Iveco Eurocargo Tector 6/10t (2004)
IVECO EUROCARGO TECTOR 6/10T (2004) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
IVECO EUROCARGO TECTOR 6/10T (2004) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual and Wiring Diagrams, to vehicles Iveco Eurocargo Tector 6/10t (2004). 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 SECTION 14 - ELECTRIC/ELECTRONIC SYSTEM Electric/electronic system - Preliminary remarks - Symbols-warnings - Symbols-assistance operations - Product code - General warnings - General warnings on the electric system - Concept of ground and electromagnetic compatibility - Practical tips - Can line - Efficiency tests on the can line - Description of basic system - Electrical characteristics - Engine components - Engine f4ae0481 - Power network - Positive network - Power cable sections - Negative network - Ground point identification - Starting - General remarks - Starting from the driver’s seat (cab hooked) - Starting from the engine compartment (cab tilted) - Alternator - Starter motor - Component code - Junction connector - Bulkhead - Instrument panel - Central dashboard - Instrument cluster - Description - Models available - Optical indicators on the cluster - (failure) indicators on the display - “pop-up” events - Cluster (pin-out) - Central interconnecting unit - Remote-control switch assembly - Fuse assembly - Connector assembly - Steering column stalk - Position of electronic control units - Body controller AND MORE....
Iveco Eurocargo Tector 6/10t (2004) - Repair, Workshop Manual and Electrical Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
e-mail