Documente Academic
Documente Profesional
Documente Cultură
REPA I R MA NUA L
MECHA NICA L
ELECTRIC/ELECTRONIC
Aquila Trucks Centres
'T||s oocooot ov|oosoata, c|aacto|st|cs, |ostoct|oosaoo
methodologyto performrepair interventions onthevehicle
and itscomponents.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistanceare specificallyqualified andequipped to perform
therepair interventions that are indicated in thisdocument.
Before performinganyintervention, check to have available
the document relating to the vehicle model on which the
intervention is beingperformed and also make sure that all
accidentpreventiondevices,suchas,asaroughguide,goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., areavailableandefficient, and further
make sure that the vehicle is put such a way that an
interventioncan be madeinsafetyconditions.
Makinginterventions strictlyobserving the indications given
here, as well as using specific tooling indicated, assures a
correct repairintervention, executiontimingobservanceand
ooatos' saot.
Eachrepair interventionmust befinalisedto therecoveryof
functionality,efficiencyandsafetyconditionsthat areprovided
byIveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of anyresponsibilityfor Iveco,
and,inparticular,wherethevehicleiscoveredbyaguarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Ivecoisavailabletoprovideall clarificationsnecessarytomake
interventions, as well as to provide indications in cases and
situationsnot included inthis document.
Inthecaseof adifferencebetweenwhat containedhereand
what actually found on the vehicle, please contact Iveco
oot.o' booo a'|o ao |otovoot|oo.'
Copy, evenpartial, of text and drawingsis forbidden.
PublicationEdited by:
IVECO S.p.A.
Customer Service
Lungo SturaLazio, 15
10156Torino (TO) - Italy
Print 603.93.641 - 2
nd
Ed. 2006
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo SturaLazio, 15
10156Torino (TO) - Italy
Producedby:
Aquila Trucks Centres
Manualsforrepairsaresplit into Sections, eachoneof whichismarked byanumeral;thecontentsof thesesections areindicated
inthegeneral table of contents.
Eachsection isgenerallydedicatedto amainUnit (e.g.: engine, gearbox, electricsystem, etc.).
Sectionswithmechanical contentsincludetechnical data, tighteningtorquecollections, tool lists, cooooct|oos o|scooooct|oos o
unitsto/fromthevehicle, overhaulsat thebenchandrelatingtroubleshooting.
Ontheelectric/electronicsystemsectiontherearethedescriptionsof theelectricnetworkandvehicleelectronicsystems,electric
schemes, componentselectriccharacteristics, componentscodesand troubleshootingrelatingto the central unitsspecificof the
electricsystem.
Themanual usesproper symbolsinitsdescriptions; thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular,
therehavebeendefinedaset of symbolsto classifywarningsandaset for assistanceoperations.
PRELIMINARY REMARKS
General danger
It includes thedangers of abovedescribed signals.
Danger of serious damagefor thevehicle
Partial or complete non observance of theseprescriptionscancause serious damages to the vehicleand sometimes
guaranteelapsetoo.
Environment protection
It indicates correct behaviour inorder that vehicleuseisenvironmentallyfriendlyasmuchas possible.
Danger for persons
||ss|o o |oco|oto obsovaoco o t|oso osc|t|oos cao caoso so |oos oaoo o osoos' saot.
SYMBOLS - WARNINGS
It indicates anadditional explanationfor apieceof information.
!
NOTE
Print 603.93.641 Base- November 2006
I
Aquila Trucks Centres
Base- November 2006 Print 603.93.641
II
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fittinginplace
Assembly
Compressionratio
Tightento torque
Tolerance
Weight difference
Tightento torque+anglevalue Rollingtorque
Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fittingpositioncheck
Preload
Measurement
Valuetofind
Check
Number ofrevolutions
Equipment Temperature
Surfacefor machining
Machinefinish
bar
Pressure
Interference
Strainedassembly
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
Replacement
Original spareparts
Aquila Trucks Centres
Eachtitleor subtitleconcerningoperationsbeingperformedisprecededbyasix-figurenumber namedPRODUCT CODE.
This number represents the PRODUCT CODE referred to bythe repair operation contained in both REPAIR TIMES and
TROUBLECODEdocument.
Asaquickreference thereareshown belowtheguidelines to readthiscode(seeRepair Timing, too).
Product Code:
Thefirst andsecondfiguresidentifythePRODUCT withinmotor vehicle.
Example:
Product 50 = Vehiclechassis;
Product 52 = Axles;
Product 53 = Transmission;
Product 76 = Electricssystem.
Unit Code:
Thethirdand fourthfiguresidentifytheUNIT withinthePRODUCT.
Example:
Product 50 = Vehiclechassis;
Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.
Sub-assemblyCode:
Thefifthandsixth figures exactly identifytheSUB-ASSEMBLY andComponent of aUnit within aPRODUCT.
Example:
Product 50 = Vehiclechassis;
Unit 01 = Chassis;
Sub-assembly 40 = Chassiscrossmembers;
Sub-assembly 13 = Rotor.
PRODUCT CODE
5 0
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
0 1
4 0
7 6
0 3
1 3
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
PRODUCT UNIT SUB -ASSEMBLY
COMPONENT
Print 603.93.641 Base- November 2006
III
Aquila Trucks Centres
GENERAL WARNINGS
Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact
immediatesuperiors whereadanger situationoccurswhichisnot described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenancehandbooks. Checkuse stateandsuitabilityof tools not subjectedto regular check.
Themanual handlingofloadsmust beassessedinadvancebecauseit also depends, besidesweight,onitssizeandon
thepath.
Handlingbymechanical means must bewithhoistersproper asfor weight as well asfor shapeandvolume. Hoisters,
ropesandhooksusedmust containclearindicationsonmaximumcarryingcapacityacceptable. Theuseof saidmeans
iscompulsorilypermitted toauthorised personnel only. Staydulyclear of theload, and, anyhow, never under it.
In disassemblingoperations, always observe provided prescriptions; prevent mechanical parts beingtaken out from
accidentallystrikingworkshoppersonnel.
Workshop jobsperformed inpairs must always beperformedinmaximumsafety; avoidoperationswhich couldbe
dangerousfor the co-operator becauseof lackof visibilityor of his/her not correct position.
Keeppersonnel not authorisedto operationsclear of workingarea.
Learnoperationandsafetyknowledgenecessaryrelatingto thevehicleprior toeachinterventiononit. Scrupulously
observe all safetywarnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
|otovoot|oo |as booo co|otoo, booo stat|o o t|o vo||c|o, oo a|| c|oc's |oo|catoo oo aaa| 'Cooto|s
cao o oso' o |so aoo |a|otooaoco |aooboo'.
Inlackofvisibilityinoperatingfromthevehicle, chargeapersononthegroundwithassistance.Donotleaveunmanned
avehicle inmotionduringrepair interventions.
Keepthevehiclestationarybyproper chocks.
Inthecaseofaninterventiononavehicleliftedfromtheground,checkthevehicletobequitesteadyonspecial support
stands and, in thecaseof liftingbymeans of alift, checkmanual/automaticsafeties tobeactivated.
Whenitisnecessarytoperformaninterventiononmethane-fedvehicles,observetheindicationscontainedinsidethe
document, aswell as all specificsafetyregulationsprovided.
Onlyremoveradiator capwhentheengineiscoldbycautiouslyunscrewingit inorder to let systemresidual pressure
out.
Inflammablefuelandall inflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful
materials12-point cards. Refuellingmust beperformedoutdoorswiththeengineoff, avoidinglit cigarettes, freeflames
orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids
accordingtowhat providedbyregulationsinforce. Compulsorilyavoidtousefoodcontainerstostoreharmful liquids.
Avoidtodrill orborepressurisedcontainers, andthrowclothsimpregnatedwithinflammablesubstancesintosuitable
containers.
Worn out, damaged or consumablepartsmust be replaced byIveco original spares.
Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidental liquidoroil spots.
Electricsocketsand electric equipment necessaryto performrepair interventionsmust meet safetyrules.
For everyintervention on vehiclehydraulic, pneumatic, conditioningand AIR - BAG systems, scrupulouslyobserve
indicationsspecified inrelatingmanual sections.
!
Base- November 2006 Print 603.93.641
IV
Aquila Trucks Centres
GENERAL WARNINGS
Cleanunitsorassembliesdetachedfromthevehicleandcarefullychecktheirintegritybeforeoverhaul.Tidyupdetached
or disassembled partswiththeir securingelements(screws, nuts, etc.) intospecial containers.
Check for theintegrityof theparts which prevent screws frombeingunscrewed: broken washers, dowels, clips, etc.
Self-lockingnutswithaninsert madeof nylonmust alwaysbereplaced.
Avoid contact of rubber partswithdiesel oil, petrol or other not compatiblesubstances.
Beforewashingunder pressuremechanical parts, protect electricconnectors, and central units, if present.
Tighteningscrews andnuts must alwaysbeaccordingtoprescriptions; IVECO commercial and assistancenetworkis
availableto giveall clarificationsnecessaryto performrepair interventionsnot providedinthisdocument.
Beforewelding:
- Disconnectall electroniccentral units,takepowercableoffbatterypositiveterminal (connect it tochassisbonding)
and detachconnectors.
- Removepaint byusingproper solvents or paint removersand cleanrelevant surfices withsoap andwater.
- Await about 15 minutesbefore welding.
- Equipwithsuitablefireresistant protectionstoprotecthosesor othercomponentswherefluidsorothermaterials
flowwhichmaycatch fireeasilyonwelding.
Shouldthevehiclebesubjectedto temperaturesexceeding80 C (dryer ovens), disassembledriveelectroniccentral
units.
Thedisposal of all liquids andfluidsmust beperformed withfull observanceof specificrulesinforce.
Put on,whererequiredbytheintervention, garmentsandprotections provided inaccident preventionrules;contact
with movingparts can cause serious injuries. Use suitable, preferablytight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leavetheengine inmotion at workshoplocationsnot providedwithapipeto scavengeexhaust gasoutside.
Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate
outdoors or in suitablyventilated areas. Put onproper inspirator ifpaint powder ispresent.
Avoidcontact withhot water orsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious
burns.Avoiddirect contactwithliquidsandfluidspresent invehiclesystems;whereanaccidental contact hasoccurred,
refer to12-point cardsfor provisions to make.
Print 603.93.641 Base- November 2006
V
Aquila Trucks Centres
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
Tostartuptheengine,donotusefastchargers.Startupmust onlybeperformedwitheitherseparatebatteriesorspecial
truck.
A wrongpolarisationofsupplyvoltageindriveelectroniccentral units(forinstance, awrongpolarisationof batteries)
cancausethemto bedestroyed.
Disconnect thebatteries fromthesystemduringtheir rechargingwithanexternal apparatus.
Onconnecting, onlyscrew up connector (temperature sensors, pressuresensors etc.) nuts at prescribed tightening
torque.
Beforedisconnectingthejunctionconnector fromanelectroniccentral unit, isolatethesystem.
Do not directlysupplyelectroniccentral units servo components at nominal vehiclevoltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as closeas possible to chassis/body
structure.
Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording
to original arrangement.
Keymemorisationproceduresareinfluencedbyelectromagneticjamming(mobilephones, etc.). Therefore, duringkey
memorisation:
1 Payattentionthat jammingsources arenot present inthecabor near the keys.
2. Keysnot insered in thepanel must be at least 1meter away.
Ifaninterventionhasto bemadeontheelectric/electronicsystem, disconnect batteriesfromthesystem;inthiscase,
alwaysdisconnect, asafirst one, thechassisbondingcablefrombatteries negativeterminal.
Beforeconnectingthebatteries to thesystem, make surethat thesystemiswell isolated.
Disconnect theexternal rechargingapparatus fromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery
terminals.
Do not causesparks to begeneratedincheckingif thecircuit isenergised.
Do not useatest lampincheckingcircuit continuity, but onlyuseproper control apparatuses.
Makesurethat theelectronicdeviceswiringharnesses(length,leadtype,location, strapping, connectionto screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurementsindriveelectroniccentral units,pluggedconnectionsandelectricconnectionsto componentscanonly
bemadeonpropertestinglineswith special plugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers,
clipsandthelikeinordertoavoidthedangerofcausingashort circuit,aswellasofdamagingpluggedconnections,which
wouldlater causecontact problems.
Beforereplacinganelectroniccontrol unit,verifythewiring.Ifnecessary,contact thelocal T.H.D.(Technical HelpDesk)
for anauthorizationor arecommendationonthepossibleinterventionsbeforereplacing.
Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable
side.
!
NOTE
Base- November 2006 Print 603.93.641
VI
Aquila Trucks Centres
Inorder to prevent damageor short-circuitingof the on-boardelectroniccontrol units, thefollowingoperationsmust
bealwayscarriedout beforestartinganyweldingoperation onthe chassis.
- If electricweldinghas to bedoneon thevehicle,
isolatetheelectricsystemasfollows:
a) disconnect thepower lead fromthe batterypositiveterminal andconnect it to thechassisearth;
b) disconnect thepower lead fromthebatterynegativeterminal;
c) disconnect theelectroniccontrol unit connectors, takingcaretoavoidtouchingthecontrol unit connector pins.
- Moreover:
a) should it benecessaryto carryout weldingoperationscloseto thecontrol unit, removeit fromitslocation.
b) whenever possible, earththeweldingmachinedirectlyto thepiecethat hasto bewelded.
112514
InthecaseofvehiclesequippedwithaDTCOdigital tachograph,donot disconnect thebatteryleadsandthenconnect
thembyjumpers to reset the electronicsystems.
This operationshouldbeavoided, as it couldcausepermanent damageto theDTCO tachograph CARD or other
on-board electronicsystems.
To reset theelectronicsystemwithout runningrisks, disconnect thevehiclebatteryand wait for 10 minutes.
It isstrictlyforbiddentocarryout anymodificationsor connectionstotheelectroniccontrol unitwiring; inparticular,
thelineinterconnectingdatabetweenthecontrol units (CAN line) must beconsidered as untouchable.
Diagnostic and maintenance operations can only be carried out byauthorised personnel with IVECO approved
equipment.
Print 603.93.641 Base- November 2006
VII
Aquila Trucks Centres
Base- November 2006 Print 603.93.641
VIII
Bonding and screening
|oat|vo |oaos cooooctoo to a ssto booooo o|ot ost bo bot| as s|ot aoo oss|b|o aoo 'sta'-cooooctoo to oac| ot|o, t|o
thento havetheir centeringtidilyandproperlymade(Figure1, re. M).
Further, followingwarnings areto be compulsorilyobservedfor electroniccomponents:
- Electroniccentral units must be connectedto systembondingwhenthey areprovided withametallicshell.
- Electroniccentral units negative cables must beconnectedboth to asystembondingpoint such as thedashboard opening
booo|o (avo|o|o 'so|a|' o 'c|a|o' cooooct|oos), aoo to batto ooat|vo to|oa|.
- Analogbonding(sensors), althoughnot connectedto batterynegativesystem/terminal bonding, must haveoptimal isolation.
Consequently, particularlyconsideredmust beparasiticresistancesinlugs: oxidising, clinchingdefects, etc.
- Screenedcircuits braidingmust onlyelectricallycontact the endtowardsthecentral unit enteredbythesignal (Figure2).
- If junction connectorsarepresent, unscreened section d, near them, must beas short aspossible (Figure2).
- Cablesmust bearranged such asto result to beparallel to referenceplane, i.e. ascloseaspossibleto chassis/bodystructure.
1. NEGATIVECABLES'STAR' CONNECTIONTOSYSTEMBONDING M
2. SC||||||CT|C|C ||T/|||C3|/||| |C C| / C/3|| TC /||||CT|C||C CC||C| ||T C. CONNECTOR
d. DISTANCE! 0
88039
Figure1
Figure2
Aquila Trucks Centres
Print 603.93.641 Base- November 2006
IX
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting
|ostoct|oos (soc||c oocooot '|ostoct|oos o taosoat|oo aoo oaat|oo' |s ava||ab|o at /ss|staoco |ot.o' .o's|os).
It isremindedthat,especiallyabout theelectricsystem,several electricsocketsareprovidedfor asseries(or optional) socketsin
order to simplifyandnormalisethe electrical interventionthat iscareof preparationpersonnel.
|o ao ocot|oo to ooot|o |ostoct|oos, |V|CC's aot|o|sat|oo |s oocossa.
Lack of observance of abovedescribed prescriptionsinvolves guarantee lapse.
It isabsolutelyforbiddento makemodificationsor connectionsto electriccentral unitswiringharnesses; inparticular,
thedatainterconnectionlinebetweencentral units(CAN line) isto beconsidered inviolable.
CONVERSIONSBETWEEN THE MAIN UNITSOF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1kW = 1.36metricHP
1kW = 1.34HP
1metricHP = 0.736kW
1metricHP = 0.986HP
1HP = 0.746kW
1HP = 1.014metricHP
Torque
1Nm = 0.1019 kgm
1kgm = 9.81Nm
Revolutions per timeunit
1rad/s = 1 rpmx 0.1046
1rpm = 1 rad/sx 9.5602
Pressure
1bar = 1.02kg/cm
2
1kg/cm
2
= 0.981 bar
1bar = 10
5
Pa
Whereaccuracyisnot particularly needed:
- Nmunit isfor thesakeofsimplicityconverted into kgmaccordingto ratio 10:1
1kgm = 10Nm;
- bar unit is for thesakeof simplicityconvertedinto kg/cm
2
accordingtoratio 1:1
1kg/cm
2
= 1bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8+32) F
Aquila Trucks Centres
Base- November 2006 Print 603.93.641
X
Aquila Trucks Centres
Revi - June2007
Print 603.93.641/A Base November 2006
TRAKKER EURO 4/5
Print 603.93.641 2
nd
edition
Base- November 2006
UPDATE DATA
Section Description Page Revision date
1 General 3, 5, 10 17, 19, 20 June2007
2 Engine 8,22,24,52,57,73,86,89,91,97128,143,144,147,168,
171, 174, 175, 180, 197, 203, 211, 214, 219, 222, 282
June2007
3 Clutch 2, 18, 19, 20, 21 June2007
4 Gearboxes 13,14, 16/1 16/6, 18, 18/1 18/2, 20, 20/1 20/6,
22/1 22/30, 23, 26 46, 46/1 46/32, 47 54, 54/1 54/4,
56/1 56/32
June2007
6 Transfer box TC 1800-TC
2200
6, 8, 10 12, 15, 24 June2007
8 Axles 58, 59, 63, 66, 79, 80, 82 86, 88, 90, 91, 92, 93, 96, 136,
162
June2007
13 Pneumaticsystem- Brakes 1, 21/1 21/2, 81 June2007
15 Programmedmaintenance 5 33 June2007
16 ElectricElectronicsystem 2, 6 10, 89, 121/1 121/4, 134/1 134/8, 139 143, 154,
156 161, 193, 198, 237, 258, 275, 284, 287
June2007
Aquila Trucks Centres
Base November 2006 Print 603.93.641/A
Print 603.93.371/A
Aquila Trucks Centres
Print 603.93.641 Base- November 2006
Section
General 1
Engines 2
Clutch 3
Gearboxes 4
Power take-off 5
Transfer boxTC 1800-TC 2200 6
Propeller shafts 7
Axles 8
Front axles 9
Suspensions 10
Wheelsandtyres 11
Steering 12
Pneumaticsystem- Brakes 13
BodyworkandChassis frame 14
Programmedmaintenance 15
Electric/electronicsystem 16
INDEX OF SECTIONS
Aquila Trucks Centres
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
GENERAL 1 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Print 603.93.641
SECTION 1
General
Page
VEHICLEIDENTIFICATION DATA 3 . . . . . . . . . .
- Vehicle IdentificationPlate 4 . . . . . . . . . . . . . . . .
- ProductionIdentificationPlate 4 . . . . . . . . . . . . .
COMMERCIAL CODING 5 . . . . . . . . . . . . . . . . . .
P.I.C. NUMBERCODING 6 . . . . . . . . . . . . . . . . . .
VEHICLECONFIGURATION 10 . . . . . . . . . . . . . . .
COMPOSITION OFTHE MODELS 11 . . . . . . . . . .
FILLINGFLUIDS 18 . . . . . . . . . . . . . . . . . . . . . . . . .
- International specificationsof lubricants
and fluids 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
2 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Aquila Trucks Centres
Chassis frame
Punching (front on right side member of
chassisframe).
Manufacturers plate
To identify the vehicle in accordance with the E.E.C. directive
(under thefront radiator cowling).
Engine
Plateontheleft rear sideofthecrankcase
Figure1
98878
Revi - June2007
GENERAL 3 TRAKKER EURO 4/5
Print 603.93.641/A 3aso |ovobo 2006
VEHICLE IDENTIFICATION DATA
PRINT603.93.641/A
T|o to aoo oobo o oo|oo, to aoo oobo o c|ass|s aoo aooactoo's |ato co|so t|o vo||c|o |ooot||cat|oo oata.
Aquila Trucks Centres
Permissible
grade of
smoke
IVECO MAGIRUSAG
Kg
Kg
Kg
Kg
a)
b)
c)
d)
e)
f)
g)
h)
Type
Wheelbase Correc-
ted
absor-
ption
value
Enginetype
Madein
N
o
ofaxles
Enginepower KW
1-
2-
3-
4-
l)
m)
i)
Kg
Kg
n)
o)
p)
Unit No
Part No
Serial No
P.I.C. No
MadeinGermany-IvecoMagirusAG
9843 8247
Figure2
4 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
Vehicle Identification Plate
Platelegend
a) Type-approval number marking(if applicable).
b) Vehicleidentificationcodenumber (V.I.N.).
c) Total tractor weight.
d) Total weight of tractor +trailer (if applicable).
e) Permissibleweight limit on 1st axle.
f) Permissibleweight limit on 2ndaxle(if applicable).
g) Permissibleweight limit on 3rdaxle.
h) Permissibleweight limit on 4th axle(if applicable).
i) Specificidentificationof type.
l) Wheelbaseinmm.
m) Enginetype.
n) Enginepower.
o) No. ofaxles.
p) Placeofmanufacture.
Production Identification Plate
ThisplateshowstheP.I.C.(productionidentificationcode
number), which is needed when referring to the spare
parts catalogue(electronicand/or Cd catalogue).
TheP.I.C. isalso givenonthevehiclewarrantycard.
Note: Whenconsultingthe catalogues, useonlythefirst
8digitsof theproduct identificationcodenumber.
Aquila Trucks Centres
TRAKKER
RANGE
NAME
AD 190 T 35
RANGE
CODE
TYPE
OFCAB
SUSPENSIONS
rear pneumatics
.../P
mechanicals
VERSION
Partial drive trucks
All-wheel drivetrucks
AT
AD
|oo /ct|vo T|o
S|ot /ct|vo |a
190
260
Trucks4x2 - 4x4
Trucks6x4 - 6x6
380
340
Trucks6x4 - 6x6
Trucks8x4x4
410
400
Trucks8x4x4 - 8x8x4
Tractors4x2 - 4x4
440
720
Tractors6x4 - 6x6
Tractors6x4 - 6x6
TOTAL
WEIGHT
All-wheel drivetractors WT
Concretemixer truck B
Partial drive tractors T
W
ENGINE
RATING
F2BGF- 310 CV
F2BVGT - 330 CV 33
F2BVGT - 360 CV
F3BWG - 410 CV 41
F3BVGT - 450 CV
F3BVGT - 500 CV 50
31
36
45
|oo /ct|vo T|o |o.
S|ot /ct|vo |a |o.
AT-N
AD-N
Revi - June2007
GENERAL 5 TRAKKER EURO 4/5
Print 603.93.641/A 3aso |ovobo 2006
Print 603.93.641/A
COMMERCIAL CODING
Aquila Trucks Centres
A A B C D B C A
AXLE CONFIGURATION - TOTAL EARTH MASS
A A B C D B C
K
AD
A
L
M
N
P
R
Chassiscab 4x2(18-20ton)
Tractor 4x2(18-20ton)
Chassiscab 6x4- 8 mm(26ton)
Chassiscab 6x4- 10mm(33ton)
Tractor 6x4- 10mm(33 ton)
ENGINE
A B C D B C A A
A
310
B
330
C
360
D
410
E
450
F 500
S
Chassiscab 8x4- 8 mm(32ton)
T Chassiscab 8x4- 10mm(32-40ton)
U
Chassiscab 4x4(18-20ton)
V Tractor 4x4(18-20ton)
H
AT
Q
Tractor 6x4- 8mm(26ton)
HABITABILITY
X
Chassiscab 6x6- 8 mm(26ton)
G
560
Y
Chassiscab 6x6- 10mm(33ton)
Z
Tractor 6x6- 10mm(33 ton)
W
Chassiscab 8x8- 10mm(32-40ton)
6 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
P.I.C. NUMBER CODING
Aquila Trucks Centres
A C D B C A
A
B
Mechanical - HR-P
Pneumatic- HR-P
A
B
Mechanical - HR-TL
Mechanical - HR-TM
C
Mechanical - HR-TP
D
Mechanical - SR
A A C D C A B
1
2
7
Chassiscab
Tractor
B
VERSION
Concretemixer
TYPE OF REAR AXLE TYPE OF SUSPENSION
E
Pneumatic- HR-TP
B A
F
Pneumatic- SR
GENERAL 7 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
H.R.= Doublereductionrear axle
S.R. = Simplereduction rear axle
T.L. = Light tandemrear axle
T.M.= Mediumtandemrear axle
T.P. = Heavytandemrear axle
Aquila Trucks Centres
7
6
5
C A A C D B A B
WHEELBASE
4
3
2
1
8 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE
C 4x2
C 6x6
3500 C 8 x4 4250 C/T 6 x4 3200
C 8 x8
C 8 x4
4750
C 6 x4
C 6 x6
3500
C 6 x6
C 6 x4
3800
T 4 x4
T 4 x2
3800
C 4 x2
C 4 x4
3800
C 8 x4
C 8 x8
5020
C 8 x4 5820
C 4 x2
C 4 x4
C 6 x4
4200
C 4 x2
C 6 x4
4200
C 4 x2
C 4 x4
C 6 x4
4500
C 6 x4 4800
C 4 x2
C 6 x4
5100
C = Chassiscabs
T = Tractors
Aquila Trucks Centres
GEAR SHIFTS
A A D B C A B C
C
B
A
DRIVE BRAKE COMBINATION
A A B C A B C D
C
B
A
1
2
3
GENERAL 9 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
16M
9M
Eurotronic- 12M
DRIVE
BRAKES
DRIVE
FRONT REAR
Right Disc Drum2D Right Disc Drum2D
Right Disc Disc Right Disc Disc
Right Drum2D Drum2D Right Drum2D Drum2D
Left Disc Drum2D Left Disc Drum2D
Left Disc Disc Left Disc Disc
Left Drum2D Drum2D Left Drum2D Drum2D
Aquila Trucks Centres
4x2 = Vehicles withtwo axleswith rear drivingaxle. 4x4 = Vehicleswithtwoaxleswithfront andreardriving
axle.
Figure3
Figure4
6x4 = Vehicleswith threeaxleswith two rear drivingaxles(in Tandem).
Figure5
6x6 = Vehicleswiththreeaxleswithfront axleand two rear drivingaxles (in Tandem).
Figure6
8x4x4 = Vehicles withfour axles: first andsecond steeringaxles, third andfourthdrivingaxles (inTandem)
8x8x4 = Vehicles withfour drivingaxleswithfirst andsecondsteeringaxles andtworear axles(in Tandem)
119160
119161
119162
119163
Revi - June2007
10 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
Print 603.93.641/A
VEHICLE CONFIGURATION
Aquila Trucks Centres
Revi - June2007
GENERAL 11 TRAKKER EURO 4/5
Print 603.93.641/A Base November 2006
COMPOSITION OF THE MODELS
MODELS4x2
GROUPS/CABIN
F2BE3681C (310 CV)
F2BE3681B(330 CV)
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
Pushing one-disc 17
Pulling one-disc 17
9S1310TO
16S1620 TD
16S2220 TO
16S2520 TO
12AS1930TD
12AS2330TO
5886/D:
451391/2DJ
ZF 8098
Front mechanic
Rear mechanic
Rear air
Cabintype
AT/AD
Cabintype
AT-N/AD-N
: Withdisc brakes
J With Duo Duplexdrumbrakes
Aquila Trucks Centres
Revi - June2007
12 GENERAL TRAKKER EURO 4/5
Base November 2006 Print 603.93.641/A
COMPOSITION OF THE MODELS
MODELS4x4
GROUPS/CABIN
1
F2BE3681C (310 CV)
F2BE3681B(330 CV)
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
Pushing one-disc 17 f f f f
Pulling one-disc 17
9S1310TO
16S1620 TD
16S2220 TO
12AS1420 TD *
12AS1930 TD
12AS2330 TO
T C 1800
T C 2200
FRONT
5985/2DJ
REAR
451391/2DJ
ZF 8098
Front mechanic
Rear mechanic
Posteriori pneumatiche
Cabin type
AT/AD
Cabintype
AT-N/AD-N
J Drumbrakes Duo Duplex
f Onlyfor 9S1310TO gearboxes
* Availableonlywithout Intarder
Aquila Trucks Centres
(continue)
Revi - June2007
GENERAL 13 TRAKKER EURO 4/5
Print 603.93.641/A Base November 2006
COMPOSITION OF THE MODELS
MODELS6x4
GROUPS/CABIN
F2BE3681B(330 CV)
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
Pushing one-disc 17
Pulling one-disc 17
9S1310TO
16S1620 TD
16S2220 TO
16S2520 TO
12AS1420 TD Y
12AS1930 TD
12AS2330 TO
5886/D:
INTERMEDIATE452146/2DJ
REAR452146/2D J
INTERMEDIATE453291/2DJ
REAR453291/2D J
TANDEM
INTERMEDIATE452191/2DJ
REAR452191/2D J
INTERMEDIATEMT 23-155/2DJ
REARMT 23-155/2D J
INTERMEDIATE MT 23-155/D :
REARMT 23-155/D :
ZF 8098
Front mechanic
Rear mechanic
Rear air
Cabintype
AT/AD h h h h h h h
Cabintype
AT-N/AD-N h h h h h h h
: Withdisc brakes
J With Duo Duplexdrumbrakes
Onlyon vehicles withright-handsteering
Onlyfor 9S1310TO gearboxes
Y Availableonlywithout Intarder
j CabintypeAD or AD-N
Aquila Trucks Centres
Revi - June2007
14 GENERAL TRAKKER EURO 4/5
Base November 2006 Print 603.93.641/A
COMPOSITION OF THE MODELS
MODELS6x4
GROUPS/CABIN
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
Pulling one-disc 17
16S2220 TO
16S2520 TO
12AS2330 TO
12AS2530 TO
5886/D:
INTERMEDIATE452191/2DJ
TANDEM REAR452191/2D J
INTERMEDIATE453291/2DJ
REAR453291/2D J
ZF8098
Front mechanic
Rear mechanic
Rear air
Cabin type
AT/AD
Cabintype
AT-N/AD-N
: Withdisc brakes
J With Duo Duplexdrumbrakes
Aquila Trucks Centres
Revi - June2007
GENERAL 15 TRAKKER EURO 4/5
Print 603.93.641/A 3aso |ovobo 2006
COMPOSITION OF THE MODELS
MODELS6x6
GROUPS/CABIN
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
|o|||o ooo-o|sc +'
16S1620 TD
16S2220 TO
12AS1930 TD
12AS2330TO
T C 1800
T C 2200
FRONT
5985/2D J
INTERMEDIATE452191/2DJ
TANDEM
REAR452191/2D J
INTERMEDIATE453291/2DJ
REAR453291/2D J
ZF 8098
Front mechanic
Rear mechanic
Cabintype
AT/AD
Cabintype
AT-N/AD-N
J With Duo Duplexdrumbrakes
Aquila Trucks Centres
Revi - June2007
16 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
COMPOSITION OF THE MODELS
MODELS8x4
GROUPS/CABIN
F2BE3681A (360 CV)
F3BE3681D(410 CV)
F3BE3681C (450 CV)
F3BE3681B(500 CV)
|o|||o ooo-o|sc +'
16S1620 TD
16S2220 TO
16S2520 TO
12AS1930TD
12AS2330TO
1 5886/D:
2 5886/D:
INTERMEDIATE452146/2D J
REAR452146/2D J
INTERMEDIATE453291/2DJ
REAR
REAR453291/2D J
REAR
INTERMEDIATE452191/2D J
REAR452191/2D J
INTERMEDIATEMT 23- 155/2D J
REARMT 23- 155/2D J
INTERMEDIATEMT 23 - 155/D :
REARMT 23- 155/D:
ZF 8099
Front mechanic
Rear mechanic
Posteriori pneumatiche
Cabin type
AT/AD h h h h h h h
Cabin type
AT-N/AD-N h h h h h h h
: Withdisc brakes
J With Duo Duplexdrumbrakes
Onlyon vehicles withright-handsteering
Aquila Trucks Centres
Revi - June2007
GENERAL 17 TRAKKER EURO 4/5
Print 603.93.641/A 3aso |ovobo 2006
COMPOSITION OF THE MODELS
MODELS8x8
GROUPS/CABIN
F3BE3681C (450 CV)
|o|||o ooo-o|sc +'
16S2220 TO
12AS2330TO
TC 2200
FRONT 5985/2DJ
REAR
INTERMEDIATE5985/2D J
INTERMEDIATE453291/2DJ
REAR453291/2DJ
ZF 8099
Front mechanic
Rear mechanic
Cabintype
AD
Cabintype
AD-N
J WithDuo-Duplexdrumbrakes
Aquila Trucks Centres
18 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Print 603.93.641
PRINT603.93.641
FILLING FLUIDS
LUBRICANTSRECOMMENDED BY IVECO PARTSTO BEFILLEDUP
Quantity
LUBRICANTSRECOMMENDED BY IVECO PARTSTO BEFILLEDUP
Liters Kg
UraniaFE 5W30
1
UraniaLD7
Engine F2B
Total capacity 1st filling: 28 25.2
Capacity:
- enginesumpminlevel
- enginesumpmaxlevel
- circulatingquantitynot return-
ingto sump
- quantity contained in the car-
tridge filter (to add when re-
placingthecartridge filter)
12.5
23
5
2.5
11.2
21
4.5
2.3
UraniaFE 5W30
1
UraniaLD7
EngineF3B
Total capacity 1
st
filling 35 31.5
Capacity:
- enginesumpat minimumlevel
- enginesumpatmaximumlevel
- quantity in circulation that
does not returnto sump
- quantitycontainedincartridge
filters (to add when changing
thecartridgefilters)
20
28
7
3
18
25.2
6.3
2.7
7.6
18.9
9.9
16.6
11.7
19.3
9.9
10.8
18.9
8.5
21
11
18.5
13
21.5
11
12
21
Gearbox
ZF 9S1310TO*
ZF 9S1311TO*
ZF 16S1620 TD*
ZF 16S1621 TD*
ZF 16S2220TO/2520TO*
ZF 16S2221TO/2521TO*
ZF 12AS1420TD*
ZF 12AS1930TD/2330 TO*
ZF 12AS1931TD/2331 TO*
* Quantity1
st
filling
TutelaTruckFE- gear
TutelaZC 90
TutelaZC 90
Tutela GI/A for arctic
climate
Transfer box TC 1800 (32180)
TC 2200 (32220)
6.5
6.5
5.5
5.5
(1) IVECO recommendsusingtheseoils for better fuel economy.IVECO supplieseachnewvehiclereadyfilledwith thistypeof
lubricant Also designedfor cold climates (minimumtemperaturedownto -30).
Aquila Trucks Centres
Revi - June2007
GENERAL 19 TRAKKER EURO 4/5
Print 603.93.641/A 3aso |ovobo 2006
Print 603.93.641/A
FILLING FLUIDS
LUBRICANTSRECOMMENDED BY IVECO PARTSTO BEFILLEDUP
Quantity
LUBRICANTSRECOMMENDED BY IVECO PARTSTO BEFILLED UP
Liters Kg
Axle5886/D (for each hub) 0.35 0.32
Front axle5985/2D 5 4.5
Front axlewheelsreduction unit 5985/2D 0.75 0.68
Rear axle451391/2D 16 14.5
TutelaW140/M-DA
TutelaW90/M-DA
1
Axlein tandem453291/2D:
- (intermediate +transm.)
- rear
27
16
24.3
14.5
TutelaW90/M-DA
1
Axlein tandem452191/2D:
- (intermediate +transm.)
27
16
24.3
14.5
Axlein tandem452146/2D:
- (intermediate +transm.)
- rear
13
11.5
11.7
10.5
Axlein tandemMT 23-155:
- (intermediate +transm.)
- rear
20
18.5
18
16.6
TutelaGI/A
Power steering 2.7*
13.5**
2.4
12
* Excludingvehicleswithsteeringrear axle
** For vehicles withsteeringrear axleonly
TutelaTRUCK
DOT SPECIAL
Clutchcircuit
(excludingvehicleswithEuro Tronicgearbox)
0.5 0.45
Water+Paraflu
11
Coolingsystem
EngineF2B Total capacity*
EngineF2BwithIntarder Total capacity*
EngineF3B Total capacity*
EngineF3BwithIntarder Total capacity*
34
50
44
64
30.6
45
39.6
58
* =Protectiveanti-freeze
(coocootat|oo 50 ooz|o o|ot 35 C)
TutelaLHM
Cabtiltingsystem 0.6 0.54
* =Protectiveanti-freeze
(coocootat|oo 50 ooz|o o|ot 35 C)
(1) Specificfor cold climates
Aquila Trucks Centres
(+) |V|CC ocoooos os|o t||s to o o||s toobta|o booo|ts |o tos o 'oo| ocooo'. T|o oo. vo||c|o |s a|oao ooo|oo
byIVECO withthistypeof lubricants(also adequatefor cold climatemin. temperatureupto -30 C).
Thesequantities arenot determinant. Theexact checkto bedonewhenchecking levels.
Revi - June2007
20 GENERAL TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
Print 603.93.641/A
International specifications of lubricants and fluids FL Products
Engineoil
Meets thespecifications:
ACEA E4 with a totallysynthetic base SAE 5W 30
IVECO Standard18-1804
ACEA E7 withamineral base SAE 15W 40
IVECO Standard18-1804T2E7
URANIA FE 5W30 (1)
UraniaLD7
Oil for total power takeoff (Multi-power)
Containingnon-EPanti-wear additives
Complies with thefollowingspecification:
API GL5withamineral base SAE 80W90
IVECO Standard18-1807
TutelaZC 90
Oil for differential gear and wheel hubs
Meets thespecifications:
API GL5withamineral base SAE 85W 140
API GL5withamineral base SAE 80W 90
IVECO Standard18-1805
TutelaW140/M-DA (hot or mildclimates)
TutelaW90/M-DA (coldclimates)
Oil for mechanical gearboxes
Containingnon-EPanti-wear additives
Meets thespecifications:
API GL4 with atotally synthetic base SAE 75W 80
API GL3withamineral base SAE 80W 90
IVECO Standard18-1807
TutelaTruck FE-Gear (1)
TutelaZC 90
Oil for hydrostatic transmissionand power steeringoil
A.T.F. DEXRON II D
A.T.F. DEXRON III
TutelaGI/A
TutelaA.T.F. 90
Greasefor general use
withbaseof lithiumsoap, consistencyN.L.G.I. no. 2
IVECO Standard18-1810
TutelaMR 2
Greasefor bearings and wheel hubs
withbaseof lithiumsoap, consistencyN.L.G.I. no. 3
IVECO Standard18-1810
TutelaMR 3
Fluidfor hydraulic brakes andclutchcontrol
complies withstandards: N.H.T.S.A. N. 116ISO 4925-Std. SAEJ 1703
CUNA NC 956-01- IVECO STANDARD 18- 1820
TutelaTRUCK DOT SPECIAL
Mineral oil for hydrauliccircuits
complies withstandards: IVECO STANDARD 18-1823 TutelaLHM
Windshieldwasher liquid,
mixtureof alcohols, water andsurfacetensioners
CUNA NC 956-11
TutelaProfessional SC 35
Greasefor centralised lubrication systems
withbaseof lithiumsoap (syntheticbase), N.L.G.I. no. 2.
Operatingtemperatures: -30 C to+140 C
TutelaCOMAR 2
Mineral oil for hydrauliccircuits
complies withstandard: IVECO STANDARD 18-1830
to beused diluted withwater at 50%
Paraflu
11
Aquila Trucks Centres
1 TRAKKER EURO 4/5 ENGINES
Print 603.93.641 Base- November 2006
SECTION 2
Engines
Page
- F2BEngine 3 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- F3BEngine 123 246 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Hydrocar pressuretake-off ontimingsystem
(P.T.O. - Optional) 247 250 . . . . . . . . . . . . . . . . . . . .
- Denox 2system 251 258 . . . . . . . . . . . . . . . . . . . . . .
- Diagnosis 259 292 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
2 TRAKKER EURO 4/5 ENGINES
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
F2BENGINE 3 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
F2B Engine
Page
VIEWSOFTHEENGINE 8 . . . . . . . . . . . . . . . . . . . .
MAIN DATA 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY CLEARANCEDATA 15 . . . . . . . . . . . . . .
TIGHTENINGTORQUES 22 . . . . . . . . . . . . . . . . . . .
TOOLS 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL - REFITTING 39 . . . . . . . . . . . . .
- Removal 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fillingthecoolingsystem 41 . . . . . . . . . . . . . . . . .
- Bleedingair fromthefuel system 42 . . . . . . . . . . .
- Checksandtests 42 . . . . . . . . . . . . . . . . . . . . . . .
ELECTRO-MAGNETIC FAN DRIVEREPLACEMENT 43 . .
- Removal 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLINGTHEENGINE 47 . . . . . . . . . . . . . . .
REPAIR OPERATIONS 54 . . . . . . . . . . . . . . . . . . . . . .
CYLINDERBLOCK 54 . . . . . . . . . . . . . . . . . . . . . . . . .
- Checksandmeasurements 54 . . . . . . . . . . . . . . .
CYLINDER LINERS 55 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingcylinder liners 56 . . . . . . . . . . . . . . . . . .
- Removal 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingandcheckingprotrusion 56 . . . . . . . . . . . .
CRANKSHAFT 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringmainjournals andcrank pins 58 . . . . . .
PRELIMINARY MEASUREMENT OFMAIN ANDBIG
ENDBEARINGSHELL SELECTION DATA 59 . . . .
- Replacingthe valvedrivegear and theoil pump
drivegear 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingmainjournal installationclearance 66 . . .
- Checkingcrankshaft endfloat 67 . . . . . . . . . . . . .
PISTON-CONNECTINGRODASSEMBLY 68 . . . . . .
- Removal 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringthediameter of thepistons 69 . . . . . . .
Aquila Trucks Centres
4 F2BENGINE TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Page
- Conditions for correct gudgeonpin-
pistoncoupling 69 . . . . . . . . . . . . . . . . . . . . . . . . .
- Pistonrings 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD 71 . . . . . . . . . . . . . . . . . . . . . . .
- Checkingconnectingrod squareness 72 . . . . . . . .
- Fittingtheconnectingrod-pistonassembly 72 . . . .
- Fittingthepiston rings 72 . . . . . . . . . . . . . . . . . . .
- Fittingtheconnectingrod-pistonassemblyinto
thecylinder liners 73 . . . . . . . . . . . . . . . . . . . . . . .
- Pistonprotrusion check 73 . . . . . . . . . . . . . . . . . .
- Checkingassemblyclearanceof bigend pins 74 . .
CYLINDERHEAD 74 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Dismountingthevalves 74 . . . . . . . . . . . . . . . . . . .
- Checkingtheplanarityoftheheadon
thecylinder block 74 . . . . . . . . . . . . . . . . . . . . . . .
VALVE 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingdust and checkingthevalves 75 . . . . . .
VALVEGUIDES 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingof valveguides 76 . . . . . . . . . . . . . . . . .
- Replacing- Reamingthevalveseats 76 . . . . . . . . .
REPLACINGINJECTORHOLDERS 76 . . . . . . . . . . . .
- Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingprotrusion of injectors 78 . . . . . . . . . . . .
TIMINGGEAR 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft drive 79 . . . . . . . . . . . . . . . . . . . . . . . . .
- Intermediate gear pin 79 . . . . . . . . . . . . . . . . . . . .
- Idler gear 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Twinidler gear 79 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe bushings 79 . . . . . . . . . . . . . . . . . . .
- Camshaft 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingcamlift andpin alignment 80 . . . . . . . . .
- Bushes 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingcamshaft bushesusingbeater 99360487 82
Page
- Removal 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVESPRINGS 83 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingthevalvesand oil seal ring 83 . . . . . . . . . . .
ROCKERSHAFT 84 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Shaft 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rocker 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THEENGINE 85 . . . . . . . . . . . . . . . . . .
DIAGRAMSHOWINGTHE LOWERCRANKCASE
FIXINGSCREWSTIGHTENINGORDER 87 . . . . .
- Fittingtheconnectingrod-pistonassemblyinto
thecylinder liners 88 . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingflywheel 91 . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingcamshaft 92 . . . . . . . . . . . . . . . . . . . . . . . . .
- Fittingpump-injectors 93 . . . . . . . . . . . . . . . . . . . .
- Fittingrocker-armshaft assembly 93 . . . . . . . . . . .
- Camshaft timing 94 . . . . . . . . . . . . . . . . . . . . . . . .
- Phonicwheel timing 96 . . . . . . . . . . . . . . . . . . . . .
- Intakeand exhaust rocker clearanceadjustment and
pre-loadingof rockerscontrollingpumpinjectors 97
ENGINE COMPLETION 98 . . . . . . . . . . . . . . . . . . . .
LUBRICATION 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pump 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Safetyrelief valve 103 . . . . . . . . . . . . . . . . . . . . . . .
- Oil overpressurevalve 104 . . . . . . . . . . . . . . . . . . .
- Heat exchanger 104 . . . . . . . . . . . . . . . . . . . . . . . .
- By-passvalve 105 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostaticvalve 105 . . . . . . . . . . . . . . . . . . . . . .
- Engineoil filters 105 . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
F2BENGINE 5 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Page
- Valveintegrated inpiston coolingnozzle 106 . . . . .
COOLING 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagneticfandrive 109 . . . . . . . . . . . . . . . . .
- Water pump 109 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat 110 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER 112 . . . . . . . . . . . . . . . . . . . . . . . . .
VGT TURBOCHARGER 112 . . . . . . . . . . . . . . . . . . . . .
- Actuator 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Solenoidvalvefor VGT control 113 . . . . . . . . . . . .
REPAIRINGACTIONS 113 . . . . . . . . . . . . . . . . . . . . . .
- Variablegeometrymovement control 114 . . . . . . .
- Checkingtheactuator 114 . . . . . . . . . . . . . . . . . . .
- Checkingactuator travel 115 . . . . . . . . . . . . . . . . . .
- Cleaningturbinebody 115 . . . . . . . . . . . . . . . . . . .
FUELSYSTEM 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overpressurevalve 119 . . . . . . . . . . . . . . . . . . . . .
- Feedpump 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injector-pump 120 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacinginjectors-pump 120 . . . . . . . . . . . . . . . . .
- Injector Phases 121 . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
6 F2BENGINE TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
F2BENGINE
Figure1
78840
F2BENGINE 7 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Aquila Trucks Centres
Level of Gas Emissions
Engine torqueandpower level
ENGINE
F 2 B E 3 6 8 1 A * P 0 0 1
-
Indicates the enginefamily
Progressiveproduction number
Engine familyevolution (also irrespectiveof thedisplacement)
Engine
Stroke andcylinder position
(3=4 stroke, vertical with post - treatment)
Number of cylinders
Fuel feed+injection(TCA,direct injectiondiesel engine)
Use(egI =truck)
Variant
TYPE PART NUMBER
A
B
360 CV/1500Nm
330 CV/1400Nm
C 310 CV/1300Nm
P
M
Euro 4- 2006
Euro5- 2006
R
S
Euro4- 2007
Euro5- 2007
Revi- June2007
8 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
PRINT603.93.641/A
VIEWS OF THE ENGINE
Aquila Trucks Centres
Max OUTPUT 230kW at 2400 rpm
Max TORQUE 1300Nm at 1200 to 1675 rpm
310HP
132 kgm
F2BE3681C: POWER-TORQUE CURVES
108514
Figure2
rpm
F2BENGINE 9 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Aquila Trucks Centres
F2BE3681B: POWER-TORQUE CURVES
108515
Max OUTPUT 245kW at 2400 rpm
Max TORQUE 1400Nm at 1080 to 1655 rpm
330HP
143 kgm
Figure3
rpm
10 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
Aquila Trucks Centres
F2BE3681A: POWER-TORQUE CURVES
108516
Max OUTPUT 265kW at 2400 rpm
Max TORQUE 1500Nm at 1200 to 1685 rpm
360HP
153 kgm
Figure4
rpm
F2BENGINE 11 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
Aquila Trucks Centres
12 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
MAIN DATA
Type F2BE3681C F2BE3681B F2BE3681A
Cycle 4-strokeDiesel engine
Fuel feed Tu rbocharged with aftercooler
Injection Direct
No of cylinders 6 in line
Bore mm 115
Stroke mm 125
+ + +.. =Total displacement cm
3
7790
Compressionratio 16 0.8
Max. output kW
(HP)
230
(310)
245
(330)
265
(360)
rpm 2400 2400 2400
Max. torque Nm
(kgm)
1300
(132)
1400
(143)
1500
(153)
rpm
1200 1675 1080 1655 1200 1685
Engine idlingspeed
no load
rpm 600 50
Maximumengine
speed no load
rpm 2660 50
Aquila Trucks Centres
F2BENGINE 13 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Type F2B
A
B
VALVE TIMING
opens beforeT.D.C. A
closesafter B.D.C. B
17
31
C
D
opens beforeB.D.C. D
closesafter T.D.C. C
48
9
X
For timingcheck
mm
X
mm
Running
mm
X
mm
_
_
0.35to 0.45
0.35to 0.45
FEED
Throughfuel pump- Filters
Injection
typeBosch
With electronicallyregulatedinjectors UIN2
pumpinjectors controlledbyoverheadcamshaft
Nozzletype Nozzletype _
Injection order 1- 4- 2- 6- 3- 5
bar
Injection pressure bar
1600
Aquila Trucks Centres
14 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
Type F2BE3681C F2BE3681B F2BE3681A
SUPERCHARGING
Turbocharger
Fixed geometry
HOLSET
Variablegeometry
type:
HOLSET
HX 40 HOLSET HE 431 V
LUBRICATION Forcedbygear pump, overpressurevalve, oil filter
bar
Oil pressure, enginehot
(100
o
C 5
o
C):
bar
at idlingspeed bar 1.5
at maximumspeed bar 5
COOLING
Bycentrifugal pump,thermostat,electro-magnetingfan,radiator
and heat exchanger
Water pump control Bybelt
Thermostat: N. 1
starts to open: 85C
fullyopen:
_
OIL FILLING
Total capacityat 1st filling
liters
28
kg
28
25.2
Capacity:
- engine sump minlevel
liters
12.5
kg
12.5
11.2
U i FE 5W30
- engine sump maxlevel
liters
11.2
23
UraniaFE 5W30
UraniaLD7
kg
23
21 UraniaLD7
- quantity in circulation that
does not flow back to the
enginesump
liters
21
kg 5
- quantity contained in the
cartridge filter (which has to
beaddedtothecartridgefilter
refill)
liters
4.5
2.5
kg
2.3
Aquila Trucks Centres
F2BENGINE 15 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
ASSEMBLY CLEARANCE DATA
Type F2B
CYLINDER BLOCK AND CRANK
MECHANISMCOMPONENTS
mm
1
Cylinder liner bore
upper
1
lower
130.200to 130.225
128.510to 128.535
Cylinder liners:
L
outer diameter:
upper
2
lower
130.161to 130.186
128.475to 128.500
2
length L
Cylinder liner -
crankcasebore
upper
lower
0.014 to 0.064
0.010 to 0.060
Outsidediameter 2 _
Cylinder liner
3
A* 115.000 to 115.012
X
inside diameter 3
B* 115.010to 115.022
Protrusion X** 0.035 to 0.065
* Available dia. class
** Under aload of 6000 kg
1
Pistons:
1
X
measuringpoint X 18
X
outsidediameter 1A 114.871to 114.883
2
outsidediameter 1B 114.881to 114.893
outsidediameter 2 46.010 to 46.018
Class A pistonssuppliedas spares.
Class Bpistonsarefitted inproductiononlyand
arenot suppliedas spares.
Piston - cylinder liner 0.117 to 0.141
Pistondiameter 1 _
X
Pistons protrusion X 0.32to 0.69
3 Gudgeonpin 3 45.994 to 46.000
Gudgeon pin - pin housing 0.010 to 0.024
Aquila Trucks Centres
16 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
F2B F2B
Type
mm
Type
FEDERAL MOGUL J MAHLEPISTON Y
1 X
X1* 1.583 (rated) 1.583 to 1.613
X
1
2
X
Pistonringgrooves X 2 1.554 to 1.574 1.550 to 1.570
X 2
X3 4.02 to 4.04
3 X *measuredon of 111mm
1 S
Pistonrings:
1
2
S
S
Compressionring S1*
1.429 to 2.463
3
2
S
S
Scraper ring S2 1.47to1.50
3 S Scraper ring S2
Slotted oil
1.47 to1.50
Slotted oil
scraper ring S3
3.970 to 3.990
DMeasured at 2 mmfromthe outside
3.970 to 3.990
1 0.247to 0.311 0.111 to 0.175
Pistonrings- 2J
grooves 2Y
0.054 to 0.104
0.050 to 0.100
3 0 .030to 0.070
Pistonrings _
X 1
Pistonringendgapin
X 1
Pistonringendgap in
cylinder liners:
2 X X1
0.30to 0.40
3 X
X2 0.55to 0.70
X3
0.35to 0.65
1
Small end bush housing
1 49.975 to 50.000
1
2
Bigend bearing
housing 2
1
Selection classes 2
3
Rated value 77.000to 77.030
77.000 to 77.010
77.011 to 77.020
77.021 to 77.030
4 Small end bush
diameter
3
outside 4 50 .055to 50.080
3
inside 3
46.015 to 46.030
S
Bigend bearingshell S
Red
Green
Yellow
2.000 to 2.010
2.011 to 2.020
2.021 to 2.030
Small end bush
- housing
0.055 to 0.105
Pistonpin - bush 0.015 to 0.036
Bigend bearingshells 0.127 - 0.254 - 0.508
Connectingrodweight
A g. 2865to 2895
Class B g . 28961 to 2925
C g. 2926to 2955
* Factory-assembled only, andnot provided with asparepart
Aquila Trucks Centres
F2BENGINE 17 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
Type
F2B
Type
mm
X
Measuringpoint X 125
Max. connectingrod
axismisalignment
tolerance //
0.08
Mainjournals 1 Rated value 82.910to 82.940
1 2
1
Selectionclass 2
3
82.910 to 82.919
82.920 to 82.929
82.930 to 82.940
1 2
Crankpins 2 Rated value 72.915to 72.945
1
Selectionclass 2
3
72.915 to 72.924
72.925 to 72.934
72.935 to 72.945
S1 S 2
Mainbearingshells S1
Red
Green
YellowD
3.000 to 3.010
3.011 to 3.020
3.021 to 3.030
Bigend bearingshells S2
Red
Green
YellowD
2.000 to 2.010
2.011 to 2.020
2.021 to 2.030
Mainbearinghousings 3 Rated value 89.000to 89.030
3
1
Selectionclass 2
3
89.000 to 89.009
89.010 to 89.019
89.020 to 89.030
Bearingshells- f
mainjournals
0.040 0.098 * - 0.040 0.110 **
Bearingshells- f
bigends
0.035 0.093 * - 0.035 0.083**
Mainbearingshells 0.127 - 0.254 - 0.508
Bigend bearingshells 0.127 - 0.254 - 0.508
X1
Mainjournal,
thrust bearing X1 39.96 to 40.00
X2
Mainbearinghousing,
thrust bearing X2 32.94 to 32.99
X 3
Thrust washer
halves X3 3.38to 3.43
Crankshaft shoulder 0.11to 0.30
1 2
Parallel // 1- 2
Concentric 1- 2
0.010
0.040
D Onlymounted in productionandnot provided with spares
f Sparesprovided: : * =standard spares- 0.127; ** =0.254- 0.508
Aquila Trucks Centres
18 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
11
Type F2B
CYLINDER HEADS - VALVE TRAIN mm
1
Valveguidehousings
incylinder head
1 12.980 to 12.997
2
2
8.023 to 8.038
3
2
Valveguide
3
13.012 to 13.025
Valveguides - housings
inthecylinder head
0.015 to 0.045
Valveguide 0.2 to 0.4
4 Valves: 4 Valves:
4
7.970 to 7.985
4
60 30 7 30
4
7.970 to 7.985
4
45
= +5'
- 0
Valvestemand its guide 0.038 to 0.068
Housinginhead for valve
seat seat
1 41.985 to 42.020
1 1
40.985 to 41.020
Outside diameter of valve
seat; angle of valve seat in
2
seat; angle of valve seat in
cylinder head:
42.060 to 42.075
2
60 - 30'
2
41.060 to 41.075
2
45 - 30'
Recessingof
valve X
0.5 to 0.8
X
valve X
1.6 to 1.9
Betweenvalve Betweenvalve
seat and head
0.040 to 0.090
Aquila Trucks Centres
F2BENGINE 19 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
Type
F2B
mm
Valveoutsidespring
height:
freeheight H 66
H
H1
2
under aload of:
H 1
H2
540 27N H1 49 .5
966 48N H2 37 .5
X
Injector protrusion X 0.7
Camshaft bush housing
fitted inthecylinder head:
1 7 80.000 to 80.030
1
2
3
Camshaft journal diameter:
1 7 75.924 to 75.940
Camshaft bushingouter
diameter: 80.090 to 80.115
Camshaft bushing
inner diameter: 1 6
7
75.990 to 76.045
76.008 to 76.063
Bushings and housings in
engineblock
0.060 to 0.115
Bushings and journals 0.050 to 0.121
Camlift:
8.07
H
7.63
8.828
1
Rocker shaft 1
37.984 to 38.000
Aquila Trucks Centres
20 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
Type
F2B
mm
Bushing housing in rocker
arms
41.000 to 41.016
53.000 to 53.019
42.000 to 42.016
Bushingouter diameter
for rocker arms:
41.097 to 41.135
53.105 to 53.156
42.066 to 42.091
Bushinginner diameter
for rocker arms:
38.025 to 38.041
50.025 to 50.041
38.015 to 38.071
Between bushings and
housings
0.081 to 0.135
0.086 to 0.156
0.050 to 0.091
Between rocker arms and
shaft
0.025 to 0.057
0.015 to 0.087
Engine brake control lever
Eccentric pin outer
diameter 2
Rocker armsshaft seat 1
49.984 50.000
38.025 38.041
Aquila Trucks Centres
F2BENGINE 21 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
Type
F2BE3681C F2BE3681B F2BE3681A
mm
Rocker arms and engine
brakecontrol lever pin
0.025 to 0.068
Rocker armshaft and seat
on engine brake control
lever
0.025 to 0.057
TURBOCHARGER
Type
Fixed geometry
HOLSET HX 40
VariablegeometryHOLSET HE431V
End float 0.025 to 0.127 0.025 to 0.127
Radial play 0.330 to 0.508 0.254 to 0.356
Aquila Trucks Centres
Revi- June2007
22 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
TIGHTENING TORQUES
Print603.93.641/A
PART TORQUE
Nm kgm
Lower crankcasefasteningscrews to cylinder block (seeFigure5)
Outer screws First stage : pre-tightening M10x1.25 25 2.5
Inner screws Secondstage : pre-tightening M16x2 140 14
Inner screws Third stage : angle closing M16x2 60
Inner screws Fourth stage : angle closing M16x2 60
Outer screws Fifth stage : angleclosing M10x1.5 90
Pipeunionfor piston coolingnozzle M 12X1.5 35 2 3.5 0.2
Intercooler fasteningscrews to cylinder block (seeFigure10)
pre-tightening
tightening
11.5 3.5
19 3
1.15 0.35
1.9 0.3
Plug 125 15 12.5 1.5
Spacer andoil sump fasteningscrews(seeFigure11) 41.5 3.5 4.1 0.3
Gearcasefasteningscrewsto cylinder block:
M10x1.25 41.5 3.5 4.1 0.3
M12x1.75 63 7 6.3 0.7
M8x1.25 23.5 1.5 2.3 1.5
Cylinder headfasteningscrew: (seeFigure 6)
First stage pre-tightening 50 5
Secondstage pre-tightening 100 10
Third stage angleclosing 90
Fourth stage angleclosing 75
Rocker armshaft fasteningscrew
First stage pre-tightening 40 4
Secondstage pre-tightening 60
Locknut for rocker armadjustingscrew 39 5 3.9 5
Screwsfor injector fasteningbrackets 36 1.5 3.65 0.2
Shoulder plate fasteningscrews to head 20 2 2 0.2
Engine support bracket fasteningscrews to cylinder head 74 8 7.4 0.8
Gear fasteningscrews to camshaft:
First stage pre-tightening 50 5
Secondstage pre-tightening 50
Phonic wheel fasteningscrews to distributiongear 8.5 1.5 0.8 0.1
Exhaust pipefasteningscrews (seeFigure8)
pre-tightening
tightening
30 3
60 3
3 03
6 0.3
Engine brake actuator cylinder fasteningscrews 19 3 1.9 0.3
Connectingrodcapfasteningscrews:
First stage pre-tightening 50 5
Secondstage pre-tightening 40
Engine flywheel fasteningscrews: M16x1.5x58
First stage pre-tightening 100 10
Secondstage pre-tightening 60
Engine flywheel spacer mount screws: M16x1.5x110:
First stage pre-tightening 100 10
Secondstage pre-tightening 120
Flywheel pulleyfasteningscrews to crankshaft:
First stage pre-tightening 70 7
Secondstage pre-tightening 50
Lubricate withoil MOLYKOTE before assembly
Lubricate withgraphitized oil beforeassembly
Aquila Trucks Centres
F2BENGINE 23 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
PART
TORQUE
PART
Nm kgm
Damper flywheel fasteningscrews: 115 15 11.5 1.5
Idler gear pin fasteningscrews:
First stage pre-tightening 30 3
Secondstage angleclosing 90
Idlegear link rodfasteningscrew 24.5 2.5 2.4 0.2
Oil pumpfasteningscrew 24.5 2.5 2.4 0.2
Oil pumpsuctionrosefasteningscrew 24.5 2.5 2.4 0.2
Front cover fasteningscrew to cylinder block 19 3 1.9 0.3
Control unit fasteningscrewto cylinder block 19 3 1.9 0.3
Supplypump fasteningscrew to gearcase 19 3 1.9 0.3
Fuel filter support fasteningscrew to cylinder head 24.5 2.5 2.4 0.2
Screwsecuringthe enginesupport to thewheelcase
First stage pre-tightening 100 10
Secondstage angleclosing 60
Turbo-compressor fasteningscrews and nuts (seeFigure10)
pre-tightening
tightening
35 5
46 2
3.5 0.5
4.6 0.2
Water pump fasteningscrewto cylinder block 24.5 2.5 2.4 0.2
Pulleyfasteningscrewto hub 55 5 5.5 0.5
Rocker armcover fasteningscrews (seeFigure12) 8.5 1.5 0.8 0.1
Thermostat boxfasteningscrewsto cylinder head 24.5 2.5 2.4 0.2
Automatictightener fasteningscrews to cylinder block 45 5 4.5 0.5
Fixed tightener fasteningscrewsto cylinder block 105 5 10.5 0.5
Fansupport fasteningscrewsto cylinder block 24.5 2.5 2.4 0.2
Starter fasteningscrews 44 4 4 0.4
Air heater oncylinder head 50 5 5 0.5
Air compressor fasteningscrew to cylinder head 74 8 7.4 0.8
Air compressor control gear fasteningnut 170 17 1
Hydraulic power steeringpumpgear fasteningnut 46.5 4.5 4.6 0.4
Air conditioner compressor fasteningscrewto support 24.5 2.5 2.4 2.5
Air conditioner compressor support fasteningscrewto cylinder block 44 4 4.4 0.4
Alternator support fasteningscrewto cylinder block 44 4 4.4 0.4
Alternator bracket fasteningscrewto cylinder block 24.5 2.5 2.4 0.2
Water pipe unions 35 3.5
Water temperaturesensor 32.5 2.5 3.2 0.2
Lubricate withoil MOLYKOTE before assembly
Lubricate withgraphitized oil beforeassembly
Aquila Trucks Centres
Revi- June2007
24 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
PRINT603.93.641/A
PART
TORQUE
PART
Nm kgm
Engine brake solenoid valvefasteningscrews 32.5 2.5 3.2 0.2
Flywheel revsensor fasteningscrew 8 2 0.8 0.2
Camshaft revsensor fasteningscrew 8 2 0.8 0.2
P.D.E solenoid connector fasteningscrew 1.62 0.3 0.1 0.3
Overboost pressure sensor fasteningscrew 8 2 0.8 0.2
Absolutepressuresensor fasteningscrew 22.5 2.5 2.2 0.2
P.W.M. control valve fasteningscrew/nut 8 2 0.8 0.2
Fuel/coolant temperaturesensor 35 3.5
Coolant temperatureindicator 23.5 2.5 2.3 0.2
Filter cloggingsensor 10 1
Oil temperatureswitch 25 1 2.5 0.1
Oil pressuresensor 25 1 2.5 0.1
Oil cloggingsensor 55 5 5.5 0.5
Electricwirefasteningscrew 8 2 0.8 0.2
Heater fasteningscrew 16 1 1.6 0.1
Power unit
M14x70/80 screw securingfront and rear elasticblocks to chassis 192.5 19.5 19.2 1.9
M16x130screwsecuringfront and rear elastic blocksto engine 278 28 27.8 2.8
M18x62 flanged HEX screw for front engineblock
Pre-tightening1
st
step 120 12
Angleclosing2
nd
step 45
M14x60 socket cheese-head TC screw for front engineblock
Pre-tightening1
st
step 60 6
Angleclosing2
nd
step 45
Flanged HEX screw for rear engineblock
Pre-tightening1
st
step 100 10
Angleclosing2
nd
step 60
Aquila Trucks Centres
44898
FRONT SIDE
Front phase:
angletightening
of inner screws
60
44897
44899
44898
Figure5
First phase:
preliminarytightening
of outer screws
(25 Nm)
FRONT SIDE
FRONT SIDE
Secondphase:
preliminary
tighteningof
inner screws
(140Nm)
Fifthphase:
angletightening
of outer screws
90
44898
FRONT SIDE
Third phase:
angletightening
of inner screws
60
FRONT SIDE
F2BENGINE 25 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
LOWER CRANKCASE FIXING SCREWS TIGHTENING SEQUENCE
Aquila Trucks Centres
44900
Figure6
DIAGRAM OF EXHAUST MANIFOLD FIXINGSCREWS TIGHTENING SEQUENCE
45359
DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE
1 8
6 3 2 7 6 3 4 7 6 3 2 7
5 4 8 5 2 8 5 4 1 1
Figure7
70567A
DIAGRAM OF ROCKER SHAFT FIXING SCREWS TIGHTENING SEQUENCE
Figure8
26 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
455361
Figure9
Figure10
DIAGRAM OF OIL SUMP FIXING SCREWS TIGHTENING SEQUENCE
45362
DIAGRAM OF HEAT EXCHANGER FIXING SCREWS TIGHTENING SEQUENCE
1
8
12 11 10 3
9 13
14
4 5 6 7 2
Figure11
DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE
SEQUENCE: Preliminarytightening 4- 3 - 1 - 2
Tightening 1 - 4 - 2 - 3
45360
F2BENGINE 27 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
Aquila Trucks Centres
Figure12
DIAGRAM OF ROCKER COVER FIXING SCREWS TIGHTENING SEQUENCE
45363
17 14 13 1 4 5 8
18
19
20
16 15 12 2 3 6 7
11
10
9
28 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
F2BENGINE 29 TRAKKEREURO 4/5
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TOOLS
TOOL NO. DESCRIPTION
99322230 Rotarytelescopicstand
99340051 Extractor for crankshaft front gasket
99340052 Extractor for crankshaft rear gasket
99340205 Puller withsliide-hammer
99342149 Extractor for injector-holder
99346245 Tool to install thecrankshaft front gasket
Aquila Trucks Centres
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Print603.93.331/A
TOOLS
TOOL NO. DESCRIPTION
99346246 Tool to install thecrankshaft rear gasket
99348004 Universal extractor for 5to 70 mminternal components
99350072 Box wrenchfor transmission gear support fixingscrews
99350074 Box wrench for block junctionbolts to thelower crankcase
99360177 Injector housingplug
99360184
Tool for removingand refittingpiston rings
(105-160 mm)
Aquila Trucks Centres
F2BENGINE 31 TRAKKEREURO 4/5
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TOOLS
TOOL NO. DESCRIPTION
99360192
Elasticbelt assemblingtool
99360264 Tool to takedown-fit engine valves
99360288 Tool to remove valve guide
99360292 Tool to install gasket onvalveguide
99360294 Tool to drivevalveguide
(usewith 99360288)
99360314 Tool to remove cartridgefilters
Aquila Trucks Centres
32 F2BENGINE TRAKKEREURO 4/5
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TOOLS
TOOL NO. DESCRIPTION
99360321 Tool to rotateengine flywheel
99360334 Tool for checkingcylinder liners protrusion
99360335 Cylinder linerscompressioncap(to beusedwith99360334)
99360351 Tool to stop engineflywheel
99360487
Tool to takedownandfit camshaft bushes
99360500 Tool to lift crankshaft
Aquila Trucks Centres
F2BENGINE 33 TRAKKEREURO 4/5
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TOOLS
TOOL NO. DESCRIPTION
99360551 Bracket to takedownandfit engine flywheel
99360558 Tool to lift andtransport rocker shaft
99360585 Tool for liftingand handlingengine
99360605
Belt to insert pistonincylinder liner (60- 125mm)
99360612 Tool for positioningengineT.D.C.
99360613 Tool for timingof phonicwheel on timinggear
Aquila Trucks Centres
34 F2BENGINE TRAKKEREURO 4/5
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Print603.93.331/A
TOOLS
TOOL NO. DESCRIPTION
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners
99360724 Ring(115 mm) (usewith 99360706)
99361035 Brackets fixingtheengineto rotarystand99322230
99365054 Tool for injector holder heading
99370415
Tool to detect cylinder liner protrusion
(usewith 99395603)
Aquila Trucks Centres
F2BENGINE 35 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
TOOLS
TOOL NO. DESCRIPTION
99378100
Tool for printing engine identification plates (to be used with
special punches)
99378130
Punches for printingengineidentificationplates
(consistingof: 99378101 (A) - 99378102 (B) - 99378103(C) -
99378104 (D) - 99378105 (E) - 99378106 (F) - 99378107 (G) -
99378108 (V))
99389834
Torquescrewdriver to calibratescrewsforinjectorsolenoidvalve
99390310 Valveguidesleeker
99390772 Tool to removeresiduesfrominjector holder
99390804 Tool to threadinjector holders to beextracted
Aquila Trucks Centres
36 F2BENGINE TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
TOOLS
TOOL NO. DESCRIPTION
99394014 Guidebush (to beused with 99394041or 99394043)
99394041
Cutter to rectify injector holder housing (to be used with
99394014)
99394043
Reamer to rectify injector holder lower side (to be used with
99394014)
99395215
Gaugefor centre distancecheckbetween camshaft and idlegear
99395216
|oaso|o a| o aoo|a t||too|o .|t| +/2' aoo 3/+' sooao
couplings
99395603 Dial gauge(0 - 5mm)
Aquila Trucks Centres
F2BENGINE 37 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
TOOLS
TOOL NO. DESCRIPTION
99395687 Reaminggauge(50-178mm)
99396033 Centeringringof crankshaft front cap
Aquila Trucks Centres
38 F2BENGINE TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Deactivate the batteries by disconnecting the
electric wires or opening the current main switch,
lift thecowlingandtilt cab.
Disconnect thetransmission, asdescribedinsection
4.
Operations to becarriedout inthelower side:
- drainthecoolant inapropercontainer,byremovingthe
radiator drainplug(12);
- remove the piping(11) between the radiator and the
water pump;
- drain power steering oil in a proper container, by
disconnectingdeliveryandreturn lines (20and18);
- disconnect pipings (13 and 14) fromthe water pump
fitting;
- disconnect connector (15) fromtheelectroniccontrol
unit asfollows:
A, lift the safetylever
B, shift the connector by disconnecting it from the
control
unit
C, lift theconnector byreleasingthe pawl;
- Disconnect electric connections (1 - 4 - 5) fromthe
engine, then releasethe cablefromthestraps usedfor
fasteningto theintakemanifold;
- disconnect theelectrical cables fromthe starter motor
(16) andtheground cable (17);
- disconnect pipe(19) fromair compressor;
- disconnect the sleeve (6) connecting aftercooler
radiator-intake manifold;
- removewaterpipe(2) betweenradiatorandthermostat
assembly;
- disconnect fuel deliveryand return pipings(21);
- if present, remove the pipe support bracket (10)
fasteningscrews to theengineblock;
- rremove screws (9) (where available), then remove
air-conditioningcompressor (8) fromits support;
- without disconnecting the compressor pipes and to
prevent drainingthe climatecontrol system, fasten the
compressor to the vehicle so that it does not interfere
with theengineremoval.
112328
If washing the engine bay, adequatelyprotect the
electric/electronic components and their
connections.
NOTE
Figure13
F2BENGINE T RAKKER EURO 4/5
Base November 2006
540110 ENGINE REMOVAL - REFITTING
Removal
Aquila Trucks Centres
87197
- disconnect waterpipings(7and8) fromthermostatunit
(9) (seeDetail A);
- if present, remove the pipe fasteningscrew (1) to the
conveyor (3);
- ifpresent, removethescrewsand (12) detach theheat
guard(11);
- removethescrews(4) anddisconnect thepipe(3) from
thesupport bracket (5);
- disconnect the air pipe (6); connec tion drier
compressor (A.P.U.);
- disconnect sleeve (2) connecting outlet piping (3)
betweentheturbocharger andtheaftercooler radiator;
- disconnect the sleeve (13) connectingair filter pipings
and turbocharger manifold;
- disconnect exhaust piping(14);
- if the vehicle is fitted with mechanical transmission,
removethesupport (18) together withtheenginegear
control lever (19);
- onlyvehicleswithshort cab:removesound-proofguard
(16), bolts (15), and then take off cab suspension
crossbar (17);
Usealiftingdeviceandspinterbar 99360595(hookedtothe
engine brackets) to stretch the chains. Loosen the screws
fastening the engine brackets to el astic supports (10 7 and
22, Figure252) onthechassis.
- Slowlyraisetheenginefromitscompartment bytaking
it backwards so that the fan is released fromthe air
conveyor compartment (20) ontheradiator.
- Operate the screws to remove the fan fromthe hub.
Removetheenginecompletelywithout interferingwith
theremainingfixedpartsonthechassis,inparticularthe
wiringinterferingwith the rear right enginesupport.
Refitting
Reverse the order of detachment operations,
takinggreat carewhenfittingtheassemblyintothe
engine compartment and following the advice
below:
- checkthat the exhaust pipingis not worn or about to
deteriorate; replace, if necessary;
- tightenthescrewsand/ornutstotheprescribedtorque;
- fill thecoolingsystemwith suitable coolant, then blow
air off the cooling systemas described in the relevant
chapter;
- blowair offthefuel systemasdescribedin therelevant
chapter (operation 542011);
Tightenthenutsfasteningtheelectriccablestothe
startingmotor terminals,byapplyingthetor-
quevaluesbelow:
- nut M10 x1.5(terminal 30):
17.6 24.5Nm(1.8-2.5Kgm);
- nut M5 x0,8 (terminal 50):
2.6 4.6Nm(0.27-0.47 Kgm);
Figure 14
NOTE
4 F2 BENGINE TRAKKEREURO 4/5
Base November 2006
Aquila Trucks Centres
87198
Fillingthesystem
After conscientiously followingthe above warnings,
proceedasfollows:
- Removethecap(2) fromtheexpansiontub(3).
- Pour thecoolant into theexpansion tub(3) till it isquite
full.
Bleedingair fromthesystem
Filling the cooling system
Preliminaryoperations
For vehicles equipped with just the standard cab heating
systemor manual air-conditioning:
- Fullyopenthecoolant cockontheinstrument panel.
For vehicles equipped with the automatic air-conditioning
system:
- Setthetemperaturecontrol inthecabontheHI position.
For vehicles equipped withanadditional heater:
- Theheater must not beturnedon.
Operations
Placeasheet of cardboard betweenthecoolant radiator and
theintercoolerradiatorinordertoshortenthetimeit takesto
oac| t|o oo|oo's .o'|o tooatoo (ao. 0 C).
GENERAL WARNINGS
Fillingmust bedonewiththeengine cold.
The cap (1) must not beremoved for anyreasons
whatsoever.
Toprevent pocketsofair forminginthesystem,the
fluidhastobetransferredslowly(approximateflow
rate8 litres/min).
Forvehiclesequippedwithanadditional heater:the
percentage of glycols in the coolant must be no
greater than50%.
For vehicles equipped withanadditional heater:
- Turnontheheater.
If thetubempties completelyduringthesefirst few
minutes, stop and engineand top it up at aslower
ratethanbefore.
Restart theengine.
- Start theengineand keepthespeedjust aboveidlingfor
5min.
- After 5 min. running, top up the level of fluid in the
expansiontub, if necessary.
- Closetheexpansiontubfiller with thecap(2).
Take the engine up to top speed so that the coolant
quickly reaches the temperature of full thermostat
opening(approx. 90 C) and keep it inthis stateuntil all
theair is bled out of thesystem.
Thisischeckedbyseeingthereisno foamor airbubbles
inthetub.
Thelongest timeit takestobleedtheairfromthesystem
completely is approximately 15 minutes from the
moment when the thermostat opens (opening starts
85 2 C).
Donot takethefiller capofftheexpansiontubuntil
thefluid in thesystemhascooledcompletely.
Anytoppingupmust onlybedonewith theengine
cold.
Thisis to avoid:
1 - Operator burns.
2 - Damage to the engine since cooling system
pressurization is only created with the fluid
heatingfromtheconditionof theenginecold.
NOTE
NOTE
NOTE
NOTE
Figure15
F2BENGINE 41 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
- Bleed screw(1) on thepre-filter mounting.
- Bleed screw(2) on thefilter mounting.
- Bleed screw(4) on thefront of thecylinder head.
- Work the pump (3) on the pre-filter mountingtill fuel
withnoairbubblesinit comesout of thescrew(1);close
thescrew.
- Repeat thisstepfor screw(2).
- Repeat thisstepfor screw(4).
1
3
2
Checks and tests
Start theengine, leaveit runningat just alittlefaster
thanidlingspeedandwaitforthetemperatureofthe
coolant to reachthe level to open the thermostat.
Then, check that:
- No water leaksfromthe connectingsleevesof thepipes
intheenginecoolingandcabheatingcircuits,tighteningthe
collarsfurther if thisisnecessary.
- No oil leaks frombetween the cover and the cylinder
head, betweentheoil sumpand the crankcase, between
theoil filter anditsseat,betweentheheat exchanger and
the crankcase, or between the various pipes in the
lubricationcircuit.
- No air leaksfromthepipesconnected to thepneumatic
components involved inremoval.
- The indicator lights on the instrument panel and the
devicesdisconnectedwhenremovingtheengineall work
properly.
4
Before bleeding the fuel system connect proper
pipes to the bleeding screws located on prefilter
support, filter andcylinder headfront part, inorder
to recover fuel in suitable containers during this
operation.
Inparticular,never allowthat thefuel,comingoutof
thecylinder headdrainingscrew, stainsthecontrol
beltsofthefan, thewater pump, thealternator and
theconditioner compressor, thusdamagingthem.
Figure16
NOTE
42 F2BENGINE TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
542011 Bleeding air from the fuel system
Aquila Trucks Centres
87199
Tocut offthebatteries,removetheelectricwiresoropenthe
main switch.
Removethebumper fasteningscrews.
Move the bumper away from its respective supporting
brackets, then placeit, without subjectingthe electriccables
and the headlamp wiper pipe (if any) under tension, on a
suitablestandsoastosubsequentlyallowthecabtobetilted.
Lift theradiator grill, thentilt thecab.
Go under the vehicle and remove the plug (15) fromthe
radiator (16) and drain the coolant fluid in the appropriate
container.
Removetheclip(14) anddisconnect theradiator (16) sleeve
(13).
On the engine compartment left-hand side, remove the
screws(12) andtheheat guard(11). Takeoffthescrewsand
disconnect theair conveyor (8) climatecontrol pipes(5).
Slackenthesleevefasteningclamp(7)fromtheintercooler (6)
radiator.
Remove the air conveyor (8) fastening screws (9) to the
support bracket (10).
Removethescrew(19) anddetachtheelectricwire(18) from
theair conveyor (8).
Remove the clamp (20) and detach the air conveyor (8)
together withthesleeve (7) fromtheturbocharger (17) and
fromtheintercooler radiator (6).
Drive in thesuitableself-threadingscrewin the pin hole (3)
taking care to partially take off and finally remove with a
screwdriver theupper clip(2) fasteningthe fan air conveyor
(4) to radiator guard(1).
Removethelower clip inthesameway.
Remove the two radiator support fastening screws to the
chassis.
Removal
Figure17
F2BENGINE 43 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
543422 ELECTRO-MAGNETIC FAN DRIVE REPLACEMENT
Aquila Trucks Centres
87200
Onthe right-handside
Disconnect thepipe(1) fromthethermostat.
Remove clip (10), then disconnect sleeve(9) fromradiator
(11).
Slackentheclamps (7) and removethesleeve (6)
Remove the upper and lower clip (3) as described for the
left-handside.
Removetheradiatorfasteningscrewstothechassisandmove
the radiator unit forwards.
Removethefan(2) fasteningscrewstotheelectro-magnetic
joint (14).
Removethefan (2) together with theair conveyor (4).
Release, by acting on automatic stretcher (16), belt (15)
tension, thenremovethebelt fromthepulleys.
Disconnect the electric connection (12) of the
electro-magneticjoint (14).
Removethescrews (13) and theelectro-magneticjoint (14)
fromtheengine.
Refitting
To refit theelectro-magneticfandrive, reversethe
removal procedureandattaintothefollowingrules:
- check the control belt (15) conditions; replace it if
damagedor wornout;
- tightenthescrewsand/ornutsto theprescribedtorque;
- fill thecoolingsystemwiththeprescribedfluid,thenblow
air off thecoolingsystemas described in therespective
chapter;
The electro-magnetic joint is fitted with two
threadedholes( ) at 180 onefromtheother. In
theevent of fault, lockthejoint control drivingina
M8x16 mmscrew in these holes. In this wayit is
possibletotakethevehicletotheclosestdealership.
Figure18
NOTE
44 F2BENGINE TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Figure19
78839
ENGINE - LONGITUDINAL SECTION
F2BENGINE 45 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
78841
Figure20
ENGINE - CROSSSECTION
46 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
47562 47563
47601
Figure21
Figure22
Figure23
Beforedismantlingtheengineontherotarystand99322230,
removethe followingcomponents:
- starter (2)
- turbocharger soundproofingshield(1)
Remove the soundproofingshield(1) and plug(2)
Fix the engine to the rotarystand 99322230, bymeans of
brackets 99361035(1), removethefan.
1
1
1
1
F2BENGINE 47 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
540110 DISASSEMBLING THE ENGINE
Aquila Trucks Centres
Remove the followingcomponents:
- alternator (1);
- belt tightener support (2);
- if present, air conditioner compressor (3);
- water pump (5) andpipe;
- fixedbackstand(4).
Onlymodels equipped without Intarder
- thermostat unit (6).
73579
87202
Figure24
Figure25
Figure26
Figure27
Usinganappropriatetool (2),operateinthedirectionofthe
arrow, and remove the belt (1) driving the water pump,
alternator and fan.
Take out the screws and remove the el ectromagnetic
coupling(3).
112330
Cut thebelt (1), as it must not beusedagain.
Onlymodels equipped withIntarder
Loosen straps (2 and 4), then remove pipe (1) fromthe
cylinder headandpipe (3).
Remove the fasteningscrews, thentakeoff thermostat unit
(5).
87203
48 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
Removethefollowingcomponents:oil supplylines(1);water
coolingsupplylines (3); water discharge lines (2); oil return
lines(4); turbocharger (5); exhaust manifold(6).
87204
45254
47566
Figure28
Figure29
Figure30
Block theflywheel rotationwithtool 99360351.
Removescrews(4), thendisassembledamper (3).
Removethescrews (2) andthepulley(1).
87205
Figure31
Unscrewtheoil filter (1) bytool 99360314 (2).
Install extractor 99340051 (2) and remove theseal gaskets
(1). Unscrewthescrewsand removethecover.
Disconnect all electricconnections andsensors.
87206
Figure32
Unscrewthescrews(1) andremovetheentireheatexchanger
(2).
F2BENGINE 49 TRAKKER EURO 4/5
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PRINT603.93.641
Aquila Trucks Centres
Removethefollowingcomponents:inletmanifold(6);support
for fuel filter (1); fuel lines(2); fuel pump (3);compressor (4);
control unit (5).
47587
45661
86289
47568
Figure33
Figure34
Unscrew the screws (2), by using the proper wrench and
removethegear (1) withthe phonicwheel.
Bymeansof aproperlysplinedwrench, untightenscrews(2)
and removethetransmissiongear (1)
84377
Removetherockerarmcover (1),takeoffthescrews(2) and
remove: thecover (3),thefilter (5) andthegaskets(4and6).
Takeoff thescrews (8) andremove theblow-bycase(7).
70708
To removetheP.T.O. (if applicable):
- Disconnect theoil pipe (1).
- Unscrewthe4screws(2) and (3).
Figure35
Figure36
Figure37
Figure38
Unscrewthescrews(1);tightenascrewinareactionholeand
removethe shoulder plate (2), removethesheet gasket.
50 F2BENGINE TRAKKER EURO 4/5
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Aquila Trucks Centres
47569
45257
45259
Figure39
Figure40
Figure41
Applyextractor 99340052(2)andpull out theseal gasket(1).
Untightenthescrews(1) andtakedownthegearhousing(2).
- Removethechecksprings(2) oftheexhaust brakelever;
- Untightenthefixingscrews(1) ofrocker armshaft.
47568
Stoptheflywheel (3) rotationbymeansoftool 99360351(1),
untightenthefixingscrews(2) andremovetheflywheel.
116190
- Applytool 99360553(1) to the rocker holder shaft (2)
and removetheshaft (2) fromthecylinder head.
Figure42
Figure43
Figure44
Removepower take-off control gear (1), if any.
Removescrews(3) anddismount doublegear (2).
Removesecuringscrewand dismount articulated rod (5).
Dismount oil pump(4).
106219
F2BENGINE 51 TRAKKER EURO 4/5
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Aquila Trucks Centres
45266
47573
47572
47574
Removethecamshaftandthefixingscrewsoncylinderheads
- By means of wire ropes, lift the cylinder head (1) and
removeseals(2).
Untightenscrews(2) andremovetheengineoil sump(1) with
frame (3) andseal .
Untightenscrewsandremovesuctionrose (1).
Rotate theblock(1) to thevertical position.
116232
- Removethepiping(1) for exhaust brakepins;
- Untighten screws and remove electric connections (2)
fromsolenoidvalves;
- Untightenfixingscrews(3) of injector brackets (4).
- Removeinjectors(5).
- Install plugs99360177insteadofinjectors.
Figure45
Figure46
Figure47
Figure48
Figure49
Thecylinder headmount screws must bereplaced
at eachremoval operation.
NOTE
Revi - June2007
52 F2BENGINE TRAKKER EURO 4/5
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PRINT603.93.641/A
Aquila Trucks Centres
47576
47571
47570
By means of proper and splined wrenches, untighten the
screws(1) and (2) andremovethelower crankcase (3).
Removethecrankshaft (2) withtool 99360500 (1).
Removethecrankshaft half-bearings(1),untightenthescrews
and remove oil spraynozzles (2).
Takedowncylinderlinersasspecifiedintherelativeparagraph
onpage56.
After disassembling the engine, thoroughly clean
disassembled parts andcheck their integrity.
Instructionsfor mainchecksandmeasuresaregiven
in the following pages, in order to determine
whether thepartscan bere-used.
47575
Untighten screws (2) fixingtheconnectingrod cap (3) and
removeit.Removetheconnectingrod-pistonassemblyfrom
theupperside.Repeat theseoperationsfortheotherpistons.
Figure50
Figure51
Figure52
Figure53
NOTE
F2BENGINE 53 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Aquila Trucks Centres
A =Selectionclass 115 to 115.012mm
B=Selectionclass 115.010 to115.022 mm
In case of maximum wear max 0.150 mm or maximum
ovalizationmax 0.100 mmcomparedto thevaluesindicated
inthe figure, theliners must be replaced as theycannot be
ground, lapped or trued.
540410 CYLINDER BLOCK
540420 Checks and measurements
Internal diameter of the cylinder liners is checked for
ovalization, taper and wear, usingaboredial (1) centesimal
gauge 99395687 (2) previously reset to ring gauge (3),
diameter 115mm.
Ifa115ringgaugeisnot availableuseamicrometer
caliper.
A = 130.200 to 130.225mm
B= 128.510to 128.535mm
C = 130.161to 130.186
D= 128.475 to128.500 mm
Thefigureshowstheouterdiametersofthecylinderlinersand
therelativeseat inner diameters.
Thecylinderlinerscanbeextractedandinstalledseveraltimes
indifferent seats, if necessary.
34994
47439
47440
47441
Figure54
Figure55
Figure56
Figure57
1=1st measuring
2=2ndmeasuring
3=3rdmeasuring
Carryout measuringsoneachcylinder linerat threedifferent
levels and on two (A-B) surfaces, to one another
perpendicular, asshowninFigure.
(Demonstration)
Cylinder liners areequipped with spareparts with
'/' so|oct|oo c|ass.
NOTE
NOTE
54 F2BENGINE TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
REPAIR OPERATIONS
Aquila Trucks Centres
45150 45150a
47533
Figure58
Figure59
CYLINDERLINERSMAIN DATA
||T/|| ''
'/' = So|oct|oo c|ass a'|o aoa
Figure60
47534
BLOCKWITH CYLINDERLINERS
A mm115.000to 115.012
Bmm115.010 to 115.022
Selectionclass
A
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CYLINDER LINERS
Aquila Trucks Centres
47577
77812
16798
35012
Figure61
Figure62
Figure63
Placedetails99360706 (1and2) andplate99360724(4) as
shown in the figure, by making sure that the plate (4) is
properlyplaced on thecylinder liners.
Tightenthescrewnut (1) andremovethecylinder liner (3)
fromtheblock.
Alwaysreplacewater sealingrings (3, 4 and 5).
Install the adjustment ring (1) on the cylinder liner (2);
lubricatelower part of liner and install it in the cylinder unit
usingtheproper tool.
Check cylinder barrel protrusion with tool 99360334
(1-2-3-4) andtightenscrew(1) to 170 Nm.
Withdial gauge99395603(5) placedonbase99370415(6).
Measure the cylinder barrel protrusion compared to the
cylinderheadsupportingplane,it mustbe0,035to0,065mm
(Figure64); otherwise replace the adjusting ring (1,
Figure62) fittedwithspareparts havingdifferent thickness.
Whentheinstallationiscompleted,blockthecylinder liners
(1) to theblock (2) withstuds99360703 (3).
Fitting and checking protrusion
(Demonstration)
Figure64
CYLINDERLINER PROTRUSION
49017
The adjustment ring(1) is suppliedas spareparts
inthefollowingthicknesses: 0.08mm- 0.10mm-
0.12mm.
Figure65
NOTE
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540420 Replacing cylinder liners
Removal
Aquila Trucks Centres
116410
Figure66
Figure67
X. Detail of main journalsconnections Y. Detail of crank pinsconnections
Figure68
MAIN DATA FORTHE CRANKSHAFT PINSAND THE HALF BEARINGS
Checktheconditionof the journals andthebigend pins; theremust no besigns of scoring, ovalizationor excessivewear.
The datagiven refer to thenormal diameter of thepins.
47537 47538
Upper mainjournal half bearing
Lower mainjournal half bearings
BUFF
BUFF
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PRINT603.93.641/A
5408 CRANKSHAFT
Aquila Trucks Centres
MEASURINGCRANKPINS
Duringgrinding,payattentiontojournal andcrankpinsvalues
specified in figures 68 and 69.
47535
47536
Figure69
Figure70
MEASURINGTHE MAIN JOURNALS
Before grinding the crank pins using a micrometer (1),
measurethemainjournalsandthecrankpins(2) anddecide,
on the basis of the undersizing of the bearings, the final
diameter to which thepins areto beground.
It is advisable to enter thevalues found in atable
(Figure71).
All journalsandcrankpinsmust alsobegroundto
the sameundersizing class, in order to avoid any
alteration to shaft balance.
Figure71
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
36061
MIN.
MAX.
MIN.
MAX.
CRANK PINS
NOTE NOTE
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PRINT603.93.641
540812 Measuring main journals and crank pins
Aquila Trucks Centres
For each of thejournals of the crankshaft, it isnecessaryto carryout the followingoperations:
MAIN JOURNALS:
- Determine the class of diameter of the seat in the
crankcase.
- Determinetheclass of diameter of themainjournal.
- Select the class of thebearingshellsto mount.
CRANKPINS:
- Determine the class of diameter of the seat in the
connectingrod.
- Determinetheclass of diameter of thecrankpin.
- Select the class of thebearingshellsto mount.
DEFINING THE CLASSOF DIAMETER OF THE SEATSFOR BEARING SHELLSON THE CRANKCASE
On thefront of thecrankcase, two setsof numbersaremarkedinthe positionshown(Figure72at top).
- The first set of digits (four) isthecouplingnumber of thecrankcase with its base.
- The followingseven digits, takensingly, aretheclassof diameter of eachof theseatsreferred to (Figure72at bottom).
- Each of thesedigits maybe 1, 2 or 3.
47535
89.000 to 89.009
89.010 to 89.019
89.020 to 89.030
Figure72
CLASS
MAIN BEARINGHOUSING
NOMINAL DIAMETER
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PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
Aquila Trucks Centres
To obtain the required assemblyclearances, the main and bigend bearingshells needto beselected as described
hereunder.
Thisoperationmakesit possibleto identifythemost suitablebearingshellsforeachofthejournals(thebearingshells,ifnecessary,
can havedifferent classes fromone journal to another).
red
red/black
green
green/black
STD
2.000 to 2.010
2.011 to 2.020
+0.127
2.063 to 2.073
2.074 to 2.083
+0.254
2.127 to 2.137
2.138 to 2.147
+0.508
2.254 to 2.264
2.265 to 2.274
Dependingon the thickness, thebearingshells areselected
inclassesoftolerancemarkedbyacolouredsign(red-green
oo/b|ac' ooo/b|ac').
The followingtablesgive thespecifications of the mainand
bigendbearingshellsavailableassparesinthestandardsizes
(STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
* Fitted inproductiononlyand not supplied as spares
Figure73
yellow*
yellow/black*
2.021 to 2.030
red
red/black
green
green/black
STD
3.000 to 3.010
3.011 to 3.020
+0.127
3.063 to 3.073
3.074 to 3.083
+0.254
3.127 to 3.137
+0.508
2.254 to 3.264
yellow*
yellow/black*
3.021 to 3.030
2.084 to 2.093
3.084 to 3.093
NOTE
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Selecting the main and big end bearing shells
Aquila Trucks Centres
Mainjournalsandcrankpins: determiningtheclassof diameter of thejournals.
Three sets of numbers aremarked onthe crankshaft inthe positionshown bythe arrow(Figure74at top):
- The first number, of fivedigits, is thepart number of theshaft.
- Under thisnumber, ontheleft, aset of sixdigits refersto thecrankpinsandisprecededbyasingledigit showingthestatus
of thejournals(1=STD, 2 =-0.127), theother sixdigits, taken singly, givetheclass of diameter of eachof thecrankpins
theyrefer to (Figure74at top).
- The set of sevendigits, on the right, refers to themain journalsandisprecededbyasingle digit: thesingledigit shows the
statusof the journals(1=STD, 2 =-0.127), theother seven digits, taken singly, give theclass of diameter of each of the
mainjournals theyrefer to (Figure 74 at bottom).
Figure74
72.915 to 72.924
72.925 to 72.934
72.935 to 72.945
CLASS
CRANKPIN
NOMINAL DIAMETER
82.910 to 82.919
82.920 to 82.929
82.930 to 82.940
CLASS
MAIN JOURNALS
NOMINAL DIAMETER
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DEFINING THE CLASSOF DIAMETER OF THE MAIN JOURNALSAND CRANKPINS (Journalswith nominal diameter)
Aquila Trucks Centres
Selection of main half-bearings (nominal diameter pins)
After detecting, for each journal, the necessarydataon block and crankshaft, select the type of half-bearings to be used, in
compliance withthe followingtable:
STD.
1 2 3
1
2
3
green
green
red
red
red
red
green
green
green
green
red
red
green
green
green
green
red
red
Figure75
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Aquila Trucks Centres
green/black
Selection of main half-bearings (rectified pins)
If thejournals havebeenrectified, the proceduredescribed cannot beapplied.
In this case, makesure that thenew diameter of thejournals isas specifiedon thetable and install theonlyhalf-bearingtype
requiredfor thisundersizing.
-0.127
1 2 3
82.784
82.793
green/black
green/black
green/black
green/black
green/black
green/black
red/black
red/black
green/black green /black
green/black
red/black
red/black
red/black
red/black
red/black
red/black
82.794
82.803
82.804
82.814
1
2
3
red/black =
mm3.063to3.073
green/black =
mm3.073to3.084
-0.254
1 2 3
82,666
82,686
red red red
red red red
red=
mm3.127to3.137
-0.508
1 2 3
82.412
82.432
red red red
red red red
red=
mm3.254to3.264
Figure76
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Aquila Trucks Centres
Figure77
SELECTING THE BIG END BEARINGSHELLS
(JOURNALSWITH NOMINAL DIAMETER)
Therearethreemarkingsonthebodyoftheconnectingrod
|o t|o os|t|oo s|o.o |o t|o v|o. o '/'.
1
2
3
The number, indicatingtheclass of diameter of thebearing
shell seat maybe 1, 2 o 3.
Determinethetypeof bigendbearingto fit oneachjournal
byfollowingtheindicationsinthe table(Figure78).
47557
VIEW FROM A
STD.
1 2 3
1
2
3
green
green
red
red
red
red
red
red
green green
green green
green
green green
green
red
red
Class
Figure78
Letter indicatingtheclassof weight:
A = 2865to 2895g.
B = 2896to 2925g.
C = 2926to 2955g.
Number indicating the selection of the diameter of the
bigendbearingseat:
1 = 77.000 to 77.010 mm
2 = 77.011 to 77.020 mm
3 = 77.021 to 77.030 mm
Numbersidentifyingthecap-connectingrod coupling.
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Aquila Trucks Centres
green/black
Selection of connecting rod half-bearings (r ectified pins)
If pins havebeen rectified, theproceduredescribedmust beapplied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belongto, and install the half-bearings
identified accordingto therelativetable.
-0.127
1 2 3
72.789
72.798
green/black
green/black
green/black
green/black
green/black
green/black
red/black
red/black
green/black green /black
green/black
red/black
red/black
red/black
red/black
green/black
green/black
72.799
72.808
72.809
72.818
1
2
3
red/black =
mm2.074 to 2.083
green/black =
mm2.063to2.073
-0.254
1 2 3
72.671
72.680
red green green
red green green
red
mm2.127to2.137
green =
mm2.138to2.147
-0.508
1 2 3
72.417
72.426
red green green
red green green
red red gr een
red red gr een
72.427
72.437 red red gr een
red red gr een
red=
mm2.254to2.264
green =
mm2.265to2.274
72.681
72.691
Figure79
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Aquila Trucks Centres
Install thehalf-bearings(1) onthemainbearingsinthelower
crankcase(2).
Checkthe installationclearancebetweenthemainjournals
and therelativebearings asfollows:
Usingthehoist andhook99360500(1)mount thecrankshaft
(2).
After fitting the gear (1) on the crankshaft (2), heat it for
15 minutes in an oven at temperature not higher than
180 C.
Let themcool down after theinstallation.
If changingthepin (3), after fittingit on, check it protrudes
fromthecrankshaft asshownin the figure.
49020
47579
47578
49021
Figure80
Figure81
Figure82
Figure83
Install theoil spraynozzles(2) andhavethedowel coincide
with theblock hole (3).
Install thehalf-bearings (1) onthemainbearings.
Checkthat theteethofthegearsare not damagedorworn,
otherwiseremovethemusingtheappropriateextractor.
540811 Checking main journal installation
clearance
1
2
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540815 Replacingthevalvedrivegear andthe
oil pump drive gear
Aquila Trucks Centres
End float ischecked byplacingamagnetic dial gauge(1) on
thecrankshaft (2),asshowninthefigure.Ifthevalueobtained
ishigher than specified, replacetherear thrust half-bearings
and repeat this check.
- Lubricate inside screws (1) con UTDMoil, andtighten
thembytorque wrench to 140 Nmtorque, thuswith
60 angleclosing, followingthediagraminFigure 86.
Place a piece of calibrated wire on the journal of the
crankshaft (2), parallel to the longitudinal axis; install the
lower crankcase(1), byhoist and appropriate hooks.
49022
47579
47578
47588
44898
Figure84 Figure85
Figure86
Figure87
Figure88
- Removethe lower crankcase
The clearance between the main bearings and thejournals
isobtainedbycomparingthecalibratedwirelength(2) at the
maximumdeflection point, with the calibrated scaleon the
coating(1) containingthecalibrated wire (1).
Numbers shown on the scale specify the clearance in
coupling millimeters. If the clearance obtained is different
fromthe clearance required, replace the half-bearings and
repeat this check.
FRONT SIDE
Diagramshowingthe tighteningorder of the screwsfixingthelower crankcase to theblock
Checking crankshaft end float
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Makesurethepistondoesshowanytraceofseizing,scoring,
cracking; replaceas necessary.
49023
47580
Figure89
Figure90
PISTON CONNECTINGROD ASSEMBLY
1. Connectingrod body- 2. Half bearings - 3. Connectingrod cap- 4. Capfasteningscrews- 5. Seeger ring- 6. Slotted oil
control ring- 7. Scraper ring- 8. Compressionring- 9. Gudgeonpin- 10. Piston
Removal ofthepistonrings(2) usingthepliers99360184(1).
Removal
Pistonsareequippedwiththreeelasticrings:asealingring,a
trapezoidal ringand ascraper ring.
Pistons aregroupedinto classes A andBfor diameter.
49024
Figure91
Remove the piston pin seeger rings (2) using the round
tippedpliers(1).
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5408 PISTON-CONNECTING ROD ASSEMBLY
Aquila Trucks Centres
49025
32618
49026
Figure92
Figure93
Figure94
Figure95
Remove thegudgeon pin (1).
If removal isdifficult usethe appropriatebeater.
Measuring the diameter of the pistons
Measuringthegudgeonpindiameter (1) witha micrometer
(2).
Conditions for correct gudgeon pin-piston
coupling
Lubricatethepin(1) andtherelevant housingonthepiston
hubs with engine oil; piston must be inserted with a slight
finger pressureandit should not comeout bygravity.
47584
Usingamicrometer (2), measurethediameter of thepiston
(1) todeterminetheassemblyclearance;thediametershould
bemeasuredat thespecified value.
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MAIN DATA OF PISTON, RINGSAND PIN
X =0,6 0,15mm
The dimensionis measured on a 111 mm
16552
3513
Figure96
Checkthethicknessofthepistonring(2) usingamicrometer
(1).
The compression ring (2) of the 1 cavity is trapezoidal.
C|oaaoco 'X' bot.ooo t|o soa||o |o aoo |ts |oos|o |s
measuredbyplacingthepiston(1) withitsringinthecylinder
liner (3), so that thesealingringis half-projected out of the
cylinder liner.
540842 Piston rings
109108
16552
Checkthe clearancebetweentherings(2) and therelative
piston housings(1) usingafiller gauge (3).
36134
Checkthegapbetweentheendsofthesealingrings(1),using
afiller gauge(2), enteredinthecylinder liner (3).
Ifthedistancebetweenendsislowerorhigherthanthevalue
required, replacetherings.
Figure97
Figure98
Figure99
Figure100
70 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
117178
44927
Figure101
Figure102
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS
* Valuesto be obtained after installingthe bush
CONNECTING ROD MARKS
Letter indicatingtheweight class:
A = 2865to 2895g.
B = 2896to 2925g.
C = 2926to 2955g.
Number indicating the selection of diameter for
thebigend bearinghousing:
1 = 77.000 to 77.010 mm
2 = 77.011 to 77.020 mm
3 = 77.021 to 77.030 mm
Numbersidentifyingcap-connectingrod coupling
1
2
3
Data concerning the class section of connecting rod
housingandweight arestampedonthebigend.
!
When installingconnecting rods, make sure
theyall belongto thesameweight class.
VIEW FROM A
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540830 CONNECTING ROD
Aquila Trucks Centres
Check thetorsion of the connecting rod(5) bycomparing
two points(A andB) of thepin (3) on the horizontal plane
of theaxis of theconnectingrod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads byapprox. 0.5mmon thepin(3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
oppositesideBof thepin(3):thedifferencebetweenAand
B must be no greater than 0.08mm.
Checkthebendingof theconnecting rod(5) bycomparing
twopointsC andD ofthepin(3) onthevertical planeofthe
axisof theconnectingrod.
Position thevertical mount (1) of thedial gauge (2) so that
this restsonthepin(3) at point C.
Swing the connecting rod backwards and forwards seeking
thehighest positionof thepinandinthiscondition zero the
dial gauge (2).
Shift thespindle(4) withtheconnectingrod(5) andrepeat
thecheckonthehighest point ontheoppositesideDofthe
pin(3).Thedifferencebetweenpoint C andpoint Dmustbe
no greater than0.08mm.
61696
Checkingaxis alignment
Check thealignment of theaxes of theconnectingrods (1)
usingasuitabledevice (5), proceedingas follows:
- Fit theconnectingrod(1) on thespindleof thetool (5)
and lockit with the screw (4).
- Setthespindle(3)ontheV-prisms,restingtheconnecting
rod(1) on thestop bar (2).
49029
Figure103
Figure104
Figure105
Figure106
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
T|o |os oooo to bo oootoo .|t| t|o .oo 'TC|' (+)
facing upwards. Direct the ring openings so they are
staggered 120 apart.
Fitting the connecting rod- piston assembly
Carryout thesteps for removal describedonpages 68and
69inreverseorder.
The connectingrod screwscan bereused aslong
asthediameter of thethreadis not lessthan13.4
mm.
Fitting the piston rings
Checkingtorsion
61694
Checkingbending
61695
NOTE
(Demonstration)
(Demonstration)
(Demonstration)
72 F2BENGINE TRAKKEREURO 4/5
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Checking connecting rod squareness
Aquila Trucks Centres
49030
47593
Figure107
Figure108
Figure109
Fit thehalf-bearings(1),selectedasdescribedonpages59to
65, bothontheconnectingrodandonthe stand.
- all pistons belongto thesameclass, A or B;
- ideogramstampedonthepistoncrownisplacedtoward
theengineflywheel, or the cavity, on thepiston cover,
correspondsto the position of theoil spraynozzles.
61831
Connectingrod-piston assembly
Markingareaon the pistoncrownof ideogram
specifying the assembly position and the
selectionclass
Connectingrodmarkingarea (seeFigure101).
1
2
3
Fit theconnectingrod-pistonassemblies(1) intothecylinder
liners (2) using band 99360605 (1, Figure109). Check the
following:
- theringsgaps areoffset by 120 ;
Asspares, classA pistonsareprovidedandcan be
fitted also to cylinder liners belongingto class B.
Piston protrusion check
Onceassemblyis complete, check piston protrusion from
cylinder barrels: it must be 0.32-0.69 mm.
NOTE
Be verycareful that theconnecting rod does not
strikethecylinder walls.
Revi- June2007
F2BENGINE 73 TRAKKEREURO 4/5
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PRINT603.93.641/A
Fitting the connecting rod-piston assemblyinto
the cylinder liners
Aquila Trucks Centres
Install theconnectingrodcaps(1) withhalf-bearings;tighten
theconnectingrodcapfixingscrews(2) to 50Nm(5kgm)
torque. Bytool 99395216(3), tightenthescrews further at
40 angle.
Removethecapsandchecktheclearancebycomparingthe
widthof thecalibratedwirewiththescalecalibrationonthe
envelopecontainingthewire.
540610 CYLINDER HEAD
Before dismounting cylinder head, check cylinder head for
hydraulic seal byproper tooling; in caseof leaksnot caused
bycupplugs or threadedplugs, replacecylinder head.
47594
47583
36159
Figure110
Figure111
Figure112
Install andfixtool 99360264(2) withbracket (4); tightenby
lever (1) until cottersareremoved(3);removethe tool (2)
andtheupperplate(5),thespring(6)andthelowerplate(7).
Repeattheoperationonall thevalves.Turnthecylinderhead
upside down and removethevalves (8).
The planarity (1) is checked using a ruler (2) and a feeler
gauge (3). If deformations exist, surface the head using
propersurfacegrinder;themaximumamount of material to
beremovedis0.2 mm.
To checktheclearanceproceedas follows:
Connect the connectingrods to therelative main journals,
placealength of calibrated wire on the latter.
Checking the planarity of the head on the
cylinder block
(Demonstration)
After leveling, make sure that valve sinking and
injector protrusion areas describedintherelative
paragraph.
540831 Checking assembly clearance of big
end pins
In case of plugs dismounting/replacement, on
mounting, applysealant Loctite 270 on plugs.
NOTE
Dismounting the valves
Before dismountingcylinder head valves, number
themin view of their remountingin the position
observedondismountingshouldtheynot haveto
beoverhauled or replaced.
Intake valves are different formexhaust valves in
that theyhaveanotchplacedat valveheadcentre.
NOTE
NOTE
Whenreplacing, thecylinder head is supplied as a
spare part with a threaded plug, which must be
removedduringassembly.
74 F2BENGINE TRAKKEREURO 4/5
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PRINT603.93.641
Aquila Trucks Centres
MAIN DATA - VALVESAND VALVE GUIDES
* Valuesto be obtained after installingthe valve guides
92841
47509
Figure113
Figure114
Check,bymeansofamicrometer,that valvestemdiameters
are as specified; if necessary, grind the valves seat with a
grinder, removingtheminimumquantityof material.
INSTALLATION DIAGRAMFORVALVEGUIDESAND VALVES
* Valuesto be obtained after installingthe guidevalves
540667 VALVE GUIDES
*
Figure115
48625
540622 VALVE
Removing dust and checking the valves
Removecarbon dust usingthemetal brush supplied. Check
that the valves showno signs of seizureor cracking. Check
the diameter of the valve stemusing a micrometer (see
Figure114) and replaceif necessary.
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Aquila Trucks Centres
41032
45634
Figure116
Figure117
Remove valve guidesbymeansof tool 99360288.
Install by means of tool 99360288 equipped with part
99360294, which determines theexact installationposition
of valve guides into the cylinder heads; if they are not
available, install thevalveguidesinthecylinder head sothat
theyproject out bymm16.3 to 16.7 (Figure114).
After installing the valve guides, smooth their holes with
sleeker 99390310.
Reamthevalveseats(2)oncylinderheadusingasuitabletool
(1).
After reamingthe valveseats, usetool 99370415, to make
surethatthevalveposition,withrespecttothecylinderhead
surface, isthe following:
- -0.5 to -0.8 mm(recessing) of exhaust valves;
- -1.6 to 1.9 mm(recessing) of discharge valves.
To replacetheinjector holder (2), act asfollows:
- thread theholder (2) withtool 99390804(1).
Carryout operations described in figs. 118-121-122-123
- 124byfixingtoolstothecylinderheadbymeansofbraket
A.
Replacing of valve guides
Replacing- Reaming the valve seats
To replace the valve seats, remove them using the
appropriatetool.
Valve seats must be reamed whenever valves or
valveguides arereplaced or ground.
1
2
A
NOTE
(Demonstration)
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540613 REPLACING INJECTOR HOLDERS
Removal
Aquila Trucks Centres
45633
Figure118
Figure119
Figure120
- Remove anyresidue (1), withtool 99390772 (2), from
thecylinder headgroove.
1
2
- fastenextractor 99342149(2) to case(3), bytightening
thenut (1), andpull out thecasefromcylinder head.
45631
1
2
3
45635
- Lubricate sealingrings (3) and fit themto thecase (4);
fixtool 99360554(2) to thecylinder headbymeansof
bracket A, install the new case, tighten the screw (1),
upsettingthecaselower part.
1
2
4
3
A
45632
Figure121
- Adjust thecasinghole(3) withborer 99394043(1) and
guidebushing99394014(2).
1
2
3
A
F2BENGINE 77 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
Aquila Trucks Centres
45636
47585
Figure122
Figure123
- Throughmiller 99394041(1) andbushing99394014(2),
ream the injector seat in the holder (3), check the
injector protrusion fromthecylinder headplanewhich
must be 0.7mm.
Usingdial gauge(1), checktheprotrusionof theinjector (2)
whichmust be0.7mm.
Checking protrusion of injectors
1
2
3
A
44909
Figure124
INSTALLATION DIAGRAMFOR
INJECTOR HOLDER
78 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
TIMING CONTROL COMPONENT PARTS
1. Camshaft - 2. Bushing- 3. Pin- 4. Articulatedrod-
5. Camshaft control gear - 6. Idler gear - 7. Twinidler gear
- 8. Driveshaft drivinggear.
86925
86927
86928
Ratedassemblingplaybetweenidler gear bushingsandpins:
0.040 0.080 mm.
Camshaft drive
541253 Intermediate gear pin
86926
541252 Idler gear
541252 Twin idler gear
541254 Replacing the bushings
Bushings (1, Figures 128- 129) can bereplaced whenthey
areworn. Put up thebushing, thengrind it so as to bringit
to adimension of 58.010 0.10mm.
Bushingsmust beforcedinto gears (2, Figures128
- 129) byfollowingthedirectionofthearrow:they
mustbepositionedatthelevelshowninthefigures.
Figure125
Figure126
Figure127
Figure128
NOTE
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PRINT603.93.641
5412 TIMING GEAR
Aquila Trucks Centres
47506
47505
47507
Figure129
Figure130
Figure131
541211 Checking cam lift and pin alignment
Whenthecamshaft (4) isonthetailstock(1),checkalignmentofsupportingpin(3) usingacentesimal gauge(2);itmustnot exceed
0.030 mm. If misalignment exceedsthisvalue, replacetheshaft.
Inorder tocheckinstallationclearance, measurebushinnerdiameterandcamshaft pin(1) diameter;thereal clearanceisobtained
bytheir difference.
If clearanceexceeds 0.150 mm, replacebushesand, if necessary, thecamshaft.
Placethecamshaft (4) onthetailstock(1) andcheckcamlift (3) usingacentesimal gauge (2); valuesareshownintableonpage
19.
1
80 F2BENGINE TRAKKEREURO 4/5
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541210 Camshaft
Aquila Trucks Centres
The bush surfaces must not show any sign of seizing or
scoring; if theydo replace them.
47504
47508
Figure132
Figure133
MAIN DATA - CAMSHAFT ANDTOLERANCES
The surfacesof shaft supportingpin and camsmust beextremelysmooth; if yousee anysignof seizingor scoring, replace the
shaft andthe relativebushes.
MAIN DATA - CAMSHAFT BUSHES AND RELATIVEBLOCK SEATS
* Bushinner diameter after installation
541213 Bushes
Measurethebushinnerdiameterswithabaremeterandreplace
them, if thevaluemeasured exceeds thetolerancevalue.
To take down and fit back the bushes, use the proper tool
99360487.
F2BENGINE 81 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
TOLERANCES TOLERANCECHARACTERISTIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricityor coaxial alignment
OSCILLATION Circular oscillation
IMPORTANCE CLASSASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Aquila Trucks Centres
Figure134
107217
A. Drift withseat for bushings to insert/extract. - B. Grubscrewfor positioningbushings.- C. Referencemark to insert
seventh bushingcorrectly. - D. Referencemarkto insert bushings1, 2, 3, 4, 5, 6 correctly(redmarks).- E. Guidebushing. -
F. Guide line. - G. Guidebushingto secureto theseventh bushingmount. - H. Platefixingyellowbushingto cylinder head.
- I. Grip.- L. Extension coupling.
Figure135
71725
Thesequencefor removingthebushings is 7, 6, 5, 4,3, 2, 1.
Thebushingsareextractedfromthefront ofthesingleseats.
Removal doesnot requirethedrift extensionfor bushings5,
6 and 7andit is not necessaryto use theguide bushing.
Forbushings1,2,3and4it isnecessarytousetheextension
and theguidebushings.
Positionthedrift accuratelyduringthe phaseof removal.
Removal
Figure136
Assembly
1 Positionthebushingtoinsert onthedrift (A) makingthe
grubscrewonit coincidewith theseat (B) (Figure134)
on thebushing.
2 Position the guide bushing (E) and secure the guide
bushing(G) (Figure 134) ontheseat of the 7
th
bushing
with theplate(H).
3 Whiledrivinginthebushing,makethereferencemark(F)
matchthemark(M). Inthisway, whenit is drivenhome,
thelubricationholeonthebushingwill coincidewiththe
oil pipe in its seat.
The bushingis driven home when the 1
st
redreference
mark (D) is flush with the guide bushing(G).
Assemblethedrift together with the extension.
To insert bushings1, 2, 3, 4and5, proceed as follows:
71723
Figure137
To insert thebushing(6), proceed asfollows:
- Unscrew thegrip(I) and theextension(N).
- Positiontheextension(N) andtheguidebushing(E) as
shown inthefigure.
- Repeat steps 1, 2, 3.
Rear
Rear
77795
82 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
541213 Replacing camshaft bushes using beater 99360487
Aquila Trucks Centres
70000
109107
86290
MAIN DATA TO CONTROL EXHAUST AND
DISCHARGEVALVESPRING
Lubricate the valve stem and insert the valves in the
respective valve guides; fit the lower caps (1). Use tool
99360329tofit theoil seal (2) onthevalveguides(3) ofthe
exhaust valves; then, to fit thevalves, proceed asfollows.
- fit springs(6) and theupper plate (5);
- applytool 99360264 (2) andblock it with bracket (4);
tighten the lever (1) until cotters are installed (3),
removetool (2).
540665 VALVE SPRINGS
Fitting the valves and oil seal ring
71724
To insert bushing(7), proceed asfollows:
- Unscrew thegrip(I) and theextension(N).
- Refit theguide(G) fromtheinsideasshowninthefigure.
- Positionthe bushingon the drift (A) and bringit close
up to the seat, making the bushing hole match the
lubrication holein thehead. Drive it home.
The7
th
bushingisdriveninwhenthereferencemark(C)
isflushwith thebushingseat.
Beforeassembly, theflexibilityof thevalvesprings hastobe
checkedusingasuitable tool.
Compare theload and elastic deformationdatawith those
of thenew springs given in thefollowingfigure.
Rear
Figure138
Figure139
Figure140
Figure141
Figure142
87051
Should valves not have been overhauled or
replaced, remount themaccordingto numbering
performed on dismounting.
Intake valves are different formexhaust valves in
that theyhaveanotchplacedat valveheadcentre.
NOTE
Valveclosed
Valveopen
(Demonstration)
F2BENGINE 83 TRAKKEREURO 4/5
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Aquila Trucks Centres
44925
The camshaft camsdirectlycontrol rockers: 6for injectors and 12 for valves.
Injectorsandintakevalvescontrol rocker armsarekeyedonrocker armsshaft directly. Exhaust intakevalvescontrol rockerarms
arekeyedonrocker armsshaft puttinginbetween thelevers with engine brakecontrol eccentric pin.
Rockers slidedirectlyon thecamprofiles viarollers. Theother endacts on abar directlysupported bythetwo valvesstems.
A padisplacedbetweentherockeradjustingscrewandthebar.Twolubricationholesareobtainedinsidetherockers.Therocker
shaft practicallycovers the whole cylinder head; removeit to haveaccessto all theunderlyingcomponents.
Figure143
44914
44912
44913
Figure144
Figure145
Figure146
PUMPINJECTORROCKER
EXHAUST VALVESROCKER
The bushsurfaces must not showanytraceof scoringof excessive wear; otherwise, replacebushes or thewholerocker.
DISCHARGE VALVEROCKER
Rocker
SECTION A-A SECTIONB -B
SECTION A-A SECTION B -B
SECTION A-A SECTION B -B
Checkthat thesurfaceof theshaft shows no scoringor signsof seizure; if it does, replace it.
MAIN DATA OFTHEROCKERARMSHAFT
79171
Shaft
Figure147
92822
LEVERWITH ENGINEBRAKECONTROL
ECCENTRIC PIN
Figure148
84 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
5412 ROCKER SHAFT
Aquila Trucks Centres
47586
47595
47596
Figure149
Figure150
Figure151
Figure152
Fix the engine block to the stand 99322230 by means of
brackets 99361035.
Install thecylinder linersas described inpage 56.
Fit theoil spraynozzles(2), sothat thedowel coincideswith
theblock hole(3).
Placethehalf bearings(1) on the main bearings.
Place the half-bearings (1) on the main bearings in the
underblock (2).
Bymeansof suitableequipment (1) applysiliconeLOCTITE
5970 IVECO No. 2995644 to the block, as shown in the
figure.
Sealant application diagram
||t t|o |o.o cao'caso oooob|oc' .|t||o +0' o
theapplicationof thesealant.
47570
Figure153
Lubricatethehalf bearings, theninstall thecrankshaft (2) by
means of hoist andhook99360500 (1).
49021
NOTE
F2BENGINE 85 TRAKKEREURO 4/5
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PRINT603.93.641
ASSEMBLING THE ENGINE
Aquila Trucks Centres
Revi- June2007
47581
47579
Figure154
Figure155
Figure156
Fit the lower crankcase and use a torque wrench (2) to
tighten the outer screws (1) to 25 Nmaccording to the
diagrams on thefollowingpage.
Tightentheinner screws(1) to 140Nmtorquebymeansof
atorque wrench (3), then with two further angular phases
60 +60 ,usingtool 99395216(4). Tightenagaintheouter
screws (1, Figure155) with 90 angular closing, using tool
99395215 (3, Figure155).
Fit the lower crankcase by means of a suitable hoist and
hooks (1).
49022
Use new screws whenever removing the
bed-plate.
NOTE
86 F2BENGINE TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641/A
PRINT603.93.641/A
Aquila Trucks Centres
44898
FRONT SIDE
Fourth phase:
inner screws
angleclosing
(60)
44897
44899
44898
Figure157
First phase: outer
screws preliminary
tightening
(25 Nm)
FRONT SIDE
FRONT SIDE
FRONT SIDE
Secondphase:
inner screws
preliminary
tightening
(140Nm)
Fifthphase:
outer screws
angleclosing
(90)
44898
FRONT SIDE
Third phase:
inner screws
angleclosing
(60)
F2BENGINE 87 TRAKKEREURO 4/5
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PRINT603.93.641
DIAGRAM SHOWING THE LOWER CRANKCASE FIXING SCREWS TIGHTENING ORDER
Aquila Trucks Centres
49030
Rotatethecylinder assemblyplacingit vertically.
Lubricatethehalf-bearings(1) andfit themintheconnecting
rodandthecap.
Figure158
Connectingrod-piston assembly
Markingareaofideogramonthepiston
crown
Connectingrodmarkingarea
Figure159
47593
Fit theconnectingrod-pistonassemblies(2) into thepiston
liners, usingtheband 99360605(1). Checkthefollowing:
- theringsgaps areoffset by 120;
- all pistons belongto thesameclass, A or B;
- ideogram(2, Figure159),stampedonthepistoncrown,
isplacedtowardtheengineflywheel,orthecavity,onthe
pistonskirt, correspondsto thepositionof theoil spray
nozzles
Fitting the connecting rod-piston assembly
into the cylinder liners
Figure160
1
2
3
61831
Not findingit necessaryto replace theconnecting
rodbearings, youneedto fit themback in exactly
thesamesequenceand position as in removal.
Ifthebigendbearingsneedtobereplaced,choose
themaccordingtothedescriptiongivenfrompage
59to page65.
Donot makeanyadjustment onthebearingshells.
Lubricate half bearings (1), then mount them on the
connectingrodandcap
ThepistonsaresuppliedassparesinclassAandcan
also befittedinclass Bcylinder liners.
NOTE
NOTE
NOTE
88 F2BENGINE TRAKKEREURO 4/5
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Aquila Trucks Centres
47594
Figure161
Figure162
Figure163
Figure164
Figure165
Figure166
Connect theconnectingrods to therelativejournals,fit the
connectionrodcaps(1) withhalfbearings; tighten thefixing
screws (2) of the connectingrod caps to 50Nmtorque(5
kgm). Usingtool 99395216 (3), further tighten screwswith
40 angle.
Bymeans of centeringring99396033 (2), check the exact
coverposition(1),otherwiseactasnecessaryandtightenthe
screws.
Fit thesealinggasket (1), install thefittingtool 99346245(2)
and drive thesealinggasket (1) byscrewingnut (3).
Makesurethat pistons1-6areexactlyat theTDC Placethe
gasket (2) ontheblock. Fit thecylinder head(1) andtighten
screws as shown infigs. 166, 167 and 168.
Diagramshowingthe cylinder head fixingscrews tightening
order
- Preliminarytighteningbymeansof atorquewrench(1):
1
st
phase: 50Nm(5kgm:
2
nd
phase: 100Nm(10kgm)
45255
45256
45266
45267
44900
Usenew screws whenever removingthecylinder
head.
NOTE
Before reusing the screws (2), measure the
diameter ofthethread;it must beno lessthan11.4
mm; if it is, changethescrew.
Lubricate thethread of thescrewswithengineoil
beforeassembly.
NOTE
Revi- June2007
F2BENGINE 89 TRAKKEREURO 4/5
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PRINT603.93.641/A
Aquila Trucks Centres
Engines without power take-off
Tighten the screws shown in the figure by means of atorque
wrench, in compliance with the following order and tightening
torque:
no. 1screw M10x 1.5 x 100 tighteningtorque42Nm
no. 13screwsM12x 1.75x 80tighteningtorque63Nm
no. 1screw M10x 1.5 x 180 tighteningtorque42Nm
no. 3 screws M10 x 1.5x 35 tighteningtorque42 Nm
Figure167
Figure168
Figure169
45268
- Angleclosingbymeansof tool 99395216 (1):
3
rd
phase: 90 angle
4
th
phase: 75 angle
Fit theoil pump(4),intermediategears(2) withrod(1) and
tightenscrews (3) intwo phases:
preliminarytightening 30 Nm
angleclosing 90
Applysealant LOCTITE 5970 IVECO No. 2995644 to the
gear housingusingtheproper equipment (1).
The sealer string(1) diameter isto be 1,5
47597
47598
Figure170
Install the gear housing within 10 of the application
of thesealant.
no. 2 screws M18 x 1.25x 125 tighteningtorque
24 Nm
:
Engines with power take-off
no. 1screw M10x 1.5 x 170 tighteningtorque42Nm
no. 10screwsM12x 1.75x 80tighteningtorque63Nm
no. 1screw M10x 1.5 x 180 tighteningtorque42Nm
no. 3 screws M10 x 1.5x 35 tighteningtorque42 Nm
84390
no.2screwsM12x1.75x125tighteningtorque63
Nm
Thecaster ( ) istheangleformedbythekingpinaxiswiththe
vertical to the ground when observingthevehicle fromthe
side.
Iftheextensionof thekingpin axisfallsforwardsto thepoint
wherethewheel restsontheground,inthedirectionoftravel
of the vehicle, the caster is byconvention positive (A); it is
negative(B) if it fallsbehindthepoint wherethewheelsrest
on the ground, and zero if it is exactlyvertical to the point
wherethe wheelsrest ontheground.
Thisanglemakesit possibletokeep thefront wheelsstraight
whenthevehicleistravellinginastraight lineandfor themto
returnstraight ontheir own after thepositiontheytakein a
bendassoonasthedriver letsgoofthesteeringwheel.
A B
+
_
Steeringwheel angles Kingpinangle
Theseangles,suitablycalculated, producetheright balanceof
theforcescreatedwhenthevehicleismoving,indifferentload
conditions,whichtendto alter thepositionof thewheelson
theground.
- camber;
- kingpinangle;
- caster;
- toe-in.
Figure3
27 TRAKKER EURO 4/5 WHEELALIGNMENT
Print 603.93.641 Base- November 2006
r
GENERAL INFORMATION
Aquila Trucks Centres
- tyrepressure;
- wheel hubbearingclearance;
- clearance between steering tie-rod pins and levers on
stub axles;
- efficiencyof shockabsorbers;
- wheelrims,whichmusthavenobucklingoutoftolerance.
Check thewheel geometrywiththeinstrument 99305354.
32813
32814
32815
Figure4
Figure5
Figure6
Thetoe-inistheresult ofthedifferencebetweenthedistances
A andB(inmm) measuredonthehorizontal axisoftherims,
when observingthevehiclefromabove.
Thisproduceslight drivingandlowtyreconsumption.
Toe-inispositiveif Bisgreater thanA.
Toe-inwill bezero if Bis equal to A.
Toe-inisnegativeif Bislessthan A.
A
B
A
B
A
B
Wheel toe-in
32973
32974
Figure7
Figure8
Beforemovingontothechecks,it isnecessarytomakeapre-
liminaryinspectionofsomepartsofthevehiclethat mayaffect
wheel geometry.Ifanytroubleisfound,it will havetoberecti-
fiedinorder toavoidincorrect measurements.Thechecksto
makearethefollowing:
Set thevehiclewithitswheelsin theposition of straight-line
travel onaflat surface.Lift therearofthevehicleandplacethe
boards(3)underthewheels.Lowerthevehicle,braketherear
wheels andfit onthehook(1) withtherule(2).
Lift thefront ofthevehicleandplaceoscillators(1) underthe
wheels, lockingthemwiththeclamps(2).
Positioning clips and headlights
!
The checks and anywork on the wheel geometry
must be done with the vehicle with a static load.
Periodically make sure the light clusters are set
correctly.
FRONT WHEEL ALIGNMENT
(4X2 VEHICLES)
28 TRAKKER EURO 4/5 WHEELALIGNMENT
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Connect theplugsof the measuringunit to thetransformer
and turn on the switch. Loosen the locking screw of the
oaso|o oo|t aoo ||t t|o |oos s||o|o. |oss t|o 'o cooto'
button (3) for at least two seconds, five lineswill appear on
thedisplay (1).
32975
32977
32976
Figure9
Figure10
Figure11
Positiontheself-centringclip(2),fittedwithappropriatefixing
pins(1),ontherimof thewheel.Usingtheknob(3), lockthe
clipon thewheel, checkingit is properlyanchored.
Fit themeasuringunit (3) ontheclips(1) andfastenitwiththe
screw(2). Repeat thesestepsontheother wheel.
Electronic compensation of rim eccentricity
Turnthewheel slowlybyhandandprojectthelightsignalonto
thecorrespondingscaleoftherule (5).
Measureand notedown the minimumand maximumtravel
of thelight signal: e.g., 12and 8.
Calculatethemeantravel:12+8=20:2=10andpositionthe
wheel onthemeanvaluecalculated, markingitsposition.
|oss t|o 'o cooto' bottoo (3) aa|ot||| t|o .|oo| too-|o |||
(2) comes onandthedigital indicator (1) showsan artificial
value.
Repeat thesestepson theother wheel.
Ta'o cao t|o |aso boa ooos oot ||t aoooo's oos.
it wouldseverelydamagetheir sight.
Figure12
Figure13
32978
Pressthebrakepedal andlockit inpositionwiththetool (1)
positionedagainsttheseat,therebykeepingthevehiclebraked
for theentirecycleof measurement.
Wheel alignment
Level themeasuringunits(3) withthespirit level (1) andlock
themin positionwiththe screw(2).
Move therules (4) until theyarecentred bythe light signal
emittedbythemeasuringunitandnotedownthevaluesgiven.
32979
Lower thevehiclesothat thewheels,inthemarkedposition,
rest completelyinthemiddleoftheoscillatingplates,andfree
thesefromtheir bases, takingout thepins(4).
29 TRAKKER EURO 4/5 WHEELALIGNMENT
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Figure14
Figure15
13952
If the values are not the same, turn the wheels until the
pointersofthelightsignalsareontwoequalvalues(A),exactly
themean value of the two readingsmade beforehand. This
producesperfect wheel alignment.
With the measuringunits still level and the wheels perfectly
aligned, usingthelever (1), movethelensshield.
Usingthelever (2), direct thepointer of thelight signal onto
the millimetre scale of the rule (3) corresponding to the
diameter of therim.
Repeat thesesteps ontheoppositemeasuringunit andread
off the value of the toe-ins given in mmon the millimetre
scales.
Thealgebraicsumofthesetwomeasurementsmust givethe
requiredvalue.
Thetoe-inis adjustedwith thetransversetierodso
as, for eachwheel,to haveatoe-in equal to half the
requiredvalue.
32980
Checking wheel toe-in
32981
Figure16
Checking wheel deviation
With the front wheels aligned with the rear ones and the
measuringunits level, pressthecamber button(3); theLED
(2) will comeonandthedisplay(1) will showthevalueofthe
camber, that hasto be 1.
Thedeviationischeckedwhilereadingthetoe-in.
Thepartial valueof thetoe-inmeasured ontherule (3) has
to beequal to thevaluemeasured ontherule ontheother
wheel.
If,however,thereisadifferenceinthesevalues,e.g.-2and+3,
thetotal toe-inis+1andisthereforecorrect,butat thesame
timeit indicatesadeviationbetweenthewheels(onewheel
further forwardthantheother) of 5lines.
Thisnumberoflinesiscalculatedwiththealgebraicsumofthe
valuesmeasured:+3-(-2) =5,ormoresimplybycountingthe
linesbetweenthe two values.
Eachlinecorrespondsto adeviationof 2mm.
When the deviation is greater than 10 lines (20 mm), it is
necessarytomakeadditional checks, toverifythestateofthe
leafsprings(whether oneof thesehasgivenway, or whether
thechassisor axleare out of shape).
Checking camber
Thecamber isafixedvaluethat cannot beadjusted.
Therefore, if you find the value is not as required,
detach and remove the axle to make the relevant
checksand replacements if necessary.
NOTE
30 TRAKKER EURO 4/5 WHEELALIGNMENT
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
32982
32983
Figure17
Figure18
Still withthefront wheelsaligned withtherear ones, loosen
theknurledknobs (2) andreset thegraduated sector (3) on
thepointer (1) of theoscillatingplate.
Turn the wheels 20 inwards and press the kingpin angle
button(3) twice;theLED(2) will comeonandthedisplay(1)
will showninehorizontal lines.
32984
Figure19
Turn the wheels 20 outwards and press the kingpin angle
button (3) again; the display (1) will show the value of the
kingpinanglethat hasto be 7.
32985
32986
Figure20
Figure21
Without movingthewheel, press thecaster button(3). The
LED (1) will comeonand thedisplay(2) will showthevalue
of thecaster, which hasto betherequiredvalue.
Withthewheelsturnedstraight, reset thegraduated sectors
(5) on thepointer (2) of theoscillatingplates (4).
If thesteeringangles tobemeasured aregreater than30, it
isnecessarytousethe20mark(1) ontheoscillatingplateand
t|o coosooo|o ooo o t|o aooatoo socto as '0'
reference indices.
Turnthewheelstoreacharequiredangle(internal orexternal
wheel angle).
Thencheckthat thesteeringangle(external orinternal wheel
angle) of the opposite wheel corresponds to the required
value, rememberingto use thecorrespondingscalewiththe
signshownon theoscillatingplate to read off theangle.
The caster and kingpin angle are fixed values that
cannot beadjusted.
Therefore, if youfindthevalues arenot asrequired,
detach and remove the axle to make the relevant
checksand replacements if necessary.
NOTE
31 TRAKKER EURO 4/5 WHEELALIGNMENT
Print 603.93.641 Base- November 2006
Checking kingpin angle and caster
Aquila Trucks Centres
Figure22
71743
Fit therule(4) onthefront wheels, checkingtheslide (2) is
exactlyinthemiddleof thetwoannular groovesof theshaft
(3).
Fit themeasuringunitsontherearwheelsasdescribedabove
for thewheels of thefront axle.
Projectthelightsignal ontherule(1) andnotedownthevalue
shown.
Repeat thismeasurement ontheother wheel andcheckthat
thevalueshownisthesameastheonenoteddown;ifit isnot,
thoroughlycheck over the assemblyof therear axleonthe
vehicle:ifyoufindnotrouble,checkthechassishasnot lostits
s|ao, o||o.|o t|o ocoooos oosc|boo |o t|o '3oo.o'
- C|ass|s' soct|oo.
71557
Figure23
WHEEL ALIGNMENT OF VEHICLES WITH
ADDED CENTRAL AXLE (8X4X4)
Figure24
Figure25
Detachtheswivel head(4) oftherearlongitudinal tierod(2)
from the steering lever (5) of the central axle with the
extractor 99347068.
72397
71558
Lift thevehicle, positiontheoscillatingplates(1and4) ofthe
device 99305123 under the wheels of the steering axles,
lockingthemwiththespecificclamps(2) andplacetheboards
(3) under therear wheels.
Provisionallyfittheswivel head(4) backontothelever (5) and
screwdownthefixingnut (6) without fullylockingit.
!
Check thedistancebetweenthecentredistances of
theswivel headsof thetierod(2).It must be953
10mm.Ifitisnot,loosenthescrew(1)fixingthecollar
(2) and turnthetierod(2) appropriately.
Checking rear axle alignment
32 TRAKKER EURO 4/5 WHEELALIGNMENT
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Figure26
Figure27
Figure28
Figure29
Figure30
71559
Checkfront axlewheel geometryusingdevice99305123(1)
according to procedure described and illustrated for 4X2
vehicles.
71745
After checkingand adjustingthetoe-in, if necessary, set the
.|oo|s sta||t aoo c|oc' t|o stoo|o bo |s |o t|o 'stoo|o
cooto' os|t|oo, t|at |s t|o ootc| oftheshaft(1) coincides
withthenotch of thesteeringbox (2).
38861
Lockthesteeringwheel withthetool (1).
Check that thedistancebetween thecentredistancesofthe
swivel head(1) andofthefork(5) ofthemiddlelongitudinal
tierod (3) is1735 2mm.
Ifthisisnot so, disconnect theswivel head(1) fromthelever
(2) with the extractor, loosenthecollar (4) andturn the tie
rod(3) appropriatelytoget therequireddistance;then,fitthe
swivel head (1) backonto the lever (2).
71746
Eachturnof thetierod(3) correspondsto achange
inits lengthof 0.75mm.
Disconnect theswivel heads(1, Figure29) fromthesteering
lever (2, Figure29) fromthecentral axle.
Fit the light cluster (1) of the device 99305123 onto the
wheelsofthecentral axle,repeat thechecksand, ifnecessary,
adjust thetoe-inas donefor thefront axle.
71560
NOTE
33 TRAKKER EURO 4/5 WHEELALIGNMENT
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Figure31
Figure32
Figure33
Figure34
\|t| t|o .|oo|s sta||t aoo t|o stoo|o bo |o t|o 'stoo|o
cooto' os|t|oo, c|oc' t|at t|o| o o t|o s.|vo| |oao (2) oos
exactlyinto the tapered hole of the lever (1). If it does not,
loosenthecollar (3) fixingtheswivel headtothetierod and
turn the swivel head appropriately to achieve the above
condition.
Inthisway, thewheelsof thecentral axlewill bealignedwith
thoseofthefrontaxle(permittedalignmenttolerance0 0.5
mm).
Fittheswivel headbackontotherespectiveleverpermanently
bytighteningthenutsto the requiredtorque.
71744
71561
Position the steering box in the steering centre position.
Check there is 107 mm between the face of the driving
cylinder (4) andthecentredistanceoftheswivel head(6); if
this is not so, disconnect this with the extractor, loosenthe
collar (5),turntheswivel head(6) appropriatelytoobtainthe
required distance and fit the swivel head back on in this
position.
Disconnecttheswivel head(2) fromtheidlerarm(1) andtake
thecylinder (4) into its closed position.
Check that thedistancebetweenthe centredistanceof the
swivel head(4) andthecentredistanceoftheswivel head(1)
is578mm. If thisisnot so,loosenthecollar (2) and turnthe
swivel head(1) appropriatelytoobtaintherequireddistance.
71562
71563
Fit theswivel head(2) backontotheidler arm.
With the steering box in the steering centre position, the
distanceX between theswivel head (2) and thefaceof the
cylinder (3) is140 2mm.
Figure35
After resettingthegraduated sectors on the pointers of the
oscillatingplates (1), turn the wheels so that the left front
wheel ispositioned ontheinternal steeringangleand check
that theother wheelsareturned bytherequiredangle.
Repeat the checkonthesteeringangles, positioningtheleft
front wheel on theexternal steeringangle.
71564
Checking steering angles
34 TRAKKER EURO 4/5 WHEELALIGNMENT
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
1 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
SECTION 10
Suspensions
Page
FRONT ANDREAR
MECHANICAL SUSPENSIONS 3 . . . . . . . . . . .
- Description 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SHOCKABSORBERS 23 . . . . . . . . . . . . . .
REARSHOCKABSORBERS 24 . . . . . . . . . . . . . . . .
AIRSUSPENSION 25 . . . . . . . . . . . . . . . . . . . . . . . .
- Chassisframelifting, loweringand self-levelling
withremote control 25 . . . . . . . . . . . . . . . . . . . .
- SavingLevels 25 . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRSUSPENSION SYSTEMDIAGRAMS 26 . . . . . .
- Rear air suspensionmaindiagramfor 4x2T/P
tractors 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rear air suspensionmaindiagram
for 4x4vehicles(trucks) 27 . . . . . . . . . . . . . . . . .
- Workingdiagramof pneumatic rear suspensions
for 6x4- 8x4vehicles(trucksand tractors) 28 . . .
MAIN DATA 29 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pneumaticsystem 29 . . . . . . . . . . . . . . . . . . . . . .
MAIN COMPONENTSOFTHEPNEUMATIC
SYSTEM 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reliefvalve 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fault diagnosis 30 . . . . . . . . . . . . . . . . . . . . . . . . .
- Level sensor 30 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electropneumatic distributor 31 . . . . . . . . . . . . . .
- Air lowpressuremanometer switch 31 . . . . . . . .
- Air spring 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSISADJUSTMENT 32 . . . . . . . . . . . . . . . . . . .
- Rear pneumatic suspension
for vehicles 4x2- 4x4 32 . . . . . . . . . . . . . . . . . . .
- Rear pneumatic suspension for vehicles
6x4 - 8x4 withSR rear axles 33 . . . . . . . . . . . . . .
- Rear pneumatic suspension for vehicles
6x4 - 8x4 withHRrear axles 34 . . . . . . . . . . . . . .
Aquila Trucks Centres
2 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Page
DIAGNOSTICS 35 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Diagnosis Instruments 35 . . . . . . . . . . . . . . . . . . .
- Diagnosis onCluster 37 . . . . . . . . . . . . . . . . . . . .
- DTC - FMI error codes 39 . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 68 . . . . . . . . . . . . . . . . . .
TOOLS 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPERIMENTAL TOOLS 73 . . . . . . . . . . . . . . . . . .
FRONT LEAF SPRING REMOVAL-REFITTING 75 . .
- Removal 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFINTERMEDIATEAXLE
LEAFSPRING (8X4VEHICLES) 76 . . . . . . . . . . .
- Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARLEAFSPRING
(4X2 - 4X4 VEHICLES) 77 . . . . . . . . . . . . . . . . . .
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARLEAFSPRING
ON CANTILEVER TYPESUSPENSIONS
(6X4 - 6X6 - 8X4 - 8X8 VEHICLES) 78 . . . . . . . .
- Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Procedurefor assemblyof the slipper block and
mountingbrackets for thelongitudinal bars 79 . . .
- TighteningtheU-boltsclampingtheleaf
springto thecentral pivot 79 . . . . . . . . . . . . . . . .
REARCANTILEVERSUSPENSION
(6X4 - 6X6 - 8X4 - 8X8 VEHICLES) 80 . . . . . . . .
- Removal-refittingof central pivot 80 . . . . . . . . . .
- Removal-refittingofcentral pivot shaft 80 . . . . . .
- Renewal of bearings 80 . . . . . . . . . . . . . . . . . . . .
- Removal-refittingofhanger bracket 80 . . . . . . . . .
- Removal of thecentral pivot 80 . . . . . . . . . . . . . .
Page
- Removal of thecentral pivot shaft 80 . . . . . . . . . .
- Removal of the hanger bracket 80 . . . . . . . . . . . .
- Renewal of thebearings 80 . . . . . . . . . . . . . . . . .
- Refittingthehanger bracket 81 . . . . . . . . . . . . . .
- Refittingthecentral pivot shaft 82 . . . . . . . . . . . .
- Refittingthecentral pivot 82 . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARAXLE
LONGITUDINAL ARM 84 . . . . . . . . . . . . . . . . . .
REMOVAL-REFITTING OFINTERMEDIATE
AXLELONGITUDINAL ARM 84 . . . . . . . . . . . . .
REMOVAL-REFITTING OFREARAXLE
TRIANGULARARMFOR VEHICLES
WITH AIRSUSPENSION 84 . . . . . . . . . . . . . . . .
- Removal 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE SUSPENSION ARM
FLEXIBLEPIN 85 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Dismounting 85 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTRIANGULARSWINGINGARM
BALL ARTICULATED JOINT 85 . . . . . . . . . . . . . .
- Dismounting 86 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOCKABSORBERS 88 . . . . . . . . . . . . . . . . . . . . . .
- Removal 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-ROLL BARS 88 . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-ROLL BAR 89 . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT ANTI-ROLL BAR 89 . . . . . . . . . . . . . . . . . .
AUXILIARY AXLEANTI-ROLL BAR
(8X4 VEHICLES) 89 . . . . . . . . . . . . . . . . . . . . . . .
REARANTI-ROLL BAR 89 . . . . . . . . . . . . . . . . . . . .
INTERMEDIATEAXLEANTI-ROLLBAR
(6X4 - 6X6 - 8X4 - 8X8 VEHICLES) 89 . . . . . . . .
- Removal 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
39614
Figure1
FRONT SUSPENSION
The front suspension systemis comprised of parabolic or
semi-elliptic leaf springs with double-actinghydraulic shock
absorbers andananti-roll bar.
REARSUSPENSION
4x4- 4x2vehicles:parabolicor semi-ellipticleaf springswith
double-actinghydraulic shockabsorbersandanti-roll bars.
6x4 - 6x6 - 8x4 - 8x8 vehicles: cantilever leaf springs and
anti-roll bars.
FRONT SUSPENSION COMPONENTS
1. Bumpstopwith fixings - 2. ClampingU-bolts- 3. Nut - 4. Plate - 5. Leaf spring- 6. Nut - 7. Washers - 8. Bush-
9. Shacklepins- 10. Plate - 11. Shackleplate- 12. Rubber bush - 13. Metal bush - 14. Nuts
3 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
FRONT AND REAR MECHANICAL SUSPENSIONS
Description
Aquila Trucks Centres
39615
Figure2
REARSUSPENSION COMPONENTS
1. ClampingU-bolts - 2. Plate- 3. Leaf spring- 4. Nut - 5. Hanger - 6. Screw- 7. Washers- 8. Bushes-
9. Shacklepins- 10. Nut - 11. Clampingplates- 12. Shackleplates- 13. Hanger - 14. Bumpstop
4 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
39616
Figure3
REARCANTILEVERSUSPENSION COMPONENTS
1. Hanger bracket - 2. Hanger bracket - 3. Angular contact bearing- 4. Central pivot shaft - 5. Central pivot -
6. Adjustment shim- 7. Plate- 8. Bolt - 9. Seal - 10. Cap - 11. Springclip - 12. Plugwithgasket - 13. Plugwithgasket -
14. Nut withwasher - 15. Leaf spring- 16. ClampingU-bolt - 17. Spacer
1
5 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
72212
Figure4
FRONT SUSPENSION WITH PARABOLIC LEAF SPRINGS: 4x2 - 6x4VEHICLES
6 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
90640
Figure5
FRONT SUSPENSION WITH SEMI-ELLIPTIC LEAFSPRINGS: 4x2- 4x4 - 6x4 - 6x6VEHICLES
7 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
90641
Figure6
FRONT SUSPENSION WITH PARABOLIC LEAF SPRINGS: 4x4 - 6x6VEHICLES
8 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
72217
Figure7
FRONT SUSPENSION WITH PARABOLIC LEAF SPRINGS: 8x4 - 8x8VEHICLES
9 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
72215
Figure8
REARSUSPENSION WITH PARABOLIC LEAF SPRINGS: 4x2 - 4x4VEHICLES
10 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
72218
Figure9
REARSUSPENSION WITH SEMI-ELLIPTIC LEAFSPRINGS: 4x2- 4x4VEHICLES
11 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
72216
Figure10
REARCANTILEVERSUSPENSION WITH PARABOLIC LEAFSPRINGS: 6x4- 6x6- 8x4 - 8x8 VEHICLES
12 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
39622
Figure11
REARCANTILEVERSUSPENSION WITH SEMI-ELLIPTIC LEAFSPRINGS: 6x4 - 6x6 - 8x4- 8x8VEHICLES
13 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
14 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
MAIN DATA
FRONT SUSPENSION: 4x2 - 4x4- 6x4 - 8x4 MODELS
mm
8tonsparabolicleaf springs
No. 2
No. 4
L
Springlength
(measuredat eyecentres)
1900
+0
- 6
S
Leaf thickness(measuredat centre)
- 1
st
- 2
nd
leaf
- 3
rd
leaf
30
22
S Distancebetweenleaves 3
L
Leaf width 90 0.5
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D
d
D=outsidediameter of eye
d=insidediameter of eye 20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 4.2 6%
Aquila Trucks Centres
15 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
FRONT SUSPENSION: 6x6 - 8x4- 8x8 MODELS
mm
8tonsparabolicleaf springs
No. 2
No. 4
L
Springlength
(measuredat eyecentres)
1900
+0
- 6
S
Leaf thickness(measuredat centre)
- master leaf
- 2
nd
- 3
rd
leaf
25
26
S Distancebetweenleaves 3
L
Leaf width 90
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D d
D=outsidediameter of eye
d=insidediameter of eye 20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 4.41
Aquila Trucks Centres
16 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
FRONT SUSPENSION: 4x2 - 4x4- 6x4 - 6x6 - 8x4 - 8x8MODELS
mm
9tonsparabolicleaf springs:
No. 2
No. 4
L
Springlength
(measuredat eyecentres)
1900
+ 0
- 6
S
Leaf thickness(measuredat centre)
- master leaf
- 2
nd
- 3
rd
leaf
27
28
S Distancebetweenleaves 3
L
Leaf width 90
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D d
D=outsidediameter of eye
d=insidediameter of eye
20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 3.63
Aquila Trucks Centres
17 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
FRONT SUSPENSION: 4x2 - 4x4- 6x4 - 6x6MODELS
mm
9tonssemi-ellipticleafsprings: No. 2
L
Springlength
(measuredat eyecentres)
1900
+ 0
- 6
S
Leaf thickness(1
st
9
th
leaf) 16
S Distancebetweenleaves 3
L
Leaf width 90
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D d
D=outsidediameter of eye
d=insidediameter of eye
20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 3.21
Aquila Trucks Centres
18 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
REAR SUSPENSION: 4x2- 4x4MODELS
mm
13.5tonsparabolicleaf springs: No. 2
L
Mainspringlength
(measuredat eyecentres)
Helper springlength
(measuredat block centres)
1800 3
1800 3
S
Thicknessof main springleaves
(measuredat centre)
Thicknessof helper springleaf
(measuredat centre)
26
40
S Distancebetweenleaves 3
L
Leaf width 100
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D d
D=outsidediameter of eye
d=insidediameter of eye
20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN
Flexibilityafter interventionof helper springmm/KN
3.45
1.47
Aquila Trucks Centres
19 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
REAR SUSPENSION: 4x2- 4x4MODELS
mm
14tonssemi-elliptic leaf springs: No. 2
L
Mainspringlength
(measuredat eyecentres)
Helper springlength
1800 3
1360 3
S
Thicknessof main springleaves
(1
st
8
th
leaves)
Thicknessof helper springleaves
(1
st
6
th
leaves)
Distancebetweenmainandhelper spring
17
15
10
L
Distancebetweenleaves 100
D
Insidediameter ofmaster leaf eye
(bush seat)
60.1 60.2
D d
D=outsidediameter of eye
d=insidediameter of eye
20.2 20.5
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN
Flexibilityafter interventionof helper springmm/KN
2.27
0.9
Aquila Trucks Centres
20 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
REAR SUSPENSION: 6x4- 6x6MODELS
mm
13tonssemi-elliptic leaf springs: No. 2
L
Springlength 1485 2
S Leaf thickness
(measuredat centre)
22
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 4
th
8
th
leaves
96
100
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 0.34
REAR SUSPENSION: 6x4- 8x4MODELS
mm
16tonsparabolicleaf springs: No. 2
L
Springlength: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf
1480 2
1040
S LLeaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf (measured at centre)
27
58
S Distancebetweenleaves 3
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 3
rd
4
th
leaves
96
100
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 0.23
Aquila Trucks Centres
21 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
REAR SUSPENSION: 6x4- 6x6MODELS
mm
16.5tonssemi-elliptic: No. 2
L
Springlength 1475 2
S
Leaf thickness
(measuredat centre)
22
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 4
th
11
th
leaves
96
100
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 0.25
REAR SUSPENSION: 6x4- 6x6- 8x4 MODELS
mm
10.5tonsparabolicleaf springs: No. 2
L
Springlength: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf
1480 2
1040
S
LLeaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf (measured at centre)
26
43
S Distancebetweenleaves 3
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 3
rd
4
th
leaves
96
100
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 0.39
Aquila Trucks Centres
22 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
REAR SUSPENSION: 6x4- 6x6- 8x4 - 8x8MODELS
mm
13tonsparabolicleaf springs: No. 2
L
Leaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf
1480 2
1040
S
Leaf thickness: 1
st
- 2
nd
- 3
rd
leaves
4
th
leaf (measured at centre)
26
53
S Distancebetweenleaves 3
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 3
rd
4
th
leaves
96
100
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 0.29
REAR SUSPENSION: 6x4- 6x6 - 8x4 - 8x8
mm
16tonssemi-elliptic leaf springs: No. 2
L
Springlength 1480 2
S Leaf thickness
(measuredat centre)
22
L
Leaf width: 1
st
3
rd
leaves
Leaf width: 4
th
13
th
leaves
96
100
NEW LEAFSPRINGCHECK DATA
Flexibilitymm/KN 0.22
Aquila Trucks Centres
23 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
FRONT SHOCK ABSORBERS
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween theeyecentreand theend:
Open
Closed
Stroke
778 3
448 3
330
777 3
452 3
324
MODELS 4x2 - 6x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween theeyecentreand theend:
Open
Closed
Stroke
754 3
434 3
320
751 3
435 3
316
TRACTORS 4x2 - 6x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween theeyecentreand theend:
Open
Closed
Stroke
754 3
434 3
320
754 3
432 3
322
CABIN TRUCK 4x2 - 6x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween theeyecentreand theend:
Open
Closed
Stroke
754 3
434 3
320
754 3
432 3
322
MODELS 8x4 - 8x8
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween theeyecentreand theend:
Open
Closed
Stroke
689 3
409 3
280
693 3
413 3
280
MODELS 4x4 - 6x6
Aquila Trucks Centres
24 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
REAR SHOCK ABSORBERS
SHOCKABSORBERS SACHSBOGE ARVIN
L
Lengthbetween rubber bush mountingsurfaces:
Open
Closed
Stroke
720 3
410 3
310
720 3
412 3
308
MODELS 4x2- 4x4
SHOCKABSORBERS SACHSBOGE
L
Lengthbetween rubber bush mountingsurfaces:
Open
Closed
Stroke
762 3
432 3
330
-
-
-
MODELS 4x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween rubber bush mountingsurfaces:
Open
Closed
Stroke
652 3
402 3
250
652 3
404 3
248
MODELS 4x2- 4x4 - 6x4- 6x6- 8x4
SHOCKABSORBERS
MANNESMANN
SACHS
ARVIN
L
Lengthbetween rubber bush mountingsurfaces:
Open
Closed
Stroke
840 3
500 3
340
839 3
500 3
339
MODELS 6x4 - 6x6 - 8x4- 8x8
Aquila Trucks Centres
The air suspensions are highly flexible; they have a
considerable vibration-damping capacity and, above all,
|osoct|vo o t|o |oao oo t|o vo|| c|o, ooo to t|o ssto's
so|-ao,ostoot, t|o 'c|ass|s ao oao soaco' o|staoco
stays constant. By simply pressing a push-button the air
sosoos|oos cao c|aoo t|o 'c|ass| s ao oao soaco'
o|staocoaoo t|oooo t|o|o||t o t|o vo||c|o's |oao|o ooc'.
Besides the well-known benefits provided by the air
suspension, theECASsystemprovides:
- considerablereduction inair consumption;
- readyresponseto the variousadjustment processes;
- simplified systems;
- widesafetymargins;
- full systemdiagnosis.
The ECAS (Electronically Controlled Air Suspension)
ssto aotoat|ca||cooto|s t|o oo|oa| |ovo| o t|o vo||c|o's
air suspensions.
All the above operations anyhow have the constraint of
specificoperatingconditionsandtheassociatedsafetydevices
of thesystems connectedto them.
TheECASelectronic control unit automaticallycontrolsthe
level (distanceoff theroadsurface) of thechassisframewith
the actual values supplied by the sensors, comparingthem
withthenominal values savedinmemory.
In the event of moving awayor the attitude changing, the
electronic control unit governs the electro-pneumatic
assemblieswithwhichtheactual level iscorrectedcompared
to the nominal oneset or savedpreviouslybythedriver.
The system has a remote control for lifting/lowering and
levellingthechassis frameandit ispossibleto workwiththe
vehicleeither stationaryor moving.
Besideslifting, loweringandself-levelling, theremotecontrol
makes it possibleto saveother chassis frame attitudelevels
and call themupwhenrequired.
Chassis frame lifting, lowering and
self-levelling with remote control
Lifting, loweringand levellingthevehicle before loadingand
unloadingit isdonewiththeremote control located next to
t|o o|vo's soat.
The remote control can be removed fromits mountingso
thesemanoeuvrescanbedone fromtheground too.
Lift/lower thechassisframeasdescribedbelow:
- TurntheignitionswitchontoMAR(start).Theyellowand
red indicator lights (9) and (10) will come on for
approximately 3seconds.
- Press the push-button(1 and8) to select therear axle.
Theindicator light A-Bcomeson to showtheselection
made(to cancel the selection, pressthebuttonagain).
- Pressingthebuttons(5and6) andkeepingthempressed
lifts or lowersthechassis frame.
Brieflypressthepush-button(3),thechassisframewill goback
into its normal self-levellingposition.
Theindicatorlight (9) goesout assoonasthenormal level is
reached.
T|o 'STC|' os|-bottoo (+) stos ao act|oo t|o ssto |s
performing.
!
When unloadingheavy loads or containers (with a
crane), lower thechassisframecompletely.
!
Do not stop the engine if the indicator light (10)
comes on. If the indicator light (9) comes on while
driving,stopthevehicleandturntheignitionkeyonto
'STC|', ato ao|ato| () socooos, too t|o
key onto MAR (start). If after approximately two
secondstheindicatorlight(9)doesnotgoout,callthe
ServiceNetwork.
!
After loading/unloadingandbeforestartingoff again,
you must bring the vehicle back into its normal
self-levellingpositionbypressingthe button(3).
Saving Levels
Withbuttons(2) and(7),it ispossibletosaveandcall uptwo
chassis-framepositions:
- Takethechassisframetotherequiredheightbyfollowing
theaboveinstructions.
- Press the STOP button (4) and keep it pressed while
pressingoneof thebuttons(2) or (7).
- Release the button (4). The chassis-frame position has
been saved.
Tocall upasavedposition,presstheassociatedbutton(2) or
(7).
78792
Figure12
25 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
AIR SUSPENSION
Aquila Trucks Centres
Rear air suspension main diagram for 4x2T/P (tractors)
73706
1. Checkvalve- 2. Rear axleelectropneumaticdistributor - 3. Rear level sensor - 4. Pressure control intake-
5. Rear axleair spring- 6. Pressurerelief valvewithlimited return- 7. Condensatehandbleeder - 8. 20lt. air reservoirs -
9. Pressuregauge(openingpressure8bar) - 10. Pilot lamp(air suspensionlow pressure).
Figure13
26 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
AIR SUSPENSION SYSTEM DIAGRAMS
Aquila Trucks Centres
Rear air suspension main diagram for 4x4 vehicles (trucks)
60905
1. Checkvalve- 2. Rear axleelectropneumaticdistributor - 3. Rear level sensor - 4. Pressure control intake-
5. Rear axleair spring- 6. Pressurereliefvalvewithlimited return- 7. Condensatehandbleeder - 8. 20lt. air reservoirs -
9. Pressuregauge(openingpressure8bar) - 10. Pilot lamp(air suspensionlow pressure).
Figure14
27 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Working diagram of pneumatic rear suspensions for 6x4 - 8x4vehicles(trucks and tractors)
77868
+. C|oc' va|vo 2. |oa a|o o|octo-oooat|c cooto| va|vo 3. |oa |ovo| sooso +. |oa a|o a| s|o 5. |ossoo tost
o|ot 6. Cooto||oo ossoo va|vo .|t| |||too otoo (ooo|o ossoo 8.5 bas) . |aooa| cooooosato b|ooo va|vo
8. 30-||to a| tao's . |ossoo s.|tc| (ooo|o ossoo 8 bas) +0. |||ot |a (a| sosoos|oo |o. ossoo)
Figure15
28 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Print 603.93.371 Aquila Trucks Centres
29 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
MAIN DATA
Pneumatic system
DESCRIPTION
Relief valve
- Type: KNORR-BREMSEDR4248 - WABCO 434 100232
Openingpressure
8,5
+0
- 0,3
bar
Electropneumaticdistributors
- Type: WABCO 472 880001
Power supplyvoltage
24 V
+6
- 4.4
Ratedcurrent 0.34A
Operatingpressure 5 13bar
Level sensors
- Type: WABCO 4410500120
Power supplyvoltage Pulse 8 to16 V
Measurement criteria Inductive
Current absorption Max 90 mA
Lever angle Max 100
Air lowpressuremanometer switch
- Type: TDSF13046 S
Operatingvoltage 12/24 V
Electricloadallowed 0.001 1A
Max. operatingpressure 12 bar
Handcondensatebleeder
- Type: VOSS52089975
Max. operatingpressure 13 bar
Air reservoirs
Reservoirs 20 Litres
Electronic unit
- Type: WABCO 446170211
Supplyvoltage
24V
Aquila Trucks Centres
The sensor consists of a coil, fixed to the chassis, where a
pistonconnected bymeansofacamto thelever securedto
thevehicleaxleismoved.
At achangeinthedistancebetweenchassisandvehicleaxle,
theleverrotatesandmovesthepistoncausingtheconsequent
changeoftheself-inductanceofthecoil electricallyconnected
to the electroniccontrol unit.
Level sensor
Theleversensorconstantlyinformstheelectroniccontrol unit
on the changes in the chassis attitude with respect to the
roadway.
20437
73807
Thisisalimited-returnvalvecarryingout two functions:
- Stopping the flow of compressed air feeding the
reservoirswhenthepressureinsidethelatter decreases
under aset value(calibration) duetoamalfunctionorto
excessivewithdrawals.
- Feeding these reservoirs as soon as the brakingsystem
achievesavalueensuringaperfect efficiencyinbraking.
Figure16
Figure17
30 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
MAIN COMPONENTS OF THE PNEUMATIC SYSTEM
793824 Relief valve
Fault diagnosis
INCONVENIENT POSSIBLECAUSE SOLUTION
Breathingat outlet Leakfromthemembrane Overhaul theequipment replacingworncomponents
Air leakformthe two
half-bodyconnection
Leakfromthemembranefixing
Deliverybreathing (in
the atmosphere) with
feedingat apressure
lower than the ratedone
Leakformtheintakevalveor form
therelevant seat
Overhaul theequipment replacingworncomponents.
Aquila Trucks Centres
The manometer switch is located near the service air
reservoir,onthedeliverypipingfortheair springsuspensions.
Itsfunctionistoindicatelow(<8bar) feedpressurethrough
anoptical indicator onthedashboard
73810
30106
It isaflexibleelement containingair under pressureandable
tochangeitsextensionirrespectiveofthevalueoftheapplied
load.
5007 Air spring
Air low pressure manometer switch Electropneumatic distributor
52723
The electropneumatic distributor consists of a group of
solenoid valves, whose concentration reduces both the
structurevolumeandtheuseof connections.
Thesolenoidvalvesare directlycontrolledbytheelectronic
control unit and allow to increase, decrease or keep the
volumeof air inthepneumaticcells.
Figure18
Figure19
Figure20
31 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
86830
REARSUSPENSION ASSEMBLY DRAWING
Figure21
CHASSIS ADJUSTMENT
Adjustment iscarriedoutbyusingpads99342647andadjustinglevellingvalvesinordertorealiseX distancesshownin thefigures.
Rear pneumatic suspension for vehicles4x2- 4x4
32 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
1 M18x 1.5screwfixingtriangular armto bracket 320 to 385 32to 38.5
2 Nut fixingair springsto the mounting 83to 101 8.3 to 10.1
3 M18x 1.5nut for screw fixinglongitudinal rod 375 to 460 37.5to 46
4 M24x 2nut withcollar for brackets fixingrear axleto rear mounting 576 to 704 57.6to 70.4
5 M20nut for screwfixingtopand bottomshockabsorber 210 to 250 21to 25
6 M20nut for pinfixingstabilizer bar to mounting 636 to 777 63.6to 77.7
7 M12nut for bolt fixingstabilizer bar to linkrod 165 to 200 16.5to 20
8 M20nut for pinfixinglink rod to mounting 636 to777 63.6to 77.7
X =60mm
Aquila Trucks Centres
86831
REARSUSPENSION ASSEMBLY
Figure22
33 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Rear pneumatic suspension for vehicles6x4- 8x4 with SR rear axles
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
1 Triangular armscrewM18at rear axlecasing 270 to 300 (27 to33)
2 Flanged nut M20to securestabiliserbaronair springsupport andtosecurearticulated
connectingrodonchassis bracket
636 to 777 (63.6 to 77.7)
3 Nut for screwto secureelastic anchoringmember to articulated connectingrod 165 to 200 (16.5 to 20)
4 Nut to secureair springtosupport 83to 101 (8.3to 10.1)
5 Nut M24withcollar for bracketsto secure rear axleto suspensionsupport 576 to 704 (57.6 to 70.4)
6 Nut M20to securerear axleshockabsorber on topand bottom 210 to 250 (21 to25)
7 Nut M18x1,5to securesiderods 375 to 460 (37.5 to 46)
8 ScrewM18to securetriangular armto bracket 320 to 385 (32 to38.5)
X =125mm
Aquila Trucks Centres
99005
REARSUSPENSION ASSEMBLY
Figure23
34 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Rear pneumatic suspension for vehicles6x4- 8x4 with HR rear axles
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
1 Flanged nut M20to securestabiliserbaronair springsupport andtosecurearticulated
connectingrodonchassis bracket
636 to 777 (63.6 to 77.7)
2 Nut for screwto secureelastic anchoringmember to articulated connectingrod 100 to 122 (10 to12)
3 Nut to secureair springtosupport 83to 101 (8.3to 10.1)
4 Nut M20to securerear axleshockabsorber on topand bottom 210 to 250 (21 to25)
5 Nut M24withcollar for bracketsto secure rear axleto suspensionsupport 540 to 660 (54 to66)
X =64mm
Aquila Trucks Centres
Fault diagnosis comprises two sections:
- Thefirst one, organizedbyerror codes(DTC-FMI), concernsfaults that maybeidentified bytheECAScontrol unit directly.
T|oso ao|ts ao a|o| o ao o|oct|c o|octoo|c oooat|c oatoo.
- Thesecondone,organizedbysymptoms,describesthepossiblefaultstheelectroniccontrol unit cannot identifydirectly.These
faults aremainlyof amechanical nature.
SECTION I
ECASsystemtroubleshootingcan be performed with the Cluster or with thediagnosis instrumentsModus, IWT, IT 2000 and
E.A.SY..
Diagnosis with the cluster makes it possible to estimate the situation of faults in the systemin advance, while the diagnosis
instrumentsareessential to performthorough diagnosis and operateon thesinglefaultscorrectly.
Each singleinstrument displays the diagnosisandrepair help.
Diagnosis Instruments
MODUS(Maintenanceand Diagnostic System)
A computerizedfault-diagnosisstationdedicatedto diagnosingthebrakesystems,airsuspensions,enginesandsystemscontrolled
electronically.
Thestationisequippedwithauxiliaryfunctions,suchas:programmingelectroniccontrol units,consultingthesparepartscatalogue
and servicetimeschedules.
The vehicle has a30-pin diagnosis socket to interfacewith theinstrument.
IT 2000 (IVECO ElectronicTester)
This makesit possible to takeimmediate action on the vehicle, identifyingit with thechassis number.
It savestheresults of diagnostics actions performed.
It can beusedas aportablePersonal Computer, too, beingfitted for remotediagnosis.
ByusingMODUSasthe mother station it is possibleto updateand configuretheIT 2000.
IT 2000interfaceswith thevehicleviaa30-pin diagnosis socket.
E.A.SY.
E.A.SY. systemallows to simplymakethediagnosis andprogrammingof thevarious electronic central units aboard the vehicle.
E.A.SY. systemismadeup of ECI modulecommunicatingwith theelectronic central unitsandof aPanasonicPC.
ECImodule,exploiting thePanasonicPC,alsoallowseasyontheroadinterventions:inparticular,thankstoPanasonicPCwireless
technologies(e.g. GPRS), diagnostic interventionscan beassistedbyaremoteexpert centre.
35 TRAKKEREURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
DIAGNOSTICS
Aquila Trucks Centres
98889
Figure24
36 TRAKKEREURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
98885
Figure25
/ccoss to o|aoost|c scooo |s oss|b|o t|oo| 'ao' o ' y ' aoo ' b ' 'os.
98888
Diagnosis information on thecluster is split into 4 columns:
- First column = central unit.
- Secondcolumn = central unit addressplus fault order number.
- Third column = failure type.
- Fourth column = failure frequency.
Thescreenshowsthreeerror messagesat most,but canstoreupto eight error messages. For displayinganyfurther messages,
,ost ooato ' y ' aoo ' b ' 'os.
37 TRAKKEREURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
Diagnosis on Cluster
Aquila Trucks Centres
38 TRAKKEREURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
SOLE-
NOID
VALVES-
ADDI-
TIONAL
AXLELIFT-
ING
SHORT
CIRCUIT
TO POSI-
TIVE
Additional axle
control deacti-
vated.
Additional axle
liftingsolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonadditional
axlecontrol solenoid
valve.
Check: Check isolation
from- batterypin1-
X3 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
SOLE-
NOID
VALVES-
ADDI-
TIONAL
AXLELIFT-
ING
OPEN CIR-
CUIT
Additional axle
control deacti-
vated.
Additional axle
liftingsolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonadditional
axlecontrol solenoid
valve.
Check: Check continu-
itybetweenpins 4-
X2 / 1 - X3
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
SOLE-
NOID
VALVES-
ADDI-
TIONAL
AXLELIFT-
ING
SHORT
CIRCUIT
TO
GROUND
Additional axle
automatically
lowered.
Additional axle
liftingsolenoid
valvelocked
open.
Checkwiringand con-
nectorsonadditional
axlecontrol solenoid
valve.
Check: Check isolation
from- batterypin1
X3 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
01 03 SOLE-
NOID
VALVES-
FRONT
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POSI-
TIVE
Front andrear
axles automatic
controls deacti-
vated. Front axle
manual controls
deactivated.
Front axlesole-
noidvalve
lockedclosed.
Checkwiringand con-
nectorsonfront frame
control solenoidvalve.
Check: Check isolation
from+batterypin 15
- X2/ 7- 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
01 05 SOLE-
NOID
VALVES-
FRONT
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Front andrear
axles automatic
controls deacti-
vated. Front axle
manual controls
deactivated.
Front axlesole-
noidvalve
lockedclosed.
Checkwiringand con-
nectorsonfront frame
control solenoidvalve.
Check: Check continu-
itypins 4- 15 / X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
01 06 SOLE-
NOID
VALVES-
FRONT
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Front axleauto-
maticallylowered.
Front axlesole-
noidvalve
lockedopen.
Checkwiringand con-
nectorsonfront frame
control solenoidvalve.
Check: Check isolation
from- batterypin15-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
03 03 SOLE-
NOID
VALVES-
REAR
RIGHT
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
RH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonRH engine
axleframecontrol
solenoidvalve.
Check: Check isolation
from- batterypin13-
X2 / 7 -10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
03 05 SOLE-
NOID
VALVES-
REAR
RIGHT
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
RH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonRH engine
axleframecontrol
solenoidvalve.
Check: Check continu-
itypins 4- 13 / X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
03 06 SOLE-
NOID
VALVES-
REAR
RIGHT
SHORT
CIRCUIT
TO
GROUND
RH sideengine
axleautomatically
lowered.
RH engineaxle
solenoidvalve
lockedopen.
Checkwiringand con-
nectorsonRH engine
axleframecontrol
solenoidvalve.
Check: Check isolation
from- batterypin13-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
04 03 SOLE-
NOID
VALVES-
REAR LEFT
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
LH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonLH engine
axleframecontrol
solenoidvalve.
Check: Check isolation
from- batterypin10-
X2 /7- 10X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
04 05 SOLE-
NOID
VALVES-
REAR LEFT
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
LH engineaxle
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonLH engine
axleframecontrol
solenoidvalve.
Check: Check continu-
itybetweenpins 4-
10/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
04 06 SOLE-
NOID
VALVES-
REAR LEFT
SHORT
CIRCUIT
TO
GROUND
LH sideengine
axleautomatically
lowered.
LH engineaxle
solenoidvalve
lockedopen.
Checkwiringand con-
nectorsonLH engine
axleframecontrol
solenoidvalve.
Check: Check isolation
from- batterypin10-
X2 /12 - X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
05 03 SOLE-
NOID
VALVES-
REAR
RIGHT
(THIRD
AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
RH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonRH addi-
tional axleframecon-
trol solenoid valve.
Check: Check isolation
from+batterypin 12
- X2/7- 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
05 05 SOLE-
NOID
VALVES-
REAR
RIGHT
(THIRD
AXLE)
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
RH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonRH addi-
tional axleframecon-
trol solenoid valve.
Check: Check continu-
itybetweenpins 4-
12/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
05 06 SOLE-
NOID
VALVES-
REAR
RIGHT
(THIRD
AXLE)
SHORT
CIRCUIT
TO
GROUND
RH sideaddi-
tional axleauto-
maticallylowered.
RH additional
axlesolenoid
valvelocked
open.
Checkwiringand con-
nectorsonRH addi-
tional axleframecon-
trol solenoid valve.
Check: Check isolation
from- batterypin12-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
06 03 SOLE-
NOID
VALVES-
REAR LEFT
(THIRD
AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
LH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonLH addi-
tional axleframecon-
trol solenoid valve.
Check: Check isolation
from- batterypin14-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
06 05 SOLE-
NOID
VALVES-
REAR LEFT
(THIRD
AXLE)
OPEN CIR-
CUIT
Rear axles auto-
maticcontrols
deactivated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
LH additional
axlesolenoid
valvelocked
closed.
Checkwiringand con-
nectorsonLH addi-
tional axleframecon-
trol solenoid valve.
Check: Check continu-
itybetweenpins 4-
14/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
06 06 SOLE-
NOID
VALVES-
REAR LEFT
(THIRD
AXLE)
SHORT
CIRCUIT
TO
GROUND
LH sideaddi-
tional axleauto-
maticallylowered.
LH additional
axlesolenoid
valvelocked
open.
Checkwiringand con-
nectorsonLH addi-
tional axleframecon-
trol solenoid valve.
Check: Check isolation
from- batterypin14-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
07 03 SOLE-
NOID
VALVES-
AIRINLET/
OUTLET
VALVE
SHORT
CIRCUIT
TO POSI-
TIVE
Front andrear
axles automatic
controls deacti-
vated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
Power supply
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonpower sup-
plysolenoid valve.
Check: Check isolation
from- batterypin11-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
07 05 SOLE-
NOID
VALVES-
AIRINLET/
OUTLET
VALVE
OPEN CIR-
CUIT
Front andrear
axles automatic
controls deacti-
vated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
Power supply
solenoidvalve
lockedclosed.
Checkwiringand con-
nectorsonpower sup-
plysolenoid valve.
Check: Check continu-
itybetweenpins 4-
11/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
07 06 SOLE-
NOID
VALVES-
AIRINLET/
OUTLET
VALVE
SHORT
CIRCUIT
TO
GROUND
Front andrear
axles automatic
controls deacti-
vated.
Raiseand auxili-
arydeactivated at
additional axle
peak.
Power supply
solenoidvalve
lockedopen.
Checkwiringand con-
nectorsonpower sup-
plysolenoid valve.
Check: Check isolation
from- batterypin11-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
10 02 SENSORS
- FRONT
LEVEL
SENSOR
INCOR-
RECT
PARA-
METERS
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Checksensor installa-
tion and eventual
mechanical connection
faults.
10 03 SENSORS
- FRONT
LEVEL
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Checksensor wiring
and connectors.
Check: Check isolation
from- batterypin9-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
10 05 SENSORS
- FRONT
LEVEL
SENSOR
OPEN CIR-
CUIT
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Checksensor wiring
and connectors.
Check: Check continu-
itybetweenpins 7- 9
/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 4-
5 Kohm
10 06 SENSORS
- FRONT
LEVEL
SENSOR
SHORT
CIRCUIT
TO
GROUND
No front axlele-
veling.
Front axlelevel
automaticcon-
trols disabled.
Checksensor wiring
and connectors.
Check: Check isolation
from- batterypin9-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
12 02 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
INCOR-
RECT
PARA-
METERS
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Checksensor installa-
tion and eventual
mechanical connection
faults.
12 03 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
Check: Check isolation
from+batterypin 8-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
12 05 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
OPEN CIR-
CUIT
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
Check: Check continu-
itybetweenpins 7- 8
/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 80
- 90 Ohm
12 06 SENSORS
- REAR
RIGHT
LEVEL
SENSOR
SHORT
CIRCUIT
TO
GROUND
Co '+2 Tac-
to' - |o oa
axleleveling. On
'62 Toc' o
Tacto' - Yo||o.
fault light ON.
Co '62 Toc'
o Tacto' .|t|
simultaneous LH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
1 sensor axle
'+2 Tactos'
Deactivation of
rear axlelevel
automaticcon-
trols. 2 sensor
a|o '62 Toc'
o Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
LH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
Check: Check isolation
from+batterypin 8-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
13 02 SENSORS
- REAR
LEFT
LEVEL
SENSOR
INCOR-
RECT
PARA-
METERS
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Checksensor installa-
tion and eventual
mechanical connection
faults.
13 03 SENSORS
- REAR
LEFT
LEVEL
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
Check: Check isolation
from+batterypin 5-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
13 05 SENSORS
- REAR
LEFT
LEVEL
SENSOR
OPEN CIR-
CUIT
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
Check: Check continu-
itybetweenpins 7- 5
/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 80
- 90 Ohm
13 06 SENSORS
- REAR
LEFT
LEVEL
SENSOR
SHORT
CIRCUIT
TO
GROUND
Co '62 Toc'
o Tacto' - Yo|-
lowfault light
ON.
Co '62 Toc'
o Tacto' .|t|
simultaneousRH
sensor fault - No
rear axleleveling
and auxiliary
function deacti-
vated at peak.
2 sensor axle
'62 Toc' o
Tacto' oo
functional fault.
2 sensor axle
'62 Toc' o
Tacto' .|t|
simultaneous
RH sensor fault.
Deactivation of
rear axlelevel
automaticcon-
trols andauxili-
aryat peak.
Checksensor wiring
and connectors.
Check: Check isolation
from- batterypin5-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit. Keyon
STOP.
Comparablevalues: >
1 Mohm
16 03 SENSORS
- FRONT
PRESSURE
SENSOR
SHORT
CIRCUIT
TO POSI-
TIVE
Possible front
axleoverload.
FAILUREINDI-
CATOR
TURNS
ON.LOAD IN-
DICATION IS
MISSING OR
DOESNOT
RESULT.
Checkconnector wir-
ingand components.
Measuretype:
Voltage (V)
Measurepoint
1: Connector
X1 Pin: 10
Measurepoint
2: Connector
X2 Pin: 3
Key+15ON; Typical Value:
22-26 V;
INSERT
ADAPTERBE-
TWEEN THE
UNIT AND
CABLING
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
16 05 SENSORS
- FRONT
PRESSURE
SENSOR
OPEN CIR-
CUIT
Possible front
axleoverload.
FAILUREINDI-
CATOR
TURNS
ON.LOAD IN-
DICATION IS
MISSING OR
DOESNOT
RESULT.
Checkconnector wir-
ingand components.
Measuretype:
Resistance
(KOhm)
Measurepoint
1: Connector
X2 Pin: 1
Measurepoint
2: Connector
X2 Pin: 3
Key+15OFF; Typical Value:
41KOhm;
INSERT
ADAPTERBE-
TWEEN THE
UNIT AND
CABLING
16 06 SENSORS
- FRONT
PRESSURE
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible front
axleoverload.
FAILUREINDI-
CATOR
TURNS
ON.LOAD IN-
DICATION IS
MISSING OR
DOESNOT
RESULT.
CHECKINSULATION
FROMBATTER-
Y.CHECKCOMPO-
NENT AND CON-
NECTORCABLING
INTEGRITY.
Measuretype:
Resistance
(KOhm)
Measurepoint
1: Connector
X2 Pin: 3
Measurepoint
2: Connector
X1 Pin: 12
Key+15OFF; Typical Value:
1-1.5KOhm;
INSERT
ADAPTERBE-
TWEEN THE
UNIT AND
CABLING
18 03 SENSORS
- RIGHT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
Check: Check isolation
from+batterypin 2-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
18 05 SENSORS
- RIGHT
PRESSURE
SENSOR
(AXLE)
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
Check: Check continu-
itybetweenpins 1- 2
/ X2
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 35
- 45 Kohm
18 06 SENSORS
- RIGHT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
Check: Check isolation
from- batterypin2-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 1-
1.5 Kohm
19 03 SENSORS
- LEFT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
Check: Check isolation
from+batterypin 6-
X2 /7- 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
19 05 SENSORS
- LEFT
PRESSURE
SENSOR
(AXLE)
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
Check: Check continu-
itybetweenpins 1- 6
/ X2
Measuringconditions:
Connectorsconnected
to control unit. Keyon
STOP.
Comparable values: 35
- 45 Kohm
19 06 SENSORS
- LEFT
PRESSURE
SENSOR
(AXLE)
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible engine
axleoverload.
Checkconnector wir-
ingand components.
Check: Check isolation
from- batterypin6-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 1-
1.5 Kohm
1A 03 SENSORS
- RIGHT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
Check: Check isolation
from+batterypin 4-
X3 /7- 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1A 05 SENSORS
- RIGHT
PRESSURE
SENSOR
3RD AXLE
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
Check: Check continu-
itybetweenpins 1-
X2 / 4 - X3
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 35
- 45 Kohm
1A 06 SENSORS
- RIGHT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
Check: Check isolation
from- batterypin4-
X3 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 1-
1.5 Kohm
1B 03 SENSORS
- LEFT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
Check: Check isolation
from+batterypin 3-
X3 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1B 05 SENSORS
- LEFT
PRESSURE
SENSOR
3RD AXLE
OPEN CIR-
CUIT
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
Check: Check continu-
itybetweenpins 1-
X2 / 3 - X3
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 35
- 45 Kohm
1B 06 SENSORS
- LEFT
PRESSURE
SENSOR
3RD AXLE
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axleloadsignal
missingor incor-
rect.
Possible addi-
tional axleover-
load.
Checkconnector wir-
ingand components.
Check: Check isolation
from- batterypin3-
X3 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 1-
1.5 Kohm
1C 03 SENSORS-
PRESSURE
SENSOR
RAISER
SHORT
CIRCUIT
TO POSI-
TIVE
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control disabled.
Checkconnector wir-
ingand components.
Check: Check isolation
from+batterypin 5-
X3 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
1C 05 SENSORS-
PRESSURE
SENSOR
RAISER
OPEN CIR-
CUIT
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control disabled.
Checkconnector wir-
ingand components.
Check: Check continu-
itybetweenpins 1-
X2 / 5 - X3
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 35
- 45 Kohm
1C 06 SENSORS-
PRESSURE
SENSOR
RAISER
SHORT
CIRCUIT
TO
GROUND
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control disabled.
Checkconnector wir-
ingand components.
Check: Check isolation
from- batterypin5-
X3 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 1-
1.5 Kohm
21 0B REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
IT ISNOT
POSSIBLE
TO DE-
TECT THE
FAULT
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkcorrect oper-
ationof remote con-
trol onModusinstru-
ment status para-
meters.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
22 03 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORELEC-
TRO-
VALVES
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON. Loaddistribu-
tion onaxles
control disabled.
Checkwiringand con-
nectorsonframecon-
trol solenoid valves.
Check: Check isolation
from+batterypin 4-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
22 05 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORELEC-
TRO-
VALVES
OPEN CIR-
CUIT
Pneumatic sus-
pensionlocked.
Manual trimvari-
ationscannot be
carried out. Aux-
iliaryfunction
deactivated at
peak.
ECAStotally
disabled.
Checkwiringand con-
nectorsonframecon-
trol solenoid valves.
Check: Check continu-
itybetweenpins 4-
X2 / 6.1 or 61.1 sole-
noids
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 70
- 90 Ohm
22 06 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORELEC-
TRO-
VALVES
SHORT
CIRCUIT
TO
GROUND
Pneumatic sus-
pensionlocked.
Manual trimvari-
ationscannot be
carried out. Aux-
iliaryfunction
deactivated at
peak.
ECAStotally
disabled.
Checkwiringand con-
nectorsonframecon-
trol solenoid valves.
Check: Check isolation
from- batterypin4-
X2 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: >
1 Mohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
26 02 ELEC-
TRONIC
CON-
TROL
UNIT -
MEMORY
CHECK-
SUM
SPECIFIC
DATA
NOT
CORRECT
No frameauto-
maticadjustment.
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control and
level automatic
controls dis-
abled.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Check: Reprogram
Electroniccontrol unit.
Recalibrateframelevel.
Measuringconditions:
Comparablevalues:
27 02 ELEC-
TRONIC
CON-
TROL
UNIT -
PARA-
METER
CHECK-
SUM
INCOR-
RECT
PARA-
METERS
No frameauto-
maticadjustment.
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control and
level automatic
controls dis-
abled.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Check: Reprogram
Electroniccontrol unit.
Recalibrateframelevel.
Measuringconditions:
Comparablevalues:
28 02 ELEC-
TRONIC
CON-
TROL
UNIT -
HEIGHT
SENSOR
CALIBRA-
TION
DATA
CHECK-
SUM
FAULT
INCOR-
RECT
PARA-
METERS
No frameauto-
maticadjustment.
Additional axle
cannot beraised.
Auxiliaryfunction
deactivated at
peak.
Additional axle
control and
level automatic
controls dis-
abled.
Electroniccontrol unit
configuration check.
Checkcalibration le-
vels.
Check: Reprogram
Electroniccontrol unit.
Recalibrateframelevel.
Measuringconditions:
Comparablevalues:
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
2E 03 POWER
SUPPLY -
PRESSURE
SENSORS
VOLTAGE
SUPPLY
SHORT
CIRCUIT
TO POSI-
TIVE
Fault light ON.
Axles loadsignal
missingor incor-
rect.
Possible axles
overload.
Checkconnector wiring
andcomponents.
Check: Check isolation
from+batterypin 1-
X2 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 0.5
- 4.5 V
2E 06 POWER
SUPPLY -
PRESSURE
SENSORS
VOLTAGE
SUPPLY
SHORT
CIRCUIT
TO
GROUND
Fault light ON.
Axles loadsignal
missingor incor-
rect. Additional
axlecannot be
raised. Auxiliary
function deacti-
vated at peak.
Possible axles
overload. Addi-
tional axlecon-
trol disabled.
Checkconnector wiring
andcomponents.
Check: Check isolation
from- batterypin1-
X2 / 7 - 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 30
- 50 Kohm
2E 0B POWER
SUPPLY -
PRESSURE
SENSORS
VOLTAGE
SUPPLY
IT ISNOT
POSSIBLE
TO DE-
TECT THE
FAULT
Fault light ON.
Axles loadsignal
missingor incor-
rect. Additional
axlecannot be
raised. Auxiliary
function deacti-
vated at peak.
Possible axles
overload. Addi-
tional axlecon-
trol disabled.
Checkconnector wiring
andcomponents.
Check:
A) Check isolation
from+batterypin 1-
X2 / 7 - 10- X1
B) Check isolation
from- batterypin1-
X2 / 12- X1
Measuringconditions:
A) Connectors con-
nected to control unit.
Keyon START.
B) Connectors con-
nected to control unit.
Keyon STOP.
Comparablevalues:
A) 0.5- 4.5V
B) 30- 50 Kohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
2F 03 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORECAS
REMOTE
CON-
TROL
SHORT
CIRCUIT
TO POSI-
TIVE
Remotecontrols
deactivated.
Level manual
controls dis-
abled.
Checkconnector wir-
ingand components.
Check: Check isolation
from+batterypin 13
- X1 / 7- 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparablevalues: 1-
1.5 V
2F 06 POWER
SUPPLY -
SUPPLY
VOLTAGE
FORECAS
REMOTE
CON-
TROL
SHORT
CIRCUIT
TO
GROUND
Remotecontrols
deactivated.
Level manual
controls dis-
abled.
Checkconnector wir-
ingand components.
Check: Check isolation
from- batterypin13
- X1 / 12 - X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 30
- 40 Kohm
30 03 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO POSI-
TIVE-
DATA
LINE
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkconnectors wir-
ingand components.
Check: Check isolation
from+batterypin 11
- X1 / 7- 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparable values: 22
- 26 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
30 06 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO
GROUND
- DATA
LINE
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkconnectors wir-
ingand components.
Check: Check isolation
from- batterypin11
- X1 / 12 - X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparablevalues: 6-
7 Kohm
31 03 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO POSI-
TIVE-
CLOCK
LEITUNG
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkconnectors wir-
ingand components.
Check: Check isolation
from+batterypin 8 -
X1 / 7 - 10- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon START.
Comparablevalues: 4-
4.5 V
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
31 06 REMOTE
CON-
TROL-
REMOTE
CON-
TROL 1
SHORT
CIRCUIT
TO
GROUND
- CLOCK
LINE
Deactivation re-
motecontrol 1.
Level manual
controls dis-
abled.
Checkconnectors wir-
ingand components.
Check: Check isolation
from- batterypin8 -
X1 / 12- X1
Measuringconditions:
Connectorsconnected
to control unit.
Keyon STOP.
Comparable values: 8.5
- 9.5 Kohm
3C 09 CAN LINE
- CAN
COM-
MUNICA-
TION
ERROR
ABNOR-
MAL UP-
DATE
RATE
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
condition between pin
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
tions: Connectors con-
nected to control unit.
Keyon STOP.Compar-
ablevalues: 60 ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
3D 09 CAN LINE
- MESSAGE
VSC1
(CCVS)
FROMEN-
GINE
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
condition between pin
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
tions: Connectors con-
nected to control unit.
Keyon STOP.Compar-
ablevalues: 60 ohm
3E 09 CAN LINE
- MESSAGE
EEC1
FROMEN-
GINE
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
condition between pin
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
tions: Connectors con-
nected to control unit.
Keyon STOP.Compar-
ablevalues: 60 ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
44 09 CAN LINE
- MESSAGE
TCO1
FROM
TACHO-
GRAPH
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
condition between pin
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
tions: Connectors con-
nected to control unit.
Keyon STOP.Compar-
ablevalues: 60 ohm
45 09 CAN LINE
- MESSAGE
TIME AND
DATE
FROM
TACHO-
GRAPH
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time. Incorrect
brakingadjust-
ment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control
units.Check: Check
condition between pin
15and16 on30-pole
diagnosis connec-
tor.Measuringcondi-
tions: Connectors con-
nected to control unit.
Keyon STOP.Compar-
ablevalues: 60 ohm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action
Checkstobe
performed
Measuring
conditions
Valuestobe
detected
Remarks
E7 09 CAN LINE
- DATA
UPDAT-
ING FRE-
QUENCY
FAULTY
SIGNAL
Level adjustment
delayedor ad-
vanced.
Delayedlevel
adjustment
time.
Incorrect brak-
ingadjustment.
CheckvehicleCAN
lineandrelativecon-
nectionsontherel-
evant control units.
FE 02 ELEC-
TRONIC
CON-
TROL
UNIT -
ELEC-
TRONIC
CON-
TROL
UNIT
SPECIFIC
DATA
NOT
CORRECT
Pneumatic sus-
pensionlocked.
Manual trimvari-
ationscannot be
carried out. Aux-
iliaryfunction
deactivated at
peak.
ECAStotally
disabled.
Electroniccontrol unit
configuration check.
Check: Reprogram
Electroniccontrol unit,
if fault persists, replace.
Measuringconditions:
Comparablevalues:
67 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
SECTION 2
Visible Failure Possible cause Repair action
Insufficient lubrication. Lubricatethoroughly.
Shockabsorbersnoisyor inefficient. Checkandifnecessaryreplaceshockab-
sorbers.
Wheel bearings worn with excessive
play.
Renewbearingsor adjust play.
Noisysuspension
Leaf springhangers loose. Checkhanger fixingsandifnecessaryre-
place anyloosepins or bolts.
Leaf spring pack loose due to broken
centrebolt.
Overhaul theleafspringsandrenewthe
centrebolt and self-lockingnut.
Leaf springpack loosedue to breakage
of pinssecuringthespringclamps.
Checkleaf springclampsandrenewthe
pins.
Tyrepressuresincorrect. Check andinflateto specifiedpressure.
Front wheel alignment incorrect. Checkandadjust front wheel alignment.
Vehiclepullsto oneside
Hydraulicshockabsorbers inefficient. Fit newshockabsorbers.
Vehiclepullsto oneside
Brokenleaf spring. Overhaul leaf springandrenewcompo-
nentsas required.
Incorrect loaddistribution. Distributeloadevenlyoverloadingdeck.
Leaf springcentrebolt broken. Fit newbolt.
Excessiveflexibilityof suspension
Springleaves over-stressedor broken. Overhaul theleafspringandrenewdam-
aged parts or the complete spring as
necessary.
Leaf springmountings loose. Checkmountingsandifnecessaryrenew
looseshacklepins.
Leaf spring pack loose due to broken
centrebolt.
Overhaul theleafspringsandrenewthe
centrebolt and self-lockingnut.
Squeaking, knocking, excessive noise in
general
Leaf springpack loosedue to breakage
of pinssecuringthespringclamps.
Checkleaf springclampsandrenewthe
pins..
Wheel bearingsworn.
Excessiveplayof bearings.
Renewbearings, if necessary.
Adjust axial clearancesofbearings.
Excessive wear or play of bearings at
central pivot of cantilever suspension.
Renewbearingsand/oradjustaxial clear-
ancesof bearings.
Aquila Trucks Centres
68 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
FRONT SUSPENSION
Collarednut for leaf springU-bolts 460 50 (46 5)
Flanged nut for front and rear shacklepins 710 70 (71 7)
M14flanged nut for bolt securingfront springhanger to chassisframeandfor securingcentral
pivot on8x4
180 20 (18 2)
M16nut for securingfront springhanger 275 25 (27.5 2.5)
M20flanged nut for anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
Anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
M16nut for lower shock absorber mounting 150 15 (15 1,5)
M14nut for upper shock absorber mounting 63.5 6.5 (6.3 0.6)
M20bolt for shockabsorber-axlemounting 259 26 (25.9 2.6)
Fork-securingM20 nut 400 40 (40 4)
M12nut for anti-roll bar bushingsupport 182.5 17.5 (18.2 1.7)
M20flanged nut for anti-roll bar retainingpin 756.5 20.5 (75.6 2)
REARSUSPENSION
Collarednut for leaf springU-bolts 460 50 (46 5)
Flanged nut for front and rear shacklepins 710 70 (71 7)
M20flanged nut for anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
Anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
U-bolt retainingbolt for front springpivot 192 17 (19.2 1.7)
M14bolt securingU-bolt for central pivot pin (8x4 - 8x8vehicles) 205 20 (20.5 2)
M14nut for upper and lower shockabsorber mounting 63.5 6.5 (6.3 0.6)
M24nut securingshock absorber to hanger and axle 400 40 (40 4)
M24x110bolt securingshockabsorber to chassis frame 400 40 (40 4)
M20nut or bolt securingshockabsorber to axleor hanger 380 40 (38 4)
M20bolt securingbar and shockabsorber springs support 700 15 (70 1.5)
M20nut securingshockabsorber to hanger and toair springsupport beam 230 20 (23 2)
REARCANTILEVERSUSPENSION
Nut for leafspringclampingU-bolt 825 75 (82.5 7.5)
Flanged hexhead bolt securingupper hanger bracket to chassisframe 270 55 (27 5.5)
Flanged hexhead bolt securinglower hanger bracket to upper hanger bracket 492.5 96.5 (49 9.6)
Retainingbolt for longitudinal bar to leaf springslipper block 420 (42)
Hexretainingnut for reactionbar 390 40 (39 4)
M20flanged nut for anti-roll bar retainingpin 437.5 42.5 (43.7 4.2)
M18hexnut securinglongitudinal bars 385 35 (38.5 3.5)
M18hexnut securinglongitudinal bars 417.5 57.5 (41.7 5.7)
M18hexheadbolt securingtriangular bar to hanger bracket 352.5 32.5 (35.2 3.2)
16x1.5hexbolt securingtriangular bar pivot mountingto axle 277.5 27.5 (27.7 2.7)
Hexsocket screwsecuringplateto axlecasing 430 30 (43 3)
Excludingvehicles withpneumatic suspension
Onlyfor vehicles withpneumatic suspension
Aquila Trucks Centres
69 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
TOOLS
TOOL NO. DESCRIPTION
99305117
Pneumaticcircuit checkinstruments
99321024 Hydraulicjackfor wheel removal and refitting
99327030 E.A.SY.
99331016 Unitester casefittedwith multimeter and amperometricdevice
99341003 Single-actinglift
99341011 Pair of brackets
Aquila Trucks Centres
70 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
TOOL NO. DESCRIPTION
99341015
Clamp
99341035
Highpressurepumpfor assemblyofsuspensionpivotsandhangers
99345055 Adapter platefor usewithpullers
99346001 Standard installer (usewithspecificbushes)
99346004 Threadedbush(for usewith99346001and99363245)
99346049
Tool for disassemblingand assemblingflexibleblocksonstabilizer
bar andleafspring.
Aquila Trucks Centres
71 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
TOOL NO. DESCRIPTION
99346238
Sleevefor installinginner raceof angular contact bearing(usewith
specificbushes)
99346242
Sleevefor installinginner raceof angular contact bearing(usewith
specificbushes)
99346243
Sleevefor installinginner raceof angular contact bearing(usewith
specificbushes)
99346247 Referencespacersfor ECASsuspensionadjustment
99363245 Threadedbush(for usewith99346001and 99346004)
99363296
Tool tobefittedtobearingspindleforinstallinginnerraceofangular
contact bearing (use with 99346001 - 99346004 - 99346238 -
99346243 - 99363245)
Aquila Trucks Centres
72 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
TOOL NO. DESCRIPTION
99363309
Tool tobefittedtobearingspindleforinstallinginnerraceofangular
contact bearing (use with 99346001 - 99346004 - 99346242 -
99346243 - 99363245)
99370007 Interchangeabledriver handlefor bearinginstallers
99374094
Installer for outer bearing races (134 to 215) (for use with
99370007)
99374119
Installer for springmountingoil seal
99374131
Installer for springmountingoil seal
Vehicleswith21tonssuspensions(outsidediameter ofcentral pivot shaft 88 mm)
Vehicleswith32tonssuspensions(outsidediameter ofcentral pivot shaft 120mm)
Aquila Trucks Centres
Thischaptershowstechnical constructiondrawingsofthespecial purposetool (S.P.2403),usedinservicingthesuspensiondescribed
inthissection. Thismaybebuilt bytherepair workshops.
73 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
EXPERIMENTAL TOOLS
Aquila Trucks Centres
74 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
90643
Removal
Arrange vehicleonflat groundand lockrear wheels.
Loosenfront wheels securingnuts.
Byahydraulic jack, lift the vehiclefromfront side and rest it
ontwo support stands.
Unscrew wheels securingnuts and disconnect wheels with
hydraulictruck99321024.
Positionahydraulic jacksuitable to support front axlewhen
theleaf springwill bedisconnected.
Then,lowerthehydraulicjackthat isprearrangedunderfront
axleuntil leaf springtension is released.
Removeboard (5) operatingasfollows:
- removescrews(4),operatingfromunderthevehicleand
removeboardcompleteassembly;
- removescrew(10) of rear shackle(11);
Ifscrew(10) isorientedwithitsheadtowardsthe
external side of the vehicle, it is necessary for
dismountingthevehicleto partiallydisconnect the
air filter asdescribed below:
- disconnect lower cover (2);
- removecontainer (15);
- disconnectfilteringcartridge(14)operatingon
nut (1);
NOTE
Checkthethreadofthebracketsjoiningleafsprings
to front axle; if faults are found, rectify thread
(operation500412), or replacebrackets.
Forcorrectcover (2) springsclamping,aligntomark
(12).
Tighten screws (10) with their head oriented
inwards.
Check stopspringbuffers conditions; if stopspring
buffers are found to be worn out, replace them
(operation500417).
NOTE
Tightennutsat prescribedtorque.
- remove the nut with screw (3) securingleaf springto
front support;
- unscrewnuts (6) and unthreadU bolts(7);
- disengage shock absorber (13) from suspension
operatingonfastener (8);
- removeleafspring(9).
Refitting
For reconnection, invert operations performed for
disconnectionobservingfollowingwarnings.
Figure26
75 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
500410 FRONT LEAF SPRING REMOVAL-REFITTING
Aquila Trucks Centres
90644
Figure27
Parkthevehicleonlevel groundand chocktherear wheels.
Loosenthewheel nutsonthe 2nd axle.
Usingahydraulicjack,raisethefrontofthevehicleandsupport
it on two stands.
Unscrew the wheel nuts and, using hydraulic trolley
99321024, removethewheels.
Position a hydraulic jack to support the axle when the leaf
springisdetached.
Lower the hydraulic jack supportingthe axle to relieve the
tension ontheleaf spring(2).
- Detachthefrontleafspringfromthemounting(1)before
proceedingwiththeremoval of thesecondsteeringaxle;
- removetherear shacklepin(7);
- undothefront mounting(1)todetachtheleafspringfrom
thevehicle;
- unscrewthefour nuts(4) andwithdrawtheU-bolts(3);
- remove the nut and bolt (5) and detach the shock
absorber (20) fromthesuspension;
- removethecompleteleaf spring(2).
Refitting
Carryout theremoval operationsinreverseorder, observing
thefollowinginstructions:
Removal
Inspect the threadsonthe U-bolts thesecure the
leafspringtotheaxle;ifdamaged,re-cutthethreads
(operation500412) or renewtheU-bolts.
Checktheconditionof therubberbumpstopsand
renewthemif deteriorated (operation 500417).
Tightenall nuts to theprescribed torquesettings.
Totightendownthecap(9),first tightenbolt(10) to
the prescribed torque, interposing spacer (8), and
thentightenbolt (11) without aspacer.
Before theleaf springcan be attached to thetwo
mountings, the spring must be loaded (using
suitableequipment includinghydraulicjacksandby
loading the vehicle itself), thereby causing it to
extendand bringingtheholesfor theshacklepins
into alignment.
NOTE
76 TRAKKER EURO 4/5 SUSPENSIONS
Base- November 2006 Print 603.93.641
500420 REMOVAL-REFITTING OF INTERMEDIATE AXLE LEAF SPRING (8x4 VEHICLES)
Aquila Trucks Centres
Figure28
Removal
Parkthevehicleonlevel ground and chockthefront wheels.
Usingahydraulicjack,raisethevehicleandsupport thechassis
ontwo stands.
Removethewheelsusinghydraulictrolley99321024.
Removethenuts(5) andwithdraw theU-bolts securingthe
leafspring(3) to theaxle.
Positiontrolley99306064undertheleafspringandattachthe
latter to thetrolleywiththespecificbrackets.
Removebolts(11and12) andremovethecap(2) alongwith
thespacer (9) that securesthespringshacklepin tothefront
hanger (1); unscrew nut (8) and withdraw the shackle pin
securingtheshackleplate (7) to therear hanger (6).
Operate the jack to lower the axle so that the leaf spring
centrebolt can bewithdrawn.
40533
Carryout theremoval operationsinreverseorder, observing
thefollowinginstructions:
Refitting
InspectthethreadsontheU-boltsthesecuretheleaf
spring to the axle; if damaged, restore the threads
(operation500412) or renewtheU-bolts.
Check thecondition of therubber bump stopsand
renewthemif deteriorated (operation 500417).
Tightenall nuts to theprescribed torquesettings.
Totightendownthecap(9),first tightenbolt (10) to
the prescribed torque, interposing spacer (8), and
thentightenbolt (11) without aspacer.
72339
REARSUSPENSION WITH PARABOLIC LEAF SPRING
77 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
500410 REMOVAL-REFITTING OF REAR LEAF SPRING (4x2 - 4x4VEHICLES)
Aquila Trucks Centres
Figure29
Removal
Parkthevehicleonlevel ground, chockthefront wheelsand
loosentherear wheel nuts.
Positionthebracket 99370617onahydraulic jack, placethe
jackunder theaxleandraisetherear of thevehicle.Support
the chassis frame and the intermediate and rear axles on
stands,whileensuringthat thebracketmaintainscontact with
theaxle.
Remove the wheel nuts and remove the wheels using
hydraulictrolley99321024.
Removethenuts(5)oftheU-bolts(1) securingtheleafspring
(6) to thecentral pivot.
Remove the bolts (3) and detach the longitudinal bar
mountingbracket (4) and theslipperblock (2) fromtheaxle
casing.
Proceedwiththeremoval ofthecompleteleafspringfromthe
vehicleusingasuitablejack.
71516
Carryout theremoval operationsinreverseorder, observing
thefollowinginstructions.
Refitting
InspectthethreadsontheU-boltsthesecuretheleaf
spring to the axle; if damaged, re-cut the threads
(operation500452) or renewtheU-bolts.
Fit theslipperblockandthelongitudinal barmount-
ingbracket asdescribedon page 79.
6
78 TRAKKER EURO 4/5 SUSPENSIONS
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500430 REMOVAL-REFITTING OF REAR LEAF SPRING ON CANTILEVER TYPE
SUSPENSIONS (6x4- 6x6 - 8x4 - 8x8VEHICLES)
Aquila Trucks Centres
36836
- Apply MODILAC grease to the threads of the slipper
block(1);
- applyresinfor boxframes to bolt contact surfaces and
holesinthebracket (2);
- after having aligned the parts, pre-tighten bolts (3) in
cross-wisesequenceto atorqueof 100Nm;
- finallytighten bolts(3) to atorqueof 420 Nm.
TighteningtheU-boltsclampingtheleaf spring
to the central pivot
Tightentheleafspring(4and6) clampingnuts(5and7) asfol-
lows:
- tightennuts (5) to atorqueof 300to 500 Nm
- tightennuts (7) to atorqueof 750to 900 Nm
- tightennuts (5) to atorqueof 750to 900 Nm
Figure30
79 TRAKKER EURO 4/5 SUSPENSIONS
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Procedure for assemblyof the slipper block and mounting brackets for the longitudinal bars
Aquila Trucks Centres
86426
39073
39075
39076
39077
Figure31
Figure32
Figure33
Figure34
Figure35
500440 Removal-refitting of central pivot
500442 Removal-refitting of central pivot
shaft
500443 Renewal of bearings
500449 Removal-refitting of hanger bracket
Removal of the central pivot
Removetheleafspring(1) asdescribedintherelativechapter
(operation500430).
With tools 99341011(5), 99341003(6), 99341015(7) and
reactionblock99345055(4),withdrawfromshaft(3) thecen-
tral support (1) completedwithexternal half-bearing(2).
Fit thepipe(3) ofhydraulicpump99341035(4) to thehole
inthehanger bracket (1); operatethepumpto separatethe
shaft (2) fromthebracket (1).
Removebolt(6)andplate(5) andwithdrawtheshaft(2) from
thebracket (1).
Detach the longitudinal tie-rods (2 and 3) and detach the
bracket (1). If the upper bracket (1, Figure38) is to be
replaced, removetheretainingbolts( ) and detachit from
thechassissidemembers.
Usingahydraulicpress, withdrawtheinner bearingrace (2)
of thecentral pivot shaft (1).
!
Raisethefrontofthevehicleandsupportit onstands
so that thechassis frameislevel.
Removethespringclip(6) and removethe cap(5).
Unscrewthebolts(4) andremoveplateandtheun-
derlyingadjustment shims(2).
Removal of the hanger bracket
Renewal of the bearings
Donotremovethebolt (6) andplate(5) asthesewill
prevent the shaft (2) frombeingviolentlyexpelled
fromthebracket duringthesubsequent operation.
Loosenbolt (6) byonefull turn.
Removal of the central pivot shaft
80 TRAKKER EURO 4/5 SUSPENSIONS
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REAR CANTILEVER SUSPENSION
(6x4 - 6x6- 8x4 - 8x8vehicles)
Aquila Trucks Centres
Theouter racesofthebearings(4and5) areto beremoved
fromthecentral pivot withtheaidofasuitablebearingextrac-
tiontool.
Torefit thebearings, usetool 99374094(2) withapressand
partiallyinsert thebearingsinthecentral pivot (3).
Complete the installation using a mallet and driver handle
99370007(1).
39078 39080
39079
Figure36 Figure37
Figure38
Usinginstaller (1) 99374119or 99374131, install theseal (2)
inthecentral pivot (3).
Thenfit ring(4).
Refitting the hanger bracket
Refit thelower bracket (10) totheupper bracket (1) tighten-
ingtheretainingboltsinthedirectionofarrowBtothespeci-
fiedtorque.
In cases where it was also necessary to remove the upper
bracket (1), observethefollowinginstructionon refitting:
- gradually tighten the bolts in the sequence
2-3-4-5-6-7-8-9until thepartsarebrought together;
- tighten the bolts to the specified torque first in the
direction of arrowA and thenof arrowB;
- re-tightentheboltstothespecifiedtorqueinthedirection
of arrowA.
- Tighteningtorquefor bolts securinglower bracket (10)
to upper bracket (1): 395 to 590 Nm;
- Tighteningtorqueforboltssecuringupper bracket (1) to
chassissidemember: 215to 325 Nm;
2
1
3 4 5
6 7 8 9
10
81 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
HavingobtaineddistanceB,openthedischargevalveonthe
hydraulicpump99341035 and wait at least 10minutesbe-
forefinallytighteningthebolt (1) toatorqueof 830to 665
Nm( 83to66.5kgm). Disconnect thepumptubefromthe
hanger bracket andrefit theplugto theoil inlet hole.
39081
39083
39082
39084
39385
Figure39
Figure40
Figure41
Figure42
Figure43
Insert the shaft (1) in thehanger bracket (2) with the holes
oriented asshowninthefigure; positiontheplate(4) onthe
bracket (2) andsecureit to theshaft (1) with thebolt (3).
Screwthe bolts ( ) into the holes in the shaft (1); place a
straight edge(2) alongthetopoftheboltsandcheckthat the
endsA andBareequidistant fromtheground;ifnot, adjustby
turningtheshaft (1).
Hold the shaft (1) against rotation and tighten the bolts (3,
Figure37) toatorqueof 50Nm.MeasurethedistanceA be-
tweentheendoftheshaft (1) and thehanger bracket (2).
Thedistancemeasuredmust bewithintherangeindicatedin
thetable inFigure 42.
While holdingtheshaft (2) against rotation, operatethehy-
draulicpump99341035(3) andsimultaneouslyscrewinbolt
(1) until the end of the shaft (2) is positioned at distance B
fromthebracket.
ThedistanceBmust beequal toA-C,whereA isthedistance
previouslymeasuredandC isthevalueindicatedinthetable.
ThedistanceBmust bewithintherangeindicatedinthetable.
Lubricatetheoil seal ( ) with TUTELA MR3 grease and fit
it to the shaft (2). Using tools 99346238 or 99346242 (3),
99363296or 9936330(4),99363245(5),and99346004(6),
whicharetobefittedtotheshaft (2) asshown,install theinner
bearing(1).
!
Towardstheendoftheshaftfittingprocedure,theoil
reachesapressurebetween800and1300bar.
Refitting the central pivot
82 TRAKKER EURO 4/5 SUSPENSIONS
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Refitting the central pivot shaft
Measure-
Outsidediameter ofshaft end(2)
Measure
ment
88mm 120 mm
A 217.5 220.5 211.5 215
B 213.5 216.5 205 208.5
C 4.5
+0.5
6.5
+0.5
Aquila Trucks Centres
Fit: oil seal (8) lubricatedwith TUTELA MR3greaseandcap
(11) withplug(10) positionedat thetop.Securethecap(11)
to thecentral pivot (3) withspringclip(9). Removetheplug
(10) andpourinTUTELAGI/Aoil until itflowsoutofthehole
(quantity 0,5l).
InjectTutelaMR2greaseintothegreasenipplelocatedonthe
hanger bracket: completethesuspensionrefittingprocedure
asdescribed onpage 78.
CENTRAL PIVOT COMPONENTS
1. Oil seal - 2. Oil seal - 3. Central pivot -
4. Outer race of inner bearing- 5. Inner raceof inner
bearing- 6. Outer raceof outer bearing- 7. Inner raceof
outer bearing- 8. Oil seal - 9. Springclip - 10. Plug-
11. Cap - 12. Bolt - 13. Plate - 14. Adjustment shims-
15. Shaft - 16. Seal.
39086
39087
40189
39088
Figure44
Figure45
Figure46
Figure47
Fit the central pivot (1) to the shaft (4) and, using tools
99346243 (3), 99363296 (5), 99363245 (6), 99346004 (7)
and99346001(8), fittedtotheshaft (4) asshown, install the
inner raceof theouter bearing(2).
DeterminethethicknessSofthebearingaxial playadjustment
shims(1) asfollows:
- applytheplate(2) andtightentheretainingbolts( ) to
atorqueof 30Nm;
- Remove the bolts ( ), remove theplate and measure
the distance between the end of the shaft (3) and the
inner race(4) of thebearing:
distanceA shaft protrusion
distance-A shaft stand-in
- measurethestand-inof theplatesurface(1) asshownin
Figure35: distanceB.
ThethicknessSoftheadjustment shinis givenby:
S=B+C - ( A).
A andBarethemeasureddistancesandC istheaxial playof
thebearings(0.1to0.3mm).Thenfit:adjustmentshim/softhe
calculatedthicknessandtheplate(2) andtightentheretaining
bolts( ) toatorqueof240Nm.Fittheleafspringandtighten
theu-bolt nutsin themanner described on page79.
Tapthecentral pivot afewtimesinthedirectionoftheshaft
axis,thencheckthat thepivot canfreelyrotatethrough180;
ifnot,increasethethicknessoftheadjustment shimby0.1mm.
Towardstheendoftheinstallationoperation,it will
be necessary to tap the central pivot (1) with a
mallet toensurethat theinnerracesofthebearings
seat correctlyin their respective housings.
Removetheinstallationtoolsfromtheshaft.
NOTE
83 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
Figure48
38697
36838
Figure49
Removal
Remove the retaining nuts or bolts ( ) of the longitudinal
arms (1, Figure49) or triangular arms(1, Figure48), andre-
movethearms.
LONGITUDINAL ARMSFITTEDTO 6x4- 8x4 - 8x8 VEHICLES
TRIANGULARARMFITTED TO VEHICLES
WITH AIRSUSPENSION 4x4 - 6x4- 8x4
1 1
Refitting
Refittingis the reverseof removal. Tightennuts/boltsto the
specifiedtorque.
7
84 TRAKKER EURO 4/5 SUSPENSIONS
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528913 REMOVAL-REFITTING OF REAR AXLE LONGITUDINAL ARM
528914 REMOVAL-REFITTING OF INTERMEDIATE AXLE LONGITUDINAL ARM
528918 REMOVAL-REFITTING OF REAR AXLE TRIANGULAR ARM FOR VEHICLES WITH
AIR SUSPENSION
Aquila Trucks Centres
Dismounting
Usingasuitablepressanddrift, compresstheflexiblepart of thepin (1) inorder to removethecirclip(2) and theunderlyingring
(3) with pincers.
Withdrawthepin(1) fromthesuspension arm(4).
Mounting
Carryout theremoval operationsin reverseorder, bearinginmind that the pinmountingfacemust bepositioned at 90_ to the
longitudinal axisof thesuspensionarm. Thecirclip openingmust beoriented asshown inthedetail inthefigure.
REPLACING TRIANGULAR SWINGING ARMBALL ARTICULATED JOINT
38700
79479
Figure50
Figure51
LONGITUDINAL SUSPENSION ARM
TRIANGULARSUSPENSION ARM
85 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
REPLACING THE SUSPENSION ARM FLEXIBLE PIN
Aquila Trucks Centres
88878
88877
88879
88880
88881
Figure52
Figure53
Figure54
Figure55
Figure56
Dismounting
Dismount cover (1).
Unscrewscrew(1).
Removespringring(1) bypliers.
Removeunderlyingcheck rings(2, 3).
Dismount theball articulatedjoint withM20X 1,5screw(1)
and suitabletools.
Mount ball articulatedjoint (1) into seat byprovidedbeater
!
Replacing the ball articulated joint directly on the
vehiclecanonlybeperformedontractors.Forboxed
trucks,theoperationiscarriedout at thebenchafter
detaching the reaction triangle (see procedure
described at page84).
Before replacingthe articulated joint, astand has to
be arranged under the axle in order to avoid
dangerous oscillations of it once dismounting has
beenperformed.
Mounting
Once it has been removed, the cover is to be
replacedbyanewone.
NOTE
86 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
88882
88883
88879
88884
88878
88885
Figure57
Figure58
Figure59
Figure60
Figure61
Figure62
Arrangepart (1) ofthetool ofSp.2403underoneofreaction
triangle arms to the purpose of making upper seal ring
mountingeasier.
Mount seal rings (1, 2, 3).
Removethepart oftool (1) ofSp. 2403(seepreviousfigure).
Positionspacer (1) of thetool of Sp. 2403asinfigure.
By tool (1) ofSp.2403,drawtheball articulatedjoint andseal
ring.
Tightenscrew(1) with aproper torque (135 Nm).
Mount cover (1).
87 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
Removal
Removetheshockabsorberbyremovingtheupperandlower
mountingbolts/nuts.
Inspect therubber bushes; if wornor deteriorated,
renewthem. Checkshockabsorber efficiencyusing
suitabletest equipment.
40432
40433
36780
38698
Figure63
Figure64
Figure65
Figure66
1. Hanger bracket - 2. Bushes - 3. Nut -
4. Shock absorber - 5. Bush - 6. Lower mountingbracket -
7. Nut - 8. Bolt - 9. Washer - 10. Bracket - 11. Nut.
FRONT ANTI-ROLL BARCOMPONENTS
1. Bush- 2. Bushsupport - 3. Anti-roll bar -
4. Rubber bush- 5. Bolt - 6. Linkrod - 7. Bolt -
8. Rubber bush- 9. Bracket - 10. Nut - 11. Bolt
REARANTI-ROLL BAR COMPONENTS
1. Bush- 2. Anti-roll bar - 3. Bolt - 4. Rubber bush-
5. Nut - 6. Bracket - 7. Linkrod - 8. Cap
To renew the rubber bushes (4-8, Figure65) and (4,
Figure66),useapresswithtool 99346049toremoveandin-
stall thebushes.
Refitting
Carry out the removal operations in reverse order; tighten
bolts andnuts to specifiedtorques.
5
1
2
3
4
6
7
11 10 9 8
1. Hanger bracket - 2. Bushes - 3. Nut -
4. Shock absorber - 5. Bush - 6. Lower mountingbracket -
7. Nut - 8. Bolt - 9. Washer - 10. Bracket - 11. Nut.
5009 SHOCK ABSORBERS 5289 ANTI-ROLL BARS
NOTE
88 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
38694
72233
Figure67
Figure68
Removetheanti-roll bar byremovingthenuts/bolts
securingthe pivot mountings and the cap retaining
bolts.
ASSEMBLY DRAWINGFORFRONT ANTI-ROLL BAR: 4x2- 6x4 - 8x4 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Front axle - 6. Cap.
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 4x4 - 6x6 - 8x8VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Axle- 6. Cap.
Check the bushes and/or rubber mountings and
renewthemiftheyshowsignsofwear or deteriora-
tion.
Refitting
Refit bycarryingout theremoval operationsinreverse
order; tighten nuts/bolts to thespecified torques.
Positionthehalfbushes(4) sothatthejointislocated
asshownin thefigure.
NOTE
89 TRAKKER EURO 4/5 SUSPENSIONS
Print 603.93.641 Base- November 2006
5289 ANTI -ROLL BAR
528930 FRONT ANTI -ROLL BAR
528940 AUXILIARY AXLE ANTI-ROLL BAR (8x4VEHICLES)
528960 REAR ANTI-ROLL BAR
528950 INTERMEDIATE AXLE ANTI-ROLL BAR (6x4- 6x6 - 8x4 - 8x8VEHICLES)
Removal
Aquila Trucks Centres
72234
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 6x4 - 8x4 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rear axle- 5. Rubber bush (intwo halves) - 6. Cap.
72235
Figure69
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 6x4 - 8x4 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 4. Rear axle- 5. Cap.
72236
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 6x4 - 8x4 VEHICLESWITH AIRSUSPENSION
1. Upper hanger bracket - 2. Linkrod- 3. Rubber bush(intwohalves) - 4. Anti-roll bar - 5. Rear axle - 6. Cap.
Figure70
Figure71
90 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
72237
ASSEMBLY DRAWINGFORINTERMEDIATEAXLEANTI-ROLL BAR: 6x4 - 6x6 - 8x4- 8x8VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Front axle.
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 4x2 VEHICLES
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Rear axle- 6. Cap.
72238
Figure72
ASSEMBLY DRAWINGFORREARANTI-ROLLBAR: 4x2 - 4x4 VEHICLESWITH AIRSUSPENSION
ASSEMBLING DIAGRAMFORADDITIONAL AXLE STABILISINGBARFOR8x4VEHICLES
WITH PNEUMATIC SUSPENSION
1. Upper hanger bracket - 2. Linkrod- 3. Anti-roll bar - 4. Rubber bush (intwo halves) - 5. Rear axle- 6. Cap.
Figure73
Figure74
38695
91 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
92 TRAKKER EURO 4/5 SUSPENSIONS
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Aquila Trucks Centres
1 TRAKKER EURO 4/5 WHEELSANDTYRES
Print 603.93.641 Base- November 2006
SECTION 11
5025 Wheels and tyres
Page
DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tirepressurevalues 3 . . . . . . . . . . . . . . . . . . . . .
TOOLS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 4 . . . . . . . . . . . . . . . . . . . .
- Mainoperatingfaults 4 . . . . . . . . . . . . . . . . . . . .
STATIC WHEEL BALANCING 6 . . . . . . . . . . . . . .
CORRECTION OFRESIDUAL STATIC IMBALANCE 7
TYREINFLATION PRESSURES 7 . . . . . . . . . . . . . .
HOW TYREBEHAVIOURDEPENDS
ON PRESSURE 8 . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
2 TRAKKER EURO 4/5 WHEELSANDTYRES
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
The wheel rimis the structure that confers rigidity to the
wheel and isidentified bythefollowingdimensions:
- rimdiameter,measuredacrosscentreofthewheel from
onebead seat to theother
- rimwidth, (distance between the inside of the bead
flangesacrosstherim)
Thetyreperformsthefollowingfunctions:
- to cushion the wheel against shocks transmitted from
uneven roadsurfacesusingtheelasticityofair;
MAIN DATA
- to transmit thedrivingforcedelivered bythe engine to
theroadsurfaceto movethevehicle;
- to confer the maximum grip and stability of contact
between the tyre and the road, while affording
satisfactorydurability;
- to withstandtheforces createdbysuddenbraking,hard
acceleration and thecentrifugal forces generated when
cornering;
- to ensure the stabilityof the vehicle at high speed; to
ensurethat steeringeffort is converted into directional
movement.
When checkingtyre pressures refer to thevalues
|oo|catoo |o t|o soc||c '|so aoo |a|otooaoco'
handbook.
NOTE
3 TRAKKER EURO 4/5 WHEELSANDTYRES
Print 603.93.641 Base- November 2006
DESCRIPTION
WHEELS Wheel rims Tyres
Discwithspecificcontinuousrims
22.5x9.00
22.5x9.00
22.5x8.25
13R22,5
315/80 R22.5
12R22.5
Tire pressure values
Aquila Trucks Centres
99305037 Electronicon-vehiclebalancer for front wheel balancing
TOOL No. DESCRIPTION
TOOLS
4 TRAKKER EURO 4/5 WHEELSANDTYRES
Base- November 2006 Print 603.93.641
TROUBLESHOOTING
Main operating faults
Visible Failure Possible cause Repair action
Excessivespeedover roughsurfaces. Reducespeed.
Suddenvariationsinspeedduetoviolent
accelerationor harshbraking.
Avoid all unnecessaryacceleration and
braking.
Excessivewear Excessive speed with tyres under-in-
flated.
Check tyrepressureswith tyrescold.
Tyresover-inflated. Reducetyrepressures.
Vehicle overloaded. Consult permissibleloadspecifications.
Differenceintyrepressuresbetweendif-
ferent pairsofwheels.
Check tyrepressures.
Tyresunder-inflated:wearconcentrated
onouter edgesof thetreadrather than
inthecentre.
Inflatetyresto correct pressure.
Tyres over-inflated: wear concentrated
inthecentreofthetread.
Reducetyrepressures.
Insufficient front wheel toe-in:excessive
wear oninner edgesof tyretreads.
Check andadjust toe-in.
Unevenwear
Front wheelsset toincorrect wheel ge-
ometry.
Restore correct wheel geometry.
Wheel rims deformed causing imbal-
ance.
Repairwheel rims,ifpossible, orreplace
them; thenbalancethewheels.
Tyresincorrectlyfitted torims. Fit the tyre correctly and balance the
wheel.
Rearaxleout ofparallel duetobreakage
onleaf springcentrebolt,springsof dif-
ferent lengths or buckled springs.
Overhaul thesuspension.
Excessive front wheel toe-in; excessive
wear onouter edges of tread.
Check andadjust front wheel toe-in.
(Continued)
Aquila Trucks Centres
5 TRAKKER EURO 4/5 WHEELSANDTYRES
Print 603.93.641 Base- November 2006
Visible Failure Possible cause Repair action
Front wheelsout of balance. Balancethewheels.
Vehicle pullsto oneside
Front tyresinflated to different pressur-
es.
Checkthatbothtyresareinflatedtocor-
rect pressure.
Excessivelyunevenwear betweentyres
of thesamewheel pair.
Renewthetyrethat isexcessivelyworn.
Aquila Trucks Centres
Thefront wheels canbebalanced whileonthevehicleusing
the electronic balancer 99305037; this method has the
advantageofbalancingthewheel alongwiththeotherrotating
masses.
Theoperation must becarriedout as follows:
- Jackupthefrontofthevehicleandcheckthat thewheels
canrotatefreely.
- Position the pickup unit (1) under the axle near to the
wheel,settingtheheight sothat thewheel spinnerofunit
99305037(2) isincontact withthetyre;positionanaxle
standunder theoppositeendoftheaxleandlowerthe
jack.
- Connect thelead(3) of thepickup unit to thebalancer
99305037.
- Makearadial referencemarkontyre,usingchalkorastrip
of adhesivetape.
- Turn switch (2) to the static balancing position and
sensitivityswitch(4) tonotchn 5onthegraduatedscale.
- Turnonswitch(5) for themeterlight(1) andturnonthe
strobelamp(8).
- Turn the wheel spinner switch (6) to the first speed
positioninorder to rotatethewheel.
Turn the wheel spinner switch (6) to the second speed
positionand pushthebalancer against thetyre.
Asthewheel isspinning,thestroboscopiceffectwill makethe
referencemarkappearstatic;theneedleonthemeter (1) will
movefromzerotoamaximumvalueandthenreturntozero.
Once the needle has started to fall, withdraw the balancer,
switch off the wheel spinner completely (6) and brake the
spinner motor bymeansofthebrakelever (7).
Thewheel will continuetorevolveduetoinertiaandthenew
positionof thereferencemarkshould benoted.
Readthevalueshownbytheneedleontheweightindication
meter (1). Multiplythisvaluebytentoobtainthecorrection
weight to befittedto therim.
16997
Figure1
Figure2
6 TRAKKER EURO 4/5 WHEELSANDTYRES
Base- November 2006 Print 603.93.641
502511 STATIC WHEEL BALANCING
Aquila Trucks Centres
Fit thecalculatedcorrectionweight asshowninthefigure.
Ifthemeterneedleremainsinthegreensectionduringtesting,
the wheel isalreadybalanced.
Iftheweightrequiredtobalancethewheelexceeds
100grams,dividetheweight inhalfandattach one
ofthetwopartsthusformedtotheinsideoftherim
andtheother totheoutside,makingsurethatthey
areinthe sameposition.
CORRECTION OF RESIDUAL STATIC
IMBALANCE
- Iftheweight isinzoneA, thismeansthat it istoolight and
thereforeitmustbeincreasedbytheamountshownonthe
weight indicationmeter (1, Figure2).
- Iftheweight is inthebottomzoneC, thismeansthat it is
too heavyandthereforemust bereducedbytheamount
shownontheweight indicationmeter.
- Iftheweight iszonesBorD,donotincreaseorreducethe
weight,but moveit upwards5cminthedirectionshown
bythearrowsinfigure 4.
16998
23885
Tocorrectresidualimbalance,repeattheoperationsdescribed
above,and, referringtothediagraminFigure 4andtheweight
indication onthemeter (1, Figure2), adjust as follows:
502510 TYRE INFLATION PRESSURES
Tyrepressuresmust becheckedwiththetyrescold. Takecare
to obtainanaccuratereading: too highapressurewill result in
aharshrideandexcessivewear ofthecentrepart ofthetread,
whileifthepressureistoolow, theloadwill not bedistributed
evenly over the entire tread but concentrated on the edges,
causing premature wear of these areas and damage to the
internal structureof thetyre.
Unequal tyrepressureswill affect thestabilityofthevehicleand
impair drivingsafety.
Abnormal tyrewear canoccur indifferent partsof thetread.
Figure3
Figure4
NOTE
7 TRAKKER EURO 4/5 WHEELSANDTYRES
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Thediagramsillustratehowdifferent inflationpressuresaffect
tyrebehaviour andperformance.
PERFORMANCE40%
PERFORMANCE90%
PERFORMANCE100%
CORRECT
+20%
- 40%
Figure5
(Thepercentagevaluesgiveninsidethetyresindicate
the inflation pressure levels, while the performance
valuerefers to thelifeofthetyre).
Figure6
Figure7
NOTE
If anomalous wear of front tyres is found (either insideor outside the tread), havefront wheel toe-in checked. Never
ocooo t|o a|o .o||t o a|o (t|o vo||c|o's oss .o||t bo|o ooc|aooo).
It isadvisabletochangethetyrepairfittedtooneaxlewhenbands- duetoblockwear - arevisibleover theentiretread
width(seedottedareasonpictures).
Tyresare provided withwear indicators. Replacement iscompulsorywhensuchindicatorsare reached.
NOTE
8 TRAKKER EURO 4/5 WHEELSANDTYRES
Base- November 2006 Print 603.93.641
HOW TYRE BEHAVIOUR DEPENDS
ON PRESSURE
Aquila Trucks Centres
1 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
SECTION 12
5014 Steering system
Page
DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 5 . . . . . . . . . . . . . . . . . . . .
- Mainoperatingfaults of amechanical nature 5 . .
TIGHTENINGTORQUES 7 . . . . . . . . . . . . . . . . .
TOOLS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Steeringcontrol diagramfor 4x2- 6x4 vehicles
(ZF8098 power steering) 10 . . . . . . . . . . . . . . . .
- Steeringcontrol diagramfor 4x4- 6x6 vehicles
(ZF8098 power steering) 11 . . . . . . . . . . . . . . . .
- Steeringcontrol diagramfor 8x4x4vehicles
(ZF8099 power steering) 12 . . . . . . . . . . . . . . . .
- Steeringcontrol diagramfor 8x8vehicles
(ZF8099 power steering) 13 . . . . . . . . . . . . . . . .
- Steeringhydraulic control circuit diagramfor
8x4x4 - 8x8vehicles 14 . . . . . . . . . . . . . . . . . . . .
STEERINGCONTROL 15 . . . . . . . . . . . . . . . . . . . .
HYDRAULIC STEERING 16 . . . . . . . . . . . . . . . . . . .
- Mountingsteeringwheel lever 16 . . . . . . . . . . . . .
REMOVING-REFITTINGTHE STEERING
CONTROL ASSEMBLY 17 . . . . . . . . . . . . . . . . .
- Removal 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingthe pneumaticcylinder 19 . . . . . . . . . . .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingblinker switch 22 . . . . . . . . . . . . . . . . . .
- Removal 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
2 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Page
- Mounting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN OPERATIONS 23 . . . . . . . . . . . . . . . . . . . . . .
BLEEDINGTHEPOWER
STEERINGSYSTEM 23 . . . . . . . . . . . . . . . . . . . . .
MEASURINGSTEERINGBOX PLAY AT THE
STEERINGWHEEL 23 . . . . . . . . . . . . . . . . . . . . .
CHECKINGTHE MAXIMUMPRESSUREOF
THEPOWER STEERING SYSTEM 24 . . . . . . . . .
- Settingtheautomatic hydraulicsteeringlimit 24 . .
- Check 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
ZF8098powersteeringunitisacontinuousball-typesteering
unit; it essentially consists of: housing and steering built-in
mechanical part, control valveandoperatingcylinder.
ZF 8098POWER STEERINGUNIT
27199
Figure1
3 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
DESCRIPTION
Aquila Trucks Centres
4 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
MAIN DATA
Vehicles: 4x2- 4x4 - 6x4 - 6x6
Power steeringunit
ZF 8098ball circulationwith built-inpressure
relief valve(thehydraulic guidecan beprovided
withahydraulicdeviceto automaticallyregulate
steeringanglelimit)
Variableworkingpressure 170 +10bar
Variablereductionratio:
- drivecentre 22.2:1
- steeringlock 26.2:1
Power steeringpump ZF
Min. rpm rpm 500 500
Max. rpm rpm 4700 3500
Max. pressure
(without pressurerelief valve) bar 180 180
Delivery dm
3
/min 22 16
Vehicles: 8x4x4- 8x8
Power steeringunit
ZF 8099ball circulation, dual circuit, withpressure
relief valveincircuits1and2;
and checkvalveincircuit 1
Hydraulicdeviceto automaticallyregulatesteering
anglelimit
Variableworkingpressure 140 +14bar
Variablereductionratio:
- drivecentre 22.2:1
- steeringlock 26.2:1
Assembling on compressor ancillaryongearbox Assembling oncompressor ancillaryongearbox
Power steeringpump ZF ZF
Min. rpm rpm 500 -
Max. rpm rpm 3000 4500
Max. pressure
(without pressurerelief valve)* bar 165* 180
Controlleddelivery dm
3
/min 22.5 30 16
Drivecylinder for hydraulicguide ZF 8099
Lengthbetween wheel bases:
- start of stroke mm 578
- endof stroke mm 828
- straight-linerideposition mm 702
Aquila Trucks Centres
5 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
TROUBLESHOOTING
Main operating faults of a mechanical nature
Visible Failure Possible cause Repair action
Insufficient oil incircuit. Check oil level withenginerunning; top
uptodipstickuppernotchandbleedthe
circuit.
Air inthehydraulic circuit. Checktheseal oftheintakepipeandthe
pump shaft gasket and top up the oil.
Bleed thecircuit.
Lockedor cloggedmodulatingvalve. Removethevalve, wash and checkthe
throttleholeto ensureit isnot clogged.
Oil pump flow rateis insufficient. Overhaul or replacethe pump.
Steeringstiff whenturningright andleft
Spider not slidingwell. Move the union in both directions so
that it slopesunder itsownweight.
Poor lubrication of transmission lever
bearings(onvehicleswithsecondsteer-
ing).
Greasethetransmission lever bearings.
Worn transmission lever bearings (on
vehicleswithsecondsteeringaxle).
Overhaul thetransmissionleversandre-
place wornparts.
Hydrauliccylinders not working(onve-
hicleswithsecondsteeringaxle).
Replace thefaultycylinders.
A hydraulicpumpisnot working
(6x6- 8x4x4vehicles).
Overhaul orreplacethehydraulicpump.
Inefficient internal gaskets. SendthepowersteeringtoaZF station.
Steeringis only hard to the left or the
right
Hydrauliccentrepositionisnot correct
(when the steeringwheel is released it
returns to anend position).
Havethe power steeringadjusted by a
ZF station.
Clogged modulatingvalve. Removethevalve, washandclean.
Steeringishardwhenthesteeringwheel
isturnedquickly
Hydraulicpumpflowrate is inadequate
(wear ongears).
Overhaul orreplacethehydraulicpump.
isturnedquickly
Air inthesteeringsystem. Check theseal of the intake pump and
the pump shaft gasket. Top up the oil.
Bleed thecircuit.
(Continued)
Aquila Trucks Centres
6 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Visible Failure Possible cause Repair action
Universal joint is slack. Replacetheuniversal joint.
Power steeringinternal breakdown. Sendthepower steeringtoaZFstation.
Systemoil level too low. Topupoil and bleedthecircuit.
Badwheel attitude. Makechecks andadjustments.
Hardknocksonthesteeringwheel when
steering
Unbalancedwheels. Carry out the balancingoperations fol-
|o.|o t|o |ostoct|oos |o t|o '\|oo|s
aoo Tos' soct|oo.
Draglinkkingpinsloose. Replaceanywornparts.
Hydraulicpumpnot functioningproper-
ly.
Replacethepump.
Oil seepagefrompower steeringcircuit
fittings.
Checktheefficiencyofthegasketsonthe
fittingsandreplaceanythat areworn.
Unbalancedwheels. Carry out the balancingoperations fol-
|o.|o t|o |ostoct|oos |o t|o '\|oo|s
aoo Tos' soct|oo.
Steeringwheel torsional vibration
Incorrect front wheel attitude. Make the checks and adjustments ac-
cordingtothespecificationdatagivenin
t|o '/||S' soct|oo.
Air inthehydraulic system. Check theseal of the intake pump and
the pump shaft gasket. Top up the oil.
Bleed thecircuit.
E i i h l l
Backlash in ball joints and/or flexible
mountings areslack.
Replacethekingpins.
Excessivesteeringwheel play
Universal joint is slack. Replacetheuniversal joint.
Power steeringinternal breakdown. Sendthepower steeringtoaZFstation.
Tankcover not secured. Securecover.
Loss of fluid
Deteriorationof gasketsand seals. Replace, top up fluid andbleed.
Lossoffluid
Ineverycaseit isnecessarytoestablish whereand whyhydraulicfluidisbeinglost,
eliminatethecauseand, withtheenginerunning, topupfluidtoupper markondip-
stick.
Pumpnot operatingcorrectly. Replacepump.
Insufficient pressureinthecircuit
Fluid leaking fromcouplings in power
steeringcircuit.
Check coupling seals for serviceability,
replacinganywhichare worn.
Insufficient pressureinthecircuit
Insufficient fluidlevel inthetank. Topuplevel andbleedcircuit.
Fluid leaking fromcouplings in power
steeringcircuit (8x4x4).
Check coupling seals for serviceability,
replacinganywhichare worn.
Aquila Trucks Centres
7 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm (kgm)
Hexagonal nut withcollar for steeringsupport andidler arm 226.5 22.5 (22.6 2.2)
Flanged hexagonal head screwfor fixingsteeringstand 278 28 (27.8 2.8)
Hexagonal headscrewfor steeringbox 527.5 52.5 (52.7 5.3)
Calibratedhexagonal headscrewfor steeringbox 527.5 52.5 (52.7 5.3)
Castlenut for steeringlinkageand hydrauliccylinder (*) 300 (30)
Self-lockingnut for universal joint 55 5 (5.5 0.5)
Calibratedscrewfor universal joint 55 5 (5.5 0.5)
Fasteningcollar for draglinkandtrackrod 80 10 (8 1)
Hexagonal nut for steeringboxlever 575 55 (57.5 5.5)
Self-lockingflangednut for steeringstand 226.5 22.5 (22.6 2.2)
Y Flanged hexagonal head screwfor idler arm 278 28 (27.8 2.8)
(*) If at theprescribedtorque, theslot doesnot matchthehole, continueto tightenuntil it becomespossibleto insert thesplit
pin.
Y 8x4 -8x8Vehicles
Aquila Trucks Centres
8 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
TOOLS
TOOL NO. DESCRIPTION
99347042 Steeringwheel puller
99347045 Steeringdrop armpuller
99347068 Steeringball joint remover
99355032 Wrenchfor power steeringgear retainingbolts
99374393 Pressuregaugesfor testingpower steeringsystempressure
99374398
Calibratedscaleandpointer formeasuringsteeringplay(tobeused
with99374393)
Aquila Trucks Centres
9 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
TOOL NO. DESCRIPTION
99374399
Pair of expandersto lockwheels(to beusedwith 99374393and
99374398)
Aquila Trucks Centres
90645
Figure2
10 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Steering control diagram for 4x2 - 6x4vehicles(ZF 8098power steering)
Aquila Trucks Centres
90646
Figure3
11 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
Steering control diagram for 4x4 - 6x6vehicles(ZF 8098power steering)
Aquila Trucks Centres
90647
Figure4
Theintermediaterod(1) lengthxmeasuredat thedistancebetweencentresof kingpinsandforkshall bealwaysrestoredwhen
replacingoneoftheabovementioned parts and/or checkedbeforeinspectingthewheel alignment.
- vehicles withwheel base 1500mm: x =1540 2
- vehicles withwheel base 1875mm: x =1735 2
Drivecylinderlengthmeasuredat kingpindistancebetweencentresshallbe578mmatstrokestart and828mmattheendofstroke.
12 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Steering control diagram for 8x4x4 vehicles(ZF 8099 power steering)
Aquila Trucks Centres
90648
Figure5
Theintermediaterod(1) lengthxmeasuredat thedistancebetweencentresof kingpinsandforkshall bealwaysrestoredwhen
replacingoneoftheabovementioned parts and/or checkedbeforeinspectingthewheel alignment.
- vehicles withwheel base 1500mm: x =1540 2
- vehicles withwheel base 1875mm: x =1735 2
Drivecylinderlengthmeasuredat kingpindistancebetweencentresshallbe578mmatstrokestart and828mmattheendofstroke.
13 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
Steering control diagram for 8x8vehicles (ZF 8099power steering)
Aquila Trucks Centres
90649
1. Steeringbox - 2. Oil cooler - 3. Pressure test fitting- 4. Flowindicator - 5. Compressor - 6. Circuit 2reservoir -
7. Circuit 1reservoir - 8. Pump ongearbox - 9 - Power cylinder - A. Circuit 1 returnpipe- B. Circuit 2 deliverypipe -
C. Circuit 2 deliverypipe- D. Circuit 1returnpipe- E. Power cylinder pipe.
Figure6
14 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Steering hydraulic control circuit diagram for 8x4x4- 8x8 vehicles
Aquila Trucks Centres
72848
Thesteeringcontrol isequippedwithapneumaticdeviceto
adjust theangleandheight of thesteeringwheel.
Thepositionof thesteeringwheel isadjustedbypressingthe
push-buttononthefloor of thecab:
- Press the button (3) onthefloor: thepressurized air of
the services system is sent to the steering wheel
adjustment assembly(2) releasingit.
- Manoeuvre the steering wheel (1) into the required
position(longitudinal travel alongtheaxisof thesteering
column60mm, angular travel to thevertical 40 ).
- Releasethebutton onthe floor.
Figure7
15 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
50140 STEERING CONTROL
Aquila Trucks Centres
33691
33692
33693
Checktheangulartravel oftheleverthat hastobe47 inboth
directions.
Keepingthelever (3) stationaryto preventturningthepower
steeringshaft, lock the nut (2) fixingthe lever with atorque
wrench (1) to atorqueof 575Nm.
Usingasuitablepunch, notchthecollar of thenut (1).
1
2
1
Figure8
Figure9
Figure10
If the hydraulic steeringhasto be replaced, before
reconnecting the new hydraulic guide to the
support, thesteeringwheel leveristobemounted
onthenewhydraulicguideasdescribedinfollowing
chapter.
Ifthehydraulicguideisprovidedwithasteeringlimit
automaticregulation, theautomaticregulationisto
be set as described in relevant chapter after
reconnectingthehydraulic guide.
Figure11
Mounting steering wheel lever
Securethepower steeringboxinavice.
Fit thesteeringlever (3), makingthereferencemarks(1) cut
onthedrivingshaft (2) andon thelever (3) tally.
2
1
3
33690
!
So as not to change the setting of the automatic
hydraulicsteeringlimit (if present), do not turn the
shaft (2) of the power steering box with atorque
greater than25Nm.
3
NOTE
16 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
HYDRAULIC STEERING
Aquila Trucks Centres
38660
72850
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72852
Figure12
Figure13
Figure14
Figure15
Figure16
Lift thecowlingof thecab. Set thewheelsstraight andcheck
t|at t|o stoo|o bo |s |o t|o 'sta||t a|oao' os|t|oo, so t|o
referencemark oftheshaft(1)coincideswiththereference
mark of thesteeringbox (2).
Engagethesteeringlockbytakingtheignitionkeyout.
Takethe cover (1) off thesteeringwheel (2).
Disconnect theconnection(4) of theearth cable.
Remove the nut (1), mark the assembly position of the
steeringwheel (3) on the shaft (2) and removethesteering
wheel (3).
Take out the screws (1 and 3) and take off the side guards
(2.4).
Disconnect theelectric connections(5and 6). Takethekey
(5, Figure14) out ofthesteeringwheel (3,Figure14).Fasten
thecover (1) of the interconnectingbox (2) to the box by
insertingthekey(7) inthe slots(8and 9). Thispreventsthe
cover (1) and the box (2) fromturning on each during
disassemblyandthisconditionismaintaineduntil assembly.If
thereisnokey(7), useascrewandnut ofsuitablelengthand
diameter.
Takeholdoftheinterconnectingbox(2),liftitcarefullysothat
theretainingspringpins(3) comeoutofthemounting(4) and
put it aside.
!
Remove the interconnecting box (2) from the
steeringcontrol mounting(4), keepingstrictlytothe
proceduresdescribedhereunder. This is to prevent
damaging the spiralled cable in the box, during
assembly,andtoavoidawrongreadingofthesteering
wheel angle.
Removal
501410 REMOVING-REFITTING THE
STEERING CONTROL ASSEMBLY
17 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
72832
90002
72854
72855
Figure17
Figure18
Figure19
Figure20
Figure21
Figure22
Removethepush-buttonpanels(3and5) andthecapsforthe
screws(4) fromthe instrument panel (1).
Takeout thescrews(2and4), removetheinstrument panel
(1) and put it aside.
Disconnect theconnections(1) ofthewindscreenwiper, (2)
of thedrivecontrol system, (3) of theimmobilizer.
Marktheassemblypositionoftheshaft (2, Figure14) onthe
mounting(3) andontheuniversal joint (4).Loosenthescrew
(1) and extract the universal joint (4) fromthetopshaft.
Disconnect thepipe(2).
Takeout the3 screws(1) and remove the steeringcontrol
mounting(3) fromthepedal board (2).
72831
- Removemat (5).
- Unscrewsecuringscrews(4) of thesill (3).
- Detach thesill (3) fromthevehicle.
- Undothefasteners( ) andtakeout theair opening(2)
inthefloor.
- Unscrewthe sidescrews(1) fixingthesteeringcolumn
guard.
77108
- Unscrewthescrews(2) fixingthesteeringcolumnguard
intheareaof thepedal board.
- Detach thesteeringcolumnguard(1) fromthevehicle.
18 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
72856
72857
Figure23
Figure24
Fromoutsidethecab,loosenthescrew(2) anddisconnectthe
bottomshaft (1) fromthepower steering(3) shaft. Takeout
thescrews(4) andremovethebottomshaft(1) togetherwith
theguard(5).
To refit, carryout the operations described for removal in
reverse order, tightening the screws and/or nuts to the
requiredtorque.
Refitting
!
The interconnectingbox (1) is supplied as aspare
withthestopkeyassembledasillustratedinthefigure.
After fittingit onthe steeringcontrol mounting, it is
necessarytoturnthekey(2) soastocauseit tobreak
at thepoint shownbythearrowand put thekeyin
thesteeringwheel housing, seeFigure14.
Replacing the pneumatic cylinder
Removal
Remove thesteeringgear assemblyas described under the
relevant heading(operation 501410).
Removethedamper (1) bytakingout the fixingnuts (2 and
3).
Figure25
Figure26
77551
77552
Screwasuitablecoupling(5) into the air supplyholeof the
cylinder (3) andintroduceair at apressure of 8 12bars.
!
The air pressure must be maintained throughout
removal:thisisanecessaryconditiontomakesurethe
pneumaticcylinder (3) gets released.
Shiftthesteeringgearshaft-assembly(6)completelyoutwards
( ).
Marktheassemblypositionofthescrew(7) onthemount(9).
Removethenut (1), extract thescrew(7) withthewashers
(2 and 8) and remove fromthe mount (9) the pneumatic
cylinder (3) theadjustment washer (4) and thesteeringgear
shaft assembly (6).
19 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
77553
Figure27
Figure28 Figure29
77554
77555
Positionthesteeringgear shaft mount (2) in themount (1).
MeasurethedistancesBandC betweentheinternal surface
of themount (2) andtheslidingsurface (of theabove) ofthe
mount (1) withasuitableinstrument (3) (precisionclass0.05
mm).
PARTSCOMPRISINGTHESTEERING GEARASSEMBLY
1. Pneumatic cylinder - 2. Adjustment washer - 3. Coupling- 4. Mount - 5. Washer - 6. Screw- 7. Damper -
8. Steeringgear shaft assembly- 9. Nut - 10. Washer - 11. Nut.
Determinethethicknessoftheadjustment washer (2,Figure27)
as follows.
Measure the distance A between the sliding surfaces of the
mount (1) withasuitableinstrument (precisionclass0.05mm).
20 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Mounting
Aquila Trucks Centres
77556
Figure30
Figure31
Figure32
77558
Fit onanewscrew(7) withthewasher (8) positioningitatthe
point markedduringremoval.
Fromtheoppositeside, fit onthe washer (2). ApplyLoctite
270 onthethreadofthenewnut (1) andscrewit ontothe
screw(3) todetermineaclearanceof 0.1 0.2mmbetween
thewasher (2) andthemount (3).
Check thetravel of themount (8) of thesteeringgear shaft
onthemount (3) inall directions.
Setthesteeringgearshaft mount(6) inthepositionofthestart
of travel (minimumheight of thesteeringwheel).
Removetheaircoupling(4) fromthepneumaticcylinder (5).
Screwasuitablecoupling(2) into the air supplyholeof the
newcylinder (3) andintroduceairatapressureof 8 12bars.
!
Theairpressuremust bemaintainedthroughout the
measurement and followingassembly.
Place the pneumatic cylinder (3) on the plane and put the
adjustment washer (1) onitspiston;measurethedistance(D)
withasuitableinstrument (4, precisionclass0.05mm).
S=A-(B+C+D+0.2),whereA-B-C-Darethedistances
measured and0.2 is theclearance.
77557
Put mount(2) inmount (1) andfit onthecylinder (4supplied
withair at apressureof 8 12bars) positioningit withthepin
(5) intheguidinggrooveof themount (2).
Choosetheadjustment washer (3) fromtheonessuppliedas
spares, with the thickness calculated in the preceding
measurement.
\as|o t||c'ooss. +.6 +. +.8 +. - 5-5 5.2
5.4 mm.
Lubricatethewasher (3) withgreaseandinsertitbetweenthe
cylinder (4) andthe mount (1).
Figure33
77551
Fit on thedamper (1), screwdownthe fixingnuts (2 and3)
tighteningthemto atorqueof 23Nm.
Checkthelockingofthecylinder (4):applyingatractiveforce
of 300N (30kg) to thesteeringgearshaft, inthedirectionof
thedriver, thismust not movein relation to the mount (3).
Then refit the steering gear assembly to the vehicle as
described under therelevant heading.
4
NOTE
21 TRAKKER EURO 4/5 STEERINGSYSTEM
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Aquila Trucks Centres
38660
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Figure34
Figure35
Figure36
Figure37
Figure38
Lift thecowlingof thecab. Set thewheelsstraight andcheck
t|at t|o stoo|o bo |s |o t|o 'sta||t a|oao' os|t|oo, so t|o
referencemark oftheshaft(1)coincideswiththereference
mark of thesteeringbox (2).
Engagethesteeringlockbytakingtheignitionkeyout.
Takethe cover (1) off thesteeringwheel (2).
Disconnect theconnection(4) of theearth cable.
Remove the nut (1), mark the assembly position of the
steeringwheel (3) on the shaft (2) and removethesteering
wheel (3).
Take out the screws (1 and 3) and take off the side guards
(2.4).
Disconnect theelectric connections(5and 6). Takethekey
(5, Figure36) out ofthesteeringwheel (3,Figure36).Fasten
thecover (1) of the interconnectingbox (2) to the box by
insertingthekey(7) inthe slots(8and 9). Thispreventsthe
cover (1) and the box (2) fromturning on each during
disassemblyandthisconditionismaintaineduntil assembly.If
thereisnokey(7), useascrewandnut ofsuitablelengthand
diameter.
Takeholdoftheinterconnectingbox(2),liftitcarefullysothat
theretainingspringpins(3) comeoutofthemounting(4) and
put it aside.
!
Remove the interconnecting box (2) from the
steeringcontrol mounting(4), keepingstrictlytothe
proceduresdescribedhereunder. This is to prevent
damaging the spiralled cable in the box, during
assembly,andtoavoidawrongreadingofthesteering
wheel angle.
Removal
Replacing blinker switch
22 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
90003
Figure39
Disconnect securingscrews(2) of steeringcolumnstalk(1).
Removeelectricconnectionand disconnect steeringcolumn
stalk(1).
Mounting
For mounting, invert operations described for dismounting,
tighteningthescrews and/or nuts at prescribedtorque.
Thesteeringcolumnstalksthataresuppliedasspares
havenothreadonsecuringplate.Neverthreadholes
because you might damage the components inside
steering column stalk. As the plate is made of
aluminium, it allows self-threading on securing it
through screws.
For vehicles 4x2- 4x4 - 6x4 - 6x6
To bleedthepower steeringsystem, proceedasfollows.
Fill thepowersteeringfluidreservoirwiththeprescribedfluid
(TutelaGI/A)
Turntheengineover withthestarter motor andtopupthe
fluidcontinuallyto prevent air beingdrawninto thepump.
Top up the fluid until the level remains constant abovethe
minimummarkonthedipstick.
Start theengineandrunitidling,checkingthatthelevel ofthe
fluid does not fall under the minimumlevel marked on the
dipstick.
Turn the steering wheel fromlock to lock several times to
forceanyairoutofthepower steeringcylinderuntil nomore
bubblesappear inthe fluid in thereservoir.
Acceleratetomaximumrpm,thenstoptheengineandcheck
that thefluid level doesnot rise more than1to 3cm.
33694
501430 MEASURING STEERING BOX
PLAY AT THE STEERING WHEEL
Check thereisnomechanical playin thesteeringlinkage.
Locktheleft-handwheel inthestraight-ahead position using
theexpanders99374399; raisetheaxle.
Attach the fixed pointer (2) to thewindscreen withsuction
cups, and attach the graduated scale 99374398 (1) to the
steeringwheel. Positionthepressuretester 99374393(3) (0
to 10bar and0to 160bar, pressuregaugesconnected bya
shunt valve). Connect thepipe of the pressure tester to the
fittingon the power steeringdeliverypipe. Top up the fluid
level if necessary. Start the engine and run at idle speed.
Recordthepressurereadingshownonthe0to10bargauge.
Slowlyturnthe steeringwheel to theleft until theprevious
pressurereadingisincreasedby1bar.Holdthesteeringwheel
inthis position and record the value in mmreached onthe
graduated scale99374398. Nowturn thesteeringwheel to
theright until thepressurereadingisagainincreasedby1bar,
andnotethevalueinmmonthegraduatedscale99374398.
Addtogetherthetwovaluesinmmobtainedforleft andright
steering:thetotal shouldnot exceed40mm. Lowertheaxle.
501430 BLEEDING THE POWER
STEERING SYSTEM
Figure40
MAIN OPERATIONS
For vehicles 8x4 - 8x8
Fill thehydraulicpowersteeringcasethroughtheoil reservoir
of Circuit 1.
Fill theoilreservoirofcircuit1withtheprescribedoil,startthe
engineandkeepit idling.
Topuptheoilcontinuouslytopreventthepumpfromsucking
air.
Fill the emergency pump through the oil reservoir of the
emergencycircuit.
Fill theoil reservoirwiththeprescribedoil,lift theengineaxles
fromthe ground, start the engine and keep it idling, then
engageagear.
Topuptheoilcontinuouslytopreventthepumpfromsucking
air.
Whenthetwocircuitsarefull,i.e.whentheoil level inthetwo
reservoirscannotfall belowthetopmark,start theengineand,
with the axles lifted fromthe ground, keep it idlingfor 2-3
minutes withthegear engaged.
Turnthesteeringwheelsseveral timesfromonelimit switch
to theother.
Check continuously and top up the oil in the reservoirs, if
needed.
23 TRAKKER EURO 4/5 STEERINGSYSTEM
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
This adjustment is made after fitting the power steering
systemonthevehicle,withthevehicleunloadedandthefront
wheels raisedor set on revolvingplatforms. In addition, it is
necessarytosteer bothright andleft asfollows.
Makesurethegearboxisin neutral.
Start the engineand runat aspeedof 1500 rpm.
Turn the steering wheel in one direction to bringthestop
screw(2) onthestubaxle(3) intocontact withtheaxle (1).
Inthisposition,applyanadditional forceonthesteeringwheel
to determine the automatic setting. Repeat this procedure
steeringintheoppositedirection.
Ifthereisareductioninthetravel ofthesteeringcontrol lever,
itisnecessarytoreplacethesteeringlimitingscrewconcerned
with anew one, or both screws if the trouble involves the
oppositetravel aswell.
Thescrewsare located onthetop and bottomsides of the
powersteeringbox.Maketheadjustmentasdescribedabove.
60925
CHECKING THE MAXIMUM PRESSUREOF
THE POWER STEERING SYSTEM
Usingthepressuretester 99374393,connectedasdescribed
abovo, aoo t|oo|vo's s|oo .|oo| | oc'oo, stat t|ooo|ooaoo
runat idle.Applyasteeringforceof 10 20kgtothesteering
wheel and record the pressure reading on the 0 160 bar
gauge.Repeat theoperationapplyingthesamesteeringforce
intheoppositedirection; if thereadingsobtainedarelower
thanspecified, locatethesourceof theproblem.
The maximumpressure is given on the data plate
attachedto theZF steeringbox.
Settingthe automatic hydraulic steering limit
Check
Connect apressuregauge(minimumfull-scalevalue200bar) to
thepressuretest fittingonthedeliverylinefromthepumptothe
power steeringandapplyasteeringforceat thesteeringwheel
of 50 20 Nm(correspondingto 200 80 N ona500mm
diameter steering wheel), turning the wheel to the full lock
position.Thepressurereadingshouldbewithintherangeof 35
to 70 bar. If the pressure is too high, replace the adjustment
screwswithnewonesandrepeat theadjustment procedure. If
the pressure is too low, check that the hydraulic system is
operatingproperlyand that thereareno leaks.
Figure41
NOTE
24 TRAKKER EURO 4/5 STEERINGSYSTEM
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Revi - June2007
1 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Print 603.93.641/A Base- November 2006
PRINT603.93.641/A
SECTION 13
79 Pneumatic system
52 Brakes
Page
SYMBOLSFOR AIR/HYDRAULIC SYSTEMCIRCUIT DIA-
GRAMS(MISCELLANEOUSANDGENERATORS) 5 . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEMCIRCUIT
DIAGRAMS(VALVES) 6 . . . . . . . . . . . . . . . . . . . . . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEMCIRCUIT
DIAGRAMS(TANKSANDACCUMULATORS) 12 . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEMCIRCUIT DIA-
GRAMS(CALIPERSAND CYLINDERS) 13 . . . . . . . . . .
SYMBOLSFOR AIR/HYDRAULIC SYSTEMCIRCUIT DIA-
GRAMS(HALF-JOINTSANDCOUPLING HEADS) 15 .
SYMBOLSFORAIR/HYDRAULIC SYSTEMCIRCUIT
DIAGRAMS(INDICATORSAND SWITCHES) 17 . . . .
SYMBOLSFORAIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS(BRAKES) 18 . . . . . . . . . . . . . . . .
PIPESANDCOUPLINGS 19 . . . . . . . . . . . . . . . . . . . . .
- General 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingflexiblehoseswith threaded
couplings 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingflexiblehoseswith quick-connection
couplings 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacehoses withRaufosstypefittings 21/1 . . . . . .
BRAKING SYSTEMSWITH ABS- EBL DEVICE 22 . . . .
- Maindiagramfor vehicles
4x2 - 4x4 used for haulage 22 . . . . . . . . . . . . . . . .
- Workingdiagramfor 6x4 vehiclesisolated
withanABS- EBL device 23 . . . . . . . . . . . . . . . . .
- Workingdiagramfor 6x4 - 6x6vehiclesdesignedfor
towingwithABS- EBL device 24 . . . . . . . . . . . . . .
- Workingdiagramfor 8x4x4- 8x8x4vehiclesisolated
withanABS- EBL device 25 . . . . . . . . . . . . . . . . .
- Workingdiagramfor 8x4x4- 8x8x4vehiclesdesigned
for towingwithABS- EBL device 26 . . . . . . . . . . .
BRAKING SYSTEMSWITH
ABS- EBL - ASRDEVICE 27 . . . . . . . . . . . . . . . . . . . . .
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PRINT603.93.641
Page
- Workingdiagramfor 4x2 - 4x4vehicles
designedfor towing 27 . . . . . . . . . . . . . . . . . . . . .
- Maindiagramfor vehicles
6x4with ABS - EBL - ASR 28 . . . . . . . . . . . . . . .
- Maindiagramfor vehicles 6x4- 6X6
usedfor haulagefitted withABS - EBL - ASR 29 .
- Maindiagramfor vehicles 8x4x4- 8x8x4
withABS- EBL - ASR 30 . . . . . . . . . . . . . . . . . . .
- Maindiagramfor vehicles 8x4x4- 8x4x4
usedfor haulagefitted withABS - EBL - ASR 31 .
- Brakingsystemmaincomponents
layout on thevehicle 32 . . . . . . . . . . . . . . . . . . . .
DESCRIPTION 33 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Servicebraking 33 . . . . . . . . . . . . . . . . . . . . . . . .
- Emergencybraking 33 . . . . . . . . . . . . . . . . . . . . .
- Retardingbraking 33 . . . . . . . . . . . . . . . . . . . . . .
- Parkingbraking 33 . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Front discbrakesSN7 type
(for vehicleswithpartial traction) 33 . . . . . . . . . .
- Drumbrakes 33 . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT DIAGNOSIS 34 . . . . . . . . . . . . . . . . . . . . . .
- Diagnosis Instruments 34 . . . . . . . . . . . . . . . . . . .
- Diagnosis onCluster 36 . . . . . . . . . . . . . . . . . . . .
- DTC - FMI error codes 37 . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 73 . . . . . . . . . . . . . . . . . .
TOOLS 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA - PNEUMATIC SYSTEM 82 . . . . . . . .
MAIN DATA - BRAKES 86 . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEMMAIN COMPONENTSCHECK 89
BRAKING SYSTEMMAIN COMPONENTS 92 . . . .
- Compressor 92 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 92 . . . . . . . . . . . . . . . . . . . . . . .
- Headfasteningscrewstighteningtorque 92 . . . . .
- A.P.U. (Air ProcessingUnit) 93 . . . . . . . . . . . . . .
- A.P.U. Troubleshooting
(Drier +four-wayprotectionvalve) 93 . . . . . . . .
Page
- Duplexdistributor 94 . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 94 . . . . . . . . . . . . . . . . . . . . . . .
- Pressurereducer 95 . . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 95 . . . . . . . . . . . . . . . . . . . . . . .
- Triplecontrol servo distributor 95 . . . . . . . . . . . .
- Settingat thebench 95 . . . . . . . . . . . . . . . . . . . .
- Predominanceadjustment 95 . . . . . . . . . . . . . . . .
- KNORRBREMSEAC 597B 96 . . . . . . . . . . . . . . .
- WABCO 973 009 013 96 . . . . . . . . . . . . . . . . . .
- Troubleshooting 96 . . . . . . . . . . . . . . . . . . . . . . .
- Couplingheads 97 . . . . . . . . . . . . . . . . . . . . . . . .
- Check valve(towingvehicles) 97 . . . . . . . . . . . . .
- Parkingbrakes control hand
distributor (for towingvehicles) 97 . . . . . . . . . . .
- Troubleshooting 97 . . . . . . . . . . . . . . . . . . . . . . .
- Parkingbrakes control hand
distributor (stand-alone vehicles) 98 . . . . . . . . . . .
- Troubleshooting 98 . . . . . . . . . . . . . . . . . . . . . . .
- Relayvalves 99 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 99 . . . . . . . . . . . . . . . . . . . . . . .
- Diaphragmbrakecylinder 99 . . . . . . . . . . . . . . . .
- Combinedbrakecylinder 100 . . . . . . . . . . . . . . . .
- Combinedcylinder emergencyrelief device 100 . .
REPAIR OPERATIONS 100 . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 100 . . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 101 . . . . . . . . . . . . . . . . . . . . . . .
ANTI-SKIDSYSTEM 101 . . . . . . . . . . . . . . . . . . . . . .
- ABS(Anti-LockBrakeSystem) 101 . . . . . . . . . . . .
- ASR(Anti-Slip Regulator) system 101 . . . . . . . . . .
- EBL(ElectronicBrakes Limiter) 101 . . . . . . . . . . . .
- Pressuresensor 101 . . . . . . . . . . . . . . . . . . . . . . . .
- Electroniccontrol unit 102 . . . . . . . . . . . . . . . . . . .
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Page
- Brakeanti-lockdistributor 102 . . . . . . . . . . . . . . . .
- Electropneumatic valvefor ASR 102 . . . . . . . . . . .
- Rpm sensors 102 . . . . . . . . . . . . . . . . . . . . . . . . .
- Phonicwheels 102 . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKESSN7TYPE 103 . . . . . . . . . . . .
- Operation(Seepreviousfigure) 104 . . . . . . . . . . .
CHECKS 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingtheautomaticplayrecovery
systemefficiency 104 . . . . . . . . . . . . . . . . . . . . . . .
- SN7brakecaliper components 105 . . . . . . . . . . . .
- SN7brakecalliper brakinggaskets
thicknesscheck 106 . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingbrakelinings 107 . . . . . . . . . . . . . . . . . . .
- Removingandrefittingbrake callipers 109 . . . . . . .
- Removal 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingandrefittingwheel hubs 110 . . . . . . . . .
Page
- Removal 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SN7 BRAKE CALIPEROVERHAUL 112 . . . . . . . . . . .
- Disassembly 112 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Component part cleaningandcheck 113 . . . . . . . .
- Assembly 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULINGBRAKEDISCS 115 . . . . . . . . . . . . .
TURNINGANDGRINDING BRAKEDISCS
ON THEBENCH 115 . . . . . . . . . . . . . . . . . . . . . .
TURNINGANDGRINDING BRAKEDISCS
ON THEVEHICLE 115 . . . . . . . . . . . . . . . . . . . . .
DRUMBRAKES 116 . . . . . . . . . . . . . . . . . . . . . . . . . .
DUO DUPLEX DRUM
FRONT/REARBRAKES 117 . . . . . . . . . . . . . . . . . .
- Disassembly 117 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Drumturning 120 . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacingbrakelinings 120 . . . . . . . . . . . . . . . . . . .
- Turningbrakelinings 121 . . . . . . . . . . . . . . . . . . . .
- Assembly 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Aquila Trucks Centres
5 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Print 603.93.641 Base- November 2006
PRINT603.93.641
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(MISCELLANEOUS AND GENERATORS)
DESCRIPTION SYMBOL
HYDRAULIC FLOW
AIRFLOW
ELECTRICAL LINE
ABLETO ROTATE
CROSSOVER OFCONNECTEDLINES
PRESSURE TEST POINT
QUICK-CONNECTION COUPLING
COCK
COCKWITH OUTLET
1 2
SILENCER
COMPRESSOR 0 2
ENERGY SAVINGCOMPRESSOR
0 2
4
VACUUMPUMP 3 2
HYDRAULIC PUMP
0 2
HYDRAULIC HANDPUMP
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Base- November 2006 Print 603.93.641
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
CONDENSATE SEPARATOR
FILTER 1 2
DEHUMIDIFIER
1 2
DEHUMIDIFIER
21
1
22
4
DEHUMIDIFIERWITH BUILT-IN
REGULATOR
21 1
22
23
AUTOMATIC CONDENSATION
DRAIN VALVE
CONTROLLED CONDENSATION
DRAIN VALVE
HANDCONDENSATEDRAIN VALVE
CONTROLLED ANTI-ICINGUNIT
1 2
7
AUTOMATIC ANTI-ICINGUNIT
1 2
PRESSURE REGULATOR WITH
INDEPENDENT CIRCUIT
21
22
1
23
24
PRESSURE REGULATOR
21 1
PRESSURE CONTROLLER
21 1
23
PRESSURE CONTROLLER
(GOVERNOR)
2
1
PRESSURELIMITINGVALVE
2
1
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
PROPORTIONAL REDUCINGVALVE
2
1
ADAPTER VALVE
2
1
FOURCIRCUIT PROTECTION VALVE
21
22
1
23
24
THREE CIRCUIT PROTECTION
VALVE
21
22
1 23
TWO CIRCUIT PROTECTION VALVE
21
22
1
NON-RETURN AIRINLET VALVE
2 1
LIMITED RETURN AIRINLET VALVE
2 1
SAFETY VALVE
CHECKVALVE
2 1
CHECKVALVE
2
2
1
DOUBLESHUT-OF VALVE
11 12
2
DIFFERENTIAL DOUBLESHUT-OFF
VALVE M S
U
THROTTLE VALVE WITH QUICK
RETURN 1 2
THROTTLE VALVE
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
QUICKDISCHARGE
2 1
BRAKECONTROL VALVE
21 11
22 12 P
A
BRAKECONTROL VALVE
21 11
BRAKECONTROL VALVE
21 11
4
22 12
PARKINGBRAKECONTROL VALVE
22 11
21
PARKINGBRAKECONTROL VALVE
2 1
BRAKE VALVE
2 1
CONTROL VALVE
2 1
CONTROL VALVE
22 1
21
RETARDERCONTROL VALVE
23 13 R
SERVO CONTROL VALVE
2 1
4
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
SERVO CONTROL VALVE
2 1
42 41
SERVO CONTROL VALVEFOR
SINGLELINE
2 1
4
TRAILERBREAKINGTRIPLE
CONTROL VALVE
2 1
42
41 43
TRAILERBREAKINGTRIPLE
CONTROL VALVEWITH BUILT-IN
SERVO SWITCHING
22 11
42
41 43
12
LOADSENSING VALVE
2 1
DUAL LOADSENSINGVALVE
21 11
22 12
LOADSENSINGVALVEWITH
BY-PASS
21
12
11
LOADSENSINGVALVEWITH
BUILT-IN RELAY
2
1
4
LOADSENSINGVALVEWITH
BUILT-IN RELAY WITH AIR
CONTROL
4
42 41
1 2
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Base- November 2006 Print 603.93.641
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
LOADSENSING VALVE WITH AIR
CONTROL
42 41
1 2
LOADSENSING VALVE WITH AIR
CONTROL
1
4
2
PROPORTIONAL REDUCINGVALVE 1 2
SLAVEDPROPORTIONAL
REDUCINGVALVE
1
4
2
STROKE LIMITERVALVE
1
2
LEVELLING VALVE
1
21 22
LEVELLING VALVE
1 2
LEVELLINGVALVEWITH BUILT-IN
TRAVELLIMITER
11 21
12 23
HANDOPERATEDSUSPENSION
RAISING CONTROL VALVE
24 23
21 22
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(VALVES)
DESCRIPTION SYMBOL
PROPORTIONAL CONTROL VALVE
1
2
41
42
HANDOPERATEDSUSPENSION
CONTROL VALVEWITH
ELECTRICAL MONITORING
21 11
12 22
13
1 3
ELECTROPNEUMATIC VALVE
1 2
ELECTROPNEUMATIC VALVE
1 2
ELECTROPNEUMATIC VALVE
1
21
22
HYDRAULIC MODULATOR FOR ABS
HL HR
HZ1 VL
VR HZ2
ABS
AUGMENTERVALVE
1
4
2
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL
COMPRESSED AIRTANK
BRAKE FLUIDRESERVOIR
AIRSPRING
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PRINT603.93.641
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(CALIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
VACUUMBRAKESERVO
VACUUMBRAKESERVO
DUAL CIRCUIT MASTERCYLINDER
SINGLECIRCUIT MASTER CYLINDER
AIR/HYDRAULIC CONVERTER
AIR/HYDRAULIC CONVERTER
HYDRAULIC BRAKECYLINDER
OPERATORCYLINDER
BRAKECYLINDER
SPRINGCYLINDER
COMBINEDBRAKECYLINDER
FIXED DISKBRAKE CALIPER
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(CALLIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
FLOATING DISKBRAKE CALLIPER
FLOATING DISKBRAKE CALLIPER
WITH PARKING
MECHANICAL FLOATINGDISK
BRAKE CALLIPER
SERVO CLUTCH
SERVO CLUTCH
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(HALF-JOINTS AND COUPLING HEADS)
DESCRIPTION SYMBOL
'|SC' S|||CC|||||C
A
M
ISO VERSION
'|SC' S|||CC|||||C
A
M
VERSION WITH ISO COUPLINGS
'C||/' S|||CC|||||C
A
B
ITALIAN VERSION
'C||/' S|||CC|||||C
M
A
'|/TC' S|||CC|||||C
A
M
NATO VERSION
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT
(HALF-JOINTS AND COUPLING HEADS)
DESCRIPTION SYMBOL
SEMI-COUPLING
1
2 3
5
4
V
A
Z
SINGLE LINEVERSION
SEMI-COUPLING
V
A
Z
A
M
SINGLE LINEVERSION
SEM-ICOUPLING
4
2
12
22
SINGLE LINEVERSION
SEMI-COUPLING
4
2
12
22
M
A
1
SINGLE LINEVERSION
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SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(INDICATORS AND SWITCHES)
DESCRIPTION SYMBOL
PRESSURE GAUGE
PRESSURE GAUGE
PRESSURE TRANSMITTER
LAMP
MECHANICALLY CONTROLLED
SWITCH
PRESSURE SWITCH
LOW PRESSURESWITCH
AUDIBLEWARNING
SENSOR
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18 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Base- November 2006 Print 603.93.641
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS(BRAKES)
DESCRIPTION SYMBOL
SINGLECYLINDER HYDRAULIC
BRAKE
TWIN CYLINDERHYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
WITH PARKINGBRAKE
SINGLECAMOPERATEDBRAKE
TWIN DUAL CAMOPERATED BRAKE
Aquila Trucks Centres
from1to 1,5
from2to 2,5
from2to 2,5
from2to 2,5
from3to 3,5
Replacing flexible hoses with threaded
couplings
- End-formtheseatingbush,onfittingto thevehicleor on
theworkbench, to aunion.
- The pressure exerted andthefinal distance of thefront
edgeof thecompressionringfromthat ofthereinforcing
bushmust bethevaluelistedinthescheduleasgivenin
the table.
Doublelayer
- Useonlyapproved hose
- Checktheconditionofthereplacementhose;theremust
beno cracks, cutsor incisionsonit.
- Cutthepipeto therequiredlength,cuttingat 90
_
tothe
centreline using appropriate pipe cutting pliers
99387050.
Threadonto thepipe, intheorder given:
- nut (3), compression ring(2) (larger thickness towards
thenut (3)) and reinforcingbush (1);
- bushmust beinperfect condition(it must not showany
distortion or signs of hammering).
Carefullyfollowtheinstructionsbelow:
10397
10398
10399
- Install reinforcingbushusingtool99372219,ensuringthat
there is contact between its flange and the end of the
hose;
- make sure that the end of the hose fits into the raked
grooveintheflange.
1. Reinforcingbush- 2. Pressurering- 3. Nut - 4. Union
5. Hose- h. Distancebetweenedgeof bushand edgeof
ring(seetable).
FITTINGREINFORCING BUSH
A = CORRECT METHOD OFFITTING
B = INCORRECT METHOD OFFITTING
Pipe
mm
Distancebetween
edgeof bushandring
mm(*)
Assembly
pressure
N/mm
2
6x 1
8x 1
10x1,5
12x1,6
16x 2,34
0,040
0,050
0,050
0,060
0,060
Insert theendofthehosepreparedinthiswayintotheunion
bodyuntil reinforcingbushflange bears against seating;
- Totightennutontounion,firstofall screwinbyhandand
then complete tighteningusingapolygon wrench fitted
onthetorquewrench,tobesetaccordingtothespecified
tighteningtorque.
Singlelayer
(*) Seereferenceh, Figure3.
!
Figure1
Figure2
Figure3
Ifthefittingsarebadlyassembled, do not re-usethe
hoseafter extractingthebushandseatingring.
Hydraulicsystempipingsforindustrial vehiclesareflexible
ones made of polyamide with single-layered or
double-layered structureand in the followingdiameters
( 6-8-10-12-16mm) equipped withspares inmeters.
799512 PIPES AND COUPLINGS
General
19 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Print 603.93.641 Base- November 2006
PRINT603.93.641
Aquila Trucks Centres
- Whenhosesrunthroughchassismembersormetal parts,
make sure that the holes through which theypass are
fitted withrubber grommets and that theseareingood
condition.
- Avoid sliding the hose along sharp edges which might
causecuts.
- Wherethehosehastobeattachedtoexistingpipework,
take account of the additional heat to which it maybe
subjected (power steering pipework); in this case, the
hosemust beprotectedwith shields.
- Whenthehosehasbeenconnected,checkthat it isnot
under tension between the attachment points, instead
leaving it slightly slack to take up the more substantial
variationsintemperature, especiallyfor short lengths.
- Before fitting, thoroughly clean the hoses by blowing
compressed air through themto safeguard operationof
thesystem.
- Protect thehoses if grindingor weldingoperationsare
carriedout onthevehicle; anotice isfitted inthecabin
indicating the precautions to be observed carefully to
avoiddamage.
Figure4
Replacingflexiblehoses withquick-connection
couplings
For greater safetyandconvenience inworking, it is
advisable to remove the hoses during these
operations.
Whenfittingisfinished, checkthat all seals(unions,couplings
etc.) arecompletelyfreefromleaks.
Whenfittingthehoseto the vehicle, someimportant points
requiringcareshouldbebornein mind:
- Bends must comply with minimumradii, so as to avoid
constrictions:
Minimumradiusof curvature
mm
Diameter of pipe
mm
13132
Make sure that the hoses are not in contact with
sharpedgesor withsharp metal partsor sourcesof
heat,but areat aminimumsafetydistance of 15mm
fromthese.
6x 1
8x 1
10 x1,5
12 x1,6
16 x2,34
40
50
60
75
100
!
!
Screwthecouplingintothethreadedseatingprovidedonthe
airvalveandtightenit tothetighteningtorqueindicatedinthe
table.
- Check that theseal ring(1) isinits seat;
- Tighten the coupling until the seal gasket contacts the
valve;
- Direct thevalvecorrectlyandkeepingthemovablepart
still, lockthehexagonal nuttothetorqueindicatedinthe
table.
39307
Figure5
Figure6
39306
Swivel couplings:
Banjo couplings:
Swivel andbanjo couplings:
COUPLING
THREAD TIGHTENIGTORQUE (Nm 10%)
M10x1,0mm
M12x1,5mm
M14x1,5mm
M16x1,5mm
M22x1,5mm
22
24
28
35
40
20 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
D
(mm)
When removing couplings (1) on pneumatic components,
checktheconditionoftheseal ring(2) andifnecessaryreplace.
33977
33978
6
8
12
16
Figure7
Figure8
- Onlyuseapproved type-testedhoses;
- Checktheconditionofthenewhosetoensureit hasno
cracks, cutsor scores;
- Cutthehoseat 90 ,maximumerror 15 ,withreference
totheaxis.Usepipe-cutterpliers99387050tocut tothe
requiredlength;
Figure9
33976
A
A =Mark to identifyendof tubetravel
- Useindelibleinkto markclearlytworeferencemarkson
bothdiametricallyoppositefacesof thepipeat anangle
of 75 , set at distances L
1
and L
2
, to ensure correct
fittinginplace.
!
L
1
andL
2
varyaccordingtothediameter ofthehose
andaretobemeasuredat thelongerpartofthehose
(seeFigure7).
19.8
20.5
25
27.1
17
18
22
24
22
23
28
30
L
(mm)
L
1
(mm)
L
2
(mm)
+0,5
0
+1
-0,5
+1
-0,5
Figure10
39308
- Insertthehose(2) byhandintothecoupling(1),withaforce
between30and20Nmaccordingtothehosediameter,so
thatreferencemarkL
1
isinsidethehosewhereasL
2
remains
visible.
COUPLING SEALRING
THREAD DIMENSIONS
Whenever a hose is removed from a qui ck
connection coupling, the coupling itself must be
replaced. Spare quick connection couplings are
supplied complete.
M10x1.0
M12x1.5
M14x1.5
M16x1.5
M22x1.5
10.1 x1.6
11.0 x2.0
-
15.0 x2.0
-
Quickreleaseandthreadedcouplings arenot
interchangeable. This also applies to flexible hoses
usedwithquickreleasecouplingsandflexiblehoses
usedwiththreaded couplings.
!
!
21 TRAKKER EURO 4/5 PNEUMATIC SYSTEM- BRAKES
Print 603.93.641 Base- November 2006
PRINT603.93.641
Aquila Trucks Centres
Figure10/1
Replace hoses with Raufoss type fittings
In order to remove pipe (1), fit tool 99387051 (2) on it
throughtheopening.Pushtool 99387051(2) insidefitting(3)
till releaseof polyamidepipe.
Remove pipe (1).
117651
Operations for pipe change replacement with
Raufoss type fittings aredifferent frompreviously
describedonesonlyfor what is mentioned below.
NOTE
21/1 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
Revi- June2007 Print 603.93.641/A
PRINT603.93.641/A
Aquila Trucks Centres
PNEUMATICSYSTEM- BRAKES 21/2 TRAKKEREURO 4/5
Print 603.93.641/A Revi- June2007
Aquila Trucks Centres
108145
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeon indicator - 11. Trailer slowinghandcontrol valve (optional) - 12. Tripleservocontrol valvefor
ta||o ba'|o - +3. |o. ossoo s.|tc| - ++. '|SC' |a|-coo||o o toc' - +5. '|SC' |a|-coo||o o tacto - +6. |o|o
distributor - 17. Brake light switch- 18. Enginebrake control switch- 19. Diaphragmbrakecylinder - 20. Phonicwheel -
21. Wheel speedsensor - 22. Duo Duplexdrumbrakeassembly - 23. Combined brakecylinder - 24. ABSsolenoid valve-
25. Pressuresensor - 26. Single-control relayvalve- 27. Electronic control unit - 28. Discbrakeassembly-
29. Diaphragmbrakecylinder - 30. Drumbrakeassembly-
31. Lowpressureswitch - 32. Pressuregauge- A. Services- B. Services
V 4x2vehicles
J 4x4vehicles(optional for vehicles4x2)
Figure11
22 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
BRAKING SYSTEMS WITH ABS- EBL DEVICE
Main diagram for vehicles4x2 - 4x4used for haulage
Aquila Trucks Centres
78271
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeonindicator - 11. Duplexdistributor - 12. Brakelight switch- 13. Enginebrakecontrol switch-
14. Diaphragmbrakecylinder - 15. Phonic wheel - 16. Wheel speedsensor - 17. Duo Duplexdrumbrakeassembly-
18. Combinedbrakecylinder - 19. ABSsolenoidvalve- 20. Pressuresensor - 21. Single-control relayvalve- 22. Electronic
control unit - 23. Discbrake assembly - 24. Diaphragmbrakecylinder (*) - 25. Drumbrake assembly (*) - 26. Lowpressure
switch - 27. Pressuregauge- A. Services- B. Services
(*) optional
Figure12
PNEUMATIC SYSTEM- BRAKES 23 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
Working diagram for 6x4vehicles isolated with an ABS - EBL device
Aquila Trucks Centres
108146
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeon indicator - 11. Trailer slowinghandcontrol valve (optional) - 12. Tripleservocontrol valvefor
ta||o ba'|o - +3. |o. ossoo s.|tc| - ++. '|SC' |a|-coo||o o toc' - +5. '|SC' |a|-coo||o o tacto - +6. |o|o
distributor - 17. Brake light switch- 18. Enginebrake control switch- 19. Diaphragmbrakecylinder - 20. Phonicwheel -
21. Wheel speedsensor - 22. Doubledrumbrakeassembly- 23. Combinedbrakecylinder - 24. ABSsolenoidvalve-
25. Pressuresensor - 26. Single-control relayvalve- 27. Electronic control unit - 28. Discbrakeassembly-
29. Diaphragmbrakecylinder - 30. Drumbrakeassembly-
31. Lowpressureswitch - 32. Pressuregauge- A. Services- B. Services
V 6x4vehicles
J 6x6vehicles(optional for 6x4vehicles)
Figure13
24 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Working diagram for 6x4- 6x6 vehicles designed for towing with ABS - EBL device
Aquila Trucks Centres
108147
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeonindicator - 11. Duplexdistributor - 12. Brakelight switch- 13. Enginebrakecontrol switch-
14. Diaphragmbrakecylinder - 15. Phonic wheel - 16. Wheel speedsensor - 17. Duo Duplexdrumbrakeassembly-
18. Combinedbrakecylinder - 19. ABSsolenoidvalve- 20. Pressuresensor - 21. Single-control relayvalve- 22. Electronic
control unit - 23. Discbrake assembly - 24. Proportional reducingvalve - 25. Membranebrakecylinder - 26. Duo Duplex
drumbrakeassembly- 27. Lowpressureswitch-
28. Manometer - A. Services
V 8x4x4 vehicles
J 8x8x4 vehicles(optional for vehicles 8x4x4)
Y Optional configurationdependingonthetypeof air filter andthe type of engineexhaust system.
Figure14
PNEUMATIC SYSTEM- BRAKES 25 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Working diagram for 8x4x4 - 8x8x4vehicles isolated with an ABS- EBL device
Aquila Trucks Centres
108148
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensatedischargevalve - 4. Trailer air tank - 5. 20liter trailer air tank-
6. Rear axleair tank30l - 7. Front axleair tank20l - 8. Pressuretest point - 9. Dual control relayvalve - 10. Parkingbrake
handcontrol valve- 11. Switchfor parkingbrakeonindicator - 12. Trailer slowinghandcontrol valve (optional) - 13. Triple
sovo cooto| va|vo o ta||o ba'|o - ++. |o. ossoo s.|tc| - +5. '|SC' |a|-coo||o o toc' - +6. |o|o o|st|boto -
17. Brakelight switch - 18. Enginebrakecontrol switch- 19. Diaphragmbrakecylinder - 20. Phonic wheel -
21. Wheel speedsensor - 22. Duo Duplexdrumbrakeassembly - 23. Combined brakecylinder - 24. ABSsolenoid valve-
25. Pressuresensor - 26. Single-control relayvalve- 27. Electronic control unit - 28. Discbrakeassembly-
29. Proportional reducingvalve - 30. Diaphragmbrakecylinder - 31. Duo Duplexdrumbrakeassembly-
32. Lowpressureswitch - 33. Pressuregauge- A. Services
V 8x4x4 vehicles
J 8x8x4 vehicles(optional for vehicles 8x4x4)
Y Optional configurationdependingonthetypeof air filter andthe type of engineexhaust system.
Figure15
26 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Working diagram for 8x4x4 - 8x8x4vehicles designed for towing with ABS - EBL device
Aquila Trucks Centres
108149
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeon indicator - 11. Trailer slowinghandcontrol valve (optional) - 12. Tripleservocontrol valvefor
ta||o ba'|o - +3. |o. ossoo s.|tc| - ++. '|SC' |a|-coo||o o toc' - +5. '|SC' |a|-coo||o o tacto - +6. |o|o
distributor - 17. Brake light switch- 18. Enginebrake control switch- 19. Diaphragmbrakecylinder - 20. Phonicwheel -
21. Wheel speedsensor - 22. Duo Duplexdrumbrakeassembly - 23. Combined brakecylinder - 24. ABSsolenoid valve-
25. Pressuresensor - 26. Twinstopvalve- 27. Single-control relayvalve- 28. Electroniccontrol unit - 29. Controlled pressure
checkvalve- 30. A.S.R. solenoidvalve- 31. Discbrakeassembly - 32. Diaphragmbrakecylinder - 33. Drumbrakeassembly -
34. Lowpressureswitch - 35. Pressuregauge-
A. Services
V 4x2vehicles
J 4x4vehicles(optional for 4x2vehicles)
Figure16
PNEUMATIC SYSTEM- BRAKES 27 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
BRAKING SYSTEMS WITH ABS- EBL - ASR DEVICE
Working diagram for 4x2- 4x4 vehicles designed for towing
Aquila Trucks Centres
71845
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Dual control relayvalve - 8. Parkingbrakehand control valve - 9. Switchfor parkingbrakeon
indicator - 10. Duplexdistributor - 11. Brakelight switch- 12. Enginebrakecontrol switch - 13. Diaphragmbrakecylinder -
14. Phonicwheel - 15. Wheel speed sensor - 16. Duo Duplex drumbrakeassembly - 17. Combinedbrakecylinder -
18. ABSsolenoid valve- 19. Pressuresensor - 20. Twinstopvalve- 21. Single-control relayvalve- 22. Electroniccontrol unit
23. Controlled pressurecheckvalve - 24. A.S.R. solenoid valve- 25. Discbrakeassembly- 26. Diaphragmbrakecylinder (*) -
27. Drumbrakeassembly (*) - 28. Lowpressureswitch - 29. Pressuregauge - A. Services
(*) optional
Figure17
28 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Main diagram for vehicles6x4with ABS - EBL - ASR
Aquila Trucks Centres
108150
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank20 l - 5. Rear axleair tank 20 l -
6. Front axleair tank 20 l - 7. Pressure test point - 8. Dual control relayvalve - 9. Parkingbrakehand control valve -
10. Switch for parkingbrakeon indicator 11. Trailer slowinghand control valve (optional) - 12. Tripleservo control valvefor
ta||o ba'|o - +3. |o. ossoo s.|tc| - ++. '|SC' |a|-coo||o o toc' - +5. '|SC' |a|-coo||o o tacto - +6. |o|o
distributor - 17. Brake light switch- 18. Enginebrake control switch- 19. Diaphragmbrakecylinder - 20. Phonicwheel -
21. Wheel speedsensor - 22. Duo Duplexdrumbrakeassembly - 23. Combined brakecylinder - 24. ABSsolenoid valve-
25. Pressuresensor - 26. Twinstopvalve- 27. Single-control relayvalve- 28. Electroniccontrol unit - 29. Controlled pressure
checkvalve- 30. A.S.R. solenoidvalve- 31. Discbrakeassembly - 32. Diaphragmbrakecylinder - 33. Drumbrakeassembly -
34. Lowpressureswitch - 35. Pressuregauge- A. Services
V 6x4vehicles
J 6x6vehicles(optional for 6x4vehicles)
Figure18
PNEUMATIC SYSTEM- BRAKES 29 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Main diagram for vehicles6x4 - 6X6used for haulage fitted with ABS- EBL - ASR
Aquila Trucks Centres
108151
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate dischargevalve - 4. Trailer air tank - 5. Rear axleair tank20l -
6. Front axleair tank 20 l - 7. Dual control relayvalve - 8. Parkingbrakehand control valve - 9. Switchfor parkingbrakeon
indicator - 10. Duplexdistributor - 11. Brakelight switch- 12. Enginebrakecontrol switch - 13. Diaphragmbrakecylinder -
14. Phonicwheel - 15. Wheel speed sensor - 16. Duo Duplexdrumbrakeassembly - 17. Combinedbrakecylinder -
18. ABSsolenoid valve- 19. Pressuresensor - 20. Twinstopvalve- 21. Single-control relayvalve- 22. Electroniccontrol unit
23. Controlled pressurecheckvalve - 24. A.S.R. solenoid valve- 25. Discbrakeassembly- 26. Proportional reducingvalve -
27. Diaphragmbrakecylinder - 28. Duo Duplexdrumbrakeassembly - 29. Lowpressureswitch - 30. Pressuregauge -
A. Services
V 8x4x4 vehicles
J 8x8x4 vehicles(optional for vehicles 8x4x4)
Y Optional configurationdependingonthetypeof air filter andthetype of engineexhaust system.
Figure19
30 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Main diagram for vehicles8x4x4 - 8x8x4 with ABS - EBL - ASR
Aquila Trucks Centres
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensatedischargevalve- 4. Trailer air tank- 5. Manual condensatedischargevalve-
6. Rear axleair tank20 l - 7. Front axleair tank 20l - 8. Pressure test point - 9. Dual control relayvalve - 10. Parkingbrakehand
control valve - 11. Switch for parkingbrakeon indicator - 12. Trailer slowinghandcontrol valve(optional) - 13. Tripleservo control
va|vo o ta||o ba'|o - ++. |o. ossoo s.|tc| - +5. '|SC' |a|-coo||o o toc' - +6. |o|o o|st|boto - +. 3a'o |||t s.|tc| -
18. Enginebrakecontrol switch - 19. Diaphragmbrakecylinder - 20. Phonicwheel - 21. Wheel speed sensor - 22. Duo Duplex
drumbrakeassembly - 23. Combinedbrakecylinder - 24. ABSsolenoidvalve- 25. Pressuresensor - 26. Twinstopvalve -
27. Single-control relayvalve- 28. Electroniccontrol unit - 29. Controlled pressurecheckvalve - 30. A.S.R. solenoidvalve -
31. Discbrakeassembly- 32. Proportional reducingvalve- 33. Diaphragmbrakecylinder - 34. Duo Duplexdrumbrake assembly-
35. Lowpressureswitch- 36. Pressuregauge- A. Services
V 8x4x4 vehicles
J 8x8x4 vehicles (optional for vehicles8x4x4)
Optional configurationdependingonthetypeof air filter andthetype of engineexhaust system.
108152
Figure20
PNEUMATIC SYSTEM- BRAKES 31 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Main diagram for vehicles8x4x4 - 8x8x4 used for haulage fitted with ABS- EBL - ASR
Aquila Trucks Centres
117183
Figure21
+. '||oo|c' .|oo|- 2. \|oo| too|o sooso - 3. /3S o|octo-va|vo - +. Cob|ooo ba'o c||ooo - 5. /3S o|octo-va|vo - 6. |oa|
cooto| o|a va|vo - . T||o cooto| sovo-o|st|boto - 8. \|oo| too|o sooso - . '||oo|c' .|oo| - +0. oso aoo coo||o -
++. |oo |o|o b|oo co|o .|t| oo cooto| ba'o - +2. |o|a va|vo- +3. /3S o|octo-va|vo - ++. '||oo|c' .|oo| -
15. Wheel turningsensor - 16. Relief valve - 17. A.P.U. - 18. Air reservoir- 19. Manual condensed steamdischargevalve -
20. ABSelectro-valve- 21. Drumcontrol brakeDuo Duplexaxlecomplex- 22. Disk brakeaxlecomplex - 23. Membranebrake
c||ooo a|o (o|s' ba'os) - 2+. \|oo| too|o sooso - 25. '||oo|c' .|oo|- 26. /| osovo| - 2. |o|a va|vo .|t| oo|at|oo o t|o
predominance- 28. E.SCompressor. - 29. DuplexDistributor - 30. ElectronicPower Unit -
31. Handdistributor parkingbrakecontrol
32 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Braking system main components layout on the vehicle
Aquila Trucks Centres
Pneumatically controlled pedal type, operating on all the
wheels andthetrailer.
Itfeaturestwoseparatesections,onetoactivatethefrontaxle
brakingcomponents,theotherfor therearaxlecomponents.
A third section, assistingthe two distributor sections, brakes
thetrailer.
Theduplexdistributorcontrolsthetwoseparatesectionsand
thetriplecontrol servodistributor that initsturncontrolsthe
thirdsection.
Should afailure occur inonesection, the pneumatic system
sectioningenables theothersto operateefficiently.
Thisiscombinedwiththeparkingbraking. Thedoublecircuit
systemenablesthebrakingofoneaxleevenwhenthereis a
failureinthebrakingoftheotheraxle,bymeansoftheservice
brakepedal and theparkinghand lever.
Service braking
Emergency braking
Parking braking
Thisismechanical andactuatedthroughthehanddistributor
set at theendofitsstroke. It operatesontherear wheelsof
thetractor dischargingtheair fromthespringsectionof the
pneumaticcylinder and theservo distributor control section,
thuslockingthetrailer or semi-trailer wheels.
|o t|oo|vo's soat |t |soss|b|o toc|oc' .|ot|o t|ota||o
isable,withthetrailerbrakesreleased, toensuretheefficiency
of thecombinedtractor-trailer parkingbrake.
Drum brakes
S MERITORDUODUPLEX type 410x180and410x200
Retarding braking
TheI.T.B. (Iveco Turbo Brake) enginebrakeused onCursor
enginesiscomposedof ahydraulicallycontrolledmechanism
that cancels the exhaust valve clearance. By applying this
mechanism, at the end of the compression phase, a few
degrees before the T.D.C., the exhaust valves open slightly
with aconsequent reductionin the pressure formed in the
cylinder. This takes advantage of the braking torque of the
compression phase but without havingthe followingreturn
thrust onthepiston.
Front disc brakes SN7 type (for vehicles with
partial traction)
Thediscsarekeyedonto thewheel hubsandequippedwith
ventilation fins that permit lowering the high temperature
generated under thebrakingaction.
A small electrical cableisembeddedinthebrakeliningandis
connected to the MET power unit which commando a
warninglight onthedashboardsignal thewearingofthesaid
brakelinings.
The phonic wheels of the ABS device are keyed onto the
wheel hubs.
Each brakingassembly is composed of a bodyhousing the
adjustment pins, control pins andwedgeunits.
Thewedgeunitsareoperatedbythestemofthecylindersthat
intheir turn areoperatedbycompressed air.
Thewedgeunit rollers, astheytravel, causethecontrol pins
toexpandthat,overcomingtheresistanceoftheshoereturn
springs,bringtheshoesuptothedrumtoactuatebraking.The
adjustment andcontrol pinsaremadeintegral withthebrake
bodybytwo pins that fit into aside slot. When thebraking
actionends, thereisnoair pressureinthediaphragmsection
of the combined brake cylinders and so the action of the
wedge unit return and shoe return springs take the wedge
unitsbackinto thestartingposition.
A sensor isscrewedonto oneof thetwo shoes formingthe
brake. This sensor indicates the state of wear of the brake
linings. When the sensor wirecomes into contact with the
drum, thebrakeliningwear indicator light blinks in thecab.
Whenthesensorwiregetsbroken,duetofurtherwearofthe
brake linings, the wear indicator light stays on, thereby
indicatingtheliningshavereachedtheir maximumwear limit.
PNEUMATIC SYSTEM- BRAKES 33 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESCRIPTION BRAKES
Aquila Trucks Centres
Fault diagnosis comprisestwo sections:
- Thefirst one,organizedbyerrorcodes(DTC-FMI),concernsfaultsthat maybeidentifiedbytheABScontrol unitdirectly.These
ao|ts ao a|o| o ao o|oct|c o| octoo|c oooat|c oatoo.
- Thesecondone,organizedbysymptoms,describesthepossiblefaultstheelectroniccontrol unit cannot identifydirectly.These
ao|ts ao a|o| o a oc|ao|ca| oooat|c oatoo.
SECTION I
ABSsystemtroubleshootingcanbeperformedwith theCluster or withthediagnosisinstruments Modus, IT 2000 andE.A.SY..
Diagnosiswiththeclustermakesitpossibletoestimatethesituationoffaultsinthesysteminadvance,whilethediagnosisinstruments
areessential to performthoroughdiagnosis andoperateonthesinglefaultscorrectly.
Eachsingleinstrument displaysthediagnosis andrepair help.
Diagnosis Instruments
MODUS(Maintenanceand Diagnostic System)
A computerizedfault-diagnosisstationdedicatedto diagnosingthebrakesystems, air suspensions, enginesandsystemscontrolled
electronically.
Thestationisequippedwithauxiliaryfunctions,suchas: programmingelectroniccontrol units, consultingthesparepartscatalogue
and servicetimeschedules.
Thevehicle hasa30-pindiagnosissocket to interfacewith theinstrument.
IT 2000(IVECO Electronic Tester)
Thismakesit possible totakeimmediateactionon thevehicle, identifyingit withthechassis number.
It savesthe resultsof diagnosticsactions performed.
It canbeused asaportablePersonal Computer, too, beingfittedfor remotediagnosis.
ByusingMODUSasthe mother station it ispossibleto updateandconfiguretheIT 2000.
IT 2000 interfaces withthevehicleviaa30-pin diagnosissocket.
E.A.SY.
E.A.SY. systemallowsto simplymakethediagnosisandprogrammingof thevariouselectroniccentral units aboard thevehicle.
E.A.SY. systemismadeup of ECI modulecommunicatingwith theelectroniccentral units andof aPanasonicPC.
ECI module, exploiting thePanasonicPC,alsoallowseasyontheroadinterventions: inparticular, thanksto PanasonicPC wireless
technologies(e.g. GPRS), diagnosticinterventionscan beassistedbyaremoteexpert centre.
34 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
FAULT DIAGNOSIS
Aquila Trucks Centres
98889
Figure22
A. Modus- B. EASY - C. IT 2000
A
B
C
PNEUMATIC SYSTEM- BRAKES 35 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Aquila Trucks Centres
98884
Figure23
/ccoss to o|aoost|c scooo |s oss|b|o t|oo| 'ao' o ' y ' ' b ' 'os.
98888
Diagnosis information onthecluster issplit into 4 columns:
- First column = central unit.
- Secondcolumn = central unit addressplusfault order number.
- Third column = failuretype.
- Fourthcolumn = failurefrequency.
Thescreenshowsthreeerror messages at most, but can storeupto eight error messages. For displayinganyfurther messages,
,ost ooato ' y ' aoo ' b ' 'os.
36 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Diagnosis on Cluster
Aquila Trucks Centres
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
001 01 SENSORS-
FRONT
LEFT SEN-
SOR
EXCESSIVE
AIRGAP
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
001 02 SENSORS-
FRONT
LEFT SEN-
SOR
INCOR-
RECT
TYRE
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing;
- the tyres have equal
measure (measures re-
leased byconstructor),
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
001 03 SENSORS-
FRONT
LEFT SEN-
SOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value: 1
V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
001 04 SENSORS-
FRONT
LEFT SEN-
SOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
001 05 SENSORS-
FRONT
LEFT SEN-
SOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
001 06 SENSORS-
FRONT
LEFT SEN-
SOR
SHORT
CIRCUIT
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
ConnectorX2Pin:12
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:15
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
001 07 SENSORS-
FRONT
LEFT SEN-
SOR
PHONIC
WHEEL
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
001 08 SENSORS-
FRONT
LEFT SEN-
SOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
001 09 SENSORS-
FRONT
LEFT SEN-
SOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
TERS read the velocity
of the wheel in ques-
tion.
001 0A SENSORS-
FRONT
LEFT SEN-
SOR
IRREGU-
LAR
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
001 0B SENSORS-
FRONT
LEFT SEN-
SOR
SIGNAL
NOT
PLAUSIBLE
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
001 0C SENSORS-
FRONT
LEFT SEN-
SOR
WRONG
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
If necessary,
replace the
ECU.
002 01 SENSORS-
FRONT
RIGHT
SENSOR
EXCESSIVE
AIRGAP
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
002 02 SENSORS-
FRONT
RIGHT
SENSOR
INCOR-
RECT
TYRE
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing;
- the tyres have equal
measure (measures re-
leased byconstructor),
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
002 03 SENSORS-
FRONT
RIGHT
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
Connector X1 Pin: 8
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 13 Measure
point 2: Connector
X1 Pin: 8
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
002 04 SENSORS-
FRONT
RIGHT
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:10
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 10 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
002 05 SENSORS-
FRONT
RIGHT
SENSOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:10
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 10 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
002 06 SENSORS-
FRONT
RIGHT
SENSOR
SHORT
CIRCUIT
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:13
Measure point 2:
ConnectorX2Pin:10
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:10
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 10 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
002 07 SENSORS-
FRONT
RIGHT
SENSOR
PHONIC
WHEEL
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
002 08 SENSORS-
FRONT
RIGHT
SENSOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
002 09 SENSORS-
FRONT
RIGHT
SENSOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
TERS read the velocity
of the wheel in ques-
tion.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
002 0A SENSORS-
FRONT
RIGHT
SENSOR
IRREGU-
LAR SIG-
NAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
002 0B SENSORS-
FRONT
RIGHT
SENSOR
SIGNAL
NOT
PLAUSIBLE
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
002 0C SENSORS-
FRONT
RIGHT
SENSOR
WRONG
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
If necessary,
replace the
ECU.
003 01 SENSORS-
REAR LEFT
SENSOR
EXCESSIVE
AIRGAP
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
003 02 SENSORS-
REAR LEFT
SENSOR
INCOR-
RECT
TYRE
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing;
- the tyres have equal
measure (measures re-
leased byconstructor),
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
003 03 SENSORS-
REAR LEFT
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
003 04 SENSORS-
REAR LEFT
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
003 05 SENSORS-
REAR LEFT
SENSOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
003 06 SENSORS-
REAR LEFT
SENSOR
SHORT
CIRCUIT
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:14
Measure point 2:
ConnectorX2Pin:11
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:11
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 11 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
003 07 SENSORS-
REAR LEFT
SENSOR
PHONIC
WHEEL
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
003 08 SENSORS-
REAR LEFT
SENSOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
TERS read the velocity
of the wheel in ques-
tion.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
003 09 SENSORS-
REAR LEFT
SENSOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
003 0A SENSORS-
REAR LEFT
SENSOR
IRREGU-
LAR
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
003 0B SENSORS-
REAR LEFT
SENSOR
SIGNAL
NOT
PLAUSIBLE
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
003 0C SENSORS-
REAR LEFT
SENSOR
WRONG
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
If necessary,
replace the
ECU.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
004 01 SENSORS-
REAR
RIGHT
SENSOR
EXCESSIVE
AIRGAP
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
004 02 SENSORS-
REAR
RIGHT
SENSOR
INCOR-
RECT
TYRE
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing;
- the tyres have equal
measure (measures re-
leased byconstructor),
tyrespressure.
Verifytheaxleratio.
Check cor-
rect tyre cir-
cumference.
004 03 SENSORS-
REAR
RIGHT
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
004 04 SENSORS-
REAR
RIGHT
SENSOR
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
004 05 SENSORS-
REAR
RIGHT
SENSOR
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
004 06 SENSORS-
REAR
RIGHT
SENSOR
SHORT
CIRCUIT
Possible short
circuit.
Check sensor wiring.
Check sensor efficien-
cy,replaceitifdamaged.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:18
Measure point 2:
ConnectorX2Pin:17
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
ConnectorX2Pin:17
Measure point 2:
Connector X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 17 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15ON;
1- Min.value:0.9
KOhm; Max. val-
ue: 2 KOhm;
2- Min. value:
500 KOhm;
3- Max. value:
1 V;
Carry out
the indi-
cated mea-
surements
004 07 SENSORS-
REAR
RIGHT
SENSOR
PHONIC
WHEEL
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
004 08 SENSORS-
REAR
RIGHT
SENSOR
SLIPPING Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing.
Check and
restore
clearance
between
sensor and
phonic
wheel.
Check:
Check the
integrityand
cleanliness
of the pho-
nic wheel.
Restore
clearance
between
sensor and
phonic
wheel.
Comparable
values: 0,7
0,05mm
004 09 SENSORS-
REAR
RIGHT
SENSOR
INVERTED
WIRING
Using the MEA-
SURABLE PARAME-
TERS read the velocity
of the wheel in ques-
tion.
004 0A SENSORS-
REAR
RIGHT
SENSOR
IRREGU-
LAR SIG-
NAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
004 0B SENSORS-
REAR
RIGHT
SENSOR
SIGNAL
NOT
PLAUSIBLE
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
004 0C SENSORS-
REAR
RIGHT
SENSOR
WRONG
SIGNAL
Position of the sensor
incorrect; high air gap;
false contacts in the
connector.
If necessary,
replace the
ECU.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
007 03 SOLE-
NOID
VALVES -
FRONT
LEFT ABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 3 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 6 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
007 05 SOLE-
NOID
VALVES -
FRONT
LEFT ABS
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 3
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 6
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
007 06 SOLE-
NOID
VALVES -
FRONT
LEFT ABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 3
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 6
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
008 03 SOLE-
NOID
VALVES -
FRONT
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 1 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 4 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
008 05 SOLE-
NOID
VALVES -
FRONT
RIGHTABS
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 1
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 4
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
008 06 SOLE-
NOID
VALVES -
FRONT
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 1
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 4
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
009 03 SOLE-
NOID
VALVES -
REAR LEFT
ABS SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 5 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
009 05 SOLE-
NOID
VALVES -
REAR LEFT
ABS SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 2
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 5
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
009 06 SOLE-
NOID
VALVES -
REAR LEFT
ABS SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 2
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 5
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
00A 03 SOLE-
NOID
VALVES -
REAR
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X2 Pin: 9 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Max. value:
1 V;
2- Max. value:
1 V;
Carry out
the recom-
mended
measure-
ments.
00A 05 SOLE-
NOID
VALVES -
REAR
RIGHTABS
SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 8
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 9
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
00A 06 SOLE-
NOID
VALVES -
REAR
RIGHTABS
SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 8
Measure point 2:
Connector X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X2 Pin: 9
Measure point 2:
Connector X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
00D 03 THIRD
BRAKE
RELAY -
THIRD
BRAKE
RELAY
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Checkfor afault inthe
fuse70601/ 5.
Checkfor afault inthe
connector ST93
Check that the relay
25104 (E) is working
correctly.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 14 Measure
point 2: Connector
X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
ConnectorX1Pin:14
Measure point 2:
Connector X1 Pin: 7
1- Connector
Connected; Key
+15ON;
2- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
00D 05 THIRD
BRAKE
RELAY -
THIRD
BRAKE
RELAY
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Checkfor afault inthe
fuse70601/ 5.
Checkfor afault inthe
connector ST93Check
thattherelay25104(E)
is working correctly.
Reset theECU:1- With
|o|t|oo 'o oo 'C|'
short-circuit Pin 13
(connector X1) to
ground for a time be-
tween3 and 6sec.
2- Wait for 2sec.
3- Short-circuir again
the Pin 13 connector
X1 to ground and re-
peat the procedure for
threetimes;eachshort-
circuit should last at
least 0,5 sec.If thepro-
cedure has been cor-
rectly carried out the
ASR indicator switches
on (four short pulses).
When the ignition key
isswitchedON again,it
ispossibleto deletethe
faults memory. If the
fault persists, replace
theE.C.U.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 14 Measure
point 2: Connector
X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
ConnectorX1Pin:14
Measure point 2:
Connector X1 Pin: 7
1- Connector
Connected; Key
+15ON;
2- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
00D 06 THIRD
BRAKE
RELAY -
THIRD
BRAKE
RELAY
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Checkfor afault inthe
fuse70601/ 5.
Checkfor afault inthe
connector ST93
Check that the relay
25104 (E) is working
correctly.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 14 Measure
point 2: Connector
X1 Pin: 4
2- Measure type: Re-
sistance (Ohm)
Measure point 1:
ConnectorX1Pin:14
Measure point 2:
Connector X1 Pin: 7
1- Connector
Connected; Key
+15ON;
2- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Min. value: 14
Ohm; Max. val-
ue: 21Ohm;
Carry out
the recom-
mended
measure-
ments.
00E 04 VOLTAGE LOWTEN-
SION/
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Checkfor afault inthe
fuse 70601 / 4 (Stralis
70602/ 5).
Checkfor afault inthe
fuse 70601 / 6 (Stralis
70602/ 6).
Checkfor afault inthe
supplywiring.
Check the ignition key
and voltage stability.
Checkcorrect pinloca-
tion on Electronic con-
trol unit,iffault persists,
replace.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min. value:
22V;
Max.value:28V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
00E 05 VOLTAGE GROUND
FAULTY
OR NOT
PRESENT
(pin 9 con-
nector X1)
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.
Check: Check correct
pin location on Elec-
tronic control unit, if
fault persists, replace.
Comparablevalues:
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 4 Measure
point 2: GND Pin:
GND
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 9 Measure
point 2: GND Pin:
GND
3- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 9
Measure point 2:
GND Pin: GND
4- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 4
Measure point 2:
GND Pin: GND
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
3- Connector
Not connected;
Key+15OFF;
4- Connector
Not connected;
Key+15OFF;
1- Max. value:
1 V;
2- Max. value:
1 V;
3- Max. value:
3 Ohm;
4- Max. value:
3 Ohm;
Carry out
the recom-
mended
measure-
ments.
00E 07 THIRD
BRAKE
RELAY -
SUPPLY
RELAY (IN-
SIDE THE
ELEC-
TRONIC
CON-
TROL
UNIT)
FAULT Ecu internal fail-
ure.
Before replacing the
control unit make sure
that the control unit is
poweredcorrectly.
(V) Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
010 PRESSURE
SENSOR
SHORT
CIRCUIT
Short-circuit,
faultysensor.
Check sensor wiring.
Replace sensor if dam-
aged.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min.value:0.5
V; Max. value:
4.5 V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
010 03 PRESSURE
SENSOR
SHORT
CIRCUIT
TO POS-
ITIVE
Shorted to high
source
Check sensor wiring.
Replace sensor if dam-
aged.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min.value:0.5
V; Max. value:
4.5 V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
010 05 PRESSURE
SENSOR
OPEN CIR-
CUIT OR
SHORT
CIRCUIT
TO
GROUND
Open circuit or
short-circuiting
to negative.
Check sensor wiring.
Replace sensor if dam-
aged.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 2 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min.value:0.5
V; Max. value:
4.5 V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
012 03 SOLE-
NOID
VALVES -
ASR SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO POS-
ITIVE
Possible short
circuit.
Check wiring and con-
nectors.
Measure type: Volt-
age (V) Measure
point 1: Connector
X2 Pin: 16 Measure
point 2: Connector
X1 Pin: 4
Connector
Connected; Key
+15ON;
Max. value: 1V; Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
012 05 SOLE-
NOID
VALVES -
ASR SOLE-
NOID
VALVE
OPEN CIR-
CUIT
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.Check for a
fault in thecomponent.
Reset theECU:
1- Withignitionkeyon
'C|' s|ot-c|co|t ||o
13 (connector X1) to
ground for a time be-
tween3 and 6sec.
2- Wait for 2seconds.
3-Short-circuir again
the Pin 13 connector
X1 to ground and re-
peat the procedure for
threetimes;
each short-circuit
should last at least 0,5
sec.
If the procedure has
been correctly carried
out the ASR indicator
switcheson(fourshort
pulses).
When the ignition key
isswitchedON again,it
ispossibleto deletethe
faults memory.
If the fault persists, re-
placetheE.C.U.
Measuretype: Resist-
ance (Ohm) Mea-
surepoint 1:Connec-
tor X2 Pin: 7 Mea-
surepoint 2:Connec-
tor X2 Pin: 16
Connector Not
connected; Key
+15OFF;
Min. value: 30
Ohm; Max. val-
ue: 40Ohm;
Carry out
the recom-
mended
measure-
ments.
012 06 SOLE-
NOID
VALVES -
ASR SOLE-
NOID
VALVE
SHORT
CIRCUIT
TO
GROUND
Possible short
circuit.
Check wiring and con-
nectors.
Measuretype: Resist-
ance (Ohm) Mea-
surepoint 1:Connec-
tor X2 Pin: 7 Mea-
surepoint 2:Connec-
tor X2 Pin: 16
Connector Not
connected; Key
+15OFF;
Min. value: 30
Ohm; Max. val-
ue: 40Ohm;
Carry out
the recom-
mended
measure-
ments.
017 05 ABS INDI-
CATOR
SHORT
CIRCUIT
TO
GROUND
Possible causes:
blink code ac-
tivation > 16
sec. bymeansof
switch (pin 15
ecu).
Checkfor afault inthe
fuse 14 and connector
ST18, pin5.
Measure type: Volt-
age (V) Measure
point 1: Connector
X1 Pin: 15 Measure
point 2: Connector
X1 Pin: 4
Connector
Connected; Key
+15ON;
Max. value: 1V; Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
0E7 02 CAN LINE INPLAUS-
IBLE VE-
HICLE
SPEED
Checkthat:
- thephonicwheelsare
not faulty;
- teeths are not dam-
aged or missing;
- the tyres have equal
measure (measures re-
leased byconstructor),
tyrespressure.
Verifytheaxleratio.
0E7 05 CAN LINE OPEN CIR-
CUIT OR
SHORT
CIRCUIT
TO
GROUND
OR POS-
ITIVE
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors. Check for re-
versal of CAN line
cables.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Typical Value:
60Ohm;
2- Min. value:
29 KOhm; Max.
value: 33KOhm;
Carry out
the recom-
mended
measure-
ments.
0E7 06 CAN LINE CONNEC-
TION DIS-
ABLED
Possible open
circuit or inter-
rupted cablebe-
tween.
Check wiring and con-
nectors.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
1- Typical Value:
60Ohm;
2- Min. value:
29 KOhm; Max.
value: 33KOhm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
0E7 07 CAN LINE TIMEOUT
WITH THE
RETARD-
ER
Check for correct op-
eration/connection of
the control units that
are interfaced with
each other (e.g.: EDC,
GEARBOXES, EBS,
ABS, INTARDER, SUS-
PENSIONS, IMMOBI-
LIZER, others...)
0E7 08 CAN LINE DELAY IN
THE COM-
MUNICA-
TION
WITH THE
EDC E.C.U.
(ENGINE
BRAKE)
Check for correct op-
eration/connection of
the control units that
are interfaced with
each other (e.g.: EDC,
GEARBOXES, EBS,
ABS, INTARDER, SUS-
PENSIONS, IMMOBI-
LIZER, others...)
0E7 09 CAN LINE DELAY IN
THE COM-
MUNICA-
TION
WITH THE
EDC E.C.U.
(TORQUE)
Check that the CAN
LINE is correctly con-
nected to the other
control units. Checkfor
CAN presence on the
diagnostic connector.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
3- Measure type: Re-
sistance (Ohm)
Measure point 1:
30-pole connector
Pin: 21 Measure
point 2: 30-polecon-
nector Pin: 22
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15OFF;
1- Typical Value:
60Ohm;
2- Min. value: 29
KOhm; Max. val-
ue: 33KOhm;
3- Typical Value:
60Ohm;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
0E7 0A CAN LINE DELAY IN
THE COM-
MUNICA-
TION
WITH THE
EDC E.C.U.
(ENGINE
BRAKE/RE-
TARDER)
Check that the CAN
LINE is correctly con-
nected to the other
control units. Checkfor
CAN presence on the
diagnostic connector.
1- Measure type: Re-
sistance (Ohm)
Measure point 1:
Connector X1 Pin: 1
(CAN H) Measure
point 2: Connector
X1 Pin: 3(CAN L)
2- Measure type: Re-
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
3- Measure type: Re-
sistance (Ohm)
Measure point 1:
30-pole connector
Pin: 21 Measure
point 2: 30-polecon-
nector Pin: 22
1- Connector
Connected; Key
+15OFF;
2- Connector
Not connected;
Key+15OFF;
3- Connector
Connected; Key
+15OFF;
1- Typical Value:
60Ohm;
2- Min. value:
29 KOhm; Max.
value: 33KOhm;
3- Typical Value:
60Ohm;
Carry out
the recom-
mended
measure-
ments.
0E7 0C CAN LINE INTERNAL
FAULT
Ecu internal fail-
ure.
Before replacing the
control unit make sure
that the control unit is
poweredcorrectly.
1- Measure type: Re-
sistance (KOhm)
Measure point 1:
Connector X1 ECU
Pin:1(CAN H) Mea-
surepoint 2:Connec-
tor X1 ECU Pin: 3
(CAN L)
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
3- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Not connected;
Key+15OFF;
2- Connector
Connected; Key
+15ON;
3- Connector
Connected; Key
+15ON;
1- Min. value:
29KOhm;
Max. value:
33KOhm;
2- Min. value:
22V;
Max.value:28V;
3- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
0FB 03 VOLTAGE OVER-
VOLTAGE
The alternator
charge may be
excessive.
Check battery and al-
ternator supply.
Checksupplyvoltage.
Check the
Tension
Regulator or
any false
contacts on
the earth or
positive
points.
0FD 02 ELEC-
TRONIC
CON-
TROL
UNIT
INCOR-
RECT
WHEEL
PARAME-
TERS
ReprogramABScentral
unit with correct con-
figuration.
If the error
persists to
replace
ECU.
0FD 0C ELEC-
TRONIC
CON-
TROL
UNIT
EEPROM
PARAME-
TERS NOT
CORRECT
ReprogramABScentral
unit with correct confi-
guration.
If the error
persists to
replace
ECU.
0FE 05 ELEC-
TRONIC
CON-
TROL
UNIT
ASR
FUNC-
TION DIS-
ABLED
Brake controlling
ASR disabled.
ECU connector
X2 not con-
nected or ab-
sence of ground
onPIN 2ofeach
ABS electro-
valve.
Checkcompatibilitybe-
tween vehicle system
and E.C.U. configura-
tion.
Check that
the ABS
ECU pro-
gramming is
convenient
for the ve-
hiclesystem.
Check the
CAN line
with EDC.
Check that
the EDC
ECUisprop-
erly pro-
grammed.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
0FE 05 ELEC-
TRONIC
CON-
TROL
UNIT
ABS-ASR
FUNC-
TION DIS-
ABLED
ABS / ASR dis-
abled.
ECU connector
X2 not con-
nected or ab-
sence of ground
onPIN 2ofeach
ABS electro-
valve.
Checkcompatibilitybe-
tween vehicle system
and E.C.U. configura-
tion.
Check that
the ABS
ECU pro-
gramming is
convenient
for the ve-
hiclesystem.
Check the
CAN line
with EDC.
Check that
the EDC
ECUisprop-
erly pro-
grammed.
0FE 08 ELEC-
TRONIC
CON-
TROL
UNIT
EXCESSIVE
SLIPPING
Mechanical
problems in the
ASR -System
(pneumatic
pipes, the ASR
electrovalve,
ABS-electro-
valves, ASR dis-
ablingswitch).
Check phonic wheel
and replace it if dam-
aged. Check and re-
store clearance be-
tweensensor andpho-
nic wheel.
Check: Check the in-
tegrity and cleanliness
of the phonic wheel.
Restore clearance be-
tweensensor andpho-
nic wheel.
Comparable values: 0,7
0,05mm
0FE 09 SOLE-
NOID
VALVES -
ABS SOLE-
NOID
VALVES
ACTIVA-
TION
TIMES
NOT
CORRECT
ABS valveenab-
ling time incor-
rect.
Checkthat thesolenoid
connectorsintheelec-
trical system and the
pipes in the pneumatic
systemhave not been
inverted.
DTC FMI
Failing
component
Typeof
Failure
Visiblefailure PossibleCause Repair action Checkstobeperformed
Measuring
conditions
Valuestobe
detected
Remarks
0FE 0C ELEC-
TRONIC
CON-
TROL
UNIT
INTERNAL
FAULT
Ecu internal fail-
ure.
Before replacing the
control unit make sure
that the control unit is
poweredcorrectly.
1- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 7 Measure
point 2: Connector
X1 Pin: 4
2- Measure type:
Voltage (V) Measure
point 1: Connector
X1 Pin: 8 Measure
point 2: Connector
X1 Pin: 4
1- Connector
Connected; Key
+15ON;
2- Connector
Connected; Key
+15ON;
1- Min. value: 22
V; Max. value:
28V;
2- Min. value:
22V;
Max.value:28V;
Carry out
the recom-
mended
measure-
ments.
PNEUMATIC SYSTEM- BRAKES 69 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
SECTION 2
Visible Failure Possible cause Repair action
Pneumatic system pipes leaking or
broken.
Tightenorreplace looseordamagedfit-
tings.
Replacebrokenor damagedpipes.
Insufficient or irregular systemcharging
Air compressor isfaulty. Overhaul or replaceair compressor.
Insufficient or irregular systemcharging
Pressureregulator indrier isfaulty. Overhaul or replacedrier.
Four-waysafetyvalveisfaulty. Overhaul or replace four-way safety
valve.
Leaksor breakagesinpneumaticsystem
pipes.
Tightenor replacelooseordamagedfit-
tings.
Replacebraokenor damaged pipes.
Rear axleservicebrakingisinefficient or
Brakingcontrol isfaulty. Adjust,overhaul andifnecessaryreplace
thebrakingcontrol.
Rear axleservicebrakingisinefficient or
irregular Worn or vitrified brakelinings. Overhaul or replacethebrakelinings.
Rear brakesarefaulty. Overhaul therear brakes.
Duplexdistributor isfaulty. Overhaul or replaceDuplexdistributor.
Brakecylindersarefaulty. Overhaul or replacebrakecylinders.
Leaksor breakagesinpneumaticsystem
pipes.
Tightenor replacelooseordamagedfit-
tings
Replacebrokenor damagedpipes.
Front axleservicebrakingisinefficientor
Duplexdistributor isfaulty. Overhaul or replaceDuplexdistributor.
Front axleservicebrakingisinefficientor
irregular Worn and/or vitrifiedbrakelinings. Overhaul or replacebrakelinings.
Front brakes arefaulty. Overhaul front brakes.
Diaphragmbrakecylindersarefaulty. Overhaul or replace diaphragmbrake
cylinders.
(Continue)
Aquila Trucks Centres
70 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Visible Failure Possible cause Repair action
Leaksor breakagesinpneumaticsystem
pipes.
Tightenorreplace looseordamagedfit-
tings
Replacebrokenor damagespipes.
T il i b ki i i ffi i t
Triplecontrol servo distributor is faulty. Overhaul orreplacetriplecontrol servo
distributor.
Trailer service braking is inefficient or
irregular
Duplexdistributor isfaulty. Overhaul or replace duplex control
valve.
Pressurereducer isfaulty. Overhaul or replacepressurereducer.
Worn or vitrified brakelinings. Overhaul or replacebrakelinings.
Trailer brakesisfaulty. Overhaul trailer brakes.
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
couplings.
Replacebrokenor damagedpipes.
Inefficient or no parkingbraking
Combinedbrakecylindersarefaulty. Overhaul or replace combined brake
cylinders.
p g g
Parkingbrakehandlever isfaulty. Overhaul or replacelever.
Worn or vitrified brakelinings. Overhaul or replacebrakelinings.
Relayvalveisfaulty. Overhaul or replacerelayvalve.
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
couplings.
Replacebrokenor damagedpipes.
Inefficientornoparkingbrakingontrailer
Triplecontrol servo distributor is faulty. Overhaul or replace triple action servo
control valve.
p g g
Parkingbrakehandlever isfaulty. Overhaul or replacehandlever.
Worn or vitrified trailer brakelinings. Overhaul or replacetrailer brakelinings.
Trailer brakes arefaulty. Overhaul trailer brakes.
(Continue)
Aquila Trucks Centres
PNEUMATIC SYSTEM- BRAKES 71 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Visible Failure Possible cause Repair action
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
couplings.
Replacebrokenor damagedpipes.
D l d ki b k l
Relayvalveisfaulty. Overhaul or replacerelayvalve.
Delayed parkingbrakerelease
Combinedbrakecylindersarefaulty. Overhaul or replace combined brake
cylinders.
Parkingbrakehandlever isfaulty. Overhaul or replacelever.
Rear brakesarefaulty. Overhaul rear brakes.
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
couplings.
Replacebrokenor damagedpipes.
Delayed trailer parkingbrakerelease
Triplecontrol servo distributor is faulty. Overhaul or replace triple action servo
control valve.
Parkingbrakehandlever isfaulty. Overhaul or replacehandlever.
Trailer brakes arefaulty. Overhaul trailer brakes.
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
connections.
Replacebrokenor damagedpipes.
Duplexdistributor isfaulty. Overhaul or replace Duplex control
valve.
The vehicle pulls to one side when
braking
Brakingcontrol isfaulty. Adjust,overhaul andifnecessaryreplace
load proportioningvalve.
Front brakes arefaulty. Overhaul front brakes.
Rear brakesarefaulty. Overhaul rear brakes.
Triplecontrol servo distributor is faulty. Overhaul orreplacetripleactioncontrol
valve.
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
couplings.
Replacebrokenor damagedpipes.
Insufficient trailer slow-downbraking
Pressurereducer isfaulty. Overhaul or replacepressurereducer.
Insufficient trailer slow downbraking
Triplecontrol servo distributor is faulty. Overhaul orreplacetripleactioncontrol
valve.
Parkingbrakehandlever isfaulty. Overhaul or replacelever.
(Continue)
Aquila Trucks Centres
72 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Visible Failure Possible cause Repair action
Duplexdistributor isfaulty. Overhaul or replace duplex control
valve.
B k li i b i kl
Brakingcontrol isfaulty. Adjust,overhaul andifnecessaryreplace
load proportioningvalve.
Brakeliningsbecomewornquickly
Brakesare faulty. Overhaul brakes.
Triplecontrol servo distributor is faulty. Overhaul orreplacetripleactioncontrol
valve.
Relayvalveisfaulty. Overhaul or replacerelayvalve.
B k f il i di li h
Leaksor breakagesinpneumaticsystem
pipes.
Tighten or replace loose or damaged
couplings.
Replacebrokenor damagedpipes.
Brake system failure indicator light
switched on
Four-waysaftyvalve isfaulty. Overhaul orreplacefourwayprotection
valve.
Light indicator electric circuit is badly
wired.
Find wrongconnection and rectifywir-
ing.
Parkingbrakeindicator light switchedon
Light indicator electric circuit is badly
wired.
Find wrongconnection and rectifywir-
ing.
Parkingbrakeindicator light switchedon
withhandlever inrunningposition Parkinghand lever is faulty. Overhaul or replacelever.
Pressurereducer operatingnormally. Overhaul or replacepressurereducer.
Worn brakelinings. Replacebrakelinings.
Noisybrakes
Shoereturnspringsarefaulty. Overhaul rear brakes.
Noisybrakes
Brake drums are ovalized over pre-
scribed tolerancerange.
Faceor, if necessary, replacedrums.
Aquila Trucks Centres
PNEUMATIC SYSTEM- BRAKES 73 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
TIGHTENING TORQUES
DESCRIPTION TORQUE
Compressor Nm (kgm) Compressor Nm (kgm)
Compressor, Knorr type- BREMSE 2W 460R, 464 cm
3
Headfasteningscrews 30 (3)
Pulleyfasteningnut
190
1
0
(19)
Combinedbrakecylinder
Brakecylinder ringnut 300 +30 (30 3)
Manual brakereleasescrew 15+20 (1.5 )
Diaphragmbrakecylinder (for drumbrakes)
Brakecylinder ringnut 300 +30 (30 3)
Diaphragmbrakecylinder (for disk brakes)
Nutsto securecylinder to brakecaliper
180 20
(18 2)
Front disc brakes axle 5886/D
Ringnut fixingwheel bearings 515.5 24.5 (51.5 2.4)
Cylindrical headscrewswithhexsocket to lockwheel bearingadjustment clamp 27.5 2.5 (2.7 0.2)
Self-lockinghexscrews to fixbrakecallipers tomount 615.5 61.5 (61.5 6.1)
Self-lockinghexscrewto fixbrakecalliper mount tostubaxle 312.5 16.5 (31.2 1.6)
Hexscrewfixingbrakediscto wheel hub 281.5 13.5 (28.1 1.3)
Cover for wheel hubz 130 10 (13 1)
Tapered threadedplugfor wheel hub cover 50 5 (5 0.5)
z Deposit asealer beadonlyonhub cover ledgesurface, usingdedicated dispenser. Protect threadedportion. UseLOCTITE
TYPE574asasealer
Rear drumbrakes axle 5985/2D
Wheel securingnut
600
+50
-20
60
+5
-2 (
(
Brakesupport securingscrew 362.5 33.5 (36.2 3.3)
Cover securingscrew 49 5 (4.9 5)
Support securingscrew 25 3 (2.5 3)
Axledrumbrakes452191/2D - 453291/2D - 452146/2D - 451391/2D
Screwfixingdrum 25 3 (2.5 0.3)
Cover securingscrew H 50 5 (5 0.3)
Flat-headscrew 50 5 (5 0.5)
Wheel securingnut 615 35 (61.5 3.5)
Drumbrakes on rear axleMT 23 - 155
Wheel fasteningnut 665.5 61.5 (67.8 6.2)
Drumfasteningscrew 54.5 12.5 (29 1.3)
Half-shaft fasteningscrew* 262 27 (26.7 2.7)
Wheel hub bearingringnut 932 98 (95 10)
Nut for brakesupport fasteningscrew 289.4 14.5 (29.5 1.5)
Revsensor support fasteningscrew D 6 1
* spreadthe flange/wheel hub matingsurfacewithsealer IVECO 1905685(LOCTITE14780)
applyLOCTITE245onthethreading
Aquila Trucks Centres
74 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
TOOLS
TOOL NO. DESCRIPTION
99301001 Grindingand turningmachinefor brakediscs anddrums
99301005 Brakediscturningdevice
99301006 Brakeshoeturningdevice
99305079 Brakeshoeturningdevice
99305087 Rivet press
99305117 Instrument to checkair circuits
Aquila Trucks Centres
PNEUMATICSYSTEM- BRAKES 75 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
TOOL NO. DESCRIPTION
99305121 Hot air device
99341003 Single-acting bridge (rear axles 452194/2D - 451391/2D -
453291/2D- 452191/D- 452146/2D)
99321024 Hydraulic trolleyto removeandrefit wheels
99327030 E.A.SY.
99341015 Clamp (rear axles 412191/2D - 451391/2D - 453291/2D -
452146/2D)
99341023 Grips (rear axles452191/2D- 451391/2D- 453291/2D)
Aquila Trucks Centres
76 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
TOOL NO. DESCRIPTION
99345049 Reactionblockfor extractors (driveaxle 5985/2D)
99345053 Reaction block for extractors (drive axle 5985/2D, rear axle
452146/2D)
99345055 Reactionblockforextractors(rearaxles452191/2D- 451391/2D
- 453291/2D)
99348001 Extractor with locking device (drive axle 5985/2D, rear axles
452146/2D- 452191/2D - 451391/2D- 453291/2D)
9938004 Universal maleextractor from5to 70 mm(driveaxle5985/2D)
99354207 Wrench for wheel hub caps (front axle 5886/D, drive axle
5985/2D, rear axles 452146/2D - SR145E/2D - 452191/2D -
451391/2D- 453291/2D)
Aquila Trucks Centres
PNEUMATICSYSTEM- BRAKES 77 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
TOOL NO. DESCRIPTION
99356001 Wheel brake shoe adjustment wrench (rear axles 452191/2D-
451391/2D- 453291/2D - 452146/2D)
99356006 Wrenchfordismountingandremountingfairedbrakecylinderring
nut
99370005 Gripforinterchangeabledrifts(rearaxles452191/2D-451391/2D
- 453291/2D - 452146/2D)
99370006 Grip for interchangeable drifts (front axle 5886/D, drive axle
5985/2D, rear axles 452191/2D- 451391/2D - 453291/2D)
99370007 Grip for interchangeable drifts (front axle 5886/D, drive axle
5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D)
99370317 Reactionleverwithextensiontoretainflanges(front axle5886/D,
drive axle 5985/2D, rear axles 452191/2D - 451391/2D -
453291/2D- 452146/2D)
Aquila Trucks Centres
78 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
TOOL NO. DESCRIPTION
99370715 Guide for fitting wheel hub (front axle 5886/D, rear axles
452191/2D- 451391/2D - 453291/2D
99372211 Tool to remove and refit brakeshoeretainer springs
99372213 Tool for turning brake drum (use with 99301001) (drive axle
5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D, axle5886/2D)
99372228 Hubfor positioningdismantledfloatingshoeturningtoolsonlathe
99301001
99372230 Tool forturningdismantledfloatingshoes(Rockwell410) (usewith
99301001- 99372228)
99372237 Tool to mount brake calliper sliding bush guard (front axle
5886/D)
Aquila Trucks Centres
PNEUMATICSYSTEM- BRAKES 79 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
TOOL NO. DESCRIPTION
99372238 Tool to extract brakecalliper thrust units (front axle5886/D)
99372239 Tool to mount thrust units with brake calliper guard (front axle
5886/D)
99372240 Tool to removeandrefit brakecalliperslidingbushguidebushings
(usewith 99372237 for assembly) (front axle5886/D)
99372241 Tool for notchingbrakecalliper slidingbush guide bushing(front
axle5886/D)
99373004 Key to remove brake cylinder gasket (Rockwell) (rear axles
452191/2D - 451391/2D - 453291/2D - 452146/2D, axle
5985/2D)
99374025 Installer, wheel hub inner seal (usewith 99370005)
Aquila Trucks Centres
80 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
TOOL NO. DESCRIPTION
99374093 Drift to mount bearing outer races 91-134 mm (use with
99370007) (front axle - 5886/D, drive axle 5985/2D, rear axles
452191/2D- 451391/2D - 453291/2D- 452146/2D)
99374094 Drift to mount bearing outer races 134-215 mm (use with
99370007) (rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D, axle5985/2D)
99374132 Key to mount wheel hub internal gasket (use with 99370006)
(front axles 5886/D)
99374161 Keyto mount wheel hub internal gasket (rear axles 452191/2D -
451391/2D- 453291/2D - 452146/2D)
99374377 Keyto mount wheel hub internal gasket (drive axle5985/2D)
99374451 Tool to remove and refit drive shafts (rear axles 452191/2D -
451391/2D- 453291/2D - 452146/2D)
Aquila Trucks Centres
Revi- June2007
PNEUMATICSYSTEM- BRAKES 81 TRAKKEREURO 4/5
Print 603.93.641/A 3aso |ovobo 2006
PRINT603.93.641/A
TOOL NO. DESCRIPTION
99387050 Cuttingnippers for polyamide pipes
99388001 Wrench (80 mm) for front wheel hub bearing adjustment nut
(front axle5886/D, driveaxle5985/2D)
99387051 Toolkit to remove polyamide tubes (6-8-10-12 mm) from
RAUFOSSjoints
Aquila Trucks Centres
82 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
PRINT603.93.641
MAIN DATA - PNEUMATIC SYSTEM
DESIGNATION
Compressor
- Type: WABCO 412 352 200 8 Singlecylinder
Displacement 352 cm
3
- Type: KNORR - BREMSE 2W460 R Two cylinders
Displacement 628 cm
3
APU
- Type: KNORR Z 007035
Max. workingpressure bar 13bar
Safetyvalve openingpressure bar 13+4 bar
Circuit 1 2 3 4 3 4
Fittingfor second 21 22 23 24 26
Openingpressure(The circuit 1+2 arefilled first) bar
7.5
+0.2
0
8.0
-0
0.2
Openingpressureof theintegrated safetyvalve bar >=9.2
Staticclosingpressure.
(Without compensation, with 0 bars inthecircuit out of service) bar
6.5 0.25 6.5 0.25
Workingpressure bar
8.5
-0.3
8.5
-0.5
Pressure limiter on/off pressuredifference bar <=0.65
Air tanks
Front axle 20Litres
Rear axle 20Litres
Parking+trailer 20Litres
For regeneration 5 Litres
Services 5 Litres
Engine brake control pedal valve
- Type: BOSCH A 481 110 125 - WABCO 463036019 - BENDIX CP6A
Maximumworkingpressure 12 bar
Duplex distributor
- Type: KNORR - DX 60A
Feedpressure 10.5bar
Workingpressure 10.5bar
Proportional reducing valve
- Type: KNORR DB 2116
Ratio 1.15:1
Relayvalve
- Type: KNORR - BREMSE - AC 574 AXY
Max. workingpressure 10.2 bar
- Type: KNORR - BREMSE - RP2A
Max. workingpressure 10bar
Aquila Trucks Centres
PNEUMATICSYSTEM- BRAKES 83 TRAKKEREURO 4/5
Print 603.93.641 3aso |ovobo 2006
DESIGNATION
Double-acting relay valve
- Type: WABCO 973 011 208 0
Control maximumpressure 10 bar
Variable and automatic coupling heads
- Type: MARELLI - BOSCH - KNORR - BREMSE - WABCO - GRAU
Workingpressure 8.5 bar
Triple control servo distributor
- Type: KNORR - BREMSE AC 597B - WABCO 973009013
Feedpressure 8.5 bar
Predominance 0.2 bar
Differential control pressure (ducts 41and22)
2.5 bar
0,5
0,3
Parking br ake distr ibutor (towing vehicles)
- Type: KNORR DPM60EY
Supplyand workingpressure 8.5 bar
Travel ofcontrol lever (discharge) withstart ofemergencybraking(point ofresistance) 67
Parkingbraking 73
Test brakingto check supplyto triplecontrol valve 86
Parking brake distributor (stand-alone vehicles)
- Type: KNORR DPM61EY
Supplypressure 8.5 bar
Travel ofcontrol lever (discharge) withstart ofemergencybraking(point ofresistance) 67
Parkingbraking 73
Trailer retarder control valve (optional)
- KNORRDPM 96DAX
Supplypressure 8.5 bar
Maximumangular travel of control lever 73
Air pressure switch
- TDSF13043 - F13047
Workingpressure max 15bar
Settingpressure
with increasingpressure 5.5 0.5 bar
with decreasingpressure 6.6 0.3 bar
Safety valve (for Sweden only)
- WABCO 4342050610
Maximumoperatingpressure 10bar
Controlled pressur e valve
- WABCO 434100199 - KNORR - BREMSE 1B435 47 - BENDIX VPC 4M
Openingpressure 7 bar
+0.1
- 0.3
ABS wheel anti-lock control valve
- Type: WABCO 472 195 055 0
Maximumoperatingpressure 13 bar
- Type: KNORR - BREMSE IC 57664
Maximumoperatingpressure 10,2bar
Aquila Trucks Centres
84 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
3aso |ovobo 2006 Print 603.93.641
DESIGNATION
Check valve
- Type: VOSS02 689142 00
Max. workingpressure 12bar
Impedancepressure 0.2 bar
Twin stop valve
- WABCO 4342080290
Supplypressure max 10bar
Pressure test point valve
- Type: RAUFOSS
Workingpressure max 12.5bar
- Type: SIRIT
Workingpressure max 12.5bar
Pressure sensor
- WABCO 4410400150
Measuringprinciple piezo-resistive
Permissibleoverpressure 16bar
Solenoid valve normally closed ASR control
- WABCO 4721706060
Workingpressure 5.5 11bar
Feedmaximumpressure 13bar
Voltage 24V
Current 0.69A
Electronic control unit
- WABCO 4460043200
Supplyvoltage 24V
Membrane brake cylinder (for drumbrakes)
- Type 14: BENDIX DFR 8944 B
Maximumworkingpressure 8.5 bar
Sleeve length 187 mm
Stroke min. 53 mm
- Type 14: KNORR EF 141AY
Maximumworkingpressure 8.5 bar
Sleeve length 152 mm
Stroke 53mm
- Type 16: BENDIX DFR 9023 B
Maximumworkingpressure 8.5 bar
Sleeve length 187 mm
Stroke min. 53 mm
- Type 16: KNORR EF 161AY
Maximumworkingpressure 8.5 bar
Sleeve length 152 mm
Stroke min. 53 mm
- Type 18: BENDIX EF 180 BY
Maximumworkingpressure 8.5 bar
Sleeve length 180 mm
Stroke min. 53 mm
Aquila Trucks Centres
PNEUMATIC SYSTEM- BRAKES 85 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
DESIGNATION
Combined brake cylinder
- Type 16/24 HF: KNORR 1C 56449
Maximumworkingpressure 8.5bar
Springload 7900 N
- Type 18/24 HF: KNORR 1C 55976
Maximumworkingpressure 8.5bar
Springload 7900 N
- Type 14/24: HF KNORR - BREMSE BY 9276 (Z 005732)
Maximumworkingpressure 8.5bar
Springload 10400N
- Type 16/24: HF KNORR - BREMSE BY 9331 (Z 005733)
Maximumworkingpressure 8.5bar
Springload 10400N
Membrane brake cylinder (for disk brakes)
- Type 22: KNORR - BREMSEZ 011553
Maximumworkingpressure 10.7bar
Sleevelength 141 mm
Stroke min64mm
- Type 24: KNORR - BREMSEZ 010464
Maximumworkingpressure 10.7bar
Sleevelength 141 mm
Stroke min64mm
Membrane brake cylinder (for drumbrakes)
- Type 16: KNORR EF 161NYX
Maximumworkingpressure 8.5bar
Sleevelength 152 mm
Stroke min53mm
- Type 16: KNORR EF 161PYX
Maximumworkingpressure 8.5bar
Sleevelength 190 mm
Stroke min53mm
- Type 18: KNORR EF 180PYX
Maximumworkingpressure 8.5bar
Sleevelength 190 mm
Stroke min53mm
Combined brake cylinder
- Type 16/24 HF: KNORR - BREMSE Z 007616
Springload 7900N
Stroke min53mm
- Type 18/24 HF: KNORR - BREMSE Z 007618
Springload 7900N
Stroke min53mm
Aquila Trucks Centres
86 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
MAIN DATA - BRAKES
KNORR FRONT
DISC BRAKES:
FRONT AXLE
INTERMEDIATE ADDED
AXLE
5886/D
Brakecalliper cylinders:
- number
- diameter mm
2
68
S
Brakeliningthickness:
- standard S mm
- minimumpermissible S mm
21
2
Brakediscdiameter mm 432
S
Brakediscthickness:
- normal S mm
- minimumpermissible S mm
45 0.1
37(4mmper side)
Operatingclearance G mm 0.5 1
WHEEL HUBS
Wheel hub bearings 2with taperedrollers
Hub bearingendfloat mm 0.16max
Hub bearingendfloat adjustment withringnut
Rollingtorque daNm 0.50max.
Oil for wheel hub bearings
TutelaW 140/MDA
Litres
Quantityof oil for eachhub
Kg
0.35
0.32
Aquila Trucks Centres
PNEUMATIC SYSTEM- BRAKES 87 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
MERITOR DUO-DUPLEX DRIVE AXLE MERITOR DUO DUPLEX
DRUM BRAKES
DRIVE AXLE
5985/2D
Drumdiameter:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
410 410.4
412 412.4
414 414.4
S
S1*
Brakeliningthickness:
- Nominal S mm
- 1
st
uprating S mm
- 2
nd
uprating S mm
- minimumpermissible S
1*
mm
22.95
23.95
24.95
6.95
Diameter of brake linings:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
408 409
410 411
412 413
L
Widthof brakelinings:
L mm 179 180
G
Clearance between brake linings
and drum:
G mm 0.5 1.2
E
Maximumerror of concentricityin
thedrumdiameter after turning
E mm
0.04
WHEEL HUBS WHEEL HUBS
Wheel hub bearings
Two withtaperedrollers
SET-RIGHT
Hub bearingendfloat
mm Not adjustable
Hub bearingendfloat adjustment Tighteningto torquewithringnut
Wheel hub bearingrollingtorque
0.50max
-
Oil for wheel hub bearings
TutelaW 140/MDA
Litres
Quantityof oil for eachhub
Kg
-
-
Aquila Trucks Centres
88 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
MERITOR
DUO-DUPLEX REAR
H.R. REARAXLE REAR AXLE
DUO-DUPLEX REAR
DRUM BRAKES
451391/2D 452146/2D 452191/2D 453291/2D MT 23-155/2D
Drumdiameter:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
410 410.4
412 412.4
414 414.4
S
S1*
Brakeliningthickness:
- Nominal S mm
- 1
st
uprating S mm
- 2
nd
uprating S mm
- minimumpermissible S
1*
mm
22.95
23.95
24.95
6.95
j
Diameter of brake linings:
- Nominal mm
- 1
st
uprating mm
- 2
nd
uprating mm
408 409
410 411
412 413
L
Widthof brakelinings:
L mm
199 200
G
Clearance between brake linings
and drum:
G mm 1 1.25
E
Maximumerror of concentricityin
thedrumdiameter after turning
E mm 0.04
WHEEL HUBS WHEEL HUBS
Wheel hub bearings SET-RIGHT
Two with tapered
rollers(Unit Bearing)
Hub bearingendfloat
mm
Not adjustable
Not adjustable,
tightenaccordingto
retainingringnut
torque
Hub bearingendfloat adjustment -
Wheel hub bearingrollingtorque -
Oil for wheel hub bearings
TutelaW 140/MDA
Litres
Quantityof oil for eachhub
Kg
-
-
Aquila Trucks Centres
SincethevehiclesystemisapprovedaccordingtoEuropeanroadcodestandards,itisnecessarythattheefficiencyandcomponents
areperiodicallycheckedusingtool 99305117.
Thechecksarecarriedout withthevehicleatastandstill,using compressedairfromthetanks, recharged, withtheenginerunning,
bythecompressor.
!
Alwaysblockthevehiclebeforestartinganytypeofoperation.Periodicallycheckthegaugescomparingthemwithamaster
gauge.
(continued)
PNEUMATIC SYSTEM- BRAKES 89 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
BRAKING SYSTEM MAIN COMPONENTS CHECK
DEVICE DESIGNATION CHECKS
Compressor
Checkthetightnessoffittingsand that thecompressor issecurely
fastened. Makesurethecoolingfinsarenot dirty.
Drier (optional)
Operateonableedervalveorloosenascrewedplug(withintegrated
bleeder hole) to check that theair drier isoperatingcorrectly. The
air shouldcomefromthetankwithno signsofcondensatewater.
Air tanks for:
- Front axle
- Rear axle
- Parking+trailer
- Services
- Regeneration
Check theseal and anti-rust protection.
Dischargethecondensatefromthetanksthroughthebleeder valve
Four waysafetyvalve
Check :
Maximumopeningpressure 8 bar
Static closingpressure 6.5 bar
0,5
0
Duplexdistributor
Pressthepedal totheendofitsstroke, releasingthepedal it should
returnimmediatelytoitshomeposition.
Pressurerestriction7.6 0.3bar
Checkthat thepedal gasket isnot worn, that thebrakecontrol rods
arewell securedand lubricatedwith no strain.
Check that thelever housingsarenot wornor oxidized.
Pneumaticpressure
control socket
Ensurethat theprotection plugsareinserted
Parkingbrakedistributor
(with checkingposition)
Operateontheparkingbrakedistributor until it triggers, the gauge
onthecontrol socket istoindicatethe pressuredischarge 0 bar in
1second.
Theautomaticcouplingjointpipeandthegaugearetoindicateatthe
same time apressureof 8.5 bar
Engine brake control pedal
distributor
Check functioningand seal
Loadsensingvalve
Theplateindicatesall theset valuestobecomparedtothosefound
when checkingandadjusting.
Aquila Trucks Centres
(continued)
90 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
Diaphragmcylinder
Check fastening, integrityand seal
Thebleeder holeshould bedirected downwards andnot clogged
Combinedcylinder
Check fastening, integrityand seal.
Thebleeder holeshould bedirected downwards andnot clogged
Relayvalve
Check operationandseal assessing the speedof brake cylinder
activation
Engine brake control operator
cylinder
Check operationand seal
Pressurereducer
Check set pressure(seespecificationsanddatatable)
Check operation
Triplecontrol servo
distributor for trailer
braking, with
incorporatedmodulated
power steering
Fill thetank. Connect agaugetotheautomaticcouplingheadandto
avariablecouplinghead.
At a pressure of 1 bar, coming fromthe duplex distributor, the
variablecouplinghead shouldhave apressurebetween0.8 and1.5
bar. Make afull braking(vehicleat astandstill).
Prescribedpressure must result at thecouplinghead, or apressure
that is0.5barless.Activatetheparkingbrake;at thevariablecoupling
head thepressureshouldremainthe same, or reduced by0.5bar.
Couplingheads
Check thereisno dirt or damageon thecouplingguides.
Aftercoupling,operatethebrakepedal andchecktheseal andstability
between thecouplingheads whendeliveringair at 7.5bar.
Check thereareno air leaks fromthe couplinggaskets.
Rear drumbrakes
Releasing the pedal the shoes should return quicklyand evenlyto
homeposition.
Check backlashbetweenshoesanddrum.
Check thicknessof brakelinings.
Discbrakecalliper
Brakedisc
Brakelinings
Check thewear of thebrake linings, scoringand wear of thebrake
disc, efficiencyof the pistons, wear of thedust caps.
Drumbrakes
Whenthepressureonthepedal stops,theshoesneedtoreturnto
therest positionquicklyandevenlyonall thewheels.
Check theclearancebetweenshoesanddrum.
Checkthethickness of thebrakelinings.
Aquila Trucks Centres
PNEUMATIC SYSTEM- BRAKES 91 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Pipesandfittings
Ensure that metal pipes are in perfect condition, with no dents or
cracks. Polyamide hoses must have no cracks, cuts or scores. Also
make sure that theyarenot near sharp edges of the bodywork or
chassisthat coulddamagethem.Checkthat all thebracketsfastening
thepipes are securelyfixed - loose fastenings cause vibrations that
couldgiveriseto breakages. Checkthat polyamidehosesarenot in
contactwithoil or mineral grease,rubbersolvents.Presshardonthe
brakepedal andcheckthat thepipesarenot blown.Checkthereare
noleaksfromfittings,otherwisetightenthemfully, takingcare when
tighteningnot to cause irregular pipe torsion. In all theabovecases
thepartsaretobereplacedifthereisaminimumofdoubt astotheir
efficiency.Apart fromtheir condition, it isrecommendedto replace
hosesafterconsiderablemileage,orafteraperiodoflongvehicleuse.
Thiswill avoidsuddenbreakagesdueto ageandfatigue.
Pneumaticsystemseal withengine
off below thestartingpressure
Thischeckismadeonthreaded couplings. Deliver air at apressureof
not lessthan5bar andspreadquitethicksoapywater onthejointsand
couplingsusingasoft brush, thenobservecarefullyfor signsof leaks.
Anair leakiswithintoleranceifit correspondsto asoapbubblewitha
diameterof 25mmin5seconds,or apressuredropwithin10minutes
amountingto2%of the disengagement pressure (0.22 0.02bar).
Pneumatic systemseal in partial
brakingrangewith3 bar.
For 3minutes thepressuremust remainstabilizedin thepneumatic
system. Thecheckismadewiththe parkingbrakedeactivated.
Aquila Trucks Centres
60231
Figure24
Producessufficient compressedairtofeedthebrakingsystem
and ancillaryservices.
60232
Head fastening screws tightening torque
Figure25
Tightencylinderheadfasteningscrewstothespecifiedtorque
followingthesequenceshowninthe figure.
92 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
3aso |ovobo 2006 Print 603.93.641
BRAKING SYSTEM MAIN COMPONENTS
790510 Compressor
Troubleshooting
TROUBLE POSSIBLECAUSES CURE
Oil leakage fromflange
id
Incorrect drivingtorque Tightenthescrewsto theprescribedvalues g g
on outer side
Flangebodysealingsurfacenot perfectlyflat Check the sealing sur faces, replace faulty parts or
straightenthem
Brokengasket Replacethegasket
Shaft gasket damaged Replacethega sket
Oil leakage fromhead Damaged scraper ring (this can beseen be-
causethewholeseal seat isshiny)
Replacetheentirepiston
Scraper ringisbadlyfitted Fit inp lacewiththeTOPinscriptionturnedtowardsthe
compressor head
Scraper ringsandpistonringsareall onthesame
vertical line.
Fit inplaceat 120 withreferenceto eachother
Scoredor ovalizedcylinder Grindt hecylinder andfit abigger piston
No compressionat all Deteriorated compressionor intakevalve Replacethefaultyparts
Deteriorated compressionor intakevalve Fit theringsat 120 withreferenceto eachother
Pistonperforatedor pistonelementsbroken Replacetheentirepiston
Damagedgasket Replacethegaskets
Energy-savingdevicesetonopenduringcharging
stage.
Replacethecylinder heads
Poor efficiency Wornpistonrings Replacethepiston(andpistonrings)
Air leakagebetweencylinder andhead Replacethegasket andtightenth escrews to thepre-
scribedtorque
Deterioratedenergysavingunit, intakeor com-
pressionvalves
Replacethefaultyparts
Toomuchbacklashbetweenpistonandcylinder Grindthecylinder andfi t abigger piston
Particlesofcarbonizedoilbetweentheintake
andcompressionvalves
Cleanthevalves
Mechanical noises Too muchbacklashbetweensmall end andpin,
betweenpinandpistonhole, betweenshaft and
bigend, betweenshaft andbronzecapsandbe-
tweenflangesandshaft.
Checkthetolerancesof thecouplingsinvolved
Toomuchbacklashbetweenpistonandcylinder Grindthecylinder andfi t abigger piston
Excessivedepositsbetweenpistonand
cylinder headcausedbyburnt oil.
Cleantheincrustations andreplacethevalves
Water seepage Head gasket or contact surfaces scored and
uneven.
Replacethefaultyparts
Aquila Trucks Centres
Figure26
A.P.U. Troubleshooting(Drier +four-way protection valve)
PROBLEM POSSIBLECAUSE REMEDY
Too much condensate in
the circuit
The set pressure is not
reachedinthe tank
Air lossat discharge
Air leaks aroundthe plugs
Air leaks if a section breaks
down
Cloggedfilter cartridge
Air leakingfromsafetyvalve
Wornsealinggaskets
Pistonseal isinsufficient
Leakage from the valves in the four
sections.
Defectiveoperationof thecheckvalves.
Replacethecartridge
Overhaul theequipment andreplace worncomponents
Overhaul theequipment andreplace worncomponents
Overhaul theequipment andreplace worncomponents
Overhaul thedevice, replacingthewornparts.
Overhaul thedevice, replacingthewornpartsif necessaryor
replacethedevice.
72019
Itsfunctionisto keeptheair clean andat the right moisture
level inthedistributionsystemandkeepthepressureneeded
for theoperation of theconnected systems at theoutlet.
This component integrates the functions of 4-waypressure
regulator, pressure reduction unit for parking, services and
trailer.
PNEUMATIC SYSTEM- BRAKES 93 TRAKKER EURO 4/5
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A.P.U. (Air Processing Unit)
Aquila Trucks Centres
73914
90639
Figure27 Figure28
Takes theair fromthetankanddistributes it to thebraking
elements. It is autorestrictive i.e. it limits theair output to an
established maximumpressure and as a result there is a
greater availabilityofenergyandamaximumconstantbraking
pressureregardlessof thepressurevariationsinthe tanks.
Onvehiclesfittedoutastrucksduplexdistributorsarefittedto
correct thebrakingforceofthefront axleelementsaccording
to the corrections made by the braking control (where
present).
Troubleshooting
PERFORMANCEDIAGRAM
A =Exit pressurep21/p22 [bar]
B=Shoetravel [mm]
PROBLEM POSSIBLECAUSE REMEDY
Leaksfromoutlet ducts dueto wear on
seal gaskets
Auto restriction higher or lower than
required
Wornsprings
Air leaksdueto pistongasket seals inthe
two sections
Theelectric circuit doesnot close
Theelectric circuit doesnot open
Overhaul thedeviceandreplaceworncomponents
Adjust thedevicethroughtherelevant screw
Overhaul thedeviceandreplacefaultycomponents
Overhaul thedeviceandreplacefaultycomponents
Replacetheswitch
Replacetheswitch
Air escapes from the
discharge hole
Irregular
autorestriction of
distributor
Vibrationswhen
braking
Irregular operation of
stop lamp control
switch
94 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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793110 Duplex distributor
Aquila Trucks Centres
34953
98886
Figure29
Figure30
Troubleshooting
793332 Triple control servo distributor
Cutsoffthecompressedairflowtotheuserwhenthepressure
in thelatter reachesadeterminedvalue(set point).
Setting at the bench
Set theelement onthetest benchand connect fittings1and
2 through thepipesto thegaugeandtheair supply.
Correct to theprescribedvaluethrough theadjustingscrew
and at thesametimechecktheperfect seal of theunit.
Theunit, controlledbytwo separatecircuitsof theduplex
distributorandthetractorspringbrakecircuit, controlsthe
trailer braking. It is also equipped with a predominance
regulatingdevicefittedonthelower external part.
Theunit incorporates adevice to actuatethe trailer brake
should therebeafault inthecontrol pipe.
Predominance adjustment
Theunit isequippedwith apredominanceregulatingdevice.
2
1
PROBLEM POSSIBLECAUSE REMEDY
Pressure at the outlet
fittingis different to the
set value
Valvenot adjustedproperly.
Leaksfromtheseal rings
Faultypistonandrelevant seat
Adjust theunit
Overhaul theunit replacingdamagedcomponents
Replacetheunit
98887
Figure31
KNORR- BREMSEAC 597B WABCO 973009013
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PRINT603.93.641
793321 Pressure reducer
Aquila Trucks Centres
60255
60256
Figure32 Figure33
Troubleshooting
To adjust predominance for servo distributor KNORR -
BREMSE AC 597 B, perform the following sequence of
operations:
- Removescrew(2) fromsilencer body.
- Fit a setscrew wrench in the hole through the silencer
bodyandoperateonbodyhexagonal hole (1).
- RotateCLOCKWISE toincreasepredominance.
- Rotate COUNTERCLOCKWISE to decrease
predominance.
To adjust predominance for servo distributor WABCO 973
009013, performthefollowingsequenceof operations:
- Removescrews(1) and thenremovethecover (3).
- Operateonpredominanceadjustingscrew(1).
- RotateCLOCKWISE todecreasepredominance.
- Rotate COUNTERCLOCKWISE to increase
predominance.
PROBLEM POSSIBLECAUSE REMEDY
Leaksfromsealinggaskets.
Faultyexhaust valveandvalveseat.
Wrongpredominancevalue
Air leakagefromsealinggaskets
Wornor faultypistonsandseats
Strainedsprings
Wrongpredominancevalue.
Overhaul theunit andreplacefaultycomponents
Overhaul theunit andreplacefaultycomponents
Adjust predominance
Overhaul theunit andreplacefaultycomponents
Overhaul theunit andreplacefaultycomponents
Overhaul theunit andreplacefaultycomponents
Performpredominanceadjustment.
Air leakage from
exhaust when in resting
condition
Outlet pressures are
different from the
establishedvalues
96 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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KNORR BREMSE AC 597B WABCO973 009 013
Aquila Trucks Centres
Faultyexhaust valve, relevant seat or
seal ring
Worncontrol valve, seal ringsand
component control valve
Interferenceinsidethedistributor
PROBLEM POSSIBLECAUSE REMEDY
Air escapes fromthe
exhaust withcontrol lever
Inbrakingrelease
position
Inbrakingposition
It is difficult to turn the
control lever
Checkandoverhaul theunit, replacefaultycomponents.
Carefullycleanthecomponents.
Checkandoverhaul theunit, replacefaultycomponents.
Carefullycleanthecomponents.
Overhaul theunit andmoistenall theslidingparts.
52871
33987
Figure34
Figure35
T|o vos|oo o t|o 'Va|ab|o' |o |as a o||o. covo
.|ooas t|o vos|oo o t|o '/otoat|c' |o |as a oo covo
and asidesafetyridge (1). Safetyridges areusedto prevent
improper coupling.
793319 Check valve(towing vehicles)
Enables the compressed air to flow in the direction of the
arrowmarked onthe housingandpreventsreflux.
2 1
79514
Figure36
The device enables emergency and parking braking of the
tractor and thetrailer.
The device also enables the checkingof the tractor braking
effect.Thisoperation isnecessarywhenthevehicleisparked
onverysteeproads.
Troubleshooting
798510 Coupling heads 794310 Parking brakes control hand
distributor (for towing vehicles)
PNEUMATIC SYSTEM- BRAKES 97 TRAKKER EURO 4/5
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Aquila Trucks Centres
Figure37
Theunit, insertedinthetractor parkingbrakecircuit enables
theactuation of thevehicle emergencyandparkingbraking
dischargingtheair containedin thespringcylinders.
79515
PROBLEM POSSIBLECAUSE REMEDY
Wornpiston, exhaust valve, sealingrings.
Wornpistonandrelevant seal ring.
Wornplate, gasketsseal rings.
Interferenceinsidethedistributor.
Clean carefully, ensure that all therubber components and
relevant seatsareinperfect condition.
Overhaul theunit andreplacefault ycomponents
Cleancarefullyandcheckthecomponents, overhaul theunit
andreplacefaultyparts.
Clean the components carefully,check the seal and gasket
surfaces.
Ensurethat therubber componentsandrelevant seatsarein
perfect condition.
Overhaul theunit andreplacefaultyor worncomponents, if
necessaryrestorecontact surfaces.
Cleancarefullyandcheckall thecomponents.
Overhaul theunit andreplace fault ycomponents
Whenfittinginplace, slightlygreaseall slidingparts.
If faults or wear are found that coul d compromise the
functioning, replacethecompleteunit
Air leakage from the
discharge withdistributor
lever inbrakingposition
Air leakage from the
discharge withdistributor
lever in emergency or
parkingbrakingposition.
Air leakage from
distributor control lever
cover.
The distributor control
lever is difficult to turn
Troubleshooting
98 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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794310 Parking brakes control hand
distributor (stand-alone vehicles)
Aquila Trucks Centres
Figure38
Theapparatusallowsforreducingbrakingsystemintervention
timefor front axis(valveoftypeKNORRBREMSERP2A) or
rear axis (valveof typeKNORR- BREMSEAC 574AXY).
Troubleshooting
90402
PROBLEM POSSIBLECAUSE REMEDY
Leakagefromthedeliveryorfromtheseal
rings
Leakagefromthepistonseal ringsor from
theexahust valve
Overhaul theunit andreplacefaultycomponents
Overhaul theunit andreplacethefaultyparts
Air leakage from
exhaust with control
pipe in discharge
condition
Air escapes from the
discharge withsupplyin
the control pipe
Figure39
Theunit transmitstheforceimpressedbythecompressedair
when the brake pedal is pressed to the mechanical service
brakingdevice.Incaseoffailure,thecompletecylinderistobe
replaced(thefigureshows thedrumbrakesversion).
794911 Diaphragm brake cylinder
35798
KNORR- BREMSEAC 574AXY
PNEUMATIC SYSTEM- BRAKES 99 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
793331 Relayvalves
Aquila Trucks Centres
Figure40
Figure41
36744
Thisunit featurestwo parts: one withdiaphragmfor service
brakingand onewithspring for theparkingandemergency
brakingin thecaseof failureinthe brakesystem.
Ifit isnot possibletopneumaticallyfeedthespringsectionof
thecombinedcylinder (1) it ispossibletomanuallyrelasethe
brakingto permit towing. To release the brake loosen the
screw(2) totheendof itsstroke.
36745
Combined cylinder emergency relief device
794922 Combined brake cylinder REPAIR OPERATIONS
Figure42
Before removing the combined cylinder from the vehicle
manually release the braking of the combined cylinder as
described above.
!
Itisrecommended,before removal,tocarefullyclean
mudorother impuritiesfromexternal partsasthese
could damage the cylinder if theywereto infiltrate
into it.
Ifthecylinder springsectionisfaulty, do not remove
thispart sincethisoperation could bedangerousfor
theoperator.
PROBLEM POSSIBLECAUSE REMEDY
Air escapes from the
exhaust or from the
check ring.
Air escapes from the
diaphragmsectionfeed
Perforatedor brokendiaphragm.
Diaphragmlipbroken.
Checkringfasteningscrewshavebecome
loose.
Springsectioncomponentsarestrained.
Replacethediaphragm
Tightenthescrews
Overhaul theunit andreplaceworncomponents
36476
Troubleshooting
100 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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Aquila Trucks Centres
ANTI -SKID SYSTEM
ABS (Anti-Lock Brake System)
The braking of a moving vehicle and the conseguent
decelerationandstoppingdistancesdependaboveall onthe
gripbetween thesurfacesof the tyresand theroad.
Withafullyefficient brakingsystem,afurtherimprovementin
brakingcanonlybeachievedbyactingonthefrictionof the
tyres or onthegrade of theroad surface.
Whenfacedwithespeciallytrickysituations, suchaspoorgrip
due to a wet or icy road surface, the driver is forced to
moderateuseof thebrakesinorder toavoidpartiallylocking
oneor morewheels, withtheriskof skiddingdangerously.
T|o ooct|oo o t|o '/3S' |s t|oooo to oosoo vo||c|o
stability(inall brakingconditions),preventingthewheelsfrom
lockingirrespectiveof thestate of the road surface, so asto
ensuretheavailablegripismadefull useof.
Evenin the case of emergencybraking, the systemmakes it
possibleto keepdirection, that is to turnthe steeringwheel
to avoidobstacleswithno risk of skidding.
Inshort, theanti-lockbrakesystem(ABS):
- Preventsthewheelslockingwhenthevehicleis braking,
nomatter what gripisavailableontheroad.
- Shortensstoppingdistances.
- |ov|oos saot o t|o o|vo .|o cao 'oo t|o vo||c|o's
stabilityanddirection.
Inshort, theASR anti-slipregulator system:
- Preventsthedrivingwheelsslipping, bothonstartingand
when travelling, with differential brakingon the wheels
and, if necessary, optimizingtheengine torque.
- Keepsanoptimal valueoftractionwhenthevehicleison
roadswithalowgrip coefficient.
- Improves stability especially on bends with a low grip
coefficient.
- Limitstyre wear.
ASR (Anti-Slip Regulator) system
EBL (Electronic Brakes Limiter)
T|o |3| ooct|oo c|oc's t|o oa a|o .|oo| 's||', coa|o
it withthespeed of thewheelsof the front axle.
Thecontrol unit input dataarethewheel speed andbraking
pressuremeasuredbythepressuresensorinstalledupstream
fromtherear axle ABSmodulators.
On the basisof these values, the control unit calculates the
sooo o t|o vo||c|o, t|o oa a|o .|oo| 's||' aoo t|o
minimumdeceleration contemplated.
The EBL function is activated when the driver applies an
excessive braking force for the conditions of load on the
vehicle, therebyreducingthebrakingforce ontherear axle.
The driving wheels of an industrial vehicle slipping during
accelerationhasharmful consequences,suchasareductionin
the force of traction, loss of grip between tyres and road
surfacewithconseguent lossof control over thevehicle.
The function of theASR isto prevent undesired wheel slip,
both when acceleratingand on bends, especially on icy or
s||o oaos, o o 'o-oao' oso |o oo aoo .ato.
Figure43
Pressure sensor
InABS/EBLsystems,itsjobisto informtheelectroniccontrol
unit of theextent of actionrequired bythedriver.
InEBSsystems,thiscomponent isintegratedinthe front axle,
rear axleand trailer control valves.
52722
PNEUMATIC SYSTEM- BRAKES 101 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
Troubleshooting
FAULT POSSIBLECAUSE REMEDY
Air leakfromoutlet
duringbraking
Gasket oncontrol piston
Faultyexhaust valveor relevant seat
Overhaul theunit andreplaceworncomponents
Air leakage from
couplings
Not tightenedto prescribedtorque Tightencouplingsto specifiedtorque
Aquila Trucks Centres
Figure44
Figure45
32370
Theelectroniccontrol unit is thebrainof thesystem.
It controlsthesystemsolenoidvalveaccordingto thesignals
received fromthewheel revolutions sensor.
Eachchannel featuresfourfunctioncircuits;thefirstistheinput
circuit that receivestheanalogsignalsfromthesensor onthe
relevant wheel, theyare debugged and converted to digital
datathrough the measurement of the cycleduration. There
isalso amaincircuit whichhas amicroprocessor to process
theinformationreceivedfromtheinput circuit.
Themicroprocessorcontainsasophisticatedprogramthatenables
it to determine the wheel acceleration and deceleration values,
and to make the logic combinations of the various adjustment
signals.
When necessaryit sends out two command signals that are
sent to the relevant anti-lock distributor through the third
control unit circuit, to suitablyadjust thebrakingpressure.
Thefourthand last circuit isthesafetycircuit that checksthe
efficiencyof thevarioussystemcomponents.
In the case of a failure, it not only informs the driver by
switchingontherelevant warningindicatoronthedashboard,
but it also automaticallydisconnects theentire ABSsystem,
leavingtheconventional brakingsystemfullyefficient.
This component modulates the air pressure in the brake
circuit. Whentheelectroniccontrol unit detectsawheel witha
tendencytolock,thevalveinterceptsthebrakecylinderfeed,thus
preventingthewheel locking.
35805
526714 Brake anti-lock distributor
Thedevicebrakesthedrivingwheels, throughthebrakeanti-
locking modulator, whenever it detects slipping of one or
morewheels under traction.
Thevalveis anormallyclosedtype.
Whentheelectronic control unit detects slippingof oneor
moredrivingwheels, thevalveisenergizedandenablesairto
passtothebrakeanti-lockmodulatorsthat braketherelevant
wheels. The solenoid valve de-energizes when the wheels
reachthecorrect frictionvalueon theroadsurface.
Figure46
90143
Figure47
35383
The revolutions sensors and phonic wheels find the
revolutionsoftherespectivewheels.
Thephonicwheel ishousedonthewheel hubandturnsat the
same speed as the wheel. It generates in the sensors, by
induction, alternate voltages having a frequency that is
proportional to therotationspeed of thewheel.
Thesevoltagesignalsaretransmittedtotheelectroniccontrol
unit for processing. Each wheel has a sensor and a phonic
wheel installed. This enables individual adjustment of the
brakingpressurefor eachwheel, thusperfectingthedriving
stabilityandbrakingspace.
526713 Rpm sensors
566712 Phonic wheels
102 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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526711 Electronic control unit 526724 Electropneumatic valve for ASR
Aquila Trucks Centres
Figure48
1. Drybush - 2. Threadedhose- 3. Piston - 4. Washer - 5. Springsplit pin- 6. Pin - 7. Retainingplate- 8. Supportingplate-
9. Guidepin- 10. Guide bush - 11. Slidingpin- 12. Plug- 13. Draggingdevice- 14. Wear sensor - 15. Rear axle-
16. Chain- 17. Spring- -18. Cover - 19. Adapter - 20. Chaingear - 21. Adjustingdevice- -22. Cover - 23. Brassbush -
24. Slidingpin - 25. Slidingbush - 26. Inner protection - 27. Ring- 28. Brakelining- 29. Brakediscbody- 30. Lever -
31. Cambearing.
78396
84420
SEC. AA
9 8 3 1 2
6
5
7
3
4
2
1
26 27 29 24 25 23
22
21
20
19
16
18
17
15
14
13 12 11 10
A A
28 29
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5274 FRONT DISC BRAKES SN7TYPE
Aquila Trucks Centres
Brakingstage
Duringbraking, thediaphragmcylinder rodpressesdownon
thelever (30).
Theforceistransferred totheaxle (15) bythebearinginan
off - centeredposition(31)
Through thethreadedsleeves (2) andpistons (3), theforce
isconveyed totheinner brakinglining(28).
Oncetheplaybetweenbrakelinings(28) andbrakedisc(29)
hasbeenrecovered,theforceisconveyedtotheouter brake
lining(28), dueto brakecaliper displacement.
Thebrakelinings(28) pressingonthebrakedisc(29) produce
thebrakingpower.
Releasingstage
Assoonasthepressureonthebrakeisreduced,thepressure
spring(17),therearaxle(15) alongwiththreadedsleeves(2)
and lever (32) go backto their original positions.
Automatic playrecovery
The brake is equipped with automatic adjustment device,
which keeps the operatingplay between brake linings and
brakedisc constant.
Everytimethebrakeisoperated,theadjustment device(21),
whichisintegral withthelever (32), is automaticallystarted.
If worn brake linings and brake discs increase theoperating
play, theadjustment device (21) anddraglink(13) turnthe
threaded sleeves(2) so torecover saidincreaseinplay.
Theoperatingclearanceshouldbebetween0.6and1.1mm;
lower clearances might causeoverheatingproblems.
CHECKS
Checking the automatic play recoverysystem
efficiency
40570
Figure49
Remove the lock nuts and wheels, using hydraulic stand
99321024(1).
60759
78622
Figure50
Figure51
Remove the plug (4) using the tab (3) and make sure the
adapter (2) isnot lost.
Using a suitable wrench (1), rotate the adjustment pinion
counterclockwise by 2-3 with the adapter (2, Figure 50)
installedturns, thusincreasingtheplaybetweenbrakelinings
and brakedisc.
Operatethebrakes for about 5-10timesandmakesurethe
wrench (1) moves clockwise with small increments, up to
completerecover of playbetween brakinglinings and brake
disc.
Otherwise, i.e.ifthewrenchdoesnot turn,turnsjust onceor
turns in both directions, this means the automatic play
recoverysystemis faulty. Replace the caliper, followingthe
proceduregiven subsequently, thenfit back thewheels.
Never turn the adjustingpinion (1) without fitting
the adapter (2) first. If the adapter cut torque is
overcome, theadapter getsbroken.
Tryagainwithanewadapter andif alsointhiscase
it gets broken, the caliper should be replaced
because thereisan inner damage.
2
4
1
104 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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Operation (See previous figure)
Aquila Trucks Centres
Figure52
1. Combined brakecylinder - 2. Membranebrakecylinder - 3. Rubber bushes - 4. Slidingpins- 5. Plug- 6. Adjustingunit cover
- 7. Adapter - 8. Guidepin - 9. Cover - 10. Slidingpin - 11. Brassbushes- 12. Carryingplate- 13. Protectioncowling- 14. Ring
- 15. Inner seals- 16. Bushes- 17. Plungers - 18. Brakecaliper - 19. Guidepin- 20. Brakingseal - 21. Spring-
22. Split pin - 23. Washer - 24. Pintle- 25. Checkplate.
78628
PNEUMATIC SYSTEM- BRAKES 105 TRAKKER EURO 4/5
Print 603.93.641 3aso |ovobo 2006
PRINT603.93.641
SN7 brake caliper components
Aquila Trucks Centres
Figure53
1. Brake caliper - 2. Slidingbush- 3. Rubber bush- A. Bushpositionwith newseals- A
1
. Bush position withwornout braking
seals(performanaccuratecheckwithwheels dismounted).
78625
The condition of braking seals can be visually determined
without dismountingwheels, bycheckingthat A >1mm.
Otherwise, it isneededto dismount thewheelsandperform
anaccuratecheck as describedbelow.
106 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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SN7 brake calliper braking gaskets thickness check
Aquila Trucks Centres
40569
40570
Figure54
Figure55
Setthevehicleonflatgroundandlocktherearwheels.Loosen
thenuts(1) fixingthe front wheels.
Liftthevehicleatthefrontwithahydraulicliftandsetit ontwo
stands (2).
Unscrewthefixingnuts(1) and withtheaidof thehydraulic
trolley99321024 (1) removethewheels.
527417 Replacing brake linings
49157
Figure56
Remove thescrew (1) and the wear sensor cable retaining
plate(2).
49158
Figure57
Disconnect the electrical connection (1) fromthe calliper
body.
Removethesplitpin(2),pin(3)andbrakeliningretainingplate
(4).
78623
Figure58
Press( ) onthespring(1) andremoveit. Removethewear
sensors(2) fromthebrakelinings(3).
49160
Figure59
Remove the plug (3). Turn the adjustment device (1)
operatingontheadapter counterclockwisewithawrench,to
insert the pistons within the caliper bodyand extract brake
linings (4), suitablymovingthecaliper body (3).
Neveroperatedirectlyontheregistrationpinion(1)
without havingfirst of all fittedtheadapter (2). Ifthe
cuttingtorque of the adapter is exceeded, this will
break.
Testwithanewadapter.Ifthisalsobreaks,thecaliper
must bereplacedbecauseit is damaged.
NOTE
PNEUMATIC SYSTEM- BRAKES 107 TRAKKER EURO 4/5
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Aquila Trucks Centres
49161
Figure60
Removedirt andrust fromaroundtheedgeofthebrakedisc
withascraperor anoldscrewdriver (2) restingonthecalliper
body, turningthedisc (1).
Finish the job withabrasivecloth. Remove the remains with
theaidof anaspirator, or rags andabrush.
Do not use petrol or other petroleum products that could
causetroublefor thebrakes.
Useonlymethylatedspirit or isopropyl alcohol.
Carefullyclean thesurfaces of the brakingareaof the brake
disc.
Visually check the conditions of the dust caps, if
deformedor brokenit isnecessarytoreplacethem.
This requires removing the brake calliper, so it is
recommended to remove the brake calliper body
together with the bearing plate for a thorough
overhaul.
Check that thecalliper slidesfreelyonitsguides.
If youfindanytroubleon asingle brake calliper it is wiseto
overhaul both brakecalliperscompletely.
Remove the dirt fromthe brake calliper with awire brush,
without damagingthedust caps.
Cleantheslidingsurfacesof thebrakelinings.
Checktheconditionsofthebrakediscandmakesureit isnot
corroded, scored or grooved. Light surface cracks are
acceptable, but it is necessary to grind the brake disc as
described under the relevant section heading. On the
contrary, if it isworn, replacethebrakedisc.
If one needs to be replaced, it is recommended to replace
bothbrake discs.
Checkthestateofthespringsandwearsensors,replacethem
ifnecessary.
49162
Figure61
Insert thewear sensor (2) into itsseat onthebrakelining(3).
Mount the spring (1) in the opposite sequence to that for
disassembly.
49163
Figure62
Insert thenewliningsinthebrakecalliper (1) andcheckthey
slide freelyin their seats.
!
If you find it necessaryto replace thepair of brake
linings, always replace themwith a full set for each
axle.
78624
Figure63
Usingthewrench(1),actontheadaptatorretrieverpintoget
aplaynotlowerthan0.7mmbetweenbrakeliningandbrake
disk, which can be measured usingthe thickness gauge (2).
Replace the cover (4) and lubricate it with white grease
RENOLIT HLT2.
NOTE
108 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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Aquila Trucks Centres
49158
Figure64
Maketheelectrical connection(1) andsecureittothecalliper
body.
Mount theplate(4), pin(3) andsplit pin (2).
Makesuretheexternal safetyplugandtheseal are
fitted properly in order to prevent water getting
insidetheautomaticclearancerecoverydevice.
49165
Figure65
Mount thewear sensor cableretainingplate(1).
Usingthehydraulictrolley99321024,fit onthewheels.Lower
thevehicle. Lock the nuts fixingthe wheelsto therequired
torque.
Fit thesafetycaponto thewheel hubs.
Proceedasdescribedontheoppositeside.
After repairing the vehicle brakes, press the brake pedal
repeatedly, whilethevehicleis moving, inbothdirections, in
order to wear inthebrakelinings.
49166
Figure66
Toremovethebrakelinings,keeptotheabovedescriptionin
theparagraphfor replacingbrakelinings.Removetheclamps
(2). Disconnect thediaphragmcylinder supplypipe(1).
Unscrewthenuts(4) andremovethediaphragmcylinder (3).
49167
Figure67
Removethescrews(3) anddisconnect thebrakecalliper (1)
together withthebearingplate (2).
Takecarewhenremovingandcarryingthecalliper(1)
asit isheavyandfloats onthebearingplate(2).
Refitting
For refitting, carry out the steps described for
removal in reverse order, keepingto the required
tighteningtorques.
Before inserting the diaphragm brake cylinder,
spreadthecapinthebrakecalliper operatinglever
withRENOLIT HLT2 whitegrease.
NOTE
NOTE
PNEUMATIC SYSTEM- BRAKES 109 TRAKKER EURO 4/5
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527413 Removing and refitting brake callipers
Removal
Aquila Trucks Centres
Figure68
77206
Arrangeanoil recover collector asaprecaution.
Rotate hubsoasto takeplug (1) downwards.
Unscrewthepluganddrainoil into thecontainer.
36407
Blockrotationofthewheel hubsuitablyandwiththewrench
99354207(1) unscrewtheoil cover (2).
36408
Undothesafetyscrew(3).Withthewrench99388001,unscrew
the adjustment ring nut (2), remove the washer (4), outer
bearing(1) andremovethebrakedisctogether withthewheel
hub, spacer andinternal bearing.
38596
Visually check the diameter of the gasket ring (1) has no
accidental dents or scratches.
Replacetheinternal gasketsofthe wheel hubsand,ifnecessary,
t|o |o (+), 'oo|o to t|o oosc|t|oo |voo |o t|o '|oot a|o'
section.
Usingtheadjustment ringnut, checkthat thethread(2) hasno
stiffness.Ifithas,useappropriatemeanstogetridofthestiffness.
Removetheoppositebrakeassembly, keepingthecomponents
separate.
Refitting
Makesurethesurfacesofall thepartsinsidethehub
arethoroughlyclean, withno wasteor burrs.
LubricatethebearingswithTutelaW 140/MDA oil.
Keythewheelhubonthestubaxletogetherwiththe
brakedisc. Insert the internal spacer onto the stub
axle then position the external bearing and thrust
washer.
Screwdownandlocktheadjustment ringnut tothe
requiredtorque.
36411
Strike the wheel hub a few times with a mallet in an axial
direction, turnit inbothdirectionstofreethebearingrollers.
Fit themagneticbase (1) together withthedial gauge (2) on
thewheel hub. Set thepointer of the dial gauge (3) at right
anglesto theshankof thestubaxle.
Reset thedial gaugewithapre-load of 1.5- 2 mm.
With the aid of a lever, move the wheel hub axially and
measure the end float, which must be0.16 mm(maximum
value).
On obtaining the required end float, lock the screw (5)
retainingthe adjustment ringnut (4) to therequired torque.
Figure69
Figure70
Figure71
Figure72
NOTE
8
110 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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520620 Removing and refitting wheel hubs
Removal
Aquila Trucks Centres
36412
Figure73 Figure74
Tightento torquethehub cover (1, Figure74).
Deposit asealingbead(Loctitetype574) exclusively
on the hub cover ledge surface and protect the
threadedpart.
Rotatethewheel hubuntil whenhubcover (1) ispositioned
asshowninthefigure.Restoretheprescribedquantityof oil
intothehubcover (1) throughfillinghole(2).Tightentheplug
onthehubcover (1) to theset torque.
79068
Applytool (1) 99395026 on wheel hub stud bolts and use
torquemeter 99389819(2) tocheckwhetherthewheel hub
rollingtorqueisat theset value.
PNEUMATIC SYSTEM- BRAKES 111 TRAKKER EURO 4/5
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79121
79123
79122
79124
79125
Figure75
Figure76
Figure77
Figure78
Figure79
Placethebrakecaliperonthebenchandblockit inavice.Remove
thecover (1) and makeaholeinit with aParker screw.
Refitthesupportingplate(1) andremovethefasteningscrews
(2).
Removetheslidingbushes (1).
Use tool 99372245 (2) (to be used with screw in tool
99372237) to disassembletherubber sleeve (1).
Takethe caliper to thepress.
Insert the appropriate beater in the brass bush housing(1)
(SeearrowA). Usethepressto removethebush (1).
SN7 BRAKE CALIPER OVERHAUL
Disassembly
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60742
Figure80
Placethecaliperonthebenchandblockit inavice.Usethe
wrench(4) tooperatetheclearancerecoverydevicesothat
thepiston(1) comesout ofthecaliper bodyforamaximum
of 30 mm(valueA).
Takeoff thedust-guard fromthecaliper bodyand usetool
99372238 (5) to removethe thrust pressingdevices (1) of
thecaliper together withtheprotection casings (3).
Component part cleaning and check
To wash metal parts, use asolution of hot water with Fiat
LCD detergent. Use ametal brushto removedirt fromthe
caliper bodyandthenalittlebrush to remove theresiduals
and to clear accurately the guide pin and the slidingbush
housings.
Useasynthetic brush withthe right dimensions to remove
thegrease left on the slidingbush housings.
Cleanthecaliper bodyaccuratelywithcompressed air.
Useapieceofclothsoakedwithisopropyl alcohol orsimilar
to cleantheslidingbushes accurately.
Check the wear conditions of the slidingbushes and their
housingsonthebrakecaliper body. Makesuretheyarenot
damaged or worn, especially the sliding surfaces. Fit the
bushes intheir housingsandcheck theyslideregularly.
Fit the bushes in their housings, check they slide correctly,
otherwise replace or restore their housings on the caliper
body, if needed.
ValueA must not beovercomebecause threaded
hoses (2) are synchronised. If the threaded hoses
(2) reachtheir over-travel,theyloosesynchronism
and thebrakecaliper must bereplaced.Thebrake
caliper inner partsmust never be removed.
For this reason you are recommended non to
slacken or to removethecover retainingscrews..
Regular braking depends mainly on the brake
caliper slidingontheguidepins.
Checkthewear conditions of thebrakeliningretainingpins
and the related safetypins. If they are worn or damaged,
replacetheworn parts.
It is advisableto replaceall rubber andplasticparts and the
brass bush even if theydo not seemdamaged or worn at
sight.
Assembly
Make sure all the brake caliper components are perfectly
clean. Possibleabrasiveresiduals shouldberemoved witha
clothsoaked in isopropyl alcohol or similar.
79126
Figure81
Use tool 99372239 (4) (see figureA) to fit the protection
casings (2). Use the same tool 99372239 (4) fitted on the
other side (see figure B) to insert the pistons (1). Use the
wrench(3) tooperatetheclearancerecoverydeviceandad
just thepistons (1).
Figure82
79127
Use tool 99372244 (2) (to beused with the screw in tool
99372237) to assembletherubber sleeve (1).
NOTE
NOTE
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PRINT603.93.641
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79128
79129
79130
Figure83
Figure84
Figure85
Figure86
Usetool 99372243(1) (tobeusedwithtool 99372240and
usescrewintool 99372237) to assemblethebrassbush(2)
initsseat,byblockingitsrotationbymeansof asuitabletool
(3) (punchor screwdriver).
Placethecaliperunderthepress.Usethepresstofitthebrass
bush(1) initshousinguntil iscomesout ofthelowersideby
1 mm.
Usethetool 99372242(2) tocarryout bruisinginthepoint
( ) next tothecaliperbodygroove,inordertopreventthe
brassbush(1) frommoving.
Makesuretherearenoburrsinthebushhousing,otherwise
remove them. Applywhite grease RENOLIT HLT2 on the
bush.
Placethecaliperonthebenchandblockit inthevice. Fit the
protectioncasing(2) bymeans of tool (1) 99372237.
Reversetheremoval order to fit the slidingbushes
and thesupportingplate.
60745
NOTE
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35707
Figure87
- Keyonto theshaft of thelathe 99301001(2) thebrake
disc (1) together withthe hub.
- Keyontotheshaft aset ofspacersthat eliminatetheend
float oftheassembly;screwonthelockingnutandfitthe
mount of thelatheshaft.
- Positionthetoolholder (3) inlinewiththebrakedisc(1),
then adjust thedepth of thetools.
- Proceed with turning and grinding the brake disc (1),
operatingwithone or morepassesto removematerial
dependingonthescoringfound.
During grinding, proceed gradually, advancing the
wheel in sectors to remove the turning remains
entirely.
71848
Figure88
Remove the wheel.
Fit thetool 99301005(1) onto thewheel hub.
Proceed with turningandgrindingthe brakedisc.
527411 TURNING AND GRINDING BRAKE
DISCS ON THE BENCH
527411 TURNING AND GRINDING
BRAKE DISCS ON THE VEHICLE
38597
Figure89
527411 OVERHAULING BRAKE DISCS
Examinethestateof wear of thesurfaces ofthebrakediscs.
Findingother valuesto theones given in thecharacteristics
and data, turn and grind the brake discs or, if necessary,
replacethem.
Removethescrews(1) anddetachthehub(2) fromthedisc
(3). Replace the disc (3) and refit it following the reverse
procedureto theone described above.
NOTE
For regular braking, always replaceacomplete set
of disks per axle.
NOTE
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Figure90
MERITORDUO-DUPLEX DRUMBRAKE
DIRECTION OF TRAVEL
71781
SECT. A-A
5272 DRUM BRAKES
116 PNEUMATICSYSTEM- BRAKES TRAKKEREURO 4/5
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Set thevehicleonlevel ground.Takethecoversoff thenuts
fixingthewheel and loosen the nuts.
Lift the vehicle fromthe concerned side, then place it on
special stands.
Position the hydraulic trolley 99321024 under thewheels.
Takeout the nuts fixingthewheels andtakethemoff.
40510
Figure91
Disassembly
Fullyunscrewthemanual brakingscrew(2) ofthecombined
cylinder (1).
Figure92
Figure93
39951
71782
Takeout thescrewsfixingthebrake drum(1) to thewheel
hub (2). Screw two appropriatescrews ( ) into theholes
inthedrumandtakethis out of the wheel hub.
Figure94
40513
Disconnect the electrical connection (1) for the cable
signallingbrakeliningwear.
Figure95
40514
Takeout the shoe returnsprings (2).
Remove the top shoe (1).
Brakingassemblyoverhaul wasperformedonrear
brakes.
NOTE
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5272 DUO DUPLEX DRUM
FRONT/REAR BRAKES
Aquila Trucks Centres
Figure96
71783
Freethebrakewearindicator cable (1) fromtheclipsofthe
brake plate (3) and take the cable out of the guard (2).
Remove the bottomshoe (4).
Figure97
71841
Disconnect thepipes(3and4) fromthefittings(5and2) and
removethesefromthecombinedcylinder (1).Usingwrench
99356006, loosen the fixing ring nut. Turn the combined
cylinder (1) anticlockwise, removeit fromthebrakebody.
Figure98
71842
Disconnect thepipe(1) fromthefitting(2) andremovethis
from the diaphragm brake cylinder (4). Using wrench
99366006,loosentheringnut(3).Turnthediaphragmbrake
cylinder (4) anticlockwise, removeit fromthebrakebody.
Figure99
40517
Extract the wedge-shaped control unit (1) fromthe brake
body(2).
Figure100
71791
Unscrew the guide pins (2) and take themout. Extract the
adjustment unit (1) together with the thrust pin fromthe
brakebody(3).
Figure101
71789
Unscrew theguidepins(2) and takethemout.
Extract thereactionpin(1) togetherwiththethrust pinfrom
thebrakebody(3).
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Figure102
71790
Checkthestateofwearofthepinseatsonthebrakebody(1),
iftheyarescoredor excessivelyworn, replacetheabnormal
brakebodies.
Examinethewear of thedrumsto decideontheir reuse.
Measure the diameter of the drums with a sliding gauge
without anglingthearms.
Measurethediameterat several pointstoestablishroundness
and wear, also consideringthe depth of the scoringon the
brakingsurface.
Admitted tolerance on roundness and/or eccentricity 0.25
mm.
Ifyoufindsuchwearor scoringasnot topermit restoringthe
braking surface by turning, or clear signs of overheating,
replacethedrum(seeCharacteristicsandDatatable).
Check the state of the brake shoes and replace them if
cracked.
Ifthebrakingsurfaceoftheliningsshowssignsof grease, you
need to findthecauseandeliminate it.
Theminimumadmittedthickness of the brakeliningsis6.95
mm.
If you findalower or slightlyhigher value, replacethem.
Check theintegrityand/or efficiencyof thebrakeliningwear
signal cable.
Checktheintegrityand/orefficiencyoftheshoereturnsprings.
Figure103
38357
Disassembletheautomaticadjustment unit.
Unscrewtheadjustment bushes(3) fromtheadjustmentpins
(2) and thenremovetheseals(1).
Checkthewearconditionoftheadjustmentbushouterhelical
toothingandcheck whether bushesareslidingfreelyon the
relevant adjustment pinswhenscrewing.
Figure104
38360
Check the condition of the pressure pin teeth (3), of the
relevant compressionsprings(2) andof thecopper washers
(1).
Figure105
71786
Take seal (1) off thrust pin (2). Check wear conditions for
thrust pin(2) andsurfacesofsloping planes(3) subjectedto
theoperationof shoe openingdrive rollers.
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!
Couplethebrakeliningssuitableforeachdrumaccording
totheoversizing.
Each vehicle axle must be fitted with linings of the
same type.
Fit tool 99372213 (2) into thebrakedrum.
Fit thiscombinedunit onto thelatheshaft 99301001(3).
Fitasetofspacersontheshafttoremoveunitendplay,tighten
thelocknut and placethelathesupport.
Fit theantivibrationbandonthebrakedrum.
Turnthedrums bystages, removingthe amount of material
necessaryto correct theimperfections found.
After turningremovethedrumbrake and carefullycleanit.
40520
Measurethedrumdiameters usingagaugewithout bending
the arms, find thediameter inseveral points to establishthe
ovalityandwear.
!
Themaximumdiametral oversizingadmittedfor the
drumisindicated onthedrumitself.
Thislimit must not for anyreason be exceeded as it
would jeopardize the brakingeffect and the drum
resistancecharacteristics.
527231 Drum turning
Figure106
Set thecontact pin (5) onthepressmovingsupport (4).
Rivet thebrakelinings(3) onto theshoes(2) withthebeater
(1) fittedinthepresstoolinghead.
To rivet the brake linings correctly start in the
centre, graduallyextendingto thebrakingsectors.
77085
17256
Figure107
Figure108
Remove the worn brake linings from the shoes with
compressed air press99305087 (1).
Set thecompleteshoes (4) onanadjustablestand(5).
Withachisel (2) inthepresstoolinghead(1) shear therivet
heads (3).
Eject therivets fromtheshoes.
Carefullywashandblow theshoesto cleanthem.
Fromthe lower shoes open cliptabs (6) releasing
thebushing(7).Nowremoveliningwearsensor(8)
and associatedcable.
527233 Replacing brake linings
Mount seal wear cable inverting operations described for
dismounting.
35713
Checkthat thewedgeunitsslideeasilyandthat thereareno
abrasions.
!
If wear is found on the wedge components the
completeunit must bereplaced.
Figure109
NOTE
NOTE
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38364
Figure110
Assembly
Fit theseals(2) ontheunitsoftheadjustment pins(1).Grease
thethreadof thepins(1).
Fully screw down the adjustment bushings (3) and grease
themthoroughlyontheoutsidediameter.
Greasetheinsidediameter of thethrust pins(4).
!
Whenrepairingthe brakes, replacetheseals of the
reactionand thrust pins.
To lubricate the components, use Rockwell RBSK
0253grease.
71788
Figure111
Greasetheinsideofthebrakebody(5).
Mount the thrust pin - seal assembly(6) withtheslot facing
theguidingpin(4).
Insert thethrust pin(7) intothebrakebody(5) andinsertthe
adjustment pin - seal - adjustment bushingassembly (1).
Turning brake linings Figure112
71849
Fit thehub99372228(2) ontheshaft ofthelathe 99301001
(1).Fit theplate99372230(3) onthehub(2) andsecurethe
ba'o ||o|os (+), a'|ot|o.oo| o '/|CC|+5' co|oc|oo
asshownin thefigure. Turnthebrakelinings.
71786
Greasetheseal (1) andfit it onthethrust pin (2).
Figure113
!
Takegreat caretoobservetheassemblyorderofthe
pinsthat hasto beasillustrated in Figure111.
Greaseandinsert theguidepinassemblies (4) into theseats
onthebrakebody(5).Checkthewashers(2) areinsertedand
screwdownbyafewturns.
Theguidepins(4) need tobemountedso that the
tips (3) slide in the seats of theholes in the brake
body(5).
NOTE
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Figure114
Figure115
71787
Usingthekey99373002(1),drivethemetal ringsof theseals
onto thebrakeassembly (2).
71784
Figure116
40524
Figure117
Usingdevice99301006(2), turnthebrakelinings(1).
71785
Connect theliningwear indicator cableelectrical connection
(2) helpingthefixingnut ontheshoe. Fit theshoes(1) inthe
seat.
Hook on the shoe return springs with the aid of tool
99372211(3).
Unscrewtheadjustmentunit(1) tothesameextenttoobtain
the diameter A, 2 mmless than the diameter of the brake
drumto mount.
Figure118
Figure119
40530
Greasethewedge-shapedcontrol unit (1). Insert it initsseat,
takingcarethat the rollers ( ) arepositioned in the sliding
race.
36757
Screwtheringnut (1) byhandontothesleeve(2) asfarasit
will go.
Applynon-hardeningsealant type LOCTITE573 onthefirst
fewthreads of thesleeve (2).
122 PNEUMATIC SYSTEM- BRAKES TRAKKER EURO 4/5
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Figure120
71841
Screwthecombinedcylinder (1) fullydowninto itsseat.
Check that the holes for the supplyfittings are in the same
position found on removal; if they are not, unscrew the
combinedcylinderappropriately.Mount thefittings(2and5)
andconnect thesupplypipes(3and4).Supplythediaphragm
sections of the combined cylinder by applying the service
brake.Withthewrench99356006,tightentheringnut tothe
requiredtorque.Connectthebrakeliningwearindicatorcable
electrical connection.Restoretheoperationofthecombined
cylinder (1) screwingdownthe screw(2, Figure119) fully.
Figure121
39941
Screwtheringnut (1) byhandontothesleeve(2) asfarasit
will go.Applynonsettingseal pasteofLOCTITEtype573on
thefirst threethreads of pipe (2).
71842
Screwthediaphragmbrakecylinder (4)fullydownintoitsseat.
Checkthat theholeforthesupplyfittingisinthesameposition
found onremoval; if it is not, unscrewthediaphragmbrake
cylinder (4) appropriately. Mount the fitting (2) on the
diaphragmbrakecylinder (4), hookupthesupplypipe (1).
Supplythe brake cylinder byapplyingthe service brake and
withwrench99356006tightentheringnut(3) totherequired
torque.
Figure122
Figure123
Mount thewheelsandtightenthefixingnutstotherequired
torqueaccordingto thediagramshowninthefigure.
Mount theoppositebrakeassembly.
Stat t|o vo||c|o's oo|oo aoo oo |t o a so|c|oot| |oo t|o
to fill thesystem.
Brakerepeatedlyto wear inthe brakeassemblyandrecover
theclearancebetweenthebrakeliningandthedrumwhenthe
vehicleisrunning.
60229
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BODYWORKANDCHASSISFRAME 1 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Print 603.93.371
SECTION 14
5501 Bodywork
5001 Chassis frame
Page
CAB 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General information 7 . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 8 . . . . . . . . . . . . . . . . .
REPAIR OPERATIONS 13 . . . . . . . . . . . . . . . . . . . .
BUMPER 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABIN 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal the cabin 14 . . . . . . . . . . . . . . . . . . . . . .
- Refitting 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE FRONT SHOCKABSORBER 19 .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE CABSUSPENSION FRONT
MOUNTING RUBBER-TYPEBUSHINGS 19 . . . .
- Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGCABFRONT UPPERSUPPORT
BUSHINGS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
|||CV||C ||||TT||C T|
STABILIZER BAR 20 . . . . . . . . . . . . . . . . . . . . . .
- Removal 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
2 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Page
REPLACINGREARCAB
SUSPENSION DAMPERS 22 . . . . . . . . . . . . . . . . .
- Removal 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE TRANSVERSE
TIE ROD BUSHINGS 22 . . . . . . . . . . . . . . . . . . . .
- Removal 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembling/reassemblingthebushings 22 . . . . .
- Refitting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVELLING VALVE 23 . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGINGTHECABLOCK 23 . . . . . . . . . . . . . . .
- Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABTILT CYLINDER 23 . . . . . . . . . . . . . . . . . . . . . .
REPLACINGHYDRAULIC
CABTILT CYLINDER 23 . . . . . . . . . . . . . . . . . . .
- Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checkingoil level 25 . . . . . . . . . . . . . . . . . . . . . .
- Bleedingcabtilt system 25 . . . . . . . . . . . . . . . . . .
- Cabmechanic suspension 26 . . . . . . . . . . . . . . . .
- Cabdrivingposition adjustment 26 . . . . . . . . . . .
- Cabpneumatic suspension 27 . . . . . . . . . . . . . . .
- Adjustingthelevellingvalvelinkage 27 . . . . . . . . .
REPLACINGTHE WINDSHIELD 28 . . . . . . . . . . . . .
- Removal 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE WINDINGWINDOW 29 . . . . . .
- Removal 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
REPLACINGTHE WINDOW
WINDER 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE DOORLOCK 31 . . . . . . . . . . . . .
- Removal 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHEOUTSIDE HANDLEOF THEDOOR 32 .
- Removal 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHEINSIDE HANDLE 32 . . . . . . . . . . .
- Removal 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHESIDEMIRRORS 33 . . . . . . . . . . . . .
- Removal 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHEDOOR 33 . . . . . . . . . . . . . . . . . . .
- Removal 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE FIXEDWINDOW 34 . . . . . . . . . .
- Removal 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Preparingthewindowbay 34 . . . . . . . . . . . . . . . .
- Preparingthewindow 34 . . . . . . . . . . . . . . . . . . .
- Refitting 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL 36 . . . . . . . . . . . . . . . . . . . . .
- Removal 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTRAL SWITCH DASHBOARD 36 . . . . . . . . . .
- Removal 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROTECTIONS 37 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 3 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Page
WINDSCREEN VISORROLLING DEVICE 40 . . . . .
- Removal 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSCREEN SUN VISOR REEL MOTOR
REPLACEMENT 41 . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRINTAKE LID 42 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRINTAKE LID MOTOR
REPLACEMENT 42 . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGSIDEDOOROPENING
CONTROL CABLE(AT VEHICLES) 43 . . . . . . . .
- Removing 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Lidopeningcontrol cableadjustment 45 . . . . . . .
|||V||'S S|/T +6 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Component layout 47 . . . . . . . . . . . . . . . . . . . . .
|||CV||C T| |||V||'S S|/T +8 . . . . . . . . . . . .
- Removing- refittingthecushion 48 . . . . . . . . . . .
- Removing 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingcushion slidingblocks 48 . . . .
- Removing 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheseatbelt 49 . . . . . . . . . . .
- Refitting 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Removing- refittingseatbelt connectionandright-hand
sideupholstery 49 . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheleft-hand
sideupholstery, IPSvalveand
heatingswitch 50 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- Refittingtheback 50 . . . . . . . . . . . . .
- Removing 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- Refittingtheback
adjustment lever 51 . . . . . . . . . . . . . . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheheight adjustment
device 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheseat angle
adjustment device 51 . . . . . . . . . . . . . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- |oov|o |o|tt|o t|o |o|b|o cab|o o t|o
shockabsorber adjustment device 51 . . . . . . . . . .
- Removing 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- |oov|o |o|tt|o t|o bac' ao,ostoot |ovo
segment 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheair spring 52 . . . . . . . . . . .
- Removing 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheshock absorber 52 . . . . . .
- Removing 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
4 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Page
- Removing- refittingtheheight
adjustment valve 53 . . . . . . . . . . . . . . . . . . . . . . .
- Removing 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheheight
lockingsystem 53 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingtheflexiblecableof the
horizontal lever suspension 53 . . . . . . . . . . . . . . .
- Removing 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthefast loweringmagnetic
valve 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthefast loweringswitch 54 . .
- Removing 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthelumbar
support device 54 . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthebackupholstery 55 . . . . .
- Removing 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing- refittingthecushionupholstery 55 . .
- Removing 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
|||V||'S S|/T |||||/T|C SC||| 56 . . . . . . . .
|/SS||C||'S S|/T |||||/T|C ||/C|/| 5 . .
CABIN REFRIGERATOR 58 . . . . . . . . . . . . . . . . . . .
- Preliminarychecks 58 . . . . . . . . . . . . . . . . . . . . . .
Page
- Removal 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING 59 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fan removing 59 . . . . . . . . . . . . . . . . . . . . . . . . .
- Removingtheanti-tippingprobewith
electroniccircuit onthecontrol unit 59 . . . . . . . .
- Electroniccontrol unit disassembling 60 . . . . . . . .
- Checks 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABAIR-CONDITIONING 61 . . . . . . . . . . . . . . . . .
- General 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VENTILATION 61 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description 61 . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR-CONDITIONING ANDHEATING 62 . . . . . . .
- Description 62 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Air-conditioning 62 . . . . . . . . . . . . . . . . . . . . . . .
- Heating 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Air-conditioningcontrolsassembly 62 . . . . . . . . .
- Manual 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Heatingandventilation 62 . . . . . . . . . . . . . . . . . .
COMPONENT LAYOUT (WEBASTO AIR
CONDITIONER) 63 . . . . . . . . . . . . . . . . . . . . . . .
HEATERASSEMBLY COMPONENT LAYOUT
(WEBASTO) 64 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Outsidetemperaturesensor 65 . . . . . . . . . . . . . .
- Compressor 65 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Condenser andsafetypressureswitches 66 . . . . .
- Stepper motors 67 . . . . . . . . . . . . . . . . . . . . . . . .
- Evaporator temperaturesensor 68 . . . . . . . . . . . .
- Expansionvalve 68 . . . . . . . . . . . . . . . . . . . . . . . .
ADDITIONAL AIRHEATER SYSTEM
(ON REQUEST) 69 . . . . . . . . . . . . . . . . . . . . . . .
- Description 69 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 5 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Page
FAULT DIAGNOSIS 70 . . . . . . . . . . . . . . . . . . . . . . .
- Troubleshooting 70 . . . . . . . . . . . . . . . . . . . . . . .
- Introduction 70 . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY AIRHEATER 74 . . . . . . . . . . . . . . . . . . .
GENERAL WARNINGS 75 . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 75 . . . . . . . . . . . . . . . . . .
REPAIR OPERATIONS 76 . . . . . . . . . . . . . . . . . . . . .
HEATER 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADDITIONAL AIRHEATER SYSTEM 77 . . . . . . . . .
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRRECIRCULATION DOOR
CONTROL MOTOR 77 . . . . . . . . . . . . . . . . . . . .
- Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC FAN 78 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATERRADIATOR 78 . . . . . . . . . . . . . . . . . . . . . .
- Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAP 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POLLEN FILTER 80 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
AIR-CONDITIONERCOMPRESSOR 80 . . . . . . . . .
- Removal 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR-CONDITIONERCONDENSER 81 . . . . . . . . . .
- Removal 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTSIDEAIR TEMPERATURESENSOR 81 . . . . . . .
- Removal 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACINGTHE ELECTROMAGNETIC CLUTCH 82
PROCEDURE FOR DRAININGANDRECHARGING
AIR CONDITIONINGSYSTEMSWITH
RECHARGINGSTATION 99305146AND
RECOVERY OF R134A COOLANT 84 . . . . . . . .
SAFETY STANDARDS 85 . . . . . . . . . . . . . . . . . . . . .
CONTROL FASCIA 86 . . . . . . . . . . . . . . . . . . . . . . .
OPERATION FLOW CHART 88 . . . . . . . . . . . . . . .
RECOVERINGREFRIGERANT
FROMTHEVEHICLESYSTEM 89 . . . . . . . . . . . .
CREATINGA VACUUM IN THE SYSTEM 91 . . . . .
RESTORINGOIL IN THESYSTEM 93 . . . . . . . . . . .
FILLINGTHE SYSTEMWITH REFRIGERANT 94 . . .
CHECKINGTHE PRESSURESIN
THESYSTEM 96 . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATIONSPRIORTO DISCONNECTING
THESTATION FROMTHESYSTEM 96 . . . . . . .
PROCEDURE FOR DRAININGANDRECHARGING
AIR CONDITIONINGSYSTEMSWITH
RECHARGINGSTATION 99305148AND
RECOVERY OF R134A COOLANT 97 . . . . . . . .
- Maincomponents 97 . . . . . . . . . . . . . . . . . . . . . .
SAFETY STANDARDS 98 . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL 99 . . . . . . . . . . . . . . . . . . . . . . .
- Keypad functions 99 . . . . . . . . . . . . . . . . . . . . . . .
- Emergencywarninglight panel 99 . . . . . . . . . . . .
Aquila Trucks Centres
6 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Page
PRELIMINARY CHECKS 100 . . . . . . . . . . . . . . . . . . . .
AUTOMATIC PROCEDURE 100 . . . . . . . . . . . . . . . .
ASSISTED PROCEDURE 102 . . . . . . . . . . . . . . . . . . .
LEAKFINDER FOR AIR-CONDITIONING
SYSTEMSWITH HFC
R134A (99305147) 104 . . . . . . . . . . . . . . . . . . . . .
CHASSISFRAME 105 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENINGTORQUES 105 . . . . . . . . . . . . . . . . . .
REPAIRS 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKS 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuringthebendof thechassis frame
downwardsor upwards 107 . . . . . . . . . . . . . . . . .
- Measuringthesidebendof thechassis frame 107 .
- Measuringthemovement ofthechassisframe 107
- Measuringthetorsionofthechassisframe 108 . . .
PRECAUTIONS 108 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Welds onthechassis frame 110 . . . . . . . . . . . . . . .
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 7 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
CABTYPE CABLENGTH
LOW
ROOF
INTERME
DIATE
HEIGHT
ROOF
AT
LONG
(2280x2100mm)
F F
AD
SHORT
(2280x1660mm)
F
MAIN DATA
DESIGNATION
Cabinwith mechanic suspension
Front suspension made up of:
- stabilizer bar 1
- shockabsorber with coaxial cylindricspringwith adjustingdevice 2
Rear suspension madeup of:
- shockabsorber with coaxial cylindricspringwith adjustingdevice 2
- elastic pads 2
Cabinwith pneumaticsuspension, madeupof:
- stabilizer bar
- shockabsorber with coaxial air spring 1
- levellingvalve 2
Rear suspension madeup of:
- shockabsorber with coaxial air spring 2
- levellingvalve 1
Levellingvalve
- KNORR- BREMSE:
- front, typeSV1490 - K000264 2
- rear, typeSV1491- K000661 1
Workingpressure 8.5 bar
Minimumpressureassured 0,5 bar
+0.8
- 0.2
Lever workingmaximumtravel 20
- KNORR/BREMSE SV 1490-K0002464 (front and rear)
Workingmaximumpressure 8.5 bar
Guaranteed minimumpressure
0,5 bar
+0.8
- 0.2
Lever maximumworkingtravel 20
TOOLS
TOOL NO. DESCRIPTION
99346051 Cabin front suspension bracket rubber bush
disassembling/assemblingtool
99378039 Cabin removal-refittingswingbar
Thecabisofanadvancedtype,hydraulicallytiltingbymanual
control.
Tiltingangle60 .
Constructionin pressed and welded steel.
Protection: Boxopeninganticorrosiveprotection.
Door and outer panel inner side framework coated with
galvanisedmetal sheet.
General information
5501 CAB
Cabsuspension type:
- mechanic
- pneumatic on request onlyonAT.
Aquila Trucks Centres
99119
Figure1
CABSUPPORT FOR VEHICLES4X2- 6X4
8 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Nut
Screw
226.5 22.5
278 28
22.6 2.2
27.8 2.8
2 Nut 226.5 22.5 22.6 2.2
3 Nut
Screw
179 18
146.5 14.5
17.9 1.8
14.6 1.4
Aquila Trucks Centres
99120
Figure2
CABSUPPORT FOR VEHICLES4x4- 6x6
View from A, tilted by180
BODYWORKANDCHASSISFRAME 9 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Nut
Screw
226.5 22.5
278 28
22.6 2.2
27.8 2.8
2 Nut 226.5 22.5 22.6 2.2
3 Nut
Screw
179 18
146.5 14.5
17.9 1.8
14.6 1.4
Aquila Trucks Centres
99121
Figure3
CABSUPPORT FOR VEHICLES8x4- 8x8
10 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Nut
Screw
226.5 22.5
278 28
22.6 2.2
27.8 2.8
2 Nut 226.5 22.5 22.6 2.2
3 Nut
Screw
179 18
146.5 14.5
17.9 1.8
14.6 1.4
Aquila Trucks Centres
99122
Figure4
CABIN FRONT SUSPENSION
BODYWORKANDCHASSISFRAME 11 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
TIGHTENING TORQUE
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
1 Cabin front support fasteningnut 83 101 8.3 10
2 Front left support fasteningscrew 173 212 17.3 21.2
3 Front right support fasteningscrew 161 197 16 19.7
4 Nut for screw securingright front support 132 161 13.2 16.1
5 Cabin front support fasteningscrew 109 133 10.9 13.3
6 Air spring/shock absober upper fasteningscrew 400 40
7 Front right support fasteningscrew 173 212 17.3 21.2
8 Air spring/shock absober upper fasteningscrew
Air spring/shock absorber upper fasteningnut
490 600
398 487
49 60
39.8 48.7
Aquila Trucks Centres
99123
Figure5
12 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
TIGHTENING TORQUE
DESCRIPTION
TORQUE
DESCRIPTION
Nm (Kgm)
Cab rear suspension
1 Flangedhexagonal headedscrewretaininglock 82 9 (8.2 0.8)
2 Self-lockinghexagonal nut retainingflexiblebuffer to beam 140 14 (14 1.4)
3 Hexagonal headed screwretainingtopof damper 82 8 (8.2 0.8)
4 Self-lockingnut andhexagonal headedscrewretaininglower end of damper 154 15.5 (15,4 1.5)
5 Hexagonal screwwith flangefor fasteningthebracket to thecrossbar 146.5 14.5 (14.6 1.4)
6
Hexagonal nut withself-lockingflangeand hexagonal headed screw withflange
retainingbracket to chassis
179 18 (17.9 1.8)
Hexscrewwith flangeto securesupport to cab (vehicles 8x4) 204.5 21.5 (20.4 2.1)
GASPIPE FITTINGS
5/8' - +8 ||| 15.9 1.6
3/+' - +8 ||| 15.9 1.6
+' - ++ ||| 29.8 3
Aquila Trucks Centres
See Figure 6
Operating on main switch, take current off the electric
system.
Tilt thecab.
Remove cover (1).
Disconnecttheconnector (2) fromtheF.F.C.control unit(3).
Cut wiring harness retaining clamps and disconnect
connection(4).
See Figure 7
Lift thecowling.
Remove tow hook pin(1).
Remove thefour screws (3) assuringbumper (2).
Whilesupportingit, draw bumper (2) off securingbrackets
(6).
Removescrew(5) securingearthcable(4) tothechassisand
accuratelyset bumper (2) in order not to damage it.
Operations described and illustrated in following
chaptersrefer tovehicleTractor AD380T having
its cab with a mechanical suspension. Unless
another indication is provided, these operations
are also valid for a cab with a pneumatic
suspension.Someoperations,orpart ofthem,may
beeither unnecessaryor unsuitabletovehiclesof
other versions.
500210 BUMPER
Removal
Refitting
Reattachment is carried out byproperlyreversingthe
detachment operations and tightening the nuts and
screws to the specified torque
Whenreattachment operationshavebeencompleted,
check correct operation of thelightsor units affected
bydetachment.
99141
NOTE
Figure6
Figure7
99124
BODYWORKANDCHASSISFRAME 13 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
REPAIR OPERATIONS
Aquila Trucks Centres
Removal the cabin
Position the vehicle with the front wheels in the straight
direction of running. Lift the front grille. Remove the
expansion tank cap, then partiallydrain the coolant off the
enginecoolingsystem.
Ifthecabinisequippedwithanair-conditioningunit,remove
thecaps(1and2,Figure8),applyunit 99305146pipestothe
adaptersbelow,thenblowthegasoffthecabinconditioning
system, as described in therespectivechapter.
87329
Disconnect thecoolant pipes: (6), (3) fromradiator (1).
Remove screws (2) fasteningthe pipesupport bracket (7)
on radiator (1).
Removenuts(4),thentakeoffthesteeringcontrol assembly
adjustingpedal distributor (5).
This operation must be carried out only by
authorized, qualifiedskilledpersonnel.
Removethescrewsandtakewheel splashguard(11) offthe
cabin.
Disconnect theheaterfuel pipe(13),(whereavailable),from
theadapter.
Loosen thecabin tiltingsupport cylinder (14) fasteningnut
(12).
Drainthepneumaticsystem.
Onlyfor vehicles equippedwith mechanic gearbox.
Marktheassemblypositionof thetelescopic tie-rodCardan
joint (8) on gearboxcontrol rod (10), thenremove nut (9)
with its respective screw and disconnect Cardan joint (8)
fromrod(10).
Properlysecure the telescopic tie-rod to thecabin.
Position thetwo wooden dowelsof suitablethicknessonto
the cabin supporting rear crossbar, to avoid cabin lock
engagement after thecabinhasbeen lowered.
Lower thecabin.
NOTE
Figure8
Figure9
99125
14 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
550101 CABIN
Aquila Trucks Centres
99126
Remove the bumper as describedintherespectivechapter
(operation 500210).
Fromthedoorcompartment upper side, removegasket (4).
Hook swing bar 99378039 (1) to a bridge crane or other
suitableliftingmeans, then harness thecabin.
Swingbar(1)hooks(2)must bepositionedataboutthedoor
compartment centrelineandsecuredtothelatter bymeans
of stretchingdevice (3).
Figure10
BODYWORKANDCHASSISFRAME 15 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
z Aquila Trucks Centres
Removethenuts(1) anddetachthecover (2) togetherwith
thepipes fromthebulkheadconnector.
Takeout the screws (3) and detach thecover (4) together
with thepipefromthecontrol valve.
Remove screws (6), then take cover (7) off the bulkhead
completewithpipesfromthedistributor.
Disconnect the pipe (5) of the steering assembly control
device.
Onlyfor vehicles equippedwithautomaticgearbox:
- fromdistributor (1), disconnect pipes (2 and 3).
- placeacontainer belowmaster cylinder (4), disconnect
piping(5) fromthe same, then drain theclutchfluid.
87331
87332
99127
Disconnect enginecoolant pipes (1- 2and3).
Cut thepipe-electriccablejoiningstraps.
ect theair-conditioningsystemgas pipes (3) and(4).
87333
Disconnect quick engagement air-conditioning systemgas
pipings (1 and 2), if present, byaxiallypressingthem.
Seal the air-conditioning systempipes so as to
prevent moisture or impurities getting into the
system.
!
Properlyplugthepiping(5) andmaster cylinder (4)
adapter, to prevent theclutch fluid fromdamaging
painted parts. The clutch fluid is poisonous and
corrosive:incaseofcontact,washimmediatelywith
water andmildsoap.
NOTE
Figure11
Figure12
Figure13
Figure14
16 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
87334
Disconnect theelectricconnection(6) forthetankfluidlevel
gauge.
Lift theprotectivecap(7),removethenut (9) anddisconnect
thecable(8) fromthecab.
Remove the nut (17) and disconnect the earth cable (16)
fromthechassisframe.
Remove nuts (1) andtakeoff cover (2).
Remove covers (15), release safety levers (14) and
disconnect connections (10- 11- 12 and 13).
Disconnect theelectricconnections(4)and(5) ofthemotor
pump(3) for the windscreen-headlight washer fluid.
Figure15
BODYWORKANDCHASSISFRAME 17 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Mark the assemblyposition of the universal joint (1) onthe
powersteeringshaft (3).Removethebolt (2) anddisconnect
theuniversal joint (1) fromthepower steeringshaft (3).
Takeout thescrew(4) fixingtheairspringmatingpin(5),bar
(8) andmount (9).
* Disconnect thepipe (6) fromtheshockabsorber.
Removebolt (7) securingtheairspring(5) orshockabsorber
with coaxial springto thechassis.
Repeat thesesteps on theopposite side.
* Removethenut(1) anddisconnectthetierod(3) fromthe
levellingvalve(2).
* Onlyfor pneumatic suspensioncabins.
99128
99129
Removethebolt (2) fixingthecylinder (3) for tiltingthecab
fromthecabmounting(1).
Reattachment iscarriedout byreversingtheorderof
detachment operations and by takingthe following
precautions:
Lift the cab and extract the mating pin (3) of the shock
absorber (2),bar (4) andfront cabmounting(1).Carefullylift
thecabto detach it fromthechassis frame and put it aside
appropriately.
Refitting
73160
73159
- tightenthenutsorscrewstothespecifiedtorque;
- thepneumaticpipingadapterseal rings(O-rings)
must not bereused; theymust bereplacedwith
new ones upon everyreassemblingoperation;
- seal up the tachometer electric cable ringwith
proper sealingmedium;
- check correct operation of instrument board
warninglamps;
- in case of vehicles equipped with mechanic
gearbox, restore theclutch hydraulic systemoil
tank level, then blow off air as described in the
relevant chapter;
- restoretheenginecoolant level.
Fill up the air-conditioningsystem(whereavailable)
asdescribed in therespectivechapter.
Figure16
Figure17
Figure18
Figure19
18 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
* Removethenut(5) anddisconnectthetierod(6) fromthe
levellingvalve(1).
* Takeout thescrews(2) andremovethebracket together
with thelevellingvalve (1).
* Disconnect the air pipe (6, Figure20) fromthe shock
absorber (5, Figure20).
Removescrew (3) joining bar (7) to lower support (4).
Removethebolt (7,Figure20) fixingtheshockabsorber (5,
Figure20) to the chassis frame.
Removescrews (8), anddisconnect lower support (4) from
thechassis.
* Onlyfor cabwith pneumatic suspension
REPLACING THE CAB SUSPENSION
FRONT MOUNTING RUBBER-TYPE
BUSHINGS Removal
99128
99130
73164
Usingthearm99378039,slingthecabasdescribedunderthe
|oao|o 'Cab |oova|-|o|tt|o' aoo ocooo as o||o.s.
Removethefront bumper (operation500210) asdescribed
under therelevant heading.
Remove the bolt (7) fixing the shock absorber (5) to the
chassis frame.
Disconnect thepipe (6) fromtheshockabsorber (5).
Takeout thescrew(4) fixingtheshockabsorber matingpin
(5), bar (8) and mounting(9).
Repeat thesesteps on theopposite side.
Lift the cab and extract the mating pin (3) of the shock
absorber (2),bar (4),front cabmounting(1) andremovethe
shockabsorber (2).
Usingthearm99378039,slingthecabasdescribedunderthe
|oao|o 'Cab |oova|-|o|tt|o' aoo ocooo as o||o.s.
Removethefront bumper (operation500210) asdescribed
under thesameheading.
Remove thebolt (4) anddisconnect the universal joint (3)
fromthepower steeringshaft.
Repeat the operations described for disconnecting right
lower support.
Removescrews (1), anddisconnect lower support (2) from
thechassis.
554243 REPLACING THE FRONT SHOCK
ABSORBER
For theright-hand air springonly
Removethenut (1) anddisconnect thetierod(3) fromthe
levellingvalve(2).
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
Removal
Removingtheright-hand front suspension mounting
Removingtheleft-hand front suspension mounting
73162
Figure20
Figure21
Figure22
Figure23
BODYWORKANDCHASSISFRAME 19 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
99131
87291
87292
99132
Cab suspension lower supports are of different types and
their matchingdepends on vehicle version.
Replacingbushings(2) fromsupports(1-3) isbyusingapress
and suitablebeater.
Useelements (3, 4 and 5) of tool 99346051 to fit thebush
initsseat.
Usingthearm99378039,slingthecabasdescribedunderthe
|oao|o 'Cab |oova|-|o|tt|o' aoo ocooo as o||o.s.
Remove the front bumper, operation 500210 as described
under the same heading. * Remove the nut (5) and
disconnect thetierod(6) fromthelevellingvalve(1).* Take
out thescrews(2) andremovethebracket togetherwiththe
levelling valve (1). Remove the bolt (4, Figure 23) and
disconnect the universal joint (3) fromthe power steering
shaft. Remove the shock absorbers as described under the
relevant heading. Take out the screw (3) and remove the
stabilizer bar (7) fromthe mounting(4).
* Cabwith pneumaticsuspension
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
REPLACING CABFRONT UPPERSUPPORT
BUSHINGS
|oovo t|o s|oc' absobos as oosc |boo |o t|o '|oot
s|oc' absobo o|acooot' c|at o.
Extract thebushwithelements(1,2and3) oftool99346051
and removethe bush.
REMOVING REFITTING THE STABILIZER
BAR
Removal
Removal
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
Figure24
Figure25
Figure26
Figure27
20 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Refitting
Aquila Trucks Centres
99133
CABFRONT ANCHORINGCOMPONENTS
Figure28
BODYWORKANDCHASSISFRAME 21 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
554243 REPLACING REAR CAB
SUSPENSION DAMPERS
Removal
86949
Tilt over the cabin.
Onpneumaticsuspensionscabins,disconnect thepipefrom
theair spring.
Removebolts(2and4) andtakeshockabsorber (3) offthe
upper (1) andlower (5) crossbars.
REPLACING THE TRANSVERSE TIE ROD
BUSHINGS
Removal
Removebolts(4and5), thentaketransversetierod(2) off
crossbars (1 and 3).
86951
Refitting
Reattachment is carriedout byreversingtheorder
of detachment operations and by following the
specified tighteningtorquevalues.
Disassembling/reassembling the bushings
86952
Transverse tie rod (1) elastic bushings (2 and 3) can be
replaced by using a suitable beater and press for
disassembling/reassemblingoperations.
Toreattachthetransversetierod,reversetheorder
of detaching operations, by tightening bolt (4, 5,
Figure30) nutsto thespecified torque.
Nutsareoftheself-brakingtype;it isrecommendedthatthey
are replaced with new parts every time disassembling is
performed.
Refitting
86953
PARTSMAKINGUPTHE CABIN REAR SUPPORT AND
LEFT SIDEMECHANIC SUSPENSION
Figure29
Figure30
Figure31
Figure32
22 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Removal
554255 REPLACING HYDRAULIC
CAB TILT CYLINDER
Removal
99134
The figure shows the front levelling valve; similarly, the
descriptionsofdetachment operationsalsoapplytotherear
levelling valve. Disconnect pneumatic pipes (1 and 2) from
levelling valve (4). Disconnect tie-rod (5) from the
articulation pin, then remove the fasteningscrews (3) and
takeoff levellingvalve (4).
Removal
Refitting
Reversetheorderofdetachmentoperations,and tightenthe
screwstothespecifiedtighteningtorque.Asfarastie-rod(5)
check and adjustment are concerned, see the respective
chapter.
86632
Disconnect piping(4) fromlock (1), then recover the oil in
aspecial container.
Remove screws(3), then takeoff thelock.
CHANGING THE CAB LOCK
Carryout thesteps performedfor removal inreverseorder,
observingtherequired tighteningtorques.
Refitting
Lock(4) fasteningscrews(3) must belockedwhen
cabinanchoringpin(2) isalignedto therespective
seat of lock (4).
After reattachment hasbeencompleted, checktheoil level
andproceedwithdrainasdescribedintherelevant chapter.
CAB TILT CYLINDER
Placeacontainer under oil piping (3 and 4) to recover the
oil fromthe system. Disconnect oil piping (3 and 4) from
cabintiltingcylinder (2) adapter.Removebolt (1) andnut(5),
then take off cylinder (2).
Thisoperationmustbecarriedout withthecablow-
ered.
Reattachment is carriedout byreversingtheorder
of detachment operations, bytighteningthenutsto
thespecified torque.
After reattachment hasbeencompleted, fill up and
blowair offthehydraulicsystem,asdescribedinthe
relevant chapter.
Refitting
99135
Figure33
Figure34
Figure35
NOTE
4
1
2
5
3
BODYWORKANDCHASSISFRAME 23 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
LEVELLING VALVE
Aquila Trucks Centres
24 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
102622
CABTILTING SYSTEMCOMPONENT PARTS
1. Handdriven pump- 2. Cabliftingcylinder - 3. Hydraulic actuator to releasegearboxcontrol telescopictierod (onlyfor
mechanic gearbox) - 4. Cab hitchingup lock
Figure36
Maincircuit
Secondarycircuit
Aquila Trucks Centres
- Rotatetap (2) to the position shown in figure;
- Cablowered to drive position
- take off plug (1) and check oil level as described in
relatingchapter, toppingup, if required;
- rotatetap (2) to cablowered position;
- slowlydrive lever (3) at least forty times (through full
range);
- checkoil level asdescribed in relatingchapter
Bleeding air from secondarycircuit (point 3)
- Disconnect pipingfromlock(4, Figure38) andhydraulic
actuator (3, Figure 38);
- drive lever (3) until oil is drained away into special
container;
- checkoil level asdescribed in relatingchapter.
Bleeding air fully
Incaseall cabtiltingsystemcomponentsarereplaced,bleed
air as describedonpoints1-2-3.
Bleeding cab tilt system
Bleed the air in the event of general tilt system
malfunctioning and for the following operations
(seeFigure36).
1) Replacingmanual drivepump (1);
2) replacingcabtiltingcylinder (2) andmaincircuit
pipings;
3) replacinglock(4) andsecondarycircuitpipings;
4) replacingall components of tiltingsystem.
NOTE
102620
Bleeding air from cab tilting cylinder (point 2)
102621
Bleedingair frommanual drivepump(point 1)
- takeoff plug(1);
- slowlydrivelever (3) fivetimes, (throughfull range);
- checkthelevel asdescribed in relatingchapter.
Checking oil level
102619
Cabmust beloweredinridecondition. NOTE
Position pumpdrivelever (3) asindicatedinfigure.
Remove plug (2) and check that oil level X results to be
aboveplunger (1) bysome2 mm; otherwise, top up.
Figure37
Figure38
Figure39
BODYWORKANDCHASSISFRAME 25 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
99138
LOCATION OF CABSUSPENSION COMPONENTS
1. Cross member - 2. Rubber block- 3. Rear shock absorber regulator - 4. Rear shock absorber - 5. Bracket - 6. Support -
7. Front shockabsorber - 8. Front shock absorber regulator - 9. Torsionbar - 10. Brackets- 11. Torsion bar
Cab driving position adjustment
With cab under static loadcondition, checklengthX
1
of front shock absorbers(7) andlength X
2
of rear shockabsorbers(4).
Bystatic load it is onlymeant theloadthat is determinedbythetype of cab fitting.
X
1
= 380 mm
X
2
: vehicles: 4x2- 6x4 - 8x4 =400 3 mm
vehicles: 4x4- 6x6 - 8x8 AD (short cab) =362 3 mm
vehicles: 8x8AT (longcab) =400 10mm
If different valuesarefound, rotate theregulator (3and/or 8) of relevant shock absorbers with asuitable wrench.
Theregulator isprovidedwith5marks,eachmark, startingfromthecentral referencemark,correspondingtoalength
shift of 4mm.
Figure40
NOTE
NOTE
26 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Cab mechanic suspension
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 27 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Cab pneumatic suspension
99139
LOCATION OF CABSUSPENSION COMPONENTS
+. Sov|co so| 2. |oa s|oc' absobo 3. |oot |ovo|||o va|vo +. |oot s|oc' absobo 5. T|o oo o va|vo (3)
6. Tos|oo ba . |oa |ovo|||o va|vo 8. T|o oo o va|vo () . Stab|||zo ba.
Checkand/or adjust length X
1
of tierods(5) andlengthX
2
of tierod(8).Suchlength,measuredbetweenthecenterdistances
of articulatedpins, must be:
X
1
= 94 1 mm- X
2
= 83 1 mm
554275 Adjusting the levelling valve linkage
74094
CABSUSPENSION PNEUMATIC SYSTEMWORKINGDIAGRAM
+. |||t-|aoo oot a| s|o 2. |oot |ovo|||o va|vo 3. |||t-|aoo oa a| s|o +. |ot-|aoo oa a| s|o
5. |oa |ovo|||o va|vo 6. |ot-|aoo oot a| s|o /. Sov|co so| (8.5 bas)
Figure41
Figure42
Aquila Trucks Centres
73263
90043
90044
73266
Figure43
Figure44
Figure45
Figure46
Lift the radiator cowling (10). Take out the split pin (2),
extractthepin(7) withthethrustwashers(3)anddisconnect
theshockabsorber (4) fromthemount (1).
Repeat thesesteps for theother shock absorber.
Takeout thescrews(9) fixingthehinges(8) andremovethe
radiator cowling(10) fromthecab.
Disconnect thepipes(5) for thewindow-washerliquidfrom
thefitting(6).
Removethenuts(12) anddisconnect thewindscreenwiper
(11).
Open door (3) and remove screws (1) to laterally secure
right handvent (2).
Fromfront side,removescrews(4) andtakeright handvent
(2) off supports (5).
Repeat operations for takingoff left hand vent.
If present, takeout the fixingscrews. Removethevisor.
Put thepairofsuctioncups99378031(1) onthewindscreen
and withtwo operators, oneinsidethe cab who, usingthe
right tool, removes the seal whileapplyingpressure on the
top corners of the windscreen, while the other, on the
outside,pullingonthehandlesofthesuctioncups99378031,
removesthewindscreenfromits housing.
To refit the windscreen, carryout the followingoperations:
Removal
Refitting
- Fit therubber seal on thewindscreen, insert acord(1)
intheseal (2).
- Put the suction cups of tool 99378031 on the
windscreen.
- Position it against thecab flanging.
- Press firmlyonthesuctioncups whilepullingbothends
of thecord (1) fromtheinsidesothat theseal fits onto
theflangingof thebodywork.
- Finish fittingtheparts takendown duringremoval.
28 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
552410 REPLACING THE WINDSHIELD
Aquila Trucks Centres
90045
90047
90046
90048
90049
Figure47
Figure48
Figure49
Figure50
Figure51
Lower thewindow.
Removescrews(1), unthreadtierod(3) andtakesunroller
blindassembly (2) off thedoor.
Remove thepush-buttonpanel (2) fromthearmrest (1).
Disconnect the electric connections (3), (4), from the
push-button panel (2).
Loosenscrew(2)andremovehandgrip(1) fromdoorclosing
tierod.
Press thefinsof stem(4) and removehandle (3).
Remove mouth (5) andremove screwunder it.
Remove screws(4).
Removecaps(2) andscrews(1) underthemsecuringcoating
(3).
Take coating (2) off the door paying attention on
unthreadingcables(6) fromcoatingslot.
Removescrews(3) securingcentral unit support bracket (4)
to door (1).
Remove sound deadeningguard(2) fromthedoor.
550740 REPLACING THE WINDING
WINDOW
Removal
BODYWORKANDCHASSISFRAME 29 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
90050
Figure52
Figure53
Figure54
Figure55
Figure56
Remove plastic guards (1 and 3) fromdoor (2).
73272
Extract the outside and inside bottomseals (1) fromthe
windowcompartment.
73273
Extract thewindow guide seal (1).
73274
Temporarily connect electric connections to pushbutton
panel and lift glass until fastener (2) is made accessible.
Disconnect theelectricwindowdevice(3) fromthewindow
(1) byremovingtheclamp (2).
73275
Lift thewindow (1) andextract it fromthe top (arrow).
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
30 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
90067
Figure57
Remove thewindowasdescribed in operation550740.
Disconnect theelectric connection(5).
Take out the screws (1), (3) and (4) fixing the electric
windowdevice(2) onthedoor.
550730 REPLACING THE WINDOW WIN-
DER
Removal
73277
Figure58
Extract theelectricwindow device (1) fromthe door.
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
73278
Figure59
Remove thedoor trimas describedin operation 550740.
Unhooktheclip(2) fromthetierod(3) anddisconnect this
fromtheidler (1).
If present, disconnect the electric connections (4) and (5)
fromthelock(6).
550714 REPLACING THE DOOR LOCK
Removal
73279
Figure60
Disconnect thetierod(1) fromthelever (2) of theoutside
handle (3).
BODYWORKANDCHASSISFRAME 31 TRAKKEREURO 4/5
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Aquila Trucks Centres
73280
Figure61
Unhooktheclip(3) fromthetierod(4) anddisconnect this
fromthelever (5) of the internal handle.
Take out thescrews (1) and removethe lock (2) fromthe
door.
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
73281
Figure62
Remove thedoor trimas describedin operation 550740.
Unhooktheclip(2) fromthetierod(3) anddisconnect this
fromtheidler (1) of thelock (4).
550717 REPLACING THE OUTSIDE
HANDLE OF THE DOOR
Removal
73282
Figure63
Disconnect thetierod(1) fromthelever (2) of theexternal
handle (3).
Figure64
Take off the covers (1) and (2) and the nuts(3) fixingthe
external handle(4) and detachthisfromthedoor.
Remove thetie rod (3, Figure63) fromthe handle(4).
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
Figure65
REPLACING THE INSIDE HANDLE
Removal
73284
Take off the trimas described inoperation550740.
Unhook the clip (1) fromthe tie rod (2) and disconnect this
fromthe lever (5) of the insidehandle (4). Take out thescrews
(3) and removethehandle(4) fromthe door.
32 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
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Aquila Trucks Centres
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
Figure66
REPLACING THE SIDE MIRRORS
Removal
REPLACING THE DOOR
73286
Figure67
Take off the side mirror mounting as described in the
previous operation.
Detach the inside door trim as described in operation
550740.
Remove the electric window device as described in
operation550730.
Disconnect theelectricconnections(5),(6), (7),(8) and(9)
fromthecontrol unit andtakethisout (10).
Support thedoor (1), takeout thescrews (2) and(11) and
takethedoor (1) off its hinges (3) and(12).
Removal
Whentakingoffthedoor (1),extract thewiring(4)
fromit withgreat care.
Carryout thesteps performed for removal inreverseorder,
observingtherequired tighteningtorques.
Refitting
NOTE
108622
Unscrew screws (1) and (2) andremoveplastic guards (3)
and (4).
Figure68
Disconnect electrical connections (1), (2) and (3).Remove
screws (4) and(5) and take assemblyoff thevehicle.
Carry out the steps performed for removal in
reverse order, observing the required tightening
torques.
Refitting
108877
BODYWORKANDCHASSISFRAME 33 TRAKKEREURO 4/5
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Aquila Trucks Centres
Takeoffthesidemirror mountingasdescribedintherelated
operation.
Detach the inside door trim as described in operation
550740.
550748 REPLACING THE FIXED WIN-
DOW
Removal
Preparing the window bay
Using an appropriate knife, cut and level the sealant of the
windowbaysoas to leaveathickness of between0.25and
1 mmto prevent chippingthepaintwork.
Get ridof theremainingdust and degreasethewindowbay
with theBETACLEAN 3300detergent towelettecontained
intheBETASEAL1703Sprintkit(IVECOPARTS93162553).
73287
Figure69
Extract theoutsideseal (1),applythesuctioncup99378031
(2).
Insert asuitabletool throughthesealant byacorner (arrow)
of thewindow.
Make the cut all alongtheperimeter. Remove the window
with asuctioncuphandle (2).
Before starting to cut, you need to protect the
paintwork with adhesive tape to prevent any
damage.
Do not useanylubricant duringcutting.
The bladesmust always besharp.
The filmof sealant remainingon the windscreen
will beasupport for subsequent gluing.
If the window bay has been painted after repair
work, treat it with the COMBI primer 5061
contained in thekit andwait for 15minutes.
Preparing the window
Usinganappropriateknife, cut and level thesealant of the
windowbaysoasto leaveathickness of between 0.25and
1 mmto prevent chippingthepaintwork.
Get ridof theremainingdust anddegreasethewindowbay
withtheBETACLEAN 3300detergent towelettecontained
in the BETASEAL 1703 Sprint kit (IVECO PARTS
93162553).
If using a new window, it is still necessary to
degrease the screen-printed portion with the
BETACLEAN 3300detergent towelette.
33928
Figure70
- Degreasethescreen-printedportionof thewindscreen
with the BETACLEAN 3300 detergent towelette
contained in thekit.
Mount thesealsontheinsideofthedoor,without
touchingthe areawheretheadhesionpromoter
(primer) has been applied.
Mount therubber seal on thewindow.
Performatrial assemblyand centre the window
exactly.
After centring the window, mark the reciprocal
position between the window and its seat with
stripsof adhesive tape (1).
Cut the strips of adhesive tape and remove the
window.
- Usingtheapplicatorcontainedinthekit,spreadtheglass
adhesion promoter (COMBI primer 5061) on the
screen-printedportion.It isnot necessarytouseitonthe
remainingsealant.
- Wait for 15 minutes before going ahead with the
operations so as to allow the solvent of the adhesion
promoter (COMBI primer 5061) to evaporate.
Refitting
NOTE
NOTE
NOTE
NOTE
NOTE
34 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
33929
Figure71
Using an air gun, applya bead of BETASEAL 1703 SPRINT
polyurethaneadhesivealongtheperimeterofthewindowas
evenlyas possible.
73287
Figure72
Placethewindscreeninitsseat withthesuctioncuphandle
(2).
- Alignthewindowwithitshousingbay,usingtheadhesive
tapeapplied beforehandas areference.
Thewindowmustbepositionedwithin15minutes
of applyingtheadhesive.
Start this process fromthe middle of the bottomside and
proceed without stopping all around the perimeter of the
window.
Cut off the tip of the adhesive cartridge so that the
cross-sectionof theadhesivebeadis triangular inshapewith
abaseof 5-7 mmandaheight of 12 mm.
73288
Figure73
Keepthewindowunder pressurewith twowoodenplugs(1)
and (2) positioned as shown in thefigure.
Keep the window under pressure for at least 1
hour.
Beforerefittingthepartsthat hadbeenremovedbeforehand,
checkthereare no points of infiltration.
Take care not to damage the screen-printingon
thewindowwiththeknife.
Fit theparts that had been removed back on and clean the
window.
Donot moveor deliver thevehicleuntil onehour
and thirtyminutes have passed at atemperature
of 23 C and relative humidity (RH) of 50%.
Ifthetemperatureorhumidityarelower youneed
to increasethewaitingtime.
Applysoapywater withaspongealongtheouterperimeter
and blow compressed air from the inside so as to see
whether thereisanyinfiltration.
If bubbles form, degrease the relevant part and fill it with
adhesive.
Anysealant spillingover ontheinsidecanberemovedonce
ithashardenedbycuttingit withaknifeanddetachingit with
tweezers.
NOTE
NOTE
NOTE
NOTE
BODYWORKANDCHASSISFRAME 35 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Before performing repair interventions on the
vehicle,disconnectbatteriesbyoperatingoncurrent
mainswitchandobservesafetyrules.
90051
Figure74
553710 INSTRUMENT PANEL
Removal
- Remove support (3) fromcoating(2).
- Remove screws(4and5).
- Takeoff socket holder (1).
- Takecoating(2) off dashboardcoating.
!
77066
Figure75
- Remove plugs (2) fromseat.
- Undo the fasteners and remove the light switch
assemblies (1) fromtheir compartment.
77067
Figure76
- Disconnect theelectricconnectorsandremovethelight
switchassemblies (3).
- Unscrew thescrews (2) fixingtheinstrument panel (1).
- Remove instrument panel (1) fromseat.
- Disconnect electric connections affecting dashboard
removal, markingthe respectivemountingpositions of
the electric connections, in order to make their
connectioneasier onreconnection.
Taketheninstrument panel (1) off theseat.
Refit bycarrying out theprocedures described for
removal inreverseorder.
553712 CENTRAL SWITCH DASHBOARD
Figure77
Refitting
Removal
- Remove mat (1), plugs (2) and screws (3) securing
central dashboardontop.
90052
36 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
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Aquila Trucks Centres
- Remove handgrip (1).
- Remove lid (2) and disconnect theelectricconnection
of socket (3).
- Remove lid(4) and screws(5).
90053
90054
77107
Figure78
Figure79
Figure80
- Remove frame (2).
- Remove screws(1) securingcontrols (4) to dashboard
(3).
- Remove dashboard (3) and disconnect electric
connections affecting dashboard removal, markingthe
respective mounting positions of t he electric
connections,inordertomaketheirconnectioneasieron
mounting.
- Then, takeoff dashboard (3).
- Takeoff instrument panel (Op. 553710) as describedin
relatingchapter.
- Unscrew securingscrews (1) and takeoff lightscontrol
lever coating(2).
Refit bycarrying out theprocedures described for
removal inreverseorder.
Refitting
Removal
552211 PROTECTIONS
- Unscrew thescrews (4) fixingthesill (3).
- Lift themat (5) to get to oneof the fastenersof thesill
(3).
- Detachthe sill (3) fromthe vehicle.
- Remove mat.
- Operateoncheckfins( ) andremoveairintake(2) on
thefloor.
- Unscrew thesidescrews(1) fixingthesteeringcolumn
guard.
77108
Figure81
BODYWORKANDCHASSISFRAME 37 TRAKKEREURO 4/5
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Aquila Trucks Centres
90002
77116
90055
Figure82
Figure83
Figure84
- Takeoff central switchholderdashboard(Op. 553712)
asdescribed in relatingchapter.
- Remove screws (1) securingparkingbrakelever (2) to
support.
- Unscrewthescrews(3) fixingtheblindguard(1) onthe
steeringcolumn.
- Unscrewthescrews(2) fixingthefasciacoveringtothe
steeringcolumnandto the body.
- Unscrewthescrews(2) fixingthesteeringcolumnguard
intheareaof thepedal board.
- Detachthesteeringcolumn guard (1) fromthevehicle.
- Partlytakeoff thedoor seal (2).
- Remove thesunblind rod(3).
- Take off the press-on plug (4) to access the screws
beneath.
- Unscrewthefixingscrew(5) andremovethewindshield
upright covering(1).
77110
- Takeoff instrument panel (Op. 553710) as describedin
relatingchapter.
- Unscrewsecuringscews(1) andtakeofflightscontrol lever
coating(2).
77111
Figure85
90056
Figure86
- Removelids(3) andscrews(2) under them,andtakeoff
coating(1).
- Remove screws(4).
Figure87
38 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
- Unscrew the nuts (1) fixingthe fascia coveringto the
body.
- Free the right-hand air delivery pipe (2) from the
retainingclampsanddisconnect it fromthefanbodyand
right-handdoor air opening.
- Unscrew the bottom screws (3) fixing the fascia
covering.
- Perform operations described at Figure84 and
Figure85.
77114
77115
90057
Figure88
Figure89
Figure90
- Operate fromthe instrument panel compartment and
unscrew the nuts (2) fixingthe fasciacovering to the
body.
- Freetheleft-handairdeliverypipe(1) fromtheretaining
clampsanddisconnectitfromthefanbodyandleft-hand
door air opening.
- Remove screws (1) securing lower coating (2) to
passenger side.
- Takeoff coating(2).
77105
Figure91
- Open theglovecompartment (3).
- Detach the tie rods (1).
- Unscrewthenut (2) anddetachtheglovecompartment
(3).
77113
Figure92
- Unscrew thescrews (2) fixingtheBodyControl.
- RemovetheBodyControl (1) andtosetit asideinorder
to get to thefastenersbeneath.
BODYWORKANDCHASSISFRAME 39 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
90058
Figure93
- Unscrewthetopscrews(1) fixingthefasciacovering(2)
alongtheperimeter of thewindshield.
- Remove screws(3) securingcoatingon bottom.
- Withthehelpofanassistant,detachandrotatethepanel
trimas required.
- Pay attention to the fasteners and extract the fascia
covering(2) fromthevehicle.
For refitting, invert operations described for
removal, paying particular attention to electronic
cables and their connections.
Oncereconnectionhasbeencompleted,checkthe
functionality of electric/pneumatic controls and
relatingindicator lamps.
.
87312
87314
87313
Figure94
Figure95
Figure96
Unscrewupperscrews(4),lowerscrews(3),sidescrews(2),
then removetheside utilitycompartment (1).
Takeoff cap (1), then loosen screw(2).
Unscrewupperscrews(1) andsidescrews(2), thencarefully
takeoff theutilitycompartment, disconnect the ceilinglight
and transformer connections, and remove utility
compartment (3).
553612 WINDSCREEN VISOR ROLLING
DEVICE
Removal
Refitting
40 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
87315
87316
87317
Figure97
Figure98
Figure99
Take off the covers and/or the removed devices (if any).
Unscrewupperscrews(2),sidescrews(3) and lower screw
( ).
Carefullytakeoff console (1).
Disconnect tachograph connections (2), then remove
console (3). Take off loudspeaker cover (1) and the
loudspeaker (whereavailable).
Unscrewthefirst rollingdevicefasteningnut (1) throughthe
openingfromtheloudspeaker ( ), andtheother four nuts
through theother openings.
Refitting
Reversetheremoval procedure.
87318
87319
Figure100
Refitting
Reversetheremoval procedure.
Slackenthefourfasteningscrews(1) andremovethemotor
(2).
553651 WINDSCREEN SUN VISOR REEL
MOTOR REPLACEMENT
Removal
Carefullylower therollingdevice assembly (2), disconnect
connection(1), then removetheassembly.
Figure101
BODYWORKANDCHASSISFRAME 41 TRAKKEREURO 4/5
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Aquila Trucks Centres
87320
87215
87321
Extract thescrewcoveringtrims (1).
Slackenthefasteningscrews(1) andremovethehandles(2).
Remove therim(1).
Removal
Figure102
Figure103
Figure104
87216
87217
Disconnect theconnection(3),slackenthe12fasteningnuts
(1) and removetheair intakelidassembly(2).
Disconnect the lid as described above and put it on the
workingstand.
Slackenthescrews(1),recoverthehinges(2),thegaskets(3)
and thebosses (4).
Remove thesafetyring(7) andmake thewindow (5) slide
inthedirectionshownbythearrowtoreleasethemotor (8)
lever (6).
Refitting
Reversetheremoval procedure.
550254 AIR INTAKE LID MOTOR RE-
PLACEMENT
Removing
Figure105
Figure106
42 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
550250 AIR INTAKE LID
Aquila Trucks Centres
87218
87219
Slackenthescrews (2) andremovethemotor (1).
At refitting, press the rimin contact with the window to
obtainalignment between the motor lever pin(1) and the
window lever hole (2). Make theparts slide until the lever
couplingisobtained.
Refitting
Reverse the removal procedure except for the
followingoperations.
Figure107
Figure108
87342
551644 REPLACING SIDE DOOR OPEN-
ING CONTROL CABLE
(AT VEHICLES)
||t t|o attoss bo||oo t|o o|vo's soat.|osoo sco.s (2),
then removecovering(1).
Should the lid opening control cable be broken,
you can gain access to the glove compartment
o t|o cab|o |os|oo bo||oo t|o o|vo's soat.
Removing
87228
Slackenthescrews(2),recoverthewashersandremovethe
covering(1).
Figure109
Figure110
NOTE
BODYWORKANDCHASSISFRAME 43 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
87229
87230
Operatethelever ( ) to open the lid.
Slackenthe lock nut (1) and removethe adjustingterminal
(2) fromthe lock, then release theterminal fromthe lever
cable(3).
87343
Tieupaprobe (2) to thecable(1) to betakenout,so asto
allow thenewcableto be inserted.
Figure111
Figure112
Figure113
87344
87346
87345
Figure114
Figure115
Figure116
Loosen screws(2), then removecovering(1).
Unscrewnut ( ), thenrecoverthewasher frombelowthe
wheelbox.
Disconnect and remove the remote control so as not to
damageit.
Lower door (1), loosenscrews (2) andscrew(3), thentake
off covering(4) carefully
1
2
44 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
87347
Figure117
Act on the points shown ( ), thentakeout handle (1).
Takeoff handle(1) withitsrespective cable, then untiethe
probe.
Leaveprobe(2,Figure113) inthespacebetween
thecabinandthe utilitycompartment opening.
87234
Figure118
Refitting
Reversetheremoval procedure.
Operatethenut (2) to tension thecable (4) with thelever
(3) freeand without clearance.
After adjustment, tighten the lock nut (1).
Before refittingthe covering(1, Figure 108) carry
out thelid openingcontrol adjustment.
Lid opening control cable adjustment
1
NOTE
NOTE
BODYWORKANDCHASSISFRAME 45 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
77149
Figure119
Removal
Open thedoor (5) of the glovecompartment (4).
Unscrew the fixing screws (6) and remove the glove
compartment (4) fromthevehicle.
Coato t|o |ovo () aoo b|o t|o s oat (8) |oto t|o 'a||
o.ao' os|t|oo.
Operatethelever (2) and tilt theback (1).
Undothequickcouplings(10) anddetachtheair pipes(11).
Disconnect theelectric systemconnector (12).
Unscrew thefixingnuts(3) andscrews (9) and removethe
seat (8) fromthe vehicle.
Refitting
Refit bycarryingout the proceduresdescribed for removal
inreverse order.
46 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
555010 DRIVERS SEAT
Aquila Trucks Centres
77150
Figure120
1. Back - 2. Cushion- 3. Seat tilt adjustment - 4. Cushiondepth adjustment - 5. Bellows- 6. Horizontal spring-
7. Horizontal adjustment - 8. Guides - 9. Loweringseat - 10. Adjustingthevertical shockabsorber - 11. Adjustingtheseat
height - 12. IPSpneumaticlumbar support - 13. Seat heating- 14. Back adjustment - 15. Upholstery.
BODYWORKANDCHASSISFRAME 47 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Component layout
Aquila Trucks Centres
90025
Figure121
Removing
- Lift thelever (2) for adjustingthe cushiondepth.
- Arrangethe cushion (1) in its headposition.
- Unscrew the screws (5) fixing the seat tilt adjustment
lever (4).
- Keep the lever (2) in the topposition andpush in the
direction of thearrow(A).
- Movethecushion(1) of theseat forward and lift it.
- Disconnect theelectrical connection(6) of theseat.
- Detachthe cushion (1) fromthe seat.
Refitting
- Bowdenflexiblecable(10) must bepositionedbetween
lever (9) and sittingcushion baseplate.
- Press cushionwithkeyholes (7) on rear slidingblocks.
- Draw lever (2) upwards (do not displace cushion).
- Presscushionfront keyholes(8) onfront slidingblocks.
Pushcushiondownwardsandat thesametimepushup
to thestoptowards theseat back.
Now, check that all the four sliding blocks are still
anchored in cushion base plate (cushion vertical
movements must not be possible).
- Press lever (2) accordingto the direction of arrow (B)
and pushthe cushion towardsthe seat back up to the
engagement of lever (2).
- Check thecushion to besteadilysecured accordingto
both horizontal and vertical directions.
Removing - refitting cushion sliding blocks
Removing
- Remove the cushionasshown alongside.
- Takeout plug(2) and pushout slidingblock (3).
Refitting
- Mount slidingblock (3) to seat frame(4).
- Put plug(2) into slidingblock (3) seat.
REMOVING THE DRIVERS SEAT
Removing - refitting the cushion
Figure122
77152
48 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
- Unscrewthescrew(9) fixingthetopoftheseatbelt and
takeoff the facing(1).
- Unhookthesections(5) andlift thebackupholsteryoff
thefixingtapes (2) (Velcro),
- Removetheretainer (6) of theplasticguide (10) acting
inthedirection of thearrows.
- Unscrew the screw (7) fixingthe reel and removethe
seatbelt (8) fromtheseat.
77153
Figure123
- Detach the seat cushion asdescribed above.
- Unscrew the fasteners (1) and remove the rear
upholstery (2) of theback.
Removing - refitting the seatbelt
Figure124
- Lift thebackadjustment lever(4) andunscrewthescrew
(3) fixingthe seatbelt hook.
Figure125
Removing - refitting seatbelt connection and
right-hand side upholstery
- Positionthecushion(5) forwards.
- Unscrewthescrews(4) fixingtheupholstery(6) andthe
press-oncaps (1).
- Unscrewthescrew(2) andremovethebelt connection
(3) andthe sideupholstery(6).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
77494
77495
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
BODYWORKANDCHASSISFRAME 49 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Removing
- Remove the seat cushion asdescribed above.
- Unscrew screws(1), (2) and (3).
- Foldthebackfullyforwardsandunscrewthescrew(4).
- Remove the side upholstery (5) from the seat
framework.
- Unscrew ascrew(6) and two screws(7).
- Lift safetyhook(8) inasafewayanddismount air tube
(9) fromconnector (10) (seedetail A, B).
- Separatetheelectric connector (11).
- Push the valve (12) and the switch (13) outside the
upholstery(5).
- Disconnect thehoses (14) fromthevalve(12).
Figure126
Removing - refitting the back
Removing
- Remove the seat cushion asdescribed above.
- Adjust inclination at thehighest position.
- Takeoff thesideupholstery.
- Disconnect theconnector (3) andthreeair hoses(4) if
applicable.
- Remove thesafetylock (1).
- Unscrew the screw (5) fixingthe seatbelt reel and the
screw (6) fixingtheseatbelt (7).
- Unscrew thescrews (2) fixingtheback (8).
- Remove the back(8) fromtheseat,
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing - refitting the left-hand side
upholstery, IPS valve and heating switch
Figure127
77497
77496
Markthehosesto facilitateassembly.
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
NOTE
50 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
Figure128
Removing
- Remove the seat cushion and the left-hand side
upholsteryas describedabove.
- Remove thesafetywasher (1).
- - Dismount spring(2) fromlever (3).
- Remove the spring(4) fromthepin (5).
- Remove the lever (3).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing - refitting the height adjustment
device
Removing- refittingtheseat angleadjustment
device
Removing
- Remove the seat cushion and the left-hand side
upholsteryas describedabove.
- Takeoff height adjustinglever (4) as above.
- Freethepin (1) fromthelever (2).
- Remove thelever mount (3) fromtheseat framework.
- Loosen theflexible cable fromthelever (2).
- Remove the seat adjustment device (5) fromthe seat.
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing - refitting the flexible cable of the
shock absorber adjustment device
Removing-refittingtheback adjustment lever
90027
90026
Removing
- Remove the seat cushion asdescribed above.
- Adjust inclination at thehighest position.
- Unscrew the fixingscrews (1), loosen the nut (2) and
removethe flexiblecable (3) fromthefixing(4).
- Free the threaded coupling of the cable (5) fromthe
lever (6).
- Pushtheflexiblecableout ofthemount (7) andextract
through theopening(8).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Figure129
77499
Figure130
Figure131
77501 Removing
- Remove the seat cushion asdescribed above.
- Removethesupportingwasher (1) andtheflexiblecable
(2) of thelever fromthe fixingsystem(3).
- Unscrew thescrews (4).
- Extract thepin(5) fromthelever (6).
- Extract theflexiblecable (2) fromthe seat framework.
Before putting in the springs, thread end (A) of
spring(4) into theopening(B) of spring(2).
NOTE
1 2
3
4
BODYWORKANDCHASSISFRAME 51 TRAKKEREURO 4/5
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Aquila Trucks Centres
After mountinga new suspension, projection (6)
must engage with the fixing hole of suspension
upper support.
NOTE
Removing
- Removetheseat cushion, left-handsideupholsteryand
theback asdescribed above.
- Loosen spring(1) frompin (2) of lever (3).
- Unscrew the nuts (4) and remove the plate (5), the
toothed segment (6) andthe lever (3).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing - refitting the air spring
Before fittingthe seat cushion, loosen thelocking
nut (7), adjust theflexiblecable (2) so that inthe
lowest positionoftheadjustment lever, thestiffest
vertical damping is reached, then retighten the
lockingnut.
- For fitting, carryout thesteps performedfor removal in
reverseorder.
77503
77502
90029
Figure132
Figure133
Figure134
Refitting
Removing
- Remove the seat cushion asdescribed above.
- Takeout the bottombellows fastener.
- Securesuspensionassembly(1) onthehighest position,
use special spacer (3) withdimensions shown in figure.
- Put inspacer (3) betweenframe(2) andseat suspension
(1).
- Lift thefixinghook(1) safelyandremovetheairpipe(2)
asshowninthe box.
- Unscrewthescrew(3),loosentheshock-absorberfixing
and move the air springtoward thefront.
- Turntheairspring(4) by90degreesandremoveitfrom
thebottommount (5).
Refitting
For fitting, carry out the steps performed for removal in
reverseorder.
Removing-refittingtheback adjustment lever
segment
Figure135
Removing
- Remove the seat cushion asdescribed above.
- Takeout the bottombellows fastener.
- Movethesuspensionassemblyinto itslowest position.
- Unscrewnut(1),takeout screw(2) andremovebushing
(3).
- Position suspension assembly to the highest position
(usespacer (3), Figure133).
77505
Removing - refitting the shock absorber
NOTE
52 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
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Aquila Trucks Centres
Removing - refitting the flexible cable of the
horizontal lever suspension
Removing
- Remove the seat cushion, as described above.
- Remove theheight adjustment valve.
- Unscrew support washer (1) and remove toothed
segment (2).
- Unscrew supporting washer (3) and remove the
toothed segment (4).
- Unscrewthesupportingwasher (5), unscrewthescrew
(6) andremovethelever (7).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing
- Remove the seat cushion, as described above.
- Unscrewthenut (1), removetheflexiblecable (2) from
the fixing (3) and pull the cable with the threaded
coupling(4) out of thevalvelever (5).
- Lift thefixinghooks(6) safelyand removetheair pipes
(7) (seebox A).
- Unhook the spring (8), extract the bottom bellow
fastener, unscrew the screw (9) and turn the bracket
(10) upward.
- Turn the valve (11) on the supportingpipe and pull it
abovetheend of thesupportingpipe (12).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Before fittingthe seat cushion, loosen thelocking
nut (8), adjust theflexiblecable (6) so that inthe
lowest positionoftheadjustment lever, thestiffest
vertical damping is reached, then retighten the
lockingnut. (8).
- Unscrew thebottomshock absorber fastener (4).
- Removethesupportingwasher (5) andtheflexiblecable
of thelever (6) out of thefastener (7).
Refitting
Afterfittingthenewparts,thehighest toothofthe
toothed segment (2) must adapt to the width of
the highest space of the toothed segment of the
valve(4).
77506
77507
Figure136
Figure137
Removing - refitting the height adjustment
valve
Afterfittingthenewvalve,thehighest toothofthe
toothedsegment (13) must adapt to the widthof
the highest space of the toothed segment of the
valve(14).
Removing - refitting theheight locking system
Figure138
90030
Removing
- Remove the seat cushion, as described above.
- Unscrew screws(1).
NOTE
NOTE
NOTE
BODYWORKANDCHASSISFRAME 53 TRAKKEREURO 4/5
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Aquila Trucks Centres
- Unhook thecable (2) fromthe lever (3).
- Extract theflexiblecable(2) comprehensiveofthelever
(4) fromthe opening(5).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing
- Remove the seat cushion, as described above.
- Loosen theplastic covering(6) asdescribed above.
- Unscrew screw (7).
- Disconnect thehoses (3) (4) fromthecoupling(5).
- Unscrewthefixingscrews(1) anddisconnect theswitch
(2) for fast loweringfromits seat.
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing-refittingthelumbar support device
77509
90031
Figure139
Figure140
Removing - refitting the fast lowering switch
Figure141
90032
Removing-refittingthefast loweringmagnetic
valve
Removing
- Remove the seat cushion, as described above.
- Loosen theplastic covering(1) asdescribed above.
- Disconnect thehoses(2) and(3) fromthevalve(4),the
hose(5) fromthecoupling(6) andthehose(7) fromthe
coupling(8) insidetheplasticcovering(1) (boxesA/B).
- Extract thefixingarm(9) ofthemagneticvalve(10)from
thetransverse pipe (11) andlift thevalve (10).
- Disconnect theelectric connector (12).
- Remove themagnetic valve (10) for fast loweringfrom
itsseat.
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing
- Partiallyremove the backupholstery.
- Unscrew screws (3) and take the foamoff seat back
frame.
- Disconnect thehoses (1).
- Remove the lumbar support device (2).
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
54 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
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Aquila Trucks Centres
90033
77513
Figure142
Figure143
Removing - refitting the back upholstery
Removing
- Remove the seat cushion, as described above.
- Takeoff thethreehoses and electric connection (1).
- Unhook theC-sections(1) (box A).
- Lift the lever (2) and unscrew the screw (3) fixingthe
seatbelt.
- Takeoff thefacing(6).
- Lift thebackupholstery(7) upwards off thefixingtapes
(4) (Velcro),
- Extract theseatbelt through theopening(5).
- Remove the upholstery(7) fromtheseat.
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
Removing - refitting the cushion upholstery
Removing
- Remove the seat cushion, as described above.
- Freetheupholsteryof thecushionof theseat (1) from
the edging(2) passingalongthe perimeter of theseat
bottom.
Refitting
- For fitting, carryout thesteps performedfor removal in
reverseorder.
BODYWORKANDCHASSISFRAME 55 TRAKKEREURO 4/5
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Aquila Trucks Centres
90035
Figure144
A.Height adjustingvalve- B. Pneumatic suspension - C. Magneticvalve for fast lowering- D. IPSvalves - E. Selector -
F. Foul air - G. Enteringair
90034
Figure145
56 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
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DRIVERS SEAT PNEUMATIC DIAGRAM
Aquila Trucks Centres
90037
Figure146
A. Height adjustingvalve- B. Pneumaticsuspension- C. IPSvalves- D. Fast loweringswitch- E. Foul air - F. Enteringair
90036
Figure147
BODYWORKANDCHASSISFRAME 57 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
PASSENGERS SEAT PNEUMATIC SCHEME
Aquila Trucks Centres
86980
86981
87018
87019
Figure148
Figure149
Figure150
- control unit supplyvoltageequal to 24.1V;
- switch(1) ON (orangewarninglamp ON);
- thethermostat must benot inOFFposition(seefigure);
- the protection fuse available on the dashboard electric
panel must not beblown;
- thespacearoundtherefrigeratormust befreeenoughto
ensureventilation.
- Whenthecabinhasbeenlowered,maketherefrigerator
slideforwardbyactingonhandle (1).
- Disconnect electric connection (1).
- Removescrews(3).
- Takeoff refrigerator (2) withitsrespective guide (4).
Preliminary checks
If the fridge does not work or its inner temperature is not
enough, check the followingconditions prior to makingany
replacement or maintenancework:
OFFposition
A compressor protection device is available for
cabintilting,wherebytheinstalledrefrigeratorstops
working, for safety reasons, if the vehicle (either
stationaryor running) istilted bymorethan15 .
The refrigerator mayrun down the batterywhen
theengineis not working. When the batterylevel
falls too low, the refrigerator will switch off
automatically. Correct refrigerator operation is
ensuredonlywhen theengineis running.
Removal
- Detachment is accomplished by tilting over the cabin,
removingthesound-proofingpanel below,andtakingoff
thetwo refrigerator fasteningscrews.
Refitting
Refitting is carried out by reversing the order of
removingoperations.
STOP
1
NOTE
NOTE
58 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
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CABIN REFRIGERATOR
Aquila Trucks Centres
86982
86984
86983
86985
86986
86987
Figure151
Figure152
Figure153
Figure154
Figure155
Figure156
Remove screws (1). Take threaded ring (2) out of the
connector.
Removeconnection(1) fromthe thermostat.
Fan removing
Overturn rear protection (1) as shown onthefigure, taking
carenot to applytensilestressto the thermostat probe (2).
Thefancan beremovedbytakingout screws(3).
Removeelectricconnection(1) fromthecontrol unit,taking
carenot to pull thecables.
Useascrewdrivertotakeout corehitch(1),thentakeoutthe
cablesoneat atime.
Removing the anti -tipping probe with
electronic circuit on the control unit
Removescrew(1).
Removing
2
1
1
1
2
3
1
1
1
BODYWORKANDCHASSISFRAME 59 TRAKKER EURO 4/5
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OVERHAULING
Aquila Trucks Centres
86988
86990
86989
86991
86992
86993
Figure157
Figure158
Figure159
Figure160
Figure161
Figure162
Cut theplasticstrap (1) joiningthewiringon theelectronic
control unit front part.
Ta'o ooo-t||t|o obo c|co|t (+) oot o t|o coosso's
electroniccontrol unit.
Take off the connector (1) to which the probe cable is
secured. Now,theprobecanbetakenout throughthecore
hitch, thus avoidingconnector crawling.
Disconnect all electriccables (1) fromthecontrol unit. Take
out electroniccircuit (2). Removescrew(3).
Movethecontrol unit aside, then takeconnector (1) out of
thecompressor.
Checks
Checkpropertighteningofconnector (1) forconnectionwith
thefront switch.
Refitting
Assemblingis carried out byreversingtheorder of
disassemblingoperations.
Do not use blunt tools which could damage the
circuit inner face.
1
1
1
NOTE
60 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
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Electronic control unit disassembling
Aquila Trucks Centres
85701
Figure163
Thepurposeoftheair-conditioningsystemistomakethecab
comfortableas regardsthefollowingparameters:
- temperatureandrelativehumidityof outsideair;
- temperatureandrelativehumidityinthe cab.
The system subjects the air to thermodynamic
transformations that affect its temperature, relative humidity
and purity. This isaccomplishedby:
- ventilation, or introducing air taken fromthe outside
(therefore with the temperature and humidity of the
surroundingenvironment) into thecab;
- air-conditioning, or cooling and de-humidifyingthe air,
withthepossibilityofheatingit afterwardsaspreferredso
asto changethetemperatureand humidityinthecab.
CABINTERNAL VENTILATION DIAGRAM
VENTILATION
Description
Ventilation is the function of drawingin fresh air fromthe
outside, cleaned of pollen and dust by a special filter, or
recyclingtheair inthecab.
This systemis composed of a shell, designed to house the
electric fan unit, air ducts, fresh air intake and recycled air
intake. The electric fan has several speeds to draw in and
circulatelargemassesof air.
General
CAB AIR-CONDITIONING
BODYWORKANDCHASSISFRAME 61 TRAKKER EURO 4/5
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Aquila Trucks Centres
AIR-CONDITIONING AND HEATING
Description
Thisisaccomplished byintegratingan air-conditioningand a
heatingsystem.
Thisintegrationmakesit possible tochangethetemperature
and humidityinthecab.
Air-conditioning
Air-conditioningis accomplished bytakingadvantage of the
high capacity of some gases to lower temperature
considerablyin their phase of expansion, therebymakingit
possibleto absorbheat fromthecab.
Thisconditionisobtainedbytwo different levelsofpressure
(high, when therefrigerant fluidisinits liquidstate, and low,
whenthefluidisinitsgaseousstate) that areestablishedand
maintainedduringoperationof the system.
Heating
Heatingisaccomplishedbyaradiator, intheheater unit, in
whichtheenginecoolant circulates.
Special doors allow air to pass through the radiator only
whentheheatingfunctionis activated.
The main components of the air-conditioningand heating
systemcomprise:
- compressor;
- condenser;
- thedehumidifier filter (incorporatedinthecondenser);
- three-level pressureswitch;
- expansionvalve;
- evaporator;
- heater/fanunit;
- pollen filter.
Figure164
85702
Air-conditioning controls assembly
Manual
Heating and ventilation
1. Air temperaturecontrol knob,withextremepositionsto
cut in the HI and LO functions (max and min air
tooatoo/ too tot|o|ot o os| a| too tot|o||t
for warmair).
2. Electric fan knob with relative working speeds and
operationselection;
- off (0);
- manual operation (1-2-3-4).
3. Air inlet control knob:
- facezoneair;
- faceandfeet zoneair;
- feet zoneair;
- feet andwindshieldzoneair;
- windshieldzoneair.
4. Switchto turnonair recirculation: it prevents air flowing
infromoutside.
5. Switchto turnontheair-conditioner.
62 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
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Aquila Trucks Centres
Legend
42045 Outside temperaturetransmitter
82000 Heater assembly
42608 Coolant pressureswitches
25332 Compressor insertionremotecontrol switch
84019 Compressor
86116 BodyComputer
72021 30-pindiagnosisconnector
Figure165
85703
Condenser
Drying filter
BODYWORKANDCHASSISFRAME 63 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
COMPONENT LAYOUT (WEBASTO AIR CONDITIONER)
Aquila Trucks Centres
A. Recirculationgeared motor (Ric) - E. Evaporator temperaturesensor - F. Blownair temperaturesensor - G. Modulates
blower control - H. Expansion valve.
Figure166
85704
64 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
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HEATER ASSEMBLY COMPONENT LAYOUT (WEBASTO)
Aquila Trucks Centres
|os|t|oooo oo t|o oot o t|o vo||c|o (o|vo's s|oo) so as to bo aoctoo b a tooatoo c|oso to oa||t .
Figure167
77566
Figure168
77145
Compressor
The compressor is situated in theenginebaybetween theradiator fanandthealternator.
BODYWORKANDCHASSISFRAME 65 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Outside temperature sensor
Aquila Trucks Centres
Figure169
The dehumidifier filter is integrated inthecondenser that is found on thefront of the vehicle.
The refrigeration systemusesR134afluidhighlighted onthe plateon its casing.
The safetypressureswitch assemblywithfour levels isfittedon thecondenser outlet pipe.
The two pressureswitches, whichare of theN/C and N/O type, makeit possibleto keep thepressure in the systemconstant
fromaminimumof 2.5 (N/O) to amaximumof 25bars (N/C); with valuesoutsidethis rangethesystemis deactivated.
Whereas,thetwopressureswitchesoftheN/O typeareusedtodisconnect theenginecoolingfancoil whenthesystempressure
isintheinterval 18 22bars.Thisisaccomplishedbyanearthsignal thatthetwopressureswitchessupplytotheBodyComputer
control unit.
77245
Figure170
77560 74247
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Print603.93.371
Condenser and safetypressure switches
Aquila Trucks Centres
The recirculation reductionunit is locatedon Heater/Conditioner unit.
It is directlyactivatedbytheelectroniccentral unit with ratedvoltage (24V) and it has20 to 40mA absorption.
Maximumabsorption, on arrivingat endof stroke, reaches 200 mA at power supplyput off bythecentral unit.
Thepotentiometer it isprovidedwith isused for return signal and, on first power on, thecentral unit detectsandstores endof
stroke values used to split operationrange.
N.B. If thereduction unit isbeingreplaced, it is NECESSARY to RESET system.
Figure171
77571
Figure172
77573 77572
Pin-out
BODYWORKANDCHASSISFRAME 67 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Stepper motors
PIN CABLECOLOUR SIGNAL
1 White +/- 24V
2 Purple +/- 24V
3 Blue 0V
4 Orange 0 5V
5 Green +5V
6 --- Free
Aquila Trucks Centres
Thesensor insidetheevaporatorcausesthecompressor to turnon andoff,allowingtemperatures from2 C (off) to3.5 C (on)
for VALEO and from5 C (off) to 10 C (on) for WEBASTO.
The figureshows the same characteristicsof theoutsidetemperaturesensor except for theconnection.
Figure173
77793
Figure174
Expansion valve
C
O
N
D
E
N
S
E
R
E
V
A
P
O
R
A
T
O
R
Theexpansion valveis thetypewith ablock, itsjob is
to lower the pressureof the fluid at the outlet of the
condenser (and therefore of the filter) to a pre-set
value so that the same fluid, circulating in the
evaporator, can bedrawn up bythecompressor in a
totallygaseous form.
It isthereforepossibletostatethat theexpansionvalve
fulfils threebasic functions:
S METERING
S MODULATING
S CHECKING
This is fitted on the Heater/Air-conditioner assembly
near theblower control module.
77575
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Evaporator temperature sensor
Aquila Trucks Centres
86737
Figure175
Description
The auxiliaryheater works independentlyof theengine.
Its function is to heat thecabinonly.
Theheater isconnectedtothevehiclefuel tankandelectric
system, andislocated in thecabin.
Operation
Switch-on and switch-off can be done by means of digital
timer (4) or ambient thermostat (5).
Upon switching on, the warning lamp lights up and
combustionchamber (9) preheatingis started.
After approximately 30 seconds, pump (19) sucks the fuel
from the tank and sends it to felt (5) which acts as an
evaporator.
PARTSMAKINGUPTHE AUXILIARY AIR-TYPE HEATER
At the same time, fan (4) sucks, through pipe (20), the
external air and sends it, through passage (18), to felt (5),
whereair ismixedwiththefuel.
Heatingplug(6) triggers mixburning.
Duringcombustion, theflame licks exchanger (10). Fan (2)
sucks cold air fromintake (1) andsendsit to exchanger (1)
whichheats, byyieldingheat, theair sent to thecabin.
Whencombustionisover,photoresistor (7) cutsoffheating
plug(6) bymeans of control unit (12).
Whenthetemperatureexceeds the required value, asignal
sent by ambient thermostat (15) causes reduced-power
resistor (13) to come into operation: such resistor acts on
theheaterbyreducingtherevsnumberofengine(3) andthe
fuel pump rate.
Burnt gas are finally eliminated through silencer (17) and
exhaust pipe(16).
BODYWORKANDCHASSISFRAME 69 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
ADDITIONAL AIR HEATER SYSTEM(on request)
Aquila Trucks Centres
70 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
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FAULT DIAGNOSIS
Visible Failur e Possible cause Repair action
Inefficient electricsystem Checktheelectricsystem.
Compressor pullingbelt not in normal
workingconditions and inefficient
Check the belt: if it is too loose or
stretched, adjust it or, if necessary, re-
placeit.
Inefficient electromagnetic clutch coil. Check whether the coil receives cur-
rent. Replacethecoil, if necessary.
Systemdoes not work
Inefficient systemfittings and pipes. Check and replace, if necessary, defec-
tive parts.
Incorrect distance (play) between the
front disc and the electromagnetic
clutch.
Check the distance (play). Disconnect
thecompressorandadjust thedistance,
if necessary.
Inefficient compressor. Drainthesystemasdescribedintherel-
evant chapter; disconnect the com-
pressor and replace it.
Lowcompressor oil level. Drainand refill thesystemasdescribed
intherelevant chapter.
Lackof coolingfluidinthe system. Drainand refill thesystemasdescribed
intherelevant chapter.
Incorrect distance (play) between the
front disc and the electromagnetic
clutch.
Check the distance (play). Disconnect
thecompressorandadjust thedistance,
if necessary.
Noisysystem
Low amount of coolant in the system
(greensight glass).
Drainand refill thesystemasdescribed
intherelevant chapter.
Systemis not leak-proof. Use leak-detector 99051147 to check
thesystemandthecompressor;remedy
thecoolingfluidleaks (if any).
Electromagnetic clutch does not work
properly.
Check the clutch electric connections.
Replace the electromagnetic clutch, if
necessary.
Humidityinthesystem. Drainand refill thesystemasdescribed
intherelevant chapter.
(Continue)
Troubleshooting
Introduction
Diagnosis, i.e. locatingthetroubles that causeoperation faults inthesystem, makesit possibleto identify, byanalyzingthefault
found, thecauses and, therefore, ensureprompt and saferepair so as to restorethesystemto full efficiency.
Belowisthetroubleshootingguideforfaultsmainlyofmechanicandhydraulicnaturewhichcannot berecognizedbytheelectronic
control unit.
/s oaos t|o ao|t a|o| o o|oct|c aoo o|octoo|c oatoo, oso t|o | V|CC o|octoo|c o|aoos|s |ostooots '|ooos - |./.SY.
- |T 2000', b cooooct|o t|o |ostooot to t|o o|aoos|s ta'oo aoo o||o.|o t|o |ostoct|oos sto b sto, as o|s|aoo b t|o
instrument itself.
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 71 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Visible Failur e Possible cause Repair action
Loosecompressor fastenings. Checkandtightentotorquethescrews
and boltsfasteningthecompressor
Unusual noisewith clutchengaged
Inefficient electromagnetic clutch. Checkwhetherthefault isduetomech-
anicor electriccauses, thenact accord-
ingly.
Unusual noisewith clutchengaged
Lowcompressor oil level. Drainand refill thesystemasdescribed
intherelevant chapter.
Inefficient compressor. Drain the system and refill the com-
pressor.
Unusual noisewithdisengagedclutchor
vibrations
Incorrect distance (play) between the
front disc and the electromagnetic
clutch pulley.
Check the distance (play). Disconnect
thecompressorandadjust thedistance,
if necessary.
vibrations
Inefficient electromagnetic clutch sup-
plyelectric system.
Checktheelectricsystem.
Humidityinthesystem. Drainand refill thesystemasdescribed
intherelevant chapter.
High discharge pressure and normal
suckingpressureduetothepresenceof
air in thesystem.
Drainthecoolingfluid, replacethedry-
ingfilter,deaeratethesystem,thenrefill,
asdescribed in therelevant chapter.
Insufficient cooling
Highdischargepressureandlowsucking
pressure withpresenceof water or ice
onthedryingfilteror onthepipesfrom
thecondenser outlet to theexpansion
valve.
Drain the cooling fluid, eliminate the
throttlingor replace thefaultycompo-
nent,deaeratethesystem, thenrefill,as
describedinthe relevant chapter.
Normal discharge pressure and low/
high sucking pressure due to incorrect
electromagnetic clutch engagement/
disengagement.
Changethetrinarypressuregauge.
Inefficient electricsystem. Check the electric systemand replace
defectiveparts.
Irregular electricvoltage. (Operatingvoltage19.5V 5%).Charge
thebattery.
Incorrect operationof theheatingplug. Check the electric connections, the
control unit and the plug, then act on
faultyparts.
The heater goesto block Incorrect operation of the metering
o ato 30 socooos' o|oat|o.
Check the electric system, the control
unitandthemeteringpump,thenact on
faultyparts.
Incorrect operationoftheburningunit. Checktheburningunit andtheelectric
system.
The heatingplugis switched off within
thesafetytime.
Check and replace, if necessary, the
photoresistor.
Efficient thermal limiter. Checkthethermal limiter.
(Continue)
Aquila Trucks Centres
72 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Visible Failur e Possible cause Repair action
f (
Incorrect operation of the metering
pump.
Check and replace, if necessary, the
pump.
Thefumeexhaust pipegetshot (heater
combustion)
Poor fuel pipe seal. Verifythatthefuel pipedoesnot leakor
isnot throttled.
Incorrect fuel connection. Checktheconnection.
f f
Incorrect operation of the metering
pump.
Checkthepump rate.
Heater getsstuckedafter briefcombus-
tion
Incorrect CO
2
value. Check the CO
2
value and replace the
burner, if necessary.
Inefficient, reduced power resistor. Inefficient electricsystem.
Inefficient photoresistor. Check the electric cables and verify
whether short-circuit occurs.
Irregular operation of the measuring
valve (after 30 seconds of pre-incan-
Incorrect operation of the metering
pump.
Checkandreplaceif necessary.
valve (after 30 seconds of preincan
descence)
Inefficient thermal limiter. Checkandreplaceif necessary.
Inefficient safetyswitch. Check current flow and replace, if
necessary.
Inefficient electricsystem. Check for breaks in electric cables and
fittings.
oat|o |o .oo't |o|to Inefficient heatingplug. Check and replace, if necessary, the
plug. Checktheambient thermostat.
Inefficient control unit. Checkthecontrol unit.
Heater not runningat full capacity. S.|tc| sot to 'ooocoo o.o' os|t|oo.
Heater does not yield enoughheat
Ambient thermostat not set to thede-
sired temperature.
Adjust theambient thermostat.
Inefficient electricsystem. Checktheelectricsystem.
Incorrect assemblyof fuel pump. Verifythat the fuel pump ispositioned
onthechassiswithaninclinationof 30
relativetothehorizontal planeandwith
thepower cablesfacingupwards.
Incorrect CO
2
(Carbondioxide) value
Inefficient silencer and fume exhaust
pipe.
Clean and verify that they are not
clogged. Replacethem, if necessary.
2
( )
Dirtyheat exchanger. Checkandcleantheheat exchanger.
Inefficient evaporatingfelt. Checkandreplace,ifnecessary,thefelt.
Incorrect meteringpumprate. Check the pump rate and adjust the
CO
2
value.
(Continue)
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 73 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Visible Failur e Possible cause Repair action
Inefficient safetyswitch. Checkthesafetyswitch.
Inefficient photoresistor. Check and replace, if necessary, the
photoresistor.
ff
Incorrect heater operating tempera-
ture.
Checktheambient thermostat and the
combustionair circuit.
Heater isswitchedoffduringoperation
due to afailure
Incorrect fasteningofheaterto thesup-
port.
Check the fastening bolts and tighten
themto torque.
Incorrect combustion. Checkandtroubleshoot.
Incorrect operation of the metering
pump.
Check and replace, if necessary, the
pump.
Inefficient combustion air circuit. Checkthecombustion air circuit.
Aquila Trucks Centres
74 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
MAIN DATA
Coolingfluid Type R 134A
Amount of thesystemcoolingfluid
VEHICLE COMPRESSOR
R134 COULANT
QUANTITY PROVIDED
FORIN SYSTEM
COULANT
QUANTITY CONTAINED
IN THEPIPINGS
(150 cmlength)
THAT AREUSEDFOR
RECHARGING
COULANT TOTAL
QUANTITY TOBESET
ON CHARGINGTOOL
OILQUANTITY TOBE
ADDEDINTOSYSTEM
AT EACHND 8 TYPE
CHARGING
TRAKKERAT/AD DENSO10PA 17 700g
200gforlowpressure
pipe, 200gforhigh
pressurepipe
1000g 40g
COMPRESSOR NIPPONDENSO
Type 10PA 17
Number of cylinders 10
Bore mm 29.5
Stroke mm 6
Revsnumber:
max.
min.
rpm
rpm
9000
Coolant R 134a(ecology)
Typeof oil ND 8
ELECTROMAGNETIC CLUTCH
Revsnumber:
max.
min.
rpm
rpm
9000
Disengagingtorque kgm 4
Ratedvoltage V 24
Minimumengagement voltage V 7.5
Playbetween front discandpulley mm 0.4 0.8
AUXILIARY HEATER
Air-typeheater withburner Eberspcher
Type D3L
Ratedvoltage 24V
Calorific yield:
full capacity
reduced capacity
KW (Kcal/h)
KW (Kcal/h)
3.2
1.0
Permitted max. temperature at heater air inlet +40 C
Heatingair flow rateat 0.5 mbar:
full capacity
reduced capacity
m
3
/h
m
3
/h
160
65
Aquila Trucks Centres
BODYWORKANDCHASSISFRAME 75 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
GENERAL WARNINGS
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm kgm
GASPIPESFITTINGS
5/8' - +8 ||| 15.9 1.6
3/+' - +8 ||| 15.9 1.6
+' - ++ ||| 29.8 3
86739
Figure176
Make sure that replacement parts (filter, condenser,
evaporator,pipesandfittings) aresuppliedcompletewiththe
protectioncapsagainst dirt andmoisture.
Thesecapsmust beremovedonlywhen thepart isreadyto
beinstalled.
Coossos aoo, soot|os, oc|aoos aoo ||tos, too
ao oo||vooo .|t| s|||t |otooa| osso|zat|oo, to ovoot
moisture penetration.
Verifythat gas escapeswhen the protectioncapis opened:
thiswill provethat thecomponent hasbeenstoredcorrectly.
Make surethat thepipe connections, both to one another
andto othercomponents, aremadeso astoensureperfect
tightnessofthesystem. Coolingfluidleaksdonot onlycause
systemstoppage, but also fast compressor wear.
Therefore,youshouldcheckthepresenceoftheseal ringon
thefittingmaleportion: moistenwith oil, thesameusedfor
thesystem(bearinmind,inanycase, that it differsaccording
to thetypeof coolant), andavoid, when assembling,making
cutsorburrsbetweenthecouplingsurfaces,whichcausegas
leaks.
Followtheinstructions below.
Manuallyandcarefullyinsert themaleportionintothefitting
female drill until collar (2) comes into contact with the
correspondingmetal seat in the female.
Suchcontact ensuresmechanicsupport tothepipe:seal ring
(1) pressedbetweentheinternal cylindrical portion andthe
drill provideshydraulic seal.
Do not use oversized-diameter or twin seal rings: they
temporarilyperformhydraulic seal, yet prevent the contact
betweenthemetal seats, causing,after ashort period,fitting
looseningand gas leaks.
When disconnecting the system pipes, plug the
pipes and the coolant passages (if any), so as to
avoid possible moisture or dirt penetration inside
thesystem. Thiscan badlyaffect correct operation
of thesystem.
NOTE
Aquila Trucks Centres
- Unscrewthescrews(2) fixingtheheater (5) tothecross
member onthecab.
- Detach the clamps(1) of thewiringbundles.
- Disconnect the connectors (4) and detachthe relative
electric wiring(3).
- Detachtheheater (5) fromthevehicle.
77122
77124
Figure177
- Workingfrominside the cab, unscrew the screws (1)
fixingtheair ducts (2) to the heater (3).
- Disconnect theair ducts (2) fromtheheater (3).
553210 HEATER
Removal
For disconnectingheater assembly, it is needed to:
- For vehicleswith air conditioner:
position the keyof ignition b|oc' to'|o Co' os|t|oo
aoo s.|tc| a| tooatoo to '|C\'.
- For vehicleswithout air conditioner:
fromtheinsideofthecab,turntheknobforadjustingcab
heating temperature so as to completelyopen engine
coolant tap.
- partiallydrainengine coolant.
- detachthefasciacovering(552211).
- Lift theradiator cowling.
- Unscrew the fixing screws (1) and separate thepollen
filter cover (2) to access theunderlyingfasteners.
Figure178
77123
If the cab isprovided with air conditioner, blow gas off cab
air conditioningsystem, as describedinrelatingchapter.
Figure179
Figure180
77125
Refitting
For reconnection, invert operations described for
disconnection, observingfollowingwarnings:
- tightennutsor screws at prescribedtorque;
- theenginecoolant is at theright level;
- the systemand components involved in the described
procedurework properly.
- if present, fill air conditioner systemas described in
relatingchapter
- Unscrew screws (4) securing low and high pressure
piping(5).
- Remove screws(3) near water pipings.
- Screws(3) near thewater pipes.
- Applyspecial plugsonthehigh andlow pressurepipes
and on theexpansionvalve.
NOTE
Seal air conditioning systempipings to prevent
moisture or impuritiesfromenteringthesystem.
NOTE
This operation must be carried out only by
authorized, qualifiedskilledpersonnel.
76 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
REPAIR OPERATIONS
Aquila Trucks Centres
- Disconnect theelectrical connection(4).
- Loosenclamp(1) andreleasepiping(2) fromheater (3).
- Disconnect additional heater (3) fromthecab.
77126
Figure181
Removal
- Lift theradiator cowling.
- Tilt upthecab.
- Unscrewthescrews(7) oftheclamps(6) anddisconnect
thefuel pipe(5).
- Unscrew thescrews (1).
- Disconnect the clamps (2) and detach the inlet and
outlet pipes(3).
- Unscrewthenuts(4) fixingtheadditional heatertothe
floor of thecab.
- Lower thecab.
- Closetheradiator cowling.
- Operatefrominsidethecab,advancepassengerseatand
tilt back rest.
99140
Figure182
Refitting
Refit bycarrying out the procedures described for
removal inreverseorder.
Figure183
- Take off object holder box, unscrew securingscrews,
removetheBodyControl andput asideasinFigure 90.
- Disconnect thepower supplyconnector (2).
- Unscrew thefixingscrews (1).
- Detach the air recirculationdoor control motor (3).
553153 AIR RECIRCULATION DOOR
CONTROL MOTOR
77131
Removal
Refitting
Refit bycarrying out the procedures described for
removal inreverseorder.
To perform interventions on below described
components, it could be necessary, owing to
difficult access to components, to take off the
coatings of dashboard (Op. 552211) and heater
(Op. 553210).
NOTE
BODYWORKANDCHASSISFRAME 77 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
507570 ADDITIONAL AIR HEATER SYSTEM
Aquila Trucks Centres
77137
Before proceeding to detach the heater radiator, it is
necessaryto:
- For vehicleswith air conditioner:
os|t|oo t|o 'o o |o|t|oo b|oc' to|o Co' os|t|oo aoo
s.|tc| a| tooatoo to '|C\'.
- For vehicleswithout air conditioner:
fromtheinsideofthecab,turntheknobforadjustingcab
heating temperature so as to completelyopen engine
coolant tap.
- Partiallydrainengine coolant.
- Detach the pollen filter and cover (Figure195).
- DetachBodyControl as indicated on Figure90.
- Detach the bottom covering of the fascia on the
passenger side.
- Detachtwo passenger air openings.
- Detachtheairdeliverypipefromthecentral bodytothe
rh door opening.
- Disconnect the retaining clamps (1) and separate the
water pipes(2).
553215 HEATER RADIATOR
Removal
Refitting
Refit bycarrying out the procedures described for
removal inreverseorder.
77136
- Detach the electric fan (1) fromits seat.
Figure184
Figure185
77135
Figure186
Removal
Performtheremoval procedure:
- Central instrument panel (OP. 553710).
- Disconnect theconnector (2).
- Takeoffthefixingclips (1), unscrewthescrews(3) and
detachthecovers (4) and(5).
553212 ELECTRIC FAN
Figure187
77138
- Operatingthroughthecontrol unit compartment at the
bottomof the fasciacovering, unscrew the screw (2)
fixingtheclevis (1) andfreetheheater water pipes (3).
78 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
77140
- Detachtheconnectors(1),(2) indicatedtofacilitatethe
outflow fromtheheater radiator.
Refitting
For reconnection, invert operations described for
disconnection, observingfollowingwarnings:
- tightennutsor screws at prescribedtorque;
- theenginecoolant is at theright level;
- the systemand components involved in the described
procedurework properly.
Figure188
77139
- Detachtheconnectors(1),(2) indicatedtofacilitatethe
outflow fromtheheater radiator.
- Takeoff theclipsanddetach the pipe(3).
- Unscrewthescrews(4) fixingtheradiatorto theheater.
Figure189
Figure190
77141
- Extract theheaterradiator (1) withduecautionfromthe
glovecompartment bay.
553216 TAP
Removal
77137
Figure191
Before proceeding to detach the heater radiator, it is
necessaryto:
- For vehicles with air conditioner:position the key of
|o|t|oo b|oc' to|o Co' os|t|oo a oo s.|tc| a|
tooatoo to '|C\'.
- For vehicleswithout air conditioner:
fromtheinsideofthecab,turntheknobforadjustingcab
heating temperature so as to completelyopen engine
coolant tap.
- Partiallydrainengine coolant.
- Detach the pollen filter and cover (Figure195).
- DetachBodyControl as indicated on Figure90.
- Detach the bottom covering of the fascia on the
passenger side.
- Detachtwo passenger air openings.
- Detachtheairdeliverypipefromthecentral bodytothe
rh door opening.
- Disconnect the retaining clamps (1) and separate the
water pipes(2).
BODYWORKANDCHASSISFRAME 79 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Figure192
90040
- Unscrew screws (1), take off pressure button, and cut
checkstrap (3) andtakeoff thepipingfor air duct (2).
Figure193
77138
- Operatingthroughthecontrol unit compartment at the
bottomof the fasciacovering, unscrew the screw (2)
fixingtheclevis (1) andfreetheheater water pipes (3).
Figure194
90041
- Lift fastener (2) anddisconnect piping(3) fromradiator
(1).Byspecial pliers,pressfins(5) anddisconnect tierod
(4). Removescrews andtaketap(6) off the heater.
Refitting
Refit bycarryingout the proceduresdescribed for removal
inreverse order.
- tightennutsor screws at prescribedtorque;
- theenginecoolant is at theright level;
- the systemand components involved in the described
procedurework properly.
77142
Figure195
553261 POLLEN FILTER
Removal
- Lift the cowling, lift cover (1) and remove anti-pollen
filter (2).
Refitting
Refit bycarrying out the procedures described for
removal inreverseorder.
Figure196
90042
- Discharge the air-conditioningsystembyfollowingthe
proceduredescribedunder therelevant heading.
- Working fromunder the vehicle, unscrew the fixing
screws (2) and remove the inlet and outlet pipes (3)
fromthecompressor.
553239 AIR-CONDITIONER
COMPRESSOR
Removal
80 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
- Detach the outsideair temperature sensor (1) fromits
seat.
- Lift the cowling and bleed air-conditioning system
observing the procedure that is described in relating
chapter.
- Unscrewthenut (6)anddetachthecondenserpipes(5).
- Unscrew thenut (4) fixingthepipebracket (3).
- Unscrew the fixing screws (1) and remove the
condenser (2) fromthevehicle.
77146
Figure197
Removal
77147
- Lift theradiator cowlingand disconnect theconnector
(1) and free the wiring (2) of the sensor (3) fromthe
retainingclamps(4).
553232 AIR-CONDITIONER
CONDENSER
553242 OUTSIDE AIR TEMPERATURE
SENSOR
Removal
Figure198
Figure199
77148
Refitting
Refit bycarrying out the procedures described for
removal inreverseorder.
- Loosen the automatic tightener and take off the
compressor belt.
- Disconnect thepowersupplyconnector (1,Figure 196).
- Unscrew thefixingscrews (5, Figure196).
- Takecompressor (4, Figure196) off theengine.
Seal air conditioning systempipings to prevent
moisture or impuritiesfromenteringthesystem.
NOTE
Refitting
Replacethesealinggasket.
Tightenthefasteningscrewsandtheadapterstothe
specified torque.
Fill air conditioner systemas described in relating
chapter.
Refitting
Replacethesealinggasket.
Tightenthefasteningscrewsandtheadapterstothe
specified torque.
Fill air conditioner systemas described in relating
chapter.
BODYWORKANDCHASSISFRAME 81 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
543921 REPLACING THE ELECTROMA-
GNETIC CLUTCH
Figure200
39852
Stop front disc (1) rotation, then unscrewretainingnut (2)
and removethe spacer below.
Figure201
39854
Usespecial rounded-tipplierstoremovepulley(2) retaining
snap ring(1).
39855
39915
39856
Figure202
Figure203
Figure204
Use extractor 99341001 (1), equipped with brackets
99341009 (2), to takeout pulley (3).
Remove the plate fastening screw with the envelope from
thecompressor.
Loosen screw (4), thus releasing magnetic coil (1) supply
electric cable(3).
Usespecial rounded-tippliersto removeretainingsnap ring
(2) and takeoff magneticcoil (1).
Placethenewmagneticcoil (1) inposition,so that centering
pin (2) engages into therespective hole (3).
82 BODYWORKANDCHASSISFRAME TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
39916
39917
39852
Figure205
Figure206
Figure207
Fit retainingsnapring(2). Tightenscrew(3),thensecurecoil
(1) supplyelectriccable(4) to thecompressor body.
Mount pulley (2), then retainingsnap ring(3) and adjusting
shim(1).
Mount front disc(1),stoprotation,thentightenretainingnut
(2) to atorqueof 35 40Nm(3,5 4Kgm).
39919
39920
Figure208
Figure209
Check, by means of a thickness gauge (3), that the play
between front disc (1) and pulley(2) is0.4 0.8 mm.
Iftheclearancebetweenthefrontdiscandthepulleydoesnot
correspondtotheprescribedvalue,removethefront discand
replace the adjustingring (1) with one having the suitable
thickness.
BODYWORKANDCHASSISFRAME 83 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
PROCEDURE FOR DRAINING AND
RECHARGING AIR CONDITIONING
SYSTEMS WITH RECHARGING STATION
99305146AND RECOVERY OF R134A
COOLANT
Thisstation hasbeenmadeto be used onall air-conditioning/
heatingsystems for motor vehiclesusingR134A gas.
Byconnecting the station to a refrigeratingsystemthe gas it
contains can be recovered, cleaned and made ready to be
reloaded into the system or be transferred to an external
container.Inaddition,itispossibletoseetheamountofoiltaken
o t|o ssto, ostoo |t aoo 'ot' t|o ssto.
To be operative, thestationneedsto absorbapproximately3
kgof refrigerant.
For prompt useit is advisedto haveat least 2kgof refrigerant
inthefiller cylindersandtokeepthestationaslevel aspossible.
Thestationiscomposed of:
1 control panel;
2 container to restoreanyoil recovered whenunloading;
3 flexiblehoses;
4 container to collect anyoil recoveredfromthesystem;
5 filler cylinder withgraduated scalerevolving.
Figure210
1
2
3
4
5
50631
This procedure does not describe the phases of
loading and unloading refrigerant to and from
external and internal containers or maintenance.
Therefore, please refer to the operating and
maintenance manual oftheappliance.
NOTE
84 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
A Aquila Trucks Centres
- never expose the unit or operate it in acidic or wet
environmentsorclosetoopencontainersofinflammable
substances;
- theunit must operateinplaceswith goodventilation;
- never alter thesettings of the safetyvalves and control
systems;
- neverusebottlesorotherstoragecontainersthatarenot
approvedand arenot fitted withsafetyvalves;
- never load any container over 80% of its maximum
capacity;
- never leave the unit powered if it is not to be used
immediately. Cut off themains power supplywhen it is
not plannedto usetheequipment.
SAFETY STANDARDS
- always wear gloves and goggles when working with
refrigerant gases. Contact of refrigerant liquid with the
eyes cancause blindness;
- avoid all contact with skin (low boilingpoint -30 C can
causefrostbite);
- never inhalethevapoursof refrigerant gases;
- beforeconnectingthestation withasystemor external
container, checkthat all thevalvesareclosed;
- beforedisconnectingthe station, checkthat the cycleis
over and all the valves are closed. This will prevent
dispersingrefrigerant gasinto theatmosphere;
The station is equipped with special fittings to avoid
contamination with systems using R12. Do not attempt to
adapt this unit for usewithR12.
This station is exclusively for professionally trained
operators who must be familiar with refrigerating
systems, refrigerant gasesandthedamagepressurized
equipment cancause, therefore:
!
BODYWORKANDCHASSISFRAME 85 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
FILLER CYLINDER
OIL TANK
Figure211
Figure212
50634
50632
86 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
CONTROL FASCIA
Aquila Trucks Centres
M1 Lowpressuregauge
M2 High pressuregauge
M3 Filler cylinder pressuregauge
LOW Low-pressurevalve
HIGH High-pressurevalve
REF Refrigerant filler anddrainvalve
V1 Valveonlow-pressurepipe
V2 Valveonhigh-pressurepipe
V3 Oil injectionvalvefor A/C system
V5 Oil drainage valve
V9 A/C systemwashingrefrigerant servicevalve
10 Moistureindicator
VS Safetyand drainagevalve
L3 Alarmwarninglight
L4 Maximumlevel warninglight
L5 Minimumlevel warninglight
A Unit process / bottleheater switch
LA1 Unit processindicator light
LA2 Bottleheater indicator light
B Refrigerant process / vacuumprocessswitch
LB1 Refrigerant process indicator light
LB2 Vacuumprocessindicator light
C Recoveryrecyclecycle / Fillingswitch
LC1 Recoveryrecycle cycleindicator light
LC2 Fillingindicator light
D Vacuum/ vacuumtest switch
LD1 Vacuumindicator light
LD2 Vacuumtest indicator light
Control fasciadiagramlegend
Filler cylinder legend
1 Pressure values in bar (vertical lines, revolving top
cylinder).
2 Weight of load in grams (oblique lines, revolving top
cylinder) 50 gdivisionbetween lines.
3 Tanklevel viewer (internal cylinder).
BODYWORKANDCHASSISFRAME 87 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
Drainoff oil
fromthesystem
Preparingthestation
First recovery
Wait 3-5 minutes
Second recovery
Operateonthesystem
Vacuumfor 5-10minutes
withfirst vacuumtest
Vacuumfor 30minutes
withsecondvacuumtest
Load oil
into thesystem
Loadupto 200g
refrigerant
Search for leakagewith
electronic leak finder
Fullyload
thesystem
Searchsystemfor leakagewith
electronic leak finder
Pressurecheck
Arethevalues
acceptable?
Disconnect thestation
fromthesystem
NO
NO
YES
YES
NO
NO
YES
YES
YES
NO
Is thereany
leakage?
Is thereany
leakage?
Is thereany
leakage?
Is thereany
leakage?
88 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
OPERATION FLOW CHART
Aquila Trucks Centres
RECOVERING REFRIGERANT
FROM THE VEHICLE SYSTEM
Before starting to disconnect the pipes from the
air-conditioner,checkwhether it ispossibletodotherepairs
without dischargingthegas.
Ifthisisnotpossible,thefollowingoperationsmust becarried
out:
- connectthepipemarkedHIGHunderthepressuregauge
to theevaporator inlet (theinlet isthe oneon the
pipe with a smaller diameter (H) connecting the drier
filter withtheevaporator);
- connectthepipemarkedLOWunderthepressuregauge
totheevaporatoroutlet(theoutletistheoneonthepipe
withalargerdiameter (L) connectingtheevaporatorwith
thedrier);
- open thevalvesV1and V2;
- open theLOW andHIGH cocks;
Figure213
77049
BODYWORKANDCHASSISFRAME 89 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
If the refrigerant reaches the maximum level
(maximumlevel indicatorlightL4on),therecovery
cycle must be stopped immediately by pressing
switch C onto position 0 and transferring the
refrigerant from the filler cylinder to a suitable
external bottle.
- put the switchesA, BandC backontoposition 0;
- closetheV1, V2, LOW andHIGH valves.
- connectthestationtotheelectricitymains(220V-50Hz);
- press theswitch A (Process Unit) onto position1.
Therespectiveindicator light LA1 will comeon;
- presstheswitchB(Refrigerant Process) onto position1;
- therespectiveindicator light LB1 will comeon;
- press theswitch C (RecoveryRecycle) onto position 1.
The recovery and recycling operation will start
automatically.Therespectiveindicator light LC1will come
onto signal theoperationinprogress.
On completing this operation the unit will automatically
stop and the indicator light LC1 go out. Wait for a few
minutesso that anypocketsofrefrigerant at lowpressure
remaining in the systemcan increase their pressure, by
absorbingheat, and beable to berecovered. Thestation
will automatically repeat the recoverycycle if the above
conditionsoccur;
- Continuetheoperationsfollowingtheinstructionsgiven
onthefollowingpages.
Figure214
50636
NOTE
90 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
- connect thepipestothespecificsystemconnectionsand
open theV1-V2/LOW and HIGH valves;
- press theswitchA (Process Unit) onto position1.
Therespectiveindicator light LA1 will comeon;
- press theswitchB (VacuumProcess) onto position 2.
Therespectiveindicator light LB2 will comeon;
- presstheswitchD(Vacuum) ontoposition1.Thesystem
willautomaticallystartbeingevacuatedandtherespective
indicator light LD1 will comeon to signal theoperation
inprogress.
CREATING A VACUUM IN THE SYSTEM
This operation should be carried out if all the repairs have
been performed and the systemcomponents have been
properlyrefitted.Thisoperationisthephasepriorto refilling,
thereforeproceed as follows:
Afterafewminutesofoperation(10atmost) ifthesystem
hasno leakstheindicator light LD2VACUUM TEST will
also come on. Fromthis time on, evacuation should be
continued for at least two hours to obtain a good
evacuation;
- at theendof thetimeprogrammedfor evacuation,press
theswitchD(vacuumtest) ontoposition2andleavethe
systeminthisstatefor 3-5minutes.
The indicator light LD2 VACUUM TEST is on if the
systemhasagoodseal.TheindicatorlightLD2VACUUM
TEST goes out if there is aleak. Eliminate the leak and
repeat theevacuationcycle;
- put the switches D and B back onto position 0 and
proceedwiththefollowingphase.
Figure215
50637
Do not run the vacuumcyclewhen thereiseven
minimal pressureinthestationor system.
Theindicator light LD2vacuumtest failsto come
onifthereisaleak. Stopevacuation,eliminatethe
leakandrepeat theevacuationprocedure.
NOTE NOTE
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Aquila Trucks Centres
It ispossiblethat at theendofeachrecoverycyclethestation
may have recovered lubrication oil from the compressor,
whichshouldbedrainedoffintoaspecificgraduatedcontainer
(1).
1 Slowlyopen thevalveV5 (Oil Discharge).
2 Whenall theoil hasbeendischargedintothecontainer (1)
closethevalveV5.
3 Quantifyandrecordtheamount ofoil discharged.
4 Eliminate therecoveredoil correctly.
Thisoil cannot bereused.
Thesameamount of newoil as hasbeen removedmust
beadded tothesystem.
Figure216
1
50638
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RESTORING OIL IN THE SYSTEM
Ifduringtherecoveryandrecyclephase, oil fromthesystem
hasbeenremoved, it must nowbereplenished:
- takethemeteringdevicesupplied withtheright amount
of lubricant for the system concerned, or previously
measured;
- connectthemeteringdevice(1) tothelubricant injection
valve V3;
- openthevalveV3andthencarryout thesystemvacuum
phase for afewmoments;
- open the valve mounted on the metering device
container (1). Theoil will bedrawn into thesystem;
- closethevalveV3andthevalveonthemeteringdevice
container when the required quantity of lubricant has
beendrawnin;
- disconnect the metering device (1) fromthe injection
valve V3and fit theprotectivecap backon;
Figure217
- never open the oil injection valve V3 if the systemhas
positivepressure;
- oil should onlybeinjected withavacuuminthesystem;
- theoil level must never fall under the suction pipe (air
wouldget into thesystem).
1
50639
Keeptheoil containerswell sealedinordertoavoid
contamination. In particular, remember that oil is
extremelyhygroscopic:
NOTE
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FILLING THE SYSTEM WITH
REFRIGERANT
Beforerefilling,it iswisetobeawareofsomeimportantrules:
- know the quantity of refrigerant to use (it is normally
writtenonanadhesiveplateaffixedon thevehicle);
- thefillercylinder isequippedwithaminimumlevel check
that prevents introducing incondensable gas into the
system.
Thisiswhythelast approx.600gofrefrigerant it contains
cannot beused;
- therefore, before filling, check that the cylinder contains
asufficientquantityforfilling(maximumquantitythat can
beused 3800g);
- if the pressureinside thefiller cylinder indicated on the
pressuregauge(2) isgreater thanasrequired, whichcan
beseenonthefillercylinderwindowapprox.10barmax,
dischargethe excess pressure through the valve (1) on
thepressuregaugeassemblytobringit downtotheright
level, readingthevalueon thepressuregauge.
Figure218
2
1
50640
To transfer refrigerant froman external bottleto
the filler cylinder and vice versa, refer to the
equipment manual.
Considering that the amount of refrigerant
dependsonitspressure, toknowtheactual weight
it is necessary to turn the outside of the filler
cylindersothelineofthediagrammatchesthelevel
viewer.Inthiswaywecanknowtheexact quantity
of refrigerant inthecylinder (startingweight).
Whencalculatingtheweight of therefrigerant, in
addition to the 600 g that cannot be used,
remember to increase the load byapproximately
100g(thisistheweight ofrefrigerant containedin
the station-systemconnecting pipes). The right
quantityofrefrigerant tointroduceintothesystem
willthereforebegivenby:600g+100g+(quantity
referredto thesystemcapacity).
Alwayscheckbeforefillingthattheindicatoronthe
'cooso|o' s|o.s t|o o|oaot coota|os oo
moisture, inwhichcasetheindicator will bebright
green. If this is not so, replace the filters in the
stationasinstructedintheequipment manual.
NOTE
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Aquila Trucks Centres
Whenthecylinder contains the necessaryquantityfor filling
(both pipes must already be connected to the system
connectors since the vacuumoperation has already been
performed), proceedasfollows:
- closetheLOW valve,keeptheHIGH andV1- V2valves
open;
- presstheswitchB(Refrigerant process) ontoposition1,
theindicator light LB1will comeon;
- press the switch C (Charge) onto position 2, the
respectiveindicatorlightLC2willcomeonandrefrigerant
will flowfromthestationintothesystem;
- havingloaded 200 500 gof refrigerant, dependingon
thesizeofthesystem, stopfillingbymovingtheswitchC
(Charge) onto position0;
- check thesystemisproperlysealed with theelectronic
leakfinder;
- complete filling the system until the pre-calculated
residual weight inthecylinder isreached;
(Residualweight=Total weight-Systemcapacityweight)
- complete filling, move the switches C - B and A onto
position0(A hadbeen movedfor thevacuum).
Check againthereis no leakage;
- closetheHIGH valve.
Figure219
50641
Whenfilling, ifthelevel of refrigerant inthecylinder
fallsundertherequiredquantitythesystemwill stop
andtheMinimumLevel indicator light(L5) will come
on.
NOTE
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OPERATIONS PRIOR TO DISCONNECTING
THE STATION FROM THE SYSTEM
Alwaysobservingtheabovesafetyrules,carryout thefollowing
operations:
- checkthat all thevalvesareclosed:LOW - HIGH,V1- V2;
- disconnectthepipesofvalvesV1- V2andputthecapsback
onto thesystemvalves;
- Check thesystemagainwiththeleak finder.
CHECKINGTHEPRESSURESIN THESYSTEM
After filling, leave the pipes connected and carry out the
followingcheck:
- closetheHIGH andLOW valves, V1and V2open;
- turnontheengine,switchontheair-conditioner andcheck
on the pressure gauges M1 and M2 that the pressures
correspond,normally: lowpressurenolessthan1bar,high
pressure 15 18 bar, depending on the system
specifications.
Figure220
50642
Normally, withtheair-conditionerswitchedon,air
should come out of the vents at a temperature
lowerthan5 C andafteraperiodof operationto
stabilizethe temperatureoftheducts.
NOTE
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Figure221
This procedure does not describe the charge/drain
phases of coolant frominternal/external tanksandit
does not provide indications on maiintenance
interventionsrequired.
For theseoperations, pleaserefer to theequipment
supplier useand maintenancemanual.
NOTE
115615
1.Serial port - 2. TVtemperatureprobe connector - 3. Electrical probeconnector - 4. Handle- 5. Tracer container -
6. New fluid container - 7. Fluid scales- 8. Usedfluidcontainer - 9. Taps- 10. Control console- 11. Dehydratingfilters-
12. Moisturegauge- 13. Master switch - 14. Fuse- 15. Electric plugsocket - 16. Fluidcontainer flap- 17. Vacuumpump -
18. Electronic scale- 19. Heater coil - 20. Cylinder
Tobeoperative, thestationneeds to absorb approximately
3kgof refrigerant.
Forprompt useit isadvisedtohaveat least2kgofrefrigerant
inthefillercylindersandtokeepthestationaslevel aspossible.
Thisstation hasbeenmadeto be used onall air-conditioning/
heatingsystems for motor vehiclesusingR134A gas.
Byconnecting the station to a refrigeratingsystemthe gas it
contains can be recovered, cleaned and made ready to be
reloaded into the system or be transferred to an external
container.Inaddition,itispossibletoseetheamountofoiltaken
o t|o ssto, ostoo |t aoo 'ot' t|o ssto.
Main components
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PROCEDURE FOR DRAINING AND
RECHARGING AIR CONDITIONING
SYSTEMS WITH RECHARGING STATION
99305148AND RECOVERY OF R134A
COOLANT
Aquila Trucks Centres
- always connect the pipe with the RED machine quick
couplingto theA/C systemhigh pressurebranch.
Always connect thepipe withtheBLUEmachinequick
couplingto theA/C systemlow pressurebranch.
Keep the connection pipes far away frommoving or
rotatingobjectsor parts(coolingfan, alternator etc.).
Keep the connection pipes far awayfromhot items or
parts(engineexhaust pipes, radiator etc.);
- always fill the A/C system with the amount of fluid
recommended bythemanufacturer.
Never exceedthis amount. Alwayscheck thefluidlevel
beforeeachoperation.
Alwaysaddthe correct amount of fluid.
Check the electric mains is 220-240V/50Hz before
connectingthemachineto themains;
- thecylinder must befilledto 80%of maximumcapacity
to leaveagasreserveto absorb anypressureincreases.
Never touchtheinternal cylinder taps.
Dispose of fluid extracted fromthe A/C systemand
vacuumpump inspecial wastefluidcontainers.
Change the filters at the required intervals using only
filtersrecommendedbythemanufacturer.
Only use fluids recommended by the manufacturer.
Neverswapthevacuumpumpfluidwithairconditioning
systemfluid.
Anyguaranteesonthemachinewill benullandvoidifthe
abovesafetyrulesarenot complied with.
SAFETY STANDARDS
- always wear gloves and goggles when working with
refrigerant gases. Contact of refrigerant liquid with the
eyes cancause blindness;
- avoid all contact with skin (low boilingpoint -30 C can
causefrostbite);
- never inhalethevapoursof refrigerant gases;
- beforeconnectingthestation withasystemor external
container, checkthat all thevalvesareclosed;
- beforedisconnectingthe station, checkthat the cycleis
over and all the valves are closed. This will prevent
dispersingrefrigerant gasinto theatmosphere;
- never expose the unit or operate it in acidic or wet
environmentsorclosetoopencontainersofinflammable
substances;
- theunit must operateinplaceswith goodventilation;
- never alter thesettings of the safetyvalves and control
systems;
- neverusebottlesorotherstoragecontainersthat arenot
approvedand arenot fitted withsafetyvalves;
- never load any container over 80% of its maximum
capacity;
- never leave the unit powered if it is not to be used
immediately.
Cut offthemainspowersupplywhenit isnot plannedto
usetheequipment;
This station is exclusively for professionally trained
operators who must be familiar with refrigerating
systems, refrigerant gasesandthedamagepressurized
equipment cancause, therefore:
!
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114767
Figure222
1. Keypad - 2. AlphanumericLCD - 3. Printer
Keypad functions
STOP: Usethiskeytostopthecurrent operation(recovery
- drainfluid - empty- add fluid - fill).
Press the START keyagainto start again fromthe previous
point.
ThehornisswitchedoffiftheSTOPkeyispressedduringan
alarm, anerror or at theend of anoperation.
ENTER: This key confirms the procedure or operation
flashingontheLCD.
: This keyisusedto movefromoneproceduretoanother
or fromoneoperationto another, fromtopto bottom.
: This keyisusedto movefromoneproceduretoanother
or fromoneoperationto another, frombottomtotop.
START: This key activates the confirmed procedure or
operation.
PressSTARTonlywhenrequestedtobytheLCD). NOTE
CYLINDEREMPTY ALARM: displayedandemitsanacoustic
alarmwhen too little coolant is present insidethecylinder.
NEW FLUIDCONTAINER ALARM: displayedandemitsan
acoustic alarmwhen the volume of new fluid drops below
approximately 50 cm
3
.
USED FLUID CONTAINER FULL ALARM: displayed and
emitsanacousticalarmwhenthevolumeofusedfluiddrops
exceedsapproximately200 cm
3
.
LEAKS IN A/C SYSTEM ALARM: displayed and emits an
acousticalarmafterthefirst 10minutesofvacuumifthereare
leaksintheA/C system.
Detectionof micro-leakscannot beguaranteed. NOTE
Emergency warning light panel
HIGHPRESSUREALARM: isdisplayedandemitsanacoustic
signal whenfluidpressureinthecircuit exceeds 17.5 bars.
Therecoveryoperationisautomaticallyhalted.
CYLINDER FULL ALARM: displayed and emits an acoustic
alarmwhen more than 80% of the maximumcapacity is
present in thecylinder, i.e. 9.5 kg.
RECOVERY operationisautomaticallyhalted (to cancel this
alarm, one or more A/C systems must be charged before
recoveringmorecoolant).
SERVICE ALARM: displayed and emits an acoustic alarm
when 150kgof coolant arerecovered.
To deactivate, replacethefiltersandvacuumpump fluid.
Together withthefilters, acodewill besent toeliminatethe
alarm.
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CONTROL PANEL
Aquila Trucks Centres
Checkthat theswitch (13, Figure221) is in position 0.
Check that all the machinetapsareclosed.
Connect the machineto themainsand turnon.
Checkthatthepumpfluidlevel gaugeindicatesatleasthalffull.
If thelevel islow, fuel must beadded.
Checkthe additional fluid container (6, Figure221) contains
at least 100cm
3
of fluid.
Check the machineLCD to ensure the cylinder contains at
least 3kgof coolant.
Ifnot,refill theinternal cylinder usinganexternal cylinderwith
appropriatecoolant.
AUTOMATIC PROCEDURE
All the operations are carried out automatically in the
automatic procedure: recovery and recycling, fluid drain,
vacuum, additionof newfluidand refilling.
Theamount of gasrecovered, recoveredfluid, vacuumtime,
fluid added and the amount of gas injected are printed
automaticallyat theendofeachindividual operation.
Connect the hoses to the A/C system using the quick
couplings, takingcareto connect theBLUEhose to thelow
pressure branch and the RED hose to the high pressure
branch.
If thesystemis equipped with asinglehigh or low pressure
quick coupling, onlyconnect therelevant quick coupling.
Check that thehighand lowtapsareclosed.
Turn on the vehicle engine and air conditioner for 5-10
minutes, keepingthepassenger compartment fanrunningat
maximumspeed.
Turnoff thevehicleengine.
The instrument has a four-row display with up to 20
characters per row.
Theselected itemflashes ontheoption menus.
It isindicated betweeninvertedcommas inthismanual.
AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
NEXT MENU
AVAILABILITY XXXX G
VACUUMXX MIN
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
ENTER
Followtheautomatic procedure, i.e. pressENTERwhenthe
ossao '/otoat|c ocoooo' |as|os oo t|o |C|.
<VACUUMXX MIN. >
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
2
0
<VACUUM20 MIN. >
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
Enter thevacuumtimeor confirmthe previoustime. Simply
pressENTERtoconfirmtheprevioustime.Usekeys0-...-9to
set anewtime.
<VACUUM20 MIN. >
AUTOMATIC FLUID
FLUIDXX CC
FILLINGXXXX G
VACUUM20MIN.
<AUTOMATIC FLUID >
FLUIDXX CC
FILLINGXXXX G
ENTER
Once the vacuumtime has been confirmed, the message
'/otoat|c |o|o' bo|os to |as|.
Press ENTER to confirm.
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PRELIMINARY CHECKS
Aquila Trucks Centres
<VACUUM20 MIN. >
<AUTOMATIC FLUID >
FLUIDXX CC
FILLINGXXXX G
VACUUM20MIN.
AUTOMATIC FLUID
FILLINGXXXX G
ENTER
If the automatic fluid is confirmed, the systemautomatically
addstheamount of fluid removed duringrecoveryafter the
vacuumstage.
Ifyouneedto add aquantityof fluid other thanthequantity
drainedafter recovery,set asfollows: oncethevacuumtime
|as booo coo|oo, t|o ossao '/otoat|c |o|o' bo|os to
flash.
Pressthe 'o to ovo to t|o ossao '||o|o cc', ooto
thevolumeof fluid you wishto beadded automaticallyafter
thevacuumusingthekeys0-... 9 andpress ENTER.
<VACUUM20 MIN. >
<AUTOMATIC FLUID >
FLUIDXX CC
FILLINGXXXX G
<VACUUM20 MIN. >
AUTOMATIC FLUID
FLUID 30CC
FILLINGXXXX G
3
0
VACUUM20MIN.
AUTOMATIC FLUID
<FLUID 30 CC >
FILLINGXXXX G
VACUUM20MIN.
FLUID 30CC
<FILLING XXXX G >
ENTER
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VACUUM20MIN.
AUTOMATIC FLUID
<FILLING XXXX G >
8
5
0
ENTER
Coco t|o |o|o |as booo coo|oo, t|o ossao '|||||o
' bo|os to |as|. Sot t|o ooaot|t o coo|aot |o oo .|s| to
add to theA/C system.
For example, if thequantityis850g, press thekeys8, 5 and
0 '|||||o 850 '.
After settingthequantity, confirmwithENTER.
Openthemachinehighandlowpressurefittingsandpressthe
START key.
Ifagasanalyserisinstalled, themachineteststhepurityofthe
air conditioningsystemcoolant.
If thecoolant issufficientlypure, recoverybegins.
IftheA/Csystemdoesnotachievetherequiredlevel ofpurity,
themachineruns asecond test.
Ifthesecondtestfails,themachinedisplaysthealarmmessage
'//C ssto coota|os coota|oatoo coo|aot'.
Contaminatedcoolantcannotberecoveredbecauseitwould
contaminatethe coolant insidethe machinecylinder.
Duringtherecoverystage, thesystemdisplaystheamount of
coolant recovereding.
Once recoveryis complete, themachine stops drainingand
automaticallydisplaysthespent fluid removed fromtheA/C
systemduringrecovery.
Thefluid drainoperationlasts3 minutes. If somepocketsof
coolantremainingintheA/Csystemafterthisoperationcause
thepressureto increase,themachineautomaticallybeginsto
recover thecoolant.
After draining, thevacuumoperationbeginsautomaticallyfor
thepreset time. After thefirst 10minutes, acheck isrunfor
A/C systemleaks (attention: if vacuumtimeis<10minutes,
themachinewill not checkfor leaks intheA/C system).
IfleaksarefoundintheA/C system,themachineautomatically
stos aoo o|s|as t|o '|oa's |o //C ssto' a|a (ootoct|oo
of microleaks isnot guaranteed).
If the A/C systemseal iseffective, the machinewill continue
withthevacuumoperation.
Once the vacuum stage is complete, new fluid is added
automatically according to the amount of fluid drained or
accordingtothevolumeset bytheoperator.
At theend, thesystemautomaticallyswitchesto refillingand
addstheset amount.
Once the refillingoperation is complete, close the machine
highandlowpressurefittingsandturnontheA/C systemto
checkthepressures.
|o|o t|o ossoo c|oc', t|o ac||oo o|s|as '|oss
||T|| to |ot a ossoo a|'.
Toobtainaprint-out,pressENTER.Apressuregraphmaybe
printedfor other checksbypressingtheSTART key.
After thepressure check, the machine displays the message
'||scooooct t|o | |tt|o aoo ooo |-3|'.
Nowdisconnect thequickcouplingonlyfromtheA/Csystem
(turntheengineoff if necessary) andopenthehigh andlow
pressure taps with the A/C systemrunningso that the A/C
systemdrainsoff thecoolant inthe pipes.
After approximatelyone minute, remove the machine low
pressurefittingfromthevehicleA/C systemandturnoffthe
engine.
Set themaster switch(13, Figure221) to0.
The automatic procedure maybe run even if the
A/Csystemisempty.Inthiscase,thesystembegins
directlyfromthevacuumoperation.
IftheA/C systemonlyhasonehighpressurequick
coupling, set thefillingquantityto +150g.
NOTE
ASSISTED PROCEDURE
Intheassistedprocedure, eachoperationmaybecarriedout
individuallyapart fromtherecyclingrecoverystage, whichis
followedautomaticallybythespent fuel drainstage andthe
vacuumfor theset time.
Theamount ofgasrecovered,recoveredoil,vacuumtime,oil
added and the amount of gas injected are printed
automaticallyat theendofeachindividual operation.
VACUUM20MIN.
FLUID 30CC
<FILLINGXXXX G >
Open high and low pressure fittings and
press START
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Aquila Trucks Centres
Recyclingrecovery
Connect the hoses to the A/C system using the quick
couplings, takingcareto connect theBLUEhose to thelow
pressure branch and the RED hose to the high pressure
branch.
If thesystemis equipped with asinglehigh or low pressure
quick coupling, onlyconnect therelevant quick coupling.
Turn on the vehicle engine and air conditioner for 5-10
minutes, keepingthepassenger compartment fanrunningat
maximumspeed.
Turnoff thevehicleengine.
Follow the assisted procedure, i.e. press ENTER when the
ossao '/ss|stoo ocoooo' |as|os oo t|o |C|.
If followingthe assisted procedure, press ENTER when the
ossao '|occ||o ocovo' |as|os oo t|o |C|.
Openthemachinehighandlowpressurefittingsandpressthe
START key.
Ifagasanalyserisinstalled, themachineteststhepurityofthe
air conditioningsystemcoolant.
If the coolant is sufficientlypure, recoverybegins. If theA/C
systemdoes not achieve the required level of purity, the
machinerunsasecondtest.
Ifthesecondtestfails,themachinedisplaysthealarmmessage
'//C ssto coota|os coota|oatoo coo|aot'.
Contaminatedcoolantcannotberecoveredbecauseitwould
contaminatethe coolant insidethe machinecylinder.
Duringtherecoverystage, thesystemdisplaystheamount of
coolant recovereding.
Once recoveryis complete, themachine stops drainingand
automaticallydisplaysthespent fluid removed fromtheA/C
systemduringrecovery.
Thefluiddrainoperationlasts3 minutes.
Ifsomepocketsof coolant remainingintheA/C systemafter
this operation cause the pressure to increase, the machine
automaticallybeginsto recover thecoolant.
Vacuum
Connect the hoses to the A/C system using the quick
couplings, takingcareto connect theBLUEhose to thelow
pressure branch and the RED hose to the high pressure
branch.
If thesystemis equipped with asinglehigh or low pressure
quick coupling, only connect the relevant quick coupling.
Follow the assisted procedure, i.e. press ENTER when the
ossao '/ss|stoo ocoooo' |as|os oo t|o |C|.
To so|oct vacoo, oss ||T|| .|oo t|o ossao 'Vacoo
|o' |as|os oo t|o |C|.
Setthevacuumtimeonlyifyouwishtochangethepreviously
set time.
Press ENTER to confirm.
Open themachine high and low pressure fittings and press
START.
Atthispoint,thevacuumoperationbeginsforthepresettime.
After thefirst 10minutes, acheckisrunfor A/C systemleaks
(attention:ifvacuumtimeis<10minutes,themachinewill not
checkforleaksintheA/C system).LeaksarefoundintheA/C
system, the machine automatically stops and displays the
'|oa's |o //C ssto' a|a (ootoct|oo o |co|oa's |s oot
guaranteed); inthis event, useleak detector 99305147.
If the A/C systemseal iseffective, the machinewill continue
withthevacuumoperation.
Addingnewfluid
This operation may be carried out exclusively following a
vacuumoperationand beforerefilling.
Follow the assisted procedure, i.e. press ENTER when the
ossao '/ss|stoo ocoooo' |as|os oo t|o |C|.
So|oct t|o |o|o, |.o. .|oo t|o ossao '||o|o cc' |as|os oo
the LCD.
Set thevolumeof newfluidto beadded in cm
3
.
Press ENTER to confirm.
Open at least one of thetwo machinehigh or low pressure
valvesand pressSTART.
FillingA/C systems
Follow the assisted procedure, i.e. press ENTER when the
ossao '/ss|stoo ocoooo' |as|os oo t|o |C|.
So|oct o||||o, |.o. .|oo t|o ossao '|o||||o ' |as|os
ontheLCD.
Set theamount youwishto add totheA/C systemingrams
(if an A/C systemcontains740gpresskeys7, 4and 0.
To c|oc', oosoo t|o ossao '|||||o +0' |s o|s|aoo).
Press ENTER to confirm.
PresstheSTARTkeyandopenthemachinehighpressuretap
(iftheA/C systemonlyhasonelowpressurefitting,openthe
machinelowpressuretap).
Once the refilling operation is complete, close the machine
highand lowpressurefittingsand turnontheA/C systemto
checkthepressures.
|o|o t|o ossoo c|oc', t|oac||oo o|s|as '|oss ||T||
to |ot a ossoo a|'.
To obtainaprint-out, pressENTER.
A pressuregraphmaybeprintedfor other checksbypressing
theSTART key.
After the pressurecheck, themachinedisplays themessage
'||scooooct t|o | |tt|o aoo ooo |-3|'.
NowdisconnectthequickcouplingonlyfromtheA/Csystem
(turntheengineoff if necessary) andopenthehighand low
pressure taps with the A/C systemrunningso that theA/C
systemdrainsoff thecoolant inthe pipes.
After approximatelyone minute, remove the machine low
pressurefittingfromthevehicleA/C systemandturn off the
engine.
Set themaster switch(13, Figure221) to0.
If the A/C systemonlyhas onehighpressurequickcoupling,
set thefillingquantityto +150g(thisis theamount that may
remain inthehighpressurepipe).
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Aquila Trucks Centres
LEAK FINDER FOR AIR-CONDITIONING
SYSTEMS WITH HFC R134A (99305147)
Tool L-780AmakesitpossibletoidentifyleakageofHFC134A
gasfromthesystemextremelyaccuratelyintheorder of 3.3
gayear withtheswitchonmaximumsensitivity.
Thisinstrument requiresnosettings, theoperatoronlyneeds
to select thedesiredsensitivity.
Theinstrument warnstheoperator of anygasleakagewitha
buzzer and a LED that flashes in proportion to the
concentrationof gas.
Inaddition, theLED indicatesthebatteryisflat if it goesout.
Operatingtemperatureisbetween0C and50 C.
The instrument is equipped with aflexible probe to reach
particularlydifficult fittingsor parts.
Thetwo levelsofsensitivityare:
- lowsensitivity =16.5g/year;
- highsensitivity =3.3 g/year.
Figure223
50643
Before checking vehicles, wait for the engine to
cool, thehot parts canfalsifythetest.
NOTE
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Aquila Trucks Centres
90318
Figure224
Figure225
90317
SEMITRAILER FIFTH WHEEL MOUNTINGSCHEME
SEMITRAILERPLATE ANDFIFTH WHEELMOUNTINGSCHEME
BODYWORKANDCHASSISFRAME 105 TRAKKER EURO 4/5
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5001 CHASSIS FRAME
Doublebottleneckhighresistance steel chassis.
Dimensions
Inner distancebetween sidemembers: 1016mm(front)
836 (middle)
756 mm(rear)
Note: Indicateddistances areindependent of thickness.
Sidemember sectioninner height 289 mm(front)
199 mm(rear)
Sidemember thickness:
6.7mm (180W, 190/260/340W, 400IT/WT, 440T, 260/380B)
Sidemember thickness:
7.7mm (380T/W/B, 410T/W/B, 720T/WT)
TIGHTENING TORQUES
DESCRIPTION
TORQUE
DESCRIPTION
Nm Kgm
ScrewwithM16x1.5 flangesecuringfifthwheel to chassisor plate 238 26 23.8 2.6
Nut with M16x1.5flangesecuringfifthwheel to chassisor plate 310.5 33.5 31 3.3
Nut with M16x1.5flangesecuringplateto chassis 310.5 33.5 31 3.3
ScrewwithM16x1.5 flangesecuringplateto chassis 238 26 23.8 2.6
Aquila Trucks Centres
17344
17345
17347
Figure226
Figure227
Figure228
Laterallypermissiblecurvatureof chassisframe
'a' = 3 /.
Carefullycheckfor anypeelingorcrackingall overthechassis
frame,payingspecial attentiontojointsundergreatstrain,such
as: chassis frame cross members, brackets, mounts of leaf
springsandchassisframestructural members.
Mark anypeeledor crackedpointsstraight away.
Check the rivets by striking their heads with a mallet and
touchingtheoppositesidewithyour fingers.
Mark anylooserivets with paint to helpidentifythemduring
therepair work.
17348
17349
Figure229
Figure230
Permissible curvatureofchassisframe
'b' = + /
Maximum10 mm.
|o|ss|b|o o|oooco bot.ooo 'a' aoo 'b' = 3 .
\|t| o|aooa| oasoooot bot.ooo 'c' aoo 'o' = 6 .
Inspect thechassis frame, checkingits alignment.
Ifevenat thisstageyoudetectanydeformationyouthenneed
tofreetherelevant part ofthechassisframetohelpmakean
exact measurement.
Beforethetest youneedtocheckall thepartsthat,withtheir
imperfections, affect the exact measurements (for example,
tyrepressure, weakor brokenleaf springs, etc.).
106 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
REPAIRS
CHECKS
Aquila Trucks Centres
17350
17351
17352
17353
Figure231
Figure232
Figure233
Figure234
Permissibletorsiononthechassis frame
'b' = + oac| s|oo.
To measurethe side bend of thechassisframeyouneedto
plumbthesupportingsurfacesstartingwiththetwostructural
members at aninterval of approximately1m.
Thepointsobtainedinthiswayneedtobemarkedaccurately
onthefloor.
To usetheplumbed pointsyou need to stretchout astring
passingthrough themarked pointsinaline.
Thepointsoutsidethelineindicatethestart andextentofthe
actual deformation(a).
Taketwoshims(1) ofsuchasizethatastringcanbestretched
alongthefull lengthfromthestraight portionof thebottom
or topwaist onthestructural member of the chassis frame.
Measurethedistanceofthestructural memberfromthestring
at 1-metreintervals. A different stringdistance indicatesthe
position and extent of an actual bend in the structural
member.
Measuring the side bend of the chassis frame
Measuringthe movement of thechassisframe
17354
Figure235
A movement ofthechassisframecanbemeasuredbymeans
of aset square.
To do this, place the set square at 90 to the structural
memberofthechassisframeandcheckthesquarenessofthe
crossmembersof thechassis frame.
BODYWORKANDCHASSISFRAME 107 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Measuring the bend of the chassis frame
downwards or upwards
Aquila Trucks Centres
17356
17355
17358
Figure236
Figure237
Figure238
A movement intheposition of theaxescanbechecked by
makingadiagonal measurement.Todothis,plumbthecentre
of thefront mount of thefront suspensionandthecentreof
thefront support oftherearleafspringontheflat supporting
surface, onbothsides.
||st| coao t|o o|staoco o t|o o|ots 'a' aoo 'b'. T|oo
a'o t|o o|aooa| oasoooot (o|staoco 'c' aoo 'o') o
point(2)infronttotheright topoint (2)behindtotheleftand
the opposite.
- Positiontheother sideof thechassis frame, inacentral
positionunder therearcrossmember, onthekneeof an
L-shaped iron(1).
- Set a rule crosswise and put a spirit level (2) on this,
checkingthereading.
At eachcheck point youwill need to havethesamereading
or thechassisframeisout of shape.
During the work of welding, drilling, grinding, cutting near
brake systempiping, especiallyif this is made of plastic, and
electric cables, take the appropriate precautions to protect
them,contemplatingtheirremoval ifrequired. All thepartsof
the chassis frame subject to reconditioning will need to be
protectedagainst oxidationandcorrosion.
Thisprotectionandpaintingwill needtobedonecarefullyon
all the parts concerned, as per any relevant instructions,
methodsandprecautionsof the paint manufacturers.
PRECAUTIONS
Measuring the torsion of the chassis frame
17357
Figure239
A slight torsioncanonlybemeasured withthechassisframe
freed of thecaband mechanical assemblies.
To do this check, proceedasfollows:
- Set thechassisframeontwo stands.
- Usingtwoclamps,secureonesideofthechassisframeto
the stand.
108 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
17359
17360
17361
Figure240
Figure241
Figure242
The chassis frame is reconditioned by wedge heating the
relevant part withablowpipe.
During this operation the metal needs to turn cherryred,
whichcorresponds to atemperature of 600 - 680C.
Theheated pointsmust undergo no further heating.
Let the treated parts cool slowly without using any water,
compressed air or thelike.
Straightenthesaginthechassisframedownwardsorupwards
withwedgeheatingonthetopplateofthestructural member.
Inthecaseof downwardbending, thebase(a) of theheating
wedgeisat thebottom.Inthecaseofupwardbending,dothe
opposite.
The relevant bottomor top waist of the structural member
has to be heated last in the areaof thebase of the heating
wedge.
Straighten the side bend of the chassis frame with wedge
heatingon thetopand bottomwaist of thepart concerning
thechassis frame.
Thetipof theheatingwedgehasto lieinthedirectionofthe
requiredbend.
If thebase(a, Figure44) of thetwo heatingwedges is inthe
topplateofthestructural member,thentheplatealsoneeds
to beheated, but last.
BODYWORKANDCHASSISFRAME 109 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
17365
17364
Figure243
Here wegivetheoperatinginstructionsfor proper welding:
a) Heat all aroundtheareato weld (except forQST E420
material). Do the arc weldingwith several passes, using
thoroughly dried basic electrodes, or MIG-MAG pro-
cedures with suitablefiller material. Do not overcharge
withcurrent.Theweldmust haveno edgecutsor dross.
b) Start backweldingasspecified inpoint (a).
c) Leavethestructural membersto cool slowlyandevenly.
It isnot permissibleto usejets of air or other means.
d) Grindoff theexcessmaterial.
e) Applysteel cornerstrengthening,withthesamespecifica-
tionsasthesteel usedinthechassisframe. Theapproxi-
mateminimumdimensionsaregivenintheaboveillustra-
tions.Theyaretobefixedsolelyonthevertical ribofthe
structural member andit ispossibletousebeadwelding,
dummy spots, screws or rivets. The cross section and
lengthof theweld bead, thenumber anddistributionof
the dummy spots, screws or rivets must be suited to
transmit thebendingandcuttingmomentsofthesection.
On completing the work, the part involved in welding
must beeffectivelyprotectedwithrust proofing.
A 0,3H
b H (min. 175mm)
S (0.8 1) SI
Figure244
Beforestartingwork,disconnectthenegativebatteryterminal
and connect the earth of theweldingmachinestraight onto
thepieceto weld. Plasticpipeswill need to beprotected or
removed.
Welds will have to be made solely by skilled, trained
personnel, with suitable equipment and in workmanlike
fashion.
Stripanddeoxidizethepartstoweld.Atthepointofbreakage,
ontheinsideofthestructuralmemberandalongthefull length
of therelevant section, makeaVbevel of 60.
!
No cutsarepermittedonthestructural membersat
areas of changes in profile or at points with ahigh
concentration of stresses; additionally, the line of
separationmust not concerntheholesalreadyinthe
structural member.
17362
17363
110 BODYWORKANDCHASSISFRAME TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Welds on the chassis frame
Aquila Trucks Centres
1 TRAKKEREURO 4/5 PROGRAMMEDMAINTENANCE
Print 603.93.641 Base- November 2006
SECTION 15
Programmed maintenance
Page
DIAGRAMOFPOINTSFORCHECKSAND/OR
MAINTENANCE OPERATIONS 3 . . . . . . . . . .
MAINTENANCE SERVICESCHART 5 . . . . . . . . .
PROGRAMMED MAINTENANCEWITH HOUR
INTERVALS (FOR VEHICLESUSED IN
QUARRIES ANDCONSTRUCTION SITES) 5
CHECKSAND/OR MAINTENANCE
OPERATIONS 6 . . . . . . . . . . . . . . . . . . . . . . . .
- Hour interval schedulefor quarriesandconstruction
site vehiclesandoff-roadvehicles 6 . . . . . . . . . .
TIMED OPERATIONS 7 . . . . . . . . . . . . . . . . . . . .
- Plan withhour interval for quarryandbuildingyard
vehicles and for off-road vehicles 7 . . . . . . . . . .
CHECKSAND/ORMAINTENANCE OPERATIONS
(PLAN WITH HOUR INTERVALS) 8 . . . . . . . .
M1SERVICE 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2SERVICE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3SERVICE 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMED OPERATIONSWITH HOUR
INTERVALS 15 . . . . . . . . . . . . . . . . . . . . . . . . . .
T1SERVICE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T2SERVICE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T3SERVICE 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T4SERVICE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T5SERVICE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T6SERVICE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T7SERVICE 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T8SERVICE 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROGRAMMEDMAINTENANCEWITH KM
INTERVALS (For vehiclesused on theroad for
mediumand longdistances) 19 . . . . . . . . . . . . . .
CHECKSAND/OR MAINTENANCE
OPERATIONS 20 . . . . . . . . . . . . . . . . . . . . . . . .
- Schedulewithkmintervals for vehicles usedon
theroadfor mediumand longdistances 20 . . . . .
Aquila Trucks Centres
2 TRAKKEREURO 4/5 PROGRAMMEDMAINTENANCE
Base- November 2006 Print 603.93.641
Page
EXTRA PLAN/TIMED OPERATIONS 21 . . . . . . . . .
- Plan withkilometer intervals for road use vehicles
over middleto longruns 21 . . . . . . . . . . . . . . . .
CONTROL AND/OR MAINTENANCE
INTERVENTIONS
(PLAN WITH KM INTERVALS) 22 . . . . . . . . . . .
M1SERVICE 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2SERVICE 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3SERVICE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXTRA PLAN/TIMED OPERATIONS
(PLAN WITH KM INTERVALS) 29 . . . . . . . . . . .
EP1 SERVICE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EP2 SERVICE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T1SERVICE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T2SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T3SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T4SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T5SERVICE 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T6SERVICE 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
Figure1
115273
3 TRAKKEREURO 4/5 PROGRAMMEDMAINTENANCE
Print 603.93.641 Base- November 2006
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE OPERATIONS
Aquila Trucks Centres
115274
Figure2
4 TRAKKEREURO 4/5 PROGRAMMEDMAINTENANCE
Base- November 2006 Print 603.93.641
DIAGRAM OF POINTS FOR CHECKS AND/OR MAINTENANCE OPERATIONS
Aquila Trucks Centres
Revi- June2007
PROGRAMMEDMAINTENANCE 5 TRAKKEREURO 4/5
Print 603.93.641/A Base November 2006
PRINT603.93.641/A
MAINTENANCE SERVICES CHART
OILS SERVICES EXTRA PLAN
PROGRAMMED OPERATIONS
Engine
ACEA E4 (1)
M1 M2 M3 T1 T2 T3 T4 T5 T6 T7 T8
ACEA E4 (1)
Urania
FE5W30
Every
1000
hours
Every
1500
hours
Every
3000
hours
Multipo
wer
every
800
hours
Gearbo
xoil
and
filter +
Intarder
(2)
Every 3
months
Every
year
before
winter
Every
year
before
summer
Every
year
Every
2 years
Every
3 years
(1) IVECO suggests the use of thesel ubricants toraise thevehicle fuel economy. Thenew vehicle is already equipped by IVECO
with these types of lubricants, suitable also for cold climates (minimumtemperaturedown to -30). The changeintervals
dependontheuseof theseoils.
(2) Seenoteat page 7.
The ExtraPlanoperations (designated with theletters EP) arecomplementaryto standardservices.
Theyaremaintenanceoperations to becarriedout at regular timeor mileageintervalsandconcern optional componentsthat
arenot present on all models.
Important! The correlation between kilometres and months onlyapplies in cases where the distance travelled bythevehicle
correspondsroughlytothespecified averageannual mileage.Thisisindicatedonlyinordertosuggest ahypothetical maintenance
programme,.Notethat thetimeintervalsspecifiedforExtraPlanoperationsareto beadheredtoregardlessoftheactual mileage
covered.
The kilometrefrequencyfor engine lubrication is in relation to apercentageof sulphur in diesel of under 0.5%.
NOTE: If usingdiesel withapercentageof sulphur above0.5%, theoil-change frequencyhas to behalved.
Useengine oil: ACEA E4(URANIA FE5 W 30) - ACEA7(URANIA LD7)
- ACEA E4lubricants classifiedasACEA E6cannot beusedaccordingto thechangeintervals established for class
ACEA E4.Theyshall bechangedaccordingto thetimeintervalsestablishedforlubricantsACEA E2, i.e.every400
hours.
- If classACEA E7 (UraniaLD7) engine oil is used, theengineoil and filtersmust bechanged every800hours.
- If classACEA E2 (UraniaTurbo) engineoil is used, theengineoil andfiltersmust bechanged every400hours.
- In the event of verylow annual operatingtimeor anyway below 1000 hours/year, theengineoil and the filters
shall bechanged every12 months.
- Intheevent ofoperatingtimebelow 1000hours/year,theoil of therear axles,distributor,transmission, etc. shall
bechanged at least every2 years.
- The filter dryer of thepneumatic systemmust inanycaseberenewed everyyear.
- Inthe caseof verylowannual mileage, general greasingmust becarriedout at least once ayear.
To schedule thework, keepto thefollowingchart:
PROGRAMMED MAINTENANCE WITH HOUR INTERVALS (FOR VEHICLES USED IN
QUARRIES AND CONSTRUCTION SITES)
Aquila Trucks Centres
(1) Vehicleand toolinghandlingactivityin theworkshop.
Revi- June2007
6 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
Base November 2006 Print 603.93.641/A
PRINT603.93.641/A
CHECKS AND/OR MAINTENANCE OPERATIONS
Hour interval schedule for quarries and construction site vehicles and off-road vehicles
Typeof operation M1 M2 M3
References
figure1/2
Engine
14 Changeengineoil
3 Replaceengineoil filter
12 Replacefuel filter
1-2 Replacemiscellaneousdrivebelts
13 Replaceor clean hydraulic steeringsystemfilter
15 Check-up of engineEDC systemviaMODUS, IT 2000or E.A.SY.
5 Checkvalveclearanceand adjust if necessary
16 Replacevariablegeometryturbocharger VGT air filter
1 Replaceengineauxiliarymember drive belt
2 Replaceair-conditioner compressor drivebelt
7 Checkingfan electromagneticjoint clutch wear (if applicable)
Chassis andmechanical assemblies
17 Replacefuel pre-filter
10 Checkefficiencyand clean gearbox oil bleeds
9 Checkclutch fluidlevel
11 Replacepneumatic systemdrier filter
GreasetheVGT control lever
Chassis andmechanical assemblies
28 Checkefficiencyandcleandriveaxleoil bleeds (for 4x4, 6x6, 8x8 vehicles)
25 Cleandivider oil bleeds betweenaxles
23 Cleanaxleoil bleed
General greasing
28 Changedriveaxle oil (for 4x4, 6x6, 8x8 vehicles)
Changefront sidereduction gear oil (for 4x4, 6x6, 8x8vehicles)
22 Changeaxleoil
20 Changefront wheel huboil (for 4x2, 6x4, 8x4vehicles)
21 Changetransmission assemblyoil (for 6x4, 6x6, 8x8 vehicles)
25 Changetransfer boxoil (for 4x4, 6x6, 8x8vehicles)
19 Control of theguideand support fixture
29-30 AdBluesystemfilter andpre-filter change
Cab and electric appliances
27 Checkheadlight adjustment
31 AdBluesystemtest withEASY, MODUSor IT2000
Miscellaneous
Handlingoperations(1)
Functional testingonroad
Cabin tilting/ opening/ closureof cowling
Aquila Trucks Centres
Revi- June2007
PROGRAMMEDMAINTENANCE 7 TRAKKEREURO 4/5
Print 603.93.641/A Base November 2006
TIMED OPERATIONS
T1 Every 800 hours
Simultaneouslywithamaintenance service
534501 Replacingtotal power take-off (Multi-power) oil
T2
Every 1200hours, gearboxes supplied withmineral oil (1)
Every 2400hours, ZF 9 S1310 gearboxes supplied withsynthetic oil (2)
Every 3600 hours, ZF EUROTRONIC gearboxes supplied with synthetic oil (3)
Together with maintenance operations
530105 Changeoil andfilter of ZFtransmission +Intarder
530105 Changegearboxoil
T3 Every 3months
553261 Checkinganti-pollen filter (4) condition
506011 Washingradiator guardgrid
T4 Everyyear - beforeWinter
Possibly, andsimultaneouslywithamaintenance service
506019 Checkingcoolant density
773130 Replacingadditional heater fuel filter
T5 Everyyear - beforeSummer
Possibly, andsimultaneouslywithamaintenance service
506010 Checkingpossibleradiator clogging
T6 Everyyear
Possibly, andsimultaneouslywithamaintenance service
505100 Replacingthecartridge and cleaningair filter container (5)
540450 Replacingblow-byfilter
T7 Every 2years
Possibly, andsimultaneouslywithamaintenance service
506010 Replacingenginecoolant
T8 Every 3years
Possibly, andsimultaneouslywithamaintenance service
505292 Replacingoil anddrainingclutch hydrauliccontrol
Plan with hour interval for quarry and building yard vehicles and for off-road vehicles
1) ZF Ecosplit gearboxes suppliedwithmineral oil, intheevent of verylowannual operatingtimechangetheoil everyyear
(2) ZFNewEcomidgearboxessuppliedwithsyntheticoil, intheevent ofverylowannual operatingtimechangetheoil every
2 years
(3) ZF Eurotronic gearboxes supplied with syntheticoil, in theevent of verylowannual operatingtimechangetheoil every
3 years
(4) In caseof lowruns, performfilters replacement oncea year, at everystart of Spring.
(5) Earlyair filter cloggingis generallycaused byenvironmental conditions; for this reason, air filter must be replaced when
relatingwarningfromspecial sensor is issuedindependentlyof relevant prescription, whichmust beanyhowobservedin
lack of specific indications.
Aquila Trucks Centres
Take out the oil level dipstick (1).
Fromunderneath the vehicle, remove the soundproofing
guard.
Unscrewtheplug(3) fromtheoil sumpanddraintheengine
oil off into aspecific container.
Screwtheplugbackonunderthesump andtightenit to the
requiredtorque.
Fill in with the prescribed oil quantityand quality (see the
CAPACITIES table in the GENERAL INFORMATION
section) fromthetierodcover pipeunion (2).
85493
Figure3
543420 Replace engine oil filters
85494
Figure4
Drain the oil as described in point Changing engine oil.
Remove theoil filter (1) with tool 99360314(2).
Beforerefittingthenewcartridges,moistentheseal
with engineoil.
Screwtheoil filters(1) onbyhandtobringthemintocontact
with the mount and then tighten by 3/4 of a turn to the
prescribed torque and proceed as described in point
Changing engine oil.
92826
Figure5
Using a feeler gauge, check the gap between the anchor
assembly (2) andthe pulley (1), it must be no greater than
2.5mm.
M1SERVICE
542710 Change engine oil
543450 Check electromagnetic coupling
clutch wear
1
NOTE
Figure6
115275
540843/543934 Check miscellaneous drive
belts
Visually check that the belts (1-2) are neither worn nor
deteriorated;iftheyare,changethemasdescribedintheM3
service.
Revi- June2007
8 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
Base November 2006 Print 603.93.641/A
CHECKS AND/OR MAINTENANCE
OPERATIONS
(PLAN WITH HOUR INTERVALS)
Aquila Trucks Centres
85496
Figure7
544221 Replace or clean hydraulic steering
system filter
Before takingoff thecover (1), thoroughlyclean the tank.
Thiswill prevent foreignimpuritiesfromcomingintocontact
with theoil of the hydraulicsystem.
Takethecover (1) offthetankandtakeout theoil filter (3).
Remove the coupling device (2) fromthe oil filter (3) and
replacethefilter.
Takeofftheplug(1) (afterunhookingthetransmitter) ofthe
hydraulicpowersteeringtankandcheckthatwiththeengine
runningandthewheelstravellinginastraight line,theoil level
reaches thetopreferencemarkonthedipstick.
With theenginestationaryandwheelsinastraight line, the
oil level hastoexceedthetopreferencemarkofthedipstick
by1 or 2cm; if necessary, top up thelevel bytakingoff the
cover (1).
Figure8
507210 Replace pre-filter
Whenreplacingthecartridge,it must not havebeen
pre-filled. This is to prevent impurities gettinginto
circulation that could damage the injector/pump
system components. Bleed the air from the fuel
circuit asdescribed onthe previous pages.
Unscrew thepre-filter (1) andreplaceit.
Before refitting the new cartridge, moisten the seal with
diesel or engineoil. Screw thecartridgeon byhand until it
isin contact withthemountingandthentightenby3/4 ofa
turn to therequiredtighteningtorque.
Figure9
542093 Replace fuel filter
85498
Remove thefuel filter (1) with tool 99360314.
Before refitting the new cartridge, moisten the seal with
diesel or engineoil.
Screwthenewoneonbyhand,takingcaretocheckthat the
rubber seal andthematingsurfacearecleanandinaperfect
stateof repair. Screw thecartridgeon byhand until it is in
contact withthemountingandthentightenby3/4of aturn
to therequired tighteningtorque.
Bleed the air fromthe supply system as described in the
followingparagraph.
72565
72566
530105 Clean gearbox oil breather
Removetheoil vapour breather (1) andcleanit thoroughly.
Then fit it back on, checking it is in the right position, and
tightenit to therequired torque.
Figure10
(ZF 9/16S gearboxes)
Revi- June2007
PROGRAMMEDMAINTENANCE 9 TRAKKEREURO 4/5
Print 603.93.641/A Base November 2006
PRINT603.93.641/A
Aquila Trucks Centres
Figure11
115277
(ZF 12AS gearboxes)
Removetheoil vapour breather (1) andcleanit thoroughly.
Then fit it back on, checking it is in the right position, and
tightenit to therequired torque.
Figure12
98879
Checkthelevel of the clutchfluid. Top it up if it is too low
(seethefluidstablein theGENERAL section).
505292 Check clutch fluid level
(Excluding vehicles with EuroTronic
gearbox)
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediatelywith water andaneutral soap.
Figure13
72569
503447 Replace pneumatic system drier
filter
Dischargethepressurefromthecompressedair system.
Unscrew thedrier filter (1) and replaceit. Tighten it to the
required torque, checking there is no air leakage when
pressure is restored.
Figure14
522810 Cleaning engine front axle oil
(for versions 4x4/ 6x6/ 8x8 only)
72574
Removetheoil vapour breather (1) andcleanit thoroughly.
Fit it backon, checkingit is in theright position, andtighten
it to therequiredtorque.
Revi- June2007
10 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
Base November 2006 Print 603.93.641/A
Aquila Trucks Centres
Figure15
72575
Removetheoil vapour breather (1) andcleanit thoroughly.
Fit it backon, checkingit is in theright position, andtighten
it to therequiredtorque.
505401 Clean oil breather on transfer box
(with hours intervals)
525013 Clean oil breather on axles
Figure16
72576
Remove the oil vapour breathers (1) fromthe middleaxle
and (2) fromthe rear axle and clean themthoroughly. Fit
themback on, checkingthey are in the right position, and
tightenthemto therequiredtorque.
General greasing
Handling operations
Functional on road testing
Tilting the cab, opening/closing the front
grille
Check AdBlue system using E.A.SY.
MODUS or IT2000
M2SERVICE
Check-up on EDC system with MODUS,
IT2000or E.A.SY.
Check AdBlue system using E.A.SY.
MODUS or IT2000
540613 Check valve clearance and adjust if
necessary
Toperformtheseoperationscorrectly,proceedasdescribed
under the relevant heading in the ENGINE section.
Figure17
86835
Figure18
542406 Replace variable geometry
turbocharger (VGT) valve air filter
(Cursor Engine)
72577
Usingasuitabletool, unscrew thefilter (1) andreplaceit.
Beforefittingthenewcartridge,moistentheseal withdiesel
or engineoil. Screw it on byhand until it isin contact with
the mounting and then tighten by 3/4 of a turn to the
requiredtighteningtorque.
In versions with Cursor 8 engine the filter is
assembledonthechassis.
NOTE
Revi- June2007
PROGRAMMEDMAINTENANCE 11 TRAKKEREURO 4/5
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Aquila Trucks Centres
Figure19
Figure20
72580
- With theaxlewarm, takeoff theplug(2) and drainthe
oil into aspecific container.
- Pourinfreshoil throughtheholeclosedbytheplug(1)
(see under the FLUIDS heading of the GENERAL
section).
- Cleantheoil vapour breather.
- Tighten theplugsto the required torque.
522810 Change drive axle oil
(4x4, 6x6, 8x8versions only)
522870 Change front side reduction gear oil
(4x4, 6x6, 8x8versions only)
72581
Changetheoil as follows:
- Set the plug (1) as shown in the figure and the OIL
LEVEL line exactly horizontal.
- Open thescrew (2) anddrainoff theoil into aspecific
container.
- Pourinfreshoil throughtheholeclosedbytheplug(1)
(see SPECIFICATIONS AND DATA in the REAR
AXLE section).
- Before screwing the plug (1) and screw (2) back on,
spread sealant pasteon themand tighten themto the
requiredtorque.
525110/525010 Change axle oil
Transmissionandmiddleaxle
72582
- With theaxlewarm, unscrewtheplugs (1) and (3) and
drain off the spent oil into aspecificcontainer.
- Screwtheplugsbackonandpourinfreshoil throughthe
holeclosedbytheplug(2) (for thequantity, seeunder
theFLUIDS headingof theGENERAL section).
- Cleantheoil vapour breather.
- Tighten theplugsto the required torque.
Rear axle
72583
- With theaxlewarm, unscrewtheplug(1) anddrainoff
theoil into aspecificcontainer.
- Pourinfreshoil throughtheholeclosedbytheplug(2)
(see under the FLUIDS heading of the GENERAL
section).
- Cleantheoil vapour breather of the axle.
- Tighten theplugsto the required torque.
Figure21
Figure22
Revi- June2007
12 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
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Aquila Trucks Centres
Figure23 Figure24
Figure25
79068
520620 Change front wheel hub oil
(4x2, 6x4, 8x4versions only)
72584
505401 Change reduction gear - divider oil
(4x4, 6x6, 8x8versions only)
- Withhot distributor,slackenthedrainplugs(2) anddrain
theoil in asuitable container.
- Tighten theplugs (2) to torque60 NmxTC 1800, 78
Nmx TC 2200 and clean theoil breather (4).
- Removetheplugs(1and3),fill throughtheplughole(1)
the prescribed quantity and type of oil, see chapter
GENERALITIES in the AXLE section.
Fillingiscorrect whentheoil reachestheplughole(3).Drive
in the plugs (1 and 3) and tighten themto the prescribed
torque.
501401 Check steering box fixing and
mounting
Check that the fastenings of the steering box (1) and
mounting(2) aretightenedto the required torque.
86836
505401 Change transmission assemblyoil
(6x4, 6x6, 8x8versions only)
Seetheproceduresforchangingthetransmissionandmiddle
axleoil described above.
Replace AdBlue filter and prefilter
Inorder to carryout theseoperationscorrectly, proceedas
described in the relevant chapter of section ENGINE.
Grease the VGT control lever
Proceed as follows:
- removeplug(1) andsuckoil with suitablesyringe;
- fill thewheel hubwithnewoil (forthequantityandtype
of oil, see CHARACTERISTICS AND DATA in the
AXLES section.
Oil level ischeckedthroughplug(2) slidewithmaxandmin
writingsoncover (1) inhorizontal position.
Revi- June2007
PROGRAMMEDMAINTENANCE 13 TRAKKEREURO 4/5
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Aquila Trucks Centres
Figure26
760044 Check headlight adjustment
Figure27
98882
- Placeunloadedvehicle,withtyresatprescribedpressure,
on flat ground, facing alight colour wall located at 10
metredistance.
- Mark two crosses on the wall corresponding to the
centresof thetwo headlights.
- Byusingcontrol (1), positionheadlightswithinclination
zero. Inclination can be displayed on CLUSTER display
unit.
115276
TheM3servicecomprisestheoperationsoftheM1
and M2services plustheones listed here.
543411 Replace auxiliarymember drive belt
543910 Replace air-conditioner compressor
drive belt
ASSEMBLY DIAGRAMOF BELTSFOR FAN - WATER
PUMP- ALTERNATOR AND AIR-CONDITIONER
COMPRESSOR
1. Alternator - 2. Drivebelt - 3. Fan- 4. Water pump-
5. Crankshaft - 6. Springbelt - 7. Air-conditioner
compressor - 8. Drivebelt automatic tensioner
Inorder tocarryout theseoperationscorrectly,proceedas
described in the relevant chapter of section ENGINE.
98891
- Tilt the cab and turn on the low beam. The distance
betweenthecrossesandthepointsP,whichcorrespond
to theangleof theheadlights, has to be15 cm.
- Adjust light beamaccording to horizontal and vertical
directionsbyoperatingonscrews (1and 2).
Handling operations
Functional testing on road
Cabin tilting / opening / closure of front
grille
Figure28
NOTE
Revi- June2007
14 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
Base November 2006 Print 603.93.641/A
M3SERVICE
Aquila Trucks Centres
TIMED OPERATIONS WITH
HOUR INTERVALS
T1SERVICE
72589
534501 Change Multipower total power
take-off oil (if applicable)
Set thevehiclehorizontal and stop the engine.
Positionasuitablecontainer to collect theoil.
- Unscrew thedrain plug(2).
- Unscrew thefilter (1) and clean it thoroughly.
Torestoretheoil level,screwthefilter (1) anddrainplug(2)
back on to the required torque, checkingthe state of the
seals.
Replacethemif theyhavedeteriorated. Then:
- Unscrew the plug(3) and add therequired amount of
oil (seeFLUIDSin GENERAL INFORMATION).
- Screwtheplugback on to therequiredtorque.
Figure29
2
- Withthegearboxwarm,takeofftheplugs(1) anddrain
theoil into aspecificcontainer.
72570
T2SERVICE
530105 Change oil and filter of ZF 16S
gearbox +Intarder
Figure30
52571
Remove the oil filter as follows:
- unscrewthescrew(5) fixingthefilter;
- takeoff thecover andfilter (1);
- removethecoverfromthefilterandreplaceit.Takecare
not to losethemagneticpad (4) on the outer edgeof
thefilter, as it has to berepositioned on thenewfilter;
- check the state of the o-ring (2) and replace it, if
necessary;
- greasetheo-ring(3) insertedintheassemblyopeningof
thenew filter;
- couplethenewfilter withitscover and insert it into its
seat asfar as it will go. Secure thescrew (5).
Figure31
Revi- June2007
PROGRAMMEDMAINTENANCE 15 TRAKKEREURO 4/5
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Aquila Trucks Centres
530105 Change gearbox oil
(ZF mechanical gearboxes)
98880
- With the gearbox warm, take off the plug(s) (1) and
drain theoil into aspecificcontainer.
- Theoil shouldbedrainedoff takingcarenot todirtythe
cross member beneathasit is near theoutlet onsome
types of gearbox.
- It isthereforewiseto useatool toconveytheoil away.
- Pourinfreshoil throughtheholeclosedbytheplug(2)
(for thequantity, seeunder theFLUIDSheadingof the
GENERAL section).
- Tighten theplugsto the required torque.
Figure32
3
(ZF 12AS gearbox)
115278
- With the gearbox warm, take off the plug(s) (1) and
drain theoil into aspecificcontainer.
- Theoil shouldbedrainedoff takingcarenot todirtythe
cross member beneathasit is near theoutlet onsome
types of gearbox.
- It isthereforewiseto useatool toconveytheoil away.
- Pourinfreshoil throughtheholeclosedbytheplug(2)
(for thequantity, seeunder theFLUIDSheadingof the
GENERAL section).
- Tighten theplugsto the required torque.
Figure33
T3SERVICE
553261 Checkinganti-pollenfilter condition
98890
Checkthestateof cloggingof thepollenfilter (2).
Anti-pollenfiltercanbeaccessedbyliftingfront cowlingand
under door (1).
Excessive cloggingof thepollen filters can cause a
reduction in the flow rate of air into the cab and
therefore less ventilation. This will be highlighted
especiallybyasignificant reductionintheefficiency
of thewindscreendefrostingfunction.
Figure34
NOTE
506011 Wash radiator grille
Lift thecabradiator cowlingandcarefullycleantheradiator
grille.
Revi- June2007
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Base November 2006 Print 603.93.641/A
Aquila Trucks Centres
4
T4SERVICE
506019 Check percentage of antifreeze in
the engine coolant
!
Theplug(1) mustneverbetakenout foranyreason
whatsoever.
With the engine warm, the cooling systemis in
overpressure, therefore take care when taking off
thecap(2).
98881
Takeoffthecap(2) anddrawoffasampleofthecoolantfrom
theexpansiontank(3) with thedensimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentagehas to be higher than 40%and
must not exceed 50%.
If necessary, restorethepercentageof antifreeze, bearingin
mind that the liquidneedsto be replacedevery 2years.
Figure35
!
For vehicles fitted with an additional heater, the
percentageof antifreezemust never exceed50%.
773130 Replacing additional heater fuel
filter
T5SERVICE
506010 Checking possible radiator clogging
72590
505100 Replacing air filter cartridge in dry
conditions and cleaning thecontainer
- Unhook the clamps (1) (or, dependingon theversion,
unscrewthenut) andtakeoff the bottomcover (2).
Figure36
Figure37
72591
- Unscrew the nut (4) and take out thecartridge of the
filter (3).
Beforefittingthenewcartridge,cleanitshousingthoroughly.
T6SERVICE
Revi- June2007
PROGRAMMEDMAINTENANCE 17 TRAKKEREURO 4/5
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Aquila Trucks Centres
5
T8SERVICE
505292 Changethe clutch fluid and makeair
bleeding (only versions with
mechanical transmission)
Drain off the clutch control fluid and change it (see Fluids
tablein GENERAL section).
T7SERVICE
506010 Changing engine coolant
Performproceduredescribedinrelatingparagraphinsection
ENGINE.
Figure38
72563
- Unscrewthescrews(2), takeoffthecasing,takeout the
filter (3) andreplaceit withanew one.Thefilterworks
inasingledirection, so you need to mount it with the
two strengtheningbars in view asshowninthefigure.
540450 Replacing engine blow-by filter
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediatelywith water andaneutral soap.
Figure39
After changingthe fluid, bleed the hydraulic clutch control
system.
Usetheair bleedingtool 99306010as follows:
- charge reservoir (5) with compressed air;
- fill reservoir (4) withTutelaTRUCKDOT SPECIAL fluid
- replacethecap( ) oftheclutchfluidreservoirwithone
of the caps supplied with the tool 99306010 and
connect thepipeto thecap.
1
- Attachaplastictubetothebleedscrew(2) ontheslave
cylinder (1) andimmersetheoppositeend of the tube
inacontainer containingTutelaTRUCKDOT SPECIAL
fluid,unscrewthebleedscrew(1) byonefull turn,open
thevalve(2) (seeFigure39) until apressurereadingof
1 to 1.2bar isobtainedonthepressuregauge(3);
- whentheclutchfluidflowingthroughthetubeisuniform
and free of air bubbles, close the bleed screw and
dischargetheairfromthereservoir (5) throughvalve(6).
40355
Figure40
Whenevertheclutchfluidischanged,it will alsobe
necessary to bleed the clutch master cylinder by
looseningthefitting(1, Figure39) beforebleeding
theclutch servo.
NOTE
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18 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
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Aquila Trucks Centres
Revi- June2007
PROGRAMMEDMAINTENANCE 19 TRAKKEREURO 4/5
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PRINT603.93.641/A
PROGRAMMED MAINTENANCE WITH KM INTERVALS
(For vehicles used on the road for medium and long distances)
OILS SERVICES EXTRA PLAN PROGRAMMED OPERATIONS
Engine
ACEA E4 (1)
Urania
FE5W30
M1 M2 M3 EP1 EP2 T1 T2 T3 T4 T5 T6
FE5W30
Every
100,000
km
Every
150,000
km
Every
300,000
km
Change
gearbox
oil
Every
240,000
km
Every
6months
Every
year
before
Every
year
before
Every
years
Every
2 years
Every
3 years
km km km oil
(2)
km before
winter
before
summer
(1) IVECO suggests the use of thesel ubricants toraise thevehicle fuel economy. Thenew vehicle is already equipped by IVECO
with these types of lubricants, suitable also for cold climates (minimumtemperaturedown to -30). The changeintervals
dependontheuseof theseoils.
(2) Seenoteat page 7.
- ACEA E4lubricants classifiedasACEA E6cannot beusedaccordingto thechangeintervals established for class
ACEA E4.Theyshall bechangedaccordingto thetimeintervalsestablishedforlubricantsACEA E2, i.e.every400
hours.
- If classACEA E7 (URANIA LD7) engineoil is used, theengineoil andfiltersmust be changedevery80,000km.
- If classACEA E2(URANIA TURBO) engineoil isused, theengineoil and filters must be changed every40,000
km.
- Intheevent ofverylowdistancestravelledperyearoranywaybelow100,000km/year,theengineoil andthefilters
must be changedevery 12months.
- If usingdiesel withapercentageof sulphur above0.5%, theoil-change frequencyhas to behalved.
- Intheevent of verylow distances travelled per year, the oil of therear axles, distributor, transmission, etc. must
bechanged at least every2 years.
- The filter dryer of thepneumatic systemmust inanycaseberenewed everyyear.
- Inthe caseof verylowannual mileage, general greasingmust becarriedout at least once ayear.
To schedule thework, keepto thefollowingchart:
Aquila Trucks Centres
(1) Earlycloggingoftheair cleaner is generallydueto environmental conditions. Forthisreasonit needstobereplacedwhen
signalledbythesensor irrespectiveof theguidelines that anyhowhaveto beobservedifthereareno specificinstructions
otherwise.
(2) Vehicleand toolinghandlingactivityin theworkshop.
Revi- June2007
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CHECKS AND/OR MAINTENANCE OPERATIONS
Schedule with km intervals for vehicles used on the road for medium and long distances
Typeof operation M1 M2 M3
References
figure1/2
Engine
14 Changeengineoil
3 Replaceengineoil filter
12 Replacefuel filter
4 Blow-byfilter replacement
1-2 Checkmiscellaneous drive belts
13 Replaceor clean hydraulic steeringsystemfilter
15 Check-up of engineEDC systemviaMODUS, IT 2000or E.A.SY.
5 Checkvalveclearanceand adjust if necessary
16 Replacevariablegeometryturbocharger VGT air filter
7 Checkingfan electromagneticjoint clutch wear (if applicable)
GreasetheVGT control lever
Chassis andmechanical assemblies
17 Replacefuel pre-filter
10 Checkefficiencyand clean gearbox oil bleeds
9 Checkclutch fluidlevel
11 Replacepneumatic systemdrier filter
Chassis andmechanical assemblies
28 Checkefficiencyandcleandriveaxleoil bleeds (for 4x4, 6x6, 8x8 vehicles)
25 Checkefficiencyand cleandivider oil bleedsbetweenaxles
23 Checkefficiencyand cleanaxlebleed
General greasing
28 Changedriveaxle oil (for 4x4, 6x6, 8x8 vehicles)
Changefront sidereduction gear oil (for 4x4, 6x6, 8x8vehicles)
22 Changeaxleoil
20 Changefront wheel huboil (for 4x2, 6x4, 8x4vehicles)
21 Changetransmission assemblyoil (for 6x4, 6x6, 8x8 vehicles)
25 Changetransfer boxoil (for 4x4, 6x6, 8x8vehicles)
19 Checksteeringboxand mounting
29-30 AdBluesystemfilter andpre-filter change
26 Engine air filter change (drycartridge) (1)
Cab and electric appliances
27 Checkheadlight adjustment
31 Ad Bluesystemtest withEASY, MODUSor IT2000
Miscellaneous
Handlingoperations(2)
Functional testingonroad
Cabin turning/ opening/ closure of cowling
Aquila Trucks Centres
Revi- June2007
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EXTRA PLAN/TIMED OPERATIONS
EP1 Every 120000 km, gearboxes supplied withmineral oil (1)
Every 240000 km, ZF 9 S1310gearboxes supplied withsynthetic oil (2)
Every 360000 km, ZF EUROTRONIC gearboxes supplied withsyntheticoil (3)
possibly, simultaneouslywith amaintenance service
530105 Replacinggearboxoil and filter (onlygearboxesZF +Intarder)
530105 Changegearboxoil
EP2 Every 240.000 Km
possibly, simultaneouslywith amaintenance service
543411 Replacewater pumpbelt andalternator
543910 Replaceconditioner compressor control belt
T1 Every 6months - Inparticular, at everystart of Spring
and, possibly, simultaneouslywithamaintenance service
506011 Washingradiator guardgrid
553261 Checkinganti-pollen filter (4) condition
T2 Everyyear - beforeWinter
Possibly, andsimultaneouslywithamaintenance service
506019 Checkingcoolant density
773130 Replacingadditional heater fuel filter
T3 Everyyear - beforeSummer
Possibly, andsimultaneouslywithamaintenance service
506010 Checkingpossibleradiator clogging
T4 Everyyear
Possibly, andsimultaneouslywithamaintenance service
534501 Replacingtotal power take-off (Multi-power) oil
T5 Every 2years
Possibly, andsimultaneouslywithamaintenance service
506010 Replacingenginecoolant
T6 Every 3years
Possibly, andsimultaneouslywithamaintenance service
505292 Replacingoil anddrainingclutch hydrauliccontrol
Plan with kilometer intervals for road use vehicles over middle to longruns
(1) ZF Ecosplit gearboxes suppliedwithmineral oil, intheevent of verylowannual operatingtimechangetheoil everyyear
(2) ZFNewEcomidgearboxessuppliedwithsyntheticoil, intheevent ofverylowannual operatingtimechangetheoil every
2 years
(3) ZF Eurotronic gearboxes supplied with syntheticoil, in theevent of verylowannual operatingtimechangetheoil every
3 years
(4) Earlyair filter cloggingis generallycaused byenvironmental conditions; for this reason, air filter must be replaced when
relatingwarningfromspecial sensor is issuedindependentlyof relevant prescription, whichmust beanyhowobservedin
lack of specific indications.
Aquila Trucks Centres
Take out the oil level dipstick (1).
Fromunderneath the vehicle, remove the soundproofing
guard.
Unscrewtheplug(3) fromtheoil sumpanddraintheengine
oil off into aspecific container.
Screwtheplugbackonunderthesump andtightenit to the
requiredtorque.
Fill in with the prescribed oil quantityand quality (see the
CAPACITIES table in the GENERAL INFORMATION
section) fromthetierodcover pipeunion (2).
85493
Figure41
543420 Replace engine oil filters
85494
Figure42
Drain the oil as described in point 14. Changing engine oil.
Remove theoil filter (1) with tool 99360314(2).
Beforerefittingthenewcartridges,moistentheseal
with engineoil.
Screwtheoil filters(1) onbyhandtobringthemintocontact
with the mount and then tighten by 3/4 of a turn to the
prescribed torque and proceed as described in point 14.
Changing engine oil.
92826
Figure43
Using a feeler gauge, check the gap between the anchor
assembly (2) andthe pulley (1), it must be no greater than
2.5mm.
M1SERVICE
542710 Change engine oil
543450 Check electromagnetic coupling
clutch wear
6
NOTE
Figure44
115275
540843/543934 Check miscellaneous drive
belts
Visually check that the belts (1-2) are neither worn nor
deteriorated;iftheyare,changethemasdescribedintheEP2
service.
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Base November 2006 Print 603.93.641/A
CONTROL AND/OR MAINTENANCE
INTERVENTIONS
(PLAN WITH KM INTERVALS)
Aquila Trucks Centres
85496
Figure45
544221 Replace or clean hydraulic steering
system filter
Before takingoff thecover (1), thoroughlyclean the tank.
Thiswill prevent foreignimpuritiesfromcomingintocontact
with theoil of the hydraulicsystem.
Takethecover (1) offthetankandtakeout theoil filter (3).
Remove the coupling device (2) fromthe oil filter (3) and
replacethefilter.
Takeofftheplug(1) (afterunhookingthetransmitter) ofthe
hydraulicpowersteeringtankandcheckthatwiththeengine
runningandthewheelstravellinginastraight line,theoil level
reaches thetopreferencemarkonthedipstick.
With theenginestationaryandwheelsinastraight line, the
oil level hastoexceedthetopreferencemarkofthedipstick
by1 or 2cm; if necessary, top up thelevel bytakingoff the
cover (1).
Figure46
507210 Replace pre-filter
Whenreplacingthecartridge,it must not havebeen
pre-filled. This is to prevent impurities gettinginto
circulation that could damage the injector/pump
system components. Bleed the air from the fuel
circuit asdescribed onthe previous pages.
Unscrew thepre-filter (1) andreplaceit.
Before refitting the new cartridge, moisten the seal with
diesel or engineoil. Screw thecartridgeon byhand until it
isin contact withthemountingandthentightenby3/4 ofa
turn to therequiredtighteningtorque.
Figure47
542093 Replace fuel filter
85498
Remove thefuel filter (1) with tool 99360314.
Before refitting the new cartridge, moisten the seal with
diesel or engineoil.
Screwthenewoneonbyhand,takingcaretocheckthat the
rubber seal andthematingsurfacearecleanandinaperfect
stateof repair. Screw thecartridgeon byhand until it is in
contact withthemountingandthentightenby3/4of aturn
to therequired tighteningtorque.
Bleed the air fromthe supply system as described in the
followingparagraph.
72565
72566
530105 Clean gearbox oil breather
Removetheoil vapour breather (1) andcleanit thoroughly.
Then fit it back on, checking it is in the right position, and
tightenit to therequired torque.
Figure48
(ZF 9/16S gearboxes)
Revi- June2007
PROGRAMMEDMAINTENANCE 23 TRAKKEREURO 4/5
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Aquila Trucks Centres
Figure49
(ZF 12AS gearboxes)
Removetheoil vapour breather (1) andcleanit thoroughly.
Then fit it back on, checking it is in the right position, and
tightenit to therequired torque.
Figure50
98879
Checkthelevel of the clutchfluid. Top it up if it is too low
(seethefluidstablein theGENERAL section).
505292 Check clutch fluid level
(Excludingvehicles with EuroTronic
gearbox)
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediatelywith water andaneutral soap.
Figure51
72569
503447 Replace pneumatic system drier
filter
Dischargethepressurefromthecompressedair system.
Unscrew thedrier filter (1) and replaceit. Tighten it to the
required torque, checking there is no air leakage when
pressure is restored.
Figure52
522810 Cleaning engine front axle oil
(for versions 4x4/ 6x6/ 8x8 only)
72574
Removetheoil vapour breather (1) andcleanit thoroughly.
Fit it backon, checkingit is in theright position, andtighten
it to therequiredtorque.
72567
Revi- June2007
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Base November 2006 Print 603.93.641/A
Aquila Trucks Centres
Figure53
72575
Removetheoil vapour breather (1) andcleanit thoroughly.
Fit it backon, checkingit is in theright position, andtighten
it to therequiredtorque.
505401 Clean oil breather on transfer box
between axles(with hours intervals)
525013 Clean oil breather on axles
Figure54
72576
Remove the oil vapour breathers (1) fromthe middleaxle
and (2) fromthe rear axle and clean themthoroughly. Fit
themback on, checkingthey are in the right position, and
tightenthemto therequiredtorque.
Test AdBlue system using E.A.SY.,
MODUS or IT 2000
General greasing
Handling operations
Functional on road testing
Tilting the cab, opening/closing the front
grille
M2SERVICE
Check-up on EDC system with MODUS,
IT2000or E.A.SY.
540613 Check valve clearance and adjust if
necessary
Toperformtheseoperationscorrectly,proceedasdescribed
under the relevant heading in the ENGINE section.
Figure55
86835
Figure56
72563
540450 Replace the blow-by filter
- Unscrewthescrews(2), takeoffthecasing,takeout the
filter (3) andreplaceit withanew one.Thefilterworks
inasingledirection, so you need to mount it with the
two strengtheningbars in view asshowninthefigure.
Revi- June2007
PROGRAMMEDMAINTENANCE 25 TRAKKEREURO 4/5
Print 603.93.641/A Base November 2006
Aquila Trucks Centres
72577
Figure57
Usingasuitabletool, unscrew thefilter (1) andreplaceit.
Beforefittingthenewcartridge,moistentheseal withdiesel
or engineoil. Screw it on byhand until it isin contact with
the mounting and then tighten by 3/4 of a turn to the
requiredtighteningtorque.
542406 Replace variable geometry
turbocharger (VGT) valve air filter
7
IntheCURSOR8versionsthefilterismountedon
theframe.
NOTE
72590
505100 Replacing air filter cartridge in dry
conditions and cleaning the
container
- Unhook the clamps (1) (or, dependingon theversion,
unscrewthenut) andtakeoff the bottomcover (2).
Figure58
Figure59
72591
- Unscrew the nut (4) and take out thecartridge of the
filter (3).
Beforefittingthenewcartridge,cleanitshousingthoroughly.
Grease the VGT control lever
Figure60
72580
- With theaxlewarm, takeoff theplug(2) and drainthe
oil into aspecific container.
- Pourinfreshoil throughtheholeclosedbytheplug(1)
(see under the FLUIDS heading of the GENERAL
section).
- Cleantheoil vapour breather.
- Tighten theplugsto the required torque.
522810 Change drive axle oil
(4x4, 6x6, 8x8versions only)
Revi- June2007
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Aquila Trucks Centres
Figure61
522870 Change front side reduction gear oil
(4x4, 6x6, 8x8versions only)
72581
Changetheoil as follows:
- Set the plug (1) as shown in the figure and the OIL
LEVEL line exactly horizontal.
- Open thescrew (2) anddrainoff theoil into aspecific
container.
- Pourinfreshoil throughtheholeclosedbytheplug(1)
(see SPECIFICATIONS AND DATA in the REAR
AXLE section).
- Before screwing the plug (1) and screw (2) back on,
spread sealant pasteon themand tighten themto the
requiredtorque.
525110/525010 Change axle oil
Transmissionandmiddleaxle
72582
- With theaxlewarm, unscrewtheplugs (1) and (3) and
drain off the spent oil into aspecificcontainer.
- Screwtheplugsbackonandpourinfreshoil throughthe
holeclosedbytheplug(2) (for thequantity, seeunder
theFLUIDS headingof theGENERAL section).
- Cleantheoil vapour breather.
- Tighten theplugsto the required torque.
Rear axle
72583
- With theaxlewarm, unscrewtheplug(1) anddrainoff
theoil into aspecificcontainer.
- Pourinfreshoil throughtheholeclosedbytheplug(2)
(see under the FLUIDS heading of the GENERAL
section).
- Cleantheoil vapour breather of the axle.
- Tighten theplugsto the required torque.
Figure62
Figure63
Figure64
79068
520620 Change front wheel hub oil
(4x2, 6x4, 8x4versions only)
Proceed as follows:
- removeplug(1) andsuckoil with suitablesyringe;
- fill thewheel hubwithnewoil (forthequantityandtype
of oil, see CHARACTERISTICS AND DATA in the
AXLES section.
Oil level ischeckedthroughplug(2) slidewithmaxandmin
writingsoncover (1) inhorizontal position.
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Figure65
Figure66
72584
505401 Change transfer box oil
(6x4, 6x6, 8x8versions only)
- Withhot distributor,slackenthedrainplugs(2) anddrain
theoil in asuitable container.
- Tighten theplugs (2) to torque60 NmxTC 1800, 78
Nmx TC 2200 and clean theoil breather (4).
- Removetheplugs(1and3),fill throughtheplughole(1)
the prescribed quantity and type of oil, see chapter
GENERALITIES in the AXLE section.
Fillingiscorrect whentheoil reachestheplughole(3).Drive
in the plugs (1 and 3) and tighten themto the prescribed
torque.
501401 Check steering box fixing and
mounting
Check that the fastenings of the steering box (1) and
mounting(2) aretightenedto the required torque.
86836
505401 Change transmission assemblyoil
(6x4, 6x6, 8x8versions only)
Seetheproceduresforchangingthetransmissionandmiddle
axleoil described above.
Replace AdBlue filter and prefilter
Inorder to carryout theseoperationscorrectly, proceedas
described in the relevant chapter of section ENGINE.
Figure67
760044 Check headlight adjustment
98882
- Placeunloadedvehicle,withtyresatprescribedpressure,
on flat ground, facing alight colour wall located at 10
metredistance.
- Mark two crosses on the wall corresponding to the
centresof thetwo headlights.
- Byusingcontrol (1), positionheadlightswithinclination
zero. Inclination can be displayed on CLUSTER display
unit.
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Aquila Trucks Centres
Figure68
TheM3servicecomprisestheoperationsoftheM1
and M2services.
98891
- Tilt the cab and turn on the low beam. The distance
betweenthecrossesandthepointsP,whichcorrespond
to theangleof theheadlights, has to be15 cm.
- Adjust light beamaccording to horizontal and vertical
directionsbyoperatingonscrews (1and 2).
Handling operations
Functional testing on road
NOTE
530105 Change gearbox oil
(ZF mechanical gearboxes)
98880
- With the gearbox warm, take off the plug(s) (1) and
drain theoil into aspecificcontainer.
- Theoil shouldbedrainedoff takingcarenot todirtythe
cross member beneathasit is near theoutlet onsome
types of gearbox.
- It isthereforewiseto useatool toconveytheoil away.
- Pourinfreshoil throughtheholeclosedbytheplug(2)
(for thequantity, seeunder theFLUIDSheadingof the
GENERAL section).
- Tighten theplugsto the required torque.
Figure69
M3SERVICE
EXTRA PLAN/TIMED OPERATIONS
(PLAN WITH KM INTERVALS)
EP1SERVICE
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Aquila Trucks Centres
8
(ZF 12AS gearboxes)
115278
- With the gearbox warm, take off the plug(s) (1) and
drain theoil into aspecificcontainer.
- Theoil shouldbedrainedoff takingcarenot todirtythe
cross member beneathasit is near theoutlet onsome
types of gearbox.
- It isthereforewiseto useatool toconveytheoil away.
- Pourinfreshoil throughtheholeclosedbytheplug(2)
(for thequantity, seeunder theFLUIDSheadingof the
GENERAL section).
- Tighten theplugsto the required torque.
Figure70
- Withthegearboxwarm,takeofftheplugs(1) anddrain
theoil into aspecificcontainer.
72570
530105 Replace oil and filter of ZF16S
gearbox +Intarder
Figure71
52571
Remove the oil filter as follows:
- unscrewthescrew(5) fixingthefilter;
- takeoff thecover andfilter (1);
- removethecoverfromthefilterandreplaceit.Takecare
not to losethemagneticpad (4) on the outer edgeof
thefilter, as it has to berepositioned on thenewfilter;
- check the state of the o-ring (2) and replace it, if
necessary;
- greasetheo-ring(3) insertedintheassemblyopeningof
thenew filter;
- couplethenewfilter withitscover and insert it into its
seat asfar as it will go. Secure thescrew (5).
Figure72
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Aquila Trucks Centres
9
115276
ASSEMBLY DIAGRAMOF BELTSFOR FAN - WATER
PUMP- ALTERNATOR AND AIR-CONDITIONER
COMPRESSOR
1. Alternator - 2. Drivebelt - 3. Fan- 4. Water pump-
5. Crankshaft - 6. Springbelt - 7. Air-conditioner
compressor - 8. Drivebelt automatic tensioner
In order to carryout changeoperations correctly, proceed
as described in the relevant chapter of section ENGINE.
T1SERVICE
553261 Checkinganti-pollenfilter condition
98890
Checkthestateof cloggingof thepollenfilter (2).
Anti-pollenfiltercanbeaccessedbyliftingfront cowlingand
under door (1).
Excessive cloggingof thepollen filters can cause a
reduction in the flow rate of air into the cab and
therefore less ventilation. This will be highlighted
especiallybyasignificant reductionintheefficiency
of thewindscreendefrostingfunction.
Figure73
NOTE
506011 Wash radiator grille
Lift thecabradiator cowlingandcarefullycleantheradiator
grille.
EP2SERVICE
543411 Replace water pump belt and
alternator
543910 Replace air-conditioner compressor
drive belt
Figure74
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T2SERVICE
506019 Check percentage of antifreeze in
the engine coolant
!
Theplug(1) mustneverbetakenout foranyreason
whatsoever.
With the engine warm, the cooling systemis in
overpressure, therefore take care when taking off
thecap(2).
Takeoffthecap(2) anddrawoffasampleofthecoolantfrom
theexpansiontank(3) with thedensimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentagehas to be higher than 40%and
must not exceed 50%.
If necessary, restorethepercentageof antifreeze, bearingin
mind that the liquidneedsto be replacedevery 2years.
Figure75
!
For vehicles fitted with an additional heater, the
percentageof antifreezemust never exceed50%.
98881
773130 Replacing additional heater fuel
filter
T3SERVICE
506010 Checking possible radiator clogging
T4SERVICE
72589
534501 Change Multipower total power
take-off oil (if applicable)
Set thevehiclehorizontal and stop the engine.
Positionasuitablecontainer to collect theoil.
- Unscrew thedrain plug(2).
- Unscrew thefilter (1) and clean it thoroughly.
Torestoretheoil level,screwthefilter (1) anddrainplug(2)
back on to the required torque, checkingthe state of the
seals.
Replacethemif theyhavedeteriorated. Then:
- Unscrew the plug(3) and add therequired amount of
oil (seeFLUIDSin GENERAL INFORMATION).
- Screwtheplugback on to therequiredtorque.
Figure76
T5SERVICE
506010 Changing engine coolant
Perform procedure described in relating paragraph in
section ENGINE.
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Aquila Trucks Centres
T6SERVICE
505292 Changethe clutch fluid and makeair
bleeding (only versions with
mechanical transmission)
Drain off the clutch control fluid and change it (see Fluids
tablein GENERAL section).
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediatelywith water andaneutral soap.
Figure77
After changingthe fluid, bleed the hydraulic clutch control
system.
Usetheair bleedingtool 99306010as follows:
- charge reservoir (5) with compressed air;
- fill reservoir (4) withTutelaTRUCKDOT SPECIAL fluid
- replacethecap( ) oftheclutchfluidreservoirwithone
of the caps supplied with the tool 99306010 and
connect thepipeto thecap.
1
- Attachaplastictubetothebleedscrew(2) ontheslave
cylinder (1) andimmersetheoppositeend of the tube
inacontainer containingTutelaTRUCKDOT SPECIAL
fluid,unscrewthebleedscrew(1) byonefull turn,open
thevalve(2) (seeFigure77) until apressurereadingof
1 to 1.2bar isobtainedonthepressuregauge(3);
- whentheclutchfluidflowingthroughthetubeisuniform
and free of air bubbles, close the bleed screw and
dischargetheairfromthereservoir (5) throughvalve(6).
40355
Figure78
Whenevertheclutchfluidischanged,it will alsobe
necessary to bleed the clutch master cylinder by
looseningthefitting(1, Figure77) beforebleeding
theclutch servo.
NOTE
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34 PROGRAMMEDMAINTENANCE TRAKKEREURO 4/5
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PRINT603.93.641
Aquila Trucks Centres
ELECTRIC/ELECTRONIC SYSTEM 1 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
SECTION 16
Electric/Electronic system
Page
GENERAL WARNINGSFORELECTRICAL/
ELECTRONIC COMPONENTS 3 . . . . . . . . . . . . . .
COMPONENT CODE 6 . . . . . . . . . . . . . . . . . . . . . . .
MAIN CHANGES 11 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN LINES 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN LINEASSEMBLY DRAWING 17 . . . . . . . . . . . . .
POWERNETWORK 18 . . . . . . . . . . . . . . . . . . . . . . . .
GROUNDPOINTS 19 . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL EQUIPOTENTIAL BRAID 20 . . . . . . . . . .
ALTERNATOR 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTERMOTOR 25 . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION CONNECTORS 27 . . . . . . . . . . . . . . . . . .
DIAGNOSISCONNECTOR 77 . . . . . . . . . . . . . . . . . .
BULKHEAD 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTRAL INTERCONNECTINGUNIT 84 . . . . . . . . .
FUSE 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTESWITCHES 87 . . . . . . . . . . . . . . . . . . . . . . . .
FUSEASSEMBLY BODY CONTROLLER (IBC3) 89 . . .
SUPPLEMENTARY FUSES(70000) 90 . . . . . . . . . . . . . .
INSTRUMENT BOARD 92 . . . . . . . . . . . . . . . . . . . . . .
CENTRAL DASHBOARD CONTROLS 93 . . . . . . . . . .
CONTROLSON THE STEERING WHEEL 94 . . . . . . .
REARVIEW MIRRORSAND WINDOW
REGULATORCONTROL ADJUSTMENT 95 . . . . . .
LEFT LIGHT CONTROL 54033 96 . . . . . . . . . . . . . . . .
ENGINE BRAKECONTROLAND INTARDER 99 . . . .
GEARSELECTION FUNCTION 100 . . . . . . . . . . . . . . . .
FUNCTION ENGAGINGEMERGENCY MODE
(LIMPHOME) 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Page
CLUSTER 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUSTER(PIN-OUT) 107 . . . . . . . . . . . . . . . . . . . . . . . .
BODY CONTROLLER (IBC3) 113 . . . . . . . . . . . . . . . . . .
BODY CONTROLLER 115 . . . . . . . . . . . . . . . . . . . . . . .
- Linkingconnectors 115 . . . . . . . . . . . . . . . . . . . . . .
CHASSISELECTRONIC MODULE(M.E.T.) 119 . . . . . . .
D.D.M./P.D.M. 121/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S.W.I. (STEERINGWHEEL /
STEERVATORINTERFACE) 122 . . . . . . . . . . . . . . . . .
SPIRALEDCONTACT 125 . . . . . . . . . . . . . . . . . . . . . . .
STEERINGCOLUMN
(COMPONENT LOCATION) 126 . . . . . . . . . . . . . . .
B.M. (BEDMODULE) 130 . . . . . . . . . . . . . . . . . . . . . . . .
E.B.M. (EASY BEDMODULE) 131 . . . . . . . . . . . . . . . . . .
TACHOGRAPH 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M.C. NET INTERFACE 134/1 . . . . . . . . . . . . . . . . . . . . . . .
INJECTION SYSTEMASSEMBLY 134/2 . . . . . . . . . . . . . . . .
ENGINE CONTROL UNIT OPERATION
STRATEGIES 134/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC (ECM) SYSTEMS 135 . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEMCOMPONENTS 139 . . . . . . . . . . . . . . . . . . . . .
VCM(VEHICLECONTROL MODULE)
ELECTRONIC CONTROL UNIT 163 . . . . . . . . . . . . .
IMMOBILIZER 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS-EBL 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMMON COMPONENTS 171 . . . . . . . . . . . . . . . . . .
Page
ECASSUSPENSIONS 178 . . . . . . . . . . . . . . . . . . . . . . . . .
EUROTRONIC AUTOMATIC TRANSMISSION 184 . . . .
LIMP - HOME 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CENTER 192 . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION ACTUATOR 194 . . . . . . . . . . . . . . . . . .
CLUTCH ACTUATOR 196 . . . . . . . . . . . . . . . . . . . . . . .
INTARDER 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EM(EXPANSION MODULE) ELECTRONIC
CONTROL UNIT (PTO) 206 . . . . . . . . . . . . . . . . . .
AUTOMATIC AIR CONDITIONER 209 . . . . . . . . . . . . . .
MANUAL AIRCONDITIONER 224 . . . . . . . . . . . . . . . . .
HYDRONIC D 10 WATER HEATER 228 . . . . . . . . . . . . .
SCR (SELECTIVECATALYTIC REDUCTION)
SYSTEM - DENOX 2 235 . . . . . . . . . . . . . . . . . . . . .
CENTRAL LOCKINGWITH REMOTE
CONTROL 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CHARTS 245 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aquila Trucks Centres
!
Do not ever disconnect thebatteriesfromthe systemwiththe enginerunning.
Do not start theenginewithout first havingconnectedthebatteriesin apermanent manner.
!
Keystorageproceduresareaffectedbyelectromagneticdisturbancessuchascell phonesand thelike.
Therefore, duringkeymemorization:
1. Ensuretherearenosources of disturbanceinthecabor closeto thekeys.
2. Keysnot inserted in thepanel must beat adistanceof at least 1meter.
!
When working on electronic control units, plug connections and electrical connections to the components,
measurementscanbemadeonlyonsuitabletestinglines,bymeansofspecial plugsandplug-typebushes.Donot under
anycircumstancesmakeuseofimproper devicessuchasmetal wires,screwdrivers, clipsandthelike.Inadditionto the
riskofcausingashortcircuit,thismight damageplug-typeconnectionsandthiswouldthengiverisetocontact problems.
ELECTRIC/ELECTRONIC SYSTEM 3 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Print 603.93.641
GENERAL WARNINGS FOR ELECTRICAL/ELECTRONIC COMPONENTS
- Beforeworkingonthe vehicle, immobilise thewheels withchocks.
- Donotusefastchargerstostarttheengine.Enginestartingcanbeperformedeitherbymeansofseparatebatteriesorbymeans
of aspecial truck.
- Incorrect polarisationof thepower supplyvoltage for theelectronic control units (e.g. erroneous batterypolarisation) may
damagethecomponentsirreversibly.
- Ifyouhavetodisconnect thebatteriesfromthesystem,alwaysdisconnect theframegroundcablefromthenegativeterminal
of thebatteriesfirst.
- Beforeconnectingthebatteries to thesystem, makesurethat thesystemissuitablyinsulated.
- Disconnect thebatteries fromthesystembeforerechargingthembymeansof anexternal unit.
- ||scooooct t|o otooa| oc|a|o oo|t o t|o o.o a|os booo oov|o t|o oo|t's ||os o t|o batto to|oa|s.
- At temperaturesof over 80 C (o|o ovoos), ta'o oo.o t|o |C|'s.
- At theconnectionstage, tightentheflanged nutsof theconnectors(temperatureand pressuresensors, etc.) toherequired
torque. Checktheexact polarityof thebatteryterminalswhenstartingtheenginebymeans of theauxiliarytruck.
- 3ooo .o'|o oo t|o vo||c|o's o|oct|ca|/o|octoo|c ssto o|scooooct t|o os|t|vo o|o o t|o batto.
- Beforedisconnectingtheconnector fromanelectroniccontrol unit, isolatethesystem.
- Do not cause sparks to checkwhether acircuit is live.
- Do not useatest bulbto check thecontinuityof acircuit. Onlyusetheappropriatetestingdevices.
- Donot directlypower thecomponentsassociatedwithelectroniccontrol unitswiththenominal powerratingof the vehicle.
- Makesurethatthewiringsofelectronicdevices(length,typeofcable,location,grouping,connectionofscreenbraiding,earthing,
etc.) conformwiththeIVECO systemand that theyarecarefullyrestored after repair or maintenance work. To avoid the
possiblemalfunctioningof theelectronicsystemsonboard,thewiringsof additional devicesmust followadifferent paththan
that of theabove-mentionedsystems.
- Do not connect thenegative terminalsof additional systemsto thenegativeterminalsof electronicsystems.
- Intheevent of electricweldingonthevehicle, disconnect all theelectroniccontrol unitsand/or disconnect thepower cable
fromthebatterypositiveterminal and connect it to theframeearth.
- Connectorsareviewedfromthecableside.
Aquila Trucks Centres
Inorder to prevent damageor short-circuitingof the on-boardelectroniccontrol units, thefollowingoperationsmust
bealwayscarriedout beforestartinganyweldingoperation onthe chassis.
- If electricweldinghas to bedoneon thevehicle,
isolatetheelectricsystemasfollows:
a) disconnect thepower lead fromthe batterypositiveterminal andconnect it to thechassisearth;
b) disconnect thepower lead fromthebatterynegativeterminal;
c) disconnect theelectroniccontrol unit connectors, takingcaretoavoidtouchingthecontrol unit connector pins.
- Moreover:
a) should it benecessaryto carryout weldingoperations closeto thecontrol unit, removeit fromitslocation.
b) whenever possible, earththeweldingmachinedirectlyto thepiecethat hasto bewelded.
112514
InthecaseofvehiclesequippedwithaDTCOdigital tachograph,donot disconnect thebatteryleadsandthenconnect
thembyjumpers to reset the electronicsystems.
This operationshouldbeavoided, as it couldcausepermanent damageto theDTCO tachograph CARD or other
on-board electronicsystems.
To reset theelectronicsystemwithout runningrisks, disconnect thevehiclebatteryand wait for 10 minutes.
It isstrictlyforbiddentocarryout anymodificationsor connectionstotheelectroniccontrol unitwiring; inparticular,
thelineinterconnectingdatabetweenthecontrol units (CAN line) must beconsidered as untouchable.
Diagnostic and maintenance operations can only be carried out byauthorised personnel with IVECO approved
equipment.
4 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Aquila Trucks Centres
ELECTRIC/ELECTRONIC SYSTEM 5 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Practical tips
T|o ooat|vo |oaos cooooctoo to a ssto oooo|o o|ot ost bo as s|o t as oss|b|o aoo cooooctoo to ooo aoot|o |o 'sta'
configuration; makesurethat theyaretightened in anorderlyand adequatemanner (Figure1, ref. M).
Furthermore, for electroniccomponents, theinstructionsto befollowedverycarefullyare:
- |C|'s ost bo cooooctoo to t|o ssto oooo | t|o ao ov|ooo .|t| a caso.
- ECUnegativecablesmust beconnectedbothtoasystemgroundingpoint, suchasforinstancethedashcompartment ground
(.|t| oo 'so|a|' o 'c|a|o' cooooct|oos) aoo to t|o oegativeterminal(s) ofthebattery/batteries.
- Eventhoughtheyarenot connectedto thesystemground/batterynegativeterminals, analoguegroundelements(sensors)
musthaveexcellentinsulation.Asaresult,special caremustbedevotedtotheeddyresistancesofthecableterminals:oxidation,
seam-foldingdefects, etc.
- Themetal braidof shielded circuitsmust beinelectrical contact at either endwithsystemcomponents.
- Onlyoneendoftheshieldingbraidmust beconnectedto the systemground.
- In the presence of jointingconnectors, the non-shielded portion, d, must be as short as possible in the proximityof the
connectors(Figure1).
- Thecablesmust bearrangedsoasto runparallel tothereferenceplane,i.e., ascloseaspossibleto theframe/bodystructure.
- Additional electromechanical systemsmustbeconnectedwiththegreatest caretothesystemgroundandmust not beplaced
alongsidethecablesof electroniccomponents.
SHIELDINGBY MEANSOF A METAL BRAIDOFA CABLELEADING TO AN ELECTRONIC COMPONENT -
C. CONNECTOR - d. DISTANCE! 0.
Figure1
88039
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Print 603.93.641/A
COMPONENT CODE
03000 Self-rectifyingalternator withbuilt involtageregulator
08000 Starter Motor
12015 Motor for outsideair intakedoor
12023 Windowshademotor
12032 Cab hydraulic releasepump motor
20000 Starter battery
22000 Horn
22043 Buzzer for warningthat automatic transmissiongear selector isnot in regular position
25010 Contactor for additional highbeamlampsengagement
25200 Relayfor starter
25201 Relay, preheating
25202 Relay, G.C.R. energizing
25203 Relay, G.C.R. opening
25204 Relay, remotestartingenablement, cabunlatched
25205 Relay, enginestopping
25206 Relay, rich mixturecontrol
25207 Relay, alternator D+earthing
25208 Relay, remotestart enablement, gear engaged
25209 Relayfor cuttingoff variouscomponents duringstartingstage
25210 Relay, startingenablement withtransmissioninneutral
25211 Relaywithdelayedopeningcontact for keepingG.C.R energized
25212 Relaywithdelayedclosingcontact for keepingRTE energized
25213 Relayfor supplyof users connected to ignitionswitch throughbattery positive
25222 Relayfor allowingconnectionof thermal starter
25306 Contactor for electroheater control andwindscreendefrost
25310 Relayfor allowingconnectionofinternal heatingwithpower load inhibitingrelay
25322 Relayfor connection of auxiliaryheater (1st speed)
25325 Contactor for enginewater recycle open withenginerunning
25327 Relayfor connectionof air-conditioningsystem
25332 Relayfor connectionof air-conditioningsystem
25337 Contactor for enginewater recycle closesolenoid valvewithadditional heater on
25351 Electrictrap openingcontactor
25352 Electrictrap closingcontactor
25544 Topflapenginepolarityreversecontactor for LD
25545 Topflapopen/closecomandcontactor for LD
25705 Contactor for vehicletesting
25722 Cab hydraulic releasepump switch(lowering)
25723 Cab hydraulic releasepump switch(raising)
25737 Contactor for fan (Barufaldi) electromagneticcouplingengagement
25740 Headlamp washer enable contactor
25805 Contactor for horncontrol
25818 Contactor for heater windscreen control
25866 Relayfor terminal 58
25874 Relayfor connection of power loadswithenginerunning
25897 Relayfor connectionof sidetransmissionpower takeoff
25898 Relayfor connection of rear transmission power takeoff
25900 General current relay
25901 Main current relaywithautomaticswitch
25903 Contactor for EDC disengagement
252+ ||C cooooct|o o|a '|a|o |o|a'
30001 Dippedand mainbeamheadlampwithsidelight
30010 Highbeamheadlamp
30011 Foglight
30100 Headlampaimingcontrol actuator
32002 Front directionindicator
32010 Rotarylamp
33001 Sidedirectionindicator
33004 Sidemarker lamp
34000 Multifunctional rear light
34011 Trailer light
35000 Number platelight
37000 Front/rear dimensions light
37001 Front dimensionslight
39000 Ceilinglampfor cabin insidelighting
39003 Courtesylight for steps
39009 Courtesylight for readinglights
39017 Courtesylight for adjustablecabininterior light
39020 Ashtraylamp
Aquila Trucks Centres
Revi - June2007
ELECTRIC/ELECTRONIC SYSTEM 7 TRAKKER EURO 4/5
Print 603.93.641/A Base- November 2006
39030 Cab sideopeninglightinglamp
39030 Cab sideopeninglightinglamp
39034 Whiteandred internal light unit
40011 ElectronicTachograph
40032 Sender unit for tachometer and tachograph
40046 Inductivetypechassisheight sensor (rear axle)
40047 Inductivetype chassisheight sensor (front axle)
42030 Sender unit for engineoil pressure gauge
42045 Sender unit for outdoor temperaturegauge
42100 Switchfor front brakeinsufficient air pressureindication
42101 Switchfor rear brakeinsufficient air pressureindication
42102 Switchsignallinghandbrakeapplied
42108 Switchfor trailer retarder signal
42111 Switchsignallingtrailer brakingsystemfailure
42116 Switchfor lowair pressure indicator inEBSsystem
42200 Switchsignallingpneumaticsuspensionsystemfailure
42351 Switchsignallingair filter blocked
42374 EDC clutchswitch
42379 Switchfor PTO engagement enable
42381 DriveaxleRH pressuresensor (ECAS)
42382 Lift axleRH pressuresensor (ECAS)
42389 Air pressuresensor onthirdaxlepneumatic liftingsystem
42551 Switchsignallingoil filter blocked
42608 Coolant pressuresignalling3-switchassembly
42622 Circuit 2 hydraulicoil flowindicator switch
42623 Electricswitch infront power steeringengagement valve(ZF circ. 1,5)
42624 Electricswitch infront power steeringlockvalve(ZFcirc. 1,5)
42700 Fuel filter cloggedindicator switch
44031 Fuel level gaugesender unit with reserver warninglight contact
44035 Insufficient windscreenwasher fluidlevel gaugecontrol
44036 Insufficient radiator coolant level gaugecontrol
44037 Insufficient power steeringliquid level indicator ECU
44043 Engineoil level gaugesender unit
47032 Sender unit for engineoil temperaturethermometer
47041 Water temperature transmitter for Retarder ECU
47042 Fuel temperaturesensor
47043 Enginefan temperaturesensor
47113 Thermometricswitch for pre-filter andfuel oil sedimentationtankheating
48035 Enginerpmsensor
48042 Enginerpmsensor (ontiminggear)
48043 Turbocharger speedsensor
50003 Electronicdashboard withmicroprocessor for instrument and indicator lampdisplay
50005 Multiplexinstrumentsunit module
52001 Switchwith built in indicator lamp for windscreendefrost heater
52003 Switchwith built in indicator lamp for additional heater
52005 Switchwithbuilt inw/l for heatedrear viewmirrors
52009 Switchwithbuilt inw/l for trailer light
52013 Switchfor internal aerators
52024 Switchwithbuilt inw/l for additional headlamps
52029 Central emergencycontrol switch
52035 Switchwithintegral rotaryheadlamp engagement indicator lamp
52044 Switchfor differential lockengagement
52045 Switchfor front driveengagement
52056 Switchwithbuilt-inw/lampfor ASRcutout
52057 ABScut out switch
52059 Automatictransmissionspeed selector
52070 Switchfor engagingsidepower takeoff
52071 Switchfor engagingrear power takeoff
52090 Suspension levellingswitch(ECAS)
52091 Switchwithintegral indicator lampfor heater rear mirror engagement
52092 Switchfor engineor cabheater
52093 Switchfor tail hatchlockingsafety
52094 Switchfor spot light
52200 Switchfor electric or pneumatichorns
52220 Switchfor tail hatch lockingsafety
52300 Switchfor tail hatch lockingsafety
52302 Switchwithbuilt inw/l for hazard warninglights
52304 Switchfor foglights andrear foglightsinhibitor
52307 Switchfor exterior lights
Aquila Trucks Centres
Revi - June2007
8 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641/A
52312 Switchcontrollingheadlampalignment adjustment
52324 Enginebrakeconnectingswitch
52326 Whiteandred internal lightsswitch
52502 Ignitionswitch for serviceswithstarting
52600 Main current switch
53006 Switchfor startingfromenginecompartment
53007 Switchfor stoppingenginefromenginecompartment
53022 Switchfor front differential lockcontrol
53030 Switchfor controllingstartingassistance
53061 Cab hydraulic releaseconsensusswitch
53062 Cab hydraulic releasepump switch(lowering)
53063 Cab hydraulic releasepump switch(raising)
53068 Unstableswitch for idleposition(n) with automatic transmission
53069 Unstableswitch for reverse (r) withautomatictransmission
53070 Unstableswitch for forwardgears(d) withautomatictransmission
53071 Unstableswitch for speed limiter withautomatictransmission
53300 S.|tc| o o|vo's s|oo o|oct|c .|ooo.
53302 Switchfor passenger sideelectric window
53303 Push-buttonpanel for slidingdoor openingdevicecontrol
53304 Switchfor axlepneumaticsuspensioncontrol
53305 Switchfor driveaxlepneumaticsuspensioncontrol
53306 Switchcontrollingsunroof motor
53309 Switchfor 3rdaxleraisingsystem
53311 Switchfor controllingwindowblind
53315 Switchwithbuilt intelltaletoturn onfoglights
53316 Current general contactor switch
53501 Switchsignallingvehiclestopped
53503 Switchsignallingreversinglights
53504 Front differential lockonindicator switch
53506 Four wheel driveengaged indicator switch
53507 Switchsignallingreduced gearsengaged
53508 Switchfor antistartingwithreducedgears
53509 Switchfor switchingoninterior lights
53510 Switchfor switchingonsteplights
53511 Switchsignallingcabinunlatched
53512 Switchfor antistartingenginedevicewithhandbrakeoff
53521 Switchfor signallinglongitudinal differential lock
53538 Tiltedboxindicator switch
53547 Switchfor secondarysignal frombrakepedal to EDC ECU
53565 Brakepedal pressed indicator switch
53567 Switchfor signallingsidepower takeoff engaged
53568 Switchfor signallingrear power takeoff engaged
53591 Switchfor signallingfailureof thehydraulic circuit withauxiliarysteeringthird axle
53593 Switchto light cabsideopeninglamp
53593 Tool compartment light switch
53602 Switchindicatingincompletesunshadeclosing
53606 Reed switch(control withmagnet) onmaster clutchcylinder for synchronousprotection of mechanical transmission,
70%compressed
53607 Reed switch(control withmagnet) onclutch master cylinder for EDC
53801 SwitchsignallingRockwell axle differential lockengaged
53802 SwitchsignallingRockwell axle differential lockengaged (3rd axle)
54030 4functionsteeringcolumnswitchunit
54033 6functionsteeringcolumnswitchunit
61011 3A 1-diodeholder container
61101 13A diodecontainer
61104 Air brakingsystemdrier resistor
61108 Current limiter resistancefor heater windscreensystem
61110 Pre-filter andfuel oil sedimentationtankpre-heatingresistor
61121 Resistancefor enginepreheating
61126 Terminationresistor for CAN bus
61137 Current limiter resistor for additional enginewater heater
61147 Resistor container for ACC (AdaptiveCruiseControl)
61150 Ureafilter outlet heater withSCR(SelectiveCatalyticReduction)
64000 Electricwindscreenwasher pump
65000 Windscreenwiper unit
66005 Headlampwasher pump
68000 Radio equipment
68001 Speaker
Aquila Trucks Centres
Revi - June2007
ELECTRIC/ELECTRONIC SYSTEM 9 TRAKKER EURO 4/5
Print 603.93.641/A Base- November 2006
68003 Preamplifier
68005 Feeder 24 V 12V
68007 CityBand(C.B.)
70000 Fuseholder 6 (30A)
70001 Fuseholder 8
70058 1-way20A fusecarrier
70066 Fuseholder 1-way 1afor ADR
70401 Fuseholder 4-ways
70402 Fuseholder 4-ways
70403 Fuseholder 4-ways
70601 Fuseholder with 6fuses
70602 Fuseholder with 6fuses
70603 Fuseholder with 6fuses
70604 Fuseholder with 6fuses
70605 Fuseholder with 6fuses
72006 7-pincouplingfor tractor/trailer ABS/EBSelectricconnectionCouplingwith7poles for electrical connec-
tionof trailer ABS
72010 15-polecouplingfor electrical connection to trailer
72021 30-poleconnector for theelectrical connection tothediagnostic equipment locatedoutsidethevehicle
72022 2-polecouplingfor external engine start
72025 2-pole12V connection for general power supply
72026 2-pole12V connection for telephone
72069 16-polecouplingfor OBD (OnBoardDiagnose)
78009 Closedcircuit to turbinesolenoidvalve
78016 Enginefansolenoidvalve
78050 Enginebrakesolenoid valve
78052 ABS/EBSsolenoid valve
78053 ASRsolenoid valve
78054 Solenoid valvefor engagingretarder
78055 Solenoid valvefor retarder oil accumulator
78057 EBSfront axleair pressurecontrol proportional valve
78058 EBStrailer air pressurecontrol proportional valve
78059 Duplexvalvefor EBS
78060 Solenoidvalveto excludethird-axlebrakingwithASR
78061 Oversizesolenoidvalve for axlebrakingincase of EBSECUfailure
78062 ECAD regenerationsolenoid valve (ElectronicControlledAir Dryer)
78063 ECAD bleedsolenoidvalve (ElectronicControlled Air dryer)
78171 Splitter control solenoidvalve
78182 Solenoid valvefor mechanical transmissionsynchronousprotection
78203 Solenoidvalvefor pneumatic horns
78205 Solenoid valvefor transversedifferential lock
78206 Solenoid valvefor longitudinal differential lock
78208 Solenoid valvefor total PTO engagement ontransmission
78227 Solenoid valvefor radiator water recirculation
78238 Rear axlesolenoid valveassemblyfor chassisalignment
78239 Front axlesolenoid valveassemblyfor chassisalignment
78243 Rear axleelectropneumatic distributor
78245 Solenoid valvefor total PTO disengagement ontransmission
78247 Solenoid valvefor electronicinjection
78248 Solenoid valvefor variablegeometryturbineorder
78249 Solenoid valvefor third axlepneumaticvalvecontrol
78250 Solenoid valvefor 3rdaxlelowering
78251 Solenoid valvefor engagingtransmissionsidepower takeoff
78252 Solenoid valvefor engagingtransmissionrear power takeoff
78265 Solenoid valvefor axletransverse differential lockengagement
78266 Meteringmodulesolenoid valvewithSCR (SelectiveCatalytic Reduction)
78267 Enginewater circulationsolenoid valvefor ureatank heatingwithSCR (SelectiveCatalyticReduction)
80000 Motor for right electricwindow
80001 Motor for left electricwindow
82000 Windscreendefrostingcontrol unit
82005 Auxiliaryair heater
82010 Air conditioningsystemcontrol and indicationECU
84000 Water boiler
84001 Air burner
84005 Additional heater ECU
84006 Additional heater control and indicationECU
84009 Internal temperaturesensor
84010 Meteringdevice
Aquila Trucks Centres
Revi - June2007
10 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641/A
84019 Electromagneticpulley
85000 Cigar lighter
85001 Cigar lighter outlet
85003 Heatedrearviewmirror (trailer)
85004 Heatedrearviewmirrot (wheel)
85005 Heatedrearviewmirror
85006 Electricallyadjustableheated rear viewmirror
85007 Wheel electricallyadjustableheatedrear viewmirror
85008 Trailer electricallyadjustableheatedrear viewmirror
85009 Front Heated rearviewmirror
85010 Rear viewmirror control
85011 Rearview selectionand heatedrearview mirror engagement control
85023 Electriclatch
85036 Heatedpneumaticseat (driver side)
85038 Heatedpneumaticseat (passenger side)
85065 Remotecontrol for aligningsuspensionsand raising3rd axle
85131 Volumetricsensor
85140 Electroniccontrol for SCRpumpingmodule(SelectiveCatalyticReduction)
85141 Catalyst outlet temperaturesensor withSCR (Selective Catalytic Reduction)
85142 Level and ureatanktemperaturesensorswith SCR(SelectiveCatalyticReduction)
85143 Catalyst inlet temperaturesensor withSCR(SelectiveCatalyticReduction)
85144 NOX detectionsensor with SCR
85150 EDC ECU
85152 Accelerator loadsensor (EDC)
85153 Coolant temperaturesensor (EDC)
85154 Turbofanair temperaturesensor (EDC)
85155 Turbofanair temperaturesensor (EDC)
85156 Turbo blower air temperatureandpressuresensor for EDC
85158 Turbofanair temperaturesensor (EDC)
85159 Temperatureandambient air pessuresensor for EDC
85161 Relativehumiditycombustion air andtemperaturesensorswith EDC
86002 Sensors for front brakeshoewear
86003 Sensors for rear brakeshoewear
86004 Automatictransmissionelectroniccontrol unit
86013 Sensor for signallingwater infuel filter
86015 Retarder electroniccontrol unit
86023 Vehicleraising/loweringcontrol unit Ecas
86029 Centralizeddoor lockECU
86030 Sensor detectingheat irradiation
86038 CentralizedlubeECU
86053 Multiplexcontrol andsignal unit frombedpositions
86116 Multiplexbodycomputer control unit
86119 Multiplexdriver door moduleECU
86053 Multiplexcontrol andindicationECU fromstretchers
86116 Multiplexbodycomputer ECU
86117 Multiplexfront framecomputer ECU
86118 Multiplexrear framecomputer ECU
86119 MultiplexDriver Door ModuleECU
86120 Multiplexpassenger door moduleECU
86123 MultiplexECU for steeringcontrol shaft interfacing
86124 CabinoperationwithMultiplexECU
86125 ECU for VDI (VehicleDataInterface)
86126 ECU for EM(Expansionmodule)
86127 ECU for DMI (DataManagement Interface)
86128 M.E.T. chassisECU
86129 ECU for MC-NET (MobileCommunicationNetwork)
86130 Navigator ECU
86131 Telematic ECU
86132 VCM(VehicleControl Module) ECU
88000 ABSECU
88001 ABS/EBSsystemsensor
88005 EBSsystemECU
88006 EBSrear axle air pressurecontrol modulator
88007 Potentiometricsensor for front wheel shoepositionindicator
88008 Potentiometricsensor for rear wheel shoe position indicator
88010 Rear axlebrakeapplicationpressuresensor
88011 Potentiometricsensor for thirdaxleskidwear signalling
88012 SASsensor (=SteeringAngleSensor) for EBS
88013 ESC module(=Electronic StabilityControl) for EBS
89000 Fridge
89010 Foodwarmer
Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 11 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
MAIN CHANGES
For vehicleswith Euro 4 enginetheelectric/electronic systemis subject to important variations.
Inorder to handletheincreasedcomplexityof Euro4 operationsdemanded to theenginecontrol systemextrahardwareand
software resources, the VCM(Vehicle Computer Module) hasbeenaddedso that vehiclefunctions can be reallocatedonit,
whichupto Euro 3hadbeencarriedout bytheEDC enginecontrol unit,thereforemoredevelopment flexibilityisavailablefor
vehiclefunctions. The immobilizer functionhas been also integrated on this unit.
The New BodyController (IBC3) unlike the Body Computer (BC) distributes direct positives and key-locked, protected by
external fuses(replaceable) orinternal (resettable).InthechassisthereistheMET control unit (chassiselectronicmodule) which
controls thechassis power devices, thus replacingthe FFC and RFC control units.
For theautomated transmissiononthenewEuro 4vehiclerangethegear selectorhas beenremoved. Itsfunctionsarecarried
out fromthecontrol pushbuttons locatedonthedashboard center panel combined with thepower steeringlever.
The EMcontrol unit (ExpansionModule) replaces theDMI (DataManagement Interface). It controls thepower takeoffs and
makes it possible to implement complex applications and connections to different devices through the CAN-open line. It
communicateswith theother control units through theCAN DVBline.
TheSCR(SelectiveCatalyticReduction) - Denox 2isontheentireAverage/HeavyEuro4RangewiththeUreaDosingSystem
(UDS) positionedonthelower sideof theframe.
The ENGINE ECM (EngineControl Module) replacesEDC MS 6.2.
The newCluster ismonochrome withmorefunctions compared to theprevious one.
The introduction of thenew unitsandthechangeof theprevious ones requirechanges of thevehiclesystemstructure.
The followingCAN lines areontheVCM unit:
- VDB- VehicleDataBus
- ECB- EngineControl Bus
- FMB- FuhrparkManagement Bus
Figure2
112584
UDS
VCM
ECM
EM
IBC3
CLUSTER
MET
Aquila Trucks Centres
12 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
CAN LINES
DialoguebetweentheEasyMuxsystem, vehicle systems, enginecontrol unit, SCR system, radio and various setters is carried
out bymeans of theCAN lines:
- BCB- BodyControl Bus
- VDB- VehicleDataBus
- ECB- EngineControl Bus
- IDB- Infotainment DataBus
- FMB- FuhrparkManagement Bus
BCB (Body Control Bus) communication line
It enablesthecommunicationbetweentheIBC3andMET control units of theEasyMux systemandtheothercontrol unitsof
thedifferent servicesonboard.
Technical features
- Datatransmission speed 62.500(BIT/SEC)
- Color of thewire Grey
List of Units
Ref. Description
IBC3
DDM
PDM
BM
MET
AHT-A
AHT-W
BodyController
Driver Door Modulecontrol unit
Passenger Door Module control unit
Bed Module
MET chassis control unit
Air heater
Water heater
Figure3
112585
IBC3
BM DDM
PDM AHT_A
BCB
MET
AHT_W
Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 13 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
VDB (Vehicle Data Bus) Communication Line
Allowstheelectronicsystemsonthevehicletodialogue. Theunitsconnectedto it are:EurotronicTransmission,Retarder,ABS,
Ecas, Diagnosis connector, VCM, Tachograph, ACC, SWI, EM, (Mc Net).
This linealso dialogues withtheCluster andtheBodyComputer.
Features
- Datatransmission speed 250.000(BIT/SEC)
- Color of thewire Black
List of Units
Ref. Description
MTCO
DTCO
VCM
IC
IBC3
SWI
Diagnostic Connector
ABS
McNet
RETARDER
ECASII
EUROTRONIC II
ALLISON TCM
ACC
Tachograph
Digital tachograph
VehicleControl Module control unit
Cluster
BodyController
SteeringWheel Interfacecontrol unit
30-polediagnosisconnector
ABScontrol unit
Electroniccontrol unit for Mobile Communication Network
Intarder control unit
Air suspensioncontrl unit
Eurotronic II automatic gearbox control unit
Allisonautomatic gearboxcontrol unit
Radar ACC (AdaptiveCruiseControl) control unit
Figure4
112597
SWI
MTCO/DTCO
RETARDER ABS
Diagnostic
Connector
ECAS II
VDB
IBC3
VCM
EM MCNet
ETC
ALLISON TCM /
EUROTRONIC II
IC ACC
Aquila Trucks Centres
14 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
ECB (Engine Control Bus) communication line
Allows theunits and the enginecontrol sensorsto dialoguetogether. Theunits connectedto it are:: EDC,VCM, DCU15and
theOBD connector.
Features
- Datatransmission speed 250.000(BIT/SEC)
- Color of thewire Yellow
List of Units
Ref. Description
VCM
EDC7
DCU15
OBD II Connector
VehicleControl Module Unit
Engine control unit
SCR pumpingmoduleunit
16poleconnector for OBD (onbord diagnose)
VCM
ECB
EDC7
OBD II
Connector
DCU15
Figure5
112280
Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 15 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
I.D.B. (Infotainment Data Bus) communication line
Allows communicationbetweenthe Cluster andtheRadio. Themessages sent areshownontheCLUSTER.
Technical features
- Datatransmission speed 100.000 (BIT/SEC)
- Color of thewire Blue
List of Units
Ref. Description
Radio
McNet
Radio
Electroniccontrol unit for Mobile Communication Network
Figure6
IDB McNet
RADIO
112586
Aquila Trucks Centres
16 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
F.M.B. (Fuhrpark Managemant Bus) communication line
Allowscommunicationbetweenthedifferent electronicsystems(accessories) onthevehicle,, FMS(Telephone) connectorand
VCMunit.
Technical features
- Datatransmission speed 250.000 (BIT/SEC)
- Color of thewire White
List of Units
Ref. Description
VCM
FMS
VehicleControl Module Unit
Connector FMS
FMB
FMS
Connector
VCM
Figure7
112283
Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 17 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
CAN LINE ASSEMBLY DRAWING
Figure8
112587
Aquila Trucks Centres
GROUND POINT OF BATTERIES ON LEFT
SIDEMEMBER
STARTER MOTOR AND ENGINE GROUNDPOINT
6633
6632
M1
M2
Figure9
Figure10
!
Neverdisconnect thebatteriesfromthesystemwith
theenginerunning.
Beforeconnectingthebatteriesto thesystem,make
surethat thesystemis well insulated.
Disconnect the batteries fromthe system when
chargingthem.
18 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
POWER NETWORK
The purpose of the electric systemis to generate, regulate,
storeand distributetheenergyneeded to make thevehicle
components work.
For this reason the supply of the base electric system is
ensuredbyagenerator (28V- 60A -90A alternator) andtwo
batteries, eachwith12 V170 Ah(opt 220Ah) connectedin
series.
Amobilefuseholdercontaininga20Ampfuseislocatedclose
to thebatteries. Thisfusesupplies:
- Fuseholder 70605/1
- BodyController (A07)
- Refrigerator
- ACC presetting
This fuse is not present ontheADR version.
Power cable section:
- batterydirect cable = 16mm
2
- fusecables = 4 mm
2
Attain to what detected on the vehicle for the remaining
sections.
Negative network
The batteries are connected to the frame ground with a
brown 70 mm
2
cable, at ground point M1 on the left
sidemember (Figure 9).
The starter motor is connected to the frame ground (M2)
through a70 mm
2
cable, fastened on theright sidemember
near theactual motor.
Thesamecableserves for connectingthewholeengineunit
to theframeground.
Aquila Trucks Centres
ELECTRIC/ELECTRONIC SYSTEM 19 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
GROUND POINTS
91664
M1. Batteryground - M2. Starter motor ground - M3. Upper cab ground - M4. Right inner cabground- M5. Left inner cab
ground - M6. Front right frameground - M7. Engineground- T1- T2. Equipotential braid
Figure11
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20 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ELECTRICAL EQUIPOTENTIAL BRAID
Thoughgenerallyprotectedagainst theinfluenceofon-boardequipmentvoltage,electroniccomponentsneverthelessremainpar-
ticularlysensitiveelectromagneticcompatibilityissues, of different naturesuchas:
- generated bythevehicles
- external.
A suitablesizeflexibleelectrolyticcopperbraidhasbeenprovidedonthevehiclestominimizethesephenomenaandreturnmain
cab andframestructures totheequipotential state.
Check that thebraidis properlyattached totheframeandthecab, in theevent of defectivecab grounding.
74201
T1
T2
Figure12
Aquila Trucks Centres
ELECTRIC/ELECTRONIC SYSTEM 21 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
49846
GROUNDPOINT ON THELEFT FRONT FRAME
49844
GROUNDPOINT ON THERIGHT FRONT FRAME
M6
T2
Figure13
Figure14
Aquila Trucks Centres
22 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
49849
GROUNDPOINT BEHINDTHEBODY COMPUTER
73754
GROUNDPOINT BEHIND THECLUSTER
M4
M5
Figure15
Figure16
Aquila Trucks Centres
7998
8000
8002
8003
ALTERNATOR CURRENT DELIVERY CURVE
Characteristics
WIRINGDIAGRAM
A. Alternator B. Voltageregulator
Ratedvoltage 28V
Ratedpower 90 A
Current at environment temperature1800RPM/40 A
At 25 C andratedvoltage 6000RPM/90 A
Direction of rotation clockwise, seenfrompulley
Weight 7.8kg
S
03000
L(D+)
IG(15)
B+
TECHNICAL VIEW
B
A
VOLTAGEREGULATORTEMPERATURE
CHARACTERISTICS(6000 RPM)
Figure17
Figure18
Figure19
Figure20
ELECTRIC/ELECTRONIC SYSTEM 23 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
28V - 40 A 90 A BOSCHALTERNATOR
Aquila Trucks Centres
24 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Ref. Function
Cablecolour
code
L To F.F.C. center clampJ2/B24 7009
15(IG) To remoteswitch25213 clamp87(viafuseF6-70601) 8876
S Positive(+30) 7777
B+ Clamp Salternator Positive +30power positive 7777
+30 positiveto starter motor 7777
Positive+30 7777
8535
PERSPECTIVEVIEW WITH CORRESPONDINGELECTRICAL CONNECTIONS
B
A
A
B+
Figure21
Aquila Trucks Centres
Ratedpower
Systemvoltage
Engagement system
Adjustedtime
Direction of rotation
Weight
Operatingvoltage
Water resistance
CHARACTERISTIC CURVES
4958
Characteristics Characteristics Test cond.
SpecificPower
(20 C)
TECHNICAL VIEW
WIRINGDIAGRAM
4956
4957
5.5kW
24V
Positiveapproachcontrol
30sec.
clockwise, seenfromend
of pinion
approx. 10.5kg
16V MAX. (20 C)
Water spraytest to JIS
|0203' S|'
Loadless 23V 120A MAX (3800rpmMIN.)
Load 16V (49 N-m) 690A MAX. (900rpmMIN.)
Stall 6V 1260A MAX. (73.5N-mMIN.)
08000
Figure22
Figure23 Figure24
ELECTRIC/ELECTRONIC SYSTEM 25 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
24V - 5.5 KW NIPPONDENSO STARTER MOTOR
Aquila Trucks Centres
6658
PERSPECTIVEVIEW WITH ASSOCIATEDELECTRICAL CONNECTIONS
+30
Figure25
26 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Connector Function
Cablecolour
code
+30 +30 positivefor starter motor power frombatterypositiveclamp(viatheT.G.C.) 7777
+30 +30 positiveto thealternator 7777
+30 +30 positiveto remoteswitchfor enginepreheat onconsent 7777
+50 +50 positivefor keyswitch 8888
Aquila Trucks Centres
ST06A
ST06B
ST07D
ST08A
ST08B
ST31
ST31L
ST37
ST79A
ST79B
ST79D
STY1
ST02
ST12
ST21
ST30
ST11
ST35/1
ST35/2
ST39
ST44
ST56
ST63
ST05
ST07B
ST07C
ST09A
ST10
ST13
ST20
ST31B
ST31C
ST31R
ST34
ST36
ST07A
ST19
ST09B
ST14A
ST14B
ST24
ST25
ST26A
ST31A
ST42
ST14
ST26B
ST14C
ST48
ST03
ST23
ST01
ST
ST28
ST15
ST40
ST45
ST06C
Figure26
113406
ELECTRIC/ELECTRONIC SYSTEM 27 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
JUNCTION CONNECTORS
Location of the junction connectors - cab
Thelocationof theconnectors(cab - chassis) couldchangeto suit wiringneeds.
Aquila Trucks Centres
Figure27
113407
ST72
ST54
ST65
ST64
ST70
ST73/1
ST87
ST91
ST92
ST93
ST82
ST55A
ST55B
ST67
ST68
ST81A
ST80
ST69
ST83
ST73/2
ST73/3
ST73/4
ST86
ST75A
ST75B
28 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
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Location of the junction connectors - chassis
Aquila Trucks Centres
ELECTRIC/ELECTRONIC SYSTEM 29 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
List of connectors
Name Description
ST 01 Connectionfor startingcommutator
ST 02 Connectionfor steeringcolumn
ST 03 Connectionfor speedlimiter / Cruisecontrol set
ST 05 Connectionfor Eurotronic
ST 06A Connectionfor roof panel wingsdevicesonthedriver side
ST 06B Connectionfor tachograph
ST 06C Connectionfor Toll Collect
ST 07A Connectionfor roof panel wingsdevicesonthepassenger side
ST 07B Connectionfor navigationand for IT tools
ST 07C Connectionfor heatablewindscreen
ST 07D Connectionfor rotatingheadlights
ST 08A Connectionfor DDMcontrol unit
ST 08B Connectionfor driver sidedoor
ST 09A Connectionfor PDMcontrol unit
ST 09B Connectionfor passenger sidedoor
ST 10 Connectionfor toolslighting
ST 11 Connectionfor trailer retarder brake
ST 12 Connectionfor ABS/EBStractor and trailer electrical connection
ST 13 Connectionfor auxiliaryair heater CAN line
ST 14 Connectionfor Ecas bodybuilders(cab)
ST 14A Connectionfor bodybuilders(cab)
ST 14B Connectionfor bodybuilders(cab)
ST 14C Connectionfor set updevices(Allison)
ST 15 Connectionfor couplingsinthehigh roof
ST 19 Connectionfor heater
ST 20 Connectionfor air- conditioner
ST 21 Connectionfor radiator water recirculationsolenoid valve
ST 23 Connectionfor Immobilizer antenna
ST 24 Connectionfor air conditioningsystemcontrol unit CAN line
ST 25 Connectionfor Intarder
ST 26A Connectionfor Ecas
ST 26B Connectionfor ABS/EBS
ST 28 Connectionfor rotatingheadlights
ST 30 Connectionfor ADR (tachograph) provision
ST 31 Connectionfor ECASremotecontrol
ST 31A Connectionfor cabrear
ST 31B Connectionfor auxiliaryair heating
ST 31C Connectionfor auxiliaryair heatingtemperaturesensor
ST 31L Connectionfor pneumatic heated seat
ST 31R Connectionfor pneumatic heated seat
ST 34 Cooooct|oo o /CC ov|s|oo / s||o '' oabo cooto|
ST 35/1 Connectionfor air conditioner with manual control
ST 35/2 Connectionfor air conditioningwith manual control
ST 36 Connectionfor T.G.C. / I.G.C.
ST 37 Connectionfor Toll Collect
ST 39 Connectionfor differential lock
ST 40 Connectionfor navigationand for IT tools
ST 42 Connectionfor DDM/PDMsupplies
Aquila Trucks Centres
30 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Name Description
ST 44 Connectionfor centralized closingwithremotecontrol
ST 45 Connectionfor 24 Vradio
ST 48 Connectionfor DMI / EMcontrol unit for PTO
ST 49 Connectionfor Allisonsetup
ST 54 Connectionfor ACC provision
ST 55A Connectionfor SCRsystem(Urea)
ST 55B Connectionfor SCRsystem(Urea)
ST 56 Connectionfor ADR (15) Alternator
ST 59 Connectionfor ECASbreakdownswitch/longitudinal blockageof 2
nd
front axle(8x8)
ST 63 Connectionfor auxiliarywater heater CAN line(BCB)
ST 64 Connectionfor 15-polescurrent output freepins
ST 65 CAN lineconnectionfor trailer (PTO withEM)
ST 67 Connectionfor ureadosingmodulesolenoidvalve
ST 68 Connectionfor Ureatemperaturesensor
ST 69 Connectionfor Intarder
ST 70 Connectionfor ASRsolenoid valve
ST 72 Connectionfor 35 axlesfor shoes wear and tear / transversedifferential blocking
ST 73/1 Connectionfor indicating1st front axlewear (right)
ST 73/2 Connectionfor indicating1st front axlewear (left)
ST 73/3 Connectionfor indicating2ndfront axlewear (right)
ST 73/4 Connectionfor indicating2ndfront axlewear (left)
ST 77 Connectionfor right hand side SML indicator lamp (SideMarker Lamp)
ST 78 Connectionfor left hand side SML indicator lamp (SideMarker Lamp)
ST 79A Connectionfor external cabfront
ST 79B Connectionfor windshieldwasher andwarninghornunit
ST 79D Connectionfor brakepedal switch(ABS)
ST 80 Connectionfor mechanicgearbox
ST 81A Connectionfor front lights
ST 82 Connectionfor componentsonthe engine
ST 83 Connectionfor componentsonengine
ST 85L Connectionfor left hand sideplate light
ST 85R Connectionfor right hand sideplate light
ST 86 Connectionfor T.G.C. / I.G.C.
ST 88 Connectionfor trailer connectors
ST 91 Connectionfor PTO1(DMI)
ST 92 Connectionfor PTO2(DMI)
ST 93 Connectionfor PTO3(DMI)
ST 99 Connectionfor rear axleECAS
ST Connectionfor ECAS
STY/1 Connectionfor switchon clutch
Aquila Trucks Centres
107169
Figure28
KEY SIDECONNECTORVIEW
1 2 3 1 2 3
Figure29
KEY SIDECONNECTORVIEW
107538
ELECTRIC/ELECTRONIC SYSTEM 31 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Junction connector ST01(black) - turn on key
Pin Function
Cablecolour
code
1 Positive+30for ignitionkey 7777
2 Terminal 15 ignitionkey 8887
3 Terminal 50 ignitionkey 8888
ST02(green) - connection for steering column
Pin Function
Cablecolour
code
1 CAN L line(ICB) Green
2 CAN H line(ICB) White
3 Ground 0000
4 Negativefor warninghorn 1116
5 Positive+15fromignitionkey(15) 8887
6 Positivefor steeringcolumn switchunit symbols lighting 4442
7 Positive(+30) 7906
8 Positivefromignitionkey (50) 8888
9 Speedlimiter signal 9968
10 Ground 0000
11 - -
12 - -
Aquila Trucks Centres
Figure30
101525
KEY SIDECONNECTORVIEW
32 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST03junction connector - speed limiter signal / Cruise Control Set
Pin Function
Cablecolour
code
1 Speedlimiter signal 9968
2 - -
Aquila Trucks Centres
107545
Figure31
KEY SIDECONNECTORVIEW
107538
Figure32
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 33 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST05junction connector (green) - Eurotronic II
Pin Function
Cablecolour
code
1 CAN VDBLine(L) Green
2 CAN VDBLine(H) White
3 CAN VDBLine(L) Green
4 CAN VDBLine(H) White
5 Klineautomaticgearbox 2297
6 Automaticgearboxsystempower supply (Positive+15) 8102
7 Positivesymbols lighting 4442
8 Negativesignal forwardgear withautomaticgearbox 0127
9 VCMcontrol unit pin- X3/24 0125
10 Negativesignal fromneutral positionof theautomaticgearbox 0147
11 Negativesignal reversegear withautomaticgearbox 0128
12 VCMcontrol unit pin- X3/41 0126
13 Automaticgearboxsystempower supply (Positive+30) 7101
14 Ground 0000
15 Speedlimiter signal 9968
ST06A junction connector (yellow) - roof panel wings devices on the driver side
Pin Function
Cablecolour
code
1 Positiveleft loudspeaker (preamplifier) 1188
2 Negativeleft loudspeaker (preamplifier) 1186
3 Slidingroof closingcontrol power supply 7011
4 Slidingroof openingcontrol power supply 7010
5 Positivefor warninghorn solenoidvalve 1133
6 CAN line(IDB) H White
7 CAN line(IDB) L Green
8 Positivesymbols lighting 4442
9 Positive+15 8871
10 - -
11 - -
12 - -
Aquila Trucks Centres
107545
Figure33
KEY SIDECONNECTORVIEW
Figure34
KEY SIDECONNECTORVIEW
107538
34 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST06B junction connector (yellow) - tachograph
Pin Function
Cablecolour
code
1 Isolatednegativetachographtransmitter 0058
2 Speedsignal tachographtransmitter 5517
3 Inverted signal tachographtransmitter 5516
4 Tachographtransmitter power supply 5514
5 Speedpulsefor EDC 5155
6 CAN VDBLine(H) White
7 CAN VDBLine(L) Green
8 - -
9 Ground 0000
10 Tachographpower supply(Positive+15) 8871
11 Positivesymbols lighting 4442
12 Tachographpower supply (batterypositive+Batt) after fuse70058 7768
13 Kline 2997
14 Tachographsignal distance - travelledfor Cluster 5518
15 - -
ST06C junction connector (yellow) - Toll Collect
Pin Function
Cablecolour
code
1 Positive+30 7772
2 Positivesymbols lighting 4442
3 Positive+15 8871
4 Speedsignal (tachograph) 5541
5 Ground 0000
6 Positivesymbols lighting 4444
7 - 2222
8 CAN line Yellow
9 CAN line Red
10 - 6666
11 Positive+30 7777
12 Ground 0000
Aquila Trucks Centres
107545
Figure35
KEY SIDECONNECTORVIEW
107531
Figure36
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 35 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST07A junction connector (yellow) - roof panel wings devices on the passenger side
Pin Function
Cablecolour
code
1 Positivefor front end-outlinemarker lamps 3339
2 Positivefor voltagereducer 7772
3 Loudspeaker signal (preamplifier) 1184
4 Loudspeaker signal (preamplifier) 1183
5 Positivefor readinglights(12V) 7712
6 Positive12V 7712
7 Positivefor overheadlight (whitelight) 4423
8 Positivestep lighting 4445
9 Positivefor overhead light (bluelights) 4410
10 Positivefor overheadlight (redlights) 4422
11 Negativefor sunshadecurtain 0974
12 Sunshadecurtainclosingsignal 8065
13 Positivefor sunshadecurtainmotor 8063
14 Positivefor sunshadecurtainmotor 8064
15 - -
ST07B junction connector (yellow) - navigation and it tools
Pin Function
Cablecolour
code
1 Positive+30after TGC 7772
2 Positive+15 8871
3 Speedsignal for navigator 5541
4 - -
5 CAN L line(FMB) Green
6 CAN H line(FMB) White
7 Positivefor instrumentslighting 4442
8 Reversegear signal 2268
9 - -
Aquila Trucks Centres
Figure37
KEY SIDECONNECTORVIEW
101529
105228
Figure38
KEY SIDECONNECTORVIEW
36 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST07C junction connector (black) - heatable windshield
Pin Function
Cablecolour
code
1 Power supplyto heatable windshield 8020
2 Power supplyto heatable windshield 8020
ST07D junction connector- rotating headlights
Pin Function
Cablecolour
code
1 Positivefor left hand siderotatingheadlight 1108
2 Ground for rotatingheadlight 0000
3 Positivefor right hand siderotatingheadlight 1115
Aquila Trucks Centres
107538
Figure39
KEY SIDECONNECTORVIEW
107188
Figure40
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 37 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST08A junction connector (blue) - DDM control unit
Pin Function
Cablecolour
code
1 Positive(+30) for control unit power supply 7991
2 Ground 0000
3 Signal for loudspeaker (roof panel) 1188
4 Signal for loudspeaker (roof panel) 1186
5 Klinefor diagnosis 2991
6 CAN H line(BCB) White
7 CAN L line(BCB) Green
8 Centralisedlockingcontrol signal - opening 0064
9 Centralisedlockingcontrol signal - closing 0065
10 Signal (+) external temperaturesensor 7573
11 Driver sideelectrical lockbolt 0003
12 External temperaturesensor ground 0550
Jointing connector ST08B (blue) - driver side door
Pin Function
Cablecolour
code
1 Connection2 betweensidewindowregulator switches 8862
2 Connection1 betweensidewindowregulator switches 8002
3 Mirror heatingsupply 8830
4 Positive+30(presetting) 7990
5 - -
6 - -
Aquila Trucks Centres
107538
Figure41
KEY SIDECONNECTORVIEW
Figure42
KEY SIDECONNECTORVIEW
101529
38 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST09A junction connector (blue) - PDM control unit
Pin Function
Cablecolour
code
1 Positive(+30) control unit power supply 7990
2 Ground 0000
3 Positiveright handsideloudspeaker 1184
4 Negativeright handsideloudspeaker 1183
5 Klinefor diagnosis 2290
6 CAN H line(BCB) White
7 CAN L line(BCB) Green
8 Centralisedlockingcontrol signal - opening 0064
9 Centralisedlockingcontrol signal - closing 0065
10 - -
11 Passenger sideelectrical lock bolt 0003
12 Free -
Jointing connector ST09B (white) - passenger side door
Pin Function
Cablecolour
code
1 Connection2 betweensidewindowregulator switches 8862
2 Connection1 betweensidewindowregulator switches 8002
Aquila Trucks Centres
Figure43
KEY SIDECONNECTORVIEW
Figure44
KEY SIDECONNECTORVIEW
107531
101525
ELECTRIC/ELECTRONIC SYSTEM 39 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST10junction connector (green) - Instruments lighting
Pin Function
Cablecolour
code
1 Positivefor instrumentslighting 4442
2 Positivefor instrumentslighting 4442
3 Positivefor commutator for thirdaxlelifting. 4442
4 Positivefor switchwith incorporated warninglight for heatablewindshieldenabling 4442
5 Positivefor switchwith incorporated warninglight for heatedrear viewmirrors 4442
6 Positivefor switchwith incorporated warninglight for A.S.R. disabling 4442
7 Positivefor instrumentslighting 4442
8 Positivefor instrumentslighting 4442
9 Positivefor instrumentslighting 4442
Connector of junction ST11 - trailer retarder brake
Pin Function
Cablecolour
code
1 Ground fromtrailer brakehand wheel switch(brakelight) 0927
2 Ground for trailer brakehand wheel switch(brakelight) 0000
Aquila Trucks Centres
Figure45
KEY SIDECONNECTORVIEW
Figure46
107188
KEY SIDECONNECTORVIEW
101531
40 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST12junction connector (green) -tractor and trailer ABS/EBS
Pin Function
Cablecolour
code
1 - -
2 - -
3 - -
4 - -
5 Positivepressedpedal signal (ABS) 8153
6 Positivefor stoplights (ABS) 8158
ST13junction connector (black) - auxilliaryair heater
Pin Function
Cablecolour
code
1 CAN BCBLine(L) Green
2 CAN BCBLine(H) White
Aquila Trucks Centres
ELECTRIC/ELECTRONIC SYSTEM 41 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST14junction connector - ECAS bodybuilders(cab)
Pin Function
Cablecolour
code
1 Power supplyto liftableaxleloweringor liftingswitch 8445
ST14A junction connector (blue) - for bodybuilders(cab)
Pin Function
Cablecolour
code
1 Enginestart-up signal input 8892
2 Engineturningoff signal input 0151
3 Stop lightssignal for bodybuilders 1165
4 Vehiclenot in operationsignal output 5515
5 Parkingbrakeengaged signal output 6656
6 - -
7 Speedsignal fromtachograph 5155
8 Enginecondition(output signal) 0 Venginenot inoperation/ 24 Vengineinoperation 7778
9 Gearboxinneutral position signal 8050
10 Reversegear signal 2268
11 Positive+15 8871
12 Provisionfor CruiseControl SET + 8156
13 Provisionfor CruiseControl SET - 8157
14 Provisionfor CruiseControl OFF 8154
15 Provisionfor CruiseControl RESUME 8155
16 ProvisionCruiseControl (internal /external choice) 0158
17 Ground 0000
18 Provisionfor P.T.O. 1control signal 0131
19 Provisionfor P.T.O. 2control signal 0132
20 Provisionfor P.T.O. 3control signal 0123
21 Positive+30 7772
Figure47
Figure48
KEY SIDECONNECTORVIEW
101523
KEY SIDECONNECTORVIEW
107554
Aquila Trucks Centres
Figure49
KEY SIDECONNECTORVIEW
107531
KEY SIDECONNECTORVIEW
Figure50
107538
42 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST14B junction connector (blue) - for bodybuilders(cab)
Pin Function
Cablecolour
code
1 Signal for thesecond speedlimiter 0172
2 - -
3 Clutchstatussignal 9963
4 Programmablespeedthresholdindicator signal (PTS) 5542
5 Hazardlight signal 1113
6 - -
7 - -
8 Enginerpmsignal 5584
9 External light signal 3333
ST14C junction connector (grey) - for set up devices(Allison)
Pin Function
Cablecolour
code
1 Neutral signal for PTO 145
2 Steppingswitchsignal 123
3 - -
4 PTO signal active 143
5 PTO signal active 130
6 - -
7 - -
8 Automaticneutral signal 117
9 Automaticneutral signal 101
10 Digital earth 103
11 Zoneindicator signal 113
12 - -
Aquila Trucks Centres
107538
Figure51
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 43 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST15- ST19junction connector
ST15(yellow) - Connection for couplings in the high roof
Pin Function
Cablecolour
code
1 Ground 0000
2 Positivefor slidingroofclosing 7011
3 Positivefor slidingroofopening 7010
4 Positivefor readinglight 4412
5 Positivefor overheadlights(whitelight) 4423
6 Positivefor overheadlights(red lights) 4422
7 - -
8 Left hand side loudspeaker 1186
9 Left hand side loudspeaker 1188
10 Right handsideloudspeaker 1183
11 Right handsideloudspeaker 1184
12 -- -
ST19(green) - connection for heating
Pin Function
Cablecolour
code
1 Kline 2295
2 Positivesymbols lighting 4442
3 withST 20 - 3 0506
4 withST 20 - 4 8087
5 Positivefor 1st speedauxiliaryheatingenabling(remotecontrol switch) 8884
6 Positivefor heater motor water recirculationenabling(remotecontrol switch) 7778
7 Lockedpositive 8871
8 - -
9 Ground 0000
10 Negativefor auxiliaryheater enabling 0501
11 Positivewith starter up engine 7786
12 - -
Aquila Trucks Centres
107552
Figure52
KEY SIDECONNECTORVIEW
44 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST20junction connector (green) - air conditioning system
Pin Function
Cablecolour
code
1 Kline 2296/2295
2 Positiveinstruments lighting 4442
3 withST 19 - 3 0506
4 withST 19 - 4 8087
5 Positivefor 1st speedheater enabling(remotecontrol switch) 8884
6 Remotecontrol switchsignal for compressor enabling(frompressureswitches) 9933
7 Remotecontrol switchsignal for compressor enabling(fromcontrol unit) 9933
8 Positivewith starter up engine 7778
9 Ground 0000
10 Positivecompressor control 9993
11 Positive+15 8871
12 Positiveafter TGC 7551
13 Positiveafter TGC 7551
14 - -
15 Negative(fromcontrol unit) for solenoidvalveradiator water recirculation 9552
16 Positivefor solenoidvalveradiator water recirculation 7550
17 - -
18 - -
Aquila Trucks Centres
101531
Figure53
KEY SIDECONNECTORVIEW
Figure54
KEY SIDECONNECTORVIEW
107169
1 2 3 1 2 3
ELECTRIC/ELECTRONIC SYSTEM 45 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST21junction connector (black) - solenoid valve for radiator water recirculation
Pin Function
Cablecolour
code
1 Positivefor solenoidvalveradiator water recirculation 7550
2 Negativefor solenoidvalve for radiator water recirculation 9552
ST23junction connector - immobilizer antenna
Pin Function
Cablecolour
code
1 Immobilizer antennasignal (VCMpin - X1/1) -
2 Immobilizer antennasignal (VCMpin - X1/3) -
3 - -
Aquila Trucks Centres
Figure55
KEY SIDECONNECTORVIEW
101531
Figure56
KEY SIDECONNECTORVIEW
101542
46 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST24junction connector (black) - CAN line for air conditioning system
Pin Function
Cablecolour
code
1 CAN L line(BCB) Green
2 CAN H line(BCB) White
ST25junction connector (black) - Intarder
Pin Function
Cablecolour
code
1 CAN VDBLine(L) Green
2 CAN VDBLine(H) White
3 Speedsignal for Intarder 5541
4 EOL dataentrylinefor Intarder control unit 3393
5 Kline 2293
Aquila Trucks Centres
101536
Figure57
KEY SIDECONNECTORVIEW
107183
Figure58
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 47 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST26A - ST26B junction connector
ST26A (black) - Ecas (CAN)
Pin Function
Cablecolour
code
1 CAN VDBLine(L) Green
2 CAN VDBLine(H) White
3 Kline 2294
ST26B (black) - ABS/EBS (CAN)
Pin Function
Cablecolour
code
1 CAN VDBLine(L) Green
2 CAN VDBLine(H) White
3 Kline 2299
ST28junction connector- rotating headlights
Pin Function
Cablecolour
code
1 Ground for left handsiderotatingheadlight 0000
2 Positivefor left hand siderotatingheadlight 1108
3 Free -
4 Positivefor right hand siderotatingheadlight 1115
5 Ground for right handsiderotatingheadlight 0000
Aquila Trucks Centres
107188
Figure59
KEY SIDECONNECTORVIEW
48 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST30- ST31junction connector
ST30(blue) - provision for ADR(tachograph)
Pin Function
Cablecolour
code
1 Positive(+Batt) tachograph 7768
2 - -
3 Positive(+Batt) fromIBC3 7768
4 Positive(+Batt) Cluster / Central locking 7768
5 Batterydirect positive(+Batt) after fuse70058(20A) 7972
6 Positive(+Batt) 7972
ST31(green) - connection for ECAS(remote control)
Pin Function
Cablecolour
code
1 Power supplyto equalizationadjustment system(+15) 8810
2 Ground 0000
3 Clock lineon ECASsuspensions control keyboard 6402
4 Clock lineon ECASsuspensions control keyboard 6403
5 - -
6 - -
Aquila Trucks Centres
107538
Figure60
KEY SIDECONNECTORVIEW
107188
Figure61
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 49 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST31A junction connector (green) - Cab rear
Pin Function
Cablecolour
code
1 Positivefor tool compartment lightingswitch 4448
2 Positivefor readingover head light 4412
3 Ground 0000
4 Ground for refrigerator 0000
5 Positivefor refrigerator (24 V) 7735
6 Positivepower supplyfor BedModule 7906
7 Ground 0000
8 CAN (H) LineBCB White
9 CAN Line(L) BCB Green
10 Positivefor telephoneplug(12V) 7712
11 Telephoneplugground 0000
12 Positivefor lamp 7772
ST31B junction connector (blue) - auxiliary air heating
Pin Function
Cablecolour
code
1 Auxiliaryair heater warninglight 6655
2 Positive+30 7708
3 Ground 0000
4 Power supplyto auxiliaryfuel pump for air heater 7783
5 Auxiliaryheater Kline 2295
6 Power supplyto ambient temperaturesensor for auxiliarysensor 7512
Aquila Trucks Centres
101525
Figure62
KEY SIDECONNECTORVIEW
101529
Figure63
KEY SIDECONNECTORVIEW
50 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST31C junction connector (white) - water heating temperature sensor
Pin Function
Cablecolour
code
1 Positivefor internal temperature detectionprobe 7520
2 Negativefor internal temperature detectionprobe 0000
ST31L - ST31R junction connector
ST31L - connection for pneumatic heated seat
Pin Function
Cablecolour
code
1 Ground 0000
2 Positivefor driver sideheatedpneumaticseat 8031
ST31R - connection for pneumatic heated seat
Pin Function
Cablecolour
code
1 Ground 0000
2 Positivefor passenger sideheated pneumatic seat 8031
Aquila Trucks Centres
107531
Figure64
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 51 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST34(blue) junction connector- provision for ACC / simple gearbox control H
Pin Function
Cablecolour
code
1 VCMcontrol unit pinX3/7 0179
2
Powersupplyto warninglight for ACC (AdaptiveCruiseControl) distancerulesignalling/ Power
supplyto splitter control solenoidvalve (gear reducer) mechanical gearbox
6179/9973
3 Positive5 Vfor distancecontrol with ACC (AdaptiveCruiseControl) great distance 8179
4 VCMcontrol unit pinX2/9 0139
5 Returnfromdistanceselector with ACC (AdaptiveCruiseControl) 6178
6
Power supply to distance alarmbuzzer withACC (AdaptiveCruiseControl) / Power supplyto
splitter control solenoid valve (mechanical gearbox)
1166/9974
7 Positive+15 8871
8 Positivefor instrumentslighting 4442
9 - -
Aquila Trucks Centres
107545
Figure65
KEY SIDECONNECTORVIEW
107188
Figure66
KEY SIDECONNECTORVIEW
52 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST35/1junction connector (yellow) - manual control air conditioning system
Pin Function
Cablecolour
code
1 - -
2 - -
3 - -
4 Positive+30 7550
5 - -
6 - -
7 - -
8 Ambient thermostat signal 9993
9 Negativeremotecontrol switchesair conditioningenablingcommand 0555
10 Positivesymbols lighting 4442
11 Positivefromremote control switchinternal heatingenablingconsent 8004
12 Positiveremotecontrol switchair conditioner enablingcommand 8097
13 Contact of theremotecontrol switch(87) for auxiliaryheater 1st speedenabling 8884
14 Positivefor Topflapcommandingremoteswitchcontrol 8801
15 - -
ST35/2junction connector (yellow) - manual control air conditioning system
Pin Function
Cablecolour
code
1 Positivefor windshieldelectricdefroster commandunit 8884
2 - -
3 Kline 2296
4 Positive+30fromBodyComputer 7786
5 - -
6 - -
Aquila Trucks Centres
Figure67
Figure68
KEY SIDECONNECTORVIEW
107538
107188
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 53 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST36junction connector (grey) - T.G.C. / I.G.C.
Pin Function
Cablecolour
code
1 Alternator power supplyterminal 15 8876
2 Alternator power supplyterminal 15 8876
3 Signal for TGC closing 8035
4 Signal for TGC closing 8035
5 Batterypositive(+Batt) 7972
6 Batterypositive(+Batt) for tachographand IC 7768
7 Batterypositive(+Batt) for B.C. / B.M. / diagnosis/refrigerator connector 7972
8 CAN (H) line(BCB)
9 CAN (L) line(BCB)
10 Telephonesocket positive(12V) 7712
11 Ground for telephone 0000
12 Positivefor bulb 7772
SST37C junction connector (yellow) - Toll Collect
Pin Function
Cablecolour
code
1 Positive+30after TGC 7772
2 Positivesymbols lighting 4442
3 Positive+15 8871
4 Speedsignal (tachograph) 5541
5 Ground 0000
6 - -
Aquila Trucks Centres
Figure69
107188
KEY SIDECONNECTORVIEW
54 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST39junction connector (yellow) - differential lock
Pin Function
Cablecolour
code
1 Positivesymbols lighting 4442
2 Signal fromfront transversedifferential lockcontrol switch 0902
3 Signal fromlongitudinal differential lock control switch 0903
4 Signal fromrear transverse differential lockcontrol switch 0904
5 Ground 0000
6 - -
Aquila Trucks Centres
Figure70
KEY SIDECONNECTORVIEW
101529
107531
KEY SIDECONNECTORVIEW
Figure71
ELECTRIC/ELECTRONIC SYSTEM 55 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST40junction connector - navigation and it tools
Pin Function
Cablecolour
code
1 Positive+30after TGC 7772
2 Positive+15 8871
3 Speedsignal for navigator 5541
4 Positive12V 7712
5 CAN L line(ICB) Green
6 CAN H line(ICB) Bianco
7 Positivefor instrumentslighting 4442
8 Reversegear signal 2268
9 Ground 0000
Jointing connector ST42 - DDM/PDM supplies
Pin Function
Cablecolour
code
1 Positive+30 7777
2 Positive+15 8887
Aquila Trucks Centres
Figure72
KEY SIDECONNECTORVIEW
Figure73
KEY SIDECONNECTORVIEW
113250
105243
56 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST44junction connector - centralized locking with remote control
Pin Function
Cablecolour
code
1 Clinker control 1113
2 - -
3 Batterypositive(+Batt) 7772
4 Ground 0000
5 Control for centralizedlockingto BodyComputer (door opening) 0064
6 Control for centralizedlockingto BodyComputer (door closing) 0065
7 Power supply+15 8871
8 - -
ST45junction connector- 24V connection for radio
Pin Function
Cablecolour
code
1 Positive+30for preamplifier 7772
2 Positive+15for radio receiver 8871
3 Ground 0000
4 Positivesymbols lighting 4442
5 CAN lineL (IDB) Green
6 CAN lineH (IDB) White
7 Positive+30for radio receiver 7770
8 - -
Aquila Trucks Centres
Figure74
KEY SIDECONNECTORVIEW
Figure75
KEY SIDECONNECTORVIEW
101523
107545
ELECTRIC/ELECTRONIC SYSTEM 57 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST48junction connector (yellow) - EM control unit (PTO)
Pin Function
Cablecolour
code
1 CAN L line(ICB) Green
2 CAN H line(ICB) White
3 Kline Green
4 Positive+30after TGC 7772
5 Positive+30 7166
6 Positive+15 8166
7 Ground 0000
8 Wiringfor CAN L line (SB) Green
9 Wiringfor CAN H line (SB) White
10 P.T.O. control signal 1 0131
11 P.T.O. control signal 1 0132
12 P.T.O. control signal 1 0123
13 Positive+30for bodybuildersconnector (72072C) 7795
14 Positive+30for bodybuildersconnector (72072D) 7796
15 - -
Jointing connector ST 49 - Allison transmission setup
Pin Function
Cablecolour
code
1 Starter motor remotecontrol switch ground 0008
Aquila Trucks Centres
101542
Figure76
KEY SIDECONNECTORVIEW
105251
Figure77
KEY SIDECONNECTORVIEW
58 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST54junction connector- provision for ACC
Pin Function
Cablecolour
code
1 CAN lineL (VDB) Green
2 CAN lineH (VDB) White
3 CAN lineL (VDB) Green
4 CAN lineH (VDB) White
5 Positive+15 8176
ST55A junction connector- SCR system(urea)
Pin Function
Cablecolour
code
1 CAN lineL (ECB) Green
2 CAN lineH (ECB) White
3 CAN lineL (ECB) Green
4 CAN lineH (ECB) White
5 Kline 2257
6 Positive+15 8540
7 Power supplyto combustionair relativehumidityand temperaturesensor 8173
8 Signal for combustionair relative humiditysensor 5173
9 Combustionair relativehumidityand temperaturesensor ground 0173
10 Combustionair temperaturesensor signal 5174
11 Power supplyto enginebrakesolenoid valve 9966
12 Enginebrakesolenoid valveground 0043
Aquila Trucks Centres
Figure78
101523
KEY SIDECONNECTORVIEW
Figure79
KEY SIDECONNECTORVIEW
101531
ELECTRIC/ELECTRONIC SYSTEM 59 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST55B - ST56junction connector
ST55B - SCR system power supply(urea)
Pin Function
Cablecolour
code
1 Batterypositive(+Batt) SCR System 7540
ST56(black) - Connection for ADR cut generator
Pin Function
Cablecolour
code
1 Alternator power supplyterminal 15 8876
ST59junction connector - 2
nd
front axle ECAS fault / longitudinal lock (8x8)
Pin Function
Cablecolour
code
1 ECASfault signal / front longitudinal differential locksengaged signal (8x8) 6401 / 6643
2 ECASfault signal switchearth 0000
Aquila Trucks Centres
101525
Figure80
KEY SIDECONNECTORVIEW
101542
Figure81
KEY SIDECONNECTORVIEW
60 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST63junction connector- auxiliary water heater CAN
Pin Function
Cablecolour
code
1 CAN Line(L) BCB Green
2 CAN (H) LineBCB White
ST64junction connector (black) - 15-poles current outlet free pins
Pin Function
Cablecolour
code
1 Power supplyto current outlet 8021
2 Power supplyto current outlet 7021
3 Transversedifferential blockingsignal 6621
4 Power supplyto positivetrailer interlocking+15 8075
5 Power supplyto positivetrailer interlocking+15 8075
Aquila Trucks Centres
101531
Figure82
KEY SIDECONNECTORVIEW
101536
Figure83
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 61 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST65- ST67junction connector
ST65- CAN for trailer (PTO with EM)
Pin Function
Cablecolour
code
1 CAN SBline(L) (connectionfor trailer - PTO with EM)
2 CAN SBline(H) (connectionfor trailer - PTO withEM)
ST67- UREA dosing module solenoid
Pin Function
Cablecolour
code
1 Power supplyto dosingmodulesolenoid valvewithSCR 7541
2 Ureaelectric dosingunit (-) control 9541
ST68junction connector- UREA temperature sensor
Pin Function
Cablecolour
code
1 Signal cableto ureatanklevel sensor withSCR 6543
2 UreatankwithCSR level andtemperaturesensor ground 0543
3 Signal cableto ureatanktemperaturesensor withSCR 6542
Aquila Trucks Centres
Figure84
KEY SIDECONNECTORVIEW
105334
101531
Figure85
KEY SIDECONNECTORVIEW
62 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST69junction connector- Intarder
Pin Function
Cablecolour
code
1 Solenoidvalvefor retarder oil accumulator 0311
2 Solenoidvalvefor retarder oil accumulator 9311
3 Water temperaturetransmitter for retarder 5309
4 Water temperaturetransmitter for retarder 0309
5 Solenoidvalvefor retarder enabling 0310
6 Solenoidvalvefor retarder enabling 9310
ST70junction connector (black) - ASR solenoid valve
Pin Function
Cablecolour
code
1 ASRsolenoid valve(-) control 0260
2 ASRsolenoid valvepower supply 9260
Aquila Trucks Centres
Figure86
KEY SIDECONNECTORVIEW
101542
ELECTRIC/ELECTRONIC SYSTEM 63 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST72junction connector (black) - rear block wear / transverse differential lock
Pin Function
Cablecolour
code
1 To thedeviator for signallingof transversedifferential lockof Rockwell rear axles for the thirdaxle 0041
2 To thedeviator for signallingof transversedifferential lockof Rockwell rear axles for the thirdaxle 0000
3 To thedeviator for signallingof transversedifferential lockof Rockwell rear axles for the thirdaxle 0040
4 To thesensor for circuit signallingof rear wheel shoeswear 6667
5 To thesensor for circuit signallingof rear wheel shoeswear 6664
Aquila Trucks Centres
Figure87
101531
KEY SIDECONNECTORVIEW
64 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Junction connector ST73/1 - ST73/2- ST73/3 - ST73/4
ST73/1(black) - 1
st
front axle block wear (right)
Pin Function
Cablecolour
code
1 To thesensor for circuit signallingof front wheel shoeswear 6664
2 To thesensor for circuit signallingof front wheel shoeswear 6664
ST73/2(black) - 1
st
front axle block wear (left)
Pin Function
Cablecolour
code
1 To thesensor for circuit signallingof front wheel shoeswear 6664
2 To thesensor for circuit signallingof front wheel shoeswear 0000
ST73/3(black) - 2
nd
front axle block wear (right)
Pin Function
Cablecolour
code
1 To thesensor for circuit signallingof front wheel shoeswear 6664
2 To thesensor for circuit signallingof front wheel shoeswear 6664
ST73/4(black) - 2
nd
front axle block wear (left)
Pin Function
Cablecolour
code
1 To thesensor for circuit signallingof front wheel shoeswear 6664
2 To thesensor for circuit signallingof front wheel shoeswear 0000
Aquila Trucks Centres
101531
Figure88
KEY SIDECONNECTORVIEW
101536
Figure89
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 65 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST75A junction connector - 1st front axle differential lock
Pin Function
Cablecolour
code
1 1
st
front axledifferential locksignal 6659
2 Ground 0000
ST75B junction connector - 2nd front axle differential lock
Pin Function
Cablecolour
code
1 2
nd
front axledifferential locksignal 6659
2 Ground 0000
3 Front longitudinal differential lock engagedsignal (8x8) 6643
Aquila Trucks Centres
101538
Figure90
KEY SIDECONNECTORVIEW
66 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST77- ST78JUNCTION CONNECTOR BODYBUILDERS (CHASSIS - TRUCK)
ST77(black) - Right hand side SML indicator light (Side Marker Lamp)
Pin Function
Cablecolour
code
1 Signal for sidelamps 3330
2 Ground for sidelamps 0000
3 Signal for sidelamps 3330
4 Ground for sidelamps 0000
ST78(black) - Left hand side SML indicator lamp(Side Marker Lamp)
Pin Function
Cablecolour
code
1 Signal for sidelamps 3339
2 Ground for sidelamps 0000
3 Signal for sidelamps 3339
4 Ground for sidelamps 0000
Aquila Trucks Centres
107545
Figure91
KEY SIDECONNECTORVIEW
Figure92
KEY SIDECONNECTORVIEW
107531
ELECTRIC/ELECTRONIC SYSTEM 67 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST79A junction connector (yellow) - external cab front
Pin Function
Cablecolour
code
1 Ground 0000
2 Positiveto refrigeratingfluidpressuresignallingswitch (air conditioner) 9993
3 Positivefromrefrigeratingfluid pressuresignallingswitch (air conditioner) 9993
4 Positivefor solenoidvalveradiator water recirculation 7550
5 Signal fromswitchonclutchfor VCM (clutchcylinder 20%compressed) 0160
6 Gearboxsynchronousprotection solenoidcontrol earth (clutch cylinder 70%compressed) 9975
7 Positivefor windscreenunit (high speed) 8881
8 Positivefor windscreenunit (lowspeed) 8882
9 Positivefor windscreenunit 8880
10 Positivefor windscreenunit 8873
11 Radiator water recirculation solenoidvalve command 9552
12 Negativefromrefrigeratingfluid pressure signallingswitch(enginecooling) 0583
13 Negativefromrefrigeratingfluid pressure signallingswitch(enginecooling) 0582
14 - -
15 - -
Jointing connector ST79B (yellow) - windshield washer and warning hornunit
Pin Function
Cablecolour
code
1 Signal for warninghorn 1116
2 Electrical pumppower headlight wipers 8821
3 Signal fromtheBodyComputer for windshield washer liquid low level indicator control 5521
4 Windshield washer control signal 8886
5 - -
6 - -
7 - -
8 - -
9 - -
Aquila Trucks Centres
101545
Figure93
KEY SIDECONNECTORVIEW
68 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST79D junction connector (green) - brake pedal switch(ABS)
Pin Function
Cablecolour
code
1 Positive+30 7150
2 Positivefor stoplights 8158
3 Positivepressed pedal signal 8153
4 Positive+30 7150
5 - -
6 - -
Aquila Trucks Centres
105251
Figure94
KEY SIDECONNECTORVIEW
Figure95
KEY SIDECONNECTORVIEW
105334
ELECTRIC/ELECTRONIC SYSTEM 69 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST80junction connector (black) - mechanical gearbox
Pin Function
Cablecolour
code
1 Signal for reverselightslight up switch 2268
2 Ground for reverselightslightingupswitch 0000
3 Ground for anti-start systemwithgearsengaged switchand for reverselight light upswitch 0000
4 Ground for anti-start systemwithgearsengaged switchand for reverselight light upswitch 8050
5 Signal for reduced gearsengaged signallingswitch 9992
6 Ground for reduced gearsengaged signallingswitch 0000
ST81A junction connector (black) - front lights
Pin Function
Cablecolour
code
1 Side / left front direction indicator power supply 1129
2 Right / left front sidelight power supply 3339
3 Left lowbeampower supply 2231
4 Left highbeampower supply 2219
5 Right / left foglamp power supply 2228
6 - -
7 Right side/ front directionindicator power supply 1123
8 - -
9 Right lowbeampower supply 2223
10 Right highbeampower supply 2221
11 Headlamp alignment corrector control 9936
12 Supplementaryhead lamppower supply 2229
Aquila Trucks Centres
105251
Figure96
KEY SIDECONNECTORVIEW
Figure97
KEY SIDECONNECTORVIEW
105334
70 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST82junction connector (black) - components on engine
Pin Function
Cablecolour
code
1 - -
2 - -
3 Signal for engineventilationtemperaturesensor 5166
4 - -
5 - -
6 - -
7 - -
8 - -
9 Signal for engineoil level thermometer transmitter 5505
10 Signal for engineoil level thermometer transmitter 5506
11 Ground for fuel filter clogged signallingswitch 0000
12 Signal for fuel filter cloggedsignallingswitch 5531
ST83junction connector (black) - components on engine
Pin Function
Cablecolour
code
1 Engineoil level transmitter signal 5506
2 Engineoil level transmitter signal 5505
3 Blocked fuel filter switchsignal 5531
4 Power drivelowoil level switch signal 5525
5 Positive+15for UDSpower unit 8540
6 - -
Aquila Trucks Centres
101531
Figure98
KEY SIDECONNECTORVIEW
KEY SIDECONNECTORVIEW
105334
Figure99
ELECTRIC/ELECTRONIC SYSTEM 71 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST86- ST88junction connector
ST86(black) - T.G.C. connection
Pin Function
Cablecolour
code
1 TGC Off relayexcitation 8845
2 TGC Onrelayexcitation 8835
ST86(black) - I.G.C. connection
Pin Function
Cablecolour
code
1 Provision 8045
2 TGC Onrelayexcitation 8035
ST88(black) - trailer connectors
Pin Function
Cablecolour
code
1 Trailer axlelift signal 6442
2 Trailer brakelowair pressure 6689
3 Positive+30for trailer socket 7790
4 Positive+15for trailer ABSsocket 8847
5 Trailer ABSfault signal 6671
6 Loadcompartment lightingpower supply 2224
Aquila Trucks Centres
101538
Figure100
KEY SIDECONNECTORVIEW
72 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST91- ST92- ST93junction connector
ST91(black) - PTO1 (EM)
Pin Function
Cablecolour
code
1 PTO 1power take-off returnsignal 6131
2 PTO 1solenoid valvepower supply 9131
3 Negativeconsent for power take-off PTO 1 0391
4 Ground 0000
ST92(black) - PTO2 (EM)
Pin Function
Cablecolour
code
1 PTO 2power take-off returnsignal 6132
2 PTO 2solenoid valvepower supply 9132
3 Negativeconsent for power take-off PTO 2 0392
4 Ground 0000
ST93(black) - PTO3 (EM)
Pin Function
Cablecolour
code
1 PTO 3power take-off returnsignal 6133
2 PTO 3solenoid valvepower supply 9133
3 Negativeconsent for power take-off PTO 3 0393
4 Ground 0000
Aquila Trucks Centres
101551
Figure101
KEY SIDECONNECTORVIEW
ELECTRIC/ELECTRONIC SYSTEM 73 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
ST99junction connector (black) - rear axle ECAS
Pin Function
Cablecolour
code
1 Level sensor ground 0400
2 Right rear axlelevel sensor signal 5421
3 Left rear axlelevel sensor signal 5422
4 Rear axlepositiveelectro pneumaticdistributor 9400
5 Rear axlegroundelectropneumatic distributor 9423
6 Ground for rear axle electro pneumatic distributor left valvecommand 9425
7 Ground for rear axle electro pneumatic distributor right valvecommand 9424
Aquila Trucks Centres
107178
Figure102
KEY SIDECONNECTORVIEW
Figure103
KEY SIDECONNECTORVIEW
107169
1 2 3 1 2 3
74 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
ST junction connector- ECAS remote control
Pin Function
Cablecolour
code
1 Positivefor remotecontrol power supply (pin 1) 7777
2 Negativefor remotecontrol (pin2) 0000
3 Communicationlinewithremotecontrol (pin3) 3333
4 Communicationlinewithremotecontrol (pin4) 8888
STY/1junction connector (black) - switch on clutch
Pin Function
Cablecolour
code
1 Ground 0000
2 Signal fromswitchonclutchfor VCM 0160
3 - -
Aquila Trucks Centres
Figure104
KEY SIDECONNECTORVIEW
113251
ELECTRIC/ELECTRONIC SYSTEM 75 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
15-pin current outlet for trailer electric connection (72010)
Pin Function
Cablecolour
code
1 Left hand sidetrailer directionindicators 1180
2 Right handsidetrailer directionindicators 1185
3 Trailer back foglight 2283
4 Ground 0000
5 Left trailer end-outlinemarker 3339
6 Right trailer end-outlinemarker 3330
7 Trailer stop lights 1179
8 Trailer reverselight 2226
9 Power supplyto trailer outlet after fusefor T.M.P. devices 7790
10 Transversedifferential blockingsignal 6621
11 Power supplyto positivetrailer interlockings+15 8075
12 Warninglight signallingtrailer axlelifted 6442
13 Ground 0000
14 Power supplyto current outlet 7021
15 Power supplyto current outlet 8021
Aquila Trucks Centres
Figure105
KEY SIDECONNECTORVIEW
113252
76 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
7-pin current outlet for trailer electric connection
72000- normal 7-pin current outlet for trailer electric connection
Pin Function
Cablecolour
code
1 Ground 0000
2 Left trailer end-outlinemarker 3339
3 Left hand sidetrailer directionindicators 1180
4 Trailer stop lights 1179
5 Right handsidetrailer directionindicators 1185
6 Trailer end-outlinemarker 3330
7 Free -
72001- auxiliary 7-pin current outlet for trailer electric connection
Pin Function
Cablecolour
code
1 Ground 0000
2 Trailer interlockingspower supplywithterminal +15 8075
3 Trailer reverselight 2226
4 Free -
5 Warninglight signallingtrailer axlelifted 6442
6 Power supplyto trailer outlet after fusefor T.M.P. devices 7790
7 Trailer back foglight 2283
72006- -pin current outlet for trailer ABS electric connection
Pin Function
Cablecolour
code
1 Positiveafter fusefor trailer ABS 7772
2 Power supplyafter fusefor ABS/ speedlimiter 8847
3 Ground 0000
4 Ground 0000
5 Trailer ABSfault warninglight 6671
6 C/| '' ||oo (S3) WS/BI
7 C/| '|' ||oo (S3) GN/VE
Aquila Trucks Centres
113302
Figure106
DIAGNOSISCONNECTOR(FRONT VIEW)
Pins27,28,29,30 might beprintedwithdifferent positionsfromthosereportedinthis picture.
1
7
13
19 25
2
8
14
20
26
3
9
15
21
4
10
16
22
5
11
17
23
6 12
18
24
30 27
28 29
19 25
20
26
21
22
17
23
18
24
(+)
(--) ( v)
ELECTRIC/ELECTRONIC SYSTEM 77 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
DIAGNOSIS CONNECTOR
Diagnosis connector - 72021
Pin System Function
Cablecolour
code
1 Free - -
2 EDC (ECM) K 2298
3 Free - -
4 ABS/ EBS+ECAS K 2299
5 Free - -
6 Intarder / EM K 2293
7 Free - -
8 BodyController / DDM/ PDM K 2295
9 Free - -
10 Heater / Air conditioner K 2296
11 Sov|co actoat|oo |o to '|/|' +15 8802
12 VCM K 2292
13 Free - -
14 Cluster / tachograph K 2994
15 Free - -
16 UREA (SCRsystem) K 2257
17 Free - -
18 EUROTRONIC / ALLISON K 2297
19 Free - -
20 Programmingretarder EOL - 3393
21 CAN H (VDB) H Ws/Bi
22 CAN L (VDB) L Gn/Ve
23 Free - -
24 Free - -
25 Startupsignal - 8050
26 Signal ground - 0050
27 Free - -
28 Speedsignal (B7) v 5542
29 Signal ground 31 0050
30 Positive +30 7772
Aquila Trucks Centres
113328
Figure107
KEY SIDECONNECTORVIEW
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
78 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
OBD DIAGNOSIS CONNECTOR(BLUE)
Pin Function
Cablecolour
code
1 - -
2 - -
3 - -
4 Ground 0000
5 Signal ground 0050
6 CAN lineH (ECB) White
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 CAN lineL (ECB) Green
15 - -
16 Batterydirect positive(+Batt) 7721
Aquila Trucks Centres
The newbayonet connectorsmakesignal continuitymuch morereliablethantheprevious system.
85750 73658
C E A D B
1 28 39
11 38 40 27 19
12 20
LEFT-HAND DRIVE
Connector A \||to (oo)
Connector B 3o.o (|C/S)
Connector C Yo||o. (SC|)
Connector D - Blue(EuroTronic/PTO/INTARDER)
Connector E Cooo (||C//||)
RIGHT-HAND DRIVING
Connector A \||to (||C//||)
Connector B 3o.o (|ooToo|c/|TC/||T/||||)
Connector C Yo||o. (SC|)
Connector D 3|oo (|C/S)
Connector E Cooo (oo)
C E A D B
1 28 39
11 38 40 27 19
12 20
85750 73658
Figure108
Figure109
ELECTRIC/ELECTRONICSYSTEM 79 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
BULKHEAD
Aquila Trucks Centres
80 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
Brown bulkhead B
Pin Description
Cablecolour
code
1 Groundof level andloadpressureon axlesensors 0400
2 Rear right axle level sensor signal 5421
3 Rear left axlelevel sensor (only truck) 5422
4 - -
5 CAN - L Line(SB) Green
6 CAN - H Line(SB) White
7 Positivefor rear axleelectro pneumaticdistributor 9400
8 Groundfor rear axleelectro pneumatic distributor loading/unloadingcommand 9423
9 Groundfor rear axleelectro pneumatic distributor left valvecommand (onlytruck) 9425
10 Groundfor rear axleelectro pneumatic right valvecommand 9424
11 Air pressureTransmitter signal (rear brakes) 5561
12 Power supplyfor air pressure transmitter for brakingsystem 5560
13 Groundfor air pressuretransmitter for brakingsystem 0560
14 Air pressuretransmitter signal (front brakes) 5562
15 Sensor signal of loadpressureon axles- right axle 5443
16 Sensor signal of loadpressureon axles- left axle(onlytruck) 5444
17 - -
18 - -
19 Signal for raised trailer indicator 6442
20 CAN - L Line(BCB) Green
21 CAN - H Line(BCB) White
22 Groundfromsignallingswitchgear boxin aneutral position 8050
23 Power supplyfor electronictachograph transmitter 5514
24 Invertedsignal fromelectronictachographtransmitter 5516
25 Speedsignal fromelectronictachographtransmitter 5517
26 Groundfor electronictachographtransmitter 0058
27 Positive+15for air block turbineVGT (Shut-Off)electro valve 8360
28 Positive+15for MET control unit 8871
29 Positive+15for resistanceof dryer brakingsystem 8840
30 Positivefor TGC closure (TGC On) 8035
31 Positivefor TGC aperture (TGC Off) 8045
32 Groundfromsignallingswitchtilted caisson 6607
33 - -
34 Positivefor headlampillumination loadingdeck 2224
35 Positivefor supplementarydepth projectors 2229
36 - -
37 Failuresignal trailer ABS/EBS 6671
38 Positive+15for power socket trailer ABS/EBS 8847
39 Positive+30for 15pin power socket electrical connection trailer 7790
40 Direct positive+Bat batteryfor Tachograph 7972
Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 81 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Yellow wall pass C
Pin Description
Cablecolour
code
1 GroundfromconnectedsignallingswitchPTO 1 6131
2 Safetysensor signal for max. brakingbridgewith front axle failurewith ABS 6245
3 Positive+15for safetysensor for max. brakingbridgewith front axlefailurewith ABS 8847
4 ABSspeedsensor front right wheel 5571
5 ABSspeedsensor front right wheel 5571
6 |os|t|vo '|V' so|ooo|o va|vo (oo|oaooo)coaoo oot ||t .|oo| 9920
7 Positivefor solenoidvalvecommand PTO 1 9131
8 |os|t|vo '/V' so|ooo|o va|vo (|oaooo) coaoo oot ||t .|oo| 9918
9 Groundfor centralisedlubrication control unit 0000
10 Positive+15for centralisedlubricationcontrol unit 8898
11 ABSspeedsensor rear right wheel 5573
12 ABSspeedsensor rear right wheel 5573
13 |os|t|vo '|V' (oo|oaooo) so|ooo|o va|vo coaoo oa ||t .|oo| 9930
14 Groundfromswitch connectionconsent PTO 1 0391
15 |os|t|vo '/V' (|oaooo) so|ooo|o va|vo coaoo oa ||t .|oo| 9928
16 GroundfromsignallingswitchPTO 2connected 6132
17 Positivefor solenoidvalvecommand PTO 2 9132
18 Groundfromswitch connectionconsent PTO 2 0392
19 GroundfromsignallingswitchPTO 3connected 6133
20 Groundfor shieldingof CAN outfittedlines 0999
21 CAN-L line(SB) for fitters Green
22 CAN-H (SB)linefor fitters White
23 Positivefor solenoidvalvecommand PTO 3 9123
24 Groundfor ASRsolenoidvalve 0260
25 PositiveASR solenoidvalvecommand 9260
26 Groundfromswitch connectionconsent PTO 3 0393
27 Positive+30for fitters (72072Dconnector) 7795
28 Groundfor e with+15 clampconnected(72072C/D connectors) 0975
29 |os|t|vo '/V' (|oaooo) so|ooo|o va|vo coaoo |ot oa .|oo| 9929
30 Positivefor solenoidvalvesynchronousprotection mechanical gear change 8871
31 |os|t|vo '|V' (|oaooo)so|ooo|o va|vo coaoo |ot oa .|oo| 9931
32 |os|t|vo '/V' (|oaooo) so|ooo|o va|vo coaoo |ot oot .|oo| 9919
33 Groundfor solenoid valve synchronous protectionmechanical gear change 9975
34 |os|t|vo '|V' (oo|oaooo) so|ooo|o va|vo coaoo oot |ot .|oo| 9921
35 ABSspeedsensor front left wheel 5570
36 ABSspeedsensor front left wheel 5570
37 ABSspeedsensor rear left wheel 5572
38 ABSspeedsensor rear left wheel 5572
39 - -
40 Groundfor ABSsolenoid valves 0000
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82 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Blue wall pass D
Pin Description
Cablecolour
code
1 Positive+15for Eurotronic2 / Mass fromconnected slowgearssignallingswitch(9gear
changes)
8101 / 0177
2 Groundfor Eurotronic 2 / Positive for connection of electro valvereducedgears (9gear
changes)
0000 / 9973
3 Positivefor gear changebeeper/ Positivefor electro valve connection normal gears (9 gear
changes)
6100 / 9974
4 Groundfor gear changebeeper 1101
5 - -
6 Positive+30for Eurotronic2 7101
7 KlineEurotronic 2 (18-pindiagnosisconnector) 2297
8 CAN - L Line(VDB) Green
9 CAN - H Line(VDB) White
10 CAN - L Line(VDB) Green
11 CAN - H Line(VDB) White
12 Speedsignal fromintegral traction tachographtransmitter (Retarder) 5103
13 Positivefor integral traction tachograph transmitter (Retarder) 8300
14 Groundfor water temperaturesensor for Retarder 0309
15 Signal water temperaturesensor for Retarder 5309
16 Positivefor oil accumulator electro valveRetarder 9311
17 Groundfor oil accumulator electro valveRetarder 0311
18 Positivefor electro valveconnection Retarder 9310
19 Positivefor electro valveconnection Retarder 0310
20 Positivefor Air heater supplementarypump /KLineKwater heater (10-pindiagnosis connec-
tor)
7783 / 2295
21 Positivefor control andsignallingunit supplementaryheater 7775
22 Command for supplementaryheater withpassagefor micro-switch with commandlever heat-
er tap
7506
23 Positivefromswitch for internal aerator 7711
24 Positive+30for supplementarywater heater 7708
25 Groundfor supplementaryfuel pump Air heater 0000
26 CAN - L line(BCB) Green
27 CAN - H line(BCB) White
28 CAN - L line(BCB) Green
29 CAN - H line(BCB) White
30 Positivefor electro valvewater re-circulationengine block 9506
31 Positivefor warninglight supplementaryconnected heater/connection consent electro valve
water re-circulationengine block
6605
32 Groundfor integral tractiontachographtransmitter (Retarder) 0000
33 Positive+15alternator (TGC withADR) 8876
34 Positive+15alternator (TGC withADR) 8876
35 Ground(TGC ADR) 0000
36 - -
37 Groundfromsafetycontrol unit switch - TGC signal (ADR) Off 0176
38 Groundfromsafetycontrol unit switch - TGC signal (ADR) On 0178
39 - -
40 - -
Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 83 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Green wall pass E
Pin Description
Cablecolour
code
1 CAN - L line(ECB) Green
2 CAN - H line(ECB) White
3 - -
4 - -
5 - -
6 - -
7 Positive+15alternator 8876
8 Groundfromrequest EDC systemdiagnosis switch (predisposition) 0163
9 Groundfromrequest EDC systemdiagnosis switch (predisposition) 5163
10 ACC Power supply 8176
11 Load signal fromalternator 7009
12 Positivefor front thermal mirror 8830
13 Positive+15for EDC (fromIBC3) 8015
14 Groundfor front thermal mirror 0000
15 - -
16 CAN L line(VDB) Green
17 CAN H line(VDB) White
18 CAN L line(VDB) Green
19 CAN H line(VDB) White
20 - -
21 - -
22 KlineEDC control unit (2-pin diagnosisconnector) 2298
23 Positive+30for startingengine connection (clamp50) 8888
24 Positivefor connectionelectro magnetic compressor joint (Valeo) 9993
25 Direct positivebattery(+Bat) for SCR control unit 7540
26 - -
27 KlineSCR control unit (16-pin diagnosis connector) 2257
28 - -
29 - -
30 Groundfromlow coolingwater level sensor warninglight) 5520
31 - -
32 Groundfromlow coolingwater level sensor 5527
33 Positivefor connectionventilator engine(baruffaldi) 5166
34 Positivefor electro magnetic joint connectionswitch (baruffaldi ventilator) 5187
35 Groundfor electro magneticjoint connectionswitch (baruffaldi ventilator) 0014
36 - -
37 Engine rpmsensor signal for bodybuilders(ST14B) 5587
38 - -
39 Positive+30for EDC 7151
40 Positive+30for EDC 7151
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CENTRAL INTERCONNECTING UNIT
Ref. Description
1 Fuseholder
2 BodyController (IBC3)
3 Mini switches
4 Micro remotecontrol switches
5 OBD
112588
Figure110
Aquila Trucks Centres
Figure111
112589
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
70001 70602 70605
ELECTRIC/ELECTRONICSYSTEM 85 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
FUSE
Fuseholder 70602
Ref. Function Delivery (A) Terminal
1 DDM/ Driver power windows 20/15 +30/+15
2 PDM/ Passenger power windows 20/15 +30/+15
3 EDC 30 +30
4 ABS 5 +15
5 - 15 +30
6 ABS 15 +30
Fuseholder 70605
Ref. Function Delivery (A) Terminal
1 Fridge/ tool collect / OBD / Datacommunication+navigation 10 +BAT
2 ECAS/EM 5 +15
3 ECAS 7.5 +30
4 Retarder / ABS 10 +30
5 Retarder 10 +15
6 Heated seats/central lubrication/door lockwithRF 7.5 +15
Fuseholder 70001
Ref. Function Delivery (A) Terminal
1 EUROTRONIC 2 10 +30
2 Air conditioner 15 +30
3 Air conditioner 5 +30
4 Additional heater 15 +30
5 Additional heater 5 +30
6 Courtesylights 5 +30
7 ACC/Heated windscreen/tool collect/Datacommunication+navigation 10 +15
8 MC-NET / Beacon lights/headlamp washer pump 10 +30
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Fuseholder 70401
Ref. Function Delivery (A) Terminal
1 Sun visors 7.5 +15
2 - - -
3 - - +30
4 12V internal lighting 5 -
Fuseholder 70402
Ref. Function Delivery (A) Terminal
1 Heated windscreen 25 +30
2 VGT solenoidvalve/servoshift 10 +15
3 Heated mirrors 15 +15
4 Heated windscreen 25 +30
Fuseholder 70403
Ref. Function Delivery (A) Terminal
1 EM 15 +30
2 EM 15 +30
3 ACC 5 +15
4 SRC (UREA) 20 +batt.
Figure112
112590
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
70401
70402
70403
Aquila Trucks Centres
Figure113
112591
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
ELECTRIC/ELECTRONIC SYSTEM 87 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Print 603.93.641
REMOTE SWITCHES
Ref. Description
Component
code
A Hornremotecontrol switch 25805
B Remote control switchfor water heater (opt.) 25337
C - -
D Remote control switchfor electrical bushopening 25352
E Remote control switchfor water heater (opt.) 25325
F - -
G Electrical manholelock remotecontrol switch 25351
H Remote control switchfor manual climatecontrol system(opt.) 25310
I Remote control switchfor manual climatecontrol system(opt.) 25874
K Remote control switchfor electro-magnetic engagement of baruffaldi fan 25737
L Remote control switchfor manual climatecontrol system 25332B
M Remote control switchfor manual climatecontrol system 25322
N Remotecontrol switchfor vehiclediagnosis (opt.) 25705
O Remote control switchfor manual climatecontrol system(opt.) 25332A
P Remote control switchfor manual climatecontrol system(opt.) 25327
R Remotecontrol switchfor headlamp washer consensus(opt.) 25740
S Remotecontrol switchfor mainelectric/mechanicswitch(opt.) 25203/25903
T Remote control switchfor mainelectric switch(opt.) 25202
U Enginestart upremote control switch 25200
V Remote control switchfor key15distribution 25213
W - -
X - -
Y - -
Z - -
Aquila Trucks Centres
Figure114
112598
88 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
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Additional remote control switches
PositionedbehindtheBODY COMPUTER.
Ref. Description
Component
code
GA Remotecontrol switchfor heatedwindscreencontrol 25306
GB - -
GC Remotecontrol switchfor heatedwindscreen 25818
GD - -
GE - -
GF - -
GG - -
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Revi - June2007
ELECTRIC/ELECTRONIC SYSTEM 89 TRAKKER EURO 4/5
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Print 603.93.641/A
FUSE ASSEMBLY BODY CONTROLLER(IBC3)
FUSES IBC3
Ref. Function Rating(A) Terminal
F1 - 10 +15/1
F2 - 20 +15
F3 VCM/ SWI 10 +30
F4 Tachograph/ BedModule/ Cluster / Centralisedclosure 5 +BAT
F5 - 20 +30
F6 - 20 +30
F7 - 20 +30
F8 - 20 +30
F9 ST14A bodybuildersconnector / 72072D (EM-framework) 10 +30
F10 Beeper 10 +30
F11 Tensionreducer / Radio 20 +30
F12 Air dryer resistance 10 +15
F13 Bodybuilders connector 72072C (EM- cabin) 10 +30
F14 30-pinjunction/ Cigarettelighter 10 +30
F15 Radio/ Acclimatiser 5 +15/1
F16 - 20 +15/1
112599
Figure115
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
Aquila Trucks Centres
A. Auxiliaryfuseholder
Figure116
A
113408
90 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
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Print 603.93.641
SUPPLEMENTARY FUSES (70000)
Theyarelocatedontheleftsideofthevehicle,nexttothebatteriesandtheTGC.Thefusecompartmentcanbeaccessedbylevering
onthetwospringsavailableoncover (A).
Aquila Trucks Centres
49731
1 2 3 4 5 6
Figure117
ELECTRIC/ELECTRONIC SYSTEM 91 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Ref. Function DeliveryA
1 MET 30
2 MET 30
3 Presetting 30
4 Presetting 30
5 Current tap- ABS/EBS 30
6 Presetting 30
Aquila Trucks Centres
Figure118
113329
92 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
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INSTRUMENT BOARD
Ref. Description
1 Revscounter
2 Coolant thermometer
3 Fuel level gauge
4 Speedometer
5 Headlamptrimcontrol
6 External light switch
7 Foglight actuationswitch
8 Auxiliaryheadlamp actuationswitch
9 Rear foglight actuation switch
10 Optical indicator cluster
11 Optical indicator cluster
12 Display
13 Optical indicator cluster
14 Free
15 ABSactuationswitch(if available)
16 Free
17 ASRactuation switch(if available)
18 Emergencylight actuationswitch
19 Speedlimiter cut-in switch
20 Parkingbrake
21 Free
22 Free
Aquila Trucks Centres
113410
Figure119
20
22
21
1
19
18
2 3 4 5 6 7 8 9 10 11
12
15
13
14
16
17
8b 20b
23
24
ELECTRIC/ELECTRONIC SYSTEM 93 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
CENTRAL DASHBOARD CONTROLS
Ref. Description
1 Switchfor enginebrakeengagement
2 Control for electrichatchpit (OPT)
3 Pneumatichorns
4 Power takeoff switch1 (OPT)
5 Heatedwindscreenactuation switch(OPT)
6 Sunshadecurtaincontrol (OPT)
7 Central roof lamp cabinlights
8 Multipower power takeoff control (OPT)
8b Loadingplatformlight actuationswitch
9 Roof sideroof lampscabinlightscontrol
10 Fuel heater (OPT)
11 Rearviewmirrorsheating(beforeit wasembeddedintothedoor)
12 Switchfor immediatelyconnectingsupplementarywater heater (OPT)
13 Engine/cabinpre-heatingselector (OPT)
14 Switchfor connectingsupplementaryair heater (OPT - for manual versiononly)
15 Power takeoff 2(OPT)
16 Supplementarywater heater thermostat (OPT)
17 Keyswitchfor ECO - POWER function
18 Heating/ventingor air conditioner controls(OPT)
19 12V current outlet
20 Front differential lockingswitch
20b Rotatinglampsswitch (OPT)
21 Rear differential lockingswitch
22 Longitudinal differential lockingswitch
23 Lighter
24 30-pindiagnosis outlet
Aquila Trucks Centres
Left hand side:
4. KEY y
KEY b
5. KEY +
KEY -
Right hand side:
1. MEBU KEY/OK
2. PAGE PUSH BUTTON
3. ESCAPE KEY
4
5
1
2
3
74202
Figure120
94 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
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CONTROLS ON THE STEERING WHEEL
Thesteeringwheel featuressomekeysthat enableselectingand controllingcertainfunctions.
Aquila Trucks Centres
2
1
3
4 4
79494
Figure121
ELECTRIC/ELECTRONIC SYSTEM 95 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
REARVIEW MIRRORS AND WINDOW REGULATOR CONTROL ADJUSTMENT
Ref. Description
1 Rearviewmirror orientation control
2 Mirror selector control
3 Driver windowregulator
4 Passenger windowregulator
Key2onASwasplacedontheleftandinitsplacetherewasthemirrorheatingkeythat onAT/ADisplacedoncentral dashboard
asseries.
Adjustment functionsfor rearviewmirrorsandwindowregulator control aremanagedbyDDMandFDMunits, andconsequently
theyarepresent asoptionals.
EXTERNAL REARVIEW MIRRORS HEATING
Bypressingtherelatedbutton,therearview mirrorsheatingisactivatedandtherelatediconisdisplayedonthedisplay.Todeactivate
suchfunction, pressthebuttonagain.Theiconwill not bedisplayedanymore. It ispossibletoselectthisfunctionalsowithmoving
vehicle. Heatinghasa maximum lengthof 30 minutes.
Aquila Trucks Centres
73985
73988
1 8
9 16
Figure122
96 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
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LEFT LIGHT CONTROL 54033
Ref. Description
1 Windshield wiper (top speed)
2 Windshield wiper (slowspeed)
3 Windshield wiper (intermittent)
4 Windshield wiper (onestroke)
5 -
6 Dippedlightson
7 Light flashes
8 Ground
9 Washer electrical pumpcontrol
10 -
11 -
12 -
13 -
14 -
15 Right direction indicator
16 Left directionindicator
Aquila Trucks Centres
108919
73988
Figure123
1 8
9 16
ELECTRIC/ELECTRONICSYSTEM 97 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
RIGHT LIGHT CONTROL 54030
Print603.93.641
Ref. Description
1 Intarder (Position 4)
2 Changegear (down)
3 Cruise Control (set/acceleration)
4 Cruise Control (Resume)
5 Intarder (Position 1)
6 Intarder (Position 3)
7 Intarder (Position 2)
8 -
9 Intarder (Position 5)
10 Intarder (Position 6)
11 Cruise Control (deceleration)
12 -
13 -
14 -
15 Changegear (up)
16 Ground(fromtheSWI)
Aquila Trucks Centres
108920
RIGHT MULTIFUNCTION LEVER
Themultifunctionlever locatedontheright sideofthesteeringcolumnenablesinsertionof theenginebrakefunctionandthe
intarder wheninstalled.
The former is selected bymovingthe lever to positions 1and2 and remainso evenwhenthesamelever isused to selected
theintarder functionat positions 3, 4, 5 and 6related to available brakingpower ratings.
Whentheenginebrakefunctionisselectedthecontrol leversignal istransmittedtothe(SteeringWheel Interface) S.W.I.center.
Whichactivatestheenginebrakeon warninglight onInstrument Cluster IC,andviaBodyComputerB.C. sendstherequest fro
engineraketo theEDC, EBS and automated EuroTroniccenter (when present).
Whentheoperator selectstheenginebrakemanually,selection isdisplayedintheCluster withablinkingwarninglight, which
goestosteadywhentheenginebrake isturnedon.Inthemanual mode, enginebrakeactionisalsoconditionedbyaccelerator
pedalrelease.Intheautomaticmode,theenginebrakeisactivatedbytheEDCcenteronreceiptofarequest fromtheEBScenter.
Inthis condition, the EDC center pilots the enginebrakeelectro valveand theVGT actuator to thefullyclosedposition.
Figure124
1
2
3
4
5
6
98 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Aquila Trucks Centres
Vehicles with Intarder mechanical gearshift
Position 0 = disenabled
Position 1 = 50%enginebrake
Position 2 = 100%enginebrake +20%Intarder
Position 3 = 100%enginebrake +40%Intarder
Position 4 = 100%enginebrake +60%Intarder
Position 5 = 100%enginebrake +80%Intarder
Position 6 = 100%enginebrake +100%Intarder
Vehicles with Intarder EuroTronictransmission
Position 0 = disenabled
Position 1 = 50%enginebrake
Position 2 = 100%enginebrake +25%Intarder
Position 3 = 100%enginebrake +50%Intarder
Position 4 = 100%enginebrake +75%Intarder
Position 5 = 100%enginebrake +100%Intarder
Position 6 = 100%enginebrake +100%Intarder *
(*) The intarder can be more effective with automatic downshifting
managedbythetransmissionelectroniccontrol centre.
Vehicles with mechanical gearshift or Eurotronic transmission in themanual mode without
Intarder
Position 0 = disenabled
Position 1 = 50%enginebrake
Position 2 = 100%enginebrake
Vehicles with Eurotronic transmission in the automatic mode without Intarder
Position 0 = disenabled
Position 1 = 100%enginebrake
Position 2 = 100%enginebrake+downshiftinginthe
automaticmode
Figure125
Figure126
Figure127
Figure128
108920
1
2
3
4
5
6
1
2
3
4
5
6
1
2
0
1
2
0
108920
108920
108920
ELECTRIC/ELECTRONICSYSTEM 99 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
ENGINE BRAKE CONTROL AND INTARDER
Aquila Trucks Centres
Figure129
108921
NOTE
100 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
Base- November 2006 Print 603.93.641
GEAR SELECTION FUNCTION
OnthenewrangeofEuro4vehiclesthegearselectorhasbeeneliminated.Itsfunctionsareperformedbythecontrol pushbutton
panel on thecentral panel of thedashboard, incombination with thedrive control systemlever.
1. Pushbutton D - AUTO/SEMI mode
2. Pushbutton N - neutral
3. Pushbutton R- Reversegear
4. Drivecontrol system- gear selection
Driving in manual mode(semi)
1) Parkingbrakeengaged.
2) Start theengine
3) Gearboxin neutral (position N).
+) 3|o| oss os|bottoo '|' (+). T|o aotoat|c ssto |s act|vatoo aoo t|o ca|co|atoo |c'-o oa |s ooaoo.T|o o|s|a
s|o.s t|o |c'-o oa toot|o .|t| '/|TC'.
5) Too o t|o aotoat|c ssto b a a|o oss|o bottoo '|'. T|o o|s| a assos o s|o.|o '/|TC' to 'S|||'.
6) Thepick-upgear canbecorrectedwiththefollowingoperationsonthedrivecontrol system(4):Byslightlymovingthedrive
control systemupwards (pullingit) the gearboxshiftsone ratio up.Byslightlymovingthedrivecontrol systemdownwards
(pressingit) thegearboxshiftsoneratiodown.Bykeepingthedrivecontrol systeminthedesiredposition(pulling/ pressing
it) thegearboxshifts two ratios up or down respectively.
The followingpick-upgearsare available: 1
st
, 2
nd
, 3
rd
, 4
th
, 5
th
.
7) Presstheaccelerator pedal releasingtheparkingbrake. The vehicle starts (theclutch engages automatically).
Changingratio while drivingthevehicle
Shiftingupto ahigher ratio
- Byslightlymovingthedrivecontrol system(4) downwards (pressingit) the gearboxshiftsone ratio up.
- Bykeepingthedrivecontrol system(4) in this position thegearbox shifts two ratios up.
Shiftingdown to alower ratio
- Byslightlymovingthedrivecontrol system(4) downwards (pressingit) the gearboxshiftsone ratio down.
- Bykeepingthedrivecontrol system(4) in this position thegearboxshifts two ratios down.
Aquila Trucks Centres
NOTE
NOTE
ELECTRIC/ELECTRONICSYSTEM 101 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Driving in automatic mode (Auto)
1) Parkingbrakeengaged.
2) Start theengine
3) Gearboxin neutral (position N).
+) 3|o| oss os|bottoo '|' (+). T|o aotoat|c ssto |s act|vatoo aoo t|o ca|co|atoo |c'-o oa |s ooaoo.T|o o|s|a
s|o.s t|o |c'-o oa toot|o .|t| '/|TC'.
5) After enteringAUTO mode, thesameguidelinesgivenfor theSEMI modeapply(points 6 and 7) for selectingthepick-up
gear.
Changingratio while drivingthevehicle
Whiledrivingthevehiclethedisplayshows theengagedratio. All theratio changingoperationsareautomaticanddepend on
thesituationof drivingthevehicle, theload, thepositionoftheaccelerator pedal, thespeedandnumber of revolutions ofthe
engine. Thegear canalwaysbechanged manuallywiththedrivecontrol system(4), without havingto leave automatic mode.
Keepingtheengagedratio
| |o aotoat|c ooo oo .aot to 'oo t|o ooaoo at|o, oo oooo to b|o| oss os|bottoo '|' (+). T|o oabo .||| ass
on to manual mode (SEMI). Later operations on thegearboxare possibleonlybypullingor pressingthedrive control system
(+) (as oosc|boo o o|v|o |o aooa| ooo). To ass bac' |oto aotoat|c ooo, oo oooo to b|o| oss os|bottoo '|'
(1).
Pass into neutral (Position N)
|oss os|bottoo '|' (2). T|o o|s|a s|o.s |.|os|t|oo|o |o ooota| '|' |as |o|t ovo t|o ot|o ooat|oos o c|ao|o
ratio.Itisalwayspossibletopassintoneutral startingfromanyratio.Whenthevehicleisdrivingforwards,fromtheneutral position
(|) |t |s a|.as oss|b|o to ooao a oabo at|o. |o t||s oo oooo to b|o| oss os|bottoo '|' (+).
So asnot to wearout themechanical partsof theclutch control, if stoppingthevehiclefor longer than 1- 2minutes
(for instance, inaqueue, at alevel crossing, etc.), thegearboxmust be put into neutral (N).
This closes theclutch and the control systemis lightened.
Reverse gear
- \|t| t|o vo||c|o stat|ooa, b|o| oss os|bottoo '|' (3). T|o s|o. ovoso oa at|o (||) |s ooaoo.
- Press the accelerator pedal. Thevehiclestarts(theclutchengages automatically).
Withthevehiclestationaryandinreversegear it ispossibletochangebetweenthetwo reversegear ratiosRL(slow)
and RH (fast) byusingthe drivecontrol system(4)
Byslightlymovingthe drivecontrol systemupwards (pullingit) RH
Byslightlymovingthe drivecontrol systemdownwards (pressingit) RL
Operations in slow mode
For manoeuvringin harsh drivingconditions (off-road, for instance) thereisasupplementaryoperating mode, with the aid of
whichthedriver canfinetunetheclutchaccordingto thetravel of theaccelerator pedal (upto 100%). In thiswaytheengine
speed is limited and rapidvehicleaccelerationis prevented.
Turningon
- Thevehiclemust bestationary
Forward drive manoeuvres
- |oss aoo |o|o os|bottoo '|' (+) ( > 2 soc.) T|o o.ao o|vo aoooov o ooo |s toooo oo. T|o o|s|a s|o.s
'S|C\'
Reverse drivemanoeuvres
- |oss aoo |o|o os|bottoo '|' (> 2 s oc.) T|o ovoso o|vo aoooovo ooo |s toooo oo. T|o o|s|a s|o.s
'|| S|C\'
Aquila Trucks Centres
Figure130
108922
NOTE
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Base- November 2006 Print 603.93.641
Turningoff
With thevehiclestationary
- 3|o| oss os|bottoo '|' (+). T|o ca|co|atoo |c'-o oa |s ooaoo aoo aotoat|c ooo toooo oo
o b|o| oss os|bottoo '|' (3) . T|o s|o. ovoso oa at|o (||) |s ooaoo.
Duringtheforwarddrivemanoeuvre:
- 3|o| oss os|bottoo '|' (+). T|o aotoat|c ssto |s act|vatoo o ooato t|o '|c'-oo.o.
Duringthereverse drivemanoeuvre:
- 3|o| oss os|bottoo '|' (3). o ooato t|o '|c'-oo.o.
FUNCTION ENGAGING EMERGENCY MODE (LIMP HOME)
This is anemergencyfunction in which thenormal systemof automaticcontrol is put out of service.
1) Engagement
Indicator (Display): LH =engageemergencymode (whenchangingratio).
2) Activation by the driver
Ignition turned off (until theindicator isturnedoff).
Ignition turned on, within 5seconds:
Press pushbutton N (2) for at least 5 seconds.
3) Indicator LH
After turningon emergencymode (when changingratio).
Gearboxin neutral.
Clutch released (open).
4) Clutch status indicator
Bar with arrowtip pointingupwards (5) (blinking) =clutchreleased.
Bar with arrowtip pointingdownwards(6) =theclutchisabout to engageor is engaged.
Whenchangingratio, blinkingstops: (as soonasanew ratio is engagedit starts blinkingagain!)
5) Operations to perform
After turningon theemergencymode (seepoint 3), start uptheengine.
Whentheengine is running, pressandthenreleaseagainthebrakepedal.
Engagetherequiredpick-upgear.
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NOTE
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ELECTRIC/ELECTRONICSYSTEM 103 TRAKKEREURO 4/5
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Forwards:
- Byslightlymovingthedrivecontrol system(4) upwards(pullingit) thegearboxshifts oneratio up.
- Byslightlymovingthedrivecontrol system(4) downwards (pressingit) the gearboxshiftsone ratio down.
Inreversegear:
- 3|o| oss os|bottoo '|' (3). (t|o s|o. ovoso oa at|o '||' |s ooaoo).
- Byslightlymovingthedrivecontrol system(4) upwards(pullingit) thegearboxpassestothefast reversegear ratioRH.
Engagetheclutch: presspushbuttonD (1) until thebars stopblinkingwiththearrowtip pointingupwardsandwhenthebars
appear withthe arrowtippointingdownwards (5/ 6).
The clutchcanbeengagedslowlyor even suddenly.
If thevehicleaccidentallymovesonaslope withagear engaged, theclutchwill automaticallyengage
||sooao t|o c|otc|. b|o| oss os|bottoo '|' (+) o a|tooat|vo| oss t|o ba'o ooa|.
| oo oss|o t|o ba'o ooa| t|o c| otc| |s ooaoo .|t| t|o os|bottoo '|' (+) (o oa|o vo||c|o |c'-o o||||),
inorder to be ableto releasetheclutchagain withthebrakepedal, it will benecessaryto first brieflytakeyour foot
off the brake pedal: aratio shift will onlybepossiblewith the vehicle stationary.
Leavingemergencymode.
Turnoff theignitionandwait for theindicator to disappear.
Whennext startingupthesystemwill beinnormal mode.
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CLUSTER
Proceed as followsto removetheCluster:
|so a sco.o|vo o |ovoao |os |oo t|o t.o s|ots |o t|o
two groups of switches (A) located in theupper panel.
|oovo t|o t.o otoct|oo cas.
|ooso t|o oo aoo| ota|oo sco .s (3).
|ovo t|o aoo| as a oot.aos as o ss|b|o ato o|ocat-
ingthesteeringwheel far fromthepanel.
||scooooct t|o t.o C|osto attac||o sco.s.
|oosoo t|o oo ota|oo sco.s (C).
49733
49837
C C
C
C
c
Figure131
Figure132
Figure133
49733
A
A
B
B
B
B
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ELECTRIC/ELECTRONICSYSTEM 105 TRAKKEREURO 4/5
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Cluster (optical indicators)
Ref. Description
1 External lights
2 Auxiliaryheadlamps
3 High-beamheadlamps
4 Generic anomaly/failuresignal
5 Generic alarm
6 Fogheadlamps
7 Rear foglights
8 * Retarder
9 * Engine brake
10 Vehiclesuspensionsnot inrunning trim
11 Third axlelifted
12 Pick-upassist provision
13 Mirror heating
14 Longitudinal tandemdifferential locking
15 Longitudinal/transverserear differential locking
16 Left indicator light
17 Longitudinal differential locking
18 Longitudinal/transversefront differential locking
19 OBDII anomaly
* Warninglight: blinkingwiththefunctionrequested bythedriver; ON steadywiththefunction
actuated
102385
1 2 3 4 5 6 7
19
18
17
16
15
10
11
12
13
14
8
9
Figure134
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Ref. Description
20 Power take-off 1 (PTO 1)
21 Power take-off 2 (PTO 2)
22 Instrument panel failure (Cluster)
23 Right indicator light
24 Immobilizer
25 Analogrevs counter
26 Temperature/timedisplay
27 Instrument illuminationitensity/temperature/timedisplaybutton
28 Coolant temperature(hightemperaturewarninglight)
29 Full/tripodometer displaybutton
30 Hand brake ON
31 Emergencylights
32 Brakingsystemfailure
33 Display
34 Fuel level
35 Fuel level (low level warninglight)
36 Odometer/mileageindicator displaybutton
37 Tachographanomaly
38 Full/tripodometer/mileageindicator display
39 Analogspeedometer
102386
20
21
22
23
25 26 27 28 35 36 37 38 39
30
31
32
34 29 33
24
Figure135
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Print 603.93.641
CLUSTER (PIN-OUT)
Connector A - Blue
Pin Description
Cable
colour code
1 - -
2 CAN H line(VDB) White
3 CAN L line(VDB) Green
4 17 - -
18 Positive+15(fromIBC3) 8871
19 Ground 0000
20 Direct positivebattery(+Bat fromICB3) 7906
Connector B- Black
Pin Description
Cable
colour code
1 Kline(14-pindiagnosis connector) 2994
2 - -
3 Trailer ABSfailuresignal 6671
4 - -
5 - -
6 - -
7 - -
8 ECMfailure signal 6150
9 Speedsignal for diagnosis connector (28-pin) 5540
10 Ground fromswitchfor tiltedcaissonsignalling 6607
11 - -
12 17 - -
18 - -
19 Speedsignal for Toll Collect (predisposition) 5541
20 - -
49837/a
Figure136
A
B
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Displayoperation
Displayvariessubject to the following:
- KeyonMARwithengineoff
- Keyon MARwithenginestartedandvehiclestationary
- KeyonMARat vehiclespeedover 15Km/h
- Keyout
Keyin MAR with engineoff
Turningthekeyto MAR displayscontrol of mainvehiclesystems.
Theirpresenceisindicatedingreen,ifall isOK,oryellowincaseofalight anomaly/breakdown,orredincaseofaseriousanomaly/
breakdown, withactivationof abuzzer.
Thelist ofsystemspresent onthevehicleandtheir statuscanbedisplayedwiththeMultiplexsystemduringStart-Up, byreceiving
thediagnosticmessagefromthevariouscenters.
SystemCheckOk or SystemCheckFailed informationisprovidedat Start-Up Test end.
Thedefectivesystemthensends its diagnosticmessagethat isdisplayedwiththeiconof thedefect under review.
TheMultiplexsystemcanindicatevehicleandelectronicsystemerrors.IncaseofanerrordetectedbytheBodyComputer,it sends
theInstrument Cluster amessagecontainingthefollowinginformation, viatheCAN line:
- thestatusof thelight associatedto thedefect (redfor aseriousand yellowfor aslight anomaly)
- theerror code
At receipt of theerror message, theInstrument Cluster displaysthe followinginthecentral displayarea:
- thecolored iconrelatedto thedefectivecomponent or center
- therelated error code
|t a|so aov|sos t|o ooato b act|vat|o t|o 3ozzo. /to ocoo|z| o t|o oo, t|o ooato ossos 'o 'C|' aoo t|o coota|
displayareareturnsshowingthepreviousinformation(virtual tool or menu).
Theiconrelated to theerror detected isstored inthelower layer of the displayor withaspecificwarning.
No options suchasto distract attentionor optionsnot related to anoperation useful for vehicle operationare availableduring
operation,whichiswhytheMenusavailableincaseofamovingvehiclearereducedtothebaseessential andscanningofthevarious
o|s|as |s obta|ooo s|| .|t| t|o '|ooo' 'o (.|t|oot oao|o t|o || st o ot|oos).
\|t| t|o vo||c|o stat|ooa, scaoo|o o t|o co|oto sot o ooos ava| |ab|o |s ooab|oo .|t| 'os '/o. o' aoo '/o. oo.o'.
Breakdown
After acknowledgingtheerror, theoperatorpresseskeyOKonthesteeringwheel andtheiconappearsinthelowerdisplaylayer.
Yellowcolor (light anomaly/breakdown):
Proceedwithcautionand contact aServiceNetworkworkshopassoon aspossible.
Red color (serious anomaly/breakdown):
Parkthevehicleontheroadsideinanon-dangerousareaorcontact theDealer or the24hourClient Center number inunusual
hoursor inadecentralizedarea.
Two menusareavailable:
- TRAVEL MENU
- DIALOGMENU
External mirrorsandlightscanalso beadjusted.
Whenthe keyis inserted, thepresent electronic systems performatest byactivatingtherelatedlights, enablingthe operator to
checktheir efficiency(andlearn of theexistenceof vehiclesystems).
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73662
LOWER
SECTION
TITLE
CENTRAL
SECTION
SL
High engine
coolant
temperature
Figure137
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Display structure
TITLE
- Speedset byCruiseControl
- SpeedLimiter set
- Supplementaryheater enabled
- Batteryvoltage
- Radio/RDSinformation
- Telephone/ EMSmessageinformation
- Gears(downshifted/normal gears), suggestedgears, auto/manual mode.
CENTRAL SECTION
- Engineoil pressure
- Engineoil level
- Consumptionindicator
- Turbo pressure
- Engineoil temperature
- Reservoir, trailer, serviceair pressure
- Front / rear / trailer brakewear (vehicleswithEBS)
- Light settingadjustment
- Mirror positioning
- Failuremessages
- Loadonthe axles (OPT)
LOWER SECTION
- Alarms
- Activefunctionsindications(intarder, etc.)
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SL Figure138
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Optical status indicators on display
Thecorrespondingiconappearsat activationof thefollowingfunctionsofoccurenceofthefollowinganomalies.
Meaning Symbol Colour Meaning Symbol Colour
Pre-heating yellow ASRon yellow
Cabunhooked
Unhookedcab enable
red
yellow
ASRoff yellow
Door open red Reduced ABSoperation yellow
Low front axlebrake
air pressure
red
Automaticchains
yellow
Low rear axlebrake
air pressure
red Trailer without EBS/ABS yellow
Low trailer brake
air pressure
red Tipper body yellow
Loadingdecklight
(tractor only)
yellow Instrument Cluster trouble red
Windscreendefroster yellow
Low hydraulicpressureof
thirdsteeringaxle
red
Minimumengine
coolant level
yellow Low enginecoolant level red
Highenginecoolant
temperature
yellow
Veryhighenginecoolant
temperature
red
Low windscreenwasher
reservoir level
yellow Low fuel level / Ad Blue yellow
Front axlebrakewear red Rear axlebrakewear red
Rear second axle
brakeworn
red
Brakewear
onaspecific wheel
red
Power steeringlowfuel level yellow Air filter clogged yellow
Oil filter clogged yellow Water in fuel filter yellow
Fuel filter clogged yellow Engineoil level too high yellow
Lowengineoil level red
Highengineoil
temperature
red
Lowengineoil pressure red Highengineoil temperature red
Low parkingbrake
air pressure
red
Brakewear
onaspecific wheel
yellow
Low trailer brake
air pressure
red Low/poor generator charge
yellow
red
After recognizingtheerror, theoperator must pressOKonthesteeringwheel andtheiconappearsinthelower displaysection.
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Meaning Symbol Colour Meaning Symbol Colour
TCO ECU failure red BMECU failure red
Parkingbrakefailure red CMECUfailure red
Secondimportance
light failure
yellow
Air conditioningsystem
failure
red
BC ECU failure yellow/red Additional heater failure red
ECM failure yellow/red SWI ECU failure red
EuroTronic failure red RFC ECUtrouble/fault yellow/red
EBSfailure red First importancelight failure red
ABSfailure red Right turnindicator fault yellow
Intarder failure red Left turn indicator fault yellow
FFC ECU trouble/fault yellow/red
Central lockingsystem
failure
yellow
DDM ECU failure red EAC defect yellow
Distancealarmsignalling yellow EAC failure red
ACC sensor defect red Trailer EBSfailure red
ACC sensor dirty red Reduced power andengine yellow
ARBenabled yellow Rotatingheadlights yellow
TPMsteeringaxlelowtire
pressure
yellow VCMfailure yellow/red
TPMengineaxlelow tire
pressure
yellow SCR failure yellow/red
Trailer: attentionthresholds
reached
yellow ASR/ ESPdisabled yellow
Trailer: anti-theft enabled yellow ESPenabled yellow
Airbagdefault/defect red Power steeringfailure red
EMdefect yellow
Power steeringliquid
lowpressure
yellow
EMfailure red
CDMECU failure red
Aquila Trucks Centres
Figure139
112594
- AdBlueFLUID LEVEL
- ENGINE OIL LEVEL
- OILPRESSURE
- AIRPRESSURE(REARAXLE- AXLE)
- BRAKEPAD WEAR(EBS)
- LOADGAUGEON AXLES
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Displayinstruments
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BODY CONTROLLER (IBC3)
TheBodyController isthecentral unit whichrepresentstheheart ofelectrical systemandtogether withMET central unit make
upEasyMuxsystem.
Thetwo central unitscommunicatebetweeneachother viaCAN line (BCB).
Insteadthroughthe CAN line (VDB), theIBC3communicateswiththevehicledifferent electronicsystems.
Bodycontroller inputs:
- Coolant lowlevel contact
- Windscreenwiper liquid lowlevel contact
- Alternator warninglamp
- Key 15
- Additional heater
- Brakesystemair lowpressuresensor
- Emergencyswitch
- Door unlockingpushbutton
- Rear foglightsswitch
- External lights switch
- Headlampattitude rectifier
- Sunroof unlock/lockcontrol
- Unfastenedseat belts
- TGC unlock/lock
- Rear crossdifferential lockingcontrol
- Front differential lockingcontrol
- Longitudinal differential lockingcontrol
- Trailer handlepressuregauge
- Heater immediateengagement control
Signals received viaCAN network:
- Gear in
- Trailer brakesignal
Bodycontroller outputs:
- Controlsillumination
- Windscreenwasher electricpump
- Lh/ rhclearanceheadlamp
- Steps light
- Internal roof lamp
- Sunroof opening/ closingrelay
- Hornspower supplyrelays
- Lighter
- Windscreenelectricdefroster power supply
- Remote control switchfor insertingloadswithkeyin
- Fitter outputs
- TGC (Current General RemoteControl Switch) / CGE(EmergencyGeneral Control) /MBS(Current General Control)
- Central door lockmotor control
- Additional mainbeamheadlight control
- Additional heater engagement control
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IBC3 displays following information on Instrument Cluster:
- Fuel level
- Oil level
- External air temperature
- Brakecircuit air pressure
IBC3 controls following devices:
Lights(parkinglights,dippedheadlights,additional lights,front foglights,rearfoglights,blinkers,stoplights,reverselights,stepslights,
cab lights, highroof cab lights, headlights attitude)
- Central locking
- Air-conditioner
- Additional heater
- Air drier
Limp Home:
It identifiescentral unit status incaseofmicro processor failure; inthiscondition, followingfunctionsare ensured:
- Power supply(batteryvoltage, key30, 15and 15/1) fromcentral unit to other cabloads
- Switchingoff of disabled TGC
- Switchingonof windscreenwiper at minimumspeed (or keepingpreviouscontrol)
- Switchingonstepslights
- Switchingonclearancelights
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BODY CONTROLLER
Linking connectors
112595
Figure140
108903
Figure141
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Body controller connector A
Pin Description
Cable
colour code
1 - -
2 PositivefromTGC (+30) 7905
3 - -
4 - -
5 - -
6 Positive+30for VCM/ SWI 7906
7 Direct batterypositive (+batt) 7768
8 Positivefromservicerelay (+15/1) 8887
9 - -
10 - -
11 - -
12 - -
13 - -
14 PositivefromTGC (+30) 7905
15 Direct batterypositive (+Bat) for DTCO (Tachograph) / central locking 7768
16 Direct batterypositive (+batt) for BM(BedModule) 7906
17 - -
18 - -
19 - -
20 - -
Body controller connector B
Ref. Description
Cable
colour code
1 Positive+15for air conditioner / bodybuilders (ST14A) 8871
2 Positivefromservicerelay (+15/1) 8887
3 Positive+30for cigar lighter / diagnosticinterface 7772
4 Positive+30for bodybuilders(connector 72072C) 7796
5 - -
6 Positive+30for voltagereducer 7772
7 Positive+15fromignitionkey 8887
8 PositivefromTGC (+30) 7905
9 Positive+30for bodybuilders(ST14A / connector 72072D) 7772
10 - -
11 - -
12 - -
13 - -
14 PositivefromTGC (+30) 7905
15 - -
16 Positive+15for brakesystemdrier heater coil 8840
17 Positive+30for hornrelay 1116
18 - -
19 - -
20 - -
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Body controller connector C (grey)
Ref. Description
Cable
colour code
1 Power supplyfor brakesystemair pressuresendingunit 5560
2 Positive+15for alternator 8876
3 Air pressuresendingunit signal (front brakes) 5562
4 Air pressuresendingunit signal (rear brakes) 5561
5 Windscreenwiper motor fixedstop(31B) 8873
6 - -
7 PositivefromTGC (+30) 7905
8 Earthfor brakesystemair pressure sendingunit 0560
9 Front marker light power supply 3339
10 Windscreenwiper motor highspeed power supply(53B) 8881
11 Windscreenwasher pump power supply 8886
12 Windscreenwiper motor lowspeed power supply(53) 8882
Body controller connector D (blue)
Ref. Description
Cable
colour code
1 Earthfromwindscreen washer fluid lowlevel sensor 5521
2 - -
3 Ground 0000
4 Chargesignal fromalternator 7009
5 Signal fromexternal temperaturesensor 7573
6 Earthfromradiator water lowlevel sensor 5527
7 CAN H line(BCB) White
8 CAN L line(BCB) Green
9 CAN L line(VDB) White
10 CAN H line(VDB) Green
11 External temperaturesensor earth 0550
12 Control unit IBC3Kline(diagnosticconnector pin8) 2995
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Body controller connector E (blue)
Ref. Description
Cable
colour code
1 Ground fromleft door button 0003
2 Ground fromright door button 0003
3 Ground fromparkingbrakeengagedswitch 6662
4 Hazardlightssignal for bodybuilders(ST14B) 1113
5 - -
6 - -
7 - -
8 Positive+15 for cabtilt enablement switch 8871
9 Positivefor openingTGC (TGC off) 8045
10 Positive+15for ECM/ VCM 8051
11 - -
12 - -
13 Positif +15pour Cluster / DTCO / MET / Eurotronic2 8871/8802
14 Enginerunningsignal for air conditioner / bodybuilders(ST14A)
S|oa| otoo oo ooto oo c||at| soo / o|sos|t|s o'oo|ooot (ST ++/)
7778
15 Vehicleparked signal for bodybuilders(ST14A) 5515
16 Reversingsignal for bodybuilders(ST14A) 2268
17 - -
18 Positivefor enablement of supplementaryheadlight activationrelay 2229
19 Positivefor sunroofclosurecontrol relay 7011
20 Positivefor sunroofopeningcontrol relay 7010
21 Positivefor TGC closure (TGC On) 8035
22 Positivefor headlamp washer pumprelay 8820
23 - -
24 Positivefor fifthwheel lightingswitch/ sidelightsfor bodybuilders (ST14B) 3333
25 Positivefor interior courtesylight 4440
26 Positivefor steplight 4445
Body controller connector F
Ref. Description
Cable
colour code
1 Positive+30for Cluster 7906
2 Signal fromheadlight alignment corrector control switch 9936
3 Positivefor independent water heatingpumpenablement 7786
4 Ground fromradiator low level sensor (for warninglight) 5520
5 Ground fromsupplementaryheadlight switch 2229
6 - -
7 Ground fromlongitudinal differential lock switch 0903
8 Ground fromhatchopeningcontrol switch 0970
9 Ground fromsupplementaryheater activation switch 0501
10 - -
11 Ground fromTGC activationswitch(TGC On) 0945
12 Ground fromexterior lightingswitch(exterior light) 3333
13 Ground fromrear foglamp switch 2284
14 - -
15 - -
16 - -
17 Positivefor symbol lighting 4442
18 Headlamp alignment corrector control switchpower supply 8871
19 - -
20 Ground fromtrailer brakehand wheel switch(brakelight) 0927
21 - -
22 Ground fromrear transversedifferential lockswitch 0904
23 Ground fromfront differential lockswitch 0902
24 Ground fromhatchopeningcontrol switch 0971
25 Control signal for central locking- locking 0064
26 Ground fromhazardlight switch 1113
27 Ground fromTGC off switch(TGC Off) 0946
28 Ground fromexterior lightingswitch(low-highbeams) 2237
29 Ground fromfoglampswitch 2228
30 - -
31 Ground fromcourtesylight onswitch 0941
32 Control signal for central locking- locking 0065
Aquila Trucks Centres
108904
Figure142
ELECTRIC/ELECTRONIC SYSTEM 119 TRAKKER EURO 4/5
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CHASSIS ELECTRONIC MODULE (M.E.T.)
MET central unit is placed on the chassis, actuates the controls and collects signals fromsensors installed outside the cab, and
communicates withICB3through CAN BCBnetwork.
Itsupplieslockedpositive(+15) toUDScentral unit (Denox2),trailer,fittersandchecksvehicleillumination.Itsuppliesotherloads
too, such asair-conditioner compressor andfuel filter andpre-filter heating.
Distributes key 15 to:
- UDS(DENOX 2)
- Trailer
- Fitters
Powers the following lights:
- Parkinglights
- Parkinglightsfor fitters
- Marker
- Brakelights
- Foglights andrear foglights
- Directionindicators
- Reversegear
Powers other loads:
- Theconditioner compressor
- Fuel filter andprefilter heating
- ECAD solenoidvalves
- Servoshift solenoidvalve
Acquires the following signals:
- Reversegear engaged
- Front differential lockedsignals
- Rear differential lockedsignals
- Longitudinal differential locksignals
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- Underdrivegearsin
- Engaging5thand 6th gears
- Suspensionsair lowpressure
- Hydraulicguideliquid low pressure
- Brakeliquidlowpressure
- Air-conditioningsystemhighor low pressure
- Air-conditioningsystemhighor low pressure
- Front axlebrakepadswear status
- Rear axlebrakepadswear status
- Front parkingbrake
- Front brakes converter cylinder endswitch
- Rear brakesconverter cylinder end switch
- Side PTO in
- Rear or total PTO in
- Clogged air filter
- Clogged air filter
- Fuel level
- Engineoil level
Pin - Out
Pin Description
Cable
colour code
A-1 Reversinglight positive +30 2226
A-2 Positive+30for trailer brakelights 1179
A-3 Positive+30for left brakelight 1177
A-4 Positive+30for right brakelight 1172
A-5 Positive+30for number platelight 3307
A-6 Positive+30for right rear sidelights 3315
A-7 Positive+30for left rear sidelights 3330
A-8 Positive+30for right trailer sidelights 3339
B-1 Positive+30for trailer rear foglamp 2283
B-2 Positive+30for rear foglamps 2283
B-3 Positive+30for right trailer directionindicators 1185
B-4 Ground fromtransversedifferential lockengaged indicator switch(1st rear axle) 0040
B-5 Ground fromtransversedifferential lockengaged indicator switch(2ndrear axle) 0041
B-6 Ground fromlongitudinal differential lock engagedindicator switch 6603
B-7 Positive+30for rear marker lights 3306
B-8 Positive+30for left rear sidelights 3305
C-1 Positive+15for trailer 8075
C-2 Positive+30for left rear directionindicators 1120
C-3 Positive+30for right rear directionindicators 1125
C-4 Positive+30for left trailer directionindicators 1180
C-5 Ground fromECASair systemlowpressureswitch / Earthfromfront longitudinal differential
lock indicator switch(8x8)
6401/6643
C-6 Ground fromrear brake wear sensor (1st rear axle) 6667
C-7 Ground fromrear brake wear sensor (2nd rear axle) 6667
C-8 - -
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A connector
Pin Description
Cable
colour code
A-1 Positive+30for left highbeam 2219
A-2 Positive+30for right lowbeam 2223
A-3 Positive+30for right high beam 2221
A-4 Positive+30for left lowbeam 2231
A-5 Signal fromwater infuel filter sensor 5530
A-6 Ground fromfront wheel blockwear sensor (2ndaxle) 6664
A-7 Ground fromfront transverselock engagedsignal switch (1st axle) 6659
A-8 Positive+30for diesel heater coil 7733
B-1 Positive+30for diesel pre-filter heater coil 7753
B-2 Headlamp alignment corrector control 9936
B-3 Ground fromswitchfor circuit II power steeringoil flowindicator 6632
B-4 Ground frompower steeringfluid lowlevel sensor 5525
B-5 Ground fromfront transverselock engagedindicator switch(2nd axle) 6659
B-6 Ground fromair filter clogswitch 6663
B-7 Ground fromfront wheel blockwear sensor (1st axle) 6664
B-8 Positive+30for foglights 2228
C-1 - -
C-2 Positive+30for front sidelights 3339
C-3 Positive+15fromIBC3 8871
C-4 CAN L line(BCB) Green
C-5 CAN H line(BCB) White
C-6 Positive+30for front / right sidedirectionindicators 1123
C-7 Positive+30for front / left sidedirection indicators 1129
C-8 Positive+15for water infuel filter presencesensor 8879
C connector
Pin Description
Cable
colour code
A-1 Positive+30for ECADregenerationsolenoid(air system) 9043
A-2 Positive+30for ECADdischargesolenoid(air system) 9043
A-3 Positive+30for rear transversedifferential locksolenoid 9325
A-4 Positive+30for longitudinal differential locksolenoid 9323
A-5 Positive+30for front transversedifferential lock solenoid 9063
A-6 Ground fromswitchinfront power steeringlock valve 6631
A-7 Ground fromsidePTO engagedindicator switch(without EM) 6132
A-8 Ground fromlow hydrauliccircuit pressureindicator with3rd steeringaxle 0491
B-1 Ground fromtrailer brakecircuit indicator switch 6689
B-2 Ground fromdistributor crawler gear engagement indicator switch(4x4) 9976
B-3 Engineoil level sendingunit signal 5505
B-5 Fuel level sendingunit 5557
B-6 Ground fromtotal/rear PTO engagedindicator switch (without EM) 6131
B-7 Ground fromswitchinfront power steeringswitchvalve 6631
B-8 Positive+15for UDScontrol unit (SCR system) 8540
C-1 Ground 0000
C-2 Engineoil level sendingunit earth 5506
C-3 Fuel level sendingunit 5555
C-4 Ground fromfour wheel driveengagement indicator switch 6602
C-5 Ground fromreverseengagement indicator switch 2268
C-6 Ground fromcrawler gear engagement indicator switch 9992
C-7 Ground fromfuel filter blockedindicator switch 5531
C-8 - -
Aquila Trucks Centres
J1 J2 J3
50239
49723
8 1
16 9
10
1
20 11
1 6
12 7
Figure142/1
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D.D.M. / P.D.M.
TheD.D.M. islocated insidetheoperator door; theP.D.M. insidethepassenger door.
Print 603.93.521
Inputs Outputs
Rearviewmirror heating Rearviewmirror heating
Rearviewmirror adjustment Rearviewmirror adjustment
Windowlifter Windowlifter
Centralizedlock Centralizedlock
TheonlydifferencebetweenD.D.M.andP.D.M.isthattheP.D.M.pinJ2/10isconnectedbymeansofajumperwithpinJ1/8towards
thegroundfor passenger modulerecognition.
Aquila Trucks Centres
Thesecontrol unit manageall thefunctionsappertainingtothetwo vehicledoors, namely:
mirror heating
mirror adjustment
window lifter
centralized lock.
Theyarelocated insidethevehicle door andremoval isasfollows:
1. removethedoor lining;
2. disassemblethe loudspeaker traybyremovingthethreefasteningscrews;
3. takeDMoff thetraybyremovingthetwo fasteningscrews
4. disconnect thethreeelectricconnectionadapters.
Disassemblingoperationsarethesamefor bothdoors.
49838
Figure142/2
121/2 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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D.D.M. / P.D.M.
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P.D.M.
CONNECTOR J1
Pin Cable Function
1 - Free
2 - Free
3 - Free
4 9965 Centralizedlock motor control (CDL)
5 9964 Centralizedlock motor control (CDL)
6 8863 Windowlifter motor control (opening)
7 8865 Windowlifter motor control (closing)
8 0000 Mass Bridge with (J2-10) for module recognition
9 - Free
10 - Free
11 0000 Negativefor centralizeddoor lockreleasepushbutton
12 0000 Negativefor mainrearviewmirror heating
13 0000 Negativefor wideanglerearviewmirror heating
14 - Free
15 2990 Klinefor diagnosis
16 7990 Center power positive
CONNECTOR J2
Pin Cable Function
1 Ws/Bi CAN H line(BCB)
2 - Approachrearviewmirror control (vertical)
3 - Approachrearviewmirror control (horizontal)
4 8851 Wideanglerearviewmirror control (return)
5 8852 Wideanglerearviewmirror control (vertical)
6 8857 Mainrearviewmirror control (return)
7 Gv/Ve CAN L line(BCB)
8 8853 Wideanglerearviewmirror control (horizontal)
9 - Approachrearviewmirror control (return)
10 0000 Mass Bridge with (J1-8) for passenger side ECU recognition
11 8859 Mainrearviewmirror control (horizontal)
12 8858 Mainrearviewmirror control (vertical)
CONNECTOR J3
Pin Cable Function
1 0962 Negativefrompassenger sideglasslifter pushbutton
2 9 - Free
10 4442 Positivefor passenger side glasslifter pushbuttonlight
11 0961 Negativefrompassenger sideglasslower pushbutton
12 0960 Negativefor passenger sideglasscontrol pushbutton+lighting
13 20 - Free
Aquila Trucks Centres
121/4 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Print 603.93.521/A
D.D.M.
CONNECTOR J1
Pin Cable Function
1 - Free
2 - Free
3 - Free
4 9965 Centralizeddoor lockmotor control
5 9964 Centralizeddoor lockmotor control
6 8863 Windowlifter motor control
7 8865 Windowlifter motor control
8 0000 Control unit earth
9 - Free
10 - Free
11 0000 Negativefor Centralized door lock
12 0000 Negativefor mainrearviewmirror heating
13 0000 Negativefor wideanglerear viewmirror heating
14 - Free
15 2991 Klinefor diagnosis
16 7991 Positivefor center power
CONNETORJ2
Pin Cable Function
1 Ws/Bi CAN H line(BCB)
2 - Free
3 - Free
4 - Free
5 - Free
6 8806 Mainrearviewmirror control (return)
7 Gv/Ve CAN L line(BCB)
8 8843 Free
9 - Free
10 - Free
11 8809 Mainrearviewmirror control (horizontal)
12 8808 Mainrearviewmirror control (vertical)
CONNECTOR J3
Pin Cable Function
1 0962 Negativefrompassenger sidewindowlifter pushbutton
2 0966 Negativefrompassenger sidewindowlower pushbutton
3 0967 Negativefromoperator side windowlifter pushbutton
4 - Free
5 - Free
6 0953 Negativefromright rearviewmirror control push button(movement to theright)
7 0954 Negativefromleft rearviewmirror control pushbutton(movement to theleft)
8 0951 Negativefromright rearviewmirror control push button(movement downwards)
9 0952 Negativefromleft rearviewmirror control push button(movement upwards)
10 4442 Positivefor passenger/operator sidewindowpushbutton lighting
11 0961 Negativefrompassenger sidewindowlower pushbutton
12 0960 Negativefor passenger sidewindowcontrol pushbutton+lighting
13 0951 Negativefor operator sidewindowcontrol pushbutton+lighting
14 - Free
15 0950 Negativefor rearviewmirror control joystickpushbuttons
16 0600 Negativefor rearviewmirror control joystickpushbuttonlighting
17 - Free
18 - Free
19 4442 Positivefor rearviewmirror control joystickpushbuttonlighting
20 - Free
Aquila Trucks Centres
50240
UPPER VIEW
FRONT VIEW
A D C B
Figure143
Figure144
122 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
S.W.I. (Steering wheel / steervator interface)
Thefunctionofthiselectroniccenterlocatedonthesteeringcolumnistogrouptogetherall controlsfromthetwosteervatorlevers
and thesteeringwheel.
It isconnectedto thevehicleelectronic systemviaaCAN line.
Aquila Trucks Centres
108924
Figure145
ELECTRIC/ELECTRONIC SYSTEM 123 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
SWI functions
Print 603.93.641
Inputs Outputs
Keyswitch MessagesonCAN line
CruiseControl keys
INTARDER lever
Changegear
Flood/dipped lights
Directionindicators
Windshield wiper
Controlson steeringwheel
Control lighting
Aquila Trucks Centres
50240
A / B C / D
Figure146
124 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Connectors
A - Right lever B- Left lever C - Steeringwheel D
1
CruiseControl
(Resume)
1 - 1 Displaypageselection 1 +30
2
CruiseControl
(Set/Acc.)
2 - 2
Displaycursor move-
ment (high)
2 -
3
Changegear
(down)
3
Wiper electro pump
controls
3 Horn 3 CAN H
4 Intarder (pos.2) 4 Wiper (top speed) 4 Lever lighting(output) 4 CAN L
5 Intarder (pos.4) 5
Directionindicators
(right)
5 Earth 5 Earth
6 Intarder (pos.6) 6 Earth 6
Menu selection/ con-
firmation
6 Lever lighting(input)
7
Changegear
(up)
7 Floodlights on 7
Maindisplayreturn
(instruments)
7 -
8
CruiseControl
(deceler.)
8 Light flashes 8
Displaycursor move-
ment (low)
8 Horn(output)
9 Intarder (pos.1) 9 Wiper (onestroke) 9 Control (-) 9 AUX 2
10 Intarder (pos.3) 10 Wiper (intermittent) 10 Control (+) 10 Earth
11 Intarder (pos.5) 11 Wiper (lowspeed)
12 Ground 12
Directionindicators
(left)
Aquila Trucks Centres
49837
49724
49725
ROTORUPPERVIEW
STATOR LOWERVIEW
Figure147
ELECTRIC/ELECTRONIC SYSTEM 125 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
SPIRALED CONTACT
Locatedbelowthesteeringwheel.
Itsfunctionis to collect all controlspresent on thesteeringwheel and send themto the SWI center.
Aquila Trucks Centres
74000
A. S.W.I center. - B. Steervator - C. Spiraledcontact - D. Start block
B C
D A
Figure148
Followtheprocedures described inthefollowingpagesincaseof spiraledcontact disassembly. NOTE
126 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
STEERING COLUMN (COMPONENT LOCATION)
Aquila Trucks Centres
72850
1
2
3
4
5
Figure149
ELECTRIC/ELECTRONIC SYSTEM 127 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Carefullyfollowtheproceduresdescribedhereundertoreplacethespiraledcontact,toavoiddamagingthespiraledcablecontained
inits boxwhendisassemblingand aligningthesteeringwheel incorrectly.
Disconnect masscableconnection (4).
Removenut (1) and marksteeringwheel assemblyposition onshaft (2) and removethesteeringwheel (3).
Aquila Trucks Centres
74000
7
6
8 9 10 11
12
13
14
Figure150
128 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Disconnect electrical connections(6and 7) fromtheS.W.I.
Securecontactrotor (9) toitscontainerbyinsertingkey(10) intoslots(11and12),topreventrotor (9) andstator(8) fromrotating
duringdisassembly.
Keepthis situationuntil assembly. Inthelack of akey, useanadequatesizenut andbolt.
Carefullyraisethecontact so elasticretainer pins(13) areremovedfromsupport (14). Storeit carefully.
Aquila Trucks Centres
72857
15
Figure151
ELECTRIC/ELECTRONIC SYSTEM 129 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Invert thesequenceof operationsdescribed abovefor reassembly.
Thespiraledcontact issuppliedsparewithitsstopkey(15) assembledasshowninthefigure. Afterassemblyonthesteeringwheel
control support, rotatethe keyto causebreakageat thepoint indicatedbythearrow andreturnit to steeringwheel seat (5).
Aquila Trucks Centres
Figure152
Press theswitch ontheinstrument panel beforeadjustingheater temperature. NOTE
106971
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B.M. (BED MODULE)
Positionedat thecab rear
TheB.C. identifiesits presencebut CANNOT bediagnosed.
Itsfunctionsareas follows
(variableconfigurationaccordingto vehicleaccessories):
- Time inhoursand minutes
- Switchingon/offof cabinterior lights(selectionof white/nightimelights).
- Opening/closingdoors.
- Opening/closingelectricwindows.
- Opening/closingelectrichatch.
- Lowering/raisingsunblinds.
- Switchingradio on/off
- Radiovolumeadjustment
- Radiotuning
- Wakeupfunction.
- Switchingadditional heater on/off.
- Temperature adjustment (onlywith additional heater switchedon). (Automatic).
- Adjustment of heater on time (9hoursmax.)
Aquila Trucks Centres
Figure153
113411
ELECTRIC/ELECTRONIC SYSTEM 131 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
E.B.M. (EASY BED MODULE)
E.B.M. (EasyBedModule) substitutestheprevious(B.M.) roughlycarryingout samefunctions. It hasthreekeysandadisplaywith
icons for thevarious functions and thevisualisation of the time. TheB.M.E. connector is thesameastheB.M. and theelectrical
connections areunchanged.
Technical features
- Supplier ITALAMEC
- Nominal Voltage 24V
- WorkingVoltage 18V 32V
- WorkingTemperature -30 C +60 C
- Absorption - standby <200mA
- Absorption - normal displaymode <200mA
- Absorption - sleep mode <3mA
- Datatransmissionspeed(CAN line) 62,500(BIT/SEC)
Pin- out
Pin Description
Cablecode
colour
1 Direct Positivebattery(+Bat) 7906
2 Ground 0000
3 - -
4 CAN L line(BCB) Green
5 CAN H line(BCB) White
6 - -
Aquila Trucks Centres
Figure154
113412
1. Confirmation key- 2. Keyfor theselectionof thedesired function- 3. Clock
132 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
E.B.M. Functions
Thefunctions whicharecarried out byE.B.M. varyaccordingto theconfigurationof theaccessoriesexpected onthe vehicle.
Function Symbol Availability
Indication of hour and minutes Always
Switchingon/ off of internal cabinlights(white lights) Always
Switchingon/ off of internal cabinlights(redlights)
Onlyfor vehicles with
medium-highroofs
Opening/closuredoors Optional
Opening/closureelectricwindows Optional
Opening/closureelectric trapdoor Optional
Lowering/raisingof sunblinds Optional
Switchingon/ off radio
Regulationofradio volume
Radiotuning
Optional
Switchingon/ off radio
Regulationvolume
SelectionCD tracks
Optional
Alarmclock setting
Onlyif thealarmclock functionis
present ontheCluster
Alarmclock repetition(snooze) / switchingoff (stop)
Onlyif thealarmclock functionis
present ontheCluster
Switchingon/ off supplementaryheater
Regulationoftemperature (if heater isswitched on)
Regulationofduration of heater functioning(max.9 hours)
Optional
Aquila Trucks Centres
TACHOGRAPH
Digital Tachograph (DTCO)
Digital Tachograph (DTCO) is aseries tachograph for new
productionvehiclesandreplacesanaloguetachographsincase
of failure.
DTCO electrical connections are the same as MTCO
electrical connections. Inthecaseof DTCO tachograph, the
sensoronthegearboxmustbereplaced;fromelectrical point
of view, thissensor isthesameasformer sensor.
Thesensor beingused for MTCO tachograph(KITAS2170)
cannot beusedonnewDTCOtachograph, forwhich KITAS
2171sensor ismounted.
This sensor (KITAS 2171 sensor) is also compatible with
MTCO sensor; however, once it hasbeenconfigured, it can
onlybeusedfor that tachographfamily.
1. Display
2. Keypad(driver-1)
3. Cardfeeder slot-1
4. Downloadinterface/ calibrationinterface
5. Keypaddriver-2
6. Cardfeeder slot-2
7. Releasebutton, printer drawer
8. Tear-off edge
9. Keysof Displaymenu
106343
Figure155
TACHOGRAPH SENSOR(KITAS2171)
108905
Figure156
DIGITAL TACHOGRAPH DTCO
ELECTRIC/ELECTRONIC SYSTEM 133 TRAKKER EURO 4/5
Print 603.93.641 Base- November 2006
Aquila Trucks Centres
134 ELECTRIC/ELECTRONIC SYSTEM TRAKKER EURO 4/5
Base- November 2006 Print 603.93.641
Pin Description Cablecolour code
1 Direct positivebattery(+Bat) 7768
2 Positiveideogramillumination(fromIBC3) 4442
3 Positive+15 (fromIBC3) 8871
A
4 CAN H line(VDB) White
A
5 Ground 0000
6 Ground 0000
7 - -
8 CAN L line(VDB) Green
1 Power supplyfor electronic tachograph transmitter 5514
2 Groundfor electronictachographtransmitter 0058
3 Speed signal for electronictachographtransmitter 5517
B
4 Invertedsignal fromelectronictachograph transmitter 5516
B
5 - -
6 Speed signal for Intarder / Navigator (pre-disposition) 5540
7 Speed signal for fitters(ST14A connector) 5155
8 Spacetravelled Signal (pre-disposition) 5518
1 -
2 -
3 -
C
4 -
C
5 -
6 -
7
8 -
1 -
2 -
3 -
D
4 -
D
5 -
6 -
7 Kline(14-pin diagnosisconnector) 2297
8 -
108906
Figure157
Aquila Trucks Centres
Figure157/1
113631
3 2 1 3 2 1 4 5 6
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M.C. NET INTERFACE
TheM.C. Net Interfacecontrol unit isintroducedinthevehiclesTrakkerEuro 4/5andactsasinterfacefor theSWI control units
(controlsonwheel),IC(Cluster) andtheRadio,bymeansoftheCAN VDBandIDBlines.TheCANICBline,whichinthevehicles
Trakker Euro 3 connected the SWI and IC control units has beenremoved.
Technical features
- Supplier ITALAMEC
- Nominal Voltage 24V
- WorkingVoltage 18V 32V
- WorkingTemperature -30 C +60 C
- Absorption- standby- 27V <5mA
Pin- out A
Pin Description
Cablecode
colour
1 Direct Positivebattery(+Bat) -
2 CAN H line(IDB) White
3 CAN L line(IDB) Green
Pin- out B
Pin Description
Cablecode
colour
1 - -
2 Ground 0000
3 - -
4 CAN H line((VDB) 7797
5 CAN L line((VDB) White
6 - Green
Aquila Trucks Centres
Figure157/2
119850
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INJECTION SYSTEM ASSEMBLY
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Ref. Description
1 Position sensor onaccelerator pedal
2 Secondaryprimarybrakeswitch
3 Sensor on clutchpedal
4 Engine brake switch
5 Right stalk
6 SWI control unit
7 Immobilizer antenna
8 Ignitionkey
9 Engine brake selector
10 Safetyfuses(30A)
11 Cabreleaseswitch
12 Handbrake engaged
13 Idleswitch
14 Diagnosticconnector
15 Relativehumidityandtemperature sensor for EDC
16 Fuel prefilter
17 Water sensor
18 Engine revs sensor
19 Injectors
20 Distribution sensor
21 Engine brake solenoid valve
22 Preheatinginsertion contactor
23 Oil pressure/temperaturesensor
24 Engine start/stop buttons
25 Baruffaldi electromagnetic joint
26 Starter
27 Coolant temperaturesensor
28 Pre-heatingresistance
29 Air pressure/temperaturesensor
30 Fuel temperaturesensor
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ENGINE CONTROL UNIT OPERATION STRATEGIES
ECM EDC7UC31 electronic control unit
The EDC7UC31control unit manages thefollowingmainfunctions:
Fuel injection
Turbinegeometryvariation
Exhaust brakeengagement
Self-diagnosis
Recovery
Also permits:
Interfacingwith other on-board electric systems onthe CAN EDBline(or ECB) SAE J1939
EOL andService programming
Diagnosis
Fuel metering
The fuel meteringis calculated in function of:
- theaccelerator pedal position fromtheVCM(VehicleControl Module)
- enginespeed
- quantityof introducedair.
The result maybecorrect infunctionof:
- thewater temperature
- thediesel temperature (DIESEL DENSITY)
or to avoid
- overloading
- overheating
- excessiveturbine speed
The deliverymaybe modifiedinthecaseof:
- enginebrakeor brakepedal activation(signalsviaCAN)
- theintervention of limitationdevices (ASR, speedlimitingdevice, etc.) (signals viaCAN)
- theintervention of ANTI-POLLUTION devices: sensor p, Sensor NOx, signalsviaCAN fromthecontrol unit DCU15
- serious problems that involve the reductioninloadand enginestalling.
Thecontrol unit, after determiningthemass of theintroducedair andmeasuringitspressureand temperature, calculatesthe
correspondingfuel mass to inject inthe involvedcylinder (mg. per delivery), also takingthediesel temperature into account
(density)
The fuel mass calculated in this way is convertedinto crankdegrees, that is, before and duringinjection.
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Correction of flow according to water temperature
Whencold,theengineencountersgreaterresistanceinoperating;thereisgreater mechanical friction,theoil isstill veryviscous,
thevariousclearances arenot yet optimised.
Inaddition, theinjectedfuel tendsto condense onthestill cold metallic surfaces.
Whentheengineis cold, morefuel is meteredthanwhen the engineishot.
De-rating
Iftheengineoverheats,theinjectionischanged,loweringtheflowrateinproportiontothetemperaturereachedbythecooling
liquid. Thecontrol unit considers theoil temperatureinthecaseof awater temperature sensor failure.
Turbinespeed adjustment
Turbinespeed is adjusted continuouslyand corrected if needed through geometryvariation.
Turbine speed adjustment
Turbinespeed is adjusted continuouslyand corrected if needed through geometryvariation.
Injection advance electronic control
The advance (startingmoment, expressed in degrees) maybe different froman injectionto the next one, also in adifferent
manner fromacylinder to another, and is calculated, similarlyto theflow rate, in function of engineload (accelerator pedal
position, engine speedandintroduced air).
The advanceiscorrected asnecessary:
- duringacceleration
- basedonwater temperature
and to obtain:
- reduced emissions, noiseand overloading
- improved vehicleacceleration
Whenstarting, ahigh advance is set basedon water temperature.
The deliveredstartingmoment feed-backisprovided bytheinjector solenoidvalveimpedancevariation.
Engine speed regulator
The control unit controls theenginespeedat all speedsandinparticular:
- minimumspeed
- and maximumspeed
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Starting the engine
Duringthefirst enginemotoringover revolutions, cylinder N phaseand recognitionsignal synchronisation occurs 1(flywheel
sensorandcamshaft sensor).Whenstarting,theacceleratorpedal signal that arrivesviaCANisignored.Thediesel deliverywhen
startingisset exclusivelybasedonthewater temperaturebymeansofaspecificmap.Whenthecontrol unit detectsanumber
ofrevolutionsandaflywheel accelerationthatissuchtoconsider theengineasstartedandnolongerdrivenbythestartingmotor,
it engages theaccelerator pedal signal..
Cold start
Ifonlyoneofthethreetemperaturesensors(water, air or fuel) registersatemperaturelower than10
o
C,thepre-post hearing
isactivated.
Upon activation of thekeycontact, thepre-heatingwarninglight turns ontheelectric dashboard(cluster display) andremains
on for avariableamount of time dependingon thetemperature (whereas theresistance at the intake manifoldheats theair)
, then it flashes. At this point, theengine maybestarted.
Withenginerunning,thewarninglampswitchesoff, whiletheresistancegoesonbeingpoweredfor acertain (variable) period
of time carryingout thepost heating.
If,withwarninglampblinking,theengineisnot startedwithin20 25seconds(absencetime) theoperationiscanceledinorder
not to dischargethebatteries.
The preheatingcurveisalso variablebasedonthebatteryvoltage.
Hot start
If thetemperaturesof referenceall exceed10
o
C, upon activationof thekeycontact,theindicator lamp turnsonfor approx.
2 sec. for abrief test, and then turnsoff. At this point, the enginemaybestarted.
Run Up
Upon activation of the keycontact, thecentral unit transfersthe information stored duringthe last engine stop to the main
memory(see: After run), and carried out asystemdiagnosis.
After Run
Eachtimetheengineisturnedoffusingthekey,thecentral unit remainspoweredforafewsecondsthankstotheinternal MAIN
RELAY.
Thispermitsthemicroprocessorto transfersomedatafromthemainmemory(volatile) toanonvolatile,erasableandrewritable
memory(EEPROM), to makeit availablefor thenext start (see: Run Up).
The dataconsistsessentiallyof:
- varioussettings(engineidling, etc.)
- thecalibrationof somecomponents
- fault memory.
This procedure lasts afew seconds, typicallyfrom2 to 7 (dependingon the quantity of datato save), after which the ECU
deactivates themainpower supply.
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Ifthishappens,systemfunctionalityremainsguaranteedupuntil thefifthtimeit isturnedoffincorrectly(alsonotconsecutively)
afterwhichanerrorisstoredinthefailurememoryanduponthefollowingenginestartup,theenginewill functionwithdegraded
services whiletheEDC warninglight remains on.
Repeatedinterruptions of theprocedurecould in fact lead to central unit damage.
Cut-off
This function cuts off deliveryduringdeceleration, duringexhaust brake, etc.
Cyclinder Balancing
This function permits an individual andpersonalisedcontrol of thefuel flowrateand thedeliverystart for eachcylinder, in a
different manner fromcylinder to cylinder, to compensatefor thehydraulic injector tolerances
The fuel flow ratedifferencebycylinder isnot signalled bythecentral unit but bythe instrument IVECO - IRISBUS.
Synchronization Search
If thesensor signal doesnot arrive to thecamshaft, thecentral unit can still detect thecylinders into whichthefuel must be
injected.
Ifthisoccurswhentheengineisalreadyrunning,thecombustionsuccessionhasalreadybeenobtained,andthereforethecentral
unit continues with thesequence on which it isalreadysynchronised.
Ifthisoccurswhentheengineisstopped,thecentral unit energisesasinglesolenoidvalve. At thelatest bythe 2ndengineshaft
revolution, aninjection will occur inthat cylinder,for whichthecentral unit onlyhastosynchroniseitselfonthecombustion
sequence and start theengine..
To reducethenumber of connections, thelengthof the connection cables withtheinjectors andas aresult, disturbancesin
thetransmittedsignal,thecontrol unit isassembleddirectlyontheenginebymeansofaheat exchangerthat permit itscooling,
usingelectricdowelsthat reducethevibrations transmitted bytheengine.
The control unit is connected to the wiringthrough3 connectors.
- 8-.a coooocto '+' o t|o cooooots oo t|o Vo||c|o
- 36-.a coooocto '2' o t|o cooooots oo t|o |o|oo
- +6-.a coooocto '3' o t|o cooooct|oo to t|o |o,octos aoo o|aost ba'o so|ooo|o va|vo
Internally, thereisan ambient pressure sensor that is usedto additionallyimprove injectionsystemmanagement.
The control unit offers anon-boarddiagnosticsystemviaCAN:
- ODB(OnBoardDiagnostic)
- Cluster diagnosis.
It isalso equipped with averyadvancedself-diagnosis systemand it is capableof recognizingand memorizing, in function of
the environmental conditions, the possible anomalies, even of an intermittent type, that occurred on the systemduring
operation, ensuringamorecorrect and reliablerepair actionwith thehelpof the IVECO-IRISBUSdiagnostic instruments.
!
It isveryimportant that thisprocedureisnot interrupted,forexamplebyturningoff theenginefromthebatterycut-off
switch,or bydisconnectingthebatterycut-offswitchbeforeat least 10secondshavepassedtheenginewasturnedoff.
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Print 603.93.641/A Revi- June2007
Aquila Trucks Centres
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Base- November 2006
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Print603.93.641
EDC (ECM) SYSTEMS
EDC 7 UC31electroniccontrol unit
A. Injector connector - B. Chassis connector - C. Sensor connector
102373
Figure158
A C
B
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Electric injector connector 3 A
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M DARKBROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
Pin Description (F3B) Description (F2B)
Cablecolour
code
Pin Description(F3B) Description(F2B)
F3B F2B
1 - Cylinder 5pump injector - N
2 - Cylinder 6pump injector - N
3 Cylinder 4-5-6 pumpinjector shared cable Cylinder 4pump injector N N
4 - Cylinder 1 pump injector control - B
5 - Cylinder 3 pump injector control - V
6 Cylinder 2 pump injector control Cylinder 2pump injector B R
7 Engine brake control solenoid Engine brake control solenoid C C
8 Engine brake control solenoid Engine brake control solenoid M M
9 - - - -
10 - - - -
11 Cylinder 1-2-3 pumpinjector shared cable Cylinder 2 pump injector control R G
12 Cylinder 3 pump injector control Cylinder 3pump injector V R
13 Cylinder 1 pump injector control Cylinder 1pump injector B R
14 Cylinder 4 pump injector control Cylinder 4 pump injector control L L
15 Cylinder 6 pump injector control Cylinder 6 pump injector control H V
16 Cylinder 5 pump injector control Cylinder 5 pump injector control Z Z
16
12
6
1 5
11
102374
Figure159
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Sensor connector 2 C
Pin Description
Cablecolour
code
1 Variablegeometryturbinecontrol solenoid M
2 - -
3 Variablegeometryturbinecontrol solenoid N
4 8 - -
9 Earth for enginerpmsensor ontimingsystem(timingsensor) B
10 Engine rpmsignal on timingsystem(timingsensor) R
11 14 - -
15 Water temperaturesensor signal S
16 17 - -
18 Fuel temperaturesensor earth CN
19 Engine rpmsensor earth (flywheel sensor) N
20 Turbocharger speed sensor earth M
21 22 - -
23 Engine rpmsensor signal (flywheel sensor) B
24 Oil temperature/pressuresensor earth M
25 Air temperature/pressuresensor earth B
26 Water temperaturesensor earth G
27 Oil temperaturesensor signal CN
28 Oil pressuresensor signal L
29 - -
30 Turbocharger speed sensor signal B
31 - -
32 Oil temperature/pressuresensor power supply C
33 Air temperature/pressuresensor power supply R
34 Air pressuresensor signal V
35 Fuel temperaturesensor signal BR
36 Air temperature sensor signal C
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M DARKBROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
102375
Figure160 6 8 16 9 15 22
36 29 30 23 3 1
4
5
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Chassis connector 1 B
Pin Description
Cablecolour
code
1 - -
2 Control unit power supplypositive (+30) 7151
3 Control unit power supplypositive (+30) 7151
4 - -
5 Ground 0151
6 Ground 0151
7 - -
8 Control unit power supplypositive (+30) 7151
9 Control unit power supplypositive (+30) 7151
10 Ground 0151
11 Ground 0151
12 Groundenablingpreheatingactivation 0094
13 15 - -
16 Groundenablingengine fanactivation 0014
17 25 - -
26 Signal fromfuel air temperature sensor 5173
27 Signal fromcombustion air humiditysensor 5174
28 Groundfor combustionair humidityandtemperaturesensors 0173
29 GroundfromEDC systemdiagnosis request switch(wiring) 5163
30 - -
31 - -
32 Groundfromenginebaystart-up button 8892
33 Engine rpmsignal for bodybuilders (ST14B) 5587
34 Can- L line(ECB) Green
35 Can- H line (ECB) White
36 39 - -
40 Positive+15(fromIBC3) 8015
41 46 - -
47 Groundfromenginebayshut-down button 0151
48 54 - -
55 Positivefor enginebrakesolenoid (wiring) 9966
56 - -
57 Positiveenablingenginefan activation 5187
58 Groundfor engine brake solenoid (wiring) 0043
59 67 - -
68 Power for combustionair humidityandtemperaturesensors 8173
69 74 - -
75 Positiveenablingpreheatingactivation 9164
76 84 - -
85 GroundfromEDC systemdiagnosis request switch(wiring) 5163
86 88 - -
89 Kline(diagnosticconnector pin 2) 2298
35
89 72
53
18 36
17
54 6
11
71
1
7
12
102376
Figure161
Aquila Trucks Centres
Figure162 Figure163
A
B
C
113564
113565
PUMP INJECTORF3A / F3B(CURSOR 10 / 13)
1. Fuel/oil seal - 2. Fuel/diesel seal - 3. Fuel/exhaust gas seal
- A. Plunger - B. Nozzle- C. Solenoid valve
PUMPINJECTORF2B(CURSOR 8)
1. Fuel/oil seal - 2. Fuel/diesel seal - 3. Fuel/exhaust gas seal -
A. Plunger - B. Nozzle- C. Solenoidvalve
Revi- June2007
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SYSTEM COMPONENTS
Pump injector (78247)
It mainlyconsists of threecomponentsas follows:
A) Solenoid valve
B) Plunger unit
C) Sprayer
ThesethreepartsCANNOT bereplaced individuallyand areNOT subject to overhaul.
The pump is actuatedmechanicallyat each cycle byarocker armand compressesthe fuel containedinthepressurechamber.
Thesprayerfeaturesthesameassemblyandoperationasaconventional injector;it isopenedbythefuel underpressureandinjects
it finepulverized into the combustion chamber.
Anelectro valvecontrolleddirectlybytheelectronic center sets deliverymodalities based on thecontrol signal.
Aninjector holder houses thelower part of the pump injector in thecylinder head.
Aquila Trucks Centres
The electro valve is of theN.A. type.
Coil resistanceis ~0.56 0.57Ohm.
Maximumoperatingvoltageis ~12 15Amp.
Basedonvoltageabsorbedbytheelectro valve, theelectroniccenter canidentifywhether injectionwascorrect ormechanical
problems exist.
It can also detect injector errorsONLY withthe enginerunningor duringstarts.
Injectorsareconnectedto thecenterwithconnectorST - Emountedontheenginefront withatwistedcable,to avoidpossible
electromagneticinterference problems, so junctions or repairs on it must NOT be performed.
Figure164
Figure165
113566
113567
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ST-E CONNECTOR
Pin
F2B F3A / F3B
Pin
ST-E
Cable Function
Pin
ECU
Cable Function
Pin
ECU
1-A R Injector 1 supply A13 B Injector 1 control A13
2-B B Injector 1 control A6 G Injector 2 control A6
3-C R Injector 2 supply - - - -
4-D G Injector 2 control - - - -
5-E R Injector 3 supply A12 V Injector 3 control A12
6-F V Injector 3 control A11 R Injector 1/2/3 supply A11
7-G N Injector 4 supply A14 L Injector 4 control A14
8-H L Injector 4 control A16 Z Injector 5 control A16
9-I N IInjector 5 supply A8 M Engine brake control electro
valve
A8
10-L Z Injector 5 control A7 C Engine brake electro valve
supply
A7
11-M N IInjector 6 supply A15 H Injector 6 control A15
12-N H Injector 6 control A3 N Injector 4/5/6 supply A3
Figure166
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M DARKBROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
113569
Aquila Trucks Centres
TECHNICAL VIEW WIRING DIAGRAM
PERSPECTIVE VIEW
Figure167
Figure168
Figure169
106983 113561
113562
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Engine coolant temperature sensor (85153)
ThisN.T.C.typesensorlocatedonthewateroutlet sumpontheengineheadleft measurescoolant temperaturefor thevarious
operatinglogicswithahot or coldengine andidentifiesinjectionenrichment requirementsfor acoldengineor fuel reduction
requirements for ahot engine.
The coolant temperaturesignal is usedfor displayon theCluster and to control thefan.
It is connected to electroniccontrol unit pins C 15 / C 26
Sensor behavior as afunction of temperature:
- 10 C 8,10 10,77 kOhm
+20 C 2,28 2,72 kOhm
+80 C 0,29 0,364 kOhm
At 60to 90 _C, voltageat C 15andC 26ranges from0.6 to 2.4V.
Connector Function Cablecolour
2 To EDC center pin C 15
3 To EDC center pin C26
Aquila Trucks Centres
TECHNICAL VIEW
8528
WIRING DIAGRAM
PERSPECTIVE VIEW RESISTANCEBEHAV IOR
Figure170
Figure171
Figure172
Figure173
113561
113562
113562
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Fuel temperature sensor (47042)
Features
Supplier BOSCH
Maximumtorque 35Nm
ThisN.T.C.typesensorlocatedonthefuel filterontheengineleftsidedetectsfuel temperatureandenablestheelectroniccontrol
unit to measurefuel densityandvolumefor deliverycorrection.
Connector Function Cablecolour
2 To EDC center pin C18
3 To EDC center pin C35
Aquila Trucks Centres
HOLESON FLYWHEEL
TECHNICAL VIEW
WIRING DIAGRAM
PERSPECTIVE VIEW
8520
Figure174
Figure175
Figure176
Figure177
106984
106986
106985
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Flywheel pulse transmitter (48035)
Features
Supplier BOSCH
Torque 8 2 Nm
Resistance 880 920
This induction type sensor located ontheflywheel generates signalsobtainedfromthemagneticflow linesthat closethrough
54holes in threeseriesof 18 in theflywheel.
The electroniccontrol unit usesthissignal to detect thevariousengine ratings and pilot theelectronic revcounter.
The revcounter does not operate in theabsenceof this signal.
T||s sooso's a| a |s |CT /||ST/3||.
Connector Function Cablecolour
1 To EDC center pin C 23
2 To EDC center pin C 19
3 Shields
Aquila Trucks Centres
TECHNICAL VIEW
WIRING DIAGRAM
PERSPECTIVE VIEW
8520
REFERENCE ON SOUND WHEEL
Figure178
Figure179
Figure180
Figure181
106987
106988
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Camshaft pulse transmitter (48042)
Features
Supplier BOSCH
Torque 8 2 Nm
Resistance 880 920
Thisinductiontypesensor located onthecamshaft generatessignals obtainedfromthemagneticflow linesthat closethrough
the6 plus1 phaseteeth of aimpulsewheel mounted on theshaft.
The electronic control unit usesthesignal generated bythissensor as aninjection step signal.
Thoughelectricallyidentical to (48035) enginerpmsensormountedinthecamshaft inisNOTinterchangeablewithit asit cable
isshorter andit features alarger diameter.
T||s sooso's a| a |s |CT /||ST/3||.
Connector Function Cablecolour
1 To EDC center pin C 10
2 To EDC center pin C 9
3 Shields
Aquila Trucks Centres
A. Pre/ort reheat resistor / 0.7 Ohm
A
Figure182
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Pre-post reheat resistor (61121)
This resistor located betweenthecylinder headandtheintake duct is usedto heat air inpre/post reheat operations.
Byinsertingthe keyswitch, when even onlyone of the water, air or gas oil temperaturesensors recordless than10 _C, the
electroniccenter activatespre/post reheatingandswitchesonthewarninglight onthecabinstrument panel foravariableperiod
accordingto temperature, after which thelight starts blinkingto informthe operator that theenginecanbestarted.
Thewarninglight goesoff after enginestart but theresistor continuesbeingsuppliedfor avariableperiodoftime to complete
post reheating.
Theoperationiscancelledto prevent uselesslydischargingthebatteryiftheengineisnot startedwithin20/25secondswiththe
warninglight blinking.
Whenreference temperatureisabove10 _C, actuatingtheignition keymakes thewarninglight go onfor some 2 seconds to
completethe test and then turnsit of to indicatetheenginecanbestarted.
Aquila Trucks Centres
1. Servicereservoir - 2. Shut-off electro valve- 3. Air filter - 4. VGT electro valve- 5. Actuator position sensor -
6. Turbineactuator - 7. EDC center
Figure183
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VGT control card
Aquila Trucks Centres
71732
1. Intakeduct air delivery- 2. Compressor - 3. Air intake- 4. Actuator - 5. Exhaust gasspeedadjustment -
6. Exhaust gas intake - 7. Exhaust gas outlet - 8. Turbine
71734 71733
MINIMUM FLOW SECTION MAXIMUMFLOW S ECTION
1. Air deliveryto intake manifold- 2. Compressor - 3. Air intake- 4. Actuator - 5. Exhaust gasdeliveryadjustment ring-
6. Exhaust gas intake - 7. Exhaust gasoutlet - 8. Turbine
Figure184
Figure185
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Variable geometry Holset turbo compressor (series HY)
Aquila Trucks Centres
TheVGTvariablegeometryturbo compressor consistsofacentrifugal compressor andaturbineprovidedwithamobiledevice
that adjusts therate of exhaust gas to theturbinerate bychangingthegas passagecrosssection.
This solution enables keepinggas and turbine rates high even when theengineis operatingat lowrpm.
Makinggasses pass through areducedcrosssection in fact increases their rate so theturbinetoo rotates faster.
Movement of the exhaust gas intake cross section partialization deviceis obtained bymeans of amechanismcontrolled bya
compressedair actuator, whichis controlledbyaproportional electro valve.
The deviceisfullyclosed at lowrpm, whileat highenginerpmtheelectroniccontrol systemincreasescrosssection to enable
incominggasses to flowwithout increasingtheir speed.
A thoroidal chamber iscast into the central bodyfor coolant passage.
Exhaust gassection with engineunder load
Highenginerpm Averageengine
rpm
Lowengine rpm
Figure186
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Operatingprinciple
Aquila Trucks Centres
A. Actuator - B. Turbinerpmsensor - C. Turbo compressor - D. VGT actuator positionsensor -
E. VGT activator control electro valve
E
D
C
B
A
Figure187
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Engine components (VGT)
Aquila Trucks Centres
1. Air intake - 2. Washer - 3. Piston - 4. External spring- 5. Internal springcontrol disc - 6. Internal spring-
7. O-Ring- 8. Springholder - 9. Run end- 10. Dust cover - 11. Control rod
Operatingprinciple
Theactuator pistonconnectedtothecontrol rodispilotedthroughthe compressedair admittedfromair intake1onthetop
of theactuator.
Modulatingair pressurevaries piston and turbinecontrol rod movement.
During its movement, the piston progressivelycompresses external spring4 until the piston base reaches internal spring6
control disc 5.
Byfurther increasingpressure, thepiston compressestheinternal springthroughdisc 5until runend, which is reachedwhen
disc 5interferes withlower runend10.
Useof thetwosprings enableschangingtheratio betweenpressureand piston travel. About 85%of rodtravel is contrasted
bytheexternal spring, theremaining15%beingcontrasted bytheinternal one.
VGT control solenoid valve
This is anN.C. typeproportional solenoid valve mounted on theenginefront, behind the fan.
ThroughaPWMsignal,theelectroniccenterpilotsthiselectrovalvetoadjust turbineactuatorfeedpressure;actuatorposition
changes modifytheexhaust gasintake crosssection on thefanbladesandthusits speed.
The VGT electro valve is connected between electronic center pins C3/C1.
Coil resistanceis ~20 30Ohm.
1
2
3
4
5
6
7
8
9
10
11
Figure188
Figure189
106994
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Actuator
Aquila Trucks Centres
This is aninductivesensor positioned onthe impeller shaft.
It generates signalsobtainedfromthe magnetic flowlines, which closethroughanotchobtainedontheshaft itself.
Thesignal generatedbythissensor isusedbytheelectroniccontrol unit toverifythattheturbinerevsnumberdoesnot exceed
themaximumvalue.
To control therevsnumber, the control unit actsonvariablegeometry.
Iftherevsnumberkeepsonincreasinguntil it reachesexcessiver.p.m.values,theelectroniccontrol unit will detect ananomaly.
The gap of this sensor CANNOT BE ADJUSTED.
It is connected on electronic control unit pinsC30 / C20.
The sensor resistance value is 400 Ohm.
Wiringdiagram
Figure190
106996
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Turbine speed sensor (48043)
Aquila Trucks Centres
Linkingconnector
Sensor external view
Wiringdiagram
50324
Figure191
50323
Figure192
50344
Figure193
Air pressure/temperaturesensor (85156).
This component incorporates atemperaturesensor and a
pressure sensor.
IIt replaces the temperature sensors (85155) and pressure
sensors (85154) availableintheprecedingsystems.
It is fitted onto the intake manifold and measures the
maximumsuppliedair flowrateused to accuratelycalculate
theamount of fuel to beinjectedat everycycle.
The sensor ispowered with5 V.
The output voltage is proportional to the pressure or
temperature measured bythesensor.
Pin (EDC) 25/C - 33/C Power supply
Pin (EDC) 36/C Temperature
Pin (EDC) 34/C Pressure
Oil temperature/pressuresensor (42030 / 47032)
Thiscomponent isidentical totheairpressure/temperature
sensor andreplaced singlesensors 47032 / 42030.
It is fittedonto the engineoil filter, in ahorizontal position.
It measurestheengine oil temperature and pressure.
The measured signal is sent to theEDC control unit which
controls, inturn,theindicator instrument onthedashboard
(low pressurewarninglights / gauge).
Pin (EDC) 24/C - 32/C Power supply
Pin (EDC) 27/C Temperature
Pin (EDC) 28/C Pressure
Theengineoil temperatureisusedonlybytheEDC control
unit.
153 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Ref Description
Control unit pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 Temp. Sign. 27C 36C
3 +5 32C 33C
4 Press. Sign. 28C 34C
Aquila Trucks Centres
1. Pulley- 2. Support - 3. Disk with fins - 4. Fan- 5. Fanadapter- 6. Roundmagnets - 7. Floatingring- 8. 24Vcoil
The fanhasaneffectivespeed, called secondspeed, that is controlled bytheEDC control unit bycoil (8) excitation.
When coil (8) isde-energised, thefanisdriven bythefour magnets (6) at aspeed (called first speed) of about 450rpm.
The first speed is activatedwhen:
- Water temperatureis less than 93 C and theIntarder andtheair conditioner areoff, or
- Water temperatureis less than 85 C and theair conditioningsystemis onbut thecircuit pressureisbelow 22 bar, or
- Water temperatureis less than 85 C and theIntarder isonwithbraking power 41%lower than max. power.
The secondspeed isactivated when:
- Water temperaturereaches93 C withIntarder offor onwith brakingpower lessthan41%,second speedwill deactivate
whentemperaturedrops to 88 C, or
- Water temperature reaches 85 C with Intarder on andbrakingpower 41%higher than max. power or air conditioning
systemon and circuit pressureequal to 22 bar.
87169
Figure194
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Fan with electromagnetic joint (F2B)
Aquila Trucks Centres
Inthisconditionthefloatingring(1) isat rest,fanmovement isthereforeinducedbythe4magnets(2) keyedinto thesupport.
The first speedis thereforealways actuatedanddueto theeffect of the magneticfieldgenerated bythemagnets(2), thefan
can followtheoutput shaft speed up to450rpm.Higher output shaft speedswill produce aslippingbetweenthesupport (3)
and thekeyed disk (4).
87170
Figure195
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Print603.93.641
Fan at first speed position
Aquila Trucks Centres
Thesecond speedis activatedbythe EDC control unit that controls coil (1), themagnetic fieldgeneratedbythe coil attracts
thefloatingring(3) to thepulley (2), thus makingthemintegral.
Under thisconditionthefan speedis proportional to theoutput shaft speed.
87171
Figure196
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Fan with second speed on
Aquila Trucks Centres
1. Pulley- 2. Fanhub- 3. Permanent magnets - 4. Blades- 5. Fan- 6. Shaft - 7. Returnspring- 8. Piston -
9. Floatingring- 10. Air supplypipe- 11. Coil
The fanfeatures two possiblerotation speeds controlled bythe EDC center byexcitingthecompressed air electro valve for
slowspeed and bycoil (11) for second speed.
Whenneither lownor second speed is activated, thefanis drawn slowlybyfriction forces present (neutral position).
The parameters/systemsthat mayrequirefan action viatheBC center areasfollows:
- Coolant temperature
- Conditioningsystemcoolant pressure
- Intarder
Lowspeedisactivated when:
- Engine coolant temperaturereaches 80_C and theintarder is cut in at decelerationpower under 41%of maximum.
- Conditioner coolant pressurereaches 18bars.
Secondspeed isactivated when:
- Conditioner coolant pressurereaches 22bars.
- Engine coolant temperaturereaches 80_C and theintarder is cut in at decelerationpower over 41%of maximum.
- Engine coolant temperature is over 88 _C.
Whensecond speed activation isrequired, thesystempilots thefan for 5 seconds at lowspeed, thensecond speed iscut in.
This operatinglogic enablesincreasingbelt andfan component reliabilityin time.
Whenfanlowspeedremainscut infor over 1minute,thesystemactivatessecondspeeduntil control parametersreturnbelow
actionlimits.
1 2 3
4
5
6 7 8 9
10
11
Figure197
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Fan with electromagnetic junction(F3A - F3B)
Aquila Trucks Centres
Whenfanactionisnot requiredfor proper engineoperation, theEDC center pilotsthecompressedair electrovalveto move
piston(8), displaces permanent magnets (3) fromfan hub (2). Themagneticfieldgenerated bymagnets (3) is not enough to
move fanhub (2) byinduction.
The fanmayrotateslowlydueto friction present.
1 2 3
6 8
Figure198
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Fan cut out (neutral position)
Aquila Trucks Centres
Whenlowspeedactionisrequired,theEDCcenterdischargeairfromduct (10) throughthecompressedairelectro valve;piston
(8) movesanddraws permanent magnets(3) towards fanhub(2). Piston travel isensuredbyreturnspring(7) andblades(4).
Theshaft rotatesat thesamespeedas pulley (1) and theeffect ofthemagneticfield generatedbymagnets(3) is to makefan
hub (2) rotate at themaximumspeedof 650 rpm.
For F2Bthe first speed is always connected since thereare no pneumatic solenoid valve nor air exhaust systeminside the
assembly.
2 3
10
1 2 3
4
6 7 8
Figure199
107000
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Fan with first speed engaged
Aquila Trucks Centres
Whenlow speed is not enoughto properlycool theengine, theEDC center pilotssecondspeedcut-in byexcitingcoil (11).
The magnetic fieldgenerated bythe coil attracts fanhub(2) floatingring(9) to pulley(1) makingthe two unitssolidal.
Inthisconditionfan speedis the same as pulleyspeed.
1 2
9
11
Figure200
107001
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Fan with second speed cut it
Aquila Trucks Centres
Defect
The fanalways rotates at lowspeed
Defect identification
Cause
- Air supplypipeclogged
- Air supplypipebroken
- Center output does not pilot thecoil
- Interruptionof the center to coil wire
- Coils short-circuited
- Improper mechanical parts sliding
The fandoesnot rotateabove 650rpm(lowspeed)
The fanalways rotates at secondspeed - Thecenter output always pilotsthe coil
- Improper mechanical parts sliding
1. Enginebrakeswitch- 2. SteeringWheel Interface - 3. Instrument Cluster - 4. Conditioner - 5. BodyComputer -
6. Conditioner pressureswitches- 7. Fanelectro valve - 8. Fanelectro valve - 9. VCM- 10. EDC -
11. Water temperature sensor - * Thepressureswitches involvedin fancontrol are the (18-22bar) conditioner coolant
pressure warningones.
Figure201
113575
9
1
2
3
6
*
4 5
10 11
E.C.B
7
8
18BAR / 22BAR
*
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Fan control diagram
Aquila Trucks Centres
77469
Inrest conditions, gap X between pulley (1) andfloatingring(2) (subject to wear) must rangebetween0.5 and 1.2mm.
Wear upto maximumgap thicknessof 2.5mmis permitted.
Figure202
162 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Print603.93.641
lectric fan wear check
Aquila Trucks Centres
163 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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VCM (VEHICLE CONTROL MODULE) ELECTRONIC CONTROL UNIT
ThisElectronicControl Unit is interfaced withtheother on-boardelectronicsystemsthroughCAN lines:
- ECB- EngineControl Bus
- VDB- VehicleDataBus
- ICB- Instrument Cluster Bus
- FMB- FuhrparkManagemant Bus
AmongtheElectronic Control Unit input signalswefindthoseoftheaccelerator pedal sensor, deviator for signalling(ABS) stop,
switchonclutchandswitchfor Economyfunction, whichpreviouslywereconnectedto theEDC ElectronicControl Unit.
TheImmobilizer Elec. Cont. Unit is eliminatedandtheimmobilizer antennaisconnectedto theElec. Cont. Unit VCM.
TheVCMoperatesalso CruiseControl whichbeforewasconnected ontoBodyComputer.
VCM main functions
- Driveability: accelerator pedal control andgenerationoftorquerequirementsviaCAN towardstheengineaccordingtothe
driveabilitymaps, Requiredtorque=f (EngineSpeed, Accelerator Pedal Position).
- Arbitration of therequirements of TorqueandEngine Speed: fromexternal systems (Brakes, Transmission, Fitters, etc.)
towardstheengineduringthephasesof braking,changinggear,operationsinPTO mode,VCMdeterminestherequirement
withthehighest priorityandtransmits thecorrespondingrequirement of Torqueor EngineSpeedviaCAN to theengine.
- Speedlimiter: (main, programmableandsecondary) VCMdeterminestheextent oftherequirement oftorquetowardsthe
engineensuringthat theactive speedlimitsarenot exceeded.
- CruiseControl: VCMadjuststhevehiclespeedaccordingtotheset Cruisespeedbymodulatingtherequirement oftorque
transmitted viaCAN to theengine (torquelimitationor control), viatherequirement of turningontheexhaust brakeand
Intarder, integratingthecontrol functions of theconditions of engagement andrelease.
- AdaptiveCruiseControl:VCMreadsthedataoftheRadarrelatingtothedistanceoftheprecedingvehicle,adjuststhevehicle
speedaccordingto theset Cruisespeed, keepingthedistanceselectedbythedriver, modulatingtherequirement of torque
transmittedviaCANtotheengine(torquelimitationorcontrol),viatherequirementtoturnontheexhaustbrakeandIntarder,
integratingthefunctionsofcontrol oftheconditionsofengagement andreleaseand incaseof riskof collisionactivatingthe
conventional brakes(interactingwiththeEBSsystem).
- Engine starting / stoppingcontrol logic and associated safetydevices: requirement control fromcab, engine bay, fitter
connector.
- Power take off (PTO mode): management of the requirement to adjust engine speed viaCAN in accordance with the
conditionsrelatingtothePTO 0, 1, 2, 3 (pre-programmed) modes withactuationbytheengine.
- LowIdlecontrol logic: dynamic High Idlecontrol with requirement relatingto the engineviaCAN the VCM controls the
requirement for enginespeedadjustment viaCAN withactuation bytheengine.
- Exhaust Brakeactivation logic: control of driver requirements and arbitration of therequirements fromexternal systems
(Brakes, Transmission, Fitters, etc.), transmission of thevalueviaCAN andactuation bytheengine.
- Enginecoolingfanactivationlogic(Baruffaldi):management ofcontrol logic,transmissionof theactivationrequest viaCAN
and actuationbytheengine.
- ZFSimpleH Gearbox:gearboxcontrol withsolenoidactivationtopassfromlowrangeandhighrangeinconditionsofsafety
- ALLISON Gearbox: standardCAN interfacecontrol onlever side, external requirements (Fitters) and for displaylogic on
Instrument Panel.
- NewEUROTRONIC lever (used for ALLISON too): driver requirement control for sendingto EUROTRONIC gearbox
and recoveryin caseof breakdown.
- Vehiclesecuritysystem: Immobilizer
- CommunicationonCAN bus:Point-to-point communicationfromexternal busfordedicatedconnectiontoapparatusesof
Fleet Management inaccordancewithBus - FMS. Interfacefor connectionto Tester for diagnosisviaCAN of theon-board
systems.
- Others:InterfacetowardsInstrumentPanelondedicatedbus(ICBonHeavyRange) forinformation/ controlsto/ fromDriver.
HW signal generationfor fitter connector.
Aquila Trucks Centres
108925
Figure203
164 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Electronic Control Unit location
Pin - out
Connector X1
Pin Description
Cablecolor
code
1 Immobiliser aerial input signal -
2 - -
3 Immobiliser aerial output signal -
4 Positive+30(fromIBC3) 7993
5 Positive+15(fromIBC3) 8802
6 Ground 0000
7 Gearboxinneutral signal for bodybuilders(ST14A) 8050
8 Power to ACC (AdaptiveCruiseControl) distancerulereached indicator warninglight /
Positivefor splitter gear activationsolenoid (9 speedgearbox)
6179/9973
9 EDC systemfaultysignal for cluster 6150
10 Handbrakeengagedsignal for bodybuilders (ST14A) 6656
11 Power to ACC (AdaptiveCruiseControl) distancealarmbuzzer / Positivefor normal gear
activationsolenoid(9speed gearbox)
1166/9974
12 Clutchstatussignal for bodybuilders(ST14B) 9963
13 Brakelight signal for bodybuilders(ST14A) 1165
14 Signal indicatingprogrammablespeed threshold(PST) for bodybuilders (ST14B) 5542
15 Ground controllingstarter motor relay 0008
16 Positivecontrollingstarter motor relay 8888
Connector X2
Pin Description
Cablecolor
code
7 Positive5 Vfor distancecontrol with ACC (AdaptiveCruiseControl) at great distance 8179
8 Returnfromdistanceselector with ACC (AdaptiveCruiseControl) 6178
9 Ground cablefor ACC distancecontrol 0139
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165 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Pin - out
Connector X3
Pin Description
Cablecolor
code
1 CAN L line(VDB) White
2 CAN H line(VDB) Green
3 - -
4 Ground fromcoolant pressureindicator switch(22 bars) 0583
5 Ground fromcoolant pressureindicator switch(18 bars) 0582
6 - -
7 Control cablefor activatingACC 0179
8 Ground fromswitchindicatinggearboxinneutral 8050
9 - -
10 Ground fromenginebrakewiringswitch(associatedwithaccelerator pedal release) 0082
11 - -
12 Positivefromignitionkeyterminal 50 (ignitioncontrol) 8888
13 Secondspeed limiter engagement signal frombodybuilders(ST14B) 0172
14 Positivefrombrakeindicator switch (brakepedal pressed- mainbrakelights) 8153
15 Positivefrombrakeindicator switch(brakepedal released- secondarybrakelights) 8158
16 - -
17 Positivefor accelerator pedal sensor 5158
18 - -
19 CanH line(ECB) White
20 CanL line(ECB) Green
21 - -
22 - -
23 Ground fromswitch(N) for neutral positiongear withautomaticgearbox 0147
24 Ground fromswitch(D) for forward gearswithautomaticgearbox 0125
25 Ground fromswitch(D) for forward manoeuvregears withautomaticgearbox 0127
26 Enginestopsignal ( ST14A pin 2) 0151
27 Enginestart-up signal fromdiagnosticinterface/bodybuilders(ST14A) 8892
28 Ground fromstart-upenablement switch 8892
29 Signal fromcabreleaseindicator switch 0096
30 Ground fromCruiseControl cut-out switch (OFF) 8154
31 Ground fromCruiseControl resumeswitch(RESUME) 8155
32 Ground fromCruiseControl speedincreaseswitch(SET+) 8156
33 Ground fromCruiseControl speed decreaseswitch(SET-) 8157
34 Signal fromswitchindicatingengineidling 0159
35 Signal fromaccelerator pedal sensor 5157
36 - -
37 CAN H Line(FMB) White
38 CAN L Line(FMB) Green
39 - -
40 - -
41 Ground fromswitch(R) for reversegearswithautomaticgearbox 0126
42 Ground fromswitch(D) for reversemanoeuvre gearswithautomaticgearbox 0128
43 - -
44 - -
45 Ground for power take-off 3request frombodybuilders(ST14A) 0123
46 Ground for power take-off 2request frombodybuilders(ST14A) 0123
47 Ground for power take-off 1request frombodybuilders(ST14A) 0131
48 Ground fromsignallingswitchconnectionof slowgears(9gear changes) 0117
49 CruiseControl selectionsignal (INT / EXT) frombodybuilders(ST14A) 0158
50 Signal fromswitch(SL) for speedlimiter with automatic transmission 9968
51 Signal fromswitchonclutchfor VCM (clutchcylinder 20%compressed) 0160
52 Ground fromaccelerator pedal idle switch 0158
53 Ground for accelerator pedal sensor 0157
54 VCMcontrol unit Kline (diagnostic connector pin12) 2292
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166 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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IMMOBILIZER
Description and operation
Vehicles are provided with an immobilizer engine lock that is activated automaticallybyremovingthe starter key, to increase
protectionagainst theft. Keysareprovidedwithanelectronictransponder that transmitsacodedsignal to anICU centrethat only
enablesenginestart at coderecognition.
IMMOBILIZERcentral unit onEuro 4 vehicles isintegratedinto VCM.
Maintechnical features are:
D IMMO central unit integratedinto VCM
D Newkeys (colour BLUE)
D Min2 max7 programmablekeys
D Newantennaconnector
VCM/ Immobilizer procedures
Replacingakey
Addingakey
1) Cut thekeyinto based onexistingmechanical profile
2) Provideyourselfwith Code card
3) Go to environment ENGINE / VCM-IMMOBILIZER /
SPECIFIC FUNCTIONS/ KEY STORING
Replacingall keys
(loss)
CAUTION!
In this procedure, also add working remaining keys,
otherwisetheywill not be enabledanymore at start-up.
Orderthenewkeysandprogramthemasdescribedabove.
(Replacingor Addingakey)
ReplacingVCM-IMMOBILIZER
central unit
(NOT COMMUNICATINGWITH DIAGNOSISDEVICE)
1) ReplaceECMcentral unit.
2) Go to environment ENGINE \ ECM-EDC7 UC31 /
SPECIFIC FUNCTIONS / ACKNOWLEDGING NEW
ECM
(enter the electronic codethat is present oncodecard).
N.B:This operation is necessary to have the new ECM
central unit acknowledgethe VCM that is present on the
vehicle.
D IfoldVCMisoutoforderandisnot communicatingany
more, ECM must also be either replaced or re-pro-
grammed through remote services (Immo code er-
ased).
N.B:Onlyfor VCM5.4versions
D IfoldVCMisoutoforderandisnot communicatingany
morewiththeothervehiclecommunicationBUSes,the
emergencystartviaelectroniccodeinsertionisnot pos-
sible.
ReplacingVCM-IMMOBILIZER
central unit
(NOT COMMUNICATINGWITH DIAGNOSISDEVICE)
1) Cut thekeys intobasedon existingmechanical profile.
2) Performfollowingoperations:
a) Go to environment / ENGINE \ VCMIMMOBILIZER /
PROGRAMMING / OTHER / REPLACINGVCM
b) Go to environment ENGINE / VCM IMMOBILIZER /
SPECIFIC FUNCTIONS/ KEY STORING (2 newkeys)
c) Mount theoldVCMtomakeVCM / ECMdisconnection
(present 5.4 version)
d) Go to environment ENGINE / VCM IMMOBILIZER /
SPECIFIC FUNCTIONS / ACKNOWLEDGING NEW
VCM
e) Remount the new VCM and perform the start-up
operation.
Aquila Trucks Centres
108926
Figure204
EDC
3
4
6
7 8
2
1
5
167 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Componentry
Componentry
Ref. Description
1 Central unit VCM
2 Code-card
3 Electronickey
4 Antenna
5 EDC injectoncontrol eletronic centre
6 Electroinjectors
7 Indicator light EDC
8 IMMOBILIZERdownwarninglight
Aquila Trucks Centres
168 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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ABS-EBL ANTILOCK BRAKE SYSTEM - ELECTRONIC BRAKE LIMITER SYSTEM
T|o /3S |3| ba'|o ssto |s ava||ab|o as ao a|tooat|vo to t|o |3S ssto oo +2 o 62 vo||c|os.
ABS Anti Lock Brake System
Brakingamovingvehicleandisdecelerationandstoppingdistanceareessentiallydependant onadherencebetweentireandroad
surface. Improvedbrakingwith anefficient brakingsystemcanonlybeachieved byactingontirefrictionfeaturesor roadsurface
quality.
Improved brakingwith anefficient brakingsystemcanonlybeachieved byactingontirefrictionfeatures or roadsurfacequality.
Eveninoptimumconditions, absolutelysafebrakingisnot guaranteedwhencritical situationshaveto becopedwith,suchaslow
adherencedueonawet or icedroadsurface, whichobligesthevehicleoperator tomoderatebrakingactiontoprevent possible
wheel locksand consequent dangerouslossof vehiclecontrol.
TheABSthereforehasthefunctionof ensuringvehiclestabilityinanybrakingconditionbypreventingwheel locksindependently
of road surfaceconditionsand guaranteefull exploitationof availableadherence.
Inessence, theABSsystem:
- preventswheel locksduringvehicle brakinginand roadadherenceconditions
- reducesstopdistances
- offersoperator safetyfor stabilityandvehiclecontrol maintenance.
Electronic Brakes Limiter EBL
TheEBL function controls rear axle wheel skiddingbycomparingit with front wheel speed.
Dataenteringthecenter are wheel rpmandbrakingpressuremeasured by thepressuresensor installed upstreamtherear axle
ABSmodulators.
Thecenter usesthesedatatocalculatevehiclespeedanddeceleration, rear axlewheel skidandminimumdecelerationrequired.
TheEBL functionisactivatedwithrear ABSmodulatorsmaintainingset pressurewhentheoperatorsappliesexcessbrakingforce
thanrequiredfor vehicleloadconditions, inessence whenvehicledecelerationandrear axleskidthresholds are passed.
Aquila Trucks Centres
Brakingpressure
AXLE
Braking
action
Request for brakingintensity
Wheel speed
CENTER
OBJECTIVE
Skidding =0
Brakingpressure
REAR AXLE
Managesthebrakingsystembysettingdecelerationto theparametersmeasured bythevarious systemcomponents.
It communicateswithon-board electronic systemsviaaCAN lineandisconnected throughtwo polarized connectors.
Thoughofferingthepossibilityof ablinkcodedisplayedviatheASRwarninglight for preliminarydiagnosis, theelectroniccenter
is provided with anadvanced self-diagnosis systemcapable of identifyingand storinganyintermittent anomalyto an operating
systemsubject to environmental conditions, and ensuringproper and reliablerepair.
Figure205
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Operating logic
Theobjectiveoftheelectroniccenter istoslowdownthevehicleasfast aspossible, guaranteeitsstabilityandavoidthetendency
to lockwheels. Whenbraking, thecenter isinformedof thefollowingto reachtheseobjectives:
- brakingintensityrequired bytheoperator viatherear axlepressuresensor
- slowingreaction dueto pressuresmadeavailableviasignalsfromthespeedsensors.
Ongoingmonitoringandprocessingof thesedatareferredto theobjectiveset requiredactivationofrear axlemodulatingvalves
and consequent brakingoptimization.
ABS electronic center
Aquila Trucks Centres
X2 X1
Figure206
107017
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Pin out ABS center
Connector X1
Pin Description Cablecolor code
1 CAN L line(VDB) Green
2 Safetysignal sensor for maximumbrakingbridgewith axlefailurewith ABS 6245
3 CAN H line(VDB) White
4 Ground 0000
5 Ground fromswitchfor ABSexclusion 0049
6 Ground fromswitchASRexclusion 0048
7 Positive+15 8847
8 Positive+30 7710
9 Ground 0000
10 Kline(4-pindiagnosisconnector) 2299
11 - -
12 9/15-pinsafetybridge(onlywhenconnectedX1isnot connected) -
13 - -
14 - -
15 - -
Connector X2
Pin Description Cablecolor code
1 |os|t|vo '|V' (oo|oaooo)o|octo va|vo coaoo oot ||t .|oo| 9920
2 |os|t|vo '|V' (oo|oaooo)o|octo va|vo coaoo oot |ot .|oo| 9931
3 |os|t|vo '|V' (oo|oaooo)o|octo va|vo coaoo oot |ot .|oo| 9921
4 |os|t|vo '/V' (|oaooo)o|octo va|vo coaoo oot ||t .|oo| 9918
5 |os|t|vo '/V' (|oaooo)o|octo va|vo coaoo oot |ot .|oo| 9929
6 |os|t|vo '/V' (|oaooo) o|octo va| vo coaoo oot |ot .|oo| 9919
7 Ground for ASR electro valve 0260
8 |os|t|vo '|V' (oo|oaooo) o|octo va|vo coaoo oa ||t .|oo| 9930
9 |os|t|vo '/V' (|oaooo) o|octo va| vo coaoo oa ||t .|oo| 9928
10 ABSspeedsensor front right wheel 5571
11 ABSspeedsensor rear left wheel 5572
12 ABSspeedsensor front left wheel 5570
13 ABSspeedsensor front right wheel 5571
14 ABSspeedsensor rear left wheel 5572
15 ABSspeedsensor front left wheel 5570
16 PositiveASR electro command valve 9260
17 ABSspeedsensor rear right wheel 5573
18 ABSspeedsensor rear right wheel 5573
Aquila Trucks Centres
It consistsof adrier provided with afilter regeneration timer anda 4-wayprotectionvalveincorporatingapressurereducer.
Thepurposeof thedrier isto purifyand drycompressed air byadjustingsystempressureto itsratedvalue.
The4-wayprotectionvalvedistributesairconthevariouscircuitsensuringtheiroperatingpressureevenintheevent ofbreakdowns.
Thiscomponent isusedinall systemsand isratedat 10.5 +0.2 bars; for mobilebowl CMvehiclesettingis12.5+0.2bars.
TheAPU containstwosensors connectedto theMUX systemfor axlepressuredisplayonthe Cluster.
A.P.U. (Air processing unit)
Figure207
107020
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COMMON COMPONENTS
Pneumaticconnections Electric connections
11 - Fromair tankto trailer 6.1 - Positive Pressuresensor
21 - To automaticcouplingjoint 6.2 - Ground Pressure sensor
22 - To moderablecouplingjoint 6.3 - Signal Pressuresensor
42 - From(drive) CBU 6.4 - Positive Solenoid
3 - Exhaust 6.5 - NegativeSolenoid
Aquila Trucks Centres
Compressed air connections
1 - Power fromthecompressor
24 - PTO
25 - Output for 10.5bar compressedair suspension
23 - To thecompressor for EnergySaving control
3 - Ventingto outsideair
21 - To the10.5 bar axlereservoir
22 - To the10.5 bar axlereservoir
23 - To the8.5 bar parkingbrakemanual distributor andtrailer rechargeandparkingair reservoir
24 - To the8.5 bar servicereservoir
Drier electrical connections
6.1 - Negativefor thermostatic resistance
6.2 - Positivefor thermostaticresistance
4-way protection valve electrical connections
6.2 - Rear circuit air pressuresignal 5561
6.3 - Positive for power 5560
6.4 - Negative 0000
6.5 - Front circuit air pressuresignal 5562
6.6 - Positive for power 5560
6.7 - Negative 0000
TECHNICAL VIEW
WIRINGDIAGRAM
Figure208
107021
107022
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Aquila Trucks Centres
Thisnonself-limitedcoaxial component consistsofacompressedairandanelectrical section,theformerdistributingbrakingcontrol
pressureto thefront axle, therear axleand thetrailer control servodistributor.
Theelectrical sectionensuressendingthebrakingsignal to theEDC center and to thestoplight control relay.
Compressedair connections:
11 - Power fromthe axlereservoir
12 - Power fromthe axlereservoir
21 - Valveoutput to servo distributor relayvalve and
trailer control
22 - Valveoutput toaxlerelay
3 - Vent to outsideair
Electrical connections:
1 - Positivefor stoplights/EDC
2 - Input positive
3 - Positive for EDC
4 - Input positive
Figure209
Figure210
107024
107025
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Duplex distributor (ABS/EBL systems)
Aquila Trucks Centres
Thisnormallyopenelectro valveconsistsof apower coil and adischarge.
It isusedto modulatebrakingpressurewhenwheel tendencyto lockisdetectedbythe speedsensor.
VehicleswiththeEBSsystemfeaturetwo of themto control thefront axle.
Compressed air connections
1 Proportional relaypower
2 Axlebrakecylinder output
3 Discharge
PERSPECTIVEVIEW
WIRINGDIAGRAM
Figure211
107030
107031
107032
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Electro valve ABS78052
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175 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Electric connections
Wheel
Solenoid valvepin
ABS EBS
Wheel
Solenoid valvepin
78052
Cablecode ABSpin Cablecode EBSpin
Left-handfront
LHF
1
2
3
9919
0000
9921
X2/6
-
X2/3
9919
0122
9921
X4/10
X4/12
X4/11
Right-hand front
RHF
1
2
3
9918
0000
9920
X2/4
-
X2/1
9918
0118
9920
X3/1
X3/3
X3/2
Left-handrear
LHR
1
2
3
9929
0000
9931
X2/5
-
X2/2
-
-
-
-
-
-
Right-hand rear
RHR
1
2
3
9928
0000
9930
X2/9
-
X2/8
-
-
-
-
-
-
Aquila Trucks Centres
Sensors continuouslysupplytheelectroniccenter withall thedatait requiresto properlypilot theelectrovalves.
Signalsareobtainedfrommagneticflowlinesthatclosethroughtheteethofateethedwheel facingthesensorandrotatingtogether
withthewheel.
Passagefromfull toemptydueto the presenceorabsenceofthetoothcausessufficient magneticflowvariationto createinduced
electromagneticforceat sensor terminalsandthusan alternatingelectrical signal that issent totheelectroniccenter.
Theclearancebetweenthesensorandwheel, calledair gap,must obviouslybeat apre-set valueof 0.8 1.6mmforpropersignals
to besent. Resistanceof eachsensor at connection terminalsisbetween 1and2 k .
Thetoothedwheel iscalledphonicwheel becausethesignal it generateshasthesamefrequencyas asoundwave.
Thefrequencyof this signal serves to definewheel rotationspeed.
Frequencyvariations, or thespeedat which signalsfollow oneanother, defineaccelerationanddecelerationrates.
PHONIC WHEEL (A) AND SENSOR(B) PERSPECTIVEVIEWS
AIR GAP
A. Magneticflowlines
A
B
B
A
A
Figure212
107043
107044
107045
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Phonic wheel and speed sensor 88001
Aquila Trucks Centres
It warns thedriver, bythewarninglightsontheCLUSTER, of lowpressureinthefollowingsystems:
- Handbrake engaged- N.C. 6.6 0.2bars
- Lowtrailer pressurerecharge - N.C. 6.6 0.2bars
A normallyclosed6.6 0.2bar switchisalsomountedontheaxlereservoir toinformtheelectroniccenter of anyaxlecircuit low
pressuresoasto inhibit differentiated axlebrakingintheASR function.
Figure213
107046
107047
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Low pressure switch
Aquila Trucks Centres
178 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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ECAS SUSPENSIONS
Compressed air suspensions
Compressedairsuspensionsfeaturehighflexibility,highvibrationdampingandwithsystemself-adjustment constant frameto road
level clearanceindependentlyofvehicleload, that canbechangedaswell asvehicleloadheight withaspecial pushbuttonprovided
for thispurpose.
Inadditionto theknownadvantages offeredbycompressed air suspension, theECASsystemalso features:
- minimizedair consumption
- prompt responseto adjustment
- simplesystems
- topsafetylevel
- completesystemdiagnosis.
The ElectronicallyControlled Air Suspension ECAS systemprovides automatic vehicle compressed air suspension rated level
monitoring.
All theaboveoperationsaresubject tooperatingconditionsand connectedsystemsafetydevices.
The ECAS electronic provides automatic frame ground clearance control viathe real values supplied bythe sensors, which are
comparedwithstoredrateddata.Intheevent ofsettingdeviationsor variations,theelectroniccenter pilotstheelectro-pneumatic
unitsthrough whichit correctsreal levels versus thosestoredpreviouslybytheoperator.
Thesystemisprovidedwithremotecontrol forframelifting/loweringandlevelingandoperationsarepossiblebothwiththevehicle
stationaryandmoving.
Thisunit also enables other framesettinglevel storageandretrieval whenrequiredbyoperatingconditions.
Vehiclelifting, loweringandlevelingbeforeloadandunloadoperationsareviatheremotecontrol locatedontheoperator seat side.
Theremotecontrol canbeextracted fromits support so theseoperationscanalso beperformedfromgroundlevel.
Whenunloadingheavyloadsor containers withacrane, theframecanbeloweredcompletely.
Aquila Trucks Centres
74203
ECAS
B.C.
tachograph EBS
SWI
RFC
V.D.B.
I.C.B.
B.C.B. 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17 17a
18
19
20
21
22
Figure214
179 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Aquila Trucks Centres
180 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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Ref. Description Component code
1 Steeringwheel -
2 SteeringWheel Interface 86123
3 BodyComputer 86116
4 Cluster 50005
5 Rear FrameComputer 86118
6 Low pressuresensor 42200
7 Right rear axleslevel sensor 40046
8 Electronictachograph -
9 Right driveaxlesensor 42381/A
10 Left driveaxle sensor 42381/B
11 ECASelectroniccontrol unit 86023
12 Axlesolenoidvalveunit -
13 3
rd
axlecompressedair lift sensor 42389
14 Right 3
rd
axleair pressuresensor 42382/A
15 Left 3
rd
axleair pressuresensor 42382/B
16 Left axlelevel sensor 40046/B
17 Start support control switch 53030
17a 3
rd
axleleft switchremotecontrol 53309
18 Suspensionremotecontrol 85065
19 Axlelevel sensor 40046/A
20 Axlesolenoidvalveunit 78239
21 Diagnosis connector 72021
22 EBSelectroniccontrol unit 88005
Aquila Trucks Centres
ECASelectroniccontrol unit
73667
Figure215
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ECAS electronic control unit
Vendor WABCO
Voltage 18 30Vdc
Heat range -40to 75 _C
Aquila Trucks Centres
X1 X2
Figure216
107054
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Ecas control unit for air suspension system
Connector X1
Pin Description
Cablecolor
code
1 CAN L line(VDB) Green
2 Ground 0000
3 CAN H line(VDB) White
4 - -
5 Positivefor manual levellingkey(ST14 fitters connector) 8445
6 - -
7 Positive+30 7440
8 CLOCKlineonECASremote-control set 6402
9 Kline(14-pindiagnosisconnector) 2294
10 Positive+15 8810
11 Datalineon ECASremote-control set 6403
12 Ground 0000
13 Positivefor ECASremote-control set 8810
14 - -
15 Ground for ECASremote-control set 0050
16 - -
17 - -
18 - -
Connector X2
Pin Description
Cablecolor
code
1 Positivefor load pressure sensors onaxles(opt.) 8403
2 Loadpressuresensors onaxlessignal - right axle(opt.) 5443
3 - -
4 Positivefor rear axleelectro pneumaticdistributor 9400
5 Rear left axlelevel sensor signal (onlytruck) 5422
6 Loadpressuresensors onaxlessignal-left axle(opt. - onlytruck) 5444
7 Ground for load pressureonaxlessensors 0400
8 Rear right sensor level signal 5421
9 - -
10 Ground for electro pneumaticdistributor rear axleleft valvecommand(onlytruck) 9425
11 Ground for electro pneumaticdistributor rear axleload/unload valvecommand 9423
12 - -
13 Ground for electro pneumaticdistributor rear axleright valvecommand 9424
14 - -
15 - -
Aquila Trucks Centres
A
Figure217
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Electro-pneumatic axle distributor
|t coos|sts o t|oo cooto| o|oct o va|vos '/', '3' aoo 'C' aoo t|o sao oobo o coossoo a| o|st|botos.
||octo va|vo '/' aoaos t|o |oot/ootot o|st|boto.
||octo va|vo '3' aoaos t|o ||t ao sott|o o|st|boto.
||octo va|vo 'C' aoaos t|o |ot ao sott|o o|st|boto.
Theelectro-pneumaticdistributor isconnectedto thesystemviaa 4-poleconnector (A).
Ref. Description
1 ||octo va|vo '/' cooto| ooat|vo
2 ||octo va|vo '3' cooto| ooat|vo
3 ||octo va|vo 'C' cooto| ooat|vo
4 Commonpositive
Aquila Trucks Centres
EUROTRONIC AUTOMATIC TRANSMISSION
General
Thenewgenerationof AutomatedEuroTronictransmissionsisIV|CC's osooso to oo. Costoor expectationsandchanged
needs.Thedesignofgearshiftswithanewinspectedandtesttransmissiontechnologyconceptcombinedwithadvancedelectronics
hasgeneratedasystemthat guarantees:
- Economicefficiency
- Reliability
- Environmental acceptability
VIEW OF THEAUTOMATED EUROTRONIC TRANSMISSION
Thesemodernandcompletelyautomatedtransmissionsystemswithhighlyintegratedcomponentshavealreadybeendeveloped
for EDC M6.2center ELECTRONIC CONTROL DIESEL ENGINES.
Figure218
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Thesystemautomatesgear selection andmeshingbyautomaticallycontrollingtheclutchand engineduringgear shifting.
Theoperator decides whento shift gearsbyactuatingaselector lever withno needto releasetheaccelerator pedal.
Unlike previous versions, the Automated EuroTronic enables the operator to use COMPLETELY AUTOMATIC gear shifting
management.
Thesystemenablesautomaticvehiclestarandcompletelyeliminatestheclutchpedal.Onreceipt ofvehicleandoperatorsignals,
theelectronic center controls all components involved, optimizesmaneuversand managessafety.
PRODUCTIVITY Comfort Safety
Con-
sumption
Average com-
mercial speed
Maintenance
courses
Payload
Operatingcomfortandlessphysi-
cal andmental stress
Preciseandfast gear shifting
Optimizeduse
No useerrors
Selection of maximum rpmfor
enginebrakeuse
Reduced tare
Longerlinkagelinelife(theclutch
especially)
Noiseabatement (Db)
Automaticgear shifting
Design features
Theentiretransmissionshaft anduniversal joint assemblyisrelievedofconsiderableloadasgear shiftingoperationsandprocedures
areautomated. ThemainAutomated EuroTroniccountershaft gearboxconsistsof the following:
- A coupleof lowand high speedgears (SPLITTER)
- 4forwardspeeds+1reverse
TheauxiliaryboxconsistsofaG.R.E. epicyclical reductiongearmountedat thebacktodoublethenumber ofgear ratiosofthemain
gearboxand enable16forwardand 2reversespeeds.
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Description
AutomatedEuroTronicisacompletelyautomatic transmissionfeaturingaregulateddryclutchthat eliminatestheclutchpedal.
It consistsof areduced noiseemissionmaingearboxwithaplanetaryandsplit group.
Themainunit meshes withfront teethand onlytheplanetaryandsplit group aresynchronized.
The16-speedAutomated EuroTronicfeaturessixteenforwardand two reversespeeds.
TheInstrument clustersuppliedtheoperatorwithall necessarysysteminformation,suchasgearmeshed,disturbancesandthelike.
Theinsert moduleandtheclutchregulatorunitarethemostimportantstructural elementsforcompletetransmissionautomation.
Theformer consistsof thetransmissionelectronicsystem, switchingvalves, cylinder andsensors.
Thetransmissionelectronicsystemprocessesall input signalsandinsertsthespeedviatheelectromagneticvalveandtheswitching
cylinder.
Theclutchregulator isset electro-pneumaticallyandperformsall frictionactuationoperations. Inthemanual mode,theoperator
caneasilyselect speeds withthespeedselector lever.
Intheautomatic mode, theoperator onlyhas toactuatethe accelerator or brake pedal.
Speeds areselectedautomatically bythesystem.
To respect anti-pollutionregulations, all gears arehelical teeth, whichenabled abatingnoiselevel about 79 db.
Aquila Trucks Centres
8,5
1. Pressurelimiter valve- 2. Normal purge valve- 3. 10-l reservoir - 4. Air pressureswitch - 5. Pressurecontrol socket -
6. 5-l reservoir - 7. Distributor element - 8. Controlled pressurevalve- 9. Reservoir - 10. Normal purge valve- 11. APU Air
ProcessingUnit - 12. Compressor.
F=Clutch
C =Transmission
Figure219
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Transmission/clutch connection diagram with thecompressed air system
Aquila Trucks Centres
Figure220
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Displayon the Instrument Cluster
Theinformationrequired bytheoperator isdisplayedbythesystemontheInstrument Cluster central display.
Thesymbolsdisplayed bythesystemareasfollows:
Systemself-diagnosis Clutchoverload
Gear inneutral Duct disc wear
Acceleratorpedal pressedbeforeturningtheignition
key
Transmissioninthemanual mode
Slowreverseselected Transmissionintheautomaticmode,withcleardisplay
Transmissionwith theautomatic modepre-selected
but not activewithshadoweddisplay(movingat low
speed)
Fast reverseselected Speednumber selected(12
th
)
Low systemair pressure Transmissioninthemanual mode, lower speedsrec-
ommendedbythesystem
Recommended ratios (as many as 3) are displayed
withbars
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LIMP - HOME
TheLimpHomefunctionenablesremovingthevehiclewhenthesystempresentsseriousanomaliesitcannotmanageautomatically.
It cannot movethevehiclewhenpurelymechanical anomaliesarepresent. Theoperator canactivatetheLimpHomefunctionas
follows:
1. Keyswitchonstop
2. Keyswitchon+15
3. Pressthebluecolor pushbuttonon thegear shift lever within5seconds
4. Keep thebluecolor pushbuttonpressedfor at least 5 seconds.
Theoperator canselect thespeedat whichto start withgearshift lever, andcanselect asmanyas7speedsforwardand2reverse
withthe16speedtransmissionsand5and2respectivelywiththe12-speedone.Selectionismanagedbythesystemviaaninternal
delayreaction timeandnot through thespeedwithwhich thegearshift lever sensorsidentifylever movements.
Speedselectionmustbeslowtoallowthesystemtoimplement eachindividual speed,astheClusterdisplaysindividual speedswith
adelayof afewseconds.
Thespeedsthat can beset withtheLimpHomefunctioncanonlybeselectedwiththevehiclestationary.
After start speed selection, pressing the function push button for at least 2 seconds makes the systemcontrol timed clutch
engagement.
Toprevent theenginefromstopping, theclutchdisengagesautomaticallywhenthespeedoutput fromthetransmissionisbelow
areferencethreshold.Istheclutchsensorisnot operatingproperly,theclutchcanonlybeengaged/disengagedmanuallywiththe
Functionpush button.
The systemdisregards anygearshift lever movement duringvehicle movement. In particular, push button functionoperationis
excludedwhen enginerpmisover 950and reactivatedat under thisrating.
Clutchmanagement canthusalso bemanual withthefunctionpushbuttononthegearshift lever ofthebrakepedal whenengine
rpmisunder/equal to950.WhenthevehicleisstoppedwiththeLimpHomefunction,theclutchismanagedautomaticallyifpossible
or manuallyasdescribedabove.
Atvehiclestop,thesystemkeepstheLimpHomefunctionactivewiththestart speedset previouslyandthefunctionremainsactive
until systemRESET iscompleted.
Aquila Trucks Centres
1. Multi-functionlever - 2. SteeringWheel Interface - 3. Instrument Cluster - 4. PTO solenoidvalves- 5. DMI - 6. External
buzzer - 7. PTO onwarningswitches- 8. Reverselights - 9. Rear FrameComputer - 10. BodyComputer - 11. Door open
switch- 12. Switchesfor PTO1on request - 13. Switchesfor PTO2on request - 14. Tachograph- 15. Intarder Control Unit -
16. EBSControl Unit - 17. EDC Control Unit - 18. VCM- 19. Proportional solenoidvalve- 20. Water temperaturesensor -
21. Enginestop solenoidvalve - 22. Accelerator pedal - 23. ON/OFFsolenoid valve- 24. DuplexDistributor (brakepedal) -
25. VGT solenoid valve- 26. GearboxElectronic Control Unit - 27. Diagnosissocket
Figure221
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Eurotronic Automated transmission operation diagram
Aquila Trucks Centres
1.Clutchactuator -2.Tachographgearshift/transmissionoutgoingspeedsensor - 3.Gearshift/transmissionoutgoingspeedsensor
for sensor - 4. Gearshift idlingpositionsensor - 5.Framesidecentreconnector - 6.VehicleDataBusVDBCAN line - 7. System
internal CAN line- 8. Gearshift/transmissionelectroniccentre - 9. Gearshift/transmissionsidecentreconnector
Figure222
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Location of main components
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Figure223
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ELECTRONIC CONTROL UNIT
It isintegratedinto thegearshift actuator.
Automatictransmissionmanagement enablesautomatingspeedselectionandmeshingwithautomaticclutchandenginecontrol.
Itinterfaceswiththeotheron-boardelectronicsystemssuchastheEDC,EBS,INTARDERandInstrument ClusterviaaCAN V.D.B.
Vehicle DataBusline.
FromconnectionwiththeEDC systemthetransmissionelectroniccontrol unit candetectacceleratorpedal position, fuel delivery,
enginerpmandenginebrakeandkick-downactivation.
The control unit insidehousescontrol unit temperature, transmissionoil temperature and low air pressure sensors to improve
systemoperation.
FunctionAL isenabledat <5.8bar pressureanddisabledat>6bars. TheAutomatedEuroTronictransmissionelectroniccontrol
unit offers the possibilityof a Cluster displayed error code for preliminary diagnosis and is also provided with an advanced
self-diagnosissystemcapableof identifyingandstoringanyevenintermittent anomalydependent onenvironmental conditionthe
systemmayhaveencountered duringoperation, to ensuremorecorrect and reliable repair.
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Pin Cable Descriptionx1 Pin Cable Descriptionx2
1 8801 Power fromBodyComputer (J 3/6) 1
2 2297 Positive 30-pole connector for ground
diagnosis
2
3 Free 3
4 7101 Positivefromfuse70602/2(+30) 4
5 7101 Positivefromfuse70602/2(+30) 5
6 Free 6 Gearshift speedsensor mass(pin2)
7 Free 7 Signal electrovalveY17
(slowopening) (pin A)
8 WS/BI CAN VDBline 8 Signal electrovalveY16
(fast opening) (pinB)
9 Free 9 Signal electrovalveY15
(slowclosing) (pinE)
10 1101 Gearboxmalfunctionbeeper earth 10 Clutchpositionsensor analogicsignal
(pinF)
11 6100 Gearboxmalfunctionbeeper positive 11 Gearshift/transmissionoutgoingspeed
sensor signal (pin 4)
12 GN/VE CAN L VDBline 12 Signal electrovalveY14
(fast closing) (pin0)
13 13
14 14
15 15 Clutchpositionsensor power supply
(pin G)
16 0000 Negative 16 Y15 - Y17electro valvemass (pin3)
17 0000 Negative 17 Y14 - Y16electro valvemass (pinC)
18 18 Gearshift/transmission speed sensor
power supply(pin1)
19 19
20 20 Clutchpositionsensor mass(pinH)
CABSIDECONNECTOR(x1)
SENSORSIDE/CLUTCH ACTUATORCONNECTOR (x2)
Figure224
107076
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Theactuator cannot beoverhauled.
For actuator removal, transmissionmust beonNEUTRA.
Thetransmission neutral warningswitchislocated onthegearshift.
194 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
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TRANMSISSION ACTUATOR
Thetransmissionactuator ismountedonthetopofthemaingearbox.It consistsof aseriesofelectro valves, control cylinder and
sensors.Theelectroniccontrol unit powersthevariouselectrovalvestoselectedgear ratiosavailablebyusingsensorsignalsasa
feedback. Actuator operatingpressureis 7bars.
Actuator components
Y1 Inertiabrakes control electro valve
Y2 Fast Splitter control electro valve
Y3 SlowSplitter control electro valve
Y4 Speed selectioncontrol electro valve
Y5 Speed selectioncontrol electro valve
Y6 Gear meshingcontrol electro valve
Y7 Gear meshingcontrol electro valve
Y8 Downshiftedspeed epicyclical unit control electro valve
Y9 Normal speedepicyclical unit control electro valve
Y10Cmpressedair supplyelectrovalve
B2 Transmission input rpmsensor
B4 Selected speedsensor
B5 Selector positionsensor
B6 Normal anddownshiftedspeedepicyclical unit position sensor
B7 Splitter positionsensor
Electrovalvesareof theN.C. on/off typepoweredat 24Volt with~64.2 Ohmresistance at 20 C.
InductiontypetransmissioninputrpmsensorB2features~1Kohmresistanceandidentifiedrpmwitha40-teethsoundwheel.This
signal iscomparedwiththeenginerpmmeasuredbytheE.D.C.control unit;ifthetwovaluesareNOTidentical thetransmission
control unit isenabledto detect clutchslide.
InductiontypesensorsB4,B5,B6andB7,respectivelyselectorposition,epicyclical unitandsplitter,areanintegral partofthecontrol
cylinders andfeature ~69Ohmresistanceat 20 C.
Theautomaticsystempressuresensor located downstreamthe reduction gear isalso integratedinsidethe control unit.
Aquila Trucks Centres
VEHICLESIDE CONNECTOR TRANSMISSI ON SIDE CONNECTOR
Figure225
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LOCATION ON THE VEHICLE
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CLUTCH ACTUATOR
Theclutchactuator islocatedon thelower part oftheclutch bell.
|t coos|sts o oo o|octo va|vos, ao actoato c||ooo aoo a c|otc| oo os|t|oo sooso aoo |s so|tab|o to actoato +.5' s|o|o-o|sc
clutches viaa2.09ratio lever.
Intheloadmodeasdetectedbytheacceleratorpedal sensorsignal fromtheE.D.C.center,theelectroniccenterpowersthevarious
electro valvesfor slowor fast clutchengagement and release.
Thecenterusestheclutchrunpositionsensortocalculateclutchwear ateachvehiclestart,toenablefast approachesandovercome
emptyruns.
Actuator components
Y14- Fast clutch engagement electro valve
Y15- Slowclutchengagement electro valve
Y16- Fast clutch releaseelectro valve
Y17- Slowclutchreleaseelectro valve
S - Clutchrunposition sensor
T - Air vent cap
Actuator operatingpressure is11bars.
Internal channel diameters areas follows:
- 2.5mmfor fast engagement/release;
- 1.5mmfor slowengagement/release.
Actuationtimesat start, subject to load, slopeand accelerator pedal position, areasfollows:
- Initial engagement: ~1sec.
- Modulatedrelease: ~4 sec.
Thetimes changeas followsduringgear changes toenablefast andprecisesynchronization:
- Modulatedopening: ~0.6sec.
- Complete opening: ~0.3sec.
- Modulatedclosing: ~1sec.
Actuator features
- Operatingfluid: air (min. 6bar max 11.5bar)
- Power: 24Volt
- Loadonlever inoperatingconditions: 382 kg
- Operatingtemperature: 40 C +- 120 C
- Cylinder diameter: 100 mm
- Pistontravel: 70mm
Aquila Trucks Centres
Figure226
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Aquila Trucks Centres
91305
A. 20-poleconnector - B. Output transmissionrpmsensors
A
B
Figure227
Revi - March 2007
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Clutch actuator Pin-out
TheN.C. on/off typeelectro valvesarepowered at 24 Volt with ~14 20Ohmresistance.
Thesensor is powered bythecenter at 5Voltsandthereturnsignal isbetween0.5and 4.5Volt.
Theclutchactuator isconnectedto thesystemviaa20-poleconnector.
Pin Function
1 -
2 -
3 -
4 -
5 -
6 Transmissionspeedsensor mass (pin2)
7 Y17 electro valvesignal (slow opening)
8 Y16 electro valvesignal (fast opening)
9 Y15 electro valvesignal (slow closing)
10 Clutchpositionsensor analogicsignal
11 Transmissionoutput speedsensor signal (pin3)
12 Y14 electro valvesignal (fast closing)
13 -
14 -
15 Clutchpositionsensor power
16 Y15 - Y17electro valvemass
17 Y14 - Y16electro valvemass
18 Transmissionspeed sensor power (pin1)
19 -
20 Clutchpositionsensor mass
Aquila Trucks Centres
Figure228
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Accelerator pedal
Releasepedal NAintegratedintothepositionsensorisusedtodetectengineidlingpositionandenableclutchengagementatvehicle
start.
Thesignal reachestheVCMelectroniccenter viatheCAN VDBVehicleDataBaselineandissent totheAutomatedEuroTronic
transmissioncenter.
KickDownisactivated withtheaccelerator pedal inautomaticfunctionmodetravel. TheKickDownfunctionisactivated when
accelerator pedal lever (1) movethepotentiometertoposition100%,whichdoesnot correspondtopedal mechanical travel end.
Stiffenedtravel end isonlymechanical andisusedto transmit thefeelingKick Downinserted to theoperator.
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INTARDER
Operation
Theintarderisoperatedwiththe 7-positionsectorlocatedintheright directionindicator (1).INTARDERcut-inindicationisman-
agedbythe CLUSTER (2) viaaspecific warning.
ThesystemisprovidedwithaBrensomat constant velocityfunctionusedfor vehicleswithout EBS. Thisfunctionenableskeeping
avehicleonadownhill slopmovingatthespeedasselectedbytheoperator.Inthiscase,theintarderelectroniccentreautomatically
selectsthe brakingtorquerequired.
Theconstant velocityfunctionisonlyactivated|o os|t|oo '0' ato sto|o t|o sooo oos|oo.
Storagecanbeat anyofthe7selector positionsbybrieflypressingthepushbuttonprovided;withhigher pressurestoringspeed
at that moment andlowerpressuredecreaseofspeedset. Thespeedprogrammedpreviouslyisrestoredassoonastheselector
|s otoooo to os|t|oo '0'.
Pressingthepushbuttononceagaindisenablestheconstant velocityfunction.Theoil containedinthesumpissent totheintarder
hydrauliccircuit viaafilter and thecircuit isprotectedbyasafetyvalve.
Byactingonselector (1),electroniccentre(4) receivesviaSWI (3) anelectrical signal that it processesandsendsto electro valve
(7) controllingtheaccumulator and proportional electro valve(5).
Theaccumulatorcontrol electrovalveswitchesandletsairunderpressurepassthroughitspistontosendoil tothehydrauliccircuit
and reduceactiontime.
Theproportional electrovalveactsonthecontrol valvetoset itspressure.Theadjustment valveispilotedbycontrol valveoil pres-
sure.Therotorisconnectedtotherearaxleviathetransmissionshaftandthestator isconnectedtotheframethroughtheintarder
case.
Theoil contained in theareas between therotor andthestator is movedbytherotor blades to createaclosed circuit oil flow
between mobileandfixedparts.
Byimpactingthestator blades, oil causesrotor andthereforevehiclebraking. Reducedoil flowspeedbetweentherotorand the
stator transformskineticenergyintoheat,todissipatewhichoil passesthroughanoil/waterheatexchanger,whereoil heat istrans-
mitted tocoolingwater anddissipated throughthevehiclecoolingsystem.
Theheat exchangerwaterdischargepipeisprovidedwithatemperature sensor (6) that continuallysendscoolingwatertempera-
turedatato theelectroniccentreto ensuremaximumtemperatureallowed for proper engine operationis not exceeded.
If water temperature risesto reach the safetylimit for anyreason whatsoever, thecentre pilotssump control air adjustment to
reducebrakingtorque.
Theelectroniccentre receivesasignal fromtheABS/EBSsystemthat causesintarder cutout whenactuatedand it also receives
asignal fromelectronictachograph (8) enablingconstant velocityfunctionuse. This signal is sent viaaVDBcanline.
S.|tc||o to os|t|oo '0' cots t|o |otaoo o aoo ooact|vatos t|o oot|ooa| aoo accoo|ato cooto| o|octo va|vos.
Aquila Trucks Centres
1. Engine brake/Intarder selector - 2. Instrument Cluster - 3. SteeringWheel Interfacecentre -
4. Intarder electroniccentre - 5. Proportional electro valve - 6. Water temperaturesensor -
7. Accumulator on/off control electro valve - 8. Electronictachograph
Figure229
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Figure230
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Hydraulic system diagram
Description
Theoil containedinthesumpissent totheintarderhydrauliccircuit byapumpthroughafilteranda12.5barpressurelimitervalve.
Intarder on
Whentheintarderisactuatedwithcontrol (2), thecentresupplieselectrovalve(19) controllingaccumulator (10), whosepiston
ispiloted bytheserviceair systemat 9.5 bar pressureto sendoil faster to therotor/stator unit.
Whenexcited,proportional electrovalve(16) actsonvalve(16) bymovingitshydraulicspool andmovesfunctioncontrol pressure
to brakinglevel.
Pressureactsonadjustment valve (14), to createcommunication betweeninput duct Pand output ducts P 1- R.
Thus, oil frompressurelimiter electrovalve(4) movesthehydraulicspool ofvalve(8) andputsduct R
1
0intocommunicationwith
the motor/stator viaheat exchanger (9).
Pressure(13) isnot affectedbyoil pressureandclosesoil dischargeinto sump (7).
Aquila Trucks Centres
Figure231
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Speed storage and use
ByinsertingCruiseControl,thesystemautomaticallymaintainsvehicleadvancespeedwithout havingtousetheacceleratorpedal.
If vehiclespeed increasesover 2 Km/h morethan thespeed set, suchaswhentravellingdownhill for instance, theenginebrake
isactivatedautomaticallytoslowthevehicledownandmaintainthespeedreached.Theintarder isalsoactivatedifspeedincreases
byover 3 Km/h.
Itsfunctioncanonlybeactivatedwhenthefollowingconditionsaresatisfied:
- enginebrake/intarder lever cut out;
- vehicleon themovewith gear selected;
- vehiclespeed over 20Km/h;
- brakepedal released;
- clutch pedal released.
Control Vehiclespeed adjustment
ON+ Speedincrease
ON- Speeddecrease
RESUME Last storedspeed selection
OFF Speedadjustment cancellation
Adjustment iscut out whenthebrake orclutchpedal isactuated.Thesameapplieswhentheminimumspeed set isnot reached.
Topspeed is stored intheprogramme insidetheelectroniccontrol moduleandcannot bechanged.
1 Basculatingpushbutton ON hasthefollowingfunctions:
a)when pressedonce, it activatesthe functionandkeepsthespeedset at that moment bytheaccelerator pedal.
Theaccelerator pedal canthenbereleased andthevehiclekeepsmovingat thecruise speedset.
b)withthefunctionalreadyactivated, it increasesvehiclespeedwithout havingto usetheaccelerator pedal.
2 Basculatingpushbutton ON hasthe followingfunction: withthefunctionactivated, it decreasesvehiclespeed.
3 TheCruiseControl lever actuatedOFFtowards thesteeringwheel deactivatesthefunction(CC displayshaded).
4 Actuatingthesteeringwheel lever onceagain(RESUME) thevaluestored is reactivated(CC displayclear).
Aquila Trucks Centres
1. Instrument Cluster - 2. SteeringWheel Interface- 3. Engine brakeonmulti functionlever - 4. BodyComputer -
5. Tachograph- 6. EDC centre- 7. VCMcentre- 8. EBScentre- 9. EuroTroniccentre - 10. Intarder centre -
11. Diagnosisconnection- 12. Enginebrakeelectro valve - 13. VGT electro valve- 14. Accelerator pedal -
15. Brakepedal Duplexdistributor - 16. Proportional electro valve - 17. ON-OFFelectro valve-
18. Water temperaturesensor
Figure232
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Assembly
Aquila Trucks Centres
73667
A. Intarder control unit
A
Figure233
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Control unit disposition
Pin Cable Function
1 9311 Oil accumulator solenoid valvepositive
3 0310 Proportional solenoidvalvenegative
4 9310 Proportional solenoidvalvepositive
8 5541 Cluster
9 5309 Water temperaturetransmitter positive
12 3393 30-polediagnosisconnection (pin 20)
14 2293 30-polediagnosis connection (Kline - Pin6)
22 CAN VDB(H) line
27 0000 Cabmass
28 0000 Cabmass
34 0311 Oil accumulator solenoid valvenegative
37 0309 Water temperaturetransmitter negative
49 CAN VDB(L) line
53 8300 +15power supply
54 7300 +30power supply
Aquila Trucks Centres
Figure234
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EM (EXPANSION MODULE) ELECTRONIC CONTROL UNIT (PTO)
The EM(Expansion Module) control unit locatedinthecabinconto| oo|t coatoot (assooo's s|oo) cooto|s t|o o.o
takeoffsand, unliketheDMI, makesit possibleto carryout complicated applicationssuchas:
- transmission(gearbox) control fromexternal source(TCI message)
- enginecontrol fromexternal sources,likerequest andlimitationofenginerevnumber,vehiclespeedlimit, start upandengine
stop
- safetylogicsfor wastecollectionapplications
- optimizationof brakingsystemfor wastecollectionapplications
- additional headlight control
- interfacewith CAN_opennetwork
Aquila Trucks Centres
207 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
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Pin - out
Connector XI
Pin Description Cablecolour code
1 PTO1 solenoidvalve power supply 9131
2 Positive+30 7772
3 Signal for operators (72072B- pin 6) 6985
4 PTO2 solenoidvalve power supply 9132
5 Earth 0000
6 PTO3 solenoidvalve power supply 9132
7 Clutchsolenoidvalvesignal (72072A - pin4) 9995
8 Signal for operators (72072B- pin 7) 6986
9 Positive+30 7166
Connector X3
Pin Description Cablecolour code
1 CAN - H line(VDB) Sw/Bi
2 CAN - L line(VDB) Gn/Ve
3 Free -
4 LineK (diagnosisconnector pin6) 2996
5 PTO1 request 0131
6 PTO2 request 0132
7 PTO3 request 0123
8 Signal of PTO1engaged 6131
9 Signal of PTO2engaged 6132
10 Signal of PTO3engaged 6133
11 PTO1 consensussignal 0391
12 PTO2 consensussignal 0392
13 Positive+15 8166
14 Free -
15 Free -
16 PTO3 consensussignal 0393
17 Signal fromoperators(72072A - pin 3) 0991
18 Signal fromoperators(72072A - pin 1) 0992
19 Signal fromoperators(72072A - pin 2) 0993
20 Signal fromoperators(72072B- pin3) 0994
21 Signal fromoperators(72072B- pin4) 0995
22 Pin24 jumper 8990
23 Pin26 jumper 0990
24 Pin22 jumper 8990
25 Free -
26 Pin23 jumper 0990
Aquila Trucks Centres
208 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
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Connector X4
Pin Description Cablecolour code
1 Signal for operators (72072B- pin 8) 6987
2 Signal for operators (72072B- pin 9) 6988
3 Signal for operators (72072B- pin 10) 6989
4 Parkingbrakesignal (72072A - pin1) 6981
5 Neutral gear signal (72072A - pin2) 6983
6 Signal fromoperators(72072B- pin5) 0996
7 Free -
8 Free -
9 Signal fromoperators(72072C / 72072D - pin5) 0999
10 Free -
11 Free -
12 LineCAN - H (SB) - (trailer) Ws/Bi
13 LineCAN - L (SB) - (trailer) Gn/Ve
14 - 5981
15 - 5982
16 - 5991
17 LineCAN - H (SB) Ws/Bi
18 LineCAN - H (SB) Ws/Bi
19 LineCAN - L (SB) Gn/Ve
20 LineCAN - L (SB) Gn/Ve
21 Signal for operators (72072B- pin 11) 6990
22 Signal for operators (72072B- pin 12) 6991
23 Signal for operators (72072B- pin 13) 6992
24 Free -
25 Free -
26 Free -
27 Free -
28 Signal fromoperators(72072C / 72072D - pin3) 0975
29 Signal fromoperators(72072B- pin18) 5983
30 Free -
31 Signal for operators (72072B- pin 14) 6993
32 Signal for operators (72072B- pin 15) 6994
33 Free -
34 Free -
35 Free -
36 Free -
37 Free -
38 Signal fromoperators(72072B- pin20) 5992
39 Free -
40 Free -
Aquila Trucks Centres
1
2 3
4
5
6
73668B
Figure235
209 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
Print 603.93.641
AUTOMATIC AIR CONDITIONER
Inautomaticversionthesystemismanaged byanelectronicunitplacedinthelowerpartofcentral dashboardandintegratescontrol
knobs.
Theelectronicunit isconnectedto vehicleCAN BCB lineandisequipped withaveryadvanceddiagnosticsystem.
Themainobjectiveoftheunit isadjustinginternal cabintemperature (set bythedriver) dependingonexternal temperaturemea-
suredbyasuitablesensor.
Thesystem provides for thechanceof acompletelyautomaticmanagement, but anywayfor theuser it isalwayspossible, if he
so wishes, to modifythemainsystemoperatingparameters.
1. Requiredtemperatureadjustingknob
2. Fan speedadjustingknob
3. Air flow distribution knob
4. Recirculationfunctionbutton withembedded led
5. Compressor control button with embedded led
6. Internal temperaturesensor
After havingset thedesiredinternal temperature,byplacingtheothertwoknobsnext toletter A, theunit isabletoautomatically
checkthefollowingfunctions:
- Air temperatureto unions.
- Fanspeed
- Air flowsdistribution
- Supplementaryheater connectionif external temperatureis<5 C.
Inthispositiontheunit doesNOT automaticallyactivateeithercompressor orrecirculationfunction:connectionofbothofthem
ismanuallymanagedbythedriver.
RECIRCULATION FUNCTION
Connectionofthisfunctioniscompletelymanual andisobtainedthroughasuitablebuttonthatallowsclosingtheexternal airintake
byplacingthebaffleat 95%ofinternal air and 5%of external air.
Theunit automaticallydeactivatesthisfunctionafter about 20minutesif thecompressor isdisconnectedand after 30minutesis
thecompressor is connected.
COMPRESSOR CONTROL FUNCTION
Connectionofthisfunctioniscompletelymanual andisobtainedthroughasuitablebuttonthat allows connectingthecompressor
clutch after aqualitycheckof fluidinthesystemthroughsafetypressureswitches andevaporator temperaturebymeansofthe
suitablesensor.
The unit doesNOT automaticallyconnect thecompressor.
SUPPLEMENTARY HEATER CONTROL FUNCTION
WithmovingenginetheunitautomaticallyconnectsthesupplementaryAIRand/orWATER heateronlyiftheexternaltemperature
is<5 _C.
\|t| o oo|oo t|o |oato cooooct| oo ooooos oo o|vo's sott|o.
Inbothcases, thesupplementaryheater connection is signalledto thedriver onCluster display.
Aquila Trucks Centres
91304
42045. Water temperaturetransmitter - 82000. Windscreen electricdefroster assembly- 82010. Air conditioner control
electronicunit - 86030. Sun radiation measuringsensor - 84009. Ventedinternal temperaturemeasuringsensor -
84009B. Inner temperaturedetectionsensor - 42608. Coolingliquidpressuresignalingpressureswitches -
25332. Compressor connectionremotecontrol switch- 78227. 3-waysolenoidvalvefor radiator water recirculation -
84019. Compressor
Components82010- 82000areplaced inthesamecontrol assembly.
18 22 2 ,5 25
Figure236
210 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
Print 603.93.641
AUTOMATIC AIR CONDITIONER
Automatic air conditioner block diagram
Aquila Trucks Centres
77561
42045. External temperaturetransmitter - 82000. Windshielddefroster unit - 82010. Conditioner electronic control centre-
86030. Sun raydetectionsensor - 84009. Internal temperaturedetectionsensor - 42608. Coolant pressurewarningpressure
switches - 25332. Compressor onremotecontrol switch- 78227. Radiator coolant recirculation electro valve -
84019. Compressor - 86116. BodyComputer - 72021. 30-poleconnector for diagnosis
Condenser
Drier filter
86116
82000
82010 72021
86030
42608
42045
78227
84009
84019
Figure237
211 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
Print 603.93.641
Component location
Aquila Trucks Centres
77562
A. Floor reductiongear - B. Windshield defrost reduction gear motor - C. Recirculationreduction gear motor - D. Mixing
reduction gear motor - E. Blowntemperaturesensor - F. Evaporator temperaturesensor - G. Blower control module -
H. Expansionvalve
A
B C D E F G
E
E
G
F
C
A
B
D
A
H
Figure238
212 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
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Windscreen electric defroster assembly components location
Aquila Trucks Centres
77566
77567
Locatedonthedriversidevehiclefront soit isinvestedbyexternal temperature, ascloseaspossibleto reality. Itsresistanceat
25 C =~10 Kohm
Main interior temperature sensor
Locatedontheright insidethecontrol moduleandventilatedbyamotorenablingaircirculationandpreventingerroneoustem-
peraturereadingsbetweenvaluesmeasured andthecab. Its resistanceat 25 C =~10 Kohm
A) Motor
B) Fan
C) Sensor
Figure239
Figure240
213 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
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External temperature sensor
Aquila Trucks Centres
77559
77574
Thesensor placedinsidetheevaporator generates compressor connectionanddisconnection.
Disconnectionto avoid dispenser freezingoccursat atemperature <2 C, while connection at atemperature >5.5 C. Its
resistanceat 25 C =~3.28 Kohm
Blown air temperature sensor
Locateddownstreamtheheat exchanger, it givesthetemperatureofair inlet intothecabandenablesthecentreto adjust more
properly. Itsresistanceat 25 C =~10 Kohm
A) Sensor
Figure241
Figure242
214 TRAKKER EURO 4/5 ELECTRIC/ELECTRONIC SYSTEM
Base- November 2006
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Evaporator temperature sensor
Aquila Trucks Centres
77563
77565
It is aphotodiodeplacedon vehicle dashboard to point out luminous intensitythat thecabin receives fromoutside.
A) Sensor
77564
Figure243
Figure244
215 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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Print603.93.641
Sun raysensor
Aquila Trucks Centres
77571
77573
77572
Figure245
Ifasteppermotorisreplaced,it isMANDATORYtocarryoutthesystemRESET bydisconnectingandreconnecting
vehiclebatteries.
NOTE
216 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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Reduction gear motors
The four automaticsystemunitsare locatedintheheater/conditioner insidethecab, accordingto their functions.
Their electrical featuresarethesame.
Theyareactivated directlybytheelectroniccentreat 24 V ratedvoltage and absorbfrom20to 40 mA.
Motor resistance=~112 Ohm.
Maximumabsorption at travel end is 200mA, when the centrecuts supplyoff.
Their potentiometer is usedas areturn signal and when first lit, the centredetects and stores end travel values to divide the
operatingfield. It issuppliedat 5V, its resistance =~5 Kohm.
Pin-out
Pin Cablecolour
1 White +/- 24V
2 Violet +/- 24V
3 Blue 0V
4 Orange 0 5V
5 Green +5V
6 - Free
Aquila Trucks Centres
74244
A. Blower control module
A
Figure246
217 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
Print 603.93.641
Blower control module
Thiselectroniccircuit locatedintheheater/conditionerunit adjustsdoublefanradial blowerspeedwithsome200different rates
intheautomaticmodeand 8 in the manual mode.
The moduleis driven bytheunit with asignal from0to 5Volts whilefans with avoltagefrom0to 24 Volts.
Pin Cable Function
1 0000 Negativedirect from
thebattery
2 7555 Centrecontrol posi-
tive
3 7551 Positivedirect from
thebattery
Aquila Trucks Centres
77569 77568
77570
Figure247
218 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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Solenoid valve (3 ways)
This one-directional NA unit issuppliedbyabattery-directed positive.
The electronic centreadjusts its dutycyclebysupplyingamass.
This three-wayvalveperformsall dosingand by-passfunctions.
It is suppliedbyabattery-directed positive and is pilotedbythe negativesupplied bythecentre monitoringthe dutycycle.
Aquila Trucks Centres
106393
Figure248
219 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
Print 603.93.641
Compressor
NIPPODENSO
ND 10 PA 17
Coolant R134a
Lubeoil ND80
Quantityof coolant 700g
Quantityof oil 200cc.
R134acoolant is anyhow exclusivelyused in theSTRALISrange
Aquila Trucks Centres
74245
74247 77560
Figure249
220 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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Drier filter and safetypressure switches
The drier filter is integral with the condenser locatedonthevehiclefront.
The coolingsystemuses R134acoolant asspecifiedon itscover plate.
The 4-level safetypressureswitch unit is installed on thecondenser return line.
Thetwo typeNC andNA pressureswitcheskeepsystempressureconstant fromaminimumof 2.5(for theNA) toamaximum
of 25 bars(for the NC). Thesystemis cut off whenvaluesare outsidethis range.
ThetwoNA pressureswitchesareto cutout theenginecoolingfancoil whensystempressureisbetween18 and22bars.This
isachievedbymeans of amass signal the two switches transmit to theBodyComputer control centre.
Aquila Trucks Centres
74238
77575
CONDENSER EVAPORATOR
Figure250
221 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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Expansion valve
Itsfunctionisto lower liquidpressurefromthecondenser to apreset valueso bycirculatinginsidetheevaporator thecoolant
canbesucked asagasbythe compressor.
It thus completesthreebasic functions:
D DOSING
D MODULATING
D MONITORING
It is installedontheheater/conditioner unit closeto theblower control module.
Aquila Trucks Centres
77565
1
2
3
7
6
5
4
Figure251
222 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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The expansion valveis of theuniontypeandisplaced betweendrier filter and evaporator.
Itstaskischeckingandbatchingthecoolingfluidflowinorder to obtain themaximumrefrigeratingpower fromthesystemand
to lowerthecoolingliquidpressure(uponexitingthefilter) toapre-establishedvalue, sothat thefluiditself,bythencirculating
into the evaporator, can besucked bythecompressor inacompletelygaseous state.
Inthisvalve therearetwo coolingfluidpassages:
D Theloweronethat allows thecoolingfluidtopassfromdrierfilter (5) toevaporator (2).Alongthispathaspring(4) isplaced
that, suitablycalibrated, allows obtainingsuch atemperature jump (overheating) asto ensurethat thecoolingfluid, upon
entrytheevaporator, is completelyin agaseous state. Moreover thereis also amodulating element, in this case aball (3)
housed in the calibratedduct, that checksthecoolingfluid flowrateto theevaporator.
D Theupper onethat allows the coolingfluid to passfrom evaporator (1) tocompressor (6). Alongthispath instead there
isatemperaturesensor(7)that,dependingonthetemperatureuponexitingtheevaporator,allowsobtainingacontrolaction
on thecoolingfluid flowrate, through themodulatingandoverheatingcheckingelement (3), through thespring(4).
Aquila Trucks Centres
223 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Conditioner control unit
Pin Cable Function
1 - -
2 7550 Positivedirect fromthebattery
3 - -
4 2296 Klinefor diagnosis
5 Ws/Bi CAN - H (BCB) line
6 9993 Outgoingpositivecompressor electromagneticclutch signal
7 7568 Mixer reduction gear motor power supply
8 7566 Recirculationreduction gear motor power supply
9 0562 Floor reduction gear motor power supply
10 7564 Windshielddefrost reduction gear motor power supply
11 - -
12 0550 Sensor and reduction gear motor mass
13 7572 Evaporator temperaturereference signal
14 7574 Sun raysensor signal
15 7565 Recirculationpotentiometer referencevoltage
16 7561 Floor potentiometer referencevoltage
17 - -
18 2290 Internal temperaturesensor motor signal
19 - -
20 7555 Outgoingpositiveblower control modulesignal
21 0000 Negativedirect fromthebattery
22 9552 Outgoingnegativeelectro valvesignal
23 - -
24 - -
25 Gn/Ve CAN - L (BCB) line
26 0568 Mixer reduction gear motor power supply
27 7569 Internal temperaturesensor motor power supply
28 0566 Recirculationreduction gear motor power supply
29 - -
30 0564 Windshielddefrost reduction gear motor power supply
31 7562 Floor reduction gear motor power supply
32 7575 Internal temperaturesensor signal
33 7571 Blowair temperature reference signal
34 7567 Recirculationpotentiometer referencevoltage
35 7563 Windshielddefrost potentiometer referencevoltage
36 7560 5-Volt Mix / Floor / Rec/ Defrost potentiometer signal
37 40 - -
74239
74248
1 20
21 40
Figure252
Aquila Trucks Centres
73668C
5
4
Figure253
The motor for TOP FLAP function is present only in manual version, since in automatic version this function is
performed throughabowdencableconnected to air mixingmotor (MIX).
- Maximumheating =TOPFLAP closed
- Maximumcooling =TOPFLAP open
NOTE
224 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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MANUAL AIR CONDITIONER
Inthe manual versionthe refrigeratingcircuit andheater checksoccur bymeans of adevice with leverages and knobsplaced
inthelower part of thecentral dashboard.
The systemis checked byan electronic unit but by means of knobcontrols used for thefollowingfunctions:
1. Heatingwater cockcontrol
2. Internal fans speed
3. Air flows distribution
4. Compressor control switch
5. Recirculationfunctionswitch
CONTROLS DESCRIPTION
Water cock control
The knob rotationadjusts water cockposition and consequentlytheamount circulatinginsidethecabin radiator.
If supplementary WATER heater is present, this knob controls threemicroswitches usedfor thefollowingfunctions:
20% supplementaryheater water pumpactivation
60% top flapclosingmotor activation (TOP FLAP)
80% supplementaryheater connection
If supplementaryAIR heater is present, this knob controls two microswitchesused for the followingfunctions:
60% top flapclosingmotor activation (TOP FLAP)
85% supplementaryheater connection
Internal fan speed
This knob iscomposedof amultipleswitchthat controls three adjustingresistances for different motor speeds.
Air flows distributions
This control throughbowden cables allows distributing the air flowsin the desired cabin areas.
Recirculation function switch
Thisbuttonallows,throughaspecificmotor,closingtheexternal doorwithapercentageof 95%ofinternal air and5%ofexternal
air.
The motor has no position sensorssinceit works only under thetwo all-closedor all-openedconditions.
On thebuttonthereisayellow-coloured ledthat signals its connection.
There is no timelimit for this function.
Aquila Trucks Centres
225 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Compressor control switch
This buttonallows connectingtheair conditioner compressor.
The cluthclosureisconstrained by safetysystempressure switches and byfixed-calibrationevaporator thermostat
Suchthermostat,ofthemechanical type, adjuststhetemperatureinsidetheevaporator inorder to disconnect thecompressor
clutchupon reacihing~2 _C and reconnect it at ~5.5 _C
The compressor operationisconstrainedbythemanual connection of at least one fan speed.
A yellow-amber-coloured ledis present onthebutton and signals the compressor connection.
STEPPER MOTORS
Inmanual systemthereare two stepper motors placed on heater assembly
Theyarecomposed of amotor without potentiometers ahd havethe sameelectriccharacteristics.
The ratio motors areused to performthefollowingfunctions:
RECIRCULATION ( RIC )
TOP FLAP (TOP FLAP)
MOTORS
D Theyaresupplied at 24V.
D Motor resistanceis ~112 Ohm.
D No-load absorptionis about 30mA.
D Limit absorptionis about 200 mA.
Aquila Trucks Centres
42045. External temperaturesensor - 82000. Windscreendefroster assembly - 84009. Internal temperaturesensor -
42608. Coolingfluidsafetypressure switches- 25332. Compressor connection remotecontrol switch - 84019. Compressor
60%
18 22 2 ,5 25
Figure254
106972
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Block diagram
Aquila Trucks Centres
112591
Figure255
B C A
D E F
G H I
K L M
N O P
R S T
U
V
W
X
Y
Z
227 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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Air conditioner fuses remote control switches
Black-coloured fuse-holder (70604)
Position Description DeliveryA
2 Air conditioningsystem 10
3 Air conditioningsystem 5
4 Supplementaryheating 15
5 Supplementaryheating 5
Ref. Description Component code
B Water heatedremotecontrol switch (opt.) 25337
E Heated remote control switch(opt.) 25325
H Manual conditioner remotecontrol switch 25310
I Manual conditioner remotecontrol switch 25874
L Manual conditioner remotecontrol switch 25332B
M Manual conditioner remotecontrol switch 25322
O Manual conditioner remotecontrol switch (opt.) 25332A
P Manual conditioner remotecontrol switch (opt.) 25327
Aquila Trucks Centres
228 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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HYDRONIC D 10WATER HEATER
System operation
Byconnectingtheburner, theelectronic unit controlswater pump, fuel batchingpump, burner motor andignitionsparkplug.
The water pump circulates thecoolingliquidinthe coolingcircuit of the engineto beheated.
The burner motor sucks and inserts the right amount of air necessaryfor combustion.
The ignition spark plugheatsair and burns fuel injected bythebatchingpump.
Purposeof thebatchingpump is takingandinjectingfuel onto spark plug.
After 90seconds,theunit,throughtheflamesensors,checksthat theexhaust gasestemperaturevalueisincludedbetween500
and 600 C, (ignition has correctlyoccurred).
Upon reachingabout 700 C theunit disconnects the spark plugandthe burner works in self-combustion.
If theflamesensor doesnot measure theabovetemperature,therebytheburner isnot turnedon,theunit repeatstheignition
procedure. Ifit doesnot start again, theunit turnstheburner offandit will thenbemandatoryto manuallyswitchit onagain.
If theheater does not start for threeconsecutivetimes, it isblocked.
Theunit checks,throughwatertemperaturesensorandoverheatingsensor,whether combustionandburner correctlyoperate.
Thewater temperaturesensor isusedbytheunit to adjust theburnerworkingpower (maximum,medium,minimumandstand
by).
Inthe manual version, uponreaching55_C, thesystemconnects the fans inside the cabin.
The overheatingsensor isused bytheunit to turntheburner off incaseof excessivewater temperature(about 115 _C).
T|o booo ooat|o t|o |s ooto|ooo b o|vo's sott|os.
Uponturningoff,theburnerperformsawashingphasethat lastsforabout3minutesinordertobereadyforthefollowingstarting.
Theheater is connectedwith itsown control logicintheair conditioningsystemand isthereforeequipped with anelectronic
unit with related connector.
The unit is directlyassembledonto the heater.
Theheater canbedirectlydrivenbytheautomatic air conditioningsystem,bytheversionwith manual control or throughthe
Bed Moduleunit.
Aquila Trucks Centres
86116
72021
84005
84014
86053
50005
78237
52092 52002
84000
A
Figure256
106973
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COMPONENTS LOCATION
Legenda
A Thermostat 65 _C
50005 Cluster
52002 Heater connectingswitch
52092 Cabin/engineheatingswtich
72021 30-polediagnosisconnector
78237 Two-waysolenoid valve (D+)
84000 Supplementarywater heater
84005 Heater control electronic unit
84014 Fuel batchingpump
86053 Bed Module
86116 BodyComputer
Aquila Trucks Centres
230 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
Base- November 2006
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SYSTEM COMPONENTS
1) Burner motor
2) Flame sensor
3) Combustionchamber
4) Burner control unit
5) Ignitionspark plug
6) Water temperaturesensor
7) Flame pipe
8) Heat exchanger
9) Overheatingsensor
10) Water pump
11) Silencer
12) Air suction pipe
13) Fuel batchingpump
14) Bed Moduleunit
15) AutomaticWebasto air conditioner electronicunit
16) Cabin/engineheatingand heater connectingswitch
17) Air conditioner control dashboard for manual version
18) Cluster
Connection to circuit
WE. Water inlet
WA. Water outlet
V. Comburent air inlet
B. Fuel supply
A. Exhaust gasesoutlet
Aquila Trucks Centres
Figure257
106974
231 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Aquila Trucks Centres
232 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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65 _C THERMOSTAT
It isassembledontheright vehiclesidenear theburner andhasbeeninsertedinorder to allowquicklyheatingthecabinwhen
theengineis off.
It is equipped with atemperature-sensitivemembranecalibrated at 65 C.
With temperature <65_C water will onlycirculateincabin (small circuit).
Withtemperature>65_C thethermostat switchesitsposition,allowingwater to circulatebothin cabinandinengine, heating
themboth (bigcircuit).
3-WAY SOLENOID VALVE
In the WEBASTO air conditioningsystemthere is asingle 3-waysolenoid valvethat performs the functionof batchingand
bypassingcoolingwater from engine to radiator inside the cabin.
The valveis placed next to thefront left side of theengine (driver side).
It is of the NormallyOpen typeat rest andissuppliedbyadirect battery positive.
The electronic unit, byprovidingit with a mass, adjustsits workingcycle (Duty-Cicle).
WATER PUMP
The water pump isdirectlyassembled onthe lower part of theburner.
It is usedto circulatetheenginecoolingwater inthecircuit.
The supplyvoltageis 24Volt.
The minimumflowrateis about 500 l/h.
FUEL BATCHING PUMP
It isassembledonthechassisnext to fuel tankswithaslant of 15 to facilitateair drain. It isusedto takeandinject gasoil inside
theburner.
The unit supplies the pump with apulsesignal.
For acorrect operationthe internal deliverypipediameter must be 2 mmand must not exceed the length of 5 meters.
It embeds asmall fueld filter and aunidirectional checkvalve.
The fuel flow rateis about 0.2 l/min.
Aquila Trucks Centres
233 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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WATER TEMPERATURE SENSOR
It isaPTC sensor assembledonheat exchanger;it measuresdifferent water temperaturesinordertoadjust theburner power
and, onlyin manual version, upon reaching55C, it allows connectingthefans.
The sensor resistance at 20_C is~950 Ohm.
FLAME SENSOR
It isaPTC sensor assembledinsidethecombustionchamber next totheexhaust gasoutlet andmeasuresthecurrent tempera-
ture, in order to disconnect thespark plugincasetheburner hasnot beenturnedon.
It disconnectsthespark plugat anexhaust gastemperatureof about 700_C
The sensor resistance at 20 _C is~1080 Ohm.
IGNITION SPARK PLUG
It is aresistanceplaced insidethecombustionchamber.
The unit supplies it with pulses throughan internal electronic regulator.
The rated operatingvoltageis18Volt to allowitsoperation also with batteryvoltagesof ~22 Volt.
The resistanceat 20_C must be<2Ohm.
OVERHEATING SENSOR
It isatemperaturesensor assembledontheheat exchanger,itmeasuresthedifferentwatertemperaturestopossiblydisconnect
theburner upon reachingabout 115 C
Incaseof interventionthesensor restoresitself autonomously. It isnot of the manual restoringtype.
The sensor resistance at 20 C is ~10K Ohm.
BURNER MOTOR
It is embeddedinto theassemblyin therear burner part.
The rotation speed is managed bythe unit by meansof an integrated electronic regulator.
It embeds aninductivesensor that measures theenginerotationspeed.
Aquila Trucks Centres
234 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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ELECTRONIC UNIT
It is directlyassembled onheater bodyandisinterfacedwithvehiclethrough a14-pin connector.
It is connected to CAN BCBline.
It has averyadvanceddiagnostic systemand transmitspossibleerror codes on vehicleCluster.
Pin Cable Function
A1 7506 Positivefromwater cock knobmanual version(25%position)
A2 7711 Positivefromboiler activatingswitch
A3 Ws/Bi CAN H line
A4 7775 Positivefor ambient thermostat control (manual version)
B1 Gn/ve CAN H line
- - -
B3 2296 Diagnosis Kline
B4 6605 Positivefor cabin/engine heatingkeywarninglight
- -
C2 7708 Direct positivefrombattery
C3 0000 Direct negative
C4 7783 Positivefor fuel batchingpump control
- - -
- - -
Aquila Trucks Centres
235 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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SCR (SELECTIVE CATALYTIC REDUCTION) SYSTEM - DENOX 2
T|o ssto ooat|oo |s oosc|boo | o t|o '|o|oo' soct|oo o t||s aooa|.
108913
Figure258
SCR SYSTEMOPERATION DIAGRAM
PI N
Aquila Trucks Centres
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Name Description
42XX3 AD-Bluesolutionpressuresensor
47XXX AD-Bluesolutiontemperaturesensor
72069 16-polejoint for OBD (on-board diagnosis)
78266 MeasuringmodulesolenoidvalvewithSCR
78267 Enginewater circulation switchvalvefor UREA tank heatingwithSCR
84XXX Electric displacement pump withpressurecontrol valveandcirculationvalve
85140 Electronic control for SCR pumpingmodule
85141 Catalyst output temperaturesensor with SCR
85142 UREA tanklevel and temperature sensors withSCR
85143 Catalyst input temperaturesensor with SCR
85144 Nitricoxide(NOx) measuringsensor withSCR
85150 EDC control unit
85161 Combustionair relative humidityand temperaturesensors withEDC
Aquila Trucks Centres
Revi- June2007
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Pin - out
Ref. Description
Cablecolour
code
1 +for enginewater circulationsolenoid valve for ureatank heating 7542
2 +for ureafilter outlet heater 7546
3 Direct battery+(+Bat) 7540
4 Ureafilter output heater control 7540
5 CAN - H (ECB) line White
6 CAN - L (ECB) line Green
7 Spare -
8 Spare -
9 10 Spares -
11 Meteringmodule solenoid valvecontrol ground 9541
12 +for meteringmodulesolenoidvalve 7541
13 Spare -
14 Ground 0000
15 Ground 0000
16 Spare -
17 Inlet catalyst temperaturesensor ground 0544
18 Ureatank level sensor signal 6543
19 Ureatank temperature and level sensor ground 0543
20 22 Spares -
23 Engine water circulation solenoidvalvecontrol ground for ureatank heater 9542
24 +15 8540
25 Outlet catalyst temperaturesensor ground 0541
26 Outlet catalyst temperaturesensor signal 6541
27 Spare -
28 Outlet catalyst temperaturesensor signal 6544
29 Ureatank temperature sensor signal 6542
30 Spare -
31 Kline(16-pin test connector) 2257
32 Spare -
33 Ureafilter outlet heater control ground 9546
34 35 Spares -
113576
Figure259
CONNECTOR VIEW (CABLESIDE)
UDS
DCU15
Aquila Trucks Centres
105989
105990
Figure260
Figure261
CENTRAL LOCKING WITH REMOTE
CONTROL
The systemconsistsof oneor several (max. 8) transmitters
and areceiver.
Transmitter
Thetransmitter hasaspecial container ofitsown,equipped
with an eyelet and ring.. The shock-proof transmitter
container is also waterproof.
The transmitter sends the receiver avariable code (rolling
code) bymeans of aradiofrequencysignal at 433.92 MHz
(EC Directive95/56).
It isequippedwithtwobuttonsfordooropeningandclosing,
respectively.
By keeping the button pressed down for 50 msec, the
variablecodewill befullytransmitted.Ifthebuttonisactuated
continuously,however,transmissionwill beinterruptedafter
5 seconds ( 10%).
The transmitter operatingrangeis 10m.
T|o batto oaaotoos a 2 oas' sov|co ||o. |o||o.|o t|o
replacement, the transmitter maybebrieflyactuated twice
in order to restore synchronism with the receiver. This
sequence is also permitted at anytime other than battery
replacement
Receiver
Thereceiver ishousedinsideacontainerwithawhitecover,
which includes a transmitter programming button (easily
accessible and protected against unintentional actuation), a
programmingcheck green LED, and a8-wayconnector.
It is housed in instrument panel upper side, in front of
assooo's soat.
The receiver antennais housedinsidethecontainer, too.
The receiver receives and decodesthe codethat was sent
bythe transmitter, and can storeup to eight codes. Doors
lockingandunlockingcommandsgo fromthetransmitter to
the receveir, which sends the signal to Body Computer
central unit, which inturn viaCAN line sendsamessageto
Door Modules to activatethelocks.
If the vehicle is in thekey-ON condition (+15 is available),
thereceiver will performno actuationthrough theremote
control.
The receiver manages synchronization between the locks,
and resumes correct alignment through asequence of two
or several transmitter or lockkeydrives.
Blinker control
Doorlocklockingandopeningwill besignalledbythelighting
of the indicator lights. Therefore, the receiver need be
interfaced with the Body Computer control unit that
managestheabove-mentionedlights.
The receiver features an output (to the ground) that is
connected in parallel with the emergencylight switch. The
latter consists of an unstable button that actuates and
deactivates theblinkingsequence (blinker signal).
Descriptionof blinker controls:
- T1 = 120 msec (Start)
- T2 = 700 msec (Delay- Lock)
- T2 =1550 msec (Delay- Unlock)
- T3 = 120 msec (Stop)
TRANSMITTER
CENTRAL LOCKINGCONTROL UNIT (RECEIVER)
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Aquila Trucks Centres
Control unit pin-out (receiver)
Programming
The programmingstatus makesit possibleto get thereceiver to recognizethe transmittersenabled to control the respective
functions.
Programmingis accessedthrough therest state when the +15signal isnot available.
The receiver maybecontrolledbyatransmitter withauniversal code as longas at least onetransmitter is not programmed.
After avariablecode (other than theuniversal code) hasbeenprogrammed, the latter will not berecognizedanylonger.
Transmitters areprogrammedinthe FIFO mode.
Two transmitter programmingmodesare available:
- simplified programming: it allows you to programthe transmitters quickly. It can be actuated until 128 actuations are
performed after the first programming, or until it is disabled.
- Protected programming: it guaranteesthe customer against therisk of other transmitters beingprogrammed without the
knowledgeofthecustomer themselves.It involvesusingapassword(shownonthetagenclosedwiththetransmitter) that
can beobtainedfromthetransmitter code.
Simplified programming
The first code (andthesubsequent onesas well) are programmedas follows:
- press thebutton onthe receiver: theLED will light up and blink;
- theoperator presses,whilekeepingthebuttononthereceiverpresseddown,anyofthekeyofthetransmitter,whichsends
out thecode;
- thereceiver stores,afterdetectingthreesubsequent transmissioninstances(withthecurrent checksum),thecodeinto the
memory;
- thereceiver LEDwill, at theverytimewhenit recognizesthecode, light upsteadily,thussignallingthat thecodehasbeen
received: nowtheoperator mayreleasethetransmitter buttonto endtheprogramming.
Simplified programmingdisable
Simplified programmingmaybedisabledbyenteringthe passwordas follows:
- press thesmall button onthe receiver: theLED will light up and blink;
- release the small button: theLED will blinkonce;
- enter, bymeansofthesmall button, a4-digit code(password): eachdigit shall beincluded between 0and9 (codewritten
onthelabel deliveredtogetherwiththetransmitter).Anoptical feedbackwill begeneratedontheLEDeverytimethesmall
button is pressed;
- after eachdigit has been entered, wait for theLED to blinkagain to request the next digit, upto the fourth digit;
- theprocedurewill beover after the last digit isentered.
Protected programming
Everytimeanewtransmitter isto berecognizedafterfirstlyenteringthepassword,youwill need toenter thepasswordofany
ofthetransmitterspreviouslystoredintothememory.Correct recognitionofthepasswordwill besignalledbytheLEDblinking
after thepassword has been entered (if thepasswordisnot recognized, theLED will remain ON for 10 seconds). When the
LEDisblinking,keepthereceiverbuttonpresseddown,thentransmit withthenewremotecontrol tobestoredintothememory,
byfollowingthesimplified programminginstructions.
239 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Pin Function
Cablecolour
code
1 Blinker control 1113
2 Engine power supplyfor centralisedclosure(door closure)- (without DDM, PDM) 9965
2 Batterypositive 7772
4 Ground 0000
5 Central lockingcontrol (door closing) 0064
6 Central lockingcontrol (door opening) 0065
7 +15power supply 8871
8 Engine power supplyfor centralised closure(door opening) - (without DDM, PDM) 9964
Aquila Trucks Centres
MODUS
Computer-assisted diagnosis station used for diagnosis of braking systems, pneumatic suspensions, electronically-controlled
systems and engines.
The station is equipped with auxiliary functions such as electronic control unit programming, spare list cataloguereferencing,
time-charts, etc.
IT 2000
TheIVECO electronictester makesit possibletoimmediatelyinterveneonthevehicle,byrecognizingthelatter bymeans ofthe
chassis number.
This tester stores the resultsof thediagnostic operations carried out.
It can also beused as aportablePC, andisset for remotediagnosis.
ByusingMODUSasamother station, IT 2000 can beupdated and configured.
IT 2000isinterfacedwiththevehiclebymeans of a30-polediagnosistakeoff.
E.A.SY.
E.A.SY. systemallows to simplymakethediagnosis andprogrammingof thevarious electronic central units aboard the vehicle.
E.A.SY. systemismadeup of ECI modulecommunicatingwith theelectronic central unitsandof aPanasonicPC.
ECImodule,exploiting thePanasonicPC,alsoallowseasyontheroadinterventions:inparticular,thankstoPanasonicPCwireless
technologies(e.g. GPRS), diagnostic interventionscan beassistedbyaremoteexpert centre.
Figure262
101586
240 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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DIAGNOSTIC
Aquila Trucks Centres
86028
Diagnosis on Cluster
/ccoss to t|o ao|t oo |s oss|b|o t|oo| t|o 'ooo' ooct|oo 'o ( 2) ava||ab|o oo t|o stoo|o .|oo|.
1. Button y or b - 2. 3ottoo ||||/C| - 3. |ao bottoo - +. |scao bottoo - 5. 3ottoo = aoo
Too 'o s.|tc| to |/|C|/ (=+5), t|oo oss 'ooo' ooct|oo bottoo (2). t|o o|s|a .||| s|o. t|o oata oc|aoo ooo
containingthelist of availablefunctions(e.g. HI-FI, telephone, diagnostic, etc.).
Select,bymeans of function y and b button(1),thediagnosticfunction,thenconfirmcorrect selectionbymeansof function
'C|' bottoo (2).
The availableelectronic systems can beselected bymeans of select/confirmbuttons (1) and(2).
The diagnosedsystems are:
Figure263
EDC control unit errorsarenot displayed after the enginehas been started. NOTE
241 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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1 EDC 10 FFC (Front FrameComputer)
2 EUROTRONIC 11 RFC (Rear FrameComputer)
3 INTARDER 12 DDM(Drive Door Module)
4 0EBS (or ABS) 13 PDM(Passenger Door Module)
5 ECAS 14 CM(CabinModule)
6 IMMOBILIZER* 15 0ACLC (Automatic air conditioner)
7 0MTCO (Tachograph*) 16 0AHT_w(Auxiliarywater heater)
8 DC (BodyComputer) 17 0AHT_a(Auxiliaryair heater)
9 IC (Instrument Cluster)
* Functionnot active
Aquila Trucks Centres
86029
- The anomaly-freesystemisdisplayedwith aGREEN background.
- The faultysystemis displayed with aRED background
- The systems not available on the vehicle or not diagnosed (tachograph and Immobilizer) are displayed with a GREY
background.
- | sovoa| aooa||os o|atoo to a ssto ao ava||ab|o, t|o ||st cao bo oo t|oo| b oaos o bottoo (5, ||oo 262) '=' aoo
''.
Thedifferent codesshownallowyou toidentifythefaultycomponent,thetypeofstorederror (opencircuit, short-circuit,etc.),
theerror occurrencesand, finally, whether theerror iscurrentlypresent or intermittent.
86030
To o|s|a |oto|ttoot ao|ts, oss s|o|taoooos| bottoos 'C|' aoo '()' (2-5).
Figure264
Figure265
242 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Aquila Trucks Centres
73687
First screen
| sovoa| aooa||os ao oooo, t|o osoct|vo ||st cao bo oo t|oo| b oaos o bottoos '=' aoo ''.
Informationon everysinglefault is displayed on four columnswiththefollowingdata:
74225
The diagnosis informationshownon thecluster is dividedinto threescreens:
- thefirst screenallows you to displayall thestored/currentlypresent anomalies(if any);
- thesecond screenallows youto cancel intermittent errors (providedthat therespectivepasswordis available);
- thethird screen allowsyou to know the softwareversionof the various Multiplexelectroniccontrol units.
Second screen
To so|oct t|o socooo scooo, oss bottoo 'ao' oo t|o stoo|o .|oo|.
Cancelling errors
The systemcan be selected bymeans of buttonsy and b available onthesteeringwheel.
Anomalydisplaycan becancelledas follows:
- |oss '='
- T|o o|s|a .||| s|o. t|o oo|ot|oo coo| oooost. oss 'C|' to coot| ooo.
- |oto t|o oooostoo ass.oo (soo oot aaa| ||T||||C T| |/SS\C||), t|oo oss 'C|' to coo|.
Figure266
Figure267
243 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Print 603.93.641
INFORMATION ON CLUSTER
DTC FMI OC ACT
Displays the anomaly code
relatedto the fault
Indicates the typeof fault Anomalyrate counter Active/not active anomaly
condition
Two digits (hexadecimal) Two digits (hexadecimal) Three digits (decimal) Onecharacter (Y-yes, N-no)
Aquila Trucks Centres
86031
74227
Entering the password
- Select the first number of thepasswordbymeans of buttons y and b .
- Press button OKto confirmeach number.
- Press a to cancel thelatest selected number.
- After thepasswordhasbeencompleted, select the keysymbol to confirmit.
Third screen
To so|oct t|o t||o scooo, oss bottoo 'ao' ava||ab|o oo t|o stoo| o .|oo|.
Software version
The softwareversionisdisplayedonlyfor theMultiplex systemcontrol units.
The releaseof the followingcontrol units canbeselected bymeans of buttons y and b :
1. BodyComputer
2. Front FrameComputer
3. Rear FrameComputer
4. Driver Door Module
5. Passenger Door Module
6. Instrument Cluster
7. Cabine Module
Figure268
Figure269
244 TRAKKEREURO 4/5 ELECTRIC/ELECTRONICSYSTEM
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Aquila Trucks Centres
ELECTRIC/ELECTRONICSYSTEM 245 TRAKKEREURO 4/5
Print 603.93.641 Base- November 2006
Circuit charts
Page
CHART 1 DIRECT POSITIVE TO BATTERY 247
CHART 2 POSITIVE AFTER TGC (+30) 248 . . . . . .
CHART 3 POSITIVE AFTER TGC (+30) 249 . . . . . . .
CHART 4 POSITIVE AFTER TGC (+30) 250 . . .
CHART 5 POSITIVE AFTER TGC (+30) 251 . . .
CHART 6 POWER SUPPLY (+15) 252 . . . . . . . .
CHART 7 POWER SUPPLY (+15) 253 . . . . . . . .
CHART 8 POWER SUPPLY (+15) 254 . . . . . . . .
CHART 9: BODY CONTROLLER 255 . . . . . . . .
CHART 10: BODY CONTROLLER 256 . . . . . . . .
CHART11: BODY CONTROLLER 257 . . . . . . . . .
CHART 12: BODY CONTROLLER 258 . . . . . . . .
CHART 13 IC CONTROL UNIT 259 . . . . . . . . .
CHART 14 TACHOGRAPH /
DIAGNOSISSOCKET 260 . . . . . . . . .
CHART 15 STEERINGWHEEL
INTERFACE(SWI) 261 . . . . . . . . . . . .
CHART 16 DDM-BM CONTROL UNIT 262 . . . .
CHART 17 PDM CONTROL UNIT 263 . . . . . . . .
CHART 18 THERMAL MIRRORS/ CENTRALISED
LOCKING / WINDOW WINDERS
(WITHOUT DDM-PDM) 264 . . . . . .
CHART 19 VCMCONTROL UNIT 265 . . . . . . .
CHART 20: EDC (CONNECTORB) 266 . . . . . . .
CHART 21: EDC (CONNECTOR A/C - F2B) 267
CHART 22: EDC (CONNECTOR A/C - F3B) 268
CHART 23: CONTROL UNIT UDS(DENOX 2) 269
CHART 24: CONTROL UNIT MET 270 . . . . . . . .
CHART 25: CONTROL UNIT MET 271 . . . . . . . .
CHART 26: CONTROLI UNIT MET 272 . . . . . . .
CHART 27: LINE CAN-IDB/ FMB/
CONTROL UNIT / TELEMATICS/
NAVIGATOR 273 . . . . . . . . . . . . . . .
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Page
CHART 28: LINE CAN-BCB 274 . . . . . . . . . . . . . . . .
CHART 29: LINE CAN-VDB 275 . . . . . . . . . . . . . . . . .
CHART 30: LINE CAN-ECB 276 . . . . . . . . . . . . . . . . .
CHART 31 ECAS4X2 P TRACTOR 277 . . . . . . . . . .
CHART 32 ECAS4X2P/4X4P/6X4P/8X4X4P
(LORRY) 278 . . . . . . . . . . . . . . . . . . . . . .
CHART 33 ABS 279 . . . . . . . . . . . . . . . . . . . . . . . . . .
CHART 34: VENTILATION 280 . . . . . . . . . . . . . . . . .
CHART 35: MANUALLY CONTROLLED
CLIMATE CONTROL SYSTEM 281 . . . .
CHART 36: MANUALLY CONTROLLED
ADDITIONAL AIRHEATER 282 . . . . . .
CHART 37: MANUALLY CONTROLLED
ADDITIONAL AIRHEATER 283 . . . . . .
CHART 38: EUROTRONIC II 284 . . . . . . . . . . . . . . . .
CHART 39: RETARDERZF 285 . . . . . . . . . . . . . . . . .
CHART 40: CONTROL UNIT EM (PTO) 286 . . . . . .
CHART 41: RADIO RECEIVER 287 . . . . . . . . . . . . . . .
CHART 42: GENERAL MECHANICAL
POWER SWITCH (IGC) 288 . . . . . . . . . .
CHART 43: ADR (2001) 289 . . . . . . . . . . . . . . . . . . . .
CHART 44: ADR (OPT. 0129) 290 . . . . . . . . . . . . . . .
Aquila Trucks Centres
113356
ELECTRIC/ELECTRONICSYSTEM 247 TRAKKEREURO 4/5
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Print603.93.641
Chart 1: Direct positive to battery
Aquila Trucks Centres
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248 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 2: Positive after TGC (+30)
Aquila Trucks Centres
113358
ELECTRIC/ELECTRONICSYSTEM 249 TRAKKEREURO 4/5
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Chart 3: Positive after TGC (+30)
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113359
250 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 4: Positive after TGC (+30)
Aquila Trucks Centres
113360
ELECTRIC/ELECTRONICSYSTEM 251 TRAKKEREURO 4/5
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Chart 5: Positive after TGC (+30)
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113361
252 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 6: Power supply(+15)
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113362
ELECTRIC/ELECTRONICSYSTEM 253 TRAKKEREURO 4/5
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Chart 7: Power supply(+15)
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113363
254 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 8: Power supply(+15)
Aquila Trucks Centres
113364
ELECTRIC/ELECTRONICSYSTEM 255 TRAKKEREURO 4/5
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Chart 9: Bodycontroller
Aquila Trucks Centres
113365
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Chart 10: Bodycontroller
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ELECTRIC/ELECTRONICSYSTEM 257 TRAKKEREURO 4/5
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Chart 11: Bodycontroller
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Chart 12: Bodycontroller
Aquila Trucks Centres
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ELECTRIC/ELECTRONICSYSTEM 259 TRAKKEREURO 4/5
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Chart 13: IC central unit
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113369
260 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 14: Tachograph / Diagnosis socket
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113370
ELECTRIC/ELECTRONICSYSTEM 261 TRAKKEREURO 4/5
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Chart 15: Steering Wheel Interface(SWI)
Aquila Trucks Centres
113371
262 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 16: DDM-BM control unit
Aquila Trucks Centres
113372
ELECTRIC/ELECTRONICSYSTEM 263 TRAKKEREURO 4/5
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Chart 17: Passenger Door Module(PDM)
Aquila Trucks Centres
113373
264 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 18: Thermal mirrors/ Centralised locking/ Window winders (without DDM-PDM)
Aquila Trucks Centres
113374
ELECTRIC/ELECTRONICSYSTEM 265 TRAKKEREURO 4/5
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Chart 19: Electronic Control Unit VCM
Aquila Trucks Centres
113375
266 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 20: EDC (Connector B)
Aquila Trucks Centres
113376
ELECTRIC/ELECTRONICSYSTEM 267 TRAKKEREURO 4/5
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Chart 21: EDC (Connector A/C - F2B)
Aquila Trucks Centres
113377
268 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 22: EDC (Connector A/C - F3B)
Aquila Trucks Centres
113378
ELECTRIC/ELECTRONICSYSTEM 269 TRAKKEREURO 4/5
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Chart 23: Central unit UDS(DENOX 2)
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113379
270 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 24: Control unit MET
Aquila Trucks Centres
113380
ELECTRIC/ELECTRONICSYSTEM 271 TRAKKEREURO 4/5
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Chart 25: Control unit MET
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113381
272 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 26: Control unit MET
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113382
ELECTRIC/ELECTRONICSYSTEM 273 TRAKKEREURO 4/5
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Chart 27: Line CAN-IDB / FMB / Control unit / Telematics / Navigator
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113383
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Chart 28: Can line BCB
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ELECTRIC/ELECTRONICSYSTEM 275 TRAKKEREURO 4/5
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Chart 29: Can line VDB
Aquila Trucks Centres
113385
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Chart 30: Can line ECB
Aquila Trucks Centres
113386
ELECTRIC/ELECTRONICSYSTEM 277 TRAKKEREURO 4/5
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Chart 31: ECAS 4x2P (TRACTOR)
Aquila Trucks Centres
113387
278 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 32: ECAS 4X2P/4X4P/6X4P/8X4X4P (LORRY)
Aquila Trucks Centres
113388
ELECTRIC/ELECTRONICSYSTEM 279 TRAKKEREURO 4/5
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Chart 33: ABS
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113389
280 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 34: Ventilation
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113390
ELECTRIC/ELECTRONICSYSTEM 281 TRAKKEREURO 4/5
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Chart 35: Manuallycontrolled climate control system
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113391
282 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 36: Manuallycontrolled additional water heater
Aquila Trucks Centres
113392
ELECTRIC/ELECTRONICSYSTEM 283 TRAKKEREURO 4/5
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Chart 37: Manuallycontrolled additional air heater
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113579
Revi- June2007
284 ELECTRIC/ELECTRONICSYSTEM TRAKKEREURO 4/5
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Chart 38: EuroTronic II
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Chart 39: Retarder ZF
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Chart 40: Control unit EM(PTO)
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Chart 41: Radio receiver
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Chart 42: General mechanical power switch(IGC)
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Chart 43: ADR (2001)
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Chart 44: ADR (OPT. 0129)
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