Iveco EuroTech, EuroStar Repair & Service Manual 1992-2002

Catalog: 
Make: 
Price: US$ 39.00

Iveco EuroTech, EuroStar Repair & Service Manual 1992-2002

603.43.391 - Iveco Trucks EuroTech Cursor, EuroStar Cursor Repair Manual ('92-'02).pdf
603.93.121 - Iveco Trucks EuroTrakker, EuroTech, EuroStar Cursor 8-10-13 Electrical Wiring Diagrams.pdf

Complete service repair manual with electrical wiring diagrams for Iveco EuroTech, EuroStar Trucks, with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.

Iveco Trucks EuroTech, EuroStar 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.

PRODUCT DETAILS:
Total Pages: 1,321 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

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

TABLE OF CONTENTS
EUROTECH CURSOR -  EUROSTAR CURSOR...1
  REPAIR MANUAL...1
    NOTE...3
      Graphs and symbols...4
    INDEX...5
      SECTION 1 -  General...6
        General...6
          COMPOSITION OF MODELS...8
          P.I.C. CODE NUMBER...12
            Vehicle Identification Data (EUROTECH)...16
            Vehicle Identification Data (EUROSTAR)...17
          FILLING UP...18
            International designations of lubricants and fluids...19
      SECTION 2 -  Engine...20
        Engine...20
          VIEWS OF THE ENGINE...26
          TECHNICAL DESIGNATION...28
          GENERAL CHARACTERISTICS...31
          ASSEMBLY CLEARANCE DATA...34
          FAULT DIAGNOSIS...40
          DESCRIPTION...40
          DIAGNOSTIC INSTRUMENTS...40
          CONTROL UNIT TEST...41
          ENGINE TEST...41
          AUXILIARY FUNCTIONS...41
          DETECTION OF MECHANICAL FAILURE...42
          TIGHTENING TORQUE...45
          TOOLS...50
          ENGINE REMOVAL - REFITTING...60
            Removal...60
            Refitting...61
          DISMANTLING THE ENGINE ON THE BENCH...64
          REPAIR OPERATIONS...71
          CYLINDER BLOCK...71
            Checks and measurements...71
          CYLINDER LINERS...72
            Replacing cylinder liners...73
            Removal...73
            Fitting and checking protrusion...73
          CRANKSHAFT...74
            Measuring main journals and crank pins...75
            Preliminary measurement of main and big end bearing shell selection data...76
            Replacing the timing control gear and oil pump...84
            Checking main journal installation clearance...84
            Checking crankshaft end float...85
          PISTON-CONNECTING ROD ASSEMBLY...86
            Removal...86
            Measuring the diameter of the pistons...87
            Conditions for correct gudgeon pin-piston coupling...87
            Piston rings...88
          CONNECTING ROD...89
            Bushings...90
            Checking connecting rods...90
            Mounting the piston rings piston assembly...91
            Mounting the piston rings...91
            Fitting the big end bearing shells...91
            Fitting connecting rod - piston assemblies in the cylinder liners ...92
            Checking piston protrusion...92
            Checking assembly clearance of big end pins...94
          CYLINDER HEAD...94
            Taking down the valves...94
            Checking the planarity of the head on the cylinder block...94
          VALVES...94
            Removing deposits and checking the valves...94
          VALVE GUIDES...95
            Replacing of valve guides...96
            Replacing - Reaming the valve seats...96
          REPLACING INJECTOR HOLDER CASES...96
            Removal...96
            Checking protrusion of injectors...98
          TIMING GEAR...99
            Checking cam lift and pin alignment...99
            Camshaft...100
            Bushes...100
            Replacing camshaft bushes using beater 99360499...101
            Valve springs...102
            Fitting the valves and oil seal ring...102
          ROCKER SHAFT...103
          ROCKERS...103
          LUBRICATION...104
            Oil pump...106
            Overpressure valve...106
            Oil pressure control valve...107
            Heat exchanger...107
            Engine oil filters...108
          COOLING...109
            Water pump...109
            Thermostat...109
          TURBOCHARGING...112
            Turbocharger...112
            Holset HX55V turbocharger...114
          ACTUATOR ADJUSTMENT...117
            VGT Control solenoid valve...117
            Holset HY55V turbocharger...118
            Actuator...119
            Solenoid valve for VGT control...119
          FEEDING...120
            Fuel pump...121
            Injector-pump...121
            Pumping element...121
            Nozzle...121
            Solenoid valve...121
            Replacing injectors-pump...121
          INJECTOR PHASES...122
            Filling phase...122
            Injection phase...123
            Pressure Reduction phase...123
          ASSEMBLING THE ENGINE ON THE BENCH...124
          DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER...126
            Fitting the connecting rod-piston assembly into the cylinder liners...127
          ENGINE FLYWHEEL...130
            Fitting engine flywheel...130
            Fitting camshaft...131
            Fitting pump-injectors...132
            Fitting rocker-arm shaft assembly...132
            Camshaft timing...133
            Phonic wheel timing...135
            Adjusting rocker armclearance, intake, exhaust and pre-load of pump injector governing rocker arms...136
          ENGINE COMPLETION...138
      SECTION 3 -  Clutch...140
        Clutch...140
          DESCRIPTION...142
            Clutch...142
          CHARACTERISTICS AND DATA...142
          DIAGNOSTICS...143
          TIGHTENING TORQUES...146
          TOOLS...146
          REMOVING AND REFITTING...147
            Removal...147
            Refitting...147
          REMOVING AND FITTING BACK THE THRUST BEARING ...147
          REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT...147
          DRIVEN PLATE CONTROL...148
            Damping hub control...148
            Friction seal...148
          BLEEDING AIR FROM THE CLUTCH SYSTEM...148
          HYDRAULIC CONTROL...149
          CLUTCH ACTUATOR FOR ZF 16 S151/181/221 GEARBOX...150
            Fitting and adjusting the clutch wear indicator...150
            Push rod adjustment (new clutch)...151
          CLUTCH ACTUATOR FOR EUROTRONIC GEARBOX...152
            Clutch actuator push rod adjustment (new clutch)...152
            Fitting the clutch actuator...152
            Replacing the clutch actuator...152
          CHECKING AND ADJUSTING THE CLUTCH PEDAL STOPS (excluded vehicles with EuroTronic gearbox)...153
            Clutch stop...153
            Clutch pedal idle stroke...153
            Pedal timing gear stroke...153
      SECTION 4 - Gearbox...154
        Gearbox...154
          Gearboxes: ZF 16 S 181 D.D. ZF 16 S 181 O.D. ZF 16 S 221 D.D...157
            LOCATION OF GEARBOX DESCRIPTION PLATE...159
            DESCRIPTION...160
            OPERATION...162
              Slow range...162
              Fast range...163
            EPICYCLIC REDUCTION GEAR CONTROL...164
              Reduced speeds...164
              Normal speeds...165
            SPECIFICATIONS AND DATA...166
            TIGHTENING TORQUES...170
            TOOLS...171
            GEARBOX FAULT DIAGNOSIS...176
            REMOVING-REFITTING THE GEARBOX...179
              Removal...179
              Refitting...180
            OVERHAULING THE GEARBOX...181
              Servoshift gear box...181
              Removal...181
              Refitting...181
              Disassembly...181
              Assembly...183
              Removing the rear box...186
              Removing the epicyclic reduction gear unit (ERG)...186
              Fitting the epicyclic reduction gear unit (ERG)...189
              Refitting the epicyclic reduction gear unit (ERG) rear box ...192
              Removing the gearbox...192
              Removing the main shaft...195
              Removing the drive input shaft...198
              Removing the transmission shaft...199
            CHECKS...199
              Gearbox...199
              Hubs - sliding sleeves - forks...199
              Bearings...199
              Shafts - gears...199
              Synchronizing devices...199
              BK-type single-cone synchronizing devices...199
              Fitting the transmission shaft...200
              Fitting the drive input shaft...200
              Fitting the main shaft...201
              Adjusting the main shaft...203
              Fitting the gearbox...204
              Oil pump...205
              Adjusting the transmission shaft bearing end float...205
              Drive input shaft cover...206
            PNEUMATIC CONTROL OF GEARBOX...208
          ZF gearboxes with INTARDER hydraulic retarder, types: 16 S 151 D.D. 16 S 181 D.D. 16 S 221 D.D...210
            SPECIFICATIONS AND DATA...212
            TOOLS...213
              Removing the hydraulic retarder from the gearbox on the stand...220
              Refitting the hydraulic retarder...220
              Removing the epicyclic reduction gear unit (ERG) rear box...221
              Removing the epicyclic reduction gear unit (ERG)...221
              Component parts of the epicyclic reduction gear unit...224
              Fitting the epicyclic reduction gear unit (ERG)...225
              Refitting the epicyclic reduction gear unit (ERG) rear box...227
          Gearbox EUROTRONIC 1800...229
            DESCRIPTION...231
            CHARACTERISTICS AND DATA...233
            TIGHTENING TORQUES...236
            EQUIPMENT...237
            DIAGNOSIS OF MECHANICAL TYPE FAULTS...243
            EUROTRONIC 1800 TRANSMISSION REMOVAL-REFITTING...246
              Removal...246
              Refitting...247
            REPAIRS...248
              Disassembly of front box...248
              Disassembling the intermediate casing...249
              Disassembly of rear box and epicyclic reduction unit...251
              Installation of rear box and epicyclic reduction unit...253
              Axial clearance regulation on epicyclic reduction gear bearing...253
              Removal of primary shaft...257
              Primary shaft installation...258
              Removal of Splitter synchroniser...260
              Installation of Splitter synchroniser...260
              Forks installation-disinstallation...260
              Secondary shafts...260
              Central box installation...261
              Shafts timing...263
              Disinstallation of movement input shaft...264
              Installation of movement input shaft...265
              Installation of front box...265
              Disinstallation of front cover...266
              Installation of front cover...266
              Regulation of axial clearance on movement input shaft bearing ...267
              Regulation of axial clearance on secondary shaft bearings...267
            EUROTRONIC IT (INTARDER)...271
              CHARACTERISTICS AND DATA...271
              REPAIRS...272
                Disinstallation of rear box...272
                Rear box installation...273
                Regulation of axial clearance on epicyclic reduction gear bearing...273
                Regulation of axial clearance on stator...274
              CLUTCH ACTUATOR...275
                Description...275
              CHARACTERISTICS AND DATA...275
              SAFETY RULES...276
                Disinstallation...277
                Installation...279
                Operating checks...280
                Measure of piston stroke...280
          Gearbox EuroTronic 12 AS 2301 D.D...282
            DESCRIPTION...284
            SPECIFICATIONS AND DATA...285
            TIGHTENING TORQUES...288
            TOOLS...289
            OVERHAULING THE GEARBOX ...294
              Checks...294
              Gearbox actuator...294
              Removal...294
              Refitting...295
              Removing the rear box...295
              Removing the rear box...296
              Removing the epicyclic reduction gear train (E.R.G.)...297
              Fitting the epicyclic reduction gear train (E.R.G.)...299
              Adjusting epicyclic reduction gear train bearing end float...300
              Adjusting main shaft end float...301
              Synchronizing device assembly for engaging normal or reduced gears...303
              Removal...303
              Removing the middle box...306
              Removing the main shaft...308
              Removing the drive input shaft...310
              Removing the splitter synchronizing device...311
              Fitting the splitter synchronizing device...312
              Fitting the main shaft...313
              Fitting the drive input shaft...313
              Splitter control fork...316
              Disassembly - Assembly...316
              Gear control forks...316
              Removal...316
              Fitting...317
              Transmission shafts...318
              Disassembly - Assembly...318
              Fitting the middle box...318
              Fitting the front box...321
              Front cover...323
              Removal...323
              Fitting the front cover...323
              Adjusting drive input shaft bearing end float...323
              Adjusting transmission shaft bearing end float...324
              Clutch release lever...326
          Gearbox EuroTronic 12 AS 2301 D.D. with Intarder (IT)...329
            SPECIFICATION AND DATA...331
            OVERHAULING THE GEARBOX...332
              Removing the hydraulic retarder...332
              Refitting the hydraulic retarder...333
              Adjusting epicyclic reduction gear train bearing end float...333
              Adjusting stator end float...334
              Removing the rear box...335
              Removing the E.R.G...336
              Fitting the E.R.G...337
            EXPERIMENTAL TOOLS...342
      SECTION 5 - Intarder - ZF hydraulic retarder...343
        Intarder - ZF hydraulic retarder...343
          LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE...345
          GENERAL INFORMATION...346
          OPERATION...346
            Retarder engaged...347
            Retarder disengaged...348
          LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER...349
          REMOVING AND REFITTING THE RETARDER ON THE ZF S 181/221-OD GEARBOX...350
            Removal...350
            Refitting...351
            Filling with oil...351
          SPECIFICATIONS AND DATA...352
          TIGHTENING TORQUES...353
          TOOLS...354
          FAULT DIAGNOSIS...356
          OVERHAULING THE INTARDER HYDRAULIC RETARDER...360
            Hydraulic accumulator...360
            Removal...360
            Fitting...360
            Removing hydraulic retarder...360
            Checking the component parts of the hydraulic retarder...365
            Fitting the hydraulic retarder...366
            For hydraulic retarders without friction reducing valves only...366
            For both types of hydraulic retarder...367
            Stator end float adjustment...371
      SECTION 6 - Propeller shafts...373
        Propeller shafts...373
          SPECIFICATIONS AND DATA...375
          SPECIFICATIONS AND DATA (Vehicles 4x2)...377
          SPECIFICATIONS AND DATA (Vehicles 6 x 2)...378
          DIAGNOSTIC...379
          TIGHTENING TORQUES...381
          REMOVING AND REASSEMBLING THE PROPELLER SHAFT...382
            Removal...382
            Reassembly...382
          CHECKING THE PROPELLER SHAFT ON THE VEHICLE...383
          REMOVING AND FITTING BACK THE UNIVERSAL JOINTS ...384
          REMOVING AND REASSEMBLING THE SUPPORT...384
      SECTION 7 - Rear axles...385
        Rear axles...385
          Rear axle MERITOR U 177 E whit drum brakes...387
            DESCRIPTION...389
            SPECIFICATIONS AND DATA...389
            DIAGNOSTIC...392
            TIGHTENING TORQUES...394
            TOOLS...396
            REMOVING THE REAR AXLE...401
            FITTING BACK THE REAR AXLE...401
            REAR AXLE ASSEMBLY OVERHAULING...403
            WHEEL HUB OVERHAULING...403
              Removal...403
              Wheel hub component check...404
            REPLACING THEWHEEL HUB BOLTS...405
              Wheel hub reassembly...405
            REMOVINGANDREASSEMBLING THE DIFFERENTIAL (with axle on stand 99322215) ...407
              Removal...407
              Axle casing check...407
              Reassembly...408
            REPAIRING THE DIFFERENTIAL...408
              Removing the differential...408
              Removing the gearcase...410
            REMOVING THE BEVEL PINION FROM THE SUPPORT...412
              Differential component check...412
              Ressembling the gearcase...413
            REASSEMBLING THE BEVEL PINION SUPPORT...414
              Reassembling the differential housing...416
            CAP OPENING ADJUSTMENT...418
            CROWNWHEEL AND PINION CONTACT CORRECTION (AFTER ASSEMBLY)...421
              Instructions for the adjustment and operation check of the transmitter for the differential block operation control...424
          Rear Axle MERITOR U 177 E with disc brakes...425
            DESCRIPTION...427
            CHARACTERISTICS AND DATA...428
            TIGHTENING TORQUES...429
            TOOLS...431
            OVERHAULING THE REAR AXLE ASSEMBLY...435
            OVERHAULING THEWHEEL HUBS...435
              Removal...435
              Replacing wheel hub bearings...437
              Checking the parts forming the wheel hubs...437
              Replacing the wheel fixing pins...437
            REMOVING AND REFITTING THE DIFFERENTIAL (with axle on stand 99322215)...441
              Removal...441
              Checking axle housing...441
          Rear axle MERITOR MS 13-175 with drum brakes...443
            DESCRIPTION...445
            CHARACTERISTICS AND DATA...445
          Rear Axle MERITOR MS 13-175 with disc brakes...447
            DESCRIPTION...449
            CHARACTERISTICS AND DATA...449
          Rear axle 451391/1 (R 8284)...451
            DESCRIPTION...453
            SPECIFICATIONS AND DATA...454
            TIGHTENING TORQUES...455
            TOOLS...457
            REAR AXLES ASSEMBLY OVERHAUL...463
              Disassembly...463
              Epicycloid reduction gear disassembly...463
              Wheel hub disassembly...464
            CLEANING AND CHECKING WHEEL HUB AND EPICYCLOID GEAR PARTS...466
            WHEEL HUB ASSEMBLY...467
              Assembling the epicycloid reduction gear...469
            REMOVING-REFITTING THE DIFFERENTIAL...472
            REFITTING...473
            REPAIRING THE DIFFERENTIAL...474
              Removal...474
              Gear housing disassembly...475
              Removing the bevel pinion from the support...476
            CHECKING THE DIFFERENTIAL COMPONENTS...478
              Gear housing assembly...479
              Assembling the bevel pinion support...480
              Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring...480
              Differential housing assembly...482
              Gear housing bearings rolling torque adjustment...483
          Axles in Tandem...487
            Axles in Tandem (Intermediate) Meritor RP 160 E (R 2478)...489
              DESCRIPTION...491
              SPECIFICATIONS AND DATA...491
              TIGHTENING TORQUES...493
              TOOLS...497
              EXPERIMENTAL TOOLS...504
              SERVICING INTERMEDIATE AXLEASSEMBLY RP 160 E (R2478) ...507
              AIR BREATHER REMOVAL-REFITTING...507
              SERVICINGWHEEL HUBS...507
                Checking wheel hub components...508
              ASSEMBLINGWHEEL HUBS...509
              REMOVING DIFFERENTIAL GEAR . TRANSFER BOX(with rear axle on stand 99322215) ...512
              REFITTING DIFFERENTIAL GEAR . TRANSFER BOX (with rear axle on stand 99322215)...512
              REPAIRING INTER-AXLE UNIT...513
                Dismantling inter-axle unit...513
                Checking inter-axle unit components...515
                Fitting inter-axle unit...515
                Adjusting drive input shaft bearing end float...517
                Adjusting differential lock and inter-axle control pin end-stop...517
              REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING...518
                Dismantling gear cage...521
                Checking differential components...521
                Assembling gear cage...522
              ASSEMBLING DIFFERENTIAL CASING...523
                Calculatingbevel pinion positionin differential casing ...523
              COMPUTATIONAL EXAMPLES...524
                Determining the thickness of the bevel pinion bearing clearance adjustment rings ...524
                Adjusting the cap gap...527
              CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...529
              REMOVING-SERVICING-REFITTIN G INTER-AXLEOUTPUT SHAFT...532
            Axles in Tandem (Rear) Meritor RR 160 E (R 0878)...535
              DESCRIPTION...537
              SPECIFICATIONS AND DATA...537
              TIGHTENING TORQUE...539
              TOOLS...541
              SERVICING REAR AXLE ASSEMBLY RR 160 E (R 0878)...546
              AIR BREATHER REMOVAL/ INSTALLATION...546
              SERVICINGWHEEL HUBS...546
              REMOVING DIFFERENTIAL (with axle on stand 99322215) ...546
              REFITTING DIFFERENTIAL (with axle on stand 99322215)...546
              REPAIRING DIFFERENTIAL...547
                Removing differential lock...547
                Dismantling differential casing...548
                Dismantling gear cage...549
                Dismantling bevel pinion support...549
                Checking differential components...553
                Assembling gear cage...553
                Specimen calculations...555
                Assembling differential casing...555
              ADJUSTING THE CAP GAP...557
              CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)...560
            Axles in Tandem (Rear) Meritor RR 167 E (R 0878)...563
              DESCRIPTION...565
              CHARACTERISTICS AND DATA...565
              TIGHTENING TORQUES...567
              TOOLS...569
              OVERHAULING REAR AXLE ASSEMBLY RR 167 E (R 0878)...575
      SECTION 8 -  Axles...577
        Axles...577
          Front axle...579
            Front axle 5876/4 (F 8021) 5876/5 (F 8021) Steering central added axle 5876/2 (F 8021)...579
              DESCRIPTION...581
              SPECIFICATIONS AND DATA...582
              FAULT DIAGNOSIS...584
              TIGHTENING TORQUES...586
              TOOLS...589
              REMOVING AND REFITTING FRONT AXLE...593
                Vehicles with mechanical front suspension...593
                Removal...593
                Refitting...593
              REMOVING AND REFITTING FRONT AXLE...594
                Vehicles with pneumatic front suspension and longitudinal bars...594
                Removal...594
                Refitting...595
              VEHICLE CHECKS...596
                Tie rods...596
                Swivel heads...596
              CHECKING SWIVEL HEAD PLAY...596
              FRONT AXLE ASSEMBLY OVER- HAUL...597
              REMOVING - REFITTINGWHEEL HUBS...597
                Removal...597
                Replacing wheel hub bearings...598
                Replacing wheel fixing pins...599
                Refitting wheel hubs...599
                Checking wheel hub bearing end float...599
                Measuring rolling torque...600
              REMOVING AND REFITTING TRANSVERSE TIE ROD ...600
              REPLACING TRANSVERSE TIE ROD SWIVEL HEADS ...601
              REMOVING AND REFITTING LEVERS FOR LONGITUDINAL TIE ROD ...601
              REMOVING - REFITTING LEVER FOR TRANSVERSE TIE ROD...601
              REMOVING AND REFITTING PIN FOR STUB AXLE...601
                Removal...601
                Replacing kingpin bearing...602
                Checking and adjusting clearance between stub axle and axle...603
              CHECKING AND MEASURING THE AXLE BODY...604
                Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins...604
                Checking angle of holes for kingpins...605
            Axle 5876 (F 8021)...607
              DESCRIPTION...609
              SPECIFICATIONS AND DATA...610
              TIGHTENING TORQUE...611
              TOOLS...612
              FRONT AXLE ASSEMBLY OVERHAUL...616
              REMOVING - REFITTINGWHEEL HUBS...616
                Removal...616
                Refitting wheel hubs...617
          Rear axle...619
            Additional rigid rear axle 55080...619
              DESCRIPTION...621
              CHARACTERISTICS AND DATA...621
              TIGHTENING TORQUES...622
              TOOLS...623
              REPAIR OPERATIONS...625
            Additional rigid rear axle 56082/1...627
              CHARACTERISTICS AND DATA...629
              TIGHTENING TORQUES...630
              TOOLS...631
            Pneumaically lifted steering additional rear axle (57080)...633
              CHARACTERISTICS AND DATA...635
              TIGHTENING TORQUES...637
              TOOLS...638
              REPAIR OPERATIONS...642
              PNEUMATIC LIFT GENERAL...642
              GENERAL INFORMATION...642
              LOCATION OF THE MAIN HYDRAULIC SYSTEM COMPONENTS ON THE VEHICLE...643
              HYDRAULIC SYSTEM...644
              HYDRAULIC SYSTEM OUTLINE DIAGRAM...645
              VEHICLESWITH REAR AIR SPRING SUSPENSIONS AND PNEUMATIC LIFT...646
                Location of the main components on the vehicle...646
                Pneumatic principle diagram, rear air spring suspensions and pneumatic lift for additional axles with single wheels...647
                  FAULT DIAGNOSIS...648
                  TIGHTENING TORQUES (Steering and lifting device linkage)...651
                  CHARACTERISTICS AND DATA...652
                    Steering and third axle hydraulic system...652
                  MAIN HYDRAULIC SYSTEM COMPONENTS...653
                  HYDRAULIC ACCUMULATOR...653
                    Nitrogen pressure checking and recharging...653
                  OPERATOR CYLINDER...653
                    Disassembly...654
                    Assembly...654
                    Checking cylinder oil sealing on the vehicle...654
                  CENTRING CYLINDER...654
                    Disassembly...655
                    Assembly...655
                    Checking cylinder oil sealing on the vehicle...655
                  ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING...656
                    Removal...656
                    Refitting...656
                  AIR BLEEDING FROM THE HYDRAULIC CIRCUIT...657
                    Filling up and bleeding the power steering hydraulic circuit (circuit 1)...658
                    Filling up and bleeding the power steering hydraulic circuit (circuit 2)...658
          Wheel geometry...659
            GENERAL INFORMATION...661
              Steering wheel angles...661
            FRONTWHEEL GEOMETRY (4X2 vehicles)...662
              Positioning clips and headlights...662
              Electronic compensation of rim eccentricity...663
              Wheel alignment...663
              Checking wheel toe-in...664
              Checking wheel deviation...664
              Checking camber...664
              Checking kingpin angle and caster...665
              Checking rear axle alignment...666
            VEHICLE WHEEL GEOMETRY WITH CENTRAL ADDED AXLE (6X2 C)...666
              Checking steering angles...668
              Vehicle wheel geometry with steering rear added axle and pneumatic lifting...668
      SECTION 9 - Suspensions...671
        SUSPENSIONS...675
          DESCRIPTION...675
            Mechanical front suspension...675
            Air spring front suspension...675
            Air spring rear suspension...675
            Mechanical rear suspension...675
          FRONT SUSPENSION CHARACTERISTICS AND DATA...676
            Front leaf spring (vehicles with mechanical suspension)...676
            Front leaf spring (vehicles with air spring suspension)...677
            Leaf spring for additional central axle (vehicles with air spring suspension)...678
            Rear leaf spring (6x4 vehicles)...679
            Front shock absorbers...681
            Rear shock absorbers...682
          CHECKING SHOCK ABSORBERS BRAKING CAPACITY...683
          MECHANICAL FRONT SUSPENSION ASSEMBLY...685
          MECHANICAL REAR SUSPENSION ASSEMBLY...687
          REAR CANTILEVER SUSPENSION (6X2 - 6X4 vehicles) ...688
            Removing-reassembling the central support...688
            Removing-reassembling the central support shaft...688
            Replacing the bearings...688
            Removing-reassembling the bracket...688
            Removing the central support...688
            Removing the central support shaft...688
            Replacing the bracket...688
            Replacing the half bearings...688
            Reassembling the bracket...689
            Reassembling the central support shaft...690
            Reassembling the central support...690
          AIR SUSPENSION...692
            Chassis frame lifting, lowering and self-levelling with remote control ...692
            Saving Levels...692
          AIR SPRING SUSPENSION ASSEMBLIES...693
            Front air spring suspension for 4x2 vehicles: MP190E39/FP, LD440E43T/FP...693
            Front air spring suspension for 6x2P vehicles: LD260E43Y/FS - 43Y/FP...693
            Additional central axle air spring suspension for 6x2C vehicles: LD440E43TX/P...694
            Rear air spring suspension for 4x2 vehicles: LD190E39/P - 43/P, MP190E39/FP...694
            Rear air spring suspension for 4x2 vehicles: MP440E39T/P, LD440E43T/P...695
            Rear air spring suspension for 4x2 vehicles: LD440E43T/FP...695
            Rear air spring suspension for 6x2C vehicles: LD440E43TX/P...696
            Rear air spring suspension for 6x2P vehicles: MP-LD260E43Y/P...696
            Rear air spring suspension for 6x2P vehicles: LD260E43Y/FS-43Y/FP...697
            Rear air spring suspension for 6x4 vehicles: 260E..Z/P - 440E..TZ/P...697
          ATTITUDE VALUES...698
            In self-levelling conditions...698
          AIR SUSPENSION SYSTEM DIAGRAMS...700
            Rear air suspension main diagram for 4X2P vehicles...700
            Air suspension main diagram for 4x2FP vehicles...701
            Rear air suspension main diagram for 4X2T/P vehicles...702
            Air suspension main diagram for 4x2T/FP vehicles...703
            Suspension main diagram for 4x2 FP-CT/FP-GV/FP-D vehicles...704
            Suspension main diagram for 4x2FP-CM vehicles...705
            Rear air suspension main diagram for 6x2Y/PS vehicles...706
            Rear air suspension main diagram for 6x2Y/PT vehicles...707
            Air suspension main diagram for 6x2Y/FP/FS/FT vehicles...709
            Air suspension main diagram for 6x2TX/P vehicles...710
            Air suspension main diagram for 6x2Y/FP/FS-GV/FS-D vehicles...711
            Air suspension main diagram for 6x2Y/FP/FS-CM vehicles...712
            Air suspension main diagram for 6x4 Z/P - HM vehicles...713
            Air suspension main diagram for 6x4 TZ/P - HM vehicles...714
          TIGHTENING TORQUES...715
            Mechanical front suspension...715
            Pneumatic front suspension...716
            Pneumatic front suspension with bars...717
            Additional central axle air suspension 6x2C vehicles...718
            Rear air suspensions 4x2 + 6x2 C vehicles...719
            Rear air suspensions 6x2 P/PT/FT vehicles...721
            Rear air suspensions 6x2 P/PF/FS vehicles...722
            Rear air suspensions 6x2 P vehicles...723
            Rear air suspensions 6x4 vehicles...724
          TOOLS...726
          CHARACTERISTICS AND DATA...730
            Relief valve...731
          IDRAULIC SYSTEM MAIN COMPONENTS...731
            Pneumatic system...730
            Diagnostic...731
            Level sensor...731
            Electropneumatic distributor...732
            Suspension pressure gauge...732
            Air low pressure manometer switch...732
            Air spring...732
          DIAGNOSTIC...733
            Diagnosis Instruments...733
            Blink code table for ECAS .4X2 /6X4. suspension control unit...735
            Blink code table for ECAS 6X2C suspension control unit...736
            Blink code table for air-operated hoist ECAS 6X2 suspension control unit...737
          REAR SUSPENSIONS...743
            Removal...743
            Refitting...743
          REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM...744
          REMOVING-REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM...744
          REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM...744
          REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM...744
            Removal...744
            Refitting...744
          REPLACING THE SUSPENSION ARM FLEXIBLE PIN...745
            Removal...745
            Refitting...745
          STABILIZER BAR...746
          FRONT STABILIZER BAR...746
          CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)...746
          REAR STABILIZER BAR...746
          REAR ADDED AXLE STABILIZER BAR (6x2P vehicles)...746
            Removal...746
            Refitting...746
          RUBBER BUSHINGS...749
            Replacing front stabilizer bar rubber bushings...749
            Replacing rear stabilizer bar rubber bushings...749
          SHOCK ABSORBERS...750
            Removal-refitting...750
            Front axle shock absorbers (6x2 C vehicles)...750
            Central added axle shock absorbers...750
            Rear axle shock absorbers...750
            Rear added axle shock absorbers (6x2 P vehicles)...750
            Removal...750
            Refitting...750
      SECTION 10 - Wheels and tyres...751
        Wheels and tyres...751
          DESCRIPTION...753
          CHARACTERISTICS AND DATA...753
            Tyre inflation pressures...753
          TOOLS...754
          FAULT DIAGNOSIS...754
          STATIC BALANCING OF THE WHEELS...757
          CORRECTING RESIDUAL STATIC IMBALANCE...758
          TYRE PRESSURE...758
          HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE...759
      SECTION 11 - Steering system...761
        Steering system...761
          DESCRIPTION...763
            4x2 vehicle control diagram (mechanical front suspension)...764
            4x2 FP - 6x2 FP Vehicle steering control diagram with front air suspension and leaf spring...765
            4x2 - 6x2 FP Vehicle steering control diagram with front air suspension and longitudinal bars...766
            6x2 C Vehicle steering control diagram with auxiliary central axle...767
            6x2p (steering rear axle) Vehicle steering control diagram with front mechanical suspension...768
            6x2p (steering rear axle) Vehicle steering control diagram with front air suspension and longitudinal bars...769
            6x2p (steering rear axle) Vehicle steering control diagramwithfront air suspension andand leaf spring...770
          CHARACTERISTICS AND DATA...774
          FAULT DIAGNOSIS...775
          TIGHTENING TORQUES...780
          TOOLS...781
          REMOVING AND REFITTING THE POWER STEERING UNIT...783
            Removal...783
            Refitting...784
            Removing-Fitting the Steering Lever...784
          REMOVING AND REFITTING THE STEERING CONTROL ASSEMBLY...785
            Removal...785
            Refitting...786
          BLEEDING AIR FROM THE POWER STEERING CIRCUIT...787
          MEASURING PLAYS IN THE STEERING BOX DETECTED ON THE STEERINGWHEEL ...787
          CHECKING THE POWER STEERING SYSTEM MAXIMUM PRESSURE...787
          ADJUSTING THE HYDRAULIC STEERING LIMITING DEVICE...787
            Checking the hydraulic limiting of steering with vehicle running...788
            Setting the automatic hydraulic steering limit...788
            Checking...788
      SECTION 12 - Pneumatic system - Brakes...789
        Pneumatic system - Brakes...789
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...793
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)...794
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)...800
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)...801
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)...802
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...803
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)...804
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)...805
          SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)...806
          PIPES AND COUPLINGS...807
            In general...807
            End forming on rigid pipes...807
            Bending rigid pipes...808
            Cutting rigid pipes...808
            Replacing flexible hoses with threaded couplings...809
            Replacing flexible hoses with quick-connection couplings...810
          BRAKING SYSTEM...812
            Outline diagram for 4x2 vehicles 190 E...P/FP...812
            Outline diagram for 4x2 vehicles 440 E...T/P-T/FP...813
            Outline diagram for 6x2C vehicles 440 E...TX/P...814
            Outline diagram for 6x2P vehicles 260 E...Y/PS - Y/FS - Y/FP...815
            Outline diagram for 6x2P vehicles 260 E...Y/TN...816
            Outline diagram for 6x4 vehicles 260 E...Z/P-HM...817
            ABS-ASR system wiring diagram (for 4x2 vehicles)...818
            ABS-ASR system wiring diagram (for 6x2C vehicles)...819
            ABS-ASR system wiring diagram (for 6x2P vehicles)...820
            ABS-ASR system wiring diagram (for 6x2P Y/TN vehicles)...821
            ABS-ASR system wiring diagram (for 6x4 vehicles)...822
            EBS system wiring diagram (for 4x2 vehicles) 440 E... T/P-T/FP...823
            EBS system wiring diagram (for 6x2C vehicles) 440 E... TX/P...824
            Layout of the main brake system components on the vehicle...825
            Layout of the main ABS-ASR system components on the vehicle...826
            Layout of the main EBS system components on the vehicle...827
          DESCRIPTION...828
            Service braking...828
            Emergency braking...828
            Exhaust braking...828
            Parking brake...828
          BRAKES...828
            Front brakes (KNORR SB7 - SN7 type)...828
            Rear brakes (PERROT type dia. 410 x 180 - 410 x 200) ...828
          DIAGNOSTICS...829
            Diagnosis Instruments...829
            ABS Troubleshooting...831
            EBS Troubleshooting...839
          TIGHTENING TORQUES...875
          TOOLS...878
          SPECIFICATIONS AND DATA - AIR SYSTEM...888
          CHARACTERISTICS AND DATA - BRAKES...895
          CHECKING MAIN BRAKE SYSTEM COMPONENTS...899
          BRAKING SYSTEM MAIN COMPONENTS...901
            Compressor...901
            Head locking screw tightening...901
            Fault diagnosis...902
          A.P.U. (Air Processing Unit)...902
            Distributor with electric (vehicles not fitted with EBS)...903
            Duplex Distributor with electric (vehicles not fitted with EBS) ...903
            Fault diagnosis (vehicles not fitted with EBS)...903
            Triple-control servo-distributor (vehicles not fitted with EBS)...904
            Predominance adjustment...904
          KNORR - BREMSE AC 567 B...904
          WABCO 973009013...904
            Fault Diagnosis...905
            Trailer control servo-distributor (vehicles fitted with EBS ...905
            Relief valve (towing vehicles)...905
            Coupling heads...905
            Parking brake control hand distributor (towing vehicles)...906
            Parking brake control hand distributor (towing vehicles)...906
            Fault Diagnosis (Parking brake control hand distributor (towing vehicles)...906
            Rear axle electro-pneumatic modulator (for vehicles with EBS)...907
            Fault Diagnosis...907
            Relay valve (vehicles not fitted with EBS) ...908
            Axle proportional relay valve (vehicles fitted with EBS)...908
            Fault Diagnosis (vehicles not fitted with EBS)...908
            Exhaust brake control pedal valve...908
            Low-pressure switch...908
            Controlled pressure valve...909
            Fault Diagnosis...909
            Dual stop valve...909
            Pressure test point valve...909
            Diaphragm brake cylinder (for front and added front axle disc brake) ...910
            Diaphragm brake cylinder (for front and added front axle drum brake)...910
            (for front and added front axle Combined brake cylinder ...910
            Combined brake cylinder (for drum brake)...911
            Combined cylinder emergency brake release device ...911
          ANTI-SKID SYSTEMS...912
            Antilock braking system (ABS)...912
            Anti-skid system (ASR)...912
            EBS (Electronic Brake System)...912
            Electronic control unit...913
            Brake antilock distributor...913
            ASR electropneumatic valve...913
            Revolution sensor...913
            Phonic wheels...913
          BRAKE REPAIR...914
            KNORR SB7 type front disk brakes (vehicles not fitted with EBS)...914
            KNORR SBY type front disk brakes (vehicles fitted with EBS)...915
          KNORR SB7 type front disk brakes (vehicles not fitted with EBS)...914
            Operation...918
          CHECKS...918
          KNORR SBY type front disk brakes (vehicles fitted with EBS)...915
          SN7 TYPE DISK BRAKES...916
          CHECKS...918
            Checking the automatic play recovery system efficiency...918
            Checking brake lining thickness...919
            Brake lining replacement...920
          Remov.-fitting back the brake calipers Remover...923
            Remover...923
            Refitting...924
          Removing-fitting the wheel hubs...924
            Removing...924
            Refitting...925
          SB7 BRAKE CALLIPER OVERHAULING...926
            Disassembly...926
            Cleaning and checking the components...926
            Assembly...927
          BRAKE DISC OVERHAULING...928
          BRAKE DISCS TURNING AND GRINDING...928
          FRONT DRUM BRAKES...929
          REAR BRAKES...929
            Disassembly...929
            Assembly...929
          REAR DISK BRAKES...929
          REAR DRUM BRAKES...930
          REAR DRUM BRAKES OVERHAULING...930
            Disassembly...930
            Turning drums...933
            Replacing brake linings...933
      SECTION 13 -  Scheduled Maintenance...937
        SCHEDULED MAINTENANCE...939
        DESCRIPTION...939
          Service plan...939
        OPERATIONS...940
        DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCEWORK...943

Logo