Content

General information

• Vehicle identification data
• Composition of models
• P.I.C. Number coding
• Replenishing fluids

Engine

• F2B Engine
• F3A Engine
• Hidrocar pressure take-off on timing system

Clutch

• Description
• Characteristics and data
• Diagnostics
• Tightening torques
• Tools
• Removing and refitting the clutch
• Removing-refitting the thrust bearing
• Replacing the support bearing of the clutch shaft
• Removing-refitting the pedal unit
• Pedal
• Unit removal-assembly
• Checking and adjusting stops on clutch pedal
• Hydraulic control (vehicles with ZF 9 S 109 - ZF 16S 151/181/221 gearboxes)
• Clutch actuator for ZF 16 S 151/181/221 gearboxes
• Push rod adjustment
• Bleeding clutch circuit
• Clutch actuator for eurotronic automated gearbox

Gearbox

• ZF 9 S 109 D.D
• ZF 16 S 151 D.D. - ZF 16 S 181 D.D./O.D. - ZF 16 S 221 D.D.
• ZF 16 S 151 D.D. - ZF 16 S 181 D.D./O.D. - ZF 16 S 221 D.D. with intarder
• Eurotronic 12 AS 2301 D.D./O.D.
• Eurotronic 12 AS 2301 D.D./O.D. with intarder
• Allison MD 3060 PR - allison MD 3066PR 173-196 external control
• Power take-off

Hydraulic retarder

• Characteristics and data
• Diagnostic
• Tightening torques
• Tools
• Removing and reassembling the propeller shaft
• Checking the propeller shaft on the vehicle
• Removing and fitting back the universal joints
• Removing and reassembling the support

Propeller shafts

Rear axles

• Fault diagnosis
• Removing-refitting the rear axle
• Removing-refitting the differential from the rear axle on the vehicle
• Rear axle meritor MS 13-175 with disc brakes
• Rear axle meritor MS 13-175 with drum brakes
• Rear axle 451391
• Axle in tandem meritor RT 160 E/1

Front axle

• 5206 Front axles
• Front axle 5876/4 (F 8021)
• 5876/5 (F 8021)
• 5886/5 (F 9021)
• Steering central added axle 5871/2 (F 8021)
• 5258 Additional rear axle
• Additional rigid rear axle 5508 DI
• Additional rigid rear axle 55080/TI
• Rigid rear added axle with hydraulic lifting 56082/DI
• Rigid rear added axle with hydraulic lifting 56082/TI
• Steering rear added axle 57080/DI
• Steering rear added axle 57080/TI
• Wheel geomery

Front and rear suspensions

• Suspensions
• Description
• Specifications and data
• Mechanical front suspension assembly drawing
• Rear mechanical suspension assembly 18 “Cantilever” rear suspension (vehicles 6x2)
• Air suspension
• Air suspension system diagrams
• Characteristics and data
• Main components of the pneumatic system
• Fault diagnosis
• Tools
• Tightening torques
• Removal-refitting of front leaf spring
• Removing-refitting front suspension bars
• Rear suspensions
• Removing-refitting the rear axle longitudinal suspension arm
• Removing-refitting the rear added axle longitudinal suspension arm
• Removing-refitting the rear axle triangular suspension arm
• Removing-refitting the rear added axle triangular suspension arm
• Replacing the suspension arm flexible pin
• Stabilizer bar
• Front stabilizer bar
• Central added axle stabilizer bar (6x2 C vehicles)
• Rear stabilizer bar
• Rear added axle stabilizer bar (6x2P vehicles)
• Rubber bushings
• Shock absorbers
• Chassis frame adjustment

Wheels and tyres

• Description
• Characteristics and data
• Tools
• Fault diagnosis
• Static balancing of the wheels
• Correcting residual static imbalance
• Tyre pressure
• How tyre behaviour depends on pressure

Steering system

• Description
• Specifications and data
• Fault diagnosis
• Tightening torques
• Tools
• Removing-refitting the power steering system
• Steering control
• Removing-refitting the steering control assembly
• Bleeding the power steering system
• Measuring steering box play at the steering wheel
• Checking the maximum pressure of the power steering system

Air system - brakes

• Symbols for air / hydraulic system circuit diagrams (tanks and accumulators)
• Symbols for air / hydraulic system circuit diagrams (valves)
• Symbols for air-hydraulic system diagrams (tanks and accumulators)
• Symbols for air / hydraulic system circuit diagrams (converters, cylinders and callipers)
• Symbols for air/hydraulic system circuit diagrams (callipers and cylinders)
• Symbols for air / hydraulic system circuit diagrams (semi-couplings and coupling connectors)
• Symbols for air / hydraulic system circuit diagrams (semi-couplings and coupling connectors)
• Symbols for air / hydraulic system circuit diagrams (indicators and switches)
• Symbols for air / hydraulic system circuit diagrams (brakes)
• Pipings and fittings
• EBS (electronic brake system)
• Operating logic
• Auxiliary brake integration
• “ABS-EBL” system (anti-lock brake system — electronic brake limiter)
• Brakes
• Fault diagnosis Tightening torques
• Tools
• Specifications and data - pneumatic system
• Specifications and data - brakes
• Checks on main components of brake system
• Main components of the braking system
• Overhauling front disc brakes
• Brake caliper overhaul
• Overhauling rear disc brakes
• Overhauling brake discs
• Turning and grinding brake discs
• Drum brakes
• Overhauling the drum brakes

Bodywork and chassis frame

• Cab
• Cab tilting
• Cab air-conditioning
• Ventilation
• Air-conditioning and heating
• Component layout (webasto air conditioner)
• Heater assembly component layout (webasto)
• Procedure for emptying and refilling the air-conditioning systems with R134A refrigerant
• Safety standards
• Control fascia
• Operation flow chart
• Recovering refrigerant from the vehicle system
• Creating a vacuum in the system
• Restoring oil in the system
• Filling the system with refrigerant
• Checking the pressures in the system
• Operations prior to disconnecting the station from the system
• Leak finder for air-conditioning systems with HFC R134A (9905147)
• Repair operations
• Heater
• Additional air heater system
• Defrost control motor
• Air recirculation door control motor
• Electric fan
• Heater radiator
• Pollen filter
• Air-conditioner compressor
• Air-conditioner condenser
• Outside air temperature sensor

Maintenance

• Vehicle with motor cursor 8 (F2B)
• Maintenance
• Checks and/or maintenance work
• Off-plane operations
• Maintenance work
• M1 service
• M2 service
• M3 service
• M4 service
• EP1 service
• T1 service
• T2 service
• T3 service
• T4 service
• T5 service
• T6 service
• Vehicle with motor cursor 10 (F3A)
• Maintenance
• Checks and/or maintenance work
• Off-plane operations
• Maintenance work
• M1 service
• M2 service
• Extra plan maintenance
• EP1 service
• EP2 service
• EP3 service
• T1 service
• T2 service
• T3 service
• T4 service

Multiplex system

• General description of the
• multiplex system Power network
• Mass points
• List of st junction connector on
• Board the vehicle

Elektronic systems

• Multiplex system
• Automatic air conditioner
• Manual air conditioner
• Hydronic D 10 water heater
• Immobilizer
• EDC
• EBS
• ABS - EBL
• ECAS suspensions
• Eurotronic automated
• Intarder

Circuit charts

• Battery positive
• Positive after TGC (+30)
• Services supply (+15)
• BC unit (J7)
• BC unit (J4-J5) 11 Card 10: BC unit (J2-J3)
• SWI unit
• FFC unit (J2)
• RFC unit (J1)
• RFC unit (J2)
• CM unit
• DDM-BM unit
• PDM unit
• IC unit
• CAN-ICB/IDB line
• CAN-SB (EBS/ABS) line
• VDI unit / CAN-VDB line
• ECAS 4x2 FP
• ECAS 6x4 P
• ECAS 6x2 P/FP
• ECAS 4x2 Tractor
• ECAS 6x2C
• ZF retarder
• ABS
• EBS
• EuroTronic II
• Immobilizer
• Manually controlled air conditioning system
• Automatically controlled supplementary water heater
• Manually controlled supplementary water heater
• Manually controlled supplementary air heater
• EDC (Connector A) for F3A engines
• EDC (Connector A) for F2B engines
• EDC (Connector B)
• PTO with mechanical gearbox
• Radioreceiver

Block diagrams

• Start-up — recharge warning light
• EDC power supply- immobilizer warning light - EDC Blink code (warning light) — Fur wheel drive on warning light
• cruise control — accelerator pedal sensor (potentiometer) - Pre-post heating warning light
• Intarder
• Voltmeter — rev counter - engine water temperature - fuel level
• Engine oil pressure — engine oil level — window winder level - hydraulic power steering fluid level - engine water level
• Chock wear indicator - pad wear indicator - reduced gear on indicator- clogged oil filter indicator- clogged air filter indicator
• Differential block - water presence in fuel indicator
• Exterior lights
• Exterior lights
• Exterior lights — reverse light
• Hazard lights — headlight beam orientation
• Internal lights
• Windscreen wiper — horn - hour counter
• TGC
• Sunroof — windscreen washer
• Tachograph
• Engine electric fan
• Rearview mirror control - power windows
• Central door lock .
• Ecas (warning lights) - ABS (warning lights)
• EBS (warning lights) - Heated windscreen - PTO
• Retarder (warning light) - Cabin tilting
• Brake air pressure - ECAS - outside temperature
• Trip odometer / total odometer - speed limiter
• Engine oil temperature — beacon lights — sun visor