Iveco EuroTech, EuroStar Repair & Service Manual 1992-2002
Complete service repair manual with electrical wiring diagrams for Iveco EuroTech, EuroStar Trucks, with all the technical 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.
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
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
Iveco EuroTech, EuroStar Repair & Service Manual 1992-2002
