60393391C Rep. Manual EuroCargo 12-26 Ton

EUROCARGO TECTOR
12 TO 26 t
REPAIR MANUAL
”This document provides data, characteristics, instructions and
methodology to perform repair interventions on the vehicle
and its components.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified and equipped to perform
the repair interventions that are indicated in this document.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accident prevention devices, such as, as a rough guide, goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., are available and efficient, and further
make sure that the vehicle is put such a way that an
intervention can be made in safety conditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of
functionality, efficiency and safety conditions that are provided
by Iveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of any responsibility for Iveco,
and, in particular, where the vehicle is covered by a guarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Iveco is available to provide all clarifications necessary to make
interventions, as well as to provide indications in cases and
situations not included in this document.
Data and information contained in this document could result
not to be updated owing to modifications made by Iveco at
any moment for technical or commercial reasons, or because
of the need to adapt the vehicle to law requirements in
different countries.
In the case of a difference between what contained here and
what actually found on the vehicle, please contact Iveco
network before making any intervention.”
The data contained in this publication might fail to reflect the
latest changes which the Manufacturer may introduce at any
time, for technical or sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.
Produced by:
Publication Edited by:

IVECO S.p.A.
Customer Service
Lungo Stura Lazio, 15
B.U. TECHNICAL PUBLISHING
10156 Torino (TO) — Italy
Iveco Technical Publications
Lungo Stura Lazio, 15
Print 603.93.391 — 1st Ed. 2004 10156 Torino (TO) — Italy
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of
units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS — WARNINGS
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Danger of serious damage for the vehicle

Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.
General danger
! It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE It indicates an additional explanation for a piece of information.
Print 603.93.391 I Base — October 2004

SYMBOLS — ASSISTANCE OPERATIONS
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

α
Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 °C
Sealant
Cold
Adhesive
Winter
Temperature > 0 °C
Air bleeding Hot
Summer
Replacement
Original spare parts
Base — October 2004 II Print 603.93.391

PRODUCT CODE
Each title or subtitle concerning operations being performed is preceded by a six—figure number named PRODUCT CODE.
This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and
TROUBLE CODE document.
As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
Product Code: 5 0 7 6
PRODUCT UNIT SUB—ASSEMBLY PRODUCT UNIT SUB—ASSEMBLY
COMPONENT COMPONENT
The first and second figures identify the PRODUCT within motor vehicle.
Example :
Product 50 = Vehicle chassis;

Product 52 = Axles;
Product 53 = Transmission;
Product 76 = Electric ssystem.
Unit Code: 0 1 0 3
COMPONENT COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT.
Example :

Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.
Sub—assembly Code: 4 0 1 3
COMPONENT COMPONENT
The fifth and sixth figures exactly identify the SUB—ASSEMBLY and Component of a Unit within a PRODUCT.
Example :

Unit 01 = Chassis;
Sub—assembly 40 = Chassis cross members;
Sub—assembly 13 = Rotor.
Print 603.93.391 III Base — October 2004

GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general—purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co—operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph “Controls
care of user” of Use and Maintenance handbook.
In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanned
a vehicle in motion during repair interventions.
Keep the vehicle stationary by proper chocks.
In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special support
stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.
When it is necessary to perform an intervention on methane—fed vehicles, observe the indications contained inside the
document, as well as all specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 12—point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR — BAG systems, scrupulously observe
indications specified in relating manual sections.
Base — October 2004 IV Print 603.93.391

GENERAL WARNINGS
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight—fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12—point cards for provisions to make.
Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detached
or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self—locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
Print 603.93.391 V Base — October 2004

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
1 Pay attention that jamming sources are not present in the cab or near the keys.
2. Keys not insered in the panel must be at least 1 meter away.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.
Base — October 2004 VI Print 603.93.391

Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“—connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
— Electronic central units must be connected to system bonding when they are provided with a metallic shell.
— Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
— Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
— Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
— If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
— Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

d. DISTANCE ! 0
Print 603.93.391 VII Base — October 2004

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting
instructions (specific document “Instructions for transformation and preparation” is available at Assistance Network workshops).
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
For any exception to mounting instructions, IVECO’s authorisation is necessary.
Lack of observance of above described prescriptions involves guarantee lapse.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 Hp = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
(Nm and bar units are converted according to 10:1 and 1:1 for the sake of simplicity)
1 kgm = 10 Nm
1 kg/cm2 = 1 bar
Temperature
0° C = 32° F
1° C = (1 x 1.8 + 32) ° F
Base — October 2004 VIII Print 603.93.391

EUROCARGO TECTOR 12—26t
Print 603.93.391/A
Print 603.93.391 — 1st edition

Base — October 2004
UPDATE DATA
Section Description Page Revision date
1 General specification 3 ÷ 12 July 2005
2 Engine 24, 26 ÷ 29, 40, 60, 82, 99, 103, 118, 120 ÷ 125, 128 July 2005
3 Clutch 1, 3, 4, 5, 6, 11, 13, 14 July 2005
4 Gearbox 5, 6, 30, 84 July 2005
6 Rear axles 100, 102, 103, 104, 106, 135, 227 July 2005
7 Front axles 101 July 2005
8 Suspensions 54, 58, 63, 73, 80, 81 July 2005
10 Steering 1, 9, 10, 13, 16 July 2005
11 Pneumatic system — brakes 32 July 2005
13 Service plan 1 ÷ 16 July 2005
14 Electric/electronic system 2, 62, 63, 67, 75/1 ÷ 75/4, 77, 80, 82, 83, 90, 91, 104, 105, July 2005
108, 125, 129, 203, 243/1, 243/2, 542, 544, 547, 551,
556, 558, 559, 566, 568, 570, 581, 582
Print 603.93.391/A Base — October 2004

Revi — July 2005
Base — October 2004 Print 603.93.391
INDEX OF SECTIONS
Section
General specification 1
Engine 2
Clutch 3
Gearbox 4
Propeller shafts 5
Rear axles 6
Front axles 7
Suspensions 8
Wheels and tyres 9
Steering 10
Pneumatic system — brakes 11
Body and chassis 12
Service plan 13
Electric/electronic system 14
Print 603.93.391 Base — October 2004

EUROCARGO TECTOR 12—26 t GENERAL SPECIFICATIONS 1
Print 603.93.391
SECTION 1
General Specifications
Page
COMPOSITION OF THE MODELS . . . . . . . . . . 3
IDENTIFICATION DATA AND LOCATION

ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 13
FILLING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INTERNATIONAL LUBRICANT DESIGNATION 15

2 GENERAL SPECIFICATIONS EUROCARGO TECTOR 12—26 t

Print 603.93.391/A
GENERAL SPECIFICATIONS
COMPOSITION OF THE MODELS
MODELS
4x2
ML110EL17R/P
ML120EL17R/P
ML110EL21R/P
ML120EL21R/P
ML110EL21/P
ML120EL17/P
ML120EL17/R
ML110EL17/P
ML120EL21/P
ML120EL21R
ML110EL17R
ML110EL21R
ML120E18/P
ML120EL17
ML120EL21
ML110EL17
ML110EL21
ML120E18
UNITS
F4AE0481A (170 HP) S S S S S S S S
F4AE0681E (180 HP) S S
F4AE0681D (210 HP) S S S S S S S S
F4AE0681B (240 HP)
F4AE0681A (275 HP)
14” S S S S S S S S S S
Single plate
15”/16”
2855S.6 S S S S S S
2865S.6 S S S S
2870S.9 S S S S S S S S S S S S S S S S S S
2895S.9
FSO 5206B
MD 3060P
5845 S S S S S S S S S S S S S S S S
5842/5 S S
5851/5
5860
5871/5
MS08—125 S S S S S S S S S S S S S S S S
MS10—144 S S
MS10—164
MS13—165
SP145E
ZF 8095 S S
ZF 8098
TRW—TAS 55 S S S S S S S S S S S S S S S S
Mechanical front S S S S S S S S S S S S S S S S S S
Mechanical rear S S S S S S S S S
Pneumatic front
Pneumatic rear S S S S S S S S S
Disk front S S S S S S S S S S S S S S S S S S
Disk rear S S S S S S S S S S S S S S S S S S
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS = Road Sweeper; CS = Narrow track; CL = Broad track

Revi — July 2005
MODELS
ML120E18DR/P
4x2
ML120E18DKR
ML120E21R/FP
ML120E18R/FP
ML120E18D/P
ML120E21R/P
ML120E18DR
ML120E18R/P
ML120E18DK
ML120E18/FP
ML120E21/FP
ML120E18KR
ML120E21/P
ML120E18D
ML120E21R
ML120E18R
ML120E18K
ML120E21
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP) S S S S S S S S S S S S
F4AE0681D (210 HP) S S S S S S
F4AE0681B (240 HP)
F4AE0681A (275 HP)
14” S S S S S S S S S S S S S S S S S S
Single plate
15”/16”
2855S.6 S S S S S
2865S.6 S S S
2870S.9 S S S S S S S S S S S S S S S S S S
2895S.9
FSO 5206B
MD 3060P
5845
5842/5 S S S S S S S S S S S S S S S S S S
5851/5
5860
5871/5
MS08—125
MS10—144 S S S S S S S S S S S S S S S S S S
MS10—164
MS13—165
SP145E
ZF 8095 S S S S S S S S S S S S S S S S S S
ZF 8098
TRW—TAS 55
Mechanical front S S S S S S S S S S S S S S
Mechanical Rear S S S S S S S S S
Pneumatic front S S S S S
Drum rear
Base — October 2004 Print 603.93.391/A

Revi — July 2005
MODELS
ML120E24DR/P
4x2
ML120E24DKR
ML120E24R/FP
ML120E24D/P
ML120E24R/P
ML120E24DR
ML120E24DK
ML120E21KR
ML120E24KR
ML120E24FP
ML120E24/P
ML120E28/P
ML120E24D
ML120E24R
ML120E24K
ML120E21K
ML120E24
ML120E28
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP)
F4AE0681D (210 HP) S S
F4AE0681B (240 HP) S S S S S S S S S S S S S S
F4AE0681A (275 HP) S S
14” S S S S S S S S S
Single plate
15”/16” S S S S S S S S S S S S S S S S
2855S.6
2865S.6 S
2870S.9 S S
2895S.9 S S S S S S S S S S S S S S S S
FSO 5206B S S S S S S S
MD 3060P
5845
5851/5
5860
5871/5
MS08—125
MS10—164
MS13—165
SP145E
ZF 8098
TRW—TAS 55
Mechanical front S S S S S S S S S S S S S S S S
Mechanical Rear S S S S S S S S S S S
Pneumatic front
Pneumatic rear S S S S S S S
Drum rear

Revi — July 2005
MODELS
ML130E18DR/P
4x2
ML120E28R/FP
ML130E18R/FP
ML130E18D/P
ML130E18RS*
ML120E28R/P
ML130E18R/P
ML130E18DR
ML120E28/FP
ML130E18/FP
ML120E28KR
ML130E18KR
ML130E18/P
ML130E18D
ML120E28R
ML130E18R
ML120E28K
ML130E18K
ML130E18
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP) S S S S S S S S S S S S S
F4AE0681D (210 HP)
F4AE0681B (240 HP)
F4AE0681A (275 HP) S S S S S S
14” S S S S S S S S S S S S S
Single plate
15”/16” S S S S S S
2855S.6 S S S S S S
2865S.6 S
2870S.9 S S S S S S S S S S S S
2895S.9 S S S S S S
FSO 5206B
MD 3060P
5845
5842/5 S S S S S S S S S S S S S S S S S S S
5851/5
5860
5871/5
MS08—125
MS10—144 S S S S S S S S S S S S S S S S S S S
MS10—164
MS13—165
SP145E
ZF 8095 S S S S S S S S S S S S S S S S S S S
ZF 8098
TRW—TAS 55
Mechanical front S S S S S S S S S S S S S S S
Mechanical Rear S S S S S S S S S S
Pneumatic front S S S S
Disk front S S S S S S S S S S S S S S S S S S S
Disk rear S S S S S S S S S S S S S S S S S S S
Drum rear

Revi — July 2005
MODELS
4x2
ML130E18DKR
ML130E21R/FP
ML130E24R/FP
ML130E21R/P
ML130E24R/P
ML130E18DK
ML130E21/FP
ML130E24/FP
ML130E21KR
ML130E24KR
ML130E21/P
ML130E24/P
ML130E21R
ML130E24R
ML130E21K
ML130E24K
ML130E21
ML130E24
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP) S S
F4AE0681D (210 HP) S S S S S S S S
F4AE0681B (240 HP) S S S S S S S S
F4AE0681A (275 HP)
14” S S S S S S S S S S
Single plate
15”/16” S S S S S S S S
2855S.6 S
2865S.6 S S S S
2870S.9 S S S S S S S S S S
2895S.9 S S S S S S S S
FSO 5206B S S S S
MD 3060P
5845
5851/5
5860
5871/5
MS08—125
MS10—164
MS13—165
SP145E
ZF 8098
TRW—TAS 55
Pneumatic front S S S S
Pneumatic rear S S S S S S S S
Drum rear

Revi — July 2005
MODELS
4x2
ML130E24DR/P
ML130E24DKR
ML130E28R/FP
ML130E24D/P
ML130E28R/P
ML150E21R/P
ML130E24DR
ML130E24DK
ML130E28/FP
ML150E21/FP
ML130E28KR
ML130E28/P
ML150E21/P
ML130E24D
ML130E28R
ML150E21R
ML130E28K
ML130E28
ML150E21
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP)
F4AE0681D (210 HP) S S S S S
F4AE0681B (240 HP) S S S S S S
14” S S S S S
Single plate
15”/16” S S S S S S S S S S S S S S
2855S.6
2865S.6 S S S
2870S.9 S S S S S
2895S.9 S S S S S S S S S S S S S S
FSO 5206B S S S
MD 3060P S S S
5845
5842/5 S S S S S S S S S S S S S S
5851/5 S S S S S
5860
5871/5
MS08—125
MS10—144 S S S S S S S S S S S S S S
MS10—164 S S S S S
MS13—165
SP145E
ZF 8098
TRW—TAS 55
Mechanical front S S S S S S S S S S S S S S S S
Pneumatic front S S S
Drum rear

Revi — July 2005
MODELS
4x2
ML150E21R/FP
ML150E24R/FP
ML150E28R/FP
ML150E21RS*
ML150E24R/P
ML150E28R/P
ML150E24/FP
ML150E28/FP
ML150E21KR
ML150E24KR
ML150E24/P
ML150E28/P
ML150E21K
ML150E24R
ML150E28R
ML150E24K
ML150E28K
ML150E24
ML150E28
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP)
F4AE0681D (210 HP) S S S S
F4AE0681B (240 HP) S S S S S S S S
F4AE0681A (275 HP) S S S S S S S
14” S S S S
Single plate
15”/16” S S S S S S S S S S S S S S S
2855S.6
2865S.6 S
2870S.9 S S S S
2895S.9 S S S S S S S S S S S S S S S
FSO 5206B S S S S
MD 3060P S S S S S
5845
5842/5
5860
5871/5
MS08—125
MS10—144
MS10—164 S S S S S S S S S S S S S S S S S S S
MS13—165
SP145E
ZF 8098
TRW—TAS 55
Pneumatic front S S S S S
Drum rear

Revi — July 2005
MODELS
ML260E28KE (6x4)
4x2
ML180E21R/P
ML180E24R/P
ML180E28R/P
ML150E28KR
ML180E21KR
ML180E24KR
ML180E28KR
ML180E21/R
ML180E21/P
ML180E24/P
ML180E28/P
ML180E24R
ML180E28R
ML180E21K
ML180E24K
ML180E28K
ML180E21
ML180E24
ML180E28
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP)
F4AE0681D (210 HP) S S S S S S
F4AE0681B (240 HP) S S S S S S
14” S S S S S S
Single plate
15”/16” S S S S S S S S S S S S S S
2855S.6
2865S.6 S S S
2870S.9 S S S S S S
2895S.9 S S S S S S S S S S S S S S
FSO 5206B S S S
MD 3060P S S S S S S S S S
5845
5842/5
5851/5 S
5860
MS08—125
MS10—144
MS10—164 S
SP145E S
ZF 8095 S
TRW—TAS 55
Mechanical front S S S S S S S S S S S S S S S S S S S S
Mechanical Rear S S S S S S S S S S S S S
Pneumatic front
Pneumatic rear S S S S S S S
Disk front S S S S S S S S S S S S S S S S S S S S
Drum rear S
and rear pneumatic suspension; D = Double cabin (6 + 1); RS = Road Sweeper; KE = HENDRICKSON rear suspensions;
CS = Narrow track; CL = Broad track

Revi — July 2005
MODELS
4x2
ML130E18D/P
ML130E24D/P
ML140E18/FP
ML140E21/FP
ML140E24/FP
ML140E28/FP
ML140E18RS
ML140E18/P
ML140E21/P
ML140E24/P
ML140E28/P
ML130E18D
ML130E24D
ML140E18
ML140E21
ML140E24
ML140E28
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP) S S S S S S
F4AE0681D (210 HP) S S S
F4AE0681B (240 HP) S S S S S
F4AE0681A (275 HP) S S S
14” S S S S S S S S S
Single plate
15”/16” S S S S S S S
2855S.6 S S S S S
2865S.6 S S S S
2870S.9 S S S S S S S S
2895S.9 S S S S S S S S
FSO 5206B S S S S S
MD 3060P
5860CL
5860CS S S S S S S S S S S S S S S S S S
MS08—125
MS10—144 S S S S S S S S S S S S S S S S S
MS10—164
MS13—165
SP145E
ZF 8095 S S S S S S S S S S S S S S S S S
ZF 8098
TRW—TAS 55
Mechanical Rear S S S S S S S
Pneumatic rear S S S S S S S S S S
Disk front S S S S S S S S S S S S S S S S S
Disk rear S S S S S S S S S S S S S S S S S
Drum rear

Revi — July 2005
MODELS
4x2
ML150E21/FP
ML150E24/FP
ML150E28/FP
ML160E21RS
ML160E21/P
ML160E24/P
ML160E28/P
ML160E21
ML160E24
ML160E28
UNITS
F4AE0481A (170 HP)
F4AE0681E (180 HP)
F4AE0681D (210 HP) S S S S
F4AE0681B (240 HP) S S S
F4AE0681A (275 HP) S S S
14” S S S S
Single plate
15”/16” S S S S S S
2855S.6
2865S.6 S S S
2870S.9 S S S S
2895S.9 S S S S S S
FSO 5206B S S S
MD 3060P S S S S S S
5860CL S S S S S S S S S S
5860CS
MS08—125
MS10—144 S S S
MS10—164 S S S S S S S
MS13—165
SP145E
ZF 8095 S S S S S S S S S S
ZF 8098
TRW—TAS 55
Mechanical front S S S S S S S
Mechanical Rear S S S S
Pneumatic rear S S S S S S
Disk front S S S S S S S S S S
Disk rear S S S S S S S S S S
Drum rear

Revi — July 2005
Print 603.93.391
IDENTIFICATION DATA AND LOCATION ON VEHICLE
Manufacturer’s plate
For vehicle identification to comply
with EC directions (under front
radiator grille)
Engine
Flywheel cover plate on the box (left
side)
Chassis
Marking (on right side
member front end)

FILLING UP
LUBRICANTS RECOMMENDED BY IVECO PARTS TO FILLED UP Quantity
Litres kg
ACEA E3/E5
Urania LD5 Engine — 4 cylinders
min. 5.3 4.8
max 8.3 7.5

1 0.9
Engine — 6 cylinders
min. 8 7.2
max 10.8 9.7

1 0.9
Gearbox 2855S.6 5.5 5
Tutela ZC 90 2865S.6 9 8.1
2870S 9
2870S.9 5 45
4.5
2895S.9 8.3 7.5
FSO5206B 7 6.5
MD3060P 30 27
Tutela W140/M — DA Front hubs (individual) 0.2 0.18
Rear axle MS08—125 6.5 5.85

MS10—125 **11.5/12* **10.3/10.8*
MS10—164 **12.2/11.7* **10/10.5*
MS13—165 **18/19* **16.2/16.7*
SP145E
Intermediate 16.2 14.5
* Rear axle with mechanical suspension Rear 12.2 11
** Rear axle with pneumatic suspension
ZF 8095 — —
Power
Tutela GI/A ZF 8098 — —
steering
TRWTAS55 — —
Tutela TRUCK DOT

Clutch circuit — —
SPECIAL
Cooling system
Paraflu11
Total capacity — —
Cab tipping system

Tutela LHM — —

INTERNATIONAL LUBRICANT DESIGNATION
Description FL Products
Engine oil
Urania Turbo
Compliant with ACEA E2 specifications
Engine oil
Urania LD5
Compliant with ACEA E3 and ACEA E5 specifications
Differential and wheel hub oil SAE 80W/90 Tutela W 90/M—DA (Cold climates)
Compliant with MIL—L—2105 C SAE 85W/140 Tutela W140/M—DA (Hot and temperate
and API GL—5 specifications climates)
Manual gearbox oil SAE 80W/90
Contains non EP wear resistant additives Tutela ZC 90
Compliant with MIL—L2105 or API GL 3 specifications
Automatic gearbox and power steering oil
Tutela GI/A
Compliant with A.T.F. DEXRON II specifications
Grease for general use
Tutela MR 2
Lithium—soap base grease, N.L.G.I. n. 2
Specific grease for bearings and wheel hubs
Tutela MR 3
Non—mineral base grease, compatible with brake system materials and
SP 349
suitable to lubricate brake system components
Grease for general use, suitable for components not requiring special
grease (e.g., joints, pins and pivots, levers, tie rods, sliding shoes, brake
Tutela Zeta 2
callipers, etc.)
Hydraulic brakes and clutch fluid
Compliant with N.H.T.S.A. N. 116 ISO 4295 — SAE J 1703 CUNA NC Tutela TRUCK DOT SPECIAL
956—01 specifications and IVECO STANDARD 18—1820
Mineral oil for hydraulic circuits
Tutela LHM
Wear resistant and very low pour point
Window liquid, mixture of alcohols, water and surface—actives,
Arexons DP1
CUNA NC 956—11
Antifreeze, 50% concentration for temperatures up to —35°C Paraflu 11


EUROCARGO TECTOR 12—26 t ENGINE 1
Print 603.43.671/A
SECTION 2
Engine
Pagina
ENGINE IDENTIFICATION CODES . . . . . . . . . 3

MAIN SERVICING OPERATIONS TO BE PERFORMED
ON ENGINE FITTED ON VEHICLE . . . . . . . 4
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- High pressure CP3 pump . . . . . . . . . . . . . . . . 4
- Rail and fittings . . . . . . . . . . . . . . . . . . . . . . . . 4
- Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Low pressure tubing . . . . . . . . . . . . . . . . . . . . 4
- High pressure tubing . . . . . . . . . . . . . . . . . . . . 4
ENGINE REMOVAL—REFITTING . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Tests and checks . . . . . . . . . . . . . . . . . . . . . . . 7
- Engine cooling filling system . . . . . . . . . . . . . . 7
- Air bleeding from fuel system . . . . . . . . . . . . . 8
- Air bleeding from hydraulic power
steering system . . . . . . . . . . . . . . . . . . . . . . . . 8
INJECTORS REPLACEMENT . . . . . . . . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Tests and checks . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING SEAL RING FRONT COVER
DRIVING SHAFT . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING SEAL RING FLYWHEEL
HOUSING BOX . . . . . . . . . . . . . . . . . . . . . . 12
CYLINDER HEAD REMOVAL/REFITTING . . . . 13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Tests and checks . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE F4 AE 0481 . . . . . . . . . . . . . . . . . . . . . 19
ENGINE F4 AE 0681 . . . . . . . . . . . . . . . . . . . . . 115
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . 141

2 ENGINE EUROCARGO TECTOR 12—26 t

Print 603.43.671/A
ENGINE IDENTIFICATION CODES
F 4 A E 0 6 8 1 A * C +
Exhaust emission level
Homologation power
Duty No.
Injection
Cylinder No.
Engine cycle — cylinder position
Engine
Engine series evolution 0= 4—stroke,

vertical
Engine series
4 = 4 cylinders
6 = 6 cylinders
8 = DI. TCA
1 = Truck
2 = Bus
4 = M.T. vehicles
and tractors
6 = Marine
9 = Army
0681 A= 202 kW — (275 HP) 2700 rpm — 930 Nm / 1250 rpm

0481 A= 125 kW — (170 HP) 2700 rpm — 560 Nm / 1200 rpm
0681 B= 176 kW — (240 HP) 2700 rpm — 810 Nm / 1250 rpm
0481 C= 110 kW — (150 HP) 2700 rpm — 490 Nm / 1200 rpm
0681 D= 154 kW — (210 HP) 2700 rpm — 680 Nm / 1200 rpm
0481 D= 95 kW — (130 HP) 2700 rpm — 430 Nm / 1200 rpm
0681 E= 134 kW — (182 HP) 2700 rpm — 600 Nm / 1200 rpm
0681 F= 202 kW — (275 HP) 2500 rpm — 930 Nm / 1250 rpm
Model No. within D.B. Model No. within D.B.

MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE

WARNINGS Low pressure tubing
Figure 1
Follow warnings below before operations
! concerning or involving fuel system components.
- Before any engine intervention always carry out
the engine/vehicle test with the proper IVECO
test equipment, then print the results.
- To replace the EDC7 control unit follow the
Iveco procedure for electronic control unit run
engines.
- It is possible to replace but not recondition the
following fuel system parts: pressure limiting
valve, fuel pressure sensor, hydraulic
accumulator, fuel pump, high pressure CP3
pump with pressure adjustment valve. 70126
- All the Common Rail system parts are packed by A Connector properly locked
the supplier in oilpaper sheet and then in
B Connector released for removal—refitting
cardboard boxes. They shall be protected from
humidity and unpacked just before assembling. All connectors shall be in the blocking position (see Figure
1—A) with the clip (1).
- The parts shall always be clean during their
handling and assembling (even for simple To disconnect the low pressure system tubing, press on the
operations such as filter or pre—filter clip (1) (as described in 1—B) to free the connector.
replacement) to avoid dust or filth. Therefore, After disconnecting, bring again the spring clip (1) in the
the hydraulic part protection caps shall be blocking position (Figure 1—A) to avoid deformations.
removed only immediately before the part
assembling. When the low pressure system is restored, press the clip (1)
(as described in 1—B) and connect the union to its connector.
- Always follow assembling direction for electrical Bring the clip (1) in the blocking position A to guarantee the
connections. connection between the tubing and its component.
- Threaded connections shall be clamped to the The non—observance of the above mentioned connecting
prescribed coupling. procedure may cause a sudden tubing disconnection during
the vehicle starting or engine working, due to pressure.
High pressure CP3 pump High pressure tubing

The high pressure pump body cannot be overhauled. Only Since this hydraulic system contains high pressures, observe
allowed interventions are: pressure regulator integral the following norms to avoid any risks:
replacement and control gear replacement.
- Do not connect the high pressure tubing unions with a
When servicing operations on high pressure pipe are rough clamping;
required, the hexagon on pump side shall be held with proper
wrench. - Do not disconnect the high pressure tubing while the
engine is working;
Rail and fittings Always replace each high pressure tubing after disassembling
The flow limiter and the pressure limiting valve can be it once.
assembled 5 times consecutively before being replaced. They
shall be lubricated with a little oil before assembling. - Replace each fuel manifold after disassembling it once.
Lubricate the overpressure valve as well before assembling In case of clamping or loosening of the fixing connections,
and always replace its gasket. keep fuel manifolds, hydraulic accumulator (rail) and high
pressure pump firmly fixed and the component—side
Injector hexagon firm, if there is enough space.
It is not necessary and permitted to disassemble the fuel - Replace involved piping in case of drippings.
nozzle or the electromagnet.

Print 603.43.671/A
ENGINE REMOVAL/REFITTING
Figure 2
Before performing removing/refitting operations,
! disconnect the battery cables and set the vehicle in
safe and secure conditions.
Removal
Lift the radiator grille and tilt the cab. Remove the
gearbox as described in the relevant section and
then proceed as follows:
- Drain engine coolant into a proper container.
- Drain power steering system oil into a proper container.
Working from the left side of the engine:
- Disconnect the pipes (18) from the turbosupercharger
(13) and the air cleaner and the intake pipe from the
turbine (on the right side).
- Loosen the relevant chassis fastening bolts to remove
the intake duct (16) including the support.
- Disconnect the air duct (15).
- Loosen the fastening screws (6), the nut (5), remove the
supporting bracket (4) and move the gearshift lever (17)
to the right.
- Disconnect delivery (11) and return (10) pipe from the
power steering pump.
- Loosen clamps (1) and remove the aftercooler pipe (2).
- Disconnect fuel delivery pipes (9) from the control unit
and the return pipes (12) from the fuel filter support.
- Disconnect sump oil filling pipe (3).
- Disconnect the connector (8) from the control unit and
also all engine connections arriving from chassis wiring.
62242

From the engine right side: Figure 3

- Move the gear control lever (1) leftwards.
- Loosen clamps (14) and remove the after—cooler tubing
(15).
- Loosen the tightener (16) and undermine the belt.
- Unscrew relevant fastening screws, remove the
conditioner (17) compressor and place it on the
condenser, tightly fastened to prevent it form dropping.
- Remove the exhaust brake throttle valve (9) guard (12).
- Disconnect the tubing (10) , unscrew the exhaust pipe
fastening screws (7) and remove the throttle valve (9).
- Unscrew the elastic support (silent block) fastening nut
that fixes the exhaust pipe (8) to the frame and remove
it.
- Disconnect air tubing (4).
- Loosen clamps from the radiator and the thermostat
and remove the cooling fluid tubing (18).
NOTE During the refitting, do not invert the tubing (18)

position, because it will interfere with the fan.
- Disconnect the tubing (2) from the clamp that fixes it to

the head and free it from the check clamps.
- Disconnect the tubing (3) from the clamp placed as
shown (→).
- Loosen the clamp and disconnect the cooling fluid tubing
(11).
- Disconnect the alternator, starter and ground cable
electrical connections.
- Remove the clamp (5) that fixes the harness to the
engine support bracket and disconnect all those
connections coming from the harness.
- Place the lifting arm (99360595) to the engine and
tension it with a proper lifting device.
- Unscrew fastening nuts (7 and 14, Figure 2) and (6 and
13, Figure 3); then, lift the engine moving it at the same
time towards the rear part and remove it from the
compartment.
NOTE Depending on the kind of vehicle cab, the cab rear

traverse might be removed, too.
62241

Print 603.43.671/A
Refitting - There are no oil drippings between cover and head

cylinders, oil pan and base, heat exchanger oil filter and
its seatings and between the different lubrication circuits;
Invert the operations requested for removal and observe the - There are no fuel leakages from fuel tubings;
following directions:
- There are no air losses from pneumatic tubings;
- Take great care during the engine assembling;
- The warning lights on the instrument panels and the
- Check cooling fluid and air—conveyor coupling devices disconnected during the engine removal work
conditions and in case they are damaged, replace them correctly.
immediately;
- Check engine and speed gear unit elastic supports; in
case they are damaged, replace them immediately;
Engine cooling filling system
- Check if the exhaust pipe parts or its fastening elements
are damaged or about to be damaged and replace them; General rules
- Fasten screws or nuts to the prescribed torque; Figure 4
- Check accurately that the connections of the low
pressure fuel tubings to its unions are correct, as
specified in the notes concerning “main service
operations to be performed on engine fitted on vehicle”.
- Fill the cooling system with the cooling fluid and carry out
the bleeding as described in the relevant chapters;
- Fill the hydraulic steering circuit and carry out the
bleeding as described in the relevant chapter;
70469
- These operations shall be carried out when the engine

is cool.
Check that hydraulic steering oil and the cooling fluid - The cap (1) is sealed and shall never be tampered by the
do not contain filth before using them; if they do, user.
filter with appropriate net filters; in case of filling—ups, To empty or fill it use only the cap (2).
see the table REFUELING in the section
“GENERAL”. - To avoid air locks in the system, the fluid shall be poured
very slowly (about 8 l per minute).
- The antifreeze contained in the cooling fluid shall not
- Check the engine and speed gear oil level; in case of exceed 50%.
filling—ups, see the table REFUELING in the section
“GENERAL”.
Tests and checks Figure 5

Start the engine, leave it in motion at running rate
little more than the minimal and wait that the cooling
fluid temperature reaches the rate for the
thermostat to be opened , then check that:
2
1 3
O 4
- There are no water drippings from the connecting
manifolds of the engine cooling tubing and the cab
heating, and in case fasten by blocking collars further;
79450
- Open the heating fluid tap knob (1) completely.

- Remove the cap (2, Figure 4) and refuel as described
before until the expansion cup is full.

Air bleeding - Start priming pump hand control (2) until fuel goes out
- Start air bleeding from the cooling system immediately from the bleeding screw (1) without air;
after filling operations. - Close the screw (1);
- Start the engine at the minimum speed for at least 5 - Operate on the hand control until the priming pump (2)
minutes. starts idle working;
- Fill the fluid up after this time. - Start the engine and let it rotate at its minimum for some
- Close the cap 2, Figure 4, accurately and take the engine minutes to eliminate air residuals.
at high revolutions to simplify fluid cooling until the
thermostat opens.
- Note: Screen the radiator with a cardboard between it Fire danger: always close the bleeding screw to avoid
and the intercooler to quicken the operation. ! fuel leakages.
- Take the fluid temperature to 90°C ∼ (to be sure that
the thermostat will open) checking the on board
thermometer.
- When the fluid reaches the right temperature, keep the 501430 Air bleeding from hydraulic
engine at max. revolutions possible to let the air out power steering system
completely.
- Check that in the expansion cup there are no more air Check the fuel level in the tank and in case increase it.
bubbles or foam.
Lift the vehicle from the front part, start the engine and let
- The max complete deareation time is ∼ 15 minutes from it rotate at its minimum for some time.
the thermostat opening.
Check that there are no oil drippings from the hydraulic
Important warnings
circuit and check its level in the tank.
- From the moment the cap (2, Figure 4) is closed and the
engine heating starts, do not remove the cap until the Turn the steering wheel slowly in both directions to let out
engine is completely cooled. the air contained in the hydraulic system.
Consequently, in case of filling, wait until the engine is Check again the oil level in the tank and increase it, if
cool. necessary.
This will avoid two consequences:
— Scalds to the operator;
— Engine damages, since the system can be pressurized
only with a cool engine heating.
542011 Air bleeding from fuel system
Figure 6
70471
The bleeding shall be performed as follows:

- Insert in the bleeding screw (1) its proper small tube (1)
to drain the fuel in the appropriate container;
- Loosen the screw (1).

INJECTORS REPLACEMENT
Removal
Figure 7 Figure 9
99220
Place the vehicle in safety conditions. 70473
Disconnect battery terminals, lift the radiator cowling,

overturn the cab and operate as follows: Loosen fastening tappet register nuts (1) and unscrew
registers.
- Disconnect oil tubings (4 and 5) from the tappet cover Remove screws (2), rocker unit (3) consisting of support (6),
(6) and remove it; rockers (4) and shafts (5) and remove bonds (7) from the
- Remove ignition harness clamps (1); valves.
Figure 10
- Disconnect ignition harness (1) from injector
connectors, overpressure and temperature/pressure
sensors (3);
- Remove tubings (7) from the hydraulic accumulator (2)
and fuel manifolds for injectors.
Figure 8
70133
Remove injector fastening screws and with the tool

99342101 (1) remove also the injectors (2) from cylinder
heads.
Refitting
70131
Figure 11
Remove nuts (7) and disconnect electrical cables from
injectors (8).
Remove screws (1) and injector harness support (2) with the
gasket.
Remove screws (5) and air temperature/pressure sensor (6).
Remove nuts (3) and fuel manifolds (4).
NOTE The disassembled fuel manifolds (4) shall never be

used again but replaced with new ones. 70338
Assemble a new ring (2) lubricated with vaseline and a new

washer (3) on the injector (1).

Figure 12 Figure 14
70339 70342
Assemble the injectors (1) on the cylinder heads, in a way Fasten gradually and alternatively the injector fastening
that the fuel entrance hole (2) is turned towards the fuel screws (1) to 8.5±0.35 Nm torque with a dynamometrical
manifolds housing (3). wrench.
Screw fastening screws without clamping them. Fasten fuel manifold (3) fastening screws (2) to the 50 Nm
torque.
NOTE To fit down injectors use the tool 99342101
(Figure 10).
Figure 13 Figure 15
70346
91572
Assemble a new ring (3), lubricated with vaseline, on the fuel Check that the tappet registers (1) are unscrewed to avoid
manifold (2) and insert it in the cylinder head housing so that problems with rods (7) during rocker unit (2) assembling.
the position ball (5) clashes with its housing (4). Place the bond on the valve (6).
NOTE The disassembled fuel manifolds (2) shall never be The notches (•) on the bonds shall be turned
used again but replaced with new ones. ! towards the exhaust manifold.
After, assemble rocker units (2) consisting of support
(5), rockers (3) and shafts (4) and fix them to cylinder
Screw fastening nuts without clamping them. heads fastening the screws (8) to the Nm 36 torque.
During this operation, move the injector (1) so that

the manifold (2 Figure 13) can be placed correctly
into the fuel entrance hole (2, Figure 12)

Figure 16 Complete assembling inverting the operations requested for

removal, bearing in mind to:
- Fasten injector connector nuts to the prescribed torque;
- Assemble high and low pressure tubings according to
the procedures described in the paragraph “main
service operations to be performed on engine fitted
on vehicle ”;
- Fill the cooling system with cooling fluid and bleed as
described before.
Check that the cooling fluid does not contain filth

before using it; if it does, filter with appropriate net
filters; in case of filling—ups, see the table REFUELING
in the section “GENERAL”.
70520
Adjust clearance between rockers and valves through a Tests and checks
setscrew wrench (1), box wrench (3) and feeler gauge (2).
Start the engine, leave it in motion at a running rate
The clearance amounts to:
little more than the minimum and wait that the
- ± 0.05 cooling fluid temperature reaches the rate for the
- suction valves 0.25 ± 0.05
- exhaust valves 0.51 ± 0.05
- There are no water drippings from the connecting

To adjust more quickly the rocker—valve clearance, manifolds of the engine cooling tubing and the cab
operate as follows:
Rotate driving shaft, balance cylinder No. 1 valves heating, fasten blocking collars further if necessary.
and adjust the valves marked with * as described in
the tables:
4— cylinder engine REPLACING SEAL RING FRONT COVER
DRIVING SHAFT
Cylinder No. 1 2 3 4
Suction — — * * Figure 17
Exhaust — * — *
Rotate driving shaft, balance cylinder No. 4 valves

the tables:
Cylinder No. 1 2 3 4
Suction * * — —
Exhaust * — * —
6—cylinder engine
Cylinder No. 1 2 3 4 5 6
Suction — — * — * *
Exhaust — * — * — *
Rotate driving shaft, balance cylinder No. 6 valves
78256
the tables:
Cylinder No. 1 2 3 4 5 6 Apply on the front tang (2) of the driving shaft fixture
99340055 (4) and through the guiding holes of the fixture
Suction * * — * — — itself, drill the internal seal ring (1) with a drill (∅ 3,5 mm) to
Exhaust * — * — * — a depth of 5 mm..
Fix fixture (4) to the ring (1) by means of the 6 screws in the
kit e proceed with the removal of the ring by screwing up the
screw (3).

Figure 18 REPLACING SEAL RING FLYWHEEL

HOUSING BOX
Figure 20
78257
Apply the proper rod (3) of fixture 99363204 to the external

seal ring (2) as shown in the figure and use lever (4), to
remove it from the front cover (1). 78258
Apply fixture 99340056 (3) on the rear tang (5) of the driving
shaft and through the guiding holes of the fixture, drill the
internal seal ring (1) with a drill (∅ 3,5 mm) to a depth of 5
Figure 19 mm.
Fix fixture (3) to the ring (1) by means of the 6 screws (4)
in the kit e proceed with the removal of the ring by tightening
the screw (2).
Perform the removal of the external seal ring as shown and
described in Figure 18.
Figure 21
70225
Apply on the front tang (6) of the driving shaft part (5) of
fixture 99346252, fix it with screws (4) and key on it the new
seal ring (3). Position part (1) on part (5), tighten nut (2) till
complete assembly of seal ring (3) on the front cover (7).
70216
Apply on the rear tang (6) of the driving shaft part (5) of
’fixture 99346253, fix it with screws (4) and key on it the new
seal ring (3).
Position part (1) on part (5) tighten nut (2) until seal ring (3)
is fully assembled into the flywheel housing box (7).

Print 603.43.671/A
CYLINDER HEAD REMOVAL/REFITTING

Removal
Figure 22
Before removal/refitting operations disconnect
! battery terminals and place the vehicle in safety
conditions.
Lift the radiator cowling, overturn the cab and operate

as follows:
- Drain partially the cooling fluid in an appropriate tin;
- Disconnect the cooling fluid tubing (2) from
thermostat cover;
- Disconnect the air tubing (3) from the suction
manifold;
- Disconnect electrical connections;
• (4), for heater
• (12), for injectors
• (13), for water temperature sensor;
• (5) air temperature/pressure sensor;
• (14), air from the rail pressure sensor;
- Remove the part of air tubing (15) from the
remaining tubing, from the compressor (8) and
from the bracket;
- Remove the cooling fluid tubing (9) from the
compressor (8);
- Remove oil breathe pipes (11) from tappet cover
(1);
- Disconnect exhaust fuel tubing (10) from pressure
adjusting valve;
- Remove high pressure tubing (7) from the rail and
high pressure pump (6).
70474

- Remove air—conveyor (9) from turbosupercharger (3) Figure 23

and intercooler radiator (10);
- Disconnect cooling fluid tubings (1)
For vehicles with air—conditioning:
- Operating on the automatic tightener (11), loosen the
compressor (13) belt tension (12);
- Remove compressor fastening screws (13) to the
support and fix the compressor (13) accurately to avoid
gas tubing damages in the air—conditioning system;
For all types of vehicles:
- Remove heat protection (8);
- Remove exhaust tubing fastening screws (5) and exhaust
brake throttle valve (4) from the turbosupercharger (3),
taking care to fasten the latter to the frame;
- Remove the air tubing bracket fastening screws (2);
- Disconnect oil tubing from the turbosupercharger (3);
- Remove exhaust manifold fastening screws (14) from
the cylinder heads and remove it with the
turbosupercharger (3).
NOTE Close the oil and air inlet/outlet holes in the

turbosupercharger to avoid damages caused by
external bodies in it.
- Remove injectors as described before;

- Remove rocker control rods (6);
- Remove cylinder head fastening screws (7).
Place the rocker 99360585 to the cylinder head

lifting bracket. Hook it to the lifter and remove
cylinder heads.
70475

Print 603.43.671/A
Refitting Assemble injectors as described in the appropriate chapter.

For refitting invert the operations requested for removal and Assemble high and low pressure tubing as described in the
follow these warnings: paragraph “main service operations to be performed on
Check that the cylinder head attack surface and the base are engine fitted on vehicle”.
clean; - Check manifold, cooling fluid and air—conveyor
Do not dirty the cylinder head gasket; conditions and replace them in case of damage;
Assemble cylinder head, fasten and clamp the screws in three
steps, as described in the following figures. - Fasten the screw to the prescribed torque;
- Fill the cooling system with cooling fluid and bleed as
described before.
NOTE Carry out the angle closing with the tool

99395216.
Figure 24 Check that the cooling fluid does not contain filth
before using it; if it does, filter with appropriate net
filters; in case of filling—ups, see the table
REFUELING in the section “GENERAL”.
4—cylinder engine
70337
Tests and checks

Figure 25
Start the engine, leave it in motion at a running rate
little more than the minimum and wait that the
cooling fluid temperature reaches the rate for the
A - There are no water drippings from the connecting

manifolds of the engine cooling tubing and the cab
heating, and fasten by blocking collars further if
necessary.
- Low pressure fuel tubing connections and its unions are
6—cylinder engine
correct, as described in “main interventions on an
assembled vehicle”.
70476 - There are no oil drippings between cylinder cover and
head, oil pan and base, heat exchanger oil filter and
lubrication circuit tubings.
- There are no fuel leakages from fuel tubings.
Fastening screws closing order chart:
- There are no air losses from pneumatic tubings.
- 1st pre—closing step, with dynamometrical wrench:
• Screw 12x1.75x130 ( ) 35 ± 5 Nm - The warning lights on the instrument panel and the
• Screw12x1.75 x 150 ( ) 55 ± 5 Nm devices disassembled during the engine removal work
A= Front side correctly.
- 2nd 90°±5° angle closing step

- 3rd 90°±5° angle closing step


ENGINE F4 AE 0481
70756
EUROCARGO TECTOR 12—26 t ENGINE F4 AE 0481 19
Print 603.93.391
Engine F4 AE 0481
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 21
ASSEMBLY DATA — CLEARANCES . . . . . . . . . 24
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 30
AUXILIARY COMPONENTS . . . . . . . . . . . . . . . 32
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY OF THE ENGINE AT THE BENCH 40
REPAIR INTERVENTIONS . . . . . . . . . . . . . . . . . 48
CYLINDER GROUP . . . . . . . . . . . . . . . . . . . . . . 48
- Controls and measurements . . . . . . . . . . . . . . 48
- Head face check on the cylinder group . . . . . 49
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 49
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Cam lift check and pin alignment check . . . . . 50
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 51
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
- Fitting tappets — camshaft . . . . . . . . . . . . . . . . 51
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 52
- Measuring journals and crankpins . . . . . . . . . . 52
- Replacing oil pump control gear . . . . . . . . . . . 54
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 54
- Finding journal clearance . . . . . . . . . . . . . . . . . 54
- Checking output shaft shoulder clearance . . . 55
CONNECTING ROD — PISTON ASSEMBLY . . 55
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
- Measuring piston diameter . . . . . . . . . . . . . . . 56
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Conditions for proper pin—piston coupling . . . 57
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 58
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
- Checking connecting rods . . . . . . . . . . . . . . . . 59
- Checking torsion . . . . . . . . . . . . . . . . . . . . . . . 59

20 ENGINE F4 AE 0481 EUROCARGO TECTOR 12—26 t
Page Page
- Checking bending . . . . . . . . . . . . . . . . . . . . . . 59
- Fitting connecting rod—piston assembly . . . . . . 59 - Oil vapour recycling . . . . . . . . . . . . . . . . . . . . 87
- Connecting rod—piston coupling . . . . . . . . . . . 59 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 89

- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 60 - Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Fitting connecting rod—piston assembly into - Viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . 60
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
- Finding crankpin clearance . . . . . . . . . . . . . . . . 61
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
- Checking piston protrusion . . . . . . . . . . . . . . . 62
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . . 92
- Timing gear case . . . . . . . . . . . . . . . . . . . . . . . 62
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
- Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TURBOSUPERCHARGER ACTUATOR . . . . . . . . 93
- Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . 63
- Check and adjustment . . . . . . . . . . . . . . . . . . 93
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . 64
- Actuator replacement . . . . . . . . . . . . . . . . . . . 93
- Replacing engine flywheel ring gear . . . . . . . . . 64
TURBOSUPERCHARGER LAYOUT . . . . . . . . . . . 95
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 68
SYSTEM OF INJECTION FEEDING ELECTRONIC
- Removing the valves . . . . . . . . . . . . . . . . . . . . 68 TALL PRESSURE COMMON RAIL . . . . . . . . 97
- Checking cylinder head wet seal . . . . . . . . . . . 69 - General Specifications . . . . . . . . . . . . . . . . . . . 97
- Checking cylinder head supporting surface . . . 69 FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FEED SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . . 101
- Removing carbon deposits, checking and grinding valves 70 FUEL PREFILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
- Checking clearance between valve stem and FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
valve guide and valve centering . . . . . . . . . . . . 70
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 MECHANICAL SUPPLY PUMP . . . . . . . . . . . . . . . 104
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - Normal operating conditions . . . . . . . . . . . . . 104
- Regrinding — replacing the valve seats . . . . . . . 71 - Overpressure condition at outlet . . . . . . . . . . 104
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 73 - Drain conditions . . . . . . . . . . . . . . . . . . . . . . . 104
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . 73 CP3 HIGH—PRESSURE PUMP . . . . . . . . . . . . . . . . 105
- Refitting the cylinder head . . . . . . . . . . . . . . . . 73 HIGH—PRESSURE PUMP — INSIDE S

TRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 106
- Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . . 74
- Operating principle . . . . . . . . . . . . . . . . . . . . . 107
RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
- Rocker assembly . . . . . . . . . . . . . . . . . . . . . . . 75
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
- Tappet clearance adjustment . . . . . . . . . . . . . 76
DOUBLE STAGE OVERPRESSURE
- Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . 77 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
- Wiring support . . . . . . . . . . . . . . . . . . . . . . . . 79 INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 - Injector in rest position . . . . . . . . . . . . . . . . . . 111
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 - Injection start . . . . . . . . . . . . . . . . . . . . . . . . . 111
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . 85 - Injection end . . . . . . . . . . . . . . . . . . . . . . . . . . 111

- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 86 PRESSURE LIMITER FOR FUEL RETURN . . . . . . . 111

Print 603.93.391
F4AE0481A
Type
(.17)
Cycle 4 —stroke Diesel

Power Supply Intercooler supercharged
Injection Direct
Cylinder number 4 in line
∅
Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 3900
ρ Compression ratio 17 : 1
Max power kW 125
(CV) (170)
rpm 2700
Max. torque Nm 560
(kgm) (57.1)
rpm 1200
Idle engine
minimum rpm
rpm 750
Idle engine peak
rpm
rpm 3000

F4AE0481A
Type
(.17)
SUPERCHARGER With intercooler
Turbosupercharger type GARRETT GT 22

Turbosupercharger shaft radial backlash —
Turbosupercharger shaft end play —
Pressure relief valve min. opening stroke:
mm —
Pressure relief valve max. opening stroke:
mm —
Pressure corresponding to min. stroke: bar —
Pressure corresponding to max. stroke: bar —
Forced by gear pump , pressure relief valve, double
LUBRICATION
stage oil filter
Oil pressure with warm
bar engine:
— idling bar 1.2
— peak rpm bar 3.8
COOLING By centrifugal pump, regulating
thermostat, radiator, heat exchanger,
intercooler
Water pump control Through belt
Thermostat
— start of opening 81 ± 2º C
— maximum opening 96º C
FILLING
Total capacity
1st filling:
Urania Turbo liters —
Urania LD5 kg —
— engine sump Min. level. Max. level
liters 5.3 8.3
kg 4.8 7.5
— engine sump + filter
liters 6.3 9.3
kg 5.7 8.4

F4AE0481A
Type
(.17)
TIMING
start before T.D.C. A 8.5º

end after B.D.C. B 8.5º
start before T.D.C. D 51º

end after B.D.C. C 12.5º
Checking timing
mm —
X
mm —
X
Checking operation
mm 0.20 ÷ 0.30
X
mm 0.46 ÷ 0.56
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Nozzle type Injectors
Injection sequence 1—3—4—2
ba
r Injection pressure bar 250 — 1450

Print 603.93.391/A
ASSEMBLY DATA — CLEARANCES
F4AE0481A
Type
(.17)
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1
Cylinder barrels ∅1 102.009 ÷ 102.031

X
Spare pistons
∅1 type:
X Size X 60.5
Outside diameter ∅1 101.781 ÷ 101.799
∅2 Pin housing ∅2 40.008 ÷ 40.014
Piston — cylinder barrels 0.21 ÷ 0.25
Piston diameter ∅1 0.5
X
Piston protrusion X 0.28 ÷ 0.52
∅ 3 Piston pin ∅3 39.9938 ÷ 40.0002
Piston pin — pin housing 0.0078 ÷ 0.0202

Revi — July 2005
Print 603.93.391
F4AE0481A
Type
(.17)
X1 X1* 2.705 ÷ 2.735

X2 Split ring slots X2 2.420 ÷ 2.440
X3 X3 4.020 ÷ 4.040
S 1 S 1* 2.560 ÷ 2.605
S 2 Split rings S2 2.350 ÷ 2.380
S 3 S3 3.975 ÷ 4.000
* measured on 98 mm ∅
1 0.100 ÷ 0.175
Split rings — slots 2 0.040 ÷ 0.90
3 0.020 ÷ 0.065
Split rings 0.5
X1 Split ring end opening

X 2 in cylinder barrel:
X1 030 ÷ 0.40
X3
X2 0.60 ÷ 0.80
X3 0.25 ÷ 0.55
∅1
Small end bush
housing ∅1 42.987 ÷ 43.013
Big end bearing
housing ∅2 72.987 ÷ 73.013
∅ 2
∅4
∅ 3 Small end bush diameter

Outside ∅4 43.279 ÷ 43.553
Inside ∅3 40.019 ÷ 40.033
S Spare big end half
bearings S 1.955 ÷ 1.968
Small end bush — housing 0.266 ÷ 0.566
Piston pin — bush 0.0188 ÷ 0.0392
Big end half bearings 0.250 ÷ 0.500

Print 603.93.391/A
F4AE0481A
Type
(.17)

X
Size X —
Max. tolerance
on connecting rod
axis alignment —
∅1 ∅2
Journals ∅1 82.99 ÷ 83.01
Crankpins ∅2 68.987 ÷ 69.013
Main half bearings S1 2.456 ÷ 2.464

Big end half bearings S2 1.955 ÷ 1.968
S 1 S 2
*provided as spare part
Main bearings
∅ 3 No. 1—5 ∅3 87.982 ÷ 88.008
No. 2—3—4 ∅3 87.977 ÷ 88.013
Half bearings — Journals

No. 1—5 0.044 ÷ 0.106
No. 2—3—4 0.039 ÷ 0.111
Half bearings — Crankpins 0.038 ÷ 0.116
Main half bearings

0.250 ; 0.500
Big end half bearings
Shoulder journal X1 37.475 ÷ 37.545
X 1
Shoulder main bearing X2 32.23
X 2
X 3
Shoulder half—rings X3 32.30
Output shaft shoulder 0.07

Revi — July 2005
Print 603.93.391/A
F4AE0481A
Type
(.17)
CYLINDER HEAD — TIMING SYSTEM mm

∅ 1
Valve guide seats on

cylinder head ∅1 7.042 ÷ 7.062
∅ 4 Valves:
∅2 6.970 ÷ 6.990
α 60o ± 0.25o
∅2 6.970 ÷ 6.990
α α 45o ± 0.25o
Valve stem and guide 0.052 ÷ 0.092
Housing on head for
valve seat:
∅1 34.837 ÷ 34.863
∅ 1 ∅1 34.837 ÷ 34.863
Valve seat outside diameter;

∅ 2 valve seat angle on cylinder
head:
∅2 34.917 ÷ 34.931
α 60o
∅2 34.917 ÷ 34.931
α
α 45o
X 0.36 ÷ 0.94
X Sinking X 0.73 ÷ 1.33
0.054 ÷ 0.094
Between valve seat
and head 0.054 ÷ 0.094
Valve seats —

Revi — July 2005
F4AE0481A
Type
(.17)

Valve spring height:
free spring H 47.75

H H1
H 2 under a load equal to:
339.8 ± 19 N H1 35.33
741 ± 39 N H2 25.2
Injector protrusion X It cannot be adjusted

X
Camshaft bush
housings No. 1—5 59.222 ÷ 59.248
Camshaft housings
∅ ∅ ∅ No. 2—3—4 59.222 ÷ 59.248
1 23 4 5
∅ 2
Camshaft journals:
1⇒5 ∅ 1—2—3 53.995 ÷ 54.045
∅ 1 ∅ 3
Camshaft bush outside

∅ diameter with a load
of 3.3 kN: ∅ 59,222 ÷ 59,248
Bush inside diameter

∅ 54.083 ÷ 54.147
after ramming ∅
Bushes and housings

0,113 ÷ 0,165
on block
Bushes and journals 0.038 ÷ 0.152
Cam lift:
H H 7.582
H 6.045

Revi — July 2005
F4AE0481A
Type
(.17)

∅1
Tappet cap housing
on block ∅1 16.000 ÷ 16.030
∅2
∅ 3 Tappet cap outside
diameter: ∅2 15.924 ÷ 15.954
∅3 15.960 ÷ 15.975
∅2
Between tappets and housings 0.025 ÷ 0.070
Tappets —
∅ 1
Rocker shaft ∅1 21.965 ÷ 21.977
Rockers ∅2 22.001 ÷ 22.027
∅ 2
Between rockers and shaft 0.024 ÷ 0.062

Revi — July 2005
Print 603.93.391
TIGHTENING TORQUE
PART TORQUE
Nm kgm
Cylinder barrel lubrication nozzle fixing screw M8 15 ± 3 1.5 ± 0.3
Engine shaft cap fixing screw M12 1st phase 50 ± 6 5 ± 0.6
2nd phase 80 ± 6 8 ± 0.6
3rdd phase 90º ± 5º
Stud bolts M6 for camshaft sensors 8±2 0.8 ± 0.2
Stud bolts M8 for power supply pump 12 ± 2 1.2 ± 0.2
Rear gearcase fixing screw M12 77 ± 12 7.7 ± 1.2
Camshaft sensor fixing nut M6 10 ± 2 1 ± 0.2
1st phase 8±1 0.8 ± 0.1
Oil pump fixing screw M8 2nd phase 24 ± 4 2.4 ± 0.4
Front cover fixing screw M8 24 ± 4 2.4 ± 0.4
Screw M8 for camshaft longitudinal check plate fixing 24 ± 4 2.4 ± 0.4
Camshaft gear fixing screw M8 36 ± 4 3.6 ± 0.4
Connecting rod cap fixing screw M11 1st phase 60 ± 5 6 ± 0.5
2ndd phase 60º ± 5º
Underblock plate fixing screw M10 43 ± 5 4.3 ± 0.4
Nut M8 for high pressure pump gear fixing 105 ± 5 10.5 ± 0.5
Fuel pump fixing nuts M8 24 ± 4 2,4 ± 0,4
½ inch plug on the cylinder head 24 ± 4 2.4 ± 0.4
¼ inch plug on the cylinder head 36 ± 5 3.6 ± 0.5
¾ inch plug on the cylinder head 12 ± 2 1.2 ± 0.2
Injector fixing screws M6 8.5 ± 0.35 0.35 ± 0.035
Union fixing nut for injector power supply 50 ± 5 5 ± 0.5
Pre—heating grid nut M6 on the suction manifold 8±2 0.8 ± 0.2
Suction manifold fixing screw M8 24 ± 4 2.4 ± 0.4
Rear bracket fixing screw M12 for engine lifting 77 ± 12 7.7 ± 1.2
Common rail fixing M8 screws 24 ± 4 2.4 ± 0.4
High—pressure fuel pipe unions M14 20 ± 2 2 ± 0.2
Cylinder head fixing M12 screw (12x1.75x 130) 35 ± 5 3.5 ± 0.5
Cylinder head fixing M12 screw (12x1.75x 150)
} 1st phase
55 ± 5 5.5 ± 0.5
2nd phase 90º ± 5º
3rd phase 90º ± 5º
Equalizer support fixing screw 36 ± 5 3.6 ± 0.5
Valve clearance adjustment nut 24 ± 4 2.4 ± 0.4
Power supply pipe fixing nuts M14 from common rail high pressure pump 20 ± 2 2 ± 0.2
High pressure pipe union fixing screw M8 24 ± 4 2.4 ± 0.4
Head bulkhead fixing screw M6 for harness 10 ± 2 1 ± 0.2
Electric harness support fixing screw M8 for injector power supply 24 ± 4 2.4 ± 0.4
Harness fixing nuts on individual injector 1.5 ± 0.25 0.15 ± 0.025
Fuel filter—holder bracket fixing screw M8 77 ± 8 7.7 ± 0.8
Fuel filter—holder fixing screw M8 24 ± 4 2.4 ± 0.4
Fuel filter contact + ¾ turn
Oil pressure adjustment valve fixing screw M22 on the oil filter support 80 ± 8 8 ± 0.8
Oil filter support and gasket radiator fixing screw M8 24 ± 4 2.4 ± 0.4
Oil filter contact + ¾ turn

PART TORQUE
Nm kgm
11/8 inch connection on filter support for turbine lubrication 24 ± 4 2.4 ± 0.4
Pipe fixing nut M12 for turbine lubrication 10 ± 2 1 ± 0.2
Engine coolant input connection fixing screw M10 43 ± 6 4.3 ± 0.6
90° curve fixing (as necessary) on engine fluid input connection 24 ± 4 2.4 ± 0.4
Pipe on cylinder head for supercharger cooling 22 ± 2 2.2 ± 0.2
Union fixing screw M6 for engine coolant exhaust 10 ± 2 1 ± 0.2
Pin fixing on engine block for exhaust manifold 10 ± 2 1 ± 0.2
Exhaust manifold fixing screw M10 on cylinder head 53 ± 5 5.3 ± 0.5
Adapter fixing screw M12 for damper 1st phase 50 ± 5 5 ± 0.5
and damper on engine shaft 2ndd phase 90º
Pulley fixing screw M10 on engine shaft 68 ± 7 6.8 ± 0.7
Water pump fixing screw M8 24 ± 4 2.4 ± 0.4
Auxiliary part control belt screw coupling fixing screw M10 43 ± 6 4.3 ± 0.6
Fixed pulley fixing screw M10 for auxiliary part control belt 43 ± 6 4.3 ± 0.6
Flywheel housing fixing screw M10 85 ± 10 8.5 ± 1
Flywheel housing fixing screw M12 49 ± 5 4.9 ± 0.5
Heating exchanger fixing screw M6 for control unit 10 ± 2 1 ± 0.2
Heating exchanger fixing screw M8 for control unit 24 ± 4 2.4 ± 0.4
Input—output connection M12 for fuel on the heating exchanger 12 ± 2 1.2 ± 0.2
Valve cover fixing nut M8 24 ± 4 2.4 ± 0.4
Camshaft sensor fixing screw M6 8±2 0.8 ± 0.2
Engine shaft sensor fixing screw M6 8±2 0.8 ± 0.2
Engine coolant temperature sensor fixing screw M14 20 ± 3 2 ± 0.3
Oil temperature—pressure sensor fixing screw M5 6±1 0.6 ± 0.1
Fuel pressure sensor fixing screw 35 ± 5 3.5 ± 0.5
Fuel temperature sensor fixing screw M14 20 ± 3 2 ± 0.3
Air pressure/temperature sensor fixing screw on suction manifold 6±1 0.6 ± 0.1
Engine oil level sensor fixing screw M12 12 ± 2 1.2 ± 0.2
pins M10 7±1 0.7 ± 0.1
{
6 cylinders
nuts M10 43 ± 6 4 3 ± 00.6
4.3 6
Turbine fixing to the exhaust manifold
pins M8 7±1 0.7 ± 0.1
{
4 cylinders
nuts M8 24 ± 4 2.4 ± 0.4
Adapter M12 on turbine for (input) lubricant oil pipes 35 ± 5 3.5 ± 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 ± 5 3.5 ± 0.5
Oil pipe fixing on adapter M10 for block turbine lubrication 43 ± 6 4.3 ± 0.6
M8 oil exhaust pipe fixing on turbine 24 ± 4 2.4 ± 0.4
Fixing union M6 for oil return from the cylinder head to the flywheel housing 10 ± 2 1 ± 0.2
Engine flywheel fixing screw M12 1st phase 30 ± 4 3 ± 0.4
2ndd phase 60º ± 5º
Front bracket fixing screw M8 for engine lifting 24 ± 4 2.4 ± 0.4
Engine oil torque fixing screw 24 ± 4 2.4 ± 0.4

AUXILIARY COMPONENTS
PART TORQUE
Nm kgm
Air supercharger:
Control gear 5/8 inch fixing nut on the supercharger shaft 125 ± 19 12.5 ± 1.9
Fixing nut M12 to the flywheel housing 77 ± 12 7.7 ± 1.2
Alternator:
Bracket fixing nut M12 on the water input union 43 ± 6 4.3 ± 0.6
Alternator fixing nut M10 43 ± 6 4.3 ± 0.6
Climate control:
Bracket fixing screw M10 43 ± 6 4.3 ± 0.6
Supercharger fixing screw M10 24 ± 4 2.4 ± 0.4
Starter:
Starter fixing screw 43 ± 6 4.3 ± 0.6
TOOLS
TOOL No. DESCRIPTION
99305018 Kit with tooling complete of valve seat grinding tools
99305047 Spring load device
Set of 3 wrenches with insert by 9 x 12 (14 — 17 — 19 mm) to be used

99317915 with 99389829
Revolving stand for group overhaul (capacity 1000 daN, torque

99322205 120 daNm)

Print 603.93.391
TOOLS
99340055 Engine shaft front gasket extraction tool
99340056 Engine shaft rear gasket extraction tool
99341001 Double effect lift
99341009 Bracket pair
99342101 Injector extraction tool
99346252 Tool for engine shaft front gasket assembly

TOOLS
99346253 Tool for engine shaft front gasket assembly
99355019 Wrench (10mm) for hydraulic power steering pump check screw
99360076 (engine) oil filter removal tool
99360183 Pliers for piston ring removal and assembly (65—110mm)
99360268 Engine valve assembly and removal tool
99360292 Keying device for mounting on valve guide

TOOLS
99360330 Engine flywheel rotation tool
99360351 Engine flywheel check tool
Beater for camshaft bush removal and assembly

99360362 (use with tool 99370006)
99360500 Engine shaft lifting tool
99360595 Engine removal and assembly rocker arm
99360605 Band for piston insertion into the cylinder barrel (60—125 mm)

TOOLS
99361037 Engine fixing bracket to the revolving stand 99322205
99363204 Gasket extraction tool
99367121 Manual pump to measure positive and negative pressures
99370006 Interchangeable beater grip
99370415 Gauge—holder block for various relieves (use with tool 99395603)
Dynamometric wrench with engagement by 9 x 12 — 50 — 60 Nm to

99389829 be used with 99317915

Print 603.93.391
TOOLS
Dynamometric screwdriver for injector solenoid valve connector

99389834 check nut adjustment
99395216 Measurer pair for angular tightening with ½” and ¾ “ square
99395220 Universal Goniometer/Inclinometer
99395363 Square complete for connecting rod quadrature control
99395603 Gauge (0 — 5 mm)
99395687 Bore meter

Figure 1
99221
ENGINE F4AE0481 CROSS SECTION

Figure 2
70478
ENGINE F4AE0481 LONGITUDINAL SECTION

Print 603.93.391/A
ENGINE OVERHAUL
540110 DISASSEMBLY OF THE ENGINE AT
THE BENCH Figure 5
Figure 3
105163 70127
In order to apply to the engine block the engine fixing brackets The pipe (3) from the union (4) and from the supercharger
99341009 to the stand for the overhaul, operating on the (8).
engine left side, it is necessary:
Remove the fuel pipe (2) from the rail and from the
- to remove the fuel filter (4) from the support (1) by high—pressure pump (9) and remove it from the engine block,
means of tool 99360076; by removing the fixing screws (4 and 6)
- to remove the low pressure fuel pipe (2—3—5) from the
support (1)
- to remove the support (1) bracket from the block NOTE When unlocking the pipe (2) union (7), it is necessary
to prevent the union (10) rotation of the
high—pressure pump (9), by using the proper wrench.
Figure 4
On the right side
Figure 6
70126
70128
In order to remove the low—pressure fuel pipe Remove the screws (2) and remove the oil pipe (3) from the
(2—3—4, Figure 3) from the relevant connection supercharger pipe (1) and from the engine block.
unions, it is necessary to press the fastener (1) as
shown in figure B. Remove the starting engine (5) from the flywheel cover (4).
After removing the pipe, position the fastener (1) into Apply to the block the bracket 99361037 and fix by means of
its lock position, figure A, in order to avoid possible these latter the engine to the revolving stand 99322205. Drain
deformations. the engine oil by removing the plug from the sump.
Remove the fan from the engine shaft pulley.

Revi — July 2005
Print 603.93.391
Figure 7
78670
1. Connections for injectors — 2. Engine coolant temperature sensor — 3. Fuel pressure sensor — 4. Engine oil pressure and
temperature sensor — 5. Engine shaft sensor — 6. Injector — 7. Temperature—air pressure sensor — 8. Timing phase sensor —
9. Fuel temperature sensor and fuel heater — 10. Pressure adjuster — 11. Control unit EDC7
Disconnect the engine wire by disconnecting the connectors: Figure 8

(1) from the injector harness (6); (7) air temperature
/pressure sensor: (3) fuel pressure sensor; (11) control unit;
(10) high pressure pump sensor; (8) timing phase sensor; (2)
engine coolant temperature sensor on thermostat (5) rpm
sensor;
91576
Remove from the rail: the fuel pipe (4) according to the
procedures described in Figure 4. Remove the fuel pipe (5)
from the rail (2) and from the manifolds (3) for injectors.
Remove the screws (1) and the rail (2).

Figure 9 Figure 11
70130 70132
Remove from the fuel return pressure limiting device (1), the Loosen the tappet adjuster fixing nuts (1) and unscrew the
pipe (2) as described in Figure 4. adjuster.
Remove the screws (2), remove the equalizer unit (3)
Remove the pipe (4) from the air supercharger (3) and from
composed by the support (6), equalizers (4), shafts (5) and
the union (5). Remove the nut (10) Loosen the elastic hose
remove the bonds (7) from the valves. Remove the rods (8).
clamp (6) and remove the oil vapor pipe (9).
Remove the unions (13—11) and remove the pipe (12). Figure 12
Remove the nuts (7) and remove the tappet (8) cover
complete of gasket.
Figure 10
70133
Remove the injector fixing screws and by means of tool

99342101 (1) withdraw the injectors (2) from the cylinder
head.
Figure 13
70131
Remove the nuts (7) and disconnect the electric wires from
the injectors (8).
Remove the screws (1) and remove the injector harness
support (2) complete of gasket.
Remove the screws (5) and remove the air
pressure/temperature sensor (6).
Remove the nuts (3) and withdraw the fuel manifolds (4).
NOTE The removed fuel manifold (4) shall not be used 70134
again and they must be replaced by new ones.
Remove the screw (4), loosen the clamp (2) and remove the
air conveyor (1) from the turbosupercharger (3).

Figure 14 Figure 16
70135 70137
Hook the brackets (1) with metal ropes and remove the
Remove the oil pipe (5) check clamp fixing screw (4) from cylinder head (2) from the block by means of a hoister.
the exhaust manifold (1).
Remove the oil pipe (5) from the oil filter/ heating exchanger
support (7). Figure 17
Remove the nuts (2) and remove the turbosupercharger (3)
from the exhaust manifold (1).
Remove the screws (6) and remove the exhaust manifold (1)
from the cylinder head.
Figure 15
70138
Remove the cylinder head gasket (1).
Loosen the stretch of the belt (2) by means of a proper
wrench, operating the automatic belt tightener (3) and
remove the belt.
Remove the screw (4) and the automatic tightener (3).
Figure 18
70136
Remove the screws (1) and remove the air conveyor (2)
complete of heater. Remove the screws (4), remove the
cover (3) and the relevant thermostat.
Remove the head cylinder (6) fixing screws (5).
70139
NOTE The external screws pointed out are shorter.

Remove the screws (2) and disconnect the alternator (1)

Figure 19 Figure 21
70140 70142
Remove the screws (2) and remove the alternator support Remove the screws (1) and the electronic control unit (2)
(3). complete of heating exchanger.
Remove the oil filter (1) by means of tool 99360076.
Figure 20 Figure 22
70141 70143
Remove the screws (4) and remove oil By means of wrench 99355019, remove the screws (1) and
temperature/pressure sensor. (3) and remove the hydraulic power steering pump (2)
complete of oil tank (4) from the air supercharger (5)
Remove the screws (1) and remove the oil filter/heating
exchanger support (2), middle plate (6) and relevant gaskets.
Remove the oil level sensor (5) Figure 23
70144
Remove the screws (2) and the nuts (1—4) and remove the
air supercharger (3)

Figure 24 Figure 27
70145 70148
Remove the nut (1) and remove the phase sensor (2). Remove the screws (1) and remove the water pump (2).
Remove the nuts (3) and remove the high—pressure pump Remove the screws (3) and remove the roller (4).
(4) complete of power supply pump (5). Remove the screws (5) and remove the rpm sensor (6).
Figure 25 Figure 28
70149
Remove the screws (1) and remove the front cover (2).
70146
Apply the tool 99360351 (2) to the flywheel housing (1), to NOTE Write down the screw (1) assembling position
stop the flywheel (3) rotation. because they exhibit different lengths.
Loosen the screws (4)
Figure 26 Figure 29
70150
70340 Remove the screws (1) and remove the oil pump (2).
Remove the screws (2) and remove the pulley (3) and the
bumper flywheel (1). NOTE It is not possible to overhaul the oil pump (2).
Remove the screws (6) and remove the hub (5) and the
phonic wheel (4).

Figure 30 Figure 33
70151 70154
Remove tool 99360351 (2). Overturn the engine.
Remove the engine (3) flywheel fixing screws (1) to the
engine shaft (4). Remove the screws (2), remove the plate (3) and remove the
oil sump (1).
Figure 31
Figure 34
70152
Screw two pins (2) exhibiting a proper length into the engine 99222
shaft holes (3). Remove the screws (1) and remove the oil suction rose (3).
Withdraw the engine flywheel (1) in order to sling it with the
hoister and position it into the container. Remove the screws (2) and remove the stiffening plate (4).
Figure 32
Figure 35
70153
Remove the screws (1) and remove the rear cover (2).
70156
Remove the screws (1) and remove the gear (3) from the
NOTE Write down the screw (1) assembling position
camshaft (2).
because they exhibit different lengths.

Figure 36 Figure 39
70157
Remove the screws (2) and the timing gearcase (1). 70160
The second—last—bench cap (1) and its relevant support have

the half—bearing (2) equipped with shoulder.
NOTE Write down the screw (2) assembling position
because they exhibit different lengths. NOTE Write down the upper and lower half—bearing
assembling position, in the event of use, they should
be mounted in the position detected when
Figure 37 disassembling.
Figure 40
70158
Remove the connecting rod cap (2) fixing screws (1) and
remove them.
Remove the connecting rod piston assemblies from the 70161
upper side of the block.
Remove the engine shaft (2) from the block by means of tool
NOTE Maintain the half—bearings in their relevant seats 99360500 (1) and hoister.
because, in the event of use, they should be
mounted in the position detected when Figure 41
disassembling.
Figure 38
70162
70159
Remove the bench half—bearings (1).
Remove the screws (1) and remove the bench caps (2). Remove the screws (2) and remove the oil nozzles (3).

zs
REPAIR INTERVENTIONS
540410 CYLINDER GROUP
Figure 42 540420 Controls and measurements
Figure 45
70163
Remove the screws (1) and remove the camshaft (3) check
plate (2)
70166
Carefully clean the cylinder—block group, when performed

NOTE Write down the plate (2) assembling position. the engine disassembly.
Use the proper rings to transfer the cylinder group.
Carefully check that the block does not present any cracks.
Check the working plug conditions. Replace them if they are
rusty or in case of doubt about their conditions.
Figure 43 Examine the cylinder barrel surfaces; they must not present
any seizing, scoring, ovalization, taper, and excessive wearing
traces.
The internal diameter check of the cylinder barrels, to verify
the ovalization, taper and wearing entity, is performed by
means of bore meter 99395687 (1) equipped with
comparator previously set to zero on the ring gauge (2) of
the cylinder barrel diameter.
NOTE If you do not have at your disposal the ring gauge,

use a micrometer for the zero setting operation.
70164
Figure 46
Carefully withdraw the camshaft (1) from the engine block.
Figure 44
70167
The measurements must be performed for each individual

cylinder at three different heights from the barrel and on two
perpendicular surfaces: one parallel to the longitudinal engine
axis (A) and the other one perpendicular (B); usually the max
wear is detected on this latter surface and in correspondence
with the first measurement.
If you detect any ovalization, taper or wear, ream and grind
70165 the cylinder barrels. The cylinder barrel regrinding must be
performed in relation to the diameter of the spare pistons
oversized of 0.5 mm in respect of the nominal value and
Withdraw the tappets (1) from engine block. prescribed assembling clearance.
Print 603.93.391
Figure 47 Head face check on the cylinder group
±
Figure 48
70170
Check that the head face, on the cylinder group, does not
present deformations.
This check can be carried out, after a previous grains (4)
extraction by means of a calibrated ruler (2) and feeler gauge
(3).
After verified the deformation areas, perform the flattening
α of the face by means of grinding machine.
The flatness error must not be higher than 0.075 mm.
70168
The block flattening could be performed only after

! you have checked that, at finished work, the piston
projection from the cylinder barrel is not higher than
NOTE In the event of grinding operation, all the barrels the value prescribed.
must result of the same oversize (0.5 mm)
Check the conditions of the working plugs (1) of the cylinder
groups; replace them if rusty or in case of doubt about their
Check the bench bearing seats, proceeding as follows: conditions.
- mount the bench caps on the supports without When flattening is finished, restore the cylinder barrel bevel
bearings; as shown in Figure 47.
- screw the fixing screws to the torque prescribed;
5412 TIMING SYSTEM
- by means of an adequate gauge, verify that the internal 541210 Camshaft
diameter of the seats correspond to the value
prescribed. Figure 49
If you detect a higher value, replace its block
70169
CAMSHAFT MAIN DATA

The data listed are refereed to the standard pin diameter.
The surfaces of the camshaft support pins and cams must be better to replace the shaft and relevant bushes.
very smooth; if they present seizing and scoring traces, it is

541211 Cam lift check and pin alignment 541213 BUSHES

check Figure 51
Position the shaft on counterpoints and, by means of a
centesimal gauge, located on the central support, check that
the alignment error is not higher than 0.04 mm: on the
contrary, replace the shaft. Then, check the cam lifting: it must
result of 6.045 mm for the exhaust ones and of 7.582 mm for
the suction ones; if you detect different values, replace the
shaft.
Figure 50
70172
The camshaft bushes (2) must result forced in their relevant

seats.
The inner surfaces must result without seizing and wearing
traces.
By means of a bore meter (3), measure the diameter of the
rear and front bushes (2) and intermediate seats (1) for
70171
camshaft.
The measurements must be performed on two
Check the camshaft (2) support pin diameter by means of a perpendicular axes.
micrometer (1) on two perpendicular surfaces.
Figure 52
sec. A—A
85484
MAIN DATA OF THE CAMSHAFT BUSHES AND RELEVANT SEATS

* Dimensions to be obtained after the bush driving

541213 Bush replacement Fitting tappets — camshaft

Figure 53 Figure 55
70176
70174
Lubricate the tappets (1) and fit them into the relevant
To replace front and rear bushes (1), use for their removal housings on the engine block.
and refitting the tool 99360362 (2) and handgrip 99370006
(3). Figure 56
NOTE When refitting bushes (1) direct them so that

lubrication holes coincide with engine block
housing holes.
70164
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
541224 Tappets
Figure 57
Figure 54
70238
70175
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
MAIN DATA CONCERNING THE TAPPETS AND THE then tighten the screws (2) to the specified torque.
RELEVANT HOUSINGS ON THE ENGINE BLOCK

5408 OUTPUT SHAFT

540810 Measuring journals and crankpins
Figure 58 Figure 60
70179
70182
Check camshaft end float (1). Grind journals and crankpins if seizing, scoring or excessive
ovalisation are found. Before grinding the pins (2) measure
It shall be 0.23 ± 0.13 mm. them with a micrometer (1) to decide the final diameter to
Figure 59 which the pins are to be ground.
NOTE It is recommended to insert the found values in the

proper table.
See Figure 61.
Undersize classes are: 0.250 — 0.500 mm
Journals and crankpins shall always be ground to the

! same undersize class.
70180 Journals and crankpins undersize shall be marked on
the side of the crank arm No.1.
Fit nozzles (2) and tighten the fastening screws (1) to the For undersized crankpins: letter M
specified torque. For undersized journals: letter B
For undersized crankpins and journals: letters MB
Figure 61
70181
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value

Print 603.93.391
Figure 62
measured on > 45.5 mm radius

between adjacent journals 70183
OUTPUT SHAFT MAIN TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness ○
SHAPE
Cilindricity /○/
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING ON

SYSTEM CONTROL SIDE BEARINGS FRONT SIDE
70237

549215 Replacing oil pump control gear 540811 Finding journal clearance
Figure 63 Figure 65
70161
Refit the output shaft (2).

70184 Check the backlash between output shaft main journals and
Check that gear toothing (1) is not damaged or worn, the relevant bearings as follows:
otherwise remove it using the proper puller (3). Figure 66
When fitting the new gear, heat it to 180°C for 10 minutes
in an oven and then key it to the output shaft.
Fitting main bearings
Figure 64
70186
- Clean accurately the parts and remove any trace of oil;

- position a piece of calibrated wire (3) on the output shaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
70185 supports.
Figure 67
NOTE Refit the main bearings that have not been
replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm

undersize on the internal diameter.
NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the 70187
lubricating hole and fit them into their housings. Tighten the pre—lubricated screws (1) in the following three
successive stages:
The second last main half bearing (1) is fitted with shoulder
- 1st stage, with dynamometric wrench to 50 ± 6 Nm.
half rings.
- 2nd stage, with dynamometric wrench to 80 ± 6 Nm.

Figure 68 Checking output shaft shoulder clearance
α Figure 70
70188
- 3rd stage, with tool 99395216 (1) set as shown in the 70190
figure, tighten the screws (2) with 90° ± 5° angle. This check is performed by setting a magnetic—base dial gauge
(2) on the output shaft (3) as shown in the figure, standard
value is 0.068 — 0.41 mm.
Figure 69 If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
540830 CONNECTING ROD — PISTON

ASSEMBLY
70189 Figure 71
- Remove caps from supports.
The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a different
backlash value is found. Once the specified backlash is
obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.
70191
CONNECTING ROD — PISTON ASSEMBLY

COMPONENTS
1. Stop rings — 2. Pin — 3. Piston — 4. Split rings — 5. Screws
— 6. Half bearings — 7. Connecting rod — 8. Bush.
NOTE Pistons are supplied spare with 0.5 mm oversize.

540840 Pistons
Measuring piston diameter
Figure 72 Figure 75
32615
32613
Remove split rings (1) from piston (2) using pliers 99360183 Using a micrometer (2), measure the diameter of the piston
(3). (1) to determine the assembly clearance.
NOTE The diameter shall be measured at 12 mm from the

Figure 73 piston skirt.
Figure 76
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 74
84291
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter

540841 Piston pins Figure 80

Figure 77
18857 32620
To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2nd
(2). and 3rd slot and the relevant housings on the piston (2), using
Conditions for proper pin—piston coupling a feeler gauge (1).
Figure 78 Figure 81
32619 41104
Lubricate the pin (1) and its seat on piston hubs with engine DIAGRAM FOR MEASURING THE CLEARANCE X
oil; the pin shall be fitted into the piston with a slight finger BETWEEN THE FIRST PISTON SLOT AND THE
pressure and shall not be withdrawn by gravity. TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
540842 Split rings between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
Figure 79 the ring (2) protrudes half—way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
16552
Use a micrometer (1) to check split ring (2) thickness.

Figure 82 Figure 84
CONNECTING ROD BODY

1234 W
CONNECT- WEIGHT
ING ROD No.
0001 V *
↓ W
9999 X
70194
Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).
CONNECTING ROD CAP

540830 Connecting rods 1234 A 123
CONNECTING YEAR DAY
ROD No.
0001 A 1998 001
↓ B 1999 ↓
Figure 83 9999 C 2000 366
70196
D 2001
Every connecting rod is marked as follows:

! - On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the new connecting rod with the same
numbers of the replaced one.
** *
** - On body with a letter showing the weight of the
connecting rod assembled at production:
S V, 1820 — 1860 (yellow marking);
S W, 1861 — 1900 (green marking);
S X, 1901 — 1940 (blue marking);
Spare connecting rods are of the W class with green
marking*.
Material removal is not allowed.

70195
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON

PIN AND HALF BEARINGS
* Value for inside diameter to be obtained after driving in
connecting rod small end and grinding.
** Value not measurable in released condition 540834 Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
To obtain best coupling the connecting rod—cap replace.
coupling surfaces are knurled. Removal and refitting shall be performed using the proper
It is therefore recommended to not remove beater.
knurling.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.

Print 603.93.391
Checking connecting rods Checking bending

Figure 85 Figure 87
61695
61696
Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting
Check that the axes of the connecting rods (1) are parallel rod axis.
using tool 99395363 (5) as follows: Position the vertical support (1) of the dial gauge (2) to rest
- fit the connecting rod (1) on tool 99395363 (5) spindle the latter on pin (3), point C.
and lock it with screw (4); Move the connecting rod forwards and backwards to find pin
- set the spindle (3) on V—blocks by resting the connecting top position, then in this condition reset the dial gauge (2).
rod (1) on the stop bar (2). Move the spindle with the connecting rod (5) and repeat the
check of the top point on the opposite side D of the pin (3).
Checking torsion
The difference between point C and point D shall not exceed
Figure 86 0.08 mm.
Fitting connecting rod—piston assembly

Connecting rod—piston coupling
Figure 88
70198
61694
Check connecting rod (5) torsion by comparing two points The piston crown is marked as follows:
(A and B) of pin (3) on the horizontal plane of the connecting 1. Part number and design modification number;
rod axis. 2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
Position the dial gauge (2) support (1) to obtain a preload of block;
approx. 0.5 mm on the pin (3) in point A and then set the 3. Marking showing 1st slot insert testing;
dial gauge (2) to zero. Move the spindle (4) with the 4. Manufacturing date.
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A and
B shall not exceed 0.08 mm.

Print 603.93.391/A
Figure 89
NOTE Split rings are supplied spare with the following
sizes:
— standard, yellow marking;
— 0.5 mm oversize, yellow/green marking;
Figure 92
102596
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (4) are read as shown in the figure.
Figure 90
70200
Fit half bearings (1) on connecting rod and cap.
NOTE Refit the main bearings that have not been

replaced, in the same position found at removal.
Do not try to adapt the half bearings.
72705
Fitting connecting rod—piston assembly into
Fit pin (1) split rings (2). cylinder barrels
Fitting split rings
Figure 93
Figure 91
70201
32613 Lubricate accurately the pistons, including the split rings and
Use pliers 99360183 (3) to fit the split rings (1) on the piston the cylinder barrel inside.
(2). Use band 99360605 (2) to fit the connecting rod—piston
Split rings shall be fitted with the marking “TOP” facing assembly (1) into the cylinder barrels and check the following:
upwards and their openings shall be displaced with each - the number of each connecting rod shall correspond to
other by 120°. the cap coupling number.

Revi — July 2005
Print 603.93.391
Figure 94 Figure 96
70204
70202 - lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
DIAGRAM FOR CONNECTING ROD—PISTON wrench (2).
ASSEMBLY FITTING INTO BARREL
- split ring openings shall be displaced with each other by Figure 97
120°;
- connecting rod—piston assemblies shall have the same α
weight;
- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
540831 Finding crankpin clearance
Figure 95
70205
- apply tool 99395216 (1) to the socket wrench and

tighten screws (2) of 60°.
Figure 98
70203
To measure the clearance proceed as follows:

- clean the parts accurately and remove any trace of oil;
- set a piece of calibrated wire (2) on the output shaft pins
(1); 70206
- fit the connecting rod caps (3) with the relevant half - remove the cap and find the existing clearance by
bearings (4). comparing the calibrated wire width (1) with the scale
on the wire envelope (2).

Figure 99 Timing gear case

Figure 101
70207
If a different clearance value is found, replace the half bearings

and repeat the check. 70209
LOCTITE 5205 SEALANT APPLICATION AREAS

Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the Clean accurately the timing gear case (1) and the engine
connecting rod cap fastening screws to the specified torque. block.
Perfect seal is only obtained by cleaning accurately the
surface to seal.
Before the final fitting of the connecting rod cap
fastening screws, check that their diameter Smear the case with LOCTITE 5205 to obtain a bead of few
! mm diameter.
measured at the centre of the thread length is not
< 0.1 mm than the diameter measured at approx. 10 It shall be uniform (no clots), without air bubbles, thin areas
mm from screw end. or discontinuities.
Any imperfection shall be corrected as soon as possible.
Check manually that the connecting rods (1) are sliding Avoid to use excess material to seal the joint.
axially on the output shaft pins and that their end float, Excessive sealant could come out from joint sides and cause
measured with feeler gauge (2) is 0.10 — 0.33 mm.. lubricant passage clogging.
After applying the sealant, the joint shall be assembled
immediately (max 10 minutes).
Checking piston protrusion
Figure 102
Figure 100
70208 70210
Once connecting rod—piston assemblies refitting is over, use DIAGRAM FOR TIGHTENING THE REAR TIMING
dial gauge 99395603 (1) fitted with base 99370415 (2) to GEAR CASE FASTENING SCREWS
check piston (3) protrusion at T.D.C. with respect to the top Refit the case (1) to the engine block.
of the engine block. Screw the fastening screws in the same position found at
Protrusion shall be 0.28 — 0.52 mm. removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12 65 — 89 Nm

Print 603.93.391
Timing 540460 Flywheel housing

Figure 103 Figure 106
70214
70211
LOCTITE 5205 SEALANT APPLICATION AREAS
Use a felt pen to mark the driving gear (1) tooth fitted on the
Clean accurately the flywheel housing (1) and timing gear case
output shaft (2) having the mark (→) for timing on the side
coupling surfaces.
surface.
Perfect seal is only obtained by cleaning accurately the surface
Figure 104 to seal.
Smear housing (1) with LOCTITE 5205 to obtain a bead of
few mm diameter.
It shall be uniform (no clots), without air bubbles, thin areas
or discontinuities.
Any imperfection shall be corrected as soon as possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides and cause
lubricant passage clogging.
After applying the sealant, the joint shall be assembled
immediately (max 10 minutes).
70212
Figure 107
Direct the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Figure 105
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS
Refit the housing (1) to the engine block and screw the
fastening screws in the same position found at removal and
70213
tighten them to the following torque values in the sequence
Tighten the screws (1) fastening gear (2) to camshaft (3) to the shown in the figure:
specified torque. Screws M12 75 — 95 Nm

70152
70216
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
Apply tool 99346253 part (5) to the rear output shaft tang (6),
hoister.
secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing Figure 111
sealing ring (3) fitting into flywheel housing (7).
540850 ENGINE FLYWHEEL

Figure 109
70218
Tighten the screws (4) fastening the engine flywheel (3) to the
output shaft. Apply tool 99360351 (2) to the flywheel housing
(1) to stop engine flywheel (3) rotation.
Figure 112
70217
Check clutch plate supporting surface and turn it if scored. α
NOTE Engine flywheel rated thickness is 49.6 ± 0.13 mm.
540853 Replacing engine flywheel ring gear

Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel (1, Figure
109) using a generic beater and fit the new one, previously 70219
heated to 150°C for 15 — 20 minutes. Chamfering on ring gear Tighten engine flywheel (2) fastening screws (1) in two stages:
inside diameter shall be facing the engine flywheel. - 1st stage, tightening to 30 ± 4 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 60° ± 5° angle.
NOTE Tightening to angle is performed using tool

99395216.

70223
Remove the sealing ring (2) from the front cover (1), clean
70220
accurately the coupling surfaces and smear them with IVECO
Fit the oil pump (1). N. 2992545.
Tighten the fastening screws (2) to the specified torque.
Figure 117
Figure 114
70224
Clean accurately the front cover (2) surface and refit it.
70221
Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
r
Figure 118
Figure 115
70225
Apply tool 99346252 part (5) to the front output shaft tang
70222 (6), secure it by screws (4) and fit the new sealing ring (3).
Fit the water pump (1). Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into front cover (7).

99223 70363
Fit the plate (1), the rose pipe (2) and tighten the fastening Fit the phonic wheel (1) and the hub (2) on the output shaft.
screws (3) to the specified torque.
Tighten the fastening screws (3) in two stages:
Figure 120 - 1st stage, tightening to 50 ± 5 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 90° angle.
NOTE Tightening to angle is performed using tool

99395216 (4).
Fit the damper flywheel (5) and the pulley (6).

Tighten the fastening screws (7) to 68 ± 7 Nm torque.
70227
Set the gasket (1) on the oil sump (2).
NOTE If not faulty the gasket can be reused. Figure 123

r
Figure 121
70230
Fit a new sealing ring on the speed sensor (3).

Fit the speed sensor (3) on the front cover (1) and tighten the
screw (2) to the specified torque.
70154
Fit the oil sump (1) and apply the plate (3) to it.

70231 70234
Fit on the engine block: a new gasket (1), the heat exchanger Position the alternator support (1) so that pins (3 and 4) are
(2) a new gasket (3) and the oil filter support (4). set against the engine block.
Tighten the screws (5) to the specified torque. Tighten the screws (2) to the specified torque.
70232 70139
Lubricate the sealing ring (2) with engine oil and set it on the Refit the alternator (1).
oil filter (3).
Tighten the screw (2) to the specified torque.
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by ¾ turn.
Apply a new sealing ring on the oil temperature/pressure Figure 128
sensor (4) and fit it on the support (1).
Fit a new sealing ring (6) in the engine block seat.
70235
Refit the automatic belt tensioner (2).

Tighten the screw (3) to the specified torque using the proper
wrench, turn the automatic belt tensioner (2) to fit the belt (1)
on pulleys and guide rollers.

70145 70320
Refit the high pressure pump (5) including the feed pump (6) Refit the ECU (3) including the heat exchanger to the engine
and tighten the nuts (3) to the specified torque. Fit the support block and tighten the screws (2) to the specified torque.
(4) with a new sealing ring, the timing sensor (2) with a new
sealing ring and tighten the relevant fastening nut (1) to the
specified torque.
NOTE Replace support elastic elements (1).
Figure 130
540610 CYLINDER HEAD

540662 Removing the valves
Figure 133
70144
Refit the air compressor (3). Tighten the screws (2) and the
nuts (1 and 4) to the specified torque.
Figure 131
70319
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.
NOTE Should cylinder head valves be not replaced, number

them before removing in order to refit them in the
same position.
A = intake side — S = exhaust side
70143
Refit the hydraulic power steering pump (2) including the oil
tank (4) to the air compressor (5).
Use wrench 99355019 to tighten the fastening screws (3) to
the specified torque.

V
Print 603.93.391
Figure 134 Checking cylinder head wet seal

Figure 136
70321 70323
Valve removal shall be performed using tool 99360268 (1) This check shall be performed using the proper tools.
and pressing the cap (3) so that when compressing the
Use a pump to fill with water heated to approx. 90°C and 2
springs (4) the cotters (2) can be removed. Then remove the
— 3 bar pressure.
cap (3) and the springs (4).
Replace the cup plugs (1) if leaks are found, use the proper
Repeat this operation for all the valves.
beater for their removal/refitting.
Overturn the cylinder head and withdraw the valves (5).
Figure 135 NOTE Before refitting, smear the plug surfaces with
water—repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface

Figure 137
70322
Remove the sealing rings (1 and 2) from the relevant valve

guides.
NOTE Sealing rings (1) for intake valves are yellow.

70324
Sealing rings (2) for exhaust valves are green.
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.

Figure 138 Removing carbon deposits, checking and

grinding valves
Figure 140
18625
70325
Remove carbon deposits from valves using the proper metal
The rated thickness A for the cylinder head is 105 ± 0.25 mm, brush.
max. metal removal shall not exceed thickness B by 0.13 mm.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018 and
After grinding, check valve sinking. Regrind the valve removing as less material as possible.
seats, if required, to obtain the specified value.
Figure 141
540662 VALVES
Figure 139
EXHAUST INTAKE
VALVE VALVE
18882
Check the valve stem (1) using a micrometer (2), it shall be

6.970 ± 6.999.
Checking clearance between valve stem and
valve guide and valve centering
Figure 142
70326
INTAKE AND EXHAUST VALVE MAIN DATA
70327
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 ± 0.092 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.

540667 VALVE GUIDE

Figure 143 VALVE SEATS
Regrinding — replacing the valve seats
Figure 144
70330
INTAKE EXHAUST Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using tool 99305018 (1) according to the angle
79457 values shown in Figure 145.
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
Figure 145
INTAKE EXHAUST
85486
VALVE SEAT MAIN DATA

Figure 146
EXHAUST INTAKE
70332
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80° — 100°C and using the proper
them with the spare ones. Use tool 99305018 (Figure 144) beater, fit the new valve seats, previously cooled, into the
to remove as much material as possible from the valve seats cylinder head.
(take care not to damage the cylinder head) until they can
Use tool 99305018 to regrind the valve seats according to
be extracted from the cylinder head using a punch.
the values shown in Figure 145.
Figure 147
70333
After regrinding, check that valve (3) sinking value is the

specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).

Print 603.93.391
540665 VALVE SPRINGS

50676 770321
MAIN DATA TO CHECK INTAKE AND EXHAUST Position on the cylinder head: the spring (4), the upper cap
VALVE SPRINGS (3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Before refitting use tool 99305047 to check spring flexibility.
Compare load and elastic deformation data with those of the
new springs shown in the following table. Refitting the cylinder head
Figure 151
Height Under a load of

mm N
H 47.75 Free
H1 35.33 P1 339.8 ± 19 Nm
H2 25.2 P2 741 ± 39 Nm
FITTING CYLINDER HEAD
Figure 149
70335
Check cleanness of cylinder head and engine block coupling

surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “TOP” (1)
facing the head.
The arrow shows the point where the gasket thickness is
given.
NOTE Before reusing the cylinder head fastening screws

check whether they are free from damages or
distortions, otherwise replace.
70334
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.

Fitting injectors
70338
70336
Fit a new sealing ring (2) lubricated with vaseline and a new
Refit the cylinder head (1), tighten the screws (2) in three sealing washer (3) on injector (1).
successive stages according to the sequence and procedure
shown in the following figure.
Figure 155
Use tool 99395216 (3) to tighten to angle.

!
Figure 153
α A
70339
Fit injectors (1) on the cylinder head seats, directed so that

the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
70337
Cylinder head fastening screw tightening sequence: Figure 156

- 1st stage pre—tightening, with dynamometric wrench:
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
s
• Screw 12x1.75 x 150 ( ) 55 ± 5 Nm

- 2nd stage, tightening to 90° ± 5° angle
- 3rd stage, tightening to 90° ± 5° angle
A = front side
70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.

541221 RODS
32655
Rocker control rods shall not be distorted; the ball seats in

touch with the rocker adjusting screw and with tappets
91572 (arrows) shall not show seizing or wear; otherwise replace
Fit a new sealing ring (3) lubricated with vaseline on the fuel them. Intake and exhaust valve control rods are identical and
manifold (2) and fit it into the cylinder head seat so that the are therefore interchangeable.
positioning ball (5) is coinciding with the relevant housing (4).
501230 Rocker assembly

NOTE Removed fuel manifolds (2) shall not be reused but Figure 160
replaced with new ones.
Screw the fastening nuts (2, Figure 158) without locking

them.
During this operation, the injector (1) shall be

moved so that the manifold (2) is properly inserted
into the fuel inlet hole (2, Figure 155).
Figure 158 70343
ROCKER ASSEMBLY COMPONENTS:

1. Screws — 2. Bracket — 3. Shafts — 4. Rockers.
Figure 161
70342
Use the dynamometric wrench to tighten gradually and

alternately the injector fastening screws (1) to 8.5 ± 0.35 Nm
70344
torque.
SHAFT—ROCKER MAIN DATA
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm Check that shaft/rocker coupling surfaces are not showing
torque. excessive wear or damages.

Tappet clearance adjustment

70520
70345
Adjust clearance between rockers and valves using setscrew
Fit the rods (2). wrench (1), box wrench (3) and feeler gauge (2).
Position jumpers (1) on valves with marks (→) facing the Working clearance shall be as follows:
exhaust manifold. — intake valves 0.25 ± 0.05 mm
— exhaust valves 0.51 ± 0.05 mm
To carry out rocker—valve clearance adjustment

more quickly, proceed as follows:
rotate the output shaft, balance the valves of cylinder
No. 1 and adjust the valves marked with an asterisk
Figure 163 in the tables below:
cylinder No. 1 2 3 4
intake — — * *
exhaust — * — *
Rotate the output shaft, balance the valves of

cylinder No. 4 and adjust the valves marked with an
asterisk in the table below:
cylinder No. 1 2 3 4
intake * * — —
exhaust * — * —
70346
Check that tappet adjusters (1) are loosen to prevent their

balking on the rods (2, Figure 162) when refitting the rocker
assembly.
Then refit the rocker assembly consisting of: bracket (5),
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 Nm torque.

Intake manifold
Figure 165
70347
The intake manifold (4) houses the air heater (5) for cold Apply a new sealing ring (10) to the air temperature/pressure
starting. In case of failure it shall be replaced by removing the sensor and fit it on the intake manifold (4), tighten the screws
cap (6), the nuts (1), the sealing washers (2) and the washers (8) to the specified torque.
(3). Fit the new heater (5) following the removal operations
in reverse order.
The sealing washers (2) shall be replaced with new

ones.
The nuts (1) shall be tightened to the specified torque.

70348
Smear the intake manifold (1) coupling surface with sealant 99226
IVECO No. 2992545 and fit it on the cylinder head.

Fittings of pipings (3) must be tightened with 20 Nm
torque by using special wrench 99389829 (4)
Figure 167 associated to tool 99317915 (4).
Connect the fuel pipe (2) to the rail (1) following the
procedure shown in the following figure.
99224
Fit the rail (2) and tighten the screws (1) to the specified Figure 170
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut (5) to the specified torque.
Figure 168
70126
Press the clamp (1) in arrow direction (Figure B) and connect

the pipe to the rail (2, Figure 169), reset the clamp to the
initial locking position “A”.
99225
Connect the fuel pipes (1) to rail (3) and injector manifolds NOTE Check proper fuel pipe connection.
(2).

Print 603.93.391
540634 Wiring support Figure 174

Figure 171
70352 70355
Check electrical cable (5) conditions, replace if damaged by Fit a new gasket (2) on the tappet cover (1).
cutting the support (2) clamps and removing the screws (4)
that secure it to connections (3).
Fit a new gasket (1) on the support (2).
Figure 175
Figure 172
99229
99227
Fit the tappet cover (1) and tighten the nuts (2) to the
Fit the wiring support (2) and tighten the screws (1) to the specified torque.
specified torque.
Figure 173
Figure 176
99228 70357
Connect the electrical cables (1) to the injectors (3) and use Reconnect the exhaust manifold (2) with new gaskets.
the dynamometric wrench 99389834 (4) to tighten the Tighten the fastening screws (1) to the specified torque.
fastening nuts (2) to the specified torque.

70358
70360
Reconnect the turbosupercharger (3) with a new gasket to
the exhaust manifold (1) and tighten the fastening nuts (2)
to the specified torque. Connect pipe (14) to tappet cover (10) and timing case (6)
Connect the oil pipe (5) to the heat exchanger support (6) with connections (13—15) and new copper washers.
and secure it to the exhaust manifold (1) by screw (4). Connect pipe (7) to timing case (6) connection and lock it
by the elastic clamp (8).
Fit a new sealing ring on pipe (11) connection and fit it on the
tappet cover (10).
Secure the pipe (11) to the tappet cover (10) with the clip
and the nut (12), connect pipe (4) to connection (5) and air
compressor (3).
Connect the pipe (2) to the pressure limiter (1) as shown in
the following figure.
Figure 178
Figure 180
70134 70126
Connect the air duct (1) to the turbosupercharger (3) and Press the clamp (1) in arrow direction (Figure B) and connect
lock it by clamp (2). the pipe.
Secure the air duct (1) to the alternator support by screws Reset the clamp to the initial locking position A.
(4).
NOTE Check proper fuel pipe connection.

Figure 181
78670
1. Injector connections — 2. Engine coolant temperature sensor — 3. Fuel pressure sensor — 4. Engine oil temperature and
pressure sensor — 5. Output shaft sensor — 6. Injector — 7. Air temperature/pressure sensor — 8. Timing sensor —
9. Fuel heater and fuel temperature sensor — 10. Pressure regulator — 11. EDC7 control unit
Reconnect the engine cable by connecting injector wiring (6) Apply to engine lifting hooks the lifting rig 99360555, hook
connectors (1); (7) air pressure/temperature sensor; (3) rail the latter to the hoister and remove the engine from the
pressure sensor; (11) control unit; (10) high pressure pump revolving stand. Remove the brackets 99361037.
sensor; (8) timing sensor; (2) engine coolant temperature
sensor on thermostat; (5) engine speed sensor.

Print 603.93.391/A
70362
70128
Complete engine refitting as follows: Refit the bracket (2) including the fuel filter support (1) to the
engine block, tighten the screws (3) to the specified torque.
Form the right side:
Refit the starter (5) to the flywheel housing (4) and tighten
the fastening nuts to the specified torque. Figure 185
Fit the oil pipe (3) with a new sealing ring into the engine
block and secure it to the turbosupercharger (1) by the
screws (2) tightened to the specified torque.
Figure 183
105163
Screw manually the fuel filter (4) to the support (1), screw
the filter by 3/4 turn, connect the pipes (2—3—5) to the
relevant support connections (1) as shown in the following
figure.
Figure 186
70127
From the left side:

Connect the fuel pipe (2) to rail and to high pressure pump
(9), secure it by screws (4 and 6) tightened to the specified
torque.
Pipe connections (2) shall be tightened to 20 Nm

torque using the proper dynamometric wrench
99389834.
Connection (7) shall be tightened by holding at the 70126
same time the high pressure pump hexagon (10).
When removed pipe (2) shall always be replaced. Press the clamp (1) as shown in figure B.
After disconnecting the pipe, reset the clamp (1) to the initial
Connect pipe (3) to connection (4) and air locking position A, to prevent deformations.
compressor (8). When refitting is over, fill engine with the prescribed
lubricating oil in the specified quantity.

Revi — July 2005
Print 603.93.391
5450 LUBRICATION
Forced lubrication is implemented by the following Figure 187
components:
- rotor oil pump (5), set in the front part of the engine
block and controlled by the straight—tooth gear fitted on 1
the output shaft tang;
- water/oil heat exchanger (3) set in the engine block, with
oil filter support;
- oil pressure relief valve (1) built into filter support;
- by—pass valve (4) to cut out clogged oil filter, built into
filter support;
- cartridge oil filter (2).
4
Pressurised oil path
Oil return to sump

by fall
Oil inlet
70479
LUBRICATION SYSTEM LAYOUT


Print 603.93.391
543010 OIL PUMP Figure 188
NOTE Since the oil pump cannot be overhauled, it shall be

replaced when damaged.
70576
543110 HEAT EXCHANGER
Figure 189
5
6
1
70480
1. Heat exchanger body with filter support — 2. Internal gasket — 3. Water—oil heat exchanger — 4. Gasket between heat
exchanger unit and engine block — 5. Oil pressure relief valve — 6. By—pass valve to cut out clogged oil filter.
Clean accurately the heat exchanger components
Always replace the sealing gaskets.

543075 Oil pressure relief valve

Figure 190
Loosen the plug (1), withdraw the spring (3) and the relief
valve (4) from the support (5).
Check whether the valve (4) is not scored and is sliding
smoothly into its seat. The spring (3) shall not be broken or 70481
yielded.
Pressure regulation at 100°C oil temperature:
— 1.2 bar min pressure; By—pass valve to cut out clogged oil filter.
— 3.8 bar max. pressure
Flow
70482
6432 Max blow—by:

22 cm3/1’ at 0.8 bar pressure and 26.7°C temperature
MAIN DATA TO CHECK OIL PRESSURE RELIEF
VALVE SPRING

540480 Oil vapour recycling
Figure 193
70484
Oil condensate
Oil vapours
1. Pre—separator — 2. Exhaust to the outside (temporary) — 3. Filter — 4. Return to engine

The tappet cover houses the pre—separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow—by (3).
In the blow—by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).


Print 603.93.391
5432 COOLING SYSTEM

The closed loop forced—circulation cooling system consists Figure 194
of the following components:
- expansion tank with plug, with two built—in valves:
exhaust valve (2) and intake valve (1) to control system
pressure;
- radiator, for dissipating the heat subtracted to engine by
coolant;
- viscous fan;
- heat exchanger to cool the lubricating oil (see
lubrication);
- centrifugal water pump set in the front part of the engine
block;
- thermostat to control coolant circulation.
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
70485
COOLING SYSTEM LAYOUT


Print 603.93.391
543210 Water Pump Viscous fan
Sec. A-A
70486
The water pump is located in a housing obtained in the

engine block and is controlled by and a poly—V belt.
An automatic tensioner keeps the belt tension.
70487
Characteristics:
Max control speed: 2700 rpm
Max fan speed: 2565 rpm ±. 50 rpm
Operating temperature: 75°C± 4°C at 2160 rpm
fan speed

543250 Thermostat Description

The booster system is composed of: air cleaner,
Figure 197
turbosupercharger and intercooler.
The air cleaner is a dry type composed of a filtering cartridge
that is periodically changeable.
The turbosupercharger has got the function of using the
energy of engine exhaust gas in order to send pressure air to
the cylinders.
It is essentially composed of:
- a main body where a shaft supported by bushes is
located. At the ends of the bushes the turbine rotor and
compressor rotor are fitted;
- a turbine body and a compressor body fitted on the end
of the main body;
- a waste gate valve applied on the turbine body used for
determining the portion of exhaust gases and sending a
79458
part of them directly to the exhaust pipe, when the
The thermostat of the by—pass type is located in the cylinder booster pressure downstream the supercharger reaches
head and doesn’t need regulations. the calibration value;
Whenever doubts on its operation are present, replace it. - the intercooler is composed of a radiator applied on the
engine coolant radiator, and it is used for lowering the
On the thermostat body are fitted the thermometric temperature of the air coming out from the
transmitter/switch and water temperature sensor. turbosupercharger to send it to the cylinders.
A= stroke beginning: 79.4 — 83.3° C
B= stroke at 100° C: ≥ 6.6 mm
Verifying an anomalous operation of the engine, due

BOOSTER to the booster system, it is recommended, before
!
542410 Turbosupercharger performing controls on the turbosupercharger, to
check the efficiency of the sealing gaskets and the fix-
ing of the connection sleeves, making sure of clog-
Figure 198
ging absence inside intake sleeves, air cleaner or in-
side radiators. If the turbosupercharger damage is
due to a lack of lubrication, check that the oil circula-
tion pipes are not broken or obstructed, in such case
replace them or eliminate the trouble.
Bearing end play check

Position the tracer point of the magnetic—base dial gauge on
the turbosupercharger shaft end and set to zero the dial
gauge.
Move the turbosupercharger shaft axially and check that the
70489 clearance is not higher than the prescribed value.
Replace the turbosupercharger if a different value is found.
Exhaust
Compressed air
GARRET TURBOSUPERCHARGER
Booster pressure: 1.5 bar..
Actuator (WASTEGATE) opening start: 1600 rpm

542418 TURBOSUPERCHARGER ACTUATOR

Check and adjustment Actuator replacement
1 3
2 4
5
6
62873
70490
Cover the air, exhaust gas and lubrication oil inlets and
outlets. Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
Carry out an accurate external cleaning of the
turbosupercharger, using the anticorrosive and antioxidant Remove the nuts (2) and remove the actuator (1) from the
solution and perform the check on the actuator (6). supporting bracket. Fit the new actuator following the re-
moval operations in reverse order and fitting a new clip (4),
Clamp the turbosupercharger in a vice. tighten the nuts (2) to 5.6 — 6.8 Nm torque.
Disconnect the pipe of the actuator (6) and apply to the Check and adjust the actuator (1), if required, as described
actuator union, the pipe of pump 99367121 (1). in the relevant chapter.
Apply the magnetic—base dial gauge (2) on the exhaust gas Then, paint the nut (6) with safety paint.
inlet flange in the turbine.
Before refitting the turbosupercharger on engine, fill the
Position the tracer point of the gauge (2) on the tie rod (3) central body with engine oil.
end and set to zero the gauge (2).
Through the pump (1) let in compressed air, in the actuator
(6), at the prescribed pressure and make sure that such value
is kept constant for the whole check time, otherwise replace
the actuator (6).
In the above—mentioned conditions, the tie rod must have
carried out the prescribe stroke.
NOTE During the operation, beat slightly the actuator (6)

in order to eliminate possible sticking of the
actuator internal spring.
If a different value is found, loosen the nut (5) and operate

properly the knurled ring nut (4).


Print 603.93.391
TURBOSUPERCHARGER LAYOUT
Figure 201
Inlet air
Hot compressed air
Cooled compressed air
Exhaust
70491


Print 603.93.391
SYSTEM OF INJECTION FEEDING ELECTRONIC TALL PRESSURE COMMON RAIL

General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1450 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 202
78670
1. Injectors connections — 2. Engine coolant temperature sensor — 3. Fuel pressure sensor — 4. Engine oil temperature and
pressure sensor — 5. Output shaft sensor — 6. Injector — 7. Air pressure/temperature sensor — 8. Camshaft sensor — 9. Fuel
heater and fuel temperature sensor — 10. Pressure regulator — 11. EDC 7 control unit.
Through the sensors, present on the engine, the ECU con- The outlet tension is proportional to the pressure or tem-
trols the engine operation. perature obtained by the sensor.
Air pressure/temperature sensor Engine oil temperature and pressure sensor

It is a component integrating a temperature sensor and a Same as air pressure/temperature sensor, it is fitted on the
pressure sensor. engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air It measures engine oil temperature and pressure.
capacity to calculate precisely the fuel quantity to inject at
every cycle.

Fuel pressure sensor Injection control

Assembled on a rail end, it measures the fuel pressure in the The control unit, depending on information coming from
rail in order to determine the injection pressure. sensors, controls the pressure regulator, and changes
pre—injection and main injection modes.
The injection pressure value is used to control the pressure
and to determine the electric injection control length. Closed—loop control for injection pressure
Depending on engine load, measured by processing signals
Fuel temperature sensor coming from various sensors, the control unit controls the
It is a sensor that is equal to the previous one. regulator in order to always have the optimum pressure.
It measures fuel temperature to provide the control unit with Pilot and main injection spark advance control
an index of the diesel fuel thermal state. The control unit, depending on signals coming from various
sensors, computes the optimum injection point according to
Coolant temperature sensor an internal mapping.
It is a variable—resistance sensor suitable to measure the Idle speed control
coolant temperature to provide the control unit with an The control unit processes signals coming from various
index of the engine thermal state. sensors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
Output shaft sensor time of injectors.
It is an inductive sensor placed on the front engine part. Within certain thresholds, it also takes into account the
Signals generated through the magnetic flow that is closed on battery voltage.
the phonic wheel, change their frequencies depending on Maximum speed limiting
output shaft rotation speed. At 2700 rpm, the control unit limits fuel flow—rate by
reducing the injectors opening time.
Timing sensor Over 3000 rpm it deactivates the injectors.
It is an inductive sensor placed on the engine rear left part. Cut Off
It generates signals obtained from magnetic flow lines that are Fuel cut off upon release is controlled by the control unit
closed through holes obtained on the keyed gear on the performing the following logics:
camshaft. The signal generated by this sensor is used by the - it cuts off injectors supply;
ECU as injection phase signal.
- it re—activates the injectors shortly before idle speed is
Though being equal to the flywheel sensor, it is NOT reached;
interchangeable since it has a different outside shape. - it controls fuel pressure regulator.
System functionality Smoke control upon acceleration

With strong load requests, the control unit, depending on
Self—diagnosis signals received by air inlet meter and engine speed sensor,
The ECU self—diagnostic system checks signals coming from controls the pressure regulator and changes the injectors
sensors by comparing them with threshold data. actuation time, in order to avoid exhaust smokes.
Fuel temperature control
IVECO Code recognition When the fuel temperature exceeds 75 °C (measured by the
The EDC7 control unit communicates with the Immobilizer sensor placed on fuel filter) the control unit intervenes by
control unit to obtain the startup consent. reducing injection pressure.
If the temperature exceeds 90 °C, the power is reduced to
Engine pre—heating resistance check 60%.
The pre—post heating is activated when even only one of the AC compressor engagement control
water, air or fuel temperature sensors signals a temperature The control unit is able to drive engagement and
that is less than 5 °C. disengagement of the electromagnetic compressor clutch
depending on coolant temperature.
Timing recognition If the coolant temperature reaches about 150 °C, it
disengages the clutch.
By means of signals coming from camshaft sensor and
flywheel sensor, the cylinder on which fuel must be injected After Run
is recognised upon startup. The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the
following startup.

Print 603.93.391/A
FEED SYSTEM
Figure 203
High Pressure
Low Pressure
105164
1. Injector — 2. Common Rail — 3. Pressure limiter for fuel return — 4. Rail overpressure valve — 5. Prefilter assembled on
chassis — 6. High—pressure pump — 7. Mechanical rotor pump — 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The feed system is implemented by a low—pressure circuit and a high—pressure circuit.
The high—pressure circuit is composed of the following pipings:
- piping connecting high—pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low—pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high—pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high—pressure pump cooling circuit complete the system.

Revi — July 2005
Print 603.93.391

Print 603.43.671/A
FEED SYSTEM LAYOUT

This Common Rail injection system, with CP3 pump, is Figure 204
mostly different from the one adopted on the Daily range
with CP1 pump due to the different pressure regulator
position and due to the gear supply pump.
The pressure regulator, placed upstream of the EXHAUST
INTAKE (LOW PRESSURE)
high—pressure pump, adjusts the fuel flow that is necessary HIGH—PRESSURE (LOW—PRESSURE) PUMP SUPPLY
on the low—pressure system. Afterwards, the high—pressure HIGH PRESSURE
pump takes care of supplying the rail properly. This
arrangement, by pressurising the necessary fuel only,
improves the energetic efficiency and limits fuel heating in the
system.
Function of the pressure relief valve (2), assembled on the
high—pressure pump, is keeping the pressure, at the pressure
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream.
The pressure relief valve (2) intervention brings about a fuel
flow increase in the high—pressure pump cooling circuit,
through inlet and drain piping (16) from piping (8).
The pressure relief valve housed on the cylinder head,
assembled on injector return (3), limits the fuel return flow
from injectors at a pressure of 1.3 to 2 bars.
Two by—pass valves are placed in parallel with the mechanical
supply pump.
The by—pass valve (18) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure
exceeds the allowed threshold value.
The by—pass valve (17) allows filling the supply system
through the manual priming pump (10).
70493
1. High—pressure pump. — 2. Pressure relief valve on high—pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. — 4. Rail overpressure
valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. — 8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. — 12.
Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High—pressure pump cooling piping. — 17. By—pass valve. — 18. By—pass valve.


Print 603.93.391/A
FUEL PREFILTER FUEL FILTER

99231
1. Fuel filter support — 2. Fuel temperature sensor —

3. Electric fuel heater — 4. Fuel filter — 5. Adaptor —
70494 6. Heater connector — 7. Gasket.
A. Exit fitting of exhaust fuel to tank. — B. High pressure
pump exit fitting. — C. Exhaust fitting from high pressure
The fuel filter is of the high water separation type, is pump. — D. Entry fitting of exhaust fuel from common rail.
assembled on the right side of the vehicle chassis, and has the — E. Entry fitting from feed pump.
sensor (4) for detecting water in fuel placed on the cartridge It is placed on engine block in the circuit between supply
(3) base. pump and high—pressure pump (CP3).
Manual priming pump (5) and air bleeding screw (2) from Cartridge filtering degree: 4 microns, Pressure delta 2 bars.
system are placed on filter support.
The following are placed on the support: fuel temperature
The presence of condensate into filter is signalled by sensor sensor and heater resistances.
(4) when a warning light on the instrument panel is lit.
Fuel temperature, signalled by the related sensor to EDC7
control unit, allows a very accurate computation of the fuel
flow—rate to be injected into the cylinders.
If the warning light is on, it is necessary to im- The electric heater is activated when fuel temperature is
mediately operate to remove its cause; the common below 5 °C.
rail system components are quickly damaged by the
presence of water or impurities in the fuel.

Revi — July 2005
Print 603.93.391
MECHANICAL SUPPLY PUMP Drain conditions

Gear pump, fitted on the rear side of the high pressure pump
Figure 209
and used to supply it.
It is controlled by high pressure pump shaft
Normal operating conditions
Figure 207
72594
The by—pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
72592 situation the by—pass valve (1) stays closed whereas by—pass
valve (2) opens due to inlet pressure, and fuel is drained out
A Fuel inlet from tank, B fuel outlet to filter, 1—2 by—pass through B.
valves in close position
NOTE The mechanical supply pump cannot be replaced

Overpressure condition at outlet individually, therefore it cannot be removed from
the high pressure pump.
Figure 208
72593
The by—pass valve (1) cuts in when overpressure is generated

at outlet B. The existing pressure, overcoming valve spring (1)
elastic strength, makes inlet and outlet communicating
through duct (2).

CP3 HIGH—PRESSURE PUMP

Pump with 3 radial pistons controlled by the timing gear,
without needing any setting. On the rear side of the high
pressure pump is fitted the mechanical supply pump
controlled by the high pressure pump shaft.
The following work must be carried out on the feed pump / high—pressure pump assembly:
- replacing the drive gear;
- replacing the pressure regulator.
Figure 210
72595
1. Fuel outlet fitting to rail — 2. High—pressure pump — 3. Pressure regulator — 4. Control gear — 5. Fuel inlet fitting from filter
— 6. Fuel outlet fitting to filter support — 7. Fuel inlet fitting from control unit heat exchanger — 8. Fuel outlet fitting from
supply pump to filter — 9. Mechanical supply pump

HIGH—PRESSURE PUMP — INSIDE STRUCTURE

Figure 211
Sec. B—B
Sec. C—C
70498
1. Cylinder. — 2. Three—lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6— Pump shaft. —
7. Low—pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of: translated in a circular movement along a wider radius, with
the resulting alternate actuation of the three pumping
- a piston (5) actuated by a three—lobe element (2)
elements;
floating on the pump shaft (6). The element (2), being
floating on a misaligned part of the shaft (6), when the - cap intake valve (3);
shaft rotates, does not rotate therewith but is only
- ball delivery valve (4).

Operating principle
Figure 212
Sec. B — B
Sec. D — D
72597
1. Fuel outlet fitting to rail — 2. Delivery valve to rail — 3. Pumping element — 4. Pump shaft — 5. Pumping element supply duct
— 6. Pressure regulator supply duct — 7. Pressure regulator
Pumping element (3) is oriented to pump shaft (4) cam. the PWM signal received from ECU. During pumping
During intake, the pumping element is supplied through element compression stage, fuel reaches the pressure
supply duct (5). The fuel amount to be sent to the pumping required to open the delivery valve to common rail (2) and
element is set by the pressure regulator (7). The pressure to feed it through outlet (1).
regulator meters fuel flow to pumping element according to

72601
72598
Sec. C — C Sec. A — A
1. Pumping element inlet — 2. Pump lubrication ducts — 1. Fuel outlet duct — 2. Fuel outlet duct — 3. Fuel outlet
3. Pumping element inlet — 4. Main pumping element from pump with high pressure pipe fitting for common rail
supply duct — 5. Pressure regulator — 6. Pumping element
inlet — 7. Regulator exhaust duct — 8. 5 bar pressure relief
valve — 9. Fuel drain from regulator inlet
Figure 213 shows low pressure fuel paths inside the path and Figure 214 shows high pressure fuel flow through pumping
highlights: main pumping element supply duct (4), pumping element outlet ducts.
element supply ducts (1 — 3 — 6), pump lubrication ducts (2),
pressure regulator (5), 5 bar pressure relief valve (8) and fuel
drain duct (7).
Pump shaft is lubricated by fuel through delivery and return
ducts (2).
Pressure regulator (5) establishes the fuel amount to send to
pumping elements; excess fuel is drained out through duct
(9).
5 bar pressure relief valve acts as fuel exhaust manifold and
keeps 5 bar constant pressure at regulator inlet.

Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 215
the pumping elements (about 2 bars).
The amount of fuel supplying the high—pressure pump is
metered by the pressure regulator, placed on the
low—pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail. 99232
The thereby—generated pressure makes the exhaust valve

open and the compressed fuel reaches the high—pressure 1. Rail. — 2. Fuel inlet from high—pressure pump. —
circuit. 3. Overpressure valve. — 4. Pressure sensor.
The pumping element compresses the fuel till the top dead The rail volume is of reduced sizes to allow a quick
center (delivery stroke) is reached. Afterwards, the pressure pressurisation at startup, at idle and in case of high flow—rates.
decreases till the exhaust valve is closed. It anyway has enough volume as to minimise use of plenum
The pumping element piston goes back towards the bottom chambers caused by injectors openings and closings and by
dead center and the remaining fuel is decompressed. the high—pressure pump operation. This function is further
enabled by a calibrated hole being set downstream of the
When the pumping element chamber pressure becomes less high—pressure pump.
than the supply pressure, the intake valve is again opened and
the cycle is repeated. A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
The delivery valves must always be free in their movements, feed—back information, depending on which the rail pressure
free from impurities and oxidation. value is checked and, if necessary, corrected.
The rail delivery pressure is modulated between 250 and
1350 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection — reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high—pressure pump is to
be removed—refitted, be sure that hands and components
are absolutely clean.

DOUBLE STAGE OVERPRESSURE VALVE

Once the valve has been mounted at one rail end, the valve task is to protect system components in the case where a fault in
either rail pressure sensor or pump pressure regulator CP3 causes pressure excessive increment in high pressure system.
The valve is of a definitely mechanical type and has double operation threshold: 1750 bar and about 800 bar.
When pressure in the rail reaches 1750 bar, the valve first operates as a single stage valve to cause fuel to be drained away and
pressure to be consequently decreased to safety values, then it mechanically regulates pressure in the rail to about 800 bar.
This valve enables to have the engine operated for long time with limited performance and inhibits fuel excessive overheating,
so preserving the pipings returning from the tank.
Figure 216
91577

INJECTOR Injection start

The injector is similar as construction to the traditional ones, Figure 218
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator — spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift. 15
Injector in rest position

Figure 217
70506
When coil (4) is energised, it makes shutter (6) move

upwards. The control volume (9) fuel flows towards flow
15
duct (12) making a pressure drop occur in control volume
(9). Simultaneously the fuel pressure into pressure chamber
(8) makes plunger (2) lift, with following fuel injection into the
cylinder.
Injection end
When coil (4) is de—energised, shutter (6) goes back to its
closing position, in order to re—create such a force balance
as to make plunger (2) go back to its closing position and end
the injection.
NOTE The injector cannot be overhauled and therefore it

must not be disassembled.
PRESSURE LIMITER FOR FUEL RETURN

70505 It is housed on the rear cylinder head part, and adjusts the
pressure of fuel returning from injectors at a pressure
1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilot
included between 1.3 and 2 bars. By guaranteeing this
valve — 6. Ball shutter — 7. Control area — 8. Pressure
pressure to the return fuel, the fuel vapours formation inside
chamber — 9. Control volume — 10. Control duct —
injectors is avoided, optimising fuel spraying and combustion.
11. Supply duct — 12. Control fuel outlet — 13. Electric
connection — 14. Spring — 15. High—pressure fuel inlet.
Figure 219
70507
A To tank — B From injectors


ENGINE F4 AE 0681
70757
Print 603.43.671/A
Engine F4 AE 0681
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 117
ASSEMBLY DATA — CLEARANCES . . . . . . . . . 120
ENGINE F4AE0681 OVERHAUL . . . . . . . . . . . . 128
- Engine removal at the bench . . . . . . . . . . . . . . 128
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 129
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
CYLINDER HEAD VALVE SEATS . . . . . . . . . . . 131
- Cylinder head fastening screw tightening . . . . 133
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 135
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 136
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . . 137
TURBOSUPERCHARGER ACTUATOR . . . . . . 137
- Check and adjustment . . . . . . . . . . . . . . . . . . . 137
TURBOSUPERCHARGER LAYOUT . . . . . . . . . 139


Print 603.93.391
F4AE 0681E F4AE0681D F4AE 0681B F4AE 0681A

Type
(.18) (.21) (.24) (.28)
Cycle Four—stroke diesel engine

Power Supercharged with intercooler
Injection Direct
Number of cylinders 6 in—line
∅
Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 5900
ρ Compression ratio 17 : 1
Max. output kW 132 154 176 202
(HP) (180) (210) (240) (275)
rpm 2700 2700 2700 2500

Max. torque Nm 570 680 810 930
(kgm) (58) (69) (82) (95)
rpm 1200÷2100 1200÷2100 1250÷2100 1250÷2100

Loadless engine idling
rpm 650 650 — —

Loadless engine peak
rpm 3000 3000 — —

Print 603.93.391/A
F4AE0681E F4AE0681D F4AE0681B F4AE0681A

Type
(.18) (.21) (.24) (.28)
SUPERCHARGING With intercooler
Turbosupercharger type HOLSET HX 35 HOLSET HX 35 W
Turbosupercharger shaft radial backlash — —

Turbosupercharger shaft end play — —
Pressure relief valve min. opening stroke:
mm — 0.50
Pressure relief valve max. opening stroke:
mm — 1.04
Pressure corresponding to min. stroke: bar — —
Pressure corresponding to max. stroke: bar — —
Forced by gear pump , pressure relief valve,
LUBRICATION
double stage oil filter
bar Oil pressure with warm engine:

— idling bar 1.2
— peak rpm bar 3.8
COOLING By centrifugal pump, regulating thermostat,
radiator, heat exchanger, intercooler
Water pump control Through belt
Thermostat
— start of opening 81 ± 2º C
— maximum opening 96º C
FILLING
Total capacity
1st filling:
liters —
kg —
Urania Turbo Min. level Max. level
Urania LD 5 — engine sump
liters 8 10.8
kg 7.2 9.7
— engine sump + filter

liters 9 11..8
kg 8.1 10.6

Revi — July 2005
Print 603.93.391

Type
(.18) (.21) (.24) (.28)
TIMING
start before T.D.C. A 8.5º

end after B.D.C. B 8.5º
start before T.D.C. D 51º

end after B.D.C. C 12.5º
Checking timing
mm —
X
mm —
X
Checking operation
mm 0.20 ÷ 0.30
X
mm 0.45 ÷ 0.55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Nozzle type Injectors
Injection sequence 1—5—3—6—2—4
bar
Injection sequence bar 250 — 1450
Injection pressure bar

ASSEMBLY DATA — CLEARANCES

Print 603.93.391/A

Type
(.18) (.21) (.24) (.28)

∅1
Cylinder barrels: ∅1 102.009 ÷ 102.031

X
Spare pistons:
∅1 type:
X Size X 60.5
2 Outside diameter ∅1 101.721 ÷ 101.739 101.781 ÷ 101.799
∅ Pin housing ∅2 40.010 ÷ 40.016 40.008 ÷ 40.014
Piston — cylinder barrels 0.27 ÷ 0.31 0.21 ÷ 0.25
Piston diameter ∅1 0.5
X
Piston protrusion X 0.28 ÷ 0.52
∅ 3 Piston pin ∅3 39.9938 ÷ 40.0002
Piston pin — pin housing 0.0098 ÷ 0.0222 0.0078 ÷ 0.0202

Revi — July 2005

Type
(.18) (.21) (.24) (.28)
CYLINDER UNIT AND CRANKSHAFT COMPONENTS

s
mm
X 1* 2.705 ÷ 2.735
X1 Split ring slots X2 2.430 ÷ 2.450 2.420 ÷ 2.440
X2 X3 4.040 ÷ 4.060 4.020 ÷ 4.040
X3 * measured on 99 mm ∅
S 1 S 1* 2.560 ÷ 2.605
S 2 Split rings S2 2.350 ÷ 2,380
S 3 S3 3.975 ÷ 4.000
* measured on 99 mm ∅
1 0.100 ÷ 0.175
Split rings — slots 2 0.050 ÷ 0.100 0.040 ÷ 0.090
3 0.040 ÷ 0.085 0.020 ÷ 0.065
Split rings 0.5
X 1 Split ring end opening in cylinder

X 2 barrel:
X1 0.30 ÷ 0.40
X 3
X2 0.60 ÷ 0.80
X3 0.25 ÷ 0.55
∅ 1
Small end bush housing
∅1 42.987 ÷ 43.013
Big and bearing
housing ∅2 72.987 ÷ 73.013
∅ 2
∅ 4
Small end bush diameter

∅ 3 Outside ∅4 43.279 ÷ 43.553
Inside ∅3 40.019 ÷ 40.033
Spare big end half
S
bearings S 1.955 ÷ 1.968
Small end bush — housing 0.266 ÷ 0.566
Piston pin — bush 0.0188 ÷ 0.0392
Big end half bearings —

Revi — July 2005

Type
(.18) (.21) (.24) (.28)

X
Size X —
Max. tolerance on
connecting rod axis
alignment —
∅ 1 ∅ 2
Journals ∅1 82.99 ÷ 83.01
Crankpins ∅2 68.987 ÷ 69.013
Main half bearings S1 2.456 ÷ 2.464

Big end half bearings S2 1.955 ÷ 1.968
S 1 S 2
*provided as spare part
Main bearings
∅ 3 No. 1—7 ∅3 87.982 ÷ 88.008
No. 2—3—4—5—6 ∅3 87.977 ÷ 88.013
Half bearings — Journals

No. 1—7 0.044 ÷ 0.106
No. 2—3—4—5—6 0.039 ÷ 0.111
Half bearings — Crankpins 0.038 ÷ 0.116
Main half bearings

0.250 ÷ 0.500
Big end half bearings
Shoulder journal X1 37.475 ÷ 37.545
X 1
Shoulder main
bearing X2 32.23
X 2
X 3 Shoulder
half—rings X3 32.30
Output shaft shoulder 0.07

Revi — July 2005
Print 603.93.391/A

Type
(.18) (.21) (.24) (.28)

∅ 1
Valve guide seats on

cylinder head ∅1 7.042 ÷ 7.062
∅ 2 Valves:
∅2 6.970 ÷ 6.990
α 60o ± 0.25o
∅2 6.970 ÷ 6.990
α α 45o ± 0.25o
Valve stem and guide 0.052 ÷ 0.092
Housing on head for
valve seat
∅1 34.837 ÷ 34.863
∅ 1 ∅1 34.837 ÷ 34.863
Valve seat outside diameter;
∅ valve seat angle on cylinder
2
head:
∅2 34.917 ÷ 34.931
α 60o
∅2 34.917 ÷ 34.931
α
α 45o
X 0.36 ÷ 0.94
X Sinking X 0.73 ÷ 1.33
0.054 ÷ 0.094
Between valve seat
and head
0.054 ÷ 0.094
Valve seats —

Revi — July 2005

Type
(.18) (.21) (.24) (.28)

Valve spring height:
free spring H 47.75
H H 1 under a load equal to:

H 2 339.8 ± 19 N H1 35.33
741 ± 39 N H2 25.2
Injector protrusion X It cannot be adjusted

X
Camshaft bush housings

No. 1—7 59.222 ÷ 59.248
Camshaft housings
∅ ∅ ∅ No. 2—3—4—5—6 59.222 ÷ 59.248
1 2 3 4—5—6 7
∅ 2
Camshaft journals:
1⇒7 ∅ 1—2—3 53.995 ÷ 54.045
∅ 1 ∅ 3
Camshaft bush outside

∅ diameter:
with a load of 3.3 kN ∅ 59.222 ÷ 59.248
Bush inside diameter

∅ after ramming ∅ 54.083 ÷ 54.147
Bushes and housings

0.113 ÷ 0.165
on block
Bushes and journals 0.038 ÷ 0.152
Cam lift:
H H 7.582
H 6.045

Revi — July 2005
Print 603.93.391/A

Type
(.18) (.21) (.24) (.28)

∅ 1
Tappet cap housing
on block ∅1 16.000 ÷ 16.030
∅ 2
∅ 3 Tappet cap outside diameter:
∅2 15.924 ÷ 15.954
∅3 15.960 ÷ 15.975
∅ 2
Between tappets and housings 0.025 ÷ 0.070
Tappets —
∅ 1
Rocker shaft ∅1 21.965 ÷ 21.977
Rockers ∅2 22.001 ÷ 22.027
∅ 2
Between rockers and shaft 0.024 ÷ 0.062

Revi — July 2005
Print 603.93.391
Figure 1
99233
ENGINE F4AE0681 CROSS SECTION

Print 603.93.391
Figure 2
70509
ENGINE F4AE0681 LONGITUDINAL SECTION

Print 603.93.391/A
ENGINE F4AE0681 OVERHAUL

Figure 5
NOTE It is different from engine F4AE0481 overhaul as
regards what is stated below.
540110 Engine removal at the bench

Figure 3
99234
105163
Assemble brackets 99341009 (1) to engine block and secure
Apply to engine block brackets 99341009 securing engine to them to overhaul stand 99322225 (2).
overhaul stand 99322205.
Proceed then to overhaul the engine complying, unless
In order to apply a bracket to left engine side, it is otherwise stated, with what is described for four—cylinder
necessary to: engine F4AE0481.
- with tool 99360076, disassemble fuel filter (4)

from support (1);
- disconnect low—pressure fuel pipings (2—3—5)
from support (1);
- detach support bearing bracket (1) from block.
Figure 6
Figure 4
70126
In order to disconnect low—pressure fuel pipings (2 70511

— 3 — 4. Figure 3) from related connection fittings, it
is necessary to press clip (1) as shown in figure B. Remove fastening screws (1) and disconnect exhaust
After having disconnected the piping, take back clip manifold into two sections (2—3) with related gaskets.
(1) to its locking position, figure A, to avoid possible
distortions of the clip.

Revi — July 2005
Print 603.93.391
5412 TIMING SYSTEM

541210 Camshaft
Figure 7
79459
MAIN DATA ABOUT CAMSHAFT PINS
BUSHES
Figure 8
Sec. A—A
79460
MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS

*Height to be obtained after driving the bushes

Figure 9
* Measured on a radius greater than 45.5 mm 70577

** ↗ 0.500 between adjacent main journals
MAIN OUTPUT SHAFT TOLERANCES
Figure 10
MAIN BEARING ON TIMING SYSTEM INTERMEDIATE MAIN FIRST MAIN BEARING ON

CONTROL SIDE BEARINGS FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness ○
SHAPE
Cilindricity /○/
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝

Figure 11
70514
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
5406 CYLINDER HEAD

VALVE SEATS
Figure 12
EXHAUST INTAKE
85485
MAIN DATA ABOUT ENGINE VALVE SEATS
Valve seats are obtained by melting on cylinder head and

machined.

Figure 13
EXHAUST INTAKE
70332
If valve seats cannot be restored just by regrinding, it is In order to assemble the valve seats into the cylinder head,
possible to assemble the spare inserts provided. it is necessary to heat the cylinder head to 80° — 100°C and,
through a suitable beater, to assemble the new, previously
In this case, it is necessary to obtain seats into the cylinder
cooled valve seats (2) into the head.
head sized as shown in the figure and to assemble the valve
seats. Then, with tool 99305018, adjust valve seats according to the
values shown in Figure 14.
Figure 14
INTAKE EXHAUST
85486
VALVE SEAT MAIN DATA

Cylinder head fastening screw tightening Figure 17

Figure 15
70520
70336 Adjust the clearance between rocker arms and valves

through setscrew wrench (1), box wrench (3) and feeler
Assemble cylinder head (1), tighten the screws (2) in three gauge (2).
following steps, following order and mode shown in the
figure below. The operating clearance is:
— ± 0.05
— intake valves 0.25 ± 0.05 mm
NOTE The angle tightening is carried out through tool — exhaust valve 0.51 ± 0.05 mm
99395216 (3).
In order to more quickly perform the operating
clearance adjustment for rocker arms — valves,
proceed as follows:
rotate the drive shaft, balance cylinder 1 valves and
adjust the valves marked by the asterisk as shown in
the table:
Figure 16 cylinder n. 1 2 3 4 5 6
intake — — * — * *
exhaust — * — * — *
A Rotate the drive shaft, balance cylinder 6 valves and

adjust the valves marked by the asterisk as shown in
α the table:
cylinder n. 1 2 3 4 5 6
intake * * — * — —
exhaust * — * — * —
70476
Tightening order layout for cylinder head fastening screws:

- 1st step pre—tightening with dynamometric wrench:
• Screw 12x1,75x130 ( ) 35 ± 5 Nm
• Screw 12x1,75 x 150 ( ) 55 ± 5 Nm
- 2nd step tightening with a 90° ± 5° angle
- 3rd step tightening with a 90° ± 5° angle
A = Front side


Print 603.93.391
5450 LUBRICATION
The forced—circulation lubrication is carried out by the Figure 18
following components:
- rotor oil pump (5), housed in the front block part,
controlled by the straight—tooth gear keyed to the
output shaft tang;
- water/oil heat exchanger (3), housed in engine block,
with oil filter support;
- oil pressure relief valve (1) embedded into filter support;
- by—pass valve (4) to cut off clogged oil filter, embedded
into filter support;
- cartridge oil filter (2).
Routing of oil under pressure

Routing of oil return by gravity
to sump
Introduction of oil
70516
LUBRICATION SYSTEM LAYOUT

5432 COOLING SYSTEM

The engine cooling system, of the closed—loop Figure 19
forced—circulation type, is composed of the following
components:
- expansion tank whose plug embeds two valves: an
exhaust valve (2) and an intake valve (1), that adjust the
system pressure;
- radiator, whose task is dissipating heat subtracted to
engine by coolant;
- viscous fan;
- an heat exchanger to cool lubricating oil (see
lubrication);
- a water pump of the centrifugal type housed in the front
engine block part;
- a thermostat adjusting coolant circulation.
Water coming out

from thermostat
Water recirculating in engine
Water coming into pump
COOLING SYSTEM LAYOUT 70517

Print 603.93.391
BOOSTER
542410 Turbosupercharger
Figure 20
85487
TURBOSUPERCHARGER
Borg Warner Turbo Systems K27.2
Fitted on engines
F4 AE 0681 E
F4 AE 0681 D
Figure 21
70519
HOLSET TURBOSUPERCHARGER
Supercharging pressure: 1.5 bars.

(WASTEGATE) actuator opening start: 1600 rpm.
542418 TURBOSUPERCHARGER
ACTUATOR
Check and adjustment
The actuator (2) check is carried out as described for

GARRETT turbosupercharger assembled on 4—cylinder
engines.
Adjustment is carried out by operating on tie rod (1).


Print 603.93.391
TURBOSUPERCHARGER LAYOUT
Figure 22
Incoming air
Hot compressed air
Cooled compressed air
Exhaust
70518


Troubleshooting Guide
Page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
- Diagnosis through instruments . . . . . . . . . . . . . 143
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 145


FOREWORD
A good diagnosis is carried out above all with electronic diagnostic instruments (Modus/IWT/IT200) developed by Iveco.
When a vehicle enters the workshop, information provided by vehicle driver are kept under right consideration, but the first
thing to do is connecting Modus/IWT/IT2000 and carefully performing a complete diagnosis.
— failure memory reading
— parameters reading
— engine test
— etc.
It is useful to print the results, especially in case the Help Desk assistance has to be requested.
Diagnosis through instruments
MODUS
Computerised diagnostic station aimed to provide a diagnosis for braking systems, pneumatic suspensions,
electronically—controlled engines and systems.
The station is equipped with auxiliary functions such as electronic control units programming, spare parts catalogue searching,
time schedules, etc.
The vehicle is equipped with the “30—pole” diagnosis socket placed aside the U.C.I.
IWT
The IVECO WIRING TESTER expands and integrates MODUS.
This instrument has been implemented by IVECO to improve vehicle electric and electronic systems diagnosis.
The vehicle is equipped with the “30—pole” diagnosis socket placed aside the U.C.I., therefore it is necessary to use cable “4”.
IT2000
IT2000 is a diagnostic instrument of all Electronic Systems for IVECO vehicles.
It allows an immediate intervention on the vehicle recognising it from its chassis number.
It stores the results of performed diagnostic interventions.
It can be used also as portable Personal Computer and is preset for the remote diagnosis.
By using MODUS as mother station, it is possible to update and configure the IT2000.
IT2000 is interfaced with the vehicle through a 30—pole diagnosis socket placed aside the UCI.
Figure 23
70729


DIAGNOSTICS
Main engine operating anomalies:

6— The engine has cerulean smokes;
1— The engine does not start; 7— The engine has anomalous rattles;
2— The engine is excessively heated; 8— The engine stops;
3— The engine lacks efficiency; 9— Excessive or insufficient oil pressure;
4— The engine has black or dark grey smokes; 10 — Excessive fuel consumption.
5— The engine has grey smokes (tending to white);
1 THE ENGINE DOES NOT START
Efficient connections to battery terminals Clean, check, tighten terminal nuts, or replace them.
NO
YES
Efficient batteries. Carry out the checks described in ”Electric system”

NO Repair Manual.
YES
Efficient starter. Carry out the checks described in ”Electric system”

NO Repair Manual.
YES
Absence of air seepages in the low—pressure supply Remove seepage causes.

circuit. NO Perform the drain.
YES
Absence of water traces in the supply circuit. Remove seepage causes.

NO Clean the supply circuit including the tank.
YES
Efficient fuel prefilter — filter. Replace.

NO
(continued)

Efficient pre—post heating system. Diagnosis with Modus — IT2000 — IWT.

NO
YES
Efficient high—pressure pump. Engine Test with Modus — IT2000 — IWT.

NO
YES
Efficient injector. Engine Test with Modus — IT2000 — IWT.

NO Check O—Ring seal.
YES
Correct compression ratio. Revise the engine or limit intervention to affected parts
NO (valves, elastic rings, etc.).
2 THE ENGINE IS EXCESSIVELY HEATED
Correct cooling liquid level. Check possible losses and restore the level.
NO
YES
Efficient water pump and fan control belts. Check, adjust tension and possibly replace the parts.
NO
(continued)

Efficient water pump. Revise or replace the assembly.

NO
YES
Efficient thermostat. Replace.

NO
YES
Efficient radiator. Carry out an accurate washing, check whether there

NO are liquid leakages; possibly replace the part.
YES
Efficient air filter and circuit pipings. Clean or replace faulty parts.
NO
YES
The engine brake is disengaged. Check and possibly replace.

NO
YES
Efficient cylinder head. Replace.

NO
YES
Efficient fan. Replace.

NO

3 THE ENGINE LACKS POWER
Efficient fuel filters. Replace, proceeding as described in ”Use and

NO Maintenance” booklet.
YES
Efficient low— and high—pressure supply circuit. Check system fittings seal.
NO
YES
Efficient thermostat. Replace.

NO
YES
Presence of fuel in the tank. Check fuel level.

NO
YES
Efficient fuel floating device in the tank. Check small priming pump and clean the floating device
NO from possible impurities.
YES
Efficient high—pressure pump. Engine Test with Modus — IWT — IT2000, possibly
NO replace.
YES
Efficient injectors and correctly—operating flow limiter. Engine Test with Modus — IWT — IT2000, possibly
NO replace.
Check O—Ring seal.
(continued)

Efficient rail overpressure valves. Disconnect fuel return piping from rail and check the
NO presence of blow—by.
YES
Correct compression ratio. Engine Test with Modus — IWT — IT2000.

NO
YES
Efficient turbosupercharger (blades, bearings, actuators Repair or replace the assembly.

integrity) NO
YES
Efficient valve clearance. Check — restore.

NO
4 THE ENGINE HAS BLACK OR DARK

GREY SMOKES
Efficient air filter. Replace.

NO
YES
Efficient injectors. Engine Test with Modus — IWT — IT2000.

YES
Correct compression ratio. Engine Test with Modus — IWT — IT2000.

NO
(continued)

5 THE ENGINE HAS GREY SMOKES

(TENDING TO WHITE)
Efficient injectors. Engine Test with Modus — IWT — IT2000.

YES
Correct cooling liquid level. Probable cooling liquid passage in bursting chambers.
NO Replace cylinder head gasket or revise the engine.
6 THE ENGINE HAS CERULEAN SMOKES
Presence of oil in the cylinders. Excessive oil consumption.

YES Turbine oil blow—by.
Blow—by from valve guide.

ENGINE
7 THE ENGINE HAS

ANOMALOUS RATTLES
Rattle located in drive shaft. Check clearances and main journals ovalities; screws
YES securing for main caps and engine flywheel; oil pressure.
Replace the parts or revise the engine.
NO
Rattle located in connecting rods. Check clearances and connecting rod journals ovalities;
YES screws securing for connecting rod caps; connecting
rods quadrature. Replace the parts or revise the engine.
NO
Rattle located in plungers. Check clearances between plungers and cylinder

YES barrels; elastic rings integrity; plunger pins — hubs
clearance. Replace the parts or revise the engine.
NO
Rattle located in cylinder head. Check: operating clearance between rocker arms and
YES distribution setting valves. Adjust.
NO
Rattle located in distribution. Check and possibly replace the gears.

YES
YES
Rattle located in air compressor. Revise or replace the air compressor.

YES
NO
Rattle located in injectors. Check and calibrate them according to what is

YES described in S.I. 1094 or replace them.

8 THE ENGINE STOPS
Presence of fuel in the tank. Carry out the refueling and, if necessary, carry out the
NO drain.
YES
Efficient fuel filters. Replace.

NO
YES
Efficient supply circuit. Check the circuit and carry out the drain.
NO
9 INSUFFICIENT OR EXCESSIVE
OIL PRESSURE
The pressure regulating valve correctly intervenes. Check and possibly replace.
NO
YES
Efficient oil pump and delivery pipings. Check and possibly replace.
NO
YES
Efficient main and connecting rod bearings. Replace the bearings and possibly adjust the drive shaft.
NO
YES
Correct engine oil SAE viscosity. Replace the engine oil with another one with a correct
NO viscosity.

10 EXCESSIVE FUEL CONSUMPTION
Efficient fuel tank and pipings. Remove possible leakages and replace the deteriorated
NO parts.
YES
Efficient air filter. Replace.

NO


EUROCARGO TECTOR 12—26 t CLUTCH 1
Print 603.93.391/A
SECTION 3
Clutch
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS AND DATA . . . . . . . . . . . . . 5
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 10
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL AND REFITTING . . . . . . . . . . . . . . . 11

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DRIVEN PLATE OVERHAUL . . . . . . . . . . . . . . . 11

- Damper hub check . . . . . . . . . . . . . . . . . . . . . 11
- Friction gaskets . . . . . . . . . . . . . . . . . . . . . . . . 11
THRUST BEARING REMOVAL — REFITTING . . 12

REPLACING CLUTCH SHAFT SUPPORT BEARING 12
HYDRAULIC CONTROL . . . . . . . . . . . . . . . . . . 13
- Mini—servoclutch (14” clutches) . . . . . . . . . . . . 13
- Clutch disengagement cylinder

(14” clutches) . . . . . . . . . . . . . . . . . . . . . . . . . 13
- 14” clutch wear check . . . . . . . . . . . . . . . . . . . 14
- 14” clutch mounting assembly . . . . . . . . . . . . . 14
- Midi—servoclutch cylinder (15”/16” clutches) . . 15

- Clutch disengagement cylinder (15”/16” clutches) 15
- 15”/16” clutch wear check . . . . . . . . . . . . . . . . 16
- 15”/16” clutch mounting assembly . . . . . . . . . . 16

CLUTCH DISENGAGEMENT CYLINDER
TIP ADJUSTMENT (New 15”/16” clutch) . . . 17
ADJUSTMENT OF STOP AND PEDAL POSITIONING

SCREW ON THE CLUTCH PEDAL . . . . . . . 18
- Clutch pedal clearance . . . . . . . . . . . . . . . . . . . 18
- Clutch pedal travel . . . . . . . . . . . . . . . . . . . . . . 18
CLUTCH CONTROL SYSTEM BLOW—OFF

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 18

Revi — July 2005
2 CLUTCH EUROCARGO TECTOR 12—26 t
Print 603.93.391

Print 603.93.391/A
DESCRIPTION
Clutch
The clutch is of the single—plate, dry—operating type, with engagement control is hydraulic and comprises the master
engagement mechanism of the pull type with baffle spring. The cylinder, with embedded oil tank, and the operating cylinder.
SPECIFICATIONS AND DATA

13” CLUTCH A.P.
VALEO
with gearboxes: 2855S.6 — 2870S.9 BORG & BECK
Type Dry single—plate
Engagement mechanism Pull with baffle spring
Driven plate With friction gaskets
Driven plate hub With spring drives
Ø External gaskets mm 330
Ø Internal gaskets mm 194.5 200
(New) plate thickness mm 8.5 ± 0.3
Max. driven plate mismatching mm µ 0.2
Load on plate—pusher N 10100 10500
Disengagement load N 2500 2000
Minimum plate—pusher lift mm 1.5
Detachment stroke mm 10 +20 12
Max. consumption stroke mm 14 13.6
Master cylinder with embedded oil tank —

Hydraulic control
operating cylinder
Oil type Tutela TRUCK DOT SPECIAL

Revi — July 2005
13”/14” CLUTCH VALEO

with gearboxes: 2855S.6 — 2870S.9
External gaskets Ø mm 330
Internal gaskets ∅ mm 194.5
Load on plate—pusher N 12000
Disengagement load N 2600
Detachment stroke mm 10 +2
0
Max. consumption stroke mm 12.2

Hydraulic control
operating cylinder

Revi — July 2005
14” CLUTCH VALEO
External gaskets ∅ mm 350
Internal gaskets ∅ mm 195
Load on plate—pusher N 12000
Disengagement load N 2600
+2
Detachment stroke mm 10 0
Max. consumption stroke mm 12.2

Hydraulic control
operating cylinder

Revi — July 2005
FICHTEL & A.P. BORG &

15” /16” CLUTCH SACHS VALEO
BECK
External gaskets ∅ mm 380 380 380
Internal gaskets ∅ mm 220 220 220
(New) plate thickness mm 10 ± 0.3 10 ± 0.3 10 ± 0.2
Max. driven plate mismatching mm — — µ 0.3
Load on plate—pusher N 17400 19000 20000
Disengagement load N 4000 4000 3950
Minimum plate—pusher lift mm 1.7 1.7 1.7
Detachment stroke mm 12+20 12+20 12+20
Max. consumption stroke mm 16 12.5 15

Hydraulic control
operating cylinder

Revi — July 2005
Print 603.93.391
DIAGNOSTICS
Main clutch operating anomalies:
1 — Noises when the pedal is lowered; 4 — The clutch does not disengage itself;
2 — Noises when the pedal is released; 5 — The clutch slips;
3 — The clutch jerks; 6 — Anomalous driven plate gasket wear.
1 NOISES WHEN THE PEDAL

IS LOWERED
Excessively worn, damaged or scarcely lubricated thrust Replace the thrust bearing.
bearing. YES
NO
Excessive clearance between gearbox entry shaft Replace the shaft and, if necessary, the driven plate too.
grooves and related seat on driven plate hub. YES
2 NOISES WHEN THE PEDAL

IS RELEASED
Broken or excessively deteriorated driven plate springs. Replace the driven plate.
YES
NO
Worn gearbox entry shaft. Replace the shaft and, if necessary, the driven plate.
YES
NO
Thrust bearing having clearance on engagement Replace the thrust bearing.

manifold. YES

3 THE CLUTCH JERKS
Oil or grease on engine flywheel, or on driven plate Remove the inconvenience generating the fouling;
gaskets. YES accurately clean the flywheel, then replace the driven
plate.
NO
Buckled plate—pushing ring. Replace the clutch.

YES
NO
Irregularly consumed friction gaskets due to driven Replace the driven plate.
plate mismatching. YES
NO
Weak clutch baffle spring or baffle spring with broken Replace the clutch.
blades. YES
4 THE CLUTCH DOES NOT DISENGAGE

ITSELF
Oil or grease on driven plate gaskets. Remove the inconvenience generating the fouling;
YES
accurately clean the flywheel, then replace the driven
plate.
NO
Worn gearbox entry shaft grooves so that the driven Replace the shaft and, if necessary, the driven plate too.
plate sliding is prevented. YES

5 THE CLUTCH SLIPS
Worn or burnt driven plate gaskets. Replace the driven plate.

YES
NO
Weak clutch baffle spring or baffle spring with broken Replace the clutch.
blades. YES
NO
Oil or grease on driven plate gaskets. Remove the inconvenience generating the fouling and
YES replace the driven plate.
6 ANOMALOUS DRIVEN PLATE GASKET

WEAR
The driver keeps, during the drive, his foot rested on The driver must avoid this wrong attitude and rest his
the clutch pedal. YES foot on the clutch pedal only when it is necessary.
NO
Baffle spring with yielded or broken blades. Replace the clutch.

YES

TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Flanged hexagonal—head screw for securing plate—pusher to flywheel M8 23.5 ± 2.5 (2.4 ± 0.2)
Flanged hexagonal—head screw for securing plate—pusher to flywheel M10 46.5 ± 4.5 (4.7 ± 0.4)
Hexagonal nut for securing clutch timing case to engine 46 ± 5 (4.7 ± 0.5)
Screw stud securing clutch case with engine 19 ± 2 (1,9 ± 0,5)
TOOLS
TOOL No. DENOMINATION
99306010 Air drain apparatus for brakes and clutches system
99370280 Guide pin for clutch plate centring
99370306 Guide pin for clutch plate centring
99370547 Disengagement and re—engagement support for clutch assembly

(to be applied to hydraulic jack)

Print 603.93.391/A
505210 REMOVAL AND REFITTING

Removal Damper hub check
After removing the gearbox propeller shaft as described in the
relevant sections, remove the clutch assembly as follows: Visually inspect the hub and check absence of breaks; spring
drives shall not rotate into their seats and hub outline shall be
within the tolerance values specified on drawing.
Replace the entire plate if the hub shows one of the above
Figure 1 faults or hub grooved coupling sizes are out of tolerance
values.
Friction gaskets
Replace the entire driven plate if gaskets are excessively worn
or dirty with oil or grease, or burning traces or removal from
the driving plate are visible.
Figure 3
33696
Insert clutch—centering pin 99370306 (for 14” clutches) or

99370280 (for 15”/16” clutches) (1), unscrew
assembly—securing screws (2) and withdraw the assembly.
Figure 2
Before fitting a new driven plate, check its centring as follows:

Place the driven plate (1) on a lathe, then using a
magnetic—base gauge (2), check that the plate surface is not
out of line at any point.
Max. tolerance for driven plate is 0.20 mm.
33697
Withdraw pin (1) and remove the driven plate (2).
Figure 4
Refitting
For refitting, reverse the removal operations.
Check conditions of fastening screws and replace the
faulty ones.
Clean accurately threads and contact surfaces.
DRIVEN PLATE OVERHAUL

Upon overhauling the clutch plate, no repair is provided since
components are only submitted to visual inspection to
determine their wear conditions.
These checks and the overhauling procedures are specified in
the following paragraphs.
If plate is out—of—line, use a fork wrench (1) as shown in the
figure.

Revi — July 2005
Print 603.93.391
505254 THRUST BEARING REMOVAL — 540852 REPLACING CLUTCH SHAFT

REFITTING SUPPORT BEARING
Figure 5 Figure 6
33698 33699
Use the proper pliers to open the safety split ring (2) and Use the universal extractor 99348004 (1) and remove bearing
withdraw the thrust bearing (1). (2).
For refitting reverse removal operations. For refitting use the proper beater.
NOTE If fluid leaks are found from master and operating

cylinders use the provided kits to repair.

Print 603.93.391/A
HYDRAULIC CONTROL
The hydraulic control consists of the following:
- Mini—servoclutch with built—in tank
- Midi—servoclutch with built—in tank
- Clutch disengagement cylinder
Mini—servoclutch (14” clutches)

Figure 7
Stroke mm 38
min 150
Capacity tank cm3
max 200
87558
Clutch disengagement cylinder (14” clutches)

Figure 8
87559

Revi — July 2005
14” clutch mounting assembly
Figure 9
87560
14” clutch wear check
Figure 10 Figure 11
B
A
87561 87562
A = mm 108,88 (cylinder stroke with new clutch)

B = mm 72.40 (cylinder stroke with worn clutch)

Revi — July 2005
Print 603.93.391
Midi—servoclutch cylinder (15”/16” clutches)
Figure 12
Stroke mm 39
min 150
Capacity tank cm3
max 200
87563
Clutch disengagement cylinder (15”/16” clutches)
Figure 13
87564

15”/16” clutch mounting assembly
Figure 14
87565
15”/16” clutch wear check
Figure 15 Figure 16
87566 87567
A = mm 83.06 (cylinder stroke with new clutch)

B = mm 29.92 (cylinder stroke with worn clutch)

505272 CLUTCH DISENGAGEMENT

CYLINDER TIP ADJUSTMENT
(New 15”/16” clutch)
Figure 17
91580
Proceed as follows:
- measure the distance (A) between the bottom
of the spherical cavity of the clutch lever and the
servo clutch fixing surface;
- press the ball push rod until it reaches the stop
(C);
- loosen the nut (D);
- tighten or loosen rod (F) until obtaining distance
(B).
B= A—E
E = 25 mm (VALEO)

ADJUSTMENT OF STOP AND PEDAL POSITIONING SCREW ON THE CLUTCH PEDAL
Clutch pedal clearance

Axial clearance between push rod (5) connected to clutch pedal (7) and piston (6) of mini or midi servo—clutch must range between
0.5 and 1 mm. This value is checked by measuring clutch pedal idle travel, which must range between 2 and 4 mm. Clutch pedal
idle travel must be read on part outer profile as indicated in figure. If prescribed value is not matched, below described adjusting
procedure has to be performed:
- loosen lock nut (2) and screw up screw (1) until clearance is reset; then, unscrew the screw by 45° — 90° and lock the screw
by the lock nut;
- drive pedal up to stop; from stop position, let pedal freely return to rest position; pay attention to this movement, which must
be fast. Repeat this operation three times.
Then, check that clearance is correct. If it is not, drive screw (1) by 45° at a time and go on driving until correct value is obtained.
Clutch pedal travel

This operation must be only performed after adjusting the clearance, as described above:
- loosen lock nut (4) and drive screw (3) until a projection is obtained of X = 8 + 0.5 mm of the screw from lock nut plane.
NOTE Dimension control must be performed with lock nut beating against pedals set support body. The lock nut must be from
an original supply (4.8 mm height).
Figure 18
91580
CLUTCH CONTROL SYSTEM BLOW—OFF PROCEDURE

After connecting the mini servo—clutch to clutch disengaging cylinder in use position via the hose, open clutch disengaging cylinder
drain screw and pour clutch liquid contained in mini servo—clutch tank. As liquid is starting to come out from the drain screw, close
the screw.
Now, take clutch disengaging cylinder off its fastener and, keeping the cylinder upright with the push rod oriented upwards, press
up the push rod (twice).
Thereafter, repeat movement operation (twice) up to push rod bottom with the cylinder oriented horizontally and hydraulic feed
fitting oriented upwards.
Check clutch disengaging cylinder travel by fully driving the pedal and, if measured travel is not yet complying with values prescribed
on the drawing, repeat once again above described operations.

EUROCARGO TECTOR 12—26 t GEARBOX 1
Print 603.93.391
SECTION 4
Gearbox
Page
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Gears control connection . . . . . . . . . . . . . . . . 5
- Gearbox control tie—rods adjustment . . . . . . . 5
GEARBOX 2855S.6 . . . . . . . . . . . . . . . . . . . . . . 9
GEARBOX 2865S.6 . . . . . . . . . . . . . . . . . . . . . . 45
GEARBOX 2870S.9 . . . . . . . . . . . . . . . . . . . . . . 79
GEARBOX 2895S.9 . . . . . . . . . . . . . . . . . . . . . . 123
GEARBOX ALLISON MD3060P . . . . . . . . . . . . 163
GEARBOX EATON FSO5206B . . . . . . . . . . . . . 187

2 GEARBOX EUROCARGO TECTOR 12—26 t

Print 603.93.391
DIAGNOSTICS
Main gearbox operating anomalies:
1 — Noises;
2 — Spontaneous gears disengagement and engagement
irregularities;
3 — Gears engagement difficulty and hardness.
1 NOISES
Excessive clearance between gears. Revise the gearbox and replace worn gears.
YES
NO
Worn gears, bearings, synchronising rings and coupling Revise the gearbox and replace parts gears.
bodies. YES
NO
Insufficient lubricating oil level in box. Add TUTELA ZC 90 oil restoring the exact level.
YES
NO
Insufficient oil pressure (only for gearboxes equipped Replace the oil pump.
with oil pump). YES
SPONTANEOUS GEARS DISENGAGEMENT

2 AND ENGAGEMENT IRREGULARITIES
Exact engagement manoeuvre. Completely engage the gears before releasing the
YES clutch pedal.
NO
Forks breakage. Disassemble the gearbox, revise the parts and carry out
YES necessary replacements.
(continued)

Worn synchronising rings. Check gears and sliding sleeves for gears engagement,
YES replacing the deteriorated ones; replace synchronising
rings.
NO
Faulty epicyclic reduction gear operation (gearbox Check and replace the deteriorated parts.
2870.9). YES
3 GEARS ENGAGEMENT DIFFICULTY

AND HARDNESS
Fork hardening on rod. Disassemble gearbox case and search for the hardening
YES reason; carry out the suitable repairs.
NO
Sliding sleeves obstructed when displacing. Check and carry out suitable repairs.
YES
NO
Unsuitable lubricating oil quality inserted into the case. Discharge the oil and refill with TUTELA ZC 90 oil.
YES

Print 603.93.391/A
Gears control connection

Gear control connection is made up of a telescopic tie rod (6),an adjustable fixed tie rod (5) and an adjustable reaction tie rod (3).
Transmission lever (4) between telescopic tie rod (6) and adjustable fixed tie rod (5) is constrained to a support fastened to the
engine, reaction tie rod (3) is fastened at one side to adjustable fixed tie rod and at the other side to a plate (2) fastened in turn
to gearbox gears drive.
Figure 1
91581
1. Gears control lever — 2. Reaction plate secured to gears control — 3. Reaction tie rod — 4. Bearing support —
5. Adjustable fixed tie—rod — 6. Telescopic tie—rod — 7. Gears lever
Gearbox control tie—rods adjustment
Figure 2 - Check or position, if disassembled, the gears control lever

on the transverse control: upon assembling the lever, the
milling (1) must correspond with the reference notch (2)
punched on the transverse shaft;
- position the gearbox in idle;
- in order to be sure about such operation, it is enough to
longitudinally push the transverse rod: if the rod performs
the movement, it means that it is in idle.
62591

Revi — July 2005
Figure 3 - verify/adjust the fixed adjustable tie—rod length complying

with the shown dimensions (see Figures 5, 6, 7 and 8) with
a ± 0.75 mm tolerance (corresponding to 1/2 threading
turns).
Figure 5
633.5 ± 0.75 mm
62592
- It is necessary that the gearbox remains in such a 70992

condition for the whole operation. In order to be sure of MODELS 120EL17
that, in place of the Idle—R.M. switch, a screw can be
applied with equal sizes (M 16x1.5 mm) with its bit
Figure 6
chamfered at 60° that, completely screwed, blocks any
transverse rod movement for gearboxes 2855S.6 and
2865S.6 and the internal controls for gear boxes 2870S.9
and 2895S.9; it is anyhow sufficient to check whether the
neutral condition remains during the different stages 706 ± 0.75 mm
(avoiding any forcing on the lever);
Figure 4
70993
MODELS 120EL21
Figure 7
722.5 ± 0.75 mm
62593
- position the reaction plate on gears control and screw the

securing screws without completely tightening them;
- check/adjust the length (X) of the gearbox control
reaction tie—rod that must be 329 mm;
70994
MODELS 130E18 — 140E18—21 — 150E21 — 160E21 —

180E21

Revi — July 2005
Print 603.93.391
Figure 8
780.5 ± 0.75 mm
70995
MODELS 130E24—28 — 140E24—28 — 150E24—28 —

160E24—28 — 260E28KE — 180E24—28
Figure 9
62595
- close securing screws (1) of the reaction plate (2) on gear

control;
- loosen the screw previously inserted to block the gearbox
in idle position and refit the Idle—R.G. switch.


EUROCARGO TECTOR 12—26 t GEARBOX 2855S.6 9
Print 603.93.391
5302 Gearbox
2855S.6
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GEARBOX 2855S.6 REMOVAL/REFITTING . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . . 23
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . 27
- Bearings pre—load adjustment for secondary shaft 27
PRIMARY SHAFT DISASSEMBLY . . . . . . . . . . . . 33
PRIMARY SHAFT ASSEMBLY . . . . . . . . . . . . . . . 35
MOTION INLET SHAFT DISASSEMBLY . . . . . . 38
MOTION INLET SHAFT ASSEMBLY . . . . . . . . . 38
- Motion inlet shaft bearing adjustment . . . . . . . 38
SECONDARY SHAFT DISASSEMBLY . . . . . . . . 39
SECONDARY SHAFT ASSEMBLY . . . . . . . . . . . 39
INTERNAL DRIVE SHAFT DISASSEMBLY . . . . . 39
INTERNAL DRIVE SHAFT ASSEMBLY . . . . . . . . 39
EXTERNAL CONTROL SHAFT DISASSEMBLY . 40
EXTERNAL CONTROL BOX ASSEMBLY . . . . . 41
- Idle—R.M. switch adjustment . . . . . . . . . . . . . . . 43

10 GEARBOX 2855S.6 EUROCARGO TECTOR 12—26 t

Print 603.93.391
DESCRIPTION
The IVECO 2855S.6 gearbox is of the mechanical type with The gears are keyed or obtained on four shafts: motion entry,
1st, 2nd gear engagement through a double—cone primary, secondary and reverse motion shafts.
synchronising ring and 3rd, 4th, 5th and 6th gear engagement The gear obtained on the motion entry shaft and those keyed
with free—ring synchronising rings. The reverse motion on primary and reverse motion shafts idly rotate on cylindrical
engagement is with a quick—connection sliding sleeve. roller cages.
The gearbox case is made of light alloy and is composed of a Motion entry shaft and primary shaft are supported by ball
front half—case and a rear half—case. bearings in the gearbox case.
Three openings are obtained in the rear half—case for the The secondary shaft is front and rear supported by
possible application of a power takeoff. tapered—roller bearings that are axially adjustable through an
Motion transmission is realised through a series of gears, adjustment ring.
always meshed and with helical teeth. The gears engagement and selection control is mechanical.
Figure 1
79431
IVECO 2855S.6 GEARBOX ASSEMBLY


GEARBOX 2855S.6
Type Mechanical
6 forward gears and

Gears
reverse gear
Gears engagement control Mechanical
Power takeoff Upon request
Gears engagement:
1st ⇒ 2nd Double—cone synchronizer

3rd ⇒ 6th Free—ring synchronizer
Reverse gear Quick—connection type
Gears anti—disengagement Sliding sleeve holding through rollers and springs.
Gears With helical teeth
Gear ratio
First 1 : 6.433
Second 1 : 3.643
Third 1 : 2.308
Fourth 1 : 1.484
Fifth 1 : 1.000
Sixth 1 : 0.783
Reverse gear 1 : 5.630
Oil type TUTELA ZC 90
Amount 5 kg. (5.5 litres)
Fixed hubs assembly temperature 100oC to 130oC

Secondary shaft bearings With tapered rollers
Secondary shaft bearings

Through rings
pre—loading adjustment
4.0 — 4.1 — 4.2 — 4.3 — 4.4 — 4.5 — 4.6 — 4.7 — 4.8 — 4.9 —
Secondary shaft pre—loading
5.0 — 5.1 — 5.2 — 5.3
adjustment rings thickness
Supplied in a kit
Secondary shaft bearings
85oC
assembly temperature
Secondary shaft bearings 2.40 — 2.45 — 2.50 — 2.55 — 2.60 —

adjusting rings thicknesses 2.65 —2.70 — 2.75 — 2.80

Figure 2
98988

TIGHTENING TORQUES
TORQUE
PART
Nm (kgm)
1 Flanged hexagonal head screw for securing front cover 1st Step 20 ± 1 (3.3 ± 0.3)
2nd Step 25º
2 Flanged hexagonal head screw for joining half—boxes 45.5 ± 4.5 (4.6 ± 0.5)
3 Release—proof tip cover fastening screw 22.5 ± 2.5 (2.3 ± 0.2)
4 Screw for securing hub to fork control rod 39 ± 2 (4.0 ± 0.2)
5 Flanged hexagonal head screw for pin on 5th — 6th fork 14.5 ± 1.5 (1.5 ± 0.1)
6 Threaded plug with external driving hexagon for oil level 27.6 ± 2,5 (2.8 ± 0.3)
7 Flanged hexagonal head screw for securing covers on side power takeoff connection windows 38 ± 4 (3.9 ± 0.4)
8 Flanged hexagonal head screw for securing transverse axle cover on control 19 ± 2 (1.9 ± 2)
9 Transverse axle screw 30 ± 3 (3.0 ± 0.3)
10 Threaded plug with external driving hexagon for oil discharge 27.5 ± 2.5 (2.8 ± 0.3)
11 Flanged hexagonal head screw for securing rear cover on secondary shaft 58 ± 6 (5.9 ± 0.6)
12 Flanged hexagonal head screw for securing rear cover on primary shaft 43 ± 4 (4.4 ± 0.4)
13 Output flange locking nut on primary shaft 467 ± 23 (47.6 ± 2.3)
14 Flat—head screw with TORX mark to secure rib washer * 9.5 ± 0.5 (0.96 ± 0.05)
15 Flanged hexagonal head screw for securing upper cover supporting external controls 33.5 ± 3.5 (3.4 ± 0.4)
16 Flanged hexagonal head screw for securing spring check flange on external control 19 ± 2 (1.9 ± 2)
Flanged hexagonal head screw for securing upper cover for internal controls
— 45.5 ± 4.5 (4.6 ± 0.5)
(only for right—hand drive)
— Flanged hexagonal head screw for securing clutch disengagement lever support 45.5 ± 4.5 (4.6 ± 0.5)
* Apply thread—braking LOCTITE 270 on the screw

♦ Apply liquid gasket LOCTITE 510 sealant
F Apply liquid gasket LOCTITE 518 sealant
◩ Apply liquid gasket LOCTITE 5910 sealant.

TOOLS
TOOL NO. DESCRIPTION
99305121 Hot—air apparatus
99322205 Rotating stand for assembly revision

(capacity 1000 daN, couple 120 daN/m)
99222225 Assembly bearing support (to be applied on stand 99322205)
99340205 Percussion extractor
99341003 Simple—effect bridge
99341009 Pair of brackets

TOOLS
99341015 Clamp
99341017 Pair of brackets with hole
99341019 Pair of tie—rods for holds
99341025 Holds
99342143 Peg for removing reverse gear shaft (use with 99340205)

TOOLS
99348004 Universal extractors for interiors 5 to 70
99370006 Handle for interchangeable beaters
99370317 Reaction lever with flange check extension
99370349 Keyer for drive shaft front gasket assembling (use with 99370006)
99370466 Comparator—holder basis for secondary shaft bearings adjustment

(use with 99395604)

TOOLS
99370629 Gearbox bearing support during vehicle disconnection and

re—connection
99374092 Beater for external bearings race assembling (69—91) (use with
99370007)
99374201 Keyer for assembling gasket on rear gearbox cover
99396031 Calibrated rings for secondary shaft bearings adjustment (use with
99370466).
99395604 Comparator (0 — 10 mm)


Print 603.93.391
GEARBOX 2855S.6 REMOVAL/REFITTING Figure 3
Before carrying out removal/refitting operations,

! disconnect battery cables and place the vehicle
under safety conditions.
Removal
Lift the calender and turn the cabin over.
- loosen securing bolt (17), unscrew securing nuts (18)

and detach air piping supporting bracket (16);
- unscrew securing nut (2) and detach air piping
supporting bracket (1);
- unscrew securing nuts (13) and detach bracket (14) of
reaction tie—rod (12);
- loosen securing screw (6) and detach from gearbox the
gears control lever completed with tie—rod (3) and
- disconnect reverse gear switch electric connection (7);
- unscrew securing nuts (15) of clutch bell to engine that
will be able to be reached with difficulty from the lower
vehicle part.
- rotate deadening guard locking rivets below the gearbox
and remove the deadening guard;
- detach transmission shaft (9) as described in the related
section;
- unscrew securing screws (4) and detach clutch control
operating cylinder (5);
- disconnect electric connection (10) of odometer sensor
(8);
- unscrew securing screw (11) and detach air piping
support bracket;
- place an hydraulic jack equipped with support 99370629
under the gearbox;
- unscrew the remaining securing nuts of clutch bell to
engine, move the gearbox backwards and lowering the
jack remove it from below the vehicle.
Refitting
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Upon re—engaging the gearbox, pay attention that

the clutch control lever fork is correctly meshed to
the thrust bearing.
71000


GEARBOX DISASSEMBLY
Print 603.93.391
Figure 4 Figure 7
71666 71699
Place gearbox (2) on rotating stand 99322205 (3) equipped Remove flange (2), unscrew securing screws (3) and remove
with brackets 99322225 (1) and discharge lubrication oil. cover (1).
Figure 5 NOTE Disassembling rear cover from gearbox to replace

the sealing gasket can also be carried out with a
gearbox assembled on the vehicle by disconnecting
the transmission shaft and proceeding as shown for
the gearbox assembled on a rotating stand.
71667
Disassemble the external control box (1).
Figure 6
Figure 8
78685
Apply reaction lever 99370317 (1) on motion outlet flange (3) 71670
and unscrew nut on primary shaft with wrench 99355081 (2).
Remove phonic wheel (1) for odometer control.

Figure 9 Figure 12
71671
78164
Unscrew screws (1) and remove cover (2). Release the screws (2) and remove the cover (1).
Unscrew screws (3) and remove cover (4). Remove the spring (3) and extract the push rod (4).
Figure 10 Figure 13
79432
71672
With a punch (1) with an adequate diameter, push inside the Unscrew screws (2) and remove fork pin (1) from both gear-
elastic peg till it abuts. box sides.
Figure 14
Figure 11
71673
72866
Place extraction peg 99342143 (2) and percussion extractor
99340205 (3). Extract the reverse gear supporting pin and Unscrew the two securing screws for clutch disengagement
remove the gear (1) with related shoulder washer and lever support and remove it from the gearbox.
cylindric roller bearing. Unscrew screws (1), leaving a safety one (→) to be removed
after having vertically placed the gearbox.

Figure 15 Figure 17
71676
72867
Extract rear half—case (3) with rear axle 99341003 (1) Unscrew screws (1) and remove cover (2) on motion inlet
equipped with the pair of brackets 99341017 (2). shaft.
Figure 18
Figure 16
98989
Remove cylindric roller bearing from motion inlet shaft (1) and
heat contact surface (2) of front half—case. With a plastic
hammer extract motion inlet shaft (1) completed with ball
bearing.
Figure 19
71677
Assemble on primary shaft (7) motion outlet flange (2) and

lock it with nut (1). Tie with a rope (6) secondary shaft (5) to
primary shaft (7) and with the help of a lifting device extract
shafts from front half—case together with internal drive shaft
(3).
NOTE Assist the internal drive shaft when going out of its
seat by operating in the point shown (→) with
suitable tools. 98990
Extract rolling race (2) of tapered roller bearing of secondary

shaft, from front half—case (3) with extractor 99348004 (1).
NOTE Keep the complete synchronizer (4) manually Remove the adjustment ring.
assembled in order to prevent check springs and
rollers from falling. Unscrew TORX mark screw (4), take off rib washer (5) and
recover underlying bushing.

Checks
Figure 20 GEARBOX CASE
Gearbox case and related covers must not show cracks.
Contact surfaces between covers and gearbox case must not
be damaged or distorted.
Bearing seats must not be damaged or excessively worn.
SHAFTS — GEARS
Shaft seats for bearings and gear toothings must not be

damaged or worn.
71682
HUBS — SLIDING SLEEVES — FORKS
With a suitable beater, extract from rear half—case the
external race (2) of roller bearing and spacer (1). From inside
the half—case, towards the outside, extract ball bearing (3). Grooves on hubs and related sliding sleeves must not be
Always from inside the half box, unscrew TORX mark screw, damaged. The sliding sleeve must freely slide on the hub.
take off rib washer and recover underlying bushing. Sliding sleeve positioning rollers must not be damaged or
worn. Engagement toothing of sliding sleeves must not be
damaged.
Figure 21 Forks must be healthy and must not show any sign of wear.
BEARINGS
Roller bearings or roller cages must be in perfect conditions

and not show traces of wear or overheatings.
By keeping bearings manually pressed and making them
simultaneously rotate along two directions, no roughness or
noise when sliding must be detected.
72868
Extract sealing gasket (2) from motion inlet shaft cover (1).
NOTE Upon assembling, the following must always be
replaced: rings, sealing gasket and springs for sliding
Figure 22 sleeves positioning rollers.
SYNCHRONIZERS — COUPLING BODIES
Check wear of synchronising rings and respective coupling

bodies: they must not show any sign of wear.
71684 NOTE Upon assembling, do not mutually exchange the

checked parts.
Extract sealing gasket (1) from primary shaft cover (2).

GEARBOX ASSEMBLY Bearings pre—load adjustment for secondary

shaft
The bearings pre—load adjustment for the secondary shaft
Butter with hermetic type ”B” the threaded part of all can be carried out with two procedures.
screws that must be screwed in the through—holes.
Clean the joining surfaces of case and covers and Figure 25

apply ”LOCTITE 510” putty, before assembling, on
one of the two components.
Upon assembling, make sure that the sealing gaskets

are already lubrified, or butter with oil or grease the
sealing lip of inlet and primary shafts gaskets.
Do not insert oil before 20 min and do not try the

gearbox before 1h and 30 min.
Assemble bearing cages into their respective seats 71687

and oil with TUTELA ZC 90. Assemble comparator 99395604 (1) on base 99370466 (2),
pre—load it by 5 mm and zero it on an abutment plane.
Figure 23 Figure 26
71685 98991
Butter, with hermetic type ”B”, the coupling seat surface of FRONT HALF—CASE
cover (2) with sealing gasket and with keyer 99374201 (1)
assemble the sealing gasket itself.
THICKNESS (S)
Figure 24
61957
Place calibrated ring 99396031 (2) into its seat, without

adjustment ring, of bevel roller bearing on front half—case;
place base 99370466 completed with comparator (1),
previously zeroed, as shown in Figure 25.
First method — Take note of the value read on the
comparator (Example: 2.43 mm).
Second method —Take note of the value read on the
comparator and add it to calibrated ring
72869 thickness.
[Example: 2.43 + 50.5 = 52.93 mm
Butter, with hermetic type ”B”, the coupling seat surface of (Dimension B)].
cover (3) with sealing gasket and with keyer 99370349 (2) and
handle 99370006 (1) assemble the sealing gasket itself.

Figure 27 First method — Take note of the value read on the

comparator (Example 1.84 mm). The
adjustment ring value is obtained by
summing the two measured values
(Example 2.43 + 1.84 = 4.27 mm)
comparator and subtract it from the
calibrated ring thickness [Example: 50.5 —
1.84 = 48.66 mm (Dimension A)].
The adjustment ring value is obtained with formula
S=B—A Example: 52.93 — 48.66 = 4.27 mm.
NOTE The difference between the two dimensions (A—B)

98992
determines the value of the thickness to be inserted
Assemble on rear half—case (1) cover (2), spacer (1, Figure 20) into front seat.
and with beater 99374092 equipped with handle 99370007, (Taking into account that the interference on outer
assemble external race (3) of roller bearing, settling it till it track causes a bearing axial clearance reduction of
abuts. about 0.05 mm, such results to be the pre—load too
See Figure 30 for adjusting beater 99374092. in ambient temperature conditions).
Fit inner control shaft bushing into its seat, put in rib washer
(5) and screw TORX mark screw (4) with prescribed torque.
NOTE The adjustment ring rounding is always carried out
in excess. Example; thickness S = 4.27: thickness S
Figure 28 = 4.3 is taken. Measuring of dimension ”A”, carried
out with secondary shaft in vertical position, that, in
addition to facilitating the measure itself, allows
having an axial load on the rear bearing.
After having computed the thickness value of the adjustment

ring, disassemble again secondary shaft and cover from rear
half—case.
Figure 29
71690
98993
REAR HALF—CASE
Place adjustment ring (1), whose thickness is equal to the
61956
previously—obtained one, into the secondary shaft bearing
Assemble and simultaneously rotate, till it abuts, the secondary seat on the front half—case (2).
shaft completed with bearings in rear half—case (3). Place
calibrated rings 99396032 (2) on half—case (3). Arrange, as Fit inner control shaft bushing into its seat, put in rib washer
shown in the figure, base 99370466 completed with (4) and screw TORX mark screw (3) with prescribed torque.
previously—zeroed comparator (1); the comparator rod must
abut on the external bearing ring. Carry out the measure on
two diametrically—opposite points and perform the arithmetic
mean.

Figure 30
NOTE Before assembling on front half—case the motion
inlet shaft, carry out bearing adjustment as described
in the related procedure on page 39.
Figure 33
32447
Centre external race (1) of bevel roller bearing of front cover

secondary shaft on extensible beater 99374092 (2) adjusted
with socket head screw (3). Lock beater with socket head
screw (4).
Figure 31
72871
Apply LOCTITE 510 sealant on contact surfaces between

front half—case and motion inlet shaft cover.
98994
Slightly heat seat (4) of secondary shaft bearing race on front

half—case and assemble external race (3) by settling it till it
abuts with beater 99374092 (2), equipped with handle
99370007 (1).
Figure 32
Figure 34
72870
Slightly heat the ball bearing seat, assemble motion inlet shaft 72867
(1) completed with bearing (4), adjustment ring (3) and elastic
ring (2). Settle the bearing till it abuts. Assemble motion inlet shaft cover (2), screw screws (1) and
tighten them at the required torque.

Print 603.93.391/A
Figure 35 Figure 37
71859
Assemble on primary shaft (7) motion outlet flange (2) and 104957
lock it with nut (1). Put together on a bench and with the help Disassemble previously—assembled flange and nut and as-
of a lifting device, primary shaft (7), secondary shaft (5) and semble rear half—case (1). Screw union screw between rear
mutually tie them with a rope (6). half—case and front half—case and tighten them at the required
torque.
Apply sealant LOCTITE 510 on contact surface (→) between
NOTE Keep complete synchronizer (4) manually the half box and the pins for the fork.
assembled in order to prevent check springs and
rollers from falling.
Place internal drive shaft (3) and manually keep it in position.
Figure 36 Figure 38
79432
71860
Insert cylinder roller bearing into motion inlet shaft and Assemble fork pins (1) on both gearbox sides and screw
assemble on front half—case (1) the three shafts together. screws (2) by tightening them at the required torque.
Apply LOCTITE 510 sealant on contact surface (→) between
the two half—cases.

Revi — July 2005
Print 603.93.391
Figure 39 1
Figure 42
79434 71865
Apply sealer LOCTITE 510 on the surface (→) without Apply LOCTITE 510 sealant on contact surface (→) between
staining the push rod supporting area (4). rear half—case and covers.
Insert tip (4), spring (3), then mount cover (1) and fasten
screws (2) by tightening them to the specified torque.
Figure 40
Figure 43
71863
71671
Assemble shoulder rings, placing them into their own seat and
reverse gear (3) with cylindric roller bearing. Assemble reverse Assemble covers (2 and 4), screw screws (1 and 3) and tighten
gear supporting shaft (2) with a suitable beater, paying atten- them at the required torque.
tion that the arrow (1) punched on the shaft is facing the peg
insertion hole. Figure 44
Figure 41
71866
Slightly heat ball bearing (1) half—race and assemble it in its

71864
own seat on primary shaft. Assemble phonic wheel (2) for
Assemble elastic peg (1). controlling the odometer.

Figure 45 Figure 48
71867 79435
Apply LOCTITE 510 sealant on contact surface (→) between Apply LOCTITE 510 sealant on contact surface (→) between
cover and rear half—case. rear half—case and external control case.
Figure 46
Figure 49
71669
Assemble rear cover (1), screw screws (3) and tighten them
at the required torque. Assemble motion outlet flange (2).
Figure 47
71667
Assemble complete external control box (1) and screw

securing screws by tightening them at the required torque.
Assemble clutch disengagement lever and tighten the two
securing screws at the required torque.
NOTE Insert lubrication oil in the prescribed amount after

about 20 minutes from the last LOCTITE 510
78685
sealant application.
Assemble reaction bar 99370317 (1), motion outlet flange
locking nut (3), key 99355081 (2) and tighten the locking nut
at the required torque. Remove gearbox from rotating stand.

PRIMARY SHAFT DISASSEMBLY

Figure 50 Figure 53
33618 33621
Tighten primary shaft (3) in a clamp. Remove coupling body Remove 5th speed gear (1) and roller bearing below it.
(1), 6th speed synchronising ring (4) and sliding sleeve (2) for
5th and 6th speed gears, recovering check springs and rollers.
Figure 51 Figure 54
33619 33622
Remove elastic ring (1). Remove elastic ring (1).
Figure 55
Figure 52
33623
33620 Remove 4thspeed gear (7) together with roller bearing and
With extractor 99341003 (1) and brackets 99341009 (2), bush (3) and coupling body (6) with holds 99341025 (4),
remove fixed 5th and 6th speed hub (4) together with tie—rods 99341019 (2), bridge 99341003 (1) and clamp
synchronising ring (3) and 5th speed coupling body (5). 99341015 (8). Remove synchronising ring (5).

Figure 56 Figure 59
33624 33627
Remove 3rd and 4th gear sliding sleeve (1) recovering check Turn the shaft over and extract reverse gear (5) with roller
springs and rollers. bearing below it, shoulder ring (4) and rolling half—race (3)
with holds 99341025 (2), tie—rods 99341019 (7), bridge
99341003 (1) and clamp 99341015 (6).
Figure 57
Figure 60
33625
Extract 3rd
and 4th
speed fixed hub (2) and 3rd
speed
synchronising ring with holds 99341025 (5), tie—rods 33628
99341019 (7), bridge 99341003 (1) and clamp 99341015 (6).

Remove 3rd speed coupling body (4). Remove elastic ring (1).
Figure 61
Figure 58
33629
Extract 1st speed gear (3) together with roller bearing and
33626 fixed sleeve (2) for reverse gear with holds 99341023 (4),
Remove 3rd speed gear (1) and roller bearing below it. tie—rods 99341020 (6), bridge 99341003 (1) and clamp
99341015 (5).

Print 603.93.391
PRIMARY SHAFT ASSEMBLY

Figure 62 Figure 64
33630 33632
Remove coupling body (1), synchronising ring (2), elastic ring Assemble on primary shaft (1) 2nd speed gear (4), coupling
(4) and sliding sleeve (3) for 1st and 2nd speed gears recovering body (5) and synchronising ring (3).
rollers and springs. Heat fixed hub (6) for 1st and 2nd speed gears at a
temperature of 100 °C ÷ 130 °C and assemble it on primary
shaft (1) with the internal diameter chamfering facing the
opposite part of 2nd speed gear.
When keying the hub, pay attention that synchronising ring
tangential stops are inserted into respective hub seats.
Assemble elastic ring (2) with an apporpriate thickness so that
the fixed hub has no axial clearance (max allowed 0.03 mm).
Figure 63 Figure 65
33631 33633
Extract 2nd
speed (4) with roller bearing, coupling body, Assemble sliding sleeve (1) for 1st and 2nd speed gears, springs
synchronising ring and 1st and 2nd speed fixed sleeve (5) with and rollers in fixed hub seats. Assemble synchronising ring and
holds 99341023 (3), tie—rods 99341020 (2), bridge 99341003 coupling body for 1st speed gear.
(1) and clamp 99341015 (6).

Figure 66 Figure 69
33634 33637
Assemble roller bearing and 1st speed gear (1). Assemble shoulder ring (2).
Slightly heat ball bearing rolling half—race (3) and assemble it
on primary shaft (1).
Figure 67 Figure 70
33635 33638
Heat at a temperature of 100 °C ÷ 130 °C fixed hub (2) for Turn the shaft over in a clamp, assemble roller bearing and 3rd
reverse gear and assemble it on primary shaft (1); asemble speed gear (1).
elastic ring (3).
Figure 71
Figure 68
33639
Assemble coupling body (2) and synchronising ring (3). Heat

fixed hub (1) at a temperature of 100 °C ÷ 130 °C and
33636 assemble it on shaft (4) paying attention that synchronising ring
Assemble roller bearing and reverse gear (1). tangential stops are inserted into respective hub seats.

Figure 72 Figure 75
33640 33643
Assemble sliding sleeve (2) for 3rd and 4th speed gears, springs Heat the fixed hub (2) for 5th and 6th speed gears at a
and rollers into fixed hub seats. Assemble synchronising ring temperature of 100 °C ÷ 130 °C and install it on the primary
(3) and coupling body (1) for 4th speed gear. shaft with the chamfer heading towards the 5th speed gear.
When keying the hub pay attention that synchronising ring
Figure 73 Assemble elastic ring (1) with a suitable thickness so that the
fixed hub has no axial clearance (max allowed 0.03 mm).
33641
Assemble roller bearing and 4th speed gear (2). Heat bush (3)
at a temperature of 100 °C ÷ 130 °C, and assemble it on
primary shaft (4). Assemble elastic ring (1).
Figure 76
Figure 74
33644
33642
Assemble sliding sleeve (2) for 5th and 6th speed gears, springs
Assemble roller bearing, 5th speed gear (2), coupling body (1) and rollers. Assemble synchronising ring (3) and coupling body
and synchronising ring (3) for 5th speed gear. (1) for 6th speed gear.

MOTION INLET SHAFT DISASSEMBLY MOTION INLET SHAFT ASSEMBLY

Figure 77
Figure 80
71869
71872
Remove elastic ring (2) and adjustment ring (1).
Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.
Figure 78
Motion inlet shaft bearing adjustment
Figure 81
71870
Abut bearing (1) on a vice, as shown in the figure, and by

beating on shaft (2), extract it from the bearing itself.
Figure 79
62455
- Assemble bearing on motion inlet shaft.

- Measure dimension ”A”.
- Measure seeger ”B” thickness.
- Define spacer ring thickness to be inserted, by defect:
C = A— B.
71871
PARTS COMPOSING THE MOTION INLET SHAFT

1. Motion inlet shaft — 2. Elastic ring — 3. Adjustment ring — Motion inlet shaft bearing adjustment spacer ring
4. Ball bearing — 5. Cylindric roller bearing. thicknesses: mm 2.40 — 2.45 — 2.50 — 2.55 — 2.60 —
2.65 — 2.70 — 2.75 — 2.80.

INTERNAL DRIVE SHAFT DISASSEMBLY

Figure 82
Figure 84
71869 71873
Assemble adjustment ring (1) whose thickness is equal to the Mark fork (3) assembling position. Unscrew screw (4) and
previously—obtained one and assemble elastic ring (2). withdraw all forks (3) together with fork positioning rods (2)
and hub (1).
SECONDARY SHAFT DISASSEMBLY
Figure 83
33651
Remove elastic ring (1) from secondary shaft (3), extract bevel INTERNAL DRIVE SHAFY ASSEMBLY
roller bearings (2 and 4) with a suitable punch (destructive
operation). Figure 85
SECONDARY SHAFT ASSEMBLY
Slightly heat bevel roller bearings (2 and 4, Figure 83)

and assemble them on secondary shaft (3,
Figure 83). Assemble elastic ring (1, Figure 83).
71874
Place on a bench forks (4) and hub (2) according to the

position marked upon disassembling. Place the two rods (3)
inside fork holes and insert drive shaft (1). Tighten hub screw
(2) at the required torque.

EXTERNAL CONTROL SHAFT 2
Figure 89
DISASSEMBLY
Figure 86
33655 33658
Tighten the shaft going out of the box in a clamp, remove plug Unscrew screw (1) and remove spacer, upper cup (3) and
(1) and disassemble cover (2). spring (2). Remove lower cup.
Figure 87 Figure 90
78166 78167
Remove control box pin (2) and spring (1). Remove the snap ring (4) and use a punch tool (5) having the
Do not mix removed elements with those of the anti—release right diameter to push the extraction washer (1) and remove
push rod. flexible plugs (2) and (3).
Figure 91
Figure 88
33660
33657
Extract, from the control shaft (2), control selector (1) and
Unscrew screws (1) and disassemble cover (2). box (3).

Print 603.93.391
Figure 92 Figure 95
71880
NOTE Upon assembling, the drive shaft must be assembled

with the reference arrow (1) facing upwards.
33661
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater. Figure 96
EXTERNAL CONTROL BOX ASSEMBLY
Figure 93
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
33661 Figure 97
Assemble, in control box (3), sealing gasket (1) and bushes (2)
with a suitable beater.
Figure 94
78169
NOTE During installation, plug cuts shall be opposed by

180° (see detail A).
The bigger plug cut shall face the control selector (1)
33660 milled area (see detail B).
Tighten control shaft (2) in a clamp and assemble thereon box
(3) and control selector (1).

33663 78170
Assemble lower cup (1). Install the pin (2), the spring (1) and apply sealer ”LOCTITE
518” (→).
33658
33655
Install the spring (2), the upper cap (3), the spacer and the Install the cover (2) and tighten the screws to 19 Nm (1.9
screw (1) and apply threading sealer LOCTITE 270 on the kgm).
screw itself. Apply sealer ”LOCTITE 675” and refit the plug (1).
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 100
33657
Clean joining surfaces of control box and cover (2) and apply
”LOCTITE 510” adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).

Idle—R.M. switch adjustment
NOTE The below—described sequence must be compulsorily complied with.
Figure 103
gearbox with engaged idle gearbox! gearbox with engaged

reverse gear gears
62456
SWITCH ENGAGEMENT POSITIONS
For switch adjustment, it is necessary to carry out the following operations:

- apply silicone sealant on the threading;
- set gearbox in engaged reverse gear position;
- screw the switch till the reverse motion lamp turns on;
- screw again the switch by 45—60° corresponding to a stroke of 0.19—0.25 mm;
- tighten securing lock nut with a 24 wrench at a torque of 35 Nm.


Print 603.43.671/A
5302 Gearbox
2865S.6
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 47
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Rear cover sealing gasket replacement . . . . . . . 62
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
- Bearings pre—loading adjustment for secondary

shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
MOTION ENTRY SHAFT DISASSEMBLY . . . . . 73
MOTION ENTRY SHAFT ASSEMBLY . . . . . . . . 74
INTERNAL CONTROL SHAFT

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 75
INTERNAL CONTROL SHAFT ASSEMBLY . . . . 75
EXTERNAL CONTROL BOX DISASSEMBLY . . 75
EXTERNAL CONTROL BOX ASSEMBLY . . . . . 76


Print 603.43.671/A
DESCRIPTION
The IVECO 2865S.6 gearbox is of the mechanical type with The gears are keyed or obtained on four shafts: motion entry,
1st, 2nd gear engagement through a double—cone primary, secondary and reverse motion shafts.
synchronising ring and 3rd, 4th, 5th and 6th gear engagement The gear obtained on the motion entry shaft and those keyed
with free—ring synchronising rings. The reverse motion on primary and reverse motion shafts idly rotate on cylindrical
engagement is with a quick—connection sliding sleeve. roller cages.
The gearbox case is made of light alloy and is composed of a Motion entry shaft and primary shaft are supported by ball
front half—case and a rear half—case. bearings in the gearbox case.
Three openings are obtained in the rear half—case for the The secondary shaft is front and rear supported by
possible application of a power takeoff. tapered—roller bearings that are axially adjustable through an
Motion transmission is realised through a series of gears, adjustment ring.
always meshed and with helical teeth. The gears engagement and selection control is mechanical.
Figure 1
79436
IVECO 2865S.6 GEARBOX ASSEMBLY

Figure 2
Sec. A—A
78719
LONGITUDINAL SECTION OF 2865S.6 GEARSHIFT AND SECTION ON THE REVERSE GEAR SHAFT


GEARBOX 2865S.6
Type Mechanical
Gears 6 forward gears and reverse gear
Gears engagement:
1st — 2nd Double—cone synchronizer

3rd — 4th — 5th — 6th Free—ring synchronizer
Sliding sleeve holding through rollers and
Gears anti—disengagement
springs.
Gear ratio
First 1 : 9.007
Second 1 : 5.015
Third 1 : 3.206
Fourth 1 : 2.066
Fifth 1 : 1.370
Sixth 1 : 1.000
Amount 8.1 Kg. (9 lt)
Fixed hubs assembly temperature 100oC to 130oC
Secondary shaft bearings With tapered rollers
Secondary shaft bearings pre—loading

By means of rings
adjustment
4.0—4.1—4.2—4.3—4.4—4.5—4.6
Secondary shaft pre—loading adjustment rings
4.7—4.8—4.9—5.0—5.1—5.2—5.3
thickness mm
Supplied in a kit
Secondary shaft bearingsassembly
85oC
temperature

Figure 3
98995

TIGHTENING TORQUES
TORQUE
PART
Nm (kgm)
1 Flanged hexagonal head screw for securing front cover 32 ± 3 (3.3 ± 0.3)
2 Ring nut for securing entry shaft bearing 545 ± 55 (55.5 ± 5.6)
3 Flanged hexagonal head screw for joining clutch and case 45.5 ± 4.5 (4.6 ± 0.5)
4 Release—proof tip cover fastening screw 22.5 ± 2.5 (2.3 ± 0.2)
5 Screw for securing fork control rod hub 39 ± 2 (4.0 ± 0.2)
6 Threaded plug with external operating hexagon for oil level 27.5 ± 2.5 (2.8 ± 0.3)
7 Flanged hexagonal head screw for securing covers on side power takeoffs connection windows 38 ± 4 (3.9 ± 0.4)
8 Screw with plane washer for securing transverse axle cover on external control 19 ± 2 (1.9 ± 0.2)
9 Transverse axle screw 30 ± 3 (3.0 ± 0.3)
10 Threaded plug with external operating hexagon for oil discharge 27.5 ± 2.5 (2.8 ± 0.3)
11 Flanged hexagonal head screw for securing rear cover on secondary shaft 58 ± 6 (5.9 ± 0.6)
12 Flanged hexagonal head screw for securing rear cover on primary shaft 43 ± 4 (4.4 ± 0.4)
13 Locking nut for outlet primary shaft flange 467 ± 23 (47.6 ± 2.3)
14 Flanged hexagonal head screw for securing upper external controls support cover 33.5 ± 3.5 (3.4 ± 0.4)
15 Flanged hexagonal head screw for securing spring check flange on external control 19 ± 2 (1.9 ± 0.2)

• Apply liquid gasket LOCTITE 518 sealant.

TOOLS


TOOLS
99341015 Clamp
99341023 Holds
99341025 Holds

TOOLS
99348004 Universal extractors for interiors 5 to 70 mm
99355081 Bush for disassembling and re—assembling motion outlet flange nut
(use with 99370317)
99355174 Wrench for disassembling and re—assembling ring nut, gearbox top
gear shaft

TOOLS
99370466 Comparator basis

re—connection
99370007)

TOOLS
99395604 Comparator (0 — 10 mm)
99396032 Calibrated rings for secondary shaft bearings adjustment (use with
99370466)

Print 603.43.671/A
GEARBOX 2865S.5 REMOVAL/REFITTING Figure 4
Before carrying out removal/refitting operations,

! disconnect battery cables and place the vehicle
under safety conditions.
Removal

reaction tie—rod (12); loosen securing screw (6) and
detach from gearbox the gears control lever completed
with tie—rod (3) and reaction tie—rod (12);
- disconnect reverse gear switch electric connection (7);
vehicle part.
section;
- disconnect electric connection (10) of odometer sensor
(8);
support bracket;
under the gearbox;
Refitting


the thrust bearing. 71004


Print 603.43.671/A
GEARBOX DISASSEMBLY
Figure 5 Figure 8
33552 33555
Place gearbox (1) on rotating stand 99322205 (2) equipped Apply reaction lever 99370317 (1) on motion outlet flange (2)
with brackets 99322225 (3) and discharge the lubricating oil. and engage a gear.
Figure 6 Figure 9
33553 33556
Disassemble external control box (1). Loosen ring nut on motion entry shaft with wrench 99355174
(1).
Figure 7 Figure 10
33554 33557
Unscrew the two securing screws for clutch disengagement Unscrew the primary shaft screw with wrench 99355081 (1).
lever support and remove lever from gearbox.
Disassemble cover (1) on motion entry shaft.

Figure 11 Figure 13
33558 35560
Unscrew screws (1) and remove cover (2).

Disengage engaged gear, remove flange (3), uscrew screws (1)
and remove cover (2).
Figure 14
NOTE The disassembly of rear gearbox cover for replacing

the sealing gasket can be carried out also with
gearbox assembled on the vehicle, by detaching the
transmission shaft and proceeding as shown for the
gearbox assembled on rotating stand.
35561
Beat with a punch (1) and push the elastic peg till it abuts.
Figure 15
Figure 12
35562
35559
Remove phonic wheel (1) for odometer control. 99340205 (1). Withdraw the reverse gear supporting pin and
remove the same gear with related shoulder washers and
cylindrical roller bearing.

Figure 16 Figure 19
79438
Release the screws (4) and remove the cover (3).

Remove the spring (2) and extract the push rod (1). 33566
Assemble motion outlet flange (6) on primary shaft (2) and

Figure 17 lock it with nut (1). Tie secondary shaft (5) and internal control
shaft (3) with a rope (4) to primary shaft (2) and with the help
of a lifting device remove the shafts from the rear cover.
Figure 20
33564
Unscrew screws (1 and 2).
Figure 18
98996
Remove from motion entry shaft (1) the cylindrical roller

bearing and heat the cover contact surface (2). With a plastic
hammer, extract motion entry shaft (1) completed with ball
33565 bearing, elastic ring and ring nut.
Extract box (2) with bridge 99341003 (1) equipped with the Unscrew TORX mark screw (3), take off rib washer (2) and
pair of brackets 99341017 (3). recover underlying bushing.

530514 Rear cover sealing gasket replace-

ment
Figure 21
Figure 24
35568 35571
Extract rolling race (1) of the secondary shaft tapered roller Extract from primary shaft cover (1) the sealing gasket (2) with
bearing, from front cover (2) with extractor 99348004 (3). a suitable beater.
Remove the adjustment ring.
Figure 22
35569
Remove cover (1) and underlying spacer.

Extract, from case (3), the external race of secondary shaft
tapered roller bearing, and the ball bearing (2) with a suitable
beater.
From inside the half box, unscrew TORX mark screw, take off
rib washer and recover underlying bushing.
Figure 25
Figure 23
35572
35570
Extract from motion entry shaft cover (2) the sealing gasket Butter with sealing compound type “B”, the coupling seat
(1) with a suitable beater. surface of cover (1), and with keyer 99374201 (2) assemble
the sealing gasket.
Checks
Print 603.43.671/A GEARBOX ASSEMBLY
GEARBOX CASE
Butter with sealing compound type “B” the threaded
part of all screws that have to be screwed into the
through—holes.
be damaged or distorted.
Bearing seats must not be damaged or excessively worn. Clean joining surface of case and covers and apply
“LOCTITE 510” adhesive, before assembling, on one
of the two components.
Do not insert oil before 20 min. and do not try the
Assemble bearing cages into their respective seats
SHAFTS — GEARS
and oil with TUTELA ZC 90.
Shaft seats for bearings and gear toothings must not be In order to guarantee oil seal upon assembly, make
damaged or worn. sure that sealing gaskets are already lubricated, or:
butter with oil or grease the gasket sealing lip for entry
and primary shafts.

Figure 26
Grooves on hubs and related sliding sleeves must not be
damaged. The sliding sleeve must freely slide on the hub.
Sliding sleeve positioning rollers must not be damaged or
worn. Sliding sleeves engagement toothings must not be
damaged.
Forks must be intact and not show any sign of wear.
BEARINGS
33573

Butter, with sealing compound type “B”, the coupling seat
and not show traces of wear or overheating.
surface of cover (2) and with keyer 99370349 (1) and handle
Keeping the bearings pressed with a hand and making them
99370006 (3) assemble the sealing gasket.
simultaneously rotate along the two directions, no
roughnesses or noises when sliding must be detected.
Figure 27

replaced: rings, sealing gaskets and springs for sliding
sleeves positioning rollers.
SYNCHRONIZERS — COUPLING BODIES
Check wear of synchronizing rings and respective coupling 98997
bodies: they must not have any sign of wear.

Assemble cover (1), spacer and with a suitable beater, the
external race (5) of tapered roller bearing. Slightly heat the
case contact surface with ball bearing and assemble the
bearing itself.
NOTE Upon assembling, do not mutually exchange the Fit inner control shaft bushing into its seat, put in rib washer
controlled parts. (3) and screw TORX mark screw (4) with prescribed torque.

Bearings pre—loading adjustment for secondary

shaft
Figure 30
The pre—loading adjustment for secondary shaft bearings can
be carried out with two procedures.
Figure 28
33575 33601
Assemble comparator (1) on base 99370466 (2).

Pre—load it with 5 mm and zero it on a striker plane.
Figure 29
BACK COVER
61956
Assemble and simultaneously rotate secondary shaft

completed with bearings into rear case (3), so that it settles.
Place calibrated rings 99396032 (2) on case (3). Arrange, as
shown in Figure 30, base 99370466 completed with
previosuly zeroed comparator (1): the comparator rod must
abut on external bearing ring. Carry out the measure on two
33576
diametrally—opposed points and carry out the arithmetic
mean.
CLUTCH SUMP (FRONT CASE) First method — Take note of the value read on comparator
(Example: 1.84 mm). The adjustment ring
value is obtained by adding the two
THICKNESS (S)
measured values
(Example: 2.43 + 1.84 = 4.27 mm)
Second method —Take note of the value read on comparator

and subtract it from calibrated ring
thickness
61957 [Example: 50.5 — 1.84 = 48.66 mm
(dimension A)].
Place calibrated ring 99396032 (2) in the tapered roller The adjustment ring value is obtained through formula
bearing seat, without adjustment ring, on front cover; place S=B—A Example: 52.93 — 48.66 = 4.27 mm.
base 99370466 completed with previously zeroed
comparator (1), as shown in Figure 28.
The adjustment ring rounding is carried out always in
! excess. Example: thickness
First method — Take note of the value read on comparator
S = 4.27: thickness S = 4.3 is taken.
(Example: 2.43 mm).
The measure for dimension “A” is carried out with
secondary shaft in vertical position that, in addition to
Second method —Take note of the value read on comparator
making the measure itself easier, allows having an axial
and add it to calibrated ring thickness
load on rear bearing.
[Example: 2.43 + 50.5 = 52.93 mm
(dimension B)].
After having computed the adjustment ring thickness value,
disassemble again secondary shaft from rear case.
Figure 31 Figure 34
33604 33606
Place, into the secondary shaft bearing seat on front cover (1),
the adjustment ring (2) whose thickness is equal to the Slightly heat the ball bearing seat, assemble motion entry shaft
previously—obtained one. (1) completed with ball bearing, rolling half—races and ring nut
(2). Settle bearing (3) till it abuts.
Figure 32
32447
Center the external race (1) of secondary shaft tapered roller

bearing of front cover on extendable beater 99374092 (2) Figure 35
adjusted with the setscrew wrench (3). Lock the beater with
the setscrew wrench (4).
Figure 33
98998
33607
Slightly heat seat (2) of secondary shaft bearing race and
assemble external race (3) settling it till it abuts with beater
99374092 (1), equipped with handle 99370007 (6). Temporarily assemble on primary shaft the motion outlet
Fit inner control shaft bushing into its seat, put in rib washer flange and secure it with a check nut. Assemble together, on
(4) and screw TORX mark screw (5) with prescribed torque. a bench and with the help of a lifter, primary shaft (2),
secondary shaft (4) and engagement fork control shaft (3);
keep them mutually joined by means of a rope.

Figure 36 Figure 38
79439
Apply sealer LOCTITE 510 on the surface (→) without

33608
staining the push rod supporting area (1, Figure 39).
Insert cylindric roller bearing into motion entry shaft and
assemble the three shafts together on front cover (1).
Figure 39
Figure 37
33609 79438
Remove temporarily previously—assembled ring nut and nut Insert tip (1), spring (2), then mount cover (3) and fasten
and assemble gearbox case (1). Tighten screws joining front screws (4) by tightening them to the specified torque.
cover and case at the required torque.

Figure 40 Figure 43
33611 33614
Assemble shoulder rings, placing them into their own seat and Slightly heat ball bearing half—race and assemble it into its own
reverse gear (1) with the cylindrical roller bearing. Assemble seat on primary shaft. Assemble the odometer controlling
reverse gear supporting shaft with a suitable beater. phonic wheel (1).
Figure 41 Figure 44
33612 33615
Assemble elastic peg (1). Assemble rear cover (1), completed with sealing gasket, by
tightening the securing screws at the required torque.
Assemble motion outlet flange (2).
Figure 42 Figure 45
33613 33616
Assemble cover (1) by tightening the screws at the required Assemble reaction bar 99370317 (1), motion outlet flange
torque. locking nut (3), wrench 99355081 (2) and tighten the locking
nut at the required torque.


Figure 46 Figure 49
33617
33618
Lock motion outlet flange rotation with bar 99370317, engage Tighten primary shaft (3) in a clamp. Remove coupling body
a gear and with wrench 99355174 (1) tighten the ring nut on (1), 6th speed synchronising ring (4) and sliding sleeve (2) for
motion inlet shaft at the required torque. 5th and 6th speed gears, recovering check springs and rollers.
Figure 47
Figure 50
33554
Assemble cover (1), completed with sealing gasket, on motion

33619
inlet shaft and tighten securing screws at the required torque.
Assemble clutch disengagement lever and tighten securing Remove elastic ring (1).
screws at the required torque.
Figure 48 Figure 51
33553 33620
Assemble the complete external control box (1). With extractor 99341003 (1) and brackets 99341009 (2),
Insert lubrication oil in the required amount, after about 20 remove fixed 5th and 6th speed hub (4) together with
min from application of LOCTITE 510 sealant. synchronising ring (3) and 5th speed coupling body (5).
Remove gearbox from rotating stand.

Print 603.43.671/A
Figure 52 Figure 55
33621 33624
Remove 5th speed gear (1) and roller bearing below it. Remove 3rd and 4th gear sliding sleeve (1) recovering check
springs and rollers.
Figure 56
Figure 53
33625
33622
Extract 3rdand 4th
speed fixed hub (2) and 3rd
speed
Remove elastic ring (1). synchronising ring with holds 99341025 (5), tie—rods
99341019 (7), bridge 99341003 (1) and clamp 99341015 (6).
Remove 3rd speed coupling body (4).
Figure 54
Figure 57
33623
Remove 4th
speed gear (7) together with roller bearing and 33626
bush (3) and coupling body (6) with holds 99341025 (4), Remove 3rd speed gear (1) and roller bearing below it.
tie—rods 99341019 (2), bridge 99341003 (1) and clamp
99341015 (8). Remove synchronising ring (5).

Figure 58 Figure 61
33627
33630
Turn the shaft over and extract reverse gear (5) with roller
bearing below it, shoulder ring (4) and rolling half—race (3) Remove coupling body (1), synchronising ring (2), elastic ring
with holds 99341025 (2), tie—rods 99341019 (7), bridge (4) and sliding sleeve (3) for 1st and 2nd speed gears recovering
99341003 (1) and clamp 99341015 (6). rollers and springs.
Figure 59
33628
Remove elastic ring (1).
Figure 62
Figure 60
33631
Extract 2nd speed (4) with roller bearing, coupling body,

33629 synchronising ring and 1st and 2nd speed fixed sleeve (5) with
Extract 1st speed gear (3) together with roller bearing and holds 99341023 (3), tie—rods 99341020 (2), bridge 99341003
fixed sleeve (2) for reverse gear with holds 99341023 (4), (1) and clamp 99341015 (6).
tie—rods 99341020 (6), bridge 99341003 (1) and clamp
99341015 (5).

PRIMARY SHAFT ASSEMBLY

Figure 63 Figure 65
33632 33634
Assemble roller bearing and 1st speed gear (1).

Assemble on primary shaft (1) 2nd speed gear (4), coupling
body (5) and synchronising ring (3).
Heat fixed hub (6) for 1st and 2nd speed gears at a
temperature of 100 °C to 130 °C and assemble it on primary
shaft (1) with the internal diameter chamfering facing the Figure 66
opposite part of 2nd speed gear.
When keying the hub, pay attention that synchronising ring
Assemble elastic ring (2) with an apporpriate thickness so that
the fixed hub has no axial clearance (max allowed 0.03 mm).
33635
Heat at a temperature of 100 °C to 130 °C fixed hub (2) for

reverse gear and assemble it on primary shaft (1); asemble
elastic ring (3).
Figure 64 Figure 67
33633 33636
Assemble sliding sleeve (1) for 1st and 2nd speed gears, springs Assemble roller bearing and reverse gear (1).
and rollers in fixed hub seats. Assemble synchronising ring and
coupling body for 1st speed gear.

zz
Figure 68 Figure 71
33637 33640
Assemble shoulder ring (2). Assemble sliding sleeve (2) for 3rd and 4th speed gears, springs
Slightly heat ball bearing rolling half—race (3) and assemble it and rollers into fixed hub seats. Assemble synchronising ring
on primary shaft (1). (3) and coupling body (1) for 4th speed gear.
Figure 69 Figure 72
33638 33641
Turn the shaft over in a clamp, assemble roller bearing and 3rd Assemble roller bearing and 4th speed gear (2). Heat bush (3)
speed gear (1). at a temperature of 100 °C to 130 °C, and assemble it on
primary shaft (4). Assemble elastic ring (1).
Figure 70 Figure 73
33639
Assemble coupling body (2) and synchronising ring (3). Heat 33642
fixed hub (1) at a temperature of 100 °C to 130 °C and Assemble roller bearing, 5th speed gear (2), coupling body (1)
assemble it on shaft (4) paying attention that synchronising ring and synchronising ring (3) for 5th speed gear.

MOTION ENTRY SHAFT DISASSEMBLY

Figure 74 Figure 76
33643 33645
Heat fixed hub (2) for 5th and 6th speed gears, at a Unscrew ring nut (1).
temperature of 100 °C to 130 °C, and assemble it on
secondary shaft (3) with its chamfering facing 5th speed gear.
When keying the hub pay attention that synchronising ring
Assemble elastic ring (1) with a suitable thickness so that the Figure 77
fixed hub has no axial clearance (max allowed 0.03 mm).
33646
Abut bearing (2), motion entry shaft (1) on a clamp and by

beating the shaft extract ball roller bearing (2) and a rolling
half—race of motion entry shaft (1).
Figure 75
Figure 78
33644
Assemble sliding sleeve (2) for 5th and 6th speed gears, springs 33647
and rollers. Assemble synchronising ring (3) and coupling body Extract the other rolling half—race (2) from motion entry shaft
(1) for 6th speed gear. (1) with a suitable punch.

Figure 79 Figure 81
33650
Assemble ball roller bearing (2); heat the other rolling

33648
half—bearing and assemble it on motion entry shaft (1).
Temporarily screw ring nut (3).
PARTS COMPOSING THE MOTION ENTRY SHAFT SECONDARY SHAFT DISASSEMBLY

1. Cylindrical roller bearing — 2. Rolling hald—race — 3. Ball
bearing — 4. Rolling half—race — 5. Ring nut — 6. Motion Figure 82
entry shaft
33651
Remove elastic ring (1) from secondary shaft (3), and extract
tapered roller bearings (2 and 4) with a suitable punch
(destructive operation).
MOTION ENTRY SHAFT ASSEMBLY
Figure 80 SECONDARY SHAFT ASSEMBLY
Figure 83
33649 33652
Slightly heat rolling half—race (1) and assemble it on motion Slightly heat tapered roller bearings (1 and 3) and assemble
entry shaft (2). them on secondary shaft (2). Assemble elastic ring (4).

Print 603.43.671/A

DISASSEMBLY
Figure 84 EXTERNAL CONTROL SHAFT
DISASSEMBLY
Figure 86
33653
Mark fork (3) assembly position. Unscrew screw (4) and 33655
withdraw all forks (3) together with fork positioning rods (2)
and hub (1). Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Figure 87
78166
INTERNAL CONTROL SHAFT ASSEMBLY Remove control box pin (2) and spring (1).
Do not mix removed elements with those of the anti—release
push rod.
Figure 85
Figure 88
33654
Place on a bench forks (4) and hub (2) according to the

position marked upon disassembling. Place the two rods (3)
inside fork holes and insert drive shaft (1). Tighten hub screw
33657
(2) at the required torque.
Unscrew screws (1) and disassemble cover (2).
Figure 89 Figure 92
33658 33661
Unscrew screw (1) and remove spacer, upper cup (3) and Extract, from the control box (3), sealing gasket (1) and bushes
spring (2). Remove lower cup. (2) with a suitable beater.
Figure 90 Figure 93
78167 33661
Remove the snap ring (4) and use a punch tool (5) having the Assemble, in control box (3), sealing gasket (1) and bushes (2)
right diameter to push the extraction washer (1) and remove with a suitable beater.
flexible plugs (2) and (3).
Figure 91 Figure 94
33660 33660
Extract, from the control shaft (2), control selector (1) and Tighten control shaft (2) in a clamp and assemble thereon box
box (3). (3) and control selector (1).

Figure 95 Figure 98
71880
NOTE Upon assembling, the drive shaft must be assembled

with the reference arrow (1) facing upwards. 33663
Assemble lower cup (1).
Figure 96
Figure 99
78168
Insert the extraction washer (1) and use a punch tool having 33658
the right diameter to install the first plug (2). Install the second Install the spring (2), the upper cap (3), the spacer and the
plug (3) and the snap ring (4). screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Figure 97 Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 100
78169
33657
180° (see detail A). Clean joining surfaces of control box and cover (2) and apply
The bigger plug cut shall face the control selector (1) ”LOCTITE 510” adhesive on one of the two components.
milled area (see detail B). Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).

33655
78170
Install the cover (2) and tighten the screws to 19 Nm (1.9
kgm). Apply sealer ”LOCTITE 675” and refit the plug (1).
Install the pin (2), the spring (1) and apply sealer ”LOCTITE
518” (→).
Figure 103

reverse gear gears
62456
SWITCH ENGAGEMENT POSITIONS


Print 603.93.391
5302 Gearbox
2870S.9
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 81

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
- Bearings pre—load adjustment for secondary shaft 98
- Idle—Reverse Gear switch adjustment . . . . . . . 104

MOTION INLET SHAFT DISASSEMBLY . . . . . . 107

MOTION INLET SHAFT ASSEMBLY . . . . . . . . . 108
- Motion inlet shaft bearing adjustment . . . . . . . 108

INTERNAL DRIVE SHAFT DISASSEMBLY . . . . . 108
INTERNAL DRIVE SHAFT ASSEMBLY . . . . . . . . 109
EXTERNAL DRIVE CASE DISASSEMBLY . . . . . . 109

EXTERNAL DRIVE CASE ASSEMBLY . . . . . . . . . 110
EPICYCLIC REDUCTION GEAR ASSEMBLY . . . 113
- Operating diagrams about pneumatic epicyclic

reduction gear drive circuit . . . . . . . . . . . . . . . 113
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118


Print 603.93.391
DESCRIPTION
The 2870S.9 gearshift is of the mechanic type, with nine speeds and engagement of the 1st, 4th, 5th, 8th and 9th speeds by means
of free—ring synchronizing rings, whereas the 2nd, 3rd, 6th and 7th speeds are engaged by means of a double—cone synchronizing gear.
The reverse gear engagement is with quick—engagement sliding sleeve.
It is composed of a front section, comprising five ratios and reverse gear, and of a rear section comprising two ratios obtained through
epicyclic reduction gear.
The gear switch is carried out mechanically through double—”H” control; the epicyclic reduction gear engagement is carried out
mechanically with pneumatic switching.
The gearbox is equipped with an oil pump for its lubrication.
Figure 1
SEC A—A
78684
2870S.9 GEARBOX LONGITUDINAL SECTION AND REVERSE GEAR SHAFT SECTION

GEARBOX 2870S.9
Type Mechanical
Gears engagement
Mechanical
control
Gears engagement:
1st Free—ring synchronizer
2nd ⇒ 3rd Double—cone synchronizer
4th ⇒ 5th Free—ring synchronizer
6th ⇒ 7th Double—cone synchronizer
8thh ⇒ 9thh Free—ring synchronizer
Reverse
eve se gear
gea Quick—connection
Quick connection type
Gears anti— Sliding sleeve holding through rollers and springs.
disengagement
Gear ratio
First 1 : 13.200
Second 1 : 9.036
Third 1 : 6.473
Fourth 1 : 4.691
Fifth 1 : 3.548
Sixth 1 : 2.547
Seventh 1 : 1.824
Eighth 1 : 1.322
Ninth 1 : 1.000


Amount 4.5 Kg. (5lt)
Fixed hubs assem-
100oC ÷ 130oC
bly temperature
Secondary shaft
With tapered rollers
bearings
Secondary shaft
bearings
Through rings
pre—loading
adjustment
Secondary shaft
2.5 — 2.7 — 2.8 — 2.9 — 3.1 — 3.2
pre—loading
3.3 — 3.4 — 3.5 — 3.6 — 3.7 — 3.8
adjustment rings
Supplied in a kit
thickness
Secondary shaft
bearings assembly 85oC
temperature
Motion entry shaft
2.40 — 2.45 — 2.50 — 2.55 — 2.60 —
bearings adjusting
2.65 — 2.70 — 2.75 — 2.80
rings thicknesses

Print 603.93.391/A
Figure 2
Sec. A—A
104958

Revi — July 2005
Print 603.93.391
TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
1 Flanged hexagonal head screw for securing spring check flange on external control 19 ± 2 (1.9 ± 0.2)
2 Flanged hexagonal head screw for securing upper external control support cover 33.5 ± 3.5 (3.4 ± 0.4)
3 Screw for securing reduction gear control valve 23.5 ± 2.5 (2.5 ± 0.3)
4 Ring nut for securing sun gear on primary shaft 372.5 ± 19.5 (38 ± 2)
Flanged hexagonal head screw for securing pneumatic reduction gear control cylinder to rear
6 35.5 ± 3.5 (3.6 ± 0.4)
half—case
7 Flanged hexagonal head screw for securing rear cover on primary shaft 44.5 ± 4.5 (4.4 ± 0.5)
8 Output flange locking ring nut on planetary gear—holder shaft 559.5 ± 29.5 (57 ± 3)
9 Flanged hexagonal head screw for securing read cover on secondary shaft 58 ± 6 (5.9 ± 0.6)
10 Oil filter on half—case 320 ± 30 (32.6 ± 3.1)
11 Threaded plug with external manoeuvre hexagon for oil discharge 27.5 ± 2.5 (2.8 ± 0.3)
12 Hexagonal head screw for securing oil pump body to case 33.5 ± 3.5 (3.4 ± 0.4)
13 Flanged hexagonal head screw for securing transverse axle cover on drive* 19 ± 2 (1.9 ± 0.2)
14 Transverse axle screw* 30 ± 3 (3.1 ± 0.3)
15 Flanged hexagonal head screw for securing covers on side power takeoff connection windows 38 ± 4 (3.9 ± 0.4)
17 Idle positioner 78 ± 8 (8.0 ± 0.8)
18 Flanged hexagonal head screw for joining clutch cup and case 45.5 ± 4.5 (4.6 ± 0.6)
19 Flanged hexagonal head screw for securing front cover st
1 Step 20 ± 1 (2 ± 0.1)
nd
2 Step 25º
— Oval—headed screw for securing reduction gear reaction plate 21 ± 2 (2.1 ± 0.2)
— Threaded plug with external manoeuvre hexagon for oil level 27.5 ± 2.5 (2.8 ± 0.3)
Flanged hexagonal head screw for securing upper internal controls cover (only for right—hand
— 45.5 ± 4.5 (4.6 ± 0.5)
drive)

Y Apply thread—braking LOCTITE 242 sealant
F Apply liquid gasket LOCTITE 518 sealant.
Apply liquid gasket LOCTITE 5910 sealant

TOOLS
99305121 Hot—air equipment
99322205 Revolving stand for overhauling units

99322225 Unit bearing support (to be applied to stand 99322205)
99340205 Percussion puller
99341003 Single acting puller

TOOLS
99341015 Clamp
99341019 Pair of tie rods for grips
99341025 Grips

TOOLS
99342143 Peg for removing reverse gear shaft (to use with 99340205)
99345058 Thrust block for pullers
99348004 Universal extractor for interiors 5 to 70 mm
99355081 Bush for disassembling and assembling motion outlet flange nut
(use with 99370317)
99355131 Wrench (55 mm) for gearbox sun gear retaining nut

TOOLS
99370130 Tool for holding the sun gear during nut removal and refitting
99370317 Reaction lever with extension for retaining flanges
99370349 Tool for fitting gasket on gearbox front cover (to use with
99370006)
99370466 Gauge base for transmission shaft bearing adjustment (to use with
99395604)
99370629 Support for holding gearbox during removal and refitting from/on
vehicle

TOOLS
99374092 Beater for outer bearing race assembling (69—91) (use with
99370007)
99374229 Tool for refitting gasket on gearbox rear cover
99381125 Pliers for removing gearbox split rings
99395604 Comparator (0—10 mm)
99396031 Gauged rings for adjusting transmission shaft bearings (to use with
99370466)

Print 603.93.391
GEARBOX 2870S.9 REMOVAL/REFITTING

Figure 3
Before carrying out disengagement/re—engagement
! operations, disconnect battery cables and place the
vehicle under safety conditions.
Removal

- loosen securing screw (6) and detach from gearbox the
gears control lever completed with tie—rod (3) and
- disconnect reverse gear switch electric connection (16)
and range—change switch electric connection (8);
vehicle part.
section;
- disconnect air piping (13) from exhaust piping (11);
- detach terminal exhaust piping, operating on securing
clip (14) bolt and on support band (12) bolt (10);
- disconnect electric connection (15) of odometer sensor;
support bracket;
under the gearbox;
Refitting

the thrust bearing.
71005


Print 603.93.391
GEARBOX DISASSEMBLY
Figure 4 Figure 7
79429 71886
Place gearbox (2) on rotating stand 99322205 (1) equipped Unscrew securing screws and with the help of a lifting device,
with brackets 99322225 (3) and discharge lubricating oil. remove epicyclic reduction gear assembly (1).
Figure 5 Figure 8
79440 79442
Disconnect pneumatic pipings (1) of epicyclic reduction gear. Apply tool 99370130 (2) and, through wrench 99355131 (1),
Unscrew the two screws securing clutch disengagement lever unscrew sun gear check nut.
support and remove lever from gearbox.
Figure 6 Figure 9
79441 71888
Apply reaction lever 99370317 (1) and with key 99355081 (2) Remove the sun gear (1).
loosen nut securing motion outlet flange (3).

Figure 10 Figure 13
71889 79444
Remove oil distributor (1) completed with sealing rings. Unscrew screws (4), disassemble cover (5), take off spring (3)
and take out tip (2). Move gear selector hub (1) inwards.
Figure 11 Figure 14
71890 71893
Unscrew screws (1) and remove oil pump (2). Remove reverse gear cover; with a punch (1) of an adequate
diameter, push the elastic peg inside till it abuts.
Figure 15
Figure 12
71894

79443
99340205 (3). Extract reverse gear support pin (1) and
remove gear with related shoulder washers and cylindric roller
Unscrew screws (1) and remove complete case (2) of bearing.
external gear drive.

Figure 16 Figure 18
71895
Unscrew screws (1), leaving a safety one (→) to be removed 71897

after having placed the gearbox vertically.
Screw nut (1) on primary shaft (2), lift by about 10 ÷ 20 mm
primary shaft (2) together with internal drive shaft (3) and
withdraw secondary shaft (4) by laterally displacing it.
NOTE Assist internal drive shaft extraction from its seat, by

operating in the shown point (→) with suitable
tools.
Figure 17 Figure 19
71896
71898
Through extractor 99341004 (1), brackets 99341017 (2) and Lift and remove primary shaft (1) together with internal drive
reaction block 99345058 (3), extract intermediate gearbox shaft (2).
case (4). Remove synchronizing rings (3).

Figure 20 Figure 23
71678 99000
Unscrew screws (1) and remove cover (2) on motion inlet From intermediate case, extract roller bearing rolling race (1),
shaft. ball bearing (2), reduction gear engagement safety pin (4) and
Figure 21 oil piping (3).
Unscrew TORX mark screw (3), take off rib washer (4) and
98989
Remove cylindric roller bearing from motion inlet shaft (1) and
heat front half—case contact surface (2). With a plastic
hammer, extract motion inlet shaft (1) completed with ball
bearing.
Figure 22 Figure 24
98990
Extract rolling race (2) of secondary shaft bevel roller bearing

from front half—case (3) with extractor 99348004 (1).
Remove adjustment ring. 71683
Unscrew TORX mark screw (4), take off rib washer (5) and Extract sealing gasket (2) from motion inlet shaft cover (1).

Checks
Print 603.93.391
GEARBOX CASE BEARINGS

Gearbox case and related covers must not show cracks. Roller bearings or roller cages must be in perfect conditions
Contact surfaces between covers and gearbox case must not and not show traces of wear or overheatings.
be damaged or distorted. By keeping bearings manually pressed and making them
Bearing seats must not be damaged or excessively worn. simultaneously rotate along two directions, no roughness or
noise when sliding must be detected.
SHAFTS — GEARS

damaged or worn. NOTE Upon assembling, the following must always be
replaced: rings, sealing gasket and springs for sliding
Grooves on hubs and related sliding sleeves must not be

damaged. The sliding sleeve must freely slide on its hub. Sliding SYNCHRONIZERS — COUPLING BODIES
sleeve positioning rollers must not be damaged or worn.
Sliding sleeve engagement toothings must not be damaged. Check wear of synchronising rings and respective coupling
bodies: they must not show any sign of wear.
Forks must be healthy and not show any sign of wear.
NOTE Upon assembling, do not mutually exchange the

checked parts.

GEARBOX ASSEMBLY Bearings pre—load adjustment for secondary

shaft
Butter with hermetic type ”B” the threaded part of all The bearings pre—load adjustment for the secondary shaft
screws that must be screwed in the through—holes. can be carried out with two procedures.
Clean the joining surfaces of case and covers and

apply ”LOCTITE 510” putty, before assembling, on Figure 26
one of the two components.
Do not insert oil before 20 min and do not try the
Assemble bearing cages into their respective seats
and oil with TUTELA ZC 90.
To guarantee assembly oil seal, make sure that sealing
gaskets are already lubricated, or butter with oil or
grease the sealing lip of inlet and primary shafts
gaskets. 71687
Assemble comparator 99395604 (1) on base 99370466 (2),

pre—load it by 5 mm and zero it on an abutment plane.
Figure 27
98991
FRONT HALF—CASE
THICKNESS (S)
Figure 25
61957
Place calibrated ring 99396031 (2) into its seat, without

adjustment ring, of bevel roller bearing on front half—case;
place base 99370466 completed with comparator (1),
previously zeroed, as shown in the figure.
comparator (Example: 2.43 mm).
comparator and add it to calibrated ring
71686 thickness
[Example: 2.43 + 50.5 = 52.93 mm
Butter, with hermetic type ”B”, the coupling seat surface of (Dimension B)].
cover (3) with sealing gasket and with keyer 99370349 (2) and
handle 99370006 (1) assemble the sealing gasket itself.

Figure 28 Figure 31
INTERMEDIATE CASE
71900
On intermediate case (1) assemble external race (2) for

secondary shaft bearing and ball bearing (3) for primary shaft.
35465
Figure 29
Assemble and simultaneously rotate, till it abuts, the secondary
shaft (3, Figure 30) completed with bearings in rear case. Place
calibrated rings 99396031 (2, Figure 30) on the case (4,
Figure 30). Arrange, as shown in the figure, base 99370466
completed with previously—zeroed comparator (1, Figure 30);
the comparator rod must abut on the external bearing ring.
Carry out the measure on two diametrically—opposite points
and perform the arithmetic mean.

comparator (Example 1.84 mm). The
adjustment ring value is obtained by
summing the two measured values
(Example 2.43 + 1.84 = 4.27 mm)
71901
comparator and subtract it from the
calibrated ring thickness
Assemble oil pump (1) by screwing screws (2) at the required [Example: 50.5 — 1.84 = 48.66 mm
torque; rotate the intermediate case. (Dimension A, Figure 31)].
The adjustment ring value is obtained with formula
Figure 30
S=B—A Example: 52.93 — 48.66 = 4.27 mm.
NOTE The adjustment ring thickness choice is always

carried out in excess. Example; thickness S = 4.27:
thickness S = 4.3 is taken. Measuring of dimension
”A”, carried out with secondary shaft in vertical
position, that, in addition to facilitating the measure
itself, allows having an axial load on the rear bearing.
99001
Mount oil piping (5), fit inner control shaft bushing into its seat,
put in rib washer (5) and screw TORX mark screw with
prescribed torque. After having computed the thickness value of the adjustment
ring, disassemble again secondary shaft (3, Figure 30) and oil
pump (1, Figure 29).

Figure 32 Figure 35
98993
Place adjustment ring (1), whose thickness is equal to the

71693
previously—obtained one, into the secondary shaft bearing
seat on the front half—case (2). Slightly heat the ball bearing seat, assemble motion inlet shaft
(1) completed with bearing (4), adjustment ring (3) and elastic
Fit inner control shaft bushing into its seat, put in rib washer
ring (2). Settle the bearing till it abuts.
(4) and screw TORX mark screw (3) with prescribed torque.
Figure 33
NOTE Before assembling on front half—case the motion

inlet shaft, carry out bearing adjustment as described
in the related procedure on page 108.
32447
Centre external race (1) of bevel roller bearing of front cover

secondary shaft on extensible beater 99374092 (2) adjusted
with socket head screw (3). Lock beater with socket head
screw (4).
Figure 36
Figure 34
98994
Slightly heat seat (4) of secondary shaft bearing race on front 71679
half—case and assemble external race (3) by settling it till it Apply LOCTITE 510 sealant on contact surfaces (→)
abuts with beater 99374092 (2), equipped with handle between front half—case and motion inlet shaft cover.
99370007 (1).

Figure 37 Figure 39
71678
71903
Assemble motion inlet shaft cover (2), screw screws (1) and
Assemble secondary shaft (5) and simultaneously lower
tighten them at the required torque.
primary shaft (2) and internal drive shaft (3). Pay attention to
the exact insertion of synchronising rings (4).
Remove nut (1).
Figure 38
Figure 40
71898
Insert roller bearing into motion inlet shaft, then assemble

synchronising rings (3). 71904
Assemble primary shaft (1) completed with internal drive shaft

(2) without completely inserting it into motion inlet shaft. Apply LOCTITE 510 sealant on contact surface (→) between
the front half—case and intermediate case.

Figure 41 Figure 43
71905
78164
Assemble reducing gear engagement safety pin (3, Figure 23).
Assemble intermediate case (1) and screw the screws at the Insert tip (4), spring (3), then mount cover (1) and fasten
required torque. screws (2) by tightening them to the specified torque.
Figure 44
Figure 42
71907
Assemble shoulder rings, placing them into their own seat and
reverse gear (3) with cylindric roller bearing. Assemble reverse
78165 gear supporting shaft (2) with a suitable beater, paying
attention that the arrow (1) punched on the shaft is facing the
Apply sealer LOCTITE 510 on the surface (→) without peg insertion hole.

Figure 45 Figure 48
71911
71908
Assemble elastic peg (1). Apply LOCTITE 510 sealant and assemble external gear drive
Apply LOCTITE 510 sealant on contact surface (→) between (1) tightening screws (2) at the required torque.
intermediate case and cover.
Figure 46 Figure 49
71912
71909
Apply tool 99370130 (1) and, through wrench 99355131 (2)
Assemble oil pump (1) and tighten screws (2) at the required
and dynamometric wrench (3), screw sun gear check nut,
torque, assemble cover (3) and tighten screws (4) at the
tightening it at the required torque.
required torque.
Figure 47 Figure 50
71886
71910 Assemble epicyclic reduction gear assemble (1) after having

Key—in oil distributor (2) and sun gear (1). applied LOCTITE 510 sealant and tighten securing screws at
the required torque.

Figure 51 Figure 52
79440
79441
Apply reaction lever 99370317 (1) and with wrench Connect pneumatic pipings (1) of epicyclic reduction gear
99355081 (2) screw motion outlet flange securing nut (3) drive.
tightening it at the required torque. Assemble clutch disengagement lever and tighten the two
securing screws at the required torque.
NOTE Insert lubrication oil in the prescribed amount after

about 20 minutes from the last LOCTITE 510 sealant
application.
Remove gearbox from rotating stand.
Idle—Reverse Gear switch adjustment
NOTE The below—described sequence must be compulsorily followed.
Figure 53
gearbox with engaged idle gearbox gearbox with engaged
reverse gear gears
62457
SWITCH INSERTION POSITIONS ON 2870.9 GEARBOX

- Apply silicon sealant on threadings;
- Put gearbox in engaged reverse gear positions;
- Screw the switch till the reverse gear lamp turns on;
- Further screw the switch by 45—60° corresponding to a 0.19—0.25 mm stroke;
- Tighten securing lock nut with a 24—type wrench at a 35 Nm torque.


Figure 54 Figure 57
35478 35481
Remove synchronising ring and coupling body (1).

Tighten primary shaft (1) in a vice. Withdraw 4th speed gear (2) together with roller bearing.
Withdraw sliding sleeve (2) for 4th—5th gear recovering
springs, pins and rollers (3).
Figure 55 Figure 58
35479 35482
Remove elastic ring (1).

Through rounded—tip pliers, remove elastic ring (1).
Figure 59
Figure 56
35483
35480
Through extractor 99341003 (1) completed with tie—rods
Through extractor 99341003 (1) completed with brackets (2) (2), grips (4) and clamp 99341015 (3) extract 3rd speed gear
and clamp 99341015 (3), withdraw fixed 4th—5th gear hub (4). (5) together with bush (6) and roller bearing.

Figure 60 Figure 63
35484 35487
Remove synchronising ring and coupling body (1), withdraw Withdraw roller bearing (1), synchronising ring and coupling
sliding sleeve (2) recovering springs, pins and rollers. body (2).
Figure 64
Figure 61
35485
35488
Through extractor 99341003 (1) completed with tie—rods
(2), grips (4) and clamp (6), extract 2nd—3rd gear fixed hub (3) Through suitable pliers, remove elastic ring (1).
together with synchronising ring, coupling body and 2nd speed
gear (5); recover the roller bearing.
Figure 65
Figure 62
35486 35489
Turn primary shaft over, then through extractor 99341003 (1) Through extractor 99341003 (1), reaction block (2), tie—rods
completed with tie—rods (2), grips (3) and clamp (7), (3), clamp (4), grips (5), withdraw 1st speed gear (6)
withdraw reverse gear (4) together with internal bearing (6) completed with sliding sleeve, synchronising ring and roller
ring and shoulder ring (5). bearing.

PRIMARY SHAFT ASSEMBLY MOTION INLET SHAFT DISASSEMBLY

After having checked and possibly replaced all worn or broken
components, in order to assemble the primary shaft, suitably Figure 68
reverse the previously—performed operations paying
attention that:
Figure 66
71869
Remove elastic ring (2) and adjustment ring (1).
Figure 69
35490
- Fixed hubs (1) for 1st and reverse, 2nd — 3rd — 4th — 5th
speed gears must be heated at a temperature of 100 ÷
130 °C and driven into the primary shaft, paying attention
that synchronising ring stops (2) are inserted into the
respective fixed hub seats.
71870
Abut bearing (1) on a vice, as shown in the figure, and by

beating onto shaft (2), extract it from the bearing itself.
Figure 67 Figure 70
71871
35491
PARTS COMPOSING THE MOTION INLET SHAFT
1. Motion inlet shaft — 2. Elastic ring — 3. Adjustment ring —
- Elastic shoulder rings (1) are of an adequate thickness so 4. Ball bearing — 5. Cylindric roller bearing
that they do not show an axial clearance with fixed hubs
(max. allowed 0.03 mm).

MOTION INLET SHAFT ASSEMBLY SECONDARY SHAFT DISASSEMBLY

Figure 71 Figure 73
33651
Remove elastic ring (1) from secondary shaft (3) and extract
71872 bevel roller bearings (2 and 4) with a suitable punch
Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.
Motion inlet shaft bearing adjustment SECONDARY SHAFT ASSEMBLY
Figure 72
Slightly heat bevel roller bearings (2 and 4, Figure 73)
and assemble them on secondary shaft (3, Figure 73).
Assemble elastic ring (1, Figure 73).
INTERNAL DRIVE SHAFT DISASSEMBLY
62455
Figure 74
- Assemble bearing on motion inlet shaft.

- Measure dimension “A”.
- Measure seeger “B” thickness.
- Define thickness of spacer ring to be inserted, by defect:
C = A — B.
Motion inlet shaft bearing adjustment spacer ring

thicknesses: mm 2.40 — 2.45 — 2.50 — 2.55 — 2.60 —
2.65 — 2.70 — 2.75 — 2.80.
35497
Assemble adjustment ring (1, Figure 68) whose thickness is

equal to the previously—obtained one and assemble elastic Mark fork (3) assembling position. Unscrew screw (1),
ring (2, Figure 68). withdraw shaft (2) and decompose the assembly.

EXTERNAL DRIVE CASE DISASSEMBLY
Figure 75 Figure 76
1
2
3
4
5
6
7
35431 79445
PARTS COMPOSING GEARS DRIVE Secure the assembly in a vice, unscrew the four screws (1) and
disassemble valve (2) of epicyclic reduction gear drive.
1. Selection rod — 2. Shaft — 3. Synchronising rod — 4. Hub —
5. Screw — 6. 4th—5th fork — 7. 2nd—3rd fork — 8. 1st and re-
verse gear fork Figure 77
INTERNAL DRIVE SHAFT ASSEMBLY
Arrange on a bench forks (6—7—8) and hub (4) according to

the position marked upon disassembling.
Place selection rod (1) so that the grooves are inserted into
forks and hub; repeat the operation with synchronisation rod
(3) and keeping them in position, insert shaft (2).
Screw the hub (4) screw (5) at the required torque.
33655
Tighten the shaft going out of the box in a clamp, remove plug
Figure 78
78166
Remove control box pin (2) and spring (1).

push rod.

Figure 79 Figure 82
33657 33660
Unscrew screws (1) and disassemble cover (2). Extract, from the control shaft (2), control selector (1) and
box (3).
Figure 80 Figure 83
33658 33661
EXTERNAL DRIVE CASE ASSEMBLY
Figure 81 Figure 84
78167 33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove Assemble sealing gasket (1) and bushes (2) into drive case (3)
flexible plugs (2) and (3). with a suitable beater.

Print 603.93.391
Figure 85 Figure 87
33660 78168
Tighten control shaft (2) in a clamp and assemble thereon box Insert the extraction washer (1) and use a punch tool having
(3) and control selector (1). the right diameter to install the first plug (2). Install the second
Figure 88
Figure 86
78169
71880
NOTE Upon assembling, the drive shaft must be assembled The bigger plug cut shall face the control selector (1)
with the reference arrow (1) facing upwards. milled area (see detail B).

Figure 89 Figure 92
33663 78170
518” (→).
Figure 90 Figure 93
33658 33655
Figure 91 Figure 94
33657
Clean joining surfaces of control box and cover (2) and apply 79445
Assemble cover (2) and tighten screws (1) at a torque of 36.5 Apply ”LOCTITE 518” sealant, mount epicyclic reduction gear
Nm (3.7 kgm). control valve (2), fasten screws (1) and tighten them to the
Apply threading sealer LOCTITE 270 on the screws (1). specified torque.

533010 EPICYCLIC REDUCTION GEAR ASSEMBLY

Operating diagrams about pneumatic epicyclic reduction gear drive circuit
Figure 95
72458
SLOW GEAR ENGAGEMENT (1st — 2nd — 3rd — 4th — 5th AND REVERSE GEAR)
Air coming from services tank, passing through a reduction gear, is reduced to the pressure of 6.5 ÷ 6.9 bars and reaches consent
valve at union I.
By pressing the clutch, operate on the gearbox lever to engage a gear (1—2—3—4—5—RG); cam (A) is moved upwards and pushes
pin (B) leftwards.
The pin abuts on piston (C) valve and by lifting it, closes the supply to union 21.
By discharging air contained into the cylinder through the vent hole (D), air will then go out of union 22 thereby keeping gearbox
piston in slow gears.

Figure 96
72459
QUICK GEARS (6th — 7th — 8th — 9th) ENGAGEMENT
By going with lever into second “H”, cam (A) moves downwards and pushes pin (B) leftwards.
The pin abuts on piston (C) valve and, by lifting it, closes the supply to union 22 discharging air contained into the cylinder through
vent hole (D).
Air will then go out of union 21 pushing the piston in reverse and allowing to insert quick gears.

DISASSEMBLY
71916
Remove rod with fork (1), withdraw phonic wheel (3) and
71913
remove synchronising ring (2).
Abut epicyclic reduction gear assembly on a bench, unscrew Figure 101
nut (1) and remove flange (2). Unscrew screws (3) and
remove cylinder (4).
Figure 98
71917
Make three reference marks (1) on sliding sleeve—crown

assembly (2) next to the three central seats, on fixed hub, for
71914 positioning rollers.
Unscrew screw (2) and remove piston (1). Manually lift complete crown (2) and remove it, recovering
rollers, pins and springs.
Figure 99
Figure 102
71915
71918
Lift case (2) in order to free outlet shaft (3) and rod (1) for
synchronising drive fork. Through suitable pliers, remove elastic ring (1).

71922
71919
Withdraw synchroniser fixed hub (1). Through a suitable beater, push away pin (3) and withdraw
gear (2) completed with shoulder rings (1) and shims.
Recover all rollers composing the bearing.
Figure 104
Figure 107
71920
35514
Through pliers 99381125 (3), remove elastic ring (2) and
withdraw synchroniser (1). In order to remove sliding sleeve (1) from crown (2), use small
pins (3) with diameter 2 ÷ 2.3 mm and a length of 10 mm.
Figure 105
Figure 108
35515
71921
Apply a strap (2), tighten it in order to compress pins (3): in
Through a punch (1) with a suitable diameter, push the elastic such a way, the internal check ring is detached; then, withdraw
peg inwards till it abuts. sliding sleeve (1).

71923 71926
Extract sealing gasket (4) from cover (2), unscrew screws (1) Check that ball bearing (2), when rotating along the two
and disassemble cover (2) and support (3). directions, does not show roughness or noise when sliding.
In case of a replacement of the bearing itself, slightly heat
Figure 110 support (1) seat before disassembling it.
71924
Through a suitable wrench (1), unscrew screws (2) and

remove check washers (3).
Figure 111
Checks
Check that all parts composing the epicyclic reduction gear

assembly do not shown traces of excessive wear, seizures or
breakages.
Replace the affected parts.

71925
Withdraw synchronising ring (1), reaction ring (2) and recover

the spacer ring below.

ASSEMBLY
71930
71927
By using a punch (2), assemble elastic peg (2) checking pin (3).
By using grease, pre—assemble rollers (4), shims (2) and
shoulder rings (1) into planetary gear (3).
Figure 117
Figure 114
71928 71931
Assemble complete planetary gear (1) into planetary Turn planetary gear—holder shaft (1) over, assemble
gear—holder shaft (2) and key—in pin (3). synchronising rings (2) and arrange elastic check ring (4).
71932
71929 Through a feeler gauge (1), check the clearance between the
two synchronising rings (2) and (3) that must be included
Settle pin (1) on planetary gear—holder shaft (2) by using a between 0.5 and 1.9 mm. Otherwise, replace the
plastic hammer. synchronising rings.

35523
71935
Key—in sliding sleeve (1) completed with check ring (2) on
crown (3), then, by compressing ring (2), push sliding ring (1) Key—in the crown, by placing it in a neutral position with marks
into the crown till the check ring is hooked into its own seat. (1) next to the seats without rollers. Arrange the three central
rollers (2) and with a punch (3) push them into their seats.
71933
71936
Assemble hub (1) on planetary gear—holder shaft and arrange
elastic check ring (2). Key—in synchronising ring (1).
Figure 124
Figure 121
71934 71937
Arrange springs, pins and rollers (1), apart from the central Insert spacer ring (1) into its seat in case (2).
ones (→), into the hub.

71925
Assemble synchronising ring (1) and reaction ring (2).

71940
Key—in box (2) on planetary gear—holder shaft (1) and on rod

Figure 126 for control fork (3). Key—in phonic wheel (4) on planetary
gear—holder shaft (1).
case (2) and support.
71938
Assemble check washers (2), screw screws (1) and tighten

them at the required torque.
71941
71939
Assemble support (1) completed with ball bearing (2).
Place control fork (1) completed with rod as shown in the Apply LOCTITE 510 sealant on contact surface (→) between
figure. support and cover.

71958
Abundantly pre—lubricate gaskets (1 and 2) of oil piston equal

to the one used for gearbox and assemble them into their
respective seats, using suitable toolings in order to guarantee
a correct assembly. 71944
Assemble cylinder (2) and screw screws (1) tightening them

NOTE Pay attention to the correct assembly of sealing at the required torque.
gaskets (1) placed on external piston diameter.
Figure 134
Figure 131
71945
Butter with hermetic type “B” the coupling surface of cover
(1) with sealing gasket and with keyer 99574229 (2), assemble
the sealing gasket itself.
71942
Assemble cover (1) and screw screws (2) tightening them at Figure 135
Assemble piston (3) completed with sealing rings, screw the
screw (4) by tightening it at the required torque.
Figure 132
71946
Key—in flange (1) and screw nut (2) without blocking it.
71943
NOTE Nut (2) must be blocked at the required torque
after having assembled the reduction gear onto the
Apply LOCTITE 510 sealant on contact surface (→) between gearbox.
case and cylinder.


Print 603.43.671/A
5302 Gearbox 2895S.9
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 129
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
GEARBOX REMOVAL/REFITTING . . . . . . . . . . 135
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
GEARBOX DISASSEMBLING . . . . . . . . . . . . . . . 135
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
GEARBOX ASSEMBLING . . . . . . . . . . . . . . . . . . 139
- Adjusting transmission shaft bearing

pre — load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
MAIN SHAFT DISASSEMBLING . . . . . . . . . . . . . 145
MAIN SHAFT ASSEMBLING . . . . . . . . . . . . . . . . 147
INPUT SHAFT DISASSEMBLING . . . . . . . . . . . . 148
INPUT SHAFT ASSEMBLING . . . . . . . . . . . . . . . 148
TRANSMISSION SHAFT . . . . . . . . . . . . . . . . . . . 148
- Bearing replacement . . . . . . . . . . . . . . . . . . . . 148

DISASSEMBLING . . . . . . . . . . . . . . . . . . . . . . 149

ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . 149
EXTERNAL CONTROL BOX

DISASSEMBLING . . . . . . . . . . . . . . . . . . . . . . 149
EXTERNAL CONTROL BOX

ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . 150

Page
EPICYCLIC REDUCTION GEAR ASSEMBLY . . . 153
- Operating diagrams about pneumatic epicyclic

reduction gear drive circuit . . . . . . . . . . . . . . . 153
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

DESCRIPTION
Print 603.43.671/A
The 2895S.9 gearshift is of the mechanic type, with nine speeds and engagement of the 1st, 4th, 5th, 8th and 9th speeds by means
of free—ring synchronizing rings, whereas the 2nd, 3rd, 6th and 7th speeds are engaged by means of a double—cone synchronizing gear.
It consists of a front part featuring five forward gears and reverse gear and a rear part featuring two gears obtained through epicyclic
reduction gear unit (E.R.U.).
Gearshifting is performed through double H mechanical control, E.R.U. switching is through pneumatic system.
Gearbox is fitted with oil pump for lubrication.
Figure 1
99317
sec. A—A
GEARBOX 2895S.9 LONGITUDINAL SECTION AND REVERSE GEAR SHAFT SECTION

GEARBOX 2895S.9
Type Mechanical
Power takeoff On request
Gears engagement:
1st Free—ring synchronizer
2nd ⇒ 3rd Double—cone synchronizer
4th ⇒ 5th Free—ring synchronizer
6th ⇒ 7th Double—cone synchronizer
8thh ⇒ 9thh Free—ring synchronizer
Reverse
eve se gear
gea Quick—connection
Quick connection type
Gears anti—disengagement Sliding sleeve holding through rollers and
springs.
Gears Helical toothing
Gear ratio
First 1 : 13.56
Second 1 : 9.00
Third 1 : 6.54
Fourth 1 : 4.76
Fifth 1 : 3.54
Sixth 1 : 2.53
Seventh 1 : 1.84
Eighth 1 : 1.34
Ninth 1 : 1.00
Oil type Tutela ZC 90
Amount 7.5 kg (8.3 liters)

Assembling temperature for fixed hubs 100 ÷ 130oC
Transmission shaft bearings Tapered rollers
Transmission shaft bearings pre—load adjust-

Through rings
ment
2.5 — 2.6 — 2.7 — 2.8 — 2.9 — 3.0 — 3.1
Transmission shaft axial backlash adjustment 3.2 — 3.3 — 3.4 — 3.5 — 3.6 — 3.7 — 3.8
mm
rings thickness 3.9 — 4.0 — 4.1
Provided in kit
Assembling temperature for transmission
85oC
shaft bearings

Figure 2
sec. A—A
99318

Print 603.43.671/A
TIGHTENING TORQUE
TORQUE
PART
Nm (kgm)
1 Flanged hexagonal head screw for securing spring retaining flange on external control 19 ± 2 (1.9 ± 0.2)
2 Flanged hexagonal head screw for securing upper external controls support cover 33.5 ± 3.5 (3.4 ± 0.4)
3 Screw for securing reduction unit control valve 23.5 ± 2.5 (2.4 ± 0.3)
4 Ring nut for securing sun gear on main shaft 372.5 ± 19.5 (37.5 ± 2)
Flanged hexagonal head screw for securing reduction unit control pneumatic cylinder
5 35.5 ± 3.5 (3.6 ± 0.4)
to rear half box
6 Flanged hexagonal head screw for securing rear cover on main shaft 44.5 ± 4.5 (4.5 ± 0.5)
7 Ring nut for fastening output shaft on spider shaft 559.5 ± 29.5 (57 ± 3)
8 Flanged hexagonal head screw for securing rear cover on transmission shaft 58 ± 6 (5.9 ± 0.6)
9 Oil filter on rear half box 320 ± 30 (32.6 ± 3.1)
10 Threaded plug with external operating hexagon for oil drain 27.5 ± 2.5 (2.8 ± 0.3)
11 Hexagonal head screw for securing oil pump body to box 33.5 ± 3.5 (3.4 ± 0.4)
12 Flanged hexagonal head screw for securing transverse axle cover on external control* 19 ± 2 (1.9 ± 0.2)
13 Transverse axle screw* 30 ± 3 (3.1 ± 0.3)
14 Threaded plug with external operating hexagon for oil level 27.5 ± 2.5 (2.8 ± 0.3)
15 Flanged hexagonal head screw for securing covers on PTO connection openings 38 ± 4 (3.9 ± 0.4)
17 Idle positioning device 78 ± 8 (8.0 ± 0.8)
18 Ring nut for securing input shaft bearing 545 ± 55 (55.6 ± 5.6)
19 Flanged hexagonal head screw for securing front cover 31 ± 3 (3.1 ± 0.3)
20 Screw for securing gearbox clutch housing 177 ± 17 (18 ± 1.8)
22 Flanged hexagonal head screw for securing rear intermediate front half box 45.5 ± 4.5 (4.6 ± 0.5)
— Countersunk screw for securing reduction unit reaction plate 21 ± 2 (2.1 ± 0.2)

D Apply liquid gasket LOCTITE 510 sealant
Y Apply liquid gasket LOCTITE 518 sealant
♦ Apply thread—braking LOCTITE 242 on the screw

TOOLS
99305121 Hot—air equipment
99322205 Revolving stand for overhauling units

99322225 Unit bearing support (to be applied to stand 99322205)
99340205 Percussion puller

TOOLS
99341015 Clamp
99341023 Grips

TOOLS
99341025 Grips
99345058 Thrust block for pullers
99347092 Peg for removing reverse gear shaft (to use with 99340205)
99355081 Wrench (60 mm) for locking ring nut of output flange on spider shaft
(use with 99370317)
99355131 Wrench (55 mm) for locking ring nut of sun gear on primary shaft
(use with 99370130)
99355174 Wrench for disassembling and reassembling locking ring nut of

motion input

TOOLS
99370130 Tool for holding the sun gear during nut removal and refitting
99370317 Reaction lever with extension for retaining flanges
99370349 Tool for fitting gasket on gearbox front cover (to use with
99370006)
99370466 Gauge base for transmission shaft bearing adjustment (to use with
99395604)
99370629 Support for holding gearbox during removal and refitting from/on
vehicle

TOOLS
99374229 Tool for refitting gasket on gearbox rear cover
99381125 Pliers for removing gearbox split rings
99395604 Dial gauge (0 — 10 mm)
99396032 Gauged rings for adjusting transmission shaft bearings (to use with
99370466)

Print 603.43.671/A
GEARBOX REMOVAL/REFITTING
Removal Figure 4
In order to disengage the gearbox, operate as follows:
- put the vehicle on a pit or an elevator bridge;
- disconnect battery cables to avoid possible
short—circuits.
Proceed by removing the following parts:
- exhaust silencer, transmission shaft, servo clutch
cylinder for electric and pneumatic connections,
gear control tie rods.
Place under the gearbox an hydraulic lifting device
equipped with support 99370629, unscrew the nut
securing gearbox to engine, move back and withdraw
the gearbox.
35436
Apply reaction lever 99370317 (2) and using wrench

99355081 (1) loosen the output flange fastening nut.
Refitting
Suitably reverse the performed operations for the
engagement and tighten securing screws and nuts at
Figure 5
Upon re—engaging the gearbox, pay attention that the

clutch control lever fork is correctly meshed to the
thrust bearing.
GEARBOX DISASSEMBLING 35437
Loosen the fastening screws and remove the E.R.U. box (1).
NOTE Before setting the gearbox on the revolving stand,

remove the entire clutch assembly with fork lever
and drain out oil.
Figure 6
Figure 3
35438
35435 Apply tool 99370130 (2) and using wrench 99355131 (1)
Disconnect epicyclic reduction gear unit air pipes (1). loosen sun gear castle nut.

Figure 7 Figure 10
35439 35442
Withdraw the sun gear (1). Engage a gear and using wrench 99355174 (2) loosen input
shaft ring nut (1).
Figure 8
Figure 11
35440
35443
Withdraw the oil distributor (1) with sealing rings. Loosen the screws and remove the oil pump (1).
Figure 9
Figure 12
35441 35444
Loosen the screws and remove input shaft front cover (1). Loosen the screws and remove the entire external control
box (1).

Figure 13 Figure 16
35448
79444 REVERSE GEAR COMPONENTS

Unscrew screws (4), disassemble cover (5), take off spring (3) 1. Bearing spacer — 2. Shoulder ring — 3. Roller bearing —
and take out tip (2). Move gear selector hub (1) inwards. 4. Reverse speed gear — 5. Shoulder ring — 6. Shaft —
7. Split pin.
Figure 17
Figure 14
35449
35472
Remove reverse gear cover; drive down the split pin (2) using Withdraw the reverse speed gear (1) with shoulder ring and
a punch. straight roller bearings.
Figure 15 Figure 18
35447 35450
Use percussion puller 99340205 (1) with tool 99347092 (2) Move inside the gear selector hub (2)
to remove reverse gear shaft (3). Loosen gearbox fastening screws (1 and 3).

Figure 19 Figure 22
99312
35451 Remove synchronising rings (1) and remove the input shaft (2)
Remove gearbox (4) using puller 99341004 (1), brackets using a plastic hammer. Unscrew screw (4), take off rib washer
99341017 (2) and reaction block 99341058 (3). (3) and recover underlying bushing.
Figure 20 Figure 23
35455
Remove transmission shaft bearing outer ring (1) using a

punch.
35452
Tighten nut (1) on main shaft (2), lift the main shaft by approx.
10 ÷ 20 mm and withdraw the transmission shaft (3) moving Figure 24
it sideways.
Figure 21
99313
35453 Remove oil pipe (1), bearing outer ring (2) and ball bearing (3)
from the gearbox case. Unscrew screw (5), take off rib washer
Lift and remove the main shaft (1) with gear control assembly
(4) and recover bushing (3).
(2).

Checks
Print 603.43.671/A
GEARBOX CASE GEARBOX ASSEMBLING

be damaged or distorted. Smear with sealing compound type “B” the threaded
Bearing seats must not be damaged or excessively worn. part of all screws that have to be screwed into the
through—holes.
Clean joining surface of boxes and covers and apply
“LOCTITE 510” adhesive on one of the two
components before refitting.
Do not fill with oil before 20 min. and do not operate
the gearbox before 1h and 30 min.
SHAFTS — GEARS Fit bearing cages into their seats and oil with TUTELA
ZC 90.
damaged or worn. In order to guarantee oil seal at refitting, make sure
that sealing gaskets are already lubricated, or:
smear with oil or grease the sealing lip of input and
main shafts.
Grooves on hubs and sliding sleeves must not be damaged.

The sliding sleeve must slide freely on the hub. Sliding sleeve Adjusting transmission shaft bearing pre — load
positioning rollers must not be damaged or worn. Sliding
sleeves engagement teeth must not be damaged. Transmission shaft bearing pre—load can be adjusted with
Forks must be intact and not show any sign of wear. two procedures.
Figure 25
BEARINGS

and not show traces of wear or overheating.
When keeping the bearings pressed by hand and making them
rotate simultaneously along both directions, no roughness or
noise must be detected.
35457
Fit gauge (1) on base 99370466 (2).

Pre—load it at 5 mm and set it to zero on a surface plate.
NOTE At refitting always replace: rings, sealing gaskets and
springs for sliding sleeves positioning rollers.
Figure 26
SYNCHRONISERS — COUPLING BODIES
Check wear of synchronising rings and coupling bodies: they

must not show signs of wear.
NOTE At assembling stage, do not mistake the components 35458

with each other. Use a micrometer (2) to check gauged ring thickness (1).

Figure 27 Figure 30
99314
Fit temporarily cover (2) on front cover (1).

35462
Fit inner control shaft bushing into its seat, put in rib washer Fit transmission shaft bearing outer ring (2) and main shaft ball
(5) and screw TORX mark screw (4) with prescribed torque. bearing (3) on the intermediate box (1).
Figure 28
Figure 31
99315
Figure 29
35463
THICKNESS (S)
Fit the oil pump (1) and tighten the screws to the specified
torque, rotate the intermediate box.
FRONT COVER
Figure 32
35461
Place gauged ring 99396032 (2) in the tapered roller bearing

seat, without adjustment ring on front cover; place base
99370466 with gauge (1) previously set to zero as shown in
Figure 25.
First method — Take note of the value read on the gauge
(Example: 2.43 mm).
Second method — Take note of the value read on the gauge
and add it to the gauged ring thickness
99316
[Example: 2.43 + 50.5 = 52.93 mm
(Dimension B)]. Mount oil piping (5), fit inner control shaft bushing into its seat,
put in rib washer (5) and screw TORX mark screw with
prescribed torque.

Figure 33 Figure 34
35466
INTERMEDIATE BOX Fit input shaft (2) and transmission shaft outer ring (1) on front
70244
cover.
Figure 35
Assemble and simultaneously rotate transmission shaft (3,
Figure 32) with bearings into rear case, so that it settles. Place
gauged rings 99396032 (2, Figure 32) on case (4, Figure 32).
Arrange as shown in figure, base 99370466 with gauge (1,
Figure 32) previously set to zero: gauge rod must rest on
bearing outer ring. Carry out the measurement on two
diametrically opposed points and obtain the arithmetic mean.
First method — Take note of the value read on the gauge
(Example: 1.84 mm).
The adjustment ring value is obtained by
adding the two measured values
(Example: 2.43 + 1.84 = 4.27 mm)
Second method — Take note of the value read on the gauge
and subtract it from gauged ring thickness
[Example: 50.5 — 1.84 = 48.66 mm
(Dimension A)].
The adjustment ring value is obtained through formula 35467
S=B—A Example: 52.93 — 48.66 = 4.27 mm. Fit roller bearing into input shaft then fit the main shaft (1)
including gear engagement control.
Figure 36
NOTE The adjustment ring rounding is carried out always

by excess. Example: thickness S = 4.27: thickness S
= 4.3 is taken.
The measure for dimension “A” is carried out with
transmission shaft in vertical position that, in addition
to making the measure easier, enables to have axial
load on rear bearing.
35468
After calculating the adjustment ring thickness value,
Fit the transmission shaft (1), smear LOCTITE 510 adhesive
disassemble again transmission shaft (3, Figure 32) and cover
(arrow).
(2, Figure 27).

Figure 37 Figure 40
35469
Fit the intermediate box (1) and tighten screws (2) to the 35470
specified torque.
Fit tool 99370130 on the main shaft, engage a gear and with
wrench 99355174 (1) and dynamometric wrench tighten ring
Figure 38 nut to the specified torque.
78165
Apply sealer LOCTITE 510 on the surface (→) without

Figure 41
Figure 39
35471
78164
Fit the adjustment ring, smear cover (1) with LOCTITE 510,
Insert tip (4), spring (3), then mount cover (1) and fasten fit cover and tighten the screws (2) to the specified torque.
screws (2) by tightening them to the specified torque.

Figure 42 Figure 45
35448 35474
REVERSE GEAR COMPONENTS Fit down oil distributor (2) and the sun gear (1).
1. Bearing spacer — 2. Shoulder ring — 3. Roller bearings —
4. Reverse speed gear — 5. Shoulder ring — 6. Shaft —
7. Split pin.
Figure 43
35472
After fitting parts (1—2—3—4 and 5, Figure 43) in the

intermediate box (1, Figure 42), fit shaft (6, Figure 42) and
drive the split pin (2, Figure 43).
Figure 46
Figure 44
35475
35473
Position tool 99370130 (1), tighten castle nut to the specified
torque using the dynamometric wrench (2).
Fit the oil pump (2) and tighten screws to the specified torque
using the dynamometric wrench (1).

Figure 47 Figure 48
35477
35476 Smear with LOCTITE 510 (arrow) and refit gear

anti—disengagement safety pin (2) and the E.R.U. (1).
Fit covers and external gear control (1).
Tighten the screws to the specified torque using the
dynamometric wrench.
Apply reaction lever 99370317 and wrench 99355081.
Tighten output flange fastening nut to the specified torque.
Refit E.R.U. air pipes and fill with TUTELA ZC 90 (7.5 kg).
Remove the gearbox from the stand and refit the clutch
assembly.
Figure 49

reverse gear gears
62457
SWITCH ENGAGEMENT POSITIONS ON GEARBOX 2870.9


Print 603.43.671/A
MAIN SHAFT DISASSEMBLING

Figure 50 Figure 52
35478 35480
Tighten main shaft (1) in a vice. Use puller 99341003 (1) with brackets (2), and clamp
Remove 4th and 5th speed sliding sleeve (2), recovering 99341015 (3) to remove 4th and 5th speed fixed hub (4).
springs, pins and rollers (3).
Figure 51 Figure 53
35479 35481
Use round—nose pliers to remove split ring (1). Remove the synchronising ring and the coupling body (1).
Remove 4th speed gear (2) and the needle bearing.

Figure 54 Figure 57
35482 35485
Remove split ring (1). Extract 2nd and 3rd speed gear fixed hub (3), synchronising
ring, coupling body (5), and 2nd speed gear (5) using puller
99341003 (1), tie rods (2), grips (4) and clamp (6). Recover
the needle bearing.
Figure 55 Figure 58
35486
35483
Upset the main shaft and remove the reverse speed gear (4)
Remove 3rd speed gear (5) together with bush (6) and needle with bearing outer ring (6) and the shoulder ring (5) using
bearing using puller 99341003 (1), tie rods (2), grips (4) and puller 99341003 (1), tie rods (2), grips (3) and clamp (7).
clamp 99341015 (3).
Figure 56 Figure 59
35484 35487
Remove synchronising ring and coupling body (1) and Remove the needle bearing (1), the synchroniser ring and the
withdraw sliding sleeve (2) recovering springs, pins and rollers coupling body (2).
(1).

Figure 60 MAIN SHAFT ASSEMBLING
Check and replace, if required, any damaged or worn

component and then reverse the removal procedures taking
care to the following:
35488 Figure 62
Use the proper pliers to remove split ring (1).
35490
- fixed hubs (1) for 1st — 2nd — 3rd — 4th — 5th and R.G. gears
shall be heated to 100 °C ÷ 130 °C and assembled on
main shaft. When driving the hubs, pay attention that
synchronising ring stops (2) are fitted into respective fixed
hub seats;
Figure 61
Figure 63
35489
Extract 1st speed gear (6) with sliding sleeve, synchronising ring 35491
and needle bearing using puller 99341003 (1), reaction block - shoulder split rings (1) shall have proper thickness so that
(2), tie rods (3), clamp (4) and grips (5). to have no axial clearance with fixed hubs (max tolerated
0.03 mm).

INPUT SHAFT DISASSEMBLING

Figure 64 Figure 67
35492 INPUT SHAFT COMPONENTS

Loosen bearing fastening ring nut (1). 1. Straight roller bearing — 2. Half race — 3. Half race —
4. Ball bearing — 5. Ring nut — 6. Input shaft.
Figure 65
INPUT SHAFT ASSEMBLING
Suitably reverse removal operations and tighten

temporarily the ring nut (1, Figure 64).
TRANSMISSION SHAFT
35493
Bearing replacement
Fit bearing (2) into a vice and beat the shaft (1) to remove ball
bearing (2) and one half race. Figure 68
Figure 66
35496
Remove split ring (1) and extract taper roller bearing (2); use
35494
a proper punch to remove also the taper roller bearing (3).
Use puller 99341003 (1), tie rods (2) and grips (3) to remove When refitting warm slightly the bearings.
the other half race (4).

INTERNAL CONTROL SHAFT EXTERNAL CONTROL BOX

DISASSEMBLING DISASSEMBLING
Figure 69 Figure 71
35497
79446
Mark fork (3) assembling positions. Loosen screw (1),
withdraw shaft (2) and disassemble the unit. Secure the unit in a vice, unscrew the four screws (1), then
disassemble epicyclic reduction gear control valve (2).
Figure 70
Figure 72
1
2
3
4
5
6
7
33655
35431
Tighten the shaft going out of the box in a clamp, remove plug
GEAR CONTROL COMPONENTS
Figure 73
1. Selection rod — 2. Shaft — 3. Synchronising rod — 4. Hub —
5. Screw — 6. 4th and 5th speed fork —
7. 2nd and 3rd speed fork — 8. 1st and reverse
gear fork.

ASSEMBLING
Set forks (6—7—8) and hub (4) on a bench according
to the position marked at removal.
Set selection rod (1) so as to fit grooves into forks
and hub; repeat this operation with the
synchronising rod (3); keep in this position and fit
shaft (2).
Tighten hub (4) screw (5) to requested torque.
78166
Remove control box pin (2) and spring (1).

push rod.

Figure 74 Figure 77
33657 33660
Unscrew screws (1) and disassemble cover (2). Extract, from the control shaft (2), control selector (1) and
box (3).
Figure 75 Figure 78
33658 33661
Figure 76 Figure 79
78167 33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove Assemble sealing gasket (1) and bushes (2) into drive case (3)
flexible plugs (2) and (3). with a suitable beater.

Print 603.43.671/A
Figure 80 Figure 82
33660 78168
Tighten control shaft (2) in a clamp and assemble thereon box Insert the extraction washer (1) and use a punch tool having
(3) and control selector (1). the right diameter to install the first plug (2). Install the second
Figure 83
Figure 81
78169
71880
NOTE Upon assembling, the drive shaft must be assembled The bigger plug cut shall face the control selector (1)
with the reference arrow (1) facing upwards. milled area (see detail B).

Figure 84 Figure 87
33663 78170
518” (→).
Figure 85 Figure 88
33658 33655
Figure 86 Figure 89
33657
Clean joining surfaces of control box and cover (2) and apply 79445
Assemble cover (2) and tighten screws (1) at a torque of 36.5 Apply ”LOCTITE 518” sealant, mount epicyclic reduction gear
Nm (3.7 kgm). control valve (2), fasten screws (1) and tighten them to the
Apply threading sealer LOCTITE 270 on the screws (1). specified torque.

533010 EPICYCLIC REDUCTION GEAR ASSEMBLY

Operating diagrams about pneumatic epicyclic reduction gear drive circuit
Figure 90
72458
SLOW GEAR ENGAGEMENT (1st — 2nd — 3rd — 4th — 5th AND REVERSE GEAR)
Air coming from services tank, passing through a reduction gear, is reduced to the pressure of 6.5 ÷ 6.9 bars and reaches consent
valve at union I.
By pressing the clutch, operate on the gearbox lever to engage a gear (1—2—3—4—5—RG); cam (A) is moved upwards and pushes
pin (B) leftwards.
The pin abuts on piston (C) valve and by lifting it, closes the supply to union 21.
By discharging air contained into the cylinder through the vent hole (D), air will then go out of union 22 thereby keeping gearbox
piston in slow gears.

Figure 91
6.5 ÷ 6.9 bar
72459
QUICK GEARS (6th — 7th — 8th — 9th) ENGAGEMENT
By going with lever into second “H”, cam (A) moves downwards and pushes pin (B) leftwards.
The pin abuts on piston (C) valve and, by lifting it, closes the supply to union 22 discharging air contained into the cylinder through
vent hole (D).
Air will then go out of union 21 pushing the piston in reverse and allowing to insert quick gears.

DISASSEMBLY
Print 603.43.671/A
Figure 92 Figure 95
71916
Remove rod with fork (1), withdraw phonic wheel (3) and
71913 remove synchronising ring (2).
Abut epicyclic reduction gear assembly on a bench, unscrew Figure 96
nut (1) and remove flange (2). Unscrew screws (3) and
remove cylinder (4).
Figure 93
71917
Make three reference marks (1) on sliding sleeve—crown

assembly (2) next to the three central seats, on fixed hub, for
positioning rollers.
Manually lift complete crown (2) and remove it, recovering
71914
rollers, pins and springs.
Unscrew screw (2) and remove piston (1).
Figure 94 Figure 97
71915 71918
Lift case (2) in order to free outlet shaft (3) and rod (1) for
synchronising drive fork. Through suitable pliers, remove elastic ring (1).

71919 71922
Through a suitable beater, push away pin (3) and withdraw

gear (2) completed with shoulder rings (1) and shims.
Recover all rollers composing the bearing.
71920 35514
Through pliers 99381125 (3), remove elastic ring (2) and In order to remove sliding sleeve (1) from crown (2), use small
withdraw synchroniser (1). pins (3) with diameter 2 ÷ 2.3 mm and a length of 10 mm.
Figure 100
Figure 103
35515
71921
Apply a strap (2), tighten it in order to compress pins (3): in
Through a punch (1) with a suitable diameter, push the elastic such a way, the internal check ring is detached; then, withdraw
peg inwards till it abuts. sliding sleeve (1).

71926
71923
Extract sealing gasket (4) from cover (2), unscrew screws (1) Check that ball bearing (2), when rotating along the two
and disassemble cover (2) and support (3). directions, does not show roughness or noise when sliding.
In case of a replacement of the bearing itself, slightly heat
Figure 105 support (1) seat before disassembling it.
71924
Through a suitable wrench (1), unscrew screws (2) and

remove check washers (3).
Figure 106
Checks
Check that all parts composing the epicyclic reduction gear

assembly do not shown traces of excessive wear, seizures or
breakages.
Replace the affected parts.

71925
Withdraw synchronising ring (1), reaction ring (2) and recover

the spacer ring below.

ASSEMBLY
71947
71930
Pre—assemble roller bearing (3) and shoulder rings (1) into By using a punch (2), assemble elastic peg (2) checking pin (3).
planetary gear (2).
71928 71931
Assemble complete planetary gear (1) into planetary Turn planetary gear—holder shaft (1) over, assemble
gear—holder shaft (2) and key—in pin (3). synchronising rings (2) and arrange elastic check ring (4).
Figure 113
Figure 110
71932
71929
Through a feeler gauge (1), check the clearance between the
two synchronising rings (2) and (3) that must be included
Settle pin (1) on planetary gear—holder shaft (2) by using a between 0.5 and 1.9 mm. Otherwise, replace the
plastic hammer. synchronising rings.

35523
71935
Key—in sliding sleeve (1) completed with check ring (2) on
crown (3), then, by compressing ring (2), push sliding ring (1) Key—in the crown, by placing it in a neutral position with marks
into the crown till the check ring is hooked into its own seat. (1) next to the seats without rollers. Arrange the three central
rollers (2) and with a punch (3) push them into their seats.
71936
71933
Assemble hub (1) on planetary gear—holder shaft and arrange Key—in synchronising ring (1).
elastic check ring (2).
Figure 119
Figure 116
71934 71937
Arrange springs, pins and rollers (1), apart from the central Insert spacer ring (1) into its seat in case (2).
ones (→), into the hub.

71925
Assemble synchronising ring (1) and reaction ring (2).
71940
Figure 121
Key—in box (2) on planetary gear—holder shaft (1) and on rod
for control fork (3). Key—in phonic wheel (4) on planetary
gear—holder shaft (1).
case (2) and support.
71938
Assemble check washers (2), screw screws (1) and tighten

them at the required torque.
71939
71941
Assemble support (1) completed with ball bearing (2).

Place control fork (1) completed with rod as shown in the Apply LOCTITE 510 sealant on contact surface (→) between
figure. support and cover.

71958
Abundantly pre—lubricate gaskets (1 and 2) of oil piston equal

to the one used for gearbox and assemble them into their
respective seats, using suitable toolings in order to guarantee
a correct assembly. 71944
Assemble cylinder (2) and screw screws (1) tightening them

Pay attention to the correct assembly of sealing at the required torque.
! gaskets (1) placed on external piston diameter.
Figure 129
Figure 126
71945
Butter with hermetic type “B” the coupling surface of cover

(1) with sealing gasket and with keyer 99574229 (2), assemble
the sealing gasket itself.
71942
Assemble cover (1) and screw screws (2) tightening them at Figure 130
Assemble piston (3) completed with sealing rings, screw the
screw (4) by tightening it at the required torque.
Figure 127
71946
Key—in flange (1) and screw nut (2) without blocking it.
71943
NOTE Nut (2) must be blocked at the required torque after
having assembled the reduction gear onto the
Apply LOCTITE 510 sealant on contact surface (→) between gearbox.
case and cylinder.


EUROCARGO TECTOR 12—26 t ALLISON GEARBOX MD 3060P 163
Print 603.43.671/A
5302 Allison gearbox

MD 3060P
Pagina
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 165
CHARACTERISTICS AND DATA . . . . . . . . . . . 168
MAIN OPERATION ANOMALIES . . . . . . . . . . 169
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
REMOVAL/REFITTING (ALLISON) GEARBOX 179
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
REMOVAL AND REFITTING

GEARBOX CONTROL MODULE AGAIN . . 181
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
REPLACING SPEED SENSORS . . . . . . . . . . . . . 181
- Replacing turbine speed sensor . . . . . . . . . . . . 181
- Engine revolutions sensor replacement . . . . . . 182
- Replacing the output speed sensor . . . . . . . . . 182
REPLACING OIL LEVEL SENSOR . . . . . . . . . . . 182
REPLACING OIL SUCTION FILTER . . . . . . . . . 183
REPLACING THE SOLENOID VALVES . . . . . . 183
REPLACING PLANE GASKETS IN GEARBOX

CONTROL MODULE . . . . . . . . . . . . . . . . . . 184
REPLACING PRESSURE SWITCH F3 . . . . . . . . . 185
REPLACING THE SEAL RING ON THE OUTPUT

SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

164 ALLISON GEARBOX MD 3060P EUROCARGO TECTOR 12—26 t

Print 603.43.671/A
DESCRIPTION
The Allison MD 3060 P gearbox is automatic and it provides For all types of gearbox, 5th and 6th gears are overgeared up.
six forward speeds and one reverse speed by means of a
The reverse gear has a ratio that is greater than the first gear
hydrodynamic torque converter, two clutches, three brakes
that allows a better speed control on slopes.
and tree crown wheels.
Figure 1
ALLISON AUTOMATIC GEARBOX 61402

Clutches are pressure—balanced on both piston sides to pro- The torsional forces emitted by the engine are absorbed due
long the clutch life and for a more accurate control on the to the clutch/damper lockup so that they are not transmitted
whole range of gearbox gears. to gears and the remaining parts of the transmission. The wide
Planetary gears always being engaged are of the helical teeth lockup operation reduces fuel consumption and improves
type to allow a more silent gearbox operation. braking efficiency.
The hydrodynamic torque converter, in addition to being Both gearboxes are equipped with the power takeoff gear. (5
mandatory for vehicle start—up, allows a gearbox operation — Figure 2).
without shakes reducing wear of members composing the ve- The power takeoff can be installed on the left or on the right
hicle kinematic chain. side of the converter box (8 — Figure 3; 3 — Figure 4).
Figure 2
52001
ALLISON MD 3060 P AUTOMATIC GEARBOX

1. Exclusion clutch/torsional damper lockup — 2. Converter turbine — 3. Converter pump — 4. Converter box —
5. Power takeoff gear — 6. Front support — 7. Clutch box — 8. Clutch — 9. Main box — 10. Brake — 11. Front planetary gear —
12. Brake — 13. Central planetary gear — 14. Brake — 15. Rear planetary gear — 16. Rear cover — 17. Output shaft —
18. Main shaft — 19. Hydro—electric controls — 20. Clutch — 21. Oil pump — 22. Oil pump driving stub —
23. Front support sleeve — 24. Converter distributor — 25. Turbine shaft.

Figure 3
52003
MD 3060 P AUTOMATIC GEARBOX REAR RIGHT VIEW

1. Assembly pads — 2. Output speed sensor — 3. Exchanger arrangement — 4. Main pressure inlet — 5. Identifying plate —
6. Electric gearbox wiring connector — 7. Engine revolution sensor — 8. Power takeoff connection (available on both sides) —
9. Exhaust.
Figure 4
52004
MD 3060 P AUTOMATIC GEARBOX FRONT LEFT VIEW

1. Start—up crown — 2. Front torque converter cover — 3. Power takeoff connection (available on both sides) —
4. Main power takeoff — 5. Oil filling pipe and level rod (available on both sides) — 6. Assembly pads —
7. Electric gearbox wiring connector — 8. Exhaust

Gear selection is controlled by an electronic transmission con-

trol system with a microcomputer.
The closed—loop control logic employed by the electronic con-
trol system allows the transmission to adapt to changes in the
load, terrain or ambient conditions and to automatically com-
pensate for fluctuations in engine power output and for com-
ponent wear.
Electronic sensors provide information about the throttle posi-
tion, the driving range selected by the driver, the engine speed
and the turbine speed, the transmission output shaft speed and
the various system pressures.
CHARACTERISTICS AND DATA
ALLISON
TRANSMISSION
MD 3060 P
Type Automatic
Forward runnings
6 forward gears and 1 reverse gears
Reverse running
Power take—off Optional
Gears With always—engaged helical teeth
Gear ratios (:)

First 3.49
Second 1.86
Third 1.41
Fourth 1.00
Fifth 0.75
Sixth 0.65
Reverse 5.03
Type of oil Tutela GI/A
Quantity (28 litres)
(:) The gear ratio does not include torque converter gearing up

MAIN OPERATION ANOMALIES

This paragraph lists main operation anomalies that are not 4— The gearbox does not insert a specific selection;
identified by a diagnostic code. 5— The gearbox does not correctly perform the selections;
For every problem, causes and related remedies are shown. 6— No response from gear selector;
7— Clutch slippage and vibration in all ranges;
8— Low main pressure in all ranges;
NOTE For the search of failures through a diagnostic code, 9— Low lubrication pressure;
refer to section ”Electric/electronic system” of 10 — Overheatings in all ranges;
”Allison automatic gearboxes” Manual. 11 — Some oil emerges from filling pipe and/or exhaust;
12 — Intermittent noises (hum);
13 — Oil leakage from output shaft;
14 — Dirty oil.
The operation anomalies being examined in this section are as
follows:
1 — The vehicle fails to start (engine is not started up);
2 — The gearbox does not perform forward range or reverse
gear selections (it remains idle);
3 — The gearbox does not remain in forward gear or in rever-
se gear;
THE VEHICLE FAILS TO START

1
(ENGINE DOES NOT START)
Selector lever not in neutral. Select N (neutral) and try again.

YES
NO
Battery discharged. Recharge the battery.

YES
NO
Battery disconnected. Connect the battery

YES

THE GEARBOX DOES NOT PERFORM

FORWARD RANGE OR
2 REVERSE GEAR SELECTIONS
(IT REMAINS IDLE)
Engine idle speed too high. Adjust engine idle speed to between 500 and 800 rpm.
YES
NO
Fluid level low. Top up fluid to correct level.

YES
NO
Connectors loose or dirty. Connect or clean.

YES
NO
Speed sensors faulty. Replace speed sensors.

YES
THE GEARBOX DOES NOT REMAIN IN

3 FORWARD GEAR OR IN
REVERSE GEAR
Fluid leaking from solenoid valve unit. Overhaul the solenoid valve unit.
YES
NO
Faulty solenoid valve. Replace solenoid valve.

YES

THE GEARBOX DOES NOT INSERT A

4
SPECIFIC SELECTION
Incorrect fluid level. Adjust fluid level.

YES
NO

YES
NO
Fluid temperature sensor faulty. Replace fluid temperature sensor.

YES
THE GEARBOX DOES NOT CORRECTLY

5 PERFORM THE
SELECTIONS
Engine idle speed too high. Adjust engine idle speed to between 500 and 800 rpm.
YES
NO

YES
NO
Speed sensors loose. Tighten speed sensor mounting bolts.

YES
(To be continued)


YES
NO
Solenoid valves stuck or blocked. Overhaul valve block. Replace defective valves.
YES
NO RESPONSE FROM
6 GEAR SELECTOR

YES
NO
Line pressure low. See point 8.

YES
NO
Solenoid valves stuck or blocked. Overhaul valve block. Replace defective valves.
YES

CLUTCH SLIP AND VIBRATION

7 IN ALL RANGES
Incorrect signals from speed sensors. Replace the speed sensors.

YES
NO

YES
NO

YES
LOW LINE PRESSURE IN ALL

8 RANGES

YES
NO
Line filter clogged. Replace filter.

YES
NO
Intake filter blocked or faulty. Clean or replace intake filter.

YES
NO
Leaks from control module. Replace seals. Tighten any loose screws.
YES

LOW LUBRICATION PRESSURE

9

YES
NO
Lubrication filter clogged. Replace filter.

YES
OVERHEATING IN ALL RANGES

10
Air in fluid. Incorrect fluid level. Adjust fluid level.

YES
NO
Temperature sensor inaccurate. Replace temperature sensor.

YES
SOME OIL EMERGES FROM FILLING

11
PIPE AND/OR EXHAUST
Dipstick cap loose or worn. Tighten dipstick cap.

YES
Replace dipstick if necessary.
NO
Fluid level too high. Drain off fluid to obtain correct level.
YES
(To be continued)

Breather clogged. Clean or replace breather.

YES
12 INTERMITTENT NOISE (BUZZING)
Fluid level low. Top up to correct level.

YES
NO
Air entering system through fluid intake filter cartridge. Replace filter cartridge.
YES
NO
Fluid filters clogged. Replace fluid filters.

YES
NO
Air in fluid causes noisy operation of pump. Adjust fluid level.

YES
NO

YES

13 OIL LEAKAGE FROM

OUTPUT SHAFT
Seal in output flange faulty or missing. Fit a new seal.

YES
NO
Bolts of output flange loose. Tighten output flange bolts.

YES
NO
O—ring of flange retaining plate damaged or missing. Replace flange retaining plate O—ring.
YES
14 DIRTY OIL
Fluid and filters require changing. Change fluid and filters.

YES
NO
Overheating. See point 10.

YES
NO
Fluid filters/seals damaged. Replace filter/seals.

YES
NO
Inferior quality fluid. YES Use recommended fluid.

TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Screws securing converter box to engine 49 to 58 (4.9 to 5.8)
Screws securing adapter — flexible plate 34 (3.4)
Hose fittings for gearbox—exchanger connection 54 to 68 (5.4 to 6.8)
Connection ring nut of external wiring to electric gearbox connector 2 to 3 (0.2 to 0.3)
Screws securing control module to gearbox 57 to 68 (5.7 to 6.8)
Oil filter covers screws 51 to 61 (5.1 to 6.1)
Oil drain plug 25 to 32 (2.5 to 3.2)
Turbine speed sensor securing screw 12 to 14 (1.2 to 1.4)
Engine revolution sensor securing screw 30 to 35 (3 to 3.5)
Output speed sensor securing screw 30 to 35 (3 to 3.5)
Suction filter cover securing screw 12 to 14 (1.2 to 1.4)
Screw securing valve bodies to control module 12 to 14 (1.2 to 1.4)
Screws connecting pressure switch to valve body 5 to 8 (0.5 to 0.8)
Electronic gearbox connector screws 5 to 7 (0.5 to 0.7)
Pressure plugs on gearbox bottom 10 to 13 (1 to 1.3)
Output flange screws 30 to 35 (3.0 to 3.5)
Vent 12 to 16 (1.2 to 1.6)
TOOLS
99360322 Engine flywheel rotation tool
Gearbox bearing support during vehicle disconnection and

99370629
re—connection
99374013 Keying device for sealing ring assembly

Figure 5
52121
DIAGRAM SHOWING CONNECTION BETWEEN TRANSMISSION AND ENGINE

1. Engine flywheel — 2. Spacer — 3. Crankshaft — 4. Connection plate — 5. Transmission — 6. Connection plate adapter —
7. Converter housing — 8. Coupling flange — 9. Flywheel housing.

Print 603.43.671/A
REMOVAL/REFITTING (ALLISON) Figure 6

GEARBOX
Arrange vehicle on pit; if a pit is not available, arrange

! vehicle on proper hoists.
Disconnect the electric system.
Drain the cooling system.
Removal
- Lift the cowling and tilt the cab. Disconnect connections

(15) from the bracket on the gearbox;
- Disconnect the electric connection which is indicated in
figure (→) and release all gearbox electric cables, which
are constrained to the vehicle, from any clamps.
- Operate on clamp (17) to release piping (16) from
bracket (18).
- Operate on clamp (20) to release piping (19) from
gearbox.
- Loosen collar (12), remove pipe (13) after taking off
screws (11) and (14).
- Dismount support (7) operating on screws (4) and
recover U bolt (3).
- Loosen collar (5), remove sleeves (6).
- Release bracket (2) from gearbox operating on fasteners
securing the bracket to gearbox and U bolt (1), and
remove the bracket.
- Disconnect oil piping (8) from pump (10) operating on
fitting (9) and properly tie the piping to gearbox.
- Prearrange, under the gearbox, a special tool with a
hydraulic hoister and tie the gearbox to the hoister with
a rope.
91370

Set the gearbox apart from the engine operating on starter Figure 7
side and going on as below:
- remove cover (6) on flywheel box (4) and position tool
(5) at hole (10).
- Remove cover (8) on flywheel box (4) taking off screws
(7).
- Rotate flywheel (11) via tool (5), then unscrew screws
(12) operating through hole (9), these screws joining the
gearbox to engine flywheel via connection disk (13).
- Release oil filling up pipe (14) from vehicle.
- Unscrew all gearbox bell—shaped container securing
nuts (3).
- Disconnect transmission shaft (2)
- Slowly withdraw gearbox towards vehicle rear side and,
by properly handling the hoister, take gearbox off its own
seat paying attention to possible interference with the
vehicle.
Refitting
For reconnecting the gearbox, properly invert operations

described on disconnection. Recover coolant and bleed.
91363

Print 603.43.671/A

GEARBOX CONTROL MODULE AGAIN
Removal NOTE The below—described repair interventions deal only
with replacement of faulty components: for possible
Figure 8 diagnostics information pertaining there to, refer to
Section ”Electric/electronic system” of ”Allison auto-
matic gearboxes” Manual (printout No.
603.42.409).
REPLACING SPEED SENSORS

Replacing turbine speed sensor
Figure 9
52063
Position vehicle on a bridge.

Drain gearbox oil at operating temperature (71º ÷ 93ºC) re-
moving the drain plug (2) of the control module (1). After hav-
ing discharged the oil, re—assemble the plug (2) with a tighten-
ing torque equal to 25 ÷ 32 Nm.
52064
Disassemble oil filter covers (3) by unscrewing the 12 screws
securing the gearbox control module. Remove filters and ga-
skets. To replace turbine speed sensor (2), disassemble gearbox
Disconnect the electric connector connecting external wiring control module complying with the previously described pro-
to gearbox. cedure.
Hold gearbox control module with a proper hydraulic jack fit- Disconnect wiring from sensor (3).
ted with a support (module weighs 25 kg.).
Unscrew all the screws securing the gearbox control module Unscrew the two screws (1) connecting sensor to valve ca-
to the main box. sings.
By adequately operating, remove control module from gear- Install the new sensor by tightening screws (1) to a torque of
box compartment. 12 to 14 Nm.
Connect wiring (3) to sensor.
Refitting Assemble gearbox control module again according to the pre-
viously described procedure.
To assemble gearbox control module, properly reverse ope-

rations described at disconnecting.
Comply with torque shown in table on page 177.
At the end of assembly check whether oil drain plug is well
tightened, then introduce 30 litres of Tutela GI/A oil through
filling pipe.

Engine revolutions sensor replacement REPLACING OIL LEVEL SENSOR
Figure 10 Figure 12
52067
52065
To replace oil level sensor (1) disassemble gearbox control
Disconnect wiring (3) of engine revolution sensor (2). module according to the procedure described in this Section
on page 179.
Remove sensor (2) by unscrewing the screw securing it to
converter cover (1). Disconnect wiring from sensor (1).
Install the new sensor by tightening the stop screw to a torque Unscrew screws (2) an d remove sensor.
of 30 to 35 Nm. Install the the new sensor by tightening the connecting screws
Connect wiring (3) to sensor. according to the prescribed torque.
Connect wiring to sensor (1).
Assemble gearbox control module again according to the
Replacing the output speed sensor procedure described in this Section on page 179.
Figure 11
52066
Disconnect wiring (3) from output speed sensor (2).

Remove sensor (2) by unscrewing the screw securing it to the
rear cover (1).
Install a new sensor by tightening the stop screw to a torque
of 30 to 35 Nm.
Connect wiring (3) to sensor.

REPLACING OIL SUCTION FILTER REPLACING THE SOLENOID VALVES
Disassemble gearbox control module according to the

Figure 13 procedure described in the present Section on page 179.
Figure 15
52068
Disassemble gearbox control module according to the

procedure described in this Section on page 179. 52070
Disassemble filter cover (1) by unscrewing the screws securing a) Solenoid valves (1), (2) and (3) belong to the N/C type
it to oil sump (2). (Normally Closed). To operate on these solenoid valves
disconnect the wiring corresponding to the valves and
disassemble valve casings (6) from the gearbox control
Figure 14 module by unscrewing the screws connecting it to the oil
sump (4).
b) Solenoid valves (9) and (11) belong to the N/O type
(Normally open); solenoid valve (10) belongs to the N/C
type (Normally Closed). For operating on these solenoid
valves, disconnect the wiring corresponding to the differ-
ent valves and disassemble valve casings (7) from the
gearbox control module by unscrewing the screws con-
necting it to the oil sump (4).
c) To replace solenoid valve (8) (N/C type), disconnect
wiring from all the solenoid valves and disassemble valve
casing (6) and (7), by unscrewing the screws securing
them to the oil sump (4). Remove separating plate divid-
ing valve casings (6) and (7) from valve casing (5): Re-
move casing (5) from gearbox control module.
In the three case (a, b, c) proceed as follows with replacing the
52069 failed solenoid valve after disassembling the valve casing
containing it:
Remove cover (1) and replace filter (2), gasket (3) and seal (4). - Remove the pin securing the solenoid valve from the
Install cover (1) and tighten securing screws to a torque of 12 valve casing bottom.
to 14 Nm. - Remove the failed solenoid valve from the valve casing.
Assemble gearbox control module again according to the - Install the new solenoid valve with the two O—rings in the
procedure described in this Section on page 179. kit.
- Use the pin to lock the solenoid valve.
After replacing the solenoid valve assemble the solenoid valve
casings again by properly reversing the operations described
in items a, b, c, and tighten screws to a torque of 12 to 14 Nm.
Re—assemble the control module according to the procedure
described in the present Section on page 179.

REPLACING PLANE GASKETS IN GEARBOX CONTROL MODULE

Figure 16
52071
Disassemble the gearbox control module according to the - Disassemble the oil level sensor (4);
procedure described in this Section on page 179.
- Disassemble the valve casings (5), (6), (7);
The control module is connected to the main gearbox box by
- Remove the separating plate (3);
interposing a plane gasket (1), that can be replaced once having
disassembled the control module. - Replace the worn out gasket with a new one and position
it on oil sump (2) with the help of guiding pins (11);
There is second plane gasket interposed between the oil sump
(2) and the separating plate (3) on which the control module Assemble the control module again by properly reversing the
components are laying. above mentioned operations.
To replace this last gasket, proceed as follows after disassem- Comply with torque shown in table on page 177.
bling the control module from the remaining part of the gear-
Connect control module again to the main gearbox seat com-
box:
plying with the procedure described in this Section on page
- Disconnect all the internal wiring connectors (10); 179.
- Disassemble electric connector (8) from control module;
- Disassemble the oil suction filter (9);

REPLACING PRESSURE SWITCH F3 REPLACING THE SEAL RING ON THE

OUTPUT SHAFT
Figure 17
Figure 18
52074
52072
Disconnect the transmission shaft from gearbox flange (2).

Unscrew screws (1) connecting securing plate (3) to the
gearbox output shaft.
Remove the safety plate, the securing plate, the O—ring and
the gasket.
Disassemble the control module according to the procedure
described in this Section on page 179. Remove flange (2) from the rear cover (4) and use a proper
tool to remove the seal ring.
Disconnect connector (2) in pressure switch (1).
Clean the seal ring seat and remove any slag present.
Remove pressure switch (1) by unscrewing the two screws
connecting it to valve casing (3). Replace the seal ring and the O—ring. Use keying device
99374013 to insert the seal ring in its seat.
Install the new pressure switch and use the O—ring in the kit.
Assemble gearbox flange again by properly reversing the
Tighten the securing screws to a torque of 5 to 8 Nm. above mentioned operations.
Connect the pressure switch connector again. Tighten screws (1) to a torque of 30 to 35 Nm.
Assemble the control switch again according to the procedure Connect the transmission shaft to the gearbox again.
described in this Section on page 179.


EUROCARGO TECTOR 12—26 t GEARBOX EATON FSO 5206B 187
Print 603.43.671/A
5302 Gearbox
EATON FSO 5206B
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 189
POSITION OF GEARSHIFT IDENTIFICATION TAG 190
- Gear selection and engagement grid . . . . . . . . 194

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
REMOVAL/REFITTING (EATON FSO5206B)

GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . 203
GEARSHIFT OVERHAUL . . . . . . . . . . . . . . . . . . 204
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
GEAR DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . 204
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 204
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
- Disassembling the gearbox . . . . . . . . . . . . . . . 208
MOTION INLET SHAFT . . . . . . . . . . . . . . . . . . . 211
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 211
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 211
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 211
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
INTERNAL DRIVING SHAFT . . . . . . . . . . . . . . . 219
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 219
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
- Gearbox assembling . . . . . . . . . . . . . . . . . . . . 221
- Adjusting the axial play of countershaft bearings 224

188 GEARBOX EATON FSO 5206B EUROCARGO TECTOR 12—26 t

Print 603.43.671/A
DESCRIPTION
The Eaton FSO 5206 B gearshift is of the mechanic type, with The gears force—fitted onto the output shaft and the gear on
synchronized forward gear engagement. the reverse gear shaft rotate idle on cylindrical roller cages.
The gearbox is made of light alloy and is made up of a front The motion inlet shaft and the output shaft are supported, in
half case, a rear half case (which incorporates the gear the gearbox, by non—adjustable roller bearings.
engagement gearing and controls), a drive case and a clutch
The countershaft is supported, in the gearbox, by
bell.
tapered—roller bearings that can be adjusted axially by means
The rear half case has, on its sides and rear portions, special of ring shims.
openings for insertion of power takeoffs (where required).
Gear engagement synchronization is obtained by means of
Motion is transmitted by means of a constant—mesh gear set free—ring synchronizers with single cone (for 5th, 4th, 3rd
with helicoidal teeth (for 6th/5th — 4th/3rd speeds) and straight speeds and reverse) and double cone (for 1st and 2nd speeds).
teeth (for 1st speed and reverse).
The gear engagement and selection control is of the mechanic
type and is obtained by a rod on which the three engaging
forks and the 4th — 5th speed engagement fork control block
are force—fitted.
Figure 1
84438

POSITION OF GEARSHIFT IDENTIFICATION TAG

Figure 2
KZ
84439
Type of transmission Design no.

FSO 5206 H Y 05172
FS Standard code The gearbox design number is unique to each
O Overdrive customer and provides accurate information on the
5 Rated torque, x 100 lb ft (foot—pound) gearbox design level. The number must be specified
2 Series 1 when ordering spare parts.
06 Number of forward speeds The middle digit indicates the design level.
H Type of specific ratio


GEARBOX Eaton FSO 5206B
Type Mechanical
6 forward gears
Gears
reverse gear
—1, On rear part

Power takeoff (optional)
—1, On side part
Gears engagement:
- 5th — 6th / 3rd — 4th Double—cone synchronizer
- 1st — 2nd Free—ring synchronizer
Gears anti—disengagement Retention of sliding sleeves by means of

— 1st — 2nd springs, pins, balls and dowels
— 3rd — 4th / 5th — 6th springs, pins and rollers
Gears constant—mesh
— 1st — 2nd straight teeth
— 3rd — 4th / 5th — 6th helicoidal teeth
Gear ratio
First 6.08
Second 3.52
Third 2.09
Fourth 1.35
Fifth 1.00
Sixth (overdrive) 0.79
Reverse gear 5.43
Amount 6.5 Kg. (7 lt)


Output shaft
Output shaft bearings cylindrical roller type
Assembling temperature:
— fixed hubs
— bushings 85oC
— bearings
— motion outlet flange
Gear axial play:
— 1st speed 0.40 to 0.57
— 2nd — 3rd — 4th speeds 0.35 to 0.48
— 5th — 6th speeds 0.31 to 0.53
Play, in the seat, of fixed hub retaining
as near to zero as possible
snap rings
Fixed hub retaining snap ring thickness
Motion inlet shaft
Motion inlet shaft bearing cylindrical roller type
Motion inlet shaft bearing 85oC
Play, in the seat, of bearing retaining snap

rings
Bearing retaining snap ring axial play

adjusting ring thickness mm 3.70 — 3.75 — 3.80 — 3.85 — 3.90 — 3.95
Countershaft
Countershaft bearings tapered—roller type
Countershaft bearing assembling

85oC
temperature
Countershaft bearing axial play adjustment by means of shims
Play, in the seat, of bearing retaining snap

rings
2.12 — 2.07 — 2.02 — 1.97 — 1.92 — 1.87 —

Bearing retaining snap ring thickness
1.82 — 1.77


Countershaft
Bearing axial play:
— new 0.075 to 0.125
— used 0.00 to 0.05
Countershaft bearing preload adjustment By means of rings
Countershaft preload adjustment rings mm 0.051 — 0.127 — 0.254 — 0.508 — 2.40

thickness Supplied in special kits
Countershaft gear assembling

150oC
temperature
Synchronizers
Synchronizing ring wear limit check
0.5 to 1.9
dimension mm
LOCTITE sealant:
— for mating surfaces between cases and
5900
covers
— matching body on motion inlet shaft 648

Gear selection and engagement grid

Figure 3
Plain grid with idle between the 3rd and 4th speeds.
Diagram of motion transmission with the various speeds.
84440
84441

TIGHTENING TORQUES
Figure 4
84442
TORQUE
PART
Nm (kgm)
1 Screws fastening the clutch bell to the front case 69 ÷ 78 6.9 ÷ 7.8
2 Screws fastening the cover to the case 35 ÷ 39 3.5 ÷ 3.9
3 Screw fastening the 6th — 5th speed fork trunnions 20 ÷ 24 2 ÷ 2.4
4 Oil level check cap 32 ÷ 37 3.2 ÷ 3.7
5 Screws or nuts for the screws fastening the front half case to the rear half case 51 ÷ 58 5.1 ÷ 5.8
6 Screws fastening the cover to the half case 35 ÷ 39 3.5 ÷ 3.9
7 Reverse light switch 16 ÷ 22 1.6 ÷ 2.2
8 Screw fastening the small cover to the case 20 ÷ 24 2 ÷ 2.4
9 Screw fastening the small cover to the gearbox drive case 20 ÷ 24 2 ÷ 2.4
10 Neutral gear switch 16 ÷ 22 1.6 ÷ 2.2
→ Apply LOCTITE 518 on the mounting surface
NOTE Apply Loctite 641 on all threads (unless otherwise specified).

Figure 5
84443
TORQUE
PART
Nm (kgm)
1 Screw fastening the cover to the case 69 ÷ 78 6.9 ÷ 7.8
2 Screws fastening the cover to the case 69 ÷ 78 6.9 ÷ 7.8
3 Oil drain cap 32 ÷ 37 3.2 ÷ 3.7
4 Odometer revs sensor 16 ÷ 22 1.6 ÷ 2.2
M8 20 ÷ 27 2 ÷ 2.7
5 Screw for securing fork control rod hub M10 35 ÷ 39 3.5 ÷ 3.9
6 Locknut fastening the motion outlet flange to the output shaft 490 ÷ 588 49 ÷ 58.8
7 Screws fastening the gearbox drive case to the front case 35 ÷ 39 3.5 ÷ 3.9
8 Screws fastening the side cover to the gearbox drive case 20 ÷ 24 2 ÷ 2.4
Tapered screw fastening the selector block to the gear control rod; apply LOCTITE 242 on the
•
thread 35 ÷ 39 3.5 ÷ 3.9
→ Apply LOCTITE 518 on the mounting surface
NOTE Apply Loctite 641 on all threads (unless otherwise specified).

TOOLS


TOOLS
99341015 Clamp
99341023 Holds
99341025 Holds

TOOLS
99348004 Universal extractors for interiors 5 to 70

TOOLS

re—connection
99370007)

Print 603.43.671/A
REMOVAL/REFITTING (EATON FSO5206B) Figure 6

GEARBOX
Arrange vehicle on pit, locking it with chocks, or on

! proper hoists.
Disconnect the electric system.
Removal
- Lift cowling and cab. Disconnect electric connections (3)

and (11) respectively positioned on control turret and
close to motion output flange and release electric wiring
harness from any clamps.
- Dismount bracket (13) from gearbox operating on
fasteners (12);
Note: Write down the mounting position of lever (4) on
shift control stem and perform following disconnection
operation:
- Loosen securing screw (6) and take shift control lever
(4), complete with reaction tie rod (5), off the gearbox.
- Release pipe (1) from the gearbox operating on clamp
(2).
- Release pipe (14) disconnecting bracket (16) from the
gearbox by fasteners (15).
- Operating from under the gearbox, disconnect master
cylinder (8) by fasteners (7) and properly tie it to the
chassis in such a way that it does not interfere during
gearbox dismounting operation.
- Prearrange, under the gearbox, a special hoist equipped
with support 99370629.
- Disconnect transmission shaft (9) operating on fasteners
(10) and properly tie it to the chassis.
- Unscrew all bolts (17) securing gearbox bell—shaped
container to engine crankcase.
- Slowly withdraw gearbox towards vehicle rear side and,
by properly handling the hoister, take gearbox off its own
seat paying attention to possible interference with the
vehicle.
Refitting
For reconnecting the gearbox, properly invert operations

described on disconnection.
91371


Print 603.43.671/A
EXPERIMENTAL TOOLS
This chapter illustrates the technical working drawing of the experimental tools (S.P. 2413) used in the gearshift overhaul described
in this section, which can be manufactured by the repair workshop operators themselves.

530210 GEARSHIFT OVERHAUL Disassembling

Figure 8
NOTE The unit must be washed thoroughly prior to
overhauling. The specific and/or general equipment
must be used for the purpose for which they are
intended. The disassembled parts must be put in the
special container by following the disassembling
sequence, in order to facilitate re—assembling.
Upon re—assembling, the parts must always be
replaced with new ones: the gaskets and seal rings,
elastic pins, safety snap rings and springs. The nuts
and screws must be tightened to the specified
torque, and their threads must be dry, degreased
and spread with LOCTITE 641. The lubricant and
detergents must be disposed of in compliance with
the specific regulations in force.
Overhaul operations must be carried out by means
of the specific tools indicated. On disassembling,
parts must be put aside by following the 84445
disassembling sequence, to facilitate later
re—assembling. If no reference mark is found on rod (2), mark the assembling
position of lever (4).
Loosen screw (1) and remove lever (4).
Checks Remove sleeve (3).
The gears, synchronizing rings, matching bodies and
engagement sliding sleeves must not show faults or excessive
tooth wear. Figure 9
The output shaft must be free from dents, especially on the
gear roller cage rotating surface.
The reverse speed idler gear shaft surface must be smooth and
free from scoring.
The gearbox half cases must not show cracks and the bearing
seats must not be damaged nor worn, to prevent the bearing
outer races from rotating in the seats.
Verify that the shoulder spacers are not damaged nor worn.
The gear engaging forks must not show cracks and must slide
freely, yet with no notable play, on the control rod.
Verify that the control forks are in full working order.
Verify that the bearings and bushings are not worn, damaged
or overheated. 84446
Remove the neutral gear signalling switch (3) with cap (2)
530220 GEAR DRIVE CASE below and oil vapour vent (1).
Figure 7
Figure 10
84444
Use ropes, hooks and a hoist to position and secure gearbox

(1) on support 99322225 (5) of rotary stand 99322205 (4). 84447
Put the gear lever in neutral.
Remove screws (2) and take gear drive case (3) off the Remove screws (1) and take off small cover (2) with gasket
gearbox. (5). Take out spring (3) and pin (4).

Figure 11 Figure 14
84448
Remove screws (2), take off cover (1) and bracket (3).
84451
Remove cap (1), with punch (6), take off plug (2) linking
selector (5) to rod (4).
Figure 12
Figure 15
84449
84452
Remove snap ring (5) and take collar (4), springs (3 and 2) and
Take note of the assembly position of selector (2) on rod (3).
collar (1) off rod (6).
Take rod (3) out of case (1) and selector (1), then remove the
latter.
Figure 13
Assembling
Figure 16
84450
84453
Remove snap ring (1) from rod (2).
Use a suitable beater and coupler to replace, where necessary,
bushings (2 and 3) and seal ring (4). Gasket (1) must be
replaced only if it is damaged.

Figure 17 Figure 19
84454
Place selector (3) in case (1) in the same position taken note 84456
of upon disassembling, then insert rod (4) and link with plug
(2). Fit a new seal ring (3) on cover (4), then mount the same with
a new gasket (2) and bracket (6) on case (1). Fasten the screws
by means of washers (5) and tighten them to the specified
torque.
NOTE When removing plug (2), properly support rod (4)
to prevent blows caused by ramming from affecting Figure 20
the case bushings.
Figure 18
84447
Insert pin (4) and spring (3) into the case.

Mount small cover (2) with a new gasket (5), then fasten
screws (1) to the specified torque.
Figure 21
84455
Mount snap ring (1), cup (3), springs (4 and 5), cup (6) and
snap ring (7) on rod (2).
NOTE Fit new snap rings.
84446
Insert cap (2) in the case, then fasten switch (3) by tightening
it to the specified torque. Fasten vent (1) and tighten it to the
specified torque.

Refitting
Figure 22 Figure 23
84445
84457
Fit a new sleeve (3) onto the case.
Mount lever (4) on rod (2) so that the assembly reference Fit the gear drive case (2) back to the gearbox, then tighten
marks match one another. Fasten screw (1) to the specified the screws to the specified torque.
torque.
NOTE The seal gasket placed in the case must be replaced

only if it is damaged.
Figure 24
84458
PARTS MAKING UP THE GEAR DRIVE CASE.

Disassembling the gearbox

Figure 25 Figure 28
84459 84462
Stop rotation of flange (1) by applying lever 99370317 (2) to Take off arbor (2) by means of striking extractor 99340205
the same, then remove retaining nut (3). (1).
Remove reverse gear (4) complete with shoulder rings (3),
roller bearings (5) and spacer ring (6).
Figure 26
Figure 29
84460
Take flange (3) out of the output shaft by means of an

extractor made up of bridge 99341003 (1) and brackets 84463
99341017 (2) applied as shown.
Turn the gearbox upside down.
Eject the elastic pin by means of a suitable punch (4).
Figure 27 Remove protecting cap (6). Use a punch and take, by acting
in the direction of the arrow, arbor (5) out of clutch bell (1)
and fork (3), then remove the latter.
Remove screws (2) and take clutch bell (1) off the front case.
84461
Place the gearbox in a vertical position.

Remove screws (1) then take off cover (2).
Remove small cover (3) and snap ring (4) below.

Print 603.43.671/A
Figure 30 Figure 33
84464
Remove screws (1) and take off cover (2), spacer (3) and 84466
adjusting ring (4). Remove screws (1), take off small cover (2) with gasket (3),
Remove screws (6) and take off cover (5). then take out spring (4) and pin (5).
Figure 31 Figure 34
84467
84465
Remove screws (1) with the washers and take out fork
Remove snap ring (2) retaining bearing (4) to the motion inlet trunnions (2) complete with seal ring (3).
shaft (1), then remove spacer (3). Take note of the position of screws (7) and screws with nuts
(4), then remove them. Take front half case (5) off rear half
case (6).
Figure 32
Figure 35
84457
84468
Put the gearshift in neutral.
Remove screws (1) and take gear drive case (2) off the Remove fork (2) complete with dowels (1) from sliding sleeve
gearbox. (4) and selector (3).

Figure 36 Figure 38
84471
Remove phonic wheel (1), spacer (2) and ring (3) of roller
84469 bearing.
Secure output shaft (2) with a rope, then lift it by about 20 mm Figure 39
by means of a hoist so as to be able to move away countershaft
(1) and remove the motion inlet shaft (3) and the underlying
synchronizing ring and the roller bearing.
NOTE This operation must be performed with the greatest

care to prevent the ends of output shaft (2) and of
fork supporting shaft (4) from jamming in the
relevant bearing or support bushing.
Take output shaft (2) out of the rear half case,
remove fork supporting shaft (4) from the output
shaft, then place both shafts on a suitable container.
Remove countershaft (1).
84472
Remove screws (1), take off cover (2) and remove spacer (3).
Figure 37 Figure 40
84473
Remove the following items from rear half case (5): bushing
(4) supporting the fork supporting shaft, the tapered—roller
84470
bearing outer race (1) and roller bearing outer race (2).
Turn rear half case (4) upside down.
Remove revs sensor (3). NOTE When removing outer race (2), pay attention to the
Remove screws (2) and take off cover (1). possible escape of rollers (3) of the same from their
own seat.
Repeat the same operations on the front half case.

MOTION INLET SHAFT

Disassembling
Figure 41
84474
PARTS MAKING UP THE MOTION INLET SHAFT

1. Snap ring — 2. Spacer ring — 3. 4. 5. Cylindrical roller bearing — 6. Motion inlet shaft — 7. Matching body
Use ordinary tools to take the cylindrical roller bearing inner

race (5) and matching body (7) off the motion inlet shaft (6).
Assembling
Heat roller bearing inner race (5) to ~ 85 °C, then Figure 42
fit it onto motion inlet shaft (6).
Apply LOCTITE 648 on inner teeth (→) of matching
body (7), then mount the latter onto motion inlet
shaft (6).
OUTPUT SHAFT
Disassembling
NOTE All snap rings are provided with replacement parts

of different thickness in order to obtain correct
assembly play. Snap rings must be disassembled and
re—assembled with care so as not to score the
output shaft surface.
Prior to taking apart the output shaft, verify that the
axial play of every single gear falls within the
84475
prescribed values.
Take note of the assembling position of
synchronizers — matching bodies, hubs and sliding Take 5th — 6th gear engagement sliding sleeve (2) off hub (1);
sleeves, so as to be able to fit them back in the same pay attention to the escape of rollers (3), pins (4) and springs
positions. (5), then recover the same.
Remove snap ring (6).

Figure 43 Figure 46
84476 33628
Remove hub (5) with the synchronizer (6) below, by means Take off snap ring (1).
of an extractor made up of bridge 99341003 (1), brackets
99341019 (2), grips 99341025 (4) and clamp 99341015 (3).
Figure 44 Figure 47
84477 33629
Take off matching body (1), 6th speed gear (2) and roller cage Use an extractor made up of grips 99341023 (4), tie bars
(3). 99341020 (6), bridge 99341003 (1) and clamp 99341015 (5)
Remove snap ring (4). to remove 1st speed gear (3) and fixed hub (2) for reverse
gear.
Figure 45
Figure 48
84478
Turn the output shaft upside down.

Use an extractor made up of bridge 99341003 (1), tie bars
84479
99341019 (7), grips 99341025 (2) and clamp 99341015 (6),
to remove reverse gear (5), shoulder ring (4) and roller Remove matching body (1), inner ring (2), intermediate ring
bearing inner race (3), then take out the roller bearing below. (3), synchronizing ring (4) and roller cage (5).

Figure 49 Figure 51
84480
Take 1st — 2nd gear

engagement sliding sleeve (2) off hub (1);
pay attention to the escape of balls (5), springs (3) and dowels
(4), then recover the same. Remove dowels (6) and take off
snap ring (7).
Figure 50
84482
Turn output shaft (1) upside down. Remove snap ring (2). Use
a hydraulic press to remove 4th speed gear (11), matching
body (10), synchronizing ring (6), synchronizing unit (8),
synchronizing ring (7), matching body (6), 3rd speed gear (5),
roller cage (4) and bushing (3).
84481
Use a hydraulic press to remove 1st speed gear (7) together

with matching body (6), synchronizing ring (3), intermediate Figure 52
ring (4), ring (5) and hub (2) from output shaft (1).
84483
Take 3rd — 4th gear engagement sliding sleeve (2) off hub (1);
pay attention to the escape of hub of rollers (3), pins (2) and
springs (5), then recover the same.

Figure 53
84484
PARTS MAKING UP THE OUTPUT SHAFT

Assembling
Print 603.43.671/A
Figure 54 Figure 56
84485
84487
Check the amount of wear of synchronizing rings by acting as
follows: Heat hub (2) to a temperature of 85°C, then fit it onto output
shaft (1) so that:
NOTE The synchronizing rings must, after inspection, be
marked on their respective matching bodies in order - the higher shoulder faces downwards (see relevant
to avoid exchanging their position when section);
re—assembling. - the narrower openings (3) are inserted into the
synchronizing ring projections (4);
- Visually check that the friction surface is not corrugated. - the wider openings (7) of the hub are aligned with
Rotate synchronizing ring (1) so as to ensure correct match on synchronizing ring openings (5) and inner ring tabs (6).
matching body (2).
Use a thickness gauge (3) to check, on two diametrically
opposed points, the clearance between the two parts.
If the measured value does not fall within the range of 0.5 ÷
1.9 mm, replace the synchronizing ring.
Figure 55
Figure 57
84486
Mount roller cage (2), 2nd speed gear (3) and matching body
(4) on output shaft (1). 84488
Mount inner ring (5) and intermediate ring (6) so that the tabs
are inserted into the matching body (4) slots, then mount Mount snap ring (1), the thickness of which produces axial play
synchronizing ring (7) so that the outer side openings match of the same, into its own seat (2), as near to zero as possible.
with ring (5) inner tabs. Check axial play of 2nd speed gear (2), which must fall within
the range of 0.35 ÷ 0.48 mm.

Figure 58 Figure 60
84509
84480
Lubricate roller cage (3), then fit it onto output shaft (1).
Mount sliding sleeve (2) on hub (1) by turning it in the Mount 1st speed gear (2).
direction shown in the figure.
Mount dowels (6), springs (3), dowels (4) and balls (5), then
secure them below sliding sleeve (2).
Figure 61
Figure 59
84510
Heat hub (4) to a temperature of ~ 85°C, then fit it onto

84507 output shaft (1).
Mount synchronizing ring (7) so that its projections (8) are Mount snap ring (2), the thickness of which produces axial play
inserted into the narrowest openings of hub (9). of the same into its own seat (3), as near to zero as possible.
Mount inner ring (5) and intermediate ring (3) so that the inner Check axial play of 1st speed gear (5), which must fall within
tabs (4) of the latter match with the outer side openings of the range of 0.40 ÷ 0,57 mm.
synchronizing ring (7).
Mount matching body (1) so that the slots (2) of the same are
inserted in the tabs of ring (5).

Figure 62 Figure 65
84511
Lubricate roller cage (3), then fit it onto output shaft (1) and 33639
mount reverse gear (2). Mount matching body (2) and synchronizing ring (3). Heat hub
(1) to a temperature of 85°C, then fit it onto shaft (4), taking
Figure 63 care that the synchronizing ring tangent stops are inserted into
the respective seats of the hub.
Check axial play of 3rd speed gear, which must fall within the
range of 0.35 ÷ 0.48 mm.
Figure 66
84512
Heat the rear roller bearing inner race (2) to ~ 85 °C, then
fit it onto output shaft (1).
Figure 64
84514
Mount springs (5) and small pins (4) on hub (2). Mount 3rd —
4th gear engagement sliding sleeve (1) on hub (2), then place
the former so that it is slightly lifted compared to hub (2), then
insert rollers (3) between small pins (4) and sliding sleeve (2).
84513
Turn the shaft (placed in the vice) upside down, mount roller
cage (1) and 3rd speed gear (2).

Figure 67 Figure 70
84518
Mount snap ring (1), the thickness of which produces axial play
of the same into its own seat (2), as near to zero as possible.
84515
Mount synchronizing ring (1) so that the tangent stop

Figure 71
projections of the same are positioned in the wheel hub, then
mount matching body (2).
Figure 68
84508
Lubricate roller cage (3), then fit it, together with 6th speed
84516
gear (2), onto output shaft (1).
Lubricate roller cage (3) and insert it into the4th speed gear Figure 72
(2), then mount the same on output shaft (1).
Figure 69
84517
Heat bushing (2) to a temperature of ~ 85°C, then fit it onto

84519
output shaft (1). Check axial play of 4th speed gear, which must
fall within the range of 0.35 ÷ 0.48 mm. Mount matching body (2) and synchronizing ring (1).

Figure 73 Figure 75
84522
Mount springs (5) and small pins (4) on hub (2).

Mount 3rd — 4th gear engagement sliding sleeve (1) on hub (2),
then place the former so that it is slightly lifted compared to
hub (2), then insert rollers (3) between small pins (4) and
sliding sleeve (2).
84520
INTERNAL DRIVING SHAFT
Heat hub (2) to a temperature of ~ 85°C, then fit it onto Disassembling
output shaft (1) taking care that the tangent stop projections
(3) of the synchronizing ring are positioned in the openings of Figure 76
the hub itself.
Check axial play of 6th speed gear (4), which must fall within
the range of 0.31 ÷ 0.53 mm.
Figure 74
84535
Secure the internal driving shaft unit firmly in a vice.
NOTE Mark the assembly position of every single part of

the unit.
Take out gear engagement enable key (4) by turning
84521 the forks in the proper direction.
Take forks (3 — 2 — 1) out of shaft (5).
Mount snap ring (1), the thickness of which produces axial play
of the same into its own seat (2), as near to zero as possible.

Assembling
Figure 77 The internal driving shaft unit is assembled by reversing the
order of disassembling operations.
NOTE Apply LOCTITE 270 on screw thread (3, Figure 77),

then tighten the screw to a torque of 35 ÷ 39 Nm.
84523
Remove screw (3), then take block (1), the selection key (5)
and selector (2) out of shaft (4).
Figure 78
84524
PARTS MAKING UP THE INTERNAL DRIVING SHAFT UNIT

1. Selection key — 2. Shaft — 3. Gear engagement enable key — 4. Selector — 5. 5th — 6th speed control fork — 6. Pads — 7. Block
— 8. Screw — 9. Pin — 10. 3rd — 4th speed control fork — 11. 1st — 2nd speed control fork — 12. Reverse gear control fork.

Print 603.43.671/A
Gearbox assembling
Prior to assembling the gearbox, verify that the half cases and Figure 81
the covers are clean, and that all the gaskets and sealing
materials have been removed from the mating surfaces. When
fitting the fastening screws to the clearance holes, apply
LOCTITE 641 sealant to the threads.
Figure 79
84527
Apply LOCTITE 5900 on cover (2) mating surface, then

mount the cover on rear half case (1).
Tighten fastening screws (3) to the specified torque.
Mount output shaft roller bearing (4).
Figure 82
84525
Use a suitable beater (1) to replace, if necessary, internal

driving shaft bushings (2) and the caps below, the front half
case and rear half case.
NOTE Apply LOCTITE 5900 on the outside of caps, then

mount the latter with their concave side facing the
inside of the half case.
84528
Temporarily mount output shaft rear cover (2) on rear case

Figure 80 (1), then tighten fastening screws (3) to the specified torque.
Figure 83
84526
Use beater 99374092 and handle 99370007 to mount the

tapered—roller bearing outer race (3) into rear half case (1), 84529
so that it is slightly embedded compared to the case plane.
Mount spacer ring (2). Place internal driving shaft (2) onto output shaft (1), then
secure it firmly by means of a suitable rope.

Figure 84 Figure 86
84530
84532
Place countershaft (2) in rear half case (3). Lift the unit (1) thus Mount motion inlet shaft (2) by slightly lifting output shaft (5)
assembled. Apply tool SP. 2413 (4) to the output shaft end, and opening out countershaft (1).
secure it by means of nut (5) and insert it into the rear half case. Remove the rope.
Place fork (4) pads (3) on sliding sleeve (7), then connect fork
While performing this operation, verify that the output shaft
(4) to selector (8) pin.
is inserted into the support bearing, the internal driving shaft
Force—fit tool SP. 2413 (6) onto motion inlet shaft (2).
is inserted into its respective bushing, and that the
countershaft can be matched with the output shaft.
Figure 87
Figure 85
84533
84531
Use beater 99374092 and handle 99370007 to mount the
countershaft tapered—roller bearing outer race (2) into front
Mount synchronizing ring (3) and roller bearing (2) on output half case (1), so that it is slightly embedded compared to half
shaft (1). case (1) outer plane by ~ 5 mm.
Mount cylindrical roller bearing (3) for the motion inlet shaft.

Figure 88 Figure 90
84466
Insert pin (5) with spring (4) into the front half case.
Mount small cover (2) with a new gasket (3). Fasten screws
84538 (1) and tighten them to the specified torque.
Apply LOCTITE 5900 on rear half case (3) mating surface,
then mount front half case (2). Remove tool SP. 2413 (1).
Figure 91
Figure 89
84465
Mount spacer (3) on cylindrical roller bearing (4), then secure

it to motion inlet shaft (1) by means of a new snap ring (2).
Figure 92
84467
Fasten screws (7) and the screws with nuts (4) in the original
assembly position, then tighten them to the specified torque.
Mount a new seal ring (3) on pins (2).
Apply LOCTITE 5900 on the mounting flange of pins (2), then
insert the latter into the front half case so that they fit into the
5th — 6th speed engagement fork seats.
Fasten screws (1) with washers, then tighten them to the
specified torque.
84534
Use coupler 99370349 (2) and handle 99370007 (1) to fit a

new seal ring (3) to motion inlet shaft cover (4).

Figure 93 Figure 95
84541
Loosen screws (1) and fasten them again so as to slightly lock

cover (2).
84539
Use a thickness gauge (4) to measure, at four equidistant
points, the distance ’X’ between cover (2) and front half case
Apply LOCTITE 5900 on motion inlet shaft cover (1) mating (3).
surface, then mount it on front half case (3). The thickness S of adjusting ring (4, Figure 94) is obtained as
Fasten screws (2) and tighten them to the specified torque. follows:
S=A—X+P
Adjusting the axial play of countershaft where:
bearings
A = thickness of the adjusting ring used for measuring;
Figure 94
X = average value of measurements made;
P = bearing preload:
— new bearings 0.075 ÷ 0.125 mm
— used bearings 0.00 ÷ 0.05 mm
After measuring the thickness of the adjusting ring, remove
screws (1) and cover (2).
Choose an adjusting ring from among those supplied as spares,
of the calculated thickness, then mount it in place of the one
used for measuring.
Apply LOCTITE 5900 on cover (2) mating surface, then
mount the cover on half case (3). Apply LOCTITE 641 on
screw (1) threads, then fasten the screws with new safety
washers and tighten them to the specified torque.
84540
Mount adjusting ring (4) (of the greatest thickness among

those of the replacement parts supplied) on tapered—roller
bearing outer race (5), then mount spacer (3).
With the tapered—roller bearing embedded, spacer

! (3) must jut out of half case (6) plane.
Mount cover (2) on half case (6), fasten screws (1) without the
safety washers, tighten them evenly and, at the same time, turn
the motion inlet shaft in both directions of rotation in order
to correctly embed the bearings and feel some resistance
when rotating.

Figure 96 Figure 99
84542
84470
Turn the gearbox upside down. Remove screws (1), take off
cover (2) and remove tool SP. 2413 (3). Apply LOCTITE 5900 on cover (1) mating surface, then
mount the cover on rear half case (4).
Apply LOCTITE 641 on screw (2) threads, then fasten and
tighten the screws to the specified torque.
Figure 97
Mount revs sensor (3) and tighten it to the specified torque.
Figure 100
84543
Take the seal ring off cover (3).

Use coupler 99374201 (1) to mount a new seal ring (2) into
cover (3).
Figure 98 84544
Lubricate the lip of seal ring (4) fitted into the rear cover.
Heat flange (3) to ~ 85°C, fit it onto the output shaft, then
fasten locknut (1) onto the output shaft.
Stop rotation of flange (1) by means of tool 99370317 (2)
applied as shown in the figure.
Fasten nut (1) to the specified torque, then remove tool (2).
84471
Mount roller bearing ring (3), spacer (2) and phonic wheel (1).

84545
84463
Apply a thin coat of grease to roller bearings (3 and 5) and
spacer (4), then fit the roller bearings into gear (6).
Turn the gearbox upside down.
Lubricate shoulder rings (2 and 7), place them into the rear half
Fit back clutch bell (1), then tighten fastening screws (2) to the
case, then mount gear (6). Mount arbor (1).
specified torque.
Place fork (3) on clutch bell (1), then mount shaft (5).
Secure fork (3) to shaft (5) by inserting elastic pin (4). Mount
new protecting caps (6).
Figure 102
Figure 104
84461
Mount a new snap ring (4).

Apply LOCTITE 5900 on small cover (3), then mount the 84457
latter in the rear half case.
Apply LOCTITE 5900 on side cover (2), then mount the latter Fit gear drive case (2) back to the gearbox, then tighten screws
in the rear half case. (1) to the specified torque.
Apply LOCTITE 641 on screw (1) threads, then tighten the
screws to the specified torque. The seal gasket inserted into the case must be
! replaced only if it is damaged.
Manually check the engagement of every single gear.
Mount the oil drain cap and tighten it to the specified torque.
Fill the gearbox with the proper amount of lubricating oil of
the specified type.
Mount the level check and oil filling cap, then tighten it to the
specified torque.

EUROCARGO TECTOR 12—26 t PROPELLER SHAFTS 1
SECTION 5
Propeller shafts
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROPELLER SHAFT LAYOUT ON VEHICLES . 8
PROPELLER SHAFT SPECIFICATIONS

AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 11
SLIDING PROPELLER SHAFT

REMOVAL— REFITTING . . . . . . . . . . . . . . . . 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FIXED PROPELLER SHAFT

REMOVAL— REFITTING . . . . . . . . . . . . . . . . 12
CHECKING PROPELLER SHAFTS ON

VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 PROPELLER SHAFTS EUROCARGO TECTOR 12—26 t

DESCRIPTION
Motion transmission from engine—gearbox to rear axle The front end of the sliding propeller shaft is composed, in
occurs through a propeller shaft that is sliding in a single addition to the universal joint, of a moving grooved sleeve
section or in two sections composed of a fixed front shaft and also, which allows the shaft to modify its length in order to
a sliding rear shaft. dampen possible axial transmission displacements, due to
Coupling between assemblies and shaft is implemented by rear axle oscillations.
universal joints.
Figure 1
72680
VIEW FROM ”A” VIEW FROM ”B”
SLIDING PROPELLER SHAFT OF THE “GKN” TYPE — 120/150 FLANGE
Figure 2
VIEW FROM ”A” VIEW FROM ”B” 72681
SLIDING PROPELLER SHAFT OF THE “DANA” TYPE — 120/150 FLANGE

Figure 3
72682
VIEW FROM ”A”
Figure 4
VIEW FROM ”A” 72683
SLIDING PROPELLER SHAFT OF THE “DANA” TYPE — 150/150 FLANGE

Figure 5
72684
VIEW FROM ”A” VIEW FROM ”C” VIEW FROM ”B”
FIXED PROPELLER SHAFT OF THE “GKN” TYPE — 120/120 FLANGE
Figure 6

72685
FIXED PROPELLER SHAFT OF THE “DANA” TYPE — 120/120 FLANGE

Figure 7
72686
FIXED PROPELLER SHAFT OF THE “GKN” TYPE — 150/120 FLANGE
Figure 8
72687
FIXED PROPELLER SHAFT OF THE “DANA” TYPE — 150/120 FLANGE

Figure 9
VIEW FROM ”A” VIEW FROM ”B”

72688
Figure 10
VIEW FROM ”A” VIEW FROM ”B” 72689
FIXED PROPELLER SHAFT OF THE DANA TYPE

PROPELLER SHAFT LAYOUT ON VEHICLES
Figure 11
72690

PROPELLER SHAFT SPECIFICATIONS AND DATA
PITCH 3105 3330 3690 4185 4455 4815 5175 5670
L L1 L L1 L L1 L L1 L L1 L L1 L L1 L
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
MODEL GEARBOX TYPE min max min max min max min max min max min max min max min max
110/120 EL 17 2855.6 1725 to 1835 985 965 to 1076 1330 990 to 1100 1330 1485 to 1595 1330 1750 to 1860 1630 1740 to 1850 — — — —
110/120 EL 17 2870.9 1540 to 1650 — 1765 to 1875 1140 990 to 1100 1140 1485 to 1595 1140 1750 to 1860 1610 1650 to 1760 — — — —
110/120 EL 21 2865.6 1580 to 1690 — 1810 to 1920 1180 990 to 1100 1180 1485 to 1595 1180 1750 to 1860 1560 1750 to 1860 — — — —
110/120 EL 21 2870.9 1420 to 1530 — 1650 to 1760 1020 990 to 1100 1020 1485 to 1595 1020 1750 to 1860 1390 1750 to 1860 — — — —
PITCH 3105 3690 4185 4455 4815 5175 5670 6570
L L1 L L1 L L1 L L1 L L2 L1 L L2 L1 L L3 L2 L1 L
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
120/130/140 E 18 2855.6 1690 to 1800 1300 965 to 1075 1300 1460 to 1570 1395 1630 to 1740 1740 1650 to 1760 1300 1035 1410 to 1520 1300 1310 1630 to 1740 1300 1110 1110 1630 to 1740
120/130/140 E 18—21 2870.9 1490 to 1600 1110 965 to 1075 1110 1460 to 1570 1110 1725 to 1835 1730 1460 to 1570 — 1730 1830 to 1940 1110 1110 1830 to 1940 — 1270 1850 1830 to 1940
120/130/140 E 21 2865.6 1650 to 1760 1180 965 to 1075 1180 1460 to 1570 1235 1740 to 1850 1610 1740 to 1850 — 1860 1865 to 1975 1350 1030 1830 to 1940 — 1350 1880 1875 to 1965
120/130/140 E 24—28 2895.9 1410 to 1520 — 1990 to 2100 1030 1455 to 1565 1030 1725 to 1835 1380 1725 to 1835 — 1895 1580 to 1690 — 1895 2075 to 2185 — 1090 1895 1875 to 1985
120/130/140 E 24 FSO5206B 1540 to 1650 1155 965 to 1075 1155 1460 to 1570 1155 1740 to 1850 1500 1740 to 1850 — 1740 1865 to 1975 — — 1830 to 1940 — — — 1875 to 1985
150/160 E 21 2865.6 1635 to 1745 1190 1040 to 1150 1270 1445 to 1555 1270 1715 to 1825 1630 1715 to 1825 — 1860 1830 to 1940 1350 1020 1830 to 1940 — 1350 1880 1865 to 1975
150/160 E 21 2870.9 1475 to 1585 — 2065 to 2175 1115 1445 to 1555 1115 1715 to 1825 1470 1715 to 1825 — 1700 1830 to 1940 1190 1020 1830 to 1940 — 1190 1880 1865 to 1975
150/160 E 24 FSO5206B 1500 to 1610 1085 1020 to 1130 1160 1425 to 1535 1160 1695 to 1805 1510 1695 to 1805 — 1740 1825 to 1935 1240 1020 1820 to 1930 — 1240 1880 1850 to 1960
150/160 E 24—28 2895.9 1350 to 1460 — 1930 to 2040 1030 1410 to 1520 1030 1690 to 1800 1380 1690 to 1800 — 1380 2045 to 2155 — 1895 2030 to 2140 — 1090 1895 1845 to 1955
PITCH 3105 PITCH 3830 4190
L L1 L L2 L1 L
mm mm mm mm mm mm
MODEL GEARBOX TYPE min max MODEL GEARBOX TYPE min max min max min max min max
130/140 E 18 RS 2865.9 1635 to 1745 260 E 28 KE 2895.9 1975 to 2085 673 to 833 1095 1255 to 1365 673 to 833
150/160 E 21 RS 2870.9 1440 to 1550
PITCH 3690 4185 4590 4815 5175 5670 6210 6570
L1 L L1 L L1 L L1 L L1 L L2 L1 L L2 L1 L L2 L1 L
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
180 E 21 2865.6 1190 1030 to 1140 1270 1440 to 1550 1270 1845 to 1955 1630 1960 to 1800 1860 1825 to 1935 1270 1085 1825 to 1935 1350 1895 1475 to 1585 1350 1895 1845 to 1955
180 E 21 2870.9 — 2035 to 2145 1115 1425 to 1535 1115 1825 to 1935 1470 1690 to 1800 1700 1825 to 1935 1115 1085 1825 to 1935 1190 1895 1480 to 1590 1190 1895 1825 to 1935
180 E 24—28 2895.9 — 1950 to 2060 1030 1420 to 1530 1030 1825 to 1935 1380 1695 to 1805 1605 1830 to 1940 1030 1085 1820 to 1930 1090 1895 1490 to 1600 1090 1895 1850 to 1960
180 E 24 FSO5206B 1085 1020 to 1130 1160 1440 to 1550 1160 1845 to 1955 1510 1710 to 1820 1740 1850 to 1960 1240 1020 1825 to 1935 1240 1880 1500 to 1610 1240 1880 1850 to 1960


DIAGNOSTICS
Main propeller shaft anomalies:
1 — Transmission noises and vibration
1 TRANSMISSION NOISES AND

VIBRATION
Shaft distortion Replace the shaft.

YES
NO
Unbalanced shaft. Carry out balancing check and determine the points
YES where balancing plates must be welded.
NO
Excessive clearance between grooved profiles. Replace the shaft.

YES
NO
Loosening of screws and nuts for securing shaft to Take care, after an accurate check, of completely
gearbox sleeves or on rear axle. YES tightening those screws and nuts that are loosened, and
replace damaged parts if required.
NO
Seized or excessively worn propeller shaft universal Revise or replace the universal joints.
joints. YES
NO
Insufficient lubrication for the various parts. Proceed with the lubrication by operating on suitable
YES greasers.
TIGHTENING TORQUES
TORQUE
PART
Nm (kgm)
M10 screw for securing transmission flanges 63.5 ± 6.5 (6.4 ± 0.6)
M12 screw for securing transmission flanges 101 ± 10 (10.3 ± 1)
M14 screw for securing transmission flanges 133.5 ± 13.5 (13.6 ± 1.4)
Self—locking flanged nut for elastic support fastening screw 82 ± 8 (8.3 ± 0.9)

505620 SLIDING PROPELLER SHAFT FIXED PROPELLER SHAFT

REMOVAL— REFITTING REMOVAL— REFITTING
Removal
Figure 12 Figure 14
33700
Set the vehicle under safety conditions and operate as 33701

described below:
Removal/refitting of these propeller shafts is similar to the
- rotate locking rivets for dampening guard (6) under the sliding one, apart from the presence of a rear support (2) on
gearbox and remove it; the fixed shaft, that must be detached from the chassis after
- position an hydraulic jack equipped with support having unscrewed the four securing bolts and detached the
99370618 under the propeller shaft and suitably constrain sliding propeller shaft (1) from the fixed one.
it;
- unscrew the four securing bolts (2) and detach propeller
shaft (1) from gearbox;
Figure 13
CHECKING PROPELLER SHAFTS ON

VEHICLE
Figure 15
33702
- unscrew the four securing bolts and detach propeller shaft

(1) from rear axle;
- lower the hydraulic jack and remove propeller shaft from Propeller shafts are provided by the manufacturer as
the vehicle. assemblies ready for being assembled.
Refitting They are statically and dynamically balanced.
The welded plates to propeller shafts are balancing plates.
In case of lack of plates, it is necessary to balance the shaft
For the refitting, carry out in reverse order the again.
operations described for the removal, complying with By operating on the propeller shaft and simultaneously, in
the following warnings: reverse order, on the sliding sleeve, check that there is no
Self—locking nuts must always be replaced and excessive clearance among grooved parts.
tightened at the required torque. By operating on sleeve forks, check that spiders are not worn;
Check whether arrows on the sliding part and on otherwise, replace them.
shaft are aligned.

EUROCARGO TECTOR 12—26 t REAR AXLES 1
SECTION 6
5250 Rear axles
Page
AXLES IN TANDEM ARVINMERITOR SP 145 E 3
ARVINMERITOR AXLE MS08 — 125 . . . . . . . . . 85

2 REAR AXLES EUROCARGO TECTOR 12—26 t

EUROCARGO TECTOR 12—26 t AXLES IN TANDEM 3
Axles in tandem
ArvinMeritor SP 145 E
Page
PD 145 E (R 2468) (INTERMEDIATE) . . . . . . . . . . . . 5
PR 140 E (R 0868) (REAR) . . . . . . . . . . . . . . . . . . . . . 55

4 AXLES IN TANDEM EUROCARGO TECTOR 12—26 t

EUROCARGO TECTOR 12—26 t AXLES IN TANDEM (INTERMEDIATE) 5
Axles in tandem (Intermediate)

ArvinMeritor PD 145 E (R 2468)
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION OF DIFFERENTIAL UNIT PLATES —

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . 20
INTERMEDIATE AXLE DISCONNECTION/

RECONNECTION (with Hendrickson suspensions) 23
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . 23
SERVICING INTERMEDIATE AXLE

ASSEMBLY PD 145 E (R 2468) . . . . . . . . . . . 25
AIR BREATHER REMOVAL—REFITTING . . . . . . 25
SERVICING WHEEL HUBS . . . . . . . . . . . . . . . . . 25
- Checking wheel hub components . . . . . . . . . . 26
ASSEMBLING WHEEL HUBS . . . . . . . . . . . . . . . 27
REMOVING DIFFERENTIAL GEAR — TRANSFER BOX

(with rear axle on stand 99322215) . . . . . . . . 30
REFITTING DIFFERENTIAL GEAR — TRANSFER BOX

REPAIRING INTER-AXLE UNIT . . . . . . . . . . . . . 31
- Dismantling inter-axle unit . . . . . . . . . . . . . . . . 31
- Checking inter-axle unit components . . . . . . . . 33
- Fitting inter-axle unit . . . . . . . . . . . . . . . . . . . . 33
- Adjusting drive input shaft bearing end float . . . 35
- Adjusting differential lock and inter-axle

control pin end-stop . . . . . . . . . . . . . . . . . . . . 36
REPAIRING MAIN DIFFERENTIAL—

DISMANTLING DIFFERENTIAL CASING . . . 36

6 AXLES IN TANDEM (INTERMEDIATE) EUROCARGO TECTOR 12—26 t
Page
- Dismantling gear cage . . . . . . . . . . . . . . . . . . . . 40
- Checking differential components . . . . . . . . . . . 40
- Assembling gear cage . . . . . . . . . . . . . . . . . . . . 41
ASSEMBLING DIFFERENTIAL CASING . . . . . . . 42
- Calculating bevel pinion position

in differential casing . . . . . . . . . . . . . . . . . . . . . 42
COMPUTATIONAL EXAMPLES . . . . . . . . . . . . . 43
- Adjusting the cap gap . . . . . . . . . . . . . . . . . . . . 46
CORRECTING THE CROWN WHEEL AND PINION

CONTACTS (AFTER ASSEMBLY) . . . . . . . . . 48
REMOVING—SERVICING—REFITTING INTER-AXLE
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . 51

DESCRIPTION
The intermediate axle is a bearing axle type with a simple helical toothing (pinion — ring gear assembly) and a wheelwork
reduction; it consists of a box made in metal sheet, housing a box (side pinion — crown wheel assembly).
reduction differential and a main differential. Drive transmission The adjustment of the bevel pinion assembly is made through
from the reduction to main differential is achieved through a adjusting rings placed between the two taper roller bearings.
helical gear pair. The reduction differential is made up by a drive You can also adjust the bevel pinion position with reference to
input shaft keying: the front support, the oil pump, the driving the ring bevel gear by changing the thickness of the pack of the
gear housing the front crown wheel and side pinion assembly;
rings, which are inserted between the taper bearing under the
the rear crown gear is housed on the axle box and keyed on
head and the bevel pinion support.
the drive output shaft.
A sliding sleeve is mounted on the rear crown wheel to lock The wheelwork box is supported by two taper roller bearings
the differential; the sliding sleeve is driven by a pneumatic and can be adjusted axially through two threaded ring nuts.
device through a fork. The axle is provided with a pneumatic control differential
Taper roller bearing axial clearance is adjusted by inserting locking device.
shims between front and wheelwork support; the main The wheel hubs are supported by two tapered—roller bearings
differential is made up by a pair of bevel reduction gears with floating on a post and adjustable by means of a threaded nut.
Figure 1
87225

LOCATION OF DIFFERENTIAL UNIT PLATES — REAR AXLE

The plates contain all information and details relating to either DIFFERENTIAL UNIT and REAR AXLE.
On real axle, two plates are present: one on the differential unit and one in same position on rear axle box. On the notifications
of interventions under guarantee, rear axle box and differential unit plate data must always be shown. It is suggested always to read
and copy out shown data before any repair so as to order correct spare parts and transmit correct information to either IVECO
Service Network.
Plate is never to be removed from the unit.
Figure 2
87207
IVECO identification plate ARVINMERITOR identification plate

A = identifies rear axle type A = identifies the family the item is belonging to / the
B = drawing number model
C = production progressive number B = drawing number
C = ArvinMeritor series number
D = rear axle ratio
E = production date

Axle type: PD 145 E (R 2468)

Bearing axle with simple reduction,
with a pneumatic control
differential locking device
MAIN DIFFERENTIAL ASSEMBLY
Crown wheel and pinion assembly 3.73 (11/41) — 3.91 (11/43) — 5.86 (7/41)
reduction ratio (pinion/ring gear 4.10 (10/43) — 4.33 (9/39) — 4.63 (8/37)
teeth number) 4.88 (18/39) — 5.29 (7/37) — 6.83 (6/41)
Bevel pinion bearings 2 taper roller bearings
Bevel pinion bearing rolling torque
New bearings Nm 1.12 to 5.08

kgm 0.112 to 0.508
Reused bearings Nm 1.68 to 3.39
kgm 0.168 to 0.339
Bevel pinion bearing pre—load
through shims
adjustment
Thickness of bevel pinion bearing 5.30—5.33—5.35—5.38—5.40—5.50—5.60

pre—load adjusting rings 5.70—5.80—5.90—6.00—6.10—6.13—6.15—6.18—6.20
Clearance between pinion and ring

gear mm
new gears 0.20 to 0.46
reused gears
recover working conditions
Clearance adjustment between Through ring nuts

pinion and ring gear
Cap opening out mm 0.08 to 0.22
Differential box bearing

rolling torque Nm 1.7 to 3.9
kgm 0.17 to 0.39
Cap opening out adjustment Through ring nuts
Rolling torque between side gear

pinions and crown wheels Nm Max. 68
kgm Max. 6.8
Bevel pinion positioning with Through adjusting shims

reference to differential box
Thickness of adjusting rings inserted

between bearing ring and 0.076 — 0.127 — 0.254
differential carrier

REDUCTION DIFFERENTIAL ASSEMBLY
Reduction differential bearings 2 taper roller bearings
Reduction differential bearing

axial clearance mm 0.05 to 0.20
Reduction differential bearing axial Through adjusting shims

clearance adjustment
Thickness of reduction differential

bearing adjusting shims mm 0.076 — 0.127 — 0.254
WHEEL HUBS
Wheel hub bearings Two taper roller bearings
Hub bearing axial clearance mm 0.00 to 0.05
Wheel hub bearing rolling

torque Nm Max. 1.96
kgm Max. 0.20
Wheel hub bearing axial clearance Through nut

adjustment
Axle oil TUTELA W140/M—DA
with Hendrickson suspension Litres (kg) 16 2 (14.6)

16.2 (14 6)
Dry weight kg 586

Maximum capacity (GAW) kg 10500

TIGHTENING TORQUES
Figure 3
84394
TORQUE
PART
Nm (kgm)
1 Screw fixing input shaft mount M12x1.75 122.5 ± 22.5 (12.4 ± 2.2)
2 Nut fixing flange to input shaft M45x1.5 950 ± 135 (96.8 ± 13.7)
3 Nut fixing parts on bevel pinion M 45x1.5 1492.5 ± 272.5 (152.1 ± 27.7)
4 Screw fixing bevel pinion cover M 10 x 1.5 55 ± 15 (5.6 ± 1.5)
5 Screw fixing mesh filter M 26x1.5 65 min. (6.6 min)
6 Screw fixing oil pump to mounting 37.5 ± 7.5 (3.8 ± 0.7)
7 Screw fixing caps: to differential gear housing M 20x2.5 485 ± 55 (49.4 ± 5.6)
8 Nut fixing output shaft M39x1.5 745 ± 135 (75.9 ± 13.7)
9 Screw fixing output shaft bearing mount 57.5 ± 10.5 (5.8 ± 1)
10 Transfer box differential locking cylinder M 60x2 122.5 ± 13.5 (12.4 ± 1.3)
11 Screw fastening the differential case to the rear axle housing. 67.5 ± 7.5 (6.8 ± 0.7)

Figure 4
77210
TORQUE
PART
Nm (kgm)
10 Nut locking transmitter M 16x1 55 ± 20 (5.6 ± 2)
11 Differential locking cylinder M 60x2 122.5 ± 13.5 (12.4 ± 1.3)
12 Screw fixing half boxes M 12x1.75 142.5 ± 12.5 (14.5 ± 12.5)
13 Self—locking nut fixing bevel ring gear to the half box M 16x1.5 255 ± 35 (25.9 ± 3.5)
14 Oil filter coupling M 22x2.5 67.5 ± 12.5 (6.8 ± 1.2)

Figure 5
85492
CROSS-SECTION THROUGH WHEEL HUB FOR AXLE IN TANDEM PD 145 E
PART TORQUE
Nm (kgm)
1 Nut fastening the drum to the wheel hub 40 ± 4 (4 ± 0.4)
2 Ring nut to lock nut adjusting wheel hubs 392.3 ± 20 (40 ± 2)
3 Screw to secure half shaft to wheel hub 232.4 ± 24.5 (23.2 ± 2.4)
+50
4 Wheel securing nuts 600 60 +5
—20 —2
5 Nut for brake shoe mounting securing screw 289 ± 14 (29.5 ± 1.5)
Figure 6
C—C SECTION
37983
VARIANT WITH ANTI—SKID DEVICE

TOOLS
99305121 Heater
99322205 Rotary stand for unit overhauling (capacity 1000 daN, torque 120
daN/m)
99322215 Axle overhaul stand
Unit holder (to be mounted on stand 99322205)

99322225
Single—acting lift
99341003
Pair of brackets
99341012

TOOLS
99341015 Clamp
99341016 Pair of brackets with holes
99345029 Threaded block (use with 99345098)
99345055 Reaction block for puller tools
99345098 Installation tool for assembly of bearing and cylindrical gear on the
differential bevel pinion shaft (use with 99345029)
99345103 Wheel hub fitting tool

TOOLS
99348001 Puller tool with clamping device
99355025 Wrench for differential gearcase bearing adjustment ring nuts
Wrench (75 mm) for differential bevel pinion nut

99355069 (to be used with 99370317)

99355088 (to be used with 99370317)
99355131 Wrench (55 mm) for the nut of the drive input flange of the transfer
box (use with 99370317)
99355167 Wrench (114 mm) for wheel hub bearing adjustment nut

TOOLS
99360311 Oil filter wrench
99370005 Hand—grip for interchangeable drift punches
99370007 Hand—grip for interchangeable drift punches
99370317 Reaction lever and extension for flange lock
99370509 Hook to remove differential gearcase half—housing
99370616 Support to remove—fit back differential

TOOLS
Universal support to remove—fit back rear axles

99370617
Stand to hold differential half—housing when tightening crown

99371047 wheel screws (to be used with 99322205 — 99322225)
99374093 Drift punch for installation of bearing outer races (91÷134) (use with
99370007)
99374094 Drift punch for installation of bearing outer races (134÷215) (use
with 99370007)
99374134 Installer, wheel hub inner seal
99374162 Installer, transfer case input shaft seal

TOOLS
99374163 Keying device for assembling the distributor motion output shaft seal
99381125 Pliers for removal of circlips on transfer box shaft
99389816 4 x torque multiplier, with square connection, 3/4” in, 1” out

(maximum torque 2745 Nm)
99389819 Torque wrench (0 — 10 Nm) with 1/4” square fitting
99395026 Tool for measuring hub rolling drag torque (use with torque
wrench)
99395027 Tool for determining thickness of differential bevel pinion

adjustment shims (use with 99395693)

EXPERIMENTAL TOOLS
This heading covers the technical working drawings of the experimental tools (S.P.), used when overhauling the rear axle described
in this section, that can be made in your repair shop.



INTERMEDIATE AXLE Figure 7

DISCONNECTION/ RECONNECTION
(with Hendrickson suspensions)
NOTE Prior to carrying out detachment/reattachment

operations, disconnect the batteries by acting on
the master current switch.
Disconnection
Proceed as follows:
- Place a suitable elevating trolley 99370617 under the

differential of the axle to be removed.
- Disconnect propeller shafts (5) and anchor them
properly to the chassis.
- Disconnect electric connections (6) and air piping (7)
from the relevant differential locking devices.
- Disconnect piping (8).
- Disconnect brake wear sensor connections (1) and free
wiring from the straps on the axle.
- Disconnect the bracket (3) from the axle complete with
adjustment tie rods; operating on the fasteners (4) and
anchor them properly to the chassis.
- Disconnect reaction triangle fasteners (2) and free it
from the axle.
- Withdraw the axle.
Reconnection
For refitting, carry out the operations described for
removal in reverse order, keeping to the required
tightening torques for the screws and/or nuts.
Afterwards, check that:

- There is no air leakage from the air pipes.
- The lubricating oil of the axle housing is at the right level.
- The differential locking indicator lamp works properly; if
it does not, proceed as described under the relevant
heading.
1. Brake wear sensor connection — 2. Reaction triangle fastener — 3. Tie rod fixing bracket — 4. Tie rod fastener
— 5. Propeller shaft — 6. Electric connection — 7. Air piping — 8. Piping.
74092


525010 SERVICING INTERMEDIATE AXLE

ASSEMBLY PD 145 E (R 2468)
525030 SERVICING WHEEL HUBS
NOTE Removal/installation operations concerning the
following units: axle shafts, brake shoes and drums,
air breather, differential can be performed with the Figure 9
unit on the vehicle.
Before placing the axle assembly on the stand, loosen the

bottom plug and drain the oil.
525013 AIR BREATHER

REMOVAL—REFITTING
Figure 8
77222
Lock the differential gear, operating as follows: unscrew the

screw (7) and screw it down in the hole (8): screw down the
screw fully to get the differential lock to go in.
Figure 10
77221
Set the rear axle assembly on the stand 99322215,

Check that the air breather (1) is not clogged; if it is, remove 19341
it, clean it carefully and fit it back on.
NOTE Place a container under the wheel hub to recover
the oil.
NOTE The identification data of the rear axle assembly PD
145 E (R 2468) are given on the plate (2).
Unscrew the screws (3) fixing the drive shaft (2) and extract
it from the hub (1).
Figure 11
19349
Remove the screws fixing the drum (1) to the wheel hub (2) and
screw them down in the holes (→) to extract the drum (1).
Figure 12 Figure 14
36295
Only dismantle the phonic wheel (1) if it is to be replaced. Do

77223 so using a suitable lever.
Using the wrench 99355167 (1) unscrew the lock nut (2)
locking the bearing adjustment nut (4).
Figure 15
Extract the retaining ring nut (3), unscrew the bearing
adjustment nut (4) and take out the bearing (5).
Figure 13
19354
NOTE If the phonic wheel (1, Figure 14) is not to be

dismantled, do not use it as a support.
77224
Disassemble the wheel hub (1). In case of difficulty, use the

Use a general purpose bronze drift (1) to remove inner bearing
puller comprised of: arms 99341016 (2), yoke 99341003 (3)
cup (2).
and block 99345055 (4), applied as shown in the figure.
Sealing ring (3) will also be expelled.
Proceed in the same way to remove the outer bearing cup.
NOTE When putting aside the wheel hub, take care not to Checking wheel hub components
damage the phonic wheel (1, Figure 14).
Clean every single hub component thoroughly.
Examine axle drive shafts and make sure they are free
from any distortion.
Check wheel mounting bolts: if their threads are
distorted or damaged replace without hesitation on
a power press.
Lubricate bearings and rock roller cages; rotation must
be smooth without any sign of binding.
Check condition of wheel bearing adjuster nut and axle sleeve
end threads: if necessary, change the nuts.
Check the oil slinger: if damaged, replace.
Discard old seals and fit new ones.

525030 ASSEMBLING WHEEL HUBS

Figure 16 Figure 18
40326
36298
Refit phonic wheel (2), if necessary, by heating to a
temperature of 150°C. Ensure phonic wheel is perfectly
Ensure the rest surface of screw heads is free from burrs, slags bedded onto hub seat after installation.
or nicks before fitting new screws (3). Check squareness of phonic wheel (2) as follows.
The load to be applied to screw heads for driving them into Position wheel hub (4) with taper roller bearings on base of
their seats must not exceed 2300 Kg. column drill. Interpose a spacer between base and outer
When driving operation is completed, screws should abut bearing race (5) so that wheel hub may turn.
perfectly on the wheel hub face : maximum squareness Rest a plate (7) on the internal bearing roller ring (3).
tolerance 0,2 mm. Turn handle (8) to raise base so that drill chuck comes into
If the oil slinger (2) was removed in order to be replaced, coat contact with plate (7) and bearings (3 and 5) are slightly
oil slinger and hub mating face with sealing compound that can pre-loaded.
resist heat to temperatures of 40 to 250°C.
NOTE Turn wheel hub to settle bearings when pre-loading.

Figure 17
Position magnetic base dial gauge with flat base stylus as shown
in figure and turn wheel hub. Check that maximum squareness
error for phonic wheel (2) does not exceed 0,2 mm.
Figure 19
36299
Fit taper roller bearing outer races in wheel hub using handle
99370007 (1) and drift (2): 99374094 for outer bearing race
(3) and 99374094 for inner bearing race.
NOTE When fitting race (3) do not use phonic wheel (1)
62665
as a support base.
Press fit until bearings are 5 mm from abutting end
and then complete operation by hand. Place the tapered roller bearing (1) in the outer ring (2). Using
the keying device 99374134 (3) fit the gasket (under a press)
in the wheel hub.

Figure 20 Figure 22
77225 19366
Lubricate the bearing seat on the sleeve and the wheel hub
seal (1) with TUTELA W 140/M—DA oil. Fit the lock ring (2).
Position the tapered roller bearing in the wheel hub (1) and, If the nut (1) for the locating dowel does not match any of the
using the tool 99345103 (2) applied as in the figure, fit the lock ring holes (2) (see →), progressively undo the adjusting
wheel hub (1) onto the sleeve. nut (1) until the lock ring can be inserted. (Consider also the
end play specification obtained with the previous operation).
Figure 21
Figure 23
36304
Tighten nut (1). Then adjust wheel hub bearing end play as
follows. 36305
Use wrench 99355167 (2) to tighten nut (1) to a torque of
98.1 Nm (10 kgm). Tighten nut (1) and torque it to 392.3 Nm (40±2 kgm) using
wrench 99355167 (2).
NOTE Tighten nut by turning hub simultaneously in both

directions to settle bearings.
Figure 24
Loosen nut (1) to obtain an end play of 0.2 ÷ 0.3 mm.
Place a magnetic base dial gauge (1) on wheel hub (3); rest
gauge stylus on sleeve (2) and check wheel hub end play. It
should not be over 0.00 ÷ 0.05 mm.

Figure 25 Figure 26
36307 36309
Fit the drum (1) onto the wheel hub (2).

Smear “Type B” sealing compound on both contact surfaces
Apply tool 99395026 (1) to the wheel hub pins and, using a
between the drive shaft and the wheel hub.
torque wrench, check that the rolling torque is no greater than:
Insert the drive shaft (4), screw down the screws (3) fixing the
1.96 Nm (0.20 kgm).
drive shaft (4) to the hub (2) and tighten them, using a torque
This torque must correspond to a maximum end float of the wrench, to the prescribed torque.
bearings of 0.05 mm. Repeat this operation on the opposite side.
After these operations, replenish the axle housing with
TUTELA W 140/M—DA oil of the prescribed quantity and
proceed to check the transmitter for signalling differential
locking works properly.
Check the efficiency of the ABS sensors as described in the
“Fault—Diagnosis Guide” manual.
Figure 27
77226
COMPONENTS OF WHEEL HUB

1. Screw — 2. Drive shaft — 3. Nut — 4. Safety ring — 5. Nut — 6. External tapered roller bearing — 7. Wheel hub — 8. Internal roller
bearing — 9. Seal — 10. “Phonic” wheel — 11. Drum brake — 12. Oil sump — 13. Rear axle sleeve.

526210 REMOVING DIFFERENTIAL GEAR — Figure 30

TRANSFER BOX (with rear axle on
stand 99322215)
Figure 28
77227
Loosen differential carrier (1) retaining screws. Screw in three

screws to be used as extractors and separate differential
77222 carrier from axle housing by means of eyebolts and metal
ropes.
Use mounting 99370616 for differential carrier
Lock the differential gear, operating as follows: unscrew the removal with axle assembled on vehicle.
screw (7) and screw it down in the hole (8): screw down the
screw fully to get the differential lock to go in.
REFITTING DIFFERENTIAL GEAR —

Figure 29 TRANSFER BOX (with rear axle on stand
99322215)
Figure 31
36344
77228
Use retainer 99370317 (3) to stop flange (1) rotation.
Unscrew drive flange (1) retaining nut using wrench 99355131
Coat the axle housing to differential mating face with sealant.
(2) and torque adaptor (4).
Insert differential in axle housing. Tighten nuts (1) and screws
Remove screws (5) and disconnect axle housing output shaft
with lock washers to the specified torque using a torque
mounting (6).
wrench (2).
Fit differential axle shafts as described in 525030 operation.
Backout screw (3) to release the differential lock device; insert
screw in its seat.

Figure 32 Position the transfer box differential gear housing (1) on the
rotary stand 99322205 (2) together with the mount
99322225 (3).
Unscrew the screws (4) and remove the guard.
Using tool 99360311 unscrew the oil filter (5).
Figure 35
36346
Turn the axle housing by 90°. Insert support (1) with drive
output shaft (2) in the axle housing and tighten screw to the
specified torque.
Figure 33
77230
Stop flange (1) rotation with tool 99370317 (2). Undo flange
retaining nut using wrench 99355088 (3) and torque adaptor
(4).
Figure 36
36347
Stop flange (1) rotation by means of retainer 99370317 (4).

With wrench 99355131 (2) and torque adaptor (3) tighten
output shaft flange (1) retaining nut to the specified torque.
Once assembly operations are completed, pour the specified 36350
quantity of TUTELA W140/M—DA oil into the axle housing.
Then check efficiency of differential lock connection sending Remove nuts fixing mounting (1) to differential carrier and
unit. take it out together with input shaft, oil pump, gear and
inter-axle differential.
526060 REPAIRING INTER-AXLE UNIT Remove shims (2).
Dismantling inter-axle unit Separate the differential housing as described in the relative
chapter.
Figure 34
Figure 37
77231
77229 Remove cylinder (1) complete with inter-axle differential lock

Detach the transfer box differential gear housing as described piston (2) and withdraw yoke (4) drive pin (3).
under the relevant heading.

Figure 38 Figure 41
36352 84395
Remove the spring (1) and strip yoke (2), sleeve (3) and rear Tighten drive input shaft in a vice.
planetary gear (4). Remove snap ring (1) and take out differential gear assembly
(2), gear (3) and thrust ring (4).
Figure 39 Figure 42
84396
36353
If the planet gear unit needs disassembling, make a mark (1),
Use a punch to expel cup (1) of rear planetary gear bearing by means of a punch, on both half cases, in order to ensure
(4, Figure 38). correct match when re—assembling.
Unscrew screws (2), then separate the two half cases. Take
off the spider unit, remove the four gears and pinion and the
Figure 40 four spider thrust washers.
Figure 43
36354
36356
Use extractor 99348001 (1) and reaction block (2) to
dismantle cone (3) of rear planetary gear (4) roller bearing. Remove nut (1) and separate flange (2) from drive input shaft
(3) by means of a suitable extractor.

Figure 44 Checking inter-axle unit components
Accurately clean each single component and check for wear in

view of their possible re-use.
NOTE Make sure all screw, stud and ring nut threads are
cleaned accurately so that clearance and torque
specifications are not effected.
Always renew sealing rings, retaining rings and washers.
36357
Use a press to extract the drive input shaft (1) from bearing
cage (2) and oil pump (3).
Fitting inter-axle unit
Figure 45 Figure 47
36430 36359
Remove screws (1), separate oil pump (2) from bearing cage Tighten the drive input shaft (1) in a vice and install the oil pump
(3) and take out bearing (4). (3).
Heat the bearing (2) to 100°C for 15 minutes and fit it on using
a drift.
Figure 46 Figure 48
36358 36360
Remove spring (2), oil pressure relief valve (1) and cup (3) of Using drift 99374093 (2) partially press fit cup (3) of bearing
bearing (4, Figure 45) from bearing cage (4). (2, Figure 45) in bearing cage (4). Complete installation
manually using handle 99370007 (1).

Figure 49 Figure 51
X
84398
Smear the thrust ring (4) with grease and arrange it under gear
(3);
- secure the gear on the drive input shaft (6),
- then differential gear assembly (2) and fasten by means of
36361
snap ring (1).
Mount seal ring (3) with tool 99374162 on support (4). Turn the input shaft (6) upside down and spline flange (5) onto
Install bearing cage (4) on oil pump (5) so that exhaust (→) it.
matches the valve seat (2). Fit washer (7) and screw in retaining nut (8) without fully
Insert spring (1) in the seat for oil pressure relief valve and fit tightening it.
the plug.
Use a feeler gauge to check distance X between sealing ring (3) Figure 52
and mounting (4) at four equi-distant points. Distance X should
be between 0.38 ÷ 0.76 mm.
Figure 50
36363
Use drift 99374093 (2) and handle 99370007 (1) to fit bearing
(2, Figure 53) cup (3) in the rear-axle differential carrier.
Figure 53
84397
Mount the planet gear unit (if previously disassembled) by

following the procedure below. Apply the specific lubricant
used for the rear axle housing on all the other parts of the
planet gear unit.
Mount the gears and pinion and the thrust washer on the
spider.
Place the pinion unit and spider in one of half cases (1). Mount
the remaining half case onto the half case with the spider unit.
Make sure that the marks (2) available on each half case are
aligned to one another.
Screw four of the cap screws (3) after applying LOCTITE.
36364
Screw the remaining cap screws (3) after applying LOCTITE
on the thread, then tighten them to a torque of 60 ÷ 75 Nm. Heat bearing (2) to 100°C for 15 minutes and fit on rear side
gear shaft (1).

Adjusting drive input shaft bearing end float
Figure 54 Figure 56
36367
36352
Proceed as follows to adjust shaft bearing end play:
- fit the drive input shaft into the inter-axle differential
Place rear side gear (4) complete with sleeve (3) and fork (2) carrier;
on bearing cup (3, Figure 52). Then fit spring (1) on fork (2). - tighten screws (2) without washers;
- turn the input shaft in both directions to bed bearings; at
the same time, tighten screws (2) without locking them;
- use a feeler gauge (4) to measure, at four equally-spaced
points, the gap between bearing cage (3) and carrier rest
face;
Figure 55 - thickness S, corresponding to the shim pack necessary for
adjusting bearing end play is calculated as follows:
S=A+B
- where A is the mean value resulting from the four
measurements taken earlier;
- B = 0.013 is the mean value of bearing end play
(0.05 ÷ 0.20 mm);
- remove screws (2) and raise the drive input shaft by
6 ÷ 12 mm.
- fit the shim pack of the correct thickness.
NOTE The shim pack must consist of at least three shims,

with the thickest in the middle.
Shims are supplied as spares in the following range
of thickness: 0.076 — 0.127 — 0.254 mm.
77232
Mount the spindle (1) governing the transfer box differential Figure 57
locking, lubricate the new seal (2) and fit it on the piston (3)
and insert this into the cylinder (4). Apply sealant on the thread
of the cylinder (4). Screw this into the differential gear housing,
tightening it to the prescribed torque.
36368
Fit new oil filter (5), fit guard (4) and secure it to differential
carrier together with bearing cage (3) by screws (2).
Check input shaft bearing (1) end play using a dial gauge. End
play should be 0.05 to 0.20 mm.
In case of a different reading, replace the shim pack with
another one of the appropriate thickness.

Adjusting differential lock and inter-axle Figure 60

control pin end-stop
Figure 58
77235
77233 Release the coupling (1) with a rubber skirt and remove it from
the fork (2).
Adjust shaft (2) end-stop as follows:
- loosen capscrew (1);
- let 6 bar compressed air into the cylinder (3); Figure 61
- tighten capscrew (1) until in contact with shaft (2);
- furtherly tighten capscrew (1) by 1/4 ÷ 1/2 turn and lock
jam nut (4);
- Use tool 99370317 to lock flange rotation (1, Figure 57)
and tighten the retaining nut to the specified torque.
526210 REPAIRING MAIN DIFFERENTIAL—

DISMANTLING DIFFERENTIAL
CASING
77236
Figure 59 Take out the spring (1) and the fork (2) from inside the
differential gear housing.
Figure 62
77234
Take out the switch (1) signalling differential locking, unscrew

the screw (2) to cut in manual differential locking, the cylinder
(3) together with the ram (4) and the seal (5) and extract the
spindle (6). 36373
Using a punch, eject the ram (4) from the cylinder (3).
Remove split pin (3) and roll pin (1); dismantle caps (2) and
bearing adjusting nuts (4).

Figure 63 Figure 66
77231
36374
Use a sling hook to extract the gear cage (1) complete with Remove the cylinder (1) together with the piston (2) of the
crown wheel and bearings. differential locking—transfer box and extract the pin (3)
governing the fork (4).
Figure 64
Figure 67
5
36349
36352
Stop rotation of flange (1) by means of retainer 99370317 (2);
with wrench 99355088 (3) and torque adaptor (4) loosen Remove drive shaft (3, Figure 57).
flange (1) retaining nut. Remove spring (1) and strip fork (2), sleeve (3) and rear
Remove cover (5). planetary gear (4).
Figure 65 Figure 68
40678 77237
Remove nuts retaining bearing cage (1) to differential carrier. Block rotation of the bevel pinion with the tool S.P. 2373 (1);
Pull out bearing cage complete with input shaft, oil pump, gear with wrench 99344069 (2) and the multiplier (3) remove the
and inter-axle differential. nut fastening the bearings to the bevel pinion and the washer
Remove shims (2). beneath.

Figure 69 Figure 71
77238 36381
Apply on the housing a special extractor S.P. 2346, (5) and Place tool 99348001 (2) under the taper roller bearing (1) and
extract the pinion from the parts: spacer (1), gear (2), spacer pull it off the bevel pinion (3) using a press.
(3) and bearing (4).
Then remove the above—mentioned parts from the housing.
Figure 70
36380
Dismantle carrier bearing cups (1, 2, 3) using a drift.

Figure 72
77240
INTER-AXLE DIFFERENTIAL COMPONENTS — EXPLODED VIEW

Dismantling gear cage Figure 76

Figure 73
19382
19379
Mark the two casing halves (2 and 3) and the spider as
Use hook (1) to raise the gear cage assembly and position on indicated in the figure.
stand 99371047 (3). Unscrew screws (1) joining the casing halves. Lift the casing half
(2).
Figure 74 Figure 77
19383
Remove differential gear (2) with the associated thrust washer

36316
(1). Remove spider (6) with the four planetary gears (5)
Unscrew nuts (1) and remove them with screws. Drive out complete with thrust washers (3). Take the spider/planetary
bevel crown wheel (2). gear assembly apart. Remove the other differential gear with
its thrust washer from the half cage (4).
Figure 75
Checking differential components
Thoroughly clean the individual parts making up the

differential. Lubricate the bearings and spin the roller cages
freely; these should rotate evenly without tight spots.
Check the seating surfaces of the bevel crown wheel and the
bedding surface of the half cage so that the crown wheel
adheres to it perfectly; distortion of these faces would cause
vibration of the crown wheel attachment screws,
compromising the satisfactory operation of the unit.
36317
NOTE Thoroughly clean threads of screws, studs and ring

Use tool 99348001 (1) and reaction block 99345055 (2) to nuts to prevent clearance or torque settings from
remove bearing (3) and bearing (4). being altered.

Check that there is no excessive wear in the splined portion Figure 80

for fitting the flange to the pinion; if there is, replace the pinion.
Check the planetary gears and associated thrust washers, the

spider and differential gears and thrust washers.
Replace all seals and gaskets, the locking pin for the adjustment
ring nut and all lock washers.
NOTE If it should be necessary to replace the crown wheel

or pinion, both must be replaced as the parts are
supplied as matched pairs.
19383
Fit spider (6) complete with planetary gears (5) and associated
thrust washers (3) to half cage (4).
Position second differential gear (2) with thrust washer (1).
Assembling gear cage Figure 81
Figure 78
36323
19397
Lock the differential with the parts (1); fit on the half box (3).
Heat the support bearing (2) for the opposite side of the Check that the marks made at the time of removal coincide.
locking differential in a circulating air oven to a temperature of Apply a few drops of “LOCTITE 270” on the thread of the
100˚C for about 15’ and fit it to the gear cage (3) using a screws (2).
suitable drift (1). Tighten the screws (2) to the prescribed torque.
NOTE It is always advisable to renew screws (2).
Figure 79
Figure 82
19391
34850
Position half cage (2) on fixture 99371047. Heat bearing (1) in a circulating air oven to a temperature of
Position differential gear thrust washer (1) in the half cage (2) 100˚C for about 15’ and fit it to the gear cage (2) using a
and then fit differential gear. suitable drift.

Figure 83 1. part number;

2. tooth combination number.
This number (example: 12/41) indicates that the pinion
has 12 teeth and the crown wheel 41;
3. pinion/crown wheel pair set number.
All final drive sets are available as pairs: therefore pinion
and crown wheel bear the same number which is
stamped on head end for pinions and the outer face for
crown wheels;
NOTE Never use a pinion and crown wheel set unless both
components have the same number.
36324
Heat bevel crown wheel (1) in a circulating air oven to a

temperature of 100˚C for about 15’ and position it on its 4. variation number needed to determine the thickness of
seating on the gear cage, ensuring that the holes for the bevel the shim pack interposed between pinion bearing cage
crown wheel/gear cage attachment screws are lined up. and differential carrier (in the example below, this number
is identified as CP).
Every crown wheel is marked with a variation number which
Figure 84 indicates the nominal assembly distance. Use this number to
calculate the thickness of the shim pack that is interposed
between pinion bearing cage and differential carrier.
The variation number (CP + 0,1 or CP — 0,1) is stamped on
crown wheel outer face.
5. Pinion/crown wheel set manufacturing and inspection
month and year.
6. Specified pinion/crown wheel set clearance.
Part number and tooth combination number are stamped on
threaded end of all pinions. Number may alternatively be
located on outer diameter of crown wheel. On any
pinion/crown wheel set, crown wheel will always bear an even
stamped category number (e.g. 36786), whereas
36325
corresponding pinion will bear an odd number (e.g. 36787).
Allow the bevel crown wheel to cool before positioning the To determine the thickness of the shim pack to be
screws. Use torque wrench (1) to tighten self locking nuts (2) interposed between bearing cage and differential carrier
to the specified torque. proceed as follows:
1. measure the thickness of the shim pack removed
with the old final drive gear set. Use a micrometer or
other suitable gauge and record the value found;
2. read the CP marked on pinion to be replaced: if it is
a plus (+) number or a minus (—) number
respectively subtract or add it from the value
ASSEMBLING DIFFERENTIAL CASING obtained under 1. above;
Calculating bevel pinion position in differential Take note of the result.
casing
Figure 85
NOTE The value obtained in 2. will be used to calculate the
3 thickness of the shim to be interposed between
1,2,3 pinion bearing cage and differential carrier for
OPTION correct new final drive assembly.
1,2 3. read the CP marked on the new pinion.

Either add or subtract this value — depending on
1,2,3,4,5,6 whether the sign is a plus or a minus — to or from the
19416
value noted under 2. above.
If a new final drive set is installed, it will be necessary to know The result indicates the thickness which the new shim
the meaning of the markings on pinion and crown wheel in pack should have.
order to position the pinion correctly: Refer to the following examples which cover all the possible
calculation cases.

COMPUTATIONAL EXAMPLES Figure 87

Case 1: mm
Original shim pack thickness 0.76
CP marked on pinion +2 +0.05
Resulting value 0.81
CP marked on new pinion +5 —0.12
Thickness for new shim pack 0.69
Case 2:
Original shim pack thickness 0.76
CP marked on pinion —2 —0.05
Resulting value —0.71
CP marked on new pinion +5 —0.12
Thickness for new shim pack —0.59 77239
Case 3:
Measure the thickness of the adjustment ring (6) found on
Original shim pack thickness —0.76 removal and note down the value (dimension A).
CP marked on pinion + 2 +0.05 Tighten the tool 99395027 (8) in a vice and place the following
Resulting value 0.81 on it:
CP marked on new pinion —5 +0.12 - the bearing (7) on the pinion side;
Thickness for new shim pack 0.93 - the ring (6) previously measured.
Case 4: - the gear (5);
Original shim pack thickness —0.76 - the spacer (4);
CP marked on pinion —2 —0.05 - the bearing (3).
Resulting value 0.71 Screw down the ring nut (2) and tighten it fully.
CP marked on new pinion —5 +0.12 Position part (1) of tool 99395027 (8), equipped with a dial
Thickness for new shim pack 0.83 gauge, on the bearing (3) and reset the dial gauge on the end
of the tool (8).
Then remove:
NOTE The difference between the value of the thickness - the part (1);
of the new pack and that of the old one must be - the ring nut (2);
added to or subtracted from, depending on the - the bearing (3);
case, the thickness of the adjustment ring (6,
Figure 87). - the spacer (4);
- the gear (5);
- the ring (6) the bearing (7) from the tool (8).
Figure 86
Figure 88
36383
Place the bevel pinion position adjustment rings (4) in the box
77241
and, using grip 99370007 (1) and drift 99374094 (2), mount
the external ring (3) for the bevel pinion bearing. Insert the tool 99394027 (8, Figure 87) in the differential gear
Fit remaining bearing cups using drift 99374093. housing, comprehensive of the bearing (7, Figure 87), ring (6),
gear (5), spacer (4), bearing (3). Screw down the ring nut (1)
on the tool 99394027.

Figure 89 First example:

A = 13.12 mm
B = + 0.13 mm
C = 0.2 mm
S = 13.12 — (+ 0.13) + 0.2 =
S = 13.12 — 0.13 + 0.2 = 13.19 mm.
Second example:
A = 13.12 mm
B = — 0.13 mm
C = 0.2 mm
S = 13.12 — (— 0.13) + 0.2 =
S = 13.12 + 0.13 + 0.2 = 13.45 mm.
36387
Remove from the box the tool 99395027 (8, Figure 87) and
Screw down the ring nut (2, Figure 90) tightening it until, with take out the bearings, spacers and gear as shown in the figure.
a dynamometer, you measure a rolling torque of:
- 1.12 to 5.08 Nm if the bearings are new,
Figure 91
- 1.68 to 3.39 Nm if the bearings have already been used.
Figure 90
36386
Heat the bearing (2) to 100°C for 15 min. and, with a specific
drift, fit it on the bevel pinion.
78313
Figure 92
Reposition part (1) of tool 99395027, with the dial gauge
previously reset on the bearing (3) and measure any difference
(dimension B).
The thickness S of the ring, or of the adjustment rings, is given
by the following formula:
S = A — (± B) + C
where:
A = Thickness of the adjustment ring(s) fitted to reset the
dial gauge;
B = Value of the difference measured;
C = 0.2 mm coefficient that takes account of the
36385
expansion of the bearings due to the interference of
assembly on the bevel pinion. Insert the bevel pinion (3) in the box, simultaneously keying
onto it the adjustment ring (1) of the thickness determined in
the preceding measurements and the gear (2); screw the part
99345029 (4) onto the bevel pinion (3).

Figure 93 Figure 95
20670
77242 Position the caps taking care to make the reference marks
coincide.
Block rotation of the bevel pinion with the tool S.P. 2373 (5). Insert the screws, together with the washers, and tighten
Screw down the inserter 99345098 (4) onto the part (4, them, using a torque wrench, to the prescribed torque.
Figure 92) and fully drive in the gear (3). Then check that the external rings of the bearings slide, with
Remove the inserter (4). a light pressure, in their respective seats without sticking.
Fit on the spacer ring (1). Again unscrew the fastening screws with the washers and
Heat the bearing (2) to 100°C for 15 min. and fit it onto the remove the caps.
pinion.
Screw the inserter (4) back onto the part (4, Figure 92) and
take the bearing (2) into contact with its seat. Figure 96
Figure 94
94191
Using the hook (1), lift the gear housing (2) previously
assembled and position it on the differential casing (3).
Figure 97
77237
Block rotation of the bevel pinion with the tool S.P. 2373 (1).
Screw down the nut fastening the bevel pinion bearings and
tighten it to the prescribed torque.
NOTE To tighten the nut use the wrench 99355069 (2)

torque wrench and multiplier 99389816 (3).
77245
Position the caps (2), screw down the screws (1) with the
washers and tighten them to the prescribed torque.

Figure 98 2nd METHOD

A. Diagonally and centrally on the outer machined seats of
both caps (2, Figure 100) position two dial gauges (1) with
magnetic base as shown in Figure 100;
Figure 100
77246
Lubricate taper roller bearings (1) and fit outer races.

Screw in adjustment ring nuts (2).
77247
Adjusting the cap gap B. proceed as described in point ”1”;

Adjusting and checking retraction of the caps can be done with C. after eliminating the end float further tighten the two
two methods: adjustment lock rings (4) to obtain a retraction of the caps
1st METHOD (2) of 0.08 to 0.22 mm, which corresponds to the sum of
the readings on the dial gauges (1).
1. Use wrench 99355025 (3, Figure 100) to tighten the
adjustment lock rings (4) of the bearings until eliminating
the pinion—crown wheel clearance and end float. At the
same time check that the crown wheel does not force on Figure 101
the pinion;
2. using a suitable micrometer positioned diagonally and
centrally in points (X—Y—arrows, Figure 99);
measure and note the distance of the caps;
Figure 99
49248
Adjust the axial clearance between the teeth of the pinion —

crown wheel unit which must be 0.20 to 0.46 mm proceeding
as follows:
- stop the bevel pinion from turning using tool 99370317;
- position the magnetic—based dial gauge (1) as illustrated;
- using wrench 99355025 (3) slacken the adjustment lock
ring on the crown wheel side and tighten, to the same
extent, the adjustment lock ring (2) of the opposite side.
60636 The purpose of this is to leave the previously—adjusted
cap retraction unchanged;
3. further tighten the two adjustment lock rings (4,
- proceed as described until obtaining the specified
Figure 100) to obtain a retraction of the caps (2,
clearance.
Figure 100), measured on Axis X or on axis Y as
described in point ”2” of: 0.08 to 0.22 mm which The clearance should be checked on 4 points the same
corresponds to a preload on the bearings of 1.7 to 3.9 Nm distance apart.
(0.17 to 0.39 kgm).

19453
Contacts too much towards the crown wheel teeth top land
Conditions A—B. Indicates that the pinion is fastened to much
49246 towards the outside and therefore needs further adjustment.
Use a magnetic—based dial gauge (1) to check that the crown To adjust the exact position of the pinion, remove shims under
wheel (2) does not have any upper wobble above 0.20 mm. the pinion support to obtain the exact contact.
If it does, disassemble the differential unit and find the cause. Condition A. After removing the shims, take the clearance
towards maximum.
Refit and repeat the adjustment operations described
Condition B. Measure the clearance and restore it after
previously.
removing shims.
Figure 103
Figure 106
1
19451
4
Apply a light layer of Prussian blue on the crown wheel. 3
Turn the pinion and measure the impression of the contact of
the pinion teeth on the crown wheel teeth.
Clearance reduction
The following figures show possible contacts and how to
correct any errors.
Figure 104 Clearance increase 19454
THEROETICAL CONTACT AREA
1. Release, concave side of tooth

2. Top land
3. Pulling, convex side of tooth
19452 4. Heel
Contacts too much on crown wheel teeth bottom land PULLING. Central tending towards the top land on the tooth
face and central on the tooth profile.
Conditions C—D. Indicates that the pinion is fastened too
deeply and needs further adjustment. RELEASE. Central tending to the heel on the tooth face and
To adjust the exact position of the pinion shims should be central on the tooth profile.
added under the pinion support to obtain the exact contact.
Indicates that the pinion is fastened correctly.
Condition C. Measure the clearance and restore it after
The contact position can be further changed by changing the
adding shims.
pinion—crown wheel clearance.
Condition D. After adding shims, take the clearance towards
Condition E. Lower the clearance.
minimum.
Condition F. Increase the clearance.

CORRECTING THE CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)

Figure 107
THEORETICAL CONTACTS
PULLING RELEASE
(CONVEX SIDE OF RING GEAR) (CONCAVE SIDE OF RING GEAR)
TIP TIP
HEEL TOP HEEL

LAND
BOTTOM LAND BOTTOM LAND
— PULLING : CENTRAL TENDING TOWARDS THE TOP LAND ON THE TOOTH FACE
AND CENTRAL ON THE TOOTH PROFILE
— RELEASE : CENTRAL TENDING TOWARDS THE HEEL ON THE TOOTH FACE
CONDITION “A”
PULLING RELEASE
TIP TIP
HEEL TOP HEEL

LAND
— PULLING RELEASE : CONTACTS TOO MUCH AT TIP

— PULLING : CONTACT TOO MUCH AT TOP LAND
— RELEASE : CONTACT TOO MUCH AT HEEL
— CORRECTIVE ACTION : REMOVE SHIMS AND INCREASE CLEARANCE TO MAXIMUM
CONDITION “B”
TIP TIP
HEEL TOP HEEL

LAND
— PULLING — RELEASE : CONTACTS TOO MUCH AT TIP

— CORRECTIVE ACTION : MEASURE THE CLEARANCE AND RESTORE THE CLEARANCE
CONDITION “C”
TIP TIP
HEEL TOP HEEL

LAND
— PULLING — RELEASE : CONTACTS TOO MUCH ON BOTTOM LAND

— CORRECTIVE ACTION : MEASURE THE CLEARANCE, ADD SHIMS AND RESTORE CLEARANCE
60676

Figure 108
CONDITION “D”
TIP TIP
HEEL TOP HEEL

LAND

— PULLING: : CONTACT TOO MUCH AT HEEL
— RELEASE : CONTACT TOO MUCH AT TOP LAND
— CORRECTIVE ACTION : ADD SHIMS AND REDUCE CLEARANCE TO MINIMUM
CONDITION “E”
TIP TIP
HEEL TOP HEEL

LAND
— PULLING : CONTACT TOO MUCH AT HEEL

— CORRECTIVE ACTION : REDUCE CLEARANCE
CONDITION “F”
TIP TIP
HEEL TOP HEEL

LAND

— CORRECTIVE ACTION : INCREASE CLEARANCE
60677

77248
77249
Fit on the spring pin (1) and the split pin (3) to lock the ring
nuts (2—4). Position the fork (2) in the groove of the coupling (1) and fit
this on the toothing (3) of the differential gear.
NOTE If the spring pin or the split pin do not coincide with
their respective seats on the ring nuts, slightly turn
these so it is possible to insert the spring pin or the Figure 112
split pin,
Figure 110
77234
Mount the spindle (6). Lubricate the new seal (5) and fit it on
the piston (4) and insert this into the cylinder (3). Apply sealant
on the thread of the cylinder (3) and screw it down into the
differential casing, tightening it to the prescribed torque.
77236
Fit on the spring (1) and the fork (2) from inside the differential Screw down the screw (2) so as to provisionally prevent the
casing. differential gear unlocking.
Remove the differential casing from the mounting and fit it
back on the axle housing as described under the relevant
heading.

526082 REMOVING—SERVICING—REFITTING
Mount the differential locking — transfer box (Figure 55, page INTER-AXLE OUTPUT SHAFT
35) and adjust it as described under the heading, “Adjusting
differential locking—transfer box pin limit switch.” Figure 115
Figure 113
36344
Stop rotation of flange (1) with retainer 99370317 (3). With

wrench 99355131 (2) and torque adaptor (4) loosen shaft
40678
flange (1) retaining nut.
Removing retaining nuts (5) and separate shaft bearing cage (6)
from axle housing.
Position on the differential casing the adjustment rings (2) of
the thickness determined under the heading “Adjusting drive Figure 116
input shaft bearing end float” and fit on the mount (1)
comprehensive of the reduction gear transfer box.
Figure 114
36388
Tighten the drive output shaft (3) in a vice; remove the nut
securing flange (2) to drive output shaft (3) and dismantle
flange (2) from shaft (3) using an extractor.
Figure 117
36349
Block rotation of the flange (1) using tool 99370317 (2); with
wrench 99355088 (3) and multiplier (4) tighten the nut
fastening the flange (1) to the prescribed torque.
Fit on the cover (5) with a new gasket.
Remove the differential casing — transfer box from the
mounting 99322228 and fit it back on the axle housing as
described under the relevant heading.
36389
Remove sealing ring (1) from bearing cage (2) and take out
snap ring (3) retaining bearing cup (4) and snap ring (5).


X
36390
Extract the drive output shaft (5) complete with bearings (2

36393
and 3) and bearing cup (1) from bearing cage (4).
Use a suitable extractor to remove bearings (2 and 3) from
the drive output shaft (5). Reverse the removal operation sequence to reassemble the
output shaft unit.
After using tool 99374163 to assemble seal ring (3), use a
Figure 119 thickness gauge to check distance X between seal ring (3) and
support at four equidistant points.
Distance X must be between 0.38 ÷ 0.76 mm.
Tighten nut (2) fastening flange (1) to the drive output shaft
(4) to the specified torque. Then check that end play is
between 0.025 ÷ 0.102 mm
using a magnetic base dial gauge (3) positioned on shaft (4).
If reading is other than specified, replace the snap ring (5,
Figure 117) with one of the correct thickness.
NOTE Snap rings are supplied in the following thickness

range: 5.30 — 5.33 — 5.35 — 5.38 — 5.40 — 5.50 — 5.60
— 5.70 — 5.80 — 5.90 — 6.00 — 6.10 — 6.13 — 6.15 —
36391
6.18 — 6.20
Use a punch to drive bearing (3, Figure 118) cup (1) off Figure 122
bearing cage (2).
Figure 120
36346
36392
Rotate the axle housing by 90°.
Fit bearing cage (1) complete with drive output shaft (2) in the
axle housing and tighten nuts to the specified torque.
With drift 99374093 (2) partially press fit bearing cup (3) in
bearing cage (4).
Complete bearing cup fitting using drift 99374093 and handle
99370007 (1).

Figure 123
36394
DRIVE OUTPUT SHAFT COMPONENTS


EUROCARGO TECTOR 12—26 t AXLES IN TANDEM (REAR) 55
Axles in tandem (Rear)

ArvinMeritor PR 140 E (R 0868)
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 57
LOCATION OF DIFFERENTIAL UNIT — COMPLETE

REAR AXLE DESCRIPTION PLATES . . . . . . . 58
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SERVICING REAR AXLE

ASSEMBLY PR 140 E (R 0868) . . . . . . . . . . . . 68
AIR BREATHER REMOVAL/INSTALLATION . . . 68
OVERHAULING WHEEL HUBS . . . . . . . . . . . . . 68
REMOVING DIFFERENTIAL
(with axle on stand 99322215) . . . . . . . . . . . . 68
REFITTING DIFFERENTIAL
REPAIRING DIFFERENTIAL . . . . . . . . . . . . . . . . 69
- Removing differential lock . . . . . . . . . . . . . . . . 69
- Dismantling differential casing . . . . . . . . . . . . . 70
- Dismantling gear cage . . . . . . . . . . . . . . . . . . . 71
- Dismantling bevel pinion support . . . . . . . . . . . 71
- Checking differential components . . . . . . . . . . 75
- Assembling gear cage . . . . . . . . . . . . . . . . . . . . 75
- Specimen calculations . . . . . . . . . . . . . . . . . . . 77
- Assembling differential casing . . . . . . . . . . . . . . 77
ADJUSTING THE CAP GAP . . . . . . . . . . . . . . . . 79
CORRECTING THE CROWN WHEEL AND PINION

CONTACTS (AFTER ASSEMBLY) . . . . . . . . . 82

56 AXLES IN TANDEM (REAR) EUROCARGO TECTOR 12—26 t

DESCRIPTION
The axle is a bearing axle type with a simple reduction; it You can also adjust the bevel pinion position with reference
consists of a box made in stamped steel sheet and properly to the ring bevel gear by changing the thickness of the pack of
strengthened. the rings, which are inserted between the differential box and
The differential consists of a reduction helical—toothed gear the bevel pinion support.
pair (pinion — ring gear assembly) and a wheelwork box (side The wheelwork box is supported by two taper roller bearings
pinion — crown wheel assembly). and can be adjusted axially through two threaded ring nuts.
The pinion is supported by two taper roller bearings and by The axle is provided with a pneumatic control differential
one straight roller bearing. locking device.
The adjustment of the bevel pinion assembly is made through The wheel hubs are supported by two taper roller bearings
adjusting rings placed between the two taper roller bearings. floating on the tube, which can be adjusted by means of a
threaded nut.
Figure 1
87295

LOCATION OF DIFFERENTIAL UNIT — COMPLETE REAR AXLE DESCRIPTION PLATES

The plates contain all information and details relating to either DIFFERENTIAL UNIT or complete REAR AXLE.
Service Network.
Figure 2
86620
A = identifies rear axle type A = identifies the family the item is belonging to/the
D = rear axle ratio
E = production date


Axle type: PR 140 E (R 0868)
Bearing axle with simple reduction.
DIFFERENTIAL ASSEMBLY
3.73 (11/41) — 3.91 (11/43) — 5.86 (7/41)
Crown wheel and pinion assembly 4.10 (10/43) — 4.30 (10/41) — 4.63 (8/37)
reduction ratio (pinion/ring gear 4.88 (18/39) — 5.29 (7/37) — 6.83 (6/41)
teeth number)
Bevel pinion bearings 2 taper roller bearings and 1 straight roller bearing
Bevel pinion bearing rolling torque

(without gasket)
new bearings Nm 1.5 to 5.5
kgm 0.15 to 0.55
reused bearings Nm 1.5 to 3.1
kgm 0.15 to 0.31
Bevel pinion bearing pre—load
through shims
adjustment
Thickness of bevel pinion bearing 5.19 — 5.22 — 5.30 — 5.32 — 5.52 — 5.55 — 5.45 — 5.60 —
pre—load adjusting rings mm 8.10 — 8.20 — 8.22 — 8.30 — 8.38 — 8.48 — 8.58
Clearance between pinion

and ring gear mm 0.20 to 0.46
Clearance adjustment between

pinion and ring gear Through ring nuts
Cap opening out mm 0.08 to 0.22
Differential box bearing

rolling torque Nm 1.7 to 3.9
kgm 0.17 to 0.39
Rolling torque between side

pinions and crown wheels Nm Max. 68
kgm Max. 6.8
Bevel pinion positioning with Through adjusting shims

Thickness of adjusting rings

inserted between bevel pinion 0.125 — 0.200 — 0.500
support and differential box

WHEEL HUBS
Wheel hub bearings Two taper roller bearings
Hub bearing axial clearance 0.00 to 0.05
Wheel hub bearing rolling torque

Nm Max. 1.96
kgm Max. 0.20
Wheel hub bearing axial clearance Through nut

adjustment

Hendrickson suspension Litres (kg) 12.2 (11)

TIGHTENING TORQUES
Figure 3
36395
SECTION OF DIFFERENTIAL PR 140 E (R 0868)
TORQUE
PART
Nm (kgm)
1 Nut to secure parts on bevel pinion 1392.5± 142 (139.2 ±14.2)
2 Transmitter locking nut 40 ± 5 (4 ± 0.5)
Differential locking device M6x1 (10.9) 14 ± 2 (1.4 ± 0.2)
3
cover securing screw M6x1 (8.8) 11±1 (1.1 ± 0.1)
Half box securing screw 1st step: pre—tightening 60 ± 5 (6 ± 0.5)
4
2nd step: angle closing 85º ÷ 95º
Screw to secure bevel pinion
5 support to differential box 1st step: pre—tightening 60 ± 5 (6 ± 0.5)
Self—locking nut to secure ring bevel gear to half box
6 1st step: pre—tightening 100 ± 5 (10 ± 0.5)
Screws and nuts to secure differential to axle box
7 1st step: pre—tightening 100 ± 5 (10 ± 0.5)
8 Screw to secure caps to differential box 527.5± 57.5 (52.75 ±5.75)
9 Differential locking device drive shaft 57.5 ± 7.5 (5.75 ± 0.7)

Figure 4
85492
SECTION ON THE REAR AXLE WHEEL HUB IN TANDEM PR 145 2/D
TORQUE
PART
Nm (kgm)
1 Nut fixing the drum to the wheel hub 40 ± 4 (4 ± 0.4)
2 Ring nut locking wheel hub adjustment nut 392.3 ± 20 (40 ± 2)
3 Screw fixing drive shaft to wheel hub 232.4 ± 24.5 (23.2 ± 2.4)
+50 +5
4 Nut fixing wheels 600 60 —2
—20
5 Nut for screw securing brake mounting 289 ± 14 (29.5 ± 1.5)

TOOLS
99305121 Heater
99322205 Rotary stand for unit overhauling (capacity 1000 daN, torque 120
daN/m)
99322215 Stand for axle overhauling
Unit holder (to be mounted on stand 99322205)

99322225
Single—acting lift
99341003
Pair of brackets
99341012

TOOLS
99341015 Clamp
99341016 Pair of brackets with holes
99345055 Reaction block for puller tools
99345103 Wheel hub fitting tool
99348001 Puller tool with clamping device
99355025 Wrench for differential gearcase bearing adjustment ring nuts

TOOLS

99355088 (to be used with 99370317)
99355167 Wrench (114 mm) for wheel hub bearing adjustment nut
99370005 Tool to extract gaskets
99370007 Tool to extract gaskets
99370317 Reaction lever and extension for flange lock
99370509 Hook to remove differential gearcase half—housing

TOOLS
99370616 Support to remove—fit back differential
Universal support to remove—fit back rear axles

99370617
Stand to hold differential half—housing when tightening crown

99371047 wheel screws (to be used with 99322205 — 99322225)
99374093 Drift punch for installation of bearing outer races (91÷134) (use with
99370007)
99374094 Drift punch for installation of bearing outer races (134÷215) (use
with 99370007)
99374134 Guide to assemble wheel hub

TOOLS
99389816 4 x torque multiplier, with square connection, 3/4” in, 1” out

(maximum torque 2745 Nm)
99389819 Torque wrench (0 — 10 Nm) with 1/4” square fitting
99395026 Tool for measuring hub rolling drag torque (use with torque
wrench)
99395027 Tool for determining thickness of differential bevel pinion adjust-

ment shims (use with 99395603)
993395603 Dial gauge (0÷5 mm)

525010 SERVICING REAR AXLE 526210 REMOVING DIFFERENTIAL

ASSEMBLY PR 140 E (R 0868) (with axle on stand 99322215)
Figure 5 Figure 7
19340
36396
Proceed as follows to lock the differential: unscrew the
threaded plug (2) and fit in its place screw (1) available on
Before placing the axle assembly on the stand, loosen the cylinder cover. Tighten screw fully in until the differential lock
bottom plug and drain the oil. is activated.
Remove the drive shafts as described on page 25; unscrew the
screws fixing the differential casing (1) and screw down three
Place axle on service stand 99322215. screws, that in this phase act as extractors, and extract it from
the axle housing with two metal rope eyebolts.
NOTE Rear axle identification data are provided on the

plate located on left hand side leaf spring mount.
525013 AIR BREATHER REMOVAL/

INSTALLATION
REFITTING DIFFERENTIAL
Figure 6 (with axle on stand 99322215)
Figure 8
34811
Ensure that air breather or tube (1) is not blocked; if so,

34827
dismantle, clean thoroughly and reassemble the unit.
Apply sealant to the rear axle housing contact surface.
525030 OVERHAULING WHEEL HUBS
For the operations:
overhauling the wheel hubs (555030), follow the directions
given for the Meritor rear axle PD 145 E.

Figure 9 Figure 11
36311
36798
Fit the differential into the axle casing; screw in nuts (2) and
screws (3) complete with lock washers and tighten them to Use wrench 99355168 (2) to unscrew fork control shaft (1)
the specified torque using torque wrench (1). and withdraw.
Fit drive shafts into the differential as described in Figure 26,
page 29; release the differential lock (if the axle has one) by
unscrewing screw (1, Figure 7). Fit this screw in its seat on the
cylinder cover and tighten plug (2, Figure 7), with washer, in Figure 12
the threaded hole previously occupied by the screw. Finally,
fill the axle case with the specified amount of TUTELA W
140/M—DA oil and check the operation of the differential lock
activation sending unit.
526210 REPAIRING DIFFERENTIAL

Removing differential lock
36313
Figure 10 Withdraw spring (2) and flat washer (1). Remove fork (3)
complete with sliding sleeve (4).
Figure 13
36312
Position differential casing assembly (1) on swivelling stand

99322005 (3) complete with support 99322228 (2).
Only for axles with a differential locking device. 19373
Remove screw (4); screws (5) and cover (6) with copper
washer, cylinder (7) with piston and sealing ring.
Use a punch to drive out the two roll pins (3) and separate
fork (1) from sliding sleeve (2).

Dismantling differential casing Figure 17

Figure 14
19455
19376
Straighten and withdraw cotter pin (1) and unscrew lock ring Using hook 99370509 (1), withdraw the gear cage complete
(2) adjusting gear cage support bearings. with bevel crown wheel and bearing outer races (2).
Figure 15 Figure 18
19374
Unscrew retaining screws (1) with washers (2) and remove 36315
plate (3).
Unscrew lock ring (4) adjusting gear cage support bearings. Prevent flange (1) from rotating using holding tool 99370317
(3). Using wrench 99355088 (2) and adaptor (4), loosen the
bevel pinion retaining nut.
Figure 19
Figure 16
36428
Unscrew the screws securing the bevel pinion support to the

36314 differential casing.
Unscrew screws (1) with washers (2), remove caps (3) and Withdraw support (1) and bevel pinion from differential
support bearing lock rings (4). casing (3). Remove shims (2) adjusting the pinion position with
respect to the crown wheel.

Dismantling gear cage Figure 23

Figure 20
19382
Mark the two casing halves (2 and 3) and the spider as

19379
indicated in the figure.
Unscrew screws (1) joining the casing halves. Lift the casing half
Use hook (1) to raise the gear cage assembly and position on (2).
stand 99371047 (3).
Figure 24
Figure 21
19383
Remove differential gear (2) with the associated thrust washer

(1). Remove spider (6) with the four planetary gears (5)
complete with thrust washers (3). Take the spider/planetary
gear assembly apart. Remove the other differential gear with
36316 its thrust washer from the half cage (4).
Unscrew nuts (1) and remove them with screws. Drive out
bevel crown wheel (2).
526249 Dismantling bevel pinion support

Figure 22
Figure 25
19384
36317
Prevent the flange from rotating using tool 99370317 (2) and
Use tool 99348001 (1) and reaction block 99345055 (2) to use a universal extractor or appropriate tool (1) to remove
remove bearing (3) and bearing (4). the transmission attachment flange from the bevel pinion.

Figure 26 Figure 28
19388
Use a punch to remove seal carrier cover (2) from bevel

36318
pinion support (1). Then remove front bearing from support.
Position the pinion support under a press and drive out bevel
pinion (2) complete with intermediate bearing, rear bearing
and adjustment ring from bevel pinion support (1). Remove
adjustment ring from bevel pinion.
Figure 27 Figure 29
36319 19389
Apply a drift to the point arrowed in the diagram and drive out
Apply tool 99348001 (2) under taper roller bearing (1) and use outer race (2) of front bearing from bevel pinion support (3).
a press to remove from bevel pinion (3). If necessary, remove Upturn the support and remove the intermediate bearing
rear bearing (4) from bevel pinion (3) in the same way outer race (1).

Figure 30
20958
DIFFERENTIAL COMPONENTS (with differential lock)

1. Bevel pinion nut — 2. Flange — 3. Deflector — 4 .Seal holder cover — 5. Screw — 6. Washer — 7. Front bearing — 8. Outer race —
9. Support — 10. Adjustment shim — 11. Adjustment ring — 12. Outer race — 13. Intermediate bearing — 14. Bevel pinion —
15. Rear bearing — 16. Lock nut — 17. Sending unit — 18. Plug — 19. Adjustment ring nut — 20. Spring — 21. Shaft — 24 .Cylinder —
25. Piston — 26. Sealing ring — 27. Copper ring — 28. Cover — 29. Screws — 30. Screw — 31. Washers — 32. Copper washer —
33. Threaded plug — 34 .Sliding sleeve — 35. Roll pins — 36. Fork — 37. Screws — 38. Washer — 39. Plate — 40. Screw —
41. Washer — 42. Cap — 43. Thrust washer — 44. Planetary gear — 45. Differential gear — 46. Thrust washer — 47. Half cage —
48. Bearing — 49. Outer race — 50. Screw — 51. Spider — 52. Screw — 53. Bevel crown wheel — 54. Half cage — 55. Nut —
56. Cap — 57. Locking pin — 58. Differential casing.

Figure 31
36321
SECTION OF DIFFERENTIALS PR 140 E (R0868)
Figure 32
36321
View of differential unit with differential lock device.

Checking differential components Figure 34
Thoroughly clean the individual parts making up the

differential. Lubricate the bearings and spin the roller cages
freely; these should rotate evenly without tight spots.
Check the seating surfaces of the bevel crown wheel and the
bedding surface of the half cage so that the crown wheel
adheres to it perfectly; distortion of these faces would cause
vibration of the crown wheel attachment screws,
compromising the satisfactory operation of the unit.
NOTE Thoroughly clean threads of screws, studs and ring 19391

nuts to prevent clearance or torque settings from Position half cage (2) on fixture 99371047.
being altered. Position differential gear thrust washer (1) in the half cage (2)
and then fit differential gear.
Check that there is no excessive wear in the splined portion
Figure 35
for fitting the flange to the pinion; if there is, replace the pinion.
Check the planetary gears and associated thrust washers, the

spider and differential gears and thrust washers.
Replace all seals and gaskets, the locking pin for the adjustment
ring nut and all lock washers.
NOTE If it should be necessary to replace the crown wheel

19383
or pinion, both must be replaced as the parts are
supplied as matched pairs. Fit spider (6) complete with planetary gears (5) and associated
thrust washers (3) to half cage (4).
Position second differential gear (2) with thrust washer (1).
Figure 36
Assembling gear cage
Figure 33
36323
Lock the differential with the parts (1); fit on the half box (3).
Check that the marks made at the time of removal coincide.
Apply a few drops of “LOCTITE 270” on the thread of the
screws (2).
Tighten the screws (2) to the prescribed torque.
19397
Heat the support bearing (2) for the opposite side of the
locking differential in a circulating air oven to a temperature of NOTE It is always advisable to renew screws (2).
100˚C for about 15’ and fit it to the gear cage (3) using a
suitable drift (1).

Figure 37 Figure 40
19413 19378
Heat front bearing (1) in a circulating air oven to a If the old pinion/crown wheel assembly is to be refitted,
temperature of 100˚C for about 15’ and fit it to its seat on the position shim pack (2) and bevel pinion support (1) on the
bevel pinion (2) using a suitable drift. differential casing (3), making sure that the groove through
which oil passes is correctly lined up.
Figure 38
Figure 41
3,5
1,2
1,2
1,2,3,4,5,6
19414
19416
Lubricate seal carrier cover (1) seat with differential oil and
install it in support (2), using a suitable locking ring. Where a new pinion/crown wheel assembly has to be fitted,
it is necessary to understand the information stamped on the
pinion and on the crown wheel in order to determine the
Figure 39 correct location of the pinion, in other words:
1. part number;
2. tooth combination number;
3. pinion/crown wheel assembly pairing number;
4. variation number to determine the thickness of the
stack of shims to be placed between the pinion sup-
port and the differential casing (this variation number
is indicated by CP in the examples);
5. month and year of manufacture and inspection of the
pinion/crown wheel assembly;
6. nominal end play of the pinion/crown wheel assembly.
The part number and the tooth combination number are
stamped at the threaded end of all pinions. However,
alternatively, they may be found on the outside diameter
of the crown wheel.
19415
Position drive attachment flange (1) complete with deflector

(2) on the splined part of the bevel pinion. Use a drift to drive In any pinion/crown wheel assembly, the crown wheel will
fully home. It is advisable to carry out this operation using a always have an even category number (for example 36786)
press. stamped on it, while the corresponding pinion will have an odd
Temporarily tighten the retaining nut. number (for example 36787).

The tooth combination number (for example 5—37) indicates Example 2

that the pinion has 5 teeth and the crown wheel 37, equal to Thickness of original stack 0.76 mm
a drive ratio of 7.4 / 1. C.P. engraved on crown wheel — 0.05 + 0.05
- Pinion/crown wheel assemblies are matched pairs. Measurement obtained 0.81 mm
- Both parts are, therefore, engraved with the same number. C.P. engraved on the new crown wheel + 0.13 + 0.13
On pinions, this number is generally engraved on the end of the New thickness of stack to be used 0.94 mm
head while on crown wheels it is generally engraved on the
outside diameter Example 3
Thickness of original stack 0.76 mm
C.P. engraved on crown wheel + 0.05 — 0.05
Measurement obtained 0.71 mm
NOTE Never use a pinion and a crown wheel which do not
C.P. engraved on the new crown wheel — 0.13 — 0.13
have the same number.
New thickness of stack to be used 0.58 mm
Every crown wheel has a variation number which indicates the Example 4
nominal assembly distance. Use this variation number to Thickness of original stack 0.76 mm
calculate the thickness of the shims to be placed between the C.P. engraved on crown wheel — 0.05 + 0.05
pinion support and the differential casing. Measurement obtained 0.81 mm
This variation number (for example C.P. + 0.1, or C.P. — 0.1 C.P. engraved on the new crown wheel — 0.13 — 0.13
mm) is stamped on the outer part of the crown wheel. New thickness of stack to be used 0.68 mm
To calculate the thickness of the shims to be placed between

the pinion support and the differential casing, proceed as
follows :
NOTE The shims to be placed between the differential
1. measure the thickness of the shim pack used with the
casing and the bevel pinion support are supplied as
pinion/crown wheel assembly to be replaced. Use a
spare parts in thicknesses of 0.05 — 0.125 — 0.200 —
micrometer or gauge and take note of the measure-
0.500 mm.
ment recorded;
2. read the C.P. engraved on the crown wheel to be re-
placed. If this number represents a plus value (+), Every pinion and every crown wheel is marked with the
subtract it from the measurement recorded above at month and year in which they were ground and inspected
point 1. jointly to form a matched pair.
If this number represents a minus value (—), add it to
the measurement recorded at point 1 above. On the pinions, this information is given at the head end.
On the crown wheels, this information is shown on the
Take note of this measurement. outside diameter.
All assemblies are engraved with a number which shows the
nominal end play between the pinion and crown wheel
NOTE The measurement obtained at point 2 will be used obtained when machining was finished. This end play is
to calculate the shim pack to be placed between the shown on the outside diameter of the crown wheel.
pinion support and the differential casing, depending
on the new pinion/crown wheel assembly. Assembling differential casing
Figure 42
7. Read the C.P. engraved on the new crown wheel.
Add or subtract the value according to algebraic
value (+ add, — subtract) from the measurement re-
corded at point 2.
The value obtained indicates the thickness of the new
shim pack to be used.
Refer to the following examples which cover all possible

calculation combinations.
Specimen calculations
Example 1
Thickness of original stack 0.76 mm
C.P. engraved on crown wheel + 0.05 — 0.05 36328
Measurement obtained 71 mm
C.P. engraved on the new crown wheel + 0.13 + 0.13 Fit the eight screws (2) complete with washers and tighten
New thickness of pack to be used 0.84 mm them, using torque wrench (1), to the specified torque.

Figure 43 Figure 45
19419
36329
Use hook (1) to lift gear cage (2), assembled previously, and
Swivel the stand through 90˚. position it on differential casing (3).
Prevent the flange from rotating using tool 99370317 (3).
Position polygon wrench 99355088 (1) and use adaptor (2)
and torque wrench (4) to tighten the pinion retaining nut to
the specified torque. Figure 46
Recheck the rolling torque of the bevel pinion, the values are
shown in the table on page 59.
NOTE Note that the rolling torque increases by 1.5 Nm

when the seal is lubricated.
Figure 44 36330
Position caps (2), screw in screws (1) with washers and tighten
to the specified torque.
Figure 47
20670
Position the caps, taking care to line up the reference marks.

Insert the screws complete with washers and tighten them
using a torque wrench to the specified torque.
Then check that the outer races of the bearings slide into their
housings when pushed gently without sticking. 36331
Unscrew the retaining screws with washers again and remove Lubricate taper roller bearings (1) and fit outer races.
the caps. Screw in adjustment ring nuts (2).

ADJUSTING THE CAP GAP Figure 49

Adjusting and checking retraction of the caps can be done
with two methods:
1st METHOD
same time check that the crown wheel does not force
on the pinion;
60635
Figure 48
B. proceed as described in point ”1”;

C. after eliminating the end float further tighten the two
adjustment lock rings (4, Figure 49) to obtain a retraction
of the caps (2) of 0.080 to 0.22 mm, which corresponds
to the sum of the readings on the dial gauges (1).
Figure 50
60636
3. further tighten the two adjustment lock rings (4,

Figure 49) to obtain a retraction of the caps (2,
Figure 49), measured on Axis X or on axis Y as described
in point ”2” of: 0.080 to 0.22 mm which corresponds to 49248
a preload on the bearings of 1.7 to 3.9 Nm (0.17 to 0.39
kgm).
Adjust the axial clearance between the teeth of the pinion
— crown wheel unit which must be 0.21 to 0.45 mm
2nd METHOD proceeding as follows:
A. Diagonally and centrally on the outer machined seats of - stop the bevel pinion from turning using tool 99370317;
both caps (2, Figure 49) position two dial gauges (1) with - position the magnetic—based dial gauge (1) as illustrated;
magnetic base as shown in Figure 49;
- using wrench 99355025 (3) slacken the adjustment lock
ring on the crown wheel side and tighten, to the same
The purpose of this is to leave the previously—adjusted
clearance.
The clearance should be checked on 4 points the same
distance apart.

Figure 51 Figure 53
19452
Contacts too much on crown wheel teeth bottom land

deeply and needs further adjustment.
49246
To adjust the exact position of the pinion shims should be
added under the pinion support to obtain the exact contact.
Use a magnetic—based dial gauge (1) to check that the crown
adding shims.
wheel (2) does not have any upper wobble above 0.20 mm.
If it does, disassemble the differential unit and find the cause. Condition D. After adding shims, take the clearance towards
minimum.
Reassemble and repeat the adjustment operations described
above.
Figure 54
Figure 52
19453
Contacts too much towards the crown wheel teeth top land
Conditions A—B. Indicates that the pinion is fastened to
19451 much towards the outside and therefore needs further
adjustment.
To adjust the exact position of the pinion, remove shims
Apply a light layer of Prussian blue on the crown wheel. under the pinion support to obtain the exact contact.
Turn the pinion and measure the impression of the contact
Condition A. After removing the shims, take the clearance
of the pinion teeth on the crown wheel teeth.
towards maximum.
The following figures show possible contacts and how to
correct any errors. Condition B. Measure the clearance and restore it after
removing shims.

Figure 55
4
3
Clearance reduction
Clearance increase
19454

2. Top land
4. Heel
PULLING. Central tending towards the top land on the tooth
RELEASE. Central tending to the heel on the tooth face and
central on the tooth profile.
Condition E. Lower the clearance.
Condition F. Increase the clearance.


Figure 56
PULLING RELEASE
TIP TIP
HEEL TOP HEEL

LAND
CONDITION “A”
PULLING RELEASE
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “B”
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “C”
TIP TIP
HEEL TOP HEEL

LAND

60676

Figure 57
CONDITION “D”
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “E”
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “F”
TIP TIP
HEEL TOP HEEL

LAND

60677

Figure 58 Figure 59
49249 49250
Replace the safety split pin (1) and fold it; repeat this Place the pin (4) into its housing.
operation on the opposite side. Fit the fork (2) and spring (3) to the pin (4) and push it in all
the way. Fit the piston (5), complete with ring and cover (6),
then fit the sliding sleeve (1) and spring plugs (7).

EUROCARGO TECTOR 12—26 t ARVINMERITOR AXLE MS 08—125 85
Print 603.93.391
5250 ArvinMeritor Axle

MS 08—125
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 87

TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . . . 88
FEATURES AND DATA . . . . . . . . . . . . . . . . . . . 89
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 91
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
REAR AXLE DISCONNECTION—RECONNECTION 100
- Rear axle disconnection

Vehicles with a mechanical suspension . . . . . . . 100
- Rear axle disconnection

Vehicles with a pneumatic suspension . . . . . . . 102
- Axle reconnection . . . . . . . . . . . . . . . . . . . . . . 103
DIFFERENTIAL DISCONNECTION—RECONNECTION
WITH THE AXLE ON THE VEHICLE . . . . . . 104
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 104
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . 104
REAR AXLE ASSEMBLY OVERHAUL . . . . . . . . . 105
- Air vent disconnection and reconnection . . . . 105
- Wheel hub overhaul . . . . . . . . . . . . . . . . . . . . 105
- Check parts making up the wheel hubs . . . . . . 109
- Replacement of wheel holding down studs . . . 109
- Wheel hub mounting . . . . . . . . . . . . . . . . . . . . 109
FIXING THE DIFFERENTIAL . . . . . . . . . . . . . . . . 113
- Dismounting the differential box . . . . . . . . . . . 113
DISMOUNTING THE WHEELWORK BOX . . . 114
BEVEL PINION SUPPORT

DISASSEMBLING . . . . . . . . . . . . . . . . . . . . . . 115

86 ARVINMERITOR AXLE MS 08—125 EUROCARGO TECTOR 12—26 t
Page
- Check of parts making up the differential . . . . . 118
MOUNTING THE WHEELWORK BOX . . . . . . 118
MOUNTING BEVEL PINION SUPPORT . . . . . . 119
CALCULATION EXAMPLES . . . . . . . . . . . . . . . . 122
MOUNTING THE DIFFERENTIAL BOX . . . . . . . 122
- Adjusting cap opening out . . . . . . . . . . . . . . . . 123
FIXING CROWN WHEEL AND PINION ASSEMBLY

CONTACTS (AFTER MOUNTING) . . . . . . . 126
- Directions to adjust and check the operation

of the transmitter for checking differential
locking device insertion. . . . . . . . . . . . . . . . . . . 130

Print 603.93.391
DESCRIPTION The wheelwork box is supported by two taper roller bearings

and can be adjusted axially through two threaded ring nuts.
Axle ARVINMERITOR MS 08—125 is a bearing axle type with The wheel hubs are supported by two taper roller bearings
a simple reduction; it consists of a box made in stamped steel floating on the tube; they can be adjusted by means of a
sheet and properly strengthened. threaded nut.
The differential is characterised by a hypoidal—toothed gear All axles are pre—set for mounting the differential locking
assembly. device.
The pinion is supported by two taper roller bearings and by The wheel hubs are keyed, with constant lubrication (Long
one straight roller bearing. Life) bearings “UNIT — BEARING”, on the axle box tubes.
The adjustment of the bevel pinion assembly is made through The bearings do not require any adjusting.
adjusting rings placed between the two taper roller bearings. The brakes are disk brakes with floating brake calipers.
You can also adjust the bevel pinion position with reference The brake disks are keyed on the wheel hubs.
to the ring bevel gear by changing the thickness of the pack The brake calipers are supported by flanges that are secured
of the rings, which are inserted between the differential box to the axle box tubes.
and the bevel pinion support.
Figure 1
60332
VIEW OF AXLE H 127 E ASSEMBLY


Service Network.
Figure 2
86620
D = rear axle ratio
E = production date
TECHNICAL NAME
Type of brake Serial number
Place of manufacture Ratio
Type of wheel side/pinion bearings Prototype
M S 08 1 2 5 X X X X XXX XXX X
Axle casing thickness: 12.7 ÷ 13 mm
Ring gear diameter: 337/387 mm
Single ratio
Capacity (t.)
MERITOR
Rear only

FEATURES AND DATA

Axle type:
MS 08—125
DIFFERENTIAL GROUP
3.07 (14/43) — 3.31 (13/43) — 3.73 (11/41) —

Crown wheel and pinion assembly
4.10 (10/41) — 4.30 (10/43) — 4.56 (9/41) —
reduction ratio
4.88 (8/39)
2 taper roller bearings and 1 straight roller

Bevel pinion bearings
bearing
Bevel pinion rolling torque Nm 1.5 ÷ 5.5

(bearing pre—load without gasket) kgm 0.15 ÷ 0.55
Thickness of bevel pinion bearing pre—load

pre load
adjusting rings mm 6.00-6.05 6.08-6.15 6.18-6.25 6.28-6.30 6.33-6.40
Clearance between pinion and ring gear mm 0.20 ÷ 0.45
Clearance adjustment between pinion and

ring gear Through ring nuts
Cap opening out mm 0.15 ÷ 0.33
Rolling torque between side pinions and

crown wheels Nm 68 max.
Bevel pinion positioning with reference to

differential box Through adjusting shims
Thickness of adjusting rings inserted

between bevel pinion support and
differential box mm 0.125 — 0.160 — 0.200 — 0.500

Axle type:
MS 08—125
WHEEL HUBS
Wheel hub bearings UNIT—BEARING
Hub bearing axial clearance —
Nm —
Wheel hub bearing rolling torque
kgm —
Adjusting the wheel hub bearing axial Adjusting cannot be executed

clearance Tightening with securing ring nut torque
Axle oil TUTELA W140/M—DA (SAE 85W 140)

Quantity Mechanical suspension Litres (kg) 6.5 (5.85)
Pneumatic suspension Litres (kg) 6.5 (5.85)
GAW (MAX carrying capacity) kg 8500

DIAGNOSTICS
Axle main operation faults:
1 — Wheel hub noise;

2 — Axle noise;
3 — Noise at release;
4 — Noise on draught;
5 — Noise on turning.
1 WHEEL HUB NOISE
Inefficient wheel hub bearings. Dismount hub and replace bearings.

YES
2 AXLE NOISE
Insufficient lubricant oil level. Check that no leaks are present from the gaskets or the
YES axle box, and recover level.
NO
Splines to match half shafts with differential crown gears Overhaul axle and replace worn out or damaged parts.
damaged. YES
NO
Adjusting is not correct, or differential assembly gears or Locate trouble and overhaul assembly.
bearings are impaired. YES

3 NOISE AT RELEASE
Matching clearance between pinion and ring bevel gear Detach wheelwork inspection cover and adjust clearance
is not correct. YES between pinion and ring gear.
4 NOISE ON DRAUGHT
Insufficient lubrication. Check that no leaks are present from the gaskets or the
YES axle box, and recover level.
NO
Wheelwork box bearings out of adjustment or impaired. Overhaul assembly.

YES
NO
Contact of teeth between pinion and ring bevel gear is Adjust contact.
not correct. YES
5 NOISE ON TURNING
Side pinion—crown wheel assembly clearance is not Overhaul or replace assembly.

correct. YES

TIGHTENING TORQUES
Figure 3
60333
SECTION OF DIFFERENTIAL
TORQUE
PART
Nm (kgm)
1 Nut to secure parts on bevel pinion 1122.5 ± 122.5 (112.5 ± 12.25)
2 Nut for screw to secure ring gear to differential half box 1st step: pre—tightening 70 ± 5 (7 ± 0.5)
2nd step: slant closing 110° ÷ 120°
Screw/nut to secure differential 1st step: pre—tightening 60 ± 5 (6 ± 0.5)
3
to axle box 2nd step: slant closing 70° ÷ 80°
4 Screw to secure caps to differential box 272.5 ± 27.5 (27.25 ± 2.75)
Screw to secure bevel pinion support 1st step: pre—tightening 60 ± 5 (6± 0.5)
5
to differential box 2nd step: slant closing 55° ÷ 65°
7 Differential locking drive shaft (apply “Loctite 242” on thread) 57.5 ± 7.5 (5.75 ± 0.75)
8 Differential locking cover securing screw M 6x1 (10.9) 14 ± 7.5 (5.75 ± 0.75)
M 6x1 (8.8) 11 ± 1 (1.1 ± 0.1)
9 Safety plate securing screw 31.5 ± 3.5 (3.1 ± 0.3)
Differential half box securing screw 1st step: pre—tightening 60 ± 5 (6 ± 0.5)
10*
2nd step: slant closing 90° ÷ 100°
* The screws must be replaced by new screws on every dismounting

Figure 4
60334
WHEEL HUB SECTION
TORQUE
PART
Nm (kgm)
1 Brake caliper securing screw 187 ± 19 (18.7 ± 1.9)
2 Wheel securing nut 490 ± 50 (49 ± 5)
3 Screw to secure half shaft to wheel hub 150 ± 15 (15 ± 1.5)
4 Nut to secure wheel hub bearing 864.5 ± 86.5 (86.45 ± 8.65)
5 Screw to secure brake disk to wheel hub 40 ± 4 (4 ± 0.2)
— Nut to brake cylinder to brake caliper — —
* Apply sealant IVECO 1905685 (LOCTITE 14780)
on hub — half shaft contact surface

Print 603.93.391
Figure 5
ROTATION DIRECTION
FOR FORWARD GEAR
F—F PARTIAL SECTION
60335
MOUNTING SENSOR FOR ABS DEVICE

TOOLS
99301005 Brake disk grinding assembly
99305121 Hot air device
99322205 Rotary stand for assembly overhaul (1000 daN carrying capacity, 120
daNm torque)
Axle overhaul stand

99322215
Support to support assemblies (to apply to stand no. 99322205)

99322225
Single—acting bridge
99341003

TOOLS
Pair of brackets
99341009
99341015 Clamp
99345089 Reaction block for extractors
99348001 Extractor with locking device
99355025 Wrench for ring nuts to adjust differential wheelwork box bearings
99355168 Wrench to dismount and remount shaft on differential locking fork

TOOLS
99355177 Wrench (90 mm) for wheel hub bearing adjusting nut
99370007 Handgrip for exchangeable beaters
99370317 Reaction lever with extension for flange check
99370509 Hook to extract differential wheelwork half box
99370616 Support to disconnect and reconnect differential
Universal support to support axles during disconnection and

99370617 reconnection
99370709 Tool to drive out wheel hub bearing

TOOLS
99370710 Tool for mounting wheel hub
99370711 Guide for mounting wheel hub
99374093 Beater to mount bearing outer tracks (91 — 134) to be used with tool
no. 99370007
99389819 Dynamometric wrench (0 — 10 Nm) with 1/4“ square connection
99395027 Tool to determine differential bevel pinion adjusting shims (to be

used with tool no. 99395603)
99395603 Comparator (0 — 5 mm)

525010
Print 603.93.391/A
REAR AXLE DISCONNECTION—RECONNECTION
Figure 6
105099
Rear axle disconnection Screw up brake cylinder (4) screws (3) to prevent braking.
Vehicles with a mechanical suspension Disconnect air piping (2) from brake cylinder (4).
Unscrew nuts and screws (12) and detach pipe fitting support
bracket (11).
Place the vehicle on flat ground and lock front wheels. Cut off fastening clamps and displace electrical cables and air
Take off wheel securing nut guards and loosen nuts. pipes.
Lift vehicle from the rear side and position it on two support Locate a hydraulic jack, provided with support no. 99370617,
stands. under the axle.
Position hydraulic truck no. 99321024 under the wheels, take
off wheel securing nuts and detach wheels.
Unscrew screws (8) from related nuts and detach
transmission shaft (9) from the differential connection sleeve.
Disconnect air piping (1) from differential locking device (6).
Disconnect electric connections: (7) for differential locking in
switch; (5) for braking gasket wear warning device, (10) for
ABS r.p.m. sensors.

Revi — July 2005
Print 603.93.391
Figure 7
60361
Unscrew nuts (5) and disconnect shock absorbers (1) from If you have to overhaul the axle (525010 operation), you need
the lower supports. to perform following complementary operations:
Unscrew securing nuts (4) and extract brackets (3) joining the - 794922 Spring Cylinder Disconnection—Reconnection
leaf spring to the axle. (see section “BRAKING SYSTEM”).
Turn torsion bar (2) and fasten it to frame.
Lower the hydraulic jack and extract the rear axle.

Print 603.93.391/A
Rear axle disconnection

Vehicles with a pneumatic suspension
Figure 8
105088
Place the vehicle on flat ground and lock front wheels. Screw up brake cylinder (4) screws (5) to prevent braking.
Take off wheel securing nut guards and loosen nuts. Disconnect air piping (12).
Lift vehicle from the rear side and position it on two support Cut off fastening clamps (6) between electrical cables and air
stands. pipes.
Position hydraulic truck no. 99321024 under the wheels, take Disconnect tie rods (2) for the equalising valves from swinging
off wheel securing nuts and detach wheels. arms.
NOTE Should you operate on the brake caliper, check

efficiency of the braking gasket wear recovery
device as described in related chapter.
Unscrew screws (10) from related nuts and detach

transmission shaft (1) from the differential connection sleeve.
Disconnect air piping (7) from differential locking device (8).
Disconnect electric connections:
(9) for locking differential in warning switch;
(3) for braking gasket wear warning device,
(11) for ABS r.p.m. sensors.

Revi — July 2005
Figure 9
105089
Disconnect Panhard bar (7) from rear axle box by unscrewing

bolts (6). Axle reconnection
Position a hydraulic jack, provided with support no. 99370617,
under the axle in order to support it during successive
operations.
Disconnect shock absorber (4) from swinging arm by By using the hydraulic jack provided with support 99370617,
unscrewing nut (5) and extracting related joining screw. position rear axle on swinging arms resting plates and
Unscrew nuts (3) and unthread U bolts (2) anchoring rear axle complete the reconnection by reversing the operations
box to swinging arms supports, then recover anchoring cap(1). described for disconnection while observing prescribed
tightening torques for locking the screws and/or nuts
Lower the hydraulic jack and extract the rear axle. Self—locking nuts must be replaced at each dismounting
If you have to overhaul the axle (525010 operation), you need operation by new ones.
to perform following complementary operations:
On termination, check that:
- 794922 Spring Cylinder Disconnection—Reconnection
(see section “BRAKING SYSTEM”). - no air leaks are present from pneumatic pipelines;
- axle box lubricant oil level is maintained;
- the differential locking warning lamp works correctly; if it
does not, operate as described in related chapter.

Revi — July 2005
525010 DIFFERENTIAL DISCONNECTION—RECONNECTION WITH THE AXLE ON THE

Figure 10 VEHICLE
Disconnection
Place the vehicle on flat ground and lock front wheels.
Drain axle box oil from dedicated plug (6).
Detach transmission shaft (10) from the differential sleeve.
Unscrew plug (3) from differential locking device (4) and
screw screw (2) replacing the plug in order to put in the
differential locking.
Disconnect: electric connections (5) for differential locking
switch and air piping (1) from differential locking device (4).
Unscrew half shaft securing screws and extract half shafts from
the axle box.
Locate support no. 99370616 (9) under the differential by
means of the hydraulic truck, and constrain the differential
sleeve (8) brackets.
Unscrew screws and nuts (7) securing the differential
assembly to the axle box.
Take plugs (→) off the three threaded holes and screw
suitable screws into the holes in order to extract the
differential from the axle box.
105100
Reconnection
After completing disconnection operations:
For reconnection, invert the operations described for - screw drain plug (6) and recover level with set oil quality
disconnection, observing what set below: and quantity;
- replace the self—locking nuts by new ones on each - check that no leaks are present from the air piping of the
dismounting operation; differential locking device, and that the differential locking
- check that the differential locking is in. device is inserted;
- check that the differential locking warning lamp, placed in
After accurate cleaning of the parts, apply a sealing the cab, works correctly; if it does not, operate as
paste on the threads of the screws securing the described in related chapter.
differential box and half shafts.

Revi — July 2005
Print 603.93.391
525010 REAR AXLE ASSEMBLY 525013 Air vent disconnection and

OVERHAUL reconnection
Figure 13
NOTE Disconnection and reconnection operations for:
half shafts — brake calipers — brake disks — air vent
— differential, can be also performed with the
assembly mounted on the vehicle.
Figure 11
34811
Check that air vent (1) is not clogged; if it is, dismount it,
accurately clean it and remount it.
525030 Wheel hub overhaul

60336
Figure 14
Before positioning the axle assembly on the overhaul stand,
drain the oil by unscrewing the axle box lower plug, unscrew
nuts (1) and detach brake cylinder (2).
NOTE Before detaching brake cylinder (2), make sure that

the cylinder is free by checking that the rear screw
is thoroughly unscrewed.
Figure 12
60339
If the axle is provided with a differential locking device, insert

it before dismounting the half shafts, observing following
procedure:
- unscrew threaded plug (1) and put in screw (2) replacing
it; the screw can be found on the cylinder cover;
- turn transmission connection flange (3) in order that the
sliding sleeve matches the differential half box;
- screw up screw (2) until the differential locking device can
be inserted.
60337
Locate rear axle (1) on stand no. 99322215 (2).
NOTE Rear axle identification data are taken onto plate (3),
which is secured near the leaf spring connection
support.

Print 603.93.391/A
Figure 15 Figure 18
60401
60398
Extract wear sensors (2—4) from braking gaskets (1—3) and
Extract the ABS r.p.m. sensor, if present, from the brake caliper keep apart support (5) for supporting the sensor cables.
connection flange. Extract electric connection (2) from Figure 19
support blade (1).
Figure 16
60342
Remove plug (2) from brake caliper (1). Observing figure
warning below, operate on screw (3) clockwise in order to
60399 increase the clearance between braking gaskets and brake
disk.
Unscrew screw (1) securing fork (2) and support (4) to brake
caliper (3). Extract fork (2) from brake caliper (3). Figure 20
Figure 17
60402
NOTE Before operating on screw (3, Figure 19), keep

thrust plate (1) in contact with adjusting pin (3) to
60400 prevent thrust plate pin (2) to go out of pin (3)
Remove springs (2—5—6) from braking gaskets (1—3) and milling (4). Should it happen, the pin would be
thrust plate (4). dragged into rotation by screw (3, Figure 19) and
cause casing (5) to be twisted and damaged.

Revi — July 2005
Print 603.93.391
Figure 21 Figure 23
60403 60345
Unscrew braking gaskets (1—2) from brake caliper (3). Check Unscrew screws (1 and 4) and detach brake caliper (2) from
that the braking gaskets are not fouled, damaged or vitrified, the axle box flange (3).
and that wear is within the tolerance limits that are indicated
in the chapter about the brakes; otherwise, replace all braking
gaskets, even if the fault affects one gasket only. Figure 24
Figure 22
60346
Place a container under wheel hub (1) to recover oil.

60344 Lock wheel hub rotation by check tool no. 99370317 (3).
Extract braking gasket thrust plate (2) from brake caliper (1). Unscrew half shaft (4) securing screws (2).
Clean and remove any trace of rust from braking gasket and
thrust plate seats paying attention not to damage the
protection casings. Operate on the brake caliper and check Figure 25
that it can slide free on the guide pins. Check also that pin
protection casings are not damaged. If caliper sliding is
obstructed, even partially, replace bushes and brake caliper
protection casings as indicated in related chapter. Verify the
braking gaskets wear recovery device as described in the
chapter about the brake caliper.
60347
Take half shaft (2) off wheel hub (1).

Figure 26 Figure 29
60348 60351
Lift ring nut (1) dent (→). Unscrew securing screws (1) and detach brake disk (3) from
wheel hub (2).
Figure 27
Figure 30
60349 60352
Unscrew ring nut (2) locking the wheel hub bearing by wrench
no. 99355177 (1). Take off safety ring (3). NOTE Only dismount bearing (3) in case of replacement.
Figure 28
Drive out bearing (3), jointly with spacing ring (4), from wheel
hub (2) by tool no. 99370709 (1).
NOTE Bearing (3) driving force: 40,000 ÷100,000 N.
60350
Screw tool no. 99370711 (2) on the tube. Sling brake disk (3)
with a rope, hook the rope to a lifting device and extract wheel
hub (1) from the axle box tube.

Check parts making up the wheel hubs Wheel hub mounting

Figure 32
Accurately clean the single parts making up the wheel
hub. Inspect the half shafts and check that they are
free from deformation or wear.
Check brake disk (1, Figure 31), as described in
related chapter.
Bevel wheel (2, Figure 31), obtained from cold—machining on
the disk must be free from dents; otherwise, replace the brake
disk.
Check wheel holding down studs (3, Figure 31): if they show
any deformation or damages in the thread, replace them
operating under the press according to what set in below
chapter. Verify axle box tube thread: small faults can be
removed by a thread dressing tool.
Replace the wheel hub bearing securing ring nuts with new
ones. 99239
Drive bearing (2) into wheel hub (3) by tool no. 99370710 (1)
(under the press). The mounting dimension is indicated in the
figure.
525035 Replacement of wheel holding down NOTE The bearing driving force through the press must be
studs 40000 ÷100000 N.
Figure 31
Figure 33
60353
If the wheel holding down studs (3) are to be replaced, before

mounting the new ones, make sure that the wheel holding
60355
down stud head is free from slag, burr or dents.
The driving of the wheel holding down studs must be Fit spacing ring (2) in wheel hub (1) in such a way that it
executed by applying a load on wheel holding down stud head correctly rests on bearing (3).
not exceeding 2300 kg. After driving completion, check that Check, on two opposite points, that the spacing ring (2)
the wheel holding down studs are perfectly at the ledge and hollow with reference to the wheel hub plane results to be 0
the squareness error is not over 0.2 mm. ÷ 0.07 mm.

Figure 34 Figure 37
ROTATION DIRECTION — NUT UNSCREWING
60351 60357
Mount brake disk (3) on wheel hub (2) and tighten securing Dent the bearing securing ring nut collar as indicated in the
screws (1) with the set torque. figure.
Figure 35
NOTE The notching must be made as near tube milling side
as possible with a depth ≥ 1/3 ÷ ≤ 2/3 of X, the collar
width.
Figure 38
60350
Screw tool no. 99370711 (2) on the axle box tube. Lubricate,
with oil TUTELA W140/M—DA, tool (2) and key wheel hub
(1). Dismount tool no. 99370711 (2).
Figure 36
60358
Lock wheel hub (1) rotation through check tool no. 99370317
(4).
Smear sealant IVECO 1905685 (LOCTITE 14780) on flange
— wheel hub half shaft (2) contact surfaces and enter the half
shaft into the wheel hub.
Screw screws (3) to secure half shaft (2) to wheel hub (1) and
tighten them with the set torque through a dynamometric key.
60356
Position safety ring (4) in order to put the tongue into the tube
spline, and screw a new ring nut (5). Tighten ring nut (5) with
the set torque by wrench no. 99355177, over—gear (2) and
dynamometric key (3).

Figure 39 Figure 42
60359
60401
Position brake caliper (1) on axle box flange (2) and tighten
securing screws (3) with the set torque. Fit wear sensors (2—4) in braking gaskets (1—3) and position
cable support (5) on the brake caliper.
Figure 40
Figure 43
60344
Position braking gasket rest plate (2) in brake caliper (1).
60400
Position springs (2—5—6) on braking gaskets (1—3) and thrust

plate (4).
NOTE Make sure that the pin pintle is correctly positioned
in plate groove (2).
Figure 44
Figure 41
60407
Put a new fork (2) for braking gasket check in cable support
(1) and brake caliper (3).
60403
Enter braking gaskets (1—2) into brake caliper (3).

Figure 45
60405
Screw a new screw (2) to secure cable support (3) and fork
(1) to brake caliper (4) and tighten it with the set torque.
Inserire il connettore (6) nella lamella di supporto (5).
Mount the r.p.m. sensor, if present, in the brake caliper support
flange, and thoroughly push it up to contact with the phonic
wheel.
Figure 46
60406
Temporarily mount plug (3) for the braking gasket wear

adjusting screw.
NOTE After reconnecting the rear axle on the vehicle.

Check the efficiency of the braking gasket wear
recovery device, as described in related chapter,
and replace plug (3) with a new plug.
Reconnect brake cylinders (2) and tighten nuts (1) with the set
torque.
When mounting is terminated, fill the axle box with lubricating
oil, according to set quality and quantity.

526210 FIXING THE DIFFERENTIAL

Dismounting the differential box
Figure 50
Figure 47
19373
36312
Position differential box (1) on rotary stand no. 99322005 (3) Push off two spring pins (3) through a punch and put apart fork
equipped with support no. 99322225 (2). (1) from sliding sleeve (2).
Only for axles with a differential locking device.
Take off screw (4); remove screws (5) and dismount cover (6)
with a copper washer, and cylinder (7), with piston and seal Figure 51
ring.
Figure 48
19455
Straighten and extract safety clip (1) and unscrew ring nut (2)
to adjust wheelwork box support bearings.
36798
Unscrew fork drive shaft (1) through wrench (2) and extract
it.
Figure 52
Figure 49
19374
36313 Unscrew check screws (1) with safety washers (2) and take off
plate (3).
Extract spring (2) and flat washer (1); extract fork (3) with
Unscrew ring nut (4) to adjust wheelwork box support
sliding sleeve (4).
bearings.
Figure 53 Figure 56
36314 36428
Unscrew screws (1) with washers (2); take off caps (3) and ring Unscrew the screws to secure the bevel pinion support to the
nuts (4) to check support bearings. differential box.
Extract support (1), with the bevel pinion, from differential box
(3); take off shims (2) to position the pinion with reference to
the ring gear.
Figure 54
DISMOUNTING THE WHEELWORK BOX
Figure 57
19376
Extract the wheelwork box, with the ring bevel gear and outer
rings (2) for support bearings, through hook no. 99370509 (1).
19379
Lift complete wheelwork box by hook (1) and position it on

support base no. 99371047 (3).
Figure 55
Figure 58
36315
36316
Lock flange (1) rotation with tool 99370317 (3). With a
suitable wrench (2) and an overgear (4) loosen bevel pinion Unscrew nuts (1) and remove them with the screws; drive out
flange check nut. ring bevel gear (2).

Print 603.93.391
526249 BEVEL PINION SUPPORT

DISASSEMBLING
Figure 59 Figure 62
19384
36317
Extract bearing (3) and bearing (4) through tool no. 99348001 Lock the flange rotation with tool no. 99370317 (2), then
(1) and reaction block no. 99341014 (2). extract the transmission connection flange from the bevel
pinion and with universal extractor, or with a proper tool (1).
Figure 60
Figure 63
19382
Mark two half boxes (2 and 3) and the cross as indicated in the 36318
figure. Position the bevel pinion support under the press and push
Unscrew screws (1) joining the two half boxes; lift half box (2), bevel pinion (2) — including the middle bearing, rear bearing
and adjusting ring — off bevel pinion (1); take the adjusting ring
Figure 61 off the bevel pinion.
Figure 64
19383
Remove crown wheel (2) with its rib washer (1). Take off cross 36319
(6), with four side pinions (5) including rib washer (3); split the Apply tool no. 99348001 (2) under taper roller bearing (1) and
cross — side pinion assembly. Remove the second crown wheel extract the tool from bevel pinion (3) by the press. If necessary,
with its rib washer from half box (4). extract, in the same way, rear bearing (4) from bevel pinion (3)

Figure 65 Figure 66
19388 19389
Push gasket cover (2) off bevel pinion support (1) using a Operate on the point indicated by the arrow with a beater and
punch; then extract the front bearing from the support. push front bearing outer ring (2) off bevel pinion support (3).
Put the support upside down and push off middle bearing
outer ring (1).
Figure 67
20958
PARTS MAKING UP THE DIFFERENTIAL (with differential locking device)

1. Bevel pinion nut — 2. Flange — 3. Baffle — 4. Gasket cover — 5. Screw — 6. Washer — 7. Front bearing — 8. Outer ring —
9. Support — 10. Adjusting shims — 11. Adjusting ring — 12. Outer ring — 13. Middle bearing — 14. Bevel pinion — 15. Rear
bearing — 16. Lock—nut — 17. Transmitter — 18. Plug — 19. Adjusting ring nut — 20. Spring — 21. Shaft — 24. Cylinder — 25. Piston
— 26. Seal ring — 27. Copper ring — 28. Cover — 29. Screws — 30. Screw — 31. Washers — 32. Copper washer — 33. Threaded
plug — 34. Sliding sleeve — 35. Spring pins — 36. Fork — 37. Screws — 38. Washer — 39. Plate — 40. Screw — 41. Washer —
42. Cap — 43. Rib washer — 44. Side pinion — 45. Crown wheel — 46. Rib washer — 47. Half box — 48. Bearing — 49. Outer ring
— 50. Screw — 51. Cross — 52. Screw — 53. Ring bevel gear — 54. Half box — 55. Nut — 56. Cap — 57. Safety split pin —
58. Differential box.

Figure 68
33519
PARTS MAKING UP THE DIFFERENTIAL (without differential locking device)

9. Support — 10. Adjusting shims — 11. Adjusting ring — 12. Outer ring — 13. Middle bearing — 14. Bevel pinion — 15. Rear
bearing — 16. Lock—nut — 17. Transmitter — 18. Plug — 19. Adjusting ring nut — 20. Cap — 21. Washer — 22. Screw — 23. Plate —
24. Washer — 25. Screws — 26. Rib washer — 27. Side pinion — 28. Crown wheel — 29. Rib washer — 30. Half box — 31. Bearing
— 32. Outer ring — 33. Screw — 34. Cross — 35. Screw — 36. Ring bevel gear — 37. Half box — 38. Nut — 39. Bearing — 40. Outer
ring — 41. Cap — 42. Safety split pin — 43. Adjusting ring nut — 44. Differential box

Check of parts making up the differential Figure 70
Accurately clean the single parts making up the differential.

Lubricate the bearings and make the roller housing turn free;
its rotation must be normal and it must not show any
hardening.
Check rest surfaces of the ring bevel gear and ledge of the half
box to the purpose that the ring gear can adhere perfectly, as
deformation of said planes should cause vibrations of the ring
gear securing screws, jeopardising assembly correct operation.
NOTE Accurately clean the threads of screws, screw studs

and ring nuts in order to avoid alterations in 19391
adjusting clearance and closing torque values.
Position half box (2) on support base no. 99371047.
Position rib washer (1) of the crown wheel in the half box (2),
Check that splined space for flange keying on the pinion does then mount the crown wheel.
not look excessively worn out; if it does, replace the pinion.
Figure 71
Check the side pinions with related rib washers, the cross and
the crown wheels with the rib washers.
Replace, with new parts, all sealing elements, the safety clip for
the adjusting ring nut and all safety washers.
NOTE If the ring bevel gear or the pinion should be

replaced, you need to replace both, as parts are
supplied twinned.
19383
Mount cross (6), with side pinions (5) and rib washers (3),on
half box (4).
Position second crown wheel (2), with rib washer (1).
Figure 72
MOUNTING THE WHEELWORK BOX
Figure 69
36323
Lock differential gear with parts (1); assemble half—case (3).

Verify that marks made upon disassembling coincide. Butter
19397 some drops of “LOCTITE 270” on half—case locking screws (2)
Heat, in an air circulation furnace, for about 15’ at 100 °C thread. Screw screws (2) and tighten them as follows: 1st step,
temperature, support bearing (2) at the differential locking tightening through a dynamometric wrench follows at the
device opposite side and drive it on wheelwork box (3) with required torque; 2nd step: screw closure with a required angle.
proper beater (1).

526249 MOUNTING BEVEL PINION

SUPPORT
Figure 73 Figure 76
34850 36326
Heat, in an air circulation furnace, for about 15’ at 100 °C Through beater no. 99374093 (1), drive, under the press, the
temperature, bearing (1) and drive it on wheelwork box (2) middle bearing outer ring, in its seat, into the support, avoiding
with a proper beater. to go on up to the ledge.
Repeat the same operation from the opposite side for the front
Figure 74
bearing outer ring.
Manually terminate the driving of bearing outer rings by beater
no. 99374094 with handgrip no. 99370007.
Figure 77
34851
Heat, in an air circulation furnace, for about 15’ at 100 ÷ 150

°C temperature, ring bevel gear (1) and position it, in its seat,
on the wheelwork box, checking that it turns free; get matching
of the holes for screws securing the ring bevel gear —
wheelwork box assembly.
Figure 75
36327
Measure the adjusting ring (4) thickness found on dismounting

and take note of their value (dimension A).
Tighten tool no. 99395027 (6) in the vice, and position, on the
tool:
- bearing (5) on pinion side;
- previously measured adjusting ring/s (4), and bearing (3).
Screw ring nut (2) and tighten it up.
Position part (1) of tool no. 99395027 (6) provided with a
comparator on bearing (3) and reset the comparator
99395603 at tool (6) end. Then remove:
36325
- part (1);
After the ring bevel gear has cooled, arrange screws and tighten
self—locking nuts (2) as follows: - ring nut (2);
- 1st step, tightening through a dynamometric wrench (1) at - bearing (3);
the required torque;
- 2nd step, closure with the required angle. - ring/s (4) from tool (6).

Figure 78 Figure 79
36429
19410
Position support (4) on bearing (5, Figure 77) and bearing (3)
on support (4). Heat, in an air circulation furnace, for about 15’ at 100 °C
Screw ring nut (2) tightening it until following rolling torque is temperature, middle bearing (4) and rear bearing (2), and drive
found by a torque—meter: rear bearing (2) on bevel pinion (3) through dedicated beater
1.5 ÷ 6 Nm for new bearings; (1).
1.5 ÷ 3.4 Nm for already used bearings.
Figure 80
Position again part (1), with previously reset comparator, on
bearing (3) and find possible deviation (dimension B).
Thickness S of the adjusting ring/s is given by following formula:

S = A — (± B) + C
where:
A= Thickness of the adjusting ring/s mounted to reset the

comparator;
B= Value of found deviation;
C= 0.05 mm coefficient which takes into account bearing

expansion caused by mounting interference on the
bevel pinion.
First example:
A= 13.12 mm
33495
B= + 0.13 mm
C= 0.05 mm Lock the bearing making, on the bevel pinion, a dent in ten
equidistant points as indicated in the figure.
S = 13.12 — (+ 0.13) + 0.05 = This operation is to be performed carefully, using a dedicated
S = 13.12 — 0.13 + 0.05 = 13.04 mm punch.
Second example:
NOTE Print diameter must be within 3.40 ÷ 4.10 mm
A = 13.12 mm range; above limits respectively correspond to 0.30
B =— 0.13 mm and 0.44 mm depth on using a 4000 kg load with a
C = 0.05 mm ball of 10 mm diameter.
S = 13.12 — (— 0.13) + 0.05 =

S = 13.12 — 0.13 + 0.05 = 13.35 mm Select an adjusting ring having the same thickness found
(Figure 77) and position it on the bevel pinion.
Then remove parts of tool (6, Figure 77). Mount the support, with front and middle bearing outer rings,
on the bevel pinion.

Figure 81 Figure 84
19413 19378
Heat, in an air circulation furnace, for 15’ at 100 °C If you use the same pinion — ring gear assembly that was
temperature, front bearing (1) and position it, in its seat, on removed on dismounting, position shim pack (2) and bevel
bevel pinion (2) through a proper beater. pinion support (1) on differential box (3), making sure that the
groove for oil passage is exactly aligned.
Figure 82
Figure 85 3,5
1,2
1,2
1,2,3,4,5,6
19414
19416
Lubricate gasket cover seat (1) with differential oil and mount
the cover, in its seat, on support (2), with a proper tool for If a new pinion — ring gear assembly has to be mounted, to
keying. determine pinion exact positioning, it is necessary to know the
meaning of the prints made on the pinion and on the ring gear,
Figure 83 namely:
1. Part number.
2. Tooth combination number.
3. Matching number of pinion — ring gear assembly.
4. Variation number to determine the thickness of the
shim pack to be inserted between the pinion support
and the differential box (in following examples, this
variation number is indicated by CP).
5. Month and year of pinion — ring gear assembly
production and test.
6. Nominal clearance of pinion — ring gear assembly.
printed at the threaded end of all pinions; however,
alternatively, they can be printed on the outer diameter
19415
of the ring gear.
Position transmission connection flange (1), with baffle (2), on
the splined portion of the bevel pinion and fully set it, using a In any pinion — ring gear assembly, the ring gear shall always
proper beater; it is advisable to execute this operation under have an even class number printed (e.g. 36786), while the
the press. correspondent pinion shall always have an odd class number
Temporarily tighten the check nut. printed (e.g. 36787).

The tooth combination number (e.g. 5—37) indicates that the Example 2:
pinion has 5 teeth and the ring gear 37, corresponding to 7.4/1 Original pack thickness 0.76 mm
transmission ratio. C.P. printed on the ring gear — 0.05 + 0.05
All pinion — ring gear assemblies are supplied twinned. Measure got 0.81 mm
Therefore, both parts have the same printed number. C.P. printed on new ring gear + 0.13 + 0.13
Usually, in pinions, this number is printed on the head end, New thickness of the pack to be used 0.94 mm
while, in ring gears, it is printed on the outer diameter.
Example 3:
Original pack thickness 0.76 mm
C.P. printed on the ring gear + 0.05 — 0.05
NOTE Never use pinion — ring gear assemblies which do Measure got 0.71 mm
not have the same numbers. C.P. printed on new ring gear — 0.13 — 0.13
New thickness of the pack to be used 0.58 mm
Example 4:
Each ring gear has a variation number which indicates the Original pack thickness 0.76 mm
mounting nominal distance; use this variation number in C.P. printed on the ring gear — 0.05 + 0.05
calculating the thickness of the shims to be inserted between Measure got 0.81 mm
the pinion support and the differential box. C.P. printed on new ring gear — 0.13 — 0.13
This variation number (e.g. C.P. + 0.1 or C.P. — 0.1 mm) is New thickness of the pack to be used 0.68 mm
printed on the outside of the ring gear.
To calculate the thickness of the shims to be inserted
between the pinion support and the differential box, operate
NOTE Shims to be inserted between differential box and
in the following way:
bevel pinion support are supplied as spare parts
1. Measure the thickness of the shim pack used with the with 0.075 — 0.125 — 0.200 — 0.500 mm thickness.
pinion — ring gear assembly to be replaced, using a
micrometer gauge or a caliper and taking note of the
value.
2. Read the C.P. number printed on the ring gear to be On each pinion and on each ring gear, the month and year
replaced; if this number corresponds to a positive (+) are indicated on which the assemblies have been jointly
value, subtract it from measure previously taken at lapped and tested to make pairs.
point 1. This indication is placed on the head end on the pinions;
If this number corresponds to a negative (—) value, add on the outer diameter on the ring gears.
it to measure previously taken at point 1.
Take note of this value. On all assemblies a number is printed indicating the
nominal clearance between pinion and ring gear got at the
end of the machining process; this clearance is indicated
NOTE Measure taken at point 2 will be used to determine on the outer diameter of the ring gear.
the thickness of the shim pack to be inserted
between the pinion support and the differential box
according to new pinion — ring gear assembly.
MOUNTING THE DIFFERENTIAL BOX
Figure 86
3. Read the C.P. number printed on the new ring gear.
Add/subtract this value to/from measure taken at
point 2, according to algebraic sign (+ adding, —
subtracting).
Value got indicates the thickness of the new shim pack
to be used.
Refer to following examples, which cover all possible
CALCULATION EXAMPLES
36328
Example 1:
Original pack thickness 0.76 mm Arrange eight screws (2) completed with washers and tighten
C.P. printed on the ring gear + 0.05 — 0.05 them in two steps as described below:
Measure got 0.71 mm - 1st step: tightening through a dynamometric wrench at the
C.P. printed on new ring gear + 0.13 + 0.13 required torque;
New thickness of the pack to be used 0.84 mm - 2nd step: screws closure with the required angle.

Print 603.93.391
Figure 87 Figure 89
60897
36329
Rotate the stand by 90°. Position taper roller bearing outer rings (3) on respective inner
Lock flange rotation through tool no. 99370317 (3). rings. Through hook no. 99370509 (1), lift previously
Position 12—point wrench no. 99355088 (1) and, through assembled wheelwork box (2) and position it on the
over—gear (2) and dynamometric wrench (4), tighten the differential box.
pinion check nut with the set torque.
Check again the bevel pinion rolling torque; torque values are Figure 90
shown in the table at page 93.
NOTE With a lubricated gasket, the rolling torque

increases by 1.5 Nm.
Position the caps taking care to match the reference marks.

Put in the screws with the washers and tighten them with the
set torque with a dynamometric wrench.
60898
Figure 88 Position caps (2) checking correct location of bearing outer

rings.
Screw screws (1) with washers without locking them
completely.
Lubricate the taper roller bearings.
Screw adjusting ring nuts (3) up to contact with bearing outer
rings.
Reconnect brake cylinders (2) and tighten nuts (1) with the set
torque.
Adjusting cap opening out

Adjusting and checking cap opening out can be carried out
according to two methods.
1ST METHOD
1. Through wrench no. 99355025 (3, Figure 92), tighten
20670 bearing adjusting ring nuts (4, Figure 92) until clearance
between pinion — ring gear assembly and axial clearance
Then check that bearing outer rings slide through a slight is removed and, at the same time, check the ring gear not
pressure in their seats without crawling. to exert an excessive force against the pinion.
Unscrew again the check screws with the washers and take off 2. By proper micrometer gauge, positioned diagonally and
the caps. centrally at points (x— y arrows, Figure 91), find cap
distance and note it.

Figure 91 Figure 93
34876
60636
3. Further tighten two adjusting ring nuts (4, Figure 92) Adjust the axial clearance between the teeth of pinion — ring
causing a cap (2, Figure 92) opening out which is gear assembly, which must result 0.20 ÷ 0.45 mm, observing
measured as described at point 2, namely: 0.15 ÷ 0.33 below procedure:
mm, corresponding to 1.7 ÷ 3.9 Nm (0.17 ÷ 0.39 kgm) - lock bevel pinion rotation through tool no. 99370317;
pre—load on the bearings.
- position magnetic base comparator (1) as indicated in the
2ND METHOD figure;
- through wrench no. 99355025 (3), loosen the adjusting
ring nut on the ring gear side and tighten, by the same
Figure 92 amount, adjusting ring nut (2) on the opposite side;
purpose of this operation is to maintain unvaried the
previously adjusted cap opening out;
- go on as described until you get the set clearance.
Clearance must be checked on 4 equidistant points.
Figure 94
60635
A. Diagonally and centrally position two magnetic base

comparators (1) on machined outer seats of both caps
(2), as indicated in the figure.
B. Operate as described at point 1.
C. After removing axial clearance, further tighten two
adjusting ring nuts (4) causing a cap (2) opening out of 34874
0.15 ÷ 0.33 mm, corresponding to the addition of values Through a magnetic base comparator (2), check that ring gear
read on comparators (1). (1) does not wobble by more than 0.20 mm. If it does,
dismount the differential assembly and find cause.

Then remount and repeat adjusting operations previously Figure 97

described at pages 76—77.
Figure 95
19453
Contacts too outwards, towards ring gear tooth crest.

Conditions A—B. It means that the pinion is set too outwards;
therefore, it has to be further adjusted.
To adjust the pinion at its exact position, you need to remove
shims under the pinion support in order to get a precise
contact.
34877
Condition A. After adding shims, increase clearance towards
maximum clearance.
Apply, with a paintbrush, a thin layer of Prussian blue on the Condition B. Find clearance and recover, after adding shims.
ring gear.
Turn the pinion and find the print of the contact of pinion teeth
on ring gear teeth.
In following figures, possible contact types are illustrated, as Figure 98
well as the way to correct possible errors.
1
Figure 96
4
3
Clearance decrease
Clearance increase 19454
THEORETICAL CONTACT AREA

19452
1. Release, tooth hollow side. — 2. Top. — 3. Draw, tooth
Contact too deep in ring gear tooth bottom land. convex side. — 4. Heel.
Conditions C—D. It means that the pinion is set too deep;

DRAW. Central draw pointing towards top on tooth face and
therefore, it has to be further adjusted.
central draw on tooth profile.
To adjust the pinion at its exact position, you need to add
shims under the pinion support in order to get a precise RELEASE. Central release pointing towards heel on tooth face
contact. and central release on tooth profile.
Condition C. Find clearance and recover, after adding shims. It means that pinion is correctly set.
Condition D. After adding shims, decrease clearance towards Contact position can be further modified by varying pinion —
minimum clearance. ring gear clearance.
Condition E. Remove clearance.
Condition F. Increase clearance.

FIXING CROWN WHEEL AND PINION ASSEMBLY CONTACTS (AFTER MOUNTING)

Figure 99
DRAW RELEASE
(RING GEAR CONVEX SIDE) (RING GEAR HOLLOW SIDE)
CREST CREST
HEEL TOP HEEL
— DRAW: CENTRAL DRAW POINTING TOWARDS TOP ON TOOTH FACE AND CENTRAL
DRAW ON TOOTH PROFILE.
— RELEASE: : CENTRAL RELEASE POINTING TOWARDS HEEL ON TOOTH FACE AND CENTRAL
RELEASE ON TOOTH PROFILE.
CONDITION “A”
DRAW
(RING GEAR CONVEX SIDE) RELEASE
CREST CREST
HEEL TOP HEEL
— DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS CREST

— DRAW: CONTACT EXCESSIVELY TOWARDS TOP
— RELEASE: CONTACT EXCESSIVELY TOWARDS HEEL
— CORRECTIVE ACTIONS: TAKE OFF SHIMS AND INCREASE CLEARANCE TO MOST
CONDITION “B”
CREST CREST
HEEL TOP HEEL

— DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS CREST
— CORRECTIVE ACTIONS: FIND CLEARANCE, ADD SHIMS AND RECOVER CLEARANCE
CONDITION “C”
CREST CREST
HEEL TOP HEEL

— DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS BOTTOM LAND
— CORRECTIVE ACTIONS: FIND CLEARANCE, ADD SHIMS AND RECOVER CLEARANCE
60676

Figure 100
CONDITION “D”
CREST CREST
HEEL TOP HEEL
— DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS BOTTOM LAND

— DRAW: CONTACT EXCESSIVELY TOWARDS HEEL
— RELEASE: CONTACT EXCESSIVELY TOWARDS TOP
— CORRECTIVE ACTIONS: ADD SHIMS AND DECREASE CLEARANCE TO LEAST
CONDITION “E”
CREST CREST
HEEL TOP HEEL
— DRAW: CONTACT EXCESSIVELY TOWARDS HEEL

— RELEASE: CONTACT EXCESSIVELY TOWARDS TOP
— CORRECTIVE ACTIONS: DECREASE CLEARANCE
CONDITION “F”
CREST CREST
HEEL TOP HEEL
— DRAW: CONTACT EXCESSIVELY TOWARDS TOP

— RELEASE: CONTACT EXCESSIVELY TOWARDS HEEL
— CORRECTIVE ACTIONS: INCREASE CLEARANCE
60677

19455 36335
Put again safety clip (1) and fold it up.

Mount sliding sleeve (2) into fork (1) and drive the two spring
NOTE If the seat on ring nut (2) does not collimate, turn pins.
ring nut (2) by minimum amount needed to Position fork, with sliding sleeve, in its seat.
correctly position the safety clip.
19374
Position plate (3) and safety washers (2), and tighten securing
screws (1) with the set torque.
If plate (3) does not match ring nut (4) notch, slightly turn ring 36782
nut (4) until plate (3) is matching. Put in return spring (2) and flat washer (1).
NOTE In case of axles without a differential locking device,

do not perform the operations described below.

36336 19461
Mount drive shaft (2) and screw it into fork (3) through wrench Put the copper gasket in the cover seat, the position cover (1)
(1). and secure it through four screws (2) with their safety gaskets.
36337 36339
Screw screw (1) to engage differential manual locking device.

Lubricate seal ring (2), put it, in its seat, on piston (1) and position Take differential box off support no. 993922225 and reconnect
the piston on fork drive shaft (3). it to the axle box.
Figure 107
36338
Mount cylinder (1) on piston (2).

Directions to adjust and check the operation of the transmitter for checking differential
locking device insertion.
Adjusting and checking the operation of the transmitter (two—function type transmitter) for checking differential locking device
insertion is carried out with the axle mounted on the vehicle and operating as described below:
1) With differential locking device inserted, screw the transmitter up to contact closing, checking, in the cab, that the warning
indicator light goes on.
2) As the warning indicator light in the cab goes on, screw the transmitter by one turn more.
3) Tighten the transmitter locking lock—nut with 40 Nm (4 kgm) torque.
4) Unlock differential locking device engagement drive and check that contacts are closed (in this condition, the indicator red
light in the cab must be off).
5) By using the screw for differential locking device manual insertion, partially put in the locking device screwing the screw in the
dedicated hole on the operating cylinder cover up to contact opening (in this condition, the indicator red light in the cab must
be blinking).
6) Unscrew the screw in order to put off the differential manual locking device.
Fit the screw, in its seat, on the operating cylinder cover and screw the plug with washer into the threaded hole previously
held by the screw.

EUROCARGO TECTOR 12—26 t ARVINMERITOR AXLE MS10 — 144 131
Print 603.93.391

MS10 — 144
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 133

TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . . . 134
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 137
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
REAR AXLE REMOVAL/REFITTING

(vehicles with pneumatic suspensions) . . . . . . 147
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

(vehicles with mechanical suspensions) . . . . . . 148
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
OVERHAULING THE REAR AXLE ASSEMBLY . 149
OVERHAULING THE WHEEL HUBS . . . . . . . . . 149
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
- Replacing wheel hub bearings . . . . . . . . . . . . . 150
- Checking the parts forming the wheel hubs . . . 151
- Replacing the wheel fixing pins . . . . . . . . . . . . 151
REMOVAL THE DIFFERENTIAL

(with axle on stand no. 99322215) . . . . . . . . . 154
REFITTING THE DIFFERENTIAL

- Disassembly the differential box . . . . . . . . . . . . 155
- Disassembly the wheelwork box . . . . . . . . . . . 157
- Disassembly bevel pinion support . . . . . . . . . . 158

132 ARVINMERITOR AXLE MS10 — 144 EUROCARGO TECTOR 12—26 t
Page
- Check of parts making up the differential . . . . . 159
- Assembly the wheelwork box . . . . . . . . . . . . . 159
- Assembly bevel pinion support . . . . . . . . . . . . . 161
- Assembly the differential box . . . . . . . . . . . . . . 165
- Adjusting cap opening out . . . . . . . . . . . . . . . . 167
BEVEL TORQUE CONTACTS CORRECTION

(AFTER ASSEMBLY) . . . . . . . . . . . . . . . . . . . . 169
AXLES WITH DIFFERENTIAL LOCKING DEVICE 172
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 173
REMOVAL THE DIFFERENTIAL

- Disassembly of the differential locking device . . 174
- Assembly of the differential locking device . . . . 175
- Directions to adjust and check the operation

of the transmitter for checking differential
locking insertion. . . . . . . . . . . . . . . . . . . . . . . . . 176

DESCRIPTION
Print 603.93.391
The axle is a bearing axle type with a simple reduction; it You can also adjust the bevel pinion position with reference
consists of a box made in stamped steel sheet and properly to the ring bevel gear by changing the thickness of the pack of
strengthened. the rings, which are inserted between the differential box and
The differential is characterised by a hypoidal—toothed gear the bevel pinion support.
assembly. The wheelwork box is supported by two taper roller bearings
The pinion is supported by two taper roller bearings and by and can be adjusted axially through two threaded ring nuts.
one straight roller bearing. Wheel hub bearings are of the permanent—lubrication,
The adjustment of the bevel pinion assembly is made through UNIT—BEARING type, and do not need adjusting.
adjusting rings placed between the two taper roller bearings.
Figure 1
86091
VIEW OF AXLE ASSEMBLY


Service Network.
Figure 2
86620
D = rear axle ratio
E = production date
TECHNICAL NAME
Axle casing thickness: 11 mm
Single ratio
Capacity: 9 ÷ 10 ton
MERITOR
Rear only

Print 603.93.391/A
Axle type:
Bearing axle with simple reduction. MS10 — 144
DIFFERENTIAL GROUP
Crown wheel and pinion assembly 2.93 (14/41) — 3.07 (14/43) — 3.42 (12/41) — 3.73 (11/41)
reduction ratio 4.11 (9/37) — 4.88 (8/39) — 5.57 (7/39) — 6.14 (7/43) —
6.83 (6/41)
Bevel pinion bearings 2 with bevel rollers and 1 with cylindric rollers
Bevel pinion rolling torque Nm 0.5 ÷ 5

(bearing pre—load without
gasket) kgm 0.05 ÷ 0.5
8.75 — 8.78 — 8.80 — 8.83 — 8.85 — 8.98 — 9.10 —

Thickness of bevel pinion bearing
9.13 — 9.15 — 9.18 — 9.20
pre—load adjusting rings
Supplied as kits
Clearance between pinion and

0.26 ÷ 0.50
ring gear

Through ring nuts
pinion and ring gear
Cap opening out 0.05 ÷ 0.23

Nm 68 máx.
pinions and crown wheels
Bevel pinion positioning with

Through adjusting shims
Thickness of adjusting rings

inserted between bevel pinion mm 0.125 — 0.200 — 0.500
support and differential box

Revi — July 2005
Print 603.93.391
Axle type:
MS10 — 144
WHEEL HUBS
Hub bearing axial clearance —
Not adjustable
Wheel hub clearance
Torque tightening by means of a nut
Dry weight: With differential lock Without differential lock

— mechanic suspension kg 471 466
— pneumatic suspension kg 476 471
— Maximum capacity kg 10700

DIAGNOSTICS
Axle main operation faults: 3 — Noise at release;
1 — Wheel hub noise; 4 — Noise on draught;
2 — Axle noise; 5 — Noise on turning.
1 WHEEL HUB NOISE
Wheel hub bearings are efficient. Dismount hub and make necessary replacements.
NO
YES
Wheel hub bearings adjusted. Adjust bearings.

NO
YES
Sufficient lubrication. Recover level and check that no leaks are present from
NO gaskets or axle box.
2 AXLE NOISE
Splines to match half shafts with differential crown gears Overhaul axle and replace worn out or damaged parts.
not damaged. NO
YES
Adjusting of wheel bearing clearance is correct. Adjust bearing clearance.

NO
YES
Adjusting is correct or differential assembly gears or Locate trouble and overhaul assembly.
bearings are not impaired. NO
YES
Lubricant oil level is sufficient. Recover level and check that no leaks are present from

3 NOISE AT RELEASE
Matching clearance between pinion and ring bevel gear Detach wheelwork inspection cover and adjust
is correct. NO clearance between pinion and ring gear.
4 NOISE ON DRAUGHT
Wheelwork box bearings adjusted or not impaired. Overhaul assembly.

NO
YES
Contact of teeth between pinion and ring bevel gear is Adjust contact.
correct. NO
YES
Sufficient lubrication. Recover level and check that no leaks are present from
5 NOISE ON TURNING
Side pinion—crown wheel assembly clearance is correct. Overhaul or replace assembly.

NO

TIGHTENING TORQUES
Figure 3
86141
SECTION ON DIFFERENTIAL MS10 — 144
TORQUE
PART
Nm (kgm)
1 Bevel pinion securing nut M39 x 1.5 1392.5 ± 142.5 (139.25 ± 14.25)
Screw to secure bevel pinion support M12 x 1.75
2 122.5 ± 27.5 (12.5 ± 2.8)
to differential box
3 Differential half box securing screw M12 x 1.75 142.5 ± 12.5 (14.5 ± 1.3)
Self—locking nut to secure ring bevel M16 x 1.5
4 255 ± 35 (26 ± 3.6)
gear to half box
— Screw to secure caps to differential box 48.5 ± 45 (49.4 ± 4.6)
Screws and nuts to secure differential 1st step: pre—tightening 100 ± 5 (10 ± 0.5)
— to axle box 2nd step: slant closing 80° ÷ 90°

Figure 4
86092
SECTION ON WHEEL HUB
TORQUE
PART
Nm (kgm)
1 Screw fastening the axle shaft to the wheel hub 150 ± 15 (15.3 ± 1.5)
2 Wheel hub bearing fastening ring 932 ± 98 (95 ± 9)
3 Screw fastening the brake disc to the wheel hub 40 ± 4 (4 ± 0.4)
4 Brake caliper fastening screw 313 ± 16 (32 ± 1.6)
5 Brake caliper fastening gauged screw 313 ± 16 (32 ± 1.6)
(A) When mounting the differential, a 0 ÷ 0.07 mm clearance must be provided between the hub outer side and the spacer side,
by carrying out two checks at 180°.
* Apply sealant IVECO 1905685 (LOCTITE 14780) to the hub/axle shaft contact surface.

Print 603.93.391
TOOLS
99301001 Grinder and lathe for brake drums and discs
99322205 Rotary stand for assembly overhaul (1000 daN carrying capacity,
120 daNm torque)
Axle overhaul stand

99322215
Support to support assemblies (to apply to stand no. 99322205)

99322225
Single—acting bridge
99341003

TOOLS
99341015 Clamp

TOOLS
99355025 Wrench for ring nuts to adjust differential wheelwork box bearings
Bush (55 mm) for differential bevel pinion nut

99355131 (to be used with tool no. 99370317)
99370007 Handgrip for exchangeable beaters
99370317 Reaction lever with extension for flange check
99370509 Hook to extract differential wheelwork half box

TOOLS
99370616 Support to disconnect and reconnect differential
Universal support to support axles during disconnection and

99370719 Wheel hub mounting guide
99370720 Wheel hub bearing driving tool
99370721 Wheel hub bearing extracting tool
99371047 Support for differential half box check during screw securing of ring
gear connection (to be used with tool no. 99322205 and 99322225)

TOOLS
99374093 Beater to mount bearing outer tracks (91 — 134)

(to be used with tool no. 99370007)
99374163 Differential bevel pinion gasket mounting coupler
99389816 Torque x 4 multiplier with 3/4” inlet, 1” outlet panel connection

(max 2745 Nm)
99389819 0—10 kgm dynamometric wrench with square 1/4” connection
99395027 Tool to determine differential bevel pinion adjusting shims

(to be used with tool no. 99395008)
99395603 Comparator (0 — 5 mm)


Print 603.93.391
REAR AXLE REMOVAL/REFITTING Figure 5

(vehicles with pneumatic suspensions)
the master current switch and blow air off the
pneumatic system.
Removal
Arrange the vehicle on a plane ground, lock front
wheels and proceed as follows:
- loosen front wheels securing nuts, lift the vehicle from
its rear and place it on support stands;
- place hydraulic trolley 99321024 under rear wheels,
remove securing nuts and detach the wheels;
- unscrew securing bolts (21) and disconnect transmission
shaft (22) from rear axle;
- disconnect electric connections (8) for signalling brake
wear, electric connections (3) for ABS revolutions
sensors and free wiring from the various check straps;
- disconnect air supply piping (4) next to union (5);
- disconnect electric connection (1) and air piping (2)
from differential locking assembly;
- place under the rear axle an hydraulic jack equipped with
support 99370617 and suspend it;
- unscrew securing screws (7) and disconnect reaction
triangle (6) from rear axle;
- unscrew securing bolts (15) to disconnect stabilising bar
(13) and securing nuts (10) to disconnect shock
absorbers (9) from rear axle;
- unscrew bolts (16) and disconnect reaction tie rods (19)
that remain anchored to the chassis;
- exhaust air from springs (20), unscrew securing nuts
(14);
- disconnect level sensor arm (11), unscrew nuts (12),
withdraw screws (17) and remove cross member (18);
- lower the hydraulic jack and withdraw the rear axle from
below the vehicle, paying attention to possible
interference with chassis parts.
Refitting
Suitably reverse the operations performed for
disconnecting and tighten securing screws and nuts
at the required torque.
Self—locking nuts must always be replaced and
tightened at the required torque.
Carry out the following checks:
- check that no leakage occurs from pneumatic
piping;
- check elastic pads conditions; if they are worn,
replace them;
- check that rear axle case lubricating oil is at
level; otherwise, fill it in;
- check the correct operation of differential gear
locking warning lamp.
98873


(vehicles with mechanical suspensions)

pneumatic system.
Removal
sensors and free wiring from the various check straps (5);
- disconnect air supply piping (6) next to union;
(8) and securing nuts (10) to disconnect shock absorbers
(7) from rear axle;
support 99370617;
- unscrew securing nuts (12) and remove stands (13),
lower the jack and remove the rear axle from below the
vehicle.
Refitting
- check stand (13) threading; if anomalies are
detected, true the threading or replace them;
piping;
- check elastic pads (11) conditions; if they are
worn, replace them;
91582

Print 603.93.391
525010 OVERHAULING THE REAR AXLE Figure 9

ASSEMBLY
NOTE The following operations can also be performed

with the assembly mounted on the vehicle:
removing refitting drive shafts — removing refitting
brake disks — removing refitting differential.
Before putting the rear axle assembly on the stand for

overhauling, drain off the oil by unscrewing the bottom plug
of the differential case.
Figure 7 86094
Remove the plug (3), turn the adjustment unit (2)

anticlockwise, with a spanner, to make the pistons move back
into the calliper body.
Figure 10
86093
Put the rear axle (1) on the overhaul stand 99322215 (2).
86095
525030 OVERHAULING THE WHEEL Remove the brake linings (1) making the calliper body (2)
HUBS float appropriately.
Disassembly
Figure 8 Figure 11
72740 86096
Remove the split pin (4), washer (3), pin (2) and plate (1)
holding the brake linings. Take out the screws (2) and remove the brake calliper (1)
from the supporting flange (3).

Figure 12 Figure 15
86100
86097 Take out the screws (2) and (4) and remove the wheel hub
Put a container under the wheel hub to collect the oil. Lock (1) from the brake disc (3).
rotation of the wheel hub (1) with the retaining tool Examine the state of wear of the brake disc (3) as described
99370317 (3). Take out the screws (2) and extract the drive in the ”BRAKE AIR SYSTEM” section.
shaft (4).
529621 Replacing wheel hub bearings
Figure 13
Figure 16
1 3
1
2
4
2
5
3
86098
86101
Lift the notching of the ring nut (5). Using the wrench
99355182 (1) and multiplier 99389816 (2), remove the ring Using a hydraulic press and tool 99370721 (1) take out the
nut (5) holding the wheel hub bearing. Take out the retaining wheel hub, spacer (3) and bearing (2).
ring (4). Figure 17
Figure 14
99240
Position the bearing (2) with the seal (4) turned as shown in
the figure on the wheel hub (3).
86099
Using the press and tool 99370720 (1) mount the bearing
Remove the wheel hub (1). If this proves difficult, use the (2): bearing drive—in load 30,000 to 90,000 N.
extractor comprising: brackets 99341017 (2), bridge If tool (1) is not available, position the bearing to the assembly
99341003 (3), block 99345053 (4), applied as shown in the dimension shown in the figure.
figure.

Figure 18 Figure 20
86103
86105
Fit the spacer ring (2) in the wheel hub (1) and check on two Screw the tool 99370719 (2) onto the sleeve (1) of the axle
diametrically opposite points that, after assembly, the ring (2) housing. Lubricate the tool external surface (1) with the oil
is sunk below the face of the wheel hub by 0.0 to 0.07 mm. prescribed for the wheel hubs.
Figure 21
Checking the parts forming the wheel hubs
Thoroughly clean the single parts comprising the

wheel hub. Examine the drive shafts and check there
is no deformation.
Check the wheel fixing pins: if there is any deformation
or damage to the thread, replace them, using a press
to extract them.
Check the threads of the nuts to adjust the hub
bearings and the threads on the ends of the axle
housing; change the nuts if necessary.
Replace all the sealing elements with new parts.
86106
525035 Replacing the wheel fixing pins Mount the brake disc (3) on the wheel hub (1) and screw
down the screws (2) and (4).
Figure 19
Figure 22
86104
Using general tools, drive the pins (1) out of the disc (2). 86107
Make sure the supporting surface for the heads of the pins Sling the brake disc (1) with a rope, hook this onto a lift and
has no burrs. fit the wheel hub (2) on the sleeve of the axle housing.
Carefully drive in the pins, applying a load no greater than Remove the tool 99370719 (3).
2300 kg on their heads.

Figure 23 Figure 26
86108
Position the retaining ring (4) so as to insert the tab into the 86110
groove of the sleeve, then screw on the ring nut (5). Using
the wrench 99355182 (1), multiplier 99389816 (2) and the Position the brake calliper (1) on the flange (3) and tighten
torque wrench (3), tighten the ring nut (5) to the required the fixing screws (2) to the required torque.
torque.
Figure 24
NOTE First screw down the brake caliper securing gauged
screw:
— vehicles equipped with mechanic suspensions
— the gauged screw must be positioned in the
lower part of the brake caliper fastening flange;
— vehicles equipped with pneumatic suspensions
upper part of the brake caliper fastening flange.
49213A
After tightening, using an appropriate tool, notch and bend

the ring nut as shown in the figure so it cannot be unscrewed.
The arrow shows the direction of unscrewing the ring nut.
Figure 25
1 Figure 27
2
4
3 5
86109
Spread IVECO 1905685 (LOCTITE 14780) sealant onto the

flange contact surfaces of the drive shaft — wheel hub and
insert the drive shaft into the axle housing. Screw down the
86095
screws (2) fixing the drive shaft (3) to the wheel hub (1) and
tighten them with the torque wrench (4) to the required Mount the brake linings (1) in the brake calliper (2).
torque. Remove the tool 99370317 (5).

Figure 28 Figure 30
72740
Mount the brake lining retaining plate (1).

Mount the pin (2), washer (3) and secure them with the split 86111
pin (4).
Provisionally mount the plug (1) for the brake lining wear
adjustment screw.
NOTE After refitting the rear axle on the vehicle, check

the efficiency of the brake lining wear recovery
device, as described in the relevant section and
replace the plug (1) with a new one.
On completing assembly, fill the axle housing with the

required quantity and grade of lubricating oil.
Figure 29
86112
WHEEL HUB COMPONENT PARTS
1. Screw — 2. Drive shaft — 3. Ring nut — 4. Retaining ring — 5. Spacer ring — 6. Bearing —
7. Wheel hub — 8. Brake disc — 9. Axle sleeve

REMOVAL THE DIFFERENTIAL Figure 33

(with axle on stand no. 99322215)
Figure 31
33462
Lift differential box (1) and correctly position it on axle box

(2).
34826
Extract the half shafts as described at page 150, unscrew

differential box (1) securing screws, screw three screws (2), Figure 34
which, in this step, work as extractors, then extract
differential box (1) from the axle box using two eyebolts and
metal ropes.
REFITTING THE DIFFERENTIAL

Figure 32
34829
Screw nuts (2) and screws (3) with the safety washers and
tighten them through dynamometric wrench (1) with
following values:
- 1st step: pre—tightening with required torque
2nd step: pre—tightening with required angle
Mount the half shafts as described in Figure 25.
Unscrew the oil drain plug and enter oil W 140/MDA
through the hole.
34827
Smear the contact surface of the axle box with sealant

”Silastic 732”.

Print 603.93.391
FIXING THE DIFFERENTIAL

Disassembly the differential box
Figure 38
Figure 35
86113
33468
Position complete differential box (1) on rotary stand no.
99322005 (3) equipped with support no. 99322225 (2). Unscrew and take off screws (1) with their washers; take off
caps (2) for support bearings. Extract bearing outer rings.
Figure 36
Figure 39
34832
Straighten and extract safety clip (1) and unscrew ring nut (2)
to adjust wheelwork box support bearings.
86115
Extract wheelwork box (2) with the ring bevel gear through
hook no. 99370509 (1).
Figure 37
86114
Take out elastic pin (2). Unscrew ring nut (1) to adjust
wheelwork box support bearings.

Figure 40
34836
Lock flange (3) rotation through check tool no. 99370317 (1).
Loosen the check nut for the bevel pinion through proper
12—point wrench and over—gear (2).
Figure 41
86116
PARTS MAKING UP THE DIFFERENTIAL
9. Support — 10. Adjusting shims — 11. Adjusting ring — 12. Outer ring — 13. Middle bearing — 14. Bevel pinion —
15. Rear bearing — 16. Lock—nut — 17. Transmitter — 18. Plug — 19. Adjusting ring nut — 20. Cap — 21. Washer — 22. Screw —
23. Rib washer — 24. Side pinion — 25. Crown wheel — 26. Rib washer — 27. Half box — 28. Bearing — 29. Outer ring — 30. Screw
— 31. Cross — 32. Screw — 33. Ring bevel gear — 34. Half box — 35. Nut — 36. Bearing — 37. Outer ring — 38. Cap — 39. Safety
split pin — 40. Adjusting ring nut — 41. Differential box — 42. Elastic pin

Figure 42 Figure 45
86117 34840
Unscrew screws (1) to secure bevel pinion support (2) to Put wheelwork assembly upside down on tool no. 99371047.
differential box (3). Extract bearing (3) through extractor no. 99348001 (1) and
reaction block no. 99345053 (2).
Figure 43 Figure 46
86118 34841
Lift and extract complete bevel pinion support (1) from Mark two half boxes (2 and 3) and the cross as indicated in the
differential box (3). Take off shims (2) to adjust pinion position figure (arrow).
with reference to the ring gear. Unscrew half box joining screws (1).
Lift half box (2).
Disassembly the wheelwork box
Figure 47
Figure 44
34842
34839
Remove crown wheel (1) and its rib washer.
Locate the wheelwork box on tool no. 99371047 (1). Remove cross (2) with side pinions together with their rib
Unscrew self—locking nuts (2) to secure ring bevel gear (3) to washers. Split cross—side pinions assembly.
the wheelwork box. Drive out the ring bevel gear through a Remove the other side pinion with its rib washer from half box
bronze beater. (3).

Figure 48 Figure 50
34843 33840
Drive out the bearing support (destructive operation) through Drive out middle bearing (1) from the bevel pinion through
a beater entered through the holes indicated by the arrow. extractor no. 99348001 (2) under the press.
Figure 51
526249 Disassembly bevel pinion support

86119
If necessary, remove safety ring (3), and take rear bearing (1)
Figure 49 out of bevel pinion (2) by using adequate tools.
Figure 52
34844
Take off previously loosened bevel pinion check nut. Position

bevel pinion support under the press as indicated in the figure
33845
and push off bevel pinion (3), with the middle bearing, rear
bearing and adjusting ring, from support (2). Remove Push gasket (1) off bevel the pinion support using proper
transmission connection flange (1). Take the adjusting ring off means; then extract front bearing (2) from the support.
the bevel pinion.

Assembly the wheelwork box

Figure 53 Figure 54
33846 33849
Heat, in an air circulation furnace, for about 15’ at 100 °C

Insert a bronze beater at the point indicated by the arrow and temperature, bearing (2) and drive it on wheelwork box (3)
push front bearing outer ring (1) off the bevel pinion support. through proper beater (1).
Put the support upside down and push off middle bearing
outer ring (2).
Figure 55
Check of parts making up the differential
Accurately clean the single parts making up the differential.

Lubricate the bearings and make the roller housing turn free;
its rotation must be normal and it must not show any
hardening. Check rest surfaces of the ring bevel gear and ledge
plane of the half box to the purpose that the ring gear can
adhere perfectly, as related deformation should cause
vibrations of the ring gear securing screws, jeopardising
assembly correct operation.
33847
Position half box (3) on tool no. 99371047.

Position crown wheel rib washer (2) in the half box, then
mount crown wheel (1).
NOTE Accurately clean all the threads in order to obtain
exact adjustments and precise tightening torques.
Figure 56
Check that splined space for flange keying on the pinion does
not look excessively worn out; if it does, replace the pinion.
Check side pinions with related rib washers, cross and crown
wheels with related rib washers.
Replace, by new parts, all sealing elements, the safety clip for
the adjusting ring nut and all safety washers.
33848
NOTE If the ring gear or the pinion should be replaced, you Mount cross (2) with side pinions (1) and their rib washers (3)
need to replace both, as parts are supplied twinned. on the half box.
If the cross has not been replaced, verify the matching of marks
made on dismounting.

Figure 57 Figure 59
33842 34850
Position second crown wheel (1) with its rib washer. Lock differential assembly with dedicated screw (3).
Heat, in an air circulation furnace, for about 15’ at 100 °C
temperature, bearing (1) and drive it on wheelwork box (2)
through proper beater.
Figure 58
Figure 60
33849
Mount half box (2). Verify the matching of marks made on

dismounting. Smear some drops of ”LOCTITE TYPE 270” to
half box threaded holes, screw screws (1) and tighten them
with the set torque (see table at page 139) through a
dynamometric wrench (3).
NOTE If new screws, supplied as spare parts (provided

with a pre—smeared locking adhesive), are
34851
mounted, just add one drop of LOCTITE.
Heat, in an air circulation furnace, for about 15’ at 100 ÷ 150°C
temperature, ring bevel gear (1) and position it, in its seat, on
Check that the side pinion — crown wheel assembly turns free, the wheelwork box, checking that it turns free; get the
without crawling. Otherwise, dismount assembly and find out matching of the holes for the screws securing the ring bevel
cause. gear to the wheelwork box.

Figure 61 In order to get an exact bevel pinion rolling torque, operate as

described below.
Figure 63
34852
Let the ring bevel gear to get cool.

Put upside down the wheelwork box on the tool.
Locate screws and close nuts (1) with the set torque (see page 36327
139) through dynamometric wrench (2).
Measure the adjusting ring (4) thickness found on mounting
and take note of their values (dimension A).
Tighten tool no. 99395027 (6) in the vice, and position, on the
tool:
- bearing (5) on pinion side;
- previously measured adjusting ring/s (4), and bearing (3).
Screw ring nut (2) and tighten it up.
Position part (1) of tool no. 99395027 (6) provided with a
comparator on bearing (3) and reset the comparator at tool
(6) end.
Then take off:
- part (1);
Assembly bevel pinion support
- ring nut (2);
- bearing (3);
Figure 62
- ring/s (4) of tool (6).
34853
Through beater no. 99374093 (1), drive, under the press, the
middle bearing outer ring, in its seat, into the support, avoiding
to go on up to the ledge. Repeat the same operation on the
opposite side for the front bearing outer ring.
Manually terminate the driving of bearing outer rings by beater
no. 99374093 with handgrip no. 99370007.

Figure 64 First example:

A = 13.12 mm
B = + 0.13 mm
C = 0.05 mm
S = 13.12 — (+ 0.13) + 0.05 =
S = 13.12 — 0.13 + 0.05 = 13.04 mm.
Second example:
A = 13.12 mm
B = — 0.13 mm
C = 0.05 mm
S = 13.12 — (— 0.13) + 0.05 =
36429 S = 13.12 + 0.13 + 0.05 = 13.30 mm.
Position support (4, Figure 64) on bearing (5, Figure 63) and
bearing (3) on support.
Screw ring nut (2) tightening it until following rolling torque is Then remove parts of tool (6, Figure 63).
found by a torque—meter: 0.5 ÷ 5 Nm.
NOTE This value is to be found without any seal ring and

with new bearings.
- If you use already used bearings this value is
within 1.13 ÷ 3.39 Nm range.
Position part (1), with previously reset comparator, on bearing Figure 65

(3) and find possible deviation (dimension B).
Thickness S of the adjusting ring/s is given by following formula:

S = A — ( B) + C
where:
- A = Thickness of the adjusting ring/s mounted to reset

the comparator;
- B = Value of found deviation;
33500
- C = 0.05 mm coefficient which takes into account bearing
expansion caused by mounting interference on the bevel
pinion. Heat, in an air circulation furnace, for about 15’ at 100 °C
temperature, rear bearing (2) and drive it on bevel pinion (3)
through proper beater (1).

Figure 66 Figure 68
33502
Select an adjusting ring (1) having the same thickness found

and position it on bevel pinion (2).
86120
Figure 69
Lock the bearing by fitting safety ring (1) onto the bevel pinion.
34860
Mount support (2) with front and middle bearing outer rings
on bevel pinion (1).
Figure 67 Figure 70
33501 34861
Heat, in an air circulation furnace, for about 15’ at 100 °C Heat, in an air circulation furnace, for about 15’ at 100 °C
temperature, bearing (2) and drive it on bevel pinion (3) temperature, front bearing (1) and drive it, in its seat, on the
through proper beater (1). bevel pinion through a proper beater.

Figure 71 Figure 74
34862 34865
Lubricate gasket (1) with oil and key it into the support. If you use the same pinion — ring gear assembly that was
removed on dismounting, position shim pack (2) and bevel
pinion support (1) on differential box (3), making sure that the
Figure 72 groove for oil passage is exactly aligned.
NOTE Do not use less than 3 shims, putting the thinnest

ones at the package ends.
Figure 75
3,5
1,2
1,2
1,2,3,4,5,6
19416
34863
Verify gasket (1) correct mounting measuring the port If a new pinion — ring gear assembly has to be mounted, to
between the support plane and gasket rest lip with feeler determine pinion exact positioning, it is necessary to know the
gauge (2); the port must result 0.40 ÷ 0.85 mm, and difference meaning of the prints made on the pinion and on the ring gear.
between min. and max. must not exceed 0.25 mm. 1. Part number.
3. Matching number of pinion — ring gear assembly.
4. Variation number to determine the thickness of the shim
Figure 73 pack to be inserted between the pinion support and the
differential box (in following examples, this variation number
is indicated by CP).
5. Month and year of pinion — ring gear assembly production
and test.
6. Nominal clearance of pinion — ring gear assembly.
printed at the threaded end of all pinions.
Usually, these numbers are printed on the front face of the ring
gears.
However, alternatively, they can be printed on the outer
diameter of the ring gear.
In any pinion — ring gear assembly, the ring gear shall always
have an even class number printed (e.g. 36786), while the
correspondent pinion shall always have an odd class number
34864
printed (e.g. 36787).
The tooth combination number (e.g. 10—41) indicates that the
Position transmission connection flange (1) with its baffle on pinion has 10 teeth and the ring gear 41, corresponding to 4.10
the splined portion of bevel pinion (2). Temporarily tighten : 1 transmission ratio.
the check nut.

All pinion — ring gear assemblies are supplied twinned. Example 3:

Therefore, both parts have the same printed number. - Original pack thickness mm 0.70
Usually, in pinions, this number is printed on the head end. - C.P. printed on the ring gear + 0.05 — 0.05
Usually, in ring gears, this number is printed on the outer - Measure got mm 0.65
diameter. - C.P. printed on new ring gear + 0.10 + 0.05
- New thickness of the pack to be used mm 0.60
Example 4:
NOTE Never use a pinion and a ring gear which do not - Original pack thickness mm 0.85
have the same numbers. - C.P. printed on the ring gear — 0.10 + 0.10
- Measure got mm 0.95
- C.P. printed on new ring gear + 0.15 + 0.15
Each ring gear has a variation number which indicates the
mounting nominal distance.
This variation number must be used when calculating the
thickness of the shims to be inserted between the pinion NOTE Shims to be inserted between differential box and
support and the differential box. bevel pinion support are supplied as spare parts
This variation number (e.g. C.P. + 0.1 or C.P. — 0.1 mm) is with 0.5 — 0.125 — 0.160 — 0.200 — 0.500 mm
printed on the outside of the ring gear. thickness.
To calculate the thickness of the shims to be inserted between
the pinion support and the differential box, operate in the
following way:
1. Measure the thickness of the shim pack used with the pinion On each pinion and on each ring gear, the month and year are
— ring gear assembly to be replaced. Use a micrometer gauge indicated on which they are jointly lapped and tested to be
or a caliper and take note of measure taken. twinned.
2. Read the C.P. number printed on the ring gear to be This indication is placed on the head end on the pinions.
replaced. If this number corresponds to a more (+) value, This indication is placed on the outer diameter on the ring
subtract it from measure previously taken at point 1. gears.
If this number corresponds to a less (—) value, add it to
measure previously taken at point 1. On all assemblies a number is printed indicating the nominal
Take note of this measure. clearance between pinion and ring gear got at the end of the
machining process.
NOTE Measure got at point 2 will be used to go on with the This clearance is indicated on the outer diameter of the ring
calculation of the thickness of the shim pack to be
gear.
inserted between the pinion support and the
differential box to be made according to new pinion
— ring gear assembly.
3. Read the C.P. number printed on the new ring gear. Assembly the differential box
Add/subtract the value to/from measure taken at point 2,
according to variation sign (+ adding, — subtracting). Figure 76
Refer to following examples, which cover all possible
CALCULATION EXAMPLES
Example 1:
- Original pack thickness mm 0.75
- C.P. printed on the ring gear + 0.05 — 0.05
- Measure got mm 0.70
- C.P. printed on new ring gear + 0.10 + 0.10
86121
Example 2:
Locate screws (2) with their washers and tighten them,
- Original pack thickness mm 0.65 through dynamometric wrench (1), with:
- C.P. printed on the ring gear — 0.05 + 0.05
- Measure got mm 0.70 - 1st step: pre—tightening: required torque;
- C.P. printed on new ring gear + 0.15 + 0.15 - 2nd step: closing: required angle.

Figure 77 Figure 79
34867 34869
Rotate the stand by 90°. - Position the caps taking care to match the dowels. Put in
Lock flange (1) rotation through tool no. 99370317 (3). the screws with the washers and tighten them with the
Position proper 12—point wrench and, through over—gear (2) set torque through a dynamometric wrench.
and dynamometric wrench (4), tighten the pinion check nut
- Then check that bearing outer rings (1) slide through a
with required torque:
slight pressure into their seats without crawling.
- Unscrew again the check screws with the washers and
take off the caps.
Figure 78
Figure 80
34867
Through torque—meter no. 9938919 (1) check again the bevel

pinion rolling torque, which must result 0.5 ÷ 5 Nm.
86122
Position taper roller bearing outer rings (3) on respective inner

NOTE With a lubricated gasket, the rolling torque rings. Through hook no. 99370509 (1), lift previously
increases by approx. 1.5 Nm. assembled wheelwork box (2) and position it on the
differential box.

Print 603.93.391
Figure 81 2ND METHOD

Figure 83
86123
Position caps (2) checking correct location of bearing outer

60635
rings.
Screw screws (1) with washers without locking them A. Diagonally and centrally position two magnetic base
completely. comparators (1) on machined outer seats of both caps
Lubricate the taper roller bearings. (2), as indicated in the figure.
Screw adjusting ring nuts (3) up to contact with bearing outer B. Go on as described at point 1.
rings. C. After removing axial clearance, further tighten two
Tighten screws (1) for caps through a dynamometric wrench adjusting ring nuts (4) causing a cap (2) opening out of
with requiredtorque. 0.05 ÷ 0.23 mm.
Adjusting cap opening out

Adjusting and checking cap opening out can be carried out
according to two methods.
1ST METHOD Figure 84
1. Through wrench no. 99355025 (3, Figure 84), tighten
bearing adjusting ring nuts (4) until clearance between
pinion — ring gear assembly and axial clearance is removed
and, at the same time, check the ring gear not to exert an
excessive force against the pinion;
2. By proper micrometer gauge, positioned diagonally and
centrally at points (x—y arrows, Figure 82), find cap
distance and note it.
Figure 82
86124
Adjust the axial clearance between the teeth of pinion — ring

gear assembly, which must result 0.26 ÷ 0.50 mm, observing
below procedure:
- lock bevel pinion rotation through tool no. 99370317;
- position magnetic base comparator (1) as indicated in the
figure;
- through wrench no. 99355025 (3), loosen the adjusting
ring nut on the ring gear side and tighten, by the same
60636
amount, adjusting ring nut (2) on the opposite side;
3. Further tighten two adjusting ring nuts (4, Figure 83) purpose of this operation is to maintain unvaried the
causing a cap (2, Figure 83) opening out which is previously adjusted cap opening out;
measured as described at point 2, namely: 0.05 ÷ 0.23
- go on as described until you get the set clearance.
mm.
Clearance must be checked on 4 equidistant points.

Figure 85 Figure 88
19453
86125
Contacts too outwards, towards ring gear tooth crest.
Through a magnetic base comparator (2), check that ring gear
(1) does not wobble by more than 0.20 mm. If it does, Conditions A—B. It means that the pinion is set too outwards;
dismount the differential assembly and find cause. Then therefore, it has to be further adjusted.
remount and repeat previously described adjusting To adjust the pinion at its exact position, you need to remove
operations. shims under the pinion support in order to get a precise
contact.
Figure 86
Condition A. After adding shims, increase clearance towards
maximum clearance.
Condition B. Find clearance and recover, after adding shims.
Figure 89
86126 4
Apply, with a paintbrush, a thin layer of lead oxide (red lead) 3
on the ring gear teeth. Turn the pinion and find the print of the
Clearance decrease
contact of pinion teeth on ring gear teeth. In following figures,
possible contact types are illustrated, as well as the way to
correct possible errors.
Figure 87
Clearance increase
19454
THEORETICAL CONTACT AREA

1. Release, tooth hollow side. — 2. Top. — 3. Draw, tooth
convex side. — 4. Heel.
19452 DRAW. Central draw pointing towards top on tooth face and
central draw on tooth profile.
Contact too deep in ring gear tooth bottom land.
Conditions C—D. It means that the pinion is set too deep; RELEASE. Central release pointing towards heel on tooth face
therefore, it has to be further adjusted. To adjust the pinion at and central release on tooth profile.
its exact position, you need to add shims under the pinion It means that pinion is correctly set.
support in order to get a precise contact.
Condition C. Find clearance and recover, after adding shims. Contact position can be further modified by varying pinion —
Condition D. After adding shims, decrease clearance towards ring gear clearance.
minimum clearance. Condition E. Remove clearance.
Condition F. Increase clearance.

BEVEL TORQUE CONTACTS CORRECTION (AFTER ASSEMBLY)

Figure 90
DRAW RELEASE
(RING GEAR CONVEX SIDE) (RING GEAR HOLLOW SIDE)
CREST CREST
HEEL TOP HEEL
—DRAW: CENTRAL DRAW POINTING TOWARDS TOP ON TOOTH FACE AND CENTRAL
DRAW ON TOOTH PROFILE.
—RELEASE: CENTRAL RELEASE POINTING TOWARDS HEEL ON TOOTH FACE AND CENTRAL
RELEASE ON TOOTH PROFILE.
CONDITION ”A”
DRAW RELEASE
CREST CREST
HEEL TOP HEEL
—DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS CREST

—DRAW: CONTACT EXCESSIVELY TOWARDS TOP
—RELEASE: CONTACT EXCESSIVELY TOWARDS HEEL
—CORRECTIVE ACTIONS: TAKE OFF SHIMS AND INCREASE CLEARANCE TO MOST
CONDITION ”B”
CREST CREST
HEEL TOP HEEL

—DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS CREST
—CORRECTIVE ACTIONS: FIND CLEARANCE, ADD SHIMS AND RECOVER CLEARANCE
CONDITION ”C”
CREST CREST
HEEL TOP HEEL

—DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS BOTTOM LAND
—CORRECTIVE ACTIONS: FIND CLEARANCE, ADD SHIMS AND RECOVER CLEARANCE
60676

Figure 91
CONDITION ”D”
CREST CREST
HEEL TOP HEEL
—DRAW—RELEASE: CONTACTS EXCESSIVELY TOWARDS BOTTOM LAND

—DRAW: CONTACT EXCESSIVELY TOWARDS HEEL
—RELEASE: CONTACT EXCESSIVELY TOWARDS TOP
—CORRECTIVE ACTIONS: ADD SHIMS AND DECREASE CLEARANCE TO LEAST
CONDITION ”E”
CREST CREST
HEEL TOP HEEL
—DRAW: CONTACT EXCESSIVELY TOWARDS HEEL

—RELEASE: CONTACT EXCESSIVELY TOWARDS TOP
—CORRECTIVE ACTIONS: DECREASE CLEARANCE
CONDITION ”F”
CREST CREST
HEEL TOP HEEL
—DRAW: CONTACT EXCESSIVELY TOWARDS TOP

—RELEASE: CONTACT EXCESSIVELY TOWARDS HEEL
—CORRECTIVE ACTIONS: INCREASE CLEARANCE
60677

Figure 92
34832
Put again safety clip (1) and fold it up.
NOTE If the seat on ring nut (2) does not collimate, turn
ring nut (2) by minimum amount needed to
correctly position the safety clip.
Figure 93
86114
Position elastic pin (1).
NOTE If plate positioning turns out to be troublesome,

rotate the ring (2) by the slightest amount until the
elastic pin can be secured to the cap.

AXLES WITH DIFFERENTIAL LOCKING DEVICE

Meritor axles with differential locking device differ from previously described Meritor axles in what contained in below chapter.
Description
The axle is provided with a pneumatic—control device to lock the differential.
Figure 94
86128
PARTS MAKING UP THE DIFFERENTIAL

1. Bevel pinion nut — 2. Flange — 3. Baffle — 4. Gasket cover — 5. Screw — 6. Washer — 7. Front bearing — 8. Outer ring — 9.
Support — 10. Adjusting shims — 11. Adjusting ring — 12. Outer ring — 13. Middle bearing — 14. Bevel pinion — 15. Rear bearing —
16. Lock—nut — 17. Transmitter — 18. Plug — 19. Adjusting ring nut — 20. Spring — 21. Shaft — 24. Cylinder — 25. Piston — 26. Seal
ring — 27. Copper ring — 28. Cover — 29. Screws — 30. Screw — 31. Washers — 32. Copper washer — 33. Threaded plug — 34.
Sliding sleeve — 35. Spring pins — 36. Fork — 37. Screw — 38. Washer — 39. Cap — 40. Rib washer — 41. Side pinion — 42. Crown
wheel — 43. Rib washer —
44. Half box — 45. Bearing — 46. Outer ring — 47. Screw — 48. Cross — 49. Screw — 50. Ring bevel gear — 51. Half box — 52. Nut
—
53. Cap — 54. Safety split pin — 55. Differential box — 56. Elastic pin

TIGHTENING TORQUES
Figure 95
86167
DIFFERENTIAL MS10 — 144 SECTION (VERSION WITH DIFFERENTIAL LOCKING)
TORQUE
PART
Nm (kgm)
2 Differential locking cover securing screw 17 ± 3 (1.7 ± 0.3)

526210 REMOVAL THE DIFFERENTIAL

Observe procedure described at page 154, remembering to Figure 98
carry out what follows:
Figure 96
33529
Through wrench no. 99355168 (2), unscrew fork drive shaft

33531 (1) and extract it.
To manually fit in the differential block, unscrew threaded plug
(1) putting in, at its place, screw (2), that you can find on the
cylinder cover. Figure 99
Turn the transmission connection flange in order that the
sliding sleeve matches the differential half box.
Screw up the screw until the differential locking device can be
inserted.
526210 FIXING THE DIFFERENTIAL

Disassembly of the differential locking device
Disassemble the transmitter.

33528
Extract spring (1) and extract fork (2), including sliding sleeve
(3).
Figure 97
Figure 100
33530 33527
Unscrew four screws (2) with safety washers (3).

Remove cover (4) with the copper ring and cylinder (1)
controlling the differential locking, including piston and seal Push off two spring pins (3) through a punch and put apart fork
ring. (1) from sliding sleeve (2).

Assembly of the differential locking device

Figure 104
Figure 101
33520 33523
Lubricate seal ring (2), fit it, in its seat, on piston (1) and
Fit sliding sleeve (2) into fork (1) and drive the two spring pins.
position the piston on fork drive shaft.
Position the fork, including the sliding sleeve, in its seat.
Figure 105
Figure 102
33524
Fit cylinder (1) on the piston.

33521
Figure 106
Put in return spring (1).
Figure 103
33525
Put the copper gasket into the cover seat, then position cover
(1) and secure it through four screws (2) with safety washers.
The screws are to be tightened with required torque (see
33522
table at page 79).
Mount drive shaft (2), applying Loctite 242 on the thread, and
screw it in the fork through wrench no. 99355168 (1).

Figure 107
33526
Enter screw (1) for engaging the manual locking of the

differential.
Directions to adjust and check the operation of the transmitter for checking differential
locking insertion.
Adjusting and checking the operation of the transmitter (two—function type transmitter) for checking differential locking insertion
is carried out with the axle mounted on the vehicle and operating as described below:
1) With differential locking inserted, screw the transmitter up to contact closing, checking, in the cab, that the warning indicator
light goes on.
2) As the warning indicator light in the cab goes on, screw the transmitter by one turn more.
3) Tighten the transmitter locking lock—nut with 40 Nm (4 kgm) torque.
4) Unlock differential locking engagement drive and check that contacts are closed (in this condition, the indicator red light in
the cab must be off).
5) By using the screw for differential locking manual insertion, partially put on locking screwing the screw in the dedicated hole
on the operating cylinder cover up to contact opening (in this condition, the indicator red light in the cab must be blinking).
6) Unscrew the screw in order to put off the differential manual locking.
Fit the screw, in its seat, on the operating cylinder cover and screw the plug with washer into the threaded hole previously
held by the screw.


MS10 — 164
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 179

TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . . . 180
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 182
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

(with pneumatic suspensions) . . . . . . . . . . . . . 191
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

(with mechanical suspensions) . . . . . . . . . . . . 192
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
DIFFERENTIAL GEAR REMOVAL AND REFITTING

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
DIFFERENTIAL GEAR REPAIR . . . . . . . . . . . . . . 199
- Differential gear disassembly . . . . . . . . . . . . . . 199
- Gearing case disassembly . . . . . . . . . . . . . . . . . 200
BEVEL PINION DISASSEMBLY FROM SUPPORT 202

Page
- Check of parts composing differential

gearing assembly . . . . . . . . . . . . . . . . . . . . . . . . 202
- Gearing case assembly . . . . . . . . . . . . . . . . . . . 203
FITTING THE SUPPORT ON THE BEVEL PINION 204
- Differential case assembly . . . . . . . . . . . . . . . . . 207
CAP RETRACTION ADJUSTMENT . . . . . . . . . . 209
BEVEL TORQUE CONTACTS CORRECTION

(AFTER ASSEMBLY) . . . . . . . . . . . . . . . . . . . . 212
- Instructions for adjusting and verifying transmitter

operation to check insertion of differential
gear locking . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
WORK ON THE VEHICLE . . . . . . . . . . . . . . . . . 216
REPLACING THE BEVEL PINION

SUPPORT SEAL RING . . . . . . . . . . . . . . . . . . 216
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

DESCRIPTION
The rear axle is of the portable type with simple reduction: it Moreover, the bevel pinion position can be adjusted with
is composed of a case made of suitably reinforced sheet made respect to the bevel crown, by changing the thickness of the
of pressed steel. pack of rings placed between differential gear case and bevel
The differential gear is characterised by an assembly of pinion support.
hypoidal toothing gears. The gearing case is supported by two bevel roller bearings and
The pinion is supported by two bearings (pinion unit) with is axially adjustable through two threaded ring nuts.
bevel rollers and a third bearing with cylindric rollers. Wheel hub bearings are of the permanent—lubrication,
Adjustment of the bevel pinion assembly is carried out UNIT—BEARING type, and do not need adjusting.
through adjustment rings placed between the two bevel roller
bearings.
Figure 1
86151
REAR AXLE ASSEMBLY VIEW


Service Network.
Figure 2
86620
D = rear axle ratio
E = production date
TECHNICAL NAME
Axle casing thickness: 11 mm
Single ratio
Capacity
MERITOR
Rear only


Rear axle type:
MS10 — 164
Carrier with simple reduction
3.07 (14/43) — 3.21 (14/45) — 3.42 (12/41) — 3.73 (11/41)
Bevel torque reduction ratio 3.91 (11/43) — 4.10 (10/41) — 4.30 (10/43) — 4.56 (9/41)
5.12 (8/41) — 5.63 (8/45) — 6.43 (7/45)

0.26 ÷ 0.50
crown

Through ring nuts
pinion and crown
Bevel pinion placement with

respect to the crown
Cap retraction mm 0.15 ÷ 0.33
Cap retraction adjustment Through ring nuts

pinions and planetary gears Nm 68 max
(kgm) (6.9 max)
Thickness of adjustment rings placed
differential gear case mm 0.125 — 0.200 — 0.500
Throttling of crown abutment
plane on half—case mm 0.20 max
WHEEL HUBS
Axial clearance adjustment of wheel

—
hub bearings
Axial clearance adjustment of wheel Not adjustables

hub bearings Torque tightening by means of a nut
Rear axle oil TUTELA W140/M—DA

Amount Liters 17.6
(kg) 15.8
Dry weight: With differential lock Without differential lock
— mechanic suspension kg 523 520
— pneumatic suspension kg 528 525
— Maximum capacity kg 10700

DIAGNOSTICS
Main rear axle operating anomalies: 3 — Release noise;
1 — Wheel hub noise; 4 — Trailing noise;
2 — Rear axle noise; 5 — Curving noise.
1 WHEEL HUBS NOISE
Insufficient lubrication. Check that no leakage occur from rear axle case and
YES restore the level.
NO
Inefficient wheel hub bearings. Proceed with disassembling hub and replacing assembly
YES bearing.
NO
Wheel hub bearings with excessive clearance. Check and possibly replace the bearings.
YES
2 REAR AXLE NOISE
Insufficient lubricating oil level. Check that no leakage occur from rear axle case and
NO
Half—shafts coupling grooves with differential planetary Revise the rear axle and replace worn or damaged
gears damaged. YES parts.
NO
Incorrect adjustment or deterioration of differential Locate the inconvenience and carry out assembly
assembly gears or bearings. YES revision.

3 RELEASE NOISE
Incorrect coupling clearance between pinion and bevel Carry out clearance adjustment between pinion and
crown. YES crown.
4 TRAILING NOISE
Insufficient lubrication. Check that no leakage occur from the case and restore
YES the level.
NO
Gearing case bearings not adjusted or deteriorated. Proceed with assembly revision.
YES
NO
Incorrect teeth contact between pinion and bevel Proceed with contact adjustment.
crown. YES
5 CURVING NOISE
Incorrect clearance in side pinion planetary assembly. Revise or replace the assembly.
YES

TIGHTENING TORQUES
Figure 3
49302
DIFFERENTIAL GEAR SECTION
TORQUE
PART
Nm (kgm)
1 Screw for securing differential gear to rear axle case
1st step torque 100 ± 5 (10.1 ± 0.5)
2nd step angle 80° ÷ 90°
2 Screw for securing differential gear half—case 1st step torque 100 ± 5 (10.1 ± 0.5)
3 Screw for securing bevel crown to half—case
1st step torque 100 ± 5 (10.1 ± 0.5)
4 Bevel pinion locking nut 1510 ± 160 (153.9 ± 16.3)
5 Screw for securing bevel pinion support 1st step torque 100 ± 5 (10.1 ± 0.5)
6 Sensor locking nut 40 ± 5 (4 ± 0.5)
— Screw for securing caps to differential gear case 730 ± 80 (74.4 ± 8.1)

Figure 4
86092
HUB SECTION
TORQUE
PART
Nm (kgm)
1 Screw fastening the axle shaft to the wheel hub 150 ± 15 (15.3 ± 1.5)
2 Wheel hub bearing fastening ring 932 ± 98 (95 ± 9)
3 Screw fastening the brake disc to the wheel hub 40 ± 4 (4 ± 0.4)
4 Brake caliper fastening screw 313 ± 16 (32 ± 1.6)
5 Brake caliper fastening gauged screw 313 ± 16 (32 ± 1.6)
(A) When mounting the differential, a 0 ÷ 0.07 mm clearance must be provided between the hub outer side and the spacer
side, by carrying out two checks at 180°.
* Apply sealant IVECO 1905685 (LOCTITE 14780) to the hub/axle shaft contact surface.

TOOLS

(1000 daN capacity, 120 daNm torque)
Stand for rear axle and front axle revision

99322215
Assembly bearing support (to be applied to stand 99322205)

99322225
Simple—effect rear axle

99341003
Pair of brackets
99341009

TOOLS
99341015 Clamp
99355025 Wrench for differential gearing case bearings adjustment ring nuts

TOOLS
(60 mm) wrench for differential bevel pinion nut

99355088 (use with 99370317)
99363204 Gasket removing tool
99370509 Differential gearing half—case extracting hook
99370616 Differential gear disconnection and reconnection support

TOOLS
Universal support for supporting rear axles during disconnection and

99371047 Differential gear half—case check support during crown union screws
securing (use with 99322205 and 99322225)
99374244 Keyer for assembling differential gear bevel pinion sealing ring

TOOLS

(max 2745 Nm)
99389819 Dynamometric wrench (0—10 Nm) with 1/4” panel connection


(with pneumatic suspensions)

pneumatic system.
Removal
sensors and free wiring from the various check straps;
- disconnect air supply piping (4) next to union (5);
support 99370617 and suspend it;
- unscrew securing screws (7) and disconnect reaction
triangle (6) from rear axle;
(13) and securing nuts (10) to disconnect shock
absorbers (9) from rear axle;
- unscrew bolts (16) and disconnect reaction tie rods (19)
that remain anchored to the chassis;
- exhaust air from springs (20), unscrew securing nuts
(14);
- disconnect level sensor arm (11), unscrew nuts (12),
withdraw screws (17) and remove cross member (18);
- lower the hydraulic jack and withdraw the rear axle from
below the vehicle, paying attention to possible
interference with chassis parts.
Refitting
piping;
- check elastic pads conditions; if they are worn,
replace them;
98873


(with mechanical suspensions)

pneumatic system.
Removal
sensors and free wiring from the various check straps (5);
- disconnect air supply piping (6) next to union;
(8) and securing nuts (10) to disconnect shock absorbers
(7) from rear axle;
support 99370617;
- unscrew securing nuts (12) and remove stands (13),
lower the jack and remove the rear axle from below the
vehicle.
Refitting
piping;
worn, replace them;
91582


ASSEMBLY


Figure 7 86094

Figure 10
86093
86095
525030 OVERHAULING THE WHEEL Remove the brake linings (1) making the calliper body (2) float
HUBS appropriately.
Disassembly
Figure 8 Figure 11
72740 86096

Figure 12 Figure 15
86100
86097 Take out the screws (2) and (4) and remove the wheel hub
Put a container under the wheel hub to collect the oil. Lock (1) from the brake disc (3).
rotation of the wheel hub (1) with the retaining tool 99370317 Examine the state of wear of the brake disc (3) as described
(3). Take out the screws (2) and extract the drive shaft (4). in the ”BRAKE AIR SYSTEM” section.

Figure 13
Figure 16
1 3
1
2
4
2
5
3
86098
86101
Lift the notching of the ring nut (5). Using the wrench
99355182 (1) and multiplier 99389816 (2), remove the ring Using a hydraulic press and tool 99370721 (1) take out the
nut (5) holding the wheel hub bearing. Take out the retaining wheel hub, spacer (3) and bearing (2).
ring (4). Figure 17
Figure 14
99240
86099
Using the press and tool 99370720 (1) mount the bearing (2):
Remove the wheel hub (1). If this proves difficult, use the bearing drive—in load 30,000 to 90,000 N.
extractor comprising: brackets 99341017 (2), bridge If tool (1) is not available, position the bearing to the assembly
99341003 (3), block 99345053 (4), applied as shown in the dimension shown in the figure.
figure.

Figure 18 Figure 20
86103
86105
Fit the spacer ring (2) in the wheel hub (1) and check on two Screw the tool 99370719 (2) onto the sleeve (1) of the axle
diametrically opposite points that, after assembly, the ring (2) housing. Lubricate the tool external surface (1) with the oil
is sunk below the face of the wheel hub by 0.0 to 0.07 mm. prescribed for the wheel hubs.
Figure 21
Checking the parts forming the wheel hubs
Thoroughly clean the single parts comprising the wheel

hub. Examine the drive shafts and check there is no
deformation.
to extract them.
86106
525035 Replacing the wheel fixing pins Mount the brake disc (3) on the wheel hub (1) and screw
down the screws (2) and (4).
Figure 19
Figure 22
86104
Using general tools, drive the pins (1) out of the disc (2). 86107
Make sure the supporting surface for the heads of the pins has Sling the brake disc (1) with a rope, hook this onto a lift and
no burrs. fit the wheel hub (2) on the sleeve of the axle housing.
Carefully drive in the pins, applying a load no greater than 2300 Remove the tool 99370719 (3).
kg on their heads.

Figure 23 Figure 26
86108
Position the retaining ring (4) so as to insert the tab into the 86110
groove of the sleeve, then screw on the ring nut (5). Using the
wrench 99355182 (1), multiplier 99389816 (2) and the Position the brake calliper (1) on the flange (3) and tighten the
torque wrench (3), tighten the ring nut (5) to the required fixing screws (2) to the required torque.
torque.
Figure 24
NOTE First screw down the brake caliper securing gauged
screw:
— vehicles equipped with mechanic suspensions —
the gauged screw must be positioned in the
lower part of the brake caliper fastening flange;
— vehicles equipped with pneumatic suspensions
upper part of the brake caliper fastening flange.
49213A
After tightening, using an appropriate tool, notch and bend the

ring nut as shown in the figure so it cannot be unscrewed.
The arrow shows the direction of unscrewing the ring nut.
Figure 25
1 Figure 27
2
4
3 5
86109
Spread IVECO 1905685 (LOCTITE 14780) sealant onto the

flange contact surfaces of the drive shaft — wheel hub and
insert the drive shaft into the axle housing. Screw down the
86095
screws (2) fixing the drive shaft (3) to the wheel hub (1) and
tighten them with the torque wrench (4) to the required Mount the brake linings (1) in the brake calliper (2).

Figure 28 Figure 30
72740

pin (4).
adjustment screw.
NOTE After refitting the rear axle on the vehicle, check the
efficiency of the brake lining wear recovery device,
as described in the relevant section and replace the
plug (1) with a new one.

Figure 29
86112
7. Wheel hub — 8. Brake disc — 9. Axle sleeve

526210 DIFFERENTIAL GEAR REMOVAL Figure 33

AND REFITTING
(with rear axle on stand 99322215)
Figure 31
86154
Insert differential gear in rear axle case, screw nuts (2 ) and

screws (3) completed with safety washers and tighten them,
through a dynamometric wrench (1), at the required torque
and according to the order shown in Figure 34.
86153
Mount the axle shafts as described in the relevant chapter.
Insert the required amount of oil into rear axle case.
Removal
Take out the axle shafts, as described in the relevant chapter,
unscrew differential gear case (1) securing screws, screw into
suitable threaded holes three screws that in this case operate
as extractors and withdraw differential gear from rear axle
case (2).
Refitting
Figure 32 Figure 34
34827
49220
Butter with IVECO 1905685 (LOCTITE 14780) sealant the Tightening order diagram (differential gear case to rear axle
rear axle case contact surface, after having cleaned the contact case) (1 — 2 — 3 — 4 — Nuts) (10 — 9 — 14 — 5 — 7 — 11 — 13
surface. — 6 — 8 — 12 — Screws)

526210 DIFFERENTIAL GEAR REPAIR Figure 38
Differential gear disassembly

Figure 35
49224
Unscrew bearing adjustment ring nut (1). With a suitable

49221 wrench, unscrew and remove screws (2) with related
washers, repeat the same operation on the opposite side;
Disassemble differential gear (1). remove caps (3) for support bearings.
Secure it onto stand 99322205 (3) with support 99322225
(2).
Figure 39
Figure 36
49225
49222
Through hook 99370509 (1) extract gearing case (2)
Unscrew transmitter (1); unscrew screws (2) and remove completed with bevel crown and external rings (3).
parts 3 — 4 — 5.
Figure 37 Figure 40
49226
49223
Lock flange (1) rotation through check tool 99370317 (2).
Push elastic pegs (1 →) outwards and withdraw sliding sleeve With wrench 99355088 (3) and multiplier (4) loosen bevel
(2). Remove spring (3), fork (4) and split pin (5). pinion nut.

Figure 41 Figure 43
72004
49228A
Unscrew nut (3), apply brackets 99341009 (2) and tool
99341003 (1) and withdraw flange (4). Turn gearing case over and remove bearing (1) (destructive
Unscrew screws (5) for securing bevel pinion support to operation).
differential gear case (7).
Withdraw complete bevel pinion support (8) from differential
gear case. Remove pinion position adjusting shims (6) with Figure 44
respect to crown and through a micrometer measure the
global thickness.
NOTE Check sealing ring (o—ring) integrity and replace it if

damaged.
Gearing case disassembly Arrange gearing case on tool 99371047 (1). Unscrew
self—locking screws (2) for securing bevel crown (3) to gearing
case. Remove bevel crown through a bronze beater.
Figure 42
Figure 45
72005
49233
Use tool 99341003 (1), brackets 99341009 (2), reaction block Mark assembly position of the two half—cases (2 and 3) and
(3) and clamp 99341015 (4), then extract bearing (5). of spider.
Unscrew screws (1) and lift half—case (2).

Figure 46
Disassemble the following parts (2—3—4—5—6—7—8—9) from

half—case (1).
49234A
PARTS COMPOSING THE GEARING CASE

1. Half—case — 2. Half—case — 3. Shoulder washer — 4. Planetary gear — 5. Spider assembly — 6. Shoulder washers —
7. Side pinions — 8. Planetary gear — 9. Shoulder washer

526210 BEVEL PINION DISASSEMBLY Figure 49

FROM SUPPORT
Figure 47
49232
Through tool 99348001 (1) extract bearing (2).
49230
Through tool 99348001 extract bearing (1) from bevel pinion

(2).
Figure 48
Check of parts composing differential gearing

assembly
Accurately clean single pieces composing the

differential gear.
Lubricate the bearings and freely rotate the
roller—holder cage; the rotation must be regular and
86721
must not shown any hardening.
Extract the bevel pinion (3) with a vice. Check bevel crown bearing surfaces and half—case
abutment plane so that the crown perfectly adheres
thereto; distortions of such planes would generate
vibrations in crown securing screws, impairing the
NOTE Due to production requirements, the two bearings correct assembly operation.
(2) of pinion (3) are kept assembled by means of a Check that the grooved section for keying flange to
special metal ring (1) that is normally left in place, pinion does not show excessive wears, otherwise
owing to its being unimportant. During the pinion replace the pinion.
disassembling phase, the ring is partially taken out,
if still present.
If not taken out, the ring could be dangerous, since
it could subsequently interfere with the bearings.
Prior to reassembling the pinion, it is therefore
essential that you check for the presence of the ring
and take it out fully.

Gearing case assembly Figure 52
Figure 50
49235
34847
Assemble half—case (2).

Place half—case (3) on tool 99371047. Make sure that marks made upon disassembling coincide.
Place planetary shoulder washer (2) on half—case and then Screw screws (1) and tighten them as follows:
assemble planetary gear (1). - 1st step: tightening through a dynamometric wrench (3)
Figure 53
Figure 51
49235A
19383
Assemble on half—case (4) spider (6) completed with side - 2nd step: closing screws (1) through tool 99395216 (3)
pinions (5) and related shoulder washers (3). with the required angle.
If the spider has not been replaced, make sure that marks
made upon disassembling coincide. Heat bearing (2) in an air circulation oven at the temperature
Place second planetary gear (2) and related shoulder washer of 100 °C for about 15’ and drive it through a suitable beater.
(1).

Figure 54 Figure 56
49234 49236A
Heat bevel crown (1) in an air circulation oven at the - 2nd step: closure, through tool 99395216 (1) with the
temperature of 100 °C ÷ 150 °C, and place it in its own seat required angle.
on gearing case, checking that it freely rotates; make holes
Heat bearing (2) in an air circulation oven at the temperature
coincide for bevel crown — gearing case securing screws by
of 100 °C for about 15’ and drive it through a suitable beater.
assembling 4 operating screws.
526249 FITTING THE SUPPORT ON THE

BEVEL PINION
Figure 57
Figure 55
72766
The bevel pinion mount (1) is supplied as a spare together with

the tapered roller bearings (2 and 3) and the seals (4 and 5).
Figure 58
49236
Let the bevel crown cool and turn gearing case over on tool.
Screw screws (1) and tighten them as follows:
- 1st step: tightening through a dynamometric wrench (2)
at the required torque;
- replace the 4 operating screws with other new ones and
apply the same required tightening torque. 49237

of 100 °C for about 15’ and drive it onto pinion (1).

Figure 59
NOTE The imprint diameter must be included between
3.40 and 4.10 mm respectively corresponding to a
depth of 0.30 ÷ 0.44 mm using a 4000—kg load with
a ball with a 10—mm diameter.
Figure 61
72006

of 100 °C for about 15’ and drive it onto bevel pinion (1).
Figure 60
72007
Through a pipe (1) suitably placed on internal bearing race (4),

drive under a press support (2) completed with bearings onto
bevel pinion (3).
NOTE The lens shows a sectional view of the pipe position

on internal bearing race.
33495
Lock the bearing by punching the bevel pinion in 10 points at

the same distance as shown in the figure.
Such operation must be accurately carried out by using a
suitable punch.

Figure 62 Figure 64
19416
In case a new pinion—crown assembly has to be assembled, it

is necessary, to determine the exact pinion positioning, to
know the meaning of the printings made on pinion and crown.
49239 1. Part number.
Place transmission connection flange (1), completed with 3. Pinion—crown assembly coupling number.
baffle (2), and with a suitable beater completely assemble it: 4. Variation number to determine the thickness of the pack
it is advisable to carry out such operation under a press. of shims to be placed between pinion support and
Temporarily tighten the check nut. differential gear case (such variation number is marked as
CP in the examples).
5. Manufacturing and testing month and year of the
pinion—crown assembly.
6. Rated clearance of pinion—crown assembly.
Part number and tooth combination number are punched at

the threaded end of all pinions.
On the crowns such numbers are usually punched on the front
Figure 63 face.
However, as an alternative, they can be found on the external
crown diameter.
In any pinion—crown assembly, the crown will always have an
even part number (for example 36786) pressed, while the
corresponding pinion will have an odd number (for example
36787).
The tooth combination number (for example 10—41) shows
that the pinion has 10 teeth and the crown 41, equal to a
transmission ratio of 4.10 : 1.
NOTE No pinion—crown assemblies must ever be used

that have not the same coupling numbers.
49240
In case the same pinion—crown assembly is used that has been

removed when disassembling, place the previously—measured
pack of shims (2) and the bevel pinion support (1) with sealing
ring (o—ring) on differential gear case (3), making sure that the
oil passage groove is exactly aligned.

Every crown has a variation number that shows the rated Example 4:
assembly distance. Original pack thickness mm 0.85
This variation number must be used when computing the C.P. punched on the crown —0.10 +0.10
shims to be placed between pinion support and differential Obtained measure mm 0.95
gear case. C.P. punched on the new crown —0.15 —0.15
This variation number (for example C.P. + 0.1 or C.P. — 0.1 New thickness of the pack to be used mm 0.80
mm) is punched on the external crown part.
In order to compute the shims to be placed between pinion
support and differential gear case, operate as follows:
1. Measure the thickness of the pack of shims used with the NOTE The shims to be placed between differential gear
pinion—crown assembly to be replaced. Use a case and bevel pinion support are supplied as spares
micrometer or a gauge and take note of the obtained in shims with 0.125 — 0.200 — 0.500 mm.
measure.
2. Read the C.P. punched on the crown to be replaced. If this
number is a higher value (+), subtract it from the obtained All assemblies have a number punched that shows the rated
measure as of section ”1”. If this number is a lower value clearance between pinion and crown obtained at the end of
(—), add it to the obtained measure as of section ”1”. working.
Take note of such measure. Such clearance is shown on the external crown diameter.
Differential case assembly

NOTE The measure obtained in section ”2” will be used to
proceed with the computation of the pack of shims
to be placed between pinion support and Figure 65
differential gear case depending on the new
pinion—crown assembly.
3. Read the C.P. punched on the new crown. Add or

subtract the value, according to the variation (+ add, —
subtract), from the measure obtained in section ”2”.
The obtained value shows the thickness of the new pack of
shims to be used.
Refer to the following examples that cover all possible
computation combinations.
Computation examples
Example 1:
49241
Original pack thickness mm 0.75
C.P. punched on the crown +0.05 —0.05
Obtained measure mm 0.70
C.P. punched on the new crown +0.10 +0.10 Arrange screws (2) and tighten them in two steps as described
New thickness of the pack to be used mm 0.80 below:
Example 2: - 1st step: tightening through a dynamometric wrench (1)
Original pack thickness mm 0.65 at the required torque;
C.P. punched on the crown —0.05 —0.05 - 2nd step: closure of screws (2) through tool 99395216
Obtained measure mm 0.70 with the required angle.
C.P. punched on the new crown +0.15 +0.15
New thickness of the pack to be used mm 0.85
Example 3:
Original pack thickness mm 0.70
C.P. punched on the crown +0.05 —0.05
Obtained measure mm 0.65
C.P. punched on the new crown —0.05 —0.05
New thickness of the pack to be used mm 0.60

Figure 66 Figure 68
49242 72008
Rotate the assembly by 90°. Place caps (2), arrange screws (1) completed with washer and
Lock flange (3) rotation through tool 99370317 (5). With completely screw them without locking them at a torque.
wrench 99355088 (2), multiplier (4) and dynamometric
wrench (1), tighten pinion check nut at the required torque.
NOTE Set the required torque on the dynamometric

wrench (1) as function of the multiplication factor of
the multiplier (4).
Figure 67 Figure 69
49225 49245
Place external bearing rings (3). Lubricate bevel roller bearings (1), manually screw adjustment
Lift, through hook 99370509 (1), the previously—assembled ring nuts (2) till they contact external bearing rings; lock screws
gearing case (2) and place it on differential gear case. (1, Figure 68) at the required torque.

CAP RETRACTION ADJUSTMENT 2ND METHOD

A. Diagonally and centrally place on the external worked
seats of both caps (2, Figure 71) two comparators (1)
with magnetic base as shown in Figure 71;
Cap retraction adjustment and check can be carried out with
two methods:
1ST METHOD
1. Tighten through wrench 99355025 (3, Figure 71) bearing
adjustment ring nuts (4) till pinion—crown and axial
clearances are zeroed, and simultaneously check that the
crown does not forces onto the pinion;
2. With a suitable micrometer diagonally and centrally
placed in points (X—Y—arrows, Figure 70), measure and
take note of cap distance;
Figure 70
Figure 71
50636 60635
B. proceed as described in section ”1”;

3. further tighten the two adjustment ring nuts (4, Figure 71)
in order to obtain a cap retraction (2, Figure 71), C. after having zeroed the axial clearance, further tighten the
measured on X axis or on Y axis as described in section two adjustment ring nuts (4, Figure 71) in order to obtain
”2”, of: 0.15 ÷ 0.33 mm that corresponds to a preload of a cap retraction (2) of 0.15 ÷ 0.33 mm, that corresponds
1.7 ÷ 3.9 Nm (0.17 ÷ 0.39 kgm) on the bearings. to the sum of the values read on the comparators (1).

Figure 72 Reassemble and repeat previously—described adjustment

operations.
Figure 74
49248
Adjust the axial clearance between pinion — crown assembly

teeth that must be 0.26 ÷ 0.50 mm proceeding as follows:
- lock bevel pinion rotation through tool 99370317; 19451
- place comparator (1) with magnetic base as in the figure;

Apply, with a brush, a slight layer of Prussian blue on the crown.
- through wrench 99355025 (3) loosen the adjustment ring Rotate the pinion and measure the contact imprint of pinion
nut on crown side and tighten with the same extent teeth on crown teeth.
adjustment ring nut (2) on the opposite side; this solution The following figures show possible contacts and the way to
is used not to change the previously—measured retraction correct possible errors.
between caps;
- proceed as described till the required clearance is
obtained.
The clearance must be checked on 4 points at the same
distance.
Figure 73
49246
Check, through a comparator (1) with magnetic base, that the

crown (2) does not show a throttling that is greater than 0.20
mm. In case it is greater, disassemble differential gear assembly
and ascertain its cause.

Figure 75 Figure 77
Contacts that are too much on crown teeth bottom land

19452
Clearance reduction
Conditions C—D. It shows that the pinion is too deeply fixed

and therefore it is necessary to further adjust it.
To adjust the exact pinion position, it is necessary to add shims
under pinion support in order to obtain the exact contact.
Condition C. Measure the clearance and restore after
addition of shims.
Condition D. After having added the shims, take the clearance
towards its minimum. Clearance increase
19454
Figure 76 THEORETICAL CONTACT AREA

1. Release, concave tooth flank
2. Tip
3. Pull, convex tooth flank
4. Heel
PULL. Central tending towards the tip on tooth band and
central on tooth profile.
RELEASE. Central tending to heel on tooth band and central
on tooth profile.
It shows that the pinion is correctly fixed.
The contact position can further be modified by changing
Contacts that are too much towards the crown teeth ridge pinion—crown clearance.
19454
Condition E. Decrease the clearance.
Conditions A—B. It shows that the pinion is fixed too Condition F. Increase the clearance.
outwardly and therefore it is necessary to further adjust it.
To adjust the exact pinion position, it is necessary to remove
shims under pinion support in order to obtain the exact
contact.
Condition A. After having removed the shims, take the
clearance towards its maximum.
Condition B. Measure the clearance and restore it after having
removed the shims.

BEVEL TORQUE CONTACTS CORRECTION (AFTER ASSEMBLY)

Figure 78
PULL RELEASE
(CONVEX CROWN FLANK) (CONCAVE CROWN FLANK)
CREST CREST
HEEL TOP HEEL
—PULL: CENTRAL TENDING TO TIP ON TOOTH BAND AND CENTRAL ON TOOTH PROFILE
—RELEASE: CENTRAL TENDING TO HEEL ON TOOTH BAND AND CENTRAL ON TOOTH
PROFILE
CONDITION ”A”
PULL RELEASE
CREST CREST
HEEL TOP HEEL
—PULL—RELEASE: CONTACTS TOO MUCH ON RIDGE

—PULL: CONTACT TOO MUCH ON TIP
—RELEASE: CONTACT TOO MUCH ON HEEL
—CORRECTIVE ACTIONS: REMOVE SHIMS AND INCREASE CLEARANCE AT ITS MAXIMUM
CONDITION ”B”
CREST CREST
HEEL TOP HEEL

—PULL—RELEASE: CONTACTS TOO MUCH ON RIDGE
—CORRECTIVE ACTIONS: MEASURE CLEARANCE, ADD SHIMS AND RESTORE CLEARANCE
CONDITION ”C”
CREST CREST
HEEL TOP HEEL

—PULL—RELEASE: CONTACTS TOO MUCH ON BOTTOM LAND
—CORRECTIVE ACTIONS: MEASURE CLEARANCE, ADD SHIMS AND RESTORE CLEARANCE
60676

Figure 79
CONDITION ”D”
CREST CREST
HEEL TOP HEEL
—PULL—RELEASE: CONTACTS TOO MUCH ON BOTTOM LAND

—PULL: CONTACT TOO MUCH ON HEEL
—RELEASE: CONTACT TOO MUCH ON TIP
—CORRECTIVE ACTIONS: ADD SHIMS AND DECREASE CLEARANCE AT ITS MINIMUM
CONDITION ”E”
CREST CREST
HEEL TOP HEEL
—PULL: CONTACT TOO MUCH ON HEEL

—RELEASE: CONTACT TOO MUCH ON TIP
—CORRECTIVE ACTIONS: DECREASE CLEARANCE
CONDITION ”F”
CREST CREST
HEEL TOP HEEL
—PULL: CONTACT TOO MUCH ON TIP

—RELEASE: CONTACT TOO MUCH ON HEEL
—CORRECTIVE ACTIONS: INCREASE CLEARANCE
60677

Figure 80 Figure 81
49249
49250
Put back in place safety split pin (1) and bend it; repeat the
operation also on the opposite side. Place pin (4) into its seat.
Assemble fork (2) and spring (3) on pin (4) and completely
push it. Assemble piston (5) completed with ring and cover
(6), and finally assemble sliding sleeve (1) and place elastic pegs
(7).

Instructions for adjusting and verifying transmitter operation to check insertion of differential gear
locking
Figure 82
49251
Adjustment and check of transmitter operation (type with two functions) to check differential gear insertion is carried out with
rear axle assembled on a vehicle and operating as described below.
1) Insert differential gear locking through vehicle compressed air or external source.
2) With differential gear locking inserted, start the transmitter till contact closure is obtained, verifying in the cabin that the warning
light turns on.
3) Since the warning light turns on in the cabin, screw the transmitter still by 1/2 to 1 turn.
4) Tighten the lock nut for locking the transmitter at the required torque.
5) Unlock differential gear locking engagement control and verify that contacts (1 and 2) are closed (in such condition the warning
light lamp in the cabin must be off).

WORK ON THE VEHICLE Figure 85

REPLACING THE BEVEL PINION SUPPORT
SEAL RING
Disassembly
Figure 83
61483
With a suitable tool, lift external ring (1) edge in two opposed
points.
61841
Unscrew flange securing nuts (1).

Detach transmission shaft (2), securing it to the chassis.
Figure 84
Figure 86
61482
Lock flange (1) rotation through check tool 99370317 (2).

With wrench 99355088 (3) and multiplier (4), unscrew bevel
pinion nut. 61483
Apply brackets 99341009 and tool 99341003, then withdraw

flange (1).
Through the two levers (2), withdraw internal ring (1).

Figure 87
72009
Remove sealing ring (1) using tool 99363204 (2).
Assembly
Accurately clean sealing ring seat from every impurity and
trace of oil.
Figure 88
1 2
61486
Arrange new sealing ring (1).

Apply keyer 99374244 (2), screw an operation nut and key
sealing ring till it abuts.
Unscrew operating nut, remove keyer 99374244 (2),
assemble the flange again and screw a new nut locking it
through a dynamometric wrench and multiplier at the
required torque.
Connect the transmission shaft again and tighten the securing


Print 603.93.391

MS13 — 165
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 221

TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . . . 222
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 224
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
REMOVING AND REFITTING THE DIFFERENTIAL

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
REPAIRING THE DIFFERENTIAL . . . . . . . . . . . . 240
- Removing the differential . . . . . . . . . . . . . . . . . 240
- Removing the gearcase . . . . . . . . . . . . . . . . . . 241
REMOVING THE BEVEL PINION

FROM THE SUPPORT . . . . . . . . . . . . . . . . . . 243
- Differential component check . . . . . . . . . . . . . 243
- Fitting the gear housing . . . . . . . . . . . . . . . . . . 244
FITTING THE MOUNT ON THE

BEVEL PINION . . . . . . . . . . . . . . . . . . . . . . . . 245

Page
- Reassembling the differential housing . . . . . . . . 247
ADJUSTING THE CAP GAP . . . . . . . . . . . . . . . . 249
CORRECTING THE CROWN WHEEL AND

PINION CONTACTS (AFTER ASSEMBLY) . . 252
- Instructions for adjusting and verifying transmitter

operation to check insertion of differential
gear locking . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
WORK ON THE VEHICLE . . . . . . . . . . . . . . . . . 256
REPLACING THE BEVEL PINION MOUNT

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

DESCRIPTION
Print 603.93.391
The rear axle is of the portable type with simple reduction: it Moreover, the bevel pinion position can be adjusted with
is composed of a case made of suitably reinforced sheet made respect to the bevel crown, by changing the thickness of the
of pressed steel. pack of rings placed between differential gear case and bevel
The differential gear is characterised by an assembly of pinion support.
hypoidal toothing gears. The gearing case is supported by two bevel roller bearings and
The pinion is supported by two bearings (pinion unit) with is axially adjustable through two threaded ring nuts.
bevel rollers and a third bearing with cylindric rollers. The wheel hub bearings are of the UNIT—BEARING,
Adjustment of the bevel pinion assembly is carried out permanent lubrication type; therefore, they do not need
through adjustment rings placed between the two bevel roller adjusting.
bearings.
Figure 1
99241
REAR AXLE ASSEMBLY VIEWS


Service Network.
Figure 2
86620
D = rear axle ratio
E = production date
TECHNICAL NAME
Axle casing thickness: 12.7 ÷ 13 mm
Single ratio
Capacity: 11.5 ÷ 13 ton
MERITOR
Rear only


Rear axle type:
MS13 — 165
Carrier with simple reduction
3.07 (14/43) — 3.42 (12/41) — 3.73 (11/41) — 3.91 (11/43)
Bevel torque reduction ratio 4.10 (10/41) — 4.30 (10/43) — 4.56 (9/41) — 4.89 (9/44)
5.63 (8/45) — 6.14 (7/43) — 6.43 (7/45)

0.26 ÷ 0.50
crown

Through ring nuts
pinion and crown
Bevel pinion placement with

respect to the crown
Cap retraction mm 0.15 ÷ 0.33
Cap retraction adjustment Through ring nuts

pinions and planetary gears Nm 68 max
(kgm) (6.9 max)
Thickness of adjustment rings placed
differential gear case mm 0.125 — 0.200 — 0.500
Throttling of crown abutment
plane on half—case mm 0.20 max
WHEEL HUBS
Axial clearance adjustment of wheel

—
hub bearings
Axial clearance adjustment of wheel Not adjustables

hub bearings Torque tightening by means of a nut
Rear axle oil TUTELA W140/M—DA

Amount Liters
(kg) 18.5
Maximum capacity kg 11600

DIAGNOSTICS
Main rear axle operating anomalies: 3 — Release noise;
1 — Wheel hub noise; 4 — Trailing noise;
2 — Rear axle noise; 5 — Curving noise.
1 WHEEL HUBS NOISE
Insufficient lubrication. Check that no leakage occur from rear axle case and
NO
Inefficient wheel hub bearings. Proceed with disassembling hub and replacing assembly
YES bearing.
NO
Wheel hub bearings with excessive clearance. Check and possibly replace the bearings.
YES
2 REAR AXLE NOISE
Insufficient lubricating oil level. Check that no leakage occur from rear axle case and
NO
Half—shafts coupling grooves with differential planetary Revise the rear axle and replace worn or damaged
gears damaged. YES parts.
NO
Incorrect adjustment or deterioration of differential Locate the inconvenience and carry out assembly
assembly gears or bearings. YES revision.

3 RELEASE NOISE
Incorrect coupling clearance between pinion and bevel Carry out clearance adjustment between pinion and
crown. YES crown.
4 TRAILING NOISE
Insufficient lubrication. Check that no leakage occur from the case and restore
YES the level.
NO
Gearing case bearings not adjusted or deteriorated. Proceed with assembly revision.
YES
NO
Incorrect teeth contact between pinion and bevel Proceed with contact adjustment.
crown. YES
5 CURVING NOISE
Incorrect clearance in side pinion planetary assembly. Revise or replace the assembly.
YES

TIGHTENING TORQUES
Figure 3
49302
DIFFERENTIAL GEAR SECTION
TORQUE
PART
Nm (kgm)
1 Screw for securing differential gear to rear axle case
1st step torque 100 (10.1 ± 0.5)
2 Screw for securing differential gear half—case 1st step torque 100 (10.1 ± 0.5)
3 Screw for securing bevel crown to half—case
1st step torque 100 (10.1 ± 0.5)
4 Bevel pinion locking nut 1510 ± 160 (153.9 ± 16.3)
5 Screw for securing bevel pinion support 1st step torque 100 (10.1 ± 0.5)
6 Sensor locking nut 40 ± 5 (4 ± 0.5)
— Screw for securing caps to differential gear case 730 ± 80 (74.4 ± 8.1)

Print 603.93.391/A
Figure 4
99242
TIGHTENING TORQUES
TORQUE
PART
Nm (Kgm)
1 Nut fixing wheels 627,5 ± 62,5 (64 ± 6,4)
2 Screw fixing drive shaft flange 262 ± 27 (26,7 ± 2,7)
3 Ring nut retaining wheel hub bearing 932 ± 98 (95 ± 10)
4 Screw fixing brake disc to wheel hub 281,5 ± 13,5 (28,7 ± 1,4)
5 Nut for screw fixing brake calliper mount 289,5 ± 14,5 (29,5 ± 1,5)
6 Screw fixing brake calliper to mount 615,5 ± 61,5 (62,7 ± 6,3)

Revi — July 2005
Print 603.93.391
TOOLS
99301001 Grinder and lathe for brake drums and discs

(1000 daN capacity, 120 daNm torque)
Stand for rear axle and front axle revision

99322215
Assembly bearing support (to be applied to stand 99322205)

99322225
Simple—effect rear axle

99341003

Print 603.93.391
TOOLS
Pair of brackets
99341009
99341015 Clamp

TOOLS
99355025 Wrench for differential gearing case bearings adjustment ring nuts
(60 mm) wrench for differential bevel pinion nut

99355088 (use with 99370317)
99363204 Gasket removing tool
99370509 Differential gearing half—case extracting hook

TOOLS
99370616 Differential gear disconnection and reconnection support
Universal support for supporting rear axles during disconnection and

99371047 Differential gear half—case check support during crown union screws
securing (use with 99322205 and 99322225)

TOOLS
99374244 Keyer for assembling differential gear bevel pinion sealing ring

(max 2745 Nm)
99389819 Dynamometric wrench (0—10 Nm) with 1/4” panel connection

Print 603.93.391

ASSEMBLY


Figure 5 84402

Figure 8
72739
72742
525030 OVERHAULING THE WHEEL Remove the brake linings (1) making the calliper body (2)
HUBS float appropriately.
Removal
Figure 6 Figure 9
72740 84403

Figure 10 Figure 13
72744 72747
Put a container under the wheel hub to collect the oil. Lock If the brake calliper supporting plate (1) is damaged, remove
rotation of the wheel hub (1) with the retaining tool it from the axle housing by taking out the bolts (2).
99370317 (3). Take out the screws (2) and extract the drive
shaft (4).
Figure 11 Figure 14
72745 72748
Lift the notching of the ring nut (5). Using the wrench Take out the screws (2) and remove the wheel hub (1) from
99355180 (1) and multiplier 99389816 (2), remove the ring the brake disc (3).
nut (5) holding the wheel hub bearing. Take out the retaining Examine the state of wear of the brake disc (3) as described
ring (4). in the ”BRAKE AIR SYSTEM” section.
Figure 12 Figure 15
72746 72749
Remove the wheel hub (1). If this proves difficult, use the The phonic wheel (1) is removed from the wheel hub (2)
extractor comprising: brackets 99341017 (2), bridge with general tools.
99341003 (3), block 99345053 (4), applied as shown in the
figure.


Figure 16 Checking the parts forming the wheel hubs
Thoroughly clean the single parts comprising the

wheel hub. Examine the drive shafts and check there
is no deformation.
to extract them.
72750
Using a hydraulic press and tool 99370708 (1) take out the
wheel hub, spacer (3) and bearing (2).
Figure 17
525035 Replacing the wheel fixing pins
Figure 19
90039
Using the press and tool 99370706 (1) mount the bearing
(2): bearing drive—in load 25,000 to 85,000 N.
Figure 18
72753
Using general tools, drive the pins (2) out of the hub (1).
Make sure the supporting surface for the heads of the pins
has no burrs.
Carefully drive in the pins, applying a load no greater than
2500 kg on their heads.
Afterwards, check that the obliquity is no greater than 0.3 mm.
72752
Fit the spacer ring (2) in the wheel hub (1) and check on two
diametrically opposite points that, after assembly, the ring (2)
is sunk below the face of the wheel hub by 0.0 to 0.145 mm.

Figure 20 Figure 23
72754 72757
If the plate (1) were disassembled, fit it back on the axle Fit the wheel hub on the sleeve of the axle housing and, using
housing and tighten the nuts (2) for the fixing screws (3) to a dial gauge (1) with a magnetic base, check that the radial
the required torque. runout of the phonic wheel (2) is no greater than 0.2 mm.
Remove the wheel hub.
Figure 21 Figure 24
72755 72748
Screw the tool 99370700 (2) onto the sleeve (1) of the axle Mount the brake disc (3) on the wheel hub (1) and screw
housing. Lubricate the tool external surface (1) with the oil down the screws (2).
prescribed for the wheel hubs.
Figure 22 Figure 25
72749 72758
Heat the phonic wheel (1) to approx. 150°C and fit it on the Sling the brake disc (1) with a rope, hook this onto a lift and
wheel hub (2). fit the wheel hub (2) on the sleeve of the axle housing.
On completing assembly, make sure the phonic wheel (1) Remove the tool 99370700 (3).
rests correctly in the seat of the hub.

Figure 26 Figure 29
72759 72761
Position the retaining ring (4) so as to insert the tab into the Spread IVECO 1905685 (LOCTITE 14780) sealant onto the
groove of the sleeve, then screw on the ring nut (5). Using flange contact surfaces of the drive shaft — wheel hub and
the wrench 99355180 (1), multiplier 99389816 (2) and the insert the drive shaft into the axle housing. Screw down the
torque wrench (3), tighten the ring nut (5) to the required screws (2) fixing the drive shaft (3) to the wheel hub (1) and
torque. tighten them with the torque wrench (4) to the required
Figure 27
Figure 30
49213A
After tightening, using an appropriate tool, notch and bend

84405
the ring nut as shown in the figure so it cannot be unscrewed.
The arrow shows the direction of unscrewing the ring nut. Position the brake calliper (1) on the flange (3) and tighten
the fixing screws (2) to the required torque.
Figure 28
Figure 31
72760
Lock rotation of the wheel hub (3) with the tool 99370317 72742
(4) and tighten the screws (2) fixing the brake disc (1) to the
Mount the brake linings (1) in the brake calliper (2).
wheel hub to the required torque.

Figure 32 Figure 34
72740

pin (4).
adjustment screw.
NOTE After refitting the rear axle on the vehicle, check

the efficiency of the brake lining wear recovery
device, as described in the relevant section and
replace the plug (1) with a new one.

Figure 33
72764
7. Wheel hub — 8. Phonic wheel — 9. Brake disc — 10. Axle sleeve

526210 REMOVING AND REFITTING Refitting

THE DIFFERENTIAL
Figure 36
(with axle on stand 99322215)
Figure 35
34827
Spread the contact surface of the axle housing with IVECO

1905685 (LOCTITE 14780) sealant, after cleaning the
72739 contact surface.
Removal Figure 37
Extract the drive shafts as described on page 233 and 234,
unscrew the screws and nuts fixing the differential case (1);
screw three screws, which in this case act as extractors, into
the threaded holes and extract the differential from the axle
housing (2).
49219
Insert the differential into the axle housing, screw down the
nuts (2) and screws (3) together with the safety washers and
tighten them, with a torque wrench (1), to the required
torque and in the sequence shown in Figure 38.
Mount the drive shafts as described on page 237.
Pour the required amount of oil into the axle housing.
Figure 38
49220
Tightening sequence diagram (differential case to axle housing)

(1 — 2 — 3 — 4 — Nuts)
(10 — 9 — 14 — 5 — 7 — 11 — 13 — 6 — 8 — 12 — Screws)

526210 REPAIRING THE DIFFERENTIAL Figure 42

Removing the differential
Figure 39
49224
Unscrew the ring nut (1) for adjusting the bearing. Using an
49221 appropriate wrench, unscrew and remove the screws (2)
with their washers; repeat this process on the opposite side.
Remove the differential (1) as described in Figure 35. Remove the supporting bearing caps (3).
Secure it to the stand 99322205 (3) with the mount
99322225 (2).
Figure 43
Figure 40
49225
49222 Using the hook 99370509 (1) extract the gearing housing (2)
together with the ring bevel gear and outer rings (3).
Unscrew the transmitter (1); unscrew the screws (2) and
remove the parts 3 — 4 — 5.
Figure 41
49223
Push the split pins (1 →) outwards and extract the sliding

sleeve (2).
Take out the spring (3), fork (4) and split pin (5).

Print 603.93.391
Figure 44 Removing the gearcase

Figure 46
49226
Using tool 99370317 (2), lock the flange (1). 49228
Using wrench 9955088 (3) and multiplier (4), loosen the Using a suitable puller (1), extract the bearing (2).
bevel pinion nut.
Figure 47
Figure 45
49228A
Turn the gearcase upside down and remove the bearing (1).
(This is a destructive operation).
49227
Remove the nut (1) and extract the flange (2). Figure 48
Remove the screws (3) fastening the bevel pinion support to
the differential housing (4).
Remove the complete bevel pinion support (5) from the
differential carrier. Remove the shims (6) for adjusting the
pinion position in relation to the crown wheel and use a
micrometer to measure the overall thickness.
NOTE Check that the seal ring is intact (O—ring), change

it if damaged.
49229
Place the gearcase on tool 9971047 (1).

Remove the locknuts (2) fastening the ring bevel gear (3) to
the gearcase.
Using a bronze beater, remove the ring bevel gear.

Figure 49 Mark the mounting positions of the two half casings (2 and
3) and spider.
Remove the screws (1) and lift the half casing (2) off the unit.
49233
Figure 50
Remove components (2 — 3 — 4 — 5 — 6 — 7 — 8 — 9) from

the half casing (1).
49234A
GEARCASE COMPONENTS
1. Half casing — 2. Half casing — 3. Crown wheel — 4. Planetary gear — 5. Spider — 6. Shoulder washer —
7. Planetary gears — 8 Crown wheel — 9 Shoulder washer

526249 REMOVING THE BEVEL PINION Figure 53

FROM THE SUPPORT
Figure 51
49232
Using a suitable tool (1), extract the bearing (2).
49230
Using tool 99348001, extract the bearing (1) from the bevel
pinion (2).
Figure 52
Differential component check
Carefully clean all differential components.

Lubricate the bearings and rotate the roller cage; it
should rotate freely and smoothly.
Inspect the ring bevel gear and half casing contact

surfaces, making sure the ring bevel gear perfectly
adheres. Warped surfaces may cause ring bevel gear
fastening screw vibration, thus undermining the unit
operation.
86721
Make sure the slotted section fastening the flange to
Take off the bevel pinion (3) (under a press) from the support the pinion is not worn. If it is, replace the pinion.
(4).
The mounting (4) is supplied as a spare part

together with preassembled tapered roller
bearings and seals.
NOTE Due to production requirements, the two bearings
(2) of pinion (3) are kept assembled by means of
a special metal ring (1) that is normally left in place,
owing to its being unimportant. During the pinion
disassembling phase, the ring is partially taken out,
if still present.
If not taken out, the ring could be dangerous, since
it could subsequently interfere with the bearings.
Prior to reassembling the pinion, it is therefore
essential that you check for the presence of the ring
and take it out fully.

Fitting the gear housing Figure 57
Figure 54
49235A
- 2nd stage: tighten the screws (1) by means of tool

99395216 (3) at 110° to 120° angle.
34847 Heat the bearing (2) at 100°C for approx. 15 min. in a
Place the half casing (3) on tool 99371047. convection furnace and fit it, using a suitable beater.
Insert the crown wheel shoulder washer (2) into the half
casing, then fit the crown wheel (1).
Figure 58
Figure 55
49244
19383
Heat the ring bevel gear (1) to a temperature of 100ºC ÷ 150ºC
Fit the spider (6), complete with planetary gears (5) and in an air circulation oven and position it in its seat, in the gear
shoulder washers (3), to the half casing (4). housing, checking it turns freely and making the holes coincide
If the spider has not been replaced, make sure the marks for the screws fixing the ring bevel gear—gear housing by fitting
made on removal match. the 4 manoeuvring screws.
Fit the second crown wheel (2) complete with shoulder
washer (1). Figure 59
Figure 56
49236
Let the ring bevel gear cool, then place the gearcase upside
49235 down on the tool.
Fit the half casing (2). Insert the screws (1) and tighten as follows:
Make sure the marks made on removal match. Insert the
- 1st stage: tighten to 100 Nm (10 kgm) torque by means
screws (1) and tighten as follows:
of a torque wrench (2);
- 1st phase: tightening with a torque wrench (3) to a
- replace the 4 manoeuvre screws with new ones and
torque of 100 Nm (10 kgm).
apply the same specified torque.

Figure 60 Figure 63
49236A
- 2nd phase: closing, with tool 99395216 (1) with an angle

of 80 to 90°.
Heat the bearing (2) to a temperature of 100°C for approx.
15 min. in an air circulation oven and drive it in with an
appropriate drift.
72767
526249 FITTING THE MOUNT ON THE

BEVEL PINION Using a press and a suitable tube (1) positioned on the inner
ring of the roller bearing (4), fit the mount (2) on the bevel
Figure 61 pinion (3).
Figure 64
72766
The bevel pinion mount (1) is supplied as a spare together with

the tapered roller bearings (2 and 3) and the seals (4 and 5).
Figure 62
72768
Heat the bearing (1) to a temperature of 100°C for 15 min.

in an air circulation oven and mount it on the bevel pinion
(2).
Lock the bearing by notching the bevel pinion at 10
equidistant points as shown in the figure. This should be done
conscientiously with a suitable punch.
49237
NOTE The diameter of the impression has to be between
Heat the bearing (2) to a temperature of 100°C for 15 min. 3.40 to 4.10 mm, corresponding to a depth of 0.30
in an air circulation oven and mount it on the bevel pinion to 0.44 mm respectively, using a load of 4000 kg
(1). with a ball with a 10 mm diameter.

Figure 65 Figure 67
1,2
1,2,3,4,5,6
49239 19416
Place the transmission fitting flange (1), complete with baffle Before assembling a new pinion—crown wheel unit, it is
(2), and fit it using a suitable beater. The use of a vice is mandatory to understand the meaning of the marks stamped
recommended. Temporarily tighten the lock nut. on both pinion and crown wheel, in order to find out the
proper pinion position.
1. Part number
2. Tooth play number
3. Pinion—crown wheel unit coupling number
Figure 66 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
following examples)
5. Pinion—crown wheel unit date of manufacturing and
testing (month and year)
6. Pinion—crown wheel unit rated backlash.
Part and tooth play numbers are marked on the pinion
threaded end.
On crown wheels, the same numbers are generally marked
on the front face.
As an alternative, they may be found on the crown wheel
outer diameter.
For any pinion—crown wheel unit, the crown wheel part
number shall always be even (for instance, 36786), whereas
49240
the corresponding pinion part number shall be odd (for
instance, 36787).
If the same pinion—crown wheel unit previously removed is The tooth play number (for example, 10—41) means the
reinstalled, fit the relative adjusting shims (2) and bevel pinion pinion features 10 teeth and crown wheel 41, corresponding
support with the seal ring (O—ring) (1) to the differential to 4.10 : 1 transmission ratio.
housing (3). Make sure the lubrication oil slot is properly
aligned.
NOTE Never use pinion—crown wheel units bearing

different numbers.

Print 603.93.391
Each crown wheel has an adjustment number specifying the Example 3:

rated mounting clearance.
Use this number to calculate the thickness of the adjusting Original shim thickness mm 0.70
shims to be fitted between pinion support and differential Crown wheel C.P. + 0.05 — 0.05
housing. Result mm 0.65
This number (for example, C.P. +0.1, or C.P. —0.1 mm), is New crown wheel C.P. — 0.05 — 0.05
stamped on the crown wheel outer diameter. New shim thickness to be used mm 0.60
To calculate the thickness of the adjusting shims to be fitted
between pinion support and differential housing, proceed
as follows: Example 4:
1. Measure the thickness of the shims fitted on the
pinion—crown wheel unit to be replaced. Use a Original shim thickness mm 0.85
micrometer or gauge and note the measurement. Crown wheel C.P. — 0.10 + 0.10
Result mm 0.70
2. Read the C.P. stamped on the crown wheel to be New crown wheel C.P. — 0.15 — 0.15
replaced. If positive (+), subtract this number from New shim thickness to be used mm 0.80
the previously taken measurement (see “1”). If the
number represents a negative value (—) add it to the
measurement taken (see “1”).
Note the result.
NOTE Spare parts shims, to be fitted between pinion
support and differential housing, are provided with
the following thickness: 0.125 — 0.200 — 0.500 mm.
NOTE The measurement obtained at “2” shall be used to

calculate the thickness of the adjusting shims to be
fitted between pinion support and differential
housing, in relation to the new pinion—crown A number, specifying the rated backlash between pinion and
wheel unit to be installed. crown wheel after manufacturing, is stamped on all units.
This number is found on the crown wheel outer diameter.
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
item “2”).
Reassembling the differential housing
The obtained value indicates the thickness of the new shims
to be fitted. Figure 68
Refer to the following examples, covering all possible
combinations.
Examples of calculation
Example 1:
Original shim thickness mm 0.75

Crown wheel C.P. + 0.05 — 0.05
Result mm 0.70
New crown wheel C.P. + 0.10 + 0.10
New shim thickness to be used mm 0.80
49241
Example 2:
Insert the screws (2) and tighten to the prescribed torque,
Original shim thickness mm 0.65 using a torque wrench (1).
Crown wheel C.P. — 0.05 + 0.05 - 1st step: tighten using the torque wrench (1) to a torque
Result mm 0.70 of 100 Nm (10 kgm);
New crown wheel C.P. + 0.15 + 0.15
New shim thickness to be used mm 0.85 - 2nd step: tighten the screw (2) using tool 9935216 with
an angle of 60° ÷ 70°.

Figure 69 Figure 71
49242 49225
Turn the unit by 90°.
Position the external rings (3) of the bearings
Using tool 99370317 (5), lock the flange (3). Using wrench
99355088 (2), multiplier (4) and torque wrench (1), tighten the Using hook 99370509 (1), lift the previously assembled
pinion lock nut to the prescribed torque (1350 to 1370 Nm). gearcase (2) and place it onto the differential housing.
Place the caps, making sure reference tabs match. Tighten the
screws, complete with washers, to the prescribed torque by
means of a torque wrench.
Figure 72
NOTE Check that the multiplication factor of the

multiplier (4) is correct.
49244
Position the caps (2), suitably settle them using a hammer and
insert the screws (3), complete with washers. Tighten the
screws to the prescribed torque, using a torque wrench (1).
Figure 70
Figure 73
20670
Then, slightly push the bearing outer rings (1), to make sure
49245
they slide smoothly within their housings.
Remove the screws, complete with washers, and caps. Lubricate the conical roller bearings (1), manually tighten the
ring nuts (2) until they touch the external bearing rings;
tighten the screws (3, Figure 72) to the prescribed torque.

ADJUSTING THE CAP GAP 2nd METHOD

Adjusting and checking retraction of the caps can be done A. Diagonally and centrally on the outer machined seats of
with two methods: both caps (2, Figure 75) position two dial gauges (1) with
1st METHOD magnetic base as shown in Figure 75;
same time check that the crown wheel does not force
on the pinion;
Figure 74 Figure 75
60636 60635
3. further tighten the two adjustment lock rings (4, Figure 75) B. proceed as described in point ”1”;
to obtain a retraction of the caps (2, Figure 75), measured
C. after eliminating the end float further tighten the two
on Axis X or on axis Y as described in point ”2” of: 0.15
adjustment lock rings (4, Figure 75) to obtain a retraction
to 0.33 mm which corresponds to a preload on the bear-
of the caps (2) of 0.15 to 0.33 mm, which corresponds
ings of 1.7 to 3.9 Nm (0.17 to 0.39 kgm).
to the sum of the readings on the dial gauges (1).

Figure 76 Refit and repeat the adjustment operations described

previously.
Figure 78
49248
Adjust the axial clearance between the teeth of the pinion

— crown wheel unit which must be 0.26 to 0.50 mm 19451
proceeding as follows:
- stop the bevel pinion from turning using tool 99370317; Apply a light layer of Prussian blue on the crown wheel.
Turn the pinion and measure the impression of the contact
- position the magnetic—based dial gauge (1) as illustrated; of the pinion teeth on the crown wheel teeth.
- using wrench 99355025 (3) slacken the adjustment lock The following figures show possible contacts and how to
ring on the crown wheel side and tighten, to the same correct any errors.
The purpose of this is to leave the previously—adjusted
clearance.
The clearance should be checked on 4 points the same
distance apart.
Figure 77
49246
Use a magnetic—based dial gauge (1) to check that the crown

wheel (2) does not have any upper wobble above 0.20 mm.
If it does, disassemble the differential unit and find the cause.

Figure 79 Figure 81
1
4
19452 3
Contacts too much on crown wheel teeth bottom land Clearance reduction
deeply and needs further adjustment.
To adjust the exact position of the pinion shims should be
added under the pinion support to obtain the exact contact. Clearance increase
adding shims.
19454
Condition D. After adding shims, take the clearance towards
minimum.

Figure 80 2. Top land
4. Heel
PULLING. Central tending towards the top land on the tooth
RELEASE. Central tending to the heel on the tooth face and
central on the tooth profile.
19453
Contacts too much towards the crown wheel teeth top land Condition E. Lower the clearance.
Conditions A—B. Indicates that the pinion is fastened to Condition F. Increase the clearance.
much towards the outside and therefore needs further
adjustment.
To adjust the exact position of the pinion, remove shims
under the pinion support to obtain the exact contact.
Condition A. After removing the shims, take the clearance
towards maximum.
Condition B. Measure the clearance and restore it after
removing shims.


Figure 82
PULLING RELEASE
TIP TIP
HEEL TOP HEEL

LAND
CONDITION “A”
PULLING RELEASE
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “B”
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “C”
TIP TIP
HEEL TOP HEEL

LAND

60676

Figure 83
CONDITION “D”
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “E”
TIP TIP
HEEL TOP HEEL

LAND

CONDITION “F”
TIP TIP
HEEL TOP HEEL

LAND

60677

Figure 84 Figure 85
49249 49250
Replace the safety split pin (1) and fold it; repeat this Place the pin (4) into its housing.
operation on the opposite side. Fit the fork (2) and spring (3) to the pin (4) and push it in all
the way. Fit the piston (5), complete with ring and cover (6),
then fit the sliding sleeve (1) and spring plugs (7).

Instructions for adjusting and verifying transmitter operation to check insertion of differential gear
locking
Figure 86
49251
Adjustment and check of transmitter operation (type with two functions) to check differential gear insertion is carried out with
rear axle assembled on a vehicle and operating as described below.
1) Insert differential gear locking through vehicle compressed air or external source.
2) With differential gear locking inserted, start the transmitter till contact closure is obtained, verifying in the cabin that the
warning light turns on.
3) Since the warning light turns on in the cabin, screw the transmitter still by 1/2 to 1 turn.
4) Tighten the lock nut for locking the transmitter at the required torque.
5) Unlock differential gear locking engagement control and verify that contacts (1 and 2) are closed (in such condition the
warning light lamp in the cabin must be off).

WORK ON THE VEHICLE

REPLACING THE BEVEL PINION MOUNT Figure 89
SEAL
Disassembly
1
Figure 87
61483
Using a suitable tool raise the outer edge of the ring (1) in
two opposed points
61481
Slacken the nuts (1) fastening the flange. Disconnect the

transmission shaft (2), fastening it to the frame.
Figure 90
Figure 88
2
1
61482 61484
Prevent the flange (1) from turning using retainer tool Using the two levers (2) remove the inner ring (1).
99370317 (2).
Using wrench 99355088 (3) and the multiplier (4) slacken
the nut for the bevel pinion and withdraw the flange (4).

Figure 91
61485
With tool 99363204 (2) positioned as shown in the figure,

remove the seal (1) from the bevel pinion mount.
Assembly
Thoroughly clean the seat of the seal of all debris and traces
of oil.
Figure 92
1 2 61486
Position the new seal (1).

Apply the keying device 99374244 (2), screw a manoeuvring
nut onto the bevel pinion and mount the seal down to the
stop.
Unscrew the manoeuvring nut, take out the keying device

99374244 (2), fit the flange back on and screw down a new
nut, locking it with a torque wrench and multiplier to the
required torque.
Fit the propeller shaft back on and tighten the fixing nuts to


EUROCARGO TECTOR 12—26 t FRONT AXLES 1
SECTION 7
5206 Front Axles
Page
AXLE 5845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AXLE 5842/5 — 5851/5 . . . . . . . . . . . . . . . . . . . . 37
AXLE 5871/5 . . . . . . . . . . . . . . . . . . . . . . . . . . 69
AXLE 5860 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2 FRONT AXLES EUROCARGO TECTOR 12—26 t

EUROCARGO TECTOR 12—26 t FRONT AXLE 5845 3
5206 Front axle 5845

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Characteristic angles . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 12
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AXLE REMOVAL AND REFITTING . . . . . . . . . 20
- Front axle removal . . . . . . . . . . . . . . . . . . . . . 20
- Front axle refitting . . . . . . . . . . . . . . . . . . . . . . 21
CHECKS ON THE VEHICLE . . . . . . . . . . . . . . . 21
- Tie rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Articulated joints . . . . . . . . . . . . . . . . . . . . . . . 21
- Check clearance of articulated joints . . . . . . . . 21
FRONT WHEEL SET UP . . . . . . . . . . . . . . . . . . 22
- Setting of clips and headlights . . . . . . . . . . . . . 22
- Electronic compensation for rim maladjustment 23
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . 23
- Toe—in check . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Check of wheel inclination (Camber) . . . . . . . 24
- Check upright angle of inclination (King Pin)

and clearance angle (Caster) . . . . . . . . . . . . . . 24
- Check steering angles . . . . . . . . . . . . . . . . . . . 25
OVERHAUL OF THE FRONT

AXLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL AND REFITTING OF WHEEL HUBS 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Replacement of sealing ring . . . . . . . . . . . . . . . 27
- Replacement of wheel stud bolts . . . . . . . . . . 28
- Wheel hub reattachment . . . . . . . . . . . . . . . . 28

4 FRONT AXLE 5845 EUROCARGO TECTOR 12—26 t
Page
- Check wheel hub end play . . . . . . . . . . . . . . . 29
- Rolling torque survey . . . . . . . . . . . . . . . . . . . . 29
- Cross tie rod removal and

refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Replacement of cross tie rod

articulated pins . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Cross tie rod lever removal and refitting . . . . . 31
- Longitudinal tie rod lever

removal and refitting . . . . . . . . . . . . . . . . . . . . 31
- Steering knuckle pin removal and refitting . . . . 31
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Steering knuckle pin bearing replacement . . . . 32
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Check and adjustment of clearance between

steering knuckle and axle . . . . . . . . . . . . . . . . . 33
CHECKS AND MEASUREMENTS

OF THE AXLE UNIT . . . . . . . . . . . . . . . . . . . 34
- Check flatness of leaf spring surfaces compared

to holes for steering knuckle pins . . . . . . . . . . 34
- Check hole inclination for steering knuckle pins 35

DESCRIPTION
Front axle 5845 has a steel structure with a double “T” section having at the end steering knuckles.
The steering knuckles’ connection is made through pins integral with the axle body and by means of four roller bearings set with
interference in the holes of the steering knuckles’ embossing.
The wheel hubs are supported by two conical roller bearings, “set right” type, set on the steering knuckle shank. The bearing
end play is predetermined by the spacer placed between them.
Figure 1
60416
AXLE SIGHT 5845

Figure 2
SECTION A—A
SECTION B—B
78725
SECTION OF FRONT AXLE F 5021 (5845) WHEEL SIDE

Figure 3
SECTION C—C
60410
ABS REVOLUTIONS SENSOR LOCATION

Characteristic angles
In order to have a good roadholding, a low tyre wear and to Upright angle of inclination
enable driving wheels to recover an upright direction after
steering, it is necessary to set the wheels according to certain Figure 5
ß
assembly angles:
- wheel angle of inclination
- upright angle of inclination
- clearance angle
- toe—in
Such angles, when correctly calculated, enable the vehicle to
maintain the right balance among the various forces involved
in its movement, in different loading conditions, which tend
to alter the wheel position on the ground.
32957
The upright angle (β) of inclination is the one resulting from

the axis passing through the upright and the vertical to the
ground, looking at the vehicle standing before it.
When the extension of the upright axis approaches the wheel
when it is touching the ground (opposite direction compared
to the wheel’s inclination), the angle is positive. It is difficult, if
not impossible, to have a negative upright angle of inclination.
The wheel angle (α) of inclination and the upright angle (β)
of inclination enable the wheel axis and the upright axis to get
closer to the tyre’s fulcrum on the ground as much as possible.
As a result, it is possible to reduce the tyre wear and to get
a low value of the steering torque.
Clearance angle
Wheel angle of inclination
Figure 6
Figure 4
γ + γ _
α α
A B
32958
The clearance angle (γ) is the one resulting from the upright
axis and the vertical to the ground, looking at the vehicle from
one side.
A B If the extension of the upright axis falls beyond the wheel’s
fulcrum on the ground in the vehicle’s direction, as a rule the
clearance angle is positive (A).
32956
It is considered negative (B) if it falls behind the wheel’s
fulcrum on the ground.
It is null if it is absolutely perpendicular to the wheel’s fulcrum
The wheel angle (α) of inclination is the one resulting from on the ground.
the axis passing through the wheel’s centre line and the Such an angle enables front wheels to keep an upright position
vertical to the ground, looking at the vehicle standing before when the vehicle is moving in an upright direction and to
it. recover such a position after taking a curve as soon as the
steering wheel is released by the driver.
The inclination is positive (A) when the wheel’s upper part
moves outside. It is negative (B) when the wheel’s upper part
moves inside.

Toe—in Figure 8
Figure 7
A
A
B
B
32359 32960
Toe—in is negative if B is lower than A.

Toe—in results from the difference between distance A and
B (value expressed in mm) measured on the rims’ horizontal
axis, looking at the vehicle from above.
In this way it is possible to drive easily and to reduce the tyre
wear. Figure 9
Toe—in is positive if B is bigger than A.
32961
Toe—in is zero if B corresponds to A.

Axle type 5845
STEERING KNUCKLE PINS
Inclination of steering knuckle pin housing 7º
∅1
Diameter of roller bearing housing on
steering knuckle:
— upper housing ∅1 mm 39.972 ÷ 39.988
— lower housing ∅2 mm 46.972 ÷ 46.988
∅2
∅3
Outside diameter of roller bearings
for steering knuckle:
— upper bearings ∅3 mm 40
— lower bearings ∅4 mm 47
∅4
Upper bearings — steering knuckle mm 0.012 ÷ 0.0028
Lower bearings — steering knuckle mm 0.012 ÷ 0.0028
∅5
Inside diameter of roller bearings

— upper bearings ∅5 mm 33.025 ÷ 33.050
— lower bearings ∅6 mm 40.025 ÷ 40.050
∅6
∅ 7
Diameter of pin for steering knuckle

— upper ∅7 mm 32.984 ÷ 33.000
— lower ∅8 mm 39.984 ÷ 40.000
∅ 8
Upper bearings — pin mm 0.025 ÷ 0.066
Lower bearings — pin mm 0.025 ÷ 0.066

5845
X1 Clearance between axle and steering
knuckle upper adjustment X1 mm 0.10 ÷ 0.35
Gap between axle and steering

X 2 knuckle lower adjustment X2 ≥ 0.25
mm
Adjusting plates X1, X2

S
0.25 mm S mm 0.50 ÷ 1.75
WHEEL HUBS
Wheel hub bearings 2 with taper rollers
Hub bearing end play mm max 0.16
not adjustable
Wheel hub clearance
locking with lock nut torque
Bearing preloading daNm 0.30
Oil for wheel hub bearings Tutela W 140/M—DA
WHEEL SET UP
Wheel inclination (vehicle with static load) 1°
Wheel incidence (vehicle with static load) 3°
Toe—in (vehicle with static load) mm 0.5 ÷ 1.5
Steering angle
Inside α 52°
Outside β 36°

DIAGNOSTICS
Main malfunctioning of front axle:
1 — Steering wheel hardness

2 — Wobble
3 — Noise
1 STEERING WHEEL HARDNESS
Front axle perfectly aligned. Reset alignment and clamp lock nuts of spring bands.
NO
YES
Regular toe—in. Make exact toe—in adjustment.

NO
YES
Regular tyre pressure. Inflate tyres according to prescribed pressure.

NO
YES
Good joint lubrication. Lubricate joints accurately.

NO
YES
Right adjustment between steering knuckle and axle. Correctly adjust clearance between steering knuckle
NO and axle.
YES
Efficient elements involved in steering knuckle rotation Check and replace worn elements.
on the pin. NO

2 WOBBLE
Regular wheel incidence. Check axle assembly, fix or replace distorted elements.
NO
YES
Front axle perfectly aligned. Reset alignment and clamp spring band nuts on the
NO axle.
YES
Regular toe—in. Make correct toe—in.

NO
YES
Efficient steering heads of track rods. Replace defective elements.

NO
YES
Regular clearance of wheel hub bearings. Adjust end play after making appropriate
NO replacements.
YES
Centred wheels: Replace defective rim.

NO Deflate and centre tyre on rim.
- centred, regular rim
- correct assembly of tyre on rim.
YES
Balanced wheels. Make wheel balancing.

NO

3 NOISE
Good lubrication of wheel hub bearings. Top up oil in wheel hubs.

NO
YES
Efficient wheel hub bearings. NO Replace worn bearings and adjust end play.
YES
Regular coupling between steering knuckle pin and Check and replace worn elements.
NO
roller bearings.

TIGHTENING TORQUES
Figure 10
SECTION A—A
78687
SECTION B—B
TORQUE
PART
Nm (kgm)
1 Flat head cap screw to clamp upper cover 16 ± 2 (1.6 ± 0.2)
2 Self—braking hexagonal head cap screw to clamp cross lever on steering knuckle 515.5 ± 24.5 (52.5 ± 2.5)
3 Self—braking hexagonal head cap screw to clamp longitudinal lever on steering knuckle 515.5 ± 24.5 (52.5 ± 2.5)
4 Nut to clamp stop block for cross tie rod 80 ± 10 (8.1 ± 1)
5 Castellated nut for steering knuckle pin 201 ± 20 (20.5 ± 2)
6 Flanged hexagonal head cap screw to clamp lower thrust block cover on steering knuckle 336 ± 17 (34.2 ± 1.7)
7 Wheel lock nut 490 ± 50 (49.9 ± 5)
8 Conical threaded cap for wheel hub cover 57.5 ± 2.5 (5.9 ± 0.25)
9 Wheel hub cover 106 ± 11 (10.8 ± 1.1)
10 Socket head cap screw to clamp adjusting stop block on wheel bearings 27.5 ± 2.5 (2.8 ± 0.25)
11 Metal ring to clamp wheel bearings 388.5 ± 18.5 (39.6 ± 1.8)
12 Hexagonal head cap screw to clamp brake disc on wheel hub 40 ± 4 (4.1 ± 0.4)
13 Self—locking hexagonal head cap screw to clamp brake callipers 188 ± 18 (19 ± 1.8)
14 Screw to clamp brake callipers support 313 ± 16 (32 ± 1.6)
15 Screw clamping steering 64.5 ± 6.5 (6.5 ± 0.7)

TOOLS
99305354 Portable optical equipment for check of wheel attitude
99306004 Mobile hydraulic truck
99321024 Hydraulic truck for wheel detachment and reattachment
Stand for axle overhaul

99322215
99341003 Simple effect puller

TOOLS
99347047 Tool for steering knuckle pin removal
Extractor for track rod head pins

99347068
99355038 Wrench (65 mm) for front wheel hub caps

(to be used with 99370317)
Handle for interchangeable beaters

99370006
99370317 Reaction lever with extension for flange holder

TOOLS
99370628 Support for axle detachment and reattachment
Rail for wheel hub assembly

99370712
Beater for assembly of bearing outside tracks (91 — 134)

99374093 (to be used with 99370007)
Locking ring for assembly of steering knuckle pin gaskets

99374171 (to be used with 99370007)
Tool for steering knuckle pin setting

99374400
99374457 Locking ring for inside wheel hub gasket setting


TOOLS
99374527 Beater for disassembly and reassembly of steering knuckle pin

bearings (to be used with 99370007)
99389819 Dynamometric wrench (0 — 10 Nm) with square connection 1/4”
99395026 Tool for hub rolling torque check (to be used with dynamometric
wrench)

520610 AXLE REMOVAL AND REFITTING

Front axle removal
Figure 11
Place the vehicle on a flat ground and clamp rear wheels.
Release front wheels’ lock nuts.
Use an hydraulic jack to lift the front part of the vehicle and
place it onto two supporting stands.
Unscrew the lock nuts and remove the wheels using hydraulic
truck 99321024.
60383
Use extractor 99347068 (4) to remove the tie rod steering Place under the axle an hydraulic jack fitted with support
knuckle (6) of the lever (5). 99370628.
Disconnect the air delivery pipe (1) from the membrane brake Unscrew the nuts (8) and remove the brackets (7) connecting
cylinders, the wire of the wheel revolution sensor (3) and the the axle spring bands and the supports (10) clamping the
wire (2) of the worn braking washer signaller. stabilizer bar (9), in order not to make it interfere with the
following operation.
Lower the hydraulic jack and extract the axle underneath the
vehicle.

Figure 12
36400
Front axle refitting Check clearance of articulated joints

Use an hydraulic jack fitted with support 99370628 to lift the Figure 13
axle, so that spring band connecting pins (4) are introduced
in the holes (5) on the spring supporting plane on the axle.
Make reattachment reversing the order of detachment
operations.
Check and adjust front wheel set up.

To lock nuts consider the couples contained in the
appropriate table on page 15.
CHECKS ON THE VEHICLE

Tie rods
Check that screws and stop block lock nuts of tie rods are
not worn and that they are clamped according to the
prescribed torque. 38654
Tie rods must not be damaged or worn as well as the Place the vehicle on a lift—bridge or a pit and do not lift the
threaded part. wheels.
Articulated joints Use a gauge to measure the distance between the articulated
Clean tie rod articulated joints, both cross and longitudinal. joint’s body and its edge making three measurements in the
Such an operation must be made with dry towels or cotton following conditions:
wool. Do not use solvents. - straight wheels dimension X;
Check that the articulated joint’s several components are not - wheels turned on the left dimension X1;
corroded for more than 1 mm and, in particular, check the - turned wheels dimension X2;
metal sheet cover next to the rolling. (completely on the right)
Calculate clearance A according to the following formula:
Check the guard: A=B—X
- it must be clamped to the joint’s body and pin through where B is the biggest value resulting from measurements X1
circlips and it must not rotate; and X2.
- it must not be worn or damaged; Such clearance must not be over 2 mm.
- press it manually and check if any grease comes out; If an higher clearance or any other fault are detected during
- check that the nut and the split pin are not worn. the checks, replace the involved element according to the
procedure described in the related chapter.

FRONT WHEEL SET UP Figure 15

Before checking, it is necessary to make a preliminary
investigation of some vehicle elements which can affect set
up. If any fault is detected, it is important to eliminate it in
order to avoid wrong measurements.
The checks to be made are the following:
- tyre pressure;
- wheel hub bearing clearance;
- clearance between track rod pins and levers on steering
knuckles;
- shock—absorber efficiency;
- wheel rims must not be dramatically distorted.
Make wheel set up check using equipment 99305354. 32974
Lift the vehicle’s front part and place the swinging plates (1)
under the wheels, clamping them with the appropriate locks
NOTE Checks and possible adjustments of wheel set up (2).
must be made with the vehicle having static load.
By and then, check perfect calibration of optical
units.
Figure 16
Setting of clips and headlights

Figure 14
32975
Place on the wheel rim the self—centring clip (2) fitted with
the right lock pins (1). Use the handle (3) to clamp the clip
32973 on wheel, checking that the wheel itself is well fixed.
Place the vehicle with the wheels in upright direction on a flat
surface. Lift the vehicle’s rear part and place the platforms
under the wheels (3). Lower the vehicle, brake the rear
wheels and set the hook (1) with the ruler (2).
Figure 17
32976
Set the detecting system (3) on the clips (1) and clamp it with
the screw (2). Repeat the same operations on the other wheel.

Electronic compensation for rim maladjust- Wheel alignment

ment Figure 20
Figure 18
32979
32977 Balance detectors (3) by using the spirit level (1) and clamp
Connect detectors’ plugs to the transformer and switch it on. them in this position by the screw (2).
Release the detector’s lock screw and lift the lens cover.
Move the rulers (4) until they are hit by the light signal
Push the button “off centre” (3) for at least two seconds, five
released by the detector and write the indicated values.
lines will be displayed on the digital (1) indicator.
Slowly rotate the wheel by hand and project the light signal
on the corresponding ruler scale (5). Figure 21
Detect and write down the minimum and maximum
excursion of the light signal: e.g. 12 and 8.
Calculate the excursion’s average value: 12 + 8 = 20 : 2 = 10
and place the wheel according to the calculated average value,
marking the new position.
Push again the button “off centre” (3) until the wheel
inclination led (2) is switched on and on the digital indicator
a fake value is displayed.
Repeat the same operations on the other wheel.
Be careful that the laser ray does not hit people’s

! eyes: it would severely harm their sight.
13952
If the values are different, turn the wheels until the light signal
Lower the vehicle so that the wheels, being in the marked indexes reach two equal values (A) and the exact average
position, touch completely the centre of the swinging plates value resulting from the two previous detections. In such a
and release the latter from the related bases by removing the way it is possible to obtain a perfect wheel alignment.
pins (4).
Figure 19
32978
Push the brake pedal and leave it in this position using the
appropriate tool (1) set against the seat, thus keeping the
vehicle braked during the whole measurement.

Toe—in check
Figure 22
The wheels’ angle of inclination is a fixed value which
cannot be adjusted.
Therefore, if a different value is detected, remove
and dismantle the axle, make the appropriate
investigations and possible replacements.
32980
Still having detectors perfectly balanced and the wheels Check upright angle of inclination (King Pin)
completely aligned, use a lever (1) to move the lens cover. and clearance angle (Caster)
Move the lever (2) and point the light signal index to the
ruler’s graph scale (3) corresponding to the rim’s diameter.
Repeat the same operations with the opposite detector and
read the toe—in values expressed in millimetres on the graph Figure 24
scales.
The algebraic sum of the two detected values must amount
to: 0.5 ÷ 1.5 mm with static load.
Toe—in adjustment is performed by operating on

the track rod so that toe—in for each wheel is from
0 to 0.5 mm.
32982
Still having the front wheels aligned with the rear ones, loose
knurled knobs (2) and set to zero the graduated sector (3)
on the swinging plate’s index (1).
Check of wheel inclination (Camber)
Figure 23 Figure 25
32981 32983
If the front wheels are aligned with the rear ones and the Turn the wheels inwards by 20° and push twice the upright
detectors are balanced, push the wheel inclination button (3) inclination button (3), the led (2) will be switched on and nine
and the led (2) will be switched on. The digital indicator (1) will horizontal lines will appear on the digital indicator (1).
give the value of the angle of inclination which must be 1°.

Check steering angles

Figure 26 Figure 28
32984 32986
Turn the wheels outwards by 20° and push again the upright With the wheels in upright direction, set to zero the
inclination button (2), the digital indicator (1) will display the graduated sectors (5) on the index (2) of the swinging plates
value of the upright angle of inclination (King Pin) which must (4).
be 7°. If the steering angles which must be detected are bigger than
30°, it is necessary to use as “0°” reference indexes the 20°
sign (1) placed on the swinging plate and the corresponding
one on the graduated sector.
Turn the inside wheel according to the prescribed value and
check that the outside wheel’s angle corresponds to the
prescribed value, considering that to make the survey it is
necessary to use as “0°” reference indexes the 20° sign (3)
placed on the swinging plate and the corresponding one on
the graduated sector.
Repeat the same operations and check steering of the
opposite wheel.
Figure 27
32985
Without moving the wheel, push the clearance angle button

(3). The led will be switched on (1) and the digital indicator
(2) will display the value of the clearance angle (Caster) which
must be 3°.
The upright angle of inclination and the clearance

angle are fixed values which cannot be adjusted.
Therefore, if different values are detected, remove

520610 OVERHAUL OF THE FRONT

AXLE ASSY
Figure 29 Figure 31
32990
60870
Use a lifter to place and clamp the axle assy (1) on stand Release the screws (2) and take off the brake callipers (1) from
99322215 (2) in order to make overhaul. the supporting flange (3).
Figure 32
520620 REMOVAL AND REFITTING OF
WHEEL HUBS
Removal
Figure 30
60871
Use torque lever 99370317 (4), to block wheel hub (2)

rotation and use wrench 99355038 (3) to unscrew oil cover
(1).
Figure 33
78421
Rotate wheel hub in order to set the screw plug (1) down;
unscrew plug and drain oil into a special container. Take off
the brake calipers.
60872
Release the screw (1), unscrew adjusting ring (2) by using

wrench 99355038 (4) and remove the washer (3).

Figure 34 Figure 36
60873 49180
Screw tool 99370712 (3) on the steering knuckle pin. Use a Remove the wheel hub as described in the related chapter.
suitable rope (1) and a hydraulic hoist to support wheel hub Take off the sealing ring and remove the bearing’s inside ring
(2) with axle 99341003 (6) and its respective brackets from the wheel hub.
99341018 and reaction block (7), all of them applied as Use the appropriate beater to remove the bearing’s outside
shown in the figure, then take wheel hub (2) complete with rings (1 and 2) from the wheel hub.
tapered—roller bearing inner race (5) and spacer (4) out of Check that the bearing’s outside ring housings on the wheel
the knuckle pin. hub are not burred as a result of the pull out operation.
NOTE Do not lay down the wheel hub on the phonic

wheel side, in order not to damage it.
Replacement of sealing ring

Figure 35 Figure 37
60874 33001
Use general tools to remove the sealing ring (3) from the Place the outside bearings’s outside ring (3) and use beater
wheel hub (5). Moisten with oil the new sealing ring’s inside 99374093 (2) and handle 99370007 (1) to make setting.
outline.
Use locking ring 99374457 (2) and handle 99370006 (1) to
place the sealing ring (3) on the wheel hub.
Replace the phonic wheel (if present).
NOTE If present, do not use the phonic wheel as a
Use general tools to remove the phonic wheel (4) from the
supporting plane.
wheel hub (5).
Before setting the phonic wheel (4), warm it up to 150°C.
Once the assembly is completed, check that the “phonic”
wheel (4) touches completely the wheel hub.
Check that the maximum orthogonality error of the phonic
wheel (4) is not higher than 0.2 mm.

Figure 38 Place the stud bolts accurately putting on their heads

a load not higher than 2300 kg.
Once the operation is completed, check the lack of

clearance between the disc plane and the area under
the stud bolt head and verify that the orthogonality
error is not higher than 0.3 mm.
Wheel hub reattachment
Figure 40
33002
Place the inside bearing’s outside ring (3) and use beater
99374093 (2) and handle (1) 99370007 to make setting.
Lubricate the inside bearing with oil SAE W

140/MDA and place it on the wheel hub.
Set the sealing ring.
Reattach the wheel hub.

60875
Check the wheel hub end play. Screw tool 99370712 (3) on the steering knuckle pin and
lubricate its outside surface using oil TUTELA W 140/M—DA.
Secure the wheel hub (2) with a rope (1) and support it with
Check the rolling torque. a lifter. Lock carefully the wheel hub (2) on the steering
knuckle pin in order not to damage the sealing ring (3,
Figure 35).
Mount spacer (4) and tapered—roller bearing inner race (5).
Release tool 99370712 (3).
520625 Replacement of wheel stud bolts Force—fit washer (6) and screw down retaining ring (7).
Figure 39
Figure 41
33004
60876
Use general tools to remove the stud bolts (1) from the brake
disc (2). Tighten ring (7, Figure 40) to the specified torque by means
Check that the supporting plane of the stud bolt heads is not of wrench 99355038 (1).
burred.

Rolling torque survey

Figure 42 Figure 44
32999 77202
Secure retaining ring (1) screw (2) to the specified torque. Apply tool (1) 99395026 on wheel hub stud bolts and use
torque meter 99389819 (2) to check whether the wheel hub
Check wheel hub end play rolling torque is at the set value.
Figure 43 Deposit a sealing bead (Loctite type 574) exclusively

on the hub cover ledge surface and protect the
threaded part.
Tighten to torque the hub cover (3).
Figure 45
32998
Hit the wheel hub in axial direction with a mallet and rotate
it in both directions in order to release the bearings’ rolls. α
Set the magnetic base (1) fitted with a gauge (2) on the wheel
hub.
Place the gauge pointer (3) perpendicular to the steering
knuckle shank (4).
Set the gauge to zero with a preload corresponding to 1.5
÷ 2 mm.
Move the wheel hub in axial direction by means of a lever and
detect the end play which must be 0.16 mm (maximum
value). 77203
If the detected value does not correspond to the prescribed Rotate the wheel hub until when hub cover (1) is positioned
one, replace the bearing unit and make a new survey. as shown in the figure. Restore the prescribed quantity of oil
into the hub cover (1) through filling hole (2). Tighten the
plug on the hub cover (1) to the set torque.

Figure 46 To reattach reverse the detachment operation

order.
Clamp the castellated lock nuts of the articulated

pins according to the prescribed torque.
Check that the nut grooves match with the cross

holes on the articulated pins. If it is not possible to
introduce the split pins, gradually raise the nut
tightening torque until the split pins are completely
60878 put in place (angle lower than 60°).
Reattach the brake callipers (1) to the flange (3) and lock the
screws (2) according to the prescribed torque. Set braking
gaskets following the procedure described in chapter “Wheel
hub overhaul” Rear axle section.
520635 Cross tie rod removsl and

refitting
520636 Replacement of cross tie rod
Figure 47
articulated pins
Figure 49
60879
Straighten and take off the split pin (1).

Unlock the nut (2) and release it partially in order to prevent
33007
the tie rod (3) from falling when it is removed.
Block the screw (4), release the nut (3) and unscrew the
Figure 48 articulated pin (2) from the cross tie rod (1).
NOTE Write down the number of turns needed to

release every articulated pin in order to screw the
new ones making the same number of turns.
Screw the articulated pin (2) in the tie rod (1). The nut (3)
must be clamped according to the prescribed torque, after
making toe—in adjustment as described in the “Wheel set up”
chapter.
60880
Use extractor (1) 99347068 to unlock the articulated pin (3)

from the lever (2). Repeat the same operations on the
opposite side, release the nut (2, Figure 47) completely and
remove the cross tie rod.

520631 Cross tie rod lever removal and refit- Figure 53

ting
Figure 50
60881 60884
Loose the screws (2) and remove the lever (3) from the Loose the screws (1) and remove the upper cover (2)
articulated pin (1). To make reattachment reverse the together with the lubricator (3).
operation order and clamp the lock screws (2) according to
the prescribed torque.
520632 Longitudinal tie rod lever Figure 54
removal and refitting
Figure 51
60882
60885
Loose the screws (1) and remove the lever (2) from the
articulated pin (3). To make reattachment reverse the Release the screws (5) and remove the cover (3) together
operation order and clamp the lock screws (1) according to with the thrust block (2), the adjusting plate (1) and the
the prescribed torque. lubricator (4).
520611 Steering knuckle pin removal and re-
fitting Figure 55
Removal
Figure 52
60886
Use tool 99347047 (1) and element (2) to unfasten the

60883 steering knuckle (4) articulated pin (3). Remove the tool, take
Release the screws (2) and remove the brake callipers off the pin (3) and remove the articulated joint (4) from the
support (1) from the axle. axle.

520615 Steering knuckle pin bearing Figure 58

replacement
Figure 56
60887 60890
Steering knuckle bearing replacement (5) is made using for

Use beater 99374171 (4) and handle 99370007 (3) to place
their disassembly and assembly beater’s elements (1—2—3)
sealing rings (2 and 5) in the steering knuckle (1).
99374527 and handle 99370007 (4).
Use element (1) and handle (4) to disassemble the sealing Refitting
ring (8) and the roller bearings (6—7) on the upper side.
Use element (3) and handle (4) to disassemble the sealing Figure 59
ring (9) and the roller bearings (10—11) on the lower side.
Figure 57
60891
Set on the axle (2) the steering knuckle (3) and place the
articulated pin (1).
Set tool 99374400 (4) on the steering knuckle (3) and fasten
it by using the same lower cover lock screws (5), clamping
them with the right torque.
Place the pin (1) in the axle conical housing, screwing the
pressure screw (6) with a torque having 10 ÷ 11 daNm.
Remove tool 99374400 (4) from the steering knuckle (3).
60889 Before placing the pin (1), it is necessary to check

Roller bearing assembly (7): that the conical housing on the axle and the pin
use element (1 and 2) and handle (4). surface are perfectly cleaned and dry, in order to
Roller bearing assembly (6): avoid oil layers which could foster the pin rotation
use element (2) and handle (4). in its place during its introduction.
Roller bearing assembly (8):
use elements (3 and 2) and handle (4).
use element (2) and handle (4).

Figure 60 Check and adjustment of clearance between

steering knuckle and axle
Figure 63
60885
60895
Place the lower cover (3) together with the lubricator (4), the
thrust block (2), the adjusting plates (1) and clamp the lock Keep the steering knuckle (3) raised and use a thickness
screw (5) according to the prescribed torque. gauge (1) to check clearance between the upper shim
adjustment of the steering knuckle and the axle (2). This value
NOTE Before making the assembly, moisten the lower must be between 0.10 and 0.35 mm.
cover (2) thrust block with grease Tutela MR2.
Repeat the same operations for the opposite steering

knuckle. Figure 64
Figure 61
60896
60893
Once the clearance between the upper shim adjustment of
Place in the steering knuckle (1) a new sealing ring (2). the steering knuckle (1) and the axle (3) has been checked,
use a thickness gauge (2) to check that between the lower
Figure 62 shim adjustment of the steering knuckle (1) and the axle’s (3)
one there is a gap not lower than 0.25 mm.
The possible clearance adjustment can be done
replacing the adjusting shims (1, Figure 60) with
spare ones having the right thickness.
As to the thickness of spare rings, see table

“SPECIFICATIONS AND DATA”.
Lubricate the whole lower and upper articulated

joint with grease MR2, checking that the grease
flows through the gasket baffle.
60884
Place the upper cover (2) together with the lubricator (3) on
the steering knuckle and clamp the screws (1) according to
the prescribed torque.

520618 CHECKS AND MEASUREMENTS OF

THE AXLE UNIT
Figure 65 Check flatness of leaf spring surfaces compared
to holes for steering knuckle pins
Figure 66
60894
Place the brake callipers support (1) on the steering knuckle

(3) and clamp lock screws (2) according to the prescribed
torque.
Complete wheel hub assembly as described on page 27. Place two bars (1) fitted with cones (3) in the steering
knuckle pin holes. Push the cones and clamp them placing the
appropriate screws on the bars.
Introduce two centring dowels (2) in the leaf spring
supporting plane (4).
Figure 67
Place on the planes (6) two bases (5) using goniometers and
introduce them in the centring dowels.
NOTE Before placing the bases with the goniometers,

check that the supporting planes are not painted or
irregular.
Place the sliding bar (2) on the goniometer’s bars (4),

adjusting its length so that the shaped edges touch the bars
(1).
Clamp the screws of the stop block (7) and the goniometer’s
lock screws (3) to the bars (4).

Figure 68
Check the angle of deformation on the goniometers’ Remove the sliding bar and the goniometer’s bases used to
graduated sectors shown by the arrows. make the survey.
Goniometers’ indexes will, of course, detect no angle
movement when the flatness of leaf spring surfaces
compared to the steering knuckle pin holes is correct.
Check hole inclination for steering knuckle
pins
Figure 69
Place on the bars (1) the supports (3) fitted with goniometers
and screw the screws (2) without clamping them.
Introduce the connecting cross tie rod (4) and tighten the
screws (2) which clamp the supports touching the bars (1).
Figure 70
Check the angle of inclination value concerning the steering to the gauge (1). The angle of inclination concerning the
knuckle pin holes on the related graduated sectors (2), next steering knuckle pin holes must be 7° ± 0°3’.


EUROCARGO TECTOR 12—26 t FRONT AXLES 5842/5 — 5851/5 37
5206 Front axles 5842/5 — 5851/5

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 45
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT AXLE REMOVAL — REFITTING

(Mechanical suspension) . . . . . . . . . . . . . . . . . 53
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FRONT AXLE REMOVAL — REFITTING

(Pneumatic suspension) . . . . . . . . . . . . . . . . . 54
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . 56
- Toe—in check . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Check upright angle of inclination (King Pin) and

clearance angle (Caster) . . . . . . . . . . . . . . . . . 57

AXLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . 59
- Removal and refitting of wheel hubs . . . . . . . . 59
- Sealing ring replacement . . . . . . . . . . . . . . . . . 59
- Wheel hubs refitting . . . . . . . . . . . . . . . . . . . . 60

38 FRONT AXLES 5842/5 — 5851/5 EUROCARGO TECTOR 12—26 t
Page
- End play adjustment of wheel hub bearings . . . 60
- Rolling torque check . . . . . . . . . . . . . . . . . . . . 60
REPLACEMENT OF WHEEL HUB BEARINGS . 61
REPLACEMENT OF STUD BOLTS

FOR WHEEL CLAMPING . . . . . . . . . . . . . . . 62
CROSS TIE ROD REMOVAL AND REFITTING 62
REPLACEMENT OF CROSS TIE

ROD ARTICULATED JOINTS . . . . . . . . . . . . 63
CROSS TIE ROD LEVER

REMOVAL AND REFITTING . . . . . . . . . . . . . 63
LONGITUDINAL TIE ROD LEVER REMOVAL

AND REFITTING . . . . . . . . . . . . . . . . . . . . . . 63
STEERING KNUCKLE PIN

REMOVAL AND REFITTING . . . . . . . . . . . . . 63
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
- Check and adjustment of clearance

between steering knuckle and axle . . . . . . . . . 65

BEARING REPLACEMENT . . . . . . . . . . . . . . . 66

OF THE AXLE UNIT . . . . . . . . . . . . . . . . . . . 67


DESCRIPTION
The front axle has a steel structure with a double “T” section having at the end steering knuckles.
The wheel hubs are supported by two conical roller bearings set on the steering knuckle shank and adjustable by a threaded
ring.
Figure 1
73841
SECTION OF FRONT AXLE 5842/5 (F 5021) WHEEL SIDE

Figure 2
73842
SECTION OF FRONT AXLE 5851/5 (F 5521) WHEEL SIDE

ß
assembly angles:
- clearance angle
- toe—in
32957


Clearance angle
Figure 3
Figure 5
γ + γ _
α α
A B
32958
A B axis and the vertical to the ground, looking at the vehicle from
one side.
32956 If the extension of the upright axis falls beyond the wheel’s
clearance angle is positive (A). It is considered negative (B) if
it falls behind the wheel’s fulcrum on the ground. It is null if it
The wheel angle (α) of inclination is the one resulting from the is absolutely perpendicular to the wheel’s fulcrum on the
axis passing through the wheel’s centre line and the vertical to ground.
the ground, looking at the vehicle standing before it. Such an angle enables front wheels to keep an upright position
The inclination is positive (A) when the wheel’s upper part when the vehicle is moving in an upright direction and to
moves outside. It is negative (B) when the wheel’s upper part recover such a position after taking a curve as soon as the
moves inside. steering wheel is released by the driver.

Toe—in
Figure 6 Figure 7
A
A
B
B
32359 32960

wear. Figure 8
32961

Axle type 5842/5 5851/5
α
Inclination of steering knuckle pin
7° ± 3’
housing
∅1
Diameter of roller bearing housing
in steering knuckle:
— upper housing ∅1 mm 41.972 to 41.988
— lower housing ∅2 mm 51.967 to 51.986
∅2
∅3
Outside diameter of roller bear-
ings for steering knuckle:
∅4
Upper bearings — steering knuckle mm 0.012 to 0.028
Lower bearings — steering knuckle mm 0.014 to 0.033
∅5

∅6
∅ 7
Diameter of pin for steering

knuckle
— upper ∅7 mm 34.984 to 35.000
— lower ∅8 mm 42.984 to 43.000
∅ 8
Upper bearings — pin mm 0 to 0.016
Lower bearings — pin mm 0 to 0.016

5842/5 5821/5
X1 Clearance between axle and steer-
ing knuckle upper adjustment X1 mm 0.10 to 0.35

X 2 knuckle lower adjustment X2 mm ≥ 0.25

S
0.25 mm S mm 0.50 to 1.75
WHEEL HUBS
Wheel hub bearings 2 with tapered rollers
Wheel hub clearance by means of a metal ring
Oil for wheel hub bearings Tutela W 140/MDA

Litres 0.23
Quantity per hub
kg 0.207
WHEEL SET UP
Wheel inclination
1°
(vehicle with static load)
Wheel incidence
1° 24”
Toe—in (vehicle with static load) mm 0.5 to 1.5

DIAGNOSTICS

2 — Wobble
3 — Noise
NO
YES

NO
YES

NO
YES

NO
YES
NO and axle.
YES
on the pin. NO

2 WOBBLE
NO
YES
NO axle.
YES

NO
YES

NO
YES
NO replacements.
YES

- centred, regular rim NO Deflate and centre tyre on rim.
YES

NO

3 NOISE

NO
YES
Efficient wheel hub bearings. Replace worn bearings and adjust end play.
NO
YES
Regular clearance between steering knuckle pin and Check and replace worn elements.
roller bearings. NO

TIGHTENING TORQUES
Figure 9
73840
TORQUE
PART
Nm (kgm)
1 Self—braking hexagonal head cap screw to clamp cross tie rod lever on steering knuckle 515.5 ± 24.5 (52.6 ± 2.5)
2 Castellated nut for articulated joint pin 201 ± 20 (20.5 ± 2)
3 Self—braking hexagonal head cap screw to clamp longitudinal lever on steering knuckle 515.5 ± 24.5 (52.6 ± 2.5)
5 Hexagonal head cap screw to clamp brake disc on wheel hub 40 ± 4 (4 ± 0.4)
6 Socket head cap screw to fasten wheel bearing adjusting clamp 27.5 ± 2.5 (2.8 ± 0.2)
7 Wheel hub cover 133.5 ± 13.5 (13.6 ± 1.3)
8 Wheel bearings securing ring nut 388.5 ± 18.5 (39.7 ± 1.9)
9 Tapered threaded plug for wheel hub cover 27 ± 2 (27.5 ± 2)
Axle 5842/5 (vehicles 130) 490 ± 50 (49.9 ÷ 5)
10 Wheel lock nuts
Axle 5851/5 (vehicles 150) 627,5 ± 62,51 (63.9 ÷ 6.4)
Self—locking hexagonal—head screw for fastening the brake backing plate to the
11 313 ± 16 (32 ± 1.6)
steering knuckle
12 Self—locking hexagonal head screw for fastening disk brake calipers to the plate 313 ± 16 (32 ± 1.6)

TOOLS
99305354 Portable optical equipment to check wheel attitude
Hydraulic truck for wheel detachment and reattachment

99321024
99322215 Stand for axle overhaul
99347068 Extractor for track rod head pins
99354207 Wrench (94.5 mm) for wheel hub cups

TOOLS

99370714
Beater for assembling external bearing race (91—134) use with

99374093 99370007

TOOLS
Locking ring for assembly of upper steering knuckle pin gasket

99374172 (to be used with 99370007)
99374173 Locking ring for assembly of lower steering knuckle pin gasket
99374233 Locking ring for assembly of inside wheel hub gasket
Tool for steering knuckle pin setting

99374400
99374529 Beater for disassembly and reassembly of steering knuckle pin

bearings (to be used with 99370007)
99389819 Dynamometric wrench (0 to 10 Nm) with square 1/4”

connection

TOOLS
wrench)

FRONT AXLE REMOVAL — REFITTING Figure 10

(Mechanical suspension)
Before carrying out disconnection/reconnection

operations, exhaust air from pneumatic system and
disconnect the batteries.
Removal
Arrange the vehicle on a plane ground, lock rear
wheels with chocks and proceed as follows:
- loosen front wheels securing nuts, lift the vehicle and

place it on support stands;
- place hydraulic trolley 99321024 under the wheels,
- place under the front axle an hydraulic jack equipped
with support 99370628;
sensors (on the right side it is necessary to remove the
heat guard) that are placed inside the longitudinal
members and free wiring from the various check straps;
- disconnect air delivery piping (2) to membrane brake
cylinders;
- unscrew split pin (4), unscrew nuts (5) and through tool
99347068 detach ball head of steering tie rod (6);
- unscrew securing nuts (8) and remove stands (9) joining
leaf springs and supports (7) for anchoring stabilising bar
(10) to front axle;
- rotate the stabilising bar so that it does not interfere with
the front axle;
- lower the hydraulic jack and withdraw the front axle
from the vehicle.
Refitting
Through the hydraulic jack equipped with support
99370628, lift the front axle so that leaf springs
joining ping are inserted into holes obtained on
spring abutment planes on the front axle.
Go on with the reconnection by performing in reverse the

operations described for the disconnection and lock screws
and nuts at the required torque.
Self—locking nuts must always be replaced and tigh-

tened at the required torque.
Verify that:
deteriorated, it is necessary to replace them.
101501

FRONT AXLE REMOVAL — REFITTING Figure 11

(Pneumatic suspension)
Before carrying out disconnection/reconnection

operations, exhaust air from pneumatic system and
disconnect the batteries.
Removal
Arrange the vehicle on a plane ground, lock rear
wheels with chocks and proceed as follows:
- loosen front wheels securing nuts, lift the vehicle and

place it on support stands;
- place hydraulic trolley 99321024 under the wheels,
- place under the front axle an hydraulic jack equipped
with support 99370628;
sensors (on the right side it is necessary to remove the
heat guard) that are placed inside the longitudinal
members and free wiring from the various check straps;
- disconnect air delivery piping (2) to membrane brake
cylinders;
- unscrew split pin (4), unscrew nuts (5) and through tool
99347068 detach ball head of steering tie rod (10);
- operating on the right vehicle side, unscrew securing nut
(6) and detach levelling valve lever (7);
- unscrew securing nuts (8) and remove stands (12)
joining leaf springs and supports (11) for anchoring
stabilising bar (9) to front axle;
- rotate the stabilising bar so that it does not interfere with
the front axle;
- lower the hydraulic jack and withdraw the front axle
from the vehicle.
Refitting
Through the hydraulic jack equipped with support
99370628, lift the front axle so that leaf springs
joining ping are inserted into holes obtained on
spring abutment planes on the front axle.
Go on with the reconnection by performing in reverse the

operations described for the disconnection and lock screws
and nuts at the required torque.
Self—locking nuts must always be replaced and tigh-

tened at the required torque.
Verify that:
deteriorated, it is necessary to replace them.
101821


- tyre pressure;
knuckles;
32974
Make wheel set up check using equipment 99305354.
(2).
NOTE Checks and possible adjustments of wheel set up
Figure 14
NOTE By and then, check perfect calibration of optical

units.
32975
on wheel, checking that the wheel itself is well fixed.
Figure 12 Figure 15
32973 32976
Place the vehicle with the wheels in upright direction on a flat Set the detecting system (3) on the clips (1) and clamp it with
surface. Lift the vehicle’s rear part and place the platforms the screw (2). Repeat the same operations on the other
under the wheels (3). Lower the vehicle, brake the rear wheel.

Electronic compensation for rim Wheel alignment

maladjustment Figure 18
Figure 16
32979
32977
Balance detectors (3) by using the spirit level (1) and clamp
Release the detector’s lock screw and lift the lens cover. Push Move the rulers (4) until they are hit by the light signal released
the button “off centre” (3) for at least two seconds, five lines by the detector and write the indicated values.
will be displayed on the digital (1) indicator.
on the corresponding ruler scale (5).
and place the wheel according to the calculated average
value, marking the new position.

Lower the vehicle so that the wheels, being in the marked

position, touch completely the centre of the swinging plates
and release the latter from the related bases by removing the
pins (4).
Figure 19
Figure 17
13952
32978
Push the brake pedal and leave it in this position using the indexes reach two equal values (A) and the exact average
appropriate tool (1) set against the seat, thus keeping the value resulting from the two previous detections. In such a
vehicle braked during the whole measurement. way it is possible to obtain a perfect wheel alignment.

Toe—in check
Figure 20
cannot be adjusted.
32980
Still having detectors perfectly balanced and the wheels

completely aligned, use a lever (1) to move the lens cover. Check upright angle of inclination (King Pin)
Move the lever (2) and point the light signal index to the and clearance angle (Caster)
scales.
Toe—in adjustment is made affecting the cross tie

rod.
32982
Figure 21 Figure 23
32981
32983
If the front wheels are aligned with the rear ones and the
detectors are balanced, push the wheel inclination button (3) Turn the wheels inwards by 20° and push twice the upright
and the led (2) will be switched on. The digital indicator (1) will inclination button (3), the led (2) will be switched on and nine
give the value of the angle of inclination which must be 1°. horizontal lines will appear on the digital indicator (1).


Figure 24 Figure 26
32984 32986
be 7°.
If the steering angles which must be detected are bigger than
opposite wheel.
Figure 25
32985

must be 2°30’.


520610 OVERHAUL OF THE FRONT Figure 30

AXLE ASSY
Figure 27
32990 60872
Use a lifter to place and clamp the axle assy (1) on stand Loosen screw (1), unscrew adjusting ring (2) by means of
99322215 (2) in order to make overhaul. wrench 99355038 (4), take out washer (3), the tapered—
roller bearing and the spacer, then take off the wheel hub in
520620 Removal and refitting of wheel hubs the proper way.
Figure 28
Sealing ring replacement

Figure 31
78421
Rotate wheel hub in order to set the screw plug (1) down;
unscrew plug and drain oil into a special container. Take off
the brake calipers. 32997
With generic tools, extract sealing ring (3).

Moisten the edges with oil.
Figure 29 With keyer 99374233 (2) and handle (1), assemble the seal-
ing ring into its own wheel hub seat.
32995
Use reaction lever 99370317(3) to stop the wheel hub rota-

tion and use wrench 99354207 (1) to release the cover (2).

Wheel hubs refitting Figure 34

Check that the surfaces of all elements inside the hub
are accurately cleaned, without slag and burrs.
Figure 32
32999
Once the requested end play has been reached, clamp the
adjusting ring (2) check screw (1) with the requested torque.
60875
Screw on the steering knuckle pin the tool 99370714 (3) and
lubricate its outside surface using oil TUTELA W 140/M—DA.
Secure with a rope (1) the wheel hub (2) and support it with
the lifter. Key the wheel hub (2) carefully on the steering Rolling torque check
knuckle pin in order not to damage the sealing ring.
Figure 35
Mount spacer (4) and tapered—roller bearing (5).
Release tool 99370714 (3).
Key the washer (6) and screw the check ring (7) with the re-
quested torque.
End play adjustment of wheel hub bearings
Figure 33
77202
Apply tool 99395026 (1) to the wheel hub studs, then use
dynamometer 99389819 (2) to verify that the wheel hub
rolling torque conforms to the specified value.
32998
Place some sealer (Loctite type 574) only on the sur-
Hit the wheel hub in axial direction with a mallet and rotate face touched by the hub cover, protecting the
it in both directions in order to release the bearings’ rolls. threaded part.
Set the magnetic base (1) fitted with a gauge (2) on the wheel
hub.
Tighten the hub cover (3) to torque.
Place the gauge pointer (3) perpendicular to the steering
knuckle shank (4).
Set the gauge to zero with a preload corresponding to 1.52
mm.
Move the wheel hub in axial direction by means of a lever and
detect the end play which must be 0.16 mm (maximum
value).
If the detected value does not correspond to the prescribed
one, replace the bearing unit and make a new survey.

Figure 36 Figure 38
78322
33002
Rotate the wheel hub until when hub cover (1) is positioned Put the inside bearing’s outside ring (3) in its place and use
as shown in the figure. Restore the prescribed quantity of oil beater 99374093 (2) and handle (1) 99370007 to settle it
into the hub cover (1) through filling hole (2). Tighten the down.
520621 REPLACEMENT OF WHEEL HUB

BEARINGS Lubricate the inside bearing with oil SAE W
140/MDA and place it in the wheel hub.
Remove the wheel hub. Set the sealing ring.
Take off the sealing ring and the bearing from the
Reattach the wheel hub.
location inside the wheel hub.
Use a beater to pull out the bearing’s outside rings
from the wheel hub.
Adjust the wheel hub end play.
Check that the bearing’s outside ring locations in
the wheel hub are not dented as a result of the pull
out operation. Check the rolling torque.
Figure 37
33001
Place outer bearing outer race (3) into its seat, then proceed
to ramming by means of beater (2) 99374093 and handle
99370007 (1).

520625 REPLACEMENT OF STUD BOLTS 520635 CROSS TIE ROD REMOVAL AND
FOR WHEEL CLAMPING REFITTING
Figure 39
Figure 40
33004
33005
Use general tools to pull out stud bolts (1) from the brake Straighten and take off the split pin (1).
disc (2). Unlock the nut (2) and release it partially in order to prevent
Check that the head supporting plane of the stud bolts is not the tie rod from falling when it is removed.
burred.
Place the stud bolts accurately and put on their Figure 41
head a load not higher than:
- 2300 kg for axle 5842/5
- 2500 kg for axle 5851/5
Once the operation is completed, check that there

is no clearance between the disc plan and the area
below the stud bolt head. Check also that the ort-
hogonality error is not higher than 0.3 mm.
33006
Use extractor (1) 99347068 to unlock the steering head (3)

from the lever (2). Repeat the same operations on the oppo-
site side, release the nuts completely and remove the cross tie
rod.
To reattach reverse the detachment operation or-
der.
Clamp the conical pin castellated lock nuts with the

requested torque.
Check that the nut grooves match with the cross

holes on the conical pins. If it is not possible to
put in place (angle lower than 60°).

520636 REPLACEMENT OF CROSS TIE 520632 LONGITUDINAL TIE ROD LEVER

ROD ARTICULATED JOINTS REMOVAL AND REFITTING
Figure 44
Figure 42
34544
33007 Release the screws (2) and remove the lever (1). To make re-
Block the screw (4), release the nut (3) and unscrew the ar- attachment reverse the operation order and clamp the
ticulated joint (2) from the cross tie rod (1). Screw the articu- screws with the requested torque.
lated joint in the tie rod and clamp it in this position locking
the lock nut with the requested torque. 520611 STEERING KNUCKLE PIN
In order to ease the cross tie rod reattachment and Removal
the following toe—in adjustment, write down the
number of turns needed to release every Figure 45
articulated joint so to avoid screwing the new one
making the same number of turns.
Reattach the cross tie rod.
Check and adjust toe—in as described in paragraph

“Front wheel set up”.
520631 CROSS TIE ROD LEVER

REMOVAL AND REFITTING 34545
Figure 43 Release the screws (2) and remove the brake callipers sup-
port (1).
34543
Release the screws (1) and remove the lever (2). To make
reattachment reverse the operation order and clamp the lock
screws with the requested torque.

Refitting
Figure 46 Figure 49
34546 34549
Use the appropriate pliers to take off the check ring (1) and Set on the axle body the steering knuckle and put the pin in
remove the cover (2) together with the lubricator. its place.
Set tool 99374400 (1) on the steering knuckle and fasten it
by using the same lower cover lock screws, clamping them
Figure 47 with the right torque.
Place the pin in the axle conical housing, screwing the pres-
sure screw (2) to a torque having 7 to 8 daNm.
Remove tool 99374400 from the steering knuckle.
Before placing the pin, it is necessary to check that the

conical housing on the axle and the pin surface are
perfectly cleaned and dry, in order to avoid oil layers
which could foster the pin rotation in its place during
its introduction.
Before making assembly, moisten the thrust block of
the lower cover using grease Tutela MR2.
34547
Release the screws (3) and remove the lower cover (2), the
adjusting plates and the thrust block (1).
Figure 48 Figure 50
34548 34547
Use tool 99347047 (1) and elements (2 and 3) to unfasten Place the lower cover (2) together with the thrust block (1)
the steering knuckle pin. and the adjusting shims; fasten the lock screws (3) with the
Remove the tools and take off the pin. requested torque.
Repeat the same operations on the opposite steering
knuckle.

Figure 51 The possible clearance adjustment can be done

replacing the adjusting shims with spare ones having
the right thickness.
As to the thickness of spare rings, see table

“SPECIFICATIONS AND DATA”.
Lubricate the whole lower and upper articulated

joint with grease MR2, checking that the grease
flows through the gasket baffle.
34546
Place the upper cover (2) together with the related seal;
place the lubricator as shown in the figure, then introduce the
safety ring (1) and check that the ring expansion is made in
the correct way.
Check and adjustment of clearance between

steering knuckle and axle
Figure 52
34550
Keep the steering knuckle raised and use a thickness gauge

(1) to check clearance between the upper shim adjustment
of the steering knuckle and the axle. This value must be
between 0.10 ÷ 0.15 mm.
Figure 53
34551
Once the clearance between the upper shim adjustment of
the steering knuckle and the axle has been checked, use a
thickness gauge (1) to check that between the lower shim
adjustment of the steering knuckle and the axle’s one there
is a gap not lower than 0.25 mm.

520615 STEERING KNUCKLE PIN Figure 55

BEARING REPLACEMENT
Figure 54
60887 60889
Steering knuckle bearing replacement (5) is made using for Roller bearing assembly (7):
their disassembly and assembly beater’s elements (1—2—3) use element (1 and 2) and handle (4).
99374529 and handle 99370007 (4). Roller bearing assembly (6):
use element (2) and handle (4).
Use element (1) and handle (4) to disassemble the sealing
ring (8) and the roller bearings (6—7) on the upper side. Roller bearing assembly (8):
use elements (3 and 2) and handle (4).
Use element (3) and handle (4) to disassemble the sealing Roller bearing assembly (9):
ring (9) and the roller bearings (10—11) on the lower side. use element (2) and handle (4).
Figure 56
34556
Use locking ring 99374173 (2) and handle 99370007 (1) to

place the lower seal; use locking ring (3) 99374172 and
handle 99370007 (1) to place the upper seal in the steering
knuckle.

520618 CHECKS AND MEASUREMENTS

OF THE AXLE UNIT
Check flatness of leaf spring surfaces compared Figure 58
Figure 57
Place two bars (1) fitted with cones (3) in the steering Place on the planes (6) two bases (5) using goniometers and
knuckle pin holes. Push the cones and clamp them placing the introduce them in the centring dowels.
appropriate screws on the bars.
Introduce two centring dowels (2) in the leaf spring support-
ing plane (4). NOTE Before placing the bases with the goniometers,
check that the supporting planes are not painted or
irregular.
Place the sliding bar (2) on the goniometer’s bars (4), adjusting
its length so that the shaped edges touch the bars (1).
Clamp the screw of the stop block (7) and the goniometer’s
Figure 59
Check the angle of deformation on the goniometers’ grad- the steering knuckle pin holes is correct.
uated sector shown by the arrows. Remove the sliding bar and the goniometer’s bases used to
Goniometers’ indexes will, of course, detect no angle move- make the survey.
ment when the flatness of leaf spring surfaces compared to
Check hole inclination for steering knuckle pins
Figure 60
Place on the bars (1) the supports (3) fitted with gonio-
meters and screw the screws (2) without clamping them.
Figure 61

EUROCARGO TECTOR 12—26 t FRONT AXLE 5871/5 69
5206 Front axle 5871/5

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 77
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . 86
- Toe—in check . . . . . . . . . . . . . . . . . . . . . . . . . . 87
- Check upright angle of inclination (King Pin) and

clearance angle (Caster) . . . . . . . . . . . . . . . . . 87
FRONT AXLE REMOVING AND REFITTING

(Mechanical and pneumatic suspension) . . . . . 89
OVERHAULING THE FRONT AXLE ASSEMBLY 89
- Removing the wheel hubs . . . . . . . . . . . . . . . . 89
- Replacing the wheel hub bearings . . . . . . . . . . 89
- Replacing seal . . . . . . . . . . . . . . . . . . . . . . . . . 90
- Replacing wheel studs . . . . . . . . . . . . . . . . . . . 90
- Refitting wheel hubs . . . . . . . . . . . . . . . . . . . . 91
- Adjusting wheel hub bearing end play . . . . . . . 91
- Checking the rolling torque . . . . . . . . . . . . . . . 91
REMOVING AND REFITTING TRACK ROD . . 92
REPLACING TRACK ROD BALL JOINT . . . . . . 92

70 FRONT AXLE 5871/5 EUROCARGO TECTOR 12—26 t
Page
CHECKING BALL JOINT END PLAY FOR TRACK

ROD AND DRAG LINK . . . . . . . . . . . . . . . . . 92
- Replacing ball joint . . . . . . . . . . . . . . . . . . . . . . 92
REMOVING AND REFITTING TRACK ROD ARMS 93
REMOVING AND REFITTING DRAG LINK ARM 93
REMOVING AND REFITTING THE KINGPIN . . 93
- Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
- Checking and adjusting play between

stub axle and axle . . . . . . . . . . . . . . . . . . . . . . 94

BEARING REPLACEMENT . . . . . . . . . . . . . . . 95
CHECKS AND MEASUREMENTS ON AXLE BODY 96
- Checking surface flatness of leaf spring

seating with respect to holes for kingpins. . . . . 96
- Checking inclination of holes for kingpins . . . . 97

DESCRIPTION
Front axle 5871/5 has a steel structure with a double “T” section having at the end steering knuckles.
The wheel hubs are supported by two conical roller bearings, “set right” type, set on the steering knuckle shank. The bearing
end play is predetermined by the spacer placed between them.
Figure 1
71175
AXLE SIGHT 5871/5

Figure 2
SEC A—A
SECTION OF FRONT AXLE WHEEL SIDE
SEC B—B
71176
FRONT AXLE PART — ABS SENSOR LOCATION

ß
assembly angles:
- clearance angle
- toe—in
32957

Clearance angle
Figure 5
Figure 3
γ + γ _
α α
A B
32958
axis and the vertical to the ground, looking at the vehicle from
one side.
A B If the extension of the upright axis falls beyond the wheel’s
32956 clearance angle is positive (A). It is considered negative (B) if
is absolutely perpendicular to the wheel’s fulcrum on the
The wheel angle (α) of inclination is the one resulting from ground. It is null if it is absolutely perpendicular to the wheel’s
the axis passing through the wheel’s centre line and the fulcrum on the ground.
vertical to the ground, looking at the vehicle standing before Such an angle enables front wheels to keep an upright position
it. when the vehicle is moving in an upright direction and to
The inclination is positive (A) when the wheel’s upper part recover such a position after taking a curve as soon as the
moves outside. It is negative (B) when the wheel’s upper part steering wheel is released by the driver.
moves inside.

Toe—in Figure 7
Figure 6
A
A
B
B
32359 32960

wear. Figure 8
32961

Axle type 5871/5
Inclination of steering knuckle pin housing 7º
∅1
Diameter of roller bearing housing on
steering knuckle:
— upper housing ∅1 mm 51.967 ÷ 51.986
— lower housing ∅2 mm 59.967 ÷ 59.986
∅2
∅3
Outside diameter of roller bearings
∅4
Upper bearings — steering knuckle mm 0.014 ÷ 0.033
Lower bearings — steering knuckle mm 0.014 ÷ 0.033
∅5

∅6
∅ 7
Diameter of pin for steering knuckle

— upper ∅7 mm 42.984 ÷ 43
— lower ∅8 mm 52.981 ÷ 53
∅ 8
Upper bearings — pin mm 0 ÷ 0.016
Lower bearings — pin mm 0 ÷ 0.019

5871/5
X1 Clearance between axle and steering
knuckle upper adjustment X1 mm 0.10 ÷ 0.35

X 2 knuckle lower adjustment X2 ≥ 0.25
mm

S
0.25 mm S mm 0.50 ÷ 1.75
WHEEL HUBS
Wheel hub bearings 2 with taper rollers
not adjustable
Wheel hub clearance
locking with lock nut torque
Oil for wheel hub bearings Tutela W 140/M—DA

Amount per hub Litres (kg) 0.35 (0.32)
WHEEL SET UP
Wheel inclination (vehicle with static load) 1°
Wheel incidence (vehicle with static load) 1°, 24”
Toe—in (vehicle with static load) mm 0÷1
Steering angle
Inside α 52°
Outside β 36°

DIAGNOSTICS

2 — Wobble
3 — Noise
NO
YES

NO
YES

NO
YES

NO
YES
NO and axle.
YES
on the pin. NO

2 WOBBLE
NO
YES
NO axle.
YES

NO
YES

NO
YES
NO replacements.
YES

centred, regular rim NO Deflate and centre tyre on rim.
correct assembly of tyre on rim.
YES

NO

3 NOISE

NO
YES
Efficient wheel hub bearings. NO Replace worn bearings and adjust end play.
YES
Regular coupling between steering knuckle pin and Check and replace worn elements.
NO
roller bearings.

TIGHTENING TORQUES
Figure 9
SEC A—A
SEC B—B
71195
TORQUE
PART
Nm (kgm)
1 Oval headed screw for securing upper cover 10.8 ± 2 (11 ± 0.2)
2 Self—braking hexagonal head screw for securing longitudinal levers on stub axle 1325 ± 75 (135 ± 7.5)
3 Self—braking hexagonal head screw for securing transverse tie rod lever on stub axle 1325 ± 75 (135 ± 7.5)
4 Clamp locking nut for transverse tie rod 80 ± 10 (8.1 ± 1)
5 Notched nut for ball head pin 201 ± 20 (20.5 ± 2)
6 Screw for securing lower cover on stub axle 117 ± 6 (11.9 ± 0.6)
7 Wheel hub cover 133.5 ± 13.5 (13.6 ± 1.3)
Cylindrical headed screw with embedded hexagon for locking wheel bearings adjustment
8 27.5 ± 2.5 (2.8 ± 0.2)
clamp
9 Wheel bearings securing ring nut 515.5 ± 24.5 (52.5 ± 2.5)
10 Bevel threaded plug for wheel hub cover 57.5 ± 2.5 (5.9 ± 0.25)
11 Hexagonal head screw for securing brake disc to wheel hub 281.5 ± 13.5 (28.6 ± 1.3)
12 Wheel securing nut 627.5 ± 62.5 (63.9 ± 6.4)
13 Self—locking hexagonal head screw for securing brake shoes 615.5 ± 61.5 (62.7 ± 6.2)
14 Screw for securing brake shoes support 313.5 ± 15.5 (31.9 ± 1.5)
15 Steering stop screws 58.5 ± 5.2 (5.9 ± 0.5)

TOOLS
99305354 Portable optical equipment to check wheel attitude
Hydraulic truck for wheel detachment and reattachment

99321024
99322215 Stand for axle overhaul
99347068 Extractor for track rod head pins
Wrench (94.5 mm) for front wheel hub caps

99354207

TOOLS

99370715
Beater for assembly of bearing outside tracks (91 — 134) to be used

99374093 with 99370007

TOOLS
Locking ring for assembly of inside wheel hub gasket

99374132 (to be used with 99370006)
99374173 Locking ring for assembly of lower steering knuckle pin gasket
99374405 Tool for steering knuckle pin setting
Beater for disassembly and reassembly of steering knuckle pin

99374530 bearings (to be used with 99370007)
Wrench for cross and longitudinal tie rod lock screws on steering
99388002 knuckle

TOOLS
99389819 Dynamometric wrench (0 — 10 Nm) with square connection 1/4”
wrench)


- tyre pressure;
knuckles;
32974
(2).
Figure 12
NOTE By and then, check perfect calibration of optical

units.
32975
Figure 10 Figure 13
32973 32976


Figure 14
32979
32977
Release the detector’s lock screw and lift the lens cover. Push Move the rulers (4) until they are hit by the light signal
the button “off centre” (3) for at least two seconds, five lines released by the detector and write the indicated values.
(1) a fake value is displayed.


pins (4).
Figure 15 Figure 17
13952
32978 If the values are different, turn the wheels until the light signal

Toe—in check
Figure 18
cannot be adjusted.
32980

scales.

rod.
32982
Figure 19 Figure 21
32981
32983


Figure 22 Figure 24
32984 32986
be 7°.
opposite wheel.
Figure 23
32985

must be 2°30’.

520610 FRONT AXLE REMOVING AND Figure 27

REFITTING
(Mechanical and pneumatic
suspension)
For front axle disconnection and reconnection, refer to the
procedure described for 5842/5 and 5851/5 front axles.
520610 OVERHAULING THE FRONT

AXLE ASSEMBLY
Using lifting gear, position and secure the axle assembly (1)
on stand 99322215 (2) for overhaul.
49179
Loosen the screw (4), remove the adjusting nut (3) with
wrench 99388001, pull out the washer (2), the outer bearing
(1) and take down the wheel hub with the relactive spacer
520620 Removing the wheel hubs and inner bearing.
Figure 25 Figure 28
36409
78421
Using suitable tools remove the seal ring (2), inner bearing
and phonic wheel (3) from the wheel hub. (1)
Unscrew the plug (1) and drain the oil into a proper
container.
520621 Replacing the wheel hub bearings
Take down the brake calipers.
Figure 29
Figure 26
49180
Using a suitable drift remove the outer rings (1 — 2) of the

bearings from the wheel hub.
49178
Use reaction lever 99370317 (3) to lock wheel hub rotation NOTE Make sure that the housings of the outer rings of
and with wrench 99354207 (2) unscrew the oil cover (1). the wheel hub bearings have not been dented by
the removal operation.

Figure 30 Figure 32
36413
Use drift 99374093 (2) to press—fit the outer race of the front
hub bearing without pushing fully home. Repeat the
operation on the opposite side for the rear bearing outer 49142
race.
ASSEMBLY POSITION OF THE SEAL RING (A) IN THE
Complete the operation of press—fitting the outer bearing
WHEEL HUB (B)
races manually using drift 99374093 (2) with handle
99370007 (1).
Heat the phonic wheel (1) to a temperature of 150° (3,
Figure 28) for 15 minutes, then fit it on the wheel hub (1) and
let it cool down. NOTE Cleaning the wheel hub cap. To prevent the
polycarbonate transparent part from getting
opaque, we advise you to wash it with cleaning
Replacing seal products normally used for the body. Never use
chlorotene solvents because they etch the
Figure 31 polycarbonate.
Replacing wheel studs
Figure 33
36410
Lubricate the inner bearing with SAE W 140M—DA

oil and position it in its housing in the wheel hub.
Using drift 99374232 (1) and handle 99370006 (2)
fit in place the seal ring (3) on the wheel hub checking
the assembly position (Figure 32).
36415
Use ordinary tools to remove studs (1) from wheel hub.

Check that the stud head mating surface is free of burrs.
Press—fit studs carefully by applying a load of not more than
2500 kg to their heads.
Once the operation is complete, check there is no play
between the disc surface and stud head undersides.

Refitting wheel hubs

Make sure that the surfaces of all components NOTE If the end play is not as required, replace the bearing
inside the hub are thoroughly clean and free from assembly e repeat the adjusting operations.
scale and burrs.
Install the wheel hub onto the stub axle. Once the specified end play is obtained, lock the adjustment
Fit the internal spacer onto the stub axle, then nut (4) retaining screw (5) to the specified torque.
position the outer bearing and thrust washer.
Checking the rolling torque
Adjusting wheel hub bearing end play Figure 36
Figure 34
77202
Apply tool (1) 99395026 on wheel hub stud bolts and use
49181 torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
Using a torque wrench (2) and wrench 99388001 (2) lock
the adjustment nut to the prescribed torque.
Deposit a sealing bead (Loctite type 574) exclusively
Figure 35 threaded part.
Tighten to torque the hub cover (3).
Figure 37
36411
Give wheel hub a few blows with a mallet in axial direction,

rotating it in both directions to free the bearing rollers.
Apply magnetic base (1) with gauge (2) to the wheel hub.
Put stylus pointer (3) perpend. to the stub axle (4) spigot. 78322
Zero the gauge with a preload of 1.5 to 2 mm.
Use a lever to move the wheel hub along the axis and Rotate the wheel hub until when hub cover (1) is positioned
measure the end play which should be 0.16 mm (max. value). as shown in the figure. Restore the prescribed quantity of oil
into the hub cover (1) through filling hole (2). Tighten the

520635 REMOVING AND REFITTING CHECKING BALL JOINT END PLAY FOR
TRACK ROD TRACK ROD AND DRAG LINK
Figure 38
The vehicle should not be jacked up.
Use a gauge (1, Figure 40) to measure the distance ”X” with
the vehicle in straight on position.
Take the measurement again with the steering turned as far
as possible, to the left (X1) and to the right (X2). Take a note
of the values measured.
Calculate the axial clearance ”A”, noting the maximum value
measured between X1 and X2.
Example:
A = max (X1, X2)—X
If the value rises above 2 mm replace the ball joint.
Figure 40
33005
Straighten and extract cotter pin (1).

Unlock nut (2) and partially unscrew it so as to prevent the
track rod from dropping when removing.
Figure 39
36914
Replacing ball joint
Figure 41
36416
Using the extractor 99347068 (1), release the ball joint (3)
from the arm (2). Repeat the same operations on the
opposite side, unscrew the nuts completely and remove the
track rod.
To refit, carry out removal operations in reverse
33007
order.
Lock screws (4), loosen nut (3) and unscrew ball joint (2)
Tighten the nuts securing the taper pins to the from track rod (1).
specified torque. Screw ball joint into rod and lock in position tightening
locking nut to the specified torque.
Check the position of the castellations on the nuts To make it easier to refit the track rod and measure
! which line up with the transverse holes in the taper the wheel convergence, note down the number of
pins; if the cotter pins will not go in, progressively turns needed to unscrew each ball joint so that the
increase the torque of the nuts until correct new ones can be screwed in by the same number
insertion is achieved (angle less than 60°). of turns.
520636 REPLACING TRACK ROD BALL Refit the track rod.

JOINT
Check and, if necessary, adjust front wheel toe—in

Before replacing swivel head (Figures 40—41) check the axial as described on “Front wheel set up”.
clearance as described below.

520631 REMOVING AND REFITTING 520611 REMOVING AND REFITTING THE

TRACK ROD ARMS KINGPIN
Removing
Figure 42 Figure 44
49182
49184
Unscrew screws (2) using wrench 99388002 (3) and remove Unscrew screws (1) and remove support (2) from the brake
arm (1). To refit, reverse the sequence of operations and calliper.
tighten the fastening screws to the specified torque.
Figure 45
520632 REMOVING AND REFITTING

DRAG LINK ARM
Figure 43 36420
Using suitable pliers, remove the retainer circlip (1) and take
out the cover (2) complete with grease nipple.
Figure 46
49183
Unscrew screws (2, Figure 43) using wrench 99388002 (3,

Figure 42) and remove arm (1). To refit, reverse the
sequence of operations, tightening the attachment screws to
the specified torque. 36421
Unscrew screws (4) and remove lower cover (3), adjustment

shims (2) and thrust bearing (1).

Figure 47 Figure 49
36424
Position lower cover (3) complete with thrust bearing (1)

36422
and adjustment shims (2). Tighten screws (4) to the specified
Use tool 99347047 (1) and part (2) to unlock swivel axle pin torque.
(3). Remove the tool and withdraw the pin. Repeat the same operations for the opposite axle.
Figure 50
Refitting
Figure 48
36420
Insert upper cover (2) complete with seal into its housing;
position grease nipple as shown in the figure, then insert
retainer circlip (1) making sure that the circlip expands
36423 correctly.
Checking and adjusting play between stub axle
Fit stub axle (1) to axle (4) and insert the pin into its housing. and axle
Apply tool 99374405 (2) to the stub axle and secure by Figure 51
means of the lower cover retaining screws. Tighten to a
suitable torque.
Press—fit the pin into the taper seating in the axle, tightening
pressure screw (3) to a torque of 15 to 16 daNm.
Remove tool 99374405 from the stub axle.
Before installing the pin, make sure that the taper

seating in the axle and the surface of the pin are
completely clean and dry to avoid oil films which
would facilitate rotation of the pin in its seating during
the installing operation.
36425
Lift the swivel axle to bring it into contact with the lower axle
facing. Use feeler gauge (1) to check clearance between upper
NOTE Before assembling, lubricate the lower cover thrust
facing of swivel axle and axle. This should be between 0.10
bearing with Tutela MR2 grease.
and 0.35 mm.

Figure 52 Figure 54
36426
When the clearance between the upper facing of the swivel

axle and the axle has been checked, confirm by means of a
feeler gauge (1) that there is a clearance between the lower
facing of the swivel axle and that of the axle of not less than 0.25
mm.
Adjustment of the clearance, if any, is obtained by
replacing the adjustment shims with others supplied
as spares having suitable thicknesses.
For spare shim thicknesses, see “CHARACTERIS-

60889
TICS AND DATA” table on page

Grease the lower and upper joint assembly with MR2 use element (1 and 2) and handle (4).
grease making sure that the grease escapes through Roller bearing assembly (6):
the deflector lips of the seals. use element (2) and handle (4).
520615 STEERING KNUCKLE PIN Roller bearing assembly (8):
BEARING REPLACEMENT use elements (3 and 2) and handle (4).
Figure 53 use element (2) and handle (4).
Figure 55
60887
Steering knuckle bearing replacement (5) is made using for

their disassembly and assembly beater’s elements (1—2—3)
99374527 and handle 99370007 (4).
Use element (1) and handle (4) to disassemble the sealing
ring (8) and the roller bearings (6—7) on the upper side. 60890
Use element (3) and handle (4) to disassemble the sealing With beater 99374173 (4) and handle 99370007 (3),
ring (9) and the roller bearings (10—11) on the lower side. assemble sealing rings (2 and 5) in stub axle (1).

520618 CHECKS AND MEASUREMENTS

ON AXLE BODY NOTE Before fitting the bases with protractors, make sure
that the seating faces have no traces of paint or
Checking surface flatness of leaf spring seating roughness.
with respect to holes for kingpins.
Apply two rods (as shown in Figure 56, ref. 1) complete with
cones (3) in the holes for knuckle pins; press the cones and Figure 57
lock them in position on the rods using relevant screws.
Insert the two locating dowels (2) into the housings in the
leaf spring seating surface.
Figure 56
Fit sliding bar (2) to protractor rods (4), adjusting the length
so that the shaped ends come into contact with rods (1).
Lock screw of clamp (7) and screws (3) securing the
protractors to the rods (4).
Apply bases (5, Figure 57) to planes (6) using protractors and
fit into centring dowels.
Figure 58
Check the angle of distortion, if any, on the graduated sectors is correct with respect to the holes for the kingpins. Remove
of the protractors shown by the arrows. the sliding bar and the bases with protractors used for the
Obviously the protractor pointers do not record any angular inspection.
deviation when the flatness of the leaf spring seating surfaces

Checking inclination of holes for kingpins
Figure 59
Fit supports (3) with protractors to rods (1) and screw up

screws (2) without tightening them.
Insert transverse link rod (4) and fully screw up screws (2)
which secure the supports in contact with rods (1).
Figure 60
Read off the value of the angle of kingpin inclination from the The value for inclination of the holes for the kingpins should
relevant graduated sectors (2) in line with the pointers (1). be 7o.


Print 603.93.391
5206 Front axle 5860

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 101
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 106
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . 111
- Toe—in check . . . . . . . . . . . . . . . . . . . . . . . . . . 112
- Check upright angle of inclination (King Pin)

and clearance angle (Caster) . . . . . . . . . . . . . . 112

AXLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . 114
- Wheel hub (flanged unit—bearing)

removal and refitting . . . . . . . . . . . . . . . . . . . . 114
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
- Replacing the wheel fastening studs . . . . . . . . 115
- Wheel hubs refitting . . . . . . . . . . . . . . . . . . . . 115
CROSS TIE ROD REMOVAL AND REFITTING 116
REPLACEMENT OF CROSS TIE

ROD ARTICULATED JOINTS . . . . . . . . . . . . 116
CROSS TIE ROD LEVER

REMOVAL AND REFITTING . . . . . . . . . . . . 116
LONGITUDINAL TIE ROD LEVER REMOVAL

AND REFITTING . . . . . . . . . . . . . . . . . . . . . . 117

REMOVAL AND REFITTING . . . . . . . . . . . . 117

Page
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
- Steering knuckle pin removal and refitting . . . . 117
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
- Checking and adjusting the play between

the kingpin and the front axle . . . . . . . . . . . . . 119

OF THE AXLE UNIT . . . . . . . . . . . . . . . . . . . 120


Print 603.93.391/A
DESCRIPTION
The front axle has a steel structure with a double “T” section having at the end steering knuckles.
The wheel hubs are supported by two conical roller bearings set on the steering knuckle shank and adjustable by a threaded
ring.
Figure 1
105124
SECTION OF FRONT AXLE 5860 CL
(Broad track)
Figure 1/1
105125
SECTION OF FRONT AXLE 5860 CS
(Narrow track)

Revi — July 2005
Print 603.93.391
ß
assembly angles:
- clearance angle
- toe—in
in its movement, in different loading conditions, which tend to
alter the wheel position on the ground.
32957


Clearance angle
Figure 2
Figure 4
γ + γ _
α α
A B
32958
A B axis and the vertical to the ground, looking at the vehicle from
one side.
32956 If the extension of the upright axis falls beyond the wheel’s
clearance angle is positive (A). It is considered negative (B) if
The wheel angle (α) of inclination is the one resulting from the is absolutely perpendicular to the wheel’s fulcrum on the
axis passing through the wheel’s centre line and the vertical to ground.
the ground, looking at the vehicle standing before it. Such an angle enables front wheels to keep an upright position
The inclination is positive (A) when the wheel’s upper part when the vehicle is moving in an upright direction and to
moves outside. It is negative (B) when the wheel’s upper part recover such a position after taking a curve as soon as the
moves inside. steering wheel is released by the driver.

Toe—in Figure 6
Figure 5
A
A
B
B
32359 32960

wear. Figure 7
32961

Axle type 5860
α
Inclination of steering knuckle pin
7°
housing
∅1
Diameter of roller bearing housing
in steering knuckle:
— upper housing ∅1 mm 41.974 to 41.988
— lower housing ∅2 mm 51.967 to 51.986
∅2
∅3
Outside diameter of roller bear-
ings for steering knuckle:
∅4
Upper bearings — steering knuckle mm 0.012 to 0.026
Lower bearings — steering knuckle mm 0.014 to 0.033
∅5

∅6
∅ 7
Diameter of pin for steering

knuckle
— upper ∅7 mm 34.984 to 35.000
— lower ∅8 mm 42.984 to 43.000
∅ 8
Upper bearings — pin mm 0 to 0.016
Lower bearings — pin mm 0 to 0.016

5860
X1 Clearance between axle and steer-
ing knuckle upper adjustment X1 mm 0.10 to 0.35

X 2 knuckle lower adjustment X2 mm ≥ 0.25

S
0.25 mm S mm 0.50 to 1.75
WHEEL HUBS
Wheel hub bearings 2 flanged unit—bearings
Hub bearing end play mm
Wheel hub clearance not adjustable
Bearing preloading
WHEEL SET UP
Wheel inclination
1°
Wheel incidence
1° 24”
Toe—in (vehicle with static load) mm 0.5 to 1.5
Max. internal steering angle 52°

Max. external steering angle 35°
Maximum capacity (GAW) kg 6100
Full front axle weight kg 308

DIAGNOSTICS

2 — Wobble
3 — Noise
NO
YES

NO
YES

NO
YES

NO
YES
NO and axle.
YES
on the pin. NO

2 WOBBLE
NO
YES
NO axle.
YES

NO
YES

NO
YES
Wheel flanged unit—bearing standard play. Replace the bearings.

NO
YES

- centred, regular rim NO Deflate and centre tyre on rim.
YES

NO

3 NOISE
Wheel unit—bearing lubrication is enough. Replace the bearings.

NO
YES
Wheel flanged unit—bearings in working order. Replace the bearings.

NO
YES
Regular clearance between steering knuckle pin and Check and replace worn elements.
roller bearings. NO

TIGHTENING TORQUES
Figure 8
99238
TORQUE
PART
Nm (kgm)
1 Wheel lock nuts 610.5 ± 30.5 (61 ÷ 3)
2 Hexagonal screw securing the brake disc and the flange to the unit—bearing 250 ± 10 (25 ± 1)
3 Wheel bearings securing ring nut 600 ± 30 (60 ± 3)
4 Socket head cap screw to fasten wheel bearing nut 27.5 ± 2.5 (2.8 ± 0.2)
6 Nut for screw securing the swivel head retaining clamp to the cross tie—rod 80 ± 10 (8 ± 1)
7 Socket head cap screw to clamp cross tie rod lever on steering knuckle 950 ± 50 (95 ± 5)
8 Castellated nut for articulated joint pin * 201 ± 20 (20.5 ± 2)
9 Steering stop screw 64.5 ± 6.5 (6.4 ± 0.6)
10 Socket head cap screw to clamp longitudinal lever on steering knuckle 950 ± 50 (95 ± 5)
11 Upper cover fastening screw ** 313 ± 16 (32 ± 1.6)
12 Self—locking hexagonal screw securing the brake calipers to the front axle 300 ± 15 (30 ± 1.5)
* Tighten up to the first notch coinciding with the cotter pin hole
** Apply Loctite 222 to the thread—stop threading


- tyre pressure;
knuckles;
32974
(2).
Figure 11
By and then, check perfect calibration of optical

units.
32975
Figure 9 Figure 12
32973 32976

Print 603.93.391

Figure 13
32979
32977
Release the detector’s lock screw and lift the lens cover. Push Move the rulers (4) until they are hit by the light signal
the button “off centre” (3) for at least two seconds, five lines released by the detector and write the indicated values.

eyes: it would severely harm their sight.

pins (4).
Figure 16
Figure 14
13952
32978

Toe—in check
Figure 17
NOTE The wheels’ angle of inclination is a fixed value
which cannot be adjusted.
32980

scales.

rod.
32982
Figure 18 Figure 20
32981
32983


Figure 21 Figure 23
32984 32986
be 7°.
opposite wheel.
Figure 22
32985

must be 1°24’.
NOTE The upright angle of inclination and the clearance


520610 OVERHAUL OF THE FRONT Figure 26

AXLE ASSY
Figure 24
99331
99329
Loosen screw (3).
Use a suitable box wrench to remove nut (2) securing wheel
Use a lifting device to position and secure front axle assembly
hub (1) to the knuckle pin.
(1) onto stand 99322215 (2) for overhauling.
Remove washer (4).
Take wheel hub bearing (1) off the knuckle pin.
520620 Wheel hub (flanged unit—bearing)

removal and refitting
Removal Figure 27
Figure 25
99332
99330 1. Flanged unit—bearing (wheel hub) —

2. Phonic wheel.
Remove brake calipers (1) as described in the “Pneumatic
system — Brakes” section.
Use reaction lever 99370317 (4) to stop flange (3) rotation. NOTE In the event that anomalies are found on the wheel
Remove fastening screws (2), take flange (3) and brake disc hub or the phonic wheel, the assembly shall be
(5) off the wheel hub (flanged unit—bearing). replaced since the spare parts are not supplied
separately.
Take care not to damage the phonic wheel when
placing the wheel hub.
NOTE Check the conditions of the brake caliper, brake
disc and gaskets, as described in the “Hydraulic
system — Brakes” section. Use a centesimal comparator to verify that phonic wheel
oscillation does not exceed 0.2 mm.
Remove the pulse transmitter from the kingpin.

Replacing the wheel fastening studs Figure 30
Figure 28
99335
Remove tool (2).

After hub bearing (1) has been force—fitted, position washer
(5), screw down nut (3), then use a box wrench to tighten
nut (3) to the specified torque.
99333
Tighten screw (4) securing nut (3) to the specified torque.
Use a generic device to remove studs (1) from hub (2). Make
sure that the stud head supporting plane is free from burrs.
Carefully fix the studs into place, by applying a load not
greater than 2,500 kg onto the stud heads. After the
operation has been completed, check for play between the
flange plane and the screw underhead (squareness error shall Figure 31
not be greater than 0.2 mm).
Wheel hubs refitting

Figure 29
99330
Fit brake disc (5) onto the wheel hub.

Fit flange (3) onto brake disc (5), then screw down screws
(2). Stop flange (3) rotation by applying lever 99370317 (4)
to the same, then tighten screws (2) to the specified torque.
Fit the pulse transmitter (if previously disassembled) into the
kingpin seat, by pushing it into contact with the phonic wheel.
Refit brake calipers (1) as described in the “Pneumatic system
99334
— Brakes” section.
Screw tool (1) down onto the knuckle pin, then lubricate the
external surface of the same with oil.
Carefully force—fit wheel hub (2) onto the knuckle pin.

520635 CROSS TIE ROD REMOVAL AND 520636 REPLACEMENT OF CROSS TIE
REFITTING ROD ARTICULATED JOINTS
Figure 32 Figure 34
33005 33007
Block the screw (4), release the nut (3) and unscrew the
Straighten and take off the split pin (1). articulated joint (2) from the cross tie rod (1). Screw the
Unlock the nut (2) and release it partially in order to prevent articulated joint in the tie rod and clamp it in this position
the tie rod from falling when it is removed. locking the lock nut with the requested torque.
Figure 33 NOTE In order to ease the cross tie rod reattachment and
the following toe—in adjustment, write down the
number of turns needed to release every
articulated joint so to avoid screwing the new one
making the same number of turns.
Reattach the cross tie rod.
Check and adjust toe—in as described in paragraph

“Front wheel set up”.
520631 CROSS TIE ROD LEVER

99337
Use extractor (1) 99347068 to unlock the steering head (3) Figure 35
from the lever (2). Repeat the same operations on the
opposite side, release the nuts completely and remove the
cross tie rod.
To reattach reverse the detachment operation or-
der.
Clamp the conical pin castellated lock nuts with the

requested torque.
NOTE Check that the nut grooves match with the cross
holes on the conical pins. If it is not possible to
99338
put in place (angle lower than 60°).
Release the screws (1) and remove the lever (2). To make
reattachment reverse the operation order and clamp the
lock screws with the requested torque.

520632 LONGITUDINAL TIE ROD LEVER Figure 39

Figure 36
99339 99342
Loosen screws (2), then remove lever (1). Reattachment is Use tool (1) and parts (2 & 3) to release the knuckle pin.
carried out by reversing the sequence of the detachment Remove the equipment and take the pin out.
operations, by locking the screws to the specified torque.
520611 STEERING KNUCKLE PIN

Removal
520615 Steering knuckle pin removal and
Figure 37 refitting
Figure 40
99340
Remove screws (1), then take off upper cover (2) and seal
ring (3).
Figure 38
60887
Kingpin (5) bearings shall be replaced by using the parts

(1—2—3) of the suitable beater and handle (4) to disassemble
and re—assemble the same.
Use part (1) and handle (4) to disassemble seal ring (8) and
roller bearings (6—7) on the upper side.
Use part (3) and handle (4) to disassemble seal ring (9) and
roller bearings (10—11) on the lower side.
99341
Loosen screws (3), then remove lower cover (2), the

adjusting plates (4) and fifth wheel (1).

Figure 41 Refitting
Figure 43
99344
Set on the axle body the steering knuckle and put the pin in
its place.
Set tool (1) on the steering knuckle and fasten it by using the
same lower cover lock screws, clamping them with the right
torque.
60889 Place the pin in the axle conical housing, screwing the
pressure screw (2) to a torque having 7 to 8 daNm.
Remove tool (1) from the steering knuckle.
use element (1 and 2) and handle (4).
Roller bearing assembly (6): NOTE Before placing the pin, it is necessary to check that
use element (2) and handle (4). the conical housing on the axle and the pin surface
Roller bearing assembly (8): are perfectly cleaned and dry, in order to avoid oil
use elements (3 and 2) and handle (4). layers which could foster the pin rotation in its
Roller bearing assembly (9): place during its introduction.
use element (2) and handle (4). Before making assembly, moisten the thrust block
of the lower cover using grease Tutela MR2.
Figure 42
Figure 44
99343 99341
Lubricate fifth wheel (1) with grease of the TUTELA MR2

Use coupler (2) and handle (1) to fix the lower sealing gasket type.
into place. Position lower cover (2) complete with fifth wheel (1) and
Turn the kingpin upside down, then use coupler (3) and adjusting shims (4), then tighten fastening screws (3) to the
handle (1) to fix the upper sealing gasket into the kingpin. specified torque.
Repeat the same operations for the opposite kingpin.

Figure 45 Adjustment of the clearance, if any, is obtained by

replacing the adjustment shims with others supplied
as spares having suitable thicknesses.
For spare shim thicknesses, see “CHARACTERIS-

TICS AND DATA” table on page
Grease the lower and upper joint assembly with MR2

grease making sure that the grease escapes through
the deflector lips of the seals.
99340
Fit upper cover (2) equipped with a new seal ring (3), then
tighten fastening screws (1) to the specified torque.
Checking and adjusting the play between the

kingpin and the front axle
Figure 46
99347
Keep the kingpin lifted upwards, then use a thickness gauge

(1) to verify that the play between the upper clearance
adjustment of the kingpin and the front axle is included
between values of 0.10 and 0.15 mm.
Figure 47
99348
After the play between the upper clearance adjustment of the
kingpin and the front axle has been checked, verify, by means
of a thickness gauge (1), that a clearance of at least 0.25 mm
exists between the lower clearance adjustment of the kingpin
and the lower clearance adjustment of the front axle.

520618 CHECKS AND MEASUREMENTS Figure 50

OF THE AXLE UNIT
Check flatness of leaf spring surfaces compared
Figure 48
Place on the planes (6) two bases (5) using goniometers and
introduce them in the centring dowels.
Place two bars (1) fitted with cones (3) in the steering
knuckle pin holes. Push the cones and clamp them placing the
appropriate screws on the bars. NOTE Before placing the bases with the goniometers,
Introduce two centring dowels (2) in the leaf spring support- check that the supporting planes are not painted or
ing plane (4). irregular.
Place the sliding bar (2) on the goniometer’s bars (4), adjust-
ing its length so that the shaped edges touch the bars (1).
Clamp the screw of the stop block (7) and the goniometer’s
Figure 49
Check the angle of deformation on the goniometers’ grad- the steering knuckle pin holes is correct.
uated sector shown by the arrows. Remove the sliding bar and the goniometer’s bases used to
Goniometers’ indexes will, of course, detect no angle move- make the survey.
ment when the flatness of leaf spring surfaces compared to

Check hole inclination for steering knuckle pins
Figure 51
Place on the bars (1) the supports (3) fitted with goniometers
and screw the screws (2) without clamping them.
Figure 52


EUROCARGO TECTOR 12—26 t FRONT AND REAR SUSPENSIONS 1
SECTION 8
5004 Suspensions
Page
FRONT AND REAR MECHANICAL

SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT AND REAR PNEUMATIC

SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . 53

2 FRONT AND REAR SUSPENSIONS EUROCARGO TECTOR 12—26 t

EUROCARGO TECTOR 12—26 t FRONT AND REAR MECHANICAL SUSPENSIONS 3
Print 603.43.761
5004 Front and rear

mechanical suspensions
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT LEAF SPRINGS . . . . . . . . . . . . . . . . . . . 5
PARABOLIC LEAF SPRING SPECIFICATIONS

AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT SUSPENSION — MODELS 110EL..—120EL.. . . . . . .

7
FRONT SUSPENSION — MODELS 120E..—130E.. 8
FRONT SUSPENSION — MODELS

120E..—120E..D—130E..—130E..D—130E18RS—140E..—
140E..RS—150E..—150E..RS . . . . . . . . . . . . . . . . 9
FRONT SUSPENSION — MODELS 160E..—160E..RS 10
FRONT SUSPENSION —
MODELS 180E..—190EL..—260E.. . . . . . . . . . . . 11
SEMI—ELLIPTICAL LEAF SPRING SPECIFICATIONS

AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT SUSPENSION — MODELS 120E..—130E.. 12

120E..D—130E..D—140E..—140E..RS—150E.. . . . 13
FRONT SUSPENSION — MODELS 180E.. . . . . . 14
FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . 15
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . . 15
REAR LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . 18
PARABOLIC LEAF SPRING SPECIFICATIONS

AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REAR SUSPENSION — MODELS 110EL..—120EL.. 20
REAR SUSPENSION — MODELS 120E..—130E.. . 21
REAR SUSPENSION —
MODELS 120E..—130E..— 130E18RS . . . . . . . . 22
REAR SUSPENSION —
MODELS 120E..—120E..D—130E..—130E..D—140E..—
140E..RS—150E..—150E18RS—160E..—160E..RS . 23

4 FRONT AND REAR MECHANICAL SUSPENSIONS EUROCARGO TECTOR 12—26 t
Page Page
REAR SUSPENSION — MODELS 180E.. . . . . . . . 24
REAR SUSPENSION — MODELS 190EL.. . . . . . . 25 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SEMI—ELLIPTICAL LEAF SPRING SPECIFICATIONS

AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 43
REAR SUSPENSION 120E..—130E.. . . . . . . . . . . . 26 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REAR SUSPENSION — MODELS - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

120E..D—130E..D—140E..—140E..RS—150E.. . . . . 27
REAR SUSPENSION 180E.. . . . . . . . . . . . . . . . . . 28 FRONT SWAY BAR . . . . . . . . . . . . . . . . . . . . . . 43
HENDRICKSON REAR SUSPENSION - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

MODELS 260E.. . . . . . . . . . . . . . . . . . . . . . . . . 29
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REAR SWAY BAR . . . . . . . . . . . . . . . . . . . . . . . . 44
REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 31 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . . 31
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . 32
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Shock absorber features and data —
Models 260E.. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REPLACING LEAF—SPRING BUSHINGS . . . . . . . 44
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DISCONNECTING AND RECONNECTING
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 38 REAR LEAF—SPRING BUSHINGS . . . . . . . . . . 44
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - Disconnecting rear bushings . . . . . . . . . . . . . . . 44
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . 39 - Reconnecting rear bushings . . . . . . . . . . . . . . . 47

FRONT MECHANICAL
SUSPENSION REMOVAL—REFITTING . . . . . . 41 - Disconnecting front bushings . . . . . . . . . . . . . . 48
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - Reconnecting front bushings . . . . . . . . . . . . . . . 48
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FRONT LEAF—SPRING BUSHINGS . . . . . . . . 49
REAR MECHANICAL SUSPENSION
REMOVAL—REFITTING . . . . . . . . . . . . . . . . . 42
- Disconnecting front bushings . . . . . . . . . . . . . . 49
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
- Reconnecting front bushings . . . . . . . . . . . . . . . 50
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . . 43 - Disconnecting rear bushings . . . . . . . . . . . . . . . 50
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 - Reconnecting front bushings . . . . . . . . . . . . . . . 51

DESCRIPTION
The suspension consists of leaf springs, two double—acting telescopic shock absorbers and a sway bar.
The leaf springs can be semi—elliptical or parabolic.
Semi—elliptical leaf springs are very stiff because all the leaves have the same thickness, from one end to the other. Furthermore,
the leaves are arranged to create high internal friction, whereby limiting the leaf spring movements.
Parabolic leaf springs are made of leaves which are thicker in the middle and narrower at the ends. The distanced arrangement
considerably reduces internal friction.
Low internal friction and the special leaf shape makes parabolic leaf springs softer, consequently ensuring greater riding comfort.
Double—acting telescopic shock absorbers counteract wheel movement upwards and downwards, ensuring excellent riding
stability.
The sway bar keeps the wheel axle and chassis parallel, cancelling any load imbalance on the wheel on any one axle.
FRONT LEAF SPRINGS
Figure 1
72519
FRONT PARABOLIC LEAF SPRING ASSEMBLY

(Models 110EL..—120EL..)
Figure 2
72521

(Models 120E..—130E..—130E..RS—140E..—140E..RS—150E..—150E..RS—160E..—160E..RS)

Figure 3
72527

(Models 180E..—260E..)
Figure 4
72523
FRONT SEMI—ELLIPTICAL LEAF SPRING ASSEMBLY

(Models 120E..—130E..—180E..)
Figure 5
72693
FRONT SEMI—ELLIPTICAL LEAF SPRING ASSEMBLY

(Models 120E..—130E..—150E..)

PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA

FRONT SUSPENSION — Models 110EL..—120EL..
mm
Parabolic leaf springs No 2
L Main leaf and second leaf length 1714 ± 3

(measured at eye centre)
S Leaf thickness
26
(measured in the middle)
S Thickness between leaves 3
Width of leaves 70 ± 0.5
NEW SPRING CHECK DATA:

Static load deflection 17
Static load flexibility 5.691 mm/kN
Main leaf eye internal diameter

D 55.5 + 0.1
(bushing housing)
— 0.2
D = bushing external diameter 57.3 + 0.6
D d
+ 0.3
d = bushing internal diameter 20.2 —0

FRONT SUSPENSION — Models 120E..—130E..

mm

S Leaf thickness
24

Static load deflection
Static load flexibility 6
6.96 mm/kN

D 55.5 + 0.1
(bushing housing)
+ 0.6
D = bushing external diameter 57.3 — 0.2
D d
+ 0.3

FRONT SUSPENSION — Models 120E..—120E..D—130E..—130E..D—130E18RS—140E..—

140E..RS—150E..—150E..RS
mm

S Leaf thickness
21
NEW SPRING CHECK DATA: 15

Static load deflection 6,69 mm/kN
Static load flexibility

D 55.5 + 0.1
(bushing housing)
+ 0.6
D d
+ 0.3

FRONT SUSPENSION — Models 160E..—160E..RS

mm
L Length of leaves 1758 ± 3

S Leaf thickness
22

Static load flexibility 6 ± 5 % mm/kN

D 55.5 + 0.1
(bushing housing)
+ 0.6
D d
+ 0.3

FRONT SUSPENSION — Models 180E..—190EL..—260E..

mm

S Leaf thickness
1st leaf (measured in the middle) 19
2nd — 3rd — 4th leaf (measured in the middle) 21

2
Static load deflection
5.53 mm/kN

D 55.5 + 0.1
(bushing housing)
+ 0.6
D d
+ 0.3

SEMI—ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA

FRONT SUSPENSION — Models 120E..—130E..
mm
Semi—elliptical leaf springs No 2

S Leaf thickness
14

Static load deflection 12
Static load flexibility 6.31 mm /kN
Main leaf eye internal diameter +0.1

D 55.5
(bushing housing) —0
+0.6
D = bushing external diameter 57.3
D d —0.2
+0.3
d = bushing internal diameter 20.2
—0

FRONT SUSPENSION — Models 120E..D—130E..D—140E..—140E..RS—150E..

mm

S Leaf thickness
13

Static load deflection 6.5
Static load flexibility 6.11 mm /kN

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

FRONT SUSPENSION — Models 180E..

mm

S Leaf thickness
(measured in the middle) 16.5

Free spring pointer 35
Flexibility 3.97 mm /kN
Main leaf eye internal diameter +0.1

D
(bushing housing) 55.5
—0
+0.6
D d —0.2
+0.3
—0

FRONT SHOCK ABSORBERS

Assembly diagrams
Figure 6
72694
SHOCK ABSORBER ASSEMBLY DIAGRAM

Figure 7
72695

(Models 120E..—130E..—140E..—150E..—160E..)

Figure 8
72696

(Models 180E..—190E..—260E..)

SHOCK ABSORBER MANNESMANN & SACHS
Length between eyebolts:

Open (mm) 618 ± 3
Closed (mm) 378 ± 3
Stroke (mm) 240
MODELS: 110EL../120EL..
SHOCK ABSORBER FICHTEL & SACHS WAY—ASSAUTO
Length between eyebolts and

extremity:
Open (mm) 709 ± 3 696 ± 3
Closed (mm) 409 ± 3 411 ± 3
MODELS: 120E../130E../ Stroke (mm) 300 285
120E..D/130E..D/
130E..RS
(continued)

SHOCK ABSORBER MANNESMANN & SACHS

extremity:
Open (mm) 714 ± 3
MODELS: 120E..—120E..D/ Stroke (mm) 300
130E..—130E..D/
140E..—140E..D/
150E..—160E..
SHOCK ABSORBER FICHTEL & SACHS

extremity:
Open (mm)
725 ± 3
Closed (mm)
435 ± 3
MODELS: 120E..D/ Stroke (mm)
290
130E..D/ (with semi—elliptical springs)
140E../140E..RS/
150E..—150E..RS

extremity:
Open (mm) 709 ± 3
Stroke (mm) 300
MODELS: 140E../140E..RS/ (with parabolic springs)
150E../150E..RS/
160E../160E..RS
ARVINMERITOR

extremity:
Open (mm) 820 ± 3
Stroke (mm) 350
MODELS: 180E../190EL../260E..

REAR LEAF SPRINGS

Figure 9
72520
REAR PARABOLIC LEAF SPRING ASSEMBLY

(Models: 110EL..—120EL..—120E..—130E..—130E..RS)
Figure 10
72522
REAR PARABOLIC LEAF SPRING ASSEMBLY

(Models: 120E..D—130E..D—140E..—140E..RS—150E..—150E..RS—160E..—160E..RS)
Figure 11
72697
REAR SEMI—ELLIPTICAL LEAF SPRING ASSEMBLY

(Models: 120E..—130E..)

Figure 12
72526

(Models: 120E..D—130E..D—150E..)
Figure 13
72524

(Model:180E..)

PARABOLIC LEAF SPRING SPECIFICATIONS AND DATA

REAR SUSPENSION — Models 110EL..—120EL..
mm
L Main leaf leaf length

(measured at eye centre) 1670 ± 3
Auxiliary spring length
(measured between ends) —
S Main leaf thickness (measured in the middle) 25

Second leaf thickness (measured in the middle) 25
Auxiliary leaf thickness (measured in the middle) 40
L
Main leaf static load deflection 14.75
Auxiliary leaf static load deflection 5
Static load 38.05 KN
Main leaf static load flexibility 5.77 mm/KN
Auxiliary leaf static load flexibility after operation 1.90 mm/KN

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

REAR SUSPENSION — Models 120E..—130E..

mm


L
Main leaf static load deflection 31
Auxiliary leaf static load deflection 3.5

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

REAR SUSPENSION — Models 120E..—130E..— 130E18RS

mm


L

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

REAR SUSPENSION —
Models 120E..—120E..D—130E..—130E..D—140E..—140E..RS—150E..—150E18RS—160E..—160E..RS
mm
L
Main leaf length 1680 ± 3

L

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

REAR SUSPENSION — Models 180E..

mm
L
Main leaf length 1680 ± 3

L

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

REAR SUSPENSION — Models 190EL..

mm
L Length of leaves 0
1680
(measured at eye centre) —6


Main leaf static load flexibility 3.12 ± 5% mm/kN
Auxiliary leaf static load flexibility after operation 1.343 ± 5% mm/kN

D 55.5 + 0.1
(bushing housing)
+ 0.6
D d
+ 0.3

SEMI—ELLIPTICAL LEAF SPRING SPECIFICATIONS AND DATA

REAR SUSPENSION 120E..—130E..
mm
L Main leaf length 1680 ± 3

Auxiliary leaf length 1254 ± 3
Main leaf thickness (1st—2nd) 14

S Main leaf thickness (3rd — 4th— 5th) 16
Auxiliary leaf thickness (1st → 11th) 10
L

D 55.5 + 0.1
(bushing housing)
d +0.6
D D = bushing external diameter 57.3
—0.2
d = bushing internal diameter 20.2 +0.3
—0

REAR SUSPENSION — Models 120E..D—130E..D—140E..—140E..RS—150E..
mm
L Main leaf length

1680 ± 3
Auxiliary leaf length (measured between ends)
1254 ± 3
S Main leaf thickness (1st → 7th) 15

width of leaves 80 ± 0.5
L
Main leaf eye internal diameter 55.5 +0,1

D
(bushing housing) 0
D d D = bushing external diameter +0.6

57.3
—0.2
d = bushing internal diameter 20.2 +0.3
0

REAR SUSPENSION 180E..
mm
L Main leaf length

1680 ± 3
Auxiliary leaf length (measured between ends)
1254 ± 3
S Main leaf thickness (1st →7th) 16

L

D 55.5 + 0.1
(bushing housing)
+0,6
57.3
D d D = bushing external diameter —0,2
20.2 +0,3
d = bushing internal diameter —0

HENDRICKSON REAR SUSPENSION Figure 14

Models 260E..
Removal
Operate as follows:
- Place the vehicle on a flat surface.

- Lock front wheels.
- Lift the rear part of the chassis and remove the wheels
of the intermediate and rear axle.
- Place a suitable lifting tool under the equalizer to be
removed.
- Disconnect the limit stop belt (12) loosening the screws
(2) and removing the brackets (1).
- Disconnect the shock absorbers (3) from the lower part
loosening the fasteners (10).
- Disconnect the suspension rubber springs (11)
loosening the screws (4).
- Remove the screws (5) and withdraw the relevant
bushes (8).
- Lower the equalizer by means of the lifting jack and
extract it from its seat.
Refitting
To reconnect follow the disconnection procedure
in the reverse order.
Note: Work properly with the lifter under the equalizer (6)
to obtain the centering of the axle box—type melting with the
silentblock (9) in order to ease the insertion of the relevant
bushes (8). Eventually lock the corresponding fasteners to
the following tightening torques:
- fastener (5) to 630 Nm;
- fastener (10) to 94 Nm;
- fastener (4) to 50 Nm.
74086
1. Limit stop belt locking bracket — 2. Bracket fastening screws — 3. Shock absorber — 4. Rubber spring fastening screws
— 5. Silentblock fastening screws — 6. Equalizer — 7. Axle box—type melting —
8. Silentblock bush — 9. Silentblock — 10. Shock absorber fastener — 11. Rubber spring — 12. Limit stop belt


REAR SHOCK ABSORBERS

Assembly diagrams
Figure 15
Section A—A
72698

Figure 16
77618

(Models 120E..—130E..—140E..—160E..—180E..—190EL..)

SHOCK ABSORBERS MANNESMANN & SACHS
Length between eyebolts

669 ± 3
Open (mm)
404 ± 3
Closed (mm)
265
Stroke (mm)
MODELS: 110EL../120EL..
SHOCK ABSORBERS FICHTEL & SACHS WAY — ASSAUTO
Length between eyelet centres

Open (mm) 714 ± 3 702 ± 3
Closed (mm) 414 ± 3 417 ± 3
Stroke (mm) 300 285
MODELS: 120E..
130E..—130E..RS/140E..
SHOCK ABSORBERS FICHTEL & SACHS

extremity:
Open (mm) 714 ± 3
MODELS: 120E../130E.. Closed (mm) 414 ± 3
120E..D/130E..D Stroke (mm) 300
130E..RS/140E..RS
150E..—150E..RS
160E..—160E..RS
ARVINMERITOR

extremity:
Open (mm)
666 ± 3
Closed (mm)
396 ± 3
Stroke (mm)
270
(with parabolic leaf springs)
MODELS: 180E../190EL..

extremity:
Open (mm) 716 ± 3
Stroke (mm) 300
MODELS: 180E..

Shock absorber features and data — Models 260E..
Figure 17
74087
SHOCK ABSORBER HENDRICKSON

FOR MODEL
Length L
Open (mm) 565 ± 3
260 E 28 KE Closed (mm) 362 ± 3
Stroke (mm) 203

DIAGNOSTICS
Main suspension operating problems:
1 — Noisy suspension 4 — The vehicle pulls to one side

2 — Irregular or excessive tyre wear 5 — The suspensions are too flexible
3 — The vehicle tends to shift to one side 6 — Creaking, knocking and noise in general
1 NOISY SUSPENSION
Insufficient lubrication. Lubricate carefully.

YES
NO
Noisy or inefficient shock absorbers. Overhaul shock absorbers.

YES
NO
Worn wheel bearings; wrong play. Carefully check bearings and replace worn parts.
YES
NO
Loosen leaf spring mounts. Check mounts and replace chassis fastening rivets, if
YES loose.
NO
Loose leaf spring bundle for broken central fastening Overhaul leaf springs and replace central pin and
pin. YES respective lock nut.
NO
Loose leaf spring bundle for broken spring fastening Check leaf spring fastening brackets and replace
bracket rivets. YES fastening rivets.

IRREGULAR OR EXCESSIVE
2
TYRE WEAR
Wrong tyre caster. Check caster and overhaul carefully.

YES
NO
Wrong wheel toe—in. Check correct wheel toe—in.

YES
NO
Low tyre pressure. Check and restore correct tyre inflation pressure.
YES
NO
Sudden accelerations. Accelerations should be gradual.

YES
NO
Unsuitable speed on gravel surfaces. Adapt speed to terrain.

YES
NO
Excessive wheel bearing play. Adjust play and lubricate bearing with TUTELA MR3
YES grease.
NO

THE VEHICLE TENDS TO

3
SHIFT TO ONE SIDE
Low, irregular tyre pressure. Check and restore correct tyre inflation pressure.
YES
NO
Wrong front wheel geometry. Check and overhaul wheel geometry.

YES
NO
Wrong front wheel bearing play. Adjust bearing play.

YES
NO
Ineffective hydraulic shock absorbers. Disassemble shock absorbers and overhaul or replace
YES them.
4 THE VEHICLE PULLS TO ONE SIDE
Incorrect load arrangement. Check load and arrange evenly on the load bed.
YES
NO
Wrong pressure of all tyres. Check and restore correct tyre inflation pressure.
YES
NO
Damaged leaf spring. Overhaul leaf spring and replace, as required.

YES

THE SUSPENSIONS ARE TOO

5
FLEXIBLE
Damaged central leaf spring union pin. Replace part and overhaul spring.
YES
NO
Damaged or broken spring leaves. Overhaul leaf spring and replace damaged parts.
YES Replace the entire leaf spring, if required.
CREAKING, KNOCKING
6
AND NOISE IN GENERAL
Loose leaf spring mounts. Check mounts and replace loose chassis fastening
YES rivets.
NO
Loose leaf spring bundle for broken central fastening Overhaul leaf springs and replace central pin and
pin. YES respective lock nut.
NO
NO
Worn bearing and/or excessive play. Carefully check bearings and replace damaged parts,
YES if required. Adjust wheel geometry.

TIGHTENING TORQUES
TORQUE
PART
Nm (kgm)
FRONT SUSPENSIONS
Leaf spring bracket fastening nut M16x1.5 238 ± 22.5 (24 ± 2.2)
Leaf spring bracket fastening nut M18x1.5 278 ± 27 (28 ± 2.7)
Leaf spring bracket fastening nut M20x1.5 464 ± 46 (47 ± 4.7)
Leaf spring to pad fastening nut 445 ± 45 (45 ± 4.6)
Leaf spring to front mount fastening nut 445 ± 45 (45 ± 4.6)
Shock absorber to chassis fastening nut M16 80 ± 8 (8 ± 0.8)
Shock absorber to axle fastening nut M16 80 ± 8 (8 ± 0.8)
Upper shock absorber fastening nut M14x1.5 64 ± 6 (6.4 ± 0.6)
Shock absorber to axle fastening nut M20 121 ± 12 (12.3 ± 1.2)
Shock absorber fork fastening nut 275 ± 55 (28 ± 5.6)
Connecting rod to chassis support screw nut 223 ± 22 (23 ± 2.3)
Connecting rod to sway bar fastening pin nut 311 ± 30 (34 ± 3)
Sway bar support to chassis fastening screw 76.5 ± 7.5 (8 ± 0.8)
Collar to sway bar support fastening screw M12 111 ± 11 (11 ± 1.1)
REAR SUSPENSION
Spring bracket on axle fastening nut M22x1.5 623 ± 62 (63.5 ± 6.3)
Leaf spring front fastening nut M20 445 ± 45 (45 ± 4.5)
Leaf spring to pad fastening screw M20 445 ± 45 (45 ± 4.5)
Rear mount to chassis fastening screw nut M16 227 ± 23 (23 ± 2.3)
Sway bar to axle mount fastening screw nut M20 311 ± 31 (32 ± 3)
Connecting rod to chassis support fastening screw nut M20 311 ± 31 (32 ± 3)
Upper shock absorber fastening nut M14x1.5 64 ± 6 (6.4 ± 0.6)
Lower shock absorber fastening nut M20 121 ± 12 (12.3 ± 1.2)
Shock absorber to chassis fastening nut M16 80 ± 8 (8 ± 0.8)
Shock absorber to axle fastening nut M16 80 ± 8 (8 ± 0.8)
Rebound to chassis fastening screw 77 ± 7 (7.9 ± 0.7)
Sway bar support to chassis fastening screw nut M12 63 ± 7 (6.4 ± 0.6)
Sway bar to connecting rod fastening nut M10 35.5 ± 3.5 (3.6 ± 0.3)
TOOLS
99346052 Bushing assembling tool

EXPERIMENTAL TOOLS
This heading covers the technical working drawings of the experimental tools (S.P.), used when overhauling the leaf springs
described in this section, that can be made in your repair shop.


500410 FRONT MECHANICAL Figure 18

SUSPENSION
REMOVAL—REFITTING
NOTE The mechanical suspension, shock absorber and
sway bar removal—refitting operations described in
the following paragraphs were carried out on
150E.. models and are, however, suitable for other
models fitting mechanical suspension systems.
Disconnect the battery cables before starting

! removal—refitting operations.
Removal
Arrange the vehicle on level ground, block the
rear wheels with wedges and proceed as follows:
- Loosen the front wheel fastening nuts, lift the vehicle and
position it on stands.
- Arrange hydraulic jack 99321024 under the wheels,
remove the fastening nuts and remove the wheels.
- Loosen the nuts (1 and 5), taking the pad (2) and remove
the shock absorber from the vehicle (4).
- Loosen the U—bolt (12) fastening nuts (9). Remove the
sway bar (8) supports (7) and remove the U—bolts taking
the plate (6) and the rebound (13).
- Loosen the nut and remove the front leaf spring (11)
anchoring pin (10) to the chassis mount.
- Loosen the nut and remove the rear pin (3) anchoring
the leaf spring (11) to the chassis, lower the axle and
remove the complete leaf spring.
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Lock nuts must be replaced and fastened at the
specified torque.
Check that:
- U—bolt threading is in good conditions. If
required, reface the threading or replace the
part.
90635

500450 REAR MECHANICAL SUSPENSION Figure 19

REMOVAL—REFITTING

Removal
front wheels and proceed as follows:
- Loosen the rear wheel fastening nuts, lift back of the

vehicle and position it on stands.
- Loosen the nuts (3) and remove the fastening U—bolts
(4).
anchoring pin (6) to the chassis support (7).
the leaf spring (5) to the chassis (1), lower the axle and
remove the complete leaf spring.
Refitting

specified torque.
Check that:
- U—bolt (4) threading is in good conditions. If
part.
79453

500910 FRONT SHOCK ABSORBERS

Removal Refitting
Figure 20
72829
Loosen the nuts (1 and 4), take the rebound (3) and remove
the shock absorber (2).
Refitting

528930 FRONT SWAY BAR

500940 REAR SHOCK ABSORBERS Removal
Removal
Figure 21 Figure 22
72830
Loosen the nuts (1 and 3) and remove the sway bar (4) with
anchoring rod (2).
Refitting

72702
Loosen the nuts (1 and 3) and remove the shock absorber (2).

528960 REAR SWAY BAR REPLACING LEAF—SPRING BUSHINGS

(For vehicles with leaf—springs provided with
bushings having a metal shell)
Removal
Figure 23 Arrange vehicle in safety conditions either on flat ground or

elevator bridge.

REAR LEAF—SPRING BUSHINGS
Suitably lock vehicle front wheels.
Figure 24
72703
Loosen the nut and remove the axle support fastening pin
(3).
Remove the nut (1), remove the pin and remove the sway
bar with reaction rod (2).
Refitting
99183
Refit by reversing the removal sequence. Fasten Lift rear axle by hydraulic jack (2) and position two stands
screws and nuts at the specified torque. (1) under the chassis in the area behind rear axle, as illustrated
in figure.
By hydraulic jack (2), unload the weight of suspension from
REPAIRS leaf—springs.
- Do not replace leaves if more than one leaf is

! broken. Disconnecting rear bushings
- Do not replace leaves if there are less than three Figure 25
leaves in the faulty spring.
- Auxiliary leaf springs with main spring and
auxiliary springs are an exception to the
specification above. In other words, they can be
replaced also if the total number of leaves in the
auxiliary spring is less than three.
- Leaf springs consists on main leaves and
supplementary leaves should be considered as
leaf springs consisting of a main spring (main
leaves) and auxiliary spring (supplementary
leaves) reason for which the main leaves can be
replaced if there are at least three while
supplementary leaves can be replaced in any
case.
- The remaining leaves of the faulty spring which
are not replaced must not present superficial 99184
alterations to visual inspection nor alternations
of shape which may compromise compliance Unscrew bolts (1) and (2), unthread the screws, paying
with original construction principles. attention not to damage the thread, and recover shackles (3).
Repeat same procedure on vehicle opposite side.

Figure 26 Figure 27
99186
99185
Screw up nut (1), as illustrated in figure.
Apply tool Sp 2507 (1), complete with 19 mm 12—point Then, screw up special nut (2) in order to unthread spring
wrench (2), inserted from special slit and engaged into bushing from support seat.
hexagonal section, that is present on the screw, to rear
support bushing in order to stop possible rotation of the tool
itself. NOTE Next figure shows a section with the correct
position of the components of tool SP 2507, that
is complying with the dismounting of bushings.
Figure 28
99187
1. Special nut 6. Washer

2. Thrust bearing 7. Nut
3. Bushing 8. Bushings
4. Screw 9. Bushing metal shell
5. Hexagonal section for 19 mm wrench.

Figure 29
99188
NOTE In the case of a missing extraction of the metal shell

of outer bushing, below described procedure has
to be performed.
Sandwich retaining spring ring (1) for 45.5 mm diameter holes

between bushing metal portions.
NOTE Next figure shows a section with the correct position of the components of tool SP 2507, that is complying with the
dismounting of bushings.
Figure 30
99189
1. Special nut 6. Retaining spring ring

2. Thrust bearing 7. Block
3. Bushing 8. Bushing metal shell
4. Screw 9. Washer
5. Block 10. Nut

Figure 31 Reconnecting rear bushings
NOTE At reconnection, only new type spring bushings

must be mounted.
Figure 32
99190
Apply tool SP2507 (1) complying as illustrated in last figure

with the extraction of outer bushing metal shell.
Remove the tool and pull out the metal shell of remaining
inner bushing by ∅ 45 mm cylindrical beater.
Repeat described procedure on vehicle opposite side.
99191
Apply either soaped water or vaseline grease both on spring

bushing surfaces and into leaf—spring housing hole.
Position new spring bushings (1) and spacer (2), and apply
tool 99346052.
Mount spring bushings by operating on nut (3).
NOTE Next figure shows a section with the correct position of the components of tool 99346052 that is complying with the
remounting of bushings.
Figure 33
99192
1. Spring bushing 4. Screw

2. Spacer 5. Washer
3. Special nut 6. Nut

Figure 34 Figure 36
99195
Apply tool Sp 2507 (1), complete with 19 mm 12—point

99193
wrench (2), inserted from special slit and engaged into
hexagonal section, that is present on the screw, to front
Position shackles (3), screw up securing bolts (1) and (2) and support bushing in order to stop possible rotation of the tool
tighten at prescribed torque. itself.
Repeat same procedure on vehicle opposite side. Then, unscrew special nut (3) in order to unthread the spring
bushing from the housing.
NOTE In the case of a missing extraction of the metal shell

of the bushings, above procedure described for
Disconnecting front bushings rear spring bushings has to be performed.
Figure 35
Reconnecting front bushings

must be mounted.
Figure 37
99194
Stop nut (1) located inside side member by a suitable wrench.

Unscrew screws (2) and unthread it, paying attention not to
damage the thread.
Then, lower the hydraulic jack in order to unthread the
leaf—springs from the support.
99196

tool 99346052 (2).

Disconnecting front bushings

Position compression plates (1) with the milling
Unscrew securing bolt and unthread the screws, paying
directed upwards as illustrated in figure to facilitate
attention not to damage the thread.
the insertion of the leaf—spring complete with spring
Repeat same procedure on vehicle opposite side
bushings into the seat without risking to damage
Then, lower the hydraulic jack in order to unthread the
bushing edges.
leaf—springs from the support.
Figure 38 Figure 40
99199
99209
Cautiously lift the hydraulic jack and correctly position the Apply tool Sp 2507 (1), complete with 19 mm 12—point
leaf—springs in their seats on both vehicle sides. wrench (2), inserted from special slit and engaged into
Screw up securing bolt and tighten at prescribed torque. hexagonal section, that is present on the screw, to front
support bushing in order to stop possible rotation of the tool
itself.
Then, unscrew special nut (3) in order to unthread the spring
DISCONNECTING AND RECONNECTING bushing from the housing.
FRONT LEAF—SPRING BUSHINGS Repeat same procedure on vehicle opposite side.
Suitably lock vehicle rear wheels.
Figure 39 NOTE In the case of a missing extraction of the metal shell
of the bushings, above procedure described for
rear leaf—springs has to be performed.
99198
Remove front bumper, unscrew securing screws and

disconnect cross member (1) supporting the wiring harness.
Lift front axle by a hydraulic jack and position two stands (2)
as illustrated in figure under chassis front cross member.
Operate on front axle by the hydraulic jack until the weight
of suspension is unloaded from leaf—springs.

Reconnecting front bushings Figure 43
At reconnection, only mount new type spring

bushings.
Position compression plates with the milling
directed upwards as illustrated in figure to facilitate
the insertion of the leaf—spring complete with spring
bushings into the seat without risking to damage
bushing edges.
Figure 41
99202
Operating on both sides, unscrew securing nuts (1) and

remove air filter assembly (2).
Figure 44
99200

tool 99346052 (2).
Cautiously lift the hydraulic jack, then correctly position the
leaf—springs in their seats.
Screw up securing bolt and tighten at prescribed torque.
99203
Unscrew securing nuts (1) and remove the support of air

Disconnecting rear bushings filter assembly (2).
Figure 42
Figure 45
99204
99201
Operating on vehicle left side, loosen tightening clamps (1) Unscrew bolts (1) and (2), unthread the screws, paying
and (4) and disconnect air intake spring sleeves (2) and (3). attention not to damage the thread, and recover shackles (3).

Figure 46 Figure 48
99205 99207
Apply tool Sp 2507 (1), complete with 19 mm 12—point Unscrew bolts (1) and (2), unthread the screws, paying
wrench (2), inserted from special slit, on rear support attention not to damage the thread, and recover shackles (3).
bushings in order to stop possible rotation of the tool itself. Perform same procedure on opposite side spring bushings.
Repeat same procedure for leaf—spring bushings.
Operating on vehicle left side:
drain diesel oil from the tank into a suitable vessel. Reconnecting front bushings

must be mounted.
Figure 47
Figure 49
99206
Unscrew securing nuts and disconnect the lower ends of

anchoring strips (1) and (2).
Shift the tank, paying attention not to damage the pipings.
99208
Position new spring bushings (1) complete with spacer and

apply tool 9934605 (2).
Mount spring bushings operating on nut (3).


EUROCARGO TECTOR 12—26 t FRONT AND REAR PNEUMATIC SUSPENSIONS 53
Print 603.93.391
5004 Front and rear

pneumatic suspensions
Page
PNEUMATIC SUSPENSIONS . . . . . . . . . . . . . . . 55
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 55
PNEUMATIC SUSPENSION ASSEMBLIES . . . . . 55
FRONT PNEUMATIC SUSPENSION . . . . . . . . . 55
LEAF SPRING SPECIFICATIONS AND DATA . 56
120E..FP/130E..FP/140E..FP/150E..FP . . . . . . . . 56
FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . 57
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . 57
REAR PNEUMATIC SUSPENSION . . . . . . . . . . 58
REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 62
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . 62
- Electronically controlled rear pneumatic suspension
diagram (For Models 110EL..P—120EL..P) . . . . 64
- Cable—and—trunk diagram of pneumatic rear
suspensions (For Models 120E..P—130E..P—140E..P—
150E..P—160E..P—180E..P—190EL..P) . . . . . . . . . 65
- Electronically controlled FULL PNEUMATIC
suspension diagram (For Models
120E..FP—130E..FP—140E..FP—150E..FP) . . . . . . 66
CHASSIS LIFTING/LOWERING
AND LEVELLING . . . . . . . . . . . . . . . . . . . . . . 67
- Remote control . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOTE CONTROL DESCRIPTION
AND OPERATION . . . . . . . . . . . . . . . . . . . . 68
- Lifting/lowering the chassis . . . . . . . . . . . . . . . 68
- Chassis self—leveling . . . . . . . . . . . . . . . . . . . . . 68
- Level ”M1” — ”M2” . . . . . . . . . . . . . . . . . . . . . 68
VEHICLE MAIN COMPONENT ARRANGEMENT 69
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 71

54 FRONT AND REAR PNEUMATIC SUSPENSIONS EUROCARGO TECTOR 12—26 t
Print 603.93.391/A
Page
Page
REAR AIR SPRINGS . . . . . . . . . . . . . . . . . . . . . . 81
- Rear pneumatic suspension of the HENDRICKSON
type (Models 110EL..P — 120EL..P) . . . . . . . . . . 74 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
MAIN PNEUMATIC SYSTEM FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . 82
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 76
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
- Controlled—pressure valve . . . . . . . . . . . . . . . . 76
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
- Low pressure indicator . . . . . . . . . . . . . . . . . . 76
FRONT AIR SPRINGS . . . . . . . . . . . . . . . . . . . . . 82
- Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
- Electro—pneumatic front axle distributor for
4 x 2 FP vehicles . . . . . . . . . . . . . . . . . . . . . . . 76 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 FRONT PNEUMATIC SUSPENSION
- Front axle lifting . . . . . . . . . . . . . . . . . . . . . . . . 77
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
- Front axle lowering . . . . . . . . . . . . . . . . . . . . . 77
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
- Self—leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
FRONT SWAY BAR . . . . . . . . . . . . . . . . . . . . . . 83
- Electro—pneumatic rear axle distributor
for 4 x 2 P/FP vehicles . . . . . . . . . . . . . . . . . . . 78 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
- Rear axle lifting . . . . . . . . . . . . . . . . . . . . . . . . . 78 REAR PNEUMATIC SUSPENSION
- Rear axle lowering . . . . . . . . . . . . . . . . . . . . . . 78
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
- Self—leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
- Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REAR AIR SPRINGS . . . . . . . . . . . . . . . . . . . . . . 85
- Air springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
- ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
REAR PNEUMATIC SUSPENSIONS
REMOVAL—REFITTING . . . . . . . . . . . . . . . . . 80 REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 85
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 81 REAR SWAY BAR . . . . . . . . . . . . . . . . . . . . . . . . 86
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Revi — July 2005
Print 603.93.391
PNEUMATIC SUSPENSIONS
INTRODUCTION
Pneumatic suspensions are very flexible and offer All operations depend on certain working conditions and
considerable vibration damping features, regardless of vehicle respective safety of the connected systems.
load. By effect of the system self—adjusting features, the The ECAS ECU automatically controls the level (distance
”chassis—road surface” distance is kept constant. A specific from the road surface) of the chassis by means of the real
button can be used to vary the ”chassis—road surface” values provided by sensors, comparing them to the nominal
distance, and consequently the vehicle load surface, in values stored in the memory.
pneumatic suspension systems. In the event of distancing or trim changes, the ECU controls
the electrical—pneumatic units to correct the real level with
In addition to the advantages of pneumatic suspensions, the
respect to the nominal values previously set or stored by the
ECAS system ensures:
driver.
- considerable air consumption reduction; The system has a remote control for lifting/lowering and
levelling the chassis. The system can be worked with the
- prompt response to adjustments;
vehicle either stationary or moving.
- system simplicity; In addition to lifting, lowering and levelling, the system can be
used to store other chassis trim levels, which can be recalled
- high safety; when required.
- complete system diagnostics.
The ECAS (Electronically Controlled Air Suspension)
system automatically controls the nominal vehicle pneumatic
suspension level.
PNEUMATIC SUSPENSION ASSEMBLIES
NOTE Models equipped with mixed suspension systems (front mechanical suspensions and rear pneumatic suspensions)
fit the front suspension of the corresponding mechanical suspension models.
FRONT PNEUMATIC SUSPENSION
Figure 1
72530
Dimension x = 60 mm
FRONT PNEUMATIC SUSPENSION ASSEMBLY
(Models 120E..FP/130E..FP/140E..FP/150E..FP)

LEAF SPRING SPECIFICATIONS AND DATA

FRONT SUSPENSION — MODELS 120E..FP/130E..FP/140E..FP/150E..FP
mm

S Leaf thickness
1st leaf (measured in the middle) 30
2nd leaf (measured in the middle) 23
NEW SPRING CHECK DATA: 54

Static load deflection 9.818 mm/KN

D 55.5 + 0.1
(bushing housing)
+0.6
D d —0.2
+0.3
—0

FRONT SHOCK ABSORBERS

Assembly diagrams
Figure 2
72792

(Models 120E..FP/130E..FP/140E..FP/150E..FP)
Length between the ends

Open (mm) 588 ± 3
Stroke (mm) 230
MODELS: 120E..FP/130E..FP
140E..FP/50E..FP

Print 603.93.391/A
REAR PNEUMATIC SUSPENSION

Figure 3
72529
Dimension x = 187 mm
REAR PNEUMATIC SUSPENSION ASSEMBLY
(NEWAY for Models 110EL..P/120EL..P)

Revi — July 2005
Print 603.93.391
Figure 4
99003
Dimension x = 185 mm
(HENDRICKSON for Models 110EL..P/120EL..P)

Figure 5
84421
Dimension x = 77 mm with axle MS10—164E

47 mm with axle MS10—144E
60 mm with lower reaction rod alignment (A)

(Models 120E../130E../140E../150E../160E..)

Figure 6
72786
Dimension x = 65 mm with axle MS13—165

54 mm with lower reaction rod alignment (A)

(Models 180E..P/190EL..P)

REAR SHOCK ABSORBERS

Assembly diagrams
Figure 7
72788

(Models 110EL..P—120EL..P)
Figure 8
72789

(Models 120E..P/FP — 130E..P/FP — 140E..P/FP — 150E..P/FP — 180E..P — 190EL..P)

Print 603.93.391/A
SHOCK ABSORBERS HENDRICKSON
Length between eyebolts and extremity:

Open (mm) 544.5 ± 3
Closed (mm) 350.1 ± 3
MODELS: 110EL..P/120EL..P Stroke (mm) 194.4
with suspensions of the
HENDRICKSON type
SHOCK ABSORBERS MANNESMANN — SACHS
ARVINMERITOR
Length between eyebolts and extremity:

Open (mm) 674 ± 3
MODELS: 120E..P/FP—130E..P/FP Stroke (mm) 270
140E..P/FP—150E..P/FP
160E..P—180E..P
190EL..P

Revi — July 2005
Print 603.93.391
Electronically controlled rear pneumatic suspension diagram

(For Models 110EL..P—120EL..P)
Figure 9
7 8 9
62390
1. Limited return air vent valve — 2. Manual condense bleeding valve — 3. Air reservoir — 4. Pressure test point — 5. One—way
valve — 6. Low pressure indicator — 7. Electro—pneumatic distributor — 8. Electronic levelling valve — 9. Axle air spring

Cable—and—trunk diagram of pneumatic rear suspensions

(For Models 120E..P—130E..P—140E..P—150E..P—160E..P—180E..P—190EL..P)
Figure 10
72787
1. Limited return air vent valve — 2. Manual condense bleeding valve — 3. Air reservoir — 4. Pressure test point —
5. One—way valve — 6. Low pressure indicator — 7. Electro—pneumatic distributor — 8. Electronic levelling valve —
9. Axle air spring

Electronically controlled FULL PNEUMATIC suspension diagram

(For Models 120E..FP—130E..FP—140E..FP—150E..FP)
Figure 11
78797
1. Limited return air vent valve — 2. Manual condense bleeding valve — 3. Air reservoir — 4. Pressure test point —
5. One—way valve — 6. Low pressure indicator — 7. Electronic levelling valve — 8. Front axle air spring —
9. Front axle electro—pneumatic distributor — 10. Rear axle electro—pneumatic distributor — 11. Rear axle air spring

CHASSIS LIFTING/LOWERING AND LEVELLING

Remote control
Figure 12
78799
The traditional controls arranged next to the driver’s seat are 1) Front axle selection *
replaced with a remote control on the left—hand side of the 2) Memory level ”1”
driver’s seat. 3) Lift chassis
This device is used to manage the various chassis trim 4) Lower chassis
functions. 5) STOP
The remote control can be extracted to make the selection 6) Level chassis
from the driver’s seat or from the ground. 7) Memory level ”2”
The remote control consists of a set of buttons and two 8) Rear axle selection
warning lights:
The remote control is connected to the system by means of
A) Front axle selection green warning light
a four—pole connector:
B) Rear axle selection green warning light
Pin 1 Power positive
Pin 2 Negative
Pin 3 Communication line with ECU
Pin 4 Communication line with ECU
See ”Operation” for remote control instructions.
* full pneumatic vehicles only

REMOTE CONTROL DESCRIPTION AND OPERATION

Lifting/lowering the chassis Chassis self—leveling
Figure 13 This operation can be carried out at any speed.
Proceed as follows to level the chassis:
- Press button (1 or 8, Figure 13) to select an axle, the
respective warning light ”A” or ”B” will come on.
- Press button (6, Figure 13).
The yellow warning light on the instrument panel will go out
when the operation is recalled to signal that the chassis has
been levelled.
This condition and the respective warning will be kept on,
also if the ignition key is switched on and off.
The ECU will automatically re—establish chassis level if the
button is not pressed at speeds over 20 km/h.
78800
Level ”M1” — ”M2”

This operation can only be activated at speeds slower than The system can store two additional trim levels ”M1” and M2”
20 km/h. as needed.
These two positions can be recalled only at speeds lower than
The set trim will be kept constant over this speed. 20 km/h.
Proceed as follows to lift/lower the chassis: Proceed as follows to activate the levels:
- Press button (1) and/or (8) to select the required axle. - Press button (1 or 8, Figure 13) to select an axle, the
The respective warning light ”A” and/or ”B” will come respective warning light ”A” or ”B” will come on.
on. - Press button (3 or 4, Figure 13).
- Press button (3) or (4) to reach the required level. During this operation, the yellow warning light on the
All solenoid valves will be de—energised and returned to instrument panel will light up signalling that trim has not been
home/hold condition when button (3) or (4) is released. reached.
During this operation, the yellow warning light on the Proceed as follows to store trim levels ”M1” and M2”:
instrument panel will light up signalling that trim has not been - Press button (1, Figure 13) to select the front axle, the
reached. respective warning light ”A” will come on.
This condition and the respective warning will be kept on, - Press button (3 or 4, Figure 13) to reach the required
also if the ignition key is switched on and off. level.
The maximum lift limit is regulated by level sensors according - REPEAT THE OPERATIONS ON THE REAR AXLE.
to the calibration set by the ECU.
- Hold button pressed button (5, Figure 13).
- Press button (2 or 7, Figure 13).
- Release button (2 or 7, Figure 13) and then button (5,
NOTE Button description refers to FP vehicle remote Figure 13).
controls.
In an emergency, press button (5, Figure 13) to stop

! levelling operations.

VEHICLE MAIN COMPONENT ARRANGEMENT

Figure 14
78951
1. Controlled pressure valve — 2. Front axle level sensor — 3. Front air spring — 4. Electro—pneumatic distributor —
5. Rear air spring — 6. Check valve — 7. Rear axle electro—pneumatic distributor — 8. Reservoir — 9. Pressure test point —
10. Rear axle level sensor


DESCRIPTION
Limited return controlled pressure valve
- Type: MARELLI — WABCO 434 100 232 0 — KNORR DR 4248
Opening pressure 8.5 bar
Air reservoir
Front suspension 15 litres
Rear suspension 15 litres
Level sensor
- Type: WABCO 441 050 012 0
Power voltage Pulse 8 ÷ 16V
Current intake Max 90 mA
Lever working range Max 100°
Electro—pneumatic distributor
- Type: WABCO 472 880 001 0 (for P models, on rear axle for FP models)
WABCO 472 880 020 0 (on front axle for FP models)
Working temperature range
— 40 °C ÷ + 80 °C
Working pressure range (input)
5 ÷ 13 bar
Maximum dynamic pressure (output control)
20 bar
Power voltage
24 V
Check valve
- Type: WABCO WESTINGHOUSE 434 014 000 0 — FERNA F100718
Working pressure range Max 20 bar
Working temperature range — 40 °C ÷ + 80 °C
Pressure test point
- Type: RAUFOSS 6237776 — SIRIT VFM 1615 — WABCO 463.703.114.0
Working temperature range — 40 °C ÷ + 80 °C
Electronic control unit
- Type: WABCO
Power voltage 18 ÷ 32 V
Working temperature range — 40 ÷ 70 °C
Manometric switch for low air pressure
- Type: TDS F13016
Working voltage 12/24 V
Permitted electric load 0.001 to 1 A
Maximum operating pressure 12 bar

DIAGNOSTICS
Main pneumatic suspension operating problems:
1 — Low or irregular pneumatic system recharging
2 — Irregular vehicle trim
3 — Chassis out of trim warning light on at speeds faster
than 20 km/h
LOW OR IRREGULAR PNEUMATIC

1 SYSTEM RECHARGING
Leaking or broken pneumatic system pipes. Close or replace loose or damaged fittings.
YES Replace broken or damaged tubes.
NO
Inefficient air compressor operation. Overhaul or replace the air compressor.

YES
NO
Inefficient pressure regulator built into A.P.U. Replace A.P.U.

YES
NO
Inefficient controlled pressure valve operation. Replace the controlled pressure valve.
YES
2 IRREGULAR VEHICLE TRIM
Leaking or broken pneumatic system pipes. Close or replace loose or damaged fittings. Replace
YES broken or damaged tubes.
NO
Wrong pneumatic and/or electrical connections. Locate wrong connections and restore.
YES
(continued)

Inefficient level sensor operation. Adjust linkages and replace level sensor, if required.
YES
NO
Inefficient electro—pneumatic distributor operation. Replace the electro—pneumatic distributor.

YES
NO
Inefficient ECU operation. Replace the ECU.

YES
CHASSIS OUT OF TRIM WARNING

3 LIGHT ON AT SPEEDS FASTER THAN
20 KM/H
Leaking or broken pneumatic system pipes. Close or replace loose or damaged fittings. Replace
YES broken or damaged tubes.
NO
Damaged electrical connections. Restore the electrical wiring.

YES
NO
Inefficient remote control operation. Replace the remote control.

YES
NO
Inefficient sensor operation. Adjust linkages and replace level sensor, if required.
YES
NO
Inefficient ECU operation. Replace the ECU.

YES

Print 603.93.391/A
TIGHTENING TORQUES
TORQUE
PART
Nm (kgm)
Front pneumatic suspension (Models 120E..FP/130E..FP/140E..FP/150E..FP/160E..FP)
Rebound fastening screw nut 62.5 ± 6.5 (6.25 ± 0.65)
Spring brackets fastening screw nut 463.5 ± 46.5 (46.35 ± 4.65)
Spring to front mount fastening screw nut 336.5 ± 33.5 (33.65 ± 3.35
Spring to pad fastening screw nut 336.5 ± 33.5 (33.65 ± 3.35)
Rear pneumatic suspension (Models: 120E..P—FP/130E..P—FP/140E..P—FP/150E..P—FP/160E..P/FP)
Reaction triangle to chassis fastening screw 352.5 ± 32.5 (35.25 ± 3.25)
Longitudinal arm bar fastening screw nut 418 ± 42 (41.8 ± 4.2)
Air spring support arm to air spring fastening screw nut 90 ± 10 (9 ± 1)
Air spring to chassis fastening screw nut 92 ± 9 (9.2 ± 0.9)
Nut for screw fastening the air—operated spring support arm to the rear axle. 545 ± 55 (54.5 ± 5.4)
Rear pneumatic suspension (Models: 180E..P/190EL..P)
Axle to air spring support arm fastening screw nut 845  170 (84.5 17)
Reaction triangle to axle fastening screw 290 30 (29  3)
Reaction bar fastening screw nut 418  42 (42.6  4.3)
Support arm to air spring fastening screw nut 100  10 (10  1)
Air spring to chassis fastening screw nut 92  9 (9.4  0.9)
Sway bar to spring support arm fastening pin nut 373.5  37.5 (38  3.8)
Sway bar support to chassis fastening screw nut (M16) 226.5  22.5 (23  2.3)
Sway bar support to chassis fastening screw nut (M12) 92  9 (9.4  0.9)
Connecting rod to chassis support fastening pin nut 359  36 (36.6  3.7)
Upper shock absorber fastening pin nut 118  12 (11.8  1.2)
Lower shock absorber fastening pin nut 187.5  18.5 (18.7  1.9)
Reaction triangle to chassis support fastening screw 418  42 (42.6  4.3)

Revi — July 2005
Print 603.93.391
Rear pneumatic suspension of the HENDRICKSON type (Models 110EL..P — 120EL..P)

Figure 15
99004
TORQUE
PART
Nm (kgm)
1 Fastening the air spring to the chassis nut 92 ± 9 (9.2 ± 0.9)
screw 112 ± 12 (11.2 ± 1.2)
2 Shock—absorber lower fastening nut 157 ± 16 (15.7 ± 1.6)
screw 193.5 ± 19.5 (19 ± 1.9)
3 Fastening the air spring to the support 50 ± 5 (5 ± 0.5)
4 Bracket fastening 445 ± 45 (44.5 ± 4.5)
5 Fastening the arm to the suspension support nut
772.5 ± 77.5 (77.2 ± 7.7)
screw
6 Bar fastening nut 201.5 ± 15.5 (20 ± 1.5)
screw M16x90 226.5 ± 22.5 (22.6 ± 2.3)
7 Fastening the support to the chassis nut 226.5 ± 22.5 (22.6 ± 2.3)
screw 278 ± 28 (27.8 ± 2.8)
8 Bar fastening screw M16x60 259 ± 26 (26 ± 2.6)

TOOLS
6810
6 81012 4 12
2 1614
6 8 10 4
2 14 0
4 12
2 14 0 16
0 16
810
8 10 12
46 12 14
16
2 14
0 16
99305117 Pneumatic circuit check instruments
99321024 Wheel removal—refitting hydraulic trolley
99387050 Polyamide tube cutter

MAIN PNEUMATIC SYSTEM

COMPONENTS
Controlled—pressure valve 793319 Check valve
Figure 16 Figure 18
1 2
20437 33987
The limited return valve has two functions: This valve allows the passage of compressed air in the direc-
tion of the arrow on the valve body, preventing it from flow-
- It cuts off the reservoir compressed air flow supply when ing back.
the pressure drops under a certain value (calibrated) due
to failures or excessive consumption.
- It supplies the reservoirs as soon as the braking system
reaches a value ensuring perfect brake application.
Electro—pneumatic front axle distributor for

Low pressure indicator 4 x 2 FP vehicles
Figure 17 Figure 19
52723 78802
This pressure switch is located near the utility air reservoir on This components consists of a control solenoid valve and
the pneumatic suspension delivery tube. two pneumatic distributors for managing both sides of the
axle. A calibrated hole is provided between the two outputs
to prevent pressure leakage between air springs and
consequent internal connection axle stabilisation.
The electro—pneumatic distributor is connected to the
system by means of a three—pole connector.

Figure 20 Operation
Figure 21
78803 78804
Pneumatic connections Front axle lifting

11 — from air reservoir The ECU energises the solenoid valve supplying the
21 — from axle electro—pneumatic distributor distributors via the air duct (11) from the reservoir and
22 — to air spring on right—hand side energising the axle electro—pneumatic distributor solenoid
23 — to air spring on left—hand side
valve ”A” (Figure 24) to supply the first distributor, closes the
Electrical connections relief to atmosphere (3, Figure 24) and opens the air intake
6.1 — Solenoid valve power positive (11, Figure 24) from the reservoir.
6.2 — Negative In this way, the air from duct (21, Figure 24) to duct (21)
6.4 — Free supplies the axle air springs via ducts (22 and 23).
Front axle lowering

In this case, the ECU energises the solenoid valve supplying
the distributor, allowing the air to be relieved from the air
springs from duct (21) to duct (21, Figure 24) and opens the
air input (3, Figure 24), which is open because the axle
electro—pneumatic solenoid valve ”A” (Figure 24) is
de—energised.
Self—leveling
The ECU, according to the position of the level sensors,
controls the front axle electro—pneumatic distributor
solenoid valve and the rear axle electro—pneumatic
distributor solenoid valves accordingly for lifting or lowering
in order to reach vehicle levelling or stored positions ”M1”
or ”M2”.

Electro—pneumatic rear axle distributor

for 4 x 2 P/FP vehicles
Figure 22 Operation
Figure 24
78805
This components consists of three control solenoid valves

”A”, ”B”, ”C” and three pneumatic distributors.
Solenoid valve ”A” manages the supply/discharge distributor.
Solenoid valve ”B” manages the right—hand chassis trim
distributor.
Solenoid valve ”C” manages the left—hand chassis trim
distributor.
70117
The distributor is connected to the system by means of a
four—pole connector.
Rear axle lifting

Figure 23 The ECU energises solenoid valve ”A” supplying the first
distributor that closes the relief to atmosphere (3) and opens
the air intake (11) from the reservoir.
The ECU then energises solenoid valve ”B” and ”C” for
supply the second and third distributor and to consequently
supply the rear axle air springs via ducts (22 and 23).
NOTE 4x2 P vehicles

Duct (21) is capped.
4x2 FP vehicles
Duct (21) is connected to front axle
electro—pneumatic distributor duct (14) for
supplying the air springs.
Rear axle lowering

In this case, the ECU energises solenoid valves ”B” and ”C”
supplying the second and third distributor, allowing the air to
78806
be relieved from the air springs from duct (3), which is open
Pneumatic connections because the axle electro—pneumatic solenoid valve ”A” is
11 — from air reservoir de—energised.
21 — to axle electro—pneumatic distributor
22 — to air spring on right—hand side
23 — to air spring on left—hand side Self—leveling
Electrical connections The ECU, according to the position of the level sensors,
6.1 — Solenoid valve ”A” power positive controls solenoid valves ”A”, ”B” and/or ”C” accordingly for
6.2 — Solenoid valve ”B” power positive lifting or lowering in order to reach vehicle levelling or stored
6.3 — Solenoid valve ”C” power positive positions ”M1” or ”M2”.
6.4 — Common negative
Level sensor 5007 Air springs

Figure 25 Figure 27
62421 30106
The level sensor consists of a coil fastened to the chassis and This elastic element contains pressurised air and changes its
a piston. extension, regardless of the applied load.
The piston is moved by an eccentric gear and a lever
connected to the axle when the height changes, whereby ECU
changing the inductance of the coil.
These variations are used by the ECU to intervene in the The ECU manages the various chassis positions according to
various phases of system work. the requests made by the driver by means of the remote
The sensor connection lever is fixed and cannot be adjusted. control.
When the key switch is switched on, the electronic control
unit performs a system check by powering, during ~ 2
seconds, the red warning light (pneumatic suspension low
Figure 26 pressure) found on the dashboard. If an anomaly is found, the
CLUSTER display will show the corresponding symbol,
according to the type of anomaly: a yellow symbol on the left
portion (anomalies and faults not critical), or a red symbol on
the right portion (critical faults). The ECU must keep the
levels required by the driver constant and, at the same time,
reduce air consumption, by cyclically monitoring the level
sensor signals, cutting in ONLY when the discrepancy
between sensors is > 5 counts.
Correction will be made with a delay of:
D approximately 1 second when the vehicle is stationary
D approximately 60 seconds when the vehicle is moving.
The ECU will store a plausibility error if the level is not
restored within a maximum time of 30 seconds.
NOTE This is ONLY valid providing that the vehicle has

been moving for at least five minutes, because the
system details checks to allow recharging the
pneumatic system.
[conteggi]
When braking, the ECU receives a signal from the brake light
switch, interrupting automatic trim adjustments. The ECU is
equipped with an extremely advanced self—diagnostic system
which is capable of recognising and storing system failures
(also intermittent), according to environmental conditions,
[gradi] during operation, for ensuring correct, reliable repairs, in
addition to blink codes displayed by the red warning light for
preliminary troubleshooting. Diagnostic, programming and
error memory deletion operations, etc., can be carried out
using the MODUS computerised diagnostic station. All
system components, except for the steering system, are
connected to the ECU, by means of a comb connector. The
62422 pin numbering and ECU type change according to the version.
Sensor nominal characteristic curve according to angular
lever movement

Print 603.93.391/A
500730 REAR PNEUMATIC SUSPENSIONS REMOVAL—REFITTING

(HENDRICKSON for Models 110EL..P—120EL..P)
Figure 28
105152
Arrange the vehicle on level ground and block the front - Loosen air spring fastening nut (9).
wheels.
- Unscrew securing nut (3) and recover washer (2) and
Remove the wheel fastening nut guards and loosen the wheel
collar(1).
fastening nuts.
Unthread anchoring pin and remove arm(4).
Lift the back of the vehicle and position it on stands.
Arrange hydraulic jack 99321024 under the wheels, remove
the wheel fastening nuts and remove the wheels.
Position a hydraulic jack provided with support 99370617 Refitting
under rear axle such as to support it during operations.
Removal
The following procedure described for one arm is valid for
both.
- Loosen nut (11), remove the anchoring pin and detach
shock absorber (10) from the support on the arm.
- Loosen the fastener and remove the level sensor tie—rod
(5).
- Unscrew nuts (7) and remove support (8).
- Remove U bolts (6) and recover anchoring cap (12).

Revi — July 2005
500940 REAR SHOCK ABSORBERS 500731 REAR AIR SPRINGS

Removal Removal
Figure 29
Figure 30
105153 105154
Unscrew higher and lower nuts (3), unthread lower Disconnect the air supply tubes (2).
anchoring pin(1) and remove shock absorber (2) from
vehicle. Loosen the fastening screws (1), loosen the nut (4) and
remove the air spring (3) from the vehicle.
Refitting Refitting
Refit by reversing the removal sequence. Fasten Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque. screws and nuts at the specified torque.

Revi — July 2005
Print 603.93.391
500910 FRONT SHOCK ABSORBERS 500711 FRONT AIR SPRINGS

Removal Removal
Figure 31 Figure 32
72820
Disconnect the air supply tube (1).

Loosen the upper fastening screws (2) and the lower
fastening screws (4). Remove the air springs from the vehicle.
Refitting

72819
Loosen upper nut (1) and lower nut (5), take the pads (2) and
(4) and remove the shock absorber (3) from the vehicle.
Refitting


Print 603.93.391
500710 FRONT PNEUMATIC SUSPENSION

REMOVAL—REFITTING
Figure 33
Removal
position it on stands.
- Loosen the nuts (6), taking the pad (10) and remove the
shock absorber (14).
- On the lower side of the vehicle, loosen the nuts (4) and
remove the U—bolt (3) taking the plate (11).
the leaf spring (12) to the chassis mount.
anchoring pin (1) to the chassis mount. Lower the axle
and remove the complete leaf spring.
- Loosen the nut (9) and disconnect the tie—rod (8).
- Loosen the nut (7), remove the screw and disconnect
the air spring from the leaf spring.
Refitting

specified torque.
Check that:
part.
528930 FRONT SWAY BAR

Removal
On the lower side of the vehicle, loosen the front

U—bolt (3) nuts (4) and remove from the housing.
- Loosen the nuts (2) fastening the sway bar connecting
rod to the chassis mount.
- Remove the mounts from the axle and remove the sway
bar (5) with connecting rod from the vehicle.
Refitting
specified torque.
Check that:
required, reface the threading or replace the 90637
part.

500730 REAR PNEUMATIC SUSPENSION

REMOVAL—REFITTING
(Models 120E..P—FP/130E..P—FP/140E..P—FP/ Figure 34
150E..P—FP/160E..P—FP)
NOTE The following paragraph describes the procedure

for model 130E..FP and is suitable also for the other
models.

Removal
position it on stands in the point shown by (⇒).
- Loosen nut (13) and remove the shock absorber (14).
- Remove the air spring (2) and (11) fastening nuts (4) and
(9).
- Remove the sway bar (10) fastening bolts (8).
- Loosen the fastening nuts and disconnect the level valve
tie—rid (12).
- Loosen the fastening nuts (6), taking the plates and
remove the U—bolts (15).
- Loosen the reaction rod (3) fastening bolts (1) and (7).
- Remove the suspension arms from the vehicle (5).
Refitting

specified torque.
Check that:
- U—bolt (15) threading is in good conditions. If
part.
72822

Print 603.93.391
500731 REAR AIR SPRINGS 500940 REAR SHOCK ABSORBERS
Removal Removal
Figure 35 Figure 36
72823
- Disconnect the air supply tubes (4).

- Loosen the chassis fastening screws (1).
- Loosen the nuts (3) and remove the air springs (2).
Refitting 72827

screws and nuts at the specified torque. - Loosen the lower fastening nuts (4).
- Loosen the upper fastening nuts (1) and take the pads.
- Remove the shock absorbers from the vehicle (3).
Refitting


500731 REAR SWAY BAR
Removal
Figure 37
72823
- Loosen the anchoring screws (4) to the axle.

- Loosen the anchoring screws (1) to the chassis.
- Remove the sway bar (3) with reaction rod (2).
Refitting


EUROCARGO TECTOR 12—26 t WHEELS AND TIRES 1
SECTION 9
5025 Wheels and Tires
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Tire pressure values . . . . . . . . . . . . . . . . . . . . 3
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 4
STATIC WHEELS BALANCING . . . . . . . . . . . . 7
CORRECTION OF RESIDUAL STATIC

UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . 8
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 8
TIRE BEHAVIOUR DEPENDING ON

PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 WHEELS AND TIRES EUROCARGO TECTOR 12—26 t

DESCRIPTION
The wheel rim shows the rigid wheel structure and is - developing on ground the motive force provided by the
identified by the following dimensions: engine and necessary for moving the vehicle;
- rim diameter, measured at the circumferential groove - ensuring the maximum adherence established by the
base (that is on the surface on which the air chamber tire—road contact with a satisfactory length;
rests);
- supporting efforts generated by sudden brakings, by
- circumferential wheel rim groove width (that is the quick accelerations and by the centrifugal force thrust in
distance between the surfaces on which the cover rests). a curve;
The tire has the following tasks: - guaranteeing vehicle stability and ensuring the
directional vehicle power.
- absorbing the majority of impacts generated by road
projections by exploiting air resiliency;
WHEEL RIMS:
Disc—type with drop center rim
MODELS 4x2 MEASURES

ML 110 EL.. 17.5” x 6.75”
ML 120 EL.. 17.5” x 6.75”
ML 120 E.. 19.5” x 8.25” — 19.5” x 6.75” — 19.5” x 7.50” — 22.5” x 6.75”
ML 130 E.. 19.5” x 6.75” — 19.5” x 7.50” — 22.5” x 6.75”
ML 140 E.. 19.5” x 6.75” — 19.5” x 7.50” — 19.5” x 8.25” — 22.5” x 6.75” — 22.5” x 7.50”
ML 150 E.. 19.5” x 6.75” — 19.5” x 7.50” — 19.5” x 8.25” — 22.5” x 6.75” — 22.5” x 7.50”
ML 160 E.. 19.5” x 6.75” — 19.5” x 7.50” — 19.5” x 8.25” — 22.5” x 6.75” — 22.5” x 7.50”
ML 180 E.. 22.5” x 8.25” — 22.5” x 9.00”
MODELS 6x4 MEASURES
260E28KE 22.5” x 8.25”
Tire pressure values
NOTE For checking tire pressure, comply with values shown in the specific “Use and Maintenance” booklet.

TOOLS
99305037 Electronic device for balancing front wheel on a vehicle
DIAGNOSTICS
Main tire anomalies:
1 — Excessive consumption.
2 — Irregular consumption.
3 — The vehicle tends on one side.
1 EXCESSIVE CONSUMPTION
Excessive speed on particularly uneven grounds. Moderate the speed.

YES
NO
Sudden running speed variations due to brusque starts Avoid every superfluous acceleration or braking.
or braking abuse. YES
NO
Excessive speed with tires with insufficient pressure. Check pressures with cold tires.
YES
NO
Tires at a pressure that is higher than the required one. Decrease the pressures.
YES
NO
Overloaded truck. Refer to data related to allowed loads.

YES

2 IRREGULAR CONSUMPTION
Tire pressure differences between a pair of wheels and Check the pressures.
the other. YES
NO
Insufficient tire pressure: the wear is centered on two Inflate the tires.
tread sides more than in the central area. YES
NO
Tires inflated at a higher pressure than the required Decrease the pressure.
one with excessive wear of central tread surface. YES
NO
Insufficient front wheel toe—in: high wear in internal Proceed with toe—in check and adjustment.
tread surfaces. YES
NO
Wrong front wheels attitude. Restore the normal wheel attitude.

YES
NO
Wheel rims distortions with following unbalancing. If possible, repair the rims and replace them; then
YES balance the wheels.
NO
Wrong tire assembly on rims. Exactly assemble the tire and balance the wheel.
YES
(continues)

Rear axle parallelism variation due to leaf spring central Revise the suspension.
pin breakage, or different—length or twisted springs. YES
NO
Excessive front wheels toe—in; excessive wear of Check and adjust the toe—in.
external tread surfaces. YES
3 THE VEHICLE TENDS ON ONE SIDE
Unbalanced front wheels. Proceed with their balancing.

YES
NO
Different inflation pressure between front tires. Check the pressures observing the exact required
YES value.
NO
Excessive wear difference between a pair of tires. Replace the excessively—worn tire.
YES

502511 STATIC WHEELS BALANCING
Figure 1 Figure 2
16997
Front wheels balancing can be carried out with wheels - Connect cable (3) of unbalance detector to device
assembled on a vehicle by using the suitable electronic 99305037.
balancing device 99305037; in this way there will be the
- Make a reference mark on the tire, composed of a radial
additional advantage of balancing the wheel together with the
track obtained with chalk or band of adhesive paper.
rotating masses.
- Put switch (2) in static balancing position and sensitivity
The operation must be carried out in the following way:
switch (4) next to notch 5 in the graded scale.
- Lift the front vehicle part and make sure that the wheels
- Insert instrument (1) light switch (5) and stroboscopic
freely rotate.
lamp switch (8).
- Arrange under the front axle near the examined wheel
- Insert starting switch (6) of device 99305037 in the first
the unbalance detector (1), placing it at such a height that
gear position in order to make the wheel rotate.
the starting roller of device 99305037 (2) comes in
contact with the tire; under the opposite front axle side, Take the starting switch (6) to the second gear and push the
place a support stand and lower the hydraulic jack. balancing device against the tire.
While the wheel is dragged rotating, it will be seen that the
stroboscopic effect on the wheel makes the reference mark
appear as unmoving; the instrument (1) indicator, starting
from zero value, reaches on the scale a maximum value and
then goes back towards zero.
When the indicator has started going back, move the
balancing device away, completely disconnect the starting
switch (6) and brake the engine through the brake lever (7).
The wheel continues to inertially rotate and the reference
marks made on the tire moves, then mark the point where
the reference moved.
Read on instrument (1) the value shown by the indicator,
multiply it by 10, thereby obtaining the counterweight value
to be applied on the rim.

Figure 3 - If the weight is in the area marked with letter A, this means
that it is too light and therefore weight must be added
according to what the instrument shows (1, Figure 2).
- If the weight is in the lower area marked with letter C, this
means that it is too heavy and then it must be decreased
by what the measuring instrument marks.
- When the weight is in the areas marked with letters B and
D, do not remove or add any weight, but rather move it
by 5 cm upwards along the arrows direction, see Figure 4.
16998
Apply the thereby—computed counterweight as shown in the

figure. 502510 TIRE PRESSURE
If during the test the instrument indicator (1, Figure 2)
remains on the green case field, the wheel is balanced.
The tire pressure values must be checked with cold tires.
Strictly take care of the pressure correctness, because, if it is
greater than the required one, it creates running stiffness and
NOTE If the required weight to balance the wheel is greater excessive wear of central tread surface, while if it is lower, the
than 600 ÷ 800 grams, divide the weight by half and load is not distributed on the whole tread but is concentrated
place the two thereby—composed parts, one half on on the side parts, early consuming them, and damaging the
the inside, and the other half to the outside of the internal tire structures.
rim, paying attention that they are in the same A pressure unbalance between tires impairs the vehicle
position. driving stability and impairs its running safety.
The anomalous tire wear can occur in different tread areas
thereof.
CORRECTION OF RESIDUAL STATIC

UNBALANCE
Figure 4
23885
In order to correct the residual unbalance, repeat the already

previously performed operations; according to the new
indication obtained on the instrument (1, Figure 2), refer to
diagram in Figure 4 and operate in the following way for the
adjustment.
TIRE BEHAVIOUR DEPENDING ON

PRESSURE
Demonstration diagrams of tire behaviour and efficiency Figure 6
depending on pressure.
NOTE (The values placed inside every figure show the

amount of tire pressure, while the efficiency is
referred to the tire life.)
+ 20%
90% EFFICIENCY
Figure 5
Figure 7
CORRECT
— 40%
40% EFFICIENCY 100% EFFICIENCY
Figure 8
It is advisable that the pair of tires assembled on an axle are The tires further have wear indicators A and B placed next
replaced when on the tread, after the small blocks to indicator TWI for PIRELLI tire (B) and next to MICHELIN
consumption, continuous bands appear extended to the (A) symbol for those of this latter manufacturer: the
whole tire width (displayed in the figures with dots). replacement is mandatory in case these indicators are
reached.


EUROCARGO TECTOR 12—26 t STEERING 1
Print 603.93.391/A
SECTION 10
5014 Steering
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 4
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ZF HYDRAULIC POWER STEERING
(8095—8098) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Hydraulic steering limiting . . . . . . . . . . . . . . . . 13
HYDRAULIC POWER STEERING DISCONNECTION
AND RECONNECTION (ZF 8095—8098) . . 14
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . 15
TRW TAS 55 HYDRAULIC POWER STEERING 17
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Rectilinear running neutral position . . . . . . . . . 18
- Right steering position . . . . . . . . . . . . . . . . . . . 19
- Left steering position . . . . . . . . . . . . . . . . . . . . 20
HYDRAULIC STEERING LIMITATION . . . . . . . 21
HYDRAULIC POWER STEERING DISCONNECTION
AND RECONNECTION (TRW TAS 55) . . . 22
- Automatic adjustment setting of hydraulic steering
limitation for TRW TAS 55 hydraulic power
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Automatic adjustment check . . . . . . . . . . . . . . 22
- Hydraulic drops adjustment . . . . . . . . . . . . . . 23
AIR DRAIN FROM HYDRAULIC
POWER STEERING CIRCUIT . . . . . . . . . . . . 24
- Hydraulic power steering oil level restoration . 24
MEASURE OF DRIVE CASE CLEARANCES DETECTED
ON STEERING WHEEL . . . . . . . . . . . . . . . . . 24
MAXIMUM PRESSURE CHECK IN
HYDRAULIC POWER STEERING SYSTEM . 24

Revi — July 2005
2 STEERING EUROCARGO TECTOR 12—26 t
Print 603.93.391

Print 603.93.391
DESCRIPTION
The steering control system, that can be found on EuroCargo vehicles, is composed of an hydraulic power steering of the
ball—circulation type controlled by a geared pump assembled together with the air compressor.
Such pump has the feature of having its oil tank integrated with the body.
Hydraulic power steering system installation view
Figure 1
72607
1. Hydraulic power steering — 2. Delivery piping — 3. Return piping — 4. Through—wall fitting on return piping — 5. Power
steering pump with integrated tank — 6. Through—wall fitting on delivery piping.
View of power steering pump assembled together with air compressor
Figure 2
72608
1. Power steering pump — 2. Hydraulic power steering oil tank — 3. Oil insertion plug with level sensor — 4. Air compressor.

Steering Hydraulic
Hydraulic power steering (with ball circula-

tion with embedded pressure limiting ZF 8095 ZF 8098 TRW/TAS 55
valve)
Variable operating pressure 150 + 15 130 + 13 150 + 10
Reduction ratio 19.6 : 1 22.2 to 26.2 : 1 20.4 : 1
No. of revolutions/steering wheel 5.4 3.1 5.7
Power steering pump with integrated tank
ZF FN4 Integral
and safety filter valve
Min. number of revolutions Revs/min 600
Max. number of revolutions Revs/min 2700
Operating pressure bar max. 180
Flow rate dm3/min 16
Maximum operating temperature 100 º C
Tutela GI/A oil

It complies with ATF DEXRON II specification
DIAGNOSTICS
Main hydraulic power steering operating anomalies:
1 — Hard steering in right and left steering; 5 — Torsional steering wheel vibrations;
2 — Hard steering only in left or right steering; 6 — Excessive steering wheel clearance;
3 — Hard steering when the steering wheel is quickly 7 — Oil leakage;
rotated; 8 — Insufficient circuit pressure.
4 — When one steers, strong impacts occur on steering
wheel;
HARD STEERING
1 IN RIGHT AND
LEFT STEERING
Insufficient system oil. Check level with running engine; top—up the oil till the
YES upper level rod mark and drain the system.
NO
Presence of air in hydraulic circuit. Check suction pipe and pump shaft gasket seal and
YES top—up the oil. Drain the system.
NO
(continues)

Locked or clogged limiting valve. Disassemble the valve, wash and check. The throttling
YES holes must not be clogged.
NO
Insufficient oil pump flow rate Replace the pump.

YES
NO
Poorly—sliding spider joint. Make the joint slidable alternatively moving it many
YES times so that it can be slanted under its own weight.
HARD STEERING ONLY IN LEFT OR

2 RIGHT STEERING
Inefficient internal gaskets. Sent the steering to a ZF or TRW station.

YES
NO
Wrong hydraulic center position (if the steering wheel Make the hydraulic power steering adjusted by a ZF
is left free, the steering spontaneously goes to an YES or TRW station.
extreme position).
HARD STEERING WHEN THE STEER-

3 ING WHEEL IS QUICKLY ROTATED
Clogge limiting valve. Disassemble the valve, wash and clean.

YES
NO
Insufficient hydraulic pump flow rate. Revise or replace the hydraulic pump.
YES
NO
Presence of air in steering system. Check suction pipe seal in pump shaft gasket and
YES top—up the oil. Drain the system.

4 WHEN ONE STEERS, STRONG IMPACTS

OCCUR ON STEERING WHEEL
Cardan joint clearance. Replace the cardan joint.

YES
NO
Internal hydraulic power steering failure. Send the hydraulic power steering to a ZF or TRW
YES station.
NO
Insufficient system oil. Top—up the oil and drain the system.
YES
NO
Wrong wheels attitude. Carry out checks and adjustments according to

YES characteristic data included in “FRONT AXLE”
section.
NO
Unbalanced wheels. Carry out the rebalancing according to the

YES instructions included in chapter “Wheels and tires”.
NO
Loosened steering tie—rod heads on levers. Replace the possibly worn parts.
YES
NO
Irregular hydraulic pump operation. Replace the hydraulic pump.

YES
NO
Oil blow—by from hydraulic power steering circuit Check fittings gaskets efficiency replacing the worn
fittings. YES ones.

5 TORSIONAL STEERING WHEEL

VIBRATIONS
Unbalanced wheels. Carry out the balancing following the instructions

YES included in chapter “Wheels and tires”.
NO
Wrong wheels attitude. Carry out checks and adjustments according to

YES characteristics data included in “FRONT AXLE”
section.
NO
Presence of air in hydraulic system. Check suction pipe and pump shaft gasket seal and
YES top—up the oil. Drain the system..
6 EXCESSIVE STEERING WHEEL

CLEARANCE
Clearance in ball joints and/or slow elastic supports. Secure the supports.
YES Replace the ball joints.
NO
Clearance in cardan joint. Replace the cardan joint.

YES
NO
Internal hydraulic power steering failure. Send the hydraulic power steering to a ZF or TRW
YES station.

7 OIL LEAKAGE
The tank cover is loosened. Secure the cover.

YES
NO
Worn sealing gaskets. Replace worn sealing gaskets, top—up the oil and drain.
YES
In any case it is necessary to establish where and why the hydraulic oil is lost, remove the reason and top—up the oil in the
tank with running engine till the upper level rod mark.
8 INSUFFICIENT CIRCUIT PRESSURE
Irregular hydraulic pump operation. Revise or replace the hydraulic pump.

YES
NO
Oil blow—by from circuit fittings. Check fittings gaskets efficiency replacing the worn
YES ones.
NO
Insufficient tank oil level. Restore the level simultaneously carrying out the
YES circuit drain.
NO
Oil blow—by from circuit fittings. Check fittings gaskets efficiency replacing the worn
YES ones.
NO
Insufficient tank oil level. Restore the level simultaneously carrying out the
YES circuit drain.

TIGHTENING TORQUES
Print 603.93.391/A
PART
HYDRAULIC
POWER ZF 8095 ZF 8098 TRW/TAS 55
STEERING
Screw for securing hydraulic power steer-
Nm (kgm) 520 ± 52 (53 ± 5.3) 560 ± 17 (57 ± 1.7) 700 ± 3.5 (71 ± 0.3)
ing to support
Nut for securing lever on shaft Nm (kgm) 520 ± 52 (53 ± 5.3) 550 ± 55 (56 ± 5.6) 700 ± 3.5 (71 ± 0.3)
Screw for securing the support to chassis Nm (kgm) 655 ± 65 (67 ± 6.6) 655 ± 65 (67 ± 6.6) —
Screw to hydraulically limit steering Nm (kgm) 12 ± 3 (1.2 ± 0.3) 12 ± 3 (1.2 ± 0.3) —
Nut for securing hydraulic steering limiter
adjustment screws on hydraulic power Nm (kgm) — — 75 ± 7.5 (7.3 ± 0.7)
steering
Nut for securing M22x1.5 steering wheel Nm (kgm) 73 ± 7 (7.4 ± 0.7) 73 ± 7 (7.4 ± 0.7) 73 ± 7 (7.4 ± 0.7)
TOOLS
99347042 Driving steering wheel extractor.
99347068 Extractor for steering tie—rods head pins.
99374393 Tool with manometers for checking hydraulic ZF hydraulic power

steering pressure.
99374398 Graded sector and index for checking steering wheel clearance
(use with 99374393).

Revi — July 2005
ZF HYDRAULIC POWER STEERING (8095—8098)

Description
The ZF hydraulic power steering with ball circulation This solely mechanical steering movement is servo—assisted
control and a compact shape, is mainly composed of a case by pressurised oil supplied by an engine—operated ZF pump.
and an embedded power steering mechanical part, of a
The control valve is composed of rotating distributor,
control valve and an operating cylinder. As can be seen in
supported on rollers in the worm screw and equipped with
Figure 4 and Figure 5, the rotating movement given to the
six control grooves on perimeter and of worm screw end
steering wheel is transmitted without friction from power
supported in the steering case and equipped with six control
steering shaft to piston through an infinite sequence of balls
grooves as well.
and then transformed into an axial piston movement. The
toothing of piston driven into case meshes into The rotating distributor at the same time operates also as
toothed—sector shaft toothing and makes it rotatingly move. lower connection element of steering shaft and rotates with
The steering control arm fixed onto this shaft transmits the the worm screw till the steering wheel is rotated.
torque to wheel steering tie—rods.
Figure 3
105037
HYDRAULIC POWER STEERING ZF—TYPE

Revi — July 2005
Print 603.93.391
Figure 4
27200
CONTROL VALVE IN NEUTRAL POSITION

A. Case — B. Piston — C. Rotating distribution/steering shaft — D. Control case/worm screw — E. Torsion bar —
F. Toothed—sector shaft — G. Pressure limiting valve — H. Re—suction valve — Q. Oil tank — R. ZF blade pump — S. Flow—rate
limiting valve.
This synchronous rotary motion is due to the fact that the To avoid that with the whole hydraulic pressure it is possible
worm screw and the rotating distributor (C) are connected to steer till the right and left limit stop and in some cases
through a torsion bar (E, Figure 4) that keeps the control damage the driving tie—rods, the ZF—Servocom is equipped
valve in a neutral position (rectilinear running) till the steering with hydraulic steering limiting (Figure 6).
wheel is rotated.
A re—suction valve (H, Figure 4) is assembled into the drive
When a torque is transmitted from steering wheel or steering case with which return circuit oil can be sucked when it is
wheels to worm screw, the torsion bar is subjected to a necessary to steer without hydraulic servoassistance.
distortion in its elastic area, so that between rotating
distributor (C) and worm screw end, that operates as control Moreover, according to the driving system execution, a
case (D), a relative movement occurs. This causes a pump delivery pressure limiting valve is also assembled
distributor control grooves displacement with respect to according to a pre—established maximum value.
worm screw ends grooves, so that the control valve passes In the operating drawings (Figure 4 and Figure 5) the control
from neutral position to operating position. The pressurised valve and oil flow are schematically shown. The valve (S) is
oil by the control valve (G) can now cross the open control shown in a transverse section, so that its operation and
grooves and penetrate into one of the two operating cylinder connection to cylinder chambers can be seen.
chambers, thereby assisting the steering movement through
the pressure on one of piston surfaces. The pressurised oil coming from the pump flows into the
central annular groove of the control case and reaches,
If the hydraulic steering servoassistance is lacking, it is always through three radial holes, the arcuate control grooves of the
possible to steer, even if with a higher effort on the steering rotary distributor.
wheel.

The mutual position of these grooves and the worm screw Through the admission ports (K), the pressurised oil
end grooves allows, in a neutral valve position, the penetrates into the axial grooves (N) of the control case and
pressurised oil to pass through admission ports till it reaches from there, after having crossed the worm screw balls
the equally arcuate grooves in the control case. These latter circulation threading, comes into the left cylinder chamber.
ones are connected through radial holes with both operating The hydraulic servoassistance is then turned on, while the
cylinder chambers. admission ports (I) closure prevents oil from returning into
Therefore, in the control valve neutral position, the the tank. The oil being present in the right cylinder chamber
pressurised oil can penetrate into the two operating cylinder is made go out and flows, through the open return ports (M),
chambers and also into the three return circuit grooves of the towards the return grooves (P) of the rotating distributor and
rotary distributor and from there reflow into the oil tank. returns, through its central hole, to the oil tank.
If the steering wheel is rotated rightwards, the If the steering wheel is rotated leftwards (not shown), the
rightward—threading piston moves rightward (Figure 5). operating cylinder piston is displaced leftwards. The
Since this piston movement must be hydraulically distributor control grooves rotate counterclockwise. The
servoassisted, the pressurised oil must penetrate into the left pressurised oil penetrates through admission ports (J) into
cylinder chamber. The three control grooves of the rotating axial grooves (O) and then into right cylinder chamber.
distributor are displaced clockwise, so that the admission The oil being present in the left cylinder chamber reflows into
ports (K) are further opened to let the pressurised oil flow. the tank through the ball circulation threading, the return
The admission ports (J) are closed and stop the pressurised ports (L), the return grooves (P) and the central rotating
oil flow towards the axial grooves (O) of the control case. distributor hole.
Figure 5
27201
CONTROL VALVE IN OPERATING POSITION FOR CLOCKWISE ROTATED STEERING WHEEL

J. Admission port — K. Admission port — L. Return port — M. Return port — N. Axial groove — O. Axial groove —
P. Return groove.

Print 603.93.391/A
Figure 6
105038
STRAIGHT LINE RIDE (both steering limiting valves are closed)

1. Right adjustment screw — 2. Left cylinder chamber — 3. Piston — 4. Right cylinder chamber — 5. Screw to hydraulically limit
”right steering — A. Left steering limiting valve — B. Right steering limiting valve
Figure 7
105039
PISTON RIGHTWARDS DISPLACEMENT (open steering limiting valves, very reduced oil pressure)
Hydraulic steering limiting In such a way, the pressurised oil being present in the left
Two valves (B and A) are axially arranged in the piston (3, operating cylinder chamber can penetrate into its right
Figure 6) for steering limiting. They are equipped with small chamber, flowing around the displaced valve piston (A) and
spring—loaded pistons, whose stems project from right and left through the open right valve (B), and then reach the return
front piston surfaces. circuit. If the piston is leftwards displaced, the valve (A) is
opened after the pre—established stroke and the pressurised
If piston is moved leftward or rightward, towards stop oil in the right cylinder chamber can flow into the return
position, stems can reach screws (1 and 5) in box and cover, cylinder, thereby reducing the pressure into the circuit
and shift. Both limiting valves remain closed till one of the chamber.
stems touches the adjustment screw. If for example the piston
is rightward displaced (Figure 7), the right steering limiting When the steering limiting valve is open, hydraulic
valve (B) is opened by screw (5) before the piston reaches the servoassistance is strongly reduced and the steering wheel can
limit stop. be rotated only with a higher effort till wheel or drive stop.

Revi — July 2005
Print 603.93.391
54130 HYDRAULIC POWER STEERING

DISCONNECTION AND Figure 10
RECONNECTION (ZF 8095—8098)
Figure 8
33688
Through extractor 99347068 (2) detach tie—rod (1) from

33686
Disconnection lever (3).
Place a vessel under the hydraulic power steering and remove
cover from tank.
Unscrew fittings (1 and 2) and detach oil delivery and return
pipings from hydraulic power steering.
Figure 9 Figure 11
33687
33689
Remove split pin (1) and unscrew nut (2). Unscrew screw (1) and disconnect connection joint. Unscrew
screws (2) securing hydraulic power steering to support.

Reconnection Figure 14
Suitably reverse the operations carried out for the

disconnection; tighten the screws at the required
tightening torques.
NOTE Having to replace the hydraulic power steering with

a new one, before its assembling on the support,
carry out the following operations.
Figure 12
33692
- lock lever securing nut (2) through a dynamometric

wrench (1) at the required torque.
Figure 15
33690
- secure the hydraulic power steering into a vice;

- assemble steering lever (3) making notches (1) align
etched on drive shaft (2) and on lever (3);
Figure 13
33693
- through a suitable punch, press nut collar (1).
NOTE
Lubricate with oil all screws securing hydraulic power
steering to support.
33691
- Check angular lever excursion that must be equal to 47°

in both directions;

Print 603.93.391/A
501430 HYDRAULIC STEERING LIMITER

ADJUSTMENT f SPACER THICKNESS, WITHOUT CODE
Front mechanical suspension
Figure 16 Left wheel Right wheel
No—loaded vehicle 3 mm 6 mm
Full—loaded vehicle 3 mm 3 mm
Front pneumatic suspension
No—loaded or 3 mm 3 mm
full—loaded vehicle
Always with front wheels on rotating plates, start the engine
up and keep it at a speed ≤ 1550 revs/min.
Steer till the wheel stops against the spacer; then, go on
steering the steering wheel for a few seconds exceeding in
such a way the steering valve reaction force till the fixed stop
is reached.
In such position the manometer will have to point out an oil
pressure equal to 35 ÷ 50 bar.
In order to correct different values, the lock nut is unscrewed
and the screw of the corresponding valve (X or Y, Figure 17)
is screwed or unscrewed.
During such phase, it is necessary to let the steering wheel free
in order to avoid undesired pressure increases.
Then close the lock nut at a torque of 30 ± 5 Nm (3 ± 0.5 kgm);
to adjust the second wheel stop, proceed in a similar way.
When the hydraulic power steering moves to A (Figure 17),
adjust valve (X), when it moves to B (Figure 17), adjust valve
27204 (Y).
1. Pump — 2. Tank — 3. Delivery piping — 4. Suction piping — When the shown pressure is greater than 50 bar, it is
5. Reflow piping — 6. Manometers necessary to (clockwise) screw the corresponding steering
X = Hydraulic steering limiting adjustment screw for limiting valve.
rotating steering control arm along “A” direction. When the shown pressure is lower than 35 bar, it is necessary
to (counterclockwise) unscrew the corresponding steering
Y = Hydraulic steering limiting adjustment screw for limiting valve. At the end of the adjustment, check again the
rotating steering control arm along “B” direction. pressure drops along the two steering directions.
Figure 17
19587
f. Dimension (see table) for the spacer to be interposed

between stops — 7. Stop
With the pair of manometers 99374393 already connected
on hydraulic power steering delivery piping fitting, abut the
front wheels onto rotating plates.
Place a spacer (f, Figure 16) of the shown thickness, see table
enclosed below, between wheel stop parts (7).

Revi — July 2005
Print 603.93.391
TRW TAS 55 HYDRAULIC POWER STEERING

Figure 18
77844
1. Hydraulic steering limiting adjustment screw — 2. Hydraulic right steering limiting adjustment screw — 3. Worm screw —
4. Hydraulic left steering limiting adjustment screw — 5. Torsion bar — 6. Rotating distributor valve — 7. Entry shaft — 8. Cover —
9. Balls — 10. Hydraulic power steering case — 11. Outlet shaft — 12. Rack piston.
Description
The ball—circulation control hydraulic power steering is This only—mechanical steering movement is servoassisted by
essentially composed of a case in which manual steering the pressurised oil supplied to an engine—actuated blade
mechanism, an hydraulic cylinder controlled by a rotating pump.
distributor valve, and hydraulic steering and safety limiting
valves are housed. If when steering the wheels are subjected to violent impacts,
the force created by the same ones is transmitted through
The rotary motion impressed to steering wheel is transmitted outlet shaft (11) to rack piston (12) and from it to worm screw
from inlet shaft (7) to worm screw (3), through the torsion bar (3). The internal hydraulic power steering system makes the
(5). rotary distributor valve (6) send highly pressurised oil into the
The worm screw (3) in turn, being connected by means of a cylinder chamber where such pressure can fight and absorb
set of balls (9) to the rack piston (12), transforms the rotary the given impact force. In this way no recoils are generated on
motion into an axial motion of this latter one. the steering wheel.
The piston rack toothing (12) meshes into the toothed—sector The hydraulic power steering is equipped with an automatic
shaft toothing and impresses a rotary motion thereto. The air drain valve.
steering control arm fixed on this shaft transmits the motion
to the wheel steering tie—rods.

Rectilinear running neutral position
Figure 19
77845
1. Flow rate limiting valve — 2. Blade oil pump — 3. Oil tank — 4. Rotary distributor valve — 5. Inlet shaft — 6. Torsion bar —
7. Worm screw — 8. Outlet shaft — 9. Rack piston.
The rotary distributor valve (4) is keyed—in on the torsion bar

(6) connecting inlet shaft (5) to worm screw (7); under
rectilinear running conditions, the valve (4) keeps open the
communication between incoming oil canalisation from blade
pump (2) and oil tank discharge (3) one.

Right steering position
Figure 20
77846
1. Flow rate limiting valve — 2. Blade oil pump — 3. Oil tank — 4. Rotary distributor vale — 5. Valve body — 6. Inlet shaft —
7. Torsion bar — 8. Hydraulic limiting valve — 9. Rack piston.
If when rotating the steering wheel the transmitted torque is This hydraulic servoassistance action is kept till the hydraulic
lower that the steering wheels resisting torque, torsion bar (7) steering limiting valve (8) intervenes or the action on the
in its elastic area is subjected to a distortion, so that the rotary steering wheel ceases that generated the torsion bar (7)
distributor (4) integral therewith rotates with respect to valve distortion.
body (5), passing from neutral condition to operating In this case, the rotary distributor (4) will be placed again in its
condition. Consequently, by closing the discharge canalisation neutral condition.
and opening the control one, the pressurised oil enters the If the hydraulic servoassistance lacks, it is always possible to
cylinder chamber affected by steering, generating the axial steer even if with a greater effort on the steering wheel.
displacement of the rack piston (9).

Left steering position
Figure 21
77847
1. Flow rate limiting valve — 2. Blade oil pump — 3. Oil tank — 4. Rotary distributor valve — 5. Valve body — 6. Inlet shaft —
7. Torsion bar — 8. Hydraulic limiting valve — 9. Rack piston.

HYDRAULIC STEERING LIMITATION
Figure 22
77848
1. Steering hydraulic limiting screw — A and B steering limiting valve — 2. Small piston — 3. Bush — 4. Valve body — 5. Spring —
6. Thrust sleeve — 7. Spacer pin — 8. Rack piston — 9. Cover — X. Left cylinder chamber — Y. Right cylinder chamber.
The two steering limiting valves A and B are housed in the rack Consequently, the pressurised oil present in the affected
piston (8) end. chamber will pass through the valve A or B opening in the
opposite chamber and from there it will be discharged into the
They are composed of a valve body (4) inside which valve
tank.
intervention adjustment bush (3) is placed, with a forced
coupling, such valve in turn operating as small piston (2) seat.
Small pistons (2) are kept in their closing position on bushes NOTE The figure shows the left steering condition.
(3) by counter—spring (5). Valves A and B are kept closed till
small pistons (2) stems are taken in contact by the rack piston
displacement:
- with adjustment screw (1) if the displacement is towards
When the hydraulic limiting valve is open, the hydraulic
the left;
servoassistance is highly reduced, and consequently it will be
- with cover (9) if the displacement is towards the right. necessary to exert a higher force on the steering wheel in
order to continue to steer till it stops.

541430 HYDRAULIC POWER STEERING Figure 24

DISCONNECTION AND
RECONNECTION (TRW TAS 55)
NOTE For disconnecting and reconnecting the TRW TAS

55 hydraulic power steering, comply with the
procedure disclosed for ZF 8095 — ZF 8098
hydraulic power steering.
60925
Make sure that the gearbox is idle.

Start the engine up and keep it at a rotation speed that is
≤ 1500 revs/min.
Rotate the steering wheel along a direction, applying thereto
a 34 Nm torque till the stop screw (2) assembled on the stub
axle (3) is taken in contact with front axle (1).
In this way bush (4, Figure 18) will go back with respect to
Automatic adjustment setting of hydraulic valve body (5, Figure 18) of affected steering limiting valve.
steering limitation for TRW TAS 55 hydraulic The position that bush (4, Figure 18) will get will make the
power steering hydraulic pressure discharged inside the affected chamber
before screw (2, Figure 18) comes in contact with front axle
(1), safeguarding hydraulic system components.
Figure 23 Repeat the same procedure steering to the opposite side.
Automatic adjustment check

The automatic adjustment check is carried out with
full—loaded vehicle moving and at low speed, both in right and
in left steerings, operating as follows.
Rotate the steering wheel along a direction till the absence of
hydraulic interlock is detected.
From this condition verify that the steering wheel rotation to
reach the steering stop (screw (2) in contact with front axle
(3)) is included between 60° and 120°.
60924 Repeat the same procedure by steering along the opposite
direction.
When detecting different values, operate as described in the
NOTE In case of an hydraulic power steering detached from following chapter ”Manual hydraulic drops adjustment”.
the vehicle, the outlet shaft rotation must not exceed
29° (equal to 1.3 revolutions of the inlet shaft (1))
with respect to center drive position marked by
references (2).
The adjustment is carried out after having assembled the

hydraulic power steering on the vehicle, with unloaded vehicle
and lifted front wheels. Moreover both right steering and left
steering must be performed operating as follows.

Hydraulic drops adjustment

Lift the vehicle from its front side, arrange the steering wheels
under straight running conditions and verify that references (2,
Figure 23) showing the drive center coincide.
NOTE The vehicle must be unloaded.
Figure 25
60926
Make sure that gearbox is idle.

Start the engine up and keep it at a rotation speed that is
Arrange under the hydraulic power steering (1) next to screw ≤1500 revs/min.
(2) a vessel to collect the possible oil outflow, unscrew screw Rotate the steering wheel by applying thereto a torque that
(2) itself and screw screw (3) equipped with spare part is ≤ 34 Nm; leftwards for left—drive vehicles or vice versa for
completed with nut (4). right—drive vehicles, till the steering stop is reached and keep
it under such position.
Stop the engine.
Loosen nut (4) and screw, using a dynamometric wrench,
NOTE Screw (3) must be screwed till distance B is 0 mm. screw (3) till a torque increase by 1.1 ÷ 2 Nm is detected.
For left—drive vehicles, steer the wheels rightwards by applying

to the steering wheel a torque that is ≤ 54 Nm (vice versa for NOTE When screwing screw (3) keep nut (4) unmoving.
right—hand drive), till stop screw (2, Figure 24) is taken in
contact with front axle (1, Figure 24).
Take wheel in straight running conditions verifying that
references (2, Figure 23) showing the drive center coincide.
Unscrew screw (3) so that distance B is 20—22 mm and lock
nut (4) at the required torque. Under the above condition, unscrew screw (3) by 2.5
Top—up the tank till the provided oil level is reached. revolutions and lock nut (4) at the required torque.
Carry out the automatic adjustment check as described in the
related chapter.

501430 AIR DRAIN FROM HYDRAULIC

POWER STEERING CIRCUIT Connect the piping of the pair of manometers on the hydraulic
Carry out the air drain from hydraulic power steering circuit power steering oil delivery piping fitting.
proceeding as follows: Possibly restore the oil level.
Start the engine up at its minimum speed and read on the
- fill with required oil (TUTELA GI/A) the circuit tank; manometer from 0 to 10 bar the pressure value at that time.
- rotate the engine with the starter and top—up the oil Slowly rotate the steering wheel leftwards till the
continuously in order to avoid that the pump sucks air. previously—read pressure value is increased by 1 bar, keep the
Top—up the oil till its level does not go below the upper steering wheel unmoving and mark on the millimeter scale
rod mark; 99374398 the reached value in mm.
- start the engine up and rotate it at minimum speed Rotate the steering wheel rightwards till a 1 bar pressure
checking that the oil level does not go below the upper increase is again obtained; read what the scale 99374398 is
rod sign; marking, sum the two left steering plus right steering values:
the sum must not exceed 40 mm.
- rotate the steering wheel many times from stop to stop Lower the front axle.
so that air cannot go out of the hydraulic power steering
cylinder till no air bubbles are noted incoming into the
tank;
- accelerate the engine at its maximum, stop it and check MAXIMUM PRESSURE CHECK IN
that the oil level in the tank does not rise more than 1 ÷ HYDRAULIC POWER STEERING SYSTEM
3 cm.
Hydraulic power steering oil level restoration
With the pair of manometers 99374393 already previously
The oil level check must be carried out with moving engine connected and the wheel on drive side locked with suitable
verifying that the level corresponds to the ”MAX” indication shims, start the engine up at its minimum speed, steer along
included on the tank side. one direction with an effort of 10 ÷ 20 kg on the steering
Under off engine conditions, the level, due to the backup of wheel and measure the pressure on the manometer from 0
oil contained in the upper tank part, will be able to exceed the to 160 bar.
”MAX” indication by two millimeters. Carry out the same operation by steering along the opposite
direction; if the detected values are different from the required
ones, search for their cause.
NOTE The maximum pressure value can be detected by

501430 MEASURE OF DRIVE CASE the ZF or TRW plate applied onto the drive case.
CLEARANCES DETECTED ON
STEERING WHEEL
Check that there are no mechanical clearances in the related
connecting tie—rods.
Lock the left wheel under straight running position with
suitable shims on coupling bar; lift the front axle.
Figure 26
78681
Arrange on the windscreen, through a suction cup, a fixed

index (2) and the millimeter sector (1) on the steering wheel.
Arrange the pair of manometers 99374393 (3) from 0 to 10
and from 0 to 160 bar, mutually connected by means of a
short—circuit valve.

EUROCARGO TECTOR 12—26 t PNEUMATIC SYSTEM — BRAKES 1
Print 603.93.391
SECTION 11
Pneumatic System — Brakes
Page
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC

SYSTEMS DIAGRAMS
(MISCELLANEOUS AND GENERATORS) . . 5

SYSTEMS DIAGRAMS (VALVES) . . . . . . . . . 6

SYSTEMS DIAGRAMS
(TANKS AND ACCUMULATORS) . . . . . . . . 12

SYSTEMS DIAGRAMS
(CONVERTERS, CYLINDERS AND CALIPERS) 13

SYSTEMS DIAGRAMS (CYLINDERS AND CALIPERS) 14

SYSTEMS DIAGRAMS
(COUPLING HALF—JOINTS AND HEADS) . 15

SYSTEMS DIAGRAMS
(SIGNALING DEVICES AND SWITCHES) . . 17

SYSTEMS DIAGRAMS (BRAKES) . . . . . . . . . . 18
PIPINGS AND FITTINGS . . . . . . . . . . . . . . . . . . 19
- In general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Rigid pipings reflanging . . . . . . . . . . . . . . . . . . . 19
- Rigid pipings bending . . . . . . . . . . . . . . . . . . . . 20
- Rigid pipings cutting . . . . . . . . . . . . . . . . . . . . . 20
- Flexible pipings replacement with threaded fittings 21
- Flexible pipings replacement with quick connection

fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 24
- Principle diagram for single vehicles

(Models 110 EL.. — 120 EL..) . . . . . . . . . . . . . . 24
- Principle diagram for vehicles adapted for towing

(Models 110 EL.. — 120 EL..) . . . . . . . . . . . . . . 25

(Models 120 E.. — 130 E.. — 140E.. — 150 E.. — 160E..)26

2 PNEUMATIC SYSTEM — BRAKES EUROCARGO TECTOR 12—26 t
Page Page
- Principle diagram for vehicles adapted for towing

(Models 120 E.. — 130 E.. — 140E.. — 150 E.. — 160E..)27
ENGINE BRAKE SWITCH . . . . . . . . . . . . . . . . . 67
(Model 180 E.. — 190EL..) . . . . . . . . . . . . . . . . . 28 ENGINE BRAKE SOLENOID VALVE . . . . . . . . . 67
- Principle diagram for vehicles adapted for towing ENGINE BRAKE CONTROL
(Model 180 E.. — 190EL..) . . . . . . . . . . . . . . . . . 29 OPERATING CYLINDER . . . . . . . . . . . . . . . . 67
- Principle diagram for single vehicles (Model 260E) MANUAL DISCHARGE VALVE . . . . . . . . . . . . . 67
(with Hendrickson suspensions) . . . . . . . . . . . 30
SAFETY VALVE (OPTIONAL) . . . . . . . . . . . . . . 68
ARRANGEMENT ON A VEHICLE
OF MAIN BRAKING SYSTEM COMPONENTS 31 DUPLEX DISTRIBUTOR . . . . . . . . . . . . . . . . . . . 68
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
- Service braking . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Unbraking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
- Safety braking . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 70
- Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Pressure limitation . . . . . . . . . . . . . . . . . . . . . . 70
- Parking braking . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Bench calibration . . . . . . . . . . . . . . . . . . . . . . . 70
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
- Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
RELAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
- Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 44 CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SPECIFICATIONS AND DATA — PARKING BRAKE CONTROL

PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . 53 MANUAL DISTRIBUTOR (SINGLE VEHICLES) 72
SPECIFICATIONS AND DATA — BRAKES . . . . . 58 - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

CHECKS OF MAIN BRAKE SYSTEM COMPONENTS 60 PARKING BRAKE CONTROL MANUAL DISTRIBUTOR
(Vehicles adapted for towing) . . . . . . . . . . . . . 73
MAIN BRAKE SYSTEM COMPONENTS . . . . . . 63
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 63
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 QUICK DISCHARGE VALVE . . . . . . . . . . . . . . . 74
A.P.U. (AIR PROCESSING UNIT) . . . . . . . . . . . . 64 TRIPLE CONTROL SERVODISTRIBUTOR AC 597 B 74
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 - Predominance adjustment . . . . . . . . . . . . . . . . 74
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Page Page
COUPLING HEADS . . . . . . . . . . . . . . . . . . . . . . 75
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 82
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 82
PRESSURE PLUG VALVE . . . . . . . . . . . . . . . . . . 75
MEMBRANE BRAKE CYLINDER BRAKE CALIPERS REVISION . . . . . . . . . . . . . . . 82

(for disc brakes and drum brakes) . . . . . . . . . . 75
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
COMBINED BRAKE CYLINDER . . . . . . . . . . . . . 76
- Check of component parts . . . . . . . . . . . . . . . 83
- Combined cylinder emergency unbraking device 76
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
BRAKE DISCS REVISION . . . . . . . . . . . . . . . . . . 86
- Repair interventions . . . . . . . . . . . . . . . . . . . . . 76
- Brake discs turning and grinding . . . . . . . . . . . . 86
ABS SYSTEM WITH EBL FUNCTION . . . . . . . . 77
BRAKE REPAIRING . . . . . . . . . . . . . . . . . . . . . . . 87
- ”ABS” Anti—Lock Brake System . . . . . . . . . . . . 77
- ”EBL” (Electronic Brake Limiter) anti—skid device 77 - Front brakes (Brake caliper KNORR SB6 type) 87
ELECTRONIC UNIT . . . . . . . . . . . . . . . . . . . . . . 77 - Front and rear brakes

(Brake caliper KNORR SN6—SN7 type) . . . . . . 88
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Operation (See previous figure) . . . . . . . . . . . 89
REVOLUTIONS SENSORS . . . . . . . . . . . . . . . . . 77
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
PHONIC WHEELS . . . . . . . . . . . . . . . . . . . . . . . 77
- Checking the automatic play recovery system
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
ELECTRO—PNEUMATIC VALVE . . . . . . . . . . . . 78 - Check of braking gaskets thickness . . . . . . . . . 90

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 REAR BRAKES REVISION . . . . . . . . . . . . . . . . . . 92
BRAKE REPAIRS - Braking gaskets replacement . . . . . . . . . . . . . . 92
(Models ML 110 EL.. / 120 EL..) . . . . . . . . . . . 79
- Front Brakes - Brake calipers disconnection and reconnection 94

(Brake calipers of the PAN 17 type) . . . . . . . . 79
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 94
- Rear Brakes
(Brake calipers of the PAN 17 type) . . . . . . . . 79 - Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 - Wheel hubs disconnection and reconnection . 95

- Brake locking system and brake operation . . . . 79 - Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Automatic braking gaskets wear recovering device 79 - Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Efficiency check for braking gaskets/brake disc wear
recovering device . . . . . . . . . . . . . . . . . . . . . . . 81 BRAKE CALIPERS REVISION TYPE SB6 . . . . . . . 96
- Braking gaskets replacement . . . . . . . . . . . . . . 81 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 - Cleaning and check of component parts . . . . . 97
- Brake calipers disconnection and reconnection 82 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Page
BRAKE CALIPER OVERHAUL TYPE SN6—SN7 . 99
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
- Component part cleaning and check . . . . . . . . 100
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
REAR DISC BRAKES REVISION

(12—18 T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
BRAKE DISCS REVISION . . . . . . . . . . . . . . . . . . 102
BRAKE DISCS TURNING

AND GRINDING . . . . . . . . . . . . . . . . . . . . . . 102
REAR DRUM BRAKES — MODEL 260E28KE . . . 103
- Brake position with Hendrickson suspension . . 103
REAR BRAKES REVISION (26 T) . . . . . . . . . . . . 104
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
- Check of component parts . . . . . . . . . . . . . . . 106
DRUM TURNING . . . . . . . . . . . . . . . . . . . . . . . . 107
BRAKING GASKETS REPLACEMENT . . . . . . . . 108
BRAKING GASKETS TURNING . . . . . . . . . . . . . 108
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Print 603.93.391
GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS

(MISCELLANEOUS AND GENERATORS)
DENOMINATION SYMBOL
HYDRAULIC FLOW
PNEUMATIC FLOW
ELECTRIC DUCT
POSSIBLE ROTATION
CROSSING OF CONNECTED DUCTS
PRESSURE CONTROL TAP
QUICK CONNECTION FITTING
COCK
1 2
COCK WITH DISCHARGE
SILENCER
COMPRESSOR 0 2
0 2
ENERGY SAVING COMPRESSOR
4
VACUUM PUMP 3 2
HYDRAULIC PUMP 0 2
MANUAL HYDRAULIC PUMP
32780

GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (VALVES)
DENOMINATION SYMBOL
CONDENSATE SEPARATOR
FILTER 1 2
DRIER 1 2
4
DRIER 21 1
22
DRIER WITH INTEGRATED 21 1

REGULATOR 22
23
AUTOMATIC CONDENSATE DRAIN

VALVE
DRIVEN CONDENSATE DRAIN

VALVE
MANUAL CONDENSATE DRAIN

VALVE
7
DRIVEN ANTIFREEZER 1 2
AUTOMATIC ANTIFREEZER
1 2
21 23
PRESSURE REGULATOR WITH 1
INDEPENDENT CIRCUIT
22 24
PRESSURE REGULATOR 1 21
PRESSURE REGULATOR 1 21
23
PRESSURE REGULATOR
(GOVERNOR) 1 2
PRESSURE LIMITING VALVE 1 2
32782 32783

DENOMINATION SYMBOL
PROPORTIONAL REDUCTION VALVE 1 2
ADAPTER VALVE 1 2
21 23
4—CIRCUIT PROTECTION VALVE 1
22 24
21
3—CIRCUIT PROTECTION VALVE 1 23
22
21
2—CIRCUIT PROTECTION VALVE 1
22
AIR INTAKE VALVE WITHOUT

RETURN 1 2
AIR INTAKE VALVE WITH

LIMITED RETURN 1 2
SAFETY VALVE
CHECK VALVE 1 2
2
CHECK VALVE 2
1
2
DOUBLE STOP VALVE
11 12
U
DOUBLE DIFFERENTIAL STOP VALVE
M S
THROTTLING VALVE WITH QUICK

RETURN 1 2
THROTTLING VALVE
32783 32784 32785

DENOMINATION SYMBOL
QUICK EXHAUST VALVE 1 2
BRAKE CONTROL DISTRIBUTOR

11 A 21
12 P 22
BRAKE CONTROL DISTRIBUTOR

11 21
BRAKE CONTROL DISTRIBUTOR 11 21
4
12 22
PARKING BRAKE CONTROL 21

DISTRIBUTOR 11 22
PARKING BRAKE CONTROL

DISTRIBUTOR 1 2
BRAKE DISTRIBUTOR
1 2
CONTROL DISTRIBUTOR
1 2
CONTROL DISTRIBUTOR 21
1 22
DECELERATOR CONTROL
DISTRIBUTOR 13 R 23
4
SERVODISTRIBUTOR
1 2
32786

DENOMINATION SYMBOL
41 42
SERVODISTRIBUTOR
1 2
SERVODISTRIBUTOR FOR
MONO—DUCT
1 2
41 42 43
TRAILER TRIPLE BRAKE
CONTROL VALVE
1 2
42
41 43
TRAILER TRIPLE BRAKE CONTROL
VALVE WITH EMBEDDED
SERVOSWITCH 11 22
12
1 2
BRAKE CORRECTOR
11 21
DOUBLE BRAKE CORRECTOR 12 22
12
21
BRAKE CORRECTOR WITH BY—PASS 11
BRAKE CORRECTOR WITH 1 2

INTEGRATED RELAY
4
4
BRAKE CORRECTOR WITH

INTEGRATED RELAY WITH 1 2
PNEUMATIC CONTROL
41 42
32786 32787

DENOMINATION SYMBOL

PNEUMATIC CONTROL
41 42

PNEUMATIC CONTROL
4
PROPORTIONAL REDUCTION VALVE 1 2
4
INTERLOCKED PROPORTIONAL
REDUCTION VALVE
1 2
2
STROKE LIMITING VALVE 1
LEVELLING VALVE
21 22
1 2
LEVELLING VALVE
12 23
LEVELLING VALVE WITH
INTEGRATED STROKE LIMITER 11 21
MANUAL SUSPENSION—LIFTING 23 24
CONTROL VALVE
21 22
32787 32788

DENOMINATION SYMBOL
2
42
GRADUAL CONTROL VALVE
41
1
13
MANUAL ELECTRIC CONTROL 11 21

SUSPENSION CONTROL VALVE
12 22
1 3
ELECTRO—PNEUMATIC VALVE
1 2
ELECTRO—PNEUMATIC VALVE 1 2
ELECTRO—PNEUMATIC VALVE 21
1 22
VR ABS HZ2
HYDRAULIC ABS MODULATOR VL HZ1
HL HR
4
POWERING VALVE
1 2
32788


(TANKS AND ACCUMULATORS)
DENOMINATION SYMBOL
COMPRESSED AIR TANK
BRAKE FLUID TANK
AIR SPRING
32789

Print 603.93.391

(CONVERTERS, CYLINDERS AND CALIPERS)
DENOMINATION SYMBOL
VACUUM SERVOBRAKE
VACUUM SERVOBRAKE
DOUBLE CIRCUIT MASTER CYLINDER
SIMPLE CIRCUIT MASTER CYLINDER
PNEUMO—HYDRAULIC CONVERTER
PNEUMO—HYDRAULIC CONVERTER
HYDRAULIC BRAKE CYLINDER
OPERATOR CYLINDER
BRAKE CYLINDER
SPRING CYLINDER
COMBINED BRAKE CYLINDER
FIXED DISC BRAKE CALIPER
32790 32791


(CYLINDERS AND CALIPERS)
DENOMINATION SYMBOL
FLOATING DISC BRAKE CALIPER
FLOATING DISC BRAKE CALIPER

WITH PARKING
MECHANICAL FLOATING DISC

BRAKE
CALIPER
SERVOCLUTCH
SERVOCLUTCH
32791


(COUPLING HALF—JOINTS AND HEADS)
DENOMINATION SYMBOL
A
“ISO” HALF—COUPLING
M
ISO VERSION
A
“ISO” HALF—COUPLING
M
VERSION WITH ISO JOINTS
A
“CUNA” HALF—COUPLING
B
ITALIAN VERSION
M
“CUNA” HALF—COUPLING
A
A
“NATO” HALF—COUPLING
M
NATO VERSION
32792 32793


(COUPLING HALF—JOINTS AND HEADS)
DENOMINATION SYMBOL
4
1 5
2 3
HALF—COUPLING
V
Z
A
VERSION WITH MONO—DUCT
A
M
HALF—COUPLING
V
Z
A
12
22
HALF—COUPLING 4
12
A
22
M
HALF—COUPLING 4
1 2
32793


(SIGNALING DEVICES AND SWITCHES)
DENOMINATION SYMBOL
MANOMETER
MANOMETER
PRESSURE TRANSMITTER
LAMP
MECHANICAL CONTROL SWITCH
PRESSURE SWITCH
LOW PRESSURE SWITCH
HOOTER
SENSOR
32794

GRAPHIC SYMBOLS FOR HYDROPNEUMATIC SYSTEMS DIAGRAMS (BRAKES)
DENOMINATION SYMBOL
SIMPLEX HYDRAULIC BRAKE
DUPLEX HYDRAULIC BRAKE
DOUBLE—SERVO HYDRAULIC BRAKE
DOUBLE—SERVO HYDRAULIC BRAKE

WITH PARKING
SIMPLEX WEDGE BRAKE
DOUBLE—DUPLEX WEDGE BRAKE
32795

Print 603.93.391
799512 PIPINGS AND FITTINGS Figure 3
In general
Hydraulic system pipings for industrial vehicles are currently of
two types:
- Flexible ones made of polyamide with single—layered or
double—layered structure and in the following diameters
(∅ 6—8—10—12—16 mm) equipped with spares in meters
- Rigid metal pipings in the following diameters (∅
4.75—6.35—8—10—12 mm). Pipings from ∅ 4.75 to ∅ 10
mm are supplied as spares in straight 4—5—6 m crop ends,
while those exceeding 10 mm are supplied as spares
31973
already cut, bent and reflanged.
Burr piping (1), insert union (2) and place it between small
Rigid pipings reflanging blocks (3) abutting pin (5). Lock piping (1) with screw (4).
Figure 1
Figure 4
C 31971
RIGID PIPINGS REFLANGING REPRESENTATION 31974
Reflanging type A Take back pin (4) to its neutral position. Screw screw (1) till
matrix die (2) comes to abut against small blocks (3) thereby
Figure 2 shaping the piping (5) end.
Reflanging type B
Figure 5
31972
Arrange on a press 99386523 (3) small blocks (1) so that the

punched numbers, showing the piping number to be worked,
are facing the matrix die (2). The choice of the matrix die (2)
depends on the diameter of the piping to be reflanged. 31975
Moreover, on every matrix die (2) the diameter of the piping Assemble matrix die (2) on press 99386523 (1).
is punched for which the same one can be used. For the reflanging process comply with what has been stated
above for reflanging type A.

Reflanging type C
Figure 6 Figure 9
31976 31979
Key on piping (1) nut (2) and ring (3). Place piping (1) into tool (3) and operating on lever (2) bend
the piping.
Figure 7 Figure 10
31980
31977
In order to free piping (2) from tool (3), operate on lever (1).
Assemble union (2) and tighten so that ring (3, Figure 6) is
locked on piping (1).
Rigid pipings bending Rigid pipings cutting

Figure 8 Figure 11
31978 31981
Place piping (2) into tool (3) 99386523 and tighten screw (1).
Assemble tool (1) 99386523 choosing parts (2) and (3) Keeping piping (2) still, rotate tool (3) till the piping is
depending on the diameter of pipings to be bent. completely cut.

After having cut the piping, burr and shape the end as previously - Carry out abutment ring reflanging upon assembly on the
described. vehicle or work bench on a fitting.
- The exerted pressure and the final distance from front
NOTE Rotating tool (3) around piping (2), screw (1) is pressure ring edge to reinforcement bush edge must be
loosened. In order to completely cut the piping, it is those mentioned in the table below.
then necessary to tighten screw (1) when it
loosening.
NOTE In case of a bad assembly, use the pipe after having

Flexible pipings replacement with threaded extracted bush and abutment ring.
fittings
Strictly comply with the following instructions:
Pipe Distance between Assembly
Figure 12 bush edge and ring pressure
mm mm (*) N/mm2
6x1 1 to 1.5 0.040

Double—
layered 8x1 2 to 2.5 0.050
10 x 1.5 2 to 2.5 0.050
Single—laye- 12 x 1.6 2 to 2.5 0.060

red
16 x 2.34 3 to 3.5 0.060
10397
- Use homologated pipes only;

- Check the spare pipe status, on which no cracks, cuts or (*) See reference h, Figure 14.
nickings must be detected;
- Cut the pipe at 90° with respect to the axis through a
suitable pipe—cutting pliers 99387050 at the necessary
length;
Figure 14
Insert on the pipe in the following order:
- nut (3), pressure ring (2) (its greater thickness must be
facing nut (3) and reinforcement bush (1);
- the bush must be in perfect conditions (it must not have
either distortions or hammering traces);
Figure 13
10399
10398 1. Reinforcement bush — 2. Pressure ring — 3. Nut — 4.

Fitting — 5. Pipe — h. Distance between bush edge and ring
REINFORCEMENT BUSH ASSEMBLY edge
A = CORRECT ASSEMBLY (see table).
B = WRONG ASSEMBLY Insert the thereby—prepared piping end into the fitting body
till the reinforcement bush flange rests within the suitable seat:
- Key the reinforcement bush with tool 99372219 - For closing the nut on the fitting, initially screw it manually
guaranteeing the contact between its flange and the pipe and then complete the tightening with a suitable box
end; wrench inserted into the dynamometric wrench, to be
calibrated according to the required tightening torque.
- make sure that the pipe end penetrates into the suitable
rake groove obtained in the flange;

Assembly of piping on vehicle is carried out by taking into Flexible pipings replacement with quick
account some important solutions: connection fittings
- Bendings must comply with minimum radiusses, in order
to avoid throttlings;
Rotating fittings:
Pipings diameter Minimum bending radius
mm mm
Figure 16
6x1 ≈ 40
8x1 ≈ 50
10 x 1.5 ≈ 60
12 x 1.6 ≈ 75
16 x 2.34 ≈ 100
Make sure that pipings are not in contact with sharp

! edges or with cutting metallic parts or with heat 39306
sources, but that are distant therefrom by a minimum
safety distance of 15 mm. Screw the fitting in the threaded seat provided on the
pneumatic valve and lock it at the tightening torque shown in
- Moreover, when crossing chassis longitudinal members or the table.
metallic parts, check that passage holes are coated with
rubber fairlead rings and that these latter ones are in good Swinging fittings:
conditions;
- Avoid that the pipe slides along cutting edges that would Figure 17
risk to create nickings;
- Having to fix the piping onto already existing ducts, take
into account the supplementary heat to which it can be
subjected (hydraulic power steering duct): in such case, the
piping must be protected with guards;
- At the end of the connection, verify that the piping,
between keying and securing, is not stretched, but must be
slightly loosened to recover higher temperature variations,
particularly for short lengths;
- Before assembling, accurately clean the pipings by blowing
compressed air in order to guarantee system operation;
Figure 15 39307
- Check that the sealing ring (1) is into its suitable seat;
- screw the fitting till it is felt that the sealing gasket abuts
onto the valve;
- adequately swing the fitting and keeping the swingable
part still, lock the hexagonal nut at the tightening torque
mentioned in the table.
13132
Rotating and swinging fittings:
- Protect the pipes in case of grinding or welding operations FITTING TIGHTENIG TORQUE (Nm + 10%)
on the vehicle; for such purpose, an adhesive plate is applied THREADING
in the cabin and shows the precautions to be observed with M 10 x 1.0 mm 22
utmost care to avoid damages.
M 12 x 1.5 mm 24
NOTE For better safety and work comfortability, it is
advisable to detach the pipings during such M 14 x 1.5 mm 28
operations.
M 16 x 1.5 mm 35
At the end of the assembly, check the perfect seal of all gaskets
(unions, fittings, etc.). M 22 x 1.5 mm 40

Figure 18 Figure 20
39308
- Manually insert pipe (2) into fitting (1), with a force varying
from 30 to 120 N depending on pipe diameter, so that the
notch L1 is placed inside the fitting while the notch L2 is
visible.
33977
- Use homologated pipes only;

- Check the spare pipe status, on which no cracks, cuts or Figure 21
nicking must be detected;
- Cut the pipe at 90° with a max 15° error with respect to
the axis through the suitable pipe—cutting pliers 99387050
at the necessary length;
Figure 19
33978
In case of disassembling of fittings (1) from pneumatic

components, check the sealing ring (2) status, and if necessary
replace it.
A
FITTING SEALING RINGS
33976
THREADING DIMENSIONS
A = Marking to identify pipe end—of—stroke M 10 x 1.0 10.1 x 1.6
- Strongly and indelibly mark with ink two reference M 12 x 1.5 11.0 x 2.0
notches on both diametrically—opposed pipe faces for an
angle ≥ 75°, placed at the distances of L1 and L2 to M 14 x 1.5 —
guarantee a correct assembly.
M 16 x 1.5 15.0 x 2.0
M 22 x 1.5 —
NOTE Dimensions L1 and L2 change depending on the
pipe diameter and must be measured from the
longest pipe part (see Figure 18).
NOTE Every time a piping is detached from a quick

0 —0.5 —0.5
D L+0.5 L1 +1
L2 +1 connection fitting, it is necessary to replace the
(mm) (mm) (mm) (mm) fitting itself. Quick connection fittings are supplied
complete as spares.
6 19.8 17 22
8 20.5 18 23 NOTE Quick connection and threaded fittings, as well as

flexible pipings used with quick connection fittings
12 25 22 28
and flexible pipings used with threaded fittings, are
not interchangeable.
16 27.1 24 30

BRAKING SYSTEM
Principle diagram for single vehicles (Models 110 EL.. — 120 EL..)
Figure 22
84013
1. Single—cylinder 225 cm3 (359 cm3 optional) compressor — 2. 0.26l silencer — 3. Air Processing Unit — 4. 15l rear axle air
tank — 5. 15l front axle air tank — 6. Manual condensate exhaust valve — 7. Safety valve (optional) — 8. Engine brake control
button — 9. Engine brake control solenoid valve — 10. Engine brake valve control cylinder — 11. Relay valve — 12. Phonic
wheel —
13. Revolutions sensor — 14. Rear axle brake disc — 15. — Rear axle brake caliper — 16. Combined cylinder — 17. Parking relay
valve — 18. Inserted parking brake signalling low pressure switch — 19. Rear axle ABS solenoid valve — 20. Manual parking
control distributor —21. Manual safety distributor (optional) — 22. Duplex distributor — 23. Front axle ABS solenoid valve —
24. Front axle brake disc — 25. Front axle brake caliper — 26. Front axle membrane cylinder — 27. Revolutions sensor —
28. Phonic wheel — 29. Quick discharge valve — 30. ABS electronic unit — 31. Parking brake luminous signaller — 32. STOP
lights — 33. Front axle/rear axle manometer — 34. STOP lights relay control switch — 35. EDC inserted brake signalling switch
—
36. Pneumatic control plug.
A. To pneumatic suspension system — B. To differential block — C. To gearbox control.

Principle diagram for vehicles adapted for towing (Models 110 EL.. — 120 EL..)
Figure 23
84014
tank — 5. 15l front axle air reservoir — 6. Manual condensate exhaust valve — 7. 15l trailer parking and reloading air tank —
8. Trailer system pressure reducer — 9. Engine brake control button — 10. Safety valve (optional) — 11. Engine brake control
solenoid valve — 12. Engine brake valve control cylinder — 13. Trailer braking control pressure switch — 14. Relay valve —
15. Rear axle ABS solenoid valve — 16. Phonic wheel — 17. Revolutions sensor — 18. Trailer coupling half—joints —
19. Triple—control trailer servodistributor — 20. Rear axle brake disc — 21. — Rear axle brake caliper — 22. Combined cylinder
— 23. Parking relay valve — 24. Inserted parking brake signalling low pressure switch — 25. Manual parking control distributor —
26. Manual safety distributor (optional) — 27. Unidirectional parking system valve — 28. Duplex distributor — 29. Front axle
ABS solenoid valve — 30. Front axle brake disc — 31. Front axle brake caliper — 32. Front axle membrane cylinder —
33. Revolutions sensor — 34. Phonic wheel — 35. Quick discharge valve — 36. ABS electronic unit — 37. Parking brake
luminous signaller — 38. STOP lights — 39. Front axle/rear axle manometer — 40. Trailer section low pressure luminous
signaller (optional) — 41. STOP lights relay control switch — 42. EDC inserted brake signalling switch — 43. Trailer low
pressure switch (optional) — 44. Pneumatic control plug.

Principle diagram for single vehicles (Models 120 E.. — 130 E.. — 140E.. — 150 E.. — 160E..)
Figure 24
84011
tank — 5. 15l front axle air reservoir — 6. Manual condensate exhaust valve — 7. Safety valve (optional) — 8. Engine brake
control button — 9. Engine brake control solenoid valve — 10. Engine brake valve control cylinder — 11. Relay valve —
12. Rear axle phonic wheel — 13. Revolutions sensor — 14. Rear axle drum brake — 15. — Rear axle combined cylinder —
16. Parking relay valve — 17. Inserted parking brake signalling low pressure switch — 18. Rear axle ABS solenoid valve —
19. Manual parking control distributor — 20. Manual safety distributor (optional) — 21. Duplex distributor — 22. Front axle ABS
solenoid valve — 23. Front axle brake disc — 24. Front axle brake caliper — 25. Front axle membrane cylinder —
26. Revolutions sensor — 27. Phonic wheel — 28. Quick discharge valve (optional Proportional reduction valve) —
29. ABS electronic unit — 30. Parking brake luminous signaller — 31. STOP lights — 32. Front axle/rear axle manometer —
33. STOP lights relay control switch — 34. EDC inserted brake signalling switch — 35. Pneumatic control plug.

Print 603.93.391
Principle diagram for vehicles adapted for towing

(Models 120 E.. — 130 E.. — 140E.. — 150 E.. — 160E..)
Figure 25
84012
tank — 5. 15l front axle air tank — 6. Manual condensate exhaust valve — 7. 15l trailer parking and reloading air tank —
8. Trailer system pressure reducer — 9. Engine brake control button — 10. Safety valve (optional) — 11. Engine brake control
solenoid valve — 12. Engine brake valve control cylinder — 13. Trailer braking control pressure switch (optional) — 14. Relay
valve — 15. Rear axle ABS solenoid valve — 16. Phonic wheel — 17. Revolutions sensor — 18. Trailer coupling half—joints —
19. Triple—control trailer servodistributor — 20. Rear axle drum brake — 21. Rear axle combined brake cylinder —
22. Parking relay valve — 23. Inserted parking brake signalling low pressure switch — 24. Manual parking control distributor —
25. Manual safety distributor — 26. Unidirectional parking system valve — 27. Coaxial duplex distributor — 28. Front axle
ABS solenoid valve — 29. Brake disc — 30. Front axle brake caliper — 31. Front axle membrane cylinder — 32. Revolutions
sensor — 33. Phonic wheel — 34. Quick discharge valve (optional Proportional reduction valve) — 35. ABS electronic unit —
36. Parking brake luminous signaller — 37. STOP lights — 38. Front axle/rear axle manometer — 39. Trailer section low
pressure luminous signaller (optional) — 40. STOP lights relay control switch — 41. EDC inserted brake signalling switch —
42. Trailer low pressure switch (optional) — 43. Pneumatic control plug.

Principle diagram for single vehicles (Model 180 E.. — 190EL..)
Figure 26
84009
1. Single—cylinder 359 cm3 compressor — 2. 0.26l silencer — 3. Air Processing Unit — 4. 20l rear axle air tank — 5. 20l front
axle air tank — 6. Manual condensate exhaust valve — 7. Safety valve (optional) — 8. Engine brake control button — 9. Engine
brake control solenoid valve — 10. Engine brake valve control cylinder — 11. Relay valve — 12. Rear axle phonic wheel —
13. Revolutions sensor — 14. Rear axle brake disc — 15. Rear axle brake calliper — 16. — Rear axle combined cylinder —
17. Relay valve — 18. Inserted parking brake signalling low pressure switch — 19. Rear axle ABS solenoid valve — 20. Manual
parking control distributor — 21. Manual safety distributor (optional) — 22. Duplex distributor — 23. Front axle ABS solenoid
valve — 24. Front axle brake disc — 25. Front axle brake caliper — 26. Front axle membrane cylinder — 27. Revolutions
sensor — 28. Front axle phonic wheel — 29. Quick discharge valve (optional Proportional reduction valve) — 30. ABS
electronic unit — 31. Parking brake luminous signaller — 32. STOP lights — 33. Front axle/rear axle manometer — 34. STOP
lights relay control switch — 35. EDC inserted brake signalling switch — 36. Pneumatic control plug.

Principle diagram for vehicles adapted for towing (Model 180 E.. — 190EL..)
Figure 27
84010
1. Single—cylinder 359 cm3 compressor — 2. 0.26l silencer — 3. Air Processing Unit — 4. 20l rear axle air tank — 5. 20l front
axle air tank — 6. Manual condensate exhaust valve — 7. 15l trailer parking and reloading air tank — 8. Trailer system
pressure reducer — 9. Engine brake control button — 10. Safety valve (optional) — 11. Engine brake control solenoid valve —
12. Engine brake valve control cylinder — 13. Trailer braking control pressure switch (optional) — 14. Relay valve — 15. Rear
axle ABS solenoid valve — 16. Phonic wheel — 17. Revolutions sensor — 18. Trailer coupling half—joints — 19. Triple—control
trailer servodistributor — 20. Rear axle disc brake — 21. Rear axle drum brake — 22. Rear axle combined brake cylinder — 23.
Relay valve — 24. Inserted parking brake signalling low pressure switch — 25. Manual parking control distributor —
26. Manual safety distributor (optional) — 27. Unidirectional parking system valve — 28. Duplex distributor — 29. Front axle
ABS solenoid valve — 30. Front axle brake disc — 31. Front axle brake caliper — 32. Front axle membrane cylinder —
33. Revolutions sensor — 34. Phonic wheel — 35. Quick discharge valve — 36. ABS electronic unit — 37. Parking brake
luminous signaller — 38. STOP lights — 39. Front axle/rear axle manometer — 40. Trailer section low pressure luminous
signaller (optional) — 41. STOP lights relay control switch — 42. EDC inserted brake signalling switch — 43. Trailer low
pressure switch (optional) — 44. Pneumatic control plug.

Principle diagram for single vehicles (Model 260E) (with Hendrickson suspensions)
Figure 28
84418
1. Single—cylinder 225 cm3 (359 cm3 optional) compressor — 2. 0.261 silencer — 3. Air Processing Unit — 4. 20L + 20L rear
axle air tank — 5. Manual condensate exhaust valve — 6. 20L front axle air tank — 7. Engine brake control button — 8. Safety
valve (optional) — 9. Brake valve control cylinder — 10. Engine brake control solenoid valve — 11. Axle ABS solenoid valve —
12. Phonic wheel — 13. Quick—release valve — 14. Rear axle speed sensor — 15. Rear axle membrane brake cylinder —
16. Rear axle drum brake — 17. Rear axle combined brake cylinder — 18. Parking relay valve — 19. Inserted parking brake
signalling low pressure switch 6.5 bar — 20. Manual parking control distributor — 21. Manual safety distributor (optional) —
22. Self—limited coaxial duplex distributor 7.6 ± 0.3 bar — 23. Quick—release valve — 24. Front axle ABS solenoid valve —
25. Front axle disc brake (diam. 430 mm or 436 mm) — 26. Front axle brake calliper — 27. Front axle membrane cylinder —
28. Front axle speed sensor — 29. Front axle phonic wheel — 30. ABS Electronic unit — 31. Parking brake luminous signaller —
32. STOP lights — 33. Front axle / rear axle manometer — 34. Stop light relay control switch — 35. EDC inserted brake
signalling switch — 36. Relay valveBraking control — 37. Pneumatic control plug.

ARRANGEMENT ON A VEHICLE
OF MAIN BRAKING SYSTEM COMPONENTS
Figure 29
78952
1. Phonic wheel — 2. Check valve — 3. Engine brake solenoid valve — 4. A.P.U. — 5. Relay valve — 6. Phonic wheel —
7. Wheels revolution sensors — 8. Combined brake cylinder — 9. Triple—control servodistributor — 10. Coupling heads —
11. Parking — trailer braking tank — 12. Hydraulic pressure control plug — 13. Wheels revolutions sensor — 14. Phonic wheel
— 15. Rear disc brake assembly — 16. Quick discharge valve — 17. Pressure relief valve — 18. Electro—pneumatic valve —
19. Air tanks — 20. Pressure control plug — 21. Pressure relief valve — 22. Front disc brake assembly — 23. Membrane brake
cylinder — 24. Wheels revolutions sensor — 25. Phonic wheel — 26. Engine brake operating cylinder — 27. Engine brake
control button — 28. Duplex distributor — 29. ABS elecronic unit — 30. Single—cylinder compressor — 31. Parking brake
distributor — 32. Trailer slowing—down control distributor (optional) — 33. Wheels revolutions sensor.

DESCRIPTION
Print 603.93.391/A
BRAKES
Service braking Front brakes
With pedal, of the electrically—controlled pneumatic type, Front brakes are of the disc type. Discs are keyed on wheel
operating on all wheels and on trailer or semitrailer. hubs and equipped with venting fins that allow lowering the
It is composed of two independent sections, one for high temperature that develops under the braking action.
activating front axle braking elements, the other section for Braking gaskets are equipped with a wear signaller connected
activating rear axle braking elements. to a warning light placed on the dashboard, which signals
A third section, interlocked with the two distributor sections, gasket wear.
is provided for braking the trailer. The duplex distributor with ABS device phonic wheels are keyed—in on wheel hubs.
electric transmitter checks the two independent sections and
the trailer control servodistributor in turn checks the above Front axle 5845
interlocked section. The pneumatic system sectioning - type: WABCO (PERROT) PAN 17 — Ø 330x34
enables, in case of failure of a section, the efficiency of the
other ones. Front axle 5842/5 — 5851/5
- type: KNORR SB6 — Ø 377x45
Safety braking
The safety braking allows reducing vehicle running speed and Front axle 5871/5
stop it in a safety space, also when a braking system failure
occurs. - type: KNORR SN7 — Ø 432x45
It must be meant as partial service braking that, due to the Front axle 5860
double circuit, anyway operates on one of the two axles.
- type: KNORR SN6 — Ø 377x45
Engine brake
The ”engine brake” system, being of the electric type, is Rear brakes
managed by the EDC unit. The exhaust brake can be
controlled in different ways, which can be selected by means Rear brakes are:
of the special switch available on the dashboard or the pedal - disc type on rear axle MS08—125, MS10—144,
on the floor to be used with the different types/conditions MS10—164, MS13—165
of the road.
Actuation can be controlled directly through the pedal - Drum brakes on tandem axle SP 145 E
available on the floor. In drum brakes, every braking assembly is composed of a
When the selector is set to position 1, the exhaust brake is body in which adjustment, control pins and wedge units are
linked to the accelerator pedal and is operated when the housed.
accelerator is released. Wedge units are actuated by cylinder stem in turn actuated
When the selector is set to position 2, engine brake/service by compressed air.
brake are coupled, with operation starting from first pedal Wedge unit rollers along their stroke generate control pin
stroke length and keeping the position. expansion that, winning jaws return spring resistance,
Every time the engine brake is inserted, the signalling panel approach jaws to drum dampening the brakings. Adjustment
warning light turns on. and control pins are made integral with the brake body by
The insertion of engine brake together with accelerator two pins that are inserted in a side milling. When the braking
pedal disables all adjustment operations connected to Cruise action ceases, air pressure is lacking in the combined brake
Control. cylinder membrane section, and consequently the jaws
return spring and wedge unit return spring actions take care
Operation of returning the wedge units into their starting position.
Independently from the type of selection being set, the EDC Braking gaskets are equipped with a wear signaller.
electronic unit drives, through connector B pin 11, the engine ABD device phonic wheels are an integral part of brake disc
brake solenoid valve. on H127E rear axle, while are keyed—in on wheel hubs in the
This one, by switching its state from N.C. to N.O., allows the other rear axles with drum brake.
engine oil to flow to operating cylinder which, in turn,
operating on the engine exhaust throttle valve, allows braking Rear axle MS08—125
it. - type: WABCO (PERROT) PAN 17 — ∅ 330x34
Parking braking Rear axle MS10—144; MS10—164

It is composed of the pneumatic control of the manual - type: KNORR SN6 — ∅ 377x45
distributor, of a spring cylinder that operates on rear wheel
brakes by locking them. Rear axle MS13—165
This system, in case the supply is lacking, automatically brakes - type: KNORR SN7 — ∅ 432x45
the vehicle.
Rear axle SP145E
- type: Duoduplex — ∅ 381x178

Revi — July 2005
Print 603.93.391
DIAGNOSTIC
Main brake system operating anomalies: 7 — Delayed parking unbraking;
8 — Delayed trailer parking unbraking;
1 — Scarce or irregular system recharge; 9 — When braking the vehicle side—skids;
2 — Scarce or irregular rear axle service braking; 10 — Insufficient trailer slowing—down braking;
3 — Scarce or irregular front axle service braking; 11 — Early braking gaskets wear;
4 — Scarce or irregular trailer service braking; 12 — Turned—on brake system failure luminous signaller;
5 — Scarce or lacking parking braking; 13 — Turned—on parking brake luminous signaller with
6 — Scarce or lacking trailer parking braking; hand lever in running position;
14 — Noisy brakes.
NOTE The complete diagnosis of electric and electronic components must be carried out through modus IT 2000 and E.A.SY.
1 SCARCE OR IRREGULAR SYSTEM

RECHARGE
Pneumatic system pipings leakages or breakages. Close or replace loosened or damaged fittings.
YES Replace broken or damaged pipings.
NO
Inefficient air compressor operation. Revise or replace the air compressor.

YES
NO
Inefficient A.P.U operation. Revise or replace the A.P.U.

YES
2 SCARCE OR IRREGULAR REAR AXLE

SERVICE BRAKING
(continues)

Worn and/or vitrified braking gaskets. Revise or replace the braking gaskets.
YES
NO
Inefficient rear brakes operation. Revise the rear brakes.

YES
NO
Inefficient Duplex distributor operation. Revise or replace the Duplex distributor.

YES
NO
Inefficient brake cylinders operation. Revise or replace the brake cylinders.

YES
NO
Inefficient ABS solenoid valve operation. - Verify the electric wiring.

YES
- Replace the ABS solenoid valve.
NO
Inefficient automatic clearance recovering device Replace the complete brake caliper.
operation. YES

3 SCARCE OR IRREGULAR FRONT AXLE

SERVICE BRAKING
NO

YES
NO
YES
NO
Inefficient front brakes operation. Revise the front brakes.

YES
NO
Inefficient relay valve operation. Revise or replace the relay valve.

YES
NO
Inefficient membrane brake cylinders operation. Revise the membrane brake cylinders.
YES
NO
Inefficient automatic clearance recovering device Replace the complete brake caliper.
operation. YES
(continues)

Inefficient ABS solenoid valve operation. - Verify the electric wiring.

YES
- Replace the ABS solenoid valve.
SCARCE OR IRREGULAR TRAILER

4 SERVICE BRAKING
NO
Inefficient triple—control servodistributor operation. Revise or replace the triple—control servodistributor.

YES
NO

YES
NO
Inefficient A.P.U. operation. Revise or replace the A.P.U.

YES
NO
YES
NO
Inefficient trailer brakes operation. Revise the trailer brakes.

YES

SCARCE OR LACKING PARKING

5 BRAKING
NO
Inefficient combined brake cylinders operation. Revise or replace the combined brake cylinders.
YES
NO
Inefficient parking brake manual distributor (hand lever) Revise or replace the hand lever.
operation. YES
NO
YES
NO

YES
NO

YES

SCARCE OR LACKING TRAILER

6 PARKING BRAKING
NO

YES
NO
operation. YES
NO
Worn and/or vitrified trailer braking gaskets. Revise or replace the trailer braking gaskets.
YES
NO

YES
NO
Inefficient trailer control servodistributor operation. - Verify the electric wiring.

YES
- Replace the trailer control servodistributor.

DELAYED PARKING
7 UNBRAKING
NO

YES
NO
Inefficient combined brake cylinders operation. Revise or replace the combined brake cylinders.
YES
NO
operation. YES
NO

YES

DELAYED TRAILER PARKING

8 UNBRAKING
NO

YES
NO
operation. YES
NO

YES
WHEN BRAKING THE VEHICLE

9
SIDE—SKIDS
NO

YES
(continues)

Inefficient front brakes operation. Revise the front brakes.

YES
NO

YES
NO

YES
INSUFFICIENT TRAILER
10 SLOWING—DOWN BRAKING
NO

YES
NO

YES
NO
Inefficient manual distributor (hand lever) operation. Revise or replace the hand lever.
YES

EARLY BRAKING GASKETS WEAR

11

YES
NO
Inefficient brakes operation. Revise the brakes.

YES
NO

YES
NO

YES
TURNED—ON BRAKE SYSTEM FAILURE

12 LUMINOUS SIGNALLER
NO

YES
NO
Wrong warning light electric circuit wiring. Detect the wrong connection and restore the wiring.
YES

TURNED—ON PARKING BRAKE

13 LUMINOUS SIGNALLER WITH HAND
LEVER IN RUNNING POSITION
Wrong warning light electric circuit wiring. Detect the wrong connection and restore the wiring.
YES
NO
operation. YES
NO

YES
14 NOISY BRAKES
Worn braking gaskets. Replace the worn gaskets.

YES
NO
Presence of foreign bodies between discs and braking Remove the foreign bodies between braking gaskets
gaskets (disc brakes). and discs.
YES
NO
Uncentered brake discs (disc brakes). Grind or replace the brake discs.
YES
NO
Inefficient jaws return springs (drum brakes). Revise the rear brakes.
YES
NO
Excessive brake drums ovalisation within required Turn or if necessary replace the drums.
tolerances (drum brakes). YES

TIGHTENING TORQUES
TORQUE
PART
Nm (kgm)
Compressor
Head clamping screws 27.5 ± 2.5 (2.8 ± 0.25)
Connecting rods caps clamping screws 13+3 (1.3+0.3)
Front brakes (Front axle 5845)

Ring nut for securing wheel hub bearings 388.5 ± 18.5 (39.6 ± 1.8)
Cylindrical—head screw with embedded hexagon for bearings adjustment clamp 27.5 ± 2.5 (2.8 ± 0.2)
Self—locking hexagonal—head screw for securing brake calipers 188 ± 18 (19 ± 1.8)
Hexagonal—head screw for securing brake disc to wheel hub 40 ± 4 (4 ± 0.4)
Wheel hub cover* 106 ± 11 (10.8 ± 1.1)
Tapered threaded plug for wheel hub cover 55 ± 5 (5.5 ± 0.5)
Brake cylinder securing nut 195 ± 15 (19.8 ± 1.5)
Front brakes (Front axle 5842/5 — 5851/5)

Self—locking hexagonal—head screw for securing brake calipers 299.5 (30.6)
Wheel hub cover* 130 ± 10 (13 ± 1)
Front brakes (Front axle 5871/5)

Self—locking hexagonal—head screw for securing brake calipers 615.5 ± 61.5 (62.5 ± 6.2)
Wheel hub cover* 130 ± 10 (13 ± 1)
Front brakes (Front axle 5860)

Wheel hub bearing fastening nut 600 ± 30 (60 ± 3)
Screw securing the disc and flange to the bearing 250 ± 10 (25 ± 1)
Thread—stop screw on the bearing fastening nut 27.5 ± 2.5 (2.7 ± 0.2)
* Apply a bead of LOCTITE 574 sealant on the cover abutting surface by means of the special measuring device. Protect the
threaded portion.

Print 603.93.391
TORQUE
PART
Nm (kgm)
Rear brakes (Rear axle MS08—125)

Self—locking screw for securing brake calipers 187 ± 19 (19 ± 1.9)
Screw for securing brake disc to wheel hub 40 ± 4 (4 ± 0.4)
Screw for securing half—shaft to wheel hub 150 ± 15 (15.2 ± 1.5)
Wheel securing nut 490 ± 50 (49.9 ± 5)
Manual unbraking screw 30 +— 06 3 +— 00.6
Rear brakes (Rear axles MS10—144; MS10—164)

Brake caliper fastening screw 187 ± 19 (19 ± 1.9)
Screw fastening the brake disc to the wheel hub 40 ± 4 (4 ± 0.4)
Screw fastening the axle shaft to the wheel hub 150 ± 15 (15 ± 1.5)
Wheel hub bearing fastening ring 932 ± 98 (93 ± 9.8)
Wheel fastening nut 490 ± 50 (49.5 ± 5)
Rear brakes (Rear axles MS13—165)

Screw fastening the brake disc to the wheel hub 281.5 ± 13.5 (28 ± 1.3)
Brake caliper support fastening screw 289.5 ± 14.5 (29 ± 1.5)
Wheel hub bearing fastening ring 932 ± 98 (93 ± 9.9)
Screw fastening the axle shaft to the wheel hub 262 ± 35 (26 ± 3.5)
Brake caliper fastening screw 738.5 ± 61.5 (74 ± 6)
Rear brakes (Rear axles SP145E)

Wheel hub adjusting nut securing ring 392.3 ± 20 (40 ± 2)
Nut for brake support fastening screw 289.5 ± 14.5 (29 ± 1.5)
Wheel fastening nut + 50
600 — 20 (60 +— 25 )
Screw fastening the axle shaft to the wheel hub 232.4 ± 24.5 (23.2 ± 2.4)

TOOLS
99301001 Grinder and turning machine for brake drums and discs
99301005 Brake discs grinding assembly
99301006 Brake jaws turning device
99305087 Riveting press
6810
6 810 4 12
2 14
6 8 1012 4 12
2 14 0 16
4
2 14 0 16
0 16 810
6 8 10 12
4 12 14
2 14 16
0 16
99305117 Pneumatic circuits control instruments
99354207 Wrench (94.5 mm) for wheel hub covers (for front axles 5842/5
— 5851/5 — 5871/5)

TOOLS
99355038 Wrench (65 mm) for wheel hub cover (for front axle 5845) and
for wheel hub bearings adjustment nut (for front axles 5842/5 —
5851/5) (use with 99370317)
99355167 Wrench (114 mm) for wheel hub bearings adjustment nut (for rear
axles PR140E — PD145E)
axle MS08—125)
axle MS13—165)
axle MS10—144; MS10—164)
99356001 Brake jaws adjustment wrench (for rear axle PR140E — PD145E)

TOOLS
99363204 Gaskets removing tool
99370006 Handle for interchangeable beaters (for front axles 5845 — 5871/5)
99370317 Reaction lever with flanges check extension
99370700 Wheel hub assembling guide (for rear axle MS13—165)
99370711 Wheel hub assembling guide (for rear axle MS08—125)
99370712 Wheel hub assembling guide (for front axle 5845)

TOOLS
99370714 Wheel hub assembling guide (for front axles 5842/5 — 5851/5)
99370715 Wheel hub assembling guide (for front axle 5871/5)
99370719 Wheel hub assembling guide (for rear axles MS10—144;

MS10—164)
99372213 Drum turning tool (use with 99301001)

(for rear axle PR140E — PD145E)
99372217 Tools for disassembling and reassembling brake jaws check springs
(for rear axle PR140E — PD145E)
99372228 Hub for placing disassembled floating jaws turning tools (to be used
with 99301001) (for rear axle PR140E — PD145E)

TOOLS
99372229 Tool for turning disassembled floating jaws (Stop—Master)

(use with 99301001 and 99372228) (for rear axle PR140E —
PD145E)
99372239 Tool for mounting the thrust presser with brake caliper protection
99372240 Tool for disassembling/re—assembling the brake caliper sliding

collar guide bushings (to be used with 99372237)
99372242 Tool for countersinking the brake caliper sliding collar guide
bushing
Tool for mounting the thrust presser inner gaskets (to be used with
99372243 99372239) and the brake caliper guide pin brass bushing (to be
used with 99372240 and the screw of 99372237)
Tool for mounting the brake caliper guide pin rubber bushing (to
99372244 be used with the screw of 99372237)

TOOLS
Tool for disassembling the brake caliper guide pin rubber bushing
99372245 (to be used with the screw of 99372237)
99373002 Coupler for mounting the wheel hub inner gasket (for rear axle
PR140E — PD145E)
99374106 Keyer for assembling internal wheel hubs gasket (use with
99370005) (for rear axle PR140E — PD145E)
99374132 Keyer for assembling internal wheel hubs gasket (use with
99370006) (for front axle 5871/5)
99374233 Keyer for assembling internal wheel hubs gasket (for front axles
5842/5 — 5851/5)
99386523 Flanging machine for brake system pipings

TOOLS
99387050 Cutting nippers for polyamide pipes
99388001 Wrench (80 mm) for wheel hub bearings adjustment nut
(for front axle 5871/5)
99389819 Dynamometric wrench (0 — 10 Nm) with 1/4” square connection
99395026 Tool for checking hub rolling torque (use with dynamometric
wrench)

Print 603.93.391
SPECIFICATIONS AND DATA — PNEUMATIC SYSTEM

DENOMINATION CHARACTERISTICS
Compressor
- Type: KNORR Single—cylinder
Displacement 225 cm3
- Type: KNORR Single—cylinder

Displacement 359 cm3 (*)
(*) series—production on Full Pneumatic models — Optional on the other models
A.P.U. (drier/4 ways)

- Type: KNORR LA 8104/5/6/7
Drier
Disconnection pressure 11.0 ± 0.2 bar
Connection/disconnection pressure difference 0.7 + 0.6 bar
Safety valve opening pressure 13.0 + 4.0 bar
Heat resistance max + 100° C
Operating temperature —40° C ÷ +80° C
Supply voltage 24 V
Power 100W 24V
4—way protection valve

Opening pressure section 21—22 ≥ 7.5 bar
Opening pressure section 23—24 ≤ 8.0 bar
Closing pressure section 21—22 6.5 ± 0.25 bar
Closing pressure section 23—24 ≥ 6.5 bar
A.P.U. (drier/4 ways) (for vehicles RS)

- Type: KNORR LA 8219/LA8220 — BOSCH 484460166/484460167
Drier
Disconnection pressure 11.0 ± 0.2 bar
Connection/disconnection pressure difference 0.7 + 0.7 bar
Safety valve opening pressure 15.5 ± 2 bar
Heat resistance max + 80° C
Operating temperature —40° C ÷ +65° C
Supply voltage 24 V
Power 100W 24V
4—way protection valve

- Type: MARELLI VPS45A — WABCO 9347140190
Opening pressure section 21—22 ≤ 7.5 bar
+0.5
Opening pressure section 23—24 ≥ 7.5 +0.2 bar
+1
Closing pressure section 21—22 6.5 —0 bar
+1
Closing pressure section 23—24 6.5 —0 bar

Air tanks
Front axle 15 l
Rear axle 15 l
Trailer + parking (for vehicles adapted for towing) 20 l
Front axle (for vehicles adapted for towing and Models 180E..) 20 l
Rear axle (for vehicles adapted for towing and Models 180E..) 20 l
Manual discharge valve

- Type: VOSS 520 899 750 0 — TECHNOMATIK TP 1609.00.00 — SIRIT VSM2215
Maximum pressure 13 bar
Safety valve
Calibration for models with mechanical suspension (optional) 12 ± 1.2 bar
Calibration for models with pneumatic suspension (optional) 12 ± 1.2 bar
Duplex distributor
- Type: KNORR DX 65 A — DX 65 B
Supply pressure 11 ± 0.2 bar
Self—limiting pressure 7.6 ± 0.3 bar
Pressure reducer (for vehicles adapted for towing)

- Type: BENDIX HVSI AC 156 B
Supply pressure 18 bar (max)
+0
Output pressure 8.5 —0.4 bar
Safety valve opening 10 ± 0.5 bar
- Type: WABCO 475 015 0310

Supply pressure 11 bar
+0
Output pressure 8.5 —0.4 bar
Safety valve opening 11 bar (max)
Relay valve
- Type: KNORR AC 574 AXY
Maximum operating pressure 10 + 0.2 bar
Thermal application field —40° ÷ 40°C
Check valve
Parking brake distributor (single vehicles)

- Type: KNORR BREMSE DFR0208A
Supply pressure 11 bar
Operating pressure 7.5 bar
Control lever excursion (discharging) with safety braking start (resistance point) 67°
Parking braking 73°

Parking brake distributor (vehicles adapted for towing)

- Type: KNORR — BREMSE DPM 90 EY
Supply and operating pressure 8.5 bar
Control lever excursion (discharging) with safety braking start (resistance point) 67°
Parking braking 73°
Control braking for supply check to trailer braking modulated servodistributor 86°
Parking brake safety distributor (upon request)

- Type: WABCO 434 205 0300
+ 0
Cylinder pressure (under which the supply is blocked) 4 — 0.6 bar
Quick discharge valve

- Type: BENDIX HVSI KX 1294/2 — WABCO 973 500 006 0
Max. operating pressure 10 bar
Triple—control servodistributor (for vehicles adapted for towing)

- Type: KNORR — BREMSE AC 597 B
Predominance 0.2 bar
+ 0.5
Distributor intervention differential pressure (ducts 41—42) 2.5 — 0.3 bar
Maximum allowed pressure 12.5 bar
- Type: WABCO 973 009 002 0

Thermal application field —40 °C...+80 °C
Moderate and automatic coupling heads

- Type: BOSCH — KNORR — WABCO — ISO
Pressure control plug valve

- Type: RAUFOSS 623.7776 — FER.NA F103 087
Max. operating pressure 12.5 bar
Membrane brake cylinder (for front axles — models 110 EL.. — 120 EL..)
- Type 22: WABCO 423 110 711 0

Membrane brake cylinder (for front axles — models 120 E.. — 130 E..)
- Type 14: KNORR IC 72563
Membrane brake cylinder (for front axles — models 140 E..)

- Type 20: KNORR Z011564



Membrane brake cylinder (for front axles — models 190 EL..)


Combined brake cylinder (for rear axles — models 110 EL.. — 120 EL..)
- Type 16/16: WABCO 925 424 839 0
Max service brake operating pressure 10 bar
Max. parking brake operating pressure 8.5 bar
Spring load 6500 N
Combined brake cylinder (for rear axles — models 120 E.. — 130 E.. — 140E..)
- Type 16/27: KNORR — BREMSE BS 8317/BS 8316 (Z005498)
Stroke 57 mm

Combined brake cylinder (for rear axles — models 150 E..)
- Type 16/24 HFL3: KNORR — BREMSE BS 8320/BS 8321
Stroke 57 mm
- Type 18/24 HFL3: KNORR — BREMSE BS 9364/BS 9365

Stroke 57 mm

- Type: 18/27: KNORR Z005396
Max service brake operating pressure 10.7 bar
Minimum stroke 57 mm

- Type: 18/27: KNORR IC 68084
Combined brake cylinder (for rear axles — models 190 EL..)

- Type: 20/27: KNORR IC 68086

- Type: 9/6000/180: BENDIX DZ 5478
Membrane brake cylinder (for rear axles — models 260 E..)

- Type 9/187: BENDIX EF 90FY
Barrel length 8.5 bar
Electronic unit for ABS/EBL system

- Type: KNORR ES 1082—II/35431 — WABCO O 486 14 110 — B 486 104 073
Supply voltage 22 ÷ 26 V
ABS/EBL system wheel anti—locking modulator

- Type: KNORR IC65307
- Type: WABCO 472 195 055 0 — KNORR 1C57664


SPECIFICATIONS AND DATA — BRAKES
FRONT AND REAR BRAKE Front axles

CALIPERS AND DISCS 5851/5 — 5842/5 Front axle
Front axle 5845
5860 5871/5
Rear axle
Rear axles Rear axle
MS08—125
MS10—144 MS13—165
MS10—164
Floating caliper Floating caliper Floating caliper

PAN 17 SB6 — SN6 KNORR SN7
Brake calipers cylinders:

∅ — number — 2 2
— diameter ∅ mm — — 68
Braking gaskets thickness:

— normal S mm 19 21 21
S
— minimum allowed S mm 2 2 2
∅ Brake discs diameter ∅ mm 330 377 432
Brake discs thickness:

— normal S mm 34 ÷ 33.85 45 45
S — minimum allowed S mm 28 41 41
WHEEL HUBS
2, tapered—roller type (for front axles)

Wheel hub bearings UNIT BEARING
UNIT BEARING (for rear axles)
Front axle bearing rolling torque:
Nm — 3 5
(kgm) — (0.3) (0.54)
Not adjustable
Wheel hubs clearance
(securing ring nut torque tightening)
Oil for wheel hub bearings Tutela SAE W 140/M DA
Amount for every hub L* (Kg) 0.23 (0.2) 0.23 (0.2) 0.33 (0.3)
* The oil amounts refer to front axles; the amounts referring to rear axles will be specified in the next edition.

Print 603.93.391
TANDEM AXLE (Meritor SP 145 E)

Rear drum brakes PD 145 E (R2468) PR 140 E (R0868)
INTERMEDIATE REAR
Drum diameter:
— Rated ∅ mm 380.9 to 381.1
∅ — 1st increase ∅ mm 382.9 to 383.1
— 2nd increase ∅ mm 384.9 to 385.1
Braking gaskets thickness:
— Rated S mm 18
— 1st increase S mm 19
— 2nd increase S mm 20
— Minimum allowed S mm 6.5
(in the area where a wear is signalled)
∅ Braking gaskets diameter:

— Rated ∅ mm 378 to 380
— 1st increase ∅ mm 380 to 382
— 2nd increase ∅ mm 382 to 384
Braking gaskets width
L mm 177 to 178.6
L
G
Clearance between braking gaskets
and drum:
G mm 0.45 to 1.55
Maximum tapering error for drum

E diameter after turning
E mm 0.04
Rear wheel hubs
Wheel hub bearings 2 with tapered rollers
Hub bearings and play 0 to 0.05 mm
Wheel hub and play Adjustable through a ring nut

with Hendrickson suspension
Liters (kg) 16.2 (14.6) 12.2 (11)

CHECKS OF MAIN BRAKE SYSTEM COMPONENTS

Since the vehicle system is homologated according to European Code standards, it is mandatory to periodically check the efficiency
of system and related components with device 99305117.
These checks must be carried out with unmoving vehicle, using the compressed air into the tanks, recharged, with started—up
engine, by the compressor.
Always lock the vehicle, before any intervention. Periodically check the manometers by comparing them with a sample
! manometer.
DEVICE DENOMINATION INTERVENTIONS
Check of fittings tightening and compressor securing; make sure that

Compressor
cooling fins are not dirty.
Check by actuating a drain valve or by loosening a screw plug (with

integrated drain hole), whether the air drier correctly operates. In
A.P.U. (Air Processing Unit)
this case air must go out of the tank without traces of condensate
water.
Air tanks
Humid Check of corrosion—preventing seal and protection.
Front axle Discharge the condensate from tanks by operating on the drain
Rear axle valve.
Trailer + parking
Completely press the pedal; when the action ceases, the pedal must
immediately go back into its rest position.
Pressure limiting: 7.6 ± 0.3 bar.
Duplex distributor
Check that the pedal gasket is not worn, that brake control tie—rods
are well tightened and lubricated, nor distorted. Check that lever
housings are neither worn nor oxidised.
Check calibration pressure (see Characteristics and data table).

Pressure relief valve
Check its functionality.
Check functionality and seal evaluating brake cylinders quick

Relay valve
intervention.
Engine brake control

Check functionality and seal.
operating cylinder
(continues)

Parking brake distributor Actuate the parking brake distributor till it snaps; the manometer
inserted on the control plug must mark the pressure discharge down
to 0 bar in 1 sec.
Parking brake distributor Simultaneously at the automatic coupling joint duct, the manometer
(with control position) must show a pressure of 7.5 bar.
Check functionality and seal.

Quick discharge valve Actuate the parking brake distributor, verify that the compressed air
is quickly discharged from the circuit.
Fill—in the tank. Connect a manometer to the automatic coupling

head, and one to the moderate coupling head.
At a pressure of 1 bar, sent by Duplex distributor, in the moderate
coupling head a pressure from 0.8 to 1.5 bar must correspond. Carry
Trailer braking triple—control
out a total braking (unmoving vehicle).
servodistributor
At the coupling head, the required braking pressure must be
available or a pressure decreased by 0.5 bar. Insert the parking brake;
at the moderate coupling head, the pressure must remain
unchanged or decreased by 0.5 bar.
Check that there are no dirt or damages in coupling guides.

At the end of the coupling, actuate the brake pedal and check seal
Coupling heads
and stability between coupling heads by inserting air at 7.5 bar.
Check that there is no air leakage from coupling gaskets.
Hydraulic or pneumatic pressure Make sure that protection plugs are inserted, check that they are
control plugs completely screwed.
Check securing, integrity and seal.

Membrane cylinder The drain hole must be downwards oriented and must not be
clogged.
Check securing, integrity and seal.

Combined cylinder The drain hole must be downwards oriented and must not be
clogged.
(continues)

Disc brake caliper

Brake disc Check braking gaskets wear status, brake disc scorings and wear,
pistons efficiency, dust—guarding casing wear conditions.
Braking gaskets
When ceasing the pressure on the pedal, the jaws must quickly and
smoothly go back on all wheels to their rest position.
Drum brakes
Check clearance between jaws and drum.
Check braking gaskets thickness.
Pipings and fittings Make sure that metal pipings are in a perfect condition, without
dents nor cracks; polyamide pipings must not show fissures, cuts or
nickings. Make further sure that they are far from body and chassis
cutting edges that could damage them. Check that all piping
anchoring brackets are well secured; their loosening in fact causes
vibrations with following danger of breakages. Verify that rubber and
cloth pipes have not come in contact with oil or mineral grease, that
are rubber solvents. Strongly press the brake pedal and check that
pipes do not show swellings, that signals leakages from internal pipe.
Check that there are no brake fluid leakages from various fittings,
otherwise it will be necessary to completely tighten them, with the
warning not to generate, during their closure, anomalous pipe
torsions. In all mentioned cases, it is necessary to replace the related
parts when there is even a minimum doubt about their efficiency.
Apart from their conditions, it is advisable to replace the hoses after
many kilometers or after a long period of vehicle use: this to avoid
a sudden breakage due to ageing and fatigue.
Pneumatic system seal with off This check is carried out on threaded fittings, inserting an air pressure
engine under the disconnection not less than 5 bar into the system, laying rather dense soapy water
pressure on joints and fittings with a soft brush and observing that there are
no leakages. An air loss is tolerated corresponding to a ∅ 25 mm
soap bubble in 5 seconds, or anyway a max pressure drop within 10
min of 2% of disconnection pressure = 0.22 + 0.02 bar.
Pneumatic system seal in the For 3 min the pressure must be kept stabilised in the pneumatic
partial braking range with 3 bar system. The check must be carried out with disconnected parking
brake.

Print 603.93.391
MAIN BRAKE SYSTEM COMPONENTS

790510 COMPRESSOR
- Knorr
Figure 30
30411
It produces the necessary compressed air for braking system

and auxiliary services.
Diagnostics
INCONVENIENCE POSSIBLE REASON REMEDY
Oil leakages from flange, ex- Incorrect tightening torque. Lock the screws according to the required values.
ternal side
Not perfectly plane flange body sealing surfaces. Check sealing surfaces, replace faulty parts or take them
back on a plane.
Broken gasket. Replace gasket.
Damaged shaft gasket. Replace gasket.
Oil leakage from the head Worn scraper ring (it is noted because all the Replace the whole piston
sealing seat is shining).
Faulty scraper ring assembling. It must be assembled with the writing TOP toward the
compressor head
Scraper ring and elastic bands all on the same Assemble piston rings at 120º one form the other
vertical line.
Scored or ovalised cylinder. Grind the cylinder and assemble a greater piston
Total lack of compression Deteriorated compression or suction valve. Replace the worn parts.
Elastic bands all on the same vertical line. Assemble the bands at 120° one to the other.
Holed piston or breakage of piston—related Replace the complete piston.
members.
Damaged gaskets. Replace the gaskets.
Scarce efficiency Worn elastic bands. Replace the piston (completed with elastic bands)
Air leakage between cylinder and head. Replace the gasket and lock the screws at the required
tightening torque.
Excessive clearance between piston and Grind the cylinder and assemble an increased piston.
cylinder.
Carbonised oil particles between suction and Clean the valves.
compression valves.
Mechanical noise Excessive clearance between connecting rod foot Check affected couplings tolerance.
and pin, between pin and piston hole, between
shaft and connecting rod head, between shaft and
bushings and between flanges and shaft.
Excessive clearance between piston and cylinder. Grind the cylinder and assemble an increased piston.
Excessive fouling between piston and cylinder Clean fouled parts and replace the valves.
head caused by burnt oil.
Water blow—by Scored and irregular head gasket or coupling Replace the faulty parts.
planes.

A.P.U. (Air Processing Unit)

Its task is keeping cleanness and correct humidity of air in the
Figure 31 distribution system and keeping the necessary output
pressure for operating the connected systems.
This component integrates the functions of four—way
pressure regulator, pressure reducer for parking, services and
trailer.
Figure 32
62628
Pneumatic connections Electric connections

Drier 6.1 — Negative for thermostatic resistance
1— From compressor
3— Exhaust
24 — To services
25 — To pneumatic suspension
4—way valve
21 — To rear axle air tank
22 — To front axle air tank 6.2 — Positive for thermostatic resistance
23 — To parking plus trailer air tank
24 — To services

Operation
Figure 33
62629
Recharge phase:
The compressed air coming from the compressor through When a pressure of ≤ 7,5 bar is reached, the
the supply fitting ”11” is arranged on the safety valve ”a” controlled—pressure valves will open, thus making it possible
(calibrated at 13+4 bar) and through the suitable channel it to feed the systems connected.
reaches the drier filter. Simultaneously, through the two unidirectional valves ”e”, air
Compressed air gives off, as it passes through the filter, its can reach the controlled—pressure valve of the secondary
own moisture and feeds the timer ”b” chamber through the sections.
calibrated hole. At the same time, it opens the unidirectional The further pressure increase and reaching a pressure > 8 bar
maintain valve ”c”, thus feeding the outlet 24 pressure intake, allow opening the controlled—pressure valves in the
pressure regulator ”d”, pneumatic suspension circuit feed secondary sections and consequently supplying the outlets
outlet 25 and, through outlet 21, the four—way protection 23 and 24
valve. This valve will convey the air below the
controlled—pressure valves of brake system outlets 21 and 22.
(continues)

When reaching the regulator calibration pressure of 10.3 +0.2 Under this failure condition, the possible connected trailer will
bar, there occurs the opening thereof and the consequent instead be automatically braked.
opening of discharge valve ”h” that generates a pressure drop
The system recharge, ensured by the regulator intervention,
inside the drier and the unidirectional keeping valve ”c”
will take back the pressure at the opening levels of the
closure and the activation of the drier filter regeneration step.
controlled—pressure valve of the faulty section (about 7.5 bar),
The slow pressure drop of the timer supply chamber allows
guaranteeing this pressure in all other component outlets.
the pressure return from systems for a time of about 20
seconds. The compressed air returning from systems, when The possible failure of all other sections will guarantee that the
passing through the filter, will guarantee its regeneration and faulty valve opening pressure is kept for the healthy sections.
will discharge itself in the atmosphere through vent 3.
Failure phase of duct 21
In case there is a failure to main four—way protection valve
circuit, the component will behave as follows:
The pressure drop that affects outlet 21 creates a general
pressure drop in the whole component till the closure
pressure is reached (6.5 bar) for the controlled—pressure
valve in the faulty section.
This pressure decrease also goes to the regulator ”d” that by
moving itself goes back to its recharge condition.
The pressure drop in duct 21 creates the displacement and
discharge opening of the safety valve ”f” for the parking duct,
that discharges the protection valve duct 23. With moving
vehicle, the parking cylinders supply will be guaranteed either NOTE With any protection valve failure, the system
by the manual self—limited distributor (single vehicles) or by supply is ensured at pressure levels that guarantee
closing the unidirectional valve (vehicles adapted for towing) brake functionality but filter regeneration will not
avoiding the vehicle self—braking. be ensured any more since this function is only
activated when reaching the regulator triggering
pressure.
Diagnostics
Excessive amount of Clogged filtering cartridge. Replace the cartridge

condensate in the cir-
cuit
The calibration pres- Air leakage from safety valve. Revise the device replacing the worn parts
sure is not reached in
the tank Worn sealing gaskets. Revise the device replacing the worn parts
Exhaust air leakage Insufficient piston seal. Revise the device replacing the worn parts
Air leakage next to Valve leakages in the four sections. Revise the device replacing the worn parts.
plugs
Air leakage in case of Faulty non—return valve operation. Revise the device replacing the worn parts, if necess-
section failure ary, or replace the device.

ENGINE BRAKE SWITCH 543730 ENGINE BRAKE CONTROL

OPERATING CYLINDER
Figure 34 Figure 36
62372 72658
It is a N.O. switch assembled on cabin floor. It provides a The operating cylinder actuates the throttle valve clogging
negative signal to the electronic unit for inserting the engine the engine exhaust gases duct.
brake.
793336 ENGINE BRAKE SOLENOID

VALVE MANUAL DISCHARGE VALVE
Figure 35 Figure 37
62382
71957
It is an on/off solenoid valve of the N.C. type placed on the This valve is assembled in tanks and its function is manually
chassis. removing the possible condensate accumulated in the
This solenoid valve, driven by the unit, suitably supplies the system tanks.
engine brake control operating cylinder. A luminous signaller,
placed on the dashboard, signals the engine brake insertion.

SAFETY VALVE (Optional) Electric connections

1 — Free
Figure 38 2 — Positive for STOP lights/Body Controller
3 — Input positive
4 — EDC positive
Figure 40
71959
It ensures the system limiting at a safety pressure in case of

lack of pressure regulator operation.
793110 DUPLEX DISTRIBUTOR
Figure 39
62579 71951
The device is divided into two independent sections whose The diagram shows the characteristic distributor curve and
adjustment members are controlled in parallel by a push rod the self—limitation value at 7.6 ± 0.3 bar.
that operates on an equalizer.
It takes air from tanks and delivers it to braking elements.
It is self—limited, that is, it limits air delivery at a maximum
established pressure and therefore there occurs a higher
energy availability and a constant maximum braking pressure
independently from pressure oscillations in tanks.
Pneumatic connections
11 — From front axle air tank
12 — From rear axle air tank
21 — To front axle
22 — To rear axle
3 — Discharge

Figure 41 Piston push rod seat (4) initially closes the exhaust and
afterwards opens upper valve (6). Compressed air, from fitting
11, passes and supplies fitting 21 and chamber A.
When in section 21 and chamber A a pressure value is
reached of about 0.15 ÷ 0.3 bar, valve (8) is also opened due
to the piston thrust effect.
Piston (7) abuts on valve (8), closes the exhaust and opens
the passage between fitting 12 and fitting 22.
In case of failure in the control section, the other one
intervenes only due to the mechanical thrust effect of upper
pistons (1 and 4).
By completely operating on control push rod (2) (maximum
stroke), the output pressure of the two sections 21 and 22
reaches 7.6 ± 0.3 bar that is the pressure self—limiting value.
In case of failure 0 (zero) bar in supply fitting, by completely
operating on control push rod (8) air must go out of fitting till
a pressure equal to or greater than 6.5 bar.
Such behaviour is guaranteed by the control push rod (2)
mechanical thrust that abuts on piston (1); afterwards, piston
(4) comes in contact with (7) and opens valve (8).
At a push rod (2) stroke of 0.5 ÷ 1.5 mm, the stop lights
contacts are closed and the engine brake contacts are opened
in microswitches (3).
Unbraking
62580 By releasing the brake pedal, the control push rod (2) and the
Under rest conditions, the exhaust is open, since spring (5) piston assembly (1 and 4) return upwards together with
pushes the pistons assembly (upper valve seat) (1 and 4) piston (7).
upwards. By going on releasing the brake pedal, the valves remain into
Valves (6 and 8) are in contact against their respective sealing their respective entry seats and afterwards the exhaust seats
seats and intercept the passage of air between air inlet fittings of pistons (4 and 7) are detached from valves and air flows to
11 and 12 and outlets 21 and 22. the atmosphere through exhaust 3.
The lower valve seat piston (7) is at rest (running) with
discharge 3 open. At the end of the release, also microswitches (3) return to
By operating on the brake pedal, control push rod (2) and their running position.
pistons assembly (1 and 4) are pushed downwards.
Diagnostics

Air leakage from Outlet ducts leakage for sealing gaskets Revise the device replacing the faulty parts.
discharge hole wear.
Distributor with irregular Self—limitation higher or lower than the re- By operating on the suitable screw, calibrate the device.
self—limitation quired one.
Vibrations when braking Springs wear. Revise the device replacing the faulty parts.
Air leakage caused by piston gaskets seal in Revise the device replacing the faulty parts.
the two sections.
Irregular stop lamp The electric circuit does not close. Replace the switch.
control switch operation
The electric circuit does not open. Replace the switch.

793321 PRESSURE RELIEF VALVE Pressure limitation

Figure 44
Figure 42
34953
Its function is stopping the compressed air flow to users

when pressure in users reaches a certain (calibration) value.
20046
When air contained into chamber (A) reaches the calibration

values, it wins the force of spring (2) and pushes pistons (1
and 3) downwards stopping the supply.
Operation If in fitting 2 the pre—established pressure is accidentally
- System supply exceeded, the piston element goes on running downwards
and valve (2) is opened for the necessary time for discharging,
Figure 43 through hole 3, the excessive pressure.
Bench calibration
Assemble the device on the test bench, and connect
fittings 1 and 2 through pipings to manometers and supply.
—0.3
Adjust through an adjustment screw at the pressure value—0
of 7.5
bar, and simultaneously check the perfect seal thereof.
70118
Air incoming from tanks freely passes through the reducer

from fitting 1 to fitting 2 till the calibration pressure is
reached.
Diagnostics

Fitting 2 pressure Uncalibrated valve. Calibrate the device.
different from Sealing rings leakage. Revise the device replacing the damaged parts.
calibration pressure
Faulty piston and related seat. Replace the device.

Print 603.93.391
793331 RELAY VALVE The device allows accelerating the compressed air discharge
from combined cylinder section, thereby shortening the
Figure 45 braking times.
90402
Diagnostics
Air leakage from ex- Leakage from entry or sealing rings. Revise the device replacing the faulty parts.
haust with discharging
control duct
Air leakage from ex- Leakage from piston gasket or dis- Revise the device replacing the faulty parts.
haust with control charge valve.
duct supply
793319 CHECK VALVE Operation

Figure 46 Figure 47
25958
1. Complete valve — 2. Spring

It allows the passage of compressed air along the direction
33987 shown by the arrow placed on valve body, preventing its
It prevents the compressed air reflow from trailer tank. reflow.
The valve is connected as follows:
1 — Supply
2 — Delivery

794310 PARKING BRAKE CONTROL The device is connected as follows:

MANUAL DISTRIBUTOR 1 — From four—way protection valve;
(Single vehicles)
21 —To quick discharge valve upstream of spring cylinders.
Figure 48
78619
The device, inserted in the tractor parking brake circuit,

allows performing the vehicle safety and parking braking by
discharging air contained in spring cylinders.
Diagnostics

Air leakage from Worn or faulty piston, discharge Carry out an accurate cleaning, making sure that the
exhaust with valve, sealing rings. rubber parts and related seats are healthy.
distributor lever in
unbraking position
Revise the device replacing the faulty parts.
Air leakage from Faulty or deteriorated piston and Carry out an accurate cleaning and check of parts, revise
exhaust with related sealing ring. the device replacing the faulty parts.
distributor lever in
safety or parking
braking position
Air leakage from Faulty or worn plate, gasket, sealing Carry out an accurate parts cleaning, check sealing
distributor control rings. surfaces and gasket, make sure that rubber part and
lever cover related seats are healthy.
Revise the device replacing faulty or worn parts, possibly
restore union plane surfaces.
Difficult distributor Interferences inside the distributor. Carry out an accurate cleaning and check of all
control lever component parts.
rotation Revise the device replacing the faulty parts, when
assembling moderately grease all sliding parts.
If such failures or wears are detected that impair the

operation, replace the complete device.

794310 PARKING BRAKE CONTROL

MANUAL DISTRIBUTOR
(Vehicles adapted for towing)
Figure 49
78618
The device allows performing the safety and parking braking

of tractor and trailer.
The parking braking is mechanical for tractor and pneumatic
for trailer.
The device further allows checking the braking tractor effect.
Such operation is mandatory when the vehicle is parked
under high slope conditions.
The device is connected as follows:
1 — From four—way protection valve
21 — To spring cylinders
22 — To trailer braking triple—control servodistributor.
Diagnostics

Air leakage from
exhaust with control
lever:
In unbraking position Faulty valve (5), related seat or sealing Check and revise the device, replacing the faulty parts.
ring Accurately clean the various pieces composing it.
In braking position Deteriorated valve (9), pistons (5), Check and revise the device, replacing the faulty parts.
sealing rings and valve (7). Accurately clean the various pieces composing it.
Difficult control lever Interference inside the distributor Revise the device and wet all sliding parts.
rotation

QUICK DISCHARGE VALVE The apparatus embeds a device that allows performing the
trailer braking even in case of control duct failure.
Figure 50
Predominance adjustment
The apparatus is equipped with a predominance adjusting
device.
Figure 52
71952
Function of the component is discharging the compressed air

from front axle membrane brake cylinders to obtain a quick
unbraking.
793332 TRIPLE CONTROL SERVODIS-

bar
TRIBUTOR AC 597 B
Figure 51
60255
The operations to be carried out for adjusting the

servodistributor predominance are performed in the
following order:
62373
- Unscrew screw (2) from silencer body.
The device, controlled by the two independent tractor - Insert a socket—head screw in the hole through silencer
circuits in duplex distributor and spring brake circuit, controls body and operate on the hexagonal body (1) hole.
trailer braking; moreover, a predominance adjusting device is - By CLOCKWISE rotating a predominance increase is
provided that is placed outside the lower part. obtained.
- By COUNTERCLOCKWISE rotating, a predominance
decrease is obtained.
Diagnostics
Air leakage from Sealing gaskets leakage. Revise the device replacing the faulty parts.
exhaust under rest Faulty discharge valve and seat. Revise the device replacing the faulty parts.
conditions
Output pressures Sealing gaskets air leakage. Revise the device replacing the faulty parts.
different from the Worn or faulty pistons and seats. Revise the device replacing the faulty parts.
established ones Yielded springs Revise the device replacing the faulty parts.

798510 COUPLING HEADS PRESSURE PLUG VALVE

- Moderate
Figure 55
- Automatic
Figure 53
71953
Pressure plugs are inserted into pneumatic system pipings or

52871 tanks, in order to facilitate connecting diagnostics
manometers.
The version for ”Moderate” duct is equipped with a red cover
and a safety projection (1), while the version for ”Automatic”
duct is equipped with a yellow cover and a lateral safety
projection (2). The safety projections are used to avoid
coupling errors.
794911 MEMBRANE BRAKE CYLINDER

Operation (for disc brakes and drum brakes)
Figure 54 Figure 56
72657
The coupling operation consists in rotating a head with

respect to the other (tractor trailer), guided by a rib that runs 71954
into a suitable guide till it locks. In this phase, seal gasket (C)
pushes downwards the shutoff valve from the other head (A), The brake cylinder transmits the force impressed by the
by overcoming the resistance of spring (B). A communication compressed air when operating the brake pedal to the
is thereby opened between the two heads guaranteeing their mechanical service braking device.
seal. By uncoupling the heads, the valves are automatically In case of anomalies, it is necessary to replace the complete
closed guaranteeing their seal. cylinder.

794922 COMBINED BRAKE CYLINDER Repair interventions

Figure 59
Figure 57
36744
The device is composed of two parts: a membrane part for
service braking and a spring part for parking and emergency 35721
braking in case of braking system failure. Before detaching the combined cylinder (1) from the vehicle,
perform the manual unbraking procedure of the combined
Combined cylinder emergency unbraking cylinder by unscrewing screw (2) till its end of stroke.
device
Figure 58 NOTE It is possible to disassemble only the membrane
section.
In case of anomaly of the cylinder spring section, do
not disassemble such part since the above
operation could be dangerous for the operator.
NOTE It is advisable, before proceeding with the

disassembly, to accurately clean the external parts
from earth and other impurities that by seeping
inside could damage the cylinder.
36745
When it is not possible to pneumatically supply the combined

cylinder (1) spring section, it is possible to manually unbrake the
vehicle to allow its towing. In order to unbrake the vehicle, it
is necessary to unscrew screw (2) till its end of stroke.
Diagnostics
Air leakage from Broken or holed membrane. Replace the membrane.

exhaust or check Membrane lip breakage.
band Check band locking screws loosening. Tighten the screw.
Air leakage from Deterioration of parts composing the Revise the device replacing the worn parts and if necessary
membrane section spring section. replace the complete cylinder.
supply
Braking force Spring breakage. Replace the complete cylinder.

decrease during
parking brakings

Print 603.93.391
ABS SYSTEM WITH EBL FUNCTION Operation

”ABS” Anti—Lock Brake System Every channel comprises four functional circuits: the first one
is the input one, that receives analogue signals emitted by the
The system is able to avoid wheel locking, that could occur sensor provided on the corresponding wheel, filters them
during the braking step, under any vehicle load condition and from parasitic signals and converts them into digital
wheel—road bed friction coefficient condition, in order to information by means of cycle length measures. Then there
guarantee better braking performances and a higher vehicle is a main circuit, that consists in a microprocessor, that
stability. processes information received by the input circuit: it has a
The system, controlled by an electronic unit, is activated at complex program that allows it to determine wheel
start—up and automatically operates for speeds greater than acceleration and deceleration values, and to perform the logic
5 km/h if, following a braking, one or more wheels tend to combination of the various adjustment signals. If necessary it
lock. emits two control signals, that are sent to the corresponding
The ABS system is able to check the engine brake exclusion electro—pneumatic valve through the third unit circuit, the
and the divider locking (if it exists). control one, to adequately adjust the braking pressure.
These components are disconnected if the trend of one or The fourth and last circuit finally is the safety one, that takes
more drive wheels to lock themselves is detected. care of verifying the efficiency of various system components.
The reconnection automatically occurs when the ABS If an anomaly is detected, it takes care not only to inform the
system action ceases. driver by turning on the suitable warning light on the
dashboard, but also to automatically disconnect the whole
”EBL” (Electronic Brake Limiter) anti—skid ABS system leaving however the traditional braking system
device in efficiency.
The ”EBL” function checks the rear axle wheels ”skid” by
comparing it with the front axle wheels speed.
Depending on these values, the electronic control unit
computes vehicle speed, deceleration and checks the
presence of ”skid” between rear axle wheels and front axle
wheels.
526713 REVOLUTIONS SENSORS
The EBL function is activated (rear ABS modulators keep the 526712 PHONIC WHEELS
imported pressure) when the driver applies an excessive
braking force with respect to load conditions being present
on the vehicle, in summary when skid thresholds on rear axle Figure 61
and vehicle deceleration thresholds are exceeded.
Data processed by the electronic control unit are wheel
revolutions and braking pressure detected by the pressure
sensor installed upstream of rear axle ABS modulators.
526711 ELECTRONIC UNIT

Figure 60
35383
Task of revolutions sensors and phonic wheels is detecting

revolutions of their respective wheels.
Operation
The phonic wheel is housed in the wheel hub and rotates at
the same wheel speed. It generates alternate voltages by
induction in the sensors, whose frequency is proportional to
the rotation speed of the respective wheel. These voltage
signals are transmitted to the unit to be adequately
71955 processed.
The electronic unit is the system brain. Its task is driving the For every wheel a sensor and a phonic wheel are assembled.
system solenoid valves depending on signals measured by This arrangement allows driving during the adjustment an
wheel revolutions sensors. individual braking pressure for every wheel, optimising
running stability and braking space.

526714 ELECTRO—PNEUMATIC VALVE - Pressure decrease
Figure 64
Figure 62
71956
35381
Task of the electropneumatic valve is modulating the air The electronic unit detects the trend of wheel to be locked
pressure on front brake circuit. and intervenes sending a pulse to solenoid valves (2 and 3).
The device is connected as follows: Solenoid valve (2) moves downwards while valve (3) moves
1 — From duplex distributor upwards. Air contained behind the membrane (4) moves
behind the membrane (1) that lock the supply. Membrane (4)
2 — To front circuit pneumohydraulic converter moves outwards and allows air contained in duct 2 to be
3 — Exhaust. discharged to the atmosphere through duct 3 reducing
pressure going out of the solenoid valve.
Operation
The electro—pneumatic valve modulates air pressure in the
brake circuit according to the signals received from the - Pressure keeping
electronic control unit in the three phases:
- Pressure increase Figure 65
Figure 63
35380 35382
The compressed air from the duplex distributor to duct 1 In this phase, the two solenoid valves are displaced
pushes membrane (1) outwards, thus allowing air to reach downwards allowing air to be arranged behind the
outlet 2 and, therefore, the brake cylinders; simultaneously, membranes (1 and 4) that, due to the greater operating
air is arranged behind the membrane (4) that closes the surface, close both supply and exhaust, thereby keeping the
exhaust allowing to increase the pressure in the duct 2. previously—reached pressure value constant in duct 2
whichever the pressure exerted on the brake pedal.

BRAKE REPAIRS
(Models ML 110 EL.. / 120 EL..)
5274 Front Brakes Automatic braking gaskets wear recovering
device
(Brake calipers of the PAN 17 type)
The braking gaskets wear recovering device is housed inside
5272 Rear Brakes the thrust element (13).
(Brake calipers of the PAN 17 type)
Every time the lever (17) is actuated by the brake cylinder,
the pin (25), assembled on it, performs an excursion in the
Description axial groove of the return sleeve (5). The width of such
The PAN 17 (PERROT—AXIAL—NEW) brake mechanically excursion corresponds to the operating clearance between
operates by means of a membrane brake cylinder if braking gaskets (7—9) and brake disc (8). If due to wear, the
assembled on front axle, or of a spring brake cylinder if distance between braking gaskets (7—9) and brake disc (8)
assembled on rear axle; the above cylinders are flanged to increases, lever (17) will have to perform a greater rotation
brake caliper body. to transmit the braking force, and consequently pin (25)
The brake caliper is of the floating type. It axially slides on integral therewith, once having reached the groove end due
guide pins (3 and 28) assembled on support (2) and braking to the lever (17) overstroke effect, will rotate the return
gaskets (7 and 9), also subjected to axial movements, are kept sleeve (5). Such rotary movement will be unidirectionally
inside the brake support (2) by a check fork (21). In this way transmitted to driven sleeve (6) by spring (14). In turn, the
the braking force is transmitted to abutment surfaces inside driven sleeve (6) transmits the rotary motion to the
the support (2). adjustment nut (12) through a tapered coupling functioning
as torsion regulator. This coupling is kept by the force that
The brake caliper (17) is transversally placed inside the brake spring (15), abutting on washer (23), exerts on driven sleeve
caliper (1), and its rotary movement, during the locking phase, (6). Screw (11) is screwed in adjustment nut (12). On the
ensures an optimum operation for the brake and a small screw (11) end, a groove is obtained in which the thrust plate
hystheresis. (10) pin is inserted.
This type of brake is equipped with braking gaskets (7—9) with This connection, during adjustment nut (12) rotation, makes
large wear volume in order to extend their replacement screw (11) unscrewed so that this latter one, operating on
times. thrust plate (10), makes the slider advance, compensating the
The braking gasket replacement operation is made easier and thickness lost by wear and approaching friction gaskets (7—9)
quicker by this very model of caliper characterised by a radial to disc (8). If under the above conditions, the brake lever (17)
type of opening. is further rotated, the actuation force between adjustment
In order to compensate for sliders wear, the actuator nut (12) and thrust element (13) or between nut (12) and
mechanism is provided with an infinitely—varying automatic screw (11) will exceed the moment that can be transmitted
adjustment device, whose action changes according to the and applied to nut (12) due to driven sleeve (6) torque
applied force. This provides a constant clearance, limiter. This latter one, then, sliding with respect to the
independently from the level of use or application of the adjustment nut (12), will not generate any mechanism
brake and together with a sturdy and rigid caliper structure, adjustment. In this way the adjustment device will not be
it ensures minimum actuator cylinder strokes, contributing to activated if the load exerted thereon will exceed the spring
increase emergency braking safety coefficients. (15) calibration value, safeguarding the system from damages.
With the direct brake cylinder assembly on caliper a very When the braking action ceases, internal components are
compact assembly is obtained with following chance of taken again into their original position from reaction springs
optimally using the device, that is the widest steering angle (27). Pin (25) oppositely rotates the return sleeve (5) and by
possible. means of the unidirectional connection, the motion will not
be transmitted to other adjustment devices that will be
Brake locking system and brake operation excluded by the rotary motion.
The brake cylinder (not shown in Figure 66 page 80) is
flanged to cover (24) of brake caliper and its shoe is inserted
into lever (17). Lever (17) and brake shaft are embedded one
into the other and the same are supported by ball bearings
(18 and 19).
The brake cylinder shoe under the pressurised air action
moves the thrust element (13), which, winning the spring
reaction (27), pushes through plate (10), the braking gasket
(9) against the internal brake disc (8) side. At the same time,
the thereby—exerted braking force is divided on the external
brake disc (8) side through the action that cover (24) of brake
caliper (1) exerts on braking gasket (7). When the braking
action ceases, springs (27) take the whole mechanism to its
original position.

Figure 66
61961
SECTION A—A
1. Brake caliper— 2. Braking gaskets support — 3. Guide pins — 4. Screw — 5. Return sleeve — 6. Driven sleeve — 7.Braking
gasket — 8.Brake disc — 9. Braking gasket — 10. thrust plate — 11. Screw — 12. Adjustment nut — 13. Thrust element —
14. Spring — 15. Spring — 16. Plug — 17. Brake lever — 18. Ball bearing — 19. Ball bearing — 20. Small springs — 21. Fork —
22. Screw — 23. Washer — 24. Brake caliper cover — 25. Pin — 26. Screw — 27. Spring — 28. Guide pin.

527420/527450 Efficiency check for braking 527417 Braking gaskets replacement

gaskets/brake disc wear recovering device
NOTE The below—described operations are referred to
Figure 67 rear brakes and must be deemed as valid also for
front brakes.
Arrange the vehicle on a plane ground and lock its rear

wheels; loosen nuts (1, Figure 67) securing the front wheels.
With an hydraulic jack lift the vehicle from its front side and
rest it on two support stands.
Unscrew securing nuts and with hydraulic trolley 99321024
(2, Figure 67) detach the wheels.
NOTE Verify the wear recovering device efficiency as

described in the related chapter.
40570
Disassemble braking gaskets as described in the chapter
about Wheel hubs revision.
Unscrew securing screws (1) and with hydraulic trolley
99321024 (2) detach the wheels.
NOTE Replace all braking gaskets even if only one of them
shows anomalies.
Figure 68
Remove dirt and rust around the braking disc edge with a
scraper or an old screwdriver, resting on the caliper body,
making disk (1) rotate.
End the work with abrasive cloth. Remove residuals by using
a suction device or with canvasses and brush.
Do not use petrol or other petroleum derivatives that could
create brake failures.
Use only denatured alcohol with methanol or isopropyl
alcohol.
Accurately clean brake disc braking area surfaces.
Checks
60342
NOTE Visually check dust—guarding casings conditions; if
Remove protection plug (2) from brake caliper (1). they show distortions or breakages, it is necessary
Through a wrench rotate adjustment screw (3) clockwise by to replace them; such operation implies the need
1/2 revolutions increasing clearance between braking gaskets of disassembling the brake caliper, so that it is
and disc. advisable to detach the brake caliper body
Slightly actuate the brakes (braking pressure about 1 bar) for completed with carrier plate for the complete
about 5 times, simultaneously verifying that the wrench revision.
rotates counterclockwise with small rotations till the
required clearance (0.7 mm) is restored between disc and Verify that the caliper freely rotates on its guides.
braking gaskets. If anomalies are detected on one brake caliper only, it is
advisable to proceed with the complete revision of both
Otherwise, if the wrench does not rotate, rotates only upon
brake calipers.
the first application or even rotates forward and backward,
Remove dirt from brake caliper using a metal brush and
this means that the device is faulty. It is then necessary to
avoiding to damage dust—guarding casings.
replace the complete caliper.
Clean braking gaskets sliding surfaces.
Check brake disc conditions as described in the related
NOTE The angular wrench movement is reduced during chapter.
the check operation. Check wear sensors conditions, and when detecting
anomalies in them, in cables or leads, replace the support
bracket completed with the above—listed parts.
At the end of the check and/or possible replacement of brake For the assembling, reverse the disassembling operations,
caliper, attach again the wheels tightening the nuts in the complying for securing the components, with the required
required sequence and tightening torque. tightening torques.

527413 Brake calipers disconnection and 527413 BRAKE CALIPERS REVISION

reconnection
Disconnection Disassembly
Figure 71
Figure 69
60336
For disassembling the braking gaskets, comply with what is
described in chapter about ”Braking gaskets replacement”. 60638
Take brake caliper (1) to bench and lock it in a vice. With a

screwdriver remove small covers (2).
NOTE If the brake caliper disconnection—reconnection
operation is related to rear axle assembled on a
vehicle it is necessary to withdraw the brake cylinder Screws (3) must not be unscrewed.
(2) by unscrewing the screw placed on its rear side. !
Disconnect supply piping from brake cylinder (2).
Remove nuts (1) and detach brake cylinder (2) from
brake caliper. Figure 72
Figure 70
60639
Unscrew screws (2) and detach brake caliper (3) from

support (1).
Figure 73
60345
Unscrew screws (1 and 4) and detach brake caliper (2) from

rear axle case flange (3).
Due to the type of brake caliper only and due to its

! weight, it is necessary to suitably support the brake
caliper during disconnection and transport.
Reconnection
For the reconnection, reverse the operations
performed for the disconnection and comply with
the required tightening torques. At the end of
61993
reconnection operations, verify the wear
recovering device efficiency as described in the Withdraw guide pins (2 and 3) from brake caliper (1) and
related chapter. from protection casings (4).
Figure 74 Figure 76
61996
61994
Check sliding pins and related bushes wear conditions on the
brake caliper body, make sure that there are no wears or
Remove protection casings (2 and 3) from brake caliper (1). damages on sliding surfaces. Insert pins in bushes and verify
Remove casing (5) from adjustment screw (4) and remove their regular sliding, otherwise proceed with their
this latter one from brake caliper (1). replacement.
Measure bush (1) diameter in many points.
Check of component parts
Figure 75 NOTE Replace all bushes even if only one of them is worn.
NOTE A regular braking very much depends on brake

caliper sliding on guide pins.
Assembly
Figure 77
61995
Lock screw (2) rotation inserting in this latter one’s groove

(→) a screwdriver. From the opposite part to brake caliper
(1), unscrew screw (3) to check its threading conditions.
When detecting anomalies, replace the complete brake
caliper.
For washing the metal parts, use an hot water solution with
Fiat LCD detergent.
By using a metal brush remove dirt from caliper body, then
with a brush remove residuals and accurately clean guide pins 60644
and sliding bushes.

Proceed with an accurate blowing of the caliper body With a beater (2) assemble bushes (3, 4 and 5) on brake
through a jet of compressed air. caliper (1) placing them into this latter one at the heights
With a canvas drenched with isopropyl alcohol or the like, mentioned in the figure. Fill with grease the room between
accurately clean the sliding pins. assembled bushes (3 and 4).

Figure 78 At the end verify that casings (7 and 8, Figure 79) are not
damaged, and that brake caliper freely slides on pins, slightly
and carefully lift casings (8, Figure 79) lip from sliding pins to
discharge possible pressurised air formed inside them.
Figure 80
60648
Place brake caliper (3) on support (2) so that sliding pins (10,
Figure 79) are inserted in support seats (2). Screw new
screws (1 and 4).
NOTE Tighten at the required torque long screw (4) and

then short screw (1). Every time screws (1 and 4)
are unscrewed or appear loosened during possible 60649
checks, it is necessary to replace them with other
new ones. Assemble new plugs (1) into brake caliper (2) bushes housing
holes.
Figure 79
61962
REPLACEABLE PART COMPOSING THE BRAKE CALIPER

1. Screw* — 2. Braking gaskets check fork* — 3. Wear sensors — 4. Support completed with wear sensors — 5. Electric cable
check spring — 6. Brake caliper — 7. Protection casing — 8. Protection casing — 9. Bush — 10. Sliding pin — 11. Screw* —
12. Plug* — 13. Plug* — 14. Screw* — 15. Bush — 16. Braking gaskets — 17. Small springs — 18. Connector support blade.
* The parts must be replaced upon every disassembly with new ones.

Figure 81 Figure 83
61995 61998
Grease screw (2) threading. Lock screw (2) rotation by Lubricate protection casings (1) lip and insert them into
inserting into this latter one’s groove (→) a screwdriver. related brake caliper (2) seats.
From the opposite part of brake caliper (1) screw screw (3)
till the screw is placed in its starting stroke conditions.
Figure 84
Figure 82
61999
Lubricate sliding pins (2 and 3) and insert them into casings

(4) and brake caliper (1).
NOTE Sliding pin (3) is of a greater length.

61997 Arrange casings (4) lip into annular grooves (→) of
Assemble casing (2) into brake caliper (1) seat. sliding pins (2 and 3).
Insert internal casing (2) part into annular screw (3) groove.
Assemble casing (2) with particular care. It is possible

! to replace the protection casing (2) without
detaching brake caliper from assembly (rear
axle/front axle) assembled on a vehicle, following the
described procedures.

527411 BRAKE DISCS REVISION

Figure 85 527411 Brake discs turning and grinding
Figure 87
max 0.75
max 0.5
35707
Key—in on lathe 99301001 (2) shaft the brake disc (1)

60651 completed with hub;
key—in a series of spacers that remove axial assembly
Examine the brake discs; they must not show breakages, and
their surface must not show cracks densities greater than the clearance, screw locking nut and apply lathe shaft support;
place tool—holder (3) axially with brake disc (1), then adjust
one shown in sector A;
tools depth;
— radial cracks shown in sector B must not have a width proceed with brake disc (1) turning, operating on one or
greater than 0.75 mm and a depth greater than 0.5 mm; more removal passes, according to detected scoring.
— irregularities shown in sector C must not have a depth
greater than 1.5 mm;
— transverse fissures on the whole braking surface as shown
in sector D are not allowed;
— the orthogonality error measured at 35 mm from the Figure 88
peripheral circumference must not be greater than 0.15
mm.
Figure 86
35704
Through lathe 99301001 proceed with grinding both brake

60351
disc working surfaces.
Examine the brake discs surfaces wear status.
When detecting different values from those included in
characteristics and data table, perform brake discs turning and
grinding operations, and if necessary replace them. NOTE During grinding operations, gradually proceed with
If it is necessary to replace them, it is advisable to replace both the advancement of sectored spring, till turning
brake discs. residuals are totally removed.
For disconnecting and reconnecting the brake disc (3),
comply with procedures included in the chapter about
”Wheel hubs revision”.
Remove screws (1) and detach hub (2) from disc (3). Replace
disc (3) and reassemble it following the reverse procedure to
the previously—described one.

Print 603.93.391
5274 BRAKE REPAIRING

Front brakes (Brake caliper KNORR SB6 type)
Figure 89
49151
SECT. A—A
49152
1. Dry bush — 2. Braking gasket — 3. Threaded barrel — 4. Spring split pin — 5. Braking gaskets check plate — 6. Check plate —
7. Small pin — 8. Brake caliper — 9. Carrier plate — 10. Small piston — 11. Cap — 12. Sliding bush — 13. Rubber guide bush —
14. Sliding pin — 15. Dragging device — 16. Cover — 17. Screw — 18. Chain wheel disc — 19. Chain — 20. Plug — 21. Adjustment
device — 22. Protection casing — 23. Securing band — 24. Sliding pin — 25. Brass guide bush — 26. Sliding bushing — 27. Internal
protection — 28. Brake disc — 29. Rear axle — 30. Lever — 31. Membrane cylinder — 32. Pressure springs.

Front and rear brakes (Brake caliper KNORR SN6—SN7 type)
Figure 90
78397
78396
SEZ. AA
1. Dry bush — 2. Threaded hose — 3. Piston — 4. Washer — 5. Spring split pin — 6. Pin — 7. Retaining plate — 8. Supporting plate
—
9. Guide pin — 10. Guide bush — 11. Sliding pin — 12. Plug — 13. Dragging device — 14. Wear sensor — 15. Rear axle —
16. Chain — 17. Spring— —18. Cover — 19. Adapter — 20. Chain gear — 21. Adjusting device— —22. Cover — 23. Brass bush —
24. Sliding pin — 25. Sliding bush — 26. Inner protection — 27. Ring — 28. Brake lining — 29. Brake disc body — 30. Lever —
31. Cam bearing.

Operation (See previous figure)

Braking stage Figure 92
During braking, the diaphragm cylinder rod presses down on
the lever (30).
The force is transferred to the axle (15) by the bearing in an
off — centered position (31)
Through the threaded sleeves (2) and pistons (3), the force
is conveyed to the inner braking lining (28).
Once the play between brake linings (28) and brake disc (29)
has been recovered, the force is conveyed to the outer brake
lining (28), due to brake caliper displacement.
The brake linings (28) pressing on the brake disc (29) produce
the braking power.
Releasing stage
As soon as the pressure on the brake is reduced, the pressure
spring (17), the rear axle (15) along with threaded sleeves (2) 78622
and lever (32) go back to their original positions.
Remove the plug (4) using the tab (3) and make sure the
Automatic play recovery adapter is not lost.
The brake is equipped with automatic adjustment device,
which keeps the operating play between brake linings and
Never turn the adjusting pinion (1) without fitting the
brake disc constant.
! adapter (2) first. If the adapter cut torque is
Every time the brake is operated, the adjustment device (21),
overcome, the adapter gets broken.
which is integral with the lever (32), is automatically started.
Try again with a new adapter and if also in this case
If worn brake linings and brake discs increase the operating
it gets broken, the caliper should be replaced because
play, the adjustment device (21) and drag link (13) turn the
there is an inner damage.
threaded sleeves (2) so to recover said increase in play.
The operating clearance should be between 0.6 and 1.1 mm;
lower clearances might cause overheating problems.
Figure 93
CHECKS
Checking the automatic play recovery system
efficiency
Figure 91
60759
Using a suitable wrench (1), rotate the adjustment pinion

counterclockwise by 2—3 with the adapter (2, Figure 92)
installed turns, thus increasing the play between brake linings
and brake disc.
Operate the brakes for about 5—10 times and make sure the
40570 wrench (1) moves clockwise with small increments, up to
Remove the lock nuts and wheels, using hydraulic stand complete recover of play between braking linings and brake
99321024 (1). disc.
Otherwise, i.e. if the wrench does not turn, turns just once or
turns in both directions, this means the automatic play
recovery system is faulty. Replace the caliper, following the
procedure given subsequently, then fit back the wheels.

Check of braking gaskets thickness

Figure 94 Verify that A is greater than 0 mm, for SB6 type calipers
(Figure 95), or greater than 1 mm, for SN6 and SN7 types
calipers (Figure 96).
Otherwise it is necessary to disassemble the wheels and
proceed with an accurate check as described below.
49155
The operation can be performed with assembled wheels.

Remove protection cap (1) (available only on SB6 type
calipers)
Figure 95
A1
49156
SECTIONS ON SB6 BRAKE CALIPER

1. Brake caliper SB6 — 2. Rubber guide bush — 3. Sliding bushing
A. Sliding bushing position with new gaskets — A1. Sliding bushing position with worn braking gaskets (carry out an accurate
check with disassembled wheels)

Figure 96
78625
SECTIONS ON SN6/SN7 BRAKE CALIPER

1. Brake caliper — 2. Rubber guide bush — 3. Sliding bushing
A. Sliding bushing position with new gaskets — A1. Sliding bushing position with worn braking gaskets (carry out an accurate
check with disassembled wheels)

REAR BRAKES REVISION

527417 Braking gaskets replacement
49158
Remove and disconnect the electric connections (1) from the

40569 caliper body. Remove the split pin (2), pin (3) and plate (4)
Arrange the vehicle on a plane ground and lock its rear wheels; fastening the brake linings.
loosen nuts (1) securing the front wheels.
Do not fasten any lifting device on the plate (4).
With an hydraulic jack lift the vehicle from its front side and !
rest it on two support stands (2).
Figure 101
Figure 98
40570 78623
Remove cap (3), act on adjusting unit (1) with the adapter
Unscrew securing nuts and with hydraulic trolley 99321024 fitted, by means of a wrench, in a counter—clockwise direction,
(1) detach the wheels. so as to make pistons go back into the caliper body, then
remove braking gaskets (5) by properly floating caliper body
(4).
Figure 99 Never operate directly on the registration pinion (1)

! without having first of all fitted the adapter (2). If the
cutting torque of the adapter is exceeded, this will
break.
Test with a new adapter. If this also breaks, the caliper
must be replaced because it is damaged.
Figure 102
49157
60862
Remove screw (1) and plate (2) for checking wear sensor
cables. Press (→) the spring (1) and remove it; replace it with a new
one if necessary.
49162
Insert wear sensor (2) into its suitable seat on braking gasket
49161 (3).
Assemble spring (1) proceeding in reverse with respect to
Remove dirt and rust around the braking disc edge with a disassembling.
scraper or an old screwdriver (2), resting on the caliper body,
making disk (1) rotate. Figure 105
End the work with abrasive cloth. Remove residuals by using
a suction device or with canvasses and brush.
Do not use petrol or other petroleum derivatives that could
create brake failures.
Use only denatured alcohol with methanol or isopropyl
alcohol.
Accurately clean brake disc braking area surfaces.
NOTE Visually check dust—guarding casings conditions; if

they show distortions or breakages, it is necessary
to replace them; such operation implies the need of
49163
disassembling the brake caliper, so that it is advisable
to detach the brake caliper body completed with Insert new gaskets in brake caliper (1) and check that they
carrier plate for the complete revision. freely slide into their own seats.
If it is necessary to replace the pair of braking gaskets,

! always replace a complete series of them for every
axle.
Verify that the caliper freely rotates on its guides.
If anomalies are detected on one brake caliper only, it is
advisable to proceed with the complete revision of both brake Figure 106
calipers.
Remove dirt from brake caliper using a metal brush and
avoiding to damage dust—guarding casings.
Clean braking gaskets sliding surfaces.
Check brake disc conditions and make sure that it is not
corroded, scored or grooved. Slight surface cracks are
acceptable, but it is necessary to go on grinding the brake disc
as described in the related chapter, otherwise if worn, replace
the brake disc.
If there occurs the need of replacing, it is advisable to replace
both brake discs.
Check springs and wear sensors conditions, if necessary
replace them.
78624
Using the wrench (1), act on the adaptator retriever pin to get
a play not lower than 0.7 mm between brake lining and brake
disk, which can be measured using the thickness gauge (2).
Replace the cover (4) and lubricate it with white grease
RENOLIT HLT2.

527413 Brake calipers disconnection and re-

connection
Disconnection
NOTE Make sure that the outer protecting plug and the
seal ring are correctly fitted, in order to prevent
water leaks inside the play automatic retriever. Figure 109
Figure 107
49166
For disconnecting the braking gaskets, comply with what has

been previously described in the paragraph about ”Braking
gaskets replacement”. Remove clamps (2). Disconnect
membrane cylinder supply piping (1).
49158 Unscrew nuts (4) and remove membrane cylinder (3).
Connect electric connection (1) and secure it to caliper body.
Assemble plate (4), small pin (3) and split pin (2).
Figure 110
Figure 108
49167
49165
Remove screws (3) and detach brake caliper (1) completed
with carrier plate (2).
Assemble wear sensor cables checking plate (1).

Using hydraulic trolley 99321024, assemble the wheels. Lower Pay attention when disconnecting and transporting
the vehicle. Lock wheel rim securing nut at the required the caliper (1) since it is heavy and floating on the
tightening torque. !
carrier plate (2).
Apply protection cup to wheel hubs. Hold the caliper on its outer side only; never put your
Proceed as described on the opposite side. fingers between caliper (1) and support plate (2).
After having ended the repairs on vehicle brakes, repeatedly
actuate the brake pedal, with moving vehicle, along both
running directions, thereby settling the braking gaskets.

Reconnection
Figure 114
For reconnecting, reverse performed operations for
disconnecting and comply with the required
tightening torques.
520620 Wheel hubs disconnection and re-

connection
Disconnection
Figure 111
38956
Visually check that gasket—holder ring (1) diameter is free from

dents or accidental abrasions.
Replace internal wheel hubs gaskets and if necessary ring (1)
complying with what is described in section about ”Front
axle”.
Verify through adjustment ring nut that threading (2) is free
77206 from hardenings, otherwise take care of removing them with
appropriate means.
Rotate wheel hub so that screw plug (1) is taken downwards; Carry out the opposite braking assembly disassembling,
unscrew the cap and drain oil in a special container. keeping the components separate.
Figure 112 Reconnection
NOTE Make sure that surfaces of all parts inside the hub are
accurately clean, free from slags and burrs.
Lubricate the bearings with SAE W 140/MDA oil.
Key—in wheel hub completed with brake disc on

stub axle. Insert internal spacer on stub axle, then
place external bearing and shoulder washer.
Screw and lock adjustment ring nut at the required
36407 torque.
Suitably lock wheel hub rotation and with wrench 99354207
(1) unscrew oil cover (2), by draining residual oil in the special
container provided.
36411
36408 Settle with some axial mallet blows on wheel hub, rotate it in
both directions to free bearing rollers. Apply magnetic base
Unscrew safety screw (3). With wrench 99388001 unscrew (1) completed with comparator (2) to wheel hub. Arrange
adjustment ring nut (2), withdraw washer (4), external bearing comparator (3) rod perpendicular to stub axle tang.
(1) and detach brake disc completed with wheel hub, spacer
and internal bearing.

527413 BRAKE CALIPERS REVISION TYPE

Reset the comparator with a pre—load of 1.5 ÷ 2 mm. SB6
Axially move, with the help of a lever, the wheel hub and check Disassembly
that its axial clearance is 0.16 mm (maximum value). Figure 118
After having obtained the provided axial clearance, lock
adjustment ring nut (4) check screw (5) at the required
torque.
Figure 116
49168
Take brake caliper to bench and lock it in a vice.
Remove clamp (3) and protection cups (1 and 2).
Figure 119
36412
Apply tool (1) 99395026 on wheel hub stud bolts and use
torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
Deposit a sealing bead (Loctite type 574) exclusively

threaded part.
Tighten to torque the hub cover (1, Figure 117). 49169
Remove sliding pins (2 and 3) and disassemble carried plate

(1) recovering washer (4).
Figure 117
Figure 120
78322
Rotate the wheel hub until when hub cover (1) is positioned 49170
as shown in the figure. Restore the prescribed quantity of oil Disassemble protection casing (3), rubber bush (1) and
into the hub cover (1) through filling hole (2). Tighten the plug through a suitable beater, brass bush (2).
on the hub cover (1) to the set torque.

Figure 121
NOTE A regular braking very much depends on brake
caliper sliding on guide pins.
Check wear conditions of braking gaskets check pins and

related safety springs; if they show distortions or wears,
replace the parts that are deteriorated.
It is advisable to replace all rubber and plastic parts and brass
bush, even if visually they do not show distortions or
deteriorations.
Assembly
Make sure that all brake caliper components are perfectly
clean; remove possible abrasive residuals with a canvas
49171 without hairs, drenched with isopropyl alcohol or the like.
Through wrench (4), operate on clearance recovering device
in order to make small piston (1) go out of caliper body for
a maximum of 30 mm (dimension A).
Remove dust—guarding casing from caliper body and through
a suitable lever remove small pistons (1) together with
protection casings (3). Figure 122
Dimension A must absolutely not be exceeded since

! threaded barrels (2) are synchronised. If threaded
barrels (2) perform an overstroke, they lose their
synchronism and the brake caliper must be replaced.
Internal brake caliper parts must absolutely not be
disassembled.
Therefore do not loosen or disassemble cover check
screws.
Cleaning and check of component parts

For washing the metal parts, use an hot water solution with 49172
Fiat LCD detergent.
By using a metal brush, remove dirt from caliper body, then Through a suitable keyer, assemble small pistons (1) together
with a brush remove residuals and accurately clean guide pins with protection casings (2).
and sliding bushes seats. Through a wrench (3) operate on clearance recovering device
Through a synthetic brush with adequate sizes, remove grease in order to make small pistons (1) go back.
residuals from sliding bushes seats.
Proceed with an accurate caliper body blowing through a
compressed air jet. Figure 123
With a canvas drenched with isopropyl alcohol or the like,
accurately clean the sliding bushes.
Check wear conditions of sliding bushes and related seats on
brake caliper body, make sure that there are no wears or
damages on sliding surfaces.
Insert bushes in their seats, verify their regular sliding,
otherwise proceed with their replacement, or restoration, if
it is necessary, from seat on caliper body.
49173
Through a suitable beater, assemble brass bush (1).

49174 49176
Through suitable toolings, carry out caulking in point (→), next Insert sliding bushes (2 and 8).
to caliper body groove to avoid brass bush (1) displacements. Assemble carrier bracket (1), inserting washer (9), securing it
Verify that there are no burrs in bush seat, otherwise remove it. with sliding pins (3 and 7) at the required torque.
Butter the bush with white RENOLIT HLT2 grease. Assemble: protection plug (4), protection casing (5) and
secure it through a clamp (6).
Before assembling brake caliper on vehicle, make sure that it
freely slides operating on plate (1) along both directions.
Figure 125
49175
Assemble rubber bush (1) so that the external ring is placed

in groove (→).
Butter the bush with SYNTHESO GL EPI green grease with
synthetical base.
Assemble protection casing (2) making sure that its sealing lip
is inserted into the suitable seat.

Print 603.93.391
BRAKE CALIPER OVERHAUL TYPE SN6—SN7 Figure 130

Disassembly
Figure 127
79121
Place the brake caliper on the bench and block it in a vice. Remove
the cover (1) and make a hole in it with a Parker screw.
Figure 128
79124
Use tool 99372245 (2) (to be used with screw in tool

99372237) to disassemble the rubber sleeve (1).
Figure 131
79122
Refit the supporting plate (1) and remove the fastening screws
(2).
Figure 129
79123
79125
Remove the sliding bushes (1). Take the caliper to the press.
Insert the appropriate beater in the brass bush housing (1)
(See arrow A). Use the press to remove the bush (1).

Figure 132
NOTE Regular braking depends mainly on the brake caliper
sliding on the guide pins.
Check the wear conditions of the brake lining retaining pins

and the related safety pins. If they are worn or damaged,
replace the worn parts.
It is advisable to replace all rubber and plastic parts and the
brass bush even if they do not seem damaged or worn at sight.
Assembly
Make sure all the brake caliper components are perfectly
clean. Possible abrasive residuals should be removed with a
cloth soaked in isopropyl alcohol or similar.
Figure 133
60742
Place the caliper on the bench and block it in a vice. Use the
wrench (4) to operate the clearance recovery device so that
the piston (1) comes out of the caliper body for a maximum
of 30 mm (value A).
Take off the dust—guard from the caliper body and use tool
99372238 (5) to remove the thrust pressing devices (1) of the
caliper together with the protection casings (3).
Value A must not be overcome because threaded

! hoses (2) are synchronised. If the threaded hoses (2)
reach their over—travel, they loose synchronism and
the brake caliper must be replaced. The brake caliper
inner parts must never be removed.
For this reason you are recommended non to slacken
or to remove the cover retaining screws.. 79126
Use tool 99372239 (4) (see figure A) 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 a wrench
Component part cleaning and check (3) to act on play restorer, so as to make pistons (1) go back.
To wash metal parts, use a solution of hot water with Fiat LCD
detergent. Use a metal brush to remove dirt from the caliper Figure 134
body and then a little brush to remove the residuals and to
clear accurately the guide pin and the sliding bush housings.
Use a synthetic brush with the right dimensions to remove the
grease left on the sliding bush housings.
Clean the caliper body accurately with compressed air.
Use a piece of cloth soaked with isopropyl alcohol or similar
to clean the sliding bushes accurately.
Check the wear conditions of the sliding bushes and their
housings on the brake caliper body. Make sure they are not
damaged or worn, especially the sliding surfaces. Fit the bushes
in their housings and check they slide regularly.
Fit the bushes in their housings, check they slide correctly,
otherwise replace or restore their housings on the caliper
body, if needed.
79127
Use tool 99372244 (2) (to be used with the screw in tool
99372237) to assemble the rubber sleeve (1).

79128
Use tool 99372243 (1) (to be used with tool 99372240 and 60745
use screw in tool 99372237) to assemble the brass bush (2)
in its seat, by blocking its rotation by means of a suitable tool Use the appropriate tool 99372242 (2) to carry out bruising
(3) (punch or screwdriver). in the point (→) next to the caliper body groove, in order to
prevent the brass bush (1) from moving.
Make sure there are no burrs in the bush housing, otherwise
remove them. Apply white grease RENOLIT HLT2 on the
bush.
Figure 138
Figure 136
79130
Place the caliper on the bench and block it in the vice. Fit the
protection casing (2) by means of tool (1) 99372237.
Reverse the removal order to fit the sliding bushes

! and the supporting plate.
79129
Place the caliper under the press. Use the press to fit the brass
bush (1) in its housing until is comes out of the lower side by
1 mm.

527411 REAR DISC BRAKES REVISION

(12—18 t) Figure 140
NOTE Overhaul the braking unit; disassemble and check

the brake caliper by following the procedure
described for front disc brakes.
Wheel hub disassembling is described in the
relevant chapter of the “Rear axle” section.
35704
Through lathe 99301001 proceed with grinding both brake

disc working surfaces.
NOTE During grinding operations, gradually proceed with

the advancement of sectored spring, till turning
residuals are totally removed.
527411 BRAKE DISCS REVISION 527411 BRAKE DISCS TURNING

AND GRINDING
Figure 141
Figure 139
35707
- Key—in on lathe 99301001 (2) shaft the brake disc (1)

completed with hub;
- key—in a series of spacers on the shaft that remove axial
38597
assembly clearance, screw locking nut and apply lathe
Examine the brake discs surfaces wear status. shaft support;
When detecting different values from those included in
- place tool—holder (3) axially with brake disc (1), then
characteristics and data table, perform brake discs turning and
adjust tools depth;
grinding operations, and if necessary replace them.
Remove screws (1) and detach hub (2) from disc (3). - proceed with brake disc (1) turning, operating on one or
Replace disc (3) and reassemble it following the reverse more removal passes, according to detected scoring.
procedure to the previously—described one.

Print 603.93.391
5272 REAR DRUM BRAKES — Model 260E28KE

Figure 142
37490
DRUM BRAKES VIEW
Brake position with Hendrickson suspension

Figure 143
FORWARD RUNNING
DIRECTION OF
ROTATION
74059
INTERMEDIATE AXLE REAR AXLE

27230 REAR BRAKES REVISION (26 t)

Disassembly Figure 147
Figure 144
17239
36748 By using a wrench 99355167 (1), equipped with extension (2)

and handle (3), disassemble locking ring nut for wheel hub
Arrange the vehicle on a plane ground. Take parking brake
bearings adjustment nut.
hand lever in running position, loosen rear half—shafts securing
nuts. With an hydraulic jack (2) lift the vehicle from its rear side
and rest it on suitable support stands (1).
Figure 148
Figure 145
17237 17240
Unscrew screws (2). Extract safety washer (1).

Remove half—shaft flange (3) from wheel hub (1) union plane
and discharge oil.
17238 17241
Withdraw half—shaft (2) from case (1). Unscrew bearing adjustment nut (1) with the help of wrench
99355167.

36745
Before detaching the complete wheels, completely unscrew 38704
manual unbraking screw (2) of combined cylinder (1). Detach brake cylinders supply fittings (1). With wrench (4)
99356006 unlock ring nuts (3) and detach cylinders (2).
38354
17243
Withdraw control wedge units (1 and 4) from brake body (2
By using hydraulic trolley 99321024 (3), detach wheel and 3).
completed with drum (2) and bearing (1).
38352 38355
With the help of tool 99372217 (3), detach jaws (4) checking With the help of a screwdriver, undrive metal ring (2) and
springs (2); detach jaws (4) from check brackets (5) after withdraw complete adjustment unit (1) from brake body (3).
having detached braking gaskets wear sensor (1).

38356 38358
Unscrew guiding pin (2) from small piston (1) and extract the Withdraw sealing gaskets (2) from thrust pins (1).
piston from the brake body. With a screwdriver, undrive metal Accurately clean all single parts composing the braking
ring (4). assemblies.
Unscrew guiding pin (3) of thrust pin (5) and extract this latter
one from brake body.
Figure 159
Proceed with disassembling the wheel completed with hub,
and the whole braking unit on the opposite side, keeping the
component parts separated.
Check of component parts

Examine the wear status of drums and braking joints: if they
show scoring, braking surface damages, ovalities or eccentricity
greater than 0.25 mm, they must be turned.
If braking gaskets show a thickness that is lower than the 38359
provided one, proceed with their replacement.
Check the wear status of adjustment pins (2) and thrust pins
If the gasket braking surface shows traces of grease, it is
(1) sliding surfaces, further check chutes (3) surfaces on which
necessary to discover the reason for grease or oil seepage into
jaws opening control rollers operate.
the braking unit, and then remove it.
Figure 160
Figure 157
38357
Divide the automatic adjustment units.

Unscrew adjustment bushes (3) from adjustment pins (2), then
38360
withdraw sealing gaskets (1).
Verify the external helical toothing wear status of adjustment Check guide pins (3) toothing wear status, integrity of related
bushes, make sure of the regular sliding of bushes when compression springs (2) and copper washers (1).
screwing them on related adjustment pints.

527231 DRUM TURNING

Figure 161 Measure drum diameter by using a sliding gauge without
angling the arms, measure the diameter in many points to
establish ovality and wear status.
Figure 163
38361
Check wear status of seats on brake bodies (1); if they show

17252
scorings or excessive wears, replace anomalous brake bodies.
Visually check ring (2) diameter, that is free from dents or Insert on lathe 99301001 shaft (3) the drum (1) completed with
accidental abrasions; if necessary replace it following the wheel centring it with suitable centring bushes.
procedure described in the ”Rear axle” section. Key—in on the shaft a series of spacers that remove axial
Replace internal wheel hub gaskets. assembly clearance, screw the locking nut and apply the lathe
support.
Figure 164
Figure 162
17253
Carry out the turning operation by gradually operating till

35713 imperfections on drum braking surface are removed.
Disassemble complete wheel from lathe, carry out an accurate
Check that wedge units easily slid and parts do not show blowing operation on brake drum.
abrasions.
The maximum diameter increase allowed in drums is 4

! mm. This limit must absolutely not be exceeded since
braking effect and drum resistance characteristics would
NOTE In case of wear of parts composing wedge units, the otherwise be impaired.
complete wedge unit must be replaced. Couple adequate braking gaskets for every single
drum depending on the increase. Every vehicle axle
must be equipped with gaskets of the same type.

527233 BRAKING GASKETS REPLACE- 527233 BRAKING GASKETS TURNING

MENT
17255
38362
Carry out worn braking gaskets detachment from jaws by using
the compressed air press 99305087 (1). Assemble jaws (1) on table (3) of lathe 99301006, and lock
Place complete jaws (4) on adjustable abutment plat (5). them with handles (2).
With chisel (2) inserted in press (1) operating head, shear
rivets (3) heads.
Expel rivets from jaws. Figure 168
Accurately clean the jaws by washing and blowing them.
NOTE Visually check that jaws do not show cracks; if they

are detected, replace anomalous jaws.
Figure 166
38363
Reset tool (1) operating on handwheel (2) and proceed with

turning.
NOTE Brake jaws turning can also be carried out by using

tool 99372228 on lathe 99301001.
35713
Apply on mobile press support (4) the abutment pin (5).

Proceed with nailing braking gaskets (3) on jaws (2) by using
beater (1) inserted in press operating head.
NOTE The correct execution of braking gaskets nailing is

carried out starting from the center, and gradually
extending it outside of braking sectors.

Assembly
38364 38366
Assemble sealing gaskets (2) on adjustment pins assemblies Insert thrust pin (1) into brake body (3) seat so that the slot
(1). is facing the drive pin (2).
Grease pin (1) threading. Grease and insert complete guide pin (2) into brake body seat
Completely screw adjustment bushes (3) and scrupulously (3); make sure that washer (5) is inserted and screw some
grease these latter ones on external diameter. turns.
Grease thrust pins (4) internal diameter.
NOTE Guide pin (2) must be assembled so that prong (4)

slides into suitable brake body (3) hole slot.
During brakes maintenance interventions, replace

! sealing gaskets of adjustment and thrust pins.
For lubricating the components, use Rockwell RBSK
0253 grease.
38365 38367
Assemble seaking gaskets (1) on thrust pins (3); make sure of Insert automatic adjustment unit (1) into adjustment pin, fit
the correct gaskets profile insertion in thrust pins groove (2). sealing gasket (2) metal ring on brake body (4).
Grease pins (3) on sliding surface and on wedge (4) sliding Lock guide pin (3) at the required torque.
chute.

38368 38370
By using keyer 99373002 (1), drive sealing gasket metal ring By using keyer 99373002 (2) drive the metal ring (1) of sealing
onto brake body (2). gasket on brake body.
Proceed as described for assembling the other jaws opening
control units.
Figure 176
Figure 174
17268
Abundantly grease wedge control units (1) and insert them

into their own seat into brake body (2) so that wedge unit
rollers rest on related thrust pins sliding races.
Figure 177
38369
Insert thrust pin (4) into brake body (1) so that the notch is
facing the guide pin (2) hole.
Grease and screw guide pin (2) at the required torque.
35717
NOTE Before proceeding with assembling thrust pins (4),
check the mark punched on them. Letter ”R” (right) Manually screw ring nut (2) on barrel (1) till its end of stroke.
or ”L” (left) shows that the brake belongs to right Apply non—hardenable sealing paste, LOCTITE 573 type, on
or left wheel. first barrel threads.

Print 603.93.391
38705 38375
Completely screw brake cylinders (2) into their own seat so Operate on adjustment units (1 and 2) till a dimension (A) is
that supply fittings are in their original position and exhaust obtained, measured with a gauge, that is by 2 mm lower than
hole is open and facing downwards. the one detected on the used drum.
Connect brake cylinders supply pipings (1).
Figure 179
38373 Figure 182

Completely screw adjustment unit (2), then unscrew by one
revolution in order to give an initial adjustment for automatic
recovery; place them so that notches (1) allow inserting the
jaws.
Figure 180
17301
Lubricate bearings seat on barrel (3) and wheel hub sealing ring
with TUTELA W 140/MDA oil.
By using hydraulic trolley 99321024 (1), place complete wheel
(2) so that internal hub diameter is perfectly centred on rear
axle case barrel (3). Place tapered roller bearing (4) into wheel
hub. Insert complete wheel till the end of its seat, taking care
38374 of aligning wheel hub with barrel (3) to avoid damaging sealing
Assemble jaws (1) into their suitable seat so that the punched gaskets profiles.
arrow (2) is oriented along the forward—running drum
rotation direction.
Hook jaws return springs (3 and 5) using tool 99372217 (4).

35768
Screw locking ring nut and tighten it through wrench 99355167 35770
(1) and dynamometric wrench (2), tighten adjustment nut at Place comparator (1) with magnetic base on hub (3). Abut rod
a torque of 98 Nm (10 kgm); at the same time, rotate hub along onto barrel (2) and check that maximum axial hub clearance is
the two directions. 0.05 mm.
Then loosen the nut down to a zero torque.
Further unscrew the nut till an axial clearance is obtained that
is included between 0.20 and 0.30 mm, corresponding to an
angular movement of about 1/6 of a revolution. Figure 187
Figure 184
35769 35771
Assemble the safety ring (2): if the nut (1) stop dowel does not Butter with hermetic type ”B” the contact surface (1) between
coincide with one of the safety ring (2) holes, change nut (1) half—shaft and wheel hub.
position taking also into account the clearance obtained in the
previous operation.
Figure 188
Figure 185
35768 35772
Screw locking ring nut and tighten it through wrench Assemble half—shaft (1), insert securing screws (2) and tighten
99355167 (1) and dynamometric wrench (2) at the required them at the required torque.
torque.

38706 36765
Supply the brake cylinders operating on service brake. With Proceed with the assembly of opposite braking unit and restore
wrench (1) 99356006, tighten combined brake cylinders rear axle oil level.
securing ring nuts (2 and 3) at the required torque. Restore operation of parking brake control cylinders (1),
completely screwing screw (2) again.
Start the vehicle engine up for a sufficient time to carry out the
system recharge.
Carry out repeated settling brakings of the braking and
clearance recovery assembly between braking gaskets and
drum with running vehicle.


EUROCARGO TECTOR 12—26 t BODY — CHASSIS 1
SECTION 12
5501 Body
5001 Chassis
Page
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- General information . . . . . . . . . . . . . . . . . . . . . 3
PROTECTIVE BODY TREATMENTS . . . . . . . . . 4
- Protective treatment . . . . . . . . . . . . . . . . . . . . 4
- Preparing the sheet metal (bonderizing) . . . . . 5
- Applying the protective paint (electrophoresis) 5
CHECKING THE GEOMETRY OF THE CHASSIS

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL RULES FOR WORKING

ON THE CHASSIS FRAME . . . . . . . . . . . . . . 5
- Preparing the chassis frame for maintenance, checking

and repair work authorized by IVECO . . . . . . . 5
- Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Welding instructions . . . . . . . . . . . . . . . . . . . . 6
- Bodybuilder work on the structural members of the

IVECO chassis frame . . . . . . . . . . . . . . . . . . . . 6
- Drilling the chassis frame . . . . . . . . . . . . . . . . . 6
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Welds on the chassis frame . . . . . . . . . . . . . . . 8
CHASSIS FRAME . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPAIRS AND CHECKS . . . . . . . . . . . . . . . . . . . 9
- Measuring the side bend of the chassis frame . 10
- Measuring the bend of the chassis frame downwards

or upwards . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Measuring the movement of the chassis frame 10
- Measuring the torsion of the chassis frame . . . 11
CHASSIS REFERENCE DIMENSIONS . . . . . . . . . 12
CAB GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . . 19
SEAL APPLICATION DIAGRAM . . . . . . . . . . . . 20
CAB ANCHORING AND TIGHTENING

TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2 BODY — CHASSIS EUROCARGO TECTOR 12—26 t
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Cab anchoring . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Replacing cab suspension front and

rear shock absorbers . . . . . . . . . . . . . . . . . . . . 27
- Removing—refitting front mounts and cab stabilizer

bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HYDRAULIC CAB LIFTING SYSTEM . . . . . . . . . 28
- Replacing hydraulic cylinder for cab

tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REPLACING WINDSCREEN WINDOW . . . . . . 29
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Vibration knife . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Harmonic wire . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Removal (with harmonic wire) . . . . . . . . . . . . . 30
- Preparing the windscreen opening . . . . . . . . . . 30
- Preparing the windscreen . . . . . . . . . . . . . . . . . 31
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Replacing the winding window . . . . . . . . . . . . . 33
- Replacing the window winder . . . . . . . . . . . . . 34
- Replacing the fixed window . . . . . . . . . . . . . . . 34
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 36
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MIDDLE INSTRUMENT PANEL . . . . . . . . . . . . . 36
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTRUMENT PANEL COVERING . . . . . . . . . . 37
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HEATING AND VENTILATION . . . . . . . . . . . . . 42
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5501 CAB
General information
The cab is an advanced one, it can be tipped up hydraulically with a mechanical control.
Tilting angle 57°.
Pressed and welded steel framework, parts made of electro—galvanized sheet steel.
Sound deadening on the underbody and anticorrosion protection in the boxed compartments.
The cab suspension is mechanical.
Figure 1
78688

PROTECTIVE BODY TREATMENTS

Protective treatment
Figure 2
Double zinc plated sheets
Single zinc plated sheets
Elements in synthetic material 78692
The choice of materials comprising the body is geared to - Fire plating: the molten zinc gets deposited on the sheet
achieving an excellent quality standard so as to offer a product metal by the effect of the heat. With this process, which
with lasting quality and performance. is mainly used for the structural elements of the body,
thicknesses of up to 20 microns can be reached, against 7
The galvanizing is done according to different technological microns obtained with the galvanic process.
processes:
The wheel arches made of synthetic material also have an
anti—corrosion function.
- Galvanic plating: the sheet metal is immersed or washed,
depending on whether it is bi—galvanization or All the boxes are protected by using galvanized sheet steel that,
galvanization, in a salt bath providing a high level of surface after painting, are sprayed on the inside with waxy oil to
finishing. prevent internal oxidation.

Preparing the sheet metal (bonderizing) CHECKING THE GEOMETRY OF THE

CHASSIS FRAME
Before doing any work it is wise to make sure that the chassis
After assembly, the body undergoes a range of treatments to
frame is perfectly level, that is with no deformation or stress
cleanse it of grease, oxidation and to preserve it from
due to the weight of the various assemblies.
corrosion.
The cycle comprises the following phases:
GENERAL RULES FOR WORKING ON THE
- Pre—degreasing: washing with an acid solution (deoxidine) CHASSIS FRAME
to eliminate the oily substances on the metal.
The criteria for performing the work permitted by IVECO on
- Degreasing: washing with a water—surfactant solution. This the chassis frames are subordinate to observance of the
solution is sprayed at a temperature of approximately following instructions:
60°C.
- Welding on the flanges of the structural members and on
- Rinsing: this is done with industrial water to eliminate the the structural members of the chassis frame is strictly
alkaline residues. prohibited.
- Activation: washing at ambient temperature with a - Drilling the flanges of the structural members is not
titanium salt solution (exposing the crystals, ”pickling”). permitted.
- Phosphatizing: washing with zinc phosphates at a - The characteristics of the chassis frame must not be
temperature of approximately 55°C. The electrolytic altered without IVECO approval.
plating of these metals forms and multiplies the crystalline
cores, creating a uniform and protective micro—crystalline
layer on the body (decontamination). Preparing the chassis frame for maintenance,
checking and repair work authorized by
- Passivating: washing with a chromium—based solution that IVECO
provides an additional layer of protection and levelling of
Parts fitted on the chassis frame that are removed before
the crystals.
checking and repairing the chassis frame must be suitably
- Rinsing: using deionized water eliminates the residues of stored and protected.
the previous solutions.
Likewise, the wirings and terminal installations must be well
- Drying: in an oven at a temperature of approximately positioned on the chassis frame to prevent damage (from any
110°C. welding, painting or rubbing on the ground).
Applying the protective paint (electrophoresis) Protect the entire installation of the chassis frame, placing
Electrophoresis treatment is performed by dipping the body suitable protection on it for workers and operators to tread
in a bath of an electro—conductive solution to which particles on.
of paint have been added in suspension. Should welding be required, keep to the instructions.
Arc welding with weld material
The weld must be good for the effects of penetration with no
cracks or inclusions and with a non—porous appearance.
The thickness of the weld material must be in proportion to
the thickness of the material to weld and must be no less than
2 mm even after any grinding.
When making the weld beads, they must be parallel to the
direction of the stress; transverse beads must be avoided.
For elements that bend, the weld must be located along the
neutral area, with a bead width in proportion to the thickness
of the sheet metal. For elements with axial compression, the
weld must be made at the end and with a concave bead.
Sudden changes in cross—section due to weld accumulation
must be avoided.

Spot welding
This must be workmanlike. Take special care over the setting of the device so as to make spot welds that ensure a fully efficient
join. Avoid positioning spots near the edge of the parts to weld.
NOTE The areas of the chassis frame involved in welding must be thoroughly cleaned and, after welding, protected with
two—component epoxy rust—proofing or another similar product, and with another coat of single— or two—component
paint.
The earth cable of the welding system must be connected on the chassis frame as close as possible to the welding zone, and never
near a rotating part (transmission, wheel hubs, etc.) nor above or under an assembly with moving parts (compressor, bearings, etc.).
Welding instructions
Before welding, which must be done so as to minimize the tension and deformation that may be created, remove the paint and
carefully deoxidize the surfaces involved.
Classification of corresponding steels in the EU:
French standards German standards British standards American standards

A 35 501 DIN 17 100 BS 4360 ASTM
E 24.2 R—St. 37.2 40 B A 283 gr. D
E 26.3 St. 42.3 43 C A 284 gr. C
E 36.4 St. 52.3 50 D —
Italian standards Swedish standards Spanish standards Belgian standards
UNI — 7070 MNC — 810 UNE — 36 080 NBN 631
Fe 37.B 13.12.00 A 360.B AE 22B or AE24B
Fe 42.C 14.13.00 A 410.C AE 26 C
Fe 52.D 21.34.01 A 510.D AE 36 D
Bodybuilder work on the structural members of the IVECO chassis frame

No modification (lengthening, shortening, drilling and/or welding on a significant scale) is authorized to the frameworks of the IVECO
chassis frame or warranty for the chassis frame is forfeit. If, when specifically requested in writing, IVECO Engineering authorizes
specific work to be performed, there are some rules of a general nature to follow in designing and performing these operations
that are stated on the following pages.
Drilling the chassis frame

When it is necessary to fit auxiliary parts or assemblies on the chassis frame, the existing holes made when making the chassis frame
must, as a rule, be used.
Drilling the flanges of the vehicle’s structural members is strictly prohibited.
In special cases (fitting brackets, angle sections, etc.) where it is necessary to make fresh holes, these must be made on the vertical
rib of the structural member and must be carefully deburred and bored.
The new holes must not be made in the areas of greatest stress (such as the spring mountings for example) and of changes to the
cross—section of the structural member.
The diameter of the holes must be suited to the thickness of the sheet metal; in no case may it exceed 15 mm. The distance from
the axis of the holes from the edges of the structural member must be no less than 40 mm. In any case, the axes of the holes must
be at a distance of no less than 50 mm from each other or from the existing holes. The holes must be staggered as shown in the
figure.
When moving the crosspiece or spring mountings, their drilling patterns must be maintained.

PRECAUTIONS
Figure 3 Figure 5
17360
17358 Straighten the side bend of the chassis frame with wedge
heating on the top and bottom waist of the part concerning
During the work of welding, drilling, grinding, cutting near the chassis frame.
brake system piping, especially if this is made of plastic, and The tip of the heating wedge has to lie in the direction of the
electric cables, take the appropriate precautions to protect required bend.
them, contemplating their removal if required. All the parts
of the chassis frame subject to reconditioning will need to be If the base of the two heating wedges is in the top plate of
protected against oxidation and corrosion. the structural member, then the plate also needs to be
This protection and painting will need to be done carefully heated, but last.
on all the parts concerned, as per any relevant instructions,
methods and precautions of the paint manufacturers.
Figure 4
Figure 6
17359 17361
The chassis frame is reconditioned by wedge heating the Straighten the sag in the chassis frame downwards or
relevant part with a blowpipe. upwards with wedge heating on the top plate of the
During this operation the metal needs to turn cherry red, structural member. In the case of downward bending, the
which corresponds to a temperature of 600 — 680 °C. base (a) of the heating wedge is at the bottom. In the case
The heated points must undergo no further heating. of upward bending, do the opposite.
Let the treated parts cool slowly without using any water, The relevant bottom or top waist of the structural member
compressed air or the like. has to be heated last in the area of the base of the heating
wedge.

Welds on the chassis frame

Figure 7 Figure 8
17364
17362
A ≅ 0,3 H
b ≅ H (min. 175 mm)
S ≅ (0,8 ÷ 1) S1 17365
17363
Before starting work, disconnect the negative battery Here we give the operating instructions for proper welding:
terminal and connect the earth of the welding machine
a) Heat all around the area to weld (except for QST E 420
straight onto the piece to weld. Plastic pipes will need to be
material). Do the arc welding with several passes, using
protected or removed.
thoroughly dried basic electrodes, or MIG—MAG
Welds will have to be made solely by skilled, trained
procedures with suitable weld material. Do not overload
personnel, with suitable equipment and in workmanlike
with current. The weld must have no edge cuts or dross.
fashion.
Remove the paint and deoxidize the parts to weld. At the b) Start back welding as specified in point (a).
point of breakage, on the inside of the structural member and
c) Leave the structural members to cool slowly and evenly.
along the full length of the relevant section, make a V bevel
of 60°. It is not permissible to use jets of air or other means.
d) Grind off the excess material.
e) Apply angular steel strengthening, with the same
specifications as the steel used in the chassis frame. The
No cuts are permitted on the structural members at approximate minimum dimensions are given in the above
areas of changes in profile or at points with a high illustrations. They are to be fixed solely on the vertical rib
concentration of stresses; additionally, the line of of the structural member and it is possible to use bead
separation must not concern the holes already in the welding, dummy spots, screws or rivets. The cross
structural member. section and length of the weld bead, the number and
distribution of the dummy spots, screws or rivets must
be suited to transmit the bending and cutting moments
of the section. On completing the work, the part
involved in welding must be effectively protected with
rust proofing.

5001 CHASSIS FRAME

REPAIRS AND CHECKS Figure 11
Inspect the chassis frame, checking its alignment.

If already at this stage you detect any deformation you then
need to free the relevant part of the chassis frame to help
make an exact measurement.
Before the test you need to check all the parts that, with their
imperfections, affect the exact measurements (for example,
tyre pressure, weak or broken leaf springs, etc.).
17347
Laterally permissible curvature of chassis frame

Figure 9 ”a” = 3 mm/m
Figure 12
17344
Check the rivets by striking their heads with a mallet and

touching the opposite side with your fingers.
Mark any loose rivets with paint to help identify them during
the repair work.
17348
Permissible curvature of chassis frame

”b” = 1 mm/m
Max. 10 mm.
Figure 10
Figure 13
17345
Carefully check for any peeling or cracking all over the chassis
frame, paying special attention to joints under great strain,
such as: chassis frame cross members, brackets, mounts of
leaf springs and chassis frame structural members.
Mark any peeled or cracked points straight away. 17349
Permissible difference between ”a” and ”b” = 3 mm.

With diagonal measurement between ”c” and ”d” = 6 mm.

Figure 14 Measuring the bend of the chassis frame

downwards or upwards
Figure 17
17350 17353
Permissible torsion on the chassis frame Take two shims (1) of such a size that a string can be
”b” = 1 mm each side. stretched along the full length from the straight portion of the
bottom or top waist on the structural member of the chassis
Measuring the side bend of the chassis frame frame.
Measure the distance of the structural member from the
Figure 15 string at 1—metre intervals. A different string distance
indicates the position and extent of an actual bend in the
structural member.
17351
To measure the side bend of the chassis frame you need to

plumb the supporting surfaces starting with the two
structural members at an interval of approximately 1 m.
The points obtained in this way need to be marked accurately Measuring the movement of the chassis frame
on the floor.
Figure 18
Figure 16
17352 17354
To use the plumbed points you need to stretch out a string A movement of the chassis frame can be measured by means
passing through the marked points in a line. of a set square.
The points outside the line indicate the start and extent of To do this, place the set square at 90° to the structural
the actual deformation (a). member of the chassis frame and check the squareness of the
cross members of the chassis frame.

Figure 19 - position the other side of the chassis frame, in a central

position under the rear cross member, on the knee of
an L—shaped iron (1);
- set a rule crosswise and put a spirit level (2) on this,
checking the reading.
At each check point you will need to have the same reading
or the chassis frame is out of shape.
17355
A movement in the position of the axes can be checked by

making a diagonal measurement. To do this, plumb the centre
of the front mount of the front suspension and the centre of
the front support of the rear leaf spring on the flat supporting
surface, on both sides.
Figure 20
17356
Firstly compare the distance of the points ”a” and ”b”. Then
make the diagonal measurement (distance ”c” and ”d”) from
point (1) in front to the right to point (2) behind to the left
and the opposite.
Measuring the torsion of the chassis frame
Figure 21
17357
A slight torsion can only be measured with the chassis frame

freed of the cab and mechanical assemblies.
To do this check, proceed as follows:
- set the chassis frame on two stands;
- using two clamps, secure one side of the chassis frame
to the stand.

CHASSIS REFERENCE DIMENSIONS

Models: 120 (mechanic suspensions)
Figure 22
78284
I = Front axle axis
II = Rear axle axis
Dimension
(mm) Wheel base (mm)
3105 3330 3690 4185 4455 4815
1001.25 1001.25 1001.25 1001.25 1001.25 1001.25
B 720 720 720 720 720 720
C 1080 1080 1080 1080 1080 1080
D 1912.5 1912.5 2182.5 2182.5 2182.5 2182.5
E 2992.5 3262.5 3217.5
F 405 405 405 405 405 405
G 405 405 405 405 405 405
H 1260
I 990 1440 1755 1890 2115
J 840 840 840 840 840 840
K 967.5 967.5 967.5 967.5 967.5 967.5
L 2272.5 2272.5 2272.5 2272.5
M 3127.5
N 832.5 832.5 832.5 832.5 832.5 832.5
O 135 135 135 135 135 135
P 787.5 787.5 787.5 787.5 787.5 787.5
Q 1147.5 1665 1980 2115 2340
R 1080 1080 1080 1080 1080 1080
S 3105 3330 3690 4185 4455 4815
T 1313 1830 1830 2145 2280 2505
U 5498 6240 6600 7410 7815 8400

Models: 120 (pneumatic suspensions)
Figure 23
78285
I = Front axle axis
II = Rear axle axis
Dimension
3105 3330 3690 4185 4455 4815
A 1001.25 1001.25 1001.25 1001.25 1001.25 1001.25
B 720 720 720 720 720 720
C 1080 1080 1080 1080 1080 1080
D 1912.5 1912.5 2182.5 2182.5 2182.5 2182.5
E 2992.5 3262.5 3217.5
F 405 405 405 405 405 405
G 405 405 405 405 405 405
H 1260
I 990 1440 1755 1890 2115
J 840 840 840 840 840 840
K 967.5 967.5 967.5 967.5 967.5 967.5
L 2272.5 2272.5 2272.5 2272.5
M 3127.5
N 832.5 832.5 832.5 832.5 832.5 832.5
O 202.5 202.5 202.5 202.5 202.5 202.5
P 787.5 787.5 787.5 787.5 787.5 787.5
Q 1147.5 1665 1980 2115 2340
R 1080 1080 1080 1080 1080 1080
S 3105 3330 3690 4185 4455 4815
T 1313 1830 1830 2145 2280 2505
U 5498 6240 6600 7410 7815 8400

Models: 130 to 160 (mechanic suspensions)
Figure 24
78286
I = Front axle axis
II = Rear axle axis
Dimension
3105 3690 4185 4455 4815 5175 5670 6570
A 1091.25 1091.25 1091.25 1091.25 1091.25 1091,25 1091,25 1091,25
B 697,5 1080 1080 1080 1080 1080 1080 1080
C 1732.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5
D 2970 3082.5 3397.5 3082.5 3217.5 3217.5
E 3960 4252.5 4297.5
F 5152.5
G 405 405 405 405 405 405 405 405
H 405 405 405 405 405 405 405 405
I 1282.5 1440
J 1170 1170 1170 1575 2092.5 2587.5
K 1215 1642.5 1957.5 2092.5 2362.5 2587.5 2902.5 3397.5
L 840 840 840 840 840 840 840 840
M 1170 1170 1170 1170 1170 1170 1170 1170
N 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5
O 3307.5 3307.5 3307.5 3307.5
P 4207.5
Q 832.5 832.5 832.5 832.5 832.5 832.5 832.5 832.5
R 157.5 157.5 157.5 157.5 157.5 157.5 157.5 157.5
S 810 810 810 810 810 810 810 810
T 1372.5 1485 1980
U 1147,5 1575 1890 2025 2295 2520 2835 3330
V 1170 1170 1170 1170 1170 1170 1170 1170
W 3105 3690 4185 4455 4815 5175 5670 6570
X 1313 1740 2055 2190 2460 2685 3000 3495
Y 5588 6600 7410 7815 8445 9030 9840 11235

Models: 130 to 160 (pneumatic suspensions)
Figure 25
78287
I = Front axle axis
II = Rear axle axis
Dimension
3105 3690 4185 4455 4815 5175 5670 6570
A 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25
B 697.5 1080 1080 1080 1080 1080 1080 1080
C 1732.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5
D 2970 3082.5 3397.5 3082.5 3217.5 3217.5
E 3960 4252.5 4297.5
F 5152.5
G 405 405 405 405 405 405 405 405
H 405 405 405 405 405 405 405 405
I 1282.5 1440
J 1170 1170 1170 1575 2092.5 2587.5
K 1215 1642.5 1957.5 2092.5 2362.5 2587.5 2902.5 3397.5
L 840 840 840 840 840 840 840 840
M 1170 1170 1170 1170 1170 1170 1170 1170
N 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5
O 3307.5 3307.5 3307.5 3307.5
P 4207.5
Q 697.5 697.5 697.5 697.5 697.5 697.5 697.5 697.5
R 157.5 157.5 157.5 157.5 157.5 157.5 157.5 157.5
S 675 675 675 675 675 675 675 675
T 137.5 1485 1980
U 1147,5 1575 1890 2025 2295 2520 2835 3330
V 1170 1170 1170 1170 1170 1170 1170 1170
W 3105 3690 4185 4455 4815 5175 5670 6570
X 1313 1740 2055 2190 2460 2685 3000 3495
Y 5588 6600 7410 7815 8445 9030 9840 11235

Models: 180 (mechanic suspensions)
Figure 26
78288
I = Front axle axis
II = Rear axle axis
Dimension
3690 4185 4590 4815 5175 5670 6210 6570
A 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25
B 1080 1080 1080 1080 1080 1080 1080 1080
C 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5
D 2970 3217.5 3217.5 3217.5 3217.5 3217.5 3217.5
E 3960 4252.5 4095 4095
F 4905 5062.5
G 405 405 405 405 405 405 405 405
H 405 405 405 405 405 405 405 405
I 1170 1170 1462.5 1417.5 1417.5
J 1032,5 1170 1507,5 1710 1980 2092.5 2092.5 2632.5
K 840 840 840 840 840 840 840 840
L 1170 1170 1170 1170 1170 1170 1170 1170
M 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5
N 3307.5 3307.5 3307.5 3307.5 3307.5
O 4185 4185
P 4972.5
Q 832.5 832.5 832.5 832.5 832.5 832.5 832.5 832.5
R 157.5 157.5 157.5 157.5 157.5 157.5 157.5 157.5
S 840 840 840 840 840 840 840
T 1507.5
U 902.5 1147.5 1504 1707 1977 2089 2089 2629
V 1170 1170 1170 1170 1170 1170 1170 1170
W 3690 4185 4590 4815 5175 5670 6210 6570
X 1133 1313 1650 1853 2123 2235 2235 2775
Y 5993 6668 7410 7838 8468 9075 9615 10515

Models: 180 (pneumatic suspensions)
Figure 27
78289
I = Front axle axis
II = Rear axle axis
Dimension
3690 4185 4590 4815 5175 5670 6210 6570
A 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25 1091.25
B 1080 1080 1080 1080 1080 1080 1080 1080
C 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5 2182.5
D 2970 3217,5 3397.5 3082.5 3217.5 3217.5 3217.5
E 3960 4252.5 4095 4095
F 4905 5062.5
G 405 405 405 405 405 405 405 405
H 405 405 405 405 405 405 405 405
I 1170 1170 1462.5 1417.5 1417.5
J 1032,5 1170 1507,5 1710 1980 2092.5 2092.5 2632.5
K 840 840 840 840 840 840 840 840
L 1170 1170 1170 1170 1170 1170 1170 1170
M 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5 2272.5
N 3307.5 3307.5 3307.5 3307.5 3307.5
O 4185 4185
P 4972.5
Q 697.5 697.5 697.5 697.5 697.5 697.5 697.5 697.5
R 157.5 157.5 157.5 157.5 157.5 157.5 157.5 157.5
S 906 906 906 906 906 906 906
T 1507.5
U 902.5 1147.5 1504 1707 1977 2089 2089 2629
V 1170 1170 1170 1170 1170 1170 1170 1170
W 3690 4185 4590 4815 5175 5670 6210 6570
X 1133 1313 1650 1853 2123 2235 2235 2775
Y 5993 6668 7410 7838 8468 9075 9615 10515

Models: 260 (Hendrikson suspensions)

Figure 28
* = Tandem axle centre line 78290
I = Front axle centre line

II = Intermediate axle centre line
III = Rear axle centre line
Dimension
(mm)
Wheel base (mm)
3824 4186
A 1091.25 1091.25
B 832.5 832.5
C 1080 1080
D 2182.5 2182.5
E 405 405
F 405 405
G 1282.5 1282.5
H 1102.5 1102.5
I 1652.5 1652.5
J 840 840
K 1170 1170
L 2272.5 2272.5
M 1380 1380
N 1372.5 1372.5
O 1192.5 1192.5
P 3824 4186
Q 1675 1675
R 1170 1170
S 4514 4876
T 1750 1750
U 7434 7796

CAB GEOMETRY
Figure 29
DRIVER’S PASSENGER’S
SEAT SEAT
A 440 — 455 440 — 465
B 1145 — 1160 1135 — 1160
C LOWER BED
D UPPER BED
E CHASSIS INSIDE UPPER EDGE
78693

SEAL APPLICATION DIAGRAM

Figure 30
SEC. A — A SEC. D — D SEC. E — E SEC. N — N
SEC. P — P
SEC. F — F
78694

Figure 31
A — SEALANT ACCORDING TO IVECO 18—1736 STANDARD Type A

(Mat. code 74040) TO APPLY IN THE INDICATED ZONES.
B — VINYL PROTECTION ACCORDING TO IVECO 18—1654

STANDARD Type E1 (Mat. code 74263) TO APPLY
UNDER THE BODY PROTECTING THE ZONES ”C”.
— BOXED STRUCTURE PROTECTION TO APPLY IN THE

HIGHLIGHTED ZONES.
: — SICAFLEX PROD. TO APPLY IN THE INDICATED ZONES.
78695


5542 CAB ANCHORING AND TIGHTENING TORQUES

Figure 32
78696
78697
CAB FRONT SUSPENSION

PART TORQUE
Nm (Kgm)
1 Hexagonal nut with flange for shock absorber upper fastening 122.5 ± 12.5 (12.2 ± 1.2)
2 Hexagonal nut for shock absorber lower fastening 122.5 ± 12.5 (12.2 ± 1.2)
3 Hexagonal screw with flange to secure bracket to cab on chassis side 296 ± 29 (29.6 ± 2.9)

Figure 33
78700
78701
SHORT CAB REAR SUSPENSION
PART TORQUE
Nm (Kgm)
1 Self—locking hexagonal nut with flange and hexagonal screw with flange to secure 179 ± 18 (17.9 ± 1.8)
bracket to chassis
2 Self—locking hexagonal nut to secure shock absorber and elastic bumper to cross 216.5 ± 21.5 (21.6 ± 2.1)
member on upper side
3 Self—locking nut and hexagonal screw for shock absorber fastening on lower side 189 ± 19 (18.9 ± 1.9)

Figure 34
78702
DOUBLE AND LONG CAB REAR SUSPENSION
PART TORQUE
Nm (Kgm)
1 Bumper securing screw 128 ± 52 (12,8 ± 5,2)
2 Screw to secure bracket to chassis 105 ± 21 (10,5 ± 2,1)
3 Screw to secure cross member connecting pipe 263 ± 53 (26,3 ± 5,3)
4 Screw to secure shock absorber 128 ± 52 (12,8 ± 5,2)

TOOLS
99370147 Cab mechanic suspension spring check tool
99378031 Two—vacuum cup grip pair to lift windows

REPAIRS 554215 Removing—refitting front mounts

5542 Cab anchoring and cab stabilizer bar
Repairs are limited to replacing broken parts.

Figure 37
554243 Replacing cab suspension front and

rear shock absorbers
Figure 35
38600
Remove the bumper bar assembly.

Disconnect the shock absorber.
Support the cab with the specific prop.
Arrange the appropriate tool 99370147 (1) to compress the
mount spring.
41851 Unscrew the mount fixing screws.
Unscrew the screws fixing the top mount to the cab and the
Figure 36 ones fixing the bracket (2) to the chassis frame. Then extract
the mount together with the stabilizer bar.
Figure 38
33911
The tool (2) compressing the spring of the mount (3) is

removed and refitted with a press (1).
Replace all worn or broken parts.
78706
In order to disassemble front shock absorbers (Figure 35), just For refitting, carry out the steps performed for removal in
unscrew nuts (2) end take out screws (1). In order to reverse order.
disassemble rear shock absorbers, it is needed to unscrew
fastenings and dodge aspiration duct (3), as well as take out
screws (1). NOTE When mounting the stabilizer bar, grease the
grooves of the bar with TUTELA Z2 grease to
To fit them, carry out the above steps in the appropriate prevent noise and wear.
reverse order.

HYDRAULIC CAB LIFTING SYSTEM

Figure 39
78707
1. Lock — 2. Cab lifting pump — 3. Cab lifting cylinder — 4. Supporting box.

554255 Replacing hydraulic cylinder for cab Vibration knife

tilting Figure 41
Figure 40
60967
A vibration cutter is made up of special shears and a suitable

set of vibrating blades with a number of oscillations electrically
99379 adjustable.
Unscrew the oil fittings (4); unscrew the nuts (1 and 2) for the It can be used to cut polyurethane sealants.
connecting pins and extract the cylinder (3).
It is important that, while cutting, the blade goes on parallel
both to the window and body, in order to prevent the blade
NOTE This operation has to be carried out with the cab from breaking.
lowered. In order to prevent the shears from overheating, it is useful to
adjust both advance and number of oscillations depending on
use conditions.
In detail (A) it is shown the scraper to be applied to vibration
shears to level sealant residue.
Figure 42
REPLACING WINDSCREEN WINDOW
General
New EuroCargo Tector windscreen windows observe the
industrial standard which concerns fixed (glued) window
fastening.
This is a great advantage, both in quality, because it assures
perfect impermeableness and resistance to water, and in
safety, because it makes structure more integral and lighter.
To detach the windscreen window, it can be operated with
either a vibration cutter provided with a suitable cutting blade
or harmonic wire.
NOTE Do not use lubricants while cutting.

Blades must be always sharp.
60968
Examples of some situations occurring on cutting glued

windows by matching blade type needed.

Harmonic wire
For cutting the sealant bead with the harmonic wire, it is Figure 45
necessary to use a tool as illustrated in Figure 44.
Figure 43
78708
The other operator, who is outside the vehicle, has to pull the
draw handle (1) while following the windscreen profile, and
cut the sealant bead.
60969 Repeat the operation for 300 mm sections throughout the
profile, properly decreasing their length along the corners of
1. Check tool — 2. Draw handle the window, until a sealant bead complete cut is achieved,
then remove the window using the vacuum cups.
Removal (with harmonic wire)
Before performing windscreen detaching operation, it is
needed to remove, from the vehicle, those components which
would hinder operations or could suffer damage while
executing these operations.
NOTE Before starting the cutting procedure, it is needed to

protect, though an adhesive tape, the painted area, Preparing the windscreen opening
in order to avoid possible damages. Figure 46
Figure 44
78709
60970
By using a suitable blade, cut and level the windscreen opening
Cut a wire section about 500 mm long and, using a check tool sealant so as to leave 0.25 to 1 mm thickness in order not to
(3), put in a wire end (1) through sealant bead (2), starting scratch paint.
from windscreen window lower centre (see Figure 45).
Remove sealant residue through compressed air, then
Fix the wire end to check tool (3), operating inside the vehicle, degrease thoroughly with heptane and expendable paper.
and the other end to the draw handle outside the vehicle.
The inside operator has to point the check tool at sealant bead
(2), about 300 mm from where wire (1) runs through. NOTE The sealant film left on the windscreen opening will
serve as a support for next gluing.

Preparing the windscreen

Figure 47 Figure 49
78713
78710
- Apply glass adhesion promoter (Primer one step
In case of recovery of the original window detached: Betaprime 5500) (2) on silk screen portion by applicator
(1).
- by using a suitable blade, cut and level the sealant bead
trying to reduce thickness as much as possible. It is not
necessary to take off the sealant thoroughly. Avoid to NOTE In case of recovery of the windscreen window, it is
touch the surface of residual sealant. Pay attention not to not needed to apply the adhesion promoter on
damage the black silk screen on window perimeter. sealant left.
Wait 15 minutes before going on with operations, so as to

let the adhesion promoter solvent evaporate.
Refitting
Figure 50
Figure 48
78711
Put in windscreen window (4) upper seal (6). Position plugs

against horizontal sinking (5) on the windscreen window
opening. Position pads against vertical (3) and horizontal (2)
sinking. Make a test assembling and perfectly center the
windscreen window. Once windscreen window centering has
78712 been completed, mark windscreen and seat mutual position
with adhesive tape strips (1). Cut the adhesive tape strips and
Degrease windscreen silk screen portion (1) with heptane (2) remove the windscreen.
and expendable paper.

Figure 51 Figure 53
78714 78716
Extrude a adhesive bead (Silicone Betamate 7185 Quik—Fix)

(1) with air gun (2) along the windscreen perimeter as regularly
NOTE Keep glass (1) under pressure for at least 10 minutes.
as possible.
Start operation from the middle of the lower side and go on
without interrupting throughout the windscreen perimeter.
Before re—attaching previously detached portions, check for
Cut the adhesive cartridge spout in such a way that extrusion lack of infiltration points.
shape is a triangle with 5 x 7 mm base and 12 mm height.
Apply suds with a sponge along the outer perimeter and blow
compressed air from inside in order to highlight possible
infiltration.
Figure 52 When bubbles are in, degrease affected portion and fill it with
the adhesive.
Possible sealant overflowed portions inside can be removed,
once the sealant has hardened, by cutting them with a blade
and detaching them with a pair of pliers.
NOTE Pay attention not to damage silk screen on the

window with the blade.
Re—attach detached portions and clean the window.
NOTE Do not handle or deliver vehicle before 10 minutes

have expired at weather conditions of 23 °C and
50% RH (Relative Humidity) climatic conditions.
When either temperature or humidity are lower,
the dwell time has to be increased.
78715
By dedicated vacuum cups (1), place the windscreen in its seat

immediately after applying sealant, then settle its position.
Position a belt (2) by using vacuum cups (1) as shims, then
tension it in such a way that an even pressure is applied
throughout the windscreen to the purpose of assuring correct
matching among window (4), adhesive (3) and windscreen
opening (5).

550740 Replacing the winding window

Figure 54 Figure 57
33919 33922
Take off the screw caps (arrows), unscrew the screws and Extract the window guide seal (1).
extract the armrest (2). Remove the push—button (1).
Figure 58
Figure 55
33922
Unhook the safety clip (1) from the lifting device (2).
33920
Using proper tool (2), take off the safety ring and dismount
handle (3). Using the pliers, dismount handles (1). Remove the Figure 59
whole panel.
Figure 56
33924
Lift the window (1) and extract it from the top (arrow).
33921 For refitting, simply carry out the steps described for
Lower the window, extract the internal and external seals (1). removal in reverse order.

550730 Replacing the window winder

Figure 62
Take the inside trim off the door as described above.
Figure 60
33927
Extract the outside seal (1), apply the suction cup 99378031
(2).
33925
NOTE Before starting to cut, you need to protect the
Unhook the clips (1), unscrew the screws (2), unhook the paintwork with adhesive tape to prevent any
window from its lifting device (4) and extract the window damage.
winder (3).
To fit it, carry out the steps described for removal in reverse
order.
Insert a suitable tool through the sealant by a corner (arrow)
of the window.
Make the cut all along the perimeter. Remove the window
with a suction cup handle (2).
Using a specific tool, level the bead of sealant remaining in the
seat of the window in the door: clean with compressed air
then fully degrease with heptane and disposable paper.
NOTE If refitting the window, it is necessary to remove the

old sealant without damaging the screen— printed
area of the window.
550478 Replacing the fixed window
Figure 61
Position the window in its seat correctly, register its position
and mark it with adhesive tape. Cut the tape and take out the
window.
33926
Lift the shields (1), unscrew the screws and remove the
rearview mirror (2). Take off the shield (3).
Remove the inside door trim.

Figure 63 Figure 65
33921
33928
Clean the screen—printed area (arrow) with a paper pad Place the windscreen in its seat with the suction cup handle
soaked in degreasing adhesion promoter. (2).
Using a suitable pad, apply the glass primer taking care not to - Align the window with its housing bay, using the adhesive
go outside the screen—printed area. tape applied beforehand as a reference.
NOTE Leave the glass primer to dry at ambient NOTE The window must be positioned within 15 minutes
temperature for at least 15 min. and anyhow for no of applying the adhesive.
longer than 24 hours.
Fit the seals on the inside of the door.

Fit the rubber seal on the window.
Figure 66
Figure 64
33930
Keep the window under pressure with two wooden plugs (1

33929 — 2) positioned as shown in the figure.
Using an appropriate gun (1), apply the adhesive (2) on the
window. NOTE It is necessary to wait at least 3 hours before moving
the vehicle in the workshop.
NOTE The bead of adhesive must be neither too big nor For delivery to the customer, it is anyhow necessary
too small, and it must be continuous. In addition, the to wait 24 hours.
end portion must join the start in order to form a
sealing ring. Take out the plugs, fit the rearview mirror and the internal
door trim back on.

553710 INSTRUMENT PANEL

Removal Figure 69
NOTE Before performing repair interventions, disconnect

batteries and observe safety rules.
Figure 67
79612
- Detach instrument panel (1) from its seat.
Refitting
Perform re—attaching operations inverting described
detaching operations.
79610
- Pull plugs (2) out of the seat;

- operate on check tongues and remove switches (1) from
their opening. 553710 MIDDLE INSTRUMENT PANEL
Removal
NOTE Before performing repair interventions, disconnect

batteries and observe safety rules.
Figure 68
Figure 70
79611
- Disconnect electric connectors and remove switch (1)

79613
sets;
- Unscrew middle instrument panel securing screws (1);
- unscrew instrument panel (3) securing screws (2).
- operate on check tongues and remove lower glove
compartments (3) to access the screws underneath;
NOTE Mark electric wiring harness to make re—attaching
operations easier. - remove the knobs (2) of air—conditioner controls in order
to access the screw underneath.

Figure 71
NOTE Mark electric wiring harness to make re—attaching
operations easier.
Figure 74
79614
- Unscrew securing screw (2) and detach the panel of

air—conditioner controls.
Figure 72
79617
- Detach middle instrument panel (1) from the vehicle.
Refitting
Perform re—attaching operations inverting described
detaching operations.
552211 INSTRUMENT PANEL COVERING
Removal
79615
- Unscrew screws (1) securing the device of Figure 75

air—conditioner controls (3) to middle instrument panel;
- unscrew screws (2) securing the middle instrument panel
on the lower side to the covering.
Figure 73
79618
Perform detaching procedure:

- instrument panel (OP. 553710) and middle instrument
panel;
- let off engine cooling water and drain conditioning system
79616 (if present);
- Pull out middle instrument panel (1);
- lift lid (1), unscrew securing screws (2) and remove glove
- disconnect electric connections (1). compartment from the vehicle (3).

Figure 76 Figure 79
79619
- Unscrew securing screws (1) and remove sill board (2)

from both sides.
Figure 77
79622
- Unscrew securing screw (1) an detach rising grip handle

(2) from both sides.
Figure 80
79620
- Unscrew securing screws (2) and remove plastic

coverings (1) under instrument panel (the figure shows
one of coverings to be removed).
Figure 78
79623
- Operate on check tongues (←) and pull out air diffusion

opening (1) from both sides.
Figure 81
79621
- Pull out door opening ring seal (4);

- pull out pressure plug (2) to access the screw underneath;
- unscrew securing screw (1);
- detach windscreen pillar covering (3) operating (from 79624
both sides) according to the direction of the arrow. - Operate from instrument panel opening, release, from
check clamps, and detach piping (1) to deliver air to
diffusion openings.

Figure 82 Figure 85
79625 78628
- Unscrew Body Control securing screws (1); - Unscrew instrument panel covering securing screws (1)
in instrument board opening and screws (2) for fastening
- remove Body Control (2) and set aside.
to support bracket.
Figure 86
Figure 83
79629
79626 - Unscrew instrument panel covering (2) upper securing

- Operate from (Body Control) opening, disconnect and screws (1) along windscreen edge perimeter.
remove piping (1) to deliver air to diffusion openings.
Figure 87
Figure 84
79630
- Operate from Body Control lower side and unscrew

79627
securing nut (1), and set aside electric components
support panel (2) to access fastening underneath;
- Unscrew side securing screws (1) from both sides of
instrument panel covering the body. - unscrew screws (3) securing instrument panel covering to
support bracket.

Figure 88 Figure 90
79631
- Unscrew screws (2) securing instrument panel support

bracket located at air conveyor (1) side.
79633
- Pull out steering wheel hub cap (1);

- unscrew nut (2) and detach steering wheel (3);
- unscrew securing screws (4) and remove steering column
covering (5);
- operating from steering column side, unscrew instrument
panel support bracket securing screws (6) (see LENS).
Figure 89 Figure 91
79632 79634
- Unscrew securing nuts (3) and detachcode central unit (1); - Unscrew securing screws (2), disconnect electric
connections and remove windscreen drive lever (1).
- unscrew screws (2) of instrument panel bracket support
to body.

Figure 92 Figure 95
79635 79638
- Unscrew securing screws (1) and detach diagnosis socket - Operate inside Body Control opening, unscrew
(2). instrument panel covering bracket (2) securing screws
(1);
Figure 93 - remove door open light wiring harness;
- remove duct diffusing air to feet.
79636 Figure 96
- Lift radiator cowling, unscrew securing screws (1) and
detach guard (2).
Figure 94
79639
- Unscrew screws (1) securing heater to instrument panel;

79637
- unscrew securing screws (3) and remove instrument
- Unscrew screws (3) securing conditioner (6) to cab front panel support bracket (2) operating from instrument
wall; board opening (as shown in box);
- unscrew expansion valve (4) securing screws (5); - remove air duct from heater to instrument panel.
- disconnect heater piping (2) and unscrew securing screws
(1).

79640
79643
- With help from a second operator, properly detach
instrument panel (1) covering from the vehicle. - Operate from heater (2) rear side and disconnect electric
cable bundle check clamps (1).
Figure 98
Figure 101
79641
Refitting
Perform instrument panel (1) covering re—attaching
operations properly inverting described detaching operations.
79645
533210 HEATING AND VENTILATION
- Remove vehicle heating and ventilation unit (1).
Removal Refitting
Figure 99
Perform heating and ventilation unit re—attaching
operations inverting described detaching operations.
79642
Perform detaching procedure on:

- instrument panel (1) (OP. 553710);
- middle instrument panel (2) (OP. 553710);
- instrument panel covering (3) (OP. 552211);
- remove interfering parts.

EUROCARGO TECTOR 12—26 t SERVICE PLAN 1
Print 603.93.391/A
SECTION 13
Service plan
Page
ELECTRONIC MAINTENANCE SCHEDULE . . . 3
DIAGNOSIS EQUIPMENT CONNECTION . . . 4
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE FREQUENCY . . . . . . . . . . . . . . . . . . . . 5
UNPLANNED MAINTENANCE SERVICE

AND TIME—DEPENDING OPERATIONS . . . 5
- Unplanned / time—depending operations

(to be carried out possibly at
the same time as a planned service operation) 5
SCHEDULED MAINTENANCE OPERATIONS . 6
UNPLANNED / TIME—DEPENDING
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
SCHEDULED MAINTENANCE OPERATION . . 9
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 9
M1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
M2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
M3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 14
EP1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
T1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
T2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
T3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
T4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
T5 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Revi — July 2005
2 SERVICE PLAN EUROCARGO TECTOR 12—26 t
Print 603.93.391

Print 603.43.671/A
ELECTRONIC MAINTENANCE SCHEDULE

One important function available on vehicles equipped with HIGHLINE—type clusters (not available on BASELINE—type clusters)
is the ELECTRONIC MAINTENANCE SCHEDULE, which can now be easily managed and programmed thanks to the latest
Modus and IT2000 release.
The scheduled service checks carried out in the workshops will now be easily recorded directly on the vehicle, and the recorded
maintenance history will be displayed.
The Dealership workshop shall, prior to delivering the vehicle, program (through the diagnosis station) the most suitable
maintenance schedule, from among those provided for by Iveco, in the on—board panel control unit.
As for the vehicle’s “mission”, a kilometer— or hour—based maintenance schedule may be chosen.
The workshops may subsequently modify such schedule according to the utilization requirements.
Once the vehicle has been delivered, the driver will be able to check out their own maintenance schedule, not only on the owner
handbook but also through their own cluster, where a special screen dedicated to this function will be available.
The customer will not be allowed to either cancel or modify the schedule: they will always have to contact an authorized Iveco
service centre.
Figure 1
85576
79486
SIGNALLING THE MAINTENANCE SCHEDULE ON THE CONTROL PANEL CLUSTER
Print 603.93.391/A Revi — July 2005

Shortly before the vehicle reaches the distance in kilometres at which the service check is to be carried out, an alarm warning
light will illuminate on the cluster, to warn the driver of the maintenance service check.
Figure 2
85780
ALARM WARNING LIGHT ON THE ”CLUSTER”
If the vehicle is serviced at a workshop equipped with diagnosis equipment, the latter will, after maintenance has been performed,
have to be connected and will store the date and the type of service check on the cluster memory. Therefore, the alarm warning
light will consequently go out.
In the event that routine maintenance is not performed at a service centre equipped with diagnosis equipment, the warning light
on the dashboard will not go out.
The purpose of this strategy is to appeal to our customers through the professional competence and skill of our service Network,
so that our customers will preferably go to an authorized workshop where all service work, including routine maintenance, is
carried out by qualified technicians.
Obviously, this system (introduced with the newest EuroCargo models) offers great advantages to customers, who will be able
to better plan their vehicles’ maintenance schedules: thus, they will always have highly efficient, top—performance vehicles.
DIAGNOSIS EQUIPMENT CONNECTION

Figure 3
85797
85781
79481
Revi — July 2005 Print 603.93.391/A

SERVICING
Service plan
The checks, maintenance interventions and adjustments required at regular frequency on vehicle parts to ensure optimal working
conditions are illustrated on the following pages.
NOTE The engine lubricant frequency in kilometres refers to a percentage of sulphur in fuel lower than 0.5%.
Halve the oil replacement frequency if fuel with a percentage of sulphur higher than 0.5% is used.
Engine lubricant oil — ACEA E5 (URANIA LD5)
NOTE - In the case lower class lubricant is used, for example ACEA E2 (Urania Turbo), halve the oil replacement
frequency.
- Change the engine lubricant oil in any case every 12 months in the event of very low distance, less than 800
hours/80,000 kilometres per year.
- Change the transmission and axle oil at least once every two years in the event of very low yearly distances.
- Carry out the general greasing procedure at least once a year in the event of very low yearly distances.
SERVICE FREQUENCY
Unplan—
Standard services Time—depending operations
ned
Use type EPI
Maintenance
M1 M2 M3 M4 T1 T2 T3 T4 T5
of automatic
gearbox
Long range national or
international transport, 80.000 160.000 240.000 480.000
km km km km
mainly motorway transport
40 000 km
40.000
Every 6 months
Short/medium range
60.000 120.000 240.000
beforee start
Everyy year
regional or inter—regional
Winter
Everyy year
pring
km km km
ery 2
ery 3
at start
ears
ears
transport
yea
of Sp
yea
Ever
Ever
st
Heavy duty transport, of W

40.000 80.000 160.000
mainly urban transport: Every
km / km / km /
tiltable vehicles, packing 20.000 km
1.600 3.200 6.400
vehicles, road cleaning /
Hours / Hours / Hours /
vehicles, distribution vehicles. 400 Hours
1 Year 2 Years 4 Years
Use of off—road vehicles
UNPLANNED MAINTENANCE SERVICE AND TIME—DEPENDING OPERATIONS

Unplanned operations are indicated by EP (Extra Plan), while time—depending operations indicated by T (time) are interventions,
complementary to standard services, referring to either time intervals, or hour intervals; however, in the latter case, optional items
are concerned, that are not generally present on vehicles.
Unplanned / time—depending operations (to be carried out possibly at the same time as a planned
service operation)
EPI
EVERY 20,000 km or 400 hours — for urban or off—road use.
EVERY 40,000 km — for long, medium or short distance hauls.
G Change automatic transmission filter and oil.
G Remove—refit and clean automatic transmission oil breather.
T1
EVERY 6 MONTHS — particularly at the beginning of spring
G Clean radiator curtain.
G Check of antipollen filters condition (1)

Revi — July 2005
T2
EVERY YEAR
G Replace pneumatic system drier filter.
T3
EVERY YEAR — before winter
G Check coolant density
G Replace supplementary heater fuel filter.
T4
EVERY TWO YEARS
G Replace air cleaner cartridge and clean container (2).
G Change engine coolant.
T5
EVERY THREE YEARS
G Replace oil and bleed hydraulic clutch system.
SCHEDULED MAINTENANCE OPERATIONS
M1 M2 M3 M4
— Tilting the cab, opening and closing the cowling, disconnecting — reconnecting engine D D D D
guards
— Handling operations D D D
— Functional testing on road D D D
— Checking cooling system piping tightness D D D
— General chassis greasing D D D D
1 Replacing blow — by filters D D D D
12 Checking clutch hydraulic system fluid level D D D D
10 Checking brake disks and shoe wear D D D D
5 Check of brake shoe wear (26t) D D D D
13 Checking headlight aiming D D
11 Checking steering articulated joint and steering column linkage D D
6 Replacing mechanical gearbox oil D D
9 Replacing axle hub oil D D
4 Replacing rear axle oil D D
7 Cleaning mechanical gearbox oil breather D D
3 Cleaning rear axle oil breather D D
UNPLANNED / TIME—DEPENDING OPERATIONS

EP1 T1 T2 T3 T4 T5
— Replacing automatic gearbox filter and oil D
— Disjoining—re—joining and cleaning automatic gearbox oil D
breather
— Check of antipollen filters condition D
14 Cleaning radiator curtain D
2 Replacing pneumatic system dryer filter D
15 Checking engine coolant density D
8 Replacing cartridge and cleaning air filter container D
15 Replacing engine coolant D
12 Replacing oil and bleeding clutch hydraulic system D
(1) In case of low distances covered, replace filters once a year, at every start of Spring.
(2) Air filter early clogging is generally caused by environmental conditions. For this reason, the filter must be replaced on signalling
by special sensor independently of prescription, that is anyhow to be observed in lack of specific indications.

Revi — July 2005
Print 603.43.671/A
Figure 4
84414

Revi — July 2005
Figure 5 17
18
19
16
23
20
22 21 105382

Revi — July 2005
Print 603.43.671/A
SCHEDULED MAINTENANCE OPERATIONS
M2 M2 M3 M4
17 Replacing engine oil D D D D
18 Replacing engine oil filter D D D D
20 Checking conditions of different control belts D D D D
21 Replacing fuel filter D D
19 Replacing fuel pre—filter D D
16 Checking steering box and support fixing D D
20 Replacing belts of different controls D D
23 Checking valve backlash and possible adjustments D D
22 Check—up engine EDC system by means of MODUS or IT 2000 D D
UNPLANNED / TIME—DEPENDING OPERATIONS
T1 T2 T3 T4 T5
— Replacing additional heater fuel filter D

Revi — July 2005
M1 SERVICE
S Handling operations 12 — Check clutch hydraulic system fluid level
S Functional testing on road
S General chassis greasing Figure 7
S Checking cooling system and hydraulic
brake pipe seal
1 — Replace the blow—by filters
Figure 6
84410
Check the level of the clutch fluid. Top it up if it is too low

(see the fluids table in the GENERAL section).
The clutch fluid is poisonous and corrosive: if you

accidentally come into contact with it, wash
77835
immediately with water and a neutral soap.
Unscrew the 6 screws (1) and remove cover (2). 17 — Changing engine oil
Remove blow—by filters (3). Take out the oil level dipstick .
Before assembling the new filters clean their housing. Remove the plug (1) from the oil sump and drain the engine
oil off into a specific container.
Figure 8
5 — Checking wear of brake shoes (26 t)

If you find too much wear, replace the worn components as
described in the relevant section ”BRAKES”.
10 — Checking wear of discs, pads

If you find too much wear, replace the worn components as
described in the relevant section ”BRAKES”.
77836

Revi — July 2005
18 — Changing engine oil filters 3 — Clean axle breather (12—18 t)

Figure 9 Figure 11
75338
Remove the oil filter (1) with tool 99360314. 84415
Remove the oil vapour breather (1) and clean it thoroughly.

NOTE Before refitting the new cartridges, moisten the seal Mount it, making sure it is in the right position and tighten it
with engine oil. to the prescribed torque.
Screw the oil filter (1) on by hand until it is in contact with

the mounting and then tighten by 3/4 of a turn to the re-
quired tightening torque.
Screw the plug back on under the sump and tighten it to the
required torque.
Pour oil into the engine through the filling—pipe (2) of the re- 4 — Changing rear axle oil
quired grade and quantity (see fluids table in the GENERAL
section).
20 — Checking miscellaneous drive belts Figure 12
See that the belts are not worn or deteriorated; if they are,
replace them as described under the relevant headings.
M2 SERVICE
NOTE The M2 service comprises the operations of the M1

service plus the ones listed here.
3 — Clean axle breather (26 t)

Figure 10
78148
- With the axle warm, drain off the oil into a specific
container by taking out the plug (2).
- Replenish with fresh oil through the hole closed by the
plug (1) (see the FLUIDS section under the heading
GENERAL INFORMATION).
34811
- Clean the rear axle oil vapour breather.
Mount it, making sure it is in the right position and tighten it - Tighten the plugs to the prescribed torque.
to the prescribed torque.

Revi — July 2005
6 — Replace mechanical transmission oil 9 — Replace hub oil (axle 5845)
Figure 13 Figure 15
77837
Replace oil as follows:

75342
- Turn wheel hub until when the hub cover (1) is
The lubricating oil must be drained off while it is warm. positioned as shown in Figure 15.
Place a container under the plug (1). Take out the plug and - Unscrew plug (2) and drain oil into a special container.
drain off the oil. Fit the plug (1) back on. Unscrew the filler
cap (2) and replenish the gearbox with lubricating oil in the - Use a syringe to suck the remaining oil.
quantity and grade prescribed in the GENERAL
INFORMATION section. Figure 16
7 — Clean mechanical transmission oil breather
Figure 14
77203
- Turn wheel hub until when the hub cover (1) is

positioned as shown in Figure 15.
- Fill in the set quantity of new oil through filling hole (2)
(see CHARACTERISTICS AND DATA).
- Screw back plug (2, Figure 15) to the set torque.
75346

Mount it, making sure it is in the right position and tighten it
to the prescribed torque.

Revi — July 2005
9 — Replace hub oil (axle 5842/5—5851/5—5871/5) 13 — Checking headlight adjustment
Figure 17 Figure 18
79069
- Unscrew plug (1).

- Use a special syringe to suck.
- Fill in the set quantity of new oil through filling hole (see
CHARACTERISTICS AND DATA).
84411
- Screw back plug (1) to the set torque.
- Switch (1) for vertical adjustment of light beam (3)

11 — Checking steering column articulation (available on the dashboard).
and linkage
- With the cab tilted, act on screw (2) for horizontal
Steering control linkage adjustment of light beam (3).
- Check that the screws and nuts fixing the clamps to the
tie rods have not deteriorated and are tightened to the
required torque.
- The tie rods must not be damaged and the threaded
portion must be integral.
Ball joints
- Clean the ball joints of the tie rods.
- This must be done with dry rags or raw cotton; use no
solvents.
- Check that the ball joints, in their components, have no
points of corrosion with sections of depth greater than
1 mm. In particular, check the sheet metal cover close to
the rolled section.
- Check the protective casing: it has to be secured to the
body and to the pin of the articulation with the split ring
and it must not turn.
- The casing must be neither deteriorated nor damaged.
- Manually crush the protective casings and check that
lubricating grease comes out.
- Check that the nuts and split pins are not deteriorated.

Revi — July 2005
16 — Checking steering box fixing and mount- M3 SERVICE

ing
19 — Changing fuel pre—filter NOTE The M3 service comprises the operations of the
Figure 19 M1 and M2 services plus the ones listed here.
20 — Changing miscellaneous drive belts
Figure 21
74341
Unscrew the pre—filter (1) and replace it.

Before refitting the new cartridge, moisten the seal with die-
sel or engine oil.
Screw the cartridge on by hand until it is in contact with the
mounting and then tighten by 3/4 of a turn to the required
tightening torque.
NOTE When replacing the cartridge, it must not have

been pre—filled. This is to prevent impurities getting
into circulation that could damage the system
components, injectors/pump.
77839
21 — Changing fuel filter To remove and fit the belt (1) back on, you need to use an
appropriate tool on the tightener (2) in the direction shown
by the arrow.
Figure 20
NOTE The tighteners are automatic, so they are not to be
adjusted after assembly.
22 — EDC system check—up using MODUS or

IT2000
23 — Checking valve clearance and adjustment

if necessary
To perform these operations correctly, proceed as described
75340
under ”ENGINE” in the relevant section.
Remove the fuel filter (1) with tool 99360314. UNPLANNED /

Before refitting the new cartridge, moisten the seal with die- TIME—DEPENDING OPERATIONS
sel or engine oil.
Screw the new one on by hand, taking care to check that the EP1 SERVICE
rubber seal and the mating surface are clean and in a perfect
state of repair. Screw the cartridge on by hand until it is in - Replace filter and automatic transmission oil
contact with the mounting and then tighten by 3/4 of a turn
to the required tightening torque. - Disconnect — reconnect and clean automatic
transmission oil breather

Revi — July 2005
T1 SERVICE T3 SERVICE
14 — Cleaning the radiator shade 15 — Checking density of antifreeze in the
engine coolant
Figure 22
Figure 24
84412
Remove any dirt from the radiator shade (1) to let air flow
towards the radiator.
84413
The plug (1) must never be taken out for any reason
whatsoever.
T2 SERVICE
With the engine warm, the cooling system is in
2 — Changing pneumatic system drier filter overpressure, therefore take care when taking off
the cap (2).
Figure 23
Take off the cap (2) and draw off a sample of the coolant from
the expansion tank (3) with the densimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentage has to be higher than 40% and
must not exceed 50%.
If necessary, restore the percentage of antifreeze, bearing in
mind that the liquid needs to be replaced every 2 years.
NOTE For vehicles fitted with an additional heater, the

77841 percentage of antifreeze must never exceed 50%.
Discharge the pressure of the compressed air system.

Unscrew the drier filter (1) and change it; tighten it to the
prescribed torque, checking there is no air leakage when - Replace additional heater fuel filter.
pressure is restored.

Revi — July 2005
T4 SERVICE T5 SERVICE
12 — Replace oil bleed clutch hydraulic system
8 — Changing the cartridge of the dry air filter
and cleaning its container (even if no clogging
signalled) Figure 26
Once a year (servicing with frequency in hours)
Once every two years (servicing with frequency in km)
Figure 25
77843
84410
Drain off the clutch control fluid and change it (see Fluids
- Operate on fastening/s and remove cover (1). table in GENERAL section).
- Take the cartridge out of the air filter.
Before fitting the new cartridge, clean its housing thoroughly.
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediately with water and a neutral soap.
15 — Replace engine coolant
Carry out the procedure described under the relevant
heading in the ”ENGINE” section.
Then proceed with air bleeding from the clutch control
hydraulic circuit by suitably operating on the bleeding valve
placed on the deaerator device operator cylinder 99306010.

Revi — July 2005
EUROCARGO TECTOR 12-26 t ELECTRIC/ELECTRONIC SYSTEM 1
Print 603.93.391
SECTION 14
Electric/Electronic system
Page
PRELIMINARY REMARKS . . . . . . . . . . . . . . . . . . . 3
SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . 3
SYMBOLS - ASSISTANCE OPERATIONS . . . . . . 4
PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . 6
GENERAL WARNINGS ON THE

ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 8
CONCEPT OF GROUND AND ELECTROMAGNETIC

COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . 9
- Practical tips . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Efficiency tests on the CAN line . . . . . . . . . . . 12
DESCRIPTION OF BASIC SYSTEM . . . . . . . . . . . 13
ELECTRICAL CHARACTERISTICS . . . . . . . . . . . . 13
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . 14
- Engine F4AE0481 . . . . . . . . . . . . . . . . . . . . . . 14
- Engine F4AE0681 . . . . . . . . . . . . . . . . . . . . . . 15
POWER NETWORK . . . . . . . . . . . . . . . . . . . . . . 16
- Positive network . . . . . . . . . . . . . . . . . . . . . . . 16
- Power cable sections . . . . . . . . . . . . . . . . . . . . 16
- Negative network . . . . . . . . . . . . . . . . . . . . . . 17
- Ground point identification . . . . . . . . . . . . . . . 18
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- General remarks . . . . . . . . . . . . . . . . . . . . . . . 25
- Starting from the driver’s seat

(Cab hooked) . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Starting from the engine compartment

(Cab tilted) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 28
COMPONENT CODE . . . . . . . . . . . . . . . . . . . . . 29
JUNCTION CONNECTOR . . . . . . . . . . . . . . . . . 34

2 ELECTRIC/ELECTRONIC SYSTEM EUROCARGO TECTOR 12-26 t
Print 603.93.391/A
Page Page
DESCRIPTION OF EDC 7 INJECTION SYSTEM . 126

BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 95
ECAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
CENTRAL DASHBOARD . . . . . . . . . . . . . . . . . . 96
ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 170
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . 98
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 AUTOMATIC GEARBOX ALLISON WTEC III . . 183
- Models available . . . . . . . . . . . . . . . . . . . . . . . 100 ELECTRONIC CENTRAL UNIT DMI (DATA

MANAGEMENT INTERFACE) (OPT. 5626) . . 231
OPTICAL INDICATORS ON THE CLUSTER . . . 101
AUXILIARY HEATER WEBASTO . . . . . . . . . . . . 233
(FAILURE) INDICATORS ON THE DISPLAY . . . 102
CENTRAL LOCKING SYSTEM WITH REMOTE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 243/1
“POP-UP” EVENTS . . . . . . . . . . . . . . . . . . . . . . . 104
FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 246
CLUSTER (PIN-OUT) . . . . . . . . . . . . . . . . . . . . . 105
- Diagnosis Instruments . . . . . . . . . . . . . . . . . . . 246
CENTRAL INTERCONNECTING UNIT . . . . . . . 106
- System initialization screen . . . . . . . . . . . . . . . 247
REMOTE-CONTROL SWITCH ASSEMBLY . . . . 107
- DIAGNOSTIC screen
(oly for Highline versions) . . . . . . . . . . . . . . . . 248
FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 108
- Meanings of anomaly codes . . . . . . . . . . . . . . . 248
CONNECTOR ASSEMBLY . . . . . . . . . . . . . . . . . 110
- Description of fault codes (SPN) . . . . . . . . . . . 249
STEERING COLUMN STALK . . . . . . . . . . . . . . . . 117
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 251
POSITION OF ELECTRONIC CONTROL UNITS 118
- Instrument Body Controller (IBC) . . . . . . . . . . 251
BODY CONTROLLER . . . . . . . . . . . . . . . . . . . . . 119
- Instrument Cluster (IC) . . . . . . . . . . . . . . . . . . 266
- Linking connectors . . . . . . . . . . . . . . . . . . . . . 119 - “EDC 7” injection system . . . . . . . . . . . . . . . . 271
CONNECTOR PIN-OUT . . . . . . . . . . . . . . . . . . 124 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . 539
TACOGRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . . 541

Revi - July 2005
Print 603.93.391
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections
of units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - WARNINGS
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Danger of serious damage for the vehicle

Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.
General danger
! It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE It indicates an additional explanation for a piece of information.

SYMBOLS - ASSISTANCE OPERATIONS
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

α
Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 °C
Sealant
Cold
Adhesive
Winter
Temperature > 0 °C
Air bleeding Hot
Summer
Replacement
Original spare parts

PRODUCT CODE
Each title or subtitle concerning operations being performed is preceded by a six-figure number named PRODUCT CODE.
This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and
TROUBLE CODE document.
As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
Product Code: 5 0 7 6
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT
The first and second figures identify the PRODUCT within motor vehicle.
Example :

Product 52 = Axles;
Product 53 = Transmission;
Product 76 = Electric ssystem.
Unit Code: 0 1 0 3
COMPONENT COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT.
Example :

Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.
Sub-assembly Code: 4 0 1 3
COMPONENT COMPONENT
The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.
Example :

Unit 01 = Chassis;
Sub-assembly 40 = Chassis cross members;
Sub-assembly 13 = Rotor.

GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to
! contact immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and
on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph “Controls
care of user” of Use and Maintenance handbook.
In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave
unmanned a vehicle in motion during repair interventions.
Keep the vehicle stationary by proper chocks.
In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special
support stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.
When it is necessary to perform an intervention on methane-fed vehicles, observe the indications contained inside
the document, as well as all specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on
harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes,
free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting
fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to
store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable
substances into suitable containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil
spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR - BAG systems, scrupulously observe
indications specified in relating manual sections.

GENERAL WARNINGS
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health;
operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has
occurred, refer to 12-point cards for provisions to make.
Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up
detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network
is available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
1 Pay attention that jamming sources are not present in the cab or near the keys.
2. Keys not insered in the panel must be at least 1 meter away.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.

Print 603.93.391
CONCEPT OF GROUND AND ELECTROMAGNETIC COMPATIBILITY

The electrical system is traditionally uni-polar. The body, the frame, the metal cases of the electromechanical components serve
as equipotential return conductors to the generators, since any point in their metal structure or any non-insulated negative terminal
is at the same reference potential, or GROUND. This is why the ground has been chosen as the reference term for the entire system
and has been assigned, conventionally, the value of zero.
For obvious construction needs, the negative network of the system includes a number of grounding points situated on the vehicle
as a function of the location of the components on the frame, the engine and the bodywork.
Ideally, all the units should be connected to a single grounding points so as to ensure that each of them, and in particular each of
the electronic devices, has a clearly defined ground reference.
For the foregoing reasons, we should distinguish between the power ground, or system ground, characterised by high direct current
intensity (> 1 A for the electromechanical components), and the analogue ground, characterised by wave shapes at given frequencies
and very modest current intensity (mA, µA of the electronic systems).
The definition of the analogue ground (or signal ground) depends on the sensitivity of the electronic systems to EMC
(electromagnetic compatibility), since eddy signals, which may be generated either by on-board or by extraneous systems, cause
the malfunctioning and/or deterioration of the systems themselves.
In order to minimise noise or interference, whether continuous or transient, generated by eddy radiation, it is essential to keep in
mind that the efficiency of the system’s reference plane or ground depends, at each connecting point, on excellent conductivity
characteristics (contact resistance approaching zero).
To sum up, we can say that the ground, understood as equipotential electrical conductor, or as potential reference term for all
on-board electrical/electronic components, is subdivided into system ground and analogue ground.
The system’s grounding points are established by the Manufacturer and must obviously be free of paint, oxidation, grease, dust, etc.
The system’s grounding points are established by the Manufacturer and must obviously be free of paint, oxidation, grease, dust, etc.
Figure 1
6616
IDEAL EQUIPOTENTIAL GROUND NETWORK

Ba. Battery - R. Loads - Rz Frame impedance - M. Ground

Practical tips
The negative leads connected to a system grounding point must be as short as possible and connected to one another in ”star”
configuration; make sure that they are tightened in an orderly and adequate manner (Figure 2, ref. M).
Furthermore, for electronic components, the instructions to be followed very carefully are:
- ECU’s must be connected to the system ground if they are provided with a case.
- ECU negative cables must be connected both to a system grounding point, such as for instance the dash compartment ground
(with no ”serial” or ”chain” connections) and to the negative terminal(s) of the battery/batteries.
- Even though they are not connected to the system ground/battery negative terminals, analogue ground elements (sensors)
must have excellent insulation. As a result, special care must be devoted to the eddy resistances of the cable terminals: oxidation,
seam-folding defects, etc.
- The metal braid of shielded circuits must be in electrical contact at either end with system components.
- Only one end of the shielding braid must be connected to the system ground.
- In the presence of jointing connectors, the non-shielded portion, d, must be as short as possible in the proximity of the
connectors (Figure 2).
- The cables must be arranged so as to run parallel to the reference plane, i.e., as close as possible to the frame/body structure.
- Additional electromechanical systems must be connected with the greatest care to the system ground and must not be placed
alongside the cables of electronic components.
Figure 2
88039
SHIELDING BY MEANS OF A METAL BRAID OF A CABLE LEADING TO AN ELECTRONIC COMPONENT

C. Connector - d. Distance ! 0.

CAN LINE
The term CAN stands for Controller Area Network. It is a dedicated cable linking together the (ECU)’s of a vehicle so as to create
a structure resembling the nervous system.
This system makes it possible to exchange large quantities of data between the various on-board electronic systems instantaneously.
It represents a TWO-DIRECTIONAL communication mode which is gaining ground in the automotive field, thanks to the reduction
in the number of conductors and reduced noise.
The data travel in keeping with a protocol that defines the communication mode:
- Data synchronisation
- Call and reply modes between the various systems
- Identification and correction of possible transmission errors
Figure 3 Instrument Cluster
CAN VDB line
L A8 Cluster control buttons

Tachograph
120 W OK
H A4
L B1 Cancel
Immobilizer
Menu UP
H B4
L
Menu DOWN
X1_1
ABS
H X1_3
Retarder
Allison
transmission
L X1_1
L 19
ECAS Mirror
H X1_3 control
H 20
L C11 Sensors Sensors

IBC
H C12
L B52 Actuators Sensors Sensors

EDC7
120 W
H B53
79487

Efficiency tests on the CAN line
The cable used for the CAN line available on the vehicle is of the twisted type.
This ensures that no electrical noise affects signals.
Grey is the colour of the sheath.
Figure 4
A B
73652
A. Sheath (gray) - B. Twisted wires (white/green)
Efficiency tests on the CAN line
In order to check the perfect working order of the CAN line available on the vehicle, a few measurements must be made.
To make these measurements, it is necessary to connect to 30-pole diagnosis connector pins 22 and 21, and measure the following:
Values to be gathered during measurements (VDB)
0Ω ∼ 60 Ω ∼ 120 Ω 0.L.
CAN line short-circuited CAN line OK One resistor shut off CAN line shut off

Print 603.93.391
DESCRIPTION OF BASIC SYSTEM

ELECTRICAL CHARACTERISTICS
1. Unipolar system with negative pole connected to frame ground
2. Rated power supply voltage of 24 Vdc, with two 12 V / 110 Ah batteries connected in series
3. Power supply of electrical system and battery recharging with alternator 28V / 70A (BOSCH) (90A - OPT).
4. Starting by means of starter motor: 24V / 4.0 kW (BOSCH)

ENGINE COMPONENTS
Engine F4AE0481 A B C D E F
Figure 5
M L I H G 101585
ENGINE VIEW LEFT SIDE

A. coolant temperature sensor - B. electrinic injection electro valve - C. engine preheat resistor - D. fuel pressure sensor - E.
oversupply air temperature/fuel pressure sensor - F. hydraulic control low fluid level indicator - G. distribution pulse sensor -
H. fuel pressure adjuster electro valve - I. fuel temperature sensor - L. edc 7 electronic center -
M. engine rpm sensor
Figure 6
D C B A 50277
ENGINE VIEW EIGHT SIDE

A. Alternator - B. Oil temoerature/pressure sensor - C. Oil level transmitter - D. Starter motor

Engine F4AE0681 A B C D E F
Figure 7
G
H
I
L 50339
M
ENGINE VIEW LEFT SIDE
A. coolant temperature sensor - B. electrinic injection electro valve - C. engine preheat resistor - D. fuel pressure sensor - E.
oversupply air temperature/fuel pressure sensor - F. hydraulic control low fluid level indicator - G. distribution pulse sensor -
H. fuel pressure adjuster electro valve - I. fuel temperature sensor - L. edc 7 electronic center -
M. engine rpm sensor
Figure 8
B
C
50338
D
ENGINE VIEW EIGHT SIDE
A. Alternator - B. Oil temoerature/pressure sensor - C. Oil level transmitter - D. Starter motor

POWER NETWORK Figure 9

Positive network
Never disconnect the system batteries when the

! internal-combustion engine is running. Prior to
connecting the batteries to the system, make sure
that the latter is properly insulated. The batteries
must be disconnected from the system when they
are to be recharged.
The aim of the electric system is to generate, control, store and

distribute the power necessary for vehicle component
operation.
To this purpose, the electronic base system power supply is
delivered by a generator (alternator 28V — 70A) and two
50358
batteries (12V, 110Ah each) connected in series.
A “positive pin” is located inside the cab, behind the dashboard POWER SUPPLY BATTERIES
(just next to the bulkhead). A 16 mm2 cable from the battery
is connected to this pin. Here, the following inputs are available: Figure 10
- Control unit interconnecting connector G and terminal A
— 10 mm2
- Starting switch (+30 / 4 mm2)
- Fuse holder 70000/1, fuse 1-4 mm2
- Fuse holder 70000/2, fuse 1-4 mm2
Power cable sections

- cable direct from the battery = 16 mm2
- cable to the UCI = 10 mm2
- cables to the fuses = 1/2,5/4mm2
- alternator cable = 16 mm2
- starting motor cable = 70 mm2
101519
POSITIVE PIN (CAB INNER SIDE)
Figure 11
NOTE In case work has to be carried out on the vehicle’s

electric/electronic network, it is recommended
that the battery positive pole be disconnected.
101510
POSITIVE PIN ELECTRIC CONNECTIONS

Negative network
Figure 12
The batteries are connected to the chassis ground by means
of a brown, 70 mm2 cable, at earth point (M6) on the right side
member. M6
The starting motor is connected to chassis ground (M8) by
means of a 70 mm2 cable fastened onto the right side member
just next to the motor itself. The same cable is used to bond
the complete internal-combustion engine assembly to the
chassis ground.
The same electric, negative equipotentiality of the chassis is
provided to the vehicle cab, by means of a stranded wire
connected onto the cab front and onto the front right side
member.
Inside the cab (behind the Body Controller) is an earth point
marked “S” and called “SIGNAL EARTH”. Here, the earths for
the electronic control units located inside the cab and the
30-pole diagnosis connector earth are available. 50358
BATTERY GROUND POINT ON THE LEFT

SIDE-MEMBER (M6)
Figure 13
M8
50354
STARTING MOTOR EARTH POINT
Figure 14
101511
ELECTRIC CONNECTIONS M6, M8

Ground point identification
Figure 15
S M2 M3M4 M7 M6 M5
M1
T1T2 M9
M8
84596
M1/M3. Left side cab internal ground - M2. Right side cab internal ground - M4. Roof panel ground - M5. Rear chassis
ground - M6. Battery ground - M7. Front part left side-member ground - M8. Starting motor ground - M9. Front part left
side-member ground - S. Cab interior ground (signal ground) - T1/T2. Negative electric unipotential plait

Earth points behind the Body Controller
The earth cable (*) from the BODY CONTROLLER is connected DIRECTLY to earth point M2.
Figure 16
MS
M2
85559
Figure 17
ELECTRIC CONNECTIONS M6, M8 101512
Earth point Description

M2 Body builder light remote-control switch. Power supply (+15) remote-control switches for diag-
nosis connector. Roof panel cable earth. Slow gear engagement switch. ABS resistor. Switch on
the right-hand pillar. Ash-tray compartment lighting. Interconnecting control unit (I) (F). Body
builder connector. Fog light remote-control switch. ABS control unit (I). Exhaust brake switch.
Electric heater.
* Body Controller
S 30-pole diagnosis connector. Immobilizer. ABS (I)

Roof panel ground point
Figure 18
M4
101513
Figure 19
ELECTRIC CONNECTIONS M4 101514
Ground point Description

M4 Tachograph, step lighting ceiling light, car radio, internal lighting ceiling light, voltage reducer, CB.

Earth points behind the Cluster
Figure 20
M1 M3
85558
Figure 21
ELECTRIC CONNECTIONS M1, M3 101515

M1 Internal ceiling light. “MENU UP” button. “MENU DOWN” button. “MENU G” button. “MENU
OK” button. Rear fog light switch. Headlamp trim control. Fog light switch. Internal light switch.
Emergency light switch. Cluster (A19).
M3 Switch on the left-side pillar. Floor cable earth. Steering column stalk (B)/(A)/(C). Cruise Control
(control). Clutch ON signalling switch.

Figure 22 Figure 23
M6
T1
50358
BATTERY EARTH POINT ON RIGHT SIDE MEMBER

(M6)
Figure 24
M8
50354
STARTING MOTOR EARTH POINT (M8)
T2
50361
EQUIPOTENTIALITY STRANDED WIRE

Rear left side-member ground point (M5)

Figure 25
M5
50362
M5 Rear lights ground
Front left side-member ground point (M9)

Figure 26
M9
50360
Figure 27
101516
ELECTRIC CONNECTIONS M9

M9 Headlamp washer pump, windscreen wiper unit, windscreen washer electric pump, radiator
water low level sensor, windscreen washer fluid low level sensor, power steering fluid low level
sensor, air filter clogging sensor, geared-down speed ON switch, sensor for signalling the presence
of water in the fuel filter, front and rear wheel shoe wear sensor, horn, body-builder connector

Front left side-member ground point (M7)

Figure 28
M7
50360
Figure 29
101517
ELECTRIC CONNECTIONS M7

M7 EDC control unit, fog headlamps, side indicator lamp (right/left), front indicator lamp (right/left),
front clearance lamp (right/left), low/high-beam headlamp (right/left), headlamp trim corrector
actuator, transverse lock switch ON, TGC, power take-off ON switch, rotary lamp, brake air drier
resistor, diesel fuel pre-filter heating resistor

Figure 30 STARTING
General remarks
Prior to acting on the vehicle, place the wedge to

! prevent the vehicle from moving accidentally.
+30 Prior to tilting the cab, make sure that the space in
front of the vehicle is enough.
Starting from the engine compartment must only be
performed when the cab is firmly secured to its
maximum opening position, with the parking lever
53508 ON and the gear lever in neutral.
30
52502
53006
50
Starting from the driver’s seat
53512 (Cab hooked)
Starting from the driver’s seat (synoptic in the figure - unbroken
line) is performed by setting key switch 52502 to position 50.
B20
53511 Thus, positive voltage is supplied to EDC7 85150 electronic
85150 control unit pin B20.
B27 +15
The same control unit controls, by means of pin B27, the
starting motor supply remote-control switch.
The EDC7 control unit, programmed with the new software
during the starting phase, checks whether the gear lever is put
50 in neutral; therefore, if the gear turns out to be engaged, it will
30 not allow starting to be enabled.
08000
If the clutch pedal is pressed, the above control will be inhibited.
52502 Key switch

85150 EDC 7 control unit
08000 Starting motor
25224 Switch for start lock with gears engaged
53006 Button for engine start from engine compartment
53512 Switch for start lock with handbrake OFF
53511 Cab unhooked signalling switch

Starting from the engine compartment Figure 31

(Cab tilted)
To tilt the cab, it is always required that the parking

! brake is actuated; make sure that the gear lever is put
in neutral, and the grill is fully open.
To tilt the cab, the following operations shall be performed:

- turn the knob clockwise until it stops; (by means of the
lever available)
- insert the available lever into the hand pump;
- act on the pump actuating lever. 84595
Starting from the engine compartment can only be performed

if the following conditions exist:
POSITION OF THE GRILL FOR CAB TILTING
- the switch for start lock with the handbrake OFF 53512 is
closed, i.e. with the handbrake ON;
Figure 32
- the switch for start lock with the gears engaged and
reversing light lighting 53508 is closed, i.e. with the gear
lever in neutral;
- the switch for signalling the unhooked cab 53511 with the
4057
cab tilted is closed towards the ground;
- key switch set to running position (+15).
2363
SWITCH FOR START LOCK WITH THE HANDBRAKE

OFF (53512)
Figure 33
SWITCH FOR SIGNALLING THE UNHOOKED CAB

(53511)

ALTERNATOR
Supplier BOSCH
Rated voltage 28V
Current 70A - 1800 RPM
Figure 34
B
+
WL
1 7998
TECHNICAL VIEW S
5
Figure 35 Figure 37 A
80
70
60
B
50
40
A
8003
30
WIRING DIAGRAM 20
A. Alternator B. Voltage regulator
Figure 36 10
0 rpm
2 4 6 8 10 12 14 16
8002
ALTERNATOR CURRENT DELIVERY CURVE
Characteristics
Rated voltage 28 V
Rated power 70 A
Current at environment temperature 1800 RPM/35 A
At 25 ºC and rated voltage 6000 RPM/70 A
8000
Direction of rotation clockwise, seen from pulley
VOLTAGE REGULATOR TEMPERATURE Weight 6.4 kg
CHARACTERISTICS (6000 RPM)

STARTER MOTOR
Supplier BOSCH
Rated voltage 24V
Rated power 4kw
Figure 38
50275
WIRING DIAGRAM
50
30
POWER RELAY
STARTER
50354
Starting
EDC7 system features a peculiar characteristic that distinguish it from previous electronic injection systems.
ECU can control engine starting function.
When turning key 52502 to starting position 50, positive voltage is provided to EDC7 PIN 20.
EDC7 PIN 37 controls a power relay providing power to starter remote switch coil thus enabling, through terminal 30, the positive
voltage required for its operation. In case of SR remote switch coil cut-off or wiring cutoff to terminal 50, the vehicle cannot be
started since EDC control unit detects on pin 37, the presence of remote switch coil resistance.
The vehicle cannot be started even if disconnecting terminal 50 and connecting it directly to +24V, for the above mentioned
reason (SR remote switch resistance not recognised).

COMPONENT CODE
03000 Self-rectifying alternator with built-in voltage regulator
08000 Starter motor
12011 Motor, lh door closing
12012 Compressor, air-conditioning system
12010 Motor, rh door closing
12019 Motor,cab tilting
19005 Thermostarter
20000 Starting battery
22000 Horn
25003 Relay, fog lights
25007 Relay for switching on reversing lights
25013 Relay for switching off low beam lights with high beams on
25035 Relay for switching on external lights
25104 Relay for switching off retarder and/or exhaust brake with ABS on
25202 Relay, G.C.R. energizing
25207 Relay, alternator D+ earthing
25213 Relay for supply of users connected to ignition switch through battery positive
25222 Relay for allowing connection of thermal starter
25307 Relay for air-conditioning compressor
25348 Remote-control switch for auxiliary heater cut-out with power take-off ON
25546 Remote-control switch for ECAS control from the box (power supply)
25547 Remote-control switch for ECAS control from the box (ground)
25548 Remote-control switch for ECAS control from the box (clock)
25549 Remote-control switch for ECAS control from the box (date)
25551 Remote-control switch for loading gate warning light actuation
25704 Relay for switching NC/NO signal for third steering axle
25709 Relay for switching off Allison diagnostics with Iveco diagnostics on
25805 Relay, horns
25810 Relay, fuel heating circuit
25813 Relay, heated rearview mirrors
25818 Relay, heated windshield
25847 Relay for cab tilting motor
25893 Relay for connection of total power takeoff
25900 General Current Relay
25xx1 Remote-control switch for headlamp washer or windscreen wiper enable
25xx2 Actuating remote-control switch (+15) from the diagnosis connector
25xx3 Remote-control switch for TGC actuation with auxiliary heater
25xx4 Remote-control switch for Telma decelerator warning light control
25xx5 Remote-control switch for Telma decelerator signalling for EDC
30001 High/low beam headlight with parking light
30011 Fog headlight
30100 Headlight alignment unit actuator
32002 Front turn signal light
32005 Front marker light
32010 Rotary beacon

33006 Right direction indicator

34000 Rear headlight cluster
35000 Number plate light
37002 Rear marker light
39000 Cab interior ceiling lamp
39003 Inspection lamp with rechargeable battery
39020 Cigar lighter light
39027 Bunk ceiling spotlight
39xx1 Glove compartment light
40011 Electronic tachograph
40032 Tachometer/tachograph sender unit
40047 Inductive type chassis height sensor (front axle)
42031 Sender unit, front brake air pressure gauge
42032 Sender unit, rear brake air pressure gauge
42200 Switch, air suspension failure signal
42351 Switch, air cleaner restriction
42379 Switch for allowing connection of transmission power take-off
42393 Speed limiter control switch
42608 Coolant pressure signalling 3-switch assembly
44031 Sender unit, fuel level indicator with w/lamp contact
44032 Engine oil indicator control
44035 Windshield fluid level indicator control
44036 Radiator waterlevel indicator control
44037 Power steering fluid level indicator control
44039 Rear brake fluid level indicator control
47033 Sender unit, thermometer, external temperature
47041 Water temperature sender for retarder control unit
48037 Automatic transmission input rpm sensor
48040 Automatic transmission output rpm sensor
50003 Electronic dashboard with microprocessor for instrument and warning light displaying
52007 Switch with built-in w/lamp, rear fog light
52019 Switch, power take-off
52021 Switch, interior lighting
52035 Switch with built-in w/lamp, rotary beacons
52306 Switch with built-in w/lamp, heated windshield
52048 Switch for retarder cutoff (from brake pedal)
52075 Switch for opening General Current Relay
52219 Loading gate actuation enable switch
52302 Switch with built-in w/lamp, hazard lights
52307 Switch, exterior lighting
52312 Switch, headlight alignment control
52321 Switch with built-in w/lamp for fog lights and rear fog lights enablement
52324 Switch, exhaust brake prearrangement
52502 Ignition key switch, starting-interlocked services
52522 Lever switch for engaging electric retarder
52600 General Current Relay

53003 Switch, windshield washer unit

53006 Switch, starting from engine compartment
53007 Switch, engine stopping from engine compartment
53008 Switch for closing General Current Relay
53040 Switch for assisted cab tilting system
53300 Switch, power window on driver’s side
53302 Switch, power window on passenger’s side
53306 Switch for sunroof motor
53309 Switch for 3rd axle raising system
53310 Switch for engaging transmission total power takeoff
53312 Switch box, Cruise Control device
53400 Switch for cluster menu control (up)
53401 Switch for cluster menu control (down)
53402 Switch for cluster menu control (c)
53403 Switch for cluster menu control (ok)
53507 Switch for signalling splitter gears engaged
53508 Switch for preventing engine starting with gear engaged and reversing light on
53511 Switch, cab unlatched signal
53512 Switch for preventing engine starting with parking brake off
53514 Limit switch, front brake system converter cylinder
53515 Limit switch, rear brake system converter cylinder
53517 Switch, cross differential lock signal
53521 Switch for signalling longitudinal differential lock
53536 Switch for signalling transmission power takeoff engaged
53541 Switch for allowing cab tilting with grille open
53592 Brake pedal switch for retarder
535xx Telma pressure switch
53800 Switch, stop signal
53801 Switch, cross differential lock (Rockwell rear axles)
53xxx Geared-down speed ON signalling switch
54031 5-function steering wheel switch
54033 6-function steering wheel switch
61000 1A 3-diode holder container (2 with common cathode)
61005 1A 1-diode holder container
61069 4-pole chassis connector for body builders (lights)
61070 5-pole chassis connector for body builders (EDC signals)
61071 20-pole cab connector for body builders
61101 Resistance, fuel heating
61104 Resistance, brake system air drier
61106 Resistance, heated windshield system
61108 Current limiting resistance, heated windshield system
61110 Resistance for prefilter heating and fuel settler
61129 Resistor holder container for retarder lever switch
61130 Resistor holder container for brake pedal pressure switch for retarder
64000 Windshield washer electric pump
65000 Windshield wiper unit
66005 Headlight washer pump
66010 Headlight washer unit timer

68001 Loudspeaker
68007 City Band
6xxxx Resistor cluster for power take-off
70000 6-fuse holder
70xx1 Cab tilting fuse
72000 Standard 7-pole coupling for electrical connection to trailer
72001 Auxialiry 7-pole coupling for electrical connection to trailer
72006 7-pole coupling for ABS tractor/trailer electrical connection
72021 Ground diagnostic equipment 30-pole electrical coupling connector
72054 6A current outlet
75000 Central Interconnecting Unit
78052 ABS system solenoid valve
78054 Solenoid valve for engaging retarder
78055 Solenoid valve for retarder oil accumulator
78174 Solenoid valve for engaging normal gears
78175 Solenoid valve for engaging splitter gears
78208 Transmission total power take-off solenoid valve
78242 Front axle electropneumatic distributor
78243 Electropneumatic distributor
78245 Solenoid valve for switching off transmission total power take-off
7xxxx Allison body builder connector
80000 Power window motor on driver’s opposite side
80001 Power window motor on driver’s side
82000 Windshield defroster unit
82005 Auxiliary air heater
84013 Ambient thermostat
84014 Auxiliary fuel pump
84017 Electronic timer
85000 Cigar lighter
85006 Electrically-adjusted heated rearview mirror (main)
85007 Electrically-adjusted heated rearview mirror (draw up)
85008 Electrically-adjusted heated rearview mirror (wide angle)
85010 Rearview mirror control
85031 Voltage dropper unit for current outlet (11 a max)
85036 Heated air-suspended seat (driver’s side)
85038 Heated air-suspended seat (driver’s opposite side)
85040 Sunroof motor with built-in switch
85100 Solenoid group, electric retarder
85130 Antitheft device control unit
85150 EDC control unit
85160 Chassis alignment control device
86002 Sensors, front brake shoe wear circuit
86003 Sensors, rear brake shoe wear circuit
86004 Electronic control unit, automatic transmission
86013 Sensor, water in fuel filter
86023 Vehicle raising/lowering control unit
86024 Electric retarder control unit
86029 Electronic control unit, centralized door closign system

860xx Telma decelerator management control unit

86116 Multiplex body computer control unit
86127 Electronic control unit for DMI (data management interface)
88000 Electronic control unit, ABS system
88001 Sensor, ABS system
89000 Food heater
Xxxx5 Switch for loading gate operation warning light
Xxxx6 External box for loading gate control

JUNCTION CONNECTOR
Location of junction connectors - cab
Print 603.93.391
Figure 39
STY05
STY07
STY09
STY10
STY15
STY20
STY25
STY33
61071
STZ2
STZ3
STZ4
ST01
ST02
ST03
ST05
ST06
ST20
ST24
ST25
STX
ST0
JC4
JC5
JC6
ST04
ST13
STA
STY18
STV
ST11 STY11
ST12
STY16
STY17
STZ5
72021
STZ1
STX3
STX4
STY12
STX2
ST21
ST22
ST23
XXXX4
ST19
JC1
JC2
JC3
101518
The location of the connectors available (cab - chassis) may be changed due to wiring requirements.

List of connectors
Name Description
61069 Body builder connector (cab)
XXXX4 Branching from the cluster for optional items
JC1 Ideograph power supply positive
JC2 Ideograph power supply positive
JC3 Cigar lighter power supply positive
JC4 Positive (+15/D+alternator) / ceiling light ground
JC5 Positive (+15/+30) / start lock signal
JC6 Positive (windscreen washer / +30)
ST0 Cruise Control cut-out signal
ST01 Power supply (+50)
ST02 ABS power supply
ST04 Auxiliary heater remote-control switch power supply
ST05 Alternator excitation
ST06 Auxiliary heater remote-control switch power supply
ST11 Sunroof power supply
ST12 Sunroof power supply
ST13 Auxiliary heater ground
ST19 Geared-down speed ON signal
ST21 Engine stop signal
ST22 Speed limiter signal
ST24 PTO1 ON signal
ST25 PTO1 ON signal
STA Insulated ground for auxiliary heater
STV Cab rear part / dashboard cable junction
STX Dashboard cable / roof panel cable junction
STX2 Remote control (ECAS)
STX3 Ceiling light cable / roof panel cable junction
STX4 Radio power supply
STY05 Manual conditioner
STY07 Remote-control switch control / diesel fuel pre-heating signal
STY09 Central locking and loudspeaker (driver’s side)
STY10 Central locking and loudspeaker (passenger’s side)
STY11 Right rotary lamp power supply
STY12 Left rotary lamp power supply
STY15 Central locking arrangement
STY16 Heated mirror control (driver’s side)
STY17 Heated mirror control (passenger’s side)
STY18 Auxiliary heater control unit cable / cab cable junction
STY20 Power take-off
STY25 ADR
STY33 Body builders (optional DMI control unit)
STZ1 Diagnosis connector (CAN line)
STZ2 ECAS control unit (CAN line)
STZ3 Electric mirror control unit (CAN line)
STZ4 DMI control unit (option) (CAN line)
STZ5 Telma/Allison (CAN line)

Location of junction connectors - chassis

Figure 40
STY24 STY26 STY22 ST16 STY32 STY25

STY3 61069 61070 STY22 STY26 STY6 STY19
STY1
STY8
STY2
STY14 STY12
STY11 STY4 STY21 STF1
STY13 STY23
101519

List of connectors
Name Description
61070 Connector for body builders (chassis) - EDC signals
61071 Connector for body builders (chassis) - lights
75010/1 Rear lights
75010/2 Trailer rear lights
ST16 Front parking brake arrangement
ST20 Insulated ground
STF1 Front axle arrangement (ECAS)
STY01 Right lights (front)
STY02 Left lights (front)
STY03 Bulkhead C/B-3 (EDC)
STY04 Conditioner arrangement
STY06 Brake air drier
STY08 Cab tilting remote-control switch ground
STY13 Front right clearance lamp
STY14 Front left clearance lamp
STY19 Differential lock (transverse longitudinal)
STY21 Exhaust brake with automatic transmission
STY22 Reversing light ignition
STY23 Stop signalling (Telma)
STY24 Insertion of power take-off on the gearbox
STY26 Geared-down speed ON signalling switch
STY32 TGC ground

Perspective view
Pin Name Connector view

1 ST0 - ST01 - ST02 - ST03 - ST19 - ST22 - ST23
1 STY8
2 ST04 - ST05 - ST11 - ST12 - ST13 - ST20 - ST21 - ST24 -

ST25 - STA - STX4 - STY7
2 STY15
2 ST16 - STY6 - STY11 - STY12 - ST13 - ST14 - STY21 -

STY24 - STY26 - STZ1 - STZ2 - STZ3 - STZ4 - STZ5
3 STY3 - STY4 - STY32
4 61069 - STF1 - STY19 - STY22 - STY23 - STY25
5 61070 - STY20

Pin Name Connector view

6 STY5
6 STX2
7 STY1 - STY2
11 75010/2
12 ST06 - STV - STX3 - STY09 - STY10 - STY16 - STY17 -

STY18 - XXXX4
13 75010/1
20 61071 - STX - STY33

Junction connector ST0 - ST01 - ST02- ST03

Figure 41
101520
CONNECTOR VIEW (CABLE SIDE)
Figure 42
101521
JUNCTION CONNECTOR ELECTRIC CONNECTIONS
ST0
Cable
Pin Function
colour code
1 Signal from the switch for Cruise Control cut-out for EDC 8154
ST01
Cable
Pin Function
colour code
1 +50 signal from key switch 8037
ST02
Cable
Pin Function
colour code
1 Power supply after the fuse for ABS 8847
ST03
Cable
Pin Function
colour code
1 +15 alternator 8876

Junction connector ST19 - ST22 - ST23 - STY8

Figure 43
101520
Figure 44
101522
Figure 45
101523
Figure 46
JUNCTION CONNECTOR ELECTRIC CONNECTIONS 101524
ST19
Cable
Pin Function
colour code
1 Geared-down speed ON warning light signal 9976
ST22
Cable
Pin Function
colour code
1 Speed limiter signal 9968
ST23
Cable
Pin Function
colour code
1 Battery positive 7777
STY8
Cable
Pin Function
colour code
1 Hydraulic cab tilting relay control ground after grill opening signalling switch 0029

Junction connector ST04 - ST05 - ST11 - ST12

Figure 47
101525
Figure 48
101526
ST04 (black)
Cable
Pin Function
colour code
1 Auxiliary heater remote-control switch power supply throughthe safety control unit 7779
ST05
Cable
Pin Function
colour code
1 Alternator excitation 7773
ST11
Cable
Pin Function
colour code
1 Trap-door opening control power supply 7010
2 Trap-door closing control power supply 7011
ST12
Cable
Pin Function
colour code
1 Trap-door opening control power supply 7010

Junction connector ST13 - ST20 - ST21 - ST24

Figure 49
101525
Figure 50
101527
ST13 (black)
Cable
Pin Function
colour code
2 - -
ST20
Cable
Pin Function
colour code
1 ABS disconnection 0049
2 - -
ST21
Cable
Pin Function
colour code
1 Engine stop control from Master Current Switch 9906
2 - -
ST24 (white)
Cable
Pin Function
colour code
1 PTO 1 return signal cable ON (rear with semi-automatic transmission) 6131
2 - -

Junction connector ST25 - STA - STX4 - STY7

Figure 51
101525
Figure 52
101528
ST25 (white)
Cable
Pin Function
colour code
1 PTO 1 return signal cable ON (lateral with semi-automatic transmission) 6132
2 - -
STA
Cable
Pin Function
colour code
STX4
Cable
Pin Function
colour code
1 Radio equipment power supply 8899
2 Ground 0001
STY7
Cable
Pin Function
colour code
1 Diesel fuel heating relay control thermometric switch 8837
2 Diesel fuel pre-heating relay control signal from EDC 0087

Junction connector STY15 - central locking arrangement

Figure 53
101529
Figure 54
101530
Cable
Pin Function
colour code
1 Central locking motor power supply (door closing) 9964
2 Central locking motor power supply (door opening) 9965

Junction connector ST16 - STY6 - STY11 - STY12

Figure 55
101531
Figure 56
101532
ST16 - front parking brake arrangement

Cable
Pin Function
colour code
1 Signal from front parking brake switch 1117
2 Ground 0000
STY6 - brake air drier
Cable
Pin Function
colour code
1 Ground 0000
2 Braking system air drier resistor power supply 8840
STY11 - right rotary lamp
Cable
Pin Function
colour code
1 Rotary lamp power supply 1115
2 Ground 0000
STY12 - left rotary lamp
Cable
Pin Function
colour code
2 Ground 0000

Junction connector STY13 - STY14 - STY21 - STY24

Figure 57
101531
Figure 58
101533
STY13 - front right clearance lamp

Cable
Pin Function
colour code
1 Right sidelight and clearance light power supply 3390
2 Ground 0000
STY14 - front left clearance lamp
Cable
Pin Function
colour code
1 Left sidelight and clearance light power supply 3380
2 Ground 0000
STY21 - exhaust brake with automatic transmission
Cable
Pin Function
colour code
1 Signal from exhaust brake switch for EDC 8159
2 EDC system power supply after the fuse 7151
STY24 - power take-off actuation enable switch
Cable
Pin Function
colour code
1 Generator or alternator excitation 7773
2 Running takeoff control solenoid valve power supply 9954

Junction connector STY26 - STZ1 - STZ2

Figure 59
101531
Figure 60
101534
STY26 - geared-down speed ON signalling switch

Cable
Pin Function
colour code
1 Ground 0000
2 Pressure switch actuated when shifting between normal and geared-down speeds 9976
STZ1 - diagnosis connector 72021
Cable
Pin Function
colour code
1 CAN line - H 6108
2 CAN line - L 6109
STZ2 - ECAS control unit
Cable
Pin Function
colour code
1 CAN line - H 6108
2 CAN line - L 6109

Junction connector STZ3 - STZ4 - STZ5

Figure 61
101531
Figure 62
101535
STZ3 - electric mirror control unit

Cable
Pin Function
colour code
1 CAN line - H 6108
2 CAN line - L 6109
STZ4 - DMI option
Cable
Pin Function
colour code
1 CAN line - H 6108
2 CAN line - L 6109
STZ5 - Telma / Allison option
Cable
Pin Function
colour code
1 CAN line - H 6108
2 CAN line - L 6109

Junction connector STY3 - STY4 - STY32

Figure 63
101536
Figure 64
101537
STY3 - C bulkhead cable / B-E bulkhead cable (EDC)

Cable
Pin Function
colour code
1 Component return connection to the EDC control unit 0150
2 Engine start (from external button) 8892
3 Reversing lamp power supply 2226
STY4 - conditioner arrangement
Cable
Pin Function
colour code
1 Manual conditioner relay control 9066
2 Compressor actuation warning light power supply 9065
3 Fan power supply enable 9071
STY32 - TGC
Cable
Pin Function
colour code
1 Master current remote-control switch ground (TGC) 0012
2 - -
3 - -

Junction connector 61069 - STF1

Figure 65
101538
Figure 66
JUNCTION CONNECTOR ELECTRIC CONNECTIONS 101539
61069 - 4-pole chassis connector for body builders (external lights)

Cable
Pin Function
colour code
1 Ground 0000
2 Left rear sidelights and clearance lights 3332
3 Rear right sidelights and clearance lights 3331
4 Key rotation prevent electromagnet power supply 8869
STF1- front ECAS arrangement
Cable
Pin Function
colour code
1 Front axle ECAS solenoid valve power supply 9413
2 ECAS front axle chassis level control sensor signal 5410
3 ECAS chassis level control sensor ground 0400
4 ECAS solenoid valve power supply after the control unit 9426

Junction connector STY19- STY22

Figure 67
101538
Figure 68
101540
STY19- transverse and longitudinal locking

Cable
Pin Function
colour code
1 Signal from Rockwell rear axle transverse locking signalling switch 6620
2 Ground 0000
3 Signal from Iveco and Rockwell rear axle transverse locking signalling switch 6621
4 Signal from longitudinal locking signalling switch 0055
STY22- reversing light ignition with automatic transmission
Cable
Pin Function
colour code
3 Reversing lamp switch power supply 2268
4 Signal cable for automatic neutral position with automatic transmission 0147

Junction connector STY23- STY25

Figure 69
101538
Figure 70
101541
STY23 - stop signalling switch with Telma decelerator

Cable
Pin Function
colour code
1 Left rear stop signalling 1177
2 Brake light relay control 1176
4 Signal from secondary brake light switch for EDC 8158
STY25 - ADR
Cable
Pin Function
colour code
1 TGC excitation through key switch 8045
2 Brake light signal from brake value transmitter with EBS 0077
3 Ground 0000
4 Alternator D+ after the power diode 0078

Junction connector 61070 - STY20

Figure 71
101542
Figure 72
101543
61070 - 5-pole chassis connector for body builders (EDC signals)

Cable
Pin Function
colour code
2 Speed limiter II signal 5502
3 Sensor 1 signal cable for engine revs diagnostic 5584
4 Gearbox idling signalling switch 8050
STY20 - power take-off
Cable
Pin Function
colour code
1 Ground 0000
2 Side power take-off signal ON 6132
3 Rear power take-off signal ON 6131
4 Electronic tachograph transmitter signal 5877
5 Electronic tachograph transmitter insulated negative 0058

Junction connector STY5 - manual conditioner

Figure 73
101545
Figure 74
101546
Cable
Pin Function
colour code
1 Manual conditioner relay control 9066
2 Compressor relay power supply 9067
3 Maximum speed relay power supply 9068
4 Compressor actuation warning light power supply 9065
5 - -
6 - -

Junction connector STX2 (gray) - remote control / control unit (ECAS)

Figure 75
101547
Figure 76
101548
Cable
Pin Function
colour code
1 Levelling control system power supply after the fuse 8810
2 Ground 0000
3 Clock line on the ECAS suspension control push-button panel 6402
4 Data line on the ECAS suspension control push-button panel 6403
5 - -
6 - -

Junction connector STY1 - right lamps cable

Figure 77
101551
Figure 78
101552
Cable
Pin Function
colour code
1 Clearance light and sidelight general power supply 3390
2 Right low-beam headlamp power supply 2223
3 Right high-beam headlamp power supply 2221
4 Headlamp trim corrector (position B) 9936
5 Front right indicator bulb 1123
6 Ground 0000
7 - -

Junction connector STY2 - left lights cable

Figure 79
101551
Figure 80
101553
Cable
Pin Function
colour code
1 Clearance light and sidelight general power supply 3380
2 Left low-beam headlamp power supply 2231
3 Left high-beam headlamp power supply 2219
4 Headlamp trim corrector (position B) 9936
5 Front left indicator bulb 1129
6 Ground 0000
7 - -

Junction connector ST06 (black) - ECAS cable arrangement

Figure 81
101554
Figure 82
101555
Cable
Pin Function
colour code
1 Pneumatic suspension low air pressure warning light (ECAS) 6401
2 Rear axle right chassis level control sensor signal (ECAS) 5421
3 Chassis level control sensor ground (ECAS) 0400
4 Rear axle left chassis level control sensor signal (ECAS) 5422
6 Front axle chassis level control sensor signal (ECAS) 5410
8 Front axle solenoid valve power supply (ECAS) 9413
9 Rear axle solenoid valve cluster power supply (ECAS) 9423
10 Rear axle solenoid valve cluster power supply (right valve) 9424
11 Rear axle solenoid valve cluster power supply (left valve) 9425
12 Solenoid valve power supply after the control unit (ECAS) 9400

Junction connector STV (blue) - dashboard cable / cab rear

Figure 83
101554
Figure 84
101556
Cable
Pin Function
colour code
1 Handbrake ON signalling optical indicator 6662
2 Cab unhooked signalling optical indicator 6666
3 General interlocking power supply after the fuse 8879
4 Ground 0000
5 - -
6 D+ alternator (downstream the diode) 7780
7 EDC control unit component ground 0150
8 Signal from handbrake ON switch 9907
9 ÷ 11 - -
12 7770

Junction connector STX3 - roof panel cable / ceiling light cable

Figure 85
101554
Figure 86
101557
Cable
Pin Function
colour code
1 Ceiling light ignition ground (switch on the door) 0003
2 Radio power supply (12v) 7770
3 Ground 0000
5 Radio amplifier power supply 7704
6 Ceiling light ignition with separate switch (trucks) 4441
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -

Print 603.93.391/A
Junction connector STY09 (gray) - driver’s side door electric lock and loudspeaker
Figure 87
101554
RETARDER CONTROL
Figure 88
105979
RETARDER CONTROL
Cable colour
Ref. Function
code
1 Preamplifier left sound speaker positive 8863
2 Preamplifier left sound speaker negative 8863
3 Sunroof closing control power supply 0066
4 Sunroof opening control power supply 0065
5 Horn electro valve positive 0064
6 CAN (IDB) H line WHITE
7 CAN (IDB) L GREEN
8 Ideogram lighting positive 1186
9 Positive under key 1188
10 - -
11 - -
12 - -

Revi - Juli 2005
Junction connector STY10 (gray) - passenger’s side door electric lock and loudspeaker
Figure 89
101554
RETARDER CONTROL
Figure 90
105980
RETARDER CONTROL
Cable colour
Ref. Function
code
3 Sunroof closing control power supply 0066
4 Sunroof opening control power supply 0065
5 Horn electro valve positive 0064
7 CAN (IDB) L GREEN
10 - -
11 - -
12 - -

Revi - Juli 2005
Junction connector STY16 (blue) - driver’s side heated mirror control

Print 603.93.391
Figure 91
101554
Figure 92
101560
Cable
Pin Function
colour code
1 Motor power supply for vertical orientation of main left rear-view mirror 8808
2 Motor power supply for horizontal orientation of main left rear-view mirror 8809
3 Motor power supply for orientation of main left rear-view mirror 8806
4 Heated rear-view mirror resistor power supply 8830
5 Ground 0000
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -

Junction connector STY17 (blue) - passenger’s side heated mirror control

Figure 93
101554
Figure 94
101561
Cable
Pin Function
colour code
1 Motor power supply for vertical orientation of main right rear-view mirror 8858
2 Motor power supply for horizontal orientation of main right rear-view mirror 8859
3 Motor power supply for orientation of main right rear-view mirror 8857
4 Heated rear-view mirror resistor power supply 8830
5 Ground 0000
6 Motor power supply for vertical orientation of passenger’s side wide-angle rear-view mirror 8852
7 Motor power supply for horizontal orientation of passenger’s side wide-angle rear-view mirror 8853
8 Motor power supply for vertical orientation of passenger’s side approach rear-view mirror 8838
9 Motor power supply for horizontal orientation of passenger’s side approach rear-view mirror 8839
10 - -
11 - -
12 - -

Junction connector STY18 (gray) - cab cable / auxiliary heater control unit cable
Figure 95
101554
Figure 96
101562
Cable
Pin Function
colour code
1 Auxiliary heater air temperature control thermostat power supply 7736
2 Positive after the fuse 7772
3 7725
4 Auxiliary heater fuel intercept solenoid valve and auxiliary fuel pump power supply 7783
5 Auxiliary heater cab heating air motor power supply 7722
7 Auxiliary heater ignition spark power supply 7705
8 Insulated ground for auxiliary heater 0022
10 Insulated ground for auxiliary heater 0022
11 Diagnostic ”K” line for ”Instrument Cluster” 2295

Print 603.93.391/A
Junction connector XXXX4 (gray) - branching-off from Cluster for optional provision
Figure 97
101554
RETARDER CONTROL
Figure 98
105981
RETARDER CONTROL
Cable colour
Ref. Function
code
3 Sunroof closing control power supply -
4 Sunroof opening control power supply -
5 Horn electro valve positive -
7 CAN (IDB) L GREEN
10 Segnale per spia carica alternatore 7778
11 - -
12 Segnale per spia insufficiente pressione aria per ECAS 6401

Revi - Juli 2005
Print 603.93.391
Junction connector 61071 - for body builders (cab)

Figure 99
101564
Figure 100
101565

Pin-out
Cable colour
Pin Function
code
1 Speed signal (to the diagnosis take-off) 5542
2 D+ alternator downstream the diode 7780
3 Optical indicator circuit power supply 8000
4 Starting enable switch 9907
5 Rear fog lamp power supply 2286
6 Positive after the fuse 7772
7 Gearbox idling signalling switch 8050
8 Engine stop signal 9906
9 Ground 0000
10 Signal from switch for Cruise Control cut-off for EDC 8154
11 Signal from switch for Cruise Control cut-off for EDC 8154
12 Signal from Cruise Control recall switch for EDC 8155
13 Signal from Cruise Control speed increase switch for EDC 8156
14 Signal from Cruise Control speed decrease switch for EDC 8157
16 Eco-Power control, EDC control unit 0169
17 Command from power take-off 1 switch to the EDC control unit 0166
18 Command from power take-off 2 switch to the EDCcontrol unit 0167
19 Command from Eco-Power switch to the EDC control unit 0168
20 - -

Junction connector STX (gray) - roof panel cable / dashboard cable

Figure 101
101564
Figure 102
101566

Pin-out
Cable colour
Pin Function
code
1 Automatic transmission control unit CAN line ”H” 6108
2 Automatic transmission control unit CAN line ”L” 6109
3 Dashboard ideograph illumination bulb power supply 4442
4 Power supply-electronic tachograph transmitter 5514
5 Electronic tachograph transmitter insulated negative 0058
6 Speed signal-electronic tachograph transmitter 5517
7 Speed signal-electronic tachograph transmitter 5516
8 General interlocking power supply after the fuse 8879
9 Power supply direct from tachograph battery 7768
10 Left channel loudspeaker (-) 1186
11 Speed signal for EDC (B7 tachograph) 5155
12 - -
13 Front door step lights 4408
14 Radio amplifier power supply 7704
15 Line ”L” for ADM control unit - electronic differential lock 1191
17 Ceiling light illumination with separate switch 1 (trucks) 4441
18 Left channel loudspeaker (+) 1188
19 Right channel loudspeaker (-) 1183
20 Right channel loudspeaker (+) 1184

Junction connector STY33 (black) - for body builders (DMI control unit - option 5626)
Figure 103
101564
Figure 104
101567

Pin-out
Cable colour
Pin Function
code
1 CAN line - L 6109
2 CAN line - H 6108
3 DMI control unit pin X1-14 5011
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 DMI control unit pin X-5 5003
15 DMI control unit pin X-18 8100
16 Reversing lamp power supply arrangement 2226
17 Gear lever neutral and parking brake ON signal 1000
18 - -
19 Brake pedal pressed signal 3310
20 Clutch pedal pressed signal 3311

Rear lights junction box - trailer arrangement

Figure 105 75010/1
75010/2 101568
Figure 106
101569

75010/1 (13 pin - white) - rear lights
Cable colour
Pin Function
code
1 Tractor rear fog lamp power supply, after IVECO check 2286
3 Rear right indicator bulb 1125
4 Rear left indicator bulb 1120
5 Right rear stop signalling 1172
6 Left rear stop signalling 1177
7 License plate light 3330
8 Right sidelights 3335
9 Left sidelights 3334
10 Right/left clearance lights 3339
11 License plate light 3330
12 Right/left clearance lights 3339
13 - -
75010/2 (11 pin - white) - trailer arrangement
Cable colour
Pin Function
code
1 Trailer rear fog lamp power supply 2282
2 Trailer right indicator light 1185
3 Trailer left indicator light 1180
4 Trailer brake lights 1179
5 Right clearance lights 3331
6 Left clearance lights 3332
7 Trailer reversing lamp power supply 2226
8 Key-controlled positive (+15) 8869
9 - -
10 - -
11 - -

75/1 ELECTRIC/ELECTRONIC SYSTEM EUROCARGO TECTOR 12-26 t
Print 603.93.391/A
15-pole socket for trailer electrical connection

Figure 106/1
105840
15-POLE SOCKET (FRONT VIEW)
Figure 106/2
105982
CONNECTION CONNECTOR ELECTRICAL LINKS

Revi - Juli 2005
EUROCARGO TECTOR 12-26 t ELECTRIC/ELECTRONIC SYSTEM 75/2
Pin - out
Cable colour
Ref. Function
code
1 Left trailer blinkers 1180
2 Right trailer blinkers 1185
3 Trailer reversing light power supply 2282
4 Ground 0000
7 Trailer stop lights 1179
8 Trailer reversing light power supply 2226
9 Spare -
10 Spare -
11 Spare -
12 Spare -
13 Spare -
14 Spare -
15 Spare -

Revi - Juli 2005
7-pole socket for trailer electrical connection

Figure 106/3
105839
CONNECTOR VIEW (CABLES/FRONT SIDE)
Figure 106/4
CONNECTOR VIEW (CABLES/FRONT SIDE) 105983

Revi - Juli 2005
72000 - 7-pole normal socket for trailer electrical connection

Cable colour
Ref. Function
code
1 Ground 0000
3 Left trailer blinkers 1180
4 Trailer stop lights 1179
5 Right trailer blinkers 1185
7 Spare -
72001 - 7-pole additional socket for trailer electrical connection

Cable colour
Ref. Function
code
1 Ground 0000
2 Key-controlled positive (+15) 8869
4 Trailer brake lights -
5 Trailer right indicator light -
6 Left clearance lights -
7 Trailer rear fog light power supply 2282
72006 - 7-pole socket for trailer ABS electrical connection

Cable colour
Ref. Function
code
1 Positive after fuse for trailer ABS 7777
2 Trailer ABS system positive (+15) 8879
3 Ground 0000
4 Ground 0000
5 Trailer ABS failure warning lamp 6671
6 Spare -
7 Spare -

Revi - Juli 2005
Print 603.93.391
Joint JC1 / JC2 / JC3

Figure 107
JOINT PERSPECTIVE VIEW 101570
Figure 108
101571
JOINT ELECTRIC CONNECTIONS - JC1 / JC2 / JC3
Joint JC1 (blue)

Cable colour
Pin Function
code
1÷9 Ideograph power supply positive 4442
Joint JC2 (blue)
Cable colour
Pin Function
code
1÷9 Ideograph power supply positive 4442
Joint JC3 (blue)
Cable colour
Pin Function
code
1÷9 Cigar lighter power supply positive 7721

Print 603.93.391/A
Joint JC4 / JC5 / JC6

Figure 109
JOINT ELECTRIC CONNECTIONS - JC4 / JC5 / JC6 105984
Joint JC4 (green)

Cable colour
Pin Function
code
1÷3 Positive +15 for general interlocking power supply after the fuse 8879
4÷6 D+ alternator 7780
7÷9 Ground from ceiling light ignition switch 0010
Joint JC5 (green)

Cable colour
Pin Function
code
1÷3 Positive +15 for power supply provided for external body builders (max. = 10 A) 8710
4÷6 Battery positive after the radio amplifier power supply fuse 7704
7÷9 Signal from start lock switch with handbrake OFF 0029
Joint JC6 (green)

Cable colour
Pin Function
code
1÷3 Windscreen washer electric pump power supply 8886
4÷6 Battery positive after the fuse 7772
7÷9 Positive +15 for general service power supply before the fuse 8887

Revi - Juli 2005
Branch points (ultrasound welds)

Print 603.93.391
Figure 110
101573
ULTRASOUND WELDING WITH INSULATION OBTAINED BY MEANS OF THERMO-SHRINKING SHEATH
Figure 111
BRANCH POINT ELECTRIC CONNECTIONS - BC / C / D / L / V2 / W1 / W2 101574
Branch
Function Cable colour code
point
BC Ideograph power supply positive (pin D1 - Body Controller) (Cluster area) 4442
C Ideograph power supply positive (central area cab section) 4442
D Positive +15 for general interlocking power supply after the fuse (cab section) 8879
L Positive +15 for general service power supply before the fuse (cab section) 8887
V2 Positive for EDC system power supply after the fuse (chassis section) 7151
W1 Pre-heating actuation enable relay ground (chassis section) 0094
W2/1 Component return connection to the EDC control unit (chassis section) 0150
W2/2 Component return connection to the EDC control unit (cab section) 0150

BULKHEAD
Figure 112
A B C
D E F
101575
Ref. Description
A Option
B EDC
C Services / Lights
D Automatic transmission
E Services / Lights
d
F ABS / ECAS

Connector ”A” (white) - cab cable / chassis cable

Print 603.93.391/A
Figure 113
d
105985
CONNECTOR ”A” ELECTRIC CONNECTIONS

Revi - Juli 2005
Print 603.93.391
Pin - out connector ”A”
Ref. Description Cable

1 Front parking brake ON switch signal 1117
2 - -
3 PTO1 ON signal 6131
4 PTO2 ON signal 6132
5 PTO actuation solenoid valve power supply 5877
6 PTO actuation solenoid valve ground 0058
7 - -
8 - -
9 Signal from PTO actuation enable switch 7773
10 PTO actuation enable switch ground 9954
11 Hydraulic cab tilting relay control ground after grill opening signalling switch 0029
12 Braking system air drier resistor power supply 8840
13 - -
16 - -
17 - -
18 - -
19 - -
20 TGC ground 0012
21 Brake light signal from brake value transmitter with EBS 0077
22 TGC excitation through key switch 8045
23 Alternator D+ after the power diode 0078
24 - -
25 - -
27 - -
28 Loading board preset -
34 - -
39 Heated diesel fuel pre-filter power supply 7753
40 - -

Print 603.93.391/A
Connector ”B” (brown) - cab cable / chassis cable

Figure 114
105986
CONNECTOR ”B” ELECTRIC CONNECTIONS

Revi - Juli 2005
Connector ”B” pin-out

1 Negative for starting sensors 0150
2 - -
3 ”+50” signal 8037
4 Starting with handbrake engaged 9906
5 Cab unhooked signal 6666
6 Fault finding (blink code) 5602
7 EDC fault telltale (+) 2298
8 EDC fault telltale (ground) 1198
9 30 pin tester Pin 2 5198
12 Rev counter 9907
13 Tachograph signal 0156
14 Tachograph ground 5535
15 Coolant temp. warning light 0535
16 Coolant temp. indicator 8051
17 Engine oil pressure warning light 0087
18 Engine oil pressure indicator 8837
19 Free -
20 Speed limiter telltale 7780
21 Exhaust brake ON telltale 8876
22 Programmable speed limiter 0169
23 Clutch brake for EDC 5120
24 Conditioner control 9066
25 Conditioner compressor remote-control switch 9067
26 Conditioner compressor actuation signal 9068
27 Conditioner 9065
28 - -
29 EDC (clutch ON signalling switch and blink-code power supply) 7151
30 Starting from engine compartment -
31 EDC primary brake signal 8153/1117
32 Accelerator pedal Pin 5 0159
37 CAN line 6108
38 CAN line 6109
39 Max speed fan (cond.) 8150
40 Low speed fan (cond.) 7777
d

Revi - Juli 2005
Print 603.93.391
Connector ”C” (white) - cab cable / chassis cable

Figure 115
101578
CONNECTOR ”C” ELECTRIC CONNECTIONS

Connector ”C” pin-out

1 Trailer rear fog light 2282
2 Reversing lights 2268
3 Rear right indicator light 1125
4 Rear left indicator light 1120
5 Trailer right indicator light 1185
7 Trailer right & left brake lights 1179
8 Trailer right sidelights 3331
9 Trailer left sidelights 3332
10 External temperature sensor 4710
11 Tractor right & left rear fog lights 2286
12 Tractor right brake light 1172
13 Tractor left brake light 1177
14 Tractor right & left license plate lights 3330
15 Rear right sidelights 3334
16 Rear left sidelights 3335
17 Rear right & left clearance lights 3339
18 Front wheel brake wear 6012
19 Rear wheel brake wear 6013
20 Windscreen washer tank low water level warning light 5521
21 Cooling water minimum level warning light 5525
22 Power steering fluid low level warning light 5520
23 Signalling the presence of water in the diesel fuel filter 5530
24 Signalling the presence of water in the diesel fuel filter 8879
25 Air filter clogged signalling 6663
26 Geared-down speeds ON warning light 9976
27 Horn 1116
28 ”+15” for body builders 8869/8869
29 Windscreen washer water pump 8886
30 Windscreen wiper motor 53/B 8881
31 Windscreen wiper motor 53 8882
32 Windscreen wiper motor 31/B 8873
33 Headlamp wiper power supply 8821
34 Engine oil level 5506
35 Engine oil level 5505
36 External temperature sensor 0512
37 - -
38 - -
39 - -
40 - -

Connector ”D” (white) - cab cable / chassis cable
Figure 116
101579
CONNECTOR ”D” ELECTRIC CONNECTIONS

Connector ”D” pin-out

1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 PTO solenoid valve ground (Allison automatic transmission) 0000
21 - -
22 - -
23 - -
24 - -
25 - -
26 Reversing lamp switch power supply (Allison automatic transmission) 2268
27 Reversing lamp power supply (Allison automatic transmission) 2226
28 - -
29 PTO actuation signal (Allison automatic transmission) 6132
30 PTO solenoid valve power supply (Allison automatic transmission) 8133
31 - -
32 - -
33 Signal from exhaust brake switch for EDC 8159
34 - -
35 Automatic neutral position signal for body builders (Allison automatic transmission) 0147
36 Resistor cluster ground for retarder pressure switches (Allison automatic transmission) 8135
37 Retarder request signal from the resistor cluster for retarder pressure switches (Allison 6164
automatic transmission)
38 Resistor cluster power supply for retarder pressure switches (Allison automatic transmission) 7124
39 - -
40 - -

Connector ”E” (green) - cab cable / chassis cable
Figure 117
101580
CONNECTOR ”E” ELECTRIC CONNECTIONS

Connector ”E” pin-out

1 Right side indicator light 1124
2 Left side indicator light 1126
3 - -
4 - -
5 Right low-beam headlamp 2223
6 Right high-beam headlamp 2221
7 Front right indicator light 1123
8 Left low-beam headlamp 2231
9 Left high-beam headlamp 2219
10 Front left indicator light 1129
11 Right & left fog lamps 2228
12 - -
13 - -
14 Headlamp trim adjustment 9936
15 - -
16 - -
17 Front right sidelights and clearance lights 3390
18 Left front sidelights and clearance lights 3380
19 Fuel level indicator ground 0616
20 Low fuel level indicator 5557
21 - -
22 Rear brake converter limit switch 6684
23 Rear brake converter limit switch 6613
24 Tachograph (B1) 5514
28 Brake fluid level sensors 6680
29 - -
30 Front brake air pressure 5562
31 Brake air pressure sensor power supply 5560
32 Rear brake air pressure 5561
33 Brake air sensor ground 0000
34 - -
35 Front differential longitudinal lock 0055
36 Rear transverse differential ON locking signal (Rockwell) 6621
37 Rear transverse differential ON locking signal (Rockwell) 6620
38 - -
39 - -
40 Fuel heating resistor 7733

Print 603.93.391/A
Connector ”F” (black) - cab cable / chassis cable

Figure 118
d
105987
CONNECTOR ”F” ELECTRIC CONNECTIONS

Revi - Juli 2005
Connector ”F” pin-out

1 - -
2 ECAS suspension (chassis-cowl) 6401
3 Right rear ECAS sensor 5421
5 Left rear ECAS sensor 5422
7 Front ECAS sensor 5410
9 Front ECAS solenoid valve 9413
10 Rear ECAS solenoid valve 9423
13 ABS solenoid valve 0000
14 Left front ABS solenoid valve 0000
15 Right front ABS solenoid valve 0000
16 Rear ABS solenoid valve 0000
17 Right rear ABS solen. valve power sup. 9931
18 Left front ABS solen. valve power sup. 9921
19 Left front ABS solen. valve power sup. 9919
20 Rh front ABS solen. valve power sup. 9918
21 Rh front ABS solen. valve power sup. 9920
22 Left rear ABS solen. valve power sup. 9930
23 Left rear ABS solen. valve power sup. 9928
24 - -
25 Trailer ABS failure warning light 6671
26 Left front ABS sensor 5570
27 Left front ABS sensor 5570
28 Right front ABS sensor 5571
29 Right front ABS sensor 5571
30 Left rear ABS sensor 5572
31 Left rear ABS sensor 5572
32 Right rear ABS sensor 5573
33 Right rear ABS sensor 5573
34 Rear right ABS solenoid valve power supply (6x4 only) 9929
35 ECAS rear / front distributor positive 9400
36 - -
37 General interlocking power supply +15 positive after the fuse 8879
38 - -
39 - -
40 Battery positive after the fuse 7777

Revi - Juli 2005
Print 603.93.391
Diagnosis connector - 72021

A 30-pin diagnosis connector, used for diagnosis of the electronic systems available on the vehicle, is found in the lower part of the
cab, below the central dashboard.
Figure 119
16 1 2
15 26 17 3
14 18 4
25 27 28 19
13 30 29 5
24 20
12 23 21 6
11 22 7
10 9 8
101582
DIAGNOSIS CONNECTOR (FRONT VIEW)
Figure 120
101583
DIAGNOSIS CONNECTOR ELECTRIC CONNECTIONS

Pin-out
Cable colour
Ref. Function Function
code
1 EDC L 1198
2 K 2298
3 ABS L 1199
4 K 2299
5 Retarder arrangement - -
6 - -
7 - -
8 Cluster / Tachograph L 1191
9 - -
10 AIR TOP 2000 heater K 2295
11 Service actuation - key turned to RUNNING +15 8876
12 Immobilizer K 2292
13 Air-conditioning unit arrangement L 1196
14 K 2296
15 - -
16 ECAS suspensions K 2294
17 - -
18 Allison automatic transmission K 2297
19 Diagnosis enable with automatic transmission - 8119
20 - -
21 CAN line H H 6108
22 CAN line L L 6109
23 Engine phase signal Phase 5198
24 Screen Braided wire -
25 Engine starting signal - 8050
26 - 8892
27 Positive +30 7772
28 Engine revs n 5584
29 Vehicle speed n 5542
30 Ground 31 0050

Bulkhead measurement adapter

This adapter makes it possible to carry out the tests by means of E.A.SY. MODUS, IT2000 and IWT, either upstream or downstream
the bulkhead, and also act on the individual bulkhead pins to make measurements by means of a multimeter (as shown by detail
A in the figure).
Figure 121
101584

Print 603.93.391
INSTRUMENT PANEL
Figure 122
91324
Ref. Description
1 Rev counter
2 Engine coolant temperature gauge
3 Fuel level gauge
4 Tachograph display
5 Headlamp trim control
6 External light switch
7 Cap
8 Fog light actuation switch
9 Rear fog light actuation switch
10 Optical indicator cluster
12 Display
14 Display menu output switch
15 Display menu actuation switch
16 Menu switch -
17 Menu switch +
18 Emergency light actuation switch
19 Speed limiter switch
20 Internal light switch (located in the central dashboard if the retarder hand lever is available)
21 Internal illumination ceiling light switch (available on long cabs only)
22 TGC actuation (where provided)

CENTRAL DASHBOARD
Figure 123
1 2 3 4 5 6 7 8 9 10 11
17
2
1 3
16 O 4
12
P
13
15
14
87154
Ref. Description
1 Arrangement for exhaust brake
2 Rotating lamp actuation switch
3 Heated windscreen actuation switch
4 Passenger’s side window regulator button
5 TGC deactivation in an emergency (ADR)
6 Sunroof control
7 Overall power takeoff control
8 Cab interior light switch (only if the retarder hand lever is available)
9 Retarder cut-out from the brake pedal
10 Loading gate
11 Auxiliary high-beam headlamps
12 WEBASTO heater control
13 Glove compartment
14 30-pole diagnosis takeoff
15 Cigar lighter
16 Cab interior heater controls (conditioner OPTION)
17 Driver’s side window regulator button

Central dashboard (models)
Figure 124
4x4
1 2 8 5 3 6 21 11
20
79483
Figure 125
EuroMidi
1 8 9
20
79484
Figure 126
Fire Fighting
1 2 8 3 6 9 11
20
79485
Ref. Description
1 Arrangement for exhaust brake
2 Rotating lamp actuation switch
3 Heated windscreen actuation switch
5 TGC deactivation in an emergency (ADR)
6 Sunroof control
8 Cab interior light switch (only if the retarder hand lever is available)
9 Retarder cut-out from the brake pedal
11 Auxiliary high-beam headlamps
20 Upper part of central dashboard (different according to the models)
21 ABS cut-out (only 4x4)

INSTRUMENT CLUSTER
Description
Figure 127
79486
The vehicle’s electric system has been modified by introducing a new instrument board called Instrument Cluster, similar to the
model available on higher range “STRALIS” vehicles.
This system has the following characteristics and is made up of:
- one instrument indicating the vehicle speed (both in km/h and mph);
- one instrument indicating engine speed
- one fuel level gauge;
- one coolant temperature gauge;
- one display showing faults and user messages;
- three optical indicator clusters;
- four buttons to scroll the various menus (model Highline only);
- one background lighting control button;
- one trip meter reset button (page shift on Baseline).
In addition to being connected to the vehicle’s CAN line, the Instrument Cluster receives a set of signals directly from a few sensors
or switches available in the vehicle’s electric system.
The Instrument Cluster also receives the signals from the four buttons for display menu control. The button operating logic is of
the standard type: the arrows allow you to shift the pages; if a page with various lines to be displayed is chosen, the display allows
you to view only 3 lines at a time or a page with a submenu. Pressing OK allows you to access the page and the “arrows” can be
used. Button C allows you to return to the previous page.

A black-and-white display is available. The lack of a colour display has been made up for by a logic associating a yellow or red warning
light to the icon indicating the information to be signalled to the driver. Direct signals are sent out to the Instrument Cluster (no
CAN line is provided) from:
- Engine oil level
- Fuel level
- Presence of water in the diesel fuel filter
- Air filter clogged signalling
- Rear converter limit switch signalling
- Rear brake oil level
- Immobilizer optical indicator
- Battery recharge indicator
- Trailer ABS failure indicator.
All the other signals are received, through the CAN line, in order to allow the relevant message to be displayed.
The Cluster does not store failures; it only displays them.
At present, the vehicle systems on which diagnosis can be made are EDC, IMMOBILIZER, ELECTRIC MIRRORS, and BODY
CONTROLLER.
With these systems, if the “HIGHLINE” model Cluster is available, a diagnosis screen can be shown on the display, which allows
you to refer to the failure codes of the concerned system.
These codes can be referred to by means of the “MENU” buttons provided on the dashboard.

Models available
Two models of the IC system are available: BASELINE and HIGHLINE.
They differ from each other in that they have (or have not) control buttons, and the screens on the IC display.
Baseline
No menu control button is provided.
Trip meter reset button (this is also used to change IC screen).
Highline
Four menu/IC screen control buttons are available.
Trip meter reset button (this is also used for trip 1 function).
Screens available with vehicle running

Baseline
time/km/partial km
time/km/partial time
time/miles/partial miles (UK customer market)
brake air pressure / engine oil pressure
Highline
time/km/partial km/°C/gear engaged (automatic transmission)
time/km/partial time/°C/gear engaged (automatic transmission)
engine oil pressure / brake air pressure
trip 1
trip 2
Screens available with stationary vehicle

Baseline
time/km/partial km
time/km/partial time
time/miles/partial miles (UK customer market)
engine oil level
brake air pressure / engine oil pressure
Highline
time/km/partial km/°C/gear engaged (automatic transmission)
time/km/partial time/°C/gear engaged (automatic transmission)
engine oil level / brake pad wear percentage (%)
engine oil pressure / brake air pressure
trip 1
trip 2
fuel litre meter index / fuel consumption indicator
engine oil level / brake pad wear percentage (%)
light check
diagnostics
vehicle maintenance
language setting / measurement unit

OPTICAL INDICATORS ON THE CLUSTER
Figure 128
79486
Description Colour Ideograph Description Colour Ideograph
External lights Green Side power takeoff 1 ON Yellow
Rear power takeoff 2 and

High-beam headlamps Blue Yellow
torque distributor both ON
Emergency lights Red Tractor left indicator Green
Instrument board failure Red Decelerator ON Yellow
Fog lights Green Exhaust brake ON Yellow
Rear fog lights Yellow Braking system failure Red
Slow gears engaged Yellow Emergency brake ON Red
Engine preheating Yellow Tractor ABS failure Yellow
Programmable speed limiter Yellow Trailer ABS failure Yellow
Special emergency brake (FF

Heated mirrors Yellow Red
vehicles) ON
Pneumatic suspension low
Front transverse differential lock Yellow Red
pressure
Longitudinal differential lock -
Yellow Trailer right indicator Green
Torque distributor (in neutral)
Rear transverse differential lock Yellow

(FAILURE) INDICATORS ON THE DISPLAY

When the functions below are actuated, or when the following anomalies occur, the corresponding symbol will appear in the display
section.
The yellow symbols (minor anomalies and failures) will appear on the left side of the display; the red symbols (serious failures) will
appear on the right side.
Figure 129
Description Colour Ideograph

79489
Minor anomaly and failure
Yellow
warning light
Serious failure warning light
Red
(stop)
Rear axle brake air low pressure Red Radiator water low level Red
Front axle brake pad wear Red EDC Red
Rear axle brake pad wear Red Gearbox failure Red
Brake fluid low level Red Gearbox oil high temperature Yellow
Rear AoH converter limit switch Red Retarder high temperature Yellow
Tractor EBS failure Red Decelerator failure Yellow
Tractor EBS failure Red Pneumatic suspension failure Red
Engine oil low pressure Red IBC failure Red
Engine coolant high temperature Red Generator charge Red
Engine oil low level Red Auxiliary generator charge Red


Power steering fluid low level Red External lighting Yellow
Cab uncoupled Red Box tipped Yellow
Loading gate Red Air filter clogged Yellow
Airbag failure Red Presence of water in the diesel Yellow

fuel prefilter
Doors open Red Windscreen washer fluid low Yellow
level
Vehicle braked by EBS Yellow Driving time anomaly Yellow
ASR ON (brake control) Yellow Carry out maintenance -
Tractor EBS failure Yellow - -
Tractor EBS failure Yellow Trailer linked -
EDC failure Yellow EDC in power takeoff mode -
Immobilizer actuation/failure Yellow Safety belts not fastened Red
Immobilizer actuation/failure Yellow Instrument board anomaly Yellow
Start-up cut out Yellow Instrument board failure Red
Gearbox failure Yellow Low external temperature -
Automatic transmission gear Yellow - -

engagement restraint
Pneumatic suspension failure Yellow CAN network failure Yellow
Pneumatic suspensions not in Yellow CAN network failure Red

running conditions
IBC anomaly Yellow

Print 603.93.391/A
Both current models allow you to display a few vehicle conditions in the base page structure, for a pre-established time. After this
screen is shown, the display will automatically go back to the latest screen available.
Below is a list of the conditions that can be displayed:
Headlamp setting
Mirror adjustment
Speed limiter
Cruise control
PTO (revs)
Engine idling speed
Figure 130
Headlamp aiming
Mirror orientation
Speed limiter
Cruise Control
PTO
Engine idling speed
85589

Revi - July 2005
CLUSTER (PIN-OUT)
Figure 131
A B
49837/a
Cable Cable
Ref. A - Blue B - Black
colour colour
1 Immobilizer warning light signal 6092 Diagnosis connector pin 8 1191
2 CAN H line 6108 ABS (connector X1-18) 6670
3 CAN L line 6109 Trailer ABS failure warning light signal 6671
4 - - Hand brake warning light signal 6662
5 - - Air pressure low warning light signal 6401
for ECAS
6 - - Rear brake oil level 6680
7 - - Rear converter limit switch 6613
8 - - - -
9 External temperature sensor 4710 - -
10 External temperature sensor 0152 Box tilted warning light signal 6607
11 Fuel level gauge earth 5557 Air filter clogged sensor 6663
12 Fuel level gauge 0616 Sensor for presence of water in the diesel 5530
fuel filter
13 - - Menu “UP” button 5900
14 Engine oil level sensor 5505 - -
15 Engine oil level sensor 5506 Menu “DOWN” button 5901
16 - - Menu “OK” button 5902
17 - - Battery recharge failed warning light signal 7780
18 +15 8879 Alternator charge warning light signal 7778
19 Earth 0000 - -
20 +30 8871 Menu “C” button 5903

Revi - July 2005
Print 603.93.391
CENTRAL INTERCONNECTING UNIT
Figure 132 1 1
79370/1
5 4
Ref. Description
1 Fuse holder (70000/3 - /1 - /2)
2 Remote-control switches
3 LED (see Immobilizer)
4 Body Controller
5 Control unit / Remote-control switches

REMOTE-CONTROL SWITCH ASSEMBLY
Figure 133
E1 E2 E3
E4
E5
E6
E7
E8
79370/3
Ref. Code Description

E1 25213 Key-controlled power supply remote-control switch
E2 25879 PTO remote-control switch
E3 25805 Horn control remote-control switch
E4 25035 External light (body builders) remote-control switches
E5 25810 Diesel fuel heating remote-control switch
E6 25003 Fog light remote-control switch
E7 25813 Heated rearview mirror remote-control switch
E8 - Remote-control switch for +15 power supply from diagnosis connector

Print 603.93.391/A
FUSE ASSEMBLY
Figure 134 70000/2 70000/1
70000/3
79370/2
70000/3 (GREEN) 70000/2 (NATURAL) 70000/1 (RED)
50340
Position Rating Function Power supply

1 30A Heated windscreen +30
2 30A Heated windscreen +30
3 - - -
70000/3
4 - - -
5 - - -
6 - - -
1 10A Auxiliary heater +30
2 10A Cigar lighter / Headlamp washer / Ceiling light +30
3 10A Fog light / Rotating lamps +30
70000/1
4 10A Conditioner / Adjustable heated mirrors +30
5 10A Heated seat +15/1
6 10A Reversing lights +15/1
1 20A Diesel fuel heating / Loading gate +30
2 20A Sunroof / Diesel fuel prefilter heating / Window regulator +30
3 20A Trailer ABS +30
70000/2
4 20A ABS +30
5 5A ABS - ECAS +15/1
6 5A ABS +30

Revi - Juli 2005
Print 603.93.391
Figure 135
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
50364
Fuse Rating Description

1 5A Body Control (15) / MICO tachograph / Instruments Cluster
2 5A Cab uncoupled / Immobilizer / Sensor for presence of water in the diesel fuel filter / Headlamp trim
corrector / Bed lights
3 10A MICO tachograph / Body Control (Left low-beam lamp - Right high-beam lamp)
4 10A Body builders
5 5A EDC7
6 5A Trailer takeoff (+15) / Chassis body builder takeoff (+15)
7 10A Central locking / Auxiliary heater / Fridge / Radio
8 10A Body Control (Right low-beam lamp - Left high-beam lamp)
9 5A Cab body builders (+15)
10 10A Body Control (left sidelights and stop lights)
11 10A Body Control (indicators - emergency lights)
12 10A Horn
13 20A Window regulators / Heated windscreen
14 20A Windscreen defrosting electric heater / Conditioner
15 10A Body Control (windscreen wiper — windscreen washer)
16 5A Brake air drier / Adjustable heated rearview mirrors / Control unit
17 5A External light body builders (+58)
18 5A Instruments Cluster
19 20A EDC7
20 10A Body Control (right sidelights and rear fog light)

CONNECTOR ASSEMBLY
Figure 136
84599

Connector “A” - “B” - “C”
Figure 137
A
7
B
2
C
1
50365
Ref. Function Cable colour code

1 Positive after TGC for body builders connector / connector IWT2 (1) 7772
2 - -
3 - -
A 4 Pin C14 positive (Body Controller) / Connector IWT2 (2) 2197
5 Electric heater positive 8879
6 Pin C16 positive (Body Controller) / Connector IWT1 (15) 1117
7 Positive for EDC / Connector IWT1 (12) 8150
1 Positive +15 for body builders 8869
B 2 Positive +15 8887
1 Pin C2 positive (Body Controller) / Roof panel cable junction 7768
2 - -
3 Diagnosis connector IWT2 (10) 0053
C 4 Diagnosis connector IWT2 (9) 9954
5 Positive for roof panel cable junction 7704
6 Positive for connector IWT1 (6) 8861

Connector “E”
Figure 138
E
1 7
6 14
50365
Cable colour
Ref. Description
code
1 - -
2 - -
3 - -
4 - -
5 - -
6 (OPT) - -
E 7 - -
8 Positive after TGC - Body Controller (D12) / Connector IWT1 (16) 8879
9 Battery positive +30 — Tachograph / Radio 7777
10 Positive +15 8879
11 - -
12 - -
13 - -
14 - -

Connector “F”
Figure 139
F
1 10
9 20
50365
Cable colour
Ref. Description
code
1 - -
2 - -
3 Positive 8887
4 15/1 positive 8051
5 - -
6 - -
7 - -
8 - -
9 - -
F
10 - -
11 Pin A15 positive (Body Controller) for parking lights 8807
12 - -
13 - -
14 - -
15 Signal ground 0000
16 Positive 7772
17 - -
18 Positive 8871
19 - 2283
20 Positive to turn on horn by means of button 1116

Connector “G” - “H”
Figure 140
G
B
H
1 4
3 8
50365
Cable colour
Ref. Description
code
A Battery positive after TGC 7777
G
B Battery positive after TGC 7701
1 - -
2 - -
H 3 Connector IWT2 (3) / Body builders light remote-control switch (30) positive 8830/7777
4 - -
5 - -
6 Positive for Body Controller (E4) / Roof panel cable junction / Cluster (A18) +15 8886/8879
7 Connector IWT1 (7) +15 8840
8 Connector IWT1 (6) +30 7772

Connector “I”
Figure 141
I
1 6
5 12
50365
Cable colour
Ref. Description
code
1 Ground 0000
2 - -
3 - -
4 Connector IWT1 (8) positive +15 8880
5 - -
6 - -
I
7 - -
8 Positive after horn TGC 1116
9 Positive (+30) for tachograph / Radio 7777
10 - -
11 - -
12 - -

Internal wiring diagram
Figure 142
84590

STEERING COLUMN STALK
Figure 143
A B
C D
TECHNICAL VIEW
Cable
Ref. Function
colour code
1 1103 Right indicator
2 0000 Earth
A 3 1109 Left indicator
4 1116 Horn control
5 1116 Horn positive (+30)
1 - -
2 2201 High-beam lamp actuation control
B 3 0000 Earth
4 2204 Headlight flashing device control
5 0000 Earth
1 8881 Windscreen wiper
2 - -
3 8882 Windscreen wiper (reset)
C 4 - -
5 0000 Earth
6 8822 Windscreen wiper (intermittent wipe)
7 8886 Windscreen wiper (electric pump control)
1 0000 Earth
2 8157 To Body Controller terminal A38 (SET+)
3 8155 To Body Controller terminal A37 (RESUME)
D 4 0000 Earth
5 8156 To Body Controller terminal A27 (SET)
6 - -
7 8154 To Body Controller terminal A28 (RESUME)

POSITION OF ELECTRONIC CONTROL UNITS
Figure 144
1 2 3 4
9 8 7 6 5
84591
Ref. Description
1 ABS
2 Rearview mirror control
3 Remote-control switch
4 Central locking control unit
5÷7 Auxiliary remote-control switches (OPT.)
8 Diode cluster
9 Resistor cluster

BODY CONTROLLER
Linking connectors
Figure 145
A
D
C
B E
84592
Ref. Description
A External lights / Rear fog lights / Start-prevent switch with hand brake OFF / High-beam headlamps / Low-
beam headlamps / Flashing the lights / Headlamp trim / Emergency lights / Indicators / Braking gasket wear /
Speed limiter / Exhaust brake selector / Door lights / Slow gear switch / Front and rear brake air pressure
sensors / Stop signal (from brake pedal switch on the duplex) / Windscreen wiper
B Power takeoff / Levels: radiator water, power steering oil, windscreen washer, TGC
C Power supply +30 (after TGC) / +30 / CAN line / Windscreen wiper motor / Windscreen washer electric
pump / Ceiling light / Step lights / Earth / Indicators / Left low-beam lamp / Right high-beam lamp / Trailer
junction (right-left indicators) / CAN line
D Left high-beam lamp / Right high-beam lamp / rear fog lights, stop lights, sidelights, clearance lights, number-
plate lights
E (High-low) gear engagement solenoid valve control

Component control connector “A” (black)
Cable
Ref. Function
colour code
1 3302 Positive for fog light remote-control switch
2 5560 Positive for brake air sensors
3 0000 Brake air sensor earth
4 6662 Signal from start-prevent switch with hand brake ON
5 9024 Signal from exhaust brake selector (PIN1)
6 9976 Geared-down speed ON warning light (signal)
7 2237 External light switch (PIN 4)
8 2282 Rear fog light switch (PIN 2)
9 8886 Control steering column stalk (PIN 7C)
10 - IVECO rear axle differential lock signal
11 9934 Signal from headlamp trim corrector (PIN 3)
12 9936 Headlamp adjustment unit control (PIN 2)
13 5561 Rear brake air pressure sensor signal
14 - -
15 9025 Signal from exhaust brake selector (PIN 7)
16 2205 Signal from slow gear selection switch selector
17 9968 Signal from speed limiter switch
18 2228 Signal from fog light switch
19 6620 Signal from Rockwell rear axle transverse differential lock signalling switch
20 6621 Signal from Rockwell / Iveco rear axle transverse differential lock signalling switch
21 5562 Front brake air pressure sensor signal
22 7728 Signal from emergency light actuation switch
23 0003 Signal from left door button
24 8882 Steering column stalk (windscreen wiper control PIN 3C)
25 1103 Steering column stalk (right indicator switch)
26 2204 Steering column stalk (headlamp flashing device button)
27 8156 Cruise Control steering column stalk ( SET-)
28 8154 Cruise Control steering column stalk (RESUME)
29 8822 Steering column stalk (windscreen wiper control PIN6)
30 8881 Steering column stalk (windscreen wiper control PIN 10)
31 0010 Signal from central ceiling light switch-on button
32 3333 External light switch (PIN 5)
33 0003 Switch on right door for external lighting
34 1117 Stop light button (stop signal)
35 1109 Left direction steering column stalk (A3)
36 2201 High-beam lamp actuation steering column stalk (B2)
37 8155 Cruise Control steering column stalk (RESUME)
38 8157 Cruise Control resume steering column stalk ( SET+)
39 6012 Front wheel shoe wear signalling
40 6013 Rear wheel shoe wear signalling

Connector “B” (white)
Cable colour
Ref. Function
code
1 6131 Rear power takeoff ON signal
2 6132 Side power takeoff ON signal
3 - Free
4 0055 Longitudinal lock ON signal
5 - Free
6 6659 Front differential lock ON signal
7 5520 Radiator water level signal (red)
8 5525 Power steering oil level signal (red)
9 5521 Windscreen washer fluid level signal (red)
10 - Free
11 - Free
12 - Free
13 - Free
14 - Free
15 - Control from TGC closing button
16 - Free
17 - Free
18 - Positive for TGC closing remote-control switch excitation
19 - Free
20 - Free

Connector “C” (black)
Cable colour
Ref. Function
code
1 - Free
2 7768 Positive +30 (prima TGC)
3 4441 Positive for internal ceiling light
4 2221 Right high-beam headlamp
5 2231 Left low-beam headlamp
6 8861 Windscreen wiper motor (53B)
7 8882 Windscreen wiper motor (53)
8 8886 Positive for windscreen washer electric pump
9 8873 Windscreen wiper motor (31B)
10 0000 Earth
11 6108 CAN “H” line
12 6109 CAN “L” line
13 - Free
14 2197 Positive after TGC
15 4408 Positive for step light
17 1180 Positive for trailer left indicators
18 1120 Positive for left indicators
19 1185 Positive for trailer right indicators
20 1125 Positive for right indicators

Connector “D” (blue)
Cable colour
Ref. Function
code
1 4442 Positive for ideograph illumination
2 - Free
3 2282 Positive for trailer reverse fog light
4 2286 Positive for reverse fog light
5 3334 Positive for rear left sidelights
6 3380 Positive for front left sidelight / Positive for front right clearance light
7 3339 Positive for rear clearance lights
8 3332 Positive for trailer left sidelight
10 2223 Right low-beam headlamp / Headlamp trim consent
11 2219 Left low-beam headlamp
14 3330 Number-plate lights
15 3335 Positive for rear right sidelights
16 3390 Positive for front right sidelights / Positive for front left clearance light
17 3331 Positive for trailer front sidelights / Positive for body builders connector external light remote-
control switch
18 1177 Positive for left stop light
19 1172 Positive for right stop light
20 1179 Positive for trailer stop light
Connector “E” (white)
Cable colour
Ref. Function
code
1 - Free
2 - Free
3 9973 Positive for high gear engagement solenoid valve control (9-speed gearbox)
4 8886 Positive +15
5 - Free
6 - Free
7 9110 Positive for geared-down speed engagement solenoid valve control (9-speed gearbox)
8 - Free

CONNECTOR PIN-OUT
Figure 146
85561 85562
CONNECTOR B CONNECTOR A
85563 85564
CONNECTOR C/D CONNECTOR E

Print 603.93.381/A
TACHOGRAPH
Figure 147 Figure 147/1
79369 105988
1. Electronic tachograph (MTCO) DIGITAL TACHOGRAPH (DTCO)
The digital tachograph (DTCO) comes as a standard item on newly produced vehicles and replaces the analog tachographs in case
of failure.
The DTCO electric connections are the same as with the MTCO. With regard to the DTCO tachograph, the sensor on the gearbox
needs be changed, which is the same as the preceding one from an electrical viewpoint.
Ref. Cable colour code Function

1 7768 Positive +30 direct to the battery
2 4444 Ideograph illumination
3 8879 Positive +15
4 6108 CAN “H” line
A
5 0066 Earth
6 0066 Earth
7 - -
8 6108 CAN “L” line
1 5514 Sensor (A) signal
2 0058 Sensor (B) signal
3 5517 Sensor (C) signal
4 5516 Sensor (D) signal
B
5 - -
6 - -
7 5515 To diagnosis connector pin 29
8 - -
1 - -
2 - -
3 - -
4 - -
C
5 - -
6 - -
7 - -
8 - -
1 - -
2 - -
3 - -
4 - -
D
5 - -
6 - -
7 1191 Signal: Cluster B1 / Diagnosis pin 8
8 - -
Revi - July 2005
Print 603.93.391
DESCRIPTION OF EDC 7 INJECTION SYSTEM
IVECO Code recognition

The EDC7 control unit communicates with the Immobilizer ECU to obtain the engine starting enable signal.
Engine pre-heating resistance control

The pre-post heating function is activated when even a single water, air or fuel temperature sensor indicates a temperature lower
than 5 ºC.
Timing phase recognition

The cylinder in which to inject the fuel is recognized through the signal from sensor on the camshafts and the sensor on the flywheel.
Injection control
Based on the information coming from the sensors, the control unit manages the pressure regulator, changes the pre-injection and
the main injection operating modes. On Tector motors pre-injection is active at any rotation speed rate of the motor.
Closed cycle control of injection pressure

Based on engine loading, as determined by processing the signals from the various sensors, the control unit manages the regulator
to have the optimal pressure at all times.
Main pilot injection advance control

Based on the signals from the different sensors, the control unit determines the optimal point according to the internal mapping.
Idling speed control

The control unit processes the signals from the different sensors and adjusts the quantity of fuel injected.
It checks the pressure regulator, varies the electro-injector injection time.
Within certain thresholds, it also takes into account battery voltage.
Maximum speed limitation

At 2700 rpm, the control unit limits fuel flow by reducing the electro-injector opening time.
At a speed of over 3000 rpm, it de-activates the electro-injectors.
Cut Off
Fuel cut off at release stage is managed by the control unit which implements the following logics:
- cuts off the power to the electro-injectors
- re-activates the electro-injectors immediately before idling speed is reached
- controls the fuel pressure regulator.

Exhaust fume control at acceleration stage

At considerable load levels, based on the signals from the air flowmeter and the engine speed sensor, the control unit manages
the pressure regulator and varies the electro-injectors actuation time, so as to prevent the emission of exhaust fume.
Fuel temperature control

When the temperature of the fuel exceeds 75 ºC (as measured by the sensor placed on the fuel filter) the control unit reduces
the injection pressure.
If the temperature exceeds 90 ºC, the power is reduced to 60%.
After Run
The control unit microprocessor makes it possible to memorize some data in the EEPROM, including the failure memory and the
Immobilizer information, so as to make them available for the subsequent starting.
Protection from overheating

If water temperature reaches 110 _C, the central control unit reduces the motor performance.
When the temperature falls below 100 _C, the motor starts to function normally again.

Injection system assembly
Figure 148
EDC
PRES OLIO
IVECO
CAN LINE
84593

Print 603.93.391/A
Ref. Description
1 Position sensor on accelerator pedal
2 Primary and secondary brake switch
3 Sensor on clutch pedal
4 Exhaust brake switch
5 Immobilizer ECU
6 Ignition key
7 Lever mounted switches
8 Cab unhooked switch
9 Handbrake engaged
10 Neutral switch
11 (20 A) protective fuse
12 Tester connector
13 Blink-Code button
14 Exhaust brake selector
15 Starter motor
16 Crankshaft sensor
17 Engine stop/start buttons
18 Preheating remote control switch
19 Fuel temperature sensor
20 Fuel heating resistor
21 Timing system sensor
22 Pressure regulator
23 Coolant temperature sensor
24 Preheating resistor
25 Electro-injectors
26 Air temperature/pressure sensor
27 Fuel temperature/pressure sensor
38 Exhaust brake solenoid valve
39 Oil temperature/pressure sensor

Revi - Juli 2005
Print 603.93.391
Arrangement of the sensors

Figure 149
50367

Component
Ref. Description
code
1 85153 Coolant temperature sensor
2 78247 Electro-injector
3 85157 RAIL pressure sensor
4 85156 Air temperature/pressure sensor
5 44037 Power steering level sensor
6 48042 Timing sensor
7 47042 Fuel temperature sensor
8 85150 EDC7 control unit
9 48035 Crankshaft sensor
10 44043 Engine oil level transmitter
11 42030 Engine oil pressure/temperature sensor
12 61121 Pre-post hearing resistance

EDC 7 electronic control unit
Figure 150
C A
50351
A. Injector connector - B. Frame connector - C. Sensor connector

The control unit is fitted onto the engine via a heat exchanger by means of elastic blocks which reduce the vibrations transmitted
to the unit by the engine.
It is powered by a fuse (20 A) placed in the UCI (fuse no. 19).
The main relay which is normally used to power the system is located inside the control unit itself.

Sensors connector “C”
Figure 151 6 8 16 9 15 22
4
Colour legend
5
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange
1 3 23 30 36 29
50350
ECU Cable
Function
Pin Colour
1÷4 - -
5 NW Ground for pressure regulator
6 - -
7 NP Control for pressure regulator
8 - -
9 PY Power supply for engine oil temperature pressure sensor
10 NY Power supply for air pressure temperature sensor
11 - -
12 GY Power supply for rail pressure sensor
13÷16 - -
17 YR Ground for fuel temperature sensor
18 YN Ground for coolant temperature sensor
19 PN Ground for engine oil temperature pressure sensor
20 GN Power supply for rail pressure sensor
21 N Power supply for air pressure / temperature sensor
22 - -
23 U Timing sensor
24 U Crankshaft sensor
25 R Crankshaft sensor
26 - -
27 GO Signal from rail pressure sensor
28 NG Signal from air pressure sensor
29 UO Signal from air temperature
30 R Ground for timing sensor
31÷32 - -
33 PO Signal from engine oil temperature sensor
34 YU Signal from diesel oil temperature sensor
35 PG Signal from engine oil pressure sensor
36 YO Signal from coolant temperature sensor

Print 603.93.391
“B” frame connector
Figure 152
71 89 72 54 6 11
1
7
12
53 35 18 36 17
50350
ECU
Cable Function
Pin
1 8150 Direct positive from battery
2 0087 Negative for diesel oil filter heating relay
3 0000 Ground
4 0094 Positive for exhaust brake solenoid valve/control relay/pre-post hearing resistance
5 9068 Air-conditioning system remote-control switch drive signal
6 - -
8 7777 Positive for clutch sensor/Blink Code button/exhaust brake button/brake pedal switch on the
duplex
9 0000 Ground
10 9067 Air-conditioning system remote-control switch drive signal
11 9966 Negative for exhaust brake solenoid valve
14 0000 Ground
15 0000 Ground
16 8885 Negative to turn on thermostarter relay
17-18 - -
19 0150 Negative for start-up buttons/stop from engine compartment/gearlever in neutral/hand brake
ON
20 8037 Positive from key-operated switch at starting stage (+50)
21 8159 Positive from exhaust brake switch
22 - Control from brake pedal position exhaust brake selector
23-25 -
26 - -
27 5162 Positive from blink code button
28 5535 Positive for “BLINK CODE” LED warning light
29 - -
30 1198 L line for 30 pin tester connector (pin 1)
31 2298 Line K for 30 pin tester connector (pin 2)
32 0169 PTO
33-35 - -
36 8837 Positive for diesel oil filter heating relay
37 8888 Positive for starter motor
38 - -

“B” frame connector

ECU
Cable Function
Pin
39 8051 Positive from key-operated switch, +15
40 0027 -
41 9907 Signal from handbrake engaged switch
42 6666 Signal from cab unhooked switch
43 0115 Positive from gearbox on neutral switch
44 9905 Positive from start button from engine compartment
45 9906 Positive from stop button from engine compartment
46 - -
47 - -
48 5198 Engine phase signal for diagnosis connector (pin 23)
49 5584 Signal for electronic rev counter
50 0158 Negative from accelerator pressed switch
51 - -
52 6109 CAN line (white wire) L
53 6108 CAN line (green wire) H
54 - -
55 5158 Positive for accelerator pedal position sensor
56 - -
57-58 - -
59 - -
60 - -
61 - -
62 5602 Clutch sensor
63 - -
64 0535 Negative for “BLINK CODE” LED
65 - -
66 - -
67-71 - -
72 0159 Signal from accelerator pressed switch
73 0159 Redundant signal from accelerator pressed switch
74 5155 -
75 - -
76 8158 Positive from secondary brake pedal switch
77 5502 Signal from second speed limiter switch
78 9071 Air-conditioning system
79 - -
80 8153 Brake light signal
81 0157 Ground for accelerator pedal position sensor
82 - -
83 5157 Signal from accelerator pedal position sensor
87 5120 PTO

Electroinjectors connector “A”
Figure 153
12 16
6 11
1 5
50350
Cable Cable
ECU
Colour Colour Function (4 cylinders) Function (6 cylinders)
Pin
(4 cylinders) (6 cylinders)
1 - - - -
2 - - - -
3 - RU - Cylinder 2 injector
4 WP WP Cylinder 4 injector Cylinder 3 injector
5 - WV - Cylinder 4 injector
6 - RW - Cylinder 2 injector
7 - - - -
8 - - - -
9 RG RG Cylinder 1 injector Cylinder 1 injector
10 UN UN Cylinder 2 injector Cylinder 6 injector
11 UG UG Cylinder 3 injector Cylinder 5 injector
12 WR WR Cylinder 4 injector Cylinder 3 injector
13 RY RY Cylinder 1 injector Cylinder 1 injector
14 - W Cylinder 4 injector
15 UO UO Cylinder 2 injector Cylinder 6 injector
16 UY UY Cylinder 3 injector Cylinder 5 injector
Colour legend
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange

Air temperature/pressure sensor (85156)

Figure 154 This component combines a temperature and a pressure
sensor.
It is fitted to the intake manifold so that, by measuring the
maximum quantity of air taken in, it makes it possible to
determine the exact amount of fuel to be injected at each cycle.
This sensor is connected to the control unit via pins 21/C - 29/C
- 10/C - 28/C.
It is powered at 5 V.
The output voltage is proportional to the pressure (or
temperature) measured by the sensor.
Pins 21/C - 29/C Temperature
Pins 10/C - 28/C Pressure
50324
EXTERIOR VIEW OF SENSOR Oil pressure/temperature sensor

This component is identical to the air temperature/ pressure
Figure 155 sensor
It is mounted horizontally on the engine oil filter.
It measures the engine oil temperature and pressure.
It is connected to the control unit via pins 19C - 33C - 9C - 35C.
The values sent are transmitted to the EDC control unit which,
in its turn, controls the indicator on the dash (indicator / low
pressure warning light).
Pins 19/C - 35/C Temperature
Pins 9/C - 33/C Pressure
The engine oil temperature is used by the EDC unit only.
50323
CONNECTION CONNECTOR Control unit Pin

Ref
Ref. Description
Oil Air
Figure 156
1 Ground 19C 21C
2 Temp. signal 35C 29C
3 +5 9C 10C
4 Press. signal 33C 28C
50344
WIRING DIAGRAM

Crankshaft sensor (48035)

This inductive type sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which
close through the openings of a toothed wheel force fitted to the crankshaft. The same signal is used to manage the electronic rev
counter.
It is connected to the control unit via pins 25C - 24C.
The sensor’s resistance value is ca 900 Ω.
Supplier BOSCH
Tightening torque 8 ± 2 Nm
Timing system sensor (48042)
This inductive sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which close
through the holes situated in gears force fitted to the camshaft. The signal generated by this sensor is used by the ECU as the injection
timing signal.
Though it is similar to the crankshaft sensor, it is not interchangeable with the latter since its outer shape is different.
The sensor’s resistance value is ca 900 Ω.
Supplier BOSCH
Tightening torque 8 ± 2 Nm
180 ± 15
2
3 1
8518 8519
TECHNICAL VIEW WIRING DIAGRAM
Figure 159
8520
PERSPECTIVE VIEW
Control unit Pin

Ref
Ref. Description
48035 48042
1 Signal 25C 23C
2 Signal 24C 30C
3 Shielding

Fuel pressure sensor (85157)

Fitted to one end of the rail, it measures the pressure of the existing fuel in order to determine the injection pressure.
The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
It is connected to the control unit on pins 20C - 27C - 12C.
It is powered at 5 V.
Figure 160
A - Distribution manifold
B - Fuel pressure sensor (85157)
Ref. Description Control unit pin

1 Ground 20C
2 Signal 27C
3 Power 12C

High pressure pump (pressure regulator)

Figure 161
Pump with 3 radial pistons controlled by the timing gears,
requiring no phase adjustment, with rotor type feed pump
fitted to the back.
A. Connection between fuel discharge outlet and filter
support
B. Connection for fuel inlet from control unit heat exchanger
C. Connection for fuel inlet from fuel filter
D. Connection between fuel outlet from feed pump and filter
E. Connection between fuel outlet and rail
1. High pressure pump
2. Feed pump
3. Pressure regulator (N.O. solenoid valve modulated by the
control unit by means of PWM signal).
Pressure regulator
Situated at the inlet of the high pressure pump, on the low
pressure system, it adjusts the quantity of fuel reaching the high
pressure pump as a function of the commands received from
the electronic control unit.
It basically consists of the following parts:
- trapezoidal section shutter;
- valve control pin;
- pre-charging spring;
- coils. A
In the absence of the control signal, the pressure regulator is
normally open, and hence the high pressure pump is in its 1 B
maximum delivery conditions. C
The control unit modulates a PWM control signal which 3
reduces, to a greater or lesser extent, the section carrying the
fuel to the high pressure pump. 2
D
This component cannot be replaced individually and hence it
cannot be taken down.
E
The amount of fuel feeding the high pressure pump is metered
by a proportional valve situated on the low pressure system -
managed by the EDC 7 control unit.
The delivery pressure to the rail is modulated between 250 and
000912t
1400 bar by the control unit working on the pressure regulator
solenoid valve.
It is a N.O. solenoid valve
Its resistance is ca 3.2 Ω.
It is connected to the control unit via pins C5 - C7.

Electroinjector
The injector features a traditional construction, save for the fact Figure 162
that it has no needle return springs.
The electroinjector essentially consists of two parts:
- actuator - atomiser consisting of a pressure rod 1, a needle
2 and nozzle 3;
- control solenoid valve, consisting of a coil 4 and pilot valve
5.
The solenoid valve controls the rise of the atomiser needle.
Injection starts
Upon being energised, coil 4 moves up the shutter 6.
50336
The fuel contained in the control volume 9 flows back towards
line 12 resulting in a pressure drop in the control volume 9.
At the same time, the fuel pressure in the pressure chamber
8 moves up the needle 2 resulting into the fuel being injected
into the cylinder. Figure 163
Injection ends
When coil 4 is de-energised, the shutter 6 closes again so as to
re-create a balance of forces which moves the needle back into
its closed position and stops the injection process.
This is a N.O. solenoid valve.

Individually connected to EDC control unit on connector A.
The resistance of the coil of each individual injector is 0.56 ÷
0.57 Ω.
000933t
INJECTION IN RESTING POSITION

1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot
valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Control line - 11. Feed
line - 12. Control fuel outlet - 13. Electrical connection - 14.
Spring - 15. High pressure fuel inlet.

Connecting connectors
Figure 164
1 2 3
50343
WIRING DIAGRAM OF THE CONNECTIONS
Figure 165
1 2 3 4 5 6
1 2 3
FAN SIDE
50349
Ref. Description Control unit Pin

1 Cylinder 2 injector 3A
CONNECTOR 1
3 Cylinder 1 injector 13 A
CONNECTOR 2
CONNECTOR 3

Coolant temperature sensor (47035)

Figure 166 This is a variable resistance sensor that is able to measure
coolant temperature and transmit a signal to the control unit
reflecting the thermal conditions of the engine.
The same signal is used by the control unit to manage the
temperature gauge on the dash.
Its resistance at 20 °C = 2.50 KΩ.
It is placed in the upper engine part.
1 2 50321
Fuel temperature sensor (47042)

Figure 167 This sensor is identical to the previous one.
It measures the temperature of the fuel and transmits a signal
to the control unit reflecting the thermal conditions of the
diesel oil.
Its resistance at 20 °C = 2.50 KΩ.
The ECU manages the relay for the control of filter heating
when the temperature of the fuel drops to ≤ 36 °C.
50322
ECU pin
Ref
Ref. Description
47035 47042
Figure 168
1 Ground 18C 17C
2 Signal 36C 34C
50348
A. Fuel temperature sensor B. Filter heating resistance

Fuel pre-filter
The water separation type fuel filter is mounted on the right Figure 169
hand side of the vehicle frame and has, on the cartridge base
3, a sensor 4 detecting the presence of water in the fuel.
The filter support houses a manual priming pup 5 and a screw
2 to bleed the air from the system.
The presence of condensate in the filter and the filter clogged
condition are revealed by sensor 4 by turning on a single
warning light in the dash.
1
2 5
If the warning light lights up, take action immediately

! to remove the cause, as common rail system
components deteriorate quickly if there is water or
impurities in the fuel.
3
000910t
Tightening torque
Bleed screw 2 6 to 8 Nm
Filtering cartridge 3 18 ± 0.1 Nm
Sensor 4 0.8 ± 0.1 Nm

Clutch sensor (42374)

Figure 170 This is an electronic proximity switch
It is fitted to the clutch pedal and determines the engagement
of the clutch
It is fitted with a yellow led indicator that lights up when the
pedal is released.
It is connected to electronic control unit via pin 62B.
50332
1. Sensitive part of sensor - 2. Tightening screws (torque 10

Nm) - 3. Brass body - 4. Yellow LED - 5. Connector.
Triggering distance
To prevent the pedal from hitting against the sensor head upon
Figure 171 being released abruptly, we recommend the following
triggering distance: 1 to 3 mm (D).
50326
Cable Control unit

A. Clutch sensor Ref. Description
colour pin
Figure 172
1 0000 Ground -
2 7151 Power supply 8B

PEDAL BODY SENSOR PART
3 0160 Signal 62B
50333
D. Triggering distance

Pre-post heating resistance

This resistance is located on the intake manifold. Figure 173 B
It is used to warm up the air in pre-post heating operations. It
is powered by a remote control switch situated on the left hand
side of the frame.
A
Its resistance is ~ 0,5 Ω.
Resistance control remote control switch A. - B. Connecting terminals

The remote control switch is connected to the EDC control
unit via pins 4B - 16B.
Figure 174
It is activated when the temperature of the water or the diesel
oil exceeds 5 °C. C
It is located in the front part of the vehicle, on the left
longitudinal.
The remote control switch coil resistance is about 15 Ω.
50325
C. Remote control switch

Load sensor on accelerator for EDC (85152)

Figure 175 The accelerator pedal position sensor is of potentiometric
type, with built in N.O. minimum switch.
It supplies to the ECU a value proportional to the activation
angle of the pedal itself, so as to determine fuel feed.
It is connected to the control unit via pins 73B - 81B - 83B - 55B
- 58B.
The resistance of the potentiometer is ca 1 KΩ.
The power supply voltage is 5 V.
50334
WIRING DIAGRAM
Figure 176
000600t
Exhaust brake solenoid valve (78050)

This is a N.C. on-off solenoid valve.
It is positioned on the left hand side of the frame. By controlling
Figure 177 this solenoid valve, the ECU opens the passage for the air
coming from the aux. unit tank to control the exhaust brake
cylinder which, in its turn, closes the throttle valve in the
exhaust manifold.
It is connected to the control unit via pins 4B - 11B.
50328
A
A. Exhaust brake solenoid valve

Adapters for diagnostic with MODUS, IT2000 and IWT

Adapter for readings on engine injector
In addition to tests through MODUS, IT2000 and IWT this adapter enables to perform readings with multimeter on individual
injectors (as shown in detail A).
Figure 178
001662t

Testing methods
Two warning lights (yellow or red) will be displayed according to the gravity of the failure.
HIGHLINE model clusters will show a “DIAGNOSTIC” screen, in the middle part of the display, which will indicate failure codes.
MODUS - IWT - IT 2000

These diagnostic instruments allow you to make a full diagnosis of the various systems available on IVECO range vehicles.
Figure 179
84589A
SCREEN ON THE DISPLAY (HIGHLINE MODEL)

ABS
Electronic control unit location on vehicle
Print 603.93.391
Figure 180
84591
A. Electronic control unit ABS
The system is able to prevent wheel locking, that could occur when braking, under any vehicle load condition and under any
wheel-roadbed friction coefficient condition, in order to guarantee better braking performances and a better vehicle stability.
The system is activated upon startup and automatically operates for speeds greater than 5 km/h if, after a braking, one or more
wheels tend to lock.
The ABS system is able to control engine brake exclusion and distributor locking (if it exists).
They are disconnected when it is detected that one or more driving wheels tend to lock.
Re-connection is automatic when the ABS system ceases to operate.
On all vehicles of the range, the system has three channels, two on front wheels and one on rear axle, apart from 3-axle vehicles
in which the system has four channels.
Purpose of the unit is processing signals coming from wheel revolution sensors and suitably driving the system solenoid valves
in order to avoid locking the wheels when braking.
Signal processing is carried out by a microprocessor that computes acceleration and deceleration values of the different wheels
and carries out the logic combination of the various adjustment signals.
If an anomaly is detected, the unit takes care of automatically excluding the whole ABS system, leaving however the traditional
braking system efficient, and of informing the driver by lighting the suitable warning light on the dashboard.

ABS
Component location on a vehicle (Electric system)
Figure 181
:
8241
: Vehicles 260 with 3 axles only
Components
Description
code
78052 Solenoid valve for ABS
88000 Electronic control unit for ABS system
88001 Sensor for ABS system

ABS
Component location on a vehicle (Pneumatic system)
Figure 182
78952
1. Phonic wheel - 2. Check valve - 3. Exhaust brake solenoid valve - 4. A.P.U. - 5. Relay valve - 6. Phonic wheel -
7. Engine revs sensor - 8. Combined brake cylinder - 9. Triple-control servodistributor - 10. Coupling heads - 11. Emer-
gency braking tank + trailer - 12. Hydraulic pressure control takeoff - 13. Wheel revs sensor - 14. Phonic wheel -
15. Rear disc brake assembly - 16. Quick-release valve - 17. Pressure reducer - 18. Electropneumatic valve - 19. Air tank -
20. Pressure control takeoff - 21. Pressure relief valve - 22. Front disc brake assembly - 23. Membrane brake cylinder - 24.
Wheel revs sensor - 25. Phonic wheel - 26. Exhaust brake cylinder - 27. Exhaust brake control button - 28. Duplex distribu-
tor - 29. ABS electronic control unit - 30. Single-cylinder compressor - 31. Emergency brake distributor - 32. Trailer
deceleration control distributor (option) - 33. Wheel revs sensor.

Electronic control unit (Bosch)

1 16 1 4 1 7 1 13
Figure 183
3 I 18 3 II 6 3 III 9 3 IV 15
62608
Connector PIN Cable colour Description

1 - CAN “L” line
2 - -
3 - CAN “H” line
4 - -
5 6684 Signal from front br. converter cylinder limit switches(only vehicles 60-100)
6 - -
7 8847 Positive (+15)
8 7710
I 9 - -
10 0050 Ground
11 - -
12 0000 Ground
13 2299 To tester connector (pin 4) line K
14 1199 To tester connector (pin 3) Line L
15 - -
16 - -
17 - -
18 6670 ABS failure warning light control
1 9921 Positive for left axle ABS solenoid valves
2 9919 Positive for left axle ABS solenoid valves
II 3 0000 Positive for left axle ABS solenoid valves
4 5570 Positive for ABS left sensor
5 5570 Negative for ABS left sensor
6 - -
1 - -
2 - -
3 - -
4 5571 Negative for ABS right sensor
III 5 5571 Positive for ABS right sensor
6 - -
7 9918 Positive for right axle ABS solenoid valves
8 9920 Positive for right axle ABS solenoid valves
9 0000 Negative for right axle ABS solenoid valve
1 9930 Positive for right rear axle (left Mod. 260) solenoid valve
2 9931 (Positive for right rear axle (Model 260 solenoid valve)
3 0000 Negative for rear axle ABS (left Mod. 260) solenoid valve
4 - -
5 5572 Positive for ABS left sensor
6 5572 Negative for ABS left sensor
7 - -
IV 8 5573 Positive for ABS right sensor
9 5573 Negative for ABS right sensor
10 9931 (Positive for rear axle ABS right Mod. 260 solenoid valve)
11 9924 Positive for rear axle ABS (right Mod. 260) solenoid valve
12 0000 (Negative for rear axle ABS right Mod. 260 solenoid valve)
13 - -
14 - -
15 - -

Duplex distributor
Figure 184
62579
000607t
Brake switch
This is a microswitch mounted directly on the duplex distributor (SWITCH).
The N.C. contact provides the control unit (pin B76) with a positive signal (with the pedal released) and is used to detect service
brake actuation so as to deactivate the Cruise Control function and cut off fuel delivery.
The N.A. contact provides the BODY CONTROLLER control unit (pin A34) with a positive signal, so that the control unit itself
can control stop light actuation.
Electric connections
Ref. Cable colour Description

1 - Power supply positive signal
2 1176 Positive signal to turn on the stop lights (Body Controller, pin E11)
3 7151 Power supply positive signal
4 8158 Positive signal with brake released for EDC control unit (pin B76)

Sound wheel and speed sensor 88001

Sensors continuously supply the electronic center with all the data it requires to properly pilot the electro valves.
Signals are obtained from magnetic flow lines that close through the teeth of a teethed wheel facing the sensor and rotating
together with the wheel.
Passage from full to empty due to the presence or absence of the tooth causes sufficient magnetic flow variation to create induced
electromagnetic force at sensor terminals and thus an alternating electrical signal that is sent to the electronic center.
The clearance between the sensor and wheel, called air gap, must obviously be at a pre-set value of 0.8 ÷ 1.6 mm for proper signals
to be sent. Resistance of each sensor at connection terminals is between 1 and 2 kW.
The toothed wheel is called sound wheel because the signal it generates has the same frequency as a sound wave.
The frequency of this signal serves to define wheel rotation speed.
Frequency variations, or the speed at which signals follow one another, define acceleration and deceleration rates.
Figure 185
A
B
000840t 000841t
SOUND WHEEL (A) AND SENSOR B) PERSPECTIVE VIEWS
AIR GAP
000842t
A. Magnetic flow lines

Diagnostics
Warning lights operation
Figure 186
1
2
79486
ABS system anomalies signalling

By inserting the key-switch, the electronic unit will carry out a system test by lighting the signalling lights placed on the dashboard
for ~2 seconds. If no failures are detected, the lights will be turned off. Otherwise, depending on the anomaly severity, the following
warning lights will remain on:
Red ABS light (1)
This warning light signals the presence of anomalies in the trailer ABS system (for towed vehicles).
This warning light signals the presence of a serious anomaly in the system, which impairs the braking system operation. In this case,
contact your IVECO Dealership immediately, since braking will, under such conditions, occur in the normal mode.
Trailer ABS red warning light (2)
It signals the presence of anomalies in the ABS system on the trailer (for vehicles suitable for towing).
Braking gasket wear signalling (HIGHLINE models)
Braking gasket wear is signalled by means of the display available on the CLUSTER, and the degree of wear is shown as a percentage
value (%).
Failure codes are not currently shown in the display.
Figure 187
Wear indicator
84598

Print 603.93.391
ECAS
General
The air suspension features great flexibility, vibration damping capacity and above all, thanks to the system’s self-adjusting functions,
it maintains the ”frame-road surface” distance constant, regardless of vehicle load. By means of a special button, the air suspension
makes it possible, among other things, to vary the ”frame-road surface” distance and hence the height of the vehicle’s loading floor.
In addition to the well known advantages of air suspension, the ECAS suspension offers:
- - an appreciable reduction in air consumption;
- - prompt action of the different adjustment processes;
- - simple system construction;
- - full safety;
- - the possibility of total system diagnosis.
The ECAS (Electronically Controlled Air Suspension) system automatically controls the nominal level of the vehicle’s air
suspension, with the possibility, for the vehicles that adopt it, of lifting the rear added axle, when required by the vehicle’s operating
conditions, and transferring the load onto the drive axle at take-off, if adherence conditions are poor (aid at take-off).
However, all the foregoing operations can take place only in specific operating conditions under the surveillance of the safety devices
equipping the systems connected to the units involved.
The ECAS automatically controls the height of the frame (the distance between the frame and the road surface) based on the actual
values sent in by the sensors, by comparing these actual values with the nominal ones stores in its memory.
If the actual level changes or departs from the nominal value or the value set previously by the driver, the control unit corrects it
by means of the electropneumatic devices.
The system is equipped with a remote control for frame lifting/lowering and levelling operations, which can be operated with the
vehicle standing or moving.
In addition to the lifting, lowering and self-levelling operations, the remote control makes it possible to save other frame levels, which
can be recalled as necessary.

Electronic control unit (86023)
Figure 188
001716t
A. ECAS electronic control unit
Supplier WABCO
Power supply voltage 18 to 32V
Thermal working range -40º to +70º
The electronic control unit makes it possible to manage the different positions of the frame as a function of the commands imparted
by the driver by means of the remote control unit. When you turn on the key-operated switch, the electronic control unit performs
a system test by powering for ca 2 sec. the yellow and red telltales located on the dash.
If a fault is detected, the red warning light will either stay permanently lit or blink, depending on its severity, while the yellow light
can stay lit only if the vehicle level is not normal or a plausibility error is detected.
Since it has to keep the running level requested by the driver constant and, at the same time, it has to reduce the consumption
of air, the control unit checks cyclically the signals coming from the level sensors and steps in ONLY if it detects a deviation for more
than five counts.
The correction is applied with a time lag, as follows:
~1 sec. if the vehicle is standing
~ 60 sec. if the vehicle is moving
If the level is not reset within a max. time interval of 30 sec. of the start of the correction, the control unit will memorise a plausibility
error.
At the braking stage, upon receiving a signal from the stop light switch, the electronic control unit stops all automatic level adjustment
operations. Though it has a Blink Code, displayed through the red warning light, for a preliminary diagnosis, the control unit has a
highly advance self-testing system that can recognise and memorise, as a function of environmental conditions, any failure, including
those of intermittent types, which may occur during system operation, so as to ensure effective and reliable repair interventions.
All tests and failure memory programming/deletion interventions, etc. can be performed by means of the computerised testing
station ”MODUS”. All system components, save for the steering system, are connected to the electronic control unit via a comb
type connector. The number of the pins, and hence the type of ECU, vary depending on the version.

Location of the components on the vehicle
Figure 189
78798
1. Controlled-pressure valve - 2. Front axle level sensor - 3. Front air-operated spring - 4. Front axle electropneumatic distribu-
tor - 5. Rear air-operated spring - 6. Check valve - 7. Rear axle electropneumatic distributor - 8. Tank - 9. Pressure control
takeoff - 10. Rear axle level sensor.

ECAS center for 4x2 P tractore rear compressed air suspension system
Figure 190 X1 X2
001717t
Connector X1
Pin Cable Function
1 GN/VE CAN ”L” line
2 --- ---
3 WS/BI CAN ”H” line
4 --- ---
5 8445 Positive from manual leveling push button (Optional)
6 --- ---
7 7440 Positive for power supply direct from the battery
8 6402 Communication line with remote control (pin 3)
9 2294 Line K for diagnosis connector (pin 4)
10 8810 Positive for key-controlled power supply
11 6403 Communication line with remote control (pin 4)
12 0000 Earth
13 8810 Positive for remote control power supply (pin 1)
14 --- ---
15 0402 Negative for remote control (pin 2)
16 --- ---
17 --- ---
18 --- ---
Connector X2
Pin Cable Function
1 --- ---
2 --- ---
3 --- ---
4 9400 Negative for front axle (pin 2) and rear axle (pin 4) solenoid valve (front / rear distributor)
5 5422 Positive for left rear axle level sensor (pin 1)
6 --- ---
7 0400 Negative for rear axle level sensors (pin 2)
8 5421 Positive for right rear axle level sensor (pin 1)
9 5410 Positive for front axle level sensor (pin 1)
10 9425 Negative for rear left chassis control solenoid valve (pin 3) (rear distributor)
11 9423 Negative for power supply solenoid valve (pin 1) (rear distributor)
12 --- ---
13 9424 Negative for rear right chassis control solenoid valve (pin 2) (rear distributor)
14 --- ---
15 --- Negative for front chassis control solenoid valve (pin 1) (front distributor)

Level sensor
Figure 191
Technical data
Power supply voltage Pulse 5 to 15V
Measuring principle Inductive
Current drained Max 100mA
Lever working range Max 100º
The level sensor is made up of a coil fastened to the frame and
a small piston.
By means of a cam and a lever connected to the axle, with each
variation in height the piston is moved inside the coil and
changes the inductance.
The electronic control unit uses these variations to intervene
during the different working stages of the system.
The connecting lever of the sensor has a fixed, non adjustable
measure. 62421
Figure 192
1 2
Figure 193
(counts) 200 204
180 183
160
160
140
138
120
114
100 10 20 30 40 50
--50 --40 --30 --20 --10 80

(degrees)
70
60
52
40
36
22 20
10
0
62422
WORKING CURVE

Axle electropneumatic distributor (78242)

This unit consists of a control solenoid valve and two pneumatic distributors for the management of both sides of the axle.
To prevent pressure transfers between the air springs and hence to stabilise the axle on, the internal connection between the outlets
is fitted with a calibrated hole.
The electropneumatic distributor is connected to the system via a 3-pin connector.
Pin 1 Positive for solenoid valve power supply “A”
Pin 2 Negative
Pin 4 -
Figure 194
78803

Rear axle electropneumatic distributor (78243)

This unit consists of three solenoid valves, ”A”, ”B” and ”C”, and as many pneumatic distributors.
Solenoid valve ”A” is responsible for the management of the supply/discharge distributor.
Solenoid valve ”B” manages the right hand side frame levelling distributor.
Solenoid valve ”C” manages the left hand side frame levelling distributor.
The electropneumatic distributor is connected to the system via a 4-pin connector.
Pin 1 Solenoid valve ”A” power supply positive
Pin 2 Solenoid valve ”B” power supply positive
Pin 3 Solenoid valve ”C” power supply positive
Pin 4 Common negative
Figure 195
78806

Remote control “85065“
Figure 196
78799
The traditional controls in the cab have been replaced by a 1) Front axle selection*
remote control unit which is located on the left. 2) Rear axle selection
3) Level ”1” memory
This device is used to manage the different frame levelling 4) Level ”2” memory
functions. 5) Frame levelling
Its pull-out construction makes it possible to make all the 6) Frame lifting
selections both from inside the cab and from the ground. 7) Frame lowering
8) STOP
It consists of a series of selection buttons and two telltales:
The remote control is connected t the system via a 4-pin
A) Green light for the selection of the front axle * connector
B) Green light for the selection of the rear axle
Pin 1 Power supply positive
Pin 2 Negative
Pin 3 Control unit communication line
Pin 4 Control unit communication line
For the use of the remote control see the ”Operation”
section.
* For full air vehicles only.

”F” Through-wall joint
Figure 197
50355
50341
Cable colour
Pin Function
code
1 - -
2 Air/ECAS suspension 6401
9 Front ECAS solenoid valve 9413

Rear air suspension operating principle diagram
Figure 198
7 8 9
62390
1. Air intake valve with limited return - 2. Manual condensate bleed valve - 3. Air tank - 4. Pressure testing tap -
5. Check valve - 6. Low pressure indicator - 7. Electropneumatic distributor - 8. Electronic levelling valve -
9. Rear axle air spring

FULL air suspension operating principle diagram
Figure 199
10 7
7 8 9 11
12
22 14 21
22
23 11
23
1 6
1 2 1 2
2 3 4 5
62391
1. Air intake valve with limited return - 2. Manual condensate bleed valve - 3. Air tank - 4. Pressure testing tap -
5. Check valve - 6. Low pressure indicator - 7. Electronic levelling valve - 8. Axle air spring - 9. Axle electropneumatic
distributor - 10. Rear axle electropneumatic distributor - 11. Rear axle air spring.

Diagnosis
If an anomaly is found, the CLUSTER display will show an error message which can be yellow (minor anomaly) or red (serious
anomaly).
If yellow symbol 2 (minor anomaly) appears, it will be shown on the left side of the display. If red symbol 3 (serious anomaly) appears,
it will be shown on the right side of the display.
The engine must not be stopped if warning light 1 comes on.
If warning light 3 comes on when the vehicle is running, stop the vehicle and turn the ignition key to “STOP”. Turn the key to “MAR”
again after approximately 7 seconds: if warning light 3 does not go out after approximately 2 seconds, contact your Dealership
immediately.
Figure 200
3
2
79489
1. Low pressure warning light - 2. System failure (YELLOW) - 3. System failure (RED)

As far as electronic systems are concerned, the respective failure messages can be shown in the display (if the CLUSTER is available
in HIGHLINE models).
Figure 201
84589A
The “diagnostic” screen is divided into four columns:

Column 1: Indicates the concerned system
Column 2: Control unit data
Column 3: Type of failure
Column 4: Frequency of failure
To access this screen, the menu control buttons available on the dashboard are used.

Print 603.93.391
ENGINE BRAKE
Simplified system operation
The ”engine brake” system is controlled by the EDC control unit.
There are three engine brake control modes which can be selected using the special switch on the centre dashboard, to be used
in the different types of situations/routes.
With the selector in the rest position, the button on the cab floor is always operational, (for intermittent use on hills and on snow
or ice).
With the selector in position 1 the engine brake is combined with the accelerator pedal, coming into action when the pedal is
released (to be used on long downhill roads with steady gradient).
With the selector in position 2 the engine brake is combined with the service brake, functioning starting from the first section of
pedal stroke and maintaining the position (essentially to be used to reduce service brake wear for routes where much use of it is
needed).
Every time the engine brake is engaged a warning lamp on the cluster turns on.
Engagement of the engine brake in combination with the accelerator pedal disables all the adjustment operations
! connected with the Cruise Control.
ENGINE
EDC
BRAKE
The lighting of the respective warning light (located on the CLUSTER) occurs through the “CAN” line.

System components
Figure 202
1 2
4
6
001521t
ENGINE BRAKE SYSTEM

1. Services air tank — 2. Solenoid valve — 3. Small cylinder - 4. Throttle valve on exhaust manifold — 5. Duplex distributor
(primary / secondary brake switch) — 6. Engine brake switch — 7. Accelerator pedal with position sensor

IMMOBILIZER
Description and operation
For better protection against theft, the vehicles have been equipped with an engine blocking system called ”Immobilizer” which
is automatically activated when the ignition key is removed. The key, in fact, contains an electronic device, known as ”Transponder”,
which transmits a coded signal to a special control unit ”ICU” that enables the engine to be started only if it recognises the code.
General characteristics
System composition
The main components of the system can be summarised as follows:
Immobilizer control unit (ICU)
Anti-theft device + No. 2 keys with electronic Transponder (non separable)
Aerial (on ignition switch)
EDC type fuel flow actuator (ACT)
Code_card (specific card with PIN electronic code and mechanical code)
Installation
For its correct operation, the system requires an installation process consisting of the following stages:
Key training
Actuator training
At the end of the process, the Immobiliser control unit is able to detect tampering attempts by recognising the components
connected to it in a univocal manner (non separable)
Operating principle
With the key set on ”ON”, the Transponder contained in the key generates a code which is received by the Immobiliser control
unit through the aerial.
The control unit transmits to the actuator a request for a validation process by communicating the code received.
The actuator deciphers the code and compares it with the data saved during the installation process.
If the comparison is successful the actuator transmits to the control unit a request to enable fuel flow.
The control unit processes the request and, if everything is correct, sends out the fuel release command to the actuator.
The vehicle can be started.

Components
7
Figure 203
EDC
8
5 6
11
EDC
2
49523
Ref. Description
1 Immobilizer control unit
2 Codecard
3 Electronic key
4 Antenna
5 Electronic fuel injection control unit (EDC)
6 Electro-injectors
7 EDC failure signalling warning light on CLUSTER (display)
8 IMMOBILIZER failure signalling warning light on CLUSTER (display)

“Immobilizer” control unit
Figure 204
The main function of the control unit is:

- to recognize the introduction and rotation of the key in the switch;
- to activate and read the secret code emitted by the ”Transponder”;
- to manage and control the processing of the codes;
- to communicate with the ”EDC” control unit;
- to memorize any failures;
- To diagnose the system.
The control unit is located in the front left part of the cab, behind the steering wheel.

Immobilizer control unit
Figure 205
3 4
3
1
1
B
A
Ref. Description Cable colour

1 Aerial -
A
2 Aerial -
3 - -
1 CAN_L line for EDC control unit (Pin 52) 6109
2 K line for 30-pin test connector (Pin 12) 2292
3 Positive signal for Immobiliser failure warning light 6092
4 CAN_H line for EDC control unit (Pin 53) 0108
B
5 - -
6 Ground 0050
7 Key-operated power supply positive (+15) 8092
8 - -

Electronic keys (No. 2)
Figure 206
The handle of the key contains an electronic device called a ”Transponder” that is NOT powered by any battery, this device
contains and transmits the secret code.
By inserting the key, the ”Transponder” is activated and therefore energized by the radio waves emitted by the antenna
(assembled on the lock of the key switch) and automatically replies by emitting the secret code. If the two codes match, the control
unit enables the vehicle to be started, if they don’t match it blocks the flow of fuel and therefore the vehicle cannot be started.
- Two keys are supplied.
- Each key contains a ”Transponder” with the relative secret code.
- IT IS VERY IMPORTANT to follow the correct procedure for key learning.
The ”Transponders” in the keys cannot be removed.
There is no master key.

Aerial
Figure 207
The antenna is assembled coaxially to the key switch.

Its function is to:
- Provide energy to the ”Transponder” of the key to send the secret code
- Receive the signal from the ”Transponder” and send it to the control unit
The antenna is connected to the control unit at PINS A1 - A2

Code Card
Figure 208
A card that shows two types of code:

- Electronic code
- Mechanical code
Electronic code
This code is essential to start the engine in an emergency situation (key is not recognized, or control unit is not functioning).
The code can be inserted by depressing the accelerator pedal.
Mechanical code
This code is necessary in the event of a request for a duplicate key (mechanical part).
Keep the Code Card in a safe place within reach.

Emergency procedure (starting)

If the vehicle will not start because the key is not recognised, the Immobiliser control unit is defective, etc., it is necessary to perform
a specific starting procedure.
It is indispensable to enter the ”Electronic code”, given in the ”Card Code”, ONLY by working on the accelerator pedal as
described below:
1. Turn the key to ON
2. After about 2 seconds, the EDC telltale starts blinking fast.
3. Press the accelerator pedal and keep it pressed for about 5 to 12 seconds.
4. The EDC telltale begins blinking slowly, as soon as the accelerator pedal is released
5. When the number of blinks corresponds to the first digit of the ”Electronic code”, press the accelerator pedal all the way
and then release it.
(While the pedal is pressed, the EDC telltale stays off).
6. Continue the reading process and the relative pressure on the accelerator pedal for the other four digits of the ”Electronic
code”.
7. At the end of the sequence, if the code introduced is correct and there are no system faults, the EDC telltale stops blinking.
The operation has been concluded correctly.
8. Start the vehicle.
To perform the emergency procedure in case the CAN line is affected by a SERIOUS FAULT, it will be necessary to refer to the
lighting messages of LED (1) available in the U.C.I. in front of the passenger’s seat. Under normal conditions, displaying will occur
by means of the EDC warning light available on the Cluster display.
Figure 209
79370A

Key memorisation process
Figure 210
KEY
1
KEY
2
In the event that the key is lost or for its replacement, a specific procedure must be followed using only the specific diagnostic
devices.
This procedure can only be carried out with the assistance of the Modus, IWT
The key memorization procedure can be carried out even if the EDC control unit is not connected.
The keys have already undergone a learning procedure, and therefore belong to that ICU.
It is possible to ”teach” new and old keys.
In each case the keys used (enabled on ignition) can never be more than three in number and can only be those used during
the last learning process.
A key that has been previously memorized but not inserted in the last learning process will not be able to start the vehicle.
The memorization procedure can only be carried out after having correctly inserted the Electronic Code shown on the Code
Card supplied.
There are two different procedures, depending on the following situations:
- Replacement or addition of one or more keys.
- Installation of a new Immobilizer control unit.
For further clarifications on this matter see manual no. 603.43.613.
Problems during memorization of keys
In the event that the procedure fails, the indicator does not go out.
1) The same key has been inserted twice non-consecutively.
2) The key has not been turned to the stop position quickly enough.
3) More than three keys have been attempted to be memorized.
4) Learning process carried out with keys that are not part of the same KIT (only in installation procedure).
5) Learning procedure carried out with keys that have already been used in other ICU.
6) Problems with learning procedure not being carried out correctly.

System self-testing
After the initial test, the behaviour of the ”code” light informs the operator about system faults, such as:
Light ”always blinking” at a frequency of ”0.3 sec. ON” and ”3 sec OFF” reveals that an error is present or that the starting
procedure in an emergency has not been performed correctly.
Light ”always blinking” at a frequency of ”0.3 sec. ON” and ”3 sec OFF” reveals that no key training process has been performed.
Light ”permanently lit” means that the key training procedure has not been performed correctly.
o As a preliminary step you can display the faults, if any, on the telltale module of the on-board panel by activating the Blink code.
For a more exhaustive diagnosis, however, it is indispensable to use the tools, such as MODUS, available to the service network.

If after accurate diagnosis it is necessary to replace one or more components, proceed as described below
!
ALL ENGINES
PART TO BE PARTS TO BE
OPERATIONS AND NOTES
REPLACED ORDERED
One or two keys • Parts Keys ⇒ Cut the keys according to the mechanical code.
(with one still ⇒ Perform ”Key memorising” in Immobilizer diagnostics (*).
available) NB. In this procedure also enter the remaining working keys
Addition of a otherwise the will NO LONGER be enabled for starting.
key
Steering lock • KEYS KIT with: ⇒ Change the steering lock and ratchets.
and/or ratchets 2 cut Parts
a ts keysSteering
eysStee g ⇒ Perform
e o ”Key ey memorising”
e o s g in Immobilizer
ob e d diagnostics
ag ost cs ((*).
)
ALL the keys lock + Ratchets ⇒ State the new mechanical code on the Code Card.
Ratchets (excluding • KIT with: ⇒ Change the ratchets.
steering lock) 2 traditional keys + NB. Traditional keys means keys without Transponder.
ratchets
Code card • Code Card ⇒ Complete the ”Code Card Duplicate Request Form” printing it
(due to loss) from MODUS and send it as mentioned in the ORDER
MANAGEMENT form of the IVECO SPARES warehouse
concerned.
Aerial • Aerial ⇒ Replace.
ECU Immobilizer • KIT ECU ⇒ Complete the ”New Immobilizer Installation Form” printing it from
Including: MODUS and send it as mentioned in the ORDER
Immobilizer ECU - MANAGEMENT form of the IVECO SPARES warehouse
2 keys to be cut concerned.
New Code Card ⇒ Cut the keys according to the mechanical code.
⇒ Perform ”Key memorising” in Immobilizer diagnostics (*).
NB. At the end of this operation, check that the electronic code
shown on the screen corresponds to the one printed on the Code
Card, if it is different, put the one on the screen on the Code Card.
⇒ In EDC diagnostics perform ”new key recognition”.
⇒ Put the old mechanical code on the new Code Card.
⇒ Scrap the old keys as it will be NO LONGER possible to use them.
EDC control unit • EDC control unit ⇒ The system recognises the new actuator automatically the first time
the ignition key is moved to Drive.
NB. To order the EDC Control Unit complete the specific form
printing it from Modus and sending it to the Market Technical help
Desk.
(*) With MODUS 2.0 (Windows), 1.6C (DOS) or IWT 1.4 release before performing ”New key memorising”, it is
! absolutely necessary to disconnect the EDC . Once the operation has been completed, clear the fault memory to prevent
the error from staying memorised on the actuator.
⇒ For subsequent releases keep to any new instructions given on the screen.

Print 603.93.391
AUTOMATIC GEARBOX ALLISON WTEC III

Gearbox assembly
Figure 211
91613
AUTOMATIC GEARBOX MD 3060 PR/3066 RH REAR VIEW
1. Mounting buffers — 2. Exchanger inlets — 3. Main pressure tap — 4. Solenoid valve assembly for retarder — 5. Identification
plate — 6. Engine rpm sensor — 7. Power take-off connection (available on both sides) — 8. Breather — 9. Heat exchanger
(EuroCargo tector)
Figure 212
52006
AUTOMATIC GEARBOX MD 3060 PR/3066 PR FRONT LH VIEW

1. Start up ring gear — 2. Converter front cover — 3. Power take-off connection (available on both sides) — 4. Main pressure
tap — 5. Retarder accumulator inlet — 6. Oil filling pipe and level rod (available on both sides) — 7. Retarder — 8. Mounting
buffers

PRINCIPLE OF OPERATION
This chapter describes the operation of main MD series gearbox components. The torque paths and the hydraulic system are
also considered.
An MD series gearbox can be split into following parts:
1. torque converter;
2. converter shutting out clutch (“Lockup”);
3. main shaft assembly;
4. hydraulic and electric control module;
5. front crown wheel assembly;
6. middle crown wheel assembly;
7. hydraulic retarder (optional);
8. rear cover assembly;
9. main box assembly;
10. clutches assembly;
11. front support assembly;
12. converter box;
Figure 213
91614

HYDRAULIC RETARDER (OPTIONAL)

Allison MD 3060P/3560P gearboxes can be equipped with hydraulic retarder to provide assisted deceleration during vehicle
braking.
The intarder can be inserted both through the lever with 6 positions present on the dashboard and through the brake pedal when
it is enabled by relating switch.
The intarder is managed by Allison gearbox central unit and is not inserted when the gearbox is in first gear condition.
When the gearbox is with a higher gear that is equal to second ratio, operation logic is as follows:
- with the selector, on the dashboard, that is inserted, on releasing the accelerator pedal, the intarder is inserted. This option
is suggested when long downhill distances are run.
- with the brake pedal enabled to drive the intarder, the brake pedal can be driven via a switch on the dashboard with 33%,
67% and 100% braking torques.
Braking torque percentage depends on brake pedal travel.
The automatic central unit limits intarder action when oil temperature trend is rising.
In particular, the braking torque starts decreasing when oil T is reaching 110 ÷ 115 °C and the torque is entirely shut out when
T is reaching 140 °C.
When the hydraulic retarder is terminating its operation, the oil is drained from the body and returned to outer accumulator.
The three braking rates available via brake pedal are as below:
PEDAL BRAKING MODERABLE

MOVEMENT (mm) PERCENTAGE PRESSURE .
(bar)
1.0 33% 0.13
2.0 67% 0.2 — 0.3
X 100% 0.7 — 0.9
The six braking rates available with the selector on the dashboard are as below:
SELECTING LEVER BRAKING

PERCENTAGE
POSITION
1 16%
2 33%
3 50%
4 66%
5 81%
6 100%

The hydraulic retarder is controlled and assisted by the electronic central unit; the electronic central unit receives signals from:
• one or more resistance modules;
• two solenoid valves;
• an oil temperature sensor in the retarder.
The electronic central unit receives the signal from brake pedal and processes the signals received from system components.
The two normally closed solenoid valves operate simultaneously, and regulate pressure in retarder recess and the application
of vehicle compressed air to accumulator.
Retarder oil temperature sensor sends the signal to the ECU. The central unit checks this data and, in case of high temperature,
actuates a luminous signal on the dashboard before decreasing the braking capability and actuating a downshift program.
In order to optimise vehicle braking, the central unit receives input signals indicated here below:
Retarder permission: it is a signal sent to the central unit to request deceleration function, to be normally inhibited (control switch
on the dashboard) with a slippery ground.
Active ABS: whenever ABS system is acting, a signal is sent to the central unit to prevent retarder insertion.
Retarder working indicator: a signal is sent to the ECU to drive braking rear lights.
Retarder oil overtemperature indicator: it is a signal sent from the central unit to a warning indicator on the dashboard to pre-warn
about a retarder effectiveness decrease, helped by upshift and downshift.
Figure 214
91615
AUTOMATIC GEARBOX RETARDER MODULE MD 3060 PR/3066 PR

1. Retarder module — 2. Retarder accumulator inlet — 3. Exchanger inlets

HYDRAULIC AND ELECTRIC CONTROL MODULE

The hydraulic and electric control module is housed in main gear box lower portion, above oil sump (5).
The module contains valve bodies (4), where there are placed solenoid valves (3) and regulating valves, which, based on
information from the electronic central unit, open and close regulating the flow and pressure of oil needed to operate the various
parts making up the gearbox.
In the module there are also placed oil filters (1) (main filter and lubricant filter), aspiration filter (8), oil level sensor (6), transmission
electric connector (7), turbine speed sensor (2), pressure switch F3 and oil temperature sensor.
Figure 215
52024
In the lower part there are also present the oil drain and main pressure and brake and clutch assemblies intakes.
Figure 216
91616
1. Lock-up clutch pressure — 2. Main filter cover — 3. Lubricant filter cover — 4. Lubricating circuit pressure —
5. Main pressures and clutches — 6. Oil drain

WTECIII GEAR SELECTOR

Figure 217
91617
1. Selector unlocking pushbutton 6. Display diagnosis pushbutton

2. “Mode on” optical indicator Pushbutton N = Neutral gear
3. Secondary mode Pushbutton D = Drive gear
4. ID Mode Pushbutton R = Reverse gear
5. Digital display
Allison gearbox can use two gear selector types:

- pushbutton gear selector;
- lever gear selector.
In both cases there is a display present which shows the various positions of the gearbox and relating gears used, as well as
the diagnosis codes stored by the central unit, the system failure warnings, and the transmission oil level, when the sensor is
present.
“MODE” pushbutton, when pressed, drives a function programmed in the electronic central unit (e.g. driving the power
take-off).
Driving is warned about by an optical indicator.
“ID MODE” shows the type of the function, programmed in the electronic central unit, which is executed when the “MODE”
pushbutton is pressed.
- (Optional) oil level and diagnosis codes can be displayed by pressing the Display Pushbutton in Lever Selector or, in the
case of Pushbutton Selector, by simultaneously pressing “UP” and “DOWN” arrows.
In the version with the selector, by pressing key (6), a set of displays can be performed on the display:
- by pressing key (6) once, “OL” (oil level) is displayed on the display;
- by pressing key (6) 2 subsequent times, the diagnosis is entered into (D1 + code, when there are more failures D2 — D3
….);
- by pressing key “MODE”, the end of errors is reached;
- by keeping either key “MODE” or the double arrows (in the version with the pushbutton) pressed for some seconds,
failures are erased from memory.

SELECTOR OPERATION
By selecting Neutral gear, N appears on the display.
By selecting Reverse gear, R appears on the display.
By selecting Drive gear, the value of the highest gear which can be reached by Transmission appears on the display.
By manually selecting a gear with either the lever or pushbutton panel, the value of relating gear will be shown by the display.
If the display is blinking, gear shift is either temporarily or permanently inhibited. The inhibition disappears if its cause is removed
either within 0.5 sec (depending on engine rpm’s) or 3 sec (depending on accelerator position sensor and output rpm’s) from
gear shift request, otherwise the operator must select the gear again.
If all display segments are simultaneously lit over 12 sec, it means that the electronic central unit has not been completing the
initialisation cycle.
To this situation there will be associated a diagnostic code storing.
A completely off display indicates either a defective connection or a fault in the line communicating with the electronic central
unit.
In the latter case, after 12 sec, “o” will appear on the display.
If the display remains off, the display is not being supplied.
More generally, “o” on the display indicates Selector failure, lever improper positioning between two gear positions or a fault
in its line communicating with the electronic central unit. Each case is associated to a diagnostic code storing.
In case of severe failure, “Check Transmission” warning indicator (on the dashboard) is lit and the gear where Transmission was
forced by electronic central unit emergency procedure appears on the Selector display.

GEARBOX USE
Lever selector
The gear selector is located on the dashboard and is of electromechanical control type; R — N — D positions selection is by pressing
unlocking pushbutton (1) and selectioning desired gear.
By selecting MODE key (3), either an alternative shift program or an alternative function can be used.
Near the selector there is display (4) present where most programmed functions are displayed.
To display diagnostic code data, press pushbutton (5); when displayed code is active, warning indicator (2) is lit.
Figure 218
91618
Pushbutton gear selector

The gear selector has six pushbuttons and one digital display (1). The six pushbuttons are: R (reverse gear), N (neutral gear),
D (drive gear), ⇑ (up), ⇓ (down) and MODE (modality).
Entering forward gears is automatic once D (drive gear) pushbutton has been pressed. Forward gears can also be shifted up
and down by pressing either ⇑ (up) or ⇓ (down) pushbuttons after selecting D (drive gear).
N (neutral gear) pushbutton has an edge jutting out upwards to make touch identification easier.
The digital display only shows one number and one letter at a time.
MODE pushbutton is to activate either a second shift program or a special function, when desired. Function used is warned
about by warning indicator (2) placed above MODE pushbutton.
The activation of most programmed functions is warned about on diplay (1). Access to diagnostic code data is by simultaneously
pressing either ⇑ (up) or ⇓ (down) pushbuttons twice.
To select codes, press MODE pushbutton.
To quit diagnosis system, press N (neutral gear) pushbutton.
When displayed code is active, warning indicator (2) is lit.

Lever / pushbutton selector operation
Figure 219
91619
R Before shifting from forward gears to reverse gear (R), or the other way round, the vehicle has to be completely
stopped. When the reverse gear is in, R appears on the display.
N The neutral position must be used to start up the engine, to make checks on the vehicle and for relatively long
engine idling. If the engine is started up with any other gear, the start up circuit has to be immediatly overhauled.
The neutral position must be entered during power take-off operation under steady conditions.
In these cases, N (neutral gear) will be indicated by the display.
Never go downhill with neutral gear, in order not to seriously damage the gearbox; also, with neutral gear, engine
! brake cannot be utilised.
D In D position, the first gear is entered and, as speed is increasing, the gear is automatically shifted up. As speed
is decreasing, the gear is shifted down. The display initially displays the highest gear available and indicates the gear
being in at that time.
5/4/3/2 In some cases, an automatic shifing down is requested by road, traffic or load conditions, with the selector set on
a position allowing engine braking effect to be gradually increased. On the display there will appear the selected
gear from the time when the gear is actually reached.
1 Enter this gear on travelling on muddy or snowy roads, or on steep slopes, or when manoeuvres are made in
narrow spaces. A low gear provides the vehicle with its maximum traction force and the engine with its maximum
braking power.

DRIVE UNDER SYSTEM FAULTY FUNCTIONING CONDITIONS

At engine start up, the luminous warning device on the dashboard first goes on, then goes off after some instants.
The switching on operation of this luminous warning device indicates either a gearbox failure or a condition where the gearbox
is temporarily inhibited.
To disable the luminous warning device and recover system operation, these operations have to be performed:
• stopping the vehicle at a safe place;
• inserting parking brake;
• simultaneously pressing both ⇑ (up) and ⇓ (down) pushbuttons once (pushbutton gear selector version or lever selector
version diagnosis pushbutton).
If the condition is only temporary, the luminous warning device does not go on and the vehicle will restart working normally.
In the case of a failure, the warning device goes on again, but, anyhow the nearest assistance centre may be reached.
The table at bottom of this page shows gears allowed in the case of either power loss or electronic central unit shutting out.
In other cases, the gear entered at that moment can be kept and no gear reversing is enabled.
Figure 220
91620
Gears which can be used under conditions where system functioning is faulty
Selected gear Enabled gear
R/N N
1 3
2/3/4 3/4
5 4/5
6 5

ELECTRONIC CONTROL SYSTEM

Allison WTECIII gearbox control system is made up of:
- electronic central unit (ECU);
- solenoids on actuator module;
- gear selector;
- accelerator position;
- turbine speed, output shaft speed and engine rpm sensor;
- pressure switch;
oil temperature sensor;
- inner wiring harness;
- outer wiring harness (implemented by vehicle preparator);
Optional components:
- oil level sensor;
special inputs and outputs (PTO — safeties present);
power take-off (PTO);
- interface for CAN line communication;
Retarder-linked components (opt):

- retarder module temperature sensor;
- retarder solenoid;
- accumulator solenoid;
- resistive modules;
- external actuators.

Figure 221
91621
1. Gear selector - 2. Turbine speed - 3. Oil level sensor - 4. Retarder temperature sensor - 5. Oil sump temperature sensor -
6. Engine rpm sensor - 7. Water temperature sensor - 8. Connection connector V.I.W. * - 9. Connector for U.C.I. connection
(Valid for Euromover Cursor) - 10. Central unit V.I.M. (Vehicle Interface Module) - 11. Accelerator pedal / EDC sensor - 12.
Output shaft speed sensor - 13. Pressure switch on actuator module

ELECTRONIC CENTRAL UNIT
Figure 222
52051
WTECIII electronic central unit has three connectors with different colours: black - S, grey - V and blue - T; the connectors
are used for managing the gear selector, interfacing the vehicle and managing transmission components, respectively.
The electronic central unit can be supplied at either 12 or 24 Volts; it manages 13 inputs and 8 outputs.
The gear selector sends signals to vehicle interface systems, and the electronic central unit receives transmission status signals
from relating sensors present on the gearbox.
The electronic central unit contains a program with all calibrations allowing to effect optimal gear shift for every type of
application and use.
After data processing, the central unit sends solenoid valve control signals in order to enter optimal gear shift.
The electronic central unit manages the gearbox; it is also able to identify transmission faults and it stores error codes; further,
the electronic central unit is provided with a function of automatic identification of some connections to remaining control
system.
During its working life, the electronic central unit constantly stores and refines gear shift characteristics.
The central unit makes constant comparisons between the ideal curve stored and actual turbine rpm curve; if the profile of
gear shift performed does not meet the ideal curve, the central unit has the capability to change many parameters in order to
improve next gear shift; this operation is known as central unit ADAPTATIVE CONTROL.
Where a new central unit is present or the central unit is connected to a diagnosis station, the central unit operates in “FAST
ADAPTATIVE” mode.

In this case, to be fast adapted, the central unit makes modifications to main parameters only, in order to approach the ideal curve
for an ideal gear shift.
When the curve has been optimised and the profile of the gear shift is close to optimum profile, the central unit shifts to “SLOW
ADAPTATIVE” mode.
On this step, the electronic central unit always tries to improve gear shifts making their profile converge to the ideal one.
In order that the profile of the gear shifts converges to the ideal one, several gear shifts may be necessary (up to 15 — 20 for each
upshift).
The electronic central unit performs an automatic identification of some system components; this function is active during the
first 30 seconds of the 24 or 49 switching on operations (depending on identified components).
The electronic central unit checks that following components/connections are present:
- retarder module,
- oil level sensor,
- accelerator position,
- engine temperature.
During the first 24/49 switching on operations, the central unit performs no storing of the configuration identified in switching
on cycle.
Only after 25th/50th switching on operation, the central unit stores the components for an automatic identification.
Should before 24th/49th switching on operation one of these components bedamaged, this component could not be
consequently stored; therefore, an automatic identification could not be performed.
Using a diagnosis station, an automatic identification cycle can be activated; this operation can be useful where the identification
of a present component was not correct or after updating the system with new components.

Solenoid valve position in gear actuator assembly
Figure 223
91622
Ref. DESCRIPTION
1 Solenoid valve D (F4) normally closed

2 Solenoid valve C (F3) normally closed
3 Solenoid valve E (F5) normally closed
4 Solenoid valve G normally closed
5 Solenoid valve B — (F2) normally open
6 Solenoid valve F (”Lockup”) normally closed
7 Connector
8 Solenoid valve A (F1) normally open
9 Pressure switch
10 Solenoid valves J x MD3070
11 Solenoid valves N x MD3070
Affected F1÷F5 clutches/brakes

198

Figure 224
ELECTRIC/ELECTRONIC SYSTEM
Wiring harness inside hydraulic and electric control module
91623
1. Oil level sensor — 2. Solenoid valve C — 3. Solenoid valve E — 4. Solenoid valve G — 5. Oil temperature sensor —
EUROCARGO TECTOR
6. Wiring harness connector separator — 7. Solenoid valve — 8. Solenoid valve F — 9. Solenoid valve A — 10. Pressure switch —
11. Turbine speed sensor — 12. Solenoid valve D — 13. Solenoid valve N (MD3070) — 14. Solenoid valve J (MD3070)
12-26
t
Print 603.93.391
Print 603.93.391
Module electric scheme

Figure 225
91624
Key
42600 Switch for gearbox low pressure regulation

44042 Oil level sensor
47012 Gearbox oil temperature sensor
4XXXX Turbine rpm sensor
A F1 clutch circuit control solenoid valve
B F2 clutch circuit control solenoid valve
C F3 clutch circuit control solenoid valve
D F4 clutch circuit control solenoid valve
E F5 clutch circuit control solenoid valve
F Direct gear or lock-up clutch circuit solenoid valve
G Solenoid valve to feed the top portion of bistable valves F1 and F2 (main control pressure)
J Solenoid valve Jx MD 3070 (for 7-gear version)
N Solenoid valve Jx MD 3070 (for 7-gear version)
Solenoid valve resistance to temperature Temperature sensor NTC

Resistance to temperature
(Ω) (Ω)
91625 91626
Nominal value = 3.26± 0.2Ω at 20 °C a — temperature sensor - retarder
b — temperature sensor - torque

VERSION WTECIII — TRANSID IDENTIFICATOR

General description
TransID was introduced in order to allow Allison Transmission to perform modifications to those components which require
modifications to calibrations but retain both their original transmission Assembled Assembly Number and original calibrated ECU
(electronic central unit) Assembled Assembly Number. TransID aim is to reduce Vehicle Original Manufacturer’s need of using
original transmission Assembled Assembly Number and original calibrated ECU (electronic central unit) Assembled Assembly
Number cross reference lists in the cases of such modification to transmission. TransID allows Vehicle Original Manufacturer to
order Assembled Assembly Numbers specific of the transmission and calibrated ECUs (electronic central units) and to receive
all modifications performed on the transmission and all corresponding calibrations. This will reduce the number of Assembled
Assembly Number exchanges which a Vehicle Original Manufacturer must adopt.
TransID system basis is creating a TransID cable in WTEC III system in order to communicate the TransID level signal of the
transmission to the ECU. This cable will be initially directly connected to Analogue Earthing cable (cable 135) to warn about
TransID level 1. TransID levels 2 to 8 will be then indicated by sequentially connecting TransID cable to the Earthing of solenoid
valves A, B, C, D, E, G and F. Corresponding to modifications performed to physical components is the ability of the ECU
(electronic central unit) of V8A WTEC III system to store up to eight calibrations. The TransID cable connection point supplies
a signal which communicates, to the ECU, wich calibration is required by transmission.
Whenever a modification of TransID level is being performed, the new TransID level calibrations will enter PROM Calibration
Configuration System (PCCS) ninety days before entering modification(s) into transmissions production. The new TransID level
calibrations will be loaded into all the ECUs which are programmed and sold after that date. These ECUs will have, in their memory,
the calibrations for the new transmission level and for all previous TransID levels and automatically load the calibration that is
correct for the transmission depending on the TransID signal which was acknowledged by Self-detection during engine first 25
start-ups.
So it is removed the problem for Vehicle Original Manufacturers of coordinating new ECU and new transmission entries, and
allows them to focus on the utilisation of previous level ECU stocks.

Connector to connect wiring harness on the gearbox

Figure 228
RECESS A
RECESS B
49516
PIN DESCRIPTION COLOUR

A Feed of solenoid valves A, D Orange
B Control of solenoid valve C Green
C Control of solenoid valve G White
D Feed of sensors Pink
E Feed of solenoid valve F Green
F Control of solenoid valve F White
G Control of solenoid valve A White
H Feed of solenoid valves B, E Brown
J Control of solenoid valve B Orange
K Control of solenoid valve E Brown
L Feed of solenoid valves C, G Yellow
M Control of solenoid valve D Blue
N Earth Green
P Temperature sensor input Brown
Q - -
R - -
S - -
T - -
U Turbine rpm sensor Blue
V Turbine rpm sensor Orange
X Oil pressure sensor signal input White
Y Oil level signal input Blue
W Identification of transmission Yellow
a - -
b - -
c - -
d - -
e Solenoid J Blue
f Solenoid N Blue
g Feed of solenoid H Yellow

TURBINE SPEED SENSOR
Figure 229
49502
A. Turbine speed sensor — B. Hydraulic and electric control module
“Turbine speed” sensor (A) is placed inside the gearbox on hydraulic and electric control module (B) and counts turbine rpm’s.
The “turbine speed” signal is generated by clutch box groove outline.
The signals from the various speed sensors enable the central unit to determine whether the shift is on selected range. Speed
sensor data are also useful to check clutch (or brake) entry pressure timing, in order to assure as smooth selections as possible.
Hydraulic problems are detected by comparing the speed sensor data of the range being entered at that moment with the data
relating to the speed sensor of this range in ECU (electronic central unit) memory.
Speed sensor resistance value
Resistance Temperature°C Temperature °F

200 Ω -40 -40
300 Ω 20 68
400 Ω 110 230

Print 603.93.381/A
SPEED SENSORS
Output Speed sensor — engine rpm sensor
C
Figure 230
49498
A. Output speed sensor — B. Engine rpm sensor — C. Converter body
“Engine rpm” signal sensor (B) is positioned on the body of converter (C). The signal is generated by ribs on torque converter
pump body.
“Output speed” signal sensor (A) is on gearbox rear cover. The signal is generated by a toothed body fixed on output shaft.
Speed sensor resistance value
Resistance Temperature°C Temperature °F

200 Ω -40 -40
300 Ω 20 68
400 Ω 110 230

Revi - Juli 2005
Print 603.93.391
Connection connectors
Figure 231
A B
49521
“Engine rpm” sensor connector

Ref. DESCRIPTION CABLE COLOUR
A Hi (high) engine rpm sensor Brown
B Lo (low) engine rpm sensor Orange
“Output speed” sensor connector

Ref. DESCRIPTION CABLE COLOUR
A Hi (high) output speed sensor Yellow
B Lo (low) output speed sensor Green

Sensors connector on gearbox
Figure 232
49596
A - -
B - -
C Analogue earth Green
D Temperature sensor retarder Orange
E - -
F - -
G - -
H - -
J - -
K - -
L Turbine rpm sensor Blue
M Turbine rpm sensor Orange
N Engine rpm sensor Orange
P Engine rpm sensor Brown
R Speed sensor output Green
S Speed sensor output Yellow

Components location
Figure 233
4 2 1
101588
1. Allison electronic central unit - 2. DMI electronic central unit - 3. Gear selector pushbutton board — 4. Switches (Allison)

Connection connectors on gearbox
Figure 234
101589
Ref. DESCRIPTION
A Engine rpm sensor (STTC)
B Gearbox connector (STTB)
C Hydraulic and electric control module connector
D Sensors connector
E Output speed connector
F Tachograph sensor prearrangement

Wiring harness — Connector “S”

Figure 235
91627
Key
ECU - S Allison gearbox central unit connector ”S”

STSA Vehicle interface connector
25709 Remote control switch to enable diagnosis from modus
25XXX Remote control switch to exclude retarder from brake pedal
52059 Gear selector

Connector “S” (Black)
Figure 236
49594
PIN CABLE CODE DESCRIPTION

1 142 Serial communication line
2 2297 Diagnosis line K
3 7124 Sensors power supply
4 - Free
5 170 Gear selector pin A
6 171 Gear selector pin B
7 172 Gear selector pin C
8 173 Gear selector pin D
9 174 Gear selector pin E
10 175 Gear selector pin M
11 8159 Engine brake signal
12 - Free
13 6108 CAN line - H
14 180 Gear selector display
15 176 Gear selector pin L
16 136 Power supply from battery + 30 (Gear selector pin R)
17 151 Serial communication line
18 - Free
19 135 Analogue earth
20 164 Retarder request
21 - Free
22 - Free
23 - Free
24 - Free
25 - Free
26 - Free
27 0141 Diagnosis enabling signal from modus (Gear selector pin P)
28 0145 Diagnosis enabling signal from modus
29 6109 CAN line - L
30 - Free
31 - Free
32 0141 Diagnosis enabling signal from modus (Gear selector pin P)

Wiring harness — Connector “V”
Figure 237
91628
Key
ECU - V Allison gearbox central unit connector ”V”

STVA Vehicle interface connector
25007 Remote control switch to put on reverse gear lights
25704 Remote control switch to activate PTO
86127 Electronic central unit for DMI (Data Management Interface)

Connector “V” (grey)
Figure 238
49594

1 7777 Power supply from battery + 30
2 - Free
3 - Free
4 113 Reverse gear lights on signal
5 - Free
6 - Free
7 - Free
8 - Free
9 - Free
10 - Free
11 0155 Connector X3 (DMI) pin 7
13 - Free
14 - Free
15 - Free
16 7777 Power supply from battery + 30
17 0000 Battery earth
19 - Free
20 - Free
21 - Free
22 - Free
23 - Free
24 - Free
25 - Free
26 8815 Locked power supply + 15
27 - Free
28 - Free
29 - Free
30 - Free
31 - Free
32 0000 Battery earth

Wiring harness — Connector “T”

Figure 239
91629
Key
ECU - T Allison gearbox central unit connector “T”

A Connector for connection to chassis cable

Connector “T” (Blue)

Figure 240
49594

1 102 Feed for solenoid valves A, D (J - for 7-gear version)
2 121 Feed for solenoid valves B, E
3 107 Feed for solenoid valve F
4 120 Solenoid valve A (n.o.)
5 103 Solenoid valve C
6 129 Solenoid valve E
7 104 Solenoid valve G
8 - Solenoid valve J (for 7-gear version)
9 124 Sensors power supply
10 156 Accelerator pedal position sensor (optional)
11 164 Retarder request
12 162 Pressure sensor input F3
13 195 Transmission identification (TID2) and accelerator pedal position sensor (optional)
14 141 Engine rpm sensor
15 149 Turbine rpm sensor
16 139 Speed sensor output
17 130 Feed for solenoid valves C, G
18 -
19 116 Feed for solenoid valves H, N (for 7-gear version)
20 128 Solenoid valve B (n.o.)
21 131 Solenoid valve D
22 110 Solenoid valve F
23 127 Solenoid valve H (for 7-gear version)
24 101 Solenoid valve N (for 7-gear version)
25 135 Analogue earth
26 165 Oil level sensor input
27 147 Oil sump temperature sensor input
28 138 Retarder temperature sensor input (optional)
29 -
30 150 Engine rpm sensor
31 140 Turbine rpm sensor
32 148 Speed sensor output

Print 603.93.391
DMI electronic central unit

(Data Management Interface for managing the data between central units and Body Controller)
Figure 241
91236
X1 X2 X3
91237

Pin - out
Connector Pin Cable Description

colour
1 7777 Battery positive +30
2 8815 Locked positive +15
3 0000 Earth
4 5601 Signal (negative) from PTO insertion switch
5 6132 PTO in signal (negative)
6 - Free
7 - Free
8 - Free
X1 9 6108 CAN line - H
10 - Free
11 - Free
13 - Free
14 8118 PTO activation prearrangement from preparators
15 - Free
16 0147 Gearbox idle signal
17 - Free
18 - Free
1 - Free
2 - Free
3 - Free
4 8149 Prearrangement of reverse gear signal from preparators
5 - Free
6 - Free
7 - Free
X2 8 - Free
9 - Free
10 - Free
11 - Free
12 - Free
13 - Free
14 - Free
15 - Free
1 - Free
2 - Free
3 - Free
4 0132 PTO insertion permission signal
X3 5 125 Retarder in signal
6 - Free
7 0155 Gear shift disabled
8 - Free
9 - Free

Vehicle interface wiring harness
Figure 242
61630

Components key
52019 Power take-off insertion switch

52048 Retarder switch
52522 Decelerator insertion lever switch
53509 Inner lights turning on switch
61129 Decelerator lever switch resistances holder
70000 Fuse holder (6 fuses)
72021 Diagnosis connector
7XXXX Preparators prearrangement connector
86116 Body Computer central unit
DDRP Retarder diagnosis connector
STSA Vehicle interface connector
STVA Vehicle interface connector
STZ5 CAN line connector

Cable-tray cable D
Figure 243
61631
Key
53503 Reverse gear lights turning on switch

53508 Switch for antiscrewing with gears in and for turning on reverse gear lights
53520 Engine brake control switch
61130 Resistances holder for decelerator brake pedal pressure switch
78208 Solenoid valve for inserting power take-off
STY21 Connection connector of remote control switch for engine brake control
STY22 Connection connector of reverse gear lights turning on switch

Connector ”D” (white)
Figure 244
50341/A
50355
Ref Description Cable Ref Description Cable

1 - - 21 - -
2 - - 22 - -
3 - - 23 - -
4 - - 24 - -
5 - - 25 - -
6 - - 26 Reverse gear lights 2268
7 - - 27 Reverse gear lights 2226
8 - - 28 - -
9 - - 29 PTO in warning indicator 6132
10 - - 30 PTO permission 8133
11 - - 31 - -
12 - - 32 - -
13 - - 33 +30 from Central Unit EDC7 8159
14 - - 34 - -
15 - - 35 Gearbox idle signal for preparators 0147
16 - - 36 Retarder pressure switches 8135
19 - - 39 - -
20 PTO earth 0000 40 - -

Print 603.93.391
DIAGNOSIS
Diagnostic codes
If the electronic central unit detects a major failure to gearbox, DO NOT SELECT GEAR warning indicator (located on vehicle
instrument panel) is lit, and SELECT reading on gear selection display does not display any reading any more. Gear selection is
limited if DO NOT SELECT GEAR warning indicator is lit. The electronic central unit is not responsive to requests for entering
gears, including changes of direction or selections from or towards Neutral gear.
The electronic central unit stores a diagnostic code when DO NOT SELECT GEAR warning indicator is lit. Use gear selector
display to display the diagnostic code. DO NOT SELECT GEAR warning indicator codes are described in code table.
Figure 245
91620
The operator can accede central unit failure memory by using proper diagnostic instruments, as well as via Gear Selector.
Opening a diagnostic session is according to following modes:
• By pressing, with the vehicle stopped, “Display Pushbutton” once (twice if Transmission is equipped with optional oil level
sensor).
• By simultaneously pressing, with the vehicle stopped, “UP” and “DOWN” arrows once (twice if Transmission is equipped
with optional oil level sensor).
The display will be blinking and display one figure/letter at a time: first it will display code position — d1, d2, d3, etc.. — (in central
unit memory), then it will show the main error code followed by the secondary error code (both being two-figure numbers;
e.g. 2 — 1 — 1 —2 for failure 21 12).
“Mode On” warning indicator is lit to warn about diagnosis mode activation.
To shift to next failure code, press “Mode” pushbutton for a short time.
Codes relating to failures not being present any more during reading can be deleted by keeping “Mode” pushbutton pressed
for about 8 — 10 sec. Performed deletion is confirmed by “Mode On” warning indicator double blinking.
To close the diagnostic session it is sufficient to press once again either the “Display Pushbutton” on lever Selector or the “N”
(Neutral gear) key on pushbutton Selector.

Diagnostic code memory

The code list position is the first item displayed, followed by main code and secondary code. Each item is displayed for two seconds.
This display type (2 sec display) goes on up to next access to code list position. Following list illustrates display cycle using code
25 - 11 as an example:
1. Code list position - d1
2. Main code - 25
3. Secondary code - 11
4. Cycle repetitions - d1
To display positions two, three, four and five (d2, d3, d4 and d5), press MODE pushbutton.
Press MODE pushbutton for a short time after displaying the fifth position in order to resume code list position sequence.
An active code is indicated by MODE IN (indicator activated) warning indicator, which is lit when a code position is displayed.
In normal operation mode, MODE IN display indicates operation in secondary mode.
A code position not containing a diagnostic code in the memory displays “−” both for main and secondary codes. Diagnostic
codes after an empty list position are not stored.
Activated Indicator Deletion. The activated indicator of a diagnostic code can be deleted; so the code can be deleted from the
code list.
Methods for deleting an activated indicator are:
1. Switching off - All activated indicators, but code 69 34 (see code table), are deleted at electronic central unit switching
off.
2. Self-deletion - Some codes delete relevant activated indicator when the condition which caused the code has not been
detected any more by the electronic central unit.
3. Manual deletion - Some activated indicators can be manually deleted in diagnostic display mode after correcting the
condition which caused the code.
If an activated indicator is deleted with the transmission locked in forward gear range or reverse gear (fail-to-range,
! range not reached), the transmission is retained in this position after deletion procedure termination. The Neutral
gear shall be selected manually.

Code and Activated Indicator Manual Deletion from Code List.

To delete either activated indicators or all codes:
1. Open diagnostic display mode.
2. Press MODE pushbutton and keep it pressed for about 3 seconds, until a single sound is emitted. All activated indicators
are deleted. To delete all codes, press MODE pushbutton and keep it pressed for 10 seconds, until two sounds are emitted.
All codes are deleted at electronic central unit switching off.
Quitting diagnostic display mode.

Quit diagnostic display mode by one of following procedures:
1. Pushbutton gear selector: either simultaneously press ⇑ (Up) and ⇓ (Down) arrow keys or press any range pushbutton,
D, N, or R. (D, N, or R). Selection is driven, provided that it is not inhibited by an active code.
2. Wait for the end of time interval available (about 10 minutes); then the system returns to normal operating mode.
3. Switch off power supply towards the electronic central unit (turn off vehicle engine by the ignition key).
Responses to diagnostic codes

Gearbox safe operation is assured by following responses by the electronic central unit to failures:
• DO NOT SELECT GEAR (DNS) response
- Release clutch ”lockup” and inhibit ”lockup” operation.
- Inhibit all selections.
- Have DO NOT SELECT GEAR warning indicator lit.
- Activate buzzer for 8 seconds when the failure is detected the first time.
- Reset selection figure on the display.
- Ignore any range selection input and disactivate pushbutton ”feedback” tone for pushbutton gear selector. On lever gear
selector, the buzzer emits a continuous tone if the selection lever is being displaced to a position different from the one
entered when the failure was detected the first time.
• Solenoid Valve Off (SOL OFF) response
- All solenoid valves are driven off (by electrically putting out solenoid valves ”A” and ”B”, their operation is switched to
hydraulic).
• Return to Previous Range (RPR) response
- When speed sensor ratio or pressure switch F3 checks relating to a selection are not successful, the ECU forces in the
same range as the one driven before the selection.
• Neutral with No Clutches (NNC) response
- When certain speed sensor ratio or pressure switch F3 checks are not successful, the electronic central unit has a neutral
gear condition entered without clutches or brakes being entered.

Diagnostic codes are stored into a list describing the latest code found as the first, up to five codes maximum. The codes in the
list provide information stored as indicated in below table (example codes). Access to code list, main code, secondary code and
activated indicator positions is through gear selector display.
Code List
Main Code Secondary Code Indicator Activated
Position
d1 21 12 YES
d2 41 12 YES
d3 23 12 NO
d4 34 12 NO
d5 56 11 NO
Displayed on diagnostic instrument selector. YES = display
d = “diagnostic” MODE IN
Following paragraphs define the various parts of the code list.

a. Code List Position. Code position in code list. Positions are displayed as ”d1” to ”d5” (Code List Position #1 to Code
List Position #5).
b. Main code. General condition or area affected by failure detected by the electronic central unit.
c. Secondary code. Area or specific condition relating to main code, where the failure was found.
d. Activated Indicator. It indicates the activation of a diagnostic code. The gear selectors display MODE IN.
Code reading and deleting

Diagnostic codes are deleted via the gear selector display. Described reading and deleting method only concerns entering
diagnostic display mode by relating pushbutton and/or gear selector lever displacements.
Diagnostic display mode can be entered to display codes at any speed. Codes can only be deleted when output speed = 0 with
lack of active yield in output speed sensor.
Code Reading. Enter diagnostic display mode by simultaneously pressing ⇑ (Up) and ⇓ (Down) arrow keys.
If an oil level sensor is mounted, the oil level is displayed as the first item. To obtain diagnostic code display, press
! either ⇑ (Up) and ⇓ (Down) arrow keys or DISPLAY MODE pushbutton a second time.

DIAGNOSTIC CODE TABLE

MAIN SEC.
ERROR TYPE TYPOLOGY FIXING
CODE CODE
Check:
- that earthing and power supply connection
directly to battery is thightened and clean
12 ECU supply voltage Level too low - that vehicle batteries are charged
- that alternator charge voltage is not either too low
(< 8 Vdc)
13 ECU supply voltage Level too low or too high
13 - that fuse VIM (Vehicle Interface Module) is in good
(< 10 Vdc)
ECU supply voltage Level too high conditions
23
- that VIM connections are steady, clean and not
(> 33 Vdc)
damaged
- that vehicle wiring harness is correct
- that ECU connections are steady, clean and not
damaged
Check:
- whether transmission is equipped with oil level
Minimum value
12 Oil level sensor
overflowed
- that engine speed sensor, output speed sensor,
14 Maximum
23 Oil level temperature sensor and oil level sensor work
value
correctly
overflowed
- that wiring harness is free from interruptions, short
circuits at the earth or short circuits at the battery
Check:
- that accelerator position sensor (TPS) connector
is corrrectly connected
- that accelerator position sensor (TPS) cable end
Accelerator pedal position Minimum value
12 is corrrectly drawn
overflowed
- that engine fuel lever is at minimum position
21 Accelerator pedal position Maximum
23 - that engine fuel lever provides correct travel on
value
accelerator position sensor (TPS) cable
overflowed
- that wiring harness to TPS is not affected by short
circuits between cables, short circuits at the
earthing or interruptions
- TPS resistance correct working and readings
3 Speed sensor Plausibility
error Check:
14 Engine rpm sensor Plausibility - that speed sensor pin connections are locked,
error clean and not damaged
22
15 Turbine rpm sensor Plausibility - that wiring harness to sensor is not affected by
error interruptions, or short circuits between cables or
16 Gearbox output rpm sensor Plausibility towards the earth
error
Check:
- that ECU connections are steady, clean and not
12 Main gear selector General failure damaged; that gear selector connector has been
13 Fault primary program General failure mounted steadily; cleannes and lack of damages
23 14 Gear selector General failure
15 Sec. pr. cannot be shifted to General failure - that wiring harness to sensor is not affected by
16 Gear selector Display down interruptions, or short circuits between cables, or
short circuits at the earthing
- gear selector correct operation
Check:
- that air temperature is lower than —32 °C
1. If it is, temperature response is correct
12 Oil sump temperature Low 2. If it is not, check that gearbox main connector
is locked, clean and not damaged
- ECU making sure that connections are steady and
pins are clean and not damaged
24 Check:
- that level rod has been installed correctly
- correct oil level
1. if the level is incorrect, top up
23 Oil sump temperature High
2. if the level is correct, check the cause of
overheating
- that ECU and gearbox connectors are locked,
clean and not damaged

MAIN SEC. ERROR TYPE TYPOLOGY FIXING

CODE CODE
00
Gearbox output rpm and reading It detects 0 with gearbox in
11 sensor neutral pos.
Gearbox output rpm and reading It detects 0 with gearbox in pos.
sensor 1 Check:
22 Gearbox output rpm and reading It detects 0 with gearbox in pos. - that speed sensor connector is
sensor 2 tightened, clean and not damaged
33 Gearbox output rpm and reading It detects 0 with gearbox in pos. - that ECU connectors are steady,
25 sensor 3 clean and not damaged
44 Gearbox output rpm and reading It detects 0 with gearbox in pos. - correct oil level
sensor 4 - that wiring harness to sensor is not
55 Gearbox output rpm and reading It detects 0 with gearbox in pos. affected by interruptions, or short
sensor 5 circuits between cables, or short
66 Gearbox output rpm and reading It detects 0 with gearbox in pos. circuit at the earthing
sensor
Gearbox output rpm and reading It detects 0 with gearbox in
77 sensor reverse pos.
Check:
- relevant TPS wiring harness correct
operation in connection to
00 interruptions or short circuits
26 Cooling circuit temperature sensor Not present - that serial connection to engine
11 position computer is steady, clean and without
damages
- that SCI wiring harness is without
open or shorted circuits
- leave vehicle idling with parking brake
in, wheels and vehicle in level position
Check
00 a. level rod to have been correctly
Gearbox in position 1 — pressure Open signal in place of closed installed
sensor F3 signal b. correct oil level
33 Gearbox in position 3 — pressure Open signal in place of closed Check:
32 sensor F3 signal - that main transmission connector is
55 Gearbox in position 5 — pressure Open signal in place of closed connected, steady, clean, not
sensor F3 signal damaged
77 Gearbox in position R — pressure Open signal in place of closed - that ECU connectors are steadily
sensor F3 signal connected, clean and not damaged
- wiring harness for interruptions or
short circuits between cables, or short
circuits at earthing
Check:
- that main transmission connector is
connected, steady, clean, not
12 damaged
33 Oil temperature sensor Too low signal failure - that ECU connectors are steadily
23 Oil temperature sensor Too high signal failure connected, clean and not damaged
- wiring harness for interruptions or
short circuits between cables, or short
circuits at earthing
12
ECU parameters (calibration) Programming error
- Incompatibility
13 ECU parameters (calibration) Programming error
- Factory data
14 ECU parameters Programming error
- Switching off data - if you are able to, reprogram ECU;
15 otherwise replace ECU
- Diagnostic data
- Counter data
ECU parameters Programming error
17 - Customer data
Check:
- that ECU connectors are steadily
Interruption with switching off connected, clean and not damaged
00 ECU power supply - that VIM is steadily connected, clean
operation in progress
and not damaged
- manufacturer-supplied wiring harness
35 for correct power supply and earthing
connections
- connections for power supply directly
16 ECU power supply Interruption with switching off to battery
operation in progress - connections for earthing directly to
battery
- correct switching on connections
MAIN SEC.
CODE CODE
00 ECU and software Incompatibility - if you are able to,
36 01 ECU and software TD not complete reprogram ECU; otherwise
02 ECU and software TD not complete replace ECU
Check:
- that main transmission
connector is connected,
steady, clean, not damaged
12 Solenoid valve A Short circuit at positive - that ECU connectors are
13 Solenoid valve B Short circuit at positive steadily connected, clean
14 Solenoid valve C Short circuit at positive and not damaged
15 Solenoid valve D Short circuit at positive - that wiring harness is not
16 Solenoid valve E Short circuit at positive torn, is without damages,
42
21 Solenoid valve F Short circuit at positive rubbing or screws passing
22 Solenoid valve G Short circuit at positive through it
23 - - - wiring harness for
24 - - interruption or short
26 - - circuits at earthing
- that not authorised repairs
were not performed
change wiring harness
(optional)
Check:
12 Solenoid valve A Short circuit at earth
13 Solenoid valve B Short circuit at earth
14 Solenoid valve C Short circuit at earth
15 Solenoid valve D Short circuit at earth
- that ECU connectors are
16 Solenoid valve E Short circuit at earth
44 steadily connected, clean
21 Solenoid valve F Short circuit at earth
and not damaged
22 Solenoid valve G Short circuit at earth
- wiring harness for
23 - -
interruptions or short
24 - -
circuits between cables, or
26 - -
shortcircuits at earthing
12 Solenoid valve A Open circuit
Check:
13 Solenoid valve B Open circuit
14 Solenoid valve C Open circuit
15 Solenoid valve D Open circuit
16 Solenoid valve E Open circuit
45 - that ECU connectors is
21 Solenoid valve F Open circuit
steadily connected, clean
22 Solenoid valve G Open circuit
and not damaged
23 - -
- wiring harness for
24 - -
interruptions
26 - -
Check:
connector has been steadily
mounted, is clean, and
21 without damages
Power supply line of solenoid valve Overcurrent
- that ECU connectors have
F
26 been steadily mounted, are
46 Power supply line of solenoid valve Overcurrent
clean, and without damages
Power supply line of solenoid valves Overcurrent
27 - that wiring harness is
A, D, B, E, C, G
without open circuits, short
circuits between cables or
short circuits towards the
earth
- replace ECU

MAIN SEC. ERROR TYPE TYPOLOGY FIXING

CODE CODE
Check:
- that output and
turbine speed sensor
01 Gear shift from pos. 0 to 1 Not performed - ratio value not correct connectors are steady,
10 Gear shift from pos. 1 to 0 Not performed - ratio value not correct clean and not
12 Gear shift from pos. 1 to 2 Not performed - ratio value not correct damaged
21 Gear shift from pos. 2 to 1 Not performed - ratio value not correct - that speed sensor
23 Gear shift from pos. 2 to 3 Not performed - ratio value not correct wiring harness is
24 Gear shift from pos. 2 to 4 Not performed - ratio value not correct without interruptions,
35 Gear shift from pos. 3 to 5 Not performed - ratio value not correct
short circuits between
51 42 Gear shift from pos. 4 to 2 Not performed - ratio value not correct cables or short circuits
43 Gear shift from pos. 4 to 3 Not performed - ratio value not correct towards the earth
45 Gear shift from pos. 4 to 5 Not performed - ratio value not correct - leave vehicle idling
46 Gear shift from pos. 4 to 6 Not performed - ratio value not correct with parking brake in,
53 Gear shift from pos. 5 to 3 Not performed - ratio value not correct wheels locked and
64 Gear shift from pos. 6 to 4 Not performed - ratio value not correct vehicle in neutral gear
65 Gear shift from pos. 6 to 5 Not performed - ratio value not correct Check:
XY - - - that level rod has been
correctly installed
- correct oil level
Check:
- that output and
Shift from 0 to 1 - Pressure sensor It does not remain closed turbine speed sensor
01 F3 connectors are steady,
Shift from 1 to 0 - Pressure sensor It does not remain closed clean and not
08 F3 damaged
Shift from 3 to 2 - Pressure sensor It does not remain closed - that speed sensor
32 F3 wiring harness is
Shift from 3 to 4 - Pressure sensor It does not remain closed without interruptions,
34 F3 short circuits between
Shift from 5 to 4 - Pressure sensor It does not remain closed cables or short circuits
54 F3 towards the earth
Shift from 5 to 6 - Pressure sensor It does not remain closed - that main wiring
52 56 F3 harness to
Shift from R to 1 - Pressure sensor It does not remain closed transmission is without
71 F3 short circuits between
Shift from R to 2 - Pressure sensor It does not remain closed cables or short circuits
72 F3 towards the earth
Shift from R to N1 - Pressure sensor It does not remain closed - leave vehicle idling
78 F3 with parking brake in,
Shift from R to 2 - Pressure sensor It does not remain closed wheels locked and
79 F3 vehicle in level
Shift from N3 to N2 - Pressure It does not remain closed position
99 sensor F3 Check:
XY - - - that level rod has been
correctly installed
- correct oil level
- -
08 Not reached - Turbine rpm’s < Engine
18 Neutral position from 1 to N1
rpm’s
Neutral position from 2 to N1 Not reached - Turbine rpm’s < Engine Check:
28 rpm’s - that output and
Neutral position from 2 to N2 Not reached - Turbine rpm’s < Engine turbine speed sensor
29 rpm’s connectors are steady,
38 Neutral position from 3 to N1 Not reached - Turbine rpm’s < Engine clean and not
rpm’s damaged
39 Not reached - Turbine rpm’s < Engine - that speed sensor
Neutral position from 3 to N3
rpm’s wiring harness is
48 Neutral position from 4 to N1 Not reached - Turbine rpm’s < Engine without interruptions,
rpm’s short circuits between
53 49
Neutral position from 4 to N3 Not reached - Turbine rpm’s < Engine cables or short circuits
rpm’s towards the earth
58 Not reached - Turbine rpm’s < Engine - leave vehicle idling
rpm’s with parking brake in,
59 Not reached - Turbine rpm’s < Engine wheels locked and
rpm’s vehicle in level
68 Not reached - Turbine rpm’s < Engine position
69 rpm’s check:
Neutral position from 6 to N4 Not reached - Turbine rpm’s < Engine - that level rod has been
78 rpm’s correctly installed
Not reached - Turbine rpm’s < Engine - correct oil level
Neutral position from R to N1
99 Neutral position from N3 to N2 or rpm’s
N2 to N3 Not reached - Turbine rpm’s < Engine
rpm’s

SEC.
MAIN CO ERROR TYPE TYPOLOGY FIXING
CODE
DE
- -
- -
01 - -
07 Gear shift from pos. 1 to 2 Not perf. - ratio val. not correct - ECU cal.
10
12 Gear shift from pos. 1 to R Not performed - ratio value not correct
Check:
24 Gear shift from pos. 2 to R Not performed - ratio value not correct
27 - that output and turbine
Gear shift from pos. 3 to 2 Not performed - ratio value not correct
32 speed sensor connectors
34 are steady, clean and not
35 damaged
42 - that speed sensor wiring
harness is without
interruptions, short circuits
between cables or short
circuits towards the earth
54 54 Gear shift from pos. 5 to 4 Not performed - ratio value not correct
56 - leave vehicle idling with
64 parking brake in, wheels
65 locked and vehicle in level
70 position
- -
71 Check:
72 Gear shift from pos. R to 1 Not performed - ratio value not correct
- that level rod has been
80 Gear shift from pos. R to 2 Not performed - ratio value not correct
correctly installed
81 - -
- correct fluid level
82 Gear shift from pos. N1 to 1 Not performed - ratio value not correct
- that EEPROM calibration is
85 correct for transmission
Gear shift from pos. N1 to 3 Not performed - ratio value not correct
95
XY - -
Gear shift from pos. N3 to 5 Not performed - ratio value not correct
parking brake in, wheels locked

and vehicle in level position
check:
- that level rod has been
correctly installed
check:
- that output and turbine
speed sensor connectors
are steady, clean and not
07 - damaged
17 Shift from 1 to R - Pressure It is not closed at gear shift termination - that speed sensor wiring
sensor F3 harness is without
27 Shift from 2 to R - Pressure It is not closed at gear shift termination interruptions, short circuits
5
sensor F3 between cables or short
87 Shift from N1 to R - Pressure It is not closed at gear shift termination circuits towards the earth
sensor F3 check
97 - - that transmission connector
is connected, steady, clean,
not damaged
- that ECU connectors have
been steadily connected, are
clean and not damaged
- pressure switch C3 wiring
harness for interruptions or
short circuits between
cables, or short circuits at
earthing

MAIN SEC.
CODE CODE
56 00 Gear shift from position 0 Torque transmission decrease Check:
- ECU calibration not correct - that output and turbine speed
11 Gear shift from position 1 Torque transmission decrease sensor connectors are steady,
- ECU calibration not correct clean and not damaged
22 Gear shift from position 2 Torque transmission decrease - that speed sensor wiring harness is
without interruptions, short
- ECU calibration not correct circuits between cables or short
33 Gear shift from position 3 Torque transmission decrease circuits towards the earth
- ECU calibration not correct - that transmission connector is
44 Gear shift from position 4 Torque transmission decrease connected, steady, clean, not
- ECU calibration not correct damaged
55 Gear shift from position 5 Torque transmission decrease - that ECU connectors have been
- ECU calibration not correct steadily connected, are clean and
66 Gear shift from position 6 Torque transmission decrease not damaged
- ECU calibration not correct - leave vehicle idling with parking
brake in, wheels locked and
77 Gear shift from position R Torque transmission decrease vehicle in level position
- ECU calibration not correct check:
- that level rod has been correctly
installed
57 11 Shift at 1 - Pressure switch F3 It warns about closed in place of leave vehicle idling with parking brake
open in, wheels locked and vehicle in level
22 Shift at 2 - Pressure switch F3 It warns about closed in place of position
open check:
44 Shift at 4 - Pressure switch F3 It warns about closed in place of - that level rod has been correctly
installed
open - correct fluid level
66 Shift at 6 - Pressure switch F3 It warns about closed in place of check:
open - that output and turbine speed
88 Shift at N1-Pressure switch F3 It warns about closed in place of sensor connectors are steady,
open clean and not damaged
99 Shift at N1 or N4 - Pressure It warns about closed in place of - that speed sensor wiring harness is
switch F3 open without interruptions, short
circuits between cables or short
check
- that transmission connector is
connected, steady, clean, not
damaged
- that ECU connectors have been
steadily connected, are clean and
not damaged
- pressure switch C3 wiring harness
for interruptions or short circuits
between cables, or short circuits at
earthing
61 00 “Retarder” overtemperatures - Check:
- “retarder” insertion system
must not allow a simultaneous
insertion of both the “retarder”
and accelerator
- fluid heat exchanger must be
correctly sized to load
62 12 “Retarder” temperature sensor - Check:
engine coolant sensor - whether “retarder” temperature
23 “Retarder” temperature sensor - measured with DDR is matching
engine coolant sensor the codes; if it is not, determine if
32 “Retarder” temperature sensor - the code is active using the gear
selector
engine coolant sensor - sensor connector must be steady,
33 “Retarder” temperature sensor - clean and without damages
engine coolant sensor - ECU connectors must be steady,
clean and without damages
- that temperature sensor circuit is
without interruptions, short
circuits between cables or short
- that serial connection to engine
computer is steady, clean and
without damages
- that SCI wiring harness is without
open circuits or short circuits

MAIN SEC.
CODE CODE
63 00 Failure in input functions -
26 Failure in input functions - Check input wiring harness, switches
40 Failure in input functions - and connectors to determine the
41 Failure in input functions - differences between various inputs
47 Failure in input functions -
Use DDR to read “retarder” steps and
12 “Retarder” modulation - identify problematic cables. Check
device failure wiring harness for short circuits
64
23 “Retarder” modulation - towards the battery, earthing cable
device failure interruption or short circuits towards
the earth
00 Serial communication line Check:
(from EDC) serial connection towards engine
11 Serial communication line computer must be steady, clean and
(from EDC) without damages
Faulty or missing signal
22 Serial communication line SCI wiring harness must be without
66 Engine cooling circuit
(from EDC) interruptions, short circuits or short
temperature data missing
33 Serial communication line circuits towards the earth
(from EDC) if DDR is not available, make sure that
34 Serial communication line transmission ECU connectors are
(from EDC) steady, clean and without damages
27 ECU Internal failure
34 ECU Internal failure Reset diagnostic code and try to start
69 35 ECU Internal failure up the vehicle again
36 ECU Internal failure If the code reappears, replace ECU

Print 603.93.391
ELECTRONIC CENTRAL UNIT DMI (DATA MANAGEMENT INTERFACE) (OPT. 5626)

Central unit DMI is an electronic central unit placed in the central units opening in the cab (at passenger side), and is connected
to other central units via CAN line. Output signals can be captured via the I/O connector to pin - 20. Information availability
depends on vehicle configuration and optional items present. In addition, the DMI can be connected to a board computer to
capture and process data in real time directly via CAN line, according to FMS standard.
The DMI can be used by:
1- Preparators via the I/O connector to pin - 20 (positioned in the central units opening), where following signals are present:
pin - 10 (I/O) - gearbox in neutral position and parking brake in
pin - 17 (I/O) - engine running
pin - 19 (I/O) - brake pedal pressed
pin - 20 (I/O) - clutch pedal pressed
2- Vehicles management system through data transmitted via CAN line. Data can be captured in real time by a board computer.
Through data processing it is possible to:
- obtain information on vehicle operation conditions (times, distances, fuel consumption, 0)
- analyse engine operation conditions and braking system use
- analyse run distances distribution, speeds, stop and start frequencies
3- Interface to PDA (Personal Digital Assistant) which provides vehicle information to be displayed on a palmar computer.
Figure 246
91236
X1 X2 X3
91237

Connector Pin Cable colour Description

1 7777 Battery positive +30
2 8887 Positive locked +15
3 0000 Earth
4 5001
5 5002
6 - Available for future use
X1 9 6108 CAN line - H
10 2290 K line - PDA connector (Palmar connection)
14 5511
16 1000 Gearbox in neutral position and parking brake in signal
17 2226 Reverse gear headlight power supply prearrangement
18 8100
1 3311 Clutch pedal pressed signal
2 1012
3 6108 CAN line - H (preparators connector (STY33)
4 5522
5 1012
6 6109 CAN line - L (preparators connector (STY33)
7 1011
X2 8 - Available for future use
4 3310 Brake pedal pressed signal
X3 5 5003
6 5004
7 9906 Engine running signal
8 9907 Start up confirmation signal

Print 603.93.391
AUXILIARY HEATER WEBASTO

Introduction
Driving a vehicle implies a remarkable physical and mental effort especially in the case of long journeys.
A comfortable environment is essential to safe driving and a prerequisite against possible and unexpected accidents.
For this purpose the vehicle can be equipped with special air-conditioning systems.
This section deals with the AIR TOP 2000 auxiliary heater
Turn off the heater to avoid risks of explosions in proximity of fuel depots, filling stations, store-rooms where dusts
! or fumes could be set on fire (coal depots, wood dust or cereals store-rooms etc.).
To avoid the risk of intoxication do not start the heater in a closed or poorly aerated environment even by means of
a time preselector.
Figure 247
85557
A. Auxiliary heater

GENERAL DESCRIPTION
The air-operated AIR TOP 2000 auxiliary heater, whose working principle is based on the evaporator, is thoroughly separated
from that of vehicle’s engine.
The heater consists essentially of the following components:
- comburent air fan
- heated air fan
- heat exchanger
- burner union and combustion pipe
The heater is controlled and monitored by means of the following units:
- electronic control unit
- flame test
- bulb
- heat lmiting device
- heat sensor
The vehicle’s fuel tank supplies the heater with fuel through a metering pump.
The AIR TOP 2000 heater is started and set in operation by a control unit and a timer device. The latter can be of different types
depending on the vehicle model on which it is assembled.
Specifications and data
Control voltage 24V

Heat power output max 2Kw
regulation 0.9 to 1.8Kw
Fuel consumption max 0,240L/h
regulation 0.12 to 0.22L/h
Electric power output max 22W
regulation 10 to 18W
Output temperature max +40ºC
regulation +10ºC to +35ºC
Air delivery max 70m3/h
Weight 2,6Kg
Figure 248
AIR-OPERATED AIR TOP 2000 HEATER

Exploded view
Figure 249
51747
SYSTEM COMPONENT PARTS

1. Timer - 2. Thermostat - 3. Electronic control unit guard - 4. Air inlet flange - 5. Top case
6. Electronic control unit with temperature sensor - 7. Heat exchanger - 8. Felt packing - 9. Hot air output duct - 10. Seal - 11.
Combustion chamber - 12. Incandescence plug - 13. Bottom case - 14. Identification plate -
15. Engine fuel system connecting unit - 16. Fuel pump - 17. Safety switch - 18. Motor - 19. Seal -
20. Photoresistance
Circuit connection system

a. Heater air input port
b. Hot air output port
c. Comburent air input line
d. Exhaust gas output line
e. Fuel feed line

Adjusting the CO2 content
The auxiliary heater system meets all safety installation standards.

The comburent air is taken from the vehicle exterior.
The exhaust lines are designed to ensure complete discharge of all gases to the vehicle exterior.
All pipes distributing the hot air inside the cab are made of materials guaranteed to resist to very high temperatures (over 130ºC).
The CO2 content in the exhaust gases is adjusted by means of a potentiometer installed in the electronic control unit or control
board. The heater is precalibrated by the Manufacturer depending on the type of hot air and comburent air fan included in the
system (refer to Figure 250).
Regulation of the heater unit is by means of the potentiometer (use a suitable screwdriver).
Turn the pointer to the right to increase the fan rpm and decrease the CO2 content. Turn the pointer to the left to reduce fan
rpm and increase the CO2 content.
If the regulation field is found to be inadequate, for example if the heating and comburent air fan was replaced, proceed to a new
preliminary regulation of the heater unit.
Preliminary heater regulation
NOTE The following procedure deletes all presetting regulation data set by the Manufacturer.
1. Remove the top case.

2. Switch the heater on.
3. Within 5 seconds from switching the unit on, quickly turn the potentiometer twice around the regulation field.
4. Adjust to the desired amount of CO2 content.
5. Switch the heater off.
6. Fit the top case and fasten it securely.
Figure 250
Adjusting the CO2 content from the control board.

OPERATION
Beginning of the combustion phase

Once the desired temperature (ranging between 10º and 45ºC) is preset, the heater can be switched on by means of the
hand/automatic device. The pilot lamp illuminates and the bulb is activated via a pulse regulation system.
The heating and comburent air motor starts to turn at high speed for about 1 sec and then gradually reduces its speed to 30%
of its potential.
If the temperature of the air entering the system is higher than the desired temperature only the heating and comburent air motor
is activated.
On the contrary, if the temperature of the air entering the system is lower than the desired temperature the combustion process
is set in operation.
After 20 seconds approximately the fuel metering pump is started by the electronic control unit or control board.
25 seconds later the fan speed is increased and kept steady for about 20 seconds, i.e. until the beginning of the combustion phase.
From the moment the flame is turned on (indicated by the flame sensor) the combustion process remains steady for the next
20 seconds, that is to say the fan speed is subjected to continuous increasing adjustments until it reaches its maximum figure (this
phase lasts 20 seconds approximately).
Should the flame go out during this phase, the starting procedure is automatically repeated.
If combustion is irregular, after two minutes the fan increases its speed for about 30 seconds with the bulb activated and the fuel
metering pump closed; the starting procedure is then repeated.
If a second attempt at starting the combustion process also proves unsuccessful, the heater is probably defective. It will go off
on its own after 80 seconds approximately.
The heating and comburent air fan is brought to peak speed for about two minutes.
The overall combustion phase lasts for about three minutes.
The control device is fitted with a green led which illuminates and remains on (fixed light) throughout normal operation of the
system. A flashing light by the same led indicates overheating.

Cab heating
While the heater is in operation exhaust gases flow to the heat exchanger. The heat developed by the combustion process is passed
on to the heat exchanger faces, absorbed by the air fed by the fan and then spread into the cab.
The temperature of the air entering the system is measured by a sensor fitted to the heater inlet side.
If the temperature of the outgoing air is lower than the preset value, the heater increases its heating power until it reaches the
specified figure.
When the system is required to work for a long time without stopping, the delivery of the metering pump is reduced every 15
minutes for 20 seconds in order to increase its heating output to 1.1 Kw.
The pump delivery is instead reduced every 30 minutes for 4 seconds if the desired heating output is less than 1.1 Kw.
Once the preset temperature is attained, the system will reduce the speed of the heating and comburent air fan and the delivery
of the fuel metering pump.
- If the temperature of the air entering the heater is higher than the figure selected beforehand, the system will function at
idling speed for about 5 seconds and then switch off the metering pump and terminate the combustion process. The fan
speed will remain steady for about 35 seconds after which it will increase (for at least 120 seconds) to 60% of its maximum
power thus allowing the heater to cool down.
- If the temperature of the air entering the heater is lower than the figure selected beforehand, the fan will function at 30%
of its maximum power.
The heater will remain on even in case a signal from the temperature sensor informs the control unit that the running temperature
is lower than the preselected figure.
Switching the system off

The led goes off as soon as the cutoff device is actuated.
If the combustion phase has not yet started (heater just switched on) or the system is running at idling speed (owing to a higher
temperature of the intake air compared to the preselected value), the heater is immediately turned off.
On the other hand, if combustion is already under way switching off of the heater involves immediate cutoff of the combustion
process. In this case the fan speed will remain steady for five seconds and then be reduced to 60% of its maximum power within
30 seconds. As soon as the control unit receives information from the temperature sensor that the flame has gone off, the fan
will rev up for about one minute and then return to 60% of its power for two more minutes. The system will then be deactivated.

Main system components

Figure 251
Electronic control unit or control board
The electronic control unit is integrated into the heater. It
is designed to ensure correct functioning of the system and
keep the combustion process constantly under control.
The purpose of the heat sensor (inside the control unit) is
to regulate the temperature while a potentiometer (also in
the control unit) is meant to adjust the speed of the heating
and comburent air fan.
The system thus ensures that the desired temperature is
quickly reached inside the cab and then kept steady
according to the preselected figure.
Figure 252 Burner union and combustion pipe

The fuel flowing inside the burner union is distributed into
the combustion pipe through the burner section.
Heating of the heat exchanger results from the combustion
of the fuel and air mix inside the pipe.
Figure 253
Heat exchanger
The heat developed by the combustion process inside the
heat exchanger is sent to the heating and comburent air fan.

Comburent and heating air fan

Figure 254
The comburent and heating air fan conveys the desired
amount of air to be combusted into the burner union
through the comburent air input port.
The heating air is delivered to the heater output port by
means of a fan.
Flame test Figure 255

The flame test is performed by a PTC type low value
resistor which adjusts its resistance depending on flame and
heating degree.
During the heating phase the condition of the flame is
therefore kept constantly under control.
TEST VALUES
- Cold
25ºC resistance 2.6 to 3.4 ohm
5 mA min
- Warm
800ºC resistance 12 to 15 ohm
test current 5 mA min
Figure 256
Bulb
The bulb enables ignition of the air and fuel mix during the
heater starting phase.
The bulb functions as an electric resistor. It is assembled
into the burner union on the flame’s opposite side.
TEST VALUES
- 25ºC resistance 1.3 to 1.44 ohm
test current 5 mA min

Heat limiting device

Figure 257
The purpose of this device is to protect the heater from
excessive operating temperatures.
Overheating protection occurs at a temperature of 150ºC.
Intervention of the heat limiting device stops the supply of
electric power to the fuel metering electric pump and cuts
off the heater which cools down and then closes
electrically.
Should operation of the burner be required after a failure
due to overheating, wait for the heat limiting device to cool
down first; then delete the failure from the control unit’s
memory by turning the heater off and on again.
The limiting device is also activated in case of compressed
air leaks (over 1 mBar) between the air intake side and the
heating air line.
Figure 258
1 2
Fuel metering pump

This pump is made up of fuel feed, metering and cutoff
components.
Fuel supply to the heater is from the vehicle’s fuel reservoir.
Assembly of the pump should be carried out according to
specified installation standards.
The metering pump should be secured by means of a
shock absorber suspension system.
When assembling the pump, follow strictly the fitting
Fuel metering pump position shown in the figure to ensure that all air bubbles
1. Pump - 2. Filter are thoroughly expelled.
The fuel pump is fixed on chassis longitudinal member.

Assembly drawing
HEATER CONNECTION SYSTEM
Figure 259
HEATER INTERNAL CONNECTION SYSTEM

X1. Air fan - X2. Fuel metering pump - X3. Flame sensor - X4. Bulb - X5. Heat limiting device - X6. Main connector - X9.
Temperature sensor - X11. Fault diagnosis K line

ST X1 connection connector
Figure 260
13 8
Cable
Ref. Description
colour
1 Air temperature adjustment thermostat supply 7736
2 Supplementary heater supply 7708
3 Timer supply 7725
4 Supplementary pump supply 7783
5 Supplementary heater blower engine supply 7722
6 Supplementary pump supply 7783
7 Supplementary heater turning-on spark plug supply 7705
8 Supplementary heater ground 0022
9 - -
10 - -
11 Diagnostic K Line 2295
12 Remote control switch supply (control) for TGC -

Print 603.93.391/A
CENTRAL LOCKING SYSTEM WITH

REMOTE CONTROL Figure 223/1
The system consists of one or several (max. 8) transmitters and
a receiver.
Transmitter
The transmitter has a special container of its own, equipped
with an eyelet and ring, in order to be hooked to the key body
and act as a pendant. The shock-proof transmitter container is
also waterproof.
The transmitter sends the receiver a variable code (rolling
code) by means of a radiofrequency signal at 433.92 MHz (EC
Directive 95/56).
It is equipped with two buttons for door opening and closing,
respectively.
By keeping the button pressed down for 50 msec, the variable
code will be fully transmitted. If the button is actuated
continuously, however, transmission will be interrupted after
5 seconds (± 10%).
The transmitter operating range is 10 m.
The battery guarantees a 2 years’ service life. Following the
replacement, the transmitter may be briefly actuated twice in
order to restore synchronism with the receiver. This sequence
is also permitted at any time other than battery replacement
Receiver 105989
The receiver is housed inside a container with a black cover,
which includes a transmitter programming button (easily TRANSMITTER
accessible and protected against unintentional actuation), a
programming check green LED, and a 8-way connector. Figure 223/2
It is housed in the lower portion of the dashboard, in front of
the passenger’s seat.
The receiver antenna is housed inside the container, too.
The receiver receives and decodes the code sent by the
transmitter and may store up to eight codes. The door opening
and closing controls come both from the transmitter and the
door locks.
The receiver directly drives the door lock actuators (2- or
4-door).
If the vehicle is in the key-ON condition (+15 is available), the
receiver will perform no actuation through the remote control.
The receiver manages synchronization between the locks, and
resumes correct alignment through a sequence of two or
several transmitter or lock key drives.
Blinker control
Door lock locking and opening will be signalled by the lighting
of the indicator lights. Therefore, the receiver need be
interfaced with the Body Controller control unit that manages
the above-mentioned lights.
The receiver features an output (to the ground) that is
connected in parallel with the emergency light switch. The
latter consists of an unstable button that actuates and
deactivates the blinking sequence (blinker signal).
Description of blinker controls:
- T1 = 300 msec (Start)
- T2 = 350 msec (Delay - Lock)
- T2 = 1050 msec (Delay - Unlock)
- T3 = 80 msec (Stop)
105990
CENTRAL LOCKING CONTROL UNIT (RECEIVER)

Revi - July 2005
Control unit pin-out (receiver)
Cable
Pin Function
colour code
1 Blinker control 7728
2 Central locking motor power supply (door closing) 9965
2 Battery positive 7777
4 Tachograph clock ground 0066
5 Central locking control (door closing) 0065
6 Central locking control (door opening) 0064
7 +15 power supply 8887
8 Central locking motor power supply (door opening) 9964
Programming
The programming status makes it possible to get the receiver to recognize the transmitters enabled to control the respective
functions.
Programming is accessed through the rest state when the +15 signal is not available.
The receiver may be controlled by a transmitter with a universal code as long as at least one transmitter is not programmed.
After a variable code (other than the universal code) has been programmed, the latter will not be recognized any longer.
Transmitters are programmed in the FIFO mode.
Two transmitter programming modes are available:
- simplified programming: it allows you to program the transmitters quickly. It can be actuated until 128 actuations are performed
after the first programming, or until it is disabled.
- Protected programming: it guarantees the customer against the risk of other transmitters being programmed without the
knowledge of the customer themselves. It involves using a password (shown on the tag enclosed with the transmitter) that
can be obtained from the transmitter code.
Simplified programming
The first code (and the subsequent ones as well) are programmed as follows:
- press the button on the receiver: the LED will light up and blink;
- the operator presses, while keeping the button on the receiver pressed down, any of the key of the transmitter, which sends
out the code;
- the receiver stores, after detecting three subsequent transmission instances (with the current checksum), the code into the
memory;
- the receiver LED will, at the very time when it recognizes the code, light up steadily, thus signalling that the code has been
received: now the operator may release the transmitter button to end the programming.
Simplified programming disable
Simplified programming may be disabled by entering the password as follows:
- press the small button on the receiver: the LED will light up and blink;
- release the small button: the LED will blink once;
- enter, by means of the small button, a 4-digit code (password): each digit shall be included between 0 and 9 (code written on
the label delivered together with the transmitter). An optical feedback will be generated on the LED every time the small button
is pressed;
- after each digit has been entered, wait for the LED to blink again to request the next digit, up to the fourth digit;
- the procedure will be over after the last digit is entered.
Protected programming
Every time a new transmitter is to be recognized after firstly entering the password, you will need to enter the password of any
of the transmitters previously stored into the memory. Correct recognition of the password will be signalled by the LED blinking
after the password has been entered (if the password is not recognized, the LED will remain ON for 10 seconds). When the LED
is blinking, keep the receiver button pressed down, then transmit with the new remote control to be stored into the memory, by
following the simplified programming instructions.

Revi - July 2005
Print 603.93.391
Fault diagnosis
Fault symptoms - general
Fault Possible cause Remedy
The heater goes off No combustion after starting or after Turn the heater off briefly and then turn it
starting procedure is repeated on again
The flame goes off during heater Turn the heater off briefly and then turn it
operation on again
Heater overheating and pilot lamp blinking Ensure the heating air is free to flow inside
the pipe
Turn the heater off briefly and then turn it
on again
Feed voltage low Charge batteries.
Turn the heater off briefly and then turn it
on again
The heater emits black smoke Comburent and/or exhaust air pipes Ensure comburent/exhaust air is free to
restricted flow inside the pipe
Fault symptoms - heater running

Fault Fault occurs after ... Remedy
The heater does not start, all leds off on immediately Faulty wiring, fuse cut off
control board
The heater does not start, led on immediately Faulty fan/control unit, fan locked
Speed extremely low, no starting immediately Faulty command or defective installation of control instrument
The fan motor starts briefly but the fan 1 second Bulb short circuit or cut off, flame test cut off or control unit faulty
does not turn
Motor off, no washing 5 seconds Fan motor locked
Washing occurs after 1 second Faulty flame
Washing occurs after 20 seconds Electronic control unit voltage low
Washing occurs after 2 mins; no pulses 120 seconds Pump wiring faulty or pump failure
from metering pump
Washing occurs after 40 to 120 sec. Metering pump or overheating protection device cut off
Washing occurs after 230 seconds Incorrect fuel quantity, fan slow/faulty, burner scaled, comburent
and exhaust air lines restricted, heat exchanger scaled, fuel
metering pump locked
Washing performed while heater is Faulty component: flame test, bulb, sensor, overheating, metering
running pump.
Motor off, no washing while heater is Fan motor either faulty or locked
running
Metering pump cycle discontinued; 30 while heater is Flame goes off owing either to gas bubbles in combustion lines or
seconds max speed after starting running upwind at the exhaust gas output port
procedure is repeated

Repair operations
Repair and maintenance operations should be carried out only by skilled personnel.
Isolate system batteries before carrying out any repair operation on the auxiliary heater.
! Especially before the cold season operate the heater at regular intervals for at least ten minutes approximately every
four weeks to prevent mechanical parts from locking with time. Overhaul the entire system before the winter season.
Carry out the following operations to obtain maximum performance from your heater:
- Ensure the heating air input and output ports are not restricted by dirt or foreign bodies; this could result in heater
overheating and consequent release of the heat limiting device.
- Clean the auxiliary heater from the outside.
- Check efficiency of electrical connections.
- Check the condition of exhaust gas and comburent air lines. Ensure they are not damaged or restricted.
- Check fuel line for tightness and filter efficiency. Replace the latter, if necessary.
Error code display

The following error codes are shown on the digital timer display in the event of a system failure.
Error code Description

F 01 No starting (after performing the starting procedure twice)
F 02 Flame cutoff
F 03 Low voltage or overvoltage
F 04 Immediate flame recognition failure
F 05 Flame test cutoff or short-circuit
F 06 Temperature sensor cutoff or short-circuit
F 07 Fuel metering pump cutoff or short-circuit
F 08 Fan motor cutoff or short-circuit or defective fan motor running speed
F 09 Bulb cutoff or short-circuit
F 10 Overheating

Print 603.93.391
FAULT DIAGNOSIS
Electronic system troubleshooting can be performed either by Cluster or the Modus and IT 2000 diagnosis instruments.
Making diagnosis by means of Cluster allows you to estimate in advance the condition of the faults found in the system, whereas
diagnosis instruments are essential to perform complete diagnosis and properly correct single faults.
Each instrument displays a diagnosis and repair work guide.
Diagnosis Instruments
MODUS (Maintenance and Diagnostic System)
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 catalogue referencing,
time-charts, etc.
The vehicle is equipped with a 30-pole diagnosis takeoff for interface with the vehicle.
IWT (IVECO Wiring Tester)
The IVECO Wiring Tester expands and integrates the MODUS.
This instrument has been designed by IVECO in order to improve the vehicle’s electric and electronic system diagnosis.
The vehicle is equipped with a 30-pole diagnosis takeoff for interface with the instrument. The connection between the instrument
and the diagnosis takeoff must be made by means of the cable identified by number 4.
IT 2000 (IVECO Electronic Tester)
The IVECO electronic tester makes it possible to immediately intervene on the vehicle, by recognizing the latter by means of the
chassis number.
This tester stores the results of the diagnostic operations carried out.
It can also be used as a portable PC, and is set for remote diagnosis.
By using MODUS as a mother station, IT 2000 can be updated and configured.
IT 2000 is interfaced with the vehicle by means of a 30-pole diagnosis takeoff.
Figure 261
101586

System initialization screen

By turning the key to MAR, the system carries out a general check of the vehicle’s conditions.
The figure below illustrates the screen shown by the display when the system is being initialized.
Figure 262
85156
If an anomaly is found, the display shows the symbol of the electronic system involved.
For Highline versions, the error code can be displayed by entering menu DIAGNOSTIC by means of the dedicated controls available
on the dashboard right-hand frame (see figure below).
Figure 263
86157
1. Previous page (ESCAPE) - 2. Submenu display/display actuation (OK) - 3. Upper line displaying button -
4. Lower line displaying button

DIAGNOSTIC screen (oly for Highline versions)

To display the DIAGNOSTIC screen, turn the key to MAR with the engine stopped, wait for the initialization screen to be displayed,
then press button “OK” to actuate the display. Use buttons ∧ or ∨ to move along until the DIAGNOSTIC screen is found.
Figure 264
85158
These screens show the faults found in the various electronic systems (EDC, ABS, ECAS, etc.).
Meanings of anomaly codes

When a anomaly has occurred on the display, the DIAGNOSTIC menu shows the following data:
Figure 265
86159
1. Symbol of the system affected by the fault

2. Control unit data
3. Type of fault
4. Anomaly occurrences

Description of fault codes (SPN)
2 XX YY
Fault code (DTC)
EuroCargo code
Control unit code (e.g. 21 = 1B)


Text
on Measuring Values to
Component failure DTC FMI Visible anomaly Possible cause Controls to be carried out Notes
Cluster conditions be found
EEPROM 22101 12 Internal EEPROM error to IBC unit Verify vehicle battery supply.
Print 603.93.391
(EEPROM CHECKSUM), the error If there is an error in diagnosis
CAN occur in case the battery instrument, carry out a failure
voltage is too low (ex. 9V), or in deletion, if the error remains
case the EEPROM is defective or replace the IBC unit.
EUROCARGOI TECTOR 12 - 26 t
faulty.
22102 12 It is impossible to activate loads, Unit output driver temperature Check wiring on all IBC outputs
TROUBLESHOOTING
lights, unavailable windscreen greater than maximum value verifying that they are not
wiper activation. (Tmax= 150°). shortcircuited to ground.
Functionalities managed by IBC Probable short-circuit to ground of
ECU are not guaranteed. one of the Body Controller unit
outputs (under this condition the
Instrument Body Controller (IBC)
IBC ECU enters in protection

mode).
IBC 22103 0 On left Cluster part, IBC words Supply voltage on line 1 included 1) Check voltage between Iveco
remain turned on. between 32 and 36 Volts. Body Controller unit pin C2
The affected voltage value is (supply line 1 input) and chassis
greater than the threshold. ground.
The error could be denounced and 2) Verify battery voltage, or
not monitored when starting the presence of battery chargers
engine. connected during startup.
Verify voltage regulator and
alternator status.
IBC 22103 1 On left Cluster part, IBC words Supply voltage on line 1 included 1) Check voltage between Iveco
remain turned on. between 8 and 18 Volts. Body Controller unit pin C2
The affected voltage value is lower (supply line 1 input) and chassis
or greater than the threshold. mass.
The error could be denounced and 2) Verify battery voltage and its
not monitored when starting the status.
engine. Verify voltage regulator and
alternator status.
IBC 22103 3 On left Cluster part, IBC words Supply voltage on line 1 greater 1) Check voltage between Iveco
remain turned on. than 36 Volts. Body Controller unit pin C2
not monitored when starting the status, check presence of battery
engine. chargers connected during startup.
alternator status.

251
Text
252
IBC 22103 4 On left Cluster part, IBC words Supply voltage on line 1 lower than 1) Check voltage between Iveco
remain turned on. 8 Volts. Body Controller unit pin C2

than the threshold. ground.
engine. Check voltage regulator and
alternator status.
IBC 22104 0 On left Cluster part, IBC words Supply voltage k30 on line 2 1) Check voltage between Iveco
remain turned on. included between 32 and 36 Volts. Body Controller unit pin D12
The affected voltage value is (supply line 2 k30 input) and chassis
not monitored when starting the presence of connected battery
engine. chargers during startup.
alternator status.
IBC 22104 1 On left Cluster part, IBC words Supply voltage k30 on line 1 1) Check voltage between Iveco
remain turned on. included between 8 and 18 Volts. Body Controller unit pin D12
or greater than the threshold. ground.
engine. 3) Check TGC status.
4) Verify voltage regulator and
alternator status.
5) Verify (10A) fuse 8-10-11-20
integrity.
IBC 22104 3 On left Cluster part, IBC words Supply voltage k30 on line 2 greater 1) Check voltage between Iveco
remain turned on. than 36 Volts. Body Controller unit pin D12
not monitored when starting the status, check presence of
engine. connected battery chargers during
startup.
Check voltage regulator and
alternator status.
Print 603.93.391
Text
IBC 22104 4 On left Cluster part, IBC words Supply voltage K30 on line 2 lower 1) Check voltage between pin
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remain turned on. than 8 Volts. D12 of Iveco Body Controller unit

engine. Check TGC, voltage regulator and
alternator status.
Verify integrity of (10A) fuses
8-10-11-20.
IBC 22105 0 On left Cluster part, IBC words Supply voltage K30 on line 3 1) Check voltage between pin
remain turned on. included between 32 and 36 Volts. D9 of Iveco Body Controller unit
The affected voltage value is (supply line 3 input k30) and chassis
alternator status.
engine. 3) Check TGC status.
4) Verify voltage regulator and
alternator status.
5) Verify integrity of (10A) fuses
8-10-11-20.
remain turned on. greater than 36 Volts. D9 of Iveco Body Controller unit
Check voltage regulator and
alternator status.

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Text
254

alternator status.
Verify integrity of (10A) fuse 20
(line 3 supply).
alternator status.
engine (EEC1 message - Engine 3) Check TGC status.
Starter Mode = 0001 or 0010). 4) Verify voltage regulator and
alternator status.
8-10-11.
remain turned on. greater than 36 Volts. D13 of Iveco Body Controller unit
alternator status.
Print 603.93.391
Text
Print 603.93.391

engine (EEC1 message - Engine 3) Check TGC, voltage regulator
Starter Mode = 0001 or 0010). and alternator status. 4) Verify
integrity of (10A) fuses 8-10-11.
remain turned on. included between 32 and 36 Volts. C14 of Iveco Body Controller unit
alternator status.
remain turned on. included between 8 and 18 Volts. C14 of Iveco Body Controller unit
engine (EEC1 message - Engine 3) Check TGC status.
Starter Mode = 0001 or 0010). 4) Verify voltage regulator and
alternator status.
8-10-11.

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Text
256
remain turned on. greater than 36 Volts. C14 of Iveco Body Controller unit

alternator status.
remain turned on. than 8 Volts. C14 of Iveco Body Controller unit
alternator status.
8-10-11.
Right direction 22108 5 On the left Cluster part a lamp is The current value acquired from Verify integrity of the 3 lamps,
lights displayed; a right indicator light is the unit is below the current check electric continuity on wiring
not turned on. threshold (I< Is) - (Is=2.7A). between IBC output (pin C20) and
One of the 3 lamps (21W) is burnt. ground.
The error is detected only when Check with indicator operation
the supply voltage is included whether between pin C20 and
between 18V and 24V. ground there is a 24V voltage.
Verify with amperometric pliers the
current value absorbed on IBC pin
C20.
If the absorbed current is < 2.7A,
open circuit.
Print 603.93.391
Text
Right trailer 22109 5 In the left Cluster part a lamp and The error is detected only when all Verify status of the two lamps on
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direction lights a plug are displayed. lamps are open circuited and the right trailer side.
No right trailer direction light is related supply is included between If the two lamps are ok, by
turned on. 18V and 32V. operating the left direction
Outputs C18 or C17 indicator, check output voltage
short-circuited to ground. between pin C19 IBC and chassis

If one of the IBC outputs, for ground (it must be included
actuating arrows on left side, is between 18V and 32V).
short-circuited to ground, the Check wiring integrity between pin
system detects an error (open C19 and lamps.
circuit on right trailer side).
Right 2210A 6 On the left Cluster part a lamp is Internal IBC unit driver Verify lamp status on right side
vehicle/trailer displayed. short-circuited to ground or (vehicle/trailer).
direction lights By actuating the right direction overloaded or with Verify by actuating the right
indicator, vehicle or trailer right overtemperature. direction indicator between pin
direction lights are not turned on. Body Controller outputs C20 or C20 and ground and between pins
C19 short-circuited to ground or C19 and ground an output voltage
current overload. equal to 24V.
The error is detected only when Check wiring integrity between IBC
voltage is included between 18V outputs and lamps.
and 32V.
Left direction 2210B 5 On the left Cluster part a lamp is The current value acquired from Verify integrity of the three lamps
lights displayed; a left trailer indicator the unit is below the current on tractor left side.
light is not turned on. threshold (I< Is) - (Is=2.7A). If the three lamps are ok, by
One of the 3 lamps (21W) is burnt. actuating the left direction
The error is detected only when indicator, check output voltage
the supply voltage is included between IBC pin C18 and chassis
between 18V and 24V. ground (it must be included
between 18V and 32V).
Check wiring integrity between pin
C18 and lamps.
Left trailer 2210C 5 In the left Cluster part a lamp and The error is detected only when all Verify integrity of the two lamps on
direction lights a plug are displayed. lamps are open circuited and the tractor left side. If the two lamps are
Left trailer direction lights turned related supply is included between ok, by actuating the right direction
off. 18V and 32V. Outputs C19 or C20 indicator, check output voltage
short-circuited to ground. If one of between IBC pin C17 and chassis
the IBC outputs, for actuating arrows ground (it must be included between
on right side, is short-circuited to 18V and 32V).
ground, the system detects an error Check wiring integrity between pin
(open circuit on left trailer side). C17 and lamps.

257
Text
258
Left 2210D 6 By actuating left direction Internal IBC unit driver Verify lamps status on left side
vehicle/trailer indicator, vehicle/trailer left short-circuited to ground or (vehicle/trailer).

direction lights direction lights are not turned on. overloaded or with Verify by actuating the left direction
overtemperature. indicator between pin C18 and
Body Controller outputs C18 or ground and between pin C17 and
C17 short-circuited to ground or ground an output voltage equal to
current overload. 24V.
The error is detected only when Check wiring integrity between IBC
voltage is included between 18V outputs and lamps.
and 32V.
Front right 2210E 5 On the left Cluster part a lamp is The current value acquired from Verify lamp status, wiring integrity
parking and displayed. the unit is below the current between output pin D16 and
clearance lights threshold (I< Is) - (Is=2.7A). lamps.
One of the 2 lamps (5W) is burnt. Check with connected running
The error is detected only when lights the output voltage between
the supply voltage is included pin D16 and chassis ground.
between 18V and 24V.
Rear left 2210F 5 On the left Cluster part a lamp is The current value acquired from Verify lamp status, wiring integrity
parking lights displayed. the unit is below the current between output pin D15 and
threshold (I< Is) - (Is=2.7A). lamps.
Right and left 22110 5 On the left Cluster part a lamp is The current value acquired from Verify lamp status and correct
number plate displayed. the unit is below the current sizing, wiring integrity between
lights Right/left number plate lights do threshold (I< Is) - (Is=2.7A). output pin D14 and lamps.
not turn on or remain on even One of the 2 lamps (5W) is burnt. Check with connected running
with key on stop. The error is detected only when lights the output voltage between
Print 603.93.391
Text
Print 603.93.391
Front right 22111 6 On the left Cluster part a lamp is Internal IBC unit driver Verify lamp status (vehicle/trailer).
parking and displayed. short-circuited to ground or Verify with connected running
clearance lights One of the following lights does overloaded or with lights between the following pins
or Rear left not turn on or remains always on: overtemperature. D17, D16, D15, D14 and ground
parking light or front right parking and clearance One of the Body Controller an output voltage equal to 24V.
Right/left lights or rear left parking light or outputs (pin D16 or D15 or D14 or Check wiring integrity between IBC
number plate right/left number plate lights or D17) short-circuited to ground or outputs (D17, D16, D15, D14) and
lights or Right right trailer parking and clearance current overloaded. lamps.
trailer parking lights. The error is detected only when
and clearance the voltage is included between
lights 18V and 32V.
Front left 22112 5 On the left Cluster part a lamp is The current value acquired from Verify lamp status.
parking and displayed, parking and/or the unit is below the current Wiring integrity between output
clearance lights clearance lights turned off. threshold (I< Is) - (Is=2.7A). pin D6 and lamps.
Rear right 22113 5 On the left Cluster part a lamp is Open-circuited IBC output D5. Verify lamp status.
parking lights displayed, rear left parking light The current value acquired from Wiring integrity between output
does not turn on. the unit is below the current pin D5 and lamps.
threshold (I< Is) - (Is=1.8A). Check with connected running
One of the 2 lamps (5W) is burnt. lights the output voltage between
The error is detected only when pin D5 and chassis ground.
the supply voltage is included
Rear right and 22114 5 On the left Cluster part a lamp is Open-circuited IBC output D7. Verify lamp status and correct
left clearance displayed, rear right and left The current value acquired from sizing, wiring integrity between IBC
lights clearance lights do not turn on. the unit is below the current output pin D7 and lamps.
threshold (I< Is) - (Is=1.8A). Check with connected running
One of the 2 lamps (5W) is burnt. lights the output voltage between
The error is detected only when pin D7 and chassis ground: it must
the supply voltage is included be equal to 24V.

259
Text
260
IBC Front left 22115 6 On the left Cluster part IBC Internal IBC unit driver Verify lamp status (vehicle/trailer).
parking and words are displayed. short-circuited to ground or Verify with connected running

clarance lights One of the following lights does overloaded or with lights between the following pins
or Rear right not turn on or remains always on. overtemperature. D6, D5, D7, D8 and ground an
parking light or Front left parking and clearance One of the Body Controller output voltage equal to 24V.
Right/left lights or rear right parking light or outputs (pin D6 or D5 or D7 or Check wiring integrity between IBC
clearance lights right/left clearance lights or left D8) short-circuited to ground or outputs (D6, D5, D7, D8) and
or Left trailer trailer parking and clearance current overloaded. lamps.
parking and lights. The error is detected only when
clearance lights the voltage is included between

18V and 32V.
Right and left 22116 5 On left Cluster part, a lamp is Open-circuited IBC output pin D4. Verify lamp status and correct
fog lights displayed. The current value acquired by the sizing, wiring integrity between IBC
Right/left fog lights are not turned unit is below the current threshold output pin D4 and lamps.
on. (I < Is) - (Is=1.8A). Check with connected low beams
One of the 2 lamps (5W) is burnt. the output voltage between pin D4
The error is detected only if supply and chassis ground: it must be equal
voltage is included between 18V to about 24V.
and 32V.
IBC Right/left 22117 6 On the left Cluster part, the IBC Short-circuited IBC outputs pins Verify lamp status and correct
vehicle fog words are displayed, right/left D4 and/or D3. sizing, wiring integrity between IBC
lights or vehicle fog lights or right/left The current value acquired by the outputs pins D4, D3 and lamps.
right/left trailer trailer fog lights are not turned unit on pin D4 or D3 is above the Check with connected low beams
fog lights on. current threshold (I > Is) - (Is=1.8A). the output voltage between pin D4
The error is detected only if supply and chassis ground: the measured
voltage is included between 18V voltage must be equal to about
and 32V. 24V.
Print 603.93.391
Text
Left stop light 22118 5 On left Cluster part, a lamp is Open-circuited or positive Verify lamp status and correct
Print 603.93.391
displayed. short-circuited IBC output pin D18. sizing, wiring integrity between IBC
Left stop light is not turned on, or The current value acquired by the output pin D18 and lamp.
is always on. unit is below the current threshold Check by pressing the brake pedal
(I < Is) - (Is=0.9A). the output voltage between pin
The lamp (5W) is burnt. D18 and chassis ground: the

The error is detected only if supply measured voltage must be equal to
voltage is included between 18V about 24V.
and 32V.
Right stop light 22119 5 On left Cluster part, a lamp is Open-circuited or positive Verify lamp status and correct
displayed. short-circuited IBC output pin D19. sizing, wiring integrity between IBC
Right stop light is not turned on, The current value acquired by the output pin D19 and lamp.
or is always on. unit is below the current threshold Check by pressing the brake pedal
(I < Is) - (Is=0.9A). the output voltage between pin
The lamp (5W) is burnt. D19 and chassis ground: the
The error is detected only if supply measured voltage must be equal to
voltage is included between 18V about 24V.
and 32V.
IBC Left stop light 2211A 6 On left Cluster part, IBC words Ground short-circuited IBC Verify lamp status and correct
or right stop are displayed. outputs pins D18 and/or D19 sizing, wiring integrity between IBC
light or right/left Right and/or left stop lights, or and/or D20. outputs pins D18, D19, D20 and
trailer lights right/left trailer lights are not The current value acquired by the lamps.
turned on. unit on pin D18 or D19 is above Check by pressing the brake pedal
the current threshold (I > Is) - the output voltage between pin
(Is=0.9A) - or the current value D18 and chassis ground, between
acquired by IBC on pin D10 is > pin D19 and chassis ground, and
1.8A. The error is detected only if between D20 and chassis ground:
supply voltage is included between the measured voltage must be
18V and 32V. equal to about 24V.
IBC Right/left arrow 2211B 2 On left Cluster part the IBC IBC inputs pin A35 and pin A25 1) Verify wiring integrity between
control switch words are displayed. both ground short-circuited. pin A34 and shunt, and between
(shunt). Right and left direction lights pin A25 and shunt.
simultaneously blink.. 2) Check shunt status and verify
presence of a short circuit between
pins A35 and A25.

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262
IBC Windscreen 2211C 2 On the left Cluster part, the IBC Interrupted supply line 6. Verify integrity of 10A fuse 15
wiper switches words are displayed. If simultaneously active switches, a (Supply line 6).

The windscreen wiper does not short circuit is possible between pin Check wiring integrity between
work, it is impossible to activate A24 (low speed), A29 pins A24, A29, A30, A9 and control
intermittence, low/high speed (intermittence), A30 (high speed) switch for windscreen wiper
and windscreen washer. and A9 (windscreen washer) for actuation speed selection.
IBC.
IBC Engine brake 2211D 2 On the left Cluster part the IBC Simultaneously active IBC inputs Verify wiring integrity between pin
mode selector words are displayed, engine pins A15 and A5. A15 and selector and between pin
brake intervenes both upon Possible short circuit between A5 and selector.
accelerator pedal release and by them. Under static conditions between
pressing brake pedal. pin A15 and ground, and between
pin A5 and ground a short circuit
must be detected.
Rear transverse 2211E 2 Blocked rear differentials. Simultaneously active IBC inputs Verify wiring integrity between pin
differential pins A19 and A20. A19 and selector and between pin
locking selector Possible short circuit to ground A20 and selector.
between them. Verify selector functionality.
IBC Front brake air 2211F 0 On the left Cluster part the IBC Front air brake pressure included 1) Verify with key on stop,
pressure sensor words are displayed, the front between 12 and 22 bars. between IBC pin A2 and A3 (wiring
brake air pressure value is not The acquired input voltage on pin side, or directly on sensor) a
displayed on Cluster. A21(Vout) divided by the supply resistance equal to 4KOhm.
voltage value (Vc) for front air 2) Check correct sensor supply
pressure sensor is included (5V) provided by IBC unit between
between 0.6V and 1V. pins A2 and A3.
3) Verify wiring integrity between
pin A21 and sensor.
Front brake air 2211F 1 On the left Cluster part the IBC Front air brake pressure included 1) Verify with key on stop,
pressure sensor words are displayed, the front between 0.5 and 6.5 bars. between IBC pin A2 and A3 (wiring
between 0.14V and 0.38V. pins A2 and A3.
pin A21 and sensor.
Print 603.93.391
Text
Front brake air 2211F 3 On the left Cluster part the IBC Front air brake pressure greater 1) Verify with key on stop,
Print 603.93.391
pressure sensor words are displayed, the front than 22 bars. between IBC pin A2 and A3 (wiring
pressure sensor is greater than 1 (5V) provided by IBC unit between

Volt. Short circuit between pins A21 pins A2 and A3.
and A2. 3) Verify wiring integrity between
pin A21 and sensor.
Front brake air 2211F 4 On the left Cluster part the IBC Front air brake pressure lower than 1) Verify with key on stop,
pressure sensor words are displayed, the front 0.5 bars. between IBC pin A2 and A3 (wiring
displayed on Cluster. A21 (Vout) divided by the supply resistance equal to 4KOhm.
pressure sensor is lower than 0.14 (5V) provided by IBC unit between
Volt. pins A2 and A3.
Short circuit to ground between 3) Verify wiring integrity between
pins A21 and A3. pin A21 and sensor.
Rear brake air 22120 0 On the left Cluster part the IBC Front air brake pressure included 1) Verify with key on stop,
pressure sensor words are displayed, the rear between 12 and 22 bars. between IBC pin A2 and A3 (wiring
between 0.6 Volt and 1 Volt. pins A2 and A3.
pin A13 and sensor.
Rear brake air 22120 1 On the left Cluster part the IBC Front air brake pressure included 1) Verify with key on stop,
pressure sensor words are displayed, the rear between 0.5 and 6.5 bars. between IBC pin A2 and A3 (wiring
between 0.14 Volt and 0.38 Volt. pins A2 and A3.
pin A13 and sensor.

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264
Rear brake air 22120 3 On the left Cluster part the IBC Front air brake pressure greater 1) Verify with key on stop,
pressure sensor words are displayed, the rear than 22 bars. between IBC pin A2 and A3 (wiring

pressure sensor is greater than 1 (5V) provided by IBC unit between
Short circuit between pins A13 and 3) Verify wiring integrity between
A2. pin A13 and sensor.
Rear brake air 22120 4 On the left Cluster part the IBC Front air brake pressure lower than 1) Verify with key on stop,
pressure sensor words are displayed, the rear 0.5 bars. between IBC pin A2 and A3 (wiring
pressure sensor is greater than 0.14 (5V) provided by IBC unit between
Short circuit to ground between 3) Verify wiring integrity between
pins A13 and A3. pin A13 and sensor.
IBC Brake air 2212B 0 On the left Cluster part the IBC The brake air pressure sensor Verify voltage between IBC pins A2
pressure sensor words are displayed, the front supply voltage (Vc) output on IBC and A3.
supply brake air pressure value is not pin A2 is included between 6V and The measured value must be equal
displayed on Cluster. 8V. to 5V.
The error is detected only when
the maximum voltage is included
between 18V and 24V, and key on
running (K15 ON).
supply brake air pressure value is not pin A2 is included between 2V and The measured value must be equal
displayed on Cluster. 4V. to 5V.
The error is detected only when Check wiring status between pin
the maximum voltage is included A2 and pressure sensor.
running (K15 ON).
Print 603.93.391
Text
Print 603.93.391
supply brake air pressure value is not pin A2 is greater than 8V. The measured value must be equal
displayed on Cluster. Possible short circuit to positive to 5V.
between pin A2 and +Vbatt. Verify that no short circuits occur
The error is detected only when between pin A2 and +Vbatt.

running (K15 ON).
IBC Brake air 2212B 4 On the left Cluster part the IBC The brake air pressure sensor 1) Verify voltage between IBC
pressure sensor words are displayed, the front supply voltage (Vc) output on IBC pins A2 and A3.
supply brake air pressure value is not pin A2 is lower than 2V. The measured value must be equal
displayed on Cluster. Possible short circuit to ground to 5V.
between IBC outputs pins A2 and Check that pins A2 and A3 are not
A3. mutually in short circuit.
The error is detected only when
running (K15 ON).
CAN VDB CAN Line 2212C 2 The CAN text si displayed on On VDB CAN line no messages Verify VDB CAN line status,
Cluster. are transmitted, probable Vehicle measuring between pins 21
Data Bus in OFF status. (CANH) and 22 (CANL) with key
Open-circuited VDB CAN line on stop, a resistance value must be
both on tachograph and on EDC detected equal to 60 Ohm ±3%.
sides.
The error CAN be diagnosed with
Modus/IT2000 tool only after having
carried out a VDB CAN line reset.
2212D 31 Not programmed IBC unit. Verify with diagnostic tool
After IBC ECU replacement, no (Modus/IT2000) upon unit data
programming has been carried out reading the presence of
with Modus on new unit. programming-pertaining data.

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266
Stepper motor 21704 12 Blocked speed and level Failure or anomaly of stepper Try carrying out an after run by
indicator pointers on Cluster. motor adjusting the pointers disconnecting Cluster 5A supply

movement. fuses (18 and 1) for 10 seconds.
If pointers are still blocked, replace
the Cluster.
IC Fuel level sensor 21705 3 The Cluster displays an ideogram Open circuit or short circuit on fuel Verify wiring between Instrument
for level indicator. level sensor, the error is detected Cluster and fuel level sensor.
Instrument Cluster (IC)
The fuel level indicating pointer only if it is active for more than 4 Verify continuity between pin 11
on Cluster is always fixed on seconds. (fuel level indicator signal) and
reserve or maximum. sensor, and between pin 12 (fuel

level indicator ground) and sensor
ground. Measuring directly only on
sensor, a 210 Ohm resistance must
be detected.
Oil level sensor 21706 0 Wrong oil level measure. Voltage delta acquired as input to Verify sensor resistance: at the
Cluster (pin A14) of oil level sensor, temperature of 20°C, the resistance
between first and second must be equal to 13 Ohm. Check
measures, is above the established wiring integrity between sensor
range. and Instrument Cluster (pins A14,
A15).
Oil level sensor 21706 1 Wrong oil level measure. Voltage delta acquired as input to Verify sensor resistance: at the
Cluster (pin A14) of oil level sensor, temperature of 20°C, the resistance
between first and second must be equal to 13 Ohm. Check
measures, is above the established wiring integrity between sensor
range. and Instrument Cluster (pins A14,
A15).
Oil level sensor 21706 3 Wrong oil level measure. Voltage provided as output from Verify sensor resistance: at the
Cluster (pin A15) to oil level sensor temperature of 20°C, the resistance
is above the established range. must be equal to 13 Ohm.
Cluster output pin A15 Check wiring integrity between
short-circuited to positive or sensor and Instrument Cluster
open-circuited. (pins A14, A15).
Oil level sensor 21706 4 Wrong oil level measure. Voltage provided as output from Verify sensor resistance: at the
Cluster (pin A15) to oil level sensor temperature of 20°C, the resistance
is below the established range. must be equal to 13 Ohm.
Cluster output pin A15 Check wiring integrity between
short-circuited to ground. sensor and Instrument Cluster
(pins A14, A15).
Print 603.93.391
Text
Ambient 21707 3 The Cluster displays -40 as Cluster pin A10 input Verify sensor resistance: measuring
Print 603.93.391
temperature external temperature value, open-circuited or short-circuited between Cluster pins A10 and A9
sensor namely the minimum default to positive. (wiring side) a resistance must be
value. detected that changes from 0.5 to
50 KOhm according to the
temperature (NTC 0.5-50 KOhm,

±5% at the temperature of 25°C).
Ambient 21707 4 The Cluster displays an icon Cluster pin A10 input Verify sensor resistance: measuring
temperature showing an analogue instrument. short-circuited to signal/chassis between Cluster pins A10 and A9
sensor The external temperature value ground. (wiring side) a resistance must be
being read with the diagnostic detected that changes from 0.5 to
instrument is equal to 80° (max. 50 KOhm according to the
value). temperature (NTC 0.5-50 KOhm,
±5% at the temperature of 25°C).
CAN CAN line 2170C 2 On Cluster the CAN text remain No message on CAN line Vehicle Verify VDB CAN line status,
on. Data Bus, or Bus off. measuring between pins 21 (CAN
VDB CAN line H short-circuited to H) and 22 (CAN L) with key on
ground, or CAN H and CAN L stop, a resistance value must be
lines mutually short-circuited. detected equal to 60 Ohm ±3%.
Check that 30-pole (diagnostic
connector) pin 21 (CAN H) and
ground are not mutually
short-circuited.
CAN 2170D 2 On Cluster the CAN text The Cluster does not receive the Verify VDB CAN 1 line:
remains on. CAN message from Iveco Body 1) Measuring with key on stop,
Controller 2 ECU (IBC), possible directly on IBC unit (connector C)
problem on VDB CAN line, between pin C11 (CAN L) and pin
information on IBC unit are not C12 (CAN H), a resistance value
transmitted to Cluster. must be detected that is equal to 20
KOhm.
2) Measuring with key on stop,
wiring side, between pin C11 (CAN
L) and C12 (CAN H) of connector
C, a resistance value must occur that
is equal to 60 Ohm ±3%.
3) Verify that between 30-pole
pins 21 (CAN H) and 22 (CAN L)
there is an impedance value equal
to 60 Ohm ± 3%, (measuring with
key on stop and connected units).

267
Text
268
CAN 2170E 2 It is impossible to start the engine The Cluster does not receive the Verify VDB CAN 1 line:
(active dragging), on Cluster CAN message (EEC1) from EDC 1) Measuring with key on stop,

Immobilizer icon and CAN text unit, dealing with engine directly on IBC unit (connector B)
remain on. information. between pin 52 (CAN L) and pin
Problem on VDB CAN line. 53 (CAN H), a resistance value
Possible communication problem must be detected that is equal to
between EDC and IMMOBILIZER. 120 Ohm.
wiring side, between pin 52 (CAN
L) and 53 (CAN H) of connector B,

a resistance value must occur that
is equal to 120 Ohm
(corresponding to internal
tachograph resistance).
CAN 2170F 2 The tachograph remains off. The Cluster does not receive the Verify VDB CAN1 line:
CAN message from tachograph 1) Measuring with key on stop,
(TCO). directly on tachograph (white
Possible problem on VDB CAN connector ”A”) between pin 8
line, information about tachograph (CAN L) and pin 4 (CAN H), a
are not transmitted to Cluster. resistance value must be detected
that is equal to 120 Ohm (internal
tachograph resistance).
wiring side, between pins 8 (CAN
L) and 4 (CAN H) of connector A,
a resistance value must occur that
is equal to 120 Ohm
(corresponding to internal EDC
resistance).
4) Check integrity of 5A fuse 1,
and 10A fuse 3.
Print 603.93.391
Text
CAN ETC 21710 2 The Cluster does not receive the Verify VDB CAN1 line:
Print 603.93.391
(Allison CAN message from electronic 1) Verify that between 30-pole
Gearbox) gearbox unit (ETC). pins 21 (CAN H) and 22 (CAN L)
Possible problem on VDB CAN there is an impedance value equal
line, information about gearbox are to 60 Ohm ± 3%, (measuring with
not transmitted to Cluster. key on stop and connected units).

CAN EBC 21711 2 The Cluster does not receive the Verify VDB CAN1 line:
(Braking CAN message from electronic 1) Verify that between 30-pole
System) braking system unit (EBC). pins 21 (CAN H) and 22 (CAN L)
ABS/EBS Possible problem on VDB CAN there is an impedance value equal
line, information about EBC ECU to 60 Ohm ± 3%, (measuring with
are not transmitted to Cluster. key on stop and connected units).
CAN ECAS 21712 2 On Cluster the CAN text The Cluster does not receive the Check fuse 5 of assembly 70000/2
remains on. Impossible CAN message from ECAS unit. that supplies ECAS unit.
suspension handling/leveling VDB CAN line connector X1 pins Verify VDB CAN line by measuring
through cabin remote control. 1 (CAN L) and 3 (CAN H) are between connector X1 pin 1 (CAN
open-circuited, information L) and pin 3 (CAN H) a resistance
pertaining suspension unit (ECAS) value that is equal to 60 Ohm ±3%.
are not transmitted to Cluster. Verify that between 30-pole pins
21(CAN H) and 22(CAN L) there
is an impedance value equal to 60
Ohm ± 3%, (measuring with key on
stop and connected units).
DRIVELINE 21713 2 The Cluster does not receive the Verify VDB CAN1 line:
RETARDER CAN message from intarder unit. 1) Verify that between 30-pole
Possible problem on VDB CAN pins 21 (CAN H) and 22 (CAN L)
line, information about intarder there is an impedance value equal
ECU are not transmitted to Cluster. to 60 Ohm ± 3%, (measuring with

269
Text
270
CAN MIRROR 21714 2 On the left Cluster part the CAN The Cluster does not receive the Verify VDB CAN1 line (green
CONTROLLER text remains on; it is impossible CAN message from the MIRROR sheath):

to activate heating and mirror CONTROLLER unit, possible 1) Measuring with key on stop,
handling. problem on VDB CAN line, lack of wiring side, between YELLOW
communication with mirror connector pins 19 (CAN L) and 20
control unit. (CAN H) there must be a resistance
value equal to 60 Ohm ±3%.

3) Check integrity of 5A fuse 16.
EEPROM 21701 12 Faulty physical memory for Verify vehicle battery supply.
Instrument Cluster unit. If there is an error in diagnosis
A CHECKSUM error is detected. instrument, carry out a failure
Internal EEPROM error to IBC unit deletion, if the error remains
(EEPROM CHECKSUM), the error replace the IBC unit.
CAN occur in case the battery
voltage is too low (ex. 9V), or in case
the EEPROM is defective or faulty.
Print 603.93.391
Component
DTC FMI Error type Visible anomaly Possible cause Recommended repairs Notes
failure
00 00 Insufficient fuel level in the Check the fuel level The possible grade of smoke
Print 603.93.391
tank. is due to the fact that, in case
of insufficient fuel, the
gearcase tries to
compensate by extending
the excitation time of the
injectors; when the fuel

arrives too much of it is used.
00 00 Fuel suction pipe in the tank Check whether the priming In case some shavings have
“EDC 7” injection system
partially clogged due to pump on the prefilter works been sucked (due to works
impurities or distortion properly. carried out by the producer
caused by overheating. on the fuel tank) perform an
If the pump knob remains
accurate cleaning of the tank.
sucked downwards because
of the suction pressure, As a matter of fact the
disassemble and check the problem might occur again
tank suction pipe. because of other shavings
remained inside the tank.
If the suction pipe is all right,
replace the prefilter.
00 00 Air intake upstream of the Check the O-Rings and the
fuel gear pump. proper connection of the pipe
unions between the tank and
the fuel pump (fasteners must
be out and unions well
hooked).
00 00 Fuel leaks from the unions or Check the O-Rings and the Unless the leak is significant,
low- pressure pipes proper connection of the pipe no performance anomalies
downstream of the fuel unions downstream of the fuel are detected
pump. pump (fasteners must be out
To check that the O-Rings
and unions well hooked).
are all right, extract the fuel
Check visually that the return piping from the tank,
low-pressure pipes are not plug its end hermetically and
damaged. operate the priming pump
by pressurizing the low
pressure circuit.

271
Component
272
failure
00 00 Excessive fuel blow-by from Disconnect the fuel return
rail overpressure valve. piping and check visually if
there is significant blow-by

from the overpressure valve.
00 00 Signal from key to gearcase Check the wiring.

EDC cuts off.
00 00 Fuel filter clogged. Replace the fuel filter. Remove the cause of the
filter clogging (empty and
clean the tank and the part

of hydraulic circuit upstream
of the filter, perform a
replenishment with clean
fuel).
00 00 Inefficient high-pressure Engine test with diagnostic Replace the high-pressure
pump. instrument. pump after having excluded
all the other possible causes.
00 00 Injector with shutter or Engine test with
solenoid core (mechanical Modus-IWT-IT2000.
part) locked in open
In case of lack of diagnostic
position.
instruments, the injector not
working is easily detectable
feeling by hand the absence of
pulsations in the relevant high
pressure pipe.
00 00 Injector locks in open In case of lack of diagnostic
position (now and then). instruments, the injector not
working is detectable feeling
by hand the absence of
pressure pipe.
Print 603.93.391
Component
failure
00 00 Injector locked in open In case of lack of diagnostic Generally, in presence of
Print 603.93.391
position (irreversibly). instruments, the injector not these symptoms, it is
working is detectable feeling instinctive to give up starting
by hand the absence of the engine. By keeping on
pulsations in the relevant high trying, however, it is possible
pressure pipe. to start the vehicle in order
to reach an Iveco workshop.

By insisting the engine starts
with one cylinder missing
and little by little the grade of
smoke decreases and it
disappears.
00 00 Injector locked in closed In case of lack of diagnostic
position. instruments, the injector not
working is detectable feeling
by hand the absence of
pressure pipe.
00 00 Clutch switch: signal missing. Operate the clutch by fully If there is no pressed clutch
pressing the pedal and reading signal, the gearcase doesn’t
the status parameters by detect it because it regards
means of the diagnostic this condition as normal. By
instrument on Modus. pressing the clutch pedal
with Cruise Control/Power
If the switch is all right and well
takeoff engaged, the engine
adjusted, check wiring,
reaches the peak rpm
connections and correct
because it tries to
assembly of the switch.
compensate the lower
engine load in order to keep
constant the speed
previously set.

273
Component
274
failure
00 00 Significant fuel blow-by After having excluded all the This problem might be due
inside the cylinder head other system to the lack of replacement of
from one or more high electrical/electronic a pipe after disassembling, or

pressure pipes and almost anomalies, disconnect (from to a wrong assembly of the
total absence of pressure in the filter support) the injector pipe that have damaged its
the rail. blow-by return piping, put its sealing end on the injector.
end in a transparent container
After having positioned a
and try starting. If the fuel flow
new pipe in its seat (with the
in the injector return is
injector fastening screws
significantly much higher than
loosen), it is necessary to
the normal one, and at the

progressively and
same time the parameter
alternatively tighten to the
reading displays the lack of
prescribed torque the
pressurization of the rail,
injector screws and the pipe
replace the damaged high
ring nut, making sure to ease
pressure pipe.
the correct mating of the
pipe end with the fuel arrival
seat in the injector.
SENSORS - 01 00 NO AVAILABLE No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC SYMPTOM behalf of the driver. sensor short-circuited or parameters by means of the
The sensor is incorporated
PRESSURE open-circuited. diagnostic instrument: in
in the EDC gearcase and it is
presence of this error, the
not individually replaceable.
supercharging air pressure will
be fixed at 970 mbar The possible painting of
engine/gearcase may
Contact the Help Desk and
compromise the correct
follow the instructions for the
detection of the
possible replacement of the
environment pressure.
gearcase.
Print 603.93.391
Component
failure
SENSORS - 01 01 SHORT CIRCUIT TO No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
Print 603.93.391
ATMOSPHERIC POSITIVE behalf of the driver. sensor short-circuited or parameters by means of the
engine/gearcase may
detection of the
gearcase.
SENSORS - 01 02 OPEN CIRCUIT OR No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC SHORT CIRCUIT TO behalf of the driver. sensor short-circuited or parameters by means of the
PRESSURE GROUND open-circuited. diagnostic instrument: in
engine/gearcase may
detection of the
gearcase.
SENSORS - 01 03 NO SIGNAL No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC behalf of the driver. sensor short-circuited or parameters by means of the
engine/gearcase may
detection of the
gearcase.
SENSORS - 01 04 SIGNAL NOT No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC PLAUSIBLE behalf of the driver. sensor short-circuited or parameters by means of the
engine/gearcase may
detection of the

gearcase.

275
Component
276
failure
SENSORS - 01 05 SUPPLY OVER THE No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC NORMAL RANGE behalf of the driver. sensor short-circuited or parameters by means of the

engine/gearcase may
detection of the
gearcase.
SENSORS - 01 06 SUPPLY BELOW THE No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC RANGE behalf of the driver. sensor short-circuited or parameters by means of the
engine/gearcase may
detection of the
gearcase.
SENSORS - 01 07 VALUE OVER THE No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC NORMAL LIMIT behalf of the driver. sensor short-circuited or parameters by means of the
engine/gearcase may
detection of the
gearcase.
SENSORS - 01 08 VALUE BELOW THE No reaction noticeable on Environment pressure Reading of measurable EDC pilot light off.
ATMOSPHERIC LIMIT behalf of the driver. sensor short-circuited or parameters by means of the
engine/gearcase may
detection of the
gearcase.
Print 603.93.391
Component
failure
SENSORS - 02 00 NO AVAILABLE Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
Print 603.93.391
COOLANT SYMPTOM temperature instrument ground-short-circuited or parameters: in presence of this
TEMPERATURE fixed at limit stop and pilot open-circuited water error, the water temperature
light lighted up. tem?perature sensor read on the gearcase will be
the same of the engine oil one.
Check by means of a
multimeter that the sensor is
all right (R = approx. 2,5
kOhm at 20 °C) between pins
1 and 2 of sensor itself.
If the sensor is not damaged,
check the wiring between the
sensor connector (wiring side)
pin 1 and connector EDC pin
C18, between sensor
connector (wiring side) pin 2
and connector EDC pin C36.
SENSORS - 02 01 SHORT CIRCUIT TO Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
COOLANT POSITIVE temperature instrument ground-short-circuited or parameters: in presence of this
Check by means of a
C18, between sensor

277
Component
278
failure
SENSORS - 02 02 OPEN CIRCUIT OR Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
COOLANT SHORT CIRCUIT TO temperature instrument ground-short-circuited or parameters: in presence of this
TEMPERATURE GROUND fixed at limit stop and pilot open-circuited water error, the water temperature

Check by means of a

C18, between sensor
SENSORS - 02 03 NO SIGNAL Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
COOLANT temperature instrument ground-short-circuited or parameters: in presence of this
Check by means of a
C18, between sensor
Print 603.93.391
Component
failure
SENSORS - 02 04 SIGNAL NOT Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
Print 603.93.391
COOLANT PLAUSIBLE temperature instrument ground-short-circuited or parameters: in presence of this
Check by means of a
C18, between sensor
SENSORS - 02 05 SUPPLY OVER THE Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
COOLANT NORMAL RANGE temperature instrument ground-short-circuited or parameters: in presence of this
Check by means of a
C18, between sensor

279
Component
280
failure
SENSORS - 02 06 SUPPLY BELOW THE Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
COOLANT RANGE temperature instrument ground-short-circuited or parameters: in presence of this

Check by means of a

C18, between sensor
SENSORS - 02 07 VALUE OVER THE Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
COOLANT NORMAL LIMIT temperature instrument ground-short-circuited or parameters: in presence of this
Check by means of a
C18, between sensor
Print 603.93.391
Component
failure
SENSORS - 03 00 NO AVAILABLE Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
Print 603.93.391
ACCELERATOR SYMPTOM potentiometer parameters using the
With the accelerator
PEDAL short-circuited. diagnostic instrument to verify
pedal at rest, the engine
the potentiometer
runs at accelerated idling
malfunctioning (the signal
(approx. 1100 rpm.)
doesn’t vary from 0% to
Pressing the pedal, the 100%).

engine progressively and
Check by means of a
uncontrollably increases
multimeter that the
the rpm up to approx
potentiometer is all right
2600 rpm.
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 1-3 and 2-3
between the idling and the
peak
If the potentiometer is all right
pedal connector (wiring side)
B83 passing through sleeve B
pin 36, between pedal
and connector EDC pin B55
passing through sleeve B pin
35, between pedal connector
(wiring side) pin 3 and
connector EDC pin B81
34.

281
Component
282
failure
SENSORS - 03 00 NO AVAILABLE a)idling accelerated at Accelerator pedal: not Reading of parameters by EDC pilot light on.
ACCELERATOR SYMPTOM approx. 1100 rpm in idling plausible signal between means of the diagnostic
a) the potentiometer signal
PEDAL position and standard idling switch and instrument to determine the

is valid and it shows that the
acceleration when the potentiometer faulty part of the accelerator
pedal is released, but the
pedal is pressed. (potentiometer or idling
state of the switch shows
switch).
b)standard idling but that the pedal is pressed
revolution and power a)check on the component that
b) the switch signal is valid
reduction when the idling switch is not damaged
and it shows that the pedal
accelerating. by means of the multimeter
is released, but the
(ON-OFF switchover between
potentiometer signal shows

pins 4 and 5 of pedal connector,
that the pedal is pressed.
component side).
In case the switch is not
damaged, research of the
switch on wiring between pedal
passingh through sleeve B pin
connector EDC pin B73 passing
through sleeve B pin 32.
b)By means of multimeter
check directly on the
component that the
potentiometer is not damaged.
In case the potentiometer is not
damaged, check wiring
between pedal connector and
connector EDC.
SENSORS - 03 00 NO AVAILABLE Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR SYMPTOM potentiometer signal multimeter directly on the
Accelerated idling at
PEDAL (possible open circuit). component that the
approx. 1100 rpm in any
potentiometer is all right (Total
pedal position.
R. = approx. 1 kOhm) between
pins 2 and 3 of connector
(component side).
If the potentiometer is all right,
check the wiring between pedal
connector and connector EDC.
Print 603.93.391
Component
failure
SENSORS - FUEL 03 00 NO AVAILABLE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
Print 603.93.391
TEMPERATURE SYMPTOM behalf of the driver. ground-short-circuited or parameters: in presence of this
open-circuited fuel error, the fuel temperature will
temperature sensor be fixed at 20 °C
Check the sensor is all right (R
= approx. 2,5 kOhm at 20 °C)

C17, between sensor
SENSORS - 03 01 SHORT CIRCUIT TO Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
ACCELERATOR POSITIVE potentiometer parameters using the diagnostic
With the accelerator instrument to verify the
PEDAL short-circuited.
pedal at rest, the engine potentiometer malfunctioning
runs at accelerated idling (the signal doesn’t vary from
(approx. 1100 rpm.) 0% to 100%).
Pressing the pedal, the Check by means of a
engine progressively and multimeter that the
uncontrollably increases potentiometer is all right (Total
the rpm up to approx R. = approx. 1 kOhm) between
2600 rpm. pins 2 and 3 of pedal connector
(component side), check the
linear resistance variance of the
potentiometer between pins
1-3 and 2-3 between the idling
and the peak
passing through sleeve B pin 35,
between pedal connector

283
Component
284
failure
SENSORS - 03 01 SHORT CIRCUIT TO a)idling accelerated at Accelerator pedal: not Reading of parameters by EDC pilot light on.
ACCELERATOR POSITIVE approx. 1100 rpm in idling plausible signal between means of the diagnostic

switch).

component side).
component that the
connector EDC.
SENSORS - 03 01 SHORT CIRCUIT TO Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR POSITIVE potentiometer signal multimeter directly on the
pedal position.
(component side).
Print 603.93.391
Component
failure
SENSORS - FUEL 03 01 SHORT CIRCUIT TO No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
Print 603.93.391
TEMPERATURE POSITIVE behalf of the driver. ground-short-circuited or parameters: in presence of this
temperature sensor be fixed at 20 5C
Check the sensor is all right (R =
approx. 2,5 kOhm at 20 5C)

C17, between sensor connector
connector EDC pin C34.
SENSORS - 03 02 OPEN CIRCUIT OR Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
ACCELERATOR SHORT CIRCUIT TO potentiometer parameters using the diagnostic
With the accelerator instrument to verify the
PEDAL GROUND short-circuited.
pedal at rest, the engine potentiometer malfunctioning
runs at accelerated idling (the signal doesn’t vary from 0%
(approx. 1100 rpm.) to 100%).
Pressing the pedal, the Check by means of a multimeter
engine progressively and that the potentiometer is all right
uncontrollably increases (Total R. = approx. 1 kOhm)
the rpm up to approx between pins 2 and 3 of pedal
2600 rpm. connector (component side),
between the idling and the peak
passing through sleeve B pin 35,

285
Component
286
failure
SENSORS - 03 02 OPEN CIRCUIT OR a)idling accelerated at Accelerator pedal: not Reading of parameters by EDC pilot light on.
ACCELERATOR SHORT CIRCUIT TO approx. 1100 rpm in idling plausible signal between means of the diagnostic
PEDAL GROUND position and standard idling switch and instrument to determine the

switch).

component side).
component that the
connector EDC.
SENSORS - 03 02 OPEN CIRCUIT OR Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR SHORT CIRCUIT TO potentiometer signal multimeter directly on the
PEDAL GROUND (possible open circuit). component that the
pedal position.
(component side).
Print 603.93.391
Component
failure
SENSORS - FUEL 03 02 OPEN CIRCUIT OR No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
Print 603.93.391
TEMPERATURE SHORT CIRCUIT TO behalf of the driver. ground-short-circuited or parameters: in presence of this
GROUND open-circuited fuel error, the fuel temperature will
approx. 2,5 kOhm at 20 °C)

SENSORS - 03 03 NO SIGNAL a)idling accelerated at Accelerator pedal: not Reading of parameters by means EDC pilot light on.
ACCELERATOR approx. 1100 rpm in idling plausible signal between of the diagnostic instrument to
PEDAL position and standard idling switch and determine the faulty part of the
accelerator (potentiometer or is valid and it shows that the
acceleration when the potentiometer
idling switch). pedal is released, but the
pedal is pressed.
b)standard idling but a)check on the component that that the pedal is pressed
the idling switch is not damaged
revolution and power by means of the multimeter b) the switch signal is valid
reduction when (ON-OFF switchover between and it shows that the pedal
accelerating. pins 4 and 5 of pedal connector, is released, but the
component side). potentiometer signal shows
In case the switch is not that the pedal is pressed.
damaged, research of the switch
on wiring between pedal
passingh through sleeve B pin 33,
b)By means of multimeter check
directly on the component that
the potentiometer is not
damaged.
damaged, check wiring between
pedal connector and connector

EDC.

287
Component
288
failure
SENSORS - 03 03 NO SIGNAL Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR potentiometer signal multimeter directly on the

pedal position.
between pins 2 and 3 of
connector (component side).
check the wiring between
pedal connector and
connector EDC.
SENSORS - 03 03 NO SIGNAL Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
ACCELERATOR potentiometer parameters using the
With the accelerator diagnostic instrument to verify
pedal at rest, the engine the potentiometer
runs at accelerated idling malfunctioning (the signal
(approx. 1100 rpm.) doesn’t vary from 0% to
100%).
Pressing the pedal, the
engine progressively and Check by means of a
uncontrollably increases multimeter that the
the rpm up to approx potentiometer is all right
2600 rpm. (Total R. = approx. 1 kOhm)
peak
34.
Print 603.93.391
Component
failure
SENSORS - FUEL 03 03 NO SIGNAL No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
Print 603.93.391
TEMPERATURE behalf of the driver. ground-short-circuited or parameters: in presence of this

SENSORS - 03 04 SIGNAL NOT a)idling accelerated at Accelerator pedal: not Reading of parameters by EDC pilot light on.
ACCELERATOR PLAUSIBLE approx. 1100 rpm in idling plausible signal between means of the diagnostic
faulty part of the accelerator is valid and it shows that the
acceleration when the potentiometer
(potentiometer or idling pedal is released, but the
pedal is pressed.
switch). state of the switch shows
a)check on the component that
revolution and power the idling switch is not damaged b) the switch signal is valid
reduction when by means of the multimeter and it shows that the pedal
accelerating. (ON-OFF switchover between is released, but the
pins 4 and 5 of pedal connector, potentiometer signal shows
component side).
component that the

connector EDC.

289
Component
290
failure
SENSORS - 03 04 SIGNAL NOT Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR PLAUSIBLE potentiometer signal multimeter directly on the

pedal position.
pedal connector and
connector EDC.
SENSORS - 03 04 SIGNAL NOT Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
ACCELERATOR PLAUSIBLE potentiometer parameters using the
With the accelerator diagnostic instrument to verify
pedal at rest, the engine the potentiometer
runs at accelerated idling malfunctioning (the signal
(approx. 1100 rpm.) doesn’t vary from 0% to
100%).
Pressing the pedal, the
engine progressively and Check by means of a
uncontrollably increases multimeter that the
the rpm up to approx potentiometer is all right
2600 rpm. (Total R. = approx. 1 kOhm)
peak
34.
Print 603.93.391
Component
failure
SENSORS - 03 05 SUPPLY OVER THE Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
Print 603.93.391
ACCELERATOR NORMAL RANGE potentiometer parameters using the
the potentiometer
(approx. 1100 rpm.)

Check by means of a
multimeter that the
2600 rpm.
peak
34.

291
Component
292
failure
SENSORS - 03 05 SUPPLY OVER THE a)idling accelerated at Accelerator pedal: not Reading of parameters by EDC pilot light on.
ACCELERATOR NORMAL RANGE approx. 1100 rpm in idling plausible signal between means of the diagnostic

switch).

component side).
component that the
connector EDC.
SENSORS - 03 05 SUPPLY OVER THE Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR NORMAL RANGE potentiometer signal multimeter directly on the
pedal position.
(component side).
Print 603.93.391
Component
failure
SENSORS - 03 06 SUPPLY BELOW THE Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
Print 603.93.391
ACCELERATOR RANGE potentiometer parameters using the
the potentiometer
(approx. 1100 rpm.)

Check by means of a
multimeter that the
2600 rpm.
peak
34.

293
Component
294
failure
SENSORS - 03 06 SUPPLY BELOW THE a)idling accelerated at Accelerator pedal: not Reading of parameters by EDC pilot light on.
ACCELERATOR RANGE approx. 1100 rpm in idling plausible signal between means of the diagnostic

switch).

component side).
component that the
connector EDC.
SENSORS - 03 06 SUPPLY BELOW THE Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR RANGE potentiometer signal multimeter directly on the
pedal position.
(component side).
Print 603.93.391
Component
failure
SENSORS - 03 07 VALUE OVER THE Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
Print 603.93.391
ACCELERATOR NORMAL LIMIT potentiometer parameters using the
the potentiometer
(approx. 1100 rpm.)

Check by means of a
multimeter that the
2600 rpm.
peak
34.

295
Component
296
failure
SENSORS - 03 07 VALUE OVER THE a)idling accelerated at Accelerator pedal: not Reading of parameters by means EDC pilot light on.
ACCELERATOR NORMAL LIMIT approx. 1100 rpm in idling plausible signal between of the diagnostic instrument to

acceleration when the potentiometer accelerator (potentiometer or
pedal is pressed. idling switch).
revolution and power the idling switch is not damaged
reduction when by means of the multimeter
accelerating. (ON-OFF switchover between

component side).
damaged.
EDC.
SENSORS - 03 07 VALUE OVER THE Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR NORMAL LIMIT potentiometer signal multimeter directly on the
pedal position.
pedal connector and
connector EDC.
Print 603.93.391
Component
failure
SENSORS - 03 08 VALUE BELOW THE Indication on the water Positively short-circuited, Reading of measurable EDC pilot light on.
Print 603.93.391
COOLANT LIMIT temperature instrument ground-short-circuited or parameters: in presence of this
Check by means of a
C18, between sensor
SENSORS - 03 08 VALUE BELOW THE Power reduction No accelerator Check by means of a EDC pilot light on.
ACCELERATOR LIMIT potentiometer signal multimeter directly on the
pedal position.
pedal connector and
connector EDC.

297
Component
298
failure
SENSORS - 03 08 VALUE BELOW THE Power reduction Accelerator pedal Reading of measurable EDC pilot light on.
ACCELERATOR LIMIT potentiometer parameters using the

the potentiometer
(approx. 1100 rpm.)
Check by means of a
multimeter that the
2600 rpm.
peak
34.
Print 603.93.391
Component
failure
SENSORS - 03 08 VALUE BELOW THE a)idling accelerated at Accelerator pedal: not Reading of parameters by means EDC pilot light on.
Print 603.93.391
ACCELERATOR LIMIT approx. 1100 rpm in idling plausible signal between of the diagnostic instrument to
acceleration when the potentiometer accelerator (potentiometer or
pedal is pressed. idling switch).
revolution and power the idling switch is not damaged
reduction when by means of the multimeter
accelerating. (ON-OFF switchover between
component side).
damaged.
EDC.
SENSORS - FUEL 04 00 NO AVAILABLE Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE SYMPTOM reduction ground short-circuited or sensor connector (wiring side)
open-circuited rail pressure pin 1 and connector EDC pin
sensor C20, between sensor connector
connector EDC pin C27,
between sensor connector
Replace the sensor after having
excluded all the other
possibilities.

299
Component
300
failure
SENSORS - FUEL 04 01 SHORT CIRCUIT TO Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE POSITIVE reduction ground short-circuited or sensor connector (wiring side)

sensor C20, between sensor
and connector EDC pin C27,
Replace the sensor after
having excluded all the other

possibilities.
SENSORS - FUEL 04 02 OPEN CIRCUIT OR Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE SHORT CIRCUIT TO reduction ground short-circuited or sensor connector (wiring side)
GROUND open-circuited rail pressure pin 1 and connector EDC pin
possibilities.
SENSORS - FUEL 04 03 NO SIGNAL Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE reduction ground short-circuited or sensor connector (wiring side)
possibilities.
Print 603.93.391
Component
failure
SENSORS - FUEL 04 04 SIGNAL NOT No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
Print 603.93.391
TEMPERATURE PLAUSIBLE behalf of the driver. ground-short-circuited or parameters: in presence of this
open-circuited fuel error, the fuel temperature
temperature sensor will be fixed at 20 °C

C17, between sensor
SENSORS - FUEL 04 04 SIGNAL NOT Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE PLAUSIBLE reduction ground short-circuited or sensor connector (wiring side)
possibilities.
SENSORS - FUEL 04 05 SUPPLY OVER THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
TEMPERATURE NORMAL RANGE behalf of the driver. ground-short-circuited or parameters: in presence of this

301
Component
302
failure
SENSORS - FUEL 04 05 SUPPLY OVER THE Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE NORMAL RANGE reduction ground short-circuited or sensor connector (wiring side)


possibilities.
SENSORS - FUEL 04 06 SUPPLY BELOW THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
TEMPERATURE RANGE behalf of the driver. ground-short-circuited or parameters: in presence of this
C17, between sensor
SENSORS - FUEL 04 06 SUPPLY BELOW THE Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE RANGE reduction ground short-circuited or sensor connector (wiring side)
possibilities.
Print 603.93.391
Component
failure
SENSORS - FUEL 04 07 VALUE OVER THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
Print 603.93.391
TEMPERATURE NORMAL LIMIT behalf of the driver. ground-short-circuited or parameters: in presence of this

C17, between sensor
SENSORS - FUEL 04 07 VALUE OVER THE Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE NORMAL LIMIT reduction ground short-circuited or sensor connector (wiring side)
possibilities.
SENSORS - FUEL 04 08 VALUE BELOW THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light off
TEMPERATURE LIMIT behalf of the driver. ground-short-circuited or parameters: in presence of this

303
Component
304
failure
SENSORS - FUEL 04 08 VALUE BELOW THE Significant power Positively short-circuited, Check the wiring between EDC pilot light winking.
PRESSURE LIMIT reduction ground short-circuited or sensor connector (wiring side)


possibilities.
SENSORS - OIL 05 00 NO AVAILABLE No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE SYMPTOM behalf of the driver. short-circuited or parameters: in presence of this
If the oil temperature is too
SIGNAL open-circuited error, the engine oil
low, a limitation of the
temperature will be fixed at
engine rpm, depending
120 °C.
upon the temperature itself,
Check that the sensor is all takes place immediately
right (R = approx. 2,5 kOhm after starting, (engine
at 20 °C). protection strategy).
If the sensor is all right, check
the wiring between the sensor
Print 603.93.391
Component
failure
ENGINE - 05 00 NO AVAILABLE The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
INJECTOR SYMPTOM cylinders. injector short-circuited or cables on the injector solenoid
It is possible that
CYLINDER 1 open-circuited. valve are properly tightened to
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two

(R = approx. 0,5 Ohm). power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder head between
connector 1 pins 3 and 4 and
electro-injector.
If the head cylinder wiring is all
right, check the engine cable
between cylinder head
connector 1 pin 3 and
connector EDC pin A13,
connector EDC pin A9.
SENSORS - OIL 05 01 SHORT CIRCUIT TO No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE POSITIVE behalf of the driver. short-circuited or parameters: in presence of this
120 °C.

305
Component
306
failure
ENGINE - 05 01 SHORT CIRCUIT TO The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
INJECTOR POSITIVE cylinders. injector short-circuited or cables on the injector solenoid
It is possible that

stored.

electro-injector.
ENGINE - 05 02 OPEN CIRCUIT OR The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
INJECTOR SHORT CIRCUIT TO cylinders. injector short-circuited or cables on the injector solenoid
It is possible that
CYLINDER 1 GROUND open-circuited. valve are properly tightened to
stored.
electro-injector.
Print 603.93.391
Component
failure
SENSORS - OIL 05 02 OPEN CIRCUIT OR No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
Print 603.93.391
TEMPERATURE SHORT CIRCUIT TO behalf of the driver. short-circuited or parameters: in presence of this
SIGNAL GROUND open-circuited error, the engine oil
120 °C.

ENGINE - 05 03 NO SIGNAL The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
INJECTOR cylinders. injector short-circuited or cables on the injector solenoid
It is possible that
stored.
electro-injector.

307
Component
308
failure
SENSORS - OIL 05 03 NO SIGNAL No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE behalf of the driver. short-circuited or parameters: in presence of this

120 °C.

SENSORS - OIL 05 04 SIGNAL NOT No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE PLAUSIBLE behalf of the driver. short-circuited or parameters: in presence of this
120 °C.
Print 603.93.391
Component
failure
ENGINE - 05 04 SIGNAL NOT The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
INJECTOR PLAUSIBLE cylinders. injector short-circuited or cables on the injector solenoid
It is possible that

stored.
electro-injector.
SENSORS - OIL 05 05 SUPPLY OVER THE No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE NORMAL RANGE behalf of the driver. short-circuited or parameters: in presence of this
120 °C.

309
Component
310
failure
ENGINE - 05 05 SUPPLY OVER THE The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
INJECTOR NORMAL RANGE cylinders. injector short-circuited or cables on the injector solenoid
It is possible that

stored.

electro-injector.
SENSORS - OIL 05 06 SUPPLY BELOW THE No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE RANGE behalf of the driver. short-circuited or parameters: in presence of this
120 °C.
Print 603.93.391
Component
failure
SENSORS - OIL 05 07 VALUE OVER THE No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
Print 603.93.391
TEMPERATURE NORMAL LIMIT behalf of the driver. short-circuited or parameters: in presence of this
120 °C.

SENSORS - OIL 05 08 VALUE BELOW THE No reaction noticeable on Oil temperature sensor Reading of measurable EDC pilot light on.
TEMPERATURE LIMIT behalf of the driver. short-circuited or parameters: in presence of this
120 °C.

311
Component
312
failure
ENGINE - 06 00 NO AVAILABLE The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that

Check the injector solenoid cylinders, because the
also error 5.8 can be stored
.
check the wiring on cylinder
head between connector 3

pins 1 and 2 and
electro-injector.
If the cylinder head wiring is all
between the cylinder head
It is possible that
also error 5.7 (6 cylinders)
or 5.8 (4 cylinders) can be
stored .
pins 3 and 4 and
electro-injector.
Print 603.93.391
Component
failure
ENGINE - 06 01 SHORT CIRCUIT TO The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
It is possible that

.
pins 1 and 2 and
electro-injector.
It is possible that
stored .
pins 3 and 4 and
electro-injector.


313
Component
314
failure
ENGINE - 06 02 OPEN CIRCUIT OR The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that

.

pins 1 and 2 and
electro-injector.
ENGINE - 06 03 NO SIGNAL The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
ENGINE - 06 04 SIGNAL NOT The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
It is possible that

.
pins 1 and 2 and
electro-injector.
ENGINE - 06 05 SUPPLY OVER THE The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.


315
Component
316
failure
ENGINE - 06 06 SUPPLY BELOW THE The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
INJECTOR RANGE cylinders. injector short-circuited or cables on the injector solenoid
It is possible that

stored.

electro-injector.
ENGINE - 06 06 SUPPLY BELOW THE The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
ENGINE - 06 07 VALUE OVER THE The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
INJECTOR NORMAL LIMIT cylinders. injector short-circuited or cables on the injector solenoid
It is possible that

stored.
electro-injector.
ENGINE - 06 07 VALUE OVER THE The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.


317
Component
318
failure
ENGINE - 06 08 VALUE BELOW THE The engine runs at 3 (5) Electrical part of cylinder n°1 Check that the nuts fixing the EDC pilot light on.
INJECTOR LIMIT cylinders. injector short-circuited or cables on the injector solenoid
It is possible that

stored.

electro-injector.
ENGINE - 06 08 VALUE BELOW THE The engine runs at 5 Electrical part of cylinder n°5 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
ENGINE - 07 00 NO AVAILABLE The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
It is possible that

.
pins 1 and 2 and
electro-injector.
ENGINE - 07 01 SHORT CIRCUIT TO The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.


319
Component
320
failure
It is possible that

stored .

pins 3 and 4 and
electro-injector.
ENGINE - 07 02 OPEN CIRCUIT OR The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
Print 603.93.391
It is possible that

stored .
pins 3 and 4 and
electro-injector.
ENGINE - 07 03 NO SIGNAL The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.


321
Component
322
failure
It is possible that

stored .

pins 3 and 4 and
electro-injector.
ENGINE - 07 04 SIGNAL NOT The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
Print 603.93.391
It is possible that

stored .
pins 3 and 4 and
electro-injector.
ENGINE - 07 05 SUPPLY OVER THE The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.


323
Component
324
failure
It is possible that

stored .

pins 3 and 4 and
electro-injector.
ENGINE - 07 06 SUPPLY BELOW THE The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
Print 603.93.391
It is possible that

stored .
pins 3 and 4 and
electro-injector.
ENGINE - 07 07 VALUE OVER THE The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.


325
Component
326
failure
It is possible that

stored .

pins 3 and 4 and
electro-injector.
It is possible that
stored .
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
ENGINE - 08 00 NO AVAILABLE The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
INJECTOR SYMPTOM cylinders. electrical part cables on the injector solenoid
It is possible that
CYLINDER 2 short-circuited or valve are properly tightened to
open-circuited. the torque of 1,5 Nm
Check the continuity and (3) cylinders, because the
resistance of the injector injectors are driven by two

solenoid valve (R = approx. power stages. In this case
0,5 Ohm) also error 5.7 (6 cylinders)
stored.
pins 1 and 2 and
electro-injector
It is possible that
stored .
head between connector 3 pins
1 and 2 and electro-injector.


327
Component
328
failure
ENGINE - 08 01 SHORT CIRCUIT TO The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
INJECTOR POSITIVE cylinders. electrical part cables on the injector solenoid
It is possible that

solenoid valve (R = approx. 0,5 power stages. In this case
Ohm) also error 5.7 (6 cylinders)
stored.

1 and 2 and electro-injector
ENGINE - 08 02 OPEN CIRCUIT OR The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
INJECTOR SHORT CIRCUIT TO cylinders. electrical part cables on the injector solenoid
It is possible that
CYLINDER 2 GROUND short-circuited or valve are properly tightened to
stored.
Print 603.93.391
Component
failure
Print 603.93.391
It is possible that

stored .
pins 1 and 2 and
electro-injector.
ENGINE - 08 03 NO SIGNAL The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
INJECTOR cylinders. electrical part cables on the injector solenoid
It is possible that
stored.


329
Component
330
failure
It is possible that

If the solenoid valve is all right, also error 5.7 (4 cylinders)
check the wiring on cylinder or 5.8 (6 cylinders) can be
head between connector 3 pins stored .
1 and 2 and electro-injector.

ENGINE - 08 04 SIGNAL NOT The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
INJECTOR PLAUSIBLE cylinders. electrical part cables on the injector solenoid
It is possible that
stored.
Print 603.93.391
Component
failure
ENGINE - 08 05 SUPPLY OVER THE The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
INJECTOR NORMAL RANGE cylinders. electrical part cables on the injector solenoid
It is possible that

stored.
ENGINE - 08 06 SUPPLY BELOW THE The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
INJECTOR RANGE cylinders. electrical part cables on the injector solenoid
It is possible that
stored.


331
Component
332
failure
ENGINE - 08 07 VALUE OVER THE The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
INJECTOR NORMAL LIMIT cylinders. electrical part cables on the injector solenoid
It is possible that

stored.

ENGINE - 08 08 VALUE BELOW THE The engine runs at 5 Electrical part of cylinder n°6 Check that the nuts fixing the EDC pilot light on.
It is possible that
.
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
ENGINE - 08 08 VALUE BELOW THE The engine runs at 3 (5) Cylinder n°2 injector Check that the nuts fixing the EDC pilot light on.
Print 603.93.391
INJECTOR LIMIT cylinders. electrical part cables on the injector solenoid
It is possible that

solenoid valve (R = approx. power stages. In this case
0,5 Ohm) also error 5.7 (6 cylinders)
stored.
pins 1 and 2 and
electro-injector
ENGINE - 09 00 NO AVAILABLE No reaction noticeable on Excessive engine revolutions Flight Recorder (Stored Data) EDC pilot light winking.
ENGINE SYMPTOM behalf of the driver. reading with Modus
Make sure the driver
OVERSPEED IWT-IT2000Driver
understands the importance
sensibilization
of proper driving.
ENGINE - 09 01 ENGINE OVERSPEED No reaction noticeable on Excessive engine revolutions Flight Recorder (Stored Data) EDC pilot light winking.
ENGINE behalf of the driver. reading with Modus
Make sure the driver
OVERSPEED IWT-IT2000Driver
understands the importance
sensibilization
of proper driving.

333
Component
334
failure
It is possible that

stored .

pins 1 and 2 and
electro-injector.
It is possible that
stored .
pins 1 and 2 and
electro-injector.
Print 603.93.391
Component
failure
Print 603.93.391
It is possible that

stored .
pins 1 and 2 and
electro-injector.
It is possible that
stored .
pins 1 and 2 and
electro-injector.


335
Component
336
failure
It is possible that

stored .

pins 1 and 2 and
electro-injector.
SENSORS - 0A 00 NO AVAILABLE Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR SYMPTOM minimum speed feasibility, or simultaneous IWT-IT2000, check that
This error is stored only if
PEDAL/BRAKE activation of brake and accelerator pedal
the brake and accelerator
PEDAL SUSPECT accelerator potentiometer signal is reset
signals are not damaged.
upon release, otherwise it is
possible that the driver has If the brake is operated while
pressed brake and accelerator the accelerator pedal is
together being pressed, the engine
runs to idle until the brake is
released, so that the vehicle
can be stopped even if the
accelerator pedal should
block in an intermediate
position. On the contrary it
is possible to accelerate
while the brake pedal is
pressed without the
intervention of any safety
strategies.
Print 603.93.391
Component
failure
SENSORS - 0A 01 SHORT CIRCUIT TO Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
Print 603.93.391
ACCELERATOR POSITIVE minimum speed feasibility, or simultaneous IWT-IT2000, check that
possible that the driver has
If the brake is operated while
pressed brake and accelerator

the accelerator pedal is
pressed without the
strategies.
SENSORS - 0A 02 OPEN CIRCUIT OR Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR SHORT CIRCUIT TO minimum speed feasibility, or simultaneous IWT-IT2000, check that
PEDAL/BRAKE GROUND activation of brake and accelerator pedal
pressed without the
strategies.

337
Component
338
failure
SENSORS - 0A 03 NO SIGNAL Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR minimum speed feasibility, or simultaneous IWT-IT2000, check that


pressed without the
strategies.
SENSORS - 0A 04 SIGNAL NOT Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR PLAUSIBLE minimum speed feasibility, or simultaneous IWT-IT2000, check that
pressed without the
strategies.
Print 603.93.391
Component
failure
SENSORS - 0A 05 SUPPLY OVER THE Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
Print 603.93.391
ACCELERATOR NORMAL RANGE minimum speed feasibility, or simultaneous IWT-IT2000, check that

pressed without the
strategies.
SENSORS - 0A 06 SUPPLY BELOW THE Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR RANGE minimum speed feasibility, or simultaneous IWT-IT2000, check that
pressed without the
strategies.

339
Component
340
failure
SENSORS - 0A 07 VALUE OVER THE Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR NORMAL LIMIT minimum speed feasibility, or simultaneous IWT-IT2000, check that

possible that the driver hasIf the brake is operated while

pressed without the
strategies.
SENSORS - 0A 08 VALUE BELOW THE Engine revolutions drop to Brake/accelerator pedal Parameters reading on Modus EDC pilot light off.
ACCELERATOR LIMIT minimum speed feasibility, or simultaneous IWT-IT2000, check that
pressed without the
strategies.
Print 603.93.391
Component
failure
SENSORS - 0B 00 NO AVAILABLE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
Print 603.93.391
BOOST SYMPTOM behalf of the driver. ground-short-circuited or parameters by means of the
The pressure sensor is
PRESSURE open-circuited air pressure diagnostic instrument: in
Power reduction (only in incorporated in the
sensor on suction manifold, presence of this error, the
the software version for temperature one. If the
or sensor supplied by a overcharging pressure will be
engine with single-stage electrical part is all right,
current that exceeds the fixed at 1600 mbar. Check the
overpressure valve). check the functionality of the

minimum or maximum limit wiring between the sensor
wastegate valve of the
turbocompressor.
SENSORS - 0B 01 SHORT CIRCUIT TO No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST POSITIVE behalf of the driver. ground-short-circuited or parameters by means of the
turbocompressor.
SENSORS - 0B 02 OPEN CIRCUIT OR No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST SHORT CIRCUIT TO behalf of the driver. ground-short-circuited or parameters by means of the
PRESSURE GROUND open-circuited air pressure diagnostic instrument: in
turbocompressor.

341
Component
342
failure
SENSORS - 0B 03 NO SIGNAL No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST behalf of the driver. ground-short-circuited or parameters by means of the

turbocompressor.

SENSORS - 0B 04 SIGNAL NOT No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST PLAUSIBLE behalf of the driver. ground-short-circuited or parameters by means of the
turbocompressor.
SENSORS - 0B 05 SUPPLY OVER THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST NORMAL RANGE behalf of the driver. ground-short-circuited or parameters by means of the
turbocompressor.
Print 603.93.391
Component
failure
SENSORS - 0B 06 SUPPLY BELOW THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
Print 603.93.391
BOOST RANGE behalf of the driver. ground-short-circuited or parameters by means of the

turbocompressor.
SENSORS - 0B 07 VALUE OVER THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST NORMAL LIMIT behalf of the driver. ground-short-circuited or parameters by means of the
turbocompressor.
SENSORS - 0B 08 VALUE BELOW THE No reaction noticeable on Positively short-circuited, Reading of measurable EDC pilot light on.
BOOST LIMIT behalf of the driver. ground-short-circuited or parameters by means of the
turbocompressor.

343
Component
344
failure
SENSORS - 0F 00 NO AVAILABLE The engine doesn’t start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
CRANKSHAFT SYMPTOM Light power reduction. signal or unfeasible signal proper fastening of the sensor.
Error 6.1 is always

Check the phonic wheel is not combined with 6.3
damaged and verify its cleaning.
The engine doesn’t start
Check the sensor is all right (R = because after a few
approx. 920 Ohm). revolutions the gearcase
disables the starter.

SENSORS - 0F 03 NO SIGNAL The engine doesn’t start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
CRANKSHAFT Light power reduction. signal or unfeasible signal proper fastening of the sensor.
Error 6.1 is always
If the sensor is not damaged, disables the starter.
SENSORS - 0F 04 SIGNAL NOT The engine doesn’t start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
CRANKSHAFT PLAUSIBLE Light power reduction. signal or unfeasible signal proper fastening of the sensor.
Error 6.1 is always
If the sensor is not damaged, disables the starter.
Print 603.93.391
Component
failure
SENSORS - 0F 05 NOISY SIGNAL
ON The engine doesn’t start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
Print 603.93.391
CRANKSHAFT WUP 1 Light power reduction. signal or unfeasible signal proper fastening of the sensor.
Error 6.1 is always

disables the starter.
SENSORS - 10 00 NO AVAILABLE Difficult starting in every Distribution shaft sensor: Check the correct sensor EDC pilot light on.
CAMSHAFT SYMPTOM condition. lack of signal or unfeasible fastening and its cleaning.
This error is always
signal
False injections and grade Check that the sensor is not combined with 6.3.
of smoke at the exhaust damaged (R = approx. 890
during starting. Ohm).
SENSORS - 10 03 NO SIGNAL Difficult starting in every Distribution shaft sensor: Check the correct sensor EDC pilot light on.
CAMSHAFT condition. lack of signal or unfeasible fastening and its cleaning.
This error is always
signal
False injections and grade Check that the sensor is not combined with 6.3.
of smoke at the exhaust damaged (R = approx. 890
during starting. Ohm).

345
Component
346
failure
SENSORS - 10 04 SIGNAL NOT Difficult starting in every Distribution shaft sensor: Check the correct sensor fastening EDC pilot light on.
CAMSHAFT PLAUSIBLE condition. lack of signal or unfeasible and its cleaning.
Check that the sensor is not This error is always
signal

False injections and grade damaged (R = approx. 890 Ohm). combined with 6.3.
of smoke at the exhaust
If the sensor is all right, check the
during starting. wiring between the sensor
connector (wiring side) pin 1 and
connector EDC pin C23, between
sensor connector (wiring side) pin 2
SENSORS - 10 06 NOISY SIGNAL ON The engine doesn’t start. Drive shaft sensor: lack of Check the cleaning and the proper EDC pilot light on.
CRANKSHAFT WUP 2 Light power reduction. signal or unfeasible signal fastening of the sensor.
Check the phonic wheel is not Error 6.1 is always
damaged and verify its cleaning. combined with 6.3
approx. 920 Ohm). The engine doesn’t start
If the sensor is not damaged, check because after a few
the wiring between the sensor revolutions the gearcase
connector EDC pin C25, between disables the starter.
sensor connector (wiring side) pin 2
SENSORS - 11 00 NO AVAILABLE The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
VEHICLE SPEED SYMPTOM work (if the failure is the maximum threshold or measurable with the diagnostic detected only with running
instrument: in presence of this error,
between the sensor and below the minimum one the vehicle speed read on the vehicle, and only in case of
the speedometer) (likely short circuit). gearcase will be fixed at 5 km/h. short circuit.
Failure memory reading by means of
Cruise Control doesn’t the diagnostic instrument: in case of If the signal is missing, no
work. intermittent error, check the error is detected because
connectors for a possible uncertain according to the gearcase
contact. the vehicle stands still.
If the error occurs, carry out the
following checks:
If the tachograph doesn’t work,
check the wiring and the
sensor-tachograph connections; If
the tachograph works but it displays
an unreasonable speed, check the
proper assembly, the cleaning and
the sensor air gap;
In case the defect persists, check the
wiring and the connections between
the tachograph connector (wiring
side) and the connector EDC pin
B74, passing through sleeve B pin 13.
Print 603.93.391
Component
failure
SENSORS - 11 01 SHORT CIRCUIT TO The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
Print 603.93.391
VEHICLE SPEED POSITIVE work (if the failure is the maximum threshold or measurable with the detected only with running
between the sensor and below the minimum one diagnostic instrument: in vehicle, and only in case of
the speedometer) (likely short circuit). presence of this error, the short circuit.
vehicle speed read on the
Cruise Control doesn’t If the signal is missing, no
gearcase will be fixed at 5
work. error is detected because

km/h. Failure memory reading
according to the gearcase
by means of the diagnostic
the vehicle stands still.
instrument: in case of
intermittent error, check the
connectors for a possible
uncertain contact.
If the error occurs, carry out
the following checks:
If the tachograph doesn’t
work, check the wiring and the
sensor-tachograph
connections; If the tachograph
works but it displays an
unreasonable speed, check
the proper assembly, the
cleaning and the sensor air gap;
In case the defect persists,
connections between the
tachograph connector (wiring
side) and the connector EDC
pin B74, passing through
sleeve B pin 13.

347
Component
348
failure
SENSORS - 11 02 OPEN CIRCUIT OR The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
VEHICLE SPEED SHORT CIRCUIT TO work (if the failure is the maximum threshold or measurable with the detected only with running
GROUND between the sensor and below the minimum one diagnostic instrument: in vehicle, and only in case of


uncertain contact.
sensor-tachograph
sleeve B pin 13.
Print 603.93.391
Component
failure
SENSORS - 11 03 NO SIGNAL The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
Print 603.93.391
VEHICLE SPEED work (if the failure is the maximum threshold or measurable with the detected only with running

uncertain contact.
sensor-tachograph
sleeve B pin 13.

349
Component
350
failure
SENSORS - 11 04 SIGNAL NOT The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
VEHICLE SPEED PLAUSIBLE work (if the failure is the maximum threshold or measurable with the detected only with running


uncertain contact.
sensor-tachograph
sleeve B pin 13.
Print 603.93.391
Component
failure
SENSORS - 11 05 SUPPLY OVER THE The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
Print 603.93.391
VEHICLE SPEED NORMAL RANGE work (if the failure is the maximum threshold or measurable with the detected only with running

uncertain contact.
sensor-tachograph
sleeve B pin 13.

351
Component
352
failure
SENSORS - 11 06 SUPPLY BELOW THE The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
VEHICLE SPEED RANGE work (if the failure is the maximum threshold or measurable with the detected only with running


uncertain contact.
sensor-tachograph
sleeve B pin 13.
Print 603.93.391
Component
failure
SENSORS - 11 07 VALUE OVER THE The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
measurable with the diagnostic
Print 603.93.391
VEHICLE SPEED NORMAL LIMIT work (if the failure is the maximum threshold or detected only with running
between the sensor and below the minimum one instrument: in presence of this vehicle, and only in case of
error, the vehicle speed read on
the speedometer) (likely short circuit). the gearcase will be fixed at 5 short circuit.
Cruise Control doesn’t km/h. Failure memory reading by If the signal is missing, no
means of the diagnostic

instrument: in case of intermittent
error, check the connectors for a according to the gearcase
possible uncertain contact. the vehicle stands still.
following checks:
sensor-tachograph connections; If
the tachograph works but it
displays an unreasonable speed,
check the proper assembly, the
In case the defect persists, check
the wiring and the connections
between the tachograph
connector (wiring side) and the
connector EDC pin B74, passing
VOLTAGE 12 00 NO AVAILABLE Idling accelerated Too low battery voltage Reading of measurable
SYMPTOM (depending upon the signal. parameters to check the battery
detected voltage), up to a voltage
maximum of 200 rpm Carry out the appropriate checks
over the standard idling on voltage regulator, batteries and
speed. recharge system.
VOLTAGE 12 01 VOLTAGE TOO HIGH Idling accelerated Too low battery voltage Reading of measurable
(depending upon the signal. parameters to check the battery
maximum of 200 rpm Carry out the appropriate
over the standard idling checks on voltage regulator,
speed. batteries and recharge system.
VOLTAGE 12 02 VOLTAGE TOO LOW Idling accelerated Too low battery voltage Reading of measurable

353
Component
354
failure
SENSORS - 12 08 VALUE BELOW THE The speedometer doesn’t Vehicle speed signal over Reading of the parameters EDC pilot light on. Error
VEHICLE SPEED LIMIT work (if the failure is the maximum threshold or measurable with the diagnostic detected only with running
between the sensor and below the minimum one instrument: in presence of this vehicle, and only in case of

the speedometer) (likely short circuit). error, the vehicle speed read on short circuit.
the gearcase will be fixed at 5
Cruise Control doesn’t km/h. Failure memory reading If the signal is missing, no
work. by means of the diagnostic error is detected because
instrument: in case of according to the gearcase
intermittent error, check the the vehicle stands still.
uncertain contact.

following checks:
sensor-tachograph connections;
If the tachograph works but it
displays an unreasonable speed,
check the proper assembly, the
In case the defect persists, check
the wiring and the connections
between the tachograph
connector (wiring side) and the
connector EDC pin B74, passing
ELECTRONIC 13 00 NO AVAILABLE Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL SYMPTOM operation due to ECU. retry.
If the problem persists, contact Possible defect warning
UNIT - SENSOR incorrectly powered
the Help Desk and follow the regarding various sensors
POWER SUPPLY sensors. Reduced power.
instructions for the possible powered by the gearcase.
replacement of the gearcase.
ELECTRONIC 13 01 SHORT CIRCUIT TO Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL POSITIVE operation due to ECU. retry.
Possible defect warning
UNIT - SENSOR incorrectly powered If the problem persists, contact regarding various sensors
POWER SUPPLY sensors. Reduced power. the Help Desk and follow the powered by the gearcase.
instructions for the possible
ELECTRONIC 13 02 OPEN CIRCUIT OR Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL SHORT CIRCUIT TO operation due to ECU. retry.
UNIT - SENSOR GROUND incorrectly powered If the problem persists, contact regarding various sensors
Print 603.93.391
Component
failure
ELECTRONIC 13 03 NO SIGNAL Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
Print 603.93.391
CONTROL operation due to ECU. retry.
ELECTRONIC 13 04 SIGNAL NOT Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL PLAUSIBLE operation due to ECU. retry.
POWER SUPPLY sensors. Reduced power. the Help Desk and follow the
ELECTRONIC 13 05 SUPPLY OVER THE Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL NORMAL RANGE operation due to ECU. retry.
UNIT - SENSOR incorrectly powered If the problem persists, contact Possible defect warning
POWER SUPPLY sensors. Reduced power. the Help Desk and follow the regarding various sensors
ELECTRONIC 13 06 SUPPLY BELOW THE Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL RANGE operation due to ECU. retry.
VOLTAGE 13 07 VOLTAGE HIGH Idling accelerated Too low battery voltage Reading of measurable
ELECTRONIC 13 07 VALUE OVER THE Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL NORMAL LIMIT operation due to ECU. retry.
VOLTAGE 13 08 VOLTAGE LOW Idling accelerated Too low battery voltage Reading of measurable
(depending upon the signal. parameters to check the
detected voltage), up to a battery voltage
checks on voltage regulator,
over the standard idling

batteries and recharge system.
speed.

355
Component
356
failure
ELECTRONIC 13 08 VALUE BELOW THE Anomalous engine Sensor power circuit fault in Erase the failure memory and EDC pilot light on.
CONTROL LIMIT operation due to ECU. retry.

SWITCH - 14 00 NO AVAILABLE Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
BRAKE PEDAL SYMPTOM operationPossible lack of signals between primary and means of the diagnostic
instrument to check the proper Check the proper fitting up
cruise con?trol/power secondary
and contemporary switchover of switch assembly on
takeoff operation
(inverse) of the brake switches, duplex.
primary and secondary.

If the result is negative, check,
directly on the component by
means of a multimeter, the
proper switchover.
If the component is not
damaged, check wiring and
component connector (wiring
side) pin 4 and connector EDC
pin B76, between component
passing through the Body
Computer and the sleeve B pin
31.
SWITCH - 14 01 SHORT CIRCUIT TO Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
BRAKE PEDAL POSITIVE operationPossible lack of signals between primary and means of the diagnostic
takeoff operation (inverse) of the brake switches, duplex.
means of a multimeter, the proper
switchover.
If the component is not damaged,
check wiring and connections
between the component
connector EDC pin B76, between
pin B80 passing through the Body
31.
Print 603.93.391
Component
failure
SWITCH - 14 02 OPEN CIRCUIT OR Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
Print 603.93.391
BRAKE PEDAL SHORT CIRCUIT TO operationPossible lack of signals between primary and means of the diagnostic
GROUND cruise con?trol/power secondary
takeoff operation

proper switchover.
31.
SWITCH - 14 03 NO SIGNAL Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
BRAKE PEDAL operationPossible lack of signals between primary and means of the diagnostic
takeoff operation
proper switchover.
31.

357
Component
358
failure
SWITCH - 14 04 SIGNAL NOT Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
BRAKE PEDAL PLAUSIBLE operationPossible lack of signals between primary and means of the diagnostic

takeoff operation
proper switchover.

31.
SWITCH - 14 05 SUPPLY OVER THE Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
BRAKE PEDAL NORMAL RANGE operationPossible lack of signals between primary and means of the diagnostic
Check the proper fitting up
cruise con?trol/power secondary instrument to check the proper
of switch assembly on
takeoff operation and contemporary switchover
duplex.
(inverse) of the brake switches,
proper switchover.
31.
Print 603.93.391
Component
failure
SWITCH - 15 00 NO AVAILABLE Cruise control/power Unfeasibility of cruise Read state parameters (EDC
Print 603.93.391
CRUISE SYMPTOM takeoffare not operating control/power takeoff ECU and Body Controller) to
CONTROL control keys identify faulty button.If the
switches work correctly, check
that the CAN message is not
present on the Cluster and
that the CAN line is up:

impedance between pin 21
and pin 22 of the 30-pin
connector must be
approximately 60 ohm
(measured with key off and all
ECUs connected).
SWITCH - 15 01 SHORT CIRCUIT TO Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE POSITIVE takeoffare not operating control/power takeoff ECU and Body Controller) to
connector must be
ECUs connected).
SWITCH - 15 02 OPEN CIRCUIT OR Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE SHORT CIRCUIT TO takeoffare not operating control/power takeoff ECU and Body Controller) to
CONTROL GROUND control keys identify faulty button.If the
connector must be
ECUs connected).

359
Component
360
failure
SWITCH - 15 03 NO SIGNAL Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE takeoffare not operating control/power takeoff ECU and Body Controller) to

connector must be
ECUs connected).
SWITCH - 15 04 SIGNAL NOT Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE PLAUSIBLE takeoffare not operating control/power takeoff ECU and Body Controller) to
connector must be
ECUs connected).
SWITCH - 15 05 SUPPLY OVER THE Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE NORMAL RANGE takeoffare not operating control/power takeoff ECU and Body Controller) to
connector must be
ECUs connected).
Print 603.93.391
Component
failure
SWITCH - 15 06 SUPPLY BELOW THE Possible lack of stop lights Unfeasible brake switches - Reading of status parameters EDC pilot light on.
Print 603.93.391
BRAKE PEDAL RANGE operationPossible lack of signals between primary and by means of the diagnostic
cruise con?trol/power secondary instrument to check the
takeoff operation proper and contemporary
duplex.
switchover (inverse) of the
brake switches, primary and
secondary.
proper switchover.
side) pin 4 and connector
EDC pin B76, between
EDC pin B80 passing through
the Body Computer and the
sleeve B pin 31.
SWITCH - 15 06 SUPPLY BELOW THE Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE RANGE takeoffare not operating control/power takeoff ECU and Body Controller) to
connector must be
ECUs connected).

361
Component
362
failure
SWITCH - 15 07 VALUE OVER THE Possible lack of stop lights Unfeasible brake switches - Reading of status parameters EDC pilot light on.
BRAKE PEDAL NORMAL LIMIT operationPossible lack of signals between primary and by means of the diagnostic
cruise con?trol/power secondary instrument to check the

takeoff operation proper and contemporary
duplex.
switchover (inverse) of the
brake switches, primary and
secondary.
proper switchover.
EDC pin B76, between
EDC pin B80 passing through
the Body Computer and the
sleeve B pin 31.
SWITCH - 15 07 VALUE OVER THE Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE NORMAL LIMIT takeoffare not operating control/power takeoff ECU and Body Controller) to
connector must be
ECUs connected).
Print 603.93.391
Component
failure
SWITCH - 15 08 VALUE BELOW THE Possible lack of stop lights Unfeasible brake switches - Reading of status parameters by EDC pilot light on.
Print 603.93.391
BRAKE PEDAL LIMIT operationPossible lack of signals between primary and means of the diagnostic
takeoff operation

proper switchover.
31.
SWITCH - 15 08 VALUE BELOW THE Cruise control/power Unfeasibility of cruise Read state parameters (EDC
CRUISE LIMIT takeoffare not operating control/power takeoff ECU and Body Controller) to
present on the Cluster and that
the CAN line is up: impedance
between pin 21 and pin 22 of
the 30-pin connector must be
ECUs connected).
SWITCH - PTO 17 00 NO AVAILABLE The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec 732.24’ PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR SYMPTOM not work on the wiring between EDC component (resistances group)
from the UCI and check that the PTO 1 = 3,5 ÷ 2,5 Volt
and switch.
resistance between pin 1 and 2 PTO 2 = 2,5 ÷ 1,5 Volt
(UCI side) is of 5,6 Kohm. Check
that reading between pin 32 and PTO 3 = 1,5 ÷ 0,5 Volt
87 of the connector 89 pin
(EDC) are those indicated in the
”Notes”.

363
Component
364
failure
SWITCH - 17 00 NO AVAILABLE Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
CLUTCH SYMPTOM control/power takeoff signal (signals the unit that completley pressing the pedal
On (software version for
the clutch is pressed while it and by reading status

single-stage valve).
is not) parameters on MODUS
IWT-IT2000Visual LED check Off (software version for
on sensor head under plastic double-stage valve).
guard (wth released clutch the
(If the pressed-clutch signal
LED must be on)If the switch
is missing, the gearcase
is not broken and well
doesn’t realize it because it
regards this state as normal).

switch assembly (distance Cruise Control/Power
from pedal 1-3 mm) takeoff do not work because
the clutch pedal is always
pressed.
CAUTION: take care of the
cable path to prevent it from
being squashed and
damaged while operating
the pedal.
SWITCH - PTO 17 01 SHORT CIRCUIT TO The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR POSITIVE not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
and switch. (resistances group) from the
UCI and check that the PTO 2 = 2,5 ÷ 1,5 Volt
resistance between pin 1 and
PTO 3 = 1,5 ÷ 0,5 Volt
2 (UCI side) is of 5,6 Kohm.
Check that reading between
pin 32 and 87 of the connector
89 pin (EDC) are those
indicated in the ”Notes”.
Print 603.93.391
Component
failure
SWITCH - 17 01 SHORT CIRCUIT TO Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
Print 603.93.391
CLUTCH POSITIVE control/power takeoff signal (signals the unit that completley pressing the pedal

pressed.
being squashed and
the pedal.
SWITCH - PTO 17 02 OPEN CIRCUIT OR The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR SHORT CIRCUIT TO not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
GROUND and switch. (resistances group) from the
PTO 3 = 1,5 ÷ 0,5 Volt

365
Component
366
failure
SWITCH - 17 02 OPEN CIRCUIT OR Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
CLUTCH SHORT CIRCUIT TO control/power takeoff signal (signals the unit that completley pressing the pedal
GROUND the clutch is pressed while it and by reading status


pressed.
being squashed and
the pedal.
SWITCH - PTO 17 03 NO SIGNAL The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
PTO 3 = 1,5 ÷ 0,5 Volt
Print 603.93.391
Component
failure
SWITCH - 17 03 NO SIGNAL Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
Print 603.93.391
CLUTCH control/power takeoff signal (signals the unit that completley pressing the pedal

(If the pressed-clutch signal is
missing, the gearcase doesn’t
realize it because it regards this
state as normal).
switch assembly (distance Cruise Control/Power takeoff
from pedal 1-3 mm) do not work because
according to the gearcase the
clutch pedal is always pressed.
being squashed and damaged
while operating the pedal.
SWITCH - PTO 17 04 SIGNAL NOT The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR PLAUSIBLE not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
PTO 3 = 1,5 ÷ 0,5 Volt
SWITCH - PTO 17 05 SUPPLY OVER THE The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR NORMAL RANGE not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
PTO 3 = 1,5 ÷ 0,5 Volt

367
Component
368
failure
SWITCH - PTO 17 06 SUPPLY BELOW THE The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR RANGE not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt

PTO 3 = 1,5 ÷ 0,5 Volt
SWITCH - PTO 17 07 VALUE OVER THE The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR NORMAL LIMIT not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
PTO 3 = 1,5 ÷ 0,5 Volt
SWITCH - PTO 17 08 VALUE BELOW THE The PTO Selector does Open circuit or short circuit Disconnect the ’Italamec PTO 0 = 4,5 ÷ 3,5 Volt
SELECTOR LIMIT not work on the wiring between EDC 732.24’ component
PTO 1 = 3,5 ÷ 2,5 Volt
PTO 3 = 1,5 ÷ 0,5 Volt
Print 603.93.391
Component
failure
SWITCH - 18 04 SIGNAL NOT Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
Print 603.93.391
CLUTCH PLAUSIBLE control/power takeoff signal (signals the unit that completley pressing the pedal

pressed.
being squashed and
the pedal.
SWITCH - 18 05 SUPPLY OVER THE Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
CLUTCH NORMAL RANGE control/power takeoff signal (signals the unit that completley pressing the pedal
realize it because it regards this
state as normal).
switch assembly (distance Cruise Control/Power takeoff
from pedal 1-3 mm) do not work because

369
Component
370
failure
SWITCH - 18 06 SUPPLY BELOW THE Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
CLUTCH RANGE control/power takeoff signal (signals the unit that completley pressing the pedal


pressed.
being squashed and
the pedal.
SWITCH - 18 07 VALUE OVER THE Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
CLUTCH NORMAL LIMIT control/power takeoff signal (signals the unit that completley pressing the pedal
realize it because it regards
this state as normal).
Print 603.93.391
Component
failure
SWITCH - 18 08 VALUE BELOW THE Not operating cruise Clutch switch: unfeasible Operate the clutch by EDC pilot light:
Print 603.93.391
CLUTCH LIMIT control/power takeoff signal (signals the unit that completley pressing the pedal

pressed.
being squashed and
the pedal.
ELECTRONIC 1A 00 NO AVAILABLE Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL SYMPTOM reduction. procedure that takes place stopped but it keeps on
The engine doesn’t stop in
UNIT - SELF TEST in the control unit each time running (vehicle moving with
the foreseen times when the
SHUTOFF the engine stops. engaged gear).
key +15 is OFF-positioned.
PATHS
Check the wiring between
AFTER-RUN
+15 of the key and gearcase
connector pin B39 passing
through the sleeve B pin 2.
Erase the failure memory and
retry: if in case of engine
normal stop the error signal
persists, contact the Help
Desk for the possible

371
Component
372
failure
ELECTRONIC 1A 01 SHORT CIRCUIT TO Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL POSITIVE reduction. procedure that takes place stopped but it keeps on

PATHS
AFTER-RUN

COMMUNICATI 1B 00 NO AVAILABLE The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - SYMPTOM Possible 7.2. start.Communication components.Carry out an
In case of wrong key, also the
IMMOBILISER problems with Immobilizer diagnosis.
Immobilizer pilot light winks
short-circuited or
(the problem is not in the
open-circuited Immobilizer
EDC gearcase).
on CAN line
COMMUNICATI 1B 01 SHORT CIRCUIT TO The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - POSITIVE Possible 7.2. start.Communication components.Carry out an
short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1B 02 OPEN CIRCUIT OR Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL SHORT CIRCUIT TO reduction. procedure that takes place stopped but it keeps on
UNIT - SELF TEST GROUND in the control unit each time running (vehicle moving with
PATHS
AFTER-RUN
Print 603.93.391
Component
failure
COMMUNICATI 1B 02 OPEN CIRCUIT OR The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
Print 603.93.391
ON LINES - SHORT CIRCUIT TO Possible 7.2. start.Communication components.Carry out an
IMMOBILISER GROUND problems with Immobilizer diagnosis.
short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1B 03 NO SIGNAL Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL reduction. procedure that takes place stopped but it keeps on
PATHS
AFTER-RUN
COMMUNICATI 1B 03 NO SIGNAL The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - Possible 7.2. start.Communication components.Carry out an
short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1B 04 SIGNAL NOT Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL PLAUSIBLE reduction. procedure that takes place stopped but it keeps on
PATHS
AFTER-RUN


373
Component
374
failure
COMMUNICATI 1B 04 SIGNAL NOT The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - PLAUSIBLE Possible 7.2. start.Communication components.Carry out an

short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1B 05 SUPPLY OVER THE Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL NORMAL RANGE reduction. procedure that takes place stopped but it keeps on

PATHS
AFTER-RUN
COMMUNICATI 1B 05 SUPPLY OVER THE The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - NORMAL RANGE Possible 7.2. start.Communication components.Carry out an
short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1B 06 SUPPLY BELOW THE Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL RANGE reduction. procedure that takes place stopped but it keeps on
PATHS
AFTER-RUN
Print 603.93.391
Component
failure
COMMUNICATI 1B 06 SUPPLY BELOW THE The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
Print 603.93.391
ON LINES - RANGE Possible 7.2. start.Communication components.Carry out an
short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1B 07 VALUE OVER THE Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL NORMAL LIMIT reduction. procedure that takes place stopped but it keeps on
PATHS
AFTER-RUN
COMMUNICATI 1B 07 VALUE OVER THE The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - NORMAL LIMIT Possible 7.2. start.Communication components.Carry out an
IMMOBILISER problems with short-circuited Immobilizer diagnosis.
or open-circuited Immobilizer
on CAN line
EDC gearcase).
ELECTRONIC 1B 08 VALUE BELOW THE Significant power Failure of the internal test It might occur if the engine is EDC pilot light on.
CONTROL LIMIT reduction. procedure that takes place stopped but it keeps on running
UNIT - SELF TEST in the control unit each time (vehicle moving with engaged
SHUTOFF the engine stops. gear).
PATHS
Check the wiring between +15
AFTER-RUN
of the key and gearcase
retry: if in case of engine normal
stop the error signal persists,
contact the Help Desk for the
gearcase.

375
Component
376
failure
COMMUNICATI 1C 08 VALUE BELOWTHE The engine doesn’t start. The engine does not Check wiring, connections, EDC pilot light winking.
ON LINES - LIMIT Possible 7.2. start.Communication components.Carry out an

short-circuited or
EDC gearcase).
on CAN line
ELECTRONIC 1D 00 NO AVAILABLE The engine rotates with 2 Power stage for cylinder Delete failure memory and try EDC pilot light on.
CONTROL SYMPTOM (3) cylinders block 1 or cylinder block 2 again.If the error remains, and
UNIT - only after having excluded an
BOOSTER 1 injector failure (see 5.x note),
contact the Help Desk and

comply with its instructions for
possible unit replacement.
ELECTRONIC 1D 01 VOLTAGE TOO HIGH The engine rotates with 2 Power stage for cylinder Delete failure memory and try EDC pilot light on.
CONTROL (3) cylinders block 1 or cylinder block 2 again.If the error remains, and
ELECTRONIC 1D 02 VOLTAGE TOO LOW The engine rotates with 2 Power stage for cylinder Delete failure memory and try EDC pilot light on.
CONTROL (3) cylinders block 1 or cylinder block 2 again.If the error remains, and
ELECTRONIC 1E 00 NO AVAILABLE The engine runs at 2 (3) Power stage for the Erase the failure memory and EDC pilot light on.
CONTROL SYMPTOM cylinders. electro-injectors of cylinders retry.
UNIT - 2-3 (four-cylinder engine) or In case the error persists, and
BOOSTER 2 4-5-6 (six-cylinder engine) only after having excluded the
faulty. injector defect (see note of 5.x)
gearcase.
ELECTRONIC 1E 01 VOLTAGE TOO HIGH The engine runs at 2 (3) Power stage for the Erase the failure memory and EDC pilot light on.
CONTROL cylinders. electro-injectors of cylinders retry.
UNIT - 2-3 (four-cylinder engine) or In case the error persists, and
BOOSTER 2 4-5-6 (six-cylinder engine) only after having excluded the
faulty. injector defect (see note of 5.x)
gearcase.
Print 603.93.391
Component
failure
ELECTRONIC 1E 02 VOLTAGE TOO LOW The engine runs at 2 (3) Power stage for the Erase the failure memory and EDC pilot light on.
Print 603.93.391
CONTROL cylinders. electro-injectors of cylinders retry.
UNIT - 2-3 (four-cylinder engine) or
In case the error persists, and
BOOSTER 2 4-5-6 (six-cylinder engine)
only after having excluded the
faulty.
injector defect (see note of
5.x) contact the Help Desk

and follow the instructions for
the possible replacement of
the gearcase.
COMMUNICATI 1F 00 NO AVAILABLE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can SYMPTOM closing resistance (120 ohms)
Off (software version for
A Module
double-stage valve).
Immobilizer either does not
intervene or it does not
allow starting.
COMMUNICATI 1F 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - Can SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
A Module cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
communication problem short-circuiting. Check that pin B53 (CAN H) must be
with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)
cranking. Possible ECAS connected. Resistance measured with key
suspension levelling off on wiring between pin B52
operation problem via and pin B53 must be equal to
remote control in cab. 120 ohm. 3) Impedance
Speedometer may stay measured between 30-pin
off. connector pin 21 (CAN H)
and pin 22 (CAN L) must be
equal to 60 ohm +/-3%
(measured with key off and
ECUs connected).

377
Component
378
failure
ON LINES - PTO: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Power Take Off cannot be viewed on earth or CAN H and CAN off directly on EDC ECU

Information Cluster. Possible L lines reciprocally between pin B52 (CAN L) and

ECUs connected).
COMMUNICATI 1F 01 SHORT CIRCUIT TO CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can POSITIVE closing resistance (120 ohms)
A Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 1F 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
ON LINES - PTO: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

379
Component
380
failure
COMMUNICATI 1F 02 OPEN CIRCUIT OR CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can SHORT CIRCUIT TO closing resistance (120 ohms)
A Module GROUND

allow starting.
COMMUNICATI 1F 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - Can SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
A Module GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).
COMMUNICATI 1F 03 NO SIGNAL CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can closing resistance (120 ohms)
A Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 1F 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 1F 04 SIGNAL NOT CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can PLAUSIBLE closing resistance (120 ohms)
A Module
allow starting.

381
Component
382
failure
COMMUNICATI 1F 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - Can PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 1F 05 SUPPLY OVER THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can NORMAL RANGE closing resistance (120 ohms)
A Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 1F 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 1F 06 SUPPLY BELOW THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can RANGE closing resistance (120 ohms)
A Module
allow starting.

383
Component
384
failure
COMMUNICATI 1F 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - Can RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 1F 07 VALUE OVER THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can NORMAL LIMIT closing resistance (120 ohms)
A Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 1F 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 1F 08 VALUE BELOW THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can LIMIT closing resistance (120 ohms)
A Module
allow starting.

385
Component
386
failure
COMMUNICATI 1F 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - Can LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 20 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
TCO1: cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
Tachograph Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
Output communication problem short-circuiting. Check that pin B53 (CAN H) must be
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 20 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 20 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Power Take Off GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).

387
Component
388
failure
ON LINES - SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
TCO1: GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU


ECUs connected).
COMMUNICATI 20 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 20 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

389
Component
390
failure
ON LINES - PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 20 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 20 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

391
Component
392
failure
ON LINES - RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 20 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 20 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PTO: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
RELAY - MAIN 21 00 NO AVAILABLE The unit remains always Main relay is not Check wiring and EDC pilot light on.
SYMPTOM supplied and the EDC disconnected connections(note: the main
The main relay is
warning light remains on relay is embedded into the
incorporated in the EDC
also with an Off keyThe EDC unit).Try and remove the
gearcase and can’t be
battery discharges. fuse and put it again in place. If
individually replaced
the inconvenience remains,
contact the Help Desk for

393
Component
394
failure
RELAY - MAIN 21 01 SHORT CIRCUIT TO The unit remains always Main relay is not Check wiring and EDC pilot light on.
POSITIVE supplied and the EDC disconnected connections(note: the main
relay is embedded into the EDC The main relay is
warning light remains on

unit).Try and remove the fuse incorporated in the EDC
also with an Off keyThe and put it again in place. If the gearcase and can’t be
battery discharges. inconvenience remains, contact individually replaced
the Help Desk for possible unit
replacement.
RELAY - MAIN 21 02 OPEN CIRCUIT OR The unit remains always Main relay is not Check wiring and EDC pilot light on.
SHORT CIRCUIT TO supplied and the EDC disconnected connections(note: the main
GROUND warning light remains on

replacement.
RELAY - MAIN 21 03 NO SIGNAL The unit remains always Main relay is not Check wiring and EDC pilot light on.
supplied and the EDC disconnected connections(note: the main
replacement.
ON LINES - LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Output communication problem short-circuiting. Check that pin B53 (CAN H) must be equal
to 120 ohm. 2) Resistance
with IMMOBILIZER for all vehicle ECUs are measured with key off on wiring
cranking. Possible ECAS connected. between pin B52 and pin B53
suspension levelling must be equal to 120 ohm. 3)
operation problem via Impedance measured between
remote control in cab. 30-pin connector pin 21 (CAN
Speedometer may stay H) and pin 22 (CAN L) must be
off. equal to 60 ohm +/-3%
ECUs connected).
RELAY - MAIN 22 04 SIGNAL NOT The unit remains always Main relay is not Check wiring and EDC pilot light on.
PLAUSIBLE supplied and the EDC disconnected connections(note: the main relay
is embedded into the EDC The main relay is
unit).Try and remove the fuse and incorporated in the EDC
also with an Off keyThe put it again in place. If the gearcase and can’t be
replacement.
Print 603.93.391
Component
failure
RELAY - MAIN 22 05 SUPPLY OVER THE The unit remains always Main relay is not Check wiring and EDC pilot light on.
connections(note: the main relay
Print 603.93.391
NORMAL RANGE supplied and the EDC disconnected
replacement.
RELAY - MAIN 22 06 SUPPLY BELOW THE The unit remains always Main relay is not Check wiring and EDC pilot light on.
RANGE supplied and the EDC disconnected connections(note: the main relay
replacement.
RELAY - MAIN 22 07 VALUE OVER THE The unit remains always Main relay is not Check wiring and EDC pilot light on.
NORMAL LIMIT supplied and the EDC disconnected connections(note: the main relay
replacement.
RELAY - MAIN 22 08 VALUE BELOW THE The unit remains always Main relay is not Check wiring and EDC pilot light on.
LIMIT supplied and the EDC disconnected connections(note: the main relay
replacement.
WARNING 24 00 NO AVAILABLE a)Preheating pilot light 1) The pre-heater warning light EDC pilot light off.
LIGHTS - SYMPTOM always on should come on for a few seconds
at key-on (lamp test). 2) Run Possible cold start difficult
PRE-POSTHEATI
b)Preheating pilot light Cluster active diagnostic because preheating is
NG procedure (pre-heater warning
always off. working, but no indications
light) with a diagnostic tool. are received from the pilot
light.
SWITCH - 24 00 NO AVAILABLE The programmable Read Body Controller state
SECOND SPEED SYMPTOM overspeed governor parameters (PROGRAMMABLE
LIMITER either doesn’t start or it SPEED LIMITER BUTTON) to
test correct operation of button.
SWITCH remains always engaged. Check correct on/off switching
with a multimeter if outcome is
negative. Run Body Controller

diagnostic procedure.

395
Component
396
failure
WARNING 24 01 SHORT CIRCUIT TO a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - POSITIVE always on light should come on for a few
Possible cold start difficult
PRE-POSTHEATI seconds at key-on (lamp test).

b)Preheating pilot light because preheating is
NG 2) Run Cluster active
diagnostic procedure
are received from the pilot
(pre-heater warning light) with
light.
a diagnostic tool.
SWITCH - 24 01 SHORT CIRCUIT TO The programmable Read Body Controller state
SECOND SPEED POSITIVE overspeed governor parameters
LIMITER either doesn’t start or it (PROGRAMMABLE SPEED
SWITCH remains always engaged. LIMITER BUTTON) to test

correct operation of button.
Check correct on/off
switching with a multimeter if
outcome is negative. Run Body
Controller diagnostic
procedure.
WARNING 24 02 OPEN CIRCUIT OR a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - SHORT CIRCUIT TO always on light should come on for a few
PRE-POSTHEATI GROUND seconds at key-on (lamp test).
light.
a diagnostic tool.
WARNING 24 03 NO SIGNAL a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - always on light should come on for a few
light.
a diagnostic tool.
WARNING 24 04 SIGNAL NOT a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - PLAUSIBLE always on light should come on for a few
light.
a diagnostic tool.
Print 603.93.391
Component
failure
WARNING 24 05 SUPPLY OVER THE a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
Print 603.93.391
LIGHTS - NORMAL RANGE always on light should come on for a few
light.
a diagnostic tool.
WARNING 24 06 SUPPLY BELOW THE a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - RANGE always on light should come on for a few
light.
a diagnostic tool.
WARNING 24 07 VALUE OVER THE a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - NORMAL LIMIT always on light should come on for a few
light.
a diagnostic tool.
WARNING 24 08 VALUE BELOW THE a)Preheating pilot light 1) The pre-heater warning EDC pilot light off.
LIGHTS - LIMIT always on light should come on for a few
light.
a diagnostic tool.
WARNING 25 00 NO AVAILABLE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - SYMPTOM doesn’t work or it remains active diagnostics in the
ENGINE BRAKE always lighted up. Cluster diagnostic procedure.
2) Check that the CAN line is
up: impedance between pin
21 and pin 22 of the 30-pin
connector must be
ECUs connected).

397
Component
398
failure
WARNING 25 01 SHORT CIRCUIT TO The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - POSITIVE doesn’t work or it remains active diagnostics in the

connector must be
ECUs connected).
SWITCH - 25 02 OPEN CIRCUIT OR The programmable Read Body Controller state

SECOND SPEED SHORT CIRCUIT TO overspeed governor parameters
LIMITER GROUND either doesn’t start or it (PROGRAMMABLE SPEED
procedure.
WARNING 25 02 OPEN CIRCUIT OR The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - SHORT CIRCUIT TO doesn’t work or it remains active diagnostics in the
ENGINE BRAKE GROUND always lighted up. Cluster diagnostic procedure.
connector must be
ECUs connected).
SWITCH - 25 03 NO SIGNAL The programmable Read Body Controller state
SECOND SPEED overspeed governor parameters
procedure.
Print 603.93.391
Component
failure
WARNING 25 03 NO SIGNAL The pilot light either CAN line failure. 1) Run warning light/indicator
Print 603.93.391
LIGHTS - doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
SWITCH - 25 04 SIGNAL NOT The programmable Read Body Controller state
SECOND SPEED PLAUSIBLE overspeed governor parameters
procedure.
SWITCH - 25 05 SUPPLY OVER THE The programmable Read Body Controller state
SECOND SPEED NORMAL RANGE overspeed governor parameters
procedure.
WARNING 25 05 SUPPLY OVER THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - NORMAL RANGE doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).

399
Component
400
failure
SWITCH - 25 06 SUPPLY BELOW THE The programmable Read Body Controller state
SECOND SPEED RANGE overspeed governor parameters

procedure.
WARNING 25 06 SUPPLY BELOW THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - RANGE doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
SWITCH - 25 07 VALUE OVER THE The programmable Read Body Controller state
SECOND SPEED NORMAL LIMIT overspeed governor parameters
procedure.
WARNING 25 07 VALUE OVER THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - NORMAL LIMIT doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
Print 603.93.391
Component
failure
SWITCH - 25 08 VALUE BELOW THE The programmable Read Body Controller state
Print 603.93.391
SECOND SPEED LIMIT overspeed governor parameters

procedure.
WARNING 26 00 NO AVAILABLE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL SYMPTOM doesn’t work or it remains impedance between pin 21
LOW PRESSURE always lighted up. and pin 22 of the 30-pin
connector must be
ECUs connected). Check
engine oil level. Run Cluster
and Body Controller
diagnostic procedures.
RELAY - GLOW 26 00 NO AVAILABLE A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG SYMPTOM resistance is not powered, control relay faulty.
possible cold start difficult
relay pin 85 and connector
and grade of smoke when
EDC pin B4, between relay pin
starting
86 and connector EDC pin
B)the pre-post heating B16.
resistance is always
powered: early wear of
the resistance, the
batteries become rapidly
discharged.
WARNING 26 01 SHORT CIRCUIT TO The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL POSITIVE doesn’t work or it remains impedance between pin 21
connector must be
and Body Controller

401
Component
402
failure
RELAY - GLOW 26 01 SHORT CIRCUIT TO A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG POSITIVE resistance is not powered, control relay faulty.

starting
the resistance, the
discharged.
WARNING 26 02 OPEN CIRCUIT OR The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL SHORT CIRCUIT TO doesn’t work or it remains impedance between pin 21
LOW PRESSURE GROUND always lighted up. and pin 22 of the 30-pin
connector must be
and Body Controller
RELAY - GLOW 26 02 OPEN CIRCUIT OR A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG SHORT CIRCUIT TO resistance is not powered, control relay faulty.
GROUND possible cold start difficult
starting
the resistance, the
discharged.
WARNING 26 03 NO SIGNAL The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL doesn’t work or it remains impedance between pin 21 and
LOW PRESSURE always lighted up. pin 22 of the 30-pin connector
must be approximately 60 ohm
ECUs connected). Check engine
oil level. Run Cluster and Body
procedures.
Print 603.93.391
Component
failure
RELAY - GLOW 26 03 NO SIGNAL A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
Print 603.93.391
PLUG resistance is not powered, control relay faulty.
starting

the resistance, the
discharged.
WARNING 26 04 SIGNAL NOT The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL PLAUSIBLE doesn’t work or it remains impedance between pin 21
connector must be
and Body Controller
WARNING 26 05 SUPPLY OVER THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL NORMAL RANGE doesn’t work or it remains impedance between pin 21
connector must be
and Body Controller
WARNING 26 06 SUPPLY BELOW THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL RANGE doesn’t work or it remains impedance between pin 21
connector must be
and Body Controller

403
Component
404
failure
WARNING 26 07 VALUE OVER THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL NORMAL LIMIT doesn’t work or it remains impedance between pin 21

connector must be
and Body Controller
WARNING 26 08 VALUE BELOW THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - LIMIT doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
WARNING 26 08 VALUE BELOW THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL LIMIT doesn’t work or it remains impedance between pin 21
connector must be
and Body Controller
RELAY - GLOW 27 04 SIGNAL NOT A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG PLAUSIBLE resistance is not powered, control relay faulty.
starting
the resistance, the
discharged.
Print 603.93.391
Component
failure
RELAY - GLOW 27 05 SUPPLY OVER THE A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
Print 603.93.391
PLUG NORMAL RANGE resistance is not powered, control relay faulty.
possible cold start difficult Check the wiring between
and grade of smoke when relay pin 85 and connector
starting EDC pin B4, between relay pin
B)the pre-post heating
B16.
powered: early wear of the
resistance, the batteries
become rapidly discharged.
RELAY - GLOW 27 06 SUPPLY BELOW THE A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG RANGE resistance is not powered, control relay faulty.
RELAY - GLOW 27 07 VALUE OVER THE A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG NORMAL LIMIT resistance is not powered, control relay faulty.
RELAY - GLOW 27 08 VALUE BELOW THE A) the pre-post heating Pre-post heating resistance Active diagnosis. EDC pilot light on.
PLUG LIMIT resistance is not powered, control relay faulty.

405
Component
406
failure
ELECTROVALVE 28 00 NO AVAILABLE The engine brake is not Positively short-circuited, Exhaust brake solenoid valve EDC pilot light on.
S - ENGINE SYMPTOM operating or is always ground-short-circuited or active diagnosis
BRAKE activated above 1000 rpm open-circuited engine brake Reading of status parameters.

solenoid valve If the result is negative, check
the solenoid valve continuity
and resistance (R = approx. 35
Ohm).
solenoid valve connection pin
1 and connector EDC pin B4,

between solenoid valve
connection pin 2 and
connector EDC pin B11.
ELECTROVALVE 28 01 SHORT CIRCUIT TO The engine brake is not Positively short-circuited, Exhaust brake solenoid valve EDC pilot light on.
S - ENGINE POSITIVE operating or is always ground-short-circuited or active diagnosis
solenoid valve If the result is negative, check the
solenoid valve continuity and
resistance (R = approx. 35
Ohm).
solenoid valve connection pin 1
and connector EDC pin B4,
connection pin 2 and connector
EDC pin B11.
ELECTROVALVE 28 02 OPEN CIRCUIT OR The engine brake is not Positively short-circuited, Exhaust brake solenoid valve EDC pilot light on.
S - ENGINE SHORT CIRCUIT TO operating or is always ground-short-circuited or active diagnosis
BRAKE GROUND activated above 1000 rpm open-circuited engine brake Reading of status parameters.
solenoid valve If the result is negative, check
the solenoid valve continuity
and resistance (R = approx. 35
Ohm).
solenoid valve connection pin
1 and connector EDC pin B4,
connection pin 2 and
Print 603.93.391
Component
failure
ELECTROVALVE 28 03 NO SIGNAL The engine brake is not Positively short-circuited, Exhaust brake solenoid valve EDC pilot light on.
active diagnosis
Print 603.93.391
S - ENGINE operating or is always ground-short-circuited or
If the result is negative, check the
solenoid valve solenoid valve continuity and
resistance (R = approx. 35 Ohm).

EDC pin B11.
ELECTROVALVE 28 04 SIGNAL NOT The engine brake is not Positively short-circuited, Exhaust brake solenoid valve EDC pilot light on.
S - ENGINE PLAUSIBLE operating or is always ground-short-circuited or active diagnosis
EDC pin B11.
ELECTROVALVE 28 05 SUPPLY OVER THE The engine brake is not Positively short-circuited, Exhaust brake solenoid valve EDC pilot light on.
S - ENGINE NORMAL RANGE operating or is always ground-short-circuited or active diagnosis
EDC pin B11.
RELAY - 29 00 NO AVAILABLE A/C compressor always Check wiring and connections.
AIR-CONDITIO SYMPTOM on or not working. Replace relay if required.
NER
COMPRESSOR
RELAY - 29 01 SHORT CIRCUIT TO A/C compressor always Check wiring and connections.
AIR-CONDITIO POSITIVE on or not working. Replace relay if required.
NER
COMPRESSOR

407
Component
408
failure
ELECTROVALVE 29 06 SUPPLY BELOW THE The engine brake is not Positively short-circuited, Exhaust brake solenoid valve active EDC pilot light on.
S - ENGINE RANGE operating or is always ground-short-circuited or diagnosis
Reading of status parameters.
BRAKE activated above 1000 rpm open-circuited engine brake

If the solenoid valve is all right, check
the wiring between solenoid valve
EDC pin B4, between solenoid
valve connection pin 2 and
ELECTROVALVE 29 07 VALUE OVER THE The engine brake is not Positively short-circuited, Exhaust brake solenoid valve active EDC pilot light on.
S - ENGINE NORMAL LIMIT operating or is always ground-short-circuited or diagnosis
BRAKE activated above 1000 rpm open-circuited engine brake If the result is negative, check the
ELECTROVALVE 29 08 VALUE BELOW THE The engine brake is not Positively short-circuited, Exhaust brake solenoid valve active EDC pilot light on.
S - ENGINE LIMIT operating or is always ground-short-circuited or diagnosis
BRAKE activated above 1000 rpm open-circuited engine brake If the result is negative, check the
RELAY - 2A 00 NO AVAILABLE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL SYMPTOM The battery becomes Check the wiring between relay pin
85 and connector EDC pin B2 a)Possible storage of 2.3
FILTER discharged. passing through sleeve E pin 38, because the fuel overheats.
b)Heater never engaged. between relay pin 86 and connector
EDC pin B36 passing through sleeve
Possible filter clogging due E pin 29.
to paraffin traces in the
fuel in presence of too low
external temperatures (<
-15 °C).
Print 603.93.391
Component
failure
RELAY - 2A 01 SHORT CIRCUIT TO a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
Print 603.93.391
HEATED FUEL POSITIVE The battery becomes
Check the wiring between a)Possible storage of 2.3
FILTER discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged. EDC pin B2 passing through
Possible filter clogging due sleeve E pin 38, between relay
to paraffin traces in the pin 86 and connector EDC pin

fuel in presence of too low B36 passing through sleeve E
external temperatures (< pin 29.
-15 °C).
RELAY - 2A 02 OPEN CIRCUIT OR A/C compressor always Check wiring and connections.
AIR-CONDITIO SHORT CIRCUIT TO on or not working. Replace relay if required.
NER GROUND
COMPRESSOR
RELAY - 2A 02 OPEN CIRCUIT OR a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL SHORT CIRCUIT TO The battery becomes
FILTER GROUND discharged.
-15 °C).
RELAY - 2A 03 NO SIGNAL A/C compressor always Check wiring and connections.
AIR-CONDITIO on or not working. Replace relay if required.
NER
COMPRESSOR
RELAY - 2A 03 NO SIGNAL a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL The battery becomes
FILTER discharged.
-15 °C).
RELAY - 2A 04 SIGNAL NOT A/C compressor always Check wiring and connections.
AIR-CONDITIO PLAUSIBLE on or not working. Replace relay if required.
NER
COMPRESSOR

409
Component
410
failure
RELAY - 2A 04 SIGNAL NOT a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL PLAUSIBLE The battery becomes
FILTER discharged.

-15 °C).
RELAY - 2A 05 SUPPLY OVER THE A/C compressor always Check wiring and connections.
AIR-CONDITIO NORMAL RANGE on or not working. Replace relay if required.
NER
COMPRESSOR
RELAY - 2A 05 SUPPLY OVER THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL NORMAL RANGE The battery becomes
FILTER discharged.
-15 °C).
RELAY - 2A 06 SUPPLY BELOW THE A/C compressor always Check wiring and connections.
AIR-CONDITIO RANGE on or not working. Replace relay if required.
NER
COMPRESSOR
RELAY - 2A 06 SUPPLY BELOW THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL RANGE The battery becomes
FILTER discharged.
-15 °C).
RELAY - 2A 07 VALUE OVER THE A/C compressor always Check wiring and connections.
AIR-CONDITIO NORMAL LIMIT on or not working. Replace relay if required.
NER
COMPRESSOR
Print 603.93.391
Component
failure
RELAY - 2A 07 VALUE OVER THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
Print 603.93.391
HEATED FUEL NORMAL LIMIT The battery becomes
FILTER discharged.

-15 °C).
RELAY - 2A 08 VALUE BELOW THE A/C compressor always Check wiring and connections.
AIR-CONDITIO LIMIT on or not working. Replace relay if required.
NER
COMPRESSOR
RELAY - START 2B 00 NO AVAILABLE The engine doesn’t start. Starter relay short-circuited Check the component is all EDC pilot light on.
SYMPTOM or open-circuited. right.
In case it is already running,
it stops. Check the wiring between
relay and connector EDC pin
B37.
ENGINE - 2B 00 NO AVAILABLE Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
CONTROL SYMPTOM after starting. monitoring. properly connected to the
The gearcase doesn’t detect,
SYSTEM pre-post heating resistance
by means of the air
PRE-POSTHEATI terminals.
temperature sensor in the
NG
Check that the pre-post suction manifold, the
heating resistance is all right (R increase in the temperature
= approx. 0,5 Ohm) due to the operation of the
resistance.
Check wiring and connections
between the pre-post heating
resistance remote control
switch pin 87 and the terminal
(+) of the resistance, passing
through sleeve E pin 40.
between terminal (-) of the
resistance and earth.
RELAY - START 2B 01 SHORT CIRCUIT TO The engine doesn’t start. Starter relay short-circuited Check the component is all EDC pilot light on.
POSITIVE or open-circuited. right.
it stops. Check the wiring between
relay and connector EDC pin

B37.

411
Component
412
failure
ENGINE - 2B 01 SHORT CIRCUIT TO Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
CONTROL POSITIVE after starting. monitoring. properly connected to the
SYSTEM pre-post heating resistance The gearcase doesn’t detect,

terminals. by means of the air
PRE-POSTHEATI
NG Check that the pre-post heating suction manifold, the
resistance is all right (R = approx. increase in the temperature
0,5 Ohm)
due to the operation of the
Check wiring and connections resistance.
resistance remote control switch
pin 87 and the terminal (+) of

the resistance, passing through
sleeve E pin 40.
RELAY - START 2B 02 OPEN CIRCUIT OR The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
SHORT CIRCUIT TO or open-circuited. Check the wiring between relay
GROUND and connector EDC pin B37.
it stops.
ENGINE - 2B 02 OPEN CIRCUIT OR Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
CONTROL SHORT CIRCUIT TO after starting. monitoring. properly connected to the
SYSTEM GROUND pre-post heating resistance The gearcase doesn’t detect,
PRE-POSTHEATI
NG Check that the pre-post heating suction manifold, the
resistance is all right (R = approx. increase in the temperature
0,5 Ohm)
due to the operation of the
Check wiring and connections resistance.
sleeve E pin 40.
RELAY - START 2B 03 NO SIGNAL The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
or open-circuited. Check the wiring between relay
it stops. and connector EDC pin B37.
Print 603.93.391
Component
failure
ENGINE - 2B 03 NO SIGNAL Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
properly connected to the
Print 603.93.391
CONTROL after starting. monitoring.
pre-post heating resistance The gearcase doesn’t detect,
SYSTEM
PRE-POSTHEATI
Check that the pre-post heating temperature sensor in the
NG resistance is all right (R = approx. suction manifold, the
0,5 Ohm)
increase in the temperature

Check wiring and connections due to the operation of the
between the pre-post heating resistance.
sleeve E pin 40.
RELAY - START 2B 04 SIGNAL NOT The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
PLAUSIBLE or open-circuited. Check the wiring between relay
In case it is already running, and connector EDC pin B37.
it stops.
RELAY - START 2B 05 SUPPLY OVER THE The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
NORMAL RANGE Check the wiring between relay
In case it is already running, or open-circuited. and connector EDC pin B37.
it stops.
RELAY - START 2B 06 SUPPLY BELOW THE The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
RANGE or open-circuited. Check the wiring between relay
it stops.
RELAY - START 2B 07 VALUE OVER THE The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
NORMAL LIMIT or open-circuited. Check the wiring between relay
it stops.
RELAY - 2B 08 VALUE BELOW THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis. EDC pilot light off.
HEATED FUEL LIMIT The battery becomes Check the wiring between relay
pin 85 and connector EDC pin a)Possible storage of 2.3
FILTER discharged.
B2 passing through sleeve E pin because the fuel overheats.
b)Heater never engaged. 38, between relay pin 86 and
Possible filter clogging due connector EDC pin B36 passing
to paraffin traces in the fuel through sleeve E pin 29.
in presence of too low
external temperatures (<
-15 °C).
RELAY - START 2B 08 VALUE BELOW THE The engine doesn’t start. Starter relay short-circuited Check the component is all right. EDC pilot light on.
LIMIT In case it is already running, or open-circuited. Check the wiring between relay
and connector EDC pin B37.
it stops.

413
Component
414
failure
SENSORS - 2C 00 NO AVAILABLE Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR SYMPTOM ground-short-circuited or parameters by means of the
The temperature sensor is
TEMPERATURE open-circuited air diagnostic instrument: in

incorporated in the pressure
tempe?rature sensor on presence of this error, the
one.
suction manifold supercharging air temperature
will be fixed at 30 °C.
If the temperature is fixed at
30 °C, check the sensor is all
right
(R = approx. 2,5 kOhm at 20

°C) pins 1 and 2 of the sensor
itself.
C21, between sensor
SENSORS - 2C 01 SHORT CIRCUIT TO Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR POSITIVE ground-short-circuited or parameters by means of the
one.
right
itself.
Print 603.93.391
Component
failure
SENSORS - 2C 02 OPEN CIRCUIT OR Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
Print 603.93.391
BOOST AIR SHORT CIRCUIT TO ground-short-circuited or parameters by means of the
TEMPERATURE GROUND open-circuited air diagnostic instrument: in
one.

right
itself.
C21, between sensor
SENSORS - 2C 03 NO SIGNAL Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR ground-short-circuited or parameters by means of the
one.
right
itself.

415
Component
416
failure
ENGINE - 2C 04 SIGNAL NOT Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
CONTROL PLAUSIBLE after starting. monitoring. properly connected to the

by means of the air
NG
resistance.

SENSORS - 2C 04 SIGNAL NOT Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR PLAUSIBLE ground-short-circuited or parameters by means of the
one.
right
itself.
C21, between sensor
Print 603.93.391
Component
failure
ENGINE - 2C 05 SUPPLY OVER THE Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
Print 603.93.391
CONTROL NORMAL RANGE after starting. monitoring. properly connected to the
by means of the air
NG

resistance.
SENSORS - 2C 05 SUPPLY OVER THE Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR NORMAL RANGE ground-short-circuited or parameters by means of the
one.
right
itself.
C21, between sensor

417
Component
418
failure
ENGINE - 2C 06 SUPPLY BELOW THE Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
CONTROL RANGE after starting. monitoring. properly connected to the

by means of the air
NG
resistance.

SENSORS - 2C 06 SUPPLY BELOW THE Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR RANGE ground-short-circuited or parameters by means of the
one.
right
itself.
C21, between sensor
Print 603.93.391
Component
failure
ENGINE - 2C 07 VALUE OVER THE Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
Print 603.93.391
CONTROL NORMAL LIMIT after starting. monitoring. properly connected to the
by means of the air
NG

resistance.
SENSORS - 2C 07 VALUE OVER THE Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR NORMAL LIMIT ground-short-circuited or parameters by means of the
one.
right
itself.
C21, between sensor

419
Component
420
failure
ENGINE - 2C 08 VALUE BELOW THE Possible grade of smoke Pre-post heating procedure Check that the cables are EDC pilot light on.
CONTROL LIMIT after starting. monitoring. properly connected to the

by means of the air
NG
resistance.

SENSORS - 2C 08 VALUE BELOW THE Slight power reduction Positively short-circuited, Reading of measurable EDC pilot light off.
BOOST AIR LIMIT ground-short-circuited or parameters by means of the
one.
right
itself.
C21, between sensor
Print 603.93.391
Component
failure
ENGINE - 2D 00 NO AVAILABLE Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
Print 603.93.391
ENGINE SPEED SYMPTOM flywheel sensor and the not significant: clear failure
Sometimes only the error
SENSING camshaft sensor signals. memory and pass the vehicle
6.3 is stored, whereas
in this case. Error 6.3 is
actually it is the camshaft
significant when it appears
signal that is faulty.
along with error 6.1 and/or
6.2. Read failure memory: In this case carry out the

check environmental inspections foreseen to
conditions associated to error. solve problem 6.2
Delete error if stored at
This error might be stored
engine speed less than 650
now and then in case of
rpm, clear failure memory and
engine stop using the
pass the vehicle. Otherwise,
under-cabin push-button.
check integrity of damper
flywheel and camshaft phonic If the damper flywheel is
wheel, cleanness and correct worn, it will be locally
fastening of the two sensors. deformed and, if the case
mating areas have begun
yielding, signs of silicone will
the visible in the surrounding
zone.
Check that on the phonic
wheel there are no shreds of
adhesive tape and that it
turns with no axial
oscillations due to possible
impact-strains.
WARNING 2D 00 NO AVAILABLE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - SYMPTOM doesn’t work or it remains active diagnostics in the
COOLANT always lighted up. Cluster diagnostic procedure.
TEMPERATURE 2) Check that the CAN line is
connector must be
ECUs connected).

421
Component
422
failure
ENGINE - 2D 01 SHORT CIRCUIT TO Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
ENGINE SPEED POSITIVE flywheel sensor and the not significant: clear failure


zone.
turns with no axial
impact-strains.
WARNING 2D 01 SHORT CIRCUIT TO The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - POSITIVE doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
Print 603.93.391
Component
failure
ENGINE - 2D 02 OPEN CIRCUIT OR Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
Print 603.93.391
ENGINE SPEED SHORT CIRCUIT TO flywheel sensor and the not significant: clear failure Sometimes only the error
SENSING GROUND camshaft sensor signals. memory and pass the vehicle in
this case. Error 6.3 is significant 6.3 is stored, whereas
when it appears along with error actually it is the camshaft
6.1 and/or 6.2. Read failure signal that is faulty.
memory: check environmental
In this case carry out the

conditions associated to error. inspections foreseen to
Delete error if stored at engine solve problem 6.2
speed less than 650 rpm, clear
failure memory and pass the This error might be stored
vehicle. Otherwise, check now and then in case of
integrity of damper flywheel and engine stop using the
camshaft phonic wheel, under-cabin push-button.
cleanness and correct fastening If the damper flywheel is
of the two sensors. worn, it will be locally
deformed and, if the case
zone.
turns with no axial
impact-strains.
WARNING 2D 02 OPEN CIRCUIT OR The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - SHORT CIRCUIT TO doesn’t work or it remains active diagnostics in the Cluster
COOLANT GROUND always lighted up. diagnostic procedure. 2) Check
TEMPERATURE that the CAN line is up:
impedance between pin 21 and
pin 22 of the 30-pin connector
ECUs connected).
WARNING 2D 03 NO SIGNAL The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - doesn’t work or it remains active diagnostics in the Cluster
COOLANT always lighted up. diagnostic procedure. 2) Check

ECUs connected).

423
Component
424
failure
ENGINE - 2D 03 NO VALID SIGNAL Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
ENGINE SPEED FROM CRK SENSOR flywheel sensor and the not significant: clear failure


zone.
turns with no axial
impact-strains.
WARNING 2D 04 SIGNAL NOT The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - PLAUSIBLE doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
Print 603.93.391
Component
failure
ENGINE - 2D 04 SIGNAL NOT Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
Print 603.93.391
ENGINE SPEED PLAUSIBLE flywheel sensor and the not significant: clear failure

zone.
turns with no axial
impact-strains.
WARNING 2D 05 SUPPLY OVER THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - NORMAL RANGE doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).

425
Component
426
failure
ENGINE - 2D 05 SUPPLY OVER THE Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
ENGINE SPEED NORMAL RANGE flywheel sensor and the not significant: clear failure


zone.
turns with no axial
impact-strains.
Print 603.93.391
Component
failure
ENGINE - 2D 06 SUPPLY BELOW THE Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
Print 603.93.391
ENGINE SPEED RANGE flywheel sensor and the not significant: clear failure

zone.
turns with no axial
impact-strains.

427
Component
428
failure
ENGINE - 2D 07 VALUE OVER THE Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
ENGINE SPEED NORMAL LIMIT flywheel sensor and the not significant: clear failure


zone.
turns with no axial
impact-strains.
Print 603.93.391
Component
failure
ENGINE - 2D 08 NO VALID SIGNAL Light power reduction. No plausibility between the Presence of error 6.3 alone is EDC pilot light on.
Print 603.93.391
ENGINE SPEED FROM CAM SENSOR flywheel sensor and the not significant: clear failure

zone.
turns with no axial
impact-strains.
WARNING 2E 00 NO AVAILABLE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC SYMPTOM doesn’t work or it remains impedance between pin 21
always lighted up. and pin 22 of the 30-pin
connector must be
ECUs connected). Run
Cluster and Body Controller

429
Component
430
failure
ELECTROVALVE 2E 00 NO AVAILABLE Significant power Positively short-circuited, Check that the connector is
S - FUEL SYMPTOM reduction. ground short-circuited or properly connected to the
PRESSURE open-circuited pressure pressure regulator.

REGULATION regulator Check by means of a
multimeter that the pressure
regulator solenoid valve is all
right (r = APPROX. 3,2 Ohm).
If the component is all right,
pressure regulator connector
and the connector EDC pin

C5-C7.
WARNING 2E 01 SHORT CIRCUIT TO The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC POSITIVE doesn’t work or it remains impedance between pin 21
connector must be
ELECTROVALVE 2E 01 SHORT CIRCUIT TO Significant power Positively short-circuited, Check that the connector is
S - FUEL POSITIVE reduction. ground short-circuited or properly connected to the
REGULATION regulator Check by means of a
C5-C7.
WARNING 2E 02 OPEN CIRCUIT OR The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC SHORT CIRCUIT TO doesn’t work or it remains impedance between pin 21
GROUND always lighted up. and pin 22 of the 30-pin
connector must be
Print 603.93.391
Component
failure
WARNING 2E 03 NO SIGNAL The pilot light either CAN line failure. Check that the CAN line is up:
Print 603.93.391
LIGHTS - EDC doesn’t work or it remains impedance between pin 21 and
always lighted up. pin 22 of the 30-pin connector
ECUs connected). Run Cluster
and Body Controller diagnostic
procedures.
WARNING 2E 04 SIGNAL NOT The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC PLAUSIBLE doesn’t work or it remains impedance between pin 21 and
procedures.
WARNING 2E 05 SUPPLY OVER THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC NORMAL RANGE doesn’t work or it remains impedance between pin 21 and
procedures.
WARNING 2E 06 SUPPLY BELOW THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - RANGE doesn’t work or it remains active diagnostics in the Cluster
COOLANT always lighted up. diagnostic procedure. 2) Check
ECUs connected).
WARNING 2E 06 SUPPLY BELOW THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC RANGE doesn’t work or it remains impedance between pin 21 and
procedures.

431
Component
432
failure
WARNING 2E 07 VALUE OVER THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - NORMAL LIMIT doesn’t work or it remains active diagnostics in the

connector must be
ECUs connected).
WARNING 2E 07 VALUE OVER THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC NORMAL LIMIT doesn’t work or it remains impedance between pin 21
connector must be
WARNING 2E 08 VALUE BELOW THE The pilot light either CAN line failure. 1) Run warning light/indicator
LIGHTS - LIMIT doesn’t work or it remains active diagnostics in the
connector must be
ECUs connected).
WARNING 2E 08 VALUE BELOW THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - EDC LIMIT doesn’t work or it remains impedance between pin 21
connector must be
Print 603.93.391
Component
failure
ELECTROVALVE 2F 02 OPEN CIRCUIT OR Significant power Positively short-circuited, Check that the connector is
Print 603.93.391
S - FUEL SHORT CIRCUIT TO reduction. ground short-circuited or properly connected to the
PRESSURE GROUND open-circuited pressure pressure regulator.
REGULATION regulator
Check by means of a

C5-C7.
ELECTROVALVE 2F 03 NO SIGNAL Significant power Positively short-circuited, Check that the connector is
S - FUEL reduction. ground short-circuited or properly connected to the
Check by means of a
C5-C7.
ELECTROVALVE 2F 04 SIGNAL NOT Significant power Positively short-circuited, Check that the connector is
S - FUEL PLAUSIBLE reduction. ground short-circuited or properly connected to the
Check by means of a
C5-C7.

433
Component
434
failure
ELECTROVALVE 2F 05 SUPPLY OVER THE Significant power Positively short-circuited, Check that the connector is
S - FUEL NORMAL RANGE reduction. ground short-circuited or properly connected to the

Check by means of a

C5-C7.
ELECTROVALVE 2F 06 SUPPLY BELOW THE Significant power Positively short-circuited, Check that the connector is
S - FUEL RANGE reduction. ground short-circuited or properly connected to the
Check by means of a
C5-C7.
ELECTROVALVE 2F 07 VALUE OVER THE Significant power Positively short-circuited, Check that the connector is
S - FUEL NORMAL LIMIT reduction. ground short-circuited or properly connected to the
Check by means of a
C5-C7.
Print 603.93.391
Component
failure
ELECTROVALVE 2F 08 VALUE BELOW THE Significant power Positively short-circuited, Check that the connector is
Print 603.93.391
S - FUEL LIMIT reduction. ground short-circuited or properly connected to the
Check by means of a

C5-C7.
ENGINE - 30 00 NO AVAILABLE The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE SYMPTOM doesn’t work. short-circuited or 3 of the instrument and Resistance measured with
FOR TD SIGNAL open-circuited. connector EDC pin B49. key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance measured
between 30-pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/-3% (measured
with key off and ECUs
connected).

435
Component
436
failure
ENGINE - 30 01 SHORT CIRCUIT TO The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE POSITIVE doesn’t work. short-circuited or 3 of the instrument and Resistance measured with

Impedance measured
connected).
ENGINE - 30 02 OPEN CIRCUIT OR The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE SHORT CIRCUIT TO doesn’t work. short-circuited or 3 of the instrument and Resistance measured with
FOR TD SIGNAL GROUND open-circuited. connector EDC pin B49. key off directly on EDC ECU
Impedance measured
connected).
Print 603.93.391
Component
failure
ENGINE - 30 03 NO SIGNAL The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
Print 603.93.391
POWER STAGE doesn’t work. short-circuited or 3 of the instrument and Resistance measured with

Impedance measured
connected).
ENGINE - 31 00 NO AVAILABLE EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE SYMPTOM instrument synchronization between connector EDC pin
FOR SYNC. signal short-circuited or B48 and diagnosis plug pin 23,
SIGNAL open-circuited. passing through the brown
(MODUS) sleeve B pin 11, is all right.
ENGINE - 31 01 SHORT CIRCUIT TO EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE POSITIVE instrument synchronization between connector EDC pin
ENGINE - 31 02 OPEN CIRCUIT OR EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE SHORT CIRCUIT TO instrument synchronization between connector EDC pin
FOR SYNC. GROUND signal short-circuited or B48 and diagnosis plug pin 23,
ENGINE - 31 03 NO SIGNAL EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE instrument synchronization between connector EDC pin

437
Component
438
failure
ENGINE - 31 04 SIGNAL NOT The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE PLAUSIBLE doesn’t work. short-circuited or 3 of the instrument and Resistance measured with

Impedance measured
connected).
ENGINE - 31 04 SIGNAL NOT EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE PLAUSIBLE instrument synchronization between connector EDC pin
ENGINE - 31 05 SUPPLY OVER THE The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE NORMAL RANGE doesn’t work. short-circuited or 3 of the instrument and Resistance measured with
Impedance measured
connected).
Print 603.93.391
Component
failure
ENGINE - 31 05 SUPPLY OVER THE EDC to diagnostic Check that the wiring EDC pilot light off
Print 603.93.391
POWER STAGE NORMAL RANGE instrument synchronization between connector EDC pin
ENGINE - 31 06 SUPPLY BELOW THE The speed indicator Speed indicator signal Check the wiring between pinCheck CAN VDB line: 1)
POWER STAGE RANGE doesn’t work. short-circuited or 3 of the instrument and Resistance measured with
Impedance measured
connected).
ENGINE - 31 06 SUPPLY BELOW THE EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE RANGE instrument synchronization between connector EDC pin

439
Component
440
failure
ENGINE - 31 07 VALUE OVER THE The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE NORMAL LIMIT doesn’t work. short-circuited or 3 of the instrument and Resistance measured with

Impedance measured
connected).
ENGINE - 31 07 VALUE OVER THE EDC to diagnostic Check that the wiring EDC pilot light off
POWER STAGE NORMAL LIMIT instrument synchronization between connector EDC pin
ENGINE - 31 08 VALUE BELOW THE The speed indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
POWER STAGE LIMIT doesn’t work. short-circuited or 3 of the instrument and Resistance measured with
Impedance measured
connected).
Print 603.93.391
Component
failure
ENGINE - 31 08 VALUE BELOW THE EDC to diagnostic Check that the wiring EDC pilot light off
Print 603.93.391
POWER STAGE LIMIT instrument synchronization between connector EDC pin
WARNING 32 00 NO AVAILABLE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL SYMPTOM doesn’t work or it remains impedance between pin 21

PRESSURE always lighted up. and pin 22 of the 30-pin
GAUGE connector must be
WARNING 32 00 NO AVAILABLE Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - SYMPTOM engine coolant active diagnostics in the
COOLANT temperature. Cluster diagnostic procedure.
TEMPERATUR 2) Check that the CAN line is
GAUGE up: impedance between pin
connector must be
ECUs connected).

441
Component
442
failure
WARNING 32 01 SHORT CIRCUIT TO The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL POSITIVE doesn’t work or it remains impedance between pin 21
PRESSURE always lighted up. and pin 22 of the 30-pin

WARNING 32 01 SHORT CIRCUIT TO Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - POSITIVE engine coolant active diagnostics in the

connector must be
ECUs connected).
WARNING 32 02 OPEN CIRCUIT OR The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL SHORT CIRCUIT TO doesn’t work or it remains impedance between pin 21
PRESSURE GROUND always lighted up. and pin 22 of the 30-pin
WARNING 32 02 OPEN CIRCUIT OR Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - SHORT CIRCUIT TO engine coolant active diagnostics in the
COOLANT GROUND temperature. Cluster diagnostic procedure.
connector must be
ECUs connected).
Print 603.93.391
Component
failure
WARNING 32 03 NO SIGNAL The pilot light either CAN line failure. Check that the CAN line is up:
Print 603.93.391
LIGHTS - OIL doesn’t work or it remains impedance between pin 21 and
PRESSURE always lighted up. pin 22 of the 30-pin connector
GAUGE must be approximately 60 ohm

procedures.
WARNING 32 03 NO SIGNAL Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - engine coolant active diagnostics in the Cluster
COOLANT temperature. diagnostic procedure. 2) Check
TEMPERATUR that the CAN line is up:
GAUGE impedance between pin 21 and
ECUs connected).
WARNING 32 04 SIGNAL NOT The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL PLAUSIBLE doesn’t work or it remains impedance between pin 21 and
procedures.
WARNING 32 04 SIGNAL NOT Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - PLAUSIBLE engine coolant active diagnostics in the Cluster
ECUs connected).

443
Component
444
failure
WARNING 32 05 SUPPLY OVER THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL NORMAL RANGE doesn’t work or it remains impedance between pin 21 and

procedures.
WARNING 32 05 SUPPLY OVER THE Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - NORMAL RANGE engine coolant active diagnostics in the Cluster

ECUs connected).
WARNING 32 06 SUPPLY BELOW THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL RANGE doesn’t work or it remains impedance between pin 21 and
procedures.
WARNING 32 07 VALUE OVER THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL NORMAL LIMIT doesn’t work or it remains impedance between pin 21 and
procedures.
WARNING 32 08 VALUE BELOW THE The pilot light either CAN line failure. Check that the CAN line is up:
LIGHTS - OIL LIMIT doesn’t work or it remains impedance between pin 21 and
procedures.
Print 603.93.391
Component
failure
SWITCH - 33 00 NO AVAILABLE The exhaust brake engages Exhaust brake selector: not Read Body Controller state
Print 603.93.391
ENGINE BRAKE SYMPTOM only if operated by means of plausible signal or lack of parameters with diagnostic
PRESELECTION the push-button on the switchover of the exhaust tool (engine brake switch not
BUTTON floor, or if operated by the brake control mode. managed by EDC).
push-button on the floor
and only by means of one of
the other two ways, even if
a different selection has

been chosen.
ENGINE - 33 00 NO AVAILABLE Significant power reduction. Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING SYMPTOM double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
SWITCH - 33 01 SHORT CIRCUIT TO The exhaust brake engages Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE POSITIVE only if operated by means of plausible signal or lack of parameters with diagnostic
been chosen.
ENGINE - 33 01 SHORT CIRCUIT TO Significant power reduction. Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING POSITIVE double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
SWITCH - 33 02 OPEN CIRCUIT OR The exhaust brake engages Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE SHORT CIRCUIT TO only if operated by means of plausible signal or lack of parameters with diagnostic
PRESELECTION GROUND the push-button on the switchover of the exhaust tool (engine brake switch not
been chosen.
SWITCH - 33 03 NO SIGNAL The exhaust brake engages Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE only if operated by means of plausible signal or lack of parameters with diagnostic
been chosen.

445
Component
446
failure
SWITCH - 33 04 SIGNAL NOT The exhaust brake Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE PLAUSIBLE engages only if operated plausible signal or lack of parameters with diagnostic
PRESELECTION by means of the switchover of the exhaust tool (engine brake switch not

BUTTON push-button on the floor, brake control mode. managed by EDC).
or if operated by the
and only by means of one
of the other two ways,
even if a different selection
has been chosen.
SWITCH - 33 05 SUPPLY OVER THE The exhaust brake Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE NORMAL RANGE engages only if operated plausible signal or lack of parameters with diagnostic
PRESELECTION by means of the switchover of the exhaust tool (engine brake switch not
BUTTON push-button on the floor, brake control mode. managed by EDC).
or if operated by the
has been chosen.
WARNING 33 06 SUPPLY BELOW THE Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - RANGE engine coolant active diagnostics in the
connector must be
ECUs connected).
SWITCH - 33 06 SUPPLY BELOW THE The exhaust brake engages Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE RANGE only if operated by means plausible signal or lack of parameters with diagnostic
PRESELECTION of the push-button on the switchover of the exhaust tool (engine brake switch not
has been chosen.
Print 603.93.391
Component
failure
WARNING 33 07 VALUE OVER THE Incorrect display of the CAN line failure. 1) Run warning light/indicator
Print 603.93.391
LIGHTS - NORMAL LIMIT engine coolant temperature. active diagnostics in the
COOLANT Cluster diagnostic procedure.
connector must be
ECUs connected).
SWITCH - 33 07 VALUE OVER THE The exhaust brake engages Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE NORMAL LIMIT only if operated by means of
plausible signal or lack of parameters with diagnostic
BUTTON floor, or if operated by the
brake control mode. managed by EDC).
been chosen.
WARNING 33 08 VALUE BELOW THE Incorrect display of the CAN line failure. 1) Run warning light/indicator
LIGHTS - LIMIT engine coolant temperature. active diagnostics in the
COOLANT Cluster diagnostic procedure.
connector must be
ECUs connected).
SWITCH - 33 08 VALUE BELOWTHE The exhaust brake engages Exhaust brake selector: not Read Body Controller state
ENGINE BRAKE LIMIT only if operated by means of plausible signal or lack of parameters with diagnostic
been chosen.
ENGINE - FUEL 34 00 NO AVAILABLE Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
PRESSURE SYMPTOM fuel gear pump. proper connection of the pipe
MONITORING unions between the tank and

hooked).

447
Component
448
failure
ENGINE - FUEL 34 00 NO AVAILABLE Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.
PRESSURE SYMPTOM unions or low-pressure proper connection of the pipe
MONITORING pipes downstream of the unions downstream of the fuel

fuel pump. pump (fasteners must be out
Possible defect of the signal
of the rail pressure sensor Check visually that the
low-pressure pipes are not
damaged. Carry out the
inspections of 8.2.
ENGINE - FUEL 34 00 NO AVAILABLE Fuel suction pipe in the tank Check whether the priming EDC pilot light winking.
PRESSURE SYMPTOM partially clogged due to pump on the prefilter works
In case some shavings have
MONITORING impurities or distortion properly.
been sucked (due to works
caused by overheating.
If the pump knob remains carried out by the producer
sucked downwards because on the fuel tank) perform an
of the suction pressure, accurate cleaning of the tank.
disassemble and check the
As a matter of fact the
tank suction pipe.
problem might occur again
If the suction pipe is all right, because of other shavings
replace the filter. remained inside the tank.
ENGINE - FUEL 34 00 NO AVAILABLE Insufficient fuel level in the Check fuel level. EDC pilot light winking.
PRESSURE SYMPTOM tank.
MONITORING
ENGINE - FUEL 34 00 NO AVAILABLE Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
PRESSURE SYMPTOM reduction. pressure in the rail is lower parameters: ?Duty Cycle rail
MONITORING or higher than the one pressure solenoid valve?
evaluated by the gearcase.
(with release 2-2001 and
subsequent ones):
in normal conditions, at idling
speed, loadless, and steady
state engine, the value must be
lower than 5%.
ENGINE - FUEL 34 01 TOO HIGH RAIL Engine stop. Max-min pressure error in Replace the overpressure EDC pilot light winking.
PRESSURE PRESSURE the rail valve
MONITORING
Check that suction and If the problem persists, carry
return lines of gasoil are not out the checks foreseen for 8.2
inverted (tank sensor) and 8.3.
Print 603.93.391
Component
failure
ENGINE - FUEL 34 02 OPEN CIRCUIT OR Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
Print 603.93.391
PRESSURE SHORT CIRCUIT TO reduction. pressure in the rail is lower parameters: ?Duty Cycle rail
MONITORING GROUND or higher than the one pressure solenoid valve?
evaluated by the gearcase. (with release 2-2001 and
subsequent ones):

speed, loadless, and steady state
engine, the value must be lower
than 5%.
ENGINE - FUEL 34 02 OPEN CIRCUIT OR Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
PRESSURE SHORT CIRCUIT TO fuel gear pump. proper connection of the pipe
MONITORING GROUND unions between the tank and
be out and unions well hooked).
ENGINE - 34 02 OPEN CIRCUIT OR Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING SHORT CIRCUIT TO reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE GROUND valve.
RELIEF VALVE
ENGINE - FUEL 34 02 OPEN CIRCUIT OR Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.
PRESSURE SHORT CIRCUIT TO unions or low-pressure proper connection of the pipe
MONITORING GROUND pipes downstream of the unions downstream of the fuel
inspections of 8.2.
ENGINE - FUEL 34 02 OPEN CIRCUIT OR Fuel suction pipe in the tank Check whether the priming EDC pilot light winking.
PRESSURE SHORT CIRCUIT TO partially clogged due to pump on the prefilter works
MONITORING GROUND impurities or distortion properly.
caused by overheating. If the pump knob remains carried out by the producer
sucked downwards because of on the fuel tank) perform an
the suction pressure, accurate cleaning of the tank.
disassemble and check the tank
suction pipe. As a matter of fact the
If the suction pipe is all right, problem might occur again
replace the filter. because of other shavings
ENGINE - FUEL 34 02 OPEN CIRCUIT OR Insufficient fuel level in the Check fuel level. EDC pilot light winking.
PRESSURE SHORT CIRCUIT TO tank.
MONITORING GROUND

449
Component
450
failure
ENGINE - 34 03 NO SIGNAL Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.

RELIEF VALVE
ENGINE - FUEL 34 03 TOO LOW RAIL Engine stop. Max-min pressure error in Replace the overpressure valve EDC pilot light winking.
PRESSURE PRESSURE the rail If the problem persists, carry out
MONITORING
Check that suction and the checks foreseen for 8.2 and
return lines of gasoil are not 8.3.
inverted (tank sensor)
ENGINE - 34 04 SIGNAL NOT Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING PLAUSIBLE reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
ENGINE - FUEL 34 04 NEGATIVE FUEL Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
PRESSURE PRESSURE DEVIATION reduction. pressure in the rail is lower parameters: ?Duty Cycle rail
subsequent ones):
than 5%.
ENGINE - FUEL 34 04 NEGATIVE FUEL Insufficient fuel level in the Check fuel level. EDC pilot light winking.
PRESSURE PRESSURE DEVIATION tank.
MONITORING
ENGINE - FUEL 34 04 NEGATIVE FUEL Fuel suction pipe in the tank
Check whether the priming EDC pilot light winking.
PRESSURE PRESSURE DEVIATION partially clogged due to pump on the prefilter works
properly. In case some shavings have
MONITORING impurities or distortion been sucked (due to works
problem might occur again
ENGINE - FUEL 34 04 NEGATIVE FUEL Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
PRESSURE PRESSURE DEVIATION fuel gear pump. proper connection of the pipe
Print 603.93.391
Component
failure
ENGINE - FUEL 34 04 NEGATIVE FUEL Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.
Print 603.93.391
PRESSURE PRESSURE DEVIATION unions or low-pressure proper connection of the pipe

inspections of 8.2.
ENGINE - 34 05 SUPPLY OVER THE Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING NORMAL RANGE reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
ENGINE - FUEL 34 05 POSITIVE FUEL Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
PRESSURE PRESSURE DEVIATION fuel gear pump. proper connection of the pipe
hooked).
ENGINE - FUEL 34 05 POSITIVE FUEL Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
PRESSURE PRESSURE DEVIATION reduction. pressure in the rail is lower parameters: ?Duty Cycle rail
evaluated by the gearcase.
(with release 2-2001 and
subsequent ones):
than 5%.
ENGINE - FUEL 34 05 POSITIVE FUEL Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.
PRESSURE PRESSURE DEVIATION unions or low-pressure proper connection of the pipe
inspections of 8.2.
ENGINE - FUEL 34 05 POSITIVE FUEL Insufficient fuel level in the Check fuel level. EDC pilot light winking.
PRESSURE PRESSURE DEVIATION tank.

MONITORING

451
Component
452
failure
ENGINE - FUEL 34 05 POSITIVE FUEL Fuel suction pipe in the tank
Check whether the priming EDC pilot light winking.
PRESSURE PRESSURE DEVIATION partially clogged due topump on the prefilter works
MONITORING impurities or distortion

tank suction pipe. As a matter of fact the

ENGINE - 34 06 SUPPLY BELOW THE Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING RANGE reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
ENGINE - FUEL 34 06 LEAKAGE IN OVERRUN Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
PRESSURE fuel gear pump. proper connection of the pipe
hooked).
ENGINE - FUEL 34 06 LEAKAGE IN OVERRUN Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.
PRESSURE unions or low-pressure proper connection of the pipe
inspections of 8.2.
ENGINE - FUEL 34 06 LEAKAGE IN OVERRUN Fuel suction pipe in the tank Check whether the priming EDC pilot light winking.
PRESSURE partially clogged due to pump on the prefilter works
MONITORING impurities or distortion properly.
tank suction pipe. As a matter of fact the
Print 603.93.391
Component
failure
ENGINE - FUEL 34 06 LEAKAGE IN OVERRUN Insufficient fuel level in the Check fuel level. EDC pilot light winking.
Print 603.93.391
PRESSURE tank.
MONITORING
ENGINE - FUEL 34 06 LEAKAGE IN OVERRUN Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
PRESSURE reduction. pressure in the rail is lower parameters: ?Duty Cycle rail

subsequent ones):
than 5%.
ENGINE - FUEL 34 07 LEAKAGE Q-BAL Fuel suction pipe in the tank Check whether the priming EDC pilot light winking.
PRESSURE partially clogged due to pump on the prefilter works In case some shavings have
MONITORING impurities or distortion properly. been sucked (due to works
disassemble and check the tank As a matter of fact the
suction pipe. problem might occur again
ENGINE - FUEL 34 07 LEAKAGE Q-BAL Insufficient fuel level in the Check fuel level. EDC pilot light winking.
PRESSURE tank.
MONITORING
ENGINE - 34 07 VALUE OVER THE Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING NORMAL LIMIT reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
ENGINE - FUEL 34 07 LEAKAGE Q-BAL Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
PRESSURE reduction. pressure in the rail is lowerparameters: ?Duty Cycle rail
subsequent ones):
than 5%.
ENGINE - FUEL 34 07 LEAKAGE Q-BAL Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
hooked).

453
Component
454
failure
ENGINE - FUEL 34 07 LEAKAGE Q-BAL Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.

inspections of 8.2.
ENGINE - 34 08 VALUE BELOW THE Significant power Intervention of the Carry out the checks foreseen EDC pilot light winking.
MONITORING LIMIT reduction. double-stage overpressure for 8.2 and 8.3.
OF PRESSURE valve.
RELIEF VALVE
SENSORS - OIL 35 00 NO AVAILABLE Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE SYMPTOM short-circuited or parameters by means of the
open-circuited. diagnostic instrument: in
incorporated in the
presence of this error, the oil
temperature one.
pressure will be fixed at 60
mbar.
Verify the wiring between the
C9, between sensor
ELECTRONIC 35 00 NO AVAILABLE Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL SYMPTOM reduction. occurs when the engine is the key and ecu connector pin
UNIT - SELF TEST switched on does not B39 coming from passaparete
SHUTOFF succeed. connector B pin 2. Erase fault
PATHS memory and retry: if after
START-UP engines shuts down the fault
Desk for a possible ecu change
Print 603.93.391
Component
failure
SENSORS - OIL 35 01 SHORT CIRCUIT TO Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
Print 603.93.391
PRESSURE POSITIVE short-circuited or parameters by means of the
open-circuited. diagnostic instrument: in
incorporated in the
temperature one.
mbar.

C9, between sensor
ELECTRONIC 35 01 SHORT CIRCUIT TO Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL POSITIVE reduction. occurs when the engine is the key and ecu connector pin
SENSORS - OIL 35 02 OPEN CIRCUIT OR Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE SHORT CIRCUIT TO short-circuited or parameters by means of the
GROUND open-circuited. diagnostic instrument: in
incorporated in the
temperature one.
mbar.
C9, between sensor
ELECTRONIC 35 02 OPEN CIRCUIT OR Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL SHORT CIRCUIT TO reduction. occurs when the engine is the key and ecu connector pin
UNIT - SELF TEST GROUND switched on does not B39 coming from passaparete

455
Component
456
failure
SENSORS - OIL 35 03 NO SIGNAL Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE short-circuited or parameters by means of the
diagnostic instrument: in The pressure sensor is
open-circuited.

presence of this error, the oil incorporated in the
pressure will be fixed at 60 temperature one.
mbar.

ELECTRONIC 35 03 NO SIGNAL Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL reduction. occurs when the engine is the key and ecu connector pin
B39 coming from passaparete The engine doesn’t stop in
UNIT - SELF TEST switched on does not
connector B pin 2. Erase fault the foreseen times when the
SHUTOFF succeed.
memory and retry: if after key +15 is OFF-positioned.
PATHS
engines shuts down the fault
START-UP persists, contact the Help Desk
for a possible ecu change
SENSORS - OIL 35 04 SIGNAL NOT Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE PLAUSIBLE short-circuited or parameters by means of the
open-circuited.
mbar.
SENSORS - OIL 35 05 SUPPLY OVER THE Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE NORMAL RANGE short-circuited or parameters by means of the
open-circuited.
mbar.
Print 603.93.391
Component
failure
SENSORS - OIL 35 06 SUPPLY BELOW THE Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
Print 603.93.391
PRESSURE RANGE short-circuited or parameters by means of the
open-circuited.
mbar.

SENSORS - OIL 35 07 VALUE OVER THE Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE NORMAL LIMIT short-circuited or parameters by means of the
open-circuited.
mbar.
ENGINE - FUEL 35 08 LEAKAGE IN LOWIDLE Fuel leaks from the pipe Check the O-Rings and the EDC pilot light winking.
inspections of 8.2.
ENGINE - FUEL 35 08 LEAKAGE IN LOWIDLE Significant power Fuel pressure adjustment: Reading of measurable EDC pilot light winking.
PRESSURE reduction. pressure in the rail is lower parameters: ?Duty Cycle rail
subsequent ones):
than 5%.

457
Component
458
failure
ENGINE - FUEL 35 08 LEAKAGE IN LOWIDLE Fuel suction pipe in the tank Check whether the priming EDC pilot light winking.
PRESSURE partially clogged due to pump on the prefilter works
MONITORING impurities or distortion


ENGINE - FUEL 35 08 LEAKAGE IN LOWIDLE Air intake upstream of the Check the O-Rings and the EDC pilot light winking.
ENGINE - FUEL 35 08 LEAKAGE IN LOWIDLE Insufficient fuel level in the Check fuel level. EDC pilot light winking.
PRESSURE tank.
MONITORING
SENSORS - OIL 35 08 VALUE BELOW THE Power reduction Oil pressure sensor Reading of measurable EDC pilot light on.
PRESSURE LIMIT short-circuited or parameters by means of the
open-circuited.
mbar.
COMMUNICATI 36 00 NO AVAILABLE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can SYMPTOM closing resistance (120 ohms)
B Module
allow starting.
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - Can SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
B Module cannot be viewed on earth or CAN H and CAN off directly on EDC ECU

ECUs connected).
COMMUNICATI 36 01 SHORT CIRCUIT TO CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can POSITIVE closing resistance (120 ohms)
B Module
allow starting.
ON LINES - Can POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

459
Component
460
failure
COMMUNICATI 36 02 OPEN CIRCUIT OR CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can SHORT CIRCUIT TO closing resistance (120 ohms)
B Module GROUND

allow starting.
ON LINES - Can SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
B Module GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).
COMMUNICATI 36 03 NO SIGNAL CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can closing resistance (120 ohms)
B Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 36 03 NO SIGNAL CAN message appears on Possible CAN line problem:
Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can Cluster.CAN messages CAN line short-circuit to
Resistance measured with key
Cluster. Possible L lines reciprocally
between pin B52 (CAN L) and
communication problem short-circuiting. Check that
pin B53 (CAN H) must be

ECUs connected).
ELECTRONIC 36 04 SIGNAL NOT Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL PLAUSIBLE reduction. occurs when the engine is the key and ecu connector pin
COMMUNICATI 36 04 SIGNAL NOT CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can PLAUSIBLE closing resistance (120 ohms)
B Module
allow starting.

461
Component
462
failure
COMMUNICATI 36 04 SIGNAL NOT CAN message appears on Possible CAN line problem:Check CAN VDB line: 1)
ON LINES - Can PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ELECTRONIC 36 05 SUPPLY OVER THE Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL NORMAL RANGE reduction. occurs when the engine is the key and ecu connector pin
COMMUNICATI 36 05 SUPPLY OVER THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can NORMAL RANGE closing resistance (120 ohms)
B Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 36 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem:Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
ELECTRONIC 36 06 SUPPLY BELOW THE Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL RANGE reduction. occurs when the engine is the key and ecu connector pin
COMMUNICATI 36 06 SUPPLY BELOW THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can RANGE closing resistance (120 ohms)
B Module
allow starting.

463
Component
464
failure
COMMUNICATI 36 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem:Check CAN VDB line: 1)
ON LINES - Can RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ELECTRONIC 36 07 VALUE OVER THE Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL NORMAL LIMIT reduction. occurs when the engine is the key and ecu connector pin
COMMUNICATI 36 07 VALUE OVER THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can NORMAL LIMIT closing resistance (120 ohms)
B Module
allow starting.
Print 603.93.391
Component
failure
COMMUNICATI 36 07 VALUE OVER THE CAN message appears on Possible CAN line problem:Check CAN VDB line: 1)
Print 603.93.391
ON LINES - Can NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
ELECTRONIC 36 08 VALUE BELOW THE Significant power The internal ECU test which Check wiring between +15 of EDC pilot light on.
CONTROL LIMIT reduction. occurs when the engine is the key and ecu connector pin
COMMUNICATI 36 08 VALUE BELOW THE CAN line. Check wiring, connections and EDC pilot light:
ON LINES - Can LIMIT closing resistance (120 ohms)
B Module
allow starting.

465
Component
466
failure
ON LINES - Can LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
BC2EDC1: Body cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
Computer to Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
EDC #1 communication problem short-circuiting. Check that pin B53 (CAN H) must be
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

467
Component
468
failure


ECUs connected).
BC2EDC1: Body GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
BC2EDC2: Body GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU

ECUs connected).
ECUs connected).

469
Component
470
failure


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

471
Component
472
failure


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

473
Component
474
failure
EBC1: Electronic cannot be viewed on earth or CAN H and CAN off directly on EDC ECU

Brake Controller Cluster. Possible L lines reciprocally between pin B52 (CAN L) and

ECUs connected).
CCVSV: Cruise cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
Control from Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
Vehicle communication problem short-circuiting. Check that pin B53 (CAN H) must be
Controller with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

475
Component
476
failure
CCVSV: Cruise GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

477
Component
478
failure


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

479
Component
480
failure


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ETC1: Electronic cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
Trasmission Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
Controller communication problem short-circuiting. Check that pin B53 (CAN H) must be

ECUs connected).
ECUs connected).

481
Component
482
failure
EBC1: Electronic GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU


ECUs connected).
ETC1: Electronic GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

483
Component
484
failure


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

485
Component
486
failure


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391

ECUs connected).
ECUs connected).

487
Component
488
failure


ECUs connected).
COMMUNICATI 3A 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AE: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Torque/Speed cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ATC (Asr) to communication problem short-circuiting. Check that pin B53 (CAN H) must be
EDC with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3A 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - DE: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Driveline communication problem short-circuiting. Check that pin B53 (CAN H) must be
Retarder to EDC with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)

ECUs connected).
COMMUNICATI 3A 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

489
Component
490
failure
COMMUNICATI 3A 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AE: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3A 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Torque/Speed GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3A 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - AE: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3A 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AE: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

491
Component
492
failure
COMMUNICATI 3A 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3A 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AE: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3A 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - AE: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3A 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AE: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

493
Component
494
failure
COMMUNICATI 3A 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AE: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3A 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3A 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - AE: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3B 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PE: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
PTO to EDC communication problem short-circuiting. Check that pin B53 (CAN H) must be
ECUs connected).

495
Component
496
failure
COMMUNICATI 3B 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PE: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3B 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PE: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3B 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - PE: Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3B 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

497
Component
498
failure
COMMUNICATI 3B 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PE: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3B 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3B 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - PE: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3B 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

499
Component
500
failure
COMMUNICATI 3B 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PE: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3B 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3B 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - PE: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3B 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DE: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

501
Component
502
failure
COMMUNICATI 3B 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - PE: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3C 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Control from ETC Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
to EDC communication problem short-circuiting. Check that pin B53 (CAN H) must be
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3C 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - VE: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Management to with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)
EDC cranking. Possible ECAS connected. Resistance measured with key

ECUs connected).
COMMUNICATI 3C 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

503
Component
504
failure
COMMUNICATI 3C 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VE: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3C 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3C 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - VE: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3C 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

505
Component
506
failure
COMMUNICATI 3C 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VE: Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3C 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3C 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - VE: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3C 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

507
Component
508
failure
COMMUNICATI 3C 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VE: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3C 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3C 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - TE: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3C 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TE: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

509
Component
510
failure
COMMUNICATI 3D 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AR: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key

Engine Brake with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)

ECUs connected).
COMMUNICATI 3D 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DR: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Retarder to with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)
Engine Brake cranking. Possible ECAS connected. Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3D 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - AR: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3D 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DR: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

511
Component
512
failure
COMMUNICATI 3D 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AR: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3D 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AR: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3D 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - AR: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3D 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AR: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

513
Component
514
failure
COMMUNICATI 3D 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AR: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3D 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VE: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3D 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - AR: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
COMMUNICATI 3D 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VE: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

515
Component
516
failure
COMMUNICATI 3D 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VE: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3D 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - AR: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3E 00 NO AVAILABLE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - TR: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
to Engine Brake communication problem short-circuiting. Check that pin B53 (CAN H) must be

ECUs connected).
COMMUNICATI 3E 01 SHORT CIRCUIT TO CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

517
Component
518
failure
COMMUNICATI 3E 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DR: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3E 02 OPEN CIRCUIT OR CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3E 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - DR: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
COMMUNICATI 3E 03 NO SIGNAL CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

519
Component
520
failure
COMMUNICATI 3E 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DR: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3E 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3E 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - DR: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
COMMUNICATI 3E 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

521
Component
522
failure
COMMUNICATI 3E 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DR: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
COMMUNICATI 3E 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3E 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - DR: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
COMMUNICATI 3E 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - TR: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

523
Component
524
failure
COMMUNICATI 3E 08 VALUE BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - DR: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ON LINES - VR: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
VM2EDC2: cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
Vehicle Cluster. Possible L lines reciprocally between pin B52 (CAN L) and
Management to communication problem short-circuiting. Check that pin B53 (CAN H) must be
EDC #2 with IMMOBILIZER for all vehicle ECUs are equal to 120 ohm. 2)

ECUs connected).
ON LINES - VR: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

525
Component
526
failure


ECUs connected).
ON LINES - VR: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
VM2EDC2: GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU

ECUs connected).
ON LINES - VR: Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

527
Component
528
failure


ECUs connected).
COMMUNICATI 3F 04 SIGNAL NOT CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VR: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
COMMUNICATI 3F 05 SUPPLY OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
Print 603.93.391
ON LINES - VR: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
COMMUNICATI 3F 06 SUPPLY BELOW THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VR: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).

529
Component
530
failure
COMMUNICATI 3F 07 VALUE OVER THE CAN message appears on Possible CAN line problem: Check CAN VDB line: 1)
ON LINES - VR: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ON LINES - TR: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - VR: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key
ECUs connected).
ON LINES - WSI: SYMPTOM Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Wheel Speed cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).

531
Component
532
failure
ON LINES - WSI: POSITIVE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ON LINES - WSI: SHORT CIRCUIT TO Cluster.CAN messages CAN line short-circuit to Resistance measured with key
Wheel Speed GROUND cannot be viewed on earth or CAN H and CAN off directly on EDC ECU
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - WSI: Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
ECUs connected).

533
Component
534
failure
ON LINES - WSI: PLAUSIBLE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - WSI: NORMAL RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
ECUs connected).

535
Component
536
failure
ON LINES - WSI: RANGE Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
ECUs connected).
Print 603.93.391
Component
failure
Print 603.93.391
ON LINES - WSI: NORMAL LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key

ECUs connected).
ECUs connected).

537
Component
538
failure
ON LINES - WSI: LIMIT Cluster.CAN messages CAN line short-circuit to Resistance measured with key


ECUs connected).
Print 603.93.391
Print 603.93.391
MAINTENANCE SCHEDULE
One important functional character is the ELECTRONIC MAINTENANCE SCHEDULE which can, with the latest Modus and
IT2000 release, be managed and programmed very easily.
The workshop service slip will be quickly registered directly on the vehicle, and the recorded maintenance history will be able to
be displayed.
The Dealerhsip Workshop shall, prior to delivering the vehicle, program the maintenance schedule (from among those established
by Iveco) into the on-board panel control unit by means of the diagnosis station.
According to the vehicle’s mission, a km- or hour-based maintenance schedule can be chosen.
The single workshop can subsequently modify the maintenance schedule according to the vehicle requirements.
After the vehicle has been delivered, the driver will be able to refer to their own maintenance schedule through the owner handbook
and also by means of their own Cluster, where a screen dedicated to this function will be available.
The customer can neither cancel or modify the program; they will have to contact an authorized Iveco service center.
Figure 266
004909t

Shortly before the vehicle has reached the distance in kilometres at which the service slip is to be made, an alarm warning light will
illuminate on the Cluster, to inform the driver that the vehicle has to be serviced at an authorized workshop.
Figure 267
004909t
Alarm warning light on Cluster
If the vehicle is serviced at a workshop where a diagnosis instrument is available, the instrument will, after maintenance has been
completed, have to be connected: it will store both the date and the type of slip into the Cluster memory, and then will cause the
alarm warning light to go out.
In the event that operational maintenance is not carried out at a service centre where a diagnosis instrument is available, the warning
light on the dashboard cannot be turned off.
At the root of this choice is a strategy aimed at making the customer more and more loyal to the brand-name through the
competence of our Dealerships, so as to induce the customer to go to an authorized workshop and have any type of maintenance
work (including operational maintenance) performed on the vehicle by qualified engineers.
This system, introduced into the latest EuroCargo, obviously gives new advantages to the customer too, who will therefore be able
to better plan their vehicle’s maintenance schedule (and will always remember to have it done). Thus, they will always be able to
rely on vehicles in perfect working order and ensuring top performance levels.
This functional character is possible provided that the vehicle is equipped with a HighLine-type Cluster. It is not available on
BaseLine-type Clusters.

Print 603.93.391
Circuit cards
Page
Card 1: Positive direct to the batteries . . . . . . . . 543
Card 2: Positive after main current switch . . . . . 544
Card 3: Positive after main current switch . . . . . 545
Card 4: Service power supply (+15/1) . . . . . . . . 546
Card 7: Body Controller . . . . . . . . . . . . . . . . . . 549
Card 10: EDC (Connector B) . . . . . . . . . . . . . . . 552
Card 11: EDC (Connector B) . . . . . . . . . . . . . . . 553
Card 12: EDC (Connector A/C - 6 ) . . . . . . . . . . 554
Card 13: EDC (Connector A/C - 4 ) . . . . . . . . . . 555
Card 14: Instrument Cluster / Tachograph . . . . . . 556
Card 15: Immobilizer . . . . . . . . . . . . . . . . . . . . . . 557
Card 16: ABS (4X2) . . . . . . . . . . . . . . . . . . . . . . 558
Card 17: ABS (6X4) . . . . . . . . . . . . . . . . . . . . . . 559
Card 18: ECAS 4X2 P . . . . . . . . . . . . . . . . . . . . . 560
Card 19: ECAS 4X2 FP . . . . . . . . . . . . . . . . . . . . 561
Card 20: Additional heater prearrangement

AIRTOP2000 . . . . . . . . . . . . . . . . . . . . 562
Card 21: Additional heater prearrangement

AIRTOP2000 with ADR . . . . . . . . . . . . 563
Card 22: Manually controlled air-conditioning . . . 564
Card 23: CAN line . . . . . . . . . . . . . . . . . . . . . . . . 565
Card 24: Cigar lighter/Horns/Electric heater . . . . . 566
Card 25: Rotating lamps/Bed lights/ Emergency

light/Headlamp washer . . . . . . . . . . . . . 567

Print 603.93.391/A
Page
Card 26: Electric window regulator/Sunroof

(with and without the Bed Module) . . . 568
Card 27: Heated prefilter/Brake air drier/Pneumatic,

heated seats . . . . . . . . . . . . . . . . . . . . . 569
Card 28: Heated mirrors/Adjustable, heated

rearview mirrors . . . . . . . . . . . . . . . . . . 570
Card 29: Main current remote-control switch

(TGC) . . . . . . . . . . . . . . . . . . . . . . . . . . 571
Card 30: Current Main Remote Control Switch

(TGC) prearrangement (TGC)/
Compliance to rules ADR (TMP) . . . . . 572
Card 31: Cab tipping/Overall power takeoff . . . . 573
Card 32: Fridge/Voltage reducer/Car radio . . . . . 574
Card 33: Loading board preset . . . . . . . . . . . . . . 575
Card 34: Body builder connectors . . . . . . . . . . . . 576
Card 35: Side- rear - total PTO /Transverse and

longitudinal differential lock . . . . . . . . . . 577
Card 36: Allison gearbox . . . . . . . . . . . . . . . . . . . 578
Card 37: Retarder (Allison gearbox) . . . . . . . . . . 579
Card 38: Central unit (DMI) (opt. 5626) . . . . . . . 580
Card 39: Central locking with remote control . . . 581
Card 40: Digital tachograph (DTCO) . . . . . . . . . . 582

Revi - Juli 2005
Print 603.93.391
Card 1: Positive direct to the batteries
101640

Print 603.93.391/A
Card 2: Positive after main current switch
101887

Revi - Juli 2005
Print 603.93.391
Card 3: Positive after main current switch
101642

Card 4: Service power supply (+15/1)
101643

Print 603.93.391/A
105991

Revi - Juli 2005
Print 603.93.391
101645

Card 7: Body Controller
101646

101647

Print 603.93.391/A
101888

Revi - Juli 2005
Print 603.93.391
Card 10: EDC (Connector B)
101649

Card 11: EDC (Connector B)
101650

Card 12: EDC (Connectors A and C — 6 cylinders)
101651

Card 13: EDC (Connectors A and C — 4 cylinders)
101652

Print 603.93.391/A
Card 14: Instrument Cluster / Tachograph prearrangement
105992

Revi - Juli 2005
Print 603.93.391
Card 15: Immobilizer
101654

Print 603.93.391/A
Card 16: ABS (4X2)
105993

Revi - Juli 2005
Card 17: ABS (6X4)
105994

Revi - Juli 2005
Print 603.93.391
Card 18: ECAS 4X2 P
101659

Card 19: ECAS 4X2 FP
101660

Card 20: Additional heater prearrangement AIRTOP2000
101661

Card 21: Additional heater prearrangement AIRTOP2000 with ADR
101662

Card 22: Manually controlled air-conditioning prearrangement
101663

Card 23: CAN line
101664

Print 603.93.391/A
Card 24: Cigar lighter/Horns/Electric heater
105997

Revi - Juli 2005
Print 603.93.391
Card 25: Rotating lamps/Bed lights/ Emergency light/Headlamp washer
101666

Print 603.93.391/A
Card 26: Electric window regulator/Sunroof (with and without the Bed Module)
105998

Revi - Juli 2005
Print 603.93.391
Card 27: Heated prefilter/Brake air drier/Pneumatic, heated seats
101668

Print 603.93.391/A
Card 28: Central closing prearrangement/Adjustable, heated rearview mirrors
105999

Revi - Juli 2005
Print 603.93.391
Card 29: Main current remote-control switch (TGC)
101670

Card 30: Current Main Remote Control Switch (TGC) prearrangement (TGC)/
Compliance to rules ADR (TMP)
101671

Card 31: Cab tipping/Overall power takeoff
101672

Card 32: Fridge/Voltage reducer/Car radio
101673

Card 33: Loading board preset
101674

Card 34: Body builder connectors
101675

Card 35: Side- rear - total PTO /Transverse and longitudinal differential lock
101676

Card 36: Allison gearbox
101678

Card 37: Retarder (Allison gearbox)
101679

Card 38: Central unit (DMI) (opt. 5626)
101681

Print 603.93.391/A
Card 39: Central locking with remote control
106000

Revi - Juli 2005
Card 40: Digital tachograph (DTCO)
106252

Revi - Juli 2005

60393391C Rep. Manual EuroCargo 12-26 Ton

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60393391C Rep. Manual EuroCargo 12-26 Ton

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EUROCARGO TECTOR

Publication Edited by:

Danger for persons

Danger of serious damage for the vehicle

NOTE It indicates an additional explanation for a piece of information.

Print 603.93.391 I Base — October 2004

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base — October 2004 II Print 603.93.391

Product 50 = Vehicle chassis;

Product 50 = Vehicle chassis;

Product 50 = Vehicle chassis;

Print 603.93.391 III Base — October 2004

Base — October 2004 IV Print 603.93.391

Print 603.93.391 V Base — October 2004

Base — October 2004 VI Print 603.93.391

Further, following warnings are to be compulsorily observed for electronic components:

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

Print 603.93.391 VII Base — October 2004

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Base — October 2004 VIII Print 603.93.391

Print 603.93.391 — 1st edition

Section Description Page Revision date

1 General specification 3 ÷ 12 July 2005

3 Clutch 1, 3, 4, 5, 6, 11, 13, 14 July 2005

4 Gearbox 5, 6, 30, 84 July 2005

7 Front axles 101 July 2005

8 Suspensions 54, 58, 63, 73, 80, 81 July 2005

10 Steering 1, 9, 10, 13, 16 July 2005

11 Pneumatic system — brakes 32 July 2005

13 Service plan 1 ÷ 16 July 2005

Print 603.93.391/A Base — October 2004

Wheels and tyres 9

Pneumatic system — brakes 11

Body and chassis 12

Print 603.93.391 Base — October 2004

COMPOSITION OF THE MODELS . . . . . . . . . . 3

IDENTIFICATION DATA AND LOCATION

INTERNATIONAL LUBRICANT DESIGNATION 15

Base — October 2004

Base — October 2004 Print 603.93.391

Print 603.93.391/A Base — October 2004

COMPOSITION OF THE MODELS

Base — October 2004 Print 603.93.391/A

COMPOSITION OF THE MODELS

Print 603.93.391/A Base — October 2004

COMPOSITION OF THE MODELS

Base — October 2004 Print 603.93.391/A

COMPOSITION OF THE MODELS

Print 603.93.391/A Base — October 2004

COMPOSITION OF THE MODELS

Base — October 2004 Print 603.93.391/A

COMPOSITION OF THE MODELS

Print 603.93.391/A Base — October 2004

COMPOSITION OF THE MODELS

Base — October 2004 Print 603.93.391/A

COMPOSITION OF THE MODELS

Print 603.93.391/A Base — October 2004

COMPOSITION OF THE MODELS

Base — October 2004 Print 603.93.391/A

IDENTIFICATION DATA AND LOCATION ON VEHICLE

Print 603.93.391 Base — October 2004