Iveco Stralis AS Euro 4/5 Workshop Service Repair Manual

-
This Workshop Service Repair manual PDF download for the Iveco Stralis AS Euro 4/5 Mechanical Electric/Electronic has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


TABLE OF CONTENTS :

SECTION 1 - General
SECTION 2 - Engine
SECTION 3 - Clutch
SECTION 4 - Gearboxes
SECTION 5 - Intarder - ZF hydraulic retarder
SECTION 6 - Propeller shafts
SECTION 7 - Rear axles
SECTION 8 - Axles
SECTION 9 - Suspensions
SECTION 10 - Wheels and tyres
SECTION 11 - Steering
SECTION 12 - Air system - Brakes
SECTION 13 - Bodywork - Chassis frame
SECTION 14 - Scheduled maintenance
SECTION 15 - Electric/Electronic system


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 603.93.531
Total Pages : 1614


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

STRALIS AS EURO 4/5
REPAIR MANUAL
MECHANICAL ELECTRIC/ELECTRONIC
PRELIMINARY REMARKS
SYMBOLS -WARNINGS
SYMBOLS - ASSISTANCE OPERATIONS
PRODUCT CODE
GENERAL WARNINGS
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
Bonding and screening
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
UPDATE DATA
INDEX OF SECTIONS
SECTION 1 - General
General
VEHICLE IDENTIFICATION DATA
Vehicle Identification Plate
Production identification plate
COMMERCIAL CODES
COMPOSITION OF MODELS
P.I.C. NUMBER CODING
REPLENISHING FLUIDS
International lubricant designation
SECTION 2 - Engine
Engine
F3A Engine
VIEWS OF THE ENGINE
TECHNICAL DESIGNATION
CHARACTERISTIC CURVES
GENERAL CHARACTERISTICS
ASSEMBLY CLEARANCE DATA
TIGHTENING TORQUE F3A ENGINE
TOOLS
ENGINE REMOVAL - REFITTING
Removal
Refitting
Filling the cooling system
Bleeding air from the supply system
Checks and tests
ELECTRO-MAGNETIC JOINT REPLACEMENT
Removal
Refitting
DISMANTLING THE ENGINE ON THE BENCH
REPAIR OPERATIONS
CYLINDER BLOCK
Checks and measurements
Cylinder liners
Replacing cylinder liners
Crankshaft
Measuring the main journals and crankpins
Preliminary measurement of main and big end bearing shell selection data
Selecting the main and big end bearing shells
Replacing the timing gear and oil pump
Checking main journal assembly clearance
Checking crankshaft end float
Piston connecting rod assembly
Piston rings
Connecting rods
Bushings
Checking connecting rods
Mounting the connecting rod — piston assembly
Mounting the piston rings
Fitting the big end bearing shells
Fitting connecting rod - piston assemblies in the cylinder liners
Checking piston protrusion
Checking crankpin assembly clearance
CYLINDER HEAD
Disassembly the valves
Checking head bearing surface on cylinder block
Valves
Removing deposits and checking the valves
Valve seats
Checking clearance between valve-stem and associated valve guide
Valve guides
Replacing injector cases
Checking injector protrusion
TIMING GEAR
Camshaft drive
Idler gear pin
Idler gear
Twin intermediategearpin
Twin idler gear
Replacing the bushings
Timing system
Checking cam lift and pin alignment
Bushings
Replacing camshaft bushings with drift 99360499
Removal
Assembly
Valve springs
ROCKER SHAFT
Shaft
Rocker arms
ENGINE ASSEMBLY ON BENCH
Fitting connecting rod - piston assemblies in cylinder liners
ENGINE FLYWHEEL
Fitting engine flywheel
Fitting camshaft
Fitting pump-injectors
Fitting rocker-arm shaft assembly
Camshaft timing
Phonic wheel timing
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
Completing Engine Assembly
LUBRICATION
Oil pump
Overpressure valve
Oil pressure control valve
Heat exchanger
By-pass valve
Thermostatic valve
Engine oil filters
Valve integrated in piston cooling nozzle
COOLING
Description
Operation
Electromagnetic coupling
Water pump
Thermostat
View of thermostat operation for versions with Intarder
TURBOCHARGING
Turbocharger HOLSET HE 531 V
Actuator
Solenoid valve for VGT control
REPAIRING ACTIONS
Variable geometry movement control
Checking the actuator
Checking actuator travel
Cleaning turbine body
FEEDING
Overpressure valve
Feed pump
Injector-pump
Replacing injectors-pump
Pressure damper
F3B Engine
VIEWS OF THE ENGINE
TECHNICAL DESCRIPTION
CHARACTERISTIC CURVES
GENERAL SPECIFICATIONS
ASSEMBLY DATA - CLEARANCE
TIGHTENING TORQUE
DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS
TOOLS
ENGINE REMOVAL-REFITTING
Removal
Refitting
Filling the cooling system
Bleeding air from the supply system
Checks and tests
ELECTRO-MAGNETIC JOINT REPLACEMENT
Removal
Refitting
DISASSEMBLY THE ENGINE ON THE BENCH
REPAIRS
CYLINDER BLOCK
Checks and measurements
Cylinder liners
Replacing the cylinder liners
Crankshaft
Measuring the main journals and crankpins
Preliminary measurement of data to select main bearing and big end bearing shells
Selecting the main bearing and big end bearing shells
Replacing the timing gear and oil pump
Checking main journal assembly clearance
Checking crankshaft end float
Connecting rod piston assembly
Piston rings
Connecting rod
Bushings
Checking connecting rods
Mounting the connecting rod — piston assembly
Mounting the piston rings
Fitting the big end bearing shells
Fitting connecting rod - piston assemblies in the cylinder liners
Checking piston protrusion
Checking crankpin assembly clearance
CYLINDER HEAD
Disassembly the valves
Checking head bearing surface on cylinder block
Valves
Valve seats
Checking clearance between valve-stem and associated valve guide
Valve guides
Replacing injector cases
Checking injector protrusion
TIMING GEAR
Camshaft drive
Idler gear pin
Idler gear
Twin intermediate gear pin
Twin idler gear
Replacing the bushings
Timing system
Checking cam lift and pin alignment
Bushings
Valve springs
ROCKER SHAFT
Shaft
Rocker arms
ENGINE ASSEMBLY ON BENCH
Fitting connecting rod - piston assemblies in cylinder liners
Fitting the cylinder head
Fitting flywheel box
ENGINE FLYWHEEL
Fitting engine flywheel
Fitting camshaft
Fitting pump-injectors
Fitting rocker-arm shaft assembly
Camshaft timing
Phonic wheel timing
Adjusting rocker arm clearance, intake, exhaust and pre-load of pump injector governing rocker arms
Completing Engine Assembly
LUBRICATION
Oil pump
Overpressure valve
Oil pressure control valve
Heat exchanger
By-pass valve
Thermostatic valve
Engine oil filters
Valve integrated in piston cooling nozzle
COOLING
Description
Operation
Electromagnetic coupling
Water pump
Thermostat
View of thermostat operation for versions with Intarder
TURBOCHARGING
Turbocharger HOLSET HE 551 V
Actuator
Solenoid valve for VGT control
REPAIR
Variable geometry movement control
Checking the actuator
Checking actuator travel
Cleaning turbine body
FEEDING
Overpressure valve
Feed pump
Injector-pump
Pressure damper
Hydrocar pressure take-off on timing system
HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)
Description
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
ENGAGING POWER TAKE-OFF
REMOVING-REFITTING POWER TAKE-OFF
Denox System 2
DeNOx2 SYSTEM
General remarks
Tank
Ad Blue fluid level gauge control
By-pass valve
Pump module
Dosing module
Catalyst
Exhaust gas temperature sensor
Humidity detecting sensor
REPAIR INTERVENTIONS ON DeNox SYSTEM
Ad Blue tank
Disconnection
Reconnection
Tank level indicator
Disconnection
Reconnection
Pump module
Disconnection
Filter + Pre-Filter
Disconnection
Reconnection
Deflecting valve
Disconnection
Inlet exhaust gas temperature sensor
Disconnection
Reconnection
Outlet exhaust gas temperature sensor
Disconnection
Reconnection
Nitrogen oxides detecting sensor (IF PRESENT)
Disconnection
Reconnection
Sucked air humidity detecting sensor
Disconnection
Reconnection
Measuring out module
Disconnection
Reconnection
Fault Diagnosis
FAULT DIAGNOSIS
Diagnosis Instruments
Cluster Diagnosis
DTC - FMI error codes
SECTION 3 - Clutch
Clutch
DESCRIPTION
Clutch
SPECIFICATIONS AND DATA
DIAGNOSTICS
Main operating faults of a mechanical nature
TIGHTENING TORQUES
TOOLS
REMOVING AND REFITTING THE CLUTCH
Removal
CHECKS
Refitting
REMOVING-REFITTING THE THRUST BEARING
REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT
REMOVING-REFITTING THE PEDAL UNIT SATA
Removal (vehicles with EuroTronic Automated gearbox)
Removal (vehicles with ZF 16 S... gearbox)
Refitting
PEDAL TYPE SATA (Vehicles with ABS)
Unit removal-assembly
CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ABS)
Clutch stop
Idle travel of clutch pedal
Pedal control valve stroke
PEDAL TYPE WABCO vehicles with EBS)
Clutch stop
Clutch pedal idle travel
Pedal control valve stroke
HYDRAULIC CONTROL vehicles with ZF 16 S... gearboxes)
Clutch actuator
SPECIFICATIONS FOR MANUAL GEARBOX PREASSEMBLY
Spring pin adjustment
BLEEDING CLUTCH CIRCUIT
SPECIFICATIONS FOR AUTOMATIC TRANSMISSION ASSEMBLY
SECTION 4 - Gearboxes
Gearboxes
Gearboxes: ZF 16 S 1920 T.D., ZF 16 S 2220 T.D./T.O., ZF 16 S 2320 T.D., ZF 16 S 2520 T.O.
DESCRIPTION
LOCATION OF GEARBOX DESCRIPTION PLATE
SPECIFICATIONS AND DATA
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
REMOVING-REFITTING THE GEARBOX
Removal
Refitting
ZF gearboxes with Intarder (IT), hydraulic retarder, types: ZF 16 S 1921 T.D., ZF 16 S 2221 T.D./T.O., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O.
SPECIFICATIONS AND DATA
TOOLS
OVERHAULING THE GEARBOX
Removing the hydraulic retarder from the gearbox on the stand
Refitting the hydraulic retarder
Adjusting stator end float
Removing the epicyclic reduction gear unit ERG) rear box
Removing the epicyclic reduction gear unit (ERG)
Refitting the epicyclic reduction gear unit (ERG) rear box
Gearboxes EuroTronic Automated: - 12 AS 1930 T.D. - 12 AS 2330 T.D./T.O. - 12 AS 2530 T.O.
DESCRIPTION
LOCATION OF GEARBOX DESCRIPTION PLATE
GEARBOX ELECTRONIC MANAGEMENT
Theoretical scheme
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
REMOVING-REFITTING GEARBOX
Removal
Refitting
Gearboxes EuroTronic Automated with Intarder: - 12 AS 1931 T.D. - 12 AS 2331 T.D./T.O. - 12 AS 2531 T.O.
SPECIFICATIONS AND DATA
TOOLS
EXPERIMENTAL TOOLS
OVERHAULING THE GEARBOX
Removing the hydraulic retarder
Refitting the hydraulic retarder
Adjusting epicyclic reduction gear train bearing end float
Adjusting stator end float
Adjusting stator end float
Removing the rear box
Disassembling the E.R.G.
Assembling the E.R.G.
EuroTronic gearboxes diagnostics
DIAGNOSTICS
Diagnosis Instruments
Cluster Diagnosis
Troubleshooting via DTC-FMI codes
SECTION 5 - Intarder - ZF hydraulic retarder
Intarder - ZF hydraulic retarder
LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE
GENERAL INFORMATION
OPERATION
Retarder engaged
Retarder disengaged
LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER
REMOVING AND REFITTING THE RETARDER ON THE ZF 16 S 1621/1921/2221 GEARBOX
Removal
Refitting
Filling with oil
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
DIAGNOSTICS
Main operating faults of a mechanical nature
OVERHAULING THE INTARDER HYDRAULIC RETARDER
Hydraulic accumulator
Removal
Fitting
Removing hydraulic retarder
Checking the component parts of the hydraulic retarder
Fitting the hydraulic retarder
Stator end float adjustment
Only for EuroTronic Automated gearboxes, operate as below
SECTION 6 - Propeller shafts
Propeller shafts
CHARACTERISTICS AND DATA
STRALIS (Tractors) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2C/6x4/6x2p)
STRALIS AS (Cabs) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2P/6x4)
DIAGNOSTIC
Main operating faults of a mechanical nature
TIGHTENING TORQUES
TOOLS
REMOVING AND REASSEMBLING THE PROPELLER SHAFT
Removal
Reassembly
CHECKING THE PROPELLER SHAFT ON THE VEHICLE
REMOVING AND FITTING BACK THE UNIVERSAL JOINTS
REMOVING AND REASSEMBLING THE SUPPORT
SECTION 7 - Rear axles
Rear axles
DIAGNOSTICS
Main operating faults of a mechanical nature
REMOVING-REFITTING THE REAR AXLE
Removal
Refitting
REMOVING-REFITTING THE DIFFERENTIAL FROM THE REAR AXLE ON THE VEHICLE
Removal
Refitting
Rear Axle ARVINMERITOR MS 13-175 with disc brakes
LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
TOOLS
OVERHAULING THE REAR AXLE ASSEMBLY
OVERHAULING THE WHEEL HUBS
Removal
Replacing wheel hub bearings
Checking the parts forming the wheel hubs
Replacing the wheel fixing pins
REMOVING AND REFITTING THE DIFFERENTIAL with axle on stand 99322215)
Removal
Refitting
REPAIRING THE DIFFERENTIAL
Removing the differential
Removing the gearcase
REMOVING THE BEVEL PINION FROM THE SUPPORT
Differential component check
Fitting the gear housing
FITTING THE MOUNT ON THE BEVEL PINION
Reassembling the differential housing
ADJUSTING THE CAP GAP
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
WORK ON THE VEHICLE
REPLACING THE BEVEL PINION MOUNT SEAL
Disassembly
Assembly
Rear axle 451391
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
REAR AXLES ASSEMBLY OVERHAUL
Disassembly
Epicycloid reduction gear disassembly
Wheel hub disassembly
CHECKING THE WHEEL HUB AND EPICYCLOID REDUCTION GEAR UNIT PARTS
WHEEL HUB ASSEMBLY
Assembling the epicycloid reduction gear
REMOVING-REFITTING THE DIFFERENTIAL
REPAIRING THE DIFFERENTIAL
Disassembly
Gear housing disassembly
Removing the bevel pinion from the support
CHECKING THE DIFFERENTIAL COMPONENTS
Gear housing assembly
Assembling the bevel pinion support
Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring
Differential housing assembly
Gear housing bearings rolling torque adjustment
Axles in tandem ARVINMERITOR MT23-155/2D
Axles Intermediate ARVINMERITOR MD11-155/2D
DESCRIPTION
SPECIFICATIONS ANDA DATA
LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
SPECIAL PURPOSE TOOLS
INTERMEDIATE REAR AXLE ASSEMBLY OVERHAUL
OVERHAULING THEWHEEL HUBS
Removal
Replacing wheel hub bearings
Checking the parts forming the wheel hubs
Replacing the wheel fixing pins
Wheel hub reassembly
DIFFERENTIAL CASE REMOVAL
Case removal
Gearing case removal
Checking the differential components
Gearing case refitting
ASSEMBLING DIFFERENTIAL CASING
Calculating bevel pinion position in differential casing
EXAMPLES
Adjust the limit switch of the differential - distributor lock control pin
Adjusting drive input shaft bearing end float
ADJUSTING THE CAP ANGLE
CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)
REMOVAL-OVERHAUL-REFITTING OF DISTRIBUTOR OUTPUT SHAFT
Adjustment of motion output shaft bearing end play
Rear axles ARVINMERITOR MR11-155/D
DESCRIPTION
LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
REPAIR OPERATIONS
SECTION 8 - Axles
Axles
Front axles
Front axle 5876 5876/4 5876/5 Steering central added axle 5876/4
DESCRIPTION
SPECIFICATIONS AND DATA
DIAGNOSTICS
Main operating faults of a mechanical nature
TIGHTENING TORQUES
TOOLS
REMOVING AND REFITTING AXLE
Vehicles with mechanical front suspension
Removal
Refitting
REMOVING AND REFITTING AXLE
Vehicles with pneumatic front suspension and longitudinal bars
Removal
Refitting
HYDRAULIC SYSTEM FOR CENTRAL ADDED AXLE STEERING (vehicles 6X2C)
Hydraulic system working diagram
CHARACTERISTICS AND DATA
CENTRING CYLINDER OPERATING DIAGRAM
Added central axle
Location on the vehicle of the main components of the hydraulic system
Hydraulic system
AIR BLEEDING FROM THE HYDRAULIC CIRCUIT
Filling up and bleeding the power steering hydraulic circuit (circuit 1)
Filling up and bleeding the power steering hydraulic circuit (circuit 2)
REPAIRS
CENTRAL ADDED AXLE AIR LIFT, 6X2C VEHICLES
GENERAL
Location on the vehicle of the main components
Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for central added axle with single wheels
VEHICLE CHECKS
Tie rods
Swivel heads
CHECKING SWIVEL HEAD PLAY
FRONT AXLE ASSEMBLY OVERHAUL
REMOVING - REFITTING WHEEL HUBS
Removal
Replacing wheel hub bearings
Replacing wheel fixing pins
Refitting wheel hubs
Checking wheel hub bearing end float
Measuring rolling torque
REMOVING AND REFITTING TRANSVERSE TIE ROD
REPLACING TRANSVERSE TIE ROD SWIVEL HEADS
LONGITUDINAL TIE ROD LEVER REMOVAL/REFITTING
CROSS TIE ROD LEVER REMOVAL/REFITTING
REMOVING AND REFITTING PIN FOR STUB AXLE
Removal
Replacing kingpin bearing
Checking and adjusting clearance between stub axle and axle
CHECKING AND MEASURING THE AXLE BODY
Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins
Checking angle of holes for kingpins
Additional rear axle
Rigid rear added axle 55080/DI
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUE
TOOLS
REMOVING-REFITTING
Removal
Refitting
REPAIRS
Rigid rear added axle with hydraulic lifting 56082/D1 (N 9171)
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUE
TOOLS
REMOVING-REFITTING
REPAIRS
Steering rear added axle with pneumatic lifting 57080/DI
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
TOOLS
REPAIRS
PNEUMATIC LIFT
GENERAL
LOCATION ON THE VEHICLE OF THE MAIN COMPONENTS OF THE HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM WORKING DIAGRAM
VEHICLES WITH PNEUMATIC REAR SUSPENSIONS AND PNEUMATIC LIFTING
Location on the vehicle of the main components
Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for rear added axle with single wheels
DIAGNOSTICS
Main operating faults of a mechanical nature
TIGHTENING TORQUES (Steering and lifting device linkage)
CHARACTERISTICS AND DATA
Steering and third axle hydraulic system
MAIN HYDRAULIC SYSTEM COMPONENTS
HYDRAULIC ACCUMULATOR
Nitrogen pressure checking and recharging
OPERATOR CYLINDER
Disassembly
Assembly
Checking cylinder oil sealing on the vehicle
CENTRING CYLINDER
Disassembly
Assembly
Checking cylinder oil sealing on the vehicle
ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING
Removal
Refitting
AIR BLEEDING FROM THE HYDRAULIC CIRCUIT
Filling up and bleeding the power steering hydraulic circuit (circuit 1)
Filling up and bleeding the power steering hydraulic circuit (circuit 2)
Wheel geometry
GENERAL INFORMATION
Steering wheel angles
FRONT WHEEL GEOMETRY (4X2 vehicles)
Positioning clips and headlights
Electronic compensation of rim eccentricity
Wheel alignment
Checking wheel toe-in
Checking wheel deviation
Checking camber
Checking kingpin angle and caster
Checking rear axle alignment
Vehicle wheel geometry with steering rear added axle and pneumatic lifting
Wheel setup for vehicles with additional centralsteering axle and pneumatic lift
SECTION 9 - Suspensions
Suspensions
SUSPENSIONS
DESCRIPTION
Mechanical front suspension
Pneumatic front suspension
Pneumatic rear suspension
SPECIFICATIONS AND DATA
Models front suspension: 4x2 (tractors)
Models front suspension: 4x2 (tractors) - 6x4 (tractors and cab-equipped vehicles)
Models front suspension: 4x2 (tractors) - 6x4 (tractors and cab-equipped vehicles)
Models front suspension: 4x2 (cab-equipped vehicles) - 6x2C (tractors) - 6x2P (tractors and cab-equipped vehicles)
Models front suspension: 4x2 (tractors and lorries) - 6x2P (tractors and lorries)
Models front suspension: 4x2 (tractors and cab-equipped vehicles) - 6x2P (cab-equipped) vehicles with pneumatic front suspension
MECHANICAL FRONT SUSPENSION ASSEMBLY DRAWING
PNEUMATIC FRONT SUSPENSION ASSEMBLY
CENTRAL ADDED AXLE SUSPENSION ASSEMBLY
Leaf spring for central added axle (vehicles with air suspension) 6x2C vehicles
Front shock absorbers
Additional axle shock absorbers
Rear shock absorbers
PNEUMATIC SUSPENSION
Chassis frame lifting, lowering and self-levelling with remote control
Saving Levels
AXLE LOAD METER
Activating function
CALIBRATION (indication on display unit)
SCHEMES OF AIR SPRING SUSPENSIONS SYSTEMS
Principle scheme of rear air spring suspensions for lorries 4x2/P
Principle scheme of suspensions for lorries 4x2/FP
Principle scheme of air spring suspensions for lorries 4x2FP-CM
Working diagram of pneumatic rear suspensions for 4x2T/P tractors
Working diagram of suspensions for 4x2T/FP-LT
Working diagram of pneumatic suspensions for tractors 6x2TX/P (without added axle lifter)
Working diagram of pneumatic suspensions for tractors 6x2TX/P (with added axle lifter)
Principle scheme of rear air spring suspensions for lorries 6x2Y/PS (with added axle lifter)
Principle scheme of rear air spring suspensions for lorries 6x2Y/PS (without added axle lifter)
Principle scheme of rear air spring suspensions for lorries 6x2Y/PT and tractors 6x2TY/PT (with added axle lifter)
Principle scheme of rear air spring suspensions for lorries 6x2Y/PT and tractors 6x2TY/PT (without added axle lifter)
Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-CM (with added axle lifter)
Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-CM (without added axle lifter)
Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-GV (with added axle lifter)
Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-GV (without added axle lifter)
Working diagram of pneumatic rear suspensions for 6x4 tractors and lorries
CHARACTERISTICS AND DATA
Pneumatic System
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM
Fault Diagnosis
Controlled pressure valve
Level sensor
Electro-Pneumatic Control Valve
Load detector pressure sensor
Low air pressure switch
Air spring
ECAS Control Unit
DIAGNOSTICS
Diagnosis Instruments
Cluster Diagnosis
Troubleshooting via DTC-FMI codes
TOOLS
SPECIAL PURPOSE TOOLS
TIGHTENING TORQUES
Mechanical front suspension
Pneumatic front suspension
Pneumatic front suspension with bars
Central added axle pneumatic suspensions 6x2 C vehicles
Pneumatic rear suspension 4x2 - 6x2 C vehicles
Pneumatic rear suspension 6x2 P/PT vehicles
Pneumatic rear suspension 6x2 P/PS vehicles
Pneumatic rear suspension 6x2 P/FP/FS vehicles (version for 3800 to 5500 wheel bases)
Pneumatic rear suspension 6x2 P/FP/FS vehicles (version for 5700 to 6050 wheel bases)
Pneumatic rear suspension 6x4 P vehicles
REMOVAL-REFITTING OF FRONT LEAF SPRING
Removal
Refitting
REMOVING-REFITTING FRONT SUSPENSION BARS
Removing longitudinal bars
Removing transverse bar
Refitting
REAR SUSPENSIONS
Removal
Refitting
REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM
REMOVING-REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM
REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM
REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM
Removal
Refitting
REPLACING THE SUSPENSION ARM FLEXIBLE PIN
Dismounting
Mounting
REPLACING TRIANGULAR SWINGING ARM BALL ARTICULATED JOINT
Dismounting
Mounting
STABILIZER BAR
FRONT STABILIZER BAR
CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)
REAR STABILIZER BAR
REAR ADDED AXLE STABILIZER BAR (6x2P vehicles)
Removal
Refitting
RUBBER BUSHINGS
Replacing front stabilizer bar rubber bushings
Replacing rear stabilizer bar rubber bushings
SHOCK ABSORBERS
Removal-refitting
Central added axle shock absorbers
Rear axle shock absorbers
Rear added axle shock absorbers 6x2 P vehicles)
Removal
Refitting
CHASSIS FRAME ADJUSTMENT
SECTION 10 - Wheels and tyres
Wheels and tyres
DESCRIPTION
CHARACTERISTICS AND DATA
Tyre inflation pressures
TOOLS
DIAGNOSTICS
Main operating faults of a mechanical nature
STATIC BALANCING OF THE WHEELS
CORRECTING RESIDUAL STATIC IMBALANCE
TYRE PRESSURE
HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE
SECTION 11 - Steering
Steering
DESCRIPTION
SPECIFICATIONS AND DATA
Scheme of the steering control of vehicles with mechanical front suspension
Vehicle steering control diagram with front air suspension and longitudinal bars
Vehicle steering control diagram with front air suspension and leaf springs
Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with mechanical front suspension
Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with pneumatic front suspension
Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with pneumatic front suspension and longitudinal bars
Scheme of the steering control of 6x2 c vehicles - having a steering central axle -with mechanical front suspension
DIAGNOSTICS
Main operating faults of a mechanical nature
TIGHTENING TORQUES
TOOLS
REMOVING-REFITTING THE POWER STEERING SYSTEM
Removal
Refitting
Removing-Fitting the Steering Lever
STEERING CONTROL
REMOVING-REFITTING THE STEERING CONTROL ASSEMBLY
Removal
Refitting
Changing the pneumatic cylinder
Removal
Refitting
Replacing direction indicator switch
Removal
BLEEDING THE POWER STEERING SYSTEM
MEASURING STEERING BOX PLAY AT THE STEERING WHEEL
CHECKING THE MAXIMUM PRESSURE OF THE POWER STEERING SYSTEM
Setting the automatic hydraulic steering limit
Check
ESP (Electronic Stability Program) CALIBRATION
SECTION 12 - Air system - Brakes
Air system - Brakes
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)
PIPINGS AND FITTINGS
In general
Flexible pipings replacementwith traditional fittings
Flexible pipings replacement with quick connection fittings
EBS (ELECTRONIC BRAKE SYSTEM)
EBS Benefits
Tractor and trailer compatibility at any time
Complete fault-diagnosis structures
OPERATING LOGIC
BRAKE SYSTEM
AUXILIARY BRAKE INTEGRATION
ESP (ELECTRONIC STABILITY PROGRAM)
“ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)
“ABS” (Anti-Lock Brake System)
EBL (Electronic Brakes Limiter)
Operating Logic
EBS SYSTEM COMPONENTS LOCATION ON VEHICLE (TRACTORS VARIANT)
LOCATION OF EBS SYSTEM COMPONENTS ON THE VEHICLE (TRUCKS VARIANT)
BRAKING SCHEMES OF EBS SYSTEMS
Theoretical scheme of EBS system for 4x2 vehicles (tractors)
EBS working diagram for 6x2p vehicles (tractors)
Theoretical scheme of EBS system for 6x2p vehicles (tractors)
Theoretical scheme of EBS system for 6x2 C vehicles (tractors)
Theoretical scheme of EBS system for 4x2 vehicles (trucks)
EBS working diagram for 6x2p vehicles (trucks)
Working diagram of EBS system for 6x2p vehicles (trucks)
LOCATION OF ABS - EBL SYSTEM COMPONENTS (TRACTOR VARIANT)
BRAKING SCHEMES OF ABS - EBL - ASR SYSTEMS
Working diagram of ABS-EBL-ASR system for 4x2 vehicles (trucks and tractors)
Working diagram of ABS-EBL-ASR system for 6x2p vehicles (trucks)
Working diagram of ABS-EBL-ASR system for 6x2p vehicles (trucks)
Working diagram of ABS-EBL-ASR system for 6x2C vehicles (tractors)
Working diagram of ABS-EBL-ASR system for 6x4 vehicles (trucks and tractors)
BRAKING SCHEMES OF ABS - EBL SYSTEMS
Working diagram of ABS-EBL system for 4x2 vehicles (trucks and tractors)
Working diagram of ABS-EBL system for 6x2C vehicles (tractors)
Working diagram of ABS-EBL system for 6x2p vehicles (trucks)
Working diagram of ABS-EBL system for 6x2p vehicles (trucks)
Working diagram of ABS-EBL system for 6x4 vehicles (trucks and tractors)
DESCRIPTION
Service braking
Emergency braking
Exhaust brake
Parking brake
BRAKES
Disc Brakes
Drum Brakes
DIAGNOSTICS
Diagnosis Instruments
Cluster Diagnosis
Troubleshooting via DTC-FMI codes
TIGHTENING TORQUES
TOOLS
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM
SPECIFICATIONS AND DATA - BRAKES
CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM
MAIN COMPONENTS OF THE BRAKING SYSTEM
Compressor
Head locking screw tightness
Fault diagnosis
A.P.U. (Air Processing Unit)
Duplex control valve (vehicles without EBS)
Fault Diagnosis (vehicles without EBS)
CBU - Central Brake Unit (vehicles with EBS)
Relay valve (vehicles without EBS)
Proportional relay valve for front axle (vehicles with EBS)
Fault Diagnosis (vehicles without EBS)
Coupling heads
Redundancy valve (for 4x2 and 6x2 trucks)
ABS-EBS solenoid valve
Dual stop valve
Triple servo control valve (vehicles without EBS)
Predominance control
Fault Diagnosis
Trailer servo control valve (vehicles with EBS)
Parking brake hand control valve (vehicles suited to towing)
Pressure test point valve
Manual control valve to slow down the trailer (optional extra)
Fault Diagnosis (parking brake control valve)
Controlled pressure valve
Fault Diagnosis
Check valve (vehicles suited to towing)
Low-pressure switch
Electro-pneumatic valve for ASR
Speed sensor
Phonic wheels
Electronic control unit
Pressure sensor
Diaphragm brake cylinder (for front and added front axle disc brake)
Combined brake cylinder (for front and rear disc brake)
Combined brake cylinder (for front and rear drum brake)
Combined cylinder emergency brake release device
Repair operations
Fault diagnosis
ESP SYSTEM COMPONENTS
ESP SYSTEM SELF-LEARNING AND CALIBRATION
DISC BRAKES KNORR TYPE (CALIPER SN7)
Operation (See previous figure)
CHECKS
Checking the automatic play recovery system efficiency
Brake caliper components
Check of braking seals thickness
OVERHAULING FRONT DISC BRAKES
Replacing brake linings
Removing and refitting brake callipers
Removal
Refitting
Removing and refitting wheel hubs
Removal
Refitting
BRAKE CALIPER OVERHAUL
Disassembly
Component part cleaning and check
Assembly
OVERHAULING REAR DISC BRAKES
Replacing brake linings
OVERHAULING BRAKE DISCS
TURNING AND GRINDING BRAKE DISCS
DRUM BRAKES
OVERHAULING THE DRUM BRAKES
Removing the rear drum brakes
Turning drums
Replacing brake linings
Assembly
SECTION 13 - Bodywork - Chassis frame
Bodywork - Chassis frame
CAB
General information
FEATURES AND DATA
TOOLS
TIGHTENING TORQUES
REPAIR WORK
BUMPER
Removal
Refitting
CABIN
Removal
Refitting
REPLACING THE FRONT SHOCK ABSORBER
Removal
Refitting
REPLACING THE CAB SUSPENSION FRONT MOUNTING RUBBER-TYPE BUSHINGS
Removal
Refitting
REPLACING THE CAB FRONT MOUNT BUSHINGS
Removal
Refitting
REMOVING - REFITTING THE STABILIZER BAR
Removal
Refitting
CHANGING THE REAR SHOCK ABSORBER
Removal
Refitting
CHANGING THE CAB LOCK
Removal
Refitting
CHANGING THE SWINGING BRACKET BUSHING
Removal
Refitting
Adjusting the front levelling valve linkwork
ELECTRICALLY DRIVEN CAB TILT
MANUALLY DRIVEN CAB TILT
Removal
Refitting
Checking the oil level
Periodic level check
MANUALLY DRIVEN CAB TILT
REPLACING HYDRAULIC CAB TILT CYLINDER
Removal
Refitting
Checking oil level
Bleeding cab tilt system
Bleeding air frommanual drive pump (point 1)
Bleeding air from cab tilting cylinder (point 2)
Bleeding air from secondary circuit (point 3)
Bleeding air fully
REPLACING THE WIND SHIELD
Removal
Refitting
REPLACING THE WINDING WINDOW
Removal
Refitting
REPLACING THE WINDOW WINDER
Removal
Refitting
REPLACING THE DOOR LOCK
Removal
Refitting
REPLACING THE OUTSIDE HANDLE OF THE DOOR
Removal
Refitting
CHANGING THE INSIDE HANDLE
Removal
Refitting
CHANGING THE SIDE MIRRORS
Removal
Refitting
CHANGING THE DOOR
Removal
Refitting
REPLACING THE FIXED WINDOW
Removal
Preparing the window bay
Preparing the window
Refitting
INSTRUMENT PANEL
Removal
Refitting
CENTRAL INSTRUMENT PANEL
Removal
Refitting
FASCIA COVERING
Removal
Refitting
AIR INTAKE LID REMOVAL AND REFITTING
Removal
Refitting
AIR INTAKE LID MOTOR REPLACEMENT
Removing
Refitting
WINDSCREEN SUN VISOR REEL REMOVAL/REFITTING
Removal
Refitting
WINDSCREEN SUN VISOR REEL MOTOR REPLACEMENT
Removing
Refitting
REPLACING SIDE DOOR OPENING CONTROL CABLE
Removing
Fitting
Lid opening control adjustment
CABIN REFRIGERATOR
Preliminary checks
Removal
Refitting
OVERHAULING
Removing
Fan disassembling
Disassembling the anti-tipping probe with electronic circuit on the control unit
Electronic control unit disassembling
Checks
Fitting
DRIVER’S SEAT
Removal
Refitting
Component layout
REMOVING THE DRIVER’S SEAT
Removal
Fitting
Removing-fitting the cushion slider
Removal
Fitting
Removing-fitting the seatbelt
Fitting
Removing-fitting seatbelt connection and right-hand side upholstery
Fitting
Removing - fitting the left-hand side upholstery, IPS valve and heating switch
Removal
Fitting
Removing - fitting the back
Removal
Fitting
Removing - fitting the back adjustment lever
Removal
Fitting
Removing - fitting the height adjustment device
Removal
Fitting
Removing - fitting the seat angle adjustment device
Removal
Fitting
Removing - fitting the flexible cable of the shock absorber adjustment device
Removal
Fitting
Removing - fitting the back adjustment lever segment
Removal
Fitting
Removing - fitting the air spring
Removal
Fitting
Removing - fitting the shock absorber
Removal
Fitting
Removing - fitting the height adjustment valve
Removal
Fitting
Removing - fitting the height locking system
Removal
Fitting
Removing - fitting the flexible cable of the horizontal lever suspension
Removal
Fitting
Removing - fitting the fast lowering magnetic valve
Removal
Fitting
Removing - fitting the fast lowering switch
Removal
Fitting
Removing - fitting the lumbar support device
Removal
Fitting
Removing - fitting the back upholstery
Removal
Fitting
Removing - fitting the cushion upholstery
Removal
Fitting
CAB AIR-CONDITIONING
General
VENTILATION
Description
AIR-CONDITIONING AND HEATING
Description
Air-conditioning
Heating
Air-conditioning controls assembly
Automatic
Manual
Heating and ventilation
COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)
HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)
MAIN COMPONENTS OF AIR CONDITIONER AND HEATER (WEBASTO)
Outside temperature sensor
Inside temperature sensor
Three-way solenoid valve (WEBASTO)
Compressor
Dehumidifier filter and safety pressure switches
Geared motors
Evaporator temperature sensor
Blown air temperature sensor
Expansion valve
ADDITIONAL AIR HEATER SYSTEM (on request)
Description
Operation
DIAGNOSTICS
Troubleshooting
Introduction
CHARACTERISTICS AND DATA
GENERAL WARNINGS
TIGHTENING TORQUES
REPAIR OPERATIONS
HEATER
Removal
Refitting
ADDITIONAL AIR HEATER SYSTEM
Removal
Refitting
DEFROST CONTROL MOTOR
Removal
Refitting
AIR RECIRCULATION DOOR CONTROL MOTOR
Removal
Refitting
AIR MIXING DOOR CONTROL MOTOR
Removal
Refitting
HEATER RADIATOR TEMPERATURE SENSOR
Removal
Refitting
FLOOR AIR DOOR CONTROL MOTOR
Removal
Refitting
ELECTRIC FAN
Removal
Refitting
HEATER RADIATOR
Removal
Refitting
TAP
Removal
Refitting
POLLEN FILTER
Removal
Refitting
AIR-CONDITIONER COMPRESSOR
Removal
Refitting
AIR-CONDITIONER CONDENSER
Removal
Refitting
OUTSIDE AIR TEMPERATURE SENSOR
Removal
Refitting
REPLACING THE ELECTROMAGNETIC CLUTCH
PROCEDURE FOR DRAINING AND RECHARGING AIR CONDITIONING SYSTEMS WITH RECHARGING STATION 99305146 AND RECOVERY OF R134A COOLANT
SAFETY STANDARDS
CONTROL FASCIA
OPERATION FLOW CHART
RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM
CREATING A VACUUM IN THE SYSTEM
RESTORING OIL IN THE SYSTEM
FILLING THE SYSTEM WITH REFRIGERANT
CHECKING THE PRESSURES IN THE SYSTEM
OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM
PROCEDURE FOR DRAINING AND RECHARGING AIR CONDITIONING SYSTEMS WITH RECHARGING STATION 99305148 AND RECOVERY OF R134A COOLANT
Main components
SAFETY STANDARDS
CONTROL PANEL
Keypad functions
Emergency warning light panel
PRELIMINARY CHECKS
AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
LEAK FINDER FOR AIR-CONDITIONING SYSTEMS WITH HFC R134A (99305147)
DIAGNOSTICS INSTRUMENTS
MODUS - IT 2000 - E.A.SY.
MODUS
IT 2000
E.A.SY.
CHASSIS
TIGHTENING TORQUES
CHASSIS FRAME
REPAIRS
CHECKS
Measuring the bend of the chassis frame downwards or upwards
Measuring the side bend of the chassis frame
Measuring the movement of the chassis frame
Measuring the torsion of the chassis frame
PRECAUTIONS
Welds on the chassis frame
SECTION 14 - Scheduled maintenance
Scheduled maintenance
MAINTENANCE SERVICES CHART
CHECKS AND/OR MAINTENANCEWORK
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCEWORK
MAINTENANCE WORK
CHECKS AND/OR MAINTENANCE WORK
M1 SERVICE
M2 SERVICE
EXTRA PLAN MAINTENANCE
EP1 SERVICE
EP2 SERVICE
EP3 SERVICE
EP4 SERVICE
T1 SERVICE
T2 SERVICE
T3 SERVICE
T4 SERVICE
SECTION 15 - Electric/Electronic system
Electric/Electronic system
GENERAL WARNINGS FOR ELECTRICAL/ELECTRONIC COMPONENTS
COMPONENT CODE
MAIN CHANGES
CAN LINES
CAN LINE ASSEMBLY DRAWING
POWER NETWORK
MASS POINTS
ELECTRICAL EQUIPOTENTIAL BRAID
28 V - 40 A ÷ 90 A “BOSCH”ALTERNATOR
24V - 5,5 KW “NIPPONDENSO” STARTER MOTOR
JUNCTION CONNECTORS
CONNECTOR FOR BODYBUILDERS (CAB)
CONNECTOR FOR BODYBUILDERS (CHASSIS)
CONNECTOR FOR BODYBUILDERS (CHASSIS-TRUCK)
DIAGNOSIS OUTLET
OBD CONNECTOR
RECEPTACLE CONNECTOR
REMOTE-CONTROL SWITCH / FUSE HOLDER CONTROL UNIT
FUSES
SUPPLEMENTARY REMOTE SWITCHES
SUPPLEMENTARY FUSES (70000)
INSTRUMENT BOARD
CONTROLS ON THE CENTRAL BOARD
CONTROLS ON THE STEERING WHEEL
REARVIEW MIRRORS AND WINDOW REGULATOR CONTROL ADJUSTMENT
EXTERNAL REARVIEW MIRRORS HEATING
LIGHT CONTROL
ENGINE BRAKE CONTROL AND INTARDER
GEAR SELECTION FUNCTION
FUNCTION ENGAGING EMERGENCY MODE (LIMP HOME)
MULTIPLEX SYSTEM
Cluster
Cluster (optical indicators)
Pin-out connectors
Display operation
Display structure
Optical status indicators on display
Display instruments
Body computer
F.F.C. - R.F.C. (Front Frame Computer - Rear Frame Computer)
F.F.C. (Services / Engine)
R.F.C.
D.D.M. / P.D.M. / Cab module
D.D.M. / P.D.M.
P.D.M.
D.D.M.
C.B. (Cab module) Opt
S.W.I. (Steering wheel / steervator interface)
SPIRALED CONTACT
STEERING COLUMN (COMPONENT LOCATION)
B.M. (BED MODULE)
TACHOGRAPH
EDC (ECM) SYSTEMS
SYSTEM COMPONENTS
VCM (VEHICLE CONTROL MODULE) ELECTRONIC CONTROL UNIT
IMMOBILIZER
ABS-EBL ANTI—LOCK BRAKE SYSTEM - ELECTRONIC BRAKE LIMITER SYSTEM
BRAKE SYSTEM EBS2 (ELECTRONIC BRAKE SYSTEM - 2)
COMMON COMPONENTS
AXLE LOAD METER
PRESSURE SENSORS
EUROTRONIC AUTOMATIC TRANSMISSION
ELECTRONIC CENTER
TRANMSISSION ACTUATOR
LOCATION ON THE VEHICLE
CLUTCH ACTUATOR
INTARDER
DMI (DATA MANAGEMENT INTERFACE) (PTO) ELECTRONIC CONTROL UNIT
AUTOMATIC AIR CONDITIONER
MANUAL AIR CONDITIONER
HYDRONIC D 10 WATER HEATER
COMPONENTS LOCATION
SYSTEM COMPONENTS
SCR (SELECTIVE CATALYTIC REDUCTION) SYSTEM - DENOX 2
CENTRAL LOCKING WITH REMOTE CONTROL
DIAGNOSTIC
INFORMATION ON CLUSTER
CIRCUIT CARD
Card 1 Power supply voltage (+30)
Card 2 Power supply voltage (+30) after TGC
Card 3 Power supply voltage (+30) after TGC
Card 4 Power supply voltage (+30) after TGC
Card 5 Power supply voltage (+15)
Card 6 Power supply voltage (+15)
Card 7 Body Computer (BC)
Card 8 Body Computer (BC)
Card 9 Body Computer (BC)
Card 10 Body Computer (BC)
Card 11 Steering Wheel Interface (SWI)
Card 12 Front Frame Computer (FFC)
Card 13 Front Frame Computer (FFC)
Card 14 Rear Frame Computer (RFC)
Card 15 Rear Frame Computer (RFC)
Card 16 Cabin Module (CM)
Card 17 Driver Dool Module (DDM) / Bed Module (BM)
Card 18 Passenger Door Module (PDM)
Card 19 Instrument Cluster (IC) / Tachograph
Card 20 Can lines “ICB” - “IDB” - “FMB”
Card 21 Can lines “SB” (EBS2-ABS)
Card 22 Can lines “BCB”
Card 23 Can lines “VDB”
Card 24 Can lines “ECB”
Card 25 Ecas 4x2 P (Tractor)
Card 26 Ecas 4x2 FP (Tractor)
Card 27 Ecas 4x2 P / FP (Truck)
Card 28 Ecas 6x4 P
Card 29 Ecas 6x2 P / FP / C (3rd axle liftable)
Card 30 Ecas 6x2 P / FP (3rd axle not liftable)
Card 31 Ecas 6x2 C (Tractor - 3rd axle not liftable)
Card 32 Retarder ZF
Card 33 ABS
Card 34 EBS2
Card 35 Eurotronic II
Card 36 Cooling / Engine ventilation
Card 37 Hand-operated conditioning system
Card 38 Automatic conditioning system
Card 39 Automatically controlled supplementary water heater
Card 40 Hand-operated supplementary water heater
Card 41 Supplementary air -operated heater (manual / automatic)
Card 42 EDC (connector B)
Card 43 EDC (connector A)
Card 44 DMI PTO control unit
Card 45 Radio receiver
Card 46 ADR (2001 94/9/EG)
Card 47 ADR (OPT. 0129)
Card 48 Electronic Control Unit VCM
Card 49 Electronic Control Unit DCU 15 (System SCR)
BLOCK DIAGRAM
Diagram 1: A. Start-up B. Engine revs signal for body builders C. Recharge
Diagram 2: A. EDC power supply B. EDC / VCM failure C. Snow chains fitted D. All-wheel drive ON
Diagram 3: A. Cruise Control B. Accelerator pedal sensor C. Preheating
Diagram 4: ABS/EBS
Diagram 5: A. Voltmeter B. Revs counter C. Engine water temperature D. Fuel level
Diagram 6: A. Engine oil level indication B. Engine oil pressure indication C. windscreen washer fluid level indication D. Power steering oil level indication E. Engine water indication
Diagram 7: A. Brake wear signal (ABS) B. Brake wear signal (EBS) C. Geared-down speed ON signal D. Oil filter clogging signal E. Air filter clogging signal
Diagram 8: A. Hand brake ON signal B. Transverse differential lock (on-road) C. Transverse differential lock (off-road) D. Longitudinal differential lock E. Signalling the presence of water in the diesel fuel filter
Diagram 9: External lights
Diagram 10: A. Low-beam headlights B. High-beam headlights C. Fog lights/rear fog lights
Diagram 11: A. Brake lights B. Brake lights C. Reversing lights D. Fifth wheel lighting
Diagram 12: A. Indicator/emergency lights B. Headlamp adjustment
Diagram 13: Internal lights
Diagram 14: A. Windscreen wiper B. Horn C. Counter
Diagram 15: TGC
Diagram 16: A. Sunroof B. Headlamp washer
Diagram 17: Tachograph
Diagram 18: A. Diagnosis B. Diagnosis (optical indicators) C. Engine fan control D. Manual air conditioner control
Diagram 19: A. Rear-view mirror control B. Window regulator control
Diagram 20: A. Central locking control
Diagram 21: A. ECAS (optical indicators) B. ABS (optical indicators)
Diagram 22: A. EBS (optical indicators) B. Heated windscreen C. P.T.O.
Diagram 23: A. Decelerator (optical indicator) B. Diesel fuel filter clogged C. Cabin tilting
Diagram 24: A. Brake air pressure indication B. Front/rear axle load indication C. External temperature indication
Diagram 25: A. Full/partial km displaying B. Gear engaged displaying C. Speed limiter D. Clutch switch signal
Diagram 26: A. Engine oil temperature signal B. Rotary lamp control C. Sun visor control

-