Iveco Stralis AS (Euro 4/5) Service Manual / Repair Manual - Wiring Diagrams View larger

Iveco Stralis AS (Euro 4/5) Service Manual / Repair Manual - Wiring Diagrams

English Service Manual and Wiring Diagrams, to vehicles Iveco Stralis AS (Euro 4/5).

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LANGUAGE: English.
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PAGES: 1614
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IVECO STRALIS AS (EURO 4/5) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to vehicles Iveco Stralis AS (Euro 4/5).

 

CONTENTS:


STRALIS AS EURO 4/5
- REPAIR MANUAL
-- MECHANICAL ELECTRIC/ELECTRONIC
-- PRELIMINARY REMARKS
-- SYMBOLS -WARNINGS
-- SYMBOLS - ASSISTANCE OPERATIONS
-- PRODUCT CODE
-- GENERAL WARNINGS
-- GENERAL WARNINGS ON THE ELECTRIC SYSTEM
-- Bonding and screening
-- OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
-- CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
-- UPDATE DATA
-- INDEX OF SECTIONS
-- SECTION 1 - General
-- General
-- VEHICLE IDENTIFICATION DATA
-- Vehicle Identification Plate
-- Production identification plate
-- COMMERCIAL CODES
-- COMPOSITION OF MODELS
-- P.I.C. NUMBER CODING
-- REPLENISHING FLUIDS
-- International lubricant designation
-- SECTION 2 - Engine
-- Engine
-- F3A Engine
-- VIEWS OF THE ENGINE
-- TECHNICAL DESIGNATION
-- CHARACTERISTIC CURVES
-- GENERAL CHARACTERISTICS
-- ASSEMBLY CLEARANCE DATA
-- TIGHTENING TORQUE F3A ENGINE
-- TOOLS
-- ENGINE REMOVAL - REFITTING
-- Removal
-- Refitting
-- Filling the cooling system
-- Bleeding air from the supply system
-- Checks and tests
-- ELECTRO-MAGNETIC JOINT REPLACEMENT
-- Removal
-- Refitting
-- DISMANTLING THE ENGINE ON THE BENCH
-- REPAIR OPERATIONS
-- CYLINDER BLOCK
-- Checks and measurements
-- Cylinder liners
-- Replacing cylinder liners
-- Crankshaft
-- Measuring the main journals and crankpins
-- Preliminary measurement of main and big end bearing shell selection data
-- Selecting the main and big end bearing shells
-- Replacing the timing gear and oil pump
-- Checking main journal assembly clearance
-- Checking crankshaft end float
-- Piston connecting rod assembly
-- Piston rings
-- Connecting rods
-- Bushings
-- Checking connecting rods
-- Mounting the connecting rod — piston assembly
-- Mounting the piston rings
-- Fitting the big end bearing shells
-- Fitting connecting rod - piston assemblies in the cylinder liners
-- Checking piston protrusion
-- Checking crankpin assembly clearance
-- CYLINDER HEAD
-- Disassembly the valves
-- Checking head bearing surface on cylinder block
-- Valves
-- Removing deposits and checking the valves
-- Valve seats
-- Checking clearance between valve-stem and associated valve guide
-- Valve guides
-- Replacing injector cases
-- Checking injector protrusion
-- TIMING GEAR
-- Camshaft drive
-- Idler gear pin
-- Idler gear
-- Twin intermediategearpin
-- Twin idler gear
-- Replacing the bushings
-- Timing system
-- Checking cam lift and pin alignment
-- Bushings
-- Replacing camshaft bushings with drift 99360499
-- Removal
-- Assembly
-- Valve springs
-- ROCKER SHAFT
-- Shaft
-- Rocker arms
-- ENGINE ASSEMBLY ON BENCH
-- Fitting connecting rod - piston assemblies in cylinder liners
-- ENGINE FLYWHEEL
-- Fitting engine flywheel
-- Fitting camshaft
-- Fitting pump-injectors
-- Fitting rocker-arm shaft assembly
-- Camshaft timing
-- Phonic wheel timing
-- Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
-- Completing Engine Assembly
-- LUBRICATION
-- Oil pump
-- Overpressure valve
-- Oil pressure control valve
-- Heat exchanger
-- By-pass valve
-- Thermostatic valve
-- Engine oil filters
-- Valve integrated in piston cooling nozzle
-- COOLING
-- Description
-- Operation
-- Electromagnetic coupling
-- Water pump
-- Thermostat
-- View of thermostat operation for versions with Intarder
-- TURBOCHARGING
-- Turbocharger HOLSET HE 531 V
-- Actuator
-- Solenoid valve for VGT control
-- REPAIRING ACTIONS
-- Variable geometry movement control
-- Checking the actuator
-- Checking actuator travel
-- Cleaning turbine body
-- FEEDING
-- Overpressure valve
-- Feed pump
-- Injector-pump
-- Replacing injectors-pump
-- Pressure damper
-- F3B Engine
-- VIEWS OF THE ENGINE
-- TECHNICAL DESCRIPTION
-- CHARACTERISTIC CURVES
-- GENERAL SPECIFICATIONS
-- ASSEMBLY DATA - CLEARANCE
-- TIGHTENING TORQUE
-- DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS
-- TOOLS
-- ENGINE REMOVAL-REFITTING
-- Removal
-- Refitting
-- Filling the cooling system
-- Bleeding air from the supply system
-- Checks and tests
-- ELECTRO-MAGNETIC JOINT REPLACEMENT
-- Removal
-- Refitting
-- DISASSEMBLY THE ENGINE ON THE BENCH
-- REPAIRS
-- CYLINDER BLOCK
-- Checks and measurements
-- Cylinder liners
-- Replacing the cylinder liners
-- Crankshaft
-- Measuring the main journals and crankpins
-- Preliminary measurement of data to select main bearing and big end bearing shells
-- Selecting the main bearing and big end bearing shells
-- Replacing the timing gear and oil pump
-- Checking main journal assembly clearance
-- Checking crankshaft end float
-- Connecting rod piston assembly
-- Piston rings
-- Connecting rod
-- Bushings
-- Checking connecting rods
-- Mounting the connecting rod — piston assembly
-- Mounting the piston rings
-- Fitting the big end bearing shells
-- Fitting connecting rod - piston assemblies in the cylinder liners
-- Checking piston protrusion
-- Checking crankpin assembly clearance
-- CYLINDER HEAD
-- Disassembly the valves
-- Checking head bearing surface on cylinder block
-- Valves
-- Valve seats
-- Checking clearance between valve-stem and associated valve guide
-- Valve guides
-- Replacing injector cases
-- Checking injector protrusion
-- TIMING GEAR
-- Camshaft drive
-- Idler gear pin
-- Idler gear
-- Twin intermediate gear pin
-- Twin idler gear
-- Replacing the bushings
-- Timing system
-- Checking cam lift and pin alignment
-- Bushings
-- Valve springs
-- ROCKER SHAFT
-- Shaft
-- Rocker arms
-- ENGINE ASSEMBLY ON BENCH
-- Fitting connecting rod - piston assemblies in cylinder liners
-- Fitting the cylinder head
-- Fitting flywheel box
-- ENGINE FLYWHEEL
-- Fitting engine flywheel
-- Fitting camshaft
-- Fitting pump-injectors
-- Fitting rocker-arm shaft assembly
-- Camshaft timing
-- Phonic wheel timing
-- Adjusting rocker arm clearance, intake, exhaust and pre-load of pump injector governing rocker arms
-- Completing Engine Assembly
-- LUBRICATION
-- Oil pump
-- Overpressure valve
-- Oil pressure control valve
-- Heat exchanger
-- By-pass valve
-- Thermostatic valve
-- Engine oil filters
-- Valve integrated in piston cooling nozzle
-- COOLING
-- Description
-- Operation
-- Electromagnetic coupling
-- Water pump
-- Thermostat
-- View of thermostat operation for versions with Intarder
-- TURBOCHARGING
-- Turbocharger HOLSET HE 551 V
-- Actuator
-- Solenoid valve for VGT control
-- REPAIR
-- Variable geometry movement control
-- Checking the actuator
-- Checking actuator travel
-- Cleaning turbine body
-- FEEDING
-- Overpressure valve
-- Feed pump
-- Injector-pump
-- Pressure damper
-- Hydrocar pressure take-off on timing system
-- HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)
-- Description
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- ENGAGING POWER TAKE-OFF
-- REMOVING-REFITTING POWER TAKE-OFF
-- Denox System 2
-- DeNOx2 SYSTEM
-- General remarks
-- Tank
-- Ad Blue fluid level gauge control
-- By-pass valve
-- Pump module
-- Dosing module
-- Catalyst
-- Exhaust gas temperature sensor
-- Humidity detecting sensor
-- REPAIR INTERVENTIONS ON DeNox SYSTEM
-- Ad Blue tank
-- Disconnection
-- Reconnection
-- Tank level indicator
-- Disconnection
-- Reconnection
-- Pump module
-- Disconnection
-- Filter + Pre-Filter
-- Disconnection
-- Reconnection
-- Deflecting valve
-- Disconnection
-- Inlet exhaust gas temperature sensor
-- Disconnection
-- Reconnection
-- Outlet exhaust gas temperature sensor
-- Disconnection
-- Reconnection
-- Nitrogen oxides detecting sensor (IF PRESENT)
-- Disconnection
-- Reconnection
-- Sucked air humidity detecting sensor
-- Disconnection
-- Reconnection
-- Measuring out module
-- Disconnection
-- Reconnection
-- Fault Diagnosis
-- FAULT DIAGNOSIS
-- Diagnosis Instruments
-- Cluster Diagnosis
-- DTC - FMI error codes
-- SECTION 3 - Clutch
-- Clutch
-- DESCRIPTION
-- Clutch
-- SPECIFICATIONS AND DATA
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING AND REFITTING THE CLUTCH
-- Removal
-- CHECKS
-- Refitting
-- REMOVING-REFITTING THE THRUST BEARING
-- REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT
-- REMOVING-REFITTING THE PEDAL UNIT SATA
-- Removal (vehicles with EuroTronic Automated gearbox)
-- Removal (vehicles with ZF 16 S... gearbox)
-- Refitting
-- PEDAL TYPE SATA (Vehicles with ABS)
-- Unit removal-assembly
-- CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ABS)
-- Clutch stop
-- Idle travel of clutch pedal
-- Pedal control valve stroke
-- PEDAL TYPE WABCO vehicles with EBS)
-- Clutch stop
-- Clutch pedal idle travel
-- Pedal control valve stroke
-- HYDRAULIC CONTROL vehicles with ZF 16 S... gearboxes)
-- Clutch actuator
-- SPECIFICATIONS FOR MANUAL GEARBOX PREASSEMBLY
-- Spring pin adjustment
-- BLEEDING CLUTCH CIRCUIT
-- SPECIFICATIONS FOR AUTOMATIC TRANSMISSION ASSEMBLY
-- SECTION 4 - Gearboxes
-- Gearboxes
-- Gearboxes: ZF 16 S 1920 T.D., ZF 16 S 2220 T.D./T.O., ZF 16 S 2320 T.D., ZF 16 S 2520 T.O.
-- DESCRIPTION
-- LOCATION OF GEARBOX DESCRIPTION PLATE
-- SPECIFICATIONS AND DATA
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING-REFITTING THE GEARBOX
-- Removal
-- Refitting
-- ZF gearboxes with Intarder (IT), hydraulic retarder, types: ZF 16 S 1921 T.D., ZF 16 S 2221 T.D./T.O., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O.
-- SPECIFICATIONS AND DATA
-- TOOLS
-- OVERHAULING THE GEARBOX
-- Removing the hydraulic retarder from the gearbox on the stand
-- Refitting the hydraulic retarder
-- Adjusting stator end float
-- Removing the epicyclic reduction gear unit ERG) rear box
-- Removing the epicyclic reduction gear unit (ERG)
-- Refitting the epicyclic reduction gear unit (ERG) rear box
-- Gearboxes EuroTronic Automated: - 12 AS 1930 T.D. - 12 AS 2330 T.D./T.O. - 12 AS 2530 T.O.
-- DESCRIPTION
-- LOCATION OF GEARBOX DESCRIPTION PLATE
-- GEARBOX ELECTRONIC MANAGEMENT
-- Theoretical scheme
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING-REFITTING GEARBOX
-- Removal
-- Refitting
-- Gearboxes EuroTronic Automated with Intarder: - 12 AS 1931 T.D. - 12 AS 2331 T.D./T.O. - 12 AS 2531 T.O.
-- SPECIFICATIONS AND DATA
-- TOOLS
-- EXPERIMENTAL TOOLS
-- OVERHAULING THE GEARBOX
-- Removing the hydraulic retarder
-- Refitting the hydraulic retarder
-- Adjusting epicyclic reduction gear train bearing end float
-- Adjusting stator end float
-- Adjusting stator end float
-- Removing the rear box
-- Disassembling the E.R.G.
-- Assembling the E.R.G.
-- EuroTronic gearboxes diagnostics
-- DIAGNOSTICS
-- Diagnosis Instruments
-- Cluster Diagnosis
-- Troubleshooting via DTC-FMI codes
-- SECTION 5 - Intarder - ZF hydraulic retarder
-- Intarder - ZF hydraulic retarder
-- LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE
-- GENERAL INFORMATION
-- OPERATION
-- Retarder engaged
-- Retarder disengaged
-- LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER
-- REMOVING AND REFITTING THE RETARDER ON THE ZF 16 S 1621/1921/2221 GEARBOX
-- Removal
-- Refitting
-- Filling with oil
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- OVERHAULING THE INTARDER HYDRAULIC RETARDER
-- Hydraulic accumulator
-- Removal
-- Fitting
-- Removing hydraulic retarder
-- Checking the component parts of the hydraulic retarder
-- Fitting the hydraulic retarder
-- Stator end float adjustment
-- Only for EuroTronic Automated gearboxes, operate as below
-- SECTION 6 - Propeller shafts
-- Propeller shafts
-- CHARACTERISTICS AND DATA
-- STRALIS (Tractors) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2C/6x4/6x2p)
-- STRALIS AS (Cabs) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2P/6x4)
-- DIAGNOSTIC
-- Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING AND REASSEMBLING THE PROPELLER SHAFT
-- Removal
-- Reassembly
-- CHECKING THE PROPELLER SHAFT ON THE VEHICLE
-- REMOVING AND FITTING BACK THE UNIVERSAL JOINTS
-- REMOVING AND REASSEMBLING THE SUPPORT
-- SECTION 7 - Rear axles
-- Rear axles
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- REMOVING-REFITTING THE REAR AXLE
-- Removal
-- Refitting
-- REMOVING-REFITTING THE DIFFERENTIAL FROM THE REAR AXLE ON THE VEHICLE
-- Removal
-- Refitting
-- Rear Axle ARVINMERITOR MS 13-175 with disc brakes
-- LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
-- DESCRIPTION
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- OVERHAULING THE REAR AXLE ASSEMBLY
-- OVERHAULING THE WHEEL HUBS
-- Removal
-- Replacing wheel hub bearings
-- Checking the parts forming the wheel hubs
-- Replacing the wheel fixing pins
-- REMOVING AND REFITTING THE DIFFERENTIAL with axle on stand 99322215)
-- Removal
-- Refitting
-- REPAIRING THE DIFFERENTIAL
-- Removing the differential
-- Removing the gearcase
-- REMOVING THE BEVEL PINION FROM THE SUPPORT
-- Differential component check
-- Fitting the gear housing
-- FITTING THE MOUNT ON THE BEVEL PINION
-- Reassembling the differential housing
-- ADJUSTING THE CAP GAP
-- CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
-- WORK ON THE VEHICLE
-- REPLACING THE BEVEL PINION MOUNT SEAL
-- Disassembly
-- Assembly
-- Rear axle 451391
-- DESCRIPTION
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REAR AXLES ASSEMBLY OVERHAUL
-- Disassembly
-- Epicycloid reduction gear disassembly
-- Wheel hub disassembly
-- CHECKING THE WHEEL HUB AND EPICYCLOID REDUCTION GEAR UNIT PARTS
-- WHEEL HUB ASSEMBLY
-- Assembling the epicycloid reduction gear
-- REMOVING-REFITTING THE DIFFERENTIAL
-- REPAIRING THE DIFFERENTIAL
-- Disassembly
-- Gear housing disassembly
-- Removing the bevel pinion from the support
-- CHECKING THE DIFFERENTIAL COMPONENTS
-- Gear housing assembly
-- Assembling the bevel pinion support
-- Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring
-- Differential housing assembly
-- Gear housing bearings rolling torque adjustment
-- Axles in tandem ARVINMERITOR MT23-155/2D
-- Axles Intermediate ARVINMERITOR MD11-155/2D
-- DESCRIPTION
-- SPECIFICATIONS ANDA DATA
-- LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- SPECIAL PURPOSE TOOLS
-- INTERMEDIATE REAR AXLE ASSEMBLY OVERHAUL
-- OVERHAULING THEWHEEL HUBS
Removal
Replacing wheel hub bearings
Checking the parts forming the wheel hubs
Replacing the wheel fixing pins
Wheel hub reassembly
-- DIFFERENTIAL CASE REMOVAL
Case removal
Gearing case removal
Checking the differential components
Gearing case refitting
-- ASSEMBLING DIFFERENTIAL CASING
Calculating bevel pinion position in differential casing
-- EXAMPLES
Adjust the limit switch of the differential - distributor lock control pin
Adjusting drive input shaft bearing end float
-- ADJUSTING THE CAP ANGLE
-- CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)
-- REMOVAL-OVERHAUL-REFITTING OF DISTRIBUTOR OUTPUT SHAFT
Adjustment of motion output shaft bearing end play
-- Rear axles ARVINMERITOR MR11-155/D
-- DESCRIPTION
-- LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUES
-- REPAIR OPERATIONS
-- SECTION 8 - Axles
-- Axles
-- Front axles
-- Front axle 5876 5876/4 5876/5 Steering central added axle 5876/4
-- DESCRIPTION
-- SPECIFICATIONS AND DATA
-- DIAGNOSTICS
Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING AND REFITTING AXLE
Vehicles with mechanical front suspension
Removal
Refitting
-- REMOVING AND REFITTING AXLE
Vehicles with pneumatic front suspension and longitudinal bars
Removal
Refitting
-- HYDRAULIC SYSTEM FOR CENTRAL ADDED AXLE STEERING (vehicles 6X2C)
Hydraulic system working diagram
-- CHARACTERISTICS AND DATA
-- CENTRING CYLINDER OPERATING DIAGRAM
Added central axle
Location on the vehicle of the main components of the hydraulic system
Hydraulic system
-- AIR BLEEDING FROM THE HYDRAULIC CIRCUIT
Filling up and bleeding the power steering hydraulic circuit (circuit 1)
Filling up and bleeding the power steering hydraulic circuit (circuit 2)
-- REPAIRS
-- CENTRAL ADDED AXLE AIR LIFT, 6X2C VEHICLES
-- GENERAL
Location on the vehicle of the main components
Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for central added axle with single wheels
-- VEHICLE CHECKS
Tie rods
Swivel heads
-- CHECKING SWIVEL HEAD PLAY
-- FRONT AXLE ASSEMBLY OVERHAUL
-- REMOVING - REFITTING WHEEL HUBS
Removal
Replacing wheel hub bearings
Replacing wheel fixing pins
Refitting wheel hubs
Checking wheel hub bearing end float
Measuring rolling torque
-- REMOVING AND REFITTING TRANSVERSE TIE ROD
-- REPLACING TRANSVERSE TIE ROD SWIVEL HEADS
-- LONGITUDINAL TIE ROD LEVER REMOVAL/REFITTING
-- CROSS TIE ROD LEVER REMOVAL/REFITTING
-- REMOVING AND REFITTING PIN FOR STUB AXLE
Removal
Replacing kingpin bearing
Checking and adjusting clearance between stub axle and axle
-- CHECKING AND MEASURING THE AXLE BODY
Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins
Checking angle of holes for kingpins
-- Additional rear axle
-- Rigid rear added axle 55080/DI
-- DESCRIPTION
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUE
-- TOOLS
-- REMOVING-REFITTING
Removal
Refitting
-- REPAIRS
-- Rigid rear added axle with hydraulic lifting 56082/D1 (N 9171)
-- DESCRIPTION
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUE
-- TOOLS
-- REMOVING-REFITTING
-- REPAIRS
-- Steering rear added axle with pneumatic lifting 57080/DI
-- DESCRIPTION
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REPAIRS
-- PNEUMATIC LIFT
-- GENERAL
-- LOCATION ON THE VEHICLE OF THE MAIN COMPONENTS OF THE HYDRAULIC SYSTEM
-- HYDRAULIC SYSTEM
-- HYDRAULIC SYSTEM WORKING DIAGRAM
-- VEHICLES WITH PNEUMATIC REAR SUSPENSIONS AND PNEUMATIC LIFTING
Location on the vehicle of the main components
Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for rear added axle with single wheels
-- DIAGNOSTICS
Main operating faults of a mechanical nature
-- TIGHTENING TORQUES (Steering and lifting device linkage)
-- CHARACTERISTICS AND DATA
Steering and third axle hydraulic system
-- MAIN HYDRAULIC SYSTEM COMPONENTS
-- HYDRAULIC ACCUMULATOR
Nitrogen pressure checking and recharging
-- OPERATOR CYLINDER
Disassembly
Assembly
Checking cylinder oil sealing on the vehicle
-- CENTRING CYLINDER
Disassembly
Assembly
Checking cylinder oil sealing on the vehicle
-- ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING
Removal
Refitting
-- AIR BLEEDING FROM THE HYDRAULIC CIRCUIT
Filling up and bleeding the power steering hydraulic circuit (circuit 1)
Filling up and bleeding the power steering hydraulic circuit (circuit 2)
-- Wheel geometry
-- GENERAL INFORMATION
Steering wheel angles
-- FRONT WHEEL GEOMETRY (4X2 vehicles)
Positioning clips and headlights
Electronic compensation of rim eccentricity
Wheel alignment
Checking wheel toe-in
Checking wheel deviation
Checking camber
Checking kingpin angle and caster
Checking rear axle alignment
Vehicle wheel geometry with steering rear added axle and pneumatic lifting
Wheel setup for vehicles with additional centralsteering axle and pneumatic lift
-- SECTION 9 - Suspensions
-- Suspensions
-- SUSPENSIONS
-- DESCRIPTION
-- Mechanical front suspension
-- Pneumatic front suspension
-- Pneumatic rear suspension
-- SPECIFICATIONS AND DATA
-- Models front suspension: 4x2 (tractors)
-- Models front suspension: 4x2 (tractors) - 6x4 (tractors and cab-equipped vehicles)
-- Models front suspension: 4x2 (tractors) - 6x4 (tractors and cab-equipped vehicles)
-- Models front suspension: 4x2 (cab-equipped vehicles) - 6x2C (tractors) - 6x2P (tractors and cab-equipped vehicles)
-- Models front suspension: 4x2 (tractors and lorries) - 6x2P (tractors and lorries)
-- Models front suspension: 4x2 (tractors and cab-equipped vehicles) - 6x2P (cab-equipped) vehicles with pneumatic front suspension
-- MECHANICAL FRONT SUSPENSION ASSEMBLY DRAWING
-- PNEUMATIC FRONT SUSPENSION ASSEMBLY
-- CENTRAL ADDED AXLE SUSPENSION ASSEMBLY
-- Leaf spring for central added axle (vehicles with air suspension) 6x2C vehicles
-- Front shock absorbers
-- Additional axle shock absorbers
-- Rear shock absorbers
-- PNEUMATIC SUSPENSION
-- Chassis frame lifting, lowering and self-levelling with remote control
-- Saving Levels
-- AXLE LOAD METER
-- Activating function
-- CALIBRATION (indication on display unit)
-- SCHEMES OF AIR SPRING SUSPENSIONS SYSTEMS
-- Principle scheme of rear air spring suspensions for lorries 4x2/P
-- Principle scheme of suspensions for lorries 4x2/FP
-- Principle scheme of air spring suspensions for lorries 4x2FP-CM
-- Working diagram of pneumatic rear suspensions for 4x2T/P tractors
-- Working diagram of suspensions for 4x2T/FP-LT
-- Working diagram of pneumatic suspensions for tractors 6x2TX/P (without added axle lifter)
-- Working diagram of pneumatic suspensions for tractors 6x2TX/P (with added axle lifter)
-- Principle scheme of rear air spring suspensions for lorries 6x2Y/PS (with added axle lifter)
-- Principle scheme of rear air spring suspensions for lorries 6x2Y/PS (without added axle lifter)
-- Principle scheme of rear air spring suspensions for lorries 6x2Y/PT and tractors 6x2TY/PT (with added axle lifter)
-- Principle scheme of rear air spring suspensions for lorries 6x2Y/PT and tractors 6x2TY/PT (without added axle lifter)
-- Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-CM (with added axle lifter)
-- Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-CM (without added axle lifter)
-- Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-GV (with added axle lifter)
-- Principle scheme of air spring suspensions for lorries 6x2Y/FP/FS-GV (without added axle lifter)
-- Working diagram of pneumatic rear suspensions for 6x4 tractors and lorries
-- CHARACTERISTICS AND DATA
-- Pneumatic System
-- MAIN COMPONENTS OF THE PNEUMATIC SYSTEM
-- Fault Diagnosis
-- Controlled pressure valve
-- Level sensor
-- Electro-Pneumatic Control Valve
-- Load detector pressure sensor
-- Low air pressure switch
-- Air spring
-- ECAS Control Unit
-- DIAGNOSTICS
-- Diagnosis Instruments
-- Cluster Diagnosis
-- Troubleshooting via DTC-FMI codes
-- TOOLS
-- SPECIAL PURPOSE TOOLS
-- TIGHTENING TORQUES
-- Mechanical front suspension
-- Pneumatic front suspension
-- Pneumatic front suspension with bars
-- Central added axle pneumatic suspensions 6x2 C vehicles
-- Pneumatic rear suspension 4x2 - 6x2 C vehicles
-- Pneumatic rear suspension 6x2 P/PT vehicles
-- Pneumatic rear suspension 6x2 P/PS vehicles
-- Pneumatic rear suspension 6x2 P/FP/FS vehicles (version for 3800 to 5500 wheel bases)
-- Pneumatic rear suspension 6x2 P/FP/FS vehicles (version for 5700 to 6050 wheel bases)
-- Pneumatic rear suspension 6x4 P vehicles
-- REMOVAL-REFITTING OF FRONT LEAF SPRING
-- Removal
-- Refitting
-- REMOVING-REFITTING FRONT SUSPENSION BARS
-- Removing longitudinal bars
-- Removing transverse bar
-- Refitting
-- REAR SUSPENSIONS
-- Removal
-- Refitting
-- REMOVING-REFITTING THE REAR AXLE LONGITUDINAL SUSPENSION ARM
-- REMOVING-REFITTING THE REAR ADDED AXLE LONGITUDINAL SUSPENSION ARM
-- REMOVING-REFITTING THE REAR AXLE TRIANGULAR SUSPENSION ARM
-- REMOVING-REFITTING THE REAR ADDED AXLE TRIANGULAR SUSPENSION ARM
-- Removal
-- Refitting
-- REPLACING THE SUSPENSION ARM FLEXIBLE PIN
-- Dismounting
-- Mounting
-- REPLACING TRIANGULAR SWINGING ARM BALL ARTICULATED JOINT
-- Dismounting
-- Mounting
-- STABILIZER BAR
-- FRONT STABILIZER BAR
-- CENTRAL ADDED AXLE STABILIZER BAR (6x2 C vehicles)
-- REAR STABILIZER BAR
-- REAR ADDED AXLE STABILIZER BAR (6x2P vehicles)
-- Removal
-- Refitting
-- RUBBER BUSHINGS
-- Replacing front stabilizer bar rubber bushings
-- Replacing rear stabilizer bar rubber bushings
-- SHOCK ABSORBERS
-- Removal-refitting
-- Central added axle shock absorbers
-- Rear axle shock absorbers
-- Rear added axle shock absorbers 6x2 P vehicles)
-- Removal
-- Refitting
-- CHASSIS FRAME ADJUSTMENT
-- SECTION 10 - Wheels and tyres
-- Wheels and tyres
-- DESCRIPTION
-- CHARACTERISTICS AND DATA
-- Tyre inflation pressures
-- TOOLS
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- STATIC BALANCING OF THE WHEELS
-- CORRECTING RESIDUAL STATIC IMBALANCE
-- TYRE PRESSURE
-- HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE
-- SECTION 11 - Steering
-- Steering
-- DESCRIPTION
-- SPECIFICATIONS AND DATA
-- Scheme of the steering control of vehicles with mechanical front suspension
-- Vehicle steering control diagram with front air suspension and longitudinal bars
-- Vehicle steering control diagram with front air suspension and leaf springs
-- Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with mechanical front suspension
-- Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with pneumatic front suspension
-- Scheme of the steering control of 6x2 p vehicles - having a steering rear axle - with pneumatic front suspension and longitudinal bars
-- Scheme of the steering control of 6x2 c vehicles - having a steering central axle -with mechanical front suspension
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING-REFITTING THE POWER STEERING SYSTEM
-- Removal
-- Refitting
-- Removing-Fitting the Steering Lever
-- STEERING CONTROL
-- REMOVING-REFITTING THE STEERING CONTROL ASSEMBLY
-- Removal
-- Refitting
-- Changing the pneumatic cylinder
-- Removal
-- Refitting
-- Replacing direction indicator switch
-- Removal
-- BLEEDING THE POWER STEERING SYSTEM
-- MEASURING STEERING BOX PLAY AT THE STEERING WHEEL
-- CHECKING THE MAXIMUM PRESSURE OF THE POWER STEERING SYSTEM
-- Setting the automatic hydraulic steering limit
-- Check
-- ESP (Electronic Stability Program) CALIBRATION
-- SECTION 12 - Air system - Brakes
-- Air system - Brakes
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS)
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
-- SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALLIPERS)
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALLIPERS AND CYLINDERS)
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING CONNECTORS)
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES)
-- SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)
-- PIPINGS AND FITTINGS
-- In general
-- Flexible pipings replacementwith traditional fittings
-- Flexible pipings replacement with quick connection fittings
-- EBS (ELECTRONIC BRAKE SYSTEM)
-- EBS Benefits
-- Tractor and trailer compatibility at any time
-- Complete fault-diagnosis structures
-- OPERATING LOGIC
-- BRAKE SYSTEM
-- AUXILIARY BRAKE INTEGRATION
-- ESP (ELECTRONIC STABILITY PROGRAM)
-- “ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)
-- “ABS” (Anti-Lock Brake System)
-- EBL (Electronic Brakes Limiter)
-- Operating Logic
-- EBS SYSTEM COMPONENTS LOCATION ON VEHICLE (TRACTORS VARIANT)
-- LOCATION OF EBS SYSTEM COMPONENTS ON THE VEHICLE (TRUCKS VARIANT)
-- BRAKING SCHEMES OF EBS SYSTEMS
-- Theoretical scheme of EBS system for 4x2 vehicles (tractors)
-- EBS working diagram for 6x2p vehicles (tractors)
-- Theoretical scheme of EBS system for 6x2p vehicles (tractors)
-- Theoretical scheme of EBS system for 6x2 C vehicles (tractors)
-- Theoretical scheme of EBS system for 4x2 vehicles (trucks)
-- EBS working diagram for 6x2p vehicles (trucks)
-- Working diagram of EBS system for 6x2p vehicles (trucks)
-- LOCATION OF ABS - EBL SYSTEM COMPONENTS (TRACTOR VARIANT)
-- BRAKING SCHEMES OF ABS - EBL - ASR SYSTEMS
-- Working diagram of ABS-EBL-ASR system for 4x2 vehicles (trucks and tractors)
-- Working diagram of ABS-EBL-ASR system for 6x2p vehicles (trucks)
-- Working diagram of ABS-EBL-ASR system for 6x2p vehicles (trucks)
-- Working diagram of ABS-EBL-ASR system for 6x2C vehicles (tractors)
-- Working diagram of ABS-EBL-ASR system for 6x4 vehicles (trucks and tractors)
-- BRAKING SCHEMES OF ABS - EBL SYSTEMS
-- Working diagram of ABS-EBL system for 4x2 vehicles (trucks and tractors)
-- Working diagram of ABS-EBL system for 6x2C vehicles (tractors)
-- Working diagram of ABS-EBL system for 6x2p vehicles (trucks)
-- Working diagram of ABS-EBL system for 6x2p vehicles (trucks)
-- Working diagram of ABS-EBL system for 6x4 vehicles (trucks and tractors)
-- DESCRIPTION
-- Service braking
-- Emergency braking
-- Exhaust brake
-- Parking brake
-- BRAKES
-- Disc Brakes
-- Drum Brakes
-- DIAGNOSTICS
-- Diagnosis Instruments
-- Cluster Diagnosis
-- Troubleshooting via DTC-FMI codes
-- TIGHTENING TORQUES
-- TOOLS
-- SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM
-- SPECIFICATIONS AND DATA - BRAKES
-- CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM
-- MAIN COMPONENTS OF THE BRAKING SYSTEM
-- Compressor
-- Head locking screw tightness
-- Fault diagnosis
-- A.P.U. (Air Processing Unit)
-- Duplex control valve (vehicles without EBS)
-- Fault Diagnosis (vehicles without EBS)
-- CBU - Central Brake Unit (vehicles with EBS)
-- Relay valve (vehicles without EBS)
-- Proportional relay valve for front axle (vehicles with EBS)
-- Fault Diagnosis (vehicles without EBS)
-- Coupling heads
-- Redundancy valve (for 4x2 and 6x2 trucks)
-- ABS-EBS solenoid valve
-- Dual stop valve
-- Triple servo control valve (vehicles without EBS)
-- Predominance control
-- Fault Diagnosis
-- Trailer servo control valve (vehicles with EBS)
-- Parking brake hand control valve (vehicles suited to towing)
-- Pressure test point valve
-- Manual control valve to slow down the trailer (optional extra)
-- Fault Diagnosis (parking brake control valve)
-- Controlled pressure valve
-- Fault Diagnosis
-- Check valve (vehicles suited to towing)
-- Low-pressure switch
-- Electro-pneumatic valve for ASR
-- Speed sensor
-- Phonic wheels
-- Electronic control unit
-- Pressure sensor
-- Diaphragm brake cylinder (for front and added front axle disc brake)
-- Combined brake cylinder (for front and rear disc brake)
-- Combined brake cylinder (for front and rear drum brake)
-- Combined cylinder emergency brake release device
-- Repair operations
-- Fault diagnosis
-- ESP SYSTEM COMPONENTS
-- ESP SYSTEM SELF-LEARNING AND CALIBRATION
-- DISC BRAKES KNORR TYPE (CALIPER SN7)
-- Operation (See previous figure)
-- CHECKS
-- Checking the automatic play recovery system efficiency
-- Brake caliper components
-- Check of braking seals thickness
-- OVERHAULING FRONT DISC BRAKES
-- Replacing brake linings
-- Removing and refitting brake callipers
-- Removal
-- Refitting
-- Removing and refitting wheel hubs
-- Removal
-- Refitting
-- BRAKE CALIPER OVERHAUL
-- Disassembly
-- Component part cleaning and check
-- Assembly
-- OVERHAULING REAR DISC BRAKES
-- Replacing brake linings
-- OVERHAULING BRAKE DISCS
-- TURNING AND GRINDING BRAKE DISCS
-- DRUM BRAKES
-- OVERHAULING THE DRUM BRAKES
-- Removing the rear drum brakes
-- Turning drums
-- Replacing brake linings
-- Assembly
-- SECTION 13 - Bodywork - Chassis frame
-- Bodywork - Chassis frame
-- CAB
-- General information
-- FEATURES AND DATA
-- TOOLS
-- TIGHTENING TORQUES
-- REPAIR WORK
-- BUMPER
-- Removal
-- Refitting
-- CABIN
-- Removal
-- Refitting
-- REPLACING THE FRONT SHOCK ABSORBER
-- Removal
-- Refitting
-- REPLACING THE CAB SUSPENSION FRONT MOUNTING RUBBER-TYPE BUSHINGS
-- Removal
-- Refitting
-- REPLACING THE CAB FRONT MOUNT BUSHINGS
-- Removal
-- Refitting
-- REMOVING - REFITTING THE STABILIZER BAR
-- Removal
-- Refitting
-- CHANGING THE REAR SHOCK ABSORBER
-- Removal
-- Refitting
-- CHANGING THE CAB LOCK
-- Removal
-- Refitting
-- CHANGING THE SWINGING BRACKET BUSHING
-- Removal
-- Refitting
-- Adjusting the front levelling valve linkwork
-- ELECTRICALLY DRIVEN CAB TILT
-- MANUALLY DRIVEN CAB TILT
-- Removal
-- Refitting
-- Checking the oil level
-- Periodic level check
-- MANUALLY DRIVEN CAB TILT
-- REPLACING HYDRAULIC CAB TILT CYLINDER
-- Removal
-- Refitting
-- Checking oil level
-- Bleeding cab tilt system
-- Bleeding air frommanual drive pump (point 1)
-- Bleeding air from cab tilting cylinder (point 2)
-- Bleeding air from secondary circuit (point 3)
-- Bleeding air fully
-- REPLACING THE WIND SHIELD
-- Removal
-- Refitting
-- REPLACING THE WINDING WINDOW
-- Removal
-- Refitting
-- REPLACING THE WINDOW WINDER
-- Removal
-- Refitting
-- REPLACING THE DOOR LOCK
-- Removal
-- Refitting
-- REPLACING THE OUTSIDE HANDLE OF THE DOOR
-- Removal
-- Refitting
-- CHANGING THE INSIDE HANDLE
-- Removal
-- Refitting
-- CHANGING THE SIDE MIRRORS
-- Removal
-- Refitting
-- CHANGING THE DOOR
-- Removal
-- Refitting
-- REPLACING THE FIXED WINDOW
-- Removal
-- Preparing the window bay
-- Preparing the window
-- Refitting
-- INSTRUMENT PANEL
-- Removal
-- Refitting
-- CENTRAL INSTRUMENT PANEL
-- Removal
-- Refitting
-- FASCIA COVERING
-- Removal
-- Refitting
-- AIR INTAKE LID REMOVAL AND REFITTING
-- Removal
-- Refitting
-- AIR INTAKE LID MOTOR REPLACEMENT
-- Removing
-- Refitting
-- WINDSCREEN SUN VISOR REEL REMOVAL/REFITTING
-- Removal
-- Refitting
-- WINDSCREEN SUN VISOR REEL MOTOR REPLACEMENT
-- Removing
-- Refitting
-- REPLACING SIDE DOOR OPENING CONTROL CABLE
-- Removing
-- Fitting
-- Lid opening control adjustment
-- CABIN REFRIGERATOR
-- Preliminary checks
-- Removal
-- Refitting
-- OVERHAULING
-- Removing
-- Fan disassembling
-- Disassembling the anti-tipping probe with electronic circuit on the control unit
-- Electronic control unit disassembling
-- Checks
-- Fitting
-- DRIVER’S SEAT
-- Removal
-- Refitting
-- Component layout
-- REMOVING THE DRIVER’S SEAT
-- Removal
-- Fitting
-- Removing-fitting the cushion slider
-- Removal
-- Fitting
-- Removing-fitting the seatbelt
-- Fitting
-- Removing-fitting seatbelt connection and right-hand side upholstery
-- Fitting
-- Removing - fitting the left-hand side upholstery, IPS valve and heating switch
-- Removal
-- Fitting
-- Removing - fitting the back
-- Removal
-- Fitting
-- Removing - fitting the back adjustment lever
-- Removal
-- Fitting
-- Removing - fitting the height adjustment device
-- Removal
-- Fitting
-- Removing - fitting the seat angle adjustment device
-- Removal
-- Fitting
-- Removing - fitting the flexible cable of the shock absorber adjustment device
-- Removal
-- Fitting
-- Removing - fitting the back adjustment lever segment
-- Removal
-- Fitting
-- Removing - fitting the air spring
-- Removal
-- Fitting
-- Removing - fitting the shock absorber
-- Removal
-- Fitting
-- Removing - fitting the height adjustment valve
-- Removal
-- Fitting
-- Removing - fitting the height locking system
-- Removal
-- Fitting
-- Removing - fitting the flexible cable of the horizontal lever suspension
-- Removal
-- Fitting
-- Removing - fitting the fast lowering magnetic valve
-- Removal
-- Fitting
-- Removing - fitting the fast lowering switch
-- Removal
-- Fitting
-- Removing - fitting the lumbar support device
-- Removal
-- Fitting
-- Removing - fitting the back upholstery
-- Removal
-- Fitting
-- Removing - fitting the cushion upholstery
-- Removal
-- Fitting
-- CAB AIR-CONDITIONING
-- General
-- VENTILATION
-- Description
-- AIR-CONDITIONING AND HEATING
-- Description
-- Air-conditioning
-- Heating
-- Air-conditioning controls assembly
-- Automatic
-- Manual
-- Heating and ventilation
-- COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)
-- HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)
-- MAIN COMPONENTS OF AIR CONDITIONER AND HEATER (WEBASTO)
-- Outside temperature sensor
-- Inside temperature sensor
-- Three-way solenoid valve (WEBASTO)
-- Compressor
-- Dehumidifier filter and safety pressure switches
-- Geared motors
-- Evaporator temperature sensor
-- Blown air temperature sensor
-- Expansion valve
-- ADDITIONAL AIR HEATER SYSTEM (on request)
-- Description
-- Operation
-- DIAGNOSTICS
-- Troubleshooting
-- Introduction
-- CHARACTERISTICS AND DATA
-- GENERAL WARNINGS
-- TIGHTENING TORQUES
-- REPAIR OPERATIONS
-- HEATER
-- Removal
-- Refitting
-- ADDITIONAL AIR HEATER SYSTEM
-- Removal
-- Refitting
-- DEFROST CONTROL MOTOR
-- Removal
-- Refitting
-- AIR RECIRCULATION DOOR CONTROL MOTOR
-- Removal
-- Refitting
-- AIR MIXING DOOR CONTROL MOTOR
-- Removal
-- Refitting
-- HEATER RADIATOR TEMPERATURE SENSOR
-- Removal
-- Refitting
-- FLOOR AIR DOOR CONTROL MOTOR
-- Removal
-- Refitting
-- ELECTRIC FAN
-- Removal
-- Refitting
-- HEATER RADIATOR
-- Removal
-- Refitting
-- TAP
-- Removal
-- Refitting
-- POLLEN FILTER
-- Removal
-- Refitting
-- AIR-CONDITIONER COMPRESSOR
-- Removal
-- Refitting
-- AIR-CONDITIONER CONDENSER
-- Removal
-- Refitting
-- OUTSIDE AIR TEMPERATURE SENSOR
-- Removal
-- Refitting
-- REPLACING THE ELECTROMAGNETIC CLUTCH
-- PROCEDURE FOR DRAINING AND RECHARGING AIR CONDITIONING SYSTEMS WITH RECHARGING STATION 99305146 AND RECOVERY OF R134A COOLANT
-- SAFETY STANDARDS
-- CONTROL FASCIA
-- OPERATION FLOW CHART
-- RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM
-- CREATING A VACUUM IN THE SYSTEM
-- RESTORING OIL IN THE SYSTEM
-- FILLING THE SYSTEM WITH REFRIGERANT
-- CHECKING THE PRESSURES IN THE SYSTEM
-- OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM
-- PROCEDURE FOR DRAINING AND RECHARGING AIR CONDITIONING SYSTEMS WITH RECHARGING STATION 99305148 AND RECOVERY OF R134A COOLANT
-- Main components
-- SAFETY STANDARDS
-- CONTROL PANEL
--