Iveco EuroCargo Tector 12 to 26 t Workshop Service Repair Manual

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This Workshop Service Repair manual PDF download for the Iveco EuroCargo Tector 12 to 26 t 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 Specifications
SECTION 2 - Engine
SECTION 3 - Clutch
SECTION 4 - Gearbox
SECTION 5 - Propeller shafts
SECTION 6 - Rear axles
SECTION 7 - Front Axles
SECTION 8 - Suspensions
SECTION 9 - Wheels and Tires
SECTION 10 - Steering
SECTION 11 - Pneumatic System - Brakes
SECTION 12 - Body - Chassis
SECTION 13 - Service plan


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 603.93.111
Total Pages : 886


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EUROCARGO TECTOR 12 TO 26 t
REPAIR MANUAL
SPECIAL REMARKS
Graph and symbols
UPDATING DATE
INDEX OF SECTIONS
SECTION 1 - General Specifications
General Specifications
COMPOSITION OF THE MODELS
IDENTIFICATION DATA AND LOCATION ON VEHICLE
FILLING UP
INTERNATIONAL LUBRICANT DESIGNATION
SECTION 2 - Engine
Engine
ENGINE IDENTIFICATION CODES
MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE
WARNINGS
High pressure CP3 pump
Rail and fittings
Injector
Low pressure tubing
High pressure tubing
ENGINE REMOVAL-REFITTING
Removal
Refitting
Tests and checks
Engine cooling filling system
Air bleeding from fuel system
Air bleeding from hydraulic power steering system
INJECTORS REPLACEMENT
Removal
Refitting
Tests and checks
REPLACING SEAL RING FRONT COVER DRIVING SHAFT
REPLACING SEAL RING FLYWHEEL HOUSING BOX
CYLINDER HEAD REM OVAL/REFITTING
Removal
Refitting
Tests and checks
Engine F4 AE 0481
GENERAL SPECIFICATIONS
ASSEMBLY DATA - CLEARANCES
TIGHTENING TORQUE
AUXILIARY COMPONENTS
TOOLS
ENGINE OVERHAUL
DISASSEMBLY OF THE ENGINE AT THE BENCH
REPAIR INTERVENTIONS
CYLINDER GROUP
Controls and measurements
Head face check on the cylinder group
TIMING SYSTEM
Camshaft
Cam lift check and pin alignment check
BUSHES
Bush replacement
Tappets
Fitting tappets - camshaft
OUTPUT SHAFT
Measuring journals and crankpins
Replacing oil pump control gear
Fitting main bearings
Finding journal clearance
Checking output shaft shoulder clearance
CONNECTING ROD - PISTON ASSEMBLY
Pistons
Measuring piston diameter
Piston pins
Conditions for proper pin-piston coupling
Split rings
Connecting rods
Bushes
Checking connecting rods
Checking torsion
Checking bending
Fitting connecting rod-piston assembly
Connecting rod-piston coupling
Fitting split rings
Fitting connecting rod-piston assembly into cylinder barrels
Finding crankpin clearance
Checking piston protrusion
Timing gear case
Timing
Flywheel housing
ENGINE FLYWHEEL
Replacing engine flywheel ring gear
CYLINDER HEAD
Removing the valves
Checking cylinder head wet seal
Checking cylinder head supporting surface
VALVES
Removing carbon deposits, checking and grinding valves
Checking clearance between valve stem and valve guide and valve centering
VALVE GUIDE
VALVE SEATS
Regrinding - replacing the valve seats
VALVE SPRINGS
FITTING CYLINDER HEAD
Refitting the cylinder head
Fitting injectors
RODS
Rocker assembly
Tappet clearance adjustment
Intake manifold
Wiring support
LUBRICATION
OIL PUMP
HEAT EXCHANGER
Oil pressure relief valve
Oil vapour recycling
COOLING SYSTEM
Water Pump
Viscous fan
Thermostat
BOOSTER
Turbosupercharger
Description
TURBOSUPERCHARGER ACTUATOR
Check and adjustment
Actuator replacement
TURBOSUPERCHARGER LAYOUT
COMMON RAIL
General Specifications
FEED SYSTEM
FEED SYSTEM LAYOUT
FUEL PREFILTER
FUEL FILTER
MECHANICAL SUPPLY PUMP
Normal operating conditions
Overpressure condition at outlet
Drain conditions
CP3 HIGH-PRESSURE PUMP
HIGH-PRESSURE PUMP - INSIDE STRUCTURE
Operating principle
Operation
RAIL
OVERPRESSURE VALVE
FLOWLIMITERS
INJECTOR
Injector in rest position
Injection start
Injection end
PRESSURE LIMITER FOR FUEL RETURN
Engine F4 AE 0681
GENERAL SPECIFICATIONS
ASSEMBLY DATA - CLEARANCES
ENGINE F4AE0681 OVERHAUL
Engine removal at the bench
TIMING SYSTEM
Camshaft
BUSHES
CYLINDER HEAD VALVE SEATS
Cylinder head fastening screw tightening
LUBRICATION
COOLING SYSTEM
BOOSTER
Turbosupercharger
TURBOSUPERCHARGER ACTUATOR
Check and adjustment
TURBOSUPERCHARGER LAYOUT
Troubleshooting Guide
FOREWORD
Diagnosis through instruments
DIAGNOSTICS
SECTION 3 - Clutch
Clutch
DESCRIPTION
Clutch
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
TOOLS
REMOVAL AND REFITTING
Removal
Refitting
DRIVEN PLATE OVERHAUL
Damper hub check
Friction gaskets
BLEEDING AIR FROM CLUTCH CIRCUIT
THRUST BEARING REMOVAL - REFITTING
REPLACING CLUTCH SHAFT SUPPORT BEARING
HYDRAULIC CONTROL
Servo-assisted master cylinder (14” - 13”/14” clutches)
Connections
Master cylinder (15”/16” clutches)
Slave cylinder (14” - 13”/14” clutches)
Clutch wear layout (13”/14” - 14” clutches)
Operating cylinder (15”/16” clutches)
WEAR INDICATOR REFITTING AND ADJUSTMENT (15/16” clutches)
ADJUSTING OPERATING CYLINDER PUSH ROD (New 15/16” clutch)
CHECKING AND ADJUSTING THE CLUTCH PEDAL (14” - 13”/14” clutches)
Clutch pedal stop
Clutch pedal idle stroke
CHECKING AND ADJUSTING THE CLUTCH PEDAL (15”/16” clutches)
Clutch pedal stop
Clutch pedal idle stroke
SECTION 4 - Gearbox
Gearbox
DIAGNOSTICS
Gears control connection
Gearbox control tie-rods adjustment
Gearbox 2855.6
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
GEARBOX 2855.6 DISENGAGEMENT/RE-ENGAGEMENT
Disengagement
Re-engagement
GEARBOX DISASSEMBLY
Checks
GEARBOX ASSEMBLY
Bearings pre-load adjustment for secondary shaft
PRIMARY SHAFT DISASSEMBLY
PRIMARY SHAFT ASSEMBLY
MOTION INLET SHAFT DISASSEMBLY
MOTION INLET SHAFT ASSEMBLY
Motion inlet shaft bearing adjustment
SECONDARY SHAFT DISASSEMBLY
SECONDARY SHAFT ASSEMBLY
INTERNAL DRIVE SHAFT DISASSEMBLY
INTERNAL DRIVE SHAFY ASSEMBLY
EXTERNAL CONTROL SHAFT DISASSEMBLY
EXTERNAL CONTROL BOX ASSEMBLY
Idle-R.M. switch adjustment
Gearbox 2865.6
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
GEARBOX 2865.5 DISENGAGEMENT/ RE-ENGAGEMENT
Disengagement
Re-engagement
GEARBOX DISASSEMBLY
Rear cover sealing gasket replacement
Checks
GEARBOX ASSEMBLY
Bearings pre-loading adjustment for secondary shaft
PRIMARY SHAFT DISASSEMBLY
PRIMARY SHAFT ASSEMBLY
MOTION ENTRY SHAFT DISASSEMBLY
MOTION ENTRY SHAFT ASSEMBLY
SECONDARY SHAFT DISASSEMBLY
SECONDARY SHAFT ASSEMBLY
INTERNAL CONTROL SHAFT DISASSEMBLY
INTERNAL CONTROL SHAFT ASSEMBLY
EXTERNAL CONTROL SHAFT DISASSEMBLY
EXTERNAL CONTROL BOX ASSEMBLY
Idle-R.M. switch adjustment
Gearbox 2870.9
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
GEARBOX 2870.9 DISENGAGEMENT/RE-ENGAGEMENT
Disengagement
Re-engagement
GEARBOX DISASSEMBLY
Checks
GEARBOX ASSEMBLY
Bearings pre-load adjustment for secondary shaft
Idle-Reverse Gear switch adjustment
PRIMARY SHAFT DISASSEMBLY
PRIMARY SHAFT ASSEMBLY
MOTION INLET SHAFT DISASSEMBLY
MOTION INLET SHAFT ASSEMBLY
Motion inlet shaft bearing adjustment
SECONDARY SHAFT DISASSEMBLY
SECONDARY SHAFT ASSEMBLY
INTERNAL DRIVE SHAFT DISASSEMBLY
INTERNAL DRIVE SHAFT ASSEMBLY
EXTERNAL DRIVE CASE DISASSEMBLY
EXTERNAL DRIVE CASE ASSEMBLY
EPICYCLIC REDUCTION GEAR ASSEMBLY
Operating diagrams about pneumatic epicyclic reduction gear drive circuit
DISASSEMBLY
Checks
ASSEMBLY
Gearbox 2895.9
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUE
TOOLS
GEARBOX DISENGAGEMENT/ RE-ENGAGEMENT
Disengagement
Re-engagement
GEARBOX DISASSEMBLING
Checks
GEARBOX ASSEMBLING
Adjusting transmission shaft bearing pre - load
Idle-R.M. switch adjustment
MAIN SHAFT DISASSEMBLING
MAIN SHAFT ASSEMBLING
INPUT SHAFT DISASSEMBLING
INPUT SHAFT ASSEMBLING
TRANSMISSION SHAFT
Bearing replacement
INTERNAL CONTROL SHAFT DISASSEMBLING
INTERNAL CONTROL SHAFT ASSEMBLING
EXTERNAL CONTROL BOX DISASSEMBLING
EXTERNAL CONTROL BOX ASSEMBLY
EPICYCLIC REDUCTION GEAR ASSEMBLY
Operating diagrams about pneumatic epicyclic reduction gear drive circuit
DISASSEMBLY
Checks
ASSEMBLY
Allison gearbox MD 3060P
DESCRIPTION
CHARACTERISTICS AND DATA
MAIN OPERATION ANOMALIES
TIGHTENING TORQUES
TOOLS
DISCONNECTING AND CONNECTING GEARBOX CONTROL MODULE AGAIN
Disconnecting Figure
Refitting
REPLACING SPEED SENSORS
Replacing turbine speed sensor
Engine revolutions sensor replacement
Replacing the output speed sensor
REPLACING OIL LEVEL SENSOR
REPLACING OIL SUCTION FILTER
REPLACING THE SOLENOID VALVES
REPLACING PLANE GASKETS IN GEARBOX CONTROL MODULE
REPLACING PRESSURE SWITCH F3
REPLACING THE SEAL RING ON THE OUTPUT SHAFT
Gearbox EATON FSO 5206B
DESCRIPTION
POSITION OF GEARSHIFT IDENTIFICATION TAG
SPECIFICATIONS AND DATA
Gear selection and engagement grid
TIGHTENING TORQUES
TOOLS
EXPERIMENTAL TOOLS
GEARSHIFT OVERHAUL
Checks
GEAR DRIVE CASE
Disassembling
Assembling
Refitting
Disassembling the gearbox
MOTION INLET SHAFT
Disassembling
Assembling
OUTPUT SHAFT
Disassembling
Assembling
INTERNAL DRIVING SHAFT
Disassembling
Assembling
Gearbox assembling
Adjusting the axial play of countershaft bearings
SECTION 5 - Propeller shafts
Propeller shafts
DESCRIPTION
PROPELLER SHAFT LAYOUT ON VEHICLES
PROPELLER SHAFT SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
SLIDING PROPELLER SHAFT REMOVAL-REFITTING
Removal
Refitting
FIXED PROPELLER SHAFT REMOVAL- REFITTING
CHECKING PROPELLER SHAFTS ON VEHICLE
SECTION 6 - Rear axles
Rear axles
AXLES IN TANDEM Meritor SP 145 E
Axles in tandem (Intermediate) Meritor PD 145 E (R 2468)
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
EXPERIMENTAL TOOLS
INTERMEDIATE AXLE DISCONNECTION/ RECONNECTION (with Hendrickson suspensions)
Disconnection
Reconnection
SERVICING INTERMEDIATE AXLE ASSEMBLY PD 145 E (R 2468)
AIR BREATHER REMOVAL-REFITTING
SERVICING WHEEL HUBS
Checking wheel hub components
ASSEMBLING WHEEL HUBS
REMOVING DIFFERENTIAL GEAR - TRANSFER BOX (with rear axle on stand 99322215)
REFITTING DIFFERENTIAL GEAR - TRANSFER BOX (with rear axle on stand 99322215)
REPAIRING INTER-AXLE UNIT
Dismantling inter-axle unit
Checking inter-axle unit components
Fitting inter-axle unit
Adjusting drive input shaft bearing end float
Adjusting differential lock and inter-axle control pin end-stop
REPAIRING MAIN DIFFERENTIAL DISMANTLING DIFFERENTIAL CASING
Dismantling gear cage
Checking differential components
Assembling gear cage
ASSEMBLING DIFFERENTIAL CASING
Calculating bevel pinion position in differential casing
COMPUTATIONAL EXAMPLES
Adjusting the cap gap
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
REMOVING-SERVICING-REFITTING INTER-AXLE OUTPUT SHAFT
Tandem axles (Rear) Meritor PR 140 E (R 0868)
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
SERVICING REAR AXLE ASSEMBLY PR 140 E (R 0868)
AIR BREATHER REMOVAL/ INSTALLATION
OVERHAULING WHEEL HUBS
REMOVING DIFFERENTIAL (with axle on stand 99322215)
REFITTING DIFFERENTIAL (with axle on stand 99322215)
REPAIRING DIFFERENTIAL
Removing differential lock
Dismantling differential casing
Dismantling gear cage
Dismantling bevel pinion support
Checking differential components
Assembling gear cage
Specimen calculations
Assembling differential casing
ADJUSTING THE CAP GAP
CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
SECTION 7 - Front Axles
Front Axles
Front axle 5845
DESCRIPTION
Characteristic angles
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
TOOLS
AXLE DETACHMENT AND REATTACHMENT
Front axle detachment
Front axle reattachment
CHECKS ON THE VEHICLE
Tie rods
Articulated joints
Check clearance of articulated joints
FRONT WHEEL SET UP
Setting of clips and headlights
Electronic compensation for rim maladjustment
Wheel alignment
Toe-in check
Check of wheel inclination (Camber)
Check upright angle of inclination (King Pin) and clearance angle (Caster)
Check steering angles
OVERHAUL OF THE FRONT AXLE ASSY
DETACHMENT ANDREATTACHMENT OFWHEEL HUBS
Detachment
Replacement of sealing ring
Replacement of wheel stud bolts
Wheel hub reattachment
Check wheel hub end play
Rolling torque survey
Cross tie rod detachment and reattachment
Replacement of cross tie rod articulated pins
Cross tie rod lever detachment and reattachment
Longitudinal tie rod lever detachment and reattachment
Steering knuckle pin detachment and reattachment
Detachment
Steering knuckle pin bearing replacement
Reattachment
Check and adjustment of clearance between steering knuckle and axle
CHECKS AND MEASUREMENTS OF THE AXLE UNIT
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins.
Check hole inclination for steering knuckle pins
Front axles 5842/5 - 5851/5
DESCRIPTION
Characteristic angles
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
TOOLS
FRONT WHEEL SET UP
Setting of clips and headlights
Electronic compensation for rim maladjustment
Wheel alignment
Toe-in check
Check of wheel inclination (Camber)
Check upright angle of inclination (King Pin) and clearance angle (Caster)
Check steering angles
OVERHAUL OF THE FRONT AXLE ASSY
Removal and refitting of wheel hubs
Sealing ring replacement
Wheel hubs refitting
End play adjustment of wheel hub bearings
Rolling torque survey
REPLACEMENT OFWHEEL HUB BEARINGS
REPLACEMENT OF STUD BOLTS FOR WHEEL CLAMPING
CROSS TIE ROD REMOVAL AND REFITTING
REPLACEMENT OF CROSS TIE ROD ARTICULATED JOINTS
CROSS TIE ROD LEVER REMOVAL AND REFITTING
LONGITUDINAL TIE ROD LEVER REMOVAL AND REFITTING
STEERING KNUCKLE PIN REMOVAL AND REFITTING
Removal
Refitting
Check and adjustment of clearance between steering knuckle and axle
STEERING KNUCKLE PIN BEARING REPLACEMENT
CHECKS AND MEASUREMENTS OF THE AXLE UNIT
Check flatness of leaf spring surfaces compared to holes for steering knuckle pins
Check hole inclination for steering knuckle pins
Front axle 5871/5
DESCRIPTION
Characteristic angles
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
TOOLS
FRONT WHEEL SET UP
Setting of clips and headlights
Electronic compensation for rim maladjustment
Wheel alignment
Toe-in check
Check of wheel inclination (Camber)
Check upright angle of inclination (King Pin) and clearance angle (Caster)
Check steering angles
OVERHAULING THE FRONT AXLE ASSEMBLY (Mechanical and pneumatic suspension)
OVERHAULING THE FRONT AXLE ASSEMBLY
Removing the wheel hubs
Replacing the wheel hub bearings
Replacing seal
Replacing wheel studs
Refitting wheel hubs
Adjusting wheel hub bearing end play
Checking the rolling torque
REMOVING AND REFITTING TRACK ROD
REPLACING TRACK ROD BALL JOINT
CHECKING BALL JOINT END PLAY FOR TRACK ROD AND DRAG LINK
Replacing ball joint
REMOVING AND REFITTING TRACK ROD ARMS
REMOVING AND REFITTING DRAG LINK ARM
REMOVING AND REFITTING THE KINGPIN
Removing
Refitting
Checking and adjusting play between stub axle and axle
STEERING KNUCKLE PIN BEARING REPLACEMENT
CHECKS AND MEASUREMENTS ON AXLE BODY
Checking surface flatness of leaf spring seating with respect to holes for kingpins
Checking inclination of holes for kingpins
SECTION 8 - Suspensions
Suspensions
Front and rear mechanical suspensions
DESCRIPTION
FRONT LEAF SPRINGS
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA
FRONT SUSPENSION - Models 110EL..-120EL..
FRONT SUSPENSION - Models 120E..-130E..
FRONT SUSPENSION - Models 120E..-120E..D-130E..-130E..D-130E18RS-150E..-150E..RS
FRONT SUSPENSION - Models 180E..-260E..
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA
FRONT SUSPENSION - Models 120E..-130E..
FRONT SUSPENSION - Models 120E..D-130E..D-150E..
FRONT SUSPENSION - Models 180E..
FRONT SHOCK ABSORBERS
Assembly diagrams
SPECIFICATIONS AND DATA
REAR LEAF SPRINGS
PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA
REAR SUSPENSION - Models 110EL..-120EL..
REAR SUSPENSION - Models 120E..-130E..
REAR SUSPENSION - Models 120E..-130E..- 130E18RS
REAR SUSPENSION - Models 120E..-120E..D-130E..-130E..D-150E..-150E18RS
REAR SUSPENSION - Models 180E..
SEMI-ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA
REAR SUSPENSION 120E..-130E..
REAR SUSPENSION - Models 120E..D-130E..D-150E..
REAR SUSPENSION 180E..
HENDRICKSON REAR SUSPENSION Models 260E..
Disconnection
Reconnection
REAR SHOCK ABSORBERS
Assembly diagrams
SPECIFICATIONS AND DATA
Shock absorber features and data - Models 260E..
DIAGNOSTICS
TIGHTENING TORQUES
FRONT MECHANICAL SUSPENSION REMOVAL-REFITTING
Removal
Refitting
REAR MECHANICAL SUSPENSION REMOVAL-REFITTING
Removal
Refitting
FRONT SHOCK ABSORBERS
Removal
Refitting
REAR SHOCK ABSORBERS
Removal
Refitting
FRONT SWAY BAR
Removal
Refitting
REAR SWAY BAR
Removal
Refitting
REPAIRS
Leaf spring disassembly
Checks
BUSHING REPLACEMENT
Removal
Refitting
Leaf spring assembly
Front and rear pneumatic suspensions
PNEUMATIC SUSPENSIONS
INTRODUCTION
PNEUMATIC SUSPENSION ASSEMBLIES
FRONT PNEUMATIC SUSPENSION
LEAF SPRING SPECIFICATIONS AND DATA
FRONT SUSPENSION - MODELS 120E..FP/130E..FP/150E..FP
FRONT SHOCK ABSORBERS
Assembly diagrams
SPECIFICATIONS AND DATA
REAR PNEUMATIC SUSPENSION
REAR SHOCK ABSORBERS
Assembly diagrams
SPECIFICATIONS AND DATA
Electronically controlled rear pneumatic suspension diagram (NEWAY for Models 110EL..P-120EL..P)
Cable-and-trunk diagram of pneumatic rear suspensions (For Models 120E..P-130E..P-150E..P-180E..P)
Electronically controlled FULL PNEUMATIC suspension diagram (For Model 120E..FP-130E..FP-150E..FP)
Rear pneumatic suspension vehicle wiring diagram
Front and rear pneumatic suspension vehicle wiring diagram
CHASSIS LIFTING/LOWERING AND LEVELLING
Remote control
REMOTE CONTROL DESCRIPTION AND OPERATION
Lifting/lowering the chassis
Chassis self-leveling
Level ”M1” - ”M2”
VEHICLE MAIN COMPONENT ARRANGEMENT
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
TOOLS
MAIN PNEUMATIC SYSTEM COMPONENTS
Controlled-pressure valve
Low pressure indicator
Check valve
Electro-pneumatic front axle distributor for 4 x 2 FP vehicles
Operation
Front axle lifting
Front axle lowering
Self-leveling
Electro-pneumatic rear axle distributor for 4 x 2 P/FP vehicles
Operation
Rear axle lifting
Rear axle lowering
Self-leveling
Level sensor
Air springs
ECU
REAR PNEUMATIC SUSPENSIONS REMOVAL-REFITTING
Removal
Refitting
REAR SHOCK ABSORBERS
Removal
Refitting
REAR SWAY BAR
Removal
Refitting
REAR AIR SPRINGS
Removal
Refitting
FRONT SHOCK ABSORBERS
Removal
Refitting
FRONT AIR SPRINGS
Removal
Refitting
FRONT PNEUMATIC SUSPENSION REMOVAL-REFITTING
Removal
Refitting
FRONT SWAY BAR
Removal
Refitting
REAR PNEUMATIC SUSPENSION REMOVAL-REFITTING
Removal
Refitting
REAR AIR SPRINGS
Removal
Refitting
REAR SHOCK ABSORBERS
Removal
Refitting
REAR SWAY BAR
Removal
Refitting
SECTION 9 - Wheels and Tires
Wheels and Tires
DESCRIPTION
SPECIFICATIONS AND DATA
Tire pressure values
TOOLS
DIAGNOSTICS
STATIC WHEELS BALANCING
CORRECTION OF RESIDUAL STATIC UNBALANCE
TIRE PRESSURE
TIRE BEHAVIOUR DEPENDING ON PRESSURE
SECTION 10 - Steering
Steering
DESCRIPTION
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUES
TOOLS
ZF HYDRAULIC POWER STEERING (8095-8098)
Description
Hydraulic steering limiting
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (ZF 8095-8098)
Disconnection
Reconnection
HYDRAULIC STEERING LIMITER ADJUSTMENT
TRW TAS 55 HYDRAULIC POWER STEERING
Description
Rectilinear running neutral position
Right steering position
Left steering position
HYDRAULIC STEERING LIMITATION
HYDRAULIC POWER STEERING DISCONNECTION AND RECONNECTION (TRW TAS 55)
Automatic adjustment setting of hydraulic steering limitation for TRW TAS 55 hydraulic power steering
Automatic adjustment check
Hydraulic drops adjustment
AIR DRAIN FROM HYDRAULIC POWER STEERING CIRCUIT
Hydraulic power steering oil level restoration
MEASURE OF DRIVE CASE CLEARANCES DETECTED ON STEERING WHEEL
MAXIMUM PRESSURE CHECK IN HYDRAULIC POWER STEERING SYSTEM
SECTION 11 - Pneumatic System - Brakes
Pneumatic System - Brakes
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (MISCELLANEOUS AND GENERATORS)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (VALVES)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (TANKS AND ACCUMULATORS)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (CYLINDERS AND CALIPERS)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (COUPLING HALF-JOINTS AND HEADS)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (SIGNALING DEVICES AND SWITCHES)
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (BRAKES)
PIPINGS AND FITTINGS
In general
Rigid pipings reflanging
Rigid pipings bending
Rigid pipings cutting
Flexible pipings replacement with threaded fittings
Flexible pipings replacement with quick connection fittings
BRAKING SYSTEM
Principle diagram for single vehicles (Models 110 EL.. - 120 EL..)
Principle diagram for vehicles adapted for towing (Models 110 EL.. - 120 EL..)
Principle diagram for single vehicles (Models 120 E.. - 130 E.. - 150 E..)
Principle diagram for vehicles adapted for towing (Models 120 E.. - 130 E.. - 150 E..)
Principle diagram for single vehicles (Model 180 E..)
Principle diagram for vehicles adapted for towing (Model 180 E..)
Principle diagram for single vehicles (Model 260E) (with Hendrickson suspensions)
ARRANGEMENT ON A VEHICLE OF MAIN BRAKING SYSTEM COMPONENTS
DESCRIPTION
Service braking
Safety braking
Engine brake
Operation
Parking braking
BRAKES
Front brakes
Rear brakes
DIAGNOSTIC
TIGHTENING TORQUES
TOOLS
SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM
SPECIFICATIONS AND DATA - BRAKES
CHECKS OF MAIN BRAKE SYSTEM COMPONENTS
MAIN BRAKE SYSTEM COMPONENTS
COMPRESSOR
Diagnostics
A.P.U. (Air Processing Unit)
Operation
Diagnostics
ENGINE BRAKE SWITCH
ENGINE BRAKE SOLENOID VALVE
ENGINE BRAKE CONTROL OPERATING CYLINDER
MANUAL DISCHARGE VALVE
SAFETY VALVE (Optional)
DUPLEX DISTRIBUTOR
Unbraking
Diagnostics
PRESSURE RELIEF VALVE
Operation
Pressure limitation
Bench calibration
Diagnostics
RELAY VALVE
Diagnostics
CHECK VALVE
Operation
PARKING BRAKE CONTROL MANUAL DISTRIBUTOR (Single vehicles)
Diagnostics
PARKING BRAKE CONTROL MANUAL DISTRIBUTOR (Vehicles adapted for towing)
Diagnostics
QUICK DISCHARGE VALVE
TRIPLE CONTROL SERVODISTRIBUTOR
Predominance adjustment
Diagnostics
COUPLING HEADS
Operation
PRESSURE PLUG VALVE
MEMBRANE BRAKE CYLINDER (for disc brakes and drum brakes)
COMBINED BRAKE CYLINDER
Combined cylinder emergency unbraking device
Repair interventions
Diagnostics
ABS SYSTEMWITH EBL FUNCTION
”ABS” Anti-Lock Brake System
”EBL” (Electronic Brake Limiter) anti-skid device
ELECTRONIC UNIT
Operation
REVOLUTIONS SENSORS
PHONIC WHEELS
Operation
ELECTRO-PNEUMATIC VALVE
Operation
BRAKE REPAIRS MODELS ML 110 EL.. / 120 EL..)
Front Brakes (Brake calipers of the PAN 17 type)
Rear Brakes (Brake calipers of the PAN 17 type)
Description
Brake locking system and brake operation
Automatic braking gaskets wear recovering device
Efficiency check for braking gaskets/brake disc wear recovering device
Braking gaskets replacement
Brake calipers disconnection and reconnection
Disconnection
Reconnection
BRAKE CALIPERS REVISION
Disassembly
Check of component parts
Assembly
BRAKE DISCS REVISION
Brake discs turning and grinding
BRAKE REPAIRING
Front brakes (Brake caliper KNORR SB6 type)
Front and rear brakes (Brake caliper KNORR SN6-SN7 type)
Operation (See previous figure)
CHECKS
Checking the automatic play recovery system efficiency
Check of braking gaskets thickness
REAR BRAKES REVISION
Braking gaskets replacement
Brake calipers disconnection and reconnection
Disconnection
Reconnection
Wheel hubs disconnection and reconnection
Disconnection
Reconnection
BRAKE CALIPERS REVISION TYPES B6
Disassembly
Cleaning and check of component parts
Assembly
BRAKE CALIPER OVERHAUL TYPE SN6-SN7
Disassembly
Component part cleaning and check
Assembly
REAR DISC BRAKES REVISION (12-18 t)
BRAKE DISCS REVISION
BRAKE DISCS TURNING AND GRINDING
REAR DRUM BRAKES - Model 260E28KE
Brake position with Hendrickson suspension
REAR BRAKES REVISION (26 t)
Disassembly
Check of component parts
DRUM TURNING
BRAKING GASKETS REPLACEMENT
BRAKING GASKETS TURNING
Assembly
SECTION 12 - Body - Chassis
Body - Chassis
CAB
General information
PROTECTIVE BODY TREATMENTS
Protective treatment
Preparing the sheet metal (bonderizing)
Applying the protective paint (electrophoresis)
CHECKING THE GEOMETRY OF THE CHASSIS FRAME
GENERAL RULES FORWORKING ON THE CHASSIS FRAME
Preparing the chassis frame for maintenance, checking and repair work authorized by IVECO
Spot welding
Welding instructions
Bodybuilder work on the structural members of the IVECO chassis frame
Drilling the chassis frame
PRECAUTIONS
Welds on the chassis frame
CHASSIS FRAME
REPAIRS AND CHECKS
Measuring the side bend of the chassis frame
Measuring the bend of the chassis frame downwards or upwards
Measuring the movement of the chassis frame
Measuring the torsion of the chassis frame
CHASSIS REFERENCE DIMENSIONS
CAB GEOMETRY
SEAL APPLICATION DIAGRAM
CAB ANCHORINGCAB ANCHORING AND TIGHTENING TORQUES
TOOLS
REPAIRS
Cab anchoring
Replacing cab suspension front and rear shock absorbers
Removing-refitting front mounts and cab stabilizer bar
HYDRAULIC CAB LIFTING SYSTEM
Replacing hydraulic cylinder for cab tilting
REPLACING WINDSCREEN WINDOW
General
Vibration knife
Harmonic wire
Removal (with harmonic wire)
Preparing the windscreen opening
Preparing the windscreen
Refitting
Replacing the winding window
Replacing the window winder
Replacing the fixed window
INSTRUMENT PANEL
Removal
Refitting
MIDDLE INSTRUMENT PANEL
Removal
Refitting
INSTRUMENT PANEL COVERING
Removal
Refitting
HEATING AND VENTILATION
Removal
Refitting
SECTION 13 - Service plan
Service plan
SERVICING
Service plan
SERVICE FREQUENCY
EXTRA PLAN OPERATIONS
Extra plan operations (to be carried out possibly at the same time as a planned service operation)
SCHEDULED MAINTENANCE OPERATIONS
EXTRA-PLAN OPERATIONS
SCHEDULED MAINTENANCE OPERATIONS
EXTRA-PLAN OPERATIONS
M1 SERVICE
M2 SERVICE
M3 SERVICE
EXTRA-PLAN MAINTENANCE
EP1 SERVICE
EP2 SERVICE
EP3 SERVICE
EP4 SERVICE
EP5 SERVICE

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