Eurocargo Tector 12-26t Repair Manual
Eurocargo Tector 12-26t Repair Manual
Eurocargo Tector 12-26t Repair Manual
12 TO 26 t
REPAIR MANUAL
Produced by:
SPECIAL REMARKS
Workshop Manuals - concerning the mechanical part - are divided into several Sections. Each Section is characterised by a number
and its content is shown on the general index to be found at the beginning of each workshop manual.
Each section deals generally with one of the main Assemblies (engine, transmission, etc.)
Each section deals with the following topics:
Specifications and technical data, Tightening torques, Special tools, Troubleshooting (fault diagnosis), Component removal/refitting,
Repair operations.
To facilitate manual consultation, the different subjects are generally dealt with (where possible), following the same sequence.
This manual also provides graphs and symbols instead of description of parts, operations or operating procedures (see next page),
to give a more immediate and friendly reference.
Example:
1
Furthermore, within each section, every heading or sub-heading concerning the operations to be carried out is preceded by a six
digit number. This number is the Product Code that is to be found in the repair operation described in the FLAT RATE MANUALS
and in the FAILURE CODES publication.
For quick reference the indication for reading this code is described below (see also the Flat Rate Manuals).
5 0
Product code:
PRODUCT
ASSEMBLY
SUBASSEMBLY
COMPONENT
The first two figures identify the PRODUCT within the vehicle.
Example :
Product
50 = Frame;
Product
52 = Axles;
Product
53 = Gearbox, etc.
0 1
Assembly code:
PRODUCT
ASSEMBLY
SUBASSEMBLY
COMPONENT
Figure three and four identify the ASSEMBLY within the PRODUCT
Example :
Product
50 = Frame;
Assembly
01 = Chassis;
Assembly
02 = Bumpers-Under run-bars, etc.
4 0
Subassembly code:
PRODUCT
ASSEMBLY
SUBASSEMBLY
COMPONENT
Figure five and six identify exactly the SUB-ASSEMBLY and the Assembly Component within the PRODUCT
Example :
Product
50 = Frame;
Assembly
01 = Chassis;
Subassembly 40 = Chassis cross members, etc.
Print 603.93.111
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Compression ratio
Tighten to torque
Tolerance
Weight difference
Rolling torque
Press or caulk
Replacement
Original spare parts
Regulation
Adjustment
Rotation
Warning
Note
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment
Temperature
bar
Pressure
Interference
Strained assembly
Oversized
Higher than.
Maximum, peak
Thickness
Clearance
Undersized
Less than.
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 C
Cold
Winter
Air bleeding
Temperature > 0 C
Hot
Summer
Print 603.93.111
UPDATING DATE
Section
Print 603.93.111
Description
Page
Revision date
Print 603.93.111
INDEX OF SECTIONS
Section
Print 603.93.111
General Specifications
Engine
Clutch
Gearbox
Propeller shafts
Rear axles
Axles
Suspensions
Steering system
10
11
12
Scheduled maintenance
13
DAILY
Print 603.93.111
GENERAL SPECIFICATIONS
SECTION 1
General Specifications
Page
Print 603.93.111
11
FILLING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
GENERAL SPECIFICATIONS
Print 603.43.761
Print 603.93.111
GENERAL SPECIFICATIONS
Print 603.43.761/B
ML120EL17/P
ML120EL17/R
ML120EL17R/P
S
S
S
S
S
S
S
S
ML120E18
S
S
S
ML120EL17
S
S
S
S
ML120EL21R
ML120EL21R/P
ML120EL21/P
ML110EL21/P
ML110EL21R
ML110EL21R/P
ML120E18/P
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ML120EL21
Single plate
(170 HP) S
(180 HP)
(210 HP)
(240 HP)
(275 HP)
13
S
14
13/14
15/16
S
ML110EL17R/P
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML110EL21
UNITS
ML110EL17R
ML110EL17
MODELS
4X2
ML110EL17/P
GENERAL SPECIFICATIONS
COMPOSITION OF THE MODELS
S
S
S
S
ZF 8095
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical rear
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
Pneumatic front
S
Pneumatic rear
Disk front
Disk rear
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
GENERAL SPECIFICATIONS
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ZF 8095
ML120E18DR/P
ML120E18DK
ML120E18DKR
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ML120E21R/FP
ML120E18DR
ML120E21R/P
ML120E18D/P
ML120E21R
ML120E18D
ML120E21/FP
ML120E18KR
ML120E21/P
ML120E18K
ML120E21
Single plate
(170 HP)
(180 HP) S
(210 HP)
(240 HP)
(275 HP)
13
14
S
13/14
S
15/16
S
ML120E18R/FP
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML120E18R/P
UNITS
ML120E18R
MODELS
4x2
ML120E18/FP
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical Rear
Pneumatic front
Pneumatic rear
Disk front
Disk rear
S
S
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
GENERAL SPECIFICATIONS
Single plate
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ZF 8095
S
S
ML120E24R/FP
ML120E24K
ML120E24KR
ML120E24D
ML120E24D/P
ML120E24DR
ML120E24DR/P
ML120E24DK
ML120E24DKR
ML120E28/P
ML120E24R/P
ML120E28
ML120E24R
(170 HP)
(180 HP)
(210 HP) S
(240 HP)
(275 HP)
13
14
S
13/14
15/16
ML120E24FP
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML120E24/P
UNITS
ML120E24
ML120E21K
MODELS
4X2
ML120E21KR
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical Rear
Pneumatic front
Pneumatic rear
Disk front
Disk rear
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
GENERAL SPECIFICATIONS
ZF 8095
ML130E18K
ML130E18KR
ML130E18RS*
ML130E18D
ML130E18D/P
ML130E18DR
ML130E18DR/P
ML120E28KR
ML120E28K
ML130E18R/FP
ML130E18R/P
ML130E18R
ML130E18/FP
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ML130E18/P
Si l plate
Single
l t
(170 HP)
(180 HP)
(210 HP)
(240 HP)
(275 HP) S
13
14
13/14
15/16
S
ML130E18
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML120E28R/P
ML120E28R/FP
UNITS
ML120E28R
MODELS
4X2
ML120E28/FP
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical Rear
Pneumatic front
Pneumatic rear
Disk front
Disk rear
S
S
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
GENERAL SPECIFICATIONS
S
S
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ZF 8095
ML130E24KR
ML130E24K
ML130E24R/FP
ML130E21KR
ML130E24R/P
ML130E21K
ML130E24R
ML130E21R/FP
ML130E24/FP
ML130E21R/P
ML130E24/P
ML130E21R
ML130E21/FP
ML130E24
Single plate
(170 HP)
(180 HP)
(210 HP)
(240 HP)
(275 HP)
13
14
13/14
15/16
ML130E21/P
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML130E18DKR
UNITS
ML130E18DK
MODELS
4X2
ML130E21
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical Rear
Pneumatic front
Pneumatic rear
S
S
S
S
S
S
Disk front
Disk rear
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
S
S
S
S
S
S
ML130E28KR
ML130E28R/FP
ML130E28R/P
ML130E28R
ML130E28/FP
S
S
S
S
S
S
S
S
S
S
ML130E28/P
ML130E28
ML130E24DKR
ML130E24DK
ML150E21R/P
ML150E21R
ZF 8095
ML150E21/FP
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ML150E21/P
Single plate
(170 HP)
(180 HP)
(210 HP)
(240 HP)
(275 HP)
13
14
13/14
15/16
ML150E21
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML130E24DR
UNITS
ML130E24D/P
ML130E24D
MODELS
4X2
ML130E28K
GENERAL SPECIFICATIONS
ML130E24DR/P
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical Rear
Pneumatic front
S
Pneumatic rear
S
S
S
S
Disk front
Disk rear
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
Single plate
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-144
MS10-164
MS13-165
SP145E
ZF 8095
S
S
ML150E28K
ML150E28R/FP
ML150E28R/P
ML150E24KR
ML150E28R
ML150E24K
ML150E28/FP
ML150E24R/FP
ML150E28/P
ML150E24R/P
ML150E28
ML150E24R
ML150E24/FP
ML150E24/P
ML150E24
ML150E21RS*
(170 HP)
(180 HP)
(210 HP) S
(240 HP)
(275 HP)
13
14
S
13/14
15/16
ML150E21KR
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML150E21K
MODELS
4X2
UNITS
GENERAL SPECIFICATIONS
ML150E21R/FP
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
TRW-TAS 55
Mechanical front
Mechanical Rear
Pneumatic front
Pneumatic rear
Disk front
Disk rear
S
S
S
Drum rear
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper
Print 603.93.111
10
GENERAL SPECIFICATIONS
Single plate
2855.6
2865.6
2870.9
2895.9
FSO 5206B
MD 3060P
5845
5842/5
5851/5
5871/5
MS08-125
MS10-125
MS10-164
MS13-165
SP145E
ZF 8095
S
S
S
S
S
S
ML260E28KE (6x4)
ML180E28KR
ML180E28K
ML180E28R/P
ML180E28R
ML180E28/P
ML180E28
ML180E24KR
ML180E24K
ML180E24R/P
ML180E24R
ML180E21KR
ML180E24/P
ML180E21K
ML180E24
ML180E21R/P
(170 HP)
(180 HP)
(210 HP)
(240 HP)
(275 HP) S
13
14
13/14
15/16 S
ML180E21/R
F4AE0481A
F4AE0681E
F4AE0681D
F4AE0681B
F4AE0681A
ML180E21/P
UNITS
ML180E21
ML150E28KR
MODELS
4X2
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
ZF 8098
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
TRW-TAS 55
Mechanical front
Mechanical Rear
S
S
Pneumatic front
S
Pneumatic rear
Disk front
Disk rear
Drum rear
S
S
K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with front
and rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper; KE = HENDRICKSON rear suspensions
Print 603.93.111
GENERAL SPECIFICATIONS
11
Manufacturers plate
For vehicle identification to comply
with EC directions (under front
radiator grille)
Engine
Flywheel cover plate on
the box (left side)
Chassis
Marking (on right side
member front end)
Print 603.93.111
12
GENERAL SPECIFICATIONS
FILLING UP
LUBRICANTS RECOMMENDED BY IVECO
Urania Turbo
Urania LD5
Quantity
PARTS TO FILLED UP
Litres
kg
min.
5.3
4.8
max
8.3
7.5
0.9
min.
7.2
max
10.8
9.7
0.9
2855.5
5.5
2865.6
2870 9
2870.9
9
5
8.1
45
4.5
2895.9
FSO5206B
8.3
7
7.5
6.5
MD3060P
28
25
0.2
0.18
6.5
**11.5/12*
**12.2/11.7*
**18/19*
5.85
**10.3/10.8*
**10/10.5*
**16.2/16.7*
16.2
12.2
14.5
11
Engine 4 cylinders
Engine 6 cylinders
Gearbox
Tutela ZC 90
Tutela W140/M - DA
ZF 8095
ZF 8098
TRWTAS55
Tutela GI/A
Power
steering
Clutch circuit
Paraflu11
Cooling system
Total capacity
Tutela LHM
MS08-125
MS10-125
MS10-164
MS13-165
SP145E
Intermediate
Rear
Print 603.93.111
GENERAL SPECIFICATIONS
13
Description
FL Products
Engine oil
Compliant with ACEA E2 specifications
Urania Turbo
Engine oil
Compliant with ACEA E3 and ACEA E5 specifications
Urania LD5
SAE 80W/90
SAE 85W/140
Tutela ZC 90
Tutela GI/A
Tutela MR 2
Tutela MR 3
SP 349
Grease for general use, suitable for components not requiring special
grease (e.g., joints, pins and pivots, levers, tie rods, sliding shoes, brake
callipers, etc.)
Lithium-soap base grease, N.L.G.I. n. 2
Tutela Zeta 2
Tutela LHM
Arexons DP1
Paraflu 11
Print 603.93.111
14
GENERAL SPECIFICATIONS
Print 603.93.111
ENGINE
SECTION 2
Engine
Page
Print 603.93.111
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL-REFITTING . . . . . . . . . . . . . .
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTORS REPLACEMENT . . . . . . . . . . . . . . . . .
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
12
13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
ENGINE F4 AE 0481 . . . . . . . . . . . . . . . . . . . . . . .
19
ENGINE F4 AE 0681 . . . . . . . . . . . . . . . . . . . . . . .
115
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . .
141
ENGINE
Print 603.93.111
ENGINE
Homologation power
Duty No.
Injection
Cylinder No.
Engine cycle cylinder position
Engine
0= 4-stroke,
vertical
4 = 4 cylinders
6 = 6 cylinders
8 = DI. TCA
1 = Truck
2 = Bus
4 = M.T. vehicles
and tractors
6 = Marine
9 = Army
0681
0481
0681
0481
0681
0481
0681
0681
Print 603.93.111
A=
A=
B=
C=
D=
D=
E=
F=
202
125
176
110
154
95
134
202
kW kW kW kW kW kW kW kW -
(275 HP) 2700 rpm (170 HP) 2700 rpm (240 HP) 2700 rpm (150 HP) 2700 rpm (210 HP) 2700 rpm (130 HP) 2700 rpm (182 HP) 2700 rpm (275 HP) 2500 rpm -
ENGINE
Figure 1
70126
Injector
It is not necessary and permitted to disassemble the fuel
nozzle or the electromagnet.
Print 603.93.111
ENGINE
ENGINE REMOVAL-REFITTING
Figure 2
Removal
Lift the radiator cowling and overturn the cab.
Remove gearbox as described in the relevant
section and proceed as follows:
- Drain the engine coolant in a proper container.
- Drain the hydraulic steering system oil in a proper
container.
From the engine left side:
- Disconnect tubings (18) from the compressor (13), the
air cleaner and the turbine suction tubing (on the right
side).
- Remove the suction tube (16) and its support by
unscrewing the frame fastening nuts.
- Disconnect air tubing (15).
- Unscrew fastening screws (6), the nut (5), remove the
clamp (4) and move the gear lever rightwards (17).
- Disconnect delivery (11) and return (10) tubing from the
hydraulic steering pump.
- Loosen clamps (1) and remove the after-cooler tube (2).
- Disconnect fuel tubings; delivery tubings (9) from the
control unit support and return ones (12) from the fuel
filter support.
- Disconnect the oil pan tubing (3).
- Disconnect the connector (8) from the control unit and
all those connections coming from the harness.
62242
Print 603.93.111
ENGINE
Figure 3
62241
Print 603.93.111
Refitting
ENGINE
70469
Figure 5
3
4
79450
Print 603.93.111
ENGINE
Air bleeding
- Start air bleeding from the cooling system immediately
after filling operations.
- Start priming pump hand control (2) until fuel goes out
from the bleeding screw (1) without air;
- Start the engine and let it rotate at its minimum for some
minutes to eliminate air residuals.
542011
501430
Check the fuel level in the tank and in case increase it.
Lift the vehicle from the front part, start the engine and let
it rotate at its minimum for some time.
Check that there are no oil drippings from the hydraulic
circuit and check its level in the tank.
Turn the steering wheel slowly in both directions to let out
the air contained in the hydraulic system.
Check again the oil level in the tank and increase it, if
necessary.
Figure 6
70471
Print 603.93.111
ENGINE
INJECTORS REPLACEMENT
Removal
Figure 9
Figure 7
70472
70473
Figure 8
70133
Refitting
Figure 11
70131
Print 603.93.111
10
ENGINE
Figure 12
Figure 14
70342
70339
Figure 15
Figure 13
70346
70341
Print 603.93.111
ENGINE
11
Figure 16
70520
4- cylinder engine
Cylinder No.
Suction
Exhaust
1
-
2
*
3
*
-
4
*
*
Figure 16/1
1
*
*
2
*
-
3
*
4
-
6-cylinder engine
Cylinder No.
Suction
Exhaust
1
-
2
*
3
*
-
4
*
5
*
-
6
*
*
Print 603.93.111
1
*
*
2
*
-
3
*
4
*
-
5
*
6
-
78256
12
ENGINE
REPLACING SEAL
HOUSING BOX
Figure 16/2
RING
FLYWHEEL
Figure 16/4
78257
78258
Apply fixture 99340056 (3) on the rear tang (5) of the driving
shaft and through the guiding holes of the fixture, drill the
internal seal ring (1) with a drill ( 3,5 mm) to a depth of 5
mm.
Fix fixture (3) to the ring (1) by means of the 6 screws (4)
in the kit e proceed with the removal of the ring by tightening
the screw (2).
Perform the removal of the external seal ring as shown and
described in figure 16/2.
Figure 16/3
Figure 16/5
70225
Apply on the front tang (6) of the driving shaft part (5) of
fixture 99346252, fix it with screws (4) and key on it the new
seal ring (3). Position part (1) on part (5), tighten nut (2) till
complete assembly of seal ring (3) on the front cover (7).
70216
Apply on the rear tang (6) of the driving shaft part (5) of
fixture 99346253, fix it with screws (4) and key on it the new
seal ring (3).
Position part (1) on part (5) tighten nut (2) until seal ring (3)
is fully assembled into the flywheel housing box (7).
Print 603.93.111
ENGINE
13
70474
Print 603.93.111
14
ENGINE
Figure 18
70475
Print 603.93.111
ENGINE
15
Refitting
!
Figure 19
4-cylinder engine
70337
Figure 20
6-cylinder engine
70476
Print 603.93.111
16
ENGINE
Print 603.93.111
ENGINE F4 AE 0481
70756
ENGINE F4 AE 0481
19
Engine F4 AE 0481
Print 603.93.111
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
Page
21
24
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
30
AUXILIARY COMPONENTS . . . . . . . . . . . . . . .
32
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .
40
40
REPAIR INTERVENTIONS . . . . . . . . . . . . . . . . .
48
CYLINDER GROUP . . . . . . . . . . . . . . . . . . . . . .
48
48
49
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
49
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
50
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
51
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
52
52
54
54
54
55
55
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
56
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
57
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
58
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
59
- Checking torsion . . . . . . . . . . . . . . . . . . . . . . .
59
20
ENGINE F4 AE 0481
- Checking bending . . . . . . . . . . . . . . . . . . . . . .
Page
59
59
87
59
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
89
60
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .
91
- Viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
60
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
61
62
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
62
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . .
92
- Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
- Flywheel housing . . . . . . . . . . . . . . . . . . . . . . .
63
TURBOSUPERCHARGER ACTUATOR . . . . . . . .
93
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . .
64
93
64
- Actuator replacement . . . . . . . . . . . . . . . . . . .
93
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
68
TURBOSUPERCHARGER LAYOUT . . . . . . . . . . .
95
68
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . .
97
69
- General Specifications . . . . . . . . . . . . . . . . . . .
97
69
FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
101
FUEL PREFILTER . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
104
Page
70
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
104
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
104
71
- Drain conditions . . . . . . . . . . . . . . . . . . . . . . .
104
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . .
73
105
73
73
106
- Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . .
74
- Operating principle . . . . . . . . . . . . . . . . . . . . .
107
RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
- Rocker assembly . . . . . . . . . . . . . . . . . . . . . . .
75
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
76
OVERPRESSURE VALVE . . . . . . . . . . . . . . . . . . . .
110
- Intake manifold . . . . . . . . . . . . . . . . . . . . . . . .
77
FLOW LIMITERS . . . . . . . . . . . . . . . . . . . . . . . . . .
110
- Wiring support . . . . . . . . . . . . . . . . . . . . . . . .
79
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
111
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
- Injection start . . . . . . . . . . . . . . . . . . . . . . . . .
111
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . .
85
- Injection end . . . . . . . . . . . . . . . . . . . . . . . . . .
111
86
111
Print 603.93.111
ENGINE F4 AE 0481
21
GENERAL SPECIFICATIONS
Type
F4AE0481A
(.17)
Cycle
4 stroke Diesel
Power Supply
Intercooler supercharged
Injection
Direct
Cylinder number
4 in line
Bore
mm
102
Stroke
mm
120
cm3
3900
Compression ratio
Max power
Max. torque
17 : 1
kW
(CV)
125
(170)
rpm
Nm
(kgm)
2700
560
(57.1)
rpm
1200
rpm
750
rpm
3000
Idle engine
minimum rpm
Idle engine peak
rpm
Print 603.93.111
22
ENGINE F4 AE 0481
F4AE0481A
(.17)
Type
SUPERCHARGER
With intercooler
Turbosupercharger type
GARRETT GT 22
-
mm
bar
bar
LUBRICATION
bar
COOLING
Urania Turbo
Urania LD5
1.2
3.8
81 2 C
96 C
FILLING
Total capacity
1st filling:
liters
kg
- engine sump
liters
kg
Min. level.
5.3
4.8
Max. level
8.3
7.5
liters
6.3
9.3
kg
5.7
8.4
Print 603.93.111
ENGINE F4 AE 0481
23
F4AE0481A
(.17)
Type
TIMING
start before T.D.C.
end after B.D.C.
A
B
8.5
8.5
D
C
51
12.5
Checking timing
mm
mm
mm
0.20 0.30
mm
0.46 0.56
Bosch
X
X
Checking operation
X
FUEL FEED
Injection
Type:
Nozzle type
Injectors
Injection sequence
1-3-4-2
bar
Injection pressure
Print 603.93.111
bar
250 - 1450
24
ENGINE F4 AE 0481
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
1
X
1
X
2
mm
Cylinder barrels
102.009 102.031
Spare pistons
type:
Size
Outside diameter
Pin housing
X
1
2
60,5
101.781 101.799
40.008 40.014
0.116 0.134
Piston protrusion
Piston pin
0.5
0.28 0.52
39.9938 40.0002
0.0078 0.0202
Print 603.93.111
ENGINE F4 AE 0481
F4AE0481A
(.17)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
X1
X2
X3
S 1
S 2
S 3
25
mm
X1*
X2
X3
2.705 2.735
2.420 2.440
4.020 4.040
Split rings
S 1*
S2
S3
2.560 2.605
2.350 2.380
3.975 4.000
* measured on 98 mm
Split rings - slots
1
2
3
Split rings
X1
X2
0.5
X3
0.100 0.175
0.040 0.90
0.020 0.065
X1
X2
X3
030 0.40
0.60 0.80
0.25 0.55
42.987 43.013
72.987 73.013
4
3
S
Print 603.93.111
43.279 43.553
40.019 40.033
1.955 1.968
0.266 0.566
0.0188 0.0392
0.250 0.500
26
ENGINE F4 AE 0481
F4AE0481A
(.17)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
mm
X
Size
Max. tolerance
on connecting rod
axis alignment
1
S1
Journals
Crankpins
1
2
82.99 83.01
68.997 69.013
S1
S2
2.456 2.464
1.955 1.968
3
3
87.982 88.008
87.982 88.008
S 2
*provided as spare part
Main bearings
No. 1-3-4-5
No. 2
Half bearings Journals
No. 1-3-4-5
No. 2
0.041 0.103
0.041 0.103
0.033 0.041
0.250 ; 0.500
Shoulder journal
X1
37.475 37.545
X2
32.23
Shoulder half-rings
X3
32.30
X1
X2
X3
0.07
Print 603.93.111
ENGINE F4 AE 0481
F4AE0481A
(.17)
Type
CYLINDER HEAD TIMING SYSTEM
1
mm
27
7.042 7.062
6.970 6.990
60o 0.25o
6.970 6.990
45o 0.25o
Valves:
0.052 0.092
34.837 34.863
34.837 34.863
Sinking
Between valve seat
and head
Valve seats
Print 603.93.111
34.917 34.931
60o
34.917 34.931
45o
0.59 1.11
0.96 1.48
0.054 0.094
0.054 0.094
-
28
ENGINE F4 AE 0481
F4AE0481A
(.17)
Type
CYLINDER HEAD TIMING SYSTEM
mm
H1
H2
47.75
H1
H2
35.33
25.2
It cannot be adjusted
1 23 4 5
Camshaft bush
housings No. 1-5
59.222 59.248
Camshaft housings
No. 2-3-4
59.222 59.248
2
Camshaft journals:
15
1
1-2-3
53.995 54.045
59,222 59,248
54.083 54.147
0,113 0,165
0.038 0.152
Cam lift:
H
6.045
7.582
Print 603.93.111
ENGINE F4 AE 0481
29
F4AE0481A
(.17)
Type
CYLINDER HEAD TIMING SYSTEM
mm
1
Tappet cap housing
on block
2
3
16.000 16.030
2
3
15.924 15.954
15.960 15.975
0.025 0.070
-
1
Rocker shaft
21.965 21.977
Rockers
22.001 22.027
2
Between rockers and shaft
Print 603.93.111
0.024 0.162
30
ENGINE F4 AE 0481
TIGHTENING TORQUE
PART
TORQUE
1st phase
2nd phase
3rdd phase
1st phase
2nd phase
1st phase
2ndd phase
90 5
82
12 2
77 12
47 5
24 4
10 2
81
24 4
24 4
24 4
36 4
60 5
0.8 0.2
1.2 0.2
7.7 1.2
4.7 0.5
2.4 0.4
1 0.2
0.8 0.1
2.4 0.4
2.4 0.4
2.4 0.4
3.6 0.4
6 0.5
60 5
4.3 0.4
10.5 0.5
2,4 0,4
2.4 0.4
3.6 0.5
1.2 0.2
0.35 0.035
75 5
1st phase
2nd
phase
3rd phase
kgm
1.5 0.3
5 0.6
8 0.6
43 5
105 5
24 4
24 4
36 5
12 2
8.5 0.35
Nm
15 3
50 6
80 6
50 5
82
24 4
77 12
24 4
20 2
35 5
5 0.5
0.8 0.2
2.4 0.4
7.7 1.2
2.4 0.4
2 0.2
3.5 0.5
55 5
5.5 0.5
90 5
90 5
36 5
3.6 0.5
24 4
2.4 0.4
20 2
2 0.2
24 4
2.4 0.4
10 2
1 0.2
24 4
2.4 0.4
1.5 0.25
0.15 0.025
77 8
7.7 0.8
24 4
2.4 0.4
contact + turn
80 8
8 0.8
24 4
2.4 0.4
contact + turn
Print 603.93.111
ENGINE F4 AE 0481
PART
TORQUE
{
{
Print 603.93.111
31
Nm
24 4
10 2
43 6
24 4
22 2
10 2
10 2
53 5
50 5
kgm
2.4 0.4
1 0.2
4.3 0.6
2.4 0.4
2.2 0.2
1 0.2
1 0.2
5.3 0.5
5 0.5
90
68 7
24 4
43 6
43 6
85 10
49 5
10 2
24 4
12 2
24 4
82
82
20 3
61
35 5
20 3
61
12 2
71
43 6
6.8 0.7
2.4 0.4
4.3 0.6
4.3 0.6
8.5 1
4.9 0.5
1 0.2
2.4 0.4
1.2 0.2
2.4 0.4
0.8 0.2
0.8 0.2
2 0.3
0.6 0.1
3.5 0.5
2 0.3
0.6 0.1
1.2 0.2
0.7 0.1
4 3 00.6
4.3
6
0.7 0.1
2.4 0.4
71
24 4
35 5
35 5
43 6
24 4
10 2
30 4
3.5 0.5
3.5 0.5
4.3 0.6
2.4 0.4
1 0.2
3 0.4
60 5
24 4
24 4
2.4 0.4
2.4 0.4
32
ENGINE F4 AE 0481
AUXILIARY COMPONENTS
PART
Air supercharger:
Control gear 5/8 inch fixing nut on the supercharger shaft
Fixing nut M12 to the flywheel housing
Alternator:
Bracket fixing nut M12 on the water input union
Alternator fixing nut M10
Climate control:
Bracket fixing screw M10
Supercharger fixing screw M10
Starter:
Starter fixing screw
TORQUE
Nm
kgm
125 19
77 12
12.5 1.9
7.7 1.2
43 6
43 6
4.3 0.6
4.3 0.6
43 6
24 4
4.3 0.6
2.4 0.4
43 6
4.3 0.6
Print 603.93.111
ENGINE F4 AE 0481
33
TOOLS
TOOL No.
DESCRIPTION
99305018
99305047
99322205
99340055
99340056
99341001
Print 603.93.111
34
ENGINE F4 AE 0481
TOOLS
TOOL No.
DESCRIPTION
99341009
Bracket pair
99342101
99346252
99346253
99355019
99360076
Print 603.93.111
ENGINE F4 AE 0481
35
TOOLS
TOOL No.
DESCRIPTION
99360183
99360268
99360330
99360351
99360362
99360500
Print 603.93.111
36
ENGINE F4 AE 0481
TOOLS
TOOL No.
DESCRIPTION
99360595
99360605
Band for piston insertion into the cylinder barrel (60-125 mm)
99361037
99363204
99370006
99370415
Print 603.93.111
ENGINE F4 AE 0481
37
TOOLS
TOOL No.
DESCRIPTION
99389834
99395216
99395363
99395603
Gauge (0 5 mm)
99395687
Bore meter
Print 603.93.111
38
ENGINE F4 AE 0481
Figure 1
70477
Print 603.93.111
ENGINE F4 AE 0481
39
Figure 2
70478
Print 603.93.111
40
ENGINE F4 AE 0481
ENGINE OVERHAUL
540110 DISASSEMBLY OF THE ENGINE AT
THE BENCH
Figure 5
Figure 3
70125
70127
The pipe (3) from the union (4) and from the supercharger
(8).
Remove the fuel pipe (2) from the rail and from the
high-pressure pump (9) and remove it from the engine block,
by removing the fixing screws (4 and 6)
Figure 4
70126
70128
Remove the screws (2) and remove the oil pipe (3) from the
supercharger pipe (1) and from the engine block.
Remove the starting engine (5) from the flywheel cover (4).
Print 603.93.111
41
ENGINE F4 AE 0481
Figure 7
78670
1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure and
temperature sensor - 5. Engine shaft sensor - 6. Injector - 7. Temperature-air pressure sensor - 8. Timing phase sensor 9. Fuel temperature sensor and fuel heater - 10. Pressure adjuster - 11. Control unit EDC7
Figure 8
70236
Remove from the rail: the fuel pipe (7) according to the
procedures described in Figure 4. Remove the fuel pipe (5)
from the rail (2) and from the manifolds (6) for injectors.
42
ENGINE F4 AE 0481
Figure 9
Figure 11
70130
70132
Remove from the fuel return pressure limiting device (1), the
pipe (2) as described in Figure 4.
Loosen the tappet adjuster fixing nuts (1) and unscrew the
adjuster.
Remove the screws (2), remove the equalizer unit (3)
composed by the support (6), equalizers (4), shafts (5) and
remove the bonds (7) from the valves. Remove the rods (8)
Remove the pipe (4) from the air supercharger (3) and from
the union (5). Remove the nut (10) Loosen the elastic hose
clamp (6) and remove the oil vapor pipe (9).
Figure 12
Figure 10
70133
Remove the nuts (7) and disconnect the electric wires from
the injectors (8).
Remove the screws (1) and remove the injector harness
support (2) complete of gasket.
Remove the screws (5) and
pressure/temperature sensor (6).
remove
the
air
Remove the nuts (3) and withdraw the fuel manifolds (4).
70134
Remove the screw (4), loosen the clamp (2) and remove the
air conveyor (1) from the turbosupercharger (3)
Print 603.93.111
43
ENGINE F4 AE 0481
Figure 14
Figure 16
70137
70135
Remove the oil pipe (5) check clamp fixing screw (4) from
the exhaust manifold (1).
Remove the oil pipe (5) from the oil filter/ heating exchanger
support (7).
Hook the brackets (1) with metal ropes and remove the
cylinder head (2) from the block by means of a hoister.
Figure 17
Figure 15
70138
70136
Remove the screws (1) and remove the air conveyor (2)
complete of heater. Remove the screws (4), remove the
cover (3) and the relevant thermostat.
Remove the head cylinder (6) fixing screws (5).
70139
Print 603.93.111
44
ENGINE F4 AE 0481
Figure 19
Figure 21
70140
70142
Remove the screws (1) and the electronic control unit (2)
complete of heating exchanger.
Remove
the
screws
(4)
temperature/pressure sensor.
Figure 22
and
remove
70141
70143
oil
Figure 23
70144
Remove the screws (2) and the nuts (1-4) and remove the
air supercharger (3)
Print 603.93.111
45
ENGINE F4 AE 0481
Figure 24
Figure 27
70145
Remove the nut (1) and remove the phase sensor (2).
Remove the nuts (3) and remove the high-pressure pump (4)
complete of power supply pump (5).
70148
Remove the screws (1) and remove the water pump (2).
Remove the screws (3) and remove the roller (4).
Remove the screws (5) and remove the rpm sensor (6).
Figure 25
Figure 28
70149
Remove the screws (1) and remove the front cover (2).
70146
Figure 29
70340
Remove the screws (2) and remove the pulley (3) and the
bumper flywheel (1).
Remove the screws (6) and remove the hub (5) and the
phonic wheel (4).
Print 603.93.111
Remove the screws (1) and remove the oil pump (2).
70150
46
ENGINE F4 AE 0481
Figure 30
Figure 33
70151
70154
70152
Screw two pins (2) exhibiting a proper length into the engine
shaft holes (3).
Withdraw the engine flywheel (1) in order to sling it with the
hoister and position it into the container.
70155
Remove the screws (1) and remove the oil suction rose (3).
Remove the screws (2) and remove the stiffening plate (4).
Figure 32
Figure 35
70153
Remove the screws (1) and remove the rear cover (2).
70156
Remove the screws (1) and remove the gear (3) from the
camshaft (2).
Print 603.93.111
47
ENGINE F4 AE 0481
Figure 36
Figure 39
70157
70160
!
Figure 37
70158
Remove the connecting rod cap (2) fixing screws (1) and
remove them.
Remove the connecting rod piston assemblies from the
upper side of the block.
70161
Remove the engine shaft (2) from the block by means of tool
99360500 (1) and hoister.
Figure 41
Figure 38
70162
70159
Remove the screws (1) and remove the bench caps (2).
Print 603.93.111
48
ENGINE F4 AE 0481
zs
REPAIR INTERVENTIONS
540410 CYLINDER GROUP
540420 Controls and measurements
Figure 42
Figure 45
70163
Remove the screws (1) and remove the camshaft (3) check
plate (2)
70166
Figure 43
70164
Figure 46
Carefully withdraw the camshaft (1) from the engine block.
Figure 44
70167
70165
ENGINE F4 AE 0481
49
Figure 47
Figure 48
70170
Check that the head face, on the cylinder group, does not
present deformations.
This check can be carried out, after a previous grains (4)
extraction by means of a calibrated ruler (2) and feeler gauge
(3).
After verified the deformation areas, perform the flattening
of the face by means of grinding machine.
The flatness error must not be higher than 0.075 mm.
70168
!
!
5412
541210
TIMING SYSTEM
Camshaft
Figure 49
70169
50
ENGINE F4 AE 0481
541211
541213
BUSHES
Figure 51
70172
70171
sec. A-A
85484
Print 603.93.111
541213
ENGINE F4 AE 0481
Bush replacement
51
Figure 53
70176
70174
To replace front and rear bushes (1), use for their removal
and refitting the tool 99360362 (2) and handgrip 99370006
(3).
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 56
70164
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
541224
Tappets
Figure 57
Figure 54
70238
70175
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
52
ENGINE F4 AE 0481
5408
540810
Figure 58
OUTPUT SHAFT
Measuring journals and crankpins
Figure 60
70179
70182
!
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Figure 61
70181
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Base - February 2003
Print 603.93.111
53
ENGINE F4 AE 0481
Figure 62
70183
TOLERANCE CHARACTERISTIC
Roundness
Cilindricity
Parallelism
Verticality
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
Taper
GRAPHIC SYMBOL
//
//
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
INTERMEDIATE MAIN
BEARINGS
70237
Print 603.93.111
54
ENGINE F4 AE 0481
549215
540811
Figure 65
Figure 63
70161
70186
- fit caps (1), including the half bearings (2) on the relevant
supports.
Figure 67
70187
55
ENGINE F4 AE 0481
Figure 68
Figure 70
70188
3rd
Figure 69
70190
540830
Figure 71
70189
70191
Print 603.93.111
56
ENGINE F4 AE 0481
540840 Pistons
Measuring piston diameter
Figure 72
Figure 75
32615
32613
Remove split rings (1) from piston (2) using pliers 99360183
(3).
Figure 73
Figure 76
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 74
84291
Print 603.93.111
540841
57
ENGINE F4 AE 0481
Piston pins
Figure 80
Figure 77
18857
32620
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Figure 81
32619
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
540842
41104
Split rings
Figure 79
16552
Print 603.93.111
58
ENGINE F4 AE 0481
Figure 82
Figure 84
WEIGHT
0001
9999
70194
540830
Connecting rods
1234
CONNECTING
ROD No.
123
YEAR
DAY
0001
A 1998
B 1999
001
9999
C 2000
D 2001
366
Figure 83
70196
**
**
540834
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
Print 603.93.111
ENGINE F4 AE 0481
59
Checking bending
Figure 85
Figure 87
61695
61696
Check that the axes of the connecting rods (1) are parallel
using tool 99395363 (5) as follows:
- fit the connecting rod (1) on tool 99395363 (5) spindle
and lock it with screw (4);
- set the spindle (3) on V-blocks by resting the connecting
rod (1) on the stop bar (2).
Checking torsion
Figure 86
70198
61694
60
ENGINE F4 AE 0481
Figure 89
Figure 92
70199
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (4) are read as shown in the figure.
Figure 90
70200
72705
70201
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
Base - February 2003
ENGINE F4 AE 0481
Figure 94
61
Figure 96
70204
70202
- lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2).
Figure 97
540831
Figure 95
70205
Figure 98
70203
Print 603.93.111
70206
62
ENGINE F4 AE 0481
Figure 99
Figure 101
70207
70209
70208
70210
Print 603.93.111
63
ENGINE F4 AE 0481
Timing
540460
Figure 103
Flywheel housing
Figure 106
70214
70211
Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark () for timing on the side
surface.
Figure 104
70212
Direct the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Figure 107
Figure 105
70215
70213
Tighten the screws (1) fastening gear (2) to camshaft (3) to the
specified torque.
Print 603.93.111
Refit the housing (1) to the engine block and screw the
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
shown in the figure:
Screws M12
75 - 95 Nm
Screws M10
44 - 53 Nm
64
ENGINE F4 AE 0481
Figure 108
Figure 110
70152
70216
Apply tool 99346253 part (5) to the rear output shaft tang (6),
secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
540850
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
hoister.
Figure 111
ENGINE FLYWHEEL
Figure 109
70218
Tighten the screws (4) fastening the engine flywheel (3) to the
output shaft. Apply tool 99360351 (2) to the flywheel housing
(1) to stop engine flywheel (3) rotation.
Figure 112
70217
!
540853
70219
!
Base - February 2003
Print 603.93.111
ENGINE F4 AE 0481
Figure 113
65
Figure 116
70223
70220
Remove the sealing ring (2) from the front cover (1), clean
accurately the coupling surfaces and smear them with IVECO
N. 2992545.
Figure 117
Figure 114
70224
70221
Clean accurately the front cover (2) surface and refit it.
Tighten the screws (1) to the specified torque.
Figure 115
70225
70222
Print 603.93.111
Apply tool 99346252 part (5) to the front output shaft tang
(6), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into front cover (7).
66
ENGINE F4 AE 0481
Figure 119
Figure 122
70226
70363
Fit the plate (1), the rose pipe (2) and tighten the fastening
screws (3) to the specified torque.
Fit the phonic wheel (1) and the hub (2) on the output shaft.
Tighten the fastening screws (3) in two stages:
- 1st stage, tightening to 50 5 Nm torque with
dynamometric wrench;
Figure 120
Figure 121
70230
Fit the oil sump (1) and apply the plate (3) to it.
Tighten the screws (2) to the specified torque.
Print 603.93.111
ENGINE F4 AE 0481
Figure 124
67
Figure 126
70231
70234
Fit on the engine block: a new gasket (1), the heat exchanger
(2) a new gasket (3) and the oil filter support (4).
Figure 125
Figure 127
70232
Lubricate the sealing ring (2) with engine oil and set it on the
oil filter (3).
70139
Figure 128
70235
68
ENGINE F4 AE 0481
Figure 129
Figure 132
70145
70320
Refit the high pressure pump (5) including the feed pump (6)
and tighten the nuts (3) to the specified torque. Fit the support
(4) with a new sealing ring, the timing sensor (2) with a new
sealing ring and tighten the relevant fastening nut (1) to the
specified torque.
Refit the ECU (3) including the heat exchanger to the engine
block and tighten the screws (2) to the specified torque.
Figure 130
540610
540662
CYLINDER HEAD
Removing the valves
Figure 133
70144
Refit the air compressor (3). Tighten the screws (2) and the
nuts (1 and 4) to the specified torque.
Figure 131
70319
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch () of the exhaust valve (2) head
distinguishes it from the intake valve.
!
70143
Refit the hydraulic power steering pump (2) including the oil
tank (4) to the air compressor (5).
Use wrench 99355019 to tighten the fastening screws (3) to
the specified torque.
Base - February 2003
Print 603.93.111
ENGINE F4 AE 0481
69
Figure 134
Figure 136
70321
70323
70322
70324
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.
Print 603.93.111
70
ENGINE F4 AE 0481
Figure 138
Figure 140
18625
70325
The rated thickness A for the cylinder head is 105 0.25 mm,
max. metal removal shall not exceed thickness B by 0.13 mm.
540662
VALVES
Figure 139
EXHAUST
VALVE
INTAKE
VALVE
18882
70326
70327
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 0.092 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Base - February 2003
Print 603.93.111
540667
ENGINE F4 AE 0481
71
VALVE GUIDE
VALVE SEATS
Regrinding replacing the valve seats
Figure 143
Figure 144
70330
INTAKE
EXHAUST
79457
Figure 145
INTAKE
EXHAUST
85486
Print 603.93.111
72
ENGINE F4 AE 0481
Figure 146
EXHAUST
INTAKE
70332
Figure 147
70333
Print 603.93.111
540665
ENGINE F4 AE 0481
73
VALVE SPRINGS
Figure 148
Figure 150
50676
770321
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
H
H1
H2
Height
mm
47.75
35.33
25.2
Under a load of
N
Free
P1
339.8 19
P2
741 39
70334
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
Print 603.93.111
74
ENGINE F4 AE 0481
Fitting injectors
Figure 152
Figure 154
70338
70336
Refit the cylinder head (1), tighten the screws (2) in three
successive stages according to the sequence and procedure
shown in the following figure.
Fit a new sealing ring (2) lubricated with vaseline and a new
sealing washer (3) on injector (1).
Figure 155
Figure 153
70339
Figure 156
70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
Print 603.93.111
ENGINE F4 AE 0481
541221
Figure 157
75
RODS
Figure 159
32655
70341
Fit a new sealing ring (3) lubricated with vaseline on the fuel
manifold (2) and fit it into the cylinder head seat so that the
positioning ball (5) is coinciding with the relevant housing (4).
501230
Rocker assembly
Figure 160
Figure 158
70343
70342
Print 603.93.111
70344
76
ENGINE F4 AE 0481
Figure 164
70520
70345
!
Figure 163
cylinder No.
intake
exhaust
1
-
2
*
3
*
-
4
*
*
1
*
*
2
*
-
3
*
4
-
70346
Print 603.93.111
ENGINE F4 AE 0481
77
Intake manifold
Figure 165
70347
The intake manifold (4) houses the air heater (5) for cold
starting. In case of failure it shall be replaced by removing the
cap (6), the nuts (1), the sealing washers (2) and the washers
(3). Fit the new heater (5) following the removal operations
in reverse order.
Print 603.93.111
78
ENGINE F4 AE 0481
Figure 166
Figure 169
70348
70351
Figure 167
Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.
70349
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut (5) to the specified torque.
Figure 170
Figure 168
70126
70350
Connect new fuel pipes (1) to rail (3) and injector manifolds
(2).
When removed, pipes (1) shall always be replaced.
Print 603.93.111
540634
ENGINE F4 AE 0481
Wiring support
79
Figure 174
Figure 171
70352
70355
Figure 175
Figure 172
70356
70353
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
Figure 173
Fit the tappet cover (1) and tighten the nuts (2) to the
specified torque.
Figure 176
70354
70357
Connect the electrical cables (1) to the injectors (3) and use
the dynamometric wrench 99389834 (4) to tighten the
fastening nuts (2) to the specified torque.
Print 603.93.111
80
ENGINE F4 AE 0481
Figure 177
Figure 179
70358
70360
Connect pipe (14) to tappet cover (10) and timing case (6)
with connections (13-15) and new copper washers.
Connect pipe (7) to timing case (6) connection and lock it
by the elastic clamp (8).
Fit a new sealing ring on pipe (11) connection and fit it on the
tappet cover (10).
Secure the pipe (11) to the tappet cover (10) with the clip
and the nut (12), connect pipe (4) to connection (5) and air
compressor (3).
Connect the pipe (2) to the pressure limiter (1) as shown in
the following figure.
Figure 178
Figure 180
70134
70126
Print 603.93.111
81
ENGINE F4 AE 0481
Figure 181
78670
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air temperature/pressure sensor - 8. Timing sensor 9. Fuel heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC7 control unit
Print 603.93.111
82
ENGINE F4 AE 0481
Figure 182
Figure 184
70362
70128
Refit the bracket (2) including the fuel filter support (1) to the
engine block, tighten the screws (3) to the specified torque.
Figure 185
Fit the oil pipe (3) with a new sealing ring into the engine
block and secure it to the turbosupercharger (1) by the
screws (2) tightened to the specified torque.
Figure 183
70125
Screw manually the fuel filter to the support (1), screw the
filter by turn, connect the pipes (2-3-4) to the relevant
support connections (1) as shown in the following figure.
Figure 186
70127
70126
Print 603.93.111
5450
ENGINE F4 AE 0481
83
LUBRICATION
Figure 187
2
3
Print 603.93.111
84
ENGINE F4 AE 0481
Print 603.93.111
543010
OIL PUMP
85
ENGINE F4 AE 0481
Figure 188
70576
543110
HEAT EXCHANGER
Figure 189
5
6
1
4
70480
1. Heat exchanger body with filter support - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat
exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.
Clean accurately the heat exchanger components
Always replace the sealing gaskets.
Print 603.93.111
86
ENGINE F4 AE 0481
543075
Figure 190
Loosen the plug (1), withdraw the spring (3) and the relief
valve (4) from the support (5).
Check whether the valve (4) is not scored and is sliding
smoothly into its seat. The spring (3) shall not be broken or
yielded.
Pressure regulation at 100C oil temperature:
- 1.2 bar min pressure;
- 3.8 bar max. pressure
Figure 191
70481
Figure 192
Flow
70482
6432
Max blow-by:
22 cm3/1 at 0.8 bar pressure and 26.7C temperature
Print 603.93.111
540480
87
ENGINE F4 AE 0481
Figure 193
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine
The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).
Print 603.93.111
88
ENGINE F4 AE 0481
Print 603.93.111
5432
ENGINE F4 AE 0481
89
COOLING SYSTEM
Figure 194
Print 603.93.111
70485
90
ENGINE F4 AE 0481
Print 603.93.111
543210
91
ENGINE F4 AE 0481
Water Pump
Viscous fan
Figure 195
Figure 196
Sec. A-A
70486
70487
Characteristics:
Print 603.93.111
2700 rpm
Operating temperature:
92
ENGINE F4 AE 0481
543250
Thermostat
Description
The booster system is composed of: air cleaner,
turbosupercharger and intercooler.
Figure 197
79458
BOOSTER
542410 Turbosupercharger
Figure 198
Exhaust
Compressed air
GARRET TURBOSUPERCHARGER
Booster pressure: 1.5 bar..
Actuator (WASTEGATE) opening start: 1600 rpm
Print 603.93.111
ENGINE F4 AE 0481
93
Figure 200
4
5
6
62873
70490
Cover the air, exhaust gas and lubrication oil inlets and
outlets.
Carry out an accurate external cleaning of the
turbosupercharger, using the anticorrosive and antioxidant
solution and perform the check on the actuator (6).
Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
Remove the nuts (2) and remove the actuator (1) from the
supporting bracket. Fit the new actuator following the removal operations in reverse order and fitting a new clip (4),
tighten the nuts (2) to 5.6 6.8 Nm torque.
Position the tracer point of the gauge (2) on the tie rod (3)
end and set to zero the gauge (2).
Print 603.93.111
94
ENGINE F4 AE 0481
Print 603.93.111
ENGINE F4 AE 0481
95
TURBOSUPERCHARGER LAYOUT
Figure 201
Inlet air
Hot compressed air
Cooled compressed air
Exhaust
70491
Print 603.93.111
96
ENGINE F4 AE 0481
Print 603.93.111
97
ENGINE F4 AE 0481
COMMON RAIL
General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1450 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 202
78670
1. Injectors connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air pressure/temperature sensor - 8. Camshaft sensor - 9. Fuel
heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC 7 control unit.
Through the sensors, present on the engine, the ECU controls the engine operation.
The outlet tension is proportional to the pressure or temperature obtained by the sensor.
Print 603.93.111
98
ENGINE F4 AE 0481
Injection control
The control unit, depending on information coming from
sensors, controls the pressure regulator, and changes
pre-injection and main injection modes.
Closed-loop control for injection pressure
Depending on engine load, measured by processing signals
coming from various sensors, the control unit controls the
regulator in order to always have the optimum pressure.
Pilot and main injection spark advance control
The control unit, depending on signals coming from various
sensors, computes the optimum injection point according to
an internal mapping.
Idle speed control
The control unit processes signals coming from various
sensors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
time of injectors.
Within certain thresholds, it also takes into account the
battery voltage.
Maximum speed limiting
At 2700 rpm, the control unit limits fuel flow-rate by reducing
the injectors opening time.
Over 3000 rpm it deactivates the injectors.
Cut Off
Fuel cut off upon release is controlled by the control unit
performing the following logics:
- it cuts off injectors supply;
- it re-activates the injectors shortly before idle speed is
reached;
- it controls fuel pressure regulator.
Smoke control upon acceleration
With strong load requests, the control unit, depending on
signals received by air inlet meter and engine speed sensor,
controls the pressure regulator and changes the injectors
actuation time, in order to avoid exhaust smokes.
Fuel temperature control
When the fuel temperature exceeds 75 C (measured by the
sensor placed on fuel filter) the control unit intervenes by
reducing injection pressure.
If the temperature exceeds 90 C, the power is reduced to
60%.
AC compressor engagement control
The control unit is able to drive engagement and
disengagement of the electromagnetic compressor clutch
depending on coolant temperature.
If the coolant temperature reaches about 150 C, it
disengages the clutch.
After Run
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the
following startup.
Print 603.93.111
99
ENGINE F4 AE 0481
FEED SYSTEM
Figure 203
High Pressure
Low Pressure
78671
1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on
chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The feed system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
Print 603.93.111
100
ENGINE F4 AE 0481
Print 603.93.111
ENGINE F4 AE 0481
101
Figure 204
EXHAUST
70493
1. High-pressure pump. 2. Pressure relief valve on high-pressure pump, 5 bars. 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. 4. Rail overpressure valve.
5. Common Rail. 6. Pressure sensor. 7. Injector. 8. Return piping. 9. Control unit heat exchanger. 10. Mechanical priming pump. 11. Prefilter assembled on chassis. 12. Fuel
tank. 13. Mechanical supply pump. 14. Fuel filter. 15. Pressure regulator. 16. High-pressure pump cooling piping. 17. By-pass valve. 18. By-pass valve.
Print 603.93.111
102
ENGINE F4 AE 0481
Print 603.93.111
ENGINE F4 AE 0481
FUEL PREFILTER
103
FUEL FILTER
Figure 205
Figure 206
70494
70495
1. Fuel filter support - 2. Fuel temperature sensor 3. Electric fuel heater - 4. Fuel filter - 5. Heater connector.
It is placed on engine block in the circuit between supply
pump and high-pressure pump (CP3).
Cartridge filtering degree: 4 microns, Pressure delta 2 bars.
The following are placed on the support: fuel temperature
sensor and heater resistances.
Fuel temperature, signalled by the related sensor to EDC7
control unit, allows a very accurate computation of the fuel
flow-rate to be injected into the cylinders.
If the warning light is on, it is necessary to immediately operate to remove its cause; the common
rail system components are quickly damaged by the
presence of water or impurities in the fuel.
Print 603.93.111
104
ENGINE F4 AE 0481
Drain conditions
Gear pump, fitted on the rear side of the high pressure pump
and used to supply it.
It is controlled by high pressure pump shaft
Figure 209
72594
72592
A Fuel inlet from tank, B fuel outlet to filter, 1-2 by-pass valves
in close position
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
situation the by-pass valve (1) stays closed whereas by-pass
valve (2) opens due to inlet pressure, and fuel is drained out
through B.
Figure 208
72593
Print 603.93.111
ENGINE F4 AE 0481
105
The high pressure pump-mechanical supply pump unit cannot be overhauled and therefore it must not be disassembled
nor its fastening screws must be tampered with.
The only admitted operation is control gear replacement.
Figure 210
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear - 5. Fuel inlet fitting from filter 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from supply
pump to filter - 9. Mechanical supply pump
Print 603.93.111
106
ENGINE F4 AE 0481
Sec. B-B
Sec. C-C
70498
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
Print 603.93.111
ENGINE F4 AE 0481
107
Operating principle
Figure 212
Sec. B B
Sec. D D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element supply duct 6. Pressure regulator supply duct - 7. Pressure regulator
Print 603.93.111
108
ENGINE F4 AE 0481
Figure 213
Sec. C C
Figure 214
72598
72601
Sec. A A
1. Pumping element inlet - 2. Pump lubrication ducts 3. Pumping element inlet - 4. Main pumping element
supply duct - 5. Pressure regulator - 6. Pumping element
inlet - 7. Regulator exhaust duct - 8. 5 bar pressure relief
valve - 9. Fuel drain from regulator inlet
Figure 213 shows low pressure fuel paths inside the path and
highlights: main pumping element supply duct (4), pumping
element supply ducts (1 3 6), pump lubrication ducts (2),
pressure regulator (5), 5 bar pressure relief valve (8) and fuel
drain duct (7).
Print 603.93.111
Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the pumping elements (about 2 bars).
ENGINE F4 AE 0481
109
RAIL
Figure 215
70499
Print 603.93.111
110
ENGINE F4 AE 0481
OVERPRESSURE VALVE
The overpressure valve (1750 bars) on the rail is used to protect system components in case of flow limiter interventions.
Figure 216
70500
70502
1. Body 2. Small piston 3. Stop 4. Spring 5. Direct tank discharge 6. Seat on rail.
A
IIf the 1750 bar fuel pressure is exceeded in rail, the small
piston is displaced and the excess pressure is discharged
into the tank.
FLOW LIMITERS
They are placed on rail fuel outlet fittings, and are used to protect engine or vehicle integrity in case of internal leaks (for example,
locked-open spray nozzle) or external leaks (example: damaged high-pressure pipings).
In such cases, system operation is, within certain limits, allowed through components remained unaffected in other cylinders.
After having blocked fuel from going out of the rail, the flow limiter is automatically re-primed under spring operation.
If however the reason for its intervention is not removed, upon the following startup attempt, the engine could
operate only at idling or at low speeds or be again turned off depending on the amount of leakage.
Figure 217
Figure 218
1
5 2
70501
70503
Print 603.93.111
ENGINE F4 AE 0481
111
Injection start
Figure 219
Figure 221
15
70504
INJECTOR
The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
70506
Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
15
Figure 222
70505
70507
A
Print 603.93.111
112
ENGINE F4 AE 0481
Print 603.93.111
ENGINE F4 AE 0681
70757
ENGINE F4 AE 0681
115
Engine F4 AE 0681
Page
Print 603.93.111
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . .
117
120
128
128
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .
129
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
CYLINDER HEAD
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . .
131
133
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
136
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . .
137
TURBOSUPERCHARGER ACTUATOR . . . . . . . .
137
137
TURBOSUPERCHARGER LAYOUT . . . . . . . . . . .
139
116
ENGINE F4 AE 0681
Print 603.93.111
ENGINE F4 AE 0681
117
GENERAL SPECIFICATIONS
Type
Cycle
Power
Injection
Direct
Number of cylinders
6 in-line
Bore
mm
102
Stroke
mm
120
5900
Compression ratio
Max. output
Max. torque
17 : 1
kW
(HP)
132
(180)
154
(210)
176
(240)
202
(275)
rpm
Nm
(kgm)
2700
600
61.2
2700
600
61.2
2700
600
61.2
2500
680
69.3
rpm
12002100
12002100
12502100
12502100
rpm
650
650
rpm
3000
3000
Print 603.93.111
118
ENGINE F4 AE 0681
Type
With intercooler
SUPERCHARGING
HOLSET HX 35 W
mm
0.50
mm
bar
bar
1.04
-
Turbosupercharger type
Turbosupercharger shaft radial backlash
Turbosupercharger shaft end play
Pressure relief valve min. opening stroke:
Pressure relief valve max. opening stroke:
Pressure corresponding to min. stroke:
Pressure corresponding to max. stroke:
LUBRICATION
bar
COOLING
1.2
3.8
By centrifugal pump, regulating thermostat,
radiator, heat exchanger, intercooler
Through belt
81 2 C
96 C
FILLING
Total capacity
1st filling:
liters
kg
Urania Turbo
Urania LD 5
Min. level
Max. level
- engine sump
liters
kg
8
7.2
10.8
9.7
liters
kg
9
8.1
11..8
10.6
Print 603.93.111
ENGINE F4 AE 0681
119
Type
TIMING
start before T.D.C.
end after B.D.C.
A
B
8.5
8.5
D
C
51
12.5
Checking timing
mm
mm
mm
0.20 0.30
mm
0.45 0.55
X
X
Checking operation
X
FUEL FEED
Injection
Type:
Bosch
Nozzle type
Injection sequence
1-5-3-6-2-4
bar
Print 603.93.111
Injection sequence
bar
Injection pressure
bar
250 - 1450
120
ENGINE F4 AE 0681
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
1
X
1
X
2
mm
Cylinder barrels:
Spare pistons:
type:
Size
Outside diameter
Pin housing
X
1
2
102.009 102.031
60.5
101.721 101.739
40.010 40.016
101.781 101.799
40.008 40.014
0.260 0.300
Piston protrusion
Piston pin
0.5
0.28 0.52
39.9938 40.0002
0.0098 0.0222
0.0078 0.0202
Print 603.93.111
ENGINE F4 AE 0681
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
s
X1
X2
X3
S 1
S 2
S 3
121
X 1*
X2
X3
mm
2.705 2.735
2.430 2.450
2.420 2.440
4.040 4.060
4.020 4.040
* measured on 99 mm
Split rings
S 1*
S2
S3
2.560 2.605
2.350 2,380
3.975 4.000
* measured on 99 mm
Split rings - slots
1
2
3
Split rings
X1
X2
X3
0.100 0.175
0.050 0.100
0.040 0.090
0.040 0.085
0.020 0.065
0.5
0.30 0.40
0.60 0.80
0.25 0.55
42.987 43.013
72.987 73.013
4
3
S
Print 603.93.111
43.279 43.553
40.019 40.033
1.955 1.968
0.266 0.566
0.0188 0.0392
-
122
ENGINE F4 AE 0681
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
mm
X
Size
Max. tolerance on
connecting rod axis
alignment
1
S 1
Journals
Crankpins
1
2
82.993 83.013
68.987 69.013
S1
S2
2.456 2.464
1.955 1.968
3
3
87.982 88.008
87.982 88.008
S 2
*provided as spare part
Main bearings
No. 134-5- 6-7
No. 2
Half bearings Journals
No. 134-5- 6-7
No. 2
0.041 0.103
0.041 0.103
0.033 0.041
0.250 0.500
Shoulder journal
X1
37.475 37.545
Shoulder main
bearing
X2
32.23
Shoulder
half-rings
X3
32.30
X 1
X 2
X 3
0.07
Print 603.93.111
ENGINE F4 AE 0681
Type
CYLINDER HEAD TIMING SYSTEM
1
mm
123
7.042 7.062
6.970 6.990
60o 0.25o
6.970 6.990
45o 0.25o
Valves:
0.052 0.092
34.837 34.863
34.837 34.863
Sinking
Between valve seat
and head
Valve seats
Print 603.93.111
34.917 34.931
60o
34.917 34.931
45o
0.59 1.11
0.96 1.48
0.054 0.094
0.054 0.094
-
124
ENGINE F4 AE 0681
Type
CYLINDER HEAD TIMING SYSTEM
mm
Valve spring height:
free spring
H 1
H 2
47.75
H1
H2
35.33
25.2
It cannot be adjusted
4-5-6 7
2 3
59.222 59.248
Camshaft housings
No. 2-3-4-5-6
59.222 59.248
2
Camshaft journals:
17
1-2-3
53.995 54.045
59.222 59.248
54.083 54.147
0.113 0.165
0.038 0.152
Cam lift:
H
6.045
7.582
Print 603.93.111
ENGINE F4 AE 0681
125
Type
CYLINDER HEAD TIMING SYSTEM
mm
1
Tappet cap housing
on block
2
3
2
16.000 16.030
15.924 15.954
15.960 15.975
0.025 0.070
Tappets
1
Rocker shaft
21.965 21.977
Rockers
22.001 22.027
2
Between rockers and shaft
Print 603.93.111
0.024 0.162
126
ENGINE F4 AE 0681
Figure 1
70508
Print 603.93.111
ENGINE F4 AE 0681
127
Figure 2
70509
Print 603.93.111
128
ENGINE F4 AE 0681
540110
Figure 3
70510
70125
Figure 4
70126
70511
Print 603.93.111
5412
541210
ENGINE F4 AE 0681
129
TIMING SYSTEM
Camshaft
Figure 7
79459
BUSHES
Figure 8
Sec. A-A
79460
130
ENGINE F4 AE 0681
Figure 9
*
**
70577
Figure 10
INTERMEDIATE MAIN
BEARINGS
70237
TOLERANCES
SHAPE
DIRECTION
POSITION
OSCILLATION
TOLERANCE CHARACTERISTIC
Roundness
Cilindricity
Parallelism
Verticality
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
Taper
GRAPHIC SYMBOL
//
//
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Print 603.93.111
ENGINE F4 AE 0681
131
Figure 11
70514
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
5406
CYLINDER HEAD
VALVE SEATS
Figure 12
EXHAUST
INTAKE
85485
Print 603.93.111
132
ENGINE F4 AE 0681
Figure 13
EXHAUST
INTAKE
70332
Figure 14
INTAKE
EXHAUST
85486
Print 603.93.111
133
ENGINE F4 AE 0681
Figure 17
Figure 15
70520
70336
cylinder n.
intake
exhaust
Figure 16
70476
1
-
2
*
3
*
-
4
*
5
*
-
6
*
*
1
*
*
2
*
-
3
*
4
*
-
5
*
6
-
Print 603.93.111
134
ENGINE F4 AE 0681
Print 603.93.111
5450
ENGINE F4 AE 0681
135
LUBRICATION
Figure 18
70516
Print 603.93.111
136
5432
ENGINE F4 AE 0681
COOLING SYSTEM
Figure 19
Print 603.93.111
70517
ENGINE F4 AE 0681
137
BOOSTER
542410 Turbosupercharger
Figure 19/1
85487
TURBOSUPERCHARGER
Borg Warner Turbo Systems K27.2
Fitted on engines
F4 AE 0681 E
F4 AE 0681 D
Figure 20
70519
HOLSET TURBOSUPERCHARGER
Supercharging pressure: 1.5 bars.
(WASTEGATE) actuator opening start: 1600 rpm.
542418
TURBOSUPERCHARGER
ACTUATOR
Check and adjustment
The actuator (2) check is carried out as described for
GARRETT turbosupercharger assembled on 4-cylinder
engines.
Adjustment is carried out by operating on tie rod (1).
Print 603.93.111
138
ENGINE F4 AE 0681
Print 603.93.111
ENGINE F4 AE 0681
139
TURBOSUPERCHARGER LAYOUT
Figure 21
Incoming air
Hot compressed air
Exhaust
70518
Print 603.93.111
140
ENGINE F4 AE 0681
Print 603.93.111
ENGINE
141
Troubleshooting Guide
Page
Print 603.93.111
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
143
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
145
142
ENGINE
Print 603.93.111
ENGINE
143
FOREWORD
A good diagnosis is carried out above all with electronic diagnostic instruments (Modus/IWT/IT200) developed by Iveco.
When a vehicle enters the workshop, information provided by vehicle driver are kept under right consideration, but the first
thing to do is connecting Modus/IWT/IT2000 and carefully performing a complete diagnosis.
- failure memory reading
- parameters reading
- engine test
- etc.
It is useful to print the results, especially in case the Help Desk assistance has to be requested.
70729
Print 603.93.111
144
ENGINE
Print 603.93.111
ENGINE
145
DIAGNOSTICS
Main engine operating anomalies:
12345-
YES
Efficient batteries.
NO
NO
NO
NO
YES
Efficient starter.
YES
YES
YES
Replace.
NO
(continued)
Print 603.93.111
146
ENGINE
YES
YES
Efficient injector.
NO
NO
YES
YES
(continued)
Base - February 2003
Print 603.93.111
ENGINE
147
YES
Efficient thermostat.
Replace.
NO
YES
Efficient radiator.
NO
YES
YES
YES
Replace.
NO
YES
Efficient fan.
Replace.
NO
Print 603.93.111
148
ENGINE
YES
YES
Efficient thermostat.
Replace.
NO
YES
YES
NO
NO
YES
YES
(continued)
Base - February 2003
Print 603.93.111
ENGINE
149
YES
YES
YES
Check restore.
NO
Replace.
NO
YES
Efficient injectors.
NO
YES
(continued)
Print 603.93.111
150
ENGINE
Efficient injectors.
NO
NO
YES
Print 603.93.111
ENGINE
151
ENGINE
YES
YES
NO
NO
NO
NO
YES
NO
Print 603.93.111
152
ENGINE
YES
Replace.
NO
YES
INSUFFICIENT OR EXCESSIVE
OIL PRESSURE
YES
YES
YES
Print 603.93.111
10
ENGINE
153
YES
Replace.
NO
Print 603.93.111
154
ENGINE
Print 603.93.111
CLUTCH
SECTION 3
Clutch
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
- Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
10
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
- Friction gaskets . . . . . . . . . . . . . . . . . . . . . . . .
11
12
12
12
HYDRAULIC CONTROL . . . . . . . . . . . . . . . . . .
13
13
- Connections . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
14
15
15
16
17
18
18
18
19
19
19
CLUTCH
Print 603.93.111
CLUTCH
DESCRIPTION
Clutch
The clutch is of the single-plate, dry-operating type, with
engagement mechanism of the pull type with baffle spring. The
Dry single-plate
Engagement mechanism
Driven plate
External gaskets
mm
Internal gaskets
mm
mm
8.5 0.3
mm
0.2
Load on plate-pusher
10100
10500
Disengagement load
2500
2000
mm
Detachment stroke
mm
10 +20
12
mm
14
13.6
Hydraulic control
Oil type
Print 603.93.111
A.P.
BORG & BECK
VALEO
330
194.5
200
1.5
CLUTCH
13/14 CLUTCH
with gearboxes: 2855.6 2870.9
VALEO
Type
Dry single-plate
Engagement mechanism
Driven plate
External gaskets
mm
330
Internal gaskets
mm
194.5
mm
9.4 0.3
mm
0.2
Load on plate-pusher
12000
Disengagement load
2600
mm
1.5
Detachment stroke
mm
10
mm
12.2
Hydraulic control
Oil type
+2
0
Print 603.93.111
CLUTCH
14 CLUTCH
with gearboxes: 2865.6 2870.9
VALEO
Type
Dry single-plate
Engagement mechanism
Driven plate
mm
350
Internal gaskets
mm
195
mm
9.4 0.3
mm
0.2
Load on plate-pusher
12000
Disengagement load
2600
mm
1.5
Detachment stroke
mm
10
mm
12.2
Oil type
Print 603.93.111
External gaskets
Hydraulic control
+2
0
CLUTCH
FICHTEL &
SACHS
15 /16 CLUTCH
with gearboxes: 2895.9 - FSO 5206B
Type
Dry single-plate
Engagement mechanism
Driven plate
External gaskets
mm
380
380
380
Internal gaskets
mm
220
220
220
mm
10 0.3
10 0.3
10 0.2
mm
0.3
Load on plate-pusher
17400
19000
20000
Disengagement load
4000
4000
3950
mm
1.7
1.7
1.7
Detachment stroke
mm
12+20
12+20
12+20
mm
16
Hydraulic control
Oil type
VALEO
12.5
15
Print 603.93.111
CLUTCH
DIAGNOSTICS
Main clutch operating anomalies:
1 - Noises when the pedal is lowered;
2 - Noises when the pedal is released;
3 - The clutch jerks;
NO
NO
NO
Print 603.93.111
CLUTCH
YES
NO
NO
NO
YES
NO
Print 603.93.111
CLUTCH
NO
NO
YES
YES
The driver must avoid this wrong attitude and rest his
foot on the clutch pedal only when it is necessary.
NO
Print 603.93.111
10
CLUTCH
TIGHTENING TORQUES
PART
Flanged hexagonal-head screw for securing plate-pusher to flywheel
Flanged hexagonal-head screw for securing plate-pusher to flywheel
Hexagonal nut for securing clutch timing case to engine M8
M8
M10
TORQUE
Nm
(kgm)
23.5 2.5
(2.4 0.2)
46.5 4.5
(4.7 0.4)
46 5
(4.6 0.4)
TOOLS
TOOL No.
DENOMINATION
99306010
99370280
99370306
99370547
Print 603.93.111
CLUTCH
11
Figure 1
Friction gaskets
Replace the entire driven plate if gaskets are excessively worn
or dirty with oil or grease, or burning traces or removal from
the driving plate are visible.
Figure 3
33696
Refitting
Figure 4
Print 603.93.111
12
CLUTCH
505254
540852
Figure 5
REPLACING CLUTCH
SUPPORT BEARING
SHAFT
Figure 6
33698
33699
Use the proper pliers to open the safety split ring (2) and
withdraw the thrust bearing (1).
For refitting reverse removal operations.
Print 603.93.111
13
CLUTCH
HYDRAULIC CONTROL
The hydraulic control to disengage the clutch can, depending on the model, be solely hydraulic or pneumatically servo-assisted.
The fluid required by the system to work is contained in a reservoir integrated in the master cylinder.
Figure 7
72864
A: Maximum stroke = 38 mm
1. Air supply coupling - 2. Fluid reservoir - 3. Oil outlet - 4. Air exhaust - 5. Master cylinder - 6. Piston
Connections
Air supply pressure (Coupling 1)
Hydraulic pressure (Coupling 3)
Print 603.93.111
10 bar
50 bar
14
CLUTCH
62450
Print 603.93.111
15
CLUTCH
62451
A. Maximum disengagement position B. Nominal position C. Position with maximum worn clutch
Stroke (mm)
(
)
13/14 VALEO
17.76
18.69
14 VALEO
17.76
18.69
Clutch
61272
16
CLUTCH
Figure 12
61275
70987
Remove the plastic rod, the rubber seal and the metal stop.
Turn worn clutch mark (3) on the new servo clutch from
rest position to 90 LH or RH, according to clutch
manufacturer.
Remove the plastic rod (1) from the servo clutch; the rubber
seal (2) shall not move.
Secure the seal (2) with the metal stop (3).
Figure 16
Figure 13
61276
70990
!
70989
Fit the plastic rod (1) against the servo clutch stop.
Push the seal (2).
Base - February 2003
Print 603.93.111
505272
CLUTCH
17
Figure 18
75233
Proceed as follows:
- measure the distance (A) between the bottom
of the spherical cavity of the clutch lever and the
servo clutch fixing surface;
- press the ball push rod until it reaches the stop
(C);
- loosen the nut (D);
18
CLUTCH
72865
Print 603.93.111
CLUTCH
19
39696
Print 603.93.111
20
CLUTCH
Print 603.93.111
GEARBOX
SECTION 4
Gearbox
Page
Print 603.93.111
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX 2855.6 . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX 2865.6 . . . . . . . . . . . . . . . . . . . . . . .
45
GEARBOX 2870.9 . . . . . . . . . . . . . . . . . . . . . . .
79
GEARBOX 2895.9 . . . . . . . . . . . . . . . . . . . . . . .
123
GEARBOX MD3060P . . . . . . . . . . . . . . . . . . . . .
163
GEARBOX FSO5206B . . . . . . . . . . . . . . . . . . . .
185
GEARBOX
Print 603.93.111
GEARBOX
DIAGNOSTICS
Main gearbox operating anomalies:
1
2
Noises;
Spontaneous gears disengagement and engagement
irregularities;
Gears engagement difficulty and hardness.
NOISES
NO
NO
NO
YES
YES
NO
Forks breakage.
(continued)
Print 603.93.111
GEARBOX
NO
NO
NO
Print 603.93.111
GEARBOX
Figure 1
62590
1. Gears control lever 2. Reaction plate secured to gears control 3. Adjustment tie-rod 4. Bearing support
5. Adjustable fixed tie-rod 6. Telescopic tie-rod 7. Gears lever
Figure 2
62591
Print 603.93.111
GEARBOX
Figure 3
Figure 5
633.5 0.75 mm
62592
70992
MODELS 120EL17
Figure 6
706 0.75 mm
Figure 4
MODELS 120EL21
70993
Figure 7
62593
722.5 0.75 mm
70994
Print 603.93.111
GEARBOX
Figure 8
780.5 0.75 mm
70995
Figure 9
62595
Print 603.93.111
GEARBOX
Print 603.93.111
GEARBOX 2855.6
5302
Gearbox
2855.6
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
15
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
GEARBOX 2855.6
DISENGAGEMENT/RE-ENGAGEMENT . . . .
21
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
21
- Re-engagement . . . . . . . . . . . . . . . . . . . . . . . .
21
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . .
23
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . .
27
27
33
35
38
38
38
39
39
39
39
40
41
43
10
GEARBOX 2855.6
Print 603.93.111
GEARBOX 2855.6
11
Print 603.43.761
DESCRIPTION
The IVECO 2855.6 gearbox is of the mechanical type with 1st,
2nd gear engagement through a double-cone synchronising
ring and 3rd, 4th, 5th and 6th gear engagement with free-ring
synchronising rings. The reverse motion engagement is with
a quick-connection sliding sleeve.
The gearbox case is made of light alloy and is composed of a
front half-case and a rear half-case.
Three openings are obtained in the rear half-case for the
possible application of a power takeoff.
Motion transmission is realised through a series of gears,
always meshed and with helical teeth.
Figure 1
79431
Print 603.93.111
12
GEARBOX 2855.6
2855.6
Type
Mechanical
Gears
Mechanical
Power takeoff
Upon request
Gears engagement:
1st 2nd
Double-cone synchronizer
3rd 6th
Free-ring synchronizer
Reverse gear
Gears anti-disengagement
Quick-connection type
Sliding sleeve holding through rollers and springs.
Gears
Gear ratio
First
Second
Third
Fourth
Fifth
Sixth
Reverse gear
1 : 6.433
1 : 3.643
1 : 2.308
1 : 1.484
1 : 1.000
1 : 0.783
1 : 5.630
Oil type
Amount
TUTELA ZC 90
5 kg. (5.5 litres)
100oC to 130oC
Print 603.93.111
Print 603.93.111
GEARBOX 2855.6
13
Through rings
4.0 - 4.1 - 4.2 - 4.3 - 4.4 - 4.5 - 4.6 - 4.7 - 4.8 - 4.9 - 5.0 5.1 - 5.2 - 5.3
Supplied in a kit
85oC
14
GEARBOX 2855.6
Figure 2
78683
Print 603.93.111
GEARBOX 2855.6
15
TIGHTENING TORQUES
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
-
TORQUE
Nm
(kgm)
32 3
(3.3 0.3)
45.5 4.5
(4.6 0.5)
22.5 2.5
(2.3 0.2)
39 2
(4.0 0.2)
14.5 1.5
(1.5 0.1)
27.6 2,5
(2.8 0.3)
38 4
(3.9 0.4)
19 2
(1.9 2)
30 3
(3.0 0.3)
27.5 2.5
(2.8 0.3)
58 6
(5.9 0.6)
43 4
(4.4 0.4)
467 23
(47.6 2.3)
33.5 3.5
(3.4 0.4)
19 2
(1.9 2)
45.5 4.5
(4.6 0.5)
45.5 4.5
(4.6 0.5)
Print 603.93.111
16
GEARBOX 2855.6
TOOLS
TOOL No.
DENOMINATION
99305121
Hot-air apparatus
99322205
99222225
99340205
Percussion extractor
99341003
Simple-effect bridge
99341009
Pair of brackets
Print 603.93.111
GEARBOX 2855.6
17
TOOLS
TOOL No.
DENOMINATION
99341015
Clamp
99341017
99341019
99341020
99341025
Holds
99342143
Print 603.93.111
18
GEARBOX 2855.6
TOOLS
TOOL No.
DENOMINATION
99348004
99370006
99370007
99370317
99370349
Keyer for drive shaft front gasket assembling (use with 99370006)
99370466
Print 603.93.111
GEARBOX 2855.6
19
TOOLS
TOOL No.
DENOMINATION
99370629
99374092
99374201
99396031
99395604
Comparator (0 10 mm)
Print 603.93.111
20
GEARBOX 2855.6
Print 603.93.111
GEARBOX 2855.6
DISENGAGEMENT/RE-ENGAGEMENT
GEARBOX 2855.6
21
Figure 3
Disengagement
Lift the calender and turn the cabin over.
- loosen securing bolt (17), unscrew securing nuts (18)
and detach air piping supporting bracket (16);
- unscrew securing nut (2) and detach air piping
supporting bracket (1);
- unscrew securing nuts (13) and detach bracket (14) of
reaction tie-rod (12);
- loosen securing screw (6) and detach from gearbox the
gears control lever completed with tie-rod (3) and
reaction tie-rod (12);
- disconnect reverse gear switch electric connection (7);
- unscrew securing nuts (15) of clutch bell to engine that
will be able to be reached with difficulty from the lower
vehicle part.
- rotate deadening guard locking rivets below the gearbox
and remove the deadening guard;
- detach transmission shaft (9) as described in the related
section;
- unscrew securing screws (4) and detach clutch control
operating cylinder (5);
- disconnect electric connection (10) of odometer sensor
(8);
- unscrew securing screw (11) and detach air piping
support bracket;
- place an hydraulic jack equipped with support 99370629
under the gearbox;
- unscrew the remaining securing nuts of clutch bell to
engine, move the gearbox backwards and lowering the
jack remove it from below the vehicle.
Re-engagement
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Print 603.93.111
22
GEARBOX 2855.6
Print 603.93.111
GEARBOX 2855.6
23
GEARBOX DISASSEMBLY
Figure 4
Figure 7
71666
71699
Figure 5
71667
Figure 6
Figure 8
78685
Print 603.93.111
71670
24
GEARBOX 2855.6
Figure 9
Figure 12
71671
78164
Figure 13
Figure 10
79432
71672
Unscrew screws (2) and remove fork pin (1) from both gearbox sides.
Figure 14
Figure 11
71673
72866
GEARBOX 2855.6
Figure 15
25
Figure 17
71676
Figure 16
72867
71680
Remove cylindric roller bearing from motion inlet shaft (1) and
heat contact surface (2) of front half-case. With a plastic
hammer extract motion inlet shaft (1) completed with ball
bearing.
Figure 19
71677
Print 603.93.111
71681
26
GEARBOX 2855.6
Checks
GEARBOX CASE
Figure 20
SHAFTS - GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
71682
Figure 21
BEARINGS
Roller bearings or roller cages must be in perfect conditions
and not show traces of wear or overheatings.
By keeping bearings manually pressed and making them
simultaneously rotate along two directions, no roughness or
noise when sliding must be detected.
72868
Extract sealing gasket (2) from motion inlet shaft cover (1).
Figure 22
71684
Print 603.93.111
GEARBOX 2855.6
GEARBOX ASSEMBLY
27
71687
Figure 23
71685
71688
FRONT HALF-CASE
THICKNESS (S)
Figure 24
61957
72869
28
GEARBOX 2855.6
First method -
Figure 27
71689
Assemble on rear half-case (1) cover (2), spacer (1, Figure 20)
and with beater 99374092 equipped with handle 99370007,
assemble external race (3) of roller bearing, settling it till it
abuts.
See Figure 30 for adjusting beater 99374092.
Figure 28
Figure 29
71690
71691
REAR HALF-CASE
61956
Print 603.93.111
GEARBOX 2855.6
29
Print 603.43.761/B
Figure 30
Figure 33
32447
72871
71692
72870
Slightly heat the ball bearing seat, assemble motion inlet shaft
(1) completed with bearing (4), adjustment ring (3) and elastic
ring (2). Settle the bearing till it abuts.
Print 603.93.111
72867
Assemble motion inlet shaft cover (2), screw screws (1) and
tighten them at the required torque.
Base - February 2003
30
GEARBOX 2855.6
Print 603.43.761
Figure 35
Figure 37
71859
79433
Disassemble previously-assembled flange and nut and assemble rear half-case (1). Screw union screw between rear
half-case and front half-case and tighten them at the required
torque.
Figure 36
Figure 38
79432
71860
Print 603.93.111
GEARBOX 2855.6
Figure 39
31
Figure 42
79434
71865
Figure 40
Figure 43
71863
Assemble shoulder rings, placing them into their own seat and
reverse gear (3) with cylindric roller bearing. Assemble reverse
gear supporting shaft (2) with a suitable beater, paying attention that the arrow (1) punched on the shaft is facing the peg
insertion hole.
71671
Figure 41
71866
71864
Slightly heat ball bearing (1) half-race and assemble it in its own
seat on primary shaft. Assemble phonic wheel (2) for
controlling the odometer.
Base - February 2003
32
GEARBOX 2855.6
Figure 48
Figure 45
71867
79435
Figure 46
Figure 49
71669
Assemble rear cover (1), screw screws (3) and tighten them
at the required torque. Assemble motion outlet flange (2).
Figure 47
71667
78685
GEARBOX 2855.6
33
Figure 50
33618
Figure 51
33621
Remove 5th speed gear (1) and roller bearing below it.
Figure 54
33619
33622
Figure 52
33623
33620
Print 603.93.111
4th
34
GEARBOX 2855.6
Figure 56
Figure 59
33624
33627
Remove 3rd and 4th gear sliding sleeve (1) recovering check
springs and rollers.
Turn the shaft over and extract reverse gear (5) with roller
bearing below it, shoulder ring (4) and rolling half-race (3) with
holds 99341025 (2), tie-rods 99341019 (7), bridge 99341003
(1) and clamp 99341015 (6).
Figure 57
Figure 60
33625
3rd
4th
3rd
Extract
and
speed fixed hub (2) and
speed
synchronising ring with holds 99341025 (5), tie-rods
99341019 (7), bridge 99341003 (1) and clamp 99341015 (6).
Remove 3rd speed coupling body (4).
33628
Figure 58
33629
1st
33626
Remove 3rd speed gear (1) and roller bearing below it.
Extract
speed gear (3) together with roller bearing and
fixed sleeve (2) for reverse gear with holds 99341023 (4),
tie-rods 99341020 (6), bridge 99341003 (1) and clamp
99341015 (5).
Print 603.93.111
GEARBOX 2855.6
35
Figure 64
33630
33632
Figure 63
Figure 65
33631
33633
Assemble sliding sleeve (1) for 1st and 2nd speed gears, springs
2nd
Print 603.93.111
36
GEARBOX 2855.6
Figure 69
Figure 66
33634
33637
Figure 67
Figure 70
33635
33638
Turn the shaft over in a clamp, assemble roller bearing and 3rd
speed gear (1).
Figure 71
Figure 68
33639
33636
Print 603.93.111
GEARBOX 2855.6
Figure 72
37
Figure 75
33640
33643
Assemble sliding sleeve (2) for 3rd and 4th speed gears, springs
Heat the fixed hub (2) for 5th and 6th speed gears at a
temperature of 100 C 130 C and install it on the primary
shaft with the chamfer heading towards the 5th speed gear.
When keying the hub pay attention that synchronising ring
tangential stops are inserted into respective hub seats.
Assemble elastic ring (1) with a suitable thickness so that the
fixed hub has no axial clearance (max allowed 0.03 mm).
33641
Assemble roller bearing and 4th speed gear (2). Heat bush (3)
at a temperature of 100 C 130 C, and assemble it on
primary shaft (4). Assemble elastic ring (1).
Figure 76
Figure 74
33644
33642
Assemble roller bearing, 5th speed gear (2), coupling body (1)
and synchronising ring (3) for 5th speed gear.
Print 603.93.111
Assemble sliding sleeve (2) for 5th and 6th speed gears, springs
and rollers. Assemble synchronising ring (3) and coupling body
(1) for 6th speed gear.
38
GEARBOX 2855.6
Figure 80
71869
71872
Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.
Figure 78
Figure 79
62455
71871
Print 603.93.111
39
GEARBOX 2855.6
71869
71873
33651
Remove elastic ring (1) from secondary shaft (3), extract bevel
roller bearings (2 and 4) with a suitable punch (destructive
operation).
Print 603.93.111
40
GEARBOX 2855.6
Figure 89
Figure 86
33655
33658
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Figure 90
Figure 87
78166
78167
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Figure 91
Figure 88
33660
33657
Extract, from the control shaft (2), control selector (1) and
box (3).
Print 603.93.111
GEARBOX 2855.6
Figure 92
41
Figure 95
71880
33661
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 96
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
Figure 97
33661
Assemble, in control box (3), sealing gasket (1) and bushes (2)
with a suitable beater.
Figure 94
78169
!
33660
42
GEARBOX 2855.6
Figure 98
Figure 101
33663
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
Figure 99
Figure 102
33658
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
33655
Figure 100
33657
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
Print 603.93.111
GEARBOX 2855.6
43
Figure 103
idle gearbox!
62456
Print 603.93.111
44
GEARBOX 2855.6
Print 603.93.111
GEARBOX 2865.6
5302
45
Gearbox
2865.6
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
47
49
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
51
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
57
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
57
- Re-engagement . . . . . . . . . . . . . . . . . . . . . . . .
57
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . .
59
62
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . .
63
64
68
71
73
74
74
74
75
75
75
76
78
46
GEARBOX 2865.6
Print 603.93.111
GEARBOX 2865.6
47
DESCRIPTION
The IVECO 2865.6 gearbox is of the mechanical type with 1st,
2nd gear engagement through a double-cone synchronising
ring and 3rd, 4th, 5th and 6th gear engagement with free-ring
synchronising rings. The reverse motion engagement is with
a quick-connection sliding sleeve.
The gearbox case is made of light alloy and is composed of a
front half-case and a rear half-case.
Three openings are obtained in the rear half-case for the
possible application of a power takeoff.
Motion transmission is realised through a series of gears,
always meshed and with helical teeth.
Figure 1
79436
Print 603.93.111
48
GEARBOX 2865.6
Figure 2
Sec. A-A
78719
LONGITUDINAL SECTION OF 2865.6 GEARSHIFT AND SECTION ON THE REVERSE GEAR SHAFT
Print 603.93.111
GEARBOX 2865.6
49
2865.6
Type
Mechanical
Gears
Mechanical
Power takeoff
Upon request
Gears engagement:
1st 2nd
3rd 4th 5th 6th
Reverse gear
Gears anti-disengagement
Gears
Double-cone synchronizer
Free-ring synchronizer
Quick-connection type
Sliding sleeve holding through rollers and
springs.
With helical teeth
Gear ratio
Print 603.93.111
First
Second
Third
Fourth
Fifth
Sixth
Reverse gear
1 : 9.007
1 : 5.015
1 : 3.206
1 : 2.066
1 : 1.370
1 : 1.000
1 : 8.170
Oil type
Amount
TUTELA ZC 90
8.1 Kg. (9 lt)
100oC to 130oC
By means of rings
4.0-4.1-4.2-4.3-4.4-4.5-4.6
4.7-4.8-4.9-5.0-5.1-5.2-5.3
Supplied in a kit
85oC
50
GEARBOX 2865.6
Figure 3
79437
Print 603.93.111
GEARBOX 2865.6
51
TIGHTENING TORQUES
TORQUE
Nm
(kgm)
Flanged hexagonal head screw for securing front cover
32 3
(3.3 0.3)
Ring nut for securing entry shaft bearing
545 55 (55.5 5.6)
Flanged hexagonal head screw for joining clutch and case
45.5 4.5 (4.6 0.5)
Release-proof tip cover fastening screw
22.5 2.5 (2.3 0.2)
Screw for securing fork control rod hub
39 2
(4.0 0.2)
Threaded plug with external operating hexagon for oil level
27.5 2.5 (2.8 0.3)
Flanged hexagonal head screw for securing covers on side power takeoffs connection windows
38 4
(3.9 0.4)
Screw with plane washer for securing transverse axle cover on external control
19 2
(1.9 0.2)
Transverse axle screw
30 3
(3.0 0.3)
Threaded plug with external operating hexagon for oil discharge
27.5 2.5 (2.8 0.3)
Flanged hexagonal head screw for securing rear cover on secondary shaft
58 6
(5.9 0.6)
Flanged hexagonal head screw for securing rear cover on primary shaft
43 4
(4.4 0.4)
Locking nut for outlet primary shaft flange
467 23 (47.6 2.3)
Flanged hexagonal head screw for securing upper external controls support cover
33.5 3.5 (3.4 0.4)
Flanged hexagonal head screw for securing spring check flange on external control
19 2
(1.9 0.2)
Flanged hexagonal head screw for securing clutch disengagement lever support
46.5 4.5 (4.6 0.4)
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
-
Print 603.93.111
52
GEARBOX 2865.6
TOOLS
TOOL No.
DENOMINATION
99305121
Hot-air apparatus
99322205
99322225
99340205
Percussion extractor
99341003
Simple-effect bridge
99341009
Pair of brackets
Print 603.93.111
GEARBOX 2865.6
53
TOOLS
TOOL No.
DENOMINATION
99341015
Clamp
99341017
99341019
99341020
99341023
Holds
99341025
Holds
Print 603.93.111
54
GEARBOX 2865.6
TOOLS
TOOL No.
DENOMINATION
99342143
99348004
99355081
99355174
99370006
99370007
Print 603.93.111
GEARBOX 2865.6
55
TOOLS
TOOL No.
DENOMINATION
99370317
99370349
Keyer for drive shaft front gasket assembling (use with 99370006)
99370466
Comparator basis
99370629
99374092
99374201
Print 603.93.111
56
GEARBOX 2865.6
TOOLS
TOOL No.
DENOMINATION
99395604
Comparator (0 10 mm)
99396032
Print 603.93.111
GEARBOX 2865.6
57
Figure 4
Disengagement
Lift the calender and turn the cabin over.
Re-engagement
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Print 603.93.111
71004
58
GEARBOX 2865.6
Print 603.93.111
GEARBOX 2865.6
59
GEARBOX DISASSEMBLY
Figure 5
Figure 8
33552
33555
Figure 6
Figure 9
33553
33556
Figure 7
Figure 10
33554
33557
Print 603.93.111
60
GEARBOX 2865.6
Figure 11
Figure 13
33558
35560
35561
Beat with a punch (1) and push the elastic peg till it abuts.
Figure 15
Figure 12
35562
35559
Print 603.93.111
GEARBOX 2865.6
Figure 16
61
Figure 19
79438
33566
Figure 17
33564
Figure 18
Figure 20
33565
33567
Extract box (2) with bridge 99341003 (1) equipped with the
pair of brackets 99341017 (3).
Print 603.93.111
62
GEARBOX 2865.6
530514
Figure 21
Figure 24
35568
35571
Extract from primary shaft cover (1) the sealing gasket (2) with
a suitable beater.
Figure 22
35569
Figure 25
35570
Extract from motion entry shaft cover (2) the sealing gasket
(1) with a suitable beater.
35572
Checks
GEARBOX 2865.6
63
GEARBOX ASSEMBLY
GEARBOX CASE
Gearbox case and related covers must not show cracks.
Contact surfaces between covers and gearbox case must not
be damaged or distorted.
Bearing seats must not be damaged or excessively worn.
SHAFTS GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
BEARINGS
Roller bearings or roller cages must be in perfect conditions
and not show traces of wear or overheating.
Keeping the bearings pressed with a hand and making them
simultaneously rotate along the two directions, no
roughnesses or noises when sliding must be detected.
33573
Figure 27
Print 603.93.111
64
GEARBOX 2865.6
Figure 30
33601
33575
BACK COVER
61956
33576
THICKNESS (S)
61957
Print 603.93.111
GEARBOX 2865.6
Figure 31
65
Figure 34
33604
Place, into the secondary shaft bearing seat on front cover (1),
the adjustment ring (2) whose thickness is equal to the
previously-obtained one.
33606
Slightly heat the ball bearing seat, assemble motion entry shaft
(1) completed with ball bearing, rolling half-races and ring nut
(2). Settle bearing (3) till it abuts.
Figure 32
32447
Figure 35
33607
33605
Print 603.93.111
66
GEARBOX 2865.6
Figure 38
Figure 36
79439
33608
Figure 39
Figure 37
33609
79438
Insert tip (1), spring (2), then mount cover (3) and fasten
screws (4) by tightening them to the specified torque.
Print 603.93.111
GEARBOX 2865.6
Figure 40
67
Figure 43
33611
33614
Assemble shoulder rings, placing them into their own seat and
reverse gear (1) with the cylindrical roller bearing. Assemble
reverse gear supporting shaft with a suitable beater.
Slightly heat ball bearing half-race and assemble it into its own
seat on primary shaft. Assemble the odometer controlling
phonic wheel (1).
Figure 44
Figure 41
33612
33615
Figure 42
Figure 45
33613
33616
Print 603.93.111
68
GEARBOX 2865.6
Figure 49
33617
33618
Figure 47
Figure 50
33554
33619
33553
33620
Print 603.93.111
GEARBOX 2865.6
69
Figure 55
Figure 52
33621
Remove 5th speed gear (1) and roller bearing below it.
33624
Remove 3rd and 4th gear sliding sleeve (1) recovering check
springs and rollers.
Figure 56
Figure 53
33625
33622
3rd
4th
3rd
Extract
and
speed fixed hub (2) and
speed
synchronising ring with holds 99341025 (5), tie-rods
99341019 (7), bridge 99341003 (1) and clamp 99341015 (6).
Remove 3rd speed coupling body (4).
Figure 54
Figure 57
33623
4th
Remove
speed gear (7) together with roller bearing and
bush (3) and coupling body (6) with holds 99341025 (4),
tie-rods 99341019 (2), bridge 99341003 (1) and clamp
99341015 (8). Remove synchronising ring (5).
Print 603.93.111
33626
Remove
3rd
70
GEARBOX 2865.6
Figure 58
Figure 61
33627
Turn the shaft over and extract reverse gear (5) with roller
bearing below it, shoulder ring (4) and rolling half-race (3) with
holds 99341025 (2), tie-rods 99341019 (7), bridge 99341003
(1) and clamp 99341015 (6).
33630
Figure 59
33628
33631
2nd
33629
Extract 1st speed gear (3) together with roller bearing and
fixed sleeve (2) for reverse gear with holds 99341023 (4),
tie-rods 99341020 (6), bridge 99341003 (1) and clamp
99341015 (5).
Base - February 2003
Print 603.93.111
GEARBOX 2865.6
71
Figure 65
33632
33634
1st
Figure 66
33635
Figure 67
33633
Assemble sliding sleeve (1) for 1st and 2nd speed gears, springs
33636
Print 603.93.111
72
GEARBOX 2865.6
zz
Figure 68
Figure 71
33637
33640
Assemble sliding sleeve (2) for 3rd and 4th speed gears, springs
Figure 69
33638
33641
Turn the shaft over in a clamp, assemble roller bearing and 3rd
speed gear (1).
Assemble roller bearing and 4th speed gear (2). Heat bush (3)
at a temperature of 100 C to 130 C, and assemble it on
primary shaft (4). Assemble elastic ring (1).
Figure 70
Figure 73
33639
33642
Assemble roller bearing, 5th speed gear (2), coupling body (1)
and synchronising ring (3) for 5th speed gear.
Print 603.93.111
GEARBOX 2865.6
73
Figure 76
33643
5th
6th
33645
Figure 77
33646
33644
Assemble sliding sleeve (2) for 5th and 6th speed gears, springs
and rollers. Assemble synchronising ring (3) and coupling body
(1) for 6th speed gear.
Print 603.93.111
33647
Extract the other rolling half-race (2) from motion entry shaft
(1) with a suitable punch.
74
GEARBOX 2865.6
Figure 79
Figure 81
33650
33648
33651
Remove elastic ring (1) from secondary shaft (3), and extract
tapered roller bearings (2 and 4) with a suitable punch
(destructive operation).
33649
33652
Print 603.93.111
GEARBOX 2865.6
75
Figure 84
Figure 86
33653
33655
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Figure 87
78166
Figure 88
33654
33657
76
GEARBOX 2865.6
Figure 89
Figure 92
33658
33661
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 93
78167
33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Assemble, in control box (3), sealing gasket (1) and bushes (2)
with a suitable beater.
Figure 91
Figure 94
33660
33660
Extract, from the control shaft (2), control selector (1) and
box (3).
Print 603.93.111
GEARBOX 2865.6
77
Figure 98
Figure 95
71880
33663
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
Figure 97
33658
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 100
78169
Print 603.93.111
33657
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
78
GEARBOX 2865.6
Figure 101
Figure 102
33655
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
Figure 103
gearbox with engaged
reverse gear
idle gearbox!
62456
Print 603.93.111
GEARBOX 2870.9
5302
79
Gearbox
2870.9
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
81
82
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
85
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
GEARBOX 2870.9
DISENGAGEMENT/RE-ENGAGEMENT . . . .
91
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
91
- Re-engagement . . . . . . . . . . . . . . . . . . . . . . . .
91
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . .
93
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . .
98
98
104
105
107
107
108
108
108
108
108
109
109
110
113
113
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
80
GEARBOX 2870.9
Print 603.93.111
GEARBOX 2870.9
81
Print 603.43.761
DESCRIPTION
The 2870.9 gearshift is of the mechanic type, with nine speeds and engagement of the 1st, 4th, 5th, 8th and 9th speeds by means of
free-ring synchronizing rings, whereas the 2nd, 3rd, 6th and 7th speeds are engaged by means of a double-cone synchronizing gear.
The reverse gear engagement is with quick-engagement sliding sleeve.
It is composed of a front section, comprising five ratios and reverse gear, and of a rear section comprising two ratios obtained through
epicyclic reduction gear.
The gear switch is carried out mechanically through double-H control; the epicyclic reduction gear engagement is carried out
mechanically with pneumatic switching.
The gearbox is equipped with an oil pump for its lubrication.
Figure 1
SEC A-A
78684
Print 603.93.111
82
GEARBOX 2870.9
2870.9
Type
Mechanical
Gears
Gears engagement
control
Mechanical
Power takeoff
Upon request
Gears engagement:
1st
Free-ring synchronizer
2nd 3rd
Double-cone synchronizer
4th 5th
Free-ring synchronizer
6th 7th
Double-cone synchronizer
8thh 9thh
Free-ring synchronizer
Reverse
eve se gear
gea
Quick-connection
Quick
connection type
Gears antidisengagement
Gears
Gear ratio
First
Second
Third
Fourth
Fifth
Sixth
Seventh
Eighth
Ninth
Reverse gear
1 : 13.200
1 : 9.036
1 : 6.473
1 : 4.691
1 : 3.548
1 : 2.547
1 : 1.824
1 : 1.322
1 : 1.000
1 : 11.650
Print 603.93.111
GEARBOX 2870.9
83
TUTELA ZC 90
4.5 Kg. (5lt)
100oC 130oC
Secondary shaft
bearings
Secondary shaft
bearings
pre-loading
adjustment
Secondary shaft
pre-loading
adjustment rings
thickness
Secondary shaft
bearings assembly
temperature
Motion entry shaft
bearings adjusting
rings thicknesses
Print 603.93.111
Through rings
84
GEARBOX 2870.9
Figure 2
Sec. A-A
79428
Print 603.93.111
GEARBOX 2870.9
85
TIGHTENING TORQUES
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
*
TORQUE
Nm
(kgm)
19 2
(1.9 0.2)
33.5 3.5
(3.4 0.4)
23.5 2.5
(2.5 0.3)
372.5 19.5
(38 2)
Flanged hexagonal head screw for securing spring check flange on external control
Flanged hexagonal head screw for securing upper external control support cover
Screw for securing reduction gear control valve
Ring nut for securing sun gear on primary shaft
Flanged hexagonal head screw for securing pneumatic reduction gear control cylinder to rear
35.5 3.5
half-case
Flanged hexagonal head screw for securing rear cover on primary shaft
44.5 4.5
Output flange locking ring nut on planetary gear-holder shaft
559.5 29.5
Flanged hexagonal head screw for securing read cover on secondary shaft
58 6
Oil filter on half-case
320 30
Threaded plug with external manoeuvre hexagon for oil discharge
27.5 2.5
Hexagonal head screw for securing oil pump body to case
33.5 3.5
Flanged hexagonal head screw for securing transverse axle cover on drive*
19 2
Transverse axle screw*
30 3
Flanged hexagonal head screw for securing covers on side power takeoff connection windows
38 4
Screw for securing fork control rod hub
39 2
Idle positioner
78 8
Flanged hexagonal head screw for joining clutch cup and case
45.5 4.5
Flanged hexagonal head screw for securing front cover
32 3
Flanged hexagonal head screw for securing clutch disengagement lever support
46.5 4.5
Oval-headed screw for securing reduction gear reaction plate
21 2
Threaded plug with external manoeuvre hexagon for oil level
27.5 2.5
Flanged hexagonal head screw for securing upper internal controls cover (only for right-hand
45.5 4.5
drive)
(3.6 0.4)
(4.4 0.5)
(57 3)
(5.9 0.6)
(32.6 3.1)
(2.8 0.3)
(3.4 0.4)
(1.9 0.2)
(3.1 0.3)
(3.9 0.4)
(4.0 0.2)
(8.0 0.8)
(4.6 0.6)
(3.3 0.3)
(4.6 0.4)
(2.1 0.2)
(2.8 0.3)
(4.6 0.5)
Print 603.93.111
86
GEARBOX 2870.9
TOOLS
TOOL No.
DESCRIPTION
99305121
Hot-air equipment
99322205
99322225
99340205
Percussion puller
99341003
99341004
Print 603.93.111
GEARBOX 2870.9
87
TOOLS
TOOL No.
DESCRIPTION
99341009
Pair of brackets
99341015
Clamp
99341017
99341019
99341020
99341025
Grips
Print 603.93.111
88
GEARBOX 2870.9
TOOLS
TOOL No.
DESCRIPTION
99342143
Peg for removing reverse gear shaft (to use with 99340205)
99345058
99348004
99355081
99355131
99370006
Print 603.93.111
GEARBOX 2870.9
89
TOOLS
TOOL No.
DESCRIPTION
99370007
99370130
Tool for holding the sun gear during nut removal and refitting
99370317
99370349
Tool for fitting gasket on gearbox front cover (to use with
99370006)
99370466
Gauge base for transmission shaft bearing adjustment (to use with
99395604)
99370629
Print 603.93.111
90
GEARBOX 2870.9
TOOLS
TOOL No.
DESCRIPTION
99374092
99374229
99381125
99395604
99396031
Gauged rings for adjusting transmission shaft bearings (to use with
99370466)
Print 603.93.111
GEARBOX 2870.9
91
Disengagement
Lift the calender and turn the cabin over.
- loosen securing bolt (23), unscrew securing nuts (24)
and detach air piping supporting bracket (22);
- unscrew securing nut (2) and detach air piping
supporting bracket (1);
- unscrew securing nuts (19) and detach bracket (20) of
reaction tie-rod (18);
- loosen securing screw (6) and detach from gearbox the
gears control lever completed with tie-rod (3) and
reaction tie-rod (18);
- disconnect reverse gear switch electric connection (16)
and range-change switch electric connection (8);
- unscrew securing nuts (21) of clutch bell to engine that
will be able to be reached with difficulty from the lower
vehicle part.
- rotate deadening guard locking rivets below the gearbox
and remove the deadening guard;
- detach transmission shaft (9) as described in the related
section;
- disconnect air piping (13) from exhaust piping (11);
- detach terminal exhaust piping, operating on securing
clip (14) bolt and on support band (12) bolt (10);
- unscrew securing screws (4) and detach clutch control
operating cylinder (5);
- disconnect electric connection (15) of odometer sensor;
- unscrew securing screw (17) and detach air piping
support bracket;
- place an hydraulic jack equipped with support 99370629
under the gearbox;
- unscrew the remaining securing nuts of clutch bell to
engine, move the gearbox backwards and lowering the
jack remove it from below the vehicle.
Re-engagement
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Print 603.93.111
92
GEARBOX 2870.9
Print 603.93.111
GEARBOX 2870.9
93
GEARBOX DISASSEMBLY
Figure 4
Figure 7
79429
71886
79440
79442
Figure 6
Figure 9
79441
Apply reaction lever 99370317 (1) and with key 99355081 (2)
loosen nut securing motion outlet flange (3).
Print 603.93.111
71888
94
GEARBOX 2870.9
Figure 10
Figure 13
71889
79444
Unscrew screws (4), disassemble cover (5), take off spring (3)
and take out tip (2). Move gear selector hub (1) inwards.
Figure 11
Figure 14
71893
71890
Figure 12
71894
79443
Print 603.93.111
GEARBOX 2870.9
Figure 16
95
Figure 18
71895
71897
Figure 17
Figure 19
71896
71898
Lift and remove primary shaft (1) together with internal drive
shaft (2).
Remove synchronizing rings (3).
Base - February 2003
96
GEARBOX 2870.9
Figure 20
Figure 23
71678
71899
71680
Remove cylindric roller bearing from motion inlet shaft (1) and
heat front half-case contact surface (2). With a plastic hammer,
extract motion inlet shaft (1) completed with ball bearing.
Figure 24
Figure 22
71681
71683
Extract sealing gasket (2) from motion inlet shaft cover (1).
Print 603.93.111
GEARBOX 2870.9
97
Checks
GEARBOX CASE
BEARINGS
SHAFTS GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
Print 603.93.111
98
GEARBOX 2870.9
GEARBOX ASSEMBLY
71687
71688
FRONT HALF-CASE
THICKNESS (S)
Figure 25
61957
71686
Print 603.93.111
GEARBOX 2870.9
Figure 28
99
Figure 31
INTERMEDIATE CASE
71900
Figure 29
First method -
71901
Figure 30
71902
Print 603.93.111
100
GEARBOX 2870.9
Figure 32
Figure 35
71691
71693
Slightly heat the ball bearing seat, assemble motion inlet shaft
(1) completed with bearing (4), adjustment ring (3) and elastic
ring (2). Settle the bearing till it abuts.
Figure 33
32447
Figure 34
71692
71679
Print 603.93.111
GEARBOX 2870.9
Figure 37
101
Figure 39
71678
71903
Assemble motion inlet shaft cover (2), screw screws (1) and
tighten them at the required torque.
Figure 38
Figure 40
71898
Print 603.93.111
71904
102
GEARBOX 2870.9
Figure 41
Figure 43
71905
78164
Insert tip (4), spring (3), then mount cover (1) and fasten
screws (2) by tightening them to the specified torque.
Figure 44
Figure 42
71907
78165
Assemble shoulder rings, placing them into their own seat and
reverse gear (3) with cylindric roller bearing. Assemble reverse
gear supporting shaft (2) with a suitable beater, paying
attention that the arrow (1) punched on the shaft is facing the
peg insertion hole.
Print 603.93.111
GEARBOX 2870.9
Figure 45
103
Figure 48
71911
71908
Figure 46
71912
71909
Assemble oil pump (1) and tighten screws (2) at the required
torque, assemble cover (3) and tighten screws (4) at the
required torque.
Figure 47
71886
71910
Print 603.93.111
104
GEARBOX 2870.9
Figure 52
Figure 51
79440
79441
Figure 53
gearbox with engaged
reverse gear
idle gearbox
62457
Print 603.93.111
GEARBOX 2870.9
105
Figure 57
35481
35478
Figure 58
35482
35479
Figure 59
Figure 56
35483
35480
Print 603.93.111
106
GEARBOX 2870.9
Figure 60
Figure 63
35484
35487
Figure 61
35485
35488
Figure 65
Figure 62
35486
35489
Print 603.93.111
GEARBOX 2870.9
107
Figure 68
Figure 66
71869
- Fixed hubs (1) for 1st and reverse, 2nd 3rd 4th 5th
speed gears must be heated at a temperature of 100
130 C and driven into the primary shaft, paying attention
that synchronising ring stops (2) are inserted into the
respective fixed hub seats.
71870
Figure 70
71871
35491
Print 603.93.111
108
GEARBOX 2870.9
Figure 71
Figure 73
33651
71872
Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.
Remove elastic ring (1) from secondary shaft (3) and extract
bevel roller bearings (2 and 4) with a suitable punch
(destructive operation).
Figure 72
62455
Figure 74
GEARBOX 2870.9
109
Figure 76
1
2
3
5
8
6
7
35431
79445
Secure the assembly in a vice, unscrew the four screws (1) and
disassemble valve (2) of epicyclic reduction gear drive.
Figure 77
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Figure 78
78166
110
GEARBOX 2870.9
Figure 79
Figure 82
33660
33657
Extract, from the control shaft (2), control selector (1) and
box (3).
Figure 80
Figure 83
33658
33661
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 84
78167
33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Assemble sealing gasket (1) and bushes (2) into drive case (3)
with a suitable beater.
Print 603.93.111
GEARBOX 2870.9
Figure 85
111
Figure 87
33660
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
Figure 88
Figure 86
78169
71880
!
!
Print 603.93.111
112
GEARBOX 2870.9
Figure 89
Figure 92
33663
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
Figure 90
Figure 93
33658
33655
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 91
Figure 94
33657
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
Base - February 2003
79445
Print 603.93.111
GEARBOX 2870.9
113
72458
SLOW GEAR ENGAGEMENT (1st 2nd 3rd 4th 5th AND REVERSE GEAR)
Air coming from services tank, passing through a reduction gear, is reduced to the pressure of 6.5 6.9 bars and reaches consent
valve at union I.
By pressing the clutch, operate on the gearbox lever to engage a gear (1-2-3-4-5-RG); cam (A) is moved upwards and pushes pin
(B) leftwards.
The pin abuts on piston (C) valve and by lifting it, closes the supply to union 21.
By discharging air contained into the cylinder through the vent hole (D), air will then go out of union 22 thereby keeping gearbox
piston in slow gears.
Print 603.93.111
114
GEARBOX 2870.9
Figure 96
72459
Print 603.93.111
GEARBOX 2870.9
115
DISASSEMBLY
Figure 97
Figure 100
71916
71913
Remove rod with fork (1), withdraw phonic wheel (3) and
remove synchronising ring (2).
Figure 101
Figure 98
71917
71914
Figure 99
Figure 102
71915
Lift case (2) in order to free outlet shaft (3) and rod (1) for
synchronising drive fork.
Print 603.93.111
71918
116
GEARBOX 2870.9
Figure 103
Figure 106
71922
71919
Figure 104
Figure 107
71920
35514
In order to remove sliding sleeve (1) from crown (2), use small
pins (3) with diameter 2 2.3 mm and a length of 10 mm.
Figure 105
Figure 108
35515
71921
Print 603.93.111
GEARBOX 2870.9
Figure 109
117
Figure 112
71923
71926
Extract sealing gasket (4) from cover (2), unscrew screws (1)
and disassemble cover (2) and support (3).
Check that ball bearing (2), when rotating along the two
directions, does not show roughness or noise when sliding.
In case of a replacement of the bearing itself, slightly heat
support (1) seat before disassembling it.
Figure 110
71924
Figure 111
Checks
Check that all parts composing the epicyclic reduction gear
assembly do not shown traces of excessive wear, seizures or
breakages.
Replace the affected parts.
71925
Print 603.93.111
118
GEARBOX 2870.9
ASSEMBLY
Figure 113
Figure 116
71930
71927
By using a punch (2), assemble elastic peg (2) checking pin (3).
Figure 117
Figure 114
71928
71931
Figure 115
Figure 118
71932
71929
GEARBOX 2870.9
Figure 119
119
Figure 122
35523
Figure 120
71935
71933
71936
Figure 121
71934
Arrange springs, pins and rollers (1), apart from the central
ones (), into the hub.
Print 603.93.111
71937
120
GEARBOX 2870.9
Figure 125
Figure 128
71925
71940
Figure 126
71938
Figure 127
71941
71939
Print 603.93.111
GEARBOX 2870.9
Figure 130
121
Figure 133
71958
71944
Figure 131
71945
Figure 135
Figure 132
71946
Key-in flange (1) and screw nut (2) without blocking it.
71943
Print 603.93.111
122
GEARBOX 2870.9
Print 603.93.111
GEARBOX 2895.9
5302
123
Gearbox 2895.9
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
125
126
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
129
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
130
GEARBOX DISENGAGEMENT/
RE-ENGAGEMENT . . . . . . . . . . . . . . . . . . . .
135
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
135
- Re-engagement . . . . . . . . . . . . . . . . . . . . . . . .
135
GEARBOX DISASSEMBLING . . . . . . . . . . . . . . .
135
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
139
GEARBOX ASSEMBLING . . . . . . . . . . . . . . . . . .
139
139
144
145
147
148
148
TRANSMISSION SHAFT . . . . . . . . . . . . . . . . . . .
148
- Bearing replacement . . . . . . . . . . . . . . . . . . . .
148
149
149
149
150
124
GEARBOX 2895.9
Page
EPICYCLIC REDUCTION GEAR ASSEMBLY . . .
153
153
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
155
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
158
Print 603.93.111
GEARBOX 2895.9
125
DESCRIPTION
The 2870.9 gearshift is of the mechanic type, with nine speeds and engagement of the 1st, 4th, 5th, 8th and 9th speeds by means of
free-ring synchronizing rings, whereas the 2nd, 3rd, 6th and 7th speeds are engaged by means of a double-cone synchronizing gear.
It consists of a front part featuring five forward gears and reverse gear and a rear part featuring two gears obtained through epicyclic
reduction gear unit (E.R.U.).
Gearshifting is performed through double H mechanical control, E.R.U. switching is through pneumatic system.
Gearbox is fitted with oil pump for lubrication.
Figure 1
A
79451
Sec. A-A
GEARBOX 2895.9 LONGITUDINAL SECTION AND REVERSE GEAR SHAFT SECTION
Print 603.93.111
126
GEARBOX 2895.9
2895.9
Type
Mechanical
Gears
Mechanical
Power takeoff
On request
Gears engagement:
1st
Free-ring synchronizer
2nd 3rd
Double-cone synchronizer
4th 5th
Free-ring synchronizer
6th 7th
Double-cone synchronizer
8thh 9thh
Free-ring synchronizer
Reverse
eve se gear
gea
Quick-connection
Quick
connection type
Gears anti-disengagement
Gears
Helical toothing
Gear ratio
First
Second
Third
Fourth
Fifth
Sixth
Seventh
Eighth
Ninth
Reverse gear
Oil type
Amount
1 : 13.56
1 : 9.00
1 : 6.54
1 : 4.76
1 : 3.54
1 : 2.53
1 : 1.84
1 : 1.34
1 : 1.00
1 : 13.15
Tutela ZC 90
7.5 kg (8.3 liters)
Print 603.93.111
mm
Print 603.93.111
GEARBOX 2895.9
100 130oC
Tapered rollers
Through rings
85oC
127
128
GEARBOX 2895.9
Figure 2
sec. A-A
79452
Print 603.93.111
GEARBOX 2895.9
129
TIGHTENING TORQUE
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
*
D
Flanged hexagonal head screw for securing spring retaining flange on external control
Flanged hexagonal head screw for securing upper external controls support cover
Screw for securing reduction unit control valve
Ring nut for securing sun gear on main shaft
Flanged hexagonal head screw for securing reduction unit control pneumatic cylinder
to rear half box
Flanged hexagonal head screw for securing rear cover on main shaft
Ring nut for fastening output shaft on spider shaft
Flanged hexagonal head screw for securing rear cover on transmission shaft
Oil filter on rear half box
Threaded plug with external operating hexagon for oil drain
Hexagonal head screw for securing oil pump body to box
Flanged hexagonal head screw for securing transverse axle cover on external control*
Transverse axle screw*
Threaded plug with external operating hexagon for oil level
Flanged hexagonal head screw for securing covers on PTO connection openings
Screw for securing fork control rod hub
Idle positioning device
Ring nut for securing input shaft bearing
Flanged hexagonal head screw for securing front cover
Flanged hexagonal head screw for securing tangential stops block
Screw for securing gearbox clutch housing
Flanged hexagonal head screw for securing rear intermediate front half box
Countersunk screw for securing reduction unit reaction plate
Print 603.93.111
TORQUE
Nm
(kgm)
19 2
(1.9 0.2)
33.5 3.5
(3.4 0.4)
23.5 2.5
(2.4 0.3)
372.5 19.5 (37.5 2)
35.5 3.5
(3.6 0.4)
44.5 4.5
559.5 29.5
58 6
320 30
27.5 2.5
33.5 3.5
19 2
30 3
27.5 2.5
38 4
39 2
78 8
545 55
31 3
24.5 2.5
177 17
45.5 4.5
21 2
(4.5 0.5)
(57 3)
(5.9 0.6)
(32.6 3.1)
(2.8 0.3)
(3.4 0.4)
(1.9 0.2)
(3.1 0.3)
(2.8 0.3)
(3.9 0.4)
(4.0 0.2)
(8.0 0.8)
(55.6 5.6)
(3.1 0.3)
(2.5 0.2)
(18 1.8)
(4.6 0.5)
(2.1 0.2)
130
GEARBOX 2895.9
TOOLS
TOOL No.
DESCRIPTION
99305121
Hot-air equipment
99322205
99322225
99340205
Percussion puller
99341003
99341004
Print 603.93.111
GEARBOX 2895.9
131
TOOLS
TOOL No.
DESCRIPTION
99341009
Pair of brackets
99341015
Clamp
99341017
99341019
99341020
99341023
Grips
Print 603.93.111
132
GEARBOX 2895.9
TOOLS
TOOL No.
DESCRIPTION
99341025
Grips
99345058
99347092
Peg for removing reverse gear shaft (to use with 99340205)
99355081
Wrench (60 mm) for locking ring nut of output flange on spider shaft
(use with 99370317)
99355131
Wrench (55 mm) for locking ring nut of sun gear on primary shaft
(use with 99370130)
99355174
Print 603.93.111
GEARBOX 2895.9
133
TOOLS
TOOL No.
DESCRIPTION
99370006
99370130
Tool for holding the sun gear during nut removal and refitting
99370317
99370349
Tool for fitting gasket on gearbox front cover (to use with
99370006)
99370466
Gauge base for transmission shaft bearing adjustment (to use with
99395604)
99370629
Print 603.93.111
134
GEARBOX 2895.9
TOOLS
TOOL No.
DESCRIPTION
99374229
99381125
99395604
99396032
Gauged rings for adjusting transmission shaft bearings (to use with
99370466)
Print 603.93.111
GEARBOX 2895.9
GEARBOX DISENGAGEMENT/
RE-ENGAGEMENT
Disengagement
135
Figure 4
Re-engagement
Suitably reverse the performed operations for the
engagement and tighten securing screws and nuts at
the required torque.
Figure 5
GEARBOX DISASSEMBLING
35437
Loosen the fastening screws and remove the E.R.U. box (1).
35438
35435
136
GEARBOX 2895.9
Figure 7
Figure 10
35439
35442
Figure 11
35440
35443
Figure 12
35441
Loosen the screws and remove input shaft front cover (1).
35444
Print 603.93.111
137
GEARBOX 2895.9
Figure 13
Figure 16
35448
79444
Unscrew screws (4), disassemble cover (5), take off spring (3)
and take out tip (2). Move gear selector hub (1) inwards.
Figure 14
35449
35472
Remove reverse gear cover; drive down the split pin (2) using
a punch.
Withdraw the reverse speed gear (1) with shoulder ring and
straight roller bearings.
Figure 18
Figure 15
35450
35447
Print 603.93.111
138
GEARBOX 2895.9
Figure 19
Figure 22
35451
35454
Remove synchronising rings (1) and remove the input shaft (2)
using a plastic hammer.
Figure 23
Figure 20
35455
Tighten nut (1) on main shaft (2), lift the main shaft by approx.
10 20 mm and withdraw the transmission shaft (3) moving
it sideways.
Figure 24
Figure 21
35456
35453
Lift and remove the main shaft (1) with gear control assembly
(2).
Base - February 2003
Remove oil pipe (1), bearing outer ring (2) and ball bearing (3)
from the gearbox case.
Print 603.93.111
139
GEARBOX 2895.9
Checks
GEARBOX CASE
Gearbox case and related covers must not show cracks.
Contact surfaces between covers and gearbox case must not
be damaged or distorted.
Bearing seats must not be damaged or excessively worn.
SHAFTS - GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
GEARBOX ASSEMBLING
BEARINGS
Roller bearings or roller cages must be in perfect conditions
and not show traces of wear or overheating.
When keeping the bearings pressed by hand and making them
rotate simultaneously along both directions, no roughness or
noise must be detected.
35457
Figure 26
Print 603.93.111
35458
140
GEARBOX 2895.9
Figure 27
Figure 30
35459
35462
Fit transmission shaft bearing outer ring (2) and main shaft ball
bearing (3) on the intermediate box (1).
Figure 28
Figure 31
35460
Figure 29
35463
THICKNESS (S)
Fit the oil pump (1) and tighten the screws to the specified
torque, rotate the intermediate box.
FRONT COVER
Figure 32
35461
35464
Print 603.93.111
GEARBOX 2895.9
Figure 33
141
Figure 34
35466
INTERMEDIATE BOX
70244
Fit input shaft (2) and transmission shaft outer ring (1) on front
cover.
Figure 35
35467
Fit roller bearing into input shaft then fit the main shaft (1)
including gear engagement control.
Figure 36
!
!
35468
142
GEARBOX 2895.9
Figure 37
Figure 40
35469
Fit the intermediate box (1) and tighten screws (2) to the
specified torque.
35470
Fit tool 99370130 on the main shaft, engage a gear and with
wrench 99355174 (1) and dynamometric wrench tighten ring
nut to the specified torque.
Figure 38
78165
35471
78164
Insert tip (4), spring (3), then mount cover (1) and fasten
screws (2) by tightening them to the specified torque.
Base - February 2003
Fit the adjustment ring, smear cover (1) with LOCTITE 510,
fit cover and tighten the screws (2) to the specified torque.
Print 603.93.111
GEARBOX 2895.9
Figure 42
143
Figure 45
35448
35474
Fit down oil distributor (2) and the sun gear (1).
1. Bearing spacer - 2. Shoulder ring - 3. Roller bearings 4. Reverse speed gear - 5. Shoulder ring - 6. Shaft 7. Split pin.
Figure 43
35472
35475
35473
Fit the oil pump (2) and tighten screws to the specified torque
using the dynamometric wrench (1).
Print 603.93.111
144
GEARBOX 2895.9
Figure 47
Figure 48
35477
35476
Figure 49
gearbox with engaged
reverse gear
idle gearbox!
62457
Print 603.93.111
GEARBOX 2895.9
145
Print 603.43.761
Figure 52
35478
35480
Figure 51
Figure 53
35479
Print 603.93.111
35481
146
GEARBOX 2895.9
Figure 54
Figure 57
35482
35485
Extract 2nd and 3rd speed gear fixed hub (3), synchronising
ring, coupling body (5), and 2nd speed gear (5) using puller
99341003 (1), tie rods (2), grips (4) and clamp (6). Recover
the needle bearing.
Figure 55
Figure 58
35486
35483
Remove 3rd speed gear (5) together with bush (6) and needle
bearing using puller 99341003 (1), tie rods (2), grips (4) and
clamp 99341015 (3).
Figure 56
Upset the main shaft and remove the reverse speed gear (4)
with bearing outer ring (6) and the shoulder ring (5) using
puller 99341003 (1), tie rods (2), grips (3) and clamp (7).
Figure 59
35484
35487
Remove the needle bearing (1), the synchroniser ring and the
coupling body (2).
Print 603.93.111
GEARBOX 2895.9
147
Figure 60
Figure 62
35488
35490
fixed hubs (1) for 1st 2nd 3rd 4th 5th and R.G. gears
shall be heated to 100 C 130 C and assembled on
main shaft. When driving the hubs, pay attention that
synchronising ring stops (2) are fitted into respective fixed
hub seats;
Figure 61
Figure 63
35489
Extract 1st speed gear (6) with sliding sleeve, synchronising ring
and needle bearing using puller 99341003 (1), reaction block
(2), tie rods (3), clamp (4) and grips (5).
Print 603.93.111
35491
148
GEARBOX 2895.9
Figure 67
35492
1. Straight roller bearing - 2. Half race - 3. Half race 4. Ball bearing - 5. Ring nut - 6. Input shaft.
Figure 65
35493
Fit bearing (2) into a vice and beat the shaft (1) to remove ball
bearing (2) and one half race.
TRANSMISSION SHAFT
Bearing replacement
Figure 68
Figure 66
35496
35494
Use puller 99341003 (1), tie rods (2) and grips (3) to remove
the other half race (4).
Base - February 2003
Remove split ring (1) and extract taper roller bearing (2); use
a proper punch to remove also the taper roller bearing (3).
When refitting warm slightly the bearings.
Print 603.93.111
GEARBOX 2895.9
149
Figure 69
Figure 71
35497
79446
Secure the unit in a vice, unscrew the four screws (1), then
disassemble epicyclic reduction gear control valve (2).
Figure 70
Figure 72
1
2
3
5
8
6
7
33655
35431
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Figure 73
Print 603.93.111
150
GEARBOX 2895.9
Figure 74
Figure 77
33660
33657
Extract, from the control shaft (2), control selector (1) and
box (3).
Figure 75
Figure 78
33658
33661
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 79
78167
33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Assemble sealing gasket (1) and bushes (2) into drive case (3)
with a suitable beater.
Print 603.93.111
GEARBOX 2895.9
Figure 80
151
Figure 82
33660
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
Figure 83
Figure 81
78169
71880
!
!
Print 603.93.111
152
GEARBOX 2895.9
Figure 84
Figure 87
33663
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
Figure 85
Figure 88
33658
33655
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 86
Figure 89
33657
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
79445
Print 603.93.111
GEARBOX 2895.9
153
72458
SLOW GEAR ENGAGEMENT (1st 2nd 3rd 4th 5th AND REVERSE GEAR)
Air coming from services tank, passing through a reduction gear, is reduced to the pressure of 6.5 6.9 bars and reaches consent
valve at union I.
By pressing the clutch, operate on the gearbox lever to engage a gear (1-2-3-4-5-RG); cam (A) is moved upwards and pushes pin
(B) leftwards.
The pin abuts on piston (C) valve and by lifting it, closes the supply to union 21.
By discharging air contained into the cylinder through the vent hole (D), air will then go out of union 22 thereby keeping gearbox
piston in slow gears.
Print 603.93.111
154
GEARBOX 2895.9
Figure 91
72459
Print 603.93.111
Figure 92
Figure 95
71916
71913
Remove rod with fork (1), withdraw phonic wheel (3) and
remove synchronising ring (2).
Figure 96
Figure 93
71917
71914
71915
Lift case (2) in order to free outlet shaft (3) and rod (1) for
synchronising drive fork.
71918
156
GEARBOX 2895.9
Figure 98
Figure 101
71919
71922
Figure 102
71920
35514
In order to remove sliding sleeve (1) from crown (2), use small
pins (3) with diameter 2 2.3 mm and a length of 10 mm.
Figure 100
Figure 103
35515
71921
Print 603.93.111
GEARBOX 2895.9
Figure 104
157
Figure 107
71926
71923
Extract sealing gasket (4) from cover (2), unscrew screws (1)
and disassemble cover (2) and support (3).
Figure 105
Check that ball bearing (2), when rotating along the two
directions, does not show roughness or noise when sliding.
In case of a replacement of the bearing itself, slightly heat
support (1) seat before disassembling it.
71924
Checks
Check that all parts composing the epicyclic reduction gear
assembly do not shown traces of excessive wear, seizures or
breakages.
Replace the affected parts.
71925
Print 603.93.111
158
GEARBOX 2895.9
ASSEMBLY
Figure 108
Figure 111
71947
71930
By using a punch (2), assemble elastic peg (2) checking pin (3).
Figure 112
Figure 109
71928
71931
Figure 110
71932
71929
GEARBOX 2895.9
Figure 114
Figure 117
35523
Figure 115
71935
71936
71933
Figure 116
71934
Arrange springs, pins and rollers (1), apart from the central
ones (), into the hub.
Print 603.93.111
159
71937
160
GEARBOX 2895.9
Figure 120
Figure 123
71925
Figure 121
71938
Figure 122
71939
71941
Print 603.93.111
GEARBOX 2895.9
Figure 125
161
Figure 128
71958
71944
Figure 126
71945
Figure 130
Figure 127
71946
Key-in flange (1) and screw nut (2) without blocking it.
71943
Print 603.93.111
162
GEARBOX 2895.9
Print 603.93.111
5302
163
Allison gearbox
MD 3060P
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
165
168
169
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . .
177
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
177
179
- Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . .
179
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
179
179
179
180
180
180
181
181
182
183
183
164
Print 603.93.111
165
DESCRIPTION
The Allison MD 3060 P gearbox is automatic and it provides
six forward speeds and one reverse speed by means of a
hydrodynamic torque converter, two clutches, three brakes
and tree crown wheels.
For all types of gearbox, 5th and 6th gears are overgeared up.
The reverse gear has a ratio that is greater than the first gear
that allows a better speed control on slopes.
Figure 1
Print 603.93.111
61402
166
Clutches are pressure-balanced on both piston sides to prolong the clutch life and for a more accurate control on the
whole range of gearbox gears.
Planetary gears always being engaged are of the helical teeth
type to allow a more silent gearbox operation.
The hydrodynamic torque converter, in addition to being
mandatory for vehicle start-up, allows a gearbox operation
without shakes reducing wear of members composing the vehicle kinematic chain.
Figure 2
52001
Print 603.93.111
167
Figure 3
52003
52004
Print 603.93.111
168
ALLISON
MD 3060 P
Type
Automatic
Forward runnings
Reverse running
Power take-off
Optional
Gears
3.49
1.86
1.41
1.00
0.75
0.65
5.03
Type of oil
Quantity
Tutela GI/A
(28 litres)
(:) The gear ratio does not include torque converter gearing up
Base - February 2003
Print 603.93.111
169
NO
Battery discharged.
NO
Battery disconnected.
Print 603.93.111
170
NO
NO
Connect or clean.
YES
NO
NO
Print 603.93.111
171
NO
NO
NO
YES
NO
YES
(To be continued)
Print 603.93.111
172
YES
NO
YES
NO RESPONSE FROM
GEAR SELECTOR
NO
See point 8.
YES
NO
Print 603.93.111
173
NO
YES
NO
YES
See point 8.
YES
NO
YES
Replace filter.
NO
YES
NO
Print 603.93.111
YES
174
YES
NO
10
YES
Replace filter.
NO
11
YES
NO
(To be continued)
Base - February 2003
Print 603.93.111
Breather clogged.
12
YES
175
NO
YES
NO
YES
NO
YES
NO
Print 603.93.111
YES
See point 8.
176
13
YES
NO
NO
14
DIRTY OIL
NO
Overheating.
YES
NO
YES
Replace filter/seals.
YES
NO
Print 603.93.111
177
TIGHTENING TORQUES
PART
TORQUE
Nm
49 to 58
34
54 to 68
2 to 3
57 to 68
51 to 61
25 to 32
12 to 14
30 to 35
30 to 35
12 to 14
12 to 14
5 to 8
5 to 7
10 to 13
30 to 35
12 to 16
(kgm)
(4.9 to 5.8)
(3.4)
(5.4 to 6.8)
(0.2 to 0.3)
(5.7 to 6.8)
(5.1 to 6.1)
(2.5 to 3.2)
(1.2 to 1.4)
(3 to 3.5)
(3 to 3.5)
(1.2 to 1.4)
(1.2 to 1.4)
(0.5 to 0.8)
(0.5 to 0.7)
(1 to 1.3)
(3.0 to 3.5)
(1.2 to 1.6)
TOOLS
TOOL No.
DENOMINATION
99360322
99370629
99374013
Print 603.93.111
178
Figure 5
52121
Print 603.93.111
Figure 6
179
Figure 7
52063
52064
Refitting
Assemble gearbox control module again according to the previously described procedure.
Print 603.93.111
180
Figure 8
Figure 10
52067
52065
Figure 9
52066
Print 603.93.111
181
Figure 11
Figure 13
52068
52070
a)
Solenoid valves (1), (2) and (3) belong to the N/C type
(Normally Closed). To operate on these solenoid valves
disconnect the wiring corresponding to the valves and
disassemble valve casings (6) from the gearbox control
module by unscrewing the screws connecting it to the oil
sump (4).
b)
c)
Figure 12
52069
Remove cover (1) and replace filter (2), gasket (3) and seal (4).
Install cover (1) and tighten securing screws to a torque of 12
to 14 Nm.
Assemble gearbox control module again according to the
procedure described in this Section on page 179.
Print 603.93.111
182
52071
Print 603.93.111
183
Figure 15
Figure 16
52074
52072
Remove the safety plate, the securing plate, the O-ring and the
gasket.
Remove flange (2) from the rear cover (4) and use a proper
tool to remove the seal ring.
Clean the seal ring seat and remove any slag present.
Replace the seal ring and the O-ring. Use keying device
99374013 to insert the seal ring in its seat.
Print 603.93.111
184
Print 603.93.111
5302
185
Gearbox
EATON FSO 5206B
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
187
188
189
192
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
193
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
195
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . .
199
GEARSHIFT OVERHAUL . . . . . . . . . . . . . . . . . .
200
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200
200
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . .
200
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203
204
207
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . .
207
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . .
207
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
207
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . .
207
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . .
211
215
- Disassembling . . . . . . . . . . . . . . . . . . . . . . . . .
215
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . .
216
- Gearbox assembling . . . . . . . . . . . . . . . . . . . .
217
220
186
Print 603.93.111
187
DESCRIPTION
The Eaton FSO 5206 B gearshift is of the mechanic type, with
synchronized forward gear engagement.
The gears force-fitted onto the output shaft and the gear on
the reverse gear shaft rotate idle on cylindrical roller cages.
The motion inlet shaft and the output shaft are supported, in
the gearbox, by non-adjustable roller bearings.
The rear half case has, on its sides and rear portions, special
openings for insertion of power takeoffs (where required).
Motion is transmitted by means of a constant-mesh gear set
with helicoidal teeth (for 6th/5th - 4th/3rd speeds) and straight
teeth (for 1st speed and reverse).
Figure 1
84438
Print 603.93.111
188
KZ
84439
Type of transmission
FSO 5206 H
FS
O
5
2
06
H
Standard code
Overdrive
Rated torque, x 100 lb ft (foot-pound)
Series 1
Number of forward speeds
Type of specific ratio
Design no.
Y 05172
The gearbox design number is unique to each
customer and provides accurate information on the
gearbox design level. The number must be specified
when ordering spare parts.
The middle digit indicates the design level.
Print 603.93.111
189
6 forward gears
Gears
reverse gear
Mechanical
-1, On rear part
-1, On side part
Gears engagement:
- 5th 6th / 3rd 4th
- 1st 2nd
Reverse gear
Free-ring synchronizer
Quick-connection type
Gears anti-disengagement
- 1st 2nd
- 3rd 4th / 5th 6th
Gears
- 1st 2nd
- 3rd 4th / 5th 6th
Print 603.93.111
Double-cone synchronizer
Gear ratio
First
Second
Third
Fourth
Fifth
Sixth (overdrive)
Reverse gear
6.08
3.52
2.09
1.35
1.00
0.79
5.43
Oil type
Amount
TUTELA ZC 90
6.5 Kg. (7 lt)
190
85oC
0.40 to 0.57
0.35 to 0.48
0.31 to 0.53
as near to zero as possible
85oC
Countershaft
Countershaft bearings
Countershaft bearing assembling
temperature
85oC
by means of shims
tapered-roller type
Print 603.93.111
191
0.075 to 0.125
0.00 to 0.05
By means of rings
mm 0.051 - 0.127 - 0.254 - 0.508 - 2.40
Supplied in special kits
150oC
Synchronizers
Synchronizing ring wear limit check
dimension
mm
LOCTITE sealant:
- for mating surfaces between cases and
covers
- matching body on motion inlet shaft
Print 603.93.111
0.5 to 1.9
5900
648
192
Plain grid with idle between the 3rd and 4th speeds.
Diagram of motion transmission with the various speeds.
84440
84441
Print 603.93.111
193
TIGHTENING TORQUES
Figure 4
84442
PART
1
2
3
4
5
6
7
8
9
10
TORQUE
Nm
(kgm)
69 78
6.9 7.8
35 39
3.5 3.9
20 24
2 2.4
32 37
3.2 3.7
51 58
5.1 5.8
35 39
3.5 3.9
16 22
1.6 2.2
20 24
2 2.4
20 24
2 2.4
16 22
1.6 2.2
Print 603.93.111
194
Figure 5
84443
PART
1
2
3
4
M8
M10
6 Locknut fastening the motion outlet flange to the output shaft
7 Screws fastening the gearbox drive case to the front case
8 Screws fastening the side cover to the gearbox drive case
Tapered screw fastening the selector block to the gear control rod; apply LOCTITE 242 on the
thread
Apply LOCTITE 518 on the mounting surface
5
TORQUE
Nm
(kgm)
69 78
6.9 7.8
69 78
6.9 7.8
32 37
3.2 3.7
16 22
1.6 2.2
20 27
2 2.7
35 39
3.5 3.9
490 588 49 58.8
35 39
3.5 3.9
20 24
2 2.4
35 39
3.5 3.9
Print 603.93.111
195
TOOLS
TOOL No.
DENOMINATION
99305121
Hot-air apparatus
99322205
99322225
99340205
Percussion extractor
99341003
Simple-effect bridge
99341009
Pair of brackets
Print 603.93.111
196
TOOLS
TOOL No.
DENOMINATION
99341015
Clamp
99341017
99341019
99341020
99341023
Holds
99341025
Holds
Print 603.93.111
197
TOOLS
TOOL No.
DENOMINATION
99342143
99348004
99370006
99370007
99370317
99370349
Keyer for drive shaft front gasket assembling (use with 99370006)
Print 603.93.111
198
TOOLS
TOOL No.
DENOMINATION
99370629
99374092
99374201
Print 603.93.111
199
EXPERIMENTAL TOOLS
This chapter illustrates the technical working drawing of the experimental tools (S.P. 2413) used in the gearshift overhaul described
in this section, which can be manufactured by the repair workshop operators themselves.
Print 603.93.111
200
530210
GEARSHIFT OVERHAUL
Disassembling
Checks
The gears, synchronizing rings, matching bodies and
engagement sliding sleeves must not show faults or excessive
tooth wear.
The output shaft must be free from dents, especially on the
gear roller cage rotating surface.
The reverse speed idler gear shaft surface must be smooth and
free from scoring.
The gearbox half cases must not show cracks and the bearing
seats must not be damaged nor worn, to prevent the bearing
outer races from rotating in the seats.
Verify that the shoulder spacers are not damaged nor worn.
The gear engaging forks must not show cracks and must slide
freely, yet with no notable play, on the control rod.
Verify that the control forks are in full working order.
Verify that the bearings and bushings are not worn, damaged
or overheated.
530220
Figure 7
84445
84446
Remove the neutral gear signalling switch (3) with cap (2)
below and oil vapour vent (1).
Figure 6
Figure 9
84444
84447
Remove screws (1) and take off small cover (2) with gasket
(5). Take out spring (3) and pin (4).
Print 603.93.111
Figure 10
201
Figure 13
84448
Remove screws (2), take off cover (1) and bracket (3).
84451
Remove cap (1), with punch (6), take off plug (2) linking
selector (5) to rod (4).
Figure 11
Figure 14
84449
Remove snap ring (5) and take collar (4), springs (3 and 2) and
collar (1) off rod (6).
Figure 12
84452
Assembling
Figure 15
84450
84453
Print 603.93.111
202
Figure 16
Figure 18
84454
Place selector (3) in case (1) in the same position taken note
of upon disassembling, then insert rod (4) and link with plug
(2).
84456
Fit a new seal ring (3) on cover (4), then mount the same with
a new gasket (2) and bracket (6) on case (1). Fasten the screws
by means of washers (5) and tighten them to the specified
torque.
Figure 19
Figure 17
84447
84455
Mount snap ring (1), cup (3), springs (4 and 5), cup (6) and
snap ring (7) on rod (2).
!
84446
Insert cap (2) in the case, then fasten switch (3) by tightening
it to the specified torque. Fasten vent (1) and tighten it to the
specified torque.
Base - February 2003
Print 603.93.111
203
Refitting
Figure 21
Figure 22
84445
84457
Fit the gear drive case (2) back to the gearbox, then tighten
the screws to the specified torque.
Figure 23
84458
Print 603.93.111
204
Figure 27
84459
84462
Figure 25
Figure 28
84460
84463
Figure 26
84461
Print 603.93.111
Figure 29
205
Figure 32
84464
Remove screws (1) and take off cover (2), spacer (3) and
adjusting ring (4).
Remove screws (6) and take off cover (5).
Figure 30
84466
Remove screws (1), take off small cover (2) with gasket (3),
then take out spring (4) and pin (5).
Figure 33
84467
84465
Remove snap ring (2) retaining bearing (4) to the motion inlet
shaft (1), then remove spacer (3).
Figure 31
Remove screws (1) with the washers and take out fork
trunnions (2) complete with seal ring (3).
Take note of the position of screws (7) and screws with nuts
(4), then remove them. Take front half case (5) off rear half
case (6).
Figure 34
84457
84468
Remove fork (2) complete with dowels (1) from sliding sleeve
(4) and selector (3).
Base - February 2003
206
Figure 35
Figure 37
84471
84469
Remove phonic wheel (1), spacer (2) and ring (3) of roller
bearing.
Figure 38
Remove screws (1), take off cover (2) and remove spacer (3).
Figure 39
Figure 36
84473
84470
Remove the following items from rear half case (5): bushing
(4) supporting the fork supporting shaft, the tapered-roller
bearing outer race (1) and roller bearing outer race (2).
Print 603.93.111
207
84474
Assembling
Heat roller bearing inner race (5) to ~ 85 C, then
fit it onto motion inlet shaft (6).
Apply LOCTITE 648 on inner teeth () of matching
body (7), then mount the latter onto motion inlet
shaft (6).
Figure 41
OUTPUT SHAFT
Disassembling
84475
Take 5th - 6th gear engagement sliding sleeve (2) off hub (1);
pay attention to the escape of rollers (3), pins (4) and springs
(5), then recover the same.
Remove snap ring (6).
Print 603.93.111
208
Figure 42
Figure 45
84476
33628
Figure 46
84477
33629
Take off matching body (1), 6th speed gear (2) and roller cage
(3).
Remove snap ring (4).
Figure 44
Figure 47
84478
84479
Print 603.93.111
Figure 48
209
Figure 50
84480
1st
- 2nd
Take
gear engagement sliding sleeve (2) off hub (1);
pay attention to the escape of balls (5), springs (3) and dowels
(4), then recover the same. Remove dowels (6) and take off
snap ring (7).
Figure 49
84482
Turn output shaft (1) upside down. Remove snap ring (2). Use
a hydraulic press to remove 4th speed gear (11), matching
body (10), synchronizing ring (6), synchronizing unit (8),
synchronizing ring (7), matching body (6), 3rd speed gear (5),
roller cage (4) and bushing (3).
84481
Figure 51
84483
Take 3rd - 4th gear engagement sliding sleeve (2) off hub (1);
pay attention to the escape of hub of rollers (3), pins (2) and
springs (5), then recover the same.
Print 603.93.111
210
Figure 52
84484
Print 603.93.111
211
Assembling
Figure 53
Figure 55
84485
84487
Figure 54
Figure 56
84486
Mount roller cage (2), 2nd speed gear (3) and matching body
(4) on output shaft (1).
Mount inner ring (5) and intermediate ring (6) so that the tabs
are inserted into the matching body (4) slots, then mount
synchronizing ring (7) so that the outer side openings match
with ring (5) inner tabs.
Print 603.93.111
84488
Mount snap ring (1), the thickness of which produces axial play
of the same, into its own seat (2), as near to zero as possible.
Check axial play of 2nd speed gear (2), which must fall within
the range of 0.35 0.48 mm.
212
Figure 57
Figure 59
84509
84480
Lubricate roller cage (3), then fit it onto output shaft (1).
Mount 1st speed gear (2).
Figure 60
Figure 58
84510
84507
Print 603.93.111
Figure 61
213
Figure 64
84511
Lubricate roller cage (3), then fit it onto output shaft (1) and
mount reverse gear (2).
Figure 62
33639
Mount matching body (2) and synchronizing ring (3). Heat hub
(1) to a temperature of 85C, then fit it onto shaft (4), taking
care that the synchronizing ring tangent stops are inserted into
the respective seats of the hub.
Check axial play of 3rd speed gear, which must fall within the
range of 0.35 0.48 mm.
Figure 65
84512
84514
Mount springs (5) and small pins (4) on hub (2). Mount 3rd 4th gear engagement sliding sleeve (1) on hub (2), then place
the former so that it is slightly lifted compared to hub (2), then
insert rollers (3) between small pins (4) and sliding sleeve (2).
84513
Turn the shaft (placed in the vice) upside down, mount roller
cage (1) and 3rd speed gear (2).
Print 603.93.111
214
Figure 66
Figure 69
84518
Mount snap ring (1), the thickness of which produces axial play
of the same into its own seat (2), as near to zero as possible.
84515
Figure 70
Figure 67
84508
84516
4th
speed gear
6th
speed
Figure 71
Figure 68
84517
84519
Print 603.93.111
Figure 72
215
Figure 74
84522
84520
Figure 73
84535
!
84521
Mount snap ring (1), the thickness of which produces axial play
of the same into its own seat (2), as near to zero as possible.
Print 603.93.111
216
Assembling
The internal driving shaft unit is assembled by reversing the
order of disassembling operations.
Figure 76
84523
Remove screw (3), then take block (1), the selection key (5)
and selector (2) out of shaft (4).
Figure 77
84524
Print 603.93.111
217
Gearbox assembling
Prior to assembling the gearbox, verify that the half cases and
the covers are clean, and that all the gaskets and sealing
materials have been removed from the mating surfaces. When
fitting the fastening screws to the clearance holes, apply
LOCTITE 641 sealant to the threads.
Figure 80
Figure 78
84527
Figure 79
Figure 82
84526
Print 603.93.111
84529
Place internal driving shaft (2) onto output shaft (1), then
secure it firmly by means of a suitable rope.
218
Figure 83
Figure 85
84530
Place countershaft (2) in rear half case (3). Lift the unit (1) thus
assembled. Apply tool SP. 2413 (4) to the output shaft end,
secure it by means of nut (5) and insert it into the rear half case.
While performing this operation, verify that the output shaft
is inserted into the support bearing, the internal driving shaft
is inserted into its respective bushing, and that the
countershaft can be matched with the output shaft.
84532
Mount motion inlet shaft (2) by slightly lifting output shaft (5)
and opening out countershaft (1).
Remove the rope.
Place fork (4) pads (3) on sliding sleeve (7), then connect fork
(4) to selector (8) pin.
Force-fit tool SP. 2413 (6) onto motion inlet shaft (2).
Figure 86
Figure 84
84533
84531
Print 603.93.111
Figure 87
219
Figure 89
84466
84538
Insert pin (5) with spring (4) into the front half case.
Mount small cover (2) with a new gasket (3). Fasten screws
(1) and tighten them to the specified torque.
Figure 88
84465
Figure 91
84467
Fasten screws (7) and the screws with nuts (4) in the original
assembly position, then tighten them to the specified torque.
Mount a new seal ring (3) on pins (2).
Apply LOCTITE 5900 on the mounting flange of pins (2), then
insert the latter into the front half case so that they fit into the
5th - 6th speed engagement fork seats.
Fasten screws (1) with washers, then tighten them to the
specified torque.
84534
Print 603.93.111
220
Figure 92
Figure 94
84541
84539
where:
A = thickness of the adjusting ring used for measuring;
Figure 93
0.075 0.125 mm
- used bearings
0.00 0.05 mm
Mount cover (2) on half case (6), fasten screws (1) without the
safety washers, tighten them evenly and, at the same time, turn
the motion inlet shaft in both directions of rotation in order
to correctly embed the bearings and feel some resistance
when rotating.
Print 603.93.111
Figure 95
221
Figure 98
84542
Turn the gearbox upside down. Remove screws (1), take off
cover (2) and remove tool SP. 2413 (3).
Figure 96
84470
Figure 99
84543
84544
Lubricate the lip of seal ring (4) fitted into the rear cover.
Heat flange (3) to ~ 85C, fit it onto the output shaft, then
fasten locknut (1) onto the output shaft.
Stop rotation of flange (1) by means of tool 99370317 (2)
applied as shown in the figure.
Fasten nut (1) to the specified torque, then remove tool (2).
84471
Mount roller bearing ring (3), spacer (2) and phonic wheel (1).
Print 603.93.111
222
Figure 100
Figure 102
84545
84463
Figure 101
Figure 103
84461
84457
Fit gear drive case (2) back to the gearbox, then tighten screws
(1) to the specified torque.
Mount the oil drain cap and tighten it to the specified torque.
Fill the gearbox with the proper amount of lubricating oil of
the specified type.
Mount the level check and oil filling cap, then tighten it to the
specified torque.
Print 603.93.111
PROPELLER SHAFTS
SECTION 5
Propeller shafts
Page
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
11
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
11
12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
PROPELLER SHAFTS
Print 603.93.111
PROPELLER SHAFTS
DESCRIPTION
Motion transmission from engine-gearbox to rear axle
occurs through a propeller shaft that is sliding in a single
section or in two sections composed of a fixed front shaft and
a sliding rear shaft.
Coupling between assemblies and shaft is implemented by
universal joints.
Figure 1
VIEW FROM A
VIEW FROM B
72680
Figure 2
VIEW FROM A
VIEW FROM B
72681
Print 603.93.111
PROPELLER SHAFTS
Figure 3
72682
VIEW FROM A
Figure 4
VIEW FROM A
72683
Print 603.93.111
PROPELLER SHAFTS
Figure 5
72684
VIEW FROM A
VIEW FROM C
VIEW FROM B
VIEW FROM A
VIEW FROM C
VIEW FROM B
72685
PROPELLER SHAFTS
Figure 7
72686
VIEW FROM A
VIEW FROM C
VIEW FROM B
72687
VIEW FROM A
VIEW FROM C
VIEW FROM B
Print 603.93.111
PROPELLER SHAFTS
Figure 9
VIEW FROM A
VIEW FROM B
72688
VIEW FROM A
VIEW FROM B
72689
PROPELLER SHAFTS
72690
Print 603.93.111
PROPELLER SHAFTS
PITCH
3330
L
mm
min
L1
mm
3690
L
mm
max
min
L1
mm
4185
L
mm
1330
1485 to 1595
1330
1750 to 1860
1630
1740 to 1850
110/120 EL 17
2870.9
1540 to 1650
1765 to 1875
1140
990 to 1100
1140
1485 to 1595
1140
1750 to 1860
1610
1650 to 1760
110/120 EL 21
2865.6
1580 to 1690
1810 to 1920
1180
990 to 1100
1180
1485 to 1595
1180
1750 to 1860
1560
1750 to 1860
110/120 EL 21
2870.9
1420 to 1530
1650 to 1760
1020
990 to 1100
1020
1485 to 1595
1020
1750 to 1860
1390
1750 to 1860
min
max
min
L1
mm
max
L
mm
min
L1
mm
L1
mm
L1
mm
L
mm
L1
mm
L
mm
1300
1460 to 1570
1395
1630 to 1740
1740
1650 to 1760
1300
1035
1410 to 1520
1300
1310
1630 to 1740
1300
1110
1110
1630 to 1740
120/130 E 18-21
2870.9
1490 to 1600
1110
965 to 1075
1110
1460 to 1570
1110
1725 to 1835
1730
1460 to 1570
1730
1830 to 1940
1110
1110
1830 to 1940
1270
1850
1830 to 1940
120/130 E 21
2865.6
1650 to 1760
1180
965 to 1075
1180
1460 to 1570
1235
1740 to 1850
1610
1740 to 1850
1860
1865 to 1975
1350
1030
1830 to 1940
1350
1880
1875 to 1965
120/130 E 24-28
2895.9
1410 to 1520
1990 to 2100
1030
1455 to 1565
1030
1725 to 1835
1380
1725 to 1835
1895
1580 to 1690
1895
2075 to 2185
1090
1895
1875 to 1985
120/130 E 24
FSO5206B
1540 to 1650
1155
965 to 1075
1155
1460 to 1570
1155
1740 to 1850
1500
1740 to 1850
1740
1865 to 1975
1830 to 1940
1875 to 1985
150 E 21
2865.6
1635 to 1745
1190
1040 to 1150
1270
1445 to 1555
1270
1715 to 1825
1630
1715 to 1825
1860
1830 to 1940
1350
1020
1830 to 1940
1350
1880
1865 to 1975
150 E 21
2870.9
1475 to 1585
2065 to 2175
1115
1445 to 1555
1115
1715 to 1825
1470
1715 to 1825
1700
1830 to 1940
1190
1020
1830 to 1940
1190
1880
1865 to 1975
150 E 24
FSO5206B
1500 to 1610
1085
1020 to 1130
1160
1425 to 1535
1160
1695 to 1805
1510
1695 to 1805
1740
1825 to 1935
1240
1020
1820 to 1930
1240
1880
1850 to 1960
150 E 24-28
2895.9
1350 to 1460
1930 to 2040
1030
1410 to 1520
1030
1690 to 1800
1380
1690 to 1800
1380
2045 to 2155
1895
2030 to 2140
1090
1895
1845 to 1955
3830
PITCH
L
mm
L1
mm
130 E 18 RS
2865.9
1635 to 1745
150 E 21 RS
2870.9
1475 to 1585
3690
L1
mm
GEARBOX TYPE
260 E 28 KE
2895.9
4185
L
mm
L1
mm
max
L1
mm
max
max
min
min
L1
mm
max
L1
mm
max
min
1095
max
L1
mm
min
max
673 to 833
5670
L
mm
min
max
L2
mm
L1
mm
max
6210
L
mm
min
L2
mm
L1
mm
max
6570
L
mm
min
L2
mm
L1
mm
max
L
mm
GEARBOX TYPE
180 E 21
2865.6
1190
1030 to 1140
1270
1440 to 1550
1270
1845 to 1955
1630
1960 to 1800
1860
1825 to 1935
1270
1085
1825 to 1935
1350
1895
1475 to 1585
1350
1895
1845 to 1955
180 E 21
2870.9
2035 to 2145
1115
1425 to 1535
1115
1825 to 1935
1470
1690 to 1800
1700
1825 to 1935
1115
1085
1825 to 1935
1190
1895
1480 to 1590
1190
1895
1825 to 1935
180 E 24-28
2895.9
1950 to 2060
1030
1420 to 1530
1030
1825 to 1935
1380
1695 to 1805
1605
1830 to 1940
1030
1085
1820 to 1930
1090
1895
1490 to 1600
1090
1895
1850 to 1960
180 E 24
FSO5206B
1085
1020 to 1130
1160
1440 to 1550
1160
1845 to 1955
1510
1710 to 1820
1740
1850 to 1960
1240
1020
1825 to 1935
1240
1880
1500 to 1610
1240
1880
1850 to 1960
max
L
mm
1255 to 1365
5175
L
mm
min
L2
mm
673 to 833
4815
L
mm
min
4190
L
mm
1975 to 2085
4590
L
mm
min
min
max
MODEL
Print 603.93.111
min
MODEL
min
L2
mm
965 to 1075
max
max
L3
mm
1300
GEARBOX TYPE
min
L2
mm
1690 to 1800
MODEL
max
L
mm
6570
2855.6
PITCH
min
L2
mm
5670
max
120/130 E 18
min
max
L
mm
min
GEARBOX TYPE
3105
min
L1
mm
max
MODEL
PITCH
max
L
mm
5175
min
L
mm
990 to 1100
L
mm
max
L1
mm
1330
4815
min
L
mm
965 to 1076
L1
mm
max
L1
mm
985
L
mm
min
L
mm
1725 to 1835
4455
max
L1
mm
2855.6
4185
min
L
mm
110/120 EL 17
3690
max
L1
mm
5670
GEARBOX TYPE
3105
min
L
mm
5175
4815
MODEL
PITCH
max
L1
mm
4455
min
max
10
PROPELLER SHAFTS
Print 603.93.111
PROPELLER SHAFTS
11
DIAGNOSTICS
Main propeller shaft anomalies:
1 - Transmission noises and vibration
Shaft distortion
NO
Unbalanced shaft.
YES
NO
NO
YES
NO
NO
TIGHTENING TORQUES
PART
M10 screw for securing transmission flanges
M12 screw for securing transmission flanges
M14 screw for securing transmission flanges
Self-locking flanged nut for elastic support fastening screw
Print 603.93.111
TORQUE
Nm
(kgm)
63.5 6.5
(6.4 0.6)
101 10
(10.3 1)
133.5 13.5 (13.6 1.4)
82 8
(8.3 0.9)
Base - February 2003
12
PROPELLER SHAFTS
505620
Removal
Figure 14
Figure 12
33701
33700
33702
Refitting
For the refitting, carry out in reverse order the
operations described for the removal, complying with
the following warnings:
Self-locking nuts must always be replaced and
tightened at the required torque.
Check whether arrows on the sliding part and on
shaft are aligned.
Print 603.93.111
SECTION 6
5250
Rear axles
Page
Print 603.93.111
Print 603.93.111
AXLE IN TANDEM
AXLES IN TANDEM
Meritor SP 145 E
Page
Print 603.93.111
53
AXLE IN TANDEM
Print 603.93.111
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . .
18
21
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
21
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . .
21
23
23
23
24
25
28
28
29
29
31
31
33
34
34
38
38
39
Page
ASSEMBLING DIFFERENTIAL CASING . . . . . . . . .
40
40
COMPUTATIONAL EXAMPLES . . . . . . . . . . . . . .
41
44
46
REMOVING-SERVICING-REFITTING
INTER-AXLE OUTPUT SHAFT . . . . . . . . . . .
49
Print 603.93.111
DESCRIPTION
The intermediate axle is a bearing axle type with a simple reduction; it consists of a box made in metal sheet, housing a reduction differential and a main differential. Drive transmission
from the reduction to main differential is achieved through a
helical gear pair. The reduction differential is made up by a drive
input shaft keying: the front support, the oil pump, the driving
gear housing the front crown wheel and side pinion assembly;
the rear crown gear is housed on the axle box and keyed on
the drive output shaft.
A sliding sleeve is mounted on the rear crown wheel to lock
the differential; the sliding sleeve is driven by a pneumatic device through a fork.
Taper roller bearing axial clearance is adjusted by inserting
shims between front and wheelwork support; the main differential is made up by a pair of bevel reduction gears with helical
Axle type:
Bearing axle with simple reduction,
with a pneumatic control
differential locking device
MAIN DIFFERENTIAL ASSEMBLY
Crown wheel and pinion assembly
reduction ratio (pinion/ring gear
teeth number)
Bevel pinion bearings
1/5.86 (7/41)
1/5.29 (7/37)
1/4.63 (8/37)
2 taper roller bearings
Print 603.93.111
Nm
kgm
Nm
kgm
1.12 to 5.08
0.112 to 0.508
1.68 to 3.39
0.168 to 0.339
through shims
5.30-5.33-5.35-5.38-5.40-5.50-5.60
5.70-5.80-5.90-6.00-6.10-6.13-6.15-6.18-6.20
0.20 to 0.46
mm
Nm
kgm
0.08 to 0.22
1.7 to 3.9
0.17 to 0.39
Through ring nuts
Max. 68
Max. 6.8
0.05 to 0.20
WHEEL HUBS
Two taper roller bearings
Nm
kgm
0.00 to 0.05
Max. 1.96
Max. 0.20
Through nut
Litres (kg)
16 2 (14.6)
16.2
(14 6)
Print 603.93.111
TIGHTENING TORQUES
Figure 1
84394
TORQUE
PART
Nm
(kgm)
122.5 22.5
(12.4 2.2)
950 135
(96.8 13.7)
1492.5 272.5
(152.1 27.7)
55 15
(5.6 1.5)
65 min.
(6.6 min)
37.5 7.5
(3.8 0.7)
485 55
(49.4 5.6)
745 135
(75.9 13.7)
57.5 10.5
(5.8 1)
10
122.5 13.5
(12.4 1.3)
11
67.5 7.5
(6.8 0.7)
Print 603.93.111
10
Figure 2
77210
TORQUE
PART
Nm
(kgm)
55 20
(5.6 2)
10
11
122.5 13.5
(12.4 1.3)
12
142.5 12.5
(14.5 12.5)
13
Self-locking nut fixing bevel ring gear to the half box M 16x1.5
255 35
(25.9 3.5)
14
67.5 12.5
(6.8 1.2)
Print 603.93.111
11
Figure 3
85492
TORQUE
Nm
(kgm)
40 4
(4 0.4)
392.3 20
(40 2)
232.4 24.5
(23.2 2.4)
+50
-20
289
600
60 +5
-2
(29)
Figure 4
C-C SECTION
37983
12
TOOLS
TOOL No.
DENOMINATION
99305121
Heater
99322205
Rotary stand for unit overhauling (capacity 1000 daN, torque 120
daN/m)
99322215
99322225
Single-acting lift
99341003
Pair of brackets
99341012
Print 603.93.111
13
TOOLS
TOOL No.
DENOMINATION
99341015
Clamp
99341016
99345029
99345055
99345098
99345103
Print 603.93.111
14
TOOLS
TOOL No.
DENOMINATION
99348001
99355025
99355069
99355088
99355131
Wrench (55 mm) for the nut of the drive input flange of the transfer
box (use with 99370317)
99355167
Print 603.93.111
15
TOOLS
TOOL No.
DENOMINATION
99360311
99370005
99370007
99370317
99370509
99370616
Print 603.93.111
16
TOOLS
TOOL No.
DENOMINATION
99370617
99371047
99374093
Drift punch for installation of bearing outer races (91134) (use with
99370007)
99374094
99374134
99374162
Print 603.93.111
17
TOOLS
TOOL NO.
DESCRIPTION
99374163
Keying device for assembling the distributor motion output shaft seal
99381125
99389816
99389819
99395026
Tool for measuring hub rolling drag torque (use with torque
wrench)
99395027
Tool for determining thickness of differential bevel pinion adjustment shims (use with 99395693)
Print 603.93.111
18
EXPERIMENTAL TOOLS
This heading covers the technical working drawings of the experimental tools (S.P.), used when overhauling the rear axle described
in this section, that can be made in your repair shop.
Print 603.93.111
Print 603.93.111
19
20
Print 603.93.111
INTERMEDIATE AXLE
DISCONNECTION/ RECONNECTION
(with Hendrickson suspensions)
21
Figure 5
Disconnection
Proceed as follows:
- Place a suitable elevating trolley 99370617 under the
differential of the axle to be removed.
- Disconnect propeller shafts (5) and anchor them
properly to the chassis.
- Disconnect electric connections (6) and air piping (7)
from the relevant differential locking devices.
- Disconnect piping (8).
- Disconnect brake wear sensor connections (1) and free
wiring from the straps on the axle.
- Disconnect the bracket (3) from the axle complete with
adjustment tie rods; operating on the fasteners (4) and
anchor them properly to the chassis.
- Disconnect reaction triangle fasteners (2) and free it
from the axle.
- Withdraw the axle.
Reconnection
Suitably reverse the operations performed for
disconnecting checking the electric connections.
1. Brake wear sensor connection - 2. Reaction triangle fastener - 3. Tie rod fixing bracket - 4. Tie rod fastener 5. Propeller shaft - 6. Electric connection - 7. Air piping - 8. Piping
74092
Print 603.93.111
22
Print 603.93.111
525010
525030
Removal/installation operations concerning the following units: axle shafts, brake shoes and drums, air
breather, differential can be performed with the unit
on the vehicle.
23
Figure 7
Before placing the axle assembly on the stand, loosen the bottom plug and drain the oil.
525013
AIR BREATHER
REMOVAL-REFITTING
Figure 6
77222
77221
19341
!
!
19349
Remove the screws fixing the drum (1) to the wheel hub (2) and
screw them down in the holes () to extract the drum (1).
Print 603.93.111
24
Figure 10
Figure 12
36295
77223
Using the wrench 99355167 (1) unscrew the lock nut (2) locking the bearing adjustment nut (4).
Extract the retaining ring nut (3), unscrew the bearing adjustment nut (4) and take out the bearing (5).
Figure 13
Figure 11
19354
If the phonic wheel (1, Figure 12) is not to be dismantled, do not use it as a support.
77224
Print 603.93.111
525030
25
Figure 14
Figure 16
40326
36298
Ensure the rest surface of screw heads is free from burrs, slags
or nicks before fitting new screws (3).
The load to be applied to screw heads for driving them into
their seats must not exceed 2300 Kg.
When driving operation is completed, screws should abut
perfectly on the wheel hub face : maximum squareness tolerance 0,2 mm.
If the oil slinger (2) was removed in order to be replaced, coat
oil slinger and hub mating face with sealing compound that can
resist heat to temperatures of 40 to 250C.
Figure 15
Refit phonic wheel (2), if necessary, by heating to a temperature of 150C. Ensure phonic wheel is perfectly bedded onto
hub seat after installation.
Check squareness of phonic wheel (2) as follows.
Position wheel hub (4) with taper roller bearings on base of
column drill. Interpose a spacer between base and outer bearing race (5) so that wheel hub may turn.
Rest a plate (7) on the internal bearing roller ring (3).
Turn handle (8) to raise base so that drill chuck comes into
contact with plate (7) and bearings (3 and 5) are slightly preloaded.
Position magnetic base dial gauge with flat base stylus as shown
in figure and turn wheel hub. Check that maximum squareness
error for phonic wheel (2) does not exceed 0,2 mm.
Figure 17
36299
Fit taper roller bearing outer races in wheel hub using handle
99370007 (1) and drift (2): 99374094 for outer bearing race
(3) and 99374094 for inner bearing race.
Print 603.93.111
62665
Place the tapered roller bearing (1) in the outer ring (2). Using
the keying device 99374134 (3) fit the gasket (under a press)
in the wheel hub.
26
Figure 18
Figure 20
77225
Lubricate the bearing seat on the sleeve and the wheel hub
seal (1) with TUTELA W 140/M-DA oil.
Position the tapered roller bearing in the wheel hub (1) and,
using the tool 99345103 (2) applied as in the figure, fit the
wheel hub (1) onto the sleeve.
19366
Figure 19
Figure 21
36304
Tighten nut (1). Then adjust wheel hub bearing end play as follows.
Use wrench 99355167 (2) to tighten nut (1) to a torque of
98.1 Nm (10 kgm).
36305
Place a magnetic base dial gauge (1) on wheel hub (3); rest
gauge stylus on sleeve (2) and check wheel hub end play. It
should not be over 0.00 0.05 mm.
Base - February 2003
Print 603.93.111
Figure 23
27
Figure 24
36307
Apply tool 99395026 (1) to the wheel hub pins and, using a
torque wrench, check that the rolling torque is no greater than:
1.96 Nm (0.20 kgm).
This torque must correspond to a maximum end float of the
bearings of 0.05 mm.
36309
Figure 25
77226
Print 603.93.111
28
Figure 28
Figure 26
77227
77222
Use mounting 99370616 for differential carrier removal with axle assembled on vehicle.
REFITTING
DIFFERENTIAL
GEAR
Figure 27
Figure 29
36344
77228
Use retainer 99370317 (3) to stop flange (1) rotation. Unscrew drive flange (1) retaining nut using wrench 99355131
(2) and torque adaptor (4).
Remove screws (5) and disconnect axle housing output shaft
mounting (6).
Print 603.93.111
29
Position the transfer box differential gear housing (1) on the rotary stand 99322205 (2) together with the mount 99322225 (3).
Unscrew the screws (4) and remove the guard.
Using tool 99360311 unscrew the oil filter (5).
Figure 30
Figure 33
36346
Turn the axle housing by 90. Insert support (1) with drive output shaft (2) in the axle housing and tighten screw to the specified torque.
Figure 31
77230
Stop flange (1) rotation with tool 99370317 (2). Undo flange
retaining nut using wrench 99355088 (3) and torque adaptor
(4).
Figure 34
36347
526060
Figure 32
36350
77231
77229
Print 603.93.111
30
Figure 36
Figure 39
84395
36352
Remove the spring (1) and strip yoke (2), sleeve (3) and rear
planetary gear (4).
Figure 37
84396
36353
Figure 38
36354
Use extractor 99348001 (1) and reaction block (2) to dismantle cone (3) of rear planetary gear (4) roller bearing.
36356
Remove nut (1) and separate flange (2) from drive input shaft
(3) by means of a suitable extractor.
Print 603.93.111
Figure 42
31
Make sure all screw, stud and ring nut threads are
cleaned accurately so that clearance and torque specifications are not effected.
36357
Use a press to extract the drive input shaft (1) from bearing
cage (2) and oil pump (3).
Figure 45
36430
36359
Remove screws (1), separate oil pump (2) from bearing cage
(3) and take out bearing (4).
Tighten the drive input shaft (1) in a vice and install the oil pump
(3).
Heat the bearing (2) to 100C for 15 minutes and fit it on using
a drift.
Figure 44
Figure 46
36358
36360
Remove spring (2), oil pressure relief valve (1) and cup (3) of
bearing (4, Figure 43) from bearing cage (4).
Using drift 99374093 (2) partially press fit cup (3) of bearing
(2, Figure 43) in bearing cage (4). Complete installation manually using handle 99370007 (1).
Print 603.93.111
32
Figure 47
Figure 49
X
84398
36361
Smear the thrust ring (4) with grease and arrange it under gear
(3);
- secure the gear on the drive input shaft (6),
- then differential gear assembly (2) and fasten by means of
snap ring (1).
Turn the input shaft (6) upside down and spline flange (5) onto
it.
Fit washer (7) and screw in retaining nut (8) without fully
tightening it.
Figure 50
Figure 48
36363
Use drift 99374093 (2) and handle 99370007 (1) to fit bearing
(2, Figure 51) cup (3) in the rear-axle differential carrier.
Figure 51
84397
Mount the planet gear unit (if previously disassembled) by following the procedure below. Apply the specific lubricant used
for the rear axle housing on all the other parts of the planet gear
unit.
Mount the gears and pinion and the thrust washer on the spider.
Place the pinion unit and spider in one of half cases (1). Mount
the remaining half case onto the half case with the spider unit.
Make sure that the marks (2) available on each half case are
aligned to one another.
Screw four of the cap screws (3) after applying LOCTITE.
Screw the remaining cap screws (3) after applying LOCTITE
on the thread, then tighten them to a torque of 60 75 Nm.
36364
Heat bearing (2) to 100C for 15 minutes and fit on rear side
gear shaft (1).
Print 603.93.111
33
Figure 52
36367
36352
Place rear side gear (4) complete with sleeve (3) and fork (2)
on bearing cup (3, Figure 50). Then fit spring (1) on fork (2).
Figure 53
77232
Figure 55
36368
Fit new oil filter (5), fit guard (4) and secure it to differential
carrier together with bearing cage (3) by screws (2).
Check input shaft bearing (1) end play using a dial gauge. End
play should be 0.05 to 0.20 mm.
In case of a different reading, replace the shim pack with
another one of the appropriate thickness.
Print 603.93.111
34
Figure 58
Figure 56
77235
77233
Release the coupling (1) with a rubber skirt and remove it from
the fork (2).
526210
Figure 57
Take out the spring (1) and the fork (2) from inside the differential gear housing.
Figure 60
77234
36373
Remove split pin (3) and roll pin (1); dismantle caps (2) and
bearing adjusting nuts (4).
Print 603.93.111
Figure 61
35
Figure 64
77231
36374
Use a sling hook to extract the gear cage (1) complete with
crown wheel and bearings.
Remove the cylinder (1) together with the piston (2) of the
differential locking-transfer box and extract the pin (3) governing the fork (4).
Figure 62
Figure 65
5
36349
36352
Figure 66
40678
77237
Block rotation of the bevel pinion with the tool S.P. 2373 (1);
with wrench 99344069 (2) and the multiplier (3) remove the
nut fastening the bearings to the bevel pinion and the washer
beneath.
Base - February 2003
36
Figure 67
Figure 69
77238
Apply on the housing a special extractor S.P. 2346, (5) and extract the pinion from the parts: spacer (1), gear (2), spacer (3)
and bearing (4).
Then remove the above-mentioned parts from the housing.
36381
Place tool 99348001 (2) under the taper roller bearing (1) and
pull it off the bevel pinion (3) using a press.
Figure 68
36380
Print 603.93.111
37
Figure 70
77240
Print 603.93.111
38
Figure 74
Figure 71
19382
19379
Use hook (1) to raise the gear cage assembly and position on
stand 99371047 (3).
Mark the two casing halves (2 and 3) and the spider as indicated in the figure.
Unscrew screws (1) joining the casing halves. Lift the casing half
(2).
Figure 75
Figure 72
19383
36316
Unscrew nuts (1) and remove them with screws. Drive out
bevel crown wheel (2).
Figure 73
Print 603.93.111
39
Figure 78
19383
Fit spider (6) complete with planetary gears (5) and associated
thrust washers (3) to half cage (4).
Position second differential gear (2) with thrust washer (1).
Figure 79
36323
19397
Heat the support bearing (2) for the opposite side of the locking differential in a circulating air oven to a temperature of
100C for about 15 and fit it to the gear cage (3) using a suitable drift (1).
Lock the differential with the parts (1); fit on the half box (3).
Check that the marks made at the time of removal coincide.
Apply a few drops of LOCTITE 270 on the thread of the
screws (2).
Tighten the screws (2) to the prescribed torque.
Figure 77
Figure 80
19391
34850
40
1.
2.
Figure 81
part number;
tooth combination number.
This number (example: 12/41) indicates that the pinion
has 12 teeth and the crown wheel 41;
pinion/crown wheel pair set number.
All final drive sets are available as pairs: therefore pinion
and crown wheel bear the same number which is
stamped on head end for pinions and the outer face for
crown wheels;
3.
!
36324
Heat bevel crown wheel (1) in a circulating air oven to a temperature of 100C for about 15 and position it on its seating
on the gear cage, ensuring that the holes for the bevel crown
wheel/gear cage attachment screws are lined up.
Figure 82
36325
4.
6.
Figure 83
3
1,2,3
OPTION
1,2
3.
1,2,3,4,5,6
19416
COMPUTATIONAL EXAMPLES
Case 1:
Original shim pack thickness
CP marked on pinion +2
Resulting value
CP marked on new pinion +5
Thickness for new shim pack
Case 2:
Original shim pack thickness
CP marked on pinion -2
Resulting value
CP marked on new pinion +5
Thickness for new shim pack
Case 3:
Original shim pack thickness
CP marked on pinion + 2
Resulting value
CP marked on new pinion -5
Thickness for new shim pack
Case 4:
Original shim pack thickness
CP marked on pinion -2
Resulting value
CP marked on new pinion -5
Thickness for new shim pack
41
Figure 85
mm
0.76
+0.05
0.81
-0.12
0.69
0.76
-0.05
-0.71
-0.12
-0.59
-0.76
+0.05
0.81
+0.12
0.93
-0.76
-0.05
0.71
+0.12
0.83
Figure 84
77239
Measure the thickness of the adjustment ring (6) found on removal and note down the value (dimension A).
Tighten the tool 99395027 (8) in a vice and place the following
on it:
- the bearing (7) on the pinion side;
- the ring (6) previously measured.
- the gear (5);
- the spacer (4);
- the bearing (3).
Screw down the ring nut (2) and tighten it fully.
Position part (1) of tool 99395027 (8), equipped with a dial
gauge, on the bearing (3) and reset the dial gauge on the end
of the tool (8).
Then remove:
-
Figure 86
36383
Place the bevel pinion position adjustment rings (4) in the box
and, using grip 99370007 (1) and drift 99374094 (2), mount
the external ring (3) for the bevel pinion bearing.
Fit remaining bearing cups using drift 99374093.
Print 603.93.111
77241
Insert the tool 99394027 (8, Figure 85) in the differential gear
housing, comprehensive of the bearing (7, Figure 85), ring (6),
gear (5), spacer (4), bearing (3). Screw down the ring nut (1)
on the tool 99394027.
Base - February 2003
42
First example:
Figure 87
A = 13.12 mm
B = + 0.13 mm
C = 0.2 mm
S = 13.12 - (+ 0.13) + 0.2 =
S = 13.12 0.13 + 0.2 = 13.19 mm.
Second example:
A = 13.12 mm
B = - 0.13 mm
C = 0.2 mm
S = 13.12 - (- 0.13) + 0.2 =
S = 13.12 + 0.13 + 0.2 = 13.45 mm.
36387
Screw down the ring nut (2, Figure 88) tightening it until, with
a dynamometer, you measure a rolling torque of:
Remove from the box the tool 99395027 (8, Figure 85) and
take out the bearings, spacers and gear as shown in the figure.
Figure 89
Figure 88
36386
Heat the bearing (2) to 100C for 15 min. and, with a specific
drift, fit it on the bevel pinion.
78313
Figure 90
36385
Print 603.93.111
Figure 91
43
Figure 93
20670
77242
Block rotation of the bevel pinion with the tool S.P. 2373 (5).
Screw down the inserter 99345098 (4) onto the part (4,
Figure 90) and fully drive in the gear (3).
Remove the inserter (4).
Fit on the spacer ring (1).
Heat the bearing (2) to 100C for 15 min. and fit it onto the
pinion.
Screw the inserter (4) back onto the part (4, Figure 90) and
take the bearing (2) into contact with its seat.
Position the caps taking care to make the reference marks coincide.
Insert the screws, together with the washers, and tighten
them, using a torque wrench, to the prescribed torque.
Then check that the external rings of the bearings slide, with
a light pressure, in their respective seats without sticking.
Again unscrew the fastening screws with the washers and remove the caps.
Figure 94
Figure 92
94191
Using the hook (1), lift the gear housing (2) previously assembled and position it on the differential casing (3).
Figure 95
77237
Block rotation of the bevel pinion with the tool S.P. 2373 (1).
Screw down the nut fastening the bevel pinion bearings and
tighten it to the prescribed torque.
77245
Position the caps (2), screw down the screws (1) with the
washers and tighten them to the prescribed torque.
Print 603.93.111
44
2nd METHOD
Figure 96
77246
B.
C. after eliminating the end float further tighten the two adjustment lock rings (4) to obtain a retraction of the caps
(2) of 0.08 to 0.22 mm, which corresponds to the sum of
the readings on the dial gauges (1).
1st METHOD
1.
2.
Use wrench 99355025 (3, Figure 98) to tighten the adjustment lock rings (4) of the bearings until eliminating the
pinion-crown wheel clearance and end float. At the same
time check that the crown wheel does not force on the
pinion;
Figure 99
49248
Adjust the axial clearance between the teeth of the pinion crown wheel unit which must be 0.20 to 0.46 mm proceeding
as follows:
- stop the bevel pinion from turning using tool 99370317;
- position the magnetic-based dial gauge (1) as illustrated;
60636
3.
Print 603.93.111
Figure 100
45
Figure 103
19453
Contacts too much towards the crown wheel teeth top land
49246
Figure 101
Figure 104
1
19451
3
Clearance reduction
Figure 102
19454
Clearance increase
THEROETICAL CONTACT AREA
19452
1.
2.
Top land
3.
4.
Heel
Print 603.93.111
46
THEORETICAL CONTACTS
PULLING
(CONVEX SIDE OF RING GEAR)
RELEASE
(CONCAVE SIDE OF RING GEAR)
TIP
TIP
HEEL
TOP
LAND
HEEL
BOTTOM LAND
BOTTOM LAND
- PULLING
- RELEASE
CONDITION A
PULLING
RELEASE
TIP
TIP
HEEL
TOP
LAND
HEEL
BOTTOM LAND
BOTTOM LAND
- PULLING RELEASE
- PULLING
- RELEASE
- CORRECTIVE ACTION
:
:
:
CONDITION B
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
HEEL
BOTTOM LAND
- PULLING - RELEASE
- CORRECTIVE ACTION
CONDITION C
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
HEEL
BOTTOM LAND
- PULLING - RELEASE
- CORRECTIVE ACTION
Print 603.93.111
47
Figure 106
CONDITION D
TIP
HEEL
TIP
TOP
LAND
HEEL
BOTTOM LAND
BOTTOM LAND
- PULLING - RELEASE
- PULLING:
- RELEASE
- CORRECTIVE ACTION
:
:
:
CONDITION E
TIP
HEEL
TIP
TOP
LAND
HEEL
BOTTOM LAND
BOTTOM LAND
- PULLING
- RELEASE
- CORRECTIVE ACTION
:
:
CONDITION F
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
- PULLING
- RELEASE
- CORRECTIVE ACTION
:
:
HEEL
BOTTOM LAND
60677
Print 603.93.111
48
Figure 107
Figure 109
77248
Fit on the spring pin (1) and the split pin (3) to lock the ring
nuts (2-4).
77249
Position the fork (2) in the groove of the coupling (1) and fit
this on the toothing (3) of the differential gear.
Figure 110
Figure 108
77234
77236
Fit on the spring (1) and the fork (2) from inside the differential
casing.
Mount the spindle (6). Lubricate the new seal (5) and fit it on
the piston (4) and insert this into the cylinder (3). Apply sealant
on the thread of the cylinder (3) and screw it down into the
differential casing, tightening it to the prescribed torque.
Screw down the screw (2) so as to provisionally prevent the
differential gear unlocking.
Remove the differential casing from the mounting and fit it
back on the axle housing as described under the relevant
heading.
Print 603.93.111
49
526082 REMOVING-SERVICING-REFITTING
INTER-AXLE OUTPUT SHAFT
Figure 113
Figure 111
36344
40678
Figure 112
5
36388
Tighten the drive output shaft (3) in a vice; remove the nut securing flange (2) to drive output shaft (3) and dismantle flange
(2) from shaft (3) using an extractor.
Figure 115
36349
Block rotation of the flange (1) using tool 99370317 (2); with
wrench 99355088 (3) and multiplier (4) tighten the nut fastening the flange (1) to the prescribed torque.
Fit on the cover (5) with a new gasket.
Remove the differential casing transfer box from the mounting 99322228 and fit it back on the axle housing as described
under the relevant heading.
36389
Remove sealing ring (1) from bearing cage (2) and take out
snap ring (3) retaining bearing cup (4) and snap ring (5).
Print 603.93.111
50
Figure 116
Figure 119
3
4
5
36390
36393
!
36391
Use a punch to drive bearing (3, Figure 116) cup (1) off bearing cage (2).
Figure 120
Figure 118
36346
36392
With drift 99374093 (2) partially press fit bearing cup (3) in
bearing cage (4).
Complete bearing cup fitting using drift 99374093 and handle
99370007 (1).
Print 603.93.111
51
Figure 121
36394
Print 603.93.111
52
Print 603.93.111
53
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
57
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
64
64
64
REMOVING DIFFERENTIAL
(with axle on stand 99322215) . . . . . . . . . . . .
64
REFITTING DIFFERENTIAL
(with axle on stand 99322215) . . . . . . . . . . . .
64
REPAIRING DIFFERENTIAL . . . . . . . . . . . . . . . .
65
65
66
67
67
71
71
- Specimen calculations . . . . . . . . . . . . . . . . . . .
73
73
75
78
54
Print 603.93.111
55
DESCRIPTION
The axle is a bearing axle type with a simple reduction; it
consists of a box made in stamped steel sheet and properly
strengthened.
The differential consists of a reduction helical-toothed gear
pair (pinion ring gear assembly) and a wheelwork box (side
pinion crown wheel assembly).
The pinion is supported by two taper roller bearings and by
one straight roller bearing.
The adjustment of the bevel pinion assembly is made through
adjusting rings placed between the two taper roller bearings.
You can also adjust the bevel pinion position with reference
to the ring bevel gear by changing the thickness of the pack of
the rings, which are inserted between the differential box and
the bevel pinion support.
The wheelwork box is supported by two taper roller bearings
and can be adjusted axially through two threaded ring nuts.
The axle is provided with a pneumatic control differential
locking device.
The wheel hubs are supported by two taper roller bearings
floating on the tube, which can be adjusted by means of a
threaded nut.
Axle type:
Bearing axle with simple reduction.
DIFFERENTIAL ASSEMBLY
Crown wheel and pinion assembly
reduction ratio (pinion/ring gear
teeth number)
1/5.86 (7/41)
1/5.29 (7/37)
1/4.63 (8/37)
Nm
kgm
Nm
kgm
Print 603.93.111
1.5 to 5.5
0.15 to 0.55
1.5 to 3.1
0.15 to 0.31
through shims
5.19 - 5.22 - 5.30 - 5.32 - 5.52 - 5.55 - 5.45 - 5.60 8.10 - 8.20 - 8.22 - 8.30 - 8.38 - 8.48 - 8.58
0.20 to 0.46
56
mm
0.08 to 0.22
Nm
kgm
1.7 to 3.9
0.17 to 0.39
Max. 68
Max. 6.8
WHEEL HUBS
Wheel hub bearings
Hub bearing axial clearance
Max. 1.96
Max. 0.20
Through nut
12.2 (11)
Print 603.93.111
57
TIGHTENING TORQUES
Figure 1
36395
7
8
9
TORQUE
Nut to secure parts on bevel pinion
Transmitter locking nut
Differential locking device
M6x1 (10.9)
cover securing screw
M6x1 (8.8)
Half box securing screw
1st step: pre-tightening
2nd step: angle closing
Screw to secure bevel pinion
support to differential box
1st step: pre-tightening
2nd step: angle closing
Self-locking nut to secure ring bevel gear to half box
1st step: pre-tightening
2nd step: angle closing
Screws and nuts to secure differential to axle box
1st step: pre-tightening
2nd step: angle closing
Screw to secure caps to differential box
Differential locking device drive shaft
Print 603.93.111
Nm
(kgm)
1392.5 142
(139.2 14.2)
40 5
(4 0.5)
14 2
(1.4 0.2)
(1.1 0.1)
111
60 5
(6 0.5)
85 95
60 5
(6 0.5)
55 65
(10 0.5)
100 5
115 125
(10 0.5)
100 5
80 90
527.5 57.5
(52.75 5.75)
57.5 7.5
(5.75 0.7)
Base - February 2003
58
Figure 2
85492
PART
1
TORQUE
Nm
(kgm)
40 4
(4 0.4)
392.3 20
(40 2)
232.4 24.5
(23.2 2.4)
600
+50
-20
289
+5
60 -2
(29)
Print 603.93.111
59
TOOLS
TOOL No.
DESCRIPTION
99305121
Heater
99322205
Rotary stand for unit overhauling (capacity 1000 daN, torque 120
daN/m)
99322215
99322225
Single-acting lift
99341003
Pair of brackets
99341012
Print 603.93.111
60
TOOLS
TOOL No.
DESCRIPTION
99341015
Clamp
99341016
99345055
99345103
99348001
99355025
Print 603.93.111
61
TOOLS
TOOL No.
DESCRIPTION
99355088
99355167
99370005
99370007
99370317
99370509
Print 603.93.111
62
TOOLS
TOOL No.
DESCRIPTION
99370616
99370617
99371047
99374093
Drift punch for installation of bearing outer races (91134) (use with
99370007)
99374094
99374134
Print 603.93.111
63
TOOLS
TOOL No.
DESCRIPTION
99389816
99389819
99395026
Tool for measuring hub rolling drag torque (use with torque
wrench)
99395027
Tool for determining thickness of differential bevel pinion adjustment shims (use with 99395603)
993395603
Print 603.93.111
64
525010
526210
REMOVING DIFFERENTIAL
(with axle on stand 99322215)
Figure 5
Figure 3
19340
36396
525013
Figure 4
Figure 6
34811
34827
Print 603.93.111
65
Figure 7
Figure 9
36311
Fit the differential into the axle casing; screw in nuts (2) and
screws (3) complete with lock washers and tighten them to
the specified torque using torque wrench (1).
Fit drive shafts into the differential as described in Figure 30,
page 70; release the differential lock (if the axle has one) by
unscrewing screw (1, Figure 5). Fit this screw in its seat on the
cylinder cover and tighten plug (2, Figure 5), with washer, in
the threaded hole previously occupied by the screw. Finally,
fill the axle case with the specified amount of TUTELA W
140/M-DA oil and check the operation of the differential lock
activation sending unit.
36798
Figure 10
Withdraw spring (2) and flat washer (1). Remove fork (3)
complete with sliding sleeve (4).
Figure 8
Figure 11
36312
19373
Use a punch to drive out the two roll pins (3) and separate
fork (1) from sliding sleeve (2).
Print 603.93.111
66
Figure 15
Figure 12
19455
19376
Straighten and withdraw cotter pin (1) and unscrew lock ring
(2) adjusting gear cage support bearings.
Figure 13
19374
36315
Figure 14
36428
36314
Unscrew screws (1) with washers (2), remove caps (3) and
support bearing lock rings (4).
67
Figure 21
Figure 18
19382
19379
Use hook (1) to raise the gear cage assembly and position on
stand 99371047 (3).
Figure 19
19383
36316
Unscrew nuts (1) and remove them with screws. Drive out
bevel crown wheel (2).
526249
Figure 20
Figure 23
19384
36317
Prevent the flange from rotating using tool 99370317 (2) and
use a universal extractor or appropriate tool (1) to remove
the transmission attachment flange from the bevel pinion.
Base - February 2003
68
Figure 24
Figure 26
19388
36318
Position the pinion support under a press and drive out bevel
pinion (2) complete with intermediate bearing, rear bearing
and adjustment ring from bevel pinion support (1). Remove
adjustment ring from bevel pinion.
Figure 25
Figure 27
36319
Apply tool 99348001 (2) under taper roller bearing (1) and use
a press to remove from bevel pinion (3). If necessary, remove
rear bearing (4) from bevel pinion (3) in the same way
(destructive operation).
Base - February 2003
19389
Apply a drift to the point arrowed in the diagram and drive out
outer race (2) of front bearing from bevel pinion support (3).
Upturn the support and remove the intermediate bearing
outer race (1).
Print 603.93.111
69
Figure 28
20958
Print 603.93.111
70
Figure 29
36321
36321
Print 603.93.111
71
Figure 32
19391
19383
Fit spider (6) complete with planetary gears (5) and associated
thrust washers (3) to half cage (4).
Position second differential gear (2) with thrust washer (1).
Figure 34
36323
Lock the differential with the parts (1); fit on the half box (3).
Check that the marks made at the time of removal coincide.
Apply a few drops of LOCTITE 270 on the thread of the
screws (2).
Tighten the screws (2) to the prescribed torque.
19397
Heat the support bearing (2) for the opposite side of the
locking differential in a circulating air oven to a temperature of
100C for about 15 and fit it to the gear cage (3) using a
suitable drift (1).
Print 603.93.111
72
Figure 38
Figure 35
19413
19378
Figure 36
Figure 39
3,5
1,2
1,2
1,2,3,4,5,6
19414
19416
Lubricate seal carrier cover (1) seat with differential oil and
install it in support (2), using a suitable locking ring.
Figure 37
19415
7.
73
Example 2
Thickness of original stack
0.76 mm
C.P. engraved on crown wheel - 0.05
+ 0.05
Measurement obtained
0.81 mm
C.P. engraved on the new crown wheel + 0.13 + 0.13
New thickness of stack to be used
0.94 mm
Example 3
Thickness of original stack
0.76 mm
C.P. engraved on crown wheel + 0.05
- 0.05
Measurement obtained
0.71 mm
C.P. engraved on the new crown wheel - 0.13
- 0.13
New thickness of stack to be used
0.58 mm
Example 4
Thickness of original stack
0.76 mm
C.P. engraved on crown wheel - 0.05
+ 0.05
Measurement obtained
0.81 mm
C.P. engraved on the new crown wheel - 0.13
- 0.13
New thickness of stack to be used
0.68 mm
Specimen calculations
Example 1
Thickness of original stack
0.76 mm
C.P. engraved on crown wheel + 0.05
- 0.05
Measurement obtained
71 mm
C.P. engraved on the new crown wheel + 0.13 + 0.13
New thickness of pack to be used
0.84 mm
Print 603.93.111
36328
Fit the eight screws (2) complete with washers and tighten
them, using torque wrench (1), to the specified torque.
Base - February 2003
74
Figure 41
Figure 43
19419
36329
Use hook (1) to lift gear cage (2), assembled previously, and
position it on differential casing (3).
Figure 44
Figure 42
36330
Position caps (2), screw in screws (1) with washers and tighten
to the specified torque.
Figure 45
20670
36331
Print 603.93.111
75
Figure 47
2.
60635
Figure 46
B. proceed as described in point 1;
Figure 48
60636
3.
2nd METHOD
A. Diagonally and centrally on the outer machined seats of
both caps (2, Figure 47) position two dial gauges (1) with
magnetic base as shown in Figure 47;
49248
Print 603.93.111
76
Figure 49
Figure 51
19452
49246
Figure 52
Figure 50
19453
Contacts too much towards the crown wheel teeth top land
19451
Print 603.93.111
77
Figure 53
4
3
Clearance reduction
Clearance increase
19454
1.
2.
Top land
3.
4.
Heel
Print 603.93.111
78
THEORETICAL CONTACTS
PULLING
(CONVEX SIDE OF RING GEAR)
RELEASE
(CONCAVE SIDE OF RING GEAR)
TIP
TIP
HEEL
TOP
LAND
HEEL
BOTTOM LAND
BOTTOM LAND
- PULLING
- RELEASE
CONDITION A
PULLING
TIP
HEEL
RELEASE
TIP
TOP
LAND
BOTTOM LAND
BOTTOM LAND
-
PULLING RELEASE
PULLING
RELEASE
CORRECTIVE ACTION
:
:
:
:
HEEL
CONDITION B
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
- PULLING - RELEASE
- CORRECTIVE ACTION
:
:
HEEL
BOTTOM LAND
CONDITION C
TIP
HEEL
TOP
LAND
BOTTOM LAND
- PULLING - RELEASE
- CORRECTIVE ACTION
TIP
:
:
HEEL
BOTTOM LAND
Print 603.93.111
79
Figure 55
CONDITION D
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
BOTTOM LAND
-
PULLING - RELEASE
PULLING:
RELEASE
CORRECTIVE ACTION
:
:
:
:
HEEL
CONDITION E
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
BOTTOM LAND
- PULLING
- RELEASE
- CORRECTIVE ACTION
:
:
:
HEEL
CONDITION F
TIP
HEEL
TIP
TOP
LAND
BOTTOM LAND
- PULLING
- RELEASE
- CORRECTIVE ACTION
:
:
HEEL
BOTTOM LAND
60677
Print 603.93.111
80
Figure 56
Figure 57
49249
49250
Replace the safety split pin (1) and fold it; repeat this
operation on the opposite side.
Print 603.93.111
FRONT AXLES
SECTION 7
5206
Front Axles
Page
Print 603.93.111
AXLE 5845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
AXLE 5871/5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
FRONT AXLES
Print 603.93.111
Print 603.43.761
5206
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
- Characteristic angles . . . . . . . . . . . . . . . . . . . .
10
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
12
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
15
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
20
20
21
21
- Tie rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
- Articulated joints . . . . . . . . . . . . . . . . . . . . . . .
21
21
22
22
23
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . .
23
- Toe-in check . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
24
25
26
26
- Detachment . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
28
28
Page
- Check wheel hub end play . . . . . . . . . . . . . . .
29
29
30
30
31
31
31
- Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
32
- Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . .
32
33
34
34
35
Print 603.93.111
DESCRIPTION
Front axle 5845 has a steel structure with a double T section having at the end steering knuckles.
The steering knuckles connection is made through pins integral with the axle body and by means of four roller bearings set with
interference in the holes of the steering knuckles embossing.
The wheel hubs are supported by two conical roller bearings, set right type, set on the steering knuckle shank. The bearing end
play is predetermined by the spacer placed between them.
Figure 1
60416
Print 603.93.111
Figure 2
SECTION A-A
SECTION B-B
78725
Print 603.93.111
Figure 3
SECTION C-C
60410
Print 603.93.111
Characteristic angles
In order to have a good roadholding, a low tyre wear and to
enable driving wheels to recover an upright direction after
steering, it is necessary to set the wheels according to certain
assembly angles:
Clearance angle
Figure 6
Figure 4
B
32958
B
32956
Print 603.93.111
Toe-in
Figure 7
Figure 8
32359
32960
Figure 9
32961
Print 603.93.111
10
Axle type
1
Diameter of roller bearing housing on
steering knuckle:
- upper housing
1
- lower housing
2
mm
mm
39.972 39.988
46.972 46.988
mm
mm
40
47
mm
0.012 0.0028
mm
0.012 0.0028
mm
mm
33.025 33.050
40.025 40.050
mm
mm
32.984 33.000
39.984 40.000
mm
0.025 0.066
mm
0.025 0.066
2
3
6
7
Print 603.93.111
11
Print 603.43.761/B
5845
X1
X 2
mm
0.10 0.35
X2
mm
0.25
mm
0.50 1.75
0.25 mm
WHEEL HUBS
mm
max 0.16
not adjustable
locking with lock nut torque
Bearing preloading
daNm 0.30
Tutela W 140/M-DA
WHEEL SET UP
Steering angle
Inside
Outside
Print 603.93.111
mm
0.5 1.5
52
36
Base - February 2003
12
DIAGNOSTICS
Main malfunctioning of front axle:
1 Steering wheel hardness
2 Wobble
3 Noise
YES
Regular toe-in.
YES
YES
YES
YES
Print 603.93.111
13
WOBBLE
YES
YES
Regular toe-in.
YES
YES
NO
YES
Centred wheels:
- centred, regular rim
- correct assembly of tyre on rim.
YES
Balanced wheels.
Print 603.93.111
14
NOISE
NO
YES
NO
YES
NO
Print 603.93.111
15
TIGHTENING TORQUES
Figure 10
SECTION A-A
78687
SECTION B-B
TORQUE
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Print 603.93.111
Nm
16 2
515.5 24.5
515.5 24.5
80 10
201 20
336 17
490 50
57.5 2.5
106 11
27.5 2.5
388.5 18.5
40 4
188 18
313 16
64.5 6.5
(kgm)
(1.6 0.2)
(52.5 2.5)
(52.5 2.5)
(8.1 1)
(20.5 2)
(34.2 1.7)
(49.9 5)
(5.9 0.25)
(10.8 1.1)
(2.8 0.25)
(39.6 1.8)
(4.1 0.4)
(19 1.8)
(32 1.6)
(6.5 0.7)
16
TOOLS
TOOL No.
DESIGNATION
99305354
99306004
99321024
99322215
99341003
99341018
Print 603.93.111
17
TOOLS
TOOL No
DESIGNATION
99347047
99347068
99355038
99370006
99370007
99370317
Print 603.93.111
18
TOOLS
TOOL No
DESCRIPTION
99370628
99370712
99374093
99374171
99374400
99374457
Print 603.93.111
19
TOOLS
TOOL No.
DESIGNATION
99374527
99389819
99395026
Tool for hub rolling torque check (to be used with dynamometric
wrench)
Print 603.93.111
20
520610
60383
21
Figure 12
36400
Articulated joints
Clean tie rod articulated joints, both cross and longitudinal.
Such an operation must be made with dry towels or cotton
wool. Do not use solvents.
Check that the articulated joints several components are not
corroded for more than 1 mm and, in particular, check the
metal sheet cover next to the rolling.
Check the guard:
- it must be clamped to the joints body and pin through
circlips and it must not rotate;
- it must not be worn or damaged;
- press it manually and check if any grease comes out;
- check that the nut and the split pin are not worn.
Print 603.93.111
38654
22
Figure 15
Before checking, it is necessary to make a preliminary investigation of some vehicle elements which can affect set up. If any
fault is detected, it is important to eliminate it in order to avoid
wrong measurements.
The checks to be made are the following:
- tyre pressure;
- wheel hub bearing clearance;
- clearance between track rod pins and levers on steering
knuckles;
- shock-absorber efficiency;
- wheel rims must not be dramatically distorted.
Make wheel set up check using equipment 99305354.
32974
Lift the vehicles front part and place the swinging plates (1)
under the wheels, clamping them with the appropriate locks
(2).
Figure 16
32975
32973
Place on the wheel rim the self-centring clip (2) fitted with the
right lock pins (1). Use the handle (3) to clamp the clip on
wheel, checking that the wheel itself is well fixed.
32976
Set the detecting system (3) on the clips (1) and clamp it with
the screw (2). Repeat the same operations on the other wheel.
Base - February 2003
Print 603.93.111
23
Wheel alignment
Figure 20
Figure 18
32979
32977
Balance detectors (3) by using the spirit level (1) and clamp
them in this position by the screw (2).
Move the rulers (4) until they are hit by the light signal released by the detector and write the indicated values.
Figure 21
If the values are different, turn the wheels until the light signal
indexes reach two equal values (A) and the exact average
value resulting from the two previous detections. In such a
way it is possible to obtain a perfect wheel alignment.
Figure 19
32978
Push the brake pedal and leave it in this position using the appropriate tool (1) set against the seat, thus keeping the vehicle
braked during the whole measurement.
Print 603.93.111
24
Toe-in check
Figure 22
32980
Still having detectors perfectly balanced and the wheels completely aligned, use a lever (1) to move the lens cover.
Move the lever (2) and point the light signal index to the
rulers graph scale (3) corresponding to the rims diameter.
Repeat the same operations with the opposite detector and
read the toe-in values expressed in millimetres on the graph
scales.
The algebraic sum of the two detected values must amount
to: 0.5 1.5 mm with static load.
Figure 24
32982
Still having the front wheels aligned with the rear ones, loose
knurled knobs (2) and set to zero the graduated sector (3)
on the swinging plates index (1).
Figure 23
32981
32983
If the front wheels are aligned with the rear ones and the detectors are balanced, push the wheel inclination button (3) and
the led (2) will be switched on. The digital indicator (1) will give
the value of the angle of inclination which must be 1.
Print 603.93.111
25
Figure 28
32984
32986
With the wheels in upright direction, set to zero the graduated sectors (5) on the index (2) of the swinging plates (4).
If the steering angles which must be detected are bigger than
30, it is necessary to use as 0 reference indexes the 20
sign (1) placed on the swinging plate and the corresponding
one on the graduated sector.
Turn the inside wheel according to the prescribed value and
check that the outside wheels angle corresponds to the prescribed value, considering that to make the survey it is necessary to use as 0 reference indexes the 20 sign (3) placed
on the swinging plate and the corresponding one on the
graduated sector.
Repeat the same operations and check steering of the opposite wheel.
Figure 27
32985
Print 603.93.111
26
520610
Figure 29
Figure 31
32990
60870
Use a lifter to place and clamp the axle assy (1) on stand
99322215 (2) in order to make overhaul.
Release the screws (2) and take off the brake callipers (1) from
the supporting flange (3).
Figure 32
520620
Detachment
Figure 30
60871
Use torque lever 99370317 (4), to block wheel hub (2) rotation and use wrench 99355038 (3) to unscrew oil cover (1).
Figure 33
78421
Rotate wheel hub in order to set the screw plug (1) down;
unscrew plug and drain oil into a special container. Take off
the brake calipers.
60872
Print 603.93.111
27
Figure 36
Figure 34
60873
49180
Figure 37
60874
33001
Use general tools to remove the sealing ring (3) from the
wheel hub (5). Moisten with oil the new sealing rings inside
outline.
Use locking ring 99374457 (2) and handle 99370006 (1) to
place the sealing ring (3) on the wheel hub.
Replace the phonic wheel (if present).
Use general tools to remove the phonic wheel (4) from the
wheel hub (5).
Before setting the phonic wheel (4), warm it up to 150C.
Once the assembly is completed, check that the phonic
wheel (4) touches completely the wheel hub.
Check that the maximum orthogonality error of the phonic
wheel (4) is not higher than 0.2 mm.
Place the outside bearingss outside ring (3) and use beater
99374093 (2) and handle 99370007 (1) to make setting.
Print 603.93.111
28
Figure 38
Place the inside bearings outside ring (3) and use beater
99374093 (2) and handle (1) 99370007 to make setting.
Screw tool 99370712 (3) on the steering knuckle pin and lubricate its outside surface using oil TUTELA W 140/M-DA.
Secure the wheel hub (2) with a rope (1) and support it with
a lifter. Lock carefully the wheel hub (2) on the steering
knuckle pin in order not to damage the sealing ring (3,
Figure 35).
Mount spacer (4) and tapered-roller bearing inner race (5).
Release tool 99370712 (3).
Force-fit washer (6) and screw down retaining ring (7).
520625
Figure 39
Figure 41
33004
Use general tools to remove the stud bolts (1) from the brake
disc (2).
Check that the supporting plane of the stud bolt heads is not
burred.
Base - February 2003
60876
Print 603.93.111
29
Figure 44
77202
32999
Apply tool (1) 99395026 on wheel hub stud bolts and use
torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
Figure 43
Figure 45
32998
Hit the wheel hub in axial direction with a mallet and rotate
it in both directions in order to release the bearings rolls.
Set the magnetic base (1) fitted with a gauge (2) on the wheel
hub.
Place the gauge pointer (3) perpendicular to the steering
knuckle shank (4).
Set the gauge to zero with a preload corresponding to 1.5
2 mm.
Move the wheel hub in axial direction by means of a lever and
detect the end play which must be 0.16 mm (maximum
value).
If the detected value does not correspond to the prescribed
one, replace the bearing unit and make a new survey.
Print 603.93.111
77203
Rotate the wheel hub until when hub cover (1) is positioned
as shown in the figure. Restore the prescribed quantity of oil
into the hub cover (1) through filling hole (2). Tighten the
plug on the hub cover (1) to the set torque.
30
Figure 46
!
60878
Reattach the brake callipers (1) to the flange (3) and lock the
screws (2) according to the prescribed torque. Set braking
gaskets following the procedure described in chapter Wheel
hub overhaul Rear axle section.
520635
520636
Figure 47
Figure 49
60879
33007
Block the screw (4), release the nut (3) and unscrew the articulated pin (2) from the cross tie rod (1).
Figure 48
Screw the articulated pin (2) in the tie rod (1). The nut (3)
must be clamped according to the prescribed torque, after
making toe-in adjustment as described in the Wheel set up
chapter.
60880
Print 603.93.111
520631
31
Figure 53
Figure 50
60881
60884
Loose the screws (2) and remove the lever (3) from the articulated pin (1). To make reattachment reverse the operation order and clamp the lock screws (2) according to the
prescribed torque.
Loose the screws (1) and remove the upper cover (2) together with the lubricator (3).
520632
Figure 54
Figure 51
60882
Loose the screws (1) and remove the lever (2) from the articulated pin (3). To make reattachment reverse the operation order and clamp the lock screws (1) according to the
prescribed torque.
60885
Release the screws (5) and remove the cover (3) together
with the thrust block (2), the adjusting plate (1) and the lubricator (4).
520611
Figure 55
Figure 52
60886
60883
Release the screws (2) and remove the brake callipers support (1) from the axle.
Print 603.93.111
32
520615
Figure 58
Figure 56
60887
60890
Reattachment
Figure 59
Figure 57
60891
Set on the axle (2) the steering knuckle (3) and place the articulated pin (1).
Set tool 99374400 (4) on the steering knuckle (3) and fasten
it by using the same lower cover lock screws (5), clamping
them with the right torque.
Place the pin (1) in the axle conical housing, screwing the
pressure screw (6) with a torque having 10 11 daNm.
Remove tool 99374400 (4) from the steering knuckle (3).
60889
Print 603.93.111
33
Figure 60
Figure 63
60885
Place the lower cover (3) together with the lubricator (4), the
thrust block (2), the adjusting plates (1) and clamp the lock
screw (5) according to the prescribed torque.
60895
Figure 64
Figure 61
60896
60893
The possible clearance adjustment can be done replacing the adjusting shims (1, Figure 60) with spare
ones having the right thickness.
As to the thickness of spare rings, see table SPECIFICATIONS AND DATA.
Lubricate the whole lower and upper articulated
joint with grease MR2, checking that the grease
flows through the gasket baffle.
60884
Place the upper cover (2) together with the lubricator (3) on
the steering knuckle and clamp the screws (1) according to
the prescribed torque.
Print 603.93.111
34
520618
Figure 65
Figure 66
60894
Place two bars (1) fitted with cones (3) in the steering
knuckle pin holes. Push the cones and clamp them placing the
appropriate screws on the bars.
Introduce two centring dowels (2) in the leaf spring supporting plane (4).
Figure 67
Place on the planes (6) two bases (5) using goniometers and
introduce them in the centring dowels.
Place the sliding bar (2) on the goniometers bars (4), adjusting
its length so that the shaped edges touch the bars (1).
Clamp the screws of the stop block (7) and the goniometers
lock screws (3) to the bars (4).
Base - February 2003
Print 603.93.111
35
Figure 68
Check the angle of deformation on the goniometers graduated sectors shown by the arrows.
Goniometers indexes will, of course, detect no angle movement when the flatness of leaf spring surfaces compared to
the steering knuckle pin holes is correct.
Place on the bars (1) the supports (3) fitted with goniometers
and screw the screws (2) without clamping them.
Introduce the connecting cross tie rod (4) and tighten the
screws (2) which clamp the supports touching the bars (1).
Figure 70
Print 603.93.111
36
Print 603.93.111
5206
37
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Characteristic angles . . . . . . . . . . . . . . . . . . . .
41
43
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . .
48
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
53
53
54
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . .
54
- Toe-in check . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55
55
56
57
57
57
58
58
58
59
60
60
61
61
38
Page
LONGITUDINAL TIE ROD LEVER REMOVAL
AND REFITTING . . . . . . . . . . . . . . . . . . . . . . . .
61
61
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
63
64
65
65
66
Print 603.93.111
39
DESCRIPTION
The front axle has a steel structure with a double T section having at the end steering knuckles.
The steering knuckles connection is made through pins integral with the axle body and by means of four roller bearings set with
interference in the holes of the steering knuckles embossing.
The wheel hubs are supported by two conical roller bearings set on the steering knuckle shank and adjustable by a threaded ring.
Figure 1
73841
Print 603.93.111
40
Figure 2
73842
Print 603.93.111
41
Characteristic angles
In order to have a good roadholding, a low tyre wear and to
enable driving wheels to recover an upright direction after
steering, it is necessary to set the wheels according to certain
assembly angles:
Clearance angle
Figure 3
Figure 5
B
32958
B
32956
42
Toe-in
Figure 6
Figure 7
32359
32960
Figure 8
32961
Print 603.93.111
43
Axle type
5851/5 (F 5521)
7 3
1
Diameter of roller bearing housing
in steering knuckle:
- upper housing
1
- lower housing
2
mm
mm
mm
mm
42
52
mm
0.012 to 0.028
mm
0.014 to 0.033
mm
mm
35
43
mm
mm
mm
0 to 0.016
mm
0 to 0.016
41.972 to 41.988
51.967 to 51.986
2
3
6
7
34.984 to 35.000
42.984 to 43.000
Print 603.93.111
44
5842/5 (F 5021)
X1
X2
5821/5 (F 5521)
mm
0.10 to 0.35
mm
0.25
mm
0.50 to 1.75
0.25 mm
WHEEL HUBS
Wheel hub bearings
Hub bearing end play
max 0.16
Bearing preloading
daNm
0.30
Tutela W 140/MDA
Litres 0.23
kg 0.207
Wheel inclination
(vehicle with static load)
Wheel incidence
(vehicle with static load)
1 24
mm
0.5 to 1.5
Print 603.93.111
45
DIAGNOSTICS
Main malfunctioning of front axle:
1 Steering wheel hardness
2 Wobble
3 Noise
YES
Regular toe-in.
YES
YES
YES
YES
Print 603.93.111
46
WOBBLE
NO
YES
NO
YES
Regular toe-in.
YES
NO
YES
NO
YES
Centred wheels:
- centred, regular rim
- correct assembly of tyre on rim.
YES
Balanced wheels.
Print 603.93.111
47
NOISE
NO
YES
YES
Print 603.93.111
48
TIGHTENING TORQUES
Figure 9
73840
TORQUE
Nm
(kgm)
1 Self-braking hexagonal head cap screw to clamp cross tie rod lever on steering knuckle 515.5 24.5
(52.6 2.5)
2 Castellated nut for articulated joint pin
201 20
(20.5 2)
3 Self-braking hexagonal head cap screw to clamp longitudinal lever on steering knuckle
515.5 24.5
(52.6 2.5)
4 Flanged hexagonal head cap screw to clamp lower thrust block cover on steering knuckle
336 17
(34.2 1.7)
5 Hexagonal head cap screw to clamp brake disc on wheel hub
40 4
(4 0.4)
6 Socket head cap screw to fasten wheel bearing adjusting clamp
27.5 2.5
(2.8 0.2)
7 Wheel hub cover
133.5 13.5
(13.6 1.3)
8 Wheel bearings securing ring nut
388.5 18.5
(39.7 1.9)
9 Tapered threaded plug for wheel hub cover
27 2
(27.5 2)
Axle 5842/5 (vehicles 130)
490 50
(49.9 5)
10 Wheel lock nuts
Axle 5851/5 (vehicles 150)
627,5 62,51 (63.9 6.4)
Self-locking hexagonal-head screw for fastening the brake backing plate to the
11
313 16
(32 1.6)
steering knuckle
12 Self-locking hexagonal head screw for fastening disk brake calipers to the plate
313 16
(32 1.6)
PART
Print 603.93.111
49
TOOLS
TOOL No.
DESIGNATION
99305354
99321024
99322215
99347047
99347068
99354207
Print 603.93.111
50
TOOLS
TOOL No.
99355038
DESIGNATION
99370007
99370317
99370628
99370714
99374093
Print 603.93.111
51
TOOLS
TOOL No.
DESIGNATION
99374172
99374173
99374233
99374400
99374529
99389819
Print 603.93.111
52
TOOLS
TOOL No.
DESIGNATION
99395026
Tool for hub rolling torque check (to be used with dynamometric
wrench)
Print 603.93.111
53
Figure 11
Before checking, it is necessary to make a preliminary investigation of some vehicle elements which can affect set up. If
any fault is detected, it is important to eliminate it in order to
avoid wrong measurements.
The checks to be made are the following:
- tyre pressure;
- wheel hub bearing clearance;
- clearance between track rod pins and levers on steering
knuckles;
- shock-absorber efficiency;
- wheel rims must not be dramatically distorted.
32974
Lift the vehicles front part and place the swinging plates (1)
under the wheels, clamping them with the appropriate locks
(2).
Figure 12
32975
Place on the wheel rim the self-centring clip (2) fitted with the
right lock pins (1). Use the handle (3) to clamp the clip on
wheel, checking that the wheel itself is well fixed.
Figure 13
32973
Print 603.93.111
32976
Set the detecting system (3) on the clips (1) and clamp it with
the screw (2). Repeat the same operations on the other
wheel.
54
Wheel alignment
Figure 16
Figure 14
32979
32977
Balance detectors (3) by using the spirit level (1) and clamp
them in this position by the screw (2).
Move the rulers (4) until they are hit by the light signal released
by the detector and write the indicated values.
Figure 15
13952
32978
Push the brake pedal and leave it in this position using the appropriate tool (1) set against the seat, thus keeping the vehicle
braked during the whole measurement.
Base - February 2003
If the values are different, turn the wheels until the light signal
indexes reach two equal values (A) and the exact average
value resulting from the two previous detections. In such a way
it is possible to obtain a perfect wheel alignment.
Print 603.93.111
55
Toe-in check
Figure 18
32980
Still having detectors perfectly balanced and the wheels completely aligned, use a lever (1) to move the lens cover.
Move the lever (2) and point the light signal index to the
rulers graph scale (3) corresponding to the rims diameter.
Repeat the same operations with the opposite detector and
read the toe-in values expressed in millimetres on the graph
scales.
The algebraic sum of the two detected values must amount
to: 0.5 1.5 mm with static load.
32982
Still having the front wheels aligned with the rear ones, loose
knurled knobs (2) and set to zero the graduated sector (3) on
the swinging plates index (1).
Figure 19
32981
If the front wheels are aligned with the rear ones and the detectors are balanced, push the wheel inclination button (3) and
the led (2) will be switched on. The digital indicator (1) will give
the value of the angle of inclination which must be 1.
Print 603.93.111
32983
56
Figure 24
32984
32986
With the wheels in upright direction, set to zero the graduated sectors (5) on the index (2) of the swinging plates (4).
If the steering angles which must be detected are bigger than
30, it is necessary to use as 0 reference indexes the 20
sign (1) placed on the swinging plate and the corresponding
one on the graduated sector.
Turn the inside wheel according to the prescribed value and
check that the outside wheels angle corresponds to the prescribed value, considering that to make the survey it is necessary to use as 0 reference indexes the 20 sign (3) placed
on the swinging plate and the corresponding one on the
graduated sector.
Repeat the same operations and check steering of the opposite wheel.
Figure 23
32985
Print 603.93.111
520610
57
Figure 28
Figure 25
32990
Use a lifter to place and clamp the axle assy (1) on stand
99322215 (2) in order to make overhaul.
520620
60872
Figure 26
78421
Rotate wheel hub in order to set the screw plug (1) down;
unscrew plug and drain oil into a special container. Take off
the brake calipers.
32997
Figure 27
32995
Use reaction lever 99370317(3) to stop the wheel hub rotation and use wrench 99354207 (1) to release the cover (2).
Print 603.93.111
58
Figure 32
32999
Once the requested end play has been reached, clamp the
adjusting ring (2) check screw (1) with the requested torque.
60875
Screw on the steering knuckle pin the tool 99370714 (3) and
lubricate its outside surface using oil TUTELA W 140/M-DA.
Secure with a rope (1) the wheel hub (2) and support it with
the lifter. Key the wheel hub (2) carefully on the steering
knuckle pin in order not to damage the sealing ring.
Mount spacer (4) and tapered-roller bearing (5).
Release tool 99370714 (3).
Key the washer (6) and screw the check ring (7) with the requested torque.
34541
Place tool (1) 99395026 on the wheel hub stud bolts and use
dynamometer 99389819 (2) to check that the wheel hub
rolling torque is 3.0 Nm.
32998
Hit the wheel hub in axial direction with a mallet and rotate
it in both directions in order to release the bearings rolls.
Set the magnetic base (1) fitted with a gauge (2) on the wheel
hub.
Place the gauge pointer (3) perpendicular to the steering
knuckle shank (4).
Set the gauge to zero with a preload corresponding to 1.52
mm.
Move the wheel hub in axial direction by means of a lever and
detect the end play which must be 0.16 mm (maximum
value).
If the detected value does not correspond to the prescribed
one, replace the bearing unit and make a new survey.
Base - February 2003
Place some sealer (Loctite type 574) only on the surface touched by the hub cover, protecting the
threaded part.
Screw the hub cover with the requested torque.
Reset hubs in the wheels and the prescribed (0.2
litres) quantity of oil (Tutela W 140/MDA).
Print 603.93.111
520621
59
Figure 35
Take off the sealing ring and the bearing from the
location inside the wheel hub.
Use a beater to pull out the bearings outside rings
from the wheel hub.
Check that the bearings outside ring locations in
the wheel hub are not dented as a result of the pull
out operation.
33002
Put the inside bearings outside ring (3) in its place and use
beater 99374093 (2) and handle (1) 99370007 to settle it
down.
Figure 34
Lubricate the inside bearing with oil SAE W
140/MDA and place it in the wheel hub.
Set the sealing ring.
Place outer bearing outer race (3) into its seat, then proceed
to ramming by means of beater (2) 99374093 and handle
99370007 (1).
Print 603.93.111
60
520625
520635
Figure 37
Figure 36
33004
Use general tools to pull out stud bolts (1) from the brake
disc (2).
Check that the head supporting plane of the stud bolts is not
burred.
Place the stud bolts accurately and put on their
head a load not higher than:
33005
33006
Print 603.93.111
520636
520632
61
Figure 41
Figure 39
34544
33007
Block the screw (4), release the nut (3) and unscrew the articulated joint (2) from the cross tie rod (1). Screw the articulated joint in the tie rod and clamp it in this position locking
the lock nut with the requested torque.
Release the screws (2) and remove the lever (1). To make reattachment reverse the operation order and clamp the
screws with the requested torque.
520611
Removal
Figure 42
520631
34545
Figure 40
Release the screws (2) and remove the brake callipers support (1).
34543
Release the screws (1) and remove the lever (2). To make
reattachment reverse the operation order and clamp the lock
screws with the requested torque.
Print 603.93.111
62
Refitting
Figure 43
Figure 46
34546
Use the appropriate pliers to take off the check ring (1) and
remove the cover (2) together with the lubricator.
Figure 44
34549
Set on the axle body the steering knuckle and put the pin in
its place.
Set tool 99374400 (1) on the steering knuckle and fasten it by
using the same lower cover lock screws, clamping them with
the right torque.
Place the pin in the axle conical housing, screwing the pressure
screw (2) to a torque having 7 to 8 daNm.
Remove tool 99374400 from the steering knuckle.
34547
Release the screws (3) and remove the lower cover (2), the
adjusting plates and the thrust block (1).
Figure 47
Figure 45
34548
34547
Place the lower cover (2) together with the thrust block (1)
and the adjusting shims; fasten the lock screws (3) with the requested torque.
Repeat the same operations on the opposite steering knuckle.
Print 603.93.111
63
The possible clearance adjustment can be done replacing the adjusting shims with spare ones having
the right thickness.
Figure 48
34546
Place the upper cover (2) together with the related seal; place
the lubricator as shown in the figure, then introduce the safety
ring (1) and check that the ring expansion is made in the correct way.
34550
Keep the steering knuckle raised and use a thickness gauge (1)
to check clearance between the upper shim adjustment of
the steering knuckle and the axle. This value must be between
0.10 0.15 mm.
Figure 50
34551
64
520615
Figure 52
Figure 51
60887
60889
Figure 53
34556
Print 603.93.111
65
520618
Figure 56
Figure 54
Place two bars (1) fitted with cones (3) in the steering
knuckle pin holes. Push the cones and clamp them placing the
appropriate screws on the bars.
Introduce two centring dowels (2) in the leaf spring supporting plane (4).
Place on the planes (6) two bases (5) using goniometers and
introduce them in the centring dowels.
Place the sliding bar (2) on the goniometers bars (4), adjusting
its length so that the shaped edges touch the bars (1).
Clamp the screw of the stop block (7) and the goniometers
lock screws (3) to the bars (4).
Figure 55
Check the angle of deformation on the goniometers graduated sector shown by the arrows.
Goniometers indexes will, of course, detect no angle movement when the flatness of leaf spring surfaces compared to
Print 603.93.111
66
Place on the bars (1) the supports (3) fitted with goniometers and screw the screws (2) without clamping them.
Introduce the connecting cross tie rod (4) and tighten the
screws (2) which clamp the supports touching the bars (1).
Figure 58
Print 603.93.111
67
Print 603.43.761
5206
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
69
- Characteristic angles . . . . . . . . . . . . . . . . . . . .
71
73
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
75
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
78
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
83
83
84
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . .
84
- Toe-in check . . . . . . . . . . . . . . . . . . . . . . . . . .
85
85
85
86
87
87
87
87
- Replacing seal . . . . . . . . . . . . . . . . . . . . . . . . .
88
88
89
89
89
90
90
68
Page
CHECKING BALL JOINT END PLAY
FOR TRACK ROD AND DRAG LINK . . . . . .
90
90
91
91
91
- Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
92
93
94
94
95
Print 603.93.111
69
DESCRIPTION
Front axle 5871/5 has a steel structure with a double T section having at the end steering knuckles.
The steering knuckles connection is made through pins integral with the axle body and by means of four roller bearings set with
interference in the holes of the steering knuckles embossing.
The wheel hubs are supported by two conical roller bearings, set right type, set on the steering knuckle shank. The bearing end
play is predetermined by the spacer placed between them.
Figure 1
71175
Print 603.93.111
70
Figure 2
SEC A-A
SEC B-B
71176
Print 603.93.111
71
Characteristic angles
In order to have a good roadholding, a low tyre wear and to
enable driving wheels to recover an upright direction after
steering, it is necessary to set the wheels according to certain
assembly angles:
Figure 5
Figure 3
B
32958
B
32956
72
Toe-in
Figure 6
Figure 7
32359
32960
Figure 8
32961
Print 603.93.111
73
Axle type
1
Diameter of roller bearing housing on
steering knuckle:
- upper housing
1
- lower housing
2
mm
mm
51.967 51.986
59.967 59.986
mm
mm
52
60
mm
0.014 0.033
mm
0.014 0.033
mm
mm
43
53
mm
mm
42.984 43
52.981 53
mm
0 0.016
mm
0 0.019
2
3
6
7
Print 603.93.111
74
5871/5
X1
X 2
mm
0.10 0.35
X2
mm
0.25
mm
0.50 1.75
0.25 mm
WHEEL HUBS
mm
not adjustable
locking with lock nut torque
Bearing preloading
daNm 0.50
max 0.16
Tutela W 140/M-DA
Litres (kg)
0.35 (0.32)
WHEEL SET UP
1, 24
Steering angle
Inside
Outside
Base - February 2003
mm
01
52
36
Print 603.93.111
75
DIAGNOSTICS
Main malfunctioning of front axle:
1 Steering wheel hardness
2 Wobble
3 Noise
YES
Regular toe-in.
YES
YES
YES
YES
Print 603.93.111
76
WOBBLE
YES
YES
Regular toe-in.
YES
YES
Adjust end
replacements.
play
after
NO
making
appropriate
YES
Centred wheels:
centred, regular rim
correct assembly of tyre on rim.
YES
Balanced wheels.
Print 603.93.111
77
NOISE
NO
YES
NO
YES
Print 603.93.111
NO
78
TIGHTENING TORQUES
Figure 9
SEC A-A
SEC B-B
71195
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TORQUE
Nm
10.8 2
1325 75
1325 75
80 10
201 20
117 6
133.5 13.5
(kgm)
(11 0.2)
(135 7.5)
(135 7.5)
(8.1 1)
(20.5 2)
(11.9 0.6)
(13.6 1.3)
27.5 2.5
(2.8 0.2)
515.5 24.5
57.5 2.5
281.5 13.5
627.5 62.5
615.5 61.5
313.5 15.5
58.5 5.2
(52.5 2.5)
(5.9 0.25)
(28.6 1.3)
(63.9 6.4)
(62.7 6.2)
(31.9 1.5)
(5.9 0.5)
Print 603.93.111
79
TOOLS
TOOL No.
DESIGNATION
99305354
99321024
99322215
99347047
99347068
99354207
Print 603.93.111
80
TOOLS
TOOL No.
DESIGNATION
99370006
99370007
99370317
99370628
99370715
99374093
Print 603.93.111
81
TOOLS
TOOL No.
DESIGNATION
99374132
99374173
99374405
99374530
99388001
99388002
Wrench for cross and longitudinal tie rod lock screws on steering
knuckle
Print 603.93.111
82
TOOLS
TOOL No.
DESIGNATION
99389819
99395026
Tool for hub rolling torque check (to be used with dynamometric
wrench)
Print 603.93.111
83
Figure 11
Lift the vehicles front part and place the swinging plates (1)
under the wheels, clamping them with the appropriate locks
(2).
Figure 12
32975
Place on the wheel rim the self-centring clip (2) fitted with the
right lock pins (1). Use the handle (3) to clamp the clip on
wheel, checking that the wheel itself is well fixed.
Figure 13
32973
Print 603.93.111
32976
Set the detecting system (3) on the clips (1) and clamp it with
the screw (2). Repeat the same operations on the other
wheel.
84
Wheel alignment
Figure 16
Figure 14
32979
32977
Balance detectors (3) by using the spirit level (1) and clamp
them in this position by the screw (2).
Move the rulers (4) until they are hit by the light signal
released by the detector and write the indicated values.
Figure 17
13952
32978
Push the brake pedal and leave it in this position using the
appropriate tool (1) set against the seat, thus keeping the
vehicle braked during the whole measurement.
If the values are different, turn the wheels until the light signal
indexes reach two equal values (A) and the exact average
value resulting from the two previous detections. In such a
way it is possible to obtain a perfect wheel alignment.
Print 603.93.111
85
Toe-in check
Figure 18
32980
32982
Still having the front wheels aligned with the rear ones, loose
knurled knobs (2) and set to zero the graduated sector (3)
on the swinging plates index (1).
Figure 19
32981
If the front wheels are aligned with the rear ones and the
detectors are balanced, push the wheel inclination button (3)
and the led (2) will be switched on. The digital indicator (1) will
give the value of the angle of inclination which must be 1.
Print 603.93.111
32983
86
Figure 24
32984
32986
Figure 23
32985
Print 603.93.111
520610
87
Figure 27
520610
Using lifting gear, position and secure the axle assembly (1)
on stand 99322215 (2) for overhaul.
49179
520620
Loosen the screw (4), remove the adjusting nut (3) with
wrench 99388001, pull out the washer (2), the outer bearing
(1) and take down the wheel hub with the relactive spacer
and inner bearing.
Figure 28
Figure 25
36409
78421
Unscrew the plug (1) and drain the oil into a proper
container.
Take down the brake calipers.
Using suitable tools remove the seal ring (2), inner bearing
and phonic wheel (3) from the wheel hub. (1)
520621
Figure 29
Figure 26
49180
Print 603.93.111
88
Figure 32
Figure 30
36413
Use drift 99374093 (2) to press-fit the outer race of the front
hub bearing without pushing fully home. Repeat the
operation on the opposite side for the rear bearing outer
race.
Complete the operation of press-fitting the outer bearing
races manually using drift 99374093 (2) with handle
99370007 (1).
Heat the phonic wheel (1) to a temperature of 150 (3,
Figure 28) for 15 minutes, then fit it on the wheel hub (1) and
let it cool down.
49142
!
Replacing seal
Figure 31
36410
Print 603.93.111
89
Figure 36
Figure 34
77202
49181
Apply tool (1) 99395026 on wheel hub stud bolts and use
torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
Figure 35
Figure 37
36411
Put stylus pointer (3) perpend. to the stub axle (4) spigot.
Zero the gauge with a preload of 1.5 to 2 mm.
Use a lever to move the wheel hub along the axis and
measure the end play which should be 0.16 mm (max. value).
Print 603.93.111
78322
Rotate the wheel hub until when hub cover (1) is positioned
as shown in the figure. Restore the prescribed quantity of oil
into the hub cover (1) through filling hole (2). Tighten the
plug on the hub cover (1) to the set torque.
90
520635
Figure 38
The vehicle should not be jacked up.
Use a gauge (1, Figure 40) to measure the distance X with
the vehicle in straight on position.
Take the measurement again with the steering turned as far
as possible, to the left (X1) and to the right (X2). Take a note
of the values measured.
Calculate the axial clearance A, noting the maximum value
measured between X1 and X2.
Example:
A = max (X1, X2)-X
If the value rises above 2 mm replace the ball joint.
Figure 40
33005
Figure 39
36914
36416
Using the extractor 99347068 (1), release the ball joint (3)
from the arm (2). Repeat the same operations on the
opposite side, unscrew the nuts completely and remove the
track rod.
To refit, carry out removal operations in reverse
order.
520636
33007
Lock screws (4), loosen nut (3) and unscrew ball joint (2)
from track rod (1).
Screw ball joint into rod and lock in position tightening
locking nut to the specified torque.
Print 603.93.111
520631
REMOVING
AND
TRACK ROD ARMS
REFITTING
Figure 42
91
520611
49182
49184
Unscrew screws (1) and remove support (2) from the brake
calliper.
Figure 45
520632
REMOVING AND
DRAG LINK ARM
REFITTING
36420
Using suitable pliers, remove the retainer circlip (1) and take
out the cover (2) complete with grease nipple.
Figure 43
Figure 46
49183
Print 603.93.111
36421
92
Figure 47
Figure 49
36424
36422
Use tool 99347047 (1) and part (2) to unlock swivel axle pin
(3). Remove the tool and withdraw the pin.
Refitting
Figure 48
36420
36423
Fit stub axle (1) to axle (4) and insert the pin into its housing.
Apply tool 99374405 (2) to the stub axle and secure by
means of the lower cover retaining screws. Tighten to a
suitable torque.
Press-fit the pin into the taper seating in the axle, tightening
pressure screw (3) to a torque of 15 to 16 daNm.
Remove tool 99374405 from the stub axle.
Insert upper cover (2) complete with seal into its housing;
position grease nipple as shown in the figure, then insert
retainer circlip (1) making sure that the circlip expands
correctly.
Lift the swivel axle to bring it into contact with the lower axle
facing. Use feeler gauge (1) to check clearance between upper
facing of swivel axle and axle. This should be between 0.10
and 0.35 mm.
Print 603.93.111
Figure 52
93
Figure 54
36426
520615
Figure 53
60889
60887
60890
Print 603.93.111
94
520618
Apply two rods (as shown in Figure 56, ref. 1) complete with
cones (3) in the holes for knuckle pins; press the cones and
lock them in position on the rods using relevant screws.
Insert the two locating dowels (2) into the housings in the
leaf spring seating surface.
Figure 57
Figure 56
Fit sliding bar (2) to protractor rods (4), adjusting the length
so that the shaped ends come into contact with rods (1).
Lock screw of clamp (7) and screws (3) securing the
protractors to the rods (4).
Apply bases (5, Figure 57) to planes (6) using protractors and
fit into centring dowels.
Figure 58
Print 603.93.111
95
Figure 60
Read off the value of the angle of kingpin inclination from the
relevant graduated sectors (2) in line with the pointers (1).
Print 603.93.111
The value for inclination of the holes for the kingpins should
be 7o.
96
Print 603.93.111
SECTION 8
5004
Suspensions
Page
Print 603.93.111
43
Print 603.93.111
Print 603.43.761
5004
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION
MODELS 120E..-120E..D-130E..-130E..D130E18RS-150E..-150E..RS . . . . . . . . . . . . . . .
FRONT SUSPENSION
MODELS 180E..-260E.. . . . . . . . . . . . . . . . . . .
10
11
11
FRONT SUSPENSION
MODELS 120E..D-130E..D-150E.. . . . . . . . . . .
12
13
14
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . .
14
15
17
19
REAR SUSPENSION
MODELS 110EL..-120EL.. . . . . . . . . . . . . . . . .
19
REAR SUSPENSION
MODELS 120E..-130E.. . . . . . . . . . . . . . . . . . .
20
REAR SUSPENSION
MODELS 120E..-130E..-130E18RS . . . . . . . . .
21
REAR SUSPENSION
MODELS 120E..-120E..D-130E..-130E..D150E..-150E18RS . . . . . . . . . . . . . . . . . . . . . . .
22
23
24
24
REAR SUSPENSION
MODELS 120E..-130E..D-150E.. . . . . . . . . . . .
25
26
Page
HENDRICKSON REAR SUSPENSION
Models 260E.. . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . .
27
29
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . .
29
30
31
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . .
36
37
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
38
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
39
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
40
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . .
41
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
Print 603.93.111
DESCRIPTION
The suspension consists of leaf springs, two double-acting telescopic shock absorbers and a sway bar.
The leaf springs can be semi-elliptical or parabolic.
Semi-elliptical leaf springs are very stiff because all the leaves have the same thickness, from one end to the other. Furthermore,
the leaves are arranged to create high internal friction, whereby limiting the leaf spring movements.
Parabolic leaf springs are made of leaves which are thicker in the middle and narrower at the ends. The distanced arrangement
considerably reduces internal friction.
Low internal friction and the special leaf shape makes parabolic leaf springs softer, consequently ensuring greater riding comfort.
Double-acting telescopic shock absorbers counteract wheel movement upwards and downwards, ensuring excellent riding
stability.
The sway bar keeps the wheel axle and chassis parallel, cancelling any load imbalance on the wheel on any one axle.
Figure 1
72519
72521
Print 603.93.111
Figure 3
72527
72523
72693
Print 603.93.111
No 2
1714 3
Leaf thickness
(measured in the middle)
26
Width of leaves
70 0.5
17
5.691 mm/kN
Print 603.93.111
55.5 + 0.1
57.3
- 0.2
+ 0.6
20.2
+ 0.3
-0
No 2
1758 3
Leaf thickness
(measured in the middle)
24
Width of leaves
80 0.5
L
NEW SPRING CHECK DATA:
Static load deflection
Static load flexibility
6
6.96 mm/kN
55.5 + 0.1
57.3
+ 0.6
- 0.2
20.2
+ 0.3
-0
Print 603.93.111
No 2
1758 3
Leaf thickness
(measured in the middle)
21
Width of leaves
80 0.5
15
6,69 mm/kN
55.5 + 0.1
Print 603.93.111
57.3
+ 0.6
- 0.2
20.2
+ 0.3
-0
10
No 2
1758 3
Leaf thickness
1st leaf (measured in the middle)
2nd - 3rd - 4th leaf (measured in the middle)
19
21
Width of leaves
80 0.5
2
5.53 mm/kN
55.5 + 0.1
57.3
+ 0.6
- 0.2
20.2
+ 0.3
-0
Print 603.93.111
11
No 2
1758 3
Leaf thickness
(measured in the middle)
14
Width of leaves
80 0.5
12
6.31 mm /kN
Print 603.93.111
55.5
+0.1
-0
57.3
+0.6
-0.2
20.2
+0.3
-0
12
No 2
1758 3
Leaf thickness
(measured in the middle)
13
Width of leaves
80 0.5
6.5
6.11 mm /kN
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
Print 603.93.111
13
No 2
1758 3
Leaf thickness
(measured in the middle)
16.5
Width of leaves
80 0.5
35
3.97 mm /kN
Print 603.93.111
55.5
+0.1
-0
57.3
+0.6
-0.2
20.2
+0.3
-0
14
72694
72695
Print 603.93.111
15
Figure 8
72696
SHOCK ABSORBER
Length between eyebolts:
Open (mm)
Closed (mm)
Stroke (mm)
MODELS: 110EL../120EL..
SHOCK ABSORBER
MODELS: 120E../130E../
120E..D/130E..D/
130E..RS
618 3
378 3
240
FICHTEL & SACHS
WAY-ASSAUTO
709 3
409 3
300
696 3
411 3
285
(continued)
Print 603.93.111
16
SHOCK ABSORBER
MODELS:
120E..-120E..D/
130E..-130E..D/
140E../150E..
120E..D/
130E..D/
140E../
150E..-150E..RS
140E../
150E../150E..RS
709 3
409 3
300
SHOCK ABSORBER
Length between eyebolts and
extremity:
Open (mm)
Closed (mm)
Stroke (mm)
MODELS:
725 3
435 3
290
SHOCK ABSORBER
MODELS:
714 3
414 3
300
SHOCK ABSORBER
MODELS:
820 3
470 3
350
180E..
Print 603.93.111
17
72520
72522
72697
18
Figure 12
72526
72524
Print 603.93.111
19
No 2
1670 3
-
25
25
40
Width of leaves
70 0.5
14.75
5
38.05 KN
5.77 mm/KN
1.90 mm/KN
Print 603.93.111
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
20
No 2
1680 3
-
25
25
38
Width of leaves
80 0.5
31
3.5
38.05 KN
6.55 mm/KN
2.12 mm/KN
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
Print 603.93.111
21
No 2
1680 3
-
24
24
37
Width of leaves
80 0.5
32
7.25
41.251 KN
5.658 mm/KN
2.105 mm/KN
Print 603.93.111
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
22
No 2
1680 3
23
38
Width of leaves
80 0.5
4
9.5
4.36 mm/KN
1.82 mm/KN
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
Print 603.93.111
23
No 2
1680 3
24
38
Width of leaves
80 0.5
4
6.5
3.87 mm/KN
1.73 mm/KN
Print 603.93.111
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
24
No 2
1680 3
14
16
10
Width of leaves
80 0.5
42
51
5.17 mm/KN
1.67 mm/KN
1254 3
55.5 + 0.1
57.3
+0.6
-0.2
20.2
+0.3
-0
Print 603.93.111
25
No 2
1680 3
15
10
width of leaves
80 0.5
35
46
3.87 mm/KN
1.504 mm/KN
1254 3
Print 603.93.111
55.5
+0,1
0
57.3
20.2
+0.6
-0.2
+0.3
0
26
No 2
1680 3
16
10
Width of leaves
80 0.5
27
44
3.193 mm/KN
1.39 mm/KN
1254 3
57.3
+0,6
- 0,2
20.2
+0,3
-0
55.5 + 0.1
Print 603.93.111
27
Figure 14
Disconnection
Operate as follows:
- Place the vehicle on a flat surface.
- Lock front wheels.
- Lift the rear part of the chassis and remove the wheels
of the intermediate and rear axle.
- Place a suitable lifting tool under the equalizer to be
removed.
- Disconnect the limit stop belt (12) loosening the screws
(2) and removing the brackets (1).
- Disconnect the shock absorbers (3) from the lower part
loosening the fasteners (10).
- Disconnect the suspension rubber springs (11)
loosening the screws (4).
- Remove the screws (5) and withdraw the relevant
bushes (8).
- Lower the equalizer by means of the lifting jack and
extract it from its seat.
Reconnection
To reconnect follow the disconnection procedure
in the reverse order.
Note: Work properly with the lifter under the equalizer (6)
to obtain the centering of the axle box-type melting with the
silentblock (9) in order to ease the insertion of the relevant
bushes (8). Eventually lock the corresponding fasteners to
the following tightening torques:
- fastener (5) to 630 Nm;
- fastener (10) to 94 Nm;
- fastener (4) to 50 Nm.
74086
1. Limit stop belt locking bracket - 2. Bracket fastening screws - 3. Shock absorber - 4. Rubber spring fastening screws 5. Silentblock fastening screws - 6. Equalizer - 7. Axle box-type melting 8. Silentblock bush - 9. Silentblock - 10. Shock absorber fastener - 11. Rubber spring - 12. Limit stop belt
Print 603.93.111
28
Print 603.93.111
29
Section A-A
72698
77618
30
SHOCK ABSORBERS
669 3
404 3
265
MODELS: 110EL../120EL..
SHOCK ABSORBERS
MODELS: 120E..
130E..-130E..RS
714 3
414 3
300
702 3
417 3
285
714 3
414 3
300
SHOCK ABSORBERS
MODELS: 180E..
WAY - ASSAUTO
SHOCK ABSORBERS
MODELS: 120E..D/130E..D
140E..
150E..-150E..RS
666 3
396 3
270
FICHTEL & SACHS
SHOCK ABSORBERS
Length between eyebolts and
extremity:
Open (mm)
Closed (mm)
Stroke (mm)
716 3
416 3
300
MODELS: 180E..
Print 603.93.111
31
74087
SHOCK ABSORBER
FOR MODEL
260 E 28 KE
Print 603.93.111
HENDRICKSON
Length L
Open (mm)
Closed (mm)
Stroke (mm)
565 3
362 3
203
32
DIAGNOSTICS
Main suspension operating problems:
1
2
3
Noisy suspension
Irregular or excessive tyre wear
The vehicle tends to shift to one side
4
5
6
NOISY SUSPENSION
Insufficient lubrication.
Lubricate carefully.
YES
NO
NO
NO
YES
YES
NO
NO
Print 603.93.111
33
IRREGULAR OR EXCESSIVE
TYRE WEAR
NO
NO
NO
Sudden accelerations.
NO
NO
YES
NO
Print 603.93.111
34
NO
NO
NO
NO
NO
Print 603.93.111
35
NO
YES
YES
YES
YES
YES
CREAKING, KNOCKING
AND NOISE IN GENERAL
NO
NO
NO
Print 603.93.111
36
TIGHTENING TORQUES
PART
FRONT SUSPENSIONS
Leaf spring bracket fastening nut
Leaf spring bracket fastening nut
Leaf spring bracket fastening nut
Leaf spring to pad fastening nut
Leaf spring to front mount fastening nut
Shock absorber to chassis fastening nut
Shock absorber to axle fastening nut
Upper shock absorber fastening nut
Shock absorber to axle fastening nut
Shock absorber fork fastening nut
Connecting rod to chassis support screw nut
Connecting rod to sway bar fastening pin nut
Sway bar support to chassis fastening screw
Collar to sway bar support fastening screw
REAR SUSPENSION
Spring bracket on axle fastening nut
Leaf spring front fastening nut
Leaf spring to pad fastening screw
Rear mount to chassis fastening screw nut
Sway bar to axle mount fastening screw nut
Connecting rod to chassis support fastening screw nut
Upper shock absorber fastening nut
Lower shock absorber fastening nut
Shock absorber to chassis fastening nut
Shock absorber to axle fastening nut
Rebound to chassis fastening screw
Sway bar support to chassis fastening screw nut
Sway bar to connecting rod fastening nut
TORQUE
M16x1.5
M18x1.5
M20x1.5
M16
M16
M14x1.5
M20
M12
M22x1.5
M20
M20
M16
M20
M20
M14x1.5
M20
M16
M16
M12
M10
Nm
(kgm)
238 22.5
278 27
464 46
445 45
445 45
80 8
80 8
64 6
121 12
275 55
223 22
311 30
76.5 7.5
111 11
(24 2.2)
(28 2.7)
(47 4.7)
(45 4.6)
(45 4.6)
(8 0.8)
(8 0.8)
(6.4 0.6)
(12.3 1.2)
(28 5.6)
(23 2.3)
(34 3)
(8 0.8)
(11 1.1)
623 62
445 45
445 45
227 23
311 31
311 31
64 6
121 12
80 8
80 8
77 7
63 7
35.5 3.5
(63.5 6.3)
(45 4.5)
(45 4.5)
(23 2.3)
(32 3)
(32 3)
(6.4 0.6)
(12.3 1.2)
(8 0.8)
(8 0.8)
(7.9 0.7)
(6.4 0.6)
(3.6 0.3)
Print 603.93.111
500410
37
Figure 18
FRONT MECHANICAL
SUSPENSION
REMOVAL-REFITTING
Disconnect the battery cables before starting
removal-refitting operations.
Removal
Arrange the vehicle on level ground, block the
rear wheels with wedges and proceed as follows:
- Loosen the front wheel fastening nuts, lift the vehicle and
position it on stands.
- Arrange hydraulic jack 99321024 under the wheels,
remove the fastening nuts and remove the wheels.
- Loosen the nuts (1 and 5), taking the pad (2) and remove
the shock absorber from the vehicle (4).
- Loosen the U-bolt (12) fastening nuts (9). Remove the
sway bar (8) supports (7) and remove the U-bolts taking
the plate (6) and the rebound (13).
- Loosen the nut and remove the front leaf spring (11)
anchoring pin (10) to the chassis mount.
- Loosen the nut and remove the rear pin (3) anchoring
the leaf spring (11) to the chassis, lower the axle and
remove the complete leaf spring.
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Lock nuts must be replaced and fastened at the
specified torque.
Check that:
- U-bolt threading is in good conditions. If
required, reface the threading or replace the
part.
72700
Print 603.93.111
38
500450
Figure 19
Removal
Arrange the vehicle on level ground, block the
front wheels and proceed as follows:
- Loosen the rear wheel fastening nuts, lift back of the
vehicle and position it on stands.
- Arrange hydraulic jack 99321024 under the wheels,
remove the fastening nuts and remove the wheels.
- Loosen the nuts (3) and remove the fastening U-bolts
(4).
- Loosen the nut and remove the front leaf spring (5)
anchoring pin (6) to the chassis support (7).
- Loosen the nut and remove the rear pin (2) anchoring
the leaf spring (5) to the chassis (1), lower the axle and
remove the complete leaf spring.
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Lock nuts must be replaced and fastened at the
specified torque.
Check that:
- U-bolt (4) threading is in good conditions. If
required, reface the threading or replace the
part.
79453
Print 603.93.111
39
Refitting
Figure 20
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
72829
Loosen the nuts (1 and 4), take the rebound (3) and remove
the shock absorber (2).
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Figure 22
72830
Loosen the nuts (1 and 3) and remove the sway bar (4) with
anchoring rod (2).
Refitting
72702
Loosen the nuts (1 and 3) and remove the shock absorber (2).
Print 603.93.111
40
528960
REPAIRS
Removal
Figure 23
72703
Loosen the nut and remove the axle support fastening pin
(3).
Remove the nut (1), remove the pin and remove the sway
bar with reaction rod (2).
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Checks
Carefully clean all parts with diesel fuel or solvent.
Make sure that the bushings are well anchored in the
spring and pad holes. Make sure that the internal
surface is not ovalised and that the pins are neither
worn nor misshapen. Replace if this is not so.
Print 603.93.111
41
BUSHING REPLACEMENT
Removal
Figure 24
33854
Position the leaf spring (1) under a press (4) and remove the
bushing (2) from its housing with a ram (3).
Refitting
Refit by reversing the removal sequence.
Print 603.93.111
42
Print 603.93.111
5004
43
PNEUMATIC SUSPENSIONS . . . . . . . . . . . . . . .
45
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .
45
45
45
46
46
47
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . .
47
47
48
51
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . .
51
52
53
54
Print 603.93.111
58
- Remote control . . . . . . . . . . . . . . . . . . . . . . . .
58
59
59
- Chassis self-leveling . . . . . . . . . . . . . . . . . . . . .
59
- Level M1 - M2 . . . . . . . . . . . . . . . . . . . . .
59
44
Page
Page
60
71
61
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
62
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
71
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
64
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
66
72
- Controlled-pressure valve . . . . . . . . . . . . . . . .
66
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
66
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
- Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
72
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
66
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
67
73
67
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
- Self-leveling . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
73
68
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
68
68
74
- Self-leveling . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
- Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
- Air springs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
75
- ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
70
75
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
71
76
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
Print 603.93.111
45
PNEUMATIC SUSPENSIONS
INTRODUCTION
Pneumatic suspensions are very flexible and offer
considerable vibration damping features, regardless of vehicle
load. By effect of the system self-adjusting features, the
chassis-road surface distance is kept constant. A specific
button can be used to vary the chassis-road surface
distance, and consequently the vehicle load surface, in
pneumatic suspension systems.
In addition to the advantages of pneumatic suspensions, the
ECAS system ensures:
- considerable air consumption reduction;
- prompt response to adjustments;
- system simplicity;
- high safety;
Models equipped with mixed suspension systems (front mechanical suspensions and rear pneumatic suspensions) fit
the front suspension of the corresponding mechanical suspension models.
72530
Dimension x = 60 mm
FRONT PNEUMATIC SUSPENSION ASSEMBLY
(Models 120E..FP/130E..FP/150E..FP)
Print 603.93.111
46
No 2
1739 3
Leaf thickness
1st leaf (measured in the middle)
2nd leaf (measured in the middle)
30
23
Width of leaves
80 0.5
54
9.818 mm/KN
55.5 + 0.1
57.3
20.2
+0.6
-0.2
+0.3
-0
Print 603.93.111
47
72792
SHOCK ABSORBERS
588 3
358 3
230
MODELS: 120E..FP/130E..FP
150E..FP
Print 603.93.111
48
72529
Dimension x = 187 mm
REAR PNEUMATIC SUSPENSION ASSEMBLY
(NEWAY for Models 110EL..P/120EL..P)
Print 603.93.111
49
Figure 4
84421
Dimension x =
Print 603.93.111
50
Figure 5
72786
Dimension x =
Print 603.93.111
51
72788
72789
52
SHOCK ABSORBERS
Length between eyebolts:
Open (mm)
Closed (mm)
Stroke (mm)
MODELS: 110EL..P/120EL..P
SHOCK ABSORBERS
669 3
404 3
265
MANNESMANN - SACHS
674 3
404 3
270
Print 603.93.111
53
62390
1. Limited return air vent valve 2. Manual condense bleeding valve 3. Air reservoir 4. Pressure test point 5. One-way
valve 6. Low pressure indicator 7. Electro-pneumatic distributor 8. Electronic levelling valve 9. Axle air spring
Print 603.93.111
54
72787
1. Limited return air vent valve 2. Manual condense bleeding valve 3. Air reservoir 4. Pressure test point
5. One-way valve 6. Low pressure indicator - 7. Electro-pneumatic distributor 8. Electronic levelling valve
9. Axle air spring
Print 603.93.111
55
78797
1. Limited return air vent valve 2. Manual condense bleeding valve 3. Air reservoir - 4. Pressure test point
5. One-way valve 6. Low pressure indicator 7. Electronic levelling valve 8. Front axle air spring
9. Front axle electro-pneumatic distributor 10. Rear axle electro-pneumatic distributor 11. Rear axle air spring
Print 603.93.111
SA MODULE
BATTERY
Figure 11
40011 Electronic odometer 40046 Rear axle inductive chassis height sensor 42200 Pneumatic suspension failure warning switch 52502 Utility and ignition key switch
53000 Warning light test switch 58250 Suspension failure warning light 58254 Suspension low pressure warning light 58255 Suspension no travel condition warning light
58905 Optional systems ten warning light panel 70000 Fuse holder 6 72021 30-pole stationary diagnostic electrical connection socket 78243 Electro-pneumatic distributor
85160 Chassis trim variation control device 86023 Vehicle lifting/lowering control unit
+ BATTERY
56
EUROCARGO TECTOR 12-26 t
Print 603.93.111
SA MODULE
BATTERY
Print 603.93.111
50294
Figure 12
40011 Electronic odometer 40046 Rear axle inductive chassis height sensor 40047 Front axle inductive chassis height sensor 42200 Pneumatic suspension failure warning switch
52502 Utility and ignition key switch 53000 Warning light test switch 58250 Suspension failure warning light 58254 Suspension low pressure warning light 58255 Suspension no travel
condition warning light 58905 Optional systems ten warning light panel 70000 Fuse holder 6 72021 30-pole stationary diagnostic electrical connection socket
72242 Front axle electro-pneumatic distributor 78243 Electro-pneumatic distributor 85160 Chassis trim variation control device 86023 Vehicle lifting/lowering control unit
+ BATTERY
57
58
78799
1)
2)
3)
4)
5)
6)
7)
8)
Power positive
Negative
Communication line with ECU
Communication line with ECU
Print 603.93.111
59
78800
Level M1 - M2
This operation can only be activated at speeds slower than
20 km/h.
The set trim will be kept constant over this speed.
Proceed as follows to lift/lower the chassis:
- Press button (1, Figure 14) to select the front axle, the
respective warning light A will come on.
Print 603.93.111
60
78951
1. Controlled pressure valve 2. Front axle level sensor 3. Front air spring 4. Electro-pneumatic distributor
5. Rear air spring 6. Check valve 7. Rear axle electro-pneumatic distributor 8. Reservoir 9. Pressure test point
10. Rear axle level sensor
Print 603.93.111
61
8.5 bar
15 litres
15 litres
Power voltage
Pulse 8 16V
Current intake
Max 90 mA
Max 100
- 40 C + 80 C
5 13 bar
20 bar
24 V
Check valve
- Type: WABCO WESTINGHOUSE 434 014 000 0
Working pressure range
Max 20 bar
- 40 C + 80 C
- 40 C + 80 C
Working voltage
Permitted electric load
Maximum operating pressure
Print 603.93.111
18 32 V
- 40 70 C
12/24 V
0.001 to 1 A
12 bar
62
DIAGNOSTICS
Main pneumatic suspension operating problems:
1 - Low or irregular pneumatic system recharging
2 - Irregular vehicle trim
3 - Chassis out of trim warning light on at speeds faster
than 20 km/h
NO
NO
Replace A.P.U.
YES
NO
NO
(continued)
Base - February 2003
Print 603.93.111
63
NO
NO
NO
NO
NO
NO
Print 603.93.111
64
TIGHTENING TORQUES
PART
TORQUE
Nm
(kgm)
62.5 6.5
(6.25 0.65)
463.5 46.5
(46.35 4.65)
336.5 33.5
(33.65 3.35
336.5 33.5
(33.65 3.35)
250 306
(25 30.6)
435 530
(43.5 53)
819 1002
(81.9 100.2)
119 146
(11.9 14.6)
425 440
(42.5 44)
794 971
(79.4 97.1)
40 54
(4 5.4)
435 530
(43.5 53)
56 69
83 101
(5.6 6.9)
(8.3 10.1)
U-bolts must be fastened diagonally in several times to ensure contact between adapter and axle before reaching
maximum specified torque.
(35.25 3.25)
418 42
(41.8 4.2)
90 10
(9 1)
92 9
(9.2 0.9)
545 55
(54.5 5.4)
Nut for screw fastening the air-operated spring support arm to the rear axle.
Print 603.93.111
65
TORQUE
PART
Rear pneumatic suspension (Models: 180E..P)
Axle to air spring support arm fastening screw nut
Reaction triangle to axle fastening screw
Reaction bar fastening screw nut
Support arm to air spring fastening screw nut
Air spring to chassis fastening screw nut
Sway bar to spring support arm fastening pin nut
Sway bar support to chassis fastening screw nut (M16)
Sway bar support to chassis fastening screw nut (M12)
Connecting rod to chassis support fastening pin nut
Upper shock absorber fastening pin nut
Lower shock absorber fastening pin nut
Reaction triangle to chassis support fastening screw
Nm
(kgm)
845 170
290 30
418 42
100 10
92 9
373.5 37.5
226.5 22.5
92 9
359 36
118 12
187.5 18.5
418 42
(84.5 17)
(29 3)
(42.6 4.3)
(10 1)
(9.4 0.9)
(38 3.8)
(23 2.3)
(9.4 0.9)
(36.6 3.7)
(11.8 1.2)
(18.7 1.9)
(42.6 4.3)
TOOLS
TOOL No.
DESCRIPTION
6810
4 12
2 1614
0
6 81012
4
2 14
0 16
6 8 10
4
12
2
14
0 16
8 10
46 12
14
2
0 16
810
12
14
16
99305117
99321024
99387050
Print 603.93.111
66
793319
Figure 16
Check valve
Figure 18
20437
33987
This valve allows the passage of compressed air in the direction of the arrow on the valve body, preventing it from flowing back.
Figure 19
52723
78802
Print 603.93.111
67
Operation
Figure 20
Figure 21
78803
Pneumatic connections
11 - from air reservoir
21 - from axle electro-pneumatic distributor
22 - to air spring on right-hand side
23 - to air spring on left-hand side
Electrical connections
6.1 - Solenoid valve power positive
6.2 - Negative
6.4 - Free
78804
Self-leveling
The ECU, according to the position of the level sensors,
controls the front axle electro-pneumatic distributor
solenoid valve and the rear axle electro-pneumatic
distributor solenoid valves accordingly for lifting or lowering
in order to reach vehicle levelling or stored positions M1
or M2.
Print 603.93.111
68
Figure 22
Figure 24
78805
Figure 23
4x2 P vehicles
4x2 FP vehicles
Duct (21) is connected to front axle
electro-pneumatic distributor duct (14) for
supplying the air springs.
Pneumatic connections
11 - from air reservoir
21 - to axle electro-pneumatic distributor
22 - to air spring on right-hand side
23 - to air spring on left-hand side
Electrical connections
6.1 - Solenoid valve A power positive
6.2 - Solenoid valve B power positive
6.3 - Solenoid valve C power positive
6.4 - Common negative
Base - February 2003
Self-leveling
The ECU, according to the position of the level sensors,
controls solenoid valves A, B and/or C accordingly for
lifting or lowering in order to reach vehicle levelling or stored
positions M1 or M2.
Print 603.93.111
Level sensor
69
Figure 25
Figure 27
62421
30106
Figure 26
ECU
The ECU manages the various chassis positions according to
the requests made by the driver by means of the remote
control.
When the key switch is switched on, the electronic control
unit performs a system check by powering, during ~ 2
seconds, the red warning light (pneumatic suspension low
pressure) found on the dashboard. If an anomaly is found, the
CLUSTER display will show the corresponding symbol,
according to the type of anomaly: a yellow symbol on the left
portion (anomalies and faults not critical), or a red symbol on
the right portion (critical faults). The ECU must keep the
levels required by the driver constant and, at the same time,
reduce air consumption, by cyclically monitoring the level
sensor signals, cutting in ONLY when the discrepancy
between sensors is > 5 counts.
Correction will be made with a delay of:
D approximately 1 second when the vehicle is stationary
D approximately 60 seconds when the vehicle is moving.
The ECU will store a plausibility error if the level is not
restored within a maximum time of 30 seconds.
[conteggi]
[gradi]
62422
When braking, the ECU receives a signal from the brake light
switch, interrupting automatic trim adjustments. The ECU is
equipped with an extremely advanced self-diagnostic system
which is capable of recognising and storing system failures
(also intermittent), according to environmental conditions,
during operation, for ensuring correct, reliable repairs, in
addition to blink codes displayed by the red warning light for
preliminary troubleshooting. Diagnostic, programming and
error memory deletion operations, etc., can be carried out
using the MODUS computerised diagnostic station. All
system components, except for the steering system, are
connected to the ECU, by means of a comb connector. The
pin numbering and ECU type change according to the version.
70
72815
Refitting
Removal
The following procedure described for one arm is valid for
both.
- Disconnect the electrical connections (4) to prevent
damage.
- Loosen nut (8), remove the anchoring pin and detach
shock absorber (9) from the support on the arm.
- Remove the nuts (7) and the rear axle anchoring
brackets (10).
Print 603.93.111
71
Figure 29
Figure 31
72816
Loosen the upper and lower nuts (3), remove the upper and
lower anchoring pins (1) and remove the shock absorber (2)
from the vehicle.
Refitting
72818
Refitting
Figure 30
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
72817
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Print 603.93.111
72
Figure 32
72820
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
72819
Loosen upper nut (1) and lower nut (5), take the pads (2) and
(4) and remove the shock absorber (3) from the vehicle.
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Print 603.93.111
500710
73
Figure 34
Removal
Arrange the vehicle on level ground, block the
rear wheels with wedges and proceed as follows:
- Loosen the front wheel fastening nuts, lift the vehicle and
position it on stands.
- Arrange hydraulic jack 99321024 under the wheels,
remove the fastening nuts and remove the wheels.
- Loosen the nuts (6), taking the pad (10) and remove the
shock absorber (14).
- On the lower side of the vehicle, loosen the nuts (4) and
remove the U-bolt (3) taking the plate (11).
- Loosen the nut and remove the rear pin (13) anchoring
the leaf spring (12) to the chassis mount.
- Loosen the nut and remove the front leaf spring (12)
anchoring pin (1) to the chassis mount. Lower the axle
and remove the complete leaf spring.
- Loosen the nut (9) and disconnect the tie-rod (8).
- Loosen the nut (7), remove the screw and disconnect
the air spring from the leaf spring.
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Lock nuts must be replaced and fastened at the
specified torque.
Check that:
- U-bolt threading is in good conditions. If
required, reface the threading or replace the
part.
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Lock nuts must be replaced and fastened at the
specified torque.
Check that:
- U-bolt threading is in good conditions. If
required, reface the threading or replace the
part.
Print 603.93.111
72821
74
500730
Figure 35
Removal
Arrange the vehicle on level ground, block the
rear wheels with wedges and proceed as follows:
- Loosen the front wheel fastening nuts, lift the vehicle and
position it on stands in the point shown by ().
- Arrange hydraulic jack 99321024 under the wheels,
remove the fastening nuts and remove the wheels.
- Loosen nut (13) and remove the shock absorber (14).
- Remove the air spring (2) and (11) fastening nuts (4) and
(9).
- Remove the sway bar (10) fastening bolts (8).
- Loosen the fastening nuts and disconnect the level valve
tie-rid (12).
- Loosen the fastening nuts (6), taking the plates and
remove the U-bolts (15).
- Loosen the reaction rod (3) fastening bolts (1) and (7).
- Remove the suspension arms from the vehicle (5).
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Lock nuts must be replaced and fastened at the
specified torque.
Check that:
- U-bolt (15) threading is in good conditions. If
required, reface the threading or replace the
part.
72822
Print 603.93.111
500731
500940
Removal
75
Removal
Figure 36
Figure 37
72823
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
72827
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Print 603.93.111
76
500731
Removal
Figure 38
72823
Refitting
Refit by reversing the removal sequence. Fasten
screws and nuts at the specified torque.
Print 603.93.111
SECTION 9
5025
Print 603.93.111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . .
Print 603.93.111
DESCRIPTION
The wheel rim shows the rigid wheel structure and is
identified by the following dimensions:
and ensuring
the
WHEEL RIMS:
Disc-type with drop center rim
MODELS 4x2
MEASURES
ML 110 EL..
17.5 x 6.75
ML 120 EL..
17.5 x 6.75
ML 120 E..
ML 130 E..
ML 140 E..
19.5 x 6.75 - 19.5 x 7.50 - 19.5 x 8.25 - 22.5 x 6.75 - 22.5 x 7.50
ML 150 E..
19.5 x 6.75 - 19.5 x 7.50 - 19.5 x 8.25 - 22.5 x 6.75 - 22.5 x 7.50
ML 180 E..
MODELS 6x4
260E28KE
MEASURES
22.5 x 8.25
For checking tire pressure, comply with values shown in the specific Use and Maintenance booklet.
Print 603.93.111
TOOLS
TOOL No.
DENOMINATION
99305037
DIAGNOSTICS
Main tire anomalies:
1 Excessive consumption.
2 Irregular consumption.
3 The vehicle tends on one side.
EXCESSIVE CONSUMPTION
NO
NO
NO
NO
Overloaded truck.
Print 603.93.111
IRREGULAR CONSUMPTION
NO
NO
NO
NO
NO
NO
(continues)
Print 603.93.111
NO
NO
NO
Print 603.93.111
502511
Figure 1
Figure 2
16997
Print 603.93.111
Figure 3
502510
TIRE PRESSURE
23885
Print 603.93.111
Figure 6
90% EFFICIENCY
Figure 5
Figure 7
- 40%
CORRECT
40% EFFICIENCY
100% EFFICIENCY
Figure 8
Print 603.93.111
10
Print 603.93.111
STEERING
SECTION 10
5014
Steering
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
13
14
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . .
15
16
17
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
19
20
21
22
23
24
24
Print 603.93.111
24
STEERING
Print 603.93.111
STEERING
DESCRIPTION
The steering control system, that can be found on EuroCargo vehicles, is composed of an hydraulic power steering of the
ball-circulation type controlled by a geared pump assembled together with the air compressor.
Such pump has the feature of having its oil tank integrated with the body.
72607
1. Hydraulic power steering 2. Delivery piping 3. Return piping 4. Through-wall fitting on return piping 5. Power
steering pump with integrated tank 6. Through-wall fitting on delivery piping.
72608
1. Power steering pump 2. Hydraulic power steering oil tank 3. Oil insertion plug with level sensor 4. Air compressor.
Print 603.93.111
STEERING
Steering
Hydraulic
Hydraulic power steering (with ball circulation with embedded pressure limiting
valve)
Variable operating pressure
Reduction ratio
No. of revolutions/steering wheel
Power steering pump with integrated tank
and safety filter valve
Min. number of revolutions Revs/min
Max. number of revolutions Revs/min
Operating pressure
bar
Flow rate
dm3/min
Maximum operating temperature
ZF 8095
ZF 8098
TRW/TAS 55
150 + 15
19.6 : 1
5.4
130 + 13
22.2 to 26.2 : 1
3.1
150 + 10
20.4 : 1
5.7
ZF FN4 Integral
600
2700
max. 180
16
100 C
DIAGNOSTICS
Main hydraulic power steering operating anomalies:
1
2
3
5
6
7
8
HARD STEERING
IN RIGHT AND
LEFT STEERING
Check level with running engine; top-up the oil till the
upper level rod mark and drain the system.
YES
NO
NO
(continues)
Base - February 2003
Print 603.93.111
STEERING
NO
NO
NO
YES
NO
NO
Print 603.93.111
STEERING
NO
NO
NO
NO
Unbalanced wheels.
YES
NO
NO
NO
YES
Print 603.93.111
STEERING
Unbalanced wheels.
YES
NO
NO
YES
YES
NO
NO
Print 603.93.111
STEERING
OIL LEAKAGE
NO
In any case it is necessary to establish where and why the hydraulic oil is lost, remove the reason and top-up the oil in the
tank with running engine till the upper level rod mark.
NO
YES
YES
YES
NO
NO
NO
Print 603.93.111
STEERING
TIGHTENING TORQUES
PART
HYDRAULIC
POWER
STEERING
ZF 8095
ZF 8098
TRW/TAS 55
Nm (kgm)
Nm (kgm)
Nm (kgm)
Nm (kgm)
15 5 (1.5 0.5)
15 5 (1.5 0.5)
Nm (kgm)
73 7 (7.4 0.7)
73 7 (7.4 0.7)
73 7 (7.4 0.7)
TOOLS
TOOL No.
DENOMINATION
99347042
99347068
99374393
99374398
Print 603.93.111
10
STEERING
Figure 3
62596
Print 603.93.111
11
STEERING
Figure 4
27200
Print 603.93.111
12
STEERING
Figure 5
27201
Print 603.93.111
STEERING
13
Figure 6
27202
Figure 7
27203
PISTON RIGHTWARDS DISPLACEMENT (open steering limiting valves, very reduced oil pressure)
Print 603.93.111
14
STEERING
54130
Figure 10
Figure 8
33688
Disconnection
33686
Figure 11
Figure 9
33687
33689
Print 603.93.111
STEERING
Reconnection
15
Figure 14
Figure 12
33692
Figure 15
33690
Figure 13
33693
!
Lubricate with oil all screws securing hydraulic power
steering to support.
33691
Print 603.93.111
16
STEERING
501430
Figure 16
27204
6 mm
3 mm
3 mm
Figure 17
19587
Print 603.93.111
STEERING
17
77844
1. Hydraulic steering limiting adjustment screw 2. Hydraulic right steering limiting adjustment screw 3. Worm screw
4. Hydraulic left steering limiting adjustment screw 5. Torsion bar 6. Rotating distributor valve 7. Entry shaft 8. Cover
9. Balls 10. Hydraulic power steering case 11. Outlet shaft 12. Rack piston.
Description
The ball-circulation control hydraulic power steering is
essentially composed of a case in which manual steering
mechanism, an hydraulic cylinder controlled by a rotating
distributor valve, and hydraulic steering and safety limiting
valves are housed.
The rotary motion impressed to steering wheel is transmitted
from inlet shaft (7) to worm screw (3), through the torsion bar
(5).
The worm screw (3) in turn, being connected by means of a
set of balls (9) to the rack piston (12), transforms the rotary
motion into an axial motion of this latter one.
The piston rack toothing (12) meshes into the toothed-sector
shaft toothing and impresses a rotary motion thereto. The
steering control arm fixed on this shaft transmits the motion
to the wheel steering tie-rods.
Print 603.93.111
18
STEERING
77845
1. Flow rate limiting valve - 2. Blade oil pump - 3. Oil tank - 4. Rotary distributor valve - 5. Inlet shaft - 6. Torsion bar 7. Worm screw - 8. Outlet shaft - 9. Rack piston.
Print 603.93.111
STEERING
19
77846
1. Flow rate limiting valve - 2. Blade oil pump - 3. Oil tank - 4. Rotary distributor vale - 5. Valve body - 6. Inlet shaft 7. Torsion bar - 8. Hydraulic limiting valve - 9. Rack piston.
Print 603.93.111
20
STEERING
77847
1. Flow rate limiting valve - 2. Blade oil pump - 3. Oil tank - 4. Rotary distributor valve - 5. Valve body - 6. Inlet shaft 7. Torsion bar - 8. Hydraulic limiting valve - 9. Rack piston.
Print 603.93.111
21
STEERING
77848
1. Steering hydraulic limiting screw - A and B steering limiting valve - 2. Small piston - 3. Bush - 4. Valve body - 5. Spring 6. Thrust sleeve - 7. Spacer pin - 8. Rack piston - 9. Cover - X. Left cylinder chamber - Y. Right cylinder chamber.
The two steering limiting valves A and B are housed in the rack
piston (8) end.
They are composed of a valve body (4) inside which valve
intervention adjustment bush (3) is placed, with a forced
coupling, such valve in turn operating as small piston (2) seat.
Small pistons (2) are kept in their closing position on bushes
(3) by counter-spring (5). Valves A and B are kept closed till
small pistons (2) stems are taken in contact by the rack piston
displacement:
- with adjustment screw (1) if the displacement is towards
the left;
- with cover (9) if the displacement is towards the right.
Print 603.93.111
22
STEERING
541430
Figure 24
60925
60924
Print 603.93.111
23
STEERING
Figure 25
60926
Print 603.93.111
24
STEERING
501430
Carry out the air drain from hydraulic power steering circuit
proceeding as follows:
- fill with required oil (TUTELA GI/A) the circuit tank;
- rotate the engine with the starter and top-up the oil
continuously in order to avoid that the pump sucks air.
Top-up the oil till its level does not go below the upper
rod mark;
- start the engine up and rotate it at minimum speed
checking that the oil level does not go below the upper
rod sign;
- rotate the steering wheel many times from stop to stop
so that air cannot go out of the hydraulic power steering
cylinder till no air bubbles are noted incoming into the
tank;
- accelerate the engine at its maximum, stop it and check
that the oil level in the tank does not rise more than 1
3 cm.
501430
78681
Print 603.93.111
Print 603.43.761
SECTION 11
Pneumatic System Brakes
Page
Print 603.93.111
12
13
14
15
17
18
19
- In general . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
20
20
21
22
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
26
Page
Page
- Principle diagram for vehicles adapted for towing
(Models 120 E.. - 130 E.. - 150 E..) . . . . . . . . . .
27
67
28
67
67
68
DUPLEX DISTRIBUTOR . . . . . . . . . . . . . . . . . . .
68
- Unbraking . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
70
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
- Pressure limiting . . . . . . . . . . . . . . . . . . . . . . . .
70
- Bench calibration . . . . . . . . . . . . . . . . . . . . . . .
70
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
RELAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
30
ARRANGEMENT ON A VEHICLE
OF MAIN BRAKING SYSTEM COMPONENTS
31
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Service braking . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Safety braking . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Parking braking . . . . . . . . . . . . . . . . . . . . . . . . .
32
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .
71
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
44
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
72
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
53
58
60
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
63
74
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . .
63
74
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
- Predominance adjustment . . . . . . . . . . . . . . . .
74
64
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
COUPLING HEADS . . . . . . . . . . . . . . . . . . . . . .
75
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
67
75
...
73
Print 603.93.111
Page
Page
75
82
76
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
83
76
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
- Repair interventions . . . . . . . . . . . . . . . . . . . . .
76
86
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
86
77
BRAKE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . .
87
77
- Front brakes
(KNORR brake caliper, SB6 type) . . . . . . . . . .
87
77
ELECTRONIC UNIT . . . . . . . . . . . . . . . . . . . . . .
77
88
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
REVOLUTIONS SENSORS . . . . . . . . . . . . . . . . .
77
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
PHONIC WHEELS . . . . . . . . . . . . . . . . . . . . . . .
77
89
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
90
ELECTRO-PNEUMATIC VALVE . . . . . . . . . . . . .
78
92
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
92
BRAKE REPAIRS
MODELS ML 110 EL.. / 120 EL..) . . . . . . . . . .
79
94
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
94
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . .
95
- Front Brakes
(Brake calipers of the PAN 17 type) . . . . . . . .
79
- Rear Brakes
(Brake calipers of the PAN 17 type) . . . . . . . .
79
95
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
95
79
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . .
95
96
79
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
81
97
81
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
99
82
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
- Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
82
100
- Reconnection . . . . . . . . . . . . . . . . . . . . . . . . .
82
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100
Print 603.93.111
Page
REAR DISC BRAKES REVISION (12-18 t) . . . . .
102
102
102
103
103
104
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
106
DRUM TURNING . . . . . . . . . . . . . . . . . . . . . . . .
107
108
108
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Print 603.93.111
SYMBOL
HYDRAULIC FLOW
PNEUMATIC FLOW
ELECTRIC DUCT
POSSIBLE ROTATION
COCK
SILENCER
COMPRESSOR
2
4
VACUUM PUMP
HYDRAULIC PUMP
32780
Print 603.93.111
SYMBOL
CONDENSATE SEPARATOR
FILTER
DRIER
DRIER
21
22
21
22
23
CONDENSATE
DRAIN
AUTOMATIC ANTIFREEZER
2
21 23
22 24
PRESSURE REGULATOR
21
PRESSURE REGULATOR
21
23
PRESSURE
(GOVERNOR)
REGULATOR
32782
32783
Print 603.93.111
SYMBOL
ADAPTER VALVE
21 23
22 24
3-CIRCUIT PROTECTION VALVE
21
23
22
21
22
SAFETY VALVE
CHECK VALVE
2
2
CHECK VALVE
1
2
DOUBLE STOP VALVE
11
12
U
THROTTLING VALVE
32783
Print 603.93.111
32784
32785
SYMBOL
1
11
21
12
22
21
11
21
12
4
22
11
21
22
21
22
BRAKE DISTRIBUTOR
CONTROL DISTRIBUTOR
CONTROL DISTRIBUTOR
DECELERATOR CONTROL
DISTRIBUTOR
13
23
4
SERVODISTRIBUTOR
1
32786
Print 603.93.111
SYMBOL
41
42
SERVODISTRIBUTOR
1
2
4
SERVODISTRIBUTOR FOR
MONO-DUCT
41
42
43
2
41
BRAKE CORRECTOR
42
43
11
12
22
11
21
12
22
12
BRAKE CORRECTOR WITH BY-PASS
21
11
2
4
4
41
42
32786
Print 603.93.111
32787
10
SYMBOL
41
42
4
INTERLOCKED PROPORTIONAL
REDUCTION VALVE
2
2
1
LEVELLING VALVE
21
LEVELLING VALVE
MANUAL SUSPENSION-LIFTING
CONTROL VALVE
22
12
23
11
21
23
24
21
22
32787
32788
Print 603.93.111
11
SYMBOL
2
42
41
1
13
11
21
12
22
3
1
ELECTRO-PNEUMATIC VALVE
ELECTRO-PNEUMATIC VALVE
ELECTRO-PNEUMATIC VALVE
21
22
VR
VL
ABS
HL
HZ2
HZ1
HR
4
POWERING VALVE
1
32788
Print 603.93.111
12
SYMBOL
AIR SPRING
32789
Print 603.93.111
13
Print 603.43.761
SYMBOL
VACUUM SERVOBRAKE
VACUUM SERVOBRAKE
PNEUMO-HYDRAULIC CONVERTER
PNEUMO-HYDRAULIC CONVERTER
OPERATOR CYLINDER
BRAKE CYLINDER
SPRING CYLINDER
32790
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32791
14
SYMBOL
MECHANICAL
BRAKE
CALIPER
FLOATING
DISC
SERVOCLUTCH
SERVOCLUTCH
32791
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15
SYMBOL
A
ISO HALF-COUPLING
M
ISO VERSION
A
ISO HALF-COUPLING
M
VERSION WITH ISO JOINTS
A
CUNA HALF-COUPLING
B
ITALIAN VERSION
M
CUNA HALF-COUPLING
A
NATO HALF-COUPLING
M
NATO VERSION
32792
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32793
16
SYMBOL
4
2
HALF-COUPLING
V
Z
A
VERSION WITH MONO-DUCT
A
M
HALF-COUPLING
V
Z
A
VERSION WITH MONO-DUCT
12
22
HALF-COUPLING
4
2
22
M
HALF-COUPLING
4
1
32793
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17
SYMBOL
MANOMETER
MANOMETER
PRESSURE TRANSMITTER
LAMP
PRESSURE SWITCH
HOOTER
SENSOR
32794
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18
SYMBOL
32795
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799512
19
In general
Hydraulic system pipings for industrial vehicles are currently of
two types:
- Flexible ones made of polyamide with single-layered or
double-layered structure and in the following diameters
( 6-8-10-12-16 mm) equipped with spares in meters
- Rigid metal pipings in the following diameters (
4.75-6.35-8-10-12 mm). Pipings from 4.75 to 10 mm
are supplied as spares in straight 4-5-6 m crop ends, while
those exceeding 10 mm are supplied as spares already cut,
bent and reflanged.
31973
Burr piping (1), insert union (2) and place it between small
blocks (3) abutting pin (5). Lock piping (1) with screw (4).
Figure 1
Figure 4
31971
31974
Take back pin (4) to its neutral position. Screw screw (1) till
matrix die (2) comes to abut against small blocks (3) thereby
shaping the piping (5) end.
Reflanging type A
Figure 2
Reflanging type B
Figure 5
31972
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31975
20
Reflanging type C
Figure 6
Figure 9
31976
31979
Place piping (1) into tool (3) and operating on lever (2) bend
the piping.
Figure 7
Figure 10
31980
31977
Figure 8
Figure 11
31978
In order to free piping (2) from tool (3), operate on lever (1).
31981
Place piping (2) into tool (3) 99386523 and tighten screw (1).
Keeping piping (2) still, rotate tool (3) till the piping is
completely cut.
Print 603.93.111
After having cut the piping, burr and shape the end as previously
described.
21
Figure 12
mm
Assembly
pressure
N/mm2
6x1
1 to 1.5
0.040
8x1
2 to 2.5
0.050
10 x 1.5
2 to 2.5
0.050
12 x 1.6
2 to 2.5
0.060
16 x 2.34
3 to 3.5
0.060
Double-layered
Single-layered
10397
Figure 14
10399
10398
1. Reinforcement bush - 2. Pressure ring - 3. Nut - 4. Fitting 5. Pipe - h. Distance between bush edge and ring edge
(see table).
Insert the thereby-prepared piping end into the fitting body till
the reinforcement bush flange rests within the suitable seat:
- For closing the nut on the fitting, initially screw it manually
and then complete the tightening with a suitable box
wrench inserted into the dynamometric wrench, to be
calibrated according to the required tightening torque.
22
with
quick
Rotating fittings:
Pipings diameter
mm
6x1
40
8x1
50
10 x 1.5
60
12 x 1.6
75
16 x 2.34
100
Figure 16
39306
39307
- Check that the sealing ring (1) is into its suitable seat;
- screw the fitting till it is felt that the sealing gasket abuts
onto the valve;
- adequately swing the fitting and keeping the swingable
part still, lock the hexagonal nut at the tightening torque
mentioned in the table.
13132
At the end of the assembly, check the perfect seal of all gaskets
(unions, fittings, etc.).
Base - February 2003
M 10 x 1.0 mm
22
M 12 x 1.5 mm
24
M 14 x 1.5 mm
28
M 16 x 1.5 mm
35
M 22 x 1.5 mm
40
Print 603.93.111
Figure 18
23
Figure 20
39308
33977
- Manually insert pipe (2) into fitting (1), with a force varying
from 30 to 120 N depending on pipe diameter, so that the
notch L1 is placed inside the fitting while the notch L2 is
visible.
Figure 21
Figure 19
33978
FITTING
SEALING RINGS
THREADING
DIMENSIONS
33976
M 10 x 1.0
10.1 x 1.6
M 12 x 1.5
11.0 x 2.0
M 14 x 1.5
M 16 x 1.5
M 22 x 1.5
15.0 x 2.0
-
D
(mm)
0
L+0.5
L1
-0.5
+1
L2
-0.5
+1
(mm)
(mm)
(mm)
19.8
17
22
20.5
18
23
12
25
22
28
16
27.1
24
30
Print 603.93.111
24
BRAKING SYSTEM
Principle diagram for single vehicles (Models 110 EL.. - 120 EL..)
Figure 22
84013
1. Single-cylinder 225 cm3 (359 cm3 optional) compressor - 2. 0.26l silencer - 3. Air Processing Unit - 4. 15l front axle air
tank - 6. Manual condensate exhaust valve - 7. Safety valve (optional) - 8. Engine brake control button - 9. Engine brake
control solenoid valve - 10. Engine brake valve control cylinder - 11. Relay valve - 12. Phonic wheel - 13. Revolutions sensor 14. Rear axle brake disc - 15. - Rear axle brake caliper - 16. Combined cylinder - 17. Parking relay valve - 18. Inserted parking
brake signalling low pressure switch - 19. Rear axle ABS solenoid valve - 20. Manual parking control distributor 21. Manual safety distributor (optional) - 22. Duplex distributor - 23. Front axle ABS solenoid valve - 24. Front axle brake
disc - 25. Front axle brake caliper - 26. Front axle membrane cylinder - 27. Revolutions sensor - 28. Phonic wheel 29. Quick discharge valve - 30. ABS electronic unit - 31. Parking brake luminous signaller - 32. STOP lights - 33. Front
axle/rear axle manometer - 34. STOP lights relay control switch - 35. EDC inserted brake signalling switch 36. Pneumatic control plug.
A. To pneumatic suspension system - B. To differential block - C. To gearbox control.
Print 603.93.111
25
Principle diagram for vehicles adapted for towing (Models 110 EL.. - 120 EL..)
Figure 23
84014
1. Single-cylinder 225 cm3 (359 cm3 optional) compressor - 2. 0.26l silencer - 3. Air Processing Unit - 4. 15l front axle air
tank 5. 15l Axle air reservoir - 6. Manual condensate exhaust valve - 7. 15l trailer parking and reloading air tank 8. Trailer system pressure reducer - 9. Engine brake control button - 10. Safety valve (optional) - 11. Engine brake control
solenoid valve - 12. Engine brake valve control cylinder - 13. Trailer braking control pressure switch - 14. Relay valve 15. Rear axle ABS solenoid valve - 16. Phonic wheel - 17. Revolutions sensor - 18. Trailer coupling half-joints 19. Triple-control trailer servodistributor - 20. Rear axle brake disc - 21. - Rear axle brake caliper - 22. Combined cylinder 23. Parking relay valve - 24. Inserted parking brake signalling low pressure switch - 25. Manual parking control distributor 26. Manual safety distributor (optional) - 27. Unidirectional parking system valve - 28. Duplex distributor - 29. Front axle
ABS solenoid valve - 30. Front axle brake disc - 31. Front axle brake caliper - 32. Front axle membrane cylinder - 33.
Revolutions sensor - 34. Phonic wheel - 35. Quick discharge valve - 36. ABS electronic unit - 37. Parking brake luminous
signaller - 38. STOP lights - 39. Front axle/rear axle manometer - 40. Trailer section low pressure luminous signaller
(optional) - 41. STOP lights relay control switch - 42. EDC inserted brake signalling switch - 43. Trailer low pressure switch
(optional) - 44. Pneumatic control plug.
A. To pneumatic suspension system - B. To differential block - C. To gearbox control.
Print 603.93.111
26
Principle diagram for single vehicles (Models 120 E.. - 130 E.. - 150 E..)
Figure 24
84011
1. Single-cylinder 225 cm3 (359 cm3 optional) compressor - 2. 0.26l silencer - 3. Air Processing Unit - 4. 15l front axle air
tank - 5. 15l Axle air reservoir - 6. Manual condensate exhaust valve - 7. Safety valve (optional) - 8. Engine brake control
button - 9. Engine brake control solenoid valve - 10. Engine brake valve control cylinder - 11. Relay valve - 12. Rear axle
phonic wheel - 13. Revolutions sensor - 14. Rear axle drum brake - 15. - Rear axle combined cylinder - 16. Parking relay
valve - 17. Inserted parking brake signalling low pressure switch - 18. Rear axle ABS solenoid valve - 19. Manual parking
control distributor - 20. Manual safety distributor (optional) - 21. Duplex distributor - 22. Front axle ABS solenoid valve 23. Front axle brake disc - 24. Front axle brake caliper - 25. Front axle membrane cylinder - 26. Revolutions sensor 27. Phonic wheel - 28. Quick discharge valve (optional Proportional reduction valve) - 29. ABS electronic unit 30. Parking brake luminous signaller - 31. STOP lights - 32. Front axle/rear axle manometer - 33. STOP lights relay control
switch - 34. EDC inserted brake signalling switch - 35. Pneumatic control plug.
A. To pneumatic suspension system - B. To differential block - C. To gearbox control.
Print 603.93.111
27
84012
1. Single-cylinder 225 cm3 (359 cm3 optional) compressor - 2. 0.26l silencer - 3. Air Processing Unit - 4. 15l rear axle air
tank - 5. 15l front axle air tank - 6. Manual condensate exhaust valve - 7. 15l trailer parking and reloading air tank 8. Trailer system pressure reducer - 9. Engine brake control button - 10. Safety valve (optional) - 11. Engine brake control
solenoid valve - 12. Engine brake valve control cylinder - 13. Trailer braking control pressure switch (optional) - 14. Relay
valve - 15. Rear axle ABS solenoid valve - 16. Phonic wheel - 17. Revolutions sensor - 18. Trailer coupling half-joints - 19.
Triple-control trailer servodistributor - 20. Rear axle drum brake - 21. Rear axle combined brake cylinder 22. Parking relay valve - 23. Inserted parking brake signalling low pressure switch - 24. Manual parking control distributor 25. Manual safety distributor - 26. Unidirectional parking system valve - 27. Coaxial duplex distributor - 28. Front axle ABS
solenoid valve - 29. Brake disc - 30. Front axle brake caliper - 31. Front axle membrane cylinder - 32. Revolutions sensor 33. Phonic wheel - 34. Quick discharge valve (optional Proportional reduction valve) - 35. ABS electronic unit - 36. Parking
brake luminous signaller - 37. STOP lights - 38. Front axle/rear axle manometer - 39. Trailer section low pressure luminous
signaller (optional) - 40. STOP lights relay control switch - 41. EDC inserted brake signalling switch - 42. Trailer low
pressure switch (optional) - 43. Pneumatic control plug.
A. To pneumatic suspension system - B. To differential block - C. To gearbox control.
Print 603.93.111
28
84009
1. Single-cylinder 359 cm3 compressor - 2. 0.26l silencer - 3. Air Processing Unit - 4. 20l rear axle air tank - 5. 20l front axle
air tank - 6. Manual condensate exhaust valve - 7. Safety valve (optional) - 8. Engine brake control button - 9. Engine brake
control solenoid valve - 10. Engine brake valve control cylinder - 11. Relay valve - 12. Rear axle phonic wheel 13. Revolutions sensor - 14. Rear axle brake disc - 15. Rear axle brake calliper - 16. - Rear axle combined cylinder 17. Relay valve - 18. Inserted parking brake signalling low pressure switch - 19. Rear axle ABS solenoid valve - 20. Manual
parking control distributor - 21. Manual safety distributor (optional) - 22. Duplex distributor - 23. Front axle ABS solenoid
valve - 24. Front axle brake disc - 25. Front axle brake caliper - 26. Front axle membrane cylinder - 27. Revolutions sensor
- 28. Front axle phonic wheel - 29. Quick discharge valve (optional Proportional reduction valve) - 30. ABS electronic unit
- 31. Parking brake luminous signaller - 32. STOP lights - 33. Front axle/rear axle manometer - 34. STOP lights relay
control switch - 35. EDC inserted brake signalling switch - 36. Pneumatic control plug.
A. To pneumatic suspension system - B. To differential block - C. To gearbox control.
Print 603.93.111
29
Principle diagram for vehicles adapted for towing (Model 180 E..)
Figure 27
84010
1. Single-cylinder 359 cm3 compressor - 2. 0.26l silencer - 3. Air Processing Unit - 4. 20l rear axle air tank - 5. 20l front axle
air tank - 6. Manual condensate exhaust valve - 7. 15l trailer parking and reloading air tank - 8. Trailer system pressure
reducer - 9. Engine brake control button - 10. Safety valve (optional) - 11. Engine brake control solenoid valve - 12. Engine
brake valve control cylinder - 13. Trailer braking control pressure switch (optional) - 14. Relay valve - 15. Rear axle ABS
solenoid valve - 16. Phonic wheel - 17. Revolutions sensor - 18. Trailer coupling half-joints - 19. Triple-control trailer
servodistributor - 20. Rear axle disc brake - 21. Rear axle drum brake - 22. Rear axle combined brake cylinder - 23. Relay
valve - 24. Inserted parking brake signalling low pressure switch - 25. Manual parking control distributor 26. Manual safety distributor (optional) - 27. Unidirectional parking system valve - 28. Duplex distributor - 29. Front axle
ABS solenoid valve - 30. Front axle brake disc - 31. Front axle brake caliper - 32. Front axle membrane cylinder 33. Revolutions sensor - 34. Phonic wheel - 35. Quick discharge valve - 36. ABS electronic unit - 37. Parking brake
luminous signaller - 38. STOP lights - 39. Front axle/rear axle manometer - 40. Trailer section low pressure luminous
signaller (optional) - 41. STOP lights relay control switch - 42. EDC inserted brake signalling switch - 43. Trailer low
pressure switch (optional) - 44. Pneumatic control plug.
A. To pneumatic suspension system - B. To differential block - C. To gearbox control.
Print 603.93.111
30
Principle diagram for single vehicles (Model 260E) (with Hendrickson suspensions)
Figure 28
84418
1. Single-cylinder 225 cm3 (359 cm3 optional) compressor - 2. 0.261 silencer - 3. Air Processing Unit - 4. 20L + 20L axle air
tank - 5. Manual condensate exhaust valve - 6. 20L front axle air tank - 7. Engine brake control button - 8. Safety valve
(optional) - 9. Brake valve control cylinder - 10. Engine brake control solenoid valve - 11. Axle ABS solenoid valve - 12. Phonic
wheel - 13. Quick-release valve - 14. Rear axle speed sensor - 15. Rear axle membrane brake cylinder - 16. Rear axle drum
brake - 17. Rear axle combined brake cylinder - 18. Parking relay valve - 19. Inserted parking brake signalling low pressure
switch 6.5 bar - 20. Manual parking control distributor - 21. Manual safety distributor (optional) - 22. Self-limited coaxial duplex
distributor 7.6 0.3 bar - 23. Quick-release valve - 24. Front axle ABS solenoid valve - 25. Front axle disc brake (diam. 430
mm or 436 mm) - 26. Front axle brake calliper - 27. Front axle membrane cylinder - 28. Front axle speed sensor - 29. Front
axle phonic wheel - 30. ABS Electronic unit - 31. Parking brake luminous signaller - 32. STOP lights 33. Front axle / rear axle manometer - 34. Stop light relay control switch - 35. EDC inserted brake signalling switch 36. Relay valveBraking control - 37. Pneumatic control plug.
Print 603.93.111
31
ARRANGEMENT ON A VEHICLE
OF MAIN BRAKING SYSTEM COMPONENTS
Figure 29
78952
1. Phonic wheel - 2. Check valve - 3. Engine brake solenoid valve - 4. A.P.U. - 5. Relay valve - 6. Phonic wheel 7. Wheels revolution sensors - 8. Combined brake cylinder - 9. Triple-control servodistributor - 10. Coupling heads 11. Parking - trailer braking tank - 12. Hydraulic pressure control plug - 13. Wheels revolutions sensor - 14. Phonic wheel 15. Rear disc brake assembly - 16. Quick discharge valve - 17. Pressure relief valve - 18. Electro-pneumatic valve 19. Air tanks - 20. Pressure control plug - 21. Pressure relief valve - 22. Front disc brake assembly - 23. Membrane brake
cylinder - 24. Wheels revolutions sensor - 25. Phonic wheel - 26. Engine brake operating cylinder - 27. Engine brake
control button - 28. Duplex distributor - 29. ABS elecronic unit - 30. Single-cylinder compressor - 31. Parking brake
distributor - 32. Trailer slowing-down control distributor (optional) - 33. Wheels revolutions sensor.
Print 603.93.111
32
DESCRIPTION
Service braking
With pedal, of the electrically-controlled pneumatic type,
operating on all wheels and on trailer or semitrailer.
It is composed of two independent sections, one for activating
front axle braking elements, the other section for activating
rear axle braking elements.
A third section, interlocked with the two distributor sections,
is provided for braking the trailer. The duplex distributor with
electric transmitter checks the two independent sections and
the trailer control servodistributor in turn checks the above
interlocked section. The pneumatic system sectioning enables,
in case of failure of a section, the efficiency of the other ones.
BRAKES
Front brakes
Front brakes are of the disc type. Discs are keyed on wheel
hubs and equipped with venting fins that allow lowering the
high temperature that develops under the braking action.
Braking gaskets are equipped with a wear signaller connected
to a warning light placed on the dashboard, which signals
gasket wear.
ABS device phonic wheels are keyed-in on wheel hubs.
Front axle 5845
- type: WABCO (PERROT) PAN 17 - 330x34
Front axle 5842/5 - 5851/5
Safety braking
The safety braking allows reducing vehicle running speed and
stop it in a safety space, also when a braking system failure
occurs.
It must be meant as partial service braking that, due to the
double circuit, anyway operates on one of the two axles.
Engine brake
The engine brake system, being of the electric type, is
managed by the EDC unit. The exhaust brake can be
controlled in different ways, which can be selected by means
of the special switch available on the dashboard or the pedal
on the floor to be used with the different types/conditions of
the road.
Actuation can be controlled directly through the pedal
available on the floor.
When the selector is set to position 1, the exhaust brake is
linked to the accelerator pedal and is operated when the
accelerator is released.
When the selector is set to position 2, engine brake/service
brake are coupled, with operation starting from first pedal
stroke length and keeping the position.
Every time the engine brake is inserted, the signalling panel
warning light turns on.
The insertion of engine brake together with accelerator pedal
disables all adjustment operations connected to Cruise
Control.
Operation
Independently from the type of selection being set, the EDC
electronic unit drives, through connector B pin 11, the engine
brake solenoid valve.
This one, by switching its state from N.C. to N.O., allows the
engine oil to flow to operating cylinder which, in turn,
operating on the engine exhaust throttle valve, allows braking
it.
Rear brakes
Rear brakes are:
- disc type on rear axle MS08-125, MS13-144,
MS13-164 MS13-165
- Drum brakes on tandem axle SP 145 E
In drum brakes, every braking assembly is composed of a body
in which adjustment, control pins and wedge units are housed.
Wedge units are actuated by cylinder stem in turn actuated
by compressed air.
Wedge unit rollers along their stroke generate control pin
expansion that, winning jaws return spring resistance,
approach jaws to drum dampening the brakings. Adjustment
and control pins are made integral with the brake body by two
pins that are inserted in a side milling. When the braking action
ceases, air pressure is lacking in the combined brake cylinder
membrane section, and consequently the jaws return spring
and wedge unit return spring actions take care of returning the
wedge units into their starting position.
Braking gaskets are equipped with a wear signaller.
ABD device phonic wheels are an integral part of brake disc
on H127E rear axle, while are keyed-in on wheel hubs in the
other rear axles with drum brake.
Rear axle MS08-125
- type: WABCO (PERROT) PAN 17 - 330x34
Rear axle MS10-144; MS10-164
- type: KNORR SN6 - 377x45
Parking braking
Print 603.93.111
33
DIAGNOSTIC
7
8
9
10
11
12
13
14 -
The complete diagnosis of electric and electronic components must be carried out through modus and IWT.
NO
NO
(continues)
Print 603.93.111
34
NO
NO
NO
NO
NO
YES
Print 603.93.111
35
NO
NO
NO
NO
NO
NO
(continues)
Print 603.93.111
36
NO
NO
NO
NO
NO
Print 603.93.111
37
NO
NO
NO
NO
NO
Print 603.93.111
YES
38
NO
NO
NO
NO
NO
Print 603.93.111
39
DELAYED PARKING
UNBRAKING
NO
NO
NO
NO
Print 603.93.111
40
NO
NO
NO
NO
(continues)
Base - February 2003
Print 603.93.111
YES
41
NO
YES
NO
10
INSUFFICIENT TRAILER
SLOWING-DOWN BRAKING
NO
NO
NO
Print 603.93.111
42
11
NO
NO
NO
12
YES
NO
NO
Print 603.93.111
13
43
NO
NO
14
NOISY BRAKES
NO
YES
NO
NO
NO
Print 603.93.111
44
TIGHTENING TORQUES
PART
TORQUE
Nm
(kgm)
27.5 2.5
13+3
(2.8 0.25)
(1.3+0.3)
388.5 18.5
27.5 2.5
188 18
40 4
106 11
55 5
195 15
(39.6 1.8)
(2.8 0.2)
(19 1.8)
(4 0.4)
(10.8 1.1)
(5.5 0.5)
(19.8 1.5)
388.5 18.5
27.5 2.5
299.5
40 4
130 10
55 5
195 15
(39.6 1.8)
(2.8 0.2)
(30.6)
(4 0.4)
(13 1)
(5.5 0.5)
(19.8 1.5)
515.5 24.5
27.5 2.5
615.5 61.5
41 4
130 10
55 5
195 15
(52.5 2.5)
(2.8 0.2)
(62.5 6.2)
(4 0.4)
(13 1)
(5.5 0.5)
(19.5 1.5)
Compressor
Head clamping screws
Connecting rods caps clamping screws
* Apply a bead of LOCTITE 574 sealant on the cover abutting surface by means of the special measuring device. Protect the
threaded portion.
Print 603.93.111
PART
TORQUE
Nm
(kgm)
864.5 86.5
187 19
40 4
195 15
150 15
490 50
30 -+ 06
(88.1 8.8)
(19 1.9)
(4 0.4)
(19.8 1.5)
(15.2 1.5)
(49.9 5)
3 -+ 00.6
187 19
40 4
150 15
932 98
490 50
(19 1.9)
(4 0.4)
(15 1.5)
(93 9.8)
(49.5 5)
281.5 13.5
289.5 14.5
932 98
262 35
738.5 61.5
(28 1.3)
(29 1.5)
(93 9.9)
(26 3.5)
(74 6)
392.3 20
289.5 14.5
(40 2)
(29 1.5)
(60 -+ 25 )
(23.2 2.4)
Print 603.93.111
45
+ 50
600 - 20
232.4 24.5
46
TOOLS
TOOL No.
DENOMINATION
99301001
99301005
99301006
99305087
Riveting press
6810
4 12
2 14
0 16
6 810
4 12
2 14
0 16
6 8 1012
4
14
2
0 16
6 8 10
4
12
2
14
0 16
810
12
14
16
99305117
99354207
Wrench (94.5 mm) for wheel hub covers (for front axles 5842/5
- 5851/5 - 5871/5)
Print 603.93.111
47
TOOLS
TOOL No.
DENOMINATION
99355038
Wrench (65 mm) for wheel hub cover (for front axle 5845) and
for wheel hub bearings adjustment nut (for front axles 5842/5 5851/5) (use with 99370317)
99355167
Wrench (114 mm) for wheel hub bearings adjustment nut (for rear
axles PR140E - PD145E)
99355177
Wrench (90 mm) for wheel hub bearings adjustment nut (for rear
axle MS08-125)
99355180
Wrench (105 mm) for wheel hub bearings adjustment nut (for rear
axle MS13-165)
99355182
Wrench (95 mm) for wheel hub bearings adjustment nut (for rear
axle MS10-144; MS10-164)
99356001
Print 603.93.111
48
TOOLS
TOOL No.
DENOMINATION
99363204
99370006
99370317
99370700
99370711
99370712
Print 603.93.111
49
TOOLS
TOOL No.
DENOMINATION
99370714
99370715
99370719
99372213
99372217
99372228
Hub for placing disassembled floating jaws turning tools (to be used
with 99301001) (for rear axle PR140E - PD145E)
Print 603.93.111
50
TOOLS
TOOL No.
DENOMINATION
99372229
99372239
Tool for mounting the thrust presser with brake caliper protection
99372240
99372242
99372243
Tool for mounting the thrust presser inner gaskets (to be used with
99372239) and the brake caliper guide pin brass bushing (to be
used with 99372240 and the screw of 99372237)
99372244
Tool for mounting the brake caliper guide pin rubber bushing (to
be used with the screw of 99372237)
Print 603.93.111
51
TOOLS
TOOL No.
DENOMINATION
99372245
Tool for disassembling the brake caliper guide pin rubber bushing
(to be used with the screw of 99372237)
99373002
Coupler for mounting the wheel hub inner gasket (for rear axle
PR140E - PD145E)
99374106
99374132
99374233
Keyer for assembling internal wheel hubs gasket (for front axles
5842/5 - 5851/5)
99386523
Print 603.93.111
52
TOOLS
TOOL No.
DENOMINATION
99387050
99388001
99389819
99395026
Print 603.93.111
53
CHARACTERISTICS
Compressor
- Type: KNORR
Displacement
Single-cylinder
225 cm3
- Type: KNORR
Displacement
Single-cylinder
359 cm3 (*)
Drier
Disconnection pressure
Heat resistance
max + 100 C
Operating temperature
Supply voltage
Power
-40 C +80 C
24 V
100W 24V
7.5 bar
8.0 bar
6.5 bar
Drier
Disconnection pressure
15.5 2 bar
Heat resistance
max + 80 C
Operating temperature
Supply voltage
Power
-40 C +65 C
24 V
100W 24V
Print 603.93.111
7.5 bar
+0.5
bar
+1
-0
bar
6.5 -0
6.5
54
DENOMINATION
CHARACTERISTICS
Air tanks
Front axle
Rear axle
Trailer + parking (for vehicles adapted for towing)
Front axle (for vehicles adapted for towing and Models 180E..)
Rear axle (for vehicles adapted for towing and Models 180E..)
15 l
15 l
20 l
20 l
20 l
13 bar
13 bar
Safety valve
Calibration for models with mechanical suspension (optional)
12 1.2 bar
12 1.2 bar
Duplex distributor
- Type: KNORR DX 65 A - DX 65 B
Supply pressure
Self-limiting pressure
11 0.2 bar
7.6 0.3 bar
18 bar (max)
+0
-0.4
Output pressure
8.5
10 0.5 bar
bar
11 bar
8.5
+0
-0.4
bar
11 bar (max)
Relay valve
- Type: KNORR AC 574 AXY
Maximum operating pressure
10 + 0.2 bar
-40 40C
Check valve
Maximum operating pressure
20 bar
11 bar
Operating pressure
7.5 bar
Control lever excursion (discharging) with safety braking start (resistance point)
67
Parking braking
73
Print 603.93.111
DENOMINATION
55
CHARACTERISTICS
8.5 bar
Control lever excursion (discharging) with safety braking start (resistance point)
67
Parking braking
73
86
11 bar
4 -+
0
0.6
bar
10 bar
8.5 bar
0.2 bar
2.5
+ 0.5
- 0.3
bar
12 bar
7.5 bar
12.5 bar
Membrane brake cylinder (for front axles - models 110 EL.. - 120 EL..)
- Type 22: WABCO 423 110 711 0
Max. operating pressure
Print 603.93.111
10 bar
56
DENOMINATION
CHARACTERISTICS
Membrane brake cylinder (for front axles - models 120 E.. - 130 E..)
- Type 14: KNORR IC 72563
Max. operating pressure
10.7 bar
10.7 bar
10.7 bar
10.7 bar
10.7 bar
10.7 bar
10.7 bar
10.7 bar
Combined brake cylinder (for rear axles - models 110 EL.. - 120 EL..)
- Type 16/16: WABCO 925 424 839 0
Max service brake operating pressure
10 bar
8.5 bar
Spring load
6500 N
Combined brake cylinder (for rear axles - models 120 E.. - 130 E..)
- Type 16/27: KNORR - BREMSE BS 8317/BS 8316
Stroke
57 mm
Print 603.93.111
DENOMINATION
57
CHARACTERISTICS
57 mm
57 mm
10.7 bar
8.5 bar
Minimum stroke
64 mm
8.5 bar
22 26 V
10 bar
13 bar
Print 603.93.111
58
Front axles
5851/5 - 5842/5
Rear axles
MS10-144
MS10-164
Front axle
5871/5
Rear axle
MS13-165
Floating caliper
PAN 17
Floating caliper
SB6 - SN6
Floating caliper
KNORR SN7
68
- number
- diameter
mm
mm
19
21
21
- minimum allowed
mm
mm
330
377
432
mm
34 33.85
45
45
- minimum allowed
28
41
41
mm
WHEEL HUBS
UNIT BEARING
3
(0.3)
Not adjustable
(securing ring nut torque tightening)
5
(0.54)
L* (Kg)
0.23 (0.2)
0.33 (0.3)
* The oil amounts refer to front axles; the amounts referring to rear axles will be specified in the next edition.
Print 603.93.111
59
PD 145 E (R2468)
PR 140 E (R0868)
INTERMEDIATE
REAR
Drum diameter:
- Rated
- 1st increase
- 2nd increase
mm
mm
mm
380.9 to 381.1
382.9 to 383.1
384.9 to 385.1
S
S
S
S
mm
mm
mm
mm
18
19
20
6.5
(in the area where a wear is signalled)
- 1st increase
- 2nd increase
mm
mm
mm
378 to 380
380 to 382
382 to 384
mm
177 to 178.6
0.45 to 1.55
mm
0.04
Print 603.93.111
0 to 0.05 mm
16.2 (14.6)
12.2 (11)
60
Always lock the vehicle, before any intervention. Periodically check the manometers by comparing them with a sample
manometer.
DEVICE
DENOMINATION
INTERVENTIONS
Compressor
Air tanks
Humid
Front axle
Rear axle
Trailer + parking
Duplex distributor
Completely press the pedal; when the action ceases, the pedal must
immediately go back into its rest position.
Pressure limiting: 7.6 0.3 bar.
Check that the pedal gasket is not worn, that brake control tie-rods
are well tightened and lubricated, nor distorted. Check that lever
housings are neither worn nor oxidised.
Relay valve
(continues)
Base - February 2003
Print 603.93.111
DEVICE
61
DENOMINATION
INTERVENTIONS
Coupling heads
Hydraulic or pneumatic pressure Make sure that protection plugs are inserted, check that they are
control plugs
completely screwed.
Membrane cylinder
Combined cylinder
(continues)
Print 603.93.111
62
DEVICE
DENOMINATION
INTERVENTIONS
Check braking gaskets wear status, brake disc scorings and wear,
pistons efficiency, dust-guarding casing wear conditions.
Drum brakes
When ceasing the pressure on the pedal, the jaws must quickly and
smoothly go back on all wheels to their rest position.
Check clearance between jaws and drum.
Check braking gaskets thickness.
Pneumatic system seal with off This check is carried out on threaded fittings, inserting an air pressure
engine under the disconnection not less than 5 bar into the system, laying rather dense soapy water
on joints and fittings with a soft brush and observing that there are
pressure
no leakages. An air loss is tolerated corresponding to a 25 mm
soap bubble in 5 seconds, or anyway a max pressure drop within 10
min of 2% of disconnection pressure = 0.22 + 0.02 bar.
Pneumatic system seal in the
partial braking range with 3 bar
Print 603.93.111
63
COMPRESSOR
- Knorr
Figure 30
30411
Diagnostics
INCONVENIENCE
Oil leakages from flange, external side
Scarce efficiency
Mechanical noise
Water blow-by
Print 603.93.111
POSSIBLE REASON
Incorrect tightening torque.
REMEDY
Lock the screws according to the required values.
Not perfectly plane flange body sealing surfaces. Check sealing surfaces, replace faulty parts or take them
back on a plane.
Broken gasket.
Replace gasket.
Damaged shaft gasket.
Replace gasket.
Worn scraper ring (it is noted because all the Replace the whole piston
sealing seat is shining).
Faulty scraper ring assembling.
It must be assembled with the writing TOP toward the
compressor head
Scraper ring and elastic bands all on the same Assemble piston rings at 120 one form the other
vertical line.
Scored or ovalised cylinder.
Grind the cylinder and assemble a greater piston
Deteriorated compression or suction valve.
Elastic bands all on the same vertical line.
64
Figure 31
Figure 32
62628
Pneumatic connections
Drier
1From compressor
3Exhaust
24 - To services
25 - To pneumatic suspension
4-way valve
21 - To rear axle air tank
22 - To front axle air tank
23 - To parking plus trailer air tank
24 - To services
Electric connections
6.1 - Negative for thermostatic resistance
Print 603.93.111
65
Operation
Figure 33
62629
Recharge phase:
The compressed air coming from the compressor through
the supply fitting 11 is arranged on the safety valve a
(calibrated at 13+4 bar) and through the suitable channel it
reaches the drier filter.
(continues)
Print 603.93.111
66
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Excessive amount of
condensate in the circuit
Print 603.93.111
543730
67
Figure 36
62372
72658
793336
Figure 37
Figure 35
62382
Print 603.93.111
71957
68
Electric connections
1 - Free
2 -
3 -
Input positive
4 -
EDC positive
Figure 40
71959
793110
DUPLEX DISTRIBUTOR
Figure 39
62579
71951
Print 603.93.111
69
Piston push rod seat (4) initially closes the exhaust and
afterwards opens upper valve (6). Compressed air, from fitting
11, passes and supplies fitting 21, rear axle and chamber A.
Figure 41
Unbraking
By releasing the brake pedal, the control push rod (2) and the
piston assembly (1 and 4) return upwards together with
piston (7).
By going on releasing the brake pedal, the valves remain into
their respective entry seats and afterwards the exhaust seats
of pistons (4 and 7) are detached from valves and air flows to
the atmosphere through exhaust 3.
At the end of the release, also microswitches (3) return to
their running position.
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Springs wear.
Print 603.93.111
70
793321
Pressure limitation
Figure 44
Figure 42
34953
Operation
- System supply
Figure 43
Bench calibration
Assemble the device on the test bench, and connect fittings
1 and 2 through pipings to manometers and supply. Adjust
through an adjustment screw at the pressure value of 7.5-0.3
-0
bar, and simultaneously check the perfect seal thereof.
70118
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Fitting 2 pressure
different from
calibration pressure
Uncalibrated valve.
Sealing rings leakage.
Print 603.93.111
793331
71
RELAY VALVE
Figure 45
72659
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Leakage from piston gasket or dis- Revise the device replacing the faulty parts.
charge valve.
793319
CHECK VALVE
Operation
Figure 46
Figure 47
25958
Print 603.93.111
72
794310
Figure 48
78619
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Difficult distributor
control lever
rotation
Print 603.93.111
794310
73
Figure 49
78618
21 -
To spring cylinders
22 -
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
In unbraking position
In braking position
Print 603.93.111
74
Predominance adjustment
The apparatus is equipped with a predominance adjusting
device.
Figure 52
71952
793332
bar
Figure 51
60255
62373
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Output pressures
different from the
established ones
Print 603.93.111
798510
75
COUPLING HEADS
- Moderate
Figure 55
- Automatic
Figure 53
71953
52871
794911
Operation
Figure 54
Figure 56
72657
Print 603.93.111
71954
76
794922
Repair interventions
Figure 59
Figure 57
36744
35721
Figure 58
36745
Diagnostics
INCONVENIENCE
POSSIBLE REASON
Deterioration of parts composing the Revise the device replacing the worn parts and if necessary
spring section.
replace the complete cylinder.
Braking force
decrease during
parking brakings
Spring breakage.
REMEDY
Print 603.93.111
77
Operation
526713
526712
REVOLUTIONS SENSORS
PHONIC WHEELS
Figure 61
526711
ELECTRONIC UNIT
Figure 60
35383
Operation
71955
The electronic unit is the system brain. Its task is driving the
system solenoid valves depending on signals measured by
wheel revolutions sensors.
Print 603.93.111
78
- Pressure decrease
Figure 64
71956
2 -
3 -
Exhaust.
35381
Operation
The electro-pneumatic valve modulates air pressure in the
brake circuit according to the signals received from the
electronic control unit in the three phases:
- Pressure increase
- Pressure keeping
Figure 65
Figure 63
35380
35382
Print 603.93.111
BRAKE REPAIRS
MODELS ML 110 EL.. / 120 EL..)
5274
Front Brakes
(Brake calipers of the PAN 17 type)
5272
Rear Brakes
(Brake calipers of the PAN 17 type)
Description
The PAN 17 (PERROT-AXIAL-NEW) brake mechanically
operates by means of a membrane brake cylinder if
assembled on front axle, or of a spring brake cylinder if
assembled on rear axle; the above cylinders are flanged to
brake caliper body.
The brake caliper is of the floating type. It axially slides on
guide pins (3 and 28) assembled on support (2) and braking
gaskets (7 and 9), also subjected to axial movements, are kept
inside the brake support (2) by a check fork (21). In this way
the braking force is transmitted to abutment surfaces inside
the support (2).
The brake caliper (17) is transversally placed inside the brake
caliper (1), and its rotary movement, during the locking phase,
ensures an optimum operation for the brake and a small
hystheresis.
This type of brake is equipped with braking gaskets (7-9) with
large wear volume in order to extend their replacement
times.
The braking gasket replacement operation is made easier and
quicker by this very model of caliper characterised by a radial
type of opening.
In order to compensate for sliders wear, the actuator
mechanism is provided with an infinitely-varying automatic
adjustment device, whose action changes according to the
applied force. This provides a constant clearance,
independently from the level of use or application of the
brake and together with a sturdy and rigid caliper structure,
it ensures minimum actuator cylinder strokes, contributing to
increase emergency braking safety coefficients.
With the direct brake cylinder assembly on caliper a very
compact assembly is obtained with following chance of
optimally using the device, that is the widest steering angle
possible.
79
Print 603.93.111
80
Figure 66
61961
SECTION A-A
1. Brake caliper- 2. Braking gaskets support - 3. Guide pins - 4. Screw - 5. Return sleeve - 6. Driven sleeve - 7.Braking gasket
- 8.Brake disc - 9. Braking gasket - 10. thrust plate - 11. Screw - 12. Adjustment nut - 13. Thrust element 14. Spring - 15. Spring - 16. Plug - 17. Brake lever - 18. Ball bearing - 19. Ball bearing - 20. Small springs - 21. Fork 22. Screw - 23. Washer - 24. Brake caliper cover - 25. Pin - 26. Screw - 27. Spring - 28. Guide pin.
Print 603.93.111
527417
81
!
40570
Figure 68
Remove dirt and rust around the braking disc edge with a
scraper or an old screwdriver, resting on the caliper body,
making disk (1) rotate.
End the work with abrasive cloth. Remove residuals by using
a suction device or with canvasses and brush.
Do not use petrol or other petroleum derivatives that could
create brake failures.
Use only denatured alcohol with methanol or isopropyl
alcohol.
Accurately clean brake disc braking area surfaces.
Checks
60342
82
527413
527413
Disassembly
Figure 71
Figure 69
60336
60638
!
Figure 72
Figure 70
60639
Reconnection
For the reconnection, reverse the operations
performed for the disconnection and comply with
the required tightening torques. At the end of
reconnection operations, verify the wear
recovering device efficiency as described in the
related chapter.
Base - February 2003
61993
Figure 74
83
Figure 76
61996
61994
Figure 75
Assembly
Figure 77
61995
Print 603.93.111
60644
84
At the end verify that casings (7 and 8, Figure 79) are not
damaged, and that brake caliper freely slides on pins, slightly
and carefully lift casings (8, Figure 79) lip from sliding pins to
discharge possible pressurised air formed inside them.
Figure 78
Figure 80
60648
Place brake caliper (3) on support (2) so that sliding pins (10,
Figure 79) are inserted in support seats (2). Screw new
screws (1 and 4).
60649
Assemble new plugs (1) into brake caliper (2) bushes housing
holes.
Figure 79
61962
The parts must be replaced upon every disassembly with new ones.
Print 603.93.111
Figure 81
85
Figure 83
61995
61998
Figure 84
Figure 82
61999
Lubricate sliding pins (2 and 3) and insert them into casings (4)
and brake caliper (1).
61997
Print 603.93.111
86
527411
Figure 85
max 0.75
Figure 87
max 0.5
35707
60651
Examine the brake discs; they must not show breakages, and
their surface must not show cracks densities greater than the
one shown in sector A;
-
Figure 88
Figure 86
35704
60351
Print 603.93.111
87
5274
BRAKE REPAIRING
Front brakes (Brake caliper KNORR SB6 type)
Figure 89
49151
SECT. A-A
49152
1. Dry bush - 2. Braking gasket - 3. Threaded barrel - 4. Spring split pin - 5. Braking gaskets check plate - 6. Check plate 7. Small pin - 8. Brake caliper - 9. Carrier plate - 10. Small piston - 11. Cap - 12. Sliding bush - 13. Rubber guide bush 14. Sliding pin - 15. Dragging device - 16. Cover - 17. Screw - 18. Chain wheel disc - 19. Chain - 20. Plug - 21. Adjustment
device - 22. Protection casing - 23. Securing band - 24. Sliding pin - 25. Brass guide bush - 26. Sliding bushing - 27. Internal
protection - 28. Brake disc - 29. Rear axle - 30. Lever - 31. Membrane cylinder - 32. Pressure springs.
Print 603.93.111
88
78397
78396
SEZ. AA
1. Dry bush - 2. Threaded hose - 3. Piston - 4. Washer - 5. Spring split pin - 6. Pin - 7. Retaining plate - 8. Supporting plate - 9.
Guide pin - 10. Guide bush - 11. Sliding pin - 12. Plug - 13. Dragging device - 14. Wear sensor - 15. Rear axle 16. Chain - 17. Spring- -18. Cover - 19. Adapter - 20. Chain gear - 21. Adjusting device- -22. Cover - 23. Brass bush 24. Sliding pin - 25. Sliding bush - 26. Inner protection - 27. Ring - 28. Brake lining - 29. Brake disc body - 30. Lever 31. Cam bearing.
Print 603.93.111
89
Figure 92
78622
Remove the plug (4) using the tab (3) and make sure the
adapter is not lost.
Figure 93
CHECKS
Checking the automatic play recovery system
efficiency
Figure 91
60759
Operate the brakes for about 5-10 times and make sure the
wrench (1) moves clockwise with small increments, up to
complete recover of play between braking linings and brake
disc.
Otherwise, i.e. if the wrench does not turn, turns just once or
turns in both directions, this means the automatic play
recovery system is faulty. Replace the caliper, following the
procedure given subsequently, then fit back the wheels.
Print 603.93.111
90
49155
Figure 95
A1
49156
Print 603.93.111
91
Figure 96
78625
Print 603.93.111
92
Figure 100
49158
40569
Arrange the vehicle on a plane ground and lock its rear wheels;
loosen nuts (1) securing the front wheels.
With an hydraulic jack lift the vehicle from its front side and
rest it on two support stands (2).
Figure 101
Figure 98
78623
40570
Remove cap (3), act on adjusting unit (1) with the adapter
fitted, by means of a wrench, in a counter-clockwise direction,
so as to make pistons go back into the caliper body, then
remove braking gaskets (5) by properly floating caliper body
(4).
Figure 99
Figure 102
49157
Remove screw (1) and plate (2) for checking wear sensor
cables.
Base - February 2003
60862
Press () the spring (1) and remove it; replace it with a new
one if necessary.
Print 603.93.111
Figure 103
93
Figure 104
49162
49161
Remove dirt and rust around the braking disc edge with a
scraper or an old screwdriver (2), resting on the caliper body,
making disk (1) rotate.
End the work with abrasive cloth. Remove residuals by using
a suction device or with canvasses and brush.
Do not use petrol or other petroleum derivatives that could
create brake failures.
Use only denatured alcohol with methanol or isopropyl
alcohol.
Accurately clean brake disc braking area surfaces.
Insert wear sensor (2) into its suitable seat on braking gasket
(3).
Assemble spring (1) proceeding in reverse with respect to
disassembling.
Figure 105
49163
Insert new gaskets in brake caliper (1) and check that they
freely slide into their own seats.
!
Verify that the caliper freely rotates on its guides.
If anomalies are detected on one brake caliper only, it is
advisable to proceed with the complete revision of both brake
calipers.
Remove dirt from brake caliper using a metal brush and
avoiding to damage dust-guarding casings.
Clean braking gaskets sliding surfaces.
Check brake disc conditions and make sure that it is not
corroded, scored or grooved. Slight surface cracks are
acceptable, but it is necessary to go on grinding the brake disc
as described in the related chapter, otherwise if worn, replace
the brake disc.
If there occurs the need of replacing, it is advisable to replace
both brake discs.
Check springs and wear sensors conditions, if necessary
replace them.
Figure 106
78624
Using the wrench (1), act on the adaptator retriever pin to get
a play not lower than 0.7 mm between brake lining and brake
disk, which can be measured using the thickness gauge (2).
Replace the cover (4) and lubricate it with white grease
RENOLIT HLT2.
Print 603.93.111
94
527413
Make sure that the outer protecting plug and the seal
ring are correctly fitted, in order to prevent water
leaks inside the play automatic retriever.
Figure 107
49166
49158
49167
49165
Print 603.93.111
95
Reconnection
Figure 114
For reconnecting, reverse performed operations for
disconnecting and comply with the required
tightening torques.
520620
38956
77206
Reconnection
Make sure that surfaces of all parts inside the hub are
accurately clean, free from slags and burrs.
Lubricate the bearings with SAE W 140/MDA oil.
Key-in wheel hub completed with brake disc on stub
axle. Insert internal spacer on stub axle, then place
external bearing and shoulder washer.
36407
Figure 115
36411
36408
96
Figure 116
49168
Figure 119
36412
Apply tool (1) 99395026 on wheel hub stud bolts and use
torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
49169
78322
Rotate the wheel hub until when hub cover (1) is positioned
as shown in the figure. Restore the prescribed quantity of oil
into the hub cover (1) through filling hole (2). Tighten the plug
on the hub cover (1) to the set torque.
49170
Print 603.93.111
Figure 121
97
Assembly
49171
Figure 122
49172
Figure 123
49173
Print 603.93.111
98
Figure 124
Figure 126
49174
49176
Figure 125
49175
Print 603.93.111
99
Figure 130
Figure 127
79121
Place the brake caliper on the bench and block it in a vice. Remove
the cover (1) and make a hole in it with a Parker screw.
Figure 128
79124
Figure 131
79122
Refit the supporting plate (1) and remove the fastening screws
(2).
Figure 129
79123
79125
Print 603.93.111
100
Figure 132
Assembly
Make sure all the brake caliper components are perfectly
clean. Possible abrasive residuals should be removed with a
cloth soaked in isopropyl alcohol or similar.
Figure 133
60742
Place the caliper on the bench and block it in a vice. Use the
wrench (4) to operate the clearance recovery device so that
the piston (1) comes out of the caliper body for a maximum
of 30 mm (value A).
Take off the dust-guard from the caliper body and use tool
99372238 (5) to remove the thrust pressing devices (1) of the
caliper together with the protection casings (3).
79126
Use tool 99372244 (2) (to be used with the screw in tool
99372237) to assemble the rubber sleeve (1).
Base - February 2003
Print 603.93.111
Figure 135
101
Figure 137
79128
Use tool 99372243 (1) (to be used with tool 99372240 and
use screw in tool 99372237) to assemble the brass bush (2)
in its seat, by blocking its rotation by means of a suitable tool
(3) (punch or screwdriver).
60745
Figure 136
79130
Place the caliper on the bench and block it in the vice. Fit the
protection casing (2) by means of tool (1) 99372237.
79129
Place the caliper under the press. Use the press to fit the brass
bush (1) in its housing until is comes out of the lower side by
1 mm.
Print 603.93.111
102
527411
Figure 140
35704
527411
527411
Figure 141
Figure 139
35707
38597
Print 603.93.111
5272
103
Figure 142
37490
DIRECTION OF
ROTATION
74059
INTERMEDIATE AXLE
Print 603.93.111
REAR AXLE
104
27230
Figure 147
Figure 144
17239
36748
Figure 148
Figure 145
17237
Figure 149
17238
17240
17241
Print 603.93.111
Figure 150
105
Figure 153
36745
Figure 151
38704
Figure 154
38354
17243
Figure 152
Figure 155
38352
38355
With the help of tool 99372217 (3), detach jaws (4) checking
springs (2); detach jaws (4) from check brackets (5) after
having detached braking gaskets wear sensor (1).
Print 603.93.111
106
Figure 156
Figure 158
38356
38358
Unscrew guiding pin (2) from small piston (1) and extract the
piston from the brake body. With a screwdriver, undrive metal
ring (4).
Unscrew guiding pin (3) of thrust pin (5) and extract this latter
one from brake body.
38359
Check the wear status of adjustment pins (2) and thrust pins
(1) sliding surfaces, further check chutes (3) surfaces on which
jaws opening control rollers operate.
Figure 160
Figure 157
38357
38360
Print 603.93.111
527231
Figure 161
107
DRUM TURNING
38361
17252
Insert on lathe 99301001 shaft (3) the drum (1) completed with
wheel centring it with suitable centring bushes.
Key-in on the shaft a series of spacers that remove axial
assembly clearance, screw the locking nut and apply the lathe
support.
Figure 164
Figure 162
17253
35713
Check that wedge units easily slid and parts do not show
abrasions.
!
!
Print 603.93.111
108
527233
527233
Figure 167
Figure 165
17255
38362
Figure 166
38363
35713
Print 603.93.111
109
Assembly
Figure 169
Figure 171
38364
38366
Insert thrust pin (1) into brake body (3) seat so that the slot
is facing the drive pin (2).
Grease and insert complete guide pin (2) into brake body seat
(3); make sure that washer (5) is inserted and screw some
turns.
!
!
Figure 170
Figure 172
38365
38367
Print 603.93.111
110
Figure 173
Figure 175
38368
38370
By using keyer 99373002 (2) drive the metal ring (1) of sealing
gasket on brake body.
Proceed as described for assembling the other jaws opening
control units.
Figure 176
Figure 174
17268
38369
Insert thrust pin (4) into brake body (1) so that the notch is
facing the guide pin (2) hole.
Grease and screw guide pin (2) at the required torque.
35717
Manually screw ring nut (2) on barrel (1) till its end of stroke.
Apply non-hardenable sealing paste, LOCTITE 573 type, on
first barrel threads.
Print 603.93.111
Figure 178
111
Figure 181
38705
38375
Figure 179
38373
Figure 182
17301
38374
Assemble jaws (1) into their suitable seat so that the punched
arrow (2) is oriented along the forward-running drum rotation
direction.
Hook jaws return springs (3 and 5) using tool 99372217 (4).
Print 603.93.111
Lubricate bearings seat on barrel (3) and wheel hub sealing ring
with TUTELA W 140/MDA oil.
By using hydraulic trolley 99321024 (1), place complete wheel
(2) so that internal hub diameter is perfectly centred on rear
axle case barrel (3). Place tapered roller bearing (4) into wheel
hub. Insert complete wheel till the end of its seat, taking care
of aligning wheel hub with barrel (3) to avoid damaging sealing
gaskets profiles.
112
Figure 183
Figure 186
35768
35770
Place comparator (1) with magnetic base on hub (3). Abut rod
onto barrel (2) and check that maximum axial hub clearance is
0.05 mm.
Figure 187
Figure 184
35769
Assemble the safety ring (2): if the nut (1) stop dowel does not
coincide with one of the safety ring (2) holes, change nut (1)
position taking also into account the clearance obtained in the
previous operation.
Figure 188
Figure 185
35768
35771
35772
Print 603.93.111
Figure 189
Figure 190
38706
Print 603.93.111
113
36765
114
Print 603.93.111
BODY - CHASSIS
SECTION 12
5501 Body
5001 Chassis
Page
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General information . . . . . . . . . . . . . . . . . . . . .
- Protective treatment . . . . . . . . . . . . . . . . . . . .
- Welding instructions . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS FRAME . . . . . . . . . . . . . . . . . . . . . . . . .
10
Print 603.93.111
10
11
12
CAB GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . .
19
20
23
BODY - CHASSIS
Page
FIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Cab anchoring . . . . . . . . . . . . . . . . . . . . . . . . .
27
27
27
28
29
29
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
- Vibration knife . . . . . . . . . . . . . . . . . . . . . . . . .
29
- Harmonic wire . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
30
31
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
33
34
34
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . .
36
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
42
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Print 603.93.111
5501
BODY - CHASSIS
CAB
General information
The cab is an advanced one, it can be tipped up hydraulically with a mechanical control.
Tilting angle 57.
Pressed and welded steel framework, parts made of electro-galvanized sheet steel.
Sound deadening on the underbody and anticorrosion protection in the boxed compartments.
The cab suspension is mechanical.
Figure 1
78688
Print 603.93.111
BODY - CHASSIS
78692
Print 603.93.111
BODY - CHASSIS
Print 603.93.111
BODY - CHASSIS
Spot welding
This must be workmanlike. Take special care over the setting of the device so as to make spot welds that ensure a fully efficient
join. Avoid positioning spots near the edge of the parts to weld.
The areas of the chassis frame involved in welding must be thoroughly cleaned and, after welding, protected with
two-component epoxy rust-proofing or another similar product, and with another coat of single- or two-component
paint.
The earth cable of the welding system must be connected on the chassis frame as close as possible to the welding zone, and never
near a rotating part (transmission, wheel hubs, etc.) nor above or under an assembly with moving parts (compressor, bearings, etc.).
Welding instructions
Before welding, which must be done so as to minimize the tension and deformation that may be created, remove the paint and
carefully deoxidize the surfaces involved.
Classification of corresponding steels in the EU:
French standards
A 35 501
German standards
DIN 17 100
British standards
BS 4360
American standards
ASTM
E 24.2
E 26.3
E 36.4
Italian standards
UNI - 7070
R-St. 37.2
St. 42.3
St. 52.3
Swedish standards
MNC - 810
40 B
43 C
50 D
Spanish standards
UNE - 36 080
A 283 gr. D
A 284 gr. C
Belgian standards
NBN 631
Fe 37.B
Fe 42.C
Fe 52.D
13.12.00
14.13.00
21.34.01
A 360.B
A 410.C
A 510.D
AE 22B or AE24B
AE 26 C
AE 36 D
Print 603.93.111
BODY - CHASSIS
PRECAUTIONS
Figure 3
Figure 5
17360
17358
Figure 4
Figure 6
17359
17361
Print 603.93.111
BODY - CHASSIS
Figure 8
17364
17362
A 0,3 H
b H (min. 175 mm)
S (0,8 1) S1
17365
17363
Print 603.93.111
BODY - CHASSIS
5001
CHASSIS FRAME
REPAIRS AND CHECKS
Figure 11
17347
Figure 9
Figure 12
17344
Figure 10
Figure 13
17345
Carefully check for any peeling or cracking all over the chassis
frame, paying special attention to joints under great strain,
such as: chassis frame cross members, brackets, mounts of
leaf springs and chassis frame structural members.
Mark any peeled or cracked points straight away.
17349
Print 603.93.111
10
BODY - CHASSIS
Figure 14
Figure 17
17350
17353
17351
Figure 16
17352
17354
Print 603.93.111
BODY - CHASSIS
11
Figure 19
17355
Figure 20
17356
17357
12
BODY - CHASSIS
Figure 22
II
78284
Dimension
(mm)
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
3105
1001.25
720
1080
1912.5
3330
1001.25
720
1080
1912.5
405
405
405
405
990
840
967.5
840
967.5
832.5
135
787.5
1147.5
1080
3105
1313
5498
832.5
135
787.5
1080
3330
1830
6240
4455
1001.25
720
1080
2182.5
3262.5
405
405
1440
840
967.5
2272.5
1755
840
967.5
2272.5
1890
840
967.5
2272.5
832.5
135
787.5
1665
1080
3690
1830
6600
832.5
135
787.5
1980
1080
4185
2145
7410
832.5
135
787.5
2115
1080
4455
2280
7815
4815
1001.25
720
1080
2182.5
3217.5
405
405
1260
2115
840
967.5
2272.5
3127.5
832.5
135
787.5
2340
1080
4815
2505
8400
Print 603.93.111
Models:
BODY - CHASSIS
13
Figure 23
78285
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
Print 603.93.111
4455
1001.25
720
1080
2182.5
3262.5
405
405
3105
1001.25
720
1080
1912.5
3330
1001.25
720
1080
1912.5
405
405
405
405
990
840
967.5
840
967.5
1440
840
967.5
2272.5
1755
840
967.5
2272.5
1890
840
967.5
2272.5
832.5
202.5
787.5
832.5
202.5
787.5
832.5
202.5
787.5
832.5
202.5
787.5
4815
1001.25
720
1080
2182.5
3217.5
405
405
1260
2115
840
967.5
2272.5
3127.5
832.5
202.5
787.5
1080
3330
1830
6240
1080
3690
1830
6600
1080
4185
2145
7410
1080
4455
2280
7815
1080
4815
2505
8400
832.5
202.5
787.5
1147.5
1080
3105
1313
5498
14
BODY - CHASSIS
Models:
Figure 24
II
78286
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
3105
1091.25
697,5
1732.5
3690
1091.25
1080
2182.5
4185
1091.25
1080
2182.5
2970
405
405
405
405
405
405
405
405
1215
840
1170
1642.5
840
1170
2272.5
1170
1957.5
840
1170
2272.5
832.5
157.5
810
832.5
157.5
810
1147,5
1170
3105
1313
5588
1575
1170
3690
1740
6600
5175
1091,25
1080
2182.5
3082.5
3960
5670
1091,25
1080
2182.5
3217.5
4252.5
405
405
405
405
1170
2092.5
840
1170
2272.5
1170
2362.5
840
1170
2272.5
3307.5
1575
2587.5
840
1170
2272.5
3307.5
405
405
1282.5
2092.5
2902.5
840
1170
2272.5
3307.5
832.5
157.5
810
832.5
157.5
810
832.5
157.5
810
1890
1170
4185
2055
7410
2025
1170
4455
2190
7815
2295
1170
4815
2460
8445
832.5
157.5
810
1372.5
2520
1170
5175
2685
9030
832.5
157.5
810
1485
2835
1170
5670
3000
9840
6570
1091,25
1080
2182.5
3217.5
4297.5
5152.5
405
405
1440
2587.5
3397.5
840
1170
2272.5
3307.5
4207.5
832.5
157.5
810
1980
3330
1170
6570
3495
11235
Print 603.93.111
Models:
15
BODY - CHASSIS
Figure 25
78287
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Print 603.93.111
3105
1091.25
697.5
1732.5
3690
1091.25
1080
2182.5
4185
1091.25
1080
2182.5
2970
5175
1091.25
1080
2182.5
3082.5
3960
5670
1091.25
1080
2182.5
3217.5
4252.5
405
405
405
405
405
405
405
405
405
405
405
405
1170
2092.5
840
1170
2272.5
1170
2362.5
840
1170
2272.5
3307.5
1575
2587.5
840
1170
2272.5
3307.5
405
405
1282.5
2092.5
2902.5
840
1170
2272.5
3307.5
1215
840
1170
1642.5
840
1170
2272.5
1170
1957.5
840
1170
2272.5
697.5
157.5
675
697.5
157.5
675
697.5
157.5
675
697.5
157.5
675
697.5
157.5
675
1890
1170
4185
2055
7410
2025
1170
4455
2190
7815
2295
1170
4815
2460
8445
697.5
157.5
675
137.5
2520
1170
5175
2685
9030
697.5
157.5
675
1485
2835
1170
5670
3000
9840
1147,5
1170
3105
1313
5588
1575
1170
3690
1740
6600
6570
1091.25
1080
2182.5
3217.5
4297.5
5152.5
405
405
1440
2587.5
3397.5
840
1170
2272.5
3307.5
4207.5
697.5
157.5
675
1980
3330
1170
6570
3495
11235
16
BODY - CHASSIS
Models:
Figure 26
78288
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
5670
1091.25
1080
2182.5
3217.5
4252.5
405
405
1170
1710
840
1170
2272.5
3307.5
405
405
1170
1980
840
1170
2272.5
3307.5
405
405
1462.5
2092.5
840
1170
2272.5
3307.5
3690
1091.25
1080
2182.5
4185
1091.25
1080
2182.5
2970
4590
1091.25
1080
2182.5
3217.5
405
405
405
405
405
405
1032,5
840
1170
2272.5
1170
840
1170
2272.5
1507,5
840
1170
2272.5
832.5
157.5
832.5
157.5
840
832.5
157.5
840
832.5
157.5
840
832.5
157.5
840
832.5
157.5
840
832.5
157.5
840
902.5
1170
3690
1133
5993
1147.5
1170
4185
1313
6668
1504
1170
4590
1650
7410
1707
1170
4815
1853
7838
1977
1170
5175
2123
8468
2089
1170
5670
2235
9075
2089
1170
6210
2235
9615
6210
1091.25
1080
2182.5
3217.5
4095
4905
405
405
1417.5
2092.5
840
1170
2272.5
3307.5
4185
6570
1091.25
1080
2182.5
3217.5
4095
5062.5
405
405
1417.5
2632.5
840
1170
2272.5
3307.5
4185
4972.5
832.5
157.5
840
1507.5
2629
1170
6570
2775
10515
Print 603.93.111
Models:
17
BODY - CHASSIS
Figure 27
78289
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Print 603.93.111
5670
1091.25
1080
2182.5
3217.5
4252.5
405
405
1170
1710
840
1170
2272.5
3307.5
405
405
1170
1980
840
1170
2272.5
3307.5
405
405
1462.5
2092.5
840
1170
2272.5
3307.5
697.5
157.5
906
697.5
157.5
906
697.5
157.5
906
697.5
157.5
906
697.5
157.5
906
1504
1170
4590
1650
7410
1707
1170
4815
1853
7838
1977
1170
5175
2123
8468
2089
1170
5670
2235
9075
2089
1170
6210
2235
9615
3690
1091.25
1080
2182.5
4185
1091.25
1080
2182.5
2970
4590
1091.25
1080
2182.5
3217,5
405
405
405
405
405
405
1032,5
840
1170
2272.5
1170
840
1170
2272.5
1507,5
840
1170
2272.5
697.5
157.5
697.5
157.5
906
902.5
1170
3690
1133
5993
1147.5
1170
4185
1313
6668
6210
1091.25
1080
2182.5
3217.5
4095
4905
405
405
1417.5
2092.5
840
1170
2272.5
3307.5
4185
6570
1091.25
1080
2182.5
3217.5
4095
5062.5
405
405
1417.5
2632.5
840
1170
2272.5
3307.5
4185
4972.5
697.5
157.5
906
1507.5
2629
1170
6570
2775
10515
Base February 2003
18
BODY - CHASSIS
Models:
Figure 28
*
I
II
III
=
=
=
=
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
78290
4186
1091.25
832.5
1080
2182.5
405
405
1282.5
1102.5
1652.5
840
1170
2272.5
1380
1372.5
1192.5
4186
1675
1170
4876
1750
7796
Print 603.93.111
BODY - CHASSIS
19
CAB GEOMETRY
Figure 29
A
B
C
D
E
DRIVERS
PASSENGERS
SEAT
SEAT
440 - 455
440 - 465
1145 - 1160
1135 - 1160
LOWER BED
UPPER BED
CHASSIS INSIDE UPPER EDGE
78693
Print 603.93.111
20
BODY - CHASSIS
SEC. A - A
SEC. D - D
SEC. E - E
SEC. N - N
SEC. P - P
SEC. F - F
78694
Print 603.93.111
BODY - CHASSIS
21
Figure 31
78695
Print 603.93.111
22
BODY - CHASSIS
Print 603.93.111
5542
23
BODY - CHASSIS
Figure 32
78696
78697
TORQUE
Hexagonal nut with flange for shock absorber upper fastening
Hexagonal nut for shock absorber lower fastening
Hexagonal screw with flange to secure bracket to cab on chassis side
Print 603.93.111
Nm
122.5 12.5
122.5 12.5
296 29
(Kgm)
(12.2 1.2)
(12.2 1.2)
(29.6 2.9)
24
BODY - CHASSIS
Figure 33
78700
78701
TORQUE
Self-locking hexagonal nut with flange and hexagonal screw with flange to secure
bracket to chassis
Self-locking hexagonal nut to secure shock absorber and elastic bumper to cross
member on upper side
Self-locking nut and hexagonal screw for shock absorber fastening on lower side
Nm
179 18
(Kgm)
(17.9 1.8)
216.5 21.5
(21.6 2.1)
189 19
(18.9 1.9)
Print 603.93.111
25
BODY - CHASSIS
Figure 34
78702
TORQUE
Bumper securing screw
Screw to secure bracket to chassis
Screw to secure cross member connecting pipe
Screw to secure shock absorber
Print 603.93.111
Nm
128 52
105 21
263 53
128 52
(Kgm)
(12,8 5,2)
(10,5 2,1)
(26,3 5,3)
(12,8 5,2)
26
BODY - CHASSIS
TOOLS
TOOL No.
DENOMINATION
99370147
99378031
Print 603.93.111
BODY - CHASSIS
REPAIRS
5542
Cab anchoring
554215
554243
27
Figure 37
Figure 35
38600
41851
Figure 36
33911
28
BODY - CHASSIS
78707
Print 603.93.111
554255
BODY - CHASSIS
29
Vibration knife
Figure 41
Figure 40
60967
40575
Unscrew the oil fittings (3); unscrew the nuts (1) for the
connecting pins and extract the cylinder (2).
60968
30
BODY - CHASSIS
Harmonic wire
For cutting the sealant bead with the harmonic wire, it is
necessary to use a tool as illustrated in Figure 44.
Figure 45
Figure 43
78708
The other operator, who is outside the vehicle, has to pull the
draw handle (1) while following the windscreen profile, and
cut the sealant bead.
60969
Figure 44
78709
60970
Cut a wire section about 500 mm long and, using a check tool
(3), put in a wire end (1) through sealant bead (2), starting
from windscreen window lower centre (see Figure 45).
Fix the wire end to check tool (3), operating inside the vehicle,
and the other end to the draw handle outside the vehicle.
The inside operator has to point the check tool at sealant bead
(2), about 300 mm from where wire (1) runs through.
Print 603.93.111
BODY - CHASSIS
31
Figure 49
78713
78710
Refitting
Figure 50
Figure 48
78711
78712
32
BODY - CHASSIS
Figure 51
Figure 53
78714
78716
Figure 52
78715
Print 603.93.111
550740
BODY - CHASSIS
33
Figure 54
33919
Take off the screw caps (arrows), unscrew the screws and
extract the armrest (2). Remove the push-button (1).
33922
Figure 55
33922
Unhook the safety clip (1) from the lifting device (2).
33920
Using proper tool (2), take off the safety ring and dismount
handle (3). Using the pliers, dismount handles (1). Remove the
whole panel.
Figure 59
Figure 56
33924
Lift the window (1) and extract it from the top (arrow).
33921
Lower the window, extract the internal and external seals (1).
Print 603.93.111
34
BODY - CHASSIS
550730
Figure 60
33927
Extract the outside seal (1), apply the suction cup 99378031
(2).
33925
Unhook the clips (1), unscrew the screws (2), unhook the
window from its lifting device (4) and extract the window
winder (3).
To fit it, carry out the steps described for removal in reverse
order.
!
550478
Figure 61
Position the window in its seat correctly, register its position
and mark it with adhesive tape. Cut the tape and take out the
window.
33926
Lift the shields (1), unscrew the screws and remove the
rearview mirror (2). Take off the shield (3).
Remove the inside door trim.
Base February 2003
Print 603.93.111
BODY - CHASSIS
Figure 63
35
Figure 65
33921
33928
Place the windscreen in its seat with the suction cup handle
(2).
- Align the window with its housing bay, using the adhesive
tape applied beforehand as a reference.
Figure 66
Figure 64
33930
33929
Print 603.93.111
Take out the plugs, fit the rearview mirror and the internal
door trim back on.
Base February 2003
36
BODY - CHASSIS
553710
INSTRUMENT PANEL
Figure 69
Removal
Figure 67
79612
Refitting
Perform re-attaching operations inverting described
detaching operations.
79610
553710
Removal
Figure 68
Figure 70
79611
79613
Print 603.93.111
37
BODY - CHASSIS
Figure 71
Figure 74
79614
Refitting
Perform re-attaching operations inverting described
detaching operations.
552211
79615
Removal
Figure 75
79618
38
BODY - CHASSIS
Figure 76
Figure 79
79619
79620
79621
79624
BODY - CHASSIS
Figure 82
39
Figure 85
79625
78628
Figure 86
Figure 83
79629
79626
Figure 84
79630
79627
Print 603.93.111
40
BODY - CHASSIS
Figure 88
Figure 90
79631
Figure 89
Figure 91
79632
79634
Print 603.93.111
BODY - CHASSIS
Figure 92
41
Figure 95
79635
79638
Figure 93
79636
Figure 96
79639
42
BODY - CHASSIS
Figure 97
Figure 100
79640
79643
Figure 98
Figure 101
79641
Refitting
Perform instrument panel (1) covering re-attaching
operations properly inverting described detaching operations.
533210
Removal
79645
Refitting
Figure 99
79642
Print 603.93.111
SERVICE PLAN
SECTION 13
Service plan
Page
Print 603.93.111
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE FREQUENCY . . . . . . . . . . . . . . . . . . . .
EXTRA-PLAN OPERATIONS . . . . . . . . . . . . . . .
EXTRA-PLAN OPERATIONS . . . . . . . . . . . . . . .
M1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
EXTRA-PLAN MAINTENANCE . . . . . . . . . . . . .
12
EP1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
EP2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
EP3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
EP4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
EP5 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
SERVICE PLAN
Print 603.93.111
SERVICE PLAN
SERVICING
Service plan
The checks, maintenance interventions and adjustments required at regular frequency on vehicle parts to ensure optimal working
conditions are illustrated on the following pages.
The engine lubricant frequency in kilometres refers to a percentage of sulphur in fuel lower than 0.5%.
NOTE: halve the oil replacement frequency if fuel with a percentage of sulphur higher than 0.5% is used.
- Change the engine lubricant oil in any case every 12 months in the event of very low distance, less than 800
hours/80,000 kilometres per year.
- Change the transmission and axle oil at least once every two years in the event of very low yearly distances.
- Carry out the general greasing procedure at least once a year in the event of very low yearly distances.
SERVICE FREQUENCY
Type of use
Long distance hauls: national
or international, mainly
motorway
Short-to-medium
hauls: regional or
interregional
distance
M1
80,000
km/
3200
hours
60,000
km/
2400
hours
40,000
km/
1600
hours/
1 year
M2
160,000
km/
6400
hours
120,000
km/
4800
hours
80,000
km/
3200
hours/
2 years
M3
240,000
km/
9600
hours
M4
480,000
km/
19200
hours
240,000
km/
9600
hours
160,000
km/
6400
hours/
4 years
EP1
EP2
EP3
EP4
EP5
6
months
1
year
2
years
3
years
40,000
km
800
hours
Extra plan operations (to be carried out possibly at the same time as a planned service operation)
EPI
EVERY 20,000 km or 800 hours - for urban or off-road use.
EVERY 40,000 km - for long, medium or short distance hauls.
G Change automatic transmission filter and oil.
G Remove-refit and clean automatic transmission oil breather.
EP2
EVERY 6 MONTHS - particularly at the beginning of spring
G Clean radiator curtain.
Print 603.93.111
SERVICE PLAN
EP3
EVERY YEAR
G Replace pneumatic system drier filter.
EVERY YEAR - before winter
G Check coolant density
G Replace supplementary heater fuel filter.
EVERY YEAR - before summer
G Check conditioner coolant conditions through the gauge.
EP4
EVERY TWO YEARS
G Replace air cleaner cartridge and clean container.
G Change engine coolant.
EP5
EVERY THREE YEARS
G Replace oil and bleed hydraulic clutch system.
Cab tilting, opening and closing radiator cowling engine guard disjoining
re-joining
Handling operations
Functional testing on road
Checking cooling system piping tightness
General chassis greasing
Replacing blow by filters
Checking clutch hydraulic system fluid level
Checking brake disks and shoe wear
Check of brake shoe wear (26t)
Checking headlight aiming
Checking steering articulated joint and steering column linkage
Replacing mechanical gearbox oil
Replacing axle hub oil
Replacing rear axle oil
Cleaning mechanical gearbox oil breather
Cleaning rear axle oil breather
M1
D
M2
D
M3
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
EP2
EP3
EP4
M4
D
D
D
D
D
D
D
D
D
D
D
D
D
EXTRA-PLAN OPERATIONS
14
2
15
8
15
12
EP1
D
D
EP5
D
D
D
D
D
D
Print 603.93.111
SERVICE PLAN
Figure 1
84414
Print 603.93.111
SERVICE PLAN
Figure 2
77834
Print 603.93.111
SERVICE PLAN
M2
M3
M4
17
19
21
22
20
16
21
24
23
EXTRA-PLAN OPERATIONS
EP1 EP2 EP3 EP4 EP5
18
-
Print 603.93.111
SERVICE PLAN
M1 SERVICE
S Handling operations
S Functional testing on road
S General chassis greasing
S Checking cooling system and hydraulic
brake pipe seal
84410
!
77835
Figure 5
77836
Print 603.93.111
SERVICE PLAN
Figure 6
Figure 8
75338
84415
See that the belts are not worn or deteriorated; if they are,
replace them as described under the relevant headings.
M2 SERVICE
78148
- With the axle warm, drain off the oil into a specific
container by taking out the plug (2).
- Replenish with fresh oil through the hole closed by the
plug (1) (see the FLUIDS section under the heading
GENERAL INFORMATION).
34811
10
SERVICE PLAN
Figure 10
77837
77203
75346
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SERVICE PLAN
11
Figure 14
79069
84411
12
SERVICE PLAN
M3 SERVICE
Figure 16
74341
To remove and fit the belt (1) back on, you need to use an
appropriate tool on the tightener (2) in the direction shown
by the arrow.
75340
EXTRA-PLAN MAINTENANCE
EP1 SERVICE
- Replace filter and automatic transmission oil
- Disconnect reconnect
transmission oil breather
and
clean
automatic
Print 603.93.111
SERVICE PLAN
EP2 SERVICE
14 - Cleaning the radiator shade
13
Figure 19
84412
84413
Remove any dirt from the radiator shade (1) to let air flow
towards the radiator.
EP3 SERVICE
2 - Changing pneumatic system drier filter
The plug (1) must never be taken out for any reason
whatsoever.
With the engine warm, the cooling system is in
overpressure, therefore take care when taking off
the cap (2).
Take off the cap (2) and draw off a sample of the coolant from
the expansion tank (3) with the densimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentage has to be higher than 40% and
must not exceed 50%.
Figure 20
77841
Unscrew the drier filter (1) and change it; tighten it to the
prescribed torque, checking there is no air leakage when
pressure is restored.
Print 603.93.111
14
SERVICE PLAN
EP4 SERVICE
8 - Changing the cartridge of the dry air filter
and cleaning its container (even if no clogging
signalled)
EP5 SERVICE
12 - Replace oil bleed clutch hydraulic system
Figure 23
Figure 22
77843
84410
Drain off the clutch control fluid and change it (see Fluids
table in GENERAL section).
Print 603.93.111