Iveco Eurocargo Tector 6/10t (2003) - Repair, Service and Maintenance Manual

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IVECO EUROCARGO TECTOR 6/10T (2003) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Iveco Eurocargo Tector 6-10t (2003).

 
CONTENTS:

SECTION 1 - GENERAL SPECIFICATIONS
General specifications
- Composition of the models
- Identification data and location on vehicle
- Filling up
- International lubricant designation
SECTION 2 - ENGINE
Engine
- Engine
- Engine identification code
- Main servicing operations to be performed on engine fitted on vehicle
- Warnings
- Engine removal/refitting
- Injector replacement
- Replacementofengine frontshaft cover sealing ring
- Replacement of flywheel case sealing ring
- Cylinder head removal/refitting
- Engine f4 ae 0481
- General specifications
- Clearance data
- Tightening torque
- Auxiliary components
- Tools
- Engine overhaul
- Engine removal at the bench
- Repair operations
- Cylinder unit
- Timing system
- Bushes
- Output shaft
- Connecting rod - piston assembly
- Engine flywheel
- Cylinder head
- Valves
- Valve guide
- Valve seats
- Valve springs
- Fitting cylinder head
- Rods
- Lubrication
- Oil pump
- Heat exchanger
- Cooling system
- Booster
- Turbosupercharger actuator
- Turbosupercharger layout
- Common rail
- Hydraulic system
- Hydraulic system layout
- Fuel prefilter
- Fuel filter
- Mechanical supply pump
- Cp3 high-pressure pump
- High-pressure pump - inside structure
- Rail
- Double stage overpressure valve
- Injector
- Pressure limiter for fuel return
- Engine f4 ae 0681
- General specifications
- Assembly data - clearances
- Engine f4ae0681 overhaul
- Timing system
- Bushes
- Cylinder head valve seats
- Lubrication
- Cooling system
- Booster
- Turbosupercharger layout
- Troubleshooting guide
- Foreword
- Diagnostics
SECTION 3 - CLUTCH
Clutch
- Description
- Clutch
- Specifications and data
- Diagnostics
- Tightening torques
- Tools
- Removal and refitting
- Removal
- Refitting
- Driven plate overhaul
- Damper hub check
- Friction gaskets
- Thrust bearing removal - refitting
- Replacing clutch shaft support bearing
- Hydraulic control
- Mini servo-clutch
- Connections
- Clutch disengaging cylinder
- Clutch mounting assembly
- Clutch wear control
- Adjusting pedal and stop position screws
- Clutch pedal clearance
- Clutch pedal travel
- Clutch control drain procedure
SECTION 4 - GEARBOXES
Gearboxes
- Diagnostics
- Gears control connection
- Gearbox control tie-rods adjustment
- Gearbox 2855s.5 - 2855s.6
- Description
- Specifications and data
- Tightening torques
- Tools
- Gearbox 2855s.6 removal - refitting
- Gearbox disassembly
- Gearbox assembly
- Primary shaft disassembly
- Primary shaft assembly
- Motion inlet shaft disassembly
- Motion inlet shaft assembly
- Secondary shaft disassembly
- Secondary shaft assembly
- Internal drive shaft disassembly
- Internal drive shafy assembly
- External control shaft disassembly
- External control box assembly
- Gearbox 2865s.6
- Description
- Specifications and data
- Tightening torques
- Tools
- Gearbox 2865s.5 disengagement/ re-engagement
- Gearbox disassembly
- Gearbox assembly
- Primary shaft disassembly
- Primary shaft assembly
- Motion entry shaft assembly
- Secondary shaft disassembly
- Secondary shaft assembly
- Internal control shaft disassembly
- Internal control shaft assembly
- External control shaft disassembly
- External control box assembly
- Gearbox 2870s.9
- Description
- Specifications and data
- Tightening torques
- Tools
- Gearbox 2870s.9 disengagement/re-engagement
- Gearbox disassembly
- Gearbox assembly
- Primary shaft disassembly
- Primary shaft assembly
- Motion inlet shaft disassembly
- Motion inlet shaft assembly
- Secondary shaft disassembly
- Secondary shaft assembly
- Internal drive shaft disassembly
- Internal drive shaft assembly
- External drive case disassembly
- External control box assembly
- Epicyclic reduction gear assembly
- Disassembly
- Assembly
SECTION 5 - PROPELLER SHAFTS
Propeller shafts
- Description
- Specifications and data for ”fixed” and ”sliding” propeller shafts
- Specifications and data for ”single-section” propeller shafts
- Diagnostics
- Tightening torques
- Single-section propeller shaft disengagement - re-engagement
- Disengagement
- Re-engagement
- Sliding propeller shaft disengagement - re-engagement
- Disengagement
- Re-engagement
- Two-section propeller shaft disengagement - re-engagement
- Check of vehicle propeller shafts
SECTION 6 - REAR AXLES 4517 AND 4521
Rear axles 4517 and 4521
- Description
- Specifications and data
- Diagnostics
- Tightening torques
- Tools
- Rear axle disengagement/re-engagement (with mechanical suspensions)
- Disengagement
- Re-engagement
- Rear axle disengagement/re-engagement (with pneumatic suspensions)
- Disengagement
- Re-engagement
- Rear axle assembly revision
- Air vent disengagement - re-engagement
- Wheel hub revision
- Disassembly
- Check of parts composing wheel hubs
- Rear axle case check
- Assembly
- Differential gear repair
- Disassembly pertaining to rear axle 4517
- Disassembly pertaining to rear axle 4521
- Gearing case disassembly
- Disassembly of bevel pinion assembly
- Check of parts composing the differential gear
- Gearing case assembly
- Assembly pertaining to rear axle 4521
- Assembly pertaining to rear axle 4521
- Gearing case assembly on rear axle case
- Assembly pertaining to rear axle 4517
- Assembly pertaining to rear axle 4521
- Variation with differential locking
- Disassembly
- Checks
- Assembly
- Antiskid device sensor
- Assembly
SECTION 7 - FRONT AXLES 5833 - 5833/1
Description
- Front axle
- Characteristic angles
Specifications and data
Diagnostics
Tightening torques
Tools
Front axle disengagement/re-engagement (with mechanical suspensions)
- Disengagement
- Re-engagement
Front axle disengagement/re-engagement (with pneumatic suspensions)
- Disengagement
- Re-engagement
Front wheel attitude
- Claws and projectors placement
- Electronic rim misalignment compensation
- Wheel alignment
- Wheel toe-in check
- Wheel camber check
- King pin and caster angle check
- Steering angles check
Front axle assembly revision
Wheel hubs disengagement and re-engagement
- Disengagement
- Sealing ring replacement
- Wheel hubs re-engagement
- Axial clearance adjustment for wheel hub bearings
- Rolling torque measure
Wheel hub bearings replacement
Wheel securing risers replacement
Transverse tie-rod detachment and re-attachment
- Detachment
- Re-attachment
Transverse tie-rod stub axle replacement
Transverse tie-rod levers detachment and re-attachment
Longitudinal tie-rod lever detachment and re-attachment
Stub axle pin detachment and re-attachment
- Detachment
- Re-attachment
- Check and adjustment of clearance between stub axle and front axle
Steering knuckle pin bearing replacement
Front axle body checks and measures
- Planarity check of leaf springs bearing surfaces with respect to stub axle pin holes
- Check of stub axle pin holes camber
SECTION 8 - SUSPENSIONS
Front and rear mechanical suspensions
- Description
- Front leaf springs
- Front parabolic leaf spring specifications and data
- Models 60e.. - 100e.. With axle load up to 3400 kg
- Models 65e.. - 100e.. With axle load over 3400 kg
- Front half-elliptic leaf spring specifications and data
- Models 60e..k
- Models 65e..k - 75e..k
- Models 75e15k
- Models 80e..k - 100e..k
- Rear leaf springs
- Rear parabolic leaf spring specifications and data
- Models 60e.. - 65e.. - 75e.. - 80e..
- Models 100e..
- Rear half-elliptic leaf spring specifications and data
- Models 60e..k - 65e..k
- Models 75e..k
- Models 80e..k
- Models 100e..k
- Shock absorbers
- Assembly diagrams
- Shock absorber specifications and data
- Front shock absorbers (with parabolic leaf springs)
- Front shock absorbers (with half-elliptic leaf springs)
- Rear shock absorbers (with parabolic leaf springs)
- Rear shock absorbers (with half-elliptic leaf springs)
- Diagnostics
- Tightening torques
- Tools
- Front mechanical suspensions disengagement - re-engagement
- Disengagement
- Re-engagement
- Rear mechanical suspensions disengagement - re-engagement
- Disengagement
- Re-engagement
- Front shock absorbers
- Disengagement
- Re-engagement
- Rear shock absorbers
- Disengagement
- Re-engagement
- Front stabilising bar
- Disengagement
- Re-engagement
- Rear stabilising bar
- Disengagement
- Re-engagement
- Repair interventions
- Replacing leaf-spring bushings (for vehicles with leaf-springs provided with bushings having a metal shell)
- Disconnecting and reconnecting rear leaf-spring bushings
- Disconnecting rear bushings
- Reconnecting rear bushings
- Disconnecting front bushings
- Reconnecting front bushings
- Disconnecting and reconnecting front leaf-spring bushings
- Disconnecting front bushings
- Reconnecting front bushings
- Disconnecting rear bushings
- Reconnecting front bushings
Front and rear pneumatic suspensions
- Pneumatic suspensions
- In general
- Pneumatic suspensions assemblies
- Principle layout for rear pneumatic suspensions
- Principle layout for full pneumatic suspensions
- Main components arrangement on vehicle
- Chassis lifting, lowering and self-leveling
- Remote control
- Remote control description and operation
- Chassis lifting/lowering
- Chassis self-leveling
- ”m 1” - ”m 2” level
- Diagnostics
- Tightening torques
- Hendrickson type rear pneumatic suspension
- Tools
- Specifications and data
- Pneumatic system
- Front leaf spring (models ml 80e18fp/21fp - ml90e18fp/21fp - ml 100e18fp/21fp)
- Front shock absorbers
- Rear shock absorbers
- Main pneumatic system components
- Controlled-pressure valve
- Level sensor
- Front axle electro-pneumatic distributor for 4 x 2 fp vehicles
- Operation
- Front axle lifting
- Front axle lowering
- Self-leveling
- Rear axle electropneumatic distributor for 4 x 2 p/fp vehicles
- Operation
- Rear axle lifting
- Rear axle lowering
- Self-leveling
- Manometric low air pressure switch
- Air springs
- Electronic unit
- Front pneumatic suspensions disengagement - re-engagement
- Disengagement
- Re-engagement
- Neway type rear pneumatic suspensions disengagement - re-engagement
- Disengagement
- Re-engagement
- Front shock absorbers
- Disengagement
- Re-engagement
- Front air springs
- Disengagement
- Re-engagement
- Rear shock absorbers
- Disengagement
- Re-engagement
- Rear air springs
- Disengagement
- Re-engagement
- Front stabilising bar
- Rear stabilising bar
SECTION 9 - WHEELS AND TYRES
Wheels and tyres
- Description
- Specifications and data
- Tire pressure values
- Tools
- Diagnostics
- Static wheel balancing
- Correction of residual static unbalance
- Tire pressure
- Tire behaviour depending on pressure
SECTION 10 - STEERING SYSTEM
Steering system
- Description
- Hydraulic guide system installation view
- Specification and data
- Steering wheel control scheme
- Diagnostic
- Tightening torque
- Tools
- Power steering pump zf fn4 integral
- Description
- Zf 8090 hydraulic power steering
- Description
- Hydraulic steering limiting device
- Removing and refitting the hydraulic power steering (zf 8090)
- Removal
- Refitting
- Adjusting the hydraulic steering limiting device
- Trw tas 30 hydraulic power steering
- Description
- Neutral position - straight running
- Steering to the right
- Steering to the left
- Hydraulic steering limiting device
- Setting the trw tas 30 power steering limiting device automatic adjustment
- Checking the automatic adjustment
- Fluid leaking manual adjustment
- Bleeding the air from the hydraulic power steering circuit
- Measuring clearance in steering box at steering wheel
- Checking maximum pressure of power steering system
SECTION 11 - PNEUMATIC SYSTEM - BRAKES
Pneumatic system - brakes
- Symbols for air/hydraulic system circuit diagrams (miscellaneous and generators)
- Symbols for air/hydraulic system circuit diagrams (valves)
- Symbols for air/hydraulic system circuit diagrams (tanks and accumulators)
- Symbols for air/hydraulic system circuit diagrams (converters, cylinders and callipers)
- Symbols for air/hydraulic system circuit diagrams (cylinders and callipers)
- Symbols for air/hydraulic system circuit diagrams (half-joints and coupling heads)
- Symbols for air/hydraulic system circuit diagrams (indicators and switches)
- Symbols for air/hydraulic system circuit diagrams (brakes)
- Pipes and couplings
- Overview
- End forming on rigid pipes
- Bending rigid pipes
- Cutting rigid pipes
- Replacing flexible hoses with threaded couplings
- Replacing flexible hoses with quick connection couplings
- Braking system
- General layout for stand-alone vehicles
- General layout for towing vehicles
- Braking system main components layout on vehicle
- Description
- Service braking
- Exhaust brake
- Operation
- Parking brake
- Brakes
- Front and rear brakes
- Diagnostic
- Tightening torque
- Tools
- Specifications and data - pneumatic system
- Compressor
- A.p.u. (drier/4 ways)
- Drier
- 4-way protection valve
- Air tanks
- Duplex distributor
- Pressure limiting valve (for towable vehicles)
- Augmenter valve (towing vehicles)
- Triple control servo distributor (towing vehicles)
- Variable and automatic coupling heads
- Air/hydraulic converters
- Manual discharge valve
- Parking brake distributor (single vehicles)
- Parking brake distributor (vehicles adapted for towing)
- Dump valve
- Spring cylinder
- Abs electronic control unit
- Abs solenoid valve
- Specifications and data - brakes
- Brake system main component checks
- Braking system main components
- Compressor
- Diagnostic
- A.p.u. (air processing unit)
- Operation
- Diagnostics
- Engine brake switch
- Engine brake solenoid valve
- Engine brake control operating cylinder
- Manual discharge valve
- Safety valve (optional)
- Duplex distributor
- Brake release
- Diagnostic
- Pressure limiting valve
- Operation
- Pressure limiting
- Setting at the bench
- Diagnostic
- Triple control servo distributor
- Predominance regulation
- Diagnostic
- Coupling heads
- Operation
- Check valve
- Operation
- Air/hydraulic converters (diaphragm)
- Master cylinder
- Checks
- Refitting
- Diagnostic
- Augmenter valve (towing vehicles)
- Diagnostic
- Anti-skid systems
- Antilock braking system (abs)
- Electropneumatic valve
- Operation
- Electronic control unit
- Operation
- Rpm sensors
- Phonic wheels
- Operation
- Air bleeding from hydraulic circuit
- Front brake circuit
- Rear brake circuit
- Air bleeding from the hydraulic circuit using the deaerating device
- Parking brake control hand distributor (stand-alone vehicles)
- Diagnostic
- Parking brake control hand distributor (towing vehicles)
- Diagnostic
- Spring brake cylinder
- Operation
- Spring cylinder emergency brake release device
- Resetting the rear brakes in running condition
- Repair operations
- Diagnostic
- Repairing brakes
- Front brakes
- Operation
- Replacing front brake linings
- For 5833/1 front axle
- For any model
- For 5833 front axle
- For 5833/1 front axle
- Removing front brake callipers
- For any model
- Removing front wheel hubs
- Overhauling the brake discs
- Turning and grinding the brake discs
- Rear brakes
- Operation
- Rear brake calliper hydraulic operation diagram (girling)
- Parking brake device operation
- Automatic backlash take up device operation
- Operation of the system for taking up wear
- First operation stage (f1 < f2) - low pressure
- Second operation stage (f1 > f2) - high pressure
- Third operation stage (pressure resetting to zero) - resting position
- Parking braking
- Parking brake operation
- Replacing the rear brake linings
- Removal
- For rear axle 4517
- For any model
- Refitting
- For rear axle 4521
- For rear axle 4517
- Removing the rear brake callipers
- Removing rear wheel hubs
- Overhauling the brake callipers
- Brake callisper removal
- For rear calliper
- For front and rear calliper
- For rear calliper
- For girling rear calliper
- For brembo rear calliper
- For front and rear calliper
- Component cleaning and checking
- Brake calliper refitting
- For rear calliper (girling)
- For rear calliper (brembo)
- For front and rear calliper
- For front calliper
- For rear calliper
- For front and rear calliper
- For rear calliper
- Refitting brakes
- Refitting the front wheel hubs
- Refitting the rear wheel hubs
- Refitting the brake callipers
- Refitting the rear brake callipers
SECTION 12 - BODY - CHASSIS
Body - chassis
- Cab
- General information
- Characteristics and data
- Protective body treatments
- Protective treatment
- Preparing the sheet metal (bonderizing)
- Applying the protective paint (electrophoresis)
- Checking the geometry of the chassis frame
- General rules for working on the chassis frame
- Preparing the chassis frame for maintenance, checking and repair work authorized by iveco
- Spot welding
- Welding instructions
- Bodybuilder work on the structural members of the iveco chassis frame
- Drilling the chassis frame
- Precautions
- Welds on the chassis frame
- Chassis frame
- Repairs and checks
- Measuring the side bend of the chassis frame
- Measuring the bend of the chassis frame downwards or upwards
- Measuring the movement of the chassis frame
- Measuring the torsion of the chassis frame
- Chassis reference dimensions
- Cab geometry
- Seal application diagram
- Cab anchoring and tightening torques
- Tools
- Repairs
- Cab anchoring
- Replacing cab suspension front and rear shock absorbers
- Removing-refitting front mounts and cab stabilizer bar
- Hydraulic cab lifting system
- Replacing hydraulic cylinder for cab tilting
- Replacing windscreen window
- General
- Vibration knife
- Harmonic wire
- Removal (with harmonic wire)
- Preparing the windscreen opening
- Preparing the windscreen
- Refitting
- Replacing the winding window
- Replacing the window winder
- Replacing the fixed window
- Instrument panel
- Removal
- Refitting
- Middle instrument panel
- Removal
- Refitting
- Instrument panel covering
- Removal
- Refitting
- Heating and ventilation
- Removal
- Refitting
SECTION 13 - PROGRAMMED MAINTENANCE
Programmed maintenance
- Servicing
- Service plan
- Service frequency
- Extra plan operations
- Extra plan operation (to be carried out possibly at the same time as a planned service operation)
- Programmed maintenance operations
- Operations not included in the plan
- Programmed maintenance operations
- Operations not included in the plan
- M1 service
- M2 service
- M3 service
- M4 service
- Maintenance not included in the service
- Ep1 service
- Ep2 service
- Ep3 service
- Ep4 service
- Ep5 service
- Oil replacement and brake hydraulic system bleeding
- Front brake circuit
- Rear brake circuit
- Air bleeding from the hydraulic circuit using the deaerating device