Iveco daily euro 4 Repair Manual Download Page 386

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108855

Figure 7

Gearbox unit

5 S 300 TRANSMISSIONS

AILY

URO

Base - March 2006

Print 603.93.651

TIGHTENING TORQUES

DESCRIPTION

TORQUE

DESCRIPTION

kgm

Clutch housing, screw to fasten clutch housing to chassis

Screw to fasten clutch housing to box

15%

2.3

15%

Constant mesh shaft cover fastening screw

15%

2.3

15%

Spring retaining plug

10%

3.2

10%

Grub screw securing gear selection sector to rod

15%

6**

Screw securing p.t.o. side cover

15%

4.6

15%

Plug

15%

2.8

15%

Screw securing reverse gear shaft

15%

2.2

15%

Screw securing rear cover

15%

2.3

15%

Screw locking sleeve for transmission coupling on main shaft

120

15%

Screw securing ball bearing retaining ring

9.5

15%

0.9

15%

Screw securing control cable bracket

15%

2.3

15%

Screw securing gear control mounting

15%

2.3

15%

Nut for screw securing lever to control rod

15%

3.4

15%

Nut securing articulation pin to control lever

15%

2.3

15%

Nut for screw securing lever to control rod

15%

3.4

15%

Oil vapour breather

15%

Nut to secure articulation pin to control lever

15%

2.3

15%

Spread LOCTITE 5206 sealant on the contact surfaces

Spread LOCTITE 242 on the thread

** Spread LOCTITE 510 on the thread

Summary of Contents for daily euro 4

Page 1: ...DAILY EURO 4 REPAIR MANUAL MECHANICAL ELECTRIC ELECTRONIC ...

Page 2: ...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 R...

Page 3: ... 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 PRELIMINARY REMARKS General danger It includes the dangers of above described signals Danger of serious damage for the vehicle Parti...

Page 4: ...otation Regulation Adjustment Angle Angular value Visual inspection Fitting position check Preload Measurement Value to find Check Number of revolutions Equipment Temperature Surface for machining Machine finish bar Pressure Interference Strained assembly Oversized Higher than Maximum peak Thickness Clearance Undersized Less than Minimum Lubrication Damp Grease Selection Classes Oversizing Sealant...

Page 5: ...roduct 76 Electric ssystem Unit Code The third and fourth figures identify the UNIT within the PRODUCT Example Product 50 Vehicle chassis Unit 01 Chassis Unit 02 Bumpers Unit 03 Alternator Sub assembly Code The fifth and sixth figures exactly identify the SUB ASSEMBLY and Component of a Unit within a PRODUCT Example Product 50 Vehicle chassis Unit 01 Chassis Sub assembly 40 Chassis cross members S...

Page 6: ...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 ...

Page 7: ...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 ...

Page 8: ...nel must be at least 1 meter away 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 utilit...

Page 9: ...nnections 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 junctio...

Page 10: ...es 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 ...

Page 11: ...Print 603 93 651 Base March 2006 DAILY EURO 4 Print 603 93 651 1st edition Base March 2006 UPDATE DATA Section Description Page Revision date ...

Page 12: ...Base March 2006 Print 603 93 651 ...

Page 13: ... 1 Engine 2 Clutch 3 Gearbox 4 Propeller shafts 5 Rear axles 6 Front axle 7 Front and rear suspensions 8 Wheels and tyres 9 Steering system 10 Pneumatic system Brakes 11 Bodywork and chassis frame 12 Maintenance 13 Electric Electronic System 14 INDEX OF SECTIONS ...

Page 14: ...Base March 2006 Print 603 93 651 ...

Page 15: ... 4 Print 603 93 651 Base March 2006 Print 603 43 671 SECTION 1 General Page IDENTIFICATION DATA 3 Vehicle Identification Plate 3 COMPOSITION OF MODELS 4 ALPHANUMERICAL CODING FOR BUS IDENTIFICATION 6 REPLENISHING FLUIDS 13 ...

Page 16: ...2 GENERAL DAILY EURO 4 Base March 2006 Print 603 93 651 Print 603 43 671 ...

Page 17: ...e engine base 1 Approval number 2 Chassis number 3 PTT Total weight on ground 4 MTC Total combined weight 5 Max weight permitted on the front axle 6 Max weight permitted on the rear axle 7 Specific indication of type 8 Wheelbase mm 9 Type of engine 10 Engine rating 11 Permitted smoke level 12 Place of manufacture 13 Number of vehicle axles Figure 1 Figure 2 108533 108534 GENERAL 3 DAILY EURO 4 Pri...

Page 18: ...450511 o o o o 450517 2 Rack and pinion Powered steering o o o o o o o o o o o o o o o o FRONT MECHANICAL SUSPENSIONS independent with transverse leaf spring MK3 o o o o o o o o o o o independent with torsion bars o o o o REAR MECHANICAL Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z MECHANICAL SUSPENSIONS single leaf o o o o o o o SUSPENSIONS reinforced o o o o o o o Semi elliptical s s s s s s s s s ...

Page 19: ...R G 450511 o o o o 450517 2 o o o o Rack and pinion Power steering o o o o o o o o FRONT MECHANICAL SUSPENSIONS independent with transverse leaf spring MK3 independent with torsion bars o o o o o o o o Parabolic Z Z Z Z Z Z Z Z single leaf reinforced Semi elliptical s s s s s s s s Semi elliptic with leaf spring z z z z z z z z REAR AIR SUSPENSIONS V V V V V V V V O D Over Drive Optional extra wit...

Page 20: ...AD VEHICLES A T 25C 29 L B T 30C 35 S C T 35C 35 C D T 40C 40 C E T 50C 50 C 45 C F T 65C 60 C 65 C CUSTOMIZED VEHICLE V P PROGRAMMING FAMILY MARKET VEHICLE V M STANDARD VEHICLE V C B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 RANGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CHASSIS CABS AND DERIVATIVES ...

Page 21: ...C L T 40V 40 C M T 50V 50 C 45 C N T 65V 60 C 65 C A F1A E4 LD 96 CV B F1A E4 LD 116 CV C F1A E4 LD 136 CV D F1C E4 HD 146 CV E F1C E4 HD 176 CV E4 Euro 4 LD Light Duty HD Heavy Duty ENGINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PROGRAMMING FAMILY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 VANS AND DERIVATIVES ...

Page 22: ...35 C15 D 35 C18 D 40 C10 D 6 CAB 6 1 35 C15 D 35 C18 D 40 C10 D 40 C12 D 45 C15 D 45 C18 D 50 C18 D 60 C15 D 60 C18 D 50 C18 D 60 C15 D 60 C18 D 65 C15 D 65 C18 D 35 S12 CC 35 S 14 CC 35 S18 CC 35 C12 CC 35 C15 CC 35 C18 CC 0 CHASSIS 35 C12 CC 35 C15 CC 35 C18 CC 40 C12 CC 40 C15 CC 40 C18 CC 0 CHASSIS COWL 40 C12 CC 40 C15 CC 40 C18 CC 45 C15 CC 45 C18 CC 50 C15 CC 50 C18 CC 50 C15 CC 50 C18 CC 6...

Page 23: ...5 S18 SV 35 C10 SV 35 C12 SV 35 C15 SV 35 C18 SV V SEMI GLAZE D VAN 35 C18 SV 40 C10 SV 40 C12 SV 40 C15 SV 40 C18 SV 45 C15 SV 45 C18 SV 45 C15 SV 45 C18 SV 50 C15 SV 50 C18 SV VENDOR 35 S12 CV 35 S14 CV U VENDOR VERSION 35 S12 CV 35 S14 CV 35 C12 CV 40 C12 CV U VERSION CITY 35 C12 CV 40 C12 CV 45 C15 CV 45 C18 CV 50 C15 CV 50 C18 CV VAN 50 C15 CV 50 C18 CV 5 COMBI 29 L14 C 35 S14 C 5 COMBI 29 L1...

Page 24: ...35V T40V T50V 2 3000 L mm T25V T30V T35V T40V T50V 3 3300 mm T25V T30V T35V T40V T50V 4 3450 mm T25C T30C T35C T40C T50C T65C 5 3750 mm T30C T35C T40C T50C T65C 6 3950 L mm T30V T35V T40V T50V T65V 7 4100 mm T35C T40C 8 4350 mm T50C T65C 9 4750 mm T50C T65C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WHEELBASE ...

Page 25: ...GENERAL 11 DAILY EURO 4 Print 603 93 651 Base March 2006 A 5 SPEED 5 S 300 B 6 SPEED 6 S 400 O D C 6 SPEED 6 S 400 A O D A Automated O D Over Drive 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GEARBOX ...

Page 26: ...0V T35V T40V T50V 3 RIGHT HAND DRIVE T25C T30C T35C T40C T50C A RIGHT HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H1 1545 mm T25V T30V T35V T40V T50V A RIGHT HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H2 1900 mm T25V T30V T35V T40V T50V B RIGHT HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H3 2100 mm T30V T35V T40V T50V T65V C DRIVE INTERNAL HEIGHT OF LOADING BAY 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 27: ...city 7 6 6 79 Sump capacity max level min level 6 6 4 29 5 81 3 78 Max gradient negotiable by vehicle uphill downhill with oil at minimum level 30 Gearbox ZF 5S 300 2 1 8 Tutela TRUCK GEARLITE ZF 6S 400 O D 2 2 1 98 ZF 6S 400 A O D 2 7 2 43 Front axle 5817 5818 5819 5823 Rear axles Tutela W140 M DA SAE 80W90 NDA R S 1 35 1 21 Tutela W90 M DA SAE 80W90 NDA R G 1 35 1 21 Tutela W140 M DA SAE 85W140 ...

Page 28: ...tela GI A General purpose grease lithium soap based grease N L G I fluidity no 2 Tutela MR 2 Specific grease for wheel hubs and bearings lithium soap based grease N L G I fluidity no 3 Tutela MR 3 Hydraulic brake and clutch control fluid In conformity with N H T S A standards No 116 ISO 4925 Standard SAE J 1703 IVECO STANDARD 18 1820 Tutela TRUCK DOT SPECIAL Windscreen washer liquid Mixture of spi...

Page 29: ...F1A ENGINE 1 DAILY EURO 4 Base March 2006 Print 603 93 651 SECTION 2 5401 Engine Page F1A ENGINE 3 F1C ENGINE 157 ...

Page 30: ...2 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 31: ...LACING BELTS 14 Power steering pump alternator belt replacement 14 Disassembly 14 Assembly 14 Replacing air conditioning compressor drive belt 14 Disassembly 14 Assembly 14 Replacing timing drive belt 15 Disassembly 15 Assembling 16 REPLACING THE ELECTRIC INJECTORS 17 Removal 18 Refitting 18 CYLINDER HEAD REMOVAL AND REFITTING 19 Removal 19 Refitting 21 REPLACING HIGH PRESSURE PUMP CPH1 22 Removal...

Page 32: ...ock 78 CRANKSHAFT 79 Page Measuring main journals and crank pins 79 Checking crankshaft 80 Replacing timing control gear 82 ENGINE ASSEMBLY 82 Assembling main bearings 82 Measuring main journal assembly clearance 82 Checking crankshaft end float 83 Assembling rear seal 84 ENGINE FLYWHEEL 85 Replacing bearing supporting gearbox input shaft 85 CONNECTING ROD PISTON ASSEMBLY 86 Pistons 86 Disassembly...

Page 33: ... 124 Page Turbocharger KKK K03 2074 CCB 5 88 type 125 REPAIRS 126 Pressure relief valve 126 Checking pressure relief valve 126 GARRET GT 17 variable geometry turbosupercharger 127 General 127 Operation at low engine rpm 127 Operation at high engine rpm 127 Proportional solenoid valve controlling turbocharger actuator 128 Actuator 128 REPAIRS 129 Checking and adjusting the actuator 129 EXHAUST GAS ...

Page 34: ...ting 140 Injection timing electronic test 140 Speed governor 140 Engine starting 140 Cold starting 141 Warm starting 141 Run up 141 After run 141 Cut off 141 Cylider balancin 141 Synchronisation search 141 OPERATION 143 HYDRAULIC SYSTEM 146 Page Fuel pump 146 Fuel filter UFIfilters 147 Fuel filter Filtrauto 148 Fuel pipes 148 High pressure pump CPH1 149 Pressure control valve 150 Replacing pressur...

Page 35: ...e of the connectors Electro injector None of the couplings unions nuts on the injector body may be handled It is neither necessary nor permitted to dismantle the nozzle body or the electromagnet If working on the high pressure pipe the hexagon on the injector side must be kept stationary with a wrench Before working on pipes make sure the injector is stationary in its seat on the cylinder head Whe...

Page 36: ...e injectors replacing the air flow meter replacing the hydraulic accumulator pressure sensor common rail replacing the EDC control unit 16 changing the engine oil replacing the D P F catalyst replacing the filter differential pressure Dp sensor replacing any significant component as regards emission levels performing forced regeneration the control unit shall be programmed again by means of the IV...

Page 37: ...ece 33 Remove the screws and or fastening nuts then remove bumper 17 Remove expansion tank 3 cap 2 Act as follows from under the vehicle see figure 4 undo fastening screws 8 and 10 then remove lower side guards 11 undo fastening screws 15 then remove lower central guard 12 Apply a tube 16 to radiator pipe union detail C then unscrew cap 15 and drain the coolant into a suitable container If the veh...

Page 38: ... take sound proofing cover 1 off Disconnect tank 5 pressure sensor electric connection 3 Remove tank 5 fastening nuts 4 then take the tank off the wall Disconnect electric connection 6 of the level sensor placed under tank 5 Disconnect or remove the coolant pipes 14 from thermostat 11 15 from engine oil heat exchanger 10 19 from pipe 17 18 from radiator 16 20 from the cylinder head Properly obstru...

Page 39: ...or 17 Disconnect the electric connection from oil level sensor 26 Disconnect the fuel pipes 3 from the low pressure pipe assembly Disconnect the electric connection 6 from air conditioner compressor 8 Disconnect the electric connection 5 from starting motor 4 Place a container under the power steering pump to recover the system oil then disconnect oil inlet and delivery pipes 9 and 10 Disconnect t...

Page 40: ...e to avoid damaging the remaining parts on the vehicle in particular the steering box oil pipes NOTE As far as automatic transmission is concerned strictly adhere to the operations described in the relevant chapter in the Gearbox section NOTE Disconnect exhaust pipe 9 from the turboblower outlet pipe Disconnect vacuum pipe 29 from VGT actuator 28 only 136 HP engine Put a jack under the gearbox to ...

Page 41: ... relating engagement unions Fill the cooling system with coolant Fill the hydraulic power steering circuit and bleed the air as described under the relevant heading Check the level of oil in the engine and gearbox recharge climate control system if present as described in chapter relating to section Body and chassis check the inclination of light from headlights if needed no coolant leaks from coo...

Page 42: ...e turn to settle the belt Mount the compressor drive belt if there is one and adjust the tension as described under the relevant heading Fit the middle soundproofing guard back on 543910 Replacing air conditioning compressor drive belt Disassembly 90155 Cut elastic belt 3 as it cannot be reused Figure 6 Assembly Fit the flexible belt 3 equipped with tool 99360191 2 on the pulley 4 and apply the to...

Page 43: ...t the fixing screws 26 and remove the expansion tank 29 disconnect the electrical connection for the level indicator from the expansion tank and put the tank 29 aside appropriately Take out the screws 23 and remove the bracket 22 fixing the soundproofing cover 20 Remove the plugs 24 from the overhead and the plug 14 from the oil pump vacuum pump assembly mounting Turn the crankshaft clockwise so a...

Page 44: ...ckwise to cover the reference hole 5 located on the fixed portion of the tightener see frame B In the above conditions tighten the fixing screw 2 to a torque of 36 4 Nm Tighten screw 9 to the torque values below screw 9 securing pulley 7 to the distributing shaft with tapered shank full section 90 Nm screw 9 securing pulley 7 to the distributing shaft with cylindrical shank hollow section 130 Nm R...

Page 45: ...linder Therefore replacing an electrical injector involves the need of reprogramming the central unit by entering the IMA codes of new electrical injectors and resetting the rectification factors ZFC of the cylinder considered Replacing all electrical injectors extends the need of resetting to all the rectification coefficients ZFC of each single electrical injector 105067 At assistance code writt...

Page 46: ... 21 Figure 9 and detach the soundproofing cover 20 Figure 9 Disconnect the pipes 19 Figure 9 from the pipe 18 Figure 9 Remove fastening screws 26 Figure 9 then take off expansion tank 29 Figure 9 and disconnect level gauge electric connections 6 figure 7 and sensor 27 electric connections 28 figure 7 from the expansion tank Disconnect the pipe 20 Figure 12 from the coalescence filter 1 Figure 12 D...

Page 47: ...es 20 and 19 from coalescence filter 1 then remove the latter from the overhead Disconnect pipe 2 from the heat exchanger engine coolant outlet pipe Take off electric injectors 4 as described in the Replacing the electric injectors chapter operation 775010 Disconnect the electric connections from phase sensor 3 water temperature sensor 8 air pressure temperature sensor 9 preheating plugs 6 throttl...

Page 48: ...se union Take out the screws and disconnect the exhaust pipe 4 from the turbocharger 8 Take off the nuts 3 and remove the turbocharger 8 with its gasket from the exhaust manifold Take out the screws and remove the overhead together with the pins 99360614 Close the turbocharger air outlet inlet appropriately to prevent foreign bodies accidentally getting inside and damaging it NOTE The pins 9936061...

Page 49: ...10 to a torque of 50 2 5 Nm 2nd phase angle closing screws 1 2 3 4 5 6 90 5 screws 7 8 9 10 60 3 3rd phase angle closing screws 1 2 3 4 5 6 90 5 screws 7 8 9 10 60 3 A flywheel side Tighten the screws and nuts to the prescribed torque The seals and gaskets must not be reused but replaced with new ones 75494 Mount the cylinder head Insert the screws and tighten them in three successive stages follo...

Page 50: ... gaskets and high pressure pipe with new parts tighten the nuts screws and fittings to the specified torque values 543210 REPLACING WATER PUMP Removal Refitting If the engine has run for a period equivalent to 25 000 km the toothed timing drive belt must be replaced with a fresh one no matter what its state of wear NOTE Remove the high pressure pump as described under the relevant heading Fit two ...

Page 51: ...ove nuts 2 securing pipe 3 to throttle valve assembly 1 Loosen screws 4 securing pipe 3 to heat exchanger 5 then take throttle valve assembly 1 off the inlet manifold Refitting For refitting reverse the operations described for disconnection observing following warnings replace gasket by new parts tighten nuts and screws at prescribed torque Removal PREHEATING PLUGREMOVAL REFITTING Figure 22 10856...

Page 52: ...screws 7 then take off engine lifting bracket 8 Remove screws 9 take pipe union 2 off the cylinder head then take off heat exchanger 1 together with pipes 3 and 4 and pipe union 2 Refitting For refitting reverse the operations described for disconnection observing following warnings replace gasket by new parts tighten nuts and screws at prescribed torque fill expansion tank with coolant Removal Re...

Page 53: ...ted and aromatic hydrocarbons forming part of the particulate such as the carbon in the form of soot metals water and sulphur compounds that are ex hausted The cylindrical shaped catalyst consists of a ceramic honey comb monolith whose cells are platinum impregnated a ca talyzing substance of oxidation reactions Its total volumetric capacity is equal to 600 cm3 with a density of 400 cells per squa...

Page 54: ... exhaust system is made up of three components A system length with hose B catalyst with particulate filter DPF C silencer This system is manufactured by ArvinMeritor ArM 26 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 55: ... vehicle on a pit or auto lift Disconnect oxygen sensor electric connection 4 Remove fasteners 2 then disconnect exhaust pipe terminal 3 from turboblower flange 1 Properly support the assembly then use a suitable lever to release supporting hooks 6 and 8 from elastic dowels 5and 7 and take the assembly off the vehicle Take the assembly components apart by loosening the retaining clamps Removal F1A...

Page 56: ... filter supporting bracket 10 to the vehicle chassis unscrew and remove fastening screws 13 of flanges 15 connecting D P F catalyst 8 filter to the exhaust gas outlet pipe from turbine 14 remove D P F catalyst 8 filter Exhaust silencer removal For refitting reverse the operations described for disconnection observing following warnings check the conditions of the elastic dowels taking care to repl...

Page 57: ...oil is refilled resetting post injected fuel counter is not necessary NOTE 540743 Replacing differential sensor delta p Pressure difference between gas pressure at catalyst module inlet and gas pressure at ceramic walls filter outlet is converted into a voltage signal Vout by pressure sensor During engine running E D C 16 central unit performs checks on differential pressure sensor drift and calcu...

Page 58: ...108321 Figure 30 30 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ENGINE VIEWS ...

Page 59: ...108157 108158 108159 Figure 31 Figure 32 Figure 33 LEFT HAND SIDE VIEW FRONT VIEW REAR VIEW F1A ENGINE 31 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 60: ...108160 Figure 34 Figure 35 TOP VIEW RIGHT HAND SIDE VIEW A Turbocharger with pressure relief valve Waste Gate ENGINES 96 116 HP 108161 A 32 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 61: ... 0 06 g km Test fuel CEC RTF 73 T90 5 0 05 Smokiness The engines conform to the limits of smokiness required with the following exhaust smoke values Maximum power Bosch BSU opacimeter degrees 1 5 Maximum torque Bosch BSU opacimeter degrees 1 5 Noise emissions Maximum mean noise level Lpa of the standard engines measured according to ISO Std 3745 microphones at 1 m from the engine surfaces Idling 8...

Page 62: ...ylind 8 DI TCA 1 Truck 2 Bus 4 E M mach tractors 6 Nautical 9 Military 0481 F 71kW 96 CV 3000 3700 rpm 244 Nm 1800 2800 rpm 0481 G 85kW 116 CV 3000 3900 rpm 270 Nm 1800 2800 rpm 0481 H 100kW 136 CV 3600 3900 rpm 320 Nm 1700 2900 rpm F 1 8 4 0 E A 1 A F Type approval power 34 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 7 ENGINE IDENTIFICATION CODE ...

Page 63: ...C CURVES OF ENGINE F1AE0481F 102408 Max OUTPUT 71 kW at 3000 3700 rpm Max TORQUE 240 Nm at 1800 2800 rpm 96 HP 24 4 kgm Figure 36 rpm F1A ENGINE 35 DAILY EURO 4 Print 603 93 651 Base March 2006 CHARACTERISTIC CURVES ...

Page 64: ...409 CHARACTERISTIC CURVES OF ENGINE F1AE0481G Max OUTPUT 85 kW at 3000 3900 rpm Max TORQUE 270 Nm at 1800 2800 rpm 116 HP 27 5 kgm Figure 37 rpm 36 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 65: ...410 CHARACTERISTIC CURVES OF ENGINE F1AE0481H Max OUTPUT 100 kW at 3600 3900 rpm Max TORQUE 320 Nm at 1700 2900 rpm 136 HP 31 6 kgm Figure 38 rpm F1A ENGINE 37 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 66: ...s 38 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 EXAMPLE A IVECO trademark IVECO B IVECO name of engine variant F1AE0481A A001 C Engine serial number 1359862 D 1st digit main journal no 1 engine front E Main bearing selection diameters 12345 F Barrel selection diameters 1234 G 1st digit cylinder no 1 engine front Data obtainable from XZ engine ordering number information ...

Page 67: ...t cm3 2300 ρ Compression ratio 18 Maximum power kW HP 71 96 85 116 100 136 rpm 3900 3900 3900 Maximum torque kW HP 240 24 4 270 27 5 310 31 6 rpm 1800 3200 1800 3150 1800 Slow running of engine with no load rpm 800 Fast idling speed of engine with no load rpm 4600 Pressure at T D C bar 20 26 bar Minimum permissible pressure at T D C bar 16 The pressure is measured by setting the engine turning wit...

Page 68: ...r timing check mm X mm Operation mm X mm SUPPLY High pressure fuel feed system BOSCH EDC16 Composed of CP1 high pressure pump electro injectors hydraulic accumulator rail EDC control unit pressure and temperature sensors Pump setting With piston no 1 at T D C X Start of delivery mm Electro injectors type BOSCH CR1 2 2 Electro injectors type BOSCH CR1 2 2 Injection sequence 1 3 4 2 ba r Injection p...

Page 69: ...m 2 4 vacuum 0 64 bar valve travel mm 10 5 12 5 LUBRICATION forced by gear pump pressure relief valve oil filter with integral cartridge with total filtering bar Oil pressure with engine hot 100 C 5 C at idling speed bar 0 6 at top speed bar 4 COOLING by centrifugal pump thermostat for adjustment coolant temperature fan with electromagnetic coupling radiator heat exchanger Water pump control by be...

Page 70: ...rankcase seats interference Outside diameter 2 3 X Cylinder liners protrusion from bottom of crankcase inside diameter 3 1 Pistons supplied as spares type MAHLE MONDIAL 8 X measurement X 8 87 896 87 910 2 outside diameter 1 87 896 87 910 31 003 31 009 2 seat for pin 2 31 003 31 009 Piston cylinder sleeve 0 092 0 126 Piston diameter 1 0 4 X Piston protrusion from crankcase X 0 3 0 6 3 Piston gudgeo...

Page 71: ...ed at 2 5 mm from the outer diameter Piston rings slots 1 0 103 0 162 2 0 060 0 100 3 0 050 0 090 Piston rings 0 4 X1 2 X Piston ring end opening in cylinder liner 3 2 X X X1 0 20 0 35 3 X X2 0 60 0 80 X3 0 25 0 50 1 Small end bushing seat Ø 1 34 460 34 490 2 Connecting rod bearing seat Ø 2 62 833 62 841 connecting rod supplied as spare part 4 Small end bushing diameter 3 outside 4 34 560 34 585 S...

Page 72: ...S 1 S 2 Main bearing shells S1 2 165 2 174 S 1 S 2 Big end bearing shells S2 1 883 1 892 supplied as spare parts 3 Main bearing housings 3 No 1 2 3 4 No 5 75 588 75 614 80 588 80 614 Bearing shells main journals 0 032 0 102 Bearing shells crankpins 0 035 0 083 Main bearing shells 0 254 0 508 Big end bearing shells 0 254 508 1 X Main journal for shoulder X 1 31 020 31 170 X 2 Main bearing housing f...

Page 73: ...erference 0 028 0 059 Valve guides 0 05 0 10 0 25 4 Valves 4 5 975 6 000 4 α 5 975 6 000 44 45 7 5 4 5 975 5 990 α α 5 975 5 990 44 45 7 5 Valve stem and relevant guide 0 023 0 063 0 033 0 063 Seat on head for valve seat 1 31 390 31 415 1 1 31 390 31 415 2 Outside diameter of valve seats angle of valve seats on 2 seats angle of valve seats on cylinder head 2 31 495 31 510 y 2 α 31 495 31 510 44 5 ...

Page 74: ...3 12 H1 45 H2 N533 24 H2 35 X Injector protrusion X 2 77 3 23 Seats for tappets on cylinder head normal 12 016 12 034 Normal diameter tappets 11 988 12 000 Between tappets and seats 0 016 0 046 Camshaft pin seats in cylinder overhead 1 7 1 2 48 987 49 013 46 987 47 013 2 3 46 987 47 013 35 987 36 013 2 Camshaft bearing journals 1 2 48 925 48 950 46 925 46 950 1 3 2 2 3 46 925 46 950 35 925 35 950 ...

Page 75: ... to check spring loads 99317915 Set of six box type wrenches 14 17 19 mm 99322205 Rotary telescopic stand for overhauling assemblies capacity 700 daN torque 120 daN m 99340028 Extractor for camshaft pulley 99340035 High pressure pump toothed pulley extractor 99340059 Tool to remove crankshaft front gasket ...

Page 76: ...0058 Tool to remove crankshaft rear gasket 99342153 Tool to extract injectors 99346254 Keying device for mounting crankshaft front gasket 99346255 Keying device for mounting crankshaft rear gasket 99360076 Tool to remove cartridge filters 99360183 Pliers for mounting rings on engine pistons ...

Page 77: ...9360191 Guide for flexible belt 99360260 Tool for removing and refitting engine valves 99360306 Tool to retain engine flywheel 99360544 Arm for removing and refitting engine 99360605 Band to insert standard and oversized pistons into the cylinders 99360608 Tool for positioning timing gear ...

Page 78: ...9360614 Tool 2 for camshaft timing 99360615 Tool for crankshaft timing 99361038 Brackets securing engine to rotary stand 99322205 99367121 Manual pump to measure pressure and vacuum 99370415 Comparator holder base 99374458 Keying device for mounting oil seal gasket on camshaft front cover ...

Page 79: ... with square 1 4 connection 99389829 9x12 coupling torque wrench 5 60 Nm 99394038 Milling cutter to regrind injector seat 8140 63 engine excluded 99395216 Pair of meters for angular tightening with square 1 2 and 3 4 connection 99395363 Complete square to check for connecting rod distortion 99395603 Comparator 0 5 mm ...

Page 80: ...m 99395849 Device for checking belt tension frequency from 10 0 to 600 Hz 99396037 Centring ring for crankshaft front gasket cover EXPERIMENTAL TOOLS This section shows the working drawings for the experimental tools S P used in overhauling the engine described in this section which may be made by the repair shops ...

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Page 90: ...62 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 91: ...er drain plug M14x1 50 L 10 25 2 5 Union on crankcase for oil return from turbocharger R 3 8 50 5 Screw M6x1 fixing suction strainer 10 1 Male threaded socket plug M28x1 5 100 10 Hex screw with flange M8x1 5 L 35 fixing frame retaining oil sump 25 2 5 Hex screw with flange M6x1 L30 fixing frame retaining oil sump 10 1 Hex screw with flange M6x1 L25 fixing frame retaining oil sump 10 1 Tapered thre...

Page 92: ... with flange M8x1 25 L120 fixing air conditioner compressor 25 2 5 Hex screw with flange M8x1 25 L50 fixing air conditioner compressor mounting 25 2 5 Hex screw fixing bottom of alternator M10x1 25 L40 and M10x1 5 L50 50 5 Hex screw fixing top of alternator M10x1 25 L40 Hex screw with flange M10x1 25 for complete guide pulley roller for timing belt M10x1 25 L50 40 4 Allen head screw fixing automat...

Page 93: ...ng oil return pipe from turbocharger 10 1 Hex screw with flange M8x1 25 L40 fixing power steering pump 25 2 5 TE flanged screw M8x1 25 for power steering pump pulley fastening 25 2 5 Hex screw with flange M12x1 25 L155 fixing electromagnetic coupling mounting 90 9 Hex screw with flange M8x1 25 L20 fixing manoeuvring hooks 25 2 5 Flanged screws M10x1 25 fixing engine mounts 50 5 Oil level sensor M1...

Page 94: ...Figure 41 LONGITUDINAL CROSS SECTION OF ENGINE 108442 66 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 95: ...Figure 42 TRANSVERSE CROSS SECTION OF ENGINE 108443 F1A ENGINE 67 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 96: ...ngine by removing the plug from the oil sump Take off the fan if any from electromagnetic joint If the following parts have not already been removed do so now oil filling cap 1 sound proofing cover 2 engine cable complete with raceway 13 by disconnecting the electric connections of the same from electric injector 3 preheating plugs 5 hydraulic accumulator pressure sensor 14 throttle valve actuator...

Page 97: ... the belt 1 and remove it 75249 Take out the screw 4 and remove the automatic tightener 3 Take out the screw 2 and remove the fixed tightener 1 Take out the screws 5 and remove the pulley 6 Take out the bolt 1 the bottom screws 3 and 4 and remove the alternator 2 from the mounting 5 75251 Take out the screw 3 and remove the mounting 1 of the power steering pump 4 Using a suitable wrench remove the...

Page 98: ... gears 2 and 6 Remove the toothed belt 7 Loosen clamp 6 then disconnect pipe 5 from pipe union 7 Remove nut 4 then remove pipe 3 from filter 1 Undo screws 2 then remove coalescence filter 1 Remove screws 2 then take bracket 1 off Remove screws 4 then take oil filling pipe union 3 off Press the springs 3 in the direction shown by the arrow and disconnect the fittings of the pipe 1 recovering fuel f...

Page 99: ...base Loosen clamp 6 then disconnect fuel pipe 5 from high pressure pump 7 Remove screw 3 securing pipe 2 retaining bracket 4 to the inlet manifold Disconnect pipe 2 from hydraulic accumulator 1 and high pressure pump 7 Take out the screws 1 and remove the hydraulic accumulator 2 Remove screws 4 then disconnect low pressure pipes 5 from bracket 3 Remove coupling 1 then disconnect pipes 5 from high ...

Page 100: ...f throttle valve assembly 1 Remove screws 3 then take throttle valve assembly 1 together with its gasket off inlet manifold 2 Remove screw 4 then disassemble air pressure temperature sensor 3 Remove screws 1 then take off inlet manifold 2 together with its gasket Use wrench SP 2275 1 to disassemble preheating plugs 2 Remove nut 1 then take off phase sensor 2 Use a suitable wrench to take off tempe...

Page 101: ...acers 4 then take off exhaust manifold 1 together with its gasket complete with pipe 2 and elbow 3 Take out the screws 1 and remove the overhead 2 Figure 73 75269 Take off the gasket 1 and remove the hydraulic tappets together with the rocker arms 2 75270 Take out the screws 1 and remove the cylinder head 2 Check the protrusion of the pistons as described under the relevant heading to check the po...

Page 102: ... out the screws 1 and remove the high pressure pump 2 from the water pump mounting 3 75274 Take out the screws 1 and remove the water pump assembly 2 75275 Remove the plug 6 from the oil pump vacuum pump assembly 1 Position the crankshaft so as to be able to insert tool 99360615 5 into its hole through the hole in the plug 6 and block rotation of the crankshaft Take out the screw 3 with the spacer...

Page 103: ...2 and remove the air conditioner compressor 1 if applicable Take out the screw 2 and remove the speed sensor 1 Take out the screws 4 and remove the compressor mounting 3 Take out the plug 2 with the seal 3 and extract the oil pressure control valve 1 Undo the screws 2 and remove the oil sump 1 with the associated gasket and frame 3 108188 108187 F1A ENGINE 75 DAILY EURO 4 Print 603 93 651 Base Mar...

Page 104: ...ke out the screws 2 and remove the engine flywheel 1 Take out the screw 5 and remove the guard 4 Apply tool 99340058 2 to the rear O ring 1 and extract it from the crankcase On the same side of the connecting rod and its associated cap indicate the number of the cylinder from which the connecting rod has been removed Keep the bearing shells in their respective housings since if they are used they ...

Page 105: ...main bearing shells 2 since if they are reused they will need to be fitted in the position found during removal NOTE Note the assembly position of the top main bearing shells 2 since if they are reused they will need to be fitted in the position found during removal NOTE On completing engine removal it is necessary to clean the removed parts thoroughly and check their integrity The following pages...

Page 106: ...e slightest doubt about their sealing efficiency the caps shall be replaced Apply LOCTITE 270 sealant IVECO NO 93162429 to the caps when fitting the latter back into place Examine the surfaces of the cylinder liners they must show no sign of meshing scoring ovalization taper or excessive wear The inside diameter of the cylinder liners is checked to ascertain the extent of ovalization taper and wea...

Page 107: ...1 Undersize classes are of 0 254 0 508 mm TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS 5408 CRANKSHAFT 540810 Measuring main journals and crank pins Checking head mating surface on cylinder block On finding signs of seizure scoring or excessive ovalization on main journals and crankpins it is necessary to regrind the pins Before grinding the pins 2 measure...

Page 108: ... 125 180 15 The checks on the tolerances indicated in the figures must be made after grinding the crankshaft pins NOTE 80 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL SHAPE Circularity SHAPE Cylindricality DIRECTION Parallelism DIRECTION Perpendicularity OF POSITION Concentricity or coaxiality OSCILLATION Circular oscillation OSCILLATION Total...

Page 109: ...crankpins and main journals the rolled portion of the side races of the pins may get involved it is necessary to turn the races keeping to the data given in the figure and to do the rolling keeping to the following instructions Rolling force 1st main journal 925 25 daN 2nd 3rd 4th 5th main journal 1850 50 daN crankpin 1850 50 daN NOTE 108189 108190 108192 108191 honed waviness waviness RACE AREA F...

Page 110: ...d is coated with sealant Fit on the oil spray nozzles 2 and tighten the couplings 1 to the prescribed torque The main bearings 1 are supplied as spare parts undersized on the inside diameter by 0 254 0 508 mm 540811 Measuring main journal assembly clearance Mount the crankshaft 1 Check the clearance between the crankshaft main journals and their respective bearings by proceeding as follows Thoroug...

Page 111: ...d float of the crankshaft does not come within the prescribed values it is necessary to grind the crankshaft and accordingly change the main bearing shells NOTE The middle main bearing has half thrust washers integrated in it so it performs the function of a thrust bearing It is supplied as a spare part only with the normal shoulder thickness α Figure 115 Remove the bottom crankcase The clearance ...

Page 112: ...angle of 60 Then tighten the outer screws 1 to a torque of 36 30 Nm Carefully clean the seal seat Apply LOCTITE 510 IVECO nr 2992504 on the seal 1 for 30 in the points shown in the figure Lubricate the rear shank of the crankshaft with engine oil Fit part 2 of tool 99346255 onto the rear shank of the crankshaft secure it with the screws 3 and key the fresh seal 1 onto it Position part 4 on part 2 ...

Page 113: ...utch disk rest surface if it shows deep scoring a replacement must be performed Check conditions of the teeth of crown wheel 1 where excessive cracking or wear is found replace engine flywheel The nominal thickness of the engine flywheel is 50 0 6 mm NOTE LUK ENGINE FLYWHEEL FOR ENGINES FITTED TO THE VEHICLES EQUIPPED WITH MECHANIC TRANSMISSION SACHS ENGINE FLYWHEEL FOR ENGINES FITTED TO THE VEHIC...

Page 114: ...d on the diameter of 85 mm Fit tool 99360351 4 onto the crankcase to block rotation of the engine flywheel 1 Tighten the screws 3 fixing the engine flywheel 1 in two steps Step 1 with a torque wrench to a torque of 30 Nm Step 2 closing to an angle of 90 5408 CONNECTING ROD PISTON ASSEMBLY α Use tool 99395216 2 for the angle closing NOTE 75391 Check the pistons They must show no signs of seizure sc...

Page 115: ...icate the pin 1 and its seat on the hubs of the piston 2 with engine oil The pin must go into the piston by lightly pressing with the fingers and must not drop out by gravity 74947 The trapezoidal split rings 1st slot and the oil scraper rings 2nd slot have the word TOP etched in them when fitting them on the piston the word TOP must be facing upwards 540842 Piston rings Figure 132 16552 Figure 13...

Page 116: ...ATA OF THE CONNECTING ROD BUSHING PISTON PIN AND BEARING SHELLS Internal diameter to obtain after driving into the small end and grinding with a reamer Dimension cannot be measured in the free state Thickness of the bearing shell supplied as a spare part 540830 Connecting rods with a number indicating the weight class of the connecting rod mounted in production In addition it could be stamped with...

Page 117: ...te side B of the pin 3 the difference between A and B must be no greater than 0 08 mm Checking torsion 61694 Checking bending Check the bending of the connecting rod 5 by comparing two points C and D of the pin 3 on the vertical plane of the axis of the connecting rod Position the vertical mount 1 of the dial gauge 2 so that this rests on the pin 3 at point C Swing the connecting rod backwards and...

Page 118: ...tion the mount 1 of the dial gauge 2 so that this is positioned at point A of the piston with a pre load of 0 5 mm and zero the dial gauge 2 Shift the spindle 4 so as to position the dial gauge 2 at point B of the piston 3 and check for any deviation Figure 146 Fitting piston rings Fit the piston rings 1 on the piston 2 using the pliers 99360183 3 41097 Figure 147 Assembling connecting rod piston ...

Page 119: ... clearance lubricate the connecting rod bearing shells and fit them permanently by tightening the connecting rod cap fixing screws as described Manually check that the connecting rods slide axially on the pins of the crankshaft 75409 Figure 150 Checking piston protrusion After mounting the connecting rod piston assemblies check the protrusion of the pistons 2 at the T D C in relation to the top su...

Page 120: ...own the nut 1 so that on compressing the springs 8 it is possible to remove the cotters 6 Then take out the plates 7 and the springs 8 Using suitable pliers remove the oil seal 9 Repeat these operations on the remaining valves Turn the cylinder head over The intake 1 and exhaust 2 valves have the same diameter mushroom The central cavity of the mushroom of the intake valve 1 is distinguished from ...

Page 121: ... removal of metal must not exceed a thickness of 0 2 mm Checking cylinder head mating surface If there is any leakage from the cylinder head it must be replaced MAIN DATA OF INTAKE AND EXHAUST VALVES Remove the carbon deposits on the valves with a wire brush Check that the valves show no signs of seizure cracking or burning 540662 VALVES Removing deposits refacing and checking valves Use micromete...

Page 122: ...ve guides Remove the valve guides 2 with the drift SP 2312 1 Heat the cylinder head to 80 100 C and using the drift SP 2312 1 provided with part SP 2311 2 mount the new valve guides 3 previously chilled in liquid nitrogen Where above indicated tools are not available mount valve guides positioning them in cylinder head according to dimension indicated in Figure 139 After driving in the valve guide...

Page 123: ...gen Using a specific tool regrind the valve seats according to the angles given in Figure 165 Using the milling cutter 99394038 1 clean the injector seat of any deposits Mount the valves block the seat of the electro injectors and glow plugs using a suitable tool check the seal of the valves seats Using a dial gauge 1 check that from the plane of the cylinder head the valve recessing 2 and the pro...

Page 124: ...ECK INTAKE AND EXHAUST VALVE SPRINGS COMPLETE ROCKER ARM ASSEMBLY The rocker arm assembly is composed of the rocker arm 1 hydraulic tappet 3 made integral with each other by the clip 2 540665 VALVE SPRINGS ROCKER ARMS TAPPETS CROSS SECTION OF THE HYDRAULIC TAPPET A 32 44 0 3 end of stroke B 31 30 working position C 29 75 0 25 start of stroke 96 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 ...

Page 125: ... the position marked during removal Using tool SP 2264 2 mount the oil seals 3 on the valve guides 4 MAIN DATA HYDRAULIC TAPPETS SEATS Position the springs 8 and plates 7 on the cylinder head 5 Fit the part 4 of tool 99360260 onto the cylinder head 5 and secure it with the screws 3 Fit the part 2 of tool 99360260 onto part 4 screw down the nut 1 so that by compressing the springs 8 it is possible ...

Page 126: ...tion the toothed pulley Take out the screw 4 with the washer 5 beneath fastening the toothed pulley 3 Only engines with intake distributing shaft con tapered shank Using the extractor 99340028 2 extract the toothed pulley 1 driving the camshaft Using four self tapping screws 2 apply the tool SP 2325 3 to the seal 1 and with the extractor 5 and 6 remove the seal 1 from the overhead 4 Remove the cir...

Page 127: ...roller The four valves move by the action of the free rocker arms with no supporting shaft The rocker arms one per valve are always in contact with the corresponding cam and are kept in this position by a hydraulic reacting tappet thereby eliminating the need for periodical adjustment 75469 75471 75470 75472 75473 Figure 180 Figure 181 Figure 182 Figure 183 Figure 184 Take out the screws 1 and rem...

Page 128: ...t be finely honed if there is any sign of meshing or scoring replace the shaft 541211 Checking cam lift and pin alignment Set the shaft 1 on tailstocks and using a dial gauge on the middle mounting check that the alignment error is no greater than 0 04 mm replace the shaft if it is In addition check the cam lift it must be as prescribed replace the shaft if it is any different MAIN SPECIFICATIONS ...

Page 129: ...NS HOLLOW SECTION DISTRIBUTING SHAFT SEATS AND PINS 1 Intake valve camshaft seats 2 Exhaust valve camshaft seats 3 Exhaust valve camshaft 4 Intake valve camshaft 108199 F1A ENGINE 101 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 130: ...t the chain drive 2 on the camshafts and secure it to the overhead 1 tightening the screws 8 to the prescribed torque Screw down the screws 4 and 7 with the washers 5 and 6 and tighten them as follows Tighten the screw 7 to a torque of 50 Nm Close further with an angle of 60 Take out the pin 5 Tighten the screw 4 to a torque of 50 Nm Close further with an angle of 60 Fit on the rear cover 2 with a...

Page 131: ...orque Fit the centring tool 99396037 2 onto the shank of the crankshaft Mount the oil vacuum pump assembly 1 with a new gasket and tighten the screws 1 15 according to the following procedures Tighten the screws from no 1 to no 6 to a torque of 5 1 Nm while checking that the tool 99360037 2 turns freely Tighten the screws from no 7 to no 15 to a torque of 10 1 Nm Tighten the screws from no 1 to no...

Page 132: ...rankshaft rotation Mount the gear 2 screw down the screw 3 together with the spacer 4 and tighten it to the prescribed torque Mount the speed sensor 1 with a fresh gasket and tighten the fixing screw 2 to the prescribed torque if applicable Fit on the compressor mounting 3 and tighten the fixing screws 4 to the prescribed torque Mount the air conditioner compressor 1 if applicable and tighten its ...

Page 133: ...3 on it Mount the water pump 1 and tighten the fixing screws 2 to the prescribed torque Fit the high pressure pump 2 onto the flange of the water pump 1 and tighten the fixing screws 3 to the prescribed torque Fit the driving gear 1 onto the shaft of the high pressure pump and block rotation of this shaft by applying tool SP 2263 2 as illustrated in the figure Tighten the nut 3 to the prescribed t...

Page 134: ...nder head Mount the cylinder head 1 Screw down the fixing screws 3 and tighten them in three successive stages following the order and methods shown in the following figure Diagram of the tightening sequence for the cylinder head fixing screws 1st phase pre tightening with torque wrench screws 1 2 3 4 5 6 to a torque of 100 5 Nm screws 7 8 9 10 to a torque of 50 2 5 Nm 2nd phase angle closing scre...

Page 135: ...08328 If the engine has run for a period equivalent to 25 000 km the toothed belt must be replaced with a fresh one no matter what its state of wear NOTE Only for the intake valve distributing shaft with full section tapered shank If required to fit the timing belt 10 on the pulley 7 remove tool 99360608 8 and turn the pulley 7 clockwise by no more than half a pulley tooth NOTE Camshaft drive On c...

Page 136: ...on loosen the fixing screw 2 Keeping the fixing screw 2 stationary turn the plate 3 clockwise until its reference mark 4 coincides with the reference hole 5 of the fixed portion of the tightener In the above conditions tighten the screw 2 to a torque of 36 4 Nm Rotate the engine by two turns in its direction of rotation until the point of tool 99360615 1 engagement into the drive shaft is reached ...

Page 137: ...lexible belt 3 equipped with tool 99360191 2 on the pulley 4 and apply the tool on the pulley 1 Fit the drive ring 5 on the flexible belt 3 and fasten the ring on the compressor support Turn the drive shaft clockwise until the belt fits perfectly on the pulley 1 Figure 226 108326 108327 75503 Fit a new seal 3 on the electro injector 1 and mount this in the overhead 2 Figure 227 90155 Mount the bra...

Page 138: ...en tighten the fastening screw to the prescribed torque Using the wrench 4 of the 99317915 series and the torque wrench 99389829 3 tighten the fuel pipe fittings 1 and 2 to the prescribed torque Figure 229 Figure 230 Whenever they get removed the fuel pipes must be replaced with new ones NOTE Figure 231 108329 108330 108331 108332 Figure 232 Fit throttle valve assembly 1 together with a new gasket...

Page 139: ...hten screw 7 to the prescribed torque Fit coolant pipe 2 into the engine base Screw down screw 1 then tighten it to the prescribed torque Fit oil dipstick pipe 4 together with a new seal ring into the engine base Screw down pipe 2 and 4 fastening nut 3 to the inlet manifold then tighten it to the prescribed torque Whenever they get removed the fuel pipes 4 must be replaced with new ones NOTE 10817...

Page 140: ... a new gasket onto elbow 8 then screw down screws 7 securing EGR valve 6 to elbow 8 tighten nuts 4 and screws 3 and 7 to the prescribed torque 108189 108182 108184 108335 108183 Press the clips 3 in the direction shown by the arrow and connect the fuel recovery pipe fittings 1 to the electro injectors 2 Before fitting the turbocharger on the engine it is necessary to fill the central body with eng...

Page 141: ...eal ring screw down screws 4 then tighten them to the prescribed torque Fit bracket 1 into place screw down screws 2 then tighten them to the prescribed torque Fit coalescence filter 1 into place screw down screws 2 then tighten them to the prescribed torque Connect pipe 3 to coalescence filter 1 screw down nut 4 then tighten it to the prescribed torque Connect pipe 5 to pipe union 7 then secure i...

Page 142: ...ssure regulator 10 temperature sensor 7 deadening hood 2 if included plug 1 the engine with lubricating oil of the prescribed grade and amount Fit the swing bar to the engine lifting hooks then secure the swing bar to the hoist and take the engine off rotary stand 6 Take off brackets 99361038 9 Complete engine assembly Fit on the left and right engine mountings 3 and tighten the fixing screws to t...

Page 143: ...d under pressure to the heat exchanger 5 where it is cooled The oil continues through the oil filter 6 and goes to lubricate the relevant parts through ducts or pipes At the end of the lubrication cycle the oil returns to the sump by gravity The oil filter can be excluded by the safety valve built into it if it gets clogged The heat exchanger is also excluded by a safety valve if it gets clogged I...

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Page 145: ...e 249 It is driven directly by the oil pump transmission ratio 3 25 displacement 86 cm3 volume to drain 4 5 litres volume to drain with EGR 9 litres chamber diameter 65 mm rotor diameter 50 mm cam 7 5 mm number of blades 3 height 34 mm vacuum pump minimum speed 994 rpm vacuum pump max speed 5168 rpm vacuum pump over revs 6046 rpm vacuum pump forced over revs 7235 rpm theoretical flow rate at minim...

Page 146: ... ring 2 Washer 3 Spring 4 Valve 5 Valve casing 75522 MAIN DATA OF THE OIL PRESSURE CONTROL VALVE SPRING Oil filter with single filtration with built in by pass valve opening pressure 2 5 0 3 bar 543110 Modine heat exchanger 75524 Figure 254 Thoroughly clean the heat exchanger 1 Always change the seals 2 and 4 Built in safety valve 3 Opening pressure 0 82 1 03 bar 543475 Oil pressure control valve ...

Page 147: ...er that condenses the remaining vapours that return to the sump through another umbrella valve The portion of vapour that has not condensed is sent via a MANN HUMMEL valve to the intake duct and burnt during normal engine operation 75525 OIL VAPOUR RECIRCULATION DIAGRAM 1 MANN HUMMEL valve 2 Umbrella valves 3 Blow by filter A Labyrinth B Intake oil vapour recovery flow C Oil return flow into sump ...

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Page 149: ... an electromagnetic coupling on whose shaft a hub turns idle that is fitted with an axially mobile metal plate on which is mounted the impeller A 3 way thermostat governing the circulation of the coolant Operation The water pump driven by a poly V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylinder head When the coolant temperature reaches and exceeds ...

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Page 151: ...e control system With pressure in the system it turns on 18 5 0 98 bar it turns off 14 58 0 98 bar 75527 Figure 257 Figure 258 The water pump 3 cannot be overhauled In case of coolant leaking from the seal or damage it must be replaced The water pump casing 1 is also used as a mounting for the high pressure pump The seals 3 and 4 must always be replaced 75528 543212 Electromagnetic pulley 543210 W...

Page 152: ... use the energy of the engine s exhaust gas to send pressurized air to the cylinders The intercooler comprises a radiator included in the engine coolant radiator and its function is to lower the temperature of the air leaving the turbocharger to send it to the cylinders 108201 HOT AIR AT ATMOSPHERIC TEMPERATURE COLD EXHAUST GAS HOT COMPRESSED AIR COLD COMPRESSED AIR EXHAUST GAS 124 F1A ENGINE DAIL...

Page 153: ...d on the end of the central body an overpressure relief valve fitted on the turbine casing Its function is to choke the exhaust gas outlet detail B sending a portion of the exhaust gas straight into the exhaust pipe when the turbocharging pressure downstream from the turbocharger reaches the setting 542410 Turbocharger KKK K03 2074 CCB 5 88 type 75533 B THROTTLE VALVE OPEN Figure 263 F1A ENGINE 12...

Page 154: ...lue stays constant throughout the check replace the valve if it doesn t In the above conditions the tie rod must have made the prescribed travel On finding irregular engine operation due to the turbocharging system it is first expedient to perform the checks on the turbocharger check the efficiency of the seals and the fixingof thecouplings additionally checking there is no clogging in the intake ...

Page 155: ... these conditions a traditional turbine shall rotate slowly thus providing a limited booster pressure In the variable geometry turbine 1 the mobile blades 2 are set to max closed position and the small through sections between the blades increase the inlet gas speed Higher inlet speeds involve higher tip speeds of the turbine and therefore of the turbosupercharger Engine speed increase results in ...

Page 156: ... turbocharger that adjust the flow of exhaust gases 62869 TURBOCHARGING FUNCTIONAL DIAGRAM 1 Variable geometry turbocharger 2 Pneumatic actuator 3 Proportional solenoid valve 4 Air filter 5 EDC 16 control unit 6 Servo brake 7 Vacuum device 8 High pressure pump Figure 270 The actuator diaphragm connected to the control rod is governed by the low pressure on the top of the actuator The low pressure ...

Page 157: ...teristics but may impair engine reliability and duration Ring nut 4 is sealed with antitempering yellow paint In case of engines under guarantee each above specified intervention and or alteration to paint applied on ring nut 4 causes the lapse of the guarantee NOTE Cover air exhaust gas and lubricant inlets and outlets Clean the turbosupercharger outside accurately using anticorrosive and antioxi...

Page 158: ...rmation from the atmospheric pressure sensor water temperature sensor engine revs sensor and accelerator pedal potentiometer It drives according to ways and procedures properly programmed within its own memory both the modulating solenoid valve and the throttle valve by means of a PWM signal The modulating solenoid valve will every time is it driver by the E D C control unit 16 communicate the ser...

Page 159: ... central unit have to be copied down and entered into new central unit Where it is not possible they must be reset and self learning process must be started 772652 Air flow rate meter flow meter Recirculated gas quantity regulation is through a mushroom valve pneumatically driven under under pressure the under pressure through calibrated section fitting is taken from the tube connecting the vacuum...

Page 160: ...to reduce engine noise during this phase Figure 278 Heat exchanger mounted between turbocharger and throttle valve assembly has the task to lower exhaust gas temperature in order to reduce gas volume It consists of a body that incorporates a number of corrugated pipes The circulated exhaust gas flowing through the pipes are cooled by the engine coolant flowing inside the body Figure 279 EXHAUST GA...

Page 161: ...T actuator modulating solenoid valve 136 HP engine 8 Auxiliary vacuum tank for vehicles equipped with 136 HP engine 9 Air filter 10 Air flow meter 11 VGT actuator 12 Differential pressure sensor delta p 13 Incoming exhaust gas temperature sensor 14 Outgoing exhaust gas temperature sensor 15 DPF catalytic silencer 16 Vacuum tank 17 EDC control unit 16 18 Engine coolant temperature sensor 19 Servo b...

Page 162: ...han 530 ºC and oxygen percentage is higher than 8 oxygen being produced by the decomposition of nitrogen oxide NO2 then some combustion reactions boosted by the catalyst put before the filter burn particulate particles regeneration so keeping the filter clean Conversely if its temperature is lower the filter will get clogged with bad effects on the back pressure to the exhaust gas generated In thi...

Page 163: ...composed of nitrogen oxides are reduced or transformed into inert substances carbon dioxide steam then pass into particulate filter where the regeneration process takes place exhaust gas high temperature causes the combustion of particulate particles accumulated in the filter Particulate filter regeneration is realised when following conditions are present catalyst inlet exhaust gas temperature 23...

Page 164: ...maintain particulate filter regeneration A small quantity of this fuel which is injected into the cylinders after combustion has already taken place and remains partially unburnt leaks out through pistons spring rings into oil sump accumulating to lubrication oil Although a part of it evaporating will be burnt in the engine through recirculation system its remaining part can degrade oil characteri...

Page 165: ...The main functions of the system are basically as follows checking fuel temperature checking engine coolant temperature checking amount of fuel injected checking idling speed cutting off fuel in release phase checking cylinder balancing when idling checking anti sawing checking smokiness at exhaust on acceleration checking exhaust gas recirculation E G R checking top speed limit checking glow plug...

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Page 167: ...dling speed it varies the amount of fuel injected into the single electro injectors injection time Checking regularengine rotation anti sawing It ensures regular engine rotation at a constant rate while increasing revs The control unit processes the signals received from the sensors and determines the amount of fuel to be injected via the pressure regulator the electro injector opening time Checki...

Page 168: ...n the injected fuel tends to condense on the metal surfaces that are still cold The fuel supply for a cold engine is therefore greater than for a warm one Correcting flow rate to avoid noise smoke or overloading The behaviour that could lead to this kind of trouble is well known The designer has therefore included special instructions in the control unit to avoid it De rating In the event of the e...

Page 169: ... engine When the motor is running this indicator light goes out while the glow plugs continue to be powered for a certain length of time variable for post heating If with the indicator light flashing the engine is not started up within 20 25 seconds inattention time the operation is cancelled so as not to run down the batteries pointlessly The pre heating curve is also variable in relation to the ...

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Page 171: ... at the injection pressure calculated by the electronic control unit When the solenoid valve of an electro injector is energized by the electronic control unit fuel taken straight from the hydraulic accumulator gets injected into the relevant cylinder The hydraulic system is made out of a low pressure fuel recirculation circuit and a high pressure circuit The high pressure circuit is composed of t...

Page 172: ...144 F1A ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 173: ...r 8 Fuel electric pump non return valve 9 Injector return line pressure relief valve 10 Tank 11 Fuel electric pump 12 Fuel electric pump intake filter 13 Fuel electric pump overpressure valve 14 Pressure relief valve 15 Proportional pressure relief valve Relative pressures within the circuit a 4 15 bar p 5 35 bar b 3 5 bar p 5 0 bar c p 0 8 bar d 0 3 bar p 0 8 bar F1A ENGINE 145 DAILY EURO 4 Print...

Page 174: ...sor D Prefilter E Jet pump 773010 Fuel pump The fuel electric pump is of the volumetric low pressure type It is built into the fuel level indicator located in the fuel tank Electric connector 2 located in the upper portion of the assembly features the pins both for the electric pump and the level sensor During the installation the assembly shall not be stressed with axial loads of more than 67 N a...

Page 175: ...ons higher than 11 8 V in alarm conditions lower than 3 9 V At key on operation the sensor makes a self test issuing 2 5 second duration sound signal 112723 Normally open contact type Operation differential pressure delta p 0 8 bar NTC temperature sensor 30 C 26 114 ohm 9 7 0 C 5 896 ohm 7 3 25 C 2 057 ohm 5 6 60 C 596 ohm 3 8 100 C 186 ohm 2 0 110 C 144 ohm 2 4 Temperature range 40 C to 130 C Hea...

Page 176: ...uel filter mounting 112218 Figure 290 1 Body 2 Gasket 3 Cover bottom 4 Drain screw gasket 5 Customer reference 6 Diesel oil outlet 7 Diesel oil inlet 8 Air drain screw 9 Supplier code 10 Air bleeding or water draining screw 11 Lower bottom 12 Inner pipe 13 Filtering paper 14 Upper bottom 15 Heating earth 16 NTC1 17 NTC2 18 Clogging sensor if foreseen 19 Water sensor 20 Heating 21 Feed 22 GND NOTE ...

Page 177: ...eningscrews shallnot beremoved or tampered with The only operation that can be carried out is the replacement of the drive gear and pressure regulator NOTE 1 Low pressure feed line 2 Shaft with cam 3 3 lobe element 4 Pressure regulator 5 High pressure line non return valve 6 Delivery line 7 Low high pressure line non return valve F1A ENGINE 149 DAILY EURO 4 Print 603 93 651 Base March 2006 775010 ...

Page 178: ...unt new seal rings 1 and 2 on pressure regulator 3 and lubricate the rings with vaseline 771034 Pressure control valve The fuel pressure regulator is mounted on the low pressure circuit of the CP3 pump The pressure regulator modulates the amount of fuel sent to the high pressure circuit according to the commands received directly from the engine control unit The pressure regulator is mainly compos...

Page 179: ...tted on hydraulic accumulator 1 Small valves throttle valves or control bushes 3 with 0 85 mm have been fitted to the fuel delivery couplings which control the fuel pressure waves generated by the high pressure pump Their function is to protect the electric injectors by reducing their wear in time Fuel pressure sensor 2 may affect the accuracy of the injector minimum flow rate correction since the...

Page 180: ...losed position This recreates such a balance in the forces as to make the pin 2 return to its closed position and consequently end injection 1 Pressure rod 2 Pin 3 Nozzle 4 Coil 5 Pilot valve 6 Ball shutter 7 Control area 8 Pressure chamber 9 Control volume 10 Low pressure fuel return 11 Control pipe 12 Supply pipe 13 Electrical connection 14 High pressure fuel inlet fitting 15 Spring The electro ...

Page 181: ...t can be reprogrammed from outside without changing the hardware It processes the signals from the sensors by applying software algorithms and controls the actuators especially the electro injectors and pressure regulator The control unit records in the memory non labile area the information on the engine parameters originally set or acquired during engine operation The injection control unit has ...

Page 182: ... Glow plug electronic control unit The engine control unit in the phase of starting after starting times the operation of the glow plug control unit according to the engine temperature Glow plugs drive is through glow plugs pre heating central unit depending on engine temperature under close control of engine control central unit The pre heating control unit contains an intelligent contactor that ...

Page 183: ...arbox by the drive output shaft transmits the vehicle speed signal through the electronic tachograph to the control unit 540743 Differential pressure sensor delta p Dp This sensor detects the difference between the pressure Dp of the incoming exhaust gas and the pressure of the gas flowing out of the D P F catalyst The measured value indicates the extent of particulate PM particle accumulation or ...

Page 184: ...uring the inactive state the circuit is open The duration of the two states may be varied with the condition that the sum of the two times is equal to the length of the modulation delivery The duration of the active state determines the duty cycle which is normally expressed as a percentage of the total time Therefore if the duration of the two active and passive states are the same the duty cycle...

Page 185: ... COMPRESSOR DRIVE BELT 168 Disassembly 168 Assembly 168 POWER STEERING PUMP ALTERNATOR BELT REPLACEMENT 168 Disassembly 168 Assembly 168 REPLACING THE WATER PUMP 168 Removal 168 Refitting 168 REPLACING THE HIGH PRESSURE PUMP 169 Removal 169 Refitting 169 REPLACING THE POWER STEERING PUMP 170 Removal 170 Refitting 170 REPLACING THE DRIVE SHAFT SEAL RING AND THE FRONT COVER GASKET 170 Removal 170 Re...

Page 186: ... 233 Page Measuring main journals and crank pins 233 Checking crankshaft 234 Replacing timing control gear 236 ENGINE ASSEMBLY 236 Assembling main bearings 236 Measuring main journal assembly clearance 236 Checking crankshaft end float 237 Assembling rear seal 238 ENGINE FLYWHEEL 239 Replacing bearing supporting gearbox input shaft 239 CONNECTING ROD PISTON ASSEMBLY 239 Piston 240 Measuring piston...

Page 187: ...tion 278 Operation 278 Electromagnetic pulley 279 Page Water pump 279 Thermostat 279 TURBOCHARGING 280 Description 280 Turbocharger type MITSUBISHI TD 4 HL 13T 6 281 REPAIRS 282 Pressure relief valve 282 Pressure relief valve check 282 GARRET GT 2260 V variable geometry turbosupercharger 283 General 283 Operation at low engine rpm 283 Operation at high engine rpm 283 Proportional solenoid valve co...

Page 188: ...g 296 Injection timing electronic test 296 Speed governor 296 Engine starting 296 Cold starting 297 Warm starting 297 Run up 297 After run 297 Cut off 297 Cylinder balancing 297 Synchronization search 297 OPERATION 298 Page HYDRAULIC SYSTEM 298 Fuel pipes 298 FEED SYSTEM AND FUEL RECIRCULATION 299 HYDRAULIC SYSTEM 301 Fuel pump 301 Filtrauto fuel filter 302 UFIfilters fuel filter 303 CP3 2 high pr...

Page 189: ... of the connectors Electro injector None of the couplings unions nuts on the injector body may be handled It is neither necessary nor permitted to dismantle the nozzle body or the electromagnet If working on the high pressure pipe the hexagon on the injector side must be kept stationary with a wrench Before working on pipes make sure the injector is stationary in its seat on the cylinder head When...

Page 190: ...xhaust gasses the central unit has to be reprogrammed by IVECO diagnosis tool MODUS E A SY IT 2000 then the procedure to replace affected component has to be carried out following below indications provided by diagnosis tools replace injector replace all injectors replace flow rate meter flow meter replace hydraulic accumulator common rail replace E D C 16 central unit refill engine oil replace D ...

Page 191: ...e the screws and or fastening nuts then remove bumper 17 Remove expansion tank 3 cap 2 Act as follows from under the vehicle see figure 4 undo fastening screws 12 and 13 then remove lower side guards 14 undo fastening screws 16 then remove lower central guard 26 Apply a tube 16 to radiator pipe union detail C then unscrew cap 15 and drain the coolant into a suitable container If the vehicle is equ...

Page 192: ...ondenser drying filter and pipes if any Remove oil filling cap 1 and remove sound proofing cover 5 Loosen the straps then disconnect coolant vent pipes 2 from expansion tank 8 Disconnect tank 8 pressure sensor 7 electric connection Remove tank 8 fastening nuts 10 then remove the tank from the wall Disconnect electric connection 9 of the level sensor placed under tank 8 Loosen the straps then disco...

Page 193: ...otor 7 Disconnect servo brake vacuum pipe 8 from pipe union 12 Disconnect delivery pipe 5 and return pipe 6 from the low pressure fuel pipes Place a container under the power steering pump to recover the system oil then detach oil return and delivery pipes 11 and 10 Loosen the fastening strap then remove power steering tank 4 from the support Apply tool 99360543 3 onto the engine brackets to take ...

Page 194: ...ipes NOTE As regards the vehicles equipped with automatic transmission carefully carry out the operations described in the charter of the Gearbox unit section NOTE Disconnect exhaust pipe 8 from the turboblower outlet pipe Vehicles equipped with D P F catalyst remove the fastening screws then take exhaust pipe 8 supporting bracket 10 off gearbox unit 9 Disconnect vacuum pipe 25 from VGT actuator 2...

Page 195: ...have been fully inserted and not going to be disconnected after their being connected to relating engagement unions Fill the cooling system with coolant Fill the hydraulic power steering circuit and bleed the air as described under the relevant heading Check the level of oil in the engine and gearbox Recharge the air conditioning system if any as described in the relevant chapter in the Bodywork a...

Page 196: ... pulleys 1 and 5 543910 POWER STEERING PUMP ALTER NATOR BELT REPLACEMENT Disassembly Disassemble the compressor drive belt if there is one as described under the relevant heading Slacken off the tension of the belt 1 using a specific wrench on the automatic tightener 2 and remove the belt Assembly Mount the drive belt 1 taking care to position its ribs correctly in the respective races of the pull...

Page 197: ...ccumulator 14 and high pressure pump 9 Remove screws 18 and spacers 19 then remove high pressure pump 9 from support 15 Remove joint 16 771010 REPLACING THE HIGH PRESSURE PUMP Removal 108635 Re attachment is carried out by reversing the order of detachment operations In particular comply with the following instructions replace the seal rings gaskets high pressure pipe and oil filter with new parts...

Page 198: ...ake care of the following replace seal ring 1 with a new part and lubricate the same with engine oil prior to assembling replace the oil pipe gaskets as above tighten the nuts screws and fittings to the specified torque values After re attachment has been completed fill the hydraulic power steering circuit and bleed the air as described under the relevant heading Refitting 540440 REPLACING THE DRI...

Page 199: ... Screw down screws 2 without tightening them up Refitting 102215 Thoroughly clean cover 1 seal ring seat Screw down part 2 of tool 99346258 into the drive shaft shank Lubricate the drive shaft shank and the outside of part 2 then couple the new seal ring 3 with part 2 Place part 4 onto part 2 screw down nut 5 until seal ring 3 is fully assembled to cover 1 Both centrifugal filter 7 and cover seal ...

Page 200: ... VACUUM PUMP OIL PUMP ASSEMBLY GPOD Removal 102218 Remove screws 3 and then take off vacuum pump oil pump assembly 2 Remove connecting joint 1 from gear 4 Both centrifugal filter 1 and cover 3 seal ring must be replaced every time they are dismounted Re attachment is carried out by reversing the order of detachment operations In particular tighten the screws and nuts to the specified torque values...

Page 201: ...eat Lubricate the drive shaft rear shank with engine oil Apply part 2 of tool 99346259 to the drive shaft rear shank then secure it with screws 5 and couple the new seal ring 3 with the same Place part 1 onto part 2 screw down nut 4 until seal ring 3 is fully assembled to the base This operation involves detaching re attaching the drive shafts see relevant section 505620 detaching re attaching the...

Page 202: ...nections 4 from the pressure sensor and 2 from the level sensors both of them located on expansion tank 1 Remove nuts 3 securing expansion tank 1 to the wall then put the expansion tank aside Remove plug 6 and then take off sound proofing cover 5 Disconnect electric connections 7 from electric injectors 16 and 9 from fuel pressure sensor 8 Press clips 15 in the direction shown by the arrow then di...

Page 203: ...n the Replacing the seal ring and the front cover gasket chapter Proceed as follows by operating as described in the Power unit detachment re attachment chapter drain the cooling fluid remove the front cross member remove the expansion tank Cut the straps securing the cables to the engine then disconnect the electric connections below 12 thermostat 17 preheating plugs 20 pressure sensor 21 electri...

Page 204: ...w 17 and washer 16 and then disassemble gear 15 Remove both screw 10 and washer 11 then disassemble gear 12 and chain 14 Remove both plug 6 and screws 7 and 8 then disassemble fixed upper shoe 9 Pins 99360614 applied in order to avoid modifying timing after the toothed chain has been disassembled must be removed from the overhead only when the latter has been disassembled NOTE Remove the overhead ...

Page 205: ...f tool 99395216 NOTE NOTE 88355 Cylinder head fastening screw tightening sequence step 1 preliminary tightening by means of a torque wrench tighten screws 1 2 3 4 5 6 to 130 Nm tighten screws 7 8 9 10 to 65 Nm step 2 angle locking tighten screws 1 2 3 4 5 6 to 90º tighten screws 7 8 9 10 to 90º step 3 angle locking tighten screws 1 2 3 4 5 6 to 90º tighten screws 7 8 9 10 to 60º Tighten screws A t...

Page 206: ...er then press on moving shoe 4 fin 3 until chain stretcher 2 piston 1 is pushed to its end of stroke Release moving shoe 4 and make sure that piston 1 causes by escaping from its seat chain 5 to be subjected to tension Screw down fastening screw 4 with washer 3 without tightening up The chain 1 branch included between the two gears must be subjected to tension 102229 Chain stretcher 1 cannot be re...

Page 207: ...gth included between gear 2 and gear 4 Tighten the screw securing gear 2 to the exhaust valve distributing shaft to the specified torque Remove tools 99360614 1 and 99360615 5 Figure 25 Figure 34 Figure 35 540730 EGR HEAT EXCHANGER RE MOVAL REFITTING 105027 Remove plug 4 from expansion tank 3 Arrange special container under the radiator remove plug located on radiator right side and drain engine c...

Page 208: ...ing from cooling circuits tubes Figure 39 108632 Loosen the straps then disconnect coolant pipes 2 and 3 from EGR valve 6 Loosen screw 7 of strap 8 joiningEGR valve 6 to pipe 9 Remove screws 4 then take heat exchanger 1 complete with EGR valve 6 off the overhead 540730 EGR HEAT EXCHANGER RE MOVAL REFITTING 105027 Remove plug 4 from expansion tank 3 Arrange special container under the radiator remo...

Page 209: ...ns described for removal observing following warnings replace gaskets 2 and 3 and the straps with new parts tighten the screws to the specified torque value fill expansion tank with coolant Checks and tests Start up the engine let it run at rpm s just a little over idling and wait for coolant temperature to reach the value for opening the temperature switch then check for no water leaks existing f...

Page 210: ...de up of three components A system length with hose B catalyst with particulate filter DPF C silencer The exhaust system is manufactured by Arvin Meritor ArM BURNT GAS EXHAUST SYSTEM 182 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 211: ...ng bracket 10 to the vehicle chassis unscrew and remove fastening screws 13 of flanges 15 connecting D P F catalyst 8 filter to the exhaust gas outlet pipe from turbine 14 remove D P F catalyst 8 filter Refitting Refitting is carried out by reversing the order of the detachment operations Moreover the following instructions shall be observed check the conditions of the elastic dowels taking care t...

Page 212: ...ne oil is refilled resetting post injected fuel counter is not necessary NOTE 540743 Replacing differential sensor delta p Pressure difference between gas pressure at catalyst module inlet and gas pressure at ceramic walls filter outlet is converted into a voltage signal Vout by pressure sensor During engine running E D C 16 central unit performs checks on differential pressure sensor drift and ca...

Page 213: ...107864 Figure 45 F1C ENGINE 185 DAILY EURO 4 Print 603 93 651 Base March 2006 ENGINE VIEWS ...

Page 214: ...107865 107866 107867 Figure 46 Figure 47 Figure 48 LEFT HAND SIDE VIEW FRONT VIEW REAR VIEW 186 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 215: ...107868 Figure 49 Figure 50 TOP VIEW RIGHT HAND SIDE VIEW A Turbocharger with pressure relief valve Waste Gate ENGINE 136 HP 107869 F1C ENGINE 187 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 216: ...ling 800 rpm 72 dB A at maximum torque 84 dB A at maximum power 3800 rpm 93 dB A Engines for LD Light Duty vehicles Gas emissions Engines comply with Euro4 Gas Emission Regulation measurement at engine bench according to cycle ECE15 EUDC with following limits set by Regulation 98 69 1999 102 CEI level B CO carbon oxide 0 74 g kWh NOx nitrogen oxide 0 39 g kWh HC unburnt hydrocarbons NOx nitrogen o...

Page 217: ... vertical 4 4 cylind 6 6 cylind 8 DI TCA 1 Truck 2 Bus 4 M T vehicles and tractors 6 Marine 9 Army 0481 F 107 kW 146 CV 3500 rpm 350 Nm 35 6 kgm 1500 2800 rpm 0481 H 129 kW 176 CV 3500 rpm 400 Nm 40 7 kgm 1500 2800 rpm F 1 8 4 4 E C 1 C F Homologation power F1C ENGINE 189 DAILY EURO 4 Print 603 93 651 Base March 2006 ENGINE IDENTIFICATION CODE ...

Page 218: ... 190 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 EXAMPLE A IVECO trademark IVECO B IVECO name of engine variant F1CE0481F H A001 C Engine serial number 1359862 D 1st digit main journal no 1 engine front E Main bearing selection diameters 12345 F Barrel selection diameters 1234 G 1st digit cylinder no 1 engine front Data obtainable from XZ engine ordering number information ...

Page 219: ...108444 Figure 53 LONGITUDINAL SECTION F1C ENGINE 191 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 220: ...108445 Figure 54 F1C ENGINE CYLINDER AXIS CROSS SECTION 146 HP 192 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 221: ...108446 Figure 55 F1C ENGINE SUPPORT AXIS CROSS SECTION 146 HP F1C ENGINE 193 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 222: ...108447 Figure 56 F1C ENGINE CROSS SECTION 176 HP 194 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 223: ...TIC CURVES OF ENGINE F1C 146 HP 107872 Max OUTPUT 107 kW at 3500 rpm Max TORQUE 350 Nm at 1500 2800 rpm 146 HP 35 6 kgm Figure 57 F1C ENGINE 195 DAILY EURO 4 Print 603 93 651 Base March 2006 CHARACTERISTIC CURVES ...

Page 224: ...CHARACTERISTIC CURVES OF ENGINE F1C 176 HP 107873 Max OUTPUT 122 kW at 3500 rpm Max TORQUE 400 Nm at 1250 3000 rpm 176 HP 40 7 kgm Figure 58 196 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 225: ...nt cm3 2998 Max power KW HP 107 146 122 176 rpm 3500 3500 Max power KW HP 350 250 Max power KW HP 350 35 6 400 40 7 rpm 1500 2800 1500 2800 Engine idling speed no load rpm 800 25 Maximum engine speed no load rpm 4200 50 Pressure at T D C bar 20 26 bar Minimum permissible pressure at T D C bar 16 The pressure value is recorded by turning the engine over with the electric starter motor with oil temp...

Page 226: ...ming check mm X mm Running mm X mm FEED High pressure electronic fuel feed system BOSCH EDC16 Composed of CP3 2 high pressure pump electro injectors hydraulic accumulator rail EDC control unit pressure and temperature sensors Pump arrangement With piston n l at T D C X Start of delivery mm Injector nozzle type BOSCH CR1 2 2 Injector nozzle type BOSCH CR1 2 2 Injection order 1 3 4 2 ba r Release pr...

Page 227: ... bar 1 38 0 047 Actuator setting low pressure 0 mmHg valve fully open low pressure 0 2 bar valve stroke mm low pressure 0 64 bar valve stroke mm 0 5 2 5 9 5 11 5 LUBRICATION Forced lubrication by means of gear pump pressure relief valve and simple filtering oil filter bar Oil pressure with engine hot 100 5 C at idling speed bar 1 0 at maximum speed bar 5 0 COOLING by centrifugal pump thermostat fo...

Page 228: ...outside diameter 2 length L Cylinder liners crankcase bores negative allowance Outside diameter 2 3 X Cylinder sleeve inside diameter 3 1 Pistons supplied as spare parts type MAHLE X measuring dimension X 10 2 outside diameter 1 95 705 95 715 2 pin bore 2 36 003 36 009 Piston cylinder sleeve 0 087 0 117 Piston diameter 1 0 4 X Pistons protrusion X 0 3 0 6 3 Gudgeon pin 3 35 990 35 996 Gudgeon pin ...

Page 229: ... measured on ø of mm 0 103 0 162 Piston rings grooves 2 0 060 0 100 3 0 050 0 090 Piston rings 0 4 X1 2 X Piston ring end gap in cylinder liners 3 2 X X X1 0 20 0 35 3 X X2 0 60 0 80 X3 0 30 0 60 1 Small end bush housing Ø 1 39 460 39 490 2 Big end bearing housing Ø 2 67 833 67 848 Small end bush diameter 4 outside 4 39 570 39 595 3 inside 3 36 010 36 020 S Big end bearing shell supplied as spare ...

Page 230: ...ls S1 2 165 2 174 S 1 S 2 Big end bearing shells superior S2 inferior 1 883 1 892 1 885 1 891 supplied as spare parts 3 Main bearing housings 3 No 1 2 3 4 No 5 80 588 80 614 87 588 87 614 Bearing shells main journals 0 032 0 102 Bearing shells crankpins 0 035 0 083 Main bearing shells 0 254 0 508 Big end bearing shells 0 254 0 508 1 X Main journal for shoulder X 1 32 500 32 550 X 2 Main bearing ho...

Page 231: ...de 0 05 0 10 0 25 4 Valves 4 5 985 6 000 4 α 5 985 6 000 60 7 5 4 5 975 5 990 α α 5 975 5 990 60 7 5 Valve stem and its guide 0 023 0 053 Seat on head for valve seat 1 34 490 34 515 1 1 34 490 34 515 2 Outside diameter of valve seat angle of valve seat in cylinder 2 angle of valve seat in cylinder head 2 34 590 34 610 2 α 34 590 34 610 59 5 5 α α 2 α 34 590 34 610 59 5 5 X 0 375 0 525 X Recessing ...

Page 232: ...rotrusion X 2 77 3 23 Seats for tappets on cylinder head normal 12 016 12 034 Tappet normal 11 988 12 000 Between tappets and seats 0 016 0 046 Camshaft pin seats in cylinder overhead 1 7 1 2 48 988 49 012 46 988 47 012 2 3 46 988 47 012 35 988 36 012 2 Camshaft supporting pins 1 2 48 925 48 950 46 925 46 950 1 3 2 2 3 46 925 46 950 35 925 35 950 Between seats and supporting pins 0 032 0 087 H Use...

Page 233: ... to check spring loads 99317915 Set of six box type wrenches 14 17 19 mm 99322205 Rotary telescopic stand for overhauling assemblies capacity 700 daN torque 120 daN m 99340059 Extractor for camshaft pulley 99340060 High pressure pump toothed pulley extractor 99342153 Tool to remove crankshaft front gasket ...

Page 234: ...ing device for mounting crankshaft front gasket 99346259 Keying device for mounting crankshaft rear gasket 99358026 Wrench for alternator pulley free wheel removal refitting 99360076 Tool to remove cartridge filters 99360183 Pliers for mounting rings on engine pistons 99360186 Guide for flexible belt ...

Page 235: ...ool for hydraulic power steering control shaft 99360190 Damper pulley retaining tool 99360260 Tool for removing and refitting engine valves 99360306 Tool to retain engine flywheel 99360543 Swing bar for engine detachment re attachment 99360605 Band to insert standard and oversized pistons into the cylinders ...

Page 236: ... 2 for camshaft timing 99360615 Tool for crankshaft timing 99361041 Brackets securing engine to rotary stand 99322205 99367121 Manual pump to measure pressure and vacuum 99370415 Dial gauge base for various measurements to be used with 99395603 99389817 Dynamometric wrench 60 320 Nm with 3 4 coupling ...

Page 237: ...ch 150 800 Nm with 3 4 square coupling 99389819 Torque wrench 0 10 Nm with square 1 4 connection 99389829 9x12 coupling torque wrench 5 60 Nm 99395216 Pair of meters for angular tightening with square 1 2 and 3 4 connection 99395363 Complete square to check for connecting rod distortion 99395603 Dial gauge 0 5 mm ...

Page 238: ... DAILY EURO 4 Base March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99395687 Bore meter 50 178 mm 99395849 Belt tension control device frequency from 10 0 bis 600 Hz 99396039 Centring ring for timing gear cover ...

Page 239: ...s section shows the working drawings for the experimental tools S P used in overhauling the engine described in this section which may be made by the repair shops F1C ENGINE 211 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 240: ...MOTORI F1A F1C 212 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 241: ...MOTORI F1A F1C F1C ENGINE 213 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 242: ...MOTORI F1A F1C 214 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 243: ...MOTORI F1A F1C F1C ENGINE 215 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 244: ...MOTORI F1A F1C 216 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 245: ...MOTORI F1A F1C F1C ENGINE 217 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 246: ...g 50 5 5 0 5 Second stage angle 60º 2 5º Third stage angle 60º 2 5º M8x1 25 L 77 5 40 outer fastening screw for lower cylinder block 26 2 6 Socket head screw with flange M11x1 25x49 for connecting rod cap fastening Preliminary torque 50 5 Second stage angle 70 Socket head screw with flange M12x1 25x52 5 for engine flywheel fastening Preliminary torque 30 3 Second stage angle 90 Six lobe socket scr...

Page 247: ...astening of fuel delivery pipe anchoring bracket 10 1 Pipe union for fuel delivery pipes to rail and electric injectors M14x1 5 M12x1 5 19 2 25 2 1 9 0 2 2 5 0 2 Socket cylinder head screw M8x1 25 for fastening of electric injector retaining bracket 28 2 8 Flanged nut M8x1 25 for anchoring bracket support fastening 25 2 5 Pin fastener M12x1 25 for high pressure pump 110 11 Flanged nut M6x1 for low...

Page 248: ...w M8x1 25 for fastening of air conditioner compressor control belt idler 25 2 5 Socket cylinder head screw M10x1 5 for alternator fastening 50 5 Flanged screw M10x1 25x110 for hydraulic power steering pump fastening 40 4 Flanged screw M12x1 25 securing the power steering pump 50 5 Flanged screw M8x1 25 securing the power steering tank support 25 2 5 Flanged screws M10x1 25 for power take off cover...

Page 249: ...he electro magnetic joint 2 Remove the items below if they have not yet been removed prior to detachment upper sound proofing cover engine cable complete with raceway 6 by disconnecting the electric connections of the same from electric injectors 1 preheating plugs 3 hydraulic accumulator pressure sensor 5 throttle valve actuator 7 inlet manifold air pressure temperature sensor 8 revs sensor 4 hig...

Page 250: ... from the hydraulic accumulator 1 rail Take out the screws 2 and the brackets 3 fixing the electro injectors 1 to the cylinder overhead Using tool 99342153 1 extract the electro injectors 2 from the overhead 3 Remove the fastening screw 3 of the pipe retaining bracket 2 Disconnect the pipe 2 from the hydraulic accumulator 1 and the high pressure pump 4 Remove the screws 1 and the hydraulic accumul...

Page 251: ...ssure pump 2 Remove screws 1 then take heat exchanger 2 with its respective gasket off the engine base Remove screws 5 with spacers 4 then take off high pressure pump 3 Remove screws 6 with spacers 7 then take off power steering pump 8 Remove screws 1 then take off power steering tank support 2 Cut elastic belt 1 if any due to its being unable to be reused Remove screws 3 then remove air condition...

Page 252: ...he retaining straps then remove coolant pipes 1 and 2 Remove screw 3 and strap 5 then disconnect coolant pipe 4 from water pump 6 Loosen screw 5 then remove strap 6 Remove screws 1 then take heat exchanger 2 together with EGR valve 3 off overhead 4 and connecting pipe 7 Remove screws 2 then take cover 3 together with pipes 4 and 5 off cylinder head 1 Unscrew connections 2 4 and 6 then disconnect o...

Page 253: ...atic tightener 1 Remove the screw 2 the bolt 4 and pull the alternator 3 out of the support 1 Remove the screws 1 and take off the support 2 from the cylinder block Use the suitable wrench to remove the oil level sensor 1 Remove the fastening screw and the rev sensor 2 Remove the nuts 2 the spacers 1 and take off the exhaust manifold 3 with the relevant gasket from the cylinder head F1C ENGINE 225...

Page 254: ... 3 off water pump 6 Remove screws 1 then take water pump 2 off Remove screw 3 then take oil dipstick pipe 4 out of front cover 5 Remove the screws 3 and the cover 4 Take off the snap ring 2 Pull out the centrifugal filter 1 Stop the rotation of the engine flywheel 2 by means of tool 99360306 1 Remove the screw 2 and the damper pulley 1 Slacken the nut 2 anticlockwise because its threading is left ...

Page 255: ...7 the washer 6 the gear 5 and the chain 4 Remove the cap 4 the screws 2 and 3 and the top fixed skid 1 88271 Remove the screws 3 and disassemble the depressor oil pump unit 2 Remove the connection key 1 Figure 94 Tool 99340059 4 is used to remove the seal ring 3 from the cover 2 when the engine is installed on the vehicle Upper hydraulic chain stretcher 1 is equipped with an anti return device tha...

Page 256: ...Remove the screw 3 and the stem with the drive gear 2 from the high pressure pump control shaft 1 Remove the gear 1 and the chain 3 from the high pressure pump control shaft 2 Remove the high pressure pump control shaft 3 Remove the nuts 2 and the support 1 Stop the rotation of the hydraulic power steering pump control shaft 2 by inserting tool 99360187 3 in the shaft and fastening the tool on the...

Page 257: ...d the support 1 Remove the screws 1 and take off the over head 2 from the cylinder head 3 Remove the hydraulic tappets 1 with the rocker arms Remove the gasket 2 Take out the screws 1 and remove the cylinder head 2 Remove the cylinder head gasket 1 Check the protrusion of the pistons 2 as described under the relevant heading to check the possibility of facing the crankcase if it has deformed NOTE ...

Page 258: ...e flywheel 1 with tool 99360306 4 Take out the screws 2 and remove the engine flywheel 1 Take out the guard 3 Apply tool 99340060 2 to the rear O ring 1 and extract it from the crankcase On the same side of the connecting rod and its associated cap indicate the number of the cylinder from which the connecting rod has been removed Keep the bearing shells in their respective housings since if they a...

Page 259: ...lls 2 since if they are reused they will need to be fitted in the position found during removal NOTE Note the assembly position of the top main bearing shells 2 since if they are reused they will need to be fitted in the position found during removal NOTE On completing engine removal it is necessary to clean the removed parts thoroughly and check their integrity The following pages give the instru...

Page 260: ...gs If they are rusty or there is any doubt about their seal replace them When fitting the caps into place apply Loctite 270 sealant IVECO NO 93162429 to the same Examine the surfaces of the cylinder liners they must show no sign of meshing scoring ovalization taper or excessive wear The inside diameter of the cylinder liners is checked to ascertain the extent of ovalization taper and wear using th...

Page 261: ... arm no 1 TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS 5408 CRANKSHAFT 540810 Measuring main journals and crank pins Checking head mating surface on cylinder block On finding signs of seizure scoring or excessive ovalization on main journals and crankpins it is necessary to regrind the pins Before grinding the pins 2 measure the shaft pins with a micromete...

Page 262: ...hecks on the tolerances indicated in the figures must be made after grinding the crankshaft pins NOTE 234 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL SHAPE Circularity SHAPE Cylindricality ORIENTATION Parallelism ORIENTATION Perpendicularity POSITION Concentricity or coaxiality OSCILLATION Circular oscillation OSCILLATION Total oscill...

Page 263: ... Measured with calibrated rollers 2 5 mm JOURNAL ON TIMING SYSTEM SIDE JOURNAL ON FLYWHEEL SIDE MAIN DATA OF MAIN JOURNALS AND CRANKPINS Since during the 0 254 and 0 508 mm undersizing on the diameter of the crankpins and main journals the rolled portion of the side races of the pins may get involved it is necessary to turn the races keeping to the data given in the figure and to do the rolling ke...

Page 264: ...ed with sealant Fit on the oil spray nozzles 2 and tighten the couplings 1 to the prescribed torque The main bearings 1 are supplied as spare parts undersized on the inside diameter by 0 254 0 508 mm 540811 Measuring main journal assembly clearance Mount the crankshaft 1 Check the clearance between the crankshaft main journals and their respective bearings by proceeding as follows Thoroughly clean...

Page 265: ...ft does not come within the prescribed values it is necessary to grind the crankshaft and accordingly change the main bearing shells α Figure 139 Remove the bottom crankcase The clearance between the main bearings and their associated pins is measured by comparing the length of the calibrated wire 1 at the point of greatest crushing with the graduated scale on the casing containing the calibrated ...

Page 266: ...osing to an angle of 60 Step 3 closing to an angle of 60 Then tighten the outer screws 1 to a torque of 26 30 Nm Carefully clean the seal seat Lubricate the rear shank of the crankshaft with engine oil Fit part 2 of tool 99346259 onto the rear shank of the crankshaft secure it with the screws 3 and key the fresh seal 1 onto it Position part 4 on part 2 screw down the nut 5 to fit the seal 1 fully ...

Page 267: ...replace them if they do α Take off tool 99360351 4 Use tool 99395216 1 for the angle closing 88054 Double mass engine flywheel one integral with the drive shaft and one with the input shaft of the gearbox and in between a torsion elastic dampening system The advantages of this type of flywheel compared to the normal one are Dampening of engine irregularities transmitted to the gearbox and resultin...

Page 268: ...ameter measured is 91 4 mm X 0 5 Using a micrometer 2 measure the diameter of the piston 1 to determine the assembly clearance The diameter has to be measured at the value shown The clearance between the piston and cylinder liner can also be checked using a feeler gauge 1 as illustrated in the figure 107733 540840 Piston Measuring piston diameter The pistons are supplied as spare parts with the st...

Page 269: ...e word TOP must be facing upwards Check the thickness of the piston rings 2 with a micrometer 1 Check the clearance between the trapezoidal ring 2 1st slot and the associated slot on the piston with a feeler gauge 1 proceeding as follows insert the piston into the cylinder liner so that the ring 2 comes approximately half way out of it DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON...

Page 270: ... the associated seats on the piston 3 with a feeler gauge 1 Check the opening between the ends of the piston rings 2 inserted in the cylinder liner using a feeler gauge 1 MAIN DATA OF THE CONNECTING ROD BUSHING PISTON PIN AND BEARING SHELLS Internal diameter to obtain after driving into the small end and grinding with a reamer Dimension cannot be measured in the free state Thickness of the bearing...

Page 271: ... pre loads by approx 0 5 mm on the pin 3 at point A and zero the dial gauge 2 Shift the spindle 4 with the connecting rod 5 and compare any deviation on the opposite side B of the pin 3 the difference between A and B must be no greater than 0 08 mm Checking torsion 61694 Checking bending Check the bending of the connecting rod 5 by comparing two points C and D of the pin 3 on the vertical plane of...

Page 272: ...ogether check for distortion with the tool 99395363 8 as follows Fit the connecting rod 7 together with the piston 3 on the spindle 4 of tool 99395363 8 and lock it with the screw 5 Rest the connecting rod 7 on the bar 6 Position the mount 1 of the dial gauge 2 so that this is positioned at point A of the piston with a pre load of 0 5 mm and zero the dial gauge 2 Shift the spindle 4 so as to posit...

Page 273: ... the connecting rod bearing shells and fit them permanently by tightening the connecting rod cap fixing screws as described Manually check that the connecting rods slide axially on the pins of the crankshaft Checking piston protrusion α At the end of the connecting rod piston assembly refitting check the piston protrusion 2 at the T D C compared to the top level of the cylinder block by means of a...

Page 274: ...ool 99360260 onto part 4 screw down the nut 1 so that on compressing the springs 8 it is possible to remove the cotters 6 Then take out the plates 7 and the springs 8 Using suitable pliers remove the oil seal 9 Repeat these operations on the remaining valves Turn the cylinder head over The intake 1 and exhaust 2 valves have the same diameter mushroom The central cavity of the mushroom of the intak...

Page 275: ...val assembly Checking cylinder head mating surface If there is any leakage from the cylinder head it must be replaced MAIN DATA OF INTAKE AND EXHAUST VALVES Remove the carbon deposits on the valves with a wire brush Check that the valves show no signs of seizure cracking or burning 540662 VALVES Removing deposits refacing and checking valves Use a micrometer 2 to measure the valve stem 1 it must h...

Page 276: ...move the valve guides 2 with the drift SP 2312 1 Warm up the cylinder head to 80 100 C and by means of beater SP 2312 1 fitted with element SP 2311 2 fit the new valve guides 3 previously lubricated with engine oil Driving force 10 25 KN If the above mentioned tools are not available fit the valve guides by positioning them in the cylinder head according to the value shown in SENZA CODICE After dr...

Page 277: ... Using a specific tool regrind the valve seats according to the angles given in Figure 188 Using the milling cutter 99394038 1 clean the injector seat of any deposits Mount the valves block the seat of the electro injectors and glow plugs using a suitable tool check the seal of the valves seats Using a dial gauge 1 check that from the plane of the cylinder head the valve recessing 2 and the protru...

Page 278: ...ECK INTAKE AND EXHAUST VALVE SPRINGS COMPLETE ROCKER ARM ASSEMBLY The rocker arm assembly is composed of the rocker arm 1 hydraulic tappet 3 made integral with each other by the clip 2 540665 VALVE SPRINGS ROCKER ARMS TAPPETS CROSS SECTION OF THE HYDRAULIC TAPPET A 32 44 0 3 end of stroke B 31 30 working position C 29 75 0 25 start of stroke 250 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93...

Page 279: ...4 2 mount the oil seals 3 on the valve guides 4 MAIN DATA HYDRAULIC TAPPETS SEATS Position the springs 8 and plates 7 on the cylinder head 5 Fit the part 4 of tool 99360260 onto the cylinder head 5 and secure it with the screws 3 Fit the part 2 of tool 99360260 onto part 4 screw down the nut 1 so that by compressing the springs 8 it is possible to insert the retaining cotters 6 then unscrew the nu...

Page 280: ...ts for lifting the engine and tighten the fixing screws to the prescribed torque Remove the screws 2 and 3 and the covers 1 and 4 together with the over head seal rings Remove the nuts 4 and the top skid 3 Remove the screws 1 and the shoulder plate 2 Tilt the over head 1 and take care not to damage the seats then take off the camshafts 2 and 3 from the overhead 540650 Overhead Overhead removal 252...

Page 281: ...hain stretcher with anti return device 4 Chain 5 Hydraulic belt stretcher 6 Drive gear on driving shaft 7 Fixed skid 8 Oil pump depressor control shaft gear Hydraulic power steering pump 9 Double chain 10 High pressure pump control shaft gear 5412 TIMING SYSTEM NOTE HYDRAULIC BELT STRETCHER WITH ANTI RETURN DEVICE A Max range 76 9 0 4 mm B Piston engaged 53 6 mm C Min travel for piston disengageme...

Page 282: ...in the overhead The difference between these two measurements gives the existing clearance The nominal assembly clearance is 0 037 0 088 mm 87806 Figure 207 541211 Checking cam lift and pin alignment Place the shaft 1 on the parallels and use a centesimal dial gauge fitted on the central support to check that the alignment error does not exceed 0 04 mm otherwise change the shaft Check also the cam...

Page 283: ...valve camshaft seats 2 Exhaust valve camshaft seats 3 Intake valve camshaft 4 Exhaust valve camshaft The camshaft 3 of the suction valves can be recognised through the spring cup 4 and the dowel 6 NOTE F1C ENGINE 255 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 284: ...em to the prescribed torque Position the camshafts 3 and 4 so that the pins 99360614 1 can be inserted in the camshaft slots 2 through the over head threaded holes Rotate the driving shaft so that the tool 99360615 1 can be inserted in the shaft crank hole through the cylinder block hole in order to stop the engine in the timing system setting condition AUXILIARY ORGAN CONTROLS During this operati...

Page 285: ...e hydraulic power steering pump by inserting in the latter the tool 3 and fastening the tool on the support 1 by means of the screws 4 Fit the gear 1 on the stem 3 of the hydraulic power steering pump Drive in the screw 2 without locking it Lubricate the new seal rings 1 and 2 with engine oil and fit them on the support 3 Fit the support 1 drive in the nuts 2 and tighten them to the prescribed tor...

Page 286: ...ressure pump control stem 1 Drive in the fastening screw 3 Cynder head refitting Check that the mating surfaces of the cylinder head and crankcase are clean Keep the cylinder head gasket clean Place the gasket 1 of the cylinder head with the thickness given in section Check piston protrusion with the TOP sign facing the head It is essential to keep the gasket sealed in itspackage until just before...

Page 287: ... positioning the rocker arms 1 on the valves correctly Fit on the gasket 5 Insert the two tools SP 2264 4 into the electro injector seats for subsequent centring of the overhead on the cylinder head Mount the overhead 1 together with the tools 99360614 3 for the timing and tighten the fixing screws 2 to the prescribed torque Take out the tools SP 2264 4 Figure 226 88356 Figure 227 88357 TIMING SYS...

Page 288: ...ghtening it completely Check the conditions of the mobile skids 1 and 3 if worn out change them Position the mobile skids 1 and 3 and clamp them on the cylinder block by the pin 2 and tighten it to the prescribed torque Drive in the chain hydraulic tightener 1 and lock it to the prescribed torque Tighten the fastening screw of the gear 1 on the hydraulic power steering control stem to the prescrib...

Page 289: ...he prescribed torque Make sure that the chain 3 in the tract between the gear 2 and gear 4 is tensioned Tighten the fastening screw of the gear 2 on the exhaust valve camshaft to the prescribed torque Remove tools 99360614 1 Figure 234 Stop the rotation of the high pressure pump control shaft 1 by inserting the suitable wrench inside it 90311 Chain stretcher 1 cannot be re used for any reason afte...

Page 290: ...e element 2 of tool 99346258 in the driving shaft tang Lubricate the tang of the driving shaft and the element outside 2 and fit flush the new seal ring on this element 3 Position the element 4 on element 2 lock the nut 5 until fitting the seal ring 3 completely in the cover 1 Fit a new centrifugal filter 1 Fit a new snap ring 2 Fit the cover 3 drive in the screws 4 and tighten them to the prescri...

Page 291: ...a special lever Screw down hub 1 fastening nut 2 Use a suitable wrench 4 to tighten nut 2 to the specified torque Drive in the oil level sensor 1 and tighten it to the prescribed torque Fit the rev sensor 2 drive in the fastening screw 3 and tighten it to the prescribed torque Fit the support 2 drive in the screws 1 and tighten them to the prescribed torque 88378 Stop the rotation of the engine fl...

Page 292: ...ree wheel 2 by reversing the removal operations The free wheel 2 must be clamped on the stem 5 by applying a max torque of 85 Nm Fit the alternator 3 on the support 1 lock it with the bolt 4 and the screw 2 and tighten them to the prescribed torque Fit the automatic backstand 1 drive in the screw 2 and tighten it to the prescribed torque Operate the automatic backstand 2 with the suitable wrench f...

Page 293: ... fastening screws 1 to the speci fied torque Connect EGR valve 3 to pipe 6 with a new collar 4 then tighten fastening screw 5 to the specified torque Fit rear cover 4 with a new gasket 2 back to cylinder head 1 Screw down fastening screws 3 and tighten them to the specified torque Fit coolant pipes 1 and 3 to rear cover 2 and heat exchanger 4 and secure them with new clamps and collars Figure 260 ...

Page 294: ...ve in the screws 5 complete with spacers 6 and tighten them to the prescribed torque Figure 264 107711 Fit heat exchanger 2 complete with a new gasket onto the engine base Drive in the screws 1 and tighten them to the prescribed torque Figure 265 107710 Connect the low pressure pipes 5 with the new gaskets to the high pressure pump 2 and tighten the pipe unions 1 and 3 to the prescribed torque Dri...

Page 295: ... type wrench SP 2275 2 and torque wrench 99389819 3 tighten them to a torque of 8 10 Nm Mount the hydraulic accumulator 1 and tighten the fixing screws 2 to the prescribed torque Fit the pressure sensor 3 on the hydraulic accumulator 1 and tighten it to the prescribed torque 107744 Fit throttle valve assembly 2 together with a new gasket onto inlet manifold 1 Screw down fastening screws 3 then tig...

Page 296: ...n by the arrow then disconnect the connections of fuel recovery pipe 1 to electric injectors 2 Whenever they get removed the fuel pipes must be replaced with new ones 107749 Connect the fuel pipe 3 to the hydraulic accumulator 1 and to the high pressure pump 8 Tighten the couplings 2 and 5 using a wrench 7 in the 99317915 series and the torque wrench 99389829 6 Fasten the pipe 3 on the support bra...

Page 297: ... in the screw 1 and tighten it to the prescribed torque Fit the air conditioner compressor if any into place then tighten the fastening screws to the specified torque and fit elastic belt 4 into place as described below To fit the air conditioner compressor elastic drive belt into place tool 99360191 2 must be used Any other tool or method may cause dangerous tension to the elastic belt The elasti...

Page 298: ... of the same to electric injectors 1 preheating plugs 3 hydraulic accumulator pressure sensor 5 throttle valve actuator 7 inlet manifold air pressure temperature sensor 8 high pressure pump pressure regulator 10 phase sensor 2 thermostat coolant temperature sensor 9 channelling duct 6 upper sound proofing cover if any fill the engine with lubricating oil of the prescribed grade and amount Fit the ...

Page 299: ...xchanger where it is cooled The oil continues through the oil filter and goes to lubricate the relevant parts through ducts or pipes At the end of the lubrication cycle the oil returns to the sump by gravity The oil filter can be excluded by the safety valve built into it if it gets clogged In addition the lubricating oil feeds the chain hydraulic tightening devices for the control of the auxiliar...

Page 300: ...272 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 301: ...23 52 cm3 pumping diameter 49 5 mm number of teeth 7 height 16 mm oil pump minimum speed 780 rpm oil pump max speed 3500 rpm oil pump over revs 4200 rpm oil pump forced over revs 4900 rpm speed 3500 rpm torque Nm power draw calc W Figure 286 SECTION B B Figure 287 SECTION A A 88690 88691 Should the unit be faulty not due to the oil pressure adjusting valve change the whole unit NOTE F1C ENGINE 273...

Page 302: ...ench to remove the oil pressure adjusting valve 1 from the oil pump Vacuum pump The vacuum pump 2 Figure 284 with radial blades is also incorporated in the GPOD 1 Figure 285 It is driven directly by the oil pump transmission ratio 1 displacement 150 cm3 volume to drain 4 5 litres chamber diameter 65 mm rotor diameter 45 5 mm cam 7 5 mm number of blades 3 height 34 mm vacuum pump minimum speed 780 ...

Page 303: ...pport 7 Oil pressure switch 8 Screw 9 Heat exchanger box 10 Gasket Assembly For refitting reverse the removal operations 543070 Oil filter 543110 Heat exchanger Disassembly Remove the screws 5 and take off the heat exchanger 1 from the box 3 with the gasket 8 Remove the screws 7 and take off the oil filter support 6 from the box 3 Assembly For refitting reverse the removal operations and observe t...

Page 304: ...296 Figure 297 Figure 298 HEAT EXCHANGER SECTIONS Oil flow from heat exchanger to oil filter Oil flow from oil filter to cylinder block Oil flow from cylinder block to heat exchanger 276 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 305: ...ng from the filter 3 in the chain compartment and the oil condenses in the chamber 6 Operation The mixture which passes through the rotating filter 3 is partially purified from the oil particles as a result of centrifugation and so these particles condense on the cover walls to return to the lubrication circuit The resulting purified mixture is let in through the stem holes 1 and the diaphragm val...

Page 306: ... a hub turns idle that is fitted with an axially mobile metal plate on which is mounted the impeller A 3 way thermostat governing the circulation of the coolant Operation The water pump driven by a poly V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylinder head When the coolant temperature reaches and exceeds the working temperature it causes the therm...

Page 307: ...it It activates at 20 C and deactivates at 10 C With climate control system With pressure in the system it turns on 18 5 0 98 bar it turns off 14 58 0 98 bar 107754 Figure 301 The water pump cannot be overhauled In case of coolant leaking from the seal or damage it must be replaced 543212 Electromagnetic pulley 543210 Water pump LONGITUDINAL CROSS SECTION OF THE WATER PUMP 1 Pump casing 2 Pump dri...

Page 308: ...r is to use the energy of the engine s exhaust gas to send pressurized air to the cylinders The intercooler comprises a radiator included in the engine coolant radiator and its function is to lower the temperature of the air leaving the turbocharger to send it to the cylinders HOT AIR AT ATMOSPHERIC TEMPERATURE HOT COMPRESSED AIR COLD COMPRESSED AIR EXHAUST GAS COLD EXHAUST GAS 280 F1C ENGINE DAIL...

Page 309: ...sor rotor a turbine casing and a compressor casing mounted on the end of the central body a pressure relief valve applied on the turbine body Its function is to choke the output of the exhaust gases detail B and send part of them directly into the exhaust pipe when the supercharging pressure downstream of the turbocharger is above the rated valued 542410 Turbocharger type MITSUBISHI TD 4 HL 13T 6 ...

Page 310: ...e casing 4 at the prescribed pressure and make sure this value stays constant throughout the check replace the valve if it doesn t In the above conditions the tie rod must have made the prescribed travel On finding irregular engine operation due to the turbocharging system it is first expedient to perform the checks on the turbocharger check the efficiency of the seals and the fixingof thecoupling...

Page 311: ...itions a traditional turbine shall rotate slowly thus providing a limited booster pressure In the variable geometry turbine 1 the mobile blades 2 are set to max closed position and the small through sections between the blades increase the inlet gas speed Higher inlet speeds involve higher tip speeds of the turbine and therefore of the turbosupercharger Engine speed increase results in a gradual i...

Page 312: ... turbocharger that adjust the flow of exhaust gases 62869 TURBOCHARGING FUNCTIONAL DIAGRAM 1 Variable geometry turbocharger 2 Pneumatic actuator 3 Proportional solenoid valve 4 Air filter 5 EDC 16 control unit 6 Servo brake 7 Vacuum device 8 High pressure pump Figure 313 The actuator diaphragm connected to the control rod is governed by the low pressure on the top of the actuator The low pressure ...

Page 313: ...ristics but may impair engine reliability and duration Ring nut 4 is sealed with antitempering yellow paint In case of engines under guarantee each above specified intervention and or alteration to paint applied on ring nut 4 causes the lapse of the guarantee NOTE Cover air exhaust gas and lubricant inlets and outlets Clean the turbosupercharger outside accurately using anticorrosive and antioxida...

Page 314: ...ol unit 2 Throttle valve assembly 3 Vacuum connector 4 Water temperature sensor 5 Engine revs sensor 6 E G R pneumatic valve 7 Air flow meter 8 Inlet air filter 9 EGR modulating solenoid valve 10 VGT actuator modulating solenoid valve if any 11 Auxiliary vacuum tank vehicles equipped with 176 HP engines 12 Vacuum servo brake 13 Vacuum tank 112220 Operating The E D C electronic control unit E D C p...

Page 315: ...s equipped with a D P F catalyst the control unit program will feature a function capable of correcting the flow rate meter deviation in time The control unit will during vehicle deceleration with the pedal released overrun carry out a few checks thus determining correction factors for the flow rate meter readings self adapting process The replacement of the flow rate meter will therefore involve ...

Page 316: ...ble damage to the engine itself When the engine is switched off the throttle valve will closet o reduce the engine noise during this phase Figure 321 The heat exchanger fitted between the turboblower and the throttle valve assembly is used to lower the exhaust gas temperature in order to accordingly reduce the volume of the same It consists of a body that incorporates a number of corrugated pipes ...

Page 317: ...enoid valve 7 Vacuum tank only vehicles equipped with 176 HP engines 8 Air filter 9 Air flow rate meter air flow meter 10 VGT actuator 176 HP engine 11 Oil vapour circulating pipe 12 Differential pressure sensor delta p 13 Incoming exhaust gas temperature sensor 14 Outgoing exhaust gas temperature sensor 15 DPF catalytic silencer 16 Vacuum tank 17 Vacuum pump connector 18 EDC control unit 16 19 Se...

Page 318: ... ºC and oxygen percentage is higher than 8 oxygen being produced by the decomposition of nitrogen oxide NO2 then some combustion reactions boosted by the catalyst put before the filter burn particulate particles regeneration so keeping the filter clean On the contrary if its temperature is lower the filter is clogged with negative effects on counterpressure on exhaust gasses generated by the filte...

Page 319: ...composed of nitrogen oxides are reduced or transformed into inert substances carbon dioxide steam then pass into particulate filter where the regeneration process takes place exhaust gas high temperature causes the combustion of particulate particles accumulated in the filter Particulate filter regeneration is realised when following conditions are present catalyst inlet exhaust gas temperature 23...

Page 320: ...tral unit and set as a condition to regeneration startup During vehicle use the central unit counts post injected fuel quantity in order to activate and maintain particulate filter regeneration A small quantity of this fuel which is injected into the cylinders after combustion has already taken place and remains partially unburnt leaks out through pistons spring rings into oil sump accumulating to...

Page 321: ...s The main functions of the system are basically as follows checking fuel temperature checking engine coolant temperature checking amount of fuel injected checking idling speed cutting off fuel in release phase checking cylinder balancing when idling checking anti sawing checking smokiness at exhaust on acceleration checking exhaust gas recirculation E G R if present checking top speed limit check...

Page 322: ...294 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 323: ...eed it varies the amount of fuel injected into the single electro injectors injection time Checking regularengine rotation anti sawing It ensures regular engine rotation at a constant rate while increasing revs The control unit processes the signals received from the sensors and determines the amount of fuel to be injected via the pressure regulator the electro injector opening time Checking smoki...

Page 324: ...n the injected fuel tends to condense on the metal surfaces that are still cold The fuel supply for a cold engine is therefore greater than for a warm one Correcting flow rate to avoid noise smoke or overloading The behaviour that could lead to this kind of trouble is well known The designer has therefore included special instructions in the control unit to avoid it De rating In the event of the e...

Page 325: ... engine When the motor is running this indicator light goes out while the glow plugs continue to be powered for a certain length of time variable for post heating If with the indicator light flashing the engine is not started up within 20 25 seconds inattention time the operation is cancelled so as not to run down the batteries pointlessly The pre heating curve is also variable in relation to the ...

Page 326: ...o the high pressure pump fuel return pipe from the high pressure pump to the tank fuel exhaust pipe from the injectors to the fuel return pipe to the tank According to the high performance of this hydraulic system for reasons of safety it is necessary to avoid connecting high pressure pipe fittings with approximate tightening avoid disconnecting the high pressure pipes with the engine running NEVE...

Page 327: ...l filter 10 Fuel return pipe from the tank 11 Fuel delivery pipe to the high pressure pump 12 Air drain screw 13 Fuel return pipe to the tank 14 Pressurized fuel pipe assembly 15 High pressure fuel delivery pipe to the hydraulic accumulator rail 16 Pressure sensor 17 High pressure fuel delivery pipe to the electric injectors 18 Hydraulic accumulator rail Low pressure fuel recirculation pipes High ...

Page 328: ...r 8 Fuel electric pump non return valve 9 Injector return line pressure relief valve 10 Tank 11 Fuel electric pump 12 Fuel electric pump intake filter 13 Fuel electric pump overpressure valve 14 Pressure relief valve 15 Proportional pressure relief valve Relative pressures within the circuit a 4 15 bar p 5 35 bar b 3 5 bar p 5 0 bar c p 0 8 bar d 0 3 bar p 0 8 bar 300 F1C ENGINE DAILY EURO 4 Base ...

Page 329: ...Level sensor D Prefilter E Jet pump 773010 Fuel pump The fuel electric pump is of the volumetric low pressure type It is built into the fuel level indicator located in the fuel tank Electric connector 2 located in the upper portion of the assembly features the pins both for the electric pump and the level sensor During the installation the assembly shall not be stressed with axial loads of more th...

Page 330: ...nto operation by properly hea ting the diesel fuel before the latter is conveyed to the high pressure pump 109072 1 Body 2 Gasket 3 Cover bottom 4 Drain screw gasket 5 Customer reference 6 Diesel oil outlet 7 Diesel oil inlet 8 Air drain screw 9 Supplier code 10 Air bleeding or water draining screw 11 Lower bottom 12 Inner pipe 13 Filtering paper 14 Upper bottom 15 Heating earth 16 NTC1 17 NTC2 18...

Page 331: ...11 8 V in alarm conditions lower than 3 9 V At key on operation the sensor makes a self test issuing 2 5 second duration sound signal 112723 Optional filter clogging sensor Normally open contact type Operation differential pressure delta p 0 8 bar NTC temperature sensor 30 C 26 114 ohm 9 7 0 C 5 896 ohm 7 3 25 C 2 057 ohm 5 6 60 C 596 ohm 3 8 100 C 186 ohm 2 0 110 C 144 ohm 2 4 Temperature range 4...

Page 332: ...ure pump Euro 3 version is that it does not feature the mechanic feed pump The high pressure pump feed pump assembly cannot be overhauled therefore the fastening screws shall not be removed or tampered with The only operation that can be carried out is the replacement of the pressure regulator drive gear NOTE 304 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 775010 CP3 2 high pressure p...

Page 333: ... 88408 Mount new seal rings 1 and 2 on pressure regulator 3 and lubricate the rings with vaseline 771034 Pressure regulator The fuel pressure regulator is mounted on the low pressure circuit of the CP3 pump The pressure regulator modulates the amount of fuel sent to the high pressure circuit according to the commands received directly from the engine control unit The pressure regulator is mainly c...

Page 334: ...lator 1 there is the fuel pressure sensor 2 Fuel pressure sensor 2 is fitted on hydraulic accumulator 1 Small valves throttle valves or control bushes 3 with j 0 85 mm have been fitted to the fuel delivery couplings which control the fuel pressure waves generated by the high pressure pump Their function is to protect the electric injectors by reducing their wear in time Fuel pressure sensor 2 may ...

Page 335: ...ough the fuel pipe 12 exerts in the pressure chamber 8 a force equal to Fa Fc and thus makes the pin 2 lift and so the fuel gets in the cylinders end of injection The coil 4 isde energized andmakes theshutter 6 return to its closed position This recreates such a balance in the forces as to make the pin 2 return to its closed position and consequently end injection 1 Pressure rod 2 Pin 3 Nozzle 4 C...

Page 336: ...tside without acting on its hardware The control unit processes the signals from the sensors by applying software algorithms and also controls the actuators in particular the electric injectors and the pressure regulator The control unit records in the memory non labile area the information on the engine parameters originally set or acquired during engine operation The injection control unit incor...

Page 337: ...trol unit During the phases below starting phase post starting phase the engine management control unit will time the plug preheating control unit operation depending on the engine temperature The plugs will be triggered through the plug preheating control unit depending on the engine temperature under direct control of the engine management control unit The preheating control unit incorporates a ...

Page 338: ...box by the drive output shaft transmits the vehicle speed signal through the electronic tachograph to the control unit 540743 Differential pressure sensor delta p Dp This sensor detects the difference between the pressure Dp of the incoming exhaust gas and the pressure of the gas flowing out of the D P F catalyst The measured value indicates the extent of particulate PM particle accumulation or cl...

Page 339: ...state the circuit is open The duration of the two states may be varied with the condition that the sum of the two times is equal to the length of the modulation delivery The duration of the active state determines the duty cycle which is normally expressed as a percentage of the total time Therefore if the duration of the two active and passive states are the same the duty cycle is equal to 50 For...

Page 340: ...312 F1C ENGINE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 341: ...4 Refitting 15 THRUST BEARING REMOVAL AND REFITTING 15 HYDRAULIC CLUTCH DRIVE 16 HYDRAULIC CLUTCH DRIVE REMOVAL REFITTING 18 Removal 18 Refitting 18 PEDAL BOARD REMOVAL REFITTING 20 Removal 20 Refitting 20 PEDAL BOARD 21 CLUTCH WITH AUTOMATIC WEAR RECOVERY COMBINED WITH 6 AS 300 VD GEARBOX 22 Description 22 Operation 22 REMOVAL AND REFITTING OF CLUTCH WITH DEVICE RECOVERY COMBINED 24 Removal 24 CH...

Page 342: ...2 CLUTCH DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 343: ...eleased by traction of the collar bearing 52233 Figure 1 The introduction of a diaphragm spring or Belville washer as an elastic driving brings about important advantages such as smaller axial size and reduced sensibility of the centrifugal force due to the absence of the release lever greater constructive accuracy due to the reduced number of components improved cooling capacity due to the reduce...

Page 344: ...mentgrooves on the shaft and the relevant seat on the hub of the driven disk Replace the shaft and if necessary the driven disk also Driven disk springs are broken or weakened Replace the driven disk Clutch engagement shaft worn Replace the shaft and if necessary the driven disk also Collar bearing has excessive play in the joint Replace the collar bearing 4 The clutch does not release 5 The clutc...

Page 345: ...isk Replace the driven disk Clutch diaphragm spring weak or broken Replace the driven disk Oil or grease on the seals of the driven disk Remove the oil or grease clean the flywheel and replace the driven disk Grooves on the clutch engagement shaft are worn and impede the movement of the driven disk Replace the shaft and if necessary the driven disk YES NO 3 YES NO YES YES NO YES 4 CLUTCH JERKS THE...

Page 346: ...LUTCH SLIPS ABNORMAL WEAR OF DRIVEN DISK SEALS The driver keeps the clutch pedal pressed while driving The driver must stop this habit and use the clutch pedal only when necessary Clutch diaphragm spring blades weakened or broken Replace the clutch YES NO YES Clutch pedal height not adjusted only mechanical control The driver must stop this habit and use the clutch pedal only when necessary Adjust...

Page 347: ...ls Driven disk hub with single elastic coupling External Ø seal mm 235 0 1 Internal seal mm 160 1 5 Disk thickness new mm 7 7 0 3 Under load N 6850 Minimum thickness due to wear mm 1 25 Max off centring driven disk mm 0 2 Minimum load on thrust plate N 6850 Max release load at 9 Max release load at 9 mm release height N 1400 Maximum rise thrust pad Maximum rise thrust pad at 9 mm release height mm...

Page 348: ...pling springs External Ø seal mm 266 0 1 Internal seal mm 180 1 5 Disk thickness new mm 7 6 0 3 Under load N 9000 Minimum thickness due to wear mm 1 25 Max off centring driven disk mm 0 4 Minimum load on thrust plate N 7900 Max release load at 9 Max release load at 9 mm release height N 9100 Maximum rise thrust pad Maximum rise thrust pad at 9 mm release height mm 1 1 Disengagement stroke mm 12 1 ...

Page 349: ...ble hub springs External Ø seal mm 267 0 1 Internal seal mm 171 1 0 5 Disk thickness new mm 8 5 0 3 Under load N 8000 Minimum thickness due to wear mm 1 25 Max off centring driven disk mm 0 2 Minimum load on thrust plate N 6500 Max release load at 9 Max release load at 9 mm release height N 1600 Maximum rise thrust pad Maximum rise thrust pad at 9 mm release height mm 1 4 Disengagement stroke mm 9...

Page 350: ...ouble hub springs External Ø seal mm 280 0 0 4 Internal seal mm 170 0 0 4 Disk thickness new mm 8 5 0 3 Under load N 8000 Minimum thickness due to wear mm 1 5 Max off centring driven disk mm 0 2 Minimum load on thrust plate N 7000 Max release load at 9 Max release load at 9 mm release height N 1850 Maximum rise thrust pad Maximum rise thrust pad at 9 mm release height mm 1 5 Disengagement stroke m...

Page 351: ...th double hub springs External Ø seal mm 280 0 0 4 Internal seal mm 170 0 0 4 Disk thickness new mm 8 5 0 3 Under load N 8000 Minimum thickness due to wear mm 1 5 Max off centring driven disk mm 0 2 Minimum load on thrust plate N 7500 Max release load at 9 Max release load at 9 mm release height N 1850 Maximum rise thrust pad Maximum rise thrust pad at 9 mm release height mm 1 4 Disengagement stro...

Page 352: ...l Ø seal mm 280 0 0 4 Internal seal mm 175 0 0 4 Disk thickness new mm 8 4 0 3 Under load N 9100 Minimum thickness due to wear mm 1 5 Max off centring driven disk mm 0 2 Minimum load on thrust plate N 7900 Max release load at 9 Max release load at 9 mm release height N 1100 Maximum rise thrust pad Maximum rise thrust pad at 9 mm release height mm 1 1 Disengagement stroke mm 12 0 0 4 Max consumptio...

Page 353: ...clutch to engine flywheel 46 5 4 7 Screw securing operator cylinder mounting to gearbox 10 1 1 0 1 Screw secuing pedal board mounting Screw to secure clutch disengagement lever support to gearbox front cover 23 5 2 5 2 3 0 2 TOOLS TOOL NO DESCRIPTION 99370205 Guide pin for centring clutch driven disk 52230 Figure 2 ...

Page 354: ...shaft otherwise remove the flywheel as described in the relevant paragraph Remove the rear cover complete with sealing rings and replace the same as described at section 2 Check that the support bearing or bushing of the take up shaft on the gears fitted to the drive shaft are not worn or broken and if necessary replace them as described in the relevant paragraph 540852 Check the condition of the ...

Page 355: ...ts or petrol if any slight scratches are noted remove with an abrasive cloth position the driven disk 3 SENZA CODICE using the guide pin 2 SENZA CODICE to obtain perfect centring and to avoid straining the hub when the gears are reconnected position the thrust pad by aligning the holes with the centring grub screws 1 SENZA CODICE on the engine flywheel assemble and lock the thrust pad fixing screw...

Page 356: ...ach other in any way The cover 2 of the oil tank 3 must not be removed This assembly requires no maintenance and the hydraulic circuit must not be vented In the event of defectiveness the entire assembly needs to be replaced as it is supplied as a spare part proceeding as described under the relevant heading The clip 8 holding the push rod 9 on the assembly supplied as a spare part must not be rem...

Page 357: ...r section 254 47 mm2 Operating cylinder diameter 22 mm Operating cylinder section 346 36 mm2 Clutch pedal ratio 5 85 Hydraulic ratio 1 36 Clutch disengagement lever ratio 1 67 Overall reduction ratio 13 28 Max disengagement stroke X Y 94 F 99 J 98 7 mm Max wear stroke Y Y 67 5 F 70 8 J 69 1 mm Y 9 1 4 CLUTCH F 10 1 2 CLUTCH J 11 CLUTCH ...

Page 358: ...order taking the following precautions Do not press the clutch pedal until refitting is complete During assembly handle parts carefully Lubricate the contact surfaces of the clutch disengagement lever with the clutch pedal link pin Lubricate the contact surface of the master cylinderswivel head with the clutch pedal link pin After refitting the operating cylinder mounting to the gearbox check that...

Page 359: ...n disc marking an increase in load on the pedal during disengagement when the wear on the driven disc gets to be 90 Maximum disengagement position when new a 121 8 mm a1 112 8 mm Engagement position when new b 99 3 5 8 mm b1 89 8 mm Minimum position with worn disc c 73 3 mm c1 63 8 mm CLUTCH 19 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 360: ...the vacuum brake 3 Refitting For refitting carry out the operations described for removal in reverse order taking the following precautions tighten the nuts screws to the required tightening torque under the relevant heading refit the clutch drive cylinder as described under the relevant heading fill the brake liquid tank with the required quantity and grade and bleed the air operation 784010 as d...

Page 361: ...The only repair operations to be performed on the pedal assy are the following accelerator pedal replacement sensor replacement In any other case replace the pedal using the above mentioned components if they are serviceable NOTE CLUTCH 21 DAILY EURO 4 Print 603 93 651 Base March 2006 PEDAL BOARD ...

Page 362: ...utomatic wear recovery takes place in two separate phases Phase 1 every time the clutch is closed engaged and the clutch disc wear as detected by retainer 3 is such that the pressure plate is made to travel an extra stroke spring 4 will disengage wedge 1 which will be pulled by spring 2 and will stop again against spring 4 and retainer 5 after travelling a stroke equal to the disc wear Phase 2 whe...

Page 363: ...of the automatic wear recovery device C Position of the diaphragm spring with a worn clutch disc after operation of the automatic wear recovery device 1 Retainer 2 Lower ring 3 Upper ring 4 Clutch disc 5 Retainer 1 spring 6 Diaphragm spring 7 Wear recovery ring actuating spring 102090 Figure 20 ring 2 sliding ring 3 lifting CLUTCH 23 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 364: ...ribed in the relevant paragraph at section 2 Proceed on the engine flywheel as described in relevant paragraph operation 540853 at section 2 Check that there are no oil leaks even of a slight entity from the seal of the rear drive shaft otherwise remove the flywheel as described in the relevant paragraph Replace the seal ring as described in section 2 Check that the support bearing or bushing of t...

Page 365: ...the driven disk 3 SENZA CODICE using the guide pin to obtain perfect centring and to avoid straining the hub when the gears are reconnected position the thrust pad by aligning the holes with the grub screws 1 SENZA CODICE on the engine flywheel screw down the pressure plate fastening screws in four subsequent steps and in crossed sequence then tighten them to the specified torque CLUTCH 25 DAILY E...

Page 366: ...26 CLUTCH DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 367: ...ANSMISSION REMOVAL REFITTING 7 Removal 7 Refitting 7 Gear control check and adjustment 8 GEAR CONTROL 10 Flexible cable replacement 10 Removal 10 Refitting 11 GEAR SHIFT LEVER SUPPORT 11 Removal 11 Refitting 11 5 S 300 TRANSMISSIONS 13 6 S 400 O D TRANSMISSION 49 6 S 400 A O D TRANSMISSION 91 POWER TAKE OFF 127 ...

Page 368: ...2 TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 369: ...gement 4 Difficult speed engagement or selection 5 Leakages of lubricant NO 1 Screws which fasten the transmission to the chassis are loose Tighten loose screws properly NO Overhaul transmission and replace worn gears YES NO Gears bearings synchronizer rings and sliding sleeves worn Springs broken Replace worn or damaged components 2 Excessive backlash between gears NOISY TRANSMISSION ONLY IN REVE...

Page 370: ...place the springs Check the command or replace clutch NO 4 Wrong quality of oil in the box Insufficient oil level Drain the oil and refill with TUTELA TRUCK GEARLITE oil up to proper level Movement of sliding sleeves hindered Forks sliding sleeves synchronizer rings worn Disassemble the gearbox and look for the cause and carry out repairs if necessary NO DIFFICULT SPEED ENGAGEMENT OR SELECTION YES...

Page 371: ...r clogged Clean breather NO Input and or output shaft retaining rings worn Replace retaining rings Loose screws and or nuts which fasten covers support boxes Remove the component clean coupling surfaces Spread on them some LOCTITE 5206 sealing re fit and tighten screws and or nuts to the prescribed torque NO LEAKAGES OF LUBRICANT ...

Page 372: ...6 TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 373: ... the chain into the bracket slot Screw down the nut so as to firmly secure the gearbox unit to the bracket through the chain Remove screws 20 securing the gearbox case to the engine base Undo fastening screws 15 and elastic dowel fastening screw 21 then remove gearbox supporting crosspiece 14 together with its dowel Move the gearbox back until the gearbox input shaft has come off the clutch disc h...

Page 374: ...th the gears idling the distance F measured between the outer side of support 16 and the centre of jointed head 12 of engagement cable 4 This distance shall be 180 1 mm otherwise proceed as follows disconnect jointed head 12 from lever 13 pull out load 100 N loosen nut 14 and properly rotate jointed head 12 until distance F is obtained then tighten the nut to the prescribed torque loosen nuts 17 a...

Page 375: ...ove control lever 9 fully to the left then verify that the distance between restraint quill d and reverse gear safety barrier C is 2 P 3 mm Otherwise place a spacer of 2 P 3 mm in between the above parts open the adjusting device by lifting lock ring 6 bring lever 9 into contact with the spacer and release lock ring 6 Engagement cable adjustment 4 Engage the 5th speed then move the lever 9 forward...

Page 376: ...ever 1 Proceed as follows by acting from inside the cab see figure 4 unscrew and remove knob 1 remove protection boot 2 remove the fastening screws then take covering 3 off remove glove compartment 4 remove the fastening screws then take lower central covering 5 off 108851 Act from the upper part of the gearbox unit and use a suitable screwdriver to open out flexible cable fins 6 and 7 so that the...

Page 377: ...LIGHT or MOLIKOTE G72 grease tighten the nuts and screws to the prescribed torque adjust the gear control as described in the respective chapter Remove nuts 3 securing flange 2 to the cab floor then take flexible cable assembly 1 out Refitting Proceed as described in figures 5 and 6 by acting from inside the cab Remove fastening screws 2 then take gear shift lever support 1 off the cab Refitting 1...

Page 378: ...12 TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 379: ...RHAULING THE TRANSMISSION 28 Gear control box 28 Disassembly 28 Assembly 29 Selection and adjustment tie rod assembling 30 Disassembling the transmission 31 Disassembling the rear cover bearings 33 Disassembling the transmission bearings 33 Disassembling the main shaft 34 Drive input shaft 36 Disassembling the transmission shaft 36 CHECKS 39 Transmission 39 Hubs sliding sleeves forks 39 Bearings 3...

Page 380: ...14 5 S 300 TRANSMISSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 Page Disassembly assembly 43 Mounting the transmission 43 Adjusting the transmission shaft bearing end float 43 ...

Page 381: ...aft is supported in the transmission by tapered roller bearings that can be adjusted axially by means of ring shims Gear engagement synchronization is accomplished by means of free ring synchronizing devices with a single cone for 5th 4th 3rd gears R G and dual cone for 1st 2nd gears Control inside the transmission is accomplished with four rods a main rod to select and engage gears three rods equ...

Page 382: ...e movement given to the engagement lever 1 the driver 3 integral with it shifts the selector 5 already prepared axially with the rod 4 and consequently also the engagement rod of the chosen gear SECTION A A SECTION A A This arrangement is accomplished by shifting the selection lever 2 anticlockwise by 7 1 to the control axis which corresponds to a clockwise change in the angle of the rod 4 of 10 4...

Page 383: ...ngagement controlrod 2 When selecting engaging a gear the rod 2 simultaneously turns the plate 1 in which it is inserted In this way the plate 1 will free itself from the slot of the rod involved in engaging the gear and will lock the other two rods by inserting itself into their slots Above presetting is implemented by moving selector 2 clockwise by 7 1º with respect to control vertical axis that...

Page 384: ...Power take off Optional Speed engagement Forward speeds 5th 4th 3nd Single cone synchronizer 2nd 1st Dual cone synchronizer Reverse speed Rapid shift Speed retention mechanism Sliding sleeves retained by pawls and springs Gears Helical toothed constant mesh gears Gear ratio First 5 00 Second 2 62 Third 1 54 Fourth 1 00 Fifth 0 78 Reverse 4 58 Shaft bearings Main shaft Straight roller bearing water...

Page 385: ...gear driving load 5th speed gear removing load 80 ºC max 120 ºC 140 ºC 170 ºC 31 KN 50 KN 50 KN Input shaft Assembly temperatures front bearing 80 ºC max 120 ºC Gear axial backlash 1st 3rd 4th R 5th speed 2nd speed 0 15 0 3 mm 0 25 0 4 mm 3rd and 4th speed sliding sleeve hub retaining circlip axial backlash 0 0 05 mm 3rd and 4th speed sliding sleeve hub retaining circlip thickness 2 2 85 mm with p...

Page 386: ...g reverse gear shaft 22 15 2 2 15 9 Screw securing rear cover 23 15 2 3 15 10 Screw locking sleeve for transmission coupling on main shaft 120 15 12 15 11D Screw securing ball bearing retaining ring 9 5 15 0 9 15 12 Screw securing control cable bracket 23 15 2 3 15 13 Screw securing gear control mounting 23 15 2 3 15 14 Nut for screw securing lever to control rod 34 15 3 4 15 15 Nut securing artic...

Page 387: ... M8 screw securing the transfer case to the gearbox 21 25 2 1 2 5 4 M8 self locking nut securing the flange to the cab 3 5 0 35 5 Nut securing the jointed head to the tie rod 4 4 5 0 4 0 5 6 Plate fastening screw 7 8 9 25 0 78 0 95 After tightening nuts 4 the jointed head hole axis shall be aligned with the axis of the ball pin to which it is connected After tightening nuts 5 the vertical axes of ...

Page 388: ...nt 603 93 651 TOOLS TOOL NO DESCRIPTION 99322205 Assemblies overhaul revolving stand 99322225 Unit support to use with stand 99322205 99340205 Percussion extractor 99341002 Single acting scaffold 99341003 Single acting scaffold 99341004 Single acting scaffold ...

Page 389: ... Base March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99341012 Pair of brackets 99341015 Press 99341017 Couple of brackets whit hole 99341019 Pair of tie rods with grips 99341025 Grips 99345003 Extractor for gearbox front half casing ...

Page 390: ...ng device 99348004 Universal male extractor from 5 to 70 mm 99360521 Tool to extract and insert main shaft transmission shaft and rod fork assembly 99370006 Handle for interchangeable drivers 99370007 Handle for interchangeable drivers 99370234 Tool for fitting main shaft in rear bearing and fitting output flange on main shaft ...

Page 391: ...Transmission support during removal from and refitting to vehicle 99371057 Bracket for supporting gearbox during overhaul use with 99322205 99322225 99374091 Punch for fitting bearing external races dia 55 69 mm use with 99370007 99374452 Keying device to fit gasket on transmission rear cover use with 99370006 99374453 Keying device to fit gasket on transmission ...

Page 392: ...Base March 2006 Print 603 93 651 Figure 9 75420 LONGITUDINAL SECTION Figure 10 TRANSVERSE SECTION ON THE GEAR SELECTION ENGAGEMENT ROD POSITIONING PUSH ROD 47369 Figure 11 TRANSVERSE SECTION ON THE REVERSE GEAR ANTI ENGAGEMENT DEVICE 47371 ...

Page 393: ...49368 49364 Figure 12 Figure 13 TRANSVERSE SECTION ON INTERNAL CONTROL BOX SECTION ON GEAR ENGAGEMENT ROD POSITIONING PAWLS 5 S 300 TRANSMISSIONS 27 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 394: ... the levers 2 and 7 from the shafts 1 and 8 and extract these from the box 5 Take off the caps 4 Figure 16 Figure 17 With a punch 3 remove the spring pin 4 and extract the shaft 2 from the internal lever 1 Repeat these steps for the other shaft Figure 18 108857 Take tie rod 3 off by disconnecting jointed heads 1 from levers 4 and 7 Take tie rod 8 off by disconnecting jointed heads 9 from levers 10...

Page 395: ...m with the spring pins 3 Lubricate the roller bearings 1 Figure 19 with TUTELA MR3 grease and mount the shafts 3 and 6 complete with the internal levers 4 and 5 in the box 2 Mount the caps 8 and 9 and levers 1 and 10 on the shafts 3 and 6 tightening the nuts for the fixing screw 7 The spring pin 3 must be positioned with the cut horizontal Fit spring peg 4 with cutting edge positioned at 180 from ...

Page 396: ...ximum deviation of less than 30 lower Verify that spring 3 ends come into contact with selection lever 4 or are at least 1 mm within the same Otherwise loosen screw 1 so that spring 3 is correctly positioned due to plate 2 being released 108858 108859 108860 108861 Verify that the tie rod 4 length X as measured between the jointed head centres is not greater than 342 mm Lubricate the jointed head ...

Page 397: ...rew 5 with the washer beneath 4 Take out the lever 99370317 3 Apply the bridge 99341003 1 and clamps 99341017 2 onto the sleeve 3 Extract the sleeve 3 from the main shaft Remove the screws 1 and take off the cover 2 protecting the input shaft 3 Drill the O ring 2 Using a suitable hook and extractor 1 remove the O ring 2 from the transmission Remove the circlip 2 retaining the front bearing 3 from ...

Page 398: ...ew 6 securing the reverse gear shaft to the transmission 5 Push the two centring pins 7 downwards to free them from the transmission 5 Remove the screws 8 securing the rear cover 9 to the transmission 5 51399 74957 51402 74959 Fit the drive input shaft 1 with tool 99345003 2 and secure this to the gearbox 4 with screws 3 Screw down the screw 5 of the tool 2 to extract the gearbox from the bearing ...

Page 399: ...bearings 3 Turn over the rear cover 3 Take out the O ring 1 and the phonic wheel 2 Using a suitable punch remove the ball bearing 4 Figure 36 Remove the tachograph sensor 5 and the reversing light switch 4 Disassembling the transmission bearings Using universal extractor 99348004 1 remove the outer ring 2 of the transmission shaft bearing Using the percussion extractor 99340205 1 and part 99348004...

Page 400: ...ice Remove the roller bearing 2 and the synchronizer ring 3 Remove the sliding sleeve 6 for engaging 3rd 4th gear from the hub 5 and taking care as the plugs 8 come out with their relative balls 9 and springs 7 recover them Remove the retaining ring 4 Figure 44 Extract the hub 2 with the extractor 99348001 1 Remove the synchronizer ring 1 3rd gear 2 and roller bearing 3 Disassembling the main shaf...

Page 401: ...5 Figure 56 Figure 57 Take out the synchronizer ring 4 middle ring 3 ring 2 and roller bearing 1 Remove the sleeve 2 for engaging 1st 2nd gear from the hub 1 and taking care as the plugs 5 come outwith theirrelative balls 3 and springs 4 recover them Turn over the main shaft 1 Take out the spacer ring 2 and remove the 5th gear 3 Remove the half roller bearings 1 the synchronizer ring 3 and the ret...

Page 402: ...gure 63 Using the bridge 99341003 1 ties 99341012 2 and clamp 99341015 3 extract the reverse gear 5 and the synchronizer assembly 4 Remove the roller bearing 1 Remove the sliding sleeve 2 for engaging reverse 5th gear from the hub 1 taking care as the plugs 3 come out with their relative balls 4 and springs 5 recover them Take out the retaining ring 1 and extract the internal ring 2 of the rear be...

Page 403: ... 76011 51430 Figure 64 Figure 65 Figure 66 INPUT SHAFT ASSEMBLY DRAWING MAIN SHAFT ASSEMBLY DRAWING TRANSMISSION SHAFT ASSEMBLY DRAWING 5 S 300 TRANSMISSIONS 37 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 404: ...51431 75414 Figure 67 Figure 68 1st 2nd GEAR DUAL CONE SYNCHRONIZER ASSEMBLY 3rd 4th 5th GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY 38 5 S 300 TRANSMISSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 405: ...d gear release clearance 0 9 mm 1 Sliding sleeve 2 1st gear cog wheel 3 Synchronizer ring 4 Middle ring 5 Ring 6 Hub 7 2nd gear cog wheel 8 3rd gear cog wheel 9 4th gear cog wheel 10 Reverse gear 11 5th gear cog wheel Shafts gears The seats on the shafts for bearings must be neither damaged nor worn The toothing of the gears must be neither damaged nor worn Synchronizing devices Check the wear on ...

Page 406: ...en the main shaft 1 in a vice and mount on it the roller cage 2 reverse gear 4 and synchronizer ring 3 Heat the hub 2 for the 5th reverse gear engagement sliding sleeve to a temperature no higher than 150 C and mount it on the main shaft with a suitable punch 1 Mount the retaining ring 1 whose thickness makes for null clearance in its seat Check the end float of the reverse gear 2 It should be 0 1...

Page 407: ...40 51420 51441 51442 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Positioning the synchronizer ring 2 and the half roller bearings 1 Install the 5th speed gear 3 Heat spacer ring 2 to 90 C and install it Upset the main shaft 1 Position the roller bearing 2 on the main shaft 1 When assembling make sure the tongues of the rings 3 and 4 Figure 79 and the projections of the synchronizer ring 2 ar...

Page 408: ...he roller bearing 1 Mount the 2nd gear 4 Heat the spacer 3 to a temperature no higher than 170 C and mount it on the main shaft 1 Check the end float of the 2nd gear 4 It should be 0 15 0 30 mm Heat the bushing 2 to a temperature no higher than 170 C and mount it on the main shaft 1 Mount the roller bearing 1 and the 3rd gear 3 Position the synchronizer ring 2 on the 3rd gear 3 Make sure the tongu...

Page 409: ... of the 3rd gear 5 It should be 0 15 0 30 mm Mount the sliding sleeve 6 on the hub 5 Put the springs 7 plugs 8 and balls 9 into the seats in the hub 5 settling them under the sliding sleeve 6 Grease the roller bearing 2 and fit it on the main shaft 1 Position the synchronizer bearing 3 on the hub 5 Rods forks selector driver Disassembly assembly Determine the thickness S of the ring 1 for adjustin...

Page 410: ...nd grip 99370007 the ball bearing 7 with a general punch the bushing with ball bearing 4 and the roller bearing 5 with a general punch Position the retaining plates 3 and secure them to the box tightening the screws 2 to the required torque Heat the bearing seats of the box 1 to a temperature of approx 80ºC and mount the external ring 7 of the tapered roller bearing with punch 99374091 and grip 99...

Page 411: ... seats Set properly clutch locking plate 5 by setscrew wrench 2 to avoid control rods 1 3 4 interference with plate during next operation Screw the pin 11 of tool 99370234 into the hole in theoutput shaft 6 Mount the bushing 8 and spacer 9 on the tool 99370234 Screw on the nut 10 and at the same time lower the hoist so the output shaft 6 is positioned on the ball bearing 7 Remove the tool 99360521...

Page 412: ...ighten the screw 4 fixing the reverse gear idler shaft to the transmission 3 to the required torque Insert the push rod 6 and springs 7 8 and tighten the plug 10 with a new gasket 9 to the required torque If the side cover 1 has been removed apply LOCTITE 5206 sealant on the mating surface and tighten the screws 2 to the required tightening torque Mount the front bearing 3 retaining ring 2 on the ...

Page 413: ...he required quantity and grade 74967 74969 74968 74970 Figure 102 Figure 103 Figure 104 Figure 105 Mount the phonic wheel 2 onto the main shaft 3 Mount the reversing light switch 4 and the tachograph sensor 1 Mount the O ring 3 in the rear cover 4 with the key 99374452 1 and the grip 99370007 2 Mount the output flange 1 on the main shaft with the tool 99370234 2 Remove the tool 99370234 2 5 S 300 ...

Page 414: ...48 5 S 300 TRANSMISSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 415: ...od assembling 68 Disassembling the transmission 69 Disassembling the rear cover bearings 72 Disassembling the transmission bearings 73 Disassembling the main shaft 73 Disassembling the drive input shaft 75 Disassembling the transmission shaft 75 CHECKS 79 Transmission 79 Hubs sliding sleeves forks 79 Bearings 79 Shafts gears 79 Synchronizing devices 79 Mounting the transmission shaft 81 Mounting t...

Page 416: ...50 6 S 400 O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 417: ...ller bearings that can be adjusted axially by means of ring shims 6th 5th 4th 3rd and reverse gears new version transmissions are synchronised by means of single taper free synchroniser rings double taper wheels are used for 1st and 2nd gear Control inside the transmission is accomplished with five rods a main rod to select and engage gears four rods equipped with forks for engaging gears The exte...

Page 418: ...ooves in the rods 3rd 4th gear engagement According to the movement of the engagement lever 1 the slider 3 axial moves the rod 4 which is integral the selector 5 previously arranged and consequently the chosen 3rd and 4th gear engagement rod 9 Neutral position coincides with the 3rd 4th gear selection arrangement In this case the vertical axis of the selector lever 2 is exactly at 90 with respect ...

Page 419: ...d 5 By moving the lever 1 the slider 3 will axially move the re verse gear engagement rod 5 Safety device The transmission is equipped with a device which prevents the simultaneous engagement of two gears It consists of a suitably shaped rod 6 fitted transversally in the transmission box The slider 3 moves the rod 6 under the action of the lever 2 This keeps the selected gear engagement rod free a...

Page 420: ...gement Forward speeds 5th 6th 3rd 4th Single cone synchronizer 1st 2nd Dual cone synchronizer Reverse speed clip on in new version transmission with single taper synchroniser ring Speed retention mechanism Sliding sleeves retained by pawls and springs Gears Helical toothed constant mesh gears Gear ratio First 5 375 Second 3 154 Third 2 041 Fourth 1 365 Fifth 1 Fifth 0 791 Reverse 4 838 Shaft beari...

Page 421: ...0oC Transmission shaft Temperature for fitting bearings 80 C max 120oC 5th 4th gears 170 160oC Gear end float 1st 3rd 4th R 5th gear 2nd gear 0 15 0 40 mm 0 25 0 5 mm 5th 4th gear sliding sleeve hub retaining ring end float 0 0 15 mm 5th 4th gear sliding sleeve hub retaining ring thickness Retaining ring end float transmission shaft front bearing 0 0 1 mm main shaft roller bearing 0 0 1 mm Transmi...

Page 422: ...15 8 Screw securing reverse gear shaft 23 15 2 3 15 9 Side plug on rear cover 35 3 5 10 Screw securing rear cover 23 15 2 3 15 11 Speedometer transmitter fixing 50 5 12 Screw locking sleeve for transmission coupling on main shaft 235 23 5 13 Fixing switches and reversing lights 40 4 14D Screw securing ball bearing retaining ring 9 5 15 0 9 15 15 Nut for screw securing lever to control rod 34 15 3 ...

Page 423: ... 3 M8 screw securing the transfer case to the gearbox 21 25 2 1 2 5 4 M8 self locking nut securing the flange to the cab 3 5 0 35 5 Nut securing the jointed head to the tie rod 4 4 5 0 4 0 5 6 Plate fastening screw 2 3 15 0 78 0 95 After tightening nuts 4 the jointed head hole axis shall be aligned with the axis of the ball pin to which it is connected After tightening nuts 5 the vertical axes of ...

Page 424: ...06 Print 603 93 651 TOOL TOOL NO DESCRIPTION 99322205 Assemblies overhaul revolving stand 99322225 Unit support to use with stand 99322205 99340205 Percussion extractor 99341002 Single acting scaffold 99341003 Single acting bridge 99341004 Pair of brackets ...

Page 425: ... Base March 2006 Print 603 93 651 TOOL TOOL NO DESCRIPTION 99341012 Pair of brackets 99341015 Constrictor 99341017 Pair of brackets with hole 99341019 Pair of tie rods with grips 99341025 Grips 99345003 Extractor for gearbox front half casing ...

Page 426: ...ctor with locking device 99348004 Universal male extractor from 5 to 70 mm 99360522 Tool to extract and insert main shaft transmission shaft and rod fork assembly 99370006 Handle for interchangeable drivers 99370007 Handle for interchangeable drivers 99370234 Tool for fitting rear bearing and sleeve on main shaft ...

Page 427: ...9 Transmission support during removal from and refitting to vehicle 99371057 Bracket for supporting gearbox during overhaul use with 99322205 99322225 99374091 Punch for fitting bearing external races dia 55 69 mm use with 99370007 99374452 Keying device to fit gasket on transmission rear cover use with 99370006 99374453 Keying device to fit gasket on transmission ...

Page 428: ...62 6 S 400 O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 LONGITUDINAL SECTION Figure 8 Figure 9 87880 87881 C C ...

Page 429: ...6 S 400 O D TRANSMISSION 63 DAILY EURO 4 Base March 2006 Print 603 93 651 LONGITUDINAL SECTION Figure 10 Figure 11 Figure 12 87900 87901 87902 M M G G P P ...

Page 430: ...64 6 S 400 O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 TRANSMISSION TRANSVERSAL CROSS SECTIONS Figure 13 Figure 14 Figure 15 87885 87886 87888 Figure 16 87887 E E N N R R F F ...

Page 431: ...6 S 400 O D TRANSMISSION 65 DAILY EURO 4 Base March 2006 Print 603 93 651 TRANSMISSION TRANSVERSAL CROSS SECTIONS Figure 17 Figure 18 87889 87891 Figure 19 87890 A A D D ...

Page 432: ... With a punch 3 remove the spring pin 4 and extract the shaft 2 from the internal lever 1 Repeat these steps for the other shaft 530220 Gear control box Disassembly The used oil must be disposed of according to the law in force The coupling lever is bound to the stem by two snap pins NOTE 108857 Take tie rod 3 off by disconnecting jointed heads 1 from levers 4 and 7 Take tie rod 8 off by disconnec...

Page 433: ...the O rings 1 in the box 2 positioning them at the height shown Pack the gap between the O ring and roller bearing with grease Mount the selection and engagement levers 1 on their respective shafts 2 and fasten them with the spring pins 3 51390 87896 The spring pin 3 must be positioned with the cut horizontal Fit spring peg 4 with cutting edge positioned at 180 from spring peg 3 cutting edge in sp...

Page 434: ...imum deviation of less than α 30 lower Verify that spring 3 ends come into contact with selection lever 4 or are at least 1 mm within the same Otherwise loosen screw 1 so that spring 3 is correctly positioned due to plate 2 being released 108858 108859 108860 108861 Verify that the tie rod 4 length X as measured between the jointed head centres is not greater than 342 mm Lubricate the jointed head...

Page 435: ... and take off the rod 5 dragging device 4 Mark the assembly position of the rod 1 preventing engagement of more than one gear at the same time and remove it from the transmission Remove the screws 1 and take off the cover 2 protecting the input shaft 3 If difficult remove the sleeve 3 with extractor made up of link 99341003 1 and grips 99341017 2 and block 4 When putting away the sleeve 1 take car...

Page 436: ...43 Figure 44 Figure 45 Remove the circlip 2 retaining the front bearing 3 from the input shaft 1 Take out the plug 4 with the washer 3 and extract the spring 2 and the push rod 1 Push the two locating pins 2 downwards until taking them out of the rear cover 4 Remove the screws 3 securing the rear cover 4 to the transmission 1 90209 Remove the two fork knuckle pins 1 which control the 3rd 4th speed...

Page 437: ...0 Figure 51 Drill the cups 2 screw a special screw into them Using the screw extract the cups 2 from the rear cover 1 Remove the springs 3 and pawls 4 Remove the rod 1 controlling the 3rd 4th gear and the main rod 2 from the rear cover 3 Take out the screw 3 and remove the reverse gear shaft 1 with the mounting 2 from the rear cover 4 Remove the rod 1 from the rear cover 2 Using the extractor scre...

Page 438: ...54 Figure 55 Using universal extractor 99348004 1 remove the outer ring 2 of the transmission shaft bearing Using the percussion extractor 99340205 1 and part 99348004 2 extract the bushing with the ball bearings 3 Figure 56 Clamp the primary shaft 6 in a vice Remove the rods 10 and 11 with the relevant forks Remove the forks 3 and 4 and the small blocks Remove the RM gear 4 Remove the snap ring 8...

Page 439: ...ark the assembly position of each synchronizing de vice on the respective gear 85944 Figure 59 Figure 60 Tighten the primary shaft 1 in a vice Remove the synchroniser ring 4 and the circlip 2 Remove the circlip 3 from its housing Disassembling the main shaft 51948 NOTE 51946 Figure 61 Figure 62 Using universal extractor 99348004 1 remove the outer ring 2 of the transmission shaft bearing Disassemb...

Page 440: ...sing a hydraulic press remove the 2nd gear 10 ring 9 middle ring 8 synchronizer ring 7 synchronizer assembly 6 and the bushing 5 Take out the roller bearing 11 51954 Figure 65 Figure 66 Remove the reverse gear engagement sliding sleeve 2 from the reverse gear 1 Retrieve hub 1 and pads 3 with respective balls 4 and springs 5 85949 85946 85947 Figure 67 Figure 68 Use extractor 99348001 6 as shown in...

Page 441: ...t the 6th gear 2 and the internal ring 1 of the tapered roller bearing from the transmission shaft Using a hydraulic press remove the 5th gear 2 from the transmission shaft 1 51956 90217 Figure 73 To replace the cog wheel 1 use the same general tools for disassembly as for assembly heat it to a temperature of 80ºC Take out the retaining ring 1 holding the 5th gear 2 Disassembling the drive input s...

Page 442: ...alf roller bearings 14 3rd gear 15 6th gear 16 5th gear 90218 Figure 75 Figure 76 51962 51424 Figure 77 Using a hydraulic press remove the 4th gear 3 the synchronizer ring 2 and the synchronizer assembly 1 Remove the half roller bearings 4 1 Remove the sleeve 2 for engaging the 3rd 4th gear from the hub 1 and taking care over the plugs 3 coming out with their relative balls 4 and springs 5 recover...

Page 443: ...b 10 6th gear 11 Main shaft with 3rd gear toothing A 4th gear toothing B 12 Roller bearing 13 2nd gear 14 Dual cone synchronizing unit for 1st 2nd speed 15 Dowels with built in ball springs for 1st 2nd speed hub 16 Bushing 17 1st gear 18 Spacer ring 19 Reverse gear 20 Synchroniser ring 21 Gear 108864 Figure 78 6 S 400 O D TRANSMISSION 77 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 444: ...R ASSEMBLY 85978 Figure 79 Figure 80 3RD 4TH 5TH 6TH GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY SINGLE CONE SYNCHRONIZER ASSEMBLY REVERSE GEAR 86130 Figure 81 108865 78 6 S 400 O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 445: ...zing devices Check the wear on the synchronizer rings proceeding as follows See that the friction surface is not undulated 52510 52511 Figure 82 Figure 83 BK type single cone synchronizers for 3rd 4th 5th 6th gears Arrange the synchroniser ring 1 on the respective gear or reverse taper ring 2 With a feeler gauge check the distance S on two diametrically opposite points If the measured value S is l...

Page 446: ...reserve 2nd 1st gear 1 6 2 0 mm B 1st 2nd release clearance 0 9 1 5 mm REVERSE GEAR SYNCHRONISER A Synchronization reserve 0 9 1 4 mm B release clearance 0 35 0 85 mm 1 Hub 2 5th gear 3 Synchronizer ring 4 Sliding sleeve 5 6th gear cog wheel 6 3rd gear cog wheel 7 4th gear cog wheel 8 2nd gear cog wheel 9 1st gear cog wheel 10 Middle ring 11 Ring 12 Reverse gear 13 Reverse gear ring Figure 84 Figu...

Page 447: ...ring are positioned correctly in their seats in the hub 2 Mount the retaining ring 1 whose thickness produces null end float in its seat Check the end float of the 4th gear 2 It should be 0 15 0 40 mm Mount the sliding sleeve 1 on the hub 2 Put the springs 5 plugs 3 and balls 4 into the seats in the hub 2 settling them under the sliding sleeve 1 Position the synchronizer ring 2 on the hub 3 so tha...

Page 448: ...ning ring 1 whose thickness produces null end float in its seat Heat the internal rings 1 3 of the tapered roller bearings to a temperature of approx 80 C and with a suitable punch 1 mount them on the transmission shaft 2 Tighten the main shaft 1 and position the roller bearing 2 on it Mounting the main shaft Mount the synchronizer rings on their respective gears according to the marks made during...

Page 449: ... 3 Figure 100 are positioned correctly in the seats in the hub 2 Check the end float of the gear 4 It should be 0 25 0 5 mm Fit sliding sleeve 2 onto hub 1 Fit dowels 4 with built in springs 5 and balls 3 into hub 1 housings Position the synchronizer ring 3 middle ring 2 and ring 1 on the hub 4 taking care that the tongues of the ring 1 and the projections of the ring 3 enter the seats in the hub ...

Page 450: ...s 1 and arrange them with respect to the sliding sleeve 2 85950 85951 Figure 106 Figure 107 Fit the synchroniser ring 2 Heat the gear ring 3 to 110 150 and fit on primary shaft 1 Check reverse gear play 4 which must be 0 15 0 4 mm Heat the hub 2 to a temperature of approx 80 110 C and mount it on the main shaft 1 taking care that the projec tions 3 of the synchronizer ring are positioned in the se...

Page 451: ...3 Determine the thickness S of the ring 1 for adjusting the transmission shaft bearing end float proceeding as follows position the thinner adjustment ring 1 1 65 mm thick in the seat in the transmission 3 heat the seat of the bearing 2 to approx 60 C Mount the external ring of the bearing 2 with the punch 99374091 and grip 99370007 see Figure 115 mount the transmission shaft complete with the int...

Page 452: ...aft and external ring of the front bearing Heat the bearing seats of the rear cover 1 to a temperature of approx 80 C and mount the external ring 3 of the tapered roller bearing with punch 99374091 2 and grip 99370007 1 the ball bearing 4 and the bushing with ball bearings 7 with a general punch Position the retaining plates 6 Secure these to the rear cover tightening the screws 5 to the required ...

Page 453: ...ed and partially insert it into the rear cover 4 During this operation check that theoutput shaftgoes intothe supporting ball bearing and the control rods 5 6 go into their respective seats Screw tool 99370234 pin 7 into output shaft hole 2 and fit bushing 4 and spacer 5 on tool Screw on the nut 6 and at the same time lower the hoist so the output shaft 2 is positioned on the rear ball bearing 3 R...

Page 454: ...s 4 and springs 3 in the rear cover 1 and drive in the retaining cups 2 with a suitable punch Apply LOCTITE 5206 on gearbox attachment Warm up the front bearing inner ring 2 at 90 110 C and fit the gearbox 1 on the rear cover When fitting the gearbox check that the shafts and the control rods fit correctly in the respective seat and that the fork 1 Figure 117 does not disconnect from the clutch ro...

Page 455: ... the pins 1 Screw the pins 1 into the box checking that their ends go into the hole of the 3rd 4th gear engagement fork link 1 Figure 122 and then tighten them to the required torque Drive in the pins 2 and check that their ends fit in the knuckle hole of the clutch fork for the 5th 6th speed and tighten it to the prescribed torque 90209 Figure 131 If during these assembly operations the fork 1 Fi...

Page 456: ...tity and grade Mount the oil filler and level indicator cap tightening it to the required torque 52009 51924 51925 52118 Figure 132 Figure 133 Figure 134 Figure 135 Mount the rod 1 preventing engagement of more than one gear at the same time in the position marked during disas sembly Apply sealant to the thread of the plugs 1 3 screw them into the box tightening them to the required torque Positio...

Page 457: ...NG SYSTEM 97 Functional features 97 SYSTEM STRUCTURE 98 System central unit 98 Clutch actuator 99 Gears actuator 99 Accelerator pedal 100 Display unit 100 Gear selector 101 GEAR SELECTION AND ENGAGEMENT 102 Neutral arrangement and or 3rd 4th gear selection and engagement arrangement 102 1st 3rd gear selection election and engagement arrangement 102 5th 6th gear selection and engagement arrangement...

Page 458: ...ONNECTION 109 GEARBOX REMOVAL REFITTING 110 Removal 110 Refitting 113 GEARBOX UNIT OVERHAULING 117 CONTROL UNIT 117 Removal 117 Refitting 118 CLUTCH ACTUATOR 119 Removal 119 Refitting 120 GEARBOX ACTUATOR 120 Removal 120 Refitting 121 CHASSIS WIRING GEARBOX 121 Removal 121 Refitting 122 GEARBOX WRING GEARBOX 122 Removal 122 Refitting 123 CALIBRATION 124 ...

Page 459: ...number 7 ZF series number 108867 Figure 1 On the rear cover there is the speed selection and engagement control support On a side of the main casing there is a slot where it is possible to apply a power take off Motion transmission is carried out by a set of helical toothed constant mesh gears both for forward speeds and for reverse speed Splined or machined gears are placed on four shafts input m...

Page 460: ... O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 MAIN COMPONENTS LOCATION Figure 2 1 Gears actuator 2 Electronic central unit 3 Gearbox cable 4 Clutch actuator 5 Fork 6 Flywheel 7 Clutch disk 108868 ...

Page 461: ...e gearbox is in 1st or reverse gear position then the system disables the engine from being started up but warns by an N blinking on the display unit that the gearbox has to be put into neutral position in order that start up is enabled Check procedures Figure 3 107203 On starting up again the engine after switching off with the gearbox in neutral position the system carries out above indicated ch...

Page 462: ...ty in this case the system remains in its current condition Buzzer The buzzer is activated in following situations To warn about faults such as clutch slipping Through a calculation algorithm threshold temperature overflow is signalled by an intermitting Beep sound To show reverse gear being entered intermitting Beep sound or warn about driver s door being opened with a gear entered and engine on ...

Page 463: ...to displace his her foot from brake pedal to accelerator pedal in order to perform start operation in an easier way 2 second safety concept is applied in order to prevent driver from going out of the vehicle as if it was parked If the vehicle is skidding with its wheels locked the brakes are released in order to maintain its stability Activation Stopped uphill downhill 2 slope Press brake pedal 1s...

Page 464: ...x side connector B Vehicle side connector Figure 6 90135 From the connection to EDC 16 system gearbox central unit is able to detect accelerator pedal position and engine rpm s Connection with ABS8 ESP8 central unit is used to prevent gear shift UP on bending and manages the drive in low adhesion conditions in case of drive in mode A automatic mode New ABS system manages intelligent warning lamps ...

Page 465: ...with electronic central unit It is made up of two electrical motors drive cylinders and their sensors Clutch actuator Figure 9 90138 1 Actuator cylinder 2 Electrical motor 3 Vehicle electrical wiring harness junction block It is made up of One cylinder operating on clutch engaging disengaging lever One position sensor detecting clutch lever travel and acquainting the electronic central unit of act...

Page 466: ... best exploit the drive torque In practice if accelerator pedal is fully pressed a drive with an engine rotation speed with higher gear shift is chosen Display unit Figure 10 112601 The display unit positioned on instrument panel allows to display all information needed for system correct use e g Mode manual or automated and in both cases gear ratio entered Reverse neutral R N position Faults sign...

Page 467: ...al is operated If accelerator pedal is fully pressed a drive with an engine rotation speed with higher gear shift 3900 rpm is chosen Complete signalling on the display unit showing mode manual or automated reverse neutral position failure misuse with sound warning e g clutch overheating On bending shifting UP is inhibited This function persists for some metres after the exit from the bend Gear shi...

Page 468: ...vent movement of the other rods by engaging the grooves in the rods 3rd 4th gear engagement According to the movement of the engagement lever 1 the slider 3 axial moves the rod 4 which is integral the selector 5 previously arranged and consequently the chosen 3rd and 4th gear engagement rod 9 Neutral position coincides with the 3rd 4th gear selection arrangement In this case the vertical axis of t...

Page 469: ...e lever 1 the slider 3 will axially move the re verse gear engagement rod 5 Safety device The transmission is equipped with a device which prevents the simultaneous engagement of two gears It consists of a suitably shaped rod 6 fitted transversally in the transmission box The slider 3 moves the rod 6 under the action of the lever 2 This keeps the selected gear engagement rod free and prevents move...

Page 470: ...YDROCAR type only Speed engagement Forward speeds 5th 6th 3rd 4th Single cone synchronizer 1st 2nd Dual cone synchronizer Reverse speed Quick connect non synchronized type Speed retention mechanism Sliding sleeves retained by pawls and springs Gears Helical toothed constant mesh gears Gear ratio First 6 727 Second 3 947 Third 2 555 Fourth 1 776 Fifth 1 289 Fifth 1 000 Reverse 6 055 Shaft bearings ...

Page 471: ...0oC Transmission shaft Temperature for fitting bearings 80 C max 120oC 5th 4th gears 170 160oC Gear end float 1st 3rd 4th R 5th gear 2nd gear 0 15 0 40 mm 0 25 0 5 mm 5th 4th gear sliding sleeve hub retaining ring end float 0 0 15 mm 5th 4th gear sliding sleeve hub retaining ring thickness Retaining ring end float transmission shaft front bearing 0 0 1 mm main shaft roller bearing 0 0 1 mm Transmi...

Page 472: ...4 Constant mesh shaft cover fastening screw 23 15 2 3 15 5J Screw securing p t o side cover 46 15 4 6 15 6 Plugs for rod preventing gear engagement 32 3 2 7 Clutch actuator fastening screws 23 2 3 8 Screw securing reverse gear shaft 23 15 2 3 15 9 Screw securing rear cover 23 15 2 3 15 10 Electronic control unit fastening screws 9 5 0 9 11 Side plug on rear cover 35 3 5 12 Speedometer transmitter ...

Page 473: ...6 S 400 A O D TRANSMISSION 107 DAILY EURO 4 Base March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99327010 E A SY 99327001 Modus station ...

Page 474: ...ter by means of the chassis number It stores the results of the diagnostic work carried out It can also be used as a laptop PC and is set for remote diagnosis Using MODUS as a mother station allows you to update and configure IT 2000 E A SY The E A SY system allows you to easily diagnose and program the various electronic controls unit fitted to the vehicle It is made up of an ECI module for commu...

Page 475: ...connection makes it possible to perform the following operations Gearbox control unit data reading Error if any detection and clearing Clutch engagement release control Control unit configuring A IT 2000 B E A SY C MODUS D Body computer E Diagnosis socket MODUS IT 2000 E A SY CONNECTION Figure 18 ...

Page 476: ...ove electric cable fastening strap 1 on the clutch actuator side Press clutch actuator connector pull back spring 1 as shown by the arrow Remove connector 1 from clutch actuator 2 102134 102137 102135 102136 102138 102139 Disconnect the battery cable in engine opening Place the vehicle in a pit or on an auto lift or special supporting stands Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure...

Page 477: ... 102143 102141 102163 102144 102145 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Prior to removing the actuator verify that the clutch is closed This can be done either by means of the diagnosis instrument or by visually inspecting the position of the fork which must be perpendicular to the gearbox axis In the event that the clutch has been left open due to a mechanic or electric fa...

Page 478: ...he crossbar fastening screws 1 on the right side then remove the crossbar taking care not to drop it on the floor Remove boot 1 from its housing This operation is necessary to make the fork travel the full disengagement stroke when detaching the gearbox Remove the remaining screws securing the gearbox to the clutch bell 102146 102149 102147 102148 102150 102151 Figure 31 Figure 32 Figure 33 Figure...

Page 479: ...ly take out the gearbox taking care not to hit it or get it caught in some component Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 After the detachment operation has been completed pressure plate bearing 1 shall remain fitted into the clutch as shown in the figure Refitting Gearbox is provided by spares in second gear in order to enable primary shaft rotation through transmission sha...

Page 480: ...2158 102160 102159 102161 102145 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Manually screw down screws 1 securing the gearbox case to the base unit prior to tightening them to torque Pull the fork 3 towards the control unit so that pressure plate bearing 2 is correctly engaged into diaphragm spring 1 NOTE 114 6 S 400 A O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 481: ...gearbox by means of the four screws 2 then tighten to the specified torque Connect connector 1 to the clutch actuator Secure the gearbox cable by means of strap 1 102163 102141 102149 102165 102167 102168 Figure 48 Figure 49 Figure 50 Figure 51 Re attach the starting motor to the gearbox case front cover by tightening the screws 1 to the specified torque Figure 52 Figure 53 6 S 400 A O D TRANSMISS...

Page 482: ...169 102172 102170 102171 102143 Figure 54 Figure 55 Figure 56 Figure 57 Connect connectors 1 to the control unit Secure drive shaft 1 to the gearbox by tightening fastening screws 2 to torque After the gearbox has been re attached completely check for correct connection of electric cables Figure 58 After re attachment has been completed perform the specific calibration procedure by means of the di...

Page 483: ... replacement of the gearbox unit electric electronic components supplied with spare parts 66136114 CONTROL UNIT Removal Remove connector 4 from control unit 1 by pulling the safety retainer downwards as shown by the arrow Remove strap 6 Unscrew screws 2 3 Remove screw 5 while holding the control unit and taking care to recover spacer 7 placed behind screw 3 Take off control unit 1 Figure 59 NOTE 6...

Page 484: ...rews 2 3 5 to the specified torque Insert control unit connector 4 by securing it with the safety hook as shown by the arrow Connect the battery cable Figure 60 After re attachment has been completed perform the specific calibration procedure by means of the diagnosis instrument described on page 122 30 NOTE 118 6 S 400 A O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 Refitting ...

Page 485: ... open This condition can be inspected both visually and by getting connected to the vehicle by means of the diagnosis instrument and subsequently reading the data memory In the event that the clutch is In the event that the actuator has been taken off with the clutch open release lever 4 previously engaged with the utmost care Avoid touching the lever straight with your hands owing to the lever be...

Page 486: ...e in a pit or on an auto lift or special supporting stands Disconnect the battery cable in the engine compartment Take off the clutch actuator as described on page 119 Removal The actuator positioned in the upper part of the gearbox cannot be accessed owing to the very narrow space between the cabin floor and the actuator itself NOTE Proceed as it follows This operation must be carried out with th...

Page 487: ...rew 4 Take off supports 3 Use a suitable tool 5 to remove the eight fastening screws 1 then take off gearbox actuator 6 Clean the supporting surface of the actuator on the gearbox case NOTE Refitting Re attachment is carried out by reversing the order of detachment operations Also follow the advice below After re attachment has been completed perform the specific calibration procedure by means of ...

Page 488: ...ument that no error is found in the gearbox control unit fault memory NOTE Refitting Re attachment is carried out by reversing the order of detachment operations Also tighten the nuts or screws to the specified torque 769152104 GEARBOX WIRING GEARBOX Removal Place the vehicle in a pit or on an auto lift or special supporting stands Disconnect the battery cable in the engine compartment 102195 Figu...

Page 489: ...cified points then place it on the engine taking care that it does not get pinched Check for correct insertion of connectors which can be felt when the locking bracket has been closet Refitting After the re attachment operation has been completed verify by getting connected to the vehicle by means of the diagnosis instrument that no error is found in the gearbox control unit fault memory NOTE Remo...

Page 490: ...ching for the point of initial slip the vehicle will pick up three times putting the lever in neutral closing the clutch The procedure is interrupted when the engine is switched off Wait 10 seconds prior to the next KEY ON NOTE When the procedure has been completed check the control unit memory and verify that no error is found Calibration in case of replacement of the control unit The control uni...

Page 491: ...n neutral Carry out the operations indicated by the instrument key ON engine OFF then the dedicated calibration procedure will be started Transmission Self Adaptation Message service will appear on the display the system in automatic mode will carry out the necessary operations The procedure will be interrupted when the engine is switched off Wait 10 seconds prior to the next KEY ON NOTE When the ...

Page 492: ...126 6 S 400 A O D TRANSMISSION DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 493: ... DAILY EURO 4 Base March 2006 Print 603 93 651 TRANSMISSION Power take off Page SPECIFICATIONS AND DATA 129 TIGHTENING TORQUES 130 ASSEMBLY STANDARDS 131 POWER TAKE OFF ELECTRIC ACTUATOR 132 Description 132 Operation 132 ...

Page 494: ...128 POWER TAKE OFF DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 495: ...revs 1 0 910 PTO output rated torque at 1500 rpm Nm 120 180 Expected duration at rated torque and at 1500 rpm hours 500 Rotation direction with respect to engine Opposite Control Electric Assembly side with respect to running direction Left side Torque obtainable from gearbox Nm 175 303 Oil capacity litres 0 6 0 4 Power Take Off Drive gear taper roller bearing axial backlash 0 0 1 mm Drive gear ta...

Page 496: ...arch 2006 Print 603 93 651 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 M16x1 5 actuator fixing tang 50 5 2 Switch fixing 50 5 3 Flange fixing screw 25 2 5 M10 nuts for fixing PTO to gearbox 35 39 3 5 3 9 Smear screw thread with LOCTITE 242 ...

Page 497: ...ared with grease POLIMER 400 Adjusting ring thickness shall guarantee taper roller bearing axial backlash equal to 0 0 1 mm Screw thread shall be smeared with Loctite 242 Sealing ring 1 shall be fitted with 6 mm sinking from power take off housing 2 surface POWER TAKE OFF 131 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 498: ...ivided into two different phases The first phase consists in moving forward worm screw 7 rod 5 and sleeve 3 which coming into contact with shaft toothing 4 creates axial backstop of the rod and worm screw in an intermediate position as to the whole stroke The axial backstop of worm screw 7 preloads the spring inside the actuator and switches the electric motor off the pretensioned spring exerts en...

Page 499: ...an higher number of turns to be implemented before component deterioration The functionality is more serviceable since the engagement is softer and more silent as to the traditional systems Worm screw 7 limit stop is determined by axial load and distance covered by control rod 5 It is therefore possible to install on PTO having different stroke values without modifying or adding compensation eleme...

Page 500: ...134 POWER TAKE OFF DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 501: ...603 93 651 Base March 2006 SECTION 5 5056 Propeller shafts Page CHARACTERISTICS AND DATA 3 DIAGNOSTICS 9 TIGHTENING TORQUES 10 TOOLS 10 PROPELLER SHAFT REMOVAL AND REFITTING 11 Removal 11 Refitting 11 CHECKING PROPELLER SHAFTS ON VEHICLE 11 ...

Page 502: ...2 PROPELLER SHAFTS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 503: ...FT 4x2 Vehicles PROPELLER SHAFTS 3 DAILY EURO 4 Print 603 93 651 Base March 2006 CHARACTERISTICS AND DATA Name mm Complete spider assembly radial in the fork housings 0 03 Transmission shaft max off centring measured at centre 0 4 measured at extremities 0 25 measured on tang 0 15 Max working angle 20º ...

Page 504: ...GKN TYPE CONNECTING SHAFT 62122 50827 Figure 3 Figure 4 DANA TYPE CONNECTING SHAFT 4x2 Vehicles Figure 5 GKN TYPE CONNECTING SHAFT 75213 4 PROPELLER SHAFTS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 505: ...3000 813 2120 2210 2120 2205 2130 2215 29L 35S 14 VAN 3450 1134 2565 2655 VAN 3450 1135 2580 2665 35S 10 12 15 18 VAN 3000 763 2075 2165 2075 2160 2085 2170 35S 10 12 15 18 CHASSI CAB 3450 1085 2520 2610 2520 2605 35C 40C 10 12 VAN 2080 2165 35C 40C 10 12 35C 14 CHASSI CAB 3000 652 2080 2170 2080 2165 2090 2175 35C 10 12 18 VAN 35C 40C 10 12 15 18 CHASSI CAB 3000 602 2035 2125 2035 2120 Power trai...

Page 506: ...50 891 866 2180 2270 2180 2265 2190 2275 VAN 3300 841 343 1540 1630 1540 1625 35S 10 12 14 15 18 CHASSI CAB 3750 841 666 1980 2070 1980 2065 1990 2075 VAN 3950 841 866 2180 2270 2180 2265 2190 2275 VAN 3300 730 608 1650 1740 1650 1735 1660 1745 CHASSI CAB 3450 730 607 1815 1905 1815 1900 35C 40C 10 12 35C 14 CHASSI CAB 3750 730 652 2090 2180 2090 2175 2110 2195 VAN 3950 730 986 2315 2405 2315 2400...

Page 507: ...Propeller shaft length in mm MODEL VERSION PITCH mm Front shaft SENZA CODIC Central shaft SENZA CODICE 4 S 5 Rear shaft SENZA CODICE 2 S 5 MODEL VERSION mm SENZA CODIC 4 L L1 L L GKN supply DANA supply L1 GKN supply DANA supply CHASSIS COWL 3750 S 680 S 755 855 S 755 855 S 1080 2180 S 1080 1190 CHASSI CAB 746 722 1950 2040 1965 2050 45 50C 15 18 CHASSIS COWL S 4350 680 S 755 855 S 755 865 S 440 S ...

Page 508: ...aft SENZA CODIC Central shaft Rear shaft MODEL VERSION PITCH mm SENZA CODIC 4 Central shaft SENZA CODICE 4 L1 L L L L1 GKN supply DANA supply 60C 65C 15 18 CHASSI CAB 4350 670 801 724 1885 1975 1885 1970 60C 65C 15 18 CHASSI CAB 4750 670 730 1065 2350 2440 2350 2435 Propeller shaft length in mm MODEL VERSION PITCH Front shaft SENZA CODIC Central shaft SENZA CODICE Rear shaft Figure 5 1 2 MODEL VER...

Page 509: ...ined profiles Replace the shaft Nuts and bolts fastening shaft to either transmission or rear axle sleeves loose After a careful check tighten up the loose screws and nuts and eventually replace any damaged ones Universal joints seized up or excessively worn Overhaul or replace the universal joints Insufficient lubrication of the parts Lubricate the parts at the appropriate nipples YES NO YES NO Y...

Page 510: ...kage shaft to chassis side member fixing screw 62 5 6 5 6 3 0 6 TOOLS TOOL NO DESCRIPTION 99370618 Support for removal refitting propeller shaft YES NO Elastic dowel of central support in bad condition Replace the support Central elastic support bearing in bad condition or excessive play Replace the support Flange fixing screws or ring nuts on propeller shaft tang loose Tighten the screws or the r...

Page 511: ...em Removal When overhauling the propeller shaft always begin by removing the rear shaft CHECKING PROPELLER SHAFTS ON VEHICLE Repeat the same operations for removal in the opposite order and observe the following Make sure that the arrows shown on the moving part and on the shaft are aligned Make sure that the holes of the front flange are aligned with those of the rear flange the nuts for the flan...

Page 512: ...12 PROPELLER SHAFTS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 513: ...REAR AXLES 1 DAILY EURO 4 Base March 2006 Print 603 93 651 SECTION 6 5250 Rear axles Page DIAGNOSTICS 3 REAR AXLE NDA RS 5 REAR AXLES NDA RG 35 REAR AXLE 450511 53 REAR AXLE 450517 2 83 ...

Page 514: ...2 REAR AXLES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 515: ...ar axle casing and top up oil to correct level YES NO Wheel hub bearings inefficient Remove the hub and replace inefficient parts Wheel hub bearings out of adjustment Adjust bearings YES 2 REAR AXLES NOISE NO Lubricating oil level low Check that there are no leaks from gaskets or the rear axle casing and top up oil to correct level YES NO Drive shaft splines to fit the differential crown wheels da...

Page 516: ... and top up oil to correct level 4 NOISE DURING ACCELERATION YES Bad adjustment or wear on differential gears or bearings Locate the trouble and overhaul the unit YES NO Gear housing bearings badly set or deteriorated Overhaul the unit YES Bad tooth contact between pinion and ring bevel gear Adjust the contact 5 YES Improper clearance between planetary gears and crown wheels Overhaul or replace th...

Page 517: ...Refitting 17 OVERHAULING THE REAR AXLE ASSEMBLY 19 Air breather disassembly assembly 19 Wheel hub overhaul 19 Disassembly 19 Assembly 21 REPAIRING THE DIFFERENTIAL 22 Disassembling the differential unit 22 Gear housing removal 23 Dismounting bevel pinion 24 Checking the parts comprising the differential 25 Assembly of gear housing 26 Assembling the bevel pinion assembly 27 Assembly of differential...

Page 518: ...6 REAR AXLE NDA RS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 519: ...roller bearings also pre lapped and lubricated with rustproof protective oil The adjustment of bearing rolling torque is through adjusting rings put in between box and stop rings The clearance between pinion and crown wheel is adjusted by changing the thickness and or position of the adjustment rings though the total thickness must be the same as that of the adjustment rings removed Differential w...

Page 520: ...load adjustment rings 0 545 1 070 mm with progression of 0 025 mm Temperature at assembly of inner bearing ring on bevel pinion Position of bevel pinion with respect to differential casing By means of adjustment spacers Thickness of adjustment rings placed between bevel pinion and differential casing 3 585 4 235 mm with progression of 0 025 mm Bearings for gear housing 2 with taper rollers Differe...

Page 521: ...t of clearance between pinion and ring bevel gear By means of adjustment rings Clearance between planetary and crown wheels 0 05 0 15 mm WHEEL HUBS Wheel hub bearings UNIT BEARING Wheel hub bearings end play Wheel hub bearings rolling torque Nm kgm Adjustment of wheel hub bearings end play Not adjustable Tighten fixing ring nut to torque Rear axle oil Quantity Litres TUTELA W90 M DA SAE 80 W 90 1 ...

Page 522: ...400 500 40 50 2 Screw securing half housing and ring bevel gear 89 108 8 9 10 8 3 Oil filler plug 49 62 4 9 6 2 4 Screw securing caps to differential housing 100 120 10 12 5 Screw securing gearing inspection cover to the axle housing 80 95 8 9 5 Oil drainage plug 49 62 4 9 6 2 Apply LOCTITE 5910 on the housing Apply LOCTITE 577 on the plug thread Apply LOCTITE 573 on both sides of the gasket ...

Page 523: ...107836 Figure 3 NDA RS REAR AXLE DIFFERENTIAL SECTION REAR AXLE NDA RS 11 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 524: ...5 brake disk securing screw 13 21 1 3 2 1 3 M52x3 half shaft bearing securing ring nut 559 677 57 0 69 0 4 M12 rear axle arm bearing support securing screw 125 135 12 7 13 8 5 M14x1 5 brake caliper securing screw 176 217 17 9 22 1 M6 metal sheet guard securing screws 10 16 1 0 1 6 NDA RS REAR AXLE WHEEL HUB SECTION 107837 Figure 4 ...

Page 525: ...RO 4 Base March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99305121 Hot air drier 99322215 Front and rear axle overhaul stand 99341003 Single acting rear axle 99341009 Pair of brackets 99341011 Pair of brackets 99341015 Clamp ...

Page 526: ...CRIPTION 99345057 Extractor reaction block 99348001 Extractor with locking device 99355184 Shaft bearing ring nut wrench 99370006 Handle interchangeable drift 99370007 Grip for interchangeable punches 99370239 Tool to determine thickness of adjustment of bevel pinion use with 99395728 ...

Page 527: ... 99370317 Reaction lever with extension for flange retaining 99370617 Universal mounting to support axles during removal and refitting 99372236 Tool to move brake caliper piston back 99374022 Key to fit differential bevel pinion gasket use with 99370007 99374091 Punch to fit external races of bearings diameter 55 69 mm use with 99370007 ...

Page 528: ...DESCRIPTION 99374092 Punch to fit external races of bearings diameter 69 91 mm use with 99370007 99389819 Dynamometric wrench 0 10 Nm with 1 4 square connection 99395728 Dial gauge with mounting to be used with the tools to determine the thickness of adjustment of the bevel pinion ...

Page 529: ...els securing screws and take them off the vehicle Unscrew nut 2 adjusting hand brake linkage Release the cables from the chassis by uncoupling check springs 1 Unscrew screws 7 securing transmission shaft 8 Disconnect electrical cables 15 of the sensors of brake pad wear and phonic wheel rpm s 6 Unscrew nuts 12 securing shock absorbers 11 Take hydraulic pipes 16 of brake system off the fitting on t...

Page 530: ...18 REAR AXLE NDA RS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 531: ...of the rear axle unit are given on the plate 1 fixed near to the leaf spring attachment support 525013 Air breather disassembly assembly 525030 Wheel hub overhaul Disassembly The caliper must not be violently knocked or dropped Prevent the rubber caps coming into contact with sharp metal tools Do not dirty or wet the rubber caps with mineral grease or oil Do not dirty the pads with liquids or grea...

Page 532: ...half shaft 1 in a vice Remove denting of ring 2 engaging in ring nut 3 Using wrench 99355184 1 unscrew ring nut 2 checking bearing 3 to half shaft 4 Properly arrange half shaft 1 on hydraulic press and take out bearing 2 together with support 3 Using extractor 99348001 4 Unscrew screws 2 securing metal sheet guard 1 to support 3 Pull guard apart from support 20 REAR AXLE NDA RS DAILY EURO 4 Base M...

Page 533: ...bly on a vice Thread washer 2 and ring nut 1 Using wrench 99355184 3 tighten ring nut 1 at prescribed torque Dent washer 2 on milled portion of ring nut 1 as indicated in figure Put assembled half shaft into rear axle box Tighten screws 1 securing half shaft to rear axle arm at prescribed torque Mount brake disk 2 on half shaft 3 and tighten securing pin 1 at prescribed torque The bearing 3 must n...

Page 534: ...sive of ring gear wheelwork bearings 2 5 adjusting shims 4 and rib rings 3 out of rear axle box The brake lining with the wear indicator must be mounted on the piston side of the brake caliper NOTE Should brake calliper piston be moved backward use tool 99372236 and follow the recommendations set out in the BRAKES section NOTE Before repairing the differential it is necessary to drain off the oil ...

Page 535: ... wheel 1 from differential box 2 Using a proper beater remove spring peg 1 and unthread planetary gear holder pin 9 Rotate crown wheels 6 and 10 in such a way as to have planetary gears 3 and 7 matching the slits on differential box 4 Remove planetary gears 3 and 7 and relating thrust blocks 2 and 8 from differential box 4 Remove crown wheels 6 and 10 and relating rib thrust blocks 5 and 11 REAR A...

Page 536: ...mbly Using a proper beater beat according to direction indicated by the arrow until bevel pinion 1 complete with rear bearing fixed spacer and adjusting nut is ejected from rear axle box 2 Remove the seal 1 and the internal ring 2 of the front bearing Use a punch to remove the external rings 3 4 of the tapered roller bearings from the axle housing 1 and take out the adjustment shim 2 With axle 993...

Page 537: ...ing shim 6 Spacer 7 Ledge ring 8 Rear bearing 9 Bevel pinion 10 Ring bevel gear 11 Rib ring 12 Adjusting ring 13 Taper roller bearing 14 Differential box 15 Crown wheel rib thrust block 16 Crown wheel 17 Planetary gear rib thrust block 18 Planetary gear 19 Pin 20 Screw securing ring gear differential box 107840 Figure 32 Check for grooved section for keying the flange on the pinion not being exces...

Page 538: ...0 Rotate crown wheels in such a way that the holes of planetary gears are aligned to guide holes for pin 9 that are present on the box of differential 4 Thread pin 9 aligning the hole for spring peg 1 to the hole that is present on the box of differential 4 Using a proper beater put spring peg 1 into its seat 108046 108045 Figure 33 Figure 34 Assembly of gear housing Figure 35 108404 Using a prope...

Page 539: ...al ring 3 of the tapered roller bearing Mount provided washer 3 and inner ring 2 of taper roller bearing on dummy pinion 99370239 1 Position dummy pinion 99370239 1 assembled as in Figure 39 on the outer ring of taper roller bearing 2 On the opposite side fit the taper bearing internal ring 3 on the dummy pinion 1 and the transmission shaft flange 4 Screw nut 5 until dummy pinion is freely rotatin...

Page 540: ...ve the dummy pinion with the mounting 99395728 dial gauge and rear bearing from the axle housing If required replace adjusting ring 4 with a new one having the calculated thickness after removing bearing outer ring 3 from rear axle casing 5 by beater Then fit the new adjusting ring 4 into rear axle casing 5 Using the punch 99374092 2 and grip99370007 1 mount the external ring 3 of the tapered roll...

Page 541: ...flange 2 Position a suitable pipe 3 on the stand so that the flange 2 and the taper bearing internal ring 1 are correctly supported Use tool 99370317 2 to prevent the flange 1 from rotating Tighten the bevel pinion retainer nut to the required torque with a torque wrench 3 Mount the bevel pinion 1 in the axle housing so as to enter the internal ring 2 of the tapered roller bearing Beat on the top ...

Page 542: ...em to the required torque with the dynamometric wrench 3 108423 Figure 52 Check total rolling torque using torque meter 99389819 1 If the value of the measurement is not as required replace the adjustment rings 3 and 5 Figure 50 with another one of a suitable thickness Rolling torque must be detected at 25 ºC ambient temperature having the pinion rotating at 50 rpm speed after the pinion has run 1...

Page 543: ...y a thin layer of Prussian blue on ring gear teeth Turn the pinion and measure the impression of the contact of the pinion toothing on the crown wheel toothing Here we illustrate the possible contacts with the corrections to obtain precise coupling of the crown wheel and pinion 108427 44603 Figure 53 Figure 54 A Coupling depth B Crest C Side D Play E Greater base F Heel G Top land H Contact surfac...

Page 544: ... the key 99374022 2 and grip 99370007 3 mount the seal in the axle housing Mount flange 1 Stop the rotation of flange 1 using tool 99370317 2 Using torque wrench 3 tighten nut checking bevel pinion at prescribed torque After prescribed coupling clearance has been completed stop the rotation of flange 1 using tool 99370317 2 Unscrew the retaining nut and extract the flange 1 from the bevel pinion 1...

Page 545: ...nt the cover 1 and screw on the screws 2 Flanged screws for solution without gasket Screws with washer for solution with gasket 107856 Figure 66 According to sequence indicated in figure tighten the screws at prescribed torque Complete mounting operation observing the following Mount the drive shafts as described under the heading 525030 overhauling hubs Apply LOCTITE 577 thread locking oil on the...

Page 546: ...34 REAR AXLE NDA RS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 547: ...h 2006 Rear axles NDA RG Page DESCRIPTION 37 SPECIFICATIONS AND DATA 38 TIGHTENING TORQUES 40 TOOLS 43 OVERHAULING THE REAR AXLE ASSEMBLY 49 Air breather disassembly assembly 48 Wheel hub overhaul 48 Replacing the wheel hub bearing 49 Disassembly 49 Assembly 49 ...

Page 548: ...36 REAR AXLE NDA RG DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 549: ...wo tapered roller bearings The rolling torque of the bearings is adjusted with adjustment rings between the spacer rings and the external rings of the bearings The clearance between pinion and crown wheel is adjusted by changing the thickness and or position of the adjustment rings though the total thickness must be the same as that of the adjustment rings removed The gearing of the differential i...

Page 550: ... pre load ad justment rings 0 545 1 070 mm with progression of 0 025 mm Temperature at assembly of inner bearing ring on bevel pinion Position of bevel pinion with re spect to differential casing By means of adjustment spacers Thickness of adjustment rings placed between bevel pinion and differential casing 3 585 4 235 mm with progression of 0 025 mm Bearings for gear housing 2 with taper rollers ...

Page 551: ...gear By means of adjustment rings Clearance between planetary and crown wheels 0 05 0 15 mm WHEEL HUBS Wheel hub bearings UNIT BEARING Wheel hub bearings end play Wheel hub bearings rolling torque Nm kgm Adjustment of wheel hub bearings end play By means of nut Torquing the securing nut Rear axle oil Quantity Litres TUTELA W90 M DA SAE 80 W 90 1 35 Max capacity GAW kg 2240 ...

Page 552: ...securing nut 400 500 40 8 51 0 2 M12x1 5 ring bevel gear wheelwork box securing screw 89 108 9 0 11 0 3 M22x1 5 oil filling plug 49 62 5 0 6 32 4 Screw securing caps to differential box 100 120 10 2 12 2 5 M8x1 25 rear axle box rear cover securing screw 80 95 8 2 9 7 M22x1 5 oil draining magnetic plug 49 62 5 0 6 3 Apply Loctite 5910 on the housing Apply Loctite 577 on the plug thread ...

Page 553: ...NDA RG REAR AXLE DIFFERENTIAL SECTION 107859 Figure 3 REAR AXLE NDA RG 41 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 554: ...ing screw 2 M10x1 25 screw securing half shaft to wheel hub 63 76 6 4 7 7 3 M52x1 5 ring nut checking wheel hub bearing 545 565 55 5 57 6 4 M10x1 25 screw securing brake disk to wheel hub 69 76 7 0 7 7 5 M14x1 5 screw securing shoes support to caliper support 177 217 18 0 22 1 6 M10x1 5 screw securing brake caliper support to rear axle arm 85 97 8 7 9 8 ...

Page 555: ...arch 2006 TOOLS TOOL NO DESCRIPTION 99305121 Hot air drier 99321024 Hydraulic trolley for removing and refitting wheels 99322215 Driving and steering axle overhaul stand 99341001 Double effect bridge 99341003 Single acting rear axle 99341005 Reaction bridge ...

Page 556: ...Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99341009 Pair of retainers 99341010 Pair of retainers 99341011 Pair of retainers 99341015 Clamp 99345057 Extractor reaction block 99355087 65 mm diam box wrench for disassembly assembly wheel hub locking ring ...

Page 557: ...angeable drift 99370007 Grip for interchangeable punches 99370239 Tool for measuring thickness of bevel pinion adjustment rings to be used with 99395728 99370317 Lever and relevant extension bar to retain flanges 99370497 Tool for assembly of wheel hub 99370498 Tool for assembly of wheel hub bearing and phonic wheel ...

Page 558: ...ool to move brake caliper piston back 99374022 Keying tool for assembly of differential bevel pinion gasket to be used with 99370006 99374091 Punch to fit external races of bearings diameter 55 69 mm use with 99370007 99374092 Punch to fit external races of bearings diameter 69 91 mm use with 99370007 99389819 Torque wrench 0 to 10 mm with 1 4 square attachment ...

Page 559: ...R AXLE NDA RG 47 DAILY EURO 4 Print 603 93 651 Base March 2006 TOOLS TOOL NO DESCRIPTION 99395728 Dial gauge with support to be used with the tools to determine the adjustment thickness of the bevel pinion ...

Page 560: ...te 1 fixed near to the leaf spring attachment support NOTE 107860 107854 525030 Wheel hub overhaul Figure 7 Take out the screws 1 and remove the brake caliper 2 with its brake linings from the mounting The caliper must not be violently knocked or dropped Prevent the rubber caps coming into contact with sharp metal tools Do not dirty or wet the rubber caps with mineral grease or oil Do not dirty th...

Page 561: ... as described under the Brakes heading The bearing 1 is removed from the wheel hub with the aid of an ordinary punch Bearing 1 driving load is 2100 5000 kg NOTE 101969 Figure 12 45164 The new bearing should be mounted in the wheel hub with a press and tool 99370498 1 2 Figure 13 Mount the brake disc 1 on the wheel hub 2 and tighten the fixing screws 3 to the required torque 101970 Assembly In rest...

Page 562: ... home check that the pins are perfectly in touch with the hub maximum orthogonal tolerance 0 2 mm Figure 16 44619 Stand the bearing of the wheel hub 2 on a special mounting that permits rotation With a magnetic dial gauge 1 check the off centring of the brake disc on both sides Centering error must not exceed 0 1 mm 44621 Mount the inserter 99370497 2 on the sleeve Lubricate the sleeve with TUTELA...

Page 563: ...re brake caliper plunger must be withdrawn observe what indicated in section Brakes Apply IVECO 1905685 sealant on the contact surfaces of the drive shaft 2 with the wheel hub 1 Mount the drive shaft 2 in the sleeve Tighten the screws 3 securing the drive shaft 2 to the hub 1 to the required torque After the assembling operation has been completed fill the rear axle case with TUTELA W90 M DA oil t...

Page 564: ...52 REAR AXLE NDA RG DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 565: ...Y 67 Wheel hub overhaul 67 Replacing the wheel hub bearing 68 DIFFERENTIAL REPAIR OPERATIONS 71 Disassembly of differential locking 71 Assembling the differential locking device 71 Differential locking removal 71 Differential locking refitting 71 Adjusting the differential locking device 72 Disassembling the differential unit 72 Disassembly of gear housing 73 Assembly of gear housing 75 Assembling...

Page 566: ...54 REAR AXLE 450511 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 567: ...s is adjusted with adjustment rings between the spacer rings and the external rings of the bearings The clearance between pinion and crown wheel is adjusted by changing the thickness and or position of the adjustment rings though the total thickness must be the same as that of the adjustment rings removed The gear housing is composed of two half housings It may be of two different sizes depending ...

Page 568: ...arings By means of adjustment rings Bevel pinion bearing preload adjusting ring thickness 1 1 975 mm with progression of 0 025 mm Temperature of assembly of inner bearing ring on bevel pinion 80 C 90 C Position of bevel pinion with respect to differential casing By means of adjustment rings Thickness of adjusting ring placed between bevel pinion bearing and differential carrier 1 1 975 mm with pro...

Page 569: ... hub bearings Unit Bearing Wheel hub bearings end play Wheel hub bearings rolling torque Nm kgm Adjustment of wheel hub bearings end play Non adjustable Tightening to fixing ring nut torque Rear axle oil Quantity Litres TUTELA W140 M DA SAE 85 W 140 1 9 Dry rear axle weight With ABS kg Without ABS kg 154 6 153 g Max capacity GRW kg 3700 ...

Page 570: ... bevel pinion securing nut 400 500 40 50 2 Screw securing half housing and ring bevel gear M14 x 1 5 200 210 20 21 3 Screw securing mounting for differential locking to the axle housing or securing cover for differential locking mounting seat cover 21 25 2 1 2 5 4 Screw securing gearing inspection cover to the axle housing 21 26 2 1 2 6 5 Screw securing caps to axle housing 96 117 9 6 11 7 ...

Page 571: ...Figure 3 51862 450511 REAR AXLE DIFFERENTIAL SECTION REAR AXLE 450511 59 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 572: ...e disc to wheel hub M10x1 25 69 76 6 9 7 6 5 Screw securing caliper mounting to shoe mounting M14x1 5 180 220 18 22 6 Screw securing shoe mounting to axle housing M10x1 5 85 97 8 5 9 7 7 Screw securing guard 8 0 8 Screw securing sensor mounting 5 7 0 5 0 7 Spread the surface of the drive shaft wheel hub union with B type sealant When assembling the screws securing the timing sensor mounting apply ...

Page 573: ...e March 2006 TOOLS TOOL NO DESCRIPTION 99305121 Hot air drier 99321024 Hydraulic trolley for removing and refitting wheels 99322215 Driving and steering axle overhaul stand 99341001 Double effect bridge 99341005 Reaction bridge 99341010 Pair of retainers ...

Page 574: ...r block for pullers 99348001 Extractor with locking device 99355087 65 mm diam box wrench for disassembly assembly wheel hub locking ring 99370006 Handle interchangeable drift 99370007 Handle interchangeable drift 99370309 Tool for measuring thickness of bevel pinion adjustment rings to be used with 99395728 ...

Page 575: ...nges 99370497 Tool for assembly of wheel hub 99370498 Tool for assembly of wheel hub bearing and phonic wheel 99370617 Axle universal support during removal installation 99374022 Keying tool for assembly of differential bevel pinion gasket to be used with 99370006 99374092 Punch to fit external races of bearings diameter 69 91 mm use with 99370007 ...

Page 576: ...ase March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99389819 Torque wrench 0 to 10 mm with 1 4 square attachment 99395728 Dial gauge with support to be used with the tools to determine the adjustment thickness of the bevel pinion ...

Page 577: ...c cable of the differential locking indicator transmitter 15 For all vehicles Position a hydraulic jack equipped with the mounting 99370617 under the axle Unscrew the nuts 7 of the brackets 8 securing the axle to the leaf spring 11 Lower the hydraulic jack and extract the axle 52121 Refitting For refitting carry out the operations described for removal in reverse order observing the required tight...

Page 578: ...66 REAR AXLE 450511 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 579: ... out the screws and remove the drive shaft 1 Lift up the notch of the ring nut 1 Using the wrench 99355087 2 remove the ring nut 1 take out the washer and extract the wheel hubs 3 The identification data of the rear axle unit are given on the plate 1 fixed near to the leaf spring attachment support 525030 Wheel hub overhaul The thread of the screws securing the brake caliper is treated with adhesi...

Page 580: ...unt the brake disc 1 on the wheel hub 2 and tighten the fixing screws to the required torque If it is necessary to replace the pins of the wheel hub 1 before mounting the new ones check that the mating surface of the pin head is free from burrs dross and blisters The pins should be driven in by applying a load on their head no greater than 2000 kg After driving them home check that the pins are pe...

Page 581: ...l 2 is no greater than 0 1 mm Mount the inserter 99370497 2 on the sleeve Lubricate the sleeve with TUTELA W140 M DA oil and key the wheel hub 1 Mount the washer 1 and a new ring nut 2 Using the wrench 99355087 3 tighten the ring nut 2 to the required torque Notch the fixing ring nut 2 on the milling of the axle housing arm Figure 21 The phonic wheel 2 should be mounted in the hub with the punch 9...

Page 582: ... 25 Figure 26 Mount the support 2 and tighten the fixing screws 1 to the required torque Mount braking pads 1 Fit brake caliper 3 to support 2 then use torque wrench 4 to tighten fastening screws 1 to a torque of 32 to 36 Nm Braking pad with wear signalling unit must be mounted at brake caliper plunger side Having to move the brake caliper piston back keep to the instructions given in the BRAKES s...

Page 583: ...Finally remove the control lever 3 from the support 5 Remove the spring 1 Unscrew and remove the 4 screws 2 including washers and then disconnect the differential locking device 3 If required remove the unit as described in the following paragraphs 61869 23227 61869 Figure 27 526210 DIFFERENTIAL REPAIR OPERATIONS 526260 Disassembly of differential locking Assemble the differential locking device b...

Page 584: ...ustment screw 14 so that it is contact with the control lever 7 After this unscrew the adjustment screw by 9 5 turns corresponding to 9 5 mm travel of the screw and lock it with the fastening nut 13 Adjusting the differential locking device Disassembling the differential unit Unscrew the screws 1 complete with tab washers and spring washers and remove the gear housing inspection cover 2 complete w...

Page 585: ... housing 62099 18222 Figure 35 Figure 36 Unscrew the screws 2 remove the ring bevel gear 3 and the gear housing 4 cover 1 Remove the crown wheel 2 on the cover sidewith itsthrust washer 3 from the gear housing 1 Using a generic beater to remove the long pin 4 and the two short pins 5 from the gearing case 1 The thrust ring 2 is only present with rear axles fitted with differential locking NOTE Mar...

Page 586: ...Seal 4 Front bearing 5 Pinion shim ring 6 Fixed spacer 7 Spacer ring 8 Adjustment ring 9 Rear bearing 10 Bevel pinion 11 Ring bevel gear 12 Fixed ring 13 Adjustment ring 14 Bearing 15 Thrust ring axle with differential locking 16 Gear housing 17 Crown wheel thrust washer 18 Spider 19 Crown wheel 20 Gear housing cover 21 Screw 22 Planetary gear thrust washer 23 Planetary gear 24 Short pin 25 Long p...

Page 587: ...sher Position the two planetary gears 1 complete with thrust washers spider 2 and then insert the long pin 3 Position the crown wheel 1 gear housing side complete with thrust washer into its own housing 18226 20380 20379 18237 Figure 40 Figure 41 Figure 42 Figure 43 Assembly of gear housing Only for axles with differential lock Using tool 99305121 heat thrust ring 1 to a temperature of 120ºC 150ºC...

Page 588: ...e seat of the bearing supporting the gear housing and note the difference A1 Repeat the same operation on the seat of the other bearing and note the difference A2 Thickness S to be added to adjusting ring thickness 4 Figure 50 used for measuring for pinion positioning is obtained by the following formula 51840 A1 indicates the value measured on the right hand seat A2 indicates the value measured o...

Page 589: ... outer ring 3 from rear axle casing 5 by beater Then fit the new adjusting ring 4 into rear axle casing 5 Using the punch 99374092 2 and grip99370007 1 mount the external ring 3 of the tapered roller bearing 18251 Using a suitable punch 1 and a hydraulic press mount the internal ring 2 of the tapered roller bearing on the bevel pinion 3 Position the fixed spacer 3 and the adjustment ring 2 used pr...

Page 590: ... the required torque with a torque wrench 3 51846 74728 Using torque meter 99389819 1 detect bevel pinion rolling torque If the reading differs from the prescribed value disassemble the pinion 1 Figure 54 replace the adjuster ring 2 Figure 52 with a ring of the correct thickness Refit the pinion and repeat the rolling torque check The rolling torque must be measured at an ambient temperature of 25...

Page 591: ...hickness on stop ring 5 Refit the external ring 3 of the tapered roller bearing Heat the internal ring 4 of the tapered roller bearing to 80 C 90 C for approximately 15 min and drive it with a suitable punch onto the bevel pinion 1 Position the spacer ring 3 and adjustment ring 2 calculated beforehand to obtain the required rolling torque on the bevel pinion 1 51866 Position the axle housing as sh...

Page 592: ...61 Insert the bevel pinion 1 assembled as shown in the figure in the internal ring of the front bearing 2 and in the flange 3 Block rotation of the transmission flange with the retainer tool 99370317 Using a suitable Allen wrench and the torque wrench tighten the bevel pinion retainer nut 1 Figure 62 to the required torque To be on the safe side check the rolling torque of the bevel pinion with th...

Page 593: ...ng Mount the drive shafts as described under heading 525030 Overhauling the Hubs Screw on the oil drainage plug and tighten it to the required torque Add lubricating oil in the required quantity and grade through the hole Screw on the oil filler plug and tighten it to the required torque Take the assembly off the stand The assembly should be put back on its mounting to prevent the dust guards and ...

Page 594: ...82 REAR AXLE 450511 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 595: ...val 95 Refitting 95 OVERHAULING THE REAR AXLE ASSEMBLY 97 Air breather disassembly assembly 97 Overhaul of wheel hubs 97 Disassembly 97 Stud replacement 99 Assembly 99 DIFFERENTIAL REPAIR OPERATIONS 102 Differential locking 102 Differential unit removal 103 Gearing case removal 103 Differential components check 105 Rear axle casing check 105 Gearing case refitting 105 Differential unit refitting 1...

Page 596: ...84 REAR AXLE 450517 2 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 597: ...ed roller bearings The rolling torque of the bearings is adjusted with adjustment rings between the spacer rings and the external rings of the bearings The clearance between pinion and crown wheel is adjusted by changing the thickness and or position of the adjustment rings though the total thickness must be the same as that of the adjustment rings removed The gear housing is composed of two half ...

Page 598: ...ng preload adjustment ring thickness 1 2 mm with 0 025 mm progression Temperature for fitting inner bearing ring on bevel pinion 80 C 90 C Bevel pinion position with reference to differential casing By means of shims Thickness of adjustment rings between bevel pinion and differential casing 3 45 4 35 mm with 0 025 mm progression Bearings for gearing case 2 taper rollers Differential case bearing r...

Page 599: ...UBS Wheel hub bearings Two SET RIGHT type taper rollers Hub bearing end play 0 16 max Wheel hub bearing rolling torque Nm kgm 0 4 0 0 4 Adjustment of wheel hub bearings end play Fastening nut tightening to torque Rear axle oil Amount Litres kg Max capacity GAW kg Tutela W140 M DA SAE 85 W140 3 2 7 5000 ...

Page 600: ... inspection cover to rear axle casing 26 21 2 6 2 1 3 Screw fastening crown gear to 12RDAC5 half casing 309 5 342 5 30 9 34 2 3 Screw fastening crown gear to 10RDAC5 half casing 266 294 26 6 29 4 4 Screw fastening half casings 61 74 6 1 7 4 5 Screw fastening differential locking device or cover 23 2 3 6 Screw fastening caps to rear axle casing 102 113 10 2 11 3 Before tightening the screws smear t...

Page 601: ...ng nut 441 540 44 1 54 4 Safety screw 9 5 11 5 0 9 1 1 5 Screw fastening brake disc to wheel hub 54 59 5 4 5 9 6 Screw fastening brake calliper to rear axle 176 194 17 9 19 7 7 Screw fastening brake shoe support to rear axle casing 68 75 6 9 7 6 8 Rpm sensor support fastening screw 5 7 0 5 0 7 Apply IVECO 1905685 sealant on half shaft wheel hub joint surface Apply IVECO 1905683 sealant on the thre...

Page 602: ...TOOL NO DESCRIPTION 99305121 Hot air operated equipment 99306004 300 kg hydraulic crane 99306010 Equipment for bleeding air from brake and clutch system 99321024 Hydraulic truck for removing refitting wheels 99322215 Stand to overhaul axles 99345056 Counter block for pullers ...

Page 603: ...Puller with locking device 99357080 Wrench 91 5 mm for wheel hub bearing adjustment nut 99370006 Handle for interchangeable beaters 99370007 Handle for interchangeable beaters 99370296 Tool to find bevel pinion shims to be used with 99395728 99370317 Counter lever and relevant extension to retain flanges ...

Page 604: ...9374093 Beater to fit in place bearing outer races 91 134 to be used with 99370007 99374132 Element to fit in place wheel hub internal gasket to be used with 99370006 99374201 Element to fit in place differential bevel pinion gasket 99389819 Dynamometric wrench 0 10 Nm connection 1 4 99395026 Tool to check hub rolling torque to be used with dynamometric wrench ...

Page 605: ...17 2 93 DAILY EURO 4 Base March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99395684 Dial gauge with magnetic base 99395728 Dial gauge with support to be used with the tools for finding proper bevel pinion shims ...

Page 606: ...94 REAR AXLE 450517 2 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 607: ...eed Position the hydraulic jack fitted with support 99370617 under the rear axle Loosen the nuts 8 of the brackets 9 fastening the rear axle to the leaf spring 10 Lower the hydraulic jack and remove the rear axle 61988 Refitting For refitting carry out the operations described for removal in reverse order observing the required tightening torques for the screws and or nuts Afterwards check that Ch...

Page 608: ...96 REAR AXLE 450517 2 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 609: ...ove the brake caliper with its brake linings from the mounting 525013 Air breather disassembly assembly Take out the screws 1 and remove the brake caliper 2 with its brake linings from the mounting 525030 Overhaul of wheel hubs Disassembly The caliper must not be violently knocked or dropped Prevent the rubber caps coming into contact with sharp metal tools Do not dirty or wet the rubber caps with...

Page 610: ... washer 1 Rotate the wheel hub 1 to set downward one of the two screws 2 located between hub reliefs remove the screws and drain oil completely from wheel side Remove the other screws fastening the axle shaft 3 to the wheel hub 1 62890 Figure 15 Sling brake disk 1 with rope and hoist take off wheel hub 2 complete with brake disk 1 front 3 and rear bearings seal ring and spacer 98 REAR AXLE 450517 ...

Page 611: ...pplying a load on their head no greater than 2000 kg After driving them home check that the pins are perfectly in touch with the hub maximum orthogonal tolerance 0 2 mm Use handle 99370007 1 and beater 99374093 2 to fit taper roller bearing outer rings into the wheel hub Use a suitable punch to remove the rear taper roller bearing outer ring 1 Repeat this operation to remove the front taper roller...

Page 612: ...ealing ring 3 Fit the brake disc 3 on the wheel hub 1 and tighten the fastening screws 2 to the specified torque Fit the phonic wheel if any on the wheel hub Use tool 99374132 2 side to position the sealing ring 3 at 1 5 mm from wheel hub side surface NOTE Phonic wheel fitting shall be performed after heating it at 150ºC When fitting is over check whether the phonic wheel is resting perfectly on t...

Page 613: ...e rolling torque check whether one of the adjustment nut 1 holes is coinciding with one of the safety washer holes otherwise loosen the adjustment nut 1 until it is possible to fit the fastening screw 2 Tighten the fastening screw 2 and the adjustment nut to the specified torque Smear the contact surface between axle shaft 3 and wheel hub 1 with IVECO sealing compound 1905685 Fit axle shaft 3 tigh...

Page 614: ... disconnectthe differential locking device 2 When refitting replace the gasket located between differential locking device and rear axle casing Tighten screws 1 to the specified torque 62906 DIFFERENTIAL LOCKING DEVICE SECTION Differential locking device engagement disengagement lever stroke shall be equal to 5 mm 62907 526260 Differential locking The brake lining with the wear sensor shall be fit...

Page 615: ...case supporting bearings Remove gearing case supporting bearings 1 and 2 using puller 99348001 3 and counter block 99345056 4 Figure 39 Clamp the gearing case 2 in a vice and remove the ring bevel gear 1 from the gearing case 2 33082 33083 Mark gearing half boxes 1 and 2 loosen the fastening screws position the gearing case on a bench and remove the two half boxes Figure 40 Gearing case removal 33...

Page 616: ...se a bronze beater in arrow direction to remove the bevel pinion 1 including the rear bearing the fixed spacer and the adjustment rings from the rear axle casing 2 33088 Figure 45 33089 Remove the sealing ring 1 and the front taper roller bearing from the rear axle casing 2 Use a bronze beater to remove the front taper roller bearing outer ring Figure 46 33090 Use a bronze beater to remove the rea...

Page 617: ...der and the crown wheels with the relevant shoulder washers Replace all sealing elements the bevel pinion retaining nut and gearing case bearing adjustment nut with new parts Rear axle casing check Check whether rear axle casing is not deformed Gearing case refitting Figure 48 Fit in place the sun gear 2 with the shoulder washer set below in gearing half box 1 33092 Figure 49 33084 Fit in place th...

Page 618: ... few drops of LOCTITE 270 into crown wheel 1 holes fit the crown wheel 1 on the gearing case 2 and tighten the fastening screws to the specified torque 33097 Figure 54 33098 Figure 55 33099 Figure 56 33100 Mount the outer ring of front taper roller bearing into rear axle box using beater 99374093 1 Use beater 99374093 1 to fit in place rear taper roller bearing outer ring on rear axle casing 2 wit...

Page 619: ...usly set to zero see Figure 56 to position the rod to the bottom of the gearing case supporting bearing housing 33103 Repeat this operation for the other bearing and take note of both found values Pinion adjustment ring thickness is obtained through the following formula S B A1 A2 2 S thickness of the adjustment rings to be positioned between bevel pinion rear bearing outer ring and rear axle casi...

Page 620: ... onto the bevel pinion 2 32481 Figure 63 Position the fixed spacer 2 and the adjustment ring 3 previously used to obtain the specified rolling torque on the bevel pinion 1 32482 Figure 64 Position the complete bevel pinion into the rear axle casing Heat the front bearing 1 to 100 C for approx 15 into an air circulation furnace and then fit it down onto the bevel pinion 2 33111 If the value marked ...

Page 621: ...sure the rolling torque of the bevel pinion If the value is incorrect disassemble the pinion 2 Figure 64 and replace the adjuster ring 3 Figure 63 with a suitable ring Refit the pinion and repeat the rolling torque check Figure 69 33116 Fit gearing case supporting bearing outer rings 2 and then position the gearing case 1 previously fitted in the rear axle casing Differential unit refitting The ro...

Page 622: ...gs with ones of a different thickness but the total thickness must still be the same as that of the adjustment rings removed This is so as not to change the total rolling torque Apply a thin layer of Prussian blue on ring gear teeth by brush Turn the pinion and measure the impression of the contact of the pinion toothing on the crown wheel toothing Here we illustrate the possible contacts with the...

Page 623: ...the pinion away from the ring bevel gear to adjust clearance A Coupling depth B Crest C Side D Play Correct contact Excessive contact on side of tooth Move the pinion away from the ring bevel gear and then move the ring bevel gear to wards the pinion to adjust clearance E Greater base F Heel G Top land H Contact surface I Lateral surface Excessive contact on the top land of the tooth Move the ring...

Page 624: ...23 Fit oil drain plug 2 Pour 3 litres of W140 M DA oil through the proper hole and fit inspection and filling plug 1 51853 Figure 82 Crimp nut 1 collar on bevel pinion 2 milling as shown in the figure Do not tighten screws at higher torque value since this shall jeopardize the effect of the sealing gasket located between the connection surface and the gearing inspection cover NOTE NUT ROTATION DIR...

Page 625: ...AXLES 1 DAILY EURO 4 Print 603 93 651 Base March 2006 SECTION 7 5206 Axles Page This section contains DIAGNOSTICS 3 AXLE 5817 7 AXLE 5818 21 AXLE 5819 29 AXLE 5823 37 WHEEL GEOMETRY 49 ...

Page 626: ...2 AXLES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 627: ...ot aligned Align front wheels Irregular wheel toe in Adjust front wheel toe in Irregular tyre pressure Inflate tyres to prescribed pressure Elements involved in the stub axle rotation on the pin inefficient Check and replace the elements deteriorated AXLES 3 DAILY EURO 4 Print 603 93 651 Base March 2006 AXLES DIAGNOSTICS ...

Page 628: ... the deformed parts Front wheels not aligned Align front wheels Irregular wheel toe in Correctly adjust toe in Steering gear tie rod king pins inefficient Replace defective parts Irregular play of wheel hub bearings Replace the wheel hubs Replace the wrong rim Deflate and centre the tyre on the rim Unbalanced wheels Balance the wheels 4 AXLES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 629: ...n or relevant fixing brackets loosen Replace elastic inserts tighten fixing nuts NO YES Play between torsion bar suspension arm splines Replace worn parts and adjust torsion bar pre loading NO YES Suspension arm bushes and or articulation pins worn Replace worn parts AXLES 5 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 630: ...6 AXLES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 631: ...ECIFICATIONS AND DATA 10 TIGHTENING TORQUES 11 TOOLS 12 REMOVING AND REFITTING AXLE 5817 13 Removal 13 Refitting 13 REPAIRS 15 OVERHAULING AXLE 5817 15 Wheel hub removal and refitting 15 Removal 15 Replacing phonic wheel 16 Refitting 16 STUB AXLE REMOVAL REFITTING 17 Removal 17 Refitting 19 ...

Page 632: ...8 AXLE 5817 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 633: ...ons The steering levers are cast on the king pin of the stub axles to which are secured the brake calipers Figure 1 The wheel hubs are supported on the pins of the stub axles by UNIT BEARINGS that need neither lubrication nor adjustment The wheel rims are secured onto the wheel hubs by five screws 108374 AXLE 5817 9 DAILY EURO 4 Print 603 93 651 Base March 2006 DESCRIPTION Print 603 43 351 ...

Page 634: ... WHEEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle vehicle at static load 0º 20 Wheel caster angle vehicle at static load 3º 20 Wheel toe in vehicle at static load 2 1 mm ...

Page 635: ... the upper swinging arm jointed head to the stub axle 125 140 12 5 14 2 Nut securing the steering rod jointed head to the lever 68 83 6 8 8 3 3 Nut securing the lower swinging arm jointed head to the stub axle 160 180 16 18 4 Screw securing stub axle guard 6 7 5 0 6 0 7 5 Screw securing brake disc to wheel hub 19 5 24 9 2 2 5 6 Screw securing wheel 180 200 18 20 7 Nut securing wheel hub 320 420 32...

Page 636: ...O DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99306010 Apparatus to purge air from brakes and clutch 99321024 Hydraulic trolley for removing refitting wheels 99322215 Guide to wheel hub assembly 99347074 Puller for steering tie rod king pins ...

Page 637: ...upling 14 If it is decided to leave the brake callipers on the axle proceed to disconnect the electrical connection 1 signalling brake lining wear and the ABS sensor 4 if there is one disconnect the brake fluid pipes in correspondence with the fittings 7 and 18 after draining the system If it is decided to leave the brake callipers on the vehicle proceed to disconnect the brake fluid pipes from th...

Page 638: ...14 AXLE 5817 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 639: ...tion or remove screws 1 and take the support together with brake caliper 2 off the stub axle Support the brake caliper suitably to prevent strain on the oil pipe Remove centring pin 2 then take brake disc 1 off wheel hub 4 Remove the cup 3 from the wheel hub 4 520620 Wheel hub removal and refitting Removal Check the conditions of the brake disc and the braking gaskets as described in the BRAKING S...

Page 640: ...rce fitted screw down nut 3 Tighten the nut 3 to the required torque with the Allen wrench 2 526712 Replacing phonic wheel Refitting If any trouble is found with the wheel hub or bearing the assembly needs to be replaced since the parts are not supplied as single spares When repairing the wheel hub 1 take care not to damage the phonic wheel 3 NOTE The wheel hub must be keyed without forcing If the...

Page 641: ... two centring pins 2 Rest the brake caliper 2 with the brake linings on the stub axle 1 Tighten brake calliper 2 fixing screws to the prescribed torque Remove the wheel hubs as described under the relevant heading operation 520620 522820 STUB AXLE REMOVAL REFIT TING Removal The brake lining with its wear indicator must be mounted from the piston side of the brake caliper If it is necessary to move...

Page 642: ...er the bottom suspension arm 3 oppose the action of the transverse leaf spring Remove the nuts 2 6 securing the swivel head pin 1 5 to the stub axle 4 Using the extractor 99347074 2 remove the link pins 1 3 of the stub axle 4 and put this aside Fit the proper setscrew wrench into kingpin 1 to stop its rotation if required NOTE To block rotation of the swivel head pins 1 5 insert a suitable Allen w...

Page 643: ...ed torque Mount the guard 4 on the stub axle and secure it tightening the screws 5 to the required torque Refit the wheel hub as described in the relevant chapter operation 520620 Once removed self locking nuts 5 must not be reused To block rotation of the swivel head pins 1 2 insert a suitable Allen wrench 4 into the hexagon sunk into them NOTE Once removed self locking nuts 2 must not be reused ...

Page 644: ...20 AXLE 5817 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 645: ...RO 4 Print 603 93 651 Base March 2006 Axle 5818 Page DESCRIPTION 23 SPECIFICATION AND DATA 23 TIGHTENING TORQUES 24 TOOLS 25 OVERHAULING AXLE 5818 26 Replacing phonic wheel 27 Refitting 27 STUB AXLE REMOVAL AND REFITTING 28 ...

Page 646: ...22 AXLE 5818 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 647: ...75 AXLE 5818 23 DAILY EURO 4 Print 603 93 651 Base March 2006 DESCRIPTION Axle type 5818 WHEEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle vehicle at static load 0º 20 Wheel caster angle vehicle at static load 3º 20 Wheel toe in vehicle at static load 2 1 mm ...

Page 648: ...winging arm jointed head to the stub axle 125 140 12 5 14 2 Nut securing the steering rod jointed head to the lever 68 83 6 8 8 3 3 Nut securing the lower swinging arm jointed head to the stub axle 160 180 16 18 4 Screw securing guard to stub axle 6 7 5 0 6 0 7 5 Nut securing wheel 180 200 18 20 7 Screw securing the brake disc and flange to the wheel hub 98 1 107 9 9 8 10 7 8 Nut securing wheel hu...

Page 649: ...O DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99306010 Apparatus to purge air from brakes and clutch 99321024 Hydraulic trolley for removing refitting wheels 99322215 Guide to wheel hub assembly 99347074 Puller for steering tie rod king pins ...

Page 650: ... To remove and refit axle 5818 proceed in a similar manner as for axle 5817 Adjustment values tightening torque values and equipment are those specified in this chapter Check the conditions of the brake disc and the braking gaskets as described in the BRAKING SYSTEM section NOTE If any trouble is found with the wheel hub or bearing the assembly needs to be replaced since the parts are not supplied...

Page 651: ...nic wheel 109053 Figure 8 Refitting 109052 Lubricate the surface of the stub axle pin 2 with TUTELA MR3 grease and key the wheel hub 1 The wheel hub must be keyed without forcing If there are difficulties do not assemble since the bearing may be damaged Extract the wheel hub check the cause of the difficulties and eliminate them NOTE After hub 1 is force fitted screw down nut 3 Tighten the nut 3 t...

Page 652: ... a magnetic dial gauge check the eccentricity of the brake disc it must not exceed 0 125 mm Fit the support together with the brake caliper and braking gaskets into place back to the stub axle by tightening the fastening screws to the specified torque Figure 11 Figure 12 522820 STUB AXLE REMOVAL AND RE FITTING Perform stub axle removal and refitting as described for axle 5817 without considering t...

Page 653: ... 4 Print 603 93 651 Base March 2006 Axle 5819 Page DESCRIPTION 31 SPECIFICATION AND DATA 32 TIGHTENING TORQUES 33 TOOLS 34 REPAIR OPERATIONS 35 AXLE 5819 OVERHAUL 35 Stub axle removal and refitting 35 Removal 35 Refitting 35 ...

Page 654: ...30 AXLE 5819 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 655: ...n They are connected to the top and bottom suspension arms by swivel heads that allow turning the stub axle The brake calipers and steering levers are secured on the king pin of the stub axles The hubs are supported on the stub axle pins by Unit Bearings which need no adjustment or lubrication Figure 1 AXLE 5819 31 DAILY EURO 4 Print 603 93 651 Base March 2006 DESCRIPTION ...

Page 656: ...EEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle vehicle at static load 0o 30 20 Wheel caster angle vehicle at static load 1o 35 20 Wheel toe in vehicle at static load 2 5 1 ...

Page 657: ...per swinging arm jointed head to the stub axle 157 177 15 7 17 7 2 Nut securing the steering rod jointed head to the lever 68 83 6 8 8 3 3 Nut securing the lower swinging arm jointed head to the stub axle 157 177 15 7 17 7 4 Nut securing wheel hub 320 420 32 42 5 Screw securing plate and brake disc to wheel hub 98 108 9 8 10 8 7 Nut securing wheel 180 200 18 20 Screw securing guards to stub axle 7...

Page 658: ... optical reading tool for checking wheel trim 99306010 Apparatus to purge air from brakes and clutch 99321024 Hydraulic trolley for removing refitting wheels 99322215 Driving and steering axle overhaul stand 99347074 Tool for extracting steering tie rod king pins 99357144 Wrench for spindle pin ring nut ...

Page 659: ...s for axle 5823 Adjustment values tightening torque values and equipment are those specified in this chapter 520610 AXLE 5819 OVERHAUL 520611 Stub axle removal and refitting Remove wheel hub as described in the relevant chapter operation 520620 concerning axle 5817 Remove from stub axle 5 dust cover 2 by loosening screw 7 steering lever 3 by loosening screw 8 Loosen kingpin 1 and 6 fixing nuts fro...

Page 660: ...36 AXLE 5819 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 661: ... 5206 Axle 5823 Page DESCRIPTION 39 SPECIFICATION AND DATA 40 TIGHTENING TORQUES 41 TOOLS 42 REMOVING AND REFITTING AXLE 5823 43 Removal 43 Refitting 44 AXLE 5823 OVERHAUL 45 Wheel hub removal and refitting 45 Removal 45 Replacing phonic wheel 46 Re fitting 46 ...

Page 662: ...38 AXLE 5823 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 663: ...n They are connected to the top and bottom suspension arms by swivel heads that allow turning the stub axle The brake calipers and steering levers are secured on the king pin of the stub axles The hubs are supported on the stub axle pins by Unit Bearings which need no adjustment or lubrication Figure 1 AXLE 5823 39 DAILY EURO 4 Print 603 93 651 Base March 2006 DESCRIPTION ...

Page 664: ...UBS Wheel hubs bearings UNIT BEARING Hub bearings end play 0 11 0 14 Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle vehicle at static load 1o 20 Wheel caster angle vehicle at static load 2o 30 20 Wheel toe in vehicle at static load 2 5 1 mm ...

Page 665: ...steering rod jointed head to the lever 68 83 6 8 8 3 3 Nut securing the lower swinging arm jointed head to the stub axle 160 180 16 18 5 Nut securing wheel hub torque 50 60 5 6 angle 30 1 34 1 6 Screw securing the brake disc and flange to the wheel hub torque 43 53 4 3 5 3 angle 28 4 30 4 4 Nut securing wheel 284 5 343 3 28 4 34 3 Screw securing caliper to stub axle 7 10 0 7 1 Screw securing calip...

Page 666: ...t 603 93 651 TOOLS TOOL No DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99321024 Hydraulic truck for removing refitting operations 99322215 Stand to overhaul axles 99347074 Tool to remove drag link joints and wishbones ...

Page 667: ...to the suspension arm 13 The same steps must be performed on both left and right Adjust the load on the right and left torsion bars 9 Undo the nut 11 and unscrew the threaded pin 12 until the torsion bar 9 is entirely discharged Remove the fasteners 10 fixing the mounting 8 to the chassis frame Extract the mounting 8 from the torsion bar 9 If it is decided to leave the brake callipers on the axle ...

Page 668: ...er steering fluid and disconnect the pipes 4 and 5 disconnect the power steering column 3 in correspondence with the coupling 6 place the removal bracket on the hydraulic jack and put it all under the axle undo the chassis frame bottom fixing screws 2 and the top fixing nuts 1 lower the hydraulic jack and extract the axle 11 Refitting Reverse the steps described for removal tightening the screws o...

Page 669: ...ns are those differing from axle 5819 520620 Wheel hub removal and refitting Removal Check brake disc and lining conditions as described in the BRAKE SYSTEM section NOTE 109056 Remove safety springs 2 from pins 3 Take pins 3 out of brake caliper 6 then recover braking gasket 1 retaining clips 4 Disconnect gasket wear indicator electric connection 5 Take braking gaskets 1 out of brake caliper 6 109...

Page 670: ...ing Lubricate the surface of the stub axle pin 2 with TUTELA MR3 grease and key the wheel hub 1 If any trouble is found with the wheel hub or bearing the assembly needs to be replaced since the parts are not supplied as single spares When repairing the wheel hub take care not to damage the phonic wheel NOTE The wheel hub must be keyed without forcing If there are difficulties do not assemble since...

Page 671: ...it pins 3 into brake caliper 6 Fit safety springs 2 into pins 3 Connect braking gaskets wear indicator electric connection 5 Fit the wheel onto the flange then position the nut protection Tighten the wheel fastening nuts to the specified torque in accordance with the diagram illustrated in the figure Figure 17 109060 α 109055 α 109057 109056 89007 Use a torque wrench and a box wrench 3 to tighten ...

Page 672: ...48 AXLE 5823 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 673: ...c balancing of rim eccentricity 56 Wheel alignment 56 Checking toe in 57 Front wheel deviation test vehicle wheelbase check 57 Checking camber 58 Checking king pin angle and caster angle 58 Checking steering angles 59 Checking rear axle alignment 59 Calculating thickness of spacers to be fitted between tie rod mountings and chassis side members with the exception of vehicles equipped with 5 mm thi...

Page 674: ...50 WHEEL GEOMETRY DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 675: ...culated enablethe correctbalancing of the forces created when the vehicle is moving in the different load conditions tending to change the position of the wheels on the ground Figure 1 Caster angle Wheel camber angle The camber angle α is the angle formed by the axis passing through the wheel centre line and the vertical to the ground looking at the vehicle from the front The camber angle is posit...

Page 676: ... Figure 5 Figure 6 The toe in is negative if B is lower than A The toe in is equal to zero if B is equal to A A B A B A B The wheel toe in results from the difference between the distances A and B value expressed in mm measured on the horizontal axis of the rims looking at the vehicle from the top In this way a light drive and a low tyre consumption is obtained The toe in is positive if B is highe...

Page 677: ...el caster angle vehicle at static load 3o 20 1º 35 20 2º 30 20 Wheel toe in vehicle at static load mm 2 1 2 5 1 b Steering angle a b Internal a 47o 30 30 43º 37º 7 External b 39o 30 36º 30 45º 6 a Stub axle king pin camber α 13 38 7 1 Front suspension with transverse leaf spring 2 Front suspension with torsion bar TIGHTENING TORQUES PART TORQUE PART Nm kgm Nut fixing king pin to the side tie rod o...

Page 678: ...54 WHEEL GEOMETRY DAILY EURO 4 Base March 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99305354 Tool for checking wheel geometry 99347074 Puller for king pins ...

Page 679: ...position the board 3 Lower the vehicle brake the rear wheels and apply the hook 1 with the slide rule 2 Lift the vehicle front part and position the floating wheels 1 locking them with the locks 2 25114 32818 Figure 9 Figure 10 Position the clutch jaw 1 fitted with fixing pins 2 Operating the handgrip 3 lock the jaw on the wheel making sure that it is perfectly secured Figure 11 33137 Positioning ...

Page 680: ...ess the push button out of centre again 1 until the LED 4 of the wheel camber is lighted and on the display 3 a fictitious value is shown Repeat the operations on the other wheel Lower the vehicle sothat thewheels inthe positionpreviously marked completely rest at the centre of the floating discs 9 Loosen the floating discs 9 from their bases extracting the pins 10 Figure 12 Figure 13 Figure 14 Pr...

Page 681: ...equal to 5 lines of the toe in scale The number of lines is calculated by the algebraic sum 3 2 1 5 or counting the lines included between the two values If the values are different steer the wheels until the light signal indexes are set to two values equal A and exactly the mean value of the two previous readings In this way a perfect wheel alignment is obtained 13952 25122 52270 32295 Figure 15 ...

Page 682: ...de press the king pin camber push button 2 and the display 1 shows the king pin camber angle Steer the wheel 20 toward the inside press twice the king pin camber push button 2 the LED lights up and the display 1 shows 9 horizontal lines When the front wheels are aligned to the rear ones loosen the knurled knobs 3 and zero the graduated sector 2 on the index 1 of the floating disc When the front wh...

Page 683: ...er angle value Repeat these operations on the other wheel This check is carried out during the king pin camber check of during the caster angle check making the following operations if the prescribed steering angles exceed 30 the mark 20 1 on the floating disc 2 and the mark 30 3 on the graduated selector 4 mast be considered as initial reference values 32826 33134 Figure 23 Figure 24 Checking ste...

Page 684: ...ticking to the procedures described in the section Body and frame 44934 46951 Figure 26 Figure 27 Introduction The external width of the chassis with reference to tie rod mountings attachment point can vary from vehicle to vehicle depending on chassis assembling tolerances and side member thickness Therefore width A 864 mm is considered as an acceptable reference value on which to base correct whe...

Page 685: ...SUSPENSIONS 1 DAILY EURO 4 Print 603 93 651 Base March 2006 SUSPENSIONS SECTION 8 Suspensions Page FRONT AND REAR MECHANICAL SUSPENSIONS 3 REAR AIR SUSPENSIONS 81 ...

Page 686: ...2 SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 687: ...NICAL SUSPENSIONS 3 DAILY EURO 4 Print 603 93 651 Base March 2006 FRONT AND REAR MECHANICAL SUSPENSIONS Front and rear mechanical suspensions Page DIAGNOSTICS 5 FRONT MECHANICAL SUSPENSIONS 9 REAR MECHANICAL SUSPENSIONS 51 ...

Page 688: ...4 FRONT AND REAR MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 689: ...ehicles with torsion bar suspension Replace tie rod articulated heads Shock absorbers noisy or inefficient Check and if necessary replace shock absorbers Wheel bearings worn and with excessive backlash Replace bearings or adjust backlash Wishbone articulated heads worn Replace wishbone articulated heads NO YES NO YES NO YES NO YES NO YES YES Continues NOISY SUSPENSION FRONT AND REAR MECHANICAL SUS...

Page 690: ... fastening nuts and screws loose Check and tighten suspension fastening nuts andscrews to torque NO YES Torsion bar toothing worn Detach torsion bars and replace them and adjust pre loading NO YES Toothing of torsion bar rear supports or of wishbones worn Replace rear support or upper wishbones and adjust torsion bar pre loadings NO YES Leaf spring supports loose Check the supports and replace cha...

Page 691: ...rately inflate tyres to the prescribed pressure Replace the wheel hubs Incorrect front wheel geometry Too much front wheel bearing play Check and correct wheel geometry NO YES NO YES NO YES Inefficient hydraulic shock absorbers Torsion bar broken Remove shock absorbers and replace them Replace torsion bar and adjust pre loading NO YES NO YES Incorrect torsion bar pre loading adjustment Check and a...

Page 692: ... pre loading NO YES Incorrect torsion bar pre loading adjustment Check and adjust torsion bar pre loading NO YES Shock absorbers inefficient Check and replace the shock absorbers if necessary NO YES Overhaul the spring and replace the unusable components or if necessary the entire spring NO YES 4 EXCESSIVE SUSPENSION STIFFNESS Incorrect torsion bar pre loading adjustment Check and adjust torsion b...

Page 693: ...4 Front stabilizer bar 14 TOOLS 14 TIGHTENING TORQUES 15 Vehicles 29 L 35 S 15 TIGHTENING TORQUES 16 Vehicles 35 C 16 TIGHTENING TORQUES 17 Vehicles 29 L 35 S 35C 17 REPAIRS 18 Check the clearance of upper swinging arm articulated head 18 Check the clearance of lower swinging arm articulated head 19 OVERHAULING THE SUSPENSION 19 Suspension arms 19 Removal 19 Replacing suspension arm bushings 19 Di...

Page 694: ...RHAULING THE SUSPENSION 33 TIE RODS 33 Removal 33 Replacing swivel heads 33 Refitting 34 TORSION BARS 34 Removal 34 Replacing silentbloc and limit stops 35 Replacing link pins 35 Refitting 36 Adjusting torsion bar pre load 38 STABILIZER BAR 39 Page Removal 39 Refitting 39 FRONT SHOCK ABSORBERS 39 Removal 39 Refitting 39 TORSION BAR SUSPENSION Axle 5823 vehicles 60C 65C 41 Description 41 SPECIFICAT...

Page 695: ...rcement to the crosspiece and pins articulated to the stub axle The bottom suspension arms have reaction points for the leaf spring and the bottom mountings of the shock absorbers a single blade leaf spring made of composite material for axles 5817 mounted on vehicles 29 L and 35 S steel for axles 5818 mounted on vehicles 35 C the spring is kept inside the crosspiece by two top reaction plugs fitt...

Page 696: ... Transverse Nº 1 Transverse Nº 1 Spring length mm 1313 2 Sheet thickness measured at mm A 39 92 0 50 Sheet width measured at mm B 56 0 0 5 C 81 0 0 5 NEW LEAF SPRING CHECK DATA 29 L 35 S STATIC LOAD N 19865 21040 SAG WITH STATIC LOAD mm 71 7 68 4 DYNAMIC LOAD N 34270 37005 SAG WITH DYNAMIC LOAD mm 123 7 120 4 FLEXIBILITY 5 1 mm kN 277 307 0 DISTANCE BETWEEN SUPPORT PLUGS mm 540 600 ...

Page 697: ...06 Front leaf spring Models 35 C Transverse Nº 1 Spring length mm 1365 3 Sheet thickness mm 20 0 2 Sheet width mm 80 0 5 NEW LEAF SPRING CHECK DATA POSITION LOAD CAMBER FLEXIBILITY POSITION daN kg CAMBER mm mm 100 daN mm 100 kg STATIC LOAD 845 1 861 5 70 25 8 31 8 15 DYNAMIC LOAD 1453 3 1481 4 120 8 8 31 8 15 ...

Page 698: ...d mm 320 3 Stroke mm 85 Front stabilizer bar Models 35C 40C 45C 60C 65C 60C 65C dual cab Stabilizer bar diameter 24 22 except for dual cab TOOLS TOOL NO DESCRIPTION Hydraulic trolley for wheel removal and refitting 99321024 99347074 Extractor to take out link pins 99374179 Tool for disassembling and reassembling suspension arm flexible bushings The torsion bar is not provided for the COMBI version...

Page 699: ... securing shock absorber top and bottom 124 152 12 4 15 2 5 Screw for nut securing shock absorber mounting to bottom suspension arm 39 48 3 9 4 8 6 Nut securing bottom suspension arm ball joint to the stub axle 160 180 16 18 7 Nut securing steering gear housing tie rod ball joint to the stub axle 68 83 6 8 8 3 8 Screw securing wheel 180 200 18 20 9 Nut securing hub to stub axle 256 314 25 6 31 4 1...

Page 700: ...w for nut securing shock absorber mounting to bottom suspension arm 39 48 3 9 4 8 6 Nut securing bottom suspension arm ball joint to the stub axle 160 180 16 18 7 Nut securing steering gear housing tie rod ball joint to the stub axle 68 83 6 8 8 3 8 Nut securing wheel 180 200 18 20 9 Screw securing cover and brake disc to wheel hub 98 1 107 9 9 8 10 7 10 Screw retaining ring nut securing hub to st...

Page 701: ... 2 Screw for nut securing suspension arm to the top cross member and bottom to the cross member 170 280 17 28 3 Screw securing disc guard to the axle stub 6 7 5 0 6 0 7 4 Nut for screw securing cross member to chassis frame 83 101 8 3 10 1 5 Nut for screw securing cross member to chassis frame 83 101 8 4 10 1 6 Screw securing caliper mounting to the axle stub 170 196 17 0 19 6 7 M14 screw securing...

Page 702: ... of comparator 99395684 1 to brake disk 4 and position comparator tracer point on the top of the articulated head 2 of upper swinging arm 3 Pre load comparator by approximately 4 mm By suitable pliers 2 applied on articulated head 1 and on articulated spindle 4 apply strong pressure on head and spindle and check comparator 3 hand displacement corresponding to articulated head clearance If detected...

Page 703: ... have too much play replace the suspension arm 1 Take out the nut 6 and remove the shockabsorber 5 from the mounting 8 of the bottom suspension arm extracting the screw 7 Take out the nuts 2 extract the screws 3 and remove the bottom suspension arm 4 from the mountings of the cross member 1 500760 OVERHAULING THE SUSPEN SION Check the clearance of lower swinging arm articulated head 88692 Figure 1...

Page 704: ...refit the bottom 5 and top 1 suspension arms to the crosspiece 2 reverse the steps described for removal tightening the nuts 6 3 for the fixing screws 4 7 to the prescribed torque Self locking nuts once removed must be replaced with new ones 52326 Figure 18 Insert the bushing 2 into the suspension arm 1 Apply the parts 3 4 5 6 of the tool 99374179 as shown in the figure Screw on the nut 6 to make ...

Page 705: ...r nuts fixing the wheel Lift the front of the vehicle and rest the chassis frame on sup ports Take out the screws or nuts fixing the wheel and remove them with tool 99321024 Unscrew the top and bottom bolts 2 and remove the shock absorbers 1 from the vehicle Check the efficiency of the shock absorbers with a suitable instrument Refitting For refitting carry out the removal operations in re verse o...

Page 706: ...22 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 707: ...emoval Check the state of the brake linings and brake disc as described in the BRAKES section take out the nut locking the link pin of the tie rod 20 and with tool 99347074 19 remove the link pin 20 of the steering tie rod from the stub axle take out the nut 21 and with tool 99347074 19 remove the link pin 22 of the top suspension arm from the stub axle take out the nuts 16 and screws 18 securing ...

Page 708: ...ycomb of the bottom suspension arms 5 and 8 and the centre line of the leaf spring is aligned with the central holes della traversa 1 of the cross member 1 max error 2 mm then complete refitting by tightening the screws or nuts to the required torque position the bottom flexible plugs 6 on the cover 7 at the position found during disassembly mount the cover 7 and tighten the screws and nuts to the...

Page 709: ... same axle The purpose of the rubber pads fixed on the top mounting of the shock absorbers is to limit the upward movement of the suspension Axle 5819 vehicles 35C 40C 45C 50C Description The torsion bar suspension is composed of two bottom suspension arms two top suspension arms two longitudinal torsion bars two hydraulic shock absorbers two bottom reaction tie rods two top reaction tie rods a st...

Page 710: ...9 Top tie rod adjustment distance 378 0 15 mm Top tie rod adjustment distance 220 4 0 15 mm Bottom tie rod adjustment distance 364 5 0 15 mm Bottom tie rod adjustment distance 300 4 0 15 mm Front shock absorbers Models 35 C 40 C 45 C 50 C Mannesmann Sachs Arvin Meritor Distance between centre of eyes Open mm 430 3 444 3 mm Closed mm 280 3 286 3 mm Stroke mm 150 158 mm Stabilizer bar diameter Model...

Page 711: ...aulic trolley for wheel removal refitting 99321024 Extractor to take out tie rod link pins 99347060 Extractor to take out steering tie rod link pins and suspension arms 99347074 Wrench for ring nut securing link pins 99357144 Tool for disassembling and reassembling front suspension flexible bushings 99374241 ...

Page 712: ...28 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 713: ...11 25 9 31 7 10 Nut cross member to chassis side member lower wing fixing screw 72 88 7 3 9 11 Nut for steering box fixing screw 50 61 5 6 1 12 Nut lower arms to cross member anchoring screw 206 252 21 0 25 7 DESCRIPTION TORQUE DESCRIPTION Nm kgm 13 Ring nut ball joint to upper lower arms 83 152 8 5 15 5 14 Nut ball joint to steering knuckle 157 177 16 18 15 Nut fixing will 180 200 18 20 16 Nut fi...

Page 714: ...30 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 715: ...e not damaged Remove nut 5 and dismount shock absorber 1 fromlower swinging arm 2 Unloosen nut 4 for the screw to secure lower swinging arm 2 to cross member 3 Remove screw 3 and detach tie rod 2 from lower swinging arm 1 By suitable jack 2 positioned under wheel hub 1 load suspension Check the clearance of upper swinging arm articulated head Apply the magnetic base of comparator 99395684 1 to bra...

Page 716: ... pliers 2 applied on articulated head 3 and on lower swinging arm 1 apply strong pressure on head and arm and write down comparator 4 hand displacement corresponding to articulated head clearance If detected value is between 1 5 and 2 0 mm the swingingarm needs to be replaced as described in relating chapter Remount dismounted parts in order to make checks Check the clearance of lower swinging arm...

Page 717: ...this Take out the nut securing the link pin 5 to the mounting 7 Using the extractor 99347074 6 remove the swivel head 5 from the mounting 7 Remove the screw stay 1 from the vehicle Loosen the nut 2 and unscrew the swivel head 1 from the top tie rod 3 Screw the new swivel head 1 onto the tie rod 3 positioning it at the values shown in the figure Removal If removing the mounting 7 so as not to chang...

Page 718: ... 39 Remove the nut which fastens the articulated head 2 of the gearbox tie rod to the steering knuckle with the puller No 99347074 1 remove the articulated head 2 44935 Removal Remove the lower and upper tie rods as described in the relevant paragraph operation 500761 and go on as follows Figure 40 Loosen the nut 2 and unscrew the threaded pin 1 until the torsion bar 3 is fully unloaded Take out t...

Page 719: ...replaced with general tools 19045 Replacing silentbloc and limit stops 44673 1 2 3 4 5 6 44672 Take out the nut 5 remove the screw 4 and recover the two washers Disconnect the bottom suspension arm 3 from the cross member 1 extracting the bushing 2 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Using tool 99357151 1 loosen the ring nut and extract the link pin 2 from the suspension arm Replacin...

Page 720: ...52370 Figure 47 Figure 48 Figure 49 Figure 50 Position the top suspension arm 2 in the cross member Then insert the torsion bar 1 with the washer 3 in the cross member and in the suspension arm Refitting 44674 Figure 51 Place the washer 1 and screw the nut 2 without tightening it 19052 Position the bottom suspension arm in the cross member and insert the bushing 1 Insert the screw with its washers...

Page 721: ...bsorber Lubricate the grooved portion of the torsion bar 3 Assemble the torsion bar 3 and the support 1 so that the splines 2 of the toothed bush and of the torsion bar coincide Fix the support 1 to the chassis tightening the fastening screw nuts to the prescribed torque 74998 44675 44697 Figure 52 Figure 53 Figure 54 Figure 55 Connect the stub axle 3 to the link pins of the top 1 and bottom 4 sus...

Page 722: ...he same on both wheels Measure on both sides of the vehicle the distance from ground H of the side frame upper thread measured as near as possible the suspension connecting area The height H must correspond to the value given in the table below 20986 74999 Figure 57 Figure 58 38 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 Adjusting torsion bar pre load HEIGHT OFF GRO...

Page 723: ...evel ground Lock the rear wheels with scotches remove the wheel rim guards and loosen the screws or nuts fixing the wheel Lift the front of the vehicle and rest the chassis frame on supports Take out the screws or nuts fixing the wheel and remove them with tool 99321024 Unscrew the top and bottom bolts 2 then remove the shock absorbers 1 from the vehicle Refitting To fit it back on perform the ste...

Page 724: ...40 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 725: ... on the same axle The purpose of the rubber pads fixed on the top mounting of the shock absorbers is to limit the upward movement of the suspension Axle 5823 vehicles 60C 65C Description The torsion bar suspension is composed of two bottom suspension arms two top suspension arms two longitudinal torsion bars two hydraulic shock absorbers two bottom reaction tie rods two top reaction tie rods a sta...

Page 726: ...ottom tie rod adjustment distance 369 0 5 mm Bottom tie rod adjustment distance 300 4 0 5 mm Lower linkage adjustment for recently manufactured vehicles 363 5 0 5 mm Lower linkage adjustment for recently manufactured vehicles 299 mm 0 3 0 377 0 15 mm 219 0 15 mm Front shock absorbers Models 60 C 65 C Mannesmann Sachs ARVIN Distance between centre of eyes Open mm 430 3 400 3 Closed mm 280 3 280 3 S...

Page 727: ...cross member to chassis side member lower wing fixing screw 80 8 11 Nut for steering box fixing screw 50 61 5 1 6 2 12 Nut lower arms to cross member anchoring screw 206 252 21 0 25 7 DESCRIPTION TORQUE DESCRIPTION Nm kgm 13 Ring nut ball joint to upper lower arms 83 152 8 5 15 5 14 Nut ball joint to steering knuckle 157 177 16 18 15 Nut fixing will 284 5 343 3 28 4 34 3 16 Nut fixing steering box...

Page 728: ...44 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 729: ...N Hydraulic trolley for wheel removal and refitting 99321024 Tool for removing front suspension rubber bushes 99347027 Extractor to take out link pins 99347060 Extractor to take out link pins and suspension arms 99347074 Tool for link pins fixing screw 99357144 Tool for refitting front suspension rubber bushes 99374166 ...

Page 730: ...on it according to the values show in the above figure Remove the nut fastening the steering box tie rod kingpin 4 from stub axle lever use puller 99347074 2 to remove the kingpin 4 Remove suspension lever 1 upper tie rod 3 Loosen the nut 3 and loosen the threaded pin 2 until the torsion bar 1 is completely released 500764 Lower tie rod articulated heads replacement 500666 TORSION BARS Removal It ...

Page 731: ... Figure 68 Figure 69 Figure 70 Figure 71 Position rubber bushes 2 5 in cross member 1 Apply tool 99374166 4 to bushes 2 5 as shown in the figure Hold the screw 6 and tighten the nut 3 until fitting in place the rubber bushes 2 5 Apply tool 99347027 5 as shown in the figure Hold the screw 6 tighten the nut 4 and remove the rubber bushes 3 and 7 from the cross member 1 Rubber bush replacement Remova...

Page 732: ...uding the washer 4 and the circlip 3 Figure 72 Figure 73 Figure 74 Figure 75 Fit the sleeve 3 on the torsion bar 1 and in the adjustment lever 2 so that the marks on these components coincide as shown in the following figure Set the washer 1 and screw the nut 2 without locking it The rear part of the torsion bars is marked with AD AS to identify respectively the right bar and the left bar 44674 Fi...

Page 733: ...ark on sleeve 3 D Reference mark on torsion bar 4 E Reference mark on left torsion bar F Reference mark on right torsion bar After refitting torsion bar 4 sleeve 3 adjustment lever 2 secure the sleeve 3 to the bracket with the circlip 6 Refit the fuel tank if removed AD Right torsion bar AS Left torsion bar FRONT MECHANICAL SUSPENSIONS 49 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 734: ... tie rods to the relevant levers Adjust torsion bar preload as described in the following paragraph Figure 79 Figure 80 Figure 81 If a different value is found operate on the adjustment screw 1 as required taking into account that before performing this operation the vehicle shall always be lifted from ground with hydraulic jack to prevent screw damaging Once proper vehicle setup is obtained lock ...

Page 735: ...TORQUES 73 Vehicles 29 L 35 S 73 Vehicles 35 C 40 C 45 C 50 C 74 Vehicles 60 C 65 C 75 REAR LEAF SPRING 76 Vehicles 29 L 35 S 76 Removal 76 Refitting 76 Vehicles 35 C 40 C 45 C 50 C 60 C 65 C 77 Removal 77 Refitting 77 REPAIRS 78 Disassembling the leaf spring 78 Checks 78 Assembling the leaf spring 78 Replacing the bushings 78 REAR SHOCK ABSORBERS 79 Removal 79 Refitting 79 STABILIZER BAR 80 Remov...

Page 736: ...52 REAR MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 737: ...eaf spring The parabolic leaf spring is formed by leaves which have a greater thickness in the middle than at the two ends Leaves are spaced by means of shims and this reduces much of the internal friction The low internal friction and the particular form of the leaves make the parabolic leaf spring more soft this makes driving easier Hydraulic double acting telescopic shock absorbers hinder the w...

Page 738: ...ic springs No 2 L Spring length measured at eye centres 1500 3 S Leaf thickness measured at centre 24 22 S Gap between leaves L Leaf width 80 0 5 CONTROL DATA WITH NEW SPRING Spring flexibility with static load 8 6 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 Alternatively ...

Page 739: ... Spring length measured at eye centres 1415 3 S Leaf thickness measured at centre Leaf thickness measured at centre S Gap between leaves 15 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Spring flexibility with static load 6 4 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 D d d bush inner diameter 16 5 0 2 0 ...

Page 740: ...red at eye centres 1415 3 S Leaf thickness measured at centre 19 S Gap between leaves 3 1 x 3 1 x 25 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Spring flexibility with static load 10 5 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 For versions with maximum front load 1900 kg ...

Page 741: ...springs No 2 L Spring length measured at eye centres 1415 3 S Leaf thickness measured at centre 22 S Gap between leaves 3 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load 7 6 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 742: ...at eye centres 1415 3 S Leaf thickness measured at the centre thickness of the auxiliary leaf measured at the centre 18 18 S Gap between leaves 3 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load 7 6 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 743: ...L Spring length measured at eye centres 1415 3 S Leaf thickness measured at centre 22 23 S Gap between leaves 3 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Spring flexibility with static load 6 9 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 Alternatively ...

Page 744: ...es 1415 3 S Leaf thickness measured at centre 19 S Gap between leaves 3 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring deflection with static load Auxiliary spring deflection with static load Main spring flexibility with static load 5 6 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 745: ...aves measured at the centre thickness of the auxiliary leaf measured at the centre 18 19 28 S Gap between leaves 3 L Leaf width 70 0 5 CONTROL DATA WITH NEW SPRING Main spring deflection with static load Flexibility with static load after aux spring action 9 3 mm kN 3 4 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 0 2 D d D bush outer diameter 40 0 02 0 07 d bush inner diameter 16 5 0 2 0...

Page 746: ...4 S Leaf thickness measured at the centre main leaf 1st 4th auxiliary leaf 1st 2nd 9 15 S Gap between leaves L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 20 2 mm kN 10 4 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 747: ...15 4 S Leaf thickness measured at the centre main leaf 1st 4th auxiliary leaf 1st 3rd 9 15 S Gap between leaves L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 19 7 mm kN 6 4 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 748: ...entre of eyes 1415 4 S Leaf thickness measured at the centre master leaf 1st 7th additional leaf 1st 6th 9 8 S Gap between leaves 7 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 15 mm kN 3 6 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 1...

Page 749: ... S Leaf thickness measured at the centre master leaf 1st 4th additional leaf 5th 7th 9 15 S Gap between leaves L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 19 7 mm kN 5 8 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 750: ...tre of eyes 1415 4 S Leaf thickness measured at the centre master leaf 1st 7th additional leaf 1st 6th 9 8 S Gap between leaves 10 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 14 5 mm kN 3 4 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter ...

Page 751: ...S Leaf thickness measured at the centre master leaf 1st 4th additional leaf 1st 3th 9 16 S Gap between leaves 10 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 19 7 mm kN 4 9 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 ...

Page 752: ...gth measured at eye centres 1415 3 S Leaf thickness measured at the centre master leaf 22 24 S Gap between leaves 3 10 L Leaf width 60 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load 5 6 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 D d D bush outer diameter 40 0 0 1 d bush inner diameter 16 5 0 2 0 Alternatively ...

Page 753: ...S Leaf thickness measured at the centre master leaf 1st 4th additional leaf 1st 2nd 11 22 S Gap between leaves L Leaf width 70 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 9 3 mm kN 3 1 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 0 2 D d D bush outer diameter 40 0 02 0 07 d bush inner diameter 16 5 0 2 0 ...

Page 754: ...15 S Leaf thickness measured at the centre master leaf 1st 10th auxiliary leaf thickness 1st 10th 9 7 S Gap between leaves 9 L Leaf width 70 0 5 CONTROL DATA WITH NEW SPRING Main spring flexibility with static load Flexibility with static load after aux spring action 8 5 mm kN 2 4 mm kN D Main leaf eye inner diameter Bush seat 40 0 5 0 2 D d D bush outer diameter 40 0 02 0 07 d bush inner diameter...

Page 755: ... 50 C Arvin Meritor Sachs Distance between centre of eyes Open 571 3 mm 565 3 mm Closed 350 3 mm 345 3 mm Stroke 221 mm 220 mm Models 60 C 65 C Arvin Meritor Sachs Distance between centre of eyes Open 564 3 mm 565 3 mm Closed 347 3 mm 345 3 mm Stroke 217 mm 220 mm Rear stabilizer bar Models 29 L 35 S 35 C 40 C 45 C 50 C Vans 45 C 50 C Truck Chassis Cabs 60 C 65 C Stabilizer bar diameter mm 20 20 2...

Page 756: ...h 2006 Print 603 93 651 TOOLS TOOL NO DESCRIPTION 99306064 Hydraulic trolley to support leaf spring during removal and refitting 99321024 Hydraulic trolley for wheel removal and refitting 99370617 Bracket for removal refitting and or support of rear axle ...

Page 757: ...ng shock absorber to chassis 124 152 12 4 15 2 4 M16 nut securing shock absorber to rear axle 124 152 12 4 15 2 5 M14 nuts for U bolts securing leaf spring to rear axle 118 144 11 8 14 4 6 M10 nut securing spring buffer support bracket 47 58 4 7 5 8 7 Securing articulated connecting rod to upper bracket M16x2 screw 137 167 13 7 16 7 M16x2 nut 124 152 12 4 15 2 8 M10x1 5 nut securing bracket for st...

Page 758: ...uring top and bottom shock absorber 124 152 12 4 15 2 4 M10 nut for screw securing stabilizer bar support cap 26 4 35 3 2 6 3 5 5 M10 nut for screw joining stabilizer bar anchoring connecting rods 26 4 35 3 2 6 3 5 6 M16 screw for nut securing connecting rod to mounting 179 4 220 6 17 9 22 7 M16 screw for nut securing rear leaf spring 139 170 13 9 17 8 M16 screw for nut securing shackle to rear mo...

Page 759: ...ng leaf spring to rear axle 150 190 15 3 19 3 4 Nut for screw fastening brackets and spacers to stabilizer bar supporting rod 5 Screw for rear leaf spring fastening nut 186 152 18 6 15 2 6 Screw for nut fastening connecting rods to support 186 152 18 6 15 2 7 Nut for screw fastening stabilizer bar spacer and rod to support 109 9 137 7 11 2 14 8 M10 screw for nut fastening support to chassis 26 4 3...

Page 760: ...ring 2 to the shackle 8 of the rear mounting 9 Lower the trolley 99306064 and extract the leaf spring Figure 86 REAR SUSPENSION WITH SINGLE BLADE PARABOLIC LEAF SPRING Check the threads of brackets which fasten the leaf springs to the axle if they are damaged re machine the threads operation 500412 or replace the brackets Tighten the nuts to the prescribed driving torque Following the order shown ...

Page 761: ... axle to be able to remove the centring setscrew of the leaf spring from it and extract the leaf spring When lowering the rear axle make sure the brake system pipes are not put under strain Figure 87 REAR SUSPENSION WITH SEMI ELLIPTICAL LEAF SPRING Check the threads of brackets which fasten the leaf springs to the axle if they are damaged re machine the threads operation 500412 or replace the brac...

Page 762: ...ivets Place the leaf spring in the vice of the suitable bench clamping it near the central pin remove the relevant nut and extract the central coupling pin Unscrew the fastening nut 2 of the central pin 7 and extract the pin Open the pack side clips 5 lifting the two ends that are bent on the main leaf Open the vice and disassemble the leaf spring Disassembling the leaf spring 19075 Figure 88 Leaf...

Page 763: ...AR AXLE SHOCK ABSORBERS VEHICLES 29 L 35 S Figure 90 REAR AXLE SHOCK ABSORBERS VEHICLES 35 C 65 C Figure 91 50977 Remove the shock absorber 1 extracting the upper and lower fastening nuts or bolts of the shock absorber 112214 REAR MECHANICAL SUSPENSIONS 79 DAILY EURO 4 Print 603 93 651 Base March 2006 500940 REAR SHOCK ABSORBERS ...

Page 764: ...ibed torques Removal REAR STABILIZER BAR VEHICLES 29 L 35 S Figure 92 REAR STABILIZER BAR VEHICLES 35 C 65 C Figure 93 50978 Remove stabilizer bar 3 from its attachment points by removing nuts 4 and screws 1 together with the fastening nuts then release the bar from articulated rod 2 112215 NOTE 80 REAR MECHANICAL SUSPENSIONS DAILY EURO 4 Base March 2006 Print 603 93 651 528960 STABILIZER BAR ...

Page 765: ...nd height values 86 ELECTRIC SYSTEM WABCO ECAS 87 PNEUMATIC SYSTEM WABCO ECAS 88 PNEUMATIC SYSTEM ON VEHICLE 89 Vehicles without ABS 89 Vehicles with ABS 90 CHASSIS SELF LEVELLING LIFTING AND LOWERING 91 Operation 91 MAIN SYSTEM COMPONENTS 91 PNEUMATIC SUPPLY UNIT 91 Specifications and data 91 ELECTRONIC CONTROL UNIT 91 ECU programming setting 92 LEVEL SENSOR 92 Level sensor replacement 92 Removal...

Page 766: ...ensing valve replacement 94 Removal 94 Refitting 94 Load sensing valve adjustment on vehicle 94 REAR SUSPENSION OVERHAUL 95 LEAF SPRING 95 Removal 95 Refitting 95 REAR SHOCK ABSORBERS 95 Removal 95 Refitting 95 REAR STABILIZER BAR 95 Removal 95 Refitting 95 PANHARD REACTION BAR 96 Removal 96 Refitting 96 ...

Page 767: ...2 Vehicle irregular conditions 2 YES NO Pneumatic system pipe leaks or breakage Tighten or replace loosen or damaged connections Replace broken or damaged pipes Faulty pneumatic and or electric connections Find and reset faulty connections YES Level sensor malfunctioning Adjust levers and replace level sensor if required NO YES ECU malfunctioning Replace ECU NO VEHICLE IRREGULAR CONDITIONS YES YES...

Page 768: ...S WABCO TYPE for 29L 35S vehicles WABCO system in addition to known advantages offered by pneumatic suspension enables the following significant air consumption reduction ready response to the different adjustment processes friendly systems high safety performance complete system diagnostic The WABCO system controls automatically the rated level of vehicle pneumatic suspensions The above mentioned...

Page 769: ...essure control 30ºC to 65ºC 12 7 bar 12V DC 14 to 17 1 bar Level sensors Type WABCO 441 050 012 0 ECU Type WABCO 446 055 450 0 Rated voltage 12V Double circuit load sensing valve vehicles without ABS Type BOSCH NM FV 98 347 ref 796803 Ratio 0 15 Pneumatic actuator Type ELLENA EE6492 Operating temperature Operating pressure 20ºC to 80ºC max 8 bar Air tank litres 31 Rear air spring Mod 29 L 35 S Max...

Page 770: ...meter 40 0 05 0 2 D bush outer diameter 40 2 0 0 15 d bush inner diameter 16 5 0 2 0 Rear shock absorbers Mannesmann Sachs ARVIN MERITOR Length between eye centres Open mm 460 3 460 3 480 3 Closed mm 315 3 315 3 315 3 Stroke mm 145 145 165 Stabilizer bar Models 29 L 35 S Stabilizer bar diameter mm 20 Levelling and height values Suspension condition Distance between upper chassis edge and road leve...

Page 771: ...ure switch 52090 Suspension levelling switch 52502 Key switch 53051 Suspension lifting control switch 53052 Suspension lowering control switch 58713 Failure warning led 58918 Board with 32 optical indications plus instruments 78233 Vehicle lifting solenoid valve unit 86023 Vehicle lifting lowering control unit Legend 61099 REAR AIR SUSPENSIONS 87 DAILY EURO 4 Print 603 93 651 Base March 2006 ELECT...

Page 772: ...sensor 13 Left air spring 14 Electrocompressor and distribution valve unit 15 Right chassis control solenoid valve 16 Left chassis control solenoid valve 17 Choke valve 18 Drier filter 19 Air spring discharge solenoid valve 20 One way valve 21 Compressor 22 One way valve 23 Intake filter 24 Compressor motor 25 Motor control relay 26 Diagnosis socket For vehicles without ABS only Legend 000216T Ele...

Page 773: ...ontrol unit 7 Chassis lifting control button 8 Hydraulic brake corrector 9 Corrector control pneumatic cylinder 10 Left air spring 11 Pneumatic feeding unit 12 Left level sensor 13 Central diagnosis connector Legend 112174 REAR AIR SUSPENSIONS 89 DAILY EURO 4 Print 603 93 651 Base March 2006 Print 603 93 281 PNEUMATIC SYSTEM ON VEHICLE Vehicles without ABS ...

Page 774: ...n 5 Manual chassis levelling control button 6 Electronic control unit 7 Chassis lifting control button 8 Left air spring 9 Pneumatic feeding unit 10 Left level sensor 11 Central diagnosis connector Legend 112175 90 REAR AIR SUSPENSIONS DAILY EURO 4 Print 603 93 651 Base March 2006 Vehicles with ABS ...

Page 775: ...uired to supply the pneumatic system and enables to bleed air from the pneumatic system to lower the load bed 62357 The ECU is the mastermind of the system It controls every logic function of suspensions under both static and dynamic stage ECU receives signals from the control switches set in the cab and lifts and lowers the load bed accordingly It also receives signals from the level sensors and ...

Page 776: ...ting Insert the special spacers provided 99346151 between the chassis and the rear axle measuring 65 mm lower the chassis completely by depressing the proper video push button max lowering set ECU by depressing the proper video push button 62358 Level sensors inform constantly the ECU on distance changes between chassis and road level Level sensors consists of a coil secured to the chassis and a s...

Page 777: ...nge its extension irrespectively of the applied load 62360 Position the vehicle on level ground Lift the rear part of the vehicle and rest the chassis on the proper stands Use the hydraulic jack to support the rear axle Bleed the system and disconnect the air spring 3 supply pipe 2 Loosen upper 1 and lower fastening nuts Lower the rear axle and remove the air spring 3 Air spring replacement Remova...

Page 778: ...the screws 3 and disconnect the pneumatic actuator 2 Loosen the fastening screws of the load sensing valve 1 and remove it including the pneumatic actuator 2 Load sensing valve replacement Removal Figure 111 Figure 112 Refitting Reverse removal operations to perform refitting Perform load sensing valve adjustment as shown in the relevant paragraphs Load sensing valve adjustment on vehicle 62433 Lo...

Page 779: ...gure 114 Figure 115 62363 500450 LEAF SPRING Removal 500940 REAR SHOCK ABSORBERS Removal Lift the rear part of the vehicle and use the jack to support the rear axle Loosen the upper 3 and the lower 1 fastening nuts and remove the shock absorber 2 Refitting Reverse removal operations to perform refitting Refitting Reverse removal operations to perform refitting Refitting Reverse removal operations ...

Page 780: ...ng Reverse removal operations to perform refitting Loosen the Panhard reaction bar 4 fastening screws 3 and 5 and remove it Loosen the relay rod 2 fastening screws 1 and 6 and remove it 96 REAR AIR SUSPENSIONS DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 781: ...Y EURO 4 Print 603 93 651 Base March 2006 SECTION 9 5025 Wheel and tyres Page DESCRIPTION 3 Tyre pressure 4 TOOLS 5 FAULT DIAGNOSIS 5 STATIC BALANCING OF THE WHEELS 8 TYRE PRESSURE 9 HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE 9 ...

Page 782: ...2 WHEEL AND TYRES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 783: ... life to withstand the forces generated by sudden braking hard acceleration and by the thrust of centrifugal force on bends to ensure the stability of the vehicle even at high speeds to ensure the steerability of the vehicle 44928 Figure 1 1 Tyre section rated width mm 2 Tyre height width ratio percentage e g H S 0 75 3 Tyre structure R Radial 4 Wheel rim diameter in inches 5 Load and speed index ...

Page 784: ...ple weight on front axle in kg 1527 1700 1950 TL105 107T twin weight on front axle in kg 2898 3225 3700 215 65 R16 simple weight on front axle in kg 1613 1795 2060 TL107 109R twin weight on front axle in kg 3055 3399 3900 225 65 R16 simple weight on front axle in kg 1754 1952 2240 TL110 112R twin weight on front axle in kg 3321 3695 4240 Tyre type Inflation pressure Tyre type 4 bar 4 5 bar 5 25 ba...

Page 785: ...ear 2 Irregular wear 3 Wehicle pulls to one side 1 Excessive speed on particularly uneven ground Tyres pressures too high Reduce pressures Sudden variations in speed violent or harsh braking Avoid all unnecessary acceleration or braking Excessive speed with tyre pressures too low Check tyre pressures cold Truck overloaded Consult data on loads permitted NO NO YES NO YES NO YES YES YES Reduce speed...

Page 786: ...essure too high with excessive wear in the middle of the tread Reduce pressure NO YES Insufficient toe in of front wheels substantial wear on the inside surfaces of the tread Check and adjust toe in NO YES Front wheel geometry incorrect Restore normal wheel geometry NO YES Distortion of wheel rims causing imbalance If possible repair the rims or replace then balance the wheels Tyres incorrectly fi...

Page 787: ...uspension YES 3 VEHICLE PULLS TO ONE SIDE Front wheels out of balance Balance the wheels NO YES Front tyres at different pressures Check pressures ensuring that both are at the correct value NO YES Excessive difference in wear between a pair of tyres Replace excessively worn tyre YES Excessive toe in of front wheels excessive wear of the outside surfaces of the tread Check and adjust toe in NO YES...

Page 788: ...g the height so that the spin up wheel of unit 99305037 2 is in contact with the tyre position a support stand under the opposite side of the axle and lower the hydraulic jack 16998 Figure 3 Figure 4 23885 Figure 5 Connect the cable 3 of the imbalance detector to unit 99305037 Make a reference mark on the tyre by drawing a radial mark with chalk or using a strip of gummed paper Turn switch 2 to th...

Page 789: ...igher than required a harsh ride and excessive wear of the centre of the tread will result while if it is lower the load is not distributed over the whole tread but is concentrated at either side causing premature wear of these areas and also damaging the internal structure of the tyre Unequal pressures between tyres affects the driving stability of the vehicle and impairs operating safety Tyre ab...

Page 790: ...10 WHEEL AND TYRES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 791: ...CKS AND OPERATIONS ON THE VEHICLE 16 Checking maximum pressure 16 Checking hydraulic steering centre for ZF power steering only 16 Bleeding the air from the hydraulic system 16 SWIVEL HEADS 16 PROTECTION CASINGS 16 STEERING GEAR CONTROL 16 Vehicles equipped with an Air Bag 16 SAFETY STANDARDS TO BE OBSERVED DURING REPAIR OR MAINTENANCE OPE RATIONS ON VEHICLES EQUIPPED WITH AIR BAG SYSTEM PROVIDED ...

Page 792: ...oner from vehicle 20 Removing and scrapping non activated Air Bag module from a repairable vehicle 20 Air Bag module deployment Remote activation 21 Activating Air Bag modules and electronic pretensioners installed on unrecoverable vehicles 21 Upper steering gear shaft removal 23 For vehicles equipped with Air Bag 23 For all vehicles 23 Refitting 24 Lower steering gear shaft removal 24 Refitting 2...

Page 793: ...tor support on F1C engines it is flanged onthe leftside ofthe enginebase The pump incorporates the overpressure control valve STEERING GEAR General Generally the steering gear members consist of a full steering gear control a steering box the linkage joining the driving wheels and for the hydraulic type steering box of an hydraulic pump an oil tank and oil piping In vehicle system 35C 65C with F1C...

Page 794: ...er steering pump blade type with pressure relief valve incorporated Motor FIA FIC Type ZF 7612 955117 ZF 7682 955133 Minimum RGM rpm 500 750 Maximum RGM rpm 8500 3500 Maximum pressure bar 100 10 115 10 Minimum delivery dm3 min Adjusted delivery dm3 min 9 0 75 9 0 8 Turning circle theoretical value m Wheelbase mm MODELS 29 L 35 S 35 C 1 35 C 2 40 C 45 C 50 C 60 C 65 C Tyres 205 225 70 R 15 195 65 R...

Page 795: ...NG TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Screw steering box fastening nut 50 61 5 6 1 2 Nut securing the jointed head to the steering box rod 70 100 7 10 3 Nut ball joint to steering arm 68 83 6 8 8 3 SPECIFIC TOOLS TOOL NO DESCRIPTION 99347074 Knuckle pivot extractor ...

Page 796: ...ir in hydraulic circuit Check suction tube and pump shaft seal for leaks Bleed system and top up the oil Pump regulating valve jammed or blocked Replace the power steering pump Insufficient oil pump delivery Overhaul or replace pump Universal joint not serviceable Make joint free to slide by moving it to and fro several times so that it tilts under its own weight 6 Excessive play at the steering w...

Page 797: ... YES 3 STEERING STIFF WHEN THE WHEEL IS TURNED QUICKLY Regulating valve in pump blocked Replace the power steering pump Insufficient pump delivery gears worn Replace the hydraulic pump Air in steering system YES Insufficient oil in system Top up oil and bleed system 4 YES NO YES NO WHEN STEERING HEAVY JOLTS ARE FELT AT THE WHEEL Play in universal joint Fit a new seal Replace the power steering uni...

Page 798: ...rom hydraulic power steering circuit couplings Check coupling seals for serviceability replacing any which are worn Adjust in accordance with characteristic data for described in the section Axles Wrong wheel toe in 5 YES NO YES TORSIONAL VIBRATION OF THE STEERING WHEEL YES NO Wheels out of balance Balance in accordance with instructions given in the section Wheels and tyres Air in hydraulic syste...

Page 799: ... necessary to determine the place and the reason why there is oil leakage eliminate the cause top up oil in the tank with the engine started up to the upper mark of the dipstick 7 YES NO YES LOSS OF OIL Tank cover not secured Secure cover Seal gaskets worn Replace worn seal gaskets top up oil and bleed YES 8 INSUFFICIENT PRESSURE IN THE CIRCUIT Hydraulic pump not operating correctly Replace the po...

Page 800: ...Top up level and bleed circuit 9 THE VEHICLE TENDS TO MOVE SIDEWARDS Replace the power steering unit Check the windings and in case replace oil pressure sender Oil pressure sender malfunction 10 YES NO HYDRAULIC POWER STEERING PILOT LIGHT ALWAYS LIGHTED YES Hydraulic power steering oil level low Top up oil 10 STEERING GEAR DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 801: ...The oil come to the steering box which is similar to a mechanical steering as for general building features from the pump In fact its operation is mechanical for pinion to rack coupling The rack rod is joined to the wheels with two side tie rods The system is self bleeding bleeding is performed by completely steering to the right or to the left with the engine started and the vehicle stopped The o...

Page 802: ...ting valve are joined depending on the rotary direction of the steering wheel If the amount of torque applied to the steering wheel does not cause the wrench of the bar low wheel resistance the power steering does not intervene and the steering operates as a mechanical one 24105 24106 Figure 4 Figure 5 The oil coming from the pump through the joint 3 goes into the distributing valve circulates in ...

Page 803: ...ugh the joint 4 into the tank passing again in the distributing valve The movement of the piston in the direction of the arrow shows a right steering The drive shaft A rotating clockwise with respect to the distributing valve B drives the oil under pressure coming from the pump through the ports C to the left chamber along the ports E and joins the discharge and the right chamber circuit by means ...

Page 804: ...OWER STEERING OPERATION DIAGRAM NEUTRAL POSITION HYDRAULIC POWER STEERING OPERATION DIAGRAM LEFT STEERING 24107 19594 Figure 7 Figure 8 POWER STEERING TYPE ZF Operation With the steering wheel positioned to straight running the bush 2 is arranged so that the passage of both feeding and discharge oil of the operating cylinder is closed The oil pressures in the right and left chamber of the operatin...

Page 805: ...nds it to the relevant feeding piping depending on the steering direction of the operating cylinder chambers Meanwhile the oil contained in the chamber opposite to the fed one returns in the distributor From the latter one it flows in the discharge grooves of the bush 2 then through the piping 6 returns in the tank 3 In this way the hydraulic interlocking is obtained 19595 19596 Figure 9 Figure 10...

Page 806: ...ND OPERATIONS ON THE VEHICLE Checking maximum pressure 520636 SWIVEL HEADS 501438 PROTECTION CASINGS Check that the protection casings of the knuckle heads are in perfect condition and that their pivots do not present play otherwise replace them as described below Loosen the nut 3 securing the knuckle head 2 to the tie rod 4 Remove the nut fixing the knuckle head to the steering gear lever and usi...

Page 807: ...mn support electronic control unit anchoring area and modules coil cable dashboard in the area of the passenger Air Bag If any faulty condition is found replace the faulty component Accidents with Air Bag module activation In case of front impact with total system activation the following components must be replaced Air Bag modules pretensioners electronic control unit coil cable STEERING GEAR 17 ...

Page 808: ...of the above cases Safety Standards to observe when handling Air Bag modules Driver and passenger Air Bags usually activate in case of collision through the action of the electronic activation control Gas mainly nitrogen produced under these conditions are not toxic Personnel operating on safety system shall strictly observe the following safety standards Personnel operating on these devices shall...

Page 809: ...damaged during disposal Safety Standards to observe when handling pretensioners In case of front impact driver and passenger pretensioners usually activate just a minute before Air Bag modules Personnel operating on these devices shall be suitably trained and must observe the following precautions when handling activated pretensioners i e with activated propelling gas wear protective gloves and go...

Page 810: ...he proper sealed nylon bag send to authorised collection disposal centre dispose of recycle or scrap deployed Air Bag module and pretensioner using the suitable procedure After any impact involving pretensioner activation the seat belt is unserviceable and must be replaced Propelling gas residues shall be considered with attention These residues that are mostly concentrated on the generator body o...

Page 811: ...ng Air Bag modules and electronic pretensioners installed on unrecoverable vehicles This procedure is to be used when scrapping a vehicle with one or more live Air Bag modules This procedure is valid whether Air Bag system and or electronic pretensioners are sound or not It is recommended to activate pyrotechnic charges on vehicles by directly connecting the electric connector of each module to re...

Page 812: ...the pretensioner or Air Bag module to the connecting braid of the remote activation device connect connector C2 to remote activation device place people in a safe place connect the remote control device to a 12 Volts circuit or equivalent device press the double activation push button to activate all pretensioners and Air Bag modules at the same time after activating the Air Bag modules and preten...

Page 813: ...g wheel 3 Set front wheels in straight running and mark steering wheel assembly position 1 on upper steering gear shaft 2 Remove the steering wheel 1 from the shaft 2 For vehicles with Air Bag make sure not to extract or damage coil device cable 3 After removal non activated Air Bag modules must be stored with plate laying on the surface in a suitable key locked cabinet For all vehicles Remove fix...

Page 814: ...pper steering gear shaft as described in the relevant chapter operation 541415 Lift cover 1 from floor Unscrew the three fixing screws 2 of lower shaft 3 support 4 Make sure that steering wheel removal has lifted the top cap of the coil device If the top cap turns it will be necessary to block it by bringing it to the outside If you hear a click it means that the cap is blocked For any removals of...

Page 815: ...teering 3 For refitting reverse removal operations and observe the following recommendations after refitting the hydraulic power steering to the front cross member or to the driving axle turn the pinion up to bring the rack to the end of the stroke Turn again the pinion to the opposite direction for a number of turns equal to half of the turns required to the rack to complete the whole stroke appr...

Page 816: ...e observe the following precautions replace o rings 1 and clamps 2 and 4 with new parts lubricate protective boot 3 seats on power steering unit 10 to facilitate assembly of the boots tighten steering linkage joints 5 at 100 10 Nm 10 1 kgm POWER STEERING SYSTEM SPARE PARTS 1 O ring 2 Clamp 3 Protective boot 4 Clamp 5 Steering linkage 6 Nut 7 Head 8 Tube 9 Tube 10 Power steering unit 11 Rubber bush...

Page 817: ...o that of 8140 engines F1C engine power steering pump Power steering pump overhaul procedure Replace the power steering pump if poor operation is found F1A engine power steering pump 86013 Figure 27 501450 POWER STEERING PUMP STEERING GEAR 27 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 818: ...28 STEERING GEAR DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 819: ...INDERS 14 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS SEMI COUPLINGS AND COUPLING HEADS 15 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS INDICATORS AND SWITCHES 17 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS BRAKES 19 PIPES AND COUPLINGS 19 General 19 Re flanging rigid pipes 19 Bending rigid pipes 20 Cutting rigid pipes 20 Replacing flexible hoses with threa...

Page 820: ...ydraulic circuit vehicles not equipped with ABS 56 Bleeding air from the hydraulic circuit with deaerator device vehicles not equipped with ABS 56 Page Air bleeding from the ABS ESP system hydraulic circuit 57 ABS 8 ESP 8 system bleeding procedure sequence 58 Mechanically controlled load sensing valve vehicles 35C 59 Regulation of load proportioning valve on vehicle 59 Dual mechanically controlled...

Page 821: ...OF BRAKE CALIPERS 70 2x44 2x48 2x60 Brembo brake calipers 70 1x52 1x60 Brembo brake calipers 71 OVERHAUL OF BRAKE DISCS 72 MACHINING AND GRINDING OF DISC BRAKES 72 OVERHAULING PARKING BRAKE 73 WHEEL NUT TIGHTENING SEQUENCE 73 Assembly 75 Adjusting parking brake 75 STEERING ANGLE SENSOR 76 Page Replacing 76 REPLACING THE ESP COMPONENTS 76 Calibration 76 LONGITUDINAL ACCELERATION SENSOR 77 Removal 7...

Page 822: ...4 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 823: ... SYSTEM CIRCUIT DIAGRAMS MISCELLANEOUS AND GENERATORS DESCRIPTION SYMBOL HYDRAULIC FLOW AIR FLOW ELECTRICAL LINE ABLE TO ROTATE CROSSOVER OF CONNECTED LINES PRESSURE TEST POINT QUICK RELEASE COUPLING COCK COCK WITH OUTLET 1 2 SILENCER COMPRESSOR 0 2 ENERGY SAVING COMPRESSOR 0 2 4 VACUUM PUMP 3 2 HYDRAULIC PUMP 0 2 HYDRAULIC HAND PUMP ...

Page 824: ...IFIER 1 2 DEHUMIDIFIER 21 1 22 4 DEHUMIDIFIER WITH BUILT IN REGULATOR 21 1 22 23 AUTOMATIC CONDENSATION DRAIN VALVE CONTROLLED CONDENSATION DRAIN VALVE HAND CONDENSATE DRAIN VALVE CONTROLLED ANTI ICING UNIT 1 2 7 AUTOMATIC ANTI ICING UNIT 1 2 PRESSURE REGULATOR WITH INDEPENDENT CIRCUIT 21 22 1 23 24 PRESSURE CONTROLLER 21 1 PRESSURE CONTROLLER 21 1 23 PRESSURE CONTROLLER GOVERNOR 2 1 PRESSURE LIMI...

Page 825: ... VALVE 2 1 MATCHING VALVE 2 1 FOUR CIRCUIT PROTECTION VALVE 21 22 1 23 24 THREE CIRCUIT PROTECTION VALVE 21 22 1 23 TWO CIRCUIT PROTECTION VALVE 21 22 1 NON RETURN AIR INLET VALVE 2 1 NON RETURN AIR INLET VALVE 2 1 SAFETY VALVE CHECK VALVE 2 1 CHECK VALVE 2 2 1 DOUBLE SHUT OFF VALVE 11 12 2 DIFFERENTIAL DOUBLE SHUT OFF VALVE M S U THROTTLE VALVE WITH QUICK RETURN 1 2 THROTTLE VALVE CONTROL VALVE 2...

Page 826: ...UIT DIAGRAMS VALVES DESCRIPTION SYMBOL DUMP VALVE 2 1 BRAKE CONTROL VALVE 21 11 22 12 P A BRAKE CONTROL VALVE 21 11 BRAKE CONTROL VALVE 21 11 4 22 12 PARKING BRAKE CONTROL VALVE 22 11 21 PARKING BRAKE CONTROL VALVE 2 1 BRAKE VALVE 2 1 CONTROL VALVE 2 1 CONTROL VALVE 22 1 21 RETARDER CONTROL VALVE 23 13 R SERVO CONTROL VALVE 2 1 4 ...

Page 827: ...NTROL VALVE FOR SINGLE LINE 2 1 4 TRAILER BREAKING TRIPLE CONTROL VALVE 2 1 42 41 43 TRAILER BREAKING TRIPLE CONTROL VALVE WITH BUILT IN SERVO SWITCHING 22 11 42 41 43 12 LOAD PROPORTIONING VALVE 2 1 DUAL LOAD PROPORTIONING VALVE 21 11 22 12 LOAD PROPORTIONING VALVE WITH BY PASS 21 12 11 LOAD PROPORTIONING VALVE WITH BUILT IN RELAY 2 1 4 LOAD PROPORTIONING VALVE WITH BUILT IN RELAY WITH AIR CONTRO...

Page 828: ...N SYMBOL LOAD PROPORTIONING VALVE WITH AIR CONTROL 42 41 1 2 LOAD PROPORTIONING VALVE WITH AIR CONTROL 1 4 2 PROPORTIONAL REDUCING VALVE 1 2 SLAVED PROPORTIONAL REDUCING VALVE 1 4 2 SLAVED LIMITING VALVE 1 2 LEVELLING VALVE 1 21 22 LEVELLING VALVE 1 2 HAND OPERATED SUSPENSION RAISING CONTROL VALVE 11 21 12 23 LEVELLING VALVE WITH BUILT IN TRAVEL LIMITER 24 23 21 22 ...

Page 829: ...M CIRCUIT DIAGRAMS VALVES DESCRIPTION SYMBOL PROPORTIONAL CONTROL VALVE 1 2 41 42 HAND OPERATED SUSPENSION CONTROL VALVE WITH ELECTRICAL MONITORING 21 11 12 22 13 1 3 ELECTROPNEUMATIC VALVE 1 2 ELECTROPNEUMATIC VALVE 1 2 ELECTROPNEUMATIC VALVE 1 21 22 HYDRAULIC MODULATOR FOR ABS HL HR HZ1 VL VR HZ2 ABS AUGMENTER VALVE 1 4 2 ...

Page 830: ...UMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS TANKS AND ACCUMULATORS DESCRIPTION SYMBOL COMPRESSED AIR TANK BRAKE FLUID RESERVOIR AIR SPRING ...

Page 831: ...IRCUIT DIAGRAMS CONVERTERS CYLINDERS AND CALIPERS DESCRIPTION SYMBOL VACUUM SERVO BRAKE VACUUM SERVO BRAKE DUAL CIRCUIT MASTER CYLINDER SINGLE CIRCUIT MASTER CYLINDER AIR HYDRAULIC CONVERTER AIR HYDRAULIC CONVERTER HYDRAULIC BRAKE CYLINDER SLAVE CYLINDER BRAKE CYLINDER SPRING CYLINDER COMBINED BRAKE CYLINDER FIXED DISK BRAKE CALIPER ...

Page 832: ...arch 2006 Print 603 93 651 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS CALIPERS AND CYLINDERS DESCRIPTION SYMBOL FLOATING DISK BRAKE CALIPER FLOATING DISK BRAKE CALIPER WITH PARKING MECHANICAL FLOATING DISK BRAKE CALIPER SERVO CLUTCH SERVO CLUTCH ...

Page 833: ... 651 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS SEMI COUPLINGS AND COUPLING HEADS DESCRIPTION SYMBOL ISO SEMICOUPLING A M ISO VERSION ISO SEMICOUPLING A M VERSIONWITHISOCOUPLINGS CUNA SEMICOUPLING A B ITALIAN VERSION CUNA SEMICOUPLING M A NATO SEMICOUPLING A M NATO VERSION ...

Page 834: ...C SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS SEMI COUPLINGS AND COUPLING HEADS DESCRIPTION SYMBOL SEMI COUPLING 1 2 3 5 4 V A Z SINGLE LINE VERSION SEMI COUPLING V A Z A M SINGLE LINE VERSION SEMI COUPLING 4 2 12 22 SINGLE LINE VERSION SEMI COUPLING 4 2 12 22 M A 1 SINGLE LINE VERSION ...

Page 835: ...2006 Print 603 93 651 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS INDICATORS AND SWITCHES DESCRIPTION SYMBOL PRESSURE GAUGE PRESSURE GAUGE PRESSURE TRANSMITTER LAMP MECHANICAL OPERATED SWITCH PRESSURE SWITCH LOW PRESSURE SWITCH AUDIBLE WARNING SENSOR ...

Page 836: ...93 651 GRAPHIC SYMBOLS FOR AIR HYDRAULIC SYSTEM CIRCUIT DIAGRAMS BRAKES DESCRIPTION SYMBOL SINGLE CYLINDER HYDRAULIC BRAKE TWIN CYLINDER HYDRAULIC BRAKE DUAL SERVO HYDRAULIC BRAKE DUAL SERVO HYDRAULIC BRAKE WITH PARKING BRAKE SINGLE CAM OPERATED BRAKE TWIN DUAL CAM OPERATED BRAKE ...

Page 837: ...ng against pin 5 Lock pipe 1 with screw 4 31971 31974 31973 Move pin 4 to neutral position Tighten screw 1 until matrix die 2 comes up against blocks 3 thus forming the end of the pipe 5 31972 31975 Position of press 99386523 3 the blocks 1 so that the stamped numbers indicating the diameter of the pipes to be worked are facing towards the due 2 The choice of the matrix die 2 depends on the diamet...

Page 838: ...remove the pipe 2 from the tool 3 use lever 1 31978 31981 Fit tool 1 99386523 and select components 2 and 3 according to the diameter of the pipe to be bent Position pipe 2 in tool 3 99386523 and tighten screw 1 By holding the pipe 2 still rotate the tool 3 until the pipe has been completely cut Cutting rigid pipes Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 20 HYDRO PNEUMATIC SYSTEM B...

Page 839: ...ntact between its flange and end of the hose Make sure that the end of the hose penetrates into the rake throat of the flange 1 Reinforcement bush 2 Pressure ring 3 Nut 4 Union fitting 5 Hose h Distance between bush edge and ring edge see table After having cut the pipe deburr and shape the ends as described previously ASSEMBLY OF REINFORCEMENT BUSH A CORRECT ASSEMBLY B INCORRECT ASSEMBLY Hose mm ...

Page 840: ...als unions couplings etc are completely free from leaks When fitting the hose to the vehicle some important points should be borne in mind Bends must comply with minimum radii so as to avoid constrictions Minimum radius of curvature mm Diameter of pipe mm 13132 6 x 1 8 x 1 10 x 1 5 12 x 1 6 16 x 2 34 40 50 60 75 100 Screw the coupling into the threaded seating provided on the air valve and tighten...

Page 841: ...m L2 mm 0 5 0 1 0 5 1 0 5 Figure 21 39308 Insert the hose 2 by hand into the coupling 1 with a force between 30 and 120 N according to the diameter of the hose so that reference mark L1 is inside the hose while mark L2 remains visible COUPLING SEAL RING DIMENSIONS THREAD M 10 x 1 0 M 12 x 1 5 M 14 x 1 5 M 16 x 1 5 M 22 x 1 5 10 1 x 1 6 11 0 x 2 0 15 0 x 2 0 L1 and L2 vary according to the diameter...

Page 842: ... suspensions 6 Parking brake lever 7 Rear brake caliper 8 Rear brake disc 9 Dual pneumatic operated load proportioning valve for vehicles with pneumatic suspensions 10 Front brake disc 11 Front brake caliper A From pneumatic suspension circuit 24 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 BRAKING SYSTEM Outline diagram for vehicles 29L 35S without ABS ...

Page 843: ...test point 6 Parking brake lever 7 Rear brake caliper 8 Rear brake disc 9 Electronic control unit 10 Wheel revolutions sensor 11 Phonic wheel 12 Front brake disc 13 Front brake caliper HYDRO PNEUMATIC SYSTEM BRAKES 25 DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 29L 35S with ABS 8 ...

Page 844: ...ar brake caliper 8 Rear brake disc 9 Yaw sensor 10 Longitudinal acceleration sensor 11 Electronic control unit 12 Wheel revolutions sensor 13 Phonic wheel 14 Front brake disc 15 Front brake caliper 16 Steering angle sensor 26 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 29L 35S with ESP 8 ...

Page 845: ...e for vehicles with mechanical suspensions 6 Parking brake lever 7 Rear brake caliper 8 Rear brake disc 9 Dual pneumatic operated load proportioning valve for vehicles with pneumatic suspensions 10 Front disc brake 11 Front brake caliper A From the pneumatic suspension circuit 109110 HYDRO PNEUMATIC SYSTEM BRAKES 27 DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 35C wit...

Page 846: ...point 6 Parking brake lever 7 Rear brake disc 8 Rear brake caliper 9 Electronic control unit 10 Wheel revolutions sensor 11 Phonic wheel 12 Front brake disc 13 Front brake caliper 109111 28 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 35C with ABS 8 ...

Page 847: ...Rear brake disc 8 Rear brake caliper 9 Electronic control unit 10 Wheel revolutions sensor 11 Phonic wheel 12 Front brake disc 13 Front brake caliper 14 Yaw sensor 15 Longitudinal acceleration sensor 16 Steering angle sensor HYDRO PNEUMATIC SYSTEM BRAKES 29 DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 35C with ESP 8 ...

Page 848: ...ke lever 7 Parking drum brake 8 Rear brake disc 9 Rear brake caliper 10 Electronic control unit 11 Wheel revolutions sensor 12 Phonic wheel 13 Front brake disc 14 Front brake caliper 109113 30 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 40C 45C 50C 60C 65C with ABS 8 ...

Page 849: ... 8 Yaw sensor 9 Longitudinal acceleration sensor 10 Rear brake disc 11 Rear brake caliper 12 Electronic control unit 13 Wheel revolutions sensor 14 Phonic wheel 15 Front brake disc 16 Front brake caliper 17 Steering angle sensor HYDRO PNEUMATIC SYSTEM BRAKES 31 DAILY EURO 4 Base March 2006 Print 603 93 651 Outline diagram for vehicles 40C 45 50C 60C 65 with ESP 8 ...

Page 850: ...t brake disc 4 Vacuum pump 5 Vacuum tank 6 Pressure test points 7 Brake force corrector 8 Rear brake disc 9 Rear brake caliper 32 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 Braking system main components layout Vehicles 29L 35S ...

Page 851: ...iper 3 Front brake disc 4 Vacuum pump 5 Vacuum tank 6 Pressure test point 7 Proportional load valve 8 Rear brake disc 9 Rear brake caliper HYDRO PNEUMATIC SYSTEM BRAKES 33 DAILY EURO 4 Base March 2006 Print 603 93 651 Vehicles 35C 40C 45C 50C 60C 65C ...

Page 852: ... on vehicles with EDC there are two switches inform the ABS EDC control unit that the vehicle is braking 14 Hydraulic accumulator 15 Electrohydraulic modulator 16 Electronic control unit A Fitting the electro hydraulic modulator control unit for ABS 8 systems FRONT LH BRAKE PIPING REAR RH FRONT RH BRAKE PIPING REAR LH ELECTRICAL SYSTEM WIRING 34 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base Marc...

Page 853: ...per 13 Brake lights indicator switch on vehicles with EDC there are two switches inform the ABS EDC control unit that the vehicle is braking 14 Hydraulic accumulator 15 Electrohydraulic modulator 16 Electronic control unit A Fitting the electro hydraulic modulator control unit for ABS 8 systems Vehicles 35C 40C 45C 50C 60C 65C REAR BRAKES PIPING FRONT BRAKES PIPING ELECTRICAL SYSTEM WIRING HYDRO P...

Page 854: ...on sensor 2 Yaw sensor 3 Steering angle sensor 4 Electro hydraulic modulator control unit 107690 36 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 Location of the main brake system components on vehicles with ESP ...

Page 855: ...CRIPTION Service brake BRAKES Front and Rear disc brakes The ABS phonic wheels are fitted on the wheel hubs Front BREMBO 2x48 model 29L 35S Front BREMBO 2x48 model 35C 40C 45C 50C Front BREMBO 2x60 model 60C 65C Rear BREMBO 1x52C model 29L 35S Rear BREMBO 1x60C model 35C Rear BREMBO 2x44 model 40C 45C 50C Rear BREMBO 2x46 model 60C 65C An electric wire is embedded in the brake linings which is con...

Page 856: ...Y system allows you to easily diagnose and program the various electronic control units fitted to the vehicle It is made up of an ECI module for communication with the electronic control units and a Panasonic PC The ECI module allows you by taking advantage of the Panasonic PC to easily carry out work on the road in particular diagnostic work can be assisted by a specialized remote centre thanks t...

Page 857: ...d fittings Replace broken or damaged pipes Worn or vitrified brake linings Overhaul or replace the brake linings Automatic clearance device is faulty caliper 1x52 Replace the brake caliper Overhaul the rear brakes replacing worn parts Rear brakes are faulty Servo brake is faulty Overhaul or replace servo brake YES NO 1 YES NO YES NO YES NO YES Continue REAR AXLE SERVICE BRAKE IS INEFFICIENT OR IRR...

Page 858: ...se or damaged fittings Replace broken or damaged pipes Worn or vitrified brake linings Overhaul or replace the brake linings YES NO YES YES NO Servo brake is faulty Overhaul or replace servo brake Brake caliper is faulty Overhaul and if necessary replace brake caliper FRONT AXLE SERVICE BRAKE IS INEFFICIENT OR IRREGULAR ABS system is faulty Make diagnosis with Modus 40 HYDRO PNEUMATIC SYSTEM BRAKE...

Page 859: ...linings Rear brakes are faulty Overhaul the brakes and replace any worn parts YES NO YES NO YES NO YES 3 Tie rods are faulty Adjust or overhaul tie rods and replace any worn parts YES NO Front brakes are faulty Overhaul and if necessary replace any worn parts INEFFICIENT OR NO PARKING BRAKE ABS system is faulty Make diagnosis with Modus HYDRO PNEUMATIC SYSTEM BRAKES 41 DAILY EURO 4 Base March 2006...

Page 860: ...spring Rear calipers are faulty calipers 1x52 Overhaul calipers and replace any worn parts Leaks or breakage in hydraulic system pipes Tighten or replace loose or damaged fittings Replace broken or damaged pipes Load proportioning valve is faulty vehicles without ABS YES NO Parking drum brake is faulty 2x44 calipers Adjust or overhaul the parking drum brake and replace any worn parts YES 42 HYDRO ...

Page 861: ... rear brakes Load proportioning valve is faulty vehicles without ABS Adjust and if necessary replace load proportioning valve Brakes are faulty Overhaul brakes RAPID BRAKE LINING WEAR ABS system is faulty Make diagnosis with Modus HYDRO PNEUMATIC SYSTEM BRAKES 43 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 862: ...point due to Failure to perform yearly change Presence of water in system Use of wrong liquids Replace brake liquid use type Tutela DOT SPECIAL Presence of air in hydraulic system Bleed off any air from hydraulic system 7 NO YES NO YES NO YES TOO LONG OR ABNORMAL TRAVEL OF BRAKE PEDAL 44 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 863: ...odies between discs and brake linings Remove all foreign bodies from between brake linings and discs Disk brakes off centred Adjust or replace disc brakes YES NO 8 YES NOISY BRAKES HYDRO PNEUMATIC SYSTEM BRAKES 45 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 864: ...450311 1 450511 290 349 29 34 9 Screw securing brake disk to half shaft Rear axle NDA R S 13 21 1 3 2 1 Screw securing drive shaft to wheel hub Rear axle NDA R G 450511 63 76 6 3 7 6 Ring nut retaining wheel hub bearing Rear axle NDA R S R G 450511 618 667 61 8 66 7 Screws securing brake disc to wheel hub Rear axle NDA R S R G 450511 69 76 6 9 7 6 Screws securing caliper moutning to shoe mounting ...

Page 865: ...ub Front axle 5823 torque clamping 50 60 4 3 5 3 angle clamping 30 1º 34 1º Screw securing drive shaft to wheel hub Rear axle 450517 2 56 69 5 6 6 9 Screw securing brake caliper Rear axle 450517 2 150 177 15 17 7 Ring nut retaining wheel hub bearing Rear axle 450517 2 441 540 44 1 54 Screws securing brake disc to wheel hub Rear axle 450517 2 54 59 5 4 5 9 Screw securing shoe mounting to rear axle ...

Page 866: ...ly 99306010 Appliance to bleed air from brake and clutch systems 99321024 Hydraulic trolley for removing refitting wheels 99355087 Wrench 65 mm for wheel hub nut NDA R G 450511 99355184 Wrench for ring nut retaining drive shaft bearing rear axle NDA RS 99357080 Spanner 91 5 mm for adjusting wheel hub bearings nut Rear axle 450517 2 ...

Page 867: ...8 Tool for driving bearing and phonic wheel onto wheel hub rear axles NDA R G 450511 99372236 Tool to retract brake caliper piston rear axle NDA R S NDA R G 99372249 Parking brake shoes adjusting tool 99372269 Pair of gauges to check pressure and to adjust hydraulic brakeforce distributor 99374132 Tool for fitting wheel hub internal seal use with 99370006 Axle 450517 2 ...

Page 868: ...50 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 TOOL NO DESCRIPTION 99386523 Flanging tool for brake system pipes 99389819 Torque wrench 0 10 Nm with square 1 4 connection ...

Page 869: ... proportioning valve BOSCH 796801 Ratio 0 25 BOSCH 796803 Ratio 0 15 ABS8 system electro hydraulic modulator control unit BOSCH 0 265 231 692 vehicles 29L 35S PN IVECO spare parts 504182308 EZ BOSCH 0 265 331 896 vehicles 5C 45C 50C PN IVECO spare parts 504182310 EZ BOSCH 0 265 231 894 vehicles 60C 65C PN IVECO spare parts 504182323 EZ ABS8 ASR8 system electro hydraulic modulator control unit BOSC...

Page 870: ...isc brake diameter mm 300 290 0 2 301 0 2 290 0 2 Disc brake thickness normal S mm 28 28 0 2 30 0 2 min allowed S1 mm 8 7 8 7 9 7 S2 mm 7 7 7 7 10 5 Remaining thickness of friction material to have the light on cutting cable AXLE WHEEL HUBS Type of front axle 5817 5818 5819 5823 Wheel hub bearings UNIT BEARING Wheel hub bearings end play mm Wheel hub bearing axial clearance adjustment Not adjustab...

Page 871: ...s Nominal S mm 4 25 mm 6 2 Min allowed S1 mm Min 1 5 mm Min 3 5 Brake lining diameter Brake lining diameter Nominal mm 171 2 171 5 189 2 189 5 Brake lining width L mm 42 L Brake lining width L mm 42 G Clearance between brake linings G mm 0 2 0 5 0 3 0 4 Clearance between brake linings and drum G mm 0 2 0 5 0 3 0 4 Remaining thickness of friction material to have the light on cutting cable AXLE WHE...

Page 872: ...d fully down for a period of 1 minute of rotation of the engine Brake liquid compensation tank Check the level of the brake liquid and eventually top up with Tutela DOT SPECIAL to the specified level Change the brake liquid once per year Load proportioning valve Check that the values measured with special manometers via the test points correspond to those indicated on the self adhesive plate appli...

Page 873: ...s the vehicles with engine F1A F1C the vacuum de vice is incorporated into the vacuum oil pump unit HYDRO PNEUMATIC SYSTEM BRAKES 55 DAILY EURO 4 Base March 2006 Print 603 93 651 TROUBLE POSSIBLE CAUSES CURE Oil leakage from cover Incorrect driving torque between power reducer and engine Lock screws to correct driving torque indicated in appropriate table Cover seal surface not completely flat Che...

Page 874: ...10 Bleeding air from the hydraulic cir cuit with deaerator device vehicles not equipped with ABS Front brake circuit As an alternative you can bleed off air from the brake circuit with the deaerator device 99306010 by following the procedures below 1 load the air tank 4 2 fill the tank with brake liquid 5 3 one end of a transparent plastic pipe 6 should be fitted to the bleeder screw with the end ...

Page 875: ...s been bled visually inspect the brake fluid level and top up if necessary Do not fill with fluid that has already been used In the event that either one single phase or the entire blow off process is repeated you will have to wait at least 5 minutes in order to let the system solenoid valve cool Otherwise the valves themselves may be damaged due to overheating Prior to tightening the drain screws...

Page 876: ...ed with the rear right wheel After front left wheel bleeding has been completed as signalled by the diagnosis instrument close the drain screw and proceed with the front right wheel Open the front right wheel drain screw After rear left wheel bleeding has been completed as indicated by the diagnosis instrument tighten the drain screw and then proceed with the front left wheel Open the front left w...

Page 877: ...locked when braking you must check the device at regular intervals and eventually adjust if necessary This consists in verifying the values indicated on the plate SENZA CODICE applied on the inside of the bonnet If there is no plate or if the data is missing ask the manufacturer for a duplicate by indicating Vehicle type Number of leaf springs Vehicle pitch Weight of rear axle Number of load propo...

Page 878: ...E to check that the load sensing valve stem runs smoothly in its seat otherwise replace the sensing valve reconnect the adjustment rod 4 SENZA CODICE to the rear axle 52389 52390 Figure 44 Figure 45 Figure 46 The load sensing valve automatically regulates the braking torque generated by the brakes of the rear axle according to the load weighing on the rear axle It has the important function especi...

Page 879: ...uick action on the engine and brakes It allows the vehicle to set off safely and fast even on slippery roads or when one driving wheel is skidding It also reduces the risk of understeering when you accelerate too much when cornering Engine braking torque control MSR This system avoids driving wheel drag due to the exhaust brake It ensures vehicle stability when releasing on slippery roads e g snow...

Page 880: ...or of the various models are not interchangeable NOTE The parts inside the hydraulic unit are not compatible with mineral oil and unsuitable fluids In case of contamination by such fluids the unit shall be replaced and properly disposed of 1 Hydraulic accumulator 2 Electro hydraulic modulator 3 Electronic control unit A ABS8 connector B ESP8 connector F MC1 Front axle power supply R MC2 Rear axle ...

Page 881: ... hydraulic modulator of the various models are not interchangeable NOTE The parts inside the hydraulic unit are not compatible with mineral oil and unsuitable fluids In case of contamination by such fluids the unit shall be replaced and properly disposed of 1 Hydraulic accumulator 2 Electro hydraulic modulator 3 Electronic control unit A ABS8 connector B ESP8 connector F MC1 Front axle power suppl...

Page 882: ...every single wheel Moreover the ESP system may decrease the engine revs number by means of the engine control feature 102115 Longitudinal acceleration sensor 102116 It measures the vehicle s acceleration and deceleration changes These signals continuously inform the control unit about the vehicle s behaviour The comparison between these signals and those from the driver steering wheel position whe...

Page 883: ...r 5 Dismount braking gaskets 2 and 3 from caliper support 1 Remove screw 3 securing brake caliper 2 to support 4 Move bush 1 inside brake caliper 2 tilt the brake caliper Figure 57 109131 The braking system effects safety All repairs and servicing operations must be exclusively carried out by skilled qualified personnel The oil inlet hose to the calliper must not be disconnected during the operati...

Page 884: ...is not corroded scored or grooved Slight superficial cracks are acceptable however brake disk must be ground as described in relating chapter on the contrary if the disk is worn out it must be replaced Insert new brake liners 1 in the brake calliper mount and check that they slide in their seats Fit cable 4 into brake caliper 1 and connect the cable to braking gasket 3 For 2x60 brake calipers Retr...

Page 885: ...or from chassis cable and release the cable of the electrical connection from support blade 2 By suitable wrench disconnect hose 3 of brake liquid from pipe and drain brake liquid into special container If necessary plug the pipe preventing piping complete draining For 2x60 calipers 109122 109056 The hose has to be removed at the bench NOTE Brake liquid is venomous and corrosive in case of acciden...

Page 886: ...ous and corrosive in case of accidental contact immediately wash with water and neutral soap Check the pistons are fully retracted inside the caliper body Refit by carrying out the operations described for removal in reverse order observing the required tightening torques Drive slowly without prolonged sudden brake application during the first period of use of new brake pads because braking effici...

Page 887: ... pads rest area using suitable materials and products e g a wet cloth on the contrary do not use a nitro perchlorate based diluent petrol etc which might damage the protection cowlings Check brake disk surfaces and make sure that the disk is not corroded scored or grooved Slight superficial cracks are acceptable however brake disk must be ground as described in relating chapter on the contrary if ...

Page 888: ...e the hose if anomalies are found Slide the slippage sleeves 1 and take out the protection casings 2 109145 109146 Figure 77 Figure 78 Remove the dust covers 1 and 2 and keep the sliding bushes 3 527413 OVERHAUL OF BRAKE CALIPERS 2x44 2x48 2x60 Brembo brake calipers Disassembly For Brembo 2x44 2x48 brake caliper The hose has to be removed at the bench NOTE Brake liquid is venomous and corrosive in...

Page 889: ...liding surfaces are neither damaged or worn Insert the bushes and pistons into the seats and check that they are free to slide otherwise restore or replace as necessary A regular braking effect depends a great deal on the condition of the sliding surfaces Figure 81 Insert the dust boots 4 and 5 in their seat on the brake calliper 1 Fit the cylinders 2 and the sliding bushings 3 or 1 fFigura 77 and...

Page 890: ...ly move the sequential wheel towards the working surface in order to completely remove the swarf left over from turning Figure 84 Fit the disk brake 1 complete with the wheel hub to the late arbor 99301005 2 fit a set of spacers on the shaft to remove unit end play tighten the lock nut and apply the lathe support place the tool holder 3 along the axis of the drum brake 1 then adjust the work depth...

Page 891: ...r to the rear axle Release shoe 1 return springs 2 and 5 Save the adjusting device 3 Remove retaining brackets 4 and 6 and detach shoes 1 45048 52747 Figure 86 Figure 87 Figure 88 Dismantling parking drum brake OVERHAULING PARKING BRAKE WHEEL NUT TIGHTENING SEQUENCE AXLE TIGHTENING ORDER Tighten the screws at the specified torque in the order shown NOTE HYDRO PNEUMATIC SYSTEM BRAKES 73 DAILY EURO ...

Page 892: ...ablish whether it can be reused Measure the inner disc diameter with a sliding gauge without moving the arms to an angle Measure the drum diameter in several spots to determine ovality and wear Also examine depth of scoring on the braking surface Max permitted ovality and or eccentricity tolerance is 0 1 mm Replace the disc if wear or evident signs of overheating are found see specifications and d...

Page 893: ...e stands loosen the screw 2 completely remove the disc as described in the REAR AXLES section run the checks described on page 61 use the adjustment device 1 SENZA CODICE to obtain the distances given in the Specifications and Data table mount the disc and wheels Firmly apply the parking brake a few times to settle the sheaths of the ropes take the parking brake lever in the cab onto its third cat...

Page 894: ...the rated installation value Figure 94 STEERING ANGLE SENSOR Replacing REPLACING THE ESP COMPONENTS Some modifications or repairs affecting the ESP system components require a specific calibration procedure The repairs that require such procedure are detailed as follows replacing the electronic control unit integrated into the electrohydraulic modulator of the system s braking apparatus replacing ...

Page 895: ...ound any longer Re attachment is carried out by reversing the order of detachment operations Also follow the advice below Figure 94 Removal never change the sensor position and fastening points The sensor features an offset position compared with the vehicle centre line which must not be modified After re attachment has been completed follow the calibration procedure described below Calibration Di...

Page 896: ...o calibration procedure Unscrew the two sensor 2 fastening screws 1 by using a suitable wrench to remove the side right screw considering that the latter cannot be accessed easily Then remove sensor 2 Take off glove compartment 1 on the passenger s side If the vehicle is equipped with passenger s airbag follow the safety rules indicated in the relevant chapter of the Steering section Re attachment...

Page 897: ...when disconnecting the ducts Disconnect the electric connection Loosen the screws securing the modulator to the support bracket Remove the modulator control unit 1 109151 526741104 ELECTROHYDRAULIC MODULATOR CONTROL UNIT Refitting Disconnect the battery cables in the engine compartment Take off the hydraulic braking system fluid cap then remove the filter Suck the braking system fluid by means of ...

Page 898: ... to electrohydraulic modulator 3 Take control unit 2 out of the modulator Bench overhauling Assembly Re attachment is carried out by reversing the order of detachment operations Disassembly 80 HYDRO PNEUMATIC SYSTEM BRAKES DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 899: ...IR CONDITIONING SYSTEM MAIN COMPONENTS AND FUNCTIONAL DIAGRAM 4 AIR CONDITIONING AND HEATING 4 Description 4 Air conditioning 4 Heating 4 MAIN COMPONENTS 5 Compressor 5 Condenser 5 Drier filter 6 Expansion valve 6 Evaporator 6 CONTROL AND SAFETY DEVICES 7 Description 7 Three level pressure switch 7 Outside air temperature sensor 7 AIR CONDITIONING UNIT M MARELLI OR DENSO TYPE 8 General 8 Electroni...

Page 900: ...11 R134A refrigerant recovery and refilling station 99305146 11 CONTROL FASCIA 12 SAFETY STANDARDS 14 OPERATION FLOW CHART 15 RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM 16 CREATING A VACUUM IN THE SYSTEM 18 RESTORING OIL IN THE SYSTEM 20 FILLING THE SYSTEM WITH REFRIGERANT 21 CHECKING THE PRESSURES IN THE SYSTEM 23 OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM 23 LEAK FINDER FO...

Page 901: ...idifying the air with the possibility of heating it afterwards as preferred so as to change the temperature and humidity in the cab VENTILATION Description Ventilation is the function of drawing in fresh air from the outside cleaned of pollen and dust by a special filter or recycling the air in the cab This system is composed of a shell designed to house the electric fan unit air ducts fresh air i...

Page 902: ... and maintained during operation of the system A Refrigerant liquid inlet B Refrigerant liquid outlet H High pressure circuit L Low pressure circuit 1 Condenser 2 Three level pressure switch 3 Drier filter 4 Compressors 5 Heater fan unit 6 Evaporator 7 Expansion valve 8 Pollen filter Heating Heating is accomplished by a radiator in the heater unit in which the engine coolant circulates Special doo...

Page 903: ... 1 that comes to be virtually keyed onto the compressor shaft and makes it rotate The condenser is a heat exchanger located between the compressor and the drier filter Its function is to transformthe refrigerant fluid from its gaseous to its liquid state This transformation is made by the refrigerant fluid releasing heat to the outside air This is why the condenser is installed on the vehicle so a...

Page 904: ...gerating fluid the bottom one enabling the refrigerant to pass 5 from the drier filter to the evaporator 2 Along this route there is a spring 4 that appropriately set makes it possible to obtain such a leap in temperature overheating as to make sure that the refrigerant at the evaporator inlet is entirely in its gaseous state In addition there is also a modulating element in this case a ball 3 hou...

Page 905: ...agnetic coupling of the compressor pulley when the pressure of the fluid high pressure side in spite of the action of the condenser and radiator fan reaches dangerous limits or when the heating load conditions are not sufficient to make the refrigerant evaporate It is fitted into the left side rear view mirror The system is equipped with specific devices that by checking the pressure and temperatu...

Page 906: ...in under automatic control The air temperature at the vents is always controlled automatically to produce the temperature shown on the display in the cab unless the system is not in operation The automatic air conditioning heating system is controlled by an electronic control unit that governs both systems air conditioning and heating and determines the mixture and quantity of air to be introduced...

Page 907: ...unit 33 Condensation drain tub strip 34 Front box 35 Self tapping insert 36 Mixing foot door lever 37 Bushing 38 Transmission 39 Vent demist door lever 40 Water pipe fixing U bolt 41 Distribution cam 42 Control mounting bracket 43 Anti frost sensor 44 Wiring retainer clamp 45 Fan strip 46 Electric fan 47 Connection cover 48 Motor mounting 49 Spacer 50 Connector bracket 51 Electronic control 52 Eva...

Page 908: ... flexible transmission 29 Distribution control lever 30 Switch 31 Distribution flexible transmission 32 Connection cover 33 Motor mounting 34 Connector bracket 35 Frame bracket 36 Electric fan 37 Self tapping insert 38 Mixing foot door lever 39 Transmission 40 Distribution cam 41 Mixing bowden clamp 42 Control fixing bracket 43 Mixing foot door lever 44 Vent def door lever 45 Wiring retainer clamp...

Page 909: ...o be operative the station needs to absorb approximately 3 kg of refrigerant For prompt use it is advised to have at least 2 kg of refrigerant in the filler cylinders and to keep the station as level as possible The station is composed of 1 control panel 2 container to restore any oil recovered when unloading 3 flexible hoses 4 container to collect any oil recovered from the system 5 filler cylind...

Page 910: ...FILLER CYLINDER OIL TANK 50634 50632 Figure 14 Figure 15 12 CAB AIR CONDITIONING DAILY EURO 4 Base March 2006 Print 603 93 651 CONTROL FASCIA ...

Page 911: ... system V5 Oil drainage valve V9 A C system washing refrigerant service valve 10 Moisture indicator VS Safety and drainage valve L3 Alarm warning light L4 Maximum level warning light L5 Minimum level warning light A Unit process bottle heater switch LA1 Unit process indicator light LA2 Bottle heater indicator light B Refrigerant process vacuum process switch LB1 Refrigerant process indicator light...

Page 912: ...t of refrigerant liquid with the eyes can cause blindness avoid all contact with skin low boiling point 30 C can cause frostbite never inhale the vapours of refrigerant gases before connecting the station with a system or external container check that all the valves are closed before disconnecting the station check that the cycle is over and all the valves are closed This will prevent dispersing r...

Page 913: ...econd vacuum test Load oil into the system Load up to 200 g refrigerant Search for leakage with electronic leak finder Search system for leakage with electronic leak finder Pressure check Are the values acceptable Disconnect the station from the system NO NO YES YES NO NO YES YES YES NO Is there any leakage Is there any leakage Is there any leakage CAB AIR CONDITIONING 15 DAILY EURO 4 Print 603 93...

Page 914: ...r the pressure gauge to the evaporator inlet the inlet is the one on the pipe with a smaller diameter H connecting the drier filter with the evaporator Connect the pipe marked LOW under the pressure gauge to the evaporator outlet the outlet is the one on the pipe with a larger diameter L connecting the evaporator with the drier Open the valves V1 and V2 Open the LOW and HIGH cocks 52295 Figure 16 ...

Page 915: ...or a few minutes so that any pockets of refrigerant at low pressure remaining in the system can increase their pressure by absorbing heat and be able to be recovered The station will automatically repeat the recovery cycle if the above conditions occur put the switches A B and C back onto position 0 close the V1 V2 LOW and HIGH valves Continue the operations following the instructions given on the...

Page 916: ...e is a leak Eliminate the leak and repeat the evacuation cycle Put the switches D and B back onto position 0 and proceed with the following phase Connect the pipes to the specific system connections and open the V1 V2 LOW and HIGH valves Press the switch A Process Unit onto position 1 The respective indicator light LA1 will come on Press the switch B Vacuum Process onto position 2 The respective i...

Page 917: ...wly open the valve V5 Oil Discharge 2 When all the oil has been discharged into the container 1 close the valve V5 3 Quantify and record the amount of oil discharged 4 Eliminate the recovered oil correctly This oil cannot be reused The same amount of new oil as has been removed must be added to the system 1 50638 Figure 19 CAB AIR CONDITIONING 19 DAILY EURO 4 Print 603 93 651 Base March 2006 ...

Page 918: ...rawn into the system close the valve V3 and the valve on the metering device container when the required quantity of lubricant has been drawn in disconnect the metering device 1 from the injection valve V3 and fit the protective cap back on never open the oil injection valve V3 if the system has positive pressure oil should only be injected with a vacuum in the system the oil level must never fall...

Page 919: ...d remember to increase the load by approximately 100 g this is the weight of refrigerant contained in the station system connecting pipes The right quantity of refrigerant to introduce into the system will therefore be given by 600 g 100 g quantity referred to the system capacity Always check before filling that the indicator on the console shows the refrigerant contains no moisture in which case ...

Page 920: ...rigerant depending on the size of the system stop filling by moving the switch C Charge onto position 0 check the system is properly sealed with the electronic leak finder complete filling the system until the pre calculated residual weight in the cylinder is reached Residual weight Total weight System capacity weight complete filling move the switches C B and A onto position 0 A had been moved fo...

Page 921: ... gas from the system extremely accurately in the order of 3 3 g a year with the switch on maximum sensitivity This instrument requires no settings the operator only needs to select the desired sensitivity The instrument warns the operator of any gas leakage with a buzzer and a LED that flashes in proportion to the concentration of gas In addition the LED indicates the battery is flat if it goes ou...

Page 922: ...24 CAB AIR CONDITIONING DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 923: ...Page MAINTENANCE 3 Table of maintenance services 3 F1A ENGINE VEHICLES 4 Inspection and or maintenance interventions 4 Extra plan operations 5 F1C ENGINE VEHICLES 6 Inspection and or maintenance interventions 6 Extra plan operations 7 DIAGRAM OF CHECK AND OR MAINTENANCE POINTS 8 MAINTENANCE OPERATIONS 9 ...

Page 924: ...2 SCHEDULED MAINTENANCE DAILY EURO 4 Base March 2006 Print 603 93 651 Print 603 43 351 ...

Page 925: ...months only applies in cases where the distance travelled by the vehicle corresponds roughly to the specified average annual mileage This is indicated only in order to suggest a hypothetical maintenance programme Note that the time intervals specified for Extra Plan operations designated by letter T for Time are to be adhered to regardless of the actual mileage covered The kilometre frequency for ...

Page 926: ...00 km or 2 400 hours Every 240 000 km or 4 800 hours Every 240 000 km or 4 800 hours Every year at the start of spring Every year at the start of winter Every 2 years Every 3 years Inspection and or maintenance interventions F1A engine vehicles T f i i M1 M2 Type of intervention Every 40 000 km Every 120 000 km yp Every 40 000 km or 800 hours Every 120 000 km or 2 400 hours LUBRICATION CHANGING OI...

Page 927: ...hange the filters once a year early each spring T2 EACH YEAR before the winter season Check coolant density Check pre combustion chamber glow plug operation T3 EVERY TWO YEARS Change brake fluid and bleed brake fluid system T4 EVERY THREE YEARS even if there is no indication of the air filter clogging Change cartridge and clean air filter container 1 Change engine coolant 2 1 In case of annual cov...

Page 928: ...rs Every 240 000 km or 4 800 hours Every 240 000 km or 4 800 hours Every 240 000 km or 4 800 hours Every year at the start of spring Every year at the start of winter Every 2 years Every 3 years Inspection and or maintenance interventions F1C engine vehicles T f i i M1 M2 Type of intervention Every 40 000 km Every 120 000 km yp Every 40 000 km or 800 hours Every 120 000 km or 2 400 hours LUBRICATI...

Page 929: ...rticulate filter TI EACH YEAR especially in early springtime Check state of pollen filters In the case of low mileage change the filters once a year early each spring T2 EACH YEAR before the winter season Check coolant density Check pre combustion chamber glow plug operation T3 EVERY TWO YEARS Change brake fluid and bleed brake fluid system T4 EVERY THREE YEARS even if there is no indication of th...

Page 930: ...Figure 1 109115 8 SCHEDULED MAINTENANCE DAILY EURO 4 Base March 2006 Print 603 93 651 DIAGRAM OF CHECK AND OR MAINTENANCE POINTS ...

Page 931: ...OTE Before refitting the new cartridges moisten the seal with engine oil NOTE Check the level of brake fluid If it is low top it up see fluids table in the GENERAL section 52314 Figure 5 2 Replacing UFI Filters type fuel filter 3 Checking hydraulic brake system fluid level Disconnect chassis cable connection 6 from electronic unit connection 7 Release connection 7 from support bracket 8 Remove fas...

Page 932: ...s This must be done with dry canvas or raw cotton Use no solvents Check that the swivel heads in their components have no points of corrosion with sections affected to a depth greater than 1 mm In particular check the sheet metal cover close to the rolled section Check the protecting casing it must be secured to the body and to the pin of the joint with a retaining ring and must not rotate The cas...

Page 933: ...the arrows shown in the figure check that the spiders are not worn Replace them if they are If there is any damage refer to the PROPELLER SHAFTS section 10 Checking universal joints and propeller shaft flange fixing Figure 8 Figure 9 The lubricating oil has to be drained off while it is hot Place a container under the plug near the arrow remove the plug and drain off the oil Screw the plug back on...

Page 934: ... chamber engine plugs The belts shall be replaced as described in the respective ENGINE section EP3 service every 400 000 km or 8 000 hours operation only F1C engines 1 Replacing the timing chains chain stretchers camshaft drive gears pads The belts shall be replaced as described in the respective ENGINE section Replacing the exhaust gas catalyst vehicles equipped with D P F particulate filter The...

Page 935: ...ith a maintenance service The brake fluid is poisonous and corrosive In case of accidental contact wash immediately with water and mild soap 3 Changing the draining and braking hydraulic system fluid The fluid shall be changed as described in the respective HYDROPNEUMATIC SYSTEM BRAKE section ad regards the amount of brake fluid refer to the filling and fuelling table in the GENERAL REMARKS charte...

Page 936: ...14 SCHEDULED MAINTENANCE DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 937: ...s remote control switches identification 19 Internal electrical scheme 20 Junction connectors 21 Junction connector L 22 Junction connector M 23 Junction connector R 24 Junction connector H 25 ENGINE OPENING CENTRAL UNIT CVM 75001 26 Fuses remote control switches identification 27 Internal electrical scheme 29 Junction connectors 30 Junction connectors A 31 Junction connectors C 32 Junction connec...

Page 938: ... Description 64 Black cab junction connector LN 66 Blue instrument panel junction connector PF 68 Blue bonnet junction connector AV 69 FITTER CONNECTOR 61071 71 Page FITTER CONNECTOR 72068 72 ELECTRONIC INJECTION EDC16 73 Particular features of engines Euro 4 73 System to reduce pollutants at exhaust 74 General 74 E G R Exhaust Gas Recirculation SYSTEM 75 Operation 75 Main system components 75 E G...

Page 939: ...8 115 The ABS 8 system integrates the following functions 115 The ESP 8 system in addition to the EBS 8 system incorporates the following functions 115 Four crossed channel system x 116 Electro hydraulic modulator control unit 116 Four parallel channel system II 117 Electro hydraulic modulator control unit 117 ABS 8 control unit PIN OUT X crossed channels II parallel channels 118 ESP 8 control uni...

Page 940: ... 139 DE ACTIVATING PASSENGER AIR BAG 141 Electronic control unit 142 Central unit Pin Out 143 SPIRAL CONTACT 144 PRETENSIONERS 145 Operation principle 145 CURTAIN AIR BAG 146 COMPONENT REPLACEMENT INTERVENTIONS 147 Electronic central unit 147 Page Drive side air bag module 148 Passenger side air bag module 148 Spiral contact 149 IMMOBILIZER 150 Operation description 151 Keys 151 Body computer 152 ...

Page 941: ...0 connector code 3C cell identification co ordinates Connector between cables II connector number 6 cell number II6 Electronic component or control unit Connection to a power earth point 7777 Cable colour code Consult Base equipment Optional electrical connection in a base circuit chart Connection to earth by cable O O No protection Protection with continuous PVC tape Protection with 30 mm spiral ...

Page 942: ...ly Do not use quick chargers to start the engine Starting must only be carried out with separate batteries or with the special trolley Make sure that the polarity on the battery terminals is correct when starting from an auxiliary trolley The incorrect polarisation of the power voltage of electronic control units for exampleincorrect polarisation of thebatteries may lead to their destruction When ...

Page 943: ...erised by strong direct current intensity 1 A for electromechanical components from the analogue earth characterised by wave shapes at determinate frequencies and very low current intensity mA µA of electronic systems The definition of signal earth or analogue earth depends on the sensitivity of the electronic systems to EMC electromagnetic compatibility as parasite signals emitted by the systems ...

Page 944: ...l or chain connections and to the negative terminal of the battery ies Though they are not connected to the system earth battery negative terminal analogue earths sensors must be perfectly insulated Therefore particular care should be given to the parasite resistances of the terminals oxidation clinching defects etc In the presence of jointing connectors the unscreened section d near them should b...

Page 945: ...ile on the other only one cable connects them with the earth or supply It is also possible to have several welding points connected to one another in which several cables converge on both sides of the welding In this case the earth or supply cable will be connected to the last weld of the series Ultrasonic welding brings considerable advantages including reduction of electromagnetic interference o...

Page 946: ...osphere 25307 Relay for controlling air conditioning compressor 25336 Relay for engine cooling electromagnetic joint 25337 Relay for disconnecting air conditioning system compressor 25340 Relay compressor operation signal to EDC 25620 Relay for fuel filter clogged signal 25704 Relay for switching NC NO signal for third steering axle 25705 Relay for enabling point switching on 25810 Relay for contr...

Page 947: ...itch for engaging diesel fuel heating 47109 Switch for connection of ignition timer KSB 47207 Switch sender unit engine water temperature indicator 48035 Engine rpm sensor 48042 Engine rpm sensor on timing gear 52005 Switch with built in w l for heated rear view mirrors 52036 Switch with built in w l for engaging windscreen heater 52082 Switch with built in w lamp fog lights 52083 Switch with buil...

Page 948: ...tance for rearscreen heating 64000 Electric windscreen washer pump 65000 Windscreen wiper unit 66005 Headlamp washer pump 66010 Headlamp washer timer 68000 Radio equipment 68001 Speaker 68013 Monitor for controlling reverse gear 68014 Camera for controlling reverse gear 72016 13 pole coupling for 12V connection to trailer 72027 38 pole coupling for connection with IVECO 78000 Solenoid valve for co...

Page 949: ...t pre after heating system 86012 Electronic control unit for signalling water in fuel filter 86013 Sensor water in fuel filter 86020 Antipollution device control unit EGR 86023 Vehicle raising lowering control unit 86029 Electronic control unit for central door locking 86046 Electronic control unit for trailer lights control 86047 Electronic control unit for switching on total power takeoff 86060 ...

Page 950: ... 603 93 651 POWER NETWORK A Instrument cluster B Key switch C Steering column switch unit D Interconnection central unit CPL E Body Computer F Battery G Positive 30 distribution central unit CBA H Alternator I Engine interconnection central unit CVM 107649 Figure 4 ...

Page 951: ...al unit is positioned named CBA Its task is to provide battery 30 power supply to the different functions of the vehicle To this unit there are connected one 6 mm2 cable three 10 mm2 cables one 35 mm2 cable and one 50 mm2 cable There are present five fuses by 150 A 70 A 70 A 50 A 500 A 107621 1 Positive connection central unit CBA Figure 5 1 ...

Page 952: ...t 1 Positive 30 for alternator starter 500 50 2 Positive for engine opening central unit CVM 150 35 3 Positive 30 for CPL 70 10 4 Positive 30 for CPL 70 10 5 Positive 30 for box OPT 50 6 6 Positive 30 for CPL OPT prearrangement 10 On cable no 1 there is a 500 A fuse not visible in figure 107635 Figure 6 ...

Page 953: ...ELECTRIC ELECTRONIC SYSTEM 17 DAILY EURO 4 Base March 2006 Print 603 93 651 INSTRUMENT PANEL INTERCONNECTION CENTRAL UNITS CPL 75002 107624 Figure 7 107639 ...

Page 954: ...IC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Ref Function Sect 1 Positive from CBA fuse 70A connector B A 10 2 Positive from CBA fuse 70A connector B B 10 3 Positive from CBA OPT connector D 10 107669 Figure 8 2 ...

Page 955: ... BC Roof lamps internal relays power supply 10A F 39 Car radio chrono tachograph 15A F 40 Rh heated rear window 10A F 41 Lh heated rear window 10A F 42 Reverse lights switch 5A F 43 Windscreen wiper 20A F 44 AVAILABLE F 45 AVAILABLE F 46 AVAILABLE F 47 Driver window winder 25A F 48 Passenger window winder 25A F 49 ECU for climate control system car radio heated seats 15A F 50 Airbag 5A F 51 Chrono...

Page 956: ...ECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Internal electrical scheme 107660 Figure 10 Junction between central unit CPL and Body Computer internal lamellar junction Connector R unused pins 18 pins ...

Page 957: ...ONIC SYSTEM 21 DAILY EURO 4 Base March 2006 Print 603 93 651 Junction connectors Ref Function 1 Connector 2 Connector M 3 Connector R 4 Connector H 5 Connector D 6 Connector B 7 Connector L 107665 Figure 11 FRONT VIEW ...

Page 958: ...26 8 Positive for reverse headlamp 2226 9 10 B Can line L for parking sensors 6111 11 Positive 30 7772 12 13 Positive for central locking 9076 14 15 Positive for heated rear window 8021 16 17 Positive for rh lateral window winder 8863 18 Positive 30 for cab roof lamps 7772 19 Positive 15 for parking sensors 8879 20 21 22 23 24 25 26 27 28 B Can line H for parking sensors 6110 29 30 Positive for lh...

Page 959: ...rt up step 8849 2 3 Positive 15 for air conditioner central unit 8879 4 Positive 15 for radio 8879 5 B Can line H for radio 6110 6 Positive 15 for air bag 8879 7 Positive 30 for radio 7772 8 Positive for tachograph 5156 9 10 Earth 0000 11 8887 12 Positive for tachograph 8879 13 14 Positive 15 for rh lh window winders 8849 15 16 17 B Can line L for radio 6111 18 19 20 ...

Page 960: ...EURO 4 Base March 2006 Print 603 93 651 Junction connector R Ref Function Code 1 2 Positive 15 to control the exclusion of ASR 8879 3 4 5 6 7 8 9 10 11 12 13 14 Headlamp attitude rectifier 9934 15 16 17 18 Headlamp attitude rectifier 9935 ...

Page 961: ...lh dipped headlight 2231 4 5 6 7 Positive 15 with the exclusion of users during start up step 8849 8 Positive for reverse gear 2226 9 10 Positive 15 with exclusion for windscreen wiper remote control switches 8849 11 Positive for reverse gear on switch 2268 12 Positive for rh dipped headlight 2223 13 14 Positive 15 to stop warning switch 8879 15 Positive for stop lights control 1176 16 17 18 19 Po...

Page 962: ...26 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 ENGINE OPENING CENTRAL UNIT CVM 75001 107623 Figure 12 107622 1 Interconnection central unit CVM ...

Page 963: ...ELECTRIC ELECTRONIC SYSTEM 27 DAILY EURO 4 Base March 2006 Print 603 93 651 Fuses remote control switches identification Figure 13 107627 ...

Page 964: ...0A F 19 Baruffaldi 5A F 20 Fuel filter heater 25A F 21 Fuel pump 15A F 22 EDC16 primary loads 25A F 23 Additional heater 10A F 24 ECU ESV1 automatic gearbox PTO 15A F 30 Left and right hand front fog lights 15A IN CONTAINER OUT OF CENTRAL UNIT F 26 Trailer socket 10A F 29 Air spring suspensions 40A F 54 Air spring suspensions 40A Ref Function Maximum nominal current T02 Right and left hand full be...

Page 965: ...ELECTRIC ELECTRONIC SYSTEM 29 DAILY EURO 4 Base March 2006 Print 603 93 651 Internal electrical scheme Figure 14 107645 ...

Page 966: ...IC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Junction connectors Ref Function 1 Connector A 2 Connector D 3 Positive 30 from CBA 4 Connector F 5 Connector B 6 Connector C 7 Connector E 107646 Figure 15 REAR VIEW ...

Page 967: ...atic gearbox 8110 8 Positive 15 for total power take off 8879 9 10 11 Jumper with H7 of 75002 8849 12 Jumper with AV12 of Body Computer 8879 13 14 Earth 0000 15 16 17 Positive for diagnostics connection joint 7797 18 19 20 Positive 15 8879 21 Positive for horns 1116 22 Positive for rh full beam headlight 2221 23 Jumper for Body Computer 8879 24 25 Positive for lh full beam headlight 2219 26 Earth ...

Page 968: ...t protected direct positive on batteries 7777 13 14 15 16 17 Positive 15 7772 18 Positive for EDC MS6 system from main relay 7150 19 20 21 Positive 15 8879 22 Water in pre filter warning lamp 5530 23 Jumper between C23 and C12 7772 24 Positive 30 for automatic gearbox central unit 7772 25 26 27 28 Negative for heated rear view mirrors switch 0000 29 Positive 30 7772 30 Injection pump diesel oil fl...

Page 969: ...s D Ref Function Code A Positive 30 for key switch 7772 B Positive 30 for automatic gearbox 7772 Junction connectors E Ref Function Code A Positive for chassis cable 3390 B C Positive 15 for heated rear view mirrors 8830 Junction connectors F Ref Function Code A Positive 30 for pre heating 7772 ...

Page 970: ...s connected to earth point LM2 located at chassis left side on the side member from this point a copper braid is connected to engine block near the starter lm1 At point lm2 there are connected the earth points relating to chassis cable NEGATIVE PIN EARTH POINT ON LEFT HAND SIDE MEMBER LM2 ENGINE BLOCK BRAID LM1 Figure 16 Figure 17 Figure 18 107633 107637 107636 ...

Page 971: ... bonnet opening In bonnet in the vicinity of right front blinker there is located earth point lm4 to which connected are Rh headlamp Windscreen washer pump Horn Windscreen wiper Compressor connected remote control switch for EDC Air conditioner compressor Heated windscreen Gearbox power take off in switch Antitheft siren Air filter clogged switch In the bonnet under power assisted brake there are ...

Page 972: ...hts pushbutton Front fog lights pushbutton Speed limit setting pushbutton Radio Windscreen electric defroster control assembly Air conditioner central unit Pushbutton for heated rear window Heated mirrors switch Vehicle lifting lowering pushbuttons ECAS Tachograph lm6 S Loading platform central part lm8 Clearance rh lh front lights AIR BAG central unit lm8 S Switch for anti twisting with gears eng...

Page 973: ...duty marked with red color Environmental precautions plate according to Law no 126 of 10 04 91 Standards for user information Adhesive label with Selective disposal acc to EEC Directive no 93 86 Fast diagnosis Defect Possible causes Remedy Start defect 1 Low battery Check battery charge if regular check recharge circuit 2 Loose oxidized or burnt out con tacts Recover 3 Starter circuit defective Cf...

Page 974: ...d polarity is not allowed Operating specifications Rated voltage 14 V Rated current delivery 110A Drive side direction of rotation clockwise Maximum continuous speed 12 000 min 1 Storage temperature 40 C 110 C WIRING DIAGRAM TECHNICAL VIEW 03000 Figure 26 Figure 27 8649 8656 38 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 BOSCH KCBI 14V 110A ALTERNATOR ...

Page 975: ...nt 603 93 651 EV 12V 2 3 KW STARTER MOTOR Fast diagnosis Defect Possible causes Remedy Low drawing torque 1 Low battery Recover 2 Oxidized or loose circuit connec tions Check starter motor and battery con nections 3 Faulty brushes Check brush slide length and pressure 4 Field coils short circuited Replace coils 5 Rotor cut out or short circuited Replace rotor 6 Oval collector Grind correct or repl...

Page 976: ...ear the shunt towards CPL Weld A78 near the shunt for climate control system Weld A100 near instrument cluster shunt Weld A101 102 near rh speaker shunt CAB CABLE Weld A15 near lh window bag shunt Weld A21 a601 near central roof lamp shunt Weld A 25 near lh front shunt for cable bonnet junctions Weld A26 A18 A700 near lh front shunt for cable instrument panel junction Body Computer LN CPL connecto...

Page 977: ... shunt Weld A66 near junction for automatic gearbox bonnet side Weld A67 near central unit CPL Weld A70 near central unit EDC Weld A77 near shunt for ECAS lambda additional heater bonnet side TRUCK CHASSIS CABLE Weld A6 near rear lights shunt Weld A10 near fuel level transmitter shunt VAN CHASSIS CABLE Weld A6 A10 near lh clearance lateral headlamp shunt ...

Page 978: ... following connectors BONNET INSTRUMENT PANEL cable Connectors 600 601H 600 601B 600 601D BONNET CAB cable Connectors 600 601G 600 601A INSTRUMENT PANEL CAB cable Connectors 600 601C BONNET CHASSIS cable Connectors C4 C2 C70 All junction connectors are on vehicle left side at interconnection central unit CPL The three BONNET CHASSIS connectors are in engine opening on vehicle left side under front...

Page 979: ...ELECTRIC ELECTRONIC SYSTEM 43 DAILY EURO 4 Base March 2006 Print 603 93 651 Figure 31 107643 cab cable instrument panel cable AIR BAG cable bonnet cable ...

Page 980: ...44 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Figure 32 107644 Engine cable chassis cable ABS probes cable doors cable ...

Page 981: ...9 7 Positive 15 to antitheft siren 9140 8 Signal from antitheft central unit to siren 9142 9 Negative for power take off actuator 9136 10 Positive for power take off actuator 9135 11 Automatic gearbox central unit pin 3 6141 12 Automatic gearbox central unit pin 5 6143 13 Positive 15 8887 14 Positive for automatic gearbox gear selector 8110 15 Automatic gearbox Gear selector pin 3 White 16 Automat...

Page 982: ...d 8163 6 Signal from external temperature sensor for air conditioner 5532 7 Acceleration sensor earth ESP8 0050 8 Acceleration signal from acceleration sensor ESP8 9090 9 Positive to acceleration sensor ESP8 9091 10 Positive for differential locking system 8066 11 Positive 15 8887 12 Yaw sensor reference signal ESP8 9094 13 Yaw sensor test signal ESP8 9093 14 Positive 15 8879 15 Yaw sensor signal ...

Page 983: ... Positive for TELMA decelerator second position 9910 8 Positive for TELMA decelerator third position 9916 9 Positive for TELMA decelerator fourth position 9912 10 Positive for TELMA control switch 9911 11 Positive 15 8879 12 Positive for EDC failure warning lamp 5180 13 Negative for optical indicator for differential locking on transfer box from signalling switch 6603 14 Positive for horn 1116 15 ...

Page 984: ... for fuel level transmitter 0000 5 Signal from fuel level transmitter 5557 6 Positive 30 7772 7 8 Positive for clearance lights van 3325 9 Positive for clearance lights van 3324 10 Positive for rear door actuator 8901 11 12 5164 13 Positive for lh front parking light lh front clearance 3321 14 Positive for rh front parking light rh front clearance 3320 15 Positive 15 8879 16 17 18 19 20 Figure 36 ...

Page 985: ...on failure warning lamp to Body Computer 6008 8 Positive for plate light 3337 9 Positive for rh blinker 1125 10 Positive for heated rear window 8021 11 Positive for heated rear window 8021 12 Positive for stop rear signalling 1177 13 Positive for heated mirrors 8830 14 Positive for heated mirrors 8830 15 Positive for reverse headlamp 2226 16 Positive for lh rear blinker 1120 17 Positive for rh rea...

Page 986: ...ternal temperature sensor for air conditioner 5532 5 External temperature sensor for air conditioner 5532 6 7 Positive for cigarette lighter 7721 8 Positive 15 with the exclusion of users during start up step 8849 9 Positive 15 with the exclusion of users during start up step 8849 10 B Can line H parking sensors 6111 11 B Can line L parking sensors 6110 12 Positive for cigarette lighter 7721 10765...

Page 987: ...ngine coolant low level red 14 Engine oil low pressure red 15 EDC failure red 16 Battery not being recharged red Position Warning lamps Colour 17 EOBD yellow 18 Air spring suspension failure red 19 Engine coolant high temperature red 20 Tachograph failure symbol T yellow 21 Programmed maintenance yellow 22 Fuel reserve yellow 23 Generic failure yellow 24 Passenger airbag de activated yellow 25 Dif...

Page 988: ...position C 9935 8 Positive for headlight attitude rectifier 9934 9 Earth to instrument panel switch assembly 0000 10 11 12 13 To instrument panel switch assembly 9086 14 To instrument panel switch assembly 9085 15 16 To instrument panel switch assembly 9087 17 Positive for differential locking optical indicator 6603 18 Positive for EDC failure 5180 Where instrument cluster is replaced reprogram by...

Page 989: ...ith relating messages for settings adjustments activation service messages failure warning messages The display also displays automatic gearbox indication time indication of danger owing to ice adjustable spanner symbol for service external temperature headlamp attitude rectifier indication total partial KM Displaying messages on display screen Messages on display screen are divided into four diff...

Page 990: ...ker control to Body Computer 1111 P1 6 Flashing control to Body Computer 8024 Black 7 Parking lights control to Body Computer 3333 8 Horns 1116 9 Front fog lights control to Body Computer 2228 10 11 Front fog lights control to front fog lights on pushbutton 2228 12 1 Positive for Cruise Control 7155 2 Positive for Cruise Control 7155 P2 3 Slow down signal SET 8157 Black 4 Windscreen wiper reset in...

Page 991: ...otating translating door control 3 Self levelling air spring suspensions 4 Load area illumination 5 Front fog lights 6 Emergency lights 7 Heated rear view mirrors 8 Heated rear window 9 Rear differential locking 10 Exclusion of ASR 11 Speed limiter in Pushbutton arrangement may change depending on different preparations 107647 Figure 43 ...

Page 992: ... SWITCH ASSEMBLY 53807 Ref Function Cable Code 1 Positive 15 3320 2 Earth to Body Computer 0000 3 4 To instrument cluster headlamp attitude 9085 5 To instrument cluster MODE 9086 6 To instrument cluster MODE 9087 7 8 9 Earth to instrument cluster TRIP 0000 10 Air heater 11 12 107652 Figure 44 ...

Page 993: ...ELECTRIC ELECTRONIC SYSTEM 57 DAILY EURO 4 Base March 2006 Print 603 93 651 OPTIONAL BOX 107687 Figure 45 CENTRAL UNIT FRONT VIEW CENTRAL UNIT REAR VIEW ...

Page 994: ...emote control switch to enable compressor switching on 5 F25 10A fuse 6 T18 Remote control switch to set gearbox to neutral position automatic gearbox 7 T24 Remote control switch to enable PTO switching on 8 F28 30A fuse for positive for rear differential locking central unit 9 T23 Remote control switch to control air conditioner compressor 10 T21 Remote control switch to warn that compressor for ...

Page 995: ...0 Negative from EDC for remote control switch to enable compressor to be put on 26 27 7772 Positive 30 for remote control switch to enable compressor to be put on 28 0000 Earth for remote control switch to enable compressor to be put on 29 0000 Negative from compressor control remote control switch 30 0000 Negative from remote control switch to enable compressor to be put on 30 31 32 0000 Connecti...

Page 996: ...contrary a 16 pin connector is present named EOBD In particular on CAN line named Ccan connected are central units relating to vehicle systems and information for driver Yaw sensor present with ESP8 ABS Automatic gearbox EDC16 Decelerator Digital tachograph Body Computer This communication line is characterised in high speed data transmission relevant to electronic systems connected to it It is co...

Page 997: ...CAN line 107653 Figure 46 1 Central unit EDC16 2 Digital tachograph 3 Automatic gearbox central unit 4 Decelerator 5 Steering angle sensor ESP8 6 Body Computer 7 Alarm siren 8 Additional heater 9 Climate control system central unit 10 Central unit WABCO 11 Central unit ABS8 ESP8 ...

Page 998: ...YSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 B CAN line 107688 Figure 47 1 Rotating translating door central unit start of 2007 2 Air Bag central unit 3 Body Computer 4 Instrument cluster 5 Radio navigator 6 Blue Tooth ...

Page 999: ...ELECTRIC ELECTRONIC SYSTEM 63 DAILY EURO 4 Base March 2006 Print 603 93 651 BODY COMPUTER 86116 107624 Figure 48 1 Body Computer 2 Central unit CPL 107673 1 2 ...

Page 1000: ...ious diagnosis connector is not present any more it communicates with the two CAN lines present Bcan Ccan and instrument cluster It is mounted in the cab behind interconnection central unit CPL and interfaces with it through a 20 pin lamellar connector located inside the component It interfaces with vehicle system through three connectors two connectors are located in front side and one connector ...

Page 1001: ...ILY EURO 4 Base March 2006 Print 603 93 651 Figure 50 1 Connector CY for junction with CPL interior 2 Junction connector AV bonnet 3 Diagnosis connector EOBD 4 Junction connector LN cab 5 Junction connector PF instrument panel 107664 ...

Page 1002: ... for lh rear blinker 1120 19 Positive for rh blinker 1124 20 Signal for hand brake optical indicator 6662 21 Fuel level gauge PIN 3 0000 22 Earth for roof lamp switching on 0003 23 24 Line K for air spring suspension central unit 2294 25 Air spring suspension failure warning lamp 6008 26 Positive for rh rear fog light 2283 27 13 pole socket PIN 9 6120 28 Negative for illumination pushbutton with t...

Page 1003: ...tion Cable Code 37 38 39 4112 40 Decelerator TELMA optical indicator 6604 41 Central locking C2 0000 42 Central locking A2 0000 43 Positive for lh rear fog light 2283 44 Positive for lh stop rear light 1177 45 46 6606 47 48 _ 6630 49 Roof lamp for side hatch illumination 4113 50 51 52 ...

Page 1004: ... unit line K 2296 13 14 15 16 17 0000 18 Positive for the illumination of the symbols of switches 3320 19 Earth 0000 20 Negative for cab roof lamp switch 0000 21 Positive for the illumination of the symbol of heated rear window on 6653 22 5647 23 Camera PIN B 1 visual system for reverse gear 5 59 24 Air Bag B CAN line H 6110 25 Air Bag B CAN line L 6111 26 27 Positive 15 8849 28 Positive for winds...

Page 1005: ...xed stop for windscreen wiper PIN 2A 8873 20 Negative for remote control switch to switch on headlight wipers 0000 21 Negative for automatic gearbox central unit PIN 45 0000 22 Line K for central unit ABS ASR 2299 23 24 Negative from brake liquid level sensor 6661 25 Generator charge optical indicator 7778 26 Line K for central unit EDC 16 2298 27 Negative for electronic tachometer transmitter PIN...

Page 1006: ...ontrol for remote control switch to switch on windscreen wiper 8879 41 42 43 Central locking antenna PIN 2 44 C CAN Line L Steering angle sensor PIN 1 CAN line closing resistance 45 C CAN Line H Steering angle sensor PIN 3 CAN line closing resistance 46 Positive for antitheft siren 30 47 Line K for additional heater 48 C CAN Line L ABS automatic gearbox EDC16 2950 49 C CAN Line H ABS automatic gea...

Page 1007: ...ternator charge alternator signal L 9 Clutch status activated not activated 10 Reverse gear engaged positive 11 12 Cruise control set 13 Cruise control set 14 Cruise control reset 15 Cruise control on 16 17 Earth 18 Power take off 1 19 Power take off 2 20 Power take off 3 Positioned in the cab near junction connectors Air Bags at the bottom to the right 101564 Figure 54 ...

Page 1008: ... 651 FITTER CONNECTOR 72068 Ref Function 1 Activating secondary speed limiter 2 Activating speed limiter 3 Selecting idling and 2 speeds 4 Vehicle speed signal 5 Positive 15 key 6 Power take off activated 7 Horn activated 8 9 10 Engine rotation speed 11 12 101554 Figure 55 ...

Page 1009: ...d on the intake manifold after the intercooler Constant regeneration particulate trap is mounted on engine exhaust Through data processing engine rpm s H2O temperature oil temperature lambda probe signal etc the central unit calculates the quantity of particulate accumulated in filter and chooses to increase exhaust gas temperature through post injection in order to burn particulate accumulated in...

Page 1010: ...id valve 6 Air filter 7 Air flow rate meter flow meter 8 Oil vapours recirculation tube 9 Differential pressure delta p sensor 10 Inlet exhaust gas temperature sensor 11 Outlet exhaust gas temperature sensor 12 DPF catalysed silencer 13 Vacuum tank 14 Vacuum unit fitting 15 EDC 16 central unit 16 Power assisted clutch 17 Throttle valve assembly 18 Air pressure sensor 105058 Exhaust gasses Recircul...

Page 1011: ...sucked in air temperature sensor is built in Operation Operation principle is based on a heated membrane put in between a measurement channel through which inlet air entering the engine is flowing The heated film membrane is kept at constant temperature about 120 C higher than incoming air temperature by heating resistance The air mass which runs through measurement channel tends to take out heat ...

Page 1012: ...oxygen percentage is higher than 8 oxygen being produced by the decomposition of nitrogen oxide NO2 then some combustion reactions boosted by the catalyst put before the filter burn particulate particles regeneration so keeping the filter clean On the contrary if its temperature is lower the filter is clogged with negative effects on counterpressure on exhaust gasses generated by the filter In thi...

Page 1013: ...Base March 2006 Print 603 93 651 Particulate filter components location 1 Lambda probe 2 Exhaust gas temperature sensor 3 TO Pressure sensor at filter inlet 4 Exhaust gas temperature sensor 5 TO Pressure sensor at filter outlet Figure 60 102393 ...

Page 1014: ...ttle valve is mounted on inlet manifold Its task is to regulate the flow rate of air coming in from the intercooler that is to be mixed with exhaust gasses recirculated by E G R valve according to a programmed percentage The throttle valve is driven by an electrical actuator controlled by a PWM signal from central unit EDC 16 Figure 62 Air from intercooler Cooled exhaust gasses Engine coolant Hot ...

Page 1015: ...necessary to start up a regeneration E G R system is of course shut out during regeneration in order to prevent post injections vapours from being sucked into the cylinder During vehicle run the central unit processes plenty of information on filter status which are relevant to have correct filter operation and reach duration targets In particular there are constantly counted and saved on non vola...

Page 1016: ...ntral unit makes some checks on filter differential pressure sensor drift e g with engine stopped pressure value is the same upstream and downstream of filter So some parameters are calculated and engine running values are consequently rectified Replacing delta p sensor involves resetting the rectifications Replacing engine oil During vehicle life time the central unit counts up the quantity of po...

Page 1017: ...njector mounting sequence is important and cannot be changed in service operations without reprogramming the central unit it is not possible to replace one or more injectors without reprogramming the central unit where an injector is replaced it is suggested to note down its code before mounting it since it is problematic to read its value on the vehicle It is obvious to conclude that where the ce...

Page 1018: ...ding to the signals from the sensors and the mapped values the control unit operates the pressure regulator varies the pilot injection time to 2200 rpm varies the main injection time Checking idling adjustment The control unit processes the signals from the various sensors and regulates the amount of fuel injected it operates the pressure regulator it varies the injection times of the electro inje...

Page 1019: ...ng pilot and main injection timing According to the signals from the various sensors including the absolute pressure sensor built into the control unit the control unit determines the optimum point of injection according to internal mapping Checking injection pressure closed cycle Depending on the engine load determined by processingthe signals from the various sensors the control unit operates th...

Page 1020: ... engine the timing and cylinder no 1 recognition signals flywheel sensor and camshaft sensor are synchronized The accelerator pedal signal is ignored on starting Starting delivery is set only according to water temperature by a special map When the control unit detects such speed and acceleration of the flywheel as to be able to consider the engine started up and no longer driven by the starter mo...

Page 1021: ...t and handling This function permits individual customized control over the delivery of fuel and the start of delivery for each cylinder even differently from one cylinder to another to compensate for the hydraulic tolerances of the injector The differences in flow delivery specifications between the various injectors cannot be evaluated directly by the control unit This information is supplied by...

Page 1022: ...pressure and temperature sensors 9 48042 Timing system shaft sensor 10 85157 Fuel pressure sensor 11 48035 Engine shaft sensor 12 78247 Electrical injectors 13 25231 Glow plugs pre heating central unit 14 Throttle valve assembly 15 19010 Pre heating glow plug 16 44030 Fuel electric pump with level gauge 17 78209 E G R solenoid valve 18 12012 AC compressor 19 85159 Flow meter 20 58701 EDC warning l...

Page 1023: ...Figure 64 112286 ELECTRIC ELECTRONIC SYSTEM 87 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1024: ... SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Bosch EDC16 control unit PERSPECTIVE VIEW A Engine side injection cable connector K Bonnet cab cable connector A Central unit EDC Figure 65 Figure 66 107683 107621 A K A ...

Page 1025: ...e 20 7158 Distributing shaft sensor positive 23 0165 Boosting air pressure and temperature sensor negative 26 Throttle valve actuator 27 white Drive shaft sensor 28 5591 Rail sensor power supply 31 9924 Cylinder injector 2 33 0000 Cylinder injector 4 35 Engine oil level signal 37 5151 Air flow meter air temperature signal available with EGR 39 Engine oil level signal 40 5152 Boosting air pressure ...

Page 1026: ...1 Pin Cable colour code Function 52 5592 Fuel temperature sensor signal 53 5151 Boosting air temperature sensor signal 56 Throttle valve actuator 58 5154 Water temperature sensor signal 60 8150 EGR solenoid valve F Power seats f Signal seats Pins not highlighted are not used ...

Page 1027: ... sensor 16 Negative from power takeoff if any state selector 17 Signal from brake pedal pressed for stop light ignition 22 p differential sensor 25 2298 K line 27 5180 Exhaust gas temperature sensor 1 28 8051 15 30 0157 Accelerator pedal sensor negative pin 3 31 5157 Accelerator pedal sensor signal pin 6 38 8155 Cruise Control resume 42 Speed limiter button 45 5157 Accelerator pedal sensor power s...

Page 1028: ...8 8156 Fuel filter heating remote control switch positive 70 Compressor switching on 71 EDC warning light negative 72 0155 Main relay negative 75 5517 Vehicle speed signal tachometer 77 8154 Cruise Control off 78 8156 Cruise Control set 79 8167 Coolant pressure switch 80 8158 Brake pedal signal 81 5530 Water in fuel filter 86 8294 Lambda probe 87 8293 Lambda probe 90 Positive for engine cooling el...

Page 1029: ...value compared with the other Both of these signals V are detected by the control unit that processes them according to stored threshold values and manages the injection system as an accelerator pedal position set by the driver At the output of these potentiometers a variable voltage is available which corresponds to the potentiometer resistance value It is connected to the EDC control unit connec...

Page 1030: ... central unit ESP8 at PIN 30 Clutch pedal switch 42374 An N C switch connected to electronic centre pin K58 is mounted on the clutch pedal The clutch pedal actuated signal is used by the centre to identify gear condition selected and gear shifts In absence of the pedal pressed switch signal the centre disenables the Cruise Control function 1 Brake pedal switches 1 Clutch pedal switch Figure 70 Fig...

Page 1031: ...ed back to the control centre for information on any preheat centre defect or plug earth shirt circuit Preheat centre pin out 31 Mass 86 Start switch 15 ST EDC electronic centre pin K93 DI EDC electronic centre pin K52 30 Battery positive 30 G1 Preheat plugs G2 Preheat plugs G3 Preheat plugs G4 Preheat plugs Preheat plugs CONTROL VALUES With constant di 11V power supply maximum current absorbed 18...

Page 1032: ...6 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 R p m timing sensors F1C 1 R p m sensor 2 Phonic wheel on drive shaft 3 Timing sensor 4 Phonic wheel on camshaft Figure 75 88056 ...

Page 1033: ...ELECTRIC ELECTRONIC SYSTEM 97 DAILY EURO 4 Base March 2006 Print 603 93 651 1 Phonic wheel on camshaft 2 Identification slots 3 Sensor Figure 76 88264 88267 Timing sensor stroke F1C ...

Page 1034: ...rated by the lack of some teeth synchronisation gap occurring at each drive shaft turn is the reference signal which enables the central unit to detect the lead of the pair of pistons 1 4 with respect to PMS This signal is also used by the control unit to detect the engine rotation speed the duration of injection and to control the rev counter PHONIC WHEEL MOUNTING 1 Phonic wheel TECHNICAL VIEW OF...

Page 1035: ...honic wheel distributing shaft pulley covers while moving the sensor thus blocking the magnetic field with resulting low output signal On the contrary the sensor generates a high signal next to the openings and when a magnetic field is available Phase sensor signals are acquired and the engine position is recognized according to the sequence of the phonic wheel notches The mounting function makes ...

Page 1036: ...linder 3 axial displacement by fuel delivery partialization When solenoid 1 is not activated the magnetic core is moved to its rest position by preload spring 6 In these conditions cylinder 3 is in a position to offer maximum fuel passage cross section Control electro valve 78013 is connected to centre connector A pins 19 and 49 1 Solenoid 2 Magnetic core 3 Cylinder 4 Fuel input 5 Fuel output 6 Pr...

Page 1037: ...lic accumulator there is located the fuel pressure sensor Pressure sensor Fitted to a rail end it measures fuel pressure present to the purpose of determining existing fuel pressure Pressure value is used to control pressure and determine injection electric control duration 85157 It is connected to the central unit at pins A 8 43 28 It is fed at 5 V 1 Rail 2 Pressure sensor PRESSURE LIMITER OPERAT...

Page 1038: ...ral unit on connector A Pin 1 sensor Pin A23 earth Pin 2 sensor Pin A53 temperature signal Pin 3 sensor Pin A13 5V supply Pin 4 sensor Pin A40 0 5V pressure signal Course of sensor in relation to the temperature Temperature Resistance 40 C 48 50 kOhm 20 C 15 67 kOhm 0 C 5 86 kOhm 20 C 2 50 kOhm 40 C 1 17 kOhm 60 C 0 59 kOhm 80 C 0 32 kOhm 100 C 0 18 kOhm 120 C 0 11 kOhm Course of sensor in relatio...

Page 1039: ...nformation about the engine temperature conditions The same signal is used via CAN lines to control the instrument cluster where the gauge is present Fuel temperature sensor This is an NTC sensor located on the fuel filter It detects the temperature of the fuel to give the control unit information about the fuel oil temperature conditions It is connected to pins 52 and 51 ofconnector Aof thecontro...

Page 1040: ...ergised and causes the shutter 6 to move upwards The fuel of the control volume 9 flows towards the backflow duct 10 causing a drop in the pressure in the control area 7 At the same time the pressure of the fuel in the pressure chamber 8 causes the needle 2 to rise resulting in fuel injection to the cylinder 3rd phase end of injection The coil 4 is not activated and makes the shutter 6 return to t...

Page 1041: ...er cooling The electrical fan remote control switch is activated or deactivated by the centre according to the temperature of the coolant over supply air the fuel Engine coolant temperature Activated at over 96 C and deactivated at under 84 C Over supply air temperature Activated at over 75 C and deactivated at under 65 C Fuel temperature Activated at over 20 C and deactivated at under 10 C ELECTR...

Page 1042: ...or thus blocking the magnetic field with resulting low output signal On the contrary the sensor generates a high signal next to the openings and when a magnetic field is available Phase sensor signals are acquired and the engine position is recognized according to the sequence of the phonic wheel notches The mounting function makes it possible to identify signal errors and interferences if any The...

Page 1043: ...W OF THE SOUND WHEEL AND SENSOR 1 Sound wheel 2 Crankshaft sensor Figure 98 Figure 99 0003319t Characteristics of flywheel rpm and timing system sensors These are inductive sensors The flywheel sensor 48035 is connected at pins 27 and 12 of connector A of the control unit It is also used to control the electronic rev counter on the instrument cluster The resistance at 20 C is approx 860 Ohm SENSOR...

Page 1044: ...inder 3 axial displacement by fuel delivery partialization When solenoid 1 is not activated the magnetic core is moved to its rest position by preload spring 6 In these conditions cylinder 3 is in a position to offer maximum fuel passage cross section Control electro valve 78013 is connected to centre connector A pins 19 and 49 1 Solenoid 2 Magnetic core 3 Cylinder 4 Fuel input 5 Fuel output 6 Pre...

Page 1045: ...ic accumulator there is located the fuel pressure sensor Pressure sensor Fitted to a rail end it measures fuel pressure present to the purpose of determining existing fuel pressure Pressure value is used to control pressure and determine injection electric control duration 85157 It is connected to the central unit at pins A 8 43 28 It is fed at 5 V 1 Rail 2 Pressure sensor PRESSURE LIMITER OPERATI...

Page 1046: ...ergised and causes the shutter 6 to move upwards The fuel of the control volume 9 flows towards the backflow duct 10 causing a drop in the pressure in the control area 7 At the same time the pressure of the fuel in the pressure chamber 8 causes the needle 2 to rise resulting in fuel injection to the cylinder 3rd phase end of injection The coil 4 is not activated and makes the shutter 6 return to t...

Page 1047: ... A2 A3 A19 A34 Pin 1 sensor Pin A23 ECU earth Pin 2 sensor Pin A53 ECU temperature signal Pin 3 sensor Pin A13 ECU 5V supply Pin 4 sensor Pin A40 ECU 0 5V pressure signal Course of sensor in relation to the temperature Temperature Resistance 40 C 48 50 kOhm 20 C 15 67 kOhm 0 C 5 86 kOhm 20 C 2 50 kOhm 40 C 1 17 kOhm 60 C 0 59 kOhm 80 C 0 32 kOhm 100 C 0 18 kOhm 120 C 0 11 kOhm Course of sensor in ...

Page 1048: ...ater cooling The electrical fan remote control switch is activated or deactivated by the centre according to the temperature of the coolant over supply air the fuel Engine coolant temperature Activated at over 96 C and deactivated at under 84 C Over supply air temperature Activated at over 75 C and deactivated at under 65 C Fuel temperature Activated at over 20 C and deactivated at under 10 C ELEC...

Page 1049: ...4 Base March 2006 Print 603 93 651 FUEL FILTER Figure 109 107676 1 Positive for power supply 2 Heater 3 Water present sensor 4 Filter clogged sensor 5 Fuel temperature sensor 6 Fuel temperature sensor 7 Earth for heater 8 Earth 1 8 2 3 4 5 6 7 ...

Page 1050: ...114 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 FUEL PUMP FUEL LEVEL Figure 110 112287 1 Level sensor 2 Level sensor 3 Negative for fuel pump 4 Positive for fuel pump ...

Page 1051: ...ads or when one driving wheel is skidding It also reduces the risk of understeering when you accelerate too much when cornering MSR Engine braking torque control This system avoids driving wheel drag due to the exhaust brake It ensures vehicle stability when releasing on slippery roads e g snow ice and assists in keeping the path when cornering and shifting down especially on slippery roads It req...

Page 1052: ...gonal power supply or FL RR with ABS8 ESP8 systems MC2 RF LR diagonal power supply or FR RL with ABS8 ESP8 systems LF or FL with ABS8 ESP8 systems Left front axle output RR Right rear axle output RF or FR with ABS8 ESP8 systems Right front axle output LR or RL with ABS8 ESP8 systems Left rear axle output 102113 Figure 111 116 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651...

Page 1053: ...nector B ESP8 connector MC1 Front axle power supply MC2 Rear axle power supply LF or FL with ABS8 ESP8 systems Left front axle output RR Right rear axle output RF or FR with ABS8 ESP8 systems Right front axle output LR or RL with ABS8 ESP8 systems Left rear axle output 102114 Figure 112 ELECTRIC ELECTRONIC SYSTEM 117 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1054: ...Front right sensor earth 5571 10 10 Front right sensor 5571 11 11 Diagnosis K line 2299 12 12 13 13 Decelerator deactivation with ABS system ON 0000 14 14 15 15 CAN L line Green 16 6 Front left sensor earth 5570 17 17 Rear left sensor earth 5572 18 18 Positive after fuse KL 15 8879 19 19 Rear right sensor 5573 20 20 Stop signalling switch brake lights 1176 21 21 22 22 23 23 24 24 25 25 26 26 CAN H...

Page 1055: ...r reference signal 9091 19 19 Voltage stabilization signal to the acceleration sensor 9091 20 20 Side acceleration sensor signal 9092 21 21 Side acceleration sensor signal earth 0050 22 22 Decelerator deactivation with ABS system ON 0000 23 23 24 24 1199 25 25 26 6 Front left sensor earth 5570 27 27 Rear left sensor earth 5572 28 28 Positive after fuse 15 8879 29 29 Rear right sensor 5573 30 30 St...

Page 1056: ...0 Front sensor 5570 11 Diagnosis line K 2299 12 13 De activating the decelerator with ABS in 0000 14 CAN line L Green 15 16 17 18 19 20 21 22 23 24 25 26 27 Left rear sensor 5571 28 Positive after fuse for ABS KL 15 8847 29 Front sensor earth 5570 30 Stop signalling switch Stop lights 1173 31 Switch to enable engine brake to be put on ASR ESP passive switch 8800 32 33 34 35 White 36 37 38 39 40 41...

Page 1057: ...rear sensor 5572 8 Left rear sensor earth 5573 9 Right front sensor earth 5571 10 Right front sensor 5571 11 Diagnosis line K 2299 12 13 De activating the decelerator with ABS in 0000 14 CAN line L Green 15 16 17 18 19 20 21 22 23 24 25 26 Left front sensor earth 5570 27 5572 28 Positive after fuse KL 15 8879 29 Right rear sensor 5573 30 Stop signalling switch Stop lights 1173 31 Switch for the ex...

Page 1058: ...es the running behaviour based on the data provided and the ESP comes into operation by acting on the brakes The hydraulic modulator controls brake pressure for every single wheel as quick as possible The ESP may through engine management reduce the number of revolutions of the engine itself in order to withstand vehicle deceleration The ESP system is always active in the background i e it compare...

Page 1059: ...SP brakes the front left wheel 4 The vehicle recovers stability Sudden steering Vehicle running on a slippery road 101865 1 The vehicle risks skidding understeering the ESP brakes the rear right wheel and reduces the engine revs number 2 The vehicle recovers stability Figure 118 Figure 119 ELECTRIC ELECTRONIC SYSTEM 123 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1060: ...ngine intervention of the ESP and ASR MSR torque increase decrease over the entire speed range Traction Control actuation enabled up to the speed of 60 k p h electronic locking of differential with no reference to the dragged wheels Stability intervention ESP enabled over the entire speed range ABS enabled over the entire speed range EBD enabled over the entire speed range ASR deactivation is reco...

Page 1061: ...ng No correction of the rear axle braking pressure DANGER OF SPINNING THROUGH 180 DEGREES The warning light also warns the driver of low brake fluid level hand brake ON brake pads worn Installing the esp components Installation of the electro hydraulic modulator control unit is similar in ASB 8 systems too NOTE 107690 1 Acceleration sensor 2 Yaw sensor 3 Steering angle sensor 4 Electro hydraulic m...

Page 1062: ... calibration NOTE 102115 It measures the motion of the vehicle around its own vertical axis yaw as well as the vehicle s side acceleration These signals continuously inform the control unit about the vehicle s behaviour The comparison between these signals and those from the driver steering wheel position wheel spin number speed and pressure on the brake pedal accelerator position allows the ESP c...

Page 1063: ...SP system may decrease the engine revs number by means of the engine control feature Longitudinal acceleration sensor calibration 112243 In a horizontal position you will obtain the sensor zero condition through the diagnosis instrument i e you will assign its absolute zero position Use a diagnosis instrument to clear the errors Carry out a road test to make the control unit verify whether errors ...

Page 1064: ... checking toe in you will obtain the sensor zero condition through the diagnosis instrument i e you will assign its absolute zero position Use a diagnosis instrument to clear the errors Carry out a road test to make the control unit verify whether errors are still found Drive along a straight road at a speed of approximately 50 k p h Steer to the right and then to the left several times after maki...

Page 1065: ...imately 50 k p h Brake suddenly as if in an emergency after making sure you do not endanger other drivers you should feel the system respond on the brake pedal This test makes the control unit verify whether errors are still found Drive back to the service centre then use a diagnosis instrument to verify that the anomaly is no longer found Replacing ESP central unit needs the longitudinal accelera...

Page 1066: ...g positions Below is events time sequence from the time of electrical pulse triggering off by electronic central unit Time t1 Time when inflation system is triggered off Thereafter inflation pressure starts rising in the cushion which is still enclosed inside module cover The module is made up of a plastic layer located at steering wheel centre Driver s body is still in almost normal position Figu...

Page 1067: ...ELECTRIC ELECTRONIC SYSTEM 131 DAILY EURO 4 Base March 2006 Print 603 93 651 107678 Figure 127 ...

Page 1068: ...ing Central unit is capable to detect this deceleration by two sensors one electromechanical sensor and one electronic sensor that are placed inside it The cushions made of a synthetic fibre are respectively housed at steering wheel centre and at an opening of the instrument panel in front of passengers At each start up operation the central unit puts on the warning lamp and keeps it on for about ...

Page 1069: ...d during an accident is to be considered still active Therefore undeployed components to be removed from vehicles due to faults guarantee expiry or other causes must be returned to the special centre through the procedure described below All the system components have been specifically designed to work on vehicles of a specific brand and type Therefore air bags cannot be adapted re used or install...

Page 1070: ...they will not be damaged heating the outer surfaces of the vehicle with normal paint drying systems It is prohibited to use naked flames near the modules All electronic control units including the air bag system should always be removed if their temperature in certain environments may reach or exceed 85 C Health hazards The precautions to be taken when handling deployed air bags are the following ...

Page 1071: ... acids greases and heavy metals Contact with these substances may cause the formation of poisonous harmful gas or explosive compounds Never use naked flames near air bag devices and system components Any spare parts should be stored in their original packing and temporary storage should follow the same procedure as for an undeployed air bag removed from the vehicle i e a key lockable metal cabinet...

Page 1072: ...must not be used and must be returned to the supplier stating the reason Pretensioners should not be carried by the belt Pretensioners must be protected from sparks and naked flames they should not contact surfaces for over 6 hours with temperatures above 100 ºC The gas generator propellant that is not burnt is inflammable therefore the parts of the generator should never be taken to pieces damage...

Page 1073: ... copper or chloride e g potassium chloride If the propellant is based on sodium azide or potassium nitrate the combustion residues are highly alkaline and corrosive Always wear appropriate protection for the eyes and skin Deployed air bags should always be stored in dry suitably ventilated places Removing or scrapping an air bag module that has not been deployed from a reparable vehicle If the con...

Page 1074: ...ed by the vehicle manufacturer to the air bag module 5 Connect connector C2 to the remote deployment device 6 Connect the remote deployment device to a 12 V circuit or equivalent device 7 Make sure all persons are under shelter 8 Wear accident prevention goggles and protective clothing 9 Press the double deployment button 10 After deploying an air bag module let it cool before touching it about 20...

Page 1075: ...or pretensioner to the connection bridle of the remote deployment device 10 Connect connector C2 to the remote deployment device 11 Make people go to a safe place 12 Connect the remote deployment device to a 12 V circuit or equivalent device 13 Press the double activation button to deploy all the air bag modules and pretensioners at the same time 14 After deploying the air bag modules and pretensi...

Page 1076: ...140 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Figure 130 107679 ...

Page 1077: ...ntrol pretensioner 7 safety belts with drive side electronic control pretensioner 8 safety belts with central electronic control pretensioner 9 lh rh lateral sensor 10 lh rh curtain air bag DE ACTIVATING PASSENGER AIR BAG Passenger air bag can be disabled from instrument cluster menu directly by the driver Air bag central unit will send a message through B Can line to instrument cluster which acti...

Page 1078: ...tes electric energy for normal operation of the control unit and generate the signal for triggering the explosive capsule This way system operation is guaranteed if the crash causes a power system failure for example damage or breakage of the battery power cable cut off etc PERSPECTIVE VIEW OF THE ELECTRONIC CONTROL UNIT WITH TWO CONNECTORS A Black B Brown A B Figure 131 73792 The control unit mus...

Page 1079: ... Rh lateral sensor 5 5 6 6 7 7 8 8 9 9 Lh pretensioner 10 10 Lh pretensioner 11 11 Rh pretensioner 12 Positive for power supply 12 Rh pretensioner 13 13 14 14 15 15 16 Earth 16 17 Central pretensioner 17 Lh curtain air bag 18 Central pretensioner 18 Lh curtain air bag 19 19 Rh curtain air bag 20 20 Rh curtain air bag 21 Positive for driver air bag 21 22 Negative for driver air bag 22 23 Negative f...

Page 1080: ...contact is also equipped with a device which automatically locks spiral contact rotation when spiral contact is removed from steering wheel this is done in order to prevent upper cap that is not constrained any more from freely rotating so causing the cables to unexpectedly unwind or wind up and creating consequent risks of cable breakage On steering wheel mounting operation the device is automati...

Page 1081: ...as occurred Operation principle At the time when a determined deceleration of the vehicle occurs the electronic sensor that is placed in control central unit sends a signal which ignites gas generator pyrotechnic charge detonator Propellant combustion develops a gas the pressure of which generates a force pushing rack piston upwards Rack piston upward movement rotates gear wheels which reverse tap...

Page 1082: ...curtain air bags are provided These devices intervene in case of a side crash For this purpose two lh rh sensors are present which detect the occurrence of this event For the connections of these components see central unit pin out and relating electrical scheme Figure 135 107677 A B 107686 A Curtain air bag B Side crash sensor ...

Page 1083: ...olating them by applying an adhesive tape on pins Figure 136 waiting for at least ten minutes before resuming operations removing the protection under which central unit is located operating using a small screwdriver on connector stops locking connector fastening levers and rotating thelevers inwards disconnecting the connectors from central unit unscrewing the three screws which fasten central un...

Page 1084: ...g connector there is since vehicle production mounted a specific resistance for simulating the charge R 2 15 Ohm 0 35 NOTE Passenger side air bag module For removing air bag module the following is needed observing safety rules disconnecting battery cables first negative cable then positive cable and isolating them by applying an adhesive tape on pins waiting for at least ten minutes before resumi...

Page 1085: ...able connector to spiral device cable and fixing spiral device cable to steering column through suitable clamp mounting the two half shells of steering column fixing them to their support plate through special screws cautiously entering the cable to be connected to drive side air bag module into special slit on steering wheel hub mounting the steering wheel making previously marked references matc...

Page 1086: ...150 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 IMMOBILIZER Figure 138 107684 1 Instrument cluster 2 Central unit EDC 16 3 Body Computer 4 Antenna on start up switch ...

Page 1087: ...us in battery Where such event occurs in order to make a system test vehicle must be stopped and engine put off Rotate the key again warning lamp will go on and shall go off after approximately 1 second Where warning lamp remains on after this test too repeat the operation keeping engine stopped up for more than 30 seconds if the problem persists comply with provided prescriptions appearing on dis...

Page 1088: ... main tasks are acknowledging that the key was entered into the switch and rotated activating and reading the secret code issued by Transponder managing code check and processing communicating with central unit EDC storing any failures making system diagnosis AV 7 AV 8 antenna signal input Transponder Figure 139 112242 1 EDBD diagnosis connector 2 AV connector 1 2 ...

Page 1089: ...stem is working On the contrary if it behaves in a different way it means that key was not acknowledged star up not possible Figure 140 107620 A Immobilizer warning lamp B EDC failure warning lamp Figure 141 112288 Antenna It is mounted coaxial to key switch and has the task of supplying Transponder for sending the secret code receiving the signal from Transponder and sending it to central unit It...

Page 1090: ... remote services to reset the plan instrument cluster Programmed Maintenance keys and or radio commands need to be learnt again Replacing Body Computer not readable without remote services BC already programmed by Iveco is sent and it will be necessary to have old keys acknowledged on new Body Computer Rewrite maintenance plan Information stored in old B C are lost Replacing EDC16 No particular pr...

Page 1091: ...er A M the gear is selected directly by the control unit The electronic control unit picks up all the signals required to meet the safety conditions and the parameters programmed in the same It also drives the electric actuating motor s for gear selection engagement and clutch control The information required for driving is in any case made available to the driver by means of the display To ensure...

Page 1092: ...ody Computer 5 Switching on reverse lights 6 IMMOBILIZER central unit 7 Central unit ABS8 ASP8 8 Central unit EDC 9 Gears lever 10 Pushbutton board 11 Central unit gearbox 12 PTO 13 Clutch actuator 14 Gearbox actuator 112289 Figure 142 156 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1093: ...m the gearbox control unit is able to detect the position of the accelerator pedal and also the engine revs number Connection with the ABS8 ESP8 control unit is used to prevent the UP gear shift at bends and also control driving under poor grip conditions in case of mode A driving The new ABS system controls smart warning lights incorporated into the on board panel These warning lights come on to ...

Page 1094: ...actuator pin 4 12 Sensor speed signal clutch actuator pin 2 13 Clutch actuator pin 5 sensor voltage signal 5 V 15 Sensor direction signal gear engaging gearshift actuator pin 4 16 Sensor voltage signal 12 V gear engaging gearshift actuator pin 3 17 Sensor voltage signal 12 V gearbox actuator selector pin 3 18 Sensor direction signal gearbox actuator selector pin 4 33 Earth clutch actuator pin 1 35...

Page 1095: ...gnal option 17 CAN C H line 18 CAN C EDC line 28 CAN C EDC line 29 CAN L line 33 Free 37 Free 38 Free 39 KL 30 40 CAN L ZF LINE 41 CAN H ZF LINE 43 KL 15 44 Hand brake in signal 45 Signal to Body Computer 46 PTO status signal 47 PTO in signal 49 Gearbox in neutral position remote control switch control 51 Speed signal 52 Diagnosis line K heater Body Computer Connector control unit PIN OUT vehicle ...

Page 1096: ...rol unit for gear selection and engagement It is made up of two electric motors control cylinders and respective sensors 90139 Position of actuator 101872 1 Gear engaging electric motor 2 Gear selection electric motor Figure 147 Figure 148 160 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1097: ... Pin Function 1 Electric motor negative 2 Earth 3 Sensor voltage signal 4 Sensor direction signal 5 Sensor speed signal 6 Electric motor positive Voltage 12 V Output 95 W Torque 0 72 Nm at 125 C nmax 5400 r p m 101873 Wiring diagram Characteristics of electric motor Figure 149 ...

Page 1098: ...hat detects the clutch lever stroke by informing the electronic control unit of the actuating cylinder position and the clutch plate wear 90137 90138 1 Actuating cylinder 2 Electric motor 3 Vehicle electric wiring junction block Figure 150 Figure 151 162 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1099: ...h 2 Incremental sensor speed signal 3 Electric motor positive 4 Incremental sensor direction signal 5 Sensor voltage signal 6 Electric motor negative Max torque 0 65 Nm No load revs number 5800 r p m Output 80 W 0 3 Nm 2 500 r p m 101873 Wiring diagram Characteristics of electric motor Figure 152 ...

Page 1100: ...x control unit The kick down function can be actuated during running in the automatic mode When the pedal is pressed down almost fully 98 e g when overtaking the system will automatically shift down by one speed thus making it possible to use the deflecting torque at its best In practice if the accelerator pedal is pressed fully down the vehicle will ride at a running speed with a higher gear shif...

Page 1101: ...or PIN FUNCTION 1 KL 15 2 GROUND 3 CAN L 4 CAN L 5 6 108873 Gear selector is an electronic component placed in the cab at driver side It is interfaced with gearbox central unit through CAN communication line in order to signal that the driver is going to select and engage a gear Figure 156 ...

Page 1102: ...r Accelerator pedal position is provided to gearbox central unit through proper communication line by electronic central unit EDC which learns the position thanks to load transmitter directly mounted on accelerator pedal Engine rpm sensor The sensor is mounted at engine flywheel Engine rotation speed values are transmitted to electronic central unit EDC which through proper communication line tran...

Page 1103: ...th in STATIONARY and NON STATIONARY conditions In NON STATIONARY conditions valid are following conditions First gear can be put in and vehicle moved Once started with vehicle moving gear cannot be shifted any more PTO can be disengaged with gearbox in both gear and neutral position Depending on signal coming in to Pins self implementing device acknowledges if it is working with either a mechanica...

Page 1104: ...PTO disengaging procedure To disengage the power take off the following operations must be carried out 1 press the PTO button 2 wait at least 0 5 seconds 3 release the PTO button The operation will be carried out only if the PTO button is kept depressed for more than 0 5 seconds The PTO button will be ignored until the next 5 seconds have elapsed In the event that the power take off is not disenga...

Page 1105: ...gear ratio entered Reverse gear neutral R N position Signalling faults SERVICE gearbox failure SERVICE serious gearbox failure associated to sound warning SERVICE clutch excessive temperature associated to sound warning Gearbox failure in SERVICE mode message that can only be displayed at Assistance Network Figure 159 ELECTRIC ELECTRONIC SYSTEM 169 DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1106: ...hicle perimetral portion doors and bonnet switches and also any battery and siren disconnections BC directly controls external siren It also activates inserted alarm LEDs activates blinkers and transmits all information to Instrument Cluster via B CAN for managing VPS Vehicle Protection System warning lamp on the dashboard Body Computer controls and diagnoses alarm siren receives input from vehicl...

Page 1107: ...e that is described in this section has a number of differences with respect to previous version 30 pole diagnosis connector located on vehicle right side in front of passenger was replaced by a 16 pin connector It is placed on vehicle left side near interconnection central unit CPL This connector is placed on Body Computer it is a part of the component Therefore connection cables are not present ...

Page 1108: ...108874 Figure 161 A IT 2000 B Modus C EASY D Body Computer E Diagnosis connector EOBD 172 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1109: ...80 CARD 6B DIFFERENTIAL LOCKING HEATED REAR WINDOW AND WINDSCREEN 181 CARD 7A AIR SPRING SUSPENSION 182 CARD 7B ADDITIONAL HEATER POWER TAKE OFF 183 CARD 8 CRUISE CONTROL CLIMATE CONTROL SYSTEM 184 CARD 9A AUTOMATIC GEARBOX 185 CARD 9B ESP 8 186 CARD 10 EXTERNAL ILLUMINATION 187 CARD 11A ASR 188 CARD 11B CAMERA 189 CARD 12 EXTERNAL ILLUMINATION 190 CARD 13A AIR BAG 191 CARD 13B ABS8 192 CARD 14A E...

Page 1110: ...174 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 ...

Page 1111: ...ELECTRIC ELECTRONIC SYSTEM 175 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 1 Power network 107694 ...

Page 1112: ...176 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 2 Cab interior components 107695 ...

Page 1113: ...ELECTRIC ELECTRONIC SYSTEM 177 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 3 Window winders Electric mirrors 107696 ...

Page 1114: ...178 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 4 Cab interior components 107697 ...

Page 1115: ...ELECTRIC ELECTRONIC SYSTEM 179 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 5 Various loads 107698 ...

Page 1116: ...180 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 6A Telma decelerator 107699 ...

Page 1117: ...ELECTRIC ELECTRONIC SYSTEM 181 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 6B Differential locking Heated rear window and windscreen 107700 ...

Page 1118: ...182 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 7A Air spring suspension 112226 ...

Page 1119: ...ELECTRIC ELECTRONIC SYSTEM 183 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 7B Additional heater Power take off 112227 ...

Page 1120: ...184 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 8 Cruise control Climate control system 112228 ...

Page 1121: ...ELECTRIC ELECTRONIC SYSTEM 185 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 9A Automatic gearbox 112229 ...

Page 1122: ...186 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 9B ESP 8 112230 ...

Page 1123: ...ELECTRIC ELECTRONIC SYSTEM 187 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 10 External illumination 112231 ...

Page 1124: ...188 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 11A ASR 112232 ...

Page 1125: ...ELECTRIC ELECTRONIC SYSTEM 189 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 11B Camera 112233 ...

Page 1126: ...190 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 12 External illumination 112234 ...

Page 1127: ...ELECTRIC ELECTRONIC SYSTEM 191 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 13A AIR BAG 112235 ...

Page 1128: ...192 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 13B ABS8 112236 ...

Page 1129: ...ELECTRIC ELECTRONIC SYSTEM 193 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 14A EDC 16 112237 ...

Page 1130: ...194 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 14B EDC 16 112238 ...

Page 1131: ...ELECTRIC ELECTRONIC SYSTEM 195 DAILY EURO 4 Base March 2006 Print 603 93 651 Card 15B Cab interior components 112239 ...

Page 1132: ...196 ELECTRIC ELECTRONIC SYSTEM DAILY EURO 4 Base March 2006 Print 603 93 651 Card 16 CAN lines 112240 Tachograph Parking sensors ...

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Iveco daily euro 4, Repair Manual

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