Iveco - Euro Trakker 4 - 5 - Manual PDF

TRAKKER EURO 4/5
REPA I R MA NUA L
MECHA NICA L
ELECTRIC/ELECTRONIC
Aquila Trucks Centres
'T||s oocooot ov|oosoata, c|aacto|st|cs, |ostoct|oosaoo
methodologyto performrepair interventions onthevehicle
and itscomponents.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistanceare specificallyqualified andequipped to perform
therepair interventions that are indicated in thisdocument.
Before performinganyintervention, check to have available
the document relating to the vehicle model on which the
intervention is beingperformed and also make sure that all
accidentpreventiondevices,suchas,asaroughguide,goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., areavailableandefficient, and further
make sure that the vehicle is put such a way that an
interventioncan be madeinsafetyconditions.
Makinginterventions strictlyobserving the indications given
here, as well as using specific tooling indicated, assures a
correct repairintervention, executiontimingobservanceand
ooatos' saot.
Eachrepair interventionmust befinalisedto therecoveryof
functionality,efficiencyandsafetyconditionsthat areprovided
byIveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of anyresponsibilityfor Iveco,
and,inparticular,wherethevehicleiscoveredbyaguarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Ivecoisavailabletoprovideall clarificationsnecessarytomake
interventions, as well as to provide indications in cases and
situationsnot included inthis document.
Inthecaseof adifferencebetweenwhat containedhereand
what actually found on the vehicle, please contact Iveco
oot.o' booo a'|o ao |otovoot|oo.'
Copy, evenpartial, of text and drawingsis forbidden.
PublicationEdited by:
IVECO S.p.A.
Customer Service
Lungo SturaLazio, 15
10156Torino (TO) - Italy
Print 603.93.641 - 2
nd
Ed. 2006
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo SturaLazio, 15
10156Torino (TO) - Italy
Producedby:
Manualsforrepairsaresplit into Sections, eachoneof whichismarked byanumeral;thecontentsof thesesections areindicated
inthegeneral table of contents.
Eachsection isgenerallydedicatedto amainUnit (e.g.: engine, gearbox, electricsystem, etc.).
Sectionswithmechanical contentsincludetechnical data, tighteningtorquecollections, tool lists, cooooct|oos o|scooooct|oos o
unitsto/fromthevehicle, overhaulsat thebenchandrelatingtroubleshooting.
Ontheelectric/electronicsystemsectiontherearethedescriptionsof theelectricnetworkandvehicleelectronicsystems,electric
schemes, componentselectriccharacteristics, componentscodesand troubleshootingrelatingto the central unitsspecificof the
electricsystem.
Themanual usesproper symbolsinitsdescriptions; thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular,
therehavebeendefinedaset of symbolsto classifywarningsandaset for assistanceoperations.
PRELIMINARY REMARKS
General danger
It includes thedangers of abovedescribed signals.
Danger of serious damagefor thevehicle
Partial or complete non observance of theseprescriptionscancause serious damages to the vehicleand sometimes
guaranteelapsetoo.
Environment protection
It indicates correct behaviour inorder that vehicleuseisenvironmentallyfriendlyasmuchas possible.
Danger for persons
||ss|o o |oco|oto obsovaoco o t|oso osc|t|oos cao caoso so |oos oaoo o osoos' saot.
SYMBOLS - WARNINGS
It indicates anadditional explanationfor apieceof information.
!
NOTE
Print 603.93.641 Base- November 2006
I
Base- November 2006 Print 603.93.641
II
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fittinginplace
Assembly
Compressionratio
Tightento torque
Tolerance
Weight difference
Tightento torque+anglevalue Rollingtorque
Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fittingpositioncheck
Preload
Measurement
Valuetofind
Check
Number ofrevolutions
Equipment Temperature
Surfacefor machining
Machinefinish
bar
Pressure
Interference
Strainedassembly
Oversized
Higher than .
Maximum, peak
Thickness
Clearance
Undersized
Less than .
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature <0 C
Cold
Winter
Air bleeding
Temperature >0 C
Hot
Summer
Replacement
Original spareparts
Eachtitleor subtitleconcerningoperationsbeingperformedisprecededbyasix-figurenumber namedPRODUCT CODE.
This number represents the PRODUCT CODE referred to bythe repair operation contained in both REPAIR TIMES and
TROUBLECODEdocument.
Asaquickreference thereareshown belowtheguidelines to readthiscode(seeRepair Timing, too).
Product Code:
Thefirst andsecondfiguresidentifythePRODUCT withinmotor vehicle.
Example:
Product 50 = Vehiclechassis;
Product 52 = Axles;
Product 53 = Transmission;
Product 76 = Electricssystem.
Unit Code:
Thethirdand fourthfiguresidentifytheUNIT withinthePRODUCT.
Example:
Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.
Sub-assemblyCode:
Thefifthandsixth figures exactly identifytheSUB-ASSEMBLY andComponent of aUnit within aPRODUCT.
Example:
Unit 01 = Chassis;
Sub-assembly 40 = Chassiscrossmembers;
Sub-assembly 13 = Rotor.
PRODUCT CODE
5 0
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
0 1
4 0
7 6
0 3
1 3
COMPONENT
COMPONENT
COMPONENT
COMPONENT
COMPONENT
III
GENERAL WARNINGS
Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact
immediatesuperiors whereadanger situationoccurswhichisnot described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenancehandbooks. Checkuse stateandsuitabilityof tools not subjectedto regular check.
Themanual handlingofloadsmust beassessedinadvancebecauseit also depends, besidesweight,onitssizeandon
thepath.
Handlingbymechanical means must bewithhoistersproper asfor weight as well asfor shapeandvolume. Hoisters,
ropesandhooksusedmust containclearindicationsonmaximumcarryingcapacityacceptable. Theuseof saidmeans
iscompulsorilypermitted toauthorised personnel only. Staydulyclear of theload, and, anyhow, never under it.
In disassemblingoperations, always observe provided prescriptions; prevent mechanical parts beingtaken out from
accidentallystrikingworkshoppersonnel.
Workshop jobsperformed inpairs must always beperformedinmaximumsafety; avoidoperationswhich couldbe
dangerousfor the co-operator becauseof lackof visibilityor of his/her not correct position.
Keeppersonnel not authorisedto operationsclear of workingarea.
Learnoperationandsafetyknowledgenecessaryrelatingto thevehicleprior toeachinterventiononit. Scrupulously
observe all safetywarnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
|otovoot|oo |as booo co|otoo, booo stat|o o t|o vo||c|o, oo a|| c|oc's |oo|catoo oo aaa| 'Cooto|s
cao o oso' o |so aoo |a|otooaoco |aooboo'.
Inlackofvisibilityinoperatingfromthevehicle, chargeapersononthegroundwithassistance.Donotleaveunmanned
avehicle inmotionduringrepair interventions.
Keepthevehiclestationarybyproper chocks.
Inthecaseofaninterventiononavehicleliftedfromtheground,checkthevehicletobequitesteadyonspecial support
stands and, in thecaseof liftingbymeans of alift, checkmanual/automaticsafeties tobeactivated.
Whenitisnecessarytoperformaninterventiononmethane-fedvehicles,observetheindicationscontainedinsidethe
document, aswell as all specificsafetyregulationsprovided.
Onlyremoveradiator capwhentheengineiscoldbycautiouslyunscrewingit inorder to let systemresidual pressure
out.
Inflammablefuelandall inflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful
materials12-point cards. Refuellingmust beperformedoutdoorswiththeengineoff, avoidinglit cigarettes, freeflames
orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids
accordingtowhat providedbyregulationsinforce. Compulsorilyavoidtousefoodcontainerstostoreharmful liquids.
Avoidtodrill orborepressurisedcontainers, andthrowclothsimpregnatedwithinflammablesubstancesintosuitable
containers.
Worn out, damaged or consumablepartsmust be replaced byIveco original spares.
Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidental liquidoroil spots.
Electricsocketsand electric equipment necessaryto performrepair interventionsmust meet safetyrules.
For everyintervention on vehiclehydraulic, pneumatic, conditioningand AIR - BAG systems, scrupulouslyobserve
indicationsspecified inrelatingmanual sections.
!
IV
GENERAL WARNINGS
Cleanunitsorassembliesdetachedfromthevehicleandcarefullychecktheirintegritybeforeoverhaul.Tidyupdetached
or disassembled partswiththeir securingelements(screws, nuts, etc.) intospecial containers.
Check for theintegrityof theparts which prevent screws frombeingunscrewed: broken washers, dowels, clips, etc.
Self-lockingnutswithaninsert madeof nylonmust alwaysbereplaced.
Avoid contact of rubber partswithdiesel oil, petrol or other not compatiblesubstances.
Beforewashingunder pressuremechanical parts, protect electricconnectors, and central units, if present.
Tighteningscrews andnuts must alwaysbeaccordingtoprescriptions; IVECO commercial and assistancenetworkis
availableto giveall clarificationsnecessaryto performrepair interventionsnot providedinthisdocument.
Beforewelding:
- Disconnectall electroniccentral units,takepowercableoffbatterypositiveterminal (connect it tochassisbonding)
and detachconnectors.
- Removepaint byusingproper solvents or paint removersand cleanrelevant surfices withsoap andwater.
- Await about 15 minutesbefore welding.
- Equipwithsuitablefireresistant protectionstoprotecthosesor othercomponentswherefluidsorothermaterials
flowwhichmaycatch fireeasilyonwelding.
Shouldthevehiclebesubjectedto temperaturesexceeding80 C (dryer ovens), disassembledriveelectroniccentral
units.
Thedisposal of all liquids andfluidsmust beperformed withfull observanceof specificrulesinforce.
Put on,whererequiredbytheintervention, garmentsandprotections provided inaccident preventionrules;contact
with movingparts can cause serious injuries. Use suitable, preferablytight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leavetheengine inmotion at workshoplocationsnot providedwithapipeto scavengeexhaust gasoutside.
Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate
outdoors or in suitablyventilated areas. Put onproper inspirator ifpaint powder ispresent.
Avoidcontact withhot water orsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious
burns.Avoiddirect contactwithliquidsandfluidspresent invehiclesystems;whereanaccidental contact hasoccurred,
refer to12-point cardsfor provisions to make.
V
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
Tostartuptheengine,donotusefastchargers.Startupmust onlybeperformedwitheitherseparatebatteriesorspecial
truck.
A wrongpolarisationofsupplyvoltageindriveelectroniccentral units(forinstance, awrongpolarisationof batteries)
cancausethemto bedestroyed.
Disconnect thebatteries fromthesystemduringtheir rechargingwithanexternal apparatus.
Onconnecting, onlyscrew up connector (temperature sensors, pressuresensors etc.) nuts at prescribed tightening
torque.
Beforedisconnectingthejunctionconnector fromanelectroniccentral unit, isolatethesystem.
Do not directlysupplyelectroniccentral units servo components at nominal vehiclevoltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as closeas possible to chassis/body
structure.
Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording
to original arrangement.
Keymemorisationproceduresareinfluencedbyelectromagneticjamming(mobilephones, etc.). Therefore, duringkey
memorisation:
1 Payattentionthat jammingsources arenot present inthecabor near the keys.
2. Keysnot insered in thepanel must be at least 1meter away.
Ifaninterventionhasto bemadeontheelectric/electronicsystem, disconnect batteriesfromthesystem;inthiscase,
alwaysdisconnect, asafirst one, thechassisbondingcablefrombatteries negativeterminal.
Beforeconnectingthebatteries to thesystem, make surethat thesystemiswell isolated.
Disconnect theexternal rechargingapparatus fromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery
terminals.
Do not causesparks to begeneratedincheckingif thecircuit isenergised.
Do not useatest lampincheckingcircuit continuity, but onlyuseproper control apparatuses.
Makesurethat theelectronicdeviceswiringharnesses(length,leadtype,location, strapping, connectionto screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurementsindriveelectroniccentral units,pluggedconnectionsandelectricconnectionsto componentscanonly
bemadeonpropertestinglineswith special plugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers,
clipsandthelikeinordertoavoidthedangerofcausingashort circuit,aswellasofdamagingpluggedconnections,which
wouldlater causecontact problems.
Beforereplacinganelectroniccontrol unit,verifythewiring.Ifnecessary,contact thelocal T.H.D.(Technical HelpDesk)
for anauthorizationor arecommendationonthepossibleinterventionsbeforereplacing.
Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable
side.
!
NOTE
VI
Inorder to prevent damageor short-circuitingof the on-boardelectroniccontrol units, thefollowingoperationsmust
bealwayscarriedout beforestartinganyweldingoperation onthe chassis.
- If electricweldinghas to bedoneon thevehicle,
isolatetheelectricsystemasfollows:
a) disconnect thepower lead fromthe batterypositiveterminal andconnect it to thechassisearth;
b) disconnect thepower lead fromthebatterynegativeterminal;
c) disconnect theelectroniccontrol unit connectors, takingcaretoavoidtouchingthecontrol unit connector pins.
- Moreover:
a) should it benecessaryto carryout weldingoperationscloseto thecontrol unit, removeit fromitslocation.
b) whenever possible, earththeweldingmachinedirectlyto thepiecethat hasto bewelded.
112514
InthecaseofvehiclesequippedwithaDTCOdigital tachograph,donot disconnect thebatteryleadsandthenconnect
thembyjumpers to reset the electronicsystems.
This operationshouldbeavoided, as it couldcausepermanent damageto theDTCO tachograph CARD or other
on-board electronicsystems.
To reset theelectronicsystemwithout runningrisks, disconnect thevehiclebatteryand wait for 10 minutes.
It isstrictlyforbiddentocarryout anymodificationsor connectionstotheelectroniccontrol unitwiring; inparticular,
thelineinterconnectingdatabetweenthecontrol units (CAN line) must beconsidered as untouchable.
Diagnostic and maintenance operations can only be carried out byauthorised personnel with IVECO approved
equipment.
VII
VIII
Bonding and screening
|oat|vo |oaos cooooctoo to a ssto booooo o|ot ost bo bot| as s|ot aoo oss|b|o aoo 'sta'-cooooctoo to oac| ot|o, t|o
thento havetheir centeringtidilyandproperlymade(Figure1, re. M).
Further, followingwarnings areto be compulsorilyobservedfor electroniccomponents:
- Electroniccentral units must be connectedto systembondingwhenthey areprovided withametallicshell.
- Electroniccentral units negative cables must beconnectedboth to asystembondingpoint such as thedashboard opening
booo|o (avo|o|o 'so|a|' o 'c|a|o' cooooct|oos), aoo to batto ooat|vo to|oa|.
- Analogbonding(sensors), althoughnot connectedto batterynegativesystem/terminal bonding, must haveoptimal isolation.
Consequently, particularlyconsideredmust beparasiticresistancesinlugs: oxidising, clinchingdefects, etc.
- Screenedcircuits braidingmust onlyelectricallycontact the endtowardsthecentral unit enteredbythesignal (Figure2).
- If junction connectorsarepresent, unscreened section d, near them, must beas short aspossible (Figure2).
- Cablesmust bearranged such asto result to beparallel to referenceplane, i.e. ascloseaspossibleto chassis/bodystructure.
1. NEGATIVECABLES'STAR' CONNECTIONTOSYSTEMBONDING M
2. SC||||||CT|C|C ||T/|||C3|/||| |C C| / C/3|| TC /||||CT|C||C CC||C| ||T C. CONNECTOR
d. DISTANCE! 0
88039
Figure1
Figure2
IX
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting
|ostoct|oos (soc||c oocooot '|ostoct|oos o taosoat|oo aoo oaat|oo' |s ava||ab|o at /ss|staoco |ot.o' .o's|os).
It isremindedthat,especiallyabout theelectricsystem,several electricsocketsareprovidedfor asseries(or optional) socketsin
order to simplifyandnormalisethe electrical interventionthat iscareof preparationpersonnel.
|o ao ocot|oo to ooot|o |ostoct|oos, |V|CC's aot|o|sat|oo |s oocossa.
Lack of observance of abovedescribed prescriptionsinvolves guarantee lapse.
It isabsolutelyforbiddento makemodificationsor connectionsto electriccentral unitswiringharnesses; inparticular,
thedatainterconnectionlinebetweencentral units(CAN line) isto beconsidered inviolable.
CONVERSIONSBETWEEN THE MAIN UNITSOF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1kW = 1.36metricHP
1kW = 1.34HP
1metricHP = 0.736kW
1metricHP = 0.986HP
1HP = 0.746kW
1HP = 1.014metricHP
Torque
1Nm = 0.1019 kgm
1kgm = 9.81Nm
Revolutions per timeunit
1rad/s = 1 rpmx 0.1046
1rpm = 1 rad/sx 9.5602
Pressure
1bar = 1.02kg/cm
2
1kg/cm
2
= 0.981 bar
1bar = 10
5
Pa
Whereaccuracyisnot particularly needed:
- Nmunit isfor thesakeofsimplicityconverted into kgmaccordingto ratio 10:1
1kgm = 10Nm;
- bar unit is for thesakeof simplicityconvertedinto kg/cm
2
accordingtoratio 1:1
1kg/cm
2
= 1bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8+32) F
X
Revi - June2007
Print 603.93.641/A Base November 2006
TRAKKER EURO 4/5
Print 603.93.641 2
nd
edition
Base- November 2006
UPDATE DATA
Section Description Page Revision date
1 General 3, 5, 10 17, 19, 20 June2007
2 Engine 8,22,24,52,57,73,86,89,91,97128,143,144,147,168,
171, 174, 175, 180, 197, 203, 211, 214, 219, 222, 282
June2007
3 Clutch 2, 18, 19, 20, 21 June2007
4 Gearboxes 13,14, 16/1 16/6, 18, 18/1 18/2, 20, 20/1 20/6,
22/1 22/30, 23, 26 46, 46/1 46/32, 47 54, 54/1 54/4,
56/1 56/32
June2007
6 Transfer box TC 1800-TC
2200
6, 8, 10 12, 15, 24 June2007
8 Axles 58, 59, 63, 66, 79, 80, 82 86, 88, 90, 91, 92, 93, 96, 136,
162
June2007
13 Pneumaticsystem- Brakes 1, 21/1 21/2, 81 June2007
15 Programmedmaintenance 5 33 June2007
16 ElectricElectronicsystem 2, 6 10, 89, 121/1 121/4, 134/1 134/8, 139 143, 154,
156 161, 193, 198, 237, 258, 275, 284, 287
June2007
Base November 2006 Print 603.93.641/A
Print 603.93.371/A
Section
General 1
Engines 2
Clutch 3
Gearboxes 4
Power take-off 5
Transfer boxTC 1800-TC 2200 6
Propeller shafts 7
Axles 8
Front axles 9
Suspensions 10
Wheelsandtyres 11
Steering 12
Pneumaticsystem- Brakes 13
BodyworkandChassis frame 14
Programmedmaintenance 15
Electric/electronicsystem 16
INDEX OF SECTIONS
GENERAL 1 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Print 603.93.641
SECTION 1
General
Page
VEHICLEIDENTIFICATION DATA 3 . . . . . . . . . .
- Vehicle IdentificationPlate 4 . . . . . . . . . . . . . . . .
- ProductionIdentificationPlate 4 . . . . . . . . . . . . .
COMMERCIAL CODING 5 . . . . . . . . . . . . . . . . . .
P.I.C. NUMBERCODING 6 . . . . . . . . . . . . . . . . . .
VEHICLECONFIGURATION 10 . . . . . . . . . . . . . . .
COMPOSITION OFTHE MODELS 11 . . . . . . . . . .
FILLINGFLUIDS 18 . . . . . . . . . . . . . . . . . . . . . . . . .
- International specificationsof lubricants
and fluids 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Chassis frame
Punching (front on right side member of
chassisframe).
Manufacturers plate
To identify the vehicle in accordance with the E.E.C. directive
(under thefront radiator cowling).
Engine
Plateontheleft rear sideofthecrankcase
Figure1
98878
Revi - June2007
Print 603.93.641/A 3aso |ovobo 2006
VEHICLE IDENTIFICATION DATA
PRINT603.93.641/A
T|o to aoo oobo o oo|oo, to aoo oobo o c|ass|s aoo aooactoo's |ato co|so t|o vo||c|o |ooot||cat|oo oata.
Permissible
grade of
smoke
IVECO MAGIRUSAG
Kg
Kg
Kg
Kg
a)
b)
c)
d)
e)
f)
g)
h)
Type
Wheelbase Correc-
ted
absor-
ption
value
Enginetype
Madein
N
o
ofaxles
Enginepower KW
1-
2-
3-
4-
l)
m)
i)
Kg
Kg
n)
o)
p)
Unit No
Part No
Serial No
P.I.C. No
MadeinGermany-IvecoMagirusAG
9843 8247
Figure2
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
Vehicle Identification Plate
Platelegend
a) Type-approval number marking(if applicable).
b) Vehicleidentificationcodenumber (V.I.N.).
c) Total tractor weight.
d) Total weight of tractor +trailer (if applicable).
e) Permissibleweight limit on 1st axle.
f) Permissibleweight limit on 2ndaxle(if applicable).
g) Permissibleweight limit on 3rdaxle.
h) Permissibleweight limit on 4th axle(if applicable).
i) Specificidentificationof type.
l) Wheelbaseinmm.
m) Enginetype.
n) Enginepower.
o) No. ofaxles.
p) Placeofmanufacture.
Production Identification Plate
ThisplateshowstheP.I.C.(productionidentificationcode
number), which is needed when referring to the spare
parts catalogue(electronicand/or Cd catalogue).
TheP.I.C. isalso givenonthevehiclewarrantycard.
Note: Whenconsultingthe catalogues, useonlythefirst
8digitsof theproduct identificationcodenumber.
TRAKKER
RANGE
NAME
AD 190 T 35
RANGE
CODE
TYPE
OFCAB
SUSPENSIONS
rear pneumatics
.../P
mechanicals
VERSION
Partial drive trucks
All-wheel drivetrucks
AT
AD
|oo /ct|vo T|o
S|ot /ct|vo |a
190
260
Trucks4x2 - 4x4
Trucks6x4 - 6x6
380
340
Trucks6x4 - 6x6
Trucks8x4x4
410
400
Trucks8x4x4 - 8x8x4
Tractors4x2 - 4x4
440
720
Tractors6x4 - 6x6
Tractors6x4 - 6x6
TOTAL
WEIGHT
All-wheel drivetractors WT
Concretemixer truck B
Partial drive tractors T
W
ENGINE
RATING
F2BGF- 310 CV
F2BVGT - 330 CV 33
F2BVGT - 360 CV
F3BWG - 410 CV 41
F3BVGT - 450 CV
F3BVGT - 500 CV 50
31
36
45
|oo /ct|vo T|o |o.
S|ot /ct|vo |a |o.
AT-N
AD-N
Revi - June2007
Print 603.93.641/A
COMMERCIAL CODING
A A B C D B C A
AXLE CONFIGURATION - TOTAL EARTH MASS
A A B C D B C
K
AD
A
L
M
N
P
R
Chassiscab 4x2(18-20ton)
Tractor 4x2(18-20ton)
Chassiscab 6x4- 8 mm(26ton)
Chassiscab 6x4- 10mm(33ton)
Tractor 6x4- 10mm(33 ton)
ENGINE
A B C D B C A A
A
310
B
330
C
360
D
410
E
450
F 500
S
T Chassiscab 8x4- 10mm(32-40ton)
U
Chassiscab 4x4(18-20ton)
V Tractor 4x4(18-20ton)
H
AT
Q
Tractor 6x4- 8mm(26ton)
HABITABILITY
X
G
560
Y
Chassiscab 6x6- 10mm(33ton)
Z
Tractor 6x6- 10mm(33 ton)
W
Chassiscab 8x8- 10mm(32-40ton)
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
P.I.C. NUMBER CODING
A C D B C A
A
B
Mechanical - HR-P
Pneumatic- HR-P
A
B
Mechanical - HR-TL
Mechanical - HR-TM
C
Mechanical - HR-TP
D
Mechanical - SR
A A C D C A B
1
2
7
Chassiscab
Tractor
B
VERSION
Concretemixer
TYPE OF REAR AXLE TYPE OF SUSPENSION
E
Pneumatic- HR-TP
B A
F
Pneumatic- SR
Print 603.93.641 3aso |ovobo 2006
H.R.= Doublereductionrear axle
S.R. = Simplereduction rear axle
T.L. = Light tandemrear axle
T.M.= Mediumtandemrear axle
T.P. = Heavytandemrear axle
7
6
5
C A A C D B A B
WHEELBASE
4
3
2
1
3aso |ovobo 2006 Print 603.93.641
VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE
C 4x2
C 6x6
3500 C 8 x4 4250 C/T 6 x4 3200
C 8 x8
C 8 x4
4750
C 6 x4
C 6 x6
3500
C 6 x6
C 6 x4
3800
T 4 x4
T 4 x2
3800
C 4 x2
C 4 x4
3800
C 8 x4
C 8 x8
5020
C 8 x4 5820
C 4 x2
C 4 x4
C 6 x4
4200
C 4 x2
C 6 x4
4200
C 4 x2
C 4 x4
C 6 x4
4500
C 6 x4 4800
C 4 x2
C 6 x4
5100
C = Chassiscabs
T = Tractors
GEAR SHIFTS
A A D B C A B C
C
B
A
DRIVE BRAKE COMBINATION
A A B C A B C D
C
B
A
1
2
3
Print 603.93.641 3aso |ovobo 2006
16M
9M
Eurotronic- 12M
DRIVE
BRAKES
DRIVE
FRONT REAR
Right Disc Drum2D Right Disc Drum2D
Right Disc Disc Right Disc Disc
Right Drum2D Drum2D Right Drum2D Drum2D
Left Disc Drum2D Left Disc Drum2D
Left Disc Disc Left Disc Disc
Left Drum2D Drum2D Left Drum2D Drum2D
4x2 = Vehicles withtwo axleswith rear drivingaxle. 4x4 = Vehicleswithtwoaxleswithfront andreardriving
axle.
Figure3
Figure4
6x4 = Vehicleswith threeaxleswith two rear drivingaxles(in Tandem).
Figure5
6x6 = Vehicleswiththreeaxleswithfront axleand two rear drivingaxles (in Tandem).
Figure6
8x4x4 = Vehicles withfour axles: first andsecond steeringaxles, third andfourthdrivingaxles (inTandem)
8x8x4 = Vehicles withfour drivingaxleswithfirst andsecondsteeringaxles andtworear axles(in Tandem)
119160
119161
119162
119163
Revi - June2007
3aso |ovobo 2006 Print 603.93.641/A
Print 603.93.641/A
VEHICLE CONFIGURATION
Revi - June2007
COMPOSITION OF THE MODELS
MODELS4x2
GROUPS/CABIN
F2BE3681C (310 CV)
F2BE3681B(330 CV)
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
Pushing one-disc 17
Pulling one-disc 17
9S1310TO
16S1620 TD
16S2220 TO
16S2520 TO
12AS1930TD
12AS2330TO
5886/D:
451391/2DJ
ZF 8098
Front mechanic
Rear mechanic
Rear air
Cabintype
AT/AD
Cabintype
AT-N/AD-N
: Withdisc brakes
J With Duo Duplexdrumbrakes
Revi - June2007
MODELS4x4
GROUPS/CABIN
1
F2BE3681C (310 CV)
F2BE3681B(330 CV)
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
Pushing one-disc 17 f f f f
Pulling one-disc 17
9S1310TO
16S1620 TD
16S2220 TO
12AS1420 TD *
12AS1930 TD
12AS2330 TO
T C 1800
T C 2200
FRONT
5985/2DJ
REAR
451391/2DJ
ZF 8098
Front mechanic
Rear mechanic
Posteriori pneumatiche
Cabin type
AT/AD
Cabintype
AT-N/AD-N
J Drumbrakes Duo Duplex
f Onlyfor 9S1310TO gearboxes
* Availableonlywithout Intarder
(continue)
Revi - June2007
MODELS6x4
GROUPS/CABIN
F2BE3681B(330 CV)
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
Pushing one-disc 17
Pulling one-disc 17
9S1310TO
16S1620 TD
16S2220 TO
16S2520 TO
12AS1420 TD Y
12AS1930 TD
12AS2330 TO
5886/D:
INTERMEDIATE452146/2DJ
REAR452146/2D J
REAR453291/2D J
TANDEM
REAR452191/2D J
INTERMEDIATEMT 23-155/2DJ
REARMT 23-155/2D J
INTERMEDIATE MT 23-155/D :
REARMT 23-155/D :
ZF 8098
Front mechanic
Rear mechanic
Rear air
Cabintype
AT/AD h h h h h h h
Cabintype
AT-N/AD-N h h h h h h h
: Withdisc brakes
Onlyon vehicles withright-handsteering
Onlyfor 9S1310TO gearboxes
Y Availableonlywithout Intarder
j CabintypeAD or AD-N
Revi - June2007
MODELS6x4
GROUPS/CABIN
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
Pulling one-disc 17
16S2220 TO
16S2520 TO
12AS2330 TO
12AS2530 TO
5886/D:
TANDEM REAR452191/2D J
REAR453291/2D J
ZF8098
Front mechanic
Rear mechanic
Rear air
Cabin type
AT/AD
Cabintype
AT-N/AD-N
: Withdisc brakes
Revi - June2007
MODELS6x6
GROUPS/CABIN
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
|o|||o ooo-o|sc +'
16S1620 TD
16S2220 TO
12AS1930 TD
12AS2330TO
T C 1800
T C 2200
FRONT
5985/2D J
TANDEM
REAR452191/2D J
REAR453291/2D J
ZF 8098
Front mechanic
Rear mechanic
Cabintype
AT/AD
Cabintype
AT-N/AD-N
Revi - June2007
MODELS8x4
GROUPS/CABIN
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
|o|||o ooo-o|sc +'
16S1620 TD
16S2220 TO
16S2520 TO
12AS1930TD
12AS2330TO
1 5886/D:
2 5886/D:
INTERMEDIATE452146/2D J
REAR452146/2D J
REAR
REAR453291/2D J
REAR
REAR452191/2D J
INTERMEDIATEMT 23- 155/2D J
REARMT 23- 155/2D J
INTERMEDIATEMT 23 - 155/D :
REARMT 23- 155/D:
ZF 8099
Front mechanic
Rear mechanic
Posteriori pneumatiche
Cabin type
AT/AD h h h h h h h
Cabin type
AT-N/AD-N h h h h h h h
: Withdisc brakes
Onlyon vehicles withright-handsteering
Revi - June2007
MODELS8x8
GROUPS/CABIN
F3BE3681C (450 CV)
|o|||o ooo-o|sc +'
16S2220 TO
12AS2330TO
TC 2200
FRONT 5985/2DJ
REAR
REAR453291/2DJ
ZF 8099
Front mechanic
Rear mechanic
Cabintype
AD
Cabintype
AD-N
J WithDuo-Duplexdrumbrakes
3aso |ovobo 2006 Print 603.93.641
Print 603.93.641
PRINT603.93.641
FILLING FLUIDS
LUBRICANTSRECOMMENDED BY IVECO PARTSTO BEFILLEDUP
Quantity
Liters Kg
UraniaFE 5W30
1
UraniaLD7
Engine F2B
Total capacity 1st filling: 28 25.2
Capacity:
- enginesumpminlevel
- enginesumpmaxlevel
- circulatingquantitynot return-
ingto sump
- quantity contained in the car-
tridge filter (to add when re-
placingthecartridge filter)
12.5
23
5
2.5
11.2
21
4.5
2.3
UraniaFE 5W30
1
UraniaLD7
EngineF3B
Total capacity 1
st
filling 35 31.5
Capacity:
- enginesumpat minimumlevel
- enginesumpatmaximumlevel
- quantity in circulation that
does not returnto sump
- quantitycontainedincartridge
filters (to add when changing
thecartridgefilters)
20
28
7
3
18
25.2
6.3
2.7
7.6
18.9
9.9
16.6
11.7
19.3
9.9
10.8
18.9
8.5
21
11
18.5
13
21.5
11
12
21
Gearbox
ZF 9S1310TO*
ZF 9S1311TO*
ZF 16S1620 TD*
ZF 16S1621 TD*
ZF 16S2220TO/2520TO*
ZF 16S2221TO/2521TO*
ZF 12AS1420TD*
ZF 12AS1930TD/2330 TO*
ZF 12AS1931TD/2331 TO*
* Quantity1
st
filling
TutelaTruckFE- gear
TutelaZC 90
TutelaZC 90
Tutela GI/A for arctic
climate
Transfer box TC 1800 (32180)
TC 2200 (32220)
6.5
6.5
5.5
5.5
(1) IVECO recommendsusingtheseoils for better fuel economy.IVECO supplieseachnewvehiclereadyfilledwith thistypeof
lubricant Also designedfor cold climates (minimumtemperaturedownto -30).
Revi - June2007
Print 603.93.641/A
FILLING FLUIDS
Quantity
LUBRICANTSRECOMMENDED BY IVECO PARTSTO BEFILLED UP
Liters Kg
Axle5886/D (for each hub) 0.35 0.32
Front axle5985/2D 5 4.5
Front axlewheelsreduction unit 5985/2D 0.75 0.68
Rear axle451391/2D 16 14.5
TutelaW140/M-DA
TutelaW90/M-DA
1
Axlein tandem453291/2D:
- (intermediate +transm.)
- rear
27
16
24.3
14.5
TutelaW90/M-DA
1
27
16
24.3
14.5
- rear
13
11.5
11.7
10.5
Axlein tandemMT 23-155:
- rear
20
18.5
18
16.6
TutelaGI/A
Power steering 2.7*
13.5**
2.4
12
* Excludingvehicleswithsteeringrear axle
** For vehicles withsteeringrear axleonly
TutelaTRUCK
DOT SPECIAL
Clutchcircuit
(excludingvehicleswithEuro Tronicgearbox)
0.5 0.45
Water+Paraflu
11
Coolingsystem
EngineF2B Total capacity*
EngineF2BwithIntarder Total capacity*
EngineF3B Total capacity*
EngineF3BwithIntarder Total capacity*
34
50
44
64
30.6
45
39.6
58
* =Protectiveanti-freeze
(coocootat|oo 50 ooz|o o|ot 35 C)
TutelaLHM
Cabtiltingsystem 0.6 0.54
* =Protectiveanti-freeze
(coocootat|oo 50 ooz|o o|ot 35 C)
(1) Specificfor cold climates
(+) |V|CC ocoooos os|o t||s to o o||s toobta|o booo|ts |o tos o 'oo| ocooo'. T|o oo. vo||c|o |s a|oao ooo|oo
byIVECO withthistypeof lubricants(also adequatefor cold climatemin. temperatureupto -30 C).
Thesequantities arenot determinant. Theexact checkto bedonewhenchecking levels.
Revi - June2007
Print 603.93.641/A
International specifications of lubricants and fluids FL Products
Engineoil
Meets thespecifications:
ACEA E4 with a totallysynthetic base SAE 5W 30
IVECO Standard18-1804
ACEA E7 withamineral base SAE 15W 40
IVECO Standard18-1804T2E7
URANIA FE 5W30 (1)
UraniaLD7
Oil for total power takeoff (Multi-power)
Containingnon-EPanti-wear additives
Complies with thefollowingspecification:
API GL5withamineral base SAE 80W90
TutelaZC 90
Oil for differential gear and wheel hubs
API GL5withamineral base SAE 85W 140
TutelaW140/M-DA (hot or mildclimates)
TutelaW90/M-DA (coldclimates)
Oil for mechanical gearboxes
Containingnon-EPanti-wear additives
API GL4 with atotally synthetic base SAE 75W 80
TutelaTruck FE-Gear (1)
TutelaZC 90
Oil for hydrostatic transmissionand power steeringoil
A.T.F. DEXRON II D
A.T.F. DEXRON III
TutelaGI/A
TutelaA.T.F. 90
Greasefor general use
withbaseof lithiumsoap, consistencyN.L.G.I. no. 2
TutelaMR 2
Greasefor bearings and wheel hubs
withbaseof lithiumsoap, consistencyN.L.G.I. no. 3
TutelaMR 3
Fluidfor hydraulic brakes andclutchcontrol
complies withstandards: N.H.T.S.A. N. 116ISO 4925-Std. SAEJ 1703
CUNA NC 956-01- IVECO STANDARD 18- 1820
TutelaTRUCK DOT SPECIAL
Mineral oil for hydrauliccircuits
complies withstandards: IVECO STANDARD 18-1823 TutelaLHM
Windshieldwasher liquid,
mixtureof alcohols, water andsurfacetensioners
CUNA NC 956-11
TutelaProfessional SC 35
Greasefor centralised lubrication systems
withbaseof lithiumsoap (syntheticbase), N.L.G.I. no. 2.
Operatingtemperatures: -30 C to+140 C
TutelaCOMAR 2
Mineral oil for hydrauliccircuits
complies withstandard: IVECO STANDARD 18-1830
to beused diluted withwater at 50%
Paraflu
11
1 TRAKKER EURO 4/5 ENGINES
SECTION 2
Engines
Page
- F2BEngine 3 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- F3BEngine 123 246 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Hydrocar pressuretake-off ontimingsystem
(P.T.O. - Optional) 247 250 . . . . . . . . . . . . . . . . . . . .
- Denox 2system 251 258 . . . . . . . . . . . . . . . . . . . . . .
- Diagnosis 259 292 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 TRAKKER EURO 4/5 ENGINES
F2BENGINE 3 TRAKKER EURO 4/5
F2B Engine
Page
VIEWSOFTHEENGINE 8 . . . . . . . . . . . . . . . . . . . .
MAIN DATA 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY CLEARANCEDATA 15 . . . . . . . . . . . . . .
TIGHTENINGTORQUES 22 . . . . . . . . . . . . . . . . . . .
TOOLS 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL - REFITTING 39 . . . . . . . . . . . . .
- Removal 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fillingthecoolingsystem 41 . . . . . . . . . . . . . . . . .
- Bleedingair fromthefuel system 42 . . . . . . . . . . .
- Checksandtests 42 . . . . . . . . . . . . . . . . . . . . . . .
ELECTRO-MAGNETIC FAN DRIVEREPLACEMENT 43 . .
- Removal 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLINGTHEENGINE 47 . . . . . . . . . . . . . . .
REPAIR OPERATIONS 54 . . . . . . . . . . . . . . . . . . . . . .
CYLINDERBLOCK 54 . . . . . . . . . . . . . . . . . . . . . . . . .
- Checksandmeasurements 54 . . . . . . . . . . . . . . .
CYLINDER LINERS 55 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingcylinder liners 56 . . . . . . . . . . . . . . . . . .
- Removal 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingandcheckingprotrusion 56 . . . . . . . . . . . .
CRANKSHAFT 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringmainjournals andcrank pins 58 . . . . . .
PRELIMINARY MEASUREMENT OFMAIN ANDBIG
ENDBEARINGSHELL SELECTION DATA 59 . . . .
- Replacingthe valvedrivegear and theoil pump
drivegear 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingmainjournal installationclearance 66 . . .
- Checkingcrankshaft endfloat 67 . . . . . . . . . . . . .
PISTON-CONNECTINGRODASSEMBLY 68 . . . . . .
- Removal 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringthediameter of thepistons 69 . . . . . . .
4 F2BENGINE TRAKKER EURO 4/5
Page
- Conditions for correct gudgeonpin-
pistoncoupling 69 . . . . . . . . . . . . . . . . . . . . . . . . .
- Pistonrings 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD 71 . . . . . . . . . . . . . . . . . . . . . . .
- Checkingconnectingrod squareness 72 . . . . . . . .
- Fittingtheconnectingrod-pistonassembly 72 . . . .
- Fittingthepiston rings 72 . . . . . . . . . . . . . . . . . . .
- Fittingtheconnectingrod-pistonassemblyinto
thecylinder liners 73 . . . . . . . . . . . . . . . . . . . . . . .
- Pistonprotrusion check 73 . . . . . . . . . . . . . . . . . .
- Checkingassemblyclearanceof bigend pins 74 . .
CYLINDERHEAD 74 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Dismountingthevalves 74 . . . . . . . . . . . . . . . . . . .
- Checkingtheplanarityoftheheadon
thecylinder block 74 . . . . . . . . . . . . . . . . . . . . . . .
VALVE 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingdust and checkingthevalves 75 . . . . . .
VALVEGUIDES 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingof valveguides 76 . . . . . . . . . . . . . . . . .
- Replacing- Reamingthevalveseats 76 . . . . . . . . .
REPLACINGINJECTORHOLDERS 76 . . . . . . . . . . . .
- Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingprotrusion of injectors 78 . . . . . . . . . . . .
TIMINGGEAR 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft drive 79 . . . . . . . . . . . . . . . . . . . . . . . . .
- Intermediate gear pin 79 . . . . . . . . . . . . . . . . . . . .
- Idler gear 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Twinidler gear 79 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe bushings 79 . . . . . . . . . . . . . . . . . . .
- Camshaft 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingcamlift andpin alignment 80 . . . . . . . . .
- Bushes 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingcamshaft bushesusingbeater 99360487 82
Page
- Removal 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVESPRINGS 83 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingthevalvesand oil seal ring 83 . . . . . . . . . . .
ROCKERSHAFT 84 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Shaft 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rocker 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THEENGINE 85 . . . . . . . . . . . . . . . . . .
DIAGRAMSHOWINGTHE LOWERCRANKCASE
FIXINGSCREWSTIGHTENINGORDER 87 . . . . .
- Fittingtheconnectingrod-pistonassemblyinto
thecylinder liners 88 . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingflywheel 91 . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingcamshaft 92 . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingpump-injectors 93 . . . . . . . . . . . . . . . . . . . .
- Fittingrocker-armshaft assembly 93 . . . . . . . . . . .
- Camshaft timing 94 . . . . . . . . . . . . . . . . . . . . . . . .
- Phonicwheel timing 96 . . . . . . . . . . . . . . . . . . . . .
- Intakeand exhaust rocker clearanceadjustment and
pre-loadingof rockerscontrollingpumpinjectors 97
ENGINE COMPLETION 98 . . . . . . . . . . . . . . . . . . . .
LUBRICATION 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pump 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Safetyrelief valve 103 . . . . . . . . . . . . . . . . . . . . . . .
- Oil overpressurevalve 104 . . . . . . . . . . . . . . . . . . .
- Heat exchanger 104 . . . . . . . . . . . . . . . . . . . . . . . .
- By-passvalve 105 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostaticvalve 105 . . . . . . . . . . . . . . . . . . . . . .
- Engineoil filters 105 . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Valveintegrated inpiston coolingnozzle 106 . . . . .
COOLING 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagneticfandrive 109 . . . . . . . . . . . . . . . . .
- Water pump 109 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat 110 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER 112 . . . . . . . . . . . . . . . . . . . . . . . . .
VGT TURBOCHARGER 112 . . . . . . . . . . . . . . . . . . . . .
- Actuator 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Solenoidvalvefor VGT control 113 . . . . . . . . . . . .
REPAIRINGACTIONS 113 . . . . . . . . . . . . . . . . . . . . . .
- Variablegeometrymovement control 114 . . . . . . .
- Checkingtheactuator 114 . . . . . . . . . . . . . . . . . . .
- Checkingactuator travel 115 . . . . . . . . . . . . . . . . . .
- Cleaningturbinebody 115 . . . . . . . . . . . . . . . . . . .
FUELSYSTEM 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overpressurevalve 119 . . . . . . . . . . . . . . . . . . . . .
- Feedpump 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injector-pump 120 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacinginjectors-pump 120 . . . . . . . . . . . . . . . . .
- Injector Phases 121 . . . . . . . . . . . . . . . . . . . . . . . . .
F2BENGINE
Figure1
78840
F2BENGINE 7 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Level of Gas Emissions
Engine torqueandpower level
ENGINE
F 2 B E 3 6 8 1 A * P 0 0 1
-
Indicates the enginefamily
Progressiveproduction number
Engine familyevolution (also irrespectiveof thedisplacement)
Engine
Stroke andcylinder position
(3=4 stroke, vertical with post - treatment)
Number of cylinders
Fuel feed+injection(TCA,direct injectiondiesel engine)
Use(egI =truck)
Variant
TYPE PART NUMBER
A
B
360 CV/1500Nm
330 CV/1400Nm
C 310 CV/1300Nm
P
M
Euro 4- 2006
Euro5- 2006
R
S
Euro4- 2007
Euro5- 2007
Revi- June2007
8 F2BENGINE TRAKKEREURO 4/5
PRINT603.93.641/A
VIEWS OF THE ENGINE
Max OUTPUT 230kW at 2400 rpm
Max TORQUE 1300Nm at 1200 to 1675 rpm
310HP
132 kgm
F2BE3681C: POWER-TORQUE CURVES
108514
Figure2
rpm
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
F2BE3681B: POWER-TORQUE CURVES
108515
330HP
143 kgm
Figure3
rpm
3aso |ovobo 2006 Print 603.93.641
F2BE3681A: POWER-TORQUE CURVES
108516
360HP
153 kgm
Figure4
rpm
Print 603.93.641 3aso |ovobo 2006
3aso |ovobo 2006 Print 603.93.641
MAIN DATA
Type F2BE3681C F2BE3681B F2BE3681A
Cycle 4-strokeDiesel engine
Fuel feed Tu rbocharged with aftercooler
Injection Direct
No of cylinders 6 in line
Bore mm 115
Stroke mm 125
+ + +.. =Total displacement cm
3
7790
Compressionratio 16 0.8
Max. output kW
(HP)
230
(310)
245
(330)
265
(360)
rpm 2400 2400 2400
Max. torque Nm
(kgm)
1300
(132)
1400
(143)
1500
(153)
rpm
1200 1675 1080 1655 1200 1685
Engine idlingspeed
no load
rpm 600 50
Maximumengine
speed no load
rpm 2660 50
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Type F2B
A
B
VALVE TIMING
opens beforeT.D.C. A
closesafter B.D.C. B
17
31
C
D
opens beforeB.D.C. D
closesafter T.D.C. C
48
9
X
For timingcheck
mm
X
mm
Running
mm
X
mm
_
_
0.35to 0.45
0.35to 0.45
FEED
Throughfuel pump- Filters
Injection
typeBosch
With electronicallyregulatedinjectors UIN2
pumpinjectors controlledbyoverheadcamshaft
Nozzletype Nozzletype _
Injection order 1- 4- 2- 6- 3- 5
bar
Injection pressure bar
1600
3aso |ovobo 2006 Print 603.93.641
Type F2BE3681C F2BE3681B F2BE3681A
SUPERCHARGING
Turbocharger
Fixed geometry
HOLSET
Variablegeometry
type:
HOLSET
HX 40 HOLSET HE 431 V
LUBRICATION Forcedbygear pump, overpressurevalve, oil filter
bar
Oil pressure, enginehot
(100
o
C 5
o
C):
bar
at idlingspeed bar 1.5
at maximumspeed bar 5
COOLING
Bycentrifugal pump,thermostat,electro-magnetingfan,radiator
and heat exchanger
Water pump control Bybelt
Thermostat: N. 1
starts to open: 85C
fullyopen:
_
OIL FILLING
Total capacityat 1st filling
liters
28
kg
28
25.2
Capacity:
- engine sump minlevel
liters
12.5
kg
12.5
11.2
U i FE 5W30
- engine sump maxlevel
liters
11.2
23
UraniaFE 5W30
UraniaLD7
kg
23
21 UraniaLD7
- quantity in circulation that
does not flow back to the
enginesump
liters
21
kg 5
- quantity contained in the
cartridge filter (which has to
beaddedtothecartridgefilter
refill)
liters
4.5
2.5
kg
2.3
Print 603.93.641 3aso |ovobo 2006
ASSEMBLY CLEARANCE DATA
Type F2B
CYLINDER BLOCK AND CRANK
MECHANISMCOMPONENTS
mm
1
Cylinder liner bore
upper
1
lower
130.200to 130.225
128.510to 128.535
Cylinder liners:
L
outer diameter:
upper
2
lower
130.161to 130.186
128.475to 128.500
2
length L
Cylinder liner -
crankcasebore
upper
lower
0.014 to 0.064
0.010 to 0.060
Outsidediameter 2 _
Cylinder liner
3
A* 115.000 to 115.012
X
inside diameter 3
B* 115.010to 115.022
Protrusion X** 0.035 to 0.065
* Available dia. class
** Under aload of 6000 kg
1
Pistons:
1
X
measuringpoint X 18
X
outsidediameter 1A 114.871to 114.883
2
outsidediameter 1B 114.881to 114.893
outsidediameter 2 46.010 to 46.018
Class A pistonssuppliedas spares.
Class Bpistonsarefitted inproductiononlyand
arenot suppliedas spares.
Piston - cylinder liner 0.117 to 0.141
Pistondiameter 1 _
X
Pistons protrusion X 0.32to 0.69
3 Gudgeonpin 3 45.994 to 46.000
Gudgeon pin - pin housing 0.010 to 0.024
3aso |ovobo 2006 Print 603.93.641
F2B F2B
Type
mm
Type
FEDERAL MOGUL J MAHLEPISTON Y
1 X
X1* 1.583 (rated) 1.583 to 1.613
X
1
2
X
Pistonringgrooves X 2 1.554 to 1.574 1.550 to 1.570
X 2
X3 4.02 to 4.04
3 X *measuredon of 111mm
1 S
Pistonrings:
1
2
S
S
Compressionring S1*
1.429 to 2.463
3
2
S
S
Scraper ring S2 1.47to1.50
3 S Scraper ring S2
Slotted oil
1.47 to1.50
Slotted oil
scraper ring S3
3.970 to 3.990
DMeasured at 2 mmfromthe outside
3.970 to 3.990
1 0.247to 0.311 0.111 to 0.175
Pistonrings- 2J
grooves 2Y
0.054 to 0.104
0.050 to 0.100
3 0 .030to 0.070
Pistonrings _
X 1
Pistonringendgapin
X 1
Pistonringendgap in
cylinder liners:
2 X X1
0.30to 0.40
3 X
X2 0.55to 0.70
X3
0.35to 0.65
1
Small end bush housing
1 49.975 to 50.000
1
2
Bigend bearing
housing 2
1
Selection classes 2
3
Rated value 77.000to 77.030
77.000 to 77.010
77.011 to 77.020
77.021 to 77.030
4 Small end bush
diameter
3
outside 4 50 .055to 50.080
3
inside 3
46.015 to 46.030
S
Bigend bearingshell S
Red
Green
Yellow
2.000 to 2.010
2.011 to 2.020
2.021 to 2.030
Small end bush
- housing
0.055 to 0.105
Pistonpin - bush 0.015 to 0.036
Bigend bearingshells 0.127 - 0.254 - 0.508
Connectingrodweight
A g. 2865to 2895
Class B g . 28961 to 2925
C g. 2926to 2955
* Factory-assembled only, andnot provided with asparepart
Print 603.93.641 3aso |ovobo 2006
Type
F2B
Type
mm
X
Measuringpoint X 125
Max. connectingrod
axismisalignment
tolerance //
0.08
Mainjournals 1 Rated value 82.910to 82.940
1 2
1
Selectionclass 2
3
82.910 to 82.919
82.920 to 82.929
82.930 to 82.940
1 2
Crankpins 2 Rated value 72.915to 72.945
1
Selectionclass 2
3
72.915 to 72.924
72.925 to 72.934
72.935 to 72.945
S1 S 2
Mainbearingshells S1
Red
Green
YellowD
3.000 to 3.010
3.011 to 3.020
3.021 to 3.030
Bigend bearingshells S2
Red
Green
YellowD
2.000 to 2.010
2.011 to 2.020
2.021 to 2.030
Mainbearinghousings 3 Rated value 89.000to 89.030
3
1
Selectionclass 2
3
89.000 to 89.009
89.010 to 89.019
89.020 to 89.030
Bearingshells- f
mainjournals
0.040 0.098 * - 0.040 0.110 **
Bearingshells- f
bigends
0.035 0.093 * - 0.035 0.083**
Mainbearingshells 0.127 - 0.254 - 0.508
Bigend bearingshells 0.127 - 0.254 - 0.508
X1
Mainjournal,
thrust bearing X1 39.96 to 40.00
X2
Mainbearinghousing,
thrust bearing X2 32.94 to 32.99
X 3
Thrust washer
halves X3 3.38to 3.43
Crankshaft shoulder 0.11to 0.30
1 2
Parallel // 1- 2
Concentric 1- 2
0.010
0.040
D Onlymounted in productionandnot provided with spares
f Sparesprovided: : * =standard spares- 0.127; ** =0.254- 0.508
3aso |ovobo 2006 Print 603.93.641
11
Type F2B
CYLINDER HEADS - VALVE TRAIN mm
1
Valveguidehousings
incylinder head
1 12.980 to 12.997
2
2
8.023 to 8.038
3
2
Valveguide
3
13.012 to 13.025
Valveguides - housings
inthecylinder head
0.015 to 0.045
Valveguide 0.2 to 0.4
4 Valves: 4 Valves:
4
7.970 to 7.985
4
60 30 7 30
4
7.970 to 7.985
4
45
= +5'
- 0
Valvestemand its guide 0.038 to 0.068
Housinginhead for valve
seat seat
1 41.985 to 42.020
1 1
40.985 to 41.020
Outside diameter of valve
seat; angle of valve seat in
2
seat; angle of valve seat in
cylinder head:
42.060 to 42.075
2
60 - 30'
2
41.060 to 41.075
2
45 - 30'
Recessingof
valve X
0.5 to 0.8
X
valve X
1.6 to 1.9
Betweenvalve Betweenvalve
seat and head
0.040 to 0.090
Print 603.93.641 3aso |ovobo 2006
Type
F2B
mm
Valveoutsidespring
height:
freeheight H 66
H
H1
2
under aload of:
H 1
H2
540 27N H1 49 .5
966 48N H2 37 .5
X
Injector protrusion X 0.7
Camshaft bush housing
fitted inthecylinder head:
1 7 80.000 to 80.030
1
2
3
Camshaft journal diameter:
1 7 75.924 to 75.940
Camshaft bushingouter
diameter: 80.090 to 80.115
Camshaft bushing
inner diameter: 1 6
7
75.990 to 76.045
76.008 to 76.063
Bushings and housings in
engineblock
0.060 to 0.115
Bushings and journals 0.050 to 0.121
Camlift:
8.07
H
7.63
8.828
1
Rocker shaft 1
37.984 to 38.000
3aso |ovobo 2006 Print 603.93.641
Type
F2B
mm
Bushing housing in rocker
arms
41.000 to 41.016
53.000 to 53.019
42.000 to 42.016
Bushingouter diameter
for rocker arms:
41.097 to 41.135
53.105 to 53.156
42.066 to 42.091
Bushinginner diameter
for rocker arms:
38.025 to 38.041
50.025 to 50.041
38.015 to 38.071
Between bushings and
housings
0.081 to 0.135
0.086 to 0.156
0.050 to 0.091
Between rocker arms and
shaft
0.025 to 0.057
0.015 to 0.087
Engine brake control lever
Eccentric pin outer
diameter 2
Rocker armsshaft seat 1
49.984 50.000
38.025 38.041
Print 603.93.641 3aso |ovobo 2006
Type
F2BE3681C F2BE3681B F2BE3681A
mm
Rocker arms and engine
brakecontrol lever pin
0.025 to 0.068
Rocker armshaft and seat
on engine brake control
lever
0.025 to 0.057
TURBOCHARGER
Type
Fixed geometry
HOLSET HX 40
VariablegeometryHOLSET HE431V
End float 0.025 to 0.127 0.025 to 0.127
Radial play 0.330 to 0.508 0.254 to 0.356
Revi- June2007
TIGHTENING TORQUES
Print603.93.641/A
PART TORQUE
Nm kgm
Lower crankcasefasteningscrews to cylinder block (seeFigure5)
Outer screws First stage : pre-tightening M10x1.25 25 2.5
Inner screws Secondstage : pre-tightening M16x2 140 14
Inner screws Third stage : angle closing M16x2 60
Inner screws Fourth stage : angle closing M16x2 60
Outer screws Fifth stage : angleclosing M10x1.5 90
Pipeunionfor piston coolingnozzle M 12X1.5 35 2 3.5 0.2
Intercooler fasteningscrews to cylinder block (seeFigure10)
pre-tightening
tightening
11.5 3.5
19 3
1.15 0.35
1.9 0.3
Plug 125 15 12.5 1.5
Spacer andoil sump fasteningscrews(seeFigure11) 41.5 3.5 4.1 0.3
Gearcasefasteningscrewsto cylinder block:
M10x1.25 41.5 3.5 4.1 0.3
M12x1.75 63 7 6.3 0.7
M8x1.25 23.5 1.5 2.3 1.5
Cylinder headfasteningscrew: (seeFigure 6)
First stage pre-tightening 50 5
Secondstage pre-tightening 100 10
Third stage angleclosing 90
Fourth stage angleclosing 75
Rocker armshaft fasteningscrew
Secondstage pre-tightening 60
Locknut for rocker armadjustingscrew 39 5 3.9 5
Screwsfor injector fasteningbrackets 36 1.5 3.65 0.2
Shoulder plate fasteningscrews to head 20 2 2 0.2
Engine support bracket fasteningscrews to cylinder head 74 8 7.4 0.8
Gear fasteningscrews to camshaft:
Phonic wheel fasteningscrews to distributiongear 8.5 1.5 0.8 0.1
Exhaust pipefasteningscrews (seeFigure8)
pre-tightening
tightening
30 3
60 3
3 03
6 0.3
Engine brake actuator cylinder fasteningscrews 19 3 1.9 0.3
Connectingrodcapfasteningscrews:
Engine flywheel fasteningscrews: M16x1.5x58
Engine flywheel spacer mount screws: M16x1.5x110:
Flywheel pulleyfasteningscrews to crankshaft:
Lubricate withoil MOLYKOTE before assembly
Lubricate withgraphitized oil beforeassembly
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
PART
TORQUE
PART
Nm kgm
Damper flywheel fasteningscrews: 115 15 11.5 1.5
Idler gear pin fasteningscrews:
Secondstage angleclosing 90
Idlegear link rodfasteningscrew 24.5 2.5 2.4 0.2
Oil pumpfasteningscrew 24.5 2.5 2.4 0.2
Oil pumpsuctionrosefasteningscrew 24.5 2.5 2.4 0.2
Front cover fasteningscrew to cylinder block 19 3 1.9 0.3
Control unit fasteningscrewto cylinder block 19 3 1.9 0.3
Supplypump fasteningscrew to gearcase 19 3 1.9 0.3
Fuel filter support fasteningscrew to cylinder head 24.5 2.5 2.4 0.2
Screwsecuringthe enginesupport to thewheelcase
Turbo-compressor fasteningscrews and nuts (seeFigure10)
pre-tightening
tightening
35 5
46 2
3.5 0.5
4.6 0.2
Water pump fasteningscrewto cylinder block 24.5 2.5 2.4 0.2
Pulleyfasteningscrewto hub 55 5 5.5 0.5
Rocker armcover fasteningscrews (seeFigure12) 8.5 1.5 0.8 0.1
Thermostat boxfasteningscrewsto cylinder head 24.5 2.5 2.4 0.2
Automatictightener fasteningscrews to cylinder block 45 5 4.5 0.5
Fixed tightener fasteningscrewsto cylinder block 105 5 10.5 0.5
Fansupport fasteningscrewsto cylinder block 24.5 2.5 2.4 0.2
Starter fasteningscrews 44 4 4 0.4
Air heater oncylinder head 50 5 5 0.5
Air compressor fasteningscrew to cylinder head 74 8 7.4 0.8
Air compressor control gear fasteningnut 170 17 1
Hydraulic power steeringpumpgear fasteningnut 46.5 4.5 4.6 0.4
Air conditioner compressor fasteningscrewto support 24.5 2.5 2.4 2.5
Air conditioner compressor support fasteningscrewto cylinder block 44 4 4.4 0.4
Alternator support fasteningscrewto cylinder block 44 4 4.4 0.4
Alternator bracket fasteningscrewto cylinder block 24.5 2.5 2.4 0.2
Water pipe unions 35 3.5
Water temperaturesensor 32.5 2.5 3.2 0.2
Lubricate withoil MOLYKOTE before assembly
Lubricate withgraphitized oil beforeassembly
Revi- June2007
PRINT603.93.641/A
PART
TORQUE
PART
Nm kgm
Engine brake solenoid valvefasteningscrews 32.5 2.5 3.2 0.2
Flywheel revsensor fasteningscrew 8 2 0.8 0.2
Camshaft revsensor fasteningscrew 8 2 0.8 0.2
P.D.E solenoid connector fasteningscrew 1.62 0.3 0.1 0.3
Overboost pressure sensor fasteningscrew 8 2 0.8 0.2
Absolutepressuresensor fasteningscrew 22.5 2.5 2.2 0.2
P.W.M. control valve fasteningscrew/nut 8 2 0.8 0.2
Fuel/coolant temperaturesensor 35 3.5
Coolant temperatureindicator 23.5 2.5 2.3 0.2
Filter cloggingsensor 10 1
Oil temperatureswitch 25 1 2.5 0.1
Oil pressuresensor 25 1 2.5 0.1
Oil cloggingsensor 55 5 5.5 0.5
Electricwirefasteningscrew 8 2 0.8 0.2
Heater fasteningscrew 16 1 1.6 0.1
Power unit
M14x70/80 screw securingfront and rear elasticblocks to chassis 192.5 19.5 19.2 1.9
M16x130screwsecuringfront and rear elastic blocksto engine 278 28 27.8 2.8
M18x62 flanged HEX screw for front engineblock
Pre-tightening1
st
step 120 12
Angleclosing2
nd
step 45
M14x60 socket cheese-head TC screw for front engineblock
Pre-tightening1
st
step 60 6
Angleclosing2
nd
step 45
Flanged HEX screw for rear engineblock
Pre-tightening1
st
step 100 10
Angleclosing2
nd
step 60
44898
FRONT SIDE
Front phase:
angletightening
of inner screws
60
44897
44899
44898
Figure5
First phase:
preliminarytightening
of outer screws
(25 Nm)
FRONT SIDE
FRONT SIDE
Secondphase:
preliminary
tighteningof
inner screws
(140Nm)
Fifthphase:
angletightening
of outer screws
90
44898
FRONT SIDE
Third phase:
angletightening
of inner screws
60
FRONT SIDE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
LOWER CRANKCASE FIXING SCREWS TIGHTENING SEQUENCE
44900
Figure6
DIAGRAM OF EXHAUST MANIFOLD FIXINGSCREWS TIGHTENING SEQUENCE
45359
DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE
1 8
6 3 2 7 6 3 4 7 6 3 2 7
5 4 8 5 2 8 5 4 1 1
Figure7
70567A
DIAGRAM OF ROCKER SHAFT FIXING SCREWS TIGHTENING SEQUENCE
Figure8
3aso |ovobo 2006 Print 603.93.641
455361
Figure9
Figure10
DIAGRAM OF OIL SUMP FIXING SCREWS TIGHTENING SEQUENCE
45362
DIAGRAM OF HEAT EXCHANGER FIXING SCREWS TIGHTENING SEQUENCE
1
8
12 11 10 3
9 13
14
4 5 6 7 2
Figure11
DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE
SEQUENCE: Preliminarytightening 4- 3 - 1 - 2
Tightening 1 - 4 - 2 - 3
45360
Print 603.93.641 3aso |ovobo 2006
Figure12
DIAGRAM OF ROCKER COVER FIXING SCREWS TIGHTENING SEQUENCE
45363
17 14 13 1 4 5 8
18
19
20
16 15 12 2 3 6 7
11
10
9
3aso |ovobo 2006 Print 603.93.641
Print603.93.331/A
TOOLS
TOOL NO. DESCRIPTION
99322230 Rotarytelescopicstand
99340051 Extractor for crankshaft front gasket
99340052 Extractor for crankshaft rear gasket
99340205 Puller withsliide-hammer
99342149 Extractor for injector-holder
99346245 Tool to install thecrankshaft front gasket
Print603.93.331/A
TOOLS
99346246 Tool to install thecrankshaft rear gasket
99348004 Universal extractor for 5to 70 mminternal components
99350072 Box wrenchfor transmission gear support fixingscrews
99350074 Box wrench for block junctionbolts to thelower crankcase
99360177 Injector housingplug
99360184
Tool for removingand refittingpiston rings
(105-160 mm)
Print603.93.331/A
TOOLS
99360192
Elasticbelt assemblingtool
99360264 Tool to takedown-fit engine valves
99360288 Tool to remove valve guide
99360292 Tool to install gasket onvalveguide
99360294 Tool to drivevalveguide
(usewith 99360288)
99360314 Tool to remove cartridgefilters
Print603.93.331/A
TOOLS
99360321 Tool to rotateengine flywheel
99360334 Tool for checkingcylinder liners protrusion
99360335 Cylinder linerscompressioncap(to beusedwith99360334)
99360351 Tool to stop engineflywheel
99360487
Tool to takedownandfit camshaft bushes
99360500 Tool to lift crankshaft
Print603.93.331/A
TOOLS
99360551 Bracket to takedownandfit engine flywheel
99360558 Tool to lift andtransport rocker shaft
99360585 Tool for liftingand handlingengine
99360605
Belt to insert pistonincylinder liner (60- 125mm)
99360612 Tool for positioningengineT.D.C.
99360613 Tool for timingof phonicwheel on timinggear
Print603.93.331/A
TOOLS
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners
99360724 Ring(115 mm) (usewith 99360706)
99361035 Brackets fixingtheengineto rotarystand99322230
99365054 Tool for injector holder heading
99370415
Tool to detect cylinder liner protrusion
(usewith 99395603)
TOOLS
99378100
Tool for printing engine identification plates (to be used with
special punches)
99378130
Punches for printingengineidentificationplates
(consistingof: 99378101 (A) - 99378102 (B) - 99378103(C) -
99378104 (D) - 99378105 (E) - 99378106 (F) - 99378107 (G) -
99378108 (V))
99389834
Torquescrewdriver to calibratescrewsforinjectorsolenoidvalve
99390310 Valveguidesleeker
99390772 Tool to removeresiduesfrominjector holder
99390804 Tool to threadinjector holders to beextracted
TOOLS
99394014 Guidebush (to beused with 99394041or 99394043)
99394041
Cutter to rectify injector holder housing (to be used with
99394014)
99394043
Reamer to rectify injector holder lower side (to be used with
99394014)
99395215
Gaugefor centre distancecheckbetween camshaft and idlegear
99395216
|oaso|o a| o aoo|a t||too|o .|t| +/2' aoo 3/+' sooao
couplings
99395603 Dial gauge(0 - 5mm)
TOOLS
99395687 Reaminggauge(50-178mm)
99396033 Centeringringof crankshaft front cap
Deactivate the batteries by disconnecting the
electric wires or opening the current main switch,
lift thecowlingandtilt cab.
Disconnect thetransmission, asdescribedinsection
4.
Operations to becarriedout inthelower side:
- drainthecoolant inapropercontainer,byremovingthe
radiator drainplug(12);
- remove the piping(11) between the radiator and the
water pump;
- drain power steering oil in a proper container, by
disconnectingdeliveryandreturn lines (20and18);
- disconnect pipings (13 and 14) fromthe water pump
fitting;
- disconnect connector (15) fromtheelectroniccontrol
unit asfollows:
A, lift the safetylever
B, shift the connector by disconnecting it from the
control
unit
C, lift theconnector byreleasingthe pawl;
- Disconnect electric connections (1 - 4 - 5) fromthe
engine, then releasethe cablefromthestraps usedfor
fasteningto theintakemanifold;
- disconnect theelectrical cables fromthe starter motor
(16) andtheground cable (17);
- disconnect pipe(19) fromair compressor;
- disconnect the sleeve (6) connecting aftercooler
radiator-intake manifold;
- removewaterpipe(2) betweenradiatorandthermostat
assembly;
- disconnect fuel deliveryand return pipings(21);
- if present, remove the pipe support bracket (10)
fasteningscrews to theengineblock;
- rremove screws (9) (where available), then remove
air-conditioningcompressor (8) fromits support;
- without disconnecting the compressor pipes and to
prevent drainingthe climatecontrol system, fasten the
compressor to the vehicle so that it does not interfere
with theengineremoval.
112328
If washing the engine bay, adequatelyprotect the
electric/electronic components and their
connections.
NOTE
Figure13
F2BENGINE T RAKKER EURO 4/5
Base November 2006
540110 ENGINE REMOVAL - REFITTING
Removal
87197
- disconnect waterpipings(7and8) fromthermostatunit
(9) (seeDetail A);
- if present, remove the pipe fasteningscrew (1) to the
conveyor (3);
- ifpresent, removethescrewsand (12) detach theheat
guard(11);
- removethescrews(4) anddisconnect thepipe(3) from
thesupport bracket (5);
- disconnect the air pipe (6); connec tion drier
compressor (A.P.U.);
- disconnect sleeve (2) connecting outlet piping (3)
betweentheturbocharger andtheaftercooler radiator;
- disconnect the sleeve (13) connectingair filter pipings
and turbocharger manifold;
- disconnect exhaust piping(14);
- if the vehicle is fitted with mechanical transmission,
removethesupport (18) together withtheenginegear
control lever (19);
- onlyvehicleswithshort cab:removesound-proofguard
(16), bolts (15), and then take off cab suspension
crossbar (17);
Usealiftingdeviceandspinterbar 99360595(hookedtothe
engine brackets) to stretch the chains. Loosen the screws
fastening the engine brackets to el astic supports (10 7 and
22, Figure252) onthechassis.
- Slowlyraisetheenginefromitscompartment bytaking
it backwards so that the fan is released fromthe air
conveyor compartment (20) ontheradiator.
- Operate the screws to remove the fan fromthe hub.
Removetheenginecompletelywithout interferingwith
theremainingfixedpartsonthechassis,inparticularthe
wiringinterferingwith the rear right enginesupport.
Refitting
Reverse the order of detachment operations,
takinggreat carewhenfittingtheassemblyintothe
engine compartment and following the advice
below:
- checkthat the exhaust pipingis not worn or about to
deteriorate; replace, if necessary;
- tightenthescrewsand/ornutstotheprescribedtorque;
- fill thecoolingsystemwith suitable coolant, then blow
air off the cooling systemas described in the relevant
chapter;
- blowair offthefuel systemasdescribedin therelevant
chapter (operation 542011);
Tightenthenutsfasteningtheelectriccablestothe
startingmotor terminals,byapplyingthetor-
quevaluesbelow:
- nut M10 x1.5(terminal 30):
17.6 24.5Nm(1.8-2.5Kgm);
- nut M5 x0,8 (terminal 50):
2.6 4.6Nm(0.27-0.47 Kgm);
Figure 14
NOTE
4 F2 BENGINE TRAKKEREURO 4/5
Base November 2006
87198
Fillingthesystem
After conscientiously followingthe above warnings,
proceedasfollows:
- Removethecap(2) fromtheexpansiontub(3).
- Pour thecoolant into theexpansion tub(3) till it isquite
full.
Bleedingair fromthesystem
Filling the cooling system
Preliminaryoperations
For vehicles equipped with just the standard cab heating
systemor manual air-conditioning:
- Fullyopenthecoolant cockontheinstrument panel.
For vehicles equipped with the automatic air-conditioning
system:
- Setthetemperaturecontrol inthecabontheHI position.
For vehicles equipped withanadditional heater:
- Theheater must not beturnedon.
Operations
Placeasheet of cardboard betweenthecoolant radiator and
theintercoolerradiatorinordertoshortenthetimeit takesto
oac| t|o oo|oo's .o'|o tooatoo (ao. 0 C).
GENERAL WARNINGS
Fillingmust bedonewiththeengine cold.
The cap (1) must not beremoved for anyreasons
whatsoever.
Toprevent pocketsofair forminginthesystem,the
fluidhastobetransferredslowly(approximateflow
rate8 litres/min).
Forvehiclesequippedwithanadditional heater:the
percentage of glycols in the coolant must be no
greater than50%.
- Turnontheheater.
If thetubempties completelyduringthesefirst few
minutes, stop and engineand top it up at aslower
ratethanbefore.
Restart theengine.
- Start theengineand keepthespeedjust aboveidlingfor
5min.
- After 5 min. running, top up the level of fluid in the
expansiontub, if necessary.
- Closetheexpansiontubfiller with thecap(2).
Take the engine up to top speed so that the coolant
quickly reaches the temperature of full thermostat
opening(approx. 90 C) and keep it inthis stateuntil all
theair is bled out of thesystem.
Thisischeckedbyseeingthereisno foamor airbubbles
inthetub.
Thelongest timeit takestobleedtheairfromthesystem
completely is approximately 15 minutes from the
moment when the thermostat opens (opening starts
85 2 C).
Donot takethefiller capofftheexpansiontubuntil
thefluid in thesystemhascooledcompletely.
Anytoppingupmust onlybedonewith theengine
cold.
Thisis to avoid:
1 - Operator burns.
2 - Damage to the engine since cooling system
pressurization is only created with the fluid
heatingfromtheconditionof theenginecold.
NOTE
NOTE
NOTE
NOTE
Figure15
- Bleed screw(1) on thepre-filter mounting.
- Bleed screw(2) on thefilter mounting.
- Bleed screw(4) on thefront of thecylinder head.
- Work the pump (3) on the pre-filter mountingtill fuel
withnoairbubblesinit comesout of thescrew(1);close
thescrew.
- Repeat thisstepfor screw(2).
1
3
2
Checks and tests
Start theengine, leaveit runningat just alittlefaster
thanidlingspeedandwaitforthetemperatureofthe
coolant to reachthe level to open the thermostat.
Then, check that:
- No water leaksfromthe connectingsleevesof thepipes
intheenginecoolingandcabheatingcircuits,tighteningthe
collarsfurther if thisisnecessary.
- No oil leaks frombetween the cover and the cylinder
head, betweentheoil sumpand the crankcase, between
theoil filter anditsseat,betweentheheat exchanger and
the crankcase, or between the various pipes in the
lubricationcircuit.
- No air leaksfromthepipesconnected to thepneumatic
components involved inremoval.
- The indicator lights on the instrument panel and the
devicesdisconnectedwhenremovingtheengineall work
properly.
4
Before bleeding the fuel system connect proper
pipes to the bleeding screws located on prefilter
support, filter andcylinder headfront part, inorder
to recover fuel in suitable containers during this
operation.
Inparticular,never allowthat thefuel,comingoutof
thecylinder headdrainingscrew, stainsthecontrol
beltsofthefan, thewater pump, thealternator and
theconditioner compressor, thusdamagingthem.
Figure16
NOTE
542011 Bleeding air from the fuel system
87199
Tocut offthebatteries,removetheelectricwiresoropenthe
main switch.
Removethebumper fasteningscrews.
Move the bumper away from its respective supporting
brackets, then placeit, without subjectingthe electriccables
and the headlamp wiper pipe (if any) under tension, on a
suitablestandsoastosubsequentlyallowthecabtobetilted.
Lift theradiator grill, thentilt thecab.
Go under the vehicle and remove the plug (15) fromthe
radiator (16) and drain the coolant fluid in the appropriate
container.
Removetheclip(14) anddisconnect theradiator (16) sleeve
(13).
On the engine compartment left-hand side, remove the
screws(12) andtheheat guard(11). Takeoffthescrewsand
disconnect theair conveyor (8) climatecontrol pipes(5).
Slackenthesleevefasteningclamp(7)fromtheintercooler (6)
radiator.
Remove the air conveyor (8) fastening screws (9) to the
support bracket (10).
Removethescrew(19) anddetachtheelectricwire(18) from
theair conveyor (8).
Remove the clamp (20) and detach the air conveyor (8)
together withthesleeve (7) fromtheturbocharger (17) and
fromtheintercooler radiator (6).
Drive in thesuitableself-threadingscrewin the pin hole (3)
taking care to partially take off and finally remove with a
screwdriver theupper clip(2) fasteningthe fan air conveyor
(4) to radiator guard(1).
Removethelower clip inthesameway.
Remove the two radiator support fastening screws to the
chassis.
Removal
Figure17
543422 ELECTRO-MAGNETIC FAN DRIVE REPLACEMENT
87200
Onthe right-handside
Disconnect thepipe(1) fromthethermostat.
Remove clip (10), then disconnect sleeve(9) fromradiator
(11).
Slackentheclamps (7) and removethesleeve (6)
Remove the upper and lower clip (3) as described for the
left-handside.
Removetheradiatorfasteningscrewstothechassisandmove
the radiator unit forwards.
Removethefan(2) fasteningscrewstotheelectro-magnetic
joint (14).
Removethefan (2) together with theair conveyor (4).
Release, by acting on automatic stretcher (16), belt (15)
tension, thenremovethebelt fromthepulleys.
Disconnect the electric connection (12) of the
electro-magneticjoint (14).
Removethescrews (13) and theelectro-magneticjoint (14)
fromtheengine.
Refitting
To refit theelectro-magneticfandrive, reversethe
removal procedureandattaintothefollowingrules:
- check the control belt (15) conditions; replace it if
damagedor wornout;
- tightenthescrewsand/ornutsto theprescribedtorque;
- fill thecoolingsystemwiththeprescribedfluid,thenblow
air off thecoolingsystemas described in therespective
chapter;
The electro-magnetic joint is fitted with two
threadedholes( ) at 180 onefromtheother. In
theevent of fault, lockthejoint control drivingina
M8x16 mmscrew in these holes. In this wayit is
possibletotakethevehicletotheclosestdealership.
Figure18
NOTE
Figure19
78839
ENGINE - LONGITUDINAL SECTION
78841
Figure20
ENGINE - CROSSSECTION
47562 47563
47601
Figure21
Figure22
Figure23
Beforedismantlingtheengineontherotarystand99322230,
removethe followingcomponents:
- starter (2)
- turbocharger soundproofingshield(1)
Remove the soundproofingshield(1) and plug(2)
Fix the engine to the rotarystand 99322230, bymeans of
brackets 99361035(1), removethefan.
1
1
1
1
540110 DISASSEMBLING THE ENGINE
Remove the followingcomponents:
- alternator (1);
- belt tightener support (2);
- if present, air conditioner compressor (3);
- water pump (5) andpipe;
- fixedbackstand(4).
Onlymodels equipped without Intarder
- thermostat unit (6).
73579
87202
Figure24
Figure25
Figure26
Figure27
Usinganappropriatetool (2),operateinthedirectionofthe
arrow, and remove the belt (1) driving the water pump,
alternator and fan.
Take out the screws and remove the el ectromagnetic
coupling(3).
112330
Cut thebelt (1), as it must not beusedagain.
Onlymodels equipped withIntarder
Loosen straps (2 and 4), then remove pipe (1) fromthe
cylinder headandpipe (3).
Remove the fasteningscrews, thentakeoff thermostat unit
(5).
87203
Removethefollowingcomponents:oil supplylines(1);water
coolingsupplylines (3); water discharge lines (2); oil return
lines(4); turbocharger (5); exhaust manifold(6).
87204
45254
47566
Figure28
Figure29
Figure30
Block theflywheel rotationwithtool 99360351.
Removescrews(4), thendisassembledamper (3).
Removethescrews (2) andthepulley(1).
87205
Figure31
Unscrewtheoil filter (1) bytool 99360314 (2).
Install extractor 99340051 (2) and remove theseal gaskets
(1). Unscrewthescrewsand removethecover.
Disconnect all electricconnections andsensors.
87206
Figure32
Unscrewthescrews(1) andremovetheentireheatexchanger
(2).
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Removethefollowingcomponents:inletmanifold(6);support
for fuel filter (1); fuel lines(2); fuel pump (3);compressor (4);
control unit (5).
47587
45661
86289
47568
Figure33
Figure34
Unscrew the screws (2), by using the proper wrench and
removethegear (1) withthe phonicwheel.
Bymeansof aproperlysplinedwrench, untightenscrews(2)
and removethetransmissiongear (1)
84377
Removetherockerarmcover (1),takeoffthescrews(2) and
remove: thecover (3),thefilter (5) andthegaskets(4and6).
Takeoff thescrews (8) andremove theblow-bycase(7).
70708
To removetheP.T.O. (if applicable):
- Disconnect theoil pipe (1).
- Unscrewthe4screws(2) and (3).
Figure35
Figure36
Figure37
Figure38
Unscrewthescrews(1);tightenascrewinareactionholeand
removethe shoulder plate (2), removethesheet gasket.
3aso |ovobo 2006 Print 603.93.641
47569
45257
45259
Figure39
Figure40
Figure41
Applyextractor 99340052(2)andpull out theseal gasket(1).
Untightenthescrews(1) andtakedownthegearhousing(2).
- Removethechecksprings(2) oftheexhaust brakelever;
- Untightenthefixingscrews(1) ofrocker armshaft.
47568
Stoptheflywheel (3) rotationbymeansoftool 99360351(1),
untightenthefixingscrews(2) andremovetheflywheel.
116190
- Applytool 99360553(1) to the rocker holder shaft (2)
and removetheshaft (2) fromthecylinder head.
Figure42
Figure43
Figure44
Removepower take-off control gear (1), if any.
Removescrews(3) anddismount doublegear (2).
Removesecuringscrewand dismount articulated rod (5).
Dismount oil pump(4).
106219
Print 603.93.641 3aso |ovobo 2006
45266
47573
47572
47574
Removethecamshaftandthefixingscrewsoncylinderheads
- By means of wire ropes, lift the cylinder head (1) and
removeseals(2).
Untightenscrews(2) andremovetheengineoil sump(1) with
frame (3) andseal .
Untightenscrewsandremovesuctionrose (1).
Rotate theblock(1) to thevertical position.
116232
- Removethepiping(1) for exhaust brakepins;
- Untighten screws and remove electric connections (2)
fromsolenoidvalves;
- Untightenfixingscrews(3) of injector brackets (4).
- Removeinjectors(5).
- Install plugs99360177insteadofinjectors.
Figure45
Figure46
Figure47
Figure48
Figure49
Thecylinder headmount screws must bereplaced
at eachremoval operation.
NOTE
Revi - June2007
PRINT603.93.641/A
47576
47571
47570
By means of proper and splined wrenches, untighten the
screws(1) and (2) andremovethelower crankcase (3).
Removethecrankshaft (2) withtool 99360500 (1).
Removethecrankshaft half-bearings(1),untightenthescrews
and remove oil spraynozzles (2).
Takedowncylinderlinersasspecifiedintherelativeparagraph
onpage56.
After disassembling the engine, thoroughly clean
disassembled parts andcheck their integrity.
Instructionsfor mainchecksandmeasuresaregiven
in the following pages, in order to determine
whether thepartscan bere-used.
47575
Untighten screws (2) fixingtheconnectingrod cap (3) and
removeit.Removetheconnectingrod-pistonassemblyfrom
theupperside.Repeat theseoperationsfortheotherpistons.
Figure50
Figure51
Figure52
Figure53
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
A =Selectionclass 115 to 115.012mm
B=Selectionclass 115.010 to115.022 mm
In case of maximum wear max 0.150 mm or maximum
ovalizationmax 0.100 mmcomparedto thevaluesindicated
inthe figure, theliners must be replaced as theycannot be
ground, lapped or trued.
540410 CYLINDER BLOCK
540420 Checks and measurements
Internal diameter of the cylinder liners is checked for
ovalization, taper and wear, usingaboredial (1) centesimal
gauge 99395687 (2) previously reset to ring gauge (3),
diameter 115mm.
Ifa115ringgaugeisnot availableuseamicrometer
caliper.
A = 130.200 to 130.225mm
B= 128.510to 128.535mm
C = 130.161to 130.186
D= 128.475 to128.500 mm
Thefigureshowstheouterdiametersofthecylinderlinersand
therelativeseat inner diameters.
Thecylinderlinerscanbeextractedandinstalledseveraltimes
indifferent seats, if necessary.
34994
47439
47440
47441
Figure54
Figure55
Figure56
Figure57
1=1st measuring
2=2ndmeasuring
3=3rdmeasuring
Carryout measuringsoneachcylinder linerat threedifferent
levels and on two (A-B) surfaces, to one another
perpendicular, asshowninFigure.
(Demonstration)
Cylinder liners areequipped with spareparts with
'/' so|oct|oo c|ass.
NOTE
NOTE
3aso |ovobo 2006 Print 603.93.641
REPAIR OPERATIONS
45150 45150a
47533
Figure58
Figure59
CYLINDERLINERSMAIN DATA
||T/|| ''
'/' = So|oct|oo c|ass a'|o aoa
Figure60
47534
BLOCKWITH CYLINDERLINERS
A mm115.000to 115.012
Bmm115.010 to 115.022
Selectionclass
A
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
CYLINDER LINERS
47577
77812
16798
35012
Figure61
Figure62
Figure63
Placedetails99360706 (1and2) andplate99360724(4) as
shown in the figure, by making sure that the plate (4) is
properlyplaced on thecylinder liners.
Tightenthescrewnut (1) andremovethecylinder liner (3)
fromtheblock.
Alwaysreplacewater sealingrings (3, 4 and 5).
Install the adjustment ring (1) on the cylinder liner (2);
lubricatelower part of liner and install it in the cylinder unit
usingtheproper tool.
Check cylinder barrel protrusion with tool 99360334
(1-2-3-4) andtightenscrew(1) to 170 Nm.
Withdial gauge99395603(5) placedonbase99370415(6).
Measure the cylinder barrel protrusion compared to the
cylinderheadsupportingplane,it mustbe0,035to0,065mm
(Figure64); otherwise replace the adjusting ring (1,
Figure62) fittedwithspareparts havingdifferent thickness.
Whentheinstallationiscompleted,blockthecylinder liners
(1) to theblock (2) withstuds99360703 (3).
Fitting and checking protrusion
(Demonstration)
Figure64
CYLINDERLINER PROTRUSION
49017
The adjustment ring(1) is suppliedas spareparts
inthefollowingthicknesses: 0.08mm- 0.10mm-
0.12mm.
Figure65
NOTE
3aso |ovobo 2006 Print 603.93.641
540420 Replacing cylinder liners
Removal
116410
Figure66
Figure67
X. Detail of main journalsconnections Y. Detail of crank pinsconnections
Figure68
MAIN DATA FORTHE CRANKSHAFT PINSAND THE HALF BEARINGS
Checktheconditionof the journals andthebigend pins; theremust no besigns of scoring, ovalizationor excessivewear.
The datagiven refer to thenormal diameter of thepins.
47537 47538
Upper mainjournal half bearing
Lower mainjournal half bearings
BUFF
BUFF
Revi- June2007
PRINT603.93.641/A
5408 CRANKSHAFT
MEASURINGCRANKPINS
Duringgrinding,payattentiontojournal andcrankpinsvalues
specified in figures 68 and 69.
47535
47536
Figure69
Figure70
MEASURINGTHE MAIN JOURNALS
Before grinding the crank pins using a micrometer (1),
measurethemainjournalsandthecrankpins(2) anddecide,
on the basis of the undersizing of the bearings, the final
diameter to which thepins areto beground.
It is advisable to enter thevalues found in atable
(Figure71).
All journalsandcrankpinsmust alsobegroundto
the sameundersizing class, in order to avoid any
alteration to shaft balance.
Figure71
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
36061
MIN.
MAX.
MIN.
MAX.
CRANK PINS
NOTE NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
540812 Measuring main journals and crank pins
For each of thejournals of the crankshaft, it isnecessaryto carryout the followingoperations:
MAIN JOURNALS:
- Determine the class of diameter of the seat in the
crankcase.
- Determinetheclass of diameter of themainjournal.
- Select the class of thebearingshellsto mount.
CRANKPINS:
connectingrod.
- Determinetheclass of diameter of thecrankpin.
- Select the class of thebearingshellsto mount.
DEFINING THE CLASSOF DIAMETER OF THE SEATSFOR BEARING SHELLSON THE CRANKCASE
On thefront of thecrankcase, two setsof numbersaremarkedinthe positionshown(Figure72at top).
- The first set of digits (four) isthecouplingnumber of thecrankcase with its base.
- The followingseven digits, takensingly, aretheclassof diameter of eachof theseatsreferred to (Figure72at bottom).
- Each of thesedigits maybe 1, 2 or 3.
47535
89.000 to 89.009
89.010 to 89.019
89.020 to 89.030
Figure72
CLASS
MAIN BEARINGHOUSING
NOMINAL DIAMETER
Print 603.93.641 3aso |ovobo 2006
PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
To obtain the required assemblyclearances, the main and bigend bearingshells needto beselected as described
hereunder.
Thisoperationmakesit possibleto identifythemost suitablebearingshellsforeachofthejournals(thebearingshells,ifnecessary,
can havedifferent classes fromone journal to another).
red
red/black
green
green/black
STD
2.000 to 2.010
2.011 to 2.020
+0.127
2.063 to 2.073
2.074 to 2.083
+0.254
2.127 to 2.137
2.138 to 2.147
+0.508
2.254 to 2.264
2.265 to 2.274
Dependingon the thickness, thebearingshells areselected
inclassesoftolerancemarkedbyacolouredsign(red-green
oo/b|ac' ooo/b|ac').
The followingtablesgive thespecifications of the mainand
bigendbearingshellsavailableassparesinthestandardsizes
(STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
* Fitted inproductiononlyand not supplied as spares
Figure73
yellow*
yellow/black*
2.021 to 2.030
red
red/black
green
green/black
STD
3.000 to 3.010
3.011 to 3.020
+0.127
3.063 to 3.073
3.074 to 3.083
+0.254
3.127 to 3.137
+0.508
2.254 to 3.264
yellow*
yellow/black*
3.021 to 3.030
2.084 to 2.093
3.084 to 3.093
NOTE
3aso |ovobo 2006 Print 603.93.641
Selecting the main and big end bearing shells
Mainjournalsandcrankpins: determiningtheclassof diameter of thejournals.
Three sets of numbers aremarked onthe crankshaft inthe positionshown bythe arrow(Figure74at top):
- The first number, of fivedigits, is thepart number of theshaft.
- Under thisnumber, ontheleft, aset of sixdigits refersto thecrankpinsandisprecededbyasingledigit showingthestatus
of thejournals(1=STD, 2 =-0.127), theother sixdigits, taken singly, givetheclass of diameter of eachof thecrankpins
theyrefer to (Figure74at top).
- The set of sevendigits, on the right, refers to themain journalsandisprecededbyasingle digit: thesingledigit shows the
statusof the journals(1=STD, 2 =-0.127), theother seven digits, taken singly, give theclass of diameter of each of the
mainjournals theyrefer to (Figure 74 at bottom).
Figure74
72.915 to 72.924
72.925 to 72.934
72.935 to 72.945
CLASS
CRANKPIN
NOMINAL DIAMETER
82.910 to 82.919
82.920 to 82.929
82.930 to 82.940
CLASS
MAIN JOURNALS
NOMINAL DIAMETER
Print 603.93.641 3aso |ovobo 2006
DEFINING THE CLASSOF DIAMETER OF THE MAIN JOURNALSAND CRANKPINS (Journalswith nominal diameter)
Selection of main half-bearings (nominal diameter pins)
After detecting, for each journal, the necessarydataon block and crankshaft, select the type of half-bearings to be used, in
compliance withthe followingtable:
STD.
1 2 3
1
2
3
green
green
red
red
red
red
green
green
green
green
red
red
green
green
green
green
red
red
Figure75
3aso |ovobo 2006 Print 603.93.641
green/black
Selection of main half-bearings (rectified pins)
If thejournals havebeenrectified, the proceduredescribed cannot beapplied.
In this case, makesure that thenew diameter of thejournals isas specifiedon thetable and install theonlyhalf-bearingtype
requiredfor thisundersizing.
-0.127
1 2 3
82.784
82.793
green/black
green/black
green/black
green/black
green/black
green/black
red/black
red/black
green/black green /black
green/black
red/black
red/black
red/black
red/black
red/black
red/black
82.794
82.803
82.804
82.814
1
2
3
red/black =
mm3.063to3.073
green/black =
mm3.073to3.084
-0.254
1 2 3
82,666
82,686
red red red
red red red
red=
mm3.127to3.137
-0.508
1 2 3
82.412
82.432
red red red
red red red
red=
mm3.254to3.264
Figure76
Print 603.93.641 3aso |ovobo 2006
Figure77
SELECTING THE BIG END BEARINGSHELLS
(JOURNALSWITH NOMINAL DIAMETER)
Therearethreemarkingsonthebodyoftheconnectingrod
|o t|o os|t|oo s|o.o |o t|o v|o. o '/'.
1
2
3
The number, indicatingtheclass of diameter of thebearing
shell seat maybe 1, 2 o 3.
Determinethetypeof bigendbearingto fit oneachjournal
byfollowingtheindicationsinthe table(Figure78).
47557
VIEW FROM A
STD.
1 2 3
1
2
3
green
green
red
red
red
red
red
red
green green
green green
green
green green
green
red
red
Class
Figure78
Letter indicatingtheclassof weight:
A = 2865to 2895g.
B = 2896to 2925g.
C = 2926to 2955g.
Number indicating the selection of the diameter of the
bigendbearingseat:
1 = 77.000 to 77.010 mm
2 = 77.011 to 77.020 mm
3 = 77.021 to 77.030 mm
Numbersidentifyingthecap-connectingrod coupling.
3aso |ovobo 2006 Print 603.93.641
green/black
Selection of connecting rod half-bearings (r ectified pins)
If pins havebeen rectified, theproceduredescribedmust beapplied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belongto, and install the half-bearings
identified accordingto therelativetable.
-0.127
1 2 3
72.789
72.798
green/black
green/black
green/black
green/black
green/black
green/black
red/black
red/black
green/black
red/black
red/black
red/black
red/black
green/black
green/black
72.799
72.808
72.809
72.818
1
2
3
red/black =
mm2.074 to 2.083
green/black =
mm2.063to2.073
-0.254
1 2 3
72.671
72.680
red green green
red green green
red
mm2.127to2.137
green =
mm2.138to2.147
-0.508
1 2 3
72.417
72.426
red green green
red green green
red red gr een
red red gr een
72.427
72.437 red red gr een
red red gr een
red=
mm2.254to2.264
green =
mm2.265to2.274
72.681
72.691
Figure79
Print 603.93.641 3aso |ovobo 2006
Install thehalf-bearings(1) onthemainbearingsinthelower
crankcase(2).
Checkthe installationclearancebetweenthemainjournals
and therelativebearings asfollows:
Usingthehoist andhook99360500(1)mount thecrankshaft
(2).
After fitting the gear (1) on the crankshaft (2), heat it for
15 minutes in an oven at temperature not higher than
180 C.
Let themcool down after theinstallation.
If changingthepin (3), after fittingit on, check it protrudes
fromthecrankshaft asshownin the figure.
49020
47579
47578
49021
Figure80
Figure81
Figure82
Figure83
Install theoil spraynozzles(2) andhavethedowel coincide
with theblock hole (3).
Install thehalf-bearings (1) onthemainbearings.
Checkthat theteethofthegearsare not damagedorworn,
otherwiseremovethemusingtheappropriateextractor.
540811 Checking main journal installation
clearance
1
2
3aso |ovobo 2006 Print 603.93.641
540815 Replacingthevalvedrivegear andthe
oil pump drive gear
End float ischecked byplacingamagnetic dial gauge(1) on
thecrankshaft (2),asshowninthefigure.Ifthevalueobtained
ishigher than specified, replacetherear thrust half-bearings
and repeat this check.
- Lubricate inside screws (1) con UTDMoil, andtighten
thembytorque wrench to 140 Nmtorque, thuswith
60 angleclosing, followingthediagraminFigure 86.
Place a piece of calibrated wire on the journal of the
crankshaft (2), parallel to the longitudinal axis; install the
lower crankcase(1), byhoist and appropriate hooks.
49022
47579
47578
47588
44898
Figure84 Figure85
Figure86
Figure87
Figure88
- Removethe lower crankcase
The clearance between the main bearings and thejournals
isobtainedbycomparingthecalibratedwirelength(2) at the
maximumdeflection point, with the calibrated scaleon the
coating(1) containingthecalibrated wire (1).
Numbers shown on the scale specify the clearance in
coupling millimeters. If the clearance obtained is different
fromthe clearance required, replace the half-bearings and
repeat this check.
FRONT SIDE
Diagramshowingthe tighteningorder of the screwsfixingthelower crankcase to theblock
Checking crankshaft end float
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Makesurethepistondoesshowanytraceofseizing,scoring,
cracking; replaceas necessary.
49023
47580
Figure89
Figure90
PISTON CONNECTINGROD ASSEMBLY
1. Connectingrod body- 2. Half bearings - 3. Connectingrod cap- 4. Capfasteningscrews- 5. Seeger ring- 6. Slotted oil
control ring- 7. Scraper ring- 8. Compressionring- 9. Gudgeonpin- 10. Piston
Removal ofthepistonrings(2) usingthepliers99360184(1).
Removal
Pistonsareequippedwiththreeelasticrings:asealingring,a
trapezoidal ringand ascraper ring.
Pistons aregroupedinto classes A andBfor diameter.
49024
Figure91
Remove the piston pin seeger rings (2) using the round
tippedpliers(1).
3aso |ovobo 2006 Print 603.93.641
5408 PISTON-CONNECTING ROD ASSEMBLY
49025
32618
49026
Figure92
Figure93
Figure94
Figure95
Remove thegudgeon pin (1).
If removal isdifficult usethe appropriatebeater.
Measuring the diameter of the pistons
Measuringthegudgeonpindiameter (1) witha micrometer
(2).
Conditions for correct gudgeon pin-piston
coupling
Lubricatethepin(1) andtherelevant housingonthepiston
hubs with engine oil; piston must be inserted with a slight
finger pressureandit should not comeout bygravity.
47584
Usingamicrometer (2), measurethediameter of thepiston
(1) todeterminetheassemblyclearance;thediametershould
bemeasuredat thespecified value.
Print 603.93.641 3aso |ovobo 2006
MAIN DATA OF PISTON, RINGSAND PIN
X =0,6 0,15mm
The dimensionis measured on a 111 mm
16552
3513
Figure96
Checkthethicknessofthepistonring(2) usingamicrometer
(1).
The compression ring (2) of the 1 cavity is trapezoidal.
C|oaaoco 'X' bot.ooo t|o soa||o |o aoo |ts |oos|o |s
measuredbyplacingthepiston(1) withitsringinthecylinder
liner (3), so that thesealingringis half-projected out of the
cylinder liner.
540842 Piston rings
109108
16552
Checkthe clearancebetweentherings(2) and therelative
piston housings(1) usingafiller gauge (3).
36134
Checkthegapbetweentheendsofthesealingrings(1),using
afiller gauge(2), enteredinthecylinder liner (3).
Ifthedistancebetweenendsislowerorhigherthanthevalue
required, replacetherings.
Figure97
Figure98
Figure99
Figure100
3aso |ovobo 2006 Print 603.93.641
117178
44927
Figure101
Figure102
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS
* Valuesto be obtained after installingthe bush
CONNECTING ROD MARKS
Letter indicatingtheweight class:
A = 2865to 2895g.
B = 2896to 2925g.
C = 2926to 2955g.
Number indicating the selection of diameter for
thebigend bearinghousing:
1 = 77.000 to 77.010 mm
2 = 77.011 to 77.020 mm
3 = 77.021 to 77.030 mm
Numbersidentifyingcap-connectingrod coupling
1
2
3
Data concerning the class section of connecting rod
housingandweight arestampedonthebigend.
!
When installingconnecting rods, make sure
theyall belongto thesameweight class.
VIEW FROM A
Print 603.93.641 3aso |ovobo 2006
540830 CONNECTING ROD
Check thetorsion of the connecting rod(5) bycomparing
two points(A andB) of thepin (3) on the horizontal plane
of theaxis of theconnectingrod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads byapprox. 0.5mmon thepin(3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
oppositesideBof thepin(3):thedifferencebetweenAand
B must be no greater than 0.08mm.
Checkthebendingof theconnecting rod(5) bycomparing
twopointsC andD ofthepin(3) onthevertical planeofthe
axisof theconnectingrod.
Position thevertical mount (1) of thedial gauge (2) so that
this restsonthepin(3) at point C.
Swing the connecting rod backwards and forwards seeking
thehighest positionof thepinandinthiscondition zero the
dial gauge (2).
Shift thespindle(4) withtheconnectingrod(5) andrepeat
thecheckonthehighest point ontheoppositesideDofthe
pin(3).Thedifferencebetweenpoint C andpoint Dmustbe
no greater than0.08mm.
61696
Checkingaxis alignment
Check thealignment of theaxes of theconnectingrods (1)
usingasuitabledevice (5), proceedingas follows:
- Fit theconnectingrod(1) on thespindleof thetool (5)
and lockit with the screw (4).
- Setthespindle(3)ontheV-prisms,restingtheconnecting
rod(1) on thestop bar (2).
49029
Figure103
Figure104
Figure105
Figure106
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
T|o |os oooo to bo oootoo .|t| t|o .oo 'TC|' (+)
facing upwards. Direct the ring openings so they are
staggered 120 apart.
Fitting the connecting rod- piston assembly
Carryout thesteps for removal describedonpages 68and
69inreverseorder.
The connectingrod screwscan bereused aslong
asthediameter of thethreadis not lessthan13.4
mm.
Fitting the piston rings
Checkingtorsion
61694
Checkingbending
61695
NOTE
(Demonstration)
(Demonstration)
(Demonstration)
3aso |ovobo 2006 Print 603.93.641
Checking connecting rod squareness
49030
47593
Figure107
Figure108
Figure109
Fit thehalf-bearings(1),selectedasdescribedonpages59to
65, bothontheconnectingrodandonthe stand.
- all pistons belongto thesameclass, A or B;
- ideogramstampedonthepistoncrownisplacedtoward
theengineflywheel, or the cavity, on thepiston cover,
correspondsto the position of theoil spraynozzles.
61831
Connectingrod-piston assembly
Markingareaon the pistoncrownof ideogram
specifying the assembly position and the
selectionclass
Connectingrodmarkingarea (seeFigure101).
1
2
3
Fit theconnectingrod-pistonassemblies(1) intothecylinder
liners (2) using band 99360605 (1, Figure109). Check the
following:
- theringsgaps areoffset by 120 ;
Asspares, classA pistonsareprovidedandcan be
fitted also to cylinder liners belongingto class B.
Piston protrusion check
Onceassemblyis complete, check piston protrusion from
cylinder barrels: it must be 0.32-0.69 mm.
NOTE
Be verycareful that theconnecting rod does not
strikethecylinder walls.
Revi- June2007
PRINT603.93.641/A
Fitting the connecting rod-piston assemblyinto
the cylinder liners
Install theconnectingrodcaps(1) withhalf-bearings;tighten
theconnectingrodcapfixingscrews(2) to 50Nm(5kgm)
torque. Bytool 99395216(3), tightenthescrews further at
40 angle.
Removethecapsandchecktheclearancebycomparingthe
widthof thecalibratedwirewiththescalecalibrationonthe
envelopecontainingthewire.
540610 CYLINDER HEAD
Before dismounting cylinder head, check cylinder head for
hydraulic seal byproper tooling; in caseof leaksnot caused
bycupplugs or threadedplugs, replacecylinder head.
47594
47583
36159
Figure110
Figure111
Figure112
Install andfixtool 99360264(2) withbracket (4); tightenby
lever (1) until cottersareremoved(3);removethe tool (2)
andtheupperplate(5),thespring(6)andthelowerplate(7).
Repeattheoperationonall thevalves.Turnthecylinderhead
upside down and removethevalves (8).
The planarity (1) is checked using a ruler (2) and a feeler
gauge (3). If deformations exist, surface the head using
propersurfacegrinder;themaximumamount of material to
beremovedis0.2 mm.
To checktheclearanceproceedas follows:
Connect the connectingrods to therelative main journals,
placealength of calibrated wire on the latter.
Checking the planarity of the head on the
cylinder block
(Demonstration)
After leveling, make sure that valve sinking and
injector protrusion areas describedintherelative
paragraph.
540831 Checking assembly clearance of big
end pins
In case of plugs dismounting/replacement, on
mounting, applysealant Loctite 270 on plugs.
NOTE
Dismounting the valves
Before dismountingcylinder head valves, number
themin view of their remountingin the position
observedondismountingshouldtheynot haveto
beoverhauled or replaced.
Intake valves are different formexhaust valves in
that theyhaveanotchplacedat valveheadcentre.
NOTE
NOTE
Whenreplacing, thecylinder head is supplied as a
spare part with a threaded plug, which must be
removedduringassembly.
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
MAIN DATA - VALVESAND VALVE GUIDES
* Valuesto be obtained after installingthe valve guides
92841
47509
Figure113
Figure114
Check,bymeansofamicrometer,that valvestemdiameters
are as specified; if necessary, grind the valves seat with a
grinder, removingtheminimumquantityof material.
INSTALLATION DIAGRAMFORVALVEGUIDESAND VALVES
* Valuesto be obtained after installingthe guidevalves
540667 VALVE GUIDES
*
Figure115
48625
540622 VALVE
Removing dust and checking the valves
Removecarbon dust usingthemetal brush supplied. Check
that the valves showno signs of seizureor cracking. Check
the diameter of the valve stemusing a micrometer (see
Figure114) and replaceif necessary.
Print 603.93.641 3aso |ovobo 2006
41032
45634
Figure116
Figure117
Remove valve guidesbymeansof tool 99360288.
Install by means of tool 99360288 equipped with part
99360294, which determines theexact installationposition
of valve guides into the cylinder heads; if they are not
available, install thevalveguidesinthecylinder head sothat
theyproject out bymm16.3 to 16.7 (Figure114).
After installing the valve guides, smooth their holes with
sleeker 99390310.
Reamthevalveseats(2)oncylinderheadusingasuitabletool
(1).
After reamingthe valveseats, usetool 99370415, to make
surethatthevalveposition,withrespecttothecylinderhead
surface, isthe following:
- -0.5 to -0.8 mm(recessing) of exhaust valves;
- -1.6 to 1.9 mm(recessing) of discharge valves.
To replacetheinjector holder (2), act asfollows:
- thread theholder (2) withtool 99390804(1).
Carryout operations described in figs. 118-121-122-123
- 124byfixingtoolstothecylinderheadbymeansofbraket
A.
Replacing of valve guides
Replacing- Reaming the valve seats
To replace the valve seats, remove them using the
appropriatetool.
Valve seats must be reamed whenever valves or
valveguides arereplaced or ground.
1
2
A
NOTE
(Demonstration)
3aso |ovobo 2006 Print 603.93.641
540613 REPLACING INJECTOR HOLDERS
Removal
45633
Figure118
Figure119
Figure120
- Remove anyresidue (1), withtool 99390772 (2), from
thecylinder headgroove.
1
2
- fastenextractor 99342149(2) to case(3), bytightening
thenut (1), andpull out thecasefromcylinder head.
45631
1
2
3
45635
- Lubricate sealingrings (3) and fit themto thecase (4);
fixtool 99360554(2) to thecylinder headbymeansof
bracket A, install the new case, tighten the screw (1),
upsettingthecaselower part.
1
2
4
3
A
45632
Figure121
- Adjust thecasinghole(3) withborer 99394043(1) and
guidebushing99394014(2).
1
2
3
A
Print 603.93.641 3aso |ovobo 2006
45636
47585
Figure122
Figure123
- Throughmiller 99394041(1) andbushing99394014(2),
ream the injector seat in the holder (3), check the
injector protrusion fromthecylinder headplanewhich
must be 0.7mm.
Usingdial gauge(1), checktheprotrusionof theinjector (2)
whichmust be0.7mm.
Checking protrusion of injectors
1
2
3
A
44909
Figure124
INSTALLATION DIAGRAMFOR
INJECTOR HOLDER
3aso |ovobo 2006 Print 603.93.641
TIMING CONTROL COMPONENT PARTS
1. Camshaft - 2. Bushing- 3. Pin- 4. Articulatedrod-
5. Camshaft control gear - 6. Idler gear - 7. Twinidler gear
- 8. Driveshaft drivinggear.
86925
86927
86928
Ratedassemblingplaybetweenidler gear bushingsandpins:
0.040 0.080 mm.
Camshaft drive
541253 Intermediate gear pin
86926
541252 Idler gear
541252 Twin idler gear
541254 Replacing the bushings
Bushings (1, Figures 128- 129) can bereplaced whenthey
areworn. Put up thebushing, thengrind it so as to bringit
to adimension of 58.010 0.10mm.
Bushingsmust beforcedinto gears (2, Figures128
- 129) byfollowingthedirectionofthearrow:they
mustbepositionedatthelevelshowninthefigures.
Figure125
Figure126
Figure127
Figure128
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
5412 TIMING GEAR
47506
47505
47507
Figure129
Figure130
Figure131
541211 Checking cam lift and pin alignment
Whenthecamshaft (4) isonthetailstock(1),checkalignmentofsupportingpin(3) usingacentesimal gauge(2);itmustnot exceed
0.030 mm. If misalignment exceedsthisvalue, replacetheshaft.
Inorder tocheckinstallationclearance, measurebushinnerdiameterandcamshaft pin(1) diameter;thereal clearanceisobtained
bytheir difference.
If clearanceexceeds 0.150 mm, replacebushesand, if necessary, thecamshaft.
Placethecamshaft (4) onthetailstock(1) andcheckcamlift (3) usingacentesimal gauge (2); valuesareshownintableonpage
19.
1
3aso |ovobo 2006 Print 603.93.641
541210 Camshaft
The bush surfaces must not show any sign of seizing or
scoring; if theydo replace them.
47504
47508
Figure132
Figure133
MAIN DATA - CAMSHAFT ANDTOLERANCES
The surfacesof shaft supportingpin and camsmust beextremelysmooth; if yousee anysignof seizingor scoring, replace the
shaft andthe relativebushes.
MAIN DATA - CAMSHAFT BUSHES AND RELATIVEBLOCK SEATS
* Bushinner diameter after installation
541213 Bushes
Measurethebushinnerdiameterswithabaremeterandreplace
them, if thevaluemeasured exceeds thetolerancevalue.
To take down and fit back the bushes, use the proper tool
99360487.
Print 603.93.641 3aso |ovobo 2006
TOLERANCES TOLERANCECHARACTERISTIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricityor coaxial alignment
OSCILLATION Circular oscillation
IMPORTANCE CLASSASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Figure134
107217
A. Drift withseat for bushings to insert/extract. - B. Grubscrewfor positioningbushings.- C. Referencemark to insert
seventh bushingcorrectly. - D. Referencemarkto insert bushings1, 2, 3, 4, 5, 6 correctly(redmarks).- E. Guidebushing. -
F. Guide line. - G. Guidebushingto secureto theseventh bushingmount. - H. Platefixingyellowbushingto cylinder head.
- I. Grip.- L. Extension coupling.
Figure135
71725
Thesequencefor removingthebushings is 7, 6, 5, 4,3, 2, 1.
Thebushingsareextractedfromthefront ofthesingleseats.
Removal doesnot requirethedrift extensionfor bushings5,
6 and 7andit is not necessaryto use theguide bushing.
Forbushings1,2,3and4it isnecessarytousetheextension
and theguidebushings.
Positionthedrift accuratelyduringthe phaseof removal.
Removal
Figure136
Assembly
1 Positionthebushingtoinsert onthedrift (A) makingthe
grubscrewonit coincidewith theseat (B) (Figure134)
on thebushing.
2 Position the guide bushing (E) and secure the guide
bushing(G) (Figure 134) ontheseat of the 7
th
bushing
with theplate(H).
3 Whiledrivinginthebushing,makethereferencemark(F)
matchthemark(M). Inthisway, whenit is drivenhome,
thelubricationholeonthebushingwill coincidewiththe
oil pipe in its seat.
The bushingis driven home when the 1
st
redreference
mark (D) is flush with the guide bushing(G).
Assemblethedrift together with the extension.
To insert bushings1, 2, 3, 4and5, proceed as follows:
71723
Figure137
To insert thebushing(6), proceed asfollows:
- Unscrew thegrip(I) and theextension(N).
- Positiontheextension(N) andtheguidebushing(E) as
shown inthefigure.
- Repeat steps 1, 2, 3.
Rear
Rear
77795
3aso |ovobo 2006 Print 603.93.641
541213 Replacing camshaft bushes using beater 99360487
70000
109107
86290
MAIN DATA TO CONTROL EXHAUST AND
DISCHARGEVALVESPRING
Lubricate the valve stem and insert the valves in the
respective valve guides; fit the lower caps (1). Use tool
99360329tofit theoil seal (2) onthevalveguides(3) ofthe
exhaust valves; then, to fit thevalves, proceed asfollows.
- fit springs(6) and theupper plate (5);
- applytool 99360264 (2) andblock it with bracket (4);
tighten the lever (1) until cotters are installed (3),
removetool (2).
540665 VALVE SPRINGS
Fitting the valves and oil seal ring
71724
To insert bushing(7), proceed asfollows:
- Refit theguide(G) fromtheinsideasshowninthefigure.
- Positionthe bushingon the drift (A) and bringit close
up to the seat, making the bushing hole match the
lubrication holein thehead. Drive it home.
The7
th
bushingisdriveninwhenthereferencemark(C)
isflushwith thebushingseat.
Beforeassembly, theflexibilityof thevalvesprings hastobe
checkedusingasuitable tool.
Compare theload and elastic deformationdatawith those
of thenew springs given in thefollowingfigure.
Rear
Figure138
Figure139
Figure140
Figure141
Figure142
87051
Should valves not have been overhauled or
replaced, remount themaccordingto numbering
performed on dismounting.
NOTE
Valveclosed
Valveopen
(Demonstration)
Print 603.93.641 3aso |ovobo 2006
44925
The camshaft camsdirectlycontrol rockers: 6for injectors and 12 for valves.
Injectorsandintakevalvescontrol rocker armsarekeyedonrocker armsshaft directly. Exhaust intakevalvescontrol rockerarms
arekeyedonrocker armsshaft puttinginbetween thelevers with engine brakecontrol eccentric pin.
Rockers slidedirectlyon thecamprofiles viarollers. Theother endacts on abar directlysupported bythetwo valvesstems.
A padisplacedbetweentherockeradjustingscrewandthebar.Twolubricationholesareobtainedinsidetherockers.Therocker
shaft practicallycovers the whole cylinder head; removeit to haveaccessto all theunderlyingcomponents.
Figure143
44914
44912
44913
Figure144
Figure145
Figure146
PUMPINJECTORROCKER
EXHAUST VALVESROCKER
The bushsurfaces must not showanytraceof scoringof excessive wear; otherwise, replacebushes or thewholerocker.
DISCHARGE VALVEROCKER
Rocker
SECTION A-A SECTIONB -B
SECTION A-A SECTION B -B
SECTION A-A SECTION B -B
Checkthat thesurfaceof theshaft shows no scoringor signsof seizure; if it does, replace it.
MAIN DATA OFTHEROCKERARMSHAFT
79171
Shaft
Figure147
92822
LEVERWITH ENGINEBRAKECONTROL
ECCENTRIC PIN
Figure148
3aso |ovobo 2006 Print 603.93.641
5412 ROCKER SHAFT
47586
47595
47596
Figure149
Figure150
Figure151
Figure152
Fix the engine block to the stand 99322230 by means of
brackets 99361035.
Install thecylinder linersas described inpage 56.
Fit theoil spraynozzles(2), sothat thedowel coincideswith
theblock hole(3).
Placethehalf bearings(1) on the main bearings.
Place the half-bearings (1) on the main bearings in the
underblock (2).
Bymeansof suitableequipment (1) applysiliconeLOCTITE
5970 IVECO No. 2995644 to the block, as shown in the
figure.
Sealant application diagram
||t t|o |o.o cao'caso oooob|oc' .|t||o +0' o
theapplicationof thesealant.
47570
Figure153
Lubricatethehalf bearings, theninstall thecrankshaft (2) by
means of hoist andhook99360500 (1).
49021
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
ASSEMBLING THE ENGINE
Revi- June2007
47581
47579
Figure154
Figure155
Figure156
Fit the lower crankcase and use a torque wrench (2) to
tighten the outer screws (1) to 25 Nmaccording to the
diagrams on thefollowingpage.
Tightentheinner screws(1) to 140Nmtorquebymeansof
atorque wrench (3), then with two further angular phases
60 +60 ,usingtool 99395216(4). Tightenagaintheouter
screws (1, Figure155) with 90 angular closing, using tool
99395215 (3, Figure155).
Fit the lower crankcase by means of a suitable hoist and
hooks (1).
49022
Use new screws whenever removing the
bed-plate.
NOTE
PRINT603.93.641/A
44898
FRONT SIDE
Fourth phase:
inner screws
angleclosing
(60)
44897
44899
44898
Figure157
First phase: outer
screws preliminary
tightening
(25 Nm)
FRONT SIDE
FRONT SIDE
FRONT SIDE
Secondphase:
inner screws
preliminary
tightening
(140Nm)
Fifthphase:
outer screws
angleclosing
(90)
44898
FRONT SIDE
Third phase:
inner screws
angleclosing
(60)
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DIAGRAM SHOWING THE LOWER CRANKCASE FIXING SCREWS TIGHTENING ORDER
49030
Rotatethecylinder assemblyplacingit vertically.
Lubricatethehalf-bearings(1) andfit themintheconnecting
rodandthecap.
Figure158
Connectingrod-piston assembly
Markingareaofideogramonthepiston
crown
Connectingrodmarkingarea
Figure159
47593
Fit theconnectingrod-pistonassemblies(2) into thepiston
liners, usingtheband 99360605(1). Checkthefollowing:
- theringsgaps areoffset by 120;
- all pistons belongto thesameclass, A or B;
- ideogram(2, Figure159),stampedonthepistoncrown,
isplacedtowardtheengineflywheel,orthecavity,onthe
pistonskirt, correspondsto thepositionof theoil spray
nozzles
Fitting the connecting rod-piston assembly
into the cylinder liners
Figure160
1
2
3
61831
Not findingit necessaryto replace theconnecting
rodbearings, youneedto fit themback in exactly
thesamesequenceand position as in removal.
Ifthebigendbearingsneedtobereplaced,choose
themaccordingtothedescriptiongivenfrompage
59to page65.
Donot makeanyadjustment onthebearingshells.
Lubricate half bearings (1), then mount them on the
connectingrodandcap
ThepistonsaresuppliedassparesinclassAandcan
also befittedinclass Bcylinder liners.
NOTE
NOTE
NOTE
3aso |ovobo 2006 Print 603.93.641
47594
Figure161
Figure162
Figure163
Figure164
Figure165
Figure166
Connect theconnectingrods to therelativejournals,fit the
connectionrodcaps(1) withhalfbearings; tighten thefixing
screws (2) of the connectingrod caps to 50Nmtorque(5
kgm). Usingtool 99395216 (3), further tighten screwswith
40 angle.
Bymeans of centeringring99396033 (2), check the exact
coverposition(1),otherwiseactasnecessaryandtightenthe
screws.
Fit thesealinggasket (1), install thefittingtool 99346245(2)
and drive thesealinggasket (1) byscrewingnut (3).
Makesurethat pistons1-6areexactlyat theTDC Placethe
gasket (2) ontheblock. Fit thecylinder head(1) andtighten
screws as shown infigs. 166, 167 and 168.
Diagramshowingthe cylinder head fixingscrews tightening
order
- Preliminarytighteningbymeansof atorquewrench(1):
1
st
phase: 50Nm(5kgm:
2
nd
phase: 100Nm(10kgm)
45255
45256
45266
45267
44900
Usenew screws whenever removingthecylinder
head.
NOTE
Before reusing the screws (2), measure the
diameter ofthethread;it must beno lessthan11.4
mm; if it is, changethescrew.
Lubricate thethread of thescrewswithengineoil
beforeassembly.
NOTE
Revi- June2007
PRINT603.93.641/A
Engines without power take-off
Tighten the screws shown in the figure by means of atorque
wrench, in compliance with the following order and tightening
torque:
no. 1screw M10x 1.5 x 100 tighteningtorque42Nm
no. 13screwsM12x 1.75x 80tighteningtorque63Nm
no. 3 screws M10 x 1.5x 35 tighteningtorque42 Nm
Figure167
Figure168
Figure169
45268
- Angleclosingbymeansof tool 99395216 (1):
3
rd
phase: 90 angle
4
th
phase: 75 angle
Fit theoil pump(4),intermediategears(2) withrod(1) and
tightenscrews (3) intwo phases:
preliminarytightening 30 Nm
angleclosing 90
Applysealant LOCTITE 5970 IVECO No. 2995644 to the
gear housingusingtheproper equipment (1).
The sealer string(1) diameter isto be 1,5
47597
47598
Figure170
Install the gear housing within 10 of the application
of thesealant.
no. 2 screws M18 x 1.25x 125 tighteningtorque
24 Nm
:
Engines with power take-off
no. 10screwsM12x 1.75x 80tighteningtorque63Nm
no. 3 screws M10 x 1.5x 35 tighteningtorque42 Nm
84390
no.2screwsM12x1.75x125tighteningtorque63
Nm
d no. 8 screw M10x 1,5 x 120

no. 2 screw M10x 1,5 x 120(applyto thethread
LOCTITE 275)
Figure171
0.5
0.2
NOTE
47592
Base November 2006 Print 603.93.641
PRINT603.93.641
Revi- June2007
PRINT603.93.641/A
Secondphase:closingtoangleof60 withtool 99395216(1).
49036
Figure172
Figure173
Thecrankshaft hasalocatingpegthat hastocouple
with therelevant seat on theengine flywheel.
49037
Figure174
Position the flywheel (1) on the crankshaft, lubricate the
thread of the screws (2) with engine oil and screw them
down. Lock rotation with tool 99360351 (3). Lock the
screws (2) intwo phases.
First phase: pre-tightening with torque wrench (4) to a
torque of 100 Nm(10 kgm).
If the teeth of the ring gear mounted on the
flywheel,forstartingtheengine,areverydamaged,
replacetheringgear.It must befittedafterheating
theringgear to atemperatureof approx. 200 C.
Fitting flywheel
Fit thesealinggasket (1), install thefittingtool 99346246(2)
and drive thesealinggasket byscrewingthenut (3).
45258
540850 FLYWHEEL
60668
DETAIL OFPUNCH MARKSON ENGINEFLYWHEEL FOR PISTON POSITIONS
A.Holeonflywheel withonereferencemark,correspondingtotheTDC ofpistons3-4.- B.Holeonflywheel withonereference
mark, correspondingto theTDC of pistons 1-6. - C. Holeon flywheel with onereferencemark, corresponding
to theTDC of pistons 2-5.- D. Holeonflywheel withtwo reference marks, positioncorrespondingto 54 .
VIEW OF HOLES:
A - B- C
VIEW OF HOLES:
D
Figure175
NOTE
NOTE
Figure176
Figure177
Fit the camshaft (4), positioning it observingthe reference
marks ( ) as shown in thefigure.
Lubricatetheseal (3) and fit it on theshoulder plate (2).
Mount theshoulderplate(2) withthesheetmetal gasket (1)
and tightenthescrews (5) to therequiredtorque.
73843
72436
Figure178
Figure179
Position the crankshaft with the pistons 1 and 6 at thetop
deadcentre(T.D.C.).
This situationoccurs when:
1. The holewithreferencemark(5) of theengineflywheel
(4) can beseen throughtheinspection window.
2. Thetool 99360612 (1), throughthe seat (2) of theengine
speedsensor,entersthehole(3) intheengineflywheel (4).
Ifthisconditiondoesnot occur,turntheengineflywheel (4)
appropriately.
Remove thetool 99360612 (1).
Replace the idle gear bushing (1) when wear is
detected.After installingthebushing,adjust it to
58.010 0.10mm.
- Apply gauge 99395215 (1), check and record the
positionof the rod (3) for thegear, tightenthe screw
(2) to theprescribed torque.
45376
- Remove thegear (1) and tighten screws (2) bymeans
of proper wrench, to theprescribedtorque.
45269
NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
Fitting camshaft
Figure180
Figure181
Positionthegear (2) onthecamshaft so that the4 slotsare
centredwiththeholes for fixingthecamshaft, without fully
lockingthescrews (5).
Usingthedial gaugewithamagnetic base(1),checkthat the
c|oaaoco bot.ooo t|o oas (2 aoo 3) |s 0.03 0.+5 ,
if this is not so, adjust the clearanceas follows:
- Loosen thescrews (4) fixingtheidlegear (3).
- Loosenthescrew(2,Figure 178) fixingthelinkrod.Shift
the link rod (3, Figure 178) to obtain the required
clearance.
- Lock the screw (2, Figure 178) fixing the link rod and
screws (4) fixingtheidlegear to therequired torque.
Figure182
Figure183
44908
Fit theseals(1) (2) (3) on theinjectors.
Before refitting the rocker-arm shaft assembly,
makesurethatall theadjustmentscrewshavebeen
fullyunscrewed.
Usingtool 99360144(3), fastentheblocks(4) to therocker
arms (2).
Applythetool 99360558(1) totherocker armshaft (5) and
mount theshaft onthe cylinder head.
73533
Fitting pump-injectors
71775
Mount:
- The injectors (2) and, usingatorquewrench, lock the
bracket fixingscrews to atorqueof 36,5 Nm.
- The exhaust brake cylinders (1) and (4) and, using a
torque wrench, fixthemto atorqueof 19 Nm.
- Thecrosspieces(3) onthevalvestem,all withthelargest
holeon thesameside.
Fitting rocker-arm shaft assembly
45270
5
NOTE
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PRINT603.93.641
Applythe tool 99360321(6) to thegear housing(3).
- Mount theenginebrake lever retainingsprings (3).
- Connectthepipe(2) totheenginebrakecylinders(4) and
to thecylinder with theenginebrakesolenoid valve(1).
Figure184
Figure185
Figure186
45261
Lockthescrews (2) fixingtherocker-armshaft as follows:
- 1
st
phase: tighteningtoatorqueof 40Nm(4kgm) with
thetorquewrench(1).
- 2
nd
phase: closing with an angle of 60 usingthe tool
99395216 (3).
60574
71776
71777
Figure187
Mount the electric wiring (2), securing it on the
electro-injectors with atorque screwdriver (1) to atorque
of 1.36- 1.92 Nm.
Camshaft timing
The arrowshows thedirection of rotation of the
enginewhen running.
Using the above-mentioned tool, turn the engine
flywheel (1) inthedirectionofrotationoftheengine
so as to take the piston of cylinder no.1 to
approximatelytheT.D.C.inthephaseofcombustion.
This condition occurs when the hole with one
reference mark (4), after the hole with two
referencemarks(5) ontheengineflywheel (1),can
beseenthrough theinspectionwindow (2).
NOTE
Figure188
SCHEME OFSCREW TIGHTENING SEQUENCE
SECURING ROCKER ARMS
Screw screws (1 - 2 - 3) until rocker arms are brought to
contact relating seats on cylinder head, tighten the screws
according to sequence indicated in figure operating in two
steps as indicated insuccessive figure.
70567A
3aso |ovobo 2006 Print 603.93.641
71774
106535
60575
Figure189
Figure190
The exact position of piston no.1 at the T.D.C. is obtained
whenin theabove-describedconditionsthetool 99360612
(1) goesthroughtheseat (2) oftheenginespeedsensorinto
thehole(3) in the engineflywheel (4).
Ifthisisnot thecase,turnandadjust theengineflywheel (4)
appropriately.
Set thedial gaugewiththemagnetic stand (1) with therod
(flat based) on theroller (2) of therocker armthat governs
theinjector of cylinder no.1 and pre-load it by 6mm.
The camshaft is in step if at the cam lift values of
4.90 0.05 mmtherearethefollowingconditions:
1) Theholemarkedwithanotch (5) canbeseenthrough
theinspection window
2) The tool 99360612 (1) through the seat (2) of the
enginespeedsensor goesintothehole(3) intheengine
flywheel (4).
77259
If you do not obtain the conditions illustrated in Figure191
and describedinpoints 1and2, proceed as follows:
1) Loosen the screws (2) securing the gear (1) to the
camshaft andutilizetheslots(1,Figure193) onthegear
(2, Figure 193).
2) Turn the engine flywheel appropriately so as to bring
about the conditions described in points 1 and 2
Figure191, it beingunderstoodthat the camlift must
not changeat all.
3) Lock thescrews(2) and repeat thecheck as described
above.
4) Tightenthe screws(2) to therequiredtorque.
Figure191
Figure192
With tool 99360321 (6, Figure188), turn the crankshaft
clockwise until the pointer of the dial gauge reaches the
minimumvaluebeyondwhich it canno longer fall.
Reset thedial gauge.
Turn the engine flywheel anticlockwise until the dial gauge
gives areadingfor thelift ofthecamofthecamshaft of 4.90
0.05mm.
Duringthemeasurement,thedial gaugerod must
always beat right angles to theenginecentreline
and NOT to thehead surface.
NOTE
Print 603.93.641 3aso |ovobo 2006
71778
77259
Figure193
Turn the flywheel (4) again to bring about the following
conditions:
- Notch(5) visiblethroughthelowerinspectionwindow;
- The tool 99360612 (1) inserted in the hole (3) in the
engine flywheel (4) through theseat (2) of the engine
speed sensor.
77260
Phonic wheel timing
Turn the output shaft bringing cylinder piston 1 at
compressionstageto TDC.; turn theflywheel byabout 1/4
turninoppositedirectionthannormal directionofrotation.
Turn the flywheel again according to normal direction of
rotationuntil theholemarkedwiththedoublenotch(4) can
beseenthroughtheinspection hole set under theflywheel
housing.Fit tool 99360612(5) into theflywheel sensor seat
(6).
Fit tool 99360613(2),throughthetimingsensorseat,onthe
tooth ( ) obtainedonthephonicwheel.
Should tool (2) fitting be difficult, slacken screws (3) and
direct thephonicwheel (1) properlyto positionthetool (2)
on thetooth. Tighten the screws(3).
Mount the gear (2, Figure193) with the 4 slots (1,
Figure193) centred with the fixing holes of the camshaft,
lockingtherelevant screwstotherequiredtighteningtorque.
Check the timingof the shaft by first turning the flywheel
clockwisetodischargethecamcompletelyandthenturnthe
flywheel anticlockwiseuntil thedial gaugegivesareadingof:
4.90 0.05mm
Checkthe timingconditions described inFigure 191.
Figure194
Figure195
Whenit is not possibleto adjust advancethrough theslots
(1) andthecamshaft turnsbecauseintegral withthegear (2);
thusthecamlift referencevaluevariesandit is necessaryto
proceed in thefollowingway:
1) Fastenthescrews(2,Figure192) androtatetheengine
flywheel clockwiseby ~1/2 turn;
2) Turn the engine flywheel anticlockwise until the dial
gauge gives a reading of the lift of t he cam of the
camshaft of 4.90 0.05mm
3) Takeoutthescrews(2,Figure 192) andremovethegear
(2) fromthe camshaft.
3aso |ovobo 2006 Print 603.93.641
- Using an appropriate wrench (4), loosen the
adjustment screwuntil thepumpingelement isat the
end-of-stroke;
- Tighten the adjustment screw, with a dynamometric
wrench, to 5 Nmtighteningtorque (0.5 kgm);
- Untightentheadjustment screwby1/2 to 3/4rotation;
- Locknut at prescribedtorque.
Adjustment of clearances between rockers and valve studs
and preloadingof pump injector rockers should becarried
out with extremecare.
Takethe cylinder where clearancemust be adjusted to the
bursting phase; its valves are closed while balancing the
symmetriccylinder valves.
Symmetric cylindersare 1-6, 2-5 and 3-4.
In order to properlyoperate, followthese instructions and
dataspecifiedonthetable.
Adjustment of clearance between the rockers and rods
controllingintake and exhaust valves:
- Use apolygonal wrench to slacken thelockingnut (1)
of therocker armadjustingscrew (2).
- Insert thestripof feeler gauge(3) correspondingtothe
workingclearance(page13);
- Tighten or untighten the adjustment screw with the
appropriatewrench;
- Makesurethat thegaugeblade (3) canslidewithaslight
friction;
- Lockthenut (1), byblockingtheadjustment screw.
Pre-loadingof rockers controllingpump injectors:
- Using a polygonal wrench, loosen the nut lockingthe
rocker adjustment screw (5) controlling the pump
injector (6);
ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS
44936A
Figure196
FIRING ORDER 1-4-2-6-3-5
In order to carryout operations abovecorrectly,
performsequence indicated in table, checking, at
eachrotationphase,that positioncorrect usingpin
99360612 to be inserted in hole identified by a
notch on flywheel, correspondingto the position
of pistons(seedetail fig. 173).
NOTE
Revi- June2007
PRINT603.93.641/A
Intakeandexhaust rocker clearanceadjustment andpre-loadingof rockerscontrollingpumpinjectors
Clockwise
start-up and
rotation
Balancing
cylinder
valveno.
Adjusting
clearanceof
cylinder valve
no.
Adjusting
pre-loadingof
cylinder
injector no.
1 and6 at
P.M.S.
6 1 5
120 3 4 1
120 5 2 4
120 1 6 2
120 4 3 6
120 2 5 3
Figure197
Figure198
84377
Fit therocker cover (1).
Fit theblow-bycase (7) and itsgasket and then tighten the
screws (8) to the prescribedtorque.
Install thefilter (5) and thegaskets(4and6).
Thefilter (5) operationisunidirectional, therefore
it must beassembledwith the two sight supports
asillustrated in thefigure.
84392
ApplysiliconeLOCTITE5970IVECO No. 2995644onthe
blow-bycaseandformastring(2) of 1.5 , asshown
inthefigure.
||t t|o b|o.-b caso (+) .|t||o +0' o soa|o
application.
Figure199
0.5
0.2
NOTE
NOTE
47573
Rotatetheengine, then fit theoil suction strainer.
Placegasket (4) onoil sump(1),thenpositionframe(3) and
fit thesump onto theengine base bytighteningscrews (2)
to thespecifiedtorque.
ENGINE COMPLETION
Maketheenginecompletebyeither fittingordisconnecting
theitems below:
- power take-off (P.T.O.), if any, andits respectivepipes;
- air compressor completewith power steeringpump;
- fuel pump;
- full fuel filter support andpipes;
- EDC control unit;
- intakemanifold;
- preheatingresistor;
- heat exchanger;
- oil filter (lubricatethegasket);
- exhaust manifold;
- turboblower andits respectivewater and oil pipes;
- damper flywheel andpulley;
- thermostat unit;
- belt stretcher, water pumpandalternator;
- electromagneticjoint;
- drive belt;
- belt stretcher (if any), air-conditioner compressor;
- drive belt;
- oil level dipstick;
- electric connections and sensors.
Thoroughlyclean cover (3) drain holeand suction ducts.
Fit thecover (3) andtightenthefasteningscrews(2) to the
prescribed torque.
Apply silicone LOCTITE 5970 IVECO No.
29955644 on the blow-by case (7) surface of
engines fitted with P.T.O. according to the
proceduredescribedinthefollowingfigure.
NOTE
The fittings of thecooling water and lubricatingoil
pipes of theturbocharger haveto betightened toa
torque of:
- 35 5 Nm, water pipefittings;
- 55 5 Nm, oil pipe femalefitting;
- 20-25 Nm, oil pipemale fitting.
NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
Tofitthebelt(1) useappropriateequipment(2) toadjustthe
belt tensioner inthedirection indicated bythearrow.
Figure200
Automatic tensioners do not require further
adjustments after the installation.
NOTE
Figure201
- Supplyenginewith oil provided quantity.
Dismount engine fromstand and mount starter.
Mount:
- sounddeadeningguard;
- pipes.
106224
Applytool 99360321(2) to gearsbox (1).
Mount springbelt (3) ondrivingshaft pulley, mount chock
99360192 (4) on compressor pulley (5) for climatecontrol
system. Position spring belt (3) in the opening of tool
360+2 a'oo .|t| 'coso 8'.
Bytool 99360321, rotatedrivingshaft (6) accordingto the
direction of the arrow ( ) until springbelt (5) is correctly
positionedon compressor pulley (3).
To fit the elastic belt commanding the climate
control compressor, you must use tool number
99360192 (4). Any other method might cause
tension that would be harmful to the elastic belt
itself.
NOTE
While operating, keep tool 99360192 (4) in
contact to pulley (3) and at the sametime guide
springbelt (5) inorder to prevent it fromtwisting.
NOTE
Springbelt must be replaced bya new one after
everydismountingoperation.
NOTE
Figure202
COMPRESSORCONTROL BELT
ASSEMBLY DIAGRAM
1. Alternator - 2. Air conditioner compressor -
3. Electromagneticjoint;- 4. Water pump -
5. Crankshaft - 6. Springbelt
102650
112329
Print 603.93.641 3aso |ovobo 2006
3aso |ovobo 2006 Print 603.93.641
Figure203
44918
DETAIL A
A
Dropping oil
Pressure oil
Droppingoil
Pressure oil
Lubrication circuit
5430 LUBRICATION
Enginelubricationisobtainedwithagearpumpdrivenbythe
crankshaft viagears.
A heat exchangergovernsthetemperatureofthelubricating
oil.
Theoil filter,signallingsensorsandsafetyvalvesareinstalled
intheintercooler.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
3aso |ovobo 2006 Print 603.93.641
The oil pump (1) cannot be overhauled. On finding any
damage, replace the oil pumpassembly.
Seeunder therelevant headingfor replacingthegear (2) of
thecrankshaft.
60560
77820
112327
Figure204
Figure205
MAIN DATA TO CHECKTHESAFETY RELIEF
VALVE SPRING
OIL PUMPCROSS-SECTION
+. Saot o||o va|vo Stat o ooo|o ossoo +0.+ 0.1bars
Safety relief valve
Figure206
190 6N
324 9N
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
543010 Oil pump
Theoil overpressurevalveislocatedontheleft-handsideof
thecrankcase.
Start of openingpressure 5bars.
73542 88819
Figure207
Figure208
MAIN DATA TO CHECKTHEOIL OVERPRESSURE
VALVE SPRING
HEAT EXCHANGER
The followingelementsarefitted on theintercooler: 1. Transmitter for lowpressure warninglamp- 2. By-pass valve- 3. Oil
temperature sensor - 4. Oil pressure sensor for singlegauge- 5. Heat valve. Number of intercooler elements: 7
Oil overpressure valve
543110 Heat exchanger
77818
168 9
308 15
Figure209
3aso |ovobo 2006 Print 603.93.641
This is anew generation of filters that permit much more
thorough filtration as theyareableto holder backagreater
amount of particles of smaller dimensions than those held
back byconventional filters witha paper filteringelement.
Thesehigh-filtration devices, to dateused onlyin industrial
processes, make it possibleto:
- reducethewear of enginecomponents over time;
- maintain the performance/specifications of the oil and
therebylengthen thetimeintervals betweenchanges.
External spiral winding
The filteringelements areclosely woundbyaspiral so that
eachfoldisfirmlyanchoredto thespiral withrespect tothe
others. Thisproduces auniformuseof theelement evenin
theworst conditions such as coldstartingwith fluids witha
high viscosity and peaks of flow. In addition, it ensures
uniformdistributionoftheflowovertheentirelengthofthe
filteringelement,withconsequent optimizationofthelossof
loadandof its workinglife.
Mount upstream
To optimize flow distribution and the rigidity of the filtering
element, this has an exclusive mount composed of a strong
meshmadeofnylonandanextremelystrongsyntheticmaterial.
Filteringelement
Composedof inert inorganicfibresboundwithanexclusive
resin to a structure with graded holes, the element is
manufactured exclusively to precise procedures and strict
qualitycontrol.
Mount downstream
A mount for the filteringelement and astrongnylonmesh
makeit evenstronger,whichisespeciallyhelpful duringcold
starts andlongperiods of use.Theperformanceofthefilter
remainsconstant andreliablethroughout itsworkinglifeand
fromoneelement to another,irrespectiveofthechangesin
workingconditions.
Structural parts
Theo-rings equippingthefilteringelement ensureaperfect
seal between it and the container, eliminatingby-pass risks
and keeping filter performance constant. Strong
corrosion-proof bottoms and a sturdy internal metal core
completethestructure of thefilteringelement.
Whenmountingthefilters, keep to thefollowingrules:
- Oil andfit newseals.
- Screw down the filters to bring the seals into contact
with thesupportingbases.
- Tighten thefilter to atorque of 35 40Nm.
73545
47447
73546
Figure210
The valve quicklyopens at apressureof: 3bars.
Thermostatic valve
Start of opening:
- travel 0.1mmat atemperatureof 82 2 C.
End of opening:
- travel 8mmat atemperatureof 97 C.
Engine oil filters
By-pass valve
Figure211
Figure212
Print 603.93.641 3aso |ovobo 2006
109080
Figure213
The valve allows oil to enter only above the threshold
pressure of 1.7 0.2 bar. This permits fillingthecircuit and
therefore lubricating the most stressed parts even when
workingat lower pressures.
Valve integrated in piston coolingnozzle
3aso |ovobo 2006 Print 603.93.641
Figure214
Description
The engine cooling systemworks with forced circulation
inside closed circuit and canbe connectedto anadditional
heater (if any) andto the intarder intercooler.
It consists mainlyof thefollowingcomponents:
- anexpansionreservoirwhoseplug(1) incorporatestwo
va|vos o|sc|ao aoo c|ao cooto|||o t|o ssto
pressure.
- acoolant level sensorplacedat thebottomoftheexpan-
sionreservoir with two couplingpoints.
Right drive vehicles:
D couplingpoint for sensor S1 6.2 litres
Left drivevehicles:
D couplingpoint for sensor S1 6 litres
- anenginecoolingunit todissipatetheheat takenbythe
coolant fromthe enginethrough the intercooler.
- aheat exchanger to cool down lubricationoil;
- a water pump with centrifugal systemincorporated in
thecylinder block;
- anelectricfan consistingof a 2-speedelectro-magnetic
joint equippedwithaneutral wheel shaft hubfittedwith
ametal plate movingalongtheaxis and where thefan
is installed. It is controlled electronicallyby thevehicle
Multiplexsystem.
- a3-waythermostat controllingthecoolant circulation.
Operation
The water pump is actuated by the crankshaft through a
poli-Vbelt andsendscoolant tothecylinderblock,especially
to the cylinder head (bigger quantity). When the coolant
temperature reaches and overcomes the operating
temperature, the thermostat is opened and fromhere the
coolantflowsintotheradiatorandiscooleddownbythefan.
The pressure inside the system depending on the
temperature variation is controlled by the discharge and
charge valves incorporated in theexpansionreservoir filling
plug(1).
The dischargevalvehasadoublefunction:
- keepthesystemunderlight pressureinordertoraisethe
coolant boilingpoint;
- dischargethepressuresurplusintheatmosphereasare-
sult of thecoolant high temperature.
The charge valve makes it possible to transfer the coolant
from the expansion reservoir to the radiator when a
depression isgenerated inside the systemas aresult of the
coolant volume reduction depending on the fall in the
coolant temperature.
Dischargevalveopening:
D 1
st
breather 0.9 bar
D 2
nd
breather 1.2 bar
Chargevalveopening -0.03 bar
Cap(1) tighteningtorque(1) 8 1 Nm
Water leavingthe thermostat
Water enteringthepump
+0.2
- 0.1
Water circulatingintheengine
92824
COOLINGCIRCUIT VERSION WITHOUT INTARDER
+0.2
- 0.1
+0
- 0.02
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
5432 COOLING
92825
Water issuingfrom thethermostat
Water flowing towards the pump
Water circulating in the engine
Vent
Specific elements of the version wi th INTARDER
COOLINGCIRCUIT VERSION WITH INTARDER
Figure215
3aso |ovobo 2006 Print 603.93.641
ELECTROMAGNETIC FAN DRIVESECTION
The electro-magnetic fan driveactiondepends on:
- thecoolant temperature;
- theclimatecontrol systemfluid pressure (if any);
- theslowingdownaction of theintarder on (if any).
Coolant temperaturefor:
- engagement 93 C
- disengagement 88 C
With climatecontrol system
Climatecontrol systemfluid pressure:
- 2
nd
speed engagement 22bar
With intarder
With brakingpower below41%of maximumpower.
- 2
nd
speed engagement 93 C
With brakingpower over 41%of maximumpower:
- 2
nd
speed engagement 85 C
Figure216
78842
543210 Electromagnetic fan drive
Using a feeler gauge, check the gap between the anchor
assembly (2) andthe pulley (1), it must be no greater than
2.5mm.
Astothedescriptionof theelectro-magneticjoint operation
and servicing, seetheVolume3.
Figure217
WATER PUMP SECTION
Thewater pumpconsists of: rotor, seal bearingandcontrol
pulley.
44915
543210Water pump
Makesure that thepumpcasinghasno crackingor
water leakage; otherwise, replacetheentire pump.
NOTE
92826
NEW VERSION
Figure218
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PRINT603.93.641
Figure219
Figure220
45357
Water issuingfromthermostat
45358
TO THEHEATER
TO BY-PASS FROMTHEHEAD
TO EXPANSION TANK
FROMTHEHEAD
TO RADIATOR
543250Thermostat
TO THEHEATER THERMOSTAT OPERATION VIEW
Checkthethermostat worksproperly; replaceit if indoubt.
Temperatureof start of travel 84 C 2 C.
Minimumtravel 15 mmat 94 C 2 C.
3aso |ovobo 2006 Print 603.93.641
61905 61906
SYSTEMWITH THERMOSTAT OFF
VIEWS OFRADIATOR THERMOSTAT OPERATION FORGEARBOX WITH INTARDER
SYSTEMWITH THERMOSTAT ON
A. Gearbox heat exchanger - B. Engine- C. Thermostat closed- D. Thermostat open- 1. Inlet fromradiator - 2. Return from
cabinheater - 3. Inlet fromheader tank- 4. Deliveryto cabin heater - 5. To engine water pump - 6. Outlet fromthehead-
7. Deliveryto gearboxheat exchanger - 8. Returnfromheat exchanger to thermostat - 9. Enginere-circulation(breather) to
header tank- 10. Deliveryto radiator.
Figure221
Print 603.93.641 3aso |ovobo 2006
Compressed air (hot)
Intakeair
Engine exhaust gas
Compressed air (cooled)
Figure222
The turbochargingsystemconsists of:
- air filter;
- Aturbochargerwithfixedgeometry(330CVand360CV
engines) or withvariablegeometry(310CV engines);
- '|otocoo|o' ao|ato.
44916
DIAGRAMOF SUPERCHARGINGWITH THE VGT TURBOCHARGER
VGT TURBOCHARGER
Operatingprinciple
The variable geometry turbocharger (VGT) consists of a
centrifugal compressor and a turbine, equipped with a
mobiledevicewhichadjuststhespeedbychangingthearea
of thepassingsection of exhaust gases to theturbine.
Thanksto this solution, gas velocityandturbinespeed can
behigheven when theengineisidling.
If thegas is made to go throughanarrowpassage, in fact,
it flows faster, so that theturbinerotates morequickly.
The movement of the device, choking the exhaust gas
flowingsection,iscarriedout byamechanism,activatedby
apneumaticactuator.
Thisactuatorisdirectlycontrolledbytheelectroniccontrol
unit byaproportional solenoidvalve.
The deviceisinmaximumclosingconditionat idlespeed.
At high engine operating speed, the electronic control
systemis activated and increases the passing section, in
order to allow the in-coming gases to flow without
increasingtheir speed.
A toroidal chamber is obtained duringthecastingprocess
inthecentral bodyfor thepassageof thecoolant.
3aso |ovobo 2006 Print 603.93.641
5424 TURBOCHARGING
72421
Figure223
a Gradientcharacterizedbytheeffectoftheexternal spring
(4, Figure 223).
b Gradient characterized bythe effect of the external (4,
Figure223) and internal (6) springs.
Actuator
Stroke [mm]
[bar]
Solenoid valve for VGT control
This N.C. proportional solenoid valve is located on the
left-handsideof thecrankcaseunder the turbine.
The electronic control unit, viaa PWM signal, controls the
solenoidvalve, governingthesupplypressureof theturbine
actuator, which, on changing its position, modifies the
cross-sectionoftheflowofexhaust gases ontothebladesof
theimpeller and thereforeitsspeed.
The resistanceof the coil is approx. 20-30Ohms.
Workingprinciple (SeeFigure223)
Theactuatorpiston,connectedtothedriverod,iscontrolled
with thecompressedair introducedthroughtheair inlet (1)
on thetop of theactuator.
Modulating the air pressure varies the movement of the
piston and turbine control rod. As the piston moves, it
progressively compresses the external spring (4) until the
baseofthepistonreachesthedisc (5) controllingtheinternal
spring(6).
Onfurtherincreasingthepressure,thepiston,viathedisc(5),
interfereswiththebottomlimit stop (10).
Usingtwospringsmakesitpossibletovarytheratiobetween
thepistonstrokeandthepressure.Approximately85%ofthe
strokeof therodisopposedbytheexternal springand15%
bytheinternal one.
REPAIRING ACTIONS
Ifvaluesbeyondtolerancearedetected,checktheefficiency
of:
- shut-off valve;
- pressure sensor;
- engine cable pressure sensor connection (if oxidised,
clean with aspecific product);
- lack of electrical defects in solenoid valve VGT
(continuityconnection);
- actuator moved by active diagnosis as described in
relatingchapter, in caseof locking, grease bushingwith
lubricant Kernite(for high temperatures); if the trouble
persists, replacetheactuator;
- sliding sleeve: it must slide freely when operated
manually. Iflockedandifthebushcheckis not sufficient
or effective, ornofaultsaredetectedintheother points,
ooo aot|o|zat|oo o t|o 'o| |os'' a'ot ooato,
change the turbocharger according to the standard
procedures.
Ifanomalousengineoperationisfound,whichisdue
totheboostingsystem,it isadvisablethat youcheck
theefficiencyof seal gasketsand thefasteningofconnecting
sleevesprior tocarryingout thechecksontheturboblower.
Also check for obstructions in thesuckingsleeves, air filter.
If the turbocharger damage is due to alack of lubrication,
checkthat theoil circulationpipesarenot damaged.
If so, changethemor eliminatethecause.
NOTE
After carryingout the above mentioned checks, check the
turbocharger operationwithanEngineTest byusingIVECO
diagnosis equipment (Modus- IT 2000- E.A.SY.) according
to therelevant procedure.
Thetest mustbeperformedinfollowingconditions: NOTE
- engine coolant temperature >50 C;
- batteryup (voltage>22V) for compressiontest;
- efficient rechargingsystem.
1. Air inlet - 2. Gasket - 3. Piston- 4. External spring-
5. Internal springcontrol disc - 6. Internal spring-
7. O-ring- 8. Springholder - 9. Limit stop - 10. Dust seal -
11. Control rod
71834
Figure224
Print 603.93.641 3aso |ovobo 2006
'+06226 106227
106228
Figure225 Figure226
Figure227
Remove screws (2) and take actuator (1) off
turbocompressor (7).
Remove screw (6), underlying disk (5), ring (4) and
disconnecttierod(3) ofactuator (1) fromthepinofvariable
geometrydrivinglever (8).
Accuratelycleanpin( ) oflever (8) andbushing( ) oftie
rod(3) usingaclothmadeof non abrasivemicro fibre.
Checkactuator efficiency(1) operatingas follows.
Apply, to fitting (2) of actuator (1), compressed air feed
piping provided with pressure regulator (4). By using the
pressureregulator,introduce,intotheactuator,compressed
airslowlymodulatingit,from0 3.5bar;tierod(3)ofactuator
(1) must movewithout jamming;otherwise,replaceactuator
(1).
Checkforanyactuatorleaksat indicatedpoints( ) applying,
on thesepoints, asolutionof suds.
When actuator (1) is fed with compressed air, no bubbles
must be found at indicated points ( ); otherwise, replace
actuator (1).
Variable geometry movement control
Do not useabrasivepaper of anykind. NOTE
Visuallycheckthe conditions of bushing( ) of tie rod (3)
and pin ( ) of lever (8); wheretheyare foundto beworn
out, replaceactuator (1) or turbocompressor (7).
Check variable geometry inner driving mechanism
movement by operating on lever (8); jamming must not
occur;otherwise,cleanturbinebody, asdescribedinrelating
chapter.
Checking the actuator
3aso |ovobo 2006 Print 603.93.641
106229
106230
106231
106232
Figure228
Figure229
Figure230
Figure231
Lubricatebushing( ) oftierod(3) andpin( ) oflever (8)
withlithium-basedCastrol LMGREASEtypeandreconnect
actuator (1) to turbocompressor (7) operatingas follows.
Connect tierod(3) to lever (8).
Mount newring(4),mount disk(5) andscrewupscrew(6).
Screw up screws (2) securing actuator (1) to
Tighten screws(2and6) at 25Nmtorque.
Check travel X of tie rod (2) of actuator (1) operating as
follows.
MeasuredistanceX1betweenactuator (1) andcross-axisof
eyelet (4).
Apply,tofittingofactuator (1),piping(3) for compressedair
feedprovidedwithpressureregulator.Byusingthepressure
regulator,introduce,intoactuator (1) compressedair slowly
modulatingit,from0 3,5bar,until lever (5) istakentoitsend
of travel.
Measure again the distance between actuator (1) and
cross-axis of eyelet (4) dimension X2.
Travel X of tierod (2) of actuator (1) is givenbyfollowing
subtraction X = X2-X1 and must result to be equal to
11.5 0.5mm.
Markmountingpositionof clamp (2) on central body (1).
On threadingand nut (4), applyantioxidant spraylubricant
and, operatingon nut (4), loosen clamp (2).
Slightlyrotateclamp (2) usingpliers(5).
Markmountingpositionof turbinebody(3) oncentral body
(1).
Byacopper hammer, beat ontwo opposite points(~180)
on turbinebody (2) to separate turbine bodyfromcentral
body(1).
Cleaning turbine body
Checking actuator travel
Inoperation,takeparticularcaretoavoiddamaging
turbinerotor.
NOTE
After dismounting turbine body, check variable geometry
movement as described in relating chapter; where
improvement in movement is not found with respect to
previous check, replaceturbocompressor.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
106233
106235
106234
106236
106237
Figure232
Figure233
Figure234
Figure235
Figure236
Accuratelycleanslot ring(1) and areaaround turbinebody
fromcarbonaceousdepositsandcheckthat the ringmoves
freely, otherwise, replaceturbocompressor.
By suitable scraper and abrasive paper, accurately clean
surfaces ( ) of turbine body (1) from carbonaceous
deposits, takingcareto avoid damagingthe surfaces.
Dismount clamp(1) fromcentral body(2) andcheckthatthe
clampdoesnot result to bedamaged;otherwisereplacethe
clamp.
Dismount seal ring(1),external withrespect tocentral body
(2).
Accuratelycleanseal ring(1) andcheckthattheringdoesnot
result to bedamaged; otherwisereplacethering.
Check turbine rotor (1); there must not be found:
carbonaceous deposits, deformation, cracks, blade scoring;
also, turbinemust turn freely.
Bycomparator, check clearance of turbine rotor stem(1);
clearancemust result to be:
- axial clearance: 0.025 0.127 mm
- radial clearance: 0.254 0.356 mm.
Whereeitherclearancevaluesover aboveonesor anyone
of above mentioned faults are found, replace
turbocompressor.
Beforecleaningturbinesidecentral body,properly
protect oil, water and air inlets and outlets ( ) in
order to prevent dirt or foreign bodies from
enteringturbocompressor.
NOTE
Any small cracks between slots and ring can be
accepted, because they do not impair
turbocompressor operation conditions.
NOTE
3aso |ovobo 2006 Print 603.93.641
106238
106235
106240
Figure237
Figure238
Figure239
surfaces ( ) of central body (1) from carbonaceous
deposits, taking care to avoid damaging the surfaces and
variablegeometryring.
Then,withcompressedair,cleanvariablegeometrysurfaces
and ringfromremoved residues.
Checkagain, asdescribed in relatingchapters:
- variablegeometrymovement;
- actuator;
- actuator travel.
Positionclamp (1) oncentral body(2)
Mount turbinebody (1) on central body (2) takingcare to
avoiddamagingturbinerotorandalignturbinebodyvariable
geometryslot ring.Donotforcemountingoperation: incase
of jamming, it might damage variable geometry with
consequent regulation systemfaultyoperation.
Oncemountinghasbeencompleted,makesurethat turbine
bodyresults to bematched correctlyoncentral body.
Positionturbinebodyoncentral bodyandclamponcentral
bodyin such away that marks, made on dismounting, are
matching.
Tighten nut clampingtheclamp at 11.3 Nmtorque.
- actuator;
- actuator travel.
Should clamp (1) be replaced with an integrated
heat guard,anewactuatorhastobemountedwith
an integrated heat guard at the place of existing
one.
NOTE
Position accuratelycleaned seal ringon central body.
Apply a thin layer of antiscuff paste on cleaned matching
surfaces: central body / turbinebody.
Print 603.93.641 3aso |ovobo 2006
Figure240
ENGINEFEED SCHEME
1. Fuel filter - 2. Pressure dampingdevice - 3. Pressure control valve (start of openingat 5bar) - 4. Feedpump-
5. Fuel pre-filter with primingpump - 6. Valve, to recirculatefuel frominjectors, integrated in feedpump(start of openingat
3.5bar) - 7. Central unit - 8. Heat exchanger - 9. One-wayvalveto returnfuel to tank (start of openingat 0.2 bar) -
10. Pump injectors
A. Fuel arrivingat injectors- B. Fuel returningto tank
115265
Fuel is supplied via a fuel pump, filter and pre-filter, 6
pump-injectors governed bythe camshaft via rocker arms
and bytheelectroniccontrol unit.
Returncircuit
Supplycircuit
3aso |ovobo 2006 Print 603.93.641
FUEL SYSTEM
92830
Fuel pumpfittedonto thepower steeringpump
1. Overpressurevalve- 2. Deliveringfuel to injectors-
3. Suckinginfuel - 4. Pressurecontrol valve
92829
Pumpperformances
Pumprotationspeed (rpm)
Minimumflowrate (l/h)
2600
310
600
45
170
12
100
Test
conditions
Negativepressure
onaspiration (bar)
Pressureondelivery
(bar)
Testliquid
temperature (C)
Testliquid
0.5
5
30
0.3
3
30
0.3
0,3
30
0.3
0.3
30
ISO 4113
Fieldof use
Overrunningrotationspeed(max5min)(rpm)
Dieseloil temperature (C)
Filteringrateonaspiration
(micron)
Negativepressureonaspiration (bar)
2600
4100max
-25/+80
30
0.5max
Pressurecontrol valve
Valvecalibration 5 8.8
Injectors returnvalve
Valvecalibration 3.2 3.8
73547
Figure241
Fuel pumpfitted onto thecamshaft drive
/. |oo| |o|ot 3. |oo| oo||vo C. 3-ass oot
|. |oo| otoo o t|o o-|o,octos
|. |ossoo o||o va|vo Coo|o ossoo. 5-8 bas
Feed pump
Figure242
98870
SECTION ON FEED PUMP
1. Oil and fuel leaks indicator
Figure243
Figure244
Pumpperformances
4100
310
900
45
250
12
140
6
Test
conditions
Negativepressure
onaspiration (bar)
Pressureondelivery
(bar)
Testliquid
temperature (C)
Testliquid
0.5
5
50
0.3
3
50
0.3
0.3
50
0.3
0.3
20
ISO 4113
Fieldof use
(micron)
4100
5800max
-25/+80
0.5max
-25/+120
Valvecalibration
Valvecalibration
Anoverpressurevalveisasingle-actingvalve,calibratedto0.2
0.3bar, placedonthepipingthat returns fuel to tank.The
overpressure valve prevents fuel duct incylinder headfrom
emptyingwith enginestopped.
5 5.8
3.4 3.8
Print 603.93.641 3aso |ovobo 2006
Overpressure valve
44908
Injector-pump
+. |oo|/o|| soa| 2. |oo|/o|oso| soa| 3. |oo|/o|aost as soa|
Theinjector-pumpiscomposedof:pumpingelement,nozzle,
solenoidvalve.
Figure245
Plunger
The plunger is operated byarocker armgoverned directly
bythecamof thecamshaft.
The plunger is able to ensure ahigh deliverypressure. The
return stroke is made bymeans of areturnspring.
Nozzle
Garagesareauthorized to performfault diagnosis solelyon
the entire injection systemand may not work inside the
injector-pump, which must onlybe replaced.
A specific fault-diagnosis program, included in the control
unit, is able to check the operation of each injector (it
deactivatesoneatatimeandchecksthedeliveryoftheother
five).
Fault diagnosis makes it possibleto distinguish errors of an
electrical originfromones of amechanical/hydraulicorigin.
It indicates brokenpump-injectors.
It isthereforenecessarytointerpret all thecontrol unit error
messages correctly.
Anydefectsin the injectorsare to beresolvedbyreplacing
them.
Solenoid valve
Thesolenoid, which isenergizedat eachactivephaseofthe
cycle, viaasignal fromthecontrol unit,controlsaslidevalve
that shuts off theplunger delivery pipe.
When thesolenoid is not energized, thevalveis open, the
fuel ispumpedbut it flowsbackinto thereturnpipewiththe
normal transfer pressureof approximately5 bars.
Whenthesolenoidisenergized,thevalveshutsandthefuel,
not beingableto flowback into thereturnpipe, is pumped
into the nozzleat high pressure, causingtheneedleto lift.
The amount of fuel injecteddepends on thelengthof time
theslidevalveisclosedandthereforeon thetimefor which
thesolenoidis energized.
Thesolenoidvalveisjoinedto theinjectorbodyandcannot
beremoved.
On the top there are two screws securing the electrical
wiringfromthe control unit.
To ensuresignal transmission,tightenthescrewswithatorque
.ooc| to a toooo o +.36 +.2 | (0.+36 0.+2 ').
775010 Replacing injectors-pump
Injectors have to be replaced with great care (for their
removal seethe description on pages 51and 52, for fitting
themsee thedescription on pages 93and94).
If this job is done with the engine on the vehicle,
before removing theinjectors-pump drain off the
fuel contained in thepipes in thecylinder headby
unscrewingthe deliveryand return fittings onthe
cylinder head.
NOTE
0 411 700 002
XXXXXX XXXX X
868USA /
87060
Figure246
For eachreplaced injector, connect to MODUS or IT2000
station or to E.A.SY: then, when required bythe program,
enter the code, that is stamped on the injector ( ), for
reprogrammingthecentral unit.
When checkingthe clearanceof the rocker arms,
itisimportant tochecktheinjector-pumppre-load.
NOTE
3aso |ovobo 2006 Print 603.93.641
1. Fuel valve- 2. Plunger - 3. Fuel outlet -
4. Fillingandbackflow passage
60669
Injector Phases
Filling phase
During thefillingphase the plunger (2) runs up to thetop
position.
After passingthe highest point of the cam, therocker arm
roller comes near thebase ringof the cam.
Thefuel valve(1) is openandfuel can flowinto theinjector
viathebottompassage (4) of thecylinder head.
Fillingcontinuesuntil theplunger reachesitstoplimit.
Figure247
Begin of injection
The injection phase begins when, at a certain point in the
downphaseoftheplunger,thesolenoidvalvegetsenergized
and thefuel valve (1) shuts.
Themoment deliverybegins,appropriatelycalculatedbythe
electronic control unit, depends ontheworkingconditions
of theengine.
Thecamcontinueswiththerockerarmto pushtheplunger
(2) andtheinjectionphasecontinuesaslongasthefuel valve
(1) stays shut.
60670
Figure248
Print 603.93.641 3aso |ovobo 2006
60671
Figure249
End of injection
Injection ceases when thefuel valve (1) opens, at acertain
point in thedown stroke of theplunger, after thesolenoid
valvegets de-energized.
Thefuel flows backthroughtheopen valve(1), theinjector
holes and thepassage (4) into thecylinder head.
The time for which the solenoid valve stays energized,
appropriatelycalculatedbytheelectroniccontrol unit, isthe
durationofinjection(delivery)andit dependsontheworking
conditionsof theengine.
3aso |ovobo 2006 Print 603.93.641
123 TRAKKER EURO 4/5 F3BENGINE
F3B Engine
Page
VIEWSOFTHEENGINE 125 . . . . . . . . . . . . . . . . . . .
TECHNICAL DESCRIPTION 128 . . . . . . . . . . . . . . . .
CHARACTERISTIC CURVES 129 . . . . . . . . . . . . . . . .
MAIN DATA 132 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY DATA - CLEARANCE 135 . . . . . . . . . . . .
TIGHTENINGTORQUE 142 . . . . . . . . . . . . . . . . . . .
DIAGRAMSOF TIGHTENINGSEQUENCEOF
MAIN ENGINECOMPONENTS 145 . . . . . . . . . . .
TOOLS 149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL-REFITTING 159 . . . . . . . . . . . . .
- Removal 159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fillingthecoolingsystem 163 . . . . . . . . . . . . . . . . .
- Bleedingair fromthefuel system 164 . . . . . . . . . .
- Checksandtests 164 . . . . . . . . . . . . . . . . . . . . . . .
ELECTRO-MAGNETIC FAN DRIVEREPLACEMENT 165
- Removal 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF THEENGINE 169 . . . . . . . . . . . . .
REPAIRS 177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDERBLOCK 177 . . . . . . . . . . . . . . . . . . . . . . .
- Checksandmeasurements 177 . . . . . . . . . . . . . . .
- Cylinder liners 178 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe cylinder liners 179 . . . . . . . . . . . . . .
- Crankshaft 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringthemain journalsandcrankpins 181 . . .
- Preliminarymeasurement of datato select
main bearingand bigend bearingshells 182 . . . . . .
- Selectingthemainbearingand bigend
bearingshells 183 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe timinggear
and oil pumpdrive 189 . . . . . . . . . . . . . . . . . . . . .
- Checkingmainjournal assembly
clearance 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingcrankshaft endfloat 190 . . . . . . . . . . . . .
- Connectingrod pistonassembly 191 . . . . . . . . . . .
Page
- Pistonrings 193 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connectingrod 194 . . . . . . . . . . . . . . . . . . . . . . . .
- Bushings 195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingconnectingrodssquareness 195 . . . . . . .
- |ooot|o t|o cooooct|o oo |stoo assob| +6
- Mountingthepistonrings 196 . . . . . . . . . . . . . . . .
- Fittingthebigendbearingshells 196 . . . . . . . . . . .
- Fittingconnectingrod- pistonassembliesin
thecylinder liners 197 . . . . . . . . . . . . . . . . . . . . . .
- Checkingpistonprotrusion 197 . . . . . . . . . . . . . . .
- Checkingcrankpin assemblyclearance 198 . . . . . . .
CYLINDERHEAD 198 . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblythe valves 198 . . . . . . . . . . . . . . . . . .
- Checkingheadbearingsurfaceoncylinder
block 198 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Valves 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Valveseats 199 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingclearancebetweenvalve-stem
and associatedvalveguide 200 . . . . . . . . . . . . . . . .
- Valveguides 200 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacinginjector holders 200 . . . . . . . . . . . . . . . .
- Checkinginjector protrusion 202 . . . . . . . . . . . . . .
TIMINGGEAR 203 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft drive 203 . . . . . . . . . . . . . . . . . . . . . . . .
- Idler gear pin 203 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Idler gear 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Twinintermediategear pin 203 . . . . . . . . . . . . . . .
- Twinidler gear 203 . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe bushings 203 . . . . . . . . . . . . . . . . . .
- Timingsystem 204 . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingcamlift andpin alignment 204 . . . . . . . .
- Bushings 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Valvesprings 207 . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKERSHAFT 208 . . . . . . . . . . . . . . . . . . . . . . . . .
- Shaft 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rocker arms 209 . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAKKER EURO 4/5 124 F3BENGINE
Page
ENGINE ASSEMBLY 210 . . . . . . . . . . . . . . . . . . . . . . .
- Fittingconnectingrod- pistonassembliesin
cylinder liners 213 . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingthecylinder head 214 . . . . . . . . . . . . . . . . .
- Fittingflywheel boxhousing 215 . . . . . . . . . . . . . .
ENGINE FLYWHEEL 216 . . . . . . . . . . . . . . . . . . . . . .
- Fittingengineflywheel 216 . . . . . . . . . . . . . . . . . . .
- Fittingcamshaft 217 . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingpump-injectors 218 . . . . . . . . . . . . . . . . . . .
- Fittingrocker-armshaft assembly 218 . . . . . . . . . . .
- Camshaft timing 219 . . . . . . . . . . . . . . . . . . . . . . .
- Phonicwheel timing 221 . . . . . . . . . . . . . . . . . . . .
- Adjust intakeand exhaust rocker armclearance,
and pumpinjector preload 222 . . . . . . . . . . . . . . .
- CompletingEngineAssembly 223 . . . . . . . . . . . . .
LUBRICATION 227 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pump 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Safetyrelief valve 229 . . . . . . . . . . . . . . . . . . . . . . .
- Oil overpressurevalve 230 . . . . . . . . . . . . . . . . . . .
- Heat exchanger 230 . . . . . . . . . . . . . . . . . . . . . . . .
- By-passvalve 231 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostaticvalve 231 . . . . . . . . . . . . . . . . . . . . .
- Engineoil filters 231 . . . . . . . . . . . . . . . . . . . . . . . .
- Valveintegrated inpiston coolingnozzle 232 . . . . .
COOLING 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Description 233 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagneticfandrive 235 . . . . . . . . . . . . . . . .
- Water pump 235 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat 235 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Viewof thermostat operation
for versionswithIntarder 236 . . . . . . . . . . . . . . . .
TURBOCHARGING 237 . . . . . . . . . . . . . . . . . . . . . . .
- Turbocharger HOLSET HE 551V 237 . . . . . . . . . .
- Actuator 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Solenoidvalvefor VGT control 238 . . . . . . . . . . . .
REPAIR 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Variablegeometrymovement control 239 . . . . . . .
- Checkingtheactuator 239 . . . . . . . . . . . . . . . . . . .
- Checkingactuator travel 240 . . . . . . . . . . . . . . . . .
- Cleaningturbinebody 240 . . . . . . . . . . . . . . . . . . .
- Turbocharger HOLSET HX 50W 243 . . . . . . . . . .
REPAIRS 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASTEGATE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUELSYSTEM 245 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overpressurevalve 246 . . . . . . . . . . . . . . . . . . . . .
- Feedpump 246 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injector-pump 246 . . . . . . . . . . . . . . . . . . . . . . . . .
- Pressuredamper 246 . . . . . . . . . . . . . . . . . . . . . . .
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
VIEWS OF THE ENGINE
LEFT SIDEVIEW OF ENGINE
Figure1
71695
FRONT VIEW OFENGINE
Figure2
106682
3aso |ovobo 2006 Print 603.93.641
REAR VIEW OF ENGINE
Figure3
71694
RIGHT SIDE VIEW OF ENGINE
Figure4
112172
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Figure5
73530
TOPVIEW OFENGINE
Revi- June2007
PRINT603.93.641/A
TECHNICAL DESCRIPTION
Level of Gas Emissions
Engine torqueandpower level
ENGINE
F 2 B E 3 6 8 1 A * P 0 0 1
-
Indicates the enginefamily
Progressiveproduction number
Engine familyevolution (also irrespectiveof thedisplacement)
Engine
Stroke andcylinder position
(3=4 stroke, vertical with post - treatment)
Number of cylinders
Fuel feed+injection(TCA,direct injectiondiesel engine)
Use(egI =truck)
Variant
TYPE PART NUMBER
A
B
360 CV/1500Nm
330 CV/1400Nm
C 310 CV/1300Nm
P
M
Euro 4- 2006
Euro5- 2006
R
S
Euro4- 2007
Euro5- 2007
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
CHARACTERISTIC CURVES
Max. POWER : 302 kW 410 HP 1900 rpm
Max. TORQUE : 1900 Nm 194 kgm 1000 to 1515 rpm
Figure6
108521
CHARACTERISTIC CURVESOFENGINEF3BE3681D
rpm
3aso |ovobo 2006 Print 603.93.641
Max. POWER : 332 kW 450 HP 1900 rpm
Figure7
108522
CHARACTERISTIC CURVESOFENGINEF3BE3681C
rpm
Print 603.93.641 3aso |ovobo 2006
Max. POWER : 368 kW 500HP 1900 rpm
Figure8
108523
CHARACTERISTIC CURVESOFENGINEF3BE3681B
rpm
3aso |ovobo 2006 Print 603.93.641
MAIN DATA
Type F3BE3681D F3BE3681C F3BE3681B
Cycle 4-stroke diesel
Supply
Turbocharged with intercooler
Injection
Direct
Number of cylinders 6 in line
j
Bore mm 135
Stroke mm 150
+ + +.. =
Total displacement
cm
3
12880
Compressionratio 16.5: 1
Maximumpower kW
(HP)
302
(410)
332
(450)
368
(500)
rpm 1900 1900 1900
Maximumtorque Nm
(kgm)
1900
(194)
2200
(224)
2300
(234)
rpm 1000 to 1515 1000 to 1435 1000 to 1525
Lowidlespeed
no load
rpm 550 50
Fast idlingspeed with
no load
rpm 2320 50
Print 603.93.641 3aso |ovobo 2006
Type F3B
A
B
TIMING SYSTEM
Start beforeT.D.C. A
End after B.D.C. B
19
36
C
D
Start beforeB.D.C. D
End after T.D.C. C
50
9
X
To check timing
mm
X
mm
Operation
mm
X
mm
_
_
0.40 0.05
0.60 0.05
SUPPLY Viafuel pump - Filters
Injection
typeBosch
With UIN 31injectors with electronic adjustment.
Injectors-pumpcontrolledbycamshaft in head.
Nozzles type Nozzles type -
Injection sequence 1- 4- 2- 6- 3- 5
bar
Injection pressure bar 2000
3aso |ovobo 2006 Print 603.93.641
Type
F3B
410 CV
F3B
450 CV - 500 CV
TURBOCHARGING
Holset with fixed geometryand
WASTEGATE
Holset
variable
geometry
Turbocharger type HX 50W HE551V
LUBRICATION
Forcedviagear pump, pressurerelief valve,
oil filter
bar
Oil pressure with engine
warm(100 5C): bar
at slow running bar 1.5
at fast idlingspeed bar 5
COOLING
Viacentrifugal pump, thermostat, electro-magnetic drive fan,
radiator, heat exchanger
Water pump drive With belt
Thermostat N. 1
starts opening: 84 2 C
full aperture 94 2 C
REPLENISHING
Total capacity
1
st
filling
lit
g
liters
kg
35
31.5
Capacity
- engine sump at
minimumlevel
lit 20 liters
kg
20
18
UraniaFE 5W30
- engine sump at
maximumlevel
lit 28 UraniaLD7 liters
kg
28
25.2
- quantityin circulation
that
doesnot return to sump doesnot return to sump
liters
kg
7
6.3
- quantitycontained in
cartridgefilter (to addwhen
changingthecartridgefilter) changingthecartridgefilter)
liters
kg
3
2.7
Print 603.93.641 3aso |ovobo 2006
ASSEMBLY DATA - CLEARANCE
Type F3B
CYLINDERASSEMBLY AND CRANK MEMBERS mm
1
Cylinder liner seats
top
1
bottom
153.500to 153.525
152.000to 152.025
Cylinder liners:
L
2
outsidediameter:
top
2
bottom
153.461to 153.486
151.890to 151.915
2
length L _
Cylinder liners-
crankcaseseats
top
bottom
0.014 to 0.039
0.085 to 0.135
Outsidediameter 2 _
3 Cylinder liners:
X
inside diameter 3A* 135.000to 135.013
inside diameter 3B* 135.011to 135.024
protrusion X** 0.045 to 0.075
* Selection class
** Under aload of 8000 kg
1
Pistons: FEDERAL MOGUL
1
X
measurement X 18
X
outsidediameter 1A
D
134.861to 134.873
2 outsidediameter 1B
DD
134.872to 134.884
seat for pin 2 54.010to 54.018
* Selectionclass
Piston - cylinder liners
A*
B*
0.127 to 0.152
0.127 to 0.152
Pistondiameter 1 _
X
Pistonprotrusion X 0.12to 0.42
3 Pistongudgeonpin 3 53.994 to 54.000
Pistongudgeonpin- pin seat 0.010 to 0.024
D
Class A pistonssuppliedas spares.
DD
Class Bpistonsarefitted inproductiononlyand arenot suppliedasspares.
3aso |ovobo 2006 Print 603.93.641
F3B
Type
F3B
Type
mm
1 X FEDERAL MOGUL
X
1
3
2
X
X
X1*
Pistonringslots X2
FEDERAL MOGUL
2.427
1.550 to 1.570( ) / 3.060 to 3.080
3 X
Piston ringslots X2
X3
* measuredon of 130 mm
1.550 to 1.570 ( ) / 3.060 to 3.080
0.020 to 5.040
1 S
Pistonrings:
- scraper trapezoidal S1* 2.296 to 2.340
1
2
S
S
- scraper trapezoidal S1*
- compressionbevelled S2
- milledscraper ringwith
2.296 to 2.340
1.470 1.500 ( ) / 2.970 2.990
3
2
S
S
- milledscraper ringwith
slotsandinternal spring S3
* d t 25 f
4.970 to 4.990
* measured at 2.5 mmfrom
outer
1 0.087 to 0.131
Piston rings- slots 2 0.050to 0.100
3 0.030 to 0.070
Pistonrings _
X1
2 X
Pistonringendgapin
cylinder liner
3
2 X
X
X1 0.40 to 0.50
3 X
X2 0.65 to 0.80
X3 0.40 to 0.75
1
Small end bushingseat
1 59.000 to 59.030
2
Connectingrodbearingseat
2
1
Selectionclass 2 2
3
94.000 to 94.010
94.011 to 94.020
94.021 to 94.030
4 Small end bushingdiameter
3
outside 4 59.085 to 59.110
3
inside 3 54.019 to 54.035
S
Bigend bearingshells S
Red
Green
Yellow
1.965 to 1.975
1.976 to 1.985
1.986 to 1.995
Small end pushing- seat 0.055 to 0.110
Pistongudgeonpin- bushing 0.019 to 0.041
Bigend bearingshells -
Weight of connectingrod
A
4741 to 4780 g
Classes B
C
4781 to 4820 g
4821 to 4860 g
Onlymounted on productionandnot provided with spare.
Oldpart number
Print 603.93.641 3aso |ovobo 2006
Type
F3B
Type
mm
X
Measurement X
Maximumerror
125
Maximumerror
on alignment of connecting
rodaxe // 0.08
1 2
Mainjournals 1
- nominal
- class 1
- class 2
- class 3
99.970 to 100.000
99.970 to 99.979
99.980 to 99.989
99.990 to 100.000 1 2
Crankpins 2
- nominal
- class 1
- class 2
- class 3
89.970 to 90.000
89.970 to 89.979
89.980 to 89.989
89.990 to 90.000
S1 S 2 Mainbearingshells S1
Red
Green
Yellow*
3.110 to 3.120
3.121 to 3.130
3.131 to 3.140
Bigend bearingshells S2
Red
Green
Yellow*
1.965 to 1.975
1.976 to 1.985
1.986 to 1.995
3
Mainbearinghousings 3 106.300to 106.330
Bearingshells- mainjournals f 0,060 to 0,108* - 0,061to 0,119 ** - 0,060to 0,130***
Bearingshells - crankpinsf 0,050 to 0,108* - 0,051to 0,109 ** - 0,050to 0,098***
Mainbearingshells 0.127 - 0.254 - 0.508
Bigend bearingshells 0.127- 0.254- 0.508
X1
Mainjournal for shoulder X1 47.95 to 48.00
X2
Mainbearinghousing
for shoulder X2 40.94 to 40.99
X 3
Half thrust washers X3 3.38to 3.43
Crankshaft shoulder 0.10to 0.30
1 2
Alignment // 1- 2
Roundness 1- 2
0.025
0.040
* Fittedinproduction onlyand not supplied asspares
f Supplied as spares: * standard; ** =0.127; *** =0.254- 0.508
3aso |ovobo 2006 Print 603.93.641
Type F3B
CYLINDER HEAD - TIMING SYSTEM mm
1
Guidevalveseats
on cylinder head 1 15.980 to 15.997
2
2
Valveguides
10.015 to 10.030
3
Valveguides
3 16.012 to 16.025
Valveguides andseats on head 0.015 to 0.045
Valveguides _
4 Valves:
4
4
9.960 to 9.975
60 30 7 30
9.960 to 9.975
45 30 7 30
Valvestemand relevant guide 0.040 to 0.070
Seat onhead for valve seat:
1
1
1
49.185 to 49.220
46.985 to 47.020
2
* provided with spare
Outsidediameter of valve
seats on cylinder head:
2
2
49.260 to 49.275
47.060 to 47.075
49.460 to 49.475*
47.260 to 47.275*
Valveseats 0,2
X
Recessing
0.45to 0.75
X
Recessing
X
1.65to 1.95
Print 603.93.641 3aso |ovobo 2006
Type
F3B
Type
mm
Betweenvalve Betweenvalve
seat and head 0.040 to 0.090
Valvespringheight:
freespring H 76
H
H 1
under aload of:
H
H 1
H2
775 39N H1 59
H2
1366 68N H2 46
X
Injector protrusion X 0.52to 1.34
Seatsfor camshaft bushings
incylinder head:
1 7 88.000 to 88.030
1
2
3
Camshaft supportingpins:
1 7 82.950 to 82.968
Outsidediameter of
bushings for camshaft: 88.153 to 88.183
Bushinginside diameter: 83.018 to 83.085
Bushings and seats in
cylinder head
0.123 to 0.183
Bushings and supportingpins 0.050 to 0.135
Useful camheight
9.231
H
9.5607
13.376
1
Rocker armshaft 1 41.984 to 42.000
3aso |ovobo 2006 Print 603.93.641
Type
F3B
Type
mm
Seatsfor bushings in
rocker arms:
45.000 to 45.016
59.000 to 59.019
46.000 to 46.016
Outsidediameter of
bushings for rocker arms:
45.090 to 45.130
59.100 to 59.140
46.066 to 46.091
Insidediameter of bushings
for rocker arms:
42.025 to 42.041
56.030 to 56.049
42.015 to 42.071
Bushings and seats:
0.074 to 0.130
0.081 to 0.140
0.050 to 0.091
Rocker armbushings andshaft:
0.025 to 0.057
0.015 to 0.087
Engine brake control lever
Eccentric pin outer
diameter 2
Rocker armsshaft seat 1
55.981 to 56.000
42.025 to 42.041
Print 603.93.641 3aso |ovobo 2006
Type
F3B
mm
Rocker arms and engine
brakecontrol lever pin
0.030 to 0.068
Rocker armshaft and seat
on engine brake control
lever
0.025 to 0.057
TURBOCHARGER
Type
End play
Radial movement
Holset with fixed geometry
HX 50
0.025 0.127
0.381 0.610
Holset withvariablegeometry
HE551V
0.051 0.152
0.381 0.533
3aso |ovobo 2006 Print 603.93.641
TIGHTENING TORQUE
PART
TORQUE
PART
Nm kgm
Screwsfixinglower crankcaseto crankcase(see Figure9)
Outsidescrews M12x1.75 First phase: pre-tightening 30 (3)
InsidescrewsM18x2 Second phase: pre-tightening 120 (12)
InsidescrewsM 18x2 Third phase: closingto angle 60
InsidescrewsM 18x2 Fourth phase: closingto angle 55
Outsidescrews M12x1,75 Fifth phase: closingto angle 60
Pistoncoolingnozzleunion 35 2 (3.5 0.2)
Screwsfixingheat exchanger to crankcase (seeFigure13)
pre-tightening 11.5 3.5 (1.15 0.35)
tightening 19 3 (1.9 0.3)
Screwsfixingsuctionstrainer to lower crankcase 24.5 2.5 (2.4 0.25)
Screwsfixingoil sump spacer (seeFigure14)
pre-tightening(1 16) 38 (3.8)
tightening(17 32) 45 (4.5)
Screwsfixinggearboxto crankcase M12x1.75 (see Figure16) 63 7 (6.3 0.7)
Screwsfixingcontrol unit to lower crankcase 24 2.5 (2.4 0.25)
Screwsfixingcylinder head(seeFigure10)
First phase pre-tightening 60 (6)
Secondphase pre-tightening 120 (12)
Third phase closingto angle 90
Fourth phase closingto angle 65
Screwsfixingrocker armshaft
Secondphase closingto angle 60
Locknut for rocker armadjustment screw 39 5 (3.9 0.5)
Screwsfor injector brackets 30 35 (3 3.5)
Screwsfixingplasticcover 8.5 1.5 (0.85 0.15)
Screwsfixingshoulder plateto head 19 3 (1.9 0.3)
Screwsfixingengine mount bracket to cylinder head
Before assembly, lubricate withUTDM oil
Before assembly, lubricate withgraphitizedoil
Revi- June2007
PRINT603.93.641/A
PART
TORQUE
PART
Nm kgm
Screwsfixingengine mount bracket to flywheel casing
Screwsfixingcamshaft gear
First phase pre-tighteningirst 60 (6)
Screwsfixingphonic wheel oncamshaft gear 8.5 1.5 (0.85 0.15)
Screwsfixingexhaust manifold (seeFigure11)
pre-tightening 40 5 (4 0.5)
tightening 70 5 (3.2)
Screwsfixingengine brake actuator cylinder 19 3 (1.9 0.3)
Screwsfixingconnectingrodcap
Screwsfixingengine flywheel
Screwsfixingdamper flywheel
Screwsfixingmiddlegear pins
Screwsfixingidlegear adjustment connectingrod: 24.5 2.5 (2.45 0.25)
Screwsfixingoil pump 24.5 2.5 (2.45 0.25)
Screwsfixingcrankshaft gasket front cover 24.5 2.5 (2.45 0.25)
Screwsfixingfuel pump/ filter mount 19 (1.9)
Screwfixingcontrol unit mount 19 3 (1.9 0.3)
Screwsandnutsfixingturbocharger (seeFigure12) 74 8 (7.4 0.8)
Screwfixingthermostat assembly 30 3 (3 0.3)
Screwsfixingwater pump 24.5 2.5 (2.45 0.25)
Screwsfixingfan hub to spacer 30 (3)
Screwfixingfan spacer to pulley 30 (3)
Screwsfixingfan mount to crankcase 100 (10)
Screwsecuringsteadytensioner 105 5 (10 0.5)
Screwsecuringautomatic belt tensioner 50 5 (5 0.5)
Screwsfixingfixedpulleyfor auxiliarymember drivebelt to crankcase 105 5 (10.5 0.5)
Screwsfixingstarter motor 74 8 (7.4 0.8)
Screwsfixingair heater 50 5 (5 0.5)
Screwsfixingair compressor 74 8 (7.4 0.8)
Revi- June2007
Print603.93.641/A
PART
TORQUE
PART
Nm kgm
Nut fixingair compressor gear 170 10 (17 1)
Screwsfixingalternator: M10x1.5 l =35 mm 44 4 (4.4 0.4)
M10x1.5 l =60mm 44 4 (4.4 0.4)
Screwsfixinghydraulic power steeringpump 46.5 4.5 (4.65 0.45)
Screwsfixingair-conditioner compressor to themount 24.5 2.5 (2.5 0.25)
Screwsfixingguard 24.5 2.5 (2.5 0.25)
Filter cloggingsensor fixing 55 5 (5.5 0.5)
Water / fuel temperaturesensor fixing 35 (3.5)
Transmitter / thermometric switchfixing 25 (2.5)
Air temperaturetransmitter fixing 35 (3.5)
Pulsetransmitter fixing 8 2 (0.8 0.2)
Fixingenginebrakesolenoidvalve 32 3 (3.2 0.3)
Engine
M14X70/80 screw securingfront andrear silentblocksto chassis 192.5 19.5 19.2 1.9
M16X130screwsecuringfront and rear silentblocks to engine 278 28 27.8 2.8
M18X62flangedhexscrew for front crankcase
M14X60socket cheese-headscrewfor front crankcase
Flanged hexscrew for rear crankcase
60593
FRONT SIDE
Fourth phase:
closinginside
screws to angle
55
60592
60594
60593
Figure9
First phase:
pre-tightening
outsidescrews
30Nm
FRONT SIDE
FRONT SIDE
Secondphase:
pre-tightening
inside screws
120 Nm
Fifthphase:
closingoutside
screws to angle
60
60593
FRONT SIDE
Third phase:
closinginside
screws to angle
60
FRONT SIDE
DIAGRAMOF TIGHTENING SEQUENCE OF LOWER CRANKCASE FIXING SCREWS
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS
60580
Figure10
Figure11
Figure12
DIAGRAMOF TIGHTENINGSEQUENCE OF EXHAUST MANIFOLD FIXING SCREWS
DIAGRAMOF TIGHTENING SEQUENCE OF SCREWSAND NUTSFIXINGTURBOCHARGER
ON EXHAUST MANIFOLD
60581
60582
DIAGRAMOF TIGHTENING SEQUENCE OF CYLINDER HEAD FIXING SCREWS
3aso |ovobo 2006 Print 603.93.641
60666
Figure13
Figure14
DIAGRAM OF TIGHTENING SEQUENCE OF ENGINE OIL SUMP FIXING SCREWS
108830
DIAGRAMOF TIGHTENING SEQUENCE OF HEAT EXCHANGER FIXINGSCREWS
Figure15
DIAGRAM OF TIGHTENING SEQUENCE FOR SCREWSFIXING ROCKER COVER
117545
Revi- June2007
PRINT603.93.641/A
60633
Tighteningsequence
4 screwsM12 x 1.75x 35
10screws M12 x 1.75x 100
1 screwM12x 1.75 x 120
2 screwsM12 x 1.75x 70
2 screwsM12 x 1.75x 193
:
Figure16
DIAGRAMOF TIGHTENING SEQUENCE OF SCREWSFIXING GEAR HOUSING TO CRANKCASE
Figure17
SCHEME OF THETIGHTENINGORDEROF ROCKER ARMSSHAFTSFASTENINGSCREWS
70567A
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
Print 603.93.641 3aso |ovobo 2006
TOOLS
TOOL No. DESCRIPTION
99322230 Rotarytelescopicstand
(capacity2000daN, torque 375 daN/m)
99340053 Tool to remove crankshaft front gasket
99340054 Tool to removecrankshaft rear gasket
99340205 Puller with slidehammer
99342149 Extractor for injector box
99342155
Tool to extract injectors
3aso |ovobo 2006 Print 603.93.641
TOOLS
99346250 Keyto fit crankshaft front gasket
99346251 Keyto fit crankshaft rear gasket
99348004 Universal extractor for interiors from5 to 70mm
99350072 Socket wrenchfor screwsfasteninglowercrankcaseto crankcase
99360143 Drift to fit - remove valve guide
99360180 Plugs(6) protectinginjector seats
Print 603.93.641 3aso |ovobo 2006
TOOLS
99360184 Pliersfor removingandrefittingpistonrings(105-106 mm)
99360192 Guidefor flexiblebelt
99360261 Tool for removingand refittingenginevalves
(usewith specific plates)
99360263 Platefor removingandrefittingenginevalves
(usewith 99360261)
99360296 Drift for refittingvalveguide (usewith 99360143)
99360314 Tool to remove oil filter (engine)
3aso |ovobo 2006 Print 603.93.641
TOOLS
99360321 Tool to rotateengine flywheel (usewith 99360325)
99360325 Spacer (use with99360321)
99360329 Keyingdevicefor mountinggasket on valve guide
99360334 Compressiontool to measurecylinder liner protrusion
(usewith 99370415-99395603 and specific plates)
99360336 Spacers(usewith99360334)
99360338 Plateto compress cylinder liners
(usewith 99360334-99360336)
Print 603.93.641 3aso |ovobo 2006
TOOLS
99360351 Tool to holdengine flywheel
99360499 Drift to removeand refit camshaft bushings
99360500 Tool to lift crankshaft
99360551 Bracket to removeand refit engineflywheel
99360553 Tool to assembleandinstall rocker armshaft
99360585 Beamto removeand refit engine
3aso |ovobo 2006 Print 603.93.641
TOOLS
99360605 Collar to insert piston in cylinder liner (60-125mm)
99360612 Tool to positionengine T.D.C.
99360613 Tool for phonicwheel timingon camshaft
99360703 Tool to holdcylinder liners
99360706 Tool to extract cylinder liners (usewithspecific rings)
99360728 Ring(135 mm) (usewith 99360706)
Print 603.93.641 3aso |ovobo 2006
TOOLS
99361036 Brackets fixingengineto rotarystand99322230
99365056 Tool to upset injector housing
99370415 Dial gaugebaseto measurecylinder liner protrusion
(usewith 99395603)
99378100 Tool to punch enginedataplates (use withspecific punches)
99378130 Punches for printingengineidentificationplates
(consistingof: 99378101 (A) - 99378102 (B) - 99378103(C) -
99378104 (D) - 99378105 (E) - 99378106 (F) - 99378107 (G) -
99378108 (V))
99389834 Torquescrewdriver to calibrate injector solenoid valve
connector retainingnut
3aso |ovobo 2006 Print 603.93.641
TOOLS
99390330 Valveguidereamer
99390772 Tool to remove remainsfrominjector housingseat
99390804 Tool to threadinjector housingto extract (usewith 99390805)
99390805 Guidebushing(usewith 99390804)
99394015 Guidebushing(usewith 99394041or 99394043)
99394041
Millingcutter to regrind injector seat (use with 99394015)
Print 603.93.641 3aso |ovobo 2006
TOOLS
99394043
Reamer to regrind bottomof injector housing
(usewith 99394015)
99395216
|a| o otos o aoo|a t||too|o .|t| sooao +/2'
aoo 3/+' cooooct|oo
99395219
Gaugeto determinecentredistance between camshaft
and idlegear
99395603 Dial gauge(0 5 mm)
99395687 Boremeter (50 178 mm)
99396035
Crankshaft front gasket cover centringring
3aso |ovobo 2006 Print 603.93.641
- Set the vehicle on the level over a pit. Lock the rear
wheels andtilt up the cab.
- Break the electric circuit by disconnecting the positive
cable of thebattery.
- Lift theradiator cowlingandtilt upthecab.
- Disconnect thegearboxasdescribedunder therelevant
|oao|o, '||scooooct|o t|o Coabo'.
- Drain the hydraulic power steering and engine cooling
systems.
Steps to performontheengineintakeside:
- Disconnectthepipe(8) fromthepowersteeringtank(9)
and thepipe(5) fromthepower steeringpump (6).
- Disconnect pipes fromoverpressure valve (7) for fuel
returnto tank;
- Disconnect the air pipe (12) from the turbocharger
actuatorairfilter.Disengagethepipe(10) supplyingairto
thefan hubfromtheclamps andthefitting(13).
- Disconnect thetube(3) of theair compressor.
- Disconnect the pipes (4) and (14) from the air
compressor,freeingthemfromtheclamps(16) and(18)
ontheengine.
- Withthehose(2),removethepipe(4) fromtheseat on
theintakemanifold.
- With thefitting(1), removethe pipe(14).
- Disconnect thecoolant piping(17) and(15) andremove
it byfreeingit fromtheclamps.
- Disconnect theengineair intake sleeve(11).
106241
!
If washing the engine bay, adequately protect the
connections.
Figure18
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
ENGINE REMOVAL-REFITTING
Removal
Asapreliminaryoperationit iswisetodisconnect thewiring
(11) that will remain fastened to the chassis frame,
proceedingas follows:
- Acting on the air intake side, disengage the wiring (11),
disconnectingit fromthe enginecablewith the connector
(17).
- Disconnect theelectrical connection(3) ofthehydraulic
power steeringtank (4).
- Remove the entire mount of the engine starting and
stopping buttons (2) together with the power steering
tank(4),afterdisconnectingthepipe(5),bytakingout the
screws(1).
Fromtheelectroniccontrol unit (8), disconnect thebottom
connector (9), proceedingas follows:
- A Lift thesafetylever.
- BMovetheconnector, disconnectingit fromthecontrol
unit.
- C Lift theconnector, unhookingthestop tooth.
- Disconnect theearthcable(10) fromthecrankcaseand
theelectromagneticclutchcablefor theair-conditioning
compressor, viatheconnector (12).
- Disconnect theelectrical connections (7) onthestarter
motor (6).
- Disconnect the electrical connections (15) of the
alternator (16).
- Disconnect theelectrical connectionfromthe valve on
thecontrol unit (8).
- Disconnect thediesel pipe (18) fromthemount of the
control unit (8).
- Thenfreethewiring(11) fromtheclamps(14) secured
to the engine air intake duct (13) and carefully place it
awaytothesideofthevehiclesoitwill not interferewith
theremoval oftheengine.
109152
Figure19
3aso |ovobo 2006 Print 603.93.641
73903
Figure20
Fromunderneaththevehicle:
- Disconnectthecoolantpipe(3) fromtheengineandfrom
the radiator, thenremoveit.
- Disconnect thecoolant pipe(2), loosenandremovethe
belt (6) from the pulley of the air-conditioning
compressor byusingtheautomatictensioner.
- Disconnect thecompressor (9) fromtheenginemount
(8) bytakingout thescrews(7) and (10).
- Without disconnectingthepipes of thecompressor and
thenwithoutdischargingtheair-conditioningsystem,free
thepipes(5) fromthebrackets(1and4),suitablytiethe
compressor to vehicle so it does not interferewith the
operationsof removingtheengine.
Print 603.93.641 3aso |ovobo 2006
Before bleeding the supply system, connect tubes
onto the bleed screws located on the pre-filter
mount,filter and front of thecylinder headinorder
torecoverthefuel insuitablecontainersduringthisoperation.
In particular, prevent the fuel, on comingout of the bleed
screwonthecylinderhead,fromfoulingthebeltsdrivingthe
fan, water pump, alternator and air-conditioner compressor,
damagingthem.
Workingontheengineexhaust side(drivo's s|oo), ocooo
asfollows:
- Disconnect theair sleeve (6).
- Free the air-conditioningpipes (5) fromthe clamp (4)
securedonto themanifold(3).
- Disconnect thecoolant pipes(9) and(11) fromtheengine.
- Remove the engine air intake manifold (12),
disconnectingit fromthesleeve (21), fastenings(8) and
(13), flexible sleeve (14); disconnect the oil vapour
recoverypipe(7)anddisconnect theairintakepipeofthe
compressor (20).
- Disconnect theexhaust pipe(16) byactingonthecollar
(15) and remove the bracket (17) by undoing the
fasteners.
- Anchortheenginetothebeam99360585andkeepthe
tool under tension beforeremovingtheenginemounts.
- Take out the front (10) and rear (18) and (19) screws
fixingtheenginemounts onbothsides.
- Slowlytake the engineout of its bay, drawingit slightly
back so as to free the fan (2) fromthe bay of the air
conveyor (1) ontheradiator.
- Removethefanfromthehub byusingthe four screws.
Take out the engine completely, taking care over any
interference with the remaining parts secured to the
chassis frame, especiallythe wiringinterfering with the
right-handrear enginemount.
- Disconnect the air bleed pipe (22) fromthe Intarder
coolant pipe.
73904
Figure21
If washing the engine, adequately protect the
connections.
Refitting
Torefit theengine,carryout thestepsdescribedforremoval
inreverseorder,takingspecial careoverthestepsrequiredto
install theassemblyintheenginebay,andkeeptothefollowing
instructions:
- Checktheflexiblemountingsof the engineandgearbox
assemblies; replacethemif deteriorated.
- Check that the parts of the exhaust pipe have not
deteriorated or are about to deteriorate, inwhichcase
theyshouldbereplaced.
- Tightenthescrewsand/or nuts to therequiredtorque.
- Fill thecoolingsystemwithcoolant asrequiredunderthe
relevant heading.
- Bleedtheair fromthesupplysystemasdescribedunder
therelevant heading(542011).
- Fill thehydraulicpower steeringcircuit andbleedoff the
air asdescribedunder therelevant heading(501030).
- Check theengineoil level.
Fit the chassis frame cable to the engine and hook up the
connector to thecontrol unit asdescribedhereunder:
A Insert thestoptoothin itsseat.
B Hookuptheconnector.
C Pushthesafetylever asfar as thestop.
NOTE
NOTE
3aso |ovobo 2006 Print 603.93.641
87198
Figure22
Fillingthesystem
After conscientiously followingthe above warnings,
proceedasfollows:
- Removethecap(2) fromtheexpansiontub(3).
- Pour thecoolant into theexpansion tub(3) till it isquite
full.
Filling the cooling system
Preliminaryoperations
For vehicles equipped with just the standard cab heating
systemor manual air-conditioning:
- Fullyopenthecoolant cockontheinstrument panel.
For vehicles equipped with the automatic air-conditioning
system:
- Setthetemperaturecontrol inthecabontheHI position.
- Theheater must not beturnedon.
Operations
Placeasheet of cardboard betweenthecoolant radiator and
theintercoolerradiatorinordertoshortenthetimeit takesto
oac| t|o oo|oo's .o'|o tooatoo (ao. 0 C).
Fillingmust bedonewiththeengine cold.
The cap (1) must not be removed for anyreasons
whatsoever.
Toprevent pockets of air forminginthesystem, the
fluidhas to betransferredslowly (approximateflow
rate8 litres/min).
For vehiclesequipped withanadditional heater: the
percentage of glycols in the coolant must be no
greater than50%.
- Turnontheheater.
If thetub empties completelyduringthese first few
minutes,stopandengineandtopitupataslowerrate
thanbefore.
Restart theengine.
- Start theengineand keepthespeedjust aboveidlingfor
5min.
- after 5 min. running, top up the level of fluid in the
expansiontub, if necessary.
- closetheexpansiontub filler with thecap (2).
Take the engine up to top speed so that the coolant
quickly reaches the temperature of full thermostat
opening(approx. 90 C) and keep it inthis stateuntil all
theair is bled out of thesystem.
Thisischeckedbyseeingthereisno foamor airbubbles
inthetub.
Thelongest timeit takestobleedtheairfromthesystem
completely is approximately 15 minutes from the
moment when the thermostat opens (opening starts
85 2 C).
Donot takethefiller capoff theexpansiontubuntil
thefluid in thesystemhascooledcompletely.
Anytoppingup must onlybe donewith theengine
cold.
Thisis to avoid:
1 - Operator burns.
2 - Damage to the engine since cooling system
pressurization is only created with the fluid
heatingfromthecondition of theenginecold.
Bleedingair fromthesystem
NOTE
NOTE
NOTE
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
- Bleed screw(1) on thepre-filter mounting.
- Bleed screw(2) on thefilter mounting.
- Bleed screw(4) on thefront of thecylinder head.
- Work the pump (3) on the pre-filter mountingtill fuel
withnoairbubblesinit comesout of thescrew(1);close
thescrew(1).
Under no circumstances let fuel foul the water
pumpalternator drivebelt, etc.
1
3
2
Checks and tests
Start theengine, leaveit runningat just alittlefaster
thanidlingspeedandwaitforthetemperatureofthe
coolant to reachthe level to open the thermostat.
Then, check that:
- nowaterleaksfromtheconnectingsleevesofthepipesin
theenginecoolingand cabheatingcircuits, tighteningthe
collarsfurther if thisisnecessary.
- nooil leaksfrombetweenthecoverandthecylinderhead,
betweentheoil sumpandthecrankcase,betweentheoil
filter and its seat, between the heat exchanger and the
crankcase, orbetweenthevariouspipesinthelubrication
circuit.
- no air leaks fromthe pipes connected to thepneumatic
components involved inremoval.
- theindicatorlightsontheinstrumentpanel andthedevices
disconnected when removing the engine all work
properly.
4
Beforestartingtheengine,bleedtheairfromthefuel
system,applyingspecial tubestothebleedscrewsto
runthebled fuel off into aspecific container.
Figure23
NOTE
3aso |ovobo 2006 Print 603.93.641
542011 Bleeding air from the fuel system
87382
Figure24
Tocut offthebatteries,removetheelectricwiresoropenthe
main switch.
Lift thecalender and tilt thecabin.
Go under the vehicle and remove the plug (13) fromthe
radiator (14) and drain the coolant fluid in the appropriate
container.
Removetheclip(11) anddisconnect theradiator (12) sleeve
(14).
Removetheclimatecontrol systempipe(8) fasteningscrew
(if fitted) to theair conveyor (9).
Removetheair conveyor (9) fasteningscrews(10) fromthe
support bracket.
Remove the two sleevefasteningscrews to the intercooler
radiator (5).
Removenut (16),thendisconnect electriccable(17).Slacken
the clamp (15) and remove the air conveyor (9) fromthe
turbocharger (18) and fromtheintercooler radiator (5).
Slackenthesleeve(6) fasteningclamp(7) fromtheintercooler
(5) radiator.
Drive in the suitable self-threadingscrewin thepinhole (2)
taking care to partially take off and finally remove with a
screwdriver the upper clip (3) fastening the fan air (4)
conveyor to theradiator guard (1).
Removethelower clip inthesameway.
Removal
Print 603.93.641 3aso |ovobo 2006
543422 ELECTRO-MAGNETIC FAN DRIVE REPLACEMENT
107398
Figure25
Disconnect thepipe(1) fromthethermostat.
Removetheclip(10) anddisconnect thesleeve(9) fromthe
radiator (11).
Slackentheclamps (7) and removethesleeve (6).
Remove the upper and lower clip (3) as described for the
left-handside.
Removetheradiator support fasteningscrewsonthechassis
and movetheradiator unit forwards.
Lift air conveyor (4) anddisconnect it fromthevehicle.
Remove the radiator support fastening screws (2) on the
chassisandmove theradiator unit forwards(14).
Removethefanfasteningscrews(2).
Loosenbelt(18) tensionbyactingonautomaticbelt-stretcher
(19), then remove thebelt fromthepulleys.
Disconnect the electric connection (12) from the
electro-magneticfandrive(14).
Lockengineshaft rotation.
Removesecuringscrewsanddismount damper (20).
Unscrewscrew(16) and dismount pulley(17).
Disconnect pneumatic piping(15) fromelectromagneticfan
drive(14).
Removethefanfasteningscrews(13) totheelectro-magnetic
fandrive(14).
Refitting
To refit the electro-magnetic fan drive, reverse the
removal procedureandattain tothe followingrules:
- check the control belt (18) conditions; replace it if
damagedor wornout;
- tightenthescrews and/or nutsto the prescribed torque;
- fill thecoolingsystemwiththeprescribedfluid,thenblow
air off thecoolingsystemas described in the respective
chapter;
The electro-magnetic fan drive is fitted with two
threadedholes( ) at180 onefromtheother.Inthe
eventoffault,lockthejointcontrol drivinginaM8x16
mmscrewintheseholes. Inthiswayit ispossibleto
takethevehicleto theclosest dealership.
NOTE
3aso |ovobo 2006 Print 603.93.641
Figure26
73581
LONGITUDINAL SECTION OFTHE ENGINE
Print 603.93.641 Base November 2006
120149
Figure27
TRANSVERSESECTION OFTHEENGINE
Revi - June2007
PRINT603.93.641/A
- pipes (3, 4and 7);
- electrical cables (5);
- sounddeadeningguard (6);
- pipes (1 and2).
60481
106215
106239
60484
60485
60486
Onthe right-handsideof the engine
- thefuel cartridgefilter (1).
- thehydraulicpower steeringtank(2).
- theelectrical connections.
- compressor (1) complete with oversteering pump (2)
and feedpump (3).
- Usingtheright tool (3),turnit inthedirectionshownby
thearrowandremovetheair-conditioner drivebelt (1).
- Removetheair-conditioner (2) together withtheengine
mounting.
- theoil overpressurevalve (1).
- theenginemounting(1).
Before fastening the engine on rotary stand 99322230,
dismount or disconnect followingparts:
Figure28
Figure29
Figure30
Figure31
Figure32
Figure33
Ontheleft-handsideof theengine
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
540110 DISASSEMBLY OF THE ENGINE
73582
Figure34
Securetheengineto therotarystand99322030 withthebrackets99361036(1).
3aso |ovobo 2006 Print 603.93.641
Revi - June2007
PRINT603.93.641/A
71701
71702
92840
Figure35
Figure36
Figure37
Figure38
Ifpresent,dismountfan(1)fromelectromagneticfandrive(2).
Usetool (1) 99360351to lock theflywheel.
Operatethe6Allen screws(1) to removethedamper (2).
Figure39
73584
Usinganappropriate tool (1), turn it inthedirectionshown
bythearrowandremovetheauxiliarymember drivebelt(2).
If present, dismount compressor for climate control system
and relatingdrivingspringbelt.
73585
Remove thealternator (1), electric fan drive (2), automatic
tensioners(3and5),pulley(4),waterpump(6)andpulley(7).
Spring belt must be replaced bya new one after
NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
98863
Figure40
Figure41
Disconnect the pipes (3 and 4) from the V.G.T control
solenoidvalves.
Removethethermostatassembly(1) togetherwiththeV.G.T.
control solenoid valve(2).
71707
Figure42
Remove thefollowingcomponents: water deliverypipe(5);
wateroutlet pipe(1);actuatorcontrol air pipe(2);oil delivery
pipes (3); oil return pipes (4); turbo-compressor unit (6);
exhaust manifold(7).
Figure43
60490
Applyextractor 99340053(2)andtakeoutthecrankshaftseal
(1); now removetheflange (3).
(Version without Intarder)
Figure44
98864
Disconnect the pipes (3 and 6) from the V.G.T control
solenoidvalves. Removethewaterinlet/outlet pipeassembly
(1) together withtheV.G.T. control solenoidvalve (2).
(Version withIntarder)
Figure45
60492
Usetool 99360314 to slackentheoil filters(1).
(Version without Intarder)
60493
- Slackenthescrews (1) andremovetheintercooler (4);
- Slackenthescrews (2) andremovethewater pipe (3).
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Figure46
Figure47
Figure48
(Version withIntarder)
70708
TheremovetheP.T.O. (if fitted):
- disconnect theoil pipe (1);
- slacken the4 screws(2) and(3).
- Slackenthescrews (1) andremovetheintercooler (4);
- Slackenthescrews (2) andremovethethermostat (3).
106218
Dismount followingparts:fuel filtersupport(1);relatingpipes;
starter (2);supportforenginestartuppushbuttons(3);airfilter
for PWM valve (4); intake manifold (5) complete with
resistancefor enginepreheating; enginecentral unit (6);
72674
60575
60497
- Slackenthescrews(2) andremovethegear (1) together
withthephonic wheel.
- Slackenthescrews(1);driveoneoftheminatorquehole
inordertoremovetheshoulderplate(2) andextract the
metal sheet gasket.
Figure49
Figure50
Figure51
85480
Removetherockerarmcover (1),takeoffthescrews(2) and
extract thecover (3),thefilter (5) andthegaskets(4 and6).
Removethescrews (8) andtheblow-bycase(7).
60498
60500
60499
60501
Figure52
Figure53
Figure54
Figure55
Figure56
Unscrewthescrews(2) andremovetheidlegear (1).
Withtheflywheel lockingtool 99360351(1) fitted, unscrew
the fixingscrews (2). Take off the tool (1) and extract the
flywheel (3).
Fit ontheextractor 99340054(2) andextract thegasket (1).
Unscrewthescrews(1) andremovethegear housing(2).
106219
Figure57
If present, dismount P.T.O. drivinggear (1).
Removescrews(3) anddismount doublegear (2).
Removesecuringscrewand dismount articulated rod (5).
Dismount oil pump(4).
117546
- Releasethechecksprings(3) oftheexhaust brakelever.
- Disconnect the electrical connections (1) from the
injector.
- Remove exhaust brake pins (4) and slave cylinder (6)
pipes (5).
- Removethehead injector wiring.
Thewiringhasto beextractedfromthefront.
Revi - June2007
PRINT603.93.641/A
60514
120150
60515
60516
60517
Figure58
Figure59
Figure60
Figure61
Figure62
Figure63
Applytool 99360553(1) to therocker shaft (2) andremove
theshaft (2) fromthecylinder head.
- Unscrewthescrews (2) fixingthebrackets (3);
- hooktool 99342155part (9) to pump injector (1);
- mount part (8) onpart (9) restingpart oncylinder head;
- screwnut(7)andextractpumpinjector (1) fromcylinder
head.
- unscrew the screws (4) and removethe exhaust brake
pins(5).
- unscrewthescrews andremovetheslavecylinder (6).
- Insert theplugs 99360180(1) inplaceof theinjectors.
- Extract thecamshaft (2).
- Unscrewthescrewsfixingthe cylinder head (3).
- Usingmetal ropes, lift thecylinder head (1).
- Takeoff thegasket (2).
Unscrewthescrews(2) andtakeout theengineoil sump (1)
together withtheframe (3) andgasket.
Unscrewthescrewsandtakeout thesuctionstrainer (1).
116190
Thecylinder headmountscrews must bereplaced
at eachremoval operation.
NOTE
Revi - June2007
60519
60518
Figure64
Figure65
Figure66
Figure67
Figure68
Untighten screws (2) fixingtheconnectingrod cap (3) and
remove it. Remove the connectingrod-piston (1) assembly
fromtheupper side. Repeat these operations for theother
pistons.
Usinganappropriatewrenchandthehexwrenchunscrewthe
screws(1) and (2) and takeoff thecrankcasebase.
47574
Turnthe crankcase(1) upright.
47570
Usingtool 99360500(1), removethe crankshaft (2).
47571
Extract the main bearingshells(1), unscrewthescrews and
takeout theoil nozzles(2).
Remove thecylinder liners as described under the relevant
headingonpage179.
After removingtheengine, youneedto clean the
removedpartsthoroughlyandchecktheirintegrity.
Thefollowingpagesgivetheinstructionsformaking
thechecksandthemainmeasurementstomaketo
determinewhether thepartscan bereused.
Keep the bigend bearingshells in their respective
housingsand/ornotedowntheir assemblyposition
since, if reusingthem, theywill needto befittedin
theposition found uponremoval.
Note down the assemblypositionof the top and
bottommain bearingshells since, if reusingthem,
theywill need to be fitted in the position found
upon removal.
NOTE
NOTE
NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
A =Selectionclass 135.000 to 135.013 mm
B=Selectionclass 135.011to 135.024mm
X =Selectionclassmarkingarea
On finding maximum wear greater than 0.150 mm or
maximumovalization of 0.100 mmcompared to the values
showninthefigure, youneedto replacethecylinder liner as
nogrinding, facingor reconditioningispermitted.
540410 CYLINDER BLOCK
540420 Checks and measurements
The inside diameter of the cylinder liners is checked to
ascertaintheextent of ovalization, taper and wear usingthe
gauge 99395687 (2) fitted with the dial gauge (1), zeroed
beforehandontheringgauge (3) of diameter 135 mm.
Ifyoudonot havearinggaugeofdiameter 135mm,
useamicrometer for this purpose.
A = 153.500to 153.525mm
B = 152.000to 152.025mm
C = 153.461to 153.486mm
D = 151.890to 151.915mm
Thediagramshowninthefiguregivestheoutsidediameterof
thecylinder liner andinsidediameter of itsseat.
The cylinder liners can, if necessary, beextracted andfitted
several times in different seats.
34994
60595
60597
Figure69
Figure70
Figure71
Figure72
1=1
st
measurement
2=2
nd
measurement
3=3
rd
measurement
Themeasurementshaveto bemadeoneachsinglecylinder
linerat threedifferent heightsandontwolevels(A-B) atright
anglesto each other asshownin figure.
(Demonstration)
Thecylinder linersaresupplied assparepartswith
so|oct|oo c|ass '/'.
60596
X
NOTE
NOTE
Print 603.93.641 3aso |ovobo 2006
REPAIRS
3aso |ovobo 2006 Print 603.93.641
Cylinder liners
108832
Figure73
Figure74
MAIN CYLINDERLINERDATA
||T/|| ''
'Y' - So|oct|oo c|ass a'|o aoa
Figure75
CRANKCASEASSEMBLY WITH CYLINDER LINERS
A mm135.000to 135.013
Bmm135.011to 135.024
* Selectionclass
60598
108833
Print 603.93.641 3aso |ovobo 2006
540420 Replacing the cylinder liners
47577
16798
60521
Figure76
Figure77
Figure78
Figure79
Positiontheparts99360706(2) andtheplate99360728(4)
asshowninthefigure,checkingthat theplate(4) restsonthe
cylinder liner correctly.
Screwdownthenut ofscrew(1) andextractthecylinderliner
(3) fromthecrankcase.
Alwaysreplacethewater seals(3, 4and5).
Fit theadjustment ring(1) onthecylinder liner (2).Lubricate
thebottomof it andmount it in thecylinder assemblyusing
theappropriatetool.
Checktheprotrusionofthecylinder linerswithtool 99360334
(2) and tighteningthescrew (1) to atorque of 225Nm.
Usingthedial gauge 99395603suppliedasstandardwiththe
dial gaugebase99370415(3),checkthat theprotrusionofthe
cylinder liner over thesupportingfaceofthecylinder headis
0.045 - 0.075 mm(Figure79); if this is not so, replace the
adjustment ring(1, Figure77), supplied as aspare part with
several thicknesses.
On completingassembly, lock the cylinder liners (1) to the
crankcase(2) withthepins99360703(3).
Assemblyandcheckingprotrusion
Figure80
CYLINDERLINER PROTRUSION
49017
Theadjustment ring(1) issupplied asasparepart
withthefollowingthicknesses: 0.08mm- 0.10mm
- 0.12 mm- 0.14mm.
60520
0.045to 0.075
Removal
NOTE
Revi - June2007
PRINT603.93.641/A
5408 Crankshaft
108835
117547
Figure81
Figure82
X. Detail of themainjournal unions Y. Detail of thecrankpin unions
MAIN DATA OF CRANKSHAFT AND MAIN BEARING SHELLS
Check thestateof themainjournals andcrankpinsof thecrankshaft. Theymust not bescoredor be too ovalizedor worn. The
datagivenrefer to thenormal diameter of thejournals.
Topmainbearingshells
Bottommainbearingshells
Figure83
108834
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
540812 Measuring the main journals and crankpins
47535
47536
Figure84
Figure85
MEASURINGTHE MAIN JOURNALS
Before grindingthejournals, useamicrometric gauge (1) to
measurethejournalsoftheshaft (2)andestablish,onthebasis
oftheundersizingofthesparebearingshells,towhatdiameter
it isnecessarytoreducethejournals.
It is advisable to note the measurements in atable
(Figure85).
All themainjournalsandcrankpinsshouldalwaysbe
groundtothesameundersizingclasssoasnottoalter
thebalanceof theshaft.
Figure86
Tablefor notingdownthe measurements of the main journals andcrankpins of thecrankshaft.
MAIN JOURNALS
36061
Minimum
Maximum
Minimum
Maximum
CRANKPINS
MEASURINGTHE CRANKPINS
Whengrinding,paytheutmost attentiontothevaluesofthe
unions of the main journals and of the crankpins given in
Figure82and Figure83.
NOTE NOTE
3aso |ovobo 2006 Print 603.93.641
Preliminary measurement of data toselect main bearing and big end bearing shells
For eachof thejournalsofthecrankshaft, it isnecessarytocarryout thefollowingoperations:
MAIN JOURNALS:
crankcase.
- Determinetheclass of diameter of themainjournal.
- Select theclassof thebearingshellsto mount.
CRANKPINS:
connectingrod.
- Determinetheclass of diameter of thecrankpin.
- Select theclassof thebearingshellsto mount.
DEFINING THE CLASSOF DIAMETER OFTHE SEATSFOR BEARING SHELLSON THECRANKCASE
Onthefront of the crankcasetwosetsof numbersaremarked in thepositionshown.
- Thefirst set of digits(four) isthecouplingnumber ofthecrankcasewithits base.
- Thesecondset of digits (seven) is theclass of diameter of eachof theseatsreferred to.
- Eachof thesedigitsmaybe 1, 2 or 3.
47535
Figure87
106.300 to 106.309
106.310 to 106.319
106.320 to 106.330
CLASS
MAIN BEARING
HOUSING NOMINAL
DIAMETER
Toobtaintherequiredassemblyclearances,themainbearingandbigendbearingshellshavetobeselectedasdescribed
hereunder.
Thisoperationmakesit possibleto identifythemost suitedbearingshellsforeachofthejournalsoftheshaft (thebearingshellsmay
even havedifferent classesfor different pins).
Figure88
red
red/black
green
green/black
STD
1.965to 1.975
1.976to 1.985
+0.127
2.028to 2.038
2.039to 2.048
+0.254
2.092to 2.102
2.103to 2.112
+0.508
2.219to 2.229
2.230to 2.239
red
red/black
green
green/black
STD
3.110to 3.120
3.121to 3.130
+0.127
3.173to 3.183
3.184to 3.193
+0.254
3.237to 3.247
+0.508
3.364to 3.374
Dependingonthethickness,thebearingshellsareselectedin
classesoftolerancemarkedbyacolour (red-green-red/black
- green/black).
Figure88givesthespecificationsof themainbearingandbig
endbearingshellsavailableassparepartsinthestandardsizes
(STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
Bigendbearingshells
Mainbearingshells
NOTE
Print 603.93.641 3aso |ovobo 2006
Selecting the main bearing and big end bearing shells
Threesetsof numbers aremarked onthecrankshaft intheposition shown bythearrow(Figure89at top):
- Thefirst number, of fivedigits, isthepart number of theshaft.
- Under thisnumber, onthe left, aset of sixdigitsrefersto thecrankpinsandisprecededbyasingledigit showingthestatus
ofthejournals(1=STD, 2=-0.127),theothersixdigits,takensingly,givetheclassofdiameter ofeachof thecrankpinsthey
refer to (Figure89at top).
- Theset ofsevendigits, ontheright,referstothemainjournalsandisprecededbyasingledigit:thesingledigit showsthestatus
ofthejournals(1=STD,2=-0.127),theothersevendigits,takensingly,givetheclassofdiameterofeachof themainjournals
theyrefer to(Figure89at bottom).
Figure89
MAIN JOURNALS
99.970to 99.979
89.970to 89.979
89.980to 89.989
89.990to 90.000
CLASS
CRANKPIN
NOMINAL DIAMETER
99.980to 99.989
99.990to 100.000
CLASS
MAIN JOURNALS
NOMINAL DIAMETER
3aso |ovobo 2006 Print 603.93.641
DEFINING THECLASSOF DIAMETER OF THE MAIN JOURNALSANDCRANKPINS (journals withnominal diameter)
After readingoffthedata, for eachof themainjournals,onthecrankcaseandcrankshaft, youchoosethetypeofbearingshellsto
useaccordingto thefollowingtable:
STD.
1 2 3
1
2
3
green
green
red
red
red
red
green
green
green
green
red
red
green
green
green
green
green
green
Figure90
CLASS
Print 603.93.641 3aso |ovobo 2006
SELECTING THE MAIN BEARING SHELLS
green/black
If thejournalshavebeen ground, theprocedure describedso far cannot beapplied.
Inthiscase, it isnecessaryto checkthat thenew diameter of thejournalsisasshown inthetableand tomount theonlytypeof
bearingshell envisaged for therelevant undersizing.
-0.127
1 2 3
99.843
99.852
green/black
green/black
green/black
green/black
green/black
green/black
red/black
red/black
green/black
red/black
red/black
red/black
red/black
green/black
green/black
99.853
99.862
99.863
99.873
1
2
3
red/black=
mm3.173to 3183
green/black=
mm3.184to 3.193
-0.254
1 2 3
99.726
99.746
red red red
red red red
red=
mm3.237to 3.247
-0.508
1 2 3
99.472
99.492
red red red
red red red
red=
mm3.364to 3.374
Figure91
CLASS
3aso |ovobo 2006 Print 603.93.641
SELECTING THE MAIN BEARINGSHELLS (GROUND JOURNALS)
Figure92
SELECTING THE BIGEND BEARING SHELLS
(JOURNALSWITH NOMINAL DIAMETER)
Therearethreemarkingsonthebodyof theconnectingrod
|o t|o os|t|oo |oo|catoo as '/'.
Letter indicatingtheclassofweight:
A = 4741 to 4780g.
B = 4781 to 4820g.
C = 4821 to 4860g.
Numberindicatingtheselectionof thediameterofthebig
endbearingseat:
1 = 94.000 to 94.010mm
2 = 94.011 to 94.020mm
3 = 94.021 to 94.030mm
Numbersidentifyingthecap-connectingrod coupling.
1
2
3
The number, indicatingtheclass of diameter of thebearing
shell seat maybe 1, 2 o 3.
Determinethetypeof bigendbearingtofit oneachjournal
byfollowingtheindicationsinthe table(Figure93).
47557
VIEW FROM A
STD.
1 2 3
1
2
3
green
green
red
red
red
red
red
red
green green
green green
green
green green
green
green
green
CLASS
Figure93
Print 603.93.641 3aso |ovobo 2006
green/black
If thejournalshavebeen ground, theprocedure describedso far cannot beapplied.
Inthiscase,it isnecessarytocheck(foreachoftheundersizings) whichfieldoftoleranceincludesthenewdiameterofthecrankpins
and tomount thebearingshells identifiedwiththerelevant table.
-0.127
1 2 3
89.843
89.852
green/black
green/black
green/black
green/black
green/black
green/black
red/black
red/black
green/black
red/black
red/black
red/black
red/black
green/black
green/black
89.853
89.862
89.863
89.873
1
2
3
red/black=
mm2.028to 2.038
green/black=
mm2.039to 2.048
-0.254
1 2 3
89.726
89.735
red green green
red green green
red=
mm2.092to 2.102
green =
mm2.103to 2.112
-0.508
1 2 3
89.472
89.481
red green green
red green green
red red green
red red green
89.482
89.492 red red green
red red green
red=
mm2.219to 2.229
green =
mm2.230to 2.239
89.736
89.746
Figure94
CLASS
3aso |ovobo 2006 Print 603.93.641
SELECTING BIG END BEARING SHELLS(GROUNDJOURNALS)
Arrange the bearingshells (1) onthemainbearinghousings
inthecrankcasebase (2).
Check the assemblyclearancebetween themainjournalsof
thecrankshaft andtheir bearings, proceedingasillustratedon
thefollowingpages.
Using the tackle and hook 99360500 (1), mount the
crankshaft (2).
Whenfittingthegear (1) onthecrankshaft (2), heat it for no
longer than2hoursinanovenat atemperatureof 180 C.
After drivingit in, leaveit to cool.
Ifchangingthepin(3),afterfittingiton,checkitprotrudesfrom
thecrankshaft asshowninthefigure.
108836
47579
47578
49021
Figure95
Figure96
Figure97
Figure98
Mount theoil nozzles(2), makingthegrubscrewmatchthe
hole(3) onthecrankcase.
Arrange thebearingshells (1) onthemain bearinghousings.
Check that the toothingof thegear isneither damaged nor
worn; if it is, take it out with an appropriate extractor and
replaceit.
540811 Checking main journal assembly
clearance
Print 603.93.641 3aso |ovobo 2006
540815 Replacing the timing gear
and oil pump drive
Theendfloat ischeckedbysettingadial gauge(1) 99395603
with amagneticbase on the crankshaft (2) asshown inthe
figure.Ifyoufindtheclearancetobegreaterthanasrequired,
replace the rear main bearing shells carrying the thrust
bearingsand repeat the clearancecheck.
- Lubricate the internal screws (1) with UTDM oil and
tighten themwith atorque wrench (3) to atorque of
120 Nm, using tool 99395216 (4), to an angle of 60 ,
followingthediagramof Figure 101.
Set two journals of the crankshaft (2) parallel to the
longitudinal axis, a section of calibrated wire. Using
appropriatehooksandtackle,mountthelowercrankcase(1).
60559
47579
47578
47588
60593
Figure99 Figure100
Figure101
Figure102
Figure103
- Removethelower crankcase.
Theclearancebetween themainbearings andtheir journals
ismeasuredbycomparingthewidthtakenonbythecalibrated
wire (2) at thepoint ofgreatest crushingwiththegraduated
scaleonthecase (1) containingthecalibratedwire.
Thenumbersonthescalegivetheclearanceof thecoupling
in millimetres. If you find the clearance is not as required,
replacethebearingshells andrepeat thecheck.
FRONT SIDE
DIAGRAMOFSEQUENCEFORTIGHTENING THESCREWSFIXINGTHEBOTTOMCRANKCASE TO THECRANKCASE
Checking crankshaft end float
3aso |ovobo 2006 Print 603.93.641
Check the pistons. They must show no signs of seizure,
scoring, crackingor excessive wear; replacethemif theydo.
60608
60607
Figure104
Figure105
PISTON - CONNECTINGRODASSEMBLY
1. Connectingrodbody- 2. Bearingshells - 3. Connectingrodcap - 4. Capfixingscrews - 5. Seeger ring-
6. Slotted scraper ring- 7. Scraper ring- 8. Compressionring- 9. Piston gudgeonpin- 10. Piston
Removing the piston rings fromthe piston (2) using pliers
99360184(1).
Removal
Thepistonsarefittedwiththreerings:thefirstoneisaV-seal,
thesecondoneabevelledsealandthethirdoneascraperring.
Thepistonsareselectedintwoclasses,A andB,accordingto
diameter.
49024
Figure106
Removingtherings(2) retainingthepistongudgeonpinusing
round-nosepliers(1).
Print 603.93.641 3aso |ovobo 2006
5408 Connecting rod piston assembly
49025 32618
49026
Figure107
Figure108
Figure109
Figure110
Removingthepistongudgeon pin(1).
If removal isdifficult, useanappropriatedrift.
Measuringpistondiameter
Measuringthediameterofthepin(1) usingamicrometer (2).
Lubricatethepin(1) anditsseatsonthehubsinsidethepiston
with engine oil. The pin has to go into the piston bylightly
pressingit with thefingers andmust not drop out.
71714
Usingamicrometer (2), measurethediameter of thepiston
(1) todeterminetheassemblyclearance. Thediameterhasto
bemeasuredat thevalueshown.
Conditions for correct pin-piston coupling
3aso |ovobo 2006 Print 603.93.641
MAIN DATA OF THEPISTON, PISTON RINGSANDPIN
F Dimensiondetectedon130mm . - J measured at 2.5mmfromouter - X =0,8 0,1
* Oldpart number - ** Newpart number
16552
3513
Figure111
Figure112
Figure113
Checkthethicknessofthepistonring(2) withamicrometer
(1).
T|o soa| (2) o t|o +st s|ot |as a V s|ao. T|o c|oaaoco 'X'
betweentheseal anditsseat ismeasuredbysettingthepiston
(1) withtheringinthecylinderliner (3) sothattheseal comes
half out of thecylinder liner.
540842 Piston rings
114973
60610
Checktheclearancebetweentheseals(2) andtheirseatson
thepiston(1) withafeeler gauge (3).
36134
Figure114
Usingafeelergauge(2),checktheopeningbetweentheends
of theseals(1) insertedin thecylinder liner (3).
Ifyoufindthedistancebetweentheendsislessthanorgreater
thanasrequired, replacethepistonrings.
Figure115
Print 603.93.641 3aso |ovobo 2006
117180
71716
Figure116
Figure117
MAIN DATA OF THEBUSHING, CONNECTINGROD, PIN ANDBEARING SHELLS
* Measurement to bemadeafter drivinginthebushing.
Connectingrod punchmarkings
Letter indicatingtheclassofweight:
A = 4741 to 4780g.
B = 4781 to 4820g.
C = 4821 to 4860g.
Number indicatingtheselectionof thediameter
of thebigend bearingseat:
1 = 94.000 to 94.010mm
2 = 94.011 to 94.020mm
3 = 94.021 to 94.030mm
Number indicatingtheselectionof diameter
for thebigendbearinghousing:
1
2
3
Punched on thebigend of the connectingrod are the
data relating to the section in classes relating to the
connectingrodseatsand theweights.
VIEW FROM A
On assembling the connecting rods, check
theyareall of thesameclass of weight.
NOTE
3aso |ovobo 2006 Print 603.93.641
540830 Connecting rod
Check thetorsion of the connecting rod(5) bycomparing
two points(A and B) of thepin (3) on the horizontal plane
of theaxis of theconnectingrod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads byapprox. 0.5mmon thepin(3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
oppositesideBof thepin(3):thedifferencebetweenA and
Bmust be no greater than 0.08mm.
Check thebendingof theconnecting rod (5) bycomparing
twopointsC andDofthepin(3) onthevertical planeofthe
axisof theconnectingrod.
Positionthevertical mount(1) ofthedial gauge(2)sothatthis
restsonthepin(3) at point C.
Swingtheconnectingrodbackwardsandforwardsseekingthe
highest position of thepinandinthis conditionzero thedial
gauge(2).Shiftthespindle(4) withtheconnectingrod(5) and
repeat thecheckonthehighest point ontheoppositesideD
of the pin (3). Thedifferencebetweenpoint C and point D
must be no greater than 0.08mm.
61695
61696
Checkingaxis alignment
Check thealignment of theaxes of theconnectingrods (1)
with asuitabledevice (5), proceedingas follows:
Fit theconnectingrod(1) onthe spindleof thetool (5) and
lockit with the screw(4).
Setthespindle(3) ontheV-prisms,restingtheconnectingrod
(1) onthestopbar (2).
Figure118
Figure119
Figure120
Checkingtorsion
61694
Checkingbending
Checking connecting rods squareness
73535
Checkthebushinginthesmall endhas not comelooseand
shows no sign of scoringor seizure; replace it if it does.
Thebushing(2) isremovedandfittedwithasuitabledrift (1).
Whendrivingit in,makeabsolutelysurethat theholesforthe
oil to pass through in the bushing and small end coincide.
Usingaboringmachine, rebore thebushingso as to obtain
a o|aoto o 5+.0+ 5+.035.
Figure121
(Demonstration)
(Demonstration)
(Demonstration)
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
540834 Bushings
1
2
3
73536
74052
60614
49030
Figure122
Figure123
Figure124
Figure125
Thepiston(1) hasto befittedontheconnectingrod(2) so
that thegraphic symbol (4), showingtheassemblyposition
in the cylinder liner, and the punch marks (3) on the
connectingrod areobserved asshowninthefigure.
Fit thepin(2) andfastenit onthepiston (1) withtheseeger
rings (3).
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
T|o |os oooo to bo oootoo .|t| t|o .oo 'TC|' (+)
facing upwards. Direct the ring openings so they are
staggered 120 apart.
Fit the bearingshells (1), selected as described under the
|oao|o 'So|oct|o t|o a|o aoo b| ooo boa|o s|o||s', oo
both theconnectingrod and thecap.
If reusing bearing shells that have been removed, fit them
back into their respective seats in the positions marked
duringremoval.
Mountingthe connectingrodpistonassembly Mounting the piston rings
Fitting the big end bearing shells
3aso |ovobo 2006 Print 603.93.641
60616
Figure126
Figure127
/SS||3|Y ||/C|/| C| CC|||CT||C |C| ||STC| /SS||3|Y || CY|||||| |||||
+. Cooooct|o oo |stoo assob| 2. /oa o ooc| a'|o oo t|o to o t|o |stoo,
sbo| s|o.|o assob| os|t|oo aoo so|oct|oo c|ass 3. Cooooct|o oo ooc| a' aoa
Fitting connecting rod- piston assemblies in
the cylinder liners
With theaid of theclamp 99360605 (1, Figure 126), fit the
cooooct|o oo |stoo assob| (2) |o t|o c||ooo ||oos,
accordingto thediagramof Figure 127, checkingthat:
- The openings of the piston rings are staggered 120
apart.
- The pistons areall of thesameclass, A or B.
- Thesymbol punchedonthetopofthepistonsfacesthe
engineflywheel, or therecessintheskirt of thepistons
tallies withthe oil nozzles.
befitted in class Bcylinder liners.
60615
Checking piston protrusion
Oncompletingassembly,checktheprotrusionofthepistons
o t|o c||ooo ||oos, |t ost bo 0.+2 0.+2 .
NOTE
Be verycareful that theconnecting rod does not
strikethecylinder walls.
Revi- June2007
PRINT603.93.641/A
Checking head bearing surface on cylinder
block
Mount theconnectingrodcaps(1) togetherwiththebearing
shells. Tightenthescrews(2) fixingtheconnectingrodcaps
to a torque of 60 Nm(6 kgm). Usingtool 99395216 (3),
further tightenthescrews with an angleof 60 .
47594
47583
36159
Figure128
Figure129
Figure130
Mount and secure the tool 99360263(2) with thebracket
(4).Screwdownwiththedevice99360261(1) tobeableto
removethecotters(3).Takeout thetool (2) andextract the
top plate(5), spring(6) and bottomplate (7).
Repeat this processon all thevalves.
Turnover thecylinder headand take out thevalves(8).
Checkthesupportingsurface(1) oftheheadonthecylinder
block witharule (2) and afeeler gauge (3). If you find any
deformation, level the head on asurface grinder; maximum
amount of material that canberemoved0.2 mm.
540831 Checking crankpin assembly
clearance
To measure the clearance, carry out the following
operations.
Connect theconnectingrodsto therelevant journalsofthe
crankshaft,placingalengthofcalibratedwireonthejournals.
(Demonstration)
After this process, you need to check the valve
recessingandinjector protrusion.
Removethecapsanddeterminetheclearancebycomparing
thewidthofthecalibratedwirewiththegraduatedscaleon
thecase containingthe calibrated wire.
Uponfinal assembly:checkthediameter ofthethreadofthe
screws(2),it must benolessthan13.4mm;ifit is,changethe
screw. Lubricatethecrankpinsandconnectingrodbearings.
Tighten thescrews(2) asdescribed above.
Thethreadof thescrews (2),before assembly,has
to belubricated with engineoil.
NOTE
540610 CYLINDER HEAD
Before dismounting cylinder head, check cylinder head for
hydraulic seal byproper tooling; in caseof leaksnot caused
bycupplugs or threadedplugs, replacecylinder head.
In case of plugs dismounting/replacement, on
mounting, applysealant Loctite 270 on plugs.
NOTE
Disassemblythe valves
Before dismountingcylinder head valves, number
themin view of their remountingin the position
observedondismountingshouldtheynot haveto
beoverhauled or replaced.
NOTE
NOTE
Whenreplacing, thecylinder head is supplied as a
spare part with a threaded plug, which must be
removedduringassembly.
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
MAIN DATA OFVALVES AND VALVEGUIDES
* Measurement to bemadeafter drivinginthe valveguides
71718
73555
Figure131
Figure132
Check with a micrometer that the diameter of the valve
stemsisas indicated. If necessary, grind thevalveseatswith
agrindingmachine, removingaslittlematerial as possible.
1 2
MAIN DATA OF VALVESEATS
+. |ota'o va|vo soat 2. ||aost va| vo soat
Thevalveseatsareregroundwhenever thevalves
or valve guidesaregroundandreplaced.
540661 Valve seats
Regrinding replacing valve seats
NOTE
48625
540622 Valves
Decarbonizingandcheckingvalves
Removethecarbondepositsonthevalveswithawirebrush.
Check that the valves show no signs of seizure or cracking
and check with amicrometer that the valve stemdiameter
comes within therequired values (see Figure132); replace
thevalves if it doesnot.
Figure133
Print 603.93.641 3aso |ovobo 2006
Figure134
41032
Check the valve seats (2). If you find any slight scoringor
burns, regrindthemwithasuitabletool (1) accordingto the
anglesshowninFigure 133.Ifit isnecessaryto replacethem,
usingthesametool andtakingcarenot to affect thecylinder
head, remove as much material as possible fromthe valve
seatssothat,withapunch,it ispossibletoextract themfrom
thecylinder head.
Heat thecylinder head to 80 100 C and, usingadrift, fit
in the new valve seats (2), chilled beforehand in liquid
nitrogen. Using tool 99305019 (1), regrind the valve seats
accordingto theangles shown in Figure133.
Afterregrindingthevalveseats,usingtool 99370415anddial
gauge 99395603, check that the position of the valves in
relation to theplaneof the cylinder head is:
- -0.45 -0.75 mm(recessing) intake valves
- -1.65 -1.95 mm(recessing) exhaust valves.
108838
Figure135
Checking clearance between valve-stem and
associated valve guide
Usingadial gaugewithamagneticbase,checktheclearance
between the valve stem and the associated guide. If the
clearanceistoogreat,changethevalveand,ifnecessary,the
valveguide.
540667 Valve guides
Replacingvalveguides
The valve guidesare removed with thedrift 99360143.
Theyarefitted with the drift 99360143equipped withpart
99360296.
Part 99360296determinestheexact positionof assemblyof
thevalveguidesinthecylinderhead.Iftheyarenot available,
youneedtodrivethevalveguidesintothecylinder headso
theyprotrude by 30.8 31.2mm.
After drivingin thevalveguides, reboretheir holes withthe
smoother 99390330.
Figure136
540613 Replacing injector holders
Removal
60619
To replacetheinjector holder (2), proceedasfollows:
- Thread the holder (2) with tool 99390804 (1).
ThestepsdescribedinFigs.137- 139- 140- 141needtobe
carried out byfixing the tools, with the bracket A, to the
cylinder head.
(Demonstration)
3aso |ovobo 2006 Print 603.93.641
60621
Figure137
Figure138
- Usingthetool99390772(2) removeanyresidues(1)left
inthegrooveof the cylinder head.
- Screw theextractor 99342149 (2) into the holder (3).
Screwdownthenut (1) and taketheholder out ofthe
cylinder head.
60620
Assembly
Figure139
60622
- Lubricatetheseals(3) andfit themonthecase(4).Using
tool 99365056 (2) secured to the cylinder head with
bracket A, drivein thenew holder, screwingdownthe
screw (1) upsettingthebottomportionof the holder.
60623
Figure140
- Usingthereamer 99394041(1-2),reboretheholeinthe
holder (3).
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
60624
47585
Figure141
Figure142
- Using the milling cutter 99394043 (1-2), regrind the
injector seat in theinjector holder (3).
Checkinjector protrusion(2) with the dial gauge (1).
The protrusion must be 0.52- 1.34 mm.
Checking injector protrusion
108839
Figure143
INJECTOR HOLDERASSEMBLY DIAGRAM
3aso |ovobo 2006 Print 603.93.641
Revi- June2007
PRINT603.93.641/A
5412 TIMING GEAR
86925
86934
Figure144
Figure145
Figure146
TIMING CONTROL COMPONENT PARTS
1. Camshaft - 2. Bushing- 3. Pin- 4. Articulatedrod-
5. Camshaft control gear - 6. Idler gear - 7. Twinidler gear -
8. Drive shaft drivinggear.
Camshaft drive
541253 Idler gear pin
541252 Idler gear
108840
541253 Twin intermediate gear pin
541252 Twin idler gear
541254 Replacing the bushings
Bushings (2, Figure 143), can be replaced when they are
worn.Put upthebushing,thenboreit toobtainthediameter
shown on Figure145or .Figure 146
The bushing must be driven into the gear by
followingthedirection of thearrowandsettingthe
latter to the dimension shown on Figure145 or
.Figure146
Rated assemblingplaybetweengear bushings andpins:
||oo ++5 0.0+5 0.085 mm
||oo ++6 0.0+5 0.085 mm.
NOTE
47506
47505
47507
Figure147
Figure148
Figure149
541211 Checking cam lift and pin alignment
Still withthecamshaft (4) set onthetailstocks(1), checkthealignment ofthesupportingpins(3) withthedial gauge (2); it must
beno greater than0.030mm. If youfindagreater misalignment, replacethe shaft.
To checktheassemblyclearance, measuretheinsidediameter ofthebushingsandthediameter ofthepins (1) ofthecamshaft:
thedifferencewill givetheactual clearance.
If you find anyclearances over 0.135 mm, replacethebushings and, if necessary, thecamshaft as well.
Set thecamshaft (4) onthetailstocks(1) andcheckthelift ofthecams(3) withthedial gauge (2); thevaluesaregiveninthetable
on page139.
1
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PRINT603.93.641
541210 Timing system
Thesurfaceof thebushingsmust showno signof seizingor
scoring; replacethemif theydo.
Measure the inside diameter of the bushings with a bore
gauge.
108841
60627
Figure150
Figure151
MAIN DATA OF THECAMSHAFT AND TOLERANCES
The surfacesof thesupportingpins of the shaft and thoseof thecams needto beextrasmooth.
Whereas, if theyshowanysigns of seizingor scoring, you shouldreplacetheshaft and the relevant bushings.
MAIN DATA OFTHEBUSHINGSFOR THE CAMSHAFT AND SEATSON THECYLINDERHEAD
* Bushinginsidediameter after drivingin
541213 Bushings
If you findahigher value than thetolerance, replacethem.
To remove and fit the bushings, use the appropriate drift
99360499.
Print 603.93.641 3aso |ovobo 2006
TOLERANCES FEATURESUBJECT OF TOLERANCE SYMBOL
DIRECTION Perpendicularity
POSITION Concentricityor coaxiality
SWING Circular oscillation
CLASSOF IMPORTANT ASCRIBED TO PRODUCT CHARACTERISTICS SYMBOL
CRUCIAL
IMPORTANT
SECONDARY
3aso |ovobo 2006 Print 603.93.641
77795
107217
Figure152
Figure153
A = Drift withseat for bushings to insert/extract.
B = Grub screw for positioningbushings.
C = Reference mark to insert seventh bushingcorrectly.
D = Reference mark to insert bushings1, 2, 3, 4, 5, 6 correctly(yellow marks).
E = Guidebushing.
F = Guideline.
G = Guidebushingto secure to theseventh bushingmount.
H = PlatefixingbushingGto cylinder head.
I = Grip.
L = Extension coupling.
Assemblethedrift together with the extension.
To insert bushings1, 2, 3, 4and5, proceed as follows:
1 positionthebushingtoinsertonthedrift (A) makingthe
grubscrewonit coincidewith theseat (B) (Figure152)
on thebushing;
2 position the guide bushing (E) and secure the guide
bushing(G) (Figure152) ontheseat of the 7
th
bushing
with theplate(H);
3 whiledrivinginthebushing,makethereferencemark(F)
matchthemark(M).Inthisway,whenit isdrivenhome,
thelubricationholeonthebushingwill coincidewiththe
oil pipe in its seat.
The bushing is driven home when the 1
st
yellow
referencemark (D) is flush with the guide bushing(G).
71725
Figure154
Thesequencefor removingthebushingsis7,6, 5, 4, 3, 2,1.
Thebushingsareextractedfromthefront ofthesingleseats.
Removal doesnot requirethedrift extensionfor bushings5,
6 and 7andit is not necessaryto use theguide bushing.
Forbushings1,2,3and4it isnecessarytousetheextension
and theguidebushings.
Positionthedrift accuratelyduringthe phaseof removal.
Removal Assembly
Front
Rear
Replacingcamshaft bushings with drift 99360499
Drift
Print 603.93.641 3aso |ovobo 2006
71723
71724
Figure155
Figure156
To insert thebushing(6), proceed asfollows:
- Positionthe extension (N) and theguide bushingE as
shown inthefigure.
- Repeat steps 1, 2, 3.
To insert bushing(7), proceed asfollows:
- Refit theguide(G) fromtheinsideasshowninthefigure.
- Positionthe bushingon the drift (A) and bringit close
up to the seat, making the bushing hole match the
lubrication holein thehead. Drive it home.
The7
th
bushingisdriveninwhenthereferencemark(C)
isflushwith thebushingseat.
Front
Rear
Front
Rear
540665 Valve springs
70000
Figure157
Beforeassembly, theflexibilityof thevalvesprings hastobe
checkedwithasuitabletool.
Compare theload and elastic deformationdatawith those
of thenew springs given in thefollowingfigure.
108842
Figure158
MAIN DATA TO CHECKTHESPRING FORINTAKE
AND EXHAUST VALVES
Freespring
Valveclosed
Valveopen
775 39N
1366 68N
(Demonstration)
Figure159
Figure160
Figure161
Fittingvalves and oil seal
Lubricate the valve stem and insert the valves in the
respective valve guides; fit the lower caps (1). Use tool
99360329tofit theoil seal (2) onthevalveguides(3) ofthe
exhaust valves; then, to fit thevalves, proceed asfollows.
86290
- Mount thesprings (6) andthe top plate (5).
- Fit thetool 99360263(2) andsecureit withthebracket
(4). Screw down the lever (1) to beable to fit on the
cotters (3). Takeoff the tool (2).
5412 ROCKER SHAFT
44925
The cams of thecamshaft control the rocker arms directly: 6 for theinjectors and 12 for the valves.
Injectorsandintakevalvescontrol rockerarmsarekeyedonrockerarmsshaft directly.Exhaust intakevalvescontrol rockerarms
arekeyedonrocker armsshaft puttinginbetween thelevers with engine brakecontrol eccentric pin.
The rocker arms rundirectlyon the profilesof thecamsbymeansof rollers.
The other endactsonacrosspiecethat rests on thestemof the two valves.
Thereis apadbetween the rocker armadjustment screw and thecrosspiece.
Therearetwo lubricationducts inside the rocker arms.
The length of therocker armshaft is basicallythesameasthat of thecylinder head. It has to be detached to beableto reach
all thepartsbeneath.
87051
Should valves not have been overhauled or
replaced, remount themaccordingto numbering
performed on dismounting.
NOTE
3aso |ovobo 2006 Print 603.93.641
73557
MAIN DATA OFTHEROCKERARMSHAFT
Checkthat thesurfaceof theshaft shows no scoringor signsof seizure; if it does, replace it.
Figure162
71728
71729
71730
Figure163
Figure164
Figure165
PUMPINJECTORROCKERARMS
INTAKEVALVEROCKERARMS
Checkthesurfacesofthebushings, whichmust showno signsofscoringor excessivewear; if theydo, replacetherocker arm
assembly.
EXHAUST VALVE ROCKER ARM
Rocker arms
SECTION
A-A
SECTIO
N
B-B
SECTION
A-A
SECTION
B-B
SECTION
A-A
SECTION
B-B
Shaft
92842
Figure166
LEVERWITH ENGINEBRAKECONTROL
ECCENTRIC PIN
Print 603.93.641 3aso |ovobo 2006
3aso |ovobo 2006 Print 603.93.641
ENGINE ASSEMBLY
ApplyLOCTITE 5970 IVECO No. 2995644siliconeonthe
crankcase using the appropriate tools (1) as shown in
Figure171.
47586
47595
Figure167
Figure168
Figure169
Figure170
Using the brackets 99361036, secure the crankcase to the
stand 99322230.
Mount thecylinder linersas describedonpage179.
Mount the oil nozzles (2), makingthegrub screwcoincide
with thehole(3) inthe crankcase.
Arrangethebearingshells(1) onthemainbearinghousings.
Arrangethebearingshells(1) on themainbearinghousings
inthecrankcasebase (2).
47570
Lubricatethe bearingshells then mount the crankshaft (2)
usingthetackle and hook 99360500(1).
49021
Not finding it necessary to replace the main
bearings, you need to fit thembackin exactlythe
samesequenceand position as inremoval.
Choose main bearings, if theyareto bereplaced,
basoo oo so|oct|oo oosc|boo |o c|ato 'So|oct|o
a|o aoo b| ooo boa|os'.
NOTE
Revi- June2007
PRINT603.93.641/A
Figure171
60559
47581
47579
Figure172
Figure173
Figure174
Usingatorquewrench (3), tighten the insidescrews (1) to
atorqueof 120 Nm. Thentighten themto an angle of 60
and 55 with tool 99395216 (4) with another two phases.
Regrindtheoutsidescrews(1,Figure 173) withclosuretoan
angleof 60 usingtool 99395216(4).
Mount thelower crankcase (1) usingappropriatetackleand
hooks.
60632
Sealant application diagram.
Mount the lower crankcase within 10 min. of
applyingthesealant.
NOTE
Use new screws whenever removing the
bed-plate.
NOTE
Bytorquewrench (2), tighten(1) outer Hexsplinedscrews
at 30 Nmtorqueobservingtheschemesat next page.
60593
FRONT SIDE
Fourth phase:
closinginside
screwsto angle
55
60592
60594
Figure175
First phase:
pre-tightening
outsidescrews
30Nm
FRONT SIDE
FRONT SIDE
FRONT SIDE
Secondphase:
pre-tightening
inside screws
120 Nm
Fifthphase:
closingoutside
screws to angle
60
FRONT SIDE
Third phase:
closinginside
screws to angle
60
60593
60593
DIAGRAMOF TIGHTENING SEQUENCE OF LOWER CRANKCASE FIXING SCREWS
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
49030
Lubricate the bearing shells (1 and 3) and fit themon the
connectingrod (2) and onthe cap (4).
60615
Figure176
Cooooct|o oo |stoo assob|
Areaof punchmarkingon thetopofthe
pistonwiththesymbol for the mounting
position and selectionclass.
Areaof connectingrod punchmarking
Figure177
60616
Turn the cylinder block, settingit upright.
Lubricate the pistons, piston rings and inside the cylinder
liners. With the aid of theclamp 99360605 (1) mount the
cooooct|o oo |stoo assob||os (2) |o t|o c||ooo ||oos
accordingto Figure 177. Check that:
- Thenumber ofeachconnectingrodcorrespondstothe
capcouplingnumber.
- The symbol (2, Figure177) punchedonthetop of the
pistons faces the engine flywheel or the recess in the
pistonskirt tallieswiththepositionof theoil nozzles.
Fitting connecting rod- piston assemblies in
cylinder liners
Figure178
1
2
3
Not finding it necessary to replace theconnecting
rodbearings,youneedtofit thembackinexactlythe
samesequenceand position as inremoval.
Choose main bearings, if they are to be replaced,
basoo oo so|oct|oo oosc|boo |o c|ato 'So|oct|o
a|o aoo b| ooo boa|os'.
Do not makeanyadjustment onthebearingshells.
also befittedinclass Bcylinder liners.
NOTE
NOTE
NOTE
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PRINT603.93.641
47594
Figure179
Figure180
Figure181
Figure182
Figure183
Figure184
Connect the connecting rods to the relevant pins of the
crankshaft, mount the connectingrod caps (1) together with
thebearingshells. Tightenthescrews(2) fixingtheconnecting
rodcapsto atorqueof 60 Nm(6kgm). Usingtool 99395216
(3), tightenthe screws further with an angleof 60 .
Using the centring ring 99396035 (2), check the exact
positionof thecover (1). Ifit is wrong, proceedaccordingly
and lockthescrews (3).
Key on the gasket (1), mount the key 99346250 (2) and,
screwingdownthenut (3), driveinthegasket (1).
Checkthat thepistons 1-6areexactlyat theT.D.C.
Put the gasket (2) onthecrankcase.
Diagramof thetighteningsequence of thescrewsfixingthe
cylinder head.
- Pre-tighteningwith thetorque wrench (1):
1
st
phase: 60 Nm(6 kgm).
2
nd
phase: 120Nm(12kgm).
60563
60564
60515
60565
61270
Before reusing the screws (2), measure the
diameter ofthethread;it must beno lessthan13.4
mm; if it is, changethescrew.
Lubricate thethread of thescrewswithengineoil
beforeassembly.
Lubricate thethread of the screwswith engineoil
beforeassembly.
NOTE
NOTE
Use new screws whenever removingthe cylinder
head.
NOTE
Mount the cylinder head (1) and tighten the screws as
shown inFigs. 183, 184and185.
Revi- June2007
PRINT603.93.641/A
Fitting the cylinder head
Usingatorquewrench, tighten the highlighted screws with
thefollowingsequenceandtorque:
4 screwsM12 x 1.75x 35 56 to 70 Nm
10screws M12 x 1.75x 100 56 to 70 Nm
1 screwM12x 1.75 x 120 56 to 70 Nm
2 screwsM12 x 1.75x 70 56 to 70 Nm
Figure185
Figure186
Figure187
60566
- Closingto anglewith tool 99395216 (1):
3
rd
phase: angleof 90
4
th
phase: angle of 65 .
Mount theoil pump (5), themiddlegears (2) together with
thelinkrod (1) andthePTO drivinggear (3).
Tighten thescrews(4) to therequired torque.
ApplyLOCTITE 5970 IVECO No. 2995644siliconeonthe
flywheel usingappropriatetools(1) asshowninthefigure.
47592
71773
60633
Figure188
Figure189
Keyonthegasket (1),fit thekey99346251(2) and,screwing
downthenut (3), driveinthegasket.
Mount thegear housingwithin 10min.ofapplying
thesealant.
60568
2 screwsM12x 1.75 x 193 56 to 70 Nm
:
Fitting flywheel housing
NOTE
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PRINT603.93.641
Secondphase:closingtoangleof90 withtool 99395216(1).
49036
60668
Figure190
Figure191
DETAIL OFPUNCH MARKSON ENGINEFLYWHEEL FOR PISTON POSITIONS
A. Holeon flywheel withonereference mark, correspondingto the TDC of pistons3-4. - B. Holeon flywheel with one
referencemark, correspondingto theTDC of pistons 1-6.- C.Holeon flywheel withonereference mark, corresponding
to theTDC of pistons 2-5.- D. Holeonflywheel withtwo reference marks, positioncorrespondingto 54 .
Thecrankshaft hasalocatingpegthat hastocouple
with therelevant seat on theengine flywheel.
VIEW OF HOLES:
A - B- C
VIEW OF HOLES:
D
49037
Figure192
Position the flywheel (1) on the crankshaft, lubricate the
thread of the screws (2) with engine oil and screw them
down. Lock rotation with tool 99360351 (3). Lock the
screws (2) inthreephases.
First phase: pre-tightening with torque wrench (4) to a
Iftheteethof theringgear mounted ontheengine
flywheel, for startingtheengine, areverydamaged,
replacetheringgear. It must befittedafter heating
theringgear to atemperatureof approx. 200 C.
Fitting engine flywheel
NOTE
NOTE
3aso |ovobo 2006 Print 603.93.641
540850 ENGINE FLYWHEEL
Figure193
Figure194
- Fit theidlegear (1) back on and lock thescrews (2) to
therequiredtorque.
60571
- Apply the gauge 99395219 (1). Check and adjust the
position of the link rod (3) for the idle gear. Lock the
screw (2) to the required torque.
60570
Fit the camshaft (4), positioning it observingthe reference
marks ( ) as shown in thefigure.
Lubricatetheseal (3) and fit it on theshoulder plate (2).
Mount theshoulderplate(2) withthesheetmetal gasket (1)
and tightenthescrews (5) to therequiredtorque.
73843
72436
Figure195
Figure196
Position the crankshaft with the pistons 1 and 6 at thetop
deadcentre(T.D.C.).
This situationoccurs when:
1. The holewithreferencemark(5) of theengineflywheel
(4) can beseen throughtheinspection window.
2. Thetool 99360612 (1), throughthe seat (2) of theengine
speedsensor,entersthehole(3) intheengineflywheel (4).
Ifthisconditiondoesnot occur,turntheengineflywheel (4)
appropriately.
Print 603.93.641 3aso |ovobo 2006
Fitting camshaft
60572
Figure197
Figure198
Positionthegear (2) onthecamshaft so that the4 slotsare
centredwiththeholes for fixingthecamshaft, without fully
lockingthescrews (5).
Usingthedial gaugewithamagnetic base(1),checkthat the
c|oaaoco bot.ooo t|o oas (2 aoo 3) |s 0.0+ 0.+5 ,
if this is not so, adjust the clearanceas follows:
- Loosen thescrews (4) fixingtheidlegear (3).
- Loosenthescrew(2,Figure 195) fixingthelinkrod.Shift
the link rod (3, Figure 195) to obtain the required
clearance.
- Lock the screw (2, Figure 195) fixing the link rod and
screws(4,Figure 197) fixingtheidlegeartotherequired
torque.
Figure199
Figure200
108843
Fit theseals(1) (2) (3) on theinjectors.
Before refitting the rocker-arm shaft assembly,
make sure that all the adjustment screws have
beenfullyunscrewed.
Usingtool 99360144(3), fastentheblocks(4) to therocker
arms (2).
Applythetool 99360553(1) totherocker armshaft (5) and
mount theshaft onthe cylinder head.
73533
5
Fitting pump-injectors
116724
Mount:
- The injectors (2) and, usingatorquewrench, lock the
bracket fixingscrews to atorqueof 30 35Nm.
- The exhaust brake cylinders (1) and (4) and, using a
torque wrench, fixthemto atorqueof 19 Nm.
- Thecrosspieces(3) onthevalvestem,all withthelargest
holeon thesameside.
Fitting rocker-arm shaft assembly
NOTE
3aso |ovobo 2006 Print 603.93.641
Applytool 99360321(7) andspacer (6) togearshousing(3).
- Mount theenginebrake lever retainingsprings (3).
- Connectthepipe(2) totheenginebrakecylinders(4) and
to thecylinder with theenginebrakesolenoid valve(1).
Figure201
Figure202
Figure203
116722
Lockthescrews (2) fixingtherocker-armshaft as follows:
- 1
st
phase: tighteningtoatorqueof 80Nm(8kgm) with
thetorquewrench(1).
- 2
nd
phase: closing with an angle of 60 usingthe tool
99395216 (3).
117548
71776
117543
Figure204
Use strips(2) to fixcable(3) to pipe(1) correspondingto
whitecolor notches machined bothoncableandonpipe.
The arrowshows thedirection of rotation of the
enginewhen running.
Using the above-mentioned tool, turn the flywheel
(1) inthedirectionofrotationof theenginesoasto
takethepistonofcylinder no.1to approximatelythe
T.D.C. inthe phase of combustion.
This condition occurs when the hole with one
reference mark (4), after the hole with two
referencemarks(5) ontheengineflywheel (1),can
beseenthrough theinspectionwindow (2).
Camshaft timing
Figure205
NOTE
SCHEME OFSCREW TIGHTENING SEQUENCE
SECURING ROCKER ARMS
Screw screws (1 - 2 - 3) until rocker arms are brought to
contact relating seats on cylinder head, tighten the screws
according to sequence indicated in figure operating in two
steps as indicated insuccessive figure.
70567A
1
Revi- June2007
PRINT603.93.641/A
71774
60575
Figure206
Figure207
Figure208
Figure209
The exact position of piston no.1 at the T.D.C. is obtained
whenin theabove-describedconditionsthetool 99360612
(1) goesthroughtheseat (2) oftheenginespeedsensorinto
thehole(3) in the flywheel (4).
If this is not the case, turn and adjust the flywheel (4)
appropriately.
Set thedial gaugewiththemagnetic stand (1) with therod
(flat based) on theroller (2) of therocker armthat governs
theinjector of cylinder no.1 and pre-load it by 6mm.
The camshaft is in step if at the cam lift values of
5.33 0,05 mmtherearethefollowingconditions:
1) anotch(5) canbeseenthroughtheinspectionwindow;
2) thetool 99360612(1) throughtheseat(2) oftheengine
speed sensor goes into the hole (3) in the engine
flywheel (4).
77259
If you do not obtain the conditions illustrated in Figure208
and describedinpoints 1and2, proceed as follows:
1) loosen the screws (2) securing the gear (1) to the
camshaft and utilize the slots (1) on the gear (2,
Figure210);
2) turn theflywheel appropriatelyso asto bringabout the
conditionsdescribedinpoints1and2Figure208,itbeing
understoodthat thecamlift must not change at all;
3) lock the screws (2) and repeat thecheck as described
above;
4) tightenthescrews (2) to therequired torque.
106535
With tool 99360321 (6, Figure205), turn the crankshaft
clockwise until the pointer of the dial gauge reaches the
minimumvaluebeyondwhich it canno longer fall.
Reset thedial gauge.
Turn the flywheel anticlockwise until thedial gauge gives a
readingfor thelift of the camof the camshaft of 5.33 0.05
mm.
Duringthemeasurement,thedial gaugerod must
always beat right angles to theenginecentreline
and NOT to thehead surface.
NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
71778
77259
Figure210
Turn the flywheel (4) again to bring about the following
conditions:
- anotch(5) canbeseenthroughtheinspectionwindow;
- the tool 99360612 (1) inserted in the hole (3) in the
flywheel (4) through the seat (2) of the enginespeed
sensor.
77260
Phonic wheel timing
Turnthecrankshaft bytakingthepistonof cylinderno.1into
the compression phase at T.D.C.; turn the flywheel in the
opposite direction to the normal direction of rotation by
approximately 1/4 of aturn.
Again turn the flywheel in its normal direction of rotation
until you see the hole marked with the double notch (4)
through the inspection hole under the flywheel housing.
Insert tool 99360612(5) intotheseat oftheflywheel sensor
(6).
Insert thetool 99360613(2),viatheseatofthephasesensor,
onto thetooth ( ) obtainedonthephonicwheel.
Shouldinsertingthetool (2) provedifficult,loosenthescrews
(3) andadjust thephonicwheel (1) appropriatelyso that the
tool (2) getspositionedonthetoothcorrectly.Goaheadand
tightenthescrews (3).
Mount the gear (2, Figure210) with the 4 slots (1,
Figure210) centred with the fixing holes of the camshaft,
lockingtherelevant screwstotherequiredtighteningtorque.
Check the timingof the shaft by first turning the flywheel
clockwisetodischargethecamcompletelyandthenturnthe
flywheel anticlockwiseuntil thedial gaugegivesareadingof
5.33 0.05mm.
Checkthe timingconditions described inFigure 208.
Figure211
Figure212
When the adjustment with the slots (1) is not enough to
makeupthephasedifferenceandthecamshaft turnsbecause
itbecomesintegralwiththegear (2);asaresult,thereference
valueof thecamlift varies, in this situation it isnecessaryto
proceed as follows:
1) lock the screws (2, Figure209) and turn the engine
flywheel clockwisebyapprox. 1/2turn;
2) turntheflywheel anticlockwiseuntil thedial gaugegives
areadingof thelift of thecamof the camshaft of
5.33 0.05mm;
3) takeout thescrews(2, Figure209) andremovethegear
(2) fromthe camshaft.
Print 603.93.641 3aso |ovobo 2006
- With a suitable wrench (4), screw down the
adjustment screwto takethepumpingelement to its
limit.
- Tighten theadjustment screw with a torquewrench
to atorqueof 5 Nm(0.5kgm).
- Unscrewtheadjustment screwby1/2 3/4ofaturn.
- Tighten the locking nut to a torque of 39 Nm
(3.9 kgm).
The adjustment of theclearance between the rocker arms
andthecrosspiecesgoverningtheintakeandexhaust valves
and the adjustment of the pre-load of the pump injector
governingrocker armshasto bedone veryconscientiously.
Take thecylinder whose clearanceyou want to adjust into
thecombustionphase. Thevalvesof thiscylinder areclosed
while theybalancethoseof the symmetric cylinder.
The symmetric correspondenceof thecylinders is 1- 6, 2-
5 and 3- 4.
Toperformtheseoperationscorrectly,proceedasdescribed
belowandas illustratedin the table.
Adjustingclearancebetweenrocker arms and crosspieces
governingtheintakeandexhaust valves
- Using a box wrench, loosen the nut (1) locking the
adjustment screw.
- Insert thestripof feeler gauge(3) correspondingtothe
workingclearance(page133);
- Useasuitablewrench to screwor unscrewrocker arm
(2) adjustingscrew.
- Check that the blade of the feeler gauge(3) can slide
with alight amount of friction.
- Lock thenut (1) holdingtheadjustment screwstill.
Pre-load of pumpinjector governingrocker arms
- Using a box wrench, loosen the nut locking the
adjustment screw of therocker arms (5) governingthe
pumpinjector (6).
ADJUSTING INTAKE, EXHAUST AND INJECTION ROCKERARMS
60577
Figure213
FIRING SEQUENCE1 - 4 - 2 - 6- 3 - 5
To performthe aboveadjustmentscorrectly, it is
mandatory to follow the sequence given in the
table, checking the position at each phase of
rotationwiththe pin99360612 to be inserted in
hole identified by a notch on flywheel,
correspondingto TPD (seedetail figure190).
NOTE
Revi- June2007
Adjust intake and exhaust rocker arm clearance, and pump injector preload
PRINT603.93.641/A
Startingand
clockwise
rotation
Balance
valves of
cylinder no.
Adjust
clearanceof
valves of
cylinder no.
Adjust
pre-load of
injectors of
cylinder no.
1and6 at TDC 6 1 5
120 3 4 1
120 5 2 4
120 1 6 2
120 4 3 6
120 2 5 3
||t t|o b|o.-b caso (+) .|t||o +0' o soa|o
application.
Fit thecover (3) andtightenthefasteningscrews(2) to the
prescribed torque.
Thefilter (5) operationisunidirectional,thereforeit
must be assembled with the two sight supportsas
illustrated in thefigure.
Fit therocker cover (1).
Fit theblow-bycase (7) and itsgasket and then tighten the
Install thefilter (5) and thegaskets(4and6).
60665
Figure214
Figure215
Figure216
Apply silicone LOCTITE 5970 (IVECO No.
2995644) ontheblow-bycase(7)surfaceofengines
fitted with P.T.O. according to the procedure
describedinthe followingfigure.
85480
ApplysiliconeLOCTITE5970(IVECO No.2995644) onthe
blow-bycaseandformastring(2) of 1,5 , asshown
inthefigure.
85481
0.5
0.2
.
NOTE
NOTE
NOTE
Turnengine and mount oil rosepipe.
Arrange gasket (4) onoil sump (1), position frame (3) and
mount thesumponengineblock screwingupscrews(2) at
prescribed torque:
Completing Engine Assembly
Complete the enginebyfittingor hookingupthe following
parts:
- power take-off (P.T.O., if present) andrelatingpipes;
- fuel pump;
- support completewith fuel filter and pipes;
- EDC central unit;
- intakemanifold;
- preheatingresistance;
- heat exchanger;
- oil filters, lubricatingthegasket;
- exhaust manifold;
- turbocompressor and relatingwater and oil pipes;
- pulleyand dampingflywheel;
- thermostat assembly;
- belt tensioner, water pump, alternator;
- electromagneticjoint;
- belt tensioner, if present, air-conditioner compressor;
- starter;
- oil level rod;
- electrical connectionsandsensors.
The fittings of thecooling water and lubricatingoil
pipes of theturbocharger haveto betightened toa
torque of:
- 35 5 Nm, water pipefittings;
- 55 5 Nm, oil pipe femalefitting;
- 20-25 Nm, oil pipemale fitting.
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
- refuel enginewith providedoil quantity;
- dismount enginefromrotarystandandtakeoffbrackets
(99361036) securingthe engine.
Mount:
- oil pressureregulationvalve;
- engineleft support;
- air compressor completewith hydraulic guidepump;
- sounddeadeningguard;
- pipes.
- if present, climate control systemcompressor driving
belt similarlyto belt (1, Figure217);
Figure217
106224
Belt tensioner is of automatic type; therefore,
further adjusting is not provided after mounting.
NOTE
- drivingbelt.
To mount belt (1), belt tensioner (2) hasto beoperatedby
propertooling(3)accordingtothedirectionindicatedbythe
arrowin Figure.
Figure218
106223
Figure219
Applytool 99360321(2) providedwithspacer 99360325to
gears box (1).
Mount springbelt (3) ondrivingshaft pulley, mount chock
99360192 (4) on compressor pulley (5) for climatecontrol
system. Position spring belt (3) in the opening of tool
360+2 a'oo .|t| 'coso +0/+3'.
Bytool 99360321(2), rotate drivingshaft accordingto the
direction of the arrow ( ) until springbelt (3) is correctly
positionedon compressor pulley (5).
Springbelt must be replaced bya new one after
NOTE
/SS||3|Y ||/C|/| C| |/| \/T|| ||||
ALTERNATOR DRIVE BELT
+. /|tooato 2. ||octoaoot|c coo||o
3. \ato o +. Cao's|at
108844
Inthecaseof engineswith climatecontrol system
compressor springdriving belt, for mounting the
belt, tool 99360192 (4) must be used. Different
methodsmaycausetensionsimpairingspringbelt.
NOTE
While operating, keep tool 99360192 (4) in
contactto pulleyandatthesametimeguidespring
belt (3) inorder to prevent it fromtwisting.
NOTE
Replacingspringbelt withengineonthevehicleis
fromengine openingafter tiltingthe cab.
NOTE
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
COMPRESSORCONTROL BELT
ASSEMBLY DIAGRAM
1. Crankshaft - 2. Air conditioner compressor -
3. Electromagneticcoupling- 4. Water pump-
5. Crankshaft - 6. Springbelt.
108845
Figure220
Print 603.93.641 3aso |ovobo 2006
3aso |ovobo 2006 Print 603.93.641
71735
DETAIL A
Oil falling
Oil under pressure
B - to cylinders 1 - 2 - 3
C - to cylinder 4
D - to cylinders 5 - 6
Exhaust brake solenoid valve with piston driving the
exhaust brakeof the 4
th
cylinder.
Engine lubrication is obtainedwith agear pumpdriven
bythecrankshaft viagears.
A heat exchanger governs the temperature of the
lubricatingoil. It housestwooil filters, indicatorsensors
and safetyvalves.
Lubricationcircuit
Figure221
Print 603.93.641 3aso |ovobo 2006
5430 LUBRICATION
PRINT603.93.641
3aso |ovobo 2006 Print 603.93.641
The oil pump (1) cannot be overhauled. On finding any
damage, replace the oil pumpassembly.
Seeunder therelevant headingfor replacingthegear (2) of
thecrankshaft.
60560
73540
MAIN DATA TO CHECKTHEOVERPRESSURE
VALVE SPRING
OIL PUMPCROSS-SECTION
+. Saot o||o va|vo 2. Stat o ooo|o ossoo +0 1 bars.
Safety relief valve
Figure222
Figure223
Figure224
108846
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
543010 Oil pump
Theoil overpressurevalveislocatedontheleft-handsideof
thecrankcase.
Start of openingpressure 5bars.
73542
MAIN DATA TO CHECKTHEOIL OVERPRESSURE
VALVE SPRING
HEAT EXCHANGER
T|o |oat oc|aoo |s |ttoo .|t|. +. C|| tooatoo taos|tto 2. C|| ossoo taos|tto
3. |||to bass va|vo +. T|oostat
Number of heat exchanger elements: 11.
Oil overpressure valve
543110 Heat exchanger
106250
73543
Figure225
Figure226
Figure227
3aso |ovobo 2006 Print 603.93.641
This is anew generation of filters that permit much more
thorough filtration as theyareableto holder backagreater
amount of particles of smaller dimensions than those held
back byconventional filters witha paper filteringelement.
Thesehigh-filtration devices, to dateused onlyin industrial
processes, make it possibleto:
- reducethewear of enginecomponents over time;
- maintain the performance/specifications of the oil and
therebylengthen thetimeintervals betweenchanges.
External spiral winding
The filteringelements areclosely woundbyaspiral so that
eachfoldisfirmlyanchoredto thespiral withrespect tothe
others. Thisproduces auniformuseof theelement evenin
theworst conditions such as coldstartingwith fluids witha
high viscosity and peaks of flow. In addition, it ensures
uniformdistributionoftheflowovertheentirelengthofthe
filteringelement,withconsequent optimizationofthelossof
loadandof its workinglife.
Mount upstream
To optimizeflow distribution and the rigidityof thefiltering
element, this hasan exclusivemount composedof astrong
mesh made of nylon and an extremely strong synthetic
material.
Filteringelement
Composedof inert inorganicfibresboundwithanexclusive
resin to a structure with graded holes, the element is
manufactured exclusively to precise procedures and strict
qualitycontrol.
Mount downstream
A mount for the filteringelement and astrongnylonmesh
makeit evenstronger,whichisespeciallyhelpful duringcold
starts andlongperiods of use.Theperformanceofthefilter
remainsconstant andreliablethroughout itsworkinglifeand
fromoneelement to another,irrespectiveofthechangesin
workingconditions.
Structural parts
Theo-rings equippingthefilteringelement ensureaperfect
seal between it and the container, eliminatingby-pass risks
and keeping filter performance constant. Strong
corrosion-proof bottoms and a sturdy internal metal core
completethestructure of thefilteringelement.
Whenmountingthefilters, keep to thefollowingrules
- Oil andfit newseals.
- Screw down the filters to bring the seals into contact
with thesupportingbases.
- Tighten thefilter to atorque of 35-40 Nm.
73545
47447
73546
The valve quicklyopens at apressureof: 3bars.
Thermostatic valve
Start of opening:
- travel 0.1mmat atemperatureof 82 2 C.
End of opening:
- - travel 8 mmat atemperatureof 97 C.
Engine oil filters
By-pass valve
Figure228
Figure229
Figure230
Print 603.93.641 3aso |ovobo 2006
109080
Figure231
The valve allows oil to enter only above the threshold
pressure of 1.7 0.2 bar. This permits fillingthecircuit and
therefore lubricating the most stressed parts even when
workingat lower pressures.
Valve integrated in piston coolingnozzle
3aso |ovobo 2006 Print 603.93.641
Figure232
Description
The engine cooling systemworks with forced circulation
inside closed circuit and canbe connectedto anadditional
heater (if any) andto the intarder intercooler.
It consists mainlyof thefollowingcomponents:
- anexpansionreservoirwhoseplug(1) incorporatestwo
va|vos o|sc|ao aoo c|ao cooto|||o t|o ssto
pressure.
- acoolant level sensorplacedat thebottomoftheexpan-
sionreservoir with two couplingpoints:
right drivevehicles:
left drivevehicles:
D couplingpoint for sensor S1 6 litres
- anenginecoolingunit todissipatetheheat takenbythe
coolant fromthe enginethrough the intercooler.
- aheat exchanger to cool down lubricationoil;
- a water pump with centrifugal systemincorporated in
thecylinder block;
- anelectricfan consistingof a 2-speedelectro-magnetic
joint equippedwithaneutral wheel shaft hubfittedwith
ametal plate movingalongtheaxis and where thefan
is installed. It is controlled electronicallyby thevehicle
Multiplexsystem.
- a3-waythermostat controllingthecoolant circulation.
Operation
The water pump is actuated by the crankshaft through a
poli-Vbelt andsendscoolant tothecylinderblock,especially
to the cylinder head (bigger quantity). When the coolant
temperature reaches and overcomes the operating
temperature, the thermostat is opened and fromhere the
coolantflowsintotheradiatorandiscooleddownbythefan.
The pressure inside the system depending on the
temperature variation is controlled by the discharge and
charge valves incorporated in theexpansionreservoir filling
plug(1).
The dischargevalvehasadoublefunction:
- keepthesystemunderlight pressureinordertoraisethe
coolant boilingpoint;
- dischargethepressuresurplusintheatmosphereasare-
sult of thecoolant high temperature.
The charge valve makes it possible to transfer the coolant
from the expansion reservoir to the radiator when a
depression isgenerated inside the systemas aresult of the
coolant volume reduction depending on the fall in the
coolant temperature.
Dischargevalveopening:
D 1
st
breather 0.9 bar
D 2
nd
breather 1.2 bar
Chargevalveopening -0.03 bar
Plugtighteningtorque (1): 8 1 Nm
+0.2
- 0.1
Water enteringthepump
+0.2
- 0.1
+0
- 0.02
92843
COOLINGCIRCUIT VERSION WITHOUT INTARDER
Print 603.93.641 3aso |ovobo 2006
5432 COOLING
PRINT603.93.641
Figure233
92844
COOLINGCIRCUIT VERSION WITH INTARDER
Vent
Water leaving the thermostat
Water circulating in the engine
Water entering the pump
Specific elements of the version wi th
INTARDER
3aso |ovobo 2006 Print 603.93.641
77469
Figure234
543210 Electromagnetic fan drive
assembly(2) andthepulley (1), it must beno greater than2.5
mm.
Theelectro-magnetic fan driveactiondepends on:
- thecoolant temperature;
- theclimate control systemfluid pressure(if any);
- theslowingdown action of theintarder on(if any).
Idlingcondition:
- watertemperatureislessthan93_C andboththeIntarder
andtheair-conditioningunit (whereavailable) areOFF;
- coolant temperature is less than 85_C and the
air-conditioningsystemis ON (pressureinside thecircuit
is lessthan18bar);
- coolant temperatureislessthan85_C,andtheIntarder is
ON,withitsbrakingpower lessthan41%ofitsmaximum
power.
The first speedis actuated when:
- coolant temperature reaches 85_C, and the Intarder is
ON, with its braking power greater than 41% of its
maximumpower;
- coolant temperature reaches 85_C and the
air-conditioningsystemis ON (pressureinside thecircuit
in higher than 18 bar);
The secondspeed isactuatedwhen:
- coolant temperature reaches 93_C, and the Intarder is
either OFFor ON with its brakingpower less than41%
(speed is deactuated when temperature falls down to
88_C);
- coolanttemperaturereaches85%,theIntarderisON(with
itsbrakingpowergreaterthan41%ofitsmaximumpower),
or the air-conditioning systemis ON and the pressure
insidethecircuit is 22bar.
When second speed actuation is required, the systemwill
drivethefanfor 5secondsatthefirstspeedandthenengages
thesecondspeed.Thiswill increasebelt andfancomponent
wear intime. When thefan first speedisactuated for more
than1 minute, the systemactuates thesecond speeduntil
thecontrol parameters fall under theoperationlevels.
Astothedescriptionoftheelectro-magneticfandriveopera-
t|oo aoo sov|c|o, soot|o '|aooa| o o|oct|c/o|octoo|c ss-
to oa||o' - Volume3
60631
Figure235
Figure236
Figure237
543250 Thermostat
Thewater pumpis composedof: impeller, bearing, seal and
drivingpulley.
Checkthat thepump bodyhas no cracks or water
leakage; if it does, replacetheentirewater pump.
CROSS-SECTION OFTHEWATER PUMP
View of thermostat operation
60747
TO THE
EXPANSION
TUB
FROM
THEENGINE
TO THE
BY PASS
60748
TO THE
RADIATOR
TO THE
EXPANSION
TUB
TO THE
BY PASS
FROM
THEENGINE
Checkthethermostat worksproperly; replaceit if indoubt.
Temperatureof start of travel 84 C 2 C.
Minimumtravel 15 mmat 94 C 2 C.
NOTE
543210 Water pump
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
72675
72676
Figure238
COLDOPERATION WITH
CLOSEDTHERMOSTAT
HOT OPERATION WITH
OPEN THERMOSTAT
A - Water circulatingintheengineand theintarder.
B - To water pump.
A - Water circulatingintheengineand theintarder.
B - Fromtheradiator to the water pump.
C - To radiator.
Figure239
View of thermostat operation for versions with
Intarder
3aso |ovobo 2006 Print 603.93.641
Compressed air (hot)
Intakeair
Engine exhaust gas
Compressed air (cooled)
Figure240
71737
TURBOCHARGINGDIAGRAM
Turbocharger HOLSET HE 551V
Workingprinciple
Thevariablegeometryturbocharger (VGT) iscomposedof
a centrifugal compressor and a turbine equipped with a
mobiledevicethat,bychangingtheareaofcross-sectionof
the passage of the exhaust gases going to the turbine,
governs thespeed.
Thanksto this solution, it is possibleto keepthespeedof
thegasesandturbinehighevenwhen theengineisrunning
at lowspeed.
Bymakingthegasespassthroughsmall cross-sections,they
flow faster, so that theturbine turnsfaster aswell.
Themovement ofthedevicechangingthecross-sectionof
theflowofexhaust gasesisaccomplishedwithamechanism
operated byapneumaticactuator.
Thisactuatoriscontrolleddirectlybytheelectroniccontrol
unit viaaproportional solenoid valve.
This deviceismost closed at lowspeed.
At highenginespeeds,theelectroniccontrol systemincreases
thecross-sectionof thepassageto permit theincominggases
to flow without increasingtheir speed too much.
Cast inthecentral bodythereisatoroidal chamber forthe
coolant to pass through.
The turbochargingsystemiscomposedof:
- anair filter;
- A turbocharger withfixedgeometryandWASTEGATE
(410 HP engines) or with variable geometry for 450
HP/500HPengines;
- ao '|otocoo|o' ao|ato.
Print 603.93.641 3aso |ovobo 2006
5424 TURBOCHARGING
72421
Figure241
a Gradientcharacterizedbytheeffectoftheexternal spring
(4, Figure 241).
b Gradient characterized bythe effect of the external (4,
Figure241) and internal (6, Figure241) springs.
Actuator
Stroke [mm]
[bar]
Solenoid valve for VGT control
This N.C. proportional solenoid valve is located on the
left-handsideof thecrankcaseunder the turbine.
The electronic control unit, viaa PWM signal, controls the
solenoidvalve, governingthesupplypressureof theturbine
actuator, which, on changing its position, modifies the
cross-sectionoftheflowofexhaust gases ontothebladesof
theimpeller and thereforeitsspeed.
The VGT solenoid valve is connected to the electronic
control unit betweenpins C1/C3.
The resistanceof the coil is approx. 20-30Ohms.
Workingprinciple (SeeFigure241)
Theactuatorpiston,connectedtothedriverod,iscontrolled
with thecompressedair introducedthroughtheair inlet (1)
on thetop of theactuator.
Modulating the air pressure varies the movement of the
piston and turbine control rod. As the piston moves, it
progressively compresses the external spring (4) until the
baseofthepistonreachesthedisc (5) controllingtheinternal
spring(6).
Onfurtherincreasingthepressure,thepiston,viathedisc(5),
interfereswiththebottomlimit stop (10).
Usingtwospringsmakesitpossibletovarytheratiobetween
thepistonstrokeandthepressure.Approximately85%ofthe
strokeof therodisopposedbytheexternal springand15%
bytheinternal one.
REPAIR
Ifvaluesbeyondtolerancearedetected,checktheefficiency
of:
- shut-off valve;
- pressure sensor;
- engine cable pressure sensor connection (if oxidised,
clean with aspecific product);
- lack of electrical defects in solenoid valve VGT
(continuityconnection);
- actuator moved by active diagnosis as described in
relatingchapter, in caseof locking, grease bushingwith
lubricant Kernite(for high temperatures); if the trouble
persists, replacetheactuator;
- sliding sleeve: it must slide freely when operated
manually. Iflockedandifthebushcheckis not sufficient
or effective, ornofaultsaredetectedintheother points,
ooo aot|o|zat|oo o t|o 'o| |os'' a'ot ooato,
change the turbocharger according to the standard
procedures.
Ifanomalousengineoperationisfound,whichisdue
totheboostingsystem,it isadvisablethat youcheck
theefficiencyof seal gasketsand thefasteningofconnecting
sleevesprior tocarryingout thechecksontheturboblower.
Also check for obstructions in thesuckingsleeves, air filter.
If the turbocharger damage is due to alack of lubrication,
checkthat theoil circulationpipesarenot damaged.
If so, changethemor eliminatethecause.
NOTE
After carryingout the above mentioned checks, check the
turbocharger operationwithanEngineTest byusingIVECO
diagnosis equipment (Modus- IT 2000- E.A.SY.) according
to therelevant procedure.
Thetest mustbeperformedinfollowingconditions:
- engine coolant temperature >50 C;
- batteryup (voltage>22V) for compressiontest;
- efficient rechargingsystem.
NOTE
1. Air inlet - 2. Gasket - 3. Piston- 4. External spring-
5. Internal springcontrol disc - 6. Internal spring-
7. O-ring- 8. Springholder - 9. Limit stop - 10. Dust seal -
11. Control rod
71834
Figure242
3aso |ovobo 2006 Print 603.93.641
'+06226 106227
106228
Figure243 Figure244
Figure245
Remove screws (2) and take actuator (1) off
Remove screw (6), underlying disk (5), ring (4) and
disconnecttierod(3) ofactuator (1) fromthepinofvariable
geometrydrivinglever (8).
Accuratelycleanpin( ) oflever (8) andbushing( ) oftie
rod(3) usingaclothmadeof non abrasivemicro fibre.
Checkactuator efficiency(1) operatingas follows.
Apply, to fitting (2) of actuator (1), compressed air feed
piping provided with pressure regulator (4). By using the
pressureregulator,introduce,intotheactuator,compressed
airslowlymodulatingit,from0 3.5bar;tierod(3)ofactuator
(1) must movewithout jamming;otherwise,replaceactuator
(1).
Checkforanyactuatorleaksat indicatedpoints( ) applying,
on thesepoints, asolutionof suds.
When actuator (1) is fed with compressed air, no bubbles
must be found at indicated points ( ); otherwise, replace
actuator (1).
Variable geometry movement control
Do not useabrasivepaper of anykind. NOTE
Visuallycheckthe conditions of bushing( ) of tie rod (3)
and pin ( ) of lever (8); wheretheyare foundto beworn
out, replaceactuator (1) or turbocompressor (7).
Check variable geometry inner driving mechanism
movement by operating on lever (8); jamming must not
occur;otherwise,cleanturbinebody, asdescribedinrelating
chapter.
Checking the actuator
Print 603.93.641 3aso |ovobo 2006
106229
106230
106231
106232
Figure246
Figure247
Figure248
Figure249
Lubricatebushing( ) oftierod(3) andpin( ) oflever (8)
withlithium-basedCastrol LMGREASEtypeandreconnect
actuator (1) to turbocompressor (7) operatingas follows.
Connect tierod(3) to lever (8).
Mount newring(4),mount disk(5) andscrewupscrew(6).
Screw up screws (2) securing actuator (1) to
Tighten screws(2and6) at 25Nmtorque.
Check travel X of tie rod (2) of actuator (1) operating as
follows.
MeasuredistanceX1betweenactuator (1) andcross-axisof
eyelet (4).
Apply,tofittingofactuator (1),piping(3) for compressedair
feedprovidedwithpressureregulator.Byusingthepressure
regulator,introduce,intoactuator (1) compressedair slowly
modulatingit,from0 3,5bar,until lever (5) istakentoitsend
of travel.
Measure again the distance between actuator (1) and
cross-axis of eyelet (4) dimension X2.
Travel X of tierod (2) of actuator (1) is givenbyfollowing
subtraction X = X2-X1 and must result to be equal to
11.5 0.5mm.
Markmountingpositionof clamp (2) on central body (1).
On threadingand nut (4), applyantioxidant spraylubricant
and, operatingon nut (4), loosen clamp (2).
Slightlyrotateclamp (2) usingpliers(5).
Markmountingpositionof turbinebody(3) oncentral body
(1).
Byacopper hammer, beat ontwo opposite points(~180)
on turbinebody (2) to separate turbine bodyfromcentral
body(1).
Cleaning turbine body
Checking actuator travel
Inoperation,takeparticularcaretoavoiddamaging
turbinerotor.
After dismounting turbine body, check variable geometry
movement as described in relating chapter; where
improvement in movement is not found with respect to
previous check, replaceturbocompressor.
NOTE
3aso |ovobo 2006 Print 603.93.641
106233
106235
106234
106236
106237
Figure250
Figure251
Figure252
Figure253
Figure254
Accuratelycleanslot ring(1) and areaaround turbinebody
fromcarbonaceousdepositsandcheckthat the ringmoves
freely, otherwise, replaceturbocompressor.
surfaces ( ) of turbine body (1) from carbonaceous
deposits, takingcareto avoid damagingthe surfaces.
Dismount clamp(1) fromcentral body(2) andcheckthatthe
clampdoesnot result to bedamaged;otherwisereplacethe
clamp.
Dismount seal ring(1),external withrespect tocentral body
(2).
Accuratelycleanseal ring(1) andcheckthattheringdoesnot
result to bedamaged; otherwisereplacethering.
Check turbine rotor (1); there must not be found:
carbonaceous deposits, deformation, cracks, blade scoring;
also, turbinemust turn freely.
Bycomparator, check clearance of turbine rotor stem(1);
clearancemust result to be:
- axial clearance: 0.051 0.152 mm
- radial clearance: 0.381 0.533 mm.
Whereeitherclearancevaluesover aboveonesor anyone
of above mentioned faults are found, replace
turbocompressor.
Beforecleaningturbinesidecentral body,properly
protect oil, water and air inlets and outlets ( ) in
order to prevent dirt or foreign bodies from
enteringturbocompressor.
NOTE
Any small cracks between slots and ring can be
accepted, because they do not impair
turbocompressor operation conditions.
NOTE
Print 603.93.641 3aso |ovobo 2006
106238
106235
106240
Figure255
Figure256
Figure257
surfaces ( ) of central body (1) from carbonaceous
deposits, taking care to avoid damaging the surfaces and
variablegeometryring.
Then,withcompressedair,cleanvariablegeometrysurfaces
and ringfromremoved residues.
- variablegeometrymovement;
- actuator;
- actuator travel.
Positionclamp (1) oncentral body(2)
Mount turbinebody (1) on central body (2) takingcare to
avoiddamagingturbinerotorandalignturbinebodyvariable
geometryslot ring.Donotforcemountingoperation: incase
of jamming, it might damage variable geometry with
consequent regulation systemfaultyoperation.
Oncemountinghasbeencompleted,makesurethat turbine
bodyresults to bematched correctlyoncentral body.
Positionturbinebodyoncentral bodyandclamponcentral
bodyin such away that marks, made on dismounting, are
matching.
Tighten nut clampingtheclamp at 11.3 Nmtorque.
- actuator;
- actuator travel.
Should clamp (1) be replaced with an integrated
heat guard,anewactuatorhastobemountedwith
an integrated heat guard at the place of existing
one.
NOTE
Position accuratelycleaned seal ringon central body.
Apply a thin layer of antiscuff paste on cleaned matching
surfaces: central body / turbinebody.
3aso |ovobo 2006 Print 603.93.641
Theturboblowerisofthetypeequippedwithpressurerelief
valve.
It is essentiallymadeupof:
- acentral bodywhichincorporatesa shaft supportedby
bushings at the opposite ends of which the turbine
impeller and thecompressor rotor arefitted;
- aturbine bodyand acompressor body, both of which
mountedon thecentral bodyend;
- an overpressure relief valve fitted to the turbine body.
The function of this valve is to choke the exhaust gas
outlet, by conveying part of the gas directly into the
exhaust pipe, whentheboostingpressuredownstream
thecompressor reachesthecalibration value.
71766
Figure258
54249 WASTEGATE
Wastegate check and calibration
Cover the air, exhaust gas and lubricating oil inlets and
outlets. Make a thorough cleaning of the turboblower
outsidebyusingan anti-oxidant andcorrosion-proof fluid.
REPAIRS
If anomalous engine operation is found, which is
dueto theboostingsystem, it isadvisablethat you
checktheefficiencyofseal gasketsandthefastening
of connecting sleeves prior to carrying out the
checks on the turboblower. Also check for
obstructions in the sucking sleeves, air filter and
radiators. If the turboblower damage is due to
lacking lubrication, check that the oil circulation
pipesarenotbrokenorclogged;ifso,replacethem
or eliminatethetrouble.
NOTE
Print 603.93.641 3aso |ovobo 2006
542410 Turbocharger HOLSET HX 50W
86940
71770
71771
Figure259
Figure260
Figure261
If thewastegate valve (3, Figure259) turnsout to bestuck,
disconnect tierod(1) fromlever (2), byremovingsnap ring
(3).
Use device 99367121 (2, Figure 259) to convey weak
pressureintothevalvebody(3) again, tocheckwhetherthe
valveisstuck.If so,replacevalve(3,Figure259) asdescribed
intherelevant chapter.
Otherwise, check of the efficiency of the mechanism as
follows.
Take off the cover (1) to be able to inspect the turbine
mechanismgovernedbythe actuator.
Check through the inspection hole (2) that the internal
linkagecontrol (1) isnot stiff or seized;if it is, thenlubricate
it. And if the defect isnot eliminated, replacetheturbine.
Figure262
86939
Disconnect thepipefromwastegatevalve(3) union,thenfit
device99367121 (2) pipe to theunion.
Placethemagnetic-standcomparator (1) tipontotierod(4)
end, then reset thecomparator.
Use device 99367121 (2) to let compressed air (pressure:
1.75 0.01bar) into thevalvebody(3), thenmakesurethat
suchvalueremainsunchangedovertheentiredurationofthe
check. Otherwise, replace the valve, as described in the
relevant chapter.
Under theaboveconditions, thetierodwill haveto makea
travel of 0.43 1.95mm.
Ifadifferentvalueisfound,loosennut (6)andproperlyrotate
tierod(5) suchthattierodtravel ataboveindicatedpressure
results to be0.86to 1.40.
Replacing the wastegate valve
(see Figure 260)
Takeoffclip(3) securingtierod(4) tolever (2),thenremove
valve (4, Figure259) fromthe turboblower by taking off
fasteningnuts (4, Figure259).
Fit the new valve by reversing the order of disassembling
operations, thenadjust thetierodstrokeasdescribedinthe
relevant chapter.
Before fittingthe turbocharger to the engine, it is
necessaryto fill themain bodywith lubricatingoil.
NOTE
3aso |ovobo 2006 Print 603.93.641
Figure263
ENGINEFEED SCHEME
1. Fuel filter - 2. Pressuredamper - 3. Pressurecontrol valve (start of openingat 5bar) - 4. Feedpump- 5. Fuel pre-filter
with primingpump- 6. Valve, to recirculatefuel frominjectors, integrated in feedpump(start of openingat 3.5 bar) -
7. Central unit - 8. Heat exchanger - 9. Overpressurevalveto return fuel to tank (start of openingat 0.2 bar) -
10. Pump injectors
A. Fuel arrivingat injectors- B. Fuel returningto tank
108847
Fuel is supplied via a fuel pump, filter and pre-filter, 6
pump-injectorsgovernedbythecamshaft viarockerarms
and bytheelectronic control unit.
Returncircuit
Supplycircuit
Print 603.93.641 3aso |ovobo 2006
FUEL SYSTEM
92830
Engine feedpumpfor vehicles 4x2- 4x4- 6x4
1. Overpressurevalve- 2. Deliveringfuel to injectors-
3. Suckinginfuel - 4. Pressurecontrol valve
92829
Pumpperformances
2600
310
600
45
170
12
100
Test
conditions
Negativepressure
onaspiration (bar)
Pressureondelivery
(bar)
Testliquid
temperature (C)
Testliquid
0.5
5
30
0.3
3
30
0.3
0,3
30
0.3
0.3
30
ISO 4113
Fieldof use
(micron)
2600
4100max
-25/+80
30
0.5max
Valvecalibration 5 5.8
Valvecalibration 3.4 3.8
Figure264
Feed pump
Figure265
Anoverpressurevalveisasingle-actingvalve,calibratedto0.2
0.3bar, placedonthepipingthat returns fuel to tank.The
overpressure valve prevents fuel duct incylinder headfrom
emptyingwith enginestopped.
102405
Figure266
Injector-pump
INJECTOR SECTION
The new pump injectors are capable, thanks to the higher
injection pressure, of atomizingthe fuel in the combustion
chambertoagreaterextent,thusimprovingcombustionand
thereforereducingthepollutingexhaust emissions.
Figure267
102606
Pressure damper
FUEL PRESSUREDAMPER
The fuel pressure damper located on the delivery pipe
betweenthefuel filter and thecylinder headis designed to
damp counter-pressure increases in the delivery pipe and
filter dueto injection pressuresurges.
3aso |ovobo 2006 Print 603.93.641
Overpressure valve
247 TRAKKER EURO 4/5 HYDROCARPOWERTAKE-OFFON TIMINGSYSTEM
Hydrocar power take-off
on timing system
Page
HYDROCAR POWERTAKE-OFF
ON TIMING SYSTEM- (P.T.O. OPTIONAL) 249 .
- Description 249 . . . . . . . . . . . . . . . . . . . . . . . . . . .
248 TRAKKER EURO 4/5 HYDROCARPOWERTAKE-OFFON TIMINGSYSTEM
249 TRAKKEREURO 4/5 HYDROCARPOWERTAKE-OFFONTIMINGSYSTEM
HYDROCAR POWER TAKE-OFF ON TIMING SYSTEM- (P.T.O. OPTIONAL)
Output revnumber/enginerevnumber ratio 1.14
Output nominal torque (Nm) 600
Foreseendurationwithnominal torque (hours) 500 (with1500 rpm)
Rotation direction(compared to theengine) Opposite
Mountingside (vehicletravellingdirection) Top
Control system Air
108621
Figure1
Description
It isapowertakeoffbasedononeaxle,withgear movement andclutchengagement whichisset inmotionbythetiminggears
regardless of the vehicle clutch. It can be used with the vehicle stati onary or travelling and continuously; it can be
engaged/disengaged with the engineon.
The power takeoff can be fitted for the direct pump coupling, or withaflangefor theuniversal shaft.
250 TRAKKEREURO 4/5 HYDROCARPOWERTAKE-OFFONTIMINGSYSTEM
DENOX 2SYSTEM 251 TRAKKER EURO 4/5
Denox System2
Page
DENOX2SYSTEM 253 . . . . . . . . . . . . . . . . . . . . . . .
- General remarks 253 . . . . . . . . . . . . . . . . . . . . . . .
- Tank 255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- AdBluefluidlevel gauge control 255 . . . . . . . . . . . .
- Switchvalve 255 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pumpmodule 256 . . . . . . . . . . . . . . . . . . . . . . . . .
- Dosingmodule 256 . . . . . . . . . . . . . . . . . . . . . . . .
- Catalyst 256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Exhaust gastemperaturesensor 257 . . . . . . . . . . .
- Humiditydetectingsensor 258 . . . . . . . . . . . . . . . .
252 DENOX 2SYSTEM TRAKKER EURO 4/5
Figure1
116403
1. Pump module- 2. Tankheatingvalve - 3. Pre-filters- 4. Tankvent pipe- 5. Ad Bluetank- 6. Dosingmodule-
7. Dosingvalve- 8. Mixer - 9/10. Exhaust gasestemperaturesensors - 11. NO
x
detection sensors(*) -
12. Diaphragmpump- 13. Multi-waysmagneticvalve - 14. Coolingvalve- 15. Main filter
* Futureapplication
General remarks
Inorder to keeptheexhaust emissionvalues of nitricoxides(NO
x
) withinthelimits prescribedbythe Euro 4 standard,with
lowfuel consumption,asystemfor post-processingoftheabovesubstancesfoundinexhaust gashasbeenfittedtothevehicles.
This systemessentiallyconsists of anelectronic-control oxidizingcatalyst.
Thesystemconverts,throughtheSCR(SelectiveCatalyticReduction) process, nitricoxides(NO
x
) intoinert compounds:free
nitrogen (N
2
) andwater vapour (H
2
O).
TheSCRprocessisbasedonaseriesof chemical reactions,whichleads, dueto ammoniareactingwithexhaust gasoxygen, to
areductionof nitric oxides (NO
x
) found in exhaust gas.
DENOX 2SYSTEM 253 TRAKKEREURO 4/5
DeNO
x
2SYSTEM
112632
Figure2
The systemis essentiallymadeupof:
- atank (10) for reagent solution (water - urea: AdBlue),
equipped with level gauge (9);
- anH
2
O switchvalve (1);
- pumpmodule(8);
- amixingand injectionmodule (2);
- catalyst (5);
- two exhaust gas temperature sensors (3, 4) on catalyst
(5);
- amoisture detection sensor (7) fitted ontheengineair
intakepipedownstreamfromthe air cleaner.
SCRsystemiselectronicallymanagedbyDCU(DosingCon-
trol Unit) incorporated into pump module (10); depending
on engine rpm, supplied torque, exhaust gas temperature,
quantityofnitrogenoxidesandhumidityofairsuckedin,the
control unit regulatestheflowrateofAdBluesolutiontobe
let into the system.
POSITION OF SCR SYSTEM COMPONENTSON THEVEHICLE
1. H
2
O valve- 2. By-pass valve- 3. Inflowexhaust gastemperaturesensor - 4. Output exhaust gastemperaturesensor -
7. Suckedair humidityandtemperaturesensor - 5. Catalyst - 6. Nitricoxidedetectingsensor (*) -
8. Pump module- 9. Level gauge- 10. Water-ureasolution(AdBlue) tank
* Futureapplication
Pump module (8) takes reagent solution out of tank (10),
thensendsit underpressureinto measuringout module(2);
finally, thereagent solutionisinjectedinto theexhaust pipe
upstreamof catalyst (5).
The first stageof theprocess takes placeinthefirst part of
thecatalytic converter: dueto theeffect ofthe exhaust gas
temperature, thereagent solution evaporates instantlyand
is hydrolysed to ammonia (2NH
3
) and carbon dioxide
(CO
2
). At the same time, the solution evaporates to bring
downtheexhaustgastemperatureto levelsclosetotheopti-
mumtemperature required for theprocess.
Exhaust gases containingammoniaat the temperature re-
quiredfor thereactionenter thecatalytic converter, where
thesecondstageoftheprocesstakesplace:theammoniare-
actswith theoxygeninthe exhaust gases and isconverted
to free nitrogen (N
2
) andsteam(H
2
O).
254 DENOX 2SYSTEM TRAKKEREURO 4/5
FUNCTIONAL WIRINGDIAGRAM
The AdBlue fluid level gauge control consists of a device
made up of a set of resistors, a float, a NTC temperature
sensor, and a coil used to heat the fluid under low
temperature conditions.
It informsthecontrol unit of anycurrent changedueto the
resistordeterminedbythefloat positionwithrespect tothe
AdBluefluid level.
102295
116181
102308
108127
Figure3
Figure4
Figure5
Figure6
Thetankequippedwithlevel gaugecontrol (1) containsthe
reducing substance required for the SCR process, which
consists of a35%-ureaand water solution called AdBlue.
AdBlue fluid level gauge control
1. AdBlueliquid dischargeline - 2. AdBluefluid return
pipe- 3. Engine coolinghot fluidinlet pipe -
4. AdBlue(NTC) temperaturesensor - 5. Enginecooling
hot fluid outlet pipe - 6. Float (level sensor) - 7. AdBlue
fluid heatingcoil - 8. AdBlueair vent
1. Coolant inlet - 2. Coolant outlet - 6. Electrical
connection
The valve, which is a Normally Closed type valve, allows
AdBluetankto be heated byenginecoolant.
TheNTC(Figure5)temperaturesensorcontrolstheby-pass
valvewhichclosesoropens(dependingontemperature) the
passageof the enginecoolinghot fluid into theheatingcoil.
Switch valve
Tank
108128
108129
Figure7 Figure8
1. Pipeof AdBlue returnto thetank - 2. Pipeof AdBlue
return frommeasuringout module - 3. AdBluesolution
outlet - 4. AdBluesolutioninlet - 5. Electrical connection -
6. DUC (DosingControl Unit) connector -
7. Filter - 8. Pre-filter.
Catalyst(1),equippedwithsound-proofingmaterial,replaces
theexhaust silencer.
Insidethecatalyst,theexhaust gasnitricoxidesare,byreact-
ingwithammonia,convertedintofreenitrogenandwaterva-
pour.
Temperature sensors (2 and 3) and nitric oxide detecting
sensor (4) arefittedonto catalyst (1).
Dosing module
Figure9
Pump module
1. AdBlueinlet - 2. Electrical connection-
3. AdBlueoutlet
Itstaskisto measureout theAdBlue solutionto besent to
theexhaust pipeupstreamof catalyst.
Catalyst
102301
102303
Figure10
Figure11
1. Supplyvoltage- 2. Variableoutput voltage - 3. Connector - 4. Signal cable (grey) - 5. Earthcable(white) - 6. Sensor.
Thefunctionof this sensor is to sendthecontrol unit thecatalyst inlet and outlet exhaust gas temperaturevaluesrequiredto
calculatetheamount of ureato beinjected into the system.
102304
Exhaust gas temperature sensor
102311
Figure12
Figure13
ELECTRIC BLOCKDIAGRAM
1. Earth- 2. Temperature- 3. Power supplyunit - 4. Humiditypercent value- A. Sample frequencygenerator -
B. Referenceoscillator - C. NTC temperaturesensor - D. Amplifier lowpass filter
102312
1. Temperature- 2. Earth- 3. Humiditypercent value - 4. Power supply.
This sensor is located on the air filter output conveyor, and is usedto informthecontrol unit of theamount (percentage) of
humidityfound in sucked air, to determinethecalculationof nitric oxideemissions.
Humidity detecting sensor
DIAGNOSIS 259 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Diagnosis
Page
DIAGNOSIS 261 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Diagnosis Instruments 261 . . . . . . . . . . . . . . . . . . .
- Diagnosis onCluster 263 . . . . . . . . . . . . . . . . . . . .
- DTC - FMI error codes 265 . . . . . . . . . . . . . . . . . .
- Troubleshootingaccordingtosymptoms 289 . . . .
260 DIAGNOSIS TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Fault diagnosis comprises two sections:
- The first one, organizedbyerror codes(DTC-FMI), concernsfaultsthat maybeidentified bythe EDC control unit directly.
Thesefaults aremainlyof anelectric- electronic- pneumatic nature.
- Thesecondone,organizedbysymptoms,describesthepossiblefaultstheelectroniccontrol unit cannot identifydirectly.These
faults are mainlyof amechanical - pneumatic nature.
SECTION 1
EDC systemtrouble shootingcan be either byCluster or diagnosis tools Modus, IT 2000andE.A.SY.
Diagnosis with the cluster makes it possible to estimate the situation of faults in the systemin advance, while the diagnosis
instrumentsareessential to performthorough diagnosis and operateon thesinglefaultscorrectly.
Each singleinstrument displays the diagnosisandrepair help.
Diagnosis Instruments
MODUS(Maintenanceand Diagnostic System)
A computerizedfault-diagnosisstationdedicatedto diagnosingthebrakesystems,airsuspensions,enginesandsystemscontrolled
electronically.
Thestationisequippedwithauxiliaryfunctions,suchas:programmingelectroniccontrol units,consultingthesparepartscatalogue
and servicetimeschedules.
The vehicle has a30-pin diagnosis socket to interfacewith theinstrument.
IT 2000 (IVECO ElectronicTester)
This makesit possible to takeimmediate action on the vehicle, identifyingit with thechassis number.
It savestheresults of diagnostics actions performed.
It can beusedas aportablePersonal Computer, too, beingfitted for remotediagnosis.
ByusingMODUSasthe mother station it is possibleto updateand configuretheIT 2000.
IT 2000interfaceswith thevehicleviaa30-pin diagnosis socket.
E.A.SY.
E.A.SY. systemallows to simplymakethediagnosis andprogrammingof thevarious electronic central units aboard the vehicle.
E.A.SY. systemismadeup of ECI modulecommunicatingwith theelectronic central unitsandof aPanasonicPC.
ECImodule,exploiting thePanasonicPC,alsoallowseasyontheroadinterventions:inparticular,thankstoPanasonicPCwireless
technologies(e.g. GPRS), diagnostic interventionscan beassistedbyaremoteexpert centre.
DIAGNOSIS 261 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
DIAGNOSIS
PRINT603.93.641
99378
Figure1
1. Modus- 2. E.A.SY.- 3. IT 2000
262 DIAGNOSIS TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
98885
Figure2
/ccoss to o|aoost|c scooo |s oss|b|o t|oo| 'ao' o ' y ' ' b ' 'os.
98888
Diagnosis information on thecluster is split into 4 columns:
- First column = central unit.
- Secondcolumn = central unit address plus fault order number.
- Third column = failure type.
- Fourth column = failurefrequency.
Thescreenshowsthreeerror messagesat most,but canstoreupto eight error messages. For displayinganyfurther messages,
,ost ooato ' y ' aoo ' b ' 'os.
Print 603.93.641 3aso |ovobo 2006
Diagnosis on Cluster
3aso |ovobo 2006 Print 603.93.641
DTC FMI
Failing
component
Typeof
Failure
Visible failure PossibleCause Repair action
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
113 ACCELER-
ATOR
PEDAL/
BRAKE
PEDAL
SUSPECT
Vehicle acceler-
ationveryslow.
Engine idlespeed:
500 rpm.
Accelerator
pedal and brake
pressed simulta-
neously(for too
long);
Accelerator
pedal blockedor
faulty;
Incorrect use of
vehicle.
Check the accelerator
pedal signal and pedal
mechanical movement.
116 CLUTCH
SIGNAL
SUSPECT
The parameter
reading shows
that the clutch is
pressed.
Clutch switch
faulty or wiring
problems in
pedal.
Check clutch pedal
switchandwiring.
117 BRAKE
PEDAL
SIGNAL
ERROR
Slight power re-
duction
Main and sec-
ondary brake
switch not syn-
chronised.
One of the two
brake pedal
switches maybe
stuck.
Checkthesynchronisa-
tion of both switches
(signal) and wiring.
119 PLAUSIBIL-
ITY +15
Possible mech-
anical problem
(inpawl) orelec-
trical problem.
Checkwiring.
121 SPEED LI-
MITER W/
LIGHT
Warninglight per-
manentlyoff.
Short circuit or
defectivewiring.
Checkwiring.
122 WARN-
ING LIGHT
EOBD
Warninglight per-
manentlyoff.
Short circuit or
defectivewiring.
Checkwiring.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
123 EDC LAMP Warninglight per-
manentlyoff.
Short circuit or
defectivewiring.
Checkwiring.
124 COLD
START
LAMP
Warninglight per-
manentlyoff.
Short circuit or
defectivewiring.
Checkwiring.
125 MAIN
RELAY DE-
FECT
Possibleproblems
duringafter-run.
Relay short cir-
cuit to battery
positive or
ground.
Check wiring between
ECMand battery.
Replacerelayif necess-
ary.
126 BATTERY
VOLTAGE
Possibleproblems
duringafter-run.
Alternator or
batterydefective.
Possible wiring
problem.
Checkwiring.
Replace alternator
regulator or battery
Replacethealternatorif
necessary.
127 ENGINE
BRAKE
ELECTRO-
VALVE
Engine brake not
operational.
Relay or wiring
short-circuited
or interrupted.
Checkwiring.
ary.
128 MAIN
RELAY -
SHORT
CIRCUIT
TO BAT-
TERY
Possibleproblems
duringafter-run.
Relay short cir-
cuit to battery
positive or
ground.
Relay may be
faulty.
ECMand battery.
ary.
129 AIR-
CONDI-
TIONER
COM-
PRESSOR
RELAY
Possibleproblems
duringafter-run.
Relay short cir-
cuit to battery
positive or
ground.
Relay may be
faulty.
ECMand battery.
ary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
12A RELAIS
FOR EN-
GINE
BRAKE
VALVE
Possibleproblems
duringafter-run.
Relay short cir-
cuit to battery
positive or
ground.
Relay may be
faulty.
ECMand battery.
ary.
12B THERMO-
STARTER
RELAY 1
(HEATER)
Heater not work-
ing.
Relay or wiring
short-circuited
or interrupted.
Checkwiring.
ary.
12C THERMO-
STARTER
RELAY 2
Heater not work-
ing.
Relay or wiring
short-circuited
or interrupted.
Checkwiring.
ary.
12E MANAGE-
MENTSYS-
TEM PRE/
POST-
HEATING
(ACTIVE)
Grid heater per-
manently operat-
ing.
Grid heater
short circuited
to ground.
Checkwiringandcom-
ponent.
131 COOL-
ANT TEM-
PERATURE
SENSOR
No reaction no-
ticeable on behalf
of thedriver.
Sensorshort-cir-
cuited or value
implausible.
Check the wiring. Re-
place sensor if necess-
ary.
132 COOL-
ANT TEM-
PERATURE
SENSOR
(TEST)
Slight power re-
duction.
Operationinex-
treme environ-
mental condi-
tions or sensor
inaccurate.
Ensuretheengineisnot
working in extreme
environmental condi-
tions.
Check the wiring and
thesensor accuracy.
Replace sensor if
necessary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
133 AIR TEM-
PERATURE
SENSOR
BOOST
AIR
Slight power re-
duction.
Sensorshort-cir-
cuited or value
implausible.
ary.
134 BOOST
PRESSURE
SENSOR
No reaction per-
ceivable by the
driver.
Parameter recov-
ery value: 2700
mbar.
Sensorshort-cir-
cuited or differ-
ence between
environmental
pressure and
turbo pressure
implausible.
Check the wiring. Also
check the environ-
mental pressuresensor.
Replace sensor if
necessary.
135 FUEL TEM-
PERATURE
SENSOR
Slight power re-
duction.
Sensorshort-cir-
cuited or value
implausible.
ary.
138 OIL PRES-
SURE SEN-
SOR
No reaction per-
ceivable by the
driver.
Parameter recov-
ery value: 3000
mbar.
Sensorshort-cir-
cuited or value
implausible.
Checkthewiringandoil
level.
Replace sensor if
necessary.
13A OIL TEM-
PERATURE
SENSOR
No reaction per-
ceivable by the
driver.
Parameter recov-
eryvalue: coolant
temperature
value (if intact)
otherwise
120 C).
Sensorshort-cir-
cuited or value
implausible.
ary.
13C ATMOS-
PHERIC
TEMPERA-
TURESEN-
SOR(HU-
MIDTIY?)
No reaction per-
ceivable by the
driver.
Parameter recov-
eryvalue: 40 C.
Sensorshort-cir-
cuited or value
implausible.
ary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
141 CRANK-
SHAFT
SPEED
No reaction no-
ticeable on behalf
of thedriver.
Signal inter-
rupted or wiring
problem.
Sensor installa-
tion maynot be
correct.
Check wiring and in-
stallation.
Replace sensor if
necessary.
142 ENGINE
WORKING
ONLY
WITH
CAM-
SHAFT
SENSOR
No reaction per-
ceivable by the
driver.
Signal inter-
rupted or wiring
problem.
Sensor installa-
tion maynot be
correct.
stallation.
Replace sensor if
necessary.
143 CAM-
SHAFT
SENSOR
No reaction per-
ceivable by the
driver.
Signal inter-
rupted or wiring
problem.
Sensor installa-
tion maynot be
correct.
stallation.
Replace sensor if
necessary.
144 FAULT BE-
TWEEN
FLY-
WHEEL
SENSOR
AND
CAM-
SHAFT
No reaction no-
ticeable on behalf
of thedriver.
Signal inter-
rupted or wiring
problem.
Flywheel and
timingsensor in-
stallationmaybe
incorrect.
stallation of both sen-
sors.
145 FAN
RELAY
No reaction per-
ceivable by the
driver.
Fanoff.
Short circuit or
fan actuator
faulty.
Check the wiring and
thefan actuator.
Replace the actuator if
necessary.
148 AIR-
CONDI-
TIONER
COM-
PRESSOR
RELAY
Air conditioner
permanentlyoff.
Wiring or relay
short-circuited.
placerelayif necessary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
149 PRE-HEAT-
INGRELAY
FUEL
FILTER
Filter heater not
working.
Wiring or filter
heater short-cir-
cuited.
placethefilter heater if
necessary.
151 INJECTOR
CYLINDER
1
The engine runs
on 5cylinders.
Injector no.1
electric trouble.
Check correct tightness
to torque of the con-
nectors on the solenoid
valve of the injector
(1.36- 1.92 Nm). Check
theintegrityof the injec-
tor coil and replace the
injector if defective. If the
coil is integral, check the
wiringbetween thesole-
noidvalveandEDC con-
nector.
152 INJECTOR
CYLINDER
2
The engine runs
on 5cylinders.
Injector no.2
electric trouble.
Checkcorrect tightness
nectorsonthesolenoid
(1.36-1.92Nm).Check
the integrity of the in-
jector coil and replace
theinjector ifdefective.
If the coil is integral,
check the wiring be-
tween the solenoid
valve and EDC con-
nector.
153 INJECTOR
CYLINDER
3
The engine runs
on 5cylinders.
Injector no.3
electric trouble
Check correct tightness
nectors on the solenoid
(1.36- 1.92Nm).Check
theintegrityoftheinjec-
tor coil and replace the
injectorifdefective.Ifthe
coil is integral, checkthe
wiringbetweenthesole-
noidvalveandEDCcon-
nector.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
154 INJECTOR
CYLINDER
4
The engine runs
on 5cylinders
Injector no.4
electric trouble
(1.36-1.92Nm).Check
tween the solenoid
valve and EDC con-
nector.
155 INJECTOR
CYLINDER
5
The engine runs
on 5cylinders
Injector no.5
electric trouble
(1.36-1.92Nm).Check
tween the solenoid
valve and EDC con-
nector.
156 INJECTOR
CYLINDER
6
The engine runs
on 5cylinders
Injector no.6
electric trouble
(1.36-1.92Nm).Check
tween the solenoid
valve and EDC con-
nector.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
161 INJECTOR
CYLINDER
1 / SHORT
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible short
circuit in con-
nections. Poss-
ible problem in
injector coil.
Possible prob-
lem in control
unit.
Checkwiring.
Possible internal prob-
lemalso inECM.
Replace the injector if
necessary.
162 INJECTOR
CYLINDER
2 / SHORT
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible short
circuit in con-
nections. Poss-
ible problem in
injector coil.
Possible prob-
lem in control
unit.
Checkwiring.
lemalso inECM.
necessary.
163 INJECTOR
CYLINDER
3 / SHORT
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible short
circuit in con-
nections. Poss-
ible problem in
injector coil.
Possible prob-
lem in control
unit.
Checkwiring.
lemalso inECM.
necessary.
164 INJECTOR
CYLINDER
4 / SHORT
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible short
circuit in con-
nections. Poss-
ible problem in
injector coil.
Possible prob-
lem in control
unit.
Checkwiring.
lemalso inECM.
necessary.
165 INJECTOR
CYLINDER
5 / SHORT
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible short
circuit in con-
nections. Poss-
ible problem in
injector coil.
Possible prob-
lem in control
unit.
Checkwiring.
lemalso inECM.
necessary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
166 INJECTOR
CYLINDER
6 / SHORT
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible short
circuit in con-
nections.
Possible prob-
lem in injector
coil.
Possible prob-
lem in control
unit.
Checkwiring.
lemalso inECM.
necessary.
167 INJECTOR
CYLINDER
1 / OPEN
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem(or dis-
connectedinter-
nally).
Possible prob-
lem in control
unit (capacitor).
Checkwiring.
lemalso inECM.
necessary.
168 INJECTOR
CYLINDER
2 / OPEN
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem(or dis-
connectedinter-
nally).
Possible prob-
lem in control
unit (capacitor).
Checkwiring.
lemalso inECM.
necessary.
169 INJECTOR
CYLINDER
3 / OPEN
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem(or dis-
connectedinter-
nally).
Possible prob-
lem in control
unit (capacitor).
Checkwiring.
lemalso inECM.
necessary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
16A INJECTOR
CYLINDER
4 / OPEN
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem(or dis-
connectedinter-
nally).
Possible prob-
lem in control
unit (capacitor).
Checkwiring.
lemalso inECM.
necessary.
16B INJECTOR
CYLINDER
5 / OPEN
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not op-
erating.
Possible injector
connection
problem(or dis-
connectedinter-
nally).
Possible prob-
lem in control
unit (capacitor).
Checkwiring.
lemalso inECM.
necessary.
16C INJECTOR
CYLINDER
6 / OPEN
CIRCUIT
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem(or dis-
connectedinter-
nally).
Possible prob-
lem in control
unit (capacitor).
Checkwiring.
lemalso inECM.
necessary.
16D COMPRES-
SION TEST
IN PROG-
RESS
Compression
Test in progress.
After carrying out the
compression test, turn
thekeyOFF(after-run).
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
16E THE MINI-
MUM
NUMBER
OF INJEC-
TIONS
WAS NOT
REACHED:
STOP THE
ENGINE
Morethan2injec-
tors not operat-
ing.
See individual faults in
injectors.
171 BENCH 1
CC
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem.
Injectors short-
circuited.
Checkwiring.
lemalso inECM.
necessary.
173 BENCH 2
CC
One or more in-
jectors(bank 1or
bank 2) not oper-
ating.
Possible injector
connection
problem.
Injectors short-
circuited.
Checkwiring.
lemalso inECM.
necessary.
17C BENCH 1
INJEC-
TORS
CHECK
(INTER-
NAL ECU)
One or more in-
jectors(bank 1or
bank 2) may not
beoperating.
Fault in control
unit.
Replace the engine
control unit.
189 EGR
POWER
ST. SHORT
TO BATT.
No fault per-
ceived by the
driver.
EGR not working.
Short circuit or
EGR actuator
faulty.
Checkwiring.
ReplacetheEGRactua-
tor if necessary.
191 TURBINE
ACTUA-
TOR
CON-
TROL
ELECTRO-
VALVE
Poor perform-
ance
VGTactuatoror
wiringdefective.
Check VGT wiringand
actuator.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
192 TURBINE
ACTUA-
TOR
CON-
TROL
ELECTRO-
VALVE
SHORT
CIRCUIT
TO POSI-
TIVE
Poor perform-
ance
VGTactuatoror
wiringdefective.
Check VGT wiringand
actuator.
193 TURBINE
WHEEL
REVS SEN-
SOR
Poor perform-
ance
Airfilter blocked
or turbine rpm
sensor signal im-
plausible.
Check theair filter and
check parameters
linked with the turbine
by performing a road
test (parameteracquisi-
tion).
198 FAULT ON
AT LEAST
TWO OF
THE FOL-
LOWING
SENSORS:
TURBINE
SPEED,
BOOT
PRESSURE
AND EX-
HAUST
GAS PRES-
SURE
Poor perform-
ance
Sensorsignal im-
plausible.
Sensor may be
faulty.
Determine which tur-
bine component
caused theproblem.
199 TURBO-
CHARGER
CON-
TROL
BOOST
PRESSURE
FAILURE
(PCR)
Poor perform-
ance
Turbo sensor or
actuator maybe
faulty.
Air filter maybe
blocked.
Check turbine sensors
and actuator (para-
meter acquisition).
Checkwhether airfilter
isblocked.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
19A TURBINE
SPEED EX-
CEEDING
EVERY
PER-
MITTED
RANGE
Poor perform-
ance
Turbo sensor or
actuator maybe
faulty.
Air filter maybe
blocked.
Check turbine sensors
and actuator (para-
meter acquisition).
Checkwhether airfilter
isblocked.
19B TURBINE
IN OVER-
SPEED
(THE
FAULT IS
NOT DIS-
PLAYED IF
IT IS
CAUSED
BY A LOW
ATMOS-
PERIC
PRESSURE)
Poor perform-
ance
Airfilter blocked
or turbine rpm
sensor signal im-
plausible.
Check theair filter and
check parameters
linked with the turbine
by performing a road
test (parameteracquisi-
tion).
19F NOx SEN-
SOR
ERROR
No effect per-
ceived by the
driver.
Sensorsignal im-
plausible.
Noxsensormay
befaulty.
Checkthe Noxsensor.
1A5 TIMEOUT
OF CAN
MESSAGE
DM1DCU
No effect per-
ceived by the
driver.
Problems in the
Denoxtronic
(on the CAN
line).
Checkwiring.
Check and correct any
faults in the Denox-
tronic control unit.
1A6 TIMEOUT
OF CAN
MESSAGE
SCR1
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
CheckCAN linewiring.
Check Denoxtronic
control unit wiring and
operation.
1AE HUMIDITY
SENSOR
No effect per-
ceived by the
driver.
Sensorshort-cir-
cuitedor faulty.
Checkwiring
Replace sensor if
necessary.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
1AF SERIOUS
EOBD
FAULT
FROM DE-
NOX-
TRONIC
(EOBD
FLASHING
LIGHT)
No effect per-
ceived by the
driver.
Problems in Ad-
Blue dosing sys-
tem.
Check the faults in the
Denoxtronic and con-
sult the control unit
troubleshootingguide.
1B1 ERROR
ON CAN
CON-
TROLLER
A
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
Check terminal resis-
tances.
1B2 ERROR
ON CAN
CON-
TROLLER
B
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
tances.
1B3 ERROR
ON CAN
CON-
TROLLER
C
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
tances.
1B4 TIMEOUT
CAN
MESSAGE
BC2EDC1
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
Check BC wiring and
operation.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
1B5 TIMEOUT
CAN
MESSAGE
VM2EDC
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
CheckVCMwiringand
operation.
1B7 ERROR
ON MESS-
AGESCAN
IN TRANS-
MISSION
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
Check ECM wiringand
operation.
1B9 ERROR
ON THE
EOBD
LIGHT
MAN-
AGED BY
THE
CLUSTER)
No effect per-
ceived by the
driver.
MIL/Body Con-
troller warning
light defective.
Consult theBodyCon-
troller troubleshooting
guide and check the
CAN line.
1BA TIMEOUT
CAN
MESSAGE
DASH DIS-
PLAY
No effect per-
ceived by the
driver.
CAN messages
from VCM in-
consistent.
Consult the VCM
troubleshooting guide
and check the CAN
line.
1BC TIMEOUT
CAN
MESSAGE
AMB-
COND
No effect per-
ceived by the
driver.
CAN messages
from VCM in-
consistent.
Consult the VCM
and check the CAN
line.
1BD TIMEOUT
CAN
MESSAGE
CCVS
No effect per-
ceived by the
driver.
CAN messages
from VCM or
BC inconsistent.
Consult the VCM/BC
and check the CAN
line.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
1C2 ERROR
MESSAGE
CAN ETC1
No effect per-
ceived by the
driver.
CAN messages
fromETC (gear-
box) inconsist-
ent.
Check the ETC con-
nection with the CAN
line.
1C3 TIMEOUT
IN RECEIV-
ING TC01
CAN
MESSAGE
No effect per-
ceived by the
driver.
CAN messages
from TCO in-
consistent.
Check the TCO con-
line.
1C6 ERROR
MESSAGE
CAN
TSC1-PE
No effect per-
ceived by the
driver.
CAN messages
from TCU
(Transmission
Control Unit) in-
consistent.
Check the TCU con-
line.
1C8 ERROR
MESSAGE
CAN
TSC1-VE
No effect per-
ceived by the
driver.
CAN messages
from TCU
(Transmission
Control Unit) in-
consistent.
Check the TCU con-
line.
1D1 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Electrical inter-
ferenceor inter-
nal control unit
problems.
If the error persists to
replaceECU.
1D2 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Poor control
unit program-
ming/flash
Possible internal
fault.
Reprogramthe central
unit. If the error is re-
peated, replace the
central unit, if needed.
1D3 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Poor control
unit program-
ming/flash
Possible internal
fault.
peated, replace the
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
1D4 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Ecu internal fail-
ure.
replaceECU.
1D5 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Ecu internal fail-
ure.
replaceECU.
1D6 ECU IN-
TERNAL
ERROR
(TPU)
Control unit
deactivation.
Electronic inter-
ference or con-
trol unit faulty.
replaceECU.
1D8 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Ecu internal fail-
ure.
replaceECU.
1E2 IMMOBIL-
IZER
Theenginefailsto
start.
ProbleminCAN
line or immobi-
liser control unit.
Check the Immobiliser
control unit iscorrectly
connected.
Enter the Immobiliser
PIN code during the
emergencyprocedure.
1E3 ERROR
FOR ECU
INTERNAL
MONI-
TORING
No effect per-
ceived by the
driver.
Ecu internal fail-
ure.
replaceECU.
1E4 ERROR
FOR ECU
INTERNAL
MONI-
TORING
No effect per-
ceived by the
driver.
Ecu internal fail-
ure.
replaceECU.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
1E5 SENSORS
POWER
SUPPLY
FAULT
(12V)
No effect per-
ceived by the
driver.
Excessive/insuffi-
cient battery
voltage or poss-
ible internal con-
trol unit problem.
Check battery voltage
or connections with
theECM.
Replace the control
unit if necessary.
1E6 SENSOR
POWER
SUPPLY 1
No effect per-
ceived by the
driver.
Excessive/insuffi-
cient battery
voltage or poss-
ible internal con-
trol unit problem.
or connections with
theECM.
Replace the control
unit if necessary.
1E7 SENSOR
POWER
SUPPLY 2
No effect per-
ceived by the
driver.
Excessive/insuffi-
cient battery
voltage or poss-
ible internal con-
trol unit problem.
or connections with
theECM.
CheckECU,ifrequired.
1E8 SENSOR
POWER
SUPPLY 3
No effect per-
ceived by the
driver.
Excessive/insuffi-
cient battery
voltage or poss-
ible internal con-
trol unit problem.
or connections with
theECM.
Replace the control
unit if necessary.
1E9 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Excessive/insuffi-
cient battery
voltage or poss-
ible internal con-
trol unit problem
or connections with
theECM.
Replace the control
unit if necessary.
1EA ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Excessive/insuffi-
cient battery
voltage or poss-
ible internal con-
trol unit problem.
or connections with
theECM.
Replace the control
unit if necessary.
1EB ATMOS-
PHERIC
PRESSURE
SENSOR
No effect per-
ceived by the
driver.
Environmental
pressurerecovery
value: 700mbar.
Fault in sensor
inside control
unit.
ChangeECU.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
1FA TOO
HIGH
NUMBER
OF RE-
GENER-
ATIONS
DEMAND
No reaction per-
ceivable by the
driver.
Too many filter
regenerationscar-
ried out.
Particulate filter
maybe blocked.
Checkfilter.
1FB PERMA-
NENT RI-
GENER-
ATION
ON TRAP
PARTICLE
No reaction per-
ceivable by the
driver.
Catalytic con-
verter not in-
stalled or dam-
aged.
Check catalytic con-
verter visually.
1FC FIRST SEN-
SOR EX-
AUSTED
GAS TEM-
PERATURE
No reaction per-
ceivable by the
driver.
Temperature
sensors dam-
aged or incor-
rectlyfitted.
Check information and
condition of sensors.
21F TOO
HIGH EFFI-
CIENCY
OF CATA-
LYST SYS-
TEM
No reaction no-
ticeable on behalf
of thedriver.
Actuator coil
faulty or not
within specified
tolerancelimits.
Check actuator condi-
tion.
225 INTER-
RUPTED
AFTER-
RUN
Slight power re-
duction.
The control unit
is turned off by
the general
switchinsteadof
bythekey(k15).
Possible prob-
leminmainrelay
or connections.
Check wiring and then
replacethemainrelay.
228 MAIN
RELAY -
SHORT
CIRCUIT
TO
GROUND
Slight power re-
duction.
Short circuit in
main relay or
relayfaulty.
battery and ECM and
then replace the main
relay.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
232 COOL-
ANT TEM-
PERATURE
SENSOR
ABSO-
LUTE TEST
Slight power re-
duction
Extreme envi-
ronmental
conditions or
sensor incor-
rectlyadjusted.
Ensure the engine is
working in non-critical
conditions.
Check the sensor con-
nectionsandaccuracy.
Replace sensor if
necessary.
238 OIL LOW
PRESSURE
Slight power re-
duction
Sensor incor-
rectly adjusted
or faults in lu-
bricationsystem.
Check the lubrication
system.
23A OIL TEM-
PERATURE
ABOVE
NORMAL
Slight power re-
duction
Sensor incor-
rectly adjusted
or faults in lu-
bricationsystem.
Check the lubrication
system.
27C BENCH 2
INJEC-
TORS
CHECK
(INTER-
NAL ECU)
One or more in-
jectors(bank 1or
bank 2) may not
beoperating
Fault in control
unit.
Replace the engine
control unit.
292 TURBINE
ACTUA-
TOR
CON-
TROL
ELECTRO-
VALVE
SHORT
CIRCUIT
TO
GROUND
Poor perform-
ance
VGTactuatoror
wiringdefective.
Check VGT wiringand
actuator.
2A6 TIMEOUT
OF CAN
MESSAGE
SCR2
No effect per-
ceived by the
driver
Problem in the
Denoxtronic
(on the CAN
line).
Checkwiring.
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
2AF SERIOUS
EOBD
FAULT
FROM DE-
NOX-
TRONIC
(EOBD
FLASHING
LIGHT)
No effect per-
ceived by the
driver.
Problems in Ad-
Blue dosing sys-
tem.
2B4 TIMEOUT
CAN
MESSAGE
BC2EDC2
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
Check BC wiring and
operation.
2C6 TIMEOUT
OF CAN
MESSAGE
TSC1-PE
PASSIVE
No effect per-
ceived by the
driver.
CAN messages
from TCU
(Transmission
Control Unit) in-
consistent.
Check the TCU con-
line.
2C8 ERROR
MESSAGE
CAN
TSC1-VR
No effect per-
ceived by the
driver.
CAN messages
from TCU
(Transmission
Control Unit) in-
consistent.
Check the TCU con-
line.
2C9 ERROR
MESSAGE
CAN TIME-
DATE
No effect per-
ceived by the
driver.
CAN messages
fromTC (tacho-
graph) inconsist-
ent.
Check the tachograph
connection with the
CAN line.
2D3 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Poor control
unit program-
ming/flash
Possible internal
fault.
peated, replace the
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
2FF ERROR
CHECK OF
CRITICAL
TIME FOR
OIL DILU-
TION
Slight power re-
duction
Oil over-diluted. Changetheengine oil.
392 TURBINE
ACTUA-
TOR
CON-
TROL
ELECTRO-
VALVE
Poor perform-
ance
Connection
damaged.
Battery voltage
excessive (ECU
overheating).
CheckVGTconnection
and actuator.
3AF SERIOUS
EOBD
FAULT
FROM DE-
NOX-
TRONIC
(EOBD
FLASHING
LIGHT)
No effect per-
ceived by the
driver.
Problems in Ad-
Blue dosing sys-
tem.
3C8 TIMEOUT
OF CAN
MESSAGE
TSC1-VE
PASSIVE
No effect per-
ceived by the
driver.
CAN messages
from TCU
(Transmission
Control Unit) in-
consistent.
Check the TCU con-
line.
3C9 ERROR
MESSAGE
CAN
HRDV
No effect per-
ceived by the
driver.
CAN configur-
ationincorrect.
CAN connec-
tionsdefective.
Terminal resis-
tance not suit-
able.
Check BC wiring and
operation.
3D3 ECU
OVERRUN
MONI-
TORING
ERROR
No effect per-
ceived by the
driver.
Poor control
unit program-
ming/flash
Possible internal
fault.
peated, replace the
DTC FMI
Failing
component
Typeof
Failure
Checks to be
performed
Measuring
conditions
Values to be
detected
Remarks
3FA REGENER-
ATION
DEMAND
NUMBER2
No effect per-
ceived by the
driver.
Too many re-
generations car-
ried out.
Check particulate filter
and faults insensors.
4AF SERIOUS
EOBD
FAULT
FROM DE-
NOX-
TRONIC
(EOBD
FLASHING
LIGHT)
No effect per-
ceived by the
driver.
Problems in Ad-
Blue dosing sys-
tem.
4C8 TIMEOUT
OF CAN
MESSAGE
TSC1-VR
PASSIVE
No effect per-
ceived by the
driver.
CAN messages
from TCU
(Transmission
Control Unit) in-
consistent.
Check the TCU con-
line.
4FA REGENER-
ATION
DEMAND
NUMBER3
No effect per-
ceived by the
driver.
Too many re-
generations car-
ried out.
Check particulate filter
and faults insensors.
5AF DM1DCU
SPN5
MESSAGE
No effect per-
ceived by the
driver.
Problems in Ad-
Blue dosing sys-
tem.
Base Novembre 2006
PRINT603.93.641
SECTION 2
Trouble shooting according to symptoms
Visible Failur e Possible cause Repair action
Inefficient battery. Pre-heatingresistor alwayson.
Checkalternator efficiency.
Checkelectrical connectionsat thebat-
teryterminals.
Starter inefficient. Check/ replace.
Air heater inefficient. Check power supply and ground con-
nection.
Check heater remote control switch
with activediagnosis.
Engine does not start
Main remote control switch (main
relay) inefficient.
Checkfuseefficiency.
Check remotecontrol switch with ac-
tive diagnosis.
Fuel pumpinefficient. Check efficiency by checking the filter
input pressure.
Checksuctiontightness.
Fuel pre-filter - filter inefficient. Checkif clogged / change.
0.3 bar valveonfuel return inefficient. Check its efficiency. If blocked, replace
it.
Fuel circuit inefficient. Check the systemtightness and carry
out bleeding.
Coolant level wrong. Check possible leaks and restore the
level.
Water pumpandfancontrol beltsinef-
ficient.
Check,adjust tensionandchangecom-
ponents, if needed.
Water pump inefficient. Overhaul or changetheassembly.
Thermostat inefficient. Check if it remains blocked in closed
position or partiallyopen.
Change.
Engine overheating
Radiator inefficient. Wash accuratelyandcheckif thereare
anyfluidleaks. Changethecomponent,
if needed.
Air filter and circuit pipes inefficient. Make surethe manifoldsand the pipes
arenot clogged.
Check the filter clogging indicator.
Changethefilter.
Cylinder headgasket inefficient. Check the water circuit pressure and
changethecylinder headgaskets.
Faninefficient. Replace.
(Continue)
Fuel circuit inefficient. Checkif themeshfilter inthetank, the
fuel pre-filter and filter are clogged; in
this case changethem.
Checkifthe0,3bar valveonthefuel re-
turn is blocked in open position (low
pressure) or in closed position (high
temperature), andthenreplaceit.
Checkpossiblecircuit leaksandthefuel
pumpefficiency.
Injectors inefficient. Seizureof theplunger of oneof thein-
jectors may occur or fuel may leak
through theO - Ring.
Carry out the Engine Test and proceed
accordingto theinstructions displayed.
Engine air suctioncircuit inefficient. Removecircuitnecksandreplacetheair
filter if clogged.
Checkthe cartridgecloggingindicator.
Exhaust gascircuit inefficient. Eliminateexhaust manifoldleaks.
Engine lacks power Workingtemperaturenot correct. Checkcoolingsystem.
VGT actuator inefficient. Carryout theEngineTest on thebasis
oftheinstructionsdisplayedbythediag-
nosis instrument.
Turbo-compressor inefficient. Carryout the Engine Test on the tur-
bineandcheckintegrityofthefollowing
turbo-compressor components:
- rotatingblades;
- bearings;
- modulatingvalve;
- VGT filter clogged;
- turbineactuator;
Changefaultycomponent.
Engine Test with Modus IT2000
E.A.SY..
Injection mechanical systeminefficient. Checkwear oftheinjector rockerarms,
the roller, the rocker armbushes and
thecamshaft tappets.
Valveclearance inefficient. Adjust valve clearance.
(Continue)
Headgasket inefficient. Headgrindingandchangegasket.
Injector holder inefficient. Replaceit.
Engine brake low efficiency
Turbo-compressor cooling system
tightness inefficient.
Overhaul turbine.
Badfuel quality. Checkif thereis water in thereservoir
and removeit.
Pistonringsinefficient. Overhaul piston-cylinder assembly.
Engine smokeislight blue
Turbo-compressor lubrication system
tightness inefficient.
Overhaul turbine.
Valveoil seal tightness inefficient. Changevalveguidegasket.
Engine brakecomponents inefficient. Check correct operation of engine
brakeactuatorcylindersofcontrol sole-
noidvalve.
Check cylinder control oil pipe tight-
ness.
Checkexhaust valveclearance.
Turbo-compressor inefficient. VGT blockedinopenposition.
VGT actuator faulty (tierod blow-by).
Modulatingvalve faulty.
Wrongair supplyto modulatingvalve.
Changeinefficient components.
Fuel inthereservoir. Carryout bleedingafter refuelling.
Infficiency of mesh filter, fuel pre-filter
and filter.
Clean the mesh filter and replace the
pre-filter and filter.
Engine stops
Reservoir pipes not correctly con-
nected.
Ifthepipesareinverted,thevehiclecan
beturned off after 200 300 kmeven
if the reservoir is without fuel because
theenginefuel pipehasalower height
of suction.
Invert thepipes.
(Continue)
Air filter inefficient. Change.
Excessivefuel consumption
Fuel reservoir and pipes inefficient. Eliminate possible leaks and replace
worn out components.
Overpressurevalveworks not correct-
ly.
Checkandreplace, if needed.
Excessive or insufficient oil pressure
Oil pump and oil deliverypipes ineffic-
ient.
Checkandreplace, if needed.
Excessiveor insufficient oil pressure
Mainjournalsandconnectingrodbear-
ings inefficient.
Replacebearings and rectifythecrank-
shaft, if needed.
Engine oil SAE viscositynot correct. Changethe engine oil with one having
theright viscosity.
1 TRAKKER EURO 4/5 CLUTCH
Base- November 2006
Print 603.93.641
Print 603.93.641
SECTION 3
Clutch
Page
DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Clutch 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6 . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 8 . . . . . . . . . . . . . . . . . . . .
TOOLS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING ANDREFITTINGTHE CLUTCH 9 . . . . .
- Removal 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING-REFITTINGTHE THRUST BEARING 10 . .
REPLACINGTHE SUPPORT BEARING
OFTHECLUTCH SHAFT 10 . . . . . . . . . . . . . . . . . . . .
REMOVING-REFITTINGTHE PEDAL UNIT 11 . . . . . .
- Removal (vehicleswithEuroTronicgearbox) 11 . .
- Removal (vehicleswith ZF9S/16S... gearbox) 12 .
- Refitting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PEDAL 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Unit removal-assembly 13 . . . . . . . . . . . . . . . . . . .
CHECKINGAND ADJUSTINGSTOPS
ON CLUTCH PEDAL
(vehicleswith ZF 9S/16Sgearboxes) 14 . . . . . . . . . . . . .
- Clutchstop 14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Idletravel ofclutchpedal 14 . . . . . . . . . . . . . . . . .
- Pedal control valvestroke 14 . . . . . . . . . . . . . . . .
HYDRAULIC CONTROL
(Vehicles withZF 9S/16Sgearboxes) 15 . . . . . . . . . . . .
Revi - June2007
2 TRAKKER EURO 4/5 CLUTCH
Base- November 2006
Print 603.93.641/A
Page
Print 603.93.641/A
- Master cylinder 15 . . . . . . . . . . . . . . . . . . . . . . . .
- Clutchactuator 17 . . . . . . . . . . . . . . . . . . . . . . . .
SPRINGPIN ADJUSTMENT GEARBOX
ASSEMBLY 18 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONSFORGEARBOX ASSEMBLY
EUROTRONIC 12AS1930/2330/2530 19 . . . . .
SPRINGPIN ADJUSTMENT GEARBOX
EUROTRONIC 12AS1420TD 20 . . . . . . . . . . .
BLEEDINGCLUTCH CIRCUIT 21 . . . . . . . . . . . . . . .
3 TRAKKEREURO 4/5 CLUTCH
Base- November 2006
Print 603.93.641
Print603.93.641
DESCRIPTION
MAIN DATA
+' C||TC o |23 oo|oos S +3+0 TC / S +3++ TC oaboos oc|oooo
Type
VALEO * SACHS**
Type
Drysingle plate
Engagement mechanism '|o||' .|t| o|a|a s|o
Driven disc With friction seal
Driven dischub With springdrive
Liningouter mm 430 430 1
Lininginner mm 242 240 +3
Platethickness (new) mm 10 0.3
Max. off-centeringof
drivenplate mm
0.4 0.40
Loadedminimum
on newpressureplate N
34000 30900
Loadedmaximum
with release N
8200 7000
Minimumrisethrust pad mm 1.7
Disengagement stroke mm 12
+2
12
+2
Maximumdepression
stroke mm
15.1 15
Clutch control:
- For mechanicgearboxes, maincylinder with built-in oil tank,
clutchactuator withtotal recoveryfor drivendiscwear
- For Euro Tronic gearboxes, electric-pneumatic actuator
controlled bythegearboxcontrol unit
Typeof fluid TutelaTRUCK DOT SPECIAL
* For manual gearboxes(except for 9 speed 9S...)
** For EuroTronic gearboxes
Clutch
Theclutchis of drytypewith onediscandfittedwith pull or pushengagingmechanismwithdiaphragmspring. For thevehicles
withZF9/16Smechanicgearbox, theclutchcontrol ishydro-pneumaticandincludesthemaincylinder,withbuilt-inoil tank,and
theclutch actuator.For thevehicleswithEuro Tronic gearbox, theclutch control ispneumatic and electronicallycontrolledby
thegearboxcontrol unit.
Base- November 2006
Print 603.93.641
+' C||TC - o |23 oo|oo .|t| oabo - S +3+0 TC / S +3++ TC
Type
SACHS
Type
Drysingle plate
Clutch mechanism Push with diaphragmspring
Driven plate With friction seal
Driven platehub With doubletorsionsprings
Liningouter mm 430 1
Lining inner mm 242
Platethickness (new) mm 10 0.3
Max. off-centering
drivenplate mm 0.2
Loadon pressure plate
(new)
Min. N
Max. N
18600
20800
Releaseload N 5800
Minimumriseof thrust pad mm 1.7
Disengagement stroke mm 10+2
Maximumdepression
stroke mm
11
Hydraulic control
Master cylinder withoil tank incorporated- slavecylinder
with total take-upof driven platewear
Lubricant TutelaTRUCK DOT SPECIAL
Base- November 2006
Print 603.93.641
+' C||TC - |33 oo|oos VALEO * SACHS**
Type Dry singleplate Type Dry singleplate
Engagement mechanism '|o||' .|t| o|a|a s|o
Driven disc With friction seal
Driven dischub With doubleflexiblecoupling
Liningouter mm 430 430 1
Lininginner mm 260 254
Platethickness (new) mm 10.6 0.3
Max. off-centeringof
drivenplate mm
0.4 0.40
Loadon pressure plate
(new)
Min. N
35000 34200
Loadedmaximum
with release (new) N
8600 7900
Minimumrisethrust pad mm 1.7
Disengagement stroke mm 12
+2
12
+2
Maximumdepression
stroke mm
16.6 18
Hydraulic control
- For mechanic gearboxes, maincylinder with built-in oil tank,
clutchactuator withtotal recoveryfor drivendiscwear
- For Euro Tronic gearboxes, electric-pneumatic actuator
controlled bythegearboxcontrol unit
Oil type TutelaTRUCK DOT SPECIAL
* For manual gearboxes
** For EuroTronic gearboxes
Base- November 2006
Print 603.93.641
TROUBLESHOOTING
Thrust bearingexcessivelyworn, dam-
agedor not properlylubricated.
Replacethrust bearing.
Noisewhenclutch pedal is depressed
Excessive play between the splines on
the transmission input shaft and the
relativehousingindriven platehub.
Replace the shaft and also the driven
plateif necessary.
Springsof drivenplatebrokenor weak. Replacedriven plate.
Noisewhenthepedal is released
Transmissioninput shaft worn. Replace the shaft and also the driven
plateif necessary.
Thrust bearinghas playin engagement
sleeve.
Replacethethrust bearing.
Oil or greaseonengineflywheel or on
drivenplatelinings
Eliminatetheproblemcausingthecon-
tamination; clean flywheel thoroughly
then replace drivenplate.
Theclutchsnatches
Pressure platedistorted. Replacetheclutch.
Theclutchsnatches
Uneven wear of friction linings due to
run-out of driven plate.
Replacethedriven plate.
Diaphragm spring weak or fingers
broken.
Replacethedriven plate.
Oil or greaseondriven platelinings. Replace the shaft and also the driven
plateif necessary.
The clutchdoesnot disengage
Transmissioninput splinedamagedthus
preventingdriven platefromsliding.
Checkandadjustthestrokeoftheoper-
ator cylinder withno load.
Airinthehydrauliccircuit (vehicleswith
EuroTronic transmissionexcluded).
Bleed thecircuit.
Driven platelinings worn or burnt. Replacethedriven plate.
The clutchslips
Diaphragm spring weak or fingers
broken.
Replacetheclutch.
Oil or greaseondriven platelinings. Eliminate the problem causing the
contaminationandreplacedrivenplate
(Continue)
For anyactuator operation failure, on vehicles fitted with EuroTronic transmission, see the related transmission
diagnosis.
NOTE
Base- November 2006
Print 603.93.641
Driver resting his foot on the clutch
pedal while driving.
Drivermust avoidtheharmful habit and
rest his foot on the clutch pedal only
whennecessary.
Abnormal wear of drivenplatelinings
Disc ringstrained. Replacedisc ring.
Abnormal wear of drivenplatelinings
Diaphragm spring with weakened or
brokenfingers.
Replacetheclutch.
Insufficient operator cylinder stroke. Checkandadjustthestrokeoftheoper-
ator cylinder withno load.
Base- November 2006
Print 603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
Flangedhexscrew fixingpressureplate to flywheel M12 65 7 (6.5 0.7)
Nut for stud bolt fixingclutchcasingto crankcase M10 46 5 (4.6 0.5)
Stud bolt fixingclutch casingto crankcaseM10x80 19 2 (2 0.2)
TOOLS
99306010
Tool to bleed air fromhydraulicclutch circuit
99348004 Universal extractor, internal from5 to 70mm
99370264 Guidepin to centre clutchdisc
99370280 Guidepin to centre clutchdisc
99370547
Mount for removingandrefittingclutchassembly
(to fit onto thehydraulic jack)
Figure1
Figure2
Fit the clutch locatingpin 99370264 or 99370280 (1) into
thesupport bearingof thetransmissioninput shaft.
38438
Figure3
40194
Fit themount 99370547 (1) onthehydraulicjackandapply
themount to thepressureplate(3).Unscrewthescrews(2)
and removethe pressureplatefromthe engineflywheel.
40195
Removetheclutchdisc (2) byremovingatthesametimethe
locatingpin99370264 or 99370280 (1).
This operation comprises:
- Removing-refittingpropellershafts(seerelevant section
505620).
- Removing-refittinggearbox (seerelevant section530210).
Removal
Checks
The checks to makeareas follows:
- Thesupportingsurfaceofthedrivendisc, ontheengine
flywheel, must not be particularly worn or have too
muchscoring.
- Thetoothingoftheringgearoftheengineflywheel must
beneither deteriorated nor too badlyworn.
Ifthisisnot thecase, removetheengineflywheel (operation
540850).
In addition, check thereis not even theslightest leakage of
lubricant fromtheseal of thecrankshaft rear cover: inwhich
case, removethe flywheel as described under the relevant
heading. Removetherear cover together with theseal and
replaceit as describedinsection 2.
Check that the bearingor bushing supportingthegearbox
input shaft mounted onthe crankshaft isneither worn nor
deteriorated, in which caseit should be replaced.
Checkthestateofthepressureplate,thesupportingsurface
ofthedrivendiscmust haveno deformation, wearor signof
overheatingand its springor diaphragmmust besound.
Checkthestate of thedrivendisc:
- thefriction liningsmust not betoo worn, nor haveany
sign of overheating, nor befouledwith oil or grease.
- its hub must not have too much playon the gearbox
input shaft.
- thetorsionspringsofthehubmustnot turnintheirseats
or be broken.
If you find anytroubleat all, replacethe part concerned.
The clutchassemblyis supplied asa spareinkit form.
The followingaresuppliedsingly:
- The driven disc and thethrust bearing.
Inthiscaseitisnecessarytomount thenewpartsofthesame
supplyasthe torsion springbeingreused.
Base- November 2006
Print 603.93.641
Print603.93.641
505210 REMOVING AND REFITTING THE
CLUTCH
505620).
- clutch removal/refitting(operation 505210).
505620).
Usingsuitablepliers, open thesnap ring(1), takethethrust
bearing(2) out of thepressureplate.
Reversethesesteps for fitting.
- Fit thegearboxbackonafter spreadingthesplinedshaft
with Molikotemolybdenumdisulphidegrease.
- Adjust the push rod of the operator cylinder as
described under the relevant heading (operation
505272).
505254 REMOVING-REFITTING THE
THRUST BEARING
36800
Figure4
Figure5
Figure6
Before fittinganew driven disc it is necessary to check its
centringas follows:
Positionthedriven disc (1) onalathe.Then, withtheaid of
adial gaugewith amagneticbase(2), checkthat thesurface
of thediscisnot off centre anywhere.
The maximumpermissible eccentricityof the driven disc is
0.20mm.
If thedisc is off centre,useaforkwrench(1) asshowninthe
figure.
Refitting
Fit the clutch assemblyback on by performingthe
operations described for removal in reverseorder
and observingthefollowinginstructions:
- Thoroughly clean the supportingsurface of the clutch
plate of the engine flywheel with spirits or petrol. Any
light scoringyoufindonit canberemovedwithabrasive
cloth.
- Position the driven disc, always usingthe guide pinfor
perfect centringto prevent harmful stressesonthehub
whenrefittingthegearbox.
- Position the clutch platebymatchingtheholesfor the
fixingscrews with the ones on the engineflywheel.
- Mount and lockthe fixingscrews of thepressureplate
to therequired torque.
The newpart hasto beof thesamesupplyas the
pressure platebeingreused.
540852 REPLACING THESUPPORT BEAR-
ING OF THE CLUTCH SHAFT
40196
Usingtheappropriatepliersremove thesplit ring(3).
Using the universal extractor 99348004 (1) remove the
bearing(2).
For refitting, usetheappropriatebeater.
Refit thesplit ring.
Figure7
NOTE
Base- November 2006
Print 603.93.641
Disconnect thepiping(2).
Takeout thescrews(3) anddisconnect thesteeringcontrol
mount (1) fromthe pedal unit (4).
72831
72833
72832
84419
72834
99142
Figure8
Figure9
Figure10
Figure11
Figure12
Figure13
Removethepush-buttonpanels(3and5) andthescrewcaps
(4) fromtheinstrumentpanel(1).Takeout thescrews(2and
4), remove theinstrument panel (1) and put it aside.
Disconnect theconnections(1) ofthewindscreenwiper,(2)
of thedrivecontrol systemand (3) of theimmobilizer.
Takeout thescrews(2),removetheheel rest (1) andlift the
mat (3).
Remove thescrews(1and3) andthe guard (2).
Fromoutside the cab, lift the radiator cowling, extract the
grommet (1) withthewiringfromthepedal unit (6).Discon-
nect thepiping(4) fromthecoupling(5). Disconnect sensor
(2) electricconnection fromdistributor (3).
Removal (vehicles with EuroTronic gearbox)
Base- November 2006
Print 603.93.641
PEDAL UNIT
99143
72837
38805
38806
99144
Figure14
Figure15
Figure16
Figure17
Figure18
Take out the screws(4) fixingthe cover (5) of thecontrol
valve(6).Graduallyliftthecover (5) todischargethepressur-
ized air in thesystem.
Take out the screws (1-3) fixingthe wiringclamps (2) and
pedal unit to thecab.
Takeout thescrew(2) fixingthebracket (1) supportingthe
pipingandwiringanddisconnect thepedal unit fromthecab.
Removal
(vehicles with ZF 9S/16S... gearbox)
Disconnect the steeringcontrol mount as described in fig-
oos 8 +0 ++ - +2.
Removethebracket (1) stoppingtheclutchpedal. Takeout
thescrews (2) fixingthemaster cylinder to thepedal unit.
Removethebracket (1) stoppingthebrakepedal. Takeout
thethreescrews(2) fixingthecontrol valvetothepedal unit.
Thisdiffersfromremovingthepedal unit onvehicleswiththe
EuroTronic gearboxinthefollowing.
Lift the radiator cowling, disconnect the piping(3-4) fromthe
splitter control button (5). Disconnect theelectric connection
(1) of themaster cylinder (2) and removethis, together with
theoil reservoir,fromthepedal unit (6). Completedisconnect-
|o t|o ooa| oo|t as oosc|boo |o |oos +3 ++ - +5.
Base- November 2006
Print 603.93.641
72838
38808
Figure19
Figure20
For refitting,carryout thestepsdescribed for removal inre-
verseorder.Thenadjust thetravel ofthepedalsasdescribed
under therelevant heading.
PEDAL
Unit removal-assembly
(see Figure 20)
Takeout the springs (11) to returnthe pedals(13*-15).
Eject thespringpins (7) so as to free the levers(1* and 2)
fromthepedals(13* and15),whichyoushouldthenextract
fromthepedal unit mount (18). To replacetheroller bear-
ings (9), use:
- thepercussionextractor 99340205to removethem;
- asuitabledrift to fit them.
Refitting
+. 3a'o cooto| |ovo 2. C|otc| cooto| |ovo - 3. |o||o boa|os +. ||o 5. |o' 6. |asto c||ooo - . S|o |o
8. S||tto cooto| bottoo - . |o||o boa|os +0. \as|o ++. |oto o s|o +2. |ooa| covo +3. C|otc | ooa|
++. Cooto| va|vo +5. 3a'o ooa| +6. 3a'o ooa| |||t sto sco. +. 3a'o ooa| sto bac'ot +8. |ooa| oo|t ooot
+. C|otc| ooa| sto bac'ot 20. C|otc| ooa| |||t sto sco.
* Excludingvehicles with theEuroTronic gearbox.
Therollerbearingsandassociatedshaftshavetobe
lubricated withTUTELA MR3 grease.
Complete assemblybycarryingout thesteps per-
formedfor removal inreverseorder.
Witheachremoval,theseals(1) of thecouplingof
thecontrol valvecover(2)havetobereplacedwith
new ones.
Tightenthescrewsandnutstotherequiredtorque.Afterre-
fitting,checkandifnecessaryadjust thetravel ofthepedal as
describedunder therelevant heading.
NOTE
NOTE
Base- November 2006
Print 603.93.641
Print603.93.641
Clutch stop
CheckthedistanceA betweenthepedal unit mount (1) and
theendofthescrew(2).It hastobe32.5mm,turnthescrew
appropriatelyif it is not.
Idle travel of clutch pedal
Workthe clutchpedal (9) to take thecap(6) into contact
with thepiston(5) of themaster cylinder.
In this condition, check the distance B between theclutch
pedal (9) andthescrew(7) that hastobe 1- 2mm,turnthe
screw (7) appropriatelyif it is not.
ThedistanceB correspondsto theclearanceof 0.5- 1mm
between the cap (6) and thepiston (5) in the condition of
theclutch pedal (9) incontact with the screw(7).
Pedal control valve stroke
After adjusting the position of the bottomand top stop,
adjust the travel of thepistonof the pedal control valve.
Taketheclutchpedal (9) intocontact withthebottomstop
screw (2) andkeep it inthisposition.
Press the button of the control valve (3) fully down and,
keeping it pressed, position the angle bracket (4) so that
bot.ooo |t aoo t|o bottoo t|oo |s a o|staoco o 0.5 + .
Thisisto prevent thepedal control valvefromstoppingthe
clutch pedal.
108470
Figure21
Base- November 2006
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CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL
(vehicles with ZF 9S/16S gearboxes)
The hydrauliccontrol is composed of:
- master cylinder withoil reservoir built in;
- clutchactuator withfull recoveryof drivendisc wear.
Master cylinder
Figure22
HYDRAULIC CONTROL
(Vehicles with ZF 9S/16S gearboxes)
MASTER CYLINDER VIEW (* onlyfor vehicles withF3Bengine)
108620
On master cylinder therearemountedfollowingproximity
(read) switches:
- S
1
N.A. (mounted on N.C. master cylinder) to disable
Cruise Control;
- S
2
N.A.(mountedonN.A.mastercylinder) onlypresent
on vehicles with F3Bengineto protect synchronisers
(synchro protection).
Base- November 2006
Print 603.93.641
Figure23
99355
FUNCTIONAL SCHEME
1. Push rod - 2. Piston- 3. Magnetic ring- 4. Cylinder
S
1
= Proximityswitchto disableCruise Control
S
2
= Proximityswitchto protect gearboxsynchronisers
C
1
= Workingstoke31mm
C
2
= Workingstoke42mm
F = Forceappliedbyclutch pedal
P = Hydraulicpressure at servoclutch
Closed
Opened
Closed
Opened
21.5
Switch S2 goes off at piston (2) stroke of 21.5 mmcorrespondingto 70%of clutch pedal disengagement travel,
correspondingin turn to servoshift drivingpoint.
NOTE
Base- November 2006
Print 603.93.641
CHARACTERISTICS S1 S2
Voltage V 48max
Current:
min mA 5 5
max mA 400 700
Power W 10max 20max
Permanent
current mA
250 max 700 max
Figure24
Figure25
1. Feed (compressed air)
3. Bleed (compressed air)
4. Drive (clutch liquid)
32. Bleed screw
* Fittingfor valvedrive
Functional scheme
1. Feed (compressed air)
3. Bleed (compressed air)
4. Drive (clutch liquid)
Service pressure:
- clutchliquid(P4) 40 bar
- air (P1) 11.5 bar
Max pressure:
- clutchliquid(P4) 120 bar
- air (P1) 13 bar
102607
102608
Base- November 2006
Print 603.93.641
Print603.93.641
Clutch actuator
Revi- June2007
Performfollowingoperations:
- measure dimension (A) between clutch lever
spherical cavityandactuator fixingplane;
Disengagement lever must rest against thrust
bearing.
- push ball spring pin up to stop (G); screw, or
unscrew, spring pin (F) until dimension (B) is
obtained.
B =A - E
(Seevaluesshowninbelow table).
EnginesF2BwithpushclutchSACHSongearboxes
9S1310/11 TO do not needanyadjustment.
Figure26
114974
NOTE
It is necessaryto observe this adjustment to make
thewornplateindicatortrip, whichislocatedinthe
operatorcylinder,closetothecompletewearofthe
friction linings.
The plate wear (90%of the friction material) is
indicated by a significant increase in load on the
pedal whendisengagingthe clutch.
NOTE
NOTE Shouldanyoil leaks fromthe main cylinder and/or
the clutch actuator be detected, replace the
involved component and bleed the hydraulic
system.
Base- November 2006
Print 603.93.641/A
Print603.93.641/A
SPRING PIN ADJUSTMENT GEARBOX ASSEMBLY
Engine Clutch E (mm)
F2B
Push clutchSACHS
do not need
any
adjustment
Pull clutches VALEO 30
F3B Pull clutches VALEO 35
Revi- June2007
A) Specifications for adjustingtheclutchservo, whennew
and whenthe clutch is replaced:
+. |oasoo o|staoco ' A' bot.ooo t|o c|otc| |ovo ba||
socket baseandthe clutch servo fasteningsurface. The
lever shouldberestingon thethrust bearing.
2. Adjust the rod using the following equation:
L=A-(B-C)=33 aoo socoo .|t| |oc'oot ' F'.
Tighteningtorque52 Nm.
4. Fit thepushrodin the lever ball socket.
5. Fit theclutchservoandsecureusingthefourhex-headed
bolts.
6. |osco. sco. |o 'H' aoo t|oo ot||too .|oo t|o
pistonisforward.
. Cooooct o|oct|ca| coooocto ' D' aoo a| oo||vo |o
'G'.
C) Replacingtheclutch servo:
If replacingtheclutch servo alone, proceedasdescribed
under point B, |oav|o os|oo ao,ostoot sott| o 'L'
unchanged.
114975
Figure27
- |oasoo o|oos|oo 'B' .|t| t|o c|otc| sovo
at t|o ooo o |ts tavo| (sco. |o 'H' ooo).
- Theclutch wear travel to theclutch servo,set
using software, is standardised at 30 mm,
corresponding to clutch plate wear of 3 mm
(minimumguaranteedclutch platewear).
NOTE
!
Beforeconnectingtheairpipe,ensurethattheclutch
servo is correctlyfastenedto the clutchcasing.
B) Fittingthe clutch servo to the clutch casing:
+. |osco. t|o sco. |o 'H' oo t|o |osoct|oo |o|o to
allow air to emergefromtheinner chamber.
2. Movetheclutchservopistonbackbyhandtoovercome
theresistance of theinternal spring.
3. |ot||too |o 'H' b |aoo to |o|o t|o |stoo bac'.
Base- November 2006
Print 603.93.641/A
SPECIFICATIONS FOR GEARBOX ASSEMBLY EUROTRONIC 12AS 1930/2330/2530
Revi- June2007
120466
Figure28
Incaseof replacement of theclutch actuator, thepreviouslyset push rodlengthremains unvaried.
The pushrod adjustment onlyoccurs when thedrivendisc or thediscpusher are replaced.
NOTE
Differentlyfromordinaryoperations,incaseofvehiclesequippedwith12AS1420gearbox,insteadofthewearlevel,
thedisconnectingstroke is adjusted. If the adjustment is not carried out correctly, the discpusher is damaged.
C = B +33 mm
Example:
B=57 mm
C=57 mm+33 mm=90mm
Assemble thepushrod (2) into theclutchactuator (3). Loosenthescrew(4) onthe clutchactuator (3) until thecylinder
comesout.
Measuretheheight C betweenthespherical headof the push rod and thebearingsurfaceof the clutch actuator.
Adjust thepush rod to reachtheheight C.
Insert thepushrod(2) into the head of the disconnectingfork (1).
Push forwards the disconnecting fork (1) and measure height in B.
Height C calculation
Height C adjustment
Base- November 2006
Print 603.93.641/A
SPRING PIN ADJUSTMENT GEARBOX EUROTRONIC 12AS 1420TD
BLEEDING CLUTCH CIRCUIT
Bleed air fromclutch hydraulic circuit after repairingclutch
assemblyor followingperiodic oil changes.Useair remover
99306010 for thispurposeas follows:
- introduce compressed air into reservoir (5);
- fill reservoir (4) withTutelaTRUCKDOT SPECIALfluid;
- replace clutch reservoir cover ( ) with one of those
providedwithdevice99306010andconnect deviceline
to cover.
1
40355
- applyaplastic pipeto bleedscrew (2) of slave cylinder
(1) and immerse the opposite end of the pipe in a
recipient containingTutelaTRUCKDOT SPECIAL fluid.
Undobleedscrew(1) byoneturn,open(seeFigure 29)
crock (2) until pressuregauge (3) showsareadingof 1
1,2 bars;
- whenclutchfluidemergingfromcircuitisfreeofbubbles,
tightenbleed screw and drain air fromdevicereservoir
(5) throughvalve(6).
Figure29
Figure30
Whenclutchfluidischanged,bleedmastercylinder
by loosening fitting (1, Figure29) before bleeing
clutch servo.
NOTE
Revi- June2007
Base- November 2006
Print 603.93.641/A
Base- November 2006
Print 603.93.641
Print603.93.641
GEARBOXES 1 TRAKKER EURO 4/5
SECTION 4
5302 Gearboxes
Page
GEARBOX ZF9 S1310T.O. 3 12 . . . . . . . . . . . . . . .
GEARBOX ZF 16 S1620T.D. - 2220 T.D. - 2520T.O. 13 22
ZF 16S1621T.D. - 2221 T.D. - 2521T.O.
WITH INTARDER 23 40 . . . . . . . . . . . . . . . . . . . . . . . .
EUROTRONIC AUTOMATED
12AS1420T.D. 41 46 . . . . . . . . . . . . . . . . . . . . . . .
EUROTRONIC AUTOMATED
12AS1930T.D.
12AS2330T.O 47 56 . . . . . . . . . . . . . . . . . . . . . . .
EUROTRONIC AUTOMATED WITH INTARDER
12AS1931T.D.
12AS2331T.O. 57 72 . . . . . . . . . . . . . . . . . . . . . . .
EUROTRONIC GEARBOXESDIAGNOSTICS 73 170 . .
2 GEARBOXES TRAKKER EURO 4/5
GEARBOXZF 9S1310T.O 3 TRAKKER EURO 4/5
5302 Gearbox
ZF 9S 1310T.O.
Page
GENERAL 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OFGEARBOX
DESCRIPTION PLATE 6 . . . . . . . . . . . . . . . . . . . . . . .
GEARCONTROL MODULEE13MP 7 . . . . . . . . . . .
DIAGRAMOF MODULEE 13 MP 8 . . . . . . . . . . . . . .
GEARCONTROLLEVER 9 . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 GEARBOXZF 9S1310T.O TRAKKER EURO 4/5
112206
Figure1
Gearbox ZF9S1310T.O.ismechanical typewithsynchronizedgear engagement,withtheexclusionofpickupgearandreverse
gear, featuringfront engagement.
Itismadeupofaapart featuring4forwardgearswithreversegear,apickupgearandaEpicyclicReductionGearUnit ofplanetary
gearstypeontherear part.
TheE.R.G.unit(EpicyclicReductionGearUnit) enablessplittingthenumberofgears ofthefourspeedgearbox,thus,nineforward
gearsare available, crawler gear included, that canbeengaged in sequence
Theservoshift isadevicecomprisingamechanical/pneumaticmodulethat integratestheGPattractionvalveslockingtheclutch
lanesandHigh/ Lowswitching.
Thedeviceworksmechanicallyif thepneumaticsystembreaksdown.
GENERAL
112207
Figure2
LOCATION OF GEARBOX DESCRIPTION PLATE
A = Typeof transmission F =Tachometer gear ratio
B = ZFdrawingno. G =Typeof power take-off
C = Production sequencenumber H =Power take-offgear ratio
D = Sparepart IVECO drawingno. I =Replacement oil amount
E = Transmissiongear ratio L =ZF lubricant list name
P.T.O. =Power take-off
Figure3
112208
GEAR CONTROL MODULE E13MP
1.Control tower - 2. Gear control moduleE13MP- 3.Servocontrol - 4.AirSupplyModule- 5.Pneumaticpreselectionconnec-
tion, linkedto switch onHigh- Lowlever - 6. Electrical connector for solenoidvalves- 7. Pressureswitch- 8. GREcylinder pneu-
matic connection line- 9. Neutral switch
Themechanically/ pneumaticallyoperatedmoduleE13MPintegratesthevalvesactivatingtheGP,lanelockandHigh- Lowspeed
switching.
It offersthefollowingadvantages:
- gearsare selected andengagedfaster andwith lesseffort;
- dampingof vibrationsfromthe control linkage, thusreducingnoiselevels;
- lessstressonthesynchronisers.
Figure4
112209
Thisoperationisto becarriedout onlywherethebearingisto replace. NOTE
Thisoperationisto becarriedout onlywherethebearingisto replace. NOTE
1. GREpneumaticswitch - 2. ValveenablingGREengagement -3. Lanelock- 4. Pressureswitch- 5. VCMcontrol unit - 6. Lane
lockingsolenoidvalve- 7. GREswitchingvalve-8. GREcylinder - 9. Switchingsolenoidvalve
Lock speed range switching
- Preventsswitchingfromhighto lowspeedwhenacertainnumber of revs isexceeded.
- Protects thesynchronisersfromexcessivelyhighperipheral speeds.
- Protects theclutchandenginefromover-revving.
EXAMPLE:
If you arein 5thgear and therevspeedis >1000 rpmit will NOT bepossibleto drop to 4th gear.
Lane lock
- Preventsincorrect engagement of 4
th
1
st
insteadof 4
th
5
th
Thedriver intendsto passfrom4thto 5thgear byswitchingtheGPlever tohigh, but hasforgottento select GP - Highonthe
selector: thelanelockfunctionisactivated to prevent selectionof lane.
- Preventsincorrect engagement of 8
th
5
th
Thelanelock function preventsincorrect engagement of 8
th
5
th
at arunningspeed of above 2000rpm.
DIAGRAM OF MODULE E 13MP
Figure5
112210
GEAR CONTROL LEVER
H =high gears- L =lowgears
Whenengaginggearswithsuper H, it ispossibleto changetheratiousingtheleverswitchonthegearselector. Iftheleverswitch
|s sot to '|o.' oas +
st
to 4
th
ao so|octoo. | |t |s sot to '||' oas 5
th
to 8
th
areselected.
Theneutral positionisat thecentreof lane.
MAIN DATA
GEARBOX ZF 9S1310T.O.
Type
Input torqueNm
Mechanical
Forwardgears
Reversegear
9
1
Control for thefour maingears
E.R.U* control
Mechanical type
Pneumatictype
Power takeoff Onrequest
Gear Engagement:
1
st
- 2
nd
- 3
rd
- 4
th
speedsand E.R.U. Freeringsynchronizer
PickupspeedandReversespeed Fast engage type
Disengagement protection
Slidingsleeves lockedbyrollersand springs
Gears Helical toothing
E.R.U * =Epicyclicreductiongear unit
T.O. =TruckOver Drive(Multiplied)
Gear ratios
Crawler
First speed
Secondspeed
Third speed
Fourthspeed
Fifthspeed
Sixthspeed
Seventhspeed
Eighthspeed
Reversespeed
9.48
6.58
4.68
3.48
2.62
1.89
1.35
1.00
0.75
8.97
Typeof Oil
Quantity
TutelaTruck FE-Gear
TutelaZC 90
7.5Kg. (8.5lt)
Revi-June2007
GEARBOXESZF16S1620T.D.- 2220T.D.- 2520T.O. 13 TRAKKEREURO 4/5
Base- November 2006
Print 603.93.641/A
Print603.93.641/A
Gearboxes:
ZF 16 S 1620T.D.
ZF 16 S 2220T.D.
ZF 16 S 2520T.O.
Page
DESCRIPTION 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF GEARBOX DESCRIPTION
PLATE 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 16/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Slow range 16/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fast range 16/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EPICYCLIC REDUCTION GEAR CONTROL 16/4 . . . . .
- Reducedspeeds 16/4 . . . . . . . . . . . . . . . . . . . . . . . .
- Normal speeds 16/5 . . . . . . . . . . . . . . . . . . . . . . . . .
PNEUMATIC CONTROL OF GEARBOX 16/6 . . . . . . . .
MAIN DATA 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 19 . . . . . . . . . . . . . . . . . . . .
TOOLS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX FAULT DIAGNOSIS 20/5 . . . . . . . . . . . . . . .
REMOVAL-REFITTINGTHEGEARBOX 21 . . . . . . . . .
- Removal 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGTHEGEARBOX 22/1 . . . . . . . . . . . . . .
- Servoshift gear box 22/1 . . . . . . . . . . . . . . . . . . . . .
- Removal 22/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 22/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assemby 22/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 GEARBOXESZF16S1620T.D.- 2220T.D.- 2520T.O. TRAKKEREURO 4/5
Base- November 2006
Print 603.93.641/A
Page
- Removingtherear box 22/7 . . . . . . . . . . . . . . . . . .
- Removingtheepicyclic reduction gear unit
(ERG) 22/7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingthe epicyclicreduction gear unit
(ERG) 22/9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refittingtheepicyclic reductiongear unit
(ERG) rear box 22/12 . . . . . . . . . . . . . . . . . . . . . . . .
- Removingthegearbox 22/12 . . . . . . . . . . . . . . . . . . .
- Removingthemainshaft 22/15 . . . . . . . . . . . . . . . . .
- Removingthedriveinput shaft 22/18 . . . . . . . . . . . .
- Removingthetransmission shaft 22/19 . . . . . . . . . . .
CHECKS 22/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Gerabox 22/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bearings 22/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Shafts - gears 22/19 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Hubs- slidingsleeves - forks 22/19 . . . . . . . . . . . . . .
- Rodsforks 22/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Synchronizingdevices 22/20 . . . . . . . . . . . . . . . . . . .
- BK-typesingle-conesynchronizingdevices 22/20 . . . .
- Fittingthetransmissionshaft 22/20 . . . . . . . . . . . . . .
- Fittingthe driveinput shaft 22/20 . . . . . . . . . . . . . . .
- Fittingthe main shaft 22/22 . . . . . . . . . . . . . . . . . . . .
- Adjustingthemain shaft 22/24 . . . . . . . . . . . . . . . . . .
- Fittingthe gearbox 22/25 . . . . . . . . . . . . . . . . . . . . . .
- Adjustingsplitter drivefork 22/26 . . . . . . . . . . . . . . .
- Oilpump 22/27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjustingthetransmissionshaft bearingend
float 22/27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Driveinput shaft cover 22/28 . . . . . . . . . . . . . . . . . .
Revi-June2007
71107
Figure1
TheZF16S1620/ 1920/ 2220gearboxesintheT.D.(direct
drive) or T.O. (overdrive) versionsarecomposedof:
- A central box containing the main shaft, input shaft,
layshaftandthegearsforthefourforwardspeedsandone
reversegear.
- A rear boxcontainingtheEpicyclicReductionGearUnit
(ERG). Its functionis to double the number of forward
speedsbyusingepicyclicgears withhelical toothing.
Thisproducesarangeofgearsthat, startingwiththefour
incomingspeeds,makesit possibletohaveeightdifferent
ratios at the output (four normal speeds plus four
reducedspeeds).
- A front box containingthe step-up gearing, called the
's||tto', t|at a'os |t oss|b|o o oac| o t|o o||t
forward speeds and for the reverse gear to obtain an
additional doubleselection.
T|o 's||tto' t|oooo |a|vos t|o stao bot.ooo t.o
successiveratiosandeachgear isdividedintoaslowratio
(L =slowratio) and afast ratio (S=fast ratio).
Thesegearboxesthereforehavesixteenforwardspeedswith
finelystaggered ratios that canbe engaged in successionand
two reversegears.
Thesynchronizingdevicesarethesingle-conetype.
Lubrication ismadewithagear pump.
The double-H speed control is fitted with an air-operated
'sovos||t' oov|co to |ovo sooo so|oct|oo aoo
engagement.
Theservoshift is adevicecomprisingamechanical/pneumatic
moduleandadouble-actingcylinder.
Theadvantagesof this deviceare:
- Faster speedselection andengagement withlesseffort.
- It cushionsthevibrations of the control linkage, reducing
noise.
- Less synchronizingdevicestress.
Thedeviceworksmechanicallyifthepneumaticsystembreaks
down.
GEARBOXESZF 16S1620T.D.- 2220T.D.- 2520T.O. 15 TRAKKER EURO 4/5
Base- November 2006
Print 603.93.641
DESCRIPTION
PRINT603.93.641
Figure2
112202
16=Number of forward
gears
S=Synchronized
1620/1920/2220 input
torque
IT =intarder
A = Typeof transmission
B = ZFdrawingno.
C = Productionsequencenumber
D = Sparepart IVECO drawingno.
E = Transmissiongear ratio
P.T.O. = Power take-off
F = Tachometer gear ratio
G = Typeof power take-off
H = Power take-off gear ratio
I = Replacement oil amount
L = ZF lubricant list name
16S 1620/2220/2520
16 GEARBOXESZF 16S1620T.D.- 2220T.D.- 2520T.O. TRAKKER EURO 4/5
Base- November 2006
Print 603.93.641
Figure2/1
61225
DETAIL OFSERVOSHIFT SPEEDCONTROL
1. Control valvelever - 2. Speed control lever - 3. Idle roller - 4. Exhaust - 5. Control piston- 6. Intake- 7. Cylinder -
8. Reaction spring- 9. Longitudinal tierod connection lever
16/1 TRAKKEREURO 4/5 GEARBOXESZF16S1620T.D.- 2220T.D.- 2520T.O.
Print 603.93.641/A Revi- June2007
119421
Figure2/2
PNEUMATIC DIAGRAMFOR PRE-SELECTION IN SLOW RANGE
Atthesametime,thevalve(6)movesandopensthepassage
for the air between the inlet duct (11) and the duct (3)
connectingwith the right-handchamber of the cylinder of
thesplitter (2).
On pressingtheclutch pedal, the air reachingtheinhibitor
valve(14) suppliesthedoublecontrol valve(8) throughthe
connectingpipe(13).
Theair reachingthevalve (8) passes throughtheinlet duct
(11) and, findingthe passage clear, supplies the right-hand
c|abo o t|o c||ooo o t|o 's|| tto' (2) t|oo| t|o
connectingduct (3).
Thepistonofthiscylinder,movingtotheleft,thendrivesthe
entiretraindownline,causingtheslowrangeto beengaged.
The air fromthe services reservoir supplies the inhibitor
valve(14) andthepre-selector (1) simultaneously, through
theconnectingpipe (15).
On shiftingthe pre-selector (1) downwards (position L of
slowrange),theairreachingthepre-selector (1) throughthe
connectingpipe(16) supplies thedoublecontrol valve (8).
The pressurized air, supplying the above-mentioned valve
(8), pushes thepistons (4 and 9) to theleft.
Themovement ofthepistons(4and9) makesit possiblefor
the valve (7) to return to its seat and discharge the air
contained in the left-hand chamber of the cylinder of the
's||tto' (2) |oto t|o atos|oo t|oo| t|o cooooct|o
duct (12).
Pressurizedair
OPERATION
Slow range
Figure2/3
PNEUMATIC DIAGRAMFOR PRE-SELECTION IN FAST RANGE
At thesametime,thevalve(7) movesandopensthepassage
for the air between the inlet duct (11) and the duct (12)
connectingwiththeright-handchamberofthecylinderofthe
's||tto' (2).
On pressing the clutch pedal, the air reachingthe inhibitor
valve(14) suppliesthedoublecontrol valve (8) throughthe
connectingpipe(13).
The air reachingthe valve (8) passes through the inlet duct
(11) and, finding the passage clear, supplies the right-hand
c|abo o t|o c||ooo o t|o 's|| tto' (2) t|oo| t|o
connectingduct (12).
Thepistonofthiscylinder,movingtotheright,thendrivesthe
entire train downline, causingthefast rangeto beengaged.
Theairfromtheservicesreservoir suppliestheinhibitorvalve
(14) and the pre-selector (1) simultaneously, through the
connectingpipe(15).
On shiftingthe pre-selector (1) upwards (positionS of fast
range),theairpassagebetweenthesupplypipe(15) andthe
doublecontrol valve(8) isclosed,settingtheconnectingpipe
(16) incommunication with theoutlet pipe(17).
Asaresult of theair beingdischargedbythedoublecontrol
valve(8),thereactionofthespring(10) andofthesprings(5)
pushes thepistons (4and9) to theright.
Themovement ofthepistons(4and9) makesit possiblefor
the valve (6) to return to its seat and discharge the air
contained in the right-hand chamber of thecylinder of the
's||tto' (2) |oto t|o atos|oo t|oo| t|o cooooct|o
duct (3).
Pressurizedair
119422
Fast range
86338
Figure2/4
PNEUMATIC SYSTEMDIAGRAMOF REDUCED SPEEDENGAGEMENT
The movement of the piston causes the contact of the
electric switch to close, whichturnsontheindicator light in
thecabwith thetortoisesymbol.
T|o a| o t|o vo||c|o's oooat| c ssto |s ooocoo to a
pressureof 9.5barsbythepressurereductionunit (1).Itthen
supplies theinhibitor valve D.
Now, taking the control lever onto the reduced speed
position (1
st
H), thebodyA,integral withthespeedcontrol
rod, opens the valve E that, via the pipe F, supplies the
cylinder G.
The piston of thecylinder G, movingto the right, activates
theERG.
At the same time, thevalveB closes, makingit possiblefor
theair fromthepipe C to dischargeinto theatmosphere.
The reduced speeds can be used in both slow
rangeandfast rangeconditions, dependingonthe
positionof the pre-selector.
NOTE
EPICYCLIC REDUCTION GEAR CONTROL
Reduced speeds
86337
Figure2/5
PNEUMATIC SYSTEMDIAGRAMOF NORMAL SPEED ENGAGEMENT
The movement of the piston causes the contact of the
electricswitchto close, whichturnsofftheindicator light in
thecab.
T|o a| o t|o vo||c|o's oooat| c ssto |s ooocoo to a
pressureof 9.5barsbythepressurereductionunit (1).Itthen
supplies theinhibitor valveD.
Now,takingthecontrol leverontothenormal speedposition
(2
nd
H),thebodyA,integral withthespeedcontrol rod,opens
thevalveBthat, viathe pipeC, supplies thecylinder G.
Thepistonofthecylinder G,movingto theright, deactivates
theERG.
At thesametime,thevalveEcloses,makingitpossibleforthe
air fromthepipe F to dischargeinto theatmosphere.
Thenormal speedscanbeusedinboth slowrange
and fast range conditions, depending on the
positionof the pre-selector.
1 2
3 4
5 6
7 8
R
A B C
E
D
I F
G
22
21
1
26
25
NOTE
Normal speeds
Figure2/6
The splitter (slow speeds - fast speeds) and epicyclic
reductiongear unit areair operatedandcontrolledwiththe
speed control lever.
Theselector (1) pre-selectstheL range (slow) and Vrange
(fast) viathedoublecontrol valve (5). Theyareinsertedvia
theinhibitor valve (2) when the clutchpedal ispressed.
The epicyclic unit engages and disengages automatically
whenpassingfromthe 1st H to the 2nd H andviceversa.
When the gearbox is in neutral, the drivingcylinder (6) is
operated bythepressurized air via thecontrol valve (9).
Through the piping (12), the distributor (10) supplies the
servo-clutch (4) that, if operated with the clutch pedal,
supplies theservoshift (11) throughthepiping(13).
A switch(8) onthegearboxcontrol turnsonthereversing
light when reversegear is engaged.
Theswitch(7) signallingwhenthegearboxisinneutral ison
thecover of thegear control.
Another switchontheERGdrivingcylinder (6) turnsonthe
indicator light in the cab (with the symbol of the tortoise)
whentheepicyclic reduction gear is engaged.
DIAGRAMOF PNEUMATIC CONTROL OF GEARBOX WITH SERVOSHIFT
1. Splitter control selector - 2. Inhibitor valve- 3. Servicesreservoir - 4. Servo-clutch- 5. Double control valve- 6. ERGdriving
cylinder - 7. Switchsignallinggearbox inneutral - 8. Reversegear switch- 9. Control valve- 10. Distributor -
11. Servoshift - 12. Piping- 13. Piping
119423
Print603.93.331
PNEUMATIC CONTROL OF GEARBOX
17 GEARBOXESZF16S1920T.D.- 2220T.D./T.O.- 2320T.D.- 2520T.O. TRAKKEREURO 4/5
Base- November 2006
Print 603.93.641
PRINT603.93.641
MAIN DATA
GEARBOX
Type Mechanical
Torqueat input
ZF16S 1620T.D.
ZF16S 2220T.D.
ZF16S 2520T.O.
1700
2200
2500
Speeds 16forward speeds
2 reversespeeds
Control of thefour main
speeds
ERG control *
Splitter control
Mechanical
Pneumatic
Pneumatic
Power take-off On request
Gear engagement:
Forward speeds Freeringsynchronizer
Bk-typesinglecone1
st
-2
nd
-3
rd
-4
th
-5
th
-6
th
speed
Reverse gear Quick engagement
Gear anti-disengagement Slidingsleeves heldby
pawlsandsprings.
Gear wheels Helical-toothed
* ERG=Epicyclic reductiongear unit
T.D. =Truck Direct Drive
T.O. =TruckOver Drive (Multiplied)
Revi- June2007
18 GEARBOXESZF16S1920T.D.- 2220T.D./T.O.- 2320T.D.- 2520T.O. TRAKKEREURO 4/5
Base- November 2006
Print 603.93.641/A
Print603.93.641/A
PRINT603.93.641/A
GEARBOX
ZF 16S1620T.D.
ZF 16S1920T.D.
ZF 16S2220T.D.
ZF 16S2520T.O.
Gear ratio
1
a
2
a
3
a
4
a
5
a
6
a
7
a
8
a
9
a
10
a
11
a
12
a
13
a
14
a
15
a
16
a
1
a
RM
2
a
RM
16.41
13.80
11.28
9.49
7.76
6.53
5.43
4.57
3.59
3.02
2.47
2.08
1.70
1.43
1.19
1.00
15.36
12.92
13.80
11.54
9.49
7.93
6.53
5.46
4.57
3.82
3.02
2.53
2.08
1.74
1.43
1.20
1.00
0.84
12.92
10.80
Typeof oil
TutelaTruck FE-Gear
TutelaZC 90
Quantity
ZF16S 1620T.D. Kg
litres
ZF16S 1920T.D. Kg
ZF16S 2220T.D./T.O. litres
Drychange
10
11
12
13
Transmissionandmainshaft bearings taperedrollers
taperedrollers
Driveoutput flangeassemblytemperatu-
re
Max. 70 C
Transmissionshaft gear assembly
temperature 160 180 C
18/1 TRAKKEREURO 4/5 GEARBOXESZF16S1620T.D.- 2220T.D.- 2520T.O
Print603.93.331/A
GEARBOX
Mainandtransmissionshaftbearingandfi-
xedhubassemblytempature 100
End float: with adjustingring without adjustingring
- ERG* planet wheel shaft bearing 0 0.1 mm 0 0.26mm
- ERG* fixed hub split ring
- Transmission shaft bearingsplit ring
0 0.1 mm
0 0.1 mm
End float of gear of driveinput shaft, first,
second and third speed minimum0.2 mm
Fourth speed gear end float minimum0.05mm
End float between planet wheel holder
and ERG* planet wheels
0.4 1.3 mm
End float of bearings of shafts: main and
transmission on driveinput side 0.0 0.1 mm
Mainshaft rear bearingsplit ringendfloat 0.0 0.05mm
Wearlimit checkdistanceofsynchronizer
rings:
- first/second speed
- third/fourthspeed
- ERG*
1.5mmat 50 Nm(5kgm)
0.8 mm
1.2 mm
Reverse gear idler endfloat 0.4 1.5 mm
End float or pre-load of half rings of main
and drive input shafts
from- 0.05to +0.05
* ERG=Epicyclic reductiongear unit
Print603.93.331
GEARBOX
Distancefor theclearanceadjustment of the sliding
blocks of thesplitter control fork onthe relevant blocks of thesplitter control fork onthe relevant
slidingsleeve 94.1mm
107.9 mm
Clearance of theslidingblocksof the forks inthe
seats of theslidingsleeves 0.6 1.2 mm
Assemblydistance of twin-lipped seal on rear cover 12.5
+1.0
mm
19 GEARBOXESZF16S1620T.D.- 2220T.D.- 2520T.O.. TRAKKEREURO 4/5
Base- November 2006
Print 603.93.641
PRINT603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Screwsfixingsplitter box 50 5
2 Screwsfixingoil pump 46 4.6
3 Screwsfixingdriveinput shaft cover 46 4.6
4 Screwsfixinggearbox 43 4.3
5 Screwsfixingvalveto gearbox 23 2.3
6 ScrewsfixingERG* cylinder to the box 50 5.0
7 Self-lockingnutsfixingsplitter control rodsandERGto pistons 150 15.0
8 Screwsfixingdriveoutput flange 120 12
9 Screwsfixingrear cover 50 5
10 ScrewsfixingPTO fittingcover 79 7.9
11 ScrewsfixingERG* box 50 5
Fixingscrews
- M18 x 1.5
- M22 x 1.5
- M24 x 1.5
35
50
60
3.5
5
6
Clutch disengagement bearingdriveforksupport fasteningscrews 150 15
ScrewsfixingRMgearboxbottomcover 49 4.9
Screwsfixinggearboxsidecover 23 2.3
Socket-headscrews fixingpipes 35 3.5
Oil drainplugs 80 8.0
Oil drainplugs M38x 1.5with magnetic filter 140 14.0
Pressure switches/ pulsetransmitters 50 5.0
Screwsfixingoil pump cover 46 4.6
Switcheson gearbox 35 3.5
Screwsfixingsplitter control valve 9,5 0.9
Nut for screw fixinglever to gearboxcontrol rod 5 4.9
Threaded pinsfor articulationof ERG* control fork 250z 25z
Oil vapour breather pipe 10 1
Push rods for positioningrods 50 5
Screwfor reversegear shaft retainingplate (if applicable) 86 8.6
Screwsfixingfork on splitter control shaft 60 6
Figure3
102917
Revi- June2007
Base- November 2006
Print 603.93.641/A
PRINT603.93.641/A
TOOLS
99322205 Rotarystand for overhaulingassemblies
99322225 Standfor supportingassemblies (to befittedonstand99322205)
99340205 Percussion extractor
99341003 Single-actingbridge
99341012 Pair of brackets
20/1 TRAKKER EURO 4/5 GEARBOXESZF 16S1620T.D.- 2220T.D.- 2520T.O.
Print 603.93.641/A Revi - June2007
TOOLS
99341015 Clamp
99341019 Pair of tierodswith grips
99341020
99341021
Pair of tierodswith grips
99341022 Grips
99341024
99341025
Grips
99345058 Extractor reactionblock
TOOLS
99345097
Reactiontool to extract sungear and drivein mainshaft oil pipe
99347092
Pinto extract gearbox front andrear centringpins
(usewith99340205)
99360502 Rings toremoveandrefit reduction gear unit
99370006 Gripfor interchangeabledrifts
99370007 Gripfor interchangeabledrifts
99370113
Beater for mountingthegasket and/or bushingsofcontrol boxfor
thegears
Print 603.93.331/A
TOOLS
99370415
Door baseofcomparator to adjust secondaryshaft bearings
(to beusedwith99395604)
99370420
Keyfor fittinggasket ongearboxfront cover
(usewith99370006)
99370449 Tool to extract and insert main shaft
99370450 Tool to adjust splitter control fork
99370465 Tool to notch safetyplates
99370565 M10eyebolts (2) for liftingvariousassemblies
TOOLS
99370629
Mount to support gearboxwhenremovingand refitting
it on thevehicle
99371050
Bracketsto support gearboxwhenoverhauling
(usewith99322205 - 99322225)
99374093
Drift to mount external bearingraces (91-134)
(usewith99370007)
99374221 Keyto fit gasketsonrear cover
99374370
Keyto fit oil deflector on direct driveshaft
(use99370006)
99395604 Dial gauge (0-10mm)
GEARBOX FAULT DIAGNOSIS
Principal operational anomalies:
Visible Failure Possible cause Repair action
Excessiveclearancebetweengears. Overhaul the gearbox and replace worn
gears.
NOISE
Gears, bearings, synchronizer rings and
connectingpartsworn.
Replacewornparts.
Insufficient lubricating oil level in the
gearbox.
Topuptocorrect level with TutelaZC
90 or TutelaTruck Fe-Gear oil.
Gearsnot properlyengaged. Fullyengagegearsbeforereleasingclutch
pedal.
GEARS DISENGAGE
Gearshift forksbroken. Remove transmission, overhaul and
replacepartsasnecessary.
GEARS DI SENGAGE
SPONTANEOUSLY AND
ENGAGE INCORRECTLY
Synchroniser ringsworn Inspect gears and slidingsleeves for gear
engagement, replacing any which are
damaged; replacesynchroniser rings
Defectiveoperationofepicyclicreduction
gear
Inspect and replacedamaged parts
Forksstiff onrods Dismantle the transmission and look for
the cause of the stiffness; repair as
necessary
GEARS DIFFICULT AND STIFF
TO ENGAGE
Movement of slidingsleeves obstructed Inspect and repair as necessary
TO ENGAGE
Transmissionfilled withunsuitable fluid. Draintheoil andrefill withTutelaZC 90
or TutelaTruck Fe-Gear oil
Clutchnot disengaging Adjust control or replace.
Defective air pipeconnections Checktheconnectionsandrestorethem
ifnecessary.
Air pipe bent and/or crushed Replacethepipe
PNEUMATI C CONTROL
Air leaksfromthepipe. Checkthereareno leaksinthepipes and
fittings;useanacousticapplianceorsoapy
water. Replace or tighten the seal if
necessary.
PNEUMATI C CONTROL
SYSTEM DEFECTIVE OR
INEFFICIENT *
Air leaks from the pressure reduction
valve.
Replacethevalveor its seals.
Defective pressure reduction valve
setting.
Check the valve pressure. Replace if
necessary.
Air leaks from the inhibitor valves.
Inhibitor valvesdo not work.
Check the inhibitor valves. If necessary,
replacethevalvesor their seals.
Air leaksfromthedrivingcylinders. Replacethegasketsandsealsofthedriving
cylinders.
* Thecheckshaveto bemadewiththeengineswitchedoff andtheair tanksfull.
71751
Figure4
To removethegearbox, proceed asfollows:
- Set thevehicleover apit or on alift.
- Disconnect the battery cables to prevent any
short-circuiting.
- Disconnect thecable(11)usingtheconnectors( ) and
breakingthesafetyleadoff thescrew (10).
- Disconnect theconnector (7) andthepipe(8) fromthe
power take-off (if applicable).
- Disconnect theair pipes (4) and(5).
- Freethepipes (6) fromthe clamps(12).
- Undoingthefasteners (13), disconnect thetierod(14)
fromthegearbox.
- Loosenthescrew(2) andextract thelever (3) together
with the tie rod (1) fromthegearboxafter markingits
position for reassembly.
- Removethefasteners(15) ofthegearboxbell,accessible
fromabove.
Removal
Forgearboxeswiththeintarder,proceedasfollows:
- Drainofftheenginecoolant anddisconnect the
pipes fromtheheat exchanger.
- If the cross member of the chassis frame
prevents you fromremovingthe gearbox, you
need to drainoff theoil fromtheintarder; take
out the nuts and screws fixing the heat
exchanger to the intarder, remove the stud
boltsanddetach theheat exchanger.
NOTE
PRINT603.93.641
530210 REMOVING-REFITTING THE GEARBOX
45369
Figure5
Workingfromunder thevehicle:
- Disconnect thepipes(1) and(2),previouslyfreedfrom
theclamps.
- Unscrew thenuts(5) and tie the clutchcylinder (6) to
t|o vo||c|o's c|ass|s ao ao|ato|.
- Undoing the side fasteners (8), take off the cross
member (7).
- Place a hydraulic jack equipped with the mount
99370629(1, SENZA CODICE) under thegearbox.
- Disconnect the propeller shaft (10) by undoing the
sco.s () aoo t|o |t to t|o vo||c|o' s c|ass|s ao
appropriatelyso it will not interferewiththeremoval of
thegearbox.
- Complete removingthe gearboxbell fasteners (4).
- Afterwards, extract the gearbox fromthe engine by
bringingit suitablybackout ofthe spaceoccupiedbythe
exhaust pipe(3). Thenlower thejack and take out the
gearbox.
Figure6
Forgearboxeswiththeintarder,proceedasfollows:
- Refit the heat exchanger to the intarder,
insertingnewseals;fit thestudboltsandtighten
thefixingscrewandnutstotherequiredtorque.
- Connect the coolant pipes to the heat
exchanger and replenish the gearbox with the
requiredamount of oil.
- Fill the engine cooling systemas described in
Section2 Engine.
Carryout theoperationsperformedfor removal in
reverseorderandtightenthefixingnutsandscrews
71752
Refitting
NOTE
BaseNovember 2006 Print 603.93.641
Figure6/1
Figure6/2
Figure6/3
Figure6/4
530220 Servoshift gear box
Removal
There follows a description of the operations for
overhaulingtheZF 16 S 2520 gearbox that, unless
stated otherwise, hold for the ZF 16 S 1920/2220/
2320 gearboxes too.
Fit thesupportingbrackets 99371031to theassembly.
Using ropes with hooks and a movable lift, position the
assemblyon the rotarystand 99322205 together with the
mount 99322225.
61226
Notedowntheassemblypositionofthepipes(3and4) and
disconnect themfromthe gearbox (5) by unscrewingthe
fittings (2 and 6) together with thewashers.
Unscrew thefixingscrews(1) and removethegearbox (5)
together withtheservoshift fromthegearbox.
The servoshift cannot beoverhauled. Replaceit if
you find anytrouble.
Refitting
Forrefitting,carryout thestepsdescribedforremoval
inreverseorder, fittingnewseals and tighteningthe
fixingscrews(1) andfittings(2and6) to therequired
torque.
61227
Unscrewthefitting(2) anddisconnect theair pipe (3) from
thedistributor (4).
61257
Unscrew the screws (1, Figure6/2) and disconnect the
servoshift (1) fromthe gearbox (2).
Takeout the pushrod (3) with thespring(4).
61228
Marktheassemblyposition of thelever (7) on the rod(6).
Loosen the nut (5) andremove thelever (7) fromthe rod
(6).
Extract thecup(8).
Remove:
- thevalve(3) after takingout thescrews (4).
- theswitches(1and9) withtheir washersandpushrods
(2 and 10).
- the plug (13) with its washer, the spring (12) and the
push rod(11).
530210 OVERHAULING THE GEARBOX Disassembly
NOTE
NOTE
Washtheassemblythoroughlybeforeoverhauling.
The specific and/or general tools must be used in
thewayfor which theyweredesigned.
Tofacilitateassembly, put theremovedpartsaway
on thespecifictrayin their order of removal.
Upon assembly, the following must always be
replaced with new parts: the gaskets and seals,
spring pins, safety plates and springs. Nuts and
screwsmust betightenedtotheprescribedtorque
with their thread dryand degreased.
Keepto thespecificregulationswhen disposingof
lubricant anddetergents.
NOTE
61229
Figure6/5
61230
Figure6/6
Unscrew thescrews (1) andtakeoff the top cover (2).
Extract thepin(3).
Takeoffthecirclip(3) andextractthepiston(2)togetherwith
thering(1).
61259
Figure6/7
Remove thecirclip (2) fromthe rod (1).
Usethewasher (4) to limit theaction of thespring (5) and
removethe split ring(3), extract the washer (4), thespring
(5) andthe washer (6).
61231
Figure6/8
Unscrew theplugs(2) with thewashers, extract thesprings
(1) andremovethelevers(6).
If necessary, take out thepins(3).
Unscrew thescrews (4) and removethe cover (5).
Removethecirclips(1) andtakeoutthepins(2) fasteningthe
drive(4) to the rod (3).
61232
Figure6/9
Movethesleeve(1) in the directionof the arrow.
Strike apunch onthe top of thelever (6) to make it come
out ofthebearing(3) andpin(2),freeingthelatter fromthe
groove(4) in the rod (5).
61233
Figure6/10
61234
Figure6/11
61235
Figure6/12
Notedowntheassemblypositionofthelevers(2and3) and
takethemout of the box (4) extractingthe rod (1).
Usingthemaleextractor 99348004,extract thebushing(2)
and theseal (1) fromthebox (3).
61236
Figure6/13
Notedowntheassemblypositionofthelockingelement(1)
and drive (2) and take them out of the box (4) after
extractingthesleeve (3).
Positionthelockingelement (1) andthedrive(2) inthebox
(4) as markedduringremoval andput onthesleeve (3).
61236
Figure6/14
Usingdrift 99370113, mount thebushing(2) inthebox(3).
Usingasuitablekeyingdevice, fit theseal (1) inthebox (3).
Lubricate theinsideof theseal (1) withgrease.
61235
Figure6/15
When assembling, always replace the sealing
elementswithnewparts:rings,copperwashers,flat
gaskets, o-rings androller bearings with the pins.
Checkthat thespringshavenot brokennoryielded.
Assembly
NOTE
61234
Figure6/16
Positionthelevers(2and3) inthebox (4) asmarkedduring
removal andput on therod (1).
Figure6/17
61233
Movethesleeve(1) in the directionof the arrow.
Fit a new roller bearing (3) and pin (2) on the lever (6).
Positiontherod(5) sothat thegroove(4) correspondswith
theroller (3) andpin (2).
Resting the lever (6) on a flat surface, carefully strike the
bearing(3) and pin(2) sotheygo into aposition flushwith
thetop of the lever (6) andcorrectlyenter thegroove (4)
intherod (5).
Figure6/18
61232
Fastenthedrive(4) totherod(3),puttingonthepins(2) and
mount newcirclips(1) on these.
Figure6/19
61231
On therod(1), position: thewasher (6), spring(5), washer
(4) and fit onanewsplit ring(3).
Fit onanewcirclip(2).
Figure6/20
61259
Fit on the cover (5) with a new gasket, screw down the
screws (4) andtightenthemto therequiredtorque.
Position thelevers (6) onthepins (3). Screwdown theplugs
(2) withthenewwashersandsprings(1) andtightenthemto
therequiredtorque.
61230
Figure6/21
61229
Figure6/22
Fit anew ring(1) on the piston (2) and fit this in the box,
securingit withthecirclip (3).
Insert thepin(3) in thebox.
Put the top cover (2) on withanewgasket.
Screwdownthescrews(1) andtightenthemtotherequired
torque.
43812
Figure6/23
Positionthepushrod(3) withthespring(4) inthebox (2).
Refit theservoshift (1) withanewgasket.
61257
Figure6/24
Complete gearboxassemblybyfitting:
- push rod(11), spring(12), plug(13) withanew seal;
- push rods (2 and 10), switches (1 and 9) with thenew
washers;
- cup (8), lever (7) ontherod(6) inthepositionmarked
duringremoval andtighten thenut (5) to therequired
torque.
- valve(3) andtighten screws(4) tothespecifiedtorque.
Screwdownthescrews(1) andtightenthemtotherequired
torque.
Connect the air pipe (3) to the distributor (4), screwing
downthefitting(2) withnewcoppergasketsandtightening
it to therequiredtorque.
Refitting
61227
Figure6/25
Figure6/26
61226
Refit thegearbox (5), screwdownthefixingscrews(1) and
tightenthemto therequiredtorque.
Connect thepipes (3 and 4) to thebox (5), intheposition
foundat removal,withthefittings(2and6) togetherwiththe
new washers.
Figure6/27
61237
PARTSCOMPRISINGTHE GEARBOX
Unscrew nut (2), unthread plunger (3) complete with two
seal ringsandwithantivibrationringfromrod(5) controlling
epicyclicreductionunit.Removeseal ring(6).Takeoffrod(5)
seal (4) with ascrew driver. Unscrew push rod 145N (1)
positioningrod(5). Remove plug(8) and dismount pin (7).
71114
37329
Figure6/28
Figure6/29
Figure6/30
Figure6/31
Figure6/32
Remove the gearbox (1) as described under the relevant
heading.
Take noteof theassemblingpositionof pipes (3) on G.R.E.
control cylinder (5),thendisconnect thepipesbyunscrewing
adapters (6) completewithwashers.
Unscrew thescrews (1). Screw theeyebolts 99370565 (3)
ontotherearbox.Usinghooks(4) andamovablelift,detach
therear box (2) fromthegearbox.
Take off safety plate (if present), unscrew two screws (1),
takeoff pushdisk (2) andunderlyingseal ring.
37330
Extract the drive output flange (3) using the extractor
composed of: tie rods 99341018 (2), bridge 99341003(1),
reaction block 99345058(4).
Removing the epicyclic reduction gear unit
(ERG)
Removing the rear box
102653
37312
Figure6/33
102652
Extract 3epicyclic reduction unit boxcenteringpins (3) by
knockout 99340205 (1) andpin99347092 (2)
Figure6/34
37331
Unscrewscrews(2), takeoff cover (1) and removesupport
bearingandseal ringfromthecover.
Figure6/35
Figure6/36
37332
Unscrewthepins(2and3) andremovethebox(1) fromthe
ERG unit.
37333
Extract therod (3), fork(1) together withtheslidingblocks
controllingtheERG unit.
Remove the middle plate (2).
71115
Figure6/37
Removethecouplingbody(1) together withthefifthwheel
bearingandsynchronizer ring(2) fromthehubfor thesliding
sleeve.
71116
61219
Figure6/38
Figure6/39
Takethefifthwheel bearing(2) out ofthecouplingbody(1).
Taking care over the blocks (5) and the springs (3 and 4)
comingout of thehub(1),taketheslidingsleeve (2) out of
thehub. Removethecirclip(6).
For bearing disassembly, follow the instructions
provided onpage 27of this section.
NOTE
61252
Figure6/40
With an extractor composed of bridge 99341003 (1),
brackets 99341015 (2), reaction part 99345058 (3) and
clamp99341015(4),extract thehub(6) fortheslidingsleeve
fromtheERGshaft (5).
71117
Figure6/41
Figure6/42
Remove theringgear (1) fromtheplanet wheel shaft (2).
61220
Remove thesynchronizer ring(1) and thecouplingbody (3)
together withtheplate (2) fromtheringgear (4).
Leveringunder the coupling body (3), extract this fromthe
plate(2).
71118
Figure6/43
Figure6/44
19527
Takeoffthering(2) andseparatetheringgear (3) fromthe
mount (1).
Takeoffthespacer(2),pushthespringpins(4) insidethepins
(3) and, with an appropriate drift, extract the pins (3) from
the planet wheel shaft (1). Extract the planet wheels (7)
togetherwiththeadjustment rings(5-8) androllers(6) from
theplanet wheel shaft (1).
Fitting the epicyclic reduction gear unit (ERG)
To fit the epicyclic reduction gear unit, carryout thesteps
describedfor removal inreverse order. Theoperationsand
assembly phases requiring specific tools, clearance checks,
adjustmentsor special precautionsaredescribedbelow.The
tighteningtorques aregiveninthe specific table.
Figure6/45
61176
COMPONENT PARTSOFTHE EPICYCLIC REDUCTION GEAR UNIT
Figure6/46
Whenfittingtheinternal ringsofthe bearingsand
thehubfortheslidingsleeve,theywill first needto
beheatedtoapproximately100 C for roughly15
minutes.
Fit thepins(2) ofthebearingsintheplanet wheel holder (1),
a'|o t|o ooooco a's '0' ooc|oo oo t|o |os ta||
with theholes (3) for thespringpins.
Fit thespringpins in theholes (3) andnotch them.
NOTE
Beforeputtingthesynchronizingdevicesbacktogether,check
the wear of the synchronizer rings (1) and of the coupling
bodies (3). Using a feeler gauge (2), measure the distance
betweenthesynchronizerring(1) andthecouplingbody(3)
at two oppositepoints. If the measured distance (X) is less
than1.2mm,replacethesynchronizerring(1)orthecoupling
body(3).
Do not get thechecked partsmixedup (it isrecommended
to markthem).
Figure6/47
13211
119424
71119
71410
Figure6/48
Figure6/49
Checkthe clearancebetweenthering(1) and itsseat.
The clearancehas to bebetween 0.0 and 0.1mm.
COMPONENT PARTSOFTHE EPICYCLIC REDUCTION GEARUNIT SYNCHRONIZING DEVICE
Thecirclip(1) issuppliedasasparewithadifferent
thickness.
NOTE
Figure6/50
19565
Usingthekeyingdevice99374221(1) fit theseal inthecover
(2) of thedrive output flange.
Figure6/51
Figure6/52
Figure6/53
Figure6/54
Torefittherearboxoftheepicyclicreductiongearunit,carry
out thesteps describedfor removal inreverseorder.
Theoperationsandassemblyphasesrequiringspecifictools,
clearance checks, adjustments or special precautions are
describedbelow.
The tighteningtorquesaregiven in thespecific table.
37312
Screw theeyebolts (3) onto the rear box (2), fit theropes
with hooks(4) and, with amovablelift, mount therear box
on thegearbox.
Aftertighteningthetwoscrewsfixingthedriveoutput flange
(2), fit the safety plate on them and notch it with tool
99370465 (1).
Take the gearboxoff thestand and restore theoil level.
37359
106401
Removetherear boxof theepicyclic reductiongear unit as
describedunder therelevant heading.
Dismount oil vapour vent (1) andplug(2).
Remove the splitter drivingcylinder (3) together with the
rings (4-5).
Take off the ring(9). Unscrew thenut (7) andremovethe
piston(8) fromtherod(6).
If present, disassemblethespacer ring(2) fromtheprimary
shaft (1).
Refitting the epicyclic reduction gear unit
(ERG) rear box
Removing the gearbox
119200
61178
Figure6/55
Extract thereversegear shaft (1).
61179
Figure6/56
Disassemble the tube (2) from the primary shaft (3),
ov|oos| oaso|o t|o tobo's o,oct|oo o t|o s|at
itself.
61180
Figure6/57
Unscrew screws(1) and dismount drive cover (2).
Figure6/58
Unscrew thescrews (1) andtakeoff the cover (2).
Take out thereverseidler gear (1) together with the roller
bearings (2 and 3).
Takeoffthethrust washer (4),spring(3), thrust washer (2),
adjustment ring(1) and gasket (5).
Figure6/59
Unscrew screws(1) and dismount oil pump (2).
Figure6/60
To removetheoil pump(2), do not unscrewthe
screws (4). Thesescrews securethecover (3) to
thepumpbodyandareunscrewedwhen thepart
hasbeenremovedsolelytooverhaul theoil pump.
NOTE
102655
Screws(1,Figure6/58and1,Figure6/60) must be
replaceat everydismountingoperationsincetheir
threadiscoattedwithsealingmicro capsules.
NOTE
102654
119201
Figure6/61
Fit suitablehooks (1) onto thefront cover (2) and, usinga
ropeand lift, remove it fromthegearbox (3).
61185
Figure6/62
Remove the adjustment rings (1) fromthe tapered roller
bearing(3). Takeoff thegasket (2).
Usingextractor 99340205andtool 99347092, removethe
cover centeringpins (3) in front (1) of thegear box (2).
Unscrew thescrews (4) and thenutsfixingthe front cover
(1) to thegearbox (2).
61186
Figure6/63
If necessary, loosen thesplitter shaft hardener markedwith
235N ( ), unscrew the two hexagon socket head cap
fasteningscrews(2),extract thesplittercontrol shaft (1) and
removethe relative fork(3) completewith slidingmanifold
pads.
Figure6/64
Use the eyebolt 99360502 (1) to remove the secondary
shaft (2) fromthegearbox,aftermakingsurethatit hasbeen
releasedfromthe primaryone (3).
Figure6/65
102774
119462
119199
Lift the notch of the retainingring (1) and remove the half
rings (2). Usingasuitable extractor, removethe ringinside
thetaperedroller bearing(3), extract thethrust washer (4).
37325
Figure6/66
Figure6/67
Figure6/68
Unscrew the2 screws (1) and take out thesplitter control
valve(2).
Removethegear bolt (5) together with thespringfromthe
gearbox(1).Usinganappropriatedrift,extractthetwoouter
rings(3)and(6) ofthebearings,ERGside,ofthetransmission
and main shafts. Dismount filter (4) and clean it accurately.
Clean the lubricating oil delivery pipes (2) with a jet of
compressedair.
61190
Do not dismantle thesplitter control valve (2), it
cannot be overhauled. Replace it if you find any
trouble.
Removing the main shaft
NOTE
102660
Removethemotioninput shaft.Insert thetool 99370449(1)
into the primary shaft (2) and constrain with the relative
retainingnut. Releasethecontrol rods (3) operatingwitha
suitablescrew(4) on the latch(2, Figure6/67).
Clamp tool 99370449 (1) to thehoist, lift primaryshaft (2)
and tightenit byavice.
Remove tool 99370449(1).
Figure6/69
102662
When disassembling the rods and the forks, be
sureto takenoteofthecorrect assemblyposition.
NOTE
Figure6/70
Figure6/71
Figure6/72
Fromprimaryshaft, dismount: ring(1), bearing(2), thegear
ofIVgear(3),bearing(4),couplingbody(5) andsynchroniser
ring(6).
Byan extractor made up of: bridge99341003 (1), tie rods
99341020(2), block 99345058(3), grips99341024 (6) and
clamp 99341015(5), dismount, fromprimaryshaft (4):
- gear of III gear (12);
- couplingbody(11);
- synchroniser ring(10);
- synchroniser unit (9);
- spacer ring(8);
- bushing(7).
Dismount needlebearing(13).
102663
102664
102665
71120
Figure6/73
Overturnthemainshaft intheviceandtakeoutthesplit ring
(1).
71121
Figure6/74
Takeout thereversegear (4) andtheinternal ring(6) ofthe
bearing, ERG side, with an extractor composed of: grips
99341024 (3), tierods 99341019(2), bridge99341004(1),
reaction block 99345058(7), clamp 99341015 (5).
Dismantle the synchronizer unit (1). Remove the sliding
sleeve(3) fromthehub(2),takingcareoverthepins(5) and
springs (4) comingout inorder to collect them.
71122
Figure6/75
Figure6/76
Extract thegearof 1
st
gear (5),couplingbody(4) andbushing
(3) ofthebearingofthegear ofreversegearbyanextractor
made up of: grips 99341024 (6), tie rods 99341020 (8),
bridge 99341004 (1), counter-block 99345058 (2), clamp
99341015 (7).
102666
Dismount, fromprimaryshaft (1), needle bearing(2).
Figure6/77
102667
Dismount, from primary shaft (1), needle bearing (2),
couplingbody(3).
71123
Figure6/78
Removethesynchronizingring(2) fromtheprimaryshaft(1).
Figure6/79
102786
By an extractor made up of: bridge 99341004 (1),
counter-block 99345058 (2), tie rods 99341024 (3), grips
99341024(5),clamp99341015(4), dismount:gearofII gear
(9), coupling body (8), synchroniser ring (7), synchroniser
unit (6) andbushing(10).
Figure6/80
102665
Dismantle the synchronizer unit (1). Remove the sliding
sleeve(3) fromthehub(2),takingcareoverthepins(5) and
springs (4) comingout inorder to collect them.
27469
27168
27470
19525
Figure6/81
Figure6/82
Figure6/83
Figure6/84
Figure6/85
Takeout the split ring(1) and removethe tube (2).
Takeout theretainingring(1) andthedivided ringbeneath.
61192
Tighten the drive input shaft (5) in the vice. Remove the
slidingsleeve (2) fromthehub(1) and takingcareover the
pins(3) andsprings(4) comingout inorder to collect them.
Extract thecouplingbody (5), gear (6) and internal ring(3)
of thedriveinput shaft bearingwithanextractor composed
of:
- grips 993410245(7);
- tierods 99341021 (8);
- bridge99341003 (1);
- reaction block 99345058(2);
- clamp 99341015(4).
Extract thebearings(1and2) and thesynchronizer ring(3).
Removing the drive input shaft
37326
Figure6/86
Takeoff thesplit ring(1) andusinganappropriateextractor
take out the internal ring(2) of the bearingon thesplitter
side.
Use the same method, after turningover the transmission
shaft,to extract theinternal ringof the bearingontheERG
side.
The two roller bearings of the transmission shaft
are not interchangeable. Take care to put them
asideseparatelyandtomarkthemso theywill not
get swapped over duringassembly.
Usingahydraulic press, extract thegears(3, 4 and 5) from
thetransmission shaft.
Removing the transmission shaft
NOTE
Contact surfaces between covers and gear box must not
result to be damaged or deformed. Remove any sealant
residuesfromthethreadedholesfor thescrewsfasteningoil
pumpanddriveinlet cover.
Theseats of thebearings,shaftsandgear control rodsmust
beneither damagednor too worn.
Checkthat theholes, pipesandlubricationgrooves arenot
obstructed bygrease or foreign bodies.
Bearings
Theroller bearingsor rollercagesmust beinaperfect state
of repair and show no signsof wear or overheating.
Shafts - gears
Thebearingseatsontheshaftsmust beneitherdamagednor
worn. Thegear teeth must beneither damaged nor worn.
Hubs - sliding sleeves - forks
The grooves on the hubs and sliding sleeves must not be
damaged.Theslidingsleevehastoslidefreelyonthehub.The
blocks or pins for positioningtheslidingsleevemust not be
damagedor worn. The couplingteethof the slidingsleeves
must not be damaged.
Rods - forks
Theforksmust beintegral andtheir blocksmust havenoend
float,intheradial throat of thesleeve,greater than0.6 1.2
mm.
Where fork (5) is dismounted, on mounting, adjust its
position on rod(6) asdescribed in relatingchapter.
1. Rodwithreverse gear fork- 2. Slidingblocks - 3. Rod withI-II gear fork - 4. RodwithIII-IV gear fork-
5. Splitter drive fork- 6. Rod for fork (5) - 7. Screw- 8. Rodfor fork (9) - 9. epicyclicreductionunit drive fork
102775
Figure6/87
CHECKS
Gearbox
The gearboxandits covers must have no cracks.
Figure6/88
61193
Positionthesynchronizer ring(1) onthecouplingbody(2).
Turn the synchronizer ring (1) so as to ensure correct
couplingon thecouplingbody(2).
Using a feeler gauge, check the distance A on two
diametricallyoppositepoints.
It must be no less than:
- 0.8 for thegears and splitter;
- 1.2 for theepicyclicreductiongear unit.
Synchronizing devices
Checkthe wear of thesynchronizer ringsas follows:
After the check, the synchronizer rings must be
marked on the respective gears to prevent their
position getting swapped over at the time of
assembly.
- Visuallycheckthat thefrictionsurfaceisnot undulated.
BK-type single-cone synchronizing devices
Figure6/89
61194
1. Couplingbody- 2. Synchronizer ring- 3. Compression
spring- 4. Pin- 5. Synchronizer hub- 6. Slidingsleeve.
NOTE
Figure6/90
61196
Heat the gears (5, 4 and 3) to 160 C 180 C for
approximately 15 minutes and drive themonto the shaft
usingapress.
To mount the transmission shaft, carry out the steps
adjustments or special precautions aredescribed below.
For assembly, the internal rings of the tapered
roller bearings must first be heated to
approximately 100 C for roughly 15minutes.
Mount theinternal ringofthebearing(2) onthesplitter side,
thecirculip (1) and checktheclearancebetweenthe circlip
(1) andits seat with afeeler gauge; theclearancehas to be
between0.0 and 0.1mm.
Fitting the transmission shaft
NOTE
71141
Figure6/91
Ifyouneedtoreplacethering(3) ofthedriveinput shaft(4),
to removeit use general tools, for assemblyusethekeying
device99374370 (2) andgrip 99370006(1).
Tomount thedriveinput shaft,carryoutthestepsdescribed
for removal inreverseorder.
Theoperationsandassemblyphasesrequiringspecifictools,
clearance checks, adjustments or special precautions are
describedbelow.
Fitting the drive input shaft
61197
Figure6/92
COMPONENT PARTSOFTHEDRIVE INPUT SHAFT
27249
1
2
Figure6/93
Usingafeeler gauge, checkthe endfloat of thedriveinput
gear (2), it must beat least 0.2 mm.
Inaddition,checkthetolerancebetweenthedividedring(1)
and itsseat, it has to bebetween-0.05 +0.05mm.
The divided ring (1) is supplied as a spare with
different thicknesses.
After mountingthedividedring (1), fit onto it theretaining
ringandnotch it at two diametricallyoppositepoints.
NOTE
Figure6/94
COMPONENT PARTSOFTHEMAIN SHAFT
Fitting the main shaft
102776
Figure6/95
102777
Tighten primaryshaft (1) byavice and mount, on it:
- lubricated needle bearing(2);
- gear of II gear (6);
- couplingbody(5);
- synchroniser ring(4).
Heathub(3)at 120Ctemperatureandmount it on primary
shaft (1), payingattentionthat synchroniser ringprojections
arecorrectlypositionedinto hub (3) seats.
Checkthat gear (6) axial clearanceis 0.2 mm.
Figure6/96
Figure6/97
Thesplitring(2) issuppliedasasparewithdifferent
thicknesses.
Heat taper roller bearing (3) at 100C and mount it on
primaryshaft (1).
Mount springring(2).
Check theclearance between the split ring(2) andits seat
withafeelergauge.Theclearancehastobebetween0.0and
0.1mm.
NOTE
Mount slidingsleeve (2) on hub (1). Fit, into hub (1) seats:
springs (3) and pins (4) adjustingthemunder slidingsleeve
(2).
Heat bushing(5) at 120 C andmount it on primaryshaft.
102778
102779
Mount, onprimaryshaft (1):
- synchroniser ring(7) insuchawaythat projectionsare
fit into hub(2) seats;
- couplingring(6);
- gear of I gear (4).
Heat toothed ring (3) at 120 C and mount it on primary
shaft (1).
Checkthat theaxial clearanceof gear of Igear (4) is0.2mm.
Figure6/98
102780
Heat bushing(2) at 120Candmount it onprimaryshaft (1).
- gear(3) of reversegear.
Figure6/99
102781
Checkthat theaxial clearanceof gear (4) ofreversegear is
0.4 1.15mm.
Figure6/100
61203
Determineribringthicknessfor gear ofIVgear,operatingas
below.
MeasurethedistanceAbetweentheendoftheshaft (1) and
theseat (2) supportingthetapered roller bearing.
Mount the thrust washer (3) and measure the distance B
betweenthisandtheend of themain shaft (1).
ThedifferenceA- Bmust bebetween+0.07and-0.08mm..
Ifadifferent valueisfound,replaceribring(3) byanotherone
havingsuitable thickness.
Adjusting the main shaft
102782
Put primaryshaft (1) upsidedown.
For the operation, usetool 99370449. NOTE
- gear of III gear (6);
- couplingbody(5);
- synchroniser ring(4).
Heathub(3) at 120Ctemperatureandmount it onprimary
shaft (1), payingattentionthat synchroniser ringprojections
arecorrectlypositionedinto hub (3) seats.
Checkthat gear (6) axial clearanceis 0.2 mm.
Figure6/101
102783
Mount slidingsleeve (2) on hub (1). Fit, into hub (1) seats:
springs (3) and pins (4) adjustingthemunder slidingsleeve
(2).
Figure6/102
102784
Mount, onprimaryshaft (1), spacer ring(3).
Heat bushing(2) at 120Candmount it onprimaryshaft (1).
Mount:
- synchroniser ring(10) insuchawaythat itsprojections
arepositioned into hub(4) seats;
- couplingbody(9);
- gear ofIVgear (7),completewithrollerbearings(6and
8);
- spacer ring(5).
Figure6/103
Figure6/104
Figure6/105
61205
Assembletheadjustmentring(1) havingathicknesssetinthe
previous measurements.
Mount thebearing(3), previouslyheatedto 100 C.
Mount thedividedring(2) whosethicknessproducesanend
float for it inits seat of -0.05 +0.05mm.
Mount theretainingring(1) andnotchit atseveral pointsthe
samedistance apart under thedividedring(2).
Checkthat theaxial clearanceof gear of IV gear (4) is 0.05
mm.
102785
To mount the gearbox assembly, carry out the steps
adjustments or special precautions aredescribed below.
The tighteningtorquesaregiven in thespecific table.
The flat gaskets should be fitted dry, without any jointing
compoundor grease.
Before fitting the twin-lipped seals, fill the gap
betweenthetwo lips withTUTELA MR3.
Any rings and seals, ringnuts, spring pins, safety
plates and self-lockingscrews found to be worn
and all parts that are not fully efficient or are
scored, dented or deformed must be replaced at
thetimeof assembly.
Threadofscrewsfasteningoil pumpanddriveinlet
cover is originally coated with sealing material;
therefore, screws must bereplaced bynewones
at everydismountingoperation.
Fitting the gearbox
NOTE
Figure6/106
102662
Heat bearings (3 and 6) seats at 60 C temperature and
mount bearings outer rings with handgrip 99370007 and
knocker 99374093.
Mount oil filter (4), pipings (2) and latch (5) with relating
spring..
Figure6/107
Figure6/108
Figure6/109
Clamp the primary shaft (2) in a vice and introduce tool
99370449 (1) into it and constrain it using the related
retainingnut. Hookthe tool 99370449(1) to the lifter and
lift theprimaryshaft (2) andinsert it insidethegear box(3),
being careful to assemble the rods and forks in the same
position measured during the disassembly phase. Using a
suitablescrewinsertedinthe gear boxhole, push thelatch
sothat therodscanbeinsertedintheir correspondingseats
71126
Usetheeyebolt 99360502(1) tolift thesecondaryshaft (2)
andinsert it,afterproperlymovingtheprimaryone,insidethe
gear box.
Mount tool 99370450 (2) on gearbox. For gearboxes 16 S
1920/2220/2520 tool 99370450 (2) must be provided with
spacer (3) havingfollowingthickness:
- 16 S1920/2220=13.8mm.
- 16 S2520=13.5mm.
Insert thesplitterdriveforkcontrol rodandsecureit bymeans
of nut (1).
Adjusting splitter drive fork
Usingthe two socket-head screws (2), position thesplitter
control fork(1) sothat thetwoslidingblocks(4) arecentred
inthethroat of theslidingsleeve. Usetwo feeler gauges(3)
for this purpose.
After makingthe adjustment, tightenthetwo screws (2) to
therequiredtorque.
Screw the splitter control rod setscrew onto the gearbox,
tighteningit to therequired torque.
Taketheadjustment tool 99370450(2,Figure6/109) out of
the gearbox together with the spacer (3) after unscrewing
thenut (1, Figure6/109).
Figure6/110
119301
119302
119426
Adjusting the transmission shaft bearing end
float
Todismantletheoil pump:unscrewthescrews(1),takethe
cover (2) off the pump body (5) and extract fromthis the
external (3) andinternal (4) rotors.
To reassembly, carryout thesesteps in reverseorder.
61208
Figure6/111
534010 Oil pump
Applyalight layer of LOCTITE 574onthemating
surfaceof thecover (2).
Figure6/112
DeterminethethicknessSof therings(2, Figure6/114) for
adjustingtheend float of the transmissionshaft bearing(2)
asfollows:
- Turntheshafts andcheckthat theouter ring(2) ofthe
bearing rests without any clearance on the bearing
rollers.
- MeasurethedistanceA betweentheplaneof thefront
box (1) and the outer ring (2) at two diametrically
oppositepoints.
Figure6/113
61210
Measure the depth B of the seat of the bearing (2,
Figure6/113) onthepump body (1).
The thickness Sof theadjustment ring(2) is determinedby
thefollowingequation:
S=[ B - (A - C)] - D
Where:
- A - B, measurements taken;
- C, thickness of gasket;
- D, end float of 0- 0.1 mm.
NOTE
61185
Position anewgasket ongear box (2).
Mount front cover (1).
Screw screws (4) without fully tightening them, fully fit in
centering pins (3) and tighten screws (4) with prescribed
torque.
Figure6/114
102787
102774
Figure6/115
Mount oil pump (2) complete withadjustingring(2).
Screw new screws (1) and tighten themwith prescribed
torque.
Figure6/116
61212
To replace theseals (1) andbushings (2), usegeneral tools
to remove- fit them.
To fit the seal (5) usethe keyingdevice 99370420 (4) and
grip99370006 (3).
530511 Drive input shaft cover
Figure6/117
Determine the thickness S of the driveinput shaft bearing
adjustment ringas follows:
- Turnthedriveinput shaft andcheck that theouter ring
(1) restswithout anyclearanceorpre-loadontherollers
of the internal ringof thebearing.
- Measuretheprotrusionofthebearing(1) fromtheplane
of thefront cover (2), distanceA.
Figure6/118
61214
- Measure the depth B of the seat of the bearing (1,
Figure6/118) onthecover (2).
The thickness Sof theadjustment ring(1) is determinedby
thefollowingequation:
S=[ B - (A - C)] - D
Where:
- A - B, measurements taken;
- C, thickness of gasket;
- D, end float of 0- 0.1 mm.
Figure6/119
Mount new gasket (2).
Position adjusting ring (1), by thickness determined in
previous measurement, on the outer ring of taper roller
bearing(3).
102789
119202
Figure6/120
Mount cover (1).
Screw new screws (2) and tighten themwith prescribed
torque.
71127
Usetool 99345097to assemblethetube (3) intheprimary
shaft and check that its projection is equal to what was
measured upon disassembly (if this information is not
available, check that the tube penetrates approx. 10 mm
inside the box).
Mount thespacer (5) onthemainshaft (4),positiontheseal
(6) in theseat of thesplitter drivingcylinder.
Positionthecut of thering(7) bythehole( ).
Mount theseals (8 and 9) on the cylinder (6) andlubricate
them.
Fit thecylinder (6) in thegearbox.
Position thetool 99370450 (1) onthegearbox (3) so as to
keepthecylinder (6) in the seat. Supplythesplitter control
valve(2,Figure6/68)withcompressedair (max.6.8bars) and
listentochecktheinternal pistonworksandtherearenoair
leaks.
Takeoff thetool 99370450 (1).
Mount rod positioningpegs.
Refit theepicyclicreductiongear unit boxasdescribedunder
therelevant heading.
Replenish the gearbox with lubricating oil of the required
gradeand quantity.
NOTE
102655
Mount new gasket (5).
Mount: adjusting ring (1) having the thickness that was
determinedinpreviousmeasurement, ribring(2),spring(3)
and rib ring(4).
Figure6/121
102790
Figure6/122
61180
Put gear boxupside down.
Mount gear of reversegear transmission(1) completewith
needlebearings(2and3).Mount theshaftforgearofreverse
gear.
Figure6/123
61179
Mount cover (2) with anew gasket, screw screws (1) and
tightenthemwithprescribedtorque.
Figure6/124
6
Recover theadjustment ringsfromthe stator and
fromtheepicyclicassemblyshaft bearing.
NOTE
Revi - June2007
GEARBOXESZF 16S1621T.D.- 2221T.D.- 2521T.O. 23 TRAKKER EURO 4/5
Base- November 2006
Print 603.93.641/A
PRINT603.93.641/A
ZF gearboxes
with Intarder, hydraulic retarder,
types:
ZF 16S 1621T.D.
ZF 16S 2221T.D.
ZF 16S 2521T.O.
Page
MAIN DATA 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGTHEGEARBOX 32 . . . . . . . . . . . . .
- Removingthehydraulicretarder fromthe
gearboxonthestand 32 . . . . . . . . . . . . . . . . . . . .
- Refittingthehydraulic retarder 34 . . . . . . . . . . . .
- Recordingthebearingendclearanceofthe
epicycloidal reductionunit 33 . . . . . . . . . . . . . . . .
- Removingtheepicyclicreduction
gear unit (ERG) 35 . . . . . . . . . . . . . . . . . . . . . . . .
- Component parts of theepicyclic
reductiongear unit 35 . . . . . . . . . . . . . . . . . . . . .
- Refittingtheepicyclic reductiongear unit
(ERG) rear box 40 . . . . . . . . . . . . . . . . . . . . . . . .
24 GEARBOXESZF 16S1621T.D.- 2221T.D.- 2521T.O. TRAKKER EURO 4/5
Base- November 2006
Print 603.93.641
PRINT603.93.641
Base- November 2006
Print 603.93.641
PRINT603.93.641
MAIN DATA
GEARBOX WITH INTARDER
16S1621 T.D. 16S2221 T.D.
16S2521 T.O.
Maximumbrakingtorque Nm 3000
Brakingcapacity kW 420
Typeof oil
TutelaTruckFE-Gear
TutelaZC 90
Typeof oil
Quantityafter overhauling l
gearbox and retarder drained
completely kg
18.5
16.5
21.5
19.5
71142
Figure1
GEARBOX ASSEMBLY WITH RETARDER
The technical data, tighteningtorques and procedure for overhaulingthe gearboxdiffer fromthe 16 S1620T.D.
- 16 S2220T.D. - 16 S2520 T.O. gearboxinthe following.
NOTE
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PRINT603.93.641/A
TOOLS
99322205 Rotarystand for overhaulingassemblies
99322225
Standforsupportingassemblies(tobefittedonstand99322205)
99340205 Puller withslide-hammer
99341004
Single-actingbridge
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99341015 Clamp
99341018 Pair of bracketswithhole
99341019 Pair of tie rods with grips
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99341022 Grips
99341024 Grips
99341025 Grips
99342143 Pin to extract reverse gear shaft (usewith99340205)
99345058 Extractor reactionblock
99345097 Reactiontool to extract sun gear and drive in main shaft oil pipe
Revi- June2007
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99347092
Pin to extract gearbox front andrear centringpins
99370006
Gripfor interchangeable drifts
99370007
99370113 Drift to mount seal and/or bushings on gearbox
99370415 Dial gaugestand to adjust transmissionshaft bearingend float
(usewith 99395604)
99370420
Keyfor fittinggasket ongearboxfront cover
(usewith 99370006)
Revi- June2007
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99370449 Hook to lift main shaft
99370450 Tool to adjust splitter control fork
99370465 Tool to notch safetyplates
99370565 M10 eyebolts (2) for liftingvarious assemblies
99370629 Mount to support gearboxwhenremovingandrefittingit on the
vehicle
99371050 Brackets to support gearbox when overhauling (use with
99322205- 99322225)
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PRINT603.93.641/A
99374093
Drift tomount external bearingraces( 91 134mm) (usewith
99370007)
99374221
Keyto fit gasketsonrear cover
99374370
Keytofit oil deflector on direct driveshaft (usewith99370006)
99395604 Dial gauge(0 10mm)
PRINT603.93.641
Revi- June2007
Figure2
Figure3
Figure4
If applicable, remove the four nuts (2) fixing the heat
exchanger (1) to thehydraulicretarder (3) and detach the
heat exchanger (1).
Remove thescrew(1) andthe washer (2) beneath. Extract
theplug(3) with theseal (4), oil filter (5) and magnet (6).
Drainanyoil that ispresent.
Block rotation of the sleeve (2) by applying the lever
99370317(1) to it andremovethescrews (3),disc (5) and
underlyingseal (4).
70934
70936
43196
Fit thebrackets 99371050 (3) onto the assembly.
Usingropeswith hooksandamovable lift, put theassembly
on therotarystand99322205 (2) together withthemount
99322225 (4).
Take off the plug(5) and drain the lubricatingoil fromthe
gearbox.
Take off the plug(1) and drain the lubricatingoil fromthe
hydraulic retarder.
Removing the hydraulic retarder from the
gearbox on the stand
Figure5
102791
Figure6
Using an extractor composed of thebridge 99341003 (3),
brackets 99341018 (2) and reaction block 99345058 (4),
removethe sleeve (1) fromtheshaft (5).
78344
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PRINT603.93.641/A
530210 OVERHAULING THE GEARBOX
Revi- June2007
Figure7
Figure8
Removethescrews(2)fixingthehydraulicretarder (1)tothe
rear box (3).
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2).
With special ropes and lifter, detach the hydraulic retarder
(2) fromthe rear box (4).
Remove thegasket (3).
Prior to reattachment determine the thickness of the ball
bearingend clearanceadjustment ringas follows:
102792
119427
Refitting the hydraulic retarder
Figure9
Figure10
- measurethedistancebetweenthematingsurface(1) of
thehalfboxdeceleratorandthebearingsupportsurface
(1, Figure9): dimension B;
- measure the thickness of the gasket between the
decelerator andthetransmission: dimensionC.
Thickness S of adjustment ring is given by the following
equation:
S=[B+C - A] - G
where:
- B- C - A =measuredvalues
- G =0.1 mm: ball bearingend play (1, Figure 9) (0 to
0.1mm).
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2)
and lift it with ahoist.
Fit anewgasket (3) ontherear box (4).
Mount thehydraulicretarder (2) ontherearbox (4) making
surethat thegasket (3) gets positioned correctly.
44005
119427
Recording the bearing end clearance of the
epicycloidal reduction unit
78321
Determine theball bearingend clearance adjustment shim
(1) as follows:
- measuretheprojectionofthebearing(1) fromtherear
boxsurface(2): dimension A.
Figure11
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Revi- June2007
Figure12
Figure13
Figure14
Screwdownthescrews(2) fixingthehydraulicretarder (1) to
therear box (3) andtighten themto theprescribedtorque.
Heat theflange(2) toapprox. 80 C andfit it onto thespider
shaft (1).
Fit onanewseal (5),thedisc(4),screwdownthescrews(3)
and tightenthemto theprescribed torque.
99370317 (3) and tighten the fixing screws (2) to the
prescribed torque.
70948
70949
102794
Figure15
Figure16
Figure17
Position themagnet (6) onthefilter (5) andinsert this into
thehydraulic retarder. Fit theplug(3) with anewseal (4).
Screwdown thefasteningscrew(1) with thewasher (2).
Fit twonewseals(2) onthehydraulicretarder(3) andmount
theheat exchanger (1) (if applicable).
Screwdownthefour nuts(2) fixingtheheat exchanger (1) to
the hydraulic retarder (3) and tighten themto theprescribed
torque.
70936
70955
70934
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Revi- June2007
43798
Figure18
43799
Figure19
Remove the hydraulic retarder as described under the
relevant heading.
Takeoffthefittings( ) and disconnect thepipes (1and3)
fromthecylinder (4).Removethecylinder (4) fromtheERG
rear box (2).
Removethenut (1) and extract thepiston(2) fromtherod
(3).
37353
Figure20
Using the percussion extractor 99340205 (2) and part
99342143(3),extracttwoofthethreecentringpinsfromthe
ERG rear box (1).
43801
Figure21
Here wedescribethesteps to remove and fit the
ERG epicyclic reduction gear unit that differ from
theones given for gearboxeswithout theIntarder.
Removetheseal (5),gasket (4),switch(3),pushrod(2) and
retainingpush rod 145N (6) fromtheERG rear box (1).
Take out the screws fixing the ERG rear box (1) to the
gearbox (2). Fasten the retaining plate (3) to the shaft (4)
withtwoscrews. Usingaropeand hydrauliclift, removethe
ERG box (1) fromthegearbox (2).
43802
Figure22
(ERG)
(ERG) rear box
NOTE
Thearrowsshowtheoutsidepinstoextract;there
isathirdpin inside.
NOTE
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Revi- June2007
Figure23
Placetheepicycloidal reduction unit (2) ontheworkbench
anddisassemblethetwoG.R.E.control knucklejoint pins(1)
(8, Figure 24) .
Remove the intarder oil pumpintake pipe (3).
Figure24
36804
Using the extractor composed of bridge 99341003(1), tie
rods99341018 (3) andblock99345058 (2) fitted onto the
ERGbox,asshowninthefigure, extract thebearing(5) and
thebox (6) fromtheERG shaft (4).
Figure25
61216
Using the extractor composed of bridge 99341004 (1),
brackets 99341012 (2), part 99345058 (4) and clamp
99341015 (3), extract thegear (6) fromtheERGshaft (5).
Takeoff theplate (7) with thetube(8) for lubrication.
Figure26
61217
Whileextractingthem,holdbacktherod(7) tothen
takeit out of thebox (6) when it is freed fromthe
fork (8).
Takethefork(8) withitsblocksout oftheslidingsleeve(9).
Remove the fifthwheel bearing(2) fromthe gear (1).
Figure27
61218
Takethesynchronizerring(1) out of theslidingsleevehub.
NOTE
119428
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61219
Figure28
Takingcareovertheblocks(5) andsprings(3and4) coming
out ofthehub(1),extracttheslidingsleeve(2) fromthehub
and removetheseal (6).
Figure29
61221
Extract hub(6) forslidingsleevefromepicyclicreductionunit
shaft ( 5) with extractor made up of bridge 99341003 (1),
brackets99341021(2),counter-part99341058(3) andgrips
99341025 (7) clamp 99341015(4).
61220
Takeoff thesynchronizerring(1) andthecouplingbody(3)
together withtheplate (2).
Levering under the coupling body (3), extract it fromthe
plate(2).
Figure30
Figure31
COMPONENT PARTSOFTHE EPICYCLIC REDUCTION GEARUNIT SYNCHRONIZING DEVICE
*
102795
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61253
Figure32
Figure33
71128
COMPONENT PARTSOFTHE EPICYCLIC
REDUCTION GEARUNIT
COMPONENT PARTS OF THEERGCONTROL AND BOX
1. Gasket - 2. ERG - 3. Plate- 4. Bushing- 5. Fifthwheel bearing- 6. Gear - 7. Gasket - 8. Slidingblocks- 9. Fork -
10. Nozzle tube- 11. ERG box - 12. Pinfor fork articulationwith washer - 13. Gasket - 14. Cover - 15. Screw- 16. Ball
bearing- 17. Adjustment ring- 18. Plugwith seal - 19. Plugwith seal - 20. Sensor - 21. Screwwithwasher - 22. Cylinder -
23. Seal - 24. Seal - 25. Nut - 26. Seal - 27. Spacer ring- 28. Piston - 29. Seal - 30. Rod- 31. Tube- 32. Pin.
Remove the epicyclic reduction gear unit as described for
gearboxes with no Intarder.
*
*
61222
Figure34
Remove theball bearing(1) fromtheERG box (2).
Unscrew thescrews (3) and removethe cover (4).
Unscrew thescrew (5).
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61254
Figure35
43806
Figure36
Position the plate(2) together with the tube (3) on theERG
(4).
Heat theseat oftheball bearing(1) ontheERGrear box(2)
to approx. 60C and mount theball bearing(1).
43812
Figure37
Placeanewgasket (7) on theplate(6).
Partiallyfit theball bearing(3) with thebox (4) on theERG
shaft (2).
Insert therod (9) into itsseat inthebox (4).
Positionthe fork (8) in theslot of theshaft (9) and keepit
inthispositionuntil theassembly of the ball bearing(3) on
the shaft (2) has been completed, heating the seat of the
latter.
Checkthattheplateslots(6) coincidewiththoseoftheplate
(2, Figure 35), otherwise, the epicycloidal reduction unit
(G.R.E.) rear box cannot bereattached.
61223
Figure38
When fitting the bearing (3), guide the tube (5)
withapunch(1) so it goes intoitsseat ( ) inthe
box (4).
Set thefork (2) with itsblocks on theslidingsleeve(1).
Constrainthefork (2, Figure37) to theboxusingtwo joint
pins (1), andtighten themto theprescribedtorque.
Insert the intarder oil pump intake pipe (3) into the
appropriateseat.
Figure39
Heat thegear (1) toatemperatureof160C forno
longer than10sec.
Fit thegear (1) on theERG shaft (3).
NOTE
NOTE
119428
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61224
Figure40
Put anew gasket onthegearbox (2) andrefit the ERGrear
box (1).
Fit the two centringpins ( ) and tighten the fixingscrews
(6) to therequiredtorque.
Mount the cover (3) with a new gasket and tighten the
screws (5) to the required torque.
Screwdown theplug(4).
37353
Figure41
Changetheseals(4and6), spacer ring(5) of thepiston (3)
and lubricatethem.
Fit the piston (3) onthe rod (1) and tightenthe nut (2) to
therequiredtorque.
43815
Figure42
Insert thepushrod(2) intothegearboxandfittheswitch (3)
with thewasher. Mount theretainingpush rod 145N (6).
Lubricatetheseal (5),gasket (4) andmount themonthebox
(1).
Lubricate theinsideof thecylinder (7), fit it on thebox (1)
and tightenthefixingscrews (6) to therequiredtorque.
Connect the pipes (2 and 4) to the cylinder (7), screwing
downthefittings(3and5) withnewwashersandtightening
themto the required torque.
Reconnect hydraulic decelerator as described in relating
chapter andfill the unit with oil by prescribed quantityand
quality.
43802
Figure43
Refitting the epicyclic reduction gear unit
(ERG) rear box
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Revi- June2007
Revi - June2007
GEARBOXEuroTronic12AS1420T.D. 41 TRAKKER EURO 4/5
Base- November 2006
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PRINT603.93.641/A
Gearbox
Euro Tronic 12AS 1420T.D.
Page
DESCRIPTION 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OFGEARBOX DESCRIPTION
PLATE 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 46 . . . . . . . . . . . . . . . . . . . .
TOOLS 46/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGTHE GEARBOX 46/6 . . . . . . . . . . . . . .
- Checks 46/6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Preliminaryworks 46/6 . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH ACTUATOR 46/6 . . . . . . . . . . . . . . . . . . . . . . .
- Clutchactuator removal 46/6 . . . . . . . . . . . . . . . . . .
- Clutchactuator reassembly 46/7 . . . . . . . . . . . . . . . .
GEARBOX ACTUATOR 46/7 . . . . . . . . . . . . . . . . . . . . .
- Gearboxactuator removal 46/7 . . . . . . . . . . . . . . . . .
- Gearboxactuator reassembly 46/8 . . . . . . . . . . . . . .
REARBOX 46/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rear boxremoval 46/8 . . . . . . . . . . . . . . . . . . . . . . .
- Rear boxdisassembly 46/9 . . . . . . . . . . . . . . . . . . . . .
- Synchronizer disassembly 46/11 . . . . . . . . . . . . . . . . . .
- Synchronizer assembly 46/11 . . . . . . . . . . . . . . . . . . . .
SATELLITEHOLDER SHAFT 46/12 . . . . . . . . . . . . . . . . . .
- Satelliteholder shaft disassembly 46/13 . . . . . . . . . . . .
- Satelliteholder shaft assembly 46/14 . . . . . . . . . . . . . .
- Rear boxassembly 46/15 . . . . . . . . . . . . . . . . . . . . . . .
- Output cover assembly 46/15 . . . . . . . . . . . . . . . . . . .
- Output flangeassembly 46/16 . . . . . . . . . . . . . . . . . . .
CLUTCH CASING 46/16 . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCONNECTINGFORK 46/16 . . . . . . . . . . . . . . . . . . . .
Revi - June2007
42 GEARBOXEuroTronic12AS1420T.D. TRAKKER EURO 4/5
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Page
- Disassembly 46/16 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 46/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblyof thefront cover 46/16 . . . . . . . . . . . . .
- Disassemblyof theoil pump 46/17 . . . . . . . . . . . . . .
- Clutchcasingremoval 46/17 . . . . . . . . . . . . . . . . . . . .
- Disassemblyof theinput shaft 46/18 . . . . . . . . . . . . .
- Shaft removal 46/18 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblyof themainshaft 46/19 . . . . . . . . . . . . . .
SPLITTERCONTROL FORK 46/21 . . . . . . . . . . . . . . . . . .
- Disassembly/Assembly 46/21 . . . . . . . . . . . . . . . . . . .
GEARCONTROLFORKS 46/21 . . . . . . . . . . . . . . . . . . . .
- Disassembly 46/21 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 46/21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECONDARY SHAFT 46/21 . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 46/21 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 46/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assemblyof themainshaft 46/22 . . . . . . . . . . . . . . . .
- Assemblyof themotioninput shaft 46/23 . . . . . . . . .
- Rear boxassembly 46/24 . . . . . . . . . . . . . . . . . . . . . .
- Rear boxdisassembly 46/24 . . . . . . . . . . . . . . . . . . . .
GEARBOX CASING 46/24 . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 46/24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 46/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Shaft reassembly 46/25 . . . . . . . . . . . . . . . . . . . . . . . .
- Clutchcasingreassembly 46/26 . . . . . . . . . . . . . . . . .
- Adjustment of theaxial clearance of bearings of the
motion input shaft and of thesecondaryshaft 46/27 .
- Adjustment of theaxial clearanceofthemotion input
shaft 46/28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjustment of thesecondaryshaft axial clearance 46/29
- Assemblyof thefront cover 46/29 . . . . . . . . . . . . . . .
Revi- June2007
GEARBOX EuroTronic 12AS1420T.D. 43 TRAKKEREURO 4/5
Base- November 2006
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PRINT603.93.641/A
DESCRIPTION
The EuroTronicgearbox 12AS1420 T.D. is mechanical with electro-pneumatic control.
The driver can choosewhether to programgear selection/engagement manuallyor automatically. The shafts and gearshave
helical toothingthat reducesoperatingnoise.
The main shaft gear couplingisobtained withsleeveswithfront toothing.
The splitter andepicyclic reductiongear unit engagement is synchronized.
Thespeedsareselectedwithfinelystaggeredratiosandcanbeengagedinsuccessionwiththecouplingoftheepicyclicreduction
oa oo|t '||C' aoo t|o 'S||tto' s|o. o ast sooo oo|t.
Co ooa|o t|o '||C', t|o sooos o t|o a|o s|at ao ooob|oo. T|o at| os obta|ooo |o t||s .a ao ot|o ooob|oo .|t| t|o
ooaooot o t|o 'S||tto'. |ac| s|o|o at|o |s t|os o|v|ooo |oto a ast o s|o. at|o.
T.D. = Truck Direct drive
Figure1
112211
B = ZF drawingno.
C = Production sequencenumber
E = Transmission gear ratio
44 GEARBOX EuroTronic 12AS1420T.D. TRAKKEREURO 4/5
Base- November 2006
Print 603.93.641
PRINT603.93.641
Figure2
LONGITUDINAL SECTION WITH INTEGRATED OVERRUN BRAKEANDOIL PUMP
112212
Revi- June2007
GEARBOX EuroTronic 12AS1420T.D. 45 TRAKKEREURO 4/5
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PRINT603.93.641/A
MAIN DATA
GEARBOXES
EuroTronic Automated
12AS1420T.D.
Type Mechanical
Torqueactivated Nm 1400
Forward gears
Reverse gears
12
2
Typeof runningcontrol electronically-operated semi-automatic
Rear power takeoff optional
Gear engagement:
E.R.U.* and splitter engagement
byfront engagement sleeves
freeringsynchroniser
Gears constantlyengaged straight toothed
Gear ratios
1
st
2
nd
3
rd
4
th
5
th
6
th
7
th
8
th
9
th
10
th
11
th
12
th
1
st
reversegear
2
nd
reversegear
12.384
10.369
8.428
6.487
5.176
4.182
3.009
2.480
1.920
1.951
1.238
1.000
13.072
10.561
Typeof oil
- 1
st
filling Litres
kg
TutelaTruckFe-Gear
TutelaZC 90
9.3
8.3
* ERG = Epicyclicreductiongear unit
T.D. = Truck Direct Drive
Revi- June2007
46 GEARBOX EuroTronic 12AS1420T.D. TRAKKEREURO 4/5
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Print 603.93.641/A
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Screwsfixinggearboxactuator 23 2.3
2 Screwsfixingcover 46 7.9
3 Screwsfixingclutch actuator 23 2.3
4 Screw cap to discharge air fromclutch actuator 22 2.2
5 Screwsfixingrear boxto middlebox 50 4.6
6 Screwsfixingrear cover 46 4.6
7 Screwsfixingflange retainingplate 79 7,9
8 Speedsensor 45 4.5
9 Screwsfixingmiddleboxto front box 50 5
ScrewplugM10x1 on rear box 606 1.5
ScrewplugM24x1 on rear box 606 6 0,6
120500
Figure3
GEARBOXEuroTronic 12AS1420T.D. 46/1 TRAKKEREURO 4/5
PRINT603.93.641/A
TOOLS
Hot air device
99305121
99322205
Rotarystand for overhaulingassemblies
99322225
Mount to support assemblies (to fit onto stand 99322205)
Percussion extractor
99340205
99341003
Single-actingbridge
99341011
Pair of brackets
46/2 GEARBOX EuroTronic 12AS1420T.D. TRAKKEREURO 4/5
Revi- June2007 Print 603.93.641/A
99341013
Pair of brackets
99341015
Clamp
99341017
Pair of bracketswithhole
99341021
Pair of tie rods with grips
99341025
Grips
99342143
Pin to extract gearbox front andrear centringpins
(usewith 99340205)
PRINT603.93.641/A
99345054
Extractor reactionblock
99348004
Universal puller for inner sides from5 to 70mm
99366811
Set of M10 eyebolts (3) to removeandrefit gearboxes
99370006
99370007
99370172
Tools (6) to mount gearbox epicyclic reduction gear train
synchronizer rings
99370317
Reactionlever withextension to fasten drive output flange
99370415
Dial gaugebaseto adjust transmission shaft bearings (usewith
99395604)
99370465
Tool to notch safetyplates
99374092
Drift to mount outer racesof bearings (69- 91)
(usewith 99370007)
99374093
Drift to mount external bearingraces( 91 134 mm)
(usewith 99370007)
99374221
Driver to mount seals on back cover
99374336
Driver to fit seals on the front cover of thegearbox (usewith
99370006)
99395604
Dial gauge(0 - 10mm)
120464
120465
Unscrewtheplug(1) anddrainoil into aproper container.
!
Beforeoverhauling, washtheassemblyaccurately
Thespecificand/orgenericequipmenthastobeused
inthewayit is designed for.
Tomakeassemblyeasier,put awaythedisassembled
components inthe provided trayaccordingto their
disassemblyorder.
Duringassembly, the followingcomponents shall be
alwaysreplacedwithnewones:gaskets,sealingrings,
plungers, safetyplates and springs. Nuts and screws
shall betightenedaccordingto thepreset torqueand
their threadingshall bedryanddegreased.
As regards lubricant and detergent disposal, see the
specific standards.
Duringtheoverhaul,alwaysuseprotectiveglovesto
handle heated components.
Checks
Gears, synchronizing rings, coupling bodies and sliding
sleeves for couplingshall not to showfailuresor excessive
wear of teeth.
The mainshaft shall not haveanynotch, aboveall on the
slidingsurfaceof gear couplingand rotatingslidingsleeves.
Pins of the reverse counter gear shall have asmooth and
groove-freesurface.
Gearboxesshall not havecracksand bearingseatsshall not
bedamagedo wornout inorder to prevent bearingouter
rings fromrotatingintheir seats.
Make sure that shoulder spacers are not worn out or
damaged.
The gear coupling forks shall not show cracks and the
related control rods have to slide freely, but without a
significant clearance, intheguideseats.
Makesurethat control fork shoes areperfectlyefficient.
Makesurethat lubricationholes, groovesandpipesarenot
cloggedbygreaseo foreignmatters.
Make sure that bearings are not worn out, damaged or
overheated.
Preliminaryworks
Figure4
Figure5
CLUTCH ACTUATOR
Clutch actuator removal
Cut offconnectionsoftheelectric wiringfromthegearbox
actuator (1) andfromthe output revssensor (2).
Loosen thescrews (4) beforeremovingthe hexagonnuts,
complete with washers. Then remove the clutch actuator
(3), completewith hexagon-head screws.
Remove theprotectivecover (5).
Removethespherical push rod(6) fromthedisconnecting
fork (7).
Theadjustment ofthepushrod(6) isdescribed
intheclutch sectionof this manual
NOTE
120465
120467
Figure6
Figure7
Assemble the clutch actuator (3) onto the gearbox. Make
surethat connections areinthe correct position.
Insert thescrews into the (4) actuator andtightenthefour
hexagon nuts, complete withwashers, accordingto theset
torque (23Nm).
Loosen the screw on the actuator and let the piston
protrude. Duringthis operation, check the correct housing
of thepushrod (6) inthedisconnectingfork (7).
Tighten thescrew accordingto theset torque (22Nm).
Assemble the cover (5).
Connect theelectricwiringtotheclutchactuator (3), tothe
gearbox actuator (1) andto the output revs sensor (2).
Removethescrews(1) andcut out theactuator (3) andthe
relatedgasket. (4)
Remove the compression springs (6) andthe stop pins(7).
Replacethetwo cylindrical pins (5), if damaged.
Clutch actuator reassembly
The electronic control unit is built-in in the
actuator. These components cannot be
overhauled.
NOTE
GEARBOX ACTUATOR
Gearbox actuator removal
Donot bendthecableandmakesurethat it isnot
too taut.
Avoidanyfriction point.
Makesurethat connectorsareinserted correctly.
Make sure that the oil vapor breather (2) is not clogged,
otherwisecleanit.
120468
120469
Figure8
Figure9
Position anewgasket onthe clutch casing(4).
Lubricate the solenoid valve stems (3-4-5) with silicone
greaseandset themto neutral position.
Positiontherods(8-9-10) inneutral position.
Insert thestop pins (12) and thecompression springs (11).
Put thegearboxonto two squarepiecesofwood, fromthe
friction housingside.
Gearbox actuator reassembly
The gearbox has not to lay on the tang of the
motioninput shaft.
With extractor 99340205 and pin 99342143 remove the
centeringpins(1).
Remove thehexagon-headscrews (2) of therear box.
Compression springs (11) shall have the same
length(abt. 50 mm).
NOTE
Before cutting-out the rear box, disassemblethe
gearboxactuatorandtheidleswitch,asdescribed
intheprevious paragraphs.
NOTE
Assemblethe actuator (1) onto the front box (7), making
sure that the ends of the solenoid valve stems are exactly
positioned in the rod seats (8-9-10). Tighten the fastening
screws (2) accordingto theset torque (23 Nm).
REAR BOX
Rear box removal
Figure10
120470
120471
120473
120474
Figure11
Figure12
Figure13
Figure14
Figure15
Bymeans of special ropesand lift, removecarefullytherear
box (1), completed with the epicyclical reduction gear
assembly (GRE).
Holdthecontrol rod (2).
Remove thethrust washer (1).
Remove themagnet (2) and cleanit.
Removethescrews(3), thedisc(2) and theflange(1) from
thesatelliteholder shaft.
If removal is difficult, use the bridge 99341003 (4) and the
brackets 99341017 (5), which are so applied as in the
followingfigure.
Removethescrews(1) anddisconnect theoutput cover (2).
Removetheradial sealingring(3) bymeansofaproper tool,
without damagingtheoutput cover.
Fasten thetwo eyebolts 99366811 (1) to the output flange
(2).
The control rod (2) is not fastened to the control
arm. If not held, it might fall.
Remove the control rod(2) fromthecontrol arm.
120472
Rear box disassembly
120475
COMPONENT PARTSOFTHE REAR BOX
Figure16
120476
120477
Figure17
Figure18
With apress, removethe satelliteholder shaft (1) fromthe
supporting roll bearing (2). Turn the rear box (3) upside
down.
Pushdownwardstheslidingsleeve(3) andthesynchronizing
ring(4) (to idle position).
During this operation, pawls and compression
springs of thesynchronizer might comeout.
NOTE
45946
120478
1\20479
Figure19
Figure20
Figure21
Figure22
Removethediscclutch(2)andthecouplinghub(1) fromthe
box.
Disassemblethesafetyring(3),whichisinstalledbetweenthe
disc clutch(1) and the couplinghub (2).
Under press, disassembleroll bearingfromtherear box.
Disassemblesupports(2) fromthebox.
Remove the shoes (5) fromtheslidingsleeve (3).
Remove thecontrol arm(1) and therelatedsupports.
Remove theshoes (5) fromthecontrol arm(1).
Put aclothontothesynchronizerassembly(1)sothat,during
its disassembly, springs (5) and pawls (4) are held while
comingout fromtheir seats.
70855
Insert springs (2) and pawls (3) into the synchronizingring
seats (1) andfasten themwithtools99370172 (4).
Synchronizer assembly
70856
Position the synchronizingring (2) onto the synchronizing
ring(3) sothat theycanbeassembledontotheslidingsleeve
(1). Assemble the synchronizer assembly (1) onto the
coupling body with the annular groove ( ) facing
downwards.
Figure23
Synchronizer disassembly
70854
1. Synchronizer assembly- 2. Synchronizer ring- 3. Sliding
sleeve- 4. Pawl - 5. Spring- 6. Synchronizingring
Remove the tools 99370172 (4) only when
explicitlyrequiredbytheassemblyproceduresin
thefollowingsections.
NOTE
MAIN COMPONENTSOF THE SATELLITEHOLDER SHAFT
Figure24
120480
SATELLITE HOLDER SHAFT
120481
120482
120483
120484
120485
Figure25
Figure26
Figure27
Figure28
Figure29
Remove the safetyring (1), for example bymeans of two
small screwdrivers and removethecrown (2) as well.
Tightenthe safetyring(1) withpliers. Removethecoupling
hub (2) byliftingit frominside, as shown inthefigure.
Remove thesafetyring(3).
Pre-tighten the shoulder ring (4, Figure 29), the roll thrust
bearing(3, Figure29) andtheBellevillespring(2, Figure29)
intwo 180 shiftedpoints.
Use the most suitable locking device (1) (an example is
shown inthefigure).
Remove pins(2) fromsatellitegears (1).
Remove carefullythesatellitegears (1), completewithrolls
and washers.
Remove theextractor (1, Figure27), the shoulder ring(4),
theroll thrust bearing(3) and the Bellevillespring(2) from
Remove the oil pipe (1), if damaged.
Satellite holder shaft disassembly
!
Whendisconnected, the crown(2) might fall.
The locking is used to pre-load the Belleville
spring and make the satellite gear disassembly
easier (1, Figure28).
NOTE
120486
120487
120488
120489
Figure30
Figure31
Figure32
Figure33
Removewashers(1and4) andwashersandrollers(2) from
thesatellitegears (3).
Spreadgreaseonthesatellitegear hole(3) andinsert all rolls
(2) withtherelated washers (1and4).
Withpliers,tightentheendsofthesnapring(1)andassemble
thecouplingbody(2) onto theG.R.E. shaft.
Insert carefullythepre-assembledsatellitegears(4) into the
satelliteholder shaft.
Insert carefullyleveled pins (5) into the respective holes of
Assemble the snap ring(3) makingsure that it is correctly
housed in the groove of thesatelliteholder shaft.
Remove the tool used for the pre-loadingof the Belleville
spring(2, fFigure31).
Put thecrown(1)ontothesupport andassemblethesatellite
holder shaft (2)
Fastenthecrownwiththesafetyring(3).
The lengthof satellitegear, satellite holder shaft
and thethicknessof washersvaries accordingto
thegearboxtype.
NOTE
Satellite holder shaft assembly
AssembletheBellevillespring(2),theroll thrust bearing(3)
and the shoulder ring (4) on the satellite holder shaft, if
damaged, andfastenthen asdescribed in disassembly.
Fasteningisusedto pre-loadtheBellevillespring
and makethesatellitegear assemblyeasier.
NOTE
Make sure that the safety ring (3) is housed
correctly in the groove provided in the crown
bottom.
NOTE
120490
120492
120478
120493
120494
Figure34
Figure35
Figure36
Figure37
Figure38
Heat the seat of thebearing (1) of therear box (2) at 120
C and assemblethebearing(1).
Rotatetherear box and put it ontwo supports.
Assemble the coupling hub (1) and the disc clutch (2)
completewithsafetyring(3) into rear box.
Assemble the previously assembled synchronizer set (3)
onto thecouplingbody (2).
Remove thetools (1) 99370172.
Assemble theshoes (6) into thecontrol arm(8) andinsert
theminto theslidingsleeve (4).
Heattheinnerring(5,figure37) oftheroll bearingat abt.120
C temperature.
Insert the satellite holder shaft (1) into the heated roll
bearing, makingsurethat it reachedtheaxial beat.
Turntherear box (2) andassemble theremainingparts:
Withlockingset 99374221(1), assemblethesealingring(2)
into the cover (3).
Fit the cover (3) on the rear box and fully tighten the
hexagonal head screws(4).
Tighteningtorque=46 Nm
Rear box assembly
Tomakeassemblyeasier,sticksupports(7) inthe
rear boxwithLoctite no. 241.
NOTE
Output cover assembly
120495
120497
120496
120498
120499
Figure39
Figure40
Figure41
Figure42
Figure43
Heat theoutput flange (1) at max. 160C temperatureand
push it onto the satellite holder shaft teeth to the axial
contact.
Assemble the disc (2) and tightenthescrews (3) according
to theset torque.
Screwthetransmitters(1and2) accordingtotheset torque.
Fasten the gear transmission (1) to the support brackets
99322225 (3), which are arranged on the rotary stand
99322205 (2).
Remove the two hexagon head screws (2).
Removethedisconnectingbearing(1) andthedisconnecting
fork (3) fromthemotioninput shaft.
Removethefasteningscrews(1and3) andremovethefront
cover (2), thecover (4) andthe diaphragm(5).
Remove theadjustingrings(7, 8) and the gasket (6).
Output flange assembly DISCONNECT ING FORK
Disassembly
Assembly
Disassemblyof the front cover
Greasethebearingsurfacesofthedisconnectingbearing(1).
Assemble thebearing(1) andthe disconnectingfork (3) so
that it meshesthebearing.
Torque-tighten thescrews(2).
Tighteningtorque=115Nm
CLUTCH CASING
120501
120502
120503
120504
120505
Figure44
Figure45
Figure46
Figure47
Figure48
Remove thepump cover (3) and remove theshaft (2) and
therotor (1) fromtheconnectingplate.
Remove the oil collectingdiscs (4) fromtheinput shaft (2).
Removethebrakepiston(1) andremovethediscs(3and4),
takingnoteof their arrangement.
Replacethecylindrical pins, if damaged (2).
Put thefront cover (3) ontotwosupports,asshowninfigure.
Remove the pipe (2) under press usinga suitable torque
block. Removethe O-ring(4) andthe sealingring(5) from
thepipe. (2).
With extractor 99340205 and pin 99342143, remove the
centeringpins(1).
Remove the screws (2) fastening the clutch casing to the
gearbox.
Fasten two eyebolts 99366811 (1) to the clutch casing. By
means of special ropes and lift, carefullyremove the clutch
casing(2).
Disassemblyof the oil pump
Clutch casing removal
120506
120509
120507
120510
120511
120512
Figure49
Figure50
Figure51
Figure52
Figure53
Figure54
Removethecomponent (2) andtheoil pipe(1),ifdamaged.
Movelaterallythe intermediate gear (4) of the reverse, so
that it doesnot interferewith other gears.
Remove themotion input shaft (1) completewith fork (2)
and splitter control rod(3).
Bymeansof special ropesandlift, carefullyremovethemain
shaft (1) completewithcontrol rod(3) andforks(2),moving
thesecondaryshaft laterally.
Remove the secondaryshaft (1) fromthegearbox.
Remove thereversegear (2) complete withrolls.
Put aclothontothesynchronizerassembly(1)sothat,during
disassembly,springs(2) andpawls(3) areheldwhilecoming
out fromtheir seats.
Disassembletheslidingsleeve (4).
Insert holds99341025betweenthecouplinghub(6) andthe
synchronizing ring (5). With the tools 99341021, 9934103
and 99341015, remove the conical roll bearing (2) and
remove the motion input shaft, according to the following
order:phonicwheel (3),helical gear (4),couplinghub(6) and
synchronizingring(5).
Disassemblyof the input shaft
Shaft removal
120513
120514
Figure55
Makesurethat therubber edgeof theoil collectingdisc (1)
isnot damagedor spoiled. In this case, replaceit.
If necessary, removethesafetyring(2) and thecover (3).
Make surethat thehole of the electric pin (4), used for oil
feeding, is not clogged.
Figure56
Disassemblyof the main shaft
MAIN SHAFT MAJOR COMPONENTS
120515
120519
120518
120520
120521
Figure57
Figure58
Figure59
Figure60
Figure61
Vicetighten themain shaft.
Remove thesafetyring(1) and couplinghub (4), complete
with thesynchronizingring(3).
With the bridge 99341003, the brackets 99341011, the
reaction block 99345054 and the tightener 99341015,
removethe conical roller bearing(2).
Remove theshoulder ring(1), thethird gear (3), complete
with roll crowns, (2and4) andtheslidingsleeve (5).
Rotatethemainshaft (1) andvicetightenfromtheinput side.
Remove thesafetyring(5)
torqueblock99345054andthepress99341015removethe
first gear (2).
Fromthe main shaft, remove the bushing (5), the sleeve
holder (3) and the roll cage (1).
Rotatethemainshaft and vicetightenit.
With brackets 99341017, bridge 99341003 and press
99341015, removethesecond gear (4).
Fromthemainshaft,removethebushing(1),thedisc(2),the
sleeveholder (3) and theroll cage (5).
torque block 99345054 and the press 99341015 remove
thereverse gear (4) withthebearing(5)
Remove the roll cage (3) andthe slidingsleeve (2).
Revi- June2007 Print 603.93.641
PRINT603.93.641
120522
120523
120524
Figure62
Figure63
Figure64
Remove the small block (2) fromthe splitter synchronizer
connectingfork(1) and assemblethenew small blocks.
Removetheinnerrings(5and10) oftherollerbearingsfrom
the secondaryshaft (9), usingthe extractor 99347100 (1),
the holds 99347132 (4), the insert 99345057 (10) and
suitablebrackets (2).
Remove under pressthe doublegear (7) andthe gear (8).
Do not change the control forks (1) and (4). If
necessary, check the serial numbers of the
packinglist.
NOTE
Disassembly
Positionthering(3) onto thecontrol shaft.
Insert the control forks (1 and 4) into the ring correct
position.
Theremoval forceofeachgearcanreach500kN. NOTE
SPLITTER CONTROL FORK
Disassembly/Assembly
GEAR CONTROL FORKS
SECONDARY SHAFT
Disassembly
Releaseand removethecontrol forks (1) and(4).
Removethering(3) hinderingthesimultaneouscouplingof
thecontrol shaft (2).
PRINT603.93.641/A
120525
120526
120527
Figure65
Figure66
Figure67
Heat thegears(3and4) at amaximum170C temperature.
Put theheatedgearsoneon another onapress andcenter
themas shown in thefigure.
Insert thesecondaryshaft (5) ontotheheatedgearsandset
it rapidlyto axial beat.
Assemble the safetyring(2).
Heat theinner ringsof theconical roll bearings(1and6) for
15minutes at amaximumtemperaturerangingfrom120to
130 C. Assemblethemonto thesecondaryshaft checking
theaxial beat.
Insert the sliding sleeve (2) onto the sleeve holder (4,
Figure66)
Lubricatetheroll cage (3) andpushit onto the bushing (5,
fFigure 66).
Assemblethereversegear (4),insertingit ontotherollcrown
(3) and the main shaft, respectively. The drivingteeth have
to facethesleeve holder (4, Figure66).
Heat theinner ringoftheconical roll bearing(5) formax.15
minutes at atemperature rangingfrom120 to 130 C and
assembleitonthemainshaft,makingsurethat it reachedthe
axial beat.
By means of a thickness gauge, measure the safety ring
thickness(6).
Choosethesafetyring(6) inorder to get anaxial clearance
rangingfrom0and0,1 mm.
Assemble the chosensafetyring.
Rotatethemainringof 180.
Vicetighten themain shaft (1).
Lubricate theroll cage (2) and pushit on theshaft.
Assemble thegear of the first gear (3) makingsure that its
drivingteeth are facingthemotion output.
Assembly
Assemblyof the main shaft
Heat thesleeveholder (4) at 120C temperatureandpush
it onto theteeth of themaingear.
Heat thebushing(5) at 120C andassembleit onthemain
shaft.
120528
120518
120529
120513
Figure68
Figure69
Figure70
Figure71
Lubricate the roll cage (5) and assemble it onto the main
shaft.
Assemblethegearofthesecondgear (4) ontothemainshaft.
Heat thesleeve holder (3) at abt. 120 C temperatureand
pushit ontotheteethofthemainshaft until theaxial contact
isreached.
Heat thedisk(2) andthebush(1) toatemperatureofabout
120 C andpush themontheshaft (6),until theyreachthe
axle.
Heat theinner ringoftheconical roll bearing(2) formax.15
minutesat atemperaturerangingfrom120and130C and
pushinontothemainshaft until theaxial contact isreached.
With athicknessgauge, measurethethicknessof thesafety
ring(1).
Chooseasafetyringallowingtoget anaxial clearanceranging
from0 to 0,1mm.
Assemble the chosensafetyring.
Assemblethecouplinghub(4) andthesynchronizingring(3)
onto the shaft.
Makesurethat theplunger (4) is assembled.
Assemblethecover (3) and thesafetyring(2).
Insert the oil collectingdisc (1) into themotion input shaft
to theaxial beat.
Assemble the slidingsleeve (5) onto the sleeve holder (3,
Figure68).
Lubricatetheroll crowns(2and4) andinsert themontothe
gear (3).
Assemblethegear set, completewith roll crowns, onto the
bushing(1, Figure 68).
Assembletheshoulder ring(1) onto the main shaft.
Assemblyof the motion input shaft
120530
120531
120532
120533
Figure72
Figure73
Figure74
Figure75
Assemblethesynchronization ring(2) andthecouplinghub
(3) onto theshaft (1).
Lubricate the gear inner track (4) and assemble the latter
onto the input shaft.
Thedrivingteethfacedownwardsandmeshtheinnerteeth
of thecouplinghub.
Assemble thephonicwheel (5).
Heat theinner ringoftheconical roller bearing(6) at 120C
and assemble it onto the input shaft, making sure that it
reached theaxial beat.
With athicknessgauge, measurethethicknessof thesafety
ring(7).
Chooseasafetyringallowingtoguaranteeanaxial clearance
rangingfrom0to 0,1mmandassemble it onto themotion
input shaft (1).
Remove theplug(1) fromthegearbox (4).
Incase of bearingreplacement, remove theouter rings(3,5
and 6) bymeans of asuitableextractor.
Removetheoil pipe (2) byextractingit towards theoutput,
takingnoteof its position for afollowingre-assembly.
The projections of thesynchronization ringface
downwards and have to insert into theholes of
thesynchronizinghub.
NOTE
Rear box assembly
Assembletheslidingsleeve (6) onto themotioninput shaft
(5) andset it to beat.
Assemble the synchronizer as described in the specific
chapter,completewithsprings(4),pawls(3),ring(7),hub(8)
and assemble it onto the shaft.
Set theslidingsleeve (6) to central position.
Assemble the oil collectingdiscs (1 and 2).
Rear box disassembly
GEARBOX CASING
Disassembly
Remove the plug(2) fromtheclutchcasing(1).
Ifbearingsarereplaced,removetheouterrings(3) bymeans
of asuitableextractor.
Screw the plug (2) with a new sealing ring and
tightenit accordingto theset torque (60Nm).
Bymeansofasuitabletool,assembletheouterrings
(3) of thebearings.
Re-assemble the cylindrical pins (4), if previously
removed.
120535
120534
120509
120536
Figure76
Figure77
Figure78
Figure79
Heat evenlytheseat oftheconical roll bearings(5)
and (6) in the gearboxat 100C.
Assemble the outer rings (5 and 6) in the related
seats, bymeansof asuitabletool, to theaxial beat.
Heatevenlytheseat ofthemotioninputshaftat100
C and, bymeansofasuitabletool,insert theouter
ring(3) of thebearingto theaxial beat.
Fasten the outer ring (3) caulking it in four
equidistant points.
Assembletheoil pipe(2) insertingitfromtheoutput
side, according to the position observed during
disassembly. If necessary, replacethe pipeO-rings.
Greaseproperlythe O-rings andtheir seats.
Screw the plug (1) with a new sealing ring and
tightenit accordingto theset torque (60Nm).
Insert thespacer (2) and the roll crowns (1 and 3) into the
reverse gear (4).
Assemble the complete reverse gear into the gearbox (6)
and push it laterally.
Assemblethesecondaryshaft (1) into thebox (2).
Hook themain shaft (1) asshowninthefigureand insert it
into the box, complete with control rod (3), forks (2) and
sleeves.
Movelaterallythesecondaryshaft to make theinput of the
mainshaft into thegearboxeasier.
Make the reverse gear mesh the main and secondaryshaft
ones.
Assemblethemotioninput shaft (1),completewithfork(2)
and control rod of thesplitter (3).
Assembly
Shaft reassembly
Make sure that the oil pipe (5) is assembled
correctlyin the gearbox.
NOTE
Figure80
Insert partiallythecylindrical pins(1) andtorque-tightenthe
fasteningscrewsof theclutchcasing(50Nm).
Completetheinsertionofthecylindrical pins(1) to theaxial
beat.
120504
Sealingsurfaceshaveto becleanandwithout oil
and grease.
NOTE
120537
Figure81
Apply two guides on the oil pipes (2) to make coupling
betweentheclutch casing(1) andthegearbox (3) easier.
Cleanthebox sealingsurfaces.
Clutch casing reassembly
Spreadthesealingsurfaceofthegearbox(3) withLoctiteno.
574.
Laycarefullytheclutchcasing(1) onto thegearbox (3).Use
theoil pipe guide for centering.
Makesurethat pipes(1and3) arecorrectlyassembledinthe
clutchcasing(leveled with the surface).
Figure82
Adjustment of theaxial clearanceof bearingsof themotion input shaftand of thesecondaryshaft
Maketheinput shaft rotateforwardsandbackwardsseveral timestoaligntheconical rollersofthebearingandmaketheouter
ringcontact.
|o ooo to ca oot ao,ostoots oosc|boo |o t|o o||o.|o aos, ao |o|t|a| 'oo|| c|oaaoco' |s ooo|oo.
With apin, make the outer rings of thebearings contact theconical rolls.
Bymeansof asharp object, make surethat bearingrolls do not move.
Clearance is null whentheconical rollsarestill, dueto no pre-load. NOTE
120538
Adjustment of the axial clearance of the
motion input shaft
120539
120540
120541
Figure83
Figure84
Figure85
With athickness gauge, measure thedistance between the
boxsealingsurfaceandtheupperedgeof thebearingouter
ring.
With adepth gauge, measure the depth of the step in the
front cover.
Height D
Measurethethicknessof thetube plate.
2,00+2,20+0,35- 2,50=2,05mm
Theconical roll bearingof themotioninput shaft
isadjustedwith apre-load rangingfrom0,25 to
0,35mm.
NOTE
Height A
Height B
Measurethegasket thickness.
Height C
A =2,00 mm
B=2,20 mm
C =0,35 mm
D =2,50 mm
A +B +C - D =S
Thickness with minimum pre-load:
S1 =2,05 mm+0,25mm=2,30 mm
Thickness with maximum pre-load:
S2=2,05mm+0,35mm=2,40 mm
The thickness S of the adjustingringshall be chosenamong
the spare available ones in the interval of calculated
thicknesses S1S2.
Assemble thechosenadjustingthickness.
S=ratedvaluewithnull clearance
Example
120542
120543
120544
Figure86
Figure87
Figure88
With athickness gauge, measure thedistance between the
upper board of the bearingouter ringand the box sealing
surface.
Measure between the pump cover upper edge and the
sealingsurfaceof the front cover.
7,55- 0,20+0,35- 6,80 =0,90 mm
Theconical roll bearingof thesecondaryshaft is
adjusted with a pre-load rangingfrom0,15 and
0,25mm.
NOTE
Adjustment of the secondary shaft axial
clearance
Height E
Height F
Measurethegasket thickness.
Height C
Calculation example:
E =6,80 mm
F =0,20 mm
G=7,55 mm
C =0,35 mm
G - F +C - E =S
Thickness with minimum pre-load:
S1 =0,90 mm+0,15mm=1,05 mm
Thickness with maximum pre-load:
S2 =0,90 mm+0,25mm=1,15 mmm
The thickness S of the adjustingringshall be chosenamong
the spare available ones in the interval of calculated
thicknesses S1 S2.
Assemblethechosenadjustingthickness.ssemblethechosen
adjustingthickness.
Assemblyof the front cover
Figure89
120545
Height G
Measurebetweenthepumpcover upper edgeandthefirst
step.
LightlygreasetheO-ring(2) andinsert it onthefront cover
(1).
S=ratedvaluewithnull clearance
Figure90
Assemble the pipe(1) under press.
120547
NOTE
120546
Figure91
Withlockingset 99374336(1),assemblethesealingring(2).
Observe the overall height A =31.50 mm0.30 mm.
Assembleonto theplate, therotor (1), the pump shaft (2)
and thepumpcover (3).
Mount theoil collection disks (4).
Figure92
Cleanthecouplingsurfacesofthefront cover (1) andofthe
clutch casing.
120548
All sealing surfaces and threaded holes M10 on
theclutchcasinghaveto becleanandwithout oil
and grease.
NOTE
Put thegasket (2) onto theclutchcasing.
Assemble the previouslyset adjustingrings(3) and (4).
Figure93
120501
- Moistenwithalcohol the outer circumferenceof the
sealingring.
- The ringsealingedgehas to faceoutwards.
- Lightlygreasetheringseal lip.
Tightenthefasteningscrews(2) accordingto theset torque
(46 Nm).
Figure94
Moistentheplatefasteningscrews(1) Loctiteno.
241.
NOTE
120549
Figure95
Assemblethefront cover (1) onto theclutchcasing(3).
Replacethecylindrical pins (4), if damaged(4).
Assemble the discs (5 e 6) according to the arrangement
shown inthefigure.
Assemble the brake piston (3), the diaphragm(2) and the
brakecover (1).
Tightenthecoverscrews(1) accordingtotheset torque(46
Nm).
120550
Revi- June2007
GEARBOXESEuroTronicAutomated12AS1930T.D.- 2330T.O. 47 TRAKKEREURO 4/5
PRINT603.93.641/A
Gearboxes
EuroTronic Automated:
- 12AS 1930 T.D.
- 12AS 2330 T.O.
Page
DESCRIPTION 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF GEARBOX
DESCRIPTION PLATE 49 . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX ELECTRONIC MANAGEMENT 50 . . . . . .
MAIN DATA 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 52 . . . . . . . . . . . . . . . . . . . .
TOOLS 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING-REFITTING GEARBOX 55 . . . . . . . . . . . .
- Removal 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGTHEGEARBOX 56/1 . . . . . . . . . . . . . .
- Checks 56/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Gearbox actuator 56/1 . . . . . . . . . . . . . . . . . . . . . . .
- Removal 56/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 56/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingtherear box 56/2 . . . . . . . . . . . . . . . . . . .
- Removingtherear box 56/3 . . . . . . . . . . . . . . . . . . .
- Removingtheepicyclic reduction gear train
(E.R.G.) 56/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingtheepicyclic reduction gear train(E.R.G.) 56/6
- Adjustingepicyclicreduction gear train bearingend
float 56/7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjustingmain shaft end float 56/8 . . . . . . . . . . . . . .
- Synchronizingdeviceassemblyfor engaging
normal or reduced gears 56/10 . . . . . . . . . . . . . . . . . .
- Removal 56/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 56/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingthemiddlebox 56/13 . . . . . . . . . . . . . . . . .
48 GEARBOXESEuroTronicAutomated12AS1930T.D.- 2330T.O. TRAKKEREURO 4/5
Print603.93.641/A
Page
- Removingthemainshaft 56/15 . . . . . . . . . . . . . . . . .
- Removingthedriveinput shaft 56/17 . . . . . . . . . . . .
- Removingthesplitter synchronizingdevice 56/18 . . .
- Fittingthe splitter synchronizingdevice 56/19 . . . . . .
- Fittingthe driveinput shaft 56/20 . . . . . . . . . . . . . . .
- Fittingthe main shaft 56/20 . . . . . . . . . . . . . . . . . . . .
- Splitter control fork 56/23 . . . . . . . . . . . . . . . . . . . . .
- Disassembly - Assembly 56/23 . . . . . . . . . . . . . . . . . .
- Gear control forks 56/23 . . . . . . . . . . . . . . . . . . . . . .
- Removal 56/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 56/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingthe middle box 56/24 . . . . . . . . . . . . . . . . . . .
- Transmissionshafts 56/24 . . . . . . . . . . . . . . . . . . . . .
- Disassembly - Assembly 56/24 . . . . . . . . . . . . . . . . . .
- Fittingthe front box 56/27 . . . . . . . . . . . . . . . . . . . . .
- Front cover 56/29 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 56/29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingthe front cover 56/29 . . . . . . . . . . . . . . . . . . .
- Adjustingdriveinput shaft bearingendfloat 56/29 . .
- Adjustingtransmissionshaft bearingend float 56/30 .
- Clutch releaselever 56/32 . . . . . . . . . . . . . . . . . . . . .
Revi- June2007
Eurotronic Automated gearboxisan electrical-pneumaticdrive mechanical typegearboxelectronicallymanagedbycentral unit.
It has twelve forward gears and two reversegears.
Gears selectionandengagement functionsareactuated bythehelp of an electroniccentral unit controllingclutchhandlingand
oo|oo 's oo|o oa s||t. /oooat|c oov|co |os|oo t|o oabo oocoasos socoooa s|at 's ac|||tat|o oa ooaooot.
Allgearboxfunctionsaremanagedbyanelectroniccentral unit,whichreceivessignalsfromvariouselectricalandelectronicsystems
aboard viaCAN lineandcontrolsvariouscomponentsoptimisingmanoeuvres and managingmanoeuvres safety.
The driver can choosewhether to actuategear selection manuallyor in semiautomatic mode, or to usecompletelyautomatic
management.
With semiautomaticoperation, thedriver engages the variousgears veryeasilybydrivingtheselector lever,without needingto
release accelerator pedal.
With automaticoperation, thedriver onlydrives accelerator or brakepedal; thegearsareengagedautomatically.
The gears are selected with finely shifted ratios and can be entered successively. Positioned in gearbox rear side is G.R.E.
(Epicycloidal Reducer), that canbeinsertedbyaslidingsleeveshift. Theslidingsleeveallowsto double front boxratiosnumber.
Soc| oobo cao bo ot|o o|t||| oo v|a 'S||tto' ooaooot. |ac| s|o|o at|o coosooooot| oso|ts to bo s||t |oto ao o|t|o
s|o. o ast at|o. T|o ooaooots o C.|.|. aoo 'S||tto' ao soc|oo|soo.
A displayunit oninstrument panel warns about each systemoperation, as well asanyoperation faults.
Figure1
112203
B = ZF drawingno.
C = Production sequencenumber
E = Transmission gear ratio
Print 603.93.641 3aso |ovobo 2006
DESCRIPTION
PRINT603.93.641
BC = BodyComputer
ICB = Instrument Cluster Bus
VDB = Vehicle DataFrame
ECM = EngineControl Module
ECB = EngineControl Bus
EM = Expansion Module
MET = Electronic Chassis Module
Figure2
112442
Revi- June2007
PRINT603.93.641/A
GEARBOX ELECTRONIC MANAGEMENT
Theoretical scheme
Revi- June2007
PRINT603.93.641/A
MAIN DATA
GEARBOXES EuroTronic
12AS1930T.D. 12AS2330T.O.
Type Mechanical
Torque
activated
Nm
1900 2300
Forward gears
Reverse gears
12
2
12
2
Typeof runningcontrol semiautomatic/automaticwithelectronicmanagement
Sideand/or rear power
take-off
optional
Gear clutch :
Splitter andG.R.E clutch.*
through synchroniser frontal clutchsleeveswithfree ring
Gears with epicyclicteethconstantlymeshing
Gear ratios
1
st
2
nd
3
rd
4
th
5
th
6
th
7
th
8
th
9
th
10
th
11
th
1
st
reversegear
2
nd
reversegear
15.86
12.33
9.57
7.44
5.87
4.57
3.47
2.70
2.10
1.63
1.29
1.00
14.68
11.41
12.33
9.59
7.44
5.78
4.57
3.55
2.70
2.10
1.63
1.27
1.00
0.78
11.41
8.88
Typeof oil
- 1
st
filling Litres
kg
TutelaTruckFe-Gear
TutelaZC 90
12
11
* ERG = Epicyclicreductiongear unit
T.D. = Truck Direct Drive
T.O. = Truck Over Drive(Multiplied)
Revi- June2007
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Screwsfixinggearboxactuator 23 2.3
2 Screwfixingoil pump 10 1
3 Screwsfixingdriveinput shaft cover 23 2.3
4
Screwfixingclutch uncouplinglever control pin:
- M 12 8.8
- M 12 10.9
79
115
7.9
11.5
5 Screwsfixingcover (spread LOCTITE241onthethread) 79 7.9
6 Screwsfixingclutch actuator 23 2.3
7 Screw cap to discharge air fromclutch actuator 22 2.2
8 Screwsfixingrear boxto middlebox 46 4.6
9 Screwsfixingflange retainingplate 120 12
10 Screwsfixingrear cover 5 4.6
11 Speedsensor 45 4.5
12 Screwsfixingmiddleboxto front box 50 5
Pin on rod(spreadLOCTITE 262onthethread) 23 2.3
Oil vapour vent 10 1
ScrewplugM10x1 on rear box 15 1.5
ScrewplugM24x1 on rear box 60 6
ScrewM12fixingpower take-off baycover 79 7.9
ScrewplugM24x1.5 on middle box 60 6
Screwfixingplates retainingforkjoint pins on rear box 23 2.3
117518
Figure3
Revi- June2007
TOOLS
Hot air device
99305121
99322205
Rotarystand for overhaulingassemblies
99322225
Mount to support assemblies (to fit onto stand 99322205)
99341003
Single-actingbridge
99341013
Reactionblock
99341015
Clamp
Revi- June2007
99341018
Pair of bracketswithhole
99345057
Extractor reactionblock
99345078
Extractortoremovedriveinput shaft bearing(usewith99345105)
993450998
Inserter to fit bearingon main shaft, rear side and to insert rear
flangeof gearbox
99345105
Extractor for gearbox drive input shaft bearing (use with
99345078)
99347100
Small extractor (usewithspecific rings with 99347132)
GEARBOXESEuroTronicAutomated12AS1930T.D.- 2330T.O. 54/1 TRAKKEREURO 4/5
PRINT603.93.641/A
TOOLS
99347132
Ringgrips to extract gearbox transmission shaft bearings (use
with 99345057- 99347100)
99360323
Tool to turndriveinput shaft whenrefittingthegearboxtothe
engine
99360526
Tool to extract andinsert mainshaft (usewith99360527) and
to drive in gearbox drive input shaft bearing (use with
99345098)
99360527
Tool retaininggearboxmainshaft forks(usewith99360526)
99366811
Set of M10 eyebolts (3) to removeandrefit gearboxes
99370006
54/2 GEARBOXESEuroTronicAutomated12AS1930T.D.- 2330T.O. TRAKKEREURO 4/5
99370007
99370153
Tool forpositioningmainshaft whenremovingthetransmission
shaftsandfor retaininggearbox reversegear pins
99370172
Tools (6) to mount gearbox epicyclic reduction gear train
synchronizer rings
99370317
Reactionlever withextension to fasten drive output flange
99370415
Dial gaugebaseto adjust transmission shaft bearings (usewith
99395604)
99370499
Guides(no.3) tomount Splittersynchronizingdeviceassembly
99370629 Mount tosupport gearboxwhenremovingandfittingitbackon
thevehicle
99374092
Drift to mount outer races of bearings (69 - 91) (use with
99370007)
99374221
Driver to mount seals on back cover
99374336
Driver to fit seals on the front cover of thegearbox (usewith
99370006)
99395604
Dial gauge(0 - 10mm)
73651
Figure4
To removethegearbox, proceed asfollows:
- set thevehicleover apit or onalift;
- disconnect the battery cables to avoid any possible
short-circuiting;
- removeanysound-proofingguardsthat maybefittedon
theengineandthe entryboards;
- drainenginecoolant;
- disconnect the wiring via the connectors ( ) and
disengage it fromanyclamps;
- disconnecttheelectrical connections(3) and(18)onthe
electronic control unit;
- disconnect theair supplypipe (19);
- * disengagethewater deliveryand return pipes (4and
12) fromthesleeves (1) ontheengine;
- * disconnect the water deliverypipe (4) viathesleeve
(13) anddisengageit fromanyclamps on thegearbox;
- * disconnect the water return pipe (12) viathesleeve
(16) (det. C) and disengage it fromanyclamps on the
gearbox; removethe air pipe(17) too;
- disconnect theair pipe (7) of theservo-clutch cylinder
(8) (det. A);
- remove the fasteners (9) (det. A) of the servo-clutch
cylinder and extract it fromthegearbox;
- disconnect the drier air discharge pipe (10) fromthe
discharge pipe(11) (det. B);
- remove the outlet pipe (11) disconnecting it fromthe
associated collars on the silencer and turbine and
disengagingit fromthefastener on thechassis frame;
- put a hydraulic jack fitted with the mount 99370629
under thegearbox and slingthegearbox mount;
- removethescrews(6) (det.A) fixingthecrosspiece(5)
to thechassisframeandremovethecrosspiece;
- disconnectthepropellershaft (15) usingthescrews(14)
aoo astoo |t to t|o vo||c|o's c|ass|s ao so |t .oo't
interfere withthe removal of thegearbox;
- takeout thescrews(2) fixingthegearboxto theengine;
- takethegearbox out of itsseat.
Removal
There follows adescription of the operations for
removing-refitting a gearbox with Intarder that,
barring the asterisked operations, hold for the
gearboxwithout intarder too.
Ifthecrossmemberofthechassisframepreventsyou
fromremovingthegearbox,youneedtodrainoffthe
oil fromthe intarder; takeout thenuts and screws
fixingtheheat exchangertotheintarder,removethe
studboltsand detachtheheat exchanger.
For gearboxes with intarder, proceedas follows: apply
LOCTITE510 onto thethreadof thestud boltsfixing
the heat exchanger and screw then onto the
gearbox; connect the refrigerant fluid pipes to the
heat exchanger and replenish the gearbox with the
required amount of oil; fill the engine coolingsystem
as described inSection 2Engine.
Carryout theoperations described for removal in
reverseorderandtightenthefixingnutsandscrews
Refitting
NOTE
NOTE
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
530210 REMOVING-REFITTING GEARBOX
56 GEARBOXESEuroTronicAutomated12AS1930T.D.- 2330T.O. TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Figure4/1
Checks
The gears, synchronizer rings, coupling bodies and sliding
couplingsmust shownosignof failureor excessivetoothing
wear.
The main shaft must haveno indentation, especiallyon the
slidingsurfacesof thegear rotationandcouplingsleeves.
Thereverseidlegearshaftsmust haveapolishedsurfacefree
fromscoring.
Thegearboxesmust shownosignofcrackingandthebearing
seats must be neither damaged nor worn, so as to prevent
theouter rings of the bearings fromturningin their seats.
Checktheshoulder spacersareneither worn nordamaged.
The gear couplingforks must show no sign of crackingand
therelevant control rodsmust slidefreely, but without any
appreciable play, in their guide seats.
Checkthat theshoes of thedriveforks arefullyefficient.
Checkthat theholes, grooves and lubrication pipes arenot
obstructed bygrease or foreign bodies.
Checkthe bearings arenot worn, damagedor overheated.
530210 OVERHAULING THE
GEARBOX
!
Wash theassemblythoroughlybeforeoverhauling.
Thespecificand/orgeneral toolsmust beusedinthe
wayfor which theyweredesigned.
Tofacilitateassembly,put theremovedpartsawayon
thespecific trayin their order of removal.
Upon assembly, the following must always be
replacedwithnewparts:thegasketsandseals,spring
pins,safetyplatesandsprings.Nutsandscrewsmust
be tightened to the prescribed torque with their
thread dryand degreased.
Keep to the specific regulations when disposing of
lubricant anddetergents.
530520 Gearbox actuator
Removal
Unscrew the ringnut (1 and 5) and disconnect theelectric
wiring(2) fromthespeed sensor (6and7).
Detach the wiring(2) fromthe clips ( ) securingit to the
middlebox.
Remove thenuts (4) and detachthe actuator (3) fromthe
front box.
Figure4/2
78649
78650
Fasten the gearbox (1) to brackets 99322225 (3) on the
rotatingstand 99322205(2).
Remove the plugandbleed thelubrication oil.
PRINT603.93.641/A
70828
70863
70830
Figure4/3
Figure4/4
Figure4/5
Figure4/6
Set anew gasket (6) on thefront case (7).
Lubricate the stems of the solenoid valves (3-4-5) with
siliconegreaseandput theminto aneutral position. Put the
rods(8-9-10) into aneutral position.Fit theactuator (1) on
thefront box (7) verifyingthat the endof thestems of the
solenoidvalvesiscorrectlypositionedintheseatsoftherods
(8-9-10). Tighten the fixing screws (2) to the prescribed
torque.After removingthegearboxfromthestandusedfor
overhaul, refit theclutch actuator (3, Figure 4/1) and make
surethewiring(2, Figure 4/1) isnot damaged.
Extract thesprings (6-7-8) andthepawls (6).
99370317 (3) andslightlyloosen the screws(2).
!
The springs (7 and 8) are of equal length, the
spring(6) islarger.
Remove thepin (4) fromtherod (5).
Remove the switch (1) together with the gasket (2) and
extract thecap(3).
78651
Takeout thescrews(2) anddetachtheactuator (1) withits
gasket.
!
The electronic control unit is integrated in the
actuator and these cannot be overhauled. See
under thediagnosis headingfor the check.
Checkthat theoil vapourvent (3) isnotclogged;ifit is,clean
it.
Disconnect speedactuators(1) asdescribedintherelevant
chapter.
Refitting
117521
70832
70833
70834
70835
Figure4/7
Figure4/8
Figure4/9
Figure4/10
Figure4/11
Removethescrews(1) fixingtheplates(2) fasteningthepins
(4) andextract thesetogetherwiththeseal (3) fromtherear
box (7).
Extract thetwo centringpins(5). Remove the screws(6).
Fit theeyebolt 99366811tothesleeve(8) and,usingspecial
ropesandlifter,detachtherear box(7) fromthemiddleone
(9).
Remove the oil pipe (1). Notedowntheassemblyposition
of thefork(3) andplugs(6) andremovethem.Remove:the
rod (2), synchronizingdevice assembly (4) and connecting
sleeve(5).
Remove theadjustment ring(3) and the plate(1) together
with thecouplingbody(2).
Removethescrews(3), disc(4) andseal (5) andextract the
sleeve (2) fromthe spider shaft. Should extraction prove
difficult,useanextractor (1) appliedasillustratedinthefigure.
Remove thescrews(2) and takeoff thecover (1).Remove
thespider shaft bearingend float adjustment ring(3).
45946
70837
70836
70838
70839
70840
Figure4/12
Figure4/13
Figure4/14
Figure4/15
Figure4/16
Figure4/17
Usingapress,extractthespidershaft (1) fromthesupporting
roller bearing(2). Turn the rear box (3) upside-down and
extract theroller bearing(2).
Removing the epicyclic reduction gear train
(E.R.G.)
Usingascrewdriver,removethecirclip(3) fasteningthering
gear withinternal toothing(4) to theringgearwithexternal
toothing(2) andremove themfromtheE.R.G. (1).
Extract the toothed ring(2) fromthe ringgear with internal
toothing(1).
Usingpliers(2),tightentheendsofthecirclip(3) andremove
thecouplingbody(4) fromtheE.R.G. shaft (1).
Usingapunch,extract thepins(5) fromthespider shaft (6).
Remove the planetary gears (3) fromthe spider shaft (6),
togetherwiththerollers(2) andshimadjustment rings(1and
4).
Extract the toothed shaft (3) from the spider shaft (1)
together withtherings(2).
70841
70843
70842
Figure4/18 Figure4/19
Extract oneof thepins (1) fromthe toothed shaft (2) and
extract therings(3) fromthis.
Usingasuitableextractor,removetheroller bearingring(1)
fromthespider shaft (2).
Using apunch, extract the disc (3) fromthe inside of the
spider shaft (2).
PARTSCOMPRISINGTHE E.R.G.
1. Circlip- 2. Ringgear with external toothing- 3. Toothed ring- 4. Ringgear with internal toothing- 5. Bearing- 6. Circlip-
7. Circlip- 8. Couplingbody- 9. Pins- 10. Ring- 11. Toothed spindle- 12. Disc- 13. Spider shaft - 14. Pin- 15. Shim
adjustment ring- 16. Rollers- 17. Shimadjustment ring- 18. Planetarygear.
Figure4/20
70844
70840
70845
70982
70838
70983
Figure4/21
Figure4/22
Figure4/23
Figure4/24
Figure4/25
Figure4/26
Heat theinsidering(2) oftheroller bearingto 120 C andfit
it onthe spider shaft (3).
Fit onthecirclip(1). Fit onthedisc (4).
Drivethe rings (1 and3) onto thetoothedspindle (2) and
fit on thepin (4).
Insert the spindle (3) together with the rings (2) onto the
spider shaft (1).
Smear grease into the hole of the planetarygear (5) and
insert the rollers (3) with the associated shimadjustment
rings (2 and 4). Fit the planetarygears (5) onto the spider
shaft (6), fasteningthemto it withthepins (1).
Usingpliers(2), tightentheendsof thecirclip (3) andfit the
couplingbody(4) onto theE.R.G. shaft (1).
Fit the ring gear with internal toothing(5) onto the spider
shaft (3) togetherwiththetoothedring(4),andtheringgear
withexternal toothing(2) andfastenthetworinggearswith
thecirclip(1).
Fitting the epicyclic reduction gear train
(E.R.G.)
45951
45943
70847
Figure4/27
Figure4/28
Figure4/29
Heat theseat ofthebearing(1) oftherearbox(2) to120 C
and mount thebearing(1).
Rest thespider shaft (1) onan appropriatespacer.
Heat theinsideringofthebearing(2) to 120 C anddriveit
together withtherear box (3) onto thespider shaft (1).
Determinetheball bearingendfloatadjustment thickness(3)
byproceedingasfollows:
- measure thedepth of theseat onthecover (1) of the
bearing(3), distance A;
- measure the protrusion of the bearing (3) fromthe
surfaceof therear box (2), distanceB.
ThethicknessSoftheadjustment ringis determinedbythe
followingequation:
S=(A - B) - C
Where:
A and B= measurements
C = end float 0 0.1 mm
For example:
A = 5.4mm
B = 5mm
C = 0 0.1 mm
S = (5.4 - 5) - (0 0.1mm) =0.3 0.4 mm
Adjusting epicyclic reduction gear train
bearing end float
45954
70848
70849
70850
Figure4/30
Figure4/31
Figure4/32
Figure4/33
Usingthedriver 99374221(1),fittheseal (2) inthecover(3).
Mount theadjustment ring(1), ofthethickness determined
in the preceding measurement, on the bearing (2,
Figure4/28) of thespider shaft (3).
SpreadIVECO sealant 1905685onthematingsurfaceofthe
cover (4) withthebox(5) andfit it ontothebox, tightening
thescrews (2) to the prescribedtorque.
Heat thesleeve (1) to 90 C and fit it onto the spider shaft
(1). Fit on anew seal (4), the disc (3) and screws (2) and
tightenthemto theprescribed torque.
Adjusting main shaft end float
Positiontwo calibratedblocks(2) ontherear box (4).Place
acalibrated rule (1) on themand, using adepth gauge (3),
measure the distancebetweenthe top sideof theruleand
theend of thespider shaft (5), distance A.
70851
70852
Figure4/34
Figure4/35
Fit theconnectingsleeve (7) together withthecirclip(5) on
themainshaft (6).
Positiontwocalibratedblocks(2) onthemiddlebox (4) and
place acalibrated rule (1) onthem.
!
Thecalibratedblocks andrulemust bethesame
onesusedintheprecedingmeasurement.
Usingadepthgauge (3), measurethedistance betweenthe
topendofthecirclip(5) andthetopsideofthecalibratedrule,
distanceB.
Thethickness Sof themainshaft endfloat adjustment ringis
determinedbythefollowingequation:
S=(A - B) - 2
For your information (see Figure4/36), subtracting the
thicknessof thecalibrated blocks andrule:
- fromthe distance A gives thedistanceX corresponding
to thedistancebetween the endof the spider shaft (2)
fromthematingsurfaceof therear box (1).
- fromthedistance Bgives the distance Y corresponding
to the distance between the circlip (4) and the mating
surfaceof themiddlebox (3).
GEARBOXESEuroTronicAutomated 12AS1930T.D. - 2330T.O. 56/9 TRAKKER EURO 4/5
PRINT603.93.641/A
Positiontheadjustment ring(2) (of thethicknessdetermined
intheprecedingmeasurements) onthemainshaft (5).Mount
theconnectingsleeve(1) andthetube(4).
Mount theplate (6) together withthecouplingbody(3).
70853
70854
70855
70856
70857
Figure4/36
Figure4/37
Figure4/38
Figure4/39
Figure4/40
Synchronizing device assembly for engaging
normal or reduced gears
Removal
1. Synchronizingdeviceassembly - 2. Synchronizingdevice
ring- 3. Slidingsleeve - 4. Pawl - 5. Spring-
6. Synchronizingdevicering.
Put aclothon thesynchronizingdeviceassembly(1) so that,
whendismantlingit,thesprings(5) andpawls(4) areheldback
astheycomeout of their seats.
Put the springs (2) and pawls (3) into the seats of the
synchronizingdevicerings(1) andfastenthemwiththetools
99370172(4).
Positionthesynchronizingdevicering(2) onthesynchronizing
devicering(3) so that it ispossibletofit theslidingsleeve(1)
onto them. On completing assembly, remove the tools
99370172(4).
Fitthesynchronizingdeviceassembly(1) onthecouplingbody
(3, Figure4/36) withtheringgroove ( ) facingdownwards.
Fitting
56/10 GEARBOXESEuroTronicAutomated 12AS1930T.D. - 2330T.O. TRAKKER EURO 4/5
Revi - June2007 Print 603.93.641/A
70858
70860
70859
117521
70862
Figure4/41
Figure4/42
Figure4/43
Figure4/44
Figure4/45
Positionthefork(1)withtheplugs(3)andthereliefs(' ) facing
asillustrated inthefigure.
Fit ontherod(4) andconnect it tothefork(1). Fit ontheoil
pipe(2).
Takeout thescrews(1) andremovethecover (2) withitsseal
(3). Removethe screw(4) withthewasher (5).
Spread IVECO sealant 1905685 onto the matingsurface of
the middle box (6). Fit the eyebolts 99368811 (1) to the
sleeve(2). Usingropes andalifter, positiontherear box (4)
coaxiallyto themiddleone (6).
Screwdownthescrews(6) withouttighteningthem;insertthe
centringpins(5) andtightenthescrews(6) to theprescribed
torque.
Fit theforkjoint pins(4) withfreshseals (3) and tightenthe
screws (1) fixing the fastening plates (2) to the prescribed
torque.
Fit: thescrew(4) withanewwasher (5) andtightenit tothe
prescribedtorque.
Fit the cover (2) with afresh seal (3) and tighten the fixing
screws(1) to theprescribedtorque.
prescribedtorque.
Insert therod(3) ofappropriatediameter intheholeforthe
screw(4,Figure4/42) andintheoil pipe(5) toguidethisinto
itsseat, whileloweringtherear box (4). Lower therear box
(4),payingattentionthat thespidershaft, oil pipe(5) androd
(7) go into their seat correctly.
70863
78299
70864
Fit thecap(3) andtheswitch(1) withanewgasket(2).Spread
LOCTITE262ontothethreadofthepin(4),screwitontothe
rod(5) andtightenthemto theprescribed torque.
Fit thepawls(9) andthesprings(6-7-8).
Refit the gear actuator (1) as described under the relevant
heading.
Connecttheelectricwiring(2) tothespeedsensor (6),tighten
thefixingringnut (5) andsecurethewiring(2) totheboxby
insertingit intheclips( ).
Refit the clutch actuator (3) and tighten the nuts (4) to the
prescribedtorque.
COMPONENT PARTSOFTHE REARBOX OFTHEEPICYCLIC REDUCTION GEARTRAIN
!
Thesprings(7- 8) areof equal length, thespring
(6) islarger.
Figure4/48
70865
78301
78302
78300
70870
Figure4/49
Figure4/50
Figure4/51
Figure4/52
Figure4/53
Detachthegearactuatorandtherearboxasdescribedunder
the relevant headings. Remove the E.R.G. drive rod (4),
connectingsleeve (5), adjustment ring(3) and theplate (1)
together withthecouplingbody(2). Removethe small pipe
(6).
Fit theplate99370153(1) to themiddlebox (2) so that the
grooveinsidetheplatecoincideswiththekey(5) of themain
shaft (6).
Fasten the pins (4) by fitting the brackets (3) of the plate
99370153to themiddlebox (2).
Turnthegearbox through180 .
Takeout thescrews(2) and removethe pin(3) in thejoint
of theclutchuncouplinglever (1) withthislever.
Removethescrews(4) fixingthefront cover (5) tothefront
box.
Screw down two screws (1) into the front cover (2) and
detach thisfromthefront box (3).
Removethecap(3),thespring(4) fromthetransmissionshaft
(5) and theadjustment rings(1-2-6 -).
Removing the middle box
70871
78303
70875
Figure4/54
Figure4/55
Figure4/56
Figure4/57
Figure4/58
Figure4/59
Removethecirclip (4) fasteningthebearing(1) to thedrive
input shaft (3). Removethecirclip(2) fromthebearing(1).
Usingtheextractors99345078(1)and99345105(2),extract
theball bearing(4) fromthedriveinput shaft (3).
Removethespeedsensor (5) and thecap(4) beneath.
Takeout thefour centringpins (1).
Removethescrews(2) fixingthemiddlebox (6) tothefront
box (3).
Fit the eyebolt 99366811 (1) onto thefront box (2). Using
special ropesandahoist, detach thefront box (2) fromthe
middleone(3). Removethemetal seal included.
Takeout thescrews (1) and removethebrackets(2) ofthe
plate 99370153. Extract the reverse gear pins (3) fromthe
middlebox (4).
Removethephonicwheel (2) fromthedriveinput shaft (1).
Extract theoil pipes (4-6) fromthemiddlebox (7).
Spread apart thetransmissionshafts(3-5) andremovethem
fromthemiddlebox (7).
78305
78304
!
Toperformthefollowingoperations,thegearbox
must be positioned as shown in Figure4/59 in
order to avoid any chance of the transmission
shaftsfalling.
117519
70876
70877
Figure4/60
Figure4/61
Figure4/62
Figure4/63
Fit tool 99360527(1) onto thedriveinput shaft (9) andthe
rods(2and3);fitparts(6-7and8) oftool 99360526(4) onto
thedriveinput shaft (9).
Hooktool 99360526(4) ontothelifter andextract themain
shaft(5) togetherwiththedriveinput shaft(9)androds(2and
3) fromthesupportingbearing.
Remove the reverse gears (3) together with the roller
bearings(2).
Removetheplate99370153(4).
If replacement isnecessary, removethecentringpins(1).
Turnthemiddlebox (1) upside-down,removethecirclip(2)
and, workingfrominsidethebox, removetheroller bearing
(4).
Usingapunch,andoperatingthroughtheopenings( ) ofthe
middlebox (1), removetheexternal rings(3) of thetapered
roller bearings for transmissionshafts.
Clampthemainshaft (6) inaviceandremovetool 99360526
(1) and 99360527(2).
Removetherods(3and 4) withtherelevant forks.
78307
!
Beforeremovingthepins(1) heat theseatsofthe
boxto ~90 C. !
To remove the fork (5), the ring of the
synchronizing device has to be in the middle
position.
Removing the main shaft
117520
70881
Through the bay of the coupling sleeve (1), using suitable
pliers, tightentheendsofthecirclip(2) andremovethedrive
input shaft (3) fromthemainshaft (4), see Figure4/65.
Remove thecouplingsleeve (1) and the tube (2) fromthe
main shaft (3).
Turnthemainshaft(3) upside-downandremovethecoupling
sleeve(4) fromit; removethekey(5) fromthehole( ) in
theshaft (3) andextract it.
Extract:
- spacer (5);
- reversegear (6);
- spacer (7);
- couplingsleeve(8);
- spacer (9);
- 2
nd
gear (10);
- spacers (11and 12);
- gear (13);
- spacer (14);
- tube(15).
!
To extract theshoulder spacers (5 - 7 - 9- 11 - 12
-14)itisnecessarytoturnthemsothattheirtoothing
iswiththegroovesof theshaft (3).
85482
70883
70885
70884
70886
Figure4/66
Figure4/67
Figure4/68
Figure4/69
Ifnecessary, removethecirclips(1) fromthegears(7 - 10- 14
- 17, Figure4/65) and extract thetoothedring(2).
Removing the drive input shaft
Extract thering(2), key(3) andgear (4) fromthedriveinput
shaft (1).
Turn the drive input shaft (1) upside-down, lift thenotches
( ) of thesafetycover (2) and takeit off.
Removethehalf rings (2) fromthedrive input shaft (1) and
extract fromit:
- thrust washer (3);
- thrust bearing(4);
- bushing(6) together with circlip(5);
- gear (9);
- synchronizingdeviceassembly(12).
70887
70889
70888
Figure4/70
Figure4/71
If necessary, removethecirclips(1-3) fromthegear (4) and
extract thetoothed ring(2).
Put thesynchronizingdeviceassembly(1) ontheworkbench,
cover it with acloth to prevent thepins (8) andsprings (7)
gettinglost duringsubsequent dismantling.
Holding back the synchronizing device ring (6), lift the
synchronizingdevicering(2);thesewill get freed:toothedring
(5), threeclips(7) and threepins(8).
Removethekey(4) andextract thetoothedsleeve(3) from
thetoothedring(5).
COMPONENT PARTSOFTHE DRIVEINPUT SHAFT
Removing the splitter synchronizing device
Figure4/72
70759
70891
Figure4/73
Figure4/74
Fitting the splitter synchronizing device
Insert the three springs (6) and three pins (7) in the
synchronizingdevicering(1) andkeepthemintheir seat with
thecentringpins99370499(2).
Positionthetoothedring(3) onthesynchronizingdevicering
(5).Fitthesynchronizingdevicering(1) inthetoothedring(3)
andonthesynchronizingdevicering(6) sothat thecentring
pins99370499(2)driveontothepins(4) ofthesynchronizing
device ring (5). Press on the synchronizing device ring (1)
uniformlysothatthecomponentsoftheassemblyfit together
correctly. Takeout thecentringpins(2).
Insertthetoothedsleeve(1) inthetoothedring(2) sothat theracebetweenthetwotoothingscorrespondstotheinsidetoothing
of thering(2) andallowsit to rotate.
Turnthe sleeve(1) so that theholein it coincideswith oneof thethreebays ( ) of thetoothed ring(1).
Theninsert thekey(3) asshowninthefigure.
70892
70885
70884
70893
Figure4/75
Figure4/76
Figure4/77
Figure4/78
Onthedriveinput shaft (1), fit:
- synchronizingdeviceassembly(15);
- gear (10) together with circlips(9and12) andtoothed
ring(11);
- bushing(6) withcirclip(5);
- thrust washer (3).
- half rings(2).
Fit on anewsafetycover (2) andnotchit ( ) at three/four
equidistant points. Turn over thedriveinput shaft (1).
On the drive input shaft (1), fit: gear (4), key (3) and thrust
washer (2).
Fitting the drive input shaft
|o t|o oas (+), |t. |ovoso +
st
2
nd
gearsandtoothedrings
(2) and fastenthemto thegears withthe circlips(1 and3).
Fitting the main shaft
78309
78310
78311
78312
Figure4/79
Figure4/80
Figure4/81
Figure4/82
Clampthemainshaft (2) inavice.Fit onthetube(1).Putthe
shoulder spacer (3) intheringgroove ( ). Turn thespacer
(3) so that itsinternal toothingrestsonthat ofthemainshaft
(2).
Insert thekey(4) inthespacer (3) so asto prevent rotation
and keepit inposition.
Mount the2
nd
speed gear (2), put thespacer (4) inthering
groove( ). Turnthespacer (4) sothat itsinternal toothing
rests onthat of the main shaft (1). Insert the key (3) in the
spacer (4) and keep it in position.
Put thespacer (3) intheringgroove( ). Turnthespacer (3)
sothat itsinternal toothingrestsonthat ofthemainshaft (1).
Insert thekey(2) inthespacer and keepit inposition.
Mount the 1
st
speed gear (2), put thespacer (4) in the ring
groove( ). Turnthespacer (4) sothat itsinternal toothing
rests onthat of the main shaft (1). Insert the key (3) in the
spacer (4) and keep it in position.
PRINT603.93.641/A
78314
78315
Figure4/83
Figure4/84
Figure4/85
Fit onthe1
st
/Reversegearcouplingsleeve (1) withthelarger
internal groove( ) turnedto thesideof thekey(2).
Put thespacer (3) intheringgroove( ). Turnthespacer (3)
Insert thekey(2) inthespacer (3) andkeep it in position.
Fit onthegear (2). Put thespacer (4) intheringgroove( )
Slideout thekey(3) and insert it fromtheupper sideofthe
shaft intoitskeywayandinall thespacerssothatthebent part
intersinto thehole ( ) of theshaft (1).
117536
70903
Figure4/86
Turnover themainshaft (2) andfit onthesleeve(1) withthe
bay (4) coincidingwiththekey(5).
Fit onthetube (3).
70904
Figure4/87
Usingsuitablepliers,tighten theends ofthecirclip(2) and fit
thedriveinput shaft (1) onto themainshaft (3).
!
Makesurethatthecirclip(2)getscorrectlypositioned
intheseat of themainshaft (3).
70879
117524
Figure4/88
Figure4/89
Splitter control fork
Disassembly - Assembly
Extract the plugs (2) fromthe splitter synchronizingdevice
couplingfork(1) andfit onthenewplugs.
Dismantlethegearcontrol forkassembly(1),suitablyadjusting
thering(3) to prevent thegearssimultaneouslycouplingand
extractingfromtherod(6):thecouplingfork(5)*,pin(4),fork
(2) and ring(3).
Gear control forks
Removal
70760
70761
Figure4/90
Figure4/91
Insert the pin (1) in the seat on the rod (3). Drive the
reverse/1
st
gear couplingfork(2) onto therod (3), adjusting
itsothat thepin(1) getspositionedinthebay( ) ofthefork
(2).
Drivethering(1) andthe2
nd
/3
rd
gearcouplingfork(3) onto
the rod (2). Position the fork (3) in thering(1) so that on
turningitthebay( ) ofthefork(3) isinsertedinthering(1).
Fitting
85938
Figure4/92
Position thefork (2) andthering(1) assembled together as
indicatedsothatthecompartment( ) ofthefork(3)engages
reverse/ 1
st
gear engagesinto thering(1).
78318
78319
70909
Figure4/93
Figure4/94
Figure4/95
Figure4/96
Removetheinsiderings(1-3) of theroller bearingsfromthe
transmissionshaft (2), usingtheextractor 99347100(4),grips
(6) and plug99345057(5).
To fit therings (1 - 3) ontheshaft (2) it is necessaryto first
heat themto 120 C.
Heattheseat (3)ofthecylindricalrollerbearing(1) to~90 C,
fit this andfastenit to themiddleboxwiththecirclip (2).
If removed, refit thecentringpins (4) after heatingtheseats
of theboxto ~90 C.
Fit theplate 99370153 (2) onto themiddlebox (1).
Frominsidethe box (1), heat theseats of therings(4) to ~
90 C, transmission shaft bearings. Fit on the rings (4) with
driver 99370092(3) andgrip99370007(2).
Place thereverse gears(1) together withtheroller bearings
(2) inthemiddlebox.
70910
Figure4/97
Fitting the middle box
Transmission shafts
Disassembly - Assembly
117525
70912
78320
70915
Figure4/98
Figure4/99
Figure4/100
Figure4/101
Figure4/102
Fit theforkassembly(1) ontothemainshaft (2),verifyingthat
theforksarecorrectlypositionedontheirrespectivecoupling
sleeves.
Mount thesplitter couplingfork(1) positioningtheplugs(2)
onthetoothed couplingring(3).
Fit tool 99360527(1) onto thedriveinput shaft (8) andthe
rods(2and3).Fitparts(5-6-7) oftool 99360526(4) ontothe
driveinput shaft (8).
Hookthetool 99360526 (1) onto thelifter andfit themain
shaft assembly (5) inthe gearbox, verifyingthat theshaft (5)
and therods(3 and4) get correctlyinserted intheir seats.
Removethetools99360526(1) and99360527 (2).
Mount the transmission shafts (1 and 3) so that on joining
themto themainshaft (2) the marks stamped on themare
aligned. Usetheslots ( ) of thephonicwheel (4) to check
this.
117526
117527
78305 70917
Insert thepins (3) inthe middle box (4) andin the reverse
gears(1, Figure4/98), fasteningthemto thebox(4) withthe
brackets (2) of plate99370153and thescrews(1).
Fit ontheoil pipes (1 and2).
COMPONENT PARTSOFTHE MIDDLE BOX
!
Withnogearsengaged,theshaftsmustturnfreely,
otherwise the alignment of the marks (see
Figure4/102) will not becorrect.
Figure4/105
!
Toperformthefollowingoperations,thegearbox
must be positioned as shown in Figure4/104 in
order to avoid anychance of the reverse gears
falling.
117528
Figure4/106
Fitting the front box
70819
70920
70921
78304
Figure4/107
Figure4/108
Figure4/109
Figure4/110
Removethescrew(1),lift thecover (2),removethevents(3)
and cleanthemor replacethem.
Thenreassemble theparts.
Carefullycleanthe oil filter (6) andfit it backinits seat.
Iftheplugs(4) havebeenremoved,it isnecessarytofit them
backon withnewseals(5).
Heat thefront box (1) to 90 C in correspondencewiththe
seatsfortheexternal rings(2-3) ofthetaperedrollerbearings
and fit theseon.
Spread IVECO sealant 1905685 onto the matingsurface of
themiddlebox (5).
Fit theeyebolt 99368811(1) onto thefront box (2).
Usingropesandahoist,liftthebox(2) andpositionitcoaxially
to themiddlebox (5).
Insert therods (6), of suitablediameter,intotheseatsin the
front box (2) oftheoil pipes (7 and8) andintothesetoo.
Lower thebox (2) checkingthat the rods(3and4) andthe
oil pipes (7 and8) arecorrectlyinsertedintheir seat.
Removetheeyebolt (1) andtheguiderods(6).
Screw down the screws (2) fixingthe front box (3) to the
middle box (6). Insert the centringpins (1) and tighten the
screws(2) to theprescribedtorque.
Mount thecap(4) andthespeedsensor (5), tighteningit to
theprescribedtorque.
70922
70985
70871
70924
Figure4/111
Figure4/112
Figure4/113
Figure4/114
Figure4/115
Usingthetools99345098(1) comprisingparts(3-4and5)and
99360526comprisingparts(6- 7-8),fittheball bearing(11)
onthedriveinput shaft (9) andinthefront box (10).
Fit thecirclip (4) fasteningthebearing(1) to thedriveinput
shaft (3).
Fit thecirclip(2) onto thebearing(1).
Front cover
Removal
Removethescrews(3) andtakeoffthedriveinput shaftcover
(1) fromthefront cover (2).
Takeoutthescrews(1) and,throughthefrontcover (5),take
out theoil pumpcomprising: cover (2), rotor (3) andstator
(4).
Introduce compressed air through the hole ( ) and expel
through the front cover (5): the overrun brake piston (8)
comprehensive of gasket (9), clutch plates with external
toothing (6), clutch plates with internal toothing (7) and
supportingring(10).
Fitting the front cover
Recomposethefront cover (5) byreversingtheoperations
described for removal, without parts(6- 7 - 8).
Adjusting drive input shaft bearing end float
Determine the thickness S of the drive input shaft bearing
adjustment ringbyproceedinginthefollowingway:
- checkthat thecirclip(1) ofthebearing(2) restsinitsseat;
- measure the protrusion of the bearing (2) from the
surfaceof thefront box (3), distance A.
!
Thegasket (9) must alwaysbereplaced.
78322
70986
70925
70870
Figure4/116
Figure4/117
Figure4/118
Figure4/119
- measurethedepthoftheseat onthefront cover (1) of
thebearing(2, Figure4/115), distanceB.
The thickness Sof the adjustment ringis determinedbythe
followingequation:
S=(A -B) - C
Where:
A-B = measurements
C = end float 0 0.1mm
For example:
A = 5.50 mm
B = 3.90 mm
C = 0 0.1mm
S = (5.50-3.90) - 0 0.+=+.5 +.60
Adjustingtransmission shaft bearing end float
Determine thethickness Sof the transmission shaft bearing
endfloat adjustmentringsbyproceedinginthefollowingway:
- turntheshaftsandcheckthat theexternal rings(1-3) of
the bearings rest with no play on the rollers of the
bearings;
- measure the distance between thesurface of thefront
box (2) and theexternal rings(1 - 3);
D external ring(1) pumpside, distanceA.
D external ring(3) overrunbrakeside, distanceB
- measure the distance between thesurface of thefront
cover (2) and theoil pump(1), distanceC;
- mount theoverrunbrakediscsupportingring(3) inthe
seat on the front cover (2) and measure the distance
betweenthisandthesurfaceofthecover (2),distanceD.
ThethicknessSof theadjustment ringsisdeterminedbythe
followingequation:
D oil pump side S=A +C +F
A - C =measurements
F = end float 0.05
For example:
S =2 +0.05 ( 0.05) = 2 2.+
D overrunbrakesideS=B+D+F
B- C =measurements
F = end float 0.05
For example:
S=1.95 +0.15( 0.05) = 2.05 2.+5
On the external rings of the bearings supporting the drive
input andtransmissionshafts,mount theendfloat adjustment
rings(1-2and6)ofthethicknessdeterminedinthepreceding
measurements. Insert the spring(4) and the cap (3) in the
transmissionshaft (5).
70926
70869
70927
46007
70928
Figure4/120
Figure4/121
Figure4/122
Figure4/123
Inthesequenceshowninthefigure,position:thesupporting
ring(3), clutchplates withinternal toothing(2) andclutch
plates withexternal toothing(1).
Spread IVECO sealant 1905685 onto the surface of the
front box (1) matingwiththecover (2). Adjust thekeyof
the oil pump shaft so that it coincides with the coupling
millingof the transmission shaft. Fit on the cover (2) and
tightenthescrews (3) to the prescribedtorque.
Usingthedriver 99374336(2)andgrip99370007(1),fitthe
seal (3) inthe driveinput shaft cover (4).
Lubricatethesealingsurfaceof theseal withUnisilikon.
Spread IVECO sealant 1905285 onto the surface of the
front box (1) matingwith thecover (2). Mount the cover
(2).SpreadLOCTITE241ontothethreadofthescrews(3)
and tightenthemtotheprescribedtorque.
70929
70930
70865
Figure4/124
Figure4/125
Figure4/126
Figure4/127
Thebushings(2and4) andseals(1and 5) of thelever (3)
ao c|aooo b os|o a so|tab|o o|t o oov|o |tt|o
newparts.
Insert the joint pin (4) into the lever (2) and tighten the
screws(3), fixingit to thefront box (1), to theprescribed
torque.
Turnover thegearbox.
Remove the plate 99370153 (1) and the brackets (3)
fasteningthepins(4) fromthemiddlebox (2).
Fit: the plate (1) together with the coupling body (2),
adjustment ring(3), connectingsleeve(5) androd(4).
Fit thesmall pipe(6).Completeassemblyofthegearboxby
refittingtherear box andthespeed actuator as described
under therelevant headings.
On completingassembly, replenish the gearbox with the
prescribedgradeandquantityof lubricatingoil.
87268
Clutch release lever
GEARBOXESEuroTronicAutomatedwithIntarder 57 TRAKKEREURO 4/5
Gearboxes
EuroTronic Automated with Intarder
- 12AS 1931 T.D.
- 12AS 2331 T.D./T.O.
Page
MAIN DATA 59 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPERIMENTAL TOOLS 61 . . . . . . . . . . . . . . . . . .
OVERHAULINGTHEGEARBOX 62 . . . . . . . . . . .
- Removingthehydraulic retarder 62 . . . . . . . . . . .
- Refittingthehydraulic retarder 63 . . . . . . . . . . . .
- Adjustingepicyclicreduction gear train
bearingend float 63 . . . . . . . . . . . . . . . . . . . . . . .
- Adjustingstator end float 64 . . . . . . . . . . . . . . . .
- Removingtherear box 66 . . . . . . . . . . . . . . . . . .
- DisassemblingtheE.R.G. 66 . . . . . . . . . . . . . . . . .
- AssemblingtheE.R.G. 68 . . . . . . . . . . . . . . . . . . .
58 GEARBOXESEuroTronicAutomatedwithIntarder TRAKKEREURO 4/5
MAIN DATA
GEARBOXES
12AS1931T.D.
GEARBOXES
12 AS1931 T.D.
12AS2331T.D./T.O.
Maximumbraking
torque Nm 3200
Brakingcapacity Kw 500
Typeof oil
Quantityafter overhauling
gearbox and retarder drained
completely
litres
kg
TutelaTruckFe- Gear
TutelaZC 90
21
18.9
Figure1
70831
This differs fromthe 12AS1930T.D. - 12AS2330T.D./T.O. gearboxin thefollowing:
T.D.= TruckDirect Drive
T.O. = TruckOver Drive (Multiplied)
NOTE
TOOLS
99345056 Reactionblockfor extractors
99370565 M10 eyebolts (2) for liftingvarious assemblies
Thisheadingcoverstheworkingdrawingfor theexperimental tool (S.P. 2396) usedwhenoverhaulingthegearboxdescribed
inthissection, whichcanbemadebytherepair shop.
EXPERIMENTAL TOOLS
Figure2
Figure3
Figure4
Figure5
Figure6
Unscrewtheringnut (1 and5) anddisconnect theelectric
wiring(2) fromthespeed sensor (6and7).
Detach the wiring(2) fromtheclips ( ) securingit to the
middlebox.
Remove thenuts (4) and detach the actuator (3) fromthe
front box.
Fir spacers SP. 2396 (2) and fasten the gearbox (1) to
brackets99322225 (3) ontherotatingstand99322205(4).
Drainoff thelubricatingoil byremovingtheplugs fromthe
Intarder andfromthegearbox.
If applicable, remove the four nuts (2) fixing the heat
exchanger (1) to thehydraulicretarder (3) and detach the
heat exchanger (1).
Remove thescrew(1) andthe washer (2) beneath. Extract
theplug(3) with theseal (4), oil filter (5) and magnet (6).
99370317(1) to it andremovethescrews (3),disc (4) and
underlyingseal (5).
78649
70934
70936
78324
78652
Removing the hydraulic retarder
Figure7
Figure8
Figure9
Figure10
Figure11
Using an extractor composed of thebridge 99341003 (3),
brackets 99341018 (2) and reaction block 993410134 (4),
removethe sleeve (1) fromtheshaft (5).
Removethescrews(1)fixingthehydraulicretarder (2)tothe
rear box (3).
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2).
With special ropes and lifter, detach the hydraulic retarder
(2) fromthe rear box (5).
Remove theadjustment rings (3 and 4) and thegasket (6).
Determinetheball bearingendfloatadjustment thickness(1)
byproceedingasfollows:
- measure the protrusion of the bearing (1) fromthe
surfaceof therear box (2): distanceA;
- measurethedistancebetweenthesealingsurface(1) of
thehalf boxof theretarder and the supportingsurface
of the bearing(1, Figure10): distanceB;
retarder and gearbox: distance C.
The thickness S of the adjustment ring is given by the
followingequation:
S=[ B +C - A ] - G
where:
- B- C - A =measurements
- G=0.1 mm: end float of theball bearing (1Figure 10)
(0 0.1mm)
Before refitting, determinethe thickness of the adjustment
rings (3and4, Figure9) as follows:
Adjusting epicyclic reduction gear train
bearing end float
78344
78321
78325
44005
78326
Refitting the hydraulic retarder
Figure12
Figure13
Figure14
DeterminethethicknessSofthestatorendfloatadjustment
ring:
- usingadepthgauge(1) andcalibratedrule(2), measure
the distance between the sealing surface of the half
boxes and the supporting surface of the stator (3):
distance A;
Fit the eyebolt 99370565 (1) to the hydraulic retarder (2)
and lift it with ahoist.
Position the adjustment rings (3 and 5) of the thickness
determined in theprecedingmeasurements on thebearing
(4) andontheseat ( ) of thestator.
Fit anewgasket (6) ontherear box.
Mount thehydraulicretarder (2) ontherearbox (7) making
surethat thegasket (6) gets positioned correctly.
Screwdownthescrews(2) fixingthehydraulicretarder (1) to
therear box (3) andtighten themto theprescribedtorque.
70946
70948
78327
- with depth gauge (1) and calibrated ruler (2), measure
distance B betweenadjustingring(5, ) rest surfaceand
hydraulic decelerator rest surface;
retarder and gearbox: distance C.
ThethicknessSofthestatorendfloatadjustmentringisgiven
bythefollowingsum:S=A+B+C+D
- A, B and C = measurements
- D = 0.05 mm: stator endfloat adjustment
ringpre-load. (- 0.05 0.05mm)
Figure15
106403
Adjusting stator end float
Figure16
Figure17
Heat theflange(2) toapprox. 80 C andfit it onto thespider
shaft (1).
Fit onanewseal (5),thedisc(4),screwdownthescrews(3)
and tightenthemto theprescribed torque.
prescribed torque.
70949
70954
Figure18
Position themagnet (6) onthefilter (5) andinsert this into
thehydraulic retarder. Fit theplug(3) with anewseal (4).
Screwdown thefasteningscrew(1) with thewasher (2).
70936
Figure19
Figure20
Fit twonewseals(2) onthehydraulicretarder(3) andmount
theheat exchanger (1) (if applicable).
Screwdownthefour nuts(2) fixingtheheat exchanger (1) to
the hydraulic retarder (3) and tighten themto theprescribed
torque.
70955
70934
Figure21
Connect theelectricwiring(1) to thespeedsensor (3) and
tightentheringnut (2).
Replenish the gearbox with the prescribed grade and
quantityof lubricatingoil.
70933
Figure22
Disconnect thegearactuator, asdescribedintherespective
chapter.
Remove the hydraulic retarder as described under the rel-
evant heading.
Remove the fasteningscrews (4) of theplates (3) retaining
thepins (6) andremovethepins with theO-rings (5) from
thecentral case(7).
Takeoff thelocatingpins (2) and remove therear case (1)
fasteningscrews(8).
70937
Figure23
Apply the flange fastening plate (4) on the planetary gear
shaft (3) andleaveenoughclearancetolet therope(2) pass
through.
Hook therope to ahoist (1) andremovetherear case (5)
fromthecentral case (6).
85851
Figure24
Figure25
Using a press, extract the E.R.G. spider shaft (1) fromthe
supporting ball bearing (2). Turn the rear box (3)
upside-downandextract theball bearing (2).
Remove thescrews (2) securingthe gear (3) to the spider
shaft (1).
48941
70941
Figure26
Usinganextractor composedof: bridge99341004(1),stays
99341012 (2), reaction block 99345056 (3) and clamp
99341015(5), extract thegear (6) fromthespider shaft (4).
70942
Disassembling the E.R.G.
Figure27
Figure28
Usingpliers (2), tighten theends of the seeger ring(3) and
removethe couplingbody (4) fromtheE.R.G. shaft (1).
Usingasuitableextractor,removetheroller bearingring(1)
fromthespidershaft (2). Usingapunch, extract thedisc (3)
fromtheinside of thespider shaft (2).
70838
70842
Figure29
Figure30
Usingapunch,extract thepins(5) fromthespider shaft (6).
Remove the planetary gears (3) fromthe spider shaft (6),
togetherwiththerollers(2) andshimadjustment rings(1and
4).
Extract the toothed spindle (3) fromthe spider shaft (1)
together withtherings(2).
70839
70840
Figure31
Figure32
Usingascrewdriver,removetheseegerring(3) fasteningthe
ring gear with internal toothing (4) to the ring gear with
external toothing(2) andremovethemfromtheE.R.G.(1).
Extract thetoothedring(2) fromtheringgear withinternal
toothing(1).
70836
70837
70943
Figure33
PARTSCOMPRISINGTHE E.R.G.
1. Circlip - 2. Ringgear withexternal toothing- 3. Toothed ring- 4. Ringgear withinternal toothing- 5. Bearing- 6. Circlip- 7.
Circlip- 8. Couplingbody- 9. Pins - 10. Ring- 11. Toothed spindle- 12. Disc- 13. Spider shaft - 14. Pin- 15. Shim
adjustment ring- 16. Rollers- 17. Shimadjustment ring- 18. Planetarygear - 19. Gear - 20. Screw.
Figure34
Heat theinsidering(2) of the roller bearingto and fit it on
thespider shaft (3).
Fit onthecirclip(1). Fit onthedisc (4).
70844
Assembling the E.R.G.
Figure35
Extract oneofthepins(1) fromthetoothedspindle (2) and
extract therings(3) fromthis.
71841
70845
70982
70840
70983
70941
Figure36
Figure37
Figure38
Figure39
Figure40
Drivethe rings (1 and3) onto thetoothedspindle (2) and
fit on thepin (4).
Insert the spindle (3) together with the rings (2) onto the
spider shaft (1).
Smear grease into the hole of the planetarygear (5) and
insert the rollers (3) with the associated shimadjustment
rings (2and4).
Fit theplanetarygears(5) onto thespider shaft (6),fastening
themto it withthepins (1).
Onthespidershaft(3),fit:theringgearwithinternaltoothing
(5) together withthetoothedring(4),andtheringgearwith
external toothing(2) and fastenthetworinggearswiththe
circlip(1).
Heatthegear (3) to120 C 130 Candfit itontothespider
shaft (1).Screwdownthefixingscrews(2) andtightenthem
to theprescribedtorque.
Heat theseat of thebearing(1) of therear box (2) to90 C
and mount thebearing(1).
48944
Figure41
48946
70937
Figure42
Figure43
Figure44
Figure45
Rest thespider shaft (1) onanappropriatespacer. Heat the
inside ringof the bearing(2) to approx. 100 C and driveit
together withtherear box (3) onto thespider shaft (1).
Takeout thescrews (1) and removethecover (2) with its
seal (3). Remove thescrew (4) with thewasher (5).
Hook the rope to a hoist and position the rear case (5)
coaxiallycompared to thecentral case(8).
Fit areinforcement (4) having the suitable diameter in the
screw hole (1, Figure45) andintheoil pipe (6) inorder to
leadthepipe into itsseat when therear caseislowered.
Lower therear case (5) and make sure the planetarygear
shaft,theoil pipe(6) andthebar (7) arefittedcorrectlyinthe
respectiveseats.
Screwdown thescrews(1) without tighteningthem; insert
the centring pins (2) and tighten the screws (1) to the
prescribed torque.
Fit theforkjoint pins(6) withfreshseals(5) andtightenthe
screws (4) fixingthe fasteningplates (3) to the prescribed
torque.
78364
85852
Applysealer IVECO 1905685onthecentral case (8) mating
surface. Apply the shaft (3), the planetary gear shaft (3)
fasteningplate(2) leavingenoughclearanceto let the rope
(1) passthrough.
70950
Figure46
Fit: thescrew(4) withanewwasher (5) andtightenit tothe
prescribed torque.
Fit the cover (2) with afresh seal (3) andtighten thefixing
Thenrefit thehydraulicretarder (6) asdescribedunder the
relevant heading.
EuroTronicGEARBOXESDIAGNOSTICS 73 TRAKKER EURO 4/5
EuroTronic Gearboxes Diagnostic
Page
FAULT DIAGNOSIS 75 . . . . . . . . . . . . . . . . . . . . . .
- Cluster Diagnosis 77 . . . . . . . . . . . . . . . . . . . . . . .
- DTC-FMI error codes 78 . . . . . . . . . . . . . . . . . . .
74 EuroTronicGEARBOXESDIAGNOSTICS TRAKKER EURO 4/5
EUROTRONIC troubleshootingcanbe performed withtheCluster or Modus, E.A.SY. andIT 2000 diagnosisinstruments.
Diagnosisviacluster makesit possibletoestimatethefault situationinthesysteminadvance, whilethefault-diagnosisinstruments
areessential to makeathoroughdiagnosisand operatecorrectlyonthe singlefaults.
For eachsingleinstrument it displaysthediagnosis andrepair help.
A computerizedfault-diagnosisstationdedicatedto diagnosingthebrakesystems, air suspensions, enginesandsystemscontrolled
electronically.
Thestationisequippedwithauxiliaryfunctions,suchas: programmingelectroniccontrol units, consultingthesparepartscatalogue
Thevehicle hasa30-pindiagnosissocket to interfacewith theinstrument.
IT 2000(IVECO Electronic Tester)
Thismakesit possible totakeimmediateactionon thevehicle, identifyingit withthechassis number.
It savesthe resultsof diagnosticsactions performed.
It canbeused asaportablePersonal Computer, too, beingfittedfor remotediagnosis.
ByusingMODUSasthe mother station it ispossibleto updateandconfiguretheIT 2000.
IT 2000 interfaces withthevehicleviaa30-pin diagnosissocket.
E.A.SY.
E.A.SY. systemallowsto simplymakethediagnosisandprogrammingof thevariouselectroniccentral units aboard thevehicle.
E.A.SY. systemismadeup of ECI modulecommunicatingwith theelectroniccentral units andof aPanasonicPC.
ECI module, exploiting thePanasonicPC,alsoallowseasyontheroadinterventions: inparticular, thanksto PanasonicPC wireless
technologies(e.g. GPRS), diagnosticinterventionscan beassistedbyaremoteexpert centre.
FAULT DIAGNOSIS
99378
Figure1
1. E.A.SY. - 2. IT 2000- 3. Modus
76 EuroTronicGEARBOXESDIAGNOSTICS TRAKKER EURO 4/5
98885
Figure2
98888
Diagnosis information onthecluster issplit into 4 columns:
- Secondcolumn = central unit addressplusfault order number.
- Third column = failuretype.
- Fourthcolumn = failurefrequency.
Thescreenshowsthreeerror messages at most, but can storeupto eight error messages. For displayinganyfurther messages,
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
SENSORS
-TRANS-
MISSION
OUTPUT
SPEED
WRONG
SIGNAL
Checktheclutch
actuator and theinteg-
rityof theconnections
with thegear actuator
(electroniccontrol
unit)
Gear actua-
tor replace-
ment (con-
trol unit)
SIGNALS-
SENSOR-
TACHO-
GRAPH
SENSOR
WRONG
SIGNAL
Other errors
91,100,177 present.
Short circuit to
ground to pin 8
- CAN H poss-
ible.
CheckvehicleCAN. Measuretype:
Resistance
(Ohm)
Measurepoint
1: Connector
(vehicleside)
Pin: 8
Measurepoint
2: Connector
(vehicleside)
Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
SIGNALS-
SENSOR-
TACHO-
GRAPH+O
UTPUT
SHAFT
SPEED
SENSOR
BOTH
SPEED
SENSORS
FAULTY
If theoutput speed
signal 1is available,
thereareno restric-
tionsonthesystem.
Checkvehicle-endwir-
ing.
Checkandreplacede-
fectiveoutput sensor.
Error 99,101
set; Output
speed >
2500 rpm;
Vehicle
speed too
high.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
CAN LINE
- ENGINE-
RE-
QUESTED
ENGINE
TORQUE
WRONG
SIGNAL
Vehiclemoving:
No calculation of ve-
hicleweight and gear
resistance possible.
Impossibleto calcu-
late startinggear.
T|o o|vo's oooost
will besubstituted by
theinformation on
thethrottlepedal
position.
Oncecouplingis
over, anamount of
fuel equivalent to the
throttlepedal value
will bereleased.
The clutchcoupling
qualitycould bere-
duced.
Duringcruisecontrol
operationit is not
possible to release
anyamount of fuel
becausethethrottle
pedal valueis0.
After theclutch has
engaged, the amount
of fuel will bere-
leasedbytheEDC.
Poor couplingquality
after changinggear.
Vehiclestationary:
Startingis possible.
On reachingthe stop,
theaveragestarting
gear will beengaged.
No additional func-
tional restrictions.
Checkaccelerator/ac-
celerator wiring.
Replace/repair acceler-
ator/periphery.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
CAN LINE
- ENGINE-
LOW IDLE
SWITCH
WRONG
SIGNAL
Further errorssaved
inEDC.
Pleasemakealso adi-
agnosischeck on EDC
system.
CAN LINE
- ENGINE-
CON-
TROL
MESSAGE
TIMEOUT Checkfusebox fuses.
CAN LINE
- ENGINE-
CON-
TROL
MESSAGE
TIMEOUT Inthe EEC1
messagetime-
out at thefol-
lowingsignals:
- Idlingswitch
- Kickdown
switch
- Accelerator
pedal position
- Enginetorque
ratio calculation
Pleasemakealso adi-
agnosischeck on EDC
system.
CAN LINE
- ENGINE-
NUMBER
OF EN-
GINE
REVS.
WRONG
SIGNAL
Resistance
(Ohm)
Measurepoint
1: Connector
(vehicleside)
Pin: 8
Measurepoint
2: Connector
(vehicleside)
Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
02 05 SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y2)
SPLITTER
SHORT
CIRCUIT
TO
GROUND
Vehiclemoving: gear-
boxlocked, the
clutchopensauto-
maticallywhenthe
vehiclestops. Vehicle
stationary: gearbox
automaticallyin neu-
tral, impossible to
continuedriving.
Replacingthegearbox
actuator (control unit)
03 05 SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y3)
SPLITTER
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
04 05 SHIFTING
ACTUA-
TOR- (Y4)
SOLE-
NOID
VALVE
GEAR
SELEC-
TION
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
05 05 SHIFTING
ACTUA-
TOR- (Y5)
SOLE-
NOID
VALVE
GEAR
SELEC-
TION
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
06 05 SHIFTING
ACTUA-
TOR- (Y6)
SOLE-
NOID
VALVE
GEAR EN-
GAGE-
MENT
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
07 05 SHIFTING
ACTUA-
TOR- (Y7)
SOLE-
NOID
VALVE
GEAR EN-
GAGE-
MENT
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
08 05 SHIFTING
ACTUA-
TOR- (Y8)
SOLE-
NOID
VALVE
RANGE
LOW
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
09 05 SHIFTING
ACTUA-
TOR- (Y9)
SOLE-
NOID
VALVE
RANGE
HIGH
SHORT
CIRCUIT
TO
GROUND
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
0A 05 SHIFTING
ACTUA-
TOR-
(Y10)
MAIN
VALVE
SHORT
CIRCUIT
TO
GROUND
Impossibleto change
gear, not even in
neutral.
The selected gear
stays engaged.
The vehicle can only
set off againinpar-
ticular conditions
(gear selected =<
the8
th
gear).
Replacingthegearbox
0B 05 DEVICE-
WARNING
LAMP/
BUZZER
SHORT
CIRCUIT
TO
GROUND
Possible short circuit. Checkwiring 1- Measuretype:
Voltage(V)
Measurepoint 1:
Connector for
ECU power
supply
- vehicleside.
Pin: 11
Measurepoint 2:
Connector for
ECU power
supply
- vehicleside.
Pin: 16
2- Measuretype:
Voltage (V)
Measurepoint 1:
Connector for
ECU power
supply
- vehicleside.
Pin: 11
Measurepoint 2:
Connector for
ECU power
supply
- vehicleside.
Pin: 17
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
1- Min. value:
22V;
Max. value: 28
V;
2- Min. value:
22V;
Max. value: 28
V;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
0D 05 DEVICE -
REAR PTO
- REAR
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO
GROUND
PTO 1 not available.
No additional system
restrictions.
Checkwiring, control
contactor, connections
with theMUX system
and gear lever
0D 05 DEVICE -
REAR PTO
- REAR
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO
GROUND
For STRALIS please
checkeither for a
possible short be-
tween9131 and 0131
cables or check for a
possible wiringinver-
siononST67con-
nector (PIN 4of 0131
cablecould bein-
verted with PIN 2 of
9131 cable).
0E 05 DEVICE -
PTO 2 -
LATERAL
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO
GROUND
PTO2not available.
restrictions
with theMUX system
and gear lever
0E 05 DEVICE -
PTO 2 -
LATERAL
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO
GROUND
For STRALIS please
checkeither for a
possible short be-
tween9131 and 0131
siononST67con-
cablecould bein-
9131 cable).
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
11 05 SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y1)
SHORT
CIRCUIT
TO
GROUND
Vehiclemoving:
The speedincreases
aremanaged as the
changes.
The speedincreases
arenot possible
whentheengine is at
lowspeed.
The engagement time
increases.
Vehiclestationary:
The engagement time
islonger.
Replacingthegearbox
12 05 CLUTCH
ACTUA-
TOR-
(Y17) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
SLOW
SHORT
CIRCUIT
TO
GROUND
Clutch control is im-
plementedviathe
fast clutchuncoupling
solenoidvalve. It de-
creasescomfort
whenmanoeuvring.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 9
Measurepoint
2: Connector
for clutchactua-
tor
- gearboxside
Pin: 16
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm; Max.
value: 20Ohm;
13 05 CLUTCH
ACTUA-
TOR-
(Y15) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
SLOW
SHORT
CIRCUIT
TO
GROUND
plementedviathe
creasescomfort
whenmanoeuvring.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 7
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 16
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm; Max.
value: 20Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
14 05 CLUTCH
ACTUA-
TOR-
(Y16) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
FAST
SHORT
CIRCUIT
TO
GROUND
plementedviathe
creasescomfort
whenmanoeuvring.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint
1: Connector
for clutchactua-
tor
- gearboxside
Pin: 12
Measurepoint
2: Connector
for clutchactua-
tor
- gearboxside
Pin: 17
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm;
Max. value: 20
Ohm;
15 05 CLUTCH
ACTUA-
TOR-
(Y14) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
FAST
SHORT
CIRCUIT
TO
GROUND
plementedviathe
creasescomfort
whenmanoeuvring.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint
1: Connector
for clutchactua-
tor
- gearboxside
Pin: 8 Measure
point 2: Con-
nector for
clutchactuator
- gearboxside
Pin: 17
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm;
Max. value: 20
Ohm;
16 05 SUPPLY
VOLTAGE
- DEVICE
SHORT
CIRCUIT
TO
GROUND
ECU output deacti-
vated. No informa-
tion fromthegear
lever, fromthebuz-
zer. Vehiclemoving:
Gearbox locked. Ve-
hiclestationary: Gear-
boxautomaticallyin
neutral.
Systemnot available
Control unit - gear
lever wiringcontrol
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1A 04 CAN LINE
- ENGINE-
CON-
FIGUR-
ATION
MESSAGE
TIMEOUT The systemadopts
substitutivepara-
meters.
Reducedfunctionality
for theautomatic
mode and to calcu-
latethestartinggear,
if there is alargedif-
ferencebetweenthe
parameters utilized
and theactual values.
The qualityof clutch
uncouplingmayde-
crease.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Reprogram
theelec-
tronic con-
trol unit to
rewritethe
parameters.
1A 04 CAN LINE
- ENGINE-
CON-
FIGUR-
ATION
MESSAGE
TIMEOUT Pleasemakealso adi-
agnosischeck on EDC
system.
1B 08 CAN LINE
- ENGINE-
CON-
FIGUR-
ATION
MESSAGE
WRONG
SIGNAL
The systemadopts
substitutivepara-
meters.
Reducedfunctionality
for theautomatic
mode and to calcu-
latethestartinggear,
if there is alargedif-
ferencebetweenthe
parameters utilized
and theactual values.
The qualityof clutch
uncouplingmayde-
crease.
Resistance
(Ohm)
Measurepoint
1: Connector
(vehicleside)
Pin: 8
Measurepoint
2: Connector
(vehicleside)
Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Reprogram
theelec-
tronic con-
trol unit to
rewritethe
parameters.
1B 08 CAN LINE
- ENGINE-
CON-
FIGUR-
ATION
MESSAGE
WRONG
SIGNAL
Pleasemakealso adi-
agnosischeck on EDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1C 08 CAN LINE
RE-
TARDER-
INTARDER
- BRAKING
TORQUE
WRONG
SIGNAL
Impossibleto calcu-
late the gear resis-
tance.
No automatic cal-
culationof thestart-
inggear.
The averagestarting
gear isengaged at the
stop.
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Further
CAN errors
present (183,
184, etc.).
1C 08 CAN LINE
-RE-
TARDER-
INTARDER
- BRAKING
TORQUE
WRONG
SIGNAL
Further Intarder er-
rors (e.g. 27, 29).
Check/ReplaceIntar-
der electronics.
1D 08 CAN LINE
-RE-
TARDER-
INTARDER
- WATER
TEMPERA-
TUREIN-
CREASE
WRONG
SIGNAL
There areno re-
queststo engage
lower gears, fromthe
retarder, to increase
theenginespeedto
improvethecooling
capacity.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Further
CAN errors
present (183,
184, etc.).
1D 08 CAN LINE
-RE-
TARDER-
INTARDER
- WATER
TEMPERA-
TUREIN-
CREASE
WRONG
SIGNAL
rors (e.g. 27, 28).
Check/ReplaceIntar-
der electronics.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1E 08 CAN LINE
-RE-
TARDER-
INTARDER
-CON-
FIGUR-
ATION
MESSAGE
WRONG
SIGNAL
rors (e.g. 27, 28).
Check/ReplaceIntar-
der electronics.
1E 08 CAN LINE
-RE-
TARDER-
INTARDER
-CON-
FIGUR-
ATION
MESSAGE
WRONG
SIGNAL
Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Further
CAN errors
present (183,
184, etc.).
1F 08 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
BRAKING
TORQUE
WRONG
SIGNAL
rors (e.g. 27, 28).
Check/ReplaceIntar-
der electronics.
1F 08 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
BRAKING
TORQUE
WRONG
SIGNAL
Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Further
CAN errors
present (183,
184, etc.).
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
20 08 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
CON-
FIGUR-
ATION
MESSAGE
WRONG
SIGNAL
Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Further
CAN errors
present (183,
184, etc.).
20 08 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
CON-
FIGUR-
ATION
MESSAGE
WRONG
SIGNAL
rors (e.g. 27, 28).
Check/ReplaceIntar-
der electronics.
21 04 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
CON-
FIGUR-
ATION
MESSAGE
TIMEOUT Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Further
CAN errors
present (26,
178, 183,
184, etc.).
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
21 04 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
CON-
FIGUR-
ATION
MESSAGE
TIMEOUT Further Intarder er-
rors (e.g. 27, 28).
Check/ReplaceIntar-
der electronics.
21 04 CAN LINE
-RE-
TARDER-
ENGINE
BRAKE-
CON-
FIGUR-
ATION
MESSAGE
22 0A SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y2)
SPLITTER
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
23 0A SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y3)
SPLITTER
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
24 0A SHIFTING
ACTUA-
TOR- (Y4)
SOLE-
NOID
VALVE
GEAR
SELEC-
TION
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
25 0A SHIFTING
ACTUA-
TOR- (Y5)
SOLE-
NOID
VALVE
GEAR
SELEC-
TION
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
26 0A SHIFTING
ACTUA-
TOR- (Y6)
SOLE-
NOID
VALVE
GEAR EN-
GAGE-
MENT
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
27 0A SHIFTING
ACTUA-
TOR- (Y7)
SOLE-
NOID
VALVE
GEAR EN-
GAGE-
MENT
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
28 0A SHIFTING
ACTUA-
TOR- (Y8)
SOLE-
NOID
VALVE
RANGE
LOW
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
29 0A SHIFTING
ACTUA-
TOR- (Y9)
SOLE-
NOID
VALVE
RANGE
HIGH
INTER-
RUPTION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
2A 0A SHIFTING
ACTUA-
TOR-
(Y10)
MAIN
VALVE
INTER-
RUPTION
Impossibleto change
gear, not even in
neutral.
The selected gear
stays engaged.
The vehicle can only
set off againinpar-
ticular conditions
(gear selected =<
the8
th
gear).
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
2B 0A DEVICE -
WARN-
ING
LAMP/
BUZZER
INTER-
RUPTION
Possible wiringinter-
ruption.
Checkwiring 1- Measuretype:
Voltage (V)
Measurepoint 1:
Connector for
ECU power
supply - vehicle
side. Pin: 11
Measurepoint 2:
Connector for
ECU power
supply - vehicle
side. Pin: 16
2- Measuretype:
Voltage(V)
Measurepoint 1:
Connector for
ECU power
supply - vehicle
side. Pin: 11
Measurepoint 2:
Connector for
ECU power
supply - vehicle
side. Pin: 17
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
1- Min. value:
22V; Max.
value: 28V;
2- Min. value:
22V; Max.
value: 28V;
2D 0A DEVICE -
REAR PTO
- REAR
ENGINE
PTO EN-
GAGED
INTER-
RUPTION
For STRALIS please
checkeither for a
possible short between
9131 and 0131cables
or check for apossible
wiringinversion on
ST67connector (PIN
4 of 0131 cable could
beinverted with PIN 2
of 9131 cable).
2D 0A DEVICE -
REAR PTO
- REAR
ENGINE
PTO EN-
GAGED
INTER-
RUPTION
restrictions.
with theMUX system
and gear lever
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
2E 0A DEVICE -
PTO 2 -
LATERAL
ENGINE
PTO EN-
GAGED
INTER-
RUPTION
PTO2not available.
restrictions
with theMUX system
and gear lever
2E 0A DEVICE -
PTO 2 -
LATERAL
ENGINE
PTO EN-
GAGED
INTER-
RUPTION
For STRALISplease
check either for aposs-
ibleshort between9131
and 0131cables or
check for apossiblewir-
inginversion on ST67
connector (PIN 4of
0131 cablecould bein-
verted withPIN 2of
9131 cable).
31 0A SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y1)
INTER-
RUPTION
Vehiclemoving:
The speedincreases
aremanaged as the
changes.
The speedincreases
arenot possiblewhen
theengineis at low
speed. The engage-
ment timeincreases.
Vehiclestationary:
The engagement time
islonger.
Replacingthegearbox
32 0A CLUTCH
ACTUA-
TOR-
(Y17) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
SLOW
INTER-
RUPTION
Comfort decreased
whenstartingand
manoeuvring; the
clutchis controlled
bythefast uncoupl-
ingvalve.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 9
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 16
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm;
Max. value: 20
Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
33 0A CLUTCH
ACTUA-
TOR-
(Y15) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
SLOW
INTER-
RUPTION
Comfort decreased
whenstartingand
manoeuvring; the
clutchis controlled
bythefast uncoupl-
ingvalve.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 7
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 16
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm;
Max. value: 20
Ohm;
34 0A CLUTCH
ACTUA-
TOR-
(Y16) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
FAST
INTER-
RUPTION
Comfort decreased
whenstartingand
manoeuvring; the
clutchis controlled
bythefast uncoupl-
ingvalve.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 12
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 17
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm;
Max. value: 20
Ohm;
35 0A CLUTCH
ACTUA-
TOR-
(Y14) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
FAST
INTER-
RUPTION
Comfort decreased
whenstartingand
manoeuvring; the
clutchis controlled
bythefast uncoupl-
ingvalve.
Checktheclutch
(electroniccontrol
unit)
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 8
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 17
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm;
Max. value: 20
Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
36 0A SUPPLY
VOLTAGE
- DEVICE
INTER-
RUPTION
ECU output deacti-
vated.
No informationfrom
thegear lever, from
thebuzzer.
Vehiclemoving:
Gearboxlocked. Ve-
hiclestationary: Gear-
boxautomaticallyin
neutral.
Systemnot available
Control unit - gear
lever wiringcontrol
3B 06 DEVICE -
REAR PTO
- SWITCH
SIGNAL-
LING PTO
1 EN-
GAGE-
MENT
SIGNAL
NOT
PLAUSIBLE
For STRALIS please
checkeither for a
possible short be-
tween9131 and 0131
siononST67con-
cablecould bein-
9131 cable).
3B 08 DEVICE -
REAR PTO
- SWITCH
SIGNAL-
LING PTO
1 EN-
GAGE-
MENT
SIGNAL
NOT
PLAUSIBLE
PTO1not available.
restrictions
Checkwiringbetween
thePTO1checkand
control switches
3C 08 DEVICE -
PTO 2 -
SWITCH
SIGNAL-
LING PTO
2 EN-
GAGE-
MENT
SIGNAL
NOT
PLAUSIBLE
PTO2not available.
restrictions
Checkwiringbetween
thePTO2checkand
control switches
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
3C 08 DEVICE -
PTO 2 -
SWITCH
SIGNAL-
LING PTO
2 EN-
GAGE-
MENT
SIGNAL
NOT
PLAUSIBLE
For STRALIS please
checkeither for a
possible short be-
tween9131 and 0131
siononST67con-
cablecould bein-
9131 cable).
3D 08 DEVICE -
REAR PTO
- SWITCH
SIGNAL-
LING PTO
1 EN-
GAGE-
MENT
PERMA-
NENT SIG-
NAL
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Checkwiringbetween
thePTO1checkand
control switches
3E 08 DEVICE -
PTO 2 -
SWITCH
SIGNAL-
LING PTO
2 EN-
GAGE-
MENT
PERMA-
NENT SIG-
NAL
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Checkwiringbetween
thePTO2checkand
control switches
3F 08 DEVICE -
REAR PTO
- SWITCH
SIGNAL-
LING PTO
1 EN-
GAGE-
MENT
NO SIG-
NAL
PTO1not available.
restrictions
Checkwiringbetween
thePTO1checkand
control switches
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
3F 08 DEVICE -
REAR PTO
- SWITCH
SIGNAL-
LING PTO
1 EN-
GAGE-
MENT
NO SIG-
NAL
For STRALIS please
checkeither for aposs-
ibleshort between
9131 and 0131cables
wiringinversion on
ST67connector (PIN 4
of 0131cablecould be
invertedwith PIN 2 of
9131 cable).
40 08 DEVICE -
PTO 2 -
SWITCH
SIGNAL-
LING PTO
2 EN-
GAGE-
MENT
NO SIG-
NAL
PTO2not available.
restrictions
Checkwiringbetween
thePTO2checkand
control switches
40 08 DEVICE -
PTO 2 -
SWITCH
SIGNAL-
LING PTO
2 EN-
GAGE-
MENT
NO SIG-
NAL
For STRALIS please
ibleshort between
9131 and 0131cables
wiringinversion on
9131 cable).
42 06 SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y2)
SPLITTER
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
43 06 SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y3)
SPLITTER
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
44 06 SHIFTING
ACTUA-
TOR- (Y4)
SOLE-
NOID
VALVE
GEAR
SELEC-
TION
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
45 06 SHIFTING
ACTUA-
TOR- (Y5)
SOLE-
NOID
VALVE
GEAR
SELEC-
TION
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
46 06 SHIFTING
ACTUA-
TOR- (Y6)
SOLE-
NOID
VALVE
GEAR EN-
GAGE-
MENT
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, theclutch
opens automatically
whenthevehicle
stops. Vehiclestation-
ary: gearboxautomati-
callyinneutral, im-
possible to continue
driving.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
47 06 SHIFTING
ACTUA-
TOR- (Y7)
SOLE-
NOID
VALVE
GEAR EN-
GAGE-
MENT
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
48 06 SHIFTING
ACTUA-
TOR- (Y8)
SOLE-
NOID
VALVE
RANGE
LOW
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
49 06 SHIFTING
ACTUA-
TOR- (Y9)
SOLE-
NOID
VALVE
RANGE
HIGH
SHORT
CIRCUIT
TO POSI-
TIVE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Replacingthegearbox
4A 06 SHIFTING
ACTUA-
TOR-
(Y10)
MAIN
VALVE
SHORT
CIRCUIT
TO POSI-
TIVE
Vehiclemoving:
Gearboxlocked. Ve-
hiclestationary: The
reduced gears can be
engaged.
Replacingthegearbox
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
4B 06 DEVICE -
WARN-
ING
LAMP/
BUZZER
SHORT
CIRCUIT
TO POSI-
TIVE
Possible short circuit. Checkwiring 1- Measuretype:
Voltage(V)
Measurepoint 1:
Connector for
ECU power
supply - vehicle
side. Pin: 11
Measurepoint
2: Connector
for ECU power
supply - vehicle
side. Pin: 16
2- Measuretype:
Voltage (V)
Measurepoint 1:
Connector for
ECU power
supply - vehicle
side. Pin: 11
Measurepoint 2:
Connector for
ECU power
supply - vehicle
side. Pin: 17
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
1- Min. value:
22V; Max.
value: 28V;
2- Min. value:
22V; Max.
value: 28V;
4D 06 DEVICE -
REAR PTO
- REAR
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO POSI-
TIVE
restrictions.
with theMUX system
and gear lever
4D 06 DEVICE -
REAR PTO
- REAR
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO POSI-
TIVE
For STRALIS please
ibleshort between
9131 and 0131cables
wiringinversion on
9131 cable).
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
4E 06 DEVICE -
PTO 2 -
LATERAL
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO POSI-
TIVE
PTO2not available.
restrictions
with theMUX system
and gear lever
4E 06 DEVICE -
PTO 2 -
LATERAL
ENGINE
PTO EN-
GAGED
SHORT
CIRCUIT
TO POSI-
TIVE
For STRALIS please
ibleshort between
9131 and 0131cables
wiringinversion on
9131 cable).
51 06 SHIFTING
ACTUA-
TOR- SO-
LENOID
VALVE
(Y1)
SHORT
CIRCUIT
TO POSI-
TIVE
Vehiclemoving:
Gearboxlocked. Ve-
hiclestationary: It is
possible to engage
thestartinggear.
The main valveis
onlyactivated inthe
couplingphaseif the
clutch is open.
Replacingthegearbox
52 06 CLUTCH
ACTUA-
TOR-
(Y17) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
SLOW
SHORT
CIRCUIT
TO POSI-
TIVE
Generally, gearbox
locked, systemnot
available.
Vehiclestationary:
The couplingvalve is
de-energized; the
gearbox is in neutral
whentheclutch
opens.
Replacingthegearbox
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 9
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 16
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm; Max.
value: 20Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
53 06 CLUTCH
ACTUA-
TOR-
(Y15) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
SLOW
SHORT
CIRCUIT
TO POSI-
TIVE
Generally, gearbox
locked, systemnot
available.
Vehiclestationary:
de-energized; the
whentheclutch
opens.
Replacingthegearbox
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 7
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 16
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm; Max.
value: 20Ohm;
54 06 CLUTCH
ACTUA-
TOR-
(Y16) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
FAST
SHORT
CIRCUIT
TO POSI-
TIVE
Generally, gearbox
locked, systemnot
available.
Vehiclemoving:
The clutchiskept in
thepositionrequired
bytheuncoupling
valve.
Vehiclestationary:
After acertainlength
of time the gearbox
goes into neutral.
Replacingthegearbox
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 12
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 17
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm; Max.
value: 20Ohm;
55 06 CLUTCH
ACTUA-
TOR-
(Y14) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
FAST
SHORT
CIRCUIT
TO POSI-
TIVE
Generally, gearbox
locked, systemnot
available.
Vehiclestationary:
de-energized; the
whentheclutch
opens.
Replacingthegearbox
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 8
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 17
Connector Not
connected;
Key+15OFF;
Min. value: 14
Ohm; Max.
value: 20Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
56 06 SUPPLY
VOLTAGE
- DEVICE
SHORT
CIRCUIT
TO POSI-
TIVE
After switchingover
thekey (Off-On) the
fault isrecognized
duringsystemset-up
and thedisplaydoes
not go out.
Turningthe keyonto
Off thedisplayshows
codeEE.
restrictions.
Control unit - gear
lever wiringcontrol
5A 09 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
INTERNAL
COM-
MUNICA-
TION
ERROR
Vehiclemoving: Gear-
boxlocked, theclutch
opens when theve-
hiclestops. Vehicle
stationary: Gearbox
tral.
Gearbox locked; the
systemis not available.
Replacingthegearbox
actuator
5B 04 CAN LINE
- BRAKING
SYSTEM-
CON-
TROL
MESSAGE
TIMEOUT Other CAN errors
180,181,182,183,184
and/or 177 present.
Short circuit to
ground to pin 8
- CAN H poss-
ible.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
5B 04 CAN LINE
- BRAKING
SYSTEM-
CON-
TROL
MESSAGE
TIMEOUT Impossibleto calculate
thegear resistance.
No automatic calcula-
tion of thestarting
gear.
The averagestarting
stop.
restrictions.
Checkfusebox fuses.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
5B 04 CAN LINE
- BRAKING
SYSTEM-
CONTROL
MESSAGE
TIMEOUT Messageissued
byASR/ ABS/
EBSelectronics.
CheckABS/ASR/EBS
signal travel.
Themessage
containsthe
followingsig-
nals: z_ABS:
ABS oper-
ation.
z_ASR_EDC:
Signal ASR-
EDC-Ein-
griffz_ASR_B
R : Status
ASR-
Bremsbe-
triebz_EBS:
StatusEBS
5C 08 CAN LINE
- BRAKING
SYSTEM-
ABSACTI-
VATED
WRONG
SIGNAL
Impossibleto calculate
thegear resistance.
No automatic calcula-
tion of thestarting
gear.
The averagestarting
stop. No additional
systemrestrictions.
Error 91 pres-
oot '|3C+
t|ooot' oss-
age issued by
ABS/ ASR /
EBSelectronics.
CheckABS / ASR/
EBSsignal travel.
No z_ABS
signal (signal
containedin
EBC1mess-
age).
5C 08 CAN LINE
- BRAKING
SYSTEM-
ABSACTI-
VATED
WRONG
SIGNAL
CheckCAN line.
CheckECU correct
programmino.
Measuretype:
Resistance
(Ohm) Measure
point 1: Con-
nector (vehicle
side) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
5D 08 CAN LINE
- BRAKING
SYSTEM-
ASR ACTI-
VATED
(ENGINE)
WRONG
SIGNAL
CheckCAN line.
CheckECU correct
programmino.
Measuretype:
Resistance
(Ohm) Measure
point 1: Con-
nector (vehicle
side) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
5D 08 CAN LINE
- BRAKING
SYSTEM-
ASR ACTI-
VATED
(ENGINE)
WRONG
SIGNAL
Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Error 91 pres-
oot '|3C+
t|ooot' oss-
age issued by
ABS/ ASR /
EBSelectronics.
CheckABS/ASR/EBS
signal travel.
No z_ABS
signal (signal
contained in
EBC1mess-
age).
5E 08 CAN LINE
- BRAKING
SYSTEM-
ASR ACTI-
VATED
(BRAKE)
WRONG
SIGNAL
Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Error 91 pres-
oot '|3C+
t|ooot' oss-
age issued by
ABS/ ASR /
EBSelectronics.
CheckABS / ASR/
EBSsignal travel.
No z_ABS
signal (signal
contained in
EBC1mess-
age).
5E 08 CAN LINE
- BRAKING
SYSTEM-
ASR ACTI-
VATED
(BRAKE)
WRONG
SIGNAL
CheckCAN line.
CheckECU correct
programmino.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
5F 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
CRUISE
CON-
TROL OFF
WRONG
SIGNAL
restrictions.
Resistance
(Ohm)
Measurepoint
1: Connector
(vehicleside)
Pin: 8
Measurepoint
2: Connector
(vehicleside)
Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
No
z_cc_status
signal (signal
contained in
CCVSmess-
age).
5F 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
CRUISE
CON-
TROL OFF
WRONG
SIGNAL
Error 182present
'CCVS t|ooot'
messageissued by
EDC.
Checksignal travel
EDC.
60 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
PRO-
GRAMME
D SPEED
WRONG
SIGNAL
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
No
z_cc_status
signal (signal
contained in
CCVSmess-
age).
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
60 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
PRO-
GRAMME
D SPEED
WRONG
SIGNAL
Error 182present
'CCVS t|ooot'
messageissued by
EDC.
Checksignal travel
EDC.
61 08 CAN LINE
- ENGINE-
NUMBER
OF EN-
GINE
REVS.
WRONG
SIGNAL
Vehiclemoving:
Clutch control is gov-
ernedbythetimein-
terval set bythecon-
trol unit. Reductionin
drivingcomfort.
The clutchopens
under thethreshold
fixedbythesystem;
thespeed of theen-
gineisnot checked
duringgear increases.
Vehiclestationary:
Clutch control is gov-
ernedbythetimein-
terval set bythecon-
trol unit; reductionin
manoeuvringcom-
fort.
Checkenginespeed in
error memoryunder
tions.
61 08 CAN LINE
- ENGINE-
NUMBER
OF EN-
GINE
REVS.
WRONG
SIGNAL
Pleasemakealso adi-
agnosischeck on EDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
62 08 SHIFTING
ACTUA-
TOR-
SENSORS
- INPUT
SHAFT
SPEED
WRONG
SIGNAL
Vehiclemoving:
Thetimeinterval in-
creasesbywhichgear
changes are governed.
Whenchanginggear
theclutchmaybe
partlyclosed. If the
gear is engaged, the
input speed is replaced
with theoutput speed.
Vehiclestationary:
Thetimeinterval in-
creasesbywhichgear
changes are governed.
Reductionindriving
andmanoeuvringcom-
fort.
Checkconnector
statusandsensor effi-
ciency.
Otherwisecheck:
- correct mountingof
thesensor.
- correct mounting
and playof phonic
wheel.
63 08 SENSORS
- TRANS-
MISSION
OUTPUT
SPEED
WRONG
SIGNAL
The output speedis
calculated viaredun-
dant signals, such as
thetachographsignal,
viatheCAN line.
All thegears canbe
engagedmanually.
Reduction in clutch
performancedueto
thetimeneededto
acquiretheinforma-
tion fromtheCAN
line.
Checkwiringand con-
nections.
Replacesensor if re-
quired.
1- Measuretype:
Voltage(V)
Measurepoint 1:
Connector for
clutch actuator
- gearboxside
Pin: 18
Measurepoint 2:
Connector for
clutch actuator
- gearboxside
Pin: 6
2- Measuretype:
Voltage(V)
Measurepoint 1:
Connector for
clutch actuator
- gearboxside
Pin: 11
Measurepoint 2:
Connector for
clutch actuator
- gearboxside
Pin: 6
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
64 08 SIGNALS-
SENSOR-
TACHO-
GRAPH
SENSOR
WRONG
SIGNAL
If theoutput speed
signal 1is available,
thereareno restric-
tionsonthesystem.
Checkvehicle-endwir-
ing.
Checkandreplacede-
fectiveoutput sensor.
Error 99,101
set; Output
speed >
2500 rpm;
Vehiclespeed
too high.
64 08 SIGNALS-
SENSOR-
TACHO-
GRAPH
SENSOR
WRONG
SIGNAL
Verifythecorrect
workingof thetacho-
graph.
64 08 SIGNALS-
SENSOR-
TACHO-
GRAPH
SENSOR
WRONG
SIGNAL
Or alternatevelycheck
that the storedvaluein
theECU for the axle
ratio correct is (Diag-
nosis: Idendification
CodeReading).
If thevalueisnot cor-
rect, carryout again
theprogramming(Pro-
gramming: Configur-
ationChange).
65 08 SIGNALS-
SENSOR-
TACHO-
GRAPH+O
UTPUT
SHAFT
SPEED
SENSOR
BOTH
SPEED
SENSORS
FAULTY
Vehiclemoving:
The speedincreases
aremanaged as the
changes.
The speedincreases
arenot possible
whentheengine is at
lowspeed.
The engagement time
increases.
Vehiclestationary:
The engagement time
islonger.
Wear of selec-
tor fork.
Checksignal travel as
with error 99and100.
Wear of selector fork.
Disassemble/replace
transmission.
Gear se-
lected and
displayed->
no power
transmission.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
66 03 SIGNALS-
SENSOR-
INPUT
AND
OUTPUT
SPEED
SENSOR
PLAUSIBIL-
ITY
Vehiclemoving:
The speedincreases
aremanaged as the
changes. Thespeed
increasesarenot
possible when the
engineis at low
speed. The engage-
ment timeincreases.
Vehiclestationary:
The engagement time
islonger.
Checkif theposition
of thesensors is cor-
rect. Checkthemech-
anical efficiencyof the
transmission. Check
that the vehicle is not
equipped with an elec-
tronic control unit
programmed for the
retarder, if the trans-
mission does not re-
quire it.
67 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
VEHICLE
SPEED
WRONG
SIGNAL
The systemadopts
substitutivepara-
meters. Reduced
functionalityfor the
automaticmodeand
to calculate the start-
inggear, if thereis a
large differencebe-
tweenthepara-
metersutilizedand
theactual values. The
qualityof clutch un-
couplingmayde-
crease.
Other CAN er-
rors
26,180,181,182.
Resistance
(Ohm)
Measurepoint
1: Connector
(vehicleside)
Pin: 8
Measurepoint
2: Connector
(vehicleside)
Pin: 12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Reprogram
theelec-
tronic con-
trol unit to
rewritethe
parameters.
67 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
VEHICLE
SPEED
WRONG
SIGNAL
Pleasemakealso adi-
agnosischeck on EDC
system.
67 08 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
VEHICLE
SPEED
WRONG
SIGNAL
Further errorssaved
inEDC.
EDC deactiva-
tion relaydefec-
tive.
Replacedeactivation
relay.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
68 01 SUPPLY
VOLTAGE
- ELEC-
TRONIC
CON-
TROL
UNIT
VOLTAGE
TOO
HIGH
Defectivesupply. Checkfor afault inthe
10A fuses (fuses
holder no. 70602).
1- Measure type:
Voltage(V)
Measurepoint 1:
Connector for
ECU power sup-
ply - vehicleside.
Pin: 4 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
16- 2- Measure
type: Voltage(V)
Measurepoint 1:
Connector for
ECU power sup-
ply - vehicleside.
Pin: 5 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
16- 3- Measure
type: Voltage(V)
Measurepoint 1:
Connector for
ECU power sup-
ply - vehicleside.
Pin: 4 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
17- 4- Measure
type: Voltage
(V) Measure
point 1: Con-
nector for ECU
power supply-
vehicleside.
Pin: 5 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
17
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
3- Connector
Connected;
Key+15ON;
4- Connector
Connected;
Key+15ON;
1- Min. value:
22V; Max.
value: 28V;
2- Min. value:
22V; Max.
value: 28V;
3- Min. value:
22V; Max.
value: 28V;
4- Min. value:
22V; Max.
value: 28V;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
69 02 SUPPLY
VOLTAGE
- ELEC-
TRONIC
CON-
TROL
UNIT
VOLTAGE
TOO
LOW
Defectivesupply. Checkfor afault inthe
10A fuses (fuses
holder no. 70602).
1- Measure type:
Voltage (V)
Measurepoint 1:
Connector for
ECU power sup-
ply - vehicleside.
Pin: 4 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
16- 2- Measure
type: Voltage
(V) - Measure
point 1: Con-
nector for ECU
power supply-
vehicleside. Pin:
5 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
16- 3- Measure
type: Voltage
(V) Measure
point 1: Con-
nector for ECU
power supply-
vehicleside. Pin:
4 Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
17- 4- Measure
type: Voltage(V)
Measurepoint 1:
Connector for
ECU power sup-
ply - vehicleside.
Pin: 5- Measure
point 2: Con-
nector for ECU
power supply-
vehicleside. Pin:
17
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
3- Connector
Connected;
Key+15ON;
4- Connector
Connected;
Key+15ON;
1- Min. value:
22V; Max.
value: 28V;
2- Min. value:
22V; Max.
value: 28V;
3- Min. value:
22V; Max.
value: 28V;
4- Min. value:
22V; Max.
value: 28V;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
6B 02 CLUTCH
ACTUA-
TOR-
POSITION
SENSOR
SUPPLY
OUT OF
RANGE
Vehiclemoving:
The clutchisdisen-
gagedviatimecon-
trol.
Vehiclestationary:
Impossibleto per-
formmanoeuvres. If
thevehiclehas not
startedwithinaset
time, neutral isen-
gaged.
A freshgear has to
beselected with the
gear lever to start the
vehicle.
Comfort is dimin-
ished on starting.
Checkthesensor volt-
agesupply.
Measuretype:
Voltage (V)
Measurepoint
1: Connector
for clutchactua-
tor - gearbox
sidePin: 15
Measurepoint
2: Connector
for clutchactua-
tor - gearbox
sidePin: 20
Connector
Connected;
Key+15ON;
Min. value: 4.5
V; Max. value:
5.5 V;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
6C SIGNALS-
GEAR
SHIFT
LEVER
WRONG
SIGNAL
Control lever:
No shiftingpossible
duringtravel.
/t staoost||| t|o '|ast-
stat|o oa' |s so-
lected in themanual
mode (half-automatic
mode), theautomatic
startinggear in auto-
maticmode.
If neutral is activated
or existingat standstill,
thestartinggear is
not engaged.
Neutral switch:
No shiftingpossible
duringtravel.
At standstill astar-
tinggear canbese-
lected and thevehicle
canbedrivenwitha
startinggearselected.
R gear selector sig-
nals:
If thereis afault (no
signal) in oneof the
two.
Reverse gear
switches at astand-
still andif thetip-ac-
tion speedrangese-
lector is pulledback-
wards(-/--), the low-
ratio Reversegear
(RL) isengaged.
Newshift lever:
if there is any
shiftingrequest
signal trans-
mittedinthe
VCM_TC mess-
age.
Checkwiringand con-
nectionsbetweengear
lever andEcu: nominal
valuesupplyvoltage
gear selector 24Volt.
CheckCAN linebe-
tweengear lever and
Ecu: nominal valuere-
sistance CAN H -
CAN L 60Ohm. Re-
placeCAN bus wiring
and/or CAN modules.
Checkand/or replace
rangeselector.
1- Measuretype:
Voltage (V)
Measurepoint 1:
Connector (ve-
hicleside) Pin:
11
Measurepoint 2:
Connector (ve-
hicleside) Pin:
16
2- Measure
type: Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 3
Measurepoint
2: Connector
(vehicleside)
Pin: 6
3- Measure
type: Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
1- Connector
Connected;
Key+15OFF;
2- Connector
Connected;
Key+15OFF;
3- Connector
Connected;
Key+15OFF;
1- Max. value:
19,5V;
2- Typical Value:
60Ohm;
3- Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
6C 00 SIGNALS-
GEAR
SHIFT
LEVER
WRONG
SIGNAL
The gearboxmay
havelower perform-
anceor belocked. It
dependsonthe
conditionsgenerating
it.
Select PARAMETER
READ environment.
Movetheshift lever
and verifythevalue
changes.
Checkcabling, if failure
persists, thelever is
worn.
6E 04 CAN LINE
- COM-
MUNICA-
TION
LINES-
GEAR
SHIFT
LEVER
COM-
MUNICA-
TION
ERROR
After switchingover
thekey (Off-On) the
fault isrecognized
duringsystemset-up
and thedisplayshows
theerror code; the
systemisnot avail-
able.
boxlocked, thesys-
temautomaticallyen-
gagesthelast gear
usedto start theve-
hicle.
If thegearbox has the
reverse gear engaged
t/misautomatically
put into neutral.
No informationon
thegear lever is avail-
able.
The displayshowsal-
ternatelytheerror
codeand thein-
formation on the
gear.
CheckvehicleCAN. 1- Measure
type: Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 3
Measurepoint
2: Connector
(vehicleside)
Pin: 6
2- Measure
type: Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
1- Connector
Connected;
Key+15OFF;
2- Connector
Connected;
Key+15OFF;
1- Typical Value:
60Ohm;
2- Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
6E 04 CAN LINE
- COM-
MUNICA-
TION
LINES-
GEAR
SHIFT
LEVER
COM-
MUNICA-
TION
ERROR
Checkwiringand con-
nectionsbetweengear
lever andEcu.
Measuretype:
Voltage (V)
Measurepoint 1:
Connector (ve-
hicleside) Pin:
11
Measurepoint 2:
Gear lever con-
nector Pin: 15
Connector
Connected;
Key+15ON;
Max. value: 24
V;
ReplaceCAN
gear selector
switch.
Conduct a
test drive
with function
check.
Checktrans-
mission for
leaks.
71 04 CAN LINE
-RE-
TARDER-
INTARDER
-CON-
FIGUR-
ATION
MESSAGE
TIMEOUT Impossibleto calcu-
tance.
No automatic cal-
inggear.
The averagestarting
stop.
restrictions.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
71 04 CAN LINE
-RE-
TARDER-
INTARDER
-CON-
FIGUR-
ATION
MESSAGE
TIMEOUT Check/ReplaceIntar-
der electronics.
72 00 CLUTCH
ACTUA-
TOR-
CLUTCH
ENGAGE-
MENT
NOT RE-
QUESTED,
ENGAGED
GEAR
AND STA-
TIONARY
VEHICLE
Standstill: shift to
neutral, after neutral
systemavailable.
Checkthe mechanical
operationof theclutch
unit and thepneu-
maticcircuit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
75 00 CLUTCH
ACTUA-
TOR-
CLUTCH
SELF-AD-
JUSTMENT
ERROR
Systemnot available. Checkthe mechanical
systemof theclutch
engage/disengageunit.
76 00 CLUTCH
ACTUA-
TOR-
CLUTCH
DOES
NOT DIS-
ENGAGE
Vehiclemoving:
Tryengagingthe
gear.
If thegear isengaged,
theclutch stays en-
gaged.
The gearboxstays
locked.
Vehiclestationary: If
theclutchfailsto dis-
engage, theengine
remains locked.
The systemselects
neutral automatically.
Checkthe mechanical
unit and thepneu-
maticcircuit.
77 00 CLUTCH
ACTUA-
TOR-
CLUTCH
DOES
NOT EN-
GAGE
Vehiclemoving: If the
gearbox has agear
engaged, the clutch
triesto closewiththe
highest speed. Gear-
boxlocked. Vehicle
stationary: Automatic
engagement of neu-
tral after timelag
governedbythesys-
tem.
Systemnot available.
Checkthe mechanical
unit and thepneu-
maticcircuit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
78 00 CLUTCH
ACTUA-
TOR-
(Y17) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
SLOW
MECHAN-
ICAL FAIL-
URE
Reductioninclutch
performance.
Thefunction per-
formed byadamaged
valveis performed by
another valvefollowing
this scheme:mechanical
fault of theY17 valve
>>functionperformed
byvalve Y16 mechan-
ical fault of theY16
valve>>function per-
formed byvalveY17
mechanical fault of the
Y15valve>>function
performedbyvalve
Y14mechanical fault of
theY14 valve>>
function performed by
valveY15
Checktheclutch
(electroniccontrol
unit)
79 00 CLUTCH
ACTUA-
TOR-
(Y16) SO-
LENOID
VALVE
CLUTCH
DISEN-
GAGE-
MENT
FAST
MECHAN-
ICAL FAIL-
URE
Reductioninclutch
performance.
Thefunction per-
formed byadamaged
>>functionperformed
byvalve Y16 mechan-
formed byvalveY17
Y15valve>>function
performedbyvalve
theY14 valve>>
valveY15
Checktheclutch
(electroniccontrol
unit)
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
7A 00 CLUTCH
ACTUA-
TOR-
(Y15) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
SLOW
MECHAN-
ICAL FAIL-
URE
Reductioninclutch
performance.
Thefunction per-
formed byadamaged
>>functionperformed
byvalve Y16 mechan-
formed byvalveY17
Y15valve>>function
performedbyvalve
theY14 valve>>
valveY15
Checktheclutch
(electroniccontrol
unit)
7B 00 CLUTCH
ACTUA-
TOR-
(Y14) SO-
LENOID
VALVE
CLUTCH
ENGAGE-
MENT
FAST
MECHAN-
ICAL FAIL-
URE
Reduction in clutch
performance.
The function per-
formedbyadamaged
valveisperformed by
fault of the Y17 valve
>>function per-
formedbyvalveY16
Y16 valve>>function
performed byvalve
Y17 mechanical fault of
theY15 valve>>
valveY14 mechanical
fault of the Y14 valve
>>function per-
formedbyvalveY15
Checktheclutch
(electroniccontrol
unit)
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
7C 00 CLUTCH
ACTUA-
TOR-
POSITION
SENSOR
SIGNAL
OUT OF
RANGE
Vehiclemoving:
The clutchisengaged
- disengaged viatime
lagsignal.
Vehiclestationary:
Manoeuvringimposs-
ible. If thevehiclefails
to start within acer-
tain lengthof time set
bythecontrol unit,
thegearbox automati-
callygoesinto neutral;
startingisagain poss-
ibleafter engagingthe
gear with thegear
lever. Reductionin
clutch performance.
Checkthesensor volt-
agesupply.
Measuretype:
Voltage (V)
Measurepoint 1:
Connector for
clutchactuator
- gearboxside
Pin: 10
Measurepoint 2:
Connector for
clutchactuator
- gearboxside
Pin: 20
Connector
Connected;
Key+15ON;
Min. value: 0.5
V; Max. value:
4.5 V;
7D 00 SHIFTING
ACTUA-
TOR-
PRESSURE
REDUC-
TION
VALVE
PRESSURE
TOO
HIGH AT
ALTITUDE
No systemrestric-
tion.
Checksystemsupply
air pressure7 bars.
7E 03 SHIFTING
ACTUA-
TOR-
SENSORS
- PRES-
SURE SEN-
SOR
SIGNAL
OUT OF
RANGE
No systemrestriction
if there is enoughair
inthesystem.
The Cluster failsto
displaytheAL codeif
theair systemdoes
not have the right
pressure.
The clutchiscon-
trolled with atime in-
terval; thecontrol
times mayturnout
longer.
Gear actuator replace-
ment (control unit)
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
7F 03 SHIFTING
ACTUA-
TOR-
SENSORS
- ECU
TEMPERA-
TURE
SIGNAL
OUT OF
RANGE
No systemrestric-
tion.
Replacingthegearbox
80 00 SENSORS
- OIL TEM-
PERATURE
SIGNAL
SIGNAL
OUT OF
RANGE
No systemrestric-
tion; thesystemtakes
thecontrol unit tem-
peraturesignal asref-
erence.
Reprogramand in case
replacethegearbox
actuator (control unit).
81 06 SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
SHORT
CIRCUIT
TO POSI-
TIVE
Vehiclemoving:
Whenthetrouble
occurs whilechanging
gear, the couplingsig-
nal is substituted by
thetimechecksignal.
The gearboxisthen
locked; it ispossible
to engageneutral.
Vehiclestationary: it
ispossibleto select
thestartinggear.
The main valve and
thegear coupling
valveremain active
until the clutch, on
closing, exceedsthe
referencethreshold
or thestart condi-
tionsoccur.
Verifythat sensor re-
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
81 06 SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
SHORT
CIRCUIT
TO POSI-
TIVE
CheckVDBCAN-line
integrity.
82 05 SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
SHORT
CIRCUIT
TO
GROUND
Vehiclemoving:
Whenthetrouble
thetimechecksignal.
The gearboxisthen
to engageneutral.
ispossibleto select
thestartinggear.
The main valve and
thegear coupling
valveremain active
closing, exceedsthe
referencethreshold
or thestart condi-
tionsoccur.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
82 05 SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
SHORT
CIRCUIT
TO
GROUND
CheckVDBCAN-line
integrity.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
83 0A SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
INTER-
RUPTION
Vehiclemoving:
Whenthetrouble
thetimechecksignal.
The gearboxisthen
to engageneutral.
ispossibleto select
thestartinggear.
The main valve and
thegear coupling
valveremain active
closing, exceedsthe
referencethreshold
or thestart condi-
tionsoccur.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
83 0A SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
INTER-
RUPTION
CheckVDBCAN-line
integrity.
84 00 SHIFTING
ACTUA-
TOR-
SENSORS
- GEAR
ENGAGED
SELF-AD-
JUSTMENT
ERROR
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
85 06 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SHORT
CIRCUIT
TO POSI-
TIVE
Vehiclemoving:
Onlysome gears can
beselected.
Vehiclestationary:
All thegears canbe
selected; thereverse
gears cannot bese-
lected.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
85 06 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SHORT
CIRCUIT
TO POSI-
TIVE
CheckVDBCAN-line
integrity.
85 06 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SHORT
CIRCUIT
TO POSI-
TIVE
ReplaceECU. If replac-
ingtheECU corrects
theproblem, reinstall
theoriginal ECU to
confirmthat theprob-
lemisintheECU.
86 05 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SHORT
CIRCUIT
TO
GROUND
CheckVDBCAN-line
integrity.
86 05 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SHORT
CIRCUIT
TO
GROUND
ingtheECU corrects
theoriginal ECU to
lemisintheECU.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
86 05 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SHORT
CIRCUIT
TO
GROUND
Vehiclemoving:
Onlysome gears can
beselected.
Vehiclestationary:
All thegears canbe
gears cannot bese-
lected.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
87 0A SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
INTER-
RUPTION
Vehiclemoving:
Onlysome gears can
beselected.
Vehiclestationary:
All thegears canbe
gears cannot bese-
lected.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
87 0A SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
INTER-
RUPTION
CheckVDBCAN-line
integrity.
87 0A SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
INTER-
RUPTION
ingtheECU corrects
theoriginal ECU to
lemisintheECU.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
88 00 SHIFTING
ACTUA-
TOR-
SENSORS
- GEARSE-
LECTOR
SELF-AD-
JUSTMENT
ERROR
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
89 06 SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
SHORT
CIRCUIT
TO POSI-
TIVE
Vehiclemoving: Lock-
ingengagedgear
rangeassembly.
Onlythegears of the
current gear assembly
can bechanged by
timecontrol.
Vehiclestationary:
All thestartinggears
can beselected; the
lowrangegear as-
semblycanbese-
lected bythetime
control.
The main valve and
therangevalvere-
mainactiveuntil the
clutch couplingex-
ceeds apre-arranged
threshold or therun-
ningconditionisde-
tected.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
89 06 SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
SHORT
CIRCUIT
TO POSI-
TIVE
CheckVDBCAN-line
integrity.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
8A 05 SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
SHORT
CIRCUIT
TO
GROUND
ingengagedgear
rangeassembly.
Onlythegears of the
can bechanged by
timecontrol.
Vehiclestationary:
can beselected; the
lowrangegear as-
semblycanbese-
lected bythetime
control.
The main valve and
therangevalvere-
mainactiveuntil the
clutch couplingex-
ceeds apre-arranged
ningconditionisde-
tected.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
8A 05 SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
SHORT
CIRCUIT
TO
GROUND
CheckVDBCAN-line
integrity.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
8B 0A SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
INTER-
RUPTION
ingengagedgear
rangeassembly.
Onlythegears of the
can bechanged by
timecontrol.
Vehiclestationary:
can beselected; the
lowrangegear as-
semblycanbese-
lected bythetime
control.
The main valve and
therangevalvere-
mainactiveuntil the
clutch couplingex-
ceeds apre-arranged
ningconditionisde-
tected.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
8B 0A SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
INTER-
RUPTION
CheckVDBCAN-line
integrity.
8C 00 SHIFTING
ACTUA-
TOR-
SENSORS
- RANGE
UNIT
SELF-AD-
JUSTMENT
ERROR
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
8D 06 SHIFTING
ACTUA-
TOR-
SENSORS
- SPLITTER
UNIT
SHORT
CIRCUIT
TO POSI-
TIVE
Splitter assembly
locked.
Drivingis possible
onlywiththelast
gear assemblyse-
lected bythesplitter.
If therequiredgear
cannot beengaged,
thehighest available
gear isengaged.
If thetroubleoccurs
agear change the
splitter control is
madebythetime
control.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
8E 05 SHIFTING
ACTUA-
TOR-
SENSORS
- SPLITTER
UNIT
SHORT
CIRCUIT
TO
GROUND
Splitter assembly
locked.
Drivingis possible
onlywiththelast
gear assemblyse-
If therequiredgear
cannot beengaged,
gear isengaged.
If thetroubleoccurs
agear change the
splitter control is
madebythetime
control.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
8F 0A SHIFTING
ACTUA-
TOR-
SENSORS
- SPLITTER
UNIT
INTER-
RUPTION
Splitter assembly
locked.
Drivingis possible
onlywiththelast
gear assemblyse-
If therequiredgear
cannot beengaged,
gear isengaged.
If thetroubleoccurs
agear change the
splitter control is
madebythetime
control.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
90 00 SHIFTING
ACTUA-
TOR-
SENSORS
- SPLITTER
UNIT
SELF-AD-
JUSTMENT
ERROR
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
sistanceshouldbebe-
tween60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
91 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DOES
NOT DIS-
ENGAGE
Vehiclemoving:
Whenselectingthe
changefromthe
lower gear assembly
to thehigher one,
thehighest gear of
thelower gear as-
semblyisselected.
Whenselectingthe
changefromthe
higher gear assembly
to thelower one, the
lowest gear of the
isselected.
Vehiclestationary:
If it is not possibleto
select thelower gear
assembly, thelowest
gear of the higher
gear assemblyisused
for pickingup.
It is not possibleto
engage the reverse
gear of the higher
gear assembly.
First of all remove
possible failures due to
interruptions or short-
circuit on sensors and
solenoidvalves
91 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DOES
NOT DIS-
ENGAGE
Tryto engage gears
with thevehicleat rest
and checkif thefailure
isstill present.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
91 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DOES
NOT DIS-
ENGAGE
Checkthe mechanical
systemof therange
unit.
92 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
If theselected gear
assemblycannot be
engaged, the relevant
actuator triesto re-
peat engagement for
threetimes. When
theattemptsfail, the
systemcan havethe
followingreactions:
1) Whenthe selec-
tion fromthelower
to thehigher gear as-
semblyfails, the
highest gear of the
lower assemblyisen-
gaged.
2) Whenthe selec-
tion fromthehigher
to thelower gear as-
semblyfails, the
lowest gear of the
isengaged.
Vehiclestationary: if
thelower gear as-
semblycannot bese-
lected, thelowest
gear of the higher
gear assemblyisse-
lected for pickingup.
First of all remove
solenoidvalves
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
92 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL POSI-
TION BUT
DOES
NOT
REACH
THE FINAL
POSITION
Tryto engage gears
isstill present.
92 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Checkthe mechanical
systemof therange
unit.
93 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DOES
NOT EN-
GAGE
If theselected gear
assemblycannot be
engaged, the relevant
actuator triesto re-
peat engagement for
threetimes.
If it is not possibleto
engage the freshgear
assemblythesystem
triesto go backto
theprevious one; if
this attempt fails after
acertainlengthof
timethesystemgoes
into neutral.
First of all remove
solenoidvalves
93 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DOESNOT EN-
GAGE
Tryto engage gears
isstill present.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
93 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DOES
NOT EN-
GAGE
Checkthe mechanical
systemof therange
unit.
94 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT DIS-
ENGAGE
Vehiclemoving:
The highest-lowest
gear that can bese-
lected is thehighest-
lowest oneavailable
on thegear assembly
selected previously
with thesplitter.
Vehiclestationary:
The highest-lowest
gear that can bese-
lected corresponds
to thehighest-lowest
pick-upgear onthe
gear assemblyprevi-
ouslyengagedbythe
splitter.
First of all remove
solenoidvalves
94 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT DIS-
ENGAGE
Verifythat B7sensor
resistance shouldbe
between60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
94 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT DIS-
ENGAGE
Tryto engage gears
isstill present.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
94 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT DIS-
ENGAGE
Checkthe mechanical
systemof thesplitter
unit (eventuallyre-
placethegears/splitter
shaft).
95 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Vehiclemoving: The
highest-lowest gear
that can be selected is
thehighest-lowest
oneavailableon the
gear assemblyse-
lected previouslywith
thesplitter.
Vehiclestationary:
The highest-lowest
gear that can bese-
lected corresponds to
thehighest-lowest
pick-upgear onthe
gear assemblyprevi-
ouslyengagedbythe
splitter.
First of all remove
solenoidvalves
95 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Verifythat B7sensor
resistance shouldbe
between60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
95 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Tryto engage gears
isstill present.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
95 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Checkthe mechanical
unit (eventuallyre-
placethegears/splitter
shaft).
96 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT EN-
GAGE
Systemnot available. First of all remove
solenoidvalves
96 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT EN-
GAGE
Verifythat B7sensor
resistance shouldbe
between60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
96 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT EN-
GAGE
Tryto engage gears
isstill present.
96 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DOES
NOT EN-
GAGE
Checkthe mechanical
unit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
97 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
DOES
NOT DIS-
ENGAGE
Checkthe mechanical
systemof thegear en-
gagement unit.
97 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
DOES
NOT DIS-
ENGAGE
Vehiclemoving: T/m
engagesontheprevi-
ous gear.
If theprevious gear
cannot beengaged
ooo to t|o vo||c|o's
speed, thesystemse-
lects the gear that
can beselected as
close as possibleto
theprevious gear.
Whentheattempt is
not successful the
T/mis in neutral. Ve-
hiclestationary:
If theprevious gear
cannot beengaged
theT/mgoes into
neutral.
First of all remove
solenoidvalves
97 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
DOES
NOT DIS-
ENGAGE
Tryto engage gears
isstill present.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
98 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Vehiclemoving: T/m
engagesontheprevi-
ous gear.
If theprevious gear
cannot beengaged
ooo to t|o vo||c|o's
speed, thesystemse-
lects the gear that
can beselected as
close as possibleto
theprevious gear.
Whentheattempt is
not successful the
T/mis in neutral. Ve-
hiclestationary:
If theprevious gear
cannot beengaged
theT/mgoes into
neutral.
First of all remove
solenoidvalves
98 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Tryto engage gears
isstill present.
98 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
SPLITTER
LEAVES
THE IN-
ITIAL
POSITION
BUT DOES
NOT
REACH
THE FINAL
POSITION
Checkthe mechanical
gagement unit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
99 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
DOES
NOT EN-
GAGE
Vehiclemoving: T/m
engagesonneutral.
It is necessaryto start
engaginganother
gear with thegear
lever; if thesystemis
not ableto engage
thegear it shuts
downandisno
longer available.
First of all remove
solenoidvalves
99 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
DOES
NOT EN-
GAGE
Tryto engage gears
isstill present.
99 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR SE-
LECTOR
DOES
NOT EN-
GAGE
Checkthe mechanical
gagement unit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
9A 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DOES
NOT DIS-
ENGAGE
Vehiclemoving:
The clutchisengaged
intheprevious gear.
The next attempt at
engagingwill have to
start with theselec-
tor switch. Vehicle
stationary: gear
changepermitted
onlyafter theneutral
signal has beenre-
ceived. Startingand
drivingcanbeat-
tempted withthe
gear engaged, if the
gear isequal to or
lower thanthe
lowest gear of these-
lected range.
First of all remove
solenoidvalves
9A 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DOES
NOT DIS-
ENGAGE
Tryto engage gears
isstill present.
9A 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DOES
NOT DIS-
ENGAGE
Checkthe mechanical
gagement unit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
9B 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DOES
NOT EN-
GAGE
Vehiclemoving:
T/mstays on neutral.
Another gear selec-
tion can be set with
theselector lever; if
thesystemcomes
out of the neutral
position, but thegear
isnot engaged within
acertaintime, the
systemgoes back
into neutral.
Vehiclestationary:
T/mstays on neutral.
Whenagear isen-
gagedtheclutch is
engaged. If the clutch
travel istoo long,
T/mgoes back into
theneutral position.
Another gear selec-
tion can be set with
theselector lever.
First of all remove
solenoidvalves
9B 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DOES
NOT EN-
GAGE
Tryto engage gears
isstill present.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
9B 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DOES
NOT EN-
GAGE
Checkthe mechanical
gagement unit.
9C 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
WRONG
GEAR
SHIFTING
The gearboxauto-
maticallygoes into
neutral and the clutch
stays open. Another
gear selection can be
set with theselector
lever.
First of all remove
solenoidvalves
9C 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
WRONG
GEAR
SHIFTING
Tryto engage gears
isstill present.
9C 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
WRONG
GEAR
SHIFTING
Checkthe mechanical
gagement unit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
9E 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Tryto engage gears
isstill present.
9E 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Checkthe mechanical
gagement unit.
9E 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
The main valvewill
beautomaticallyop-
erated together with
thegear valves to
coupleinthefinal
position.
If thegear hasun-
coupled completely, a
suitablegear will be
automaticallyengaged
accordingto the
speed conditions.
First of all remove
solenoidvalves
9E 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
GEAR EN-
GAGED
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Verifythat B4sensor
resistance shouldbe
between60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
9F 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
The main valvewill
beautomaticallyop-
thegear valves to
coupleinthefinal
position.
If thegear hasun-
accordingto the
speed conditions.
First of all remove
solenoidvalves
9F 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Verifythat B4sensor
resistance shouldbe
between60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
9F 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Tryto engage gears
isstill present.
9F 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
RANGE
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Checkthe mechanical
gagement unit.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
A0 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Verifythat B7sensor
resistance shouldbe
between60and90
Ohms.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Sensor con-
nector Pin: 1
Measurepoint 2:
Sensor con-
nector Pin: 2
Connector Not
connected;
Key+15OFF;
Typical Value:
69Ohm;
A0 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Tryto engage gears
isstill present.
A0 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
The main valvewill
beautomaticallyop-
thegear valves to
coupleinthefinal
position.
If thegear hasun-
accordingto the
speed conditions.
First of all remove
solenoidvalves
A0 00 SHIFTING
ACTUA-
TOR-
CONTROL
CYLIN-
DERS-
SPLITTER
UNIT
DISEN-
GAGE-
MENT
NOT RE-
QUESTED
Checkthe mechanical
systemof therange
splitter (incase replace
thesleeves and the
gears shaft).
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
A3 00 CAN LINE
- ENGINE-
TORQUE
REQUEST
NO
AVAIL-
ABLE
SYMPTOM
Speedcannot be in-
creased(during
downshifts).
Transmission
end possibilities.
Check/assemblethe
gear shift rail withdet-
ent for gate.
Gear change
shaft:
- Old: 1327
306 005
- New: 1327
306 008
Introduction
ex trans-
mission
number into
production:
12AS2301
No. 141912
AS2301
IT No.
203583
A3 00 CAN LINE
- ENGINE-
TORQUE
REQUEST
NO
AVAIL-
ABLE
SYMPTOM
Vehiclemoving:
Gear changenot syn-
chronized.
Vehiclestationary:
Startingpermitted.
Decreasein function-
alityand clutchcom-
fort.
Checkthefollowing
function vehiclecom-
ponents:
- Injectionpump
- Diesel filter- Fuel
conduct and circuit
Wiring(signal travel)
- Mechanics engine
brakeflaps
A4 08 CAN LINE
- ENGINE-
RE-
QUESTED
ENGINE
TORQUE
WRONG
SIGNAL
Further errorssaved
inEDC.
Pleasemakealso adi-
agnosischeck on EDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
A5 08 CAN LINE
- ENGINE-
ACCELER-
ATOR
PEDAL
POSITION
WRONG
SIGNAL
Further errorssaved
inEDC.
Pleasemakealso adi-
agnosischeck on EDC
system.
A5 08 CAN LINE
- ENGINE-
ACCELER-
ATOR
PEDAL
POSITION
WRONG
SIGNAL
Vehiclemoving:
Impossibleto calcu-
late startinggear.
Throttlepedal posi-
tion will be replaced
byrequest for in-
formation fromthe
driver.
The couplingquality
could bereduced.
Vehiclestationary:
Startingis possible.
On reachingthe stop,
theaveragestarting
The manoeuvringand
startingqualitycould
bereduced.
celerator wiring.Re-
place/repair acceler-
ator/periphery.
A6 00 CAN LINE
- ENGINE-
IDLE
SWITCH /
ACCELER-
ATOR
PEDAL
PLAUSIBIL-
ITY
Vehiclemoving:
Gear changingposs-
ible
Vehiclestationary:
Impossibleto start
thevehicle.
celerator wiring/idling
switch.
Replace/repair/teach-in
accelerator/periphery.
Error isset
with idling
signal 1and
accelerator
pedal posi-
tion >20%.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
A6 00 CAN LINE
- ENGINE-
IDLE
SWITCH /
ACCELER-
ATOR
PEDAL
PLAUSIBIL-
ITY
Further errorssaved
inEDC.
Pleasemakealso adi-
agnosischeck on EDC
system.
A7 08 CAN LINE
- ENGINE-
ENGINE
TORQUE
WRONG
SIGNAL
Systemnot available. CheckvehicleCAN. Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
A7 08 CAN LINE
- ENGINE-
ENGINE
TORQUE
WRONG
SIGNAL
Intermittent or incor-
rect signal.
Pleasemake
also adiagnosis
checkonEDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
A8 08 CAN LINE
- ENGINE-
LOW IDLE
SWITCH
WRONG
SIGNAL
Vehiclemoving:
No systemrestriction
present whiledriving.
Vehiclestationary:
After RESETTING
thedisplayshows
codes APor FPuntil
thethrottlepedal is
pressedandtheidling
signal is off.
If theidlingsignal fails
to arrive within acer-
tain lengthof time,
thedisplaywill show
theerror with code
AC or will no longer
showcodeFP. Start-
ingis possibleif the
control unit detectsa
throttlepotentio-
meter value>the
threshold and theen-
gineidlingspeed +a
predefinedthreshold.
Checkaccelerator /
accelerator wiring/ id-
lingswitch.
Replace/ repair /
teach-in accelerator /
periphery.
Error isset
with idling
signal 0and
accelerator
pedal posi-
tion >0%.
A9 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT -
ECU
RELAY
CUT-OFF
DOES
NOT
SWITCH
OFF
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
The relayis located
withintheE.C.U. Be-
forereplacingthe
E.C.U., check that the
voltage supplied is cor-
rect.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
AA 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT -
ECU
RELAY
CUT-OFF
DOES
NOT
SWITCH
ON
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
The relayis located
withintheE.C.U. Be-
forereplacingthe
E.C.U., check that the
voltage supplied is cor-
rect.
AB 08 CAN LINE
- ENGINE-
ENGINE
TORQUE
WRONG
SIGNAL
Vehiclemoving:
Impossibleto calcu-
late startinggear. The
information on the
torque percentageis
obtainedfromthe
o|vo's cooto|s
(throttlepedal). Ve-
hiclestationary: Start-
ingpossible. When
thevehiclestops the
systemselects the av-
erage startinggear.
Attention to possible
overloads on the
clutch.
EDC deactiva-
tion relaydefec-
tive.
Replacedeactivation
relay.
No error
savedin
EDC.
AB 08 CAN LINE
- ENGINE-
ENGINE
TORQUE
WRONG
SIGNAL
Intermittent or incor-
rect signal.
Pleasemake
also adiagnosis
checkonEDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
AE 08 CAN LINE
- ENGINE-
KICK-
DOWN
SWITCH
WRONG
SIGNAL
The kickdown func-
tion is not available.
No additional func-
Checkthefollowing
components:
- EDC-Accelerator
pedal (teach-in)
- Wiring(signal travel)
- Kickdown switch
Error onthe
signal from
thethrottle
pedal
AF 04 SUPPLY
VOLTAGE
- ELEC-
TRONIC
CON-
TROL
UNIT
SIGNAL
KEY (+15)
NOT
PRESENT
Defectivesupply(+
15).
Checkfor afault inthe
10A fuses (fuses
holder no. 70602).
1- Measuretype:
Voltage (V)
Measurepoint 1:
Connector for
ECU power
supply
- vehicleside.
Pin: 1
Measurepoint 2:
Connector for
ECU power
supply
- vehicleside.
Pin: 16
2- Measuretype:
Voltage (V)
Measurepoint 1:
Connector for
ECU power
supply
- vehicleside.
Pin: 1
Measurepoint 2:
Connector for
ECU power
supply - vehicle
side. Pin: 17
1- Connector
Connected;
Key+15ON;
2- Connector
Connected;
Key+15ON;
1- Min. value:
22V; Max.
value: 28V;
2- Min. value:
22V; Max.
value: 28V;
B0 00 SIGNALS-
GEAR
SHIFT
LEVER
SHIFT
LEVER
POSITION
NOT DE-
FINED
The gearboxmay
havelower perform-
anceor belocked.
It depends on the
conditionsgenerating
it.
Select PARAMETER
READ environment.
Movetheshift lever
and verifythevalue
changes.
Checkcabling, if failure
persists, thelever is
worn.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
B1 04 CAN LINE
-COM-
MUNICA-
TION
LINES-
VEHICLE
COM-
MUNICA-
TION
ERROR
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
VerifyCAN line(for a
possible disconnection
of ST11 connector).
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
B1 04 CAN LINE
-COM-
MUNICA-
TION
LINES-
VEHICLE
COM-
MUNICA-
TION
ERROR
Checkwiring
B2 04 CAN LINE
-COM-
MUNICA-
TION
LINES-
VEHICLE
COM-
MUNICA-
TION
ERROR
(WARN-
ING)
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
of ST11 connector).
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
B2 04 CAN LINE
-COM-
MUNICA-
TION
LINES-
VEHICLE
COM-
MUNICA-
TION
ERROR
(WARN-
ING)
Checkwiring
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
B3 00 CAN LINE
-COM-
MUNICA-
TION
LINES-
VEHICLE
QUEUE
OVERRUN
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
of ST11 connector).
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
B3 00 CAN LINE
-COM-
MUNICA-
TION
LINES-
VEHICLE
QUEUE
OVERRUN
Checkwiring
B4 04 CAN LINE
- ENGINE-
CONTROL
MESSAGE
TIMEOUT Vehiclemoving: gear-
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
B4 04 CAN LINE
- ENGINE-
CONTROL
MESSAGE
TIMEOUT Inthe EEC1message
timeout at thefol-
lowingsignals:
- theoretical injection
volumeEDC
- current injected vol-
umeEDC
- output speed of en-
gine
Pleasemakealso adi-
agnosischeck on EDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
B4 04 CAN LINE
- ENGINE-
CONTROL
MESSAGE
B5 04 CAN LINE
- ENGINE-
CON-
TROL
MESSAGE
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
B6 04 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
CON-
TROL
MESSAGE
TIMEOUT No vehiclespeed
basedonwheels(re-
dundant 2 output
speed information, if
output speedis not
detectedon2
nd
out-
put speedsensor of
CAN tachograph).
No servicebrakesig-
nal.
Whenrunningbyin-
ertia, the service
brakesignal is con-
sidered active.
No CruiseControl
activeinformation.
Impossibleto calcu-
late startinggear.
The ensuingvariable
single fault messageis
deleted.
The clutchalways dis-
engagesat theasso-
ciatedbrakepedal
enginespeed(higher
enginerevs).
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
The follow-
ingsignals
arein
CCVS:-Veh.
speed v_fzg
(km/h)-Brake
switchz_fbr
(1 active/0
not ac-
tive)-Cruise
control
target speed
v_cc_set
(km/h)-Cruis
econtrol
statusvcc
status
B6 04 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
CON-
TROL
MESSAGE
agnosischeck on EDC
system.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
B6 04 CAN LINE
- CRUISE
CON-
TROL /
VEHICLE
SPEED -
CONTROL
MESSAGE
B7 04 CAN LINE
- RE-
TARDER-
ENGINE
BRAKE-
CONTROL
MESSAGE
TIMEOUT No calculation of ve-
Impossibleto calcu-
late startinggear. No
information on ex-
haust braketorque. If
theexhaust brakeis
activated, thecoupl-
ingqualitycan turn
out poor at the start
of coupling.
The exhaust brakeis
considered as not
activated.
No additional func-
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
ERC1_ER
contains the
current en-
ginebrake
torque.
B7 04 CAN LINE
- RE-
TARDER-
ENGINE
BRAKE-
CONTROL
MESSAGE
agnosischeck on Intar-
der.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
B7 04 CAN LINE
- RE-
TARDER-
ENGINE
BRAKE-
CONTROL
MESSAGE
B8 04 CAN LINE
- RE-
TARDER-
INTARDER
- CON-
TROL
MESSAGE
Impossibleto calcu-
latethestartinggear.
The averagestarting
No additional func-
tional restrictions
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
Message
ERC1_DR
contains:
-Secondary
retarder
braketorque
-Request, in-
creaseinen-
ginespeed
B8 04 CAN LINE
- RE-
TARDER-
INTARDER
- CON-
TROL
MESSAGE
agnosischeck on Intar-
der.
B8 04 CAN LINE
- RE-
TARDER-
INTARDER
- CON-
TROL
MESSAGE
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
BC 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
IN-
CORRET
WORKING
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Delete the fault mem-
ory: if theerror re-
mains, call the Help
Desk and followtheir
instructions to repro-
gramor replace the
control unit if necess-
ary.
BD 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
IN-
CORRET
WORKING
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Delete the fault mem-
ory: if theerror re-
mains, call the Help
Desk and followtheir
instructions to repro-
gramor replace the
control unit if necess-
ary.
BE 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
PRO-
GRAM-
MING
DATA
NOT
VALID
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Reprogramthe elec-
tronic control unit to
rewritethepara-
meters.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
BF 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
PRO-
GRAM-
MING
DATA
NOT
VALID
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
Reprogramthe elec-
tronic control unit to
rewritethepara-
meters.
C0 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
EEPROM
ACCESS
FAILURE
Impossibleto calcu-
The averagestarting
No additional func-
tional restrictions
Erasethefailure mem-
oryandretry.If the
problempersists, con-
tact theHelp Desk
and followtheinstruc-
tionsfor thepossible
replacement of the
gearcase.
C1 01 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT -
ECU TEM-
PERATURE
TOO
HIGH
Vehiclemoving:
Gear changing
blocked.
The clutchopens
whenthevehicle
stops and neutral is
engaged.
Impossibleto keep
on driving.
The displayalternate-
lyshowsthetoo high
temperature and the
information on the
gear.
Verifyfluid level. ECU tem-
peratureon
electronics
circuit board
greater than
125 C and
oiltempera-
ture greater
than130 C.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
C2 08 CAN LINE
- BRAKING
SYSTEM-
FRONT
WHEELS
SPEED
NO SIG-
NAL
The automatic shift
unit isdeactivated.
No further systemre-
strictions.
Check/ Replacespeed
sensor.
Error en-
tered in
other elec-
tronic units
aswell
(EDC, ABS,
etc.)
C2 08 CAN LINE
- BRAKING
SYSTEM-
FRONT
WHEELS
SPEED
NO SIG-
NAL
Error stored onlyin
transmission elec-
tronic unit.
Last timeof error stor-
ageon thereadingout
tions.
Cancel FaultsMemory
C2 08 CAN LINE
- BRAKING
SYSTEM-
FRONT
WHEELS
SPEED
NO SIG-
NAL
Error still active. Vehiclespeed
sensor discon-
nected or failed.
Check/ Replacewiring
speed sensor.
Checksignal travel.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
C2 08 CAN LINE
- BRAKING
SYSTEM-
FRONT
WHEELS
SPEED
NO SIG-
NAL
Signal out of
tolerance.
Gear actuator replace-
ment (control unit)
Alternative
solution: dis-
assemble
transmission
actuator and
replace
transmission
actuator
lower sec-
tion.
C5 08 CAN LINE
- BRAKING
SYSTEM-
AVERAGE
FRONT
WHEEL
SPEED
WRONG
SIGNAL
Impossibleto calcu-
The averagestarting
No additional func-
tional restrictions
Checkfusebox fuses. Signal is con-
tainedin
CAN mess-
ao 'S\|'.
C5 08 CAN LINE
- BRAKING
SYSTEM-
AVERAGE
FRONT
WHEEL
SPEED
WRONG
SIGNAL
Messageisgen-
erated in the
ABSelectronics.
CheckABS.
C5 08 CAN LINE
- BRAKING
SYSTEM-
AVERAGE
FRONT
WHEEL
SPEED
WRONG
SIGNAL
The automatic shift
unit isdeactivated.
No further systemre-
strictions.
Check/ Replace
speed sensor.
Error en-
tered in
other elec-
tronic units
aswell
(EDC, ABS,
etc.)
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
C5 08 CAN LINE
- BRAKING
SYSTEM-
AVERAGE
FRONT
WHEEL
SPEED
WRONG
SIGNAL
Error stored onlyin
transmission elec-
tronic unit.
Last timeof error stor-
ageon thereadingout
tions.
Cancel FaultsMemory
C5 08 CAN LINE
- BRAKING
SYSTEM-
AVERAGE
FRONT
WHEEL
SPEED
WRONG
SIGNAL
Error still active. Vehiclespeed
sensor discon-
nected or failed.
Check/Replacewiring
speed sensor.
Checksignal travel.
C5 08 CAN LINE
- BRAKING
SYSTEM-
AVERAGE
FRONT
WHEEL
SPEED
WRONG
SIGNAL
Signal out of toler-
ance.
Gear actuator
replacement
(control unit)
Alternativesolution:
disassemble trans-
mission actuator and
replacetransmission
actuator lower section.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
C7 04 CAN LINE
- BRAKING
SYSTEM-
SPEED
WHEELS
MESSAGE
Impossibleto calcu-
The averagestarting
No additional func-
tional restrictions
Checkfusebox fuses. Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
C7 04 CAN LINE
- BRAKING
SYSTEM-
SPEED
WHEELS
MESSAGE
TIMEOUT Messageissued
byASR/ ABS/
EBSelectronics.
CheckABS / ASR/
EBSsignal travel.
C7 04 CAN LINE
- BRAKING
SYSTEM-
SPEED
WHEELS
MESSAGE
TIMEOUT Other errors
91,100,177 present.
Short circuit to
ground to pin 8
- CAN H poss-
ible.
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
E2 04 CAN LINE
- MUX
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
ChecktheCAN line
and theworkingof the
ot|o |C|'s coo-
nected.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
After replac-
ingany
|C|'s coo-
nected to
CAN line,
carryout the
Cancel Faults
Memory.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
E3 00 SHIFTING
ACTUA-
TOR-
ELEC-
TRONIC
CON-
TROL
UNIT - IN-
TENAL
FAILURE
APPLICA-
TION
ERROR
FORCAN
COM-
MUNICA-
TION
boxlocked, the
clutchopensauto-
maticallywhenthe
stationary: gearbox
tral, impossible to
continuedriving.
ChecktheCAN line
and theworkingof the
ot|o |C|'s coo-
nected.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
After replac-
ingany
|C|'s coo-
nected to
CAN line,
carryout the
Cancel Faults
Memory.
E7 00 CAN LINE
- COM-
MUNICA-
TION
LINES-
VCM
EEC3
TIMEOUT
ERROR
Ininitialization phase:
default config. (cur-
rent lever/no addit.
Manoeuvringmode/
normal mode).
After initialization
phase: no functional
limitation.
The message
VCM_TC is not
receivedfor ap-
prox. 150 ms or
isignored be-
causeit is not
validalwaysfor
thesametime.
Verifypresence and
recognition VCM
ECU.VerifyCAN line.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
The error
passes inter-
mittent in
phaseof in-
itialization
whenit re-
ceivesthe
corrected
message, but
onlytheshift
lever con-
figurationis
updated.
After thein-
itialization
after areset
of thesys-
tem.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
F1 08 CAN LINE
- COM-
MUNICA-
TION
LINES-
GEAR
SHIFT
LEVER
VCM_TC
CAN
MESSAGE
MISSING
Manoeuvringmode/
normal mode).
limitation.
The message
VCM_TC is not
receivedfor ap-
prox. 150 ms or
isignored be-
causeit is not
validalwaysfor
thesametime.
Verifypresence and
recognition VCM ECU.
VerifyCAN line.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
The error
passes inter-
mittent in
phaseof in-
itialization
whenit re-
ceivesthe
corrected
message, but
onlytheshift
lever con-
figurationis
updated.
After thein-
itialization
after areset
of thesys-
tem.
F6 00 CAN LINE
- COM-
MUNICA-
TION
LINES-
VCM
PTI (Power
takeoff In-
formation)
MESSAGE
TIMEOUT
ERROR
Manoeuvringmode/
normal mode).
limitation.
The message
VCM_TC is not
receivedfor ap-
prox. 150 ms or
isignored be-
causeit is not
validalwaysfor
thesametime.
Verifypresence and
recognition VCM ECU.
VerifyCAN line.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
The error
passes inter-
mittent in
phaseof in-
itialization
whenit re-
ceivesthe
corrected
message, but
onlytheshift
lever con-
figurationis
updated.
After thein-
itialization
after areset
of thesys-
tem.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
F7 00 CAN LINE
- COM-
MUNICA-
TION
LINES-
VCM
PTI (Power
takeoff In-
formation)
MESSAGE
SIGNAL
FAILURE
For STRALIS please
checkeither for a
possible short be-
tween9131 and 0131
siononST67con-
cablecould bein-
9131 cable).
F7 00 CAN LINE
- COM-
MUNICA-
TION
LINES-
VCM
PTI (Power
takeoff In-
formation)
MESSAGE
SIGNAL
FAILURE
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
FD 04 CAN LINE
- COM-
MUNICA-
TION
LINES-
VEHICLE
EM_CMD
CAN
MESSAGE
TIMEOUT
No systemrestric-
tion.
The message
EM_CMD CAN
isnot received
for approx. 150
ms or is ignored
becauseit is not
validalwaysfor
thesametime.
Verifypresence and
recognition EM (Ex-
pansionModule) ECU.
VerifyCAN line.
Measuretype:
Resistance
(Ohm)
Measurepoint 1:
Connector (ve-
hicleside) Pin: 8
Measurepoint 2:
Connector (ve-
hicleside) Pin:
12
Connector
Connected;
Key+15OFF;
Typical Value:
60Ohm;
170 EuroTronicGEARBOXESDIAGNOSTICS TRAKKEREURO 4/5
POWERTAKEOFF 1 TRAKKER EURO 4/5
SECTION 5
Power take off
Page
DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUE 5 . . . . . . . . . . . . . . . . . .
TOOLS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation(power take off disengaged) 11 . . . . . .
- Operation(power take off engaged) 12 . . . . . . . .
REMOVING - REFITTING TOTAL
POWERTAKE-OFFASSEMBLY 13 . . . . . . . . . . .
- Removal 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING 15 . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblingthemainbox 15 . . . . . . . . . . . . . . .
- Disassemblingthedriveassembly 15 . . . . . . . . . . .
- Disassemblingbearingfor shaft withgear wheel 15
- Disassemblingtheoil pump 16 . . . . . . . . . . . . . . .
- Assemblingtheoil pump 17 . . . . . . . . . . . . . . . . .
- Cleaningandcheckingparts 17 . . . . . . . . . . . . . . .
- Assemblingthebearingfor shaft
withgear wheel 18 . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingdriveassembly 18 . . . . . . . . . . . . . . . . . . . .
- Adjustingdriveoutput shaft taperedbearings 20 .
- Assemblingthemain housing 21 . . . . . . . . . . . . . .
- Adjustingball bearing 21 . . . . . . . . . . . . . . . . . . . .
2 POWERTAKEOFF TRAKKER EURO 4/5
The total power takeoff is mounted between the engine flywheel and the clutch unit. The power takeoff is equipped with a
non-synchronizedpneumatic-mechanicconnectiontotransferthedriveshaftmotiontothepickupflange.Thelubricationiscarried
out byanoil pump.
60239
CROSSSECTION
Figure1
DESCRIPTION
2
MAIN DATA
Ratio revolutions- rpm 1: 1.29
Torque 900 Nm
Direction of rotation Sameasengine
Typeof engagement/releasecontrol
Pneumatic**
Typeof lubricant
Quantity
TUTELA ZC 90- SAE80W/90
2.5l
Foreseendurationof thenominal torque(hours)* 500
Typeof motion output (vehicletravellingdirection) Rear withflange
Gearboxconnection SAE1
Weight (without flywheels) (kg) 70
Weight (withclutch flywheel) (kg) 102.6
Bearingsfor output shaft 2taperedroller bearings
Bearingsettings Usingsettingrings
Distancessettingrings
5.5 - 5.6 - 5.7- 5.8 - 5.9
6 - 6.1 - 6.2mm
Bearingfor control shaft 1ball bearing
Bearingsettings Usingsettingrings
Thickness settingrings
3.95- 4 - 4.05 - 4.10 - 4.15 - 4.20
4.25- 4.30mm
Thicknesssafetysplit ring
3.60- 3.65- 3.70- 3.80
3.85- 3.90mm
* At aspeedof 2450 rpm. Indicativevalue for theoperationwithout bumpsandvibrations
** Pressurevalue10 bar alwayssupplied
60240
Figure2
TIGHTENING TORQUE
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Plug 27.5 2.75
2 ScrewM10x140 43 4.3
3 Screw 43 4.3
4 ScrewM8x60 18 1.8
5 Joint 5.5 0.55
6 Screwfor cover 22 2.2
7 Screw 82 8.2
8 ScrewM10x1.5 10 1
9 Nut with flangefor studbolt 29 2.9
10
* Screwsmust betightened intwo stages: 1
st
stagepre-torque
2
nd
stageto angle
95
60
9,5
60
11 ScrewM8x30 18 1.8
12 ScrewM10x30 43 4.3
13 Nut M33x1.5 465 46.5
14 ScrewM8x30 18 1,8
NOTE: ApplyLOCTITE242 ontheplugsandjointsincontact withthelubricant
TOOLS
99305121 Hot air apparatus
99322205 Revolvingstandfor overhaulingunits
99341003 Double-actingbridge
99341015 Clamp
99341016 Pair of brackets withhole
99345049 Counter blockfor pullers
99360503 Rings for liftingcylinder units
99363241 Plates (2) to measure gearboxmain or transmission shaft bearing
preload
99370317 Counter lever withextensionto fastenflanges
99395216 |a| o otos o t||too|o to ao|o .|t| +/2' aoo 3/+' sooao
coupling
Thischapterillustratesthemechanical workingdrawingoftheexperimental tools(S.P.) usedtooverhaul theoverall powertakeoff
described in thissection, whichcan be manufactured bytherepair shops themselves.
EXPERIMENTAL TOOLS
Figure3
40776
EXPLODEDVIEW OUTPUT UNIT COMPONENTS
1. Safetysplit ring- 2. Joint - 3. Chokering- 4. Forkshaft - 5. Pin - 6. Screws - 7. Transmitter - 8. Washer - 9. Plug-
10. Housing- 11. Choke rings- 12. Joint - 13. Safetysplit ring- 14. Plug- 15. Vent - 16. Screws- 17. Nut - 18. Flange-
19. Seal - 20. Screws - 21. Cover - 22. Conical bearings - 23. Grooved transmissionshaft - 24. Selector fork -
25. Slidingjoint - 26. Roller bearings - 27. Screws- 28. Cover - 29. Settingring- 30. Conical bearing- 31. Shoulder ring-
32. Gear wheel
Figure4
40787
Operation (power take off disengaged)
A =Electro-pneumatic valveN.A. (usuallyopen) withswitchdisengaged
B=Electro-pneumaticvalveN.C. (usuallyclosed) with switchdisengaged
Withtheswitchinposition0(disengaged) theelectromagnetsofthevalvesA - Baredisconnectedandthereforethecircuit ofthe
valveA remainsopen andthat of valve Bremainsclosed.
Theair takeninentersvalve A bylink(2), leaves bylink(3) andpasses throughthepipesto chamber E, movingthecontrol rod
withforkD inpower takeoff positiondisengaged.
At thesametimetheair inchamber C passesthroughthe pipingto thelink(6) andpassesintotheair bylink (5).
Figure5
40787
Operation (power take off engaged)
A =Electro-pneumatic valveN.A. (usuallyclosed) withswitch disengaged
B=Electro-pneumaticvalveN.C. (usuallyopen) withswitchdisengaged
Withtheswitchinposition1(engaged) theelectromagnetsof thevalvesA - B areexcited andthereforethecircuit of thevalve
A open andopen that ofvalveB.
Theair takeninthroughlink(7)entersvalveBleavesbylink (6) andpassesthroughthepipesto chamber C, movingthecontrol
rodwithfork Dinpower takeoff positionengaged.
At thesametimetheair inchamber E passesthroughthe pipingto thelink(3) into valveA and passes into theair bylink (4).
Figure6
87020
Figure7
Removal
Thisoperationcomprises:
- Removing- refittingpropellershafts(seerelevant section
505620).
- Removing - refitting gearbox (see relevant section
530210).
- Removing-refittingclutch(seerelevant section505210).
Remove the plugs (4 and 7) and drain the oil in asuitable
container.
Fromthelower cover (3) disconnect theoil pipes(5and6).
Removethescrews (8) andthelower cover (3)
Iffitted, slackentheclampanddisconnect theoil vapourpipes
(1) fromtheexhaust pipe (2).
Removethechassis exhaust pipefasteners(2).
Figure8
87021
Removetheboltsanddisconnect the flange driveshaft (7).
Fromthepower takeoff assembly (3):
- Disconnect theelectrical connection(5);
- disconnect theair pipes (1and6);
- removethepipeunion(2) andtheoil pipe.
Removethescrews(4) andthepower takeoff assembly(3).
Ifthepowertakeoffassemblyistobeoverhauled(3).
Slackenthenut (8) fasteningthedriveoutput flange
(7).
Figure9
87022
Slacken the clamp (2) fasteningthe exhaust pipe (3) to the
muffler (1).
Figure10
Place bracket 99360551 (1) on thehydraulic lift and fit the
bracket ontheclutch couplingflywheel (2).
Removethescrews(3) anddisconnect theflywheel (2) from
thepower takeoff shaft.
87023
Figure11
87024
Removethescrews(1) andtheinspectioncover (2) fromthe
gear case(3).
Applythe flywheel rotation tool 99360321 (4) on thegear
case(3). For engines F3B, this tool shall be completed with
spacer 99360325.
NOTE
534501 REMOVING - REFITTING TOTAL POWER TAKE-OFF ASSEMBLY
87027
Figure12
87025
Remove thescrews (2) fasteningthejoint (3) to theengine
flywheel (1).
Togainaccessoftheremainingscrews(2) whichare
not visible, turn the engine flywheel with tool
99360321(4).
Figure13
Fromtheinsideof the power takeoff case, remove thetop
fasteningnuts(1) andthe bottomfasteningnuts(2).
87026
Figure14
Place ahydraulic lift fittedwithsupport 99370629(2) under
thepower takeoff case (1) and slingit withtheappropriate
chain (1).
Removethenutsandthepowertakeoffcasefromtheengine.
Refitting
To refit the power take off assembly, reverse the
removal procedure and observe the following
precautions:
- lubricate the connecting shaft tang with
MOLYCOTEHSC grease;
- apply LOCTITE 510 on the power take off
assemblysurfaceand thebottomcover;
- applyLOCTITE 242E oil on the screw or the
contact plugthreading;
- tightenthescrews/nutstotheprescribedtorque;
For angle tighteningof the clutch couplingflywheel
fasteningscrews usetool 99395216.
- the drive output flange fastening nut shall be
tightened (if it was not carried out during
overhaul) to torque 465 Nm(46,5 kgm) after
fittingthepower takeoff assembly;
- fill the assembly with the lubrication oil of the
recommended type and in the prescribed
quantity.
NOTE
NOTE
41019
41020
41021
Figure15
Figure16
Figure17
Positionthewhole assemblyontherotarystand 99322205.
Locktherotationofthelaminarcoupling(2) withthereaction
lever 99370317(1) andusingasuitablewrenchunscrewthe
retainingscrews (3). Remove the laminar coupling and the
flange.
Usingtheeyebolt 993605003(1) andlift,removetheshaft with
thegear wheel (2).
Unscrewthescrews(1),takeoffthecover (2) togetherwiththe
seal and recover theadjustment ring(3).
41022
41024
41023
Figure18
Figure19
Figure20
Usinganappropriatedrift, driveout theshaft (2) andextract
themiddlegear (1). Taketheseal out of thebox.
Usingsuitablepliers(1), removetheseeger ring(2).
Extract theball bearing(4) withtheextractor 99341003(1),
grips 99341009(2) and reactionblock99345049 (3).
Disassemblingbearingfor shaft withgear wheel
534510 Disassembling the drive assembly OVERHAULING
Disassembling the main box
41025
41026
41027
Figure21
Figure22
Figure23
Put the assemblyin avice, unscrew the nut (3), extract the
flange(2), unscrewthescrewsandremovethecover (1).
Unscrewthescrewsandtake off thecover (2); recover the
adjustment ring.
Takeoff thesplit ringandextract thefitting(1); unscrewthe
electrictransmitter.
Applytheextractor 99341002 (2) withthegrips 99341016
(1) and extract the toothedoutput shaft (3).
Takeout thegear (4).
41028
60241
41029
Figure24
Figure25
Figure26
Driveoutthespringpin(1),takeout theshaft(2) andthedrive
fork(3).
Put the toothed output shaft in avice. Using the extractor
993441002(1),grips99341009(2) andclamp99341015(3),
extract thetapered roller bearing(4).
Extracttheshaft togetherwiththegear (3) fromtheoil pump
(4). Unscrew the screws (1) securingthe oil pump (4) and
detach it fromthecover (2).
534532 Disassembling the oil pump
71567
71568
71569
Figure27 Figure28
Figure29
Cleaning and checking parts
Aftercompletingremoval,immerseall thepartsexceptforthe
bearingsinawashtankcontainingasolutionofwaterandsoda
heated to atemperature of 80 to 85C until the lubricant
residueshavedissolved.
Usingawirebrushandscraper,get ridof anydepositsonthe
parts,remainsofgasketsandtracesofLoctiteandsealantfrom
thematingsurfaces, takingcarenot todamagethem.
Washagainanddrythepartswith compressedair.
Usingabenchtopelectriccleaningmachinewithwirebrushes,
removeanyremainsof Loctiteand sealant fromthethreads
of thescrews.
Toclean thebearingsthoroughly, youneedto put themina
bath of kerosene and, with the aid of abrush, eliminate all
tracesoflubricant.
Drythemwithcompressedair,bearinginmindthat thejet of
air must not causethebearingsto turn.
Thenlubricatethebearingswithoil ofthesametypeusedfor
thegears.
Keepingthe bearings pressed down by hand while turning
themslightlyinbothdirectionsyoushouldfeel no roughness
nor hear anynoiseastheymove.
Carefully check that the rollers and cages, as well as the
external and internal rollingraces, arenot worn.
Check all the parts to decide whether to reuse them or
replacethem.
Takeoutthefixingscrews(4) andremovethecover (3) from
the pumpcasing(1).
Extract thegear shafts(5 and6) fromthepumpcasing(1).
Usingasuitableextractor,removetheroller bearing(2) from
the pumpcasing(1).
Keytheroller bearing(2) onto thedrivengear shaft (1).
Applyapressonthegear (1) soastofit theroller bearing(2)
inthepumpcasing(3).
Mount thegear (6) inthepumpcasingso that theendof the
shaft goes into thecorrespondingcompartment of theshaft
(2) ofthedrivengear (1) and thegear (7).
Thegears needto belubricated beforehand.
Put thecover (4) on the pump casing(3). Screwdownthe
fixingscrews(5) andtighten themto therequired torque.
Whenhandlingtheoil pump,takecaretheshaft (2)
ofthedrivengeardoesnotcomeout ofthegearshaft
(6).
NOTE
NOTE
Assembling the oil pump
41036
41037
41028
Figure30
Figure31
Usingafeeler gauge (2), measurethe gap (1) betweenthe
bearingandtheseat oftheseegerring.Thenselect theseeger
ringthat givestheless clearancepossible.
Put the boxinavice.
Fit onthefork(3),keyontheshaft (2) anddriveonthespring
pin(1).
Heat theinternal ringof thebearing(2) to approx.80C and
keyit onthetoothedshaft (1).
Fitting drive assembly
Figure32
41035
Figure33
Heat theinternal ringof thebearing(2) to approx.80C and
keyit onthe shaft (1).
Leaveit to cool to passonto thenext step.
Assembling the bearing for shaft wi th gear
wheel
60241
Figure34
Put theoil pump(4) onthebottomcover (2) and secureit
there with the screws (1), tightening themto the required
torque.
Whenhandlingbottomcover (2),takecaretheshaft
of thedriven gear (3) does not comeout of theoil
pump gear shaft.
NOTE
41038
41039
41040
Figure35
Figure37
Figure36
Put thegear (3) togetherwiththeslidingsleeve(2) inthebox;
insert thetoothed shaft (1).
SECTION OFDRIVEASSEMBLY
Fit ontheexternal ring(1) for thebearing.
41041
41042
41043
41044
Figure38
Figure39
Figure40
Figure41
Using an appropriate drift, fit the seal (1) in the cover (2).
ApplyLOCTITE 410 on the supportingsurface. Mount the
cover (2) andtightenthescrewstoatorqueof 18Nm.Fit on
theflange(3) andscrewdownthenut (4) byhand.
Takethebox(4) out of theviceandturnit over.Fit theroller
bearings(3), thrust washer (2) andtaperedroller bearing(1)
ontheshaft.
Fit theplates99363241(3) ontheouter ringof thebearing.
Tighten the screws (2) to a torque of 18 Nm (1.8 kgm),
correspondingtoanaxial loadofapprox. 250kg,andturnthe
output shaft.
Usingafeeler gauge (1), measure the distance between the
supportingsurfaceandtheouter ringof thebearing.
The measurement will correspond to the thickness of the
adjustment ring.
Mount theadjustment ring(1). ApplyLOCTITE510sealant
onthesupportingsurface (2). Mount thecover (3) andlock
thescrewsto atorque of 18 Nm(1.8 kgm).
Replace theseals onthefittings(2-12, Figure4) thenmount
themandpositionthesplitrings(1-13,Figure4).Screwonthe
transmitter (7, Figure4).
Tighteningthe nut (4) to atorque of 380 Nm(38
kgm) has to be doneon the vehicle, after fittingthe
driveassemblyonthemainbox.
Thethickness of theadjustment ringwill haveto be
selectedbyroundingoff.
For example,measurement 6to6.04mm,select ring
of thickness6 mm.
measurement 6.05to 6.09, select ring
of thickness6.1 mm.
NOTE
NOTE
Adjusting drive output shaft tapered bearings
41045
41047
41046
41048
41049
Figure42
Figure43
Figure44
Figure45
Figure46
Slightlyheat theseat ( ) for the ball bearingonthe box and
mount the shaft (1) with the gear wheel together with the
bearing.
Measurethedistance(A,Figure45) onthemainbox(2) with
afeeler gauge(1).
Measurethedistance(B,Figure45) onthecover (2) for the
bearingwithafeeler gauge (1).
PARTIAL SECTION OFBEARING ANDSHAFT WITH
GEARWHEEL
T|o va|oo 'C' o t|o ao,ostoot |o |s |voo b t|o o||o.|o
formula: A - B=C
Fit themiddlegear (3) inthebox, drivein(2) after replacing
theseals(1).
| t|ova|ooo 'C' |s t|osaoas t|o oo|oa| t||c'ooss
of the adjustment ring(seetableonpage 4), fit the
relevant ring.
\|ooas, | 'C' |s o|ooot, |t t|o ao,ostoot |o o
thesmaller value.
|o oa|o, 'C' = +.++ to +.++ , | t t|o |o o
4.1 mm.
Adjusting ball bearing
NOTE
Assembling the main housing
41020
41050
41019
Figure47
Fit the setting ring (3), applyLOCTITE 510 sealant to the
contactsurface;fitthecover (2) completewithchokeringand
tightenthescrews (1) to torque22Nm(2.2kg).
Fit tool 99395216(1) toaboxspannerandtightenthescrews
byafurther 60 , 2
nd
stage.
Fit thejoint (2) withtheflangeandclampit withthe reaction
lever 99370317 (1); fasten thescrews(3) to torque95 Nm
(9.5Kgm) 1
st
step.
Figure48
If the shoulder screw (2) of the oil pump gear (4) hasbeen
removed fromthe case (1), measure the adjusting washer
thickness(3) asfollows.
Temporarilyfit thebottomcover withtheoil pump.
Screwdownthescrew(2) without thewasher (3) incontact
withthedrivengear (4).
Using a feeler gauge, measure the distance between the
underside of the head of the screw (2) and the box (1),
distanceA.
Takeout thescrew(2),applyLOCTITE242Eonitsthreadand
screwit backon, placingawasher in betweenwithathickness
of:
S=A +B
whereA is the distancemeasured
B=0.3 0.1
correspondingtothedistancebetweentheendofthescrew(2)
andthedrivengear (4).
Tightenthescrew(2) to therequiredtorque.
Screw(2) has aleft-handthread.
Figure49
Figure50
Removeagainthebottomcover withtheoil pump.
Tofit theseal ringintocover (2) andontheopposite
sideofthebox, usetool SP 2481illustratedonpage
8.
NOTE
NOTE
T|/|S||| 3C TC+800 TC2200 1 TRAKKER EURO 4/5
SECTION 6
5054 Transfer box
TC 1800-TC 2200
Page
DESCRIPTION OFTRANSFERBOX
ASSEMBLY TC 1800 - TC 2200 3 . . . . . . . . . . .
MAIN DATA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VERSION WITH P.T.O. (OPT. 391-392) 5 . . . . . .
P.T.O. SPECIFICATIONS 5 . . . . . . . . . . . . . . . . . . .
USINGTHETRANSFERBOX 6 . . . . . . . . . . . . . .
- On-roaddriving(normal ratio) 6 . . . . . . . . . . . .
- Diagramof drivetransmissionwithnormal
ratio 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Off-roaddriving(reduced ratio) 8 . . . . . . . . . . .
- Center differential locking 9 . . . . . . . . . . . . . . . .
- Versionwith P.T.O. 10 . . . . . . . . . . . . . . . . . . . . .
TORQUE TRANSFER 13 . . . . . . . . . . . . . . . . . . . . .
- Transfer ratio calculation 13 . . . . . . . . . . . . . . . . .
- Control lockingdivider anddifferential gears 14 . .
TIGHTENINGTORQUES 16 . . . . . . . . . . . . . . . . .
TOOLS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION 24 . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFERBOX
REMOVING ANDREFITTING 25 . . . . . . . . . . .
- Removal 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLINGTHETRANSFERBOX 25 . . . . . .
CLEANINGANDCHECKING PARTS 29 . . . . . . . .
REPLACINGOUTPUT SHAFT COVERSEALS 29 .
2 T|/|S||| 3C TC+800 TC2200 TRAKKER EURO 4/5
Page
REPLACINGINPUT SHAFT COVER SEAL 29 . . . . . .
INPUT SHAFT 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EPICYCLIC TORQUE TRANSFERUNIT 31 . . . . . . . .
- Removal 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COUNTERSHAFT 32 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THETRANSFERBOX 33 . . . . . . . . . . .
ADJUSTING THEBEARINGPRE-LOAD 36 . . . . . . . .
- Input shaft 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Countershaft 36 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Output shaft 37 . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETING ASSEMBLY 38 . . . . . . . . . . . . . . . . . . .
- Adjustingpush-rodswitchsignallinginteraxlelocking
and P.T.O. engagement (if applicable) 39 . . . . . . .
- Adjustingpulsetransmitter 39 . . . . . . . . . . . . . . . .
- Replenishingoil 39 . . . . . . . . . . . . . . . . . . . . . . . .
The transfer box is located between the gearbox and the
middleaxle.
It iscomposed of aset of constant meshhelical spur gears.
These gears are mounted on three shafts: input shaft,
countershaft andsecondaryoutput shaft.
Theslidingtoothedsleeveforcouplingnormal gears(onroad)
and reducedgears(off road) ismountedontheinput shaft.
The interaxle differential gear that provides independent
speed transmission between the front and rear axles is
mountedon theoutput shaft.
Inaddition, thereisthedifferential lockingdevice.
Thetransfer boxismadeintwo versions:
- For vehicles with two axles (4x4) and four axles (8x8)
withadivision of 1:2:2.
- Forvehicleswiththreeaxles(6x6) withadivisionof1:4:0.
Print 603.93.641 3aso |ovobo 2006
DESCRIPTION OF TRANSFER BOX ASSEMBLY TC 1800 - TC 2200
PRINT603.93.641
MAIN DATA
TC 1800 TC 2200
Gears Constant mesh helical spur gears
Transmissionratios:
normal (onroad)
reduced(off road)
1: 1
1: 1.6
Nm
Maximuminput torque Nm 18,000 22,000
4x4vehicles
Torquereduction
1: 2.2
Torquereduction
6x6vehicles 1: 4
Bearingpre-loadfor:
input shaft
countershaft
output shaft
0.05 0.10mm
Bearingpre-loadadjustment withadjustment rings
Adjustment ringthickness
input shaft mm
countershaft .mm
output shaft mm
1-1.1-1.2-1.3-1.4-1.5-1.6-1.7-1.8-1.9
1-1.6-1.7-1.8-1.9-2.0-2.1-2.2-2.3-2.4-2.5
1-1.1-1.2-1.3-1.4-1.5-1.6-1.7-1.8-1.9-2
Thickness of adjustment
ringsfor pulse transmitter mm 1 - 1.5
Typeof oil
- for arctic climateonly
Quantity litres
TUTELA ZC 90
TUTELA GI /A
6.5
Weight of reduction
gear - divider kg 265 -
52634
Figure1
LONGITUDINAL SECTION OFTRANSFERBOX
SECT. A-A
A
B
3aso |ovobo 2006 Print 603.93.641
Figure2
62124
Print 603.93.641 3aso |ovobo 2006
VERSION WITH P.T.O. (OPT. 391-392)
P.T.O. SPECIFICATIONS
Max. torqueavailable 1,180Nm
Ratio 1: 1
Direction of rotation same asengine
P.T.O. couplingcontrol Pneumatic
Connectionversion Flange Pump
119253
Figure3
Withthecontrol knobDonI, theincomingair at thefittingI
passesthroughthedistributor andcomesout ofthefitting21
and,goingtosupplythechamber A,causesthepistontomove
to its limit stop.
Control knobpositions:
- position1=on-roaddriving.
- position2=off-road driving.
User instructions:
- releasethethrottle.
- turntheknob onto 1;
- never press the clutch pedal while operating the
reduction gear control.
ThespringBkeepstheforkandthesleeveintheon-roadratio
position.
Theairinthechamber C getsdischargedintotheatmosphere
through thefitting3.
Revi - June2007
PRINT603.93.641/A
USING THE TRANSFER BOX
On-road driving(normal ratio)
62126
Figure4
With the control knob on 1, the sleeve (1) moves in the
directionofthearrows, makingthegear (2) integral withthe
input shaft and therebycreatinga 1:1 ratio with thedivider
unit.
The drive transmission passes through thecountershaft (3),
wherethephonicwheel (5) issecuredforreadingthespeed.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Diagram of drive transmission withnormal ratio
119254
Figure5
Withthecontrol knobDon2,theincomingairat thefittingI
passesthroughthedistributor andcomesout ofthefitting22
and,goingtosupplythechamberC,causesthepistontomove
to its limit stop.
User instructions:
- Releasethethrottle.
- Turnthe knobonto 1.
- Brieflypressthethrottlepedal.
Theforkandthesleevewill movetowardstheoff-roadratio.
The movement of the piston will close the contact of the
switchthat will switchonthereducedspeedindicatorlighton
the dashboard.
Theairinthechamber Agetsdischargedintotheatmosphere
through thefitting3.
Revi - June2007
PRINT603.93.641/A
PRINT603.93.641/A
Off-road driving(reduced ratio)
62128
Figure6
With the control knob on 2, the sleeve (1) moves in the
directionofthearrows, makingthegear (4) integral withthe
input shaft andtherebycreatinga1:1.6ratio withthedivider
unit.
The drive transmission passes through thecountershaft (3),
wherethephonicwheel (5) issecuredforreadingthespeed.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Diagram of drive transmission withreduced ratio
119255
Figure7
With thecontrol knobon1, theincomingair at thefitting1
of thedistributor will not supplytheoutlets21and 22.
ThespringBkeepstheforkandthesleeveintheon-roadratio
position.
ThechambersA andC of thecylinderareincommunication
withtheatmospherethroughthebleedof thedistributor.
ThepushrodE, onreceivingtheair fromthenormallyopen
solenoid valve F, will be turned off, thereby permitting the
pistonofthechamber C to beableto move.
EM
Revi - June2007
PRINT603.93.641/A
Version with P.T.O.
Control on on-road drivingposition
Figure8
WiththeknobonpositionN,theincomingairat thefitting1
passesthroughthedistributor and comesout of thefittings
21and 22, therebysupplyingboth the chamber A and the
chamber C,causingtheforkandthesleeveto moveintothe
neutral position.
Power take-off coupling
Turning on the electric power take-off control switch
energizes thesolenoidvalves D and F simultaneously.
The normallyclosed solenoidvalve D, on energizing, opens
and supplies thepower take-off couplingcylinder G.
The normally open solenoid valve V, on energizing, closes
and prevents the air fromkeeping the safety push rod E
turned off.
Thislastconditionisnecessaryto lockthepistonandthefork
intheneutral position.
119256
Revi- June2007
T|/|S|||3CTC+800 TC2200 11 TRAKKEREURO 4/5
PRINT603.93.641/A
Control onneutral position
119257
Figure9
With thecontrol knobon2,theincomingair at thefitting1
passesthroughthedistributorandcomesout ofthefitting22
supplyingthechamber C andcausingthepistonto moveto
itslimit stop.
Theforkandthesleevewill movetowardstheoff-roadratio
gear.
The movement of the piston will close the contact of the
switch H that will switch on the reduced speed indicator
light on the dashboard and the air in the chamber A gets
dischargedinto theatmospherethrough thebleed 3of the
distributor.
ThepushrodE,onreceivingtheair fromthenormallyopen
solenoid valve F will be turned off, thereby permitting the
pistonof the chamber C to beable to move.
Revi- June2007
12 T|/|S|||3CTC+800 TC2200 TRAKKEREURO 4/5
Control onoff-roaddrivingposition
62132
Figure10
6x6 vehicles
The drivetransmittedbythe input shaft throughthe countershaft (4) will turntheplanet gear train (1), which viathe ringgear
Z
2
and theplanet wheel Z
1
will transmit thedrive to therear (3) andfront (2) output shafts.
Transfer ratio calculation
4x4 - 8x8vehicles
Front axleT
1
Z
1
Z
1
Z
2
33
33 72
0,31
Rear axleT
2
Z
2
Z
1
Z
2
72
33 72
0,68
Total transfer
T
2
T
1
0,68
0,31
2,2
Incomingtorque
Front axleT
1
Z
1
Z
1
Z
2
18
18 72
0.2
Torqueto the front wheels
Rear axleT
2
Z
2
Z
1
Z
2
72
18 72
0.8
Torqueto the rear wheels
Total transfer
T
2
T
1
0.8
0.2
4.0
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
TORQUE TRANSFER
62133
Figure11
Center differential locking
Vehicles 4x4 - 6x4 - 6x6 - 8x4 - 8x8
Lockingmust onlybeusedtodriveovermuddyandslippery
ground.
Correct operationrequirescarryingout thefollowingsteps:
- Pass on to the locking position with the vehicle
stationaryor at low speed.
- Proceed with caution.
When thebad road conditions havebeen passed, proceed
asfollows:
- |ass oo to t|o oo|oc'|o os|t|oo 'oo|o t|o vo||c|o's
speed.
- Temporarilylift thethrottle.
- Go back to thesafetyspeed
If lockingisnot immediatelyturnedoff, youneedto change
thedirection of travel in order to get ridof anytension.
!
- Onmuddyandslipperyground, never turnthe
wheels in no-load conditions when differential
lockingis engaged asthis would causedamage
(just afewsecondswouldbeenough).
- Never engage differential locking while one
wheel is turning in no-load conditions; this
would severelydamage the gears.
Incomingtorque
Torqueto the front wheels
Torqueto the rear wheels
3aso |ovobo 2006 Print 603.93.641
Figure12
Figure13 Figure14
DIAGRAMOF 4x4 VEHICLE DIFFERENTIAL LOCKINGCONTROL
1 =Longitudinal differential lockrelay
2 =Transversedifferential lock relay
Whenlockingisturnedon,theassociatedindicator lightson
thedashboard come on.
DIAGRAMOF 6x6 VEHICLE DIFFERENTIAL LOCKINGCONTROL
Figure15
119258
119259
62136
119260
Revi- June2007
PRINT603.93.641/A
62138
Figure16
SECT. A-A
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
TIGHTENING TORQUES
Print 603.93.641 3aso |ovobo 2006
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 ScrewM 14(TC 1800) 92 9 9.4 0.9
1 ScrewM 14(TC 2200 120 12 12.2 1.2
2 Pin M22x 1.5 500 50 50.9 5.1
3 ScrewM 12(TC 1800) 58 6 5.9 0.6
3 ScrewM 12(TC 2200) 78 8 7.9 0.8
4 ScrewM 6 9.5 0.5 1 0.05
5 ScrewM 6 9.5 0.5 1 0.05
6 Pulsetransmitter M18x 1.5 45 5 4.6 0.5
7 Push-rodswitch nut M 18 x 1.5 45 5 4.6 0.5
8 ScrewM 8(TC 1800) 19 2 1.9 0.2
8 ScrewM 8(TC 2200) 22.5 2.5 2.3 0.25
9 ScrewM 10 45 5 4.6 0.5
10 ScrewM 12(TC 1800) 58 6 5.9 0.6
10 ScrewM 12(TC 2200) 78 8 7.9 0.8
11 ScrewM 6* 7 1 0.7 0.1
12 ScrewplugM27 x 2(TC 1800) 100 10 9.8 1
12 ScrewplugM27 x 2(TC 2200) 55 5 5.6 0.5
13 ScrewplugM14 x 1.5(TC 1800) 60 6 6.1 0.6
13 ScrewplugM14 x 1.5(TC 2200) 78 8 7.9 0.8
14 ScrewM 5 4.5 0.5 0.46 0.05
15 ScrewM 5* (TC 1800) 4.5 0.5 0.46 0.05
15 ScrewM 5* (TC 2200) 5 0.5 0.5 0.05
16 GrubscrewM 10* 33 3 3.4 0.3
17 ScrewM 12(TC 1800) 58 6 5.9 0.6
17 ScrewM 12(TC 2200) 78 8 7.9 0.8
18 ScrewM 10 65 6.6
19 ScrewM 5 5 0.5 0.5 0.05
20 ScrewM 12(TC 1800) 58 6 5.9 0.6
20 ScrewM 12(TC 2200) 78 8 7.9 0.8
* ApplyLOCTITE AVX.
J ApplyLOCTITE 510
62139
Figure17
3aso |ovobo 2006 Print 603.93.641
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
21 ScrewM 8(TC 1800) 19 2 1,9 0.2
21 Screw8 (TC 2200) 22.5 2.5 2.3 0.25
22 Oil vapour vent 100 10 10.2 1.02
23 ScrewplugM22 (TC 1800) 70 7 7.1 0.7
23 ScrewplugM22 x 1.5(TC 2200) 110 10 11.2 1.02
24 ScrewM 6 7 1 0.7 0.1
25 Threaded filling-pipeM14 45 5 4.6 0.5
26 To|oa| ||||o-|o +/+' 45 5 4.6 0.5
27 Terminal filling-pipeM 22 x 1.5 (TC 1800) 70 7 7.1 0.7
27 Terminal filling-pipeM 22 x 1.5 (TC 2200) 78 8 7.9 0.8
28 PlugM28x 1.5 110 10 11.2 1.02
29 Push rodswitch M 14x 1.5 45 5 4.6 0.5
30 ScrewM 8(TC 1800) 19 2 1.9 0.2
30 ScrewM 8(TC 2200) 22.5 2.5 2.3 0.25
31 Special screw M12x 80 78 8 7.9 0.8
32 ScrewM 10(TC 1800)* 49 3 5 0.3
32 ScrewM 10(TC 2200)* 47 3 4.8 0.3
33 ScrewM 12 78 8 7.9 0.8
34 ScrewM 12(TC 1800) 58 6 5.9 0.6
34 ScrewM 12(TC 2200) 78 8 7.9 0.8
35 Push-rodswitch nut M 18 x 1.5 (TC 1800) 45 5 4.6 0.5
35 Push-rodswitch nut M 18 x 1.5 (TC 2200) 50 5 5.1 0.5
36 ScrewM 10(TC 1800) 45 5 4.6 0.5
36 ScrewM 10(TC 2200) 50 5 5.1 0.5
37 ScrewM 12(TC 1800) 58 6 5.9 0.6
37 ScrewM 12(TC 2200) 78 8 7.9 0.8
* ApplyLOCTITE 242
J ApplyLOCTITE 510
Whenremovingandrefittingparts, keepstrictlyto usingthespecific tools NOTE
3aso |ovobo 2006 Print 603.93.641
TOOLS
99305121 Hot-air device.
99322205
Rotary stand to overhaul assemblies (capacity 1000 daN,
torque 120 daN).
99340205 Puller withslide-hammer
99341003 Single-actingbridge.
99341009 Pair of brackets.
99341015 Clamp.
Print 603.93.641 3aso |ovobo 2006
99342143 Pin to extract epicyclic assemblyplanet pins(usewith99340205).
99345049 Extractor reactionblock.
99360502 Pair of rings to remove and refit the transfer half box.
99366067 M8eyebolts to removeand refit countershaft.
99370006 Kit for valveseat regrinding.
99370317 Reactionlever withextension to retainflanges.
3aso |ovobo 2006 Print 603.93.641
99370362
Keying device to fit gasket on front drive output shaft cover
(usewith 99370006).
99370415
Comparator holder base for adjusting secondaryshaft bearings
(usewith 99395604)
99370565 Eyeboltsto removeand refit epicyclicassembly.
99370631 Mount to removeand refit transfer box.
99371051
Bracket to support reduction transfer box while overhauling
(usewith 99322205).
99374253
Keyingdevicetofitgasketoncoversofdriveinputshaft andreardrive
output shaft.
Print 603.93.641 3aso |ovobo 2006
99395604 Dial gauge(0-10mm)
62140
Figure18
Procedureto check the oil level and refuelling
Makesure the vehicle is on level ground.
- Removetheplug(4).A small quantityofoil mayspill out.
- Makesurethat theoil reachestheplughole(4).Topup
through theplughole (1) after removingthe plug.
- Close both plugs, tightening them to the required
torque.
Changingoil
The oil should be changed periodically at the following
intervals:
- With roaduse, every 150,000km
- With heavy-dutyuse, every1,500hours
Typeof oil: TutelaZC 90 (SAE80 W 90)
TutelaGI/A for arcticclimate
Quantity: 6.5 litres
Remove the plugs (2and3) to drain the oil.
Revi- June2007
PRINT603.93.641/A
LUBRICATION
39869
62141
62142
Figure19
Figure20
Figure21
To remove the reduction gear - divider (2), proceed as
follows:
- Disconnect thebatteries.
- Disconnect theelectrical andair connections.
- Unscrewthenutsforthepropellershaft flangeretaining
screws (1- 3- 4) anddisconnect them.
- Put the bracket 99370631 on the hydraulic lift and
secureit to thereduction gear - divider.
- Unscrew the nuts for the screws fixing the reduction
gear - divider to the chassis frame.
- Lower thelift andtakeout thereduction gear - divider.
Turnthe assembly90 with its back facingupwards.
Unscrewthepush-rodswitch(1) forengagingnormal speeds
(if applicable).
Unscrew the 3 screws and take off the cover (2) with the
piston. Unscrewthe14 screws andtakeoff the cover (3).
Take off the adjustment rings for the pre-load of the
countershaft and driveinput shaft bearings.
505401 TRANSFER BOX
REMOVING AND REFITTING
Removal
Refitting
Theoperationstoperformtorefit thisassemblyare
not particularlydifficult. Therefore, it is sufficient to
repeat the steps described for removal in reverse
order.
505401 DISASSEMBLING THETRANSFER
BOX
Put thereductiongear - divider ontherotarystand
99322205 with the brackets 99371051. Set it
upright, unscrewtheplugs and drain off the oil.
Lock therotation of the flange (3) with the reaction lever
99370317 (2). Unscrew the retaining screw with an
appropriatesocket wrench(1) and takeoff theflange.
Version without P.T.O.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
62143
62145
62144
62146
39875
62147
Figure22
Figure23
Figure24
Figure25
Figure26
Figure27
Unscrewthetwo screws(1) fixingtheclamps. Unscrewthe
two fittings (2) andremove the oil pipe (3).
Unscrewthepush-rodswitch(1) forengagingtheP.T.O.and
thepush-rodswitch (2) for engagingnormal speeds.
Unscrew the 9 screws and take off thepower take-off (1)
together withtheflange (2) and drive fork.
Unscrewthe3screwsandtakeoffthecover(1) withthepiston.
Unscrewtheremaining5screws andtakeoff the cover (2).
Take off the adjustment rings for the pre-load of the
countershaft and driveinput shaft bearings.
Bothversions
Unscrew the 9 screws, then using the 3 reaction screws
screwed into the holes shown by the arrows, take off the
cover (1) andtakeout theadjustment ringsfor thepre-load
of theoutput shaft bearings.
Turntheassembly180 .
Unscrew the vehicle speed pulse transmitter (1), divider
locking indicator push-rod switch (2) and the push-rod
switch(3) for engingreducedspeeds (if applicable).
Version withP.T.O.
3aso |ovobo 2006 Print 603.93.641
62148
39872
62149
62150
62151
Figure28
Figure29
Figure30
Figure31
Figure32
Lock rotation of the flange (3) with the reaction lever
99370317 (2). Unscrew the retaining screw with an
appropriatesocket wrench(1) andtakeouttheflange;repeat
this step to takeout theflange (4).
Unscrewthe6screwsandtakeoffthecover (1) withtheseal.
Unscrew the 3 screws and take off the cover (2) with the
pistonfor lockingthedivider.
Unscrew the11 screwsandtakeoff thecover (2) together
withtheshaft(1)andthefork(3)fordividerlocking.Unscrew
the9screwsandtakeoffthecover(4) togetherwiththeseal.
Unscrewthe3screws, takeoffthecover (2) withthedriving
piston and take out the internal spring. Using an Allen
wrench,unscrewthescrewsandtakeoffthesafetyplate(1).
Unscrew the3Allenscrews (1) fixingthe internal plate.
Unscrew thescrews (4) fixingthehalf box.
Usinganappropriatepunch,takeout the2pins(2) centring
thehalf box (3).
Print 603.93.641 3aso |ovobo 2006
62153
62152
62154
62155
62156
Figure33
Figure34
Figure35
Figure36
Figure37
Position thetwo rings 99360502 (1) as showninthefigure
to balancethehalf box (2).
Using hooks and arope, lift the half box, movingit in the
direction of thearrowto freethe plate(3) fromunder the
bearingof the middle shaft.
Usingeyebolts 99370565(1), ropesand thelift, extract the
epicyclic divider (2) fromthebox.
Straightenthesafetyplate (3).Unscrew thescrews(1) then
removethephonicwheel (2).
Usingtheeyebolt 99366067(1), aropeandthelift, extract
thecountershaft (2) fromthe box.
Unscrew the 3screws (1) on the opposite sideof thebox
and extract theplate (2) that prevents you fromtakingout
theinput shaft.
Todothis,operatefromthebottomwithoutmaking
the assembly turn since when the plate gets
detachedtheinput shaft wouldfall.
NOTE
3aso |ovobo 2006 Print 603.93.641
62157
39881
39892
39893
62158
Figure38
Figure39
Figure40
Figure41
Figure42
Screw the screw and washer (1) onto the input shaft (2).
Usingaropeandthelift,extract theinput shaft (2) together
with thedrive fork(3) fromthebox.
Usingan appropriatedrift, extract theouter rings (1- 2- 3)
of thebearingsfromthe box.
CLEANING AND CHECKING PARTS
After removing the reduction gear - divider, remove the
shaftsandtheepicyclicdividerassemblyandthoroughlyclean
all theparts.
Checkthatthepartsshownosignoftoomuchwear,seizure
or cracking.
Alwaysreplacethesealswitheach removal.
REPLACING INPUT SHAFT COVER SEAL
To replacethe seal (3) of thecover (4) of therear output
shaft,youneedtotakeofftheseegerring(1) andextract the
bearing (2). The seal is fitted on with the keying device
99374253.
Theseal (1) for thecover (2) ofthefront outputshaftisfitted
usingthekeyingdevice 99370362andthegrip99370006.
Theseal (1) for thecover (2) oftheinput shaft isfittedusing
thekeyingdevice99374253.
REPLACING OUTPUT SHAFT COVER
SEALS
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
62159
62161
62160
39894
62162
Figure43
Figure44
Figure45
Figure46
Figure47
COMPONENT PARTSOFTHEINPUT SHAFT
1. Bearing- 2. Plate- 3. Spacer ring- 4. Gear - 5. Roller
bearings - 6. Spacer ring- 7. Shaft - 8. Slidingsleeve-
9. Gear - 10. Bearing.
After takingout the bearing (1), manuallyextract the gear
(9, Figure 43), roller bearings (5, Figure 43), spacer ring
(6, Figure 43) andslidingsleeve (8, Figure43).
Take out the bearing (1), too, and extract the plate (2,
Figure82),spacerring(3,Figure43),gear (4,Figure43),roller
bearings (5, Figure 43) andspacer ring(6, Figure43).
Tighten theshaft (3) in avicewith the groovedpart facing
upwards.
Mount the roller bearings (5, Figure 43) with the spacer
(6, Figure43),keyonthegear (2,Figure46) withthecoupling
toothingfacingdownwards. Mount the spacer ring(1) and
theplate(2, Figure43).
Heat theinternal ringof theroller bearing(1, Figure 43) to
80- 90C andmount it on theshaft.
Turnover theshaft and gripit in avice.
Mount the slidingsleeve (2) with theflaring (arrow) facing
upwards. Mount theroller bearings (1) andthespacer (3).
Mount the gear (9, Figure 43) with the couplingtoothing
facingthe slidingsleeve.
Heat theinternal ringof thebearing(10, Figure43) to 80-
90C and mount it ontheshaft.
The bearings (1, Figure 44 and Figure 45) are
removedusingahydraulic press.
Fitting
NOTE
3aso |ovobo 2006 Print 603.93.641
INPUT SHAFT
Removal
39886
39888
39887
39889
39890
62163
Figure48
Figure49
Figure50
Figure51
Figure52
Figure53
Unscrew the screws (1) and remove the oil seal (2). Using
the bridge 99341003, brackets 99341009 and clamp
99341015 and the reaction block 99345049, take out the
bearing(3), then unscrewthescrews (4).
Using2screws(1) screwedintotheholesshownbythearrows,
extract theplanet wheel holder (2) fromtheringgear (3).
Removethesunwheel (2) andtakeout thereardriveoutput
shaft (1).
Usingan appropriate drift through the holes (arrows), take
thebearing(1) out.
UsinganAllenwrench, unscrewthe3 grubscrews (1).
Usingapullerwithslide-hammer99340205(1) togetherwith
pin 99342143(2), takeout theshafts(3) for thegears (4).
Onversionswithadivisionratioof 1:4,usedon6x6
models, thereis no sunwheel as thetoothingison
thefront drive output shaft.
NOTE
Print 603.93.641 3aso |ovobo 2006
EPICYCLIC TORQUE TRANSFER UNIT
Removal
Ontheplanet wheel holder,mount thegears(3),keyonthe
pin(1) sothat therecess(2) coincideswith theholefor the
grubscrew(4).ApplyLOCTITEAVX onthegrubscrew(4)
andlockit totherequiredtorque.Repeat thesestepsforthe
other pins. Turn the planet wheel holder over and, after
heatingit to80- 90 C,keyontheinternal ringofthebearing.
39896
39897
39888
39898
39885
Figure54
Figure55
Figure56
Figure57
Figure58
Mount thereardriveoutput shaft (1) andthesun wheel (2)
(ifapplicable) ontheringgear andput theassemblyinavice.
Mount the planet wheel holder assembly (1), making the
centringpinscoincide. Screwdownthescrews(2) andlock
themwithatorquewrench (3) to the required torque.
Fit on theoil seal (1). ApplyLOCTITE AVX on thescrews
(2) and screwthemdown to therequired torque.
Turnover theassemblyandkeyonthebearingafterheating
themiddleringto 80 - 90 C.
Removingthebearings(1) of thecountershaft (2) presents
no difficultyasit is adestructive operation.
Fitting
Fitting
COUNTERSHAFT
Removal
Fit the new bearings (1) on the countershaft after
heatingtheinternal ringsto 80 - 90 C.
3aso |ovobo 2006 Print 603.93.641
62366
62156
62157
62155
62154
62164
Figure59
Figure60
Figure61
Figure62
Figure63
Figure64
Put the box (5) on the stand 99322205 with thebrackets
99371051 (4). Usingan appropriate drift, keyon the outer
|os (+ 2 3) o t|o boa|os.
Screwthescrewandwasher (1) onto theinput shaft.Using
aropeandthelift,mounttheshaft (2) togetherwiththedrive
fork (3) inthebox.
Insert theplate(2) andlockit byscrewingdownthe3screws
(1) ontheoppositesideof theboxto the requiredtorque,
workingfromthebottomwithout makingtheassemblyturn.
Usingtheeyebolt99366067(1),mountthecountershaft(2).
Mount thephonicwheel (1) andthesafetyplate(3). Screw
downthescrews(2) to therequiredtorqueandbendback
thesafetyplate.
Usingtheeyebolts99370565(1),mounttheepicyclicdivider
(2) inthebox. Put LOCTITE410 sealant onthesupporting
surface (3). Position the pin (4) of the plate in
correspondence with the respectivehole on the box.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
ASSEMBLING THE TRANSFER BOX
62165
62166
62167
62168
Figure65
Figure66
Figure67
Figure68
Usingthe rings 99360502 (1), hooks and arope, insert the
halfbox(2),followingthedirectionofthearrowtoinsert the
pin(4) oftheplateandtheplate(3) under thebearingofthe
middleshaft.
Usinganappropriatepunch, insert thetwocentringpins(1).
Screwdownthe3socket-headscrews(1) fixingtheinternal
plate.
Usingatorquewrench(2), tighten thescrews (3) fixingthe
half boxto the required torque.
Put onLOCTITE 510 sealant.
Positionthecover (1) together withtheseal.
The oil passage (2) has to be positioned in
correspondencewith therespectivehole(3).
NOTE
3aso |ovobo 2006 Print 603.93.641
39903
39905
39904
62149
39906
Figure69
Figure70
Figure71
Figure72
Figure73
Lockthescrews (2) of thecover to therequiredtorqueusing
atorquewrench(1).Positionthesafetyplate(3).Put LOCTITE
AVX on thescrewsand lockthemto the required torque.
Mount onthecover (3) together withthedrivingpistonand
internal spring. Spreadtheseat (2) withLOCTITE 510,then
fit onthecover (1) together with thedivider couplingdrive
fork and shaft.
Tighten the screws (2) with a torque wrench (1) to the
requiredtorque.
Mount thecover (2) together with the drivingpiston.
SpreadonLOCTITE510,fitonthecover (1) andtightenthe
screws to therequiredtorque.
Keyonthetwoflanges(1),put onthewashersand,withthe
reactionlever 99370317(3) and torquewrench (4), tighten
thescrews (2) to the required torque.
Print 603.93.641 3aso |ovobo 2006
62171
62170
62172
Figure74
Figure75
Figure76
ADJUSTING THE BEARING PRE-LOAD
Thepre-loadoftheinputshaft,countershaft andoutput shaft
isadjusted asfollows:
Input shaft
- Make sure theexternal raceof thebearingdriven into
thehousingonthe front side has reached its stop.
- Beddowntheshaft intoitsseat byapplyinganaxial load
of 50 kgon theexternal ringof the rear bearingwhile
turningtheshaft at thesametime.
- Usingadepthmicrometer (1), measuretheprotrusion
oftheexternalrace(2) ofthebearingwithrespect tothe
faceofthebox (3) at twooppositepointsat least,while
maintainingtheaxial load.
The distanceA measuredhasto be between:
TC 1800 16.3 7.5mm;
TC 2200 10.5 11.5mm.
- Usingadepthmicrometer (1),measurethedepthofthe
seat (2) of therear cover withrespect to the face.
The distanceBmeasuredhasto be between:
TC 1800 18.5 8.6mm;
TC 2200 12.5 12.6mm.
Thedifferencebetweenthetwo measurementsmadegives
the thickness S
e
of the adjustment rings; add the required
pre-load to thisvalue.
S
e
= (A B) + 0.05 mm
The thicknessesalwayshave to beselected byroundingup
to get atotal pre-load of from0.05to 0.10 mm.
Countershaft
The distanceC measuredhasto be between:
2.5and3.4mm
To this measurement, add the required pre-load to get the
thicknessS
r
:
S
r
=C +0.05 mm
3aso |ovobo 2006 Print 603.93.641
62174
62173
62175
Figure77
Figure78
Figure79
Output shaft
TC 1800
The distance D measuredhasto be between:
5.0and6.8mm
- Usingadepthmicrometer (1), measuretheprotrusionof
theseat (2) of therearcover withrespect tothe face(3).
The distance Emeasuredhasto be between:
3.9and4.0mm
the thickness S
u
S
u
= (D E) + 0.05 mm
TC 2200
- Usingadepthmicrometer (1),measurethedepthofthe
seat (2) of therear cover withrespect to the face(3).
The distanceE measuredhasto be between:
8.0and8.1mm
the thickness S
u
S
u
= (E D) + 0.05 mm
The distance D measuredhasto be between:
5.2and7.0mm
Figure80
62176
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
62177
62178
62179
62145
Figure81
Figure82
Figure83
Figure84
Put on the adjustment rings of the thickness calculated
beforehand. Then key on the cover together with the
bearing,afterheatingto 80- 90 C,andtightenthescrewsto
therequiredtorque.
beforehand.Thenfit onthecover (1) andtightenthescrews
Mount thepush-rodswitchestoengagenormal andreduced
speeds and divider locking and the vehicle speed pulse
transmitter andset themasdescribedonthefollowingpage.
beforehand. Then fit on the cover (1) together with the
spring(2).
Mount the power take-off (1) together with the flange (2)
anddrivefork.Thentightenthefixingscrewstotherequired
torque.
Mount thepush-rodswitchestoengagenormal andreduced
speeds(ifapplicable),dividerlockingandtoengagetheP.T.O.
and the vehicle speed pulse transmitter and set themas
describedonthefollowingpage.
Version without P.T.O.
Version withP.T.O.
Fit onthecoverpayingattentionto thealignment of
theslot (3) withthegrub screw (4) on theshaft.
NOTE
3aso |ovobo 2006 Print 603.93.641
COMPLETING ASSEMBLY
39913
42447
Figure85
Figure86
Keyon theflange (1) and put on thewasher (2). Usingthe
reaction lever 99370317 and atorque wrench, tighten the
screw (3) to atorqueof 500 50Nm.
Adjusting pulse transmitter
Select theadjustment ring(2) so asto obtainthedistance A
of 2 - 2.8mmwhen fittingthepulsetransmitter (1).
Replenishing oil
Screwdown the oil drain plugs.
Addtheappropriatetypeofoil totheassembly(seetableon
page3) byfollowingtheproceduredescribedonpage24.
Bothversions
Adjusting push-rod switch signalling interaxle
locking and P.T.O. engagement (if applicable)
Screw down the switch to close the el ectric
contacts, unscrewit byoneturn,thenlockthelock
nut to therequiredtorque.
Print 603.93.641 3aso |ovobo 2006
3aso |ovobo 2006 Print 603.93.641
1 TRAKKER EURO 4/5 PROPELLERSHAFTS
SECTION 7
5056 Propeller shafts
Page
MAIN DATA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Vehicles4x2 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Vehicles6x4 6 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Vehicles8x4x4 8 . . . . . . . . . . . . . . . . . . . . . . . .
- Vehicles4x4 9 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Vehicles6x6 10 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Vehicles8x8x4 10 . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 11 . . . . . . . . . . . . . . . . . . . .
- Mainoperatingfaults 11 . . . . . . . . . . . . . . . . . . . .
TOOLS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROPELLERSHAFT REMOVAL ANDREFITTING 13
- Removal 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblingtheuniversal joint 13 . . . . . . . . . . .
- Assemblingtheuniversal joint 13 . . . . . . . . . . . . .
CHECKINGPROPELLERSHAFTSON
VEHICLES 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure1
Figure2
SLIDINGPROPELLERSHAFT
PROPELLER SHAFT FOR CONNECTION WITH SPRING BEARING
Universal joint workingangle: 25
39056
39057
V||\ ||C| '/'
V||\ ||C| '/'
A
A
L
1
L
MAIN DATA
MAIN DATA
Description mm
Assembly(radial) clearanceof joint inseatsonfork 0.03
Maximumeccentricityof propeller shaft
- measured inthemiddle
- measured at theend
- measured ontheshank
0.4
0.25
0.15
Vehicles4x2
Wheelbase 3500 3800 4200 4500 4800 5100
Model Gearboxtype
L
mm
min. max.
L1
mm
L
mm
min. max.
L1
mm
L
mm
min. max.
L1
mm
L
mm
min. max.
L1
mm
L
mm
min. max.
L1
mm
L
mm
min. max.
190T 31/33 ZF 9S1310 T.O. - 935 1225 1335 1205 1350 1460 1655 1175 1285 1655 1175 1285 1880 1575 1685
190T 31/33 ZF 9S1310 T.O. +Multipower - - 1975 2085 1025 1350 1460 1475 1175 1285 1700 1250 1360 1700 1575 1685
190T 33/36 ZF 16S1620T.D. - - 2050 2160 1150 1325 1435 1595 1150 1260 1820 1220 1330 1820 1550 1660
190T 33/36 ZF 16S1620T.D. +Multipower - - 1850 1960 - 2300 2410 1420 1150 1260 1645 1220 1330 1645 1550 1660
190T 41/45/50
ZF 16S2220T.O.
ZF 16S2520T.O.
- - 1875 1985 - 2275 2385 1420 1150 1260 - - 1645 1550 1660
190T 41/45/50 ZF 16S2220/2520 T.O. +Multipower - - 1700 1810 - 2100 2210 1240 1150 1260 - - 1465 1550 1660
190T 41/45/50 ZF 12AS2330T.O. - - 1975 2085 - 2400 2510 - 2670 2780 - - - 3290 3400
190T 41/45/50 ZF 12AS2330T.O. +Multipower - - 1800 1910 - 2200 2310 - 2490 2600 - - - 3110 3220
400T 33/36 ZF 16S1620T.D. 1750 1860 - 2050 2160 - - - - - - -
400T 33/36 ZF 16S1620T.D. +Multipower 1550 1660 - 1850 1960 - - - - - - - -
400T 41/45/50
ZF 16S2220T.O.
ZF 16S2520T.O.
1550 1660 - 1875 1985 - - - - - - - -
400T 41/45/50 ZF 16S2220/2520 T.O. +Multipower 1375 1485 - 1700 1810 - - - - - - - -
400T 41/45/50 ZF 12AS2330T.O. 1675 1785 - 1975 2085 - - - - - - - -
400T 41/45/50 ZF 12AS2330T.O. +Multipower 1475 1585 - 1800 1910 - - - - - - - -
Vehicles6x4
Wheelbase 3200 3500 3820 4200
Betweengearboxand
intermediateaxle
Betweenaxles
Betweengearboxand
intermediateaxle
Betweenaxles
Betweengearboxand
intermediateaxle
Betweenaxles
Betweengearboxand
intermediateaxle
Betweenaxles
Model Gearboxtype
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L1 L
mm
min. max.
L
mm
min. max.
J 260T 31/33/B ZF 9S1310 T.O. 1450 1560 830 940 1775 1885 830 940 2025 2135 830 940 - - 830 940
J 260T 31/33/B ZF 9S1310 T.O. +Multipower 1275 1385 830 940 1575 1685 830 940 1850 1960 830 940 - - 830 940
J 260T 31/33 ZF 9S1310 T.O. - - - - - - 960 1475 1585 830 940
J 260T 31/33 ZF 9S1310 T.O. +Multipower - - - - - - 780 1475 1585 830 940
Y 260T 31/33/B ZF 9S1310 T.O. 1375 1485 670 830 1700 1810 670 830 1950 2060 670 830 - 2350 2460 830 940
Y 260T 31/33/B ZF 9S1310 T.O. +Multipower 1200 1310 670 830 1525 1635 670 830 1775 1885 670 830 - 2150 2260 830 940
Y 260T 31/33 ZF 9S1310 T.O. - - - - - - 960 1400 1510 670 830
Y 260T 31/33 ZF 9S1310 T.O. +Multipower - - - - - - 780 1400 1510 670 830
J 260T 33/36
ZF 12AS1420T.D
ZF 12AS1930T.D.
1375 1485 830 940 1675 1785 830 940 1950 2060 830 940 - 2350 2460 830 940
J 260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
+Multipower
1200 1310 830 940 1525 1635 830 940 1775 1885 830 940 - 2200 2310 830 940
J 260T 33/36 ZF 16S1620T.D. 1350 1460 830 940 1675 1785 830 940 1950 2060 830 940 - 2350 2460 830 940
J 260T 33/36 ZF 16S1620T.D. +Multipower 1175 1285 830 940 1475 1585 830 940 1750 1860 830 940 - 2150 2260 830 940
Y 260T 33/36/B ZF 16S1620T.D. 1275 1385 670 830 1600 1710 670 830 1875 1985 670 830 - - -
Y 260T 33/36/B ZF 16S1620T.D. +Multipower 1100 1210 670 830 1400 1510 670 830 1700 1810 670 830 - - -
Y 260T 33/36 ZF 16S1620T.D. - - - - - - - 2275 2385 670 830
Y 260T 33/36 ZF 16S1620T.D. +Multipower - - - - - - - 2100 2210 670 830
260/380T 41/45/50T
ZF 16S2220/2520T.O.
+Multipower
950 1060 775 955 1275 1385 775 955 1525 1635 775 955 - 1950 2060 775 955
260/380T 41/45/50 ZF 16S2220/2520T.O. 1125 1235 775 955 1450 1560 775 955 1700 1810 775 955 - 2100 2210 775 955
260/380T 41/45/50/P ZF 12AS2330T.O. 1225 1335 775 955 1550 1660 775 955 1800 1910 775 955 - 2225 2335 775 955
260/380T 41/45/50/P ZF 12AS2330T.O.+Multipower 1050 1160 775 955 1375 1485 775 955 1625 1735 775 955 - 2050 2160 775 955
f 380T 36 ZF 16S1620T.D. 1300 1410 775 955 1625 1735 775 955 1900 2010 775 955 - 2300 2410 775 955
f 380T 36 ZF 16S1620T.D.+Multipower 1125 1235 775 955 1425 1535 775 955 1700 1810 775 955 - 2100 2210 775 955
f 380T 36 ZF 12AS1930T.D. 1325 1435 775 955 1650 1760 775 955 1900 2010 775 955 - 2300 2410 775 955
f 380T 36 ZF 12AS1930T.D.+Multipower 1125 1235 775 955 1475 1585 775 955 1725 1835 775 955 - 2150 2260 775 955
J 440T 33/36T ZF 16S1620T.D. 1350 1460 830 940 1675 1785 830 940 - - - - -
J 440T 33/36T ZF 16S1620T.D.+Multipower 1175 1285 830 940 1475 1585 830 940 - - - - -
J 440T 33/36T
ZF 12AS1420T.D.
ZF 12AS1930T.D.
1375 1485 830 940 1675 1785 830 940 - - - - -
J 440T 33/36T
ZF 12AS1420T.D.
ZF 12AS1930T.D.
+Multipower 1200 1310 830 940 1525 1635 830 940 - - - - -
260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
- - - - 1900 2010 670 830 - 2300 2410 670 830
260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
+Multipower - - - - 1700 1810 670 830 - 2100 2210 670 830
440/720T 41/45/50T
ZF 16S2220/2520T.O.
+Multipower
950 1060 775 955 - - - - - - -
440/720T 41/45/50T ZF 16S2220/2520T.O. 1125 1235 775 955 - - - - - - -
440/720T 41/45/50/P ZF 12AS2330T.O. 1225 1335 775 955 - - - - - - -
440/720T 41/45/50/P ZF 12AS2330T.O.+Multipower 1050 1160 775 955 - - - - - - -
J rear axle452146
Y rear axleMT23 - 155
f rear axle453291
Vehicles6x4(it follows)
Wheelbase 4500 4800 5100
Betweengearboxandintermediate
axle
Betweenaxles Betweenaxles Betweenaxles Betweenaxles Betweenaxles
Model Gearboxtype
L1
mm
L
mm
min. max.
L
mm
min. max.
L1
mm
L
mm
min. max.
L
mm
min. max.
L1
mm
L
mm
min. max.
L
mm
min. max.
J 260T 31/33 ZF 9S1310 T.O. 1230 1475 1585 830 940 1685 1350 1460 830 940 1685 1650 1760 830 940
J 260T 31/33 ZF 9S1310 T.O. +Multipower 1050 1475 1585 830 940 1505 1350 1460 830 940 1505 1650 1760 830 940
J 260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
1165 1475 1585 830 940 1615 1350 1460 830 940 1615 1650 1760 830 940
J 260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
+Multipower
985 1475 1585 830 940 1435 1350 1460 830 940 1435 1650 1760 830 940
J 260T 33/36 ZF 16S1620T.D. 1150 1475 1585 830 940 1595 1350 1460 830 940 1595 1650 1760 830 940
J 260T 33/36 ZF 16S1620T.D. +Multipower 970 1475 1585 830 940 1420 1350 1460 830 940 1420 1650 1760 830 940
Y 260T 33/36 ZF 16S1620T.D. - - - 1595 1275 1385 670 830 - - -
Y 260T 33/36 ZF 16S1620T.D. +Multipower - - - 1420 1275 1385 670 830 - - -
260T/380T41/45/50 ZF 16S2220/2520T.O. 970 1425 1535 775 955 1420 1300 1410 775 955 1420 1600 1710 775 955
260T/380T41/45/50
ZF 16S2220/2520T.O.
+Multipower
- 2200 2310 775 955 1240 1300 1410 775 955 1240 1600 1710 775 955
f 380T 36 ZF 16S1620T.D. 1150 1425 1535 775 955 - - - - - -
f 380T 36 ZF 16S1620T.D. +Multipower 970 1425 1535 775 955 - - - - - -
Y 260T 31/33 ZF 9S1310 T.O. - - - 1685 1275 1385 670 830 - - -
Y 260T 31/33 ZF 9S1310 T.O. +Multipower - - - 1505 1275 1385 670 830 - - -
260/380T
41/45/50/P
ZF 12AS2330T.O. 1075 1425 1535 775 955 1525 1300 1410 775 955 1525 1600 1710 775 955
260/380T
41/45/50/P
ZF 12AS2330T.O. +Multipower - 2300 2410 775 955 1345 1300 1410 775 955 1345 1600 1710 775 955
260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
- - - 1615 1275 1385 670 830 - - -
260T 33/36
ZF 12AS1420T.D.
ZF 12AS1930T.D.
+Multipower
- - - 1435 1275 1385 670 830 - - -
J rear axle452146
Y rear axleMT23 - 155
f rear axle453291
Vehicles8x4x4
Wheelbase 4250 4750 5020 5820
Betweengearbox
and intermediate
axle
Between
axles
Betweengearboxand
intermediateaxle
Betweenaxles
Betweengearboxandintermediate
axle
Betweenaxles
Betweengearboxand
intermediateaxle
Betweenaxles
Model Gearboxtype
L
mm
min. max.
L
mm
min. max.
L1
mm
L
mm
min. max.
L
mm
min. max.
L1
mm
L
mm
min. max.
L
mm
min. max.
L1
mm
L
mm
min. max.
L
mm
min max
340T 36 ZF 16S1620T.D. 2400 2510 830 940 1510 1400 1510 830 940 1510 1650 1760 830 940 1820 2150 2260 830 940
340T 36 ZF 16S1620T.D. +Multipower 2200 2310 830 940 1330 1400 1510 830 940 1330 1650 1760 830 940 1645 2150 2260 830 940
340T 36 ZF 12AS1930T.D. 2400 2510 830 940 1525 1400 1510 830 940 1525 1650 1760 830 940 1840 2150 2260 830 940
340T 36 ZF 12AS1930T.D. +Multipower 2225 2335 830 940 1345 1400 1510 830 940 1345 1650 1760 830 940 1660 2150 2260 830 940
340T 36 B/P-/P ZF 16S1620T.D. 2300 2410 650 790 1510 1325 1435 650 790 1510 1600 1710 650 790 1820 2100 2210 650 790
340T 36 B/P-/P ZF 16S1620T.D. +Multipower 2150 2260 650 790 1330 1325 1435 650 790 1330 1600 1710 650 790 1645 2100 2210 650 790
340T 36/P ZF 12AS1930T.D. - - - - - 1525 1575 1685 670 830 1840 2075 2185 670 830
340T 36/P ZF 12AS1930T.D. +Multipower - - - - - 1345 1575 1685 670 830 1660 2075 2185 670 830
410T 36 ZF 16S1620T.D. 2350 2460 775 955 1505 1325 1435 775 955 1505 1600 1710 775 955 1820 2100 2210 775 955
410T 36 ZF 16S1620T.D. +Multipower 2150 2260 775 955 1330 1325 1435 775 955 1330 1600 1710 775 955 1645 2100 2210 775 955
410T 36 ZF 12AS1930T.D. 2350 2460 775 955 1525 1325 1435 775 955 1525 1600 1710 775 955 1840 2100 2210 775 955
410T 36 ZF 12AS1930T.D. +Multipower 2175 2285 775 955 1345 1325 1435 775 955 1345 1600 1710 775 955 1660 2100 2210 775 955
340T 41/45/P ZF 16S2220T.O. - - - - - 1330 1575 1685 670 830 1645 2075 2185 670 830
340T 41/45/P ZF 16S2220T.O. +Multipower - - - - - 1150 1575 1685 670 830 1465 2075 2185 670 830
340T 41/45/P ZF 12AS2330T.O. - - - - - 1435 1575 1685 670 830 1750 2075 2185 670 830
340T 41/45/P ZF 12AS2330T.O.+Multipower - - - - - - - - 1570 2075 2185 670 830
340T 41/45/B
410T 41/45/50/B
ZF 16S2220/2520T.O. 2150 2260 775 955 1330 1325 1435 775 955 1330 1600 1710 775 955 1645 2100 2210 775 955
340T 41/45 B
410T 41/45/50/B
ZF 16S2220/2520T.O.
+Multipower
2000 2110 775 955 1150 1325 1435 775 955 1150 1600 1710 775 955 1465 2100 2210 775 955
340T 41/45/B/P ZF 12AS2330T.O. 2250 2360 775 955 1435 1325 1435 775 955 1435 1600 1710 775 955 1750 2100 2210 775 955
410T 41/45/50/B ZF 12AS2330T.O. 2250 2360 775 955 1435 1325 1435 775 955 1435 1600 1710 775 955 1750 2100 2210 775 955
340T 41/45/B/P
410T 41/45/50/B
ZF 12AS2330T.O.+Multipower 2075 2185 775 955 1255 1325 1435 775 955 1255 1600 1710 775 955 1570 2100 2210 775 955
Vehicles4x4
Wheelbase 3800 4200 4500
Betweengearbox
and transfer box
Betweentransfer
boxandrear axle
Betweentransfer
boxandfront axle
Betweengearbox
and transfer box
Betweentransfer
boxandrear axle
Betweentransfer
boxandfront axle
Betweengearbox
and transfer box
Betweentransfer
boxandrear axle
Betweentransfer
boxandfront axle
Model Gearboxtype
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
190T 31/33 W ZF 9S1310 T.O. 925 1035 875 985 1800 1910 925 1035 1250 1360 1800 1910 925 1035 1525 1635 1800 1910
190T 31/33 W ZF 9S1310 T.O. +Multipower 700 810 875 985 1800 1910 700 810 1250 1360 1800 1910 700 810 1525 1635 1800 1910
190T 33/36 W ZF 12AS1420T.D./12AS1930T.D. 825 935 875 985 1800 1910 825 935 1250 1360 1800 1910 825 935 1525 1635 1800 1910
190T 33/36 W
ZF 12AS1420T.D./12AS1930T.D.
+Multipower
650 760 875 985 1800 1910 650 760 1250 1360 1800 1910 650 760 1525 1635 1800 1910
190T 33/36 W ZF 16S1620T.D. 825 935 875 985 1800 1910 825 935 1250 1360 1800 1910 825 935 1525 1635 1800 1910
190T 33/36 W ZF 16S1620T.D. +Multipower 650 760 875 985 1800 1910 650 760 1250 1360 1800 1910 650 760 1525 1635 1800 1910
190T 41/45 W ZF 16S2220T.O. +Multipower 497 587 850 960 1800 1910 497 587 1250 1360 1800 1910 497 587 1525 1635 1800 1910
190T 41/45 W ZF 12AS2330T.O. 750 860 850 960 1800 1910 750 860 1250 1360 1800 1910 750 860 1525 1635 1800 1910
190T 41/45 W ZF 12AS2330T.O. +Multipower 571 681 850 960 1800 1910 571 681 1250 1360 1800 1910 571 681 1525 1635 1800 1910
190T 41/45 W ZF 16S2220T.O. 650 760 850 960 1800 1910 650 760 1250 1360 1800 1910 650 760 1525 1635 1800 1910
400T 41/45 WT ZF 12AS2330T.O. 750 860 850 960 1800 1910 - - - - - -
400T 41/45 WT ZF 12AS2330T.O. +Multipower 571 681 850 960 1800 1910 - - - - - -
400T 41/45 WT ZF 16S2220T.O. +Multipower 497 587 850 960 1800 1910 - - - - - -
400T 41/45 WT ZF 16S2220T.O. 650 760 850 960 1800 1910 - - - - - -
Vehicles6x6
Wheelbase 3500 3820
Betweengearboxand
transfer box
Betweentransfer box
and intermediateaxle
Betweenaxles
Betweentransfer box
and front axle
Betweengearboxand
transfer box
Betweentransfer box
and intermediateaxle
Betweenaxles
Betweentransfer box
and front axle
Model Gearboxtype
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
260/380T 36W ZF 16S1620T.D. 571 681 700 810 775 955 1525 1635 825 935 700 810 775 955 1800 1910
260/380T 36W ZF 16S1620T.D. +Multipower 410 440 700 810 775 955 1525 1635 650 760 700 810 775 955 1800 1910
260/380T 36W ZF 12AS1930T.D. 571 681 700 810 775 955 1525 1635 825 935 700 810 775 955 1800 1910
260/380T 36W ZF 12AS1930T.D. +Multipower 420 460 700 810 775 955 1525 1635 650 760 700 810 775 955 1800 1910
260T 41/45 W ZF 16S2220T.O. 390 440 700 810 775 955 1525 1635 650 760 700 810 775 955 1800 1910
260T 41/45 W ZF 16S2220T.O. +Multipower - - - - 500 550 700 810 775 955 1800 1910
260T 41/45 W ZF 12AS2330T.O. 500 550 700 810 775 955 1525 1635 750 860 700 810 775 955 1800 1910
260T 41/45 W ZF 12AS2330T.O. +Multipower - - - - 570 660 700 810 775 955 1800 1910
380T 41/45 W ZF 16S2220T.O. 390 440 700 833 775 955 1525 1635 650 750 700 833 775 955 1800 1910
380T 41/45 W ZF 16S2220 T.O. +Multipower - - - - 500 550 700 833 775 955 1800 1910
380T 41/45 W ZF 12AS2330T.O. 500 550 700 810 775 955 1525 1635 750 860 700 810 775 955 1800 1910
380T 41/45 W ZF 12AS2330T.O. +Multipower - - - - 554 644 700 810 775 955 1800 1910
720T 41/45 WT ZF 16S2220T.O. 390 440 700 833 775 955 1525 1635 - - - -
720T 41/45 WT ZF 12AS2330T.O. 500 550 700 810 775 955 1525 1635 - - - -
Vehicles8x8x4
Wheelbase 4750
Betweengearboxandtransfer box Betweentransfer box and
intermediateaxle
Betweenrear axles Betweenfront axles
Betweentransfer box andfront axle
Model Gearbox
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
L
mm
min. max.
410T 45 W ZF 16S2220T.O. 1700 1810 590 700 775 955 830 940 1320 1500
410T 45 W ZF 16S2220T.O. +Multipower 1500 1610 590 700 775 955 830 940 1320 1500
410T 45 W ZF 12AS2330T.O. 1800 1910 590 700 775 955 830 940 1320 1500
410T 45 W ZF 12AS2330T.O. +Multipower 1575 1685 590 700 775 955 830 940 1320 1500
TROUBLESHOOTING
Main operating faults
Deformedshaft. Replacetheshaft.
Shaft not balanced. Check the balance and determine the
points whereyou need to weld on the
balancingplates.
Too much clearance between grooved
profiles.
Replacetheshaft.
Loosescrewsandnutsfixingtheshaft to
the sleeves on the gearbox or on the
rear axle.
After making a thorough check, fully
tighten the loose screws and nuts; re-
place anydamagedparts.
Transmissionnoiseandvibration
Universal jointsofthepropellershaft se-
ized or too worn.
Overhaul or replacetheuniversal joints.
Insufficient lubrication of the various
parts.
Lubricateviathegreasenipples.
Loose screws fixingthe flexiblemount-
ing.
Tightenthescrewsto therequiredtor-
que.
Silentblock of the central mountingde-
teriorated.
Replace themounting.
Bearingof thecentral flexible mounting
deteriorated or withtoo muchplay.
Replace themounting
Loose screws or ring nuts fixing the
flangeontheshankofthepropellershaft.
Tightenthescrewsorringnutstothere-
quiredtorque.
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
Ringnut for fixingflangeonconnectingshaft:
M40x1.5
M55x1.5
350 +50
380 +70
35+5
38+7
Screwfixingflangeonconnectingshaft: M20 x 160 450 34 45 3.4
Nut for screwfixingpropeller shaft flanges 133.5 13.5 13.3 1.3
Nut for M12screwfixingbracket for flexiblemountingto chassis frame 92 9 9.2 1
Nut for M14 fixingflexiblemountingto chassisframe 146.5 14.5 14.6 1.4
TOOLS
99370618
Mount to remove-refit propeller shaft
Figure3
Figure4
Placeahydraulicjack (4) equippedwiththemount 99370618
(3) under therear propeller shaft (2).
Disconnect thepropellershaft (2) fromtherearaxleandfrom
theflexiblemountingbyunscrewingthescrewsandnutsfixing
theflanges(1 and5).
Lower the hydraulic jack completely to detach the propeller
shaft.
Forrefitting,carryoutthestepsdescribedforremovalinreverse
order, observingthefollowing:
- The self-locking nuts always have to be replaced and
tightenedto therequired torque.
38027
38028
Figure5
38029
COMPONENT PARTSOFTHE UNIVERSAL JOINT
1. Fork - 2. Joint - 3. Split rings - 4. Bearings - 5. Slidingsleeve.
Figure6
38030
Put the universal joint assembly (1) inavice.
Usingsuitablepliers, takeoff the split rings(3, Fig. 3).
Strikeamallet onthefork(3,Fig. 4) till thebearing(2) partly
comesout of itsseat, that isuntil thejoint interfereswiththe
fork.
Turnthe part over and repeat theaboveoperations.
Takeoneof thetwo bearings(2) out byhand.
Takeout thefork(3) and, withtheaidofapunch, extract the
other bearing.
Withthesameprocedure,extractthebearingsfromtheother
forkand freethejoint.
To removetheoppositejoint, repeat theabovesteps.
Assembling the universal joint
Insert thejoint into theforkand into theforked sleeve.
Mount the bearings together with the rollers, and therefore
thesplit rings, onthepins of thejoint.
Removal andrefittingaredescribedforavehiclewith
apropeller shaft intwo sections.
505620 REPAIRS
Disassembling the universal joint
Removal
505620 PROPELLER SHAFT REMOVAL
AND REFITTING
Refitting
Repeat these steps for the front propeller shaft (1),
disconnecting it from the flange (2) of the gearbox and
removingtheflexiblemounting(3) aswell.
!
Figure7
CHECKING PROPELLER SHAFTS ON
VEHICLES
Thedriveshaftsaresupplied readyfor assembly.
Theyarestaticallyand dynamicallybalanced.
Theplateswelded to thepropeller shafts arefor balancing.
Ifthereareno plates, it isnecessarytobalancetheshaft again.
Workingon the propeller shaft and at the same time, in the
oppositedirection, ontheslidingsleeve (arrows), checkthere
isnot too muchclearancebetweenthe splines.
Workingon the forks of the sleeves (arrows), check that the
jointsarenotworn;iftheyare,replacethemasdescribedabove.
23808
1 TRAKKER EURO 4/5 AXLES
SECTION 8
Axles
Page
AXLES 3 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLES 5985/2D 13 54 . . . . . . . . . . . . . . . . . . . .
INTERMEDIATEAXLES 452191/2D . . . .
453291/2D 55 100 . . . . . .
INTERMEDIATEAXLES 452146/2D 101 132 . . . . . . . . .
REARAXLES 451391/2D . . . . . . . . . . . . .
452191/2D
453291/2D 133 168 . . . . .
REARAXLES 452146/2D 169 190 . . . . . . . . . . . . . . . . . .
AXLESIN TANDEMMERITORMT 23-155/2D:
- INTERMEDIATEAXLEMD 11-155/2D 193 234 . . . .
- REARAXLE MR11-155/2D 235 264 . . . . . . . . . . . . .
Axles
Page
REMOVING - RE-FITTING IN PLACETHEFRONT
DRIVEAXLE (4x4 - 6x6 Vehicles) 6 . . . . . . . . .
- Removal 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVINGREAR AXLES
(4x2- 4x4Vehicles) 8 . . . . . . . . . . . . . . . . . . . .
REMOVING THEREARAXLE
(6x4- 6x6- 8x4x4 Vehicles) 10 . . . . . . . . . . . . .
REMOVING THEINTERMEDIATEAXLE
(6x4- 6x6- 8x4x4 Vehicles) 11 . . . . . . . . . . . . .
- Instructionsto adjust andcheck thefunctioning
of thetransmitter that controlstheengagement
of differential and reductiongear unit locking 12 . .
REFITTINGIN PLACE THEAXLE
(Vehicles : all versions) 12 . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING
Insufficient lubrication. Checktherearenoleaksfromgasketsor
theaxlecasingandtopupoil tocorrect
level.
Wheel hubsnoisy
Wheel hub bearingsinefficient. Removethehub and replaceinefficient
parts.
Badadjustment of wheel hubbearings. Adjust bearings.
Half-shaft splinestofit planetarygearsof
epicyclic gearsareworn.
Overhaul andreplacewornordamaged
parts.
Lubricatingoil level low. Checktherearenoleaksfromgasketsor
axlecasingandtopup to correct level.
Noise
Half shaft splines to fit the differential
crownwheels damaged.
Overhaul theaxleand replace wornor
damaged parts.
Noise
Badadjustment of hubbearings. Adjust thebearings backlash.
Bad adjustment or wear on differential
gearsor bearings.
Locatethetroubleandoverhaul theunit.
Noiseat release Improper fitting backlash between
pinionandringbevel gear.
Remove the gear housing inspection
cover and adjust backlash between
pinionandringbevel gear.
Insufficient lubrication. Check that thereareno leaks fromthe
gaskets or thecasingandtopup to the
correct level.
Noiseduringacceleration Gear housingbearings badlyset or de-
teriorated.
Overhaul theunit.
Bad tooth contact between pinion and
ringbevel gear.
Adjust the contact.
Corneringnoise Improper backlash between planetary
gearsandcrownwheels.
Overhaul or replacethe unit.
40560
Figure1
Removal
Place thevehicleonflat ground and lock therear wheels.
Loosenthefront wheel fasteningnuts.
Usingahydraulicjack,lift thefront ofthevehicleandrestit on
two supportingstands.
Remove the wheel nuts then remove the wheels using
hydraulictruck99321024.
Usingpuller 99347068 (1) removetie-rod kingpin(3) from
thearm(2).
Disconnect:
- air deliveryhosesfromthediaphragmbrakecylinders;
- ABStransmitterselectriccable;
- for vehiclesthat areprovidedwithit,theelectriccablefor
brakeliningwear indicator.
522810 REMOVING - RE-FITTING IN PLACE THE FRONT DRIVE AXLE (4x4 - 6x6Vehicles)
40561
Figure2
Place ahydraulic jack with stand 99370617 under the front
driveaxle(3).
Unscrewthenutsand disconnect the propeller shaft (4).
Unscrewnuts(1) andremovetheclips(2) fasteningtheleaf
springsto theaxle.
Lower thehydraulicjackand withdrawthe axle(3)
Refitting
To re-fit in place, followtheremoval instructionsin reverse.
Nutsandboltsmust betightened totheprescribed
torques.
Check andadjust thefront wheelsgeometry.
!
40469
Figure3
Place thevehicleonflat ground and lock thefront wheels.
Removethenut guards andloosen the nuts.
Lifttherearofthevehicleandrest it ontwosupportingstands.
Set thehydraulictruck99321024under thewheels, remove
thewheel nutsthenremovethewheels.
Removethepropellershaft (1) andbrakingcontrol tie-rod(6)
fromtherear axle.
Disconnect the air hoses and electric cable (5) fromthe
differential locking device. Disconnect brake cylinder air
deliveryhoses(3).
Removethebracket (7) securinghoses, cablesandcouplings
to theaxlecasing.
Disconnectthebrakeliningwear indicatorcables(2) andABS
transmitter electric cable.
Removethehoseclamp bracket (4).
Placeahydraulicjackfittedwithsupport 99370617underthe
axle.
525010 REMOVING REAR AXLES (4x2- 4x4 Vehicles)
40470
Figure4
Unscrew the nuts (1) and remove the shock absorbers (2)
fromthelower supports.
Unscrewthesecuringscrews (5) andwithdrawthebrackets
(6) that connect theleaf springto theaxle.
Rotatethetorsionbar (4) and anchor it to thechassis.
Lower thehydraulicjackandremove therear axle(3)
40471
Figure5
Place thevehicleonflat ground and lockthefront wheels.
Removethepropeller shaft (4) fromtherear differential.
Disconnect the air hoses (2) fromthe differential locking
device and electric cable (3) fromthe differential locking
indication switch.
Remove the strap fastening the cables and hoses to the
bracket (1).
Disconnect air deliveryhoses(14) fromthebrakecylinders.
Disconnect the brake liningwear indicator cables (13) and
(12) ABStransmitter cables.
Remove from the rear of the axle casing : bracket (6)
supportingtheair hosesmultiplecouplingandthebracket (7)
that securesthebrakingcontrol tierod.
axle.
Remove the upper longitudinal tie rod (5) fromthe axle
casing.
Removethelowerlongitudinal tierods(11) fromthebrackets
(10).
Bringtheaxlebackwardso that theshoes(8) withdrawfrom
the leaf springs.
REMOVING THE REAR AXLE
(6x4- 6x6- 8x4x4Vehicles)
40472
Figure6
Place thevehicleonflat ground and lockthefront wheels.
Remove the propeller shafts (1-5) from the intermediate
differential.
Removethestrapsfasteningcablesandhosestothebrackets.
Remove the bracket (6) securing the air hoses multiple
coupling(8).
Removethebrakingcontrol tie-rod bracket (4).
Disconnect air deliveryhoses(10) fromthebrakecylinder.
Disconnect thebrake liningwear indicator cables(11).
Disconnect the air hoses (16) fromthe differential locking
device and electric cable (17) fromthe differential locking
indication switch.
Disconnect the air hose (2) fromthe differential reduction
gear unit locking device and the locking indicator switch
electriccable.
axle.
Remove the upper longitudinal tie rod (3) from the
intermediate axlecasing.
Remove the lower longitudinal tie rods fromthe brackets
(14).
Bringtheaxlebackwardsothattheshoes(13) withdrawfrom
the leaf springs.
REMOVING THE INTERMEDIATE AXLE
(6x4- 6x6- 8x4x4Vehicles)
Instructions to adjust and check th e
functioningof thetransmitter that controlsthe
engagement of differential and reduction gear
unit locking
The adjustment and verification of the transmitter (two
functiontype) that checks theengagement ofthedifferential
and reductiongear unit iscarried out with theaxlefitted on
thevehicle.
Theprocedureisasfollows:
1) Withdifferential andreductiongearlocked, screwdown
thetransmitter until the contacts close, checkingin the
cab that theindicator light switcheson.
2) When theindicator light switcheson in the cab, tighten
thetransmitter byonemoreturn.
3) Tightenthetransmitter lockingnut toatorqueof 40Nm
(4 kgm)
4= Release the differential and reduction gear unit locking
engagement and check that the contacts are closed (the
indicator light inthecab switches off).
REFITTING IN PLACE THE AXLE
(Vehicles : all versions)
Tore-fit inplace, reversetheremoval operationstakingcare
to tightenall screwsandnutsto the prescribedtorques.
Whenre-fittedinplacecheckthat:
- thereare no leaksfromtheair hoses;
- thelubricationoil intheaxlecasingisat thecorrect level;
- thedifferential lockingindicator light isworkingcorrectly.
If it doesnot, refer to therelevant chapter.
For6x4-6x6-8x4x4vehicles,iftheleafspringshoes
havebeenremoved, theproceduretore-fit inplace
|s |voo |o t|o soct|oo '|oova| - o-|tt|o |o |aco
the rear leaf spring for CANTILEVER type
sosoos|oos'.
NOTE
13 TRAKKER EURO 4/5 FRONTAXLE 5985/2D(D1385)
5228 Front Axle5985/2D (D1385)
Page
DESCRIPTION 15 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGTHEFRONT AXLE 26 . . . . . . . . .
- Wheel hub disassembly 26 . . . . . . . . . . . . . . . . . .
- Stubaxledisassembly 27 . . . . . . . . . . . . . . . . . . . .
- Driveshaft disassembly 29 . . . . . . . . . . . . . . . . . .
- Fork support disassembly 29 . . . . . . . . . . . . . . . . .
- Stubaxledisassembly 30 . . . . . . . . . . . . . . . . . . . .
- Epicycloidgear disassembly 30 . . . . . . . . . . . . . . .
CLEANINGANDCHECKING PARTS 31 . . . . . . . .
CHECKINGTHEAXLESQUARENESS 31 . . . . . . .
ASSEMBLY 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Yoke support assembling 35 . . . . . . . . . . . . . . . . .
- Driveshaft assembling 36 . . . . . . . . . . . . . . . . . . .
- Stubaxleassembling 36 . . . . . . . . . . . . . . . . . . . .
- Epicyclicreduction gear assembling 41 . . . . . . . . .
- Greasingthestubaxlepins 42 . . . . . . . . . . . . . . .
- Epicyclicgear unit lubrication 42 . . . . . . . . . . . . . .
REMOVING THEDIFFERENTIAL
(with theaxlemountedon stand 99322215) 43 .
- Checkingtheaxlehousing 43 . . . . . . . . . . . . . . . .
REFITTINGTHEDIFFERENTIAL
DIFFERENTIAL REPAIR 45 . . . . . . . . . . . . . . . . . . . .
Page
- Disassembly 45 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblingthedifferential housing 46 . . . . . . .
- Disassemblingthebevel pinion 47 . . . . . . . . . . . .
CHECKINGTHE DIFFERENTIAL COMPONENTS 47
- Assemblingthedifferential housing 48 . . . . . . . . .
- Assemblingthebevel pinionsupport 49 . . . . . . . .
- Differential 51 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjustingtherollingtorqueonthe differential
housingbearings 52 . . . . . . . . . . . . . . . . . . . . . . .
71523
Theaxleis of theload-bearing, doublereductiontype.
Thefirst reductionisprovidedbythebevel pinion/ringbevel
gear, whereas the second reduction is by means of an
epicycloidunit onthewheel hubs.
Thedifferential housing(withringbevel gear) issupportedby
taperrollerbearings,whichcanbeadjustedbymeansof two
threaded ringnuts.
The bevel pinion is supported bytwo taper roller bearings,
whichcanbeadjustedbymeansof adjustment rings.
Theaxleshaftsstart fromthedifferential andtransmit driveto
the epicycloid reduction units by means of homo-kinetic
couplings.
Two flanges are fitted at eachend of therear axlehousing,
whichservefor stub axlearticulation.
Thedrumbrakeisof theDuo/Duplextype.
Figure1
DESCRIPTION
3
MAIN DATA
Typeof axle:
5985 / 2D(D1385)
Load-bearing, doublereduction
5985/ 2D (D1385)
Bevel pinionbearings 2taper rollers
Bevel gear reductionunit ratio
27/32(1.185) - 29/37(1.276) - 28/37(1.321) - 27/37(1.370) -
24/35(1.458) - 23/36(1.565) - 21/34(1.619) - 19/33(1.737) -
21/40(1.905) - 17/35(2.059) - 17/36(2.118) - 15/34(2.267) -
13/35(2.692)
Epicyclic reduction unit/wheels
ratio
3.2
Bevel pinionbearingrollingtorque:
without gasket Nm
withlubricatedgasket Nm
6 8
7.5 9.5
Bevel pinionbearingrollingtorque
adjustment
withadjustment shims
Thickness of bevel pinion bearing
rollingtorqueadjustment shims
mm
10- 10.02 - 10.04 - 10.06 - 10.08- 10.10- 10.12 - 10.14 -
10.16- 10.18 - 10.20 - 10.22- 10.24- 10.26 - 10.28 - 10.30-
10.32- 10.34 - 10.36 - 10.38- 10.40- 10.42 - 10.44 - 10.46-
10.48- 10.50 - 10.52 - 10.54- 10.56- 10.58 - 10.60
Thicknessofbevelpinion/ringbevel
gear positionadjustment shims
mm 0.2 - 0.3 - 0.5- 1
Clearancebetweenpinionandring
bevel gear mm
0.15 0.35
Adjustment of clearance between
pinionandringbevel gear
withringnuts
WHEEL HUBS
Wheel hub bearings 2taper rollers
Wheel hubbearingsrollingtorque:
newbearingswithsurface
protection Nm 6 7+(7.5 9)
runinbearingsand new,
lubricated seals Nm
6 7+(4 5)
runinbearingsand seals
Nm 6 7+(3 4)
Driveshaft endfloat mm 0.5 1
Typeof axle:
5985 / 2D(D 1385)
Loadbearing, doublereduction
5985/ 2D (D 1385)
Axleoil TUTELA W 140/MDA
Quantity Litres
Oil for wheel hub bearings
4.5 5
TUTELA W140/MDA
G.R.W. maximumload kg 9000 - 10000
WHEEL ALIGNMENT
Wheel camber (vehiclewith static
load)
1 30'
Wheel caster (vehicle with static
load)
2 +'
Wheel toe-in
(unloadedvehicle) mm
- adjustment tolerance mm
- control tolerancemm
4x4 - 6x6 models
0.5
0.75
2
8x8models
0
0.75
2
STUB AXLE PINS
Kingpinangle 5
Thickness of adjustment shims for
clearance between axle and stub
axleupper shim X1mm
1.75- 2.00- 2.25- 2.50- 2.75 - 3.003.25 - 3.50
115266
Figure2
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Screwfixingdifferential housingtoaxlehousing 180 10 18 1
2 Locknut for bevel pinion 700 50 70 5
3 Screwfixingbevel pinionmountingto differential housing 180 10 18 1
4 Screwfixingringbevel gear to differential housing 180 10 18 1
5 Screwfixingbearingmountings 180 10 18 1
6 Self-lockingscrewfixingsafetyplate 51 4 5.1 0.4
7 Screwwithtoothed flange 180 10 18 1
8 Screwfixingdifferential lock cover 19 2 1.9 0.2
applyLOCTITEAVX
* applyLOCTITE573
98971
Figure3
WHEEL HUBLONGITUDINAL SECTION AND EPICYCLIC REDUCTION
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Nut fixingwheel 615 35 61.5 3.5
2 Screwfixingbrakemounting 324 396 32.4 39.6
3 Screwfixingsteeringlever pin 207 253 20.7 25.3
4 Screwfixingmountingfor stubaxle 324 396 32.4 39.6
5 Notchednut fixingswivel headpin 250 ** 2.5**
6 Fixingscrew 207 233 20.7 23.3
7 Fixingscrewfor mounting 22 28 2.2 2.8
8 Fixingscrewfor coverz 44 54 4.4 5.4
* applyLOCTITE510
** minimum- maximumtorque, tightento first notchcoincidingwith holefor split-pin
z applyLOCTITE573onthecontact surface
j applyMOLYCOTElubricant onthecontact surfacebeforeassembly
Z lock withLOCTITEAVX
TOOLS
99305121 Hot air device
99322205 Rotatingstandfor assemblyoverhaul
99322215
Stand for axles overhaul
99322225
Support for assemblies(tobefitted ontostand 99322205)
99345049 Reactionblock for extractors
99345053
Reactionblock for extractors
99347068
Extractor for steeringtie-rod ball joint
99348001 Extractor withlockingdevice
99348004 Universal extractor for 5to 70mm(internal)
99354207 Wrench(94.5 mm) for wheel hubbearingsadjustingnut
99355025 Wrenchfor differential gear housingbearingadjustment ringnuts
99355081 Wrench (60 mm) for differential bevel pinion nut (use with
99370317)
99370006
Gripfor interchangeablepunches
99370007 Gripfor interchangeablepunches
99370133 Tool for lockingdifferential capsspread
99370317 Reactionlever withextensionfor flangeretaining
99370509
Hookto extract differential gear half-housing
99370616
Support for differential removal andrefitting
99370617
Universal mountingto support axlesduringremoval and refitting
99372211 Tool for disassemblyandassemblyofbrakeshoeretainingspring
99374093
Punchto fit external racesofbearings(diameter 91 - 134mmuse
with99370007)
99374094
Punchtofitexternal racesofbearings(diameter 134- 215mmuse
with99370007)
99374233
Keyto fit differential bevel pinionseal
99374369
Punchtofit taperroller bearingsonstubaxle(usewith99370006)
99374371 Key to fit roller bearings and seal rings on axle fork (use with
99370006)
99374377 Keyfor assemblyof wheel hub internal seals
99374382
Punchtofit rollerbearingsonstub axlefork(usewith99370006)
99374390
Keyto fit seal ringonstub axle (usewith99370006)
99389819
Toooo .ooc| o 0 to +0 | .|t| +/+' sooao cooooct|oo
99389821 Toooo .ooc| o 0 to 0 | .|t| 3/8' sooao cooooct|oo
99395026 Tool to check rollingtorqueof hubs (usewithtorquewrench)
99395027 Tool todeterminethicknessofdifferential bevel pinionadjustment
shims(usewith99395603)
99395603
Dial gauge (0 - 5 mm)
39481
39482
39483
39484
Figure4
Figure5
Figure6
Figure7
Positiontheaxleonoverhaul stand 99322205.
Positionthewheel hub(1) so that theoil drainageplug(2) is
at thelowest point.
Unscrewthepluganddrainoff theoil into acontainer.
Tofacilitateoil drainageremoveascrew(3) onthecover (4).
Drainofftheoil fromthedifferential assembly,unscrewingthe
plugontheaxlehousingandallowingtheoil to drain into a
suitablecontainer.
Whentheoil isfullydrainedoff,tightenthedrainageholeplugs
byhand.
Loosenandremovethethreeflush-mountedhexscrews(1).
Usingasuitabletool,detachthesidepinionmountingsupport
(1) fromthehub (2) andremove- makingsurethat thering
gear, whichisintegral withthesidepinions, isnot removed.
Wheel hub disassembly
If theaxleis fitted with differential locking, secure
the engagement sleeve in position by insertinga
screwinthecylinder feedhole.
NOTE
52
522810 OVERHAULING THE FRONT AXLE
39485
39486
39487
39488
71524
Figure8
Figure9
Figure10
Figure11
Figure12
Movetheaxleshaft outwards.
Removetheseeger ring(2) and thespacer thenremovethe
gear unit (3).
Extract theshimring(1).
Usingasuitabletool, removethenotchonthenut (2).
Usingwrench99354207(1), unscrew the nut (2, Figure9).
Removethecrownsupportgearunit (56,Figure35) together
withthebearinginternal ring.
Removethewheel hub(1) togetherwiththebearing(2)from
thestubaxle(3).
Stub axle disassembly
Usingtool 99372211, releasetheshoe (2) retainingsprings
(1).
Extract both of theshoesfromtheretainingbrackets (3) by
movingthemfirst upwards, thendownwards.
71525 39492
39491
39493
39494
Figure13
Figure14
Figure15
Figure16
Figure17
Unscrew the screws (2) on the brake mounting (1) and
remove together with the guards. Extract the ABS brakes
sensor (3).
Remove the split pin (1) and unscrew thenut (2) byafew
threads, without fullyremoving.
Fit extractor 99347068(2) andremovethestubaxleball joint.
Removethetrack rod (3).
Unscrewthescrews(1-4) fixingthepin(2) andknucklelever
(3). Extract thepin (2) and thelever (3) fromtheir seats on
thestubaxle(5).
Removethestubaxle (1) and thespacer rings(3) and (2).
Figure18
Disassembletheintermediatering(2) onthestub axle (1).
39525
39495
Figure19
Removetheaxleshafts (1).
39498
Figure20
Removethescrews(2)andtheyoke(1)fromtheaxlehousing
(3).
Repeat thesameoperationonthehubontheoppositeside.
39499
Figure21
Usingsuitablepliers(1) removetheretainingring(2) andthe
support ring(4) under theyoke support (3).
Removetheseal ring.
39501
39500
Using a punch (1) extract the seal ring (2) fromthe yoke
support (3).
Removetheroller bearing(1) usingasuitablepunch(2).
71526
Usingasuitablepunch(3) ontherollerbearing(2),extractthe
bearingstogetherwiththeseal rings(1) fromtheyokesupport
(4).
552820 Yoke support disassembly
Figure22
Figure23
Figure24
Drive shaft disassembly
39502
71527
39504
Figure25
Figure26
Figure27
Removetheseal ring(3) fromthestubaxle(1) usingapunch
(2).
Removetheseeger ring(3) andextract theoil seal ring(4).
Usingextractor 99348004 (1), extract theroller bearing(5)
fromthestubaxle (2).
Remove the seal ring (1) and, using a suitable punch, the
bearingexternal ring(2).
Wheel hub disassembly
39505
39507
39506
Figure28
Figure29
Figure30
Rest thewheel hub(1) ontwo supports (2) andextract the
bearingexternal ringandseal usingapunch(3).
Unscrewthescrews(3) and, usingasuitablepunch,separate
thecover (1) fromthesidepinionsupport (2).
Overturn thesupport (1) leavingthepins(2) in theseats.
Epicyclic gear disassembly
4
Stub axle disassembly
Usingextractor 99348001andreactionblock(3) 99345049,
remove the support bearing (2) from the ring bevel
gear-support gear unit (1).
CLEANING AND CHECKING PARTS
Oncompletionof disassemblyoperations, immerseall parts
(apart from the bearings) in a washing tank containing a
solution of water and sodium carbonate, heated to a
temperatureof 80 85 C, until thelubricationresidual has
dissolved.
Useametalbrushandscrapertoremoveanyfurtherdeposits,
including residual from the seals, Loctite and sealing
compound from the mating surfaces, taking care not to
damagetheparts.
Washthepartsagainanddrywith compressedair.
On the workbench, usingan electric cleaningmachine with
rotatingmetal brushes, eliminate anyresiduals of Loctite or
sealingcompoundonthethreadsof thescrews.
The bearings must be immersed in an oil bath and carefully
cleaned with a brush in order to remove all traces of
lubrication.
Drythebearingswithcompressedair,makingsurethattheair
jet doesnot makethebearingsrotate.
CHECKING THE AXLE SQUARENESS
Inorder toreadtheanglewiththegaugeproceedasfollows:
- position thetwo support rods(1, Figure 33), complete
withcenteringcones(4), in theseats ofthekingpins,se-
curingin positionwiththerods;
- fit thegaugeassemblyand readtheanglevalues onthe
goniometers(2).
Theangleof theholesshould be 5 .
Check thelevelness of theleaf springcontact surfaces.
Inorder toreadtheanglewiththegaugeproceedasfollows:
- insert twocenteringpins(4,Figure34) ontheleaf spring
surfaces;
- usingthecenteringpins,positiontwogoniometers(2)on
the leaf springsurfaces;
- fit thetransverserods(1) onthesupportrods(3) andthe
goniometers(2), and readtheincidenceanglevalueson
therelativegoniometers.
Theaxlecaster angleshouldbe 2 17.
Lubricatethebearingswiththesametypeof oil usedforthe
epicycloidgear unit.
Pressdownonthebearingswithyour handandrotatethem
slightlyinbothdirections. Bearingmovement shouldbeboth
smooth andsilent.
Carefully check that the rollers and cages, as well as the
external and internal rollingtracks, are not worn. Check all
partstoseewhether theycanbere-usedorreplaced.Check
theaxlehousing, theyokesupportsandrelativestubaxlesfor
signs of crackingor damage.
Replaceanywornparts.
Check thestudsfixingthewheel: ifthethreadsaredamaged
or deformedtheymust be replaced. Work under apressto
extract andre-assemblethestuds.Oncompletionofassembly
operations, checkthat theorthogonal deviationisnogreater
than0.3 mm.
39508
39510
Figure31
Figure32
Extract the pins(2) fromthe support (1) together withthe
gears(3) andtheshims.
39593
Figure33
CHECKINGTHEANGLE
1. Support rod - 2. Goniometer - 3. Transverserod- 4. Centeringcones- 5. Spacer
39594
Figure34
CHECKINGTHE CASTERANGLE
1. Transverserod - 2. Goniometer - 3. Support rod - 4. Centeringpin- 5. Spacer
Figure35
ASSEMBLY
39511
39513
39512
39514
39515
71529
Figure36
Figure37
Figure38
Figure39
Figure40
Figure41
Usingpunch99374371(1) andgrip99370006(2),fittheroller
bearing(3) in theseat ontheyokesupport.
Fit thespacer (1) intheseat (2) ontheyokesupport.
Usingsuitable pliers (1) position the retainingring(3) inthe
seat ontheyokesupport (2).
Overturn thesupport (1) andfit theseal (2).
Usingkey99374371(2) andgrip99370006(3),fit theseal in
theseat ontheyokesupport (1).
Usingpunch99374382(4) andgrip99370006(3),fittheroller
bearing(2) in theyokesupport (5); then fit theseal ring(1).
Repeat thesameoperationontheoppositeside.Positionthe
seal ring(6) intheseat ontheyokesupport (5).
Yoke support assembly
Lubricatetheinternal ringonthebearing(2) and theninsert
the driveshaft (1), takingcarenot to damagetheseal ring.
Fit theyokesupport (1) ontheaxlehousing(4),remembering
tofitthemechanical steeringstopstudinthecorrect position.
Align theholesfor the fixingscrews.
Graduallyandfullytightenthescrews(3).
Useatorquewrenchto tightento the correct value.
Figure42
39517
72457
39518
71530
39520
Figure43
Figure44
Figure45
Figure46
Figure47
Usingkey99374369(1) andgrip99370006(2), fit theroller
bearing(5).Fit theoil seal ring(4) andsecuretothestubaxle
withthecirclip (3).
Usingkey 99374390and grip99370006 (2), fit theseal ring
(1) inthestubaxleseat.
Checkthatthesurfaceofthering(1),thathousesthehubseal
ring,isnotdamagedorworn.Replacethering(1) ifnecessary.
When assemblingthe ring(1), applyLOCTITE 573 on the
stub axle(2) pincontact surface( ).
Fit thestubaxle(2) andprovisionallyinsert theupper pin(1)
withtheshim(3).
Drive shaft assembly
39519
5
3
4
Stub axle assembly
39521
39523
39522
39524
39525
Figure48
Figure49
Figure50
Figure51
Figure52
Lubricatetheshoulder ring(2) andfit onthesteeringreturn
lever (1) inthepositionindicatedbythearrow(3).
Fit thespacer (3) withthepins(4) positionedasshowninthe
drawing; fit theseal ringinthesafetyringand insert between
theyokesupport and thestub axle.
Fit thelever (3) on thestub axle.
Tighten the screws (2) and use the torque wrench (1) to
tightento thecorrect value.
Partiallyextract theupper pin(1) andinsert theshim(2).
Insert theupper pin(1).
Assemblethebrakeair pipingunion support bracket (3) and
secureinposition withthescrews(2).
39526
39527
39528
71531
39530
Figure53
Figure54
Figure55
Figure56
Figure57
Fit aclamp (3) in order toraise thestubaxle(2); checkthat
thereisno clearancewithafeeler gauge(1).
If clearance is detected, replace the shim with a suitably
dimensioned shimand check that the clearance has been
eliminated.
Theshimsareavailableinvariousthicknesses:1.75;2;2.25;2.5;
2.75; 3; 3.25; 3.5.
Remove the upper pin fixingscrew, smear withLoctite and
refit, tighteningto atorqueof 230 Nm(23kgm).
Assemblethebrakebody(3) andguard(2) onthestubaxle;
smear thescrews(4) withLoctiteandtightento atorque of
360 Nm. Fit theABSsensor (1).
Fit thejaws(1) sothatthemarkedarrowisfacingtowardsthe
direction of forward movement; usingtool 99372211 fit the
returnsprings(2).
Slightlyheat thephonicwheel (1) withanelectricdrierandfit
onthewheel hub (2).
Usingtwoscrews(1) inserttheflange(2) onthestubaxle(3),
withtheoil drainageplugfacingdownwards.
Fit thecrownsupport gear unit (2) andbearingonthehub(1).
Tightenthenut (3) withthecontact surfacepre-lubricatedwith
Molycote.
Theoil flowmillingonthecrownsupport gear unit
(2) mustbepositionedperpendicularlyonthelower
part.
39531
39533
39532
39488
39534
39535
Figure58
Figure59
Figure60
Figure61
Figure62
Figure63
Fit thebearingexternal races(2and3) onthewheel hub(1)
usingpunch99374094.
Insert theexternal bearinginternal race(2) onthewheel hub
(1).
Usingkey99374377(2) fit theseal (1) onthewheel hub(3).
Fit thewheel hub(1) onthestubaxleshank(1).
Usingkey99354207(1) tightenthewheel hubfixingnut until
theassemblyrotates withdifficulty.
Strike the hub (axially) afew times with arubber mallet to
correctlysettlethebearings.
NOTE
39536
39537
39538
39539
Figure64
Figure65
Figure66
Figure67
Applytool 99389819(3) tothewheel hub(1) androtatethe
hubwith thetorquewrench(2).
Zero-set thetorquewrench (2) indexandrotate thewheel
hub at approx. 25 to 30 rpm.
Readtherollingtorqueonthetool scaled index.
This value must correspond with the data on the
SPECIFICATIONSANDDATA tableonpage18.
Ifdifferent valuesaredetected, tightenor loosenthenut until
therequired valuesareobtained.
Usingapunch(1) securethenut (2).
Assembletheshoulder ring(1) andthegear unit (2).
Usingpliers,fit theshoulderring(1) andtheseegerring(2) on
theaxleshaft.
39541
39543
39542
39544
39545
Figure68
Figure69
Figure70
Figure71
Figure72
Assembletheshimrings (2) onthepin (1).
Usinggrease, fit the rollers(2) onthepin(1).
Insert the gears(2), washers(4), spacersand pins (3) inthe
support (1).
Smear sealing compound on the mating surfaces of the
support cover (1), fit theseal and positionthecover so that
the parts indicatedbythe arrowscoincidewiththepins.
Before fitting the seal, it is advised to position the pins
accordingtoseatsonthecover, thenfit theseal.
Tighten the fixing screw to atorque of 25 Nm (2.5 kgm).
Loosenthenut (2) andslightlyunscrewthescrew(3).
Fit thecrown(2) with theexternal bevel facingtowardsthe
operator, greasethe circlip(1) andfit intheseat.
522870 Epicyclic reduction gear assembly
39546
39547
39705
39491
Figure73
Figure74
Figure75
Figure76
Fit thesidepinionsupport (2) onthewheel hub(1),usingan
Allen wrench (3), tighten thethreesunken hexscrews to a
torqueof 25Nm(2.5kgm).
Tightenthescrew(1) until it makescontact withtheaxleshaft
(3),thenloosenby1/3to 1/2of aturn,therebyobtainingan
assemblyclearanceof 0.5to 1mm.
Tightenthenut (2).
Replacethewashereachtimetheaxleshaft axial clearanceis
adjusted.
Fit thebrakedrum(1) onthewheelhubandsecureinposition
withthetwo screws.
Fit the transverse tie-rod and tighten the nut (1) to the
pre-stabilisedtorquevalue, positionthesplit-pin(2) andbend
to secureinposition.
Greasing the stub axle pins
Usingagreasepump, insert greaseinto thegreasenipples.
Pumpgreaseintotherollerbearingsleevesuntil theyarefull,
andthepressureforcesthegreasepast theseal ringsandout
ofthegapbetweenthestubaxleuprightandtheyokesupport.
Eliminatetheexcessgrease.
Epicyclic gear unit lubrication
Introduce approx. 0.75 litres (0.68 kg) of TUTELA W
140/M-DAoil,throughtheholeonthecoveroftheepicycloid
gear unit.
39548
39549
39550
39551
Figure77
Figure78
Figure79
Figure80
Positiontheaxlehousing(1) asshownin thedrawing.
Removethewheel hubs,stubaxlesandextractthedriveshafts
asdescribed in therelevant chapter.
Tightenthe differential carrier fixingscrews(2).
Fit two eyebolts(1) to thedifferential output flange.
Usingasuitablehoist and cables, removethe differential (3)
fromtheaxlehousing(2).
Usingahydraulichoist withcablesandhooks(3),positionthe
differential housing(1) intheaxle housing(2).
Insert thescrews(1) andtightentothepre-stabilisedtorque
valuewith atorquewrench.
Checking the axle housing
Check the alignment of the axle housing, as any eventual
deformation will lead to unnecessary stress and make the
assemblynoisy(seepage32).
REFITTING THE DIFFERENTIAL
(with the axle mounted on stand99322215)
To keep thecirclipseal initsseat, located between the axle
housingand thedifferential housing, applyalight coveringof
grease. Thematingsurfaceson theaxle housing(2) andthe
differential housing(1) must besmeared withLoctite 573.
525910REMOVING THE DIFFERENTIAL
(with the axle mounted on stand
99322215)
Figure81
39552
39554
39553
39555
39556
39557
Figure82
Figure83
Figure84
Figure85
Figure86
Figure87
Unscrewthescrews(1) andremovethesafetyplate (2).
Heat the points indicated bythe arrows with electric drier
99305121andunscrewthescrews(3) sealedwithLOCTITE.
Removethecaps(4) and ringnuts.
Raisethedifferential housing(2) andbearings(3) usingahoist
(1).
Viewof pinion(1) insidethedifferential carrier (2).
Useapunchto removethesecuring(1) notchand unscrew
thenut (2) as describedbelow.
Block the rotation of the drive coupling flange with the
reaction lever 99370317 (2), and loosen the drive coupling
flangefixingnut usingtheAllen wrench99355081 (1).
Unscrew the bolts that fix the bevel pinion support to the
differential carrier.
Extract thesupport (1) andbevel pinionfromthedifferential
carrier (3);removethepinion/bevel gearpositioningshims(2).
525910 DIFFERENTIAL REPAIR
Disassembly
39558
39560
39559
39561
39562
Figure88
Figure89
Figure90
Figure91
Figure92
Fit thegear housing(1) inavice(2).
Usingextractor99348001(1),extractthesupportbearing(2)
onthetoothedsidefromthedifferential housing(3).
Loosenandremovethescrews(1).
Detach theringbevel gear (2) usingapunch.
Removethedifferential housingcover (1).
Removethecrownwheel (3) fromthegearhousing,together
withtheshoulder washer (2).
Usingapunch,first extract thelongpin(1) andthenthetwo
short pins (2).
The exact position of the pins is marked on the
spider bodybyalongstripefor thelongpin, andby
two short stripesfor theshort pins.
Removethespiderandthefoursidepinionswiththerelative
shoulder washers.
Removethecrown wheel andshoulder washer.
NOTE
Disassembling the differential housing
39563
39565
39564
Figure93
Figure94
Figure95
Using an extractor, positioned as shown in the drawing,
extract thebevel pinion with bearing and support adjusting
ring(1).
Extract theseal ring(2).
Usingextractor 99348001 (1), extract the bearing(2) from
thebevel pinion.
Using apunch, remove the front and intermediate bearing
external rings (1and 2) fromthesupport.
Removetheoil baffle.
CHECKING THE DIFFERENTIAL
COMPONENTS
Carefully clean all of the individual differential components.
Lubricatethebearingsand makesurethat theroller support
cagerotatesfreely,without sticking.Checktheringbevel gear
and half-casingcontact surfaces, makingsure that the bevel
gear matches perfectly. Anyeventual deformation onthese
surfaces would cause screw vibration on the bevel gear,
leadingtoincorrect assemblyoperation.
Carefully clean all the threads to ensure exact
adjustments andprecisetighteningtorquevalues.
Check that thesplined sectionused to keytheflangeonthe
pinionis not worn. Replacethepinionif necessary.
Ifeitherthebevel gearorpinionneedtobechanged,
bothpartsmust bereplacedastheyareprovidedas
coupledspareparts.
Checkthesidepinionswithrelativeshoulderwashers,andthe
spider and crown wheelswith relativeshoulder washers.
Replace all sealing elements and safety washers with new
parts.
NOTE
NOTE
Disassembling the bevel pinion support
39566
39568
39567
39569
39570
Figure96
Figure97
Figure98
Figure99
Figure100
Setthegearingbox (3) onasuitablesupport,placeintheseat
crownwheel (1) comprisingshoulder washer (2).
Assemblethefoursidepinions(2) withtheshoulder washers
and insert thespider (4). Insert thelongpin(1) andthetwo
short pins (3).
Theexact positionof thepinsismarked onthespider body
(4) byalongstripefor thelongpin, andbytwo short stripes
for theshort pins.
Positionthecrownwheel (2) andshoulderwasherontheside
piniongear unit.
Fit thecover (1) onthedifferential housing(3) bycentering
thefixingscrewholes.
Heat theringbevel gear (1) to approx.80C, fit inpositionin
the differential housing (2) and secure with the two fixing
screws.
Fit theother screws(1) andtightenwithatorquewrench(2)
to 180 Nm.
Heat thesupport bearings withelectricdrier 99305121and
assemblein thegear housing.
Assembling the differential housing
39571
39573
39572
39574
39575
Figure101
Figure102
Figure103
Figure104
Figure105
Fit anewoil baffle onthepinionsupport.
Fullyfit theexternal ring(2) forthefrontbearingintotheseat,
usingpunch99374093(1), andtheexternal ringfor therear
bearing, usingpunch99374094, into theseat.
Proceduretofollowtodeterminethethicknessofthebevel
pinion rollingtorque adjustingring.
Measureandnotethethickness(valueA) oftheadjustingring
(1) on disassembly.
Securetool 99395027 (1) and extension(2) inavice.
Fit thefollowingpartson tool 99395027:
- thebearing(6) onthepinion-side;
- thespacerring(5),thepreviouslymeasuredadjustingring
(4) and thebearing(3).
Fullytightentheringnut (2).
Position part (1) of tool 99395027 (7) on the bearing(3),
fittedwith azero-set dial gaugeontheendof thetool (7).
Thenremove:
- the part (1);
- theringnut (2);
- thebearing(3);
- theadjustingring(4) on thetool (7).
Positionthesupport (4, Figure105) onthebearing(6,Figure
104) and assemble thebearing(3) onthesupport.
Tightentheringnut (2) byhand. Checktherollingtorqueas
indicatedinFigure106.
Assembling the bevel pinion support
39576 39577
39578
Figure106 Figure107
Figure108
Positionthecompletesupport(3) ontwoparallel blocks;using
thetorquewrench(1)appliedontool 99395027(2) andread
therollingtorque. Thisvalueshouldbe:
- 6to8Nm;ifnot,adjustbymeansoftheringnut (2,Figure
104).
Positionthepart (1, Figure104),withthedial gaugezero-set,
onthebearing(3) andreadtheeventual deviation(valueB).
ThicknessS ontheadjustingringisprovidedbythefollowing
formula:
S=A - ( B) +C
Where:
A =thickness of the adjusting ring assembled for dial
gaugezero-setting;
B =deviationvalueread;
C =0.05 mmcoefficient which takes into account the
expansion of the bearings as a result of the assembly
negativeallowanceonthebevel pinion.
First example:
A =10.12mm
B =+0.13mm
C = 0.05mm
S =10.12 - (+0.13) +0.05 =
S =10.12 - 0.13 +0.05 =10.04 mm.
Second example:
A =10.12mm
B =- 0.13 mm
C = 0.05mm
S =10.12 - (- 0,13) +0.05 =
S =10.12 +0.13 +0.05 =10.30 mm.
On completion of the operation, remove the parts of tool
99395027.
Heat thebearing(3) withelectricdrier 99305121 andfit on
thebevel pinion(4).
Fit thespacer (2).
Assemble the adjustingring(1) with the same thickness as
previouslynoted, andposition onthe bevel pinion.
Fit the bevel pinion on the support, completewith external
ringsfor bearings.
Heatthebearing(1)withelectricdrier99305121andposition
inthebevel pinion (2) seat usingapunch.
39579
39581
39580
71850
Figure109
Figure110
Figure111
Figure112
Figure113
Usingkey 99374233(1) fit the newseal (3) onthesupport
(2). Spare part seals are supplied pre-lubricated and with
greasebetweenthelips.
Positionthedrivecouplingflange(1),completewithbaffle(2),
onthesplinedsectionofthebevel pinion(3) andsettleinthe
seat with apunch.
Provisionallytightenthefixingnut (4).
Before fitting the bevel pinion support assembly on the
differential housing, checkthevalue(1) markedonthebevel
pinionand,byconsultingthetableinFigure112,thethickness
ApplyLOCTITE 573 on the differential carrier (1) contact
surface, addingLOCTITE510around the holes indicatedby
thearrows.Fit theadjustingring(2) onthedifferential carrier
(1), so that the hole (4) faces towards upper part A of the
differential carrier. Using eyebolts and cables, fit the bevel
pinionassemblysupport (3) onthedifferential carrier (1).
Tightenthefixingscrewsto thecorrect torquevalue.
oftheadjustingringtobepositionedbetweenthesupportand
thehousingwill begiven.
Example:
Ifthereferencevalue(1) markedonthebevel pinionis+0.5,
thethickness of theadjustingring must be 1.5mm.
The adjustingrings areavailableinthefollowingdimensions:
0.2, 0.3, 0.5, 1mm.
Differential
SUMMARY TABLETO DETERMINETHETHICKNESSOF
THEBEVEL PINION POSITION ADJUSTINGRING
!
ApplyLOCTITE 573 on the threads of the screws
that passthroughtheholesonthedifferential carrier
(1).
Valuemarked
onthebevel pinion
Total thickness of
adjustingring
0 0.5
0.1 0.6
0.2 0.7
0.3 0.8
0.4 0.9
0.5 1.0
0.6 1.1
0.7 1.2
0.8 1.3
0.9 1.4
1.0 1.5
39583
39585
39584
39587
Figure114
Figure115
Figure116
Figure117
Figure118
Usingthehook(1),raisethepreviouslyassembleddifferential
housing(2) andpositionon thedifferential housing(3).
Fit theexternal bearingringsandpositionthecaps(2). Apply
LOCTITEAVX onthethreadsof thescrews(1), andtighten
without fullyscrewingdown.Fittheadjustingringnuts,making
sure that theyscrew on easily. Usingatorque wrench (3),
tightenthescrews (1) to the correct torquevalue.
Adjusting the rolling torque on the gear
housing bearings
Positiontool 99370133(1) asshowninthedrawingto avoid
excessivespread onthe caps duringadjustment operations.
The total rolling torque reading is carried out when the
clearancebetweentheteethonthebevel gearpair isasnear
to thepre-stabilisedvalue aspossible.
However,thetotal rollingtorquevaluevariesaccordingtothe
reduction bevel gear pair ratio (seetablein Figure 118).
Usingtorquewrench99389819(1)andtheappropriateAllen
wrench, read the pre-stabilised torque value, adjustingthe
bearingadjustment ringnuts(3) with wrench99355025(2).
No. of
teeth
Total rolling
torque
Nm
17/35
19/33
21/34
23/36
24/35
a+(1.5 - 1.9)
a+(1.7 - 2.3)
a+(1.9 - 2.5)
a+(1.9 - 2.6)
a+(2.1 - 2.7)
a+(2.3 - 3.0)
Ratio
2.059
1.737
1.619
1.565
1.458
1.321
27/32
28/37
a+(2.5 - 3.4) 1.185
a=7.5 9.5Nm
21/40 a+(1.6 - 2.1) 1.905
27/37 a+(2.2 - 2.9) 1.370
29/37 a+(2.4 - 3.1) 1.276
13/35 a+(1.1 - 1.5) 2.692
15/34 a+(1.3 - 1.8) 2.267
17/36 a+(1.4 - 1.9) 2.118
39586
39588
Figure119
Figure120
Figure121
Figure122
Figure123
Adjust the axial clearance between the teeth on the
pinion/bevel gear, which should be 0.15 to 0.35 mm,
- Positionamagnetic stand dial gauge(1) asshowninthe
drawing.
- Using wrench 99355025 (2), tighten the bearing
adjustment ringnut (3) whilst looseningtheringnut on
theoppositesidebythesameamount.Thispreventsthe
previouslymeasured rollingtorquefromvarying.
Usingabrush(1) applyalightcoveringofPrussianblueonthe
teethof thebevel gear.
Rotatethepinionandcheckthecolouredcontact marksthat
thepinionteethhavemadeonthebevel gear teeth.
The followingdrawings illustrate possible contact marksand
theoperations required inorder to correct thefaults.
Thecontact marksshouldbeonboththeleadingface(1) and
thepushingface(2), moreor lessinthecentrebetweenthe
teeth. When working without a load, both contact zones
should be slightlyout of position in relation to the external
diameter of thebevel gear.
Ifthemarkontheleadingface(towardstheexternal diameter)
andonthepushingface(towardstheinternal diameter) isout
of position, thepinionislocated tooclose tothebevel gear.
-Solution:increasethethicknessoftheadjustingringbetween
theintermediatebearingandthebevel pinion.
If the mark on the leading face is positioned towards the
internal diameter,andonthepushingfaceitislocatedtowards
theexternal diameter of thebevel gear, thepinionislocated
too far awayfromthebevel gear axis.
- Solution: decrease the thickness of the adjusting ring
between theintermediatebearingand thebevel pinion.
40160
40161A
40161B
39552
Figure124
Positiontheplate(2) andtightenthefixingscrews(1) tothe
correct torquevalue.
If theplate(2) doesnot coincidewith thenotchon thering
nut (4), slightlyrotatetheringnut until theplateandringnut
notch coincide. Repeat this operationontheoppositeside.
55 TRAKKER EURO 4/5 INTERMEDIATEAXLES452191/2D(R9274) - 453291/2D(R9189)
5251 Intermediate axles
452191/2D (R9274)
453291/2D (R9189)
Page
DESCRIPTION 57 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING-REFITTINGTHE INTERAXLE
DIFFERENTIAL
(with theaxlemountedon thevehicle) 68 . . . . .
- Removal 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMEDIATEAXLEASSEMBLY REPAIRS 69 . . .
- Disassembly 69 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Epicyclicreduction gear disassembly 69 . . . . . . . .
- Wheel hubsdisassembly 73 . . . . . . . . . . . . . . . . .
- Assemblingtheepicyclic reductiongear 75 . . . . . .
REMOVING - REFITTING THE
FLOW DIVIDERDIFFERENTIAL
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRINGTHEINTERAXLEDIFFERENTIAL 78 . .
- Interaxledifferential unit disassembly 78 . . . . . . . .
- Differential housingdisassembly 81 . . . . . . . . . . . .
- Interaxledifferential disassembly 83 . . . . . . . . . . .
- Interaxledifferential unit assembly 87 . . . . . . . . . .
- Differential housingassembly 88 . . . . . . . . . . . . . .
- Interaxledifferential unit assembly 90 . . . . . . . . . .
56 TRAKKER EURO 4/5 INTERMEDIATEAXLES452191/2D(R9274) - 453291/2D(R9189)
Page
- Procedureto followto determinethe
thicknessof thebevel pinionrollingtorque
adjustingring 90 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjustingtherollingtorqueon the differential housing
bearings 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVESHAFT 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 98 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingparts 99 . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theintermediateaxleisoftheload-bearing,doublereduction
type.
epicycloidunit onthewheel hubs.
threaded ringnuts.
whichcanbeadjustedbymeansof adjustment shims.
The intermediate axle is fitted with aflow divider unit that
distributesthetorque betweenthe two axles.
The axle is also provided with a pneumatic device for
differential lockingandanotherdeviceforflowdividerlocking.
Figure1
71847
INTERMEDIATEAXLES452191/2D(R9274) - 453291/2D(R9189) 57 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESCRIPTION
Revi - June2007
58 INTERMEDIATEAXLES452191/2D(R9274) - 453291/2D(R9189) TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641/A
PRINT603.93.641/A
MAIN DATA
Typeof axle:
Load-bearing, singlereduction
with pneumatically controlled
differential lockingand flow divider
unit
452191/2D(R9274) 453291/2D(R9189)
Bevel pinionbearings 2taper rollersand 1straight roller
27/32(1.185) - 29/37(1.276) - 27/37(1.370) - 28/37(1.321) -
24/35(1.458) - 23/36(1.565) - 21/34(1.619) - 19/33(1.737) -
21/40(1.905) - 17/35(2.059)
Epicyclicreductionunit/wheelsratio 3.2
Bevel pinionbearingrollingtorque
Nm 1.5 3.5
Bevel pinion bearingrollingtorque
adjustment
withadjustment rings
Thickness of bevel pinion
bearingrollingtorque
adjustment rings mm
1.000 2.500 (seriesof increased thicknesses=0.02 mm)
Thickness of bevel pinion/ring
bevel gearpositionadjustment rings
mm
3.6-3.7-3.8-3.9-4.0-4.1-4.2-4.3-4.4-4.5-4.6
Clearancebetweenpinionand ring
bevel gear mm
0.20 0.33
withringnuts
Bearingtotal rollingtorque S
withringnut
WHEEL HUBS
Wheel hub bearingsrolling
torque:
new bearings with surface
protection Nm
6 7+ (12 16)
torque:
runinbearings andnew, lubricated
seals Nm
6 7+ (5 7)
torque:
runinbearingsand seals Nm 3Nm+ (2.5 4.5 Nm)
Axleoil
Quantity Litres
kg
TUTELA W140/MDA
27
24.3
G.R.W. maximumload kg 11000 16000
Revi - June2007
PRINT603.93.641/A
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Hexscrewfor cover 62 6 6.2 0.6
2 Ringnut 230 20 23 2
3 Hexscrew 67 8 6.7 .0.8
4 Self-lockingscrew 260 25 26 2.5
5 M12x 1.5threaded plug 21.5 1.5 2.1 0.1
6 Hexscrewfor cover 33 3 3 0.3
7 Self-lockingscrew
{
1
st
stage
2
nd
stage
100
300 10
10
30 1
8 Self-lockingscrewfixingsafetyplate 51 5 5 0.5
11 Self-lockingscrewfixingoil feed 16 2 1.6 0.2
12 Threadedplug 110 10 11 1
13 Cheese-headedscrew 25 2 2.5 0.2
14 Self-lockingnut 1250 50 125 5
15 Screwfixingcover 182.5 17.5 18.2 1.7
16 Nut for screwfixingoil feed 16 2 1.6 0.2
17 Self-lockingnut 700 50 70 5
18* M16screwfixingcapsto gear housing 270 25 27 2.5
19 Self-lockingnut 825 25 82.5 2.5
z applyLOCTITE573sealant oncontact surface
* applyLOCTITEAVX on thread
Figure2
115267
98970
SECTION ON EPICYCLIC REDUCTION AND WHEEL HUB
Figure3
PRINT603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Countersunkscrewfixingdrum 25 3 2.5 0.3
2A Nut fixingwheel 615 35 61.5 3.5
2B Nut fixingwheel 415 35 41.5 3.5
3 Screwfixingcover to sidepinionsupport V 50 5 5 0.5
4 Screw 50 5 5 0.5
5 Screwfixingloadbearingsleeve 295 30 29.5 0.3
d applyLOCTITE5970 onthecontact surface
V applyLOCTITE573onthread
H applyLOCTITE573onmatingsurface
* Beforemounting, slightlysmear MOLYCOTEonnut rest surface
Print 603.93.641 3aso |ovobo 2006
TOOLS
99322205 Rotatingstandforassemblyoverhaul (1000N loadbearingcapacity,
120 daNmtorque)
99322215
Stand for axles overhaul
99322225
Support for assemblies(tobefitted ontostand 99322205)
99341015
Press
99341017
Pair of brackets withhole
99341020 Pair of tierodsfor grips
99341023 Grips
99345053
Reactionblock for extractors
99348001 Extractor withlockingdevice
Revi - June2007
PRINT603.93.641/A
99354207 Wrench(94.5 mm) for wheel hubbearingsadjustingnut
99355081
Wrench (60 mm) for drive infeed flange retaining nut and flow
divider spur gear unit retainingnut
99355121 Wrenchfor flowdivider mainshaft ringnut
99363310 Tool for retainingspur gear onflow divider bevel pinion
99370005
Interchangeablegripfor punches
PRINT603.93.641
99370007 Interchangeablegripfor punches
99370122
Punch for fittingflowdivider main shaft crownwheel bushings
99370317 Reactionlever withextensionfor flangeretaining
99370509
Hookto extract differential gear half-housing
99370617
Universal mountingto support axlesduringremoval and refitting
Print 603.93.641 3aso |ovobo 2006
99370630 Mountingfor removal and refittingof flowdivider betweenaxles
99374013 Keyto fit flowdivider driveinfeed shaft seal (usewith99370006)
99374094
Punchtofitexternal racesofbearings(diameter 134- 215mmuse
with99370007)
99374161
Keyfor assemblyof wheel hub internal seals
99374233
Keytofit flowdivider driveshaft seal
99374235 Keyto fit shaft crownwheel gear front seal
Revi - June2007
PRINT603.93.641/A
99389816 + toooo o|t|||o .|t| 3/+ ' |oooo aoo +' sooao cooooct|oo
(max. 2745Nm)
99389819
Toooo .ooc| o 0 to +0 ' .|t| +/ +' sooao cooooct|oo
99389821
Toooo .ooc| o 0 to 0 ' .|t| 3/ 8' sooao cooooct|oo
99395026 Tool to check rollingtorqueof hubs (usewithtorquewrench)
99374451 Tool for driveshaft disassembly-assembly
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
shims(usewith99395603)
99395603
Dial gauge (0 - 5 mm)
40156
40157
40158
Figure4
Figure5
Figure6
Insert suitablescrewsinthetwo threadedholes(2) to act as
extractorsfor theinteraxledifferential unit.
Usingthehydraulicjack(1) placebracket 99370630(2) with
device 99370629 (4) underneath the differential-reduction
gear unit (3); remove the fasteningscrews, tighten the two
counteractingscrewstopull out theunit fromtheaxlecasing. Positionahydraulicjack(2),fittedwithsupport99370618(3),
under thepropeller shaft (1).
Disconnect thepropellershaft (1) fromtheintermediateaxle
byunscrewingthescrewsandnutsfixingthe flange(4).
Fully lower the hydraulic jack, thereby detaching the
transmissionshaft.
Disconnect theair pipingandelectrical connectionsfromthe
differential lockandflowdivider controls.
Unscrewthelower pluganddrain off theoil.
Extract the drive shafts as described under the relative
heading.
Refitting
Carryout refittingoperations byreversingthe order of the
removal procedure, bearingin mindthefollowingpoints.
- Carefullyclean andsmear LOCTITE573onthecontact
surfaces of the differential housing and the drive shaft
covers. Replace theseal.
Checkthat theinteraxledifferential engagement sleeve(1) is
correctlypositionedonthedriveshaft, withtheinternal side
of thegroove(=>) flushwiththeaxlehousing.
Check:
- that thedifferential lockfork engagesonthesleeveand
that thedifferential centeringpinsenter theholes(2);
- tightenall thescrewsto thepre-stabilisedtorque;
- connect theair pipingandelectrical connections;
- fill uptheaxlehousingwithoil.
40075
Figure7
Thedriveshaft onthedifferential locksidemust not
beremoved,butonlyextractedbyapprox.120mm.
Thisistopreventdifferential lockengagementinner
sleeve without any more half shaft guide from
inhibitingthat rear axleboxtransfer boxdifferential
istaken out.
2
NOTE
INTERAXLE DIFFERENTIAL
(with the axle mounted on the vehicle)
Removal
40052
71534
Figure8
Positiontheaxleassemblyonstand 99322215.
Position acontainer under thewheel hub (1). Unscrewthe
screws(2), removethecover (3) and drain off theoil into a
container.
Before positioningtheaxleassemblyontheoverhaul stand,
drain off the oil by unscrewing the lower plug on the axle
housing.
The drive shafts - brake drums and jaws - air
breather - interaxle differential - wheel hubs and
epicycloid reduction units removal-refitting
operations,canall becarriedout withtheunit fitted
onthevehicle.
71533
Blockthedifferential lockingdeviceslidingsleevewithascrew.
Remove the control cylinder threaded coupling (2) and
replacewith ascrew(1) (M14x 1.5).
Rotatetheaxlemechanismtofacilitateengagement between
theslidingsleeveandthe engagement sleeve; thiswill avoid
involuntarysleeve movement whilst the drive shaft is being
extracted.
Figure9
Figure10
40338
UsinganAllenwrench(2) unscrewthetwoscrews(1) fixing
thedrum; replacewith thereaction screws (5). Tightenthe
reactionscrewsandremovethedrum(4) fromthehuband,
usingasling(3), raiseand remove.
Figure11
40054
Unscrew the 3 side pinion (3) fixing screws; tighten the
reactionscrews(1) and, usingasling(2),removethesupport
(3).
Figure12
525140 Epicyclicreductiongear disassembly
NOTE
Print 603.93.641 3aso |ovobo 2006
525110 INTERMEDIATE AXLE ASSEMBLY
REPAIRS
PRINT603.93.641
Disassembly
40055
39636
39635
40056
39637
39638
Figure13
Figure14
Figure15
Figure16
Figure17
Figure18
Removethebevel gear (1) fromthemounting.
Removetheshoulder pin(2).
Usingsuitable pliers, remove the safetyring(2), extract the
gear unit (3) fromthedriveshaft (1).
Fit tool 99374451(1) intheshoulderpinseatandextract the
driveshaft (2) fromtheload bearingsleeve.
Removethespacer ring(3).
Extract thesupport pins(2) fromthesidepinionsupport (1).
Removethesidepinions(3) fromthesupport(1) andrecover
therollers andthespacer rings.
Usingapunch, remove thenotch(1) on theadjustingnut.
UsingAllenwrench99354207(1),unscrewtheadjustingnut.
525130 Wheel hub disassembly
39639
71536
71535
Figure19
Figure20
Figure21
Extractthebevel gearmounting(2),togetherwiththebearing
and wheel hub(3), fromtheloadbearingsleeve (1).
Check thesurfaceof the ring(1), onwhich thehubseal ring
rotates, isnot damagedor worn.
If necessary, replacethe ring(1).
Usingthe extractor [comprisingbridge 99341003 (8), grips
99341023(3),tierods99341003(6),press99341015(4)and
reaction block 99345053 (7)], extract the ring(replacing if
necessary) and/or theinternal ring(2) of thesleeve(5) taper
bearing.
40061
40062
Figure22
Figure23
Usingtheappropriatetools, extract theexternal andinternal
seal ringsfromthewheel hub.Withauniversal bronzepunch,
extract theexternal rings(1and2) oftheinternal andexternal
bearings.
Push out of the crown holder (1) the taper roller external
bearing(2) bymeansofaspecial beaterinsertedthroughthe
holesobtainedfromthecrown holder.
Check the load bearing sleeve (2). If damaged, replace as
follows.
Unscrewthescrews(1), removethebrakesupport plate (3)
and theaxlecasingsleeve (2).
Print 603.93.641 3aso |ovobo 2006
Carefully clean the wheel hub parts. Check the
drive shafts for deformation. If necessary,
straightenthedriveshaftsusingahydraulicpress;
ifthisdoesnot providesatisfactoryresults,replace
thedriveshafts.Checkthestudsfixingthewheel:
ifthethreadsaredamagedordeformedtheymust
bereplaced. Work under apressto extract and
re-assemble the studs. On completion of
assemblyoperations, check that the orthogonal
deviationis no greater than0.3 mm.
Lubricate the bearings and make sure that the
roller support cagerotatesfreely,rotationshould
besmooth, without hardening.
40063
Figure24
Check the oil manifold (1) and replace if damaged. Extract
withapunchinserted intheslots on thehub(3).
Check the threads onthehub bearingsadjustment nuts and
on the load bearing sleeves; replace the nuts if necessary.
Check theoil manifold andreplace if damaged.
Replaceall sealswith newparts.
Carefullycleanall theepicycloidgearunitparts.Visuallycheck
thetoothingon the bevel gear support, the bevel gear, the
crownwheel gearsand theopengear unit.
Check the spacer rings, distance ring, bearing rollers and
support pins.
Replaceanydamaged or wornparts.
CLEANING AND CHECKING WHEEL HUB AND
EPICYCLIC GEARPARTS
WHEEL HUBPARTS
1. Brakedrum- 2. Adjustingnut and screw- 3. Cover - 4. Seal - 5. Pinand roller for sidepinions- 6. Sidepinionsupport -
7. Adjustingnut - 8. Ringbevel gear support - 9. Shoulder pin- 10. Sidepinion- 11. Ringbevel gear - 12. Gear unit -
13. Driveshaft - 14. Bearing- 15. Wheel hub- 16. Stud - 17. Bearing- 18. Seal rings - 19. Support ring- 20. Oil sump-
22. Brakeunit - 23. Loadbearingsleeve - 24. Axle housing- 25. Breather
40063
Figure25
39645
40410
40064
71537
71538
Figure26
Figure27
Figure28
Figure29
Figure30
Ifthestuds(3) needtobereplaced, beforefittingnewstuds,
makesurethat thecontact surfaceontheheadisfreeofslag,
burr, blisters.
After fitting, checkthat thestudsarefullyinsertedonthehub
and that theright angleerror doesnot exceed0.3 mm.
If the oil collecting sump (2) needs to be replaced, before
assembly, smear the contact surface on the hub/sump and
hub/hubseat withLOCTITE573 sealingcompound.
Usingpunch99374094(2) andapress,fit theexternal ringon
theexternal bearing(3),stoppingapprox.5mmfromthefully
fitted position (seeFigure28).
Complete fittingoperations manually, usinggrip 99370007,
thenturnthehuboverandcarryoutthesameoperationwith
theexternal ringof theinternal bearing.
Usingahydraulicpressand key99374161 (1), withthering
(2) positionedasshowninthedrawing, fitthebrowninternal
seal ring(3) onthewheel hub (4).
(2) positioned as showninthedrawing, fit theblueexternal
Print 603.93.641 3aso |ovobo 2006
40375
71540
40377
39650
40070
Figure31
Figure32
Figure33
Figure34
Figure35
Figure36
Smear LOCTITE 573 on the seat (=>) of the load bearing
sleeve(3) ontheseal ringssupport ring(2). Heat thering(2)
withanelectricdrier and keyonthe loadbearingsleeve(3).
Heatthetaperbearinginternal ring(1) to100Candfitonthe
load bearingsleeve.
Lubricatethelip of theseal ringsandsleeve.
Fit thehub(1) ontheloadbearingsleeve (2).
Lubricatetheseal ring(3) andfit onthewheel hub.
Using an electric drier, heat the taper roller bearing (1) to
100C and fit onthebevel gear support (2) withapunch.
Fit thebevel gear support (3) andthetaper roller bearing(2)
ontheload bearingsleeve (4)
Applyathin layer of MOLYKOTE onthe contact surfaceof
theadjustingnut andtightenwithwrench99354207(1) until
the hub rotates with difficulty. Release the hub with afew
blowsfromahammer inthedirection oftheaxisandinboth
directions.
71539
Positiontheseal ringontheloadbearingsleeve.
Fit theloadbearingsleeve(3),thebrakesupportplate(4) and
dust seal disk.Smearthescrews(2) andtightentothecorrect
valuewith atorquewrench (1).
40071
40072
40069
39636
39653
Figure37
Figure38
Figure39
Figure40
Figure41
Positiontool 99395026 (1) and, usingatorquewrench(2),
read thewheel hubrollingtorque.
Oncetherequiredrollingtorquehas been achieved, secure
theadjustingnut (2) withapunchinthetwo groovesonthe
load bearingsleeve(1).
Positionthespacer ring(2) ontheload bearingsleeve.
Usingtool 99374451(1) introducethedriveshaft (2) onthe
Positionthegear unit (3) onthegroovedsectionofthedrive
shaft andthesafetyring(1) intheseat.Drivetheshoulder pin
(2) into theseat on thedriveshaft.
During hub rolling torque detection, hub rotation
speed must not exceed 40 rpm.
Wheel hub rolling torque values vary according to the
followingconditions:
- newbearingswith
surfaceprotection 6 7+(12 16) Nm
- runinbearingsand new,
lubricated seals 6 7+(5 7) Nm
- runinbearingsand seals 6 7+(2.5 4.5) Nm
525140 Assembling the epicyclic
reduction gear
Fit theshort driveshaft,withdoubletoothing,onthe
load bearingsleeveonthedifferential lockside.
NOTE
!
Print 603.93.641 3aso |ovobo 2006
39654
39655
26916
39656
40073
Figure42
Figure43
Figure44
Figure45
Figure46
Position the bevel gear (1) with the external bevel facing
outwardsand thenfit onthebevel gear support.
Smeartherollers(1) withgreaseandposition, together with
thethreespacer rings(2) onthesidepinion(4), asshownin
thedrawing.
Positionthesidepinion(4) andthespacer washer (5) inthe
sidepinionsupport.
Introducethesupport pin(3) fromthecover side, pushingit
fullyinto position.
Repeat thesameoperationfortheremainingtwosidepinion
units.
Smear athin layer of LOCTITE 573onthecontact surfaces
of thesidepinionsupport (2) andthewheel hub(1).
Fit thebrakedrum(1) onthesidepinionsupport. Securethe
brake drumwith the two cheese-headed screws (2) and
tightento atorqueof 50 5Nmwith atorquewrench(3).
SmearathinlayerofLOCTITE510onthecover (3) andside
pinionsupport (4) contact surfaces.
Position the cover so that the bevels of the support pins
coincidewiththeholes onthecover.
Smear LOCTITE 573 sealing compound on the screw (1)
threadandtightentoatorqueof 50+/- 5Nmwithatorque
wrench (2).
Pushthesidepinionsupport (2) ontothehubbymovingthe
drive couplingflangein bothdirections to facilitate toothing
engagement.Makesurethatthefixingholesonthesidepinion
support andthehub coincide.
Position thethreecheese-headed screws (4) and tightento
atorqueof 50 5Nmwith atorquewrench (3 ).
26924
71534
71541
40074
Figure47
Figure48
Figure49
Figure50
Theendfloat onthedriveshaft (1) must bebetween0.5and
1mm.
Tocarryout thisadjustment fullytightentheadjustingscrew
(2), thenunscrewbyhalf aturnandsecurewiththehexnut
(3).
Position acontainer under the wheel hub (1); unscrewthe
screws(2), removethecover (3) and drainoff theoil.
Remove the shoulder pin and fit tool 99374451 (2) inthe
shoulder pin seat, then partiallyextract the drive shaft (1).
Repeat thisoperationon theoppositeside.
Unscrewthescrewsfixingtheflowdivider-differential unit (2)
totheaxlehousing(3).Insertthereactionscrews(1) and,with
eyebolts, steel slingsandahoist,extracttheunitfromtheaxle
housing.
The flat face of the hex nut must be positioned
towards theseal ring(4).
526210 REMOVING - REFITTING THE
(with the axle mounted on stand
99322215)
Removal
Positiontheaxleassemblyonstand 99322215.
Refitting
For refitting, carryout the operationsdescribedfor removal
inreverseorder, whilst observingthefollowinginstructions.
Thedriveshaftonthedifferential locksidemust not
beremoved,butonlyextractedbyapprox.120mm.
Thisistoprevent differential lockengagement inner
sleeve without any more half shaft guide from
inhibitingthat rear axleboxtransferboxdifferential
istaken out.
NOTE
NOTE
Print 603.93.641 3aso |ovobo 2006
40076
40099
40052
40116
Figure51
Figure52
Figure53
Figure54
- clean carefully and smear LOCTITE 573 sealing
compoundonthecontactsurface(=>).Positiontheflow
divider-differential unit,makingsurethattheforkengages
on thesleeve (1, Figure51) and that thecenteringpins
enter theholes(1, Figure52).
- Smear thethreadandcontact surfaceofthescrewswith
LOCTITE573andtightentoatorqueof 260+/- 25Nm
usingatorquewrench.
Usingapunch(1) removethesafetynotchonthenut (2).
526010 REPAIRING THE
Interaxle differential unit disassembly
Positiontheinteraxledifferential unitonstand99322205,with
theappropriatebrackets.
40075
Figure55
- the load bearing sleeve (1), for differential lock
engagement, must bepositionedonthedriveshaft,with
doubletoothing,withtheinternal sideofthegrooveflush
withtheaxlehousing.
- refit the driveshafts and shoulder pins; applyLOCTITE
573onthecoversandtightentothecorrecttorquevalue.
Adjust the end float on thedriveshafts as described in
Figure47.
40117
119173
Figure56
Figure57
Applyreactionlever 99370317 (2), heat thenut and loosen
the drive couplingflange (3) fixing nut usingAllen wrench
99355081(1).
Unscrewthescrews(2) andremovethecover (1),complete
withseal ring.
40119
40121
119174
Figure58
Figure59
Figure60
Unscrewthescrews(1) and, usinganextractor (2) raisethe
cover (3) until theshaft bearingcanbeextracted.
Lift box (3) soasto obtain sufficient spaceto insert thetwo
nuts(4) in whicheyebolts(2) are fastened.
Using eyebolts (2) and slings with hooks (1), remove the
half-housing(3) bymovingtheflowdivider lockengagement
fork, takingcarenot to damageparts.
Unscrewthescrews(1) andremovetheupperpart oftheoil
feed(2).
Revi - June2007
PRINT603.93.641/A
40122
119175
40115
Figure61
Figure62
Figure63
Unscrewthegear unit (2) nut.
Fit tool 99363310 (1), blockinggear unit (2) rotation.
UsingAllen wrench 99355038 (4) and multiplier 99389816
(3) unscrew thefixingnut.
Usingappropriateextractor (2) removedrivengear (1) from
taper pinion.
Unscrewthethreescrews(1) and removetheoil feed (2).
40116
40119A
40117A
Figure64
Figure65
Figure66
Refit theflange(1) andsecurewith thenut; usinghooksand
slings, raisetheflow divider differential unit (2).
Unscrewthefourteenscrews(1) fixingthehalf-housingtothe
differential housing.
Usingeyebolts,hooksandslings, removethehalf-housing(2),
completewithbevel pin, fromthedifferential housing(1).
Revi - June2007
40111A
40113
40102
40108
40104
Figure67
Figure68
Figure69
Figure70
Figure71
Rotatethestandthrough180.
Unscrewthetwoscrewsandremovethecover(4),thepiston
(2), thefork (1) and the spring(3). Unscrew the screw and
removethesafetyplate (5).
Removetheseegerringandextract thedifferential lockfixed
sleeve(1).
Mark the assembly position of the caps in relation to the
Slightlyloosentheadjustingringnut,heat thepointsindicated
bythearrowswithdrier 99305121 andunscrewthescrews
(1) secured withLOCTITE.
Removethecaps(2).
Usinga hook, remove the differential housing(1), together
withthebearings(2) andadjustingringnut (3).
Usingauniversal punch, extract thetaper roller bearing(1)
fromthedifferential carrier.
Differential housing disassembly
40086
Figure72
Usingextractor 99348001(1-2) andreactionblock99345053
(3), extract the taper roller bearing fromthe differential
housing. Repeat thesameoperation ontheoppositeside.
2
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PRINT603.93.641
40078
Figure73
Usingsuitabletools,extract theinternal ring(1) fromtherear
bearingofthebevel pinion(2).Thisisadestructiveoperation.
40376
40079
Figure74
Positionthehalf-housing(1) ontwoparallel blocksand, using
apunch, extract the bevel pinion (2) and removethetaper
roller bearing(3).
Usingapunch (1), extract theexternal rings (2-3) fromthe
half-housingtaper roller bearings.
470077
Figure75
Using extractor 99348001 (1), extract the intermediate
bearing(2) fromthebevel pinion.
Figure76
Figure77
71544
Removetheguarddisk (1).
Removetheplug(3), completewithwasher (4), andextract
thespring(5) and piston(6).
Removetheeccentric (2).
40087
Figure78
Loosenand extract the screws (1) fixingthe ringbevel gear
(3) and cover (2) to thehalf-housing(4).
Revi - June2007
PRINT603.93.641/A
40088
40089
400910
Figure79
Figure80
Figure81
Counter-markthecover andgear housing.
Removethegearhousingcover (1) andreleasetheringbevel
gear (2) usingapunch (3).
Remove the crown wheel (2), together with the shoulder
washer (3), fromthegear housing(1).
Usingapunch(1), first extract thelongpin(2) andthenthe
two short pins(3).
40091
119176
Figure82
Figure83
Remove the spider (2) and the side pinions (3) with the
relativeshoulderwashersandcrownwheel (4) fromthegear
housing(1).
Fit theinteraxledifferential inavice; unscrewthescrews(1).
Mark half boxesasshown .
spider body(2, Figure82) byalongstripefor the
longpin,andbytwoshort stripesfortheshort pins.
Interaxle differential disassembly
NOTE
Revi - June2007
40136
40138
40139
40140
Figure84
Figure85
Figure86
Removethehalf-housing(1) andbearing(2).
Withappropriatepunch,removerivetsfromringnut(2).Use
spanner 99355121 (1) tounlockringnut (2), removespider
(3) completewithplanetarygears,thrust washersandseal (6,
Fig. 86).
1. Input shaft - 2. Drivinggear - 3. Spider - 4. Ringnut -
5. Differential half-housing- 6. Seal ring
Extract thedrivinggear (1) fromtheinput shaft andremove
theshoulder washer.
Figure87
40137
Figure88
Using a hydraulic press, extract the bearing (1) fromthe
half-housing(2) usingthecrownwheel gear unit.
CHECKINGTHEDIFFERENTIAL COMPONENTS
Carefully clean all of the individual differential-flow divider
components, replacingwornpartsand all sealingelements.
coupledspareparts.
Checkthebushingsmountedinthedrivengearand
crownwheel unit. Replaceif wornusingapress.
NOTE
NOTE
NOTE
Revi - June2007
Figure89
Revi - June2007
PRINT603.93.641/A
Figure90
Revi - June2007
40141
40411
40140
40138
Figure91
Figure92
Figure93
Figure94
Positiontheinput shaft inaviceand fit theshoulder ring(1).
If disassembled, assemble the bushingin the drivengear (2)
usingasuitable keyingdevice (1).
Fit thedriven gear (1) ontheinput shaft (2).
Assemblethehalf-housing(4) andtheseal ring.
Fit thespider (5) andsidepinions,usingwrench99355121(2)
and torque wrench (1), tighten the ringnut (3) to atorque
valueof 230 20Nm.
40142
40143
Figure95
Figure96
Aftertighteningtheringnut(1) check(withafeelergauge(3))
that thereisaclearanceof 0.40to 0.55mmbetweenthering
nut (1) andthespider (2). Ifnot, replacethenecessaryparts.
Usinga punch (1) secure the ring nut (2) as shown in the
drawing.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Interaxle differential unit assembly
40412
40413
40414
119179
Figure97
Figure98
Figure99
Figure100
Usingkey99370122(1)andpress,fitthebushinginthecrown
wheel gear unit (2).
Fit theshoulderringinthecrownwheel gear unit (3),thenfit
theseal ring(2) usingakeyingdevice (1).
Fit thecrownwheel gear unit (5) and parts(2 and3) inthe
half-housing(1).
Heattheballbearings(4) to100-110Candfitonthecrown
wheel gear unit (5). Check that the half-housing(3) andthe
bearing(4) areat adistanceof X =1.05 to 1.60 mm.
Fill the inner chamber of the half-housing(3) with 100gof
lubricatingoil.
Fit thehalf-housingassembly(1), bearing(2) andthecrown
wheel gear unit onthelower half-housing(3).
40144
40091
Figure101
Figure102
Insert thefixingscrews(2) andtightento atorqueof 67 8
Nmwithatorquewrench(1).
Placethedifferential housing(1) onasupport.Positionthecrown
wheel (4) andshoulderwasher intheseat. Fit the4sidepinions
(3),completewithshoulderwasher,andinsert inthespider (2).
Differential housing assembly
X
After assembling the bushing, make sure that it is
keyedcorrectlyontheinput shaft.
NOTE
Check alignment of marks drawn duringremoval
.
NOTE
Revi - June2007
PRINT603.93.641/A
40092
40093
40094
40095
Figure103
Figure104
Figure105
Figure106
Insert thelongpin(1) andthe two short pins.
Assemblethecrown wheel (1).
Fit theshoulder washer (1).
Fit thegear housingcover (1).
First insert the long (through) pin. The exact
positionof thepins is markedonthe spider body
byalongstripefor thelongpin, andbytwoshort
stripesfor theshort pins
40096
40097
Figure107
Figure108
thegear housing(2) andsecurewithtwo screws.
Introducetheremainingscrews(1);lockgearunitrotationusing
apressandtightenthescrews(1) toatorqueof 300 10Nm
withatorquewrench(2).
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
40098
120448
39572
40083
Figure109
Figure110
Figure111
Figure112
|s|o ao o|oct|c |oato, |oat t|o soot boa|o (+) o +5'
at atemperature of 100C and fit on the gear housing (2).
Repeat thesameoperationontheoppositeside.
Fullyfit theexternal rings(3) oftheintermediateandexternal
bearings in their seats, using punch 99374094 (1) and grip
99370007(2).
Usingafeelergauge(2) measureandnotethethicknessofthe
adjustingring(1) ondisassembly(valueA).
Securetool 99395027inaviceand fit thefollowingparts:
- thepreviouslymeasuredadjustingring(4),thespacerand
thebearing(3).
Positionpart (1) oftool 99395027(6) onthebearing(3),fitted
withazero-set dial gaugeontheendofthetool.Thenremove:
- thepart (1),theringnut (2),thebearing(3),theadjusting
ring(4) and thespacer;
Procedure to follow to determine th e
thickness of the bevel pinion rolli ng torque
adjusting ring
40085
Figure113
- positiontool 989395207andbearing(5,Figure112) inthe
half-housing(2) and positionthebearing(3, Figure113);
- tightentheringnut(4) byhandandcheck(usingatorque
wrench(1)) therollingtorque,whichshouldbe1.5- 3.5
Nm; if necessary, adjust bymeans of theringnut.
Revi - June2007
40084
40078
39701
Figure114
Figure115
Figure116
Fit the adjustingring(2), in order to position the pinion in
relation to the bevel gear, on the bevel pinion (1). The
thicknessoftheadjustingringisdeterminedbythereference
value(3) markedonthebevel pinion.
SeethetableinFigure 117.
Standard version
First example
A =10.12mm
B =+0.13mm
C =0.05 mm
S=10.12 - (+0.13) +0.05=
S=10.12 - 0.13+0.05=10.04mm.
Second example
A =10.12mm
B =- 0.13 mm
C =0.05 mm
S=10.12 - (-0.13) +0.05=
S=10.12+0.13 +0.05 =10.30mm
Reinforcedversion
First example
A =1.85 mm
B =+0.13mm
C =0.05 mm
S=1.85- (+0.13) +0.05 =
S=1.85- 0.13 +0.05 =1.77 mm.
Second example
A =1.85 mm
B =- 0.13 mm
C =0.05 mm
S=1.85- (- 0.13) +0.05=
S=1.85+0.13+0.05=2.03mm.
Heat the internal ring(1) of the rear bearingand fit onthe
bevel pinion(2).
Figure117
Summarytabletodeterminethethicknessofthebevel pinion
positionadjustingring.
11+0,20
Position the part (4), with the dial gauge zero-set, on the
bearing (2) and read the eventual deviation (value B).
Disassemblethepartsontool 99395027.
ThicknessSontheadjustingringisprovidedbythefollowing
formula:
S=A - ( B) +C
Where:
A=thicknessoftheadjustingringassembledfordial gauge
zero-setting;
B=deviationvalueread;
Revi - June2007
PRINT603.93.641/A
Valuemarked
onthebevel pinion
Total thickness
of adjustingring
- 0.5 4.6
- 0.4 4.5
- 0.3 4.4
- 0.2 4.3
- 0.1 4.2
0 4.1
+0.1 4.0
+0.2 39.9
+0.3 3.8
+0.4 3.7
+0.5 3.6
40082
40106
Figure118
Figure119
Heat the intermediate bearing(1) with an electric drier to
100 C, and position inthebevel pinion (2).
Fit adjustment ring (4) and spacer (3) with previously
measured thickness.
Positionthedifferential housing(1) on thestand.
Usingapunch, fit theroller bearing(2).
40415
40119A
Figure120
Figure121
Fit thebevel pinion (1) ontheroller bearing(2, Figure119).
Smear LOCTITE573 (2) onthecontact surface.
Raiseandfitthehalf-housing(2)onthedifferential housing(1).
Figure122
71544
Fit theeccentric (2).
Insert the piston (6) and the spring (5) in the differential
housing.
Tightentheplug(3) withanewwasher (4) andtightentothe
correct torque.
Fit theguarddisk(1).
1
Figure123
40120A
Using the torque wrench (1), tighten the screws (2) to a
torqueof 260 25Nm. Fit thespacer ringandtheadjusting
ring(3) on the bevel pinion. Heat bearing(4) usinghot air
blower at 100 C andsecureit ontaper pinion.
Revi - June2007
PRINT603.93.641/A
40121A
40123
40122A
40416
40108
Figure124
Figure125
Figure126
Figure127
Assemble the oil feed (2) and tighten the screws (1) to a
torqueof 16 2Nm.
Heat gear (1) at atemperature of 150 C and secureit on
taper pinion (2).
Positiontool99363310(1)and,usingAllenwrench99355038
(4), multiplier 99389816 (3) andtorque wrench (2) tighten
thedriven gear nut to atorqueof: 1200to 1300 Nm
Usingapunch(1), securethedrivengear nut (2).
Usingthehook,raisethedifferential housing(1),bearings(2)
and adjustingringnut (3). Positiononthe differential carrier.
Carefullypositiontheadjustingringnutsonthethreadsofthe
Figure128
If the nut (2) usedisof theNumeyer type, it does
not needto besecured.
NOTE
Fit thecaps(2) andprovisionallytightenthescrews(1).Check
that the adjusting ring nuts screw on easily. Remove the
screws, oneat atime, applyLOCTITEAVX andtightenwith
atorquewrench(3) to avalueof 270 25Nm.
Figure129
40109
Revi - June2007
Toadjusttheendfloatbetweenthebevel gearpairpinion-ring
bevel gear teeth, proceed asfollows:
- Readtheclearancevaluebetweentheteeth,whichvaries
accordingtothebevel gearpairratio,inthetableinFigure
135;
39585
Figure130
No. of
teeth
Ratio Total rollingtorque
(Nm)
17/35
21/40
19/33
21/34
23/36
24/35
27/37
28/37
29/37
27/32
2.059
1.905
1.737
1.619
1.565
1.458
1.370
1.321
1.276
1.185
3 5,9
3.1 6.1
3.3 6.4
3.4 6.6
3.4 6.7
3.6 6.9
3.7 7.1
3.8 7.3
3.0 5.0
4 7.7
Figure131
No. of
teeth
Ratio Clearancebetween
teeth
17/35
21/40
19/33
21/34
23/36
24/35
27/37
28/37
29/37
27/32
2.059
1.905
1.737
1.619
1.565
1.458
1.370
1.321
1.276
1.185
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
0.2 0.33
40417
Figure132
Usingtorquewrench99389819(1) andtheappropriateAllen
wrench(2), readthepre-stabilisedtorquevalue, adjustingthe
bearingadjustment ringnuts(3) withwrench99354001(2).
Thetotal rollingtorquereadingiscarriedout when
theclearancebetweentheteethonthebevel gear
pairisasnear tothepre-stabilisedvalueaspossible.
However, the total rolling torque value varies
accordingtothereductionbevel gearpairratio(see
tablein Figure132).
Figure133
Adjustingthe rollingtorqueon thedifferential
housing bearings
NOTE
PRINT603.93.641
40114A
40159
40160
Figure134
Figure135
Figure136
Figure137
Figure138
- Positionamagneticstanddialgauge(1)asshowninFigure
136.
- Prevent thebevel pinion fromrotatingwhilst alternately
rotatingthebevel gear and, usingagauge (1), read the
clearancebetweentheteethonthetwogearunits.Ifnot,
usingwrench99354001(2),adjust theadjustingringnut
(3).
In order to prevent the previously measured rollingtorque
fromvarying, duringadjustments of the coupling clearance
between the pinion and the bevel gear teething, tightenthe
ringnut withwrench99354001 bythe sameamount asthe
ringnut ontheoppositeis loosened.
On completion of operations, check that the two adjusting
ringnutsaresuitablypositionedtoallowthesafetyplatetobe
fitted.
Usingabrush, applyalight coveringof Prussianblue onthe
Rotate thebevel gear inbothdirections.
40161A
Ifthemarkontheleadingfaceispositionedtowardstheinter-
nal diameter,andonthepushingfaceit islocated towardsthe
external diameter of thebevel gear, thepinionislocatedtoo
far awayfromthebevel gear axis.
- Solution: decrease the thickness of the adjusting ring (2,
Figure116).
40161B
- Solution: increase the thickness of the adjusting ring (2,
Figure116).
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Figure139
Figure140
Figure141
Figure142
Figure143
40110
Assemblethesafetyplate(1);tightenthescrewwithatorque
wrench (2) to atorqueof 51 5Nm.
40111
Fit thedifferential lockingsleeve(1).
40078
Secureinpositionwiththesafetyring(1).
40115A
Fittheoil baffle(1)withthestraightsideinthevertical position,
asindicatedinFigure 146.
Secureinthethreepointsindicatedbythearrowstoprevent
counter-rotation.
40124
Fit thedifferential-flowdividerunit (1) inthehalf-housing(2).
Revi - June2007
PRINT603.93.641/A
40125
40126
Figure144
Figure145
Figure146
Figure147
Figure148
Figure149
Assemble the upper part (1) of the oil feed and tightenthe
screws(2) withawrench(3).
In the lower part of the cover (1), fit the flow divider
differential engagement sleeve (2) and the control unit
comprising: thespring(3), fork (4) and the piston(5) witha
newseal ring(6).
3 4
1
5 6
2
40127
Smear LOCTITEAVX onthecontact surface.
Fit the cover (1) and tighten the screws (3) to atorque of
182.5 Nmusingthetorquewrench(2).
40128
Usingapunch, fit theball bearing(1) ontheinput shaft.
40129
Usingkey99374233, fit theseal ring(1) inthecover; replace
theseal ring(2).
Fit thecover and tightenthescrews (2) to atorqueof 62
6Nmwith atorquewrench (1).
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PRINT603.93.641
Figure150
Figure151
Figure152
Figure153
Figure154
Figure155
40132
Fit theflange(1) ontheinput shaft.
40133
Rotatetheunit and, using: atorquewrench(1),reactionlever
(2) and Allen wrench 99355081 (3), tighten the nut to a
torqueof 800to 850 Nm.
40134
Usingapunch (1), secure the nut (2) asshown in the detail
(3).
40145
Removetheflange(3) nut safetynotch.Positionthereaction
lever (1) and unscrew the nut (2) using Allen wrench
99355081. Extract the flange(3).
40147
Unscrewthescrews(1),removethecover (2)andextractthe
driveshaft (3) and bearing.
40149
Usingapress, extract theball bearing(1) fromthedriveshaft
(2).
526064 DRIVE SHAFT
Disassembly
Figure156
Figure157
40148
40129
Usingkey99374013, fit theinternal seal ring(1) inthecover
and replacethe external seal ring(2).
Assembly
Refit thedriveshaft byreversingtheorder ofthedisassembly
operations, and tighten the screws (1, Figure 157) to the
correct torque.
Tightenthenut (1) toatorqueof 650 to 750Nm.
After havingtightenedthenut (1), securethecollar.
Checking parts
Clean and check all drive shaft parts, replacinganyworn or
damaged components. Alwaysreplacetheseal rings.
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101 TRAKKEREURO 4/5 INTERMEDIATEAXLE452146/2D(R9174)
Intermediate axle
452146/2D (R 9174)
Page
DESCRIPTION 103 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 104 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 105 . . . . . . . . . . . . . . . . .
TOOLS 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMEDIATEAXLEASSEMBLY REPAIRS 113 . . .
- Disassembly 113 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRING THE INTERAXLEDIFFERENTIAL 113 . . .
- Flowdivider differential unit disassembly 113 . . . . .
- Removingthebevel pinionfromthe support 116 .
- Gear housingdisassembly 116 . . . . . . . . . . . . . . . .
- Interaxledifferential disassembly 117 . . . . . . . . . . .
CHECKING THE INTERAXLE DIFFERENTIAL
PARTS 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Interaxledifferential assembly 121 . . . . . . . . . . . . .
- Differential housingassembly 123 . . . . . . . . . . . . .
- Assemblingthebevel pinionsupport 124 . . . . . . .
- Procedureto follow to determinethethickness
of thebevel pinionrollingtorqueadjustingring 124
- Differential housingassembly 126 . . . . . . . . . . . . .
- Differential housingbearings rollingtorque
adjustment 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure1
The intermediate axle is of the load-bearing, double
reduction type.
epicycloid unit on thewheel hubs.
The differential housing(withringbevel gear) is supported
bytaper roller bearings, which can be adjustedbymeans of
two threadedringnuts.
whichcanbeadjusted bymeans of adjustment rings.
The intermediate axle is fitted with an interaxle unit that
distributes thetorquebetween the two axles.
The axle shafts start fromthedifferential andtransmit drive
to theepicycloidreduction unitslocated inthewheel hubs.
The axle is also provided with a pneumatic device for
differential locking and another device for flow divider
locking.
The drumbrakeis of theDuo/Duplextype.
LONGITUDINAL PICTORIAL SECTION OF DIFFERENTIAL REDUCTION GEARUNIT
71545
DESCRIPTION
MAIN DATA
Typeof axle:
Load-bearing, double reduction
differential lockingand flowdivider
unit
452146/2D (R 9174)
Bevel pinionbearings 2 taper rollers
Bevel gear reduction unit ratio
34/37(1.088) - 27/32 (1.185) - 28/37(1.321) - 29/37 (1.276) -
27/37(1.370) - 24/35 (1.458) - 23/36(1.565) - 21/34 (1.619) -
19/33(1.737) - 21/40 (1.905) - 17/35(2.059) - 15/34 (2.267) -
17/36(2.118)
Epicyclic reduction unit/wheels
ratio
3.2
Bevel pinionbearingrolling
torque without seal Nm
6 8
adjustment
with adjustment rings
rollingtorqueadjustment ring
mm
10- 10.02- 10.04- 10.06 - 10.08 - 10.10 - 10.12- 10.14-
10.16 - 10.18 - 10.20- 10.22- 10.24- 10.26- 10.28- 10.30-
10.32 - 10.34 - 10.36- 10.38- 10.40- 10.42- 10.44- 10.46-
10.48 - 10.50 - 10.52- 10.54- 10.56- 10.58- 10.60
Thickness of bevel pinion/ring
bevel gear position adjustment
rings mm 0.2- 0.3 - 0.5- 1
Clearancebetween pinion
and ringbevel gear mm 0.15 0.35
with ringnuts
WHEEL HUBS
Wheel hub bearings 2 taper rollers
Wheel hubbearings rollingtorque:
protection Nm 6 7 Nm+(12 16Nm)
Wheel hubbearings rollingtorque:
runinbearingsandnew,lubricated
seals Nm 6 7 Nm+(5 7 Nm)
pinionandringbevel gear Nm 3 Nm+(2.5 4.5Nm)
Axleoil
Quantity Litres
kg
TUTELA W140/MDA
13
G.R.W. maximumload kg 11000
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Screwfor input shaft cover H 33 3 3.3 0.3
2 Ringnut for flowdivider spider 220 20 22 2
3 Oil pumpcap 21.5 1.5 2.2 0.2
4 Nut for driveshaft flange 700 50 70 5
5 Screwfor driveshaft cover H 33 3 3.3 0.3
6 Screwfor differential lock cover 19 2 1.9 0.2
7 Self-lockingscrew fixingringbevel gear 170 10 17 1
8 Screwfixingflowdivider half-housingH 110 10 11 1
9 Screwfixingbevel pinionsupport 170 10 17 1
10 Screwfixingoil manifold 9 1 0.9 0.1
11 Oil plug 80 8 8 0.8
12 Screwfor safetyplate 51 4 5.1 0.4
13 Screwfixinggear housingcaps H 180 10 18 1
14 Nut lockinggear onbevel pinionshaft 700 50 70 5
15 Screwfixingbearingretainingplate 120 10 12 10
16 Nut for input shaft flange 700 50 70 5
17 Screwfixinghousing 170 10 17 1
18 Screwfor flow divider lockingcontrol cover H 19 2 1.9 0.2
H applyLOCTITE AVX
applyLOCTITE 573
115269
Figure2
98970
Figure3
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Countersunk screwfixingdrum 25 3 2.5 0.3
2A
Nut fixingwheel
615 35
61.5 3.5
2B Nut fixingwheel 415 35
41.5 3.5
3 Screwfixingcover to crown wheel support h 50 5 5 0.5
4 Screw 50 5 5 0.5
5 Screwfixingload bearingsleeve 295 30 29.5 3
d applyLOCTITE 5970onthecontact surface
h applyLOCTITE 573 onthread
H applyLOCTITE 573 onmatingsurface
: beforemounting, slightlysmear MOLYCOTE on nut rest surface
TOOLS
99322205 Rotatingstand for assemblyoverhaul
99322215 Stand for axlesoverhaul
99322225 Support for assemblies (to be fitted on stand 99322205)
99341015 Press
99348001 Extractor with lockingdevice
99354207 Wrench (94.5mm) for wheel hubbearingsadjustingnut
99355086 Wrench for flowdivider mainshaft ringnut
99355131 Wrench (55mm) for drive infeed flange nut
99363310 Tool for retainingspur gear onflow divider bevel pinion
99370005 Gripfor interchangeable punches
99370121 Punchfor fittingcrown wheel bushings (usewith 99370006)
99370317 Reactionlever withextension for flangeretaining
99370509 Hook to extract differential gear half-housing
99370617 Universal mountingto support axlesduringremoval andrefitting
99370630 Mountingfor removal and refittingof flowdivider
99371022 Pair of differential support brackets for useduring overhaul (use
with 99322205-99322225)
99374013 Keyto fit differential bevel pinion seal (usewith 99370006)
99374093 Punchto fit external racesof bearings (usewith 99370007)
99374094 Punch to fit external races of bearings (134 - 215) (use with
99370007)
99374161 Keyfor assemblyof wheel hubinternal seals
99374233 Keyto fit flow divider driveshaft seal
99374451 Tool for axle shaft disassembly-assembly
99389816 + toooo o|t|||o .|t| 3/+ ' |oooo aoo +' sooao cooooct|oo
(max. 2745 Nm)
99389819 Toooo .ooc| o 0 to +0 | .|t| +/+' sooao cooooct|oo
99395026 Tool to checkrollingtorqueof hubs (usewith torquewrench)
shims (usewith 99395603)
99395603 Dial gauge(0 - 5mm)
Figure4
Positiontheinteraxledifferential unit (2)onstand99322205,
with brackets99371022 (1).
Apply reaction lever 99370317 (2), using Allen wrench
99355131 (1), unscrew the nut and extract the drive
couplingflange(3).
Beforepositioningtheaxleassemblyon the overhaul stand,
drain off the oil by unscrewingthe lower plugon the axle
housing.
breather - interaxle differential - wheel hubs and
epicyclic reduction units removal-refitting
operations,canall becarriedoutwiththeunitfitted
on thevehicle.
Usingapunch (1) removethesafetynotchonthenut (2).
Figure5
Figure6
Unscrew the screws and remove the interaxle control
assembly (1).
Unscrew thescrews and removethecover (2).
Figure7
Remove thescrews on thecover (2) and, usingan eyebolt
(1), removethecover (2).
Figure8
For repairs on the wheel hubs, epicyclicreduction
units, drive shaft and flow divider differential
removal-refittingoperations,followtheinstructions
forthe451391/2D- 452191/2Dintermediateaxles.
526110 REPAIRING THE INTERAXLE-
DIFFERENTIAL
Flow divider differential unit disassembly
42533
42534
42535
43536
42537
NOTE
NOTE
526110 INTERMEDIATE AXLE ASSEMBLY
REPAIRS
Disassembly
Removal
Figure9
Figure10
Figure11
Figure12
Figure13
Figure14
Extract theslidingsleeve (1) andremovetheoil feed (2).
Usingapunch (1) removethesafetynotchonthenut (2).
Fit tool 99363310(4), blockinggear unit (3) rotation.
UsingAllen wrench99355131 (2) andmultiplier 99389816
(1) unscrew thebevel pinion fixingnut.
Extract thedriven gear (1) andthe spacer.
Usingslings,raiseandremovetheflowdividerdifferential unit
(1).
Unscrewthescrewsfixingthebevel pinionsupport(1) tothe
housing(2) and, usingslings, disassembletogether with the
bevel pinion.
42538
42539
42540
42541
42542
42543
Figure15
Figure16
Figure17
Figure18
Figure19
Figure20
Remove adjustment shim(1).
Remove theguard disk (1). Removetheplug(3), complete
with washer (4), andextract thespring(5) andpiston (6).
Remove theeccentric (2).
Rotatethestandthrough 180.
Unscrew the two screws and remove the cover (1), the
piston(2),thefork(3) andthespring(4).Unscrewthescrew
and removethesafetyplate (5).
Usingsuitablepliers, actingon theretainingcirclip(2) inthe
directionindicatedbythearrows,thenextractthedifferential
lockfixedsleeve(1).
Slightly loosen the adjusting ring nut (3). Heat the points
indicated by thearrows with drier 99305121 and unscrew
the screws (1) secured with LOCTITE. Counter-mark and
theremove the caps(2).
Using hook 99370509 (1), removethe differential housing
(2), together with thebearings (3) andringnut (4).
42544
71544
45546
42547
42548
42549
Usingextractor 99348001(1), extract thebearing(2) from
thebevel pinion.
42550
42552
42551
40077
40086
40087
Figure21
Figure22
Figure23
Figure24
Figure25
Figure26
Disassembly of the bevel pinion (2) fromthe support (1)
must be carried out under apress.
Usingapunch,extract theexternal rings(1-2) ofthebearings.
Usingapunch (1), extract the roller bearing(2).
Using extractor 99348001 (1-2) and reaction block
99345055(3),extract thetaper rollerbearing fromthegear
housing. Repeat the same operation on theoppositeside.
Loosen andextract thescrews(1) fixingtheringbevel gear
(3) andcover (2) to thehalf-housing(4).
Removing the bevel pinion from the support
1
2
Gear housing disassembly
Remove the spider (2) and the side pinions (3) with the
relativeshoulderwashersandcrownwheel (4) fromthegear
housing(1).
Fit thedifferential-flowdivider (1) inavice.Using8mmAllen
wrench(2) unscrewthescrews (1).
40088
40090
40089
40091
42553
42554
Figure27
Figure28
Figure29
Figure30
Figure31
Figure32
Counter-mark thecover and gear housing.
Removethegearhousingcover (1) andreleasetheringbevel
gear (2) usingapunch(3).
Remove the crown wheel (2), together with theshoulder
washer (3), fromthegear housing(1).
Usingapunch(1), first extract thelongpin(2) andthenthe
two short pins (3).
Remove thehalf-housing(1) andcrown wheel (2).
spider body(2, Figure 30) byalongstripefor the
longpin,andbytwoshort stripesfortheshortpins.
Interaxle differential disassembly
NOTE
42555
42556
42472
42557
42558
42559
Figure33
Figure34
Figure35
Figure36
Figure37
Figure38
Usingapunch, remove the notchontheringnut (2). With
wrench99355086(1) unscrew theringnut (2), removethe
spider (3) andthesidepinionandshoulderwashers.Remove
thehalf-housing(4).
1. Input shaft - 2. Drivinggear - 3. Spider - 4. Ringnut -
5. Differential half-housing- 6. Seal ring
Extract thedrivinggear (1).
Extract theshoulder washer (1) andthebushing(2). This is
adestructiveoperation.
Acting on the crown wheel gear unit (1) in the direction
indicated bythe arrows, extract theroller bearinginternal
ring(2) andthecrownwheel gear unitfromthehalf-housing
(3).
Usingapunch,extract thebushing(2) fromthecrownwheel
gear unit (1).
Figure39
Figure40
Replaceall seal ringsandbushings if damaged.
If either the bevel gear or pinion need to be
changed, both parts must be replacedas theyare
providedas coupled spareparts.
adjustments and precise tighteningtorque values.
Carefully clean all of the individual differential-flow divider
components, replacingworn partsandall sealingelements
42561
42560
42562
42563
42564
Figure41
Figure42
Figure43
Figure44
Figure45
Positiontheinput shaft (3) inavice,heat thebushing(2) to
105C and fit ontheshaft. Fit the shoulder ring(1).
Fit thegear (1) ontheinput shaft (2).Checkthatthegear (1)
rotates freelyonthe bushing(2, Figure41).
Assemblethehalf-housing(2) andseal ringonthedrivengear
(3).
Fit thespider (1) andside pinions and fifth wheel.
Using the torque wrench (1) and wrench 99355086 (2),
tightentheringnut (3) to thecorrect torquevalue.
After tighteningtheringnut (1) check (with afeeler gauge
(3)) that thereisaclearanceof 0.05to 0.1mmbetweenthe
ringnut (1) andthespider (2). If not, replace thenecessary
parts.
CHECKING THE INTERAXLE
DIFFERENTIAL PARTS
x
NOTE
NOTE
NOTE
42565
42567
42566
42568
42569
42570
Figure46
Figure47
Figure48
Figure49
Figure50
Using apunch (1) secure the ring nut (2) as shown in the
drawing.
Usingpunch99370121(1) andgrip99370006,fit thebushing
(2) in the crownwheel gear unit (3).
Fit theseal ring(1) in thehalf-housing(2).
1. Half-housing- 2. Shoulder ring- 3. Seal ring-
4. Washer - 5. Roller bearingring- 6. Crownwheel gear
Positionthecrownwheel gear unit (1) on asupport. Fit the
shoulder ring(2, Figure 48) thehalf-housing(4), thewasher
(3). Heat the internal ring(2) for theroller bearings andfit
on thecrown wheel gear unit.
Fill the inner chamber of the half-housing(3) with 100gof
lubricating oil. Fit the previously assembled half-housing
assembly (2) on the half-housing (3) and, using a torque
wrench(5) andanAllenwrench(4), tightenthescrews (1)
to thecorrect torque, after havingsmearedthescrewswith
LOCTITEAVX.
After assemblingthe bushing, makesure that it is
keyed correctlyontheinput shaft.
NOTE
Figure51
40091
40093
40092
40094
40095
40096
Figure52
Figure53
Figure54
Figure55
Figure56
Figure57
Placethegear housing(1) onasupport.Positionthecrown
wheel (4) and shoulder washer in the seat. Fit the 4 side
pinions(3),completewithshoulderwasher,andinsert inthe
spider (2).
Insert thelongpin(1) and thetwo short pins.
Assemble the crownwheel (1).
Fit theshoulder washer (1).
Fit thegear housingcover (1).
Heat theringbevel gear (1) to approx. 80C, fit inposition
inthegear housing(2) andsecure with two screws.
!
Firstinsert thelong(through) pin.Theexact position
of thepins is marked on thespider bodybyalong
stripefor thelongpin, and bytwo short stripes for
theshort pins
Introducethe remainingscrews (1); lockgear unit rotation
usingapressandtightenthescrews(1) tothecorrecttorque
with atorquewrench (2).
adjusting ring
40097
42571
40098
42572
39572
42573
Figure58
Figure59
Figure60
Figure61
Figure62
Figure63
|s|o ao o|oct|c |oato, |oat t|o soot boa|o (+) o +5'
at atemperature of 100C and fit on the gear housing (2).
Using punch 99374093 (2) and grip 99370007 (1), fit the
bearingexternal ring (3) in the support. Repeat the same
operationontheexternal ring(4) ontheoppositeside,using
punch99374094 (5).
Usingapunch (1) fit theroller bearing(2).
Usingafeeler gauge (2) measureandnotethethickness of
theadjustingring(1) ondisassembly(valueA).
Securetool 99395027 in avice and fit thefollowingparts:
- thebearing(6) on thepinion-side;
- thepreviouslymeasuredadjustingring(4),thespacer (5)
and thebearing.
Fullytightenthe ringnut (2).
Position part (1) oftool 99395027on thebearing(3),fitted
with a zero-set dial gauge on the end of the tool. Then
remove:
- thepart (1),theringnut(2),thebearing(3),theadjusting
ring(4) and thespacer (5).
2
Position the part (1), with the dial gauge zero-set, on the
bearing (2) and read the eventual deviation (value B).
Disassemble thepartsontool 99395027.
formula:
Where:
A= thickness of the adjusting ring assembled for dial
gaugezero-setting;
B =deviation value read;
negativeallowance onthe bevel pinion.
Second example:
42574
42575
42576
42577
42578
Figure64
Figure65
Figure66
Figure67
Figure68
Position tool 989395027 and bearing (6, Figure63) in the
support (3) andpositionthebearing(2, Figure64). Tighten
theringnut (1) byhand and check (usingatorque wrench
(4))therollingtorque,whichshouldbe6- 8Nm;ifnecessary,
adjust bymeans of theringnut (1).
Heat thebearing(1) to100Candfit onthebevel pinion(2).
Fit the spacer ring (2) and the adjusting ring (1) with the
thicknesspreviouslymeasured.
Position thesupport (1) onthebevel pinion(2).
First example:
A =10.12 mm
B =+0.13 mm
C = 0.05 mm
A =10.12 mm
B =- 0.13 mm
C =0.05 mm
S A ( B) C
S 10.12 ( 0.13) 0.05
S 10.12 0.13 0.05 10.04
S 10.12 ( 0.13) 0.05
S 10.12 0.13 0.05 10.30 mm
mm
42579
42549
42580
42581
71740
42583
Figure69
Figure70
Figure71
Figure72
Figure73
Figure74
Heat thebearing(1) to100Candfit onthebevel pinion(2).
Positionthehousing(2) onastandwithbrackets99371022
(1).
Usinghook99370509(1),raisethegearhousing(2),bearings
(3) and adjusting ring nut (4). Position on the differential
housing. Carefully position the adjusting ring nuts on the
threads of thedifferential housing.
Fit the caps (2) and provisionally tighten the screws (1).
Check that the adjusting ring nuts (3) screw on easily.
Removethescrews,oneat atime,applyLOCTITEAVX and
tightenwithatorquewrench(4)tothecorrect torquevalue.
Rotatetheunit andfit:theeccentricring(1),piston(2),spring
(3) and plug(5) with anew washer (4), and tighten to the
correct torque.
Fit theguarddisk(1) andapplyabead( ) ofLOCTITE573
on thecontact surface.
42584
42585
42586
42587
42588
Figure75
Figure76
Figure77
Figure78
Figure79
Figure80
relation to thebevel gear,onthehousing(2). Thethickness
of theadjustingringisdetermined bythereferencevalue(1,
Figure76) markedonthebevel pinion.
position adjustingring.
Applyanotherbead( ) ofLOCTITE573ontheadjustment
shim.
Assemble thecompletebevel pinion support (1), applythe
bearingretainer plate (2). Usetorquewrench(3) to tighten
screws (4) to the set torque.
Fit thegear (2) andtightenthefixingnut (1) to thecorrect
torque.
16+0,20
1
2
3
4
Valuemarkedon
thebevel pinion
(1, Figure 76)
Adjusting
shim
0 0.5
0.1 0.6
0.2 0.7
0.3 0.8
0.4 0.9
0.5 1
0.6 1.1
0.7 1.2
0.8 1.3
0.9 1.4
1.0 1.5
42589
42590
42591
Figure81
Figure82
Figure83
Figure84
Position tool 99370133 (1) on the caps (2) to avoid
excessivespreadonthecapsduring adjustment operations.
The rolling torque reading is carried out when there is a
clearance between the teeth on the bevel gear pair.
However, thetotal rollingtorquevalue varies accordingto
thereduction bevel gear pair ratio (seetableinFigure 83).
Using torque wrench 99389819 (1) and the appropriate
Allen wrench(2),readthepre-stabilisedtorquevalue. Ifthe
torque value is different fromthat indicated in Figure 83,
adjusting the bearing adjustment ring nuts (3) with the
wrench(4).
If adifferent valueisread, adjust the end float between the
teeth onthe bevel pinion/gear pair, as follows:
- Positionamagneticdial gauge (1) asshowninFigure 84.
- Prevent thebevel pinionfromrotatingwhilst alternately
rotatingthebevel gear and, usingagauge(1), readthe
clearancebetweentheteethonthetwogear units.This
clearanceshould be 0.15- 0.35mm.
Ifnot,usingthewrench(3), adjust theadjustingringnut (2).
In order to prevent the previouslymeasured rollingtorque
betweenthepinionandthebevel gear teething, tightenthe
ringnut withthewrench(3) bythesameamount asthering
nut ontheoppositeisloosened.
On completionof operations, check that thetwo adjusting
ringnutsaresuitablypositionedto allowthesafetyplateto
befitted.
Remove tool 99370133.
Differential housing bearings rolling torque
adjustment
No. of
teeth
Ratio Total rollingtorque (Nm)
15/34 2.267 a+(1.3 1.8)
17/35 2.059 a+(1.5 1.9)
17/36 2.118 a+(1.4 1.9)
19/33 1.737 a+(1.7 2.3)
21/40 1.905 a+(1.6 2.1)
21/34 1.619 a+(1.9 2.5)
23/36 1.565 a+(1.9 2.6)
24/35 1.458 a+(2.1 2.7)
28/37 1.321 a+(2.3 3 )
27/32 1.185 a+(2.5 3.4)
27/37 1.370 a+(2.21 2.9)
29/37 1.276 a+(2.4 3.1)
34/37 1.088 a+(2.7 3.7)
a=7.5 9.5 Nm
Figure85
Figure86
Figure87
Figure88
Figure89
Figure90
42592
Usingabrush,applyalight coveringof Prussianblueonthe
teeth of thebevel gear.
Rotatethebevel gear inbothdirections.
40160
Thecontactmarksshouldbeonboththeleadingface(1) and
thepushingface(2), moreorlessinthecentrebetweenthe
should be slightlyout of position in relation to theexternal
40161A
If themarkontheleadingface(towardstheexternal diameter)
andonthepushingface (towardstheinternal diameter) isout
of position, thepinion is located too closeto thebevel gear.
- Solution: increase the thickness of the adjusting ring (1,
Figure75).
nal diameter,andonthepushingfaceitislocatedtowardsthe
external diameterofthebevel gear,thepinionislocatedtoo
- Solution: decrease the thickness of the adjusting ring(1,
Figure75).
40161B
42593
Assemble the safety plate (1); tighten the screws to the
correct torque.
Fit thecirclipand keythesleeve (2) for thedifferential lock.
42542
Disassemble the gear unit (2, Figure 80) and assemble the
differential - flowdivider unit (1).
Figure91
Figure92
Figure93
Figure94
Figure95
Figure96
42594
Removethegearunit (3) andfit tool 99363310(4),blocking
gear unit (3) rotation.
UsingAllen wrench99355131 (2), multiplier 99389816 (1)
andatorquewrench(5) tightenthegear nut tothecorrect
torque value.
42595
drawing.
42596
Assemble the oil feed (2) and tighten the screws to the
correct torque; keytheslidingsleeve (1).
42597
Assemblethecontrol (1) withthedifferential lock fork.
Applyabead of LOCTITE 573on thecontact surface.
42598
Fit thecover (2) andtightenthescrewstothecorrecttorque.
Heat thebearinginternal ring(1) andkeyontheinput shaft.
71547
Assemble the cover (1), complete with internal (3) and
external (2) seal rings,andtightenthescrewsto thecorrect
torque. Fit theflow divider lockingcover (5).
To fit the internal seal ring (3), use keyingdevice
99374013 and grip 99370006.
NOTE
Figure97
Figure98
42600
Rotatetheunit. Fit theflange(1) ontheinput shaft.Tighten
the nut to the correct torque value using Allen wrench
99355131 (2).
42601
drawing.
133 TRAKKER EURO 4/5 REARAXLES451391/2D(R8284) - 452191/2D(R8274) - 453291/2D(R8298)
5250 Rear axles
451391/2D (R 8284)
452191/2D (R 8274)
453291/2D (R 8298)
Page
DESCRIPTION 135 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 136 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REARAXLESASSEMBLY OVERHAUL 144 . . . . . . . .
- Removal 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Epicyclicreduction gear disassembly 144 . . . . . . . .
CHECKINGTHEWHEEL HUBANDEPICYCLIC
REDUCTION GEAR UNIT PARTS 147 . . . . . . . .
WHEEL HUBASSEMBLY 148 . . . . . . . . . . . . . . . . . .
- Assemblingtheepicyclic reductiongear 150 . . . . . .
REMOVING-REFITTINGTHE DIFFERENTIAL 153 . .
REFITTING 154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRINGTHEDIFFERENTIAL 155 . . . . . . . . . . . .
- Disassembly 155 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Differential housingdisassembly 156 . . . . . . . . . . . .
- Removingthebevel pinionsupport 157 . . . . . . . . .
CHECKINGTHEDIFFERENTIAL
COMPONENTS 159 . . . . . . . . . . . . . . . . . . . . . . .
- Differential housingassembly 160 . . . . . . . . . . . . . .
- Procedureto followto determinethethickness
of thebevel pinionrollingtorqueadjustingring 161
- Differential carrier assembly 163 . . . . . . . . . . . . . . .
- Differential housingbearingsrollingtorque
adjustment 164 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 TRAKKER EURO 4/5 REARAXLES451391/2D(R8284) - 452191/2D(R8274) - 453291/2D(R8298)
71548
The rear axle is of the double reduction type; the first
reduction is provided by the bevel pinion/ring bevel gear,
whereasthesecondreductionisbymeansofanepicyclicunit
onthewheel hubs.
threaded ringnuts.
Thebevel pinionissupportedbytwotaperrollerbearingsand
athirdstraight roller bearing.
Thebevel pinioncanbeadjustedbymeansofadjustmentrings
located betweenthetwo taper roller bearings.
Theaxleisprovided withapneumatic device for differential
locking.
theepicycloid reductionunits.
REARAXLE451391/2D
Figure1
Figure2
71549
REARAXLES452191/2D- 453291/2D
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESCRIPTION
Revi - June2007
PRINT603.93.641/A
MAIN DATA
Typeof axle:
452191/2D 451391/2D 453291/2D
differential locking
452191/2D
(R8274)
451391/2D
(R8284)
453291/2D
(R8298)
Bevel pinionbearings 2taper rollersand 1straight roller
27/32(1.185) - 29/37(1.276) - 27/37(1.370) - 28/37(1.321) -
24/35(1.458) - 23/36(1.565) - 21/34(1.619) - 19/33(1.737) -
21/40(1.905) - 17/35(2.059)
Epicycloid reduction unit/wheels
ratio
3.2
without seal Nm 1.5 3.5
adjustment
rollingtorqueadjustment rings
mm 9.80 10.80 (seriesof increased thicknesses=0,02 mm)
Thicknessof bevel pinion/ringbevel
gear positionadjustment rings
mm
3.6 - 3.7 - 3.8- 3.9 - 4.0 - 4.1- 4.2 - 4.3 - 4.4- 4.5 - 4.6
Clearancebetweenpinion
and ringbevel gear mm 0.20 0.33
withringnuts
WHEEL HUBS
Wheel hub bearingsrollingtorque:
protection Nm 6 7+(12 16)
seals Nm 6 7+(5 7)
runinbearingsand seals
Nm 6 7Nm+(2.5 4.5 Nm)
Axleoil
TUTELA W140/MDA
16
14.5
G.R.W. maximumload kg 11.000 13.000 16.000
115270
Figure3
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PRINT603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Nut fixingbevel pinion 700 50 70 5
2 Screwfixingbevel pinionsupport to differential carrier 165 15 16.5 1.5
3 Screwfixingdifferential carrier to axle 160 10 16 1
4 Screwfixingdifferential carrier to axle 160 10 16 1
5 Screwfixingbevel pinionsupport to differential carrier 280 15 28 1.5
6 Screwfixingringbevel gear to differential housing 1
st
stage
2
nd
stage
100
300 10
10
30 1
7 Screwfixingsafetyplateto gear housingcover 60 6 6 0.6
8 Cheeseheadedscrewfixingcontrol cylinder 25 2 2.5 0.2
9 Self-lockingscrew 120 10 12 1
DapplyLOCTITEAVX
applyLOCTITE573
115268
Figure4
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
3 Screwfixingcover to sidepinionsupport h 50 5 5 0.5
4 Countersunkscrew 50 5 5 0.5
5 Screwfixingloadbearingsleeve 295 30 29.5 3
d applyLOCTITE5970onconnectionsurface
h applyLOCTITE573onthread
: applyMOLYKOTEonthenut contact surface
INTERMEDIATEAXLES452191/2D(R9274) - 453291/2D(R9189) 139 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
TOOLS
99322225 Support for assemblies (to be fitted onto stand 99322205)
99341015 Press
140 INTERMEDIATEAXLES452191/2D(R9274) - 453291/2D(R9189) TRAKKEREURO 4/5
99341020 Pair of tie rods for grips
99341023 Grips
99370317)
Print 603.93.641 3aso |ovobo 2006
99356001 Wrench for adjustingwheel brakejaws
99370005 Gripfor interchangeable punches
99370317 Reactionlever withextension for flangeretaining
99370509 Hook to extract differential gear half-housing
99370616 Mountingfor removal and refittingof differential
99371022 Pair of differential support brackets for useduring overhaul (use
with 99322205-99322225)
99372211 Tool for removal and refittingof brakejaws retainingsprings
99374013 Keyto fit flowdivider driveinfeed shaft seal (usewith99370006)
Print 603.93.641 3aso |ovobo 2006
99374094 Punchtofit external racesofbearings(diameter 134- 215mmuse
with 99370007)
Block the differential locking device sliding sleeve with a
screw.
Remove the control cylinder threaded coupling (2) and
replacewith ascrew(1) (M 14 x 1.5).
Rotatetheaxlemechanismtofacilitateengagementbetween
theslidingsleeveandtheengagement sleeve;this will avoid
involuntarysleevemovement whilst thedriveshaft is being
extracted.
Position a container under the wheel hub to
recover the oil.
39628
39627
71534
Figure5
Figure6
Figure7
Beforepositioningtheaxleassemblyon the overhaul stand,
drain off the oil by unscrewingthe lower plugon the axle
housing.
Position theaxleassemblyon stand 99322215.
Unscrewthescrews(1), removethecover (3) anddrainoff
theoil into thecontainer.
breather - wheel hubs differential and epicycloid
reductionunitsremoval-refittingoperations, canall
becarried out with theunits fitted on the vehicle.
Epicyclic reduction gear disassembly
Disassembly
!
Before extractingtheaxleshaft makesurethat the
screw has beentightened(2, Figure6).
Figure8
Figure9
40338
UsinganAllenwrench(2) unscrewthetwoscrews(1) fixing
thedrum; replacewith thereactionscrews(5). Tightenthe
reactionscrewsandremovethedrum(4) fromthehuband,
usingasling(3), raiseand remove.
40054
Unscrewthe3sidepinion(3) fixingscrews;tightenthereaction
screws (1) and, usingasling(2), removethesupport (3).
1
2
NOTE
NOTE
525010 REAR AXLES ASSEMBLY
OVERHAUL
40055
39635
39636
Figure10
Figure11
Figure12
Figure13
Figure14
Removethebevel gear (1) fromthemounting.
Removetheshoulder pin(2).
Usingsuitable pliers, remove the safetyring(2), extract the
gear unit (3) fromthedriveshaft.
Fit tool 99374451(1) intheshoulderpinseatandextract the
driveshaft (2) fromtheload bearingsleeve.
Removethespacer ring(3).
Figure15
40056
Extract thesupport pins(2) fromthesidepinionsupport (1).
Removethesidepinions(3) fromthesupport(1) andrecover
therollers andthespacer rings.
39637
Usingapunch, remove thenotch(1) on theadjustingnut.
UsingAllenwrench99354207(1),unscrewtheadjustingnut.
39638
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PRINT603.93.641
Check the load bearing sleeve (2). If damaged, replace as
follows.
Unscrewthescrews(1), removethebrakesupport plate (3)
and theaxlecasingsleeve (2).
39639
71535
71536
Figure16
Figure17
Figure18
Figure19
Figure20
Extractthebevel gearmounting(2),togetherwiththebearing
and wheel hub(3), fromtheloadbearingsleeve (1).
Check thesurfaceof the ring(1), onwhich thehubseal ring
rotates, isnot damagedor worn,if necessary, replacethering
(1).
Usingthe extractor [comprisingbridge 99341003 (8), grips
99341023(3),tierods99341020(6),press99341015(4)and
reaction block 99345053 (7)], extract the ring(replacing if
necessary) and/or theinternal ring(2) of thesleeve(5) taper
bearing.
39642
Usingapunch inserted through the holes on the bevel gear
support,extract theexternal taperroller bearing(2) fromthe
bevel gear support (1).
39643
Usingauniversal bronzepunch(1), extract theexternal ring
(2) fortheinternal bearing.Theseal ringwill alsobeextracted.
Proceed in the same way to extract the external bearing
external ring. If necessary, disassemblethephonicwheel.
Screws(1) aresecuredwith LOCTITEAVX. NOTE
39644
Figure21
Figure22
CLEANING AND CHECKING WHEEL HUB
AND EPICYCLIC GEAR PARTS
Carefullycleanthewheel hubparts. Checkthedrive
shafts for deformation. If necessary, straighten the
drive shafts usingahydraulic press; if this does not
provide satisfactoryresults, replacethedriveshafts.
Check thestuds fixingthe wheel: if thethreads are
damagedordeformedtheymust bereplaced.Work
under apress to extract andre-assemble thestuds.
On completion of assembly operations, check that
theorthogonal deviationisnogreater than0.3mm.
Lubricatethebearingsandmakesurethat theroller
support cage rotates freely, rotation should be
smooth, without hardening.
Check thethreads on thehub bearings adjustment
nutsandontheloadbearingsleeves;replacethenuts
if necessary. Check the oil manifold and replace if
damaged.
Replaceall sealswith newparts.
Carefully clean all the epicycloid gear unit parts.
Visuallycheckthetoothingonthebevelgearsupport,
thebevel gear, thecrownwheel gearsandtheopen
gear unit.
Check thespacer rings, distancering, bearingrollers
and support pins.
Replaceanydamaged or wornparts.
Check the oil manifold (1) and replace if damaged. Extract
withapunchinsertedintheslotsonthehub(3).Removethe
seal ring(2).
40430
WHEEL HUBPARTS
1. Brakedrum- 2. Adjustingnut and screw- 3. Cover - 4. Seal - 5. Pinand roller for sidepinions- 6. Sidepinionsupport -
7. Adjustingnut - 8. Ringbevel gear support - 9. Sidepinion- 10. Shoulder pin- 11. Ringbevel gear - 12. Driveshaft -
13. Breather - 14. Bracket - 15. Shoulder pin- 16. Axlehousing- 17. Loadbearingsleeve- 18. Brakeunit - 19. Phonic wheel -
20. Oil sump- 21. Support ring- 22. Seal ring- 23. Seal ring- 24. Bearing- 25. Wheel hub- 26. Bearing- 27. Stud
Print 603.93.641 3aso |ovobo 2006
39645
39646
40410
71537
Figure23
Figure24
Figure25
Figure26
Ifthestuds(3) needtobereplaced, beforefittingnewstuds,
makesurethat thecontact surfaceontheheadisfreeofslag,
burr, blisters.
Usingpunch99374093(2) andapress,fit theexternal ringon
theexternal bearing(3),stoppingapprox.5mmfromthefully
fittedposition;completefittingoperationsmanually,usinggrip
99370007(1).
Complete fittingoperations manually, usinggrip 99370007,
thenturnthehuboverandcarryoutthesameoperationwith
theexternal ringof theinternal bearing.
(2) positionedasshowninthedrawing, fitthebrowninternal
After fitting, checkthat thestudsarefullyinsertedonthehub
and that theright angleerror doesnot exceed0.3 mm.
If the oil collecting sump (2) needs to be replaced, before
assembly, smear the contact surface on the hub/sump and
hub/hubseat withLOCTITE573 sealingcompound.
Refitthephonicwheel (1) and,oncompletion,makesurethat
phonicwheel is positionedperfectlyinthehubseat.
Usinga1/100thsfeeler gauge,checkthat theright angleerror
does not exceed 0.2mm.
71538
Figure27
(2) positioned as showninthedrawing, fit theblueseal ring
(3) on thewheel hub (4).
525030 WHEEL HUB ASSEMBLY
71539
71540
40375
40377
39650
40070
Figure28
Figure29
Figure30
Figure31
Figure32
Figure33
Positiontheseal ringontheloadbearingsleeve. Fit theload
bearingsleeve (3), thebrakesupport plate (4) anddust seal
disk. Smear the screws (2) and tighten to the correct value
withatorque wrench(1).
Smear LOCTITE 573 on the seat ( ) of the load bearing
sleeve(3) ontheseal ringssupport ring(2). Heat thering(2)
withanelectricdrier and keyonthe loadbearingsleeve(3).
Heatthetaperbearinginternal ring(1) to100Candfitonthe
load bearingsleeve.
Lubricatethelip of theseal ringsandsleeve.
Fit thehub(1) ontheloadbearingsleeve (2).
Lubricatetheseal ring(3) andfit onthewheel hub.
Using an electric drier, heat the taper roller bearing (1) to
100C and fit onthebevel gear support (2) withapunch.
Fit thebevel gear support (3) andthetaper roller bearing(2)
ontheload bearingsleeve (4).
Applyathin layer of MOLYKOTE onthe contact surfaceof
theadjustingnut andtightenwithwrench99354207(1) until
the hub rotates with difficulty. Release the hub with afew
blowsfromahammer inthedirection oftheaxisandinboth
directions.
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PRINT603.93.641
40071
40072
40069
39636
39653
Figure34
Figure35
Figure36
Figure37
Figure38
Positiontool 99395026 (1) and, usingatorquewrench(2),
read thewheel hubrollingtorque.
Oncetherequiredrollingtorquehas been achieved, secure
theadjustingnut (2) withapunchinthetwo groovesonthe
Positionthespacer ring(2) ontheload bearingsleeve.
Usingtool 99374451(1) introducethedriveshaft (2) onthe
Positionthegear unit (3) onthegroovedsectionofthedrive
shaft andthesafetyring(1) intheseat.Drivetheshoulder pin
(2) into theseat on thedriveshaft.
Whilst reading the wheel hub rolling torque, hub
rotationmust not exceed40rpm.
Wheel hub rolling torque values vary according to the
followingconditions:
- newbearingswith
surfaceprotection 6 7+(12 16) Nm
- runinbearingsand new,
lubricated seals 6 7+(5 7) Nm
- runinbearingsand seals 6 7+(2.5 4.5) Nm
Thedoubletoothed short half shaft is to be fittedin
thebearingshaft onthedifferential lockingside.
525140 Assembling the epicyclic
reduction gear
!
!
39654
39655
26916
39656
40073
Figure39
Figure40
Figure41
Figure42
Figure43
Position the bevel gear (1) with the external bevel facing
outwardsand thenfit onthebevel gear support.
Smeartherollers(1) withgreaseandposition, together with
thethreespacer rings(2) onthesidepinion(4), asshownin
thedrawing.
Positionthesidepinion(4) andthespacer washer (5) inthe
sidepinionsupport.
Introducethesupport pin(3) fromthecover side, pushingit
fullyinto position.
Repeat thesameoperationfortheremainingtwosidepinion
units.
Smear athin layer of LOCTITE 573, or Reinzoplast, onthe
contact surfacesofthesidepinionsupport (2) andthewheel
hub (1).
SmearathinlayerofLOCTITE510onthecover (3) andside
pinionsupport (4) contact surfaces.
Position the cover so that the bevels of the support pins
coincidewiththeholes onthecover.
Smear LOCTITE 573 sealing compound on the screw (1)
thread and tightento atorqueof 50 5 Nmwith atorque
wrench (2).
Pushthesidepinionsupport (2) ontothehubbymovingthe
drive couplingflangein bothdirections to facilitate toothing
engagement.Makesurethatthefixingholesonthesidepinion
support andthehub coincide.
Position thethreecheese-headed screws (4) and tightento
atorqueof 50 5Nmwith atorquewrench (3).
Fit thebrakedrum(1) onthesidepinionsupport. Securethe
brake drumwith the two cheese-headed screws (2) and
tightento atorqueof 50 5Nmwith atorquewrench(3).
Print 603.93.641 3aso |ovobo 2006
Figure44
39658
39659
71534
39660
39661
Figure45
Figure46
Figure47
Figure48
Figure49
Removethescrews(1) fixingthedifferentialcarriertotheaxle
housing.
Position acontainer under the wheel hub (1); unscrewthe
screws(2), removethecover (3) and drainoff theoil.
Fit tool 99374451 (1) in the shoulder pin seat thread, then
extract thedriveshaft (2) fromtheloadbearingsleeve.
Usingeyebolts, raise the pinion support (1) with aslingand
unscrewthefour screws(2) fixingthedifferential carrier.
Usingeyebolts(1) andasling, raisethedifferential carrier (2).
26924
Figure50
Theendfloat onthedriveshaft (1) must bebetween0.5and
1mm.Tocarryout thisadjustment fullytightentheadjusting
screw(2),thenunscrewbyhalfaturnandsecurewiththehex
nut (3).
526210 REMOVING-REFITTING
THE DIFFERENTIAL
The flat face of the hex nut must be positioned
towards theseal ring(4).
NOTE
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PRINT603.93.641
39662
39664
39663
39665
39666
40073
Figure51
Figure52
Figure53
Figure54
Figure55
Figure56
Fit the slidingsleeve (1) on the drive shaft (2) with double
toothing.
Smear LOCTITE 573 (1) sealingcompound on the contact
surface. Whenassemblingthedifferential housing,makesure
that the differential lock engagement fork is correctly
introducedontheslidingsleeve.
Positiontheseal ringandassemblethedifferential carrier (1).
ApplyLOCTITE573onthethreadsoftheexternalscrews(2).
Usingatorquewrench, tighten the external (2) and internal
(3) screwsto thecorrect torque.
Smear LOCTITE 573 (1) sealingcompound on the contact
surface.
Positionthebevel pinionsupport(1) onthedifferential carrier
(2). Using a torque wrench, tighten the screws (3) to the
correct torque.
Smear athin layer of LOCTITE 510 on the cover (3) and
crownwheel support(4) contact surfaces.Positionthecover
sothat thebevelsofthesupport pinscoincidewiththeholes
onthecover.Smear LOCTITE573sealingcompoundonthe
screw (1) thread and tighten to the correct torque with a
torquewrench (2).
!
ApplyabeadofLOCTITE510aroundtheoil passage
holes.
!
ApplyLOCTITE573onthethreadsofthescrews(3)
that passthrough theholes.
REFITTING
39667
39669
39668
39670
39671
39672
Figure57
Figure58
Figure59
Figure60
Figure61
Figure62
Positionthedifferential unit withthegear housingcover (1)
facingupwards,onrotatingstand99322205(2),togetherwith
support 99322225and pair of brackets 99371022 (3).
Provisionallyfit the bevel pinion support (4).
Unscrewthescrews(1) andremovethesafetyplate (2).
Heat thepointsindicatedbythearrowswithdrier 99305121
and unscrew the screws (2) fixingthe cover (secured with
LOCTITE).
Raisethegear housingcover (1).
Usinghook99370509(1),raisethegearhousing(2),together
withthetaper roller bearingsand bearingexternal rings.
Rotatethedifferential carrier through90.
Removethesafetynotchonthefixingnut.
Apply reaction lever 993701317 (2) to the drive coupling
flangeand,usingAllenwrench99355081(1),loosenthefixing
nut.
1
2
3
4
Print 603.93.641 3aso |ovobo 2006
526210 REPAIRING THE DIFFERENTIAL
Removal
39673
39675
39674
39676
39677
40086
Figure63
Figure64
Figure65
Figure66
Figure67
Figure68
Unscrewthescrewsandwashersofthedifferential carrier (3)
bevel pinion support (1). Fit the reaction screws (2) and
extract thedifferential housingsupport.
Usingauniversal punch, extract thebevel piniontaper roller
bearing(1) fromtheseat onthedifferential carrier.
Unscrew the 2 sunken hex screws (1) and remove the
differential lockingdevicecontrol cylinder (2).
Extract the piston (2), together with the seal ring (3), the
engagingfork(1) andthecompression spring(4).
Remove the circlip (1) and extract the differential lock
engagingsleeve(3) fromthegear housingcover (2).
Usingextractor 99348001(1-2) andreactionblock99345053
(3), extract the taper roller bearing fromthe differential
housing. Repeat thesameoperation ontheoppositeside.
Differential housing disassembly
39679
39681
39680
39682
39683
Figure69
Figure70
Figure71
Figure72
Figure73
Loosenand extract the screws (1) fixingthe ringbevel gear
(3) and cover (2) to thehalf-housing(4).
Counter-markthecover andgear housing( ).
Removethedifferential housingcover (1) andreleasethering
bevel gear (2).
Remove the crown wheel (2), together with the shoulder
washer (3), fromthedifferential housing(1).
short pins (3).
Removethespider (2) andthefour sidepinions(1) withthe
relativeshoulder washers.
Removethecrownwheel andtheshoulder washer.
Removethefixingnut and thedrivecouplingflange(1).
If flangeextraction provesdifficult, use auniversal extractor.
spiderbody(2) byalongstripeforthelongpin,and
bytwo short stripesfor theshort pins.
Removing the bevel pinion from the support
NOTE
Print 603.93.641 3aso |ovobo 2006
39684
39686
39685
39687
39688
39689
Figure74
Figure75
Figure76
Figure77
Figure78
Figure79
Remove the bevel pinion (1), intermediate bearing and
adjusting rings fromthe support. This operation should be
carriedout under apress; if not, useanextractor (2).
Removethebearingadjustmentring(2) fromthebevel pinion
(1).
Using universal extractor 99348001 (1), extract the
intermediatetaperrollerbearing(3) fromthebevel pinion(2).
Extract the pinion position adjustingring(2) fromthe bevel
pinion(1).
Extracttherearstraightrollerbearinginternal ring(2)fromthe
bevel pinion(1). Thisisadestructiveoperation.
Usingapunch,extracttheexternal rings(3and2) forthefront
and intermediatebearingsfromthe support (1).
cage rotates freely, rotation should be smooth, without
hardening.
COMPONENTS
Check that the grooved section on the pinion flange is not
excessivelyworn. Replacethepinionif necessary.
coupledspareparts.
NOTE
NOTE
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PRINT603.93.641
39690
39692
39691
39693
39694
39695
Figure80
Figure81
Figure82
Figure83
Figure84
Securethegear housing(1) inaviceandpositionthecrown
wheel (2) initsseat, together withtheshoulder washer (3).
and insert thespider (2).
Insert thelongpin(1) andthe two short pins.
Positionthecrownwheel (2) andshoulder washer (3) onthe
sidepiniongear unit.
Fit the cover (1) on the differential housingby makingthe
marks(madeduringdisassemblyoperations) coincide.
thegear housing(1) andsecurewithtwo fixingscrews.
Fit theremainingscrews(2) andtightenwithatorquewrench
(1) to 300 10Nm(30 1).
First insertthelong(through) pin.Theexactposition
of thepinsismarkedon the spider bodybyalong
stripefor thelongpin, and bytwo short stripes for
theshort pins.
Figure85
NOTE
39696
39572
39697
39698
39699
Figure86
Figure87
Figure88
Figure89
Figure90
|s|o ao o|oct|c |oato, |oat t|o soot boa|o (2) o +5'
at atemperatureof 100C and fit onthedifferential housing
cover usingapunch (1). Repeat the same operation onthe
other bearing.
Fit a new oil baffle on the pinion support (1) Usingpunch
99374093(2), fit the intermediatebearingexternal ringand
the front bearing external ring in the support in their
respectiveseats.
Usingafeelergauge(1) measureandnotethethicknessofthe
adjustingringon disassembly (valueA).
Securetool 99395027(6) inaviceandfitthefollowingparts:
- thepreviouslymeasuredadjustingring(4) andthebearing
(3).
Thenremove:
- the part (1),
- theringnut (2),
- thebearing(3),
Positionthesupport (4) onthebearing(5,Figure89) andthe
bearing(3) onthesupport. Tightentheringnut (2) byhand
and checkthe rollingtorque, asindicatedinFigure 91.
adjusting ring
Print 603.93.641 3aso |ovobo 2006
Position the completesupport on two parallel blocks; using
thetorquewrench(1) appliedontool99395027andreadthe
rollingtorque.Thisvalueshouldbe1.5to3.5Nm;ifnot,adjust
bymeansof theringnut (2, Figure89).
Positionthepart (1, Figure89), withthedial gaugezero-set,
ThicknessSontheadjustingringisprovidedbythefollowing
formula:
Where:
A =thicknessoftheadjustingringassembledfordial gauge
zero-setting;
39700
39701
39702
Figure91 Figure92
relation to the bevel gear, on the bevel pinion (1). The
thicknessoftheadjustingringisdeterminedbythereference
value(3) markedonthebevel pinion.
SeethetableinFigure 93.
positionadjustingring.
Heatwithanelectricdrierto100Candinserttherearstraight
rollersbearinginternal ring(1) onthebevel pinion(2).
First example:
A =10.12mm
B =+0.13mm
C =0.05 mm
S=10.12 - (+0.13) +0.05=
S=10.12 - 0.13+0.05=10.04mm.
Second example:
A =10.12mm
B=- 0.13 mm
C =0.05 mm
S=10.12 - (- 0.13) +0.05 =
S=10.12+0.13 +0.05 =10.35mm.
On completion of the operation, remove theparts of tool
99395027.
11+0,5
Figure93
Figure94
5
Revi - June2007
PRINT603.93.641/A
Valuemarkedonthe
bevel pinion
Total thicknessof
adjustingring
-0.5 4.6
-0.4 4.5
-0.3 4.4
-0.2 4.3
-0.1 4.2
0 4.1
+0.1 4.0
+0.2 3.9
+0.3 3.8
+0.4 3.7
+0.5 3.6
39703
39705
39704
39706
39707
39708
Figure95
oat t|o |otooo|ato boa|o (+) o ao. +5' at a
temperatureof 100C and fit onthebevel pinion (2); fit the
adjustingring(3) withthesamethicknessaspreviouslynoted
(page164).
Fit thepreviouslyassembledsupport (1) onthebevel pinion
(2),fittingthefront bearing.Usingkey99374013(3) andgrip
99370006, insert theoil seal ring(4).
Assemble the drive coupling flange (1) with a punch and
tightenthefixingnut byhand.
Usingapunch,fittherearstraightrollersbearing(1) inposition
onthedifferential carrier.
Provisionally assemble the bevel pinion support (2) on the
differential carrier (3), insert 2 screws (4) and washers in
diametricallyopposingpositions. Usingatorquewrench(1),
tightento atorqueof 160 10Nm(16 1kgm).
Block the drive couplingflangerotation usingreaction lever
99370317 (1) and, usingAllen wrench 99355081 (2), the
multiplier (3) and atorquewrench(4) tightenthefixingnut
to atorquevalueof 700 50Nm(70 5kgm).
Figure96
Figure97
Figure98
Figure99
Figure100
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Differential carrier assembly
wrench,checkthat thetotal rollingtorquevaluecorresponds
withthevalueindicated inFigure 104.
39671
39709
39712
39711
Figure101
Using hook 99370509 (1), position the gear housing (2)
together withtheroller bearings onthedifferential carrier.
Correctlyfit the cover (3) making the marks (made during
disassembly operations) coincide. Provisionally tighten the
screws(2) andcheckthat theadjustingringnuts(4) screw-in
easily.
Remove the screws (2), smear the threads with LOCTITE
AVXandthenre-tightenwithatorquewrench(1) toatorque
of 280 15Nm.
The rolling torque reading is carried out when there is a
clearancebetweentheteethonthebevel gearpair.However,
thetotal rollingtorquevaluevariesaccordingtothereduction
bevel gear pair ratio (seetableinFigure 104).
Differential housing bearings rolling torque
adjustment
Ifthetorquevalueisdifferentfromthat indicatedinFigure104,
adjusttheadjustmentringnuts(2) withwrench99354001(1)
until the requiredtorqueisobtained.
1
2
Figure102
Figure103
Figure104
Figure105
No. of teeth Ratio Total rollingtorque (Nm)
17/35 2.059 a+(1.5 - 2.4)
19/33 1.737 a+(1.6 - 2.6)
21/34 1.619 a+(1.9 - 3.1)
23/36 1.565 a+(1.9 - 3.2)
24/35 1.458 a+(2.1 - 3.4)
28/37 1.321 a+(2.3 - 3.8)
27/32 1.185 a+(2.5 - 4.2)
21/40 1.905 a+(1.6 - 2.6)
27/37 1.370 a+(2.2 - 3.6)
29/37 1.276 a+(2.4 - 3.9)
a=7.5 9.5Nm
Adjust theendfloat betweentheteethonthebevel gearpair
asfollows:
- ReadtheclearancevaluebetweentheteethinFigure106.
39710
39711
39704
- Positionamagnetic stand dial gauge(1) asshowninthe
drawing.
- Prevent thebevel pinionfromrotatingwithreactionlever
99370317,reversethedirectionofrotationof thebevel
gear and, usingagauge(1), read theclearancebetween
theteeth onthetwo gear units.
Ifnot, usingthewrench99354001(1, Figure108), adjust the
adjustingringnut.
In order to prevent the previously measured rollingtorque
between the pinion and the bevel gear teething, tightenthe
ringnut withthewrench99354001(1) bythesameamount
asthe ringnut ontheoppositeisloosened.
On completion of operations, check that the two adjusting
ringnutsaresuitablypositionedtoallowthesafetyplatetobe
fitted.
Usingabrush, applyalight coveringof Prussianblue onthe
Figure106
Figure107
Figure108
Figure109
Print 603.93.641 3aso |ovobo 2006
No. of teeth Ratio Clearancebetweenteeth
17/35 2.059 0.2 0.33
19/33 1.737 0.2 0.33
21/34 1.619 0.2 0.33
23/36 1.565 0.2 0.33
24/35 1.458 0.25 0.33
28/37 1.321 0.2 0.33
27/32 1.185 0.2 0.33
21/40 1.905 0.2 0.33
27/37 1.370 0.2 0.33
29/37 1.276 0.2 0.33
40160
40161B
40161A
39713
39714
26609
Figure110
Figure111
Figure112
Figure113
Figure114
Figure115
- Solution: decrease the thickness of the adjusting ring (2,
Figure92) betweenthe intermediate bearingand the bevel
pinion.
If themarkontheleadingfaceispositionedtowardstheinternal
diameter, and on the pushing face it is located towards the
external diameter of thebevel gear, thepinionislocatedtoo far
awayfromthebevel gear axis.
-Solution:increasethethicknessoftheadjustingring(2,Figure92)
between theintermediatebearingand the bevel pinion.
Assemble the engaging sleeve (1) on the gear housing
toothingand,withascrewdriver,positionthecirclip(2) inthe
groove.
Fit thedifferential lockengagement assemblycomprising:the
control cylinder, thepiston(2), theengagingfork(1) andthe
compressionspring(3).
Introduce the compression spring (1) in the differential
housing. Fit theengagingfork(2) so that fork(a) travel limit
correspondswithtravel limit (b) onthedifferential housing.
39715
Figure116
Fit anewseal ring(1) onthecontrol piston(2) andsmearwith
grease.
Introducethecontrolpiston(2) ontheengagingfork(3)inthe
compressionspring, then fit the assemblyin the gap onthe
Disassemblethebevel pinionsupport.
Fittingthedifferential ontheaxlehousing.
1. Fit theslidingsleeveonthedriveshaft.
2. Fit the gear housingassembly, takingcare that the fork
engagesinthegrooveonthesliding sleeve.
3. Tighten thescrewwhilst pushingthe driveshaft so that
the sliding sleeve engages on the differential engaging
sleeve.
4. ApplyLOCTITE573onthethreadsandundertheheads
of the screws and tighten to thecorrect torque with a
torquewrench.
5. Apply LOCTITE 573 on the contact surface, refit the
pinion support and tighten the screws to the correct
torque.
Print 603.93.641 3aso |ovobo 2006
169 TRAKKER EURO 4/5 REARAXLE452146/2D(R8174)
Rear axle
452146/2D (R 8174)
Page
DESCRIPTION 171 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 172 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REARAXLE ASSEMBLY OVERHAUL 180 . . . . . . . .
- Disassembly 180 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassemblingthedifferential housing 181 . . . . . . .
- Disassemblingthebevel pinionsupport 182 . . . . . .
CHECKINGTHEDIFFERENTIAL
COMPONENTS 182 . . . . . . . . . . . . . . . . . . . . . . .
- Assemblythedifferential housing 183 . . . . . . . . . . .
- Differential carrier assembly 186 . . . . . . . . . . . . . . .
- Adjustingtherollingtorqueonthe differential
housingbearings 187 . . . . . . . . . . . . . . . . . . . . . . .
71550
Figure1
The rear axle is of the double reduction type; the first
reduction is provided by the bevel pinion/ring bevel gear,
whereasthesecondreductionisbymeansofanepicyclicunit
onthewheel hubs.
threaded ringnuts.
Thebevel pinionissupportedbytwo taper roller bearings.
The bevel pinion can be adjusted bymeans of adjustment
shimslocatedbetween thetwotaper roller bearings.
Theaxleisprovided withapneumatic device for differential
locking.
theepicycloid reductionunits.
LONGITUDINAL PICTORIAL SECTION OFTHE DIFFERENTIAL
DESCRIPTION
MAIN DATA
Typeof axle:
differential locking
452146/2D(R8174)
Bevel pinionbearings 2taper rollers
27/32(1.185) - 28/37(1.321) - 24/35(1.458) - 23/36(1.565) -
21/34(1.619) - 19/33(1.737) - 17/35(2.059) -13/35(2.692) -
15/34(2.267) - 17/36(2.118) - 21/40(1.905) - 27/37(1.370) -
34/37(1.088)
Epicycloid reduction unit/wheels
ratio
3.2
without seal Nm
6 8
adjustment
rollingtorqueadjustment rings
mm
10- 10.02 - 10.04 - 10.06 - 10.08- 10.10- 10.12 - 10.14 -
10.16- 10.18 - 10.20 - 10.22- 10.24- 10.26 - 10.28 - 10.30-
10.32- 10.34 - 10.36 - 10.38- 10.40- 10.42 - 10.44 - 10.46-
10.48- 10.50 - 10.52 - 10.54- 10.56- 10.58 - 10.60
Thicknessof bevel pinion/ringbevel
gear positionadjustment rings
mm
0.2 - 0.3 - 0.5- 1
Clearancebetweenpinionand ring
bevel gear mm
0.15 0.35
withringnuts
WHEEL HUBS
protection Nm
6 7+(12 16)
seals Nm
6 7+(5 7)
runinbearingsand seals Nm 6 7+(2.5 4.5)
Axleoil:
Quantity Litres
kg
TUTELA W140/MDA
11.5
G.R.W. maximumload kg 11000
115271
Figure2
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 Toothedflange 180 10 18 1
2 Self-lockingscrew 19 2 1.9 0.2
3 Screwfixingbevel pinionsupport 180 10 18 1
4 Nut fixingbevel pinionflange 700 50 70 5
5 Screwfixingsupportsfor bearings Z 180 10 18 1
6 Self-lockingscrewfor safetyplate 51 4 5.1 0.4
7 Screwfixingdifferential carrier to axlehousing 180 10 18 1
8 Screwfixingringbevel gear to gear housingZ 180 10 18 1
Z applyLOCTITEAVX
h applyLOCTITE573
98970
Figure3
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
3 Screwfixingcover to sidepinionsupport h 50 5 5 0.5
4 Screw 50 5 5 0.5
5 Screwfixingloadbearingsleeve 295 30 29.5 3
d smear LOCTITE5970 onconnectionsurface
h applyLOCTITE573onthread
: beforemounting, slightlysmear MOLYCOTEonnut rest surface
175 TRAKKEREURO 4/5 REARAXLE452146/2D(R8174)
TOOLS
99322225 Support for assemblies (to be fitted onto stand 99322205)
99341015 Press
99348001 Extractor with lockingdevice
99370317)
99370616 Mountingfor removal and refittingof differential
99372211 Tool for removal and refittingof brakejaws retainingsprings
99374094 Punch to fit external races of bearings (134 - 215) (use with
99370007)
99374233 Keyto fit differential bevel pinion seal (usewith 99370006)
99395027 Tool todeterminedifferential bevelpinionadjustingshim(usewith
99395603)
99395603 Dial gauge(0-5 mm)
39552
39554
39553
39555
39556
39557
Figure4
Figure5
Figure6
Figure7
Figure8
Figure9
Heat the points indicated bythe arrows with electric drier
99305121andunscrewthescrew(1) sealedwithLOCTITE.
Removethesafetyplate(2). Unscrewthescrews (3) sealed
with LOCTITE. Removethecaps (4) andringnuts.
Raise the differential housing (2) and bearings (3) using a
hook (1).
Viewof pinion(1) insidethedifferential carrier (2).
Useapunchtoremovethesecuring(1) notchandunscrew
thenut (2) asdescribed below.
Block the rotation of the drive coupling flange with the
reaction lever 99370317 (2), and loosenthe drivecoupling
flangefixingnut usingtheAllenwrench 99355081(1).
Unscrew the bolts that fixthe bevel pinion support to the
Extract thesupport (1) andbevel pinionfromthedifferential
carrier (3); remove the pinion/bevel gear positioningshims
(2).
Forrepairsonthewheel hubs,epicycloidreduction
units, drive shaft and flow divider differential
removal-refittingoperations,followtheinstructions
forthe451391/2D- 452191/2D- 453291/2Daxles.
Disassembly
NOTE
525010 REAR AXLE ASSEMBLY OVERHAUL
39558
39560
39559
39561
39562
Figure10
Figure11
Figure12
Figure13
Figure14
Fit thegear housing(1) inavice(2).
Usingextractor99348001(1),extractthesupportbearing(2)
onthetoothedsidefromthedifferential housing(3).
Loosenandremovethescrews(1).
Detach theringbevel gear (2) usingapunch.
Removethedifferential housingcover (1).
Remove the crown wheel (3) fromthe differential housing,
together withtheshoulder washer (2).
short pins (2).
spiderbodybyalongstripefor thelongpin, andby
two short stripesfor theshort pins.
Remove the spider and the four planetary gears with the
relevant shoulder washers.
Removethecrown wheel andshoulder washer.
NOTE
Disassembling the differential housing
39563
39565
39564
Figure15
Figure16
Figure17
Using an extractor, positioned as shown in the drawing,
extract thebevel pinion with bearing and support adjusting
ring(1).
Extract theseal ring(2).
Usingextractor 99348001 (1), extract the bearing(2) from
thebevel pinion.
Using apunch, remove the front and intermediate bearing
external rings (1and 2) fromthesupport.
Removetheoil baffle.
COMPONENTS
cagerotatesfreely,without sticking.Checktheringbevel gear
and half-casingcontact surfaces, makingsure that the bevel
gear matches perfectly. Anyeventual deformation onthese
surfaces would cause screw vibration on the bevel gear,
leadingtoincorrect assemblyoperation.
Check that thesplined sectionused to keytheflangeonthe
pinionis not worn. Replacethepinionif necessary.
coupledspareparts.
Checkthesidepinionswithrelativeshoulderwashers,andthe
spider and crown wheelswith relativeshoulder washers.
Replace all sealing elements and safety washers with new
parts.
NOTE
NOTE
Disassembling the bevel pinion support
39566
39568
39567
39569
39570
Place the differential housing (3) on a suitable support,
position the crown wheel (1) in its seat, together with the
shoulder washer (2).
and insert thespider (4). Insert thelongpin(1) andthetwo
short pins (3).
Theexact positionof thepinsismarked onthespider body
(4) byalongstripefor thelongpin, andbytwo short stripes
for theshort pins.
Positionthecrownwheel (2) andshoulderwasherontheside
piniongear unit.
Fit thecover (1) onthedifferential housing(3) bycentering
thefixingscrewholes.
the differential housing (2) and secure with the two fixing
screws.
Fit theother screws(1) andtightenwithatorquewrench(2)
to thespecifiedtorque.
Heat thesupport bearings withelectricdrier 99305121and
assemblein thedifferential housing.
Figure18
Figure19
Figure20
Figure21
Figure22
Assembling the differential housing
39571
39573
39572
39574
39575
Fit anewoil baffle onthepinionsupport.
Fullyfit theexternal ring(2) forthefrontbearingintotheseat,
usingpunch99374093(1), andtheexternal ringfor therear
bearing, usingpunch99374094, into theseat.
Proceduretofollowtodeterminethethicknessofthebevel
pinion rollingtorque adjustingring.
Measure and note the thickness of theadjustingring(1) on
disassembly(valueA).
Securetool 99395027(1) andextension(2) in avice.
Fit thefollowingpartson tool 99395027:
- thespacerring(5),thepreviouslymeasuredadjustingring
(4) and thebearing(3).
Thenremove:
- the part (1);
- theringnut (2);
- thebearing(3);
Position the support (4, Figure27) on the bearing (6,
Figure26) andassemblethe bearing(3) onthesupport.
Tightentheringnut (2) byhand. Checktherollingtorqueas
indicatedinFigure28.
Figure23
Figure24
Figure25
Figure26
Figure27
39576 39577
39578
Positionthecompletesupport(3) ontwoparallel blocks;using
thetorquewrench(1) applied onthetool (2) andreadthe
rollingtorque. This valueshould be:
- 6 to 8 Nm; if not, adjust bymeans of the ringnut (2,
Figure26).
Positionthepart (1, Figure26), withthedial gaugezero-set,
formula:
Where:
A =thickness of the adjusting ring assembled for dial
gaugezero-setting;
First example:
A =10.12mm
B =+0.13mm
C =0.05 mm
S =10.12 - (+0.13) +0.05 =
S =10.12 - 0.13 +0.05 =10.04 mm
Second example
A =10.12mm
B =- 0.13 mm
C =0.05 mm
S =10.12 - (- 0.13) +0.05 =
S =10.12 +0.13 +0.05 =10.30 mm
On completion of the operation, remove the parts of tool
99395027.
Heat thebearing(3) withelectricdrier 99305121 andfit on
thebevel pinion(4).
Fit thespacer (2).
Assemble the adjustingring(1) with the same thickness as
previouslynoted, andposition onthe bevel pinion.
Fit the bevel pinion on the support, completewith external
ringsfor bearings.
Heatthebearing(1)withelectricdrier99305121andposition
inthebevel pinion (2) seat usingapunch.
Figure28 Figure29
Figure30
39579
39581
39580
71850
Figure31
Figure32
Figure33
Figure34
Figure35
Usingkey 99374233(1) fit the newseal (3) onthesupport
(2). Spare part seals are supplied pre-lubricated and with
greasebetweenthelips.
Positionthedrivecouplingflange(1),completewithbaffle(2),
onthesplinedsectionofthebevel pinion(3) andsettleinthe
seat with apunch.
Provisionallytightenthefixingnut (4).
Before fitting the bevel pinion support assembly on the
differential carrier, check the value (1) marked on the bevel
pinionand, byconsultingthetableinFigure 34,thethicknessof
ApplyLOCTITE 573 on the differential housing(1) contact
surface, addingLOCTITE510around the holes indicatedby
thearrows.Fittheadjustingring(2) onthedifferential housing
(1), so that the hole (4) faces towards upper part A of the
differential housing. Usingeyebolts and cables, fit the bevel
pinionassemblysupport (3) on thedifferential housing(1).
Tightenthefixingscrewsto thecorrect torquevalue.
theadjustingshimto bepositionedbetweenthesupport and
thecarrier will begiven.
Example:
Ifthereferencevalue(1) markedonthebevel pinionis+0.5,
thethicknessof theadjustingringmust be1.5mm.
Theadjustingringsareavailableinthefollowingdimensions:0.2,
0.3, 0.5, 1mm.
Differential carrier assembly
SUMMARY TABLETO DETERMINETHETHICKNESSOFTHE
BEVELPINION POSITION ADJUSTINGRING
!
ApplyLOCTITE 573 on the threads of the screws
thatpassthroughtheholesonthedifferentialhousing.
Valuemarkedon
thebevel pinion
Total thickness of
adjustingring
0 0.5
0.1 0.6
0.2 0.7
0.3 0.8
0.4 0.9
0.5 1.0
0.6 1.1
0.7 1.2
0.8 1.3
0.9 1.4
1.0 1.5
39583
39585
39584
39587
Usingthehook(1),raisethepreviouslyassembleddifferential
housing(2) andpositionon thedifferential housing(3).
Fit the external bearingrings and position the caps (2), and
tighten the screws (1) without fully screwingdown. Fit the
adjustingringnuts,makingsurethattheyscrewoneasily.Using
atorque wrench (3), tighten the screws (1) to the correct
torquevalue.
Thetotal rollingtorquereadingiscarriedout whenthereisa
clearancebetweentheteethonthebevel gearpair.However,
thetotal rollingtorquevaluevariesaccordingtothereduction
bevel gear pair ratio (seefollowingtable).
wrench, check that thetotal torquevaluecorresponds with
that indicated on the following table, according to the
reduction bevel gear pair ratio.
Adjustingthe rollingtorqueon thedifferential
housing bearings
Figure36
Figure37
Figure38
Figure39
Figure40
No. of
teeth
Ratio
Total rolling
torque(Nm)
13/35 2.692 a+(1.1 - 1.5)
15/34 2.267 a+(1.3 - 1.8)
17/35 2.059 a+(1.5 - 1.9)
17/36 2.118 a+(1.4 - 1.9)
19/33 1.737 a+(1.7 - 2.3)
21/34 1.619 a+(1.9 - 2.5)
21/40 1.905 a+(1.6 - 2.1)
23/36 1.565 a+(1.9 - 2.6)
24/35 1.458 a+(2.1 - 2.7)
28/37 1.321 a+(2.3 - 3.0)
27/32 1.185 a+(2.5 - 3.4)
27/37 1.370 a+(2.2 - 2.9)
34/37 1.088 a+(2.7 - 3.7)
a=7.5 9.5Nm
39586
39588
Figure41
Figure42
Figure43
Figure44
Figure45
Adjust the axial clearance between the teeth on the
pinion/bevel gear, which should be 0.15 to 0.35 mm,
- Position a magnetic dial gauge (1) as shown in the
drawing.
- Using wrench 99355205 (2), tighten the bearing
adjustment ringnut (3) whilst looseningtheringnut on
theoppositesidebythesameamount.Thispreventsthe
previouslymeasured rollingtorquefromvarying.
Usingabrush(1) applyalightcoveringofPrussianblueonthe
40160
40161A
andonthepushingface (towardstheinternal diameter) isout
of position, thepinionislocated too closeto thebevel gear.
- Solution:decreasethethicknessoftheadjustingringbetween
theintermediatebearingand thebevel pinion(2, Figure35).
nal diameter,andonthepushingfaceitislocated towardsthe
external diameter of thebevel gear, thepinionislocatedtoo
-Solution:increasethethicknessoftheadjustingringbetween
theintermediatebearingand thebevel pinion(2, Figure35).
40161B
Figure46
39552
Positiontheplate(2) andtightenthefixingscrews(1) tothe
correct torquevalue.
If theplate(2) doesnot coincidewith thenotchon thering
nut (3), slightlyrotatetheringnut until theplateandringnut
notch coincide. Repeat this operationontheoppositeside.
191 TRAKKER EURO 4/5 AXLESINTANDEMMERITORMT23-155/2D
Print 603.93.641
Base- November 2006
Axles in tandem
ARVINMERITOR MT23-155/2D
Page
AXLESIN TANDEMMT 23-155/2D
INTERMEDIATEAXLEMD11-155/2D 193 234 . . . . . . . . .
REARAXLE MR11-155/2D 235 264 . . . . . . . . . . . . . . . . . .
192 TRAKKER EURO 4/5 AXLESINTANDEMMERITORMT23-155/2D
Base- November 2006
Print 603.93.641
193 TRAKKER EURO 4/5 AXLESINTANDEM(INTERMEDIATE)
Print 603.93.641
Base- November 2006
Intermediate Axles
ARVINMERITOR MD11-155/2D
Page
DESCRIPTION 195 . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OFDIFFERENTIAL UNIT
PLATES- REARAXLE 196 . . . . . . . . . . . . . . . . . .
MAIN DATA 197 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMEDIATEREARAXLE
ASSEMBLY OVERHAUL 208 . . . . . . . . . . . . . . . . .
OVERHAULINGTHE WHEEL HUBS 208 . . . . . . . . .
- Removal 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Wheel hub component check 209 . . . . . . . . . . . . .
REPLACINGTHE WHEEL HUBBOLTS 210 . . . . . .
- Wheel hub reassembly 210 . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CARRIER REMOVAL 212 . . . . . . . . .
- Caseremoval 212 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Differential housingremoval 218 . . . . . . . . . . . . . .
- Checkingthedifferential components 219 . . . . . . .
- Refittingthedifferential housing 219 . . . . . . . . . . . .
ASSEMBLINGDIFFERENTIAL CARRIER 221 . . . . . . .
- Calculatingbevel pinionpositionin
differential carrier 221 . . . . . . . . . . . . . . . . . . . . . . .
EXAMPLES 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjust the limit switchof thedifferential
interaxlelockcontrol pin 225 . . . . . . . . . . . . . . . . .
- Adjustingdriveinput shaft bearingend float 226 . . .
ADJUSTING THECAPSPREAD 227 . . . . . . . . . . . . .
CORRECTING THEBEVEL GEARPAIR
CONTACTS(AFTER FITTING IN PLACE) 230 . .
Base- November 2006
Print 603.93.641
Page
REMOVAL-OVERHAUL-REFITTING OF
INTERAXLESHAFT 233 . . . . . . . . . . . . . . . . . . . .
- Adjustment of interaxleshaft bearing
endplay 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The intermediate axleis of the full-floating, single-reduction
type and consists of a steel case housing the inter-axle
differential andthemain differential.
Driveistransmittedfromtheinter-axledifferential tothemain
differential bymeansof two helical gears.
The rear axle is fitted with an air-controlled differential lock
device.
Wheel hubsaremountedontwotaperrollerbearingsfloating
onthesleeveandadjustedbymeansof athreaded nut.
Brakesare of thedrumDUO-DUPLEX type.
Figure1
107467
Print 603.93.641
Base- November 2006
DESCRIPTION
Base- November 2006
Print 603.93.641
LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
Theplates contain all informationanddetailsrelatingto either DIFFERENTIALUNIT and REARAXLE.
Onreal axle, two platesarepresent: oneonthedifferential unit andone insamepositiononrear axlebox. On thenotifications
ofinterventionsunder guarantee,rear axleboxanddifferential unitplatedatamustalwaysbeshown.Itissuggestedalwaystoread
andcopyout showndatabeforeanyrepair soastoorder correct sparepartsandtransmit correct informationto either IVECO
ServiceNetwork.
Plateis never to be removedfromthe unit.
Figure2
IVECO identification plate
A = identifiesrear axletype
B = drawingnumber
C = productionprogressivenumber
ARVINMERITORidentificationplate
A = identifiesthefamilytheitemisbelongingto / the
model
B = drawingnumber
C = ArvinMeritor seriesnumber
D = rear axle ratio
E = productiondate
86620
Print 603.93.641
Base- November 2006
MAIN DATA
Axletype: MT23-155/2D
Full-floating, single reduction with
air-controlled differential lock
device
DIFFERENTIAL
Final bevel gear ratio (number
of teeth: pinion/crownwheel)
Standard onmodels:
4.50(8/36) - 4.13 (8/33) - 3.78(9/34) - 3.40 (10/34)
Bevel drivepinionbearings 2taper roller
Bevel drive pinion bearing rolling
torque
Nm
Newbearings
kgm
Nm
Used bearings
kgm
2.30 7.40
0.23 0.74
3.00 5.30
0.30 0.53
Bearingdrivepinionpreloading
adjustment
byshims
Shimthicknessrangeor bevel
pinionbearingpreloading
adjustment
-
Newbearings
mm
Used bearings
mm
Bevel drive
pinion
bearingroll-
ingtorque
0.20 0.46
0.30
Base- November 2006
Print 603.93.641
Bevel pinionto crownwheel
endplayadjustment
Byringnuts
Capdivergency 0.05 0.23
Differential carrier bearing
rollingtorque Nm
kgm
1.7 3.9
0.17 0.39
Capdivergencyadjustment Byringnuts
Rollingtorquebetweenplanetary
gear anddifferential gears Nm
kgm
-
Bevel drivepinionsettingasto
differential carrier
Byshims
Thickness range for shims located
betweenintermediatebearingring
and differential carrier
-
INTER-AXLE DIFFERENTIAL UNIT
Inter-axledifferential bearings 2, taper roller
Inter-axledifferential bearing
endplay mm
0.05 0.20
Endplayadjustment Byshims
Inter-axle differential bearing shim
thicknessrange mm -
WHEEL HUBS
Wheel hub bearings Two of typeUNIT - BEARING
Wheel hub bearingend play
adjustment
Not adjustable
Torquetighteningbythreadednut
Rear axleoil
Quantity:
air suspensionlitres (kg)
TUTELA W140/M-DA
20(18)
Print 603.93.641
Base- November 2006
TIGHTENING TORQUES
PART
TORQUE
PART
Nm kgm
1 Pinionnut 1220 2035 122 203
2 Pinioncover cheese-headed screw 40 70 4 7
3 Driveinput shaft cover cylindrical-headedbolt 75 95 7.5 9.5
4 Motion input shaft nut 1200 1400 120 140
5 Sensor switch locknut 35 45 3.5 4.5
6 Pressurescrewnut 270 335 27 33.5
7 Longitudinal clamp cover cheese-headed screw 15 25 1.5 2.5
8 Differential longitudinal clamp piston 180 220 18 22
9 Adjustingscrew 55 75 5.5 7.5
10 Half-cap fasteningcheese-headed screw 650 810 65 81
11 Differential cover cheese-headedscrew 15 25 1.5 2.5
12 Cover cheese-headedscrew 520 540 52 54
13 Differential casingcheese-headedscrew 460 480 46 48
- Differential lock switch 30 50 3 5
Figure3
107466
Figure4
115272
Base- November 2006
Print 603.93.641
TIGHTENING TORQUES
PART TORQUE
Nm kgm
1 Screwfixingdrum 42to 67 4.2to 6.7
2 Screwfixingdriveshaft flange 235 to 289 23.5to 28.9
3 Ringnut for wheel hub bearings 834 to 1030 83.4to 103
4 Nut for screwfixingbrakemount 275 to 304 27.5to 30.4
D Screwfixingspeed sensor mount 5to 7 0.5to 0.7
: Spread withsealant typeIVECO 1905685 (LOCTITE14780)
D Spread LOCTITE245onthethread
A = TIMKEN bearing
B = SKF bearing
Print 603.93.641
Base- November 2006
TOOLS
99305121 Heater
99322205 Rotarystandfor overhaulingassemblies
(capacity1000daN, torque 120daNm)
99322215
Stand for axleoverhauling
99322225
Unit holder (to bemountedonstand 99322205)
99341003
Single-actinglift
99341017 Pair of brackets withholes
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99345053 Reactionblock for puller tools
99348001 Puller tool with clampingdevice
99355025 Wrenchfor differential gearcasebearingadjustment ringnuts
99355069
Wrench(75mm) for differential bevel pinion nut
99355131 Wrench(55mm) forthenutofthedriveinput flangeofthetransfer
box (usewith99370317)
Print 603.93.641
Base- November 2006
99355180 Wrench(105mm) for wheel hub bearingadjustment nut
99370005 Hand-grip for interchangeabledrift punches
99370007 Hand-grip for interchangeabledrift punches
99370317 Reactionlever and extensionfor flangelock
99370509
Hookto removedifferential gearcasehalf-housing
99370616
Support toremove-fit backdifferential
Base- November 2006
Print 603.93.641
99370617
Universal support to remove-fit backrear axles
99370700
Guideto assemblewheel hub
99370706 Tool to fit wheel hubbearing
99370708 Tool for removingwheel hub bearing
99371047
Standto holddifferential half-housingwhentighteningcrown
wheel screws(to beused with99322205 - 993222225)
99374093
Drift punchfor installationof bearingouter races (91 134) (usewith
99370007)
Print 603.93.641
Base- November 2006
99374094
Drift punchfor installationof bearingouter races(134 215) (usewith
99370007)
99374163
Installer, transfer caseoutput shaft seal
99381125 Pliersfor removal ofcirclips ontransfer boxshaft
99389816 + toooo o|t|||o, .|t| sooao cooooct|oo, 3/+' |o,
+' oot (a|o toooo 2+5 |).
99389819
Toooo .ooc| (0 - +0 |) .|t| +/+' sooao |tt|o
99395026
Tool for measuring hub rolling drag torque (use with torque
wrench)
Base- November 2006
Print 603.93.641
99395603
Dial gauge (0 5mm)
Thischapter showstechnical constructiondrawingsof thespecial purposetools (S.P. 2373) usedto servicethe axledescribed
inthissection. Thesemaybebuilt bytherepair workshops.
Print 603.93.641
Base- November 2006
EXPERIMENTAL TOOLS
49205
112513
49206
49207
Figure5
Figure6
Figure7
Figure8
Put the rear axle (1) on theoverhaul stand99322215(2).
Put acontainer under thewheel hubto collect theoil.
Lock rotation of the wheel hub (2) with the retainingtool
99370317(3).
Undothescrewsfixingthedriveshaft (4) with thewrench(1).
Takethe driveshaft (1) out ofthewheel hub(2).
Usinganappropriatetool, straightenthebendingonthering
nut (2) preventingit fromunscrewing.
Using the wrench 99355180 (1), unscrew the ring nut (2)
lockingthewheel hubbearing.Takeout theretainingring(3).
Undothescrews(4),screwreactionscrewsintothethreaded
holes(6) inorder to extract thebrakedrum(5).
Removal
525030 OVERHAULING THE WHEEL
HUBS
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Print 603.93.641
525010 INTERMEDIATE REAR AXLE
ASSEMBLY OVERHAUL
49208
49209
49210
Figure9
Figure10
Figure11
Screw tool 99370700 (1) onto the sleeve and extract the
wheel hub (2). This operation is carried out byhand, since
bearingsfloat onthesleeve.
Thephonicwheel (1) isonlyremovedifit hastobereplaced.
To removeit, useasuitablelever.
Usingthesuitabletool 99370708(1) andavice, extract the
bearing(2), alongwith therelatedadjustment ring(3).
Wheel hub component check
Tool 99370700(1) isusedto safeguardthesleeve
thread.
Carefully clean all wheel hub components. Inspect
half-shafts, makingsuretheyarenot warped.
Inspect wheel clamping bolts: if the thread is
damaged, replacethem. To extract the bolts, use a
vice.
Thebearingrotationmust befreeandsmooth.
Inspectthethreadsofwheel hubbearingadjustment
nutsandaxlecasingends;ifneeded,replacethenuts.
Replace all sealingelementswithnew ones.
NOTE
Print 603.93.641
Base- November 2006
49211
90038
49213
49214
Figure12
Figure13
Figure14
Figure15
Before replacingwheel hub bolts (3) with new ones, make
surethebolt headsupportingsurfaceisfreefromslags, burrs
or nicks.
Insert the new bolts byapplyinga load on their heads not
exceeding2,500Kg.
After insertingthebolts, makesuretheyfit completely.
Beforereplacingthewheelhubcap(2,Figure12),applyalayer
ofputtyhaving40to240 C heatresistancetothecapcontact
surfaceand hubhousing.
Toreassemblethephonicwheel (1, Figure12), pre-heat the
wheel to150 C;whenthephonicwheel hasbeenfitted,make
sureit is perfectlyrested onthehubhousing.
Put the bearing(2) on the wheel hub (3) with the seal (4)
positionedasshowninthefigure.
Fit thebearing(2) usingapressandtool 99370706(1).
Makesurethebearingisproperlyinsertedwiththewheel hub
shoulder.
Screw tool 99370700 (1) on the sleeve and assemble the
wheel hub (2), complete with bearing. Remove tool
99370700(1) andplacetheseal ring(3),insertingthetabinto
thesleeveslot, thenscrewtheringnut (4).
Usingwrench99355180(1),multiplier(2) andtorquewrench
(3),tightentheringnut(4,Figure14) totheprescribedtorque
(834to 1030 Nm).
Wheel hub reassembly
The forcefor drivinginthebearingwith thepress
hasto be40,000 to 100,000N.
NOTE
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525035 REPLACING THE WHEEL HUB
BOLTS
49216
Usingafit tool keythespacerring(5,Figure18)andcheckthat
aplayof 0 0.145 mmbetween wheel hub outer sideand
spacer side, makingtwo measuresat 180.
Lockthewheel hubwith tool 99370317(7).
Fitthedrum(1)tothewheel hub(6)andfastenit bytightening
thescrews(2) to theprescribed torque.
Applysealant IVECO 1905685 (LOCTITE 14780) to both
half-shaft flangeand wheel hubcontact surfaces.
Fit thescrews(3) fasteningthehalf-shaft (5) tothewheel hub
(6) andtightenthemwithtorquewrench(4)totheprescribed
torque.
After theseoperations,replenishtheaxlehousingwithoil up
to theright level.
49213A
Aftertightening,usinganappropriatetool,notchandbendthe
ringnut asshown so it cannot beunscrewed.
Thearrowshowsthedirection of unscrewingtheringnut.
Figure16 Figure17
49217A
WHEEL HUBCOMPONENTS
1. Screw - 2. Half-shaft - 3. Ringnut - 4. Safetyring- 5. Spacer ring- 6. Bearing- 7. Wheel hub -
8. Wheel hub cap- 9. Brake drum- 10. Axlesleeve
Figure18
Print 603.93.641
Base- November 2006
Figure19
Figure20
Figure21
Figure22
Figure23
Figure24
Case removal
Slackenthedifferential carrier (1) fasteningscrews; withdraw
thecasingfromtherear axleusingmetal eyeletsand cables.
Toremovethedifferential carrier withtherearaxle
fitted onthevehicle, usesupport 99370616.
NOTE
112446
Remove the differential clamp warningswitch (1) to fit the
carrier on thestand.
112447
Put thedifferential carrier (1) ontherotatingstand99322205
(2) together withthesupport 99322225 (3).
112448
Removethedifferential clampcover (2) fasteningscrews(1).
Takeoff thecover andthegasket.
112449
Removethepiston(1) andthe stem(2).
36372
Useapunchto takebackthefork (2) elastic pins (1) so that
thefork canbereleased fromthesleeve(3).
Removethesleeve(3) fromthecarrier.
112445
Base- November 2006
Print 603.93.641
526210 DIFFERENTIAL CARRIER REMOVAL
Figure25
Figure26
Figure27
Figure28
Figure29
112451
Press andremovethespring(1), then takeoff thefork(2).
112452
Removetheseal ring(2),thespacerfittedbelowandthecollar
(1).
112453
Clean and check the status of all differential lock assembly
parts.
112454
Removethesplit pin(1) andtheelasticpin(4).
Mark withapunchthecaps(2) andthecaseto facilitatethe
assembly.
Slackentheringnuts(3) with tool 99355025.
Removethecaps(2) and theringnuts (5).
36374
Usethesuitablehook to remove the differential housing(1)
withtheringbevel gear andthesupport bearings.
1. Plunger - 2. Stem- 3. Differential lockingswitch -
4. Spring- 5. Sleeve - 6. Cover
Print 603.93.641
Base- November 2006
Figure30
Figure31
Figure32
Figure33
Figure34
Figure35
112456
Removedentingof nut checkingflange(1).
Stop theflangerotation (1) throughtool 99370317 (2); use
wrench 99355069 (3) and themultiplier (4) to slackenthe
flangeretainingnut (1).
Removethemotioninput shaft flange (1).
112457
Takeoff the screws (1) and removethemotion input shaft
cover (2).
112458
Removetheshims(1).
112459
Removethebearing(2) outer ringfromthecover (1) of the
motion input shaft throughthepuller (3), if needed.
112460
Mark thelongitudinal clampcover (1) assemblypositionand
takeit off byslackeningthefasteningscrews(2).
112461
Removethecontrol piston(1),thediaphragmseat(2) andthe
springbelowit.
Base- November 2006
Print 603.93.641
Figure36
Figure37
Figure38
Figure39
Carefullyremove themotion input shaft assembly(1).
112463
Takeoff thefork(1) and thesleeve(2).
112464
Removethebearing(3).
Mark thegear (1,2) assemblyposition.
Removethetworollercages(3) andthespacer (4) fromthe
gear (2).
Removethehelical-toothgear (1).
112466
Removethecrown wheel andplanetarygear unit (2).
Removetherear gear (1) with thebearing.
112462
Figure40
112467
Turnthedifferential case(1) anduseabeater toremovethe
rear bearingouter ring(2), ifneeded.
Print 603.93.641
Base- November 2006
Figure41
Figure42
Figure43
Figure44
Fit thetwo spacers (4) belowthegear (3).
Underthepress,pull out theconicpinion(6) andtakeoffthe
bearing(1),theadjustingring(2), thegear (3) andthespacer
(5) fromtheconicpinion.
112468
Removethecover (2) of theconicpinion.
77237
Stop the conic pinion rotation with tool S.P.2373 (1); use
wrench99355069 (2) andthemultiplier (3) to removethe
bearingretainingnut(1,Figure41)ontheconicpinionandthe
washer below.
112470
112471
Useadrift toremoveouterraces(1) and(2) withtheirshims.
36381
Figure45
Placetool 99348001(2) underthetaperrollerbearing(1) and
pull it off thebevel pinion(3) usingapress.
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Print 603.93.641
112472
Figure46
INTER-AXLEDIFFERENTIAL COMPONENTS- EXPLODED VIEW
Print 603.93.641
Base- November 2006
19379
112475
36317
112476
19383
Figure47
Figure48
Figure49
Figure50
Figure51
Usethesuitablehook(1) tolift thewholedifferential housing
(2) and put it onthesupportingbase 99371047(3).
Usetool 99348001(1) andthereactionblock99345055(2)
to pull out bearing(3) and bearing(4).
Mark the ring gear and the differential housing position as
showninthefigure.
Removetheringgear (3) fasteningscrews(1, 2).
Turnthe caseandremovethe ringgear (3).
Removethehalf-casefasteningscrews(1).
Turnthe case.
Mark thetwo half-cases(2and 3) andthecrossasshownin
thefigure.
Split thehalf-cases.
Removethecrownwheel (2) and theoffsettingwasher (1).
Removethecross(6) withthefourplanetarygears(5) andthe
shoulder washer (3); stripthecross-planetarygear unit.
Remove the other planetarygear and the shoulder washer
fromthehalf-case(4).
Base- November 2006
Print 603.93.641
Differential housing removal
112478
112479
112480
Figure52
Figure53
Figure54
Carefullycleanthedifferential components.
Lubricate the bearings and rotate the roller cage freely: the
rotationmust beregular with no stiffness.
Checkthecontact surfacesofthebevel gearandthestopplate
of the half-box to ensure that the crown wheel adheres
properly. Any deformation of these surfaces will cause the
vibration of the fastening screws jeopardising the unit
functioning.
Fit theshoulder washer (1) and theplanetarygear (2) in the
half-case.
Assemble the pinions (1) and the fit the assembly in the
half-case.
Checking the differential components
Carefullycleanscrew, stud and ringnut threadsto
ensure proper adjustments and exact tightening
torque.
Checkthat thesplinedsectionfor theflangeconnectiononto
thepinionisnot worn. If it isreplacethepinion.
Check the planetary gears and their shoulder washers, the
spider and thecrownwheelswiththeir shoulder washers.
All sealingelements, the adjustment ringnut clip and safety
washersmust bereplacedwith new ones.
Ifit isnecessaryto replacethecrownor thepinion,
bothelementsmustbechangedastheyaresupplied
inpairs.
Refitting the differential housing
NOTE
NOTE
Fit theshoulder washer (2) andtheplanetarygear (1) onthe
If the assemblyhas not been previouslymounted,
make surethat thepinionsareinstalledcorrectly.
NOTE
Print 603.93.641
Base- November 2006
112482
112483
Figure55
Figure56
Heat theringgear insideanair-circulationovenat 100 C for
+5' aoo |t |t |o t|o soat oo t|o o|ooot|a| |oos|o, a'|o soo
that the holes for the fastening screws of the ring
gear-differential housingcoincide.
After theringgearhascooleddown,fit thescrewsandtighten
the self-locking nuts (1) with the torque wrench to the
prescribedtorque.
Heatthebearings(1,3) insideanair-circulationovenat100 C
o +5' aoo |t t|o |o t|o o|ooot|a| |oos|o b oaos o t|o
suitablebeater (3).
It is advisable to replace the screws (1) with new
ones.
NOTE
112481
Figure57
Lock the differential with the suitable tool; then fit it in the
half-case. Make surethat themarks madeat removal match.
/| soo oos o '|CCT|T| 20' oo t|o sco. t|oao|o
(1). Tighten thescrews(1) to theprescribedtorque.
It is advisable to replace the screws (1) with new
ones.
NOTE
Base- November 2006
Print 603.93.641
5. Pinion/crownwheel set manufacturingandinspection
monthand year.
6. Specified pinion/crownwheel set clearance.
Part number andtoothcombinationnumberarestampedon
threaded end of all pinions. Number may alternatively be
located on outer diameter of crown wheel. On any
pinion/crownwheel set,crownwheel will alwaysbearaneven
stamped category number (e.g. 36786), whereas
correspondingpinionwill bear an odd number (e.g. 36787).
Todeterminethethicknessoftheshimpacktobeinterposed
between bearing cage and differential carrier proceed as
follows
1. Measurethethicknessoftheshimpackremovedwith
theoldfinal drivegear set.Useamicrometer or other
suitablegaugeand recordthevalue found.
Everycrownwheel ismarkedwithavariationnumber which
indicatesthenominal assemblydistance. Usethisnumber to
calculate the thickness of the shim pack that is interposed
betweenpinionbearingcageanddifferential carrier.
Thisnumber,expressedinmm,(e.g. P.C. +0.1orP.C. - 0.1)
ismarked ontheexternal part of the ringgear.
Ifanewfinal driveset isinstalled, it will benecessaryto know
themeaningof the markings on pinion and crown wheel in
order to positionthepinioncorrectly.
1. Part number
2. Toothcombinationnumber.
Thisnumber (example: 12/41) indicatesthat thepinion
has12 teeth andthecrown wheel 41.
3. Pinion/crownwheel pair set number.
All final drivesetsare availableaspairs: thereforepinion
andcrownwheel bearthesamenumberwhichisstamped
onheadend for pinions andtheouter facefor crown
wheels.
The difference between old pack and new pack
thickness values must be added or subtracted -
dependingon cases - to or fromthe adjustingring
thickness(4, Figure59).
4. Variation number neededto determinethethicknessof
the shimpackinterposed betweenpinionbearingcage
anddifferential carrier(intheexamplebelow,thisnumber
isidentifiedasCP).
Figure58
19416
1,2
3
1,2,3
1,2,3,4,5,6
!
Neveruseapinionandcrownwheel set unlessboth
components have thesamenumber.
2. ReadtheCP markedonpinionto bereplaced:ifit isa
plus(+) number or aminus(-) number respectively
subtract or addit fromthevalueobtained under 1.
above.
Takenoteof theresult
Thevalueobtainedin2.will beusedtocalculatethe
thickness of the shimto be interposed between
pinion bearing cage and differential carrier for
correct newfinal driveassembly.
3. Read theCPmarkedon thenewpinion.
Either addor subtract thisvalue - dependingon
whether thesignisaplusoraminus - to orfromthe
valuenotedunder 2. above.
Theresultindicatesthethicknesswhichthenewshim
packshouldhave.
Refer tothefollowingexampleswhichcover all thepossible
calculationcases
EXAMPLES
OPTION
NOTE
NOTE
Print 603.93.641
Base- November 2006
ASSEMBLING DIFFERENTIAL CARRIER
Calculating bevel pinion positionin differential
carrier
Case1: mm
Original shimpackthickness 0.76
CP markedonpinion +0.05 +0.05
Resultingvalue 0,81
CP markedonnewpinion +0.12 - 0.12
Thicknessfor newshimpack 0.69
Case2:
CP markedonpinion - 0.05 - 0.05
Resultingvalue 0.71
CP markedonnewpinion +0.12 - 0.12
Case3:
CP markedonpinion +0.05 +0.05
Resultingvalue 0.81
CP markedonnewpinion - 0.12 +0.12
Case4:
CP markedonpinion - 0.05 - 0.05
Resultingvalue 0.71
CP markedonnewpinion - 0.12 +0.12
Arrange shimpack (4) for adjustingbevel pinion position in
carrier; then fit bevel pinion bearing cup (3) using handle
99370007(1) anddrift 99374093(2).
Fit theremainingouter rings usingbeaters99374093/94.
36383
112486
112485
36387
Figure59
Figure60
Figure61
Figure62
Figure63
Heat thebearing(2) to100 C for 15minutesandinstall it on
bevel pinion(1) usingadrift.
Tightenretainingnutbevel pinionusingwrench99355069(2).
Removetools99341004 and99341008.
Applytorque wrench (1) to bevel pinion retaining nut and
checkthat rollingtorqueis:
- 2.30 7.40Nmwith new bearings,
- 3.00 5.30Nmwith used bearing.
In case of a different reading, replace adjusting ring (2,
Figure62) with a thinner one if reading is higher than the
specified figureandwith athicker oneif thereadingis lower
thanthespecifiedfigure.
112487
Block the rear axle position with tools 99341004 and
99341008.
Fit theadjustingring(2).
Heat thebearing(3) at 100C o +5' aoo |t |t oo t|o |o|oo.
Insert thewasher (4) and theretainingnut (5).
Insert bevel pinion(2) incarrierandsplinespacer (3) andgear
(4) onit at thesametime.
Mount reactionblock(1) under pinion.
Drivegear (4) under press(5)
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Print 603.93.641
112489
112493
112466
112494
112495
Figure64
Figure65
Figure66
Figure67
Figure68
Applyalayer of sealer on the pinion cover and the
screws. Fasten thecover bytighteningthescrewsto
| ov|oos| oovoo, |oat t|o boa|o (2) at +00C o +5'
and fit it withthesuitablebeater ontherear gear (1).
Fit therear gear (1) andthecrownwheel andplanetarygear
unit (2) inthecase.
Fit the gear (1) makingsure that it matches with the marks
madeat removal.
Fit thespacer (1) and theroller cages(2).
oat t|oboa|o (2) at +00C o +5' aoo |t |t .|t| t|o so|tab|o
beater on themotion input shaft (1).
Print 603.93.641
Base- November 2006
112496
112498
112497
112499
112500
Figure69
Figure70
Figure71
Figure72
Figure73
Fit thecompression spring(1).
Fit themembraneseat (1).
Fit thefork(1).
Applysomesealeronthepistonthreading(1).Insertthepiston
through the forkand thecompressionspring. Tighten to the
prescribedtorque.
Insert thesleeve(2) inthefork (1).
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Print 603.93.641
112501
112462
112502
112504
112457
Figure74
Figure75
Figure76
Figure77
Figure78
Fit thecover (1) and the membranelocated below. Tighten
to theprescribed torque.
Fit thecover makingsurethat it matches with the
marksmadeat removal.
NOTE
Spread somevaselineas shownin the figure.
Fit theroller bearing(1).
Fit themotioninput shaft assembly (1) inthecase.
Adjust the limit switch of the
differential interaxle lock control pin
Adjust thelimit switchofthecontrol pinas follows:
- fill thecylinder (3) with8-bar compressed air;
- tightenthescrew(1) until it comesintocontact withthe
control pin;
- further tighten thescrew (1) by1/4 1/2 turnand lock
thestopnut (2) to theprescribed torque.
Fit thespacers(1, Figure 32) takenoff at removal.
Fit thecover (2) tighteningonly4screws(1) totheprescribed
torque.
Print 603.93.641
Base- November 2006
112506
112507
112505
Figure79
Figure80
Figure81
Figure82
Fit theflange(2).
Tightentheretainingnut (1) totheprescribedtorque.
Bruisetheretainingnut (1) asshownin thefigure.
Adjusting drive input shaft bearing end float
Proceedasfollows toadjust shaft bearingend play;
- turnthemotioninput shaft inthetwodirectionstoadjust
thebearing;
- fit adial gauge (3) and set to zero on the motion input
shaft end;
- useabar (1) andasupport,if needed,tolever andcheck
that theendplayoftheinput shaftisbetween0.01 0.09
mm. If the endplayis not includedin thisrange, add or
remove the shims (1 Figure 32) from the package
previouslyinsertedto obtaintherequiredplay;
- Tightenall thecoverscrews(2) totheprescribedtorque.
19419
Usingtheproper hook(1) lift thepreviouslyassembled gear
housing(2) andset it on thedifferential carrier (3).
Base- November 2006
Print 603.93.641
36330
36331
Fit thecaps(2), tightenthescrews(1) andthewasherstothe
prescribedtorque.
Greasethetaperroller bearings(1) andset theouterringson
them.
Screwtheadjustment ringnuts (2).
Figure83
Figure84
ADJUSTING THE CAP SPREAD
Capspreadadjustmentandcheckcanbeperformedwithtwo
methods:
1
st
METHOD
1. Tighten bearingadjustingringnuts(4) bywrench
99355025(3, Figure86) until removingthegapbetween
pinion-crownandaxle,ensurealso that thecrownisnot
forcingonpinion;
2. useaproper micrometer, set diagonallyand centred on
points(X-Y-arrows, Figure85), to measureandmark
cap distance;
2
nd
METHOD
A. Setdiagonallyandcentredontheexternal machinedseats
ofbothcaps(2,Figure86),twomagneticbasegauges(1)
asshownin Figure 86.
Figure85
3. retighten the two adjusting ring nuts (4, Figure86) to
obtainacap angle (2, Figure86),measuredasdescribed
in point 2, of 0.15 - 0 33 mmwhich corresponds to a
bearingpreload of 1.7 - 3.9 Nm(0.17 - 0.39 kgm).
60636
B. proceed as described inpoint 1;
C. removetheendplay,retightenthetwoadjustingringnuts
(4,Figure86) toobtainacapangle (2) of 0.05- 0.23mm
which corresponds to sumof the values read on the
gauges(1)
Figure86
60635
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Base- November 2006
Adjust the end playbetween pinion-crown wheel teeth to
obtain:
- 0.20to 0.46mmfor alreadyusedunits;
- 0.3mmfor newunits
and proceed as follows:
- lock bevel pinionrotationusingtool 99370317;
- positionthegaugewithmagneticbase(1) asshowninthe
figure;
- usingwrench99355025(3),loosentheadjustingringnut
on thecrownside andtighten bythesameamount the
adjusting ring nut (2) on the opposite side. Takingthis
precaution the cap angle that has been previously
adjusted is maintained;
- proceedasdescribeduntil obtainingtheprescribedvalue.
Theend playvalueshall becheckedon4 equidistant points.
49248
49246
19451
Figure87
Figure88
Figure89
Using abrush apply athin coatingof Prussian blue on the
crownwheel.
Turnthepinionandfindthecontact markbetweenthepinion
teethand thecrownwheel teeth.
The following figures show the possible contact points and
howto correct anyerrors.
Usingagaugewithmagneticstand (1) checkwhether crown
surging is not exceeding 0.20 mm, otherwise remove the
differential unit and findthecause.
Re-assemble and repeat previously described adjustment
operations.
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19453
19454
Figure90
Figure91
Contactsareexcessivelysettowardscrownwheelteethcrest.
Conditions A-B. The pinion is too far out and therefore it
requiresfurther adjustment.
To adjust theexact pinion position, shimsmust beremoved
fromunder the pinionsupport to obtain anexact contact.
ConditionA. After removingtheshims takeendplayto the
maximumvalue
Condition B. Measure the end play and restore after
removingtheshims.
Endplayreduction
Endplayincrease
1 Release, toothconcaveside
2 Tip
3 Driving, toothconvexside
4 Heel
ConditionE-F.
DRIVING.Central,tendingtowardsthetipontoothfaceand
central ontoothcontour.
RELEASE.Central,tendingtowardstheheelontoothfaceand
central ontoothcontour.
Thepinionispositionedexactly.
Contact position can be modified by changing the
pinion-crownend play.
ConditionE. Reducethe end play.
ConditionF. Increasetheendplay.
19452
Contacts areexcessivelyset oncrown wheel teeth bottom
land.
Conditions C-D. Thepinionistoodeeplyset andtherefore
it requiresfurther adjustment.
To adjust the exact pinion position, shims must be added
under thepinion support toobtainan exact contact.
ConditionC. Measuretheend playandrestoreafter adding
theshims.
Condition D. After adding the shims take end play to the
minimumvalue.
Figure92
THEORETICAL CONTACT AREA
1
2
3
4
Print 603.93.641
Base- November 2006
Figure93
THEORETICAL CONTACTS
60676
DRIVING
(CROWN WHEEL CONVEX SIDE)
CREST
RELEASE
(CROWN WHEEL CONCAVESIDE)
CREST
HEEL TIP HEEL
HEEL TIP HEEL
HEEL TIP HEEL
HEEL TIP HEEL
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
- DRIVING : CENTRAL,TENDINGTOWARDSTHETIPON TOOTH FACEANDCENTRALON TOOTHCONTOUR.
- RELEASE : CENTRAL, TENDING TOWARDS THE HEEL ON TOOTH FACE AND CENTRAL ON TOOTH
CONTOUR.
CONDITION A
DRIVING
CREST
RELEASE
CREST
- DRIVING- RELEASE : EXCESSIVECONTACTSTO CREST
- DRIVING : EXCESSIVECONTACT TO TIP
- RELEASE: EXCESSIVE : CONTACT TO HEEL
- CORRECTIVE ACTIONS : REMOVESHIMSANDINCREASE END PLAY TO MAX.
CONDITION B
CREST CREST
- DRIVING- RELEASE : EXCESSIVECONTACTSTO CREST
- CORRECTIVEACTIONS : MEASURE THEENDPLAY, REMOVESHIMSANDRESTOREEND PLAY
CONDITION C
CREST CREST
- DRIVING- RELEASE : EXCESSIVECONTACTSTO BOTTOMLAND
- CORRECTIVE ACTIONS : MEASURE THEENDPLAY, ADD SHIMSAND RESTOREENDPLAY
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CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)
Figure94
CONDITION D
60677
CREST CREST
HEEL TIP HEEL
HEEL TIP HEEL
HEEL TIP
HEEL
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
- DRIVING- RELEASE : EXCESSIVECONTACTSTO BOTTOMLAND
- DRIVING : EXCESSIVECONTACT TO HEEL
- RELEASE : EXCESSIVECONTACT TO TIP
- CORRECTIVEACTIONS : ADDSHIMSAND REDUCEENDPLAY TO MIN.
CONDITION E
- DRIVING : EXCESSIVECONTACT TO HEEL
- RELEASE : EXCESSIVECONTACT TO TIP
- CORRECTIVEACTIONS : REDUCEENDPLAY
CONDITION F
- DRIVING : EXCESSIVECONTACT TO TIP
- RELEASE : EXCESSIVECONTACT TO HEEL
- CORRECTIVEACTIONS : INCREASEENDPLAY
Note: |o caso o |o|oos |ttoo .|t|oot ||ot boa|o |ostoao o 'oov|o s||s' |t .||| bo oocossa to'aoo s|| s' aoo v|co vosa.
For theendplay, thesameconditionsshownstandvalid.
Contact marks arealwaysreferredto crownwheel teeth.
CREST CREST
CREST CREST
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112509
36335
77248
36782
112449
112511
Figure95
Figure96
Figure97
Figure98
Figure99
Figure100
Fit theseal ring(1) andthespacer below.
Fit theelasticpin(1) andthesplit pin(3) tolocktheringnuts
(2-4).
Fit thestem(2) andthepiston(1).
Fit thecover (1) as shownin thefigurewithanewgasket.
Tightenthescrews(2) to theprescribed torque.
Fit theslidingsleeve (2) onthefork(1) anddriveinthetwo
springpins.
Positiontheforkincludingtheslidingsleeveinto its seat.
Insert thereturnspring(2) andtheplainwasher (1).
Iftheelasticpinorthesplit pindo not coincidewith
therespectiveseatsontheringnuts,slightlyturnthe
ringnuts so that theelasticpinor the split pin can
befitted.
NOTE
Useanewo-ring. NOTE
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112512
112450
112469
Figure101
Figure102
Figure103
Figure104
Fill thecylinder (seearrow) with8-bar pressure.
Applysomesealer onthedifferential clampingswitch(1) and
fit it initsseat.
Connect amultimetretothedifferential clampingswitchand
tightentheswitchuntil theytouch.
Further tightenit byone turnand closewiththelocknut to
Removethedifferential casefromthestandandrefit it onthe
rear axlecase.
526082 REMOVAL-OVERHAUL-REFITTING
OF INTERAXLE SHAFT
INTERAXLESHAFT COMPONENTS
1. Nut - 2. Flange- 3. Seal ring- 4. Spacer ring-
5. Bearingouter ring- 6. Motionoutput shaft bearings -
7. Bearingouter ring- 8. Motionoutput shaft -
9. Rear axlecase
Stop rotationof flange (1) with retainer 99370317(3). With
wrench 99355131 (2) and torque adaptor (4) loosen shaft
flange (1) retainingnut.
Usealever and thesuitablebeater to removetheflange (1).
Removeand throwawaytheseal ring(3, Figure102).
Removethesnapringfromtheinteraxleshaft (4, Figure102).
112455
Pullouttheinteraxleshaft(4) togetherwiththebearings(2and
3) andtheouter ring(1).
Use asuitable extractor to removebearings (2 and 3) from
interaxle shaft (4).
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112473
36346
Figure105
Figure106
Reverse the removal operationsequence to reassemble the
interaxle shaft unit.
Afterfittingsealingring(3),useafeelergaugetocheckdistance
X betweensealingring(3) and mountingat four equi-distant
points. DistanceX must bebetween 0.38 0.76mm.
Tightennut (2) fasteningflange(1) tothedriveoutput shaftto
the specified torque. Then check that end play is between
0.025 and 0.127 mm using a magnetic stand dial gauge
positionedon shaft (4, Figure104) .
If reading is other than specified, replace the snap ring (4,
Figure102) withoneof thecorrect thickness.
Turnby90 axlecasing.
Set support (1) into axlecasingcomprisinginteraxleshaft (2)
and tightenfixingnuts to therequiredtorque.
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Adjustment of interaxle shaft bearing
end play
235 TRAKKER EURO 4/5 AXLESINTANDEM (REAR)
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5250 Rear axles
ARVINMERITOR MR11-155/2D
Page
DESCRIPTION 237 . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OFDIFFERENTIAL UNIT PLATES- REAR
AXLE 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 239 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REARAXLE ASSEMBLY OVERHAUL 246 . . . . . . . . .
OVERHAULINGTHE WHEEL HUBS 246 . . . . . . . . .
REMOVING ANDREFITTING
THEDIFFERENTIAL
(WITH AXLEON STAND 99322215) 246 . . . . .
- Removal 246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingaxlehousing 246 . . . . . . . . . . . . . . . . . . .
- Refitting 246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingthedifferential 247 . . . . . . . . . . . . . . . . .
- Removingthedifferential housing 248 . . . . . . . . . .
REMOVING THEBEVEL PINION
FROMTHESUPPORT 250 . . . . . . . . . . . . . . . . . .
- Differential component check 250 . . . . . . . . . . . . .
- Fittingthedifferential housing 251 . . . . . . . . . . . . .
FITTINGTHEMOUNT ON THE
BEVEL PINION 252 . . . . . . . . . . . . . . . . . . . . . . . .
- Reassemblingthedifferential carrier 254 . . . . . . . . .
ADJUSTING THECAPGAP 256 . . . . . . . . . . . . . . . .
CORRECTING THECROWN WHEELAND
PINION CONTACTS(AFTER ASSEMBLY) 259 . .
WORKON THEVEHICLE 262 . . . . . . . . . . . . . . . . .
REPLACINGTHE BEVELPINION
MOUNT SEAL 262 . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 262 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Therear axleistheload bearingtypewithasinglereduction.
It is composed of a pressed sheet steel box appropriately
strengthened.
Thedifferential ischaracterizedbyahypoid-toothedgeartrain.
Thepinionissupportedbytwotaperedroller bearingsandby
athirdcylindrical roller bearing.
The positionof the bevel pinion, inrelation to theringbevel
gear, isadjustedbychangingthethicknessofthepackofshims
between thedifferential caseandthebevel pinionmount.
The gearingbox is supported bytwo tapered roller bearings
and canbeadjusted axiallywithtwo threadedringnuts.
Therear axle isequipped withadifferential lockingdevice.
Thebearingsof thewheel hubsaretheUNIT-BEARINGtype
withpermanent lubrication andneedno adjustment.
Brakesareof theDUO - DUPLEX drumtype.
VIEWSOFTHE ARVINMERITORMT23-155 TANDEMAXLEASSEMBLY
107468
Figure1
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Base- November 2006
DESCRIPTION
Base- November 2006
Print 603.93.641
LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
Theplates contain all informationanddetailsrelatingto either DIFFERENTIALUNIT and REARAXLE.
Onreal axle, two platesarepresent: oneonthedifferential unit andone insamepositiononrear axlebox. On thenotifications
ofinterventionsunder guarantee,rear axleboxanddifferential unitplatedatamustalwaysbeshown.Itissuggestedalwaystoread
andcopyout showndatabeforeanyrepair soastoorder correct sparepartsandtransmit correct informationto either IVECO
ServiceNetwork.
Plateis never to be removedfromthe unit.
Figure2
IVECO identification plate
A = identifiesrear axletype
B = drawingnumber
C = productionprogressivenumber
ARVINMERITORidentificationplate
A = identifiesthefamilytheitemisbelongingto / the
model
B = drawingnumber
C = ArvinMeritor seriesnumber
D = rear axle ratio
E = productiondate
86620
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MAIN DATA
Rear axle Loadbearingwithsinglereduction
Type MT 23-155
Bevel pinionbearings 2with tapered rollers and1with cylindrical rollers
DIFFERENTIAL ASSEMBLY
Bevel gear pair reductionratio 4.50(8/36) - 4.13 (8/33) - 3.78(9/34) - 3.40 (10/34)
Clearancebetweenpinion
and ringgear mm 0.26to 0.50
Adjustment of clearance
between pinionand ringgear
With adjustment rings
Bevel pinionpositioninrelation
to ringgear
With adjustment shims
Capgap mm 0.15to 0.33
Capgap adjustment With adjustment rings
Rollingtorquebetweenplanetary
gearsandcrownwheels Nm
kgm
68max.
6.8max.
Thicknessesof adjustment
ringsbetweenbevel pinion
mount and differential case mm 0.125- 0.200 - 0.500
Wobbleof ringgear supporting
surfaceon half box mm 0.13max.
WHEEL HUBS
Wheel hub bearings Two taper roller bearings
Wheel hub bearingend float
adjustment
Byringnut
Axleoil TUTELA W140/M-DA
Quantity Litres
(kg)
18.5
(16.5)
Dryweight (Mechanical suspension) kg
(Pneumaticsuspension) kg
MaximumcapacityGRW kg
586
591
11500
Figure3
84401
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0
TIGHTENING TORQUES
PART
TORQUE
PART
Nm kgm
1 Nut fixingwheels 732 to599 73.2to 59.9
2 Screwfixingdriveshaft flange 235 to 289 23.5to 28.9
3 Ringnut retainingwheel hubbearing 834 to 1030 83.4to 103
4 Screwfixingbrakediscto wheel hub 268 to 295 26.8to 29.5
5 Nut for screwfixingbrakecalliper mount 275 to 304 27.5to 30.4
6 Screwfixingbrakecalliper to mount 554 to 677 55.4to 67.7
: Spread withsealant typeIVECO 1905685 (LOCTITE14780)
A TIMKEN bearing
B SKFbearing
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Base- November 2006
TOOLS
99305121 Heater
99322205 Rotarystandfor overhaulingassemblies
(capacity1000daN, torque 120daNm)
99322215
Stand for axleoverhauling
99322225
Unit holder (to bemountedonstand 99322205)
99341003
Single-actinglift
99341009
Pair of brackets
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99341015 Clamp
99348001 Puller tool with clampingdevice
99355025 Wrenchfor differential gearcasebearingadjustment ringnuts
99355088
Wrench(60mm) for differential bevel pinion nut
99355180 Wrench(105mm) for wheel hub bearingadjustment nut
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Base- November 2006
99363204 Tool to extract gaskets
99370317 Reactionlever and extensionfor flangelock
99370509
Hookto removedifferential gearcasehalf-housing
99370616
Support toremove-fit backdifferential
99370617
Universal support to remove-fit backrear axles
99370700
Guideto assemblewheel hub
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99370706 Tool to fit wheel hubbearing
99370708 Tool for removingwheel hub bearing
99371047
Standto holddifferential half-housingwhentighteningcrown
wheel screws(to beused with99322205 - 993222225)
99374244
Installingtool for assemblingbevel pinionseal ring
99389816 + toooo o|t|||o, .|t| sooao cooooct|oo, 3/+' |o,
+' oot (a|o toooo 2+5 |).
99389819
Toooo .ooc| (0 - +0 |) .|t| +/+' sooao |tt|o
Print 603.93.641
Base- November 2006
99341017 Pair of brackets withholes
Tighteningsequencediagram(differential caseto axlehousing)
(+ 2 3 + |ots)
(+0 ++ 5 ++ +3 6 8 +2 Sco .s)
Insert the differential into theaxlehousing, screw down the
nuts(2) andscrews(3) together withthesafetywashersand
tightenthem,withatorquewrench(1),totherequiredtorque
and inthesequenceshownin Figure 8.
Fit theaxleshafts intoplace.
Pour therequiredamount of oil into theaxlehousing.
Spread the contact surface of the axle housingwithIVECO
1905685(LOCTITE14780)sealant,aftercleaningthecontact
surface.
Refitting
Set two parallels on asuitable check surface, rest the axle
housingonit,takingcaretoprotect thethreadonthesleeves
withtheringnuts.
Positionadial gaugewithamagneticbase, put therodon a
groundportionofthesleeveand,turningtheaxlehousingon
its own axis, check it has suffered no deformation, with a
maximumoscillationfor the:
- air-suspensionaxle housing 0.3mm
Removal
Takeout theaxle shafts, undo differential case(1) fastening
screws and nuts, screw down three screws (which act as
extractors in this phase) into the special threaded holes
provided, then takethedifferential off rear axlecase(2).
526210 REMOVING AND REFITTING
THE DIFFERENTIAL
(with axle on stand99322215)
49218
61509
34827
49219
49220
Figure4
Figure5
Figure6
Figure7
Figure8
Checking axle housing
Itisnecessarytocheckthealignment oftheaxlehousingsince
anydeformationwill generateabnormal strainandmakethe
assemblynoisy.
To performthe checks on the axle housing, it is
necessarytoremovethewheel hubs.
NOTE
Wheel huboverhaulingissimilarto theintermediate
axleoverhaulingdescribedon page 208.
NOTE
525030 OVERHAULING THE WHEEL HUBS
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525010 REARAXLEASSEMBLY OVERHAUL
49221
49223
49222
49224
49225
Figure9
Figure10
Figure11
Figure12
Figure13
Remove the differential (1) as describedin Figure 4.
Secure it to the stand 99322205 (3) with the mount
99322225 (2).
Unscrew the transmitter (1); unscrew the screws (2) and
oovo t|o ats 3 + 5.
Push the split pins (1 ) outwards and extract the sliding
sleeve(2).
Takeout the spring(3), fork (4) andsplit pin (5).
Unscrewtheringnut (1) for adjustingthebearing. Usingan
appropriate wrench, unscrew and remove the screws (2)
withtheir washers; repeat thisprocessontheopposite side.
Remove thesupportingbearingcaps (3).
Usingthehook99370509(1) extractthedifferential housing
(2) together with the ringbevel gear and outer rings (3).
Removing the differential
247 TRAKKEREURO 4/5 AXLESINTANDEM(REAR)
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Base- November 2006
49226
49227
49228
49229
Figure14
Figure15
Figure16
Figure17
Usingtool 99370317 (2), lock theflange(1).
Using wrench 9955088 (3) and multiplier (4), loosen the
bevel pinion nut.
Remove thenut (1) and extract the flange (2).
Removethescrews(3) fasteningthebevel pinionsupport to
thedifferential carrier (4).
Remove the complete bevel pinion support (5) fromthe
differential carrier. Remove the shims (6) for adjusting the
pinion position in relation to the crown wheel and use a
micrometer to measuretheoverall thickness.
Usingasuitablepuller (1), extract thebearing(2).
Removing the differential housing
Placethegearcaseon tool 9971047 (1).
Removethelocknuts(2) fasteningtheringbevel gear (3) to
thegearcase.
Usingabronzebeater, removetheringbevel gear.
Figure18
49228A
Turnthegearcaseupsidedownandremovethebearing(1).
(This isadestructiveoperation).
Checkthat theseal ringisintact (O-ring), changeit
if damaged.
NOTE
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49233
49234A
Figure19
Figure20
Removecomponents (2- 3 - 4- 5- 6- 7- 8- 9) fromthe
half casing(1).
DIFFERENTIAL HOUSINGCOMPONENTS
1. Half casing- 2. Half casing- 3. Crown wheel - 4. Planetarygear - 5. Spider - 6. Shoulder washer -
7. Planetarygears - 8Crown wheel - 9 Shoulder washer
Marktheassemblingpositionofthetwohalfcases(2and3) and
cross journal, to ensurecorrect matchingandre-assembling.
Removethescrews(1) andlift thehalfcasing(2) offtheunit.
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Base- November 2006
49230
49232
Figure21
Figure22
Figure23
Usingtool 99348001,extract thebearing(1) fromthebevel
pinion(2).
Usingasuitabletool (1), extract thebearing(2).
Differential component check
Carefullycleanall differential components.
Lubricatethebearingsandrotatetheroller cage;it
should rotatefreelyandsmoothly.
Inspect the ringbevel gear and half casingcontact
surfaces, making sure the ringbevel gear perfectly
adheres.Warpedsurfacesmaycauseringbevel gear
fasteningscrewvibration,thusunderminingtheunit
operation.
Makesuretheslottedsectionfasteningtheflangeto
thepinionis not worn. If it is, replace thepinion.
526249 REMOVING THE BEVEL PINION
FROM THE SUPPORT
Themounting(4) issuppliedasasparepart together
withpreassembledtaperedrollerbearingsandseals.
86721
Takeoffthebevelpinion(3) (underapress) fromthesupport
(4).
!
Dueto productionrequirements, the two bearings
(2) of pinion(3) arekept assembled bymeans of a
special metal ring(1) that is normally left in place,
owing to its beingunimportant. During thepinion
disassemblingphase, theringis partiallytaken out,if
still present.
If not taken out, theringcouldbedangerous, since
it couldsubsequentlyinterferewiththebearings.
Prior to reassembling the pinion, it is therefore
essential that youcheckfor thepresenceofthering
and takeit out fully.
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Print 603.93.641
34847
49235
19383
49235A
49244
49236
Figure24
Figure25
Figure26
Figure27
Figure28
Figure29
Placethehalf casing(3) on tool 99371047.
Insert the crown wheel shoulder washer (2) into the half
casing, thenfit thecrown wheel (1).
Fit the spider (6), complete with planetary gears (5) and
shoulder washers (3), to thehalf casing(4).
Fit thehalf casing(2).
Make sure the marks made on removal match. Insert the
screws (1) andtightenas follows:
- 1
st
phase: tightening with a torque wrench (3) to a
- 2
nd
stage: tighten the screws (1) by means of tool
99395216 (3) at 110 to 120 angle.
Heat the bearing (2) at 100 C for approx. 15 min. in a
convectionfurnaceandfit it, usingasuitablebeater.
Heat the ringbevel gear (1) to atemperature of 100C
150C inanair circulationovenandpositionit in its seat, in
thegearhousing,checkingit turnsfreelyandmakingtheholes
coincideforthescrewsfixingtheringbevel gear-gearhousing
byfittingthe4 manoeuvringscrews.
Let theringbevel gear cool, then placethegearcaseupside
downonthetool.
Insert thescrews (1) andtighten asfollows:
- 1
st
stage: tighten to100Nm(10kgm) torquebymeans
of atorque wrench(2);
- replace the 4 manoeuvre screws with new ones and
applythesamespecifiedtorque.
Fitting the differential housing
If thespider hasnot been replaced,makesurethe
marks madeon removal match.
NOTE
Fit the second crown wheel (2) complete with shoulder
washer (1).
Lubricate everycomponent withaxleoil. NOTE
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Base- November 2006
72766
72767
Figure30
Figure31
Figure32
Figure33
Figure34
The bevel pinion mount (1) is suppliedas asparetogether
withthetaperedrollerbearings(2and3) andtheseals(4and
5).
Usingapressandasuitabletube(1) positionedontheinner
ringof theroller bearing(4), fit themount (2) on thebevel
pinion(3).
49236A
- 2
nd
phase:closing,withtool 99395216(1) withanangle
o 80 0 .
Heat thebearing(2) to atemperatureof 100 C for approx.
15 min. in an air circulation oven and drive it in with an
appropriatedrift.
526249 FITTING THE MOUNT ON THE
BEVEL PINION
49237
Heat thebearing(2) to atemperatureof 100 C for 15min.
inan air circulation oven andmount it on the bevel pinion
(1).
72768
Heat thebearing(1) to atemperatureof 100 C for 15min.
inan air circulation oven andmount it on the bevel pinion
(2).
Lock the bearing by notching the bevel pinion at 10
equidistantpointsasshowninthefigure.Thisshouldbedone
conscientiouslywith asuitable punch.
!
The diameter of the impression has to bebetween
3.+0 +.+0 , coosooo|o to a oot| o 0.30
0.44 mmrespectively, usingaload of 4000 kgwith
aball with a10 mmdiameter.
Base- November 2006
Print 603.93.641
49239
49240
19416
Figure35
Figure36
Figure37
If the same pinion-crown wheel unit previouslyremoved is
reinstalled,fittherelativeadjustingshims(2) andbevel pinion
support with the seal ring (O-ring) (1) to the differential
carrier (3). Make sure the lubrication oil slot is properly
aligned.
Before assembling a new pinion-crown wheel unit, it is
mandatorytounderstandthemeaningofthemarksstamped
on both pinion and crown wheel, in order to find out the
proper pinionposition.
1. Part number
2. Toothplaynumber
3. Pinion-crown wheel unit couplingnumber
4. Adjustment number, to define the thickness of the
shims to be fitted between pinion support and
differential housing (this number is called CP in the
followingexamples)
5. Pinion-crown wheel unit date of manufacturing and
testing(monthand year)
6. Pinion-crown wheel unit rated backlash.
Part and tooth play numbers are marked on the pinion
threadedend.
On crownwheels, thesamenumbers aregenerallymarked
on thefront face.
As an alternative, theymaybe found on the crown wheel
outer diameter.
For any pinion-crown wheel unit, the crown wheel part
number shall alwaysbeeven (for instance,36786), whereas
the corresponding pinion part number shall be odd (for
instance, 36787).
The tooth play number (for example, 10-41) means the
pinionfeatures10teethandcrownwheel 41,corresponding
to 4.10 : 1transmission ratio.
Never use pinion-crown wheel units bearing
different numbers.
1,2
3
1,2,3,4,5,6
Placethetransmissionfittingflange(1),completewithbaffle
(2), and fit it using a suitable beater. The use of a vice is
recommended. Temporarilytightenthe lock nut.
NOTE
Replacethe seal ring(O-ring) in the event that it
isdamaged, to avoid oil leaksthrough theshims.
NOTE
Print 603.93.641
Base- November 2006
Example3:
Original shimthickness mm 0.70
Crown wheel C.P. +0.05 - 0.05
Result mm 0.65
Newcrown wheel C.P. - 0.05 - 0.05
Newshimthickness to beused mm 0.60
Example4:
Crown wheel C.P. - 0.10 +0.10
Result mm 0.70
Newcrown wheel C.P. - 0.15 - 0.15
49241
Figure38
Eachcrownwheel hasanadjustment number specifyingthe
ratedmountingclearance.
Use this number to calculatethe thickness of theadjusting
shims to be fitted between pinion support and differential
housing.
This number (for example, C.P. +0.1, or C.P. -0.1 mm), is
stamped onthe crownwheel outer diameter.
Tocalculatethethicknessoftheadjustingshimstobefitted
between pinion support and differential housing, proceed
as follows:
1. Measure the thickness of the shims fitted on the
pinion-crown wheel unit to be replaced. Use a
micrometer or gauge and notethemeasurement.
2. Readthe C.P. stamped on the crown wheel to be
replaced. If positive(+), subtract this number from
t|o ov|oos| ta'oo oasoooot (soo '+'). | t|o
numberrepresentsanegativevalue(-) addit to the
oasoooot ta'oo (soo '+').
Notetheresult.
3. Read the C.P. stamped on the new crown wheel.
Add or subtract this value (add if +, subtract if -)
to/from the previously taken measurement (see
|to '2').
Theobtainedvalueindicatesthethicknessofthenewshims
to befitted.
Refer to the following examples, covering all possible
combinations.
Examples of calculation
Example1:
Crown wheel C.P. +0.05 - 0.05
Result mm 0.70
Newcrown wheel C.P. +0.10 +0.10
Example2:
Crown wheel C.P. - 0.05 +0.05
Result mm 0.70
Newcrown wheel C.P. +0.15 +0.15
A number,specifyingtheratedbacklashbetweenpinionand
crown wheel after manufacturing, is stampedonall units.
This number is foundonthecrown wheel outer diameter.
Insert the screws (2) and tighten to the prescribed torque,
usingatorque wrench (1).
- 1
st
step:tightenusingthetorquewrench(1) toatorque
of 100Nm(10kgm);
- 2
nd
step: tighten thescrew(2) usingtool 9935216with
anangleof 60 70 .
T|o oasoooot obta|ooo at '2' s|a|| bo osoo to
calculatethethickness of theadjustingshims to be
fitted between pinion support and differential
housing,inrelationtothenewpinion-crownwheel
unit to beinstalled.
Spare parts shims, to be fitted between pinion
support anddifferential housing,areprovidedwith
thefollowingthickness: 0.125- 0.200- 0.500 mm.
Reassembling the differential carrier
NOTE
NOTE
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20670
49225
49244
49245
Figure39
Figure40
Figure41
Figure42
Figure43
Turnthe unit by 90 .
Using tool 99370317 (5), lock the flange (3). Using wrench
99355088(2),multiplier (4) andtorquewrench(1), tightenthe
pinion locknut to theprescribedtorque(1350 to 1370Nm).
Placethecaps,makingsurereferencetabsmatch.Tightenthe
screws,completewithwashers,to theprescribedtorqueby
means of atorquewrench.
Then,slightlypushthebearingouter rings(1),tomakesure
theyslide smoothlywithin their housings.
Remove thescrews, completewith washers, andcaps.
Position theexternal rings (3) of thebearings
Using hook 99370509 (1), lift the previously assembled
gearcase(2) andplaceit onto thedifferential housing.
Positionthecaps(2),suitablysettlethemusingahammerand
insert the screws (3), complete with washers. Tighten the
screwsto theprescribedtorque,usingatorquewrench(1).
Lubricatetheconical rollerbearings(1),manuallytightenthe
ring nuts (2) until they touch the external bearing rings;
tightenthescrews (3, Figure42) to theprescribed torque.
49242
Checkthat themultiplicationfactorofthemultiplier
(4) is correct.
NOTE
Print 603.93.641
Base- November 2006
3. ocooo as oosc|boo |o o|ot '+',
C. after eliminating the end float further tighten the two
adjustment lock rings (4) to obtain a retraction of the
caps (2) of 0.15to 0.33 mm, whichcorrespondsto the
sumof thereadings on thedial gauges(1).
Figure44
3. further tightenthetwoadjustment lockrings(4,Figure45)
toobtainaretractionof thecaps(2,Figure45),measured
oo /|s o oo a|s Y as oosc|boo |o o|ot '2' o. 0.+5
to 0.33mmwhichcorrespondstoapreloadonthebear-
ings of 1.7 to 3.9Nm(0.17 to 0.39kgm).
60636
ADJUSTING THE CAP GAP
Adjustingand checkingretraction of the caps can bedone
with two methods:
1
st
METHOD
1. Use wrench 99355025 (3, Figure45) to tighten the
adjustment lockrings(4) ofthebearingsuntil eliminating
thepinion-crownwheel clearanceandendfloat. At the
sametimecheckthat thecrownwheel does not force
on thepinion;
2. usinga suitable micrometer positioned diagonally and
centrallyinpoints(X-Y-arrows, Figure44);
measure and notethedistanceof the caps;
2
nd
METHOD
A. Diagonallyandcentrallyontheoutermachinedseatsof
bothcaps(2,Figure45) positiontwodial gauges(1) with
magneticstandasshowninFigure 45;
Figure45
60635
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Adjust theaxial clearancebetween theteeth of the pinion
- crown wheel unit which must be 0.26 to 0.50 mm
- stopthebevel pinionfromturningusingtool 99370317;
- positionthemagnetic-baseddial gauge(1) asillustrated;
- usingwrench99355025(3) slackentheadjustment lock
ringon the crown wheel sideand tighten, to thesame
extent,theadjustment lockring(2) oftheoppositeside.
The purposeof this is to leave thepreviously-adjusted
cap retraction unchanged;
- proceed as described until obtaining the specified
clearance.
The clearance should be checked on 4 points the same
distance apart.
49248
49246
19451
Figure46
Figure47
Figure48
Applyalight layer of Prussianblue onthecrownwheel.
Turnthepinionand measuretheimpressionof thecontact
of thepinion teeth onthe crownwheel teeth.
The followingfigures show possible contacts and howto
correct anyerrors.
Useamagnetic-baseddial gauge(1) tocheckthat thecrown
wheel (2) doesnot haveanyupper wobbleabove 0.20mm.
Ifit does, disassemblethedifferential unit andfindthecause.
Refit and repeat the adjustment operations described
previously.
Print 603.93.641
Base- November 2006
19453
19454
Figure49
Figure50
Contactstoomuchtowardsthecrown wheel teethtopland
ConditionsA-B.Indicatesthatthepinionisfastenedtomuch
towardstheoutsideandthereforeneedsfurtheradjustment.
To adjust the exact position of the pinion, remove shims
under thepinionsupport to obtain the exact contact.
Condition A. After removingtheshims, take theclearance
towards maximum.
Condition B. Measure the clearance and restore it after
removingshims.
Clearance reduction
Clearance increase
1. Release, concavesideof tooth
2. Topland
3. Pulling, convex sideof tooth
4. Heel
PULLING.Central tendingtowardsthetoplandonthetooth
faceand central onthetooth profile.
RELEASE.Central tendingto theheel onthetoothfaceand
central onthe toothprofile.
Indicates that thepinion is fastened correctly.
Thecontact positioncanbefurther changedbychangingthe
pinion-crownwheel clearance.
Condition E. Lower theclearance.
Condition F. Increasetheclearance.
19452
Contactstoo muchoncrown wheel teethbottomland
Conditions C-D. Indicates that the pinion is fastened too
deeplyandneedsfurther adjustment.
To adjust theexact positionof the pinion shims should be
addedunderthepinionsupport toobtaintheexact contact.
Condition C. Measure the clearance and restore it after
addingshims.
ConditionD. Afteraddingshims,taketheclearancetowards
minimum.
Figure51
THEROETICAL CONTACT AREA
1
2
3
4
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Print 603.93.641
Figure52
THEORETICAL CONTACTS
60676
PULLING
(CONVEX SIDE OF RING GEAR)
TIP
RELEASE
(CONCAVE SIDE OF RING GEAR)
TIP
HEEL TOP
LAND
HEEL
HEEL TOP
LAND
HEEL
HEEL TOP
LAND
HEEL
HEEL TOP
LAND
HEEL
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
- PULLING : CENTRAL TENDING TOWARDSTHE TOPLAND ON THE TOOTH FACE
AND CENTRAL ON THETOOTH PROFILE
- RELEASE : CENTRAL TENDING TOWARDSTHE HEEL ON THETOOTH FACE
AND CENTRAL ON THETOOTH PROFILE
CONDITION A
PULLING
TIP
RELEASE
TIP
- PULLING RELEASE : CONTACTSTOO MUCH AT TIP
- PULLING : CONTACT TOO MUCH AT TOP LAND
- RELEASE : CONTACT TOO MUCH AT HEEL
- CORRECTIVE ACTION : REMOVE SHIMSANDINCREASE CLEARANCE TO MAXIMUM
CONDITION B
TIP TIP
- PULLING- RELEASE : CONTACTSTOO MUCH AT TIP
- CORRECTIVEACTION : MEASURETHECLEARANCEANDRESTORETHE CLEARANCE
CONDITION C
TIP TIP
- PULLING- RELEASE : CONTACTSTOO MUCH ON BOTTOMLAND
- CORRECTIVE ACTION : MEASURETHE CLEARANCE, ADD SHIMSAND RESTORE CLEARANCE
Print 603.93.641
Base- November 2006
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
Figure53
CONDITION D
60677
TIP TIP
HEEL TOP
LAND
HEEL
HEEL TOP
LAND
HEEL
HEEL TOP
LAND
HEEL
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
BOTTOMLAND
- PULLING- RELEASE : CONTACTSTOO MUCH ON BOTTOMLAND
- PULLING: : CONTACT TOO MUCH AT HEEL
- RELEASE : CONTACT TOO MUCH AT TOP LAND
- CORRECTIVE ACTION : ADD SHIMS ANDREDUCECLEARANCE TO MINIMUM
CONDITION E
- PULLING : CONTACT TOO MUCH AT HEEL
- RELEASE : CONTACT TOO MUCH AT TOP LAND
- CORRECTIVE ACTION : REDUCECLEARANCE
CONDITION F
- PULLING : CONTACT TOO MUCH AT TOP LAND
- RELEASE : CONTACT TOO MUCH AT HEEL
- CORRECTIVE ACTION : INCREASE CLEARANCE
TIP TIP
TIP TIP
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Print 603.93.641
49249 49250
Figure54 Figure55
Replace the safety split pin (1) and fold it; repeat this
operationontheoppositeside.
Placethepin (4) into itshousing.
Fit thefork(2) andspring(3) to thepin(4) andpushit inall
theway.Fit thepiston(5),completewithringandcover (6),
then fit the slidingsleeve (1) and springplugs (7).
Print 603.93.641
Base- November 2006
61482
61481
61483
61484
Figure56
Figure57
Figure58
Figure59
Slacken the nuts (1) fastening the flange. Disconnect the
transmission shaft (2), fasteningit to the frame.
Prevent the flange (1) from turning using retainer tool
99370317 (2).
Using wrench 99355088 (3) and the multiplier (4) slacken
thenut for thebevel pinionandwithdraw theflange(4).
Usingasuitable tool raise theouter edge of the ring(1) in
two opposed points
Usingthetwo levers(2) removetheinner ring(1).
REPLACING THE BEVEL PINION MOUNT
SEAL
Disassembly
1
2
1
1
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Print 603.93.641
WORK ON THE VEHICLE
61485
61486
Figure60
Figure61
With tool 99363204 (2) positioned as shownin thefigure,
removetheseal (1) fromthebevel pinion mount.
Unscrew the manoeuvringnut, take out the keyingdevice
99374244(2), fit theflangebackonandscrewdown anew
nut, locking it with a torque wrench and multiplier to the
requiredtorque.
Fit thepropeller shaft backonandtightenthefixingnuts to
therequiredtorque.
Assembly
Thoroughlycleantheseat oftheseal of all debrisandtraces
of oil.
Positionthenew seal (1).
Applythekeyingdevice99374244(2),screwamanoeuvring
nut onto thebevel pinion and mount theseal down to the
stop.
1 2
2
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Base- November 2006
Print 603.93.641
1 TRAKKER EURO 4/5 FRONTAXLES
SECTION 9
5250 Front axles
Page
FRONT AXLE5886/D 3 24 . . . . . . . . . . . . . . . . . . . .
WHEEL ALIGNMENT 25 34 . . . . . . . . . . . . . . . . . . . .
2 TRAKKER EURO 4/5 FRONTAXLES
3 TRAKKER EURO 4/5 FRONTAXLE 5886/D
Front axle5886/D
Page
DESCRIPTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Front axle 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING ANDREFITTINGTHE AXLE 14 . . . . .
- Removal 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refittinginplace 15 . . . . . . . . . . . . . . . . . . . . . . .
VEHICLECHECKS 16 . . . . . . . . . . . . . . . . . . . . . . .
- Ball joints 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tierods 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRACKROD ANDDRAG LINK
BALL JOINTSSLACKCHECK 16 . . . . . . . . . . . .
FRONT AXLEASSEMBLY OVERHAUL 17 . . . . . . .
REMOVING - REFITTING WHEEL HUBS 17 . . . . .
- Removal 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refittingwheel hubs 18 . . . . . . . . . . . . . . . . . . . .
REMOVING ANDREFITTINGIN
PLACETHETRACKROD 18 . . . . . . . . . . . . . . .
REPLACINGTRANSVERSETIEROD
BALL JOINTS 19 . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING ANDREFITTINGLEVER FOR
TRANSVERSETIEROD 19 . . . . . . . . . . . . . . . . .
REMOVING ANDREFITTINGLEVER FOR
LONGITUDINAL TIE ROD 19 . . . . . . . . . . . . . .
REMOVING ANDREFITTINGPIN
FORSTUBAXLE 19 . . . . . . . . . . . . . . . . . . . . . .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingkingpin bearing 20 . . . . . . . . . . . . . . . . .
Page
- Refitting 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Stubaxle-axleendplaycheck andadjustment 22 .
AXLEBODY CHECKSAND MEASUREMENTS 22 . .
- Checkingleaf springsupportingsurfacelevelness
withreferenceto kingpinholesusing
proper equipment 22 . . . . . . . . . . . . . . . . . . . . . .
- Kingpinseatscamber anglecheck 24 . . . . . . . . . .
71571
Figure1
The front axle is a steel structure with a double-T
cross-sectionattheendofwhichthestubaxlesarearticulated.
Thestubaxlearticulationis madewithtapered pins integral
withtheaxlebodyandbymeansoffourbearingswithrollers
driven in with interference in the holes of the stub axle
overhangs.
Thewheelhubsaresupportedbytwotaperedrollerbearings,
set right lubricatedwithoil,mountedontheshankofthestub
axleandadjustablewiththethreadedringnut.
Thebrakeis theKnorr-typedisc.
FRONT AXLE5886/D
DESCRIPTION
Front axle
MAIN DATA
Typeof axle 5886/D
KINGPINS
Angleof seats for kingpin 7
1
2
Diameterofroller bearingseatson
thestubaxle:
- topseat 1
- bottomseat 2
mm 51.967 51.986
mm 59.967 59.986
3
4
Outsidediameterofrollerbearings
for stubaxle:
- topbearings 3
- bottombearings 4
mm 52
mm 60
Stubaxlebearings mm 0.014 0.033
5
6
Inside diameter of roller bearings
for stubaxle:
- topbearings 5
- bottombearings 6
mm 43
mm 53
7
8
Diameter of pin for stub axle
- top 7
- bottom 8
mm 42.984 43.000
mm 52.981 53.000
Topbearings - pin mm 0 0.016
Bottombearings - pin mm 0 0.019
5886/D
X
X 2
1 Backlashbetweenaxleandstubaxle
upper shim X 1
Clearance between axle and stub
axlelower shim X2
mm 0.10 0.35
mm 0.25
S
Adjustment shimsX1 ; X2
0.25mm S mm 0.25 1.75
WHEEL HUBS
Wheel hub bearings 2, withtaper rollers
Hub bearings endplay mm max 0.16
Wheel hubsbacklash through ringnut
Rollingtorque
Bearingspre-load
daNm 0.50max.
Oil for wheel hub bearings TutelaW 140/MDA
Amount for eachhub litres (kg) 0.33(0.35)
WHEEL ALIGNMENT
Wheel camber angle(unloadedve-
hicle)
1
o
Wheel caster angle(unloaded
vehicle)
4x26x4Models
2 30'
8x4x4
1st axle 2 30'
2nd axle2 30'
Wheel toe-in
(unloadedvehicle) mm
Adjustment tolerance mm
Check tolerance mm
4x26x4Models
1
0.75
2
8x4x4
0
0.75
2
Axleweight kg
Maximumcapacity (GRW) kg
-
9000
TROUBLESHOOTING
Main operating faults of a mechanical nature
Front axlebadlyaligned. Restorealignment andtightenleafspring
bracket nutsto correct torque.
Irregular toe-in. Make accurate toe-in adjustment on
front wheels.
Hardsteering
Uneventyrepressure Inflatetyresto prescribed pressure.
Hardsteering
Insufficient lubricationinjoints. Carefullylubricatethejoints.
Wrongstub axle-axleadjustment. Makeanaccurateadjustmentofthestub
axis-axisend play.
Stub axle elements for rotation on pin
areinefficient.
Check andreplace strainedparts.
Unevenwheel camber Check axlemounting, repair or replace
the strainedparts.
Front axisnot aligned. Restorealignment andtightenleafspring
bracket nutsto specified torque.
Uneventoe-in. Adjust toe-in.
Wobbling
Steeringrodkingpinsinefficient. Replacestrainedparts.
Wobbling
Irregularbacklashonwheel hubbearings. Adjust end playafter makingnecessary
replacements.
Wheelsareeccentric:
trued rim, strained
tyrebadlyfittedonrim.
Replacefaultyrim
Deflate andcentretyreon rim.
Unbalancedwheels. Balancethewheels.
Wheel hub bearings insufficiently lubri-
cated.
Topupoil level inwheel hubs.
Noise
Wheel hub bearingsareworn. Replace faulty bearings and adjust end
play.
Too much slack betweenstubaxleand
needlebearings.
Check andreplacewornparts.
Figure2
98981
CROSS-SECTION OFFRONT AXLE - WHEEL SIDE
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
1 Flanged screwto securecross tiebar lever onsteeringknuckle 1400 1250 (140 125)
2 Flanged screwto secure side lever onsteeringknuckle 1400 1250 (140 125)
3 Lower thrust bearingflangedhexagonal screwonsteeringknuckle 111 123 (11.1 12.3)
4 Self-lockinghexscrewM20x1.5 fixingbrakecallipers 554 677 (55.4 67.7)
5 Nut fixingwheels 565 690 (56.5 69)
6 Hexscrewfixingbrakediscto wheel hub 268 295 (26.8 29.5)
7 Self-lockinghexscrewM16x1.5 fixingbrakecalliper mount to stub axle 298 329 (29.8 32.9)
8 Cover for wheel hub 120 140 (12 14)
9 Conical threadedplugfor wheel hub 55 60 (5.5 6)
10 Ringnut fixingwheel bearing 490 540 (49 54)
11 Cylindrical screw withrecessed hexlockingringnut 25 30 (2.5 3)
- Notchednut for steeringknucklepin 300* 30*
- Collar nut fixingbracketsfixingleaf springto axle 410 510 (41 51)
D ApplyLOCTITE574on cover/wheel hubcontact surface
* Minimumtorque - Maximumtorque, tighten uptofirst notchmatchingto split pinhole
TOOLS
TOOL NO. DESIGNATION
99305354 Wheel geometryportableoptical testingequipment
99321024 Hydraulictruck to removeandre-fit inplacethewheels
99322215 Stand for axletesting
99347047 Puller for stubaxlepin
99347068
Puller for draglinkkingpins
99354207 Wrenchfor wheel hubcup
99370006 Handlefor interchangeablebeaters
99370007 Handlefor interchangeablebeaters
99370317 Lever andrelevant extensionbar
99370628 Stand for axleremoval andinstallation
99370715
Guidefor wheel hubassembly
99374093
Beater to fit in place bearing outer tracks (to be used with
99370007)
99374132
Tool for fitting wheel hub internal gasket (to be used with
99370006)
99374173
Elementsto fit inplacekingpingasket (to beusedwith9937007)
99374405 Tool to fit kingpin
99374530
Beater to remove/re-fit in place kingpin bearing(to beusedwith
99370007)
99388001
Wrench(80mm) for wheel hubbearingadjustment ringnut
99388002
Wrenchfor screwstosecurecrossandsidetiebarlever tosteering
knuckle
99389819 Toooo .ooc| (0 - +0) .|t| sooao +/+' cooooct|oo
99395026
Tool for testinghubsrollingtorque (to beused with99389819)
Figure3
40450
Place the vehicle on flat ground and lock the rear wheels.
Loosenthefront wheel fasteningnuts.
Usingahydraulicjacklift thefront ofthevehicleandrest it on
two stands.
Take out the wheel nuts and remove the wheels with
Usingpuller 99347068(1) removethetie-rod(3) kingpinon
thearm(2)
Disconnect:
- Air deliveryhosesfrombrakediaphragmcylinders;
- ABStransmitter electric cable;
- Brakeliningswearindicatorcableifthevehicleisequipped
withthis device.
520610 REMOVING AND REFITTING THE AXLE
Removal
40451
Figure4
Setahydraulicjackfittedwithstand99370628undertheaxle
(3).
Unscrew the nuts (1) and take awaythe leaf springto axle
fasteningbrackets(2).
Lower thehydraulicjackandremove theaxle(3).
To re-fit in place, follow the removal instructions in reverse
order.
Refitting in place
Bymeansofthehydraulicjackfittedwithstand99370628lift
theaxlesothat theleafspringconnectionpins(4) locatedon
thespringsupport planesontheaxle.
All boltsaretobetightenedtotheprescribeddriving
torques indicatedin thetableon page11.
Check andadjust the front wheel geometry.
36914
Figure5
Kingpins
Cleanthetraverseanddraglinkkingpins. Checkthat theking
pincomponentsarenot strainedorbrokenIftheyare,replace
them.
Ca|co|ato s|ac' '/' os|o t|o o||o.|o oo|a.
A =B- X
whereB is thegreater valuefound frommeasurementsX1
and X2.
If thevalue ismorethan2mmreplacethekingpin.
Tie rods
Check the clamp screws and nuts, make sure theyare not
worn andthat theyaretightenedto theprescribedtorques.
Check for strain or damageandif necessaryreplacethem.
TRACK ROD AND DRAG LINK BALL
JOINTS SLACK CHECK
Do not lift the vehicle. With agauge (1, Figure5) measure
o|staoco '' .|t| t|o vo||c|o |o sta||t ooo|o os|t|oo.
Measure again with the vehicle in full left-hand (X 1) and
right-hand(X 2) steeringpositions; notethevaluesfound.
VEHICLE CHECKS
49178
77206
49179
38597
Figure6
Figure7
Figure8
|oovo t|o ba'o ca|||os as oosc |boo |o t|o '3|/|| /||
SYST||' soct|oo.
Arrangespecial oil recovercontaineratsafetydistance.Rotate
wheel hubinsuchawayastotakethreadplug(1)downwards;
unscrewplug(1) anddrain oil into thecontainer.
Usingthereactionlever 99370317(3),locktherotationofthe
wheel huband, usingwrench99354207(2), unscrewtheoil
cover (1). Drainoil completely.
Undothescrew(4),takeout theadjustment nut(3) withthe
wrench99388001, extract thewasher (2),theouterbearing
andremovethewheel hub(1) together withthespacerand
internal bearing.
Examinethe stateof wear of thebrakedisc(3) asdescribed
|o t|o '3|/|| /|| SYST||' soct|oo.
To remove the brake disc (3), take out the screws (1) and
disconnect it fromthewheel hub (2).
Usingalift, position andsecuretheaxleassembly(1) onthe
stand99322215(2) for overhaul.
520620 REMOVING - REFITTING WHEEL
HUBS
Removal
Figure9
520610 FRONT AXLE ASSEMBLY
OVERHAUL
Figure10
Refitting wheel hubs
40369
Screwthetool 99370715(1) onto thekingpinand lubricate
theouter surfaceof thekingpinwithTUTELA W140/M-DA
oil.
Carefullykeythewheel hub(2) onto thekingpinsoasnot to
damagetheseal.
Fit onthespacer (3), innerring(4) ofthetaperedroller bear-
ing.
Unscrewthetool 99370715 (1).
Keyonthewasher (5) andscrew downthestopnut (6).
Figure11
60876
Usingthewrench99388001(1) tightenthenut(6,Figure10)
to therequiredtorque.
Straighten andremovethesplit pin (1).
Loosenthenut (2) andpartiallyunscrew toavoidthetie-rod
fallingwhenbeingremoved.
Figure12
40370
Figure13
40371
Usingpuller 99347068(1) releasethekingpin(3) fromlever
(2). Repeat the same operations on the opposite side,
unscrewthenutscompletelyand removethetrackrod.
To re-fit in place follow the removal operations in
reverseorder.
Tightenthetaper pinnutstotheprescribedtorque.
Checkthatthenutnotchesmatch thetraverseholes
on the taper pins; if the split pins do not enter,
progressivelyincreasethedrivingtorqueof thenuts
until theyenter correctly(lowest angle60 )
!
520635 REMOVING AND REFITTING IN
PLACE THE TRACK ROD
Refit thetransverse tierod.
Check andif necessaryadjust thetoe-in of thefront
wheels as described under the section heading
'\|oo| Cooot'.
520635 REPLACING TRANSVERSE TIE
ROD BALL JOINTS
36418
Usingwrench 99388002 (1, Figure14), unscrewthe screws (2,
Figure15) and remove the lever (1). To refit it, carryout the
operations in reverse order, lockingthe screws to therequired
torque.
520611 REMOVING AND REFITTING PIN
FOR STUB AXLE
Removal
36419
Undothescrews(2) and detachthemount (1).
40373
Usingspecific pliers (1), take out the retainingring (2) and
extract thecover (3) together with thegreasenipple.
LEVER FOR LONGITUDINAL TIE
ROD
Lock the screw (4), loosen the nut (3) and unscrew the
articulation(2) fromthe transversetierod (1).
71755
LEVERS FOR TRANSVERSE TIE
ROD
40372
Using wrench 99388002 (3) unscrew the screws (2) and
removethelever (1). To refit it, carryout theoperationsin
reverseorder,lockingthefixingscrewstotherequiredtorque.
The nut (3) has to betightened with the clamp (5)
positionedinoneof theset-upsshowninthefigure.
To make it easier to refit the transversetierodand
thenadjustthewheel toe-in, notedownthenumber
ofturnsneededtounscreweachsinglearticulationso
astoscrewthenewonesonwiththesamenumber
of turns.
Screw the new articulation into the tie rod and lock it in
position by tightening the locking nut (3) to the required
torque.
Figure14
Figure15
Figure16
Figure17
Figure18
NOTE
NOTE
Figure19
36421
Undo the screws (4) and remove the bottomcover (3),
adjustment plates(2) andfifth wheel (1).
Figure20
Usingthetool 99347047(1) andpart(2),freethekingpin(3);
removethe tool and takeout thepin.
36422
60887
The kingpin bearings(5) are replaced byusingparts (1-2-3)
of drift 99374530andgrip99370007(4) todisassembleand
assemblethem.
520615 Replacing kingpin bearing
Figure21
Use part (1) and grip (4) to remove the seal (8) and roller
bearings(6-7) onthetopside.
Use part (3) and grip (4) to remove the seal (9) and roller
bearings(10-11) onthebottomside.
60889
Figure22
Fittingroller bearing(7):
useparts(1and 2) andgrip(4).
usepart (2) and grip (4).
useparts(3and 2) andgrip(4).
usepart (2) and grip (4).
60890
Usingthe drift 99374173 (4) andgrip 99370007(3), fit the
seals (2and5) in thestub axle(1).
Figure23
Thepartsmentionedinthefollowingtext areshown
inFigure21.
NOTE
40374
Figure24
Setontheaxle(1) thestubaxle(2) and fit thepinintoitsseat;
applytool 99374405(3) to the stub axle andfastenit with
thelower cover screws, tighteningto asuitabletorque.
Fit the pin in the axle tapered seat, tighteningthe pressure
screw(4) toatorqueof 15 16daNm.
Remove tool 99374405 fromthestub axle.
Beforefittingthepinmakesurethatthetaperedseat
on the axle andthepinsurface areperfectlyclean
and drytoavoidoil film that couldcausethepinto
rotateinitsseat whenfittingit in.
Beforefittinginplace,dampenthelowercover collar
withTutelaMR2.
!
Figure25
36421
Set the lower cover (3) with the collar (1) and shims (2);
tightenthefasteningscrews (4) at prescribedtorque.
Repeat thesameoperationfor theoppositeaxle.
Figure26
36420
Fit theuppercover (2) into itshousingtogetherwiththeseal
gasket;setthegreasenippleasshowninthefigure,thenfitthe
circlip (1) making sure that the ring expansion takes place
correctly.
NOTE
Refitting
After theclearancebetweentheupper shimofthestubaxle
andtheaxlehasbeenchecked,useafeelergauge(1) tocheck
that betweenthelowershimof thestubaxleandthat of the
axlethereisaclearance of not less than0.25mm.
Lift the stubaxleso that it is in contact withthelower shim
of the axle. Use a feeler gauge (1) to check the clearance
betweenthe stubaxleupper shimand theaxle. Theallowed
rangeisbetween 0.10 and0.15 mm.
Figure27
Figure28
36425
36426
Ifendplayadjustment isnecessary, replacetheshims
withother spares that havesuitablethicknesses.
Thethicknessesofthespareringsareindicatedinthe
SPECIFICATIONSANDDATA table (page6).
Grease the complete upper and lower joint with
MR2 makingsurethat thegreaseflows throughthe
bafflelip of the gaskets.
520618 AXLE BODY CHECKS AND
MEASUREMENTS
Set thetwo rods(1) withthecones(3) inthekingpinholes;
press down the cones and lock themin position with the
screws ontherod.
Insert thetwo set screws (2) in the seats on the leaf spring
contact surface.
Checking leaf spring supporting surface
levelnesswith referenceto kingpin holes using
proper equipment
Stub axle-axle end play check and adjustment
Figure29
Set thebases(5,Figure30) withgoniometersonthesurfaces
(6) and insert theset screws.
Beforeplacingthebaseswiththegoniometers,make
sure that there is no paint or roughness on the
contact surfaces.
NOTE
Figure30
Figure31
Set theslidingbar (2) onthegoniometer rods, adjustingthe
lengthsothat theshapedendsremaininsertedintherods(1)
Locktheclampscrew (7) andthescrews (3) that fastenthe
goniometer to therods(4)
Check for deviation angles on the goniometer scaled
sectionsindicatedbythearrows.
The goniometer indicators do not indicate any angular
displacement whenthe planarityof theleaf springcontact
surface withreferencetothestubaxlepinholesiscorrect.
Removetheslidingbar andthebases withgoniometer.
Figure32
Figure33
Kingpin seats camber angle check
Set the supports (3) with goniometers on the rods (1) and
slightlyturnthescrews(2) without lockingthem.
Insertthecouplingtrackrod(4) andtightenthescrews(2)that
fastenthesupportsintherods(1)
Thecamberanglevalueforthekingpinholesistobe7 0 3' Read the kingpin holes camber angle value in the relevant
scaledsectors (2) accordingto theindicators (1).
25 TRAKKER EURO 4/5 WHEELALIGNMENT
Wheel alignment
Page
GENERAL INFORMATION 27 . . . . . . . . . . . . . . . .
- Steeringwheel angles 27 . . . . . . . . . . . . . . . . . . .
FRONT WHEEL ALIGNMENT
(4X2 VEHICLES) 28 . . . . . . . . . . . . . . . . . . . . . . .
- Positioningclips andheadlights 28 . . . . . . . . . . . .
- Electroniccompensationof rimeccentricity 29 . .
- Wheel alignment 29 . . . . . . . . . . . . . . . . . . . . . . .
- Checkingwheel toe-in 30 . . . . . . . . . . . . . . . . . . .
- Checkingwheel deviation 30 . . . . . . . . . . . . . . . .
- Checkingcamber 30 . . . . . . . . . . . . . . . . . . . . . . .
- Checkingkingpinangleandcaster 31 . . . . . . . . . .
- Checkingrear axlealignment 32 . . . . . . . . . . . . . .
WHEEL ALIGNMENT OF VEHICLESWITH
ADDEDCENTRAL AXLE(8X4X4) 32 . . . . . . . .
- Checkingsteeringangles 34 . . . . . . . . . . . . . . . . .
To ensure satisfactory road holding performance, low tyre
wearandtoallowdrivingwheelsinthesteeringstagetoreturn
spontaneouslytostraight aheadrunningposition,frontwheels
aregiven thefollowingfittingangles:
Figure1
Thekingpinangle() is theangle formed bytheaxispassing
through the kingpin and the vertical to the ground when
observingthevehiclefromthe front.
Whentheextensionofthekingpinaxisapproachesthewheel
at its point of contact with the ground (opposite to the
camber), the angle is positive; it is extremelydifficult, if not
impossible, to haveanegativekingpinangle.
Thecamber ( ) andkingpinangle() makeit possibleforthe
axesof thewheel andkingpintocome ascloseaspossibleto
thecentreof support of thetyreontheground.
This produces low tyre consumption and a low steering
torque.
Caster
Camber
The camber ( ) is the angle formed by the axis passing
through the centreline of the wheel and thevertical to the
ground whenobservingthevehicle fromthefront.
The angle is positive (A) when the top of the wheel tilts
outwards,negative(B) whenthetopofthewheel tiltsinwards.
32956
32957
32958
Figure2
A B
Thecaster ( ) istheangleformedbythekingpinaxiswiththe
vertical to the ground when observingthevehicle fromthe
side.
Iftheextensionof thekingpin axisfallsforwardsto thepoint
wherethewheel restsontheground,inthedirectionoftravel
of the vehicle, the caster is byconvention positive (A); it is
negative(B) if it fallsbehindthepoint wherethewheelsrest
on the ground, and zero if it is exactlyvertical to the point
wherethe wheelsrest ontheground.
Thisanglemakesit possibletokeep thefront wheelsstraight
whenthevehicleistravellinginastraight lineandfor themto
returnstraight ontheir own after thepositiontheytakein a
bendassoonasthedriver letsgoofthesteeringwheel.
A B
+
_
Steeringwheel angles Kingpinangle
Theseangles,suitablycalculated, producetheright balanceof
theforcescreatedwhenthevehicleismoving,indifferentload
conditions,whichtendto alter thepositionof thewheelson
theground.
- camber;
- kingpinangle;
- caster;
- toe-in.
Figure3
r
GENERAL INFORMATION
- tyrepressure;
- wheel hubbearingclearance;
- clearance between steering tie-rod pins and levers on
stub axles;
- efficiencyof shockabsorbers;
- wheelrims,whichmusthavenobucklingoutoftolerance.
Check thewheel geometrywiththeinstrument 99305354.
32813
32814
32815
Figure4
Figure5
Figure6
Thetoe-inistheresult ofthedifferencebetweenthedistances
A andB(inmm) measuredonthehorizontal axisoftherims,
when observingthevehiclefromabove.
Thisproduceslight drivingandlowtyreconsumption.
Toe-inispositiveif Bisgreater thanA.
Toe-inwill bezero if Bis equal to A.
Toe-inisnegativeif Bislessthan A.
A
B
A
B
A
B
Wheel toe-in
32973
32974
Figure7
Figure8
Beforemovingontothechecks,it isnecessarytomakeapre-
liminaryinspectionofsomepartsofthevehiclethat mayaffect
wheel geometry.Ifanytroubleisfound,it will havetoberecti-
fiedinorder toavoidincorrect measurements.Thechecksto
makearethefollowing:
Set thevehiclewithitswheelsin theposition of straight-line
travel onaflat surface.Lift therearofthevehicleandplacethe
boards(3)underthewheels.Lowerthevehicle,braketherear
wheels andfit onthehook(1) withtherule(2).
Lift thefront ofthevehicleandplaceoscillators(1) underthe
wheels, lockingthemwiththeclamps(2).
Positioning clips and headlights
!
The checks and anywork on the wheel geometry
must be done with the vehicle with a static load.
Periodically make sure the light clusters are set
correctly.
FRONT WHEEL ALIGNMENT
(4X2 VEHICLES)
Connect theplugsof the measuringunit to thetransformer
and turn on the switch. Loosen the locking screw of the
oaso|o oo|t aoo ||t t|o |oos s||o|o. |oss t|o 'o cooto'
button (3) for at least two seconds, five lineswill appear on
thedisplay (1).
32975
32977
32976
Figure9
Figure10
Figure11
Positiontheself-centringclip(2),fittedwithappropriatefixing
pins(1),ontherimof thewheel.Usingtheknob(3), lockthe
clipon thewheel, checkingit is properlyanchored.
Fit themeasuringunit (3) ontheclips(1) andfastenitwiththe
screw(2). Repeat thesestepsontheother wheel.
Electronic compensation of rim eccentricity
Turnthewheel slowlybyhandandprojectthelightsignalonto
thecorrespondingscaleoftherule (5).
Measureand notedown the minimumand maximumtravel
of thelight signal: e.g., 12and 8.
Calculatethemeantravel:12+8=20:2=10andpositionthe
wheel onthemeanvaluecalculated, markingitsposition.
|oss t|o 'o cooto' bottoo (3) aa|ot||| t|o .|oo| too-|o |||
(2) comes onandthedigital indicator (1) showsan artificial
value.
Repeat thesestepson theother wheel.
Ta'o cao t|o |aso boa ooos oot ||t aoooo's oos.
it wouldseverelydamagetheir sight.
Figure12
Figure13
32978
Pressthebrakepedal andlockit inpositionwiththetool (1)
positionedagainsttheseat,therebykeepingthevehiclebraked
for theentirecycleof measurement.
Wheel alignment
Level themeasuringunits(3) withthespirit level (1) andlock
themin positionwiththe screw(2).
Move therules (4) until theyarecentred bythe light signal
emittedbythemeasuringunitandnotedownthevaluesgiven.
32979
Lower thevehiclesothat thewheels,inthemarkedposition,
rest completelyinthemiddleoftheoscillatingplates,andfree
thesefromtheir bases, takingout thepins(4).
Figure14
Figure15
13952
If the values are not the same, turn the wheels until the
pointersofthelightsignalsareontwoequalvalues(A),exactly
themean value of the two readingsmade beforehand. This
producesperfect wheel alignment.
With the measuringunits still level and the wheels perfectly
aligned, usingthelever (1), movethelensshield.
Usingthelever (2), direct thepointer of thelight signal onto
the millimetre scale of the rule (3) corresponding to the
diameter of therim.
Repeat thesesteps ontheoppositemeasuringunit andread
off the value of the toe-ins given in mmon the millimetre
scales.
Thealgebraicsumofthesetwomeasurementsmust givethe
requiredvalue.
Thetoe-inis adjustedwith thetransversetierodso
as, for eachwheel,to haveatoe-in equal to half the
requiredvalue.
32980
Checking wheel toe-in
32981
Figure16
Checking wheel deviation
With the front wheels aligned with the rear ones and the
measuringunits level, pressthecamber button(3); theLED
(2) will comeonandthedisplay(1) will showthevalueofthe
camber, that hasto be 1.
Thedeviationischeckedwhilereadingthetoe-in.
Thepartial valueof thetoe-inmeasured ontherule (3) has
to beequal to thevaluemeasured ontherule ontheother
wheel.
If,however,thereisadifferenceinthesevalues,e.g.-2and+3,
thetotal toe-inis+1andisthereforecorrect,butat thesame
timeit indicatesadeviationbetweenthewheels(onewheel
further forwardthantheother) of 5lines.
Thisnumberoflinesiscalculatedwiththealgebraicsumofthe
valuesmeasured:+3-(-2) =5,ormoresimplybycountingthe
linesbetweenthe two values.
Eachlinecorrespondsto adeviationof 2mm.
When the deviation is greater than 10 lines (20 mm), it is
necessarytomakeadditional checks, toverifythestateofthe
leafsprings(whether oneof thesehasgivenway, or whether
thechassisor axleare out of shape).
Checking camber
Thecamber isafixedvaluethat cannot beadjusted.
Therefore, if you find the value is not as required,
detach and remove the axle to make the relevant
checksand replacements if necessary.
NOTE
32982
32983
Figure17
Figure18
Still withthefront wheelsaligned withtherear ones, loosen
theknurledknobs (2) andreset thegraduated sector (3) on
thepointer (1) of theoscillatingplate.
Turn the wheels 20 inwards and press the kingpin angle
button(3) twice;theLED(2) will comeonandthedisplay(1)
will showninehorizontal lines.
32984
Figure19
Turn the wheels 20 outwards and press the kingpin angle
button (3) again; the display (1) will show the value of the
kingpinanglethat hasto be 7.
32985
32986
Figure20
Figure21
Without movingthewheel, press thecaster button(3). The
LED (1) will comeonand thedisplay(2) will showthevalue
of thecaster, which hasto betherequiredvalue.
Withthewheelsturnedstraight, reset thegraduated sectors
(5) on thepointer (2) of theoscillatingplates (4).
If thesteeringangles tobemeasured aregreater than30, it
isnecessarytousethe20mark(1) ontheoscillatingplateand
t|o coosooo|o ooo o t|o aooatoo socto as '0'
reference indices.
Turnthewheelstoreacharequiredangle(internal orexternal
wheel angle).
Thencheckthat thesteeringangle(external orinternal wheel
angle) of the opposite wheel corresponds to the required
value, rememberingto use thecorrespondingscalewiththe
signshownon theoscillatingplate to read off theangle.
The caster and kingpin angle are fixed values that
cannot beadjusted.
Therefore, if youfindthevalues arenot asrequired,
detach and remove the axle to make the relevant
checksand replacements if necessary.
NOTE
Checking kingpin angle and caster
Figure22
71743
Fit therule(4) onthefront wheels, checkingtheslide (2) is
exactlyinthemiddleof thetwoannular groovesof theshaft
(3).
Fit themeasuringunitsontherearwheelsasdescribedabove
for thewheels of thefront axle.
Projectthelightsignal ontherule(1) andnotedownthevalue
shown.
Repeat thismeasurement ontheother wheel andcheckthat
thevalueshownisthesameastheonenoteddown;ifit isnot,
thoroughlycheck over the assemblyof therear axleonthe
vehicle:ifyoufindnotrouble,checkthechassishasnot lostits
s|ao, o||o.|o t|o ocoooos oosc|boo |o t|o '3oo.o'
- C|ass|s' soct|oo.
71557
Figure23
WHEEL ALIGNMENT OF VEHICLES WITH
ADDED CENTRAL AXLE (8X4X4)
Figure24
Figure25
Detachtheswivel head(4) oftherearlongitudinal tierod(2)
from the steering lever (5) of the central axle with the
extractor 99347068.
72397
71558
Lift thevehicle, positiontheoscillatingplates(1and4) ofthe
device 99305123 under the wheels of the steering axles,
lockingthemwiththespecificclamps(2) andplacetheboards
(3) under therear wheels.
Provisionallyfittheswivel head(4) backontothelever (5) and
screwdownthefixingnut (6) without fullylockingit.
!
Check thedistancebetweenthecentredistances of
theswivel headsof thetierod(2).It must be953
10mm.Ifitisnot,loosenthescrew(1)fixingthecollar
(2) and turnthetierod(2) appropriately.
Checking rear axle alignment
Figure26
Figure27
Figure28
Figure29
Figure30
71559
Checkfront axlewheel geometryusingdevice99305123(1)
according to procedure described and illustrated for 4X2
vehicles.
71745
After checkingand adjustingthetoe-in, if necessary, set the
.|oo|s sta||t aoo c|oc' t|o stoo|o bo |s |o t|o 'stoo|o
cooto' os|t|oo, t|at |s t|o ootc| oftheshaft(1) coincides
withthenotch of thesteeringbox (2).
38861
Lockthesteeringwheel withthetool (1).
Check that thedistancebetween thecentredistancesofthe
swivel head(1) andofthefork(5) ofthemiddlelongitudinal
tierod (3) is1735 2mm.
Ifthisisnot so, disconnect theswivel head(1) fromthelever
(2) with the extractor, loosenthecollar (4) andturn the tie
rod(3) appropriatelytoget therequireddistance;then,fitthe
swivel head (1) backonto the lever (2).
71746
Eachturnof thetierod(3) correspondsto achange
inits lengthof 0.75mm.
Disconnect theswivel heads(1, Figure29) fromthesteering
lever (2, Figure29) fromthecentral axle.
Fit the light cluster (1) of the device 99305123 onto the
wheelsofthecentral axle,repeat thechecksand, ifnecessary,
adjust thetoe-inas donefor thefront axle.
71560
NOTE
Figure31
Figure32
Figure33
Figure34
\|t| t|o .|oo|s sta||t aoo t|o stoo|o bo |o t|o 'stoo|o
cooto' os|t|oo, c|oc' t|at t|o| o o t|o s.|vo| |oao (2) oos
exactlyinto the tapered hole of the lever (1). If it does not,
loosenthecollar (3) fixingtheswivel headtothetierod and
turn the swivel head appropriately to achieve the above
condition.
Inthisway, thewheelsof thecentral axlewill bealignedwith
thoseofthefrontaxle(permittedalignmenttolerance0 0.5
mm).
Fittheswivel headbackontotherespectiveleverpermanently
bytighteningthenutsto the requiredtorque.
71744
71561
Position the steering box in the steering centre position.
Check there is 107 mm between the face of the driving
cylinder (4) andthecentredistanceoftheswivel head(6); if
this is not so, disconnect this with the extractor, loosenthe
collar (5),turntheswivel head(6) appropriatelytoobtainthe
required distance and fit the swivel head back on in this
position.
Disconnecttheswivel head(2) fromtheidlerarm(1) andtake
thecylinder (4) into its closed position.
Check that thedistancebetweenthe centredistanceof the
swivel head(4) andthecentredistanceoftheswivel head(1)
is578mm. If thisisnot so,loosenthecollar (2) and turnthe
swivel head(1) appropriatelytoobtaintherequireddistance.
71562
71563
Fit theswivel head(2) backontotheidler arm.
With the steering box in the steering centre position, the
distanceX between theswivel head (2) and thefaceof the
cylinder (3) is140 2mm.
Figure35
After resettingthegraduated sectors on the pointers of the
oscillatingplates (1), turn the wheels so that the left front
wheel ispositioned ontheinternal steeringangleand check
that theother wheelsareturned bytherequiredangle.
Repeat the checkonthesteeringangles, positioningtheleft
front wheel on theexternal steeringangle.
71564
Checking steering angles
1 TRAKKER EURO 4/5 SUSPENSIONS
SECTION 10
Suspensions
Page
FRONT ANDREAR
MECHANICAL SUSPENSIONS 3 . . . . . . . . . . .
- Description 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SHOCKABSORBERS 23 . . . . . . . . . . . . . .
REARSHOCKABSORBERS 24 . . . . . . . . . . . . . . . .
AIRSUSPENSION 25 . . . . . . . . . . . . . . . . . . . . . . . .
- Chassisframelifting, loweringand self-levelling
withremote control 25 . . . . . . . . . . . . . . . . . . . .
- SavingLevels 25 . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRSUSPENSION SYSTEMDIAGRAMS 26 . . . . . .
- Rear air suspensionmaindiagramfor 4x2T/P
tractors 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rear air suspensionmaindiagram
for 4x4vehicles(trucks) 27 . . . . . . . . . . . . . . . . .
- Workingdiagramof pneumatic rear suspensions
for 6x4- 8x4vehicles(trucksand tractors) 28 . . .
MAIN DATA 29 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pneumaticsystem 29 . . . . . . . . . . . . . . . . . . . . . .
MAIN COMPONENTSOFTHEPNEUMATIC
SYSTEM 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reliefvalve 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fault diagnosis 30 . . . . . . . . . . . . . . . . . . . . . . . . .
- Level sensor 30 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electropneumatic distributor 31 . . . . . . . . . . . . . .
- Air lowpressuremanometer switch 31 . . . . . . . .
- Air spring 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSISADJUSTMENT 32 . . . . . . . . . . . . . . . . . . .
- Rear pneumatic suspension
for vehicles 4x2- 4x4 32 . . . . . . . . . . . . . . . . . . .
- Rear pneumatic suspension for vehicles
6x4 - 8x4 withSR rear axles 33 . . . . . . . . . . . . . .
- Rear pneumatic suspension for vehicles
6x4 - 8x4 withHRrear axles 34 . . . . . . . . . . . . . .
Page
DIAGNOSTICS 35 . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 68 . . . . . . . . . . . . . . . . . .
TOOLS 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT LEAF SPRING REMOVAL-REFITTING 75 . .
- Removal 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFINTERMEDIATEAXLE
LEAFSPRING (8X4VEHICLES) 76 . . . . . . . . . . .
- Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARLEAFSPRING
(4X2 - 4X4 VEHICLES) 77 . . . . . . . . . . . . . . . . . .
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARLEAFSPRING
ON CANTILEVER TYPESUSPENSIONS
(6X4 - 6X6 - 8X4 - 8X8 VEHICLES) 78 . . . . . . . .
- Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Procedurefor assemblyof the slipper block and
mountingbrackets for thelongitudinal bars 79 . . .
- TighteningtheU-boltsclampingtheleaf
springto thecentral pivot 79 . . . . . . . . . . . . . . . .
REARCANTILEVERSUSPENSION
(6X4 - 6X6 - 8X4 - 8X8 VEHICLES) 80 . . . . . . . .
- Removal-refittingof central pivot 80 . . . . . . . . . .
- Removal-refittingofcentral pivot shaft 80 . . . . . .
- Renewal of bearings 80 . . . . . . . . . . . . . . . . . . . .
- Removal-refittingofhanger bracket 80 . . . . . . . . .
- Removal of thecentral pivot 80 . . . . . . . . . . . . . .
Page
- Removal of thecentral pivot shaft 80 . . . . . . . . . .
- Removal of the hanger bracket 80 . . . . . . . . . . . .
- Renewal of thebearings 80 . . . . . . . . . . . . . . . . .
- Refittingthehanger bracket 81 . . . . . . . . . . . . . .
- Refittingthecentral pivot shaft 82 . . . . . . . . . . . .
- Refittingthecentral pivot 82 . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARAXLE
LONGITUDINAL ARM 84 . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFINTERMEDIATE
AXLELONGITUDINAL ARM 84 . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARAXLE
TRIANGULARARMFOR VEHICLES
WITH AIRSUSPENSION 84 . . . . . . . . . . . . . . . .
- Removal 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE SUSPENSION ARM
FLEXIBLEPIN 85 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Dismounting 85 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTRIANGULARSWINGINGARM
BALL ARTICULATED JOINT 85 . . . . . . . . . . . . . .
- Dismounting 86 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOCKABSORBERS 88 . . . . . . . . . . . . . . . . . . . . . .
- Removal 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-ROLL BARS 88 . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-ROLL BAR 89 . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT ANTI-ROLL BAR 89 . . . . . . . . . . . . . . . . . .
AUXILIARY AXLEANTI-ROLL BAR
(8X4 VEHICLES) 89 . . . . . . . . . . . . . . . . . . . . . . .
REARANTI-ROLL BAR 89 . . . . . . . . . . . . . . . . . . . .
INTERMEDIATEAXLEANTI-ROLLBAR
(6X4 - 6X6 - 8X4 - 8X8 VEHICLES) 89 . . . . . . . .
- Removal 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39614
Figure1
FRONT SUSPENSION
The front suspension systemis comprised of parabolic or
semi-elliptic leaf springs with double-actinghydraulic shock
absorbers andananti-roll bar.
REARSUSPENSION
4x4- 4x2vehicles:parabolicor semi-ellipticleaf springswith
double-actinghydraulic shockabsorbersandanti-roll bars.
6x4 - 6x6 - 8x4 - 8x8 vehicles: cantilever leaf springs and
anti-roll bars.
FRONT SUSPENSION COMPONENTS
1. Bumpstopwith fixings - 2. ClampingU-bolts- 3. Nut - 4. Plate - 5. Leaf spring- 6. Nut - 7. Washers - 8. Bush-
9. Shacklepins- 10. Plate - 11. Shackleplate- 12. Rubber bush - 13. Metal bush - 14. Nuts
FRONT AND REAR MECHANICAL SUSPENSIONS
Description
39615
Figure2
REARSUSPENSION COMPONENTS
1. ClampingU-bolts - 2. Plate- 3. Leaf spring- 4. Nut - 5. Hanger - 6. Screw- 7. Washers- 8. Bushes-
9. Shacklepins- 10. Nut - 11. Clampingplates- 12. Shackleplates- 13. Hanger - 14. Bumpstop
39616
Figure3
REARCANTILEVERSUSPENSION COMPONENTS
1. Hanger bracket - 2. Hanger bracket - 3. Angular contact bearing- 4. Central pivot shaft - 5. Central pivot -
6. Adjustment shim- 7. Plate- 8. Bolt - 9. Seal - 10. Cap - 11. Springclip - 12. Plugwithgasket - 13. Plugwithgasket -
14. Nut withwasher - 15. Leaf spring- 16. ClampingU-bolt - 17. Spacer
1
72212
Figure4
FRONT SUSPENSION WITH PARABOLIC LEAF SPRINGS: 4x2 - 6x4VEHICLES
90640
Figure5
FRONT SUSPENSION WITH SEMI-ELLIPTIC LEAFSPRINGS: 4x2- 4x4 - 6x4 - 6x6VEHICLES
90641
Figure6
72217
Figure7
72215
Figure8
REARSUSPENSION WITH PARABOLIC LEAF SPRINGS: 4x2 - 4x4VEHICLES
72218
Figure9
REARSUSPENSION WITH SEMI-ELLIPTIC LEAFSPRINGS: 4x2- 4x4VEHICLES
72216
Figure10
REARCANTILEVERSUSPENSION WITH PARABOLIC LEAFSPRINGS: 6x4- 6x6- 8x4 - 8x8 VEHICLES
39622
Figure11
REARCANTILEVERSUSPENSION WITH SEMI-ELLIPTIC LEAFSPRINGS: 6x4 - 6x6 - 8x4- 8x8VEHICLES
MAIN DATA
FRONT SUSPENSION: 4x2 - 4x4- 6x4 - 8x4 MODELS
mm
8tonsparabolicleaf springs
No. 2
No. 4
L
Springlength
(measuredat eyecentres)
1900
+0
- 6
S
Leaf thickness(measuredat centre)
- 1
st
- 2
nd
leaf
- 3
rd
leaf
30
22
S Distancebetweenleaves 3
L
Leaf width 90 0.5
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D
d
D=outsidediameter of eye
d=insidediameter of eye 20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 4.2 6%
FRONT SUSPENSION: 6x6 - 8x4- 8x8 MODELS
mm
8tonsparabolicleaf springs
No. 2
No. 4
L
Springlength
1900
+0
- 6
S
- master leaf
- 2
nd
- 3
rd
leaf
25
26
L
Leaf width 90
D
(bush seat)
60.1 60.2
D d
d=insidediameter of eye 20.2 20.5
Flexibilitymm/KN 4.41
FRONT SUSPENSION: 4x2 - 4x4- 6x4 - 6x6 - 8x4 - 8x8MODELS
mm
9tonsparabolicleaf springs:
No. 2
No. 4
L
Springlength
1900
+ 0
- 6
S
- master leaf
- 2
nd
- 3
rd
leaf
27
28
L
Leaf width 90
D
(bush seat)
60.1 60.2
D d
d=insidediameter of eye
20.2 20.5
FRONT SUSPENSION: 4x2 - 4x4- 6x4 - 6x6MODELS
mm
9tonssemi-ellipticleafsprings: No. 2
L
Springlength
1900
+ 0
- 6
S
Leaf thickness(1
st
9
th
leaf) 16
L
Leaf width 90
D
(bush seat)
60.1 60.2
D d
20.2 20.5
REAR SUSPENSION: 4x2- 4x4MODELS
mm
13.5tonsparabolicleaf springs: No. 2
L
Mainspringlength
Helper springlength
(measuredat block centres)
1800 3
1800 3
S
Thicknessof main springleaves
(measuredat centre)
Thicknessof helper springleaf
(measuredat centre)
26
40
L
Leaf width 100
D
(bush seat)
60.1 60.2
D d
20.2 20.5
Flexibilitymm/KN
Flexibilityafter interventionof helper springmm/KN
3.45
1.47
mm
14tonssemi-elliptic leaf springs: No. 2
L
Mainspringlength
Helper springlength
1800 3
1360 3
S
Thicknessof main springleaves
(1
st
8
th
leaves)
Thicknessof helper springleaves
(1
st
6
th
leaves)
Distancebetweenmainandhelper spring
17
15
10
L
Distancebetweenleaves 100
D
(bush seat)
60.1 60.2
D d
20.2 20.5
Flexibilitymm/KN
Flexibilityafter interventionof helper springmm/KN
2.27
0.9
mm
L
Springlength 1485 2
S Leaf thickness
(measuredat centre)
22
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 4
th
8
th
leaves
96
100
mm
16tonsparabolicleaf springs: No. 2
L
Springlength: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf
1480 2
1040
S LLeaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf (measured at centre)
27
58
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 3
rd
4
th
leaves
96
100
mm
16.5tonssemi-elliptic: No. 2
L
Springlength 1475 2
S
Leaf thickness
(measuredat centre)
22
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 4
th
11
th
leaves
96
100
REAR SUSPENSION: 6x4- 6x6- 8x4 MODELS
mm
10.5tonsparabolicleaf springs: No. 2
L
Springlength: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf
1480 2
1040
S
LLeaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
26
43
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 3
rd
4
th
leaves
96
100
REAR SUSPENSION: 6x4- 6x6- 8x4 - 8x8MODELS
mm
13tonsparabolicleaf springs: No. 2
L
Leaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf
1480 2
1040
S
Leaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
26
53
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 3
rd
4
th
leaves
96
100
REAR SUSPENSION: 6x4- 6x6 - 8x4 - 8x8
mm
L
Springlength 1480 2
S Leaf thickness
(measuredat centre)
22
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 4
th
13
th
leaves
96
100
FRONT SHOCK ABSORBERS
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween theeyecentreand theend:
Open
Closed
Stroke
778 3
448 3
330
777 3
452 3
324
MODELS 4x2 - 6x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Open
Closed
Stroke
754 3
434 3
320
751 3
435 3
316
TRACTORS 4x2 - 6x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Open
Closed
Stroke
754 3
434 3
320
754 3
432 3
322
CABIN TRUCK 4x2 - 6x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Open
Closed
Stroke
754 3
434 3
320
754 3
432 3
322
MODELS 8x4 - 8x8
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Open
Closed
Stroke
689 3
409 3
280
693 3
413 3
280
MODELS 4x4 - 6x6
REAR SHOCK ABSORBERS
SHOCKABSORBERS SACHSBOGE ARVIN
L
Lengthbetween rubber bush mountingsurfaces:
Open
Closed
Stroke
720 3
410 3
310
720 3
412 3
308
MODELS 4x2- 4x4
SHOCKABSORBERS SACHSBOGE
L
Open
Closed
Stroke
762 3
432 3
330
-
-
-
MODELS 4x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Open
Closed
Stroke
652 3
402 3
250
652 3
404 3
248
MODELS 4x2- 4x4 - 6x4- 6x6- 8x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Open
Closed
Stroke
840 3
500 3
340
839 3
500 3
339
MODELS 6x4 - 6x6 - 8x4- 8x8
The air suspensions are highly flexible; they have a
considerable vibration-damping capacity and, above all,
|osoct|vo o t|o |oao oo t|o vo|| c|o, ooo to t|o ssto's
so|-ao,ostoot, t|o 'c|ass|s ao oao soaco' o|staoco
stays constant. By simply pressing a push-button the air
sosoos|oos cao c|aoo t|o 'c|ass| s ao oao soaco'
o|staocoaoo t|oooo t|o|o||t o t|o vo||c|o's |oao|o ooc'.
Besides the well-known benefits provided by the air
suspension, theECASsystemprovides:
- considerablereduction inair consumption;
- readyresponseto the variousadjustment processes;
- simplified systems;
- widesafetymargins;
- full systemdiagnosis.
The ECAS (Electronically Controlled Air Suspension)
ssto aotoat|ca||cooto|s t|o oo|oa| |ovo| o t|o vo||c|o's
air suspensions.
All the above operations anyhow have the constraint of
specificoperatingconditionsandtheassociatedsafetydevices
of thesystems connectedto them.
TheECASelectronic control unit automaticallycontrolsthe
level (distanceoff theroadsurface) of thechassisframewith
the actual values supplied by the sensors, comparingthem
withthenominal values savedinmemory.
In the event of moving awayor the attitude changing, the
electronic control unit governs the electro-pneumatic
assemblieswithwhichtheactual level iscorrectedcompared
to the nominal oneset or savedpreviouslybythedriver.
The system has a remote control for lifting/lowering and
levellingthechassis frameandit ispossibleto workwiththe
vehicleeither stationaryor moving.
Besideslifting, loweringandself-levelling, theremotecontrol
makes it possibleto saveother chassis frame attitudelevels
and call themupwhenrequired.
Chassis frame lifting, lowering and
self-levelling with remote control
Lifting, loweringand levellingthevehicle before loadingand
unloadingit isdonewiththeremote control located next to
t|o o|vo's soat.
The remote control can be removed fromits mountingso
thesemanoeuvrescanbedone fromtheground too.
Lift/lower thechassisframeasdescribedbelow:
- TurntheignitionswitchontoMAR(start).Theyellowand
red indicator lights (9) and (10) will come on for
approximately 3seconds.
- Press the push-button(1 and8) to select therear axle.
Theindicator light A-Bcomeson to showtheselection
made(to cancel the selection, pressthebuttonagain).
- Pressingthebuttons(5and6) andkeepingthempressed
lifts or lowersthechassis frame.
Brieflypressthepush-button(3),thechassisframewill goback
into its normal self-levellingposition.
Theindicatorlight (9) goesout assoonasthenormal level is
reached.
T|o 'STC|' os|-bottoo (+) stos ao act|oo t|o ssto |s
performing.
!
When unloadingheavy loads or containers (with a
crane), lower thechassisframecompletely.
!
Do not stop the engine if the indicator light (10)
comes on. If the indicator light (9) comes on while
driving,stopthevehicleandturntheignitionkeyonto
'STC|', ato ao|ato| () socooos, too t|o
key onto MAR (start). If after approximately two
secondstheindicatorlight(9)doesnotgoout,callthe
ServiceNetwork.
!
After loading/unloadingandbeforestartingoff again,
you must bring the vehicle back into its normal
self-levellingpositionbypressingthe button(3).
Saving Levels
Withbuttons(2) and(7),it ispossibletosaveandcall uptwo
chassis-framepositions:
- Takethechassisframetotherequiredheightbyfollowing
theaboveinstructions.
- Press the STOP button (4) and keep it pressed while
pressingoneof thebuttons(2) or (7).
- Release the button (4). The chassis-frame position has
been saved.
Tocall upasavedposition,presstheassociatedbutton(2) or
(7).
78792
Figure12
AIR SUSPENSION
Rear air suspension main diagram for 4x2T/P (tractors)
73706
1. Checkvalve- 2. Rear axleelectropneumaticdistributor - 3. Rear level sensor - 4. Pressure control intake-
5. Rear axleair spring- 6. Pressurerelief valvewithlimited return- 7. Condensatehandbleeder - 8. 20lt. air reservoirs -
9. Pressuregauge(openingpressure8bar) - 10. Pilot lamp(air suspensionlow pressure).
Figure13
AIR SUSPENSION SYSTEM DIAGRAMS
Rear air suspension main diagram for 4x4 vehicles (trucks)
60905
1. Checkvalve- 2. Rear axleelectropneumaticdistributor - 3. Rear level sensor - 4. Pressure control intake-
5. Rear axleair spring- 6. Pressurereliefvalvewithlimited return- 7. Condensatehandbleeder - 8. 20lt. air reservoirs -
9. Pressuregauge(openingpressure8bar) - 10. Pilot lamp(air suspensionlow pressure).
Figure14
Working diagram of pneumatic rear suspensions for 6x4 - 8x4vehicles(trucks and tractors)
77868
+. C|oc' va|vo 2. |oa a|o o|octo-oooat|c cooto| va|vo 3. |oa |ovo| sooso +. |oa a|o a| s|o 5. |ossoo tost
o|ot 6. Cooto||oo ossoo va|vo .|t| |||too otoo (ooo|o ossoo 8.5 bas) . |aooa| cooooosato b|ooo va|vo
8. 30-||to a| tao's . |ossoo s.|tc| (ooo|o ossoo 8 bas) +0. |||ot |a (a| sosoos|oo |o. ossoo)
Figure15
Print 603.93.371 Aquila Trucks Centres
MAIN DATA
Pneumatic system
DESCRIPTION
Relief valve
- Type: KNORR-BREMSEDR4248 - WABCO 434 100232
Openingpressure
8,5
+0
- 0,3
bar
Electropneumaticdistributors
- Type: WABCO 472 880001
Power supplyvoltage
24 V
+6
- 4.4
Ratedcurrent 0.34A
Operatingpressure 5 13bar
Level sensors
- Type: WABCO 4410500120
Power supplyvoltage Pulse 8 to16 V
Measurement criteria Inductive
Current absorption Max 90 mA
Lever angle Max 100
Air lowpressuremanometer switch
- Type: TDSF13046 S
Operatingvoltage 12/24 V
Electricloadallowed 0.001 1A
Max. operatingpressure 12 bar
Handcondensatebleeder
- Type: VOSS52089975
Max. operatingpressure 13 bar
Air reservoirs
Reservoirs 20 Litres
Electronic unit
- Type: WABCO 446170211
Supplyvoltage
24V
The sensor consists of a coil, fixed to the chassis, where a
pistonconnected bymeansofacamto thelever securedto
thevehicleaxleismoved.
At achangeinthedistancebetweenchassisandvehicleaxle,
theleverrotatesandmovesthepistoncausingtheconsequent
changeoftheself-inductanceofthecoil electricallyconnected
to the electroniccontrol unit.
Level sensor
Theleversensorconstantlyinformstheelectroniccontrol unit
on the changes in the chassis attitude with respect to the
roadway.
20437
73807
Thisisalimited-returnvalvecarryingout two functions:
- Stopping the flow of compressed air feeding the
reservoirswhenthepressureinsidethelatter decreases
under aset value(calibration) duetoamalfunctionorto
excessivewithdrawals.
- Feeding these reservoirs as soon as the brakingsystem
achievesavalueensuringaperfect efficiencyinbraking.
Figure16
Figure17
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM
793824 Relief valve
Fault diagnosis
INCONVENIENT POSSIBLECAUSE SOLUTION
Breathingat outlet Leakfromthemembrane Overhaul theequipment replacingworncomponents
Air leakformthe two
half-bodyconnection
Leakfromthemembranefixing
Deliverybreathing (in
the atmosphere) with
feedingat apressure
lower than the ratedone
Leakformtheintakevalveor form
therelevant seat
Overhaul theequipment replacingworncomponents.
The manometer switch is located near the service air
reservoir,onthedeliverypipingfortheair springsuspensions.
Itsfunctionistoindicatelow(<8bar) feedpressurethrough
anoptical indicator onthedashboard
73810
30106
It isaflexibleelement containingair under pressureandable
tochangeitsextensionirrespectiveofthevalueoftheapplied
load.
5007 Air spring
Air low pressure manometer switch Electropneumatic distributor
52723
The electropneumatic distributor consists of a group of
solenoid valves, whose concentration reduces both the
structurevolumeandtheuseof connections.
Thesolenoidvalvesare directlycontrolledbytheelectronic
control unit and allow to increase, decrease or keep the
volumeof air inthepneumaticcells.
Figure18
Figure19
Figure20
86830
REARSUSPENSION ASSEMBLY DRAWING
Figure21
CHASSIS ADJUSTMENT
Adjustment iscarriedoutbyusingpads99342647andadjustinglevellingvalvesinordertorealiseX distancesshownin thefigures.
Rear pneumatic suspension for vehicles4x2- 4x4
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 M18x 1.5screwfixingtriangular armto bracket 320 to 385 32to 38.5
2 Nut fixingair springsto the mounting 83to 101 8.3 to 10.1
3 M18x 1.5nut for screw fixinglongitudinal rod 375 to 460 37.5to 46
4 M24x 2nut withcollar for brackets fixingrear axleto rear mounting 576 to 704 57.6to 70.4
5 M20nut for screwfixingtopand bottomshockabsorber 210 to 250 21to 25
6 M20nut for pinfixingstabilizer bar to mounting 636 to 777 63.6to 77.7
7 M12nut for bolt fixingstabilizer bar to linkrod 165 to 200 16.5to 20
8 M20nut for pinfixinglink rod to mounting 636 to777 63.6to 77.7
X =60mm
86831
REARSUSPENSION ASSEMBLY
Figure22
Rear pneumatic suspension for vehicles6x4- 8x4 with SR rear axles
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
1 Triangular armscrewM18at rear axlecasing 270 to 300 (27 to33)
2 Flanged nut M20to securestabiliserbaronair springsupport andtosecurearticulated
connectingrodonchassis bracket
636 to 777 (63.6 to 77.7)
3 Nut for screwto secureelastic anchoringmember to articulated connectingrod 165 to 200 (16.5 to 20)
4 Nut to secureair springtosupport 83to 101 (8.3to 10.1)
5 Nut M24withcollar for bracketsto secure rear axleto suspensionsupport 576 to 704 (57.6 to 70.4)
6 Nut M20to securerear axleshockabsorber on topand bottom 210 to 250 (21 to25)
7 Nut M18x1,5to securesiderods 375 to 460 (37.5 to 46)
8 ScrewM18to securetriangular armto bracket 320 to 385 (32 to38.5)
X =125mm
99005
REARSUSPENSION ASSEMBLY
Figure23
Rear pneumatic suspension for vehicles6x4- 8x4 with HR rear axles
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
1 Flanged nut M20to securestabiliserbaronair springsupport andtosecurearticulated
connectingrodonchassis bracket
636 to 777 (63.6 to 77.7)
2 Nut for screwto secureelastic anchoringmember to articulated connectingrod 100 to 122 (10 to12)
3 Nut to secureair springtosupport 83to 101 (8.3to 10.1)
4 Nut M20to securerear axleshockabsorber on topand bottom 210 to 250 (21 to25)
5 Nut M24withcollar for bracketsto secure rear axleto suspensionsupport 540 to 660 (54 to66)
X =64mm
Fault diagnosis comprises two sections:
- Thefirst one, organizedbyerror codes(DTC-FMI), concernsfaults that maybeidentified bytheECAScontrol unit directly.
T|oso ao|ts ao a|o| o ao o|oct|c o|octoo|c oooat|c oatoo.
faults aremainlyof amechanical nature.
SECTION I
ECASsystemtroubleshootingcan be performed with the Cluster or with thediagnosis instrumentsModus, IWT, IT 2000 and
E.A.SY..
Diagnosis with the cluster makes it possible to estimate the situation of faults in the systemin advance, while the diagnosis
instrumentsareessential to performthorough diagnosis and operateon thesinglefaultscorrectly.
Each singleinstrument displays the diagnosisandrepair help.
A computerizedfault-diagnosisstationdedicatedto diagnosingthebrakesystems,airsuspensions,enginesandsystemscontrolled
electronically.
Thestationisequippedwithauxiliaryfunctions,suchas:programmingelectroniccontrol units,consultingthesparepartscatalogue
The vehicle has a30-pin diagnosis socket to interfacewith theinstrument.
IT 2000 (IVECO ElectronicTester)
This makesit possible to takeimmediate action on the vehicle, identifyingit with thechassis number.
It savestheresults of diagnostics actions performed.
It can beusedas aportablePersonal Computer, too, beingfitted for remotediagnosis.
ByusingMODUSasthe mother station it is possibleto updateand configuretheIT 2000.
IT 2000interfaceswith thevehicleviaa30-pin diagnosis socket.
E.A.SY.
35 TRAKKEREURO 4/5 SUSPENSIONS
DIAGNOSTICS
98889
Figure24
98885
Figure25
/ccoss to o|aoost|c scooo |s oss|b|o t|oo| 'ao' o ' y ' aoo ' b ' 'os.
98888
Diagnosis information on thecluster is split into 4 columns:
- Secondcolumn = central unit addressplus fault order number.
- Third column = failure type.
- Fourth column = failure frequency.
Thescreenshowsthreeerror messagesat most,but canstoreupto eight error messages. For displayinganyfurther messages,
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
SOLE-
NOID
VALVES-
ADDI-
TIONAL
AXLELIFT-
ING
SHORT
CIRCUIT
TO POSI-
TIVE
Additional axle
control deacti-
vated.
Additional axle
liftingsolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonadditional
axlecontrol solenoid
valve.
Check: Check isolation
from- batterypin1-
X3 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
SOLE-
NOID
VALVES-
ADDI-
TIONAL
AXLELIFT-
ING
OPEN CIR-
CUIT
Additional axle
control deacti-
vated.
Additional axle
liftingsolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonadditional
valve.
Check: Check continu-
itybetweenpins 4-
X2 / 1 - X3
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
SOLE-
NOID
VALVES-
ADDI-
TIONAL
AXLELIFT-
ING
SHORT
CIRCUIT
TO
GROUND
Additional axle
automatically
lowered.
Additional axle
liftingsolenoid
valvelocked
open.
Checkwiringand con-
nectorsonadditional
valve.
from- batterypin1
X3 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
01 03 SOLE-
NOID
VALVES-
FRONT
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POSI-
TIVE
Front andrear
axles automatic
controls deacti-
vated. Front axle
manual controls
deactivated.
Front axlesole-
noidvalve
lockedclosed.
Checkwiringand con-
nectorsonfront frame
control solenoidvalve.
from+batterypin 15
- X2/ 7- 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
01 05 SOLE-
NOID
VALVES-
FRONT
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Front andrear
axles automatic
controls deacti-
vated. Front axle
manual controls
deactivated.
Front axlesole-
noidvalve
lockedclosed.
Checkwiringand con-
itypins 4- 15 / X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
01 06 SOLE-
NOID
VALVES-
FRONT
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Front axleauto-
maticallylowered.
Front axlesole-
noidvalve
lockedopen.
Checkwiringand con-
from- batterypin15-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
03 03 SOLE-
NOID
VALVES-
REAR
RIGHT
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
RH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonRH engine
axleframecontrol
solenoidvalve.
from- batterypin13-
X2 / 7 -10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
03 05 SOLE-
NOID
VALVES-
REAR
RIGHT
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
RH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonRH engine
axleframecontrol
solenoidvalve.
itypins 4- 13 / X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
03 06 SOLE-
NOID
VALVES-
REAR
RIGHT
SHORT
CIRCUIT
TO
GROUND
RH sideengine
axleautomatically
lowered.
RH engineaxle
solenoidvalve
lockedopen.
Checkwiringand con-
nectorsonRH engine
axleframecontrol
solenoidvalve.
from- batterypin13-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
04 03 SOLE-
NOID
VALVES-
REAR LEFT
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
LH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonLH engine
axleframecontrol
solenoidvalve.
from- batterypin10-
X2 /7- 10X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
04 05 SOLE-
NOID
VALVES-
REAR LEFT
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
LH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonLH engine
axleframecontrol
solenoidvalve.
itybetweenpins 4-
10/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
04 06 SOLE-
NOID
VALVES-
REAR LEFT
SHORT
CIRCUIT
TO
GROUND
LH sideengine
axleautomatically
lowered.
LH engineaxle
solenoidvalve
lockedopen.
Checkwiringand con-
nectorsonLH engine
axleframecontrol
solenoidvalve.
from- batterypin10-
X2 /12 - X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
05 03 SOLE-
NOID
VALVES-
REAR
RIGHT
(THIRD
AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
RH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonRH addi-
tional axleframecon-
trol solenoid valve.
from+batterypin 12
- X2/7- 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
05 05 SOLE-
NOID
VALVES-
REAR
RIGHT
(THIRD
AXLE)
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
RH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonRH addi-
itybetweenpins 4-
12/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
05 06 SOLE-
NOID
VALVES-
REAR
RIGHT
(THIRD
AXLE)
SHORT
CIRCUIT
TO
GROUND
RH sideaddi-
tional axleauto-
maticallylowered.
RH additional
axlesolenoid
valvelocked
open.
Checkwiringand con-
nectorsonRH addi-
from- batterypin12-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
06 03 SOLE-
NOID
VALVES-
REAR LEFT
(THIRD
AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
LH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonLH addi-
from- batterypin14-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
06 05 SOLE-
NOID
VALVES-
REAR LEFT
(THIRD
AXLE)
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
LH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonLH addi-
itybetweenpins 4-
14/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
06 06 SOLE-
NOID
VALVES-
REAR LEFT
(THIRD
AXLE)
SHORT
CIRCUIT
TO
GROUND
LH sideaddi-
tional axleauto-
maticallylowered.
LH additional
axlesolenoid
valvelocked
open.
Checkwiringand con-
nectorsonLH addi-
from- batterypin14-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
07 03 SOLE-
NOID
VALVES-
AIRINLET/
OUTLET
VALVE
SHORT
CIRCUIT
TO POSI-
TIVE
Front andrear
axles automatic
controls deacti-
vated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
Power supply
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonpower sup-
plysolenoid valve.
from- batterypin11-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
07 05 SOLE-
NOID
VALVES-
AIRINLET/
OUTLET
VALVE
OPEN CIR-
CUIT
Front andrear
axles automatic
controls deacti-
vated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
Power supply
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonpower sup-
plysolenoid valve.
itybetweenpins 4-
11/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
07 06 SOLE-
NOID
VALVES-
AIRINLET/
OUTLET
VALVE
SHORT
CIRCUIT
TO
GROUND
Front andrear
axles automatic
controls deacti-
vated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
Power supply
solenoidvalve
lockedopen.
Checkwiringand con-
nectorsonpower sup-
plysolenoid valve.
from- batterypin11-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
10 02 SENSORS
- FRONT
LEVEL
SENSOR
INCOR-
RECT
PARA-
METERS
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Checksensor installa-
tion and eventual
mechanical connection
faults.
10 03 SENSORS
- FRONT
LEVEL
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Checksensor wiring
and connectors.
from- batterypin9-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
10 05 SENSORS
- FRONT
LEVEL
SENSOR
OPEN CIR-
CUIT
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Checksensor wiring
and connectors.
itybetweenpins 7- 9
/ X2
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 4-
5 Kohm
10 06 SENSORS
- FRONT
LEVEL
SENSOR
SHORT
CIRCUIT
TO
GROUND
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Checksensor wiring
and connectors.
from- batterypin9-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
12 02 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
INCOR-
RECT
PARA-
METERS
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
vels.
tion and eventual
faults.
12 03 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
from+batterypin 8-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
12 05 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
OPEN CIR-
CUIT
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
itybetweenpins 7- 8
/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
12 06 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
SHORT
CIRCUIT
TO
GROUND
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
from+batterypin 8-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
13 02 SENSORS
- REAR
LEFT
LEVEL
SENSOR
INCOR-
RECT
PARA-
METERS
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
vels.
tion and eventual
faults.
13 03 SENSORS
- REAR
LEFT
LEVEL
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
from+batterypin 5-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
13 05 SENSORS
- REAR
LEFT
LEVEL
SENSOR
OPEN CIR-
CUIT
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
itybetweenpins 7- 5
/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
13 06 SENSORS
- REAR
LEFT
LEVEL
SENSOR
SHORT
CIRCUIT
TO
GROUND
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
from- batterypin5-
X2 / 12- X1
Connectorsconnected
to control unit. Keyon
STOP.
Comparablevalues: >
1 Mohm
16 03 SENSORS
- FRONT
PRESSURE
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
Possible front
axleoverload.
FAILUREINDI-
CATOR
TURNS
ON.LOAD IN-
DICATION IS
MISSING OR
DOESNOT
RESULT.
Checkconnector wir-
ingand components.
Measuretype:
Voltage (V)
Measurepoint
1: Connector
X1 Pin: 10
Measurepoint
2: Connector
X2 Pin: 3
Key+15ON; Typical Value:
22-26 V;
INSERT
ADAPTERBE-
TWEEN THE
UNIT AND
CABLING
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
16 05 SENSORS
- FRONT
PRESSURE
SENSOR
OPEN CIR-
CUIT
Possible front
axleoverload.
FAILUREINDI-
CATOR
TURNS
ON.LOAD IN-
DICATION IS
MISSING OR
DOESNOT
RESULT.
Checkconnector wir-
ingand components.
Measuretype:
Resistance
(KOhm)
Measurepoint
1: Connector
X2 Pin: 1
Measurepoint
2: Connector
X2 Pin: 3
Key+15OFF; Typical Value:
41KOhm;
INSERT
ADAPTERBE-
TWEEN THE
UNIT AND
CABLING
16 06 SENSORS
- FRONT
PRESSURE
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible front
axleoverload.
FAILUREINDI-
CATOR
TURNS
ON.LOAD IN-
DICATION IS
MISSING OR
DOESNOT
RESULT.
CHECKINSULATION
FROMBATTER-
Y.CHECKCOMPO-
NENT AND CON-
NECTORCABLING
INTEGRITY.
Measuretype:
Resistance
(KOhm)
Measurepoint
1: Connector
X2 Pin: 3
Measurepoint
2: Connector
X1 Pin: 12
Key+15OFF; Typical Value:
1-1.5KOhm;
INSERT
ADAPTERBE-
TWEEN THE
UNIT AND
CABLING
18 03 SENSORS
- RIGHT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
from+batterypin 2-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
18 05 SENSORS
- RIGHT
PRESSURE
SENSOR
(AXLE)
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
itybetweenpins 1- 2
/ X2
Connectorsconnected
to control unit.
Keyon STOP.
- 45 Kohm
18 06 SENSORS
- RIGHT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
from- batterypin2-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
1.5 Kohm
19 03 SENSORS
- LEFT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
from+batterypin 6-
X2 /7- 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
19 05 SENSORS
- LEFT
PRESSURE
SENSOR
(AXLE)
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
itybetweenpins 1- 6
/ X2
Connectorsconnected
to control unit. Keyon
STOP.
- 45 Kohm
19 06 SENSORS
- LEFT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
from- batterypin6-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
1.5 Kohm
1A 03 SENSORS
- RIGHT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
from+batterypin 4-
X3 /7- 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1A 05 SENSORS
- RIGHT
PRESSURE
SENSOR
3RD AXLE
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
itybetweenpins 1-
X2 / 4 - X3
Connectorsconnected
to control unit.
Keyon STOP.
- 45 Kohm
1A 06 SENSORS
- RIGHT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
from- batterypin4-
X3 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
1.5 Kohm
1B 03 SENSORS
- LEFT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
from+batterypin 3-
X3 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1B 05 SENSORS
- LEFT
PRESSURE
SENSOR
3RD AXLE
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
itybetweenpins 1-
X2 / 3 - X3
Connectorsconnected
to control unit.
Keyon STOP.
- 45 Kohm
1B 06 SENSORS
- LEFT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
from- batterypin3-
X3 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
1.5 Kohm
1C 03 SENSORS-
PRESSURE
SENSOR
RAISER
SHORT
CIRCUIT
TO POSI-
TIVE
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control disabled.
Checkconnector wir-
ingand components.
from+batterypin 5-
X3 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1C 05 SENSORS-
PRESSURE
SENSOR
RAISER
OPEN CIR-
CUIT
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control disabled.
Checkconnector wir-
ingand components.
itybetweenpins 1-
X2 / 5 - X3
Connectorsconnected
to control unit.
Keyon STOP.
- 45 Kohm
1C 06 SENSORS-
PRESSURE
SENSOR
RAISER
SHORT
CIRCUIT
TO
GROUND
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control disabled.
Checkconnector wir-
ingand components.
from- batterypin5-
X3 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
1.5 Kohm
21 0B REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
IT ISNOT
POSSIBLE
TO DE-
TECT THE
FAULT
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkcorrect oper-
ationof remote con-
trol onModusinstru-
ment status para-
meters.
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
22 03 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORELEC-
TRO-
VALVES
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON. Loaddistribu-
tion onaxles
control disabled.
Checkwiringand con-
nectorsonframecon-
trol solenoid valves.
from+batterypin 4-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
22 05 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORELEC-
TRO-
VALVES
OPEN CIR-
CUIT
Pneumatic sus-
pensionlocked.
Manual trimvari-
ationscannot be
carried out. Aux-
iliaryfunction
deactivated at
peak.
ECAStotally
disabled.
Checkwiringand con-
nectorsonframecon-
itybetweenpins 4-
X2 / 6.1 or 61.1 sole-
noids
Connectorsconnected
to control unit.
Keyon STOP.
- 90 Ohm
22 06 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORELEC-
TRO-
VALVES
SHORT
CIRCUIT
TO
GROUND
Pneumatic sus-
pensionlocked.
Manual trimvari-
ationscannot be
carried out. Aux-
iliaryfunction
deactivated at
peak.
ECAStotally
disabled.
Checkwiringand con-
nectorsonframecon-
from- batterypin4-
X2 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
26 02 ELEC-
TRONIC
CON-
TROL
UNIT -
MEMORY
CHECK-
SUM
SPECIFIC
DATA
NOT
CORRECT
No frameauto-
maticadjustment.
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control and
level automatic
controls dis-
abled.
vels.
Check: Reprogram
Electroniccontrol unit.
Recalibrateframelevel.
Comparablevalues:
27 02 ELEC-
TRONIC
CON-
TROL
UNIT -
PARA-
METER
CHECK-
SUM
INCOR-
RECT
PARA-
METERS
No frameauto-
maticadjustment.
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control and
level automatic
controls dis-
abled.
vels.
Check: Reprogram
Comparablevalues:
28 02 ELEC-
TRONIC
CON-
TROL
UNIT -
HEIGHT
SENSOR
CALIBRA-
TION
DATA
CHECK-
SUM
FAULT
INCOR-
RECT
PARA-
METERS
No frameauto-
maticadjustment.
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control and
level automatic
controls dis-
abled.
vels.
Check: Reprogram
Comparablevalues:
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
2E 03 POWER
SUPPLY -
PRESSURE
SENSORS
VOLTAGE
SUPPLY
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axles loadsignal
missingor incor-
rect.
Possible axles
overload.
Checkconnector wiring
andcomponents.
from+batterypin 1-
X2 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 0.5
- 4.5 V
2E 06 POWER
SUPPLY -
PRESSURE
SENSORS
VOLTAGE
SUPPLY
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axles loadsignal
missingor incor-
rect. Additional
axlecannot be
raised. Auxiliary
function deacti-
vated at peak.
Possible axles
overload. Addi-
tional axlecon-
trol disabled.
andcomponents.
from- batterypin1-
X2 / 7 - 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
- 50 Kohm
2E 0B POWER
SUPPLY -
PRESSURE
SENSORS
VOLTAGE
SUPPLY
IT ISNOT
POSSIBLE
TO DE-
TECT THE
FAULT
Fault light ON.
Axles loadsignal
missingor incor-
rect. Additional
axlecannot be
raised. Auxiliary
function deacti-
vated at peak.
Possible axles
overload. Addi-
tional axlecon-
trol disabled.
andcomponents.
Check:
A) Check isolation
from+batterypin 1-
X2 / 7 - 10- X1
B) Check isolation
from- batterypin1-
X2 / 12- X1
A) Connectors con-
nected to control unit.
Keyon START.
B) Connectors con-
Keyon STOP.
Comparablevalues:
A) 0.5- 4.5V
B) 30- 50 Kohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
2F 03 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORECAS
REMOTE
CON-
TROL
SHORT
CIRCUIT
TO POSI-
TIVE
Remotecontrols
deactivated.
Level manual
controls dis-
abled.
Checkconnector wir-
ingand components.
from+batterypin 13
- X1 / 7- 10- X1
Connectorsconnected
to control unit.
Keyon START.
1.5 V
2F 06 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORECAS
REMOTE
CON-
TROL
SHORT
CIRCUIT
TO
GROUND
Remotecontrols
deactivated.
Level manual
controls dis-
abled.
Checkconnector wir-
ingand components.
from- batterypin13
- X1 / 12 - X1
Connectorsconnected
to control unit.
Keyon STOP.
- 40 Kohm
30 03 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO POSI-
TIVE-
DATA
LINE
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkconnectors wir-
ingand components.
from+batterypin 11
- X1 / 7- 10- X1
Connectorsconnected
to control unit.
Keyon START.
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
30 06 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO
GROUND
- DATA
LINE
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
ingand components.
from- batterypin11
- X1 / 12 - X1
Connectorsconnected
to control unit.
Keyon STOP.
7 Kohm
31 03 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO POSI-
TIVE-
CLOCK
LEITUNG
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
ingand components.
from+batterypin 8 -
X1 / 7 - 10- X1
Connectorsconnected
to control unit.
Keyon START.
4.5 V
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
31 06 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO
GROUND
- CLOCK
LINE
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
ingand components.
from- batterypin8 -
X1 / 12- X1
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 8.5
- 9.5 Kohm
3C 09 CAN LINE
- CAN
COM-
MUNICA-
TION
ERROR
ABNOR-
MAL UP-
DATE
RATE
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
condition between pin
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
tions: Connectors con-
Keyon STOP.Compar-
ablevalues: 60 ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
3D 09 CAN LINE
- MESSAGE
VSC1
(CCVS)
FROMEN-
GINE
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
Keyon STOP.Compar-
ablevalues: 60 ohm
3E 09 CAN LINE
- MESSAGE
EEC1
FROMEN-
GINE
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
Keyon STOP.Compar-
ablevalues: 60 ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
44 09 CAN LINE
- MESSAGE
TCO1
FROM
TACHO-
GRAPH
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
Keyon STOP.Compar-
ablevalues: 60 ohm
45 09 CAN LINE
- MESSAGE
TIME AND
DATE
FROM
TACHO-
GRAPH
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
Keyon STOP.Compar-
ablevalues: 60 ohm
DTC FMI
Failing
component
Typeof
Failure
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
E7 09 CAN LINE
- DATA
UPDAT-
ING FRE-
QUENCY
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time.
Incorrect brak-
ingadjustment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control units.
FE 02 ELEC-
TRONIC
CON-
TROL
UNIT -
ELEC-
TRONIC
CON-
TROL
UNIT
SPECIFIC
DATA
NOT
CORRECT
Pneumatic sus-
pensionlocked.
Manual trimvari-
ationscannot be
carried out. Aux-
iliaryfunction
deactivated at
peak.
ECAStotally
disabled.
Check: Reprogram
Electroniccontrol unit,
if fault persists, replace.
Comparablevalues:
SECTION 2
Insufficient lubrication. Lubricatethoroughly.
Shockabsorbersnoisyor inefficient. Checkandifnecessaryreplaceshockab-
sorbers.
Wheel bearings worn with excessive
play.
Renewbearingsor adjust play.
Noisysuspension
Leaf springhangers loose. Checkhanger fixingsandifnecessaryre-
place anyloosepins or bolts.
Leaf spring pack loose due to broken
centrebolt.
Overhaul theleafspringsandrenewthe
centrebolt and self-lockingnut.
Leaf springpack loosedue to breakage
of pinssecuringthespringclamps.
Checkleaf springclampsandrenewthe
pins.
Tyrepressuresincorrect. Check andinflateto specifiedpressure.
Front wheel alignment incorrect. Checkandadjust front wheel alignment.
Vehiclepullsto oneside
Hydraulicshockabsorbers inefficient. Fit newshockabsorbers.
Vehiclepullsto oneside
Brokenleaf spring. Overhaul leaf springandrenewcompo-
nentsas required.
Incorrect loaddistribution. Distributeloadevenlyoverloadingdeck.
Leaf springcentrebolt broken. Fit newbolt.
Excessiveflexibilityof suspension
Springleaves over-stressedor broken. Overhaul theleafspringandrenewdam-
aged parts or the complete spring as
necessary.
Leaf springmountings loose. Checkmountingsandifnecessaryrenew
looseshacklepins.
Leaf spring pack loose due to broken
centrebolt.
Overhaul theleafspringsandrenewthe
centrebolt and self-lockingnut.
Squeaking, knocking, excessive noise in
general
Leaf springpack loosedue to breakage
of pinssecuringthespringclamps.
Checkleaf springclampsandrenewthe
pins..
Wheel bearingsworn.
Excessiveplayof bearings.
Renewbearings, if necessary.
Adjust axial clearancesofbearings.
Excessive wear or play of bearings at
central pivot of cantilever suspension.
Renewbearingsand/oradjustaxial clear-
ancesof bearings.
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
FRONT SUSPENSION
Collarednut for leaf springU-bolts 460 50 (46 5)
Flanged nut for front and rear shacklepins 710 70 (71 7)
M14flanged nut for bolt securingfront springhanger to chassisframeandfor securingcentral
pivot on8x4
180 20 (18 2)
M16nut for securingfront springhanger 275 25 (27.5 2.5)
M20flanged nut for anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
Anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
M16nut for lower shock absorber mounting 150 15 (15 1,5)
M14nut for upper shock absorber mounting 63.5 6.5 (6.3 0.6)
M20bolt for shockabsorber-axlemounting 259 26 (25.9 2.6)
Fork-securingM20 nut 400 40 (40 4)
M12nut for anti-roll bar bushingsupport 182.5 17.5 (18.2 1.7)
M20flanged nut for anti-roll bar retainingpin 756.5 20.5 (75.6 2)
REARSUSPENSION
Collarednut for leaf springU-bolts 460 50 (46 5)
Flanged nut for front and rear shacklepins 710 70 (71 7)
Anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
U-bolt retainingbolt for front springpivot 192 17 (19.2 1.7)
M14bolt securingU-bolt for central pivot pin (8x4 - 8x8vehicles) 205 20 (20.5 2)
M14nut for upper and lower shockabsorber mounting 63.5 6.5 (6.3 0.6)
M24nut securingshock absorber to hanger and axle 400 40 (40 4)
M24x110bolt securingshockabsorber to chassis frame 400 40 (40 4)
M20nut or bolt securingshockabsorber to axleor hanger 380 40 (38 4)
M20bolt securingbar and shockabsorber springs support 700 15 (70 1.5)
M20nut securingshockabsorber to hanger and toair springsupport beam 230 20 (23 2)
REARCANTILEVERSUSPENSION
Nut for leafspringclampingU-bolt 825 75 (82.5 7.5)
Flanged hexhead bolt securingupper hanger bracket to chassisframe 270 55 (27 5.5)
Flanged hexhead bolt securinglower hanger bracket to upper hanger bracket 492.5 96.5 (49 9.6)
Retainingbolt for longitudinal bar to leaf springslipper block 420 (42)
Hexretainingnut for reactionbar 390 40 (39 4)
M18hexnut securinglongitudinal bars 385 35 (38.5 3.5)
M18hexnut securinglongitudinal bars 417.5 57.5 (41.7 5.7)
M18hexheadbolt securingtriangular bar to hanger bracket 352.5 32.5 (35.2 3.2)
16x1.5hexbolt securingtriangular bar pivot mountingto axle 277.5 27.5 (27.7 2.7)
Hexsocket screwsecuringplateto axlecasing 430 30 (43 3)
Excludingvehicles withpneumatic suspension
Onlyfor vehicles withpneumatic suspension
TOOLS
99305117
Pneumaticcircuit checkinstruments
99321024 Hydraulicjackfor wheel removal and refitting
99327030 E.A.SY.
99331016 Unitester casefittedwith multimeter and amperometricdevice
99341003 Single-actinglift
99341015
Clamp
99341035
Highpressurepumpfor assemblyofsuspensionpivotsandhangers
99345055 Adapter platefor usewithpullers
99346001 Standard installer (usewithspecificbushes)
99346004 Threadedbush(for usewith99346001and99363245)
99346049
Tool for disassemblingand assemblingflexibleblocksonstabilizer
bar andleafspring.
99346238
Sleevefor installinginner raceof angular contact bearing(usewith
specificbushes)
99346242
specificbushes)
99346243
specificbushes)
99346247 Referencespacersfor ECASsuspensionadjustment
99363245 Threadedbush(for usewith99346001and 99346004)
99363296
Tool tobefittedtobearingspindleforinstallinginnerraceofangular
contact bearing (use with 99346001 - 99346004 - 99346238 -
99346243 - 99363245)
99363309
Tool tobefittedtobearingspindleforinstallinginnerraceofangular
contact bearing (use with 99346001 - 99346004 - 99346242 -
99346243 - 99363245)
99370007 Interchangeabledriver handlefor bearinginstallers
99374094
Installer for outer bearing races (134 to 215) (for use with
99370007)
99374119
Installer for springmountingoil seal
99374131
Installer for springmountingoil seal
Vehicleswith21tonssuspensions(outsidediameter ofcentral pivot shaft 88 mm)
Vehicleswith32tonssuspensions(outsidediameter ofcentral pivot shaft 120mm)
Thischaptershowstechnical constructiondrawingsofthespecial purposetool (S.P.2403),usedinservicingthesuspensiondescribed
inthissection. Thismaybebuilt bytherepair workshops.
EXPERIMENTAL TOOLS
90643
Removal
Arrange vehicleonflat groundand lockrear wheels.
Loosenfront wheels securingnuts.
Byahydraulic jack, lift the vehiclefromfront side and rest it
ontwo support stands.
Unscrew wheels securingnuts and disconnect wheels with
Positionahydraulic jacksuitable to support front axlewhen
theleaf springwill bedisconnected.
Then,lowerthehydraulicjackthat isprearrangedunderfront
axleuntil leaf springtension is released.
Removeboard (5) operatingasfollows:
- removescrews(4),operatingfromunderthevehicleand
removeboardcompleteassembly;
- removescrew(10) of rear shackle(11);
Ifscrew(10) isorientedwithitsheadtowardsthe
external side of the vehicle, it is necessary for
dismountingthevehicleto partiallydisconnect the
air filter asdescribed below:
- disconnect lower cover (2);
- removecontainer (15);
- disconnectfilteringcartridge(14)operatingon
nut (1);
NOTE
Checkthethreadofthebracketsjoiningleafsprings
to front axle; if faults are found, rectify thread
(operation500412), or replacebrackets.
Forcorrectcover (2) springsclamping,aligntomark
(12).
Tighten screws (10) with their head oriented
inwards.
Check stopspringbuffers conditions; if stopspring
buffers are found to be worn out, replace them
(operation500417).
NOTE
Tightennutsat prescribedtorque.
- remove the nut with screw (3) securingleaf springto
front support;
- unscrewnuts (6) and unthreadU bolts(7);
- disengage shock absorber (13) from suspension
operatingonfastener (8);
- removeleafspring(9).
Refitting
For reconnection, invert operations performed for
disconnectionobservingfollowingwarnings.
Figure26
500410 FRONT LEAF SPRING REMOVAL-REFITTING
90644
Figure27
Parkthevehicleonlevel groundand chocktherear wheels.
Loosenthewheel nutsonthe 2nd axle.
Usingahydraulicjack,raisethefrontofthevehicleandsupport
it on two stands.
Unscrew the wheel nuts and, using hydraulic trolley
99321024, removethewheels.
Position a hydraulic jack to support the axle when the leaf
springisdetached.
Lower the hydraulic jack supportingthe axle to relieve the
tension ontheleaf spring(2).
- Detachthefrontleafspringfromthemounting(1)before
proceedingwiththeremoval of thesecondsteeringaxle;
- removetherear shacklepin(7);
- undothefront mounting(1)todetachtheleafspringfrom
thevehicle;
- unscrewthefour nuts(4) andwithdrawtheU-bolts(3);
- remove the nut and bolt (5) and detach the shock
absorber (20) fromthesuspension;
- removethecompleteleaf spring(2).
Refitting
Carryout theremoval operationsinreverseorder, observing
thefollowinginstructions:
Removal
Inspect the threadsonthe U-bolts thesecure the
leafspringtotheaxle;ifdamaged,re-cutthethreads
(operation500412) or renewtheU-bolts.
Checktheconditionof therubberbumpstopsand
renewthemif deteriorated (operation 500417).
Tightenall nuts to theprescribed torquesettings.
Totightendownthecap(9),first tightenbolt(10) to
the prescribed torque, interposing spacer (8), and
thentightenbolt (11) without aspacer.
Before theleaf springcan be attached to thetwo
mountings, the spring must be loaded (using
suitableequipment includinghydraulicjacksandby
loading the vehicle itself), thereby causing it to
extendand bringingtheholesfor theshacklepins
into alignment.
NOTE
500420 REMOVAL-REFITTING OF INTERMEDIATE AXLE LEAF SPRING (8x4 VEHICLES)
Figure28
Removal
Parkthevehicleonlevel ground and chockthefront wheels.
Usingahydraulicjack,raisethevehicleandsupport thechassis
ontwo stands.
Removethewheelsusinghydraulictrolley99321024.
Removethenuts(5) andwithdraw theU-bolts securingthe
leafspring(3) to theaxle.
Positiontrolley99306064undertheleafspringandattachthe
latter to thetrolleywiththespecificbrackets.
Removebolts(11and12) andremovethecap(2) alongwith
thespacer (9) that securesthespringshacklepin tothefront
hanger (1); unscrew nut (8) and withdraw the shackle pin
securingtheshackleplate (7) to therear hanger (6).
Operate the jack to lower the axle so that the leaf spring
centrebolt can bewithdrawn.
40533
thefollowinginstructions:
Refitting
InspectthethreadsontheU-boltsthesecuretheleaf
spring to the axle; if damaged, restore the threads
Check thecondition of therubber bump stopsand
renewthemif deteriorated (operation 500417).
Tightenall nuts to theprescribed torquesettings.
Totightendownthecap(9),first tightenbolt (10) to
the prescribed torque, interposing spacer (8), and
thentightenbolt (11) without aspacer.
72339
REARSUSPENSION WITH PARABOLIC LEAF SPRING
500410 REMOVAL-REFITTING OF REAR LEAF SPRING (4x2 - 4x4VEHICLES)
Figure29
Removal
Parkthevehicleonlevel ground, chockthefront wheelsand
loosentherear wheel nuts.
Positionthebracket 99370617onahydraulic jack, placethe
jackunder theaxleandraisetherear of thevehicle.Support
the chassis frame and the intermediate and rear axles on
stands,whileensuringthat thebracketmaintainscontact with
theaxle.
Remove the wheel nuts and remove the wheels using
hydraulictrolley99321024.
Removethenuts(5)oftheU-bolts(1) securingtheleafspring
(6) to thecentral pivot.
Remove the bolts (3) and detach the longitudinal bar
mountingbracket (4) and theslipperblock (2) fromtheaxle
casing.
Proceedwiththeremoval ofthecompleteleafspringfromthe
vehicleusingasuitablejack.
71516
thefollowinginstructions.
Refitting
InspectthethreadsontheU-boltsthesecuretheleaf
spring to the axle; if damaged, re-cut the threads
Fit theslipperblockandthelongitudinal barmount-
ingbracket asdescribedon page 79.
6
500430 REMOVAL-REFITTING OF REAR LEAF SPRING ON CANTILEVER TYPE
SUSPENSIONS (6x4- 6x6 - 8x4 - 8x8VEHICLES)
36836
- Apply MODILAC grease to the threads of the slipper
block(1);
- applyresinfor boxframes to bolt contact surfaces and
holesinthebracket (2);
- after having aligned the parts, pre-tighten bolts (3) in
cross-wisesequenceto atorqueof 100Nm;
- finallytighten bolts(3) to atorqueof 420 Nm.
TighteningtheU-boltsclampingtheleaf spring
to the central pivot
Tightentheleafspring(4and6) clampingnuts(5and7) asfol-
lows:
- tightennuts (5) to atorqueof 300to 500 Nm
Figure30
Procedure for assemblyof the slipper block and mounting brackets for the longitudinal bars
86426
39073
39075
39076
39077
Figure31
Figure32
Figure33
Figure34
Figure35
500440 Removal-refitting of central pivot
500442 Removal-refitting of central pivot
shaft
500443 Renewal of bearings
500449 Removal-refitting of hanger bracket
Removal of the central pivot
Removetheleafspring(1) asdescribedintherelativechapter
(operation500430).
With tools 99341011(5), 99341003(6), 99341015(7) and
reactionblock99345055(4),withdrawfromshaft(3) thecen-
tral support (1) completedwithexternal half-bearing(2).
Fit thepipe(3) ofhydraulicpump99341035(4) to thehole
inthehanger bracket (1); operatethepumpto separatethe
shaft (2) fromthebracket (1).
Removebolt(6)andplate(5) andwithdrawtheshaft(2) from
thebracket (1).
Detach the longitudinal tie-rods (2 and 3) and detach the
bracket (1). If the upper bracket (1, Figure38) is to be
replaced, removetheretainingbolts( ) and detachit from
thechassissidemembers.
Usingahydraulicpress, withdrawtheinner bearingrace (2)
of thecentral pivot shaft (1).
!
Raisethefrontofthevehicleandsupportit onstands
so that thechassis frameislevel.
Removethespringclip(6) and removethe cap(5).
Unscrewthebolts(4) andremoveplateandtheun-
derlyingadjustment shims(2).
Removal of the hanger bracket
Renewal of the bearings
Donotremovethebolt (6) andplate(5) asthesewill
prevent the shaft (2) frombeingviolentlyexpelled
fromthebracket duringthesubsequent operation.
Loosenbolt (6) byonefull turn.
Removal of the central pivot shaft
REAR CANTILEVER SUSPENSION
(6x4 - 6x6- 8x4 - 8x8vehicles)
Theouter racesofthebearings(4and5) areto beremoved
fromthecentral pivot withtheaidofasuitablebearingextrac-
tiontool.
Torefit thebearings, usetool 99374094(2) withapressand
partiallyinsert thebearingsinthecentral pivot (3).
Complete the installation using a mallet and driver handle
99370007(1).
39078 39080
39079
Figure36 Figure37
Figure38
Usinginstaller (1) 99374119or 99374131, install theseal (2)
inthecentral pivot (3).
Thenfit ring(4).
Refitting the hanger bracket
Refit thelower bracket (10) totheupper bracket (1) tighten-
ingtheretainingboltsinthedirectionofarrowBtothespeci-
fiedtorque.
In cases where it was also necessary to remove the upper
bracket (1), observethefollowinginstructionon refitting:
- gradually tighten the bolts in the sequence
2-3-4-5-6-7-8-9until thepartsarebrought together;
- tighten the bolts to the specified torque first in the
direction of arrowA and thenof arrowB;
- re-tightentheboltstothespecifiedtorqueinthedirection
of arrowA.
- Tighteningtorquefor bolts securinglower bracket (10)
to upper bracket (1): 395 to 590 Nm;
- Tighteningtorqueforboltssecuringupper bracket (1) to
chassissidemember: 215to 325 Nm;
2
1
3 4 5
6 7 8 9
10
HavingobtaineddistanceB,openthedischargevalveonthe
hydraulicpump99341035 and wait at least 10minutesbe-
forefinallytighteningthebolt (1) toatorqueof 830to 665
Nm( 83to66.5kgm). Disconnect thepumptubefromthe
hanger bracket andrefit theplugto theoil inlet hole.
39081
39083
39082
39084
39385
Figure39
Figure40
Figure41
Figure42
Figure43
Insert the shaft (1) in thehanger bracket (2) with the holes
oriented asshowninthefigure; positiontheplate(4) onthe
bracket (2) andsecureit to theshaft (1) with thebolt (3).
Screwthe bolts ( ) into the holes in the shaft (1); place a
straight edge(2) alongthetopoftheboltsandcheckthat the
endsA andBareequidistant fromtheground;ifnot, adjustby
turningtheshaft (1).
Hold the shaft (1) against rotation and tighten the bolts (3,
Figure37) toatorqueof 50Nm.MeasurethedistanceA be-
tweentheendoftheshaft (1) and thehanger bracket (2).
Thedistancemeasuredmust bewithintherangeindicatedin
thetable inFigure 42.
While holdingtheshaft (2) against rotation, operatethehy-
draulicpump99341035(3) andsimultaneouslyscrewinbolt
(1) until the end of the shaft (2) is positioned at distance B
fromthebracket.
ThedistanceBmust beequal toA-C,whereA isthedistance
previouslymeasuredandC isthevalueindicatedinthetable.
ThedistanceBmust bewithintherangeindicatedinthetable.
Lubricatetheoil seal ( ) with TUTELA MR3 grease and fit
it to the shaft (2). Using tools 99346238 or 99346242 (3),
99363296or 9936330(4),99363245(5),and99346004(6),
whicharetobefittedtotheshaft (2) asshown,install theinner
bearing(1).
!
Towardstheendoftheshaftfittingprocedure,theoil
reachesapressurebetween800and1300bar.
Refitting the central pivot
Refitting the central pivot shaft
Measure-
Outsidediameter ofshaft end(2)
Measure
ment
88mm 120 mm
A 217.5 220.5 211.5 215
B 213.5 216.5 205 208.5
C 4.5
+0.5
6.5
+0.5
Fit: oil seal (8) lubricatedwith TUTELA MR3greaseandcap
(11) withplug(10) positionedat thetop.Securethecap(11)
to thecentral pivot (3) withspringclip(9). Removetheplug
(10) andpourinTUTELAGI/Aoil until itflowsoutofthehole
(quantity 0,5l).
InjectTutelaMR2greaseintothegreasenipplelocatedonthe
hanger bracket: completethesuspensionrefittingprocedure
asdescribed onpage 78.
CENTRAL PIVOT COMPONENTS
1. Oil seal - 2. Oil seal - 3. Central pivot -
4. Outer race of inner bearing- 5. Inner raceof inner
bearing- 6. Outer raceof outer bearing- 7. Inner raceof
outer bearing- 8. Oil seal - 9. Springclip - 10. Plug-
11. Cap - 12. Bolt - 13. Plate - 14. Adjustment shims-
15. Shaft - 16. Seal.
39086
39087
40189
39088
Figure44
Figure45
Figure46
Figure47
Fit the central pivot (1) to the shaft (4) and, using tools
99346243 (3), 99363296 (5), 99363245 (6), 99346004 (7)
and99346001(8), fittedtotheshaft (4) asshown, install the
inner raceof theouter bearing(2).
DeterminethethicknessSofthebearingaxial playadjustment
shims(1) asfollows:
- applytheplate(2) andtightentheretainingbolts( ) to
atorqueof 30Nm;
- Remove the bolts ( ), remove theplate and measure
the distance between the end of the shaft (3) and the
inner race(4) of thebearing:
distanceA shaft protrusion
distance-A shaft stand-in
- measurethestand-inof theplatesurface(1) asshownin
Figure35: distanceB.
ThethicknessSoftheadjustment shinis givenby:
S=B+C - ( A).
A andBarethemeasureddistancesandC istheaxial playof
thebearings(0.1to0.3mm).Thenfit:adjustmentshim/softhe
calculatedthicknessandtheplate(2) andtightentheretaining
bolts( ) toatorqueof240Nm.Fittheleafspringandtighten
theu-bolt nutsin themanner described on page79.
Tapthecentral pivot afewtimesinthedirectionoftheshaft
axis,thencheckthat thepivot canfreelyrotatethrough180;
ifnot,increasethethicknessoftheadjustment shimby0.1mm.
Towardstheendoftheinstallationoperation,it will
be necessary to tap the central pivot (1) with a
mallet toensurethat theinnerracesofthebearings
seat correctlyin their respective housings.
Removetheinstallationtoolsfromtheshaft.
NOTE
Figure48
38697
36838
Figure49
Removal
Remove the retaining nuts or bolts ( ) of the longitudinal
arms (1, Figure49) or triangular arms(1, Figure48), andre-
movethearms.
LONGITUDINAL ARMSFITTEDTO 6x4- 8x4 - 8x8 VEHICLES
TRIANGULARARMFITTED TO VEHICLES
WITH AIRSUSPENSION 4x4 - 6x4- 8x4
1 1
Refitting
Refittingis the reverseof removal. Tightennuts/boltsto the
specifiedtorque.
7
528913 REMOVAL-REFITTING OF REAR AXLE LONGITUDINAL ARM
528914 REMOVAL-REFITTING OF INTERMEDIATE AXLE LONGITUDINAL ARM
528918 REMOVAL-REFITTING OF REAR AXLE TRIANGULAR ARM FOR VEHICLES WITH
AIR SUSPENSION
Dismounting
Usingasuitablepressanddrift, compresstheflexiblepart of thepin (1) inorder to removethecirclip(2) and theunderlyingring
(3) with pincers.
Withdrawthepin(1) fromthesuspension arm(4).
Mounting
Carryout theremoval operationsin reverseorder, bearinginmind that the pinmountingfacemust bepositioned at 90_ to the
longitudinal axisof thesuspensionarm. Thecirclip openingmust beoriented asshown inthedetail inthefigure.
REPLACING TRIANGULAR SWINGING ARMBALL ARTICULATED JOINT
38700
79479
Figure50
Figure51
LONGITUDINAL SUSPENSION ARM
TRIANGULARSUSPENSION ARM
REPLACING THE SUSPENSION ARM FLEXIBLE PIN
88878
88877
88879
88880
88881
Figure52
Figure53
Figure54
Figure55
Figure56
Dismounting
Dismount cover (1).
Unscrewscrew(1).
Removespringring(1) bypliers.
Removeunderlyingcheck rings(2, 3).
Dismount theball articulatedjoint withM20X 1,5screw(1)
and suitabletools.
Mount ball articulatedjoint (1) into seat byprovidedbeater
!
Replacing the ball articulated joint directly on the
vehiclecanonlybeperformedontractors.Forboxed
trucks,theoperationiscarriedout at thebenchafter
detaching the reaction triangle (see procedure
described at page84).
Before replacingthe articulated joint, astand has to
be arranged under the axle in order to avoid
dangerous oscillations of it once dismounting has
beenperformed.
Mounting
Once it has been removed, the cover is to be
replacedbyanewone.
NOTE
88882
88883
88879
88884
88878
88885
Figure57
Figure58
Figure59
Figure60
Figure61
Figure62
Arrangepart (1) ofthetool ofSp.2403underoneofreaction
triangle arms to the purpose of making upper seal ring
mountingeasier.
Mount seal rings (1, 2, 3).
Removethepart oftool (1) ofSp. 2403(seepreviousfigure).
Positionspacer (1) of thetool of Sp. 2403asinfigure.
By tool (1) ofSp.2403,drawtheball articulatedjoint andseal
ring.
Tightenscrew(1) with aproper torque (135 Nm).
Mount cover (1).
Removal
Removetheshockabsorberbyremovingtheupperandlower
mountingbolts/nuts.
Inspect therubber bushes; if wornor deteriorated,
renewthem. Checkshockabsorber efficiencyusing
suitabletest equipment.
40432
40433
36780
38698
Figure63
Figure64
Figure65
Figure66
1. Hanger bracket - 2. Bushes - 3. Nut -
4. Shock absorber - 5. Bush - 6. Lower mountingbracket -
7. Nut - 8. Bolt - 9. Washer - 10. Bracket - 11. Nut.
FRONT ANTI-ROLL BARCOMPONENTS
1. Bush- 2. Bushsupport - 3. Anti-roll bar -
4. Rubber bush- 5. Bolt - 6. Linkrod - 7. Bolt -
8. Rubber bush- 9. Bracket - 10. Nut - 11. Bolt
REARANTI-ROLL BAR COMPONENTS
1. Bush- 2. Anti-roll bar - 3. Bolt - 4. Rubber bush-
5. Nut - 6. Bracket - 7. Linkrod - 8. Cap
To renew the rubber bushes (4-8, Figure65) and (4,
Figure66),useapresswithtool 99346049toremoveandin-
stall thebushes.
Refitting
Carry out the removal operations in reverse order; tighten
bolts andnuts to specifiedtorques.
5
1
2
3
4
6
7
11 10 9 8
1. Hanger bracket - 2. Bushes - 3. Nut -
4. Shock absorber - 5. Bush - 6. Lower mountingbracket -
7. Nut - 8. Bolt - 9. Washer - 10. Bracket - 11. Nut.
5009 SHOCK ABSORBERS 5289 ANTI-ROLL BARS
NOTE
38694
72233
Figure67
Figure68
Removetheanti-roll bar byremovingthenuts/bolts
securingthe pivot mountings and the cap retaining
bolts.
ASSEMBLY DRAWINGFORFRONT ANTI-ROLL BAR: 4x2- 6x4 - 8x4 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Front axle - 6. Cap.
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 4x4 - 6x6 - 8x8VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Axle- 6. Cap.
Check the bushes and/or rubber mountings and
renewthemiftheyshowsignsofwear or deteriora-
tion.
Refitting
Refit bycarryingout theremoval operationsinreverse
order; tighten nuts/bolts to thespecified torques.
Positionthehalfbushes(4) sothatthejointislocated
asshownin thefigure.
NOTE
5289 ANTI -ROLL BAR
528930 FRONT ANTI -ROLL BAR
528940 AUXILIARY AXLE ANTI-ROLL BAR (8x4VEHICLES)
528960 REAR ANTI-ROLL BAR
528950 INTERMEDIATE AXLE ANTI-ROLL BAR (6x4- 6x6 - 8x4 - 8x8VEHICLES)
Removal
72234
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 6x4 - 8x4 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rear axle- 5. Rubber bush (intwo halves) - 6. Cap.
72235
Figure69
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 6x4 - 8x4 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 4. Rear axle- 5. Cap.
72236
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 6x4 - 8x4 VEHICLESWITH AIRSUSPENSION
1. Upper hanger bracket - 2. Linkrod- 3. Rubber bush(intwohalves) - 4. Anti-roll bar - 5. Rear axle - 6. Cap.
Figure70
Figure71
72237
ASSEMBLY DRAWINGFORINTERMEDIATEAXLEANTI-ROLL BAR: 6x4 - 6x6 - 8x4- 8x8VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Front axle.
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 4x2 VEHICLES
72238
Figure72
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 4x2 - 4x4 VEHICLESWITH AIRSUSPENSION
ASSEMBLING DIAGRAMFORADDITIONAL AXLE STABILISINGBARFOR8x4VEHICLES
WITH PNEUMATIC SUSPENSION
Figure73
Figure74
38695
1 TRAKKER EURO 4/5 WHEELSANDTYRES
SECTION 11
5025 Wheels and tyres
Page
DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tirepressurevalues 3 . . . . . . . . . . . . . . . . . . . . .
TOOLS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATIC WHEEL BALANCING 6 . . . . . . . . . . . . . .
CORRECTION OFRESIDUAL STATIC IMBALANCE 7
TYREINFLATION PRESSURES 7 . . . . . . . . . . . . . .
HOW TYREBEHAVIOURDEPENDS
ON PRESSURE 8 . . . . . . . . . . . . . . . . . . . . . . . .
The wheel rimis the structure that confers rigidity to the
wheel and isidentified bythefollowingdimensions:
- rimdiameter,measuredacrosscentreofthewheel from
onebead seat to theother
- rimwidth, (distance between the inside of the bead
flangesacrosstherim)
Thetyreperformsthefollowingfunctions:
- to cushion the wheel against shocks transmitted from
uneven roadsurfacesusingtheelasticityofair;
MAIN DATA
- to transmit thedrivingforcedelivered bythe engine to
theroadsurfaceto movethevehicle;
- to confer the maximum grip and stability of contact
between the tyre and the road, while affording
satisfactorydurability;
- to withstandtheforces createdbysuddenbraking,hard
acceleration and thecentrifugal forces generated when
cornering;
- to ensure the stabilityof the vehicle at high speed; to
ensurethat steeringeffort is converted into directional
movement.
When checkingtyre pressures refer to thevalues
|oo|catoo |o t|o soc||c '|so aoo |a|otooaoco'
handbook.
NOTE
DESCRIPTION
WHEELS Wheel rims Tyres
Discwithspecificcontinuousrims
22.5x9.00
22.5x9.00
22.5x8.25
13R22,5
315/80 R22.5
12R22.5
Tire pressure values
99305037 Electronicon-vehiclebalancer for front wheel balancing
TOOLS
TROUBLESHOOTING
Excessivespeedover roughsurfaces. Reducespeed.
Suddenvariationsinspeedduetoviolent
accelerationor harshbraking.
Avoid all unnecessaryacceleration and
braking.
Excessivewear Excessive speed with tyres under-in-
flated.
Check tyrepressureswith tyrescold.
Tyresover-inflated. Reducetyrepressures.
Vehicle overloaded. Consult permissibleloadspecifications.
Differenceintyrepressuresbetweendif-
ferent pairsofwheels.
Check tyrepressures.
Tyresunder-inflated:wearconcentrated
onouter edgesof thetreadrather than
inthecentre.
Inflatetyresto correct pressure.
Tyres over-inflated: wear concentrated
inthecentreofthetread.
Reducetyrepressures.
Insufficient front wheel toe-in:excessive
wear oninner edgesof tyretreads.
Check andadjust toe-in.
Unevenwear
Front wheelsset toincorrect wheel ge-
ometry.
Restore correct wheel geometry.
Wheel rims deformed causing imbal-
ance.
Repairwheel rims,ifpossible, orreplace
them; thenbalancethewheels.
Tyresincorrectlyfitted torims. Fit the tyre correctly and balance the
wheel.
Rearaxleout ofparallel duetobreakage
onleaf springcentrebolt,springsof dif-
ferent lengths or buckled springs.
Overhaul thesuspension.
Excessive front wheel toe-in; excessive
wear onouter edges of tread.
Check andadjust front wheel toe-in.
(Continued)
Front wheelsout of balance. Balancethewheels.
Vehicle pullsto oneside
Front tyresinflated to different pressur-
es.
Checkthatbothtyresareinflatedtocor-
rect pressure.
Excessivelyunevenwear betweentyres
of thesamewheel pair.
Renewthetyrethat isexcessivelyworn.
Thefront wheels canbebalanced whileonthevehicleusing
the electronic balancer 99305037; this method has the
advantageofbalancingthewheel alongwiththeotherrotating
masses.
Theoperation must becarriedout as follows:
- Jackupthefrontofthevehicleandcheckthat thewheels
canrotatefreely.
- Position the pickup unit (1) under the axle near to the
wheel,settingtheheight sothat thewheel spinnerofunit
99305037(2) isincontact withthetyre;positionanaxle
standunder theoppositeendoftheaxleandlowerthe
jack.
- Connect thelead(3) of thepickup unit to thebalancer
99305037.
- Makearadial referencemarkontyre,usingchalkorastrip
of adhesivetape.
- Turn switch (2) to the static balancing position and
sensitivityswitch(4) tonotchn 5onthegraduatedscale.
- Turnonswitch(5) for themeterlight(1) andturnonthe
strobelamp(8).
- Turn the wheel spinner switch (6) to the first speed
positioninorder to rotatethewheel.
Turn the wheel spinner switch (6) to the second speed
positionand pushthebalancer against thetyre.
Asthewheel isspinning,thestroboscopiceffectwill makethe
referencemarkappearstatic;theneedleonthemeter (1) will
movefromzerotoamaximumvalueandthenreturntozero.
Once the needle has started to fall, withdraw the balancer,
switch off the wheel spinner completely (6) and brake the
spinner motor bymeansofthebrakelever (7).
Thewheel will continuetorevolveduetoinertiaandthenew
positionof thereferencemarkshould benoted.
Readthevalueshownbytheneedleontheweightindication
meter (1). Multiplythisvaluebytentoobtainthecorrection
weight to befittedto therim.
16997
Figure1
Figure2
502511 STATIC WHEEL BALANCING
Fit thecalculatedcorrectionweight asshowninthefigure.
Ifthemeterneedleremainsinthegreensectionduringtesting,
the wheel isalreadybalanced.
Iftheweightrequiredtobalancethewheelexceeds
100grams,dividetheweight inhalfandattach one
ofthetwopartsthusformedtotheinsideoftherim
andtheother totheoutside,makingsurethatthey
areinthe sameposition.
CORRECTION OF RESIDUAL STATIC
IMBALANCE
- Iftheweight isinzoneA, thismeansthat it istoolight and
thereforeitmustbeincreasedbytheamountshownonthe
weight indicationmeter (1, Figure2).
- Iftheweight is inthebottomzoneC, thismeansthat it is
too heavyandthereforemust bereducedbytheamount
shownontheweight indicationmeter.
- Iftheweight iszonesBorD,donotincreaseorreducethe
weight,but moveit upwards5cminthedirectionshown
bythearrowsinfigure 4.
16998
23885
Tocorrectresidualimbalance,repeattheoperationsdescribed
above,and, referringtothediagraminFigure 4andtheweight
indication onthemeter (1, Figure2), adjust as follows:
502510 TYRE INFLATION PRESSURES
Tyrepressuresmust becheckedwiththetyrescold. Takecare
to obtainanaccuratereading: too highapressurewill result in
aharshrideandexcessivewear ofthecentrepart ofthetread,
whileifthepressureistoolow, theloadwill not bedistributed
evenly over the entire tread but concentrated on the edges,
causing premature wear of these areas and damage to the
internal structureof thetyre.
Unequal tyrepressureswill affect thestabilityofthevehicleand
impair drivingsafety.
Abnormal tyrewear canoccur indifferent partsof thetread.
Figure3
Figure4
NOTE
Thediagramsillustratehowdifferent inflationpressuresaffect
tyrebehaviour andperformance.
PERFORMANCE40%
PERFORMANCE90%
PERFORMANCE100%
CORRECT
+20%
- 40%
Figure5
(Thepercentagevaluesgiveninsidethetyresindicate
the inflation pressure levels, while the performance
valuerefers to thelifeofthetyre).
Figure6
Figure7
NOTE
If anomalous wear of front tyres is found (either insideor outside the tread), havefront wheel toe-in checked. Never
ocooo t|o a|o .o||t o a|o (t|o vo||c|o's oss .o||t bo|o ooc|aooo).
It isadvisabletochangethetyrepairfittedtooneaxlewhenbands- duetoblockwear - arevisibleover theentiretread
width(seedottedareasonpictures).
Tyresare provided withwear indicators. Replacement iscompulsorywhensuchindicatorsare reached.
NOTE
HOW TYRE BEHAVIOUR DEPENDS
ON PRESSURE
1 TRAKKER EURO 4/5 STEERINGSYSTEM
SECTION 12
5014 Steering system
Page
DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mainoperatingfaults of amechanical nature 5 . .
TOOLS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Steeringcontrol diagramfor 4x2- 6x4 vehicles
(ZF8098 power steering) 10 . . . . . . . . . . . . . . . .
- Steeringcontrol diagramfor 4x4- 6x6 vehicles
- Steeringcontrol diagramfor 8x4x4vehicles
- Steeringcontrol diagramfor 8x8vehicles
- Steeringhydraulic control circuit diagramfor
8x4x4 - 8x8vehicles 14 . . . . . . . . . . . . . . . . . . . .
STEERINGCONTROL 15 . . . . . . . . . . . . . . . . . . . .
HYDRAULIC STEERING 16 . . . . . . . . . . . . . . . . . . .
- Mountingsteeringwheel lever 16 . . . . . . . . . . . . .
REMOVING-REFITTINGTHE STEERING
CONTROL ASSEMBLY 17 . . . . . . . . . . . . . . . . .
- Removal 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe pneumaticcylinder 19 . . . . . . . . . . .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingblinker switch 22 . . . . . . . . . . . . . . . . . .
- Removal 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Mounting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN OPERATIONS 23 . . . . . . . . . . . . . . . . . . . . . .
BLEEDINGTHEPOWER
STEERINGSYSTEM 23 . . . . . . . . . . . . . . . . . . . . .
MEASURINGSTEERINGBOX PLAY AT THE
STEERINGWHEEL 23 . . . . . . . . . . . . . . . . . . . . .
CHECKINGTHE MAXIMUMPRESSUREOF
THEPOWER STEERING SYSTEM 24 . . . . . . . . .
- Settingtheautomatic hydraulicsteeringlimit 24 . .
- Check 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF8098powersteeringunitisacontinuousball-typesteering
unit; it essentially consists of: housing and steering built-in
mechanical part, control valveandoperatingcylinder.
ZF 8098POWER STEERINGUNIT
27199
Figure1
DESCRIPTION
MAIN DATA
Vehicles: 4x2- 4x4 - 6x4 - 6x6
Power steeringunit
ZF 8098ball circulationwith built-inpressure
relief valve(thehydraulic guidecan beprovided
withahydraulicdeviceto automaticallyregulate
steeringanglelimit)
Variableworkingpressure 170 +10bar
Variablereductionratio:
- drivecentre 22.2:1
- steeringlock 26.2:1
Power steeringpump ZF
Min. rpm rpm 500 500
Max. rpm rpm 4700 3500
Max. pressure
(without pressurerelief valve) bar 180 180
Delivery dm
3
/min 22 16
Vehicles: 8x4x4- 8x8
Power steeringunit
ZF 8099ball circulation, dual circuit, withpressure
relief valveincircuits1and2;
and checkvalveincircuit 1
Hydraulicdeviceto automaticallyregulatesteering
anglelimit
Variableworkingpressure 140 +14bar
Variablereductionratio:
- drivecentre 22.2:1
- steeringlock 26.2:1
Assembling on compressor ancillaryongearbox Assembling oncompressor ancillaryongearbox
Power steeringpump ZF ZF
Min. rpm rpm 500 -
Max. rpm rpm 3000 4500
Max. pressure
(without pressurerelief valve)* bar 165* 180
Controlleddelivery dm
3
/min 22.5 30 16
Drivecylinder for hydraulicguide ZF 8099
Lengthbetween wheel bases:
- start of stroke mm 578
- endof stroke mm 828
- straight-linerideposition mm 702
TROUBLESHOOTING
Main operating faults of a mechanical nature
Insufficient oil incircuit. Check oil level withenginerunning; top
uptodipstickuppernotchandbleedthe
circuit.
Air inthehydraulic circuit. Checktheseal oftheintakepipeandthe
pump shaft gasket and top up the oil.
Bleed thecircuit.
Lockedor cloggedmodulatingvalve. Removethevalve, wash and checkthe
throttleholeto ensureit isnot clogged.
Oil pump flow rateis insufficient. Overhaul or replacethe pump.
Steeringstiff whenturningright andleft
Spider not slidingwell. Move the union in both directions so
that it slopesunder itsownweight.
Poor lubrication of transmission lever
bearings(onvehicleswithsecondsteer-
ing).
Greasethetransmission lever bearings.
Worn transmission lever bearings (on
vehicleswithsecondsteeringaxle).
Overhaul thetransmissionleversandre-
place wornparts.
Hydrauliccylinders not working(onve-
hicleswithsecondsteeringaxle).
Replace thefaultycylinders.
A hydraulicpumpisnot working
(6x6- 8x4x4vehicles).
Overhaul orreplacethehydraulicpump.
Inefficient internal gaskets. SendthepowersteeringtoaZF station.
Steeringis only hard to the left or the
right
Hydrauliccentrepositionisnot correct
(when the steeringwheel is released it
returns to anend position).
Havethe power steeringadjusted by a
ZF station.
Clogged modulatingvalve. Removethevalve, washandclean.
Steeringishardwhenthesteeringwheel
isturnedquickly
Hydraulicpumpflowrate is inadequate
(wear ongears).
Overhaul orreplacethehydraulicpump.
isturnedquickly
Air inthesteeringsystem. Check theseal of the intake pump and
the pump shaft gasket. Top up the oil.
Bleed thecircuit.
(Continued)
Universal joint is slack. Replacetheuniversal joint.
Power steeringinternal breakdown. Sendthepower steeringtoaZFstation.
Systemoil level too low. Topupoil and bleedthecircuit.
Badwheel attitude. Makechecks andadjustments.
Hardknocksonthesteeringwheel when
steering
Unbalancedwheels. Carry out the balancingoperations fol-
|o.|o t|o |ostoct|oos |o t|o '\|oo|s
aoo Tos' soct|oo.
Draglinkkingpinsloose. Replaceanywornparts.
Hydraulicpumpnot functioningproper-
ly.
Replacethepump.
Oil seepagefrompower steeringcircuit
fittings.
Checktheefficiencyofthegasketsonthe
fittingsandreplaceanythat areworn.
Unbalancedwheels. Carry out the balancingoperations fol-
|o.|o t|o |ostoct|oos |o t|o '\|oo|s
aoo Tos' soct|oo.
Steeringwheel torsional vibration
Incorrect front wheel attitude. Make the checks and adjustments ac-
cordingtothespecificationdatagivenin
t|o '/||S' soct|oo.
Air inthehydraulic system. Check theseal of the intake pump and
the pump shaft gasket. Top up the oil.
Bleed thecircuit.
E i i h l l
Backlash in ball joints and/or flexible
mountings areslack.
Replacethekingpins.
Excessivesteeringwheel play
Universal joint is slack. Replacetheuniversal joint.
Power steeringinternal breakdown. Sendthepower steeringtoaZFstation.
Tankcover not secured. Securecover.
Loss of fluid
Deteriorationof gasketsand seals. Replace, top up fluid andbleed.
Lossoffluid
Ineverycaseit isnecessarytoestablish whereand whyhydraulicfluidisbeinglost,
eliminatethecauseand, withtheenginerunning, topupfluidtoupper markondip-
stick.
Pumpnot operatingcorrectly. Replacepump.
Insufficient pressureinthecircuit
Fluid leaking fromcouplings in power
steeringcircuit.
Check coupling seals for serviceability,
replacinganywhichare worn.
Insufficient pressureinthecircuit
Insufficient fluidlevel inthetank. Topuplevel andbleedcircuit.
Fluid leaking fromcouplings in power
steeringcircuit (8x4x4).
Check coupling seals for serviceability,
replacinganywhichare worn.
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
Hexagonal nut withcollar for steeringsupport andidler arm 226.5 22.5 (22.6 2.2)
Flanged hexagonal head screwfor fixingsteeringstand 278 28 (27.8 2.8)
Hexagonal headscrewfor steeringbox 527.5 52.5 (52.7 5.3)
Calibratedhexagonal headscrewfor steeringbox 527.5 52.5 (52.7 5.3)
Castlenut for steeringlinkageand hydrauliccylinder (*) 300 (30)
Self-lockingnut for universal joint 55 5 (5.5 0.5)
Calibratedscrewfor universal joint 55 5 (5.5 0.5)
Fasteningcollar for draglinkandtrackrod 80 10 (8 1)
Hexagonal nut for steeringboxlever 575 55 (57.5 5.5)
Self-lockingflangednut for steeringstand 226.5 22.5 (22.6 2.2)
Y Flanged hexagonal head screwfor idler arm 278 28 (27.8 2.8)
(*) If at theprescribedtorque, theslot doesnot matchthehole, continueto tightenuntil it becomespossibleto insert thesplit
pin.
Y 8x4 -8x8Vehicles
TOOLS
99347042 Steeringwheel puller
99347045 Steeringdrop armpuller
99347068 Steeringball joint remover
99355032 Wrenchfor power steeringgear retainingbolts
99374393 Pressuregaugesfor testingpower steeringsystempressure
99374398
Calibratedscaleandpointer formeasuringsteeringplay(tobeused
with99374393)
99374399
Pair of expandersto lockwheels(to beusedwith 99374393and
99374398)
90645
Figure2
Steering control diagram for 4x2 - 6x4vehicles(ZF 8098power steering)
90646
Figure3
Steering control diagram for 4x4 - 6x6vehicles(ZF 8098power steering)
90647
Figure4
Theintermediaterod(1) lengthxmeasuredat thedistancebetweencentresof kingpinsandforkshall bealwaysrestoredwhen
replacingoneoftheabovementioned parts and/or checkedbeforeinspectingthewheel alignment.
- vehicles withwheel base 1500mm: x =1540 2
Drivecylinderlengthmeasuredat kingpindistancebetweencentresshallbe578mmatstrokestart and828mmattheendofstroke.
Steering control diagram for 8x4x4 vehicles(ZF 8099 power steering)
90648
Figure5
Theintermediaterod(1) lengthxmeasuredat thedistancebetweencentresof kingpinsandforkshall bealwaysrestoredwhen
replacingoneoftheabovementioned parts and/or checkedbeforeinspectingthewheel alignment.
Drivecylinderlengthmeasuredat kingpindistancebetweencentresshallbe578mmatstrokestart and828mmattheendofstroke.
Steering control diagram for 8x8vehicles (ZF 8099power steering)
90649
1. Steeringbox - 2. Oil cooler - 3. Pressure test fitting- 4. Flowindicator - 5. Compressor - 6. Circuit 2reservoir -
7. Circuit 1reservoir - 8. Pump ongearbox - 9 - Power cylinder - A. Circuit 1 returnpipe- B. Circuit 2 deliverypipe -
C. Circuit 2 deliverypipe- D. Circuit 1returnpipe- E. Power cylinder pipe.
Figure6
Steering hydraulic control circuit diagram for 8x4x4- 8x8 vehicles
72848
Thesteeringcontrol isequippedwithapneumaticdeviceto
adjust theangleandheight of thesteeringwheel.
Thepositionof thesteeringwheel isadjustedbypressingthe
push-buttononthefloor of thecab:
- Press the button (3) onthefloor: thepressurized air of
the services system is sent to the steering wheel
adjustment assembly(2) releasingit.
- Manoeuvre the steering wheel (1) into the required
position(longitudinal travel alongtheaxisof thesteering
column60mm, angular travel to thevertical 40 ).
- Releasethebutton onthe floor.
Figure7
50140 STEERING CONTROL
33691
33692
33693
Checktheangulartravel oftheleverthat hastobe47 inboth
directions.
Keepingthelever (3) stationaryto preventturningthepower
steeringshaft, lock the nut (2) fixingthe lever with atorque
wrench (1) to atorqueof 575Nm.
Usingasuitablepunch, notchthecollar of thenut (1).
1
2
1
Figure8
Figure9
Figure10
If the hydraulic steeringhasto be replaced, before
reconnecting the new hydraulic guide to the
support, thesteeringwheel leveristobemounted
onthenewhydraulicguideasdescribedinfollowing
chapter.
Ifthehydraulicguideisprovidedwithasteeringlimit
automaticregulation, theautomaticregulationisto
be set as described in relevant chapter after
reconnectingthehydraulic guide.
Figure11
Mounting steering wheel lever
Securethepower steeringboxinavice.
Fit thesteeringlever (3), makingthereferencemarks(1) cut
onthedrivingshaft (2) andon thelever (3) tally.
2
1
3
33690
!
So as not to change the setting of the automatic
hydraulicsteeringlimit (if present), do not turn the
shaft (2) of the power steering box with atorque
greater than25Nm.
3
NOTE
HYDRAULIC STEERING
38660
72850
72849
72851
72852
Figure12
Figure13
Figure14
Figure15
Figure16
Lift thecowlingof thecab. Set thewheelsstraight andcheck
t|at t|o stoo|o bo |s |o t|o 'sta||t a|oao' os|t|oo, so t|o
referencemark oftheshaft(1)coincideswiththereference
mark of thesteeringbox (2).
Engagethesteeringlockbytakingtheignitionkeyout.
Takethe cover (1) off thesteeringwheel (2).
Disconnect theconnection(4) of theearth cable.
Remove the nut (1), mark the assembly position of the
steeringwheel (3) on the shaft (2) and removethesteering
wheel (3).
Take out the screws (1 and 3) and take off the side guards
(2.4).
Disconnect theelectric connections(5and 6). Takethekey
(5, Figure14) out ofthesteeringwheel (3,Figure14).Fasten
thecover (1) of the interconnectingbox (2) to the box by
insertingthekey(7) inthe slots(8and 9). Thispreventsthe
cover (1) and the box (2) fromturning on each during
disassemblyandthisconditionismaintaineduntil assembly.If
thereisnokey(7), useascrewandnut ofsuitablelengthand
diameter.
Takeholdoftheinterconnectingbox(2),liftitcarefullysothat
theretainingspringpins(3) comeoutofthemounting(4) and
put it aside.
!
Remove the interconnecting box (2) from the
steeringcontrol mounting(4), keepingstrictlytothe
proceduresdescribedhereunder. This is to prevent
damaging the spiralled cable in the box, during
assembly,andtoavoidawrongreadingofthesteering
wheel angle.
Removal
STEERING CONTROL ASSEMBLY
72832
90002
72854
72855
Figure17
Figure18
Figure19
Figure20
Figure21
Figure22
Removethepush-buttonpanels(3and5) andthecapsforthe
screws(4) fromthe instrument panel (1).
Takeout thescrews(2and4), removetheinstrument panel
(1) and put it aside.
Disconnect theconnections(1) ofthewindscreenwiper, (2)
of thedrivecontrol system, (3) of theimmobilizer.
Marktheassemblypositionoftheshaft (2, Figure14) onthe
mounting(3) andontheuniversal joint (4).Loosenthescrew
(1) and extract the universal joint (4) fromthetopshaft.
Disconnect thepipe(2).
Takeout the3 screws(1) and remove the steeringcontrol
mounting(3) fromthepedal board (2).
72831
- Removemat (5).
- Unscrewsecuringscrews(4) of thesill (3).
- Detach thesill (3) fromthevehicle.
- Undothefasteners( ) andtakeout theair opening(2)
inthefloor.
- Unscrewthe sidescrews(1) fixingthesteeringcolumn
guard.
77108
- Unscrewthescrews(2) fixingthesteeringcolumnguard
intheareaof thepedal board.
- Detach thesteeringcolumnguard(1) fromthevehicle.
72856
72857
Figure23
Figure24
Fromoutsidethecab,loosenthescrew(2) anddisconnectthe
bottomshaft (1) fromthepower steering(3) shaft. Takeout
thescrews(4) andremovethebottomshaft(1) togetherwith
theguard(5).
To refit, carryout the operations described for removal in
reverse order, tightening the screws and/or nuts to the
requiredtorque.
Refitting
!
The interconnectingbox (1) is supplied as aspare
withthestopkeyassembledasillustratedinthefigure.
After fittingit onthe steeringcontrol mounting, it is
necessarytoturnthekey(2) soastocauseit tobreak
at thepoint shownbythearrowand put thekeyin
thesteeringwheel housing, seeFigure14.
Replacing the pneumatic cylinder
Removal
Remove thesteeringgear assemblyas described under the
relevant heading(operation 501410).
Removethedamper (1) bytakingout the fixingnuts (2 and
3).
Figure25
Figure26
77551
77552
Screwasuitablecoupling(5) into the air supplyholeof the
cylinder (3) andintroduceair at apressure of 8 12bars.
!
The air pressure must be maintained throughout
removal:thisisanecessaryconditiontomakesurethe
pneumaticcylinder (3) gets released.
Shiftthesteeringgearshaft-assembly(6)completelyoutwards
( ).
Marktheassemblypositionofthescrew(7) onthemount(9).
Removethenut (1), extract thescrew(7) withthewashers
(2 and 8) and remove fromthe mount (9) the pneumatic
cylinder (3) theadjustment washer (4) and thesteeringgear
shaft assembly (6).
77553
Figure27
Figure28 Figure29
77554
77555
Positionthesteeringgear shaft mount (2) in themount (1).
MeasurethedistancesBandC betweentheinternal surface
of themount (2) andtheslidingsurface (of theabove) ofthe
mount (1) withasuitableinstrument (3) (precisionclass0.05
mm).
PARTSCOMPRISINGTHESTEERING GEARASSEMBLY
1. Pneumatic cylinder - 2. Adjustment washer - 3. Coupling- 4. Mount - 5. Washer - 6. Screw- 7. Damper -
8. Steeringgear shaft assembly- 9. Nut - 10. Washer - 11. Nut.
Determinethethicknessoftheadjustment washer (2,Figure27)
as follows.
Measure the distance A between the sliding surfaces of the
mount (1) withasuitableinstrument (precisionclass0.05mm).
Mounting
77556
Figure30
Figure31
Figure32
77558
Fit onanewscrew(7) withthewasher (8) positioningitatthe
point markedduringremoval.
Fromtheoppositeside, fit onthe washer (2). ApplyLoctite
270 onthethreadofthenewnut (1) andscrewit ontothe
screw(3) todetermineaclearanceof 0.1 0.2mmbetween
thewasher (2) andthemount (3).
Check thetravel of themount (8) of thesteeringgear shaft
onthemount (3) inall directions.
Setthesteeringgearshaft mount(6) inthepositionofthestart
of travel (minimumheight of thesteeringwheel).
Removetheaircoupling(4) fromthepneumaticcylinder (5).
Screwasuitablecoupling(2) into the air supplyholeof the
newcylinder (3) andintroduceairatapressureof 8 12bars.
!
Theairpressuremust bemaintainedthroughout the
measurement and followingassembly.
Place the pneumatic cylinder (3) on the plane and put the
adjustment washer (1) onitspiston;measurethedistance(D)
withasuitableinstrument (4, precisionclass0.05mm).
S=A-(B+C+D+0.2),whereA-B-C-Darethedistances
measured and0.2 is theclearance.
77557
Put mount(2) inmount (1) andfit onthecylinder (4supplied
withair at apressureof 8 12bars) positioningit withthepin
(5) intheguidinggrooveof themount (2).
Choosetheadjustment washer (3) fromtheonessuppliedas
spares, with the thickness calculated in the preceding
measurement.
\as|o t||c'ooss. +.6 +. +.8 +. - 5-5 5.2
5.4 mm.
Lubricatethewasher (3) withgreaseandinsertitbetweenthe
cylinder (4) andthe mount (1).
Figure33
77551
Fit on thedamper (1), screwdownthe fixingnuts (2 and3)
tighteningthemto atorqueof 23Nm.
Checkthelockingofthecylinder (4):applyingatractiveforce
of 300N (30kg) to thesteeringgearshaft, inthedirectionof
thedriver, thismust not movein relation to the mount (3).
Then refit the steering gear assembly to the vehicle as
described under therelevant heading.
4
NOTE
38660
72850
72849
72851
72852
Figure34
Figure35
Figure36
Figure37
Figure38
Lift thecowlingof thecab. Set thewheelsstraight andcheck
t|at t|o stoo|o bo |s |o t|o 'sta||t a|oao' os|t|oo, so t|o
referencemark oftheshaft(1)coincideswiththereference
mark of thesteeringbox (2).
Engagethesteeringlockbytakingtheignitionkeyout.
Takethe cover (1) off thesteeringwheel (2).
Disconnect theconnection(4) of theearth cable.
Remove the nut (1), mark the assembly position of the
steeringwheel (3) on the shaft (2) and removethesteering
wheel (3).
Take out the screws (1 and 3) and take off the side guards
(2.4).
Disconnect theelectric connections(5and 6). Takethekey
(5, Figure36) out ofthesteeringwheel (3,Figure36).Fasten
thecover (1) of the interconnectingbox (2) to the box by
insertingthekey(7) inthe slots(8and 9). Thispreventsthe
cover (1) and the box (2) fromturning on each during
disassemblyandthisconditionismaintaineduntil assembly.If
thereisnokey(7), useascrewandnut ofsuitablelengthand
diameter.
Takeholdoftheinterconnectingbox(2),liftitcarefullysothat
theretainingspringpins(3) comeoutofthemounting(4) and
put it aside.
!
Remove the interconnecting box (2) from the
steeringcontrol mounting(4), keepingstrictlytothe
proceduresdescribedhereunder. This is to prevent
damaging the spiralled cable in the box, during
assembly,andtoavoidawrongreadingofthesteering
wheel angle.
Removal
Replacing blinker switch
90003
Figure39
Disconnect securingscrews(2) of steeringcolumnstalk(1).
Removeelectricconnectionand disconnect steeringcolumn
stalk(1).
Mounting
For mounting, invert operations described for dismounting,
tighteningthescrews and/or nuts at prescribedtorque.
Thesteeringcolumnstalksthataresuppliedasspares
havenothreadonsecuringplate.Neverthreadholes
because you might damage the components inside
steering column stalk. As the plate is made of
aluminium, it allows self-threading on securing it
through screws.
For vehicles 4x2- 4x4 - 6x4 - 6x6
To bleedthepower steeringsystem, proceedasfollows.
Fill thepowersteeringfluidreservoirwiththeprescribedfluid
(TutelaGI/A)
Turntheengineover withthestarter motor andtopupthe
fluidcontinuallyto prevent air beingdrawninto thepump.
Top up the fluid until the level remains constant abovethe
minimummarkonthedipstick.
Start theengineandrunitidling,checkingthatthelevel ofthe
fluid does not fall under the minimumlevel marked on the
dipstick.
Turn the steering wheel fromlock to lock several times to
forceanyairoutofthepower steeringcylinderuntil nomore
bubblesappear inthe fluid in thereservoir.
Acceleratetomaximumrpm,thenstoptheengineandcheck
that thefluid level doesnot rise more than1to 3cm.
33694
501430 MEASURING STEERING BOX
PLAY AT THE STEERING WHEEL
Check thereisnomechanical playin thesteeringlinkage.
Locktheleft-handwheel inthestraight-ahead position using
theexpanders99374399; raisetheaxle.
Attach the fixed pointer (2) to thewindscreen withsuction
cups, and attach the graduated scale 99374398 (1) to the
steeringwheel. Positionthepressuretester 99374393(3) (0
to 10bar and0to 160bar, pressuregaugesconnected bya
shunt valve). Connect thepipe of the pressure tester to the
fittingon the power steeringdeliverypipe. Top up the fluid
level if necessary. Start the engine and run at idle speed.
Recordthepressurereadingshownonthe0to10bargauge.
Slowlyturnthe steeringwheel to theleft until theprevious
pressurereadingisincreasedby1bar.Holdthesteeringwheel
inthis position and record the value in mmreached onthe
graduated scale99374398. Nowturn thesteeringwheel to
theright until thepressurereadingisagainincreasedby1bar,
andnotethevalueinmmonthegraduatedscale99374398.
Addtogetherthetwovaluesinmmobtainedforleft andright
steering:thetotal shouldnot exceed40mm. Lowertheaxle.
501430 BLEEDING THE POWER
STEERING SYSTEM
Figure40
MAIN OPERATIONS
For vehicles 8x4 - 8x8
Fill thehydraulicpowersteeringcasethroughtheoil reservoir
of Circuit 1.
Fill theoilreservoirofcircuit1withtheprescribedoil,startthe
engineandkeepit idling.
Topuptheoilcontinuouslytopreventthepumpfromsucking
air.
Fill the emergency pump through the oil reservoir of the
emergencycircuit.
Fill theoil reservoirwiththeprescribedoil,lift theengineaxles
fromthe ground, start the engine and keep it idling, then
engageagear.
Topuptheoilcontinuouslytopreventthepumpfromsucking
air.
Whenthetwocircuitsarefull,i.e.whentheoil level inthetwo
reservoirscannotfall belowthetopmark,start theengineand,
with the axles lifted fromthe ground, keep it idlingfor 2-3
minutes withthegear engaged.
Turnthesteeringwheelsseveral timesfromonelimit switch
to theother.
Check continuously and top up the oil in the reservoirs, if
needed.
This adjustment is made after fitting the power steering
systemonthevehicle,withthevehicleunloadedandthefront
wheels raisedor set on revolvingplatforms. In addition, it is
necessarytosteer bothright andleft asfollows.
Makesurethegearboxisin neutral.
Start the engineand runat aspeedof 1500 rpm.
Turn the steering wheel in one direction to bringthestop
screw(2) onthestubaxle(3) intocontact withtheaxle (1).
Inthisposition,applyanadditional forceonthesteeringwheel
to determine the automatic setting. Repeat this procedure
steeringintheoppositedirection.
Ifthereisareductioninthetravel ofthesteeringcontrol lever,
itisnecessarytoreplacethesteeringlimitingscrewconcerned
with anew one, or both screws if the trouble involves the
oppositetravel aswell.
Thescrewsare located onthetop and bottomsides of the
powersteeringbox.Maketheadjustmentasdescribedabove.
60925
CHECKING THE MAXIMUM PRESSUREOF
THE POWER STEERING SYSTEM
Usingthepressuretester 99374393,connectedasdescribed
abovo, aoo t|oo|vo's s|oo .|oo| | oc'oo, stat t|ooo|ooaoo
runat idle.Applyasteeringforceof 10 20kgtothesteering
wheel and record the pressure reading on the 0 160 bar
gauge.Repeat theoperationapplyingthesamesteeringforce
intheoppositedirection; if thereadingsobtainedarelower
thanspecified, locatethesourceof theproblem.
The maximumpressure is given on the data plate
attachedto theZF steeringbox.
Settingthe automatic hydraulic steering limit
Check
Connect apressuregauge(minimumfull-scalevalue200bar) to
thepressuretest fittingonthedeliverylinefromthepumptothe
power steeringandapplyasteeringforceat thesteeringwheel
of 50 20 Nm(correspondingto 200 80 N ona500mm
diameter steering wheel), turning the wheel to the full lock
position.Thepressurereadingshouldbewithintherangeof 35
to 70 bar. If the pressure is too high, replace the adjustment
screwswithnewonesandrepeat theadjustment procedure. If
the pressure is too low, check that the hydraulic system is
operatingproperlyand that thereareno leaks.
Figure41
NOTE
Revi - June2007
1 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Print 603.93.641/A Base- November 2006
PRINT603.93.641/A
SECTION 13
79 Pneumatic system
52 Brakes
Page
SYMBOLSFOR AIR/HYDRAULIC SYSTEMCIRCUIT DIA-
GRAMS(MISCELLANEOUSANDGENERATORS) 5 . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEMCIRCUIT
DIAGRAMS(VALVES) 6 . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAMS(TANKSANDACCUMULATORS) 12 . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEMCIRCUIT DIA-
GRAMS(CALIPERSAND CYLINDERS) 13 . . . . . . . . . .
SYMBOLSFOR AIR/HYDRAULIC SYSTEMCIRCUIT DIA-
GRAMS(HALF-JOINTSANDCOUPLING HEADS) 15 .
DIAGRAMS(INDICATORSAND SWITCHES) 17 . . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS(BRAKES) 18 . . . . . . . . . . . . . . . .
PIPESANDCOUPLINGS 19 . . . . . . . . . . . . . . . . . . . . .
- General 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingflexiblehoseswith threaded
couplings 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingflexiblehoseswith quick-connection
couplings 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacehoses withRaufosstypefittings 21/1 . . . . . .
BRAKING SYSTEMSWITH ABS- EBL DEVICE 22 . . . .
- Maindiagramfor vehicles
4x2 - 4x4 used for haulage 22 . . . . . . . . . . . . . . . .
- Workingdiagramfor 6x4 vehiclesisolated
withanABS- EBL device 23 . . . . . . . . . . . . . . . . .
- Workingdiagramfor 6x4 - 6x6vehiclesdesignedfor
towingwithABS- EBL device 24 . . . . . . . . . . . . . .
- Workingdiagramfor 8x4x4- 8x8x4vehiclesisolated
withanABS- EBL device 25 . . . . . . . . . . . . . . . . .
- Workingdiagramfor 8x4x4- 8x8x4vehiclesdesigned
for towingwithABS- EBL device 26 . . . . . . . . . . .
BRAKING SYSTEMSWITH
ABS- EBL - ASRDEVICE 27 . . . . . . . . . . . . . . . . . . . . .
PRINT603.93.641
Page
- Workingdiagramfor 4x2 - 4x4vehicles
designedfor towing 27 . . . . . . . . . . . . . . . . . . . . .
- Maindiagramfor vehicles
6x4with ABS - EBL - ASR 28 . . . . . . . . . . . . . . .
- Maindiagramfor vehicles 6x4- 6X6
usedfor haulagefitted withABS - EBL - ASR 29 .
- Maindiagramfor vehicles 8x4x4- 8x8x4
withABS- EBL - ASR 30 . . . . . . . . . . . . . . . . . . .
- Maindiagramfor vehicles 8x4x4- 8x4x4
usedfor haulagefitted withABS - EBL - ASR 31 .
- Brakingsystemmaincomponents
layout on thevehicle 32 . . . . . . . . . . . . . . . . . . . .
DESCRIPTION 33 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Servicebraking 33 . . . . . . . . . . . . . . . . . . . . . . . .
- Emergencybraking 33 . . . . . . . . . . . . . . . . . . . . .
- Retardingbraking 33 . . . . . . . . . . . . . . . . . . . . . .
- Parkingbraking 33 . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Front discbrakesSN7 type
(for vehicleswithpartial traction) 33 . . . . . . . . . .
- Drumbrakes 33 . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT DIAGNOSIS 34 . . . . . . . . . . . . . . . . . . . . . .
TOOLS 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA - PNEUMATIC SYSTEM 82 . . . . . . . .
MAIN DATA - BRAKES 86 . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEMMAIN COMPONENTSCHECK 89
BRAKING SYSTEMMAIN COMPONENTS 92 . . . .
- Compressor 92 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 92 . . . . . . . . . . . . . . . . . . . . . . .
- Headfasteningscrewstighteningtorque 92 . . . . .
- A.P.U. (Air ProcessingUnit) 93 . . . . . . . . . . . . . .
- A.P.U. Troubleshooting
(Drier +four-wayprotectionvalve) 93 . . . . . . . .
Page
- Duplexdistributor 94 . . . . . . . . . . . . . . . . . . . . . .
- Pressurereducer 95 . . . . . . . . . . . . . . . . . . . . . . .
- Triplecontrol servo distributor 95 . . . . . . . . . . . .
- Settingat thebench 95 . . . . . . . . . . . . . . . . . . . .
- Predominanceadjustment 95 . . . . . . . . . . . . . . . .
- KNORRBREMSEAC 597B 96 . . . . . . . . . . . . . . .
- WABCO 973 009 013 96 . . . . . . . . . . . . . . . . . .
- Couplingheads 97 . . . . . . . . . . . . . . . . . . . . . . . .
- Check valve(towingvehicles) 97 . . . . . . . . . . . . .
- Parkingbrakes control hand
distributor (for towingvehicles) 97 . . . . . . . . . . .
- Parkingbrakes control hand
distributor (stand-alone vehicles) 98 . . . . . . . . . . .
- Relayvalves 99 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Diaphragmbrakecylinder 99 . . . . . . . . . . . . . . . .
- Combinedbrakecylinder 100 . . . . . . . . . . . . . . . .
- Combinedcylinder emergencyrelief device 100 . .
REPAIR OPERATIONS 100 . . . . . . . . . . . . . . . . . . . .
ANTI-SKIDSYSTEM 101 . . . . . . . . . . . . . . . . . . . . . .
- ABS(Anti-LockBrakeSystem) 101 . . . . . . . . . . . .
- ASR(Anti-Slip Regulator) system 101 . . . . . . . . . .
- EBL(ElectronicBrakes Limiter) 101 . . . . . . . . . . . .
- Pressuresensor 101 . . . . . . . . . . . . . . . . . . . . . . . .
- Electroniccontrol unit 102 . . . . . . . . . . . . . . . . . . .
Page
- Brakeanti-lockdistributor 102 . . . . . . . . . . . . . . . .
- Electropneumatic valvefor ASR 102 . . . . . . . . . . .
- Rpm sensors 102 . . . . . . . . . . . . . . . . . . . . . . . . .
- Phonicwheels 102 . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKESSN7TYPE 103 . . . . . . . . . . . .
- Operation(Seepreviousfigure) 104 . . . . . . . . . . .
CHECKS 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingtheautomaticplayrecovery
systemefficiency 104 . . . . . . . . . . . . . . . . . . . . . . .
- SN7brakecaliper components 105 . . . . . . . . . . . .
- SN7brakecalliper brakinggaskets
thicknesscheck 106 . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingbrakelinings 107 . . . . . . . . . . . . . . . . . . .
- Removingandrefittingbrake callipers 109 . . . . . . .
- Removal 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingandrefittingwheel hubs 110 . . . . . . . . .
Page
- Removal 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SN7 BRAKE CALIPEROVERHAUL 112 . . . . . . . . . . .
- Disassembly 112 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Component part cleaningandcheck 113 . . . . . . . .
- Assembly 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGBRAKEDISCS 115 . . . . . . . . . . . . .
TURNINGANDGRINDING BRAKEDISCS
ON THEBENCH 115 . . . . . . . . . . . . . . . . . . . . . .
TURNINGANDGRINDING BRAKEDISCS
ON THEVEHICLE 115 . . . . . . . . . . . . . . . . . . . . .
DRUMBRAKES 116 . . . . . . . . . . . . . . . . . . . . . . . . . .
DUO DUPLEX DRUM
FRONT/REARBRAKES 117 . . . . . . . . . . . . . . . . . .
- Disassembly 117 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Drumturning 120 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingbrakelinings 120 . . . . . . . . . . . . . . . . . . .
- Turningbrakelinings 121 . . . . . . . . . . . . . . . . . . . .
- Assembly 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRINT603.93.641
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(MISCELLANEOUS AND GENERATORS)
DESCRIPTION SYMBOL
HYDRAULIC FLOW
AIRFLOW
ELECTRICAL LINE
ABLETO ROTATE
CROSSOVER OFCONNECTEDLINES
PRESSURE TEST POINT
QUICK-CONNECTION COUPLING
COCK
COCKWITH OUTLET
1 2
SILENCER
COMPRESSOR 0 2
ENERGY SAVINGCOMPRESSOR
0 2
4
VACUUMPUMP 3 2
HYDRAULIC PUMP
0 2
HYDRAULIC HANDPUMP
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
CONDENSATE SEPARATOR
FILTER 1 2
DEHUMIDIFIER
1 2
DEHUMIDIFIER
21
1
22
4
DEHUMIDIFIERWITH BUILT-IN
REGULATOR
21 1
22
23
AUTOMATIC CONDENSATION
DRAIN VALVE
CONTROLLED CONDENSATION
DRAIN VALVE
HANDCONDENSATEDRAIN VALVE
CONTROLLED ANTI-ICINGUNIT
1 2
7
AUTOMATIC ANTI-ICINGUNIT
1 2
PRESSURE REGULATOR WITH
INDEPENDENT CIRCUIT
21
22
1
23
24
PRESSURE REGULATOR
21 1
PRESSURE CONTROLLER
21 1
23
PRESSURE CONTROLLER
(GOVERNOR)
2
1
PRESSURELIMITINGVALVE
2
1
DESCRIPTION SYMBOL
PROPORTIONAL REDUCINGVALVE
2
1
ADAPTER VALVE
2
1
FOURCIRCUIT PROTECTION VALVE
21
22
1
23
24
THREE CIRCUIT PROTECTION
VALVE
21
22
1 23
TWO CIRCUIT PROTECTION VALVE
21
22
1
NON-RETURN AIRINLET VALVE
2 1
LIMITED RETURN AIRINLET VALVE
2 1
SAFETY VALVE
CHECKVALVE
2 1
CHECKVALVE
2
2
1
DOUBLESHUT-OF VALVE
11 12
2
DIFFERENTIAL DOUBLESHUT-OFF
VALVE M S
U
THROTTLE VALVE WITH QUICK
RETURN 1 2
THROTTLE VALVE
DESCRIPTION SYMBOL
QUICKDISCHARGE
2 1
BRAKECONTROL VALVE
21 11
22 12 P
A
BRAKECONTROL VALVE
21 11
BRAKECONTROL VALVE
21 11
4
22 12
PARKINGBRAKECONTROL VALVE
22 11
21
PARKINGBRAKECONTROL VALVE
2 1
BRAKE VALVE
2 1
CONTROL VALVE
2 1
CONTROL VALVE
22 1
21
RETARDERCONTROL VALVE
23 13 R
SERVO CONTROL VALVE
2 1
4
DESCRIPTION SYMBOL
SERVO CONTROL VALVE
2 1
42 41
SERVO CONTROL VALVEFOR
SINGLELINE
2 1
4
TRAILERBREAKINGTRIPLE
CONTROL VALVE
2 1
42
41 43
TRAILERBREAKINGTRIPLE
CONTROL VALVEWITH BUILT-IN
SERVO SWITCHING
22 11
42
41 43
12
LOADSENSING VALVE
2 1
DUAL LOADSENSINGVALVE
21 11
22 12
LOADSENSINGVALVEWITH
BY-PASS
21
12
11
BUILT-IN RELAY
2
1
4
BUILT-IN RELAY WITH AIR
CONTROL
4
42 41
1 2
DESCRIPTION SYMBOL
LOADSENSING VALVE WITH AIR
CONTROL
42 41
1 2
LOADSENSING VALVE WITH AIR
CONTROL
1
4
2
PROPORTIONAL REDUCINGVALVE 1 2
SLAVEDPROPORTIONAL
REDUCINGVALVE
1
4
2
STROKE LIMITERVALVE
1
2
LEVELLING VALVE
1
21 22
LEVELLING VALVE
1 2
LEVELLINGVALVEWITH BUILT-IN
TRAVELLIMITER
11 21
12 23
HANDOPERATEDSUSPENSION
RAISING CONTROL VALVE
24 23
21 22
DESCRIPTION SYMBOL
PROPORTIONAL CONTROL VALVE
1
2
41
42
HANDOPERATEDSUSPENSION
CONTROL VALVEWITH
ELECTRICAL MONITORING
21 11
12 22
13
1 3
ELECTROPNEUMATIC VALVE
1 2
1 2
1
21
22
HYDRAULIC MODULATOR FOR ABS
HL HR
HZ1 VL
VR HZ2
ABS
AUGMENTERVALVE
1
4
2
(TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL
COMPRESSED AIRTANK
BRAKE FLUIDRESERVOIR
AIRSPRING
PRINT603.93.641
(CALIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
VACUUMBRAKESERVO
VACUUMBRAKESERVO
DUAL CIRCUIT MASTERCYLINDER
SINGLECIRCUIT MASTER CYLINDER
AIR/HYDRAULIC CONVERTER
AIR/HYDRAULIC CONVERTER
HYDRAULIC BRAKECYLINDER
OPERATORCYLINDER
BRAKECYLINDER
SPRINGCYLINDER
COMBINEDBRAKECYLINDER
FIXED DISKBRAKE CALIPER
(CALLIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
FLOATING DISKBRAKE CALLIPER
FLOATING DISKBRAKE CALLIPER
WITH PARKING
MECHANICAL FLOATINGDISK
BRAKE CALLIPER
SERVO CLUTCH
SERVO CLUTCH
(HALF-JOINTS AND COUPLING HEADS)
DESCRIPTION SYMBOL
'|SC' S|||CC|||||C
A
M
ISO VERSION
'|SC' S|||CC|||||C
A
M
VERSION WITH ISO COUPLINGS
'C||/' S|||CC|||||C
A
B
ITALIAN VERSION
'C||/' S|||CC|||||C
M
A
'|/TC' S|||CC|||||C
A
M
NATO VERSION
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
(HALF-JOINTS AND COUPLING HEADS)
DESCRIPTION SYMBOL
SEMI-COUPLING
1
2 3
5
4
V
A
Z
SINGLE LINEVERSION
SEMI-COUPLING
V
A
Z
A
M
SINGLE LINEVERSION
SEM-ICOUPLING
4
2
12
22
SINGLE LINEVERSION
SEMI-COUPLING
4
2
12
22
M
A
1
SINGLE LINEVERSION
(INDICATORS AND SWITCHES)
DESCRIPTION SYMBOL
PRESSURE GAUGE
PRESSURE GAUGE
PRESSURE TRANSMITTER
LAMP
MECHANICALLY CONTROLLED
SWITCH
PRESSURE SWITCH
LOW PRESSURESWITCH
AUDIBLEWARNING
SENSOR
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(BRAKES)
DESCRIPTION SYMBOL
SINGLECYLINDER HYDRAULIC
BRAKE
TWIN CYLINDERHYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
WITH PARKINGBRAKE
SINGLECAMOPERATEDBRAKE
TWIN DUAL CAMOPERATED BRAKE
from1to 1,5
from2to 2,5
from2to 2,5
from2to 2,5
from3to 3,5
Replacing flexible hoses with threaded
couplings
- End-formtheseatingbush,onfittingto thevehicleor on
theworkbench, to aunion.
- The pressure exerted andthefinal distance of thefront
edgeof thecompressionringfromthat ofthereinforcing
bushmust bethevaluelistedinthescheduleasgivenin
the table.
Doublelayer
- Useonlyapproved hose
- Checktheconditionofthereplacementhose;theremust
beno cracks, cutsor incisionsonit.
- Cutthepipeto therequiredlength,cuttingat 90
_
tothe
centreline using appropriate pipe cutting pliers
99387050.
Threadonto thepipe, intheorder given:
- nut (3), compression ring(2) (larger thickness towards
thenut (3)) and reinforcingbush (1);
- bushmust beinperfect condition(it must not showany
distortion or signs of hammering).
Carefullyfollowtheinstructionsbelow:
10397
10398
10399
- Install reinforcingbushusingtool99372219,ensuringthat
there is contact between its flange and the end of the
hose;
- make sure that the end of the hose fits into the raked
grooveintheflange.
1. Reinforcingbush- 2. Pressurering- 3. Nut - 4. Union
5. Hose- h. Distancebetweenedgeof bushand edgeof
ring(seetable).
FITTINGREINFORCING BUSH
A = CORRECT METHOD OFFITTING
B = INCORRECT METHOD OFFITTING
Pipe
mm
Distancebetween
edgeof bushandring
mm(*)
Assembly
pressure
N/mm
2
6x 1
8x 1
10x1,5
12x1,6
16x 2,34
0,040
0,050
0,050
0,060
0,060
Insert theendofthehosepreparedinthiswayintotheunion
bodyuntil reinforcingbushflange bears against seating;
- Totightennutontounion,firstofall screwinbyhandand
then complete tighteningusingapolygon wrench fitted
onthetorquewrench,tobesetaccordingtothespecified
tighteningtorque.
Singlelayer
(*) Seereferenceh, Figure3.
!
Figure1
Figure2
Figure3
Ifthefittingsarebadlyassembled, do not re-usethe
hoseafter extractingthebushandseatingring.
Hydraulicsystempipingsforindustrial vehiclesareflexible
ones made of polyamide with single-layered or
double-layered structureand in the followingdiameters
( 6-8-10-12-16mm) equipped withspares inmeters.
799512 PIPES AND COUPLINGS
General
PRINT603.93.641
- Whenhosesrunthroughchassismembersormetal parts,
make sure that the holes through which theypass are
fitted withrubber grommets and that theseareingood
condition.
- Avoid sliding the hose along sharp edges which might
causecuts.
- Wherethehosehastobeattachedtoexistingpipework,
take account of the additional heat to which it maybe
subjected (power steering pipework); in this case, the
hosemust beprotectedwith shields.
- Whenthehosehasbeenconnected,checkthat it isnot
under tension between the attachment points, instead
leaving it slightly slack to take up the more substantial
variationsintemperature, especiallyfor short lengths.
- Before fitting, thoroughly clean the hoses by blowing
compressed air through themto safeguard operationof
thesystem.
- Protect thehoses if grindingor weldingoperationsare
carriedout onthevehicle; anotice isfitted inthecabin
indicating the precautions to be observed carefully to
avoiddamage.
Figure4
Replacingflexiblehoses withquick-connection
couplings
For greater safetyandconvenience inworking, it is
advisable to remove the hoses during these
operations.
Whenfittingisfinished, checkthat all seals(unions,couplings
etc.) arecompletelyfreefromleaks.
Whenfittingthehoseto the vehicle, someimportant points
requiringcareshouldbebornein mind:
- Bends must comply with minimumradii, so as to avoid
constrictions:
Minimumradiusof curvature
mm
Diameter of pipe
mm
13132
Make sure that the hoses are not in contact with
sharpedgesor withsharp metal partsor sourcesof
heat,but areat aminimumsafetydistance of 15mm
fromthese.
6x 1
8x 1
10 x1,5
12 x1,6
16 x2,34
40
50
60
75
100
!
!
Screwthecouplingintothethreadedseatingprovidedonthe
airvalveandtightenit tothetighteningtorqueindicatedinthe
table.
- Check that theseal ring(1) isinits seat;
- Tighten the coupling until the seal gasket contacts the
valve;
- Direct thevalvecorrectlyandkeepingthemovablepart
still, lockthehexagonal nuttothetorqueindicatedinthe
table.
39307
Figure5
Figure6
39306
Swivel couplings:
Banjo couplings:
Swivel andbanjo couplings:
COUPLING
THREAD TIGHTENIGTORQUE (Nm 10%)
M10x1,0mm
M12x1,5mm
M14x1,5mm
M16x1,5mm
M22x1,5mm
22
24
28
35
40
D
(mm)
When removing couplings (1) on pneumatic components,
checktheconditionoftheseal ring(2) andifnecessaryreplace.
33977
33978
6
8
12
16
Figure7
Figure8
- Onlyuseapproved type-testedhoses;
- Checktheconditionofthenewhosetoensureit hasno
cracks, cutsor scores;
- Cutthehoseat 90 ,maximumerror 15 ,withreference
totheaxis.Usepipe-cutterpliers99387050tocut tothe
requiredlength;
Figure9
33976
A
A =Mark to identifyendof tubetravel
- Useindelibleinkto markclearlytworeferencemarkson
bothdiametricallyoppositefacesof thepipeat anangle
of 75 , set at distances L
1
and L
2
, to ensure correct
fittinginplace.
!
L
1
andL
2
varyaccordingtothediameter ofthehose
andaretobemeasuredat thelongerpartofthehose
(seeFigure7).
19.8
20.5
25
27.1
17
18
22
24
22
23
28
30
L
(mm)
L
1
(mm)
L
2
(mm)
+0,5
0
+1
-0,5
+1
-0,5
Figure10
39308
- Insertthehose(2) byhandintothecoupling(1),withaforce
between30and20Nmaccordingtothehosediameter,so
thatreferencemarkL
1
isinsidethehosewhereasL
2
remains
visible.
COUPLING SEALRING
THREAD DIMENSIONS
Whenever a hose is removed from a qui ck
connection coupling, the coupling itself must be
replaced. Spare quick connection couplings are
supplied complete.
M10x1.0
M12x1.5
M14x1.5
M16x1.5
M22x1.5
10.1 x1.6
11.0 x2.0
-
15.0 x2.0
-
Quickreleaseandthreadedcouplings arenot
interchangeable. This also applies to flexible hoses
usedwithquickreleasecouplingsandflexiblehoses
usedwiththreaded couplings.
!
!
PRINT603.93.641
Figure10/1
Replace hoses with Raufoss type fittings
In order to remove pipe (1), fit tool 99387051 (2) on it
throughtheopening.Pushtool 99387051(2) insidefitting(3)
till releaseof polyamidepipe.
Remove pipe (1).
117651
Operations for pipe change replacement with
Raufoss type fittings aredifferent frompreviously
describedonesonlyfor what is mentioned below.
NOTE
21/1 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
PRINT603.93.641/A
PNEUMATICSYSTEM- BRAKES 21/2 TRAKKEREURO 4/5
108145
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeon indicator - 11. Trailer slowinghandcontrol valve (optional) - 12. Tripleservocontrol valvefor
ta||o ba'|o - +3. |o. ossoo s.|tc| - ++. '|SC' |a|-coo||o o toc' - +5. '|SC' |a|-coo||o o tacto - +6. |o|o
distributor - 17. Brake light switch- 18. Enginebrake control switch- 19. Diaphragmbrakecylinder - 20. Phonicwheel -
21. Wheel speedsensor - 22. Duo Duplexdrumbrakeassembly - 23. Combined brakecylinder - 24. ABSsolenoid valve-
25. Pressuresensor - 26. Single-control relayvalve- 27. Electronic control unit - 28. Discbrakeassembly-
29. Diaphragmbrakecylinder - 30. Drumbrakeassembly-
31. Lowpressureswitch - 32. Pressuregauge- A. Services- B. Services
V 4x2vehicles
J 4x4vehicles(optional for vehicles4x2)
Figure11
22 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
BRAKING SYSTEMS WITH ABS- EBL DEVICE
Main diagram for vehicles4x2 - 4x4used for haulage
78271
10. Switch for parkingbrakeonindicator - 11. Duplexdistributor - 12. Brakelight switch- 13. Enginebrakecontrol switch-
14. Diaphragmbrakecylinder - 15. Phonic wheel - 16. Wheel speedsensor - 17. Duo Duplexdrumbrakeassembly-
18. Combinedbrakecylinder - 19. ABSsolenoidvalve- 20. Pressuresensor - 21. Single-control relayvalve- 22. Electronic
control unit - 23. Discbrake assembly - 24. Diaphragmbrakecylinder (*) - 25. Drumbrake assembly (*) - 26. Lowpressure
switch - 27. Pressuregauge- A. Services- B. Services
(*) optional
Figure12
PNEUMATIC SYSTEM- BRAKES 23 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Working diagram for 6x4vehicles isolated with an ABS - EBL device
108146
21. Wheel speedsensor - 22. Doubledrumbrakeassembly- 23. Combinedbrakecylinder - 24. ABSsolenoidvalve-
29. Diaphragmbrakecylinder - 30. Drumbrakeassembly-
31. Lowpressureswitch - 32. Pressuregauge- A. Services- B. Services
V 6x4vehicles
J 6x6vehicles(optional for 6x4vehicles)
Figure13
3aso |ovobo 2006 Print 603.93.641
Working diagram for 6x4- 6x6 vehicles designed for towing with ABS - EBL device
108147
10. Switch for parkingbrakeonindicator - 11. Duplexdistributor - 12. Brakelight switch- 13. Enginebrakecontrol switch-
14. Diaphragmbrakecylinder - 15. Phonic wheel - 16. Wheel speedsensor - 17. Duo Duplexdrumbrakeassembly-
18. Combinedbrakecylinder - 19. ABSsolenoidvalve- 20. Pressuresensor - 21. Single-control relayvalve- 22. Electronic
control unit - 23. Discbrake assembly - 24. Proportional reducingvalve - 25. Membranebrakecylinder - 26. Duo Duplex
drumbrakeassembly- 27. Lowpressureswitch-
28. Manometer - A. Services
V 8x4x4 vehicles
J 8x8x4 vehicles(optional for vehicles 8x4x4)
Y Optional configurationdependingonthetypeof air filter andthe type of engineexhaust system.
Figure14
Print 603.93.641 3aso |ovobo 2006
Working diagram for 8x4x4 - 8x8x4vehicles isolated with an ABS- EBL device
108148
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensatedischargevalve - 4. Trailer air tank - 5. 20liter trailer air tank-
6. Rear axleair tank30l - 7. Front axleair tank20l - 8. Pressuretest point - 9. Dual control relayvalve - 10. Parkingbrake
handcontrol valve- 11. Switchfor parkingbrakeonindicator - 12. Trailer slowinghandcontrol valve (optional) - 13. Triple
sovo cooto| va|vo o ta||o ba'|o - ++. |o. ossoo s.|tc| - +5. '|SC' |a|-coo||o o toc' - +6. |o|o o|st|boto -
17. Brakelight switch - 18. Enginebrakecontrol switch- 19. Diaphragmbrakecylinder - 20. Phonic wheel -
29. Proportional reducingvalve - 30. Diaphragmbrakecylinder - 31. Duo Duplexdrumbrakeassembly-
32. Lowpressureswitch - 33. Pressuregauge- A. Services
V 8x4x4 vehicles
Y Optional configurationdependingonthetypeof air filter andthe type of engineexhaust system.
Figure15
3aso |ovobo 2006 Print 603.93.641
Working diagram for 8x4x4 - 8x8x4vehicles designed for towing with ABS - EBL device
108149
25. Pressuresensor - 26. Twinstopvalve- 27. Single-control relayvalve- 28. Electroniccontrol unit - 29. Controlled pressure
checkvalve- 30. A.S.R. solenoidvalve- 31. Discbrakeassembly - 32. Diaphragmbrakecylinder - 33. Drumbrakeassembly -
34. Lowpressureswitch - 35. Pressuregauge-
A. Services
V 4x2vehicles
Figure16
Print 603.93.641 3aso |ovobo 2006
BRAKING SYSTEMS WITH ABS- EBL - ASR DEVICE
Working diagram for 4x2- 4x4 vehicles designed for towing
71845
6. Front axleair tank 20 l - 7. Dual control relayvalve - 8. Parkingbrakehand control valve - 9. Switchfor parkingbrakeon
indicator - 10. Duplexdistributor - 11. Brakelight switch- 12. Enginebrakecontrol switch - 13. Diaphragmbrakecylinder -
14. Phonicwheel - 15. Wheel speed sensor - 16. Duo Duplex drumbrakeassembly - 17. Combinedbrakecylinder -
18. ABSsolenoid valve- 19. Pressuresensor - 20. Twinstopvalve- 21. Single-control relayvalve- 22. Electroniccontrol unit
23. Controlled pressurecheckvalve - 24. A.S.R. solenoid valve- 25. Discbrakeassembly- 26. Diaphragmbrakecylinder (*) -
27. Drumbrakeassembly (*) - 28. Lowpressureswitch - 29. Pressuregauge - A. Services
(*) optional
Figure17
3aso |ovobo 2006 Print 603.93.641
Main diagram for vehicles6x4with ABS - EBL - ASR
108150
10. Switch for parkingbrakeon indicator 11. Trailer slowinghand control valve (optional) - 12. Tripleservo control valvefor
25. Pressuresensor - 26. Twinstopvalve- 27. Single-control relayvalve- 28. Electroniccontrol unit - 29. Controlled pressure
checkvalve- 30. A.S.R. solenoidvalve- 31. Discbrakeassembly - 32. Diaphragmbrakecylinder - 33. Drumbrakeassembly -
34. Lowpressureswitch - 35. Pressuregauge- A. Services
V 6x4vehicles
Figure18
Print 603.93.641 3aso |ovobo 2006
Main diagram for vehicles6x4 - 6X6used for haulage fitted with ABS- EBL - ASR
108151
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank - 5. Rear axleair tank20l -
6. Front axleair tank 20 l - 7. Dual control relayvalve - 8. Parkingbrakehand control valve - 9. Switchfor parkingbrakeon
indicator - 10. Duplexdistributor - 11. Brakelight switch- 12. Enginebrakecontrol switch - 13. Diaphragmbrakecylinder -
14. Phonicwheel - 15. Wheel speed sensor - 16. Duo Duplexdrumbrakeassembly - 17. Combinedbrakecylinder -
18. ABSsolenoid valve- 19. Pressuresensor - 20. Twinstopvalve- 21. Single-control relayvalve- 22. Electroniccontrol unit
23. Controlled pressurecheckvalve - 24. A.S.R. solenoid valve- 25. Discbrakeassembly- 26. Proportional reducingvalve -
27. Diaphragmbrakecylinder - 28. Duo Duplexdrumbrakeassembly - 29. Lowpressureswitch - 30. Pressuregauge -
A. Services
V 8x4x4 vehicles
Y Optional configurationdependingonthetypeof air filter andthetype of engineexhaust system.
Figure19
3aso |ovobo 2006 Print 603.93.641
Main diagram for vehicles8x4x4 - 8x8x4 with ABS - EBL - ASR
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensatedischargevalve- 4. Trailer air tank- 5. Manual condensatedischargevalve-
6. Rear axleair tank20 l - 7. Front axleair tank 20l - 8. Pressure test point - 9. Dual control relayvalve - 10. Parkingbrakehand
control valve - 11. Switch for parkingbrakeon indicator - 12. Trailer slowinghandcontrol valve(optional) - 13. Tripleservo control
va|vo o ta||o ba'|o - ++. |o. ossoo s.|tc| - +5. '|SC' |a|-coo||o o toc' - +6. |o|o o|st|boto - +. 3a'o |||t s.|tc| -
18. Enginebrakecontrol switch - 19. Diaphragmbrakecylinder - 20. Phonicwheel - 21. Wheel speed sensor - 22. Duo Duplex
drumbrakeassembly - 23. Combinedbrakecylinder - 24. ABSsolenoidvalve- 25. Pressuresensor - 26. Twinstopvalve -
27. Single-control relayvalve- 28. Electroniccontrol unit - 29. Controlled pressurecheckvalve - 30. A.S.R. solenoidvalve -
31. Discbrakeassembly- 32. Proportional reducingvalve- 33. Diaphragmbrakecylinder - 34. Duo Duplexdrumbrake assembly-
35. Lowpressureswitch- 36. Pressuregauge- A. Services
V 8x4x4 vehicles
J 8x8x4 vehicles (optional for vehicles8x4x4)
Optional configurationdependingonthetypeof air filter andthetype of engineexhaust system.
108152
Figure20
Print 603.93.641 3aso |ovobo 2006
Main diagram for vehicles8x4x4 - 8x8x4 used for haulage fitted with ABS- EBL - ASR
117183
Figure21
+. '||oo|c' .|oo|- 2. \|oo| too|o sooso - 3. /3S o|octo-va|vo - +. Cob|ooo ba'o c||ooo - 5. /3S o|octo-va|vo - 6. |oa|
cooto| o|a va|vo - . T||o cooto| sovo-o|st|boto - 8. \|oo| too|o sooso - . '||oo|c' .|oo| - +0. oso aoo coo||o -
++. |oo |o|o b|oo co|o .|t| oo cooto| ba'o - +2. |o|a va|vo- +3. /3S o|octo-va|vo - ++. '||oo|c' .|oo| -
15. Wheel turningsensor - 16. Relief valve - 17. A.P.U. - 18. Air reservoir- 19. Manual condensed steamdischargevalve -
20. ABSelectro-valve- 21. Drumcontrol brakeDuo Duplexaxlecomplex- 22. Disk brakeaxlecomplex - 23. Membranebrake
c||ooo a|o (o|s' ba'os) - 2+. \|oo| too|o sooso - 25. '||oo|c' .|oo|- 26. /| osovo| - 2. |o|a va|vo .|t| oo|at|oo o t|o
predominance- 28. E.SCompressor. - 29. DuplexDistributor - 30. ElectronicPower Unit -
31. Handdistributor parkingbrakecontrol
3aso |ovobo 2006 Print 603.93.641
Braking system main components layout on the vehicle
Pneumatically controlled pedal type, operating on all the
wheels andthetrailer.
Itfeaturestwoseparatesections,onetoactivatethefrontaxle
brakingcomponents,theotherfor therearaxlecomponents.
A third section, assistingthe two distributor sections, brakes
thetrailer.
Theduplexdistributorcontrolsthetwoseparatesectionsand
thetriplecontrol servodistributor that initsturncontrolsthe
thirdsection.
Should afailure occur inonesection, the pneumatic system
sectioningenables theothersto operateefficiently.
Thisiscombinedwiththeparkingbraking. Thedoublecircuit
systemenablesthebrakingofoneaxleevenwhenthereis a
failureinthebrakingoftheotheraxle,bymeansoftheservice
brakepedal and theparkinghand lever.
Service braking
Emergency braking
Parking braking
Thisismechanical andactuatedthroughthehanddistributor
set at theendofitsstroke. It operatesontherear wheelsof
thetractor dischargingtheair fromthespringsectionof the
pneumaticcylinder and theservo distributor control section,
thuslockingthetrailer or semi-trailer wheels.
|o t|oo|vo's soat |t |soss|b|o toc|oc' .|ot|o t|ota||o
isable,withthetrailerbrakesreleased, toensuretheefficiency
of thecombinedtractor-trailer parkingbrake.
Drum brakes
S MERITORDUODUPLEX type 410x180and410x200
Retarding braking
TheI.T.B. (Iveco Turbo Brake) enginebrakeused onCursor
enginesiscomposedof ahydraulicallycontrolledmechanism
that cancels the exhaust valve clearance. By applying this
mechanism, at the end of the compression phase, a few
degrees before the T.D.C., the exhaust valves open slightly
with aconsequent reductionin the pressure formed in the
cylinder. This takes advantage of the braking torque of the
compression phase but without havingthe followingreturn
thrust onthepiston.
Front disc brakes SN7 type (for vehicles with
partial traction)
Thediscsarekeyedonto thewheel hubsandequippedwith
ventilation fins that permit lowering the high temperature
generated under thebrakingaction.
A small electrical cableisembeddedinthebrakeliningandis
connected to the MET power unit which commando a
warninglight onthedashboardsignal thewearingofthesaid
brakelinings.
The phonic wheels of the ABS device are keyed onto the
wheel hubs.
Each brakingassembly is composed of a bodyhousing the
adjustment pins, control pins andwedgeunits.
Thewedgeunitsareoperatedbythestemofthecylindersthat
intheir turn areoperatedbycompressed air.
Thewedgeunit rollers, astheytravel, causethecontrol pins
toexpandthat,overcomingtheresistanceoftheshoereturn
springs,bringtheshoesuptothedrumtoactuatebraking.The
adjustment andcontrol pinsaremadeintegral withthebrake
bodybytwo pins that fit into aside slot. When thebraking
actionends, thereisnoair pressureinthediaphragmsection
of the combined brake cylinders and so the action of the
wedge unit return and shoe return springs take the wedge
unitsbackinto thestartingposition.
A sensor isscrewedonto oneof thetwo shoes formingthe
brake. This sensor indicates the state of wear of the brake
linings. When the sensor wirecomes into contact with the
drum, thebrakeliningwear indicator light blinks in thecab.
Whenthesensorwiregetsbroken,duetofurtherwearofthe
brake linings, the wear indicator light stays on, thereby
indicatingtheliningshavereachedtheir maximumwear limit.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESCRIPTION BRAKES
Fault diagnosis comprisestwo sections:
- Thefirst one,organizedbyerrorcodes(DTC-FMI),concernsfaultsthat maybeidentifiedbytheABScontrol unitdirectly.These
ao|ts ao a|o| o ao o|oct|c o| octoo|c oooat|c oatoo.
ao|ts ao a|o| o a oc|ao|ca| oooat|c oatoo.
SECTION I
ABSsystemtroubleshootingcanbeperformedwith theCluster or withthediagnosisinstruments Modus, IT 2000 andE.A.SY..
Diagnosiswiththeclustermakesitpossibletoestimatethesituationoffaultsinthesysteminadvance,whilethediagnosisinstruments
areessential to performthoroughdiagnosis andoperateonthesinglefaultscorrectly.
Eachsingleinstrument displaysthediagnosis andrepair help.
A computerizedfault-diagnosisstationdedicatedto diagnosingthebrakesystems, air suspensions, enginesandsystemscontrolled
electronically.
Thestationisequippedwithauxiliaryfunctions,suchas: programmingelectroniccontrol units, consultingthesparepartscatalogue
Thevehicle hasa30-pindiagnosissocket to interfacewith theinstrument.
IT 2000(IVECO Electronic Tester)
Thismakesit possible totakeimmediateactionon thevehicle, identifyingit withthechassis number.
It savesthe resultsof diagnosticsactions performed.
It canbeused asaportablePersonal Computer, too, beingfittedfor remotediagnosis.
ByusingMODUSasthe mother station it ispossibleto updateandconfiguretheIT 2000.
IT 2000 interfaces withthevehicleviaa30-pin diagnosissocket.
E.A.SY.
E.A.SY. systemallowsto simplymakethediagnosisandprogrammingof thevariouselectroniccentral units aboard thevehicle.
E.A.SY. systemismadeup of ECI modulecommunicatingwith theelectroniccentral units andof aPanasonicPC.
ECI module, exploiting thePanasonicPC,alsoallowseasyontheroadinterventions: inparticular, thanksto PanasonicPC wireless
technologies(e.g. GPRS), diagnosticinterventionscan beassistedbyaremoteexpert centre.
3aso |ovobo 2006 Print 603.93.641
FAULT DIAGNOSIS
98889
Figure22
A. Modus- B. EASY - C. IT 2000
A
B
C
Print 603.93.641 3aso |ovobo 2006
98884
Figure23
98888
Diagnosis information onthecluster issplit into 4 columns:
- Secondcolumn = central unit addressplusfault order number.
- Third column = failuretype.
- Fourthcolumn = failurefrequency.
Thescreenshowsthreeerror messages at most, but can storeupto eight error messages. For displayinganyfurther messages,
3aso |ovobo 2006 Print 603.93.641
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
001 01 SENSORS-
FRONT
LEFT SEN-
SOR
EXCESSIVE
AIRGAP
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
001 02 SENSORS-
FRONT
LEFT SEN-
SOR
INCOR-
RECT
TYRE
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing;
- the tyres have equal
measure (measures re-
leased byconstructor),
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
001 03 SENSORS-
FRONT
LEFT SEN-
SOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value: 1
V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
001 04 SENSORS-
FRONT
LEFT SEN-
SOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
001 05 SENSORS-
FRONT
LEFT SEN-
SOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
001 06 SENSORS-
FRONT
LEFT SEN-
SOR
SHORT
CIRCUIT
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
001 07 SENSORS-
FRONT
LEFT SEN-
SOR
PHONIC
WHEEL
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
001 08 SENSORS-
FRONT
LEFT SEN-
SOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
not faulty;
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
001 09 SENSORS-
FRONT
LEFT SEN-
SOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
TERS read the velocity
of the wheel in ques-
tion.
001 0A SENSORS-
FRONT
LEFT SEN-
SOR
IRREGU-
LAR
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
001 0B SENSORS-
FRONT
LEFT SEN-
SOR
SIGNAL
NOT
PLAUSIBLE
connector.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
001 0C SENSORS-
FRONT
LEFT SEN-
SOR
WRONG
SIGNAL
connector.
If necessary,
replace the
ECU.
002 01 SENSORS-
FRONT
RIGHT
SENSOR
EXCESSIVE
AIRGAP
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
002 02 SENSORS-
FRONT
RIGHT
SENSOR
INCOR-
RECT
TYRE
Checkthat:
not faulty;
aged or missing;
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
002 03 SENSORS-
FRONT
RIGHT
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
Connector X1 Pin: 8
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 13 Measure
point 2: Connector
X1 Pin: 8
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
002 04 SENSORS-
FRONT
RIGHT
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:10
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 10 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
002 05 SENSORS-
FRONT
RIGHT
SENSOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:10
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 10 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
002 06 SENSORS-
FRONT
RIGHT
SENSOR
SHORT
CIRCUIT
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:10
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 10 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
002 07 SENSORS-
FRONT
RIGHT
SENSOR
PHONIC
WHEEL
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
002 08 SENSORS-
FRONT
RIGHT
SENSOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
not faulty;
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
002 09 SENSORS-
FRONT
RIGHT
SENSOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
tion.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
002 0A SENSORS-
FRONT
RIGHT
SENSOR
IRREGU-
LAR SIG-
NAL
connector.
002 0B SENSORS-
FRONT
RIGHT
SENSOR
SIGNAL
NOT
PLAUSIBLE
connector.
002 0C SENSORS-
FRONT
RIGHT
SENSOR
WRONG
SIGNAL
connector.
If necessary,
replace the
ECU.
003 01 SENSORS-
REAR LEFT
SENSOR
EXCESSIVE
AIRGAP
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
003 02 SENSORS-
REAR LEFT
SENSOR
INCOR-
RECT
TYRE
Checkthat:
not faulty;
aged or missing;
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
003 03 SENSORS-
REAR LEFT
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
003 04 SENSORS-
REAR LEFT
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
003 05 SENSORS-
REAR LEFT
SENSOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
003 06 SENSORS-
REAR LEFT
SENSOR
SHORT
CIRCUIT
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
003 07 SENSORS-
REAR LEFT
SENSOR
PHONIC
WHEEL
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
003 08 SENSORS-
REAR LEFT
SENSOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
tion.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
003 09 SENSORS-
REAR LEFT
SENSOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
not faulty;
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
003 0A SENSORS-
REAR LEFT
SENSOR
IRREGU-
LAR
SIGNAL
connector.
003 0B SENSORS-
REAR LEFT
SENSOR
SIGNAL
NOT
PLAUSIBLE
connector.
003 0C SENSORS-
REAR LEFT
SENSOR
WRONG
SIGNAL
connector.
If necessary,
replace the
ECU.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
004 01 SENSORS-
REAR
RIGHT
SENSOR
EXCESSIVE
AIRGAP
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
004 02 SENSORS-
REAR
RIGHT
SENSOR
INCOR-
RECT
TYRE
Checkthat:
not faulty;
aged or missing;
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
004 03 SENSORS-
REAR
RIGHT
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
004 04 SENSORS-
REAR
RIGHT
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
004 05 SENSORS-
REAR
RIGHT
SENSOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
004 06 SENSORS-
REAR
RIGHT
SENSOR
SHORT
CIRCUIT
Possible short
circuit.
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
004 07 SENSORS-
REAR
RIGHT
SENSOR
PHONIC
WHEEL
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
004 08 SENSORS-
REAR
RIGHT
SENSOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
not faulty;
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
004 09 SENSORS-
REAR
RIGHT
SENSOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
tion.
004 0A SENSORS-
REAR
RIGHT
SENSOR
IRREGU-
LAR SIG-
NAL
connector.
004 0B SENSORS-
REAR
RIGHT
SENSOR
SIGNAL
NOT
PLAUSIBLE
connector.
004 0C SENSORS-
REAR
RIGHT
SENSOR
WRONG
SIGNAL
connector.
If necessary,
replace the
ECU.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
007 03 SOLE-
NOID
VALVES -
FRONT
LEFT ABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 3 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 6 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
007 05 SOLE-
NOID
VALVES -
FRONT
LEFT ABS
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 3
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 6
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
007 06 SOLE-
NOID
VALVES -
FRONT
LEFT ABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 3
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 6
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
008 03 SOLE-
NOID
VALVES -
FRONT
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 1 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 4 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
008 05 SOLE-
NOID
VALVES -
FRONT
RIGHTABS
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 1
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 4
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
008 06 SOLE-
NOID
VALVES -
FRONT
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 1
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 4
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
009 03 SOLE-
NOID
VALVES -
REAR LEFT
ABS SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 5 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
009 05 SOLE-
NOID
VALVES -
REAR LEFT
ABS SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 2
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 5
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
009 06 SOLE-
NOID
VALVES -
REAR LEFT
ABS SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 2
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 5
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
00A 03 SOLE-
NOID
VALVES -
REAR
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 9 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
00A 05 SOLE-
NOID
VALVES -
REAR
RIGHTABS
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 8
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 9
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
00A 06 SOLE-
NOID
VALVES -
REAR
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
nectors.
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 8
Measure point 2:
Connector X1 Pin: 4
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 9
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
00D 03 THIRD
BRAKE
RELAY -
THIRD
BRAKE
RELAY
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
fuse70601/ 5.
connector ST93
Check that the relay
25104 (E) is working
correctly.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 14 Measure
point 2: Connector
X1 Pin: 4
sistance (Ohm)
Measure point 1:
ConnectorX1Pin:14
Measure point 2:
Connector X1 Pin: 7
1- Connector
Connected; Key
+15ON;
2- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
00D 05 THIRD
BRAKE
RELAY -
THIRD
BRAKE
RELAY
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
fuse70601/ 5.
connector ST93Check
thattherelay25104(E)
is working correctly.
Reset theECU:1- With
|o|t|oo 'o oo 'C|'
short-circuit Pin 13
(connector X1) to
ground for a time be-
tween3 and 6sec.
2- Wait for 2sec.
3- Short-circuir again
the Pin 13 connector
X1 to ground and re-
peat the procedure for
threetimes;eachshort-
circuit should last at
least 0,5 sec.If thepro-
cedure has been cor-
rectly carried out the
ASR indicator switches
on (four short pulses).
When the ignition key
isswitchedON again,it
ispossibleto deletethe
faults memory. If the
fault persists, replace
theE.C.U.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 14 Measure
point 2: Connector
X1 Pin: 4
sistance (Ohm)
Measure point 1:
ConnectorX1Pin:14
Measure point 2:
Connector X1 Pin: 7
1- Connector
Connected; Key
+15ON;
2- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
00D 06 THIRD
BRAKE
RELAY -
THIRD
BRAKE
RELAY
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
fuse70601/ 5.
connector ST93
Check that the relay
25104 (E) is working
correctly.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 14 Measure
point 2: Connector
X1 Pin: 4
sistance (Ohm)
Measure point 1:
ConnectorX1Pin:14
Measure point 2:
Connector X1 Pin: 7
1- Connector
Connected; Key
+15ON;
2- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
00E 04 VOLTAGE LOWTEN-
SION/
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
fuse 70601 / 4 (Stralis
70602/ 5).
fuse 70601 / 6 (Stralis
70602/ 6).
supplywiring.
Check the ignition key
and voltage stability.
Checkcorrect pinloca-
tion on Electronic con-
trol unit,iffault persists,
replace.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min. value:
22V;
Max.value:28V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
00E 05 VOLTAGE GROUND
FAULTY
OR NOT
PRESENT
(pin 9 con-
nector X1)
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.
Check: Check correct
pin location on Elec-
tronic control unit, if
fault persists, replace.
Comparablevalues:
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 4 Measure
point 2: GND Pin:
GND
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 9 Measure
point 2: GND Pin:
GND
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 9
Measure point 2:
GND Pin: GND
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 4
Measure point 2:
GND Pin: GND
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
3- Connector
Not connected;
Key+15OFF;
4- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Max. value:
1 V;
3- Max. value:
3 Ohm;
4- Max. value:
3 Ohm;
Carry out
the recom-
mended
measure-
ments.
00E 07 THIRD
BRAKE
RELAY -
SUPPLY
RELAY (IN-
SIDE THE
ELEC-
TRONIC
CON-
TROL
UNIT)
FAULT Ecu internal fail-
ure.
Before replacing the
control unit make sure
that the control unit is
poweredcorrectly.
(V) Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
010 PRESSURE
SENSOR
SHORT
CIRCUIT
Short-circuit,
faultysensor.
Replace sensor if dam-
aged.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min.value:0.5
V; Max. value:
4.5 V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
010 03 PRESSURE
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Shorted to high
source
aged.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min.value:0.5
V; Max. value:
4.5 V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
010 05 PRESSURE
SENSOR
OPEN CIR-
CUIT OR
SHORT
CIRCUIT
TO
GROUND
Open circuit or
short-circuiting
to negative.
aged.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min.value:0.5
V; Max. value:
4.5 V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
012 03 SOLE-
NOID
VALVES -
ASR SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
nectors.
Measure type: Volt-
age (V) Measure
point 1: Connector
X2 Pin: 16 Measure
point 2: Connector
X1 Pin: 4
Connector
Connected; Key
+15ON;
Max. value: 1V; Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
012 05 SOLE-
NOID
VALVES -
ASR SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.Check for a
fault in thecomponent.
Reset theECU:
1- Withignitionkeyon
'C|' s|ot-c|co|t ||o
13 (connector X1) to
ground for a time be-
tween3 and 6sec.
2- Wait for 2seconds.
3-Short-circuir again
the Pin 13 connector
X1 to ground and re-
peat the procedure for
threetimes;
each short-circuit
should last at least 0,5
sec.
If the procedure has
been correctly carried
out the ASR indicator
switcheson(fourshort
pulses).
When the ignition key
isswitchedON again,it
ispossibleto deletethe
faults memory.
If the fault persists, re-
placetheE.C.U.
Measuretype: Resist-
ance (Ohm) Mea-
surepoint 1:Connec-
tor X2 Pin: 7 Mea-
surepoint 2:Connec-
tor X2 Pin: 16
Connector Not
connected; Key
+15OFF;
Min. value: 30
Ohm; Max. val-
ue: 40Ohm;
Carry out
the recom-
mended
measure-
ments.
012 06 SOLE-
NOID
VALVES -
ASR SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
nectors.
Measuretype: Resist-
ance (Ohm) Mea-
surepoint 1:Connec-
tor X2 Pin: 7 Mea-
surepoint 2:Connec-
tor X2 Pin: 16
Connector Not
connected; Key
+15OFF;
Min. value: 30
Ohm; Max. val-
ue: 40Ohm;
Carry out
the recom-
mended
measure-
ments.
017 05 ABS INDI-
CATOR
SHORT
CIRCUIT
TO
GROUND
Possible causes:
blink code ac-
tivation > 16
sec. bymeansof
switch (pin 15
ecu).
fuse 14 and connector
ST18, pin5.
Measure type: Volt-
age (V) Measure
point 1: Connector
X1 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
Connector
Connected; Key
+15ON;
Max. value: 1V; Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
0E7 02 CAN LINE INPLAUS-
IBLE VE-
HICLE
SPEED
Checkthat:
not faulty;
aged or missing;
tyrespressure.
Verifytheaxleratio.
0E7 05 CAN LINE OPEN CIR-
CUIT OR
SHORT
CIRCUIT
TO
GROUND
OR POS-
ITIVE
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors. Check for re-
versal of CAN line
cables.
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Typical Value:
60Ohm;
2- Min. value:
29 KOhm; Max.
value: 33KOhm;
Carry out
the recom-
mended
measure-
ments.
0E7 06 CAN LINE CONNEC-
TION DIS-
ABLED
Possible open
circuit or inter-
rupted cablebe-
tween.
nectors.
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Typical Value:
60Ohm;
2- Min. value:
29 KOhm; Max.
value: 33KOhm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
0E7 07 CAN LINE TIMEOUT
WITH THE
RETARD-
ER
Check for correct op-
eration/connection of
the control units that
are interfaced with
each other (e.g.: EDC,
GEARBOXES, EBS,
ABS, INTARDER, SUS-
PENSIONS, IMMOBI-
LIZER, others...)
0E7 08 CAN LINE DELAY IN
THE COM-
MUNICA-
TION
WITH THE
EDC E.C.U.
(ENGINE
BRAKE)
Check for correct op-
eration/connection of
the control units that
are interfaced with
each other (e.g.: EDC,
GEARBOXES, EBS,
ABS, INTARDER, SUS-
PENSIONS, IMMOBI-
LIZER, others...)
0E7 09 CAN LINE DELAY IN
THE COM-
MUNICA-
TION
WITH THE
EDC E.C.U.
(TORQUE)
Check that the CAN
LINE is correctly con-
nected to the other
control units. Checkfor
CAN presence on the
diagnostic connector.
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
sistance (Ohm)
Measure point 1:
30-pole connector
Pin: 21 Measure
point 2: 30-polecon-
nector Pin: 22
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15OFF;
1- Typical Value:
60Ohm;
2- Min. value: 29
KOhm; Max. val-
ue: 33KOhm;
3- Typical Value:
60Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
0E7 0A CAN LINE DELAY IN
THE COM-
MUNICA-
TION
WITH THE
EDC E.C.U.
(ENGINE
BRAKE/RE-
TARDER)
Check that the CAN
LINE is correctly con-
nected to the other
control units. Checkfor
CAN presence on the
diagnostic connector.
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
sistance (Ohm)
Measure point 1:
30-pole connector
Pin: 21 Measure
point 2: 30-polecon-
nector Pin: 22
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15OFF;
1- Typical Value:
60Ohm;
2- Min. value:
29 KOhm; Max.
value: 33KOhm;
3- Typical Value:
60Ohm;
Carry out
the recom-
mended
measure-
ments.
0E7 0C CAN LINE INTERNAL
FAULT
Ecu internal fail-
ure.
poweredcorrectly.
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Connected; Key
+15ON;
3- Connector
Connected; Key
+15ON;
1- Min. value:
29KOhm;
Max. value:
33KOhm;
2- Min. value:
22V;
Max.value:28V;
3- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
0FB 03 VOLTAGE OVER-
VOLTAGE
The alternator
charge may be
excessive.
Check battery and al-
ternator supply.
Checksupplyvoltage.
Check the
Tension
Regulator or
any false
contacts on
the earth or
positive
points.
0FD 02 ELEC-
TRONIC
CON-
TROL
UNIT
INCOR-
RECT
WHEEL
PARAME-
TERS
ReprogramABScentral
unit with correct con-
figuration.
If the error
persists to
replace
ECU.
0FD 0C ELEC-
TRONIC
CON-
TROL
UNIT
EEPROM
PARAME-
TERS NOT
CORRECT
ReprogramABScentral
unit with correct confi-
guration.
If the error
persists to
replace
ECU.
0FE 05 ELEC-
TRONIC
CON-
TROL
UNIT
ASR
FUNC-
TION DIS-
ABLED
Brake controlling
ASR disabled.
ECU connector
X2 not con-
nected or ab-
sence of ground
onPIN 2ofeach
ABS electro-
valve.
Checkcompatibilitybe-
tween vehicle system
and E.C.U. configura-
tion.
Check that
the ABS
ECU pro-
gramming is
convenient
for the ve-
hiclesystem.
Check the
CAN line
with EDC.
Check that
the EDC
ECUisprop-
erly pro-
grammed.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
0FE 05 ELEC-
TRONIC
CON-
TROL
UNIT
ABS-ASR
FUNC-
TION DIS-
ABLED
ABS / ASR dis-
abled.
ECU connector
X2 not con-
nected or ab-
sence of ground
onPIN 2ofeach
ABS electro-
valve.
Checkcompatibilitybe-
tween vehicle system
and E.C.U. configura-
tion.
Check that
the ABS
ECU pro-
gramming is
convenient
for the ve-
hiclesystem.
Check the
CAN line
with EDC.
Check that
the EDC
ECUisprop-
erly pro-
grammed.
0FE 08 ELEC-
TRONIC
CON-
TROL
UNIT
EXCESSIVE
SLIPPING
Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Check phonic wheel
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
tweensensor andpho-
nic wheel.
0,05mm
0FE 09 SOLE-
NOID
VALVES -
ABS SOLE-
NOID
VALVES
ACTIVA-
TION
TIMES
NOT
CORRECT
ABS valveenab-
ling time incor-
rect.
Checkthat thesolenoid
connectorsintheelec-
trical system and the
pipes in the pneumatic
systemhave not been
inverted.
DTC FMI
Failing
component
Typeof
Failure
Measuring
conditions
Valuestobe
detected
Remarks
0FE 0C ELEC-
TRONIC
CON-
TROL
UNIT
INTERNAL
FAULT
Ecu internal fail-
ure.
poweredcorrectly.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min. value: 22
V; Max. value:
28V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
SECTION 2
Pneumatic system pipes leaking or
broken.
Tightenorreplace looseordamagedfit-
tings.
Replacebrokenor damagedpipes.
Insufficient or irregular systemcharging
Air compressor isfaulty. Overhaul or replaceair compressor.
Insufficient or irregular systemcharging
Pressureregulator indrier isfaulty. Overhaul or replacedrier.
Four-waysafetyvalveisfaulty. Overhaul or replace four-way safety
valve.
Leaksor breakagesinpneumaticsystem
pipes.
Tightenor replacelooseordamagedfit-
tings.
Replacebraokenor damaged pipes.
Rear axleservicebrakingisinefficient or
Brakingcontrol isfaulty. Adjust,overhaul andifnecessaryreplace
thebrakingcontrol.
Rear axleservicebrakingisinefficient or
irregular Worn or vitrified brakelinings. Overhaul or replacethebrakelinings.
Rear brakesarefaulty. Overhaul therear brakes.
Duplexdistributor isfaulty. Overhaul or replaceDuplexdistributor.
Brakecylindersarefaulty. Overhaul or replacebrakecylinders.
pipes.
Tightenor replacelooseordamagedfit-
tings
Front axleservicebrakingisinefficientor
Duplexdistributor isfaulty. Overhaul or replaceDuplexdistributor.
Front axleservicebrakingisinefficientor
irregular Worn and/or vitrifiedbrakelinings. Overhaul or replacebrakelinings.
Front brakes arefaulty. Overhaul front brakes.
Diaphragmbrakecylindersarefaulty. Overhaul or replace diaphragmbrake
cylinders.
(Continue)
3aso |ovobo 2006 Print 603.93.641
pipes.
Tightenorreplace looseordamagedfit-
tings
Replacebrokenor damagespipes.
T il i b ki i i ffi i t
Triplecontrol servo distributor is faulty. Overhaul orreplacetriplecontrol servo
distributor.
Trailer service braking is inefficient or
irregular
Duplexdistributor isfaulty. Overhaul or replace duplex control
valve.
Pressurereducer isfaulty. Overhaul or replacepressurereducer.
Worn or vitrified brakelinings. Overhaul or replacebrakelinings.
Trailer brakesisfaulty. Overhaul trailer brakes.
pipes.
Tighten or replace loose or damaged
couplings.
Inefficient or no parkingbraking
Combinedbrakecylindersarefaulty. Overhaul or replace combined brake
cylinders.
p g g
Parkingbrakehandlever isfaulty. Overhaul or replacelever.
Worn or vitrified brakelinings. Overhaul or replacebrakelinings.
Relayvalveisfaulty. Overhaul or replacerelayvalve.
pipes.
couplings.
Inefficientornoparkingbrakingontrailer
Triplecontrol servo distributor is faulty. Overhaul or replace triple action servo
control valve.
p g g
Parkingbrakehandlever isfaulty. Overhaul or replacehandlever.
Worn or vitrified trailer brakelinings. Overhaul or replacetrailer brakelinings.
Trailer brakes arefaulty. Overhaul trailer brakes.
(Continue)
Print 603.93.641 3aso |ovobo 2006
pipes.
couplings.
D l d ki b k l
Delayed parkingbrakerelease
Combinedbrakecylindersarefaulty. Overhaul or replace combined brake
cylinders.
Rear brakesarefaulty. Overhaul rear brakes.
pipes.
couplings.
Delayed trailer parkingbrakerelease
Triplecontrol servo distributor is faulty. Overhaul or replace triple action servo
control valve.
Parkingbrakehandlever isfaulty. Overhaul or replacehandlever.
Trailer brakes arefaulty. Overhaul trailer brakes.
pipes.
connections.
Duplexdistributor isfaulty. Overhaul or replace Duplex control
valve.
The vehicle pulls to one side when
braking
load proportioningvalve.
Front brakes arefaulty. Overhaul front brakes.
Rear brakesarefaulty. Overhaul rear brakes.
Triplecontrol servo distributor is faulty. Overhaul orreplacetripleactioncontrol
valve.
pipes.
couplings.
Insufficient trailer slow-downbraking
Pressurereducer isfaulty. Overhaul or replacepressurereducer.
Insufficient trailer slow downbraking
valve.
(Continue)
3aso |ovobo 2006 Print 603.93.641
Duplexdistributor isfaulty. Overhaul or replace duplex control
valve.
B k li i b i kl
load proportioningvalve.
Brakeliningsbecomewornquickly
Brakesare faulty. Overhaul brakes.
valve.
B k f il i di li h
pipes.
couplings.
Brake system failure indicator light
switched on
Four-waysaftyvalve isfaulty. Overhaul orreplacefourwayprotection
valve.
Light indicator electric circuit is badly
wired.
Find wrongconnection and rectifywir-
ing.
Parkingbrakeindicator light switchedon
Light indicator electric circuit is badly
wired.
Find wrongconnection and rectifywir-
ing.
Parkingbrakeindicator light switchedon
withhandlever inrunningposition Parkinghand lever is faulty. Overhaul or replacelever.
Pressurereducer operatingnormally. Overhaul or replacepressurereducer.
Worn brakelinings. Replacebrakelinings.
Noisybrakes
Shoereturnspringsarefaulty. Overhaul rear brakes.
Noisybrakes
Brake drums are ovalized over pre-
scribed tolerancerange.
Faceor, if necessary, replacedrums.
Print 603.93.641 3aso |ovobo 2006
TIGHTENING TORQUES
DESCRIPTION TORQUE
Compressor Nm (kgm) Compressor Nm (kgm)
Compressor, Knorr type- BREMSE 2W 460R, 464 cm
3
Headfasteningscrews 30 (3)
Pulleyfasteningnut
190
1
0
(19)
Combinedbrakecylinder
Brakecylinder ringnut 300 +30 (30 3)
Manual brakereleasescrew 15+20 (1.5 )
Diaphragmbrakecylinder (for drumbrakes)
Brakecylinder ringnut 300 +30 (30 3)
Diaphragmbrakecylinder (for disk brakes)
Nutsto securecylinder to brakecaliper
180 20
(18 2)
Front disc brakes axle 5886/D
Ringnut fixingwheel bearings 515.5 24.5 (51.5 2.4)
Cylindrical headscrewswithhexsocket to lockwheel bearingadjustment clamp 27.5 2.5 (2.7 0.2)
Self-lockinghexscrews to fixbrakecallipers tomount 615.5 61.5 (61.5 6.1)
Self-lockinghexscrewto fixbrakecalliper mount tostubaxle 312.5 16.5 (31.2 1.6)
Hexscrewfixingbrakediscto wheel hub 281.5 13.5 (28.1 1.3)
Cover for wheel hubz 130 10 (13 1)
Tapered threadedplugfor wheel hub cover 50 5 (5 0.5)
z Deposit asealer beadonlyonhub cover ledgesurface, usingdedicated dispenser. Protect threadedportion. UseLOCTITE
TYPE574asasealer
Rear drumbrakes axle 5985/2D
Wheel securingnut
600
+50
-20
60
+5
-2 (
(
Brakesupport securingscrew 362.5 33.5 (36.2 3.3)
Cover securingscrew 49 5 (4.9 5)
Support securingscrew 25 3 (2.5 3)
Axledrumbrakes452191/2D - 453291/2D - 452146/2D - 451391/2D
Screwfixingdrum 25 3 (2.5 0.3)
Cover securingscrew H 50 5 (5 0.3)
Flat-headscrew 50 5 (5 0.5)
Wheel securingnut 615 35 (61.5 3.5)
Drumbrakes on rear axleMT 23 - 155
Wheel fasteningnut 665.5 61.5 (67.8 6.2)
Drumfasteningscrew 54.5 12.5 (29 1.3)
Half-shaft fasteningscrew* 262 27 (26.7 2.7)
Wheel hub bearingringnut 932 98 (95 10)
Nut for brakesupport fasteningscrew 289.4 14.5 (29.5 1.5)
Revsensor support fasteningscrew D 6 1
* spreadthe flange/wheel hub matingsurfacewithsealer IVECO 1905685(LOCTITE14780)
applyLOCTITE245onthethreading
3aso |ovobo 2006 Print 603.93.641
TOOLS
99301001 Grindingand turningmachinefor brakediscs anddrums
99301005 Brakediscturningdevice
99301006 Brakeshoeturningdevice
99305079 Brakeshoeturningdevice
99305087 Rivet press
99305117 Instrument to checkair circuits
PNEUMATICSYSTEM- BRAKES 75 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
99341003 Single-acting bridge (rear axles 452194/2D - 451391/2D -
453291/2D- 452191/D- 452146/2D)
99321024 Hydraulic trolleyto removeandrefit wheels
99327030 E.A.SY.
99341015 Clamp (rear axles 412191/2D - 451391/2D - 453291/2D -
452146/2D)
99341023 Grips (rear axles452191/2D- 451391/2D- 453291/2D)
76 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
99345049 Reactionblockfor extractors (driveaxle 5985/2D)
99345053 Reaction block for extractors (drive axle 5985/2D, rear axle
452146/2D)
99345055 Reactionblockforextractors(rearaxles452191/2D- 451391/2D
- 453291/2D)
99348001 Extractor with locking device (drive axle 5985/2D, rear axles
452146/2D- 452191/2D - 451391/2D- 453291/2D)
9938004 Universal maleextractor from5to 70 mm(driveaxle5985/2D)
99354207 Wrench for wheel hub caps (front axle 5886/D, drive axle
5985/2D, rear axles 452146/2D - SR145E/2D - 452191/2D -
451391/2D- 453291/2D)
Print 603.93.641 3aso |ovobo 2006
99356001 Wheel brake shoe adjustment wrench (rear axles 452191/2D-
451391/2D- 453291/2D - 452146/2D)
99356006 Wrenchfordismountingandremountingfairedbrakecylinderring
nut
99370005 Gripforinterchangeabledrifts(rearaxles452191/2D-451391/2D
- 453291/2D - 452146/2D)
99370006 Grip for interchangeable drifts (front axle 5886/D, drive axle
5985/2D, rear axles 452191/2D- 451391/2D - 453291/2D)
99370007 Grip for interchangeable drifts (front axle 5886/D, drive axle
5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D)
99370317 Reactionleverwithextensiontoretainflanges(front axle5886/D,
drive axle 5985/2D, rear axles 452191/2D - 451391/2D -
453291/2D- 452146/2D)
3aso |ovobo 2006 Print 603.93.641
99370715 Guide for fitting wheel hub (front axle 5886/D, rear axles
452191/2D- 451391/2D - 453291/2D
99372211 Tool to remove and refit brakeshoeretainer springs
99372213 Tool for turning brake drum (use with 99301001) (drive axle
5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D, axle5886/2D)
99372228 Hubfor positioningdismantledfloatingshoeturningtoolsonlathe
99301001
99372230 Tool forturningdismantledfloatingshoes(Rockwell410) (usewith
99301001- 99372228)
99372237 Tool to mount brake calliper sliding bush guard (front axle
5886/D)
Print 603.93.641 3aso |ovobo 2006
99372238 Tool to extract brakecalliper thrust units (front axle5886/D)
99372239 Tool to mount thrust units with brake calliper guard (front axle
5886/D)
99372240 Tool to removeandrefit brakecalliperslidingbushguidebushings
(usewith 99372237 for assembly) (front axle5886/D)
99372241 Tool for notchingbrakecalliper slidingbush guide bushing(front
axle5886/D)
99373004 Key to remove brake cylinder gasket (Rockwell) (rear axles
452191/2D - 451391/2D - 453291/2D - 452146/2D, axle
5985/2D)
99374025 Installer, wheel hub inner seal (usewith 99370005)
3aso |ovobo 2006 Print 603.93.641
99374093 Drift to mount bearing outer races 91-134 mm (use with
99370007) (front axle - 5886/D, drive axle 5985/2D, rear axles
452191/2D- 451391/2D - 453291/2D- 452146/2D)
99374094 Drift to mount bearing outer races 134-215 mm (use with
99370007) (rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D, axle5985/2D)
99374132 Key to mount wheel hub internal gasket (use with 99370006)
(front axles 5886/D)
99374161 Keyto mount wheel hub internal gasket (rear axles 452191/2D -
451391/2D- 453291/2D - 452146/2D)
99374377 Keyto mount wheel hub internal gasket (drive axle5985/2D)
99374451 Tool to remove and refit drive shafts (rear axles 452191/2D -
451391/2D- 453291/2D - 452146/2D)
Revi- June2007
PRINT603.93.641/A
99387050 Cuttingnippers for polyamide pipes
99388001 Wrench (80 mm) for front wheel hub bearing adjustment nut
(front axle5886/D, driveaxle5985/2D)
99387051 Toolkit to remove polyamide tubes (6-8-10-12 mm) from
RAUFOSSjoints
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
MAIN DATA - PNEUMATIC SYSTEM
DESIGNATION
Compressor
- Type: WABCO 412 352 200 8 Singlecylinder
Displacement 352 cm
3
- Type: KNORR - BREMSE 2W460 R Two cylinders
Displacement 628 cm
3
APU
- Type: KNORR Z 007035
Max. workingpressure bar 13bar
Safetyvalve openingpressure bar 13+4 bar
Circuit 1 2 3 4 3 4
Fittingfor second 21 22 23 24 26
Openingpressure(The circuit 1+2 arefilled first) bar
7.5
+0.2
0
8.0
-0
0.2
Openingpressureof theintegrated safetyvalve bar >=9.2
Staticclosingpressure.
(Without compensation, with 0 bars inthecircuit out of service) bar
6.5 0.25 6.5 0.25
Workingpressure bar
8.5
-0.3
8.5
-0.5
Pressure limiter on/off pressuredifference bar <=0.65
Air tanks
Front axle 20Litres
Rear axle 20Litres
Parking+trailer 20Litres
For regeneration 5 Litres
Services 5 Litres
Engine brake control pedal valve
- Type: BOSCH A 481 110 125 - WABCO 463036019 - BENDIX CP6A
Maximumworkingpressure 12 bar
Duplex distributor
- Type: KNORR - DX 60A
Feedpressure 10.5bar
Workingpressure 10.5bar
Proportional reducing valve
- Type: KNORR DB 2116
Ratio 1.15:1
Relayvalve
- Type: KNORR - BREMSE - AC 574 AXY
Max. workingpressure 10.2 bar
- Type: KNORR - BREMSE - RP2A
Max. workingpressure 10bar
Print 603.93.641 3aso |ovobo 2006
DESIGNATION
Double-acting relay valve
- Type: WABCO 973 011 208 0
Control maximumpressure 10 bar
Variable and automatic coupling heads
- Type: MARELLI - BOSCH - KNORR - BREMSE - WABCO - GRAU
Workingpressure 8.5 bar
Triple control servo distributor
- Type: KNORR - BREMSE AC 597B - WABCO 973009013
Feedpressure 8.5 bar
Predominance 0.2 bar
Differential control pressure (ducts 41and22)
2.5 bar
0,5
0,3
Parking br ake distr ibutor (towing vehicles)
- Type: KNORR DPM60EY
Supplyand workingpressure 8.5 bar
Travel ofcontrol lever (discharge) withstart ofemergencybraking(point ofresistance) 67
Parkingbraking 73
Test brakingto check supplyto triplecontrol valve 86
Parking brake distributor (stand-alone vehicles)
- Type: KNORR DPM61EY
Supplypressure 8.5 bar
Travel ofcontrol lever (discharge) withstart ofemergencybraking(point ofresistance) 67
Parkingbraking 73
Trailer retarder control valve (optional)
- KNORRDPM 96DAX
Supplypressure 8.5 bar
Maximumangular travel of control lever 73
Air pressure switch
- TDSF13043 - F13047
Workingpressure max 15bar
Settingpressure
with increasingpressure 5.5 0.5 bar
with decreasingpressure 6.6 0.3 bar
Safety valve (for Sweden only)
- WABCO 4342050610
Maximumoperatingpressure 10bar
Controlled pressur e valve
- WABCO 434100199 - KNORR - BREMSE 1B435 47 - BENDIX VPC 4M
Openingpressure 7 bar
+0.1
- 0.3
ABS wheel anti-lock control valve
- Type: WABCO 472 195 055 0
Maximumoperatingpressure 13 bar
- Type: KNORR - BREMSE IC 57664
Maximumoperatingpressure 10,2bar
3aso |ovobo 2006 Print 603.93.641
DESIGNATION
Check valve
- Type: VOSS02 689142 00
Max. workingpressure 12bar
Impedancepressure 0.2 bar
Twin stop valve
- WABCO 4342080290
Supplypressure max 10bar
Pressure test point valve
- Type: RAUFOSS
Workingpressure max 12.5bar
- Type: SIRIT
Workingpressure max 12.5bar
Pressure sensor
- WABCO 4410400150
Measuringprinciple piezo-resistive
Permissibleoverpressure 16bar
Solenoid valve normally closed ASR control
- WABCO 4721706060
Workingpressure 5.5 11bar
Feedmaximumpressure 13bar
Voltage 24V
Current 0.69A
Electronic control unit
- WABCO 4460043200
Supplyvoltage 24V
Membrane brake cylinder (for drumbrakes)
- Type 14: BENDIX DFR 8944 B
Maximumworkingpressure 8.5 bar
Sleeve length 187 mm
Stroke min. 53 mm
- Type 14: KNORR EF 141AY
Stroke 53mm
- Type 16: BENDIX DFR 9023 B
Stroke min. 53 mm
- Type 16: KNORR EF 161AY
Stroke min. 53 mm
- Type 18: BENDIX EF 180 BY
Stroke min. 53 mm
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESIGNATION
Combined brake cylinder
- Type 16/24 HF: KNORR 1C 56449
Maximumworkingpressure 8.5bar
Springload 7900 N
- Type 18/24 HF: KNORR 1C 55976
Springload 7900 N
- Type 14/24: HF KNORR - BREMSE BY 9276 (Z 005732)
Springload 10400N
- Type 16/24: HF KNORR - BREMSE BY 9331 (Z 005733)
Springload 10400N
Membrane brake cylinder (for disk brakes)
- Type 22: KNORR - BREMSEZ 011553
Sleevelength 141 mm
Stroke min64mm
- Type 24: KNORR - BREMSEZ 010464
Sleevelength 141 mm
Stroke min64mm
Membrane brake cylinder (for drumbrakes)
- Type 16: KNORR EF 161NYX
Sleevelength 152 mm
Stroke min53mm
- Type 16: KNORR EF 161PYX
Sleevelength 190 mm
Stroke min53mm
- Type 18: KNORR EF 180PYX
Sleevelength 190 mm
Stroke min53mm
Combined brake cylinder
- Type 16/24 HF: KNORR - BREMSE Z 007616
Springload 7900N
Stroke min53mm
- Type 18/24 HF: KNORR - BREMSE Z 007618
Springload 7900N
Stroke min53mm
3aso |ovobo 2006 Print 603.93.641
MAIN DATA - BRAKES
KNORR FRONT
DISC BRAKES:
FRONT AXLE
INTERMEDIATE ADDED
AXLE
5886/D
Brakecalliper cylinders:
- number
- diameter mm
2
68
S
Brakeliningthickness:
- standard S mm
- minimumpermissible S mm
21
2
Brakediscdiameter mm 432
S
Brakediscthickness:
- normal S mm
- minimumpermissible S mm
45 0.1
37(4mmper side)
Operatingclearance G mm 0.5 1
WHEEL HUBS
Wheel hub bearings 2with taperedrollers
Hub bearingendfloat mm 0.16max
Hub bearingendfloat adjustment withringnut
Rollingtorque daNm 0.50max.
TutelaW 140/MDA
Litres
Quantityof oil for eachhub
Kg
0.35
0.32
Print 603.93.641 3aso |ovobo 2006
MERITOR DUO-DUPLEX DRIVE AXLE MERITOR DUO DUPLEX
DRUM BRAKES
DRIVE AXLE
5985/2D
Drumdiameter:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
410 410.4
412 412.4
414 414.4
S
S1*
- Nominal S mm
- 1
st
uprating S mm
- 2
nd
uprating S mm
- minimumpermissible S
1*
mm
22.95
23.95
24.95
6.95
Diameter of brake linings:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
408 409
410 411
412 413
L
Widthof brakelinings:
L mm 179 180
G
Clearance between brake linings
and drum:
G mm 0.5 1.2
E
Maximumerror of concentricityin
thedrumdiameter after turning
E mm
0.04
WHEEL HUBS WHEEL HUBS
Wheel hub bearings
Two withtaperedrollers
SET-RIGHT
Hub bearingendfloat
mm Not adjustable
Hub bearingendfloat adjustment Tighteningto torquewithringnut
Wheel hub bearingrollingtorque
0.50max
-
TutelaW 140/MDA
Litres
Kg
-
-
3aso |ovobo 2006 Print 603.93.641
MERITOR
DUO-DUPLEX REAR
H.R. REARAXLE REAR AXLE
DUO-DUPLEX REAR
DRUM BRAKES
451391/2D 452146/2D 452191/2D 453291/2D MT 23-155/2D
Drumdiameter:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
410 410.4
412 412.4
414 414.4
S
S1*
- Nominal S mm
- 1
st
uprating S mm
- 2
nd
uprating S mm
- minimumpermissible S
1*
mm
22.95
23.95
24.95
6.95
j
Diameter of brake linings:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
408 409
410 411
412 413
L
Widthof brakelinings:
L mm
199 200
G
Clearance between brake linings
and drum:
G mm 1 1.25
E
Maximumerror of concentricityin
thedrumdiameter after turning
E mm 0.04
WHEEL HUBS WHEEL HUBS
Wheel hub bearings SET-RIGHT
Two with tapered
rollers(Unit Bearing)
Hub bearingendfloat
mm
Not adjustable
Not adjustable,
tightenaccordingto
retainingringnut
torque
Hub bearingendfloat adjustment -
Wheel hub bearingrollingtorque -
TutelaW 140/MDA
Litres
Kg
-
-
SincethevehiclesystemisapprovedaccordingtoEuropeanroadcodestandards,itisnecessarythattheefficiencyandcomponents
areperiodicallycheckedusingtool 99305117.
Thechecksarecarriedout withthevehicleatastandstill,using compressedairfromthetanks, recharged, withtheenginerunning,
bythecompressor.
!
Alwaysblockthevehiclebeforestartinganytypeofoperation.Periodicallycheckthegaugescomparingthemwithamaster
gauge.
(continued)
Print 603.93.641 3aso |ovobo 2006
BRAKING SYSTEM MAIN COMPONENTS CHECK
DEVICE DESIGNATION CHECKS
Compressor
Checkthetightnessoffittingsand that thecompressor issecurely
fastened. Makesurethecoolingfinsarenot dirty.
Drier (optional)
Operateonableedervalveorloosenascrewedplug(withintegrated
bleeder hole) to check that theair drier isoperatingcorrectly. The
air shouldcomefromthetankwithno signsofcondensatewater.
Air tanks for:
- Front axle
- Rear axle
- Parking+trailer
- Services
- Regeneration
Check theseal and anti-rust protection.
Dischargethecondensatefromthetanksthroughthebleeder valve
Four waysafetyvalve
Check :
Maximumopeningpressure 8 bar
Static closingpressure 6.5 bar
0,5
0
Duplexdistributor
Pressthepedal totheendofitsstroke, releasingthepedal it should
returnimmediatelytoitshomeposition.
Pressurerestriction7.6 0.3bar
Checkthat thepedal gasket isnot worn, that thebrakecontrol rods
arewell securedand lubricatedwith no strain.
Check that thelever housingsarenot wornor oxidized.
Pneumaticpressure
control socket
Ensurethat theprotection plugsareinserted
Parkingbrakedistributor
(with checkingposition)
Operateontheparkingbrakedistributor until it triggers, the gauge
onthecontrol socket istoindicatethe pressuredischarge 0 bar in
1second.
Theautomaticcouplingjointpipeandthegaugearetoindicateatthe
same time apressureof 8.5 bar
Engine brake control pedal
distributor
Check functioningand seal
Loadsensingvalve
Theplateindicatesall theset valuestobecomparedtothosefound
when checkingandadjusting.
(continued)
3aso |ovobo 2006 Print 603.93.641
Diaphragmcylinder
Check fastening, integrityand seal
Thebleeder holeshould bedirected downwards andnot clogged
Combinedcylinder
Check fastening, integrityand seal.
Thebleeder holeshould bedirected downwards andnot clogged
Relayvalve
Check operationandseal assessing the speedof brake cylinder
activation
Engine brake control operator
cylinder
Check operationand seal
Pressurereducer
Check set pressure(seespecificationsanddatatable)
Check operation
Triplecontrol servo
distributor for trailer
braking, with
incorporatedmodulated
power steering
Fill thetank. Connect agaugetotheautomaticcouplingheadandto
avariablecouplinghead.
At a pressure of 1 bar, coming fromthe duplex distributor, the
variablecouplinghead shouldhave apressurebetween0.8 and1.5
bar. Make afull braking(vehicleat astandstill).
Prescribedpressure must result at thecouplinghead, or apressure
that is0.5barless.Activatetheparkingbrake;at thevariablecoupling
head thepressureshouldremainthe same, or reduced by0.5bar.
Couplingheads
Check thereisno dirt or damageon thecouplingguides.
Aftercoupling,operatethebrakepedal andchecktheseal andstability
between thecouplingheads whendeliveringair at 7.5bar.
Check thereareno air leaks fromthe couplinggaskets.
Rear drumbrakes
Releasing the pedal the shoes should return quicklyand evenlyto
homeposition.
Check backlashbetweenshoesanddrum.
Check thicknessof brakelinings.
Discbrakecalliper
Brakedisc
Brakelinings
Check thewear of thebrake linings, scoringand wear of thebrake
disc, efficiencyof the pistons, wear of thedust caps.
Drumbrakes
Whenthepressureonthepedal stops,theshoesneedtoreturnto
therest positionquicklyandevenlyonall thewheels.
Check theclearancebetweenshoesanddrum.
Checkthethickness of thebrakelinings.
Print 603.93.641 3aso |ovobo 2006
Pipesandfittings
Ensure that metal pipes are in perfect condition, with no dents or
cracks. Polyamide hoses must have no cracks, cuts or scores. Also
make sure that theyarenot near sharp edges of the bodywork or
chassisthat coulddamagethem.Checkthat all thebracketsfastening
thepipes are securelyfixed - loose fastenings cause vibrations that
couldgiveriseto breakages. Checkthat polyamidehosesarenot in
contactwithoil or mineral grease,rubbersolvents.Presshardonthe
brakepedal andcheckthat thepipesarenot blown.Checkthereare
noleaksfromfittings,otherwisetightenthemfully, takingcare when
tighteningnot to cause irregular pipe torsion. In all theabovecases
thepartsaretobereplacedifthereisaminimumofdoubt astotheir
efficiency.Apart fromtheir condition, it isrecommendedto replace
hosesafterconsiderablemileage,orafteraperiodoflongvehicleuse.
Thiswill avoidsuddenbreakagesdueto ageandfatigue.
Pneumaticsystemseal withengine
off below thestartingpressure
Thischeckismadeonthreaded couplings. Deliver air at apressureof
not lessthan5bar andspreadquitethicksoapywater onthejointsand
couplingsusingasoft brush, thenobservecarefullyfor signsof leaks.
Anair leakiswithintoleranceifit correspondsto asoapbubblewitha
diameterof 25mmin5seconds,or apressuredropwithin10minutes
amountingto2%of the disengagement pressure (0.22 0.02bar).
Pneumatic systemseal in partial
brakingrangewith3 bar.
For 3minutes thepressuremust remainstabilizedin thepneumatic
system. Thecheckismadewiththe parkingbrakedeactivated.
60231
Figure24
Producessufficient compressedairtofeedthebrakingsystem
and ancillaryservices.
60232
Head fastening screws tightening torque
Figure25
Tightencylinderheadfasteningscrewstothespecifiedtorque
followingthesequenceshowninthe figure.
3aso |ovobo 2006 Print 603.93.641
BRAKING SYSTEM MAIN COMPONENTS
790510 Compressor
Troubleshooting
TROUBLE POSSIBLECAUSES CURE
Oil leakage fromflange
id
Incorrect drivingtorque Tightenthescrewsto theprescribedvalues g g
on outer side
Flangebodysealingsurfacenot perfectlyflat Check the sealing sur faces, replace faulty parts or
straightenthem
Brokengasket Replacethegasket
Shaft gasket damaged Replacethega sket
Oil leakage fromhead Damaged scraper ring (this can beseen be-
causethewholeseal seat isshiny)
Replacetheentirepiston
Scraper ringisbadlyfitted Fit inp lacewiththeTOPinscriptionturnedtowardsthe
compressor head
Scraper ringsandpistonringsareall onthesame
vertical line.
Fit inplaceat 120 withreferenceto eachother
Scoredor ovalizedcylinder Grindt hecylinder andfit abigger piston
No compressionat all Deteriorated compressionor intakevalve Replacethefaultyparts
Deteriorated compressionor intakevalve Fit theringsat 120 withreferenceto eachother
Pistonperforatedor pistonelementsbroken Replacetheentirepiston
Damagedgasket Replacethegaskets
Energy-savingdevicesetonopenduringcharging
stage.
Replacethecylinder heads
Poor efficiency Wornpistonrings Replacethepiston(andpistonrings)
Air leakagebetweencylinder andhead Replacethegasket andtightenth escrews to thepre-
scribedtorque
Deterioratedenergysavingunit, intakeor com-
pressionvalves
Replacethefaultyparts
Toomuchbacklashbetweenpistonandcylinder Grindthecylinder andfi t abigger piston
Particlesofcarbonizedoilbetweentheintake
andcompressionvalves
Cleanthevalves
Mechanical noises Too muchbacklashbetweensmall end andpin,
betweenpinandpistonhole, betweenshaft and
bigend, betweenshaft andbronzecapsandbe-
tweenflangesandshaft.
Checkthetolerancesof thecouplingsinvolved
Toomuchbacklashbetweenpistonandcylinder Grindthecylinder andfi t abigger piston
Excessivedepositsbetweenpistonand
cylinder headcausedbyburnt oil.
Cleantheincrustations andreplacethevalves
Water seepage Head gasket or contact surfaces scored and
uneven.
Replacethefaultyparts
Figure26
A.P.U. Troubleshooting(Drier +four-way protection valve)
PROBLEM POSSIBLECAUSE REMEDY
Too much condensate in
the circuit
The set pressure is not
reachedinthe tank
Air lossat discharge
Air leaks aroundthe plugs
Air leaks if a section breaks
down
Cloggedfilter cartridge
Air leakingfromsafetyvalve
Wornsealinggaskets
Pistonseal isinsufficient
Leakage from the valves in the four
sections.
Defectiveoperationof thecheckvalves.
Replacethecartridge
Overhaul theequipment andreplace worncomponents
Overhaul thedevice, replacingthewornparts.
Overhaul thedevice, replacingthewornpartsif necessaryor
replacethedevice.
72019
Itsfunctionisto keeptheair clean andat the right moisture
level inthedistributionsystemandkeepthepressureneeded
for theoperation of theconnected systems at theoutlet.
This component integrates the functions of 4-waypressure
regulator, pressure reduction unit for parking, services and
trailer.
Print 603.93.641 3aso |ovobo 2006
A.P.U. (Air Processing Unit)
73914
90639
Figure27 Figure28
Takes theair fromthetankanddistributes it to thebraking
elements. It is autorestrictive i.e. it limits theair output to an
established maximumpressure and as a result there is a
greater availabilityofenergyandamaximumconstantbraking
pressureregardlessof thepressurevariationsinthe tanks.
Onvehiclesfittedoutastrucksduplexdistributorsarefittedto
correct thebrakingforceofthefront axleelementsaccording
to the corrections made by the braking control (where
present).
Troubleshooting
PERFORMANCEDIAGRAM
A =Exit pressurep21/p22 [bar]
B=Shoetravel [mm]
Leaksfromoutlet ducts dueto wear on
seal gaskets
Auto restriction higher or lower than
required
Wornsprings
Air leaksdueto pistongasket seals inthe
two sections
Theelectric circuit doesnot close
Theelectric circuit doesnot open
Overhaul thedeviceandreplaceworncomponents
Adjust thedevicethroughtherelevant screw
Overhaul thedeviceandreplacefaultycomponents
Overhaul thedeviceandreplacefaultycomponents
Replacetheswitch
Replacetheswitch
Air escapes from the
discharge hole
Irregular
autorestriction of
distributor
Vibrationswhen
braking
Irregular operation of
stop lamp control
switch
3aso |ovobo 2006 Print 603.93.641
793110 Duplex distributor
34953
98886
Figure29
Figure30
Troubleshooting
793332 Triple control servo distributor
Cutsoffthecompressedairflowtotheuserwhenthepressure
in thelatter reachesadeterminedvalue(set point).
Setting at the bench
Set theelement onthetest benchand connect fittings1and
2 through thepipesto thegaugeandtheair supply.
Correct to theprescribedvaluethrough theadjustingscrew
and at thesametimechecktheperfect seal of theunit.
Theunit, controlledbytwo separatecircuitsof theduplex
distributorandthetractorspringbrakecircuit, controlsthe
trailer braking. It is also equipped with a predominance
regulatingdevicefittedonthelower external part.
Theunit incorporates adevice to actuatethe trailer brake
should therebeafault inthecontrol pipe.
Predominance adjustment
Theunit isequippedwith apredominanceregulatingdevice.
2
1
Pressure at the outlet
fittingis different to the
set value
Valvenot adjustedproperly.
Leaksfromtheseal rings
Faultypistonandrelevant seat
Adjust theunit
Overhaul theunit replacingdamagedcomponents
Replacetheunit
98887
Figure31
KNORR- BREMSEAC 597B WABCO 973009013
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
793321 Pressure reducer
60255
60256
Figure32 Figure33
Troubleshooting
To adjust predominance for servo distributor KNORR -
BREMSE AC 597 B, perform the following sequence of
operations:
- Removescrew(2) fromsilencer body.
- Fit a setscrew wrench in the hole through the silencer
bodyandoperateonbodyhexagonal hole (1).
- RotateCLOCKWISE toincreasepredominance.
- Rotate COUNTERCLOCKWISE to decrease
predominance.
To adjust predominance for servo distributor WABCO 973
009013, performthefollowingsequenceof operations:
- Removescrews(1) and thenremovethecover (3).
- Operateonpredominanceadjustingscrew(1).
- RotateCLOCKWISE todecreasepredominance.
- Rotate COUNTERCLOCKWISE to increase
predominance.
Leaksfromsealinggaskets.
Faultyexhaust valveandvalveseat.
Wrongpredominancevalue
Air leakagefromsealinggaskets
Wornor faultypistonsandseats
Strainedsprings
Wrongpredominancevalue.
Overhaul theunit andreplacefaultycomponents
Adjust predominance
Performpredominanceadjustment.
Air leakage from
exhaust when in resting
condition
Outlet pressures are
different from the
establishedvalues
3aso |ovobo 2006 Print 603.93.641
KNORR BREMSE AC 597B WABCO973 009 013
Faultyexhaust valve, relevant seat or
seal ring
Worncontrol valve, seal ringsand
component control valve
Interferenceinsidethedistributor
Air escapes fromthe
exhaust withcontrol lever
Inbrakingrelease
position
Inbrakingposition
It is difficult to turn the
control lever
Checkandoverhaul theunit, replacefaultycomponents.
Carefullycleanthecomponents.
Checkandoverhaul theunit, replacefaultycomponents.
Carefullycleanthecomponents.
Overhaul theunit andmoistenall theslidingparts.
52871
33987
Figure34
Figure35
T|o vos|oo o t|o 'Va|ab|o' |o |as a o||o. covo
.|ooas t|o vos|oo o t|o '/otoat|c' |o |as a oo covo
and asidesafetyridge (1). Safetyridges areusedto prevent
improper coupling.
793319 Check valve(towing vehicles)
Enables the compressed air to flow in the direction of the
arrowmarked onthe housingandpreventsreflux.
2 1
79514
Figure36
The device enables emergency and parking braking of the
tractor and thetrailer.
The device also enables the checkingof the tractor braking
effect.Thisoperation isnecessarywhenthevehicleisparked
onverysteeproads.
Troubleshooting
798510 Coupling heads 794310 Parking brakes control hand
distributor (for towing vehicles)
Print 603.93.641 3aso |ovobo 2006
Figure37
Theunit, insertedinthetractor parkingbrakecircuit enables
theactuation of thevehicle emergencyandparkingbraking
dischargingtheair containedin thespringcylinders.
79515
Wornpiston, exhaust valve, sealingrings.
Wornpistonandrelevant seal ring.
Wornplate, gasketsseal rings.
Interferenceinsidethedistributor.
Clean carefully, ensure that all therubber components and
relevant seatsareinperfect condition.
Overhaul theunit andreplacefault ycomponents
Cleancarefullyandcheckthecomponents, overhaul theunit
andreplacefaultyparts.
Clean the components carefully,check the seal and gasket
surfaces.
Ensurethat therubber componentsandrelevant seatsarein
perfect condition.
Overhaul theunit andreplacefaultyor worncomponents, if
necessaryrestorecontact surfaces.
Cleancarefullyandcheckall thecomponents.
Overhaul theunit andreplace fault ycomponents
Whenfittinginplace, slightlygreaseall slidingparts.
If faults or wear are found that coul d compromise the
functioning, replacethecompleteunit
Air leakage from the
discharge withdistributor
lever inbrakingposition
Air leakage from the
discharge withdistributor
lever in emergency or
parkingbrakingposition.
Air leakage from
distributor control lever
cover.
The distributor control
lever is difficult to turn
Troubleshooting
3aso |ovobo 2006 Print 603.93.641
794310 Parking brakes control hand
distributor (stand-alone vehicles)
Figure38
Theapparatusallowsforreducingbrakingsystemintervention
timefor front axis(valveoftypeKNORRBREMSERP2A) or
rear axis (valveof typeKNORR- BREMSEAC 574AXY).
Troubleshooting
90402
Leakagefromthedeliveryorfromtheseal
rings
Leakagefromthepistonseal ringsor from
theexahust valve
Overhaul theunit andreplacethefaultyparts
Air leakage from
exhaust with control
pipe in discharge
condition
discharge withsupplyin
the control pipe
Figure39
Theunit transmitstheforceimpressedbythecompressedair
when the brake pedal is pressed to the mechanical service
brakingdevice.Incaseoffailure,thecompletecylinderistobe
replaced(thefigureshows thedrumbrakesversion).
794911 Diaphragm brake cylinder
35798
KNORR- BREMSEAC 574AXY
Print 603.93.641 3aso |ovobo 2006
793331 Relayvalves
Figure40
Figure41
36744
Thisunit featurestwo parts: one withdiaphragmfor service
brakingand onewithspring for theparkingandemergency
brakingin thecaseof failureinthe brakesystem.
Ifit isnot possibletopneumaticallyfeedthespringsectionof
thecombinedcylinder (1) it ispossibletomanuallyrelasethe
brakingto permit towing. To release the brake loosen the
screw(2) totheendof itsstroke.
36745
Combined cylinder emergency relief device
794922 Combined brake cylinder REPAIR OPERATIONS
Figure42
Before removing the combined cylinder from the vehicle
manually release the braking of the combined cylinder as
described above.
!
Itisrecommended,before removal,tocarefullyclean
mudorother impuritiesfromexternal partsasthese
could damage the cylinder if theywereto infiltrate
into it.
Ifthecylinder springsectionisfaulty, do not remove
thispart sincethisoperation could bedangerousfor
theoperator.
exhaust or from the
check ring.
diaphragmsectionfeed
Perforatedor brokendiaphragm.
Diaphragmlipbroken.
Checkringfasteningscrewshavebecome
loose.
Springsectioncomponentsarestrained.
Replacethediaphragm
Tightenthescrews
Overhaul theunit andreplaceworncomponents
36476
Troubleshooting
3aso |ovobo 2006 Print 603.93.641
ANTI -SKID SYSTEM
ABS (Anti-Lock Brake System)
The braking of a moving vehicle and the conseguent
decelerationandstoppingdistancesdependaboveall onthe
gripbetween thesurfacesof the tyresand theroad.
Withafullyefficient brakingsystem,afurtherimprovementin
brakingcanonlybeachievedbyactingonthefrictionof the
tyres or onthegrade of theroad surface.
Whenfacedwithespeciallytrickysituations, suchaspoorgrip
due to a wet or icy road surface, the driver is forced to
moderateuseof thebrakesinorder toavoidpartiallylocking
oneor morewheels, withtheriskof skiddingdangerously.
T|o ooct|oo o t|o '/3S' |s t|oooo to oosoo vo||c|o
stability(inall brakingconditions),preventingthewheelsfrom
lockingirrespectiveof thestate of the road surface, so asto
ensuretheavailablegripismadefull useof.
Evenin the case of emergencybraking, the systemmakes it
possibleto keepdirection, that is to turnthe steeringwheel
to avoidobstacleswithno risk of skidding.
Inshort, theanti-lockbrakesystem(ABS):
- Preventsthewheelslockingwhenthevehicleis braking,
nomatter what gripisavailableontheroad.
- Shortensstoppingdistances.
- |ov|oos saot o t|o o|vo .|o cao 'oo t|o vo||c|o's
stabilityanddirection.
Inshort, theASR anti-slipregulator system:
- Preventsthedrivingwheelsslipping, bothonstartingand
when travelling, with differential brakingon the wheels
and, if necessary, optimizingtheengine torque.
- Keepsanoptimal valueoftractionwhenthevehicleison
roadswithalowgrip coefficient.
- Improves stability especially on bends with a low grip
coefficient.
- Limitstyre wear.
ASR (Anti-Slip Regulator) system
EBL (Electronic Brakes Limiter)
T|o |3| ooct|oo c|oc's t|o oa a|o .|oo| 's||', coa|o
it withthespeed of thewheelsof the front axle.
Thecontrol unit input dataarethewheel speed andbraking
pressuremeasuredbythepressuresensorinstalledupstream
fromtherear axle ABSmodulators.
On the basisof these values, the control unit calculates the
sooo o t|o vo||c|o, t|o oa a|o .|oo| 's||' aoo t|o
minimumdeceleration contemplated.
The EBL function is activated when the driver applies an
excessive braking force for the conditions of load on the
vehicle, therebyreducingthebrakingforce ontherear axle.
The driving wheels of an industrial vehicle slipping during
accelerationhasharmful consequences,suchasareductionin
the force of traction, loss of grip between tyres and road
surfacewithconseguent lossof control over thevehicle.
The function of theASR isto prevent undesired wheel slip,
both when acceleratingand on bends, especially on icy or
s||o oaos, o o 'o-oao' oso |o oo aoo .ato.
Figure43
Pressure sensor
InABS/EBLsystems,itsjobisto informtheelectroniccontrol
unit of theextent of actionrequired bythedriver.
InEBSsystems,thiscomponent isintegratedinthe front axle,
rear axleand trailer control valves.
52722
Print 603.93.641 3aso |ovobo 2006
Troubleshooting
FAULT POSSIBLECAUSE REMEDY
Air leakfromoutlet
duringbraking
Gasket oncontrol piston
Faultyexhaust valveor relevant seat
Overhaul theunit andreplaceworncomponents
Air leakage from
couplings
Not tightenedto prescribedtorque Tightencouplingsto specifiedtorque
Figure44
Figure45
32370
Theelectroniccontrol unit is thebrainof thesystem.
It controlsthesystemsolenoidvalveaccordingto thesignals
received fromthewheel revolutions sensor.
Eachchannel featuresfourfunctioncircuits;thefirstistheinput
circuit that receivestheanalogsignalsfromthesensor onthe
relevant wheel, theyare debugged and converted to digital
datathrough the measurement of the cycleduration. There
isalso amaincircuit whichhas amicroprocessor to process
theinformationreceivedfromtheinput circuit.
Themicroprocessorcontainsasophisticatedprogramthatenables
it to determine the wheel acceleration and deceleration values,
and to make the logic combinations of the various adjustment
signals.
When necessaryit sends out two command signals that are
sent to the relevant anti-lock distributor through the third
control unit circuit, to suitablyadjust thebrakingpressure.
Thefourthand last circuit isthesafetycircuit that checksthe
efficiencyof thevarioussystemcomponents.
In the case of a failure, it not only informs the driver by
switchingontherelevant warningindicatoronthedashboard,
but it also automaticallydisconnects theentire ABSsystem,
leavingtheconventional brakingsystemfullyefficient.
This component modulates the air pressure in the brake
circuit. Whentheelectroniccontrol unit detectsawheel witha
tendencytolock,thevalveinterceptsthebrakecylinderfeed,thus
preventingthewheel locking.
35805
526714 Brake anti-lock distributor
Thedevicebrakesthedrivingwheels, throughthebrakeanti-
locking modulator, whenever it detects slipping of one or
morewheels under traction.
Thevalveis anormallyclosedtype.
Whentheelectronic control unit detects slippingof oneor
moredrivingwheels, thevalveisenergizedandenablesairto
passtothebrakeanti-lockmodulatorsthat braketherelevant
wheels. The solenoid valve de-energizes when the wheels
reachthecorrect frictionvalueon theroadsurface.
Figure46
90143
Figure47
35383
The revolutions sensors and phonic wheels find the
revolutionsoftherespectivewheels.
Thephonicwheel ishousedonthewheel hubandturnsat the
same speed as the wheel. It generates in the sensors, by
induction, alternate voltages having a frequency that is
proportional to therotationspeed of thewheel.
Thesevoltagesignalsaretransmittedtotheelectroniccontrol
unit for processing. Each wheel has a sensor and a phonic
wheel installed. This enables individual adjustment of the
brakingpressurefor eachwheel, thusperfectingthedriving
stabilityandbrakingspace.
526713 Rpm sensors
566712 Phonic wheels
3aso |ovobo 2006 Print 603.93.641
526711 Electronic control unit 526724 Electropneumatic valve for ASR
Figure48
1. Drybush - 2. Threadedhose- 3. Piston - 4. Washer - 5. Springsplit pin- 6. Pin - 7. Retainingplate- 8. Supportingplate-
9. Guidepin- 10. Guide bush - 11. Slidingpin- 12. Plug- 13. Draggingdevice- 14. Wear sensor - 15. Rear axle-
16. Chain- 17. Spring- -18. Cover - 19. Adapter - 20. Chaingear - 21. Adjustingdevice- -22. Cover - 23. Brassbush -
24. Slidingpin - 25. Slidingbush - 26. Inner protection - 27. Ring- 28. Brakelining- 29. Brakediscbody- 30. Lever -
31. Cambearing.
78396
84420
SEC. AA
9 8 3 1 2
6
5
7
3
4
2
1
26 27 29 24 25 23
22
21
20
19
16
18
17
15
14
13 12 11 10
A A
28 29
Print 603.93.641 3aso |ovobo 2006
5274 FRONT DISC BRAKES SN7TYPE
Brakingstage
Duringbraking, thediaphragmcylinder rodpressesdownon
thelever (30).
Theforceistransferred totheaxle (15) bythebearinginan
off - centeredposition(31)
Through thethreadedsleeves (2) andpistons (3), theforce
isconveyed totheinner brakinglining(28).
Oncetheplaybetweenbrakelinings(28) andbrakedisc(29)
hasbeenrecovered,theforceisconveyedtotheouter brake
lining(28), dueto brakecaliper displacement.
Thebrakelinings(28) pressingonthebrakedisc(29) produce
thebrakingpower.
Releasingstage
Assoonasthepressureonthebrakeisreduced,thepressure
spring(17),therearaxle(15) alongwiththreadedsleeves(2)
and lever (32) go backto their original positions.
Automatic playrecovery
The brake is equipped with automatic adjustment device,
which keeps the operatingplay between brake linings and
brakedisc constant.
Everytimethebrakeisoperated,theadjustment device(21),
whichisintegral withthelever (32), is automaticallystarted.
If worn brake linings and brake discs increase theoperating
play, theadjustment device (21) anddraglink(13) turnthe
threaded sleeves(2) so torecover saidincreaseinplay.
Theoperatingclearanceshouldbebetween0.6and1.1mm;
lower clearances might causeoverheatingproblems.
CHECKS
Checking the automatic play recoverysystem
efficiency
40570
Figure49
Remove the lock nuts and wheels, using hydraulic stand
99321024(1).
60759
78622
Figure50
Figure51
Remove the plug (4) using the tab (3) and make sure the
adapter (2) isnot lost.
Using a suitable wrench (1), rotate the adjustment pinion
counterclockwise by 2-3 with the adapter (2, Figure 50)
installedturns, thusincreasingtheplaybetweenbrakelinings
and brakedisc.
Operatethebrakes for about 5-10timesandmakesurethe
wrench (1) moves clockwise with small increments, up to
completerecover of playbetween brakinglinings and brake
disc.
Otherwise, i.e.ifthewrenchdoesnot turn,turnsjust onceor
turns in both directions, this means the automatic play
recoverysystemis faulty. Replace the caliper, followingthe
proceduregiven subsequently, thenfit back thewheels.
Never turn the adjustingpinion (1) without fitting
the adapter (2) first. If the adapter cut torque is
overcome, theadapter getsbroken.
Tryagainwithanewadapter andif alsointhiscase
it gets broken, the caliper should be replaced
because thereisan inner damage.
2
4
1
3aso |ovobo 2006 Print 603.93.641
Operation (See previous figure)
Figure52
1. Combined brakecylinder - 2. Membranebrakecylinder - 3. Rubber bushes - 4. Slidingpins- 5. Plug- 6. Adjustingunit cover
- 7. Adapter - 8. Guidepin - 9. Cover - 10. Slidingpin - 11. Brassbushes- 12. Carryingplate- 13. Protectioncowling- 14. Ring
- 15. Inner seals- 16. Bushes- 17. Plungers - 18. Brakecaliper - 19. Guidepin- 20. Brakingseal - 21. Spring-
22. Split pin - 23. Washer - 24. Pintle- 25. Checkplate.
78628
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
SN7 brake caliper components
Figure53
1. Brake caliper - 2. Slidingbush- 3. Rubber bush- A. Bushpositionwith newseals- A
1
. Bush position withwornout braking
seals(performanaccuratecheckwithwheels dismounted).
78625
The condition of braking seals can be visually determined
without dismountingwheels, bycheckingthat A >1mm.
Otherwise, it isneededto dismount thewheelsandperform
anaccuratecheck as describedbelow.
3aso |ovobo 2006 Print 603.93.641
SN7 brake calliper braking gaskets thickness check
40569
40570
Figure54
Figure55
Setthevehicleonflatgroundandlocktherearwheels.Loosen
thenuts(1) fixingthe front wheels.
Liftthevehicleatthefrontwithahydraulicliftandsetit ontwo
stands (2).
Unscrewthefixingnuts(1) and withtheaidof thehydraulic
trolley99321024 (1) removethewheels.
527417 Replacing brake linings
49157
Figure56
Remove thescrew (1) and the wear sensor cable retaining
plate(2).
49158
Figure57
Disconnect the electrical connection (1) fromthe calliper
body.
Removethesplitpin(2),pin(3)andbrakeliningretainingplate
(4).
78623
Figure58
Press( ) onthespring(1) andremoveit. Removethewear
sensors(2) fromthebrakelinings(3).
49160
Figure59
Remove the plug (3). Turn the adjustment device (1)
operatingontheadapter counterclockwisewithawrench,to
insert the pistons within the caliper bodyand extract brake
linings (4), suitablymovingthecaliper body (3).
Neveroperatedirectlyontheregistrationpinion(1)
without havingfirst of all fittedtheadapter (2). Ifthe
cuttingtorque of the adapter is exceeded, this will
break.
Testwithanewadapter.Ifthisalsobreaks,thecaliper
must bereplacedbecauseit is damaged.
NOTE
Print 603.93.641 3aso |ovobo 2006
49161
Figure60
Removedirt andrust fromaroundtheedgeofthebrakedisc
withascraperor anoldscrewdriver (2) restingonthecalliper
body, turningthedisc (1).
Finish the job withabrasivecloth. Remove the remains with
theaidof anaspirator, or rags andabrush.
Do not use petrol or other petroleum products that could
causetroublefor thebrakes.
Useonlymethylatedspirit or isopropyl alcohol.
Carefullyclean thesurfaces of the brakingareaof the brake
disc.
Visually check the conditions of the dust caps, if
deformedor brokenit isnecessarytoreplacethem.
This requires removing the brake calliper, so it is
recommended to remove the brake calliper body
together with the bearing plate for a thorough
overhaul.
Check that thecalliper slidesfreelyonitsguides.
If youfindanytroubleon asingle brake calliper it is wiseto
overhaul both brakecalliperscompletely.
Remove the dirt fromthe brake calliper with awire brush,
without damagingthedust caps.
Cleantheslidingsurfacesof thebrakelinings.
Checktheconditionsofthebrakediscandmakesureit isnot
corroded, scored or grooved. Light surface cracks are
acceptable, but it is necessary to grind the brake disc as
described under the relevant section heading. On the
contrary, if it isworn, replacethebrakedisc.
If one needs to be replaced, it is recommended to replace
bothbrake discs.
Checkthestateofthespringsandwearsensors,replacethem
ifnecessary.
49162
Figure61
Insert thewear sensor (2) into itsseat onthebrakelining(3).
Mount the spring (1) in the opposite sequence to that for
disassembly.
49163
Figure62
Insert thenewliningsinthebrakecalliper (1) andcheckthey
slide freelyin their seats.
!
If you find it necessaryto replace thepair of brake
linings, always replace themwith a full set for each
axle.
78624
Figure63
Usingthewrench(1),actontheadaptatorretrieverpintoget
aplaynotlowerthan0.7mmbetweenbrakeliningandbrake
disk, which can be measured usingthe thickness gauge (2).
Replace the cover (4) and lubricate it with white grease
RENOLIT HLT2.
NOTE
3aso |ovobo 2006 Print 603.93.641
49158
Figure64
Maketheelectrical connection(1) andsecureittothecalliper
body.
Mount theplate(4), pin(3) andsplit pin (2).
Makesuretheexternal safetyplugandtheseal are
fitted properly in order to prevent water getting
insidetheautomaticclearancerecoverydevice.
49165
Figure65
Mount thewear sensor cableretainingplate(1).
Usingthehydraulictrolley99321024,fit onthewheels.Lower
thevehicle. Lock the nuts fixingthe wheelsto therequired
torque.
Fit thesafetycaponto thewheel hubs.
Proceedasdescribedontheoppositeside.
After repairing the vehicle brakes, press the brake pedal
repeatedly, whilethevehicleis moving, inbothdirections, in
order to wear inthebrakelinings.
49166
Figure66
Toremovethebrakelinings,keeptotheabovedescriptionin
theparagraphfor replacingbrakelinings.Removetheclamps
(2). Disconnect thediaphragmcylinder supplypipe(1).
Unscrewthenuts(4) andremovethediaphragmcylinder (3).
49167
Figure67
Removethescrews(3) anddisconnect thebrakecalliper (1)
together withthebearingplate (2).
Takecarewhenremovingandcarryingthecalliper(1)
asit isheavyandfloats onthebearingplate(2).
Refitting
For refitting, carry out the steps described for
removal in reverse order, keepingto the required
tighteningtorques.
Before inserting the diaphragm brake cylinder,
spreadthecapinthebrakecalliper operatinglever
withRENOLIT HLT2 whitegrease.
NOTE
NOTE
Print 603.93.641 3aso |ovobo 2006
527413 Removing and refitting brake callipers
Removal
Figure68
77206
Arrangeanoil recover collector asaprecaution.
Rotate hubsoasto takeplug (1) downwards.
Unscrewthepluganddrainoil into thecontainer.
36407
Blockrotationofthewheel hubsuitablyandwiththewrench
99354207(1) unscrewtheoil cover (2).
36408
Undothesafetyscrew(3).Withthewrench99388001,unscrew
the adjustment ring nut (2), remove the washer (4), outer
bearing(1) andremovethebrakedisctogether withthewheel
hub, spacer andinternal bearing.
38596
Visually check the diameter of the gasket ring (1) has no
accidental dents or scratches.
Replacetheinternal gasketsofthe wheel hubsand,ifnecessary,
t|o |o (+), 'oo|o to t|o oosc|t|oo |voo |o t|o '|oot a|o'
section.
Usingtheadjustment ringnut, checkthat thethread(2) hasno
stiffness.Ifithas,useappropriatemeanstogetridofthestiffness.
Removetheoppositebrakeassembly, keepingthecomponents
separate.
Refitting
Makesurethesurfacesofall thepartsinsidethehub
arethoroughlyclean, withno wasteor burrs.
LubricatethebearingswithTutelaW 140/MDA oil.
Keythewheelhubonthestubaxletogetherwiththe
brakedisc. Insert the internal spacer onto the stub
axle then position the external bearing and thrust
washer.
Screwdownandlocktheadjustment ringnut tothe
requiredtorque.
36411
Strike the wheel hub a few times with a mallet in an axial
direction, turnit inbothdirectionstofreethebearingrollers.
Fit themagneticbase (1) together withthedial gauge (2) on
thewheel hub. Set thepointer of the dial gauge (3) at right
anglesto theshankof thestubaxle.
Reset thedial gaugewithapre-load of 1.5- 2 mm.
With the aid of a lever, move the wheel hub axially and
measure the end float, which must be0.16 mm(maximum
value).
On obtaining the required end float, lock the screw (5)
retainingthe adjustment ringnut (4) to therequired torque.
Figure69
Figure70
Figure71
Figure72
NOTE
8
3aso |ovobo 2006 Print 603.93.641
520620 Removing and refitting wheel hubs
Removal
36412
Figure73 Figure74
Tightento torquethehub cover (1, Figure74).
Deposit asealingbead(Loctitetype574) exclusively
on the hub cover ledge surface and protect the
threadedpart.
Rotatethewheel hubuntil whenhubcover (1) ispositioned
asshowninthefigure.Restoretheprescribedquantityof oil
intothehubcover (1) throughfillinghole(2).Tightentheplug
onthehubcover (1) to theset torque.
79068
Applytool (1) 99395026 on wheel hub stud bolts and use
torquemeter 99389819(2) tocheckwhetherthewheel hub
rollingtorqueisat theset value.
Print 603.93.641 3aso |ovobo 2006
79121
79123
79122
79124
79125
Figure75
Figure76
Figure77
Figure78
Figure79
Placethebrakecaliperonthebenchandblockit inavice.Remove
thecover (1) and makeaholeinit with aParker screw.
Refitthesupportingplate(1) andremovethefasteningscrews
(2).
Removetheslidingbushes (1).
Use tool 99372245 (2) (to be used with screw in tool
99372237) to disassembletherubber sleeve (1).
Takethe caliper to thepress.
Insert the appropriate beater in the brass bush housing(1)
(SeearrowA). Usethepressto removethebush (1).
SN7 BRAKE CALIPER OVERHAUL
Disassembly
3aso |ovobo 2006 Print 603.93.641
60742
Figure80
Placethecaliperonthebenchandblockit inavice.Usethe
wrench(4) tooperatetheclearancerecoverydevicesothat
thepiston(1) comesout ofthecaliper bodyforamaximum
of 30 mm(valueA).
Takeoff thedust-guard fromthecaliper bodyand usetool
99372238 (5) to removethe thrust pressingdevices (1) of
thecaliper together withtheprotection casings (3).
Component part cleaning and check
To wash metal parts, use asolution of hot water with Fiat
LCD detergent. Use ametal brushto removedirt fromthe
caliper bodyandthenalittlebrush to remove theresiduals
and to clear accurately the guide pin and the slidingbush
housings.
Useasynthetic brush withthe right dimensions to remove
thegrease left on the slidingbush housings.
Cleanthecaliper bodyaccuratelywithcompressed air.
Useapieceofclothsoakedwithisopropyl alcohol orsimilar
to cleantheslidingbushes accurately.
Check the wear conditions of the slidingbushes and their
housingsonthebrakecaliper body. Makesuretheyarenot
damaged or worn, especially the sliding surfaces. Fit the
bushes intheir housingsandcheck theyslideregularly.
Fit the bushes in their housings, check they slide correctly,
otherwise replace or restore their housings on the caliper
body, if needed.
ValueA must not beovercomebecause threaded
hoses (2) are synchronised. If the threaded hoses
(2) reachtheir over-travel,theyloosesynchronism
and thebrakecaliper must bereplaced.Thebrake
caliper inner partsmust never be removed.
For this reason you are recommended non to
slacken or to removethecover retainingscrews..
Regular braking depends mainly on the brake
caliper slidingontheguidepins.
Checkthewear conditions of thebrakeliningretainingpins
and the related safetypins. If they are worn or damaged,
replacetheworn parts.
It is advisableto replaceall rubber andplasticparts and the
brass bush even if theydo not seemdamaged or worn at
sight.
Assembly
Make sure all the brake caliper components are perfectly
clean. Possibleabrasiveresiduals shouldberemoved witha
clothsoaked in isopropyl alcohol or similar.
79126
Figure81
Use tool 99372239 (4) (see figureA) to fit the protection
casings (2). Use the same tool 99372239 (4) fitted on the
other side (see figure B) to insert the pistons (1). Use the
wrench(3) tooperatetheclearancerecoverydeviceandad
just thepistons (1).
Figure82
79127
Use tool 99372244 (2) (to beused with the screw in tool
99372237) to assembletherubber sleeve (1).
NOTE
NOTE
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
79128
79129
79130
Figure83
Figure84
Figure85
Figure86
Usetool 99372243(1) (tobeusedwithtool 99372240and
usescrewintool 99372237) to assemblethebrassbush(2)
initsseat,byblockingitsrotationbymeansof asuitabletool
(3) (punchor screwdriver).
Placethecaliperunderthepress.Usethepresstofitthebrass
bush(1) initshousinguntil iscomesout ofthelowersideby
1 mm.
Usethetool 99372242(2) tocarryout bruisinginthepoint
( ) next tothecaliperbodygroove,inordertopreventthe
brassbush(1) frommoving.
Makesuretherearenoburrsinthebushhousing,otherwise
remove them. Applywhite grease RENOLIT HLT2 on the
bush.
Placethecaliperonthebenchandblockit inthevice. Fit the
protectioncasing(2) bymeans of tool (1) 99372237.
Reversetheremoval order to fit the slidingbushes
and thesupportingplate.
60745
NOTE
3aso |ovobo 2006 Print 603.93.641
35707
Figure87
- Keyonto theshaft of thelathe 99301001(2) thebrake
disc (1) together withthe hub.
- Keyontotheshaft aset ofspacersthat eliminatetheend
float oftheassembly;screwonthelockingnutandfitthe
mount of thelatheshaft.
- Positionthetoolholder (3) inlinewiththebrakedisc(1),
then adjust thedepth of thetools.
- Proceed with turning and grinding the brake disc (1),
operatingwithone or morepassesto removematerial
dependingonthescoringfound.
During grinding, proceed gradually, advancing the
wheel in sectors to remove the turning remains
entirely.
71848
Figure88
Remove the wheel.
Fit thetool 99301005(1) onto thewheel hub.
Proceed with turningandgrindingthe brakedisc.
527411 TURNING AND GRINDING BRAKE
DISCS ON THE BENCH
527411 TURNING AND GRINDING
BRAKE DISCS ON THE VEHICLE
38597
Figure89
527411 OVERHAULING BRAKE DISCS
Examinethestateof wear of thesurfaces ofthebrakediscs.
Findingother valuesto theones given in thecharacteristics
and data, turn and grind the brake discs or, if necessary,
replacethem.
Removethescrews(1) anddetachthehub(2) fromthedisc
(3). Replace the disc (3) and refit it following the reverse
procedureto theone described above.
NOTE
For regular braking, always replaceacomplete set
of disks per axle.
NOTE
Print 603.93.641 3aso |ovobo 2006
Figure90
MERITORDUO-DUPLEX DRUMBRAKE
DIRECTION OF TRAVEL
71781
SECT. A-A
5272 DRUM BRAKES
3aso |ovobo 2006 Print 603.93.641
Set thevehicleonlevel ground.Takethecoversoff thenuts
fixingthewheel and loosen the nuts.
Lift the vehicle fromthe concerned side, then place it on
special stands.
Position the hydraulic trolley 99321024 under thewheels.
Takeout the nuts fixingthewheels andtakethemoff.
40510
Figure91
Disassembly
Fullyunscrewthemanual brakingscrew(2) ofthecombined
cylinder (1).
Figure92
Figure93
39951
71782
Takeout thescrewsfixingthebrake drum(1) to thewheel
hub (2). Screw two appropriatescrews ( ) into theholes
inthedrumandtakethis out of the wheel hub.
Figure94
40513
Disconnect the electrical connection (1) for the cable
signallingbrakeliningwear.
Figure95
40514
Takeout the shoe returnsprings (2).
Remove the top shoe (1).
Brakingassemblyoverhaul wasperformedonrear
brakes.
NOTE
Print 603.93.641 3aso |ovobo 2006
5272 DUO DUPLEX DRUM
FRONT/REAR BRAKES
Figure96
71783
Freethebrakewearindicator cable (1) fromtheclipsofthe
brake plate (3) and take the cable out of the guard (2).
Remove the bottomshoe (4).
Figure97
71841
Disconnect thepipes(3and4) fromthefittings(5and2) and
removethesefromthecombinedcylinder (1).Usingwrench
99356006, loosen the fixing ring nut. Turn the combined
cylinder (1) anticlockwise, removeit fromthebrakebody.
Figure98
71842
Disconnect thepipe(1) fromthefitting(2) andremovethis
from the diaphragm brake cylinder (4). Using wrench
99366006,loosentheringnut(3).Turnthediaphragmbrake
cylinder (4) anticlockwise, removeit fromthebrakebody.
Figure99
40517
Extract the wedge-shaped control unit (1) fromthe brake
body(2).
Figure100
71791
Unscrew the guide pins (2) and take themout. Extract the
adjustment unit (1) together with the thrust pin fromthe
brakebody(3).
Figure101
71789
Unscrew theguidepins(2) and takethemout.
Extract thereactionpin(1) togetherwiththethrust pinfrom
thebrakebody(3).
3aso |ovobo 2006 Print 603.93.641
Figure102
71790
Checkthestateofwearofthepinseatsonthebrakebody(1),
iftheyarescoredor excessivelyworn, replacetheabnormal
brakebodies.
Examinethewear of thedrumsto decideontheir reuse.
Measure the diameter of the drums with a sliding gauge
without anglingthearms.
Measurethediameterat several pointstoestablishroundness
and wear, also consideringthe depth of the scoringon the
brakingsurface.
Admitted tolerance on roundness and/or eccentricity 0.25
mm.
Ifyoufindsuchwearor scoringasnot topermit restoringthe
braking surface by turning, or clear signs of overheating,
replacethedrum(seeCharacteristicsandDatatable).
Check the state of the brake shoes and replace them if
cracked.
Ifthebrakingsurfaceoftheliningsshowssignsof grease, you
need to findthecauseandeliminate it.
Theminimumadmittedthickness of the brakeliningsis6.95
mm.
If you findalower or slightlyhigher value, replacethem.
Check theintegrityand/or efficiencyof thebrakeliningwear
signal cable.
Checktheintegrityand/orefficiencyoftheshoereturnsprings.
Figure103
38357
Disassembletheautomaticadjustment unit.
Unscrewtheadjustment bushes(3) fromtheadjustmentpins
(2) and thenremovetheseals(1).
Checkthewearconditionoftheadjustmentbushouterhelical
toothingandcheck whether bushesareslidingfreelyon the
relevant adjustment pinswhenscrewing.
Figure104
38360
Check the condition of the pressure pin teeth (3), of the
relevant compressionsprings(2) andof thecopper washers
(1).
Figure105
71786
Take seal (1) off thrust pin (2). Check wear conditions for
thrust pin(2) andsurfacesofsloping planes(3) subjectedto
theoperationof shoe openingdrive rollers.
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
!
Couplethebrakeliningssuitableforeachdrumaccording
totheoversizing.
Each vehicle axle must be fitted with linings of the
same type.
Fit tool 99372213 (2) into thebrakedrum.
Fit thiscombinedunit onto thelatheshaft 99301001(3).
Fitasetofspacersontheshafttoremoveunitendplay,tighten
thelocknut and placethelathesupport.
Fit theantivibrationbandonthebrakedrum.
Turnthedrums bystages, removingthe amount of material
necessaryto correct theimperfections found.
After turningremovethedrumbrake and carefullycleanit.
40520
Measurethedrumdiameters usingagaugewithout bending
the arms, find thediameter inseveral points to establishthe
ovalityandwear.
!
Themaximumdiametral oversizingadmittedfor the
drumisindicated onthedrumitself.
Thislimit must not for anyreason be exceeded as it
would jeopardize the brakingeffect and the drum
resistancecharacteristics.
527231 Drum turning
Figure106
Set thecontact pin (5) onthepressmovingsupport (4).
Rivet thebrakelinings(3) onto theshoes(2) withthebeater
(1) fittedinthepresstoolinghead.
To rivet the brake linings correctly start in the
centre, graduallyextendingto thebrakingsectors.
77085
17256
Figure107
Figure108
Remove the worn brake linings from the shoes with
compressed air press99305087 (1).
Set thecompleteshoes (4) onanadjustablestand(5).
Withachisel (2) inthepresstoolinghead(1) shear therivet
heads (3).
Eject therivets fromtheshoes.
Carefullywashandblow theshoesto cleanthem.
Fromthe lower shoes open cliptabs (6) releasing
thebushing(7).Nowremoveliningwearsensor(8)
and associatedcable.
527233 Replacing brake linings
Mount seal wear cable inverting operations described for
dismounting.
35713
Checkthat thewedgeunitsslideeasilyandthat thereareno
abrasions.
!
If wear is found on the wedge components the
completeunit must bereplaced.
Figure109
NOTE
NOTE
3aso |ovobo 2006 Print 603.93.641
38364
Figure110
Assembly
Fit theseals(2) ontheunitsoftheadjustment pins(1).Grease
thethreadof thepins(1).
Fully screw down the adjustment bushings (3) and grease
themthoroughlyontheoutsidediameter.
Greasetheinsidediameter of thethrust pins(4).
!
Whenrepairingthe brakes, replacetheseals of the
reactionand thrust pins.
To lubricate the components, use Rockwell RBSK
0253grease.
71788
Figure111
Greasetheinsideofthebrakebody(5).
Mount the thrust pin - seal assembly(6) withtheslot facing
theguidingpin(4).
Insert thethrust pin(7) intothebrakebody(5) andinsertthe
adjustment pin - seal - adjustment bushingassembly (1).
Turning brake linings Figure112
71849
Fit thehub99372228(2) ontheshaft ofthelathe 99301001
(1).Fit theplate99372230(3) onthehub(2) andsecurethe
ba'o ||o|os (+), a'|ot|o.oo| o '/|CC|+5' co|oc|oo
asshownin thefigure. Turnthebrakelinings.
71786
Greasetheseal (1) andfit it onthethrust pin (2).
Figure113
!
Takegreat caretoobservetheassemblyorderofthe
pinsthat hasto beasillustrated in Figure111.
Greaseandinsert theguidepinassemblies (4) into theseats
onthebrakebody(5).Checkthewashers(2) areinsertedand
screwdownbyafewturns.
Theguidepins(4) need tobemountedso that the
tips (3) slide in the seats of theholes in the brake
body(5).
NOTE
Print 603.93.641 3aso |ovobo 2006
Figure114
Figure115
71787
Usingthekey99373002(1),drivethemetal ringsof theseals
onto thebrakeassembly (2).
71784
Figure116
40524
Figure117
Usingdevice99301006(2), turnthebrakelinings(1).
71785
Connect theliningwear indicator cableelectrical connection
(2) helpingthefixingnut ontheshoe. Fit theshoes(1) inthe
seat.
Hook on the shoe return springs with the aid of tool
99372211(3).
Unscrewtheadjustmentunit(1) tothesameextenttoobtain
the diameter A, 2 mmless than the diameter of the brake
drumto mount.
Figure118
Figure119
40530
Greasethewedge-shapedcontrol unit (1). Insert it initsseat,
takingcarethat the rollers ( ) arepositioned in the sliding
race.
36757
Screwtheringnut (1) byhandontothesleeve(2) asfarasit
will go.
Applynon-hardeningsealant type LOCTITE573 onthefirst
fewthreads of thesleeve (2).
3aso |ovobo 2006 Print 603.93.641
Figure120
71841
Screwthecombinedcylinder (1) fullydowninto itsseat.
Check that the holes for the supplyfittings are in the same
position found on removal; if they are not, unscrew the
combinedcylinderappropriately.Mount thefittings(2and5)
andconnect thesupplypipes(3and4).Supplythediaphragm
sections of the combined cylinder by applying the service
brake.Withthewrench99356006,tightentheringnut tothe
requiredtorque.Connectthebrakeliningwearindicatorcable
electrical connection.Restoretheoperationofthecombined
cylinder (1) screwingdownthe screw(2, Figure119) fully.
Figure121
39941
Screwtheringnut (1) byhandontothesleeve(2) asfarasit
will go.Applynonsettingseal pasteofLOCTITEtype573on
thefirst threethreads of pipe (2).
71842
Screwthediaphragmbrakecylinder (4)fullydownintoitsseat.
Checkthat theholeforthesupplyfittingisinthesameposition
found onremoval; if it is not, unscrewthediaphragmbrake
cylinder (4) appropriately. Mount the fitting (2) on the
diaphragmbrakecylinder (4), hookupthesupplypipe (1).
Supplythe brake cylinder byapplyingthe service brake and
withwrench99356006tightentheringnut(3) totherequired
torque.
Figure122
Figure123
Mount thewheelsandtightenthefixingnutstotherequired
torqueaccordingto thediagramshowninthefigure.
Mount theoppositebrakeassembly.
Stat t|o vo||c|o's oo|oo aoo oo |t o a so|c|oot| |oo t|o
to fill thesystem.
Brakerepeatedlyto wear inthe brakeassemblyandrecover
theclearancebetweenthebrakeliningandthedrumwhenthe
vehicleisrunning.
60229
Print 603.93.641 3aso |ovobo 2006
3aso |ovobo 2006 Print 603.93.641
BODYWORKANDCHASSISFRAME 1 TRAKKER EURO 4/5
Print 603.93.371
SECTION 14
5501 Bodywork
5001 Chassis frame
Page
CAB 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General information 7 . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR OPERATIONS 13 . . . . . . . . . . . . . . . . . . . .
BUMPER 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABIN 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal the cabin 14 . . . . . . . . . . . . . . . . . . . . . .
- Refitting 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE FRONT SHOCKABSORBER 19 .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE CABSUSPENSION FRONT
MOUNTING RUBBER-TYPEBUSHINGS 19 . . . .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGCABFRONT UPPERSUPPORT
BUSHINGS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
|||CV||C ||||TT||C T|
STABILIZER BAR 20 . . . . . . . . . . . . . . . . . . . . . .
- Removal 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Page
REPLACINGREARCAB
SUSPENSION DAMPERS 22 . . . . . . . . . . . . . . . . .
- Removal 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE TRANSVERSE
TIE ROD BUSHINGS 22 . . . . . . . . . . . . . . . . . . . .
- Removal 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembling/reassemblingthebushings 22 . . . . .
- Refitting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVELLING VALVE 23 . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGINGTHECABLOCK 23 . . . . . . . . . . . . . . .
- Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABTILT CYLINDER 23 . . . . . . . . . . . . . . . . . . . . . .
REPLACINGHYDRAULIC
CABTILT CYLINDER 23 . . . . . . . . . . . . . . . . . . .
- Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingoil level 25 . . . . . . . . . . . . . . . . . . . . . .
- Bleedingcabtilt system 25 . . . . . . . . . . . . . . . . . .
- Cabmechanic suspension 26 . . . . . . . . . . . . . . . .
- Cabdrivingposition adjustment 26 . . . . . . . . . . .
- Cabpneumatic suspension 27 . . . . . . . . . . . . . . .
- Adjustingthelevellingvalvelinkage 27 . . . . . . . . .
REPLACINGTHE WINDSHIELD 28 . . . . . . . . . . . . .
- Removal 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE WINDINGWINDOW 29 . . . . . .
- Removal 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
REPLACINGTHE WINDOW
WINDER 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE DOORLOCK 31 . . . . . . . . . . . . .
- Removal 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHEOUTSIDE HANDLEOF THEDOOR 32 .
- Removal 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHEINSIDE HANDLE 32 . . . . . . . . . . .
- Removal 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHESIDEMIRRORS 33 . . . . . . . . . . . . .
- Removal 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHEDOOR 33 . . . . . . . . . . . . . . . . . . .
- Removal 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE FIXEDWINDOW 34 . . . . . . . . . .
- Removal 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Preparingthewindowbay 34 . . . . . . . . . . . . . . . .
- Preparingthewindow 34 . . . . . . . . . . . . . . . . . . .
- Refitting 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL 36 . . . . . . . . . . . . . . . . . . . . .
- Removal 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTRAL SWITCH DASHBOARD 36 . . . . . . . . . .
- Removal 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROTECTIONS 37 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
WINDSCREEN VISORROLLING DEVICE 40 . . . . .
- Removal 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSCREEN SUN VISOR REEL MOTOR
REPLACEMENT 41 . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRINTAKE LID 42 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRINTAKE LID MOTOR
REPLACEMENT 42 . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGSIDEDOOROPENING
CONTROL CABLE(AT VEHICLES) 43 . . . . . . . .
- Removing 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Lidopeningcontrol cableadjustment 45 . . . . . . .
|||V||'S S|/T +6 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Component layout 47 . . . . . . . . . . . . . . . . . . . . .
|||CV||C T| |||V||'S S|/T +8 . . . . . . . . . . . .
- Removing- refittingthecushion 48 . . . . . . . . . . .
- Removing 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingcushion slidingblocks 48 . . . .
- Removing 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheseatbelt 49 . . . . . . . . . . .
- Refitting 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Removing- refittingseatbelt connectionandright-hand
sideupholstery 49 . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheleft-hand
sideupholstery, IPSvalveand
heatingswitch 50 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- Refittingtheback 50 . . . . . . . . . . . . .
- Removing 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- Refittingtheback
adjustment lever 51 . . . . . . . . . . . . . . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheheight adjustment
device 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheseat angle
adjustment device 51 . . . . . . . . . . . . . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- |oov|o |o|tt|o t|o |o|b|o cab|o o t|o
shockabsorber adjustment device 51 . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- |oov|o |o|tt|o t|o bac' ao,ostoot |ovo
segment 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheair spring 52 . . . . . . . . . . .
- Removing 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheshock absorber 52 . . . . . .
- Removing 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Removing- refittingtheheight
adjustment valve 53 . . . . . . . . . . . . . . . . . . . . . . .
- Removing 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheheight
lockingsystem 53 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheflexiblecableof the
horizontal lever suspension 53 . . . . . . . . . . . . . . .
- Removing 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthefast loweringmagnetic
valve 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthefast loweringswitch 54 . .
- Removing 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthelumbar
support device 54 . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthebackupholstery 55 . . . . .
- Removing 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthecushionupholstery 55 . .
- Removing 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
|||V||'S S|/T |||||/T|C SC||| 56 . . . . . . . .
|/SS||C||'S S|/T |||||/T|C ||/C|/| 5 . .
CABIN REFRIGERATOR 58 . . . . . . . . . . . . . . . . . . .
- Preliminarychecks 58 . . . . . . . . . . . . . . . . . . . . . .
Page
- Removal 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING 59 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fan removing 59 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingtheanti-tippingprobewith
electroniccircuit onthecontrol unit 59 . . . . . . . .
- Electroniccontrol unit disassembling 60 . . . . . . . .
- Checks 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABAIR-CONDITIONING 61 . . . . . . . . . . . . . . . . .
- General 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VENTILATION 61 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description 61 . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR-CONDITIONING ANDHEATING 62 . . . . . . .
- Description 62 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Air-conditioning 62 . . . . . . . . . . . . . . . . . . . . . . .
- Heating 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Air-conditioningcontrolsassembly 62 . . . . . . . . .
- Manual 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Heatingandventilation 62 . . . . . . . . . . . . . . . . . .
COMPONENT LAYOUT (WEBASTO AIR
CONDITIONER) 63 . . . . . . . . . . . . . . . . . . . . . . .
HEATERASSEMBLY COMPONENT LAYOUT
(WEBASTO) 64 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Outsidetemperaturesensor 65 . . . . . . . . . . . . . .
- Compressor 65 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Condenser andsafetypressureswitches 66 . . . . .
- Stepper motors 67 . . . . . . . . . . . . . . . . . . . . . . . .
- Evaporator temperaturesensor 68 . . . . . . . . . . . .
- Expansionvalve 68 . . . . . . . . . . . . . . . . . . . . . . . .
ADDITIONAL AIRHEATER SYSTEM
(ON REQUEST) 69 . . . . . . . . . . . . . . . . . . . . . . .
- Description 69 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
FAULT DIAGNOSIS 70 . . . . . . . . . . . . . . . . . . . . . . .
- Introduction 70 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY AIRHEATER 74 . . . . . . . . . . . . . . . . . . .
GENERAL WARNINGS 75 . . . . . . . . . . . . . . . . . . . .
REPAIR OPERATIONS 76 . . . . . . . . . . . . . . . . . . . . .
HEATER 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADDITIONAL AIRHEATER SYSTEM 77 . . . . . . . . .
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRRECIRCULATION DOOR
CONTROL MOTOR 77 . . . . . . . . . . . . . . . . . . . .
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC FAN 78 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATERRADIATOR 78 . . . . . . . . . . . . . . . . . . . . . .
- Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAP 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POLLEN FILTER 80 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
AIR-CONDITIONERCOMPRESSOR 80 . . . . . . . . .
- Removal 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR-CONDITIONERCONDENSER 81 . . . . . . . . . .
- Removal 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTSIDEAIR TEMPERATURESENSOR 81 . . . . . . .
- Removal 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE ELECTROMAGNETIC CLUTCH 82
PROCEDURE FOR DRAININGANDRECHARGING
AIR CONDITIONINGSYSTEMSWITH
RECHARGINGSTATION 99305146AND
RECOVERY OF R134A COOLANT 84 . . . . . . . .
SAFETY STANDARDS 85 . . . . . . . . . . . . . . . . . . . . .
CONTROL FASCIA 86 . . . . . . . . . . . . . . . . . . . . . . .
OPERATION FLOW CHART 88 . . . . . . . . . . . . . . .
RECOVERINGREFRIGERANT
FROMTHEVEHICLESYSTEM 89 . . . . . . . . . . . .
CREATINGA VACUUM IN THE SYSTEM 91 . . . . .
RESTORINGOIL IN THESYSTEM 93 . . . . . . . . . . .
FILLINGTHE SYSTEMWITH REFRIGERANT 94 . . .
CHECKINGTHE PRESSURESIN
THESYSTEM 96 . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATIONSPRIORTO DISCONNECTING
THESTATION FROMTHESYSTEM 96 . . . . . . .
PROCEDURE FOR DRAININGANDRECHARGING
AIR CONDITIONINGSYSTEMSWITH
RECHARGINGSTATION 99305148AND
RECOVERY OF R134A COOLANT 97 . . . . . . . .
- Maincomponents 97 . . . . . . . . . . . . . . . . . . . . . .
SAFETY STANDARDS 98 . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL 99 . . . . . . . . . . . . . . . . . . . . . . .
- Keypad functions 99 . . . . . . . . . . . . . . . . . . . . . . .
- Emergencywarninglight panel 99 . . . . . . . . . . . .
Page
PRELIMINARY CHECKS 100 . . . . . . . . . . . . . . . . . . . .
AUTOMATIC PROCEDURE 100 . . . . . . . . . . . . . . . .
ASSISTED PROCEDURE 102 . . . . . . . . . . . . . . . . . . .
LEAKFINDER FOR AIR-CONDITIONING
SYSTEMSWITH HFC
R134A (99305147) 104 . . . . . . . . . . . . . . . . . . . . .
CHASSISFRAME 105 . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKS 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringthebendof thechassis frame
downwardsor upwards 107 . . . . . . . . . . . . . . . . .
- Measuringthesidebendof thechassis frame 107 .
- Measuringthemovement ofthechassisframe 107
- Measuringthetorsionofthechassisframe 108 . . .
PRECAUTIONS 108 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Welds onthechassis frame 110 . . . . . . . . . . . . . . .
BODYWORKANDCHASSISFRAME 7 TRAKKEREURO 4/5
CABTYPE CABLENGTH
LOW
ROOF
INTERME
DIATE
HEIGHT
ROOF
AT
LONG
(2280x2100mm)
F F
AD
SHORT
(2280x1660mm)
F
MAIN DATA
DESIGNATION
Cabinwith mechanic suspension
Front suspension made up of:
- stabilizer bar 1
- shockabsorber with coaxial cylindricspringwith adjustingdevice 2
Rear suspension madeup of:
- shockabsorber with coaxial cylindricspringwith adjustingdevice 2
- elastic pads 2
Cabinwith pneumaticsuspension, madeupof:
- stabilizer bar
- shockabsorber with coaxial air spring 1
- levellingvalve 2
Rear suspension madeup of:
- shockabsorber with coaxial air spring 2
- levellingvalve 1
Levellingvalve
- KNORR- BREMSE:
- front, typeSV1490 - K000264 2
- rear, typeSV1491- K000661 1
Workingpressure 8.5 bar
Minimumpressureassured 0,5 bar
+0.8
- 0.2
Lever workingmaximumtravel 20
- KNORR/BREMSE SV 1490-K0002464 (front and rear)
Workingmaximumpressure 8.5 bar
Guaranteed minimumpressure
0,5 bar
+0.8
- 0.2
Lever maximumworkingtravel 20
TOOLS
99346051 Cabin front suspension bracket rubber bush
disassembling/assemblingtool
99378039 Cabin removal-refittingswingbar
Thecabisofanadvancedtype,hydraulicallytiltingbymanual
control.
Tiltingangle60 .
Constructionin pressed and welded steel.
Protection: Boxopeninganticorrosiveprotection.
Door and outer panel inner side framework coated with
galvanisedmetal sheet.
General information
5501 CAB
Cabsuspension type:
- mechanic
- pneumatic on request onlyonAT.
99119
Figure1
CABSUPPORT FOR VEHICLES4X2- 6X4
8 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Nut
Screw
226.5 22.5
278 28
22.6 2.2
27.8 2.8
2 Nut 226.5 22.5 22.6 2.2
3 Nut
Screw
179 18
146.5 14.5
17.9 1.8
14.6 1.4
99120
Figure2
CABSUPPORT FOR VEHICLES4x4- 6x6
View from A, tilted by180
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Nut
Screw
226.5 22.5
278 28
22.6 2.2
27.8 2.8
2 Nut 226.5 22.5 22.6 2.2
3 Nut
Screw
179 18
146.5 14.5
17.9 1.8
14.6 1.4
99121
Figure3
CABSUPPORT FOR VEHICLES8x4- 8x8
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Nut
Screw
226.5 22.5
278 28
22.6 2.2
27.8 2.8
2 Nut 226.5 22.5 22.6 2.2
3 Nut
Screw
179 18
146.5 14.5
17.9 1.8
14.6 1.4
99122
Figure4
CABIN FRONT SUSPENSION
TIGHTENING TORQUE
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Cabin front support fasteningnut 83 101 8.3 10
2 Front left support fasteningscrew 173 212 17.3 21.2
3 Front right support fasteningscrew 161 197 16 19.7
4 Nut for screw securingright front support 132 161 13.2 16.1
5 Cabin front support fasteningscrew 109 133 10.9 13.3
6 Air spring/shock absober upper fasteningscrew 400 40
7 Front right support fasteningscrew 173 212 17.3 21.2
8 Air spring/shock absober upper fasteningscrew
Air spring/shock absorber upper fasteningnut
490 600
398 487
49 60
39.8 48.7
99123
Figure5
TIGHTENING TORQUE
DESCRIPTION
TORQUE
DESCRIPTION
Nm (Kgm)
Cab rear suspension
1 Flangedhexagonal headedscrewretaininglock 82 9 (8.2 0.8)
2 Self-lockinghexagonal nut retainingflexiblebuffer to beam 140 14 (14 1.4)
3 Hexagonal headed screwretainingtopof damper 82 8 (8.2 0.8)
4 Self-lockingnut andhexagonal headedscrewretaininglower end of damper 154 15.5 (15,4 1.5)
5 Hexagonal screwwith flangefor fasteningthebracket to thecrossbar 146.5 14.5 (14.6 1.4)
6
Hexagonal nut withself-lockingflangeand hexagonal headed screw withflange
retainingbracket to chassis
179 18 (17.9 1.8)
Hexscrewwith flangeto securesupport to cab (vehicles 8x4) 204.5 21.5 (20.4 2.1)
GASPIPE FITTINGS
5/8' - +8 ||| 15.9 1.6
3/+' - +8 ||| 15.9 1.6
+' - ++ ||| 29.8 3
See Figure 6
Operating on main switch, take current off the electric
system.
Tilt thecab.
Remove cover (1).
Disconnecttheconnector (2) fromtheF.F.C.control unit(3).
Cut wiring harness retaining clamps and disconnect
connection(4).
See Figure 7
Lift thecowling.
Remove tow hook pin(1).
Remove thefour screws (3) assuringbumper (2).
Whilesupportingit, draw bumper (2) off securingbrackets
(6).
Removescrew(5) securingearthcable(4) tothechassisand
accuratelyset bumper (2) in order not to damage it.
Operations described and illustrated in following
chaptersrefer tovehicleTractor AD380T having
its cab with a mechanical suspension. Unless
another indication is provided, these operations
are also valid for a cab with a pneumatic
suspension.Someoperations,orpart ofthem,may
beeither unnecessaryor unsuitabletovehiclesof
other versions.
500210 BUMPER
Removal
Refitting
Reattachment is carried out byproperlyreversingthe
detachment operations and tightening the nuts and
screws to the specified torque
Whenreattachment operationshavebeencompleted,
check correct operation of thelightsor units affected
bydetachment.
99141
NOTE
Figure6
Figure7
99124
REPAIR OPERATIONS
Removal the cabin
Position the vehicle with the front wheels in the straight
direction of running. Lift the front grille. Remove the
expansion tank cap, then partiallydrain the coolant off the
enginecoolingsystem.
Ifthecabinisequippedwithanair-conditioningunit,remove
thecaps(1and2,Figure8),applyunit 99305146pipestothe
adaptersbelow,thenblowthegasoffthecabinconditioning
system, as described in therespectivechapter.
87329
Disconnect thecoolant pipes: (6), (3) fromradiator (1).
Remove screws (2) fasteningthe pipesupport bracket (7)
on radiator (1).
Removenuts(4),thentakeoffthesteeringcontrol assembly
adjustingpedal distributor (5).
This operation must be carried out only by
authorized, qualifiedskilledpersonnel.
Removethescrewsandtakewheel splashguard(11) offthe
cabin.
Disconnect theheaterfuel pipe(13),(whereavailable),from
theadapter.
Loosen thecabin tiltingsupport cylinder (14) fasteningnut
(12).
Drainthepneumaticsystem.
Onlyfor vehicles equippedwith mechanic gearbox.
Marktheassemblypositionof thetelescopic tie-rodCardan
joint (8) on gearboxcontrol rod (10), thenremove nut (9)
with its respective screw and disconnect Cardan joint (8)
fromrod(10).
Properlysecure the telescopic tie-rod to thecabin.
Position thetwo wooden dowelsof suitablethicknessonto
the cabin supporting rear crossbar, to avoid cabin lock
engagement after thecabinhasbeen lowered.
Lower thecabin.
NOTE
Figure8
Figure9
99125
550101 CABIN
99126
Remove the bumper as describedintherespectivechapter
(operation 500210).
Fromthedoorcompartment upper side, removegasket (4).
Hook swing bar 99378039 (1) to a bridge crane or other
suitableliftingmeans, then harness thecabin.
Swingbar(1)hooks(2)must bepositionedataboutthedoor
compartment centrelineandsecuredtothelatter bymeans
of stretchingdevice (3).
Figure10
z Aquila Trucks Centres
Removethenuts(1) anddetachthecover (2) togetherwith
thepipes fromthebulkheadconnector.
Takeout the screws (3) and detach thecover (4) together
with thepipefromthecontrol valve.
Remove screws (6), then take cover (7) off the bulkhead
completewithpipesfromthedistributor.
Disconnect the pipe (5) of the steering assembly control
device.
Onlyfor vehicles equippedwithautomaticgearbox:
- fromdistributor (1), disconnect pipes (2 and 3).
- placeacontainer belowmaster cylinder (4), disconnect
piping(5) fromthe same, then drain theclutchfluid.
87331
87332
99127
Disconnect enginecoolant pipes (1- 2and3).
Cut thepipe-electriccablejoiningstraps.
ect theair-conditioningsystemgas pipes (3) and(4).
87333
Disconnect quick engagement air-conditioning systemgas
pipings (1 and 2), if present, byaxiallypressingthem.
Seal the air-conditioning systempipes so as to
prevent moisture or impurities getting into the
system.
!
Properlyplugthepiping(5) andmaster cylinder (4)
adapter, to prevent theclutch fluid fromdamaging
painted parts. The clutch fluid is poisonous and
corrosive:incaseofcontact,washimmediatelywith
water andmildsoap.
NOTE
Figure11
Figure12
Figure13
Figure14
87334
Disconnect theelectricconnection(6) forthetankfluidlevel
gauge.
Lift theprotectivecap(7),removethenut (9) anddisconnect
thecable(8) fromthecab.
Remove the nut (17) and disconnect the earth cable (16)
fromthechassisframe.
Remove nuts (1) andtakeoff cover (2).
Remove covers (15), release safety levers (14) and
disconnect connections (10- 11- 12 and 13).
Disconnect theelectricconnections(4)and(5) ofthemotor
pump(3) for the windscreen-headlight washer fluid.
Figure15
Mark the assemblyposition of the universal joint (1) onthe
powersteeringshaft (3).Removethebolt (2) anddisconnect
theuniversal joint (1) fromthepower steeringshaft (3).
Takeout thescrew(4) fixingtheairspringmatingpin(5),bar
(8) andmount (9).
* Disconnect thepipe (6) fromtheshockabsorber.
Removebolt (7) securingtheairspring(5) orshockabsorber
with coaxial springto thechassis.
Repeat thesesteps on theopposite side.
* Removethenut(1) anddisconnectthetierod(3) fromthe
levellingvalve(2).
* Onlyfor pneumatic suspensioncabins.
99128
99129
Removethebolt (2) fixingthecylinder (3) for tiltingthecab
fromthecabmounting(1).
Reattachment iscarriedout byreversingtheorderof
detachment operations and by takingthe following
precautions:
Lift the cab and extract the mating pin (3) of the shock
absorber (2),bar (4) andfront cabmounting(1).Carefullylift
thecabto detach it fromthechassis frame and put it aside
appropriately.
Refitting
73160
73159
- tightenthenutsorscrewstothespecifiedtorque;
- thepneumaticpipingadapterseal rings(O-rings)
must not bereused; theymust bereplacedwith
new ones upon everyreassemblingoperation;
- seal up the tachometer electric cable ringwith
proper sealingmedium;
- check correct operation of instrument board
warninglamps;
- in case of vehicles equipped with mechanic
gearbox, restore theclutch hydraulic systemoil
tank level, then blow off air as described in the
relevant chapter;
- restoretheenginecoolant level.
Fill up the air-conditioningsystem(whereavailable)
asdescribed in therespectivechapter.
Figure16
Figure17
Figure18
Figure19
* Removethenut(5) anddisconnectthetierod(6) fromthe
levellingvalve(1).
* Takeout thescrews(2) andremovethebracket together
with thelevellingvalve (1).
* Disconnect the air pipe (6, Figure20) fromthe shock
absorber (5, Figure20).
Removescrew (3) joining bar (7) to lower support (4).
Removethebolt (7,Figure20) fixingtheshockabsorber (5,
Figure20) to the chassis frame.
Removescrews (8), anddisconnect lower support (4) from
thechassis.
* Onlyfor cabwith pneumatic suspension
REPLACING THE CAB SUSPENSION
FRONT MOUNTING RUBBER-TYPE
BUSHINGS Removal
99128
99130
73164
Usingthearm99378039,slingthecabasdescribedunderthe
|oao|o 'Cab |oova|-|o|tt|o' aoo ocooo as o||o.s.
Removethefront bumper (operation500210) asdescribed
under therelevant heading.
Remove the bolt (7) fixing the shock absorber (5) to the
chassis frame.
Disconnect thepipe (6) fromtheshockabsorber (5).
Takeout thescrew(4) fixingtheshockabsorber matingpin
(5), bar (8) and mounting(9).
Repeat thesesteps on theopposite side.
Lift the cab and extract the mating pin (3) of the shock
absorber (2),bar (4),front cabmounting(1) andremovethe
shockabsorber (2).
Removethefront bumper (operation500210) asdescribed
under thesameheading.
Remove thebolt (4) anddisconnect the universal joint (3)
fromthepower steeringshaft.
Repeat the operations described for disconnecting right
lower support.
Removescrews (1), anddisconnect lower support (2) from
thechassis.
554243 REPLACING THE FRONT SHOCK
ABSORBER
For theright-hand air springonly
Removethenut (1) anddisconnect thetierod(3) fromthe
levellingvalve(2).
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
Removal
Removingtheright-hand front suspension mounting
Removingtheleft-hand front suspension mounting
73162
Figure20
Figure21
Figure22
Figure23
99131
87291
87292
99132
Cab suspension lower supports are of different types and
their matchingdepends on vehicle version.
Replacingbushings(2) fromsupports(1-3) isbyusingapress
and suitablebeater.
Useelements (3, 4 and 5) of tool 99346051 to fit thebush
initsseat.
Remove the front bumper, operation 500210 as described
under the same heading. * Remove the nut (5) and
disconnect thetierod(6) fromthelevellingvalve(1).* Take
out thescrews(2) andremovethebracket togetherwiththe
levelling valve (1). Remove the bolt (4, Figure 23) and
disconnect the universal joint (3) fromthe power steering
shaft. Remove the shock absorbers as described under the
relevant heading. Take out the screw (3) and remove the
stabilizer bar (7) fromthe mounting(4).
* Cabwith pneumaticsuspension
torques.
Refitting
REPLACING CABFRONT UPPERSUPPORT
BUSHINGS
|oovo t|o s|oc' absobos as oosc |boo |o t|o '|oot
s|oc' absobo o|acooot' c|at o.
Extract thebushwithelements(1,2and3) oftool99346051
and removethe bush.
REMOVING REFITTING THE STABILIZER
BAR
Removal
Removal
torques.
Refitting
Figure24
Figure25
Figure26
Figure27
Refitting
99133
CABFRONT ANCHORINGCOMPONENTS
Figure28
554243 REPLACING REAR CAB
SUSPENSION DAMPERS
Removal
86949
Tilt over the cabin.
Onpneumaticsuspensionscabins,disconnect thepipefrom
theair spring.
Removebolts(2and4) andtakeshockabsorber (3) offthe
upper (1) andlower (5) crossbars.
REPLACING THE TRANSVERSE TIE ROD
BUSHINGS
Removal
Removebolts(4and5), thentaketransversetierod(2) off
crossbars (1 and 3).
86951
Refitting
Reattachment is carriedout byreversingtheorder
of detachment operations and by following the
specified tighteningtorquevalues.
Disassembling/reassembling the bushings
86952
Transverse tie rod (1) elastic bushings (2 and 3) can be
replaced by using a suitable beater and press for
disassembling/reassemblingoperations.
Toreattachthetransversetierod,reversetheorder
of detaching operations, by tightening bolt (4, 5,
Figure30) nutsto thespecified torque.
Nutsareoftheself-brakingtype;it isrecommendedthatthey
are replaced with new parts every time disassembling is
performed.
Refitting
86953
PARTSMAKINGUPTHE CABIN REAR SUPPORT AND
LEFT SIDEMECHANIC SUSPENSION
Figure29
Figure30
Figure31
Figure32
Removal
554255 REPLACING HYDRAULIC
CAB TILT CYLINDER
Removal
99134
The figure shows the front levelling valve; similarly, the
descriptionsofdetachment operationsalsoapplytotherear
levelling valve. Disconnect pneumatic pipes (1 and 2) from
levelling valve (4). Disconnect tie-rod (5) from the
articulation pin, then remove the fasteningscrews (3) and
takeoff levellingvalve (4).
Removal
Refitting
Reversetheorderofdetachmentoperations,and tightenthe
screwstothespecifiedtighteningtorque.Asfarastie-rod(5)
check and adjustment are concerned, see the respective
chapter.
86632
Disconnect piping(4) fromlock (1), then recover the oil in
aspecial container.
Remove screws(3), then takeoff thelock.
CHANGING THE CAB LOCK
Carryout thesteps performedfor removal inreverseorder,
observingtherequired tighteningtorques.
Refitting
Lock(4) fasteningscrews(3) must belockedwhen
cabinanchoringpin(2) isalignedto therespective
seat of lock (4).
After reattachment hasbeencompleted, checktheoil level
andproceedwithdrainasdescribedintherelevant chapter.
CAB TILT CYLINDER
Placeacontainer under oil piping (3 and 4) to recover the
oil fromthe system. Disconnect oil piping (3 and 4) from
cabintiltingcylinder (2) adapter.Removebolt (1) andnut(5),
then take off cylinder (2).
Thisoperationmustbecarriedout withthecablow-
ered.
Reattachment is carriedout byreversingtheorder
of detachment operations, bytighteningthenutsto
thespecified torque.
After reattachment hasbeencompleted, fill up and
blowair offthehydraulicsystem,asdescribedinthe
relevant chapter.
Refitting
99135
Figure33
Figure34
Figure35
NOTE
4
1
2
5
3
LEVELLING VALVE
102622
CABTILTING SYSTEMCOMPONENT PARTS
1. Handdriven pump- 2. Cabliftingcylinder - 3. Hydraulic actuator to releasegearboxcontrol telescopictierod (onlyfor
mechanic gearbox) - 4. Cab hitchingup lock
Figure36
Maincircuit
Secondarycircuit
- Rotatetap (2) to the position shown in figure;
- Cablowered to drive position
- take off plug (1) and check oil level as described in
relatingchapter, toppingup, if required;
- rotatetap (2) to cablowered position;
- slowlydrive lever (3) at least forty times (through full
range);
- checkoil level asdescribed in relatingchapter
Bleeding air from secondarycircuit (point 3)
- Disconnect pipingfromlock(4, Figure38) andhydraulic
actuator (3, Figure 38);
- drive lever (3) until oil is drained away into special
container;
- checkoil level asdescribed in relatingchapter.
Bleeding air fully
Incaseall cabtiltingsystemcomponentsarereplaced,bleed
air as describedonpoints1-2-3.
Bleeding cab tilt system
Bleed the air in the event of general tilt system
malfunctioning and for the following operations
(seeFigure36).
1) Replacingmanual drivepump (1);
2) replacingcabtiltingcylinder (2) andmaincircuit
pipings;
3) replacinglock(4) andsecondarycircuitpipings;
4) replacingall components of tiltingsystem.
NOTE
102620
Bleeding air from cab tilting cylinder (point 2)
102621
Bleedingair frommanual drivepump(point 1)
- takeoff plug(1);
- slowlydrivelever (3) fivetimes, (throughfull range);
- checkthelevel asdescribed in relatingchapter.
Checking oil level
102619
Cabmust beloweredinridecondition. NOTE
Position pumpdrivelever (3) asindicatedinfigure.
Remove plug (2) and check that oil level X results to be
aboveplunger (1) bysome2 mm; otherwise, top up.
Figure37
Figure38
Figure39
99138
LOCATION OF CABSUSPENSION COMPONENTS
1. Cross member - 2. Rubber block- 3. Rear shock absorber regulator - 4. Rear shock absorber - 5. Bracket - 6. Support -
7. Front shockabsorber - 8. Front shock absorber regulator - 9. Torsionbar - 10. Brackets- 11. Torsion bar
Cab driving position adjustment
With cab under static loadcondition, checklengthX
1
of front shock absorbers(7) andlength X
2
of rear shockabsorbers(4).
Bystatic load it is onlymeant theloadthat is determinedbythetype of cab fitting.
X
1
= 380 mm
X
2
: vehicles: 4x2- 6x4 - 8x4 =400 3 mm
vehicles: 4x4- 6x6 - 8x8 AD (short cab) =362 3 mm
vehicles: 8x8AT (longcab) =400 10mm
If different valuesarefound, rotate theregulator (3and/or 8) of relevant shock absorbers with asuitable wrench.
Theregulator isprovidedwith5marks,eachmark, startingfromthecentral referencemark,correspondingtoalength
shift of 4mm.
Figure40
NOTE
NOTE
Cab mechanic suspension
Cab pneumatic suspension
99139
LOCATION OF CABSUSPENSION COMPONENTS
+. Sov|co so| 2. |oa s|oc' absobo 3. |oot |ovo|||o va|vo +. |oot s|oc' absobo 5. T|o oo o va|vo (3)
6. Tos|oo ba . |oa |ovo|||o va|vo 8. T|o oo o va|vo () . Stab|||zo ba.
Checkand/or adjust length X
1
of tierods(5) andlengthX
2
of tierod(8).Suchlength,measuredbetweenthecenterdistances
of articulatedpins, must be:
X
1
= 94 1 mm- X
2
= 83 1 mm
554275 Adjusting the levelling valve linkage
74094
CABSUSPENSION PNEUMATIC SYSTEMWORKINGDIAGRAM
+. |||t-|aoo oot a| s|o 2. |oot |ovo|||o va|vo 3. |||t-|aoo oa a| s|o +. |ot-|aoo oa a| s|o
5. |oa |ovo|||o va|vo 6. |ot-|aoo oot a| s|o /. Sov|co so| (8.5 bas)
Figure41
Figure42
73263
90043
90044
73266
Figure43
Figure44
Figure45
Figure46
Lift the radiator cowling (10). Take out the split pin (2),
extractthepin(7) withthethrustwashers(3)anddisconnect
theshockabsorber (4) fromthemount (1).
Repeat thesesteps for theother shock absorber.
Takeout thescrews(9) fixingthehinges(8) andremovethe
radiator cowling(10) fromthecab.
Disconnect thepipes(5) for thewindow-washerliquidfrom
thefitting(6).
Removethenuts(12) anddisconnect thewindscreenwiper
(11).
Open door (3) and remove screws (1) to laterally secure
right handvent (2).
Fromfront side,removescrews(4) andtakeright handvent
(2) off supports (5).
Repeat operations for takingoff left hand vent.
If present, takeout the fixingscrews. Removethevisor.
Put thepairofsuctioncups99378031(1) onthewindscreen
and withtwo operators, oneinsidethe cab who, usingthe
right tool, removes the seal whileapplyingpressure on the
top corners of the windscreen, while the other, on the
outside,pullingonthehandlesofthesuctioncups99378031,
removesthewindscreenfromits housing.
To refit the windscreen, carryout the followingoperations:
Removal
Refitting
- Fit therubber seal on thewindscreen, insert acord(1)
intheseal (2).
- Put the suction cups of tool 99378031 on the
windscreen.
- Position it against thecab flanging.
- Press firmlyonthesuctioncups whilepullingbothends
of thecord (1) fromtheinsidesothat theseal fits onto
theflangingof thebodywork.
- Finish fittingtheparts takendown duringremoval.
552410 REPLACING THE WINDSHIELD
90045
90047
90046
90048
90049
Figure47
Figure48
Figure49
Figure50
Figure51
Lower thewindow.
Removescrews(1), unthreadtierod(3) andtakesunroller
blindassembly (2) off thedoor.
Remove thepush-buttonpanel (2) fromthearmrest (1).
Disconnect the electric connections (3), (4), from the
push-button panel (2).
Loosenscrew(2)andremovehandgrip(1) fromdoorclosing
tierod.
Press thefinsof stem(4) and removehandle (3).
Remove mouth (5) andremove screwunder it.
Remove screws(4).
Removecaps(2) andscrews(1) underthemsecuringcoating
(3).
Take coating (2) off the door paying attention on
unthreadingcables(6) fromcoatingslot.
Removescrews(3) securingcentral unit support bracket (4)
to door (1).
Remove sound deadeningguard(2) fromthedoor.
550740 REPLACING THE WINDING
WINDOW
Removal
90050
Figure52
Figure53
Figure54
Figure55
Figure56
Remove plastic guards (1 and 3) fromdoor (2).
73272
Extract the outside and inside bottomseals (1) fromthe
windowcompartment.
73273
Extract thewindow guide seal (1).
73274
Temporarily connect electric connections to pushbutton
panel and lift glass until fastener (2) is made accessible.
Disconnect theelectricwindowdevice(3) fromthewindow
(1) byremovingtheclamp (2).
73275
Lift thewindow (1) andextract it fromthe top (arrow).
torques.
Refitting
90067
Figure57
Remove thewindowasdescribed in operation550740.
Disconnect theelectric connection(5).
Take out the screws (1), (3) and (4) fixing the electric
windowdevice(2) onthedoor.
550730 REPLACING THE WINDOW WIN-
DER
Removal
73277
Figure58
Extract theelectricwindow device (1) fromthe door.
torques.
Refitting
73278
Figure59
Remove thedoor trimas describedin operation 550740.
Unhooktheclip(2) fromthetierod(3) anddisconnect this
fromtheidler (1).
If present, disconnect the electric connections (4) and (5)
fromthelock(6).
550714 REPLACING THE DOOR LOCK
Removal
73279
Figure60
Disconnect thetierod(1) fromthelever (2) of theoutside
handle (3).
73280
Figure61
fromthelever (5) of the internal handle.
Take out thescrews (1) and removethe lock (2) fromthe
door.
torques.
Refitting
73281
Figure62
Remove thedoor trimas describedin operation 550740.
fromtheidler (1) of thelock (4).
550717 REPLACING THE OUTSIDE
HANDLE OF THE DOOR
Removal
73282
Figure63
Disconnect thetierod(1) fromthelever (2) of theexternal
handle (3).
Figure64
Take off the covers (1) and (2) and the nuts(3) fixingthe
external handle(4) and detachthisfromthedoor.
Remove thetie rod (3, Figure63) fromthe handle(4).
torques.
Refitting
Figure65
REPLACING THE INSIDE HANDLE
Removal
73284
Take off the trimas described inoperation550740.
Unhook the clip (1) fromthe tie rod (2) and disconnect this
fromthe lever (5) of the insidehandle (4). Take out thescrews
(3) and removethehandle(4) fromthe door.
torques.
Refitting
Figure66
REPLACING THE SIDE MIRRORS
Removal
REPLACING THE DOOR
73286
Figure67
Take off the side mirror mounting as described in the
previous operation.
Detach the inside door trim as described in operation
550740.
Remove the electric window device as described in
operation550730.
Disconnect theelectricconnections(5),(6), (7),(8) and(9)
fromthecontrol unit andtakethisout (10).
Support thedoor (1), takeout thescrews (2) and(11) and
takethedoor (1) off its hinges (3) and(12).
Removal
Whentakingoffthedoor (1),extract thewiring(4)
fromit withgreat care.
Carryout thesteps performed for removal inreverseorder,
observingtherequired tighteningtorques.
Refitting
NOTE
108622
Unscrew screws (1) and (2) andremoveplastic guards (3)
and (4).
Figure68
Disconnect electrical connections (1), (2) and (3).Remove
screws (4) and(5) and take assemblyoff thevehicle.
torques.
Refitting
108877
Takeoffthesidemirror mountingasdescribedintherelated
operation.
Detach the inside door trim as described in operation
550740.
550748 REPLACING THE FIXED WIN-
DOW
Removal
Preparing the window bay
Using an appropriate knife, cut and level the sealant of the
windowbaysoas to leaveathickness of between0.25and
1 mmto prevent chippingthepaintwork.
Get ridof theremainingdust and degreasethewindowbay
with theBETACLEAN 3300detergent towelettecontained
intheBETASEAL1703Sprintkit(IVECOPARTS93162553).
73287
Figure69
Extract theoutsideseal (1),applythesuctioncup99378031
(2).
Insert asuitabletool throughthesealant byacorner (arrow)
of thewindow.
Make the cut all alongtheperimeter. Remove the window
with asuctioncuphandle (2).
Before starting to cut, you need to protect the
paintwork with adhesive tape to prevent any
damage.
Do not useanylubricant duringcutting.
The bladesmust always besharp.
The filmof sealant remainingon the windscreen
will beasupport for subsequent gluing.
If the window bay has been painted after repair
work, treat it with the COMBI primer 5061
contained in thekit andwait for 15minutes.
Preparing the window
Usinganappropriateknife, cut and level thesealant of the
windowbaysoasto leaveathickness of between 0.25and
1 mmto prevent chippingthepaintwork.
Get ridof theremainingdust anddegreasethewindowbay
withtheBETACLEAN 3300detergent towelettecontained
in the BETASEAL 1703 Sprint kit (IVECO PARTS
93162553).
If using a new window, it is still necessary to
degrease the screen-printed portion with the
BETACLEAN 3300detergent towelette.
33928
Figure70
- Degreasethescreen-printedportionof thewindscreen
with the BETACLEAN 3300 detergent towelette
contained in thekit.
Mount thesealsontheinsideofthedoor,without
touchingthe areawheretheadhesionpromoter
(primer) has been applied.
Mount therubber seal on thewindow.
Performatrial assemblyand centre the window
exactly.
After centring the window, mark the reciprocal
position between the window and its seat with
stripsof adhesive tape (1).
Cut the strips of adhesive tape and remove the
window.
- Usingtheapplicatorcontainedinthekit,spreadtheglass
adhesion promoter (COMBI primer 5061) on the
screen-printedportion.It isnot necessarytouseitonthe
remainingsealant.
- Wait for 15 minutes before going ahead with the
operations so as to allow the solvent of the adhesion
promoter (COMBI primer 5061) to evaporate.
Refitting
NOTE
NOTE
NOTE
NOTE
NOTE
33929
Figure71
Using an air gun, applya bead of BETASEAL 1703 SPRINT
polyurethaneadhesivealongtheperimeterofthewindowas
evenlyas possible.
73287
Figure72
Placethewindscreeninitsseat withthesuctioncuphandle
(2).
- Alignthewindowwithitshousingbay,usingtheadhesive
tapeapplied beforehandas areference.
Thewindowmustbepositionedwithin15minutes
of applyingtheadhesive.
Start this process fromthe middle of the bottomside and
proceed without stopping all around the perimeter of the
window.
Cut off the tip of the adhesive cartridge so that the
cross-sectionof theadhesivebeadis triangular inshapewith
abaseof 5-7 mmandaheight of 12 mm.
73288
Figure73
Keepthewindowunder pressurewith twowoodenplugs(1)
and (2) positioned as shown in thefigure.
Keep the window under pressure for at least 1
hour.
Beforerefittingthepartsthat hadbeenremovedbeforehand,
checkthereare no points of infiltration.
Take care not to damage the screen-printingon
thewindowwiththeknife.
Fit theparts that had been removed back on and clean the
window.
Donot moveor deliver thevehicleuntil onehour
and thirtyminutes have passed at atemperature
of 23 C and relative humidity (RH) of 50%.
Ifthetemperatureorhumidityarelower youneed
to increasethewaitingtime.
Applysoapywater withaspongealongtheouterperimeter
and blow compressed air from the inside so as to see
whether thereisanyinfiltration.
If bubbles form, degrease the relevant part and fill it with
adhesive.
Anysealant spillingover ontheinsidecanberemovedonce
ithashardenedbycuttingit withaknifeanddetachingit with
tweezers.
NOTE
NOTE
NOTE
NOTE
Before performing repair interventions on the
vehicle,disconnectbatteriesbyoperatingoncurrent
mainswitchandobservesafetyrules.
90051
Figure74
553710 INSTRUMENT PANEL
Removal
- Remove support (3) fromcoating(2).
- Remove screws(4and5).
- Takeoff socket holder (1).
- Takecoating(2) off dashboardcoating.
!
77066
Figure75
- Remove plugs (2) fromseat.
- Undo the fasteners and remove the light switch
assemblies (1) fromtheir compartment.
77067
Figure76
- Disconnect theelectricconnectorsandremovethelight
switchassemblies (3).
- Unscrew thescrews (2) fixingtheinstrument panel (1).
- Remove instrument panel (1) fromseat.
- Disconnect electric connections affecting dashboard
removal, markingthe respectivemountingpositions of
the electric connections, in order to make their
connectioneasier onreconnection.
Taketheninstrument panel (1) off theseat.
Refit bycarrying out theprocedures described for
removal inreverseorder.
553712 CENTRAL SWITCH DASHBOARD
Figure77
Refitting
Removal
- Remove mat (1), plugs (2) and screws (3) securing
central dashboardontop.
90052
- Remove handgrip (1).
- Remove lid (2) and disconnect theelectricconnection
of socket (3).
- Remove lid(4) and screws(5).
90053
90054
77107
Figure78
Figure79
Figure80
- Remove frame (2).
- Remove screws(1) securingcontrols (4) to dashboard
(3).
- Remove dashboard (3) and disconnect electric
connections affecting dashboard removal, markingthe
respective mounting positions of t he electric
connections,inordertomaketheirconnectioneasieron
mounting.
- Then, takeoff dashboard (3).
- Takeoff instrument panel (Op. 553710) as describedin
relatingchapter.
- Unscrew securingscrews (1) and takeoff lightscontrol
lever coating(2).
Refit bycarrying out theprocedures described for
Refitting
Removal
552211 PROTECTIONS
- Unscrew thescrews (4) fixingthesill (3).
- Lift themat (5) to get to oneof the fastenersof thesill
(3).
- Detachthe sill (3) fromthe vehicle.
- Remove mat.
- Operateoncheckfins( ) andremoveairintake(2) on
thefloor.
- Unscrew thesidescrews(1) fixingthesteeringcolumn
guard.
77108
Figure81
90002
77116
90055
Figure82
Figure83
Figure84
- Takeoff central switchholderdashboard(Op. 553712)
asdescribed in relatingchapter.
- Remove screws (1) securingparkingbrakelever (2) to
support.
- Unscrewthescrews(3) fixingtheblindguard(1) onthe
steeringcolumn.
- Unscrewthescrews(2) fixingthefasciacoveringtothe
steeringcolumnandto the body.
- Unscrewthescrews(2) fixingthesteeringcolumnguard
intheareaof thepedal board.
- Detachthesteeringcolumn guard (1) fromthevehicle.
- Partlytakeoff thedoor seal (2).
- Remove thesunblind rod(3).
- Take off the press-on plug (4) to access the screws
beneath.
- Unscrewthefixingscrew(5) andremovethewindshield
upright covering(1).
77110
- Takeoff instrument panel (Op. 553710) as describedin
relatingchapter.
- Unscrewsecuringscews(1) andtakeofflightscontrol lever
coating(2).
77111
Figure85
90056
Figure86
- Removelids(3) andscrews(2) under them,andtakeoff
coating(1).
- Remove screws(4).
Figure87
- Unscrew the nuts (1) fixingthe fascia coveringto the
body.
- Free the right-hand air delivery pipe (2) from the
retainingclampsanddisconnect it fromthefanbodyand
right-handdoor air opening.
- Unscrew the bottom screws (3) fixing the fascia
covering.
- Perform operations described at Figure84 and
Figure85.
77114
77115
90057
Figure88
Figure89
Figure90
- Operate fromthe instrument panel compartment and
unscrew the nuts (2) fixingthe fasciacovering to the
body.
- Freetheleft-handairdeliverypipe(1) fromtheretaining
clampsanddisconnectitfromthefanbodyandleft-hand
door air opening.
- Remove screws (1) securing lower coating (2) to
passenger side.
- Takeoff coating(2).
77105
Figure91
- Open theglovecompartment (3).
- Detach the tie rods (1).
- Unscrewthenut (2) anddetachtheglovecompartment
(3).
77113
Figure92
- Unscrew thescrews (2) fixingtheBodyControl.
- RemovetheBodyControl (1) andtosetit asideinorder
to get to thefastenersbeneath.
90058
Figure93
- Unscrewthetopscrews(1) fixingthefasciacovering(2)
alongtheperimeter of thewindshield.
- Remove screws(3) securingcoatingon bottom.
- Withthehelpofanassistant,detachandrotatethepanel
trimas required.
- Pay attention to the fasteners and extract the fascia
covering(2) fromthevehicle.
For refitting, invert operations described for
removal, paying particular attention to electronic
cables and their connections.
Oncereconnectionhasbeencompleted,checkthe
functionality of electric/pneumatic controls and
relatingindicator lamps.
.
87312
87314
87313
Figure94
Figure95
Figure96
Unscrewupperscrews(4),lowerscrews(3),sidescrews(2),
then removetheside utilitycompartment (1).
Takeoff cap (1), then loosen screw(2).
Unscrewupperscrews(1) andsidescrews(2), thencarefully
takeoff theutilitycompartment, disconnect the ceilinglight
and transformer connections, and remove utility
compartment (3).
553612 WINDSCREEN VISOR ROLLING
DEVICE
Removal
Refitting
87315
87316
87317
Figure97
Figure98
Figure99
Take off the covers and/or the removed devices (if any).
Unscrewupperscrews(2),sidescrews(3) and lower screw
( ).
Carefullytakeoff console (1).
Disconnect tachograph connections (2), then remove
console (3). Take off loudspeaker cover (1) and the
loudspeaker (whereavailable).
Unscrewthefirst rollingdevicefasteningnut (1) throughthe
openingfromtheloudspeaker ( ), andtheother four nuts
through theother openings.
Refitting
Reversetheremoval procedure.
87318
87319
Figure100
Refitting
Slackenthefourfasteningscrews(1) andremovethemotor
(2).
553651 WINDSCREEN SUN VISOR REEL
MOTOR REPLACEMENT
Removal
Carefullylower therollingdevice assembly (2), disconnect
connection(1), then removetheassembly.
Figure101
87320
87215
87321
Extract thescrewcoveringtrims (1).
Slackenthefasteningscrews(1) andremovethehandles(2).
Remove therim(1).
Removal
Figure102
Figure103
Figure104
87216
87217
Disconnect theconnection(3),slackenthe12fasteningnuts
(1) and removetheair intakelidassembly(2).
Disconnect the lid as described above and put it on the
workingstand.
Slackenthescrews(1),recoverthehinges(2),thegaskets(3)
and thebosses (4).
Remove thesafetyring(7) andmake thewindow (5) slide
inthedirectionshownbythearrowtoreleasethemotor (8)
lever (6).
Refitting
550254 AIR INTAKE LID MOTOR RE-
PLACEMENT
Removing
Figure105
Figure106
550250 AIR INTAKE LID
87218
87219
Slackenthescrews (2) andremovethemotor (1).
At refitting, press the rimin contact with the window to
obtainalignment between the motor lever pin(1) and the
window lever hole (2). Make theparts slide until the lever
couplingisobtained.
Refitting
Reverse the removal procedure except for the
followingoperations.
Figure107
Figure108
87342
551644 REPLACING SIDE DOOR OPEN-
ING CONTROL CABLE
(AT VEHICLES)
||t t|o attoss bo||oo t|o o|vo's soat.|osoo sco.s (2),
then removecovering(1).
Should the lid opening control cable be broken,
you can gain access to the glove compartment
o t|o cab|o |os|oo bo||oo t|o o|vo's soat.
Removing
87228
Slackenthescrews(2),recoverthewashersandremovethe
covering(1).
Figure109
Figure110
NOTE
87229
87230
Operatethelever ( ) to open the lid.
Slackenthe lock nut (1) and removethe adjustingterminal
(2) fromthe lock, then release theterminal fromthe lever
cable(3).
87343
Tieupaprobe (2) to thecable(1) to betakenout,so asto
allow thenewcableto be inserted.
Figure111
Figure112
Figure113
87344
87346
87345
Figure114
Figure115
Figure116
Loosen screws(2), then removecovering(1).
Unscrewnut ( ), thenrecoverthewasher frombelowthe
wheelbox.
Disconnect and remove the remote control so as not to
damageit.
Lower door (1), loosenscrews (2) andscrew(3), thentake
off covering(4) carefully
1
2
87347
Figure117
Act on the points shown ( ), thentakeout handle (1).
Takeoff handle(1) withitsrespective cable, then untiethe
probe.
Leaveprobe(2,Figure113) inthespacebetween
thecabinandthe utilitycompartment opening.
87234
Figure118
Refitting
Operatethenut (2) to tension thecable (4) with thelever
(3) freeand without clearance.
After adjustment, tighten the lock nut (1).
Before refittingthe covering(1, Figure 108) carry
out thelid openingcontrol adjustment.
Lid opening control cable adjustment
1
NOTE
NOTE
77149
Figure119
Removal
Open thedoor (5) of the glovecompartment (4).
Unscrew the fixing screws (6) and remove the glove
compartment (4) fromthevehicle.
Coato t|o |ovo () aoo b|o t|o s oat (8) |oto t|o 'a||
o.ao' os|t|oo.
Operatethelever (2) and tilt theback (1).
Undothequickcouplings(10) anddetachtheair pipes(11).
Disconnect theelectric systemconnector (12).
Unscrew thefixingnuts(3) andscrews (9) and removethe
seat (8) fromthe vehicle.
Refitting
Refit bycarryingout the proceduresdescribed for removal
inreverse order.
555010 DRIVERS SEAT
77150
Figure120
1. Back - 2. Cushion- 3. Seat tilt adjustment - 4. Cushiondepth adjustment - 5. Bellows- 6. Horizontal spring-
7. Horizontal adjustment - 8. Guides - 9. Loweringseat - 10. Adjustingthevertical shockabsorber - 11. Adjustingtheseat
height - 12. IPSpneumaticlumbar support - 13. Seat heating- 14. Back adjustment - 15. Upholstery.
Component layout
90025
Figure121
Removing
- Lift thelever (2) for adjustingthe cushiondepth.
- Arrangethe cushion (1) in its headposition.
- Unscrew the screws (5) fixing the seat tilt adjustment
lever (4).
- Keep the lever (2) in the topposition andpush in the
direction of thearrow(A).
- Movethecushion(1) of theseat forward and lift it.
- Disconnect theelectrical connection(6) of theseat.
- Detachthe cushion (1) fromthe seat.
Refitting
- Bowdenflexiblecable(10) must bepositionedbetween
lever (9) and sittingcushion baseplate.
- Press cushionwithkeyholes (7) on rear slidingblocks.
- Draw lever (2) upwards (do not displace cushion).
- Presscushionfront keyholes(8) onfront slidingblocks.
Pushcushiondownwardsandat thesametimepushup
to thestoptowards theseat back.
Now, check that all the four sliding blocks are still
anchored in cushion base plate (cushion vertical
movements must not be possible).
- Press lever (2) accordingto the direction of arrow (B)
and pushthe cushion towardsthe seat back up to the
engagement of lever (2).
- Check thecushion to besteadilysecured accordingto
both horizontal and vertical directions.
Removing - refitting cushion sliding blocks
Removing
- Remove the cushionasshown alongside.
- Takeout plug(2) and pushout slidingblock (3).
Refitting
- Mount slidingblock (3) to seat frame(4).
- Put plug(2) into slidingblock (3) seat.
REMOVING THE DRIVERS SEAT
Removing - refitting the cushion
Figure122
77152
- Unscrewthescrew(9) fixingthetopoftheseatbelt and
takeoff the facing(1).
- Unhookthesections(5) andlift thebackupholsteryoff
thefixingtapes (2) (Velcro),
- Removetheretainer (6) of theplasticguide (10) acting
inthedirection of thearrows.
- Unscrew the screw (7) fixingthe reel and removethe
seatbelt (8) fromtheseat.
77153
Figure123
- Detach the seat cushion asdescribed above.
- Unscrew the fasteners (1) and remove the rear
upholstery (2) of theback.
Removing - refitting the seatbelt
Figure124
- Lift thebackadjustment lever(4) andunscrewthescrew
(3) fixingthe seatbelt hook.
Figure125
Removing - refitting seatbelt connection and
right-hand side upholstery
- Positionthecushion(5) forwards.
- Unscrewthescrews(4) fixingtheupholstery(6) andthe
press-oncaps (1).
- Unscrewthescrew(2) andremovethebelt connection
(3) andthe sideupholstery(6).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
77494
77495
Refitting
reverseorder.
Removing
- Remove the seat cushion asdescribed above.
- Unscrew screws(1), (2) and (3).
- Foldthebackfullyforwardsandunscrewthescrew(4).
- Remove the side upholstery (5) from the seat
framework.
- Unscrew ascrew(6) and two screws(7).
- Lift safetyhook(8) inasafewayanddismount air tube
(9) fromconnector (10) (seedetail A, B).
- Separatetheelectric connector (11).
- Push the valve (12) and the switch (13) outside the
upholstery(5).
- Disconnect thehoses (14) fromthevalve(12).
Figure126
Removing - refitting the back
Removing
- Adjust inclination at thehighest position.
- Takeoff thesideupholstery.
- Disconnect theconnector (3) andthreeair hoses(4) if
applicable.
- Remove thesafetylock (1).
- Unscrew the screw (5) fixingthe seatbelt reel and the
screw (6) fixingtheseatbelt (7).
- Unscrew thescrews (2) fixingtheback (8).
- Remove the back(8) fromtheseat,
Refitting
reverseorder.
Removing - refitting the left-hand side
upholstery, IPS valve and heating switch
Figure127
77497
77496
Markthehosesto facilitateassembly.
Refitting
reverseorder.
NOTE
Figure128
Removing
- Remove the seat cushion and the left-hand side
upholsteryas describedabove.
- Remove thesafetywasher (1).
- - Dismount spring(2) fromlever (3).
- Remove the spring(4) fromthepin (5).
- Remove the lever (3).
Refitting
reverseorder.
Removing - refitting the height adjustment
device
Removing- refittingtheseat angleadjustment
device
Removing
- Remove the seat cushion and the left-hand side
upholsteryas describedabove.
- Takeoff height adjustinglever (4) as above.
- Freethepin (1) fromthelever (2).
- Remove thelever mount (3) fromtheseat framework.
- Loosen theflexible cable fromthelever (2).
- Remove the seat adjustment device (5) fromthe seat.
Refitting
reverseorder.
Removing - refitting the flexible cable of the
shock absorber adjustment device
Removing-refittingtheback adjustment lever
90027
90026
Removing
- Adjust inclination at thehighest position.
- Unscrew the fixingscrews (1), loosen the nut (2) and
removethe flexiblecable (3) fromthefixing(4).
- Free the threaded coupling of the cable (5) fromthe
lever (6).
- Pushtheflexiblecableout ofthemount (7) andextract
through theopening(8).
Refitting
reverseorder.
Figure129
77499
Figure130
Figure131
77501 Removing
- Removethesupportingwasher (1) andtheflexiblecable
(2) of thelever fromthe fixingsystem(3).
- Unscrew thescrews (4).
- Extract thepin(5) fromthelever (6).
- Extract theflexiblecable (2) fromthe seat framework.
Before putting in the springs, thread end (A) of
spring(4) into theopening(B) of spring(2).
NOTE
1 2
3
4
After mountinga new suspension, projection (6)
must engage with the fixing hole of suspension
upper support.
NOTE
Removing
- Removetheseat cushion, left-handsideupholsteryand
theback asdescribed above.
- Loosen spring(1) frompin (2) of lever (3).
- Unscrew the nuts (4) and remove the plate (5), the
toothed segment (6) andthe lever (3).
Refitting
reverseorder.
Removing - refitting the air spring
Before fittingthe seat cushion, loosen thelocking
nut (7), adjust theflexiblecable (2) so that inthe
lowest positionoftheadjustment lever, thestiffest
vertical damping is reached, then retighten the
lockingnut.
reverseorder.
77503
77502
90029
Figure132
Figure133
Figure134
Refitting
Removing
- Takeout the bottombellows fastener.
- Securesuspensionassembly(1) onthehighest position,
use special spacer (3) withdimensions shown in figure.
- Put inspacer (3) betweenframe(2) andseat suspension
(1).
- Lift thefixinghook(1) safelyandremovetheairpipe(2)
asshowninthe box.
- Unscrewthescrew(3),loosentheshock-absorberfixing
and move the air springtoward thefront.
- Turntheairspring(4) by90degreesandremoveitfrom
thebottommount (5).
Refitting
For fitting, carry out the steps performed for removal in
reverseorder.
Removing-refittingtheback adjustment lever
segment
Figure135
Removing
- Takeout the bottombellows fastener.
- Movethesuspensionassemblyinto itslowest position.
- Unscrewnut(1),takeout screw(2) andremovebushing
(3).
- Position suspension assembly to the highest position
(usespacer (3), Figure133).
77505
Removing - refitting the shock absorber
NOTE
Removing - refitting the flexible cable of the
horizontal lever suspension
Removing
- Remove the seat cushion, as described above.
- Remove theheight adjustment valve.
- Unscrew support washer (1) and remove toothed
segment (2).
- Unscrew supporting washer (3) and remove the
toothed segment (4).
- Unscrewthesupportingwasher (5), unscrewthescrew
(6) andremovethelever (7).
Refitting
reverseorder.
Removing
- Unscrewthenut (1), removetheflexiblecable (2) from
the fixing (3) and pull the cable with the threaded
coupling(4) out of thevalvelever (5).
- Lift thefixinghooks(6) safelyand removetheair pipes
(7) (seebox A).
- Unhook the spring (8), extract the bottom bellow
fastener, unscrew the screw (9) and turn the bracket
(10) upward.
- Turn the valve (11) on the supportingpipe and pull it
abovetheend of thesupportingpipe (12).
Refitting
reverseorder.
reverseorder.
Before fittingthe seat cushion, loosen thelocking
nut (8), adjust theflexiblecable (6) so that inthe
lowest positionoftheadjustment lever, thestiffest
vertical damping is reached, then retighten the
lockingnut. (8).
- Unscrew thebottomshock absorber fastener (4).
- Removethesupportingwasher (5) andtheflexiblecable
of thelever (6) out of thefastener (7).
Refitting
Afterfittingthenewparts,thehighest toothofthe
toothed segment (2) must adapt to the width of
the highest space of the toothed segment of the
valve(4).
77506
77507
Figure136
Figure137
Removing - refitting the height adjustment
valve
Afterfittingthenewvalve,thehighest toothofthe
toothedsegment (13) must adapt to the widthof
the highest space of the toothed segment of the
valve(14).
Removing - refitting theheight locking system
Figure138
90030
Removing
- Unscrew screws(1).
NOTE
NOTE
NOTE
- Unhook thecable (2) fromthe lever (3).
- Extract theflexiblecable(2) comprehensiveofthelever
(4) fromthe opening(5).
Refitting
reverseorder.
Removing
- Loosen theplastic covering(6) asdescribed above.
- Unscrew screw (7).
- Disconnect thehoses (3) (4) fromthecoupling(5).
- Unscrewthefixingscrews(1) anddisconnect theswitch
(2) for fast loweringfromits seat.
Refitting
reverseorder.
Removing-refittingthelumbar support device
77509
90031
Figure139
Figure140
Removing - refitting the fast lowering switch
Figure141
90032
Removing-refittingthefast loweringmagnetic
valve
Removing
- Loosen theplastic covering(1) asdescribed above.
- Disconnect thehoses(2) and(3) fromthevalve(4),the
hose(5) fromthecoupling(6) andthehose(7) fromthe
coupling(8) insidetheplasticcovering(1) (boxesA/B).
- Extract thefixingarm(9) ofthemagneticvalve(10)from
thetransverse pipe (11) andlift thevalve (10).
- Disconnect theelectric connector (12).
- Remove themagnetic valve (10) for fast loweringfrom
itsseat.
Refitting
reverseorder.
Removing
- Partiallyremove the backupholstery.
- Unscrew screws (3) and take the foamoff seat back
frame.
- Disconnect thehoses (1).
- Remove the lumbar support device (2).
Refitting
reverseorder.
90033
77513
Figure142
Figure143
Removing - refitting the back upholstery
Removing
- Takeoff thethreehoses and electric connection (1).
- Unhook theC-sections(1) (box A).
- Lift the lever (2) and unscrew the screw (3) fixingthe
seatbelt.
- Takeoff thefacing(6).
- Lift thebackupholstery(7) upwards off thefixingtapes
(4) (Velcro),
- Extract theseatbelt through theopening(5).
- Remove the upholstery(7) fromtheseat.
Refitting
reverseorder.
Removing - refitting the cushion upholstery
Removing
- Freetheupholsteryof thecushionof theseat (1) from
the edging(2) passingalongthe perimeter of theseat
bottom.
Refitting
reverseorder.
90035
Figure144
A.Height adjustingvalve- B. Pneumatic suspension - C. Magneticvalve for fast lowering- D. IPSvalves - E. Selector -
F. Foul air - G. Enteringair
90034
Figure145
DRIVERS SEAT PNEUMATIC DIAGRAM
90037
Figure146
A. Height adjustingvalve- B. Pneumaticsuspension- C. IPSvalves- D. Fast loweringswitch- E. Foul air - F. Enteringair
90036
Figure147
PASSENGERS SEAT PNEUMATIC SCHEME
86980
86981
87018
87019
Figure148
Figure149
Figure150
- control unit supplyvoltageequal to 24.1V;
- switch(1) ON (orangewarninglamp ON);
- thethermostat must benot inOFFposition(seefigure);
- the protection fuse available on the dashboard electric
panel must not beblown;
- thespacearoundtherefrigeratormust befreeenoughto
ensureventilation.
- Whenthecabinhasbeenlowered,maketherefrigerator
slideforwardbyactingonhandle (1).
- Disconnect electric connection (1).
- Removescrews(3).
- Takeoff refrigerator (2) withitsrespective guide (4).
Preliminary checks
If the fridge does not work or its inner temperature is not
enough, check the followingconditions prior to makingany
replacement or maintenancework:
OFFposition
A compressor protection device is available for
cabintilting,wherebytheinstalledrefrigeratorstops
working, for safety reasons, if the vehicle (either
stationaryor running) istilted bymorethan15 .
The refrigerator mayrun down the batterywhen
theengineis not working. When the batterylevel
falls too low, the refrigerator will switch off
automatically. Correct refrigerator operation is
ensuredonlywhen theengineis running.
Removal
- Detachment is accomplished by tilting over the cabin,
removingthesound-proofingpanel below,andtakingoff
thetwo refrigerator fasteningscrews.
Refitting
Refitting is carried out by reversing the order of
removingoperations.
STOP
1
NOTE
NOTE
CABIN REFRIGERATOR
86982
86984
86983
86985
86986
86987
Figure151
Figure152
Figure153
Figure154
Figure155
Figure156
Remove screws (1). Take threaded ring (2) out of the
connector.
Removeconnection(1) fromthe thermostat.
Fan removing
Overturn rear protection (1) as shown onthefigure, taking
carenot to applytensilestressto the thermostat probe (2).
Thefancan beremovedbytakingout screws(3).
Removeelectricconnection(1) fromthecontrol unit,taking
carenot to pull thecables.
Useascrewdrivertotakeout corehitch(1),thentakeoutthe
cablesoneat atime.
Removing the anti -tipping probe with
electronic circuit on the control unit
Removescrew(1).
Removing
2
1
1
1
2
3
1
1
1
OVERHAULING
86988
86990
86989
86991
86992
86993
Figure157
Figure158
Figure159
Figure160
Figure161
Figure162
Cut theplasticstrap (1) joiningthewiringon theelectronic
control unit front part.
Ta'o ooo-t||t|o obo c|co|t (+) oot o t|o coosso's
electroniccontrol unit.
Take off the connector (1) to which the probe cable is
secured. Now,theprobecanbetakenout throughthecore
hitch, thus avoidingconnector crawling.
Disconnect all electriccables (1) fromthecontrol unit. Take
out electroniccircuit (2). Removescrew(3).
Movethecontrol unit aside, then takeconnector (1) out of
thecompressor.
Checks
Checkpropertighteningofconnector (1) forconnectionwith
thefront switch.
Refitting
Assemblingis carried out byreversingtheorder of
disassemblingoperations.
Do not use blunt tools which could damage the
circuit inner face.
1
1
1
NOTE
Electronic control unit disassembling
85701
Figure163
Thepurposeoftheair-conditioningsystemistomakethecab
comfortableas regardsthefollowingparameters:
- temperatureandrelativehumidityof outsideair;
- temperatureandrelativehumidityinthe cab.
The system subjects the air to thermodynamic
transformations that affect its temperature, relative humidity
and purity. This isaccomplishedby:
- ventilation, or introducing air taken fromthe outside
(therefore with the temperature and humidity of the
surroundingenvironment) into thecab;
- air-conditioning, or cooling and de-humidifyingthe air,
withthepossibilityofheatingit afterwardsaspreferredso
asto changethetemperatureand humidityinthecab.
CABINTERNAL VENTILATION DIAGRAM
VENTILATION
Description
Ventilation is the function of drawingin fresh air fromthe
outside, cleaned of pollen and dust by a special filter, or
recyclingtheair inthecab.
This systemis composed of a shell, designed to house the
electric fan unit, air ducts, fresh air intake and recycled air
intake. The electric fan has several speeds to draw in and
circulatelargemassesof air.
General
CAB AIR-CONDITIONING
AIR-CONDITIONING AND HEATING
Description
Thisisaccomplished byintegratingan air-conditioningand a
heatingsystem.
Thisintegrationmakesit possible tochangethetemperature
and humidityinthecab.
Air-conditioning
Air-conditioningis accomplished bytakingadvantage of the
high capacity of some gases to lower temperature
considerablyin their phase of expansion, therebymakingit
possibleto absorbheat fromthecab.
Thisconditionisobtainedbytwo different levelsofpressure
(high, when therefrigerant fluidisinits liquidstate, and low,
whenthefluidisinitsgaseousstate) that areestablishedand
maintainedduringoperationof the system.
Heating
Heatingisaccomplishedbyaradiator, intheheater unit, in
whichtheenginecoolant circulates.
Special doors allow air to pass through the radiator only
whentheheatingfunctionis activated.
The main components of the air-conditioningand heating
systemcomprise:
- compressor;
- condenser;
- thedehumidifier filter (incorporatedinthecondenser);
- three-level pressureswitch;
- expansionvalve;
- evaporator;
- heater/fanunit;
- pollen filter.
Figure164
85702
Air-conditioning controls assembly
Manual
Heating and ventilation
1. Air temperaturecontrol knob,withextremepositionsto
cut in the HI and LO functions (max and min air
tooatoo/ too tot|o|ot o os| a| too tot|o||t
for warmair).
2. Electric fan knob with relative working speeds and
operationselection;
- off (0);
- manual operation (1-2-3-4).
3. Air inlet control knob:
- facezoneair;
- faceandfeet zoneair;
- feet zoneair;
- feet andwindshieldzoneair;
- windshieldzoneair.
4. Switchto turnonair recirculation: it prevents air flowing
infromoutside.
5. Switchto turnontheair-conditioner.
Legend
42045 Outside temperaturetransmitter
82000 Heater assembly
42608 Coolant pressureswitches
25332 Compressor insertionremotecontrol switch
84019 Compressor
86116 BodyComputer
72021 30-pindiagnosisconnector
Figure165
85703
Condenser
Drying filter
COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)
A. Recirculationgeared motor (Ric) - E. Evaporator temperaturesensor - F. Blownair temperaturesensor - G. Modulates
blower control - H. Expansion valve.
Figure166
85704
HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)
|os|t|oooo oo t|o oot o t|o vo||c|o (o|vo's s|oo) so as to bo aoctoo b a tooatoo c|oso to oa||t .
Figure167
77566
Figure168
77145
Compressor
The compressor is situated in theenginebaybetween theradiator fanandthealternator.
Outside temperature sensor
Figure169
The dehumidifier filter is integrated inthecondenser that is found on thefront of the vehicle.
The refrigeration systemusesR134afluidhighlighted onthe plateon its casing.
The safetypressureswitch assemblywithfour levels isfittedon thecondenser outlet pipe.
The two pressureswitches, whichare of theN/C and N/O type, makeit possibleto keep thepressure in the systemconstant
fromaminimumof 2.5 (N/O) to amaximumof 25bars (N/C); with valuesoutsidethis rangethesystemis deactivated.
Whereas,thetwopressureswitchesoftheN/O typeareusedtodisconnect theenginecoolingfancoil whenthesystempressure
isintheinterval 18 22bars.Thisisaccomplishedbyanearthsignal thatthetwopressureswitchessupplytotheBodyComputer
control unit.
77245
Figure170
77560 74247
Print603.93.371
Condenser and safetypressure switches
The recirculation reductionunit is locatedon Heater/Conditioner unit.
It is directlyactivatedbytheelectroniccentral unit with ratedvoltage (24V) and it has20 to 40mA absorption.
Maximumabsorption, on arrivingat endof stroke, reaches 200 mA at power supplyput off bythecentral unit.
Thepotentiometer it isprovidedwith isused for return signal and, on first power on, thecentral unit detectsandstores endof
stroke values used to split operationrange.
N.B. If thereduction unit isbeingreplaced, it is NECESSARY to RESET system.
Figure171
77571
Figure172
77573 77572
Pin-out
Stepper motors
PIN CABLECOLOUR SIGNAL
1 White +/- 24V
2 Purple +/- 24V
3 Blue 0V
4 Orange 0 5V
5 Green +5V
6 --- Free
Thesensor insidetheevaporatorcausesthecompressor to turnon andoff,allowingtemperatures from2 C (off) to3.5 C (on)
for VALEO and from5 C (off) to 10 C (on) for WEBASTO.
The figureshows the same characteristicsof theoutsidetemperaturesensor except for theconnection.
Figure173
77793
Figure174
Expansion valve
C
O
N
D
E
N
S
E
R
E
V
A
P
O
R
A
T
O
R
Theexpansion valveis thetypewith ablock, itsjob is
to lower the pressureof the fluid at the outlet of the
condenser (and therefore of the filter) to a pre-set
value so that the same fluid, circulating in the
evaporator, can bedrawn up bythecompressor in a
totallygaseous form.
It isthereforepossibletostatethat theexpansionvalve
fulfils threebasic functions:
S METERING
S MODULATING
S CHECKING
This is fitted on the Heater/Air-conditioner assembly
near theblower control module.
77575
Evaporator temperature sensor
86737
Figure175
Description
The auxiliaryheater works independentlyof theengine.
Its function is to heat thecabinonly.
Theheater isconnectedtothevehiclefuel tankandelectric
system, andislocated in thecabin.
Operation
Switch-on and switch-off can be done by means of digital
timer (4) or ambient thermostat (5).
Upon switching on, the warning lamp lights up and
combustionchamber (9) preheatingis started.
After approximately 30 seconds, pump (19) sucks the fuel
from the tank and sends it to felt (5) which acts as an
evaporator.
PARTSMAKINGUPTHE AUXILIARY AIR-TYPE HEATER
At the same time, fan (4) sucks, through pipe (20), the
external air and sends it, through passage (18), to felt (5),
whereair ismixedwiththefuel.
Heatingplug(6) triggers mixburning.
Duringcombustion, theflame licks exchanger (10). Fan (2)
sucks cold air fromintake (1) andsendsit to exchanger (1)
whichheats, byyieldingheat, theair sent to thecabin.
Whencombustionisover,photoresistor (7) cutsoffheating
plug(6) bymeans of control unit (12).
Whenthetemperatureexceeds the required value, asignal
sent by ambient thermostat (15) causes reduced-power
resistor (13) to come into operation: such resistor acts on
theheaterbyreducingtherevsnumberofengine(3) andthe
fuel pump rate.
Burnt gas are finally eliminated through silencer (17) and
exhaust pipe(16).
ADDITIONAL AIR HEATER SYSTEM(on request)
FAULT DIAGNOSIS
Inefficient electricsystem Checktheelectricsystem.
Compressor pullingbelt not in normal
workingconditions and inefficient
Check the belt: if it is too loose or
stretched, adjust it or, if necessary, re-
placeit.
Inefficient electromagnetic clutch coil. Check whether the coil receives cur-
rent. Replacethecoil, if necessary.
Systemdoes not work
Inefficient systemfittings and pipes. Check and replace, if necessary, defec-
tive parts.
Incorrect distance (play) between the
front disc and the electromagnetic
clutch.
Check the distance (play). Disconnect
thecompressorandadjust thedistance,
if necessary.
Inefficient compressor. Drainthesystemasdescribedintherel-
evant chapter; disconnect the com-
pressor and replace it.
Lowcompressor oil level. Drainand refill thesystemasdescribed
Lackof coolingfluidinthe system. Drainand refill thesystemasdescribed
clutch.
if necessary.
Noisysystem
Low amount of coolant in the system
(greensight glass).
Drainand refill thesystemasdescribed
Systemis not leak-proof. Use leak-detector 99051147 to check
thesystemandthecompressor;remedy
thecoolingfluidleaks (if any).
Electromagnetic clutch does not work
properly.
Check the clutch electric connections.
Replace the electromagnetic clutch, if
necessary.
Humidityinthesystem. Drainand refill thesystemasdescribed
(Continue)
Troubleshooting
Introduction
Diagnosis, i.e. locatingthetroubles that causeoperation faults inthesystem, makesit possibleto identify, byanalyzingthefault
found, thecauses and, therefore, ensureprompt and saferepair so as to restorethesystemto full efficiency.
Belowisthetroubleshootingguideforfaultsmainlyofmechanicandhydraulicnaturewhichcannot berecognizedbytheelectronic
control unit.
/s oaos t|o ao|t a|o| o o|oct|c aoo o|octoo|c oatoo, oso t|o | V|CC o|octoo|c o|aoos|s |ostooots '|ooos - |./.SY.
- |T 2000', b cooooct|o t|o |ostooot to t|o o|aoos|s ta'oo aoo o||o.|o t|o |ostoct|oos sto b sto, as o|s|aoo b t|o
instrument itself.
Loosecompressor fastenings. Checkandtightentotorquethescrews
and boltsfasteningthecompressor
Unusual noisewith clutchengaged
Inefficient electromagnetic clutch. Checkwhetherthefault isduetomech-
anicor electriccauses, thenact accord-
ingly.
Unusual noisewith clutchengaged
Lowcompressor oil level. Drainand refill thesystemasdescribed
Inefficient compressor. Drain the system and refill the com-
pressor.
Unusual noisewithdisengagedclutchor
vibrations
clutch pulley.
if necessary.
vibrations
Inefficient electromagnetic clutch sup-
plyelectric system.
Checktheelectricsystem.
Humidityinthesystem. Drainand refill thesystemasdescribed
High discharge pressure and normal
suckingpressureduetothepresenceof
air in thesystem.
Drainthecoolingfluid, replacethedry-
ingfilter,deaeratethesystem,thenrefill,
asdescribed in therelevant chapter.
Insufficient cooling
Highdischargepressureandlowsucking
pressure withpresenceof water or ice
onthedryingfilteror onthepipesfrom
thecondenser outlet to theexpansion
valve.
Drain the cooling fluid, eliminate the
throttlingor replace thefaultycompo-
nent,deaeratethesystem, thenrefill,as
describedinthe relevant chapter.
Normal discharge pressure and low/
high sucking pressure due to incorrect
electromagnetic clutch engagement/
disengagement.
Changethetrinarypressuregauge.
Inefficient electricsystem. Check the electric systemand replace
defectiveparts.
Irregular electricvoltage. (Operatingvoltage19.5V 5%).Charge
thebattery.
Incorrect operationof theheatingplug. Check the electric connections, the
control unit and the plug, then act on
faultyparts.
The heater goesto block Incorrect operation of the metering
o ato 30 socooos' o|oat|o.
Check the electric system, the control
unitandthemeteringpump,thenact on
faultyparts.
Incorrect operationoftheburningunit. Checktheburningunit andtheelectric
system.
The heatingplugis switched off within
thesafetytime.
Check and replace, if necessary, the
photoresistor.
Efficient thermal limiter. Checkthethermal limiter.
(Continue)
f (
Incorrect operation of the metering
pump.
pump.
Thefumeexhaust pipegetshot (heater
combustion)
Poor fuel pipe seal. Verifythatthefuel pipedoesnot leakor
isnot throttled.
Incorrect fuel connection. Checktheconnection.
f f
pump.
Checkthepump rate.
Heater getsstuckedafter briefcombus-
tion
Incorrect CO
2
value. Check the CO
2
value and replace the
burner, if necessary.
Inefficient, reduced power resistor. Inefficient electricsystem.
Inefficient photoresistor. Check the electric cables and verify
whether short-circuit occurs.
Irregular operation of the measuring
valve (after 30 seconds of pre-incan-
pump.
Checkandreplaceif necessary.
valve (after 30 seconds of preincan
descence)
Inefficient thermal limiter. Checkandreplaceif necessary.
Inefficient safetyswitch. Check current flow and replace, if
necessary.
Inefficient electricsystem. Check for breaks in electric cables and
fittings.
oat|o |o .oo't |o|to Inefficient heatingplug. Check and replace, if necessary, the
plug. Checktheambient thermostat.
Inefficient control unit. Checkthecontrol unit.
Heater not runningat full capacity. S.|tc| sot to 'ooocoo o.o' os|t|oo.
Heater does not yield enoughheat
Ambient thermostat not set to thede-
sired temperature.
Adjust theambient thermostat.
Inefficient electricsystem. Checktheelectricsystem.
Incorrect assemblyof fuel pump. Verifythat the fuel pump ispositioned
onthechassiswithaninclinationof 30
relativetothehorizontal planeandwith
thepower cablesfacingupwards.
Incorrect CO
2
(Carbondioxide) value
Inefficient silencer and fume exhaust
pipe.
Clean and verify that they are not
clogged. Replacethem, if necessary.
2
( )
Dirtyheat exchanger. Checkandcleantheheat exchanger.
Inefficient evaporatingfelt. Checkandreplace,ifnecessary,thefelt.
Incorrect meteringpumprate. Check the pump rate and adjust the
CO
2
value.
(Continue)
Inefficient safetyswitch. Checkthesafetyswitch.
Inefficient photoresistor. Check and replace, if necessary, the
photoresistor.
ff
Incorrect heater operating tempera-
ture.
Checktheambient thermostat and the
combustionair circuit.
Heater isswitchedoffduringoperation
due to afailure
Incorrect fasteningofheaterto thesup-
port.
Check the fastening bolts and tighten
themto torque.
Incorrect combustion. Checkandtroubleshoot.
pump.
pump.
Inefficient combustion air circuit. Checkthecombustion air circuit.
MAIN DATA
Coolingfluid Type R 134A
Amount of thesystemcoolingfluid
VEHICLE COMPRESSOR
R134 COULANT
QUANTITY PROVIDED
FORIN SYSTEM
COULANT
QUANTITY CONTAINED
IN THEPIPINGS
(150 cmlength)
THAT AREUSEDFOR
RECHARGING
COULANT TOTAL
QUANTITY TOBESET
ON CHARGINGTOOL
OILQUANTITY TOBE
ADDEDINTOSYSTEM
AT EACHND 8 TYPE
CHARGING
TRAKKERAT/AD DENSO10PA 17 700g
200gforlowpressure
pipe, 200gforhigh
pressurepipe
1000g 40g
COMPRESSOR NIPPONDENSO
Type 10PA 17
Number of cylinders 10
Bore mm 29.5
Stroke mm 6
Revsnumber:
max.
min.
rpm
rpm
9000
Coolant R 134a(ecology)
Typeof oil ND 8
ELECTROMAGNETIC CLUTCH
Revsnumber:
max.
min.
rpm
rpm
9000
Disengagingtorque kgm 4
Ratedvoltage V 24
Minimumengagement voltage V 7.5
Playbetween front discandpulley mm 0.4 0.8
AUXILIARY HEATER
Air-typeheater withburner Eberspcher
Type D3L
Ratedvoltage 24V
Calorific yield:
full capacity
reduced capacity
KW (Kcal/h)
KW (Kcal/h)
3.2
1.0
Permitted max. temperature at heater air inlet +40 C
Heatingair flow rateat 0.5 mbar:
full capacity
reduced capacity
m
3
/h
m
3
/h
160
65
GENERAL WARNINGS
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
GASPIPESFITTINGS
5/8' - +8 ||| 15.9 1.6
3/+' - +8 ||| 15.9 1.6
+' - ++ ||| 29.8 3
86739
Figure176
Make sure that replacement parts (filter, condenser,
evaporator,pipesandfittings) aresuppliedcompletewiththe
protectioncapsagainst dirt andmoisture.
Thesecapsmust beremovedonlywhen thepart isreadyto
beinstalled.
Coossos aoo, soot|os, oc|aoos aoo ||tos, too
ao oo||vooo .|t| s|||t |otooa| osso|zat|oo, to ovoot
moisture penetration.
Verifythat gas escapeswhen the protectioncapis opened:
thiswill provethat thecomponent hasbeenstoredcorrectly.
Make surethat thepipe connections, both to one another
andto othercomponents, aremadeso astoensureperfect
tightnessofthesystem. Coolingfluidleaksdonot onlycause
systemstoppage, but also fast compressor wear.
Therefore,youshouldcheckthepresenceoftheseal ringon
thefittingmaleportion: moistenwith oil, thesameusedfor
thesystem(bearinmind,inanycase, that it differsaccording
to thetypeof coolant), andavoid, when assembling,making
cutsorburrsbetweenthecouplingsurfaces,whichcausegas
leaks.
Followtheinstructions below.
Manuallyandcarefullyinsert themaleportionintothefitting
female drill until collar (2) comes into contact with the
correspondingmetal seat in the female.
Suchcontact ensuresmechanicsupport tothepipe:seal ring
(1) pressedbetweentheinternal cylindrical portion andthe
drill provideshydraulic seal.
Do not use oversized-diameter or twin seal rings: they
temporarilyperformhydraulic seal, yet prevent the contact
betweenthemetal seats, causing,after ashort period,fitting
looseningand gas leaks.
When disconnecting the system pipes, plug the
pipes and the coolant passages (if any), so as to
avoid possible moisture or dirt penetration inside
thesystem. Thiscan badlyaffect correct operation
of thesystem.
NOTE
- Unscrewthescrews(2) fixingtheheater (5) tothecross
member onthecab.
- Detach the clamps(1) of thewiringbundles.
- Disconnect the connectors (4) and detachthe relative
electric wiring(3).
- Detachtheheater (5) fromthevehicle.
77122
77124
Figure177
- Workingfrominside the cab, unscrew the screws (1)
fixingtheair ducts (2) to the heater (3).
- Disconnect theair ducts (2) fromtheheater (3).
553210 HEATER
Removal
For disconnectingheater assembly, it is needed to:
- For vehicleswith air conditioner:
position the keyof ignition b|oc' to'|o Co' os|t|oo
aoo s.|tc| a| tooatoo to '|C\'.
- For vehicleswithout air conditioner:
fromtheinsideofthecab,turntheknobforadjustingcab
heating temperature so as to completelyopen engine
coolant tap.
- partiallydrainengine coolant.
- detachthefasciacovering(552211).
- Lift theradiator cowling.
- Unscrew the fixing screws (1) and separate thepollen
filter cover (2) to access theunderlyingfasteners.
Figure178
77123
If the cab isprovided with air conditioner, blow gas off cab
air conditioningsystem, as describedinrelatingchapter.
Figure179
Figure180
77125
Refitting
For reconnection, invert operations described for
disconnection, observingfollowingwarnings:
- tightennutsor screws at prescribedtorque;
- theenginecoolant is at theright level;
- the systemand components involved in the described
procedurework properly.
- if present, fill air conditioner systemas described in
relatingchapter
- Unscrew screws (4) securing low and high pressure
piping(5).
- Remove screws(3) near water pipings.
- Screws(3) near thewater pipes.
- Applyspecial plugsonthehigh andlow pressurepipes
and on theexpansionvalve.
NOTE
Seal air conditioning systempipings to prevent
moisture or impuritiesfromenteringthesystem.
NOTE
This operation must be carried out only by
authorized, qualifiedskilledpersonnel.
REPAIR OPERATIONS
- Disconnect theelectrical connection(4).
- Loosenclamp(1) andreleasepiping(2) fromheater (3).
- Disconnect additional heater (3) fromthecab.
77126
Figure181
Removal
- Lift theradiator cowling.
- Tilt upthecab.
- Unscrewthescrews(7) oftheclamps(6) anddisconnect
thefuel pipe(5).
- Unscrew thescrews (1).
- Disconnect the clamps (2) and detach the inlet and
outlet pipes(3).
- Unscrewthenuts(4) fixingtheadditional heatertothe
floor of thecab.
- Lower thecab.
- Closetheradiator cowling.
- Operatefrominsidethecab,advancepassengerseatand
tilt back rest.
99140
Figure182
Refitting
Refit bycarrying out the procedures described for
Figure183
- Take off object holder box, unscrew securingscrews,
removetheBodyControl andput asideasinFigure 90.
- Disconnect thepower supplyconnector (2).
- Unscrew thefixingscrews (1).
- Detach the air recirculationdoor control motor (3).
553153 AIR RECIRCULATION DOOR
CONTROL MOTOR
77131
Removal
Refitting
To perform interventions on below described
components, it could be necessary, owing to
difficult access to components, to take off the
coatings of dashboard (Op. 552211) and heater
(Op. 553210).
NOTE
507570 ADDITIONAL AIR HEATER SYSTEM
77137
Before proceeding to detach the heater radiator, it is
necessaryto:
- For vehicleswith air conditioner:
os|t|oo t|o 'o o |o|t|oo b|oc' to|o Co' os|t|oo aoo
s.|tc| a| tooatoo to '|C\'.
coolant tap.
- Partiallydrainengine coolant.
- Detach the pollen filter and cover (Figure195).
- DetachBodyControl as indicated on Figure90.
- Detach the bottom covering of the fascia on the
passenger side.
- Detachtwo passenger air openings.
- Detachtheairdeliverypipefromthecentral bodytothe
rh door opening.
- Disconnect the retaining clamps (1) and separate the
water pipes(2).
553215 HEATER RADIATOR
Removal
Refitting
77136
- Detach the electric fan (1) fromits seat.
Figure184
Figure185
77135
Figure186
Removal
Performtheremoval procedure:
- Central instrument panel (OP. 553710).
- Disconnect theconnector (2).
- Takeoffthefixingclips (1), unscrewthescrews(3) and
detachthecovers (4) and(5).
553212 ELECTRIC FAN
Figure187
77138
- Operatingthroughthecontrol unit compartment at the
bottomof the fasciacovering, unscrew the screw (2)
fixingtheclevis (1) andfreetheheater water pipes (3).
77140
- Detachtheconnectors(1),(2) indicatedtofacilitatethe
outflow fromtheheater radiator.
Refitting
For reconnection, invert operations described for
disconnection, observingfollowingwarnings:
Figure188
77139
- Detachtheconnectors(1),(2) indicatedtofacilitatethe
outflow fromtheheater radiator.
- Takeoff theclipsanddetach the pipe(3).
- Unscrewthescrews(4) fixingtheradiatorto theheater.
Figure189
Figure190
77141
- Extract theheaterradiator (1) withduecautionfromthe
glovecompartment bay.
553216 TAP
Removal
77137
Figure191
Before proceeding to detach the heater radiator, it is
necessaryto:
- For vehicles with air conditioner:position the key of
|o|t|oo b|oc' to|o Co' os|t|oo a oo s.|tc| a|
tooatoo to '|C\'.
coolant tap.
- Partiallydrainengine coolant.
- Detach the pollen filter and cover (Figure195).
- DetachBodyControl as indicated on Figure90.
- Detach the bottom covering of the fascia on the
passenger side.
- Detachtwo passenger air openings.
- Detachtheairdeliverypipefromthecentral bodytothe
rh door opening.
- Disconnect the retaining clamps (1) and separate the
water pipes(2).
Figure192
90040
- Unscrew screws (1), take off pressure button, and cut
checkstrap (3) andtakeoff thepipingfor air duct (2).
Figure193
77138
- Operatingthroughthecontrol unit compartment at the
bottomof the fasciacovering, unscrew the screw (2)
fixingtheclevis (1) andfreetheheater water pipes (3).
Figure194
90041
- Lift fastener (2) anddisconnect piping(3) fromradiator
(1).Byspecial pliers,pressfins(5) anddisconnect tierod
(4). Removescrews andtaketap(6) off the heater.
Refitting
Refit bycarryingout the proceduresdescribed for removal
inreverse order.
77142
Figure195
553261 POLLEN FILTER
Removal
- Lift the cowling, lift cover (1) and remove anti-pollen
filter (2).
Refitting
Figure196
90042
- Discharge the air-conditioningsystembyfollowingthe
proceduredescribedunder therelevant heading.
- Working fromunder the vehicle, unscrew the fixing
screws (2) and remove the inlet and outlet pipes (3)
fromthecompressor.
553239 AIR-CONDITIONER
COMPRESSOR
Removal
- Detach the outsideair temperature sensor (1) fromits
seat.
- Lift the cowling and bleed air-conditioning system
observing the procedure that is described in relating
chapter.
- Unscrewthenut (6)anddetachthecondenserpipes(5).
- Unscrew thenut (4) fixingthepipebracket (3).
- Unscrew the fixing screws (1) and remove the
condenser (2) fromthevehicle.
77146
Figure197
Removal
77147
- Lift theradiator cowlingand disconnect theconnector
(1) and free the wiring (2) of the sensor (3) fromthe
retainingclamps(4).
553232 AIR-CONDITIONER
CONDENSER
553242 OUTSIDE AIR TEMPERATURE
SENSOR
Removal
Figure198
Figure199
77148
Refitting
- Loosen the automatic tightener and take off the
compressor belt.
- Disconnect thepowersupplyconnector (1,Figure 196).
- Unscrew thefixingscrews (5, Figure196).
- Takecompressor (4, Figure196) off theengine.
Seal air conditioning systempipings to prevent
moisture or impuritiesfromenteringthesystem.
NOTE
Refitting
Replacethesealinggasket.
Tightenthefasteningscrewsandtheadapterstothe
specified torque.
Fill air conditioner systemas described in relating
chapter.
Refitting
Replacethesealinggasket.
Tightenthefasteningscrewsandtheadapterstothe
specified torque.
Fill air conditioner systemas described in relating
chapter.
543921 REPLACING THE ELECTROMA-
GNETIC CLUTCH
Figure200
39852
Stop front disc (1) rotation, then unscrewretainingnut (2)
and removethe spacer below.
Figure201
39854
Usespecial rounded-tipplierstoremovepulley(2) retaining
snap ring(1).
39855
39915
39856
Figure202
Figure203
Figure204
Use extractor 99341001 (1), equipped with brackets
99341009 (2), to takeout pulley (3).
Remove the plate fastening screw with the envelope from
thecompressor.
Loosen screw (4), thus releasing magnetic coil (1) supply
electric cable(3).
Usespecial rounded-tippliersto removeretainingsnap ring
(2) and takeoff magneticcoil (1).
Placethenewmagneticcoil (1) inposition,so that centering
pin (2) engages into therespective hole (3).
39916
39917
39852
Figure205
Figure206
Figure207
Fit retainingsnapring(2). Tightenscrew(3),thensecurecoil
(1) supplyelectriccable(4) to thecompressor body.
Mount pulley (2), then retainingsnap ring(3) and adjusting
shim(1).
Mount front disc(1),stoprotation,thentightenretainingnut
(2) to atorqueof 35 40Nm(3,5 4Kgm).
39919
39920
Figure208
Figure209
Check, by means of a thickness gauge (3), that the play
between front disc (1) and pulley(2) is0.4 0.8 mm.
Iftheclearancebetweenthefrontdiscandthepulleydoesnot
correspondtotheprescribedvalue,removethefront discand
replace the adjustingring (1) with one having the suitable
thickness.
PROCEDURE FOR DRAINING AND
RECHARGING AIR CONDITIONING
SYSTEMS WITH RECHARGING STATION
99305146AND RECOVERY OF R134A
COOLANT
Thisstation hasbeenmadeto be used onall air-conditioning/
heatingsystems for motor vehiclesusingR134A gas.
Byconnecting the station to a refrigeratingsystemthe gas it
contains can be recovered, cleaned and made ready to be
reloaded into the system or be transferred to an external
container.Inaddition,itispossibletoseetheamountofoiltaken
o t|o ssto, ostoo |t aoo 'ot' t|o ssto.
To be operative, thestationneedsto absorbapproximately3
kgof refrigerant.
For prompt useit is advisedto haveat least 2kgof refrigerant
inthefiller cylindersandtokeepthestationaslevel aspossible.
Thestationiscomposed of:
1 control panel;
2 container to restoreanyoil recovered whenunloading;
3 flexiblehoses;
4 container to collect anyoil recoveredfromthesystem;
5 filler cylinder withgraduated scalerevolving.
Figure210
1
2
3
4
5
50631
This procedure does not describe the phases of
loading and unloading refrigerant to and from
external and internal containers or maintenance.
Therefore, please refer to the operating and
maintenance manual oftheappliance.
NOTE
A Aquila Trucks Centres
- never expose the unit or operate it in acidic or wet
environmentsorclosetoopencontainersofinflammable
substances;
- theunit must operateinplaceswith goodventilation;
- never alter thesettings of the safetyvalves and control
systems;
- neverusebottlesorotherstoragecontainersthatarenot
approvedand arenot fitted withsafetyvalves;
- never load any container over 80% of its maximum
capacity;
- never leave the unit powered if it is not to be used
immediately. Cut off themains power supplywhen it is
not plannedto usetheequipment.
SAFETY STANDARDS
- always wear gloves and goggles when working with
refrigerant gases. Contact of refrigerant liquid with the
eyes cancause blindness;
- avoid all contact with skin (low boilingpoint -30 C can
causefrostbite);
- never inhalethevapoursof refrigerant gases;
- beforeconnectingthestation withasystemor external
container, checkthat all thevalvesareclosed;
- beforedisconnectingthe station, checkthat the cycleis
over and all the valves are closed. This will prevent
dispersingrefrigerant gasinto theatmosphere;
The station is equipped with special fittings to avoid
contamination with systems using R12. Do not attempt to
adapt this unit for usewithR12.
This station is exclusively for professionally trained
operators who must be familiar with refrigerating
systems, refrigerant gasesandthedamagepressurized
equipment cancause, therefore:
!
FILLER CYLINDER
OIL TANK
Figure211
Figure212
50634
50632
CONTROL FASCIA
M1 Lowpressuregauge
M2 High pressuregauge
M3 Filler cylinder pressuregauge
LOW Low-pressurevalve
HIGH High-pressurevalve
REF Refrigerant filler anddrainvalve
V1 Valveonlow-pressurepipe
V2 Valveonhigh-pressurepipe
V3 Oil injectionvalvefor A/C system
V5 Oil drainage valve
V9 A/C systemwashingrefrigerant servicevalve
10 Moistureindicator
VS Safetyand drainagevalve
L3 Alarmwarninglight
L4 Maximumlevel warninglight
L5 Minimumlevel warninglight
A Unit process / bottleheater switch
LA1 Unit processindicator light
LA2 Bottleheater indicator light
B Refrigerant process / vacuumprocessswitch
LB1 Refrigerant process indicator light
LB2 Vacuumprocessindicator light
C Recoveryrecyclecycle / Fillingswitch
LC1 Recoveryrecycle cycleindicator light
LC2 Fillingindicator light
D Vacuum/ vacuumtest switch
LD1 Vacuumindicator light
LD2 Vacuumtest indicator light
Control fasciadiagramlegend
Filler cylinder legend
1 Pressure values in bar (vertical lines, revolving top
cylinder).
2 Weight of load in grams (oblique lines, revolving top
cylinder) 50 gdivisionbetween lines.
3 Tanklevel viewer (internal cylinder).
Drainoff oil
fromthesystem
Preparingthestation
First recovery
Wait 3-5 minutes
Second recovery
Operateonthesystem
Vacuumfor 5-10minutes
withfirst vacuumtest
Vacuumfor 30minutes
withsecondvacuumtest
Load oil
into thesystem
Loadupto 200g
refrigerant
Search for leakagewith
electronic leak finder
Fullyload
thesystem
Searchsystemfor leakagewith
electronic leak finder
Pressurecheck
Arethevalues
acceptable?
Disconnect thestation
fromthesystem
NO
NO
YES
YES
NO
NO
YES
YES
YES
NO
Is thereany
leakage?
Is thereany
leakage?
Is thereany
leakage?
Is thereany
leakage?
OPERATION FLOW CHART
RECOVERING REFRIGERANT
FROM THE VEHICLE SYSTEM
Before starting to disconnect the pipes from the
air-conditioner,checkwhether it ispossibletodotherepairs
without dischargingthegas.
Ifthisisnotpossible,thefollowingoperationsmust becarried
out:
- connectthepipemarkedHIGHunderthepressuregauge
to theevaporator inlet (theinlet isthe oneon the
pipe with a smaller diameter (H) connecting the drier
filter withtheevaporator);
- connectthepipemarkedLOWunderthepressuregauge
totheevaporatoroutlet(theoutletistheoneonthepipe
withalargerdiameter (L) connectingtheevaporatorwith
thedrier);
- open thevalvesV1and V2;
- open theLOW andHIGH cocks;
Figure213
77049
If the refrigerant reaches the maximum level
(maximumlevel indicatorlightL4on),therecovery
cycle must be stopped immediately by pressing
switch C onto position 0 and transferring the
refrigerant from the filler cylinder to a suitable
external bottle.
- put the switchesA, BandC backontoposition 0;
- closetheV1, V2, LOW andHIGH valves.
- connectthestationtotheelectricitymains(220V-50Hz);
- press theswitch A (Process Unit) onto position1.
Therespectiveindicator light LA1 will comeon;
- presstheswitchB(Refrigerant Process) onto position1;
- therespectiveindicator light LB1 will comeon;
- press theswitch C (RecoveryRecycle) onto position 1.
The recovery and recycling operation will start
automatically.Therespectiveindicator light LC1will come
onto signal theoperationinprogress.
On completing this operation the unit will automatically
stop and the indicator light LC1 go out. Wait for a few
minutesso that anypocketsofrefrigerant at lowpressure
remaining in the systemcan increase their pressure, by
absorbingheat, and beable to berecovered. Thestation
will automatically repeat the recoverycycle if the above
conditionsoccur;
- Continuetheoperationsfollowingtheinstructionsgiven
onthefollowingpages.
Figure214
50636
NOTE
- connect thepipestothespecificsystemconnectionsand
open theV1-V2/LOW and HIGH valves;
- press theswitchA (Process Unit) onto position1.
Therespectiveindicator light LA1 will comeon;
- press theswitchB (VacuumProcess) onto position 2.
Therespectiveindicator light LB2 will comeon;
- presstheswitchD(Vacuum) ontoposition1.Thesystem
willautomaticallystartbeingevacuatedandtherespective
indicator light LD1 will comeon to signal theoperation
inprogress.
CREATING A VACUUM IN THE SYSTEM
This operation should be carried out if all the repairs have
been performed and the systemcomponents have been
properlyrefitted.Thisoperationisthephasepriorto refilling,
thereforeproceed as follows:
Afterafewminutesofoperation(10atmost) ifthesystem
hasno leakstheindicator light LD2VACUUM TEST will
also come on. Fromthis time on, evacuation should be
continued for at least two hours to obtain a good
evacuation;
- at theendof thetimeprogrammedfor evacuation,press
theswitchD(vacuumtest) ontoposition2andleavethe
systeminthisstatefor 3-5minutes.
The indicator light LD2 VACUUM TEST is on if the
systemhasagoodseal.TheindicatorlightLD2VACUUM
TEST goes out if there is aleak. Eliminate the leak and
repeat theevacuationcycle;
- put the switches D and B back onto position 0 and
proceedwiththefollowingphase.
Figure215
50637
Do not run the vacuumcyclewhen thereiseven
minimal pressureinthestationor system.
Theindicator light LD2vacuumtest failsto come
onifthereisaleak. Stopevacuation,eliminatethe
leakandrepeat theevacuationprocedure.
NOTE NOTE
It ispossiblethat at theendofeachrecoverycyclethestation
may have recovered lubrication oil from the compressor,
whichshouldbedrainedoffintoaspecificgraduatedcontainer
(1).
1 Slowlyopen thevalveV5 (Oil Discharge).
2 Whenall theoil hasbeendischargedintothecontainer (1)
closethevalveV5.
3 Quantifyandrecordtheamount ofoil discharged.
4 Eliminate therecoveredoil correctly.
Thisoil cannot bereused.
Thesameamount of newoil as hasbeen removedmust
beadded tothesystem.
Figure216
1
50638
RESTORING OIL IN THE SYSTEM
Ifduringtherecoveryandrecyclephase, oil fromthesystem
hasbeenremoved, it must nowbereplenished:
- takethemeteringdevicesupplied withtheright amount
of lubricant for the system concerned, or previously
measured;
- connectthemeteringdevice(1) tothelubricant injection
valve V3;
- openthevalveV3andthencarryout thesystemvacuum
phase for afewmoments;
- open the valve mounted on the metering device
container (1). Theoil will bedrawn into thesystem;
- closethevalveV3andthevalveonthemeteringdevice
container when the required quantity of lubricant has
beendrawnin;
- disconnect the metering device (1) fromthe injection
valve V3and fit theprotectivecap backon;
Figure217
- never open the oil injection valve V3 if the systemhas
positivepressure;
- oil should onlybeinjected withavacuuminthesystem;
- theoil level must never fall under the suction pipe (air
wouldget into thesystem).
1
50639
Keeptheoil containerswell sealedinordertoavoid
contamination. In particular, remember that oil is
extremelyhygroscopic:
NOTE
FILLING THE SYSTEM WITH
REFRIGERANT
Beforerefilling,it iswisetobeawareofsomeimportantrules:
- know the quantity of refrigerant to use (it is normally
writtenonanadhesiveplateaffixedon thevehicle);
- thefillercylinder isequippedwithaminimumlevel check
that prevents introducing incondensable gas into the
system.
Thisiswhythelast approx.600gofrefrigerant it contains
cannot beused;
- therefore, before filling, check that the cylinder contains
asufficientquantityforfilling(maximumquantitythat can
beused 3800g);
- if the pressureinside thefiller cylinder indicated on the
pressuregauge(2) isgreater thanasrequired, whichcan
beseenonthefillercylinderwindowapprox.10barmax,
dischargethe excess pressure through the valve (1) on
thepressuregaugeassemblytobringit downtotheright
level, readingthevalueon thepressuregauge.
Figure218
2
1
50640
To transfer refrigerant froman external bottleto
the filler cylinder and vice versa, refer to the
equipment manual.
Considering that the amount of refrigerant
dependsonitspressure, toknowtheactual weight
it is necessary to turn the outside of the filler
cylindersothelineofthediagrammatchesthelevel
viewer.Inthiswaywecanknowtheexact quantity
of refrigerant inthecylinder (startingweight).
Whencalculatingtheweight of therefrigerant, in
addition to the 600 g that cannot be used,
remember to increase the load byapproximately
100g(thisistheweight ofrefrigerant containedin
the station-systemconnecting pipes). The right
quantityofrefrigerant tointroduceintothesystem
willthereforebegivenby:600g+100g+(quantity
referredto thesystemcapacity).
Alwayscheckbeforefillingthattheindicatoronthe
'cooso|o' s|o.s t|o o|oaot coota|os oo
moisture, inwhichcasetheindicator will bebright
green. If this is not so, replace the filters in the
stationasinstructedintheequipment manual.
NOTE
Whenthecylinder contains the necessaryquantityfor filling
(both pipes must already be connected to the system
connectors since the vacuumoperation has already been
performed), proceedasfollows:
- closetheLOW valve,keeptheHIGH andV1- V2valves
open;
- presstheswitchB(Refrigerant process) ontoposition1,
theindicator light LB1will comeon;
- press the switch C (Charge) onto position 2, the
respectiveindicatorlightLC2willcomeonandrefrigerant
will flowfromthestationintothesystem;
- havingloaded 200 500 gof refrigerant, dependingon
thesizeofthesystem, stopfillingbymovingtheswitchC
(Charge) onto position0;
- check thesystemisproperlysealed with theelectronic
leakfinder;
- complete filling the system until the pre-calculated
residual weight inthecylinder isreached;
(Residualweight=Total weight-Systemcapacityweight)
- complete filling, move the switches C - B and A onto
position0(A hadbeen movedfor thevacuum).
Check againthereis no leakage;
- closetheHIGH valve.
Figure219
50641
Whenfilling, ifthelevel of refrigerant inthecylinder
fallsundertherequiredquantitythesystemwill stop
andtheMinimumLevel indicator light(L5) will come
on.
NOTE
OPERATIONS PRIOR TO DISCONNECTING
THE STATION FROM THE SYSTEM
Alwaysobservingtheabovesafetyrules,carryout thefollowing
operations:
- checkthat all thevalvesareclosed:LOW - HIGH,V1- V2;
- disconnectthepipesofvalvesV1- V2andputthecapsback
onto thesystemvalves;
- Check thesystemagainwiththeleak finder.
CHECKINGTHEPRESSURESIN THESYSTEM
After filling, leave the pipes connected and carry out the
followingcheck:
- closetheHIGH andLOW valves, V1and V2open;
- turnontheengine,switchontheair-conditioner andcheck
on the pressure gauges M1 and M2 that the pressures
correspond,normally: lowpressurenolessthan1bar,high
pressure 15 18 bar, depending on the system
specifications.
Figure220
50642
Normally, withtheair-conditionerswitchedon,air
should come out of the vents at a temperature
lowerthan5 C andafteraperiodof operationto
stabilizethe temperatureoftheducts.
NOTE
Figure221
This procedure does not describe the charge/drain
phases of coolant frominternal/external tanksandit
does not provide indications on maiintenance
interventionsrequired.
For theseoperations, pleaserefer to theequipment
supplier useand maintenancemanual.
NOTE
115615
1.Serial port - 2. TVtemperatureprobe connector - 3. Electrical probeconnector - 4. Handle- 5. Tracer container -
6. New fluid container - 7. Fluid scales- 8. Usedfluidcontainer - 9. Taps- 10. Control console- 11. Dehydratingfilters-
12. Moisturegauge- 13. Master switch - 14. Fuse- 15. Electric plugsocket - 16. Fluidcontainer flap- 17. Vacuumpump -
18. Electronic scale- 19. Heater coil - 20. Cylinder
Tobeoperative, thestationneeds to absorb approximately
3kgof refrigerant.
Forprompt useit isadvisedtohaveat least2kgofrefrigerant
inthefillercylindersandtokeepthestationaslevel aspossible.
Thisstation hasbeenmadeto be used onall air-conditioning/
heatingsystems for motor vehiclesusingR134A gas.
Byconnecting the station to a refrigeratingsystemthe gas it
contains can be recovered, cleaned and made ready to be
reloaded into the system or be transferred to an external
container.Inaddition,itispossibletoseetheamountofoiltaken
o t|o ssto, ostoo |t aoo 'ot' t|o ssto.
Main components
PROCEDURE FOR DRAINING AND
RECHARGING AIR CONDITIONING
SYSTEMS WITH RECHARGING STATION
99305148AND RECOVERY OF R134A
COOLANT
- always connect the pipe with the RED machine quick
couplingto theA/C systemhigh pressurebranch.
Always connect thepipe withtheBLUEmachinequick
couplingto theA/C systemlow pressurebranch.
Keep the connection pipes far away frommoving or
rotatingobjectsor parts(coolingfan, alternator etc.).
Keep the connection pipes far awayfromhot items or
parts(engineexhaust pipes, radiator etc.);
- always fill the A/C system with the amount of fluid
recommended bythemanufacturer.
Never exceedthis amount. Alwayscheck thefluidlevel
beforeeachoperation.
Alwaysaddthe correct amount of fluid.
Check the electric mains is 220-240V/50Hz before
connectingthemachineto themains;
- thecylinder must befilledto 80%of maximumcapacity
to leaveagasreserveto absorb anypressureincreases.
Never touchtheinternal cylinder taps.
Dispose of fluid extracted fromthe A/C systemand
vacuumpump inspecial wastefluidcontainers.
Change the filters at the required intervals using only
filtersrecommendedbythemanufacturer.
Only use fluids recommended by the manufacturer.
Neverswapthevacuumpumpfluidwithairconditioning
systemfluid.
Anyguaranteesonthemachinewill benullandvoidifthe
abovesafetyrulesarenot complied with.
SAFETY STANDARDS
- always wear gloves and goggles when working with
refrigerant gases. Contact of refrigerant liquid with the
eyes cancause blindness;
- avoid all contact with skin (low boilingpoint -30 C can
causefrostbite);
- never inhalethevapoursof refrigerant gases;
- beforeconnectingthestation withasystemor external
container, checkthat all thevalvesareclosed;
- beforedisconnectingthe station, checkthat the cycleis
over and all the valves are closed. This will prevent
dispersingrefrigerant gasinto theatmosphere;
- never expose the unit or operate it in acidic or wet
environmentsorclosetoopencontainersofinflammable
substances;
- theunit must operateinplaceswith goodventilation;
- never alter thesettings of the safetyvalves and control
systems;
- neverusebottlesorotherstoragecontainersthat arenot
approvedand arenot fitted withsafetyvalves;
- never load any container over 80% of its maximum
capacity;
- never leave the unit powered if it is not to be used
immediately.
Cut offthemainspowersupplywhenit isnot plannedto
usetheequipment;
This station is exclusively for professionally trained
operators who must be familiar with refrigerating
systems, refrigerant gasesandthedamagepressurized
equipment cancause, therefore:
!
114767
Figure222
1. Keypad - 2. AlphanumericLCD - 3. Printer
Keypad functions
STOP: Usethiskeytostopthecurrent operation(recovery
- drainfluid - empty- add fluid - fill).
Press the START keyagainto start again fromthe previous
point.
ThehornisswitchedoffiftheSTOPkeyispressedduringan
alarm, anerror or at theend of anoperation.
ENTER: This key confirms the procedure or operation
flashingontheLCD.
: This keyisusedto movefromoneproceduretoanother
or fromoneoperationto another, fromtopto bottom.
: This keyisusedto movefromoneproceduretoanother
or fromoneoperationto another, frombottomtotop.
START: This key activates the confirmed procedure or
operation.
PressSTARTonlywhenrequestedtobytheLCD). NOTE
CYLINDEREMPTY ALARM: displayedandemitsanacoustic
alarmwhen too little coolant is present insidethecylinder.
NEW FLUIDCONTAINER ALARM: displayedandemitsan
acoustic alarmwhen the volume of new fluid drops below
approximately 50 cm
3
.
USED FLUID CONTAINER FULL ALARM: displayed and
emitsanacousticalarmwhenthevolumeofusedfluiddrops
exceedsapproximately200 cm
3
.
LEAKS IN A/C SYSTEM ALARM: displayed and emits an
acousticalarmafterthefirst 10minutesofvacuumifthereare
leaksintheA/C system.
Detectionof micro-leakscannot beguaranteed. NOTE
Emergency warning light panel
HIGHPRESSUREALARM: isdisplayedandemitsanacoustic
signal whenfluidpressureinthecircuit exceeds 17.5 bars.
Therecoveryoperationisautomaticallyhalted.
CYLINDER FULL ALARM: displayed and emits an acoustic
alarmwhen more than 80% of the maximumcapacity is
present in thecylinder, i.e. 9.5 kg.
RECOVERY operationisautomaticallyhalted (to cancel this
alarm, one or more A/C systems must be charged before
recoveringmorecoolant).
SERVICE ALARM: displayed and emits an acoustic alarm
when 150kgof coolant arerecovered.
To deactivate, replacethefiltersandvacuumpump fluid.
Together withthefilters, acodewill besent toeliminatethe
alarm.
CONTROL PANEL
Checkthat theswitch (13, Figure221) is in position 0.
Check that all the machinetapsareclosed.
Connect the machineto themainsand turnon.
Checkthatthepumpfluidlevel gaugeindicatesatleasthalffull.
If thelevel islow, fuel must beadded.
Checkthe additional fluid container (6, Figure221) contains
at least 100cm
3
of fluid.
Check the machineLCD to ensure the cylinder contains at
least 3kgof coolant.
Ifnot,refill theinternal cylinder usinganexternal cylinderwith
appropriatecoolant.
AUTOMATIC PROCEDURE
All the operations are carried out automatically in the
automatic procedure: recovery and recycling, fluid drain,
vacuum, additionof newfluidand refilling.
Theamount of gasrecovered, recoveredfluid, vacuumtime,
fluid added and the amount of gas injected are printed
automaticallyat theendofeachindividual operation.
Connect the hoses to the A/C system using the quick
couplings, takingcareto connect theBLUEhose to thelow
pressure branch and the RED hose to the high pressure
branch.
If thesystemis equipped with asinglehigh or low pressure
quick coupling, onlyconnect therelevant quick coupling.
Check that thehighand lowtapsareclosed.
Turn on the vehicle engine and air conditioner for 5-10
minutes, keepingthepassenger compartment fanrunningat
maximumspeed.
Turnoff thevehicleengine.
The instrument has a four-row display with up to 20
characters per row.
Theselected itemflashes ontheoption menus.
It isindicated betweeninvertedcommas inthismanual.
AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
NEXT MENU
AVAILABILITY XXXX G
VACUUMXX MIN
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
ENTER
Followtheautomatic procedure, i.e. pressENTERwhenthe
ossao '/otoat|c ocoooo' |as|os oo t|o |C|.
<VACUUMXX MIN. >
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
2
0
<VACUUM20 MIN. >
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
Enter thevacuumtimeor confirmthe previoustime. Simply
pressENTERtoconfirmtheprevioustime.Usekeys0-...-9to
set anewtime.
<VACUUM20 MIN. >
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
VACUUM20MIN.
<AUTOMATIC FLUID >
FLUIDXX CC
FILLINGXXXX G
ENTER
Once the vacuumtime has been confirmed, the message
'/otoat|c |o|o' bo|os to |as|.
Press ENTER to confirm.
PRELIMINARY CHECKS
<VACUUM20 MIN. >
<AUTOMATIC FLUID >
FLUIDXX CC
FILLINGXXXX G
VACUUM20MIN.
AUTOMATIC FLUID
FILLINGXXXX G
ENTER
If the automatic fluid is confirmed, the systemautomatically
addstheamount of fluid removed duringrecoveryafter the
vacuumstage.
Ifyouneedto add aquantityof fluid other thanthequantity
drainedafter recovery,set asfollows: oncethevacuumtime
|as booo coo|oo, t|o ossao '/otoat|c |o|o' bo|os to
flash.
Pressthe 'o to ovo to t|o ossao '||o|o cc', ooto
thevolumeof fluid you wishto beadded automaticallyafter
thevacuumusingthekeys0-... 9 andpress ENTER.
<VACUUM20 MIN. >
<AUTOMATIC FLUID >
FLUIDXX CC
FILLINGXXXX G
<VACUUM20 MIN. >
AUTOMATIC FLUID
FLUID 30CC
FILLINGXXXX G
3
0
VACUUM20MIN.
AUTOMATIC FLUID
<FLUID 30 CC >
FILLINGXXXX G
VACUUM20MIN.
FLUID 30CC
<FILLING XXXX G >
ENTER
VACUUM20MIN.
AUTOMATIC FLUID
<FILLING XXXX G >
8
5
0
ENTER
Coco t|o |o|o |as booo coo|oo, t|o ossao '|||||o
' bo|os to |as|. Sot t|o ooaot|t o coo|aot |o oo .|s| to
add to theA/C system.
For example, if thequantityis850g, press thekeys8, 5 and
0 '|||||o 850 '.
After settingthequantity, confirmwithENTER.
Openthemachinehighandlowpressurefittingsandpressthe
START key.
Ifagasanalyserisinstalled, themachineteststhepurityofthe
air conditioningsystemcoolant.
If thecoolant issufficientlypure, recoverybegins.
IftheA/Csystemdoesnotachievetherequiredlevel ofpurity,
themachineruns asecond test.
Ifthesecondtestfails,themachinedisplaysthealarmmessage
'//C ssto coota|os coota|oatoo coo|aot'.
Contaminatedcoolantcannotberecoveredbecauseitwould
contaminatethe coolant insidethe machinecylinder.
Duringtherecoverystage, thesystemdisplaystheamount of
coolant recovereding.
Once recoveryis complete, themachine stops drainingand
automaticallydisplaysthespent fluid removed fromtheA/C
systemduringrecovery.
Thefluid drainoperationlasts3 minutes. If somepocketsof
coolantremainingintheA/Csystemafterthisoperationcause
thepressureto increase,themachineautomaticallybeginsto
recover thecoolant.
After draining, thevacuumoperationbeginsautomaticallyfor
thepreset time. After thefirst 10minutes, acheck isrunfor
A/C systemleaks (attention: if vacuumtimeis<10minutes,
themachinewill not checkfor leaks intheA/C system).
IfleaksarefoundintheA/C system,themachineautomatically
stos aoo o|s|as t|o '|oa's |o //C ssto' a|a (ootoct|oo
of microleaks isnot guaranteed).
If the A/C systemseal iseffective, the machinewill continue
withthevacuumoperation.
Once the vacuum stage is complete, new fluid is added
automatically according to the amount of fluid drained or
accordingtothevolumeset bytheoperator.
At theend, thesystemautomaticallyswitchesto refillingand
addstheset amount.
Once the refillingoperation is complete, close the machine
highandlowpressurefittingsandturnontheA/C systemto
checkthepressures.
|o|o t|o ossoo c|oc', t|o ac||oo o|s|as '|oss
||T|| to |ot a ossoo a|'.
Toobtainaprint-out,pressENTER.Apressuregraphmaybe
printedfor other checksbypressingtheSTART key.
After thepressure check, the machine displays the message
'||scooooct t|o | |tt|o aoo ooo |-3|'.
Nowdisconnect thequickcouplingonlyfromtheA/Csystem
(turntheengineoff if necessary) andopenthehigh andlow
pressure taps with the A/C systemrunningso that the A/C
systemdrainsoff thecoolant inthe pipes.
After approximatelyone minute, remove the machine low
pressurefittingfromthevehicleA/C systemandturnoffthe
engine.
Set themaster switch(13, Figure221) to0.
The automatic procedure maybe run even if the
A/Csystemisempty.Inthiscase,thesystembegins
directlyfromthevacuumoperation.
IftheA/C systemonlyhasonehighpressurequick
coupling, set thefillingquantityto +150g.
NOTE
ASSISTED PROCEDURE
Intheassistedprocedure, eachoperationmaybecarriedout
individuallyapart fromtherecyclingrecoverystage, whichis
followedautomaticallybythespent fuel drainstage andthe
vacuumfor theset time.
Theamount ofgasrecovered,recoveredoil,vacuumtime,oil
added and the amount of gas injected are printed
automaticallyat theendofeachindividual operation.
VACUUM20MIN.
FLUID 30CC
<FILLINGXXXX G >
Open high and low pressure fittings and
press START
Recyclingrecovery
branch.
quick coupling, onlyconnect therelevant quick coupling.
Turn on the vehicle engine and air conditioner for 5-10
minutes, keepingthepassenger compartment fanrunningat
maximumspeed.
Turnoff thevehicleengine.
Follow the assisted procedure, i.e. press ENTER when the
ossao '/ss|stoo ocoooo' |as|os oo t|o |C|.
If followingthe assisted procedure, press ENTER when the
ossao '|occ||o ocovo' |as|os oo t|o |C|.
Openthemachinehighandlowpressurefittingsandpressthe
START key.
Ifagasanalyserisinstalled, themachineteststhepurityofthe
air conditioningsystemcoolant.
If the coolant is sufficientlypure, recoverybegins. If theA/C
systemdoes not achieve the required level of purity, the
machinerunsasecondtest.
Ifthesecondtestfails,themachinedisplaysthealarmmessage
'//C ssto coota|os coota|oatoo coo|aot'.
Contaminatedcoolantcannotberecoveredbecauseitwould
contaminatethe coolant insidethe machinecylinder.
Duringtherecoverystage, thesystemdisplaystheamount of
coolant recovereding.
Once recoveryis complete, themachine stops drainingand
automaticallydisplaysthespent fluid removed fromtheA/C
systemduringrecovery.
Thefluiddrainoperationlasts3 minutes.
Ifsomepocketsof coolant remainingintheA/C systemafter
this operation cause the pressure to increase, the machine
automaticallybeginsto recover thecoolant.
Vacuum
branch.
quick coupling, only connect the relevant quick coupling.
To so|oct vacoo, oss ||T|| .|oo t|o ossao 'Vacoo
|o' |as|os oo t|o |C|.
Setthevacuumtimeonlyifyouwishtochangethepreviously
set time.
Open themachine high and low pressure fittings and press
START.
Atthispoint,thevacuumoperationbeginsforthepresettime.
After thefirst 10minutes, acheckisrunfor A/C systemleaks
(attention:ifvacuumtimeis<10minutes,themachinewill not
checkforleaksintheA/C system).LeaksarefoundintheA/C
system, the machine automatically stops and displays the
'|oa's |o //C ssto' a|a (ootoct|oo o |co|oa's |s oot
guaranteed); inthis event, useleak detector 99305147.
If the A/C systemseal iseffective, the machinewill continue
withthevacuumoperation.
Addingnewfluid
This operation may be carried out exclusively following a
vacuumoperationand beforerefilling.
So|oct t|o |o|o, |.o. .|oo t|o ossao '||o|o cc' |as|os oo
the LCD.
Set thevolumeof newfluidto beadded in cm
3
.
Open at least one of thetwo machinehigh or low pressure
valvesand pressSTART.
FillingA/C systems
So|oct o||||o, |.o. .|oo t|o ossao '|o||||o ' |as|os
ontheLCD.
Set theamount youwishto add totheA/C systemingrams
(if an A/C systemcontains740gpresskeys7, 4and 0.
To c|oc', oosoo t|o ossao '|||||o +0' |s o|s|aoo).
PresstheSTARTkeyandopenthemachinehighpressuretap
(iftheA/C systemonlyhasonelowpressurefitting,openthe
machinelowpressuretap).
Once the refilling operation is complete, close the machine
highand lowpressurefittingsand turnontheA/C systemto
checkthepressures.
|o|o t|o ossoo c|oc', t|oac||oo o|s|as '|oss ||T||
to |ot a ossoo a|'.
To obtainaprint-out, pressENTER.
A pressuregraphmaybeprintedfor other checksbypressing
theSTART key.
After the pressurecheck, themachinedisplays themessage
'||scooooct t|o | |tt|o aoo ooo |-3|'.
NowdisconnectthequickcouplingonlyfromtheA/Csystem
(turntheengineoff if necessary) andopenthehighand low
pressure taps with the A/C systemrunningso that theA/C
systemdrainsoff thecoolant inthe pipes.
After approximatelyone minute, remove the machine low
pressurefittingfromthevehicleA/C systemandturn off the
engine.
Set themaster switch(13, Figure221) to0.
If the A/C systemonlyhas onehighpressurequickcoupling,
set thefillingquantityto +150g(thisis theamount that may
remain inthehighpressurepipe).
LEAK FINDER FOR AIR-CONDITIONING
SYSTEMS WITH HFC R134A (99305147)
Tool L-780AmakesitpossibletoidentifyleakageofHFC134A
gasfromthesystemextremelyaccuratelyintheorder of 3.3
gayear withtheswitchonmaximumsensitivity.
Thisinstrument requiresnosettings, theoperatoronlyneeds
to select thedesiredsensitivity.
Theinstrument warnstheoperator of anygasleakagewitha
buzzer and a LED that flashes in proportion to the
concentrationof gas.
Inaddition, theLED indicatesthebatteryisflat if it goesout.
Operatingtemperatureisbetween0C and50 C.
The instrument is equipped with aflexible probe to reach
particularlydifficult fittingsor parts.
Thetwo levelsofsensitivityare:
- lowsensitivity =16.5g/year;
- highsensitivity =3.3 g/year.
Figure223
50643
Before checking vehicles, wait for the engine to
cool, thehot parts canfalsifythetest.
NOTE
90318
Figure224
Figure225
90317
SEMITRAILER FIFTH WHEEL MOUNTINGSCHEME
SEMITRAILERPLATE ANDFIFTH WHEELMOUNTINGSCHEME
5001 CHASSIS FRAME
Doublebottleneckhighresistance steel chassis.
Dimensions
Inner distancebetween sidemembers: 1016mm(front)
836 (middle)
756 mm(rear)
Note: Indicateddistances areindependent of thickness.
Sidemember sectioninner height 289 mm(front)
199 mm(rear)
Sidemember thickness:
6.7mm (180W, 190/260/340W, 400IT/WT, 440T, 260/380B)
Sidemember thickness:
7.7mm (380T/W/B, 410T/W/B, 720T/WT)
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
ScrewwithM16x1.5 flangesecuringfifthwheel to chassisor plate 238 26 23.8 2.6
Nut with M16x1.5flangesecuringfifthwheel to chassisor plate 310.5 33.5 31 3.3
Nut with M16x1.5flangesecuringplateto chassis 310.5 33.5 31 3.3
ScrewwithM16x1.5 flangesecuringplateto chassis 238 26 23.8 2.6
17344
17345
17347
Figure226
Figure227
Figure228
Laterallypermissiblecurvatureof chassisframe
'a' = 3 /.
Carefullycheckfor anypeelingorcrackingall overthechassis
frame,payingspecial attentiontojointsundergreatstrain,such
as: chassis frame cross members, brackets, mounts of leaf
springsandchassisframestructural members.
Mark anypeeledor crackedpointsstraight away.
Check the rivets by striking their heads with a mallet and
touchingtheoppositesidewithyour fingers.
Mark anylooserivets with paint to helpidentifythemduring
therepair work.
17348
17349
Figure229
Figure230
Permissible curvatureofchassisframe
'b' = + /
Maximum10 mm.
|o|ss|b|o o|oooco bot.ooo 'a' aoo 'b' = 3 .
\|t| o|aooa| oasoooot bot.ooo 'c' aoo 'o' = 6 .
Inspect thechassis frame, checkingits alignment.
Ifevenat thisstageyoudetectanydeformationyouthenneed
tofreetherelevant part ofthechassisframetohelpmakean
exact measurement.
Beforethetest youneedtocheckall thepartsthat,withtheir
imperfections, affect the exact measurements (for example,
tyrepressure, weakor brokenleaf springs, etc.).
REPAIRS
CHECKS
17350
17351
17352
17353
Figure231
Figure232
Figure233
Figure234
Permissibletorsiononthechassis frame
'b' = + oac| s|oo.
To measurethe side bend of thechassisframeyouneedto
plumbthesupportingsurfacesstartingwiththetwostructural
members at aninterval of approximately1m.
Thepointsobtainedinthiswayneedtobemarkedaccurately
onthefloor.
To usetheplumbed pointsyou need to stretchout astring
passingthrough themarked pointsinaline.
Thepointsoutsidethelineindicatethestart andextentofthe
actual deformation(a).
Taketwoshims(1) ofsuchasizethatastringcanbestretched
alongthefull lengthfromthestraight portionof thebottom
or topwaist onthestructural member of the chassis frame.
Measurethedistanceofthestructural memberfromthestring
at 1-metreintervals. A different stringdistance indicatesthe
position and extent of an actual bend in the structural
member.
Measuring the side bend of the chassis frame
Measuringthe movement of thechassisframe
17354
Figure235
A movement ofthechassisframecanbemeasuredbymeans
of aset square.
To do this, place the set square at 90 to the structural
memberofthechassisframeandcheckthesquarenessofthe
crossmembersof thechassis frame.
Measuring the bend of the chassis frame
downwards or upwards
17356
17355
17358
Figure236
Figure237
Figure238
A movement intheposition of theaxescanbechecked by
makingadiagonal measurement.Todothis,plumbthecentre
of thefront mount of thefront suspensionandthecentreof
thefront support oftherearleafspringontheflat supporting
surface, onbothsides.
||st| coao t|o o|staoco o t|o o|ots 'a' aoo 'b'. T|oo
a'o t|o o|aooa| oasoooot (o|staoco 'c' aoo 'o') o
point(2)infronttotheright topoint (2)behindtotheleftand
the opposite.
- Positiontheother sideof thechassis frame, inacentral
positionunder therearcrossmember, onthekneeof an
L-shaped iron(1).
- Set a rule crosswise and put a spirit level (2) on this,
checkingthereading.
At eachcheck point youwill need to havethesamereading
or thechassisframeisout of shape.
During the work of welding, drilling, grinding, cutting near
brake systempiping, especiallyif this is made of plastic, and
electric cables, take the appropriate precautions to protect
them,contemplatingtheirremoval ifrequired. All thepartsof
the chassis frame subject to reconditioning will need to be
protectedagainst oxidationandcorrosion.
Thisprotectionandpaintingwill needtobedonecarefullyon
all the parts concerned, as per any relevant instructions,
methodsandprecautionsof the paint manufacturers.
PRECAUTIONS
Measuring the torsion of the chassis frame
17357
Figure239
A slight torsioncanonlybemeasured withthechassisframe
freed of thecaband mechanical assemblies.
To do this check, proceedasfollows:
- Set thechassisframeontwo stands.
- Usingtwoclamps,secureonesideofthechassisframeto
the stand.
17359
17360
17361
Figure240
Figure241
Figure242
The chassis frame is reconditioned by wedge heating the
relevant part withablowpipe.
During this operation the metal needs to turn cherryred,
whichcorresponds to atemperature of 600 - 680C.
Theheated pointsmust undergo no further heating.
Let the treated parts cool slowly without using any water,
compressed air or thelike.
Straightenthesaginthechassisframedownwardsorupwards
withwedgeheatingonthetopplateofthestructural member.
Inthecaseof downwardbending, thebase(a) of theheating
wedgeisat thebottom.Inthecaseofupwardbending,dothe
opposite.
The relevant bottomor top waist of the structural member
has to be heated last in the areaof thebase of the heating
wedge.
Straighten the side bend of the chassis frame with wedge
heatingon thetopand bottomwaist of thepart concerning
thechassis frame.
Thetipof theheatingwedgehasto lieinthedirectionofthe
requiredbend.
If thebase(a, Figure44) of thetwo heatingwedges is inthe
topplateofthestructural member,thentheplatealsoneeds
to beheated, but last.
17365
17364
Figure243
Here wegivetheoperatinginstructionsfor proper welding:
a) Heat all aroundtheareato weld (except forQST E420
material). Do the arc weldingwith several passes, using
thoroughly dried basic electrodes, or MIG-MAG pro-
cedures with suitablefiller material. Do not overcharge
withcurrent.Theweldmust haveno edgecutsor dross.
b) Start backweldingasspecified inpoint (a).
c) Leavethestructural membersto cool slowlyandevenly.
It isnot permissibleto usejets of air or other means.
d) Grindoff theexcessmaterial.
e) Applysteel cornerstrengthening,withthesamespecifica-
tionsasthesteel usedinthechassisframe. Theapproxi-
mateminimumdimensionsaregivenintheaboveillustra-
tions.Theyaretobefixedsolelyonthevertical ribofthe
structural member andit ispossibletousebeadwelding,
dummy spots, screws or rivets. The cross section and
lengthof theweld bead, thenumber anddistributionof
the dummy spots, screws or rivets must be suited to
transmit thebendingandcuttingmomentsofthesection.
On completing the work, the part involved in welding
must beeffectivelyprotectedwithrust proofing.
A 0,3H
b H (min. 175mm)
S (0.8 1) SI
Figure244
Beforestartingwork,disconnectthenegativebatteryterminal
and connect the earth of theweldingmachinestraight onto
thepieceto weld. Plasticpipeswill need to beprotected or
removed.
Welds will have to be made solely by skilled, trained
personnel, with suitable equipment and in workmanlike
fashion.
Stripanddeoxidizethepartstoweld.Atthepointofbreakage,
ontheinsideofthestructuralmemberandalongthefull length
of therelevant section, makeaVbevel of 60.
!
No cutsarepermittedonthestructural membersat
areas of changes in profile or at points with ahigh
concentration of stresses; additionally, the line of
separationmust not concerntheholesalreadyinthe
structural member.
17362
17363
Welds on the chassis frame
1 TRAKKEREURO 4/5 PROGRAMMEDMAINTENANCE
SECTION 15
Programmed maintenance
Page
DIAGRAMOFPOINTSFORCHECKSAND/OR
MAINTENANCE OPERATIONS 3 . . . . . . . . . .
MAINTENANCE SERVICESCHART 5 . . . . . . . . .
PROGRAMMED MAINTENANCEWITH HOUR
INTERVALS (FOR VEHICLESUSED IN
QUARRIES ANDCONSTRUCTION SITES) 5
CHECKSAND/OR MAINTENANCE
OPERATIONS 6 . . . . . . . . . . . . . . . . . . . . . . . .
- Hour interval schedulefor quarriesandconstruction
site vehiclesandoff-roadvehicles 6 . . . . . . . . . .
TIMED OPERATIONS 7 . . . . . . . . . . . . . . . . . . . .
- Plan withhour interval for quarryandbuildingyard
vehicles and for off-road vehicles 7 . . . . . . . . . .
CHECKSAND/ORMAINTENANCE OPERATIONS
(PLAN WITH HOUR INTERVALS) 8 . . . . . . . .
M1SERVICE 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2SERVICE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3SERVICE 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMED OPERATIONSWITH HOUR
INTERVALS 15 . . . . . . . . . . . . . . . . . . . . . . . . . .
T1SERVICE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T2SERVICE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T3SERVICE 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T4SERVICE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T5SERVICE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T6SERVICE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T7SERVICE 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T8SERVICE 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROGRAMMEDMAINTENANCEWITH KM
INTERVALS (For vehiclesused on theroad for
mediumand longdistances) 19 . . . . . . . . . . . . . .
CHECKSAND/OR MAINTENANCE
OPERATIONS 20 . . . . . . . . . . . . . . . . . . . . . . . .
- Schedulewithkmintervals for vehicles usedon
theroadfor mediumand longdistances 20 . . . . .
Page
EXTRA PLAN/TIMED OPERATIONS 21 . . . . . . . . .
- Plan withkilometer intervals for road use vehicles
over middleto longruns 21 . . . . . . . . . . . . . . . .
CONTROL AND/OR MAINTENANCE
INTERVENTIONS
(PLAN WITH KM INTERVALS) 22 . . . . . . . . . . .
M1SERVICE 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2SERVICE 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3SERVICE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXTRA PLAN/TIMED OPERATIONS
(PLAN WITH KM INTERVALS) 29 . . . . . . . . . . .
EP1 SERVICE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EP2 SERVICE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T1SERVICE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T2SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T3SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T4SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T5SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T6SERVICE 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure1
115273
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE OPERATIONS
115274
Figure2
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE OPERATIONS
Revi- June2007
PROGRAMMEDMAINTENANCE 5 TRAKKEREURO 4/5
PRINT603.93.641/A
MAINTENANCE SERVICES CHART
OILS SERVICES EXTRA PLAN
PROGRAMMED OPERATIONS
Engine
ACEA E4 (1)
M1 M2 M3 T1 T2 T3 T4 T5 T6 T7 T8
ACEA E4 (1)
Urania
FE5W30
Every
1000
hours
Every
1500
hours
Every
3000
hours
Multipo
wer
every
800
hours
Gearbo
xoil
and
filter +
Intarder
(2)
Every 3
months
Every
year
before
winter
Every
year
before
summer
Every
year
Every
2 years
Every
3 years
(1) IVECO suggests the use of thesel ubricants toraise thevehicle fuel economy. Thenew vehicle is already equipped by IVECO
with these types of lubricants, suitable also for cold climates (minimumtemperaturedown to -30). The changeintervals
dependontheuseof theseoils.
(2) Seenoteat page 7.
The ExtraPlanoperations (designated with theletters EP) arecomplementaryto standardservices.
Theyaremaintenanceoperations to becarriedout at regular timeor mileageintervalsandconcern optional componentsthat
arenot present on all models.
Important! The correlation between kilometres and months onlyapplies in cases where the distance travelled bythevehicle
correspondsroughlytothespecified averageannual mileage.Thisisindicatedonlyinordertosuggest ahypothetical maintenance
programme,.Notethat thetimeintervalsspecifiedforExtraPlanoperationsareto beadheredtoregardlessoftheactual mileage
covered.
The kilometrefrequencyfor engine lubrication is in relation to apercentageof sulphur in diesel of under 0.5%.
NOTE: If usingdiesel withapercentageof sulphur above0.5%, theoil-change frequencyhas to behalved.
Useengine oil: ACEA E4(URANIA FE5 W 30) - ACEA7(URANIA LD7)
- ACEA E4lubricants classifiedasACEA E6cannot beusedaccordingto thechangeintervals established for class
ACEA E4.Theyshall bechangedaccordingto thetimeintervalsestablishedforlubricantsACEA E2, i.e.every400
hours.
- If classACEA E7 (UraniaLD7) engine oil is used, theengineoil and filtersmust bechanged every800hours.
- If classACEA E2 (UraniaTurbo) engineoil is used, theengineoil andfiltersmust bechanged every400hours.
- In the event of verylow annual operatingtimeor anyway below 1000 hours/year, theengineoil and the filters
shall bechanged every12 months.
- Intheevent ofoperatingtimebelow 1000hours/year,theoil of therear axles,distributor,transmission, etc. shall
bechanged at least every2 years.
- The filter dryer of thepneumatic systemmust inanycaseberenewed everyyear.
- Inthe caseof verylowannual mileage, general greasingmust becarriedout at least once ayear.
To schedule thework, keepto thefollowingchart:
PROGRAMMED MAINTENANCE WITH HOUR INTERVALS (FOR VEHICLES USED IN
QUARRIES AND CONSTRUCTION SITES)
(1) Vehicleand toolinghandlingactivityin theworkshop.
Revi- June2007
6 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
PRINT603.93.641/A
CHECKS AND/OR MAINTENANCE OPERATIONS
Hour interval schedule for quarries and construction site vehicles and off-road vehicles
Typeof operation M1 M2 M3
References
figure1/2
Engine
14 Changeengineoil
3 Replaceengineoil filter
12 Replacefuel filter
1-2 Replacemiscellaneousdrivebelts
13 Replaceor clean hydraulic steeringsystemfilter
15 Check-up of engineEDC systemviaMODUS, IT 2000or E.A.SY.
5 Checkvalveclearanceand adjust if necessary
16 Replacevariablegeometryturbocharger VGT air filter
1 Replaceengineauxiliarymember drive belt
2 Replaceair-conditioner compressor drivebelt
7 Checkingfan electromagneticjoint clutch wear (if applicable)
Chassis andmechanical assemblies
17 Replacefuel pre-filter
10 Checkefficiencyand clean gearbox oil bleeds
9 Checkclutch fluidlevel
11 Replacepneumatic systemdrier filter
GreasetheVGT control lever
28 Checkefficiencyandcleandriveaxleoil bleeds (for 4x4, 6x6, 8x8 vehicles)
25 Cleandivider oil bleeds betweenaxles
23 Cleanaxleoil bleed
General greasing
28 Changedriveaxle oil (for 4x4, 6x6, 8x8 vehicles)
Changefront sidereduction gear oil (for 4x4, 6x6, 8x8vehicles)
22 Changeaxleoil
20 Changefront wheel huboil (for 4x2, 6x4, 8x4vehicles)
21 Changetransmission assemblyoil (for 6x4, 6x6, 8x8 vehicles)
25 Changetransfer boxoil (for 4x4, 6x6, 8x8vehicles)
19 Control of theguideand support fixture
29-30 AdBluesystemfilter andpre-filter change
Cab and electric appliances
27 Checkheadlight adjustment
31 AdBluesystemtest withEASY, MODUSor IT2000
Miscellaneous
Handlingoperations(1)
Functional testingonroad
Cabin tilting/ opening/ closureof cowling
Revi- June2007
TIMED OPERATIONS
T1 Every 800 hours
Simultaneouslywithamaintenance service
534501 Replacingtotal power take-off (Multi-power) oil
T2
Every 1200hours, gearboxes supplied withmineral oil (1)
Every 2400hours, ZF 9 S1310 gearboxes supplied withsynthetic oil (2)
Every 3600 hours, ZF EUROTRONIC gearboxes supplied with synthetic oil (3)
Together with maintenance operations
530105 Changeoil andfilter of ZFtransmission +Intarder
530105 Changegearboxoil
T3 Every 3months
553261 Checkinganti-pollen filter (4) condition
506011 Washingradiator guardgrid
T4 Everyyear - beforeWinter
Possibly, andsimultaneouslywithamaintenance service
506019 Checkingcoolant density
773130 Replacingadditional heater fuel filter
T5 Everyyear - beforeSummer
506010 Checkingpossibleradiator clogging
T6 Everyyear
505100 Replacingthecartridge and cleaningair filter container (5)
540450 Replacingblow-byfilter
T7 Every 2years
506010 Replacingenginecoolant
T8 Every 3years
505292 Replacingoil anddrainingclutch hydrauliccontrol
Plan with hour interval for quarry and building yard vehicles and for off-road vehicles
1) ZF Ecosplit gearboxes suppliedwithmineral oil, intheevent of verylowannual operatingtimechangetheoil everyyear
(2) ZFNewEcomidgearboxessuppliedwithsyntheticoil, intheevent ofverylowannual operatingtimechangetheoil every
2 years
(3) ZF Eurotronic gearboxes supplied with syntheticoil, in theevent of verylowannual operatingtimechangetheoil every
3 years
(4) In caseof lowruns, performfilters replacement oncea year, at everystart of Spring.
(5) Earlyair filter cloggingis generallycaused byenvironmental conditions; for this reason, air filter must be replaced when
relatingwarningfromspecial sensor is issuedindependentlyof relevant prescription, whichmust beanyhowobservedin
lack of specific indications.
Take out the oil level dipstick (1).
Fromunderneath the vehicle, remove the soundproofing
guard.
Unscrewtheplug(3) fromtheoil sumpanddraintheengine
oil off into aspecific container.
Screwtheplugbackonunderthesump andtightenit to the
requiredtorque.
Fill in with the prescribed oil quantityand quality (see the
CAPACITIES table in the GENERAL INFORMATION
section) fromthetierodcover pipeunion (2).
85493
Figure3
543420 Replace engine oil filters
85494
Figure4
Drain the oil as described in point Changing engine oil.
Remove theoil filter (1) with tool 99360314(2).
Beforerefittingthenewcartridges,moistentheseal
with engineoil.
Screwtheoil filters(1) onbyhandtobringthemintocontact
with the mount and then tighten by 3/4 of a turn to the
prescribed torque and proceed as described in point
Changing engine oil.
92826
Figure5
2.5mm.
M1SERVICE
542710 Change engine oil
543450 Check electromagnetic coupling
clutch wear
1
NOTE
Figure6
115275
540843/543934 Check miscellaneous drive
belts
Visually check that the belts (1-2) are neither worn nor
deteriorated;iftheyare,changethemasdescribedintheM3
service.
Revi- June2007
CHECKS AND/OR MAINTENANCE
OPERATIONS
(PLAN WITH HOUR INTERVALS)
85496
Figure7
544221 Replace or clean hydraulic steering
system filter
Before takingoff thecover (1), thoroughlyclean the tank.
Thiswill prevent foreignimpuritiesfromcomingintocontact
with theoil of the hydraulicsystem.
Takethecover (1) offthetankandtakeout theoil filter (3).
Remove the coupling device (2) fromthe oil filter (3) and
replacethefilter.
Takeofftheplug(1) (afterunhookingthetransmitter) ofthe
hydraulicpowersteeringtankandcheckthatwiththeengine
runningandthewheelstravellinginastraight line,theoil level
reaches thetopreferencemarkonthedipstick.
With theenginestationaryandwheelsinastraight line, the
oil level hastoexceedthetopreferencemarkofthedipstick
by1 or 2cm; if necessary, top up thelevel bytakingoff the
cover (1).
Figure8
507210 Replace pre-filter
Whenreplacingthecartridge,it must not havebeen
pre-filled. This is to prevent impurities gettinginto
circulation that could damage the injector/pump
system components. Bleed the air from the fuel
circuit asdescribed onthe previous pages.
Unscrew thepre-filter (1) andreplaceit.
Before refitting the new cartridge, moisten the seal with
diesel or engineoil. Screw thecartridgeon byhand until it
isin contact withthemountingandthentightenby3/4 ofa
turn to therequiredtighteningtorque.
Figure9
542093 Replace fuel filter
85498
Remove thefuel filter (1) with tool 99360314.
diesel or engineoil.
Screwthenewoneonbyhand,takingcaretocheckthat the
rubber seal andthematingsurfacearecleanandinaperfect
stateof repair. Screw thecartridgeon byhand until it is in
contact withthemountingandthentightenby3/4of aturn
to therequired tighteningtorque.
Bleed the air fromthe supply system as described in the
followingparagraph.
72565
72566
530105 Clean gearbox oil breather
Removetheoil vapour breather (1) andcleanit thoroughly.
Then fit it back on, checking it is in the right position, and
tightenit to therequired torque.
Figure10
(ZF 9/16S gearboxes)
Revi- June2007
PRINT603.93.641/A
Figure11
115277
(ZF 12AS gearboxes)
Figure12
98879
Checkthelevel of the clutchfluid. Top it up if it is too low
(seethefluidstablein theGENERAL section).
505292 Check clutch fluid level
(Excluding vehicles with EuroTronic
gearbox)
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediatelywith water andaneutral soap.
Figure13
72569
503447 Replace pneumatic system drier
filter
Dischargethepressurefromthecompressedair system.
Unscrew thedrier filter (1) and replaceit. Tighten it to the
required torque, checking there is no air leakage when
pressure is restored.
Figure14
522810 Cleaning engine front axle oil
(for versions 4x4/ 6x6/ 8x8 only)
72574
Fit it backon, checkingit is in theright position, andtighten
Revi- June2007
Figure15
72575
505401 Clean oil breather on transfer box
(with hours intervals)
525013 Clean oil breather on axles
Figure16
72576
Remove the oil vapour breathers (1) fromthe middleaxle
and (2) fromthe rear axle and clean themthoroughly. Fit
themback on, checkingthey are in the right position, and
General greasing
Handling operations
Functional on road testing
Tilting the cab, opening/closing the front
grille
Check AdBlue system using E.A.SY.
MODUS or IT2000
M2SERVICE
Check-up on EDC system with MODUS,
IT2000or E.A.SY.
Check AdBlue system using E.A.SY.
MODUS or IT2000
540613 Check valve clearance and adjust if
necessary
under the relevant heading in the ENGINE section.
Figure17
86835
Figure18
542406 Replace variable geometry
turbocharger (VGT) valve air filter
(Cursor Engine)
72577
Usingasuitabletool, unscrew thefilter (1) andreplaceit.
Beforefittingthenewcartridge,moistentheseal withdiesel
or engineoil. Screw it on byhand until it isin contact with
the mounting and then tighten by 3/4 of a turn to the
requiredtighteningtorque.
In versions with Cursor 8 engine the filter is
assembledonthechassis.
NOTE
Revi- June2007
Figure19
Figure20
72580
- With theaxlewarm, takeoff theplug(2) and drainthe
oil into aspecific container.
- Pourinfreshoil throughtheholeclosedbytheplug(1)
(see under the FLUIDS heading of the GENERAL
section).
- Cleantheoil vapour breather.
- Tighten theplugsto the required torque.
522810 Change drive axle oil
(4x4, 6x6, 8x8versions only)
522870 Change front side reduction gear oil
72581
Changetheoil as follows:
- Set the plug (1) as shown in the figure and the OIL
LEVEL line exactly horizontal.
- Open thescrew (2) anddrainoff theoil into aspecific
container.
(see SPECIFICATIONS AND DATA in the REAR
AXLE section).
- Before screwing the plug (1) and screw (2) back on,
spread sealant pasteon themand tighten themto the
requiredtorque.
525110/525010 Change axle oil
Transmissionandmiddleaxle
72582
- With theaxlewarm, unscrewtheplugs (1) and (3) and
drain off the spent oil into aspecificcontainer.
- Screwtheplugsbackonandpourinfreshoil throughthe
holeclosedbytheplug(2) (for thequantity, seeunder
theFLUIDS headingof theGENERAL section).
Rear axle
72583
- With theaxlewarm, unscrewtheplug(1) anddrainoff
theoil into aspecificcontainer.
section).
- Cleantheoil vapour breather of the axle.
Figure21
Figure22
Revi- June2007
Figure23 Figure24
Figure25
79068
520620 Change front wheel hub oil
72584
505401 Change reduction gear - divider oil
- Withhot distributor,slackenthedrainplugs(2) anddrain
theoil in asuitable container.
- Tighten theplugs (2) to torque60 NmxTC 1800, 78
Nmx TC 2200 and clean theoil breather (4).
- Removetheplugs(1and3),fill throughtheplughole(1)
the prescribed quantity and type of oil, see chapter
GENERALITIES in the AXLE section.
Fillingiscorrect whentheoil reachestheplughole(3).Drive
in the plugs (1 and 3) and tighten themto the prescribed
torque.
501401 Check steering box fixing and
mounting
Check that the fastenings of the steering box (1) and
mounting(2) aretightenedto the required torque.
86836
505401 Change transmission assemblyoil
Seetheproceduresforchangingthetransmissionandmiddle
axleoil described above.
Replace AdBlue filter and prefilter
Inorder to carryout theseoperationscorrectly, proceedas
described in the relevant chapter of section ENGINE.
Grease the VGT control lever
Proceed as follows:
- removeplug(1) andsuckoil with suitablesyringe;
- fill thewheel hubwithnewoil (forthequantityandtype
of oil, see CHARACTERISTICS AND DATA in the
AXLES section.
Oil level ischeckedthroughplug(2) slidewithmaxandmin
writingsoncover (1) inhorizontal position.
Revi- June2007
Figure26
760044 Check headlight adjustment
Figure27
98882
- Placeunloadedvehicle,withtyresatprescribedpressure,
on flat ground, facing alight colour wall located at 10
metredistance.
- Mark two crosses on the wall corresponding to the
centresof thetwo headlights.
- Byusingcontrol (1), positionheadlightswithinclination
zero. Inclination can be displayed on CLUSTER display
unit.
115276
TheM3servicecomprisestheoperationsoftheM1
and M2services plustheones listed here.
543411 Replace auxiliarymember drive belt
543910 Replace air-conditioner compressor
drive belt
ASSEMBLY DIAGRAMOF BELTSFOR FAN - WATER
PUMP- ALTERNATOR AND AIR-CONDITIONER
COMPRESSOR
1. Alternator - 2. Drivebelt - 3. Fan- 4. Water pump-
5. Crankshaft - 6. Springbelt - 7. Air-conditioner
compressor - 8. Drivebelt automatic tensioner
Inorder tocarryout theseoperationscorrectly,proceedas
98891
- Tilt the cab and turn on the low beam. The distance
betweenthecrossesandthepointsP,whichcorrespond
to theangleof theheadlights, has to be15 cm.
- Adjust light beamaccording to horizontal and vertical
directionsbyoperatingonscrews (1and 2).
Handling operations
Functional testing on road
Cabin tilting / opening / closure of front
grille
Figure28
NOTE
Revi- June2007
M3SERVICE
TIMED OPERATIONS WITH
HOUR INTERVALS
T1SERVICE
72589
534501 Change Multipower total power
take-off oil (if applicable)
Set thevehiclehorizontal and stop the engine.
Positionasuitablecontainer to collect theoil.
- Unscrew thedrain plug(2).
- Unscrew thefilter (1) and clean it thoroughly.
Torestoretheoil level,screwthefilter (1) anddrainplug(2)
back on to the required torque, checkingthe state of the
seals.
Replacethemif theyhavedeteriorated. Then:
- Unscrew the plug(3) and add therequired amount of
oil (seeFLUIDSin GENERAL INFORMATION).
- Screwtheplugback on to therequiredtorque.
Figure29
2
- Withthegearboxwarm,takeofftheplugs(1) anddrain
72570
T2SERVICE
530105 Change oil and filter of ZF 16S
gearbox +Intarder
Figure30
52571
Remove the oil filter as follows:
- unscrewthescrew(5) fixingthefilter;
- takeoff thecover andfilter (1);
- removethecoverfromthefilterandreplaceit.Takecare
not to losethemagneticpad (4) on the outer edgeof
thefilter, as it has to berepositioned on thenewfilter;
- check the state of the o-ring (2) and replace it, if
necessary;
- greasetheo-ring(3) insertedintheassemblyopeningof
thenew filter;
- couplethenewfilter withitscover and insert it into its
seat asfar as it will go. Secure thescrew (5).
Figure31
Revi- June2007
530105 Change gearbox oil
(ZF mechanical gearboxes)
98880
- With the gearbox warm, take off the plug(s) (1) and
drain theoil into aspecificcontainer.
- Theoil shouldbedrainedoff takingcarenot todirtythe
cross member beneathasit is near theoutlet onsome
types of gearbox.
- It isthereforewiseto useatool toconveytheoil away.
(for thequantity, seeunder theFLUIDSheadingof the
GENERAL section).
Figure32
3
(ZF 12AS gearbox)
115278
types of gearbox.
GENERAL section).
Figure33
T3SERVICE
553261 Checkinganti-pollenfilter condition
98890
Checkthestateof cloggingof thepollenfilter (2).
Anti-pollenfiltercanbeaccessedbyliftingfront cowlingand
under door (1).
Excessive cloggingof thepollen filters can cause a
reduction in the flow rate of air into the cab and
therefore less ventilation. This will be highlighted
especiallybyasignificant reductionintheefficiency
of thewindscreendefrostingfunction.
Figure34
NOTE
506011 Wash radiator grille
Lift thecabradiator cowlingandcarefullycleantheradiator
grille.
Revi- June2007
4
T4SERVICE
506019 Check percentage of antifreeze in
the engine coolant
!
Theplug(1) mustneverbetakenout foranyreason
whatsoever.
With the engine warm, the cooling systemis in
overpressure, therefore take care when taking off
thecap(2).
98881
Takeoffthecap(2) anddrawoffasampleofthecoolantfrom
theexpansiontank(3) with thedensimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentagehas to be higher than 40%and
must not exceed 50%.
If necessary, restorethepercentageof antifreeze, bearingin
mind that the liquidneedsto be replacedevery 2years.
Figure35
!
For vehicles fitted with an additional heater, the
percentageof antifreezemust never exceed50%.
773130 Replacing additional heater fuel
filter
T5SERVICE
506010 Checking possible radiator clogging
72590
505100 Replacing air filter cartridge in dry
conditions and cleaning thecontainer
- Unhook the clamps (1) (or, dependingon theversion,
unscrewthenut) andtakeoff the bottomcover (2).
Figure36
Figure37
72591
- Unscrew the nut (4) and take out thecartridge of the
filter (3).
Beforefittingthenewcartridge,cleanitshousingthoroughly.
T6SERVICE
Revi- June2007
5
T8SERVICE
505292 Changethe clutch fluid and makeair
bleeding (only versions with
mechanical transmission)
Drain off the clutch control fluid and change it (see Fluids
tablein GENERAL section).
T7SERVICE
506010 Changing engine coolant
Performproceduredescribedinrelatingparagraphinsection
ENGINE.
Figure38
72563
- Unscrewthescrews(2), takeoffthecasing,takeout the
filter (3) andreplaceit withanew one.Thefilterworks
inasingledirection, so you need to mount it with the
two strengtheningbars in view asshowninthefigure.
540450 Replacing engine blow-by filter
Figure39
After changingthe fluid, bleed the hydraulic clutch control
system.
Usetheair bleedingtool 99306010as follows:
- charge reservoir (5) with compressed air;
- fill reservoir (4) withTutelaTRUCKDOT SPECIAL fluid
- replacethecap( ) oftheclutchfluidreservoirwithone
of the caps supplied with the tool 99306010 and
connect thepipeto thecap.
1
- Attachaplastictubetothebleedscrew(2) ontheslave
cylinder (1) andimmersetheoppositeend of the tube
inacontainer containingTutelaTRUCKDOT SPECIAL
fluid,unscrewthebleedscrew(1) byonefull turn,open
thevalve(2) (seeFigure39) until apressurereadingof
1 to 1.2bar isobtainedonthepressuregauge(3);
- whentheclutchfluidflowingthroughthetubeisuniform
and free of air bubbles, close the bleed screw and
dischargetheairfromthereservoir (5) throughvalve(6).
40355
Figure40
Whenevertheclutchfluidischanged,it will alsobe
necessary to bleed the clutch master cylinder by
looseningthefitting(1, Figure39) beforebleeding
theclutch servo.
NOTE
Revi- June2007
Revi- June2007
PRINT603.93.641/A
PROGRAMMED MAINTENANCE WITH KM INTERVALS
(For vehicles used on the road for medium and long distances)
OILS SERVICES EXTRA PLAN PROGRAMMED OPERATIONS
Engine
ACEA E4 (1)
Urania
FE5W30
M1 M2 M3 EP1 EP2 T1 T2 T3 T4 T5 T6
FE5W30
Every
100,000
km
Every
150,000
km
Every
300,000
km
Change
gearbox
oil
Every
240,000
km
Every
6months
Every
year
before
Every
year
before
Every
years
Every
2 years
Every
3 years
km km km oil
(2)
km before
winter
before
summer
(1) IVECO suggests the use of thesel ubricants toraise thevehicle fuel economy. Thenew vehicle is already equipped by IVECO
with these types of lubricants, suitable also for cold climates (minimumtemperaturedown to -30). The changeintervals
dependontheuseof theseoils.
(2) Seenoteat page 7.
- ACEA E4lubricants classifiedasACEA E6cannot beusedaccordingto thechangeintervals established for class
ACEA E4.Theyshall bechangedaccordingto thetimeintervalsestablishedforlubricantsACEA E2, i.e.every400
hours.
- If classACEA E7 (URANIA LD7) engineoil is used, theengineoil andfiltersmust be changedevery80,000km.
- If classACEA E2(URANIA TURBO) engineoil isused, theengineoil and filters must be changed every40,000
km.
- Intheevent ofverylowdistancestravelledperyearoranywaybelow100,000km/year,theengineoil andthefilters
must be changedevery 12months.
- If usingdiesel withapercentageof sulphur above0.5%, theoil-change frequencyhas to behalved.
- Intheevent of verylow distances travelled per year, the oil of therear axles, distributor, transmission, etc. must
bechanged at least every2 years.
- The filter dryer of thepneumatic systemmust inanycaseberenewed everyyear.
- Inthe caseof verylowannual mileage, general greasingmust becarriedout at least once ayear.
To schedule thework, keepto thefollowingchart:
(1) Earlycloggingoftheair cleaner is generallydueto environmental conditions. Forthisreasonit needstobereplacedwhen
signalledbythesensor irrespectiveof theguidelines that anyhowhaveto beobservedifthereareno specificinstructions
otherwise.
(2) Vehicleand toolinghandlingactivityin theworkshop.
Revi- June2007
CHECKS AND/OR MAINTENANCE OPERATIONS
Schedule with km intervals for vehicles used on the road for medium and long distances
Typeof operation M1 M2 M3
References
figure1/2
Engine
14 Changeengineoil
3 Replaceengineoil filter
12 Replacefuel filter
4 Blow-byfilter replacement
1-2 Checkmiscellaneous drive belts
13 Replaceor clean hydraulic steeringsystemfilter
15 Check-up of engineEDC systemviaMODUS, IT 2000or E.A.SY.
5 Checkvalveclearanceand adjust if necessary
16 Replacevariablegeometryturbocharger VGT air filter
7 Checkingfan electromagneticjoint clutch wear (if applicable)
GreasetheVGT control lever
17 Replacefuel pre-filter
10 Checkefficiencyand clean gearbox oil bleeds
9 Checkclutch fluidlevel
11 Replacepneumatic systemdrier filter
28 Checkefficiencyandcleandriveaxleoil bleeds (for 4x4, 6x6, 8x8 vehicles)
25 Checkefficiencyand cleandivider oil bleedsbetweenaxles
23 Checkefficiencyand cleanaxlebleed
General greasing
28 Changedriveaxle oil (for 4x4, 6x6, 8x8 vehicles)
Changefront sidereduction gear oil (for 4x4, 6x6, 8x8vehicles)
22 Changeaxleoil
20 Changefront wheel huboil (for 4x2, 6x4, 8x4vehicles)
21 Changetransmission assemblyoil (for 6x4, 6x6, 8x8 vehicles)
25 Changetransfer boxoil (for 4x4, 6x6, 8x8vehicles)
19 Checksteeringboxand mounting
29-30 AdBluesystemfilter andpre-filter change
26 Engine air filter change (drycartridge) (1)
Cab and electric appliances
27 Checkheadlight adjustment
31 Ad Bluesystemtest withEASY, MODUSor IT2000
Miscellaneous
Handlingoperations(2)
Functional testingonroad
Cabin turning/ opening/ closure of cowling
Revi- June2007
EP1 Every 120000 km, gearboxes supplied withmineral oil (1)
Every 240000 km, ZF 9 S1310gearboxes supplied withsynthetic oil (2)
Every 360000 km, ZF EUROTRONIC gearboxes supplied withsyntheticoil (3)
possibly, simultaneouslywith amaintenance service
530105 Replacinggearboxoil and filter (onlygearboxesZF +Intarder)
530105 Changegearboxoil
EP2 Every 240.000 Km
possibly, simultaneouslywith amaintenance service
543411 Replacewater pumpbelt andalternator
543910 Replaceconditioner compressor control belt
T1 Every 6months - Inparticular, at everystart of Spring
and, possibly, simultaneouslywithamaintenance service
506011 Washingradiator guardgrid
553261 Checkinganti-pollen filter (4) condition
T2 Everyyear - beforeWinter
506019 Checkingcoolant density
773130 Replacingadditional heater fuel filter
T3 Everyyear - beforeSummer
506010 Checkingpossibleradiator clogging
T4 Everyyear
534501 Replacingtotal power take-off (Multi-power) oil
T5 Every 2years
506010 Replacingenginecoolant
T6 Every 3years
505292 Replacingoil anddrainingclutch hydrauliccontrol
Plan with kilometer intervals for road use vehicles over middle to longruns
(1) ZF Ecosplit gearboxes suppliedwithmineral oil, intheevent of verylowannual operatingtimechangetheoil everyyear
(2) ZFNewEcomidgearboxessuppliedwithsyntheticoil, intheevent ofverylowannual operatingtimechangetheoil every
2 years
(3) ZF Eurotronic gearboxes supplied with syntheticoil, in theevent of verylowannual operatingtimechangetheoil every
3 years
(4) Earlyair filter cloggingis generallycaused byenvironmental conditions; for this reason, air filter must be replaced when
relatingwarningfromspecial sensor is issuedindependentlyof relevant prescription, whichmust beanyhowobservedin
lack of specific indications.
Take out the oil level dipstick (1).
Fromunderneath the vehicle, remove the soundproofing
guard.
Unscrewtheplug(3) fromtheoil sumpanddraintheengine
oil off into aspecific container.
Screwtheplugbackonunderthesump andtightenit to the
requiredtorque.
Fill in with the prescribed oil quantityand quality (see the
CAPACITIES table in the GENERAL INFORMATION
section) fromthetierodcover pipeunion (2).
85493
Figure41
543420 Replace engine oil filters
85494
Figure42
Drain the oil as described in point 14. Changing engine oil.
Remove theoil filter (1) with tool 99360314(2).
Beforerefittingthenewcartridges,moistentheseal
with engineoil.
Screwtheoil filters(1) onbyhandtobringthemintocontact
with the mount and then tighten by 3/4 of a turn to the
prescribed torque and proceed as described in point 14.
Changing engine oil.
92826
Figure43
2.5mm.
M1SERVICE
542710 Change engine oil
543450 Check electromagnetic coupling
clutch wear
6
NOTE
Figure44
115275
540843/543934 Check miscellaneous drive
belts
Visually check that the belts (1-2) are neither worn nor
deteriorated;iftheyare,changethemasdescribedintheEP2
service.
Revi- June2007
CONTROL AND/OR MAINTENANCE
INTERVENTIONS
(PLAN WITH KM INTERVALS)
85496
Figure45
544221 Replace or clean hydraulic steering
system filter
Before takingoff thecover (1), thoroughlyclean the tank.
Thiswill prevent foreignimpuritiesfromcomingintocontact
with theoil of the hydraulicsystem.
Takethecover (1) offthetankandtakeout theoil filter (3).
Remove the coupling device (2) fromthe oil filter (3) and
replacethefilter.
Takeofftheplug(1) (afterunhookingthetransmitter) ofthe
hydraulicpowersteeringtankandcheckthatwiththeengine
runningandthewheelstravellinginastraight line,theoil level
reaches thetopreferencemarkonthedipstick.
With theenginestationaryandwheelsinastraight line, the
oil level hastoexceedthetopreferencemarkofthedipstick
by1 or 2cm; if necessary, top up thelevel bytakingoff the
cover (1).
Figure46
507210 Replace pre-filter
Whenreplacingthecartridge,it must not havebeen
pre-filled. This is to prevent impurities gettinginto
circulation that could damage the injector/pump
system components. Bleed the air from the fuel
circuit asdescribed onthe previous pages.
Unscrew thepre-filter (1) andreplaceit.
diesel or engineoil. Screw thecartridgeon byhand until it
isin contact withthemountingandthentightenby3/4 ofa
turn to therequiredtighteningtorque.
Figure47
542093 Replace fuel filter
85498
Remove thefuel filter (1) with tool 99360314.
diesel or engineoil.
Screwthenewoneonbyhand,takingcaretocheckthat the
rubber seal andthematingsurfacearecleanandinaperfect
stateof repair. Screw thecartridgeon byhand until it is in
contact withthemountingandthentightenby3/4of aturn
to therequired tighteningtorque.
Bleed the air fromthe supply system as described in the
followingparagraph.
72565
72566
530105 Clean gearbox oil breather
Figure48
(ZF 9/16S gearboxes)
Revi- June2007
Figure49
(ZF 12AS gearboxes)
Figure50
98879
Checkthelevel of the clutchfluid. Top it up if it is too low
(seethefluidstablein theGENERAL section).
505292 Check clutch fluid level
(Excludingvehicles with EuroTronic
gearbox)
Figure51
72569
503447 Replace pneumatic system drier
filter
Dischargethepressurefromthecompressedair system.
Unscrew thedrier filter (1) and replaceit. Tighten it to the
required torque, checking there is no air leakage when
pressure is restored.
Figure52
522810 Cleaning engine front axle oil
(for versions 4x4/ 6x6/ 8x8 only)
72574
72567
Revi- June2007
Figure53
72575
505401 Clean oil breather on transfer box
between axles(with hours intervals)
525013 Clean oil breather on axles
Figure54
72576
Remove the oil vapour breathers (1) fromthe middleaxle
and (2) fromthe rear axle and clean themthoroughly. Fit
themback on, checkingthey are in the right position, and
Test AdBlue system using E.A.SY.,
MODUS or IT 2000
General greasing
Handling operations
Functional on road testing
Tilting the cab, opening/closing the front
grille
M2SERVICE
Check-up on EDC system with MODUS,
IT2000or E.A.SY.
540613 Check valve clearance and adjust if
necessary
under the relevant heading in the ENGINE section.
Figure55
86835
Figure56
72563
540450 Replace the blow-by filter
- Unscrewthescrews(2), takeoffthecasing,takeout the
filter (3) andreplaceit withanew one.Thefilterworks
inasingledirection, so you need to mount it with the
two strengtheningbars in view asshowninthefigure.
Revi- June2007
72577
Figure57
Usingasuitabletool, unscrew thefilter (1) andreplaceit.
Beforefittingthenewcartridge,moistentheseal withdiesel
or engineoil. Screw it on byhand until it isin contact with
the mounting and then tighten by 3/4 of a turn to the
requiredtighteningtorque.
542406 Replace variable geometry
turbocharger (VGT) valve air filter
7
IntheCURSOR8versionsthefilterismountedon
theframe.
NOTE
72590
505100 Replacing air filter cartridge in dry
conditions and cleaning the
container
- Unhook the clamps (1) (or, dependingon theversion,
unscrewthenut) andtakeoff the bottomcover (2).
Figure58
Figure59
72591
- Unscrew the nut (4) and take out thecartridge of the
filter (3).
Beforefittingthenewcartridge,cleanitshousingthoroughly.
Grease the VGT control lever
Figure60
72580
- With theaxlewarm, takeoff theplug(2) and drainthe
oil into aspecific container.
section).
522810 Change drive axle oil
Revi- June2007
Figure61
522870 Change front side reduction gear oil
72581
Changetheoil as follows:
- Set the plug (1) as shown in the figure and the OIL
LEVEL line exactly horizontal.
- Open thescrew (2) anddrainoff theoil into aspecific
container.
(see SPECIFICATIONS AND DATA in the REAR
AXLE section).
- Before screwing the plug (1) and screw (2) back on,
spread sealant pasteon themand tighten themto the
requiredtorque.
525110/525010 Change axle oil
Transmissionandmiddleaxle
72582
- With theaxlewarm, unscrewtheplugs (1) and (3) and
drain off the spent oil into aspecificcontainer.
- Screwtheplugsbackonandpourinfreshoil throughthe
holeclosedbytheplug(2) (for thequantity, seeunder
theFLUIDS headingof theGENERAL section).
Rear axle
72583
- With theaxlewarm, unscrewtheplug(1) anddrainoff
section).
- Cleantheoil vapour breather of the axle.
Figure62
Figure63
Figure64
79068
520620 Change front wheel hub oil
Proceed as follows:
- removeplug(1) andsuckoil with suitablesyringe;
- fill thewheel hubwithnewoil (forthequantityandtype
of oil, see CHARACTERISTICS AND DATA in the
AXLES section.
Oil level ischeckedthroughplug(2) slidewithmaxandmin
writingsoncover (1) inhorizontal position.
Revi- June2007
Figure65
Figure66
72584
505401 Change transfer box oil
- Withhot distributor,slackenthedrainplugs(2) anddrain
theoil in asuitable container.
- Tighten theplugs (2) to torque60 NmxTC 1800, 78
Nmx TC 2200 and clean theoil breather (4).
- Removetheplugs(1and3),fill throughtheplughole(1)
the prescribed quantity and type of oil, see chapter
GENERALITIES in the AXLE section.
Fillingiscorrect whentheoil reachestheplughole(3).Drive
in the plugs (1 and 3) and tighten themto the prescribed
torque.
501401 Check steering box fixing and
mounting
Check that the fastenings of the steering box (1) and
mounting(2) aretightenedto the required torque.
86836
505401 Change transmission assemblyoil
Seetheproceduresforchangingthetransmissionandmiddle
axleoil described above.
Replace AdBlue filter and prefilter
Inorder to carryout theseoperationscorrectly, proceedas
Figure67
760044 Check headlight adjustment
98882
- Placeunloadedvehicle,withtyresatprescribedpressure,
on flat ground, facing alight colour wall located at 10
metredistance.
- Mark two crosses on the wall corresponding to the
centresof thetwo headlights.
- Byusingcontrol (1), positionheadlightswithinclination
zero. Inclination can be displayed on CLUSTER display
unit.
Revi- June2007
Figure68
TheM3servicecomprisestheoperationsoftheM1
and M2services.
98891
- Tilt the cab and turn on the low beam. The distance
betweenthecrossesandthepointsP,whichcorrespond
to theangleof theheadlights, has to be15 cm.
- Adjust light beamaccording to horizontal and vertical
directionsbyoperatingonscrews (1and 2).
Handling operations
Functional testing on road
NOTE
530105 Change gearbox oil
(ZF mechanical gearboxes)
98880
types of gearbox.
GENERAL section).
Figure69
M3SERVICE
(PLAN WITH KM INTERVALS)
EP1SERVICE
Revi- June2007
8
(ZF 12AS gearboxes)
115278
types of gearbox.
GENERAL section).
Figure70
- Withthegearboxwarm,takeofftheplugs(1) anddrain
72570
530105 Replace oil and filter of ZF16S
gearbox +Intarder
Figure71
52571
Remove the oil filter as follows:
- unscrewthescrew(5) fixingthefilter;
- takeoff thecover andfilter (1);
- removethecoverfromthefilterandreplaceit.Takecare
not to losethemagneticpad (4) on the outer edgeof
thefilter, as it has to berepositioned on thenewfilter;
- check the state of the o-ring (2) and replace it, if
necessary;
- greasetheo-ring(3) insertedintheassemblyopeningof
thenew filter;
- couplethenewfilter withitscover and insert it into its
seat asfar as it will go. Secure thescrew (5).
Figure72
Revi- June2007
9
115276
ASSEMBLY DIAGRAMOF BELTSFOR FAN - WATER
PUMP- ALTERNATOR AND AIR-CONDITIONER
COMPRESSOR
1. Alternator - 2. Drivebelt - 3. Fan- 4. Water pump-
5. Crankshaft - 6. Springbelt - 7. Air-conditioner
compressor - 8. Drivebelt automatic tensioner
In order to carryout changeoperations correctly, proceed
as described in the relevant chapter of section ENGINE.
T1SERVICE
553261 Checkinganti-pollenfilter condition
98890
Checkthestateof cloggingof thepollenfilter (2).
Anti-pollenfiltercanbeaccessedbyliftingfront cowlingand
under door (1).
Excessive cloggingof thepollen filters can cause a
reduction in the flow rate of air into the cab and
therefore less ventilation. This will be highlighted
especiallybyasignificant reductionintheefficiency
of thewindscreendefrostingfunction.
Figure73
NOTE
506011 Wash radiator grille
Lift thecabradiator cowlingandcarefullycleantheradiator
grille.
EP2SERVICE
543411 Replace water pump belt and
alternator
543910 Replace air-conditioner compressor
drive belt
Figure74
Revi- June2007
T2SERVICE
506019 Check percentage of antifreeze in
the engine coolant
!
Theplug(1) mustneverbetakenout foranyreason
whatsoever.
With the engine warm, the cooling systemis in
overpressure, therefore take care when taking off
thecap(2).
Takeoffthecap(2) anddrawoffasampleofthecoolantfrom
theexpansiontank(3) with thedensimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentagehas to be higher than 40%and
must not exceed 50%.
If necessary, restorethepercentageof antifreeze, bearingin
mind that the liquidneedsto be replacedevery 2years.
Figure75
!
For vehicles fitted with an additional heater, the
percentageof antifreezemust never exceed50%.
98881
773130 Replacing additional heater fuel
filter
T3SERVICE
506010 Checking possible radiator clogging
T4SERVICE
72589
534501 Change Multipower total power
take-off oil (if applicable)
Set thevehiclehorizontal and stop the engine.
Positionasuitablecontainer to collect theoil.
- Unscrew thedrain plug(2).
- Unscrew thefilter (1) and clean it thoroughly.
Torestoretheoil level,screwthefilter (1) anddrainplug(2)
back on to the required torque, checkingthe state of the
seals.
Replacethemif theyhavedeteriorated. Then:
- Unscrew the plug(3) and add therequired amount of
oil (seeFLUIDSin GENERAL INFORMATION).
- Screwtheplugback on to therequiredtorque.
Figure76
T5SERVICE
506010 Changing engine coolant
Perform procedure described in relating paragraph in
section ENGINE.
Revi- June2007
T6SERVICE
505292 Changethe clutch fluid and makeair
bleeding (only versions with
mechanical transmission)
Drain off the clutch control fluid and change it (see Fluids
tablein GENERAL section).
Figure77
After changingthe fluid, bleed the hydraulic clutch control
system.
Usetheair bleedingtool 99306010as follows:
- charge reservoir (5) with compressed air;
- fill reservoir (4) withTutelaTRUCKDOT SPECIAL fluid
- replacethecap( ) oftheclutchfluidreservoirwithone
of the caps supplied with the tool 99306010 and
connect thepipeto thecap.
1
- Attachaplastictubetothebleedscrew(2) ontheslave
cylinder (1) andimmersetheoppositeend of the tube
inacontainer containingTutelaTRUCKDOT SPECIAL
fluid,unscrewthebleedscrew(1) byonefull turn,open
thevalve(2) (seeFigure77) until apressurereadingof
1 to 1.2bar isobtainedonthepressuregauge(3);
- whentheclutchfluidflowingthroughthetubeisuniform
and free of air bubbles, close the bleed screw and
dischargetheairfromthereservoir (5) throughvalve(6).
40355
Figure78
Whenevertheclutchfluidischanged,it will alsobe
necessary to bleed the clutch master cylinder by
looseningthefitting(1, Figure77) beforebleeding
theclutch servo.
NOTE
Revi- June2007
PRINT603.93.641
ELECTRIC/ELECTRONIC SYSTEM 1 TRAKKER EURO 4/5
SECTION 16
Electric/Electronic system
Page
GENERAL WARNINGSFORELECTRICAL/
ELECTRONIC COMPONENTS 3 . . . . . . . . . . . . . .
COMPONENT CODE 6 . . . . . . . . . . . . . . . . . . . . . . .
MAIN CHANGES 11 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN LINES 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN LINEASSEMBLY DRAWING 17 . . . . . . . . . . . . .
POWERNETWORK 18 . . . . . . . . . . . . . . . . . . . . . . . .
GROUNDPOINTS 19 . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL EQUIPOTENTIAL BRAID 20 . . . . . . . . . .
ALTERNATOR 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTERMOTOR 25 . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION CONNECTORS 27 . . . . . . . . . . . . . . . . . .
DIAGNOSISCONNECTOR 77 . . . . . . . . . . . . . . . . . .
BULKHEAD 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTRAL INTERCONNECTINGUNIT 84 . . . . . . . . .
FUSE 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTESWITCHES 87 . . . . . . . . . . . . . . . . . . . . . . . .
FUSEASSEMBLY BODY CONTROLLER (IBC3) 89 . . .
SUPPLEMENTARY FUSES(70000) 90 . . . . . . . . . . . . . .
INSTRUMENT BOARD 92 . . . . . . . . . . . . . . . . . . . . . .
CENTRAL DASHBOARD CONTROLS 93 . . . . . . . . . .
CONTROLSON THE STEERING WHEEL 94 . . . . . . .
REARVIEW MIRRORSAND WINDOW
REGULATORCONTROL ADJUSTMENT 95 . . . . . .
LEFT LIGHT CONTROL 54033 96 . . . . . . . . . . . . . . . .
ENGINE BRAKECONTROLAND INTARDER 99 . . . .
GEARSELECTION FUNCTION 100 . . . . . . . . . . . . . . . .
FUNCTION ENGAGINGEMERGENCY MODE
(LIMPHOME) 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revi - June2007
2 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Page
CLUSTER 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUSTER(PIN-OUT) 107 . . . . . . . . . . . . . . . . . . . . . . . .
BODY CONTROLLER (IBC3) 113 . . . . . . . . . . . . . . . . . .
BODY CONTROLLER 115 . . . . . . . . . . . . . . . . . . . . . . .
- Linkingconnectors 115 . . . . . . . . . . . . . . . . . . . . . .
CHASSISELECTRONIC MODULE(M.E.T.) 119 . . . . . . .
D.D.M./P.D.M. 121/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S.W.I. (STEERINGWHEEL /
STEERVATORINTERFACE) 122 . . . . . . . . . . . . . . . . .
SPIRALEDCONTACT 125 . . . . . . . . . . . . . . . . . . . . . . .
STEERINGCOLUMN
(COMPONENT LOCATION) 126 . . . . . . . . . . . . . . .
B.M. (BEDMODULE) 130 . . . . . . . . . . . . . . . . . . . . . . . .
E.B.M. (EASY BEDMODULE) 131 . . . . . . . . . . . . . . . . . .
TACHOGRAPH 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M.C. NET INTERFACE 134/1 . . . . . . . . . . . . . . . . . . . . . . .
INJECTION SYSTEMASSEMBLY 134/2 . . . . . . . . . . . . . . . .
ENGINE CONTROL UNIT OPERATION
STRATEGIES 134/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC (ECM) SYSTEMS 135 . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEMCOMPONENTS 139 . . . . . . . . . . . . . . . . . . . . .
VCM(VEHICLECONTROL MODULE)
ELECTRONIC CONTROL UNIT 163 . . . . . . . . . . . . .
IMMOBILIZER 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS-EBL 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMMON COMPONENTS 171 . . . . . . . . . . . . . . . . . .
Page
ECASSUSPENSIONS 178 . . . . . . . . . . . . . . . . . . . . . . . . .
EUROTRONIC AUTOMATIC TRANSMISSION 184 . . . .
LIMP - HOME 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CENTER 192 . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION ACTUATOR 194 . . . . . . . . . . . . . . . . . .
CLUTCH ACTUATOR 196 . . . . . . . . . . . . . . . . . . . . . . .
INTARDER 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EM(EXPANSION MODULE) ELECTRONIC
CONTROL UNIT (PTO) 206 . . . . . . . . . . . . . . . . . .
AUTOMATIC AIR CONDITIONER 209 . . . . . . . . . . . . . .
MANUAL AIRCONDITIONER 224 . . . . . . . . . . . . . . . . .
HYDRONIC D 10 WATER HEATER 228 . . . . . . . . . . . . .
SCR (SELECTIVECATALYTIC REDUCTION)
SYSTEM - DENOX 2 235 . . . . . . . . . . . . . . . . . . . . .
CENTRAL LOCKINGWITH REMOTE
CONTROL 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CHARTS 245 . . . . . . . . . . . . . . . . . . . . . . . . . . .
!
Do not ever disconnect thebatteriesfromthe systemwiththe enginerunning.
Do not start theenginewithout first havingconnectedthebatteriesin apermanent manner.
!
Keystorageproceduresareaffectedbyelectromagneticdisturbancessuchascell phonesand thelike.
Therefore, duringkeymemorization:
1. Ensuretherearenosources of disturbanceinthecabor closeto thekeys.
2. Keysnot inserted in thepanel must beat adistanceof at least 1meter.
!
When working on electronic control units, plug connections and electrical connections to the components,
measurementscanbemadeonlyonsuitabletestinglines,bymeansofspecial plugsandplug-typebushes.Donot under
anycircumstancesmakeuseofimproper devicessuchasmetal wires,screwdrivers, clipsandthelike.Inadditionto the
riskofcausingashortcircuit,thismight damageplug-typeconnectionsandthiswouldthengiverisetocontact problems.
Print 603.93.641
GENERAL WARNINGS FOR ELECTRICAL/ELECTRONIC COMPONENTS
- Beforeworkingonthe vehicle, immobilise thewheels withchocks.
- Donotusefastchargerstostarttheengine.Enginestartingcanbeperformedeitherbymeansofseparatebatteriesorbymeans
of aspecial truck.
- Incorrect polarisationof thepower supplyvoltage for theelectronic control units (e.g. erroneous batterypolarisation) may
damagethecomponentsirreversibly.
- Ifyouhavetodisconnect thebatteriesfromthesystem,alwaysdisconnect theframegroundcablefromthenegativeterminal
of thebatteriesfirst.
- Beforeconnectingthebatteries to thesystem, makesurethat thesystemissuitablyinsulated.
- Disconnect thebatteries fromthesystembeforerechargingthembymeansof anexternal unit.
- ||scooooct t|o otooa| oc|a|o oo|t o t|o o.o a|os booo oov|o t|o oo|t's ||os o t|o batto to|oa|s.
- At temperaturesof over 80 C (o|o ovoos), ta'o oo.o t|o |C|'s.
- At theconnectionstage, tightentheflanged nutsof theconnectors(temperatureand pressuresensors, etc.) toherequired
torque. Checktheexact polarityof thebatteryterminalswhenstartingtheenginebymeans of theauxiliarytruck.
- 3ooo .o'|o oo t|o vo||c|o's o|oct|ca|/o|octoo|c ssto o|scooooct t|o os|t|vo o|o o t|o batto.
- Beforedisconnectingtheconnector fromanelectroniccontrol unit, isolatethesystem.
- Do not cause sparks to checkwhether acircuit is live.
- Do not useatest bulbto check thecontinuityof acircuit. Onlyusetheappropriatetestingdevices.
- Donot directlypower thecomponentsassociatedwithelectroniccontrol unitswiththenominal powerratingof the vehicle.
- Makesurethatthewiringsofelectronicdevices(length,typeofcable,location,grouping,connectionofscreenbraiding,earthing,
etc.) conformwiththeIVECO systemand that theyarecarefullyrestored after repair or maintenance work. To avoid the
possiblemalfunctioningof theelectronicsystemsonboard,thewiringsof additional devicesmust followadifferent paththan
that of theabove-mentionedsystems.
- Do not connect thenegative terminalsof additional systemsto thenegativeterminalsof electronicsystems.
- Intheevent of electricweldingonthevehicle, disconnect all theelectroniccontrol unitsand/or disconnect thepower cable
fromthebatterypositiveterminal and connect it to theframeearth.
- Connectorsareviewedfromthecableside.
Inorder to prevent damageor short-circuitingof the on-boardelectroniccontrol units, thefollowingoperationsmust
bealwayscarriedout beforestartinganyweldingoperation onthe chassis.
- If electricweldinghas to bedoneon thevehicle,
isolatetheelectricsystemasfollows:
a) disconnect thepower lead fromthe batterypositiveterminal andconnect it to thechassisearth;
b) disconnect thepower lead fromthebatterynegativeterminal;
c) disconnect theelectroniccontrol unit connectors, takingcaretoavoidtouchingthecontrol unit connector pins.
- Moreover:
a) should it benecessaryto carryout weldingoperations closeto thecontrol unit, removeit fromitslocation.
b) whenever possible, earththeweldingmachinedirectlyto thepiecethat hasto bewelded.
112514
InthecaseofvehiclesequippedwithaDTCOdigital tachograph,donot disconnect thebatteryleadsandthenconnect
thembyjumpers to reset the electronicsystems.
This operationshouldbeavoided, as it couldcausepermanent damageto theDTCO tachograph CARD or other
on-board electronicsystems.
To reset theelectronicsystemwithout runningrisks, disconnect thevehiclebatteryand wait for 10 minutes.
It isstrictlyforbiddentocarryout anymodificationsor connectionstotheelectroniccontrol unitwiring; inparticular,
thelineinterconnectingdatabetweenthecontrol units (CAN line) must beconsidered as untouchable.
Diagnostic and maintenance operations can only be carried out byauthorised personnel with IVECO approved
equipment.
Practical tips
T|o ooat|vo |oaos cooooctoo to a ssto oooo|o o|ot ost bo as s|o t as oss|b|o aoo cooooctoo to ooo aoot|o |o 'sta'
configuration; makesurethat theyaretightened in anorderlyand adequatemanner (Figure1, ref. M).
Furthermore, for electroniccomponents, theinstructionsto befollowedverycarefullyare:
- |C|'s ost bo cooooctoo to t|o ssto oooo | t|o ao ov|ooo .|t| a caso.
- ECUnegativecablesmust beconnectedbothtoasystemgroundingpoint, suchasforinstancethedashcompartment ground
(.|t| oo 'so|a|' o 'c|a|o' cooooct|oos) aoo to t|o oegativeterminal(s) ofthebattery/batteries.
- Eventhoughtheyarenot connectedto thesystemground/batterynegativeterminals, analoguegroundelements(sensors)
musthaveexcellentinsulation.Asaresult,special caremustbedevotedtotheeddyresistancesofthecableterminals:oxidation,
seam-foldingdefects, etc.
- Themetal braidof shielded circuitsmust beinelectrical contact at either endwithsystemcomponents.
- Onlyoneendoftheshieldingbraidmust beconnectedto the systemground.
- In the presence of jointingconnectors, the non-shielded portion, d, must be as short as possible in the proximityof the
connectors(Figure1).
- Thecablesmust bearrangedsoasto runparallel tothereferenceplane,i.e., ascloseaspossibleto theframe/bodystructure.
- Additional electromechanical systemsmustbeconnectedwiththegreatest caretothesystemgroundandmust not beplaced
alongsidethecablesof electroniccomponents.
SHIELDINGBY MEANSOF A METAL BRAIDOFA CABLELEADING TO AN ELECTRONIC COMPONENT -
C. CONNECTOR - d. DISTANCE! 0.
Figure1
88039
Revi - June2007
Print 603.93.641/A
COMPONENT CODE
03000 Self-rectifyingalternator withbuilt involtageregulator
08000 Starter Motor
12015 Motor for outsideair intakedoor
12023 Windowshademotor
12032 Cab hydraulic releasepump motor
20000 Starter battery
22000 Horn
22043 Buzzer for warningthat automatic transmissiongear selector isnot in regular position
25010 Contactor for additional highbeamlampsengagement
25200 Relayfor starter
25201 Relay, preheating
25202 Relay, G.C.R. energizing
25203 Relay, G.C.R. opening
25204 Relay, remotestartingenablement, cabunlatched
25205 Relay, enginestopping
25206 Relay, rich mixturecontrol
25207 Relay, alternator D+earthing
25208 Relay, remotestart enablement, gear engaged
25209 Relayfor cuttingoff variouscomponents duringstartingstage
25210 Relay, startingenablement withtransmissioninneutral
25211 Relaywithdelayedopeningcontact for keepingG.C.R energized
25212 Relaywithdelayedclosingcontact for keepingRTE energized
25213 Relayfor supplyof users connected to ignitionswitch throughbattery positive
25222 Relayfor allowingconnectionof thermal starter
25306 Contactor for electroheater control andwindscreendefrost
25310 Relayfor allowingconnectionofinternal heatingwithpower load inhibitingrelay
25322 Relayfor connection of auxiliaryheater (1st speed)
25325 Contactor for enginewater recycle open withenginerunning
25327 Relayfor connectionof air-conditioningsystem
25332 Relayfor connectionof air-conditioningsystem
25337 Contactor for enginewater recycle closesolenoid valvewithadditional heater on
25351 Electrictrap openingcontactor
25352 Electrictrap closingcontactor
25544 Topflapenginepolarityreversecontactor for LD
25545 Topflapopen/closecomandcontactor for LD
25705 Contactor for vehicletesting
25722 Cab hydraulic releasepump switch(lowering)
25723 Cab hydraulic releasepump switch(raising)
25737 Contactor for fan (Barufaldi) electromagneticcouplingengagement
25740 Headlamp washer enable contactor
25805 Contactor for horncontrol
25818 Contactor for heater windscreen control
25866 Relayfor terminal 58
25874 Relayfor connection of power loadswithenginerunning
25897 Relayfor connectionof sidetransmissionpower takeoff
25898 Relayfor connection of rear transmission power takeoff
25900 General current relay
25901 Main current relaywithautomaticswitch
25903 Contactor for EDC disengagement
252+ ||C cooooct|o o|a '|a|o |o|a'
30001 Dippedand mainbeamheadlampwithsidelight
30010 Highbeamheadlamp
30011 Foglight
30100 Headlampaimingcontrol actuator
32002 Front directionindicator
32010 Rotarylamp
33001 Sidedirectionindicator
33004 Sidemarker lamp
34000 Multifunctional rear light
34011 Trailer light
35000 Number platelight
37000 Front/rear dimensions light
37001 Front dimensionslight
39000 Ceilinglampfor cabin insidelighting
39003 Courtesylight for steps
39009 Courtesylight for readinglights
39017 Courtesylight for adjustablecabininterior light
39020 Ashtraylamp
Revi - June2007
39030 Cab sideopeninglightinglamp
39030 Cab sideopeninglightinglamp
39034 Whiteandred internal light unit
40011 ElectronicTachograph
40032 Sender unit for tachometer and tachograph
40046 Inductivetypechassisheight sensor (rear axle)
40047 Inductivetype chassisheight sensor (front axle)
42030 Sender unit for engineoil pressure gauge
42045 Sender unit for outdoor temperaturegauge
42100 Switchfor front brakeinsufficient air pressureindication
42101 Switchfor rear brakeinsufficient air pressureindication
42102 Switchsignallinghandbrakeapplied
42108 Switchfor trailer retarder signal
42111 Switchsignallingtrailer brakingsystemfailure
42116 Switchfor lowair pressure indicator inEBSsystem
42200 Switchsignallingpneumaticsuspensionsystemfailure
42351 Switchsignallingair filter blocked
42374 EDC clutchswitch
42379 Switchfor PTO engagement enable
42381 DriveaxleRH pressuresensor (ECAS)
42382 Lift axleRH pressuresensor (ECAS)
42389 Air pressuresensor onthirdaxlepneumatic liftingsystem
42551 Switchsignallingoil filter blocked
42608 Coolant pressuresignalling3-switchassembly
42622 Circuit 2 hydraulicoil flowindicator switch
42623 Electricswitch infront power steeringengagement valve(ZF circ. 1,5)
42624 Electricswitch infront power steeringlockvalve(ZFcirc. 1,5)
42700 Fuel filter cloggedindicator switch
44031 Fuel level gaugesender unit with reserver warninglight contact
44035 Insufficient windscreenwasher fluidlevel gaugecontrol
44036 Insufficient radiator coolant level gaugecontrol
44037 Insufficient power steeringliquid level indicator ECU
44043 Engineoil level gaugesender unit
47032 Sender unit for engineoil temperaturethermometer
47041 Water temperature transmitter for Retarder ECU
47042 Fuel temperaturesensor
47043 Enginefan temperaturesensor
47113 Thermometricswitch for pre-filter andfuel oil sedimentationtankheating
48035 Enginerpmsensor
48042 Enginerpmsensor (ontiminggear)
48043 Turbocharger speedsensor
50003 Electronicdashboard withmicroprocessor for instrument and indicator lampdisplay
50005 Multiplexinstrumentsunit module
52001 Switchwith built in indicator lamp for windscreendefrost heater
52003 Switchwith built in indicator lamp for additional heater
52005 Switchwithbuilt inw/l for heatedrear viewmirrors
52009 Switchwithbuilt inw/l for trailer light
52013 Switchfor internal aerators
52024 Switchwithbuilt inw/l for additional headlamps
52029 Central emergencycontrol switch
52035 Switchwithintegral rotaryheadlamp engagement indicator lamp
52044 Switchfor differential lockengagement
52045 Switchfor front driveengagement
52056 Switchwithbuilt-inw/lampfor ASRcutout
52057 ABScut out switch
52059 Automatictransmissionspeed selector
52070 Switchfor engagingsidepower takeoff
52071 Switchfor engagingrear power takeoff
52090 Suspension levellingswitch(ECAS)
52091 Switchwithintegral indicator lampfor heater rear mirror engagement
52092 Switchfor engineor cabheater
52093 Switchfor tail hatchlockingsafety
52094 Switchfor spot light
52200 Switchfor electric or pneumatichorns
52220 Switchfor tail hatch lockingsafety
52300 Switchfor tail hatch lockingsafety
52302 Switchwithbuilt inw/l for hazard warninglights
52304 Switchfor foglights andrear foglightsinhibitor
52307 Switchfor exterior lights
Revi - June2007
52312 Switchcontrollingheadlampalignment adjustment
52324 Enginebrakeconnectingswitch
52326 Whiteandred internal lightsswitch
52502 Ignitionswitch for serviceswithstarting
52600 Main current switch
53006 Switchfor startingfromenginecompartment
53007 Switchfor stoppingenginefromenginecompartment
53022 Switchfor front differential lockcontrol
53030 Switchfor controllingstartingassistance
53061 Cab hydraulic releaseconsensusswitch
53062 Cab hydraulic releasepump switch(lowering)
53063 Cab hydraulic releasepump switch(raising)
53068 Unstableswitch for idleposition(n) with automatic transmission
53069 Unstableswitch for reverse (r) withautomatictransmission
53070 Unstableswitch for forwardgears(d) withautomatictransmission
53071 Unstableswitch for speed limiter withautomatictransmission
53300 S.|tc| o o|vo's s|oo o|oct|c .|ooo.
53302 Switchfor passenger sideelectric window
53303 Push-buttonpanel for slidingdoor openingdevicecontrol
53304 Switchfor axlepneumaticsuspensioncontrol
53305 Switchfor driveaxlepneumaticsuspensioncontrol
53306 Switchcontrollingsunroof motor
53309 Switchfor 3rdaxleraisingsystem
53311 Switchfor controllingwindowblind
53315 Switchwithbuilt intelltaletoturn onfoglights
53316 Current general contactor switch
53501 Switchsignallingvehiclestopped
53503 Switchsignallingreversinglights
53504 Front differential lockonindicator switch
53506 Four wheel driveengaged indicator switch
53507 Switchsignallingreduced gearsengaged
53508 Switchfor antistartingwithreducedgears
53509 Switchfor switchingoninterior lights
53510 Switchfor switchingonsteplights
53511 Switchsignallingcabinunlatched
53512 Switchfor antistartingenginedevicewithhandbrakeoff
53521 Switchfor signallinglongitudinal differential lock
53538 Tiltedboxindicator switch
53547 Switchfor secondarysignal frombrakepedal to EDC ECU
53565 Brakepedal pressed indicator switch
53567 Switchfor signallingsidepower takeoff engaged
53568 Switchfor signallingrear power takeoff engaged
53591 Switchfor signallingfailureof thehydraulic circuit withauxiliarysteeringthird axle
53593 Switchto light cabsideopeninglamp
53593 Tool compartment light switch
53602 Switchindicatingincompletesunshadeclosing
53606 Reed switch(control withmagnet) onmaster clutchcylinder for synchronousprotection of mechanical transmission,
70%compressed
53607 Reed switch(control withmagnet) onclutch master cylinder for EDC
53801 SwitchsignallingRockwell axle differential lockengaged
53802 SwitchsignallingRockwell axle differential lockengaged (3rd axle)
54030 4functionsteeringcolumnswitchunit
54033 6functionsteeringcolumnswitchunit
61011 3A 1-diodeholder container
61101 13A diodecontainer
61104 Air brakingsystemdrier resistor
61108 Current limiter resistancefor heater windscreensystem
61110 Pre-filter andfuel oil sedimentationtankpre-heatingresistor
61121 Resistancefor enginepreheating
61126 Terminationresistor for CAN bus
61137 Current limiter resistor for additional enginewater heater
61147 Resistor container for ACC (AdaptiveCruiseControl)
61150 Ureafilter outlet heater withSCR(SelectiveCatalyticReduction)
64000 Electricwindscreenwasher pump
65000 Windscreenwiper unit
66005 Headlampwasher pump
68000 Radio equipment
68001 Speaker
Revi - June2007
68003 Preamplifier
68005 Feeder 24 V 12V
68007 CityBand(C.B.)
70000 Fuseholder 6 (30A)
70001 Fuseholder 8
70058 1-way20A fusecarrier
70066 Fuseholder 1-way 1afor ADR
70401 Fuseholder 4-ways
70601 Fuseholder with 6fuses
72006 7-pincouplingfor tractor/trailer ABS/EBSelectricconnectionCouplingwith7poles for electrical connec-
tionof trailer ABS
72010 15-polecouplingfor electrical connection to trailer
72021 30-poleconnector for theelectrical connection tothediagnostic equipment locatedoutsidethevehicle
72022 2-polecouplingfor external engine start
72025 2-pole12V connection for general power supply
72026 2-pole12V connection for telephone
72069 16-polecouplingfor OBD (OnBoardDiagnose)
78009 Closedcircuit to turbinesolenoidvalve
78016 Enginefansolenoidvalve
78050 Enginebrakesolenoid valve
78052 ABS/EBSsolenoid valve
78053 ASRsolenoid valve
78054 Solenoid valvefor engagingretarder
78055 Solenoid valvefor retarder oil accumulator
78057 EBSfront axleair pressurecontrol proportional valve
78058 EBStrailer air pressurecontrol proportional valve
78059 Duplexvalvefor EBS
78060 Solenoidvalveto excludethird-axlebrakingwithASR
78061 Oversizesolenoidvalve for axlebrakingincase of EBSECUfailure
78062 ECAD regenerationsolenoid valve (ElectronicControlledAir Dryer)
78063 ECAD bleedsolenoidvalve (ElectronicControlled Air dryer)
78171 Splitter control solenoidvalve
78182 Solenoid valvefor mechanical transmissionsynchronousprotection
78203 Solenoidvalvefor pneumatic horns
78205 Solenoid valvefor transversedifferential lock
78206 Solenoid valvefor longitudinal differential lock
78208 Solenoid valvefor total PTO engagement ontransmission
78227 Solenoid valvefor radiator water recirculation
78238 Rear axlesolenoid valveassemblyfor chassisalignment
78239 Front axlesolenoid valveassemblyfor chassisalignment
78243 Rear axleelectropneumatic distributor
78245 Solenoid valvefor total PTO disengagement ontransmission
78247 Solenoid valvefor electronicinjection
78248 Solenoid valvefor variablegeometryturbineorder
78249 Solenoid valvefor third axlepneumaticvalvecontrol
78250 Solenoid valvefor 3rdaxlelowering
78251 Solenoid valvefor engagingtransmissionsidepower takeoff
78252 Solenoid valvefor engagingtransmissionrear power takeoff
78265 Solenoid valvefor axletransverse differential lockengagement
78266 Meteringmodulesolenoid valvewithSCR (SelectiveCatalytic Reduction)
78267 Enginewater circulationsolenoid valvefor ureatank heatingwithSCR (SelectiveCatalyticReduction)
80000 Motor for right electricwindow
80001 Motor for left electricwindow
82000 Windscreendefrostingcontrol unit
82005 Auxiliaryair heater
82010 Air conditioningsystemcontrol and indicationECU
84000 Water boiler
84001 Air burner
84005 Additional heater ECU
84006 Additional heater control and indicationECU
84009 Internal temperaturesensor
84010 Meteringdevice
Revi - June2007
84019 Electromagneticpulley
85000 Cigar lighter
85001 Cigar lighter outlet
85003 Heatedrearviewmirror (trailer)
85004 Heatedrearviewmirrot (wheel)
85005 Heatedrearviewmirror
85006 Electricallyadjustableheated rear viewmirror
85007 Wheel electricallyadjustableheatedrear viewmirror
85008 Trailer electricallyadjustableheatedrear viewmirror
85009 Front Heated rearviewmirror
85010 Rear viewmirror control
85011 Rearview selectionand heatedrearview mirror engagement control
85023 Electriclatch
85036 Heatedpneumaticseat (driver side)
85038 Heatedpneumaticseat (passenger side)
85065 Remotecontrol for aligningsuspensionsand raising3rd axle
85131 Volumetricsensor
85140 Electroniccontrol for SCRpumpingmodule(SelectiveCatalyticReduction)
85141 Catalyst outlet temperaturesensor withSCR (Selective Catalytic Reduction)
85142 Level and ureatanktemperaturesensorswith SCR(SelectiveCatalyticReduction)
85143 Catalyst inlet temperaturesensor withSCR(SelectiveCatalyticReduction)
85144 NOX detectionsensor with SCR
85150 EDC ECU
85152 Accelerator loadsensor (EDC)
85153 Coolant temperaturesensor (EDC)
85154 Turbofanair temperaturesensor (EDC)
85156 Turbo blower air temperatureandpressuresensor for EDC
85159 Temperatureandambient air pessuresensor for EDC
85161 Relativehumiditycombustion air andtemperaturesensorswith EDC
86002 Sensors for front brakeshoewear
86003 Sensors for rear brakeshoewear
86004 Automatictransmissionelectroniccontrol unit
86013 Sensor for signallingwater infuel filter
86015 Retarder electroniccontrol unit
86023 Vehicleraising/loweringcontrol unit Ecas
86029 Centralizeddoor lockECU
86030 Sensor detectingheat irradiation
86038 CentralizedlubeECU
86053 Multiplexcontrol andsignal unit frombedpositions
86116 Multiplexbodycomputer control unit
86119 Multiplexdriver door moduleECU
86053 Multiplexcontrol andindicationECU fromstretchers
86116 Multiplexbodycomputer ECU
86117 Multiplexfront framecomputer ECU
86118 Multiplexrear framecomputer ECU
86119 MultiplexDriver Door ModuleECU
86120 Multiplexpassenger door moduleECU
86123 MultiplexECU for steeringcontrol shaft interfacing
86124 CabinoperationwithMultiplexECU
86125 ECU for VDI (VehicleDataInterface)
86126 ECU for EM(Expansionmodule)
86127 ECU for DMI (DataManagement Interface)
86128 M.E.T. chassisECU
86129 ECU for MC-NET (MobileCommunicationNetwork)
86130 Navigator ECU
86131 Telematic ECU
86132 VCM(VehicleControl Module) ECU
88000 ABSECU
88001 ABS/EBSsystemsensor
88005 EBSsystemECU
88006 EBSrear axle air pressurecontrol modulator
88007 Potentiometricsensor for front wheel shoepositionindicator
88008 Potentiometricsensor for rear wheel shoe position indicator
88010 Rear axlebrakeapplicationpressuresensor
88011 Potentiometricsensor for thirdaxleskidwear signalling
88012 SASsensor (=SteeringAngleSensor) for EBS
88013 ESC module(=Electronic StabilityControl) for EBS
89000 Fridge
89010 Foodwarmer
ELECTRIC/ELECTRONICSYSTEM 11 TRAKKEREURO 4/5
MAIN CHANGES
For vehicleswith Euro 4 enginetheelectric/electronic systemis subject to important variations.
Inorder to handletheincreasedcomplexityof Euro4 operationsdemanded to theenginecontrol systemextrahardwareand
software resources, the VCM(Vehicle Computer Module) hasbeenaddedso that vehiclefunctions can be reallocatedonit,
whichupto Euro 3hadbeencarriedout bytheEDC enginecontrol unit,thereforemoredevelopment flexibilityisavailablefor
vehiclefunctions. The immobilizer functionhas been also integrated on this unit.
The New BodyController (IBC3) unlike the Body Computer (BC) distributes direct positives and key-locked, protected by
external fuses(replaceable) orinternal (resettable).InthechassisthereistheMET control unit (chassiselectronicmodule) which
controls thechassis power devices, thus replacingthe FFC and RFC control units.
For theautomated transmissiononthenewEuro 4vehiclerangethegear selectorhas beenremoved. Itsfunctionsarecarried
out fromthecontrol pushbuttons locatedonthedashboard center panel combined with thepower steeringlever.
The EMcontrol unit (ExpansionModule) replaces theDMI (DataManagement Interface). It controls thepower takeoffs and
makes it possible to implement complex applications and connections to different devices through the CAN-open line. It
communicateswith theother control units through theCAN DVBline.
TheSCR(SelectiveCatalyticReduction) - Denox 2isontheentireAverage/HeavyEuro4RangewiththeUreaDosingSystem
(UDS) positionedonthelower sideof theframe.
The ENGINE ECM (EngineControl Module) replacesEDC MS 6.2.
The newCluster ismonochrome withmorefunctions compared to theprevious one.
The introduction of thenew unitsandthechangeof theprevious ones requirechanges of thevehiclesystemstructure.
The followingCAN lines areontheVCM unit:
- VDB- VehicleDataBus
- ECB- EngineControl Bus
- FMB- FuhrparkManagement Bus
Figure2
112584
UDS
VCM
ECM
EM
IBC3
CLUSTER
MET
12 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
CAN LINES
DialoguebetweentheEasyMuxsystem, vehicle systems, enginecontrol unit, SCR system, radio and various setters is carried
out bymeans of theCAN lines:
- BCB- BodyControl Bus
- IDB- Infotainment DataBus
- FMB- FuhrparkManagement Bus
BCB (Body Control Bus) communication line
It enablesthecommunicationbetweentheIBC3andMET control units of theEasyMux systemandtheothercontrol unitsof
thedifferent servicesonboard.
Technical features
- Datatransmission speed 62.500(BIT/SEC)
- Color of thewire Grey
List of Units
Ref. Description
IBC3
DDM
PDM
BM
MET
AHT-A
AHT-W
BodyController
Driver Door Modulecontrol unit
Passenger Door Module control unit
Bed Module
MET chassis control unit
Air heater
Water heater
Figure3
112585
IBC3
BM DDM
PDM AHT_A
BCB
MET
AHT_W
VDB (Vehicle Data Bus) Communication Line
Allowstheelectronicsystemsonthevehicletodialogue. Theunitsconnectedto it are:EurotronicTransmission,Retarder,ABS,
Ecas, Diagnosis connector, VCM, Tachograph, ACC, SWI, EM, (Mc Net).
This linealso dialogues withtheCluster andtheBodyComputer.
Features
- Color of thewire Black
List of Units
Ref. Description
MTCO
DTCO
VCM
IC
IBC3
SWI
Diagnostic Connector
ABS
McNet
RETARDER
ECASII
EUROTRONIC II
ALLISON TCM
ACC
Tachograph
Digital tachograph
VehicleControl Module control unit
Cluster
BodyController
SteeringWheel Interfacecontrol unit
30-polediagnosisconnector
ABScontrol unit
Electroniccontrol unit for Mobile Communication Network
Intarder control unit
Air suspensioncontrl unit
Eurotronic II automatic gearbox control unit
Allisonautomatic gearboxcontrol unit
Radar ACC (AdaptiveCruiseControl) control unit
Figure4
112597
SWI
MTCO/DTCO
RETARDER ABS
Diagnostic
Connector
ECAS II
VDB
IBC3
VCM
EM MCNet
ETC
ALLISON TCM /
EUROTRONIC II
IC ACC
ECB (Engine Control Bus) communication line
Allows theunits and the enginecontrol sensorsto dialoguetogether. Theunits connectedto it are:: EDC,VCM, DCU15and
theOBD connector.
Features
- Color of thewire Yellow
List of Units
Ref. Description
VCM
EDC7
DCU15
OBD II Connector
VehicleControl Module Unit
Engine control unit
SCR pumpingmoduleunit
16poleconnector for OBD (onbord diagnose)
VCM
ECB
EDC7
OBD II
Connector
DCU15
Figure5
112280
I.D.B. (Infotainment Data Bus) communication line
Allows communicationbetweenthe Cluster andtheRadio. Themessages sent areshownontheCLUSTER.
Technical features
- Datatransmission speed 100.000 (BIT/SEC)
- Color of thewire Blue
List of Units
Ref. Description
Radio
McNet
Radio
Electroniccontrol unit for Mobile Communication Network
Figure6
IDB McNet
RADIO
112586
F.M.B. (Fuhrpark Managemant Bus) communication line
Allowscommunicationbetweenthedifferent electronicsystems(accessories) onthevehicle,, FMS(Telephone) connectorand
VCMunit.
Technical features
- Datatransmission speed 250.000 (BIT/SEC)
- Color of thewire White
List of Units
Ref. Description
VCM
FMS
VehicleControl Module Unit
Connector FMS
FMB
FMS
Connector
VCM
Figure7
112283
CAN LINE ASSEMBLY DRAWING
Figure8
112587
GROUND POINT OF BATTERIES ON LEFT
SIDEMEMBER
STARTER MOTOR AND ENGINE GROUNDPOINT
6633
6632
M1
M2
Figure9
Figure10
!
Neverdisconnect thebatteriesfromthesystemwith
theenginerunning.
Beforeconnectingthebatteriesto thesystem,make
surethat thesystemis well insulated.
Disconnect the batteries fromthe system when
chargingthem.
POWER NETWORK
The purpose of the electric systemis to generate, regulate,
storeand distributetheenergyneeded to make thevehicle
components work.
For this reason the supply of the base electric system is
ensuredbyagenerator (28V- 60A -90A alternator) andtwo
batteries, eachwith12 V170 Ah(opt 220Ah) connectedin
series.
Amobilefuseholdercontaininga20Ampfuseislocatedclose
to thebatteries. Thisfusesupplies:
- Fuseholder 70605/1
- BodyController (A07)
- Refrigerator
- ACC presetting
This fuse is not present ontheADR version.
Power cable section:
- batterydirect cable = 16mm
2
- fusecables = 4 mm
2
Attain to what detected on the vehicle for the remaining
sections.
Negative network
The batteries are connected to the frame ground with a
brown 70 mm
2
cable, at ground point M1 on the left
sidemember (Figure 9).
The starter motor is connected to the frame ground (M2)
through a70 mm
2
cable, fastened on theright sidemember
near theactual motor.
Thesamecableserves for connectingthewholeengineunit
to theframeground.
GROUND POINTS
91664
M1. Batteryground - M2. Starter motor ground - M3. Upper cab ground - M4. Right inner cabground- M5. Left inner cab
ground - M6. Front right frameground - M7. Engineground- T1- T2. Equipotential braid
Figure11
ELECTRICAL EQUIPOTENTIAL BRAID
Thoughgenerallyprotectedagainst theinfluenceofon-boardequipmentvoltage,electroniccomponentsneverthelessremainpar-
ticularlysensitiveelectromagneticcompatibilityissues, of different naturesuchas:
- generated bythevehicles
- external.
A suitablesizeflexibleelectrolyticcopperbraidhasbeenprovidedonthevehiclestominimizethesephenomenaandreturnmain
cab andframestructures totheequipotential state.
Check that thebraidis properlyattached totheframeandthecab, in theevent of defectivecab grounding.
74201
T1
T2
Figure12
49846
GROUNDPOINT ON THELEFT FRONT FRAME
49844
GROUNDPOINT ON THERIGHT FRONT FRAME
M6
T2
Figure13
Figure14
49849
GROUNDPOINT BEHINDTHEBODY COMPUTER
73754
GROUNDPOINT BEHIND THECLUSTER
M4
M5
Figure15
Figure16
7998
8000
8002
8003
ALTERNATOR CURRENT DELIVERY CURVE
Characteristics
WIRINGDIAGRAM
A. Alternator B. Voltageregulator
Ratedvoltage 28V
Ratedpower 90 A
Current at environment temperature1800RPM/40 A
At 25 C andratedvoltage 6000RPM/90 A
Direction of rotation clockwise, seenfrompulley
Weight 7.8kg
S
03000
L(D+)
IG(15)
B+
TECHNICAL VIEW
B
A
VOLTAGEREGULATORTEMPERATURE
CHARACTERISTICS(6000 RPM)
Figure17
Figure18
Figure19
Figure20
28V - 40 A 90 A BOSCHALTERNATOR
Ref. Function
Cablecolour
code
L To F.F.C. center clampJ2/B24 7009
15(IG) To remoteswitch25213 clamp87(viafuseF6-70601) 8876
S Positive(+30) 7777
B+ Clamp Salternator Positive +30power positive 7777
+30 positiveto starter motor 7777
Positive+30 7777
8535
PERSPECTIVEVIEW WITH CORRESPONDINGELECTRICAL CONNECTIONS
B
A
A
B+
Figure21
Ratedpower
Systemvoltage
Engagement system
Adjustedtime
Direction of rotation
Weight
Operatingvoltage
Water resistance
CHARACTERISTIC CURVES
4958
Characteristics Characteristics Test cond.
SpecificPower
(20 C)
TECHNICAL VIEW
WIRINGDIAGRAM
4956
4957
5.5kW
24V
Positiveapproachcontrol
30sec.
clockwise, seenfromend
of pinion
approx. 10.5kg
16V MAX. (20 C)
Water spraytest to JIS
|0203' S|'
Loadless 23V 120A MAX (3800rpmMIN.)
Load 16V (49 N-m) 690A MAX. (900rpmMIN.)
Stall 6V 1260A MAX. (73.5N-mMIN.)
08000
Figure22
Figure23 Figure24
24V - 5.5 KW NIPPONDENSO STARTER MOTOR
6658
PERSPECTIVEVIEW WITH ASSOCIATEDELECTRICAL CONNECTIONS
+30
Figure25
Connector Function
Cablecolour
code
+30 +30 positivefor starter motor power frombatterypositiveclamp(viatheT.G.C.) 7777
+30 +30 positiveto thealternator 7777
+30 +30 positiveto remoteswitchfor enginepreheat onconsent 7777
+50 +50 positivefor keyswitch 8888
ST06A
ST06B
ST07D
ST08A
ST08B
ST31
ST31L
ST37
ST79A
ST79B
ST79D
STY1
ST02
ST12
ST21
ST30
ST11
ST35/1
ST35/2
ST39
ST44
ST56
ST63
ST05
ST07B
ST07C
ST09A
ST10
ST13
ST20
ST31B
ST31C
ST31R
ST34
ST36
ST07A
ST19
ST09B
ST14A
ST14B
ST24
ST25
ST26A
ST31A
ST42
ST14
ST26B
ST14C
ST48
ST03
ST23
ST01
ST
ST28
ST15
ST40
ST45
ST06C
Figure26
113406
JUNCTION CONNECTORS
Location of the junction connectors - cab
Thelocationof theconnectors(cab - chassis) couldchangeto suit wiringneeds.
Figure27
113407
ST72
ST54
ST65
ST64
ST70
ST73/1
ST87
ST91
ST92
ST93
ST82
ST55A
ST55B
ST67
ST68
ST81A
ST80
ST69
ST83
ST73/2
ST73/3
ST73/4
ST86
ST75A
ST75B
Location of the junction connectors - chassis
List of connectors
Name Description
ST 01 Connectionfor startingcommutator
ST 02 Connectionfor steeringcolumn
ST 03 Connectionfor speedlimiter / Cruisecontrol set
ST 05 Connectionfor Eurotronic
ST 06A Connectionfor roof panel wingsdevicesonthedriver side
ST 06B Connectionfor tachograph
ST 06C Connectionfor Toll Collect
ST 07A Connectionfor roof panel wingsdevicesonthepassenger side
ST 07B Connectionfor navigationand for IT tools
ST 07C Connectionfor heatablewindscreen
ST 07D Connectionfor rotatingheadlights
ST 08A Connectionfor DDMcontrol unit
ST 08B Connectionfor driver sidedoor
ST 09A Connectionfor PDMcontrol unit
ST 09B Connectionfor passenger sidedoor
ST 10 Connectionfor toolslighting
ST 11 Connectionfor trailer retarder brake
ST 12 Connectionfor ABS/EBStractor and trailer electrical connection
ST 13 Connectionfor auxiliaryair heater CAN line
ST 14 Connectionfor Ecas bodybuilders(cab)
ST 14A Connectionfor bodybuilders(cab)
ST 14B Connectionfor bodybuilders(cab)
ST 14C Connectionfor set updevices(Allison)
ST 15 Connectionfor couplingsinthehigh roof
ST 19 Connectionfor heater
ST 20 Connectionfor air- conditioner
ST 21 Connectionfor radiator water recirculationsolenoid valve
ST 23 Connectionfor Immobilizer antenna
ST 24 Connectionfor air conditioningsystemcontrol unit CAN line
ST 25 Connectionfor Intarder
ST 26A Connectionfor Ecas
ST 26B Connectionfor ABS/EBS
ST 28 Connectionfor rotatingheadlights
ST 30 Connectionfor ADR (tachograph) provision
ST 31 Connectionfor ECASremotecontrol
ST 31A Connectionfor cabrear
ST 31B Connectionfor auxiliaryair heating
ST 31C Connectionfor auxiliaryair heatingtemperaturesensor
ST 31L Connectionfor pneumatic heated seat
ST 31R Connectionfor pneumatic heated seat
ST 34 Cooooct|oo o /CC ov|s|oo / s||o '' oabo cooto|
ST 35/1 Connectionfor air conditioner with manual control
ST 35/2 Connectionfor air conditioningwith manual control
ST 36 Connectionfor T.G.C. / I.G.C.
ST 37 Connectionfor Toll Collect
ST 39 Connectionfor differential lock
ST 40 Connectionfor navigationand for IT tools
ST 42 Connectionfor DDM/PDMsupplies
Name Description
ST 44 Connectionfor centralized closingwithremotecontrol
ST 45 Connectionfor 24 Vradio
ST 48 Connectionfor DMI / EMcontrol unit for PTO
ST 49 Connectionfor Allisonsetup
ST 54 Connectionfor ACC provision
ST 55A Connectionfor SCRsystem(Urea)
ST 55B Connectionfor SCRsystem(Urea)
ST 56 Connectionfor ADR (15) Alternator
ST 59 Connectionfor ECASbreakdownswitch/longitudinal blockageof 2
nd
front axle(8x8)
ST 63 Connectionfor auxiliarywater heater CAN line(BCB)
ST 64 Connectionfor 15-polescurrent output freepins
ST 65 CAN lineconnectionfor trailer (PTO withEM)
ST 67 Connectionfor ureadosingmodulesolenoidvalve
ST 68 Connectionfor Ureatemperaturesensor
ST 69 Connectionfor Intarder
ST 70 Connectionfor ASRsolenoid valve
ST 72 Connectionfor 35 axlesfor shoes wear and tear / transversedifferential blocking
ST 73/1 Connectionfor indicating1st front axlewear (right)
ST 73/2 Connectionfor indicating1st front axlewear (left)
ST 73/3 Connectionfor indicating2ndfront axlewear (right)
ST 73/4 Connectionfor indicating2ndfront axlewear (left)
ST 77 Connectionfor right hand side SML indicator lamp (SideMarker Lamp)
ST 78 Connectionfor left hand side SML indicator lamp (SideMarker Lamp)
ST 79A Connectionfor external cabfront
ST 79B Connectionfor windshieldwasher andwarninghornunit
ST 79D Connectionfor brakepedal switch(ABS)
ST 80 Connectionfor mechanicgearbox
ST 81A Connectionfor front lights
ST 82 Connectionfor componentsonthe engine
ST 83 Connectionfor componentsonengine
ST 85L Connectionfor left hand sideplate light
ST 85R Connectionfor right hand sideplate light
ST 86 Connectionfor T.G.C. / I.G.C.
ST 88 Connectionfor trailer connectors
ST 91 Connectionfor PTO1(DMI)
ST 99 Connectionfor rear axleECAS
ST Connectionfor ECAS
STY/1 Connectionfor switchon clutch
107169
Figure28
KEY SIDECONNECTORVIEW
1 2 3 1 2 3
Figure29
107538
Junction connector ST01(black) - turn on key
Pin Function
Cablecolour
code
1 Positive+30for ignitionkey 7777
2 Terminal 15 ignitionkey 8887
3 Terminal 50 ignitionkey 8888
ST02(green) - connection for steering column
Pin Function
Cablecolour
code
1 CAN L line(ICB) Green
2 CAN H line(ICB) White
3 Ground 0000
4 Negativefor warninghorn 1116
5 Positive+15fromignitionkey(15) 8887
6 Positivefor steeringcolumn switchunit symbols lighting 4442
7 Positive(+30) 7906
8 Positivefromignitionkey (50) 8888
9 Speedlimiter signal 9968
10 Ground 0000
11 - -
12 - -
Figure30
101525
ST03junction connector - speed limiter signal / Cruise Control Set
Pin Function
Cablecolour
code
2 - -
107545
Figure31
107538
Figure32
ST05junction connector (green) - Eurotronic II
Pin Function
Cablecolour
code
1 CAN VDBLine(L) Green
2 CAN VDBLine(H) White
5 Klineautomaticgearbox 2297
6 Automaticgearboxsystempower supply (Positive+15) 8102
7 Positivesymbols lighting 4442
8 Negativesignal forwardgear withautomaticgearbox 0127
9 VCMcontrol unit pin- X3/24 0125
10 Negativesignal fromneutral positionof theautomaticgearbox 0147
11 Negativesignal reversegear withautomaticgearbox 0128
12 VCMcontrol unit pin- X3/41 0126
13 Automaticgearboxsystempower supply (Positive+30) 7101
14 Ground 0000
ST06A junction connector (yellow) - roof panel wings devices on the driver side
Pin Function
Cablecolour
code
1 Positiveleft loudspeaker (preamplifier) 1188
2 Negativeleft loudspeaker (preamplifier) 1186
3 Slidingroof closingcontrol power supply 7011
4 Slidingroof openingcontrol power supply 7010
5 Positivefor warninghorn solenoidvalve 1133
6 CAN line(IDB) H White
7 CAN line(IDB) L Green
9 Positive+15 8871
10 - -
11 - -
12 - -
107545
Figure33
Figure34
107538
ST06B junction connector (yellow) - tachograph
Pin Function
Cablecolour
code
1 Isolatednegativetachographtransmitter 0058
2 Speedsignal tachographtransmitter 5517
3 Inverted signal tachographtransmitter 5516
4 Tachographtransmitter power supply 5514
5 Speedpulsefor EDC 5155
8 - -
9 Ground 0000
10 Tachographpower supply(Positive+15) 8871
12 Tachographpower supply (batterypositive+Batt) after fuse70058 7768
13 Kline 2997
14 Tachographsignal distance - travelledfor Cluster 5518
15 - -
ST06C junction connector (yellow) - Toll Collect
Pin Function
Cablecolour
code
1 Positive+30 7772
3 Positive+15 8871
4 Speedsignal (tachograph) 5541
5 Ground 0000
7 - 2222
8 CAN line Yellow
9 CAN line Red
10 - 6666
11 Positive+30 7777
12 Ground 0000
107545
Figure35
107531
Figure36
ST07A junction connector (yellow) - roof panel wings devices on the passenger side
Pin Function
Cablecolour
code
1 Positivefor front end-outlinemarker lamps 3339
2 Positivefor voltagereducer 7772
3 Loudspeaker signal (preamplifier) 1184
4 Loudspeaker signal (preamplifier) 1183
5 Positivefor readinglights(12V) 7712
6 Positive12V 7712
7 Positivefor overheadlight (whitelight) 4423
8 Positivestep lighting 4445
9 Positivefor overhead light (bluelights) 4410
10 Positivefor overheadlight (redlights) 4422
11 Negativefor sunshadecurtain 0974
12 Sunshadecurtainclosingsignal 8065
13 Positivefor sunshadecurtainmotor 8063
14 Positivefor sunshadecurtainmotor 8064
15 - -
ST07B junction connector (yellow) - navigation and it tools
Pin Function
Cablecolour
code
1 Positive+30after TGC 7772
2 Positive+15 8871
3 Speedsignal for navigator 5541
4 - -
5 CAN L line(FMB) Green
6 CAN H line(FMB) White
7 Positivefor instrumentslighting 4442
8 Reversegear signal 2268
9 - -
Figure37
101529
105228
Figure38
ST07C junction connector (black) - heatable windshield
Pin Function
Cablecolour
code
1 Power supplyto heatable windshield 8020
2 Power supplyto heatable windshield 8020
ST07D junction connector- rotating headlights
Pin Function
Cablecolour
code
1 Positivefor left hand siderotatingheadlight 1108
2 Ground for rotatingheadlight 0000
3 Positivefor right hand siderotatingheadlight 1115
107538
Figure39
107188
Figure40
ST08A junction connector (blue) - DDM control unit
Pin Function
Cablecolour
code
1 Positive(+30) for control unit power supply 7991
2 Ground 0000
3 Signal for loudspeaker (roof panel) 1188
4 Signal for loudspeaker (roof panel) 1186
5 Klinefor diagnosis 2991
6 CAN H line(BCB) White
7 CAN L line(BCB) Green
8 Centralisedlockingcontrol signal - opening 0064
9 Centralisedlockingcontrol signal - closing 0065
10 Signal (+) external temperaturesensor 7573
11 Driver sideelectrical lockbolt 0003
12 External temperaturesensor ground 0550
Jointing connector ST08B (blue) - driver side door
Pin Function
Cablecolour
code
1 Connection2 betweensidewindowregulator switches 8862
3 Mirror heatingsupply 8830
4 Positive+30(presetting) 7990
5 - -
6 - -
107538
Figure41
Figure42
101529
ST09A junction connector (blue) - PDM control unit
Pin Function
Cablecolour
code
1 Positive(+30) control unit power supply 7990
2 Ground 0000
3 Positiveright handsideloudspeaker 1184
4 Negativeright handsideloudspeaker 1183
5 Klinefor diagnosis 2290
8 Centralisedlockingcontrol signal - opening 0064
9 Centralisedlockingcontrol signal - closing 0065
10 - -
11 Passenger sideelectrical lock bolt 0003
12 Free -
Jointing connector ST09B (white) - passenger side door
Pin Function
Cablecolour
code
Figure43
Figure44
107531
101525
ST10junction connector (green) - Instruments lighting
Pin Function
Cablecolour
code
3 Positivefor commutator for thirdaxlelifting. 4442
4 Positivefor switchwith incorporated warninglight for heatablewindshieldenabling 4442
5 Positivefor switchwith incorporated warninglight for heatedrear viewmirrors 4442
6 Positivefor switchwith incorporated warninglight for A.S.R. disabling 4442
Connector of junction ST11 - trailer retarder brake
Pin Function
Cablecolour
code
1 Ground fromtrailer brakehand wheel switch(brakelight) 0927
2 Ground for trailer brakehand wheel switch(brakelight) 0000
Figure45
Figure46
107188
101531
ST12junction connector (green) -tractor and trailer ABS/EBS
Pin Function
Cablecolour
code
1 - -
2 - -
3 - -
4 - -
5 Positivepressedpedal signal (ABS) 8153
6 Positivefor stoplights (ABS) 8158
ST13junction connector (black) - auxilliaryair heater
Pin Function
Cablecolour
code
1 CAN BCBLine(L) Green
2 CAN BCBLine(H) White
ST14junction connector - ECAS bodybuilders(cab)
Pin Function
Cablecolour
code
1 Power supplyto liftableaxleloweringor liftingswitch 8445
ST14A junction connector (blue) - for bodybuilders(cab)
Pin Function
Cablecolour
code
1 Enginestart-up signal input 8892
2 Engineturningoff signal input 0151
3 Stop lightssignal for bodybuilders 1165
4 Vehiclenot in operationsignal output 5515
5 Parkingbrakeengaged signal output 6656
6 - -
7 Speedsignal fromtachograph 5155
8 Enginecondition(output signal) 0 Venginenot inoperation/ 24 Vengineinoperation 7778
9 Gearboxinneutral position signal 8050
11 Positive+15 8871
12 Provisionfor CruiseControl SET + 8156
13 Provisionfor CruiseControl SET - 8157
14 Provisionfor CruiseControl OFF 8154
15 Provisionfor CruiseControl RESUME 8155
16 ProvisionCruiseControl (internal /external choice) 0158
17 Ground 0000
18 Provisionfor P.T.O. 1control signal 0131
21 Positive+30 7772
Figure47
Figure48
101523
107554
Figure49
107531
Figure50
107538
ST14B junction connector (blue) - for bodybuilders(cab)
Pin Function
Cablecolour
code
1 Signal for thesecond speedlimiter 0172
2 - -
3 Clutchstatussignal 9963
4 Programmablespeedthresholdindicator signal (PTS) 5542
5 Hazardlight signal 1113
6 - -
7 - -
8 Enginerpmsignal 5584
9 External light signal 3333
ST14C junction connector (grey) - for set up devices(Allison)
Pin Function
Cablecolour
code
1 Neutral signal for PTO 145
2 Steppingswitchsignal 123
3 - -
4 PTO signal active 143
5 PTO signal active 130
6 - -
7 - -
8 Automaticneutral signal 117
9 Automaticneutral signal 101
10 Digital earth 103
11 Zoneindicator signal 113
12 - -
107538
Figure51
ST15- ST19junction connector
ST15(yellow) - Connection for couplings in the high roof
Pin Function
Cablecolour
code
1 Ground 0000
2 Positivefor slidingroofclosing 7011
3 Positivefor slidingroofopening 7010
4 Positivefor readinglight 4412
5 Positivefor overheadlights(whitelight) 4423
6 Positivefor overheadlights(red lights) 4422
7 - -
8 Left hand side loudspeaker 1186
9 Left hand side loudspeaker 1188
10 Right handsideloudspeaker 1183
11 Right handsideloudspeaker 1184
12 -- -
ST19(green) - connection for heating
Pin Function
Cablecolour
code
1 Kline 2295
3 withST 20 - 3 0506
4 withST 20 - 4 8087
5 Positivefor 1st speedauxiliaryheatingenabling(remotecontrol switch) 8884
6 Positivefor heater motor water recirculationenabling(remotecontrol switch) 7778
7 Lockedpositive 8871
8 - -
9 Ground 0000
10 Negativefor auxiliaryheater enabling 0501
11 Positivewith starter up engine 7786
12 - -
107552
Figure52
ST20junction connector (green) - air conditioning system
Pin Function
Cablecolour
code
1 Kline 2296/2295
2 Positiveinstruments lighting 4442
3 withST 19 - 3 0506
4 withST 19 - 4 8087
5 Positivefor 1st speedheater enabling(remotecontrol switch) 8884
6 Remotecontrol switchsignal for compressor enabling(frompressureswitches) 9933
7 Remotecontrol switchsignal for compressor enabling(fromcontrol unit) 9933
8 Positivewith starter up engine 7778
9 Ground 0000
10 Positivecompressor control 9993
11 Positive+15 8871
12 Positiveafter TGC 7551
13 Positiveafter TGC 7551
14 - -
15 Negative(fromcontrol unit) for solenoidvalveradiator water recirculation 9552
16 Positivefor solenoidvalveradiator water recirculation 7550
17 - -
18 - -
101531
Figure53
Figure54
107169
1 2 3 1 2 3
ST21junction connector (black) - solenoid valve for radiator water recirculation
Pin Function
Cablecolour
code
2 Negativefor solenoidvalve for radiator water recirculation 9552
ST23junction connector - immobilizer antenna
Pin Function
Cablecolour
code
1 Immobilizer antennasignal (VCMpin - X1/1) -
2 Immobilizer antennasignal (VCMpin - X1/3) -
3 - -
Figure55
101531
Figure56
101542
ST24junction connector (black) - CAN line for air conditioning system
Pin Function
Cablecolour
code
ST25junction connector (black) - Intarder
Pin Function
Cablecolour
code
3 Speedsignal for Intarder 5541
4 EOL dataentrylinefor Intarder control unit 3393
5 Kline 2293
101536
Figure57
107183
Figure58
ST26A - ST26B junction connector
ST26A (black) - Ecas (CAN)
Pin Function
Cablecolour
code
3 Kline 2294
ST26B (black) - ABS/EBS (CAN)
Pin Function
Cablecolour
code
3 Kline 2299
ST28junction connector- rotating headlights
Pin Function
Cablecolour
code
1 Ground for left handsiderotatingheadlight 0000
2 Positivefor left hand siderotatingheadlight 1108
3 Free -
4 Positivefor right hand siderotatingheadlight 1115
5 Ground for right handsiderotatingheadlight 0000
107188
Figure59
ST30(blue) - provision for ADR(tachograph)
Pin Function
Cablecolour
code
1 Positive(+Batt) tachograph 7768
2 - -
3 Positive(+Batt) fromIBC3 7768
4 Positive(+Batt) Cluster / Central locking 7768
5 Batterydirect positive(+Batt) after fuse70058(20A) 7972
6 Positive(+Batt) 7972
ST31(green) - connection for ECAS(remote control)
Pin Function
Cablecolour
code
1 Power supplyto equalizationadjustment system(+15) 8810
2 Ground 0000
3 Clock lineon ECASsuspensions control keyboard 6402
4 Clock lineon ECASsuspensions control keyboard 6403
5 - -
6 - -
107538
Figure60
107188
Figure61
ST31A junction connector (green) - Cab rear
Pin Function
Cablecolour
code
1 Positivefor tool compartment lightingswitch 4448
2 Positivefor readingover head light 4412
3 Ground 0000
4 Ground for refrigerator 0000
5 Positivefor refrigerator (24 V) 7735
6 Positivepower supplyfor BedModule 7906
7 Ground 0000
8 CAN (H) LineBCB White
9 CAN Line(L) BCB Green
10 Positivefor telephoneplug(12V) 7712
11 Telephoneplugground 0000
12 Positivefor lamp 7772
ST31B junction connector (blue) - auxiliary air heating
Pin Function
Cablecolour
code
1 Auxiliaryair heater warninglight 6655
2 Positive+30 7708
3 Ground 0000
4 Power supplyto auxiliaryfuel pump for air heater 7783
5 Auxiliaryheater Kline 2295
6 Power supplyto ambient temperaturesensor for auxiliarysensor 7512
101525
Figure62
101529
Figure63
ST31C junction connector (white) - water heating temperature sensor
Pin Function
Cablecolour
code
1 Positivefor internal temperature detectionprobe 7520
2 Negativefor internal temperature detectionprobe 0000
ST31L - ST31R junction connector
ST31L - connection for pneumatic heated seat
Pin Function
Cablecolour
code
1 Ground 0000
2 Positivefor driver sideheatedpneumaticseat 8031
ST31R - connection for pneumatic heated seat
Pin Function
Cablecolour
code
1 Ground 0000
2 Positivefor passenger sideheated pneumatic seat 8031
107531
Figure64
ST34(blue) junction connector- provision for ACC / simple gearbox control H
Pin Function
Cablecolour
code
1 VCMcontrol unit pinX3/7 0179
2
Powersupplyto warninglight for ACC (AdaptiveCruiseControl) distancerulesignalling/ Power
supplyto splitter control solenoidvalve (gear reducer) mechanical gearbox
6179/9973
3 Positive5 Vfor distancecontrol with ACC (AdaptiveCruiseControl) great distance 8179
4 VCMcontrol unit pinX2/9 0139
5 Returnfromdistanceselector with ACC (AdaptiveCruiseControl) 6178
6
Power supply to distance alarmbuzzer withACC (AdaptiveCruiseControl) / Power supplyto
splitter control solenoid valve (mechanical gearbox)
1166/9974
7 Positive+15 8871
9 - -
107545
Figure65
107188
Figure66
ST35/1junction connector (yellow) - manual control air conditioning system
Pin Function
Cablecolour
code
1 - -
2 - -
3 - -
4 Positive+30 7550
5 - -
6 - -
7 - -
8 Ambient thermostat signal 9993
9 Negativeremotecontrol switchesair conditioningenablingcommand 0555
11 Positivefromremote control switchinternal heatingenablingconsent 8004
12 Positiveremotecontrol switchair conditioner enablingcommand 8097
13 Contact of theremotecontrol switch(87) for auxiliaryheater 1st speedenabling 8884
14 Positivefor Topflapcommandingremoteswitchcontrol 8801
15 - -
ST35/2junction connector (yellow) - manual control air conditioning system
Pin Function
Cablecolour
code
1 Positivefor windshieldelectricdefroster commandunit 8884
2 - -
3 Kline 2296
4 Positive+30fromBodyComputer 7786
5 - -
6 - -
Figure67
Figure68
107538
107188
ST36junction connector (grey) - T.G.C. / I.G.C.
Pin Function
Cablecolour
code
1 Alternator power supplyterminal 15 8876
3 Signal for TGC closing 8035
4 Signal for TGC closing 8035
5 Batterypositive(+Batt) 7972
6 Batterypositive(+Batt) for tachographand IC 7768
7 Batterypositive(+Batt) for B.C. / B.M. / diagnosis/refrigerator connector 7972
8 CAN (H) line(BCB)
9 CAN (L) line(BCB)
10 Telephonesocket positive(12V) 7712
11 Ground for telephone 0000
12 Positivefor bulb 7772
SST37C junction connector (yellow) - Toll Collect
Pin Function
Cablecolour
code
3 Positive+15 8871
4 Speedsignal (tachograph) 5541
5 Ground 0000
6 - -
Figure69
107188
ST39junction connector (yellow) - differential lock
Pin Function
Cablecolour
code
2 Signal fromfront transversedifferential lockcontrol switch 0902
3 Signal fromlongitudinal differential lock control switch 0903
4 Signal fromrear transverse differential lockcontrol switch 0904
5 Ground 0000
6 - -
Figure70
101529
107531
Figure71
ST40junction connector - navigation and it tools
Pin Function
Cablecolour
code
2 Positive+15 8871
3 Speedsignal for navigator 5541
4 Positive12V 7712
6 CAN H line(ICB) Bianco
9 Ground 0000
Jointing connector ST42 - DDM/PDM supplies
Pin Function
Cablecolour
code
1 Positive+30 7777
2 Positive+15 8887
Figure72
Figure73
113250
105243
ST44junction connector - centralized locking with remote control
Pin Function
Cablecolour
code
1 Clinker control 1113
2 - -
3 Batterypositive(+Batt) 7772
4 Ground 0000
5 Control for centralizedlockingto BodyComputer (door opening) 0064
6 Control for centralizedlockingto BodyComputer (door closing) 0065
7 Power supply+15 8871
8 - -
ST45junction connector- 24V connection for radio
Pin Function
Cablecolour
code
1 Positive+30for preamplifier 7772
2 Positive+15for radio receiver 8871
3 Ground 0000
5 CAN lineL (IDB) Green
6 CAN lineH (IDB) White
7 Positive+30for radio receiver 7770
8 - -
Figure74
Figure75
101523
107545
ST48junction connector (yellow) - EM control unit (PTO)
Pin Function
Cablecolour
code
2 CAN H line(ICB) White
3 Kline Green
5 Positive+30 7166
6 Positive+15 8166
7 Ground 0000
8 Wiringfor CAN L line (SB) Green
9 Wiringfor CAN H line (SB) White
10 P.T.O. control signal 1 0131
13 Positive+30for bodybuildersconnector (72072C) 7795
14 Positive+30for bodybuildersconnector (72072D) 7796
15 - -
Jointing connector ST 49 - Allison transmission setup
Pin Function
Cablecolour
code
1 Starter motor remotecontrol switch ground 0008
101542
Figure76
105251
Figure77
ST54junction connector- provision for ACC
Pin Function
Cablecolour
code
1 CAN lineL (VDB) Green
2 CAN lineH (VDB) White
3 CAN lineL (VDB) Green
4 CAN lineH (VDB) White
5 Positive+15 8176
ST55A junction connector- SCR system(urea)
Pin Function
Cablecolour
code
1 CAN lineL (ECB) Green
2 CAN lineH (ECB) White
5 Kline 2257
6 Positive+15 8540
7 Power supplyto combustionair relativehumidityand temperaturesensor 8173
8 Signal for combustionair relative humiditysensor 5173
9 Combustionair relativehumidityand temperaturesensor ground 0173
10 Combustionair temperaturesensor signal 5174
11 Power supplyto enginebrakesolenoid valve 9966
12 Enginebrakesolenoid valveground 0043
Figure78
101523
Figure79
101531
ST55B - ST56junction connector
ST55B - SCR system power supply(urea)
Pin Function
Cablecolour
code
1 Batterypositive(+Batt) SCR System 7540
ST56(black) - Connection for ADR cut generator
Pin Function
Cablecolour
code
ST59junction connector - 2
nd
front axle ECAS fault / longitudinal lock (8x8)
Pin Function
Cablecolour
code
1 ECASfault signal / front longitudinal differential locksengaged signal (8x8) 6401 / 6643
2 ECASfault signal switchearth 0000
101525
Figure80
101542
Figure81
ST63junction connector- auxiliary water heater CAN
Pin Function
Cablecolour
code
1 CAN Line(L) BCB Green
2 CAN (H) LineBCB White
ST64junction connector (black) - 15-poles current outlet free pins
Pin Function
Cablecolour
code
1 Power supplyto current outlet 8021
3 Transversedifferential blockingsignal 6621
4 Power supplyto positivetrailer interlocking+15 8075
5 Power supplyto positivetrailer interlocking+15 8075
101531
Figure82
101536
Figure83
ST65- CAN for trailer (PTO with EM)
Pin Function
Cablecolour
code
1 CAN SBline(L) (connectionfor trailer - PTO with EM)
2 CAN SBline(H) (connectionfor trailer - PTO withEM)
ST67- UREA dosing module solenoid
Pin Function
Cablecolour
code
1 Power supplyto dosingmodulesolenoid valvewithSCR 7541
2 Ureaelectric dosingunit (-) control 9541
ST68junction connector- UREA temperature sensor
Pin Function
Cablecolour
code
1 Signal cableto ureatanklevel sensor withSCR 6543
2 UreatankwithCSR level andtemperaturesensor ground 0543
3 Signal cableto ureatanktemperaturesensor withSCR 6542
Figure84
105334
101531
Figure85
ST69junction connector- Intarder
Pin Function
Cablecolour
code
1 Solenoidvalvefor retarder oil accumulator 0311
2 Solenoidvalvefor retarder oil accumulator 9311
3 Water temperaturetransmitter for retarder 5309
4 Water temperaturetransmitter for retarder 0309
5 Solenoidvalvefor retarder enabling 0310
6 Solenoidvalvefor retarder enabling 9310
ST70junction connector (black) - ASR solenoid valve
Pin Function
Cablecolour
code
1 ASRsolenoid valve(-) control 0260
2 ASRsolenoid valvepower supply 9260
Figure86
101542
ST72junction connector (black) - rear block wear / transverse differential lock
Pin Function
Cablecolour
code
1 To thedeviator for signallingof transversedifferential lockof Rockwell rear axles for the thirdaxle 0041
4 To thesensor for circuit signallingof rear wheel shoeswear 6667
5 To thesensor for circuit signallingof rear wheel shoeswear 6664
Figure87
101531
Junction connector ST73/1 - ST73/2- ST73/3 - ST73/4
ST73/1(black) - 1
st
front axle block wear (right)
Pin Function
Cablecolour
code
1 To thesensor for circuit signallingof front wheel shoeswear 6664
ST73/2(black) - 1
st
front axle block wear (left)
Pin Function
Cablecolour
code
ST73/3(black) - 2
nd
front axle block wear (right)
Pin Function
Cablecolour
code
ST73/4(black) - 2
nd
front axle block wear (left)
Pin Function
Cablecolour
code
101531
Figure88
101536
Figure89
ST75A junction connector - 1st front axle differential lock
Pin Function
Cablecolour
code
1 1
st
front axledifferential locksignal 6659
2 Ground 0000
ST75B junction connector - 2nd front axle differential lock
Pin Function
Cablecolour
code
1 2
nd
front axledifferential locksignal 6659
2 Ground 0000
3 Front longitudinal differential lock engagedsignal (8x8) 6643
101538
Figure90
ST77- ST78JUNCTION CONNECTOR BODYBUILDERS (CHASSIS - TRUCK)
ST77(black) - Right hand side SML indicator light (Side Marker Lamp)
Pin Function
Cablecolour
code
1 Signal for sidelamps 3330
2 Ground for sidelamps 0000
ST78(black) - Left hand side SML indicator lamp(Side Marker Lamp)
Pin Function
Cablecolour
code
107545
Figure91
Figure92
107531
ST79A junction connector (yellow) - external cab front
Pin Function
Cablecolour
code
1 Ground 0000
2 Positiveto refrigeratingfluidpressuresignallingswitch (air conditioner) 9993
3 Positivefromrefrigeratingfluid pressuresignallingswitch (air conditioner) 9993
5 Signal fromswitchonclutchfor VCM (clutchcylinder 20%compressed) 0160
6 Gearboxsynchronousprotection solenoidcontrol earth (clutch cylinder 70%compressed) 9975
7 Positivefor windscreenunit (high speed) 8881
8 Positivefor windscreenunit (lowspeed) 8882
9 Positivefor windscreenunit 8880
10 Positivefor windscreenunit 8873
11 Radiator water recirculation solenoidvalve command 9552
12 Negativefromrefrigeratingfluid pressure signallingswitch(enginecooling) 0583
13 Negativefromrefrigeratingfluid pressure signallingswitch(enginecooling) 0582
14 - -
15 - -
Jointing connector ST79B (yellow) - windshield washer and warning hornunit
Pin Function
Cablecolour
code
1 Signal for warninghorn 1116
2 Electrical pumppower headlight wipers 8821
3 Signal fromtheBodyComputer for windshield washer liquid low level indicator control 5521
4 Windshield washer control signal 8886
5 - -
6 - -
7 - -
8 - -
9 - -
101545
Figure93
ST79D junction connector (green) - brake pedal switch(ABS)
Pin Function
Cablecolour
code
1 Positive+30 7150
2 Positivefor stoplights 8158
3 Positivepressed pedal signal 8153
4 Positive+30 7150
5 - -
6 - -
105251
Figure94
Figure95
105334
ST80junction connector (black) - mechanical gearbox
Pin Function
Cablecolour
code
1 Signal for reverselightslight up switch 2268
2 Ground for reverselightslightingupswitch 0000
3 Ground for anti-start systemwithgearsengaged switchand for reverselight light upswitch 0000
4 Ground for anti-start systemwithgearsengaged switchand for reverselight light upswitch 8050
5 Signal for reduced gearsengaged signallingswitch 9992
6 Ground for reduced gearsengaged signallingswitch 0000
ST81A junction connector (black) - front lights
Pin Function
Cablecolour
code
1 Side / left front direction indicator power supply 1129
2 Right / left front sidelight power supply 3339
3 Left lowbeampower supply 2231
4 Left highbeampower supply 2219
5 Right / left foglamp power supply 2228
6 - -
7 Right side/ front directionindicator power supply 1123
8 - -
9 Right lowbeampower supply 2223
10 Right highbeampower supply 2221
11 Headlamp alignment corrector control 9936
12 Supplementaryhead lamppower supply 2229
105251
Figure96
Figure97
105334
ST82junction connector (black) - components on engine
Pin Function
Cablecolour
code
1 - -
2 - -
3 Signal for engineventilationtemperaturesensor 5166
4 - -
5 - -
6 - -
7 - -
8 - -
9 Signal for engineoil level thermometer transmitter 5505
10 Signal for engineoil level thermometer transmitter 5506
11 Ground for fuel filter clogged signallingswitch 0000
12 Signal for fuel filter cloggedsignallingswitch 5531
ST83junction connector (black) - components on engine
Pin Function
Cablecolour
code
1 Engineoil level transmitter signal 5506
2 Engineoil level transmitter signal 5505
3 Blocked fuel filter switchsignal 5531
4 Power drivelowoil level switch signal 5525
5 Positive+15for UDSpower unit 8540
6 - -
101531
Figure98
105334
Figure99
ST86(black) - T.G.C. connection
Pin Function
Cablecolour
code
1 TGC Off relayexcitation 8845
2 TGC Onrelayexcitation 8835
ST86(black) - I.G.C. connection
Pin Function
Cablecolour
code
1 Provision 8045
2 TGC Onrelayexcitation 8035
ST88(black) - trailer connectors
Pin Function
Cablecolour
code
1 Trailer axlelift signal 6442
2 Trailer brakelowair pressure 6689
3 Positive+30for trailer socket 7790
4 Positive+15for trailer ABSsocket 8847
5 Trailer ABSfault signal 6671
6 Loadcompartment lightingpower supply 2224
101538
Figure100
ST91- ST92- ST93junction connector
ST91(black) - PTO1 (EM)
Pin Function
Cablecolour
code
1 PTO 1power take-off returnsignal 6131
2 PTO 1solenoid valvepower supply 9131
3 Negativeconsent for power take-off PTO 1 0391
4 Ground 0000
Pin Function
Cablecolour
code
4 Ground 0000
Pin Function
Cablecolour
code
4 Ground 0000
101551
Figure101
ST99junction connector (black) - rear axle ECAS
Pin Function
Cablecolour
code
1 Level sensor ground 0400
2 Right rear axlelevel sensor signal 5421
3 Left rear axlelevel sensor signal 5422
4 Rear axlepositiveelectro pneumaticdistributor 9400
5 Rear axlegroundelectropneumatic distributor 9423
6 Ground for rear axle electro pneumatic distributor left valvecommand 9425
7 Ground for rear axle electro pneumatic distributor right valvecommand 9424
107178
Figure102
Figure103
107169
1 2 3 1 2 3
ST junction connector- ECAS remote control
Pin Function
Cablecolour
code
1 Positivefor remotecontrol power supply (pin 1) 7777
2 Negativefor remotecontrol (pin2) 0000
3 Communicationlinewithremotecontrol (pin3) 3333
4 Communicationlinewithremotecontrol (pin4) 8888
STY/1junction connector (black) - switch on clutch
Pin Function
Cablecolour
code
1 Ground 0000
2 Signal fromswitchonclutchfor VCM 0160
3 - -
Figure104
113251
15-pin current outlet for trailer electric connection (72010)
Pin Function
Cablecolour
code
1 Left hand sidetrailer directionindicators 1180
2 Right handsidetrailer directionindicators 1185
3 Trailer back foglight 2283
4 Ground 0000
5 Left trailer end-outlinemarker 3339
6 Right trailer end-outlinemarker 3330
7 Trailer stop lights 1179
8 Trailer reverselight 2226
9 Power supplyto trailer outlet after fusefor T.M.P. devices 7790
10 Transversedifferential blockingsignal 6621
11 Power supplyto positivetrailer interlockings+15 8075
12 Warninglight signallingtrailer axlelifted 6442
13 Ground 0000
Figure105
113252
7-pin current outlet for trailer electric connection
72000- normal 7-pin current outlet for trailer electric connection
Pin Function
Cablecolour
code
1 Ground 0000
2 Left trailer end-outlinemarker 3339
3 Left hand sidetrailer directionindicators 1180
4 Trailer stop lights 1179
5 Right handsidetrailer directionindicators 1185
6 Trailer end-outlinemarker 3330
7 Free -
72001- auxiliary 7-pin current outlet for trailer electric connection
Pin Function
Cablecolour
code
1 Ground 0000
2 Trailer interlockingspower supplywithterminal +15 8075
3 Trailer reverselight 2226
4 Free -
5 Warninglight signallingtrailer axlelifted 6442
6 Power supplyto trailer outlet after fusefor T.M.P. devices 7790
7 Trailer back foglight 2283
72006- -pin current outlet for trailer ABS electric connection
Pin Function
Cablecolour
code
1 Positiveafter fusefor trailer ABS 7772
2 Power supplyafter fusefor ABS/ speedlimiter 8847
3 Ground 0000
4 Ground 0000
5 Trailer ABSfault warninglight 6671
6 C/| '' ||oo (S3) WS/BI
7 C/| '|' ||oo (S3) GN/VE
113302
Figure106
DIAGNOSISCONNECTOR(FRONT VIEW)
Pins27,28,29,30 might beprintedwithdifferent positionsfromthosereportedinthis picture.
1
7
13
19 25
2
8
14
20
26
3
9
15
21
4
10
16
22
5
11
17
23
6 12
18
24
30 27
28 29
19 25
20
26
21
22
17
23
18
24
(+)
(--) ( v)
DIAGNOSIS CONNECTOR
Diagnosis connector - 72021
Pin System Function
Cablecolour
code
1 Free - -
2 EDC (ECM) K 2298
3 Free - -
4 ABS/ EBS+ECAS K 2299
5 Free - -
6 Intarder / EM K 2293
7 Free - -
8 BodyController / DDM/ PDM K 2295
9 Free - -
10 Heater / Air conditioner K 2296
11 Sov|co actoat|oo |o to '|/|' +15 8802
12 VCM K 2292
13 Free - -
14 Cluster / tachograph K 2994
15 Free - -
16 UREA (SCRsystem) K 2257
17 Free - -
18 EUROTRONIC / ALLISON K 2297
19 Free - -
20 Programmingretarder EOL - 3393
21 CAN H (VDB) H Ws/Bi
22 CAN L (VDB) L Gn/Ve
23 Free - -
24 Free - -
25 Startupsignal - 8050
26 Signal ground - 0050
27 Free - -
28 Speedsignal (B7) v 5542
29 Signal ground 31 0050
30 Positive +30 7772
113328
Figure107
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
OBD DIAGNOSIS CONNECTOR(BLUE)
Pin Function
Cablecolour
code
1 - -
2 - -
3 - -
4 Ground 0000
5 Signal ground 0050
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
15 - -
16 Batterydirect positive(+Batt) 7721
The newbayonet connectorsmakesignal continuitymuch morereliablethantheprevious system.
85750 73658
C E A D B
1 28 39
11 38 40 27 19
12 20
LEFT-HAND DRIVE
Connector A \||to (oo)
Connector B 3o.o (|C/S)
Connector C Yo||o. (SC|)
Connector D - Blue(EuroTronic/PTO/INTARDER)
Connector E Cooo (||C//||)
RIGHT-HAND DRIVING
Connector A \||to (||C//||)
Connector B 3o.o (|ooToo|c/|TC/||T/||||)
Connector C Yo||o. (SC|)
Connector D 3|oo (|C/S)
Connector E Cooo (oo)
C E A D B
1 28 39
11 38 40 27 19
12 20
85750 73658
Figure108
Figure109
BULKHEAD
Brown bulkhead B
Pin Description
Cablecolour
code
1 Groundof level andloadpressureon axlesensors 0400
2 Rear right axle level sensor signal 5421
3 Rear left axlelevel sensor (only truck) 5422
4 - -
5 CAN - L Line(SB) Green
6 CAN - H Line(SB) White
7 Positivefor rear axleelectro pneumaticdistributor 9400
8 Groundfor rear axleelectro pneumatic distributor loading/unloadingcommand 9423
9 Groundfor rear axleelectro pneumatic distributor left valvecommand (onlytruck) 9425
10 Groundfor rear axleelectro pneumatic right valvecommand 9424
11 Air pressureTransmitter signal (rear brakes) 5561
12 Power supplyfor air pressure transmitter for brakingsystem 5560
13 Groundfor air pressuretransmitter for brakingsystem 0560
14 Air pressuretransmitter signal (front brakes) 5562
15 Sensor signal of loadpressureon axles- right axle 5443
16 Sensor signal of loadpressureon axles- left axle(onlytruck) 5444
17 - -
18 - -
19 Signal for raised trailer indicator 6442
20 CAN - L Line(BCB) Green
21 CAN - H Line(BCB) White
22 Groundfromsignallingswitchgear boxin aneutral position 8050
23 Power supplyfor electronictachograph transmitter 5514
24 Invertedsignal fromelectronictachographtransmitter 5516
25 Speedsignal fromelectronictachographtransmitter 5517
26 Groundfor electronictachographtransmitter 0058
27 Positive+15for air block turbineVGT (Shut-Off)electro valve 8360
28 Positive+15for MET control unit 8871
29 Positive+15for resistanceof dryer brakingsystem 8840
30 Positivefor TGC closure (TGC On) 8035
31 Positivefor TGC aperture (TGC Off) 8045
32 Groundfromsignallingswitchtilted caisson 6607
33 - -
34 Positivefor headlampillumination loadingdeck 2224
35 Positivefor supplementarydepth projectors 2229
36 - -
37 Failuresignal trailer ABS/EBS 6671
38 Positive+15for power socket trailer ABS/EBS 8847
39 Positive+30for 15pin power socket electrical connection trailer 7790
40 Direct positive+Bat batteryfor Tachograph 7972
Yellow wall pass C
Pin Description
Cablecolour
code
1 GroundfromconnectedsignallingswitchPTO 1 6131
2 Safetysensor signal for max. brakingbridgewith front axle failurewith ABS 6245
3 Positive+15for safetysensor for max. brakingbridgewith front axlefailurewith ABS 8847
4 ABSspeedsensor front right wheel 5571
6 |os|t|vo '|V' so|ooo|o va|vo (oo|oaooo)coaoo oot ||t .|oo| 9920
7 Positivefor solenoidvalvecommand PTO 1 9131
8 |os|t|vo '/V' so|ooo|o va|vo (|oaooo) coaoo oot ||t .|oo| 9918
9 Groundfor centralisedlubrication control unit 0000
10 Positive+15for centralisedlubricationcontrol unit 8898
11 ABSspeedsensor rear right wheel 5573
13 |os|t|vo '|V' (oo|oaooo) so|ooo|o va|vo coaoo oa ||t .|oo| 9930
14 Groundfromswitch connectionconsent PTO 1 0391
15 |os|t|vo '/V' (|oaooo) so|ooo|o va|vo coaoo oa ||t .|oo| 9928
16 GroundfromsignallingswitchPTO 2connected 6132
19 GroundfromsignallingswitchPTO 3connected 6133
20 Groundfor shieldingof CAN outfittedlines 0999
21 CAN-L line(SB) for fitters Green
22 CAN-H (SB)linefor fitters White
24 Groundfor ASRsolenoidvalve 0260
25 PositiveASR solenoidvalvecommand 9260
27 Positive+30for fitters (72072Dconnector) 7795
28 Groundfor e with+15 clampconnected(72072C/D connectors) 0975
29 |os|t|vo '/V' (|oaooo) so|ooo|o va|vo coaoo |ot oa .|oo| 9929
30 Positivefor solenoidvalvesynchronousprotection mechanical gear change 8871
31 |os|t|vo '|V' (|oaooo)so|ooo|o va|vo coaoo |ot oa .|oo| 9931
32 |os|t|vo '/V' (|oaooo) so|ooo|o va|vo coaoo |ot oot .|oo| 9919
33 Groundfor solenoid valve synchronous protectionmechanical gear change 9975
34 |os|t|vo '|V' (oo|oaooo) so|ooo|o va|vo coaoo oot |ot .|oo| 9921
35 ABSspeedsensor front left wheel 5570
37 ABSspeedsensor rear left wheel 5572
39 - -
40 Groundfor ABSsolenoid valves 0000
Blue wall pass D
Pin Description
Cablecolour
code
1 Positive+15for Eurotronic2 / Mass fromconnected slowgearssignallingswitch(9gear
changes)
8101 / 0177
2 Groundfor Eurotronic 2 / Positive for connection of electro valvereducedgears (9gear
changes)
0000 / 9973
3 Positivefor gear changebeeper/ Positivefor electro valve connection normal gears (9 gear
changes)
6100 / 9974
4 Groundfor gear changebeeper 1101
5 - -
6 Positive+30for Eurotronic2 7101
7 KlineEurotronic 2 (18-pindiagnosisconnector) 2297
8 CAN - L Line(VDB) Green
9 CAN - H Line(VDB) White
10 CAN - L Line(VDB) Green
11 CAN - H Line(VDB) White
12 Speedsignal fromintegral traction tachographtransmitter (Retarder) 5103
13 Positivefor integral traction tachograph transmitter (Retarder) 8300
14 Groundfor water temperaturesensor for Retarder 0309
15 Signal water temperaturesensor for Retarder 5309
16 Positivefor oil accumulator electro valveRetarder 9311
17 Groundfor oil accumulator electro valveRetarder 0311
18 Positivefor electro valveconnection Retarder 9310
19 Positivefor electro valveconnection Retarder 0310
20 Positivefor Air heater supplementarypump /KLineKwater heater (10-pindiagnosis connec-
tor)
7783 / 2295
21 Positivefor control andsignallingunit supplementaryheater 7775
22 Command for supplementaryheater withpassagefor micro-switch with commandlever heat-
er tap
7506
23 Positivefromswitch for internal aerator 7711
24 Positive+30for supplementarywater heater 7708
25 Groundfor supplementaryfuel pump Air heater 0000
26 CAN - L line(BCB) Green
27 CAN - H line(BCB) White
28 CAN - L line(BCB) Green
29 CAN - H line(BCB) White
30 Positivefor electro valvewater re-circulationengine block 9506
31 Positivefor warninglight supplementaryconnected heater/connection consent electro valve
water re-circulationengine block
6605
32 Groundfor integral tractiontachographtransmitter (Retarder) 0000
33 Positive+15alternator (TGC withADR) 8876
34 Positive+15alternator (TGC withADR) 8876
35 Ground(TGC ADR) 0000
36 - -
37 Groundfromsafetycontrol unit switch - TGC signal (ADR) Off 0176
38 Groundfromsafetycontrol unit switch - TGC signal (ADR) On 0178
39 - -
40 - -
Green wall pass E
Pin Description
Cablecolour
code
1 CAN - L line(ECB) Green
2 CAN - H line(ECB) White
3 - -
4 - -
5 - -
6 - -
7 Positive+15alternator 8876
8 Groundfromrequest EDC systemdiagnosis switch (predisposition) 0163
9 Groundfromrequest EDC systemdiagnosis switch (predisposition) 5163
10 ACC Power supply 8176
11 Load signal fromalternator 7009
12 Positivefor front thermal mirror 8830
13 Positive+15for EDC (fromIBC3) 8015
14 Groundfor front thermal mirror 0000
15 - -
16 CAN L line(VDB) Green
17 CAN H line(VDB) White
20 - -
21 - -
22 KlineEDC control unit (2-pin diagnosisconnector) 2298
23 Positive+30for startingengine connection (clamp50) 8888
24 Positivefor connectionelectro magnetic compressor joint (Valeo) 9993
25 Direct positivebattery(+Bat) for SCR control unit 7540
26 - -
27 KlineSCR control unit (16-pin diagnosis connector) 2257
28 - -
29 - -
30 Groundfromlow coolingwater level sensor warninglight) 5520
31 - -
32 Groundfromlow coolingwater level sensor 5527
33 Positivefor connectionventilator engine(baruffaldi) 5166
34 Positivefor electro magnetic joint connectionswitch (baruffaldi ventilator) 5187
35 Groundfor electro magneticjoint connectionswitch (baruffaldi ventilator) 0014
36 - -
37 Engine rpmsensor signal for bodybuilders(ST14B) 5587
38 - -
39 Positive+30for EDC 7151
40 Positive+30for EDC 7151
CENTRAL INTERCONNECTING UNIT
Ref. Description
1 Fuseholder
2 BodyController (IBC3)
3 Mini switches
4 Micro remotecontrol switches
5 OBD
112588
Figure110
Figure111
112589
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
70001 70602 70605
FUSE
Fuseholder 70602
Ref. Function Delivery (A) Terminal
1 DDM/ Driver power windows 20/15 +30/+15
2 PDM/ Passenger power windows 20/15 +30/+15
3 EDC 30 +30
4 ABS 5 +15
5 - 15 +30
6 ABS 15 +30
Fuseholder 70605
1 Fridge/ tool collect / OBD / Datacommunication+navigation 10 +BAT
2 ECAS/EM 5 +15
3 ECAS 7.5 +30
4 Retarder / ABS 10 +30
5 Retarder 10 +15
6 Heated seats/central lubrication/door lockwithRF 7.5 +15
Fuseholder 70001
1 EUROTRONIC 2 10 +30
2 Air conditioner 15 +30
3 Air conditioner 5 +30
4 Additional heater 15 +30
5 Additional heater 5 +30
6 Courtesylights 5 +30
7 ACC/Heated windscreen/tool collect/Datacommunication+navigation 10 +15
8 MC-NET / Beacon lights/headlamp washer pump 10 +30
Fuseholder 70401
1 Sun visors 7.5 +15
2 - - -
3 - - +30
4 12V internal lighting 5 -
Fuseholder 70402
1 Heated windscreen 25 +30
2 VGT solenoidvalve/servoshift 10 +15
3 Heated mirrors 15 +15
4 Heated windscreen 25 +30
Fuseholder 70403
1 EM 15 +30
2 EM 15 +30
3 ACC 5 +15
4 SRC (UREA) 20 +batt.
Figure112
112590
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
70401
70402
70403
Figure113
112591
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
Print 603.93.641
REMOTE SWITCHES
Ref. Description
Component
code
A Hornremotecontrol switch 25805
B Remote control switchfor water heater (opt.) 25337
C - -
D Remote control switchfor electrical bushopening 25352
E Remote control switchfor water heater (opt.) 25325
F - -
G Electrical manholelock remotecontrol switch 25351
H Remote control switchfor manual climatecontrol system(opt.) 25310
I Remote control switchfor manual climatecontrol system(opt.) 25874
K Remote control switchfor electro-magnetic engagement of baruffaldi fan 25737
L Remote control switchfor manual climatecontrol system 25332B
M Remote control switchfor manual climatecontrol system 25322
N Remotecontrol switchfor vehiclediagnosis (opt.) 25705
O Remote control switchfor manual climatecontrol system(opt.) 25332A
P Remote control switchfor manual climatecontrol system(opt.) 25327
R Remotecontrol switchfor headlamp washer consensus(opt.) 25740
S Remotecontrol switchfor mainelectric/mechanicswitch(opt.) 25203/25903
T Remote control switchfor mainelectric switch(opt.) 25202
U Enginestart upremote control switch 25200
V Remote control switchfor key15distribution 25213
W - -
X - -
Y - -
Z - -
Figure114
112598
Additional remote control switches
PositionedbehindtheBODY COMPUTER.
Ref. Description
Component
code
GA Remotecontrol switchfor heatedwindscreencontrol 25306
GB - -
GC Remotecontrol switchfor heatedwindscreen 25818
GD - -
GE - -
GF - -
GG - -
Revi - June2007
Print 603.93.641/A
FUSE ASSEMBLY BODY CONTROLLER(IBC3)
FUSES IBC3
Ref. Function Rating(A) Terminal
F1 - 10 +15/1
F2 - 20 +15
F3 VCM/ SWI 10 +30
F4 Tachograph/ BedModule/ Cluster / Centralisedclosure 5 +BAT
F5 - 20 +30
F6 - 20 +30
F7 - 20 +30
F8 - 20 +30
F9 ST14A bodybuildersconnector / 72072D (EM-framework) 10 +30
F10 Beeper 10 +30
F11 Tensionreducer / Radio 20 +30
F12 Air dryer resistance 10 +15
F13 Bodybuilders connector 72072C (EM- cabin) 10 +30
F14 30-pinjunction/ Cigarettelighter 10 +30
F15 Radio/ Acclimatiser 5 +15/1
F16 - 20 +15/1
112599
Figure115
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
A. Auxiliaryfuseholder
Figure116
A
113408
Print 603.93.641
SUPPLEMENTARY FUSES (70000)
Theyarelocatedontheleftsideofthevehicle,nexttothebatteriesandtheTGC.Thefusecompartmentcanbeaccessedbylevering
onthetwospringsavailableoncover (A).
49731
1 2 3 4 5 6
Figure117
Ref. Function DeliveryA
1 MET 30
2 MET 30
3 Presetting 30
4 Presetting 30
5 Current tap- ABS/EBS 30
6 Presetting 30
Figure118
113329
INSTRUMENT BOARD
Ref. Description
1 Revscounter
2 Coolant thermometer
3 Fuel level gauge
4 Speedometer
5 Headlamptrimcontrol
6 External light switch
7 Foglight actuationswitch
8 Auxiliaryheadlamp actuationswitch
9 Rear foglight actuation switch
10 Optical indicator cluster
12 Display
14 Free
15 ABSactuationswitch(if available)
16 Free
17 ASRactuation switch(if available)
18 Emergencylight actuationswitch
19 Speedlimiter cut-in switch
20 Parkingbrake
21 Free
22 Free
113410
Figure119
20
22
21
1
19
18
2 3 4 5 6 7 8 9 10 11
12
15
13
14
16
17
8b 20b
23
24
CENTRAL DASHBOARD CONTROLS
Ref. Description
1 Switchfor enginebrakeengagement
2 Control for electrichatchpit (OPT)
3 Pneumatichorns
4 Power takeoff switch1 (OPT)
5 Heatedwindscreenactuation switch(OPT)
6 Sunshadecurtaincontrol (OPT)
7 Central roof lamp cabinlights
8 Multipower power takeoff control (OPT)
8b Loadingplatformlight actuationswitch
9 Roof sideroof lampscabinlightscontrol
10 Fuel heater (OPT)
11 Rearviewmirrorsheating(beforeit wasembeddedintothedoor)
12 Switchfor immediatelyconnectingsupplementarywater heater (OPT)
13 Engine/cabinpre-heatingselector (OPT)
14 Switchfor connectingsupplementaryair heater (OPT - for manual versiononly)
15 Power takeoff 2(OPT)
16 Supplementarywater heater thermostat (OPT)
17 Keyswitchfor ECO - POWER function
18 Heating/ventingor air conditioner controls(OPT)
19 12V current outlet
20 Front differential lockingswitch
20b Rotatinglampsswitch (OPT)
21 Rear differential lockingswitch
22 Longitudinal differential lockingswitch
23 Lighter
24 30-pindiagnosis outlet
Left hand side:
4. KEY y
KEY b
5. KEY +
KEY -
Right hand side:
1. MEBU KEY/OK
2. PAGE PUSH BUTTON
3. ESCAPE KEY
4
5
1
2
3
74202
Figure120
CONTROLS ON THE STEERING WHEEL
Thesteeringwheel featuressomekeysthat enableselectingand controllingcertainfunctions.
2
1
3
4 4
79494
Figure121
REARVIEW MIRRORS AND WINDOW REGULATOR CONTROL ADJUSTMENT
Ref. Description
1 Rearviewmirror orientation control
2 Mirror selector control
3 Driver windowregulator
4 Passenger windowregulator
Key2onASwasplacedontheleftandinitsplacetherewasthemirrorheatingkeythat onAT/ADisplacedoncentral dashboard
asseries.
Adjustment functionsfor rearviewmirrorsandwindowregulator control aremanagedbyDDMandFDMunits, andconsequently
theyarepresent asoptionals.
EXTERNAL REARVIEW MIRRORS HEATING
Bypressingtherelatedbutton,therearview mirrorsheatingisactivatedandtherelatediconisdisplayedonthedisplay.Todeactivate
suchfunction, pressthebuttonagain.Theiconwill not bedisplayedanymore. It ispossibletoselectthisfunctionalsowithmoving
vehicle. Heatinghasa maximum lengthof 30 minutes.
73985
73988
1 8
9 16
Figure122
LEFT LIGHT CONTROL 54033
Ref. Description
1 Windshield wiper (top speed)
2 Windshield wiper (slowspeed)
3 Windshield wiper (intermittent)
4 Windshield wiper (onestroke)
5 -
6 Dippedlightson
7 Light flashes
8 Ground
9 Washer electrical pumpcontrol
10 -
11 -
12 -
13 -
14 -
15 Right direction indicator
16 Left directionindicator
108919
73988
Figure123
1 8
9 16
RIGHT LIGHT CONTROL 54030
Print603.93.641
Ref. Description
1 Intarder (Position 4)
2 Changegear (down)
3 Cruise Control (set/acceleration)
4 Cruise Control (Resume)
8 -
11 Cruise Control (deceleration)
12 -
13 -
14 -
15 Changegear (up)
16 Ground(fromtheSWI)
108920
RIGHT MULTIFUNCTION LEVER
Themultifunctionlever locatedontheright sideofthesteeringcolumnenablesinsertionof theenginebrakefunctionandthe
intarder wheninstalled.
The former is selected bymovingthe lever to positions 1and2 and remainso evenwhenthesamelever isused to selected
theintarder functionat positions 3, 4, 5 and 6related to available brakingpower ratings.
Whentheenginebrakefunctionisselectedthecontrol leversignal istransmittedtothe(SteeringWheel Interface) S.W.I.center.
Whichactivatestheenginebrakeon warninglight onInstrument Cluster IC,andviaBodyComputerB.C. sendstherequest fro
engineraketo theEDC, EBS and automated EuroTroniccenter (when present).
Whentheoperator selectstheenginebrakemanually,selection isdisplayedintheCluster withablinkingwarninglight, which
goestosteadywhentheenginebrake isturnedon.Inthemanual mode, enginebrakeactionisalsoconditionedbyaccelerator
pedalrelease.Intheautomaticmode,theenginebrakeisactivatedbytheEDCcenteronreceiptofarequest fromtheEBScenter.
Inthis condition, the EDC center pilots the enginebrakeelectro valveand theVGT actuator to thefullyclosedposition.
Figure124
1
2
3
4
5
6
Vehicles with Intarder mechanical gearshift
Position 0 = disenabled
Position 1 = 50%enginebrake
Position 2 = 100%enginebrake +20%Intarder
Vehicles with Intarder EuroTronictransmission
Position 6 = 100%enginebrake +100%Intarder *
(*) The intarder can be more effective with automatic downshifting
managedbythetransmissionelectroniccontrol centre.
Vehicles with mechanical gearshift or Eurotronic transmission in themanual mode without
Intarder
Vehicles with Eurotronic transmission in the automatic mode without Intarder
Position 2 = 100%enginebrake+downshiftinginthe
automaticmode
Figure125
Figure126
Figure127
Figure128
108920
1
2
3
4
5
6
1
2
3
4
5
6
1
2
0
1
2
0
108920
108920
108920
ENGINE BRAKE CONTROL AND INTARDER
Figure129
108921
NOTE
GEAR SELECTION FUNCTION
OnthenewrangeofEuro4vehiclesthegearselectorhasbeeneliminated.Itsfunctionsareperformedbythecontrol pushbutton
panel on thecentral panel of thedashboard, incombination with thedrive control systemlever.
1. Pushbutton D - AUTO/SEMI mode
2. Pushbutton N - neutral
3. Pushbutton R- Reversegear
4. Drivecontrol system- gear selection
Driving in manual mode(semi)
1) Parkingbrakeengaged.
2) Start theengine
3) Gearboxin neutral (position N).
+) 3|o| oss os|bottoo '|' (+). T|o aotoat|c ssto |s act|vatoo aoo t|o ca|co|atoo |c'-o oa |s ooaoo.T|o o|s|a
s|o.s t|o |c'-o oa toot|o .|t| '/|TC'.
5) Too o t|o aotoat|c ssto b a a|o oss|o bottoo '|'. T|o o|s| a assos o s|o.|o '/|TC' to 'S|||'.
6) Thepick-upgear canbecorrectedwiththefollowingoperationsonthedrivecontrol system(4):Byslightlymovingthedrive
control systemupwards (pullingit) the gearboxshiftsone ratio up.Byslightlymovingthedrivecontrol systemdownwards
(pressingit) thegearboxshiftsoneratiodown.Bykeepingthedrivecontrol systeminthedesiredposition(pulling/ pressing
it) thegearboxshifts two ratios up or down respectively.
The followingpick-upgearsare available: 1
st
, 2
nd
, 3
rd
, 4
th
, 5
th
.
7) Presstheaccelerator pedal releasingtheparkingbrake. The vehicle starts (theclutch engages automatically).
Changingratio while drivingthevehicle
Shiftingupto ahigher ratio
- Byslightlymovingthedrivecontrol system(4) downwards (pressingit) the gearboxshiftsone ratio up.
- Bykeepingthedrivecontrol system(4) in this position thegearbox shifts two ratios up.
Shiftingdown to alower ratio
- Byslightlymovingthedrivecontrol system(4) downwards (pressingit) the gearboxshiftsone ratio down.
- Bykeepingthedrivecontrol system(4) in this position thegearboxshifts two ratios down.
NOTE
NOTE
Driving in automatic mode (Auto)
1) Parkingbrakeengaged.
2) Start theengine
3) Gearboxin neutral (position N).
+) 3|o| oss os|bottoo '|' (+). T|o aotoat|c ssto |s act|vatoo aoo t|o ca|co|atoo |c'-o oa |s ooaoo.T|o o|s|a
s|o.s t|o |c'-o oa toot|o .|t| '/|TC'.
5) After enteringAUTO mode, thesameguidelinesgivenfor theSEMI modeapply(points 6 and 7) for selectingthepick-up
gear.
Changingratio while drivingthevehicle
Whiledrivingthevehiclethedisplayshows theengagedratio. All theratio changingoperationsareautomaticanddepend on
thesituationof drivingthevehicle, theload, thepositionoftheaccelerator pedal, thespeedandnumber of revolutions ofthe
engine. Thegear canalwaysbechanged manuallywiththedrivecontrol system(4), without havingto leave automatic mode.
Keepingtheengagedratio
| |o aotoat|c ooo oo .aot to 'oo t|o ooaoo at|o, oo oooo to b|o| oss os|bottoo '|' (+). T|o oabo .||| ass
on to manual mode (SEMI). Later operations on thegearboxare possibleonlybypullingor pressingthedrive control system
(+) (as oosc|boo o o|v|o |o aooa| ooo). To ass bac' |oto aotoat|c ooo, oo oooo to b|o| oss os|bottoo '|'
(1).
Pass into neutral (Position N)
|oss os|bottoo '|' (2). T|o o|s|a s|o.s |.|os|t|oo|o |o ooota| '|' |as |o|t ovo t|o ot|o ooat|oos o c|ao|o
ratio.Itisalwayspossibletopassintoneutral startingfromanyratio.Whenthevehicleisdrivingforwards,fromtheneutral position
(|) |t |s a|.as oss|b|o to ooao a oabo at|o. |o t||s oo oooo to b|o| oss os|bottoo '|' (+).
So asnot to wearout themechanical partsof theclutch control, if stoppingthevehiclefor longer than 1- 2minutes
(for instance, inaqueue, at alevel crossing, etc.), thegearboxmust be put into neutral (N).
This closes theclutch and the control systemis lightened.
Reverse gear
- \|t| t|o vo||c|o stat|ooa, b|o| oss os|bottoo '|' (3). T|o s|o. ovoso oa at|o (||) |s ooaoo.
- Press the accelerator pedal. Thevehiclestarts(theclutchengages automatically).
Withthevehiclestationaryandinreversegear it ispossibletochangebetweenthetwo reversegear ratiosRL(slow)
and RH (fast) byusingthe drivecontrol system(4)
Byslightlymovingthe drivecontrol systemupwards (pullingit) RH
Byslightlymovingthe drivecontrol systemdownwards (pressingit) RL
Operations in slow mode
For manoeuvringin harsh drivingconditions (off-road, for instance) thereisasupplementaryoperating mode, with the aid of
whichthedriver canfinetunetheclutchaccordingto thetravel of theaccelerator pedal (upto 100%). In thiswaytheengine
speed is limited and rapidvehicleaccelerationis prevented.
Turningon
- Thevehiclemust bestationary
Forward drive manoeuvres
- |oss aoo |o|o os|bottoo '|' (+) ( > 2 soc.) T|o o.ao o|vo aoooov o ooo |s toooo oo. T|o o|s|a s|o.s
'S|C\'
Reverse drivemanoeuvres
- |oss aoo |o|o os|bottoo '|' (> 2 s oc.) T|o ovoso o|vo aoooovo ooo |s toooo oo. T|o o|s|a s|o.s
'|| S|C\'
Figure130
108922
NOTE
Turningoff
With thevehiclestationary
- 3|o| oss os|bottoo '|' (+). T|o ca|co|atoo |c'-o oa |s ooaoo aoo aotoat|c ooo toooo oo
o b|o| oss os|bottoo '|' (3) . T|o s|o. ovoso oa at|o (||) |s ooaoo.
Duringtheforwarddrivemanoeuvre:
- 3|o| oss os|bottoo '|' (+). T|o aotoat|c ssto |s act|vatoo o ooato t|o '|c'-oo.o.
Duringthereverse drivemanoeuvre:
- 3|o| oss os|bottoo '|' (3). o ooato t|o '|c'-oo.o.
FUNCTION ENGAGING EMERGENCY MODE (LIMP HOME)
This is anemergencyfunction in which thenormal systemof automaticcontrol is put out of service.
1) Engagement
Indicator (Display): LH =engageemergencymode (whenchangingratio).
2) Activation by the driver
Ignition turned off (until theindicator isturnedoff).
Ignition turned on, within 5seconds:
Press pushbutton N (2) for at least 5 seconds.
3) Indicator LH
After turningon emergencymode (when changingratio).
Gearboxin neutral.
Clutch released (open).
4) Clutch status indicator
Bar with arrowtip pointingupwards (5) (blinking) =clutchreleased.
Bar with arrowtip pointingdownwards(6) =theclutchisabout to engageor is engaged.
Whenchangingratio, blinkingstops: (as soonasanew ratio is engagedit starts blinkingagain!)
5) Operations to perform
After turningon theemergencymode (seepoint 3), start uptheengine.
Whentheengine is running, pressandthenreleaseagainthebrakepedal.
Engagetherequiredpick-upgear.
!
NOTE
!
Forwards:
- Byslightlymovingthedrivecontrol system(4) upwards(pullingit) thegearboxshifts oneratio up.
- Byslightlymovingthedrivecontrol system(4) downwards (pressingit) the gearboxshiftsone ratio down.
Inreversegear:
- 3|o| oss os|bottoo '|' (3). (t|o s|o. ovoso oa at|o '||' |s ooaoo).
- Byslightlymovingthedrivecontrol system(4) upwards(pullingit) thegearboxpassestothefast reversegear ratioRH.
Engagetheclutch: presspushbuttonD (1) until thebars stopblinkingwiththearrowtip pointingupwardsandwhenthebars
appear withthe arrowtippointingdownwards (5/ 6).
The clutchcanbeengagedslowlyor even suddenly.
If thevehicleaccidentallymovesonaslope withagear engaged, theclutchwill automaticallyengage
||sooao t|o c|otc|. b|o| oss os|bottoo '|' (+) o a|tooat|vo| oss t|o ba'o ooa|.
| oo oss|o t|o ba'o ooa| t|o c| otc| |s ooaoo .|t| t|o os|bottoo '|' (+) (o oa|o vo||c|o |c'-o o||||),
inorder to be ableto releasetheclutchagain withthebrakepedal, it will benecessaryto first brieflytakeyour foot
off the brake pedal: aratio shift will onlybepossiblewith the vehicle stationary.
Leavingemergencymode.
Turnoff theignitionandwait for theindicator to disappear.
Whennext startingupthesystemwill beinnormal mode.
CLUSTER
Proceed as followsto removetheCluster:
|so a sco.o|vo o |ovoao |os |oo t|o t.o s|ots |o t|o
two groups of switches (A) located in theupper panel.
|oovo t|o t.o otoct|oo cas.
|ooso t|o oo aoo| ota|oo sco .s (3).
|ovo t|o aoo| as a oot.aos as o ss|b|o ato o|ocat-
ingthesteeringwheel far fromthepanel.
||scooooct t|o t.o C|osto attac||o sco.s.
|oosoo t|o oo ota|oo sco.s (C).
49733
49837
C C
C
C
c
Figure131
Figure132
Figure133
49733
A
A
B
B
B
B
Cluster (optical indicators)
Ref. Description
1 External lights
2 Auxiliaryheadlamps
3 High-beamheadlamps
4 Generic anomaly/failuresignal
5 Generic alarm
6 Fogheadlamps
7 Rear foglights
8 * Retarder
9 * Engine brake
10 Vehiclesuspensionsnot inrunning trim
11 Third axlelifted
12 Pick-upassist provision
13 Mirror heating
14 Longitudinal tandemdifferential locking
15 Longitudinal/transverserear differential locking
16 Left indicator light
17 Longitudinal differential locking
18 Longitudinal/transversefront differential locking
19 OBDII anomaly
* Warninglight: blinkingwiththefunctionrequested bythedriver; ON steadywiththefunction
actuated
102385
1 2 3 4 5 6 7
19
18
17
16
15
10
11
12
13
14
8
9
Figure134
Ref. Description
20 Power take-off 1 (PTO 1)
21 Power take-off 2 (PTO 2)
22 Instrument panel failure (Cluster)
23 Right indicator light
24 Immobilizer
25 Analogrevs counter
26 Temperature/timedisplay
27 Instrument illuminationitensity/temperature/timedisplaybutton
28 Coolant temperature(hightemperaturewarninglight)
29 Full/tripodometer displaybutton
30 Hand brake ON
31 Emergencylights
32 Brakingsystemfailure
33 Display
34 Fuel level
35 Fuel level (low level warninglight)
36 Odometer/mileageindicator displaybutton
37 Tachographanomaly
38 Full/tripodometer/mileageindicator display
39 Analogspeedometer
102386
20
21
22
23
25 26 27 28 35 36 37 38 39
30
31
32
34 29 33
24
Figure135
Print 603.93.641
CLUSTER (PIN-OUT)
Connector A - Blue
Pin Description
Cable
colour code
1 - -
4 17 - -
18 Positive+15(fromIBC3) 8871
19 Ground 0000
20 Direct positivebattery(+Bat fromICB3) 7906
Connector B- Black
Pin Description
Cable
colour code
1 Kline(14-pindiagnosis connector) 2994
2 - -
3 Trailer ABSfailuresignal 6671
4 - -
5 - -
6 - -
7 - -
8 ECMfailure signal 6150
9 Speedsignal for diagnosis connector (28-pin) 5540
10 Ground fromswitchfor tiltedcaissonsignalling 6607
11 - -
12 17 - -
18 - -
19 Speedsignal for Toll Collect (predisposition) 5541
20 - -
49837/a
Figure136
A
B
Displayoperation
Displayvariessubject to the following:
- KeyonMARwithengineoff
- Keyon MARwithenginestartedandvehiclestationary
- KeyonMARat vehiclespeedover 15Km/h
- Keyout
Keyin MAR with engineoff
Turningthekeyto MAR displayscontrol of mainvehiclesystems.
Theirpresenceisindicatedingreen,ifall isOK,oryellowincaseofalight anomaly/breakdown,orredincaseofaseriousanomaly/
breakdown, withactivationof abuzzer.
Thelist ofsystemspresent onthevehicleandtheir statuscanbedisplayedwiththeMultiplexsystemduringStart-Up, byreceiving
thediagnosticmessagefromthevariouscenters.
SystemCheckOk or SystemCheckFailed informationisprovidedat Start-Up Test end.
Thedefectivesystemthensends its diagnosticmessagethat isdisplayedwiththeiconof thedefect under review.
TheMultiplexsystemcanindicatevehicleandelectronicsystemerrors.IncaseofanerrordetectedbytheBodyComputer,it sends
theInstrument Cluster amessagecontainingthefollowinginformation, viatheCAN line:
- thestatusof thelight associatedto thedefect (redfor aseriousand yellowfor aslight anomaly)
- theerror code
At receipt of theerror message, theInstrument Cluster displaysthe followinginthecentral displayarea:
- thecolored iconrelatedto thedefectivecomponent or center
- therelated error code
|t a|so aov|sos t|o ooato b act|vat|o t|o 3ozzo. /to ocoo|z| o t|o oo, t|o ooato ossos 'o 'C|' aoo t|o coota|
displayareareturnsshowingthepreviousinformation(virtual tool or menu).
Theiconrelated to theerror detected isstored inthelower layer of the displayor withaspecificwarning.
No options suchasto distract attentionor optionsnot related to anoperation useful for vehicle operationare availableduring
operation,whichiswhytheMenusavailableincaseofamovingvehiclearereducedtothebaseessential andscanningofthevarious
o|s|as |s obta|ooo s|| .|t| t|o '|ooo' 'o (.|t|oot oao|o t|o || st o ot|oos).
\|t| t|o vo||c|o stat|ooa, scaoo|o o t|o co|oto sot o ooos ava| |ab|o |s ooab|oo .|t| 'os '/o. o' aoo '/o. oo.o'.
Breakdown
After acknowledgingtheerror, theoperatorpresseskeyOKonthesteeringwheel andtheiconappearsinthelowerdisplaylayer.
Yellowcolor (light anomaly/breakdown):
Proceedwithcautionand contact aServiceNetworkworkshopassoon aspossible.
Red color (serious anomaly/breakdown):
Parkthevehicleontheroadsideinanon-dangerousareaorcontact theDealer or the24hourClient Center number inunusual
hoursor inadecentralizedarea.
Two menusareavailable:
- TRAVEL MENU
- DIALOGMENU
External mirrorsandlightscanalso beadjusted.
Whenthe keyis inserted, thepresent electronic systems performatest byactivatingtherelatedlights, enablingthe operator to
checktheir efficiency(andlearn of theexistenceof vehiclesystems).
73662
LOWER
SECTION
TITLE
CENTRAL
SECTION
SL
High engine
coolant
temperature
Figure137
Display structure
TITLE
- Speedset byCruiseControl
- SpeedLimiter set
- Supplementaryheater enabled
- Batteryvoltage
- Radio/RDSinformation
- Telephone/ EMSmessageinformation
- Gears(downshifted/normal gears), suggestedgears, auto/manual mode.
CENTRAL SECTION
- Engineoil pressure
- Engineoil level
- Consumptionindicator
- Turbo pressure
- Engineoil temperature
- Reservoir, trailer, serviceair pressure
- Front / rear / trailer brakewear (vehicleswithEBS)
- Light settingadjustment
- Mirror positioning
- Failuremessages
- Loadonthe axles (OPT)
LOWER SECTION
- Alarms
- Activefunctionsindications(intarder, etc.)
SL Figure138
Optical status indicators on display
Thecorrespondingiconappearsat activationof thefollowingfunctionsofoccurenceofthefollowinganomalies.
Meaning Symbol Colour Meaning Symbol Colour
Pre-heating yellow ASRon yellow
Cabunhooked
Unhookedcab enable
red
yellow
ASRoff yellow
Door open red Reduced ABSoperation yellow
Low front axlebrake
air pressure
red
Automaticchains
yellow
Low rear axlebrake
air pressure
red Trailer without EBS/ABS yellow
Low trailer brake
air pressure
red Tipper body yellow
Loadingdecklight
(tractor only)
yellow Instrument Cluster trouble red
Windscreendefroster yellow
Low hydraulicpressureof
thirdsteeringaxle
red
Minimumengine
coolant level
yellow Low enginecoolant level red
Highenginecoolant
temperature
yellow
Veryhighenginecoolant
temperature
red
Low windscreenwasher
reservoir level
yellow Low fuel level / Ad Blue yellow
Front axlebrakewear red Rear axlebrakewear red
Rear second axle
brakeworn
red
Brakewear
onaspecific wheel
red
Power steeringlowfuel level yellow Air filter clogged yellow
Oil filter clogged yellow Water in fuel filter yellow
Fuel filter clogged yellow Engineoil level too high yellow
Lowengineoil level red
Highengineoil
temperature
red
Lowengineoil pressure red Highengineoil temperature red
Low parkingbrake
air pressure
red
Brakewear
onaspecific wheel
yellow
Low trailer brake
air pressure
red Low/poor generator charge
yellow
red
After recognizingtheerror, theoperator must pressOKonthesteeringwheel andtheiconappearsinthelower displaysection.
Meaning Symbol Colour Meaning Symbol Colour
TCO ECU failure red BMECU failure red
Parkingbrakefailure red CMECUfailure red
Secondimportance
light failure
yellow
Air conditioningsystem
failure
red
BC ECU failure yellow/red Additional heater failure red
ECM failure yellow/red SWI ECU failure red
EuroTronic failure red RFC ECUtrouble/fault yellow/red
EBSfailure red First importancelight failure red
ABSfailure red Right turnindicator fault yellow
Intarder failure red Left turn indicator fault yellow
FFC ECU trouble/fault yellow/red
Central lockingsystem
failure
yellow
DDM ECU failure red EAC defect yellow
Distancealarmsignalling yellow EAC failure red
ACC sensor defect red Trailer EBSfailure red
ACC sensor dirty red Reduced power andengine yellow
ARBenabled yellow Rotatingheadlights yellow
TPMsteeringaxlelowtire
pressure
yellow VCMfailure yellow/red
TPMengineaxlelow tire
pressure
yellow SCR failure yellow/red
Trailer: attentionthresholds
reached
yellow ASR/ ESPdisabled yellow
Trailer: anti-theft enabled yellow ESPenabled yellow
Airbagdefault/defect red Power steeringfailure red
EMdefect yellow
Power steeringliquid
lowpressure
yellow
EMfailure red
CDMECU failure red
Figure139
112594
- AdBlueFLUID LEVEL
- ENGINE OIL LEVEL
- OILPRESSURE
- AIRPRESSURE(REARAXLE- AXLE)
- BRAKEPAD WEAR(EBS)
- LOADGAUGEON AXLES
Displayinstruments
BODY CONTROLLER (IBC3)
TheBodyController isthecentral unit whichrepresentstheheart ofelectrical systemandtogether withMET central unit make
upEasyMuxsystem.
Thetwo central unitscommunicatebetweeneachother viaCAN line (BCB).
Insteadthroughthe CAN line (VDB), theIBC3communicateswiththevehicledifferent electronicsystems.
Bodycontroller inputs:
- Coolant lowlevel contact
- Windscreenwiper liquid lowlevel contact
- Alternator warninglamp
- Key 15
- Additional heater
- Brakesystemair lowpressuresensor
- Emergencyswitch
- Door unlockingpushbutton
- Rear foglightsswitch
- External lights switch
- Headlampattitude rectifier
- Sunroof unlock/lockcontrol
- Unfastenedseat belts
- TGC unlock/lock
- Rear crossdifferential lockingcontrol
- Front differential lockingcontrol
- Longitudinal differential lockingcontrol
- Trailer handlepressuregauge
- Heater immediateengagement control
Signals received viaCAN network:
- Gear in
- Trailer brakesignal
Bodycontroller outputs:
- Controlsillumination
- Windscreenwasher electricpump
- Lh/ rhclearanceheadlamp
- Steps light
- Internal roof lamp
- Sunroof opening/ closingrelay
- Hornspower supplyrelays
- Lighter
- Windscreenelectricdefroster power supply
- Remote control switchfor insertingloadswithkeyin
- Fitter outputs
- TGC (Current General RemoteControl Switch) / CGE(EmergencyGeneral Control) /MBS(Current General Control)
- Central door lockmotor control
- Additional mainbeamheadlight control
- Additional heater engagement control
IBC3 displays following information on Instrument Cluster:
- Fuel level
- Oil level
- External air temperature
- Brakecircuit air pressure
IBC3 controls following devices:
Lights(parkinglights,dippedheadlights,additional lights,front foglights,rearfoglights,blinkers,stoplights,reverselights,stepslights,
cab lights, highroof cab lights, headlights attitude)
- Central locking
- Air-conditioner
- Additional heater
- Air drier
Limp Home:
It identifiescentral unit status incaseofmicro processor failure; inthiscondition, followingfunctionsare ensured:
- Power supply(batteryvoltage, key30, 15and 15/1) fromcentral unit to other cabloads
- Switchingoff of disabled TGC
- Switchingonof windscreenwiper at minimumspeed (or keepingpreviouscontrol)
- Switchingonstepslights
- Switchingonclearancelights
BODY CONTROLLER
Linking connectors
112595
Figure140
108903
Figure141
Body controller connector A
Pin Description
Cable
colour code
1 - -
2 PositivefromTGC (+30) 7905
3 - -
4 - -
5 - -
6 Positive+30for VCM/ SWI 7906
7 Direct batterypositive (+batt) 7768
8 Positivefromservicerelay (+15/1) 8887
9 - -
10 - -
11 - -
12 - -
13 - -
15 Direct batterypositive (+Bat) for DTCO (Tachograph) / central locking 7768
16 Direct batterypositive (+batt) for BM(BedModule) 7906
17 - -
18 - -
19 - -
20 - -
Body controller connector B
Ref. Description
Cable
colour code
1 Positive+15for air conditioner / bodybuilders (ST14A) 8871
2 Positivefromservicerelay (+15/1) 8887
3 Positive+30for cigar lighter / diagnosticinterface 7772
4 Positive+30for bodybuilders(connector 72072C) 7796
5 - -
6 Positive+30for voltagereducer 7772
7 Positive+15fromignitionkey 8887
9 Positive+30for bodybuilders(ST14A / connector 72072D) 7772
10 - -
11 - -
12 - -
13 - -
15 - -
16 Positive+15for brakesystemdrier heater coil 8840
17 Positive+30for hornrelay 1116
18 - -
19 - -
20 - -
Body controller connector C (grey)
Ref. Description
Cable
colour code
1 Power supplyfor brakesystemair pressuresendingunit 5560
2 Positive+15for alternator 8876
3 Air pressuresendingunit signal (front brakes) 5562
4 Air pressuresendingunit signal (rear brakes) 5561
5 Windscreenwiper motor fixedstop(31B) 8873
6 - -
8 Earthfor brakesystemair pressure sendingunit 0560
9 Front marker light power supply 3339
10 Windscreenwiper motor highspeed power supply(53B) 8881
11 Windscreenwasher pump power supply 8886
12 Windscreenwiper motor lowspeed power supply(53) 8882
Body controller connector D (blue)
Ref. Description
Cable
colour code
1 Earthfromwindscreen washer fluid lowlevel sensor 5521
2 - -
3 Ground 0000
4 Chargesignal fromalternator 7009
5 Signal fromexternal temperaturesensor 7573
6 Earthfromradiator water lowlevel sensor 5527
9 CAN L line(VDB) White
10 CAN H line(VDB) Green
11 External temperaturesensor earth 0550
12 Control unit IBC3Kline(diagnosticconnector pin8) 2995
Body controller connector E (blue)
Ref. Description
Cable
colour code
1 Ground fromleft door button 0003
2 Ground fromright door button 0003
3 Ground fromparkingbrakeengagedswitch 6662
4 Hazardlightssignal for bodybuilders(ST14B) 1113
5 - -
6 - -
7 - -
8 Positive+15 for cabtilt enablement switch 8871
9 Positivefor openingTGC (TGC off) 8045
10 Positive+15for ECM/ VCM 8051
11 - -
12 - -
13 Positif +15pour Cluster / DTCO / MET / Eurotronic2 8871/8802
14 Enginerunningsignal for air conditioner / bodybuilders(ST14A)
S|oa| otoo oo ooto oo c||at| soo / o|sos|t|s o'oo|ooot (ST ++/)
7778
15 Vehicleparked signal for bodybuilders(ST14A) 5515
16 Reversingsignal for bodybuilders(ST14A) 2268
17 - -
18 Positivefor enablement of supplementaryheadlight activationrelay 2229
19 Positivefor sunroofclosurecontrol relay 7011
20 Positivefor sunroofopeningcontrol relay 7010
21 Positivefor TGC closure (TGC On) 8035
22 Positivefor headlamp washer pumprelay 8820
23 - -
24 Positivefor fifthwheel lightingswitch/ sidelightsfor bodybuilders (ST14B) 3333
25 Positivefor interior courtesylight 4440
26 Positivefor steplight 4445
Body controller connector F
Ref. Description
Cable
colour code
1 Positive+30for Cluster 7906
2 Signal fromheadlight alignment corrector control switch 9936
3 Positivefor independent water heatingpumpenablement 7786
4 Ground fromradiator low level sensor (for warninglight) 5520
5 Ground fromsupplementaryheadlight switch 2229
6 - -
7 Ground fromlongitudinal differential lock switch 0903
8 Ground fromhatchopeningcontrol switch 0970
9 Ground fromsupplementaryheater activation switch 0501
10 - -
11 Ground fromTGC activationswitch(TGC On) 0945
12 Ground fromexterior lightingswitch(exterior light) 3333
13 Ground fromrear foglamp switch 2284
14 - -
15 - -
16 - -
17 Positivefor symbol lighting 4442
18 Headlamp alignment corrector control switchpower supply 8871
19 - -
20 Ground fromtrailer brakehand wheel switch(brakelight) 0927
21 - -
22 Ground fromrear transversedifferential lockswitch 0904
23 Ground fromfront differential lockswitch 0902
24 Ground fromhatchopeningcontrol switch 0971
25 Control signal for central locking- locking 0064
26 Ground fromhazardlight switch 1113
27 Ground fromTGC off switch(TGC Off) 0946
28 Ground fromexterior lightingswitch(low-highbeams) 2237
29 Ground fromfoglampswitch 2228
30 - -
31 Ground fromcourtesylight onswitch 0941
32 Control signal for central locking- locking 0065
108904
Figure142
CHASSIS ELECTRONIC MODULE (M.E.T.)
MET central unit is placed on the chassis, actuates the controls and collects signals fromsensors installed outside the cab, and
communicates withICB3through CAN BCBnetwork.
Itsupplieslockedpositive(+15) toUDScentral unit (Denox2),trailer,fittersandchecksvehicleillumination.Itsuppliesotherloads
too, such asair-conditioner compressor andfuel filter andpre-filter heating.
Distributes key 15 to:
- UDS(DENOX 2)
- Trailer
- Fitters
Powers the following lights:
- Parkinglights
- Parkinglightsfor fitters
- Marker
- Brakelights
- Foglights andrear foglights
- Directionindicators
- Reversegear
Powers other loads:
- Theconditioner compressor
- Fuel filter andprefilter heating
- ECAD solenoidvalves
- Servoshift solenoidvalve
Acquires the following signals:
- Reversegear engaged
- Front differential lockedsignals
- Rear differential lockedsignals
- Longitudinal differential locksignals
- Underdrivegearsin
- Engaging5thand 6th gears
- Suspensionsair lowpressure
- Hydraulicguideliquid low pressure
- Brakeliquidlowpressure
- Air-conditioningsystemhighor low pressure
- Air-conditioningsystemhighor low pressure
- Front axlebrakepadswear status
- Rear axlebrakepadswear status
- Front parkingbrake
- Front brakes converter cylinder endswitch
- Rear brakesconverter cylinder end switch
- Side PTO in
- Rear or total PTO in
- Clogged air filter
- Clogged air filter
- Fuel level
- Engineoil level
Pin - Out
Pin Description
Cable
colour code
A-1 Reversinglight positive +30 2226
A-2 Positive+30for trailer brakelights 1179
A-3 Positive+30for left brakelight 1177
A-4 Positive+30for right brakelight 1172
A-5 Positive+30for number platelight 3307
A-6 Positive+30for right rear sidelights 3315
A-7 Positive+30for left rear sidelights 3330
A-8 Positive+30for right trailer sidelights 3339
B-1 Positive+30for trailer rear foglamp 2283
B-2 Positive+30for rear foglamps 2283
B-3 Positive+30for right trailer directionindicators 1185
B-4 Ground fromtransversedifferential lockengaged indicator switch(1st rear axle) 0040
B-5 Ground fromtransversedifferential lockengaged indicator switch(2ndrear axle) 0041
B-6 Ground fromlongitudinal differential lock engagedindicator switch 6603
B-7 Positive+30for rear marker lights 3306
B-8 Positive+30for left rear sidelights 3305
C-1 Positive+15for trailer 8075
C-2 Positive+30for left rear directionindicators 1120
C-3 Positive+30for right rear directionindicators 1125
C-4 Positive+30for left trailer directionindicators 1180
C-5 Ground fromECASair systemlowpressureswitch / Earthfromfront longitudinal differential
lock indicator switch(8x8)
6401/6643
C-6 Ground fromrear brake wear sensor (1st rear axle) 6667
C-7 Ground fromrear brake wear sensor (2nd rear axle) 6667
C-8 - -
A connector
Pin Description
Cable
colour code
A-1 Positive+30for left highbeam 2219
A-2 Positive+30for right lowbeam 2223
A-3 Positive+30for right high beam 2221
A-4 Positive+30for left lowbeam 2231
A-5 Signal fromwater infuel filter sensor 5530
A-6 Ground fromfront wheel blockwear sensor (2ndaxle) 6664
A-7 Ground fromfront transverselock engagedsignal switch (1st axle) 6659
A-8 Positive+30for diesel heater coil 7733
B-1 Positive+30for diesel pre-filter heater coil 7753
B-2 Headlamp alignment corrector control 9936
B-3 Ground fromswitchfor circuit II power steeringoil flowindicator 6632
B-4 Ground frompower steeringfluid lowlevel sensor 5525
B-5 Ground fromfront transverselock engagedindicator switch(2nd axle) 6659
B-6 Ground fromair filter clogswitch 6663
B-7 Ground fromfront wheel blockwear sensor (1st axle) 6664
B-8 Positive+30for foglights 2228
C-1 - -
C-2 Positive+30for front sidelights 3339
C-3 Positive+15fromIBC3 8871
C-4 CAN L line(BCB) Green
C-5 CAN H line(BCB) White
C-6 Positive+30for front / right sidedirectionindicators 1123
C-7 Positive+30for front / left sidedirection indicators 1129
C-8 Positive+15for water infuel filter presencesensor 8879
C connector
Pin Description
Cable
colour code
A-1 Positive+30for ECADregenerationsolenoid(air system) 9043
A-2 Positive+30for ECADdischargesolenoid(air system) 9043
A-3 Positive+30for rear transversedifferential locksolenoid 9325
A-4 Positive+30for longitudinal differential locksolenoid 9323
A-5 Positive+30for front transversedifferential lock solenoid 9063
A-6 Ground fromswitchinfront power steeringlock valve 6631
A-7 Ground fromsidePTO engagedindicator switch(without EM) 6132
A-8 Ground fromlow hydrauliccircuit pressureindicator with3rd steeringaxle 0491
B-1 Ground fromtrailer brakecircuit indicator switch 6689
B-2 Ground fromdistributor crawler gear engagement indicator switch(4x4) 9976
B-3 Engineoil level sendingunit signal 5505
B-5 Fuel level sendingunit 5557
B-6 Ground fromtotal/rear PTO engagedindicator switch (without EM) 6131
B-7 Ground fromswitchinfront power steeringswitchvalve 6631
B-8 Positive+15for UDScontrol unit (SCR system) 8540
C-1 Ground 0000
C-2 Engineoil level sendingunit earth 5506
C-3 Fuel level sendingunit 5555
C-4 Ground fromfour wheel driveengagement indicator switch 6602
C-5 Ground fromreverseengagement indicator switch 2268
C-6 Ground fromcrawler gear engagement indicator switch 9992
C-7 Ground fromfuel filter blockedindicator switch 5531
C-8 - -
J1 J2 J3
50239
49723
8 1
16 9
10
1
20 11
1 6
12 7
Figure142/1
121/1 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
D.D.M. / P.D.M.
TheD.D.M. islocated insidetheoperator door; theP.D.M. insidethepassenger door.
Print 603.93.521
Inputs Outputs
Rearviewmirror heating Rearviewmirror heating
Rearviewmirror adjustment Rearviewmirror adjustment
Windowlifter Windowlifter
Centralizedlock Centralizedlock
TheonlydifferencebetweenD.D.M.andP.D.M.isthattheP.D.M.pinJ2/10isconnectedbymeansofajumperwithpinJ1/8towards
thegroundfor passenger modulerecognition.
Thesecontrol unit manageall thefunctionsappertainingtothetwo vehicledoors, namely:
mirror heating
mirror adjustment
window lifter
centralized lock.
Theyarelocated insidethevehicle door andremoval isasfollows:
1. removethedoor lining;
2. disassemblethe loudspeaker traybyremovingthethreefasteningscrews;
3. takeDMoff thetraybyremovingthetwo fasteningscrews
4. disconnect thethreeelectricconnectionadapters.
Disassemblingoperationsarethesamefor bothdoors.
49838
Figure142/2
D.D.M. / P.D.M.
P.D.M.
CONNECTOR J1
Pin Cable Function
1 - Free
2 - Free
3 - Free
4 9965 Centralizedlock motor control (CDL)
5 9964 Centralizedlock motor control (CDL)
6 8863 Windowlifter motor control (opening)
7 8865 Windowlifter motor control (closing)
8 0000 Mass Bridge with (J2-10) for module recognition
9 - Free
10 - Free
11 0000 Negativefor centralizeddoor lockreleasepushbutton
12 0000 Negativefor mainrearviewmirror heating
13 0000 Negativefor wideanglerearviewmirror heating
14 - Free
15 2990 Klinefor diagnosis
16 7990 Center power positive
CONNECTOR J2
Pin Cable Function
1 Ws/Bi CAN H line(BCB)
2 - Approachrearviewmirror control (vertical)
3 - Approachrearviewmirror control (horizontal)
4 8851 Wideanglerearviewmirror control (return)
5 8852 Wideanglerearviewmirror control (vertical)
6 8857 Mainrearviewmirror control (return)
7 Gv/Ve CAN L line(BCB)
8 8853 Wideanglerearviewmirror control (horizontal)
9 - Approachrearviewmirror control (return)
10 0000 Mass Bridge with (J1-8) for passenger side ECU recognition
11 8859 Mainrearviewmirror control (horizontal)
12 8858 Mainrearviewmirror control (vertical)
CONNECTOR J3
Pin Cable Function
1 0962 Negativefrompassenger sideglasslifter pushbutton
2 9 - Free
10 4442 Positivefor passenger side glasslifter pushbuttonlight
11 0961 Negativefrompassenger sideglasslower pushbutton
12 0960 Negativefor passenger sideglasscontrol pushbutton+lighting
13 20 - Free
Print 603.93.521/A
D.D.M.
CONNECTOR J1
Pin Cable Function
1 - Free
2 - Free
3 - Free
4 9965 Centralizeddoor lockmotor control
5 9964 Centralizeddoor lockmotor control
6 8863 Windowlifter motor control
7 8865 Windowlifter motor control
8 0000 Control unit earth
9 - Free
10 - Free
11 0000 Negativefor Centralized door lock
12 0000 Negativefor mainrearviewmirror heating
13 0000 Negativefor wideanglerear viewmirror heating
14 - Free
16 7991 Positivefor center power
CONNETORJ2
Pin Cable Function
1 Ws/Bi CAN H line(BCB)
2 - Free
3 - Free
4 - Free
5 - Free
6 8806 Mainrearviewmirror control (return)
7 Gv/Ve CAN L line(BCB)
8 8843 Free
9 - Free
10 - Free
11 8809 Mainrearviewmirror control (horizontal)
12 8808 Mainrearviewmirror control (vertical)
CONNECTOR J3
Pin Cable Function
1 0962 Negativefrompassenger sidewindowlifter pushbutton
2 0966 Negativefrompassenger sidewindowlower pushbutton
3 0967 Negativefromoperator side windowlifter pushbutton
4 - Free
5 - Free
6 0953 Negativefromright rearviewmirror control push button(movement to theright)
7 0954 Negativefromleft rearviewmirror control pushbutton(movement to theleft)
8 0951 Negativefromright rearviewmirror control push button(movement downwards)
9 0952 Negativefromleft rearviewmirror control push button(movement upwards)
10 4442 Positivefor passenger/operator sidewindowpushbutton lighting
11 0961 Negativefrompassenger sidewindowlower pushbutton
12 0960 Negativefor passenger sidewindowcontrol pushbutton+lighting
13 0951 Negativefor operator sidewindowcontrol pushbutton+lighting
14 - Free
15 0950 Negativefor rearviewmirror control joystickpushbuttons
16 0600 Negativefor rearviewmirror control joystickpushbuttonlighting
17 - Free
18 - Free
19 4442 Positivefor rearviewmirror control joystickpushbuttonlighting
20 - Free
50240
UPPER VIEW
FRONT VIEW
A D C B
Figure143
Figure144
S.W.I. (Steering wheel / steervator interface)
Thefunctionofthiselectroniccenterlocatedonthesteeringcolumnistogrouptogetherall controlsfromthetwosteervatorlevers
and thesteeringwheel.
It isconnectedto thevehicleelectronic systemviaaCAN line.
108924
Figure145
SWI functions
Print 603.93.641
Inputs Outputs
Keyswitch MessagesonCAN line
CruiseControl keys
INTARDER lever
Changegear
Flood/dipped lights
Directionindicators
Windshield wiper
Controlson steeringwheel
Control lighting
50240
A / B C / D
Figure146
Connectors
A - Right lever B- Left lever C - Steeringwheel D
1
CruiseControl
(Resume)
1 - 1 Displaypageselection 1 +30
2
CruiseControl
(Set/Acc.)
2 - 2
Displaycursor move-
ment (high)
2 -
3
Changegear
(down)
3
Wiper electro pump
controls
3 Horn 3 CAN H
4 Intarder (pos.2) 4 Wiper (top speed) 4 Lever lighting(output) 4 CAN L
5 Intarder (pos.4) 5
Directionindicators
(right)
5 Earth 5 Earth
6 Intarder (pos.6) 6 Earth 6
Menu selection/ con-
firmation
6 Lever lighting(input)
7
Changegear
(up)
7 Floodlights on 7
Maindisplayreturn
(instruments)
7 -
8
CruiseControl
(deceler.)
8 Light flashes 8
Displaycursor move-
ment (low)
8 Horn(output)
9 Intarder (pos.1) 9 Wiper (onestroke) 9 Control (-) 9 AUX 2
10 Intarder (pos.3) 10 Wiper (intermittent) 10 Control (+) 10 Earth
11 Intarder (pos.5) 11 Wiper (lowspeed)
12 Ground 12
Directionindicators
(left)
49837
49724
49725
ROTORUPPERVIEW
STATOR LOWERVIEW
Figure147
SPIRALED CONTACT
Locatedbelowthesteeringwheel.
Itsfunctionis to collect all controlspresent on thesteeringwheel and send themto the SWI center.
74000
A. S.W.I center. - B. Steervator - C. Spiraledcontact - D. Start block
B C
D A
Figure148
Followtheprocedures described inthefollowingpagesincaseof spiraledcontact disassembly. NOTE
STEERING COLUMN (COMPONENT LOCATION)
72850
1
2
3
4
5
Figure149
Carefullyfollowtheproceduresdescribedhereundertoreplacethespiraledcontact,toavoiddamagingthespiraledcablecontained
inits boxwhendisassemblingand aligningthesteeringwheel incorrectly.
Disconnect masscableconnection (4).
Removenut (1) and marksteeringwheel assemblyposition onshaft (2) and removethesteeringwheel (3).
74000
7
6
8 9 10 11
12
13
14
Figure150
Disconnect electrical connections(6and 7) fromtheS.W.I.
Securecontactrotor (9) toitscontainerbyinsertingkey(10) intoslots(11and12),topreventrotor (9) andstator(8) fromrotating
duringdisassembly.
Keepthis situationuntil assembly. Inthelack of akey, useanadequatesizenut andbolt.
Carefullyraisethecontact so elasticretainer pins(13) areremovedfromsupport (14). Storeit carefully.
72857
15
Figure151
Invert thesequenceof operationsdescribed abovefor reassembly.
Thespiraledcontact issuppliedsparewithitsstopkey(15) assembledasshowninthefigure. Afterassemblyonthesteeringwheel
control support, rotatethe keyto causebreakageat thepoint indicatedbythearrow andreturnit to steeringwheel seat (5).
Figure152
Press theswitch ontheinstrument panel beforeadjustingheater temperature. NOTE
106971
B.M. (BED MODULE)
Positionedat thecab rear
TheB.C. identifiesits presencebut CANNOT bediagnosed.
Itsfunctionsareas follows
(variableconfigurationaccordingto vehicleaccessories):
- Time inhoursand minutes
- Switchingon/offof cabinterior lights(selectionof white/nightimelights).
- Opening/closingdoors.
- Opening/closingelectricwindows.
- Opening/closingelectrichatch.
- Lowering/raisingsunblinds.
- Switchingradio on/off
- Radiovolumeadjustment
- Radiotuning
- Wakeupfunction.
- Switchingadditional heater on/off.
- Temperature adjustment (onlywith additional heater switchedon). (Automatic).
- Adjustment of heater on time (9hoursmax.)
Figure153
113411
E.B.M. (EASY BED MODULE)
E.B.M. (EasyBedModule) substitutestheprevious(B.M.) roughlycarryingout samefunctions. It hasthreekeysandadisplaywith
icons for thevarious functions and thevisualisation of the time. TheB.M.E. connector is thesameastheB.M. and theelectrical
connections areunchanged.
Technical features
- Supplier ITALAMEC
- Nominal Voltage 24V
- WorkingVoltage 18V 32V
- WorkingTemperature -30 C +60 C
- Absorption - standby <200mA
- Absorption - normal displaymode <200mA
- Absorption - sleep mode <3mA
- Datatransmissionspeed(CAN line) 62,500(BIT/SEC)
Pin- out
Pin Description
Cablecode
colour
1 Direct Positivebattery(+Bat) 7906
2 Ground 0000
3 - -
6 - -
Figure154
113412
1. Confirmation key- 2. Keyfor theselectionof thedesired function- 3. Clock
E.B.M. Functions
Thefunctions whicharecarried out byE.B.M. varyaccordingto theconfigurationof theaccessoriesexpected onthe vehicle.
Function Symbol Availability
Indication of hour and minutes Always
Switchingon/ off of internal cabinlights(white lights) Always
Switchingon/ off of internal cabinlights(redlights)
Onlyfor vehicles with
medium-highroofs
Opening/closuredoors Optional
Opening/closureelectricwindows Optional
Opening/closureelectric trapdoor Optional
Lowering/raisingof sunblinds Optional
Switchingon/ off radio
Regulationofradio volume
Radiotuning
Optional
Switchingon/ off radio
Regulationvolume
SelectionCD tracks
Optional
Alarmclock setting
Onlyif thealarmclock functionis
present ontheCluster
Alarmclock repetition(snooze) / switchingoff (stop)
Onlyif thealarmclock functionis
present ontheCluster
Switchingon/ off supplementaryheater
Regulationoftemperature (if heater isswitched on)
Regulationofduration of heater functioning(max.9 hours)
Optional
TACHOGRAPH
Digital Tachograph (DTCO)
Digital Tachograph (DTCO) is aseries tachograph for new
productionvehiclesandreplacesanaloguetachographsincase
of failure.
DTCO electrical connections are the same as MTCO
electrical connections. Inthecaseof DTCO tachograph, the
sensoronthegearboxmustbereplaced;fromelectrical point
of view, thissensor isthesameasformer sensor.
Thesensor beingused for MTCO tachograph(KITAS2170)
cannot beusedonnewDTCOtachograph, forwhich KITAS
2171sensor ismounted.
This sensor (KITAS 2171 sensor) is also compatible with
MTCO sensor; however, once it hasbeenconfigured, it can
onlybeusedfor that tachographfamily.
1. Display
2. Keypad(driver-1)
3. Cardfeeder slot-1
4. Downloadinterface/ calibrationinterface
5. Keypaddriver-2
6. Cardfeeder slot-2
7. Releasebutton, printer drawer
8. Tear-off edge
9. Keysof Displaymenu
106343
Figure155
TACHOGRAPH SENSOR(KITAS2171)
108905
Figure156
DIGITAL TACHOGRAPH DTCO
Pin Description Cablecolour code
1 Direct positivebattery(+Bat) 7768
2 Positiveideogramillumination(fromIBC3) 4442
3 Positive+15 (fromIBC3) 8871
A
A
5 Ground 0000
6 Ground 0000
7 - -
1 Power supplyfor electronic tachograph transmitter 5514
2 Groundfor electronictachographtransmitter 0058
3 Speed signal for electronictachographtransmitter 5517
B
4 Invertedsignal fromelectronictachograph transmitter 5516
B
5 - -
6 Speed signal for Intarder / Navigator (pre-disposition) 5540
7 Speed signal for fitters(ST14A connector) 5155
8 Spacetravelled Signal (pre-disposition) 5518
1 -
2 -
3 -
C
4 -
C
5 -
6 -
7
8 -
1 -
2 -
3 -
D
4 -
D
5 -
6 -
7 Kline(14-pin diagnosisconnector) 2297
8 -
108906
Figure157
Figure157/1
113631
3 2 1 3 2 1 4 5 6
134/1 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
M.C. NET INTERFACE
TheM.C. Net Interfacecontrol unit isintroducedinthevehiclesTrakkerEuro 4/5andactsasinterfacefor theSWI control units
(controlsonwheel),IC(Cluster) andtheRadio,bymeansoftheCAN VDBandIDBlines.TheCANICBline,whichinthevehicles
Trakker Euro 3 connected the SWI and IC control units has beenremoved.
Technical features
- Supplier ITALAMEC
- Nominal Voltage 24V
- WorkingVoltage 18V 32V
- WorkingTemperature -30 C +60 C
- Absorption- standby- 27V <5mA
Pin- out A
Pin Description
Cablecode
colour
1 Direct Positivebattery(+Bat) -
2 CAN H line(IDB) White
3 CAN L line(IDB) Green
Pin- out B
Pin Description
Cablecode
colour
1 - -
2 Ground 0000
3 - -
4 CAN H line((VDB) 7797
5 CAN L line((VDB) White
6 - Green
Figure157/2
119850
INJECTION SYSTEM ASSEMBLY
Ref. Description
1 Position sensor onaccelerator pedal
2 Secondaryprimarybrakeswitch
3 Sensor on clutchpedal
4 Engine brake switch
5 Right stalk
6 SWI control unit
7 Immobilizer antenna
8 Ignitionkey
9 Engine brake selector
10 Safetyfuses(30A)
11 Cabreleaseswitch
12 Handbrake engaged
13 Idleswitch
14 Diagnosticconnector
15 Relativehumidityandtemperature sensor for EDC
16 Fuel prefilter
17 Water sensor
18 Engine revs sensor
19 Injectors
20 Distribution sensor
21 Engine brake solenoid valve
22 Preheatinginsertion contactor
23 Oil pressure/temperaturesensor
24 Engine start/stop buttons
25 Baruffaldi electromagnetic joint
26 Starter
27 Coolant temperaturesensor
28 Pre-heatingresistance
29 Air pressure/temperaturesensor
30 Fuel temperaturesensor
ENGINE CONTROL UNIT OPERATION STRATEGIES
ECM EDC7UC31 electronic control unit
The EDC7UC31control unit manages thefollowingmainfunctions:
Fuel injection
Turbinegeometryvariation
Exhaust brakeengagement
Self-diagnosis
Recovery
Also permits:
Interfacingwith other on-board electric systems onthe CAN EDBline(or ECB) SAE J1939
EOL andService programming
Diagnosis
Fuel metering
The fuel meteringis calculated in function of:
- theaccelerator pedal position fromtheVCM(VehicleControl Module)
- enginespeed
- quantityof introducedair.
The result maybecorrect infunctionof:
- thewater temperature
- thediesel temperature (DIESEL DENSITY)
or to avoid
- overloading
- overheating
- excessiveturbine speed
The deliverymaybe modifiedinthecaseof:
- enginebrakeor brakepedal activation(signalsviaCAN)
- theintervention of limitationdevices (ASR, speedlimitingdevice, etc.) (signals viaCAN)
- theintervention of ANTI-POLLUTION devices: sensor p, Sensor NOx, signalsviaCAN fromthecontrol unit DCU15
- serious problems that involve the reductioninloadand enginestalling.
Thecontrol unit, after determiningthemass of theintroducedair andmeasuringitspressureand temperature, calculatesthe
correspondingfuel mass to inject inthe involvedcylinder (mg. per delivery), also takingthediesel temperature into account
(density)
The fuel mass calculated in this way is convertedinto crankdegrees, that is, before and duringinjection.
Correction of flow according to water temperature
Whencold,theengineencountersgreaterresistanceinoperating;thereisgreater mechanical friction,theoil isstill veryviscous,
thevariousclearances arenot yet optimised.
Inaddition, theinjectedfuel tendsto condense onthestill cold metallic surfaces.
Whentheengineis cold, morefuel is meteredthanwhen the engineishot.
De-rating
Iftheengineoverheats,theinjectionischanged,loweringtheflowrateinproportiontothetemperaturereachedbythecooling
liquid. Thecontrol unit considers theoil temperatureinthecaseof awater temperature sensor failure.
Turbinespeed adjustment
Turbinespeed is adjusted continuouslyand corrected if needed through geometryvariation.
Turbine speed adjustment
Turbinespeed is adjusted continuouslyand corrected if needed through geometryvariation.
Injection advance electronic control
The advance (startingmoment, expressed in degrees) maybe different froman injectionto the next one, also in adifferent
manner fromacylinder to another, and is calculated, similarlyto theflow rate, in function of engineload (accelerator pedal
position, engine speedandintroduced air).
The advanceiscorrected asnecessary:
- duringacceleration
- basedonwater temperature
and to obtain:
- reduced emissions, noiseand overloading
- improved vehicleacceleration
Whenstarting, ahigh advance is set basedon water temperature.
The deliveredstartingmoment feed-backisprovided bytheinjector solenoidvalveimpedancevariation.
Engine speed regulator
The control unit controls theenginespeedat all speedsandinparticular:
- minimumspeed
- and maximumspeed
Starting the engine
Duringthefirst enginemotoringover revolutions, cylinder N phaseand recognitionsignal synchronisation occurs 1(flywheel
sensorandcamshaft sensor).Whenstarting,theacceleratorpedal signal that arrivesviaCANisignored.Thediesel deliverywhen
startingisset exclusivelybasedonthewater temperaturebymeansofaspecificmap.Whenthecontrol unit detectsanumber
ofrevolutionsandaflywheel accelerationthatissuchtoconsider theengineasstartedandnolongerdrivenbythestartingmotor,
it engages theaccelerator pedal signal..
Cold start
Ifonlyoneofthethreetemperaturesensors(water, air or fuel) registersatemperaturelower than10
o
C,thepre-post hearing
isactivated.
Upon activation of thekeycontact, thepre-heatingwarninglight turns ontheelectric dashboard(cluster display) andremains
on for avariableamount of time dependingon thetemperature (whereas theresistance at the intake manifoldheats theair)
, then it flashes. At this point, theengine maybestarted.
Withenginerunning,thewarninglampswitchesoff, whiletheresistancegoesonbeingpoweredfor acertain (variable) period
of time carryingout thepost heating.
If,withwarninglampblinking,theengineisnot startedwithin20 25seconds(absencetime) theoperationiscanceledinorder
not to dischargethebatteries.
The preheatingcurveisalso variablebasedonthebatteryvoltage.
Hot start
If thetemperaturesof referenceall exceed10
o
C, upon activationof thekeycontact,theindicator lamp turnsonfor approx.
2 sec. for abrief test, and then turnsoff. At this point, the enginemaybestarted.
Run Up
Upon activation of the keycontact, thecentral unit transfersthe information stored duringthe last engine stop to the main
memory(see: After run), and carried out asystemdiagnosis.
After Run
Eachtimetheengineisturnedoffusingthekey,thecentral unit remainspoweredforafewsecondsthankstotheinternal MAIN
RELAY.
Thispermitsthemicroprocessorto transfersomedatafromthemainmemory(volatile) toanonvolatile,erasableandrewritable
memory(EEPROM), to makeit availablefor thenext start (see: Run Up).
The dataconsistsessentiallyof:
- varioussettings(engineidling, etc.)
- thecalibrationof somecomponents
- fault memory.
This procedure lasts afew seconds, typicallyfrom2 to 7 (dependingon the quantity of datato save), after which the ECU
deactivates themainpower supply.
Ifthishappens,systemfunctionalityremainsguaranteedupuntil thefifthtimeit isturnedoffincorrectly(alsonotconsecutively)
afterwhichanerrorisstoredinthefailurememoryanduponthefollowingenginestartup,theenginewill functionwithdegraded
services whiletheEDC warninglight remains on.
Repeatedinterruptions of theprocedurecould in fact lead to central unit damage.
Cut-off
This function cuts off deliveryduringdeceleration, duringexhaust brake, etc.
Cyclinder Balancing
This function permits an individual andpersonalisedcontrol of thefuel flowrateand thedeliverystart for eachcylinder, in a
different manner fromcylinder to cylinder, to compensatefor thehydraulic injector tolerances
The fuel flow ratedifferencebycylinder isnot signalled bythecentral unit but bythe instrument IVECO - IRISBUS.
Synchronization Search
If thesensor signal doesnot arrive to thecamshaft, thecentral unit can still detect thecylinders into whichthefuel must be
injected.
Ifthisoccurswhentheengineisalreadyrunning,thecombustionsuccessionhasalreadybeenobtained,andthereforethecentral
unit continues with thesequence on which it isalreadysynchronised.
Ifthisoccurswhentheengineisstopped,thecentral unit energisesasinglesolenoidvalve. At thelatest bythe 2ndengineshaft
revolution, aninjection will occur inthat cylinder,for whichthecentral unit onlyhastosynchroniseitselfonthecombustion
sequence and start theengine..
To reducethenumber of connections, thelengthof the connection cables withtheinjectors andas aresult, disturbancesin
thetransmittedsignal,thecontrol unit isassembleddirectlyontheenginebymeansofaheat exchangerthat permit itscooling,
usingelectricdowelsthat reducethevibrations transmitted bytheengine.
The control unit is connected to the wiringthrough3 connectors.
- 8-.a coooocto '+' o t|o cooooots oo t|o Vo||c|o
- 36-.a coooocto '2' o t|o cooooots oo t|o |o|oo
- +6-.a coooocto '3' o t|o cooooct|oo to t|o |o,octos aoo o|aost ba'o so|ooo|o va|vo
Internally, thereisan ambient pressure sensor that is usedto additionallyimprove injectionsystemmanagement.
The control unit offers anon-boarddiagnosticsystemviaCAN:
- ODB(OnBoardDiagnostic)
- Cluster diagnosis.
It isalso equipped with averyadvancedself-diagnosis systemand it is capableof recognizingand memorizing, in function of
the environmental conditions, the possible anomalies, even of an intermittent type, that occurred on the systemduring
operation, ensuringamorecorrect and reliablerepair actionwith thehelpof the IVECO-IRISBUSdiagnostic instruments.
!
It isveryimportant that thisprocedureisnot interrupted,forexamplebyturningoff theenginefromthebatterycut-off
switch,or bydisconnectingthebatterycut-offswitchbeforeat least 10secondshavepassedtheenginewasturnedoff.
135 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
Print 603.93.641
Print603.93.641
EDC (ECM) SYSTEMS
EDC 7 UC31electroniccontrol unit
A. Injector connector - B. Chassis connector - C. Sensor connector
102373
Figure158
A C
B
Base- November 2006
Print 603.93.641
Electric injector connector 3 A
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M DARKBROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
Pin Description (F3B) Description (F2B)
Cablecolour
code
Pin Description(F3B) Description(F2B)
F3B F2B
1 - Cylinder 5pump injector - N
2 - Cylinder 6pump injector - N
3 Cylinder 4-5-6 pumpinjector shared cable Cylinder 4pump injector N N
4 - Cylinder 1 pump injector control - B
5 - Cylinder 3 pump injector control - V
6 Cylinder 2 pump injector control Cylinder 2pump injector B R
7 Engine brake control solenoid Engine brake control solenoid C C
8 Engine brake control solenoid Engine brake control solenoid M M
9 - - - -
10 - - - -
11 Cylinder 1-2-3 pumpinjector shared cable Cylinder 2 pump injector control R G
12 Cylinder 3 pump injector control Cylinder 3pump injector V R
13 Cylinder 1 pump injector control Cylinder 1pump injector B R
14 Cylinder 4 pump injector control Cylinder 4 pump injector control L L
15 Cylinder 6 pump injector control Cylinder 6 pump injector control H V
16 Cylinder 5 pump injector control Cylinder 5 pump injector control Z Z
16
12
6
1 5
11
102374
Figure159
Base- November 2006
Print 603.93.641
Sensor connector 2 C
Pin Description
Cablecolour
code
1 Variablegeometryturbinecontrol solenoid M
2 - -
3 Variablegeometryturbinecontrol solenoid N
4 8 - -
9 Earth for enginerpmsensor ontimingsystem(timingsensor) B
10 Engine rpmsignal on timingsystem(timingsensor) R
11 14 - -
15 Water temperaturesensor signal S
16 17 - -
18 Fuel temperaturesensor earth CN
19 Engine rpmsensor earth (flywheel sensor) N
20 Turbocharger speed sensor earth M
21 22 - -
23 Engine rpmsensor signal (flywheel sensor) B
24 Oil temperature/pressuresensor earth M
25 Air temperature/pressuresensor earth B
26 Water temperaturesensor earth G
27 Oil temperaturesensor signal CN
28 Oil pressuresensor signal L
29 - -
30 Turbocharger speed sensor signal B
31 - -
32 Oil temperature/pressuresensor power supply C
33 Air temperature/pressuresensor power supply R
34 Air pressuresensor signal V
35 Fuel temperaturesensor signal BR
36 Air temperature sensor signal C
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M DARKBROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
102375
Figure160 6 8 16 9 15 22
36 29 30 23 3 1
4
5
Base- November 2006
Print 603.93.641
Chassis connector 1 B
Pin Description
Cablecolour
code
1 - -
2 Control unit power supplypositive (+30) 7151
4 - -
5 Ground 0151
6 Ground 0151
7 - -
10 Ground 0151
11 Ground 0151
12 Groundenablingpreheatingactivation 0094
13 15 - -
16 Groundenablingengine fanactivation 0014
17 25 - -
26 Signal fromfuel air temperature sensor 5173
27 Signal fromcombustion air humiditysensor 5174
28 Groundfor combustionair humidityandtemperaturesensors 0173
29 GroundfromEDC systemdiagnosis request switch(wiring) 5163
30 - -
31 - -
32 Groundfromenginebaystart-up button 8892
33 Engine rpmsignal for bodybuilders (ST14B) 5587
34 Can- L line(ECB) Green
35 Can- H line (ECB) White
36 39 - -
41 46 - -
47 Groundfromenginebayshut-down button 0151
48 54 - -
55 Positivefor enginebrakesolenoid (wiring) 9966
56 - -
57 Positiveenablingenginefan activation 5187
58 Groundfor engine brake solenoid (wiring) 0043
59 67 - -
68 Power for combustionair humidityandtemperaturesensors 8173
69 74 - -
75 Positiveenablingpreheatingactivation 9164
76 84 - -
85 GroundfromEDC systemdiagnosis request switch(wiring) 5163
86 88 - -
89 Kline(diagnosticconnector pin 2) 2298
35
89 72
53
18 36
17
54 6
11
71
1
7
12
102376
Figure161
Figure162 Figure163
A
B
C
113564
113565
PUMP INJECTORF3A / F3B(CURSOR 10 / 13)
1. Fuel/oil seal - 2. Fuel/diesel seal - 3. Fuel/exhaust gas seal
- A. Plunger - B. Nozzle- C. Solenoid valve
PUMPINJECTORF2B(CURSOR 8)
1. Fuel/oil seal - 2. Fuel/diesel seal - 3. Fuel/exhaust gas seal -
A. Plunger - B. Nozzle- C. Solenoidvalve
Revi- June2007
Base- November 2006
Print 603.93.641/A
Print603.93.641/A
SYSTEM COMPONENTS
Pump injector (78247)
It mainlyconsists of threecomponentsas follows:
A) Solenoid valve
B) Plunger unit
C) Sprayer
ThesethreepartsCANNOT bereplaced individuallyand areNOT subject to overhaul.
The pump is actuatedmechanicallyat each cycle byarocker armand compressesthe fuel containedinthepressurechamber.
Thesprayerfeaturesthesameassemblyandoperationasaconventional injector;it isopenedbythefuel underpressureandinjects
it finepulverized into the combustion chamber.
Anelectro valvecontrolleddirectlybytheelectronic center sets deliverymodalities based on thecontrol signal.
Aninjector holder houses thelower part of the pump injector in thecylinder head.
The electro valve is of theN.A. type.
Coil resistanceis ~0.56 0.57Ohm.
Maximumoperatingvoltageis ~12 15Amp.
Basedonvoltageabsorbedbytheelectro valve, theelectroniccenter canidentifywhether injectionwascorrect ormechanical
problems exist.
It can also detect injector errorsONLY withthe enginerunningor duringstarts.
Injectorsareconnectedto thecenterwithconnectorST - Emountedontheenginefront withatwistedcable,to avoidpossible
electromagneticinterference problems, so junctions or repairs on it must NOT be performed.
Figure164
Figure165
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ST-E CONNECTOR
Pin
F2B F3A / F3B
Pin
ST-E
Cable Function
Pin
ECU
Cable Function
Pin
ECU
1-A R Injector 1 supply A13 B Injector 1 control A13
2-B B Injector 1 control A6 G Injector 2 control A6
3-C R Injector 2 supply - - - -
4-D G Injector 2 control - - - -
5-E R Injector 3 supply A12 V Injector 3 control A12
6-F V Injector 3 control A11 R Injector 1/2/3 supply A11
7-G N Injector 4 supply A14 L Injector 4 control A14
8-H L Injector 4 control A16 Z Injector 5 control A16
9-I N IInjector 5 supply A8 M Engine brake control electro
valve
A8
10-L Z Injector 5 control A7 C Engine brake electro valve
supply
A7
11-M N IInjector 6 supply A15 H Injector 6 control A15
12-N H Injector 6 control A3 N Injector 4/5/6 supply A3
Figure166
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M DARKBROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
113569
TECHNICAL VIEW WIRING DIAGRAM
PERSPECTIVE VIEW
Figure167
Figure168
Figure169
106983 113561
113562
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Engine coolant temperature sensor (85153)
ThisN.T.C.typesensorlocatedonthewateroutlet sumpontheengineheadleft measurescoolant temperaturefor thevarious
operatinglogicswithahot or coldengine andidentifiesinjectionenrichment requirementsfor acoldengineor fuel reduction
requirements for ahot engine.
The coolant temperaturesignal is usedfor displayon theCluster and to control thefan.
It is connected to electroniccontrol unit pins C 15 / C 26
Sensor behavior as afunction of temperature:
- 10 C 8,10 10,77 kOhm
+20 C 2,28 2,72 kOhm
+80 C 0,29 0,364 kOhm
At 60to 90 _C, voltageat C 15andC 26ranges from0.6 to 2.4V.
Connector Function Cablecolour
2 To EDC center pin C 15
3 To EDC center pin C26
TECHNICAL VIEW
8528
WIRING DIAGRAM
PERSPECTIVE VIEW RESISTANCEBEHAV IOR
Figure170
Figure171
Figure172
Figure173
113561
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Fuel temperature sensor (47042)
Features
Supplier BOSCH
Maximumtorque 35Nm
ThisN.T.C.typesensorlocatedonthefuel filterontheengineleftsidedetectsfuel temperatureandenablestheelectroniccontrol
unit to measurefuel densityandvolumefor deliverycorrection.
HOLESON FLYWHEEL
TECHNICAL VIEW
WIRING DIAGRAM
PERSPECTIVE VIEW
8520
Figure174
Figure175
Figure176
Figure177
106984
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Flywheel pulse transmitter (48035)
Features
Supplier BOSCH
Torque 8 2 Nm
Resistance 880 920
This induction type sensor located ontheflywheel generates signalsobtainedfromthemagneticflow linesthat closethrough
54holes in threeseriesof 18 in theflywheel.
The electroniccontrol unit usesthissignal to detect thevariousengine ratings and pilot theelectronic revcounter.
The revcounter does not operate in theabsenceof this signal.
T||s sooso's a| a |s |CT /||ST/3||.
3 Shields
TECHNICAL VIEW
WIRING DIAGRAM
PERSPECTIVE VIEW
8520
REFERENCE ON SOUND WHEEL
Figure178
Figure179
Figure180
Figure181
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Camshaft pulse transmitter (48042)
Features
Supplier BOSCH
Torque 8 2 Nm
Resistance 880 920
Thisinductiontypesensor located onthecamshaft generatessignals obtainedfromthemagneticflow linesthat closethrough
the6 plus1 phaseteeth of aimpulsewheel mounted on theshaft.
The electronic control unit usesthesignal generated bythissensor as aninjection step signal.
Thoughelectricallyidentical to (48035) enginerpmsensormountedinthecamshaft inisNOTinterchangeablewithit asit cable
isshorter andit features alarger diameter.
T||s sooso's a| a |s |CT /||ST/3||.
3 Shields
A. Pre/ort reheat resistor / 0.7 Ohm
A
Figure182
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Pre-post reheat resistor (61121)
This resistor located betweenthecylinder headandtheintake duct is usedto heat air inpre/post reheat operations.
Byinsertingthe keyswitch, when even onlyone of the water, air or gas oil temperaturesensors recordless than10 _C, the
electroniccenter activatespre/post reheatingandswitchesonthewarninglight onthecabinstrument panel foravariableperiod
accordingto temperature, after which thelight starts blinkingto informthe operator that theenginecanbestarted.
Thewarninglight goesoff after enginestart but theresistor continuesbeingsuppliedfor avariableperiodoftime to complete
post reheating.
Theoperationiscancelledto prevent uselesslydischargingthebatteryiftheengineisnot startedwithin20/25secondswiththe
warninglight blinking.
Whenreference temperatureisabove10 _C, actuatingtheignition keymakes thewarninglight go onfor some 2 seconds to
completethe test and then turnsit of to indicatetheenginecanbestarted.
1. Servicereservoir - 2. Shut-off electro valve- 3. Air filter - 4. VGT electro valve- 5. Actuator position sensor -
6. Turbineactuator - 7. EDC center
Figure183
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VGT control card
71732
1. Intakeduct air delivery- 2. Compressor - 3. Air intake- 4. Actuator - 5. Exhaust gasspeedadjustment -
6. Exhaust gas intake - 7. Exhaust gas outlet - 8. Turbine
71734 71733
MINIMUM FLOW SECTION MAXIMUMFLOW S ECTION
1. Air deliveryto intake manifold- 2. Compressor - 3. Air intake- 4. Actuator - 5. Exhaust gasdeliveryadjustment ring-
6. Exhaust gas intake - 7. Exhaust gasoutlet - 8. Turbine
Figure184
Figure185
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Variable geometry Holset turbo compressor (series HY)
TheVGTvariablegeometryturbo compressor consistsofacentrifugal compressor andaturbineprovidedwithamobiledevice
that adjusts therate of exhaust gas to theturbinerate bychangingthegas passagecrosssection.
This solution enables keepinggas and turbine rates high even when theengineis operatingat lowrpm.
Makinggasses pass through areducedcrosssection in fact increases their rate so theturbinetoo rotates faster.
Movement of the exhaust gas intake cross section partialization deviceis obtained bymeans of amechanismcontrolled bya
compressedair actuator, whichis controlledbyaproportional electro valve.
The deviceisfullyclosed at lowrpm, whileat highenginerpmtheelectroniccontrol systemincreasescrosssection to enable
incominggasses to flowwithout increasingtheir speed.
A thoroidal chamber iscast into the central bodyfor coolant passage.
Exhaust gassection with engineunder load
Highenginerpm Averageengine
rpm
Lowengine rpm
Figure186
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Operatingprinciple
A. Actuator - B. Turbinerpmsensor - C. Turbo compressor - D. VGT actuator positionsensor -
E. VGT activator control electro valve
E
D
C
B
A
Figure187
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Engine components (VGT)
1. Air intake - 2. Washer - 3. Piston - 4. External spring- 5. Internal springcontrol disc - 6. Internal spring-
7. O-Ring- 8. Springholder - 9. Run end- 10. Dust cover - 11. Control rod
Operatingprinciple
Theactuator pistonconnectedtothecontrol rodispilotedthroughthe compressedair admittedfromair intake1onthetop
of theactuator.
Modulatingair pressurevaries piston and turbinecontrol rod movement.
During its movement, the piston progressivelycompresses external spring4 until the piston base reaches internal spring6
control disc 5.
Byfurther increasingpressure, thepiston compressestheinternal springthroughdisc 5until runend, which is reachedwhen
disc 5interferes withlower runend10.
Useof thetwosprings enableschangingtheratio betweenpressureand piston travel. About 85%of rodtravel is contrasted
bytheexternal spring, theremaining15%beingcontrasted bytheinternal one.
VGT control solenoid valve
This is anN.C. typeproportional solenoid valve mounted on theenginefront, behind the fan.
ThroughaPWMsignal,theelectroniccenterpilotsthiselectrovalvetoadjust turbineactuatorfeedpressure;actuatorposition
changes modifytheexhaust gasintake crosssection on thefanbladesandthusits speed.
The VGT electro valve is connected between electronic center pins C3/C1.
Coil resistanceis ~20 30Ohm.
1
2
3
4
5
6
7
8
9
10
11
Figure188
Figure189
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Actuator
This is aninductivesensor positioned onthe impeller shaft.
It generates signalsobtainedfromthe magnetic flowlines, which closethroughanotchobtainedontheshaft itself.
Thesignal generatedbythissensor isusedbytheelectroniccontrol unit toverifythattheturbinerevsnumberdoesnot exceed
themaximumvalue.
To control therevsnumber, the control unit actsonvariablegeometry.
Iftherevsnumberkeepsonincreasinguntil it reachesexcessiver.p.m.values,theelectroniccontrol unit will detect ananomaly.
The gap of this sensor CANNOT BE ADJUSTED.
It is connected on electronic control unit pinsC30 / C20.
The sensor resistance value is 400 Ohm.
Wiringdiagram
Figure190
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Turbine speed sensor (48043)
Linkingconnector
Sensor external view
Wiringdiagram
50324
Figure191
50323
Figure192
50344
Figure193
Air pressure/temperaturesensor (85156).
This component incorporates atemperaturesensor and a
pressure sensor.
IIt replaces the temperature sensors (85155) and pressure
sensors (85154) availableintheprecedingsystems.
It is fitted onto the intake manifold and measures the
maximumsuppliedair flowrateused to accuratelycalculate
theamount of fuel to beinjectedat everycycle.
The sensor ispowered with5 V.
The output voltage is proportional to the pressure or
temperature measured bythesensor.
Pin (EDC) 25/C - 33/C Power supply
Pin (EDC) 36/C Temperature
Pin (EDC) 34/C Pressure
Oil temperature/pressuresensor (42030 / 47032)
Thiscomponent isidentical totheairpressure/temperature
sensor andreplaced singlesensors 47032 / 42030.
It is fittedonto the engineoil filter, in ahorizontal position.
It measurestheengine oil temperature and pressure.
The measured signal is sent to theEDC control unit which
controls, inturn,theindicator instrument onthedashboard
(low pressurewarninglights / gauge).
Pin (EDC) 24/C - 32/C Power supply
Pin (EDC) 27/C Temperature
Pin (EDC) 28/C Pressure
Theengineoil temperatureisusedonlybytheEDC control
unit.
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Ref Description
Control unit pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 Temp. Sign. 27C 36C
3 +5 32C 33C
4 Press. Sign. 28C 34C
1. Pulley- 2. Support - 3. Disk with fins - 4. Fan- 5. Fanadapter- 6. Roundmagnets - 7. Floatingring- 8. 24Vcoil
The fanhasaneffectivespeed, called secondspeed, that is controlled bytheEDC control unit bycoil (8) excitation.
When coil (8) isde-energised, thefanisdriven bythefour magnets (6) at aspeed (called first speed) of about 450rpm.
The first speed is activatedwhen:
- Water temperatureis less than 93 C and theIntarder andtheair conditioner areoff, or
- Water temperatureis less than 85 C and theair conditioningsystemis onbut thecircuit pressureisbelow 22 bar, or
- Water temperatureis less than 85 C and theIntarder isonwithbraking power 41%lower than max. power.
The secondspeed isactivated when:
- Water temperaturereaches93 C withIntarder offor onwith brakingpower lessthan41%,second speedwill deactivate
whentemperaturedrops to 88 C, or
- Water temperature reaches 85 C with Intarder on andbrakingpower 41%higher than max. power or air conditioning
systemon and circuit pressureequal to 22 bar.
87169
Figure194
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Fan with electromagnetic joint (F2B)
Inthisconditionthefloatingring(1) isat rest,fanmovement isthereforeinducedbythe4magnets(2) keyedinto thesupport.
The first speedis thereforealways actuatedanddueto theeffect of the magneticfieldgenerated bythemagnets(2), thefan
can followtheoutput shaft speed up to450rpm.Higher output shaft speedswill produce aslippingbetweenthesupport (3)
and thekeyed disk (4).
87170
Figure195
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Fan at first speed position
Thesecond speedis activatedbythe EDC control unit that controls coil (1), themagnetic fieldgeneratedbythe coil attracts
thefloatingring(3) to thepulley (2), thus makingthemintegral.
Under thisconditionthefan speedis proportional to theoutput shaft speed.
87171
Figure196
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Fan with second speed on
1. Pulley- 2. Fanhub- 3. Permanent magnets - 4. Blades- 5. Fan- 6. Shaft - 7. Returnspring- 8. Piston -
9. Floatingring- 10. Air supplypipe- 11. Coil
The fanfeatures two possiblerotation speeds controlled bythe EDC center byexcitingthecompressed air electro valve for
slowspeed and bycoil (11) for second speed.
Whenneither lownor second speed is activated, thefanis drawn slowlybyfriction forces present (neutral position).
The parameters/systemsthat mayrequirefan action viatheBC center areasfollows:
- Coolant temperature
- Conditioningsystemcoolant pressure
- Intarder
Lowspeedisactivated when:
- Engine coolant temperaturereaches 80_C and theintarder is cut in at decelerationpower under 41%of maximum.
- Conditioner coolant pressurereaches 18bars.
Secondspeed isactivated when:
- Conditioner coolant pressurereaches 22bars.
- Engine coolant temperaturereaches 80_C and theintarder is cut in at decelerationpower over 41%of maximum.
- Engine coolant temperature is over 88 _C.
Whensecond speed activation isrequired, thesystempilots thefan for 5 seconds at lowspeed, thensecond speed iscut in.
This operatinglogic enablesincreasingbelt andfan component reliabilityin time.
Whenfanlowspeedremainscut infor over 1minute,thesystemactivatessecondspeeduntil control parametersreturnbelow
actionlimits.
1 2 3
4
5
6 7 8 9
10
11
Figure197
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Fan with electromagnetic junction(F3A - F3B)
Whenfanactionisnot requiredfor proper engineoperation, theEDC center pilotsthecompressedair electrovalveto move
piston(8), displaces permanent magnets (3) fromfan hub (2). Themagneticfieldgenerated bymagnets (3) is not enough to
move fanhub (2) byinduction.
The fanmayrotateslowlydueto friction present.
1 2 3
6 8
Figure198
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Fan cut out (neutral position)
Whenlowspeedactionisrequired,theEDCcenterdischargeairfromduct (10) throughthecompressedairelectro valve;piston
(8) movesanddraws permanent magnets(3) towards fanhub(2). Piston travel isensuredbyreturnspring(7) andblades(4).
Theshaft rotatesat thesamespeedas pulley (1) and theeffect ofthemagneticfield generatedbymagnets(3) is to makefan
hub (2) rotate at themaximumspeedof 650 rpm.
For F2Bthe first speed is always connected since thereare no pneumatic solenoid valve nor air exhaust systeminside the
assembly.
2 3
10
1 2 3
4
6 7 8
Figure199
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Fan with first speed engaged
Whenlow speed is not enoughto properlycool theengine, theEDC center pilotssecondspeedcut-in byexcitingcoil (11).
The magnetic fieldgenerated bythe coil attracts fanhub(2) floatingring(9) to pulley(1) makingthe two unitssolidal.
Inthisconditionfan speedis the same as pulleyspeed.
1 2
9
11
Figure200
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Fan with second speed cut it
Defect
The fanalways rotates at lowspeed
Defect identification
Cause
- Air supplypipeclogged
- Air supplypipebroken
- Center output does not pilot thecoil
- Interruptionof the center to coil wire
- Coils short-circuited
- Improper mechanical parts sliding
The fandoesnot rotateabove 650rpm(lowspeed)
The fanalways rotates at secondspeed - Thecenter output always pilotsthe coil
- Improper mechanical parts sliding
1. Enginebrakeswitch- 2. SteeringWheel Interface - 3. Instrument Cluster - 4. Conditioner - 5. BodyComputer -
6. Conditioner pressureswitches- 7. Fanelectro valve - 8. Fanelectro valve - 9. VCM- 10. EDC -
11. Water temperature sensor - * Thepressureswitches involvedin fancontrol are the (18-22bar) conditioner coolant
pressure warningones.
Figure201
113575
9
1
2
3
6
*
4 5
10 11
E.C.B
7
8
18BAR / 22BAR
*
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Fan control diagram
77469
Inrest conditions, gap X between pulley (1) andfloatingring(2) (subject to wear) must rangebetween0.5 and 1.2mm.
Wear upto maximumgap thicknessof 2.5mmis permitted.
Figure202
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lectric fan wear check
163 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
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Print 603.93.641
VCM (VEHICLE CONTROL MODULE) ELECTRONIC CONTROL UNIT
ThisElectronicControl Unit is interfaced withtheother on-boardelectronicsystemsthroughCAN lines:
- ICB- Instrument Cluster Bus
- FMB- FuhrparkManagemant Bus
AmongtheElectronic Control Unit input signalswefindthoseoftheaccelerator pedal sensor, deviator for signalling(ABS) stop,
switchonclutchandswitchfor Economyfunction, whichpreviouslywereconnectedto theEDC ElectronicControl Unit.
TheImmobilizer Elec. Cont. Unit is eliminatedandtheimmobilizer antennaisconnectedto theElec. Cont. Unit VCM.
TheVCMoperatesalso CruiseControl whichbeforewasconnected ontoBodyComputer.
VCM main functions
- Driveability: accelerator pedal control andgenerationoftorquerequirementsviaCAN towardstheengineaccordingtothe
driveabilitymaps, Requiredtorque=f (EngineSpeed, Accelerator Pedal Position).
- Arbitration of therequirements of TorqueandEngine Speed: fromexternal systems (Brakes, Transmission, Fitters, etc.)
towardstheengineduringthephasesof braking,changinggear,operationsinPTO mode,VCMdeterminestherequirement
withthehighest priorityandtransmits thecorrespondingrequirement of Torqueor EngineSpeedviaCAN to theengine.
- Speedlimiter: (main, programmableandsecondary) VCMdeterminestheextent oftherequirement oftorquetowardsthe
engineensuringthat theactive speedlimitsarenot exceeded.
- CruiseControl: VCMadjuststhevehiclespeedaccordingtotheset Cruisespeedbymodulatingtherequirement oftorque
transmitted viaCAN to theengine (torquelimitationor control), viatherequirement of turningontheexhaust brakeand
Intarder, integratingthecontrol functions of theconditions of engagement andrelease.
- AdaptiveCruiseControl:VCMreadsthedataoftheRadarrelatingtothedistanceoftheprecedingvehicle,adjuststhevehicle
speedaccordingto theset Cruisespeed, keepingthedistanceselectedbythedriver, modulatingtherequirement of torque
transmittedviaCANtotheengine(torquelimitationorcontrol),viatherequirementtoturnontheexhaustbrakeandIntarder,
integratingthefunctionsofcontrol oftheconditionsofengagement andreleaseand incaseof riskof collisionactivatingthe
conventional brakes(interactingwiththeEBSsystem).
- Engine starting / stoppingcontrol logic and associated safetydevices: requirement control fromcab, engine bay, fitter
connector.
- Power take off (PTO mode): management of the requirement to adjust engine speed viaCAN in accordance with the
conditionsrelatingtothePTO 0, 1, 2, 3 (pre-programmed) modes withactuationbytheengine.
- LowIdlecontrol logic: dynamic High Idlecontrol with requirement relatingto the engineviaCAN the VCM controls the
requirement for enginespeedadjustment viaCAN withactuation bytheengine.
- Exhaust Brakeactivation logic: control of driver requirements and arbitration of therequirements fromexternal systems
(Brakes, Transmission, Fitters, etc.), transmission of thevalueviaCAN andactuation bytheengine.
- Enginecoolingfanactivationlogic(Baruffaldi):management ofcontrol logic,transmissionof theactivationrequest viaCAN
and actuationbytheengine.
- ZFSimpleH Gearbox:gearboxcontrol withsolenoidactivationtopassfromlowrangeandhighrangeinconditionsofsafety
- ALLISON Gearbox: standardCAN interfacecontrol onlever side, external requirements (Fitters) and for displaylogic on
Instrument Panel.
- NewEUROTRONIC lever (used for ALLISON too): driver requirement control for sendingto EUROTRONIC gearbox
and recoveryin caseof breakdown.
- Vehiclesecuritysystem: Immobilizer
- CommunicationonCAN bus:Point-to-point communicationfromexternal busfordedicatedconnectiontoapparatusesof
Fleet Management inaccordancewithBus - FMS. Interfacefor connectionto Tester for diagnosisviaCAN of theon-board
systems.
- Others:InterfacetowardsInstrumentPanelondedicatedbus(ICBonHeavyRange) forinformation/ controlsto/ fromDriver.
HW signal generationfor fitter connector.
108925
Figure203
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Electronic Control Unit location
Pin - out
Connector X1
Pin Description
Cablecolor
code
1 Immobiliser aerial input signal -
2 - -
3 Immobiliser aerial output signal -
6 Ground 0000
7 Gearboxinneutral signal for bodybuilders(ST14A) 8050
8 Power to ACC (AdaptiveCruiseControl) distancerulereached indicator warninglight /
Positivefor splitter gear activationsolenoid (9 speedgearbox)
6179/9973
9 EDC systemfaultysignal for cluster 6150
10 Handbrakeengagedsignal for bodybuilders (ST14A) 6656
11 Power to ACC (AdaptiveCruiseControl) distancealarmbuzzer / Positivefor normal gear
activationsolenoid(9speed gearbox)
1166/9974
12 Clutchstatussignal for bodybuilders(ST14B) 9963
13 Brakelight signal for bodybuilders(ST14A) 1165
14 Signal indicatingprogrammablespeed threshold(PST) for bodybuilders (ST14B) 5542
15 Ground controllingstarter motor relay 0008
16 Positivecontrollingstarter motor relay 8888
Connector X2
Pin Description
Cablecolor
code
7 Positive5 Vfor distancecontrol with ACC (AdaptiveCruiseControl) at great distance 8179
8 Returnfromdistanceselector with ACC (AdaptiveCruiseControl) 6178
9 Ground cablefor ACC distancecontrol 0139
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Pin - out
Connector X3
Pin Description
Cablecolor
code
1 CAN L line(VDB) White
2 CAN H line(VDB) Green
3 - -
4 Ground fromcoolant pressureindicator switch(22 bars) 0583
5 Ground fromcoolant pressureindicator switch(18 bars) 0582
6 - -
7 Control cablefor activatingACC 0179
8 Ground fromswitchindicatinggearboxinneutral 8050
9 - -
10 Ground fromenginebrakewiringswitch(associatedwithaccelerator pedal release) 0082
11 - -
12 Positivefromignitionkeyterminal 50 (ignitioncontrol) 8888
13 Secondspeed limiter engagement signal frombodybuilders(ST14B) 0172
14 Positivefrombrakeindicator switch (brakepedal pressed- mainbrakelights) 8153
15 Positivefrombrakeindicator switch(brakepedal released- secondarybrakelights) 8158
16 - -
17 Positivefor accelerator pedal sensor 5158
18 - -
19 CanH line(ECB) White
20 CanL line(ECB) Green
21 - -
22 - -
23 Ground fromswitch(N) for neutral positiongear withautomaticgearbox 0147
24 Ground fromswitch(D) for forward gearswithautomaticgearbox 0125
25 Ground fromswitch(D) for forward manoeuvregears withautomaticgearbox 0127
26 Enginestopsignal ( ST14A pin 2) 0151
27 Enginestart-up signal fromdiagnosticinterface/bodybuilders(ST14A) 8892
28 Ground fromstart-upenablement switch 8892
29 Signal fromcabreleaseindicator switch 0096
30 Ground fromCruiseControl cut-out switch (OFF) 8154
31 Ground fromCruiseControl resumeswitch(RESUME) 8155
32 Ground fromCruiseControl speedincreaseswitch(SET+) 8156
33 Ground fromCruiseControl speed decreaseswitch(SET-) 8157
34 Signal fromswitchindicatingengineidling 0159
35 Signal fromaccelerator pedal sensor 5157
36 - -
37 CAN H Line(FMB) White
38 CAN L Line(FMB) Green
39 - -
40 - -
41 Ground fromswitch(R) for reversegearswithautomaticgearbox 0126
42 Ground fromswitch(D) for reversemanoeuvre gearswithautomaticgearbox 0128
43 - -
44 - -
45 Ground for power take-off 3request frombodybuilders(ST14A) 0123
48 Ground fromsignallingswitchconnectionof slowgears(9gear changes) 0117
49 CruiseControl selectionsignal (INT / EXT) frombodybuilders(ST14A) 0158
50 Signal fromswitch(SL) for speedlimiter with automatic transmission 9968
51 Signal fromswitchonclutchfor VCM (clutchcylinder 20%compressed) 0160
52 Ground fromaccelerator pedal idle switch 0158
53 Ground for accelerator pedal sensor 0157
54 VCMcontrol unit Kline (diagnostic connector pin12) 2292
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IMMOBILIZER
Description and operation
Vehicles are provided with an immobilizer engine lock that is activated automaticallybyremovingthe starter key, to increase
protectionagainst theft. Keysareprovidedwithanelectronictransponder that transmitsacodedsignal to anICU centrethat only
enablesenginestart at coderecognition.
IMMOBILIZERcentral unit onEuro 4 vehicles isintegratedinto VCM.
Maintechnical features are:
D IMMO central unit integratedinto VCM
D Newkeys (colour BLUE)
D Min2 max7 programmablekeys
D Newantennaconnector
VCM/ Immobilizer procedures
Replacingakey
Addingakey
1) Cut thekeyinto based onexistingmechanical profile
2) Provideyourselfwith Code card
3) Go to environment ENGINE / VCM-IMMOBILIZER /
SPECIFIC FUNCTIONS/ KEY STORING
Replacingall keys
(loss)
CAUTION!
In this procedure, also add working remaining keys,
otherwisetheywill not be enabledanymore at start-up.
Orderthenewkeysandprogramthemasdescribedabove.
(Replacingor Addingakey)
ReplacingVCM-IMMOBILIZER
central unit
(NOT COMMUNICATINGWITH DIAGNOSISDEVICE)
1) ReplaceECMcentral unit.
2) Go to environment ENGINE \ ECM-EDC7 UC31 /
SPECIFIC FUNCTIONS / ACKNOWLEDGING NEW
ECM
(enter the electronic codethat is present oncodecard).
N.B:This operation is necessary to have the new ECM
central unit acknowledgethe VCM that is present on the
vehicle.
D IfoldVCMisoutoforderandisnot communicatingany
more, ECM must also be either replaced or re-pro-
grammed through remote services (Immo code er-
ased).
N.B:Onlyfor VCM5.4versions
D IfoldVCMisoutoforderandisnot communicatingany
morewiththeothervehiclecommunicationBUSes,the
emergencystartviaelectroniccodeinsertionisnot pos-
sible.
ReplacingVCM-IMMOBILIZER
central unit
(NOT COMMUNICATINGWITH DIAGNOSISDEVICE)
1) Cut thekeys intobasedon existingmechanical profile.
2) Performfollowingoperations:
a) Go to environment / ENGINE \ VCMIMMOBILIZER /
PROGRAMMING / OTHER / REPLACINGVCM
b) Go to environment ENGINE / VCM IMMOBILIZER /
SPECIFIC FUNCTIONS/ KEY STORING (2 newkeys)
c) Mount theoldVCMtomakeVCM / ECMdisconnection
(present 5.4 version)
d) Go to environment ENGINE / VCM IMMOBILIZER /
SPECIFIC FUNCTIONS / ACKNOWLEDGING NEW
VCM
e) Remount the new VCM and perform the start-up
operation.
108926
Figure204
EDC
3
4
6
7 8
2
1
5
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Componentry
Componentry
Ref. Description
1 Central unit VCM
2 Code-card
3 Electronickey
4 Antenna
5 EDC injectoncontrol eletronic centre
6 Electroinjectors
7 Indicator light EDC
8 IMMOBILIZERdownwarninglight
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ABS-EBL ANTILOCK BRAKE SYSTEM - ELECTRONIC BRAKE LIMITER SYSTEM
T|o /3S |3| ba'|o ssto |s ava||ab|o as ao a|tooat|vo to t|o |3S ssto oo +2 o 62 vo||c|os.
ABS Anti Lock Brake System
Brakingamovingvehicleandisdecelerationandstoppingdistanceareessentiallydependant onadherencebetweentireandroad
surface. Improvedbrakingwith anefficient brakingsystemcanonlybeachieved byactingontirefrictionfeaturesor roadsurface
quality.
Improved brakingwith anefficient brakingsystemcanonlybeachieved byactingontirefrictionfeatures or roadsurfacequality.
Eveninoptimumconditions, absolutelysafebrakingisnot guaranteedwhencritical situationshaveto becopedwith,suchaslow
adherencedueonawet or icedroadsurface, whichobligesthevehicleoperator tomoderatebrakingactiontoprevent possible
wheel locksand consequent dangerouslossof vehiclecontrol.
TheABSthereforehasthefunctionof ensuringvehiclestabilityinanybrakingconditionbypreventingwheel locksindependently
of road surfaceconditionsand guaranteefull exploitationof availableadherence.
Inessence, theABSsystem:
- preventswheel locksduringvehicle brakinginand roadadherenceconditions
- reducesstopdistances
- offersoperator safetyfor stabilityandvehiclecontrol maintenance.
Electronic Brakes Limiter EBL
TheEBL function controls rear axle wheel skiddingbycomparingit with front wheel speed.
Dataenteringthecenter are wheel rpmandbrakingpressuremeasured by thepressuresensor installed upstreamtherear axle
ABSmodulators.
Thecenter usesthesedatatocalculatevehiclespeedanddeceleration, rear axlewheel skidandminimumdecelerationrequired.
TheEBL functionisactivatedwithrear ABSmodulatorsmaintainingset pressurewhentheoperatorsappliesexcessbrakingforce
thanrequiredfor vehicleloadconditions, inessence whenvehicledecelerationandrear axleskidthresholds are passed.
Brakingpressure
AXLE
Braking
action
Request for brakingintensity
Wheel speed
CENTER
OBJECTIVE
Skidding =0
Brakingpressure
REAR AXLE
Managesthebrakingsystembysettingdecelerationto theparametersmeasured bythevarious systemcomponents.
It communicateswithon-board electronic systemsviaaCAN lineandisconnected throughtwo polarized connectors.
Thoughofferingthepossibilityof ablinkcodedisplayedviatheASRwarninglight for preliminarydiagnosis, theelectroniccenter
is provided with anadvanced self-diagnosis systemcapable of identifyingand storinganyintermittent anomalyto an operating
systemsubject to environmental conditions, and ensuringproper and reliablerepair.
Figure205
107016
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Operating logic
Theobjectiveoftheelectroniccenter istoslowdownthevehicleasfast aspossible, guaranteeitsstabilityandavoidthetendency
to lockwheels. Whenbraking, thecenter isinformedof thefollowingto reachtheseobjectives:
- brakingintensityrequired bytheoperator viatherear axlepressuresensor
- slowingreaction dueto pressuresmadeavailableviasignalsfromthespeedsensors.
Ongoingmonitoringandprocessingof thesedatareferredto theobjectiveset requiredactivationofrear axlemodulatingvalves
and consequent brakingoptimization.
ABS electronic center
X2 X1
Figure206
107017
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Pin out ABS center
Connector X1
Pin Description Cablecolor code
2 Safetysignal sensor for maximumbrakingbridgewith axlefailurewith ABS 6245
4 Ground 0000
5 Ground fromswitchfor ABSexclusion 0049
6 Ground fromswitchASRexclusion 0048
7 Positive+15 8847
8 Positive+30 7710
9 Ground 0000
10 Kline(4-pindiagnosisconnector) 2299
11 - -
12 9/15-pinsafetybridge(onlywhenconnectedX1isnot connected) -
13 - -
14 - -
15 - -
Connector X2
Pin Description Cablecolor code
1 |os|t|vo '|V' (oo|oaooo)o|octo va|vo coaoo oot ||t .|oo| 9920
2 |os|t|vo '|V' (oo|oaooo)o|octo va|vo coaoo oot |ot .|oo| 9931
3 |os|t|vo '|V' (oo|oaooo)o|octo va|vo coaoo oot |ot .|oo| 9921
4 |os|t|vo '/V' (|oaooo)o|octo va|vo coaoo oot ||t .|oo| 9918
5 |os|t|vo '/V' (|oaooo)o|octo va|vo coaoo oot |ot .|oo| 9929
6 |os|t|vo '/V' (|oaooo) o|octo va| vo coaoo oot |ot .|oo| 9919
7 Ground for ASR electro valve 0260
8 |os|t|vo '|V' (oo|oaooo) o|octo va|vo coaoo oa ||t .|oo| 9930
9 |os|t|vo '/V' (|oaooo) o|octo va| vo coaoo oa ||t .|oo| 9928
16 PositiveASR electro command valve 9260
It consistsof adrier provided with afilter regeneration timer anda 4-wayprotectionvalveincorporatingapressurereducer.
Thepurposeof thedrier isto purifyand drycompressed air byadjustingsystempressureto itsratedvalue.
The4-wayprotectionvalvedistributesairconthevariouscircuitsensuringtheiroperatingpressureevenintheevent ofbreakdowns.
Thiscomponent isusedinall systemsand isratedat 10.5 +0.2 bars; for mobilebowl CMvehiclesettingis12.5+0.2bars.
TheAPU containstwosensors connectedto theMUX systemfor axlepressuredisplayonthe Cluster.
A.P.U. (Air processing unit)
Figure207
107020
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COMMON COMPONENTS
Pneumaticconnections Electric connections
11 - Fromair tankto trailer 6.1 - Positive Pressuresensor
21 - To automaticcouplingjoint 6.2 - Ground Pressure sensor
22 - To moderablecouplingjoint 6.3 - Signal Pressuresensor
42 - From(drive) CBU 6.4 - Positive Solenoid
3 - Exhaust 6.5 - NegativeSolenoid
Compressed air connections
1 - Power fromthecompressor
24 - PTO
25 - Output for 10.5bar compressedair suspension
23 - To thecompressor for EnergySaving control
3 - Ventingto outsideair
21 - To the10.5 bar axlereservoir
22 - To the10.5 bar axlereservoir
23 - To the8.5 bar parkingbrakemanual distributor andtrailer rechargeandparkingair reservoir
24 - To the8.5 bar servicereservoir
Drier electrical connections
6.1 - Negativefor thermostatic resistance
6.2 - Positivefor thermostaticresistance
4-way protection valve electrical connections
6.2 - Rear circuit air pressuresignal 5561
6.3 - Positive for power 5560
6.4 - Negative 0000
6.5 - Front circuit air pressuresignal 5562
6.6 - Positive for power 5560
6.7 - Negative 0000
TECHNICAL VIEW
WIRINGDIAGRAM
Figure208
107021
107022
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Thisnonself-limitedcoaxial component consistsofacompressedairandanelectrical section,theformerdistributingbrakingcontrol
pressureto thefront axle, therear axleand thetrailer control servodistributor.
Theelectrical sectionensuressendingthebrakingsignal to theEDC center and to thestoplight control relay.
Compressedair connections:
11 - Power fromthe axlereservoir
12 - Power fromthe axlereservoir
21 - Valveoutput to servo distributor relayvalve and
trailer control
22 - Valveoutput toaxlerelay
3 - Vent to outsideair
Electrical connections:
1 - Positivefor stoplights/EDC
2 - Input positive
3 - Positive for EDC
4 - Input positive
Figure209
Figure210
107024
107025
107026
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Duplex distributor (ABS/EBL systems)
Thisnormallyopenelectro valveconsistsof apower coil and adischarge.
It isusedto modulatebrakingpressurewhenwheel tendencyto lockisdetectedbythe speedsensor.
VehicleswiththeEBSsystemfeaturetwo of themto control thefront axle.
Compressed air connections
1 Proportional relaypower
2 Axlebrakecylinder output
3 Discharge
PERSPECTIVEVIEW
WIRINGDIAGRAM
Figure211
107030
107031
107032
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Electro valve ABS78052
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Electric connections
Wheel
Solenoid valvepin
ABS EBS
Wheel
Solenoid valvepin
78052
Cablecode ABSpin Cablecode EBSpin
Left-handfront
LHF
1
2
3
9919
0000
9921
X2/6
-
X2/3
9919
0122
9921
X4/10
X4/12
X4/11
Right-hand front
RHF
1
2
3
9918
0000
9920
X2/4
-
X2/1
9918
0118
9920
X3/1
X3/3
X3/2
Left-handrear
LHR
1
2
3
9929
0000
9931
X2/5
-
X2/2
-
-
-
-
-
-
Right-hand rear
RHR
1
2
3
9928
0000
9930
X2/9
-
X2/8
-
-
-
-
-
-
Sensors continuouslysupplytheelectroniccenter withall thedatait requiresto properlypilot theelectrovalves.
Signalsareobtainedfrommagneticflowlinesthatclosethroughtheteethofateethedwheel facingthesensorandrotatingtogether
withthewheel.
Passagefromfull toemptydueto the presenceorabsenceofthetoothcausessufficient magneticflowvariationto createinduced
electromagneticforceat sensor terminalsandthusan alternatingelectrical signal that issent totheelectroniccenter.
Theclearancebetweenthesensorandwheel, calledair gap,must obviouslybeat apre-set valueof 0.8 1.6mmforpropersignals
to besent. Resistanceof eachsensor at connection terminalsisbetween 1and2 k .
Thetoothedwheel iscalledphonicwheel becausethesignal it generateshasthesamefrequencyas asoundwave.
Thefrequencyof this signal serves to definewheel rotationspeed.
Frequencyvariations, or thespeedat which signalsfollow oneanother, defineaccelerationanddecelerationrates.
PHONIC WHEEL (A) AND SENSOR(B) PERSPECTIVEVIEWS
AIR GAP
A. Magneticflowlines
A
B
B
A
A
Figure212
107043
107044
107045
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Phonic wheel and speed sensor 88001
It warns thedriver, bythewarninglightsontheCLUSTER, of lowpressureinthefollowingsystems:
- Handbrake engaged- N.C. 6.6 0.2bars
- Lowtrailer pressurerecharge - N.C. 6.6 0.2bars
A normallyclosed6.6 0.2bar switchisalsomountedontheaxlereservoir toinformtheelectroniccenter of anyaxlecircuit low
pressuresoasto inhibit differentiated axlebrakingintheASR function.
Figure213
107046
107047
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Low pressure switch
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ECAS SUSPENSIONS
Compressed air suspensions
Compressedairsuspensionsfeaturehighflexibility,highvibrationdampingandwithsystemself-adjustment constant frameto road
level clearanceindependentlyofvehicleload, that canbechangedaswell asvehicleloadheight withaspecial pushbuttonprovided
for thispurpose.
Inadditionto theknownadvantages offeredbycompressed air suspension, theECASsystemalso features:
- minimizedair consumption
- prompt responseto adjustment
- simplesystems
- topsafetylevel
- completesystemdiagnosis.
The ElectronicallyControlled Air Suspension ECAS systemprovides automatic vehicle compressed air suspension rated level
monitoring.
All theaboveoperationsaresubject tooperatingconditionsand connectedsystemsafetydevices.
The ECAS electronic provides automatic frame ground clearance control viathe real values supplied bythe sensors, which are
comparedwithstoredrateddata.Intheevent ofsettingdeviationsor variations,theelectroniccenter pilotstheelectro-pneumatic
unitsthrough whichit correctsreal levels versus thosestoredpreviouslybytheoperator.
Thesystemisprovidedwithremotecontrol forframelifting/loweringandlevelingandoperationsarepossiblebothwiththevehicle
stationaryandmoving.
Thisunit also enables other framesettinglevel storageandretrieval whenrequiredbyoperatingconditions.
Vehiclelifting, loweringandlevelingbeforeloadandunloadoperationsareviatheremotecontrol locatedontheoperator seat side.
Theremotecontrol canbeextracted fromits support so theseoperationscanalso beperformedfromgroundlevel.
Whenunloadingheavyloadsor containers withacrane, theframecanbeloweredcompletely.
74203
ECAS
B.C.
tachograph EBS
SWI
RFC
V.D.B.
I.C.B.
B.C.B. 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17 17a
18
19
20
21
22
Figure214
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Ref. Description Component code
1 Steeringwheel -
2 SteeringWheel Interface 86123
3 BodyComputer 86116
4 Cluster 50005
5 Rear FrameComputer 86118
6 Low pressuresensor 42200
7 Right rear axleslevel sensor 40046
8 Electronictachograph -
9 Right driveaxlesensor 42381/A
10 Left driveaxle sensor 42381/B
11 ECASelectroniccontrol unit 86023
12 Axlesolenoidvalveunit -
13 3
rd
axlecompressedair lift sensor 42389
14 Right 3
rd
axleair pressuresensor 42382/A
15 Left 3
rd
axleair pressuresensor 42382/B
16 Left axlelevel sensor 40046/B
17 Start support control switch 53030
17a 3
rd
axleleft switchremotecontrol 53309
18 Suspensionremotecontrol 85065
19 Axlelevel sensor 40046/A
20 Axlesolenoidvalveunit 78239
21 Diagnosis connector 72021
22 EBSelectroniccontrol unit 88005
ECASelectroniccontrol unit
73667
Figure215
107052
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ECAS electronic control unit
Vendor WABCO
Voltage 18 30Vdc
Heat range -40to 75 _C
X1 X2
Figure216
107054
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Ecas control unit for air suspension system
Connector X1
Pin Description
Cablecolor
code
2 Ground 0000
4 - -
5 Positivefor manual levellingkey(ST14 fitters connector) 8445
6 - -
7 Positive+30 7440
8 CLOCKlineonECASremote-control set 6402
9 Kline(14-pindiagnosisconnector) 2294
10 Positive+15 8810
11 Datalineon ECASremote-control set 6403
12 Ground 0000
13 Positivefor ECASremote-control set 8810
14 - -
15 Ground for ECASremote-control set 0050
16 - -
17 - -
18 - -
Connector X2
Pin Description
Cablecolor
code
1 Positivefor load pressure sensors onaxles(opt.) 8403
2 Loadpressuresensors onaxlessignal - right axle(opt.) 5443
3 - -
4 Positivefor rear axleelectro pneumaticdistributor 9400
5 Rear left axlelevel sensor signal (onlytruck) 5422
6 Loadpressuresensors onaxlessignal-left axle(opt. - onlytruck) 5444
7 Ground for load pressureonaxlessensors 0400
8 Rear right sensor level signal 5421
9 - -
10 Ground for electro pneumaticdistributor rear axleleft valvecommand(onlytruck) 9425
11 Ground for electro pneumaticdistributor rear axleload/unload valvecommand 9423
12 - -
13 Ground for electro pneumaticdistributor rear axleright valvecommand 9424
14 - -
15 - -
A
Figure217
107062
107063
107061
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Electro-pneumatic axle distributor
|t coos|sts o t|oo cooto| o|oct o va|vos '/', '3' aoo 'C' aoo t|o sao oobo o coossoo a| o|st|botos.
||octo va|vo '/' aoaos t|o |oot/ootot o|st|boto.
||octo va|vo '3' aoaos t|o ||t ao sott|o o|st|boto.
||octo va|vo 'C' aoaos t|o |ot ao sott|o o|st|boto.
Theelectro-pneumaticdistributor isconnectedto thesystemviaa 4-poleconnector (A).
Ref. Description
1 ||octo va|vo '/' cooto| ooat|vo
2 ||octo va|vo '3' cooto| ooat|vo
3 ||octo va|vo 'C' cooto| ooat|vo
4 Commonpositive
EUROTRONIC AUTOMATIC TRANSMISSION
General
Thenewgenerationof AutomatedEuroTronictransmissionsisIV|CC's osooso to oo. Costoor expectationsandchanged
needs.Thedesignofgearshiftswithanewinspectedandtesttransmissiontechnologyconceptcombinedwithadvancedelectronics
hasgeneratedasystemthat guarantees:
- Economicefficiency
- Reliability
- Environmental acceptability
VIEW OF THEAUTOMATED EUROTRONIC TRANSMISSION
Thesemodernandcompletelyautomatedtransmissionsystemswithhighlyintegratedcomponentshavealreadybeendeveloped
for EDC M6.2center ELECTRONIC CONTROL DIESEL ENGINES.
Figure218
107070
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Thesystemautomatesgear selection andmeshingbyautomaticallycontrollingtheclutchand engineduringgear shifting.
Theoperator decides whento shift gearsbyactuatingaselector lever withno needto releasetheaccelerator pedal.
Unlike previous versions, the Automated EuroTronic enables the operator to use COMPLETELY AUTOMATIC gear shifting
management.
Thesystemenablesautomaticvehiclestarandcompletelyeliminatestheclutchpedal.Onreceipt ofvehicleandoperatorsignals,
theelectronic center controls all components involved, optimizesmaneuversand managessafety.
PRODUCTIVITY Comfort Safety
Con-
sumption
Average com-
mercial speed
Maintenance
courses
Payload
Operatingcomfortandlessphysi-
cal andmental stress
Preciseandfast gear shifting
Optimizeduse
No useerrors
Selection of maximum rpmfor
enginebrakeuse
Reduced tare
Longerlinkagelinelife(theclutch
especially)
Noiseabatement (Db)
Automaticgear shifting
Design features
Theentiretransmissionshaft anduniversal joint assemblyisrelievedofconsiderableloadasgear shiftingoperationsandprocedures
areautomated. ThemainAutomated EuroTroniccountershaft gearboxconsistsof the following:
- A coupleof lowand high speedgears (SPLITTER)
- 4forwardspeeds+1reverse
TheauxiliaryboxconsistsofaG.R.E. epicyclical reductiongearmountedat thebacktodoublethenumber ofgear ratiosofthemain
gearboxand enable16forwardand 2reversespeeds.
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Description
AutomatedEuroTronicisacompletelyautomatic transmissionfeaturingaregulateddryclutchthat eliminatestheclutchpedal.
It consistsof areduced noiseemissionmaingearboxwithaplanetaryandsplit group.
Themainunit meshes withfront teethand onlytheplanetaryandsplit group aresynchronized.
The16-speedAutomated EuroTronicfeaturessixteenforwardand two reversespeeds.
TheInstrument clustersuppliedtheoperatorwithall necessarysysteminformation,suchasgearmeshed,disturbancesandthelike.
Theinsert moduleandtheclutchregulatorunitarethemostimportantstructural elementsforcompletetransmissionautomation.
Theformer consistsof thetransmissionelectronicsystem, switchingvalves, cylinder andsensors.
Thetransmissionelectronicsystemprocessesall input signalsandinsertsthespeedviatheelectromagneticvalveandtheswitching
cylinder.
Theclutchregulator isset electro-pneumaticallyandperformsall frictionactuationoperations. Inthemanual mode,theoperator
caneasilyselect speeds withthespeedselector lever.
Intheautomatic mode, theoperator onlyhas toactuatethe accelerator or brake pedal.
Speeds areselectedautomatically bythesystem.
To respect anti-pollutionregulations, all gears arehelical teeth, whichenabled abatingnoiselevel about 79 db.
8,5
1. Pressurelimiter valve- 2. Normal purge valve- 3. 10-l reservoir - 4. Air pressureswitch - 5. Pressurecontrol socket -
6. 5-l reservoir - 7. Distributor element - 8. Controlled pressurevalve- 9. Reservoir - 10. Normal purge valve- 11. APU Air
ProcessingUnit - 12. Compressor.
F=Clutch
C =Transmission
Figure219
107071
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Transmission/clutch connection diagram with thecompressed air system
Figure220
107072
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Displayon the Instrument Cluster
Theinformationrequired bytheoperator isdisplayedbythesystemontheInstrument Cluster central display.
Thesymbolsdisplayed bythesystemareasfollows:
Systemself-diagnosis Clutchoverload
Gear inneutral Duct disc wear
Acceleratorpedal pressedbeforeturningtheignition
key
Transmissioninthemanual mode
Slowreverseselected Transmissionintheautomaticmode,withcleardisplay
Transmissionwith theautomatic modepre-selected
but not activewithshadoweddisplay(movingat low
speed)
Fast reverseselected Speednumber selected(12
th
)
Low systemair pressure Transmissioninthemanual mode, lower speedsrec-
ommendedbythesystem
Recommended ratios (as many as 3) are displayed
withbars
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LIMP - HOME
TheLimpHomefunctionenablesremovingthevehiclewhenthesystempresentsseriousanomaliesitcannotmanageautomatically.
It cannot movethevehiclewhenpurelymechanical anomaliesarepresent. Theoperator canactivatetheLimpHomefunctionas
follows:
1. Keyswitchonstop
2. Keyswitchon+15
3. Pressthebluecolor pushbuttonon thegear shift lever within5seconds
4. Keep thebluecolor pushbuttonpressedfor at least 5 seconds.
Theoperator canselect thespeedat whichto start withgearshift lever, andcanselect asmanyas7speedsforwardand2reverse
withthe16speedtransmissionsand5and2respectivelywiththe12-speedone.Selectionismanagedbythesystemviaaninternal
delayreaction timeandnot through thespeedwithwhich thegearshift lever sensorsidentifylever movements.
Speedselectionmustbeslowtoallowthesystemtoimplement eachindividual speed,astheClusterdisplaysindividual speedswith
adelayof afewseconds.
Thespeedsthat can beset withtheLimpHomefunctioncanonlybeselectedwiththevehiclestationary.
After start speed selection, pressing the function push button for at least 2 seconds makes the systemcontrol timed clutch
engagement.
Toprevent theenginefromstopping, theclutchdisengagesautomaticallywhenthespeedoutput fromthetransmissionisbelow
areferencethreshold.Istheclutchsensorisnot operatingproperly,theclutchcanonlybeengaged/disengagedmanuallywiththe
Functionpush button.
The systemdisregards anygearshift lever movement duringvehicle movement. In particular, push button functionoperationis
excludedwhen enginerpmisover 950and reactivatedat under thisrating.
Clutchmanagement canthusalso bemanual withthefunctionpushbuttononthegearshift lever ofthebrakepedal whenengine
rpmisunder/equal to950.WhenthevehicleisstoppedwiththeLimpHomefunction,theclutchismanagedautomaticallyifpossible
or manuallyasdescribedabove.
Atvehiclestop,thesystemkeepstheLimpHomefunctionactivewiththestart speedset previouslyandthefunctionremainsactive
until systemRESET iscompleted.
1. Multi-functionlever - 2. SteeringWheel Interface - 3. Instrument Cluster - 4. PTO solenoidvalves- 5. DMI - 6. External
buzzer - 7. PTO onwarningswitches- 8. Reverselights - 9. Rear FrameComputer - 10. BodyComputer - 11. Door open
switch- 12. Switchesfor PTO1on request - 13. Switchesfor PTO2on request - 14. Tachograph- 15. Intarder Control Unit -
16. EBSControl Unit - 17. EDC Control Unit - 18. VCM- 19. Proportional solenoidvalve- 20. Water temperaturesensor -
21. Enginestop solenoidvalve - 22. Accelerator pedal - 23. ON/OFFsolenoid valve- 24. DuplexDistributor (brakepedal) -
25. VGT solenoid valve- 26. GearboxElectronic Control Unit - 27. Diagnosissocket
Figure221
108928
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Eurotronic Automated transmission operation diagram
1.Clutchactuator -2.Tachographgearshift/transmissionoutgoingspeedsensor - 3.Gearshift/transmissionoutgoingspeedsensor
for sensor - 4. Gearshift idlingpositionsensor - 5.Framesidecentreconnector - 6.VehicleDataBusVDBCAN line - 7. System
internal CAN line- 8. Gearshift/transmissionelectroniccentre - 9. Gearshift/transmissionsidecentreconnector
Figure222
108929
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Location of main components
Figure223
107075
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ELECTRONIC CONTROL UNIT
It isintegratedinto thegearshift actuator.
Automatictransmissionmanagement enablesautomatingspeedselectionandmeshingwithautomaticclutchandenginecontrol.
Itinterfaceswiththeotheron-boardelectronicsystemssuchastheEDC,EBS,INTARDERandInstrument ClusterviaaCAN V.D.B.
Vehicle DataBusline.
FromconnectionwiththeEDC systemthetransmissionelectroniccontrol unit candetectacceleratorpedal position, fuel delivery,
enginerpmandenginebrakeandkick-downactivation.
The control unit insidehousescontrol unit temperature, transmissionoil temperature and low air pressure sensors to improve
systemoperation.
FunctionAL isenabledat <5.8bar pressureanddisabledat>6bars. TheAutomatedEuroTronictransmissionelectroniccontrol
unit offers the possibilityof a Cluster displayed error code for preliminary diagnosis and is also provided with an advanced
self-diagnosissystemcapableof identifyingandstoringanyevenintermittent anomalydependent onenvironmental conditionthe
systemmayhaveencountered duringoperation, to ensuremorecorrect and reliable repair.
Revi - June2007
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Pin Cable Descriptionx1 Pin Cable Descriptionx2
1 8801 Power fromBodyComputer (J 3/6) 1
2 2297 Positive 30-pole connector for ground
diagnosis
2
3 Free 3
4 7101 Positivefromfuse70602/2(+30) 4
5 7101 Positivefromfuse70602/2(+30) 5
6 Free 6 Gearshift speedsensor mass(pin2)
7 Free 7 Signal electrovalveY17
(slowopening) (pin A)
8 WS/BI CAN VDBline 8 Signal electrovalveY16
(fast opening) (pinB)
9 Free 9 Signal electrovalveY15
(slowclosing) (pinE)
10 1101 Gearboxmalfunctionbeeper earth 10 Clutchpositionsensor analogicsignal
(pinF)
11 6100 Gearboxmalfunctionbeeper positive 11 Gearshift/transmissionoutgoingspeed
sensor signal (pin 4)
12 GN/VE CAN L VDBline 12 Signal electrovalveY14
(fast closing) (pin0)
13 13
14 14
15 15 Clutchpositionsensor power supply
(pin G)
16 0000 Negative 16 Y15 - Y17electro valvemass (pin3)
17 0000 Negative 17 Y14 - Y16electro valvemass (pinC)
18 18 Gearshift/transmission speed sensor
power supply(pin1)
19 19
20 20 Clutchpositionsensor mass(pinH)
CABSIDECONNECTOR(x1)
SENSORSIDE/CLUTCH ACTUATORCONNECTOR (x2)
Figure224
107076
!
Theactuator cannot beoverhauled.
For actuator removal, transmissionmust beonNEUTRA.
Thetransmission neutral warningswitchislocated onthegearshift.
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TRANMSISSION ACTUATOR
Thetransmissionactuator ismountedonthetopofthemaingearbox.It consistsof aseriesofelectro valves, control cylinder and
sensors.Theelectroniccontrol unit powersthevariouselectrovalvestoselectedgear ratiosavailablebyusingsensorsignalsasa
feedback. Actuator operatingpressureis 7bars.
Actuator components
Y1 Inertiabrakes control electro valve
Y2 Fast Splitter control electro valve
Y3 SlowSplitter control electro valve
Y4 Speed selectioncontrol electro valve
Y5 Speed selectioncontrol electro valve
Y6 Gear meshingcontrol electro valve
Y7 Gear meshingcontrol electro valve
Y8 Downshiftedspeed epicyclical unit control electro valve
Y9 Normal speedepicyclical unit control electro valve
Y10Cmpressedair supplyelectrovalve
B2 Transmission input rpmsensor
B4 Selected speedsensor
B5 Selector positionsensor
B6 Normal anddownshiftedspeedepicyclical unit position sensor
B7 Splitter positionsensor
Electrovalvesareof theN.C. on/off typepoweredat 24Volt with~64.2 Ohmresistance at 20 C.
InductiontypetransmissioninputrpmsensorB2features~1Kohmresistanceandidentifiedrpmwitha40-teethsoundwheel.This
signal iscomparedwiththeenginerpmmeasuredbytheE.D.C.control unit;ifthetwovaluesareNOTidentical thetransmission
control unit isenabledto detect clutchslide.
InductiontypesensorsB4,B5,B6andB7,respectivelyselectorposition,epicyclical unitandsplitter,areanintegral partofthecontrol
cylinders andfeature ~69Ohmresistanceat 20 C.
Theautomaticsystempressuresensor located downstreamthe reduction gear isalso integratedinsidethe control unit.
VEHICLESIDE CONNECTOR TRANSMISSI ON SIDE CONNECTOR
Figure225
107078
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LOCATION ON THE VEHICLE
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CLUTCH ACTUATOR
Theclutchactuator islocatedon thelower part oftheclutch bell.
|t coos|sts o oo o|octo va|vos, ao actoato c||ooo aoo a c|otc| oo os|t|oo sooso aoo |s so|tab|o to actoato +.5' s|o|o-o|sc
clutches viaa2.09ratio lever.
Intheloadmodeasdetectedbytheacceleratorpedal sensorsignal fromtheE.D.C.center,theelectroniccenterpowersthevarious
electro valvesfor slowor fast clutchengagement and release.
Thecenterusestheclutchrunpositionsensortocalculateclutchwear ateachvehiclestart,toenablefast approachesandovercome
emptyruns.
Actuator components
Y14- Fast clutch engagement electro valve
Y15- Slowclutchengagement electro valve
Y16- Fast clutch releaseelectro valve
Y17- Slowclutchreleaseelectro valve
S - Clutchrunposition sensor
T - Air vent cap
Actuator operatingpressure is11bars.
Internal channel diameters areas follows:
- 2.5mmfor fast engagement/release;
- 1.5mmfor slowengagement/release.
Actuationtimesat start, subject to load, slopeand accelerator pedal position, areasfollows:
- Initial engagement: ~1sec.
- Modulatedrelease: ~4 sec.
Thetimes changeas followsduringgear changes toenablefast andprecisesynchronization:
- Modulatedopening: ~0.6sec.
- Complete opening: ~0.3sec.
- Modulatedclosing: ~1sec.
Actuator features
- Operatingfluid: air (min. 6bar max 11.5bar)
- Power: 24Volt
- Loadonlever inoperatingconditions: 382 kg
- Operatingtemperature: 40 C +- 120 C
- Cylinder diameter: 100 mm
- Pistontravel: 70mm
Figure226
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91305
A. 20-poleconnector - B. Output transmissionrpmsensors
A
B
Figure227
Revi - March 2007
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Clutch actuator Pin-out
TheN.C. on/off typeelectro valvesarepowered at 24 Volt with ~14 20Ohmresistance.
Thesensor is powered bythecenter at 5Voltsandthereturnsignal isbetween0.5and 4.5Volt.
Theclutchactuator isconnectedto thesystemviaa20-poleconnector.
Pin Function
1 -
2 -
3 -
4 -
5 -
6 Transmissionspeedsensor mass (pin2)
7 Y17 electro valvesignal (slow opening)
8 Y16 electro valvesignal (fast opening)
9 Y15 electro valvesignal (slow closing)
10 Clutchpositionsensor analogicsignal
11 Transmissionoutput speedsensor signal (pin3)
12 Y14 electro valvesignal (fast closing)
13 -
14 -
15 Clutchpositionsensor power
16 Y15 - Y17electro valvemass
17 Y14 - Y16electro valvemass
18 Transmissionspeed sensor power (pin1)
19 -
20 Clutchpositionsensor mass
Figure228
107080
107081
107082
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Accelerator pedal
Releasepedal NAintegratedintothepositionsensorisusedtodetectengineidlingpositionandenableclutchengagementatvehicle
start.
Thesignal reachestheVCMelectroniccenter viatheCAN VDBVehicleDataBaselineandissent totheAutomatedEuroTronic
transmissioncenter.
KickDownisactivated withtheaccelerator pedal inautomaticfunctionmodetravel. TheKickDownfunctionisactivated when
accelerator pedal lever (1) movethepotentiometertoposition100%,whichdoesnot correspondtopedal mechanical travel end.
Stiffenedtravel end isonlymechanical andisusedto transmit thefeelingKick Downinserted to theoperator.
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INTARDER
Operation
Theintarderisoperatedwiththe 7-positionsectorlocatedintheright directionindicator (1).INTARDERcut-inindicationisman-
agedbythe CLUSTER (2) viaaspecific warning.
ThesystemisprovidedwithaBrensomat constant velocityfunctionusedfor vehicleswithout EBS. Thisfunctionenableskeeping
avehicleonadownhill slopmovingatthespeedasselectedbytheoperator.Inthiscase,theintarderelectroniccentreautomatically
selectsthe brakingtorquerequired.
Theconstant velocityfunctionisonlyactivated|o os|t|oo '0' ato sto|o t|o sooo oos|oo.
Storagecanbeat anyofthe7selector positionsbybrieflypressingthepushbuttonprovided;withhigher pressurestoringspeed
at that moment andlowerpressuredecreaseofspeedset. Thespeedprogrammedpreviouslyisrestoredassoonastheselector
|s otoooo to os|t|oo '0'.
Pressingthepushbuttononceagaindisenablestheconstant velocityfunction.Theoil containedinthesumpissent totheintarder
hydrauliccircuit viaafilter and thecircuit isprotectedbyasafetyvalve.
Byactingonselector (1),electroniccentre(4) receivesviaSWI (3) anelectrical signal that it processesandsendsto electro valve
(7) controllingtheaccumulator and proportional electro valve(5).
Theaccumulatorcontrol electrovalveswitchesandletsairunderpressurepassthroughitspistontosendoil tothehydrauliccircuit
and reduceactiontime.
Theproportional electrovalveactsonthecontrol valvetoset itspressure.Theadjustment valveispilotedbycontrol valveoil pres-
sure.Therotorisconnectedtotherearaxleviathetransmissionshaftandthestator isconnectedtotheframethroughtheintarder
case.
Theoil contained in theareas between therotor andthestator is movedbytherotor blades to createaclosed circuit oil flow
between mobileandfixedparts.
Byimpactingthestator blades, oil causesrotor andthereforevehiclebraking. Reducedoil flowspeedbetweentherotorand the
stator transformskineticenergyintoheat,todissipatewhichoil passesthroughanoil/waterheatexchanger,whereoil heat istrans-
mitted tocoolingwater anddissipated throughthevehiclecoolingsystem.
Theheat exchangerwaterdischargepipeisprovidedwithatemperature sensor (6) that continuallysendscoolingwatertempera-
turedatato theelectroniccentreto ensuremaximumtemperatureallowed for proper engine operationis not exceeded.
If water temperature risesto reach the safetylimit for anyreason whatsoever, thecentre pilotssump control air adjustment to
reducebrakingtorque.
Theelectroniccentre receivesasignal fromtheABS/EBSsystemthat causesintarder cutout whenactuatedand it also receives
asignal fromelectronictachograph (8) enablingconstant velocityfunctionuse. This signal is sent viaaVDBcanline.
S.|tc||o to os|t|oo '0' cots t|o |otaoo o aoo ooact|vatos t|o oot|ooa| aoo accoo|ato cooto| o|octo va|vos.
1. Engine brake/Intarder selector - 2. Instrument Cluster - 3. SteeringWheel Interfacecentre -
4. Intarder electroniccentre - 5. Proportional electro valve - 6. Water temperaturesensor -
7. Accumulator on/off control electro valve - 8. Electronictachograph
Figure229
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Figure230
107085
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Hydraulic system diagram
Description
Theoil containedinthesumpissent totheintarderhydrauliccircuit byapumpthroughafilteranda12.5barpressurelimitervalve.
Intarder on
Whentheintarderisactuatedwithcontrol (2), thecentresupplieselectrovalve(19) controllingaccumulator (10), whosepiston
ispiloted bytheserviceair systemat 9.5 bar pressureto sendoil faster to therotor/stator unit.
Whenexcited,proportional electrovalve(16) actsonvalve(16) bymovingitshydraulicspool andmovesfunctioncontrol pressure
to brakinglevel.
Pressureactsonadjustment valve (14), to createcommunication betweeninput duct Pand output ducts P 1- R.
Thus, oil frompressurelimiter electrovalve(4) movesthehydraulicspool ofvalve(8) andputsduct R
1
0intocommunicationwith
the motor/stator viaheat exchanger (9).
Pressure(13) isnot affectedbyoil pressureandclosesoil dischargeinto sump (7).
Figure231
108931
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Speed storage and use
ByinsertingCruiseControl,thesystemautomaticallymaintainsvehicleadvancespeedwithout havingtousetheacceleratorpedal.
If vehiclespeed increasesover 2 Km/h morethan thespeed set, suchaswhentravellingdownhill for instance, theenginebrake
isactivatedautomaticallytoslowthevehicledownandmaintainthespeedreached.Theintarder isalsoactivatedifspeedincreases
byover 3 Km/h.
Itsfunctioncanonlybeactivatedwhenthefollowingconditionsaresatisfied:
- enginebrake/intarder lever cut out;
- vehicleon themovewith gear selected;
- vehiclespeed over 20Km/h;
- brakepedal released;
- clutch pedal released.
Control Vehiclespeed adjustment
ON+ Speedincrease
ON- Speeddecrease
RESUME Last storedspeed selection
OFF Speedadjustment cancellation
Adjustment iscut out whenthebrake orclutchpedal isactuated.Thesameapplieswhentheminimumspeed set isnot reached.
Topspeed is stored intheprogramme insidetheelectroniccontrol moduleandcannot bechanged.
1 Basculatingpushbutton ON hasthefollowingfunctions:
a)when pressedonce, it activatesthe functionandkeepsthespeedset at that moment bytheaccelerator pedal.
Theaccelerator pedal canthenbereleased andthevehiclekeepsmovingat thecruise speedset.
b)withthefunctionalreadyactivated, it increasesvehiclespeedwithout havingto usetheaccelerator pedal.
2 Basculatingpushbutton ON hasthe followingfunction: withthefunctionactivated, it decreasesvehiclespeed.
3 TheCruiseControl lever actuatedOFFtowards thesteeringwheel deactivatesthefunction(CC displayshaded).
4 Actuatingthesteeringwheel lever onceagain(RESUME) thevaluestored is reactivated(CC displayclear).
1. Instrument Cluster - 2. SteeringWheel Interface- 3. Engine brakeonmulti functionlever - 4. BodyComputer -
5. Tachograph- 6. EDC centre- 7. VCMcentre- 8. EBScentre- 9. EuroTroniccentre - 10. Intarder centre -
11. Diagnosisconnection- 12. Enginebrakeelectro valve - 13. VGT electro valve- 14. Accelerator pedal -
15. Brakepedal Duplexdistributor - 16. Proportional electro valve - 17. ON-OFFelectro valve-
18. Water temperaturesensor
Figure232
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Assembly
73667
A. Intarder control unit
A
Figure233
107088
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Control unit disposition
Pin Cable Function
1 9311 Oil accumulator solenoid valvepositive
3 0310 Proportional solenoidvalvenegative
4 9310 Proportional solenoidvalvepositive
8 5541 Cluster
9 5309 Water temperaturetransmitter positive
12 3393 30-polediagnosisconnection (pin 20)
14 2293 30-polediagnosis connection (Kline - Pin6)
22 CAN VDB(H) line
27 0000 Cabmass
28 0000 Cabmass
34 0311 Oil accumulator solenoid valvenegative
37 0309 Water temperaturetransmitter negative
49 CAN VDB(L) line
53 8300 +15power supply
54 7300 +30power supply
Figure234
112596
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EM (EXPANSION MODULE) ELECTRONIC CONTROL UNIT (PTO)
The EM(Expansion Module) control unit locatedinthecabinconto| oo|t coatoot (assooo's s|oo) cooto|s t|o o.o
takeoffsand, unliketheDMI, makesit possibleto carryout complicated applicationssuchas:
- transmission(gearbox) control fromexternal source(TCI message)
- enginecontrol fromexternal sources,likerequest andlimitationofenginerevnumber,vehiclespeedlimit, start upandengine
stop
- safetylogicsfor wastecollectionapplications
- optimizationof brakingsystemfor wastecollectionapplications
- additional headlight control
- interfacewith CAN_opennetwork
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Pin - out
Connector XI
1 PTO1 solenoidvalve power supply 9131
2 Positive+30 7772
3 Signal for operators (72072B- pin 6) 6985
5 Earth 0000
7 Clutchsolenoidvalvesignal (72072A - pin4) 9995
9 Positive+30 7166
Connector X3
1 CAN - H line(VDB) Sw/Bi
2 CAN - L line(VDB) Gn/Ve
3 Free -
4 LineK (diagnosisconnector pin6) 2996
5 PTO1 request 0131
6 PTO2 request 0132
7 PTO3 request 0123
8 Signal of PTO1engaged 6131
11 PTO1 consensussignal 0391
13 Positive+15 8166
14 Free -
15 Free -
17 Signal fromoperators(72072A - pin 3) 0991
20 Signal fromoperators(72072B- pin3) 0994
22 Pin24 jumper 8990
25 Free -
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Connector X4
4 Parkingbrakesignal (72072A - pin1) 6981
5 Neutral gear signal (72072A - pin2) 6983
7 Free -
8 Free -
9 Signal fromoperators(72072C / 72072D - pin5) 0999
10 Free -
11 Free -
12 LineCAN - H (SB) - (trailer) Ws/Bi
13 LineCAN - L (SB) - (trailer) Gn/Ve
14 - 5981
15 - 5982
16 - 5991
17 LineCAN - H (SB) Ws/Bi
18 LineCAN - H (SB) Ws/Bi
19 LineCAN - L (SB) Gn/Ve
20 LineCAN - L (SB) Gn/Ve
24 Free -
25 Free -
26 Free -
27 Free -
28 Signal fromoperators(72072C / 72072D - pin3) 0975
30 Free -
33 Free -
34 Free -
35 Free -
36 Free -
37 Free -
39 Free -
40 Free -
1
2 3
4
5
6
73668B
Figure235
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AUTOMATIC AIR CONDITIONER
Inautomaticversionthesystemismanaged byanelectronicunitplacedinthelowerpartofcentral dashboardandintegratescontrol
knobs.
Theelectronicunit isconnectedto vehicleCAN BCB lineandisequipped withaveryadvanceddiagnosticsystem.
Themainobjectiveoftheunit isadjustinginternal cabintemperature (set bythedriver) dependingonexternal temperaturemea-
suredbyasuitablesensor.
Thesystem provides for thechanceof acompletelyautomaticmanagement, but anywayfor theuser it isalwayspossible, if he
so wishes, to modifythemainsystemoperatingparameters.
1. Requiredtemperatureadjustingknob
2. Fan speedadjustingknob
3. Air flow distribution knob
4. Recirculationfunctionbutton withembedded led
5. Compressor control button with embedded led
6. Internal temperaturesensor
After havingset thedesiredinternal temperature,byplacingtheothertwoknobsnext toletter A, theunit isabletoautomatically
checkthefollowingfunctions:
- Air temperatureto unions.
- Fanspeed
- Air flowsdistribution
- Supplementaryheater connectionif external temperatureis<5 C.
Inthispositiontheunit doesNOT automaticallyactivateeithercompressor orrecirculationfunction:connectionofbothofthem
ismanuallymanagedbythedriver.
RECIRCULATION FUNCTION
Connectionofthisfunctioniscompletelymanual andisobtainedthroughasuitablebuttonthatallowsclosingtheexternal airintake
byplacingthebaffleat 95%ofinternal air and 5%of external air.
Theunit automaticallydeactivatesthisfunctionafter about 20minutesif thecompressor isdisconnectedand after 30minutesis
thecompressor is connected.
COMPRESSOR CONTROL FUNCTION
Connectionofthisfunctioniscompletelymanual andisobtainedthroughasuitablebuttonthat allows connectingthecompressor
clutch after aqualitycheckof fluidinthesystemthroughsafetypressureswitches andevaporator temperaturebymeansofthe
suitablesensor.
The unit doesNOT automaticallyconnect thecompressor.
SUPPLEMENTARY HEATER CONTROL FUNCTION
WithmovingenginetheunitautomaticallyconnectsthesupplementaryAIRand/orWATER heateronlyiftheexternaltemperature
is<5 _C.
\|t| o oo|oo t|o |oato cooooct| oo ooooos oo o|vo's sott|o.
Inbothcases, thesupplementaryheater connection is signalledto thedriver onCluster display.
91304
42045. Water temperaturetransmitter - 82000. Windscreen electricdefroster assembly- 82010. Air conditioner control
electronicunit - 86030. Sun radiation measuringsensor - 84009. Ventedinternal temperaturemeasuringsensor -
84009B. Inner temperaturedetectionsensor - 42608. Coolingliquidpressuresignalingpressureswitches -
25332. Compressor connectionremotecontrol switch- 78227. 3-waysolenoidvalvefor radiator water recirculation -
84019. Compressor
Components82010- 82000areplaced inthesamecontrol assembly.
18 22 2 ,5 25
Figure236
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AUTOMATIC AIR CONDITIONER
Automatic air conditioner block diagram
77561
42045. External temperaturetransmitter - 82000. Windshielddefroster unit - 82010. Conditioner electronic control centre-
86030. Sun raydetectionsensor - 84009. Internal temperaturedetectionsensor - 42608. Coolant pressurewarningpressure
switches - 25332. Compressor onremotecontrol switch- 78227. Radiator coolant recirculation electro valve -
84019. Compressor - 86116. BodyComputer - 72021. 30-poleconnector for diagnosis
Condenser
Drier filter
86116
82000
82010 72021
86030
42608
42045
78227
84009
84019
Figure237
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Component location
77562
A. Floor reductiongear - B. Windshield defrost reduction gear motor - C. Recirculationreduction gear motor - D. Mixing
reduction gear motor - E. Blowntemperaturesensor - F. Evaporator temperaturesensor - G. Blower control module -
H. Expansionvalve
A
B C D E F G
E
E
G
F
C
A
B
D
A
H
Figure238
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Windscreen electric defroster assembly components location
77566
77567
Locatedonthedriversidevehiclefront soit isinvestedbyexternal temperature, ascloseaspossibleto reality. Itsresistanceat
25 C =~10 Kohm
Main interior temperature sensor
Locatedontheright insidethecontrol moduleandventilatedbyamotorenablingaircirculationandpreventingerroneoustem-
peraturereadingsbetweenvaluesmeasured andthecab. Its resistanceat 25 C =~10 Kohm
A) Motor
B) Fan
C) Sensor
Figure239
Figure240
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External temperature sensor
77559
77574
Thesensor placedinsidetheevaporator generates compressor connectionanddisconnection.
Disconnectionto avoid dispenser freezingoccursat atemperature <2 C, while connection at atemperature >5.5 C. Its
resistanceat 25 C =~3.28 Kohm
Blown air temperature sensor
Locateddownstreamtheheat exchanger, it givesthetemperatureofair inlet intothecabandenablesthecentreto adjust more
properly. Itsresistanceat 25 C =~10 Kohm
A) Sensor
Figure241
Figure242
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Evaporator temperature sensor
77563
77565
It is aphotodiodeplacedon vehicle dashboard to point out luminous intensitythat thecabin receives fromoutside.
A) Sensor
77564
Figure243
Figure244
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Sun raysensor
77571
77573
77572
Figure245
Ifasteppermotorisreplaced,it isMANDATORYtocarryoutthesystemRESET bydisconnectingandreconnecting
vehiclebatteries.
NOTE
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Reduction gear motors
The four automaticsystemunitsare locatedintheheater/conditioner insidethecab, accordingto their functions.
Their electrical featuresarethesame.
Theyareactivated directlybytheelectroniccentreat 24 V ratedvoltage and absorbfrom20to 40 mA.
Motor resistance=~112 Ohm.
Maximumabsorption at travel end is 200mA, when the centrecuts supplyoff.
Their potentiometer is usedas areturn signal and when first lit, the centredetects and stores end travel values to divide the
operatingfield. It issuppliedat 5V, its resistance =~5 Kohm.
Pin-out
Pin Cablecolour
1 White +/- 24V
2 Violet +/- 24V
3 Blue 0V
4 Orange 0 5V
5 Green +5V
6 - Free
74244
A. Blower control module
A
Figure246
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Blower control module
Thiselectroniccircuit locatedintheheater/conditionerunit adjustsdoublefanradial blowerspeedwithsome200different rates
intheautomaticmodeand 8 in the manual mode.
The moduleis driven bytheunit with asignal from0to 5Volts whilefans with avoltagefrom0to 24 Volts.
Pin Cable Function
1 0000 Negativedirect from
thebattery
2 7555 Centrecontrol posi-
tive
3 7551 Positivedirect from
thebattery
77569 77568
77570
Figure247
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Solenoid valve (3 ways)
This one-directional NA unit issuppliedbyabattery-directed positive.
The electronic centreadjusts its dutycyclebysupplyingamass.
This three-wayvalveperformsall dosingand by-passfunctions.
It is suppliedbyabattery-directed positive and is pilotedbythe negativesupplied bythecentre monitoringthe dutycycle.
106393
Figure248
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Compressor
NIPPODENSO
ND 10 PA 17
Coolant R134a
Lubeoil ND80
Quantityof coolant 700g
Quantityof oil 200cc.
R134acoolant is anyhow exclusivelyused in theSTRALISrange
74245
74247 77560
Figure249
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Drier filter and safetypressure switches
The drier filter is integral with the condenser locatedonthevehiclefront.
The coolingsystemuses R134acoolant asspecifiedon itscover plate.
The 4-level safetypressureswitch unit is installed on thecondenser return line.
Thetwo typeNC andNA pressureswitcheskeepsystempressureconstant fromaminimumof 2.5(for theNA) toamaximum
of 25 bars(for the NC). Thesystemis cut off whenvaluesare outsidethis range.
ThetwoNA pressureswitchesareto cutout theenginecoolingfancoil whensystempressureisbetween18 and22bars.This
isachievedbymeans of amass signal the two switches transmit to theBodyComputer control centre.
74238
77575
CONDENSER EVAPORATOR
Figure250
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Expansion valve
Itsfunctionisto lower liquidpressurefromthecondenser to apreset valueso bycirculatinginsidetheevaporator thecoolant
canbesucked asagasbythe compressor.
It thus completesthreebasic functions:
D DOSING
D MODULATING
D MONITORING
It is installedontheheater/conditioner unit closeto theblower control module.
77565
1
2
3
7
6
5
4
Figure251
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The expansion valveis of theuniontypeandisplaced betweendrier filter and evaporator.
Itstaskischeckingandbatchingthecoolingfluidflowinorder to obtain themaximumrefrigeratingpower fromthesystemand
to lowerthecoolingliquidpressure(uponexitingthefilter) toapre-establishedvalue, sothat thefluiditself,bythencirculating
into the evaporator, can besucked bythecompressor inacompletelygaseous state.
Inthisvalve therearetwo coolingfluidpassages:
D Theloweronethat allows thecoolingfluidtopassfromdrierfilter (5) toevaporator (2).Alongthispathaspring(4) isplaced
that, suitablycalibrated, allows obtainingsuch atemperature jump (overheating) asto ensurethat thecoolingfluid, upon
entrytheevaporator, is completelyin agaseous state. Moreover thereis also amodulating element, in this case aball (3)
housed in the calibratedduct, that checksthecoolingfluid flowrateto theevaporator.
D Theupper onethat allows the coolingfluid to passfrom evaporator (1) tocompressor (6). Alongthispath instead there
isatemperaturesensor(7)that,dependingonthetemperatureuponexitingtheevaporator,allowsobtainingacontrolaction
on thecoolingfluid flowrate, through themodulatingandoverheatingcheckingelement (3), through thespring(4).
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Conditioner control unit
Pin Cable Function
1 - -
2 7550 Positivedirect fromthebattery
3 - -
5 Ws/Bi CAN - H (BCB) line
6 9993 Outgoingpositivecompressor electromagneticclutch signal
7 7568 Mixer reduction gear motor power supply
8 7566 Recirculationreduction gear motor power supply
9 0562 Floor reduction gear motor power supply
10 7564 Windshielddefrost reduction gear motor power supply
11 - -
12 0550 Sensor and reduction gear motor mass
13 7572 Evaporator temperaturereference signal
14 7574 Sun raysensor signal
15 7565 Recirculationpotentiometer referencevoltage
16 7561 Floor potentiometer referencevoltage
17 - -
18 2290 Internal temperaturesensor motor signal
19 - -
20 7555 Outgoingpositiveblower control modulesignal
21 0000 Negativedirect fromthebattery
22 9552 Outgoingnegativeelectro valvesignal
23 - -
24 - -
25 Gn/Ve CAN - L (BCB) line
26 0568 Mixer reduction gear motor power supply
27 7569 Internal temperaturesensor motor power supply
28 0566 Recirculationreduction gear motor power supply
29 - -
30 0564 Windshielddefrost reduction gear motor power supply
31 7562 Floor reduction gear motor power supply
32 7575 Internal temperaturesensor signal
33 7571 Blowair temperature reference signal
34 7567 Recirculationpotentiometer referencevoltage
35 7563 Windshielddefrost potentiometer referencevoltage
36 7560 5-Volt Mix / Floor / Rec/ Defrost potentiometer signal
37 40 - -
74239
74248
1 20
21 40
Figure252
73668C
5
4
Figure253
The motor for TOP FLAP function is present only in manual version, since in automatic version this function is
performed throughabowdencableconnected to air mixingmotor (MIX).
- Maximumheating =TOPFLAP closed
- Maximumcooling =TOPFLAP open
NOTE
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MANUAL AIR CONDITIONER
Inthe manual versionthe refrigeratingcircuit andheater checksoccur bymeans of adevice with leverages and knobsplaced
inthelower part of thecentral dashboard.
The systemis checked byan electronic unit but by means of knobcontrols used for thefollowingfunctions:
1. Heatingwater cockcontrol
2. Internal fans speed
3. Air flows distribution
4. Compressor control switch
5. Recirculationfunctionswitch
CONTROLS DESCRIPTION
Water cock control
The knob rotationadjusts water cockposition and consequentlytheamount circulatinginsidethecabin radiator.
If supplementary WATER heater is present, this knob controls threemicroswitches usedfor thefollowingfunctions:
20% supplementaryheater water pumpactivation
60% top flapclosingmotor activation (TOP FLAP)
80% supplementaryheater connection
If supplementaryAIR heater is present, this knob controls two microswitchesused for the followingfunctions:
60% top flapclosingmotor activation (TOP FLAP)
85% supplementaryheater connection
Internal fan speed
This knob iscomposedof amultipleswitchthat controls three adjustingresistances for different motor speeds.
Air flows distributions
This control throughbowden cables allows distributing the air flowsin the desired cabin areas.
Recirculation function switch
Thisbuttonallows,throughaspecificmotor,closingtheexternal doorwithapercentageof 95%ofinternal air and5%ofexternal
air.
The motor has no position sensorssinceit works only under thetwo all-closedor all-openedconditions.
On thebuttonthereisayellow-coloured ledthat signals its connection.
There is no timelimit for this function.
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Compressor control switch
This buttonallows connectingtheair conditioner compressor.
The cluthclosureisconstrained by safetysystempressure switches and byfixed-calibrationevaporator thermostat
Suchthermostat,ofthemechanical type, adjuststhetemperatureinsidetheevaporator inorder to disconnect thecompressor
clutchupon reacihing~2 _C and reconnect it at ~5.5 _C
The compressor operationisconstrainedbythemanual connection of at least one fan speed.
A yellow-amber-coloured ledis present onthebutton and signals the compressor connection.
STEPPER MOTORS
Inmanual systemthereare two stepper motors placed on heater assembly
Theyarecomposed of amotor without potentiometers ahd havethe sameelectriccharacteristics.
The ratio motors areused to performthefollowingfunctions:
RECIRCULATION ( RIC )
TOP FLAP (TOP FLAP)
MOTORS
D Theyaresupplied at 24V.
D Motor resistanceis ~112 Ohm.
D No-load absorptionis about 30mA.
D Limit absorptionis about 200 mA.
42045. External temperaturesensor - 82000. Windscreendefroster assembly - 84009. Internal temperaturesensor -
42608. Coolingfluidsafetypressure switches- 25332. Compressor connection remotecontrol switch - 84019. Compressor
60%
18 22 2 ,5 25
Figure254
106972
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Block diagram
112591
Figure255
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
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Air conditioner fuses remote control switches
Black-coloured fuse-holder (70604)
Position Description DeliveryA
2 Air conditioningsystem 10
3 Air conditioningsystem 5
4 Supplementaryheating 15
5 Supplementaryheating 5
Ref. Description Component code
B Water heatedremotecontrol switch (opt.) 25337
E Heated remote control switch(opt.) 25325
H Manual conditioner remotecontrol switch 25310
I Manual conditioner remotecontrol switch 25874
L Manual conditioner remotecontrol switch 25332B
M Manual conditioner remotecontrol switch 25322
O Manual conditioner remotecontrol switch (opt.) 25332A
P Manual conditioner remotecontrol switch (opt.) 25327
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HYDRONIC D 10WATER HEATER
System operation
Byconnectingtheburner, theelectronic unit controlswater pump, fuel batchingpump, burner motor andignitionsparkplug.
The water pump circulates thecoolingliquidinthe coolingcircuit of the engineto beheated.
The burner motor sucks and inserts the right amount of air necessaryfor combustion.
The ignition spark plugheatsair and burns fuel injected bythebatchingpump.
Purposeof thebatchingpump is takingandinjectingfuel onto spark plug.
After 90seconds,theunit,throughtheflamesensors,checksthat theexhaust gasestemperaturevalueisincludedbetween500
and 600 C, (ignition has correctlyoccurred).
Upon reachingabout 700 C theunit disconnects the spark plugandthe burner works in self-combustion.
If theflamesensor doesnot measure theabovetemperature,therebytheburner isnot turnedon,theunit repeatstheignition
procedure. Ifit doesnot start again, theunit turnstheburner offandit will thenbemandatoryto manuallyswitchit onagain.
If theheater does not start for threeconsecutivetimes, it isblocked.
Theunit checks,throughwatertemperaturesensorandoverheatingsensor,whether combustionandburner correctlyoperate.
Thewater temperaturesensor isusedbytheunit to adjust theburnerworkingpower (maximum,medium,minimumandstand
by).
Inthe manual version, uponreaching55_C, thesystemconnects the fans inside the cabin.
The overheatingsensor isused bytheunit to turntheburner off incaseof excessivewater temperature(about 115 _C).
T|o booo ooat|o t|o |s ooto|ooo b o|vo's sott|os.
Uponturningoff,theburnerperformsawashingphasethat lastsforabout3minutesinordertobereadyforthefollowingstarting.
Theheater is connectedwith itsown control logicintheair conditioningsystemand isthereforeequipped with anelectronic
unit with related connector.
The unit is directlyassembledonto the heater.
Theheater canbedirectlydrivenbytheautomatic air conditioningsystem,bytheversionwith manual control or throughthe
Bed Moduleunit.
86116
72021
84005
84014
86053
50005
78237
52092 52002
84000
A
Figure256
106973
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COMPONENTS LOCATION
Legenda
A Thermostat 65 _C
50005 Cluster
52002 Heater connectingswitch
52092 Cabin/engineheatingswtich
72021 30-polediagnosisconnector
78237 Two-waysolenoid valve (D+)
84000 Supplementarywater heater
84005 Heater control electronic unit
84014 Fuel batchingpump
86053 Bed Module
86116 BodyComputer
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SYSTEM COMPONENTS
1) Burner motor
2) Flame sensor
3) Combustionchamber
4) Burner control unit
5) Ignitionspark plug
6) Water temperaturesensor
7) Flame pipe
8) Heat exchanger
9) Overheatingsensor
10) Water pump
11) Silencer
12) Air suction pipe
13) Fuel batchingpump
14) Bed Moduleunit
15) AutomaticWebasto air conditioner electronicunit
16) Cabin/engineheatingand heater connectingswitch
17) Air conditioner control dashboard for manual version
18) Cluster
Connection to circuit
WE. Water inlet
WA. Water outlet
V. Comburent air inlet
B. Fuel supply
A. Exhaust gasesoutlet
Figure257
106974
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65 _C THERMOSTAT
It isassembledontheright vehiclesidenear theburner andhasbeeninsertedinorder to allowquicklyheatingthecabinwhen
theengineis off.
It is equipped with atemperature-sensitivemembranecalibrated at 65 C.
With temperature <65_C water will onlycirculateincabin (small circuit).
Withtemperature>65_C thethermostat switchesitsposition,allowingwater to circulatebothin cabinandinengine, heating
themboth (bigcircuit).
3-WAY SOLENOID VALVE
In the WEBASTO air conditioningsystemthere is asingle 3-waysolenoid valvethat performs the functionof batchingand
bypassingcoolingwater from engine to radiator inside the cabin.
The valveis placed next to thefront left side of theengine (driver side).
It is of the NormallyOpen typeat rest andissuppliedbyadirect battery positive.
The electronic unit, byprovidingit with a mass, adjustsits workingcycle (Duty-Cicle).
WATER PUMP
The water pump isdirectlyassembled onthe lower part of theburner.
It is usedto circulatetheenginecoolingwater inthecircuit.
The supplyvoltageis 24Volt.
The minimumflowrateis about 500 l/h.
FUEL BATCHING PUMP
It isassembledonthechassisnext to fuel tankswithaslant of 15 to facilitateair drain. It isusedto takeandinject gasoil inside
theburner.
The unit supplies the pump with apulsesignal.
For acorrect operationthe internal deliverypipediameter must be 2 mmand must not exceed the length of 5 meters.
It embeds asmall fueld filter and aunidirectional checkvalve.
The fuel flow rateis about 0.2 l/min.
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WATER TEMPERATURE SENSOR
It isaPTC sensor assembledonheat exchanger;it measuresdifferent water temperaturesinordertoadjust theburner power
and, onlyin manual version, upon reaching55C, it allows connectingthefans.
The sensor resistance at 20_C is~950 Ohm.
FLAME SENSOR
It isaPTC sensor assembledinsidethecombustionchamber next totheexhaust gasoutlet andmeasuresthecurrent tempera-
ture, in order to disconnect thespark plugincasetheburner hasnot beenturnedon.
It disconnectsthespark plugat anexhaust gastemperatureof about 700_C
The sensor resistance at 20 _C is~1080 Ohm.
IGNITION SPARK PLUG
It is aresistanceplaced insidethecombustionchamber.
The unit supplies it with pulses throughan internal electronic regulator.
The rated operatingvoltageis18Volt to allowitsoperation also with batteryvoltagesof ~22 Volt.
The resistanceat 20_C must be<2Ohm.
OVERHEATING SENSOR
It isatemperaturesensor assembledontheheat exchanger,itmeasuresthedifferentwatertemperaturestopossiblydisconnect
theburner upon reachingabout 115 C
Incaseof interventionthesensor restoresitself autonomously. It isnot of the manual restoringtype.
The sensor resistance at 20 C is ~10K Ohm.
BURNER MOTOR
It is embeddedinto theassemblyin therear burner part.
The rotation speed is managed bythe unit by meansof an integrated electronic regulator.
It embeds aninductivesensor that measures theenginerotationspeed.
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ELECTRONIC UNIT
It is directlyassembled onheater bodyandisinterfacedwithvehiclethrough a14-pin connector.
It is connected to CAN BCBline.
It has averyadvanceddiagnostic systemand transmitspossibleerror codes on vehicleCluster.
Pin Cable Function
A1 7506 Positivefromwater cock knobmanual version(25%position)
A2 7711 Positivefromboiler activatingswitch
A3 Ws/Bi CAN H line
A4 7775 Positivefor ambient thermostat control (manual version)
B1 Gn/ve CAN H line
- - -
B3 2296 Diagnosis Kline
B4 6605 Positivefor cabin/engine heatingkeywarninglight
- -
C2 7708 Direct positivefrombattery
C3 0000 Direct negative
C4 7783 Positivefor fuel batchingpump control
- - -
- - -
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SCR (SELECTIVE CATALYTIC REDUCTION) SYSTEM - DENOX 2
T|o ssto ooat|oo |s oosc|boo | o t|o '|o|oo' soct|oo o t||s aooa|.
108913
Figure258
SCR SYSTEMOPERATION DIAGRAM
PI N
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Name Description
42XX3 AD-Bluesolutionpressuresensor
47XXX AD-Bluesolutiontemperaturesensor
72069 16-polejoint for OBD (on-board diagnosis)
78266 MeasuringmodulesolenoidvalvewithSCR
78267 Enginewater circulation switchvalvefor UREA tank heatingwithSCR
84XXX Electric displacement pump withpressurecontrol valveandcirculationvalve
85140 Electronic control for SCR pumpingmodule
85141 Catalyst output temperaturesensor with SCR
85142 UREA tanklevel and temperature sensors withSCR
85143 Catalyst input temperaturesensor with SCR
85144 Nitricoxide(NOx) measuringsensor withSCR
85150 EDC control unit
85161 Combustionair relative humidityand temperaturesensors withEDC
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Pin - out
Ref. Description
Cablecolour
code
1 +for enginewater circulationsolenoid valve for ureatank heating 7542
2 +for ureafilter outlet heater 7546
3 Direct battery+(+Bat) 7540
4 Ureafilter output heater control 7540
5 CAN - H (ECB) line White
6 CAN - L (ECB) line Green
7 Spare -
8 Spare -
9 10 Spares -
11 Meteringmodule solenoid valvecontrol ground 9541
12 +for meteringmodulesolenoidvalve 7541
13 Spare -
14 Ground 0000
15 Ground 0000
16 Spare -
17 Inlet catalyst temperaturesensor ground 0544
18 Ureatank level sensor signal 6543
19 Ureatank temperature and level sensor ground 0543
20 22 Spares -
23 Engine water circulation solenoidvalvecontrol ground for ureatank heater 9542
24 +15 8540
25 Outlet catalyst temperaturesensor ground 0541
26 Outlet catalyst temperaturesensor signal 6541
27 Spare -
28 Outlet catalyst temperaturesensor signal 6544
29 Ureatank temperature sensor signal 6542
30 Spare -
31 Kline(16-pin test connector) 2257
32 Spare -
33 Ureafilter outlet heater control ground 9546
34 35 Spares -
113576
Figure259
CONNECTOR VIEW (CABLESIDE)
UDS
DCU15
105989
105990
Figure260
Figure261
CENTRAL LOCKING WITH REMOTE
CONTROL
The systemconsistsof oneor several (max. 8) transmitters
and areceiver.
Transmitter
Thetransmitter hasaspecial container ofitsown,equipped
with an eyelet and ring.. The shock-proof transmitter
container is also waterproof.
The transmitter sends the receiver avariable code (rolling
code) bymeans of aradiofrequencysignal at 433.92 MHz
(EC Directive95/56).
It isequippedwithtwobuttonsfordooropeningandclosing,
respectively.
By keeping the button pressed down for 50 msec, the
variablecodewill befullytransmitted.Ifthebuttonisactuated
continuously,however,transmissionwill beinterruptedafter
5 seconds ( 10%).
The transmitter operatingrangeis 10m.
T|o batto oaaotoos a 2 oas' sov|co ||o. |o||o.|o t|o
replacement, the transmitter maybebrieflyactuated twice
in order to restore synchronism with the receiver. This
sequence is also permitted at anytime other than battery
replacement
Receiver
Thereceiver ishousedinsideacontainerwithawhitecover,
which includes a transmitter programming button (easily
accessible and protected against unintentional actuation), a
programmingcheck green LED, and a8-wayconnector.
It is housed in instrument panel upper side, in front of
assooo's soat.
The receiver antennais housedinsidethecontainer, too.
The receiver receives and decodesthe codethat was sent
bythe transmitter, and can storeup to eight codes. Doors
lockingandunlockingcommandsgo fromthetransmitter to
the receveir, which sends the signal to Body Computer
central unit, which inturn viaCAN line sendsamessageto
Door Modules to activatethelocks.
If the vehicle is in thekey-ON condition (+15 is available),
thereceiver will performno actuationthrough theremote
control.
The receiver manages synchronization between the locks,
and resumes correct alignment through asequence of two
or several transmitter or lockkeydrives.
Blinker control
Doorlocklockingandopeningwill besignalledbythelighting
of the indicator lights. Therefore, the receiver need be
interfaced with the Body Computer control unit that
managestheabove-mentionedlights.
The receiver features an output (to the ground) that is
connected in parallel with the emergencylight switch. The
latter consists of an unstable button that actuates and
deactivates theblinkingsequence (blinker signal).
Descriptionof blinker controls:
- T1 = 120 msec (Start)
- T2 = 700 msec (Delay- Lock)
- T2 =1550 msec (Delay- Unlock)
- T3 = 120 msec (Stop)
TRANSMITTER
CENTRAL LOCKINGCONTROL UNIT (RECEIVER)
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Control unit pin-out (receiver)
Programming
The programmingstatus makesit possibleto get thereceiver to recognizethe transmittersenabled to control the respective
functions.
Programmingis accessedthrough therest state when the +15signal isnot available.
The receiver maybecontrolledbyatransmitter withauniversal code as longas at least onetransmitter is not programmed.
After avariablecode (other than theuniversal code) hasbeenprogrammed, the latter will not berecognizedanylonger.
Transmitters areprogrammedinthe FIFO mode.
Two transmitter programmingmodesare available:
- simplified programming: it allows you to programthe transmitters quickly. It can be actuated until 128 actuations are
performed after the first programming, or until it is disabled.
- Protected programming: it guaranteesthe customer against therisk of other transmitters beingprogrammed without the
knowledgeofthecustomer themselves.It involvesusingapassword(shownonthetagenclosedwiththetransmitter) that
can beobtainedfromthetransmitter code.
Simplified programming
The first code (andthesubsequent onesas well) are programmedas follows:
- press thebutton onthe receiver: theLED will light up and blink;
- theoperator presses,whilekeepingthebuttononthereceiverpresseddown,anyofthekeyofthetransmitter,whichsends
out thecode;
- thereceiver stores,afterdetectingthreesubsequent transmissioninstances(withthecurrent checksum),thecodeinto the
memory;
- thereceiver LEDwill, at theverytimewhenit recognizesthecode, light upsteadily,thussignallingthat thecodehasbeen
received: nowtheoperator mayreleasethetransmitter buttonto endtheprogramming.
Simplified programmingdisable
Simplified programmingmaybedisabledbyenteringthe passwordas follows:
- press thesmall button onthe receiver: theLED will light up and blink;
- release the small button: theLED will blinkonce;
- enter, bymeansofthesmall button, a4-digit code(password): eachdigit shall beincluded between 0and9 (codewritten
onthelabel deliveredtogetherwiththetransmitter).Anoptical feedbackwill begeneratedontheLEDeverytimethesmall
button is pressed;
- after eachdigit has been entered, wait for theLED to blinkagain to request the next digit, upto the fourth digit;
- theprocedurewill beover after the last digit isentered.
Protected programming
Everytimeanewtransmitter isto berecognizedafterfirstlyenteringthepassword,youwill need toenter thepasswordofany
ofthetransmitterspreviouslystoredintothememory.Correct recognitionofthepasswordwill besignalledbytheLEDblinking
after thepassword has been entered (if thepasswordisnot recognized, theLED will remain ON for 10 seconds). When the
LEDisblinking,keepthereceiverbuttonpresseddown,thentransmit withthenewremotecontrol tobestoredintothememory,
byfollowingthesimplified programminginstructions.
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Pin Function
Cablecolour
code
1 Blinker control 1113
2 Engine power supplyfor centralisedclosure(door closure)- (without DDM, PDM) 9965
2 Batterypositive 7772
4 Ground 0000
5 Central lockingcontrol (door closing) 0064
6 Central lockingcontrol (door opening) 0065
7 +15power supply 8871
8 Engine power supplyfor centralised closure(door opening) - (without DDM, PDM) 9964
MODUS
Computer-assisted diagnosis station used for diagnosis of braking systems, pneumatic suspensions, electronically-controlled
systems and engines.
The station is equipped with auxiliary functions such as electronic control unit programming, spare list cataloguereferencing,
time-charts, etc.
IT 2000
TheIVECO electronictester makesit possibletoimmediatelyinterveneonthevehicle,byrecognizingthelatter bymeans ofthe
chassis number.
This tester stores the resultsof thediagnostic operations carried out.
It can also beused as aportablePC, andisset for remotediagnosis.
ByusingMODUSasamother station, IT 2000 can beupdated and configured.
IT 2000isinterfacedwiththevehiclebymeans of a30-polediagnosistakeoff.
E.A.SY.
Figure262
101586
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DIAGNOSTIC
86028
/ccoss to t|o ao|t oo |s oss|b|o t|oo| t|o 'ooo' ooct|oo 'o ( 2) ava||ab|o oo t|o stoo|o .|oo|.
1. Button y or b - 2. 3ottoo ||||/C| - 3. |ao bottoo - +. |scao bottoo - 5. 3ottoo = aoo
Too 'o s.|tc| to |/|C|/ (=+5), t|oo oss 'ooo' ooct|oo bottoo (2). t|o o|s|a .||| s|o. t|o oata oc|aoo ooo
containingthelist of availablefunctions(e.g. HI-FI, telephone, diagnostic, etc.).
Select,bymeans of function y and b button(1),thediagnosticfunction,thenconfirmcorrect selectionbymeansof function
'C|' bottoo (2).
The availableelectronic systems can beselected bymeans of select/confirmbuttons (1) and(2).
The diagnosedsystems are:
Figure263
EDC control unit errorsarenot displayed after the enginehas been started. NOTE
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1 EDC 10 FFC (Front FrameComputer)
2 EUROTRONIC 11 RFC (Rear FrameComputer)
3 INTARDER 12 DDM(Drive Door Module)
4 0EBS (or ABS) 13 PDM(Passenger Door Module)
5 ECAS 14 CM(CabinModule)
6 IMMOBILIZER* 15 0ACLC (Automatic air conditioner)
7 0MTCO (Tachograph*) 16 0AHT_w(Auxiliarywater heater)
8 DC (BodyComputer) 17 0AHT_a(Auxiliaryair heater)
9 IC (Instrument Cluster)
* Functionnot active
86029
- The anomaly-freesystemisdisplayedwith aGREEN background.
- The faultysystemis displayed with aRED background
- The systems not available on the vehicle or not diagnosed (tachograph and Immobilizer) are displayed with a GREY
background.
- | sovoa| aooa||os o|atoo to a ssto ao ava||ab|o, t|o ||st cao bo oo t|oo| b oaos o bottoo (5, ||oo 262) '=' aoo
''.
Thedifferent codesshownallowyou toidentifythefaultycomponent,thetypeofstorederror (opencircuit, short-circuit,etc.),
theerror occurrencesand, finally, whether theerror iscurrentlypresent or intermittent.
86030
To o|s|a |oto|ttoot ao|ts, oss s|o|taoooos| bottoos 'C|' aoo '()' (2-5).
Figure264
Figure265
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73687
First screen
| sovoa| aooa||os ao oooo, t|o osoct|vo ||st cao bo oo t|oo| b oaos o bottoos '=' aoo ''.
Informationon everysinglefault is displayed on four columnswiththefollowingdata:
74225
The diagnosis informationshownon thecluster is dividedinto threescreens:
- thefirst screenallows you to displayall thestored/currentlypresent anomalies(if any);
- thesecond screenallows youto cancel intermittent errors (providedthat therespectivepasswordis available);
- thethird screen allowsyou to know the softwareversionof the various Multiplexelectroniccontrol units.
Second screen
To so|oct t|o socooo scooo, oss bottoo 'ao' oo t|o stoo|o .|oo|.
Cancelling errors
The systemcan be selected bymeans of buttonsy and b available onthesteeringwheel.
Anomalydisplaycan becancelledas follows:
- |oss '='
- T|o o|s|a .||| s|o. t|o oo|ot|oo coo| oooost. oss 'C|' to coot| ooo.
- |oto t|o oooostoo ass.oo (soo oot aaa| ||T||||C T| |/SS\C||), t|oo oss 'C|' to coo|.
Figure266
Figure267
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INFORMATION ON CLUSTER
DTC FMI OC ACT
Displays the anomaly code
relatedto the fault
Indicates the typeof fault Anomalyrate counter Active/not active anomaly
condition
Two digits (hexadecimal) Two digits (hexadecimal) Three digits (decimal) Onecharacter (Y-yes, N-no)
86031
74227
Entering the password
- Select the first number of thepasswordbymeans of buttons y and b .
- Press button OKto confirmeach number.
- Press a to cancel thelatest selected number.
- After thepasswordhasbeencompleted, select the keysymbol to confirmit.
Third screen
To so|oct t|o t||o scooo, oss bottoo 'ao' ava||ab|o oo t|o stoo| o .|oo|.
Software version
The softwareversionisdisplayedonlyfor theMultiplex systemcontrol units.
The releaseof the followingcontrol units canbeselected bymeans of buttons y and b :
1. BodyComputer
2. Front FrameComputer
3. Rear FrameComputer
4. Driver Door Module
5. Passenger Door Module
6. Instrument Cluster
7. Cabine Module
Figure268
Figure269
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Circuit charts
Page
CHART 1 DIRECT POSITIVE TO BATTERY 247
CHART 2 POSITIVE AFTER TGC (+30) 248 . . . . . .
CHART 3 POSITIVE AFTER TGC (+30) 249 . . . . . . .
CHART 4 POSITIVE AFTER TGC (+30) 250 . . .
CHART 5 POSITIVE AFTER TGC (+30) 251 . . .
CHART 6 POWER SUPPLY (+15) 252 . . . . . . . .
CHART 9: BODY CONTROLLER 255 . . . . . . . .
CHART11: BODY CONTROLLER 257 . . . . . . . . .
CHART 13 IC CONTROL UNIT 259 . . . . . . . . .
CHART 14 TACHOGRAPH /
DIAGNOSISSOCKET 260 . . . . . . . . .
CHART 15 STEERINGWHEEL
INTERFACE(SWI) 261 . . . . . . . . . . . .
CHART 16 DDM-BM CONTROL UNIT 262 . . . .
CHART 17 PDM CONTROL UNIT 263 . . . . . . . .
CHART 18 THERMAL MIRRORS/ CENTRALISED
LOCKING / WINDOW WINDERS
(WITHOUT DDM-PDM) 264 . . . . . .
CHART 19 VCMCONTROL UNIT 265 . . . . . . .
CHART 20: EDC (CONNECTORB) 266 . . . . . . .
CHART 21: EDC (CONNECTOR A/C - F2B) 267
CHART 22: EDC (CONNECTOR A/C - F3B) 268
CHART 23: CONTROL UNIT UDS(DENOX 2) 269
CHART 24: CONTROL UNIT MET 270 . . . . . . . .
CHART 25: CONTROL UNIT MET 271 . . . . . . . .
CHART 26: CONTROLI UNIT MET 272 . . . . . . .
CHART 27: LINE CAN-IDB/ FMB/
CONTROL UNIT / TELEMATICS/
NAVIGATOR 273 . . . . . . . . . . . . . . .
Page
CHART 28: LINE CAN-BCB 274 . . . . . . . . . . . . . . . .
CHART 29: LINE CAN-VDB 275 . . . . . . . . . . . . . . . . .
CHART 30: LINE CAN-ECB 276 . . . . . . . . . . . . . . . . .
CHART 31 ECAS4X2 P TRACTOR 277 . . . . . . . . . .
CHART 32 ECAS4X2P/4X4P/6X4P/8X4X4P
(LORRY) 278 . . . . . . . . . . . . . . . . . . . . . .
CHART 33 ABS 279 . . . . . . . . . . . . . . . . . . . . . . . . . .
CHART 34: VENTILATION 280 . . . . . . . . . . . . . . . . .
CHART 35: MANUALLY CONTROLLED
CLIMATE CONTROL SYSTEM 281 . . . .
ADDITIONAL AIRHEATER 282 . . . . . .
ADDITIONAL AIRHEATER 283 . . . . . .
CHART 38: EUROTRONIC II 284 . . . . . . . . . . . . . . . .
CHART 39: RETARDERZF 285 . . . . . . . . . . . . . . . . .
CHART 40: CONTROL UNIT EM (PTO) 286 . . . . . .
CHART 41: RADIO RECEIVER 287 . . . . . . . . . . . . . . .
CHART 42: GENERAL MECHANICAL
POWER SWITCH (IGC) 288 . . . . . . . . . .
CHART 43: ADR (2001) 289 . . . . . . . . . . . . . . . . . . . .
CHART 44: ADR (OPT. 0129) 290 . . . . . . . . . . . . . . .
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Chart 1: Direct positive to battery
113357
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Chart 2: Positive after TGC (+30)
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Chart 6: Power supply(+15)
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Chart 9: Bodycontroller
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113577
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Chart 13: IC central unit
113369
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Chart 14: Tachograph / Diagnosis socket
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Chart 15: Steering Wheel Interface(SWI)
113371
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Chart 16: DDM-BM control unit
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Chart 17: Passenger Door Module(PDM)
113373
3aso |ovobo 2006 Print 603.93.641
Chart 18: Thermal mirrors/ Centralised locking/ Window winders (without DDM-PDM)
113374
Print 603.93.641 3aso |ovobo 2006
Chart 19: Electronic Control Unit VCM
113375
3aso |ovobo 2006 Print 603.93.641
Chart 20: EDC (Connector B)
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Chart 21: EDC (Connector A/C - F2B)
113377
3aso |ovobo 2006 Print 603.93.641
Chart 22: EDC (Connector A/C - F3B)
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Chart 23: Central unit UDS(DENOX 2)
113379
3aso |ovobo 2006 Print 603.93.641
Chart 24: Control unit MET
113380
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113381
3aso |ovobo 2006 Print 603.93.641
113382
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Chart 27: Line CAN-IDB / FMB / Control unit / Telematics / Navigator
113383
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Chart 28: Can line BCB
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Chart 29: Can line VDB
113385
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Print603.93.641
Chart 30: Can line ECB
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Chart 31: ECAS 4x2P (TRACTOR)
113387
3aso |ovobo 2006 Print 603.93.641
Chart 32: ECAS 4X2P/4X4P/6X4P/8X4X4P (LORRY)
113388
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Chart 33: ABS
113389
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Chart 34: Ventilation
113390
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Chart 35: Manuallycontrolled climate control system
113391
3aso |ovobo 2006 Print 603.93.641
Chart 36: Manuallycontrolled additional water heater
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Chart 37: Manuallycontrolled additional air heater
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Revi- June2007
Print603.93.641/A
Chart 38: EuroTronic II
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Print603.93.641
Chart 39: Retarder ZF
113395
3aso |ovobo 2006 Print 603.93.641
Chart 40: Control unit EM(PTO)
113580
Revi- June2007
Print603.93.641/A
Chart 41: Radio receiver
113397
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Print603.93.641
Chart 42: General mechanical power switch(IGC)
113398
Print 603.93.641 3aso |ovobo 2006
Chart 43: ADR (2001)
113399
3aso |ovobo 2006 Print 603.93.641
Chart 44: ADR (OPT. 0129)

Iveco - Euro Trakker 4 - 5 - Manual PDF

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TRAKKER EURO 4/5

d no. 8 screw M10x 1,5 x 120

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