336
Функциональная принципиальная схема….4337
Общая проверка….4338
Диагностическая информация и процедуры….4340
Снятие и установка….4346
Впускная система….4353
Конструкция и расположение узлов и деталей….4353
Функциональная принципиальная схема….4355
Принцип работы….4356
Диагностическая информация и процедуры….4357
Снятие и установка….4360
Выпускная система….4365
Меры предосторожности….4365
Конструкция и расположение узлов и деталей….4366
Функциональная принципиальная схема….4367
Диагностическая информация и процедуры….4368
Снятие и установка….4371
Система охлаждения….4375
Механические системы….4375
Меры предосторожности….4376
Конструкция и расположение узлов и деталей….4377
Общая проверка….4380
Функциональная принципиальная схема….4381
Принцип работы….4382
Диагностическая информация и процедуры….4383
Снятие и установка….4399
OLE_LINK1….4426
OLE_LINK2….4426
Пусковая система….4415
Технические характеристики….4415
Меры предосторожности….4416
Подготовка….4417
Конструкция и расположение узлов и деталей….4418
Общая проверка….4419
Принцип работы….4424
Диагностическая информация и процедуры….4425
Зарядная система….4445
Технические характеристики….4445
Меры предосторожности….4446
Подготовка….4447
Общая проверка….4448
Принцип работы….4450
Конструкция и расположение узлов и деталей….4452
Диагностическая информация и процедуры….4453
Снятие и установка….4460
Система зажигания….4465
Технические характеристики ….4465
Меры предосторожности….4466
Подготовка….4467
Конструкция и расположение узлов и деталей….4468
Общая проверка….4469
Принцип работы….4470
Диагностическая информация и процедуры….4471
Снятие и установка….4478
Система снижения токсичности выбросов….4483
Технические характеристики ….4483
Подготовка….4485
Конструкция и расположение узлов и деталей….4486
Общая проверка….4487
Принцип работы….4488
Диагностическая информация и процедуры….4489
Снятие и установка….4494
Система подвески силового агрегата….4503
Технические характеристики….4503
Конструкция и расположение узлов и деталей….4505
Снятие и установка….4508
Противоугонная система двигателя….4519
Подготовка….4519
Конструкция и расположение узлов и деталей….4520
Диагностическая информация и процедуры….4524
Снятие и установка….4534
Механическая коробка передач в сборе….4537
Технические характеристики….4537
Меры предосторожности….4539
Подготовка….4540
Конструкция и расположение узлов и деталей….4542
Общая проверка….4551
Принцип работы….4553
Диагностическая информация и процедуры….4556
Снятие и установка….4565
Разборка и сборка….4581
Бесступенчатая коробка передач….4595
Технические характеристики….4595
Меры предосторожности….4596
Подготовка….4597
Конструкция и расположение узлов и деталей….4598
Общая проверка….4601
Принцип работы….4604
Диагностическая информация и процедуры….4609
Диагностика и проверки по кодам DTC….4620
Снятие и установка….4685
Сцепление….4699
Технические характеристики….4699
Меры предосторожности….4700
Конструкция и расположение узлов и деталей….4702
Общая проверка….4704
Принцип работы….4705
Диагностическая информация и процедуры….4706
Снятие и установка….4720
Приводной вал….4731
Технические характеристики….4731
Меры предосторожности….4732
Конструкция и расположение узлов и деталей….4734
Общая проверка….4735
Принцип работы….4736
Диагностическая информация и процедуры….4737
Снятие и установка….4746
Передняя подвеска….4753
Технические характеристики….4753
Меры предосторожности….4754
Подготовка….4755
Конструкция и расположение узлов и деталей….4756
Общая проверка….4759
Принцип работы….4761
Диагностическая информация и процедуры….4763
Снятие и установка….4778
Задняя подвеска….4793
Технические характеристики….4793
Меры предосторожности….4794
Подготовка….4795
Конструкция и расположение узлов и деталей….4796
Общая проверка….4798
Принцип работы….4799
Диагностическая информация и процедуры….4800
Снятие и установка….4805
Колеса и шины….4815
Технические характеристики….4815
Меры предосторожности….4816
Подготовка….4817
Конструкция и расположение узлов и деталей….4819
Общая проверка….4820
Принцип работы….4823
Диагностическая информация и процедуры….4825
Снятие и установка….4828
Регулировка углов установки колес….4833
Технические характеристики….4833
Меры предосторожности….4834
Подготовка….4835
Общая проверка….4836
Принцип работы….4837
Диагностическая информация и процедуры….4838
Рулевая система с гидравлическим усилителем….4849
Технические характеристики….4849
Меры предосторожности….4850
Подготовка….4851
Конструкция и расположение узлов и деталей….4852
Общая проверка….4854
Принцип работы….4855
Диагностическая информация и процедуры….4856
Снятие и установка….4868
Рабочая тормозная система….4887
Технические характеристики….4887
Меры предосторожности….4888
Подготовка….4889
Конструкция и расположение узлов и деталей….4890
Общая проверка….4896
Принцип работы….4898
Диагностическая информация и процедуры….4899
Снятие и установка….4915
Механическая система стояночного тормоза….4933
Технические характеристики….4933
Меры предосторожности….4934
Подготовка….4935
Конструкция и расположение узлов и деталей….4936
Общая проверка….4937
Принцип работы….4938
Диагностическая информация и процедуры….4939
Снятие и установка….4945
Тормозная система с подсистемами ABS, TCS, EBD и ESP….4951
Технические характеристики….4951
Меры предосторожности….4952
Подготовка….4953
Схема гидравлической системы….4954
Общая проверка….4956
Снятие и установка….5022
Электрическая система кондиционирования воздуха….5031
Технические характеристики….5031
Меры предосторожности….5032
Конструкция и расположение узлов и деталей….5034
Общая проверка….5036
Схема системы кондиционирования….5040
Принцип работы….5042
Диагностическая информация и процедуры….5045
Снятие и установка….5070
Ремень безопасности….5095
Технические характеристики….5095
Меры предосторожности….5096
Подготовка….5097
Конструкция и расположение узлов и деталей….5098
Общая проверка….5099
Принцип работы….5100
Диагностическая информация и процедуры….5101
Снятие и установка….5113
Система подушек безопасности….5123
Технические характеристики….5123
Меры предосторожности….5124
Подготовка….5125
Конструкция и расположение узлов и деталей….5126
Принцип работы….5127
Диагностическая информация и процедуры….5129
Снятие и установка….5167
Крыло….5179
Технические характеристики….5179
Конструкция и расположение узлов и деталей….5180
Снятие и установка….5181
Капот….5185
Снятие и установка….5185
Автомобильные двери….5195
Принцип работы….5195
Снятие и установка….5196
Остекление….5205
Принцип работы….5205
Снятие и установка….5206
Дверные рукоятки, дверные замки и двери….5217
Снятие и установка….5217
Крышка заправочной горловины….5229
Снятие и установка….5229
Полка багажника….5233
Снятие и установка….5233
Приборная панель и центральная консоль….5237
Технические характеристики….5237
Меры предосторожности….5238
Конструкция и расположение узлов и деталей….5239
Снятие и установка….5242
Сиденья….5255
Технические характеристики….5255
Меры предосторожности….5256
Принцип работы….5257
Диагностическая информация и процедуры….5258
Снятие и установка….5268
Внутренняя отделка….5281
Меры предосторожности….5281
Подготовка….5282
Снятие и установка….5283
Наружная отделка….5307
Меры предосторожности….5307
Подготовка….5308
Снятие и установка….5309
Осветительная система….5323
Технические характеристики….5323
Меры предосторожности….5324
Подготовка….5325
Конструкция и расположение узлов и деталей….5326
Общая проверка….5328
Принцип работы….5329
Диагностическая информация и процедуры….5332
Снятие и установка….5381
Стеклоочистители и стеклоомыватели….5397
Технические характеристики….5397
Меры предосторожности….5398
Конструкция и расположение узлов и деталей….5399
Принцип работы….5401
Диагностическая информация и процедуры….5402
Снятие и установка….5444
Система звукового сигнала….5457
Конструкция и расположение узлов и деталей….5457
Принцип работы….5458
Диагностическая информация и процедуры….5459
Снятие и установка….5466
Приборы и дисплей….5471
Технические характеристики….5471
Конструкция и расположение узлов и деталей….5472
Принцип работы….5473
Диагностическая информация и процедуры….5474
Снятие и установка….5534
Зеркало заднего вида с электроприводом….5539
Электрические стеклоподъемники….5673
Технические характеристики….5673
Меры предосторожности….5674
Подготовка….5675
Принцип работы….5676
Конструкция и расположение узлов и деталей….5678
Диагностическая информация и процедуры….5679
Снятие и установка….5691
Задний парковочный радар….5697
Меры предосторожности….5697
Подготовка….5698
Конструкция и расположение узлов и деталей….5699
Диагностическая информация и процедуры….5701
Снятие и установка….5707
Система круиз-контроля….5713
Меры предосторожности….5713
Подготовка….5714
Конструкция и расположение узлов и деталей….5715
Принцип работы….5716
Диагностическая информация и процедуры….5717
Снятие и установка….5725
Система связи….5729
Принцип действия….5729
Диагностическая информация и процедуры….5730
Блок управления оборудованием кузова (BCM)….5741
Технические характеристики….5741
Конструкция и расположение узлов и деталей….5742
Принцип действия….5743
Диагностическая информация и процедуры….5744
Снятие и установка….5781
Обогрев стекол….5785
Конструкция и расположение узлов и деталей….5785
Диагностическая информация и процедуры….5786
Снятие и установка….5794
Прикуриватель….5799
Принцип работы….5799
Диагностическая информация и процедуры….5800
Снятие и установка….5806
TPMS (система контроля давления в шинах)….5813
Технические характеристики….5813
Конструкция и расположение узлов и деталей….5815
Принципиальная электрическая схема….5816
Общая проверка….5817
Принцип работы….5818
Диагностическая информация и процедуры….5819
Снятие и установка….5837
lifan-x50-rukovodstvo-po-remontu-_lf_20140923_RU….5839
01-….5839
Как пользоваться настоящим руководством….5842
Общие сведения….5842
Проверка на автомобиле….5842
Проверка состояния….5842
Предварительная подготовка….5842
Порядок обслуживания….5842
Определение терминов….5844
Международная система единиц (СИ)….5845
Предметный указатель….5845
Используемые сокращения….5845
Перечень кодов DTC….5845
Устранение неисправности….5846
Проверка и ремонт предохранителя….5846
Устранение периодической неисправности….5847
Устранение предыдущей неисправности….5849
Меры предосторожности при проведении работ….5850
Система пассивной безопасности….5850
Моторное масло….5850
Обслуживание электрооборудования….5851
Очистка автомобиля….5851
Нанесение грунтовки и антикоррозионных веществ….5851
Руководство по обслуживанию….5852
Рекомендации по обслуживанию….5852
Подъем автомобиля….5856
Идентификация автомобиля….5857
Идентификационный номер автомобиля….5857
Технические характеристики автомобиля….5859
Технические характеристики автомобиля….5859
Стандартные моменты затяжки….5864
Моменты затяжки для основных размеров крепежныхдеталей….5864
11-….5866
Механическая система двигателя ….5868
Предварительная подготовка….5868
Технические данные….5872
Меры предосторожности ….5875
Проверка на автомобиле….5876
Снятие силового агрегата….5880
Установка силового агрегата….5890
Диагностика….5899
Таблица признаков неисправности ….5899
Диагностика неисправностей….5903
Приводной ремень….5920
Компоненты….5920
Проверка….5921
Замена….5921
Впускной коллектор ….5923
Компоненты….5923
Проверка….5924
Замена….5925
Выпускной коллектор….5930
Компоненты….5930
Проверка….5931
Замена….5932
Привод газораспределительного механизма….5934
Компоненты….5934
Проверка….5935
Замена….5935
Распределительный вал ….5940
Компоненты….5940
Проверка….5941
Замена….5943
Головка цилиндров ….5948
Компоненты….5948
Проверка….5949
Замена….5950
Клапаны ….5958
Компоненты….5958
Проверка….5959
Замена….5965
Поршень и шатун ….5975
Компоненты ….5975
Проверка….5976
Замена….5983
Коленчатый вал и маховик….5997
Компоненты….5997
Проверка….5998
Замена….6002
Блок цилиндров ….6018
Компоненты….6018
Проверка….6019
Сальник коленчатого вала ….6021
Замена….6021
12-….6024
Система управления двигателем ….6026
Описание системы….6026
Схема системы….6036
Описание контактов….6037
Предварительная подготовка….6039
Технические данные….6040
Меры предосторожности….6041
Компоненты….6043
Проверка на автомобиле….6045
Диагностика ….6054
Описание системы….6054
Базовая проверка….6056
Порядок диагностики неисправностей….6057
Анализ диагностики неисправностей….6058
Считывание и удаление кодов неисправностей….6059
Считывание потока данных….6060
Проверка функционирования….6066
Таблица признаков неисправности….6067
Диагностика признаков неисправности….6070
Перечень кодов DTC….6083
Диагностика кодов DTC ….6092
Блок управления двигателем (ECM)….6142
13-….6146
Топливная система ….6148
Описание системы ….6148
Предварительная подготовка….6149
Технические данные ….6150
Меры предосторожности ….6150
Компоненты (I)….6151
Компоненты (II)….6152
Компоненты (III)….6153
Назначение и основные неисправности компонентов….6154
Проверка на автомобиле….6155
Топливный бак….6158
Проверка….6158
Замена….6159
Топливный насос….6162
Проверка….6162
Замена….6163
Топливный фильтр….6166
Проверка….6166
Замена….6167
Топливная форсунка….6169
Проверка….6169
Замена ….6169
Адсорбер….6172
Замена ….6172
Электромагнитный клапан адсорбера….6175
Проверка….6175
Замена ….6175
Топливный трубопровод….6176
Замена….6176
Датчик уровня топлива….6177
Проверка….6177
Замена….6177
Заливная горловина топливного бака ….6178
Замена….6178
Трос открывания лючка заливной горловины топливного бака ….6181
Замена….6181
14-….6184
Впускная и выпускная системы….6186
Описание системы….6186
Предварительная подготовка….6187
Технические данные ….6187
Меры предосторожности ….6187
Компоненты (I)….6188
Компоненты (II)….6189
Компоненты (III)….6190
Компоненты (IV)….6191
Назначение и основные неисправности компонентов….6192
Проверка на автомобиле….6193
Воздушный фильтр….6194
Проверка….6194
Замена….6195
Впускной трубопровод….6201
Проверка….6201
Замена….6202
Впускной коллектор….6204
Проверка….6204
Замена….6204
Узел электронной дроссельной заслонки….6210
Проверка….6210
Замена….6210
Датчик температуры и давления воздуха на впуске….6211
Проверка….6211
Клапан VVT….6212
Проверка….6212
Замена….6212
Каталитический нейтрализатор….6213
Проверка….6213
Замена….6214
Соединительный патрубок с гофрированной трубой….6218
Проверка….6218
Замена….6219
Передний глушитель….6221
Проверка….6221
Замена….6221
Задний глушитель….6224
Проверка….6224
Замена….6224
Датчик кислорода….6226
Проверка….6226
Замена….6226
15-….6228
Система охлаждения….6230
Описание системы….6230
Предварительная подготовка….6230
Технические данные ….6231
Меры предосторожности ….6231
Компоненты (I)….6232
Компоненты (II)….6233
Назначение и основные неисправности компонентов….6234
Проверка на автомобиле….6235
Охлаждающая жидкость ….6237
Замена….6237
Радиатор….6239
Проверка….6239
Замена….6240
Расширительный бачок….6247
Замена….6247
Охлаждающий вентилятор….6249
Проверка….6249
Замена….6250
Насос охлаждающей жидкости….6253
Проверка….6253
Замена….6254
Термостат….6256
Проверка….6256
Замена….6257
Трубопровод охлаждающей жидкости….6259
Замена….6259
Датчик температуры охлаждающей жидкости….6262
Проверка….6262
Замена….6262
16-….6264
Система смазки….6266
Описание системы ….6266
Предварительная подготовка….6267
Технические данные ….6268
Меры предосторожности ….6269
Компоненты….6270
Назначение и основные неисправности компонентов….6271
Проверка на автомобиле….6272
Моторное масло….6276
Замена….6276
Масляный фильтр….6278
Замена….6278
Масляный поддон….6280
Замена….6280
Масляный насос….6282
Проверка….6282
Замена….6284
Датчик давления моторного масла….6295
Проверка….6295
Замена….6296
Масляный щуп….6297
Замена….6297
17-….6298
Система зажигания….6300
Описание системы….6300
Предварительная подготовка….6300
Технические данные….6301
Меры предосторожности….6301
Компоненты (I)….6302
Компоненты (II)….6303
Назначение и основные неисправности компонентов….6303
Проверка на автомобиле….6304
Катушка зажигания ….6305
Проверка….6305
Замена….6306
Свеча зажигания ….6308
Проверка….6308
Замена….6310
Выключатель зажигания ….6311
Замена….6311
18-….6312
Системы запуска и зарядки….6314
Описание систем….6314
Предварительная подготовка….6314
Технические данные….6315
Меры предосторожности….6316
Компоненты (I)….6317
Компоненты (II)….6318
Назначение и основные неисправности компонентов….6319
Проверка на автомобиле….6320
Аккумуляторная батарея….6321
Замена….6321
Стартер….6324
Проверка….6324
Замена….6328
Генератор….6334
Проверка….6334
Замена….6336
21-….6342
Механическая трансмиссия ….6344
Подготовка….6344
Технические данные….6347
Меры предосторожности….6348
Диагностика….6349
Таблица признаков неисправностИ….6349
Диагностика неисправностИ….6351
Механизм управления трансмиссией ….6362
Компоненты….6362
Замена….6363
Трансмиссия в собре….6368
Замена….6368
Разборка….6376
Общая проверка….6380
Сборка….6381
Комплектный входной вал ….6386
Компоненты….6386
Разборка….6387
Проверка….6395
Сборка….6398
Комплектный выходной вал….6404
Компоненты….6404
Разборка….6405
Проверка….6411
Сборка….6414
Комплектный дифференциал….6420
Компоненты….6420
Разборка….6421
Проверка….6423
Сборка….6424
Промежуточная шестерня заднего хода….6427
Компоненты….6427
Проверка….6428
Замена….6429
Группа переключающих вилок….6430
Компоненты….6430
Разборка….6431
Сборка….6434
Узел переключающего механизма….6437
Компоненты….6437
Разборка….6438
Сборка….6441
Узел корпуса ….6445
Компоненты….6445
Проверка….6446
Замена….6447
22-….6452
Автоматическая трансмиссия….6454
Описание системы….6454
Предварительная подготовка….6458
Технические данные….6458
Подготовка….6459
Компоненты….6461
Электрическая схема….6463
Проверка на автомобиле….6464
Диагностика….6474
Считывание и удаление кодов DTC….6474
Считывание потока данных….6474
Таблица признаков неисправности….6476
Диагностика неисправностей….6477
Перечень кодов DTC….6485
Диагностика кодов DTC….6488
Трансмиссионная жидкость….6500
Замена….6500
Трансмиссия в сборе ….6503
Замена….6503
Датчик частоты вращения шкива….6509
Замена….6509
Датчик давления….6510
Замена….6510
Масляный поддон….6511
Замена….6511
Электромагнитные клапаны….6513
Замена….6513
Блок TCU….6515
Замена….6515
Рычаг селектора в сборе ….6516
Замена….6516
Трос селектора….6518
Замена….6518
Охладитель трансмиссионной жидкости….6520
Замена….6520
Сальник дифференциала….6522
Замена….6522
23-….6524
Сцепление….6526
Описание системы….6526
Предварительная подготовка….6527
Технические характеристики….6528
Меры предосторожности….6529
Компоненты (I)….6530
Компоненты (II)….6531
Компоненты (III)….6532
Назначение и основные неисправности компонентов….6533
Проверка на автомобиле….6534
Диагностика….6537
Таблица признаков неисправности….6537
Диагностика неисправностей….6539
Рабочая жидкость системы сцепления (тормозная жидкость) ….6546
Удаление воздуха из системы….6546
Замена….6548
Педаль сцепления….6550
Регулировка….6550
Замена….6551
Главный цилиндр сцепления….6555
Проверка….6555
Замена….6556
Рабочий цилиндр сцепления ….6560
Проверка….6560
Замена….6561
Корзина и ведомый диск сцепления ….6564
Проверка….6564
Замена….6567
Подшипник и вилка выключения сцепления ….6569
Проверка….6569
Замена….6570
Гидравлические трубопроводы системы сцепления….6571
Замена….6571
31-….6572
Передняя подвеска….6574
Описание системы….6574
Подготовка….6574
Технические данные….6575
Меры предосторожности….6576
Компоненты….6577
Назначение и основные неисправности компонентов….6578
Проверка на автомобиле….6579
Диагностика….6581
Таблица признаков неисправности….6581
Диагностика неисправностей….6582
Комплектный передний амортизатор с пружиной….6586
Замена….6586
Поворотный кулак и колесная ступица ….6596
Компоненты….6596
Замена….6597
Комплектный рычаг подвески….6607
Замена….6607
Комплектный подрамник ….6610
Замена….6610
Передний стабилизатор поперечной устойчивости ….6615
Замена….6615
Шаровый шарнир рычага подвески ….6616
Замена….6616
Ступичный подшипник ….6618
Замена….6618
32-….6622
Задняя подвеска….6624
Описание системы….6624
Подготовка….6624
Технические данные….6625
Меры предосторожности….6625
Компоненты….6626
Назначение и основные неисправности компонентов….6627
Проверка на автомобиле….6628
Диагностика….6629
Таблица признаков неисправности….6629
Диагностика неисправности….6629
Задняя ось….6630
Замена….6630
Задний амортизатор….6634
Компоненты….6634
Замена….6635
Задняя винтовая пружина….6639
Замена….6639
Задняя ступица….6641
Замена….6641
33-….6644
Колеса и шины….6646
Описание системы….6646
Предварительная подготовка….6646
Технические данные….6647
Меры предосторожности….6648
Компоненты….6649
Назначение и основные неисправности компонентов….6650
Проверка на автомобиле….6650
Диагностика….6653
Таблица признаков неисправности….6653
Диагностика неисправностей….6653
Колесо….6656
Перестановка колес….6656
Замена….6656
Балансировка колес….6658
Проверка….6658
Регулировка….6660
Углы установки колес….6661
Проверка….6661
Регулировка….6662
Запасное колесо….6665
Использование….6665
41-….6666
Приводной вал….6668
Описание системы….6668
Предварительная подготовка….6668
Технические данные….6669
Меры предосторожности….6669
Компоненты….6670
Назначение и основные неисправности компонентов….6671
Проверка на автомобиле….6671
Диагностика….6672
Таблица признаков неисправности….6672
Диагностика неисправностей….6673
Приводной вал в сборе ….6678
Проверка….6678
Замена….6678
Разборка и сборка….6683
51-….6692
Рабочая тормозная система….6694
Описание системы….6694
Предварительная подготовка….6694
Технические данные….6695
Меры предосторожности….6696
Компоненты….6697
Назначение и основные неисправности компонентов….6698
Проверка на автомобиле….6699
Диагностика….6701
Таблица признаков неисправности….6701
Диагностика неисправностей….6703
Педаль тормоза….6713
Регулировка….6713
Замена….6715
Главный тормозной цилиндр….6717
Проверка….6717
Вакуумный усилитель тормозов….6721
Компоненты….6721
Проверка….6722
Замена….6723
Тормозная жидкость….6727
Замена….6727
Прокачка….6728
Передний тормозной механизм….6730
Компоненты….6730
Проверка….6731
Замена….6733
Задний тормозной механизм….6736
Компоненты ….6736
Замена….6737
тормозной трубопровод….6741
Компоненты….6741
Замена….6742
Выключатель стоп-сигналов и датчик уровня тормозной жидкости….6745
Замена….6745
52-….6746
Стояночный тормоз….6748
Описание системы….6748
Предварительная подготовка….6748
Технические данные….6749
Меры предосторожности….6749
Компоненты….6750
Назначение и основные неисправности компонентов….6751
Проверка на автомобиле….6751
Диагностика….6752
Таблица признаков неисправности….6752
Диагностика неисправностей….6753
Рычаг стояночного тормоза….6755
Проверка….6755
Регулировка….6755
Замена….6757
Трос стояночного тормоза….6760
Замена….6760
53-….6764
Антиблокировочная система тормозов….6766
Описание системы….6766
Предварительная подготовка….6767
Технические данные….6767
Меры предосторожности….6768
Компоненты….6769
Назначение и основные неисправности компонентов….6770
Проверка на автомобиле ….6770
Диагностика….6772
Таблица признаков неисправности….6772
Диагностика неисправностей….6773
Перечень кодов DTC….6776
Диагностика кодов DTC….6778
Считывание и удаление кодов DTC….6783
Поток данных….6783
Датчик частоты вращения колеса ….6785
Замена….6785
Блок управления ABS ….6787
Замена….6787
Прокачка гидропривода системы ABS….6789
61-….6792
Рулевое управление с электроусилителем ….6794
Описание системы….6794
Электрическая схема….6795
Предварительная подготовка….6796
Технические данные….6796
Меры предосторожности….6797
Компоненты….6798
Назначение и основные неисправности компонентов….6799
Проверка на автомобиле….6800
Диагностика….6803
Считывание и удаление кодов DTC….6803
Таблица признаков неисправности….6803
Диагностика неисправностей….6805
Перечень кодов DTC….6808
Диагностика кодов DTC….6809
Рулевое колесо ….6814
Замена….6814
Рулевой вал ….6817
Проверка….6817
Замена….6818
Рулевой механизм ….6825
Замена….6825
Блок управления EPS ….6832
Замена….6832
71-….6834
Система кондиционирования воздуха ….6836
Описание системы….6836
Предварительная подготовка….6839
Технические данные….6841
Меры предосторожности….6841
Электрическая схема….6844
Компоненты….6845
Назначение и основные неисправности компонентов….6846
Проверка на автомобиле….6848
Диагностика….6855
Таблица признаков неисправности….6855
Диагностика неисправностей….6858
Хладагент….6873
Проверка….6873
Удаление….6876
Заправка….6876
Смазочное масло компрессора….6878
Слив….6878
Заправка….6878
Вакуумирование системы кондиционирования….6879
Блок HVAC ….6880
Замена….6880
Компрессор….6889
Проверка и ремонт….6889
Конденсатор и осушитель ….6896
Проверка и ремонт….6896
Контроллер системы кондиционирования ….6900
Проверка и ремонт….6900
72-….6903
Подушки безопасности….6905
Описание системы ….6905
Предварительная подготовка….6906
Технические данные….6907
Меры предосторожности….6907
Компоненты….6909
Электрическая схема….6910
Проверка на автомобиле….6911
Диагностика ….6914
Предварительная проверка ….6914
Таблица признаков неисправности….6915
Диагностика признаков неисправности….6915
Перечень кодов DTC ….6918
Диагностика кодов DTC….6922
Блок управления SRS ….6938
Замена….6938
Подушка безопасности водителя ….6941
Замена….6941
Утилизация….6943
Подушка безопасности переднего пассажира ….6948
Замена….6948
Утилизация….6950
Спиральный провод ….6952
Замена….6952
Ремни безопасности ….6955
Предварительная подготовка….6955
Технические данные….6955
Меры предосторожности….6955
Компоненты….6956
Диагностика….6957
Таблица признаков неисправности….6957
Передний ремень безопасности ….6958
Проверка….6958
Замена….6960
Задний ремень безопасности ….6964
Проверка….6964
Замена….6964
Регулятор высоты крепления ремня безопасности ….6970
Проверка….6970
Замена….6970
73-….6975
Центральный замок с дистанционным управлением ….6978
Описание системы….6978
Электрическая схема ….6979
Предварительная подготовка….6980
Технические данные ….6980
Меры предосторожности….6980
Назначение и основные неисправности компонентов….6981
Обучение ключа с пультом дистанционного управления ….6981
Проверка на автомобиле….6982
Диагностика ….6983
Таблица признаков неисправности….6983
Диагностика неисправностей ….6984
Блок управления центральным замком….6993
Замена….6993
Привод замка передней левой двери ….6995
Проверка….6995
Замена….6995
Привод замка передней правой двери ….6996
Проверка ….6996
Замена….6996
Привод замка задней левой двери ….6997
Проверка ….6997
Замена….6997
Привод замка задней правой двери ….6998
Проверка ….6998
Замена….6998
Привод замка двери багажного отделения….6999
Проверка ….6999
Замена….6999
Батарея пульта дистанционного управления ….7000
Замена….7000
74-….7002
Аудиосистема….7004
Описание системы….7004
Предварительная подготовка….7004
Технические данные….7005
Меры предосторожности….7005
Электрическая схема….7006
Компоненты….7007
Назначение и основные неисправности….7008
Проверка на автомобиле….7008
Диагностика….7009
Таблица признаков неисправности….7009
Диагностика неисправностей….7010
Радиоприемник/проигрыватель компакт-дисков….7016
Замена….7016
Динамик передней двери….7019
Проверка….7019
Замена….7020
Динамик задней двери….7022
Проверка….7022
Замена….7022
Антенна….7024
Проверка….7024
Замена….7024
75-….7028
Система информирования водителя….7030
Описание системы….7030
Предварительная подготовка….7033
Технические данные….7033
Меры предосторожности….7033
Электрическая схема (I)….7034
Электрическая схема (II)….7035
Компоненты….7036
Нназначение и основные неисправности компонентов….7036
Диагностика….7037
Таблица признаков неисправности….7037
Диагностика неисправностей….7038
Комбинация приборов….7046
Замена….7046
Многофункциональный дисплей….7049
Замена….7049
76-….7050
Задний парковочный радар ….7052
Описание системы….7052
Электрическая схема….7053
Предварительная подготовка….7054
Технические данные….7054
Меры предосторожности….7055
Компоненты….7056
Назначение и основные неисправности компонентов….7057
Проверка на автомобиле….7058
Диагностика….7060
Таблица признаков неисправности….7060
Диагностика неисправностей….7061
Выключатель фонаря заднего хода ….7067
Проверка….7067
Замена….7067
Датчик заднего парковочного радара ….7069
Проверка….7069
Замена….7070
77-….7074
Система освещения….7076
Описание системы….7076
Электрическая схема (указатели поворота, противотуманные фонари, стоп-сигналы, фонари заднего хода)….7077
Электрическая схема (габаритные огни, дневные ходовые огни, дальний/ближний свет фар)….7078
Электрическая схема (плафоны освещения салона)….7079
Предварительная подготовка….7080
Технические данные….7080
Меры предосторожности….7081
Компоненты (наружные световые приборы)….7082
Компоненты (освещение салона)….7083
Назначение и основные неисправности компонентов….7084
Проверка на автомобиле….7085
Диагностика….7087
Таблица признаков неисправности….7087
Диагностика неисправностей….7090
Фары….7112
Регулировка света фар….7112
Проверка….7113
Замена….7115
Дневные ходовые огни….7120
Замена….7120
Задний фонарь….7122
Проверка….7122
Замена….7123
Задний противотуманный фонарь….7130
Проверка….7130
Замена….7130
Передний плафон освещения салона….7134
Проверка….7134
Замена….7134
Передний плафон освещения салона(модель с люком)….7138
Проверка….7138
Замена….7138
Задний плафон освещения салона….7141
Проверка….7141
Замена….7141
Дополнительный стоп-сигнал….7145
Замена….7145
Лампа подсветки багажного отделения….7148
Проверка….7148
Замена….7148
Фонарь подсветки номерного знака….7151
Проверка….7151
Замена….7151
Комбинированный переключатель….7153
Замена….7153
78-….7156
Система звуковой сигнализации ….7158
Описание системы….7158
Предварительная подготовка….7159
Технические данные….7159
Компоненты….7160
Назначение и основные неисправности компонентов….7161
Проверка на автомобиле….7162
Диагностика….7163
Таблица признаков неисправности ….7163
Диагностика неисправностей….7163
Звуковой сигнал высокого и низкого тона….7167
Проверка….7167
Замена ….7168
Выключатель звукового сигнала….7170
Проверка….7170
Замена….7170
79-….7172
Прикуриватель….7174
Описание системы….7174
Электрическая схема….7175
Предварительная подготовка….7176
Технические данные….7176
Меры предосторожности….7176
Компоненты….7177
Назначение и основные неисправности компонентов….7177
Проверка на автомобиле….7178
Диагностика….7179
Таблица признаков неисправности ….7179
Диагностика неисправностей….7179
Прикуриватель ….7181
Замена….7181
Пепельница….7184
Замена….7184
81-….7186
Внутренняя и наружная отделка….7188
Описание системы….7188
Предварительная подготовка….7188
Технические данные….7189
Меры предосторожности….7190
Солнцезащитный козырек….7191
Замена….7191
Накладка порога передней двери….7194
Замена….7194
Накладка порога задней двери….7195
Замена….7195
Обивка передней стойки….7196
Замена….7196
Обивка средней стойки….7199
Замена….7199
Обивка задней стойки….7203
Замена….7203
Обивка передней двери….7209
Замена….7209
Обивка задней двери….7216
Замена….7216
Обивка двери багажного отделения….7222
Замена….7222
Облицовка задней панели….7225
Замена….7225
Панель задней полки….7226
Замена….7226
Поручень и обивка крыши….7227
Замена….7227
Коврик пола….7230
Замена….7230
Передний бампер….7233
Замена….7233
Задний бампер….7236
Замена….7236
Ветровое стекло….7240
Замена….7240
Стекло двери багажного отделения….7243
Замена….7243
Вентиляционная решетка….7247
Замена….7247
Крыло….7249
Замена….7249
Подкрылок….7252
Замена….7252
Лючок заливной горловины топливного бака….7256
Замена….7256
Дефлектор….7257
Замена….7257
82-….7260
Двери и дверные замки ….7262
Описание системы….7262
Предварительная подготовка….7262
Технические данные ….7263
Меры предосторожности….7263
Назначение и основные неисправности компонентов….7264
Диагностика ….7265
Двери ….7266
Регулировка….7266
Замена….7267
Петли и ограничители открывания двери ….7270
Замена….7270
Фиксатор замка двери ….7273
Регулировка….7273
Замена….7274
Замок передней двери ….7275
Замена….7275
Замок задней двери ….7281
Замена….7281
Капот двигателя ….7286
Регулировка….7286
Замена….7287
Замок капота двигателя ….7289
Замена….7289
Дверь багажного отделения ….7290
Замена….7290
Замок двери багажного отделения ….7295
Замена….7295
83-….7300
Стеклоподъемники и зеркала заднего вида ….7302
Описание системы….7302
Электрическая схема (электрические стеклоподъемники)….7303
Электрическая схема (зеркалА заднего вида с электроприводом)….7304
Электрическая схема (управление люком)….7305
Предварительная подготовка….7306
Технические данные….7306
Меры предосторожности….7307
Назначение и основные неисправности компонентов….7307
Проверка на автомобиле….7308
Диагностика….7312
Таблица признаков неисправности….7312
Диагностика неисправностей….7314
Электрический стеклоподъемник передней двери….7328
Компоненты….7328
Замена….7329
Стеклоподъемник задней двери….7334
Компоненты….7334
Замена….7335
Внутреннее зеркало заднего вида….7340
Компоненты….7340
Регулировка….7341
Замена….7342
Наружное зеркало заднего вида….7343
Регулировка….7343
Замена….7343
Люк….7346
Компоненты….7346
Замена….7347
84-….7352
Сиденья….7354
Описание системы ….7354
Предварительная подготовка….7354
Технические данные ….7354
Меры предосторожности ….7354
Проверка на автомобиле….7355
Сиденье водителя….7357
Компоненты ….7357
Регулировка….7358
Замена….7360
Сиденье переднего пассажира….7368
Регулировка….7368
Замена ….7368
Задние сиденья….7369
Компоненты….7369
Регулировка….7370
Замена….7371
85-….7376
Панель приборов и центральная консоль ….7378
Описание системы….7378
Предварительная подготовка….7378
Технические данные….7378
Меры предосторожности….7378
Компоненты (панель приборов I)….7379
Компоненты (панели приборов II)….7380
Компоненты (центральная консоль)….7381
Верхняя обивка панели приборов….7382
Замена….7382
Нижняя обивка панели приборов….7388
Замена….7388
Левый дефлектор вентиляции….7398
Замена….7398
Правый дефлектор вентиляции….7399
Замена….7399
Центральный дефлектор вентиляции….7400
Замена….7400
Обрамление комбинации приборов ….7401
Замена….7401
Перчаточный ящик….7402
Замена….7402
Центральная консоль ….7403
Замена….7403
86-….7414
Очистители и омыватели стекол ….7416
Описание системы….7416
Предварительная подготовка….7418
Технические данные….7418
Меры предосторожности….7418
Компоненты (очиститель стекла)….7419
Компоненты (омыватель стекла)….7420
Проверка на автомобиле….7421
Диагностика….7424
Таблица признаков неисправности….7424
Диагностика неисправностей….7425
Рычаг очистителя ветрового стекла….7434
Замена….7434
Рычаг очистителя заднего стекла….7437
Замена….7437
Щетка очистителя стекла ….7438
Замена….7438
Соединительная тяга и электродвигатель очистителя ветрового стекла….7439
Замена….7439
Электродвигатель очистителя заднего стекла ….7442
Замена….7442
Бачок жидкости омывателя стекла ….7443
Замена….7443
Передняя форсунка ….7446
Регулировка….7446
Замена….7446
Задняя форсунка ….7448
Регулировка….7448
Замена….7448
Обогреватель заднего стекла ….7450
Проверка….7450

Lifan X50/X60/X70 Compact SUV Repair Service Manual


INSTANT DOWNLOAD


Posted on

Iveco Stralis Trucks Repair & Service Manual


INSTANT DOWNLOAD


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

Iveco Stralis Trucks workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

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

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

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

Iveco Stralis Trucks Repair & Service Manual


INSTANT DOWNLOAD


Posted on

Iveco Astra HD8E C Trucks Workshop Repair & Service Manual


INSTANT DOWNLOAD


Complete service repair manual for Iveco Astra HD8E C Trucks, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Iveco Astra HD8E C Trucks workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TABLE OF CONTENTS
Introduction 1 from 1 to 6
General Specifications 2 from 1 to 10
Engine F3B 3 from 1 to 134
Clutch 4 from 1 to 20
Power take–off 5 from 1 to 18
Manual gearbox
ZF 16S 1620 TD –
ZF 16S 2320 TD 6 from 1 to 64
Reduction gear unit TC 1800 9.1 from 1 to 22
Reduction gear unit TC 2200 9.2 from 1 to 22
Propeller shafts 10 from 1 to 10
Axle 11 from 1 to 16
Front drive axle 12.1 from 1 to 42
Single Rear axle 12.3 from 1 to 36
Intermediate axle (in tandem) 12.4 from 1 to 42
Rear axle (in tandem) 12.5 from 1 to 36
Brakes 13.1 from 1 to 16
Wheels and tyres 13.2 from 1 to 6
Front suspensions 14.1 from 1 to 14
Rear suspensions 14.2 from 1 to 18
Steering system 15 from 1 to 38
Pneumatic system – brakes 16 from 1 to 44
Electrical system 17 from 1 to 134
Cab and chassis 18 from 1 to 14

PRODUCT DETAILS:
Total Pages: 787 pages
File Format: PDF
Language: English

WORKSHOP MANUAL HD8 Ec…1
INDEX OF SECTIONS…3
Sn 1 INTRODUCTION…5
INDEX …6
Sn 2 GENERAL SPECIFICATIONS…12
INDEX…13
Sn 3 ENGINE – F3B…23
INDEX…24
Sn 4 CLUTCH…158
INDEX…159
Sn 5 POWER TAKE-OFF…179
INDEX…180
Sn 6 MANUAL GEARBOX…198
INDEX…199
Sn 9.1 REDUCTION GEAR UNIT TC 1800…263
INDEX…264
Sn 9.2 REDUCTION GEAR UNIT TC 2200…286
INDEX…287
Sn 10 PROPELLER SHAFTS…309
INDEX…310
Sn 11 AXLE …320
INDEX…321
Sn 12.1 FRONT DRIVE AXLE…337
INDEX…338
Sn 12.3 SINGLE REAR AXLE…380
INDEX…381
Sn 12.4 INTERMEDIATE AXLE IN TANDEM…417
INDEX…418
Sn 12.5 REAR AXLE IN TANDEM…460
INDEX…461
Sn 13.1 BRAKES…497
INDEX…498
Sn 13.2 WHEELS AND TYRES…514
INDEX…515
Sn 14.1 FRONT SUSPENSIONS…521
INDEX…522
Sn 14.2 REAR SUSPENSIONS…536
INDEX…537
Sn 15 STEERING SYSTEM…555
INDEX…556
Sn 16 PNEUMATIC SYSTEM – BRAKES…594
INDEX…595
Sn 17 ELECTRICAL SYSTEM…639
INDEX…640
Sn 18 CAB AND CHASSIS…774
INDEX…775

Iveco Astra HD8E C Trucks Workshop Repair & Service Manual


INSTANT DOWNLOAD


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Iveco EuroTrakker & Trakker Trucks Repair & Service Manual


INSTANT DOWNLOAD


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

Iveco EuroTrakker & Trakker Trucks workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

03.43.461 – Iveco EuroTrakker Cursor 8 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC (’93-’04 ).pdf
03.43.811 – Iveco EuroTrakker Cursor 13 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC (’93-’04).pdf
03.93.121 – Iveco EuroTrakker_EuroTech_EuroStar Cursor 8-10-13 REPAIR MANUAL_ELECTRIC_ELECTRONIC_SYSTEM.pdf
03.93.641 – Iveco Trakker Euro 4-5 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC (’04-’13).pdf
03.93.641 – Iveco Trakker Euro 4-5 ELECTRIC_ELECTRONIC SYSTEM.pdf
PTO GUIDE FOR DEEC 2_2008_EN.pdf

TABLE OF CONTENTS
General 1
Engines 2
Clutch 3
Gearboxes 4
Power take-off 5
Transfer box TC 1800-TC 2200 6
Propeller shafts 7
Axles 8
Front axles 9
Suspensions 10
Wheels and tyres 11
Steering 12
Pneumatic system – Brakes 13
Bodywork and Chassis frame 14
Programmed maintenance 15
Electric/electronic system 16

PRODUCT DETAILS:
Total Pages: 4,021 pages
File Format: PDF
Language: English

603.43.461 – Iveco EuroTrakker Cursor 8 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC (’93-’04 )…2
EUROTRAKKER CURSOR…2
REPAIR MANUAL…2
NOTE…4
Graphs and symbols…5
INDEX…6
SECTION 1 – General…7
General…7
GENERAL…9
COMPOSITION OF THE MODELS…9
P.I.C. CODE NUMBERS…14
VEHICLE IDENTIFICATION DATA…20
FILLING UP…21
International designations of lubricants and fluids…22
SECTION 2 – Engine…23
Engine…23
VIEWS OF THE ENGINE…28
TECHNICAL DESIGNATION…31
GENERAL CHARACTERISTICS…37
ASSEMBLY CLEARANCE DATA…40
FAULT DIAGNOSIS…46
DESCRIPTION…46
DIAGNOSTIC INSTRUMENTS…46
CONTROL UNIT TEST…47
ENGINE TEST…47
AUXILIARY FUNCTIONS…47
TIGHTENING TORQUES (PROVISIONAL)…51
TOOLS…55
ENGINE REMOVAL – REFITTING…65
Removal…65
Refitting the engine…66
DISMANTLING THE ENGINE ON THE BENCH…69
REPAIR OPERATIONS…75
CYLINDER BLOCK…75
Checks and measurements…75
CYLINDER LINERS…76
Replacing cylinder liners…77
Removal…77
Fitting and checking protrusion…77
CRANKSHAFT…78
Measuring main journals and crank pins…79
SELECTING THE MAIN HALF-BEARINGS AND BIG END HALF-BEARINGS…81
DETERMINATION OF PRELIMINARY DATA FOR SELECTION…82
Replacing the timing control gear and the oil pump…91
Checking main journal installation clearance…91
Checking crankshaft end float…93
PISTON-CONNECTING ROD ASSEMBLY…94
Removal…94
Measuring the diameter of the pistons…95
Conditions for correct gudgeon pin-piston coupling…95
Piston rings…96
CONNECTING ROD…97
Checking connecting rod alignment…98
Mounting the connecting rod – piston assembly…98
Mounting the piston rings…98
Fitting the connecting rod-piston assembly into the piston liners…99
Piston protrusion check…99
Checking assembly clearance of big end pins…100
CYLINDER HEAD…100
Taking down the valves…100
Checking the planarity on cylinder head…100
VALVE…100
Removing deposits and checking the valves…100
VALVE GUIDES…101
Replacing of valve guides…102
Replacing – Reaming the valve seats…102
REPLACING INJECTOR HOLDER CASES…102
Removal…102
Checking protrusion of injectors…104
TIMING GEAR…105
Checking cam lift and pin alignment…105
Camshaft…106
Bushes…106
Replacing camshaft bushes using beater 99360487…107
VALVE SPRINGS…108
Fitting the valves and oil seal ring…108
ROCKER SHAFT…109
ROCKERS…109
LUBRICATION…110
Oil pump…110
Overpressure valve…110
Oil pressure control valve…113
Heat exchanger…113
By-pass valve…114
Thermostatic valve…114
Engine oil filters…114
COOLING…115
Water pump…115
Thermostat…115
TURBOCHARGING…119
Turbocharger HOLSET HX40V…121
Actuator adjustment…122
VGT control solenoid valve…122
Turbocharger HOLSET HY40V…127
Actuator…130
Working principle…130
Solenoid valve for VGT control…130
FUEL FEED…131
Fuel pump…132
Injector-pump…132
Pumping element…132
Nozzle…132
Solenoid valve…132
Replacing injectors-pump…132
Injector Phases…133
Filling phase…133
Injection phase…134
Pressure Reduction phase…134
ASSEMBLING THE ENGINE ON THE BENCH…135
DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER…137
Fitting the connecting rod-piston assembly into the cylinder liners…138
ENGINE FLYWHEEL…141
Replacing the toothed crown of the engine flywheel…141
Fitting engine flywheel…141
Fitting camshaft…142
Fitting pump-injectors…143
Fitting rocker-arm shaft assembly…143
Camshaft timing…144
Phonic wheel timing…146
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors…147
ENGINE COMPLETION…148
SECTION 3 – Clutch…149
Clutch…149
DESCRIPTION…151
Clutch…151
SPECIFICATIONS AND DATA…151
DIAGNOSTICS…153
TIGHTENING TORQUES…156
REMOVAL AND REFITTING…157
Removal…157
Refitting…157
REMOVING-REFITTING THE THRUST BEARING…157
REPLACING CLUTCH SHAFT SUPPORT BEARING …157
CHECKS…158
CLUTCH DISENGAGEMENT CONTROL…159
REMOVING-REFITTING THE PEDAL ASSY …159
Removal…159
Refitting…159
STRIP-DOWN AND REASSEMBLY…160
CHECKING AND ADJUSTING CLUTCH PEDAL STOPS (excluded vehicles with EuroTronic gearbox)…162
Clutch stop…162
Clutch pedal idle stroke…162
Pedal timing gear stroke…162
HYDRAULIC CONTROL vehicles with gearboxes: 2895.9-ZF 9/16 S 109-ZF 16 S 151…163
CLUTCH ACTUATOR FOR ZF 16 S 151 GEARBOXES…164
Refitting and adjusting thewear clutch indicator…164
Push rod adjustment (new clutch)…165
CLUTCH ACTUATOR FOR EUROTRONIC AUTOMATED GEARBOX…166
Clutch actuator push rod adjustment (new clutch)…166
Fitting the clutch actuator…166
Replacing the clutch actuator…166
SECTION 4 – Gearboxes…167
Gearboxes…167
Gearbox 2895.9…170
DESCRIPTION…172
Gearbox…172
CHARACTERISTICS AND DATA…173
FAULT DIAGNOSIS…174
TIGHTENING TORQUES…176
TOOLS…177
DISMANTLING TRANSMISSION…184
CHECKS…187
ASSEMBLING THE TRANSMISSION…188
ADJUSTING SECONDARY SHAFT BEARING PRELOAD…188
DISMANTLING PRIMARY SHAFT…193
FITTING THE PRIMARY SHAFT…195
TAKING DOWN THE INPUT SHAFT…195
ASSEMBLING INPUT SHAFT…196
SECONDARY SHAFT…196
Replacing the bearings…196
DISMANTLING INTERNAL GEAR CHANGE SHAFT…196
ASSEMBLING INTERNAL GEAR CHANGE SHAFT…197
DISMANTLINGEXTERNALGEARCHANGE CASING…197
Assembly…198
EPICYCLIC REDUCTION GEAR UNIT…200
DISMANTLING…202
CHECKS…206
INSTALLATION…207
Gearbox ZF 9 S 109…213
GENERAL SPECIFICATIONS…215
Description of gearbox 9 S 109…215
SPECIFICATIONS AND DATA…217
DIAGNOSTICS…220
TIGHTENING TORQUE…223
EQUIPMENT…224
REMOVAL…227
Removing the E.R.U.box…227
Reassembling the E.R.U.box…227
DISASSEMBLING THE E.R.U. BOX…228
DISASSEMBLING THE E.R.U…228
CHECKS…230
ASSEMBLING THE E.R.U…232
ASSEMBLING THE E.R.U. BOX…233
ADJUSTING THE AXIAL BACKLASH OF THE REAR BEARING…233
DISASSEMBLING THE GEARBOX…235
REMOVING THE INPUT SHAFT…238
REMOVING THE MAIN SHAFT…238
REMOVING THE TRANSMISSION SHAFT…241
REMOVING THE GEARCHANGE CASE OF GEARBOX…241
OIL PUMP…243
CHECKS…244
ASSEMBLING THE GEARCHANGE CASE…244
ASSEMBLING THE TRANSMISSION SHAFT…246
ASSEMBLING THE INPUT SHAFT…249
ASSEMBLING THE GEARBOX…249
ADJUSTING THE TRANSMISSION SHAFT BEARINGS…251
Adjusting the main shaft bearings…252
Gearbox ZF 16 S 109…256
DESCRIPTION…258
CHARACTERISTICS AND DATA…260
FAULT DIAGNOSIS…263
TIGHTENING TORQUES…266
TOOLS…267
DISMANTLING…270
Removing E.R.U. case…270
Refitting E.R.U. case…270
Dismantling E.R.U. case…271
Dismantling E.R.U…271
CHECKS…273
Assembling E.R.U. case…276
Dismantling transmission case…278
Dismantling the input shaft…281
Assembling the drive input shaft…281
Dismantling the main shaft…282
CHECKS…283
Assembling the main shaft…284
Dismantling the countershaft…287
Taking down the gear change control case…287
OIL PUMP…289
CHECKS…290
Assembling gear change control case…290
Assembling the countershaft…292
Assembling transmission case…292
Adjusting the countershaft bearings…294
Adjusting the main shaft bearings…295
Gearbox ZF 16 S 151…299
DESCRIPTION…301
OPERATION…303
CHARACTERISTICS AND DATA…307
FAULT DIAGNOSIS…311
TIGHTENING TORQUES…314
TOOLS…315
REMOVING-FITTING THE ZF GEAR CHANGE…320
Removal…320
Reassembly…321
DISMANTLING…322
Removing Epicyclic Reduction Unit (E.R.U.) assembly…322
Taking down the transmission case…323
Dismantling countershaft…326
Dismantling main shaft and drive input shaft…326
Dismantling Epicyclic Reduction Unit (E.R.U.)…330
CHECKS AND INSPECTIONS…334
Cleanliness and inspection of bearings…334
Refitting…336
Assembling Epicyclic Reduction Unit (E.R.U.)…338
Assembling main shaft and input shaft…341
Assembling the countershaft…344
Assembling the transmission case…344
Refitting Epicyclic Reduction Unit (E.R.U.)…347
Gearbox EUROTRONIC…350
INTRODUCTION…352
CHARACTERISTICS AND DATA…354
TIGHTENING TORQUE…357
EQUIPMENT…358
MECHANICAL FAULTS DIAGNOSIS…364
REPAIRS…367
Removal of front box removal…367
Removal of central box…368
Removal of rear box and epicyclic reduction unit…370
Installation of rear box and epicyclic reduction unit…372
Axial clearance regulation on epicyclic reduction gear bearing…372
Removal of primary shaft…376
Primary shaft installation…377
Removal of Splitter synchroniser…379
Installation of Splitter synchroniser…379
Forks installation-disinstallation…379
Secondary shafts…379
Central box installation…380
Shafts timing…382
Disinstallation of movement input shaft…383
Installation of movement input shaft…384
Installation of front box…384
Disinstallation of front cover…385
Installation of front cover…385
Regulation of axial clearance on movement input shaft bearing…386
Regulation of axial clearance on secondary shaft bearings…386
EUROTRONIC IT (INTARDER)…390
CHARACTERISTICS AND DATA…390
REPAIRS…391
Disinstallation of rear box…391
Rear box installation…392
Regulation of axial clearance on epicyclic reduction gear bearing…392
Regulation of axial clearance on stator…393
CLUTCH ACTUATOR…394
Description…394
CHARACTERISTICS AND DATA…394
SAFETY RULES…395
Disinstallation…396
Installation…398
Operating checks…399
Measure of piston stroke…399
Gearbox EuroTronic 12 AS 2301 D.D…401
DESCRIPTION…403
SPECIFICATIONS AND DATA…404
TIGHTENING TORQUES…407
TOOLS…408
OVERHAULING THE GEARBOX…413
Checks…413
Gearbox actuator…413
Removal…413
Refitting…414
Removing the rear box…414
Removing the rear box…415
Removing the epicyclic reduction gear train (E.R.G.)…416
Fitting the epicyclic reduction gear train (E.R.G.)…418
Adjusting epicyclic reduction gear train bearing end float…419
Adjusting main shaft end float…420
Synchronizing device assembly for engaging normal or reduced gears…422
Removal…422
Removing the middle box…425
Removing the main shaft…427
Removing the drive input shaft…429
Removing the splitter synchronizing device…430
Fitting the splitter synchronizing device …431
Fitting the main shaft…432
Fitting the drive input shaft…432
Splitter control fork…435
Disassembly – Assembly…435
Gear control forks…435
Removal…435
Fitting…436
Transmission shafts…437
Disassembly – Assembly…437
Fitting the middle box…437
Fitting the front box…440
Front cover…442
Removal…442
Fitting the front cover…442
Adjusting drive input shaft bearing end float…442
Adjusting transmission shaft bearing end float…443
Clutch release lever…445
Gearbox EuroTronic 12 AS 2301 D.D. with Intarder (IT)…448
SPECIFICATIONS AND DATA…450
OVERHAULING THE GEARBOX…451
Removing the hydraulic retarder…451
Refitting the hydraulic retarder…452
Adjusting epicyclic reduction gear train bearing end float…452
Adjusting stator end float…453
Removing the rear box…454
Removing the E.R.G…455
Fitting the E.R.G…456
EXPERIMENTAL TOOLS…461
Epicyclic reduction gear unit TC 700…463
DESCRIPTION…465
SPECIFICATIONS AND DATA…465
REDUCTION GEAR UNIT OPERATION…467
On road…467
Off road…468
Motion transmission diagram: on road…469
Motion transmission diagram: off road…470
TIGHTENING TORQUES…471
EQUIPMENT…472
REMOVING AND REFITTING THE REDUCTION GEAR UNIT…474
Removal…474
Refitting…474
DISASSEMBLING THE REDUCTION GEAR UNIT AT THE BENCH…475
DISASSEMBLING THE INPUT SHAFT (Operation to be performed under hydraulic press)…476
DISASSEMBLING THE COUNTERSHAFT…477
DISASSEMBLING THE EPICYCLIC REDUCTION GEAR UNIT…477
CLEAN OUT AND CHECKS…478
REPLACING THE SEALING RINGS ON DRIVING AND INPUT SHAFT COVERS…478
REFITTING THE COUNTERSHAFT…480
REFITTING THE EPICYCLIC REDUCTION GEAR UNIT (Differential)…480
SHAFT BEARINGS PRELOAD ADJUSTMENT…482
DRIVING SHAFT…482
Indicator switch adjustment…483
Pulse transmitter adjustment…484
Transfer case TC 1800…486
DESCRIPTION…488
SPECIFICATIONS AND DATA…488
TRANSFER CASE OPERATION…490
On-road…490
Off road…491
Transmission of motion pictorial diagram: on-road…492
Transmission of motion pictorial diagram: off-road…493
TIGHTENING TORQUE…494
EQUIPMENT…495
TRANSFER CASE REMOVALRE- FITTING IN PLACE…498
Removal…498
Re-fitting in place…498
DISMANTLING THE TRANSFER CASE AT THE BENCH…498
DISMANTLING THE INPUT SHAFT…500
DISMANTLING THE COUNTERSHAFT…501
DISMANTLING THE EPICYCLIC TRANSFER CASE…501
REPLACING THE SEAL RINGS ON THE DRIVING SHAFT COVERS…502
CLEAN OUT AND CHECK…502
FITTING IN PLACE THE INPUT SHAFT…502
FITTING IN PLACE THE COUNTERSHAFT…503
FITTING IN PLACE THE EPICYCLIC TRANSFER CASE…503
ASSEMBLING THE TRASFER CASE AT THE BENCH…504
ADJUSTING SHAFT BEARING PRELOADING…506
Prod switch adjustment…508
Pulse sender adjustment…508
Power take off…511
Power take off HYDROCAR…514
POWER TAKE OFF HYDROCAR…516
SPECIFICATIONS AND DATA…516
TIGHTENING TORQUES…518
Power take off ZF…521
POWER TAKE OFF ZF…523
SPECIFICATIONS AND DATA…523
TIGHTENING TORQUES…525
Power take off (Optional 2395)…528
DESCRIPTION…530
FEATURES AND DATA…531
TIGHTENING TORQUE…532
EQUIPMENT…533
Operation (power take off disengaged)…537
REMOVING – REFITTING TOTAL POWER TAKE-OFF ASSEMBLY…539
Removal…539
Refitting…539
OVERHAULING…540
Removing main box…540
Removing drive assembly…540
Removing bearing for shaft with gear wheel…540
Removing oil pump…541
Cleaning and checking parts…542
Fitting bearing for shaft with gear wheel…543
Fitting drive assembly…543
Adjusting drive output shaft tapered bearings…545
Adjusting ball bearing…546
SECTION 5 – Intarder – ZF hydraulic retarder…548
Intarder – ZF hydraulic retarder…548
LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE…550
GENERAL INFORMATION…551
OPERATION…551
Retarder engaged…552
Retarder disengaged…553
LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER…554
REMOVING AND REFITTING THE RETARDER ON THE ZF S 151-OD GEARBOX…555
Removal…555
Refitting…556
Filling with oil…556
SPECIFICATIONS AND DATA…557
TIGHTENING TORQUES…558
TOOLS…559
FAULT DIAGNOSIS…561
OVERHAULING THE INTARDER HYDRAULIC RETARDER…565
Hydraulic accumulator…565
Removal…565
Fitting…565
Removing hydraulic retarder…565
Checking the component parts of the hydraulic retarder…570
Fitting the hydraulic retarder…571
Stator end float adjustment…576
SECTION 6 – Propeller shafts…578
Propeller shafts…578
SPECIFICATIONS AND DATA…580
DIAGNOSTIC…585
TIGHTENING TORQUES…587
EQUIPMENT…587
REMOVING AND RE-FITTING IN PLACE THE PROPELLER SHAFT…588
REPAIR OPERATIONS…588
REMOVING THE UNIVERSAL JOINT…588
FITTING IN PLACE THE UNIVERSAL JOINT…588
CHECKING THE PROPELLER SHAFTS ON THE VEHICLE…589
SECTION 7 – Axles…590
Axles…590
AXLES…592
DIAGNOSTIC…594
REMOVING – RE-FITTING IN PLACE THE FRONT DRIVE AXLE (4×4 – 6×6 Vehicles)…596
Removal…596
Re-fitting in place…597
REMOVING REAR AXLES (4×2 – 4×4 Vehicles)…598
REMOVING THE REAR AXLE 6×4 – 6×6 – 8x4x4 Vehicles…600
REMOVING THE INTERMEDIATE AXLE 6×4 – 6×6 – 8x4x4 Vehicles…601
Instructions to adjust and check the functioning of the transmitter that controls the engagement of differential and reduction gear unit locking…602
REFITTING IN PLACE THE AXLE – Vehicles : all versions…602
Front drive axleD 1385 (5985) D 8185 (5985/2D)…605
DESCRIPTION…607
SPECIFICATIONS AND DATA…609
TIGHTENING TORQUE…611
EQUIPMENT…615
REPAIRING THE AXLE ANDWHEEL HUBS…620
Removal…620
Removing the fork support…627
Removing the stub axle…627
Removing the epicyclic reduction gear…628
CLEAN-OUT AND CHECKS…629
CHECKING THE AXLE CASING CAMBER ANGLE AND CASTER ANGLE…629
Fitting in place the fork support…632
Fitting in place the stub axle…633
Fitting in place the epicyclic reduction gear support…638
GREASING THE STUB AXLE PINS…639
EPICYCLIC UNITS LUBRICATION…639
REMOVING THE DIFFERENTIAL (with axle on stand 99322215)…640
Axle casing check…640
RE-FITTING IN PLACE THE DIFFERENTIAL (with axle on stand 99322215)…640
REPAIRING THE DIFFERENTIAL…642
Removal…642
REMOVING THE BEVEL PINION SUPPORT…644
REMOVING THE GEAR HOUSING…644
CHECKING THE DIFFERENTIAL COMPONENTS…644
FITTING IN PLACE THE GEAR HOUSING…645
FITTING IN PLACE THE BEVEL PINION SUPPORT…646
FITTING IN PLACE THE DIFFERENTIAL HOUSING…648
Adjusting the gear housing bearings rolling torque…649
Intermediate axles R 9274 (452191) R 9189 (453291) R 9274 (452191/2D) R 9189 (453291/2D)…654
DESCRIPTION…656
SPECIFICATIONS AND DATA…658
TIGHTENING TORQUES…659
EQUIPMENT…663
REMOVAL-RE-FITTING IN PLACE THE DIFFERENTIAL-REDUCTION GEAR UNIT (with axle on vehicle) …671
Removal…671
Re-fitting…671
INTERMEDIATE AXLE ASSEMBLY REPAIR OPERATIONS…673
Removal…673
Dis-assembling the epicyclic reduction unit…673
Removing the wheel hubs…674
CHECKS ON THEWHEEL HUBS AND EPICYCLIC REDUCTION GEAR COMPONENTS…676
Fitting in place the wheel hubs…676
Fitting in place the epicyclic reduction unit…679
REMOVAL-RE-FITTING IN PLACE OF THE DIFFERENTIALREDUCTION GEAR UNIT (with axle on stand 99322215)…681
Removal…681
Refitting in place…681
DIFFERENTIAL-REDUCTION GEAR UNIT REPAIR OPERATIONS …682
Removal…682
Removing the gear housing…687
Removing the differential-reduction gear unit…689
CHECKS ON DIFFERENTIAL-REDUCTION GEAR UNIT COMPONENTS…690
FITTING IN PLACE THE BEVEL PINION HOUSING…693
Procedure to determine the adjusting ring thickness for the bevel pinion rolling torque…693
FITTING IN PLACE THE DIFFERENTIAL HOUSING…695
FITTING IN PLACE THE GEAR HOUSING…696
Adjusting gearing box bearing rolling torque…697
DRIVING SHAFT…701
Removal…701
Checks…702
Refitting in place…702
Intermediate axle R 9174 (452146) R 9174 (452146/2D)…705
DESCRIPTION…707
REPAIRS…707
SPECIFICATIONS AND DATA…709
TIGHTENING TORQUES…710
EQUIPMENT…714
DIFFERENTIAL – REDUCTION GEAR UNIT REPAIR OPERATIONS…722
Removing the bevel pinion support…724
Removing the gear housing…724
Removing the differential – reduction gear unit…725
DIFFERENTIAL – REDUCTION GEAR UNIT COMPONENTS CHECK…728
Assembling the differential – reduction gear unit…728
Assembling the gear housing…730
Assembling the bevel pinion support…731
Procedure to determine the adjusting ring thickness for the bevel pinion rolling torque…731
DIFFERENTIAL HOUSING ASSEMBLY…733
Adjusting the rolling torque for the gear housing bearings…735
Rear axles R 8284 (451391) R 8274 (452191) R 8298 (453291) R 8284 (451391/2D) R 8274 (452191/2D) R 8298 (453291/2D)…740
DESCRIPTION…742
SPECIFICATIONS AND DATA…745
TIGHTENING TORQUE…746
DRIVING TORQUES…747
EQUIPMENT…750
REAR AXLE ASSEMBLY OVERHAUL OPERATIONS…756
Removing the epicyclic reduction gear…756
Removing the wheel hubs…759
CHECKING WHEEL HUB AND EPICYCLIC REDUCTION GEARCOMPONENTS…760
FITTING IN PLACE THEWHEEL HUBS…760
Fitting in place the epicyclic reduction gear…763
REMOVAL AND RE-FITTING IN PLACE THE DIFFERENTIAL…766
RE-FITTING IN PLACE…767
REMOVING THE DIFFERENTIAL HOUSING…768
Removing the gear housing…769
REMOVING THE BEVEL PINION SUPPORT…770
DIFFERENTIAL COMPONENTS CHECK…772
FITTING IN PLACE THE GEAR HOUSING…773
FITTING IN PLACE THE BEVEL PINION SUPPORT…774
Procedure to determine the thickness of the bevel pinion rolling torque adjusting ring…774
FITTING IN PLACE THE DIFFERENTIAL HOUSING…776
Adjusting the rolling torque of the gear housing bearings…777
Rear axle R 8174 (452146) R 8174 (452146/2D)…783
DESCRIPTION…785
REPAIR OPERATIONS…785
SPECIFICATIONS AND DATA…787
TIGHTENING TORQUES…788
EQUIPMENT…792
DIFFERENTIAL REPAIR OPERATIONS…797
Removal…797
REMOVING THE GEAR HOUSING…798
REMOVING THE BEVEL PINION SUPPORT…799
DIFFERENTIAL COMPONENTS CHECK…799
FITTING IN PLACE THE GEAR HOUSING…800
FITTING IN PLACE THE BEVEL PINION SUPPORT…801
FITTING IN PLACE THE DIFFERENTIAL HOUSING…803
Adjusting the rolling torque of the gear housing bearings…804
Axles in Tandem Meritor SR 145 E/2D…807
Axles in tandem (Intermediate) Meritor RD 145 E (R 2478)…809
DESCRIPTION…811
SPECIFICATIONS AND DATA…811
TIGHTENING TORQUES…813
TOOLS…817
EXPERIMENTAL TOOLS…824
! SERVICING INTERMEDIATE AXLEASSEMBLYRD145E(R2478)…827
AIR BREATHER REMOVAL-REFITTING…827
SERVICINGWHEEL HUBS…827
Checking wheel hub components…828
ASSEMBLINGWHEEL HUBS…829
REMOVING DIFFERENTIAL GEAR — TRANSFER BOX(with rear axle on stand 99322215) …832
REFITTING DIFFERENTIAL GEAR — TRANSFER BOX (with rear axle on stand 99322215)…832
REPAIRING INTER-AXLE UNIT…833
Dismantling inter-axle unit…833
Checking inter-axle unit components…835
Fitting inter-axle unit…835
Adjusting drive input shaft bearing end float…837
Adjusting differential lock and inter-axle control pin end-stop…837
REPAIRING MAIN DIFFERENTIAL – DISMANTLING DIFFERENTIAL CASING…838
Dismantling gear cage…841
Checking differential components…841
Assembling gear cage…842
ASSEMBLING DIFFERENTIAL CASING…843
Calculatingbevel pinion positionin differential casing…843
COMPUTATIONAL EXAMPLES…844
Adjusting the cap gap…847
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)…849
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT…852
Axles in tandem (Rear) Meritor RR 140 E (R 0878)…855
DESCRIPTION…857
SPECIFICATIONS AND DATA…857
TOOLS…861
SERVICING REAR AXLE ASSEMBLY RR 140 E (R 0878)…866
AIR BREATHER REMOVAL/ INSTALLATION…866
REMOVING DIFFERENTIAL (with axle on stand 99322215) …866
REFITTING DIFFERENTIAL (with axle on stand 99322215)…866
REPAIRING DIFFERENTIAL…867
Removing differential lock…867
Dismantling differential casing…868
Dismantling gear cage…869
Dismantling bevel pinion support…869
Checking differential components…873
Assembling gear cage…873
Specimen calculations…875
Assembling differential casing…875
ADJUSTING THE CAP GAP…877
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)…880
Axles in Tandem Meritor RT 153 E/2D…883
Axles in Tandem (Intermediate) Meritor RP 153 E…885
DESCRIPTION…887
SPECIFICATIONS AND DATA…887
TIGHTENING TORQUES…889
TOOLS…893
EXPERIMENTAL TOOLS…900
SERVICING INTERMEDIATE AXLE ASSEMBLY RP 153 E…903
WHEEL HUB OVERHAULING…903
Removing…903
Checks on wheel hub components…904
Refitting…904
REMOVING DIFFERENTIAL …908
REFITTING DIFFERENTIAL (axle on stand 99322215) …908
REPAIRING INTER-AXLE UNIT…909
Dismantling inter-axle unit…909
Checking inter-axle unit components…911
Fitting inter-axle unit…911
Adjusting drive input shaft bearing end float…913
Adjusting differential lock and inter-axle control pin end-stop…913
REPAIRING MAIN DIFFERENTIAL – DISMANTLING DIFFERENTIAL CASING…914
Removing the gear housing…917
Checking the differential components…918
Refitting the gear housing…918
ASSEMBLING DIFFERENTIAL CASING…920
Calculating bevel pinion position in differential casing…920
EXAMPLES…920
ADJUSTING THE CAP ANGLE…923
CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)…926
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT…930
Axles in tandem (rear) MERITOR RR 167…933
DESCRIPTION…935
CHARACTERISTICS AND DATA…936
TIGHTENING TORQUES…937
TOOLS…938
REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215) …944
Removal…944
Checking axle housing…944
Refitting…944
REPAIRING THE DIFFERENTIAL…945
Removing the differential…945
Removing the gearcase…946
REMOVING THE BEVEL PINION FROM THE SUPPORT…948
Differential component check…948
Fitting the gear housing…949
FITTING THE MOUNT ON THE BEVEL PINION…950
Reassembling the differential housing…952
ADJUSTING THE CAP GAP…954
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)…957
WORK ON THE VEHICLE…960
REPLACING THE BEVEL PINION MOUNT SEAL…960
Disassembly…960
Assembly…961
SECTION 8 – Axles…963
Axles…963
Axles 5886 (F9021) 5886/2D (F9021)…965
DESCRIPTION…967
Front axle…967
SPECIFICATIONS AND DATA…968
DIAGNOSTIC…970
TIGHTENING TORQUE…973
TOOL…975
REMOVING AND RE-FITTING THE AXLE…981
Removal…981
Refitting in place…982
VEHICLE CHECKS…983
Kingpins…983
Tie rods…983
TRACK ROD AND DRAG LINK KINGPINS SLACK CHECK…983
FRONT AXLE ASSEMBLY OVERHAUL…984
REMOVING AND RE -FITTING IN PL ACE THE WHEEL HUBS…984
Removal…984
Re-fitting in place the wheel hubs…986
Wheel hub bearings end play adjustment…986
Finding the rolling torque…986
WHEEL HUB BEARINGS REPLACEMENT…987
Wheel bolts replacement…988
REMOVAL AND RE-FITTING IN PLACE THE TRACK ROD…988
REPLACING TRANSVERSE TIE ROD SWIVEL HEADS…989
REMOVING AND REFITTING LEVERS FOR TRANSVERSE TIE ROD…989
REMOVING AND REFITTING LEVER FOR LONGITUDINAL TIE ROD…989
REMOVING AND REFITTING PIN FOR STUB AXLE…989
Removal…989
REMOVAL AND RE-FITTING IN PLACE THE DRAG LINK…990
Replacing kingpin bearing…990
Re-fitting…991
Stub axle-axle end play check and adjustment…992
AXLE BODY CHECKS AND MEASUREMENTS…992
Checking leaf spring supporting surface levelness with reference to kingpin holes using proper equipment…992
Kingpin holes camber angle check…994
Front axle 5886/D (F9021)…995
DESCRIPTION…997
Front axle 5886 / D…997
SPECIFICATIONS AND DATA…998
TIGHTENING TORQUES…1000
FRONT AXLE ASSEMBLY OVERHAUL…1001
REMOVING – REFITTINGWHEEL HUBS…1001
Removal…1001
Refitting wheel hubs…1002
Wheel geometry…1003
GENERAL INFORMATION…1005
Steering wheel angles…1005
FRONTWHEEL GEOMETRY (4X2 VEHICLES)…1006
Positioning clips and headlights…1006
Electronic compensation of rim eccentricity…1007
Wheel alignment…1007
Checking wheel toe-in…1008
Checking wheel deviation…1008
Checking camber…1008
Checking kingpin angle and caster…1009
Checking rear axle alignment…1010
WHEEL GEOMETRY OF VEHICLES WITH ADDED CENTRAL AXLE (8X4X4)…1010
Checking steering angles…1012
SECTION 9 – Suspensions…1013
Suspensions…1013
FRONT AND REAR SUSPENSIONS…1015
Description…1015
SPECIFICATIONS AND DATA FRONT SUSPENSIONS 4X2 – 6X4 – 6X6 – 4X4 MODELS…1025
FRONT SHOCK ABSORBERS…1030
REAR SHOCK ABSORBERS…1031
AIR SUSPENSION…1032
Chassis frame lifting, lowering and self-levelling with remote control …1032
Saving Levels…1032
AIR SUSPENSION SYSTEM DIAGRAMS…1033
Rear air suspension main diagram for 4x4W/P vehicles…1033
Working diagram of pneumatic rear suspensions for 6×4 HB/P, 8×4 H/P, 8×4 HB/P vehicles…1034
CHARACTERISTICS AND DATA…1035
Pneumatic system…1035
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM…1036
Relief valve…1036
Fault diagnosis…1036
Level sensor…1036
Electropneumatic distributor…1037
Air low pressure manometer switch…1037
Air spring…1037
Pneumatic rear suspension 4x4W/P vehicles…1038
Pneumatic rear suspension 8×4 H/P – HB/P vehicles…1039
FAULT DIAGNOSIS…1041
Diagnosis Instruments…1041
TIGHTENING TORQUE…1047
EQUIPMENT…1048
REMOVAL-REFITTING OF FRONT LEAF SPRING…1053
Removal…1053
Refitting…1053
REMOVAL-REFITTING OF INTERMEDIATE AXLE LEAF SPRING (8X4 VEHICLES)…1054
Removal…1054
Refitting…1054
REMOVAL-REFITTING OF REAR LEAF SPRING (4X2 – 4X4 vehicles)…1055
Removal…1055
Refitting…1055
REMOVAL-REFITTING OF REAR LEAF SPRING ON CANTILEVER TYPE SUSPENSIONS (6X4 – 6X6 – 8X4 vehicles)…1056
Removal…1056
Refitting…1056
Procedure for assembly of the slipper block and mounting brackets for the longitudinal bars…1057
Tightening theU-bolts clamping the leaf spring to the central pivot…1057
REAR CANTILEVER SUSPENSION (6×4 – 6×6 – 8×4 vehicles)…1058
Removal-refitting of central pivot…1058
Removal-refitting of central pivot shaft !…1058
Renewal of bearings…1058
Removal-refitting of hanger bracket…1058
Removal of the central pivot…1058
Removal of the central pivot shaft…1058
Removal of the hanger bracket…1058
Renewal of the bearings…1058
Refitting the hanger bracket…1059
Refitting the central pivot shaft…1060
Refitting the central pivot…1060
REMOVAL-REFITTING OF REAR AXLE LONGITUDINAL ARM…1062
REMOVAL-REFITTING OF INTERMEDIATE AXLE LONGITUDINAL ARM…1062
REMOVAL-REFITTING OF REAR AXLE TRIANGULAR ARM FOR VEHICLES WITH AIR SUSPENSION…1062
Removal…1062
Refitting…1062
REPLACEMENT OF THE FLEXIBLE PINS OF LONGITUDINAL/TRIANGULAR ARMS…1063
Disassembly…1063
Assembly…1063
SHOCK ABSORBERS…1064
Removal…1064
Refitting…1064
ANTI-ROLL BARS…1064
ANTI-ROLL BAR…1065
FRONT ANTI-ROLL BAR…1065
AUXILIARY AXLE ANTI-ROLL BAR (8X4 VEHICLES)…1065
REAR ANTI-ROLL BAR …1065
INTERMEDIATE AXLE ANTI-ROLL BAR (6X4 – 6X6 – 8X4 VEHICLES)…1065
Removal…1065
Refitting…1065
SECTION 10 – Wheels and tyres…1069
Wheels and tyres…1069
DESCRIPTION…1071
CHARACTERISTICS AND DATA…1071
Tyre inflation pressure data…1071
TOOLS…1072
DIAGNOSTIC…1072
WHEEL STATIC BALANCING…1075
CORRECTING RESIDUAL STATIC UNBALANCE…1076
TYRE PRESSURE…1076
BEHAVIOUR OF TYRES DEPENDING ON INFLATION PRESSURE…1077
SECTION 11 – Steering gear…1079
Steering gear…1079
DESCRIPTION…1081
SPECIFICATIONS AND DATA…1082
DIAGNOSTIC…1083
TIGHTENING TORQUE…1088
EQUIPMENT…1089
Steering control diagram for 4×2 – 6×4 vehicles (ZF 8098 power steering)…1091
Steering control diagram for 4×4 – 6×6 vehicles (ZF 8098 power steering)…1092
Steering control diagram for 8x4x4 vehicles (ZF 8099/1 power steering)…1093
Steering hydraulic control circuit diagram for 8x4x4 vehicles (8099/1 power steering)…1095
HYDRAULIC GUIDE…1097
Mounting steering wheel lever…1097
REMOVING AND REFITTING IN PLACE THE STEERING CONTROL ASSEMBLY…1098
Removal…1098
Fitting in place…1099
MAIN OPERATIONS…1100
Bleeding the air from the power steering circuit…1100
Measuring plays in the steering box detected on the steering wheel …1100
Checking the power steering system maximum pressure…1100
Adjusting the hydraulic steering limiting device…1100
Checking the steering hydraulic modulation device with the vehicle running…1102
Setting the automatic hydraulic steering limit…1102
Check…1102
SECTION 12 – Pneumatic system – Brakes…1103
Pneumatic system – Brakes…1103
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS)…1106
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)…1107
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)…1113
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALIPERS AND CYLINDERS)…1114
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (HALF-JOINTS AND COUPLING HEADS)…1116
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)…1118
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)…1119
PIPES AND COUPLINGS…1120
General…1120
End forming on rigid pipes…1120
Bending rigid pipes…1121
Cutting rigid pipes…1121
Replacing flexible hoses with threaded couplings …1122
Replacing flexible hoses with quick-connection couplings…1123
BRAKING SYSTEM…1125
Wiring diagram for 4×2 – 4×4 vehicles…1125
6×4 vehicles wiring diagram (the tractor version)…1126
6×4 vehicles wiring diagram (only outside Europe)…1127
6×6 vehicles wiring diagram…1128
8x4x4 vehicles wiring diagram…1129
ABS system wiring diagram (for 4×2 – 4×4 vehicles)…1130
ABS – ASR system wiring diagram (for 4×2 – 4×4 vehicles)…1131
ABS system wiring diagram (for 6×4 – 6×6 vehicles)…1132
ABS – ASR system wiring diagram (for 6×4 – 6×6 vehicles)…1133
ABS system wiring diagram (for 8x4x4 vehicles)…1134
ABS – ASR system wiring diagram (for 8x4x4 vehicles)…1135
Working diagram for 4×2 – 4×4 vehicles designed for towing with EBL device…1136
Working diagram for 6×4 vehicles isolated with an EBL device…1137
Working diagram for 6×4 – 6×6 vehicles designed for towing with EBL device…1138
Working diagram for 8x4x4 vehicles isolated with an EBL device…1139
Working diagram for 8x4x4 vehicles designed for towing with EBL device…1140
BRAKING SYSTEM…1141
Working diagram for 4×2 – 4×4 vehicles designed for towing with ABS-ASR device (without braking corrector)…1141
Working diagram for 6×4 – 6×6 vehicles designed for towing with ABS-ASR device (without braking corrector)…1142
Working diagram for isolated 6×4 vehicles with ABS-ASR device (without braking corrector)…1143
Working diagram for isolated 8x4x4 vehicles with ABS-ASR device (without braking corrector)…1144
Working diagram for 8x4x4 vehicles designed for towing with ABS-ASR device (without braking corrector)…1145
Braking system main components layout on the vehicle…1146
ABS – ASR system main components layout on the vehicle…1147
DESCRIPTION…1148
Service braking…1148
Emergency braking…1148
Retarding braking…1148
Parking braking…1148
BRAKES…1148
Front disc brakes SB7 – SN7 type (for vehicles with partial traction)…1148
Drum brakes…1148
FAULT DIAGNOSIS…1149
Diagnosis Instruments…1149
ABS Troubleshooting…1151
TIGHTENING TORQUES…1169
TOOLS…1172
SPECIFICATIONS AND DATA – PNEUMATIC SYSTEM…1181
SPECIFICATIONS AND DATA – BRAKES…1186
BRAKING SYSTEM MAIN COMPONENTS CHECK…1193
BRAKING SYSTEM MAIN COMPONENTS…1196
Compressor…1196
Head fastening screws tightening torque…1196
Diagnostic…1196
Drier…1197
Diagnostic…1197
Four-way safety valve…1197
Diagnostic…1197
Duplex distributor…1198
Diagnostic…1198
Pressure reducer…1199
Diagnostic…1199
Setting at the bench…1199
Triple control servo distributor…1199
Diagnostic…1199
Predominance adjustment…1199
KNORR BREMSE AC 597B…1200
KNORR BREMSE AC 597B WABCO 973 009 013…1200
Diagnostic…1200
Coupling heads…1201
Check valve (towing vehicles)…1201
Parking brakes control hand distributor (for towing vehicles)…1201
Diagnostic…1201
Parking brakes control hand distributor (stand-alone vehicles)…1202
Diagnostic…1202
Relay valves…1203
Diagnostic…1203
Engine brake control pedal valve…1203
Diaphragm brake cylinder…1203
Combined brake cylinder…1204
Combined cylinder emergency relief device…1204
REPAIR OPERATIONS…1204
Diagnostic…1204
BRAKING CONTROL…1205
For 6×4 – 6×6 – 8x4x4 vehicles…1206
Diagnostic…1207
ANTI-SKID SYSTEM…1207
ABS (Anti-Lock Brake System)…1207
ASR (Anti-Slip Regulator) system…1207
EBL (Electronic Brakes Limiter)…1207
Electronic control unit…1208
Brake anti-lock distributor…1208
Electropneumatic valve for ASR…1208
Rpm sensors…1208
Phonic wheels…1208
BRAKE REPAIRS…1209
FRONT DISC BRAKES SB7 TYPE (VEHICLESWITH PARTIAL TRACTION)…1209
DISC BRAKES SN7 TYPE…1210
Brakes SB7 type operation…1211
CHECKS…1211
Efficiency of automatic clearance recovery…1211
Brake lining thickness…1212
Replacing brake linings…1213
Removing and refitting SB7 brake callipers…1215
Removal…1215
Refitting…1215
Removing and refitting wheel hubs…1216
Removal…1216
Refitting…1216
OVERHAULING SB7 BRAKECAL – LIPERS…1217
Cleaning and checking component parts…1218
Assembly…1218
OVERHAULING BRAKE DISCS…1219
TURNING AND GRINDING BRAKE DISCS ON THE BENCH …1220
TURNING AND GRINDING BRAKE DISCS ON THE VEHICLE…1220
DRUM BRAKES…1221
FRONT BRAKES…1222
REAR BRAKES…1222
Disassembly…1222
Drum turning…1227
Replacing brake linings…1227
Turning brake linings…1228
Assembly…1228
SECTION 13 – Body work – Chassis…1235
Body work – Chassis…1235
CAB…1237
Specifications…1237
TIGHTENING TORQUE…1237
EQUIPMENT…1237
ANCHORAGE CAB…1238
REPAIR OPERATIONS…1240
REPLACING CAB SUSPENSION FRONT AND REAR SHOCK ABSORBERS …1240
REMOVING AND RE-FITTING INPLACE THEFRONTSUPPORTS AND CAB STABILIZER BARS…1240
REPLACING THE CAB TIPPING HYDRAULIC CYLINDER…1241
REPLACING THEWINDSCREEN…1241
REPLACING LOWERABLE DOOR WINDOWS…1242
REPLACING THEWINDOW CLOSING DEVICE…1243
REPLACINGTHEFIXEDWINDOW…1243
Replacing the roof air vent hatch…1245
CAB HEATING AND VENTILATION UNIT…1245
CHASSIS…1246
REPAIR OPERATIONS…1246
CHECKS…1246
Finding chassis bending up and down…1247
Finding chassis lateral bending…1247
Finding chassis displacement…1247
Finding chassis twist…1248
PRECAUTIONS…1248
Welds on the chassis…1250
SECTION 14 – Scheduled maintenance…1251
SCHEDULED MAINTENANCE…1253
Description…1253
Maintenance services specifications…1253
EXTRA PLAN OPERATIONS…1253
Maintenance servicing table (time intervals)…1257
CHECK AND/OR MAINTENANCE POINTS SCHEME…1259
603.43.811 – Iveco EuroTrakker Cursor 13 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC (’93-’04)…1261
EUROTRAKKER CURSOR 13…1261
REPAIR MANUAL…1261
NOTE…1263
Graphics and Symbols…1264
CONTENTS OF SECTIONS…1265
SECTION 1 – General…1266
General…1266
VEHICLE IDENTIFICATION DATA…1268
Vehicle Identification Plate…1269
Production identification plate…1269
P.I.C. NUMBER CODING…1270
COMPOSITION OF MODELS…1274
REPLENISHING FLUIDS…1280
International lubricant and fluid names…1282
SECTION 2 – Engine…1284
Engine…1284
VIEWS OF THE ENGINE…1288
TECHNICAL DESCRIPTION…1291
CHARACTERISTIC CURVES…1292
GENERAL SPECIFICATIONS…1296
ASSEMBLY DATA – CLEARANCE…1299
FAULT DIAGNOSIS…1305
Blink Code…1305
Check procedures / troubleshooting…1305
Procedures to delete faultmemory fromdriving seat…1305
EDC MS 6.2 control unit blink code table…1306
FAULT DIAGNOSIS INSTRUMENTS…1307
MODUS – IT2000…1307
I.W.T…1308
TROUBLESHOOTING…1309
Introduction…1309
Troubleshooting with Blink Code…1310
Troubleshooting by symptoms…1318
TIGHTENING TORQUES…1325
DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS…1328
TOOLS…1332
ENGINE REMOVAL-REFITTING…1342
Removal…1342
Refitting…1345
Filling the cooling system…1346
Bleeding air from the supply system…1347
Checks and tests…1347
STRIPPING THE ENGINE ON THE BENCH…1350
REPAIRS…1358
Cylinder block…1358
Checks and measurements…1358
Cylinder liners…1359
Replacing the cylinder liners…1360
Crankshaft…1361
Measuring the main journals and crankpins…1362
Selecting the main bearing and big end bearing shells…1363
Preliminary measurement of data to select main bearing and big end bearing shells…1364
Replacing the timing gear and oil pump…1371
Checking main journal assembly clearance…1371
Checking crankshaft end float…1372
Connecting rod piston assembly…1373
Piston rings…1375
Connecting rod…1376
Checking connecting rods…1377
Mounting the connecting rod – piston assembly…1377
Mounting the piston rings…1377
Fitting connecting rod piston assembly in the cylinder liners to check assembly clearances…1378
Checking assembly clearance of big end pins…1379
Cylinder head…1379
Removing valves…1379
Checking head bearing surface on cylinder block…1379
Valves…1379
Decarbonizing and checking valves…1379
Valve guides…1380
Replacing valve guides…1381
Replacing – Regrinding valve seats…1381
Replacing injector cases…1381
Checking injector protrusion…1383
Timing system…1384
Checking cam lift and pin alignment…1384
Camshaft…1385
Bushings…1385
Valve springs…1388
Rocker arm shaft…1389
Rocker arms…1389
ENGINE ASSEMBLY ON BENCH…1390
Fitting connecting rod piston assemblies in cylinder liners…1393
Fitting cylinder head…1394
Fitting flywheel box…1395
ENGINE FLYWHEEL…1396
Fitting engine flywheel…1396
Fitting camshaft…1397
Fitting pump-injectors…1398
Rocker arm holder shaft assembly…1398
Camshaft timing…1399
Phonic wheel timing…1401
Adjusting rocker armclearance, intake, exhaust and pre-load of pump injector governing rocker arms…1402
Completing assembly…1403
LUBRICATION…1405
Oil pump…1405
Overpressure valve…1405
Oil pressure control valve…1406
Heat exchanger…1406
By-pass valve…1407
Thermostatic valve…1407
Engine oil filters…1407
Lubrication circuit…1408
COOLING…1410
Water pump…1410
View of thermostat operation…1410
Cooling circuit…1412
TURBOCHARGING…1414
Turbocharger…1414
HOLSET HY55V (VGT Turbine)…1415
Actuator…1418
Working principle…1418
Solenoid valve for VGT control…1418
HOLSET HX 50W (Wastegate Turbine)…1420
Pressure relief valve…1420
FEEDING…1422
Fuel pump…1423
Injector-pump…1423
Replacing injectors-pump…1423
Injector Phases…1424
HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM – P.T.O. (OPTIONAL)…1426
Specifications and data…1427
Tightening torques…1428
Engaging power take-off…1429
Removing-refitting power take-off…1429
SECTION 3 – Clutch…1430
Clutch…1430
DESCRIPTION…1432
Clutch…1432
SPECIFICATIONS AND DATA…1432
FAULT DIAGNOSIS…1434
TIGHTENING TORQUES…1437
TOOLS…1437
REMOVING AND REFITTING THE CLUTCH…1438
Removal…1438
CHECKS…1438
Refitting…1439
REMOVING-REFITTING THE THRUST BEARING…1439
CLUTCH DISENGAGEMENT CONTROL (vehicles with ZF 16 S 151/181/221 O.D. gearboxes)…1440
REMOVING-REFITTING THE PEDAL UNIT…1440
Removal…1440
Refitting…1440
PEDAL UNIT…1441
REMOVAL-ASSEMBLY…1441
CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ZF 16 S 151 O.D./181 O.D./221 O.D. gearboxes)…1442
Clutch stop…1442
Idle travel of clutch pedal…1442
Pedal control valve stroke…1442
HYDRAULIC CONTROL (vehicles with ZF 16 S 151 O.D./181 O.D./221 O.D. gearboxes)…1443
CLUTCH ACTUATOR FOR ZF 16 S 151 O.D./181 O.D./221 O.D. GEARBOXES…1444
Fitting and adjusting the clutch wear indicator…1444
Push rod adjustment (new clutch)…1445
Push rod adjustment (vehicles with PTO opt. 2395 only)…1445
BLEEDING THE AIR FROM THE CLUTCH CIRCUIT…1445
CLUTCH ACTUATOR FOR THE EUROTRONIC 16 A S 2601 O.D. GEARBOX…1446
Clutch actuator push rod adjustment (new clutch)…1446
Fitting the clutch actuator…1446
Replacing the clutch actuator…1446
SECTION 4 – Gearbox…1448
Gearbox…1448
Gearboxes ZF 16 S 151 O.D. – ZF 16 S 181 O.D. – ZF 16 S 221 O.D…1450
LOCATION OF GEARBOX DESCRIPTION PLATE…1452
DESCRIPTION…1453
GEARBOX AIR-OPERATED CONTROL…1455
OPERATION…1456
Slow range…1456
Fast range…1457
EPICYCLIC REDUCTION GEAR CONTROL…1458
Reduced speeds…1458
Normal speeds…1459
SPECIFICATIONS AND DATA…1460
TIGHTENING TORQUES…1464
TOOLS…1465
GEARBOX FAULT DIAGNOSIS…1470
REMOVING-REFITTING THE GEARBOX…1474
Removal…1474
Refitting…1475
OVERHAULING THE GEARBOX…1476
Servoshift gear box…1476
Removal…1476
Refitting…1476
Disassembly…1476
Assembly…1478
Removing the rear box…1482
Removing the epicyclic reduction gear unit (ERG)…1482
Fitting the epicyclic reduction gear unit (ERG)…1484
Refitting the epicyclic reduction gear unit (ERG) rear box …1487
Removing the gearbox…1487
Removing the main shaft…1490
Removing the drive input shaft…1493
Removing the transmission shaft…1494
CHECKS…1494
Gearbox…1494
Hubs – sliding sleeves – forks…1494
Bearings…1494
Shafts – gears…1494
Synchronizing devices…1494
BK-type single-cone synchronizing devices…1494
Fitting the transmission shaft…1495
Fitting the drive input shaft…1495
Fitting the main shaft…1496
Adjusting the main shaft…1498
Fitting the gearbox…1499
Oil pump…1500
Adjusting the transmission shaft bearing end float…1500
Drive input shaft cover…1501
ZF gearboxes with INTARDER hydraulic retarder, types: 16 S 151 O.D. – 16 S 181 O.D. – 16 S 221 O.D…1504
SPECIFICATIONS AND DATA…1506
TOOLS…1507
Removing the hydraulic retarder from the gearbox on the stand…1514
Refitting the hydraulic retarder…1514
Removing the epicyclic reduction gear unit (ERG) rear box…1515
Removing the epicyclic reduction gear unit (ERG)…1515
Component parts of the epicyclic reduction gear unit…1518
Fitting the epicyclic reduction gear unit (ERG)…1519
Refitting the epicyclic reduction gear unit (ERG) rear box…1521
Gearbox: EuroTronic 16 AS 2601 O.D…1523
DESCRIPTION…1525
SPECIFICATIONS AND DATA…1526
TIGHTENING TORQUES…1529
TOOLS…1530
OVERHAULING THE GEARBOX…1535
Checks…1535
Gearbox actuator…1535
Removal…1535
Refitting…1536
Removing the rear box…1536
Removing the rear box…1537
Removing the epicyclic reduction gear train (E.R.G.)…1538
Fitting the epicyclic reduction gear train (E.R.G.)…1540
Adjusting epicyclic reduction gear train bearing end float…1541
Adjusting main shaft end float…1542
Synchronizing device assembly for engaging normal or reduced gears…1544
Removal…1544
Removing the middle box…1547
Removing the main shaft…1549
Removing the drive input shaft…1551
Removing the splitter synchronizing device…1552
Fitting the splitter synchronizing device…1553
Fitting the main shaft…1554
Fitting the drive input shaft…1554
Splitter control fork …1557
Disassembly – Assembly…1557
Gear control forks…1557
Removal…1557
Fitting…1558
Transmission shafts…1559
Disassembly – Assembly…1559
Fitting the middle box…1559
Fitting the front box…1562
Front cover…1564
Removal…1564
Fitting the front cover…1564
Adjusting drive input shaft bearing end float…1564
Adjusting transmission shaft bearing end float…1565
Clutch release lever…1567
Gearbox: EuroTronic 16 AS 2601 O.D. with Intarder…1570
EuroTronic Automated 16 AS 2601 O.D. with intarder…1572
SPECIFICATIONS AND DATA…1572
OVERHAULING THE GEARBOX…1573
Removing the hydraulic retarder…1573
Refitting the hydraulic retarder…1574
Adjusting epicyclic reduction gear train bearing end float…1574
Adjusting stator end float…1575
Removing the rear box…1576
Removing the E.R.G…1577
Fitting the E.R.G…1578
EXPERIMENTAL TOOLS…1583
SECTION 5 – Intarder – ZF hydraulic retarder…1584
Intarder – ZF hydraulic retarder…1584
LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE…1586
GENERAL INFORMATION…1587
OPERATION…1587
Retarder engaged…1588
Retarder disengaged…1589
LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER…1590
REMOVING AND REFITTING THE RETARDER ON THE ZF S 151/181/221-OD GEARBOX…1591
Removal…1591
Refitting…1592
Filling with oil…1592
SPECIFICATIONS AND DATA…1593
TIGHTENING TORQUES…1594
TOOLS…1595
FAULT DIAGNOSIS…1597
OVERHAULING THE INTARDER HYDRAULIC RETARDER…1601
Hydraulic accumulator…1601
Removal…1601
Fitting…1601
Removing hydraulic retarder…1601
Checking the component parts of the hydraulic retarder…1606
Fitting the hydraulic retarder…1607
Stator end float adjustment…1612
SECTION 6 – Total power take-off (Option 2395)…1614
Total power take-off (Option 2395)…1614
DESCRIPTION…1616
SPECIFICATIONS AND DATA…1617
TIGHTENING TORQUES…1618
TOOLS…1619
Operation (power take off disengaged)…1623
Operation (power take off engaged)…1624
REMOVING – REFITTING TOTAL POWER TAKE-OFF ASSEMBLY…1625
Removal…1625
Refitting…1625
OVERHAULING…1626
Removing main box…1626
Removing drive assembly…1626
Removing bearing for shaft with gear wheel…1626
Removing oil pump…1627
Cleaning and checking parts…1628
Fitting oil pump…1628
Fitting bearing for shaft with gear wheel…1629
Fitting drive assembly…1629
Adjusting drive output shaft tapered bearings…1631
Fitting main box…1632
Adjusting ball bearing…1632
SECTION 7 – Reduction gear – Divider TC 1800-TC 2200…1634
Reduction gear – Divider TC 1800-TC 2200…1634
DESCRIPTION OF REDUCTION GEAR – DIVIDER ASSEMBLY TC 1800 – TC 2200…1636
SPECIFICATIONS AND DATA…1636
VERSION WITH P.T.O. (OPT. 391-392)…1638
P.T.O. SPECIFICATIONS…1638
USING THE REDUCTION GEAR – DIVIDER…1639
On-road driving (normal ratio)…1639
Diagram of drive transmission with normal ratio…1640
Off-road driving (reduced ratio)…1641
Diagram of drive transmission with reduced ratio…1642
Version with P.T.O…1643
TORQUE DIVIDER…1646
Division ratio calculation…1646
Control locking divider and differential gears…1647
TIGHTENING TORQUES…1649
TOOLS…1653
LUBRICATION…1656
REMOVING AND REFITTING REDUCTION GEAR – DIVIDER …1657
Removal…1657
Refitting…1657
REMOVING THE REDUCTION GEAR – DIVIDER ON THE BENCH…1657
CLEANING AND CHECKING PARTS…1661
REPLACING OUTPUT SHAFT COVER SEALS…1661
REPLACING INPUT SHAFT COVER SEAL…1661
INPUT SHAFT…1662
Removal…1662
Fitting…1662
EPICYCLIC DIVIDER UNIT…1663
Removal…1663
Fitting…1664
COUNTERSHAFT…1664
Removal…1664
Fitting…1664
FITTING THE REDUCTION GEAR – DIVIDER ON THE BENCH…1665
ADJUSTING THE BEARING PRE-LOAD…1668
Input shaft…1668
Countershaft…1668
Output shaft…1669
COMPLETING ASSEMBLY…1670
Adjusting push-rod switch signalling divider locking and P.T.O. engagement (if applicable)…1671
Adjusting pulse transmitter…1671
Replenishing oil…1671
SECTION 8 – Propeller shafts…1672
Propeller shafts…1672
SPECIFICATIONS AND DATA…1674
FAULT DIAGNOSIS…1674
TIGHTENING TORQUES…1676
TOOLS…1676
PROPELLER SHAFT REMOVAL AND REFITTING…1677
Removal…1677
Refitting…1677
REPAIRS…1677
Removing the universal joint…1677
Fitting the universal joint…1677
CHECKING PROPELLER SHAFTS ON VEHICLES…1678
SECTION 9 – Axles…1680
Axles…1680
FAULT DIAGNOSIS…1682
REAR AXLE REMOVAL – REFITTING…1684
Removing the intermediate axle ( 6×4 – 8×4 – 8×8 vehicles)…1684
Removing the rear axle ( 6×4 – 8×4 – 8×8 vehicles) …1685
Refitting the rear axle…1686
Instructions for adjustments and checks on differential lock and flow divider engagement transmitter operation…1686
Front Axle 5985/2D (D1385)…1689
DESCRIPTION…1691
SPECIFICATIONS AND DATA…1692
TIGHTENING TORQUES…1694
TOOLS…1696
OVERHAULING THE FRONT AXLEE…1702
Wheel hub disassembly…1702
Stub axle disassembly…1703
Drive shaft disassembly…1705
Fork support disassembly…1705
Stub axle disassembly…1706
Wheel hub disassembly…1706
Epicycloid gear disassembly…1706
CLEANING AND CHECKING PARTS…1707
CHECKING THE AXLE HOUSING ANGLE AND INCIDENCE…1707
ASSEMBLY…1710
Fork support assembly…1711
Drive shaft assembly…1712
Stub axle assembly…1712
Epicycloid reduction gear assembly…1717
Greasing the stub axle pins…1718
Epicycloid gear unit lubrication…1718
REMOVING THE DIFFERENTIAL (with the rear axle mounted on stand 99322215)…1719
Checking the axle housing…1719
REFITTING THE DIFFERENTIAL (with the axle mounted on stand 99322215)…1719
DIFFERENTIAL REPAIR…1721
Disassembly…1721
Disassembling the gear housing…1722
Disassembling the bevel pinion support…1723
CHECKING THE DIFFERENTIAL COMPONENTS…1723
Assembling the gear housing…1724
Assembling the bevel pinion support…1725
Differential…1727
Adjusting the rolling torque on the gear housing bearings…1728
Intermediate axles 452191/2D (R 9274) 453291/2D (R 9189)…1732
DESCRIPTION…1734
SPECIFICATIONS AND DATA…1735
TIGHTENING TORQUES…1736
TOOLS…1738
REMOVING-REFITTING THE FLOW DIVIDER DIFFERENTIAL (with the axle mounted on the vehicle)…1745
Removal…1745
Refitting…1745
INTERMEDIATE AXLE ASSEMBLY REPAIRS…1746
Disassembly…1746
Epicycloid reduction gear disassembly…1746
Wheel hub disassembly…1747
Wheel hub disassembly…1750
Assembling the epicycloid reduction gear…1752
REMOVING-REFITTING THE FLOW DIVIDER DIFFERENTIAL (with the axle mounted on stand 99322215)…1754
Removal…1754
Refitting…1754
REPAIRING THE FLOW DIVIDER-DIFFERENTIAL…1755
Flow divider differential unit disassembly…1755
Gear housing disassembly…1758
Flow divider-differential disassembly…1760
Flow divider differential unit assembly…1764
Gear housing assembly…1765
Flow divider differential unit assembly…1767
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring…1767
Adjusting the rolling torque on the gear housing bearings…1771
DRIVE SHAFT…1775
Disassembly…1775
Checking parts…1776
Assembly…1776
Intermediate axle 452146/2D (R 9174)…1779
DESCRIPTION…1781
SPECIFICATIONS AND DATA…1782
TIGHTENING TORQUES…1783
TOOLS…1785
REPAIRING THE FLOW DIVIDERDIFFERENTIAL ASSEMBLY…1791
Disassembly…1791
REPAIRING THE FLOW DIVIDER DIFFERENTIAL…1791
Flow divider differential unit disassembly…1791
Removing the bevel pinion from the support…1794
Gear housing disassembly…1794
Differential – flow divider disassembly…1795
CHECKING THE DIFFERENTIAL – FLOW DIVIDER COMPONENTS…1799
Flow divider – differential unit assembly…1799
Gear housing assembly…1801
Assembling the bevel pinion support…1802
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring…1802
Differential housing assembly…1804
Gear housing bearings rolling torque adjustment…1806
Rear axles 451391/2D (R 8284) 452191/2D (R 8274) 453291/2D (R 8298)…1812
DESCRIPTION…1814
SPECIFICATIONS AND DATA…1815
TIGHTENING TORQUES…1816
TOOLS…1818
REAR AXLES ASSEMBLY OVERHAUL…1823
Disassembly…1823
Epicycloid reduction gear disassembly…1823
Wheel hub disassembly…1824
CLEANING AND CHECKING WHEEL HUB AND EPICYCLOID GEAR PARTS…1826
WHEEL HUB ASSEMBLY…1827
Assembling the epicycloid reduction gear…1829
REMOVING-REFITTING THE DIFFERENTIAL…1832
REFITTING…1833
REPAIRING THE DIFFERENTIAL…1834
Removal…1834
Gear housing disassembly…1835
Removing the bevel pinion from the support…1836
CHECKING THE DIFFERENTIAL COMPONENTS…1838
Gear housing assembly…1839
Assembling the bevel pinion support…1840
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring…1840
Differential housing assembly…1842
Gear housing bearings rolling torque adjustment…1843
Rear axle 452146/2D (R 8174)…1849
DESCRIPTION…1851
SPECIFICATIONS AND DATA…1852
TIGHTENING TORQUES…1853
TOOLS…1855
REAR AXLE ASSEMBLY OVERHAUL…1860
REPAIRING THE DIFFERENTIAL…1860
Disassembly…1860
Disassembling the gear housing…1861
Disassembling the bevel pinion support…1862
CHECKING THE DIFFERENTIAL COMPONENTS…1862
Assembling the gear housing…1863
Assembling the bevel pinion support…1864
Differential housing assembly…1866
Adjusting the rolling torque on the gear housing bearings…1867
Axles in Tandem MERITOR RT 153E/2D…1872
Axles in Tandem (Intermediate) Meritor RP 153E…1874
DESCRIPTION…1876
SPECIFICATIONS AND DATA…1876
TIGHTENING TORQUES…1878
TOOLS…1882
EXPERIMENTAL TOOLS…1889
SERVICING INTERMEDIATE AXLE ASSEMBLY RP 153E…1892
WHEEL HUB OVERHAULING…1892
Removing…1892
Checks on wheel hub components…1893
Refitting…1893
REMOVING DIFFERENTIAL (AXLE ON STAND 99322215) …1897
REFITTING DIFFERENTIAL (axle on stand 99322215)…1897
REPAIRING INTER-AXLE UNIT…1898
Dismantling inter-axle unit…1898
Checking inter-axle unit components…1900
Fitting inter-axle unit…1900
Adjusting drive input shaft bearing end float…1902
REPAIRING MAIN DIFFERENTIAL – DISMANTLING DIFFERENTIAL CASING…1903
Removing the gear housing…1906
Checking the differential components…1907
Refitting the gear housing…1907
ASSEMBLING DIFFERENTIAL CASING…1909
Calculating bevel pinion position in differential casing…1909
ADJUSTING THE CAP ANGLE…1912
CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)…1915
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT…1919
Rear Axle MERITOR U 177 E…1922
DESCRIPTION…1924
CHARACTERISTICS AND DATA…1925
TIGHTENING TORQUES…1926
TOOLS…1927
REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215) …1933
Removal…1933
Checking axle housing…1933
Refitting…1933
REPAIRING THE DIFFERENTIAL…1934
Removing the differential…1934
Removing the gearcase…1935
REMOVING THE BEVEL PINION FROM THE SUPPORT…1937
Differential component check…1937
Fitting the gear housing…1938
FITTING THE MOUNT ON THE BEVEL PINION…1939
Reassembling the differential housing…1941
ADJUSTING THE CAP GAP…1943
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)…1946
WORK ON THE VEHICLE…1949
REPLACING THE BEVEL PINION MOUNT SEAL…1949
Disassembly…1949
Assembly…1950
SECTION 10 – Front axles…1952
Front axles…1952
Front axle 5886/D (F9021)…1955
DESCRIPTION…1957
Front axle 5886 / D…1957
SPECIFICATIONS AND DATA…1958
TIGHTENING TORQUES…1960
FAULT DIAGNOSIS…1961
TOOLS…1964
REMOVING AND REFITTING FRONT AXLE…1969
Removal…1969
Refitting…1969
REMOVING AND REFITTING MIDDLE AXLE (8X4 – 8X8 VEHICLES)…1970
Removal…1970
Refitting…1970
VEHICLE CHECKS…1971
Tie rods…1971
Swivel heads…1971
CHECKING SWIVEL HEAD PLAY…1971
FRONT AXLE ASSEMBLY OVERHAUL…1972
REMOVING – REFITTINGWHEEL HUBS…1972
Removal…1972
Replacing wheel hub bearings…1973
Replacing wheel fixing pins…1974
Refitting wheel hubs…1974
Checking wheel hub bearing end float…1974
Measuring rolling torque…1975
REMOVING AND REFITTING TRANSVERSE TIE ROD…1975
REPLACING TRANSVERSE TIE ROD SWIVEL HEADS …1976
REMOVING AND REFITTING PIN FOR STUB AXLE …1976
Removal…1976
Replacing kingpin bearing…1977
Checking and adjusting clearance between stub axle and axle…1978
CHECKING AND MEASURING THE AXLE BODY…1979
Checking angle of holes for kingpins…1980
Front axle 5886/2D (F9021)…1982
DESCRIPTION…1984
Front axle 5886 / 2D…1984
SPECIFICATIONS AND DATA…1985
TIGHTENING TORQUES…1987
FRONT AXLE ASSEMBLY OVERHAUL…1988
REMOVING – REFITTING WHEEL HUBS…1988
Removal…1988
Refitting wheel hubs…1989
Wheel geometry…1992
GENERAL INFORMATION…1994
Steering wheel angles…1994
FRONT WHEEL GEOMETRY (4X2 VEHICLES)…1995
Positioning clips and headlights…1995
Electronic compensation of rim eccentricity…1996
Wheel alignment…1996
Checking wheel toe-in…1997
Checking wheel deviation…1997
Checking camber…1997
Checking kingpin angle and caster…1998
Checking rear axle alignment…1999
WHEEL GEOMETRY OF VEHICLES WITH ADDED CENTRAL AXLE (8X4X4)…1999
Checking steering angles…2001
SECTION 11 – Suspensions…2002
Suspensions…2002
FRONT AND REAR MECHANICAL SUSPENSIONS…2004
Description…2004
SPECIFICATIONS AND DATA…2015
FRONT SHOCK ABSORBERS…2025
REAR SHOCK ABSORBERS…2026
AIR SUSPENSION…2027
Chassis frame lifting, lowering and self-levelling with remote control …2027
Saving Levels…2027
Working diagram of pneumatic rear suspensions for 8×4 H/P, 8×4 HB/P vehicles…2028
CHARACTERISTICS AND DATA…2029
Pneumatic system…2029
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM…2030
Relief valve…2030
Fault diagnosis…2030
Level sensor…2030
Electropneumatic distributor…2031
Air low pressure manometer switch…2031
Air spring…2031
Rear pneumatic suspension for vehicles 8×4 H/P – HB/P…2032
FAULT DIAGNOSIS…2033
Diagnosis Instruments…2033
TIGHTENING TORQUES…2038
TOOLS…2039
REMOVAL-REFITTING OF FRONT LEAF SPRING…2044
Removal…2044
Refitting…2044
REMOVAL-REFITTING OF INTERMEDIATE AXLE LEAF SPRING (8X4 VEHICLES)…2045
Removal…2045
Refitting…2045
REMOVAL-REFITTING OF REAR LEAF SPRING (4X2 – 4X4 VEHICLES)…2046
Removal…2046
Refitting…2046
REMOVAL-REFITTING OF REAR LEAF SPRING ON CANTILEVER TYPE SUSPENSIONS (6X4 – 6X6 – 8X8 VEHICLES)…2047
Removal…2047
Refitting…2047
Procedure for assembly of the slipper block and mounting brackets for the longitudinal bars…2048
Tightening theU-bolts clamping the leaf spring to the central pivot…2048
REAR CANTILEVER SUSPENSION (6×4 – 6×6 – 8×4 – 8×8 vehicles)…2049
Removal-refitting of central pivot…2049
Removal-refitting of central pivot…2049
Renewal of bearings…2049
Removal-refitting of hanger bracket…2049
Removal of the central pivot…2049
Removal of the central pivot shaft…2049
Removal of the hanger bracket…2049
Renewal of the bearings…2049
Refitting the hanger bracket…2050
Refitting the central pivot shaft…2051
Refitting the central pivot…2051
REMOVAL-REFITTING OF REAR AXLE LONGITUDINAL ARM…2053
REMOVAL-REFITTING OF INTERMEDIATE AXLE LONGITUDINAL ARM…2053
REMOVAL-REFITTING OF REAR AXLE TRIANGULAR ARM FOR VEHICLES WITH AIR SUSPENSION…2053
Removal…2053
Refitting…2053
REPLACEMENT OF THE FLEXIBLE PINS OF LONGITUDINAL/TRIANGULAR ARMS…2054
Disassembly…2054
Assembly…2054
SHOCK ABSORBERS…2055
Removal…2055
Refitting…2055
ANTI-ROLL BARS…2055
ANTI-ROLL BAR…2056
FRONT ANTI-ROLL BAR…2056
AUXILIARY AXLE ANTI-ROLL BAR (8X4 VEHICLES)…2056
REAR ANTI-ROLL BAR…2056
INTERMEDIATE AXLE ANTI-ROLL BAR (6X4 – 6X6 – 8X4 – 8X8 VEHICLES)…2056
Removal…2056
Refitting…2056
SECTION 12 – Wheels and tyres…2060
Wheels and tyres…2060
DESCRIPTION…2062
SPECIFICATIONS AND DATA…2062
Tyre inflation pressures…2062
TOOLS…2063
FAULT DIAGNOSIS…2063
STATICWHEEL BALANCING…2066
CORRECTION OF RESIDUAL STATIC IMBALANCE…2067
TYRE INFLATION PRESSURES…2067
RELATIONSHIP OF INFLATION PRESSURE TO TYRE BEHAVIOUR…2068
SECTION 13 – Steering…2070
Steering…2070
DESCRIPTION…2072
STEERING BOX/VEHICLE COMBINATIONS…2073
SPECIFICATIONS AND DATA…2074
Vehicles: 4X2 – 4X4 – 6X4 – 6X6…2074
Vehicles: 8x4x4 – 8×8…2074
FAULT DIAGNOSIS…2075
TOOLS…2080
TIGHTENING TORQUES…2081
Steering gear arrangement for 4×2 – 6×4 vehicles (ZF 8098 steering box)…2082
Steering gear arrangement for 4×4 – 6×6 vehicles (ZF 8098 steering box)…2083
Steering gear arrangement for 8x4x4 – 8×8 vehicles (ZF 8099/1.5 steering box)…2084
Hydraulic circuit diagram for 8x4x4 – 8×8 vehicles (ZF 8099/1.5 steering box)…2085
HYDRAULIC POWER STEERING…2086
Steering lever assembly…2086
REMOVAL AND REFITTING OF COMPLETE STEERING COLUMN…2087
Removal…2087
Refitting…2088
MAIN OPERATIONS…2089
Bleeding the power steering system…2089
Measuring steering box play at the steering wheel …2089
Checking the maximum pressure of the power steering wheel…2089
Adjustment of hydraulic steering limiting valves…2089
Testing the hydraulic steering limiting valves with the vehicle in motion…2090
Setting the automatic hydraulic steering limit…2090
Checking…2090
SECTION 14 – Air system – Brakes…2092
Air system – Brakes…2092
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (MISCELLANEOUS AND GENERATORS)…2096
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (VALVES)…2097
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)…2103
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)…2104
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (CALLIPERS AND CYLINDERS)…2105
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (HALF-COUPLINGS AND COUPLING HEADS)…2106
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (HALF-COUPLINGS AND COUPLING HEADS)…2107
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (INDICATORS AND SWITCHES)…2108
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (BRAKES)…2109
PIPES AND FITTINGS…2110
General information…2110
Flaring rigid pipes…2110
Bending rigid pipes…2111
Cutting rigid pipes…2111
Replacing the flexiblehoses withconventional fittings …2112
Replacing flexible hoses with quick-coupling fittings…2113
BRAKING SYSTEM…2115
Working diagram for 4×2 – 4×4 vehicles designed for towing with ABS-ASR device…2115
Working diagram for isolated 6×4 vehicles with ABS-ASR device…2116
Working diagram for 6×4 – 6×6 vehicles designed for towing with ABS-ASR device…2117
Working diagram for isolated 8x4x4 – 8x8x4 vehicles with ABS-ASR device…2118
Working diagram for 8x4x4 – 8x8x4 vehicles designed for towing with ABS-ASR device…2119
BRAKING SYSTEM…2120
Working diagram for 4×2 – 4×4 vehicles designed for towing with ABS-ASR device…2120
Concept diagram for 6×4 vehicles isolated with EBL devices…2121
Working diagram for 6×4 – 6×6 vehicles designed for towing with EBL device…2122
Concept diagram for 8x4x4 – 8x8x4 vehicles isolated with EBL devices…2123
Working diagram for 8x4x4 – 8x8x4 vehicles designed for towing with EBL device…2124
Layout on vehicle of main components of braking system…2126
Layout on vehicle of main components of ABS-ASR system…2127
DESCRIPTION…2128
Service braking…2128
Emergency braking…2128
Retarding braking…2128
Parking brake…2128
ABS (Anti-Lock Brake System)…2128
ASR (Anti-Slip Regulator) system…2129
EBL (Electronic Brakes Limiter)…2129
BRAKES…2129
Front disc brakes type KNORR: SB7; SN7 (for vehicles with partial traction)…2129
Front brakes (for four-wheel drive vehicles) and rear brakes type MERITOR Duo – duplex Ø 410×180 and 410×200 …2129
FAULT DIAGNOSIS…2130
Diagnosis Instruments…2130
ABS Troubleshooting…2132
TIGHTENING TORQUES…2152
TOOLS…2155
SPECIFICATIONS AND DATA – PNEUMATIC SYSTEM…2163
SPECIFICATIONS AND DATA – BRAKES…2168
CHECKS ON MAIN COMPONENTS OF THE BRAKING SYSTEM…2171
CHECKS ON MAIN COMPONENTS OF THE BRAKING SYSTEM…2172
MAIN COMPONENTS OF THE BRAKING SYSTEM…2174
Compressor…2174
Head locking screw tightness…2174
Electronic control unit…2175
A.P.U. (Air Processing Unit)…2175
Triple servo control valve…2176
Predominance control…2176
Predominance control…2176
Knorr Bremse AC 597B…2176
Wabco 973 009 013…2176
Duplex control valve…2177
Coupling heads…2178
Check valve (vehicles suited to towing)…2178
Parking brake hand control valve (vehicles suited to towing)…2178
Safety valve (”for Sweden”)…2179
Parking brake hand control valve (isolated vehicles)…2179
Diaphragm brake cylinder…2180
Combined brake cylinder…2180
Combined cylinder emergency braking device…2180
Repairs…2180
Relay valve…2181
Pressure reduction unit…2181
Engine brake switch…2182
Dual servo control valve…2182
Brake anti-lock control valve…2183
ASR electropneumatic valve…2183
Speed sensor…2183
Phonic wheels…2183
BRAKE REPAIRS…2184
FRONT DISC BRAKES SB7 TYPE (VEHICLESWITH PARTIAL TRACTION)…2184
TYPE SN7 DISK BRAKES…2185
SB7 type brake operation…2187
CHECKS…2187
Efficiency of automatic clearance recovery…2187
Brake lining thickness…2188
Replacing brake linings…2189
Removing and refitting brake callipers SB7…2191
Removal…2191
Refitting…2191
Removing and refitting wheel hubs…2192
Removal…2192
Refitting…2192
OVERHAULING BRAKE CALLIPERS SB7…2193
Disassembly…2193
Cleaning and checking component parts…2194
Assembly…2194
OVERHAULING BRAKE DISCS…2195
TURNING AND GRINDING BRAKE DISCS ON THE BENCH …2196
TURNING AND GRINDING BRAKE DISCS ON THE VEHICLE…2196
DRUM BRAKES…2196
FRONT BRAKES…2197
REAR BRAKES…2197
Disassembly…2197
Turning drums…2200
Replacing brake linings…2200
Turning brake linings…2201
Assembly…2201
SECTION 15 – Bodywork – Chassis frame…2204
Bodywork – Chassis frame…2204
CAB…2206
General information…2206
TIGHTENING TORQUES…2206
Cab front suspensions…2206
Cab rear suspension…2206
TOOLS…2206
CAB ANCHORING…2207
REPAIRS…2209
REPLACING CAB SUSPENSION FRONT AND REAR SHOCK ABSORBERS…2209
REMOVING-REFITTING FRONT MOUNTS AND CAB STABILIZER BAR…2209
REPLACING HYDRAULIC CYLINDER FOR CAB TILTING…2209
Removal…2209
Refitting…2209
REPLACING THE WINDSHIELD…2210
REPLACING THE WINDING WINDOW…2211
REPLACING THE WINDOW WINDER…2212
REPLACING THE FIXED WINDOW…2212
Removal…2212
Preparing the window bay…2212
Preparing the window…2212
Refitting…2213
REPLACING SUNROOF…2214
Removal…2214
Preparing the sunroof bay…2214
Preparing the sunroof…2214
Refitting…2215
Replacing the roof air inlet door…2215
CAB VENTILATION AND HEATING UNIT…2215
CHASSIS FRAME…2216
REPAIRS AND CHECKS…2216
Measuring the bend of the chassis frame downwards or upwards…2217
Measuring the side bend of the chassis frame…2217
Measuring the movement of the chassis frame…2217
Measuring the torsion of the chassis frame…2218
PRECAUTIONS…2218
Welds on the chassis frame…2220
SECTION 16 – Scheduled maintenance…2222
Scheduled maintenance…2222
SCHEDULED MAINTENANCE…2224
Description…2224
Maintenance services specifications…2224
EXTRA PLAN OPERATIONS…2224
CHECKS AND/OR MAINTENANCE WORK…2227
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE WORK…2228
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE WORK…2229
CHECKS AND/OR MAINTENANCE WORK…2230
M1 SERVICE…2231
M2 SERVICE…2236
M3 SERVICE…2239
M4 SERVICE (Only for kilometric intervals)…2239
EXTRA PLAN MAINTENANCE…2239
EP2 SERVICE…2239
EP3 SERVICE…2240
EP4 SERVICE…2241
EP5 SERVICE…2241
603.93.121 – Iveco EuroTrakker_EuroTech_EuroStar Cursor 8-10-13 REPAIR MANUAL_ELECTRIC_ELECTRONIC_SYSTEM…2242
EUROTRAKKER – EUROTECH – EUROSTAR CURSOR 8/10/13…2242
REPAIR MANUAL ELECTRIC/ELECTRONIC SYSTEM…2242
FOREWORD…2244
GENERAL LIST OF CONTENTS…2246
Introduction…2248
General cautions for electric/electronic components…2251
Concept of earth and electromagnetic compatibility…2253
Concept of CAN LINE…2258
Technical Codes…2262
Graphic symbols and abbreviations…2268
General…2274
DESCRIPTION OF BASE SYSTEM…2276
Technical and electric specifications…2276
Cab structure…2276
Components on the engine F2B…2278
Frame structure…2282
Complete vehicle with cab tilted…2283
Vehicle transparency (Euro Tech/EuroStar)…2284
POWER NETWORK…2286
Negative network…2286
Earth points on the vehicle…2287
Positive network…2298
Starting…2302
MAIN COMPONENTS…2305
Interconnecting Control Unit (UCI)…2305
Central panel – Cursor 8 (On Road)…2323
Starter motor…2331
Alternator…2335
Steering column lever unit…2337
Ignition switch…2343
Front wall connectors (A) (EuroTech – EuroStar)…2344
Rear wall connector ( " )…2355
Connectors between cables (Base vehicle) Cursor 8/10/13…2362
Specific circuits…2390
ABS OPERATION DIAGRAM (CURSOR 8 – 10 – 13)…2392
EDC MS6.2 (Cursor 8 – 10 – 13)…2453
ECAS…2484
IMMOBILIZER…2525
Circuit Charts…2544
Keys…2546
Chart No. 1: Start up from driver’s seat…2547
Chart No. 2: Start up from engine compartment…2548
Chart No. 3: Pre-heating…2549
Chart No. 4: Recharge…2550
Chart No. 5: Instruments (fuel level – water temperature)…2551
Chart No. 6: Instruments (engine oil and brake air pressure)…2552
Chart No. 7a: Instruments (tachograph – rev counter) F2B (on)…2553
Chart No. 7b: Instruments (tachograph – rev counter) F3A/F3B (on) – F2B/F3B (off)…2554
Chart No. 8a: Warning lights (iveco control)…2555
Chart No. 8b: Warning lights F2B (on)…2556
Chart No. 8c: Warning lights F3A/F3B (on)…2557
Chart No. 8d: Warning lights F2B/F3B (off)…2558
Chart No. 9: Sidelights (cabin interior)…2559
Chart No. 10: Sidelights (vehicle exterior)…2560
Chart No. 11: Main/dipped beam headlights…2561
Chart No. 12: Additional headlights and rear foglights…2562
Chart No. 13: Direction indicators – hazard lights…2563
Chart No. 14: Brake lights – Reverse light – Horn…2564
Chart No. 15: Windscreen wiper…2565
Chart No. 16a: Interior lighting and service F2B (on)…2566
Chart No. 16b Interior lighting and service F3A/F3B (on)…2567
Chart No. 16c: Interior lighting and service F2B/F3B (off)…2568
Chart No. 17: Rearview mirrors…2569
Chart No. 18a: Window winders F2B (on) F2B/F3B (off)…2570
Chart No. 18b: Window winders F3A/F3B (on)…2571
Chart No. 19a: ABS / ASR F2B (on)…2572
Chart No. 19b: ABS / ASR F3A/F3B (on)…2573
Chart No. 19c: ABS / ASR F2BF3B (off)…2574
Chart No. 20: EBS F3A/F3B (on)…2575
Chart No. 21a: EDC (connector B) F2B (on)…2576
Chart No. 21b: EDC (connector B) F3A/F3B (on) F2B/F3B (off)…2577
Chart No. 22a: EDC (connector a – F2B)…2578
Chart No. 22b: EDC (connector A – F3B)…2579
Chart No. 23a: EUROTRONIC 1 F2B (on)…2580
Chart No. 23b: EUROTRONIC I I F3A/F3B (on) F2B/F3B (off)…2581
Chart No. 24: Manual climate control system…2582
Chart No. 25: Automatic climate control system…2583
Chart No. 26: Additional air heating manual mode…2584
Chart No. 27: Additional air heating manual mode (GGVS)…2585
Chart No. 28: Independent heating unit manual control for cabin and engine…2586
Chart No. 29: Independent heating unit manual control for cabin and engine (TMP)…2587
Chart No. 30: Main remote control switch…2588
Chart No. 31: ADR electronic main remote control switch…2589
Chart No. 32: Air TMP emergency switch…2590
Chart No. 33: Air TMP emergency switch (French)…2591
Chart No. 34: Ground startup and recharge…2592
Chart No. 35: 15-Pole socket…2593
Chart No. 36: 2X7 Pole socket (only tractor)…2594
Chart No. 37: Heated windscreen…2595
Chart No. 38: Drier heating heated pre-filter…2596
Chart No. 39: Trip computer level 1…2597
Chart No. 40: Trip computer level1 (with main current switch)…2598
Chart No. 41A: Electronic speedometer F2B (ON)…2599
Chart No. 41B: Electronic speedometer F3A/F3B (ON) F2B/F3B (OFF)…2600
Chart No. 42: Hour counter…2601
Chart No. 43: Economy Power…2602
Chart No. 44: Central door lock…2603
Chart No. 45: Multipower takeoff…2604
Chart No. 46: Right and left beacon light…2605
Chart No. 47: Sunroof…2606
Chart No. 48: Central lubrication “Lincoln” – “Vogel”…2607
Chart No. 49: Hydraulic power steering circuit…2608
Chart No. 50: Hydraulic power steering circuit (northern countries)…2609
Chart No. 51: Headlight washer and windscreen wiper…2610
Chart No. 52: Trailer braking system…2611
Chart No. 53: Immobilizer…2612
Chart No. 54: Intarder ZF…2613
Chart No. 55: ECAS for 4X2 and 6X2 (ON)…2614
Chart No. 56: ECAS for 4X2 and tractor (ON)…2615
Chart No. 57: ECAS for 6X2 P/FP and PT/FT with additional hydraulic steering axis (ON)…2616
603.93.641 – Iveco Trakker Euro 4-5 (18-72T) REPAIR MANUAL_MECHANICAL_ELECTRIC_ELECTRONIC (’04-’13)…2618
603.93.641 – Iveco Trakker Euro 4-5 ELECTRIC_ELECTRONIC SYSTEM…4320
PTO GUIDE FOR DEEC 2_2008_EN…4610

Iveco EuroTrakker & Trakker Trucks Repair & Service Manual


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